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Installation Instructions for DR92SN,
DR96SN, & DD96SN Single-Stage Gas Furnace
(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)
(Type FSP CATÉGORIE IV Direct ou four á air soufflé non direct)
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.
s a professional installer you have an obligation to know
A
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.
This furnace may be paired with a cooling unit that uses R-32
refrigerant. If the cooling unit paired with this furnace does
not use R-32, the R-32 function in the furnace control board
needs to be turned off. please see the electrical and the R-32
sections for more details.
Refrigerant systems other than 410A or R32 may require
an additional mitigation control board. Refer to the instal-
lation manual of the indoor evaporator coil to determine
installation requirements for that supplier's refrigerant
detection system.
Our continuing commitment to quality products may mean a change in specifications without notice.
© 2023
IOD-2037A
09/2023
Installer:
Affix all manuals
adjacent to the unit.
WARNING
19001 Kermier Rd. Waller, TX 77484
www.daikincomfort.com
INSTALLATION INSTRUCTIONS
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.
Only personnel that have been trained to install, adjust,
service, maintenance or repair (hereinafter, "service")
the equipment specified in this manual should service the
equipment.
This equipment is not intended for use by persons (includ-
ing children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concern-
ing use of the appliance by a person responsible for their
safety.
Children should be supervised to ensure that they do not
play with the equipment.
The manufacturer will not be responsible for any injury
or property damage arising from improper supervision,
service or service procedures. If you service this unit, you
assume responsibility for any injury or property damage
which may result. In addition, in jurisdictions that require
one or more licenses to service the equipment specified in
this manual, only licensed personnel should service the
equipment. Improper supervision, installation, adjustment,
servicing, maintenance or repair of the equipment specified
in this manual, or attempting to install, adjust, service or
repair the equipment specified in this manual without prop-
er supervision or training may result in product damage,
property damage, personal injury or death.
Do not bypass safety devices.
90% HEX
WARNING
WARNING
DO NOT LIFT
PRODUCT USING
HEAT EXCHANGER
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Table of Contents
Related Manuals for Daikin DR96SN0403A Series
Summary of Contents for Daikin DR96SN0403A Series
- Page 1 INSTALLATION INSTRUCTIONS Installation Instructions for DR92SN, DR96SN, & DD96SN Single-Stage Gas Furnace (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) (Type FSP CATÉGORIE IV Direct ou four á air soufflé non direct) RECOGNIZE THIS SYMBOL These furnaces comply with requirements embodied AS A SAFETY PRECAUTION.
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Page 2: Table Of Contents
Table of Contents AIR REQUIREMENTS section of this manual. Combustion products must be discharged to the outdoors. Safety Considerations ..........2 Connect this furnace to an approved vent system only, as Electrostatic Discharge (ESD) Precautions ....4 specified in VENT/FLUE PIPE & COMBUSTION AIR PIPE To the Installer ..............4 section of this manual. - Page 3 WARNING If the information in these instructions is not followed exactly, a fire or explosions may result causing property damage, personal injury or loss of life. -Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. - WHAT TO DO IF YOU SMELL GAS: •...
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Page 4: Electrostatic Discharge (Esd) Precautions
Drain trap must be primed at time of installation. Trap is NOTE: Discharge your body’s static electricity internally partitioned; add water to both inlet ports until before touching unit. An electrostatic discharge water appears at both sides of the outlet opening. Failure can adversely affect electrical components. - Page 5 • It must be installed per the installation instructions • The furnace heat exchanger, components, duct provided and per local and national codes. system, air filters and evaporator coils are thoroughly • It must be installed indoors in a building constructed cleaned following final construction clean up by a on site.
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Page 6: Location Requirements & Considerations
• A special accessory sub-base must be used for LOCATION REQUIREMENTS & upright counterflow unit installations over any combustible material (including wood). Refer to sub- CONSIDERATIONS base instructions for installation details. (NOTE: A sub-base will not be required if an air conditioning Follow the instructions listed below and the guidelines coil is located beneath the furnace between the provided in the Combustion and Ventilation Air... -
Page 7: Clearance And Accessibility
CLEARANCES AND ACCESSIBILITY • Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel. NOTES: • On Counterflow Installations, the air conditioning coil • For servicing or cleaning, a 24” front clearance is must be downstream on the supply (positive) side of required. -
Page 8: Thermostat Location
WARNING AVERTISSEMENT CARBON MONOXIDE POISONING HAZARD RISQUE D’INTOXICATION AU MONOXYDE DE CARBONE Failure to follow the steps outlined below for each ap- Si les étapes décrites ci-dessous ne sont pas suivies pour pliance connected to the venting system being placed into chacun des appareils raccordés au système de ventilation operation could result in carbon monoxide poisoning or au moment de sa mise en marche, cela peut entraîner une... -
Page 9: Combustion & Ventilation Requirements
• Drafts, or dead spots behind doors, in corners, or never be attached to the back of the furnace. Contact your under cabinets. distributor for proper airflow requirements and number of • Hot or cold air from registers. required ductwork connections. Refer to “Recommended •... -
Page 10: Horizontal Applications & Considerations
HORIZONTAL APPLICATIONS & Leveling Leveling ensures proper condensate drainage from CONSIDERATIONS the heat exchanger. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should have a slight tilt from back to front with the access doors downhill from the back panel approximately 1/2 to 3/4 inches. -
Page 11: Materials - Installations In The U.s.a
MATERIALS – INSTALLATIONS IN THE VENTING MATERIAL REQUIREMENTS U.S.A. ASTM STANDARD SCHEDULE 40 PIPE D1785 SDR 21 or 26 PIPE D2241 PVC, CPVC, or ABS pipe & fittings are typically used as D1784, UL 1738 venting and intake pipe materials. All 90° elbows must SYTSTEM 1738 (IPEX) ®... -
Page 12: Pipe Sizing
Vent pipe must be installed to maintain a minimum inch per foot downward slope toward the furnace to return WARNING condensate to the furnace’s drain system. Condensation may also occur in the intake pipe. This commonly takes To avoid bodily injury, fire or explosion, solvent cements must be kept away from all ignition sources (i.e., sparks, open place during the summer months when humid air enters flames, and excessive heat) as they are combustible liquids. -
Page 13: Vent Pipe Connection
Vent Pipe Connection The vent pipe outlet is sized to accept 2” pipe. Secure vent Number of Elbows PIPE pipe directly into the furnace fitting with the appropriate MODEL SIZE glue. Alternately, a small section of 2” pipe may be glued in the furnace socket and a rubber coupling installed DR92SN0403AN 114 107 100 93... - Page 14 Vent & Intake Pipe Options for Condensate Management The RF000142 coupling (Figure 9) can be secured directly to the furnace intake and/or vent if condensation/ rain water is a concern. If the RF000142 is used on the combustion air inlet, it must be installed with the arrow pointing up.
- Page 15 8. Connect drain hose to the uncapped port on the VENT-DRAIN RF000142 coupling, refer to page xx, section entitled “Horizontal Installation with Left Side Down – Alternate” for drain connection details When using the alternate venting location, either in a horizontal left side down installation or a vertical installation using down –...
- Page 16 DOWN VENTING UPFLOW MODEL FURNACES ONLY The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty. Vent & combustion air pipes may terminate vertically Use alternate vent through a roof, or horizontally through an outside wall. The &...
- Page 17 Figure 18 90° ELBOWS ELBOWS STRAIGHT Figure 15 3”-24” BETWEEN PIPES 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL Combustion Air Intake may also be snorkeled to obtain 12” min ground clearance. Alternate Vent Termination Above Anticipated Snow Level (Dual Pipe) Figure 19 Vent &...
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Page 18: Concentric Vent Termination
NOTE: In vertical installations, air conditioning coil condensate may drain into the furnace trap as long as there is a trap between the coil and the H oriz ontal Ins tallation furnace trap and the drain pipe is not terminating below the water level of the furnace trap. -
Page 19: Field Supplied Drain
Acceptable area for Hose #1 drain hole. Hose #2 Side Cut-Out 12” 45 degree 45 degree Right side shown. barb-pipe 3” barb-pipe adapter adapter Figure 23 Field Supplied Drain Installer selects right or left side drain Drain the furnace and air conditioning coil if applicable, and installs this hose accordingly. -
Page 20: Upflow Model Installed Horizontally With Left Side Down
Upflow Model Installed Horizontally with Right Side Down Minimum 5 1/2” clearance is required for the drain trap beneath the furnace. 1. Remove the clamps from both ends of the drain hoses. 2. Remove the two screws holding the drain trap to the blower deck. -
Page 21: Counterflow Model Installed Vertically
1. (Draining the RF000142 Coupling) Locate hose #2 Drain Exiting Left Side (See Figure 28) (factory installed). Cut off and discard the 45° radius 1. Install a field supplied rubber coupling secured with end. a 1 1/4” clamp to enable removing the trap for future 2. - Page 22 1. Remove the drain trap and factory installed drain tube assemblies. 2. Remove two 1’’ plugs from right side of cabinet. 3. (Draining the Collector Box) From outside the cabinet, insert the non-grommet end hose #7 into the back drain hole and secure to collector box drain port using a silver clamp.
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Page 23: Electrical Connections
ELECTRICAL CONNECTIONS 6. Connect hose #4 & hose #2 together using a straight barbed coupling and two gold clamps (factory installed). Wiring Harness 7. (Draining the Vent Elbow) Remove rubber plug from The wiring harness is an integral part of this furnace. vent –... - Page 24 The integrated control module humidifier terminal 120V WARNING HUM-H is energized with 115 volts whenever the induced draft blower is energized. This terminal can also be used to provide 115 volt power to a humidifier transformer. The Edges of sheet metal holes may be sharp. Use gloves as a precaution when removing hole plugs.
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Page 25: Field-Installed Accessories
Field Installed Accessories 1. Measure resistance between the neutral (white) Additional accessories that do not have dedicated connection and one of the burners. terminals on the furnace control board may require an Resistance should measure 10 ohms or less. additional daughter board to be installed. Please refer to service manual on your product for more information. -
Page 26: Fossil Fuel Applications
Fossil Fuel Applications This furnace can be used in conjunction with a heat pump WARNING in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which Possible property damage, personal injury or death may occur if the correct conversion kits are not installed. -
Page 27: Gas Supply And Piping
If there are no alarms or faults, the furnace will go into Inlet gas supply pressures must be maintained within the regular run mode after a warm up period. The furnace ranges specified in the following table. The supply pressure control monitors the R-32 sensor once per second. -
Page 28: Gas Valve
• Gas piping must be supported external to the furnace cabinet so that the weight of the gas line does not Pressure Manifold distort the burner rack, manifold or gas valve. Altitude Orifice Switch Pressure Change • Use black iron or steel pipe and fittings for building piping. - Page 29 Aluminum alloy tubing must not be used in exterior Manual Shut Off Valve (upstream from ground joint pipe union) locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the Alternate Gas Line outside of the cabinet. A semi-rigid connector to the Location gas piping may be used from there.
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Page 30: Gas Piping Checks
Manual Shut Off Valve WARNING (upstream from ground joint pipe union) If the gas furnace is installed in a basement, an excavated area or confined space, it is strongly recommended to con- tact a propane supplier to install a gas detecting warning device in case of a gas leak. -
Page 31: Circulating Air & Filters
Since propane gas will quickly dissolve white lead and Too much external static pressure will result in insufficient most standard com mercial compounds, special pipe dope air that can cause excessive temperature rise. This can must be used. Always use a pipe thread sealant approved cause limit switch tripping and heat exchanger failure. -
Page 32: Bottom Return Air Opening [Upflow Models]
Filters - Read This Section Before Installing The Return Air Duct work WARNING Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship Edges of sheet metal holes may be sharp. Use gloves as a pre- with this furnace, but must be provided, sized and installed caution when removing sheet metal from return air openings. -
Page 33: Horizontal Installations
Consider installing an air cleaner with deep-pleated media filter at the time of furnace installation. A deep-pleated filter with a MERV rating of 8 (minimum) will often provide better filtration to protect equipment and the air distribution system than a standard 1” filter and often has lower static pressure loss than a 1”... -
Page 34: Gas Heat Sequence Of Operation
Check for leaks using an approved chloride-free soap and • The control module performs a gas valve circuitry water solution, an electronic combustible gas detector, check to verify gas valve relay state and presence of or other approved method. Verify that all required kits voltage at the valve. -
Page 35: Cooling Mode Sequence Of Operation
3. When the center switch is pressed, the current 1. Press the left or right switch until LED displays “AC1” displayed speed will be selected, and control will (for single stage COOLING) or “AC2” (for two-stage immediately apply that speed setting. COOLING). -
Page 36: Gas Supply Pressure Measurement
GAS SUPPLY PRESSURE MEASUREMENT Gas Pressure Test The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. -
Page 37: Operation Checks
Using a leak detection solution or soap suds, check for 1. Operate furnace with burners firing for approximately leaks at outlet or screw (White-Rodgers valve). Bubbles ten minutes. Ensure all registers are open and all forming indicate a leak. SHUT OFF GAS AND REPAIR ALL duct dampers are in their final (fully or partially open) LEAKS IMMEDIATELY! position. -
Page 38: Rollout Limit
• Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the WARNING connections at and internal to the furnace. • Heat exchanger. Check for corrosion and/or buildup Do not bypass safety devices. within the heat exchanger passageways. •... -
Page 39: Induced Draft And Circulator Blowers
REPAIR AND REPLACEMENT PARTS Burners Visually inspect the burner flames periodically during the heating season. Turn on the furnace at the thermostat and • When ordering any of the listed functional parts, be allow several minutes for flames to stabilize, since any sure to provide the furnace model, manufacturing, dislodged dust will alter the flames normal appearance. -
Page 40: Stage Status Codes
1 STAGE STATUS CODES LED Display Menu Description Notes Main Menu Option Menu Er r ( xx: code numbers ) Active Alarm menu ( xx: code numbers ) Last 10 Faults Code Release Number CR Number r Fd yes, no Reset to Factory Default ( xx: Blower Speed Number F01, Blower Speed for Continous Fan Mode... -
Page 41: Stage Troubleshooting Codes
1 STAGE TROUBLESHOOTING CODES Symptom Fault Description Corrective Actions Status Normal operation I dL Normal operation None Locate and correct gas interruption Check front cover pressure switch operation and verify proper drainage (hose, wiring, contact operation), correct if necessary Furnace lockout due to an excessive Replace or realign igniter Furnace fails to number of ignition “retries”... - Page 42 1 STAGE TROUBLESHOOTING CODES Symptom Fault Description Corrective Actions Status Open fuse Replace fuse No furnace operation Short in low voltage wiring Locate and correct short in low voltage wiring Flame sense micro amp signal is minimal Clean flame sensor if coated or oxidized Inspect for Flame sensor is coated/oxidized proper flame sensor alignment Flame sensor incorrectly positioned in...
- Page 43 1 STAGE TROUBLESHOOTING CODES Symptom Fault Description Corrective Actions Status Check for correct gas pressure Check for correct Furnace fails to Open roll out switch burner alignment operate Check for and correct burner restriction Furnace fails to Check for Ignitor wiring. Ignitor Open operate Replace Damaged Ignitor...
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Page 44: Airflow Charts
AIRFLOW CHARTS DR92SN FAN & COOLING AIFLOW EXTERNAL STATIC PRESSURE (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL Watts Watts Watts Watts F04^ DR92SN0403A Y/Y1, Y2, G 1038 1003 1106 1072 1041 1011 1215 1180 1151 1121 1095 1066 1043 1017 1238 1210... - Page 45 AIRFLOW CHARTS DR92SN HEATING AIRFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT TEMP MODEL TAP # CALL RANGE RISE RISE RISE RISE RISE F01^^ F02^ DR92SN0403A* W/W1 30-60 F01^^ F02^ 1052 1010 DR92SN0603B* W/W1 35-65 1125 1084 1042 1003 1206 1166 1129 1091...
- Page 46 AIRFLOW CHARTS DD96SN FAN & COOLING AIFLOW EXTERNAL STATIC PRESSURE (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL Watts Watts Watts Watts F04^ DD96SN0403B* Y/Y1, Y2, G 1106 1076 1044 1010 1156 1125 1096 1063 1028 1237 1205 1174 1145 1115 1081 1050...
- Page 47 AIRFLOW CHARTS DD96SN HEATING AIRFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT TEMP MODEL TAP # CALL RANGE RISE RISE RISE RISE RISE F01^^ F02^ DD96SN0403B* W/W1 35-65 F01^^ F02^ 1197 1150 1102 1057 1014 DD96SN0603B* W/W1 35-65 1309 1264 1224 1180 1141...
- Page 48 AIRFLOW CHARTS DR96SN FAN & COOLING AIFLOW EXTERNAL STATIC PRESSURE (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL Watts Watts Watts Watts 1079 1055 1027 F04^ DR96SN0403A Y/Y1, Y2, G 1135 1106 1078 1049 1021 1189 1163 1138 1111 1085 1059 1032 1001...
- Page 49 AIRFLOW CHARTS DR96SN HEATING AIRFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) MODEL TSTAT CALL TAP # TEMP RANGE RISE RISE RISE RISE RISE F01^^ F02^ 1079 1055 1027 DR96SN0403A* W/W1 25-55 F01^^ F02^ 1218 1178 1140 1100 1060 1016 DR96SN0603B* W/W1 35-65 1164...
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Page 50: Wiring Diagram
WIRING DIAGRAM DR92SN, DR96SN, & DD96SN SURFACE TO 115 VAC/ 1 /60 HZ POWER SUPPLY WITH IGNITER OVERCURRENT PROTECTION DEVICE VALVE FRONT COVER WARNING: DISCONNECT 2 CIRCUIT PRESSURE POWER BEFORE CONNECTOR SERVICING. WIRING SWITCH TO UNIT MUST BE PROPERLY POLARIZED DISCONNECT AND GROUNDED FLAME... -
Page 51: Special Instructions For Products Installed In The State Of Massachusetts
SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED IN THE STATE OF MASSACHUSETTS For all side wall horizontally vented gas fueled equipment EXEMPTIONS installed in every dwelling, building or structure used in The following equipment is exempt from 248 CMR 5.08(2) whole or in part for residential purposes, including those (a)1 through 4: owned or operated by the Commonwealth and where 1. -
Page 52: Start Up Checklist
START-UP CHECKLIST Furnace Model Number Serial Number ELECTRICAL Line Voltage (Measure L1 to N and N to Ground Voltage) L - N N - G Secondary Voltage (Measure Transformer Output Voltage) R - C Blower Amps BLOWER EXTERNAL STATIC PRESSURE Return Air Sta�c Pressure IN. - Page 53 THIS PAGE INTENTIONALLY LEFT BLANK...
- Page 54 THIS PAGE INTENTIONALLY LEFT BLANK...
- Page 55 THIS PAGE INTENTIONALLY LEFT BLANK...
- Page 56 CUSTOMER FEEDBACK Daikin is very interested in all product comments. Please fill out the feedback form on the following link: https://daikincomfort.com/contact-us You can also scan the QR code on the right to be directed to the feedback page. PRODUCT REGISTRATION Thank you for your recent purchase.
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