Daikin DM92SE Service Instructions Manual
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Daikin DM92SE Service Instructions Manual

Single stage gas furnaces and accessories
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Single Stage Gas Furnaces and Accessories
O
NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL
(
, "
")
REPAIR
HEREINAFTER
SERVICE
SHOULD SERVICE THE EQUIPMENT
RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER
SERVICE OR SERVICE PROCEDURES
RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY RESULT
,
ADDITION
IN JURISDICTIONS THAT REQUIRE ONE OR MORE LICENSES TO SERVICE
THE EQUIPMENT SPECIFIED IN THIS MANUAL
SHOULD SERVICE THE EQUIPMENT
SERVICING OR REPAIR OF THE EQUIPMENT SPECIFIED IN THIS MANUAL
,
,
ATTEMPTING TO INSTALL
ADJUST
SERVICE OR REPAIR THE EQUIPMENT SPECIFIED
IN THIS MANUAL WITHOUT PROPER TRAINING MAY RESULT IN PRODUCT
,
,
DAMAGE
PROPERTY DAMAGE
PERSONAL INJURY OR DEATH
This manual is to be used by qualified, professionally trained HVAC technicians only.
Daikin does not assume any responsibility for property damage or personal injury due to
improper service procedures or services performed by an unqualified person.
The material in this manual does not supercede manufacturer's installation and operation instructions.
Our continuing commitment to quality products may mean a change in specifications without notice.
Service Instructions
DM92SE
,
,
ADJUST
SERVICE OR
THE EQUIPMENT SPECIFIED IN THIS MANUAL
. T
HE MANUFACTURER WILL NOT BE
. I
,
F YOU SERVICE THIS UNIT
YOU ASSUME
,
ONLY LICENSED PERSONNEL
. I
,
MPROPER INSTALLATION
ADJUSTMENT
.
© 2019
19001 Kermier Rd., Waller, TX 77484
www.daikincomfort.com
Cancer and Reproductive Harm
www.P65Warnings.ca.gov
. I
N
,
,
OR
-
RSD6612014r1
December 2019

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  • Page 1 PERSONAL INJURY OR DEATH This manual is to be used by qualified, professionally trained HVAC technicians only. Daikin does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.

  • Page 2: Table Of Contents

    Table of Contents IMPORTANT INFORMATION ......2 - 4 SERVICING ...........35-37 PRODUCT IDENTIFICATION ......5 - 8 TROUBLESHOOTING ........38 - 40 INSTALLATION CONSIDERATIONS ....9 - 27 SERVICING ............41 SYSTEM OPERATION ........28 SERVICING TABLE OF CONTENTS ....42 ACCESSORIES...........29 - 31 SERVICING ...........43-53 ACCESSORY WIRING DIAGRAMS ...32 - 34 MAINTENANCE ..........54 - 56 WIRING DIAGRAMS ..........57 IMPORTANT INFORMATION...

  • Page 3: Important Information

    IMPORTANT INFORMATION To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this prod- uct. For further assistance, please contact: CONSUMER INFORMATION LINE DAIKIN BRAND PRODUCTS TOLL FREE 1-855-770-5678 (U.S. only) email us at: customerservice@daikincomfort.com...
  • Page 4 IMPORTANT INFORMATION IMPORTANT INFORMATION...

  • Page 5: Product Identification

    The model and manufacturing number are used for positive identification of component parts used in manufacturing. Please use these numbers when requesting service or parts information. Brand Minor Revision D - Daikin A - Initial Release B - 1st Revision Configuration...
  • Page 6 PRODUCT IDENTIFICATION MODEL# MFG# DESCRIPTION DM92SE0403AN DM92SE0603BN Daikin Brand 92% Single Stage furnace. 34.5" tall , Upflow/Horizontal DM92SE0803BN Installation, 1-stage gas valve induced draft. Multi-speed ECM motor. DM92SE0804CN 120-volt nitride hot surface ignition. Left or right gas pipe entry. DM92SE DM92SE0805CN The furnace also features a stainless tubular heat exchanger.
  • Page 7 PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION Fossil Fuel Kit. The AFE18-60A control is designed for use where the indoor coil is locat- ed above/downstream of a gas or fossil fuel furnace when used with a heat pump. It will AFE18-60A operate with single and two stage heat pumps and single and two stage furnaces P1251305F...
  • Page 8 PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION DCVK-20 Concentric Vent Kit. This kit is designed to allow terminations of a direct vent furnace (CVENT-2) to be “concentrically” vented through a wall or roof. This kit allows a single penetration to support terminations for both the vent/flue and the combustion air intak DCVK-30 (CVENT-3)

  • Page 9: Installation Considerations

    MANUAL. OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. Daikin DM92SE furnaces are ETL certified. All furnaces are built for use with Natural gas but can be converted for use WARNING with LP gas.
  • Page 10 INSTALLATION CONSIDERATIONS National Fire Protection Association • Locate the 90% furnace so that the condensate can be piped at a downward slope away from the furnace to 1 Batterymarch Park the drain. Do not locate the furnace or its condensate Quincy, MA 02169-7471 drainage system in any area subject to below freezing temperatures without proper freeze protection.
  • Page 11 INSTALLATION CONSIDERATIONS • Isolate a nondirect furnace from an area contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors.
  • Page 12 A high quality single stage thermostat with a "C" terminal is or crawl spaces. recommended to control the DM92SE furnace. The following infor mation on air for combustion and ventilation is repro duced from the National Fuel Gas Code NFPA 54/ANSI Thermostat Location Z223.1 Section 9.3.
  • Page 13 INSTALLATION CONSIDERATIONS 9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltra- 9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be provided through opening(s) to the outdoors in accordance with the tion rate of a structure is known, the minimum required volume shall methods in 9.3.3.1 or 9.3.3.2.
  • Page 14 INSTALLATION CONSIDERATIONS (c) The minimum size of outdoor opening(s) shall be the full size Chimney or Gas Vent of outdoor opening(s) calculated in accordance with 9.3.3, multiplied by the reduction factor. The minimum dimension of air openings shall not be less than 3 in. (80 mm). NOTE: The air duct openings must have a free area of not 9.3.5 Engineered Installations.
  • Page 15 INSTALLATION CONSIDERATIONS newly redesigned line of shorter chassis furnaces. It is avail- ings where both such openings are used. The separation between ducts able in 92% AFUE upflow/horizontal model. servicing upper and lower combustion air openings shall be maintained to the source of combustion air. The upflow/horizontal 34.5"...
  • Page 16 INSTALLATION CONSIDERATIONS tions the connections can be made either through the “top” or “bottom” of the furnace. WARNING Drain Pan PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT A drain pan must be provided if the furnace is installed above IS PROPERLY SEALED.
  • Page 17 12 inches above the roof line (or the anticipated snow level) and be at least 12 DM92SE* Direct Vent (2-Pipe) and Non-Direct Vent (1-Pipe) (6) Maximum Allowable Length of Vent/Flue Pipe and inches from any vertical wall (including any anticipated Combustion Air Pipe (Ft) (1) (2) snow build up).
  • Page 18 INSTALLATION CONSIDERATIONS installation. The number of elbows tabulated represents the prohibit damage to piping connections, a coupling should be number of elbows and/or tees in each (Vent/Flue & Combustion installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings.
  • Page 19 INSTALLATION CONSIDERATIONS 12" MINIMUM 90° ELBOWS VENT/FLUE TEE 90° ELBOW TURNED 3” - 24” DOWN 12" MINIMUM ABOVE HIGHEST ANTICIPATED SNOW LEVEL 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL Alternate Horizontal Vent Termination (Dual Pipe) 90% Furnace Horizontal Termination (Single Pipe) 90°...
  • Page 20 INSTALLATION CONSIDERATIONS Determine the best location for the termination kit. Roof termination is preferred since it is less susceptible to damage, has reduced intake contaminants and less visible vent vapors. For side termination, consideration should be given to: a. Possible damage from the vapors to plants/shrubs, other equipment and building materials 9"...
  • Page 21 ¾" slope from back to front to permit condensate flow towards the front of the furnace. When installing a DM92SE horizontally with the left side down, there are two options for connecting the vent pipe to the furnace.
  • Page 22 This unit is configured for natural gas. The appropriate man- ufacturer’s propane gas conversion kit, must be applied for propane gas installations. DM92SE models using a White-Rodgers 36J22 single stage CAUTION valve use LPM-07 LP Conversion Kit. O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET...
  • Page 23 INSTALLATION CONSIDERATIONS WARNING O AVOID THE POSSIBLITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS. Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods. NOTE: Never exceed specified pressures for testing.
  • Page 24 INSTALLATION CONSIDERATIONS Use pipe dope approved for use with L.P. gas. Refer to the following illustration for typical propane gas in- stallations and piping. 5 to 15 PSIG First Stage (20 PSIG Max.) Regulator Continuous 11" W.C. 200 PSIG Second Stage Maximum Regulator Typical Propane Gas Installation...
  • Page 25 INSTALLATION CONSIDERATIONS ELECTRICAL CONNECTIONS WARNING N 90% FURNACE UPRIGHT UPFLOW INSTALLATIONS, THE DRAIN TRAP MUST O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION PROPERLY POLARIZED AND GROUNDED.
  • Page 26 INSTALLATION CONSIDERATIONS A 40 V.A. transformer and an integrated electronic control are A closed return duct system must be used, with the return built into the furnace to allow use with most cooling equipment. duct connected to the furnace. NOTE: Ductwork must never Consult the wiring diagram, located in the Technical Manual be attached to the back of the furnace.
  • Page 27 INSTALLATION CONSIDERATIONS 11. Circulator blower is de-energized following heat off delay Electronic Air Cleaner (ASAS and GSAS) or Media Air period. Cleaner (AMU and GMU) Furnace awaits next call from thermostat. The electronic air cleaner and media air cleaner are multi-po- sitional high efficiency air filtration devices that can be installed Cooling Mode in any position, except with the access door facing down.

  • Page 28: System Operation

    SYSTEM OPERATION HEATING - Abnormal Operation The control will automatically reset from lockout and restart The following presents the probable causes of questionable the ignition sequence. The diagnostic light code for this furnace operation and how to fix them. Look through the ob- problem is three short flashes followed by a pause.

  • Page 29: Accessories

    ACCESSORIES EXTERNAL FILTER RACK ( EFR02 ) SLOTS IN FILTER CLEAR SCREWS EFR02 EXTERNAL FILTER RACK KIT ON UNIT Used on Models 90% Upflow Model Furnaces UNIT SIDE PANEL FRONT OF UNIT LOWER EDGE SCREW SIDE WALL VENT KIT (0170K00000S/0170K00001S) SIDE WALL VENT KIT (0170K00000S) This side wall only vent kit #0170K00000S is to be used with 2”...
  • Page 30 ACCESSORIES CONCENTRIC VENT CONVERSION KIT (CVENT-2 (DCVK-20)  CVENT-3 (DCVK-30) The CVENT-2 (DCVK-20) (2") or the Vent CVENT-3 (DCVK-30) (3") is a concentric Maintain 12" (18" for Canada) vent kit approved with furnaces listed in minimum clearance above highest anticipated snow level. Maximum of this manual.
  • Page 31 ACCESSORIES DAIKIN DM92SE Model Furnace Accessories...

  • Page 32: Accessory Wiring Diagrams

    ACCESSORY WIRE DIAGRAMS ALL FUEL SYSTEM CONTROL BOARD - AFE1860A 24VAC P1-8 +VDC POWER SUPPLY INPUT POWER +5VDC FURNACE DEMAND P1-7 W1-FURN SUPPLY OUTPUT W2-HP BLOWER FAN DEMAND P1-4 +VDC OUTPUT 24VAC G-STAT POWER SUPPLY INPUT P1-6 (COMMON) SECOND STAGE FURNACE P1-5 G-FURN DEMAND OUTPUT...
  • Page 33 ACCESSORY WIRE DIAGRAMS For installations made prior to 2/1/11 FURNACE TWINING KIT - FTK03A (Johnson Control Board) This wiring diagram is for reference only. Not all wiring is as shown above. Refer to the appropriate wiring diagram for the unit being serviced. (For use only with 80% or 90% Single-Stage Furnaces)
  • Page 34 ACCESSORY WIRE DIAGRAMS For installations made after 2/1/11 FURNACE TWINING KIT - FTK04 (UTEC Control Board) This wiring diagram is for reference only. Not all wiring is as shown above. Refer to the appropriate wiring diagram for the unit being serviced. (For use only with 80% or 90% Single-Stage Furnaces) NOTE: Not compatible with PCBBF112 Control Boards.
  • Page 35 As more and more electronic's are introduced to the Heat- INCOMING POWER ing Trade, Polarization of incoming power and phasing of METER READS METER READS 120 VOLTS 0 VOLTS primary to secondary voltage on transformers becomes more important. Polarization has been apparent in the Appliance industry VOLT / OHM VOLT / OHM since the introduction of the three prong plug, however,...

  • Page 36: Servicing

    SERVICING CUBIC FEET GAS RATE -- CUBIC FEET PER HOUR Seconds Seconds Size of Test Dial Size of Test Dial for One for One Revolutio Revolutio cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft 1800 1636 1500 1385 1286 1200 1125...
  • Page 37 Service Problem No Heat Unsatisfactory Heat POSSIBLE CAUSE Test Method DOTS IN ANALYSIS Remedy GUIDE INDICATE "POSSIBLE CAUSE" • Power Failure Test Voltage • Blown Fuse Test Voltage • Loose Connection Check Wiring • Shorted or Broken Wires Check Wiring S-3A •...

  • Page 38: Troubleshooting

    TROUBLESHOOTING Associated Symptoms of Abnormal Operation Fault Description(s) Possible Causes Corrective Action Cautions and Notes LED Code • Furnace fails to operate. • No 115 volt power • Manual disconnect • Assure 115 and 24 volt • Turn power OFF •...
  • Page 39 TROUBLESHOOTING Associated Symptoms of Abnormal Operation Fault Description(s) Possible Causes Corrective Action Cautions and Notes LED Code • Induced draft blower runs • Pressure switch circuit • Pressure switch hose • Inspect pressure switch • Turn power OFF prior continuously with no further not closed.
  • Page 40 TROUBLESHOOTING Associated Symptoms of Abnormal Operation Fault Description(s) Possible Causes Corrective Action Cautions and Notes LED Code • Furnace not operating. • Igniter Relay Fault •Improperly connected •Check and correct • Turn power OFF prior • Integrated control module igniter. wiring from integrated to repair.
  • Page 41 Combustion Quality Other Causes Combustion quality can be affected by several factors. Major 1. Manifold Gas Pressure must be set, the gas being used, factors are venting and draining. Natural or L.P., high and low firing rates. If converted to L.P.

  • Page 42: Servicing

    SERVICING SERVICE NUMBERS CHECKING VOLTAGE .........................43 CHECKING WIRING ..........................43 S-3A THERMOSTAT AND WIRING ......................43 S-3B HEATING ANTICIPATOR ........................43 CHECKING TRANSFORMER AND CONTROL CIRCUIT ..............44 S-16A CHECKING AIR CIRCULATOR BLOWER MOTOR ................44 S-200 CHECKING DUCT STATIC........................45 S-201 CHECKING TEMPERATURE RISE ....................46 S-300 CHECKING PRIMARY LIMIT CONTROL ...................45 S-302...

  • Page 43: Checking Voltage

    S-3A THERMOSTAT AND WIRING S-1 CHECKING VOLTAGE WARNING WARNING ISCONNECT POWER BEFORE SERVICING. HIGH VOLTAGE ISCONNECT POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. ULTIPLE POWER 1. Remove the blower compartment door to gain access to SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE the thermostat low voltage wires located at the furnace PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

  • Page 44: Servicing

    SERVICING Cooling Anticipator The cooling anticipator is a small heater (resistor) in the S-16A CHECKING AIR CIRCULATOR BLOWER thermostat. During the "OFF" cycle it heats the bimetal BLOWER MOTOR element helping the thermostat call for the next cooling cycle. This prevents the room temperature from rising WARNING too high before the system is restarted.

  • Page 45: Checking Duct Static

    NOTE: Both readings may be taken simultaneously and read COOL MOTOR SPEED DIP SWITCH SETTING (S1-1, S1-2, S1-3) directly on the manometer if so desired. If an air conditioner 1 2 3 1 2 3 1 2 3 1 2 3 coil or Electronic Air Cleaner is used in conjunction with the Position OFF OFF OFF ON OFF OFF ON ON OFF OFF ON OFF furnace, the readings must also include theses components,...

  • Page 46: Checking Temperature Rise

    SERVICING Primary limit controls are nonadjustable, automatic reset, S-201 CHECKING TEMPERATURE RISE bi-metal type limit control. Refer to the following drawing for The more air (CFM) being delivered through a given furnace, the location of the primary limit. the less the rise will be; so the less air (CFM) being PRIMARY LIMIT delivered, the greater the rise.

  • Page 47: Checking Flame Rollout Control

    WARNING HIGH VOLTAGE VOLT / OHM ISCONNECT POWER BEFORE SERVICING OR METER INSTALLING THIS UNIT. ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. WARNING O AVOID POSSIBLE FIRE, ONLY RESET THE AUXILIARY LIMIT CONTROL ONCE.

  • Page 48: S-303 Induced Draft Blower Motor

    SERVICING Using a ohmmeter, test for continuity between each of the motor leads. WARNING Touch one probe of the ohmmeter to the motor frame (ground) and the other probe in turn to each lead. INE VOLTAGE NOW PRESENT If the windings do not test continuous or a reading is obtained to ground, replace the motor.

  • Page 49: Checking Main Burners

    SERVICING S-305 CHECKING MAIN BURNERS 3. If resizing is required, a new orifice of the same physical The main burners are used to provide complete size and angle with proper drill size opening should be combustion of various fuels in a limited space, and transfer installed.
  • Page 50 SERVICING NOTE: At either location, a hose fitting must be installed prior Gas Manifold Pressure Measurement and Adjustment to making the hose connection. NOTE: Use adapter kit #0151K00000S to measure gas pres- CAUTION sure on White-Rodgers 36G/J 22 gas valves. GAS LINE O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT...

  • Page 51: Checking Hot Surface Ignitor

    d. Turn on power and close thermostat “R” and “W1” Gas Valve contacts to provide a call for heat. On/Off e. Measure the gas manifold pressure with burners firing. Selector Adjust manifold pressure using the Manifold Gas Inlet Pressure Switch Pressure table shown below.

  • Page 52: Checking For Flashback

    SERVICING S-312 CHECKING FOR DELAYED IGNITION WARNING Delayed ignition is a delay in lighting a combustible mixture of gas and air which has accumulated in the combustion INE VOLTAGE NOW PRESENT chamber. Furnace design makes this extremely unlikely unless safety 6.

  • Page 53: Checking Flame Sensor

    SERVICING WARNING INE VOLTAGE NOW PRESENT These tests must be completed within a given time frame due to the operation of the ignition control. 1. Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral) at the ignition control. No voltage, check the door switch connections and wire harness for continuity.

  • Page 54: Maintenance

    MAINTENANCE Maintenance WARNING Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should HIGH VOLTAGE be cleaned (permanent) or replaced (disposable) every two ISCONNECT POWER BEFORE SERVICING OR INSTALLING THIS UNIT. ULTIPLE POWER SOURCES MAY months or as required.
  • Page 55 MAINTENANCE Inclined Manometer - to measure static pressure, BURNERS pressure drop across coils, filters, and draft. Water Manometer (12") - to test gas inlet and manifold WARNING pressure. HIGH VOLTAGE Other recording type instruments can be essential in solving LECTRICAL COMPONENTS ARE CONTAINED IN BOTH abnormal problems, however, in many instances they may be COMPARTMENTS.
  • Page 56 MAINTENANCE Should the figure you calculated not fall within five (5) percent of the nameplate rating of the unit, adjust the gas valve pressure regulator or resize orifices. CAUTION LWAYS CONNECT A MONOMETER TO THE OUTLET TAP AT THE GAS VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR.

  • Page 57: Wiring Diagrams

    WIRING DIAGRAMS MICRO CONTROLLED CIRC-H REPLACED WITH WIRING MATERIAL Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

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