Daikin DR80TN Service Instructions Manual
Daikin DR80TN Service Instructions Manual

Daikin DR80TN Service Instructions Manual

Two stage furnace with nine speed ecm motor
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Two Stage Furnace with Nine Speed ECM Motor
Pride and workmanship go into every product to provide
our customers with quality products. It is possible, however,
that during its lifetime a product may require service.
Products should be serviced only by a qualified service
technician who is familiar with the safety procedures
required in the repair and who is equipped with the proper
tools, parts, testing instruments and the appropriate service
manual. REVIEW ALL SERVICE INFORMATION IN THE
APPROPRIATE SERVICE MANUAL BEFORE
BEGINNING REPAIRS.
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
(including children) with reduced physical, sensory or
mental capacities, or lack of experience and knowledge,
unless they have been given supervision or instruction
concerning 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
proper supervision or training may result in product
damage, property damage, personal injury or death.
This furnace may be paired with a cooling unit that uses
R-32 refrigerant. If the refrigeration unit paired with this
furnace does not use R-32, the R-32 function in the furnace
control board 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
installation manual of the indoor evaporator coil to
determine installation requirements for that supplier's
refrigerant detection system.
Copyright © 2021-2023
Service Instructions
Daikin DR80TN/DD80TN
WARNING
WARNING

TABLE OF CONTENTS

IMPORTANT INFORMATION ..........................................2
PRODUCT IDENTIFICATION ..........................................4
SYSTEM OPERATION .....................................................5
SCHEDULED MAINTENANCE ......................................15
SERVICING .....................................................................19
Checking Voltage ....................................................20
Checking Wiring ......................................................20
Checking Thermostat And Wiring .........................20
Motor (Multi-Speed ECM Motor) .........................21
Checking Air Circulator Blower
Motor (9-Speed ECM Motor) .................................21
Checking Duct Static .............................................21
Checking Temperature Rise ..................................22
Checking Primary Limit Control ..........................22
Checking Auxiliary Limit Control .........................23
Checking Flame Rollout Control ........................24
Induced Draft Blower Motor ...............................25
Checking Gas Valve (Redundant) .........................25
Checking Main Burners .........................................25
Checking Orifices ...................................................25
Checking Gas Pressure .........................................26
Checking Hot Surface Ignitor ..............................28
Checking For Flashback ........................................28
Checking Pressure Switch ..................................28
Checking For Delayed Ignition .............................29
Checking Flame Sensor .......................................29
AIRFLOW TABLES .........................................................30
TROUBLESHOOTING CHART ......................................35
WIRING DIAGRAMS ......................................................42
Do not bypass safety devices.
WARNING
RSD6621304
December 2023

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Summary of Contents for Daikin DR80TN

  • Page 1: Table Of Contents

    Service Instructions Daikin DR80TN/DD80TN Two Stage Furnace with Nine Speed ECM Motor Pride and workmanship go into every product to provide TABLE OF CONTENTS our customers with quality products. It is possible, however, that during its lifetime a product may require service.
  • Page 2: Important Information

    IMPORTANT INFORMATION WARNING IMPORTANT NOTICES FIRE OR EXPLOSION HAZARD RECOGNIZE SAFETY SYMBOLS, WORDS AND Failure to follow safety warnings exactly could result LABELS in dangerous operation, serious injury, death or property damage. • Improper servicing could result in dangerous operation, serious injury, death or property damage. •...
  • Page 3: For Your Safety Read Before Operating

    IMPORTANT INFORMATION FOR YOUR SAFETY READ BEFORE OPERATING WARNING : Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to the user’s information WARNING : If you do not follow these instructions manual provided with this furnace. For assistance exactly, a fire or explosion may result causing property or additional information consult a qualified damage, personal injury or loss of life.
  • Page 4: 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. 7,8,9 Brand Minor Revision D - Daikin A - Ini�al Release B - 1st Revision Configura�on R - Upflow/Horizontal Major Revision D - Downflow/Horizontal...
  • Page 5: System Operation

    SYSTEM OPERATION An electrical disconnect must be provided at the furnace location. WARNING NOTE: Line polarity must be observed when making If the information in these instructions is not followed exactly, a fire or explosion may result causing property field connections. damage, personal injury or loss of life.
  • Page 6: Volt Thermostat Wiring

    SYSTEM OPERATION USING A SINGLE-STAGE HEATING If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring THERMOSTAT must conform to all local codes, and have a minimum A single-stage heating thermostat may be used to control temperature rating of 105°C.
  • Page 7 SYSTEM OPERATION Strictly follow the wiring guidelines in the fossil fuel kit Turn OFF power to the furnace before installing any installation instructions. All furnace connections must be accessories. Follow the humidifier or air cleaner made to the furnace two-stage integrated control module manufacturers’...
  • Page 8 SYSTEM OPERATION Low Voltage Humidifier NOTE: This furnace is equipped with a control board that is capable of monitoring for R-32 The furnace integrated control module is equipped with a low voltage terminal for providing power to an optional refrigerant leaks in the indoor evaporator coil. field-supplied 24 volt humidifier.
  • Page 9 SYSTEM OPERATION • Closure of the 2nd stage pressure switch will energize the high fire stage of the gas valve. THERMOSTAT  AVAILABLE  • The 2nd stage gas heat speed of the indoor blower is CALL  SPEEDS    energized. F01  Heating Mode Speed Selection F02 ...
  • Page 10: Circulating Air And Filters

    SYSTEM OPERATION • When the center switch is pressed, the current Upflow furnaces with air delivery of less than 1800 CFM: displayed speed will be selected, and control will Use one side return or one bottom return ductwork apply the newly selected speed in next cooling call. connection.
  • Page 11 SYSTEM OPERATION R-32 INFORMATION A duct system should be installed in accordance with Standards of the National Board of Fire Underwriters for R-32 Function the Installation of Air Conditioning, Warm Air Heating and This furnace is equipped with a control board that is Ventilating Systems, Pamphlets No.
  • Page 12 SYSTEM OPERATION If there are no alarms or faults, the furnace will go into regular run mode after a warm up period. The furnace control monitors the R-32 sensor once per second. R-32 Refrigerant Leak If the R-32 sensor on the indoor evaporator coil detects a specified concentration of R-32 refrigerant, the furnace will enter Mitigation Mode to dilute the refrigerant concentrations in case of a leak.
  • Page 13 SYSTEM OPERATION 2 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,...
  • Page 14: Status Menu

    SYSTEM OPERATION 2 STAGE STATUS CODES STATUS MENU Main Mode Menu Idle  Continuous Fan  Compressor Cooling, Low Stage  Compressor Cooling, High Stage  Gas heat, Low Stage  Gas heat, High Stage  OEM test Mode ...
  • Page 15: Scheduled Maintenance

    SCHEDULED MAINTENANCE WARNING WARNING HIGH VOLTAGE HIGH VOLTAGE To avoid personal injury or death due to To avoid personal injury or death due to electrical shock, disconnect electrical power electrical shock, disconnect electrical power before servicing or changing any electrical before servicing or changing any electrical wiring.
  • Page 16 SCHEDULED MAINTENANCE Induced Draft and Circulation Blowers The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary. Check the burner flames for: Flame Sensor (Qualified Servicer Only) Under some conditions, the fuel or air supply can create a...
  • Page 17 SCHEDULED MAINTENANCE CLOCKING A GAS METER 1. Turn off all gas appliances in the home. 2. Turn on the furnace. Ensure the furnace is operating at a 100% firing rate on 2 stage and modulating furnace product. 3. Once heating cycle is at a steady state (typically 15 minutes of operation), use a stopwatch to time how long it takes the smallest unit of measure dial on the gas meter to make a full revolution.
  • Page 18 SCHEDULED MAINTENANCE 5. Use this formula to verify the Cubic Feet per Hour (CFH) input determined in step 4 is correct: (3600 x Gas Meter Dial Size) / Time (seconds) = Cubic Feet per Hour (CFH) 3600 is used as there are 60 seconds in a minute and 60 minutes in an hour.
  • Page 19: Servicing

    SERVICING As more and more electronics are introduced to the INCOMING POWER Heating Trade, Polarization of incoming power and phasing 120.00 0.00 of primary to secondary voltage on transformers becomes more important. Polarization has been apparent in the Appliance industry since the introduction of the three prong plug, however, the Heating Industry does not use a plug for incoming power, but is hard wired.
  • Page 20: Checking Voltage

    SERVICING CHECKING VOLTAGE CHECKING THERMOSTAT AND WIRING WARNING WARNING HIGH VOLTAGE Disconnect ALL power before servicing. Disconnect ALL power before servicing or installing this unit. Multiple power sources may be present. Failure to do so may cause 1. Remove the blower compartment door to gain property damage, personal injury or death.
  • Page 21: Checking Air Circulator Blower Motor (9-Speed Ecm Motor)

    SERVICING 1. Remove blower compartment door to gain access White neutral wire connected to the Neutral terminal to the thermostat low voltage wires located at the on the control board. furnace integrated control module. Black wire connected to the CIRC H terminal on the 2.
  • Page 22: Checking Temperature Rise

    SERVICING The furnace motor cannot deliver proper air quantities of the heat exchanger. An airflow and temperature rise (CFM) against statics other than those listed. table is provided in the blower performance specification section. Determine and adjust temperature rise as follows: Too great of an external static pressure will result in 1.
  • Page 23: Limit Fault Codes

    SERVICING If the limit circuit opens and does not close within five PRIMARY LIMIT CONTROL minutes, the control assumes the blower has failed the RED LED will flash ELEVEN times. If the limit circuit opens and does not close within fifteen minutes, the control assumes the manual rollout or fuse has opened and the RED LED will flash FIVE times.
  • Page 24: Checking Flame Rollout Control

    SERVICING CHECKING FLAME ROLLOUT CONTROL A temperature activated manual reset control is mounted to the manifold assembly as shown in the following illustration AUXILIARY LIMIT CONTROL LIMIT BLOWER HOUSING AUXILIARY LIMIT CONTROL Auxiliary Limit Control Location WARNING Flame Rollout Switch Location (90% Upflow Furnace Shown, Counterflow Similar) HIGH VOLTAGE Disconnect ALL power before servicing or...
  • Page 25: Induced Draft Blower Motor

    CHECKING ORIFICES DD80TN/DR80TN model furnaces have factory installed The valve provides control of main burner gas flow, #45 natural gas orifices. pressure regulation, and 100 percent safety shut-off.
  • Page 26: Checking Gas Pressure

    SERVICING 1. Check orifice visually for distortion and/or burrs. 2. Check orifice size with orifice sizing drills. High Fire Regulator Adjust Regulator Vent STREAM B Mode The length of Dimension “A” determines the angle of Gas Stream “B”. Common Terminal(C) DENT OR White-Rodgers Model 36J54 Connected to Manometer White-Rodgers Model 36J54 Connected to Manometer...
  • Page 27: Gas Manifold Pressure Measurement And Adjustment

    SERVICING GAS MANIFOLD PRESSURE 10. Remove regulator cover screw from the high (HI) outlet pressure regulator adjust tower and turn screw MEASUREMENT AND ADJUSTMENT clockwise to increase pressure or counterclockwise Only small variations in gas pressure should be made by to decrease pressure.
  • Page 28: Checking Hot Surface Ignitor

    SERVICING e. Remove the 1/8” NPT hose barb fitting from the 2. After checking and/or replacing of hot surface ignitor, outlet pressure tap. Replace the outlet pressure reinstall burner compartment door and verify proper boss plug and seal with a high quality thread unit operation.
  • Page 29: Checking For Delayed Ignition

    SERVICING INDUCED DRAFT BLOWER PRESSURE SWITCH WARNING PRESSURE SWITCH Line Voltage now present. HOSE OPEN TO ATMOSPHERE 1/4" TEE CHECKING FLAME SENSOR COIL COVER PRESSURE SWITCH A flame sensing device is used in conjunction with the -0.75 Mode ignition control module to prove combustion. If proof of INDUCED HOSE TO INDUCED flame is not present the control will de-energize the gas...
  • Page 30: Airflow Tables

    AIRFLOW TABLES DR80TN FAN & COOLING AIRFLOW EXTERNAL STATIC PRESSURE (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL Watts Watts Watts Watts 1130 1090 1059 1022 F04^ DR80TN0403A* Y/Y1, Y2, G 1158 1113 1090 1057 1024 1270 1235 1208 1179...
  • Page 31 AIRFLOW TABLES DR80TN FAN & COOLING AIRFLOW EXTERNAL STATIC PRESSURE (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL Watts Watts Watts Watts 1420 1359 1301 1254 1206 1152 1100 1044 1825 1769 1718 1673 1629 1584 1540 1497 F04^ 1623...
  • Page 32 AIRFLOW TABLES DR80TN HEATING AIRFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) T. STAT TEMP MODEL TAP # CALL RANGE RISE RISE RISE RISE RISE F01^ W/W1 F03^^ DR80TN0403A* 15 - 45 F02^ 1130 1090 1059 1022 1158 1113 1090 1057...
  • Page 33 AIRFLOW TABLES DD80TN FAN & COOLING AIRFLOW EXTERNAL STATIC PRESSURE (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL Watts Watts Watts Watts 1120 1081 1053 1022 F04^ DD80TN0403A* Y/Y1, Y2, G 1000 1212 1198 1161 1138 1103 1076 1037 1007 1362 1342 1307...
  • Page 34 AIRFLOW TABLES DD80TN HEATING AIRFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) T. STAT TEMP MODEL TAP # CALL RANGE RISE RISE RISE RISE RISE F01^ F03^^ W/W1 DD80TN0403A* 15 - 45 F02^ 1120 1081 1053 1022 1000 F01^ W/W1 F03^^ DD80TN0603A* 25-55 F02^...
  • Page 35: Troubleshooting Chart

    TROUBLESHOOTING 2 STAGE TROUBLESHOOTING CODES Symptom Fault Description Corrective Actions Status Normal operation I dL Normal operation None Locate and correct gas interruption Replace or realign igniter Furnace lockout due to an excessive Furnace fails to number of ignition “retries” (3 total) Check flame sense signal, clean sensor if coated or operate Failure to establish flame...
  • Page 36 TROUBLESHOOTING 2 STAGE TROUBLESHOOTING CODES Symptom Fault Description Corrective Actions Status Flame sensed with no call for heat Correct short at flame sensor or in flame sensor wiring Induced draft blower and circulator blower Short to ground in flame sense circuit Check for lingering or lazy flame Verify proper runs continuously Lingering burner flame Slow closing gas...
  • Page 37 TROUBLESHOOTING 2 STAGE TROUBLESHOOTING CODES Symptom Fault Description Corrective Actions Status Gas valve is energized when it should not Check wiring in gas valve circuit Furnace fails to operate Internal gas valve error Replace integrated control board Furnace fails to operate. No 115 power to furnace or no 24 volt Restore high voltage power to furnace and integrated power to integrated control module.
  • Page 38 Troubleshooting 80% Heating (2 Stage) No Heat Is furnace power switch and Turn Power On. Set thermostat breaker turned to heat. on? Is thermostat properly set? 115 VAC at Check furnace breaker, switch, line H & Line door switch N on control board 115 VAC at Check transformer primary...
  • Page 39 Troubleshooting 80% Heating (2 Stage) Check burners for dirt, check for burner alignment, check Do burners position of orifice plate between light burners and H/E Is flame stable, Check orifice plate position for properly proper alignment with H/E Do burners enveloping flame tubes, check for flooded or stay on...
  • Page 40 Troubleshooting Error Codes - (E0 - 80%) Board flashes Error Code: E0 - Lockout due to an excessive number of ignition retries (3 total) Is hot surface Verify 115VAC present at ignitor. Applicable Models: Are burners ignitor Replace if voltage is present firing up? All 80% models glowing?
  • Page 41 Brand ® Check wiring in pressure AR9T, GR9T switch circuit. Does Repair short in wiring pressure switch circuit For Daikin wiring have any shorts to DR**TN other wires or short to ground? Method of Error Detection: Pressure Switch during heating operation.
  • Page 42: Wiring Diagrams

    WIRING DIAGRAMS TWO STAGE GAS VALVE SURFACE (WHITE IGNITER TO 115 VAC/ 1 /60 HZ RODGERS) POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE ID BLOWER TWO-STAGE PRESSURE 2 CIRCUIT SWITCH ASSEMBLY WARNING: DISCONNECT CONNECTOR POWER BEFORE SERVICING. WIRING TO UNIT MUST BE LOW FIRE HIGH FIRE PROPERLY POLARIZED...

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