Daikin DM96VC Installation Instructions Manual
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Daikin DM96VC Installation Instructions Manual

Two-stage gas furnace
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DM96VC & DC96VC
T
-S
WO
TAGE
(Type FSP CATEGORY IV Direct
or Non Direct Vent Air Furnace)
These furnaces comply with requirements
embodied in the American National Standard /
National Standard of Canada ANSI Z21.47·CSA-
2.3 Gas Fired Central Furnaces.
As a professional installer you have an obligation to know
the product better than the customer. This includes all safety
precautions and related items.
Prior to actual installation, thoroughly familiarize yourself
with this Instruction Manual. Pay special attention to all
safety warnings. Often during installation or repair it is
possible to place yourself in a position which is more
hazardous than when the unit is in operation.
Remember, it is your responsibility to install the product
safely and to know it well enough to be able to instruct a
customer in its safe use.
Safety is a matter of common sense...a matter of thinking
before acting. Most dealers have a list of specific good
safety practices...follow them.
The precautions listed in this Installation Manual are intended
as supplemental to existing practices. However, if there is
a direct conflict between existing practices and the content
of this manual, the precautions listed here take precedence.
RECOGNIZE THIS SYMBOL
AS A SAFETY PRECAUTION.
NOTE: Please contact your distributor or our website for
*
the applicable Specification Sheet referred to in this manual.
IOD-2008F
2/2017
G
F
AS
URNACE
Installer:
Affix all manuals
adjacent to the unit.
Our continuing commitment to quality products may mean a change in specifications without notice.
© 2014-2017
5151 San Felipe St., Suite 500, Houston, TX 77056
www.daikincomfort.com
INSTALLATION INSTRUCTIONS

TABLE OF CONTENTS

SAFETY CONSIDERATIONS .................................... 3
......................................... 4
........................................... 5
PRODUCT DESCRIPTION ....................................... 5
F
................................................... 5
PRODUCT APPLICATION ....................................... 5
....................................... 8
INSTALLATION POSITIONS .................................... 9
......................................... 9
....................................... 9
................................................... 9
V
................................................. 10
......................................... 10
V
LUE AND
V
P
IPE
V
P
........................................... 13
C
A
P
OMBUSTION
IR
IPE
V
V
/I
T
M
D
OF
ULTIPLE
IRECT
V
V
....................................... 18
...................................... 19
U
M
I
PFLOW
ODEL
NSTALLED
D
E
R
S
U
M
I
PFLOW
ODEL
NSTALLED
U
PFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN
................................................. 20
................. 4
................................ 7
.................................. 8
................ 8
............... 9
C
A
C
IR
ONNECTIONS
C
............ 10
ONNECTIONS
V
.............. 11
............................ 11
C
OMBUSTION
..................................... 12
A
............................ 13
V
I
...............13
..................... 15
F
I
V
F
.................... 17
ENT
URNACES
.............................. 18
................................ 18
V
....................... 19
ERTICALLY
................................... 19
.................................... 19
H
ORIZONTALLY
............................... 19
..... 9
.... 12
... 13
. 20
-

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Summary of Contents for Daikin DM96VC

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS DM96VC & DC96VC TABLE OF CONTENTS SAFETY CONSIDERATIONS ........3 ......... 4 TAGE URNACE HIPPING NSPECTION (ESD) P ....4 LECTROSTATIC ISCHARGE RECAUTIONS (Type FSP CATEGORY IV Direct ........... 5 NSTALLER PRODUCT DESCRIPTION ........5 or Non Direct Vent Air Furnace) ...........
  • Page 2 ....21 ........39 OUNTERFLOW ODEL NSTALLED ERTICALLY IRFLOW ONSIDERATIONS ........21 ........39 RAIN XITING OSSIL PPLICATIONS ........21 CTK0* WIRING ..........39 RAIN XITING IGHT ....40 OUNTERFLOW ODEL NSTALLED ORIZONTALLY OMFORT YSTEM DVANCED EATURES ....... 22 ......41 WITH IGHT URNACE...

  • Page 3: Safety Considerations

    AFETY ONSIDERATIONS WARNING Adhere to the following warnings and cautions when installing, O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER adjusting, altering, servicing, or operating the furnace. To INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE ensure proper installation and operation, thoroughly read this REFER TO THIS MANUAL OR ADDITIONAL ASSISTANCE OR manual for specifics pertaining to the installation and...

  • Page 4: Shipping Inspection

    RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Cette ventilation est nécessaire pour éviter le danger d'intoxication Las emisiones de monóxido de carbono pueden circular a través au CO pouvant survenir si un appareil produisant du monoxyde del aparato cuando se opera en cualquier modo.

  • Page 5: Product Description

    objects, etc.). If you come in contact with an ungrounded • It must be installed indoors in a building constructed on site. object, repeat step 2 before touching control or wires. 4. Discharge your body to ground before removing a new •...

  • Page 6: Location Requirements & Considerations

    • Damage or repairs due to failure to comply with WARNING these requirements are not covered under the warranty. OSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO NOTE: The Commonwealth of Massachusetts requires FIRE EXPLOSION SMOKE SOOT CONDENSATION ELECTRICAL SHOCK that the following additional requirements must also OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION be met:...

  • Page 7: Clearances And Accessibility

    • Seal off a non-direct vent furnace if it is installed DM96VC MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS near an area frequently contaminated by any of the (INCHES) above substances. This protects the non-direct vent...

  • Page 8: Existing Furnace Removal

    • In all cases, accessibility clearance must take precedence exhausts, so they shall operate at maximum speed. over clearances from the enclosure where accessibility Do not operate a summer exhaust fan. clearances are greater. 6. Follow the lighting instructions. Place the appliance Installations must adhere to the clearances to combustible being inspected in operation.

  • Page 9: Installation Positions

    around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.

  • Page 10: Alternate Electrical And Gas Line

    left discharge and counterflow furnaces with right air REEZE ROTECTION discharge. This configuration allows the flue and combustion Refer to Horizontal Applications and Conditions - Drain Trap air piping to be run vertically through the side of the furnace. and Lines. Refer to the “Recommended Installation Positions”...

  • Page 11: Vent/Flue Pipe & Combustion Air Pipe

    & C OMBUSTION WARNING This manual will refer to the pipe that discharges products of O AVOID BODILY INJURY FIRE OR EXPLOSION SOLVENT CEMENTS combustion to the outdoors as the "vent" pipe or "flue" pipe. MUST BE KEPT AWAY FROM ALL IGNITION SOURCES SPARKS OPEN The pipe that supplies air for combustion to the furnace will...

  • Page 12: Proper Vent /F

    Piping must be adequately secured and supported to prohibit PREFERRED sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three to five feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system.

  • Page 13: Canadian Vent

    The vent can be run through an existing unused chimney NOTE: In Canada, the current edition of CAN/CSA B149.1- provided the space between the vent pipe and the chimney 15 takes precedence over the preceding termination is insulated and closed with a weather-tight, corrosion-re- description.
  • Page 14 secured directly to the counterflow unit air intake pipe IRECT NSTALLATIONS coupling. A minimum of one 90° elbow should be installed on the combustion air intake “coupling” to guard against inadvertent WARNING blockage. HE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD HEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET LTERNATE...

  • Page 15: Non -Direct Vent (Single Pipe ) Piping

    DM96VC & DC96VC Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe) Maximum Allowable Length of Vent/Flue Pipe Vertical vent/flue pipe terminations should be as shown in...
  • Page 16 DOWN VENTING UPFLOW MODEL FURNACES ONLY Use alternate vent & combination air locations 6’ MAX. Vent Pipe Combustion Air Pipe Both Pipes Terminated Outside Structure Field Supplied Drain Tee on Vent Pipe 1/4” per foot min. slope Condensate trapped to prevent flue gas from escaping and routed to field supplied condensate disposal All piping and fittings must be joined per material manufacturer’s specifications...

  • Page 17: Ent Ntake Erminations Or

    sealed tight with proper flashing such as is used with a plastic plumbing vent. & C OMBUSTION IR INTAKE EASUREMENTS FOR TANDARD 6” MAX ORIZONTAL ERMINATIONS 4” MIN Center to center = 10” min / 24” max. Vertical separation: 0” - 24” 90º...

  • Page 18: Condensate Drain Lines & Drain Trap

    • The drain line between furnace and drain location must meet local and nation codes. • The drain line between furnace and drain location must maintain a 1/4 inch per foot downward slope 3”MIN toward the drain. 24”MAX • Do not trap the drain line in any other location than at 12”...

  • Page 19: Field Supplied Drain

    and secure with two field supplied #8 self-tapping IELD UPPLIED RAIN screws (see Figure 23). Drain the furnace and air conditioning coil if applicable, in 2. Locate the long drain hose #3 and cut at “B” line for a compliance with code requirements. In horizontal or 17.5"...

  • Page 20: Upflow Model Installed Horizontally With Left Side Down Alternate

    7. Use two silver clamps and secure the hoses to drain 10. Connect hose #6 & hose #5 using 100º elbow and secure trap. The trap outlet faces the front of the furnace. with two red clamps Secure the trap to the cabinet using two screws 11.

  • Page 21: Counterflow Model Installedv

    8. (Draining the Collector Box) Remove cap from left side collector box drain port (bottom in horizontal left position)and install it on right side (top) collector box drain port. 9. Install the non-grommet end of hose #11 from outside the cabinet in the upper drain hole. Install on collector and secure with a silver clamp.

  • Page 22: Counterflow Model Installed

    OUNTERFLOW ODEL NSTALLED ORIZONTALLY WITH LSO SEE RONT OVER RESSURE OCATION ON PAGE 5 ½" INIMUM CLEARANCE IS REQUIRED FOR THE DRAIN TRAP BENEATH THE FURNACE 1. Remove the factory installed drain trap and hose assemblies. Leave the 100° elbow inserted and clamped in the Figure 28 vent-drain elbow.

  • Page 23: Electrical Connections

    Hose #4 latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1. Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate.

  • Page 24: Volt Thermostat Wiring

    achieve the desired single stage cooling airflow. Use of ramp- proper unit grounding, turn off the electrical power and ing profiles and dehumidification features require a jumper be- perform the following check. tween Y1 and O. 1. Measure resistance between the neutral (white) connection NOTE: Thermostat “R”...

  • Page 25: Volt Dehumidistat Wiring

    5. Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the furnace junction box. NOTE: Ground wire may not be present on all dehumidistats. Furnace Integrated Control Module 6. Turn ON power to furnace. Once the switch is set, the dehumidify function is enabled Dehumidistat [Optional] Remote...

  • Page 26: Gas Supply And Piping

    conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box. The integrated control module single humidifier terminal (HUM) is energized with 115 volts whenever the induced NEUTRAL draft blower is energized.

  • Page 27: High Altitude Derate

    This unit is configured for natural gas. The appropriate Inlet gas supply pressures must be maintained within the manufacturer’s propane gas conversion kit, must be applied ranges specified in the following table. The supply pressure for propane gas installations. Refer to the Propane Gas and/ must be constant and available with all other household gas or High Altitude Installations for details.
  • Page 28 • Use pipe joint compound on male threads ONLY. Always Natural Gas Capacity of Pipe use pipe joint compound (pipe dope) that is APPROVED In Cubic Feet of Gas Per Hour (CFH) FOR ALL GASSES. DO NOT apply compound to the first Nominal Black Pipe Size Length of two threads.

  • Page 29: Ropane As Anks And Iping

    Manual Shut Off Valve IPING HECKS (upstream from ground joint pipe union) Alternate WARNING Gas Line Location O AVOID THE POSSIBILITY OF EXPLOSION OR FIRE NEVER USE A MATCH *Ground *Ground OR OPEN FLAME TO TEST FOR LEAKS Joint Joint Pipe Union Pipe Union Before placing unit in operation, leak test the unit and gas...

  • Page 30: Circulating Air & Filters

    2. Proper pressure regulation. (Two-stage regulation is HECKING TATIC recommended for both cost and efficiency). 3. Pressure drop in lines between regulators, and between WARNING second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all EVER ALLOW THE PRODUCTS OF COMBUSTION INCLUDING CARBON appliances.
  • Page 31 WARNING DGES OF SHEET METAL HOLES MAY BE SHARP SE GLOVES AS A PRECAUTION WHEN REMOVING SHEET METAL FROM RETURN AIR OPENINGS ILTERS ECTION EFORE NSTALLING ETURN UCT WORK Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided, sized and installed externally by the installer.

  • Page 32: Bottom Return Air Opening

    The following figure shows possible filter locations. PRIGHT NSTALLATIONS AIR FLOW Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be CENTRAL RETURN installed in the central return register or a side panel external GRILLE filter rack kit (upflows).

  • Page 33: Drain Trap Priming

    RAIN RIMING UPPLY RESSURE EASUREMENT The drain trap MUST be primed prior to furnace startup. To RESSURE prime, fill both sides of the drain trap with water. This This test is to be used for field test mode only, and it will ensures proper furnace drainage upon startup and prohibits allow gas valve pressure to be checked at 100% firing rate.
  • Page 34 Common Terminal(C) High Fire Coil Terminal (HI) Low Fire Coil Terminal (LO) White-Rodgers Model 36J54 (Two-Stage) Inlet Pressure Tap 1/8 NPT Figure 46A Open to Atmosphere Honeywell Model VR9205 Connected to Manometer High Fire Regulator Outlet Figure 47B Adjust Regulator Pressure Boss Vent Low Fire...

  • Page 35: Gas Manifold Pressurem

    9. Close thermostat “R” and “W2” contacts to provide a call Gas Line for high stage heat. 10. Remove regulator cover screw from the high (HI) outlet Shutoff pressure regulator adjust tower and turn screw clockwise Valve to increase pressure or counterclockwise to decrease pressure.

  • Page 36: Temperature Rise

    The typical value range for 1 cu. ft. of natural gas is around IRCULATOR LOWER PEEDS 1000 BTU. Check with your gas utility, if possible. In this example, the furnace is consuming 78,000 BTUH. WARNING NOTE: The final manifold pressure cannot vary by O AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK more than ±...
  • Page 37 and their corresponding taps. Verify CFM by noting the NOTE: To enable adjustments and select -5, 5, -10 or 10% trim, number displayed on the dual 7-segment LED display. you must set dip switch S5-2 to ON. If S5-2 is in the OFF position, you will receive 0% trim.

  • Page 38: Blower Heat Off Delay Timings

    8. Select the desired “heating” speed tap by positioning High High Low Stage Model Stage Stage Stage switches S4- 3,4 appropriately. Refer to figure above. Heat Cool Cool Heat Verify CFM by noting the number displayed on the dual 7- segment LED display.

  • Page 39: Ctk0* Wiring

    installation manual for the airflow delivered during cooling A ComfortNet heating/air conditioning system differs from or heat pump heating. a non-communicating/traditional system in the manner in which the indoor unit, outdoor unit and thermostat interact with one another. In a traditional system, the thermostat System Airflow Demand sends commands to the indoor and outdoor units via analog...

  • Page 40: Omfort Et Ystem Dvanced

    ™ C Typical 18 AWG thermostat wire may be used to wire the OMFORT OMPATIBLE URNACE WITH OMFORT system components. One hundred (100) feet is the maximum COMPATIBLE INGLE TAGE ONDITIONER length of wire between indoor unit and outdoor unit, or Four wires are required between the furnace and thermostat.

  • Page 41: Furnace Advanced Features Menus

    URNACE DVANCED EATURES ENUS ACCESSED THROUGH THE COMMUNICATING THERMOSTAT D IA G N O S T IC S S u b m e n u Ite m In d i ca ti o n /U se r M o d i fi a b l e O p tio n s C o m m e n ts F au lt 1 (F A U LT #1) M os t rec e nt furnac e fau lt...
  • Page 42 NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED W ITH A NON-COMMUNICATING COMPATIBLE SINGLE STAGE AIR CONDITIONER) Subm e nu Ite m Use r Modifiable Options Com m e nts Cool Airflow (CL CFM) 18, 24, 30, 36, 42, 48, or 60, Selects the airflow for the non- default is 18 communicating compatible single stage...

  • Page 43: Normal Sequence Of Operation

    • Display will then be blank for 2 seconds before HERMOSTAT displaying faults stored in history. If this furnace is installed with a communicating compatible • All faults are displayed one time, from most recent heat pump, the system is recognized as a dual fuel system. to least recent.
  • Page 44 the call is for high heat, the gas valve and induced remain on high heating speed for thirty (30) seconds draft blower will change to high stage. before switching to the low heat circulating speed. • Circulator blower is energized on heat speed following •...

  • Page 45: Operational Checks

    • Circulator blower and electronic air cleaner terminal not be yellow). Flames should extend directly outward from is de-energized. the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing • Circulator blower ramps down to OFF during the 30 tubes.

  • Page 46: Pressure Switches

    RESSURE WITCHES problems. The dual 7-segment LED display will display an error code that may contain a letter and number. The error The pressure switches are normally-open (closed during code may be used to assist in troubleshooting the unit. operation) negative air pressure-activated switches. They monitor the airflow (combustion air and flue products) ESETTING OCKOUT...

  • Page 47: Filters

    accumulation of dust which may cause overheating. Clean as ILTERS necessary. CAUTION ONDENSATE RAP AND RAIN YSTEM UALIFIED ERVICER O ENSURE PROPER UNIT PERFORMANCE ADHERE TO THE FILTER SIZES GIVEN IN THE RECOMMENDED INIMUM ILTER ABLE OR Annually inspect the drain tubes, drain trap, and field-supplied PECIFICATION HEET APPLICABLE TO YOUR MODEL drain line for proper condensate drainage.

  • Page 48: Dip Switches

    WITCHES Dip Switch Switch Bank Purpose Function Heating Off Delay 2 Stage Stat Thermostat 1 Stg Stat 5 min delay Setup 1 Stg Stat auto delay Cooling Airflow Add 5% Minus 5% Trim Add 10% Minus 10% Ramping Profile Heating Airflow Disabled Dehum Enabled...

  • Page 49: Status Codes

    TATUS ODES INTERNAL CONTROL FAULT/NO POWER NORMAL OPERATION LOCKOUT DUE TO EXCESSIVE RETRIES LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE LOW STAGE PRESSURE SWITCH STUCK OPEN OPEN HIGH LIMIT SWITCH FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT OPEN FUSE LOW FLAME SIGNAL IGNITER FAULT OR IMPROPER GROUNDING...

  • Page 50: Troubleshooting Chart

    ROUBLESHOOTING HART ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy & Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions ComfortNet™ Thermostat) Codes Message Code • Furnace fails to operate None • No 115 power to INTERNAL •...
  • Page 51 ROUBLESHOOTING HART Symptoms of Abnormal ComfortNet™ Diagnostic/ Operation (Legacy Thermostat Only Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Induced draft blower • Low stage PS1 OPEN • Pressure switch hose •...
  • Page 52 ROUBLESHOOTING HART ComfortNet™ Symptoms of Abnormal Diagnostic/ Operation (Legacy Thermostat Only Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Furnace fails to operate. • Problem with IGNITER • Improperly connected •...
  • Page 53 ROUBLESHOOTING HART ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Operation different than • Invalid memory INVALID MC • Shared data set on •...
  • Page 54 ROUBLESHOOTING HART ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Circulator blower MOTOR • Turn power OFF prior • Furnace fails to operate. motor senses TRIPS to repair...

  • Page 55: Wiring Diagram

    IRING IAGRAM Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

  • Page 56: Special Instructions For Products Installed In The State Of Massachusetts

    PECIAL NSTRUCTIONS FOR RODUCTS NSTALLED IN THE TATE OF ASSACHUSETTS For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or VENT/FLUE operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to...

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