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DR96TC* & DD96TC* Two-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.
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 herein take
precedence.
RECOGNIZE THIS SYMBOL
AS A SAFETY PRECAUTION.
Do not bypass safety devices.
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 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 installation 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.
©
2024
IOD-2044
04/2024
Installation Instructions for
Installer:
Affix all manuals
adjacent to the unit.
WARNING
WARNING
19001 Kermier Rd., Waller, TX 77484
www.daikincomfort.com
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.
WARNING
DO NOT LIFT
PRODUCT USING
HEAT EXCHANGER
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Summary of Contents for Daikin DD96TC Series
- Page 1 Installation Instructions for DR96TC* & DD96TC* Two-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 WARNING in the American National Standard/National Standard of Canada ANSI Z21.47•CSA-2.3 Gas Fired Central Only personnel that have been trained to install, adjust, Furnaces.
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Page 2: Table Of Contents
Startup Procedure & Adjustment ......38 This device, which was assembled by Daikin Comfort Technologies Normal Sequence of Operation ....... 42 Manufacturing, L.P., contains a component that is classified as an Safety Circuit Description ........42 intentional radiator. This intentional radiator has been certified by the Troubleshooting ............ -
Page 3: Fire Or Explosion Hazard
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 4: Shipping Inspection
WARNING WARNING Heating unit should not be utilized without reasonable, Should overheating occur or the gas supply fail to shut routine, inspection, maintenance and supervision. If the off, turn off the manual gas shutoff valve external to the building in which any such device is located will be vacant, furnace before turning off the electrical supply. -
Page 5: Location Requirements & Considerations
• It must be installed as a two-pipe systems for NOTE: The Commonwealth of Massachusetts combustion air. requires that the following additional • All other warranty exclusions and restrictions apply requirements must also be met: This furnace is an ETL dual-certified appliance and is appropriate for use with natural or propane gas •... - Page 6 - printing inks WARNING - chlorinated waxes or cleaners - paint removers - chlorine-based swimming pool chemicals Possible property damage, personal injury or death due to fire, explosion, smoke, soot, condensation, electrical shock - varnishes or carbon monoxide may result from improper installation, - water softening chemicals repair operation, or maintenance of this product.
- Page 7 • Counterflow Installation over a combustible floor. NOTE: Installations must adhere to the clearances If installation over a combustible floor becomes to combustible materials to which this furnace necessary, use an accessory subbase (see has been design certified. The minimum clearance information for this furnace is provided on the Specification Sheet applicable for your model for details).
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Page 8: Combustion & Ventilation Air Requirements
2. Inspect the venting system for proper size and House depressurization can cause back drafting or horizontal pitch, as required by the National Fuel Gas improper combustion of gas-fired appliances, thereby Code, ANSI Z223.1 or the Natural Gas and Propane exposing building occupants to gas combustion products Installation Code, CAN/CSA B149.1-15 and these that could include carbon monoxide. - Page 9 AVERTISSEMENT WARNING RISQUE D’INTOXICATION AU MONOXYDE DE CARBONE CARBON MONOXIDE POISONING HAZARD Si les étapes décrites ci-dessous ne sont pas suivies pour Failure to follow the steps outlined below for each chacun des appareils raccordés au système de ventilation appliance connected to the venting system being placed into au moment de sa mise en marche, cela peut entraîner une operation could result in carbon monoxide poisoning or intoxication au monoxyde de carbone ou la mort.
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Page 10: Horizontal Applications & Considerations
HORIZONTAL APPLICATIONS & CONSIDERATIONS PROVIDE 8” MINIMUM CLEARANCE BETWEEN CENTER ROD AND FURNACE CABINET TO ALLOW FOR CIRCULATOR BLOWER REMOVAL ASSURE FURNACE IS LEVEL FROM 3/8” DIAMETER END TO END AND HAS A SLIGHT THREADED ROD FORWARD TILT WITH THE FRONT (6 PLACES) OF THE FURNACE 0”-3/4”... -
Page 11: Freeze Protection
Leveling VENTING MATERIAL REQUIREMENTS Leveling ensures proper condensate drainage from ASTM STANDARD the heat exchanger. For proper flue pipe drainage, the SCHEDULE 40 PIPE D1785 furnace must be level lengthwise from end to end. The SDR 21 or 26 PIPE D2241 furnace should have a slight tilt from back to front with the D1784, UL 1738... -
Page 12: Pipe Installation
Pipe Installation This furnace is manufactured with 2” CPVC vent & intake WARNING couplings. Use transition cement to connect PVC or ABS pipe to these fittings. For furnaces requiring installation To avoid bodily injury, fire or explosion, solvent cements of 3” pipe, the transition from 2” to 3” should be done as must be kept away from all ignition sources (i.e., sparks, open close to the furnace as possible, and only when the piping flames, and excessive heat) as they are combustible liquids. -
Page 13: Termination Locations
DR96TC/DD96TC Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe) Maximum Allowable Length of Vent/Flue Pipe & Combustion Air Pipe (ft) Pipe Size Number of Elbows MODEL (in.) DR96TC0403BN DR96TC0603BN DR96TC0803BN DR96TC0804CN DR96TC1005CN DR96TC1005DN DR96TC1205DN DD96TC0403BN DD96TC0603BN DD96TC0804CN DD96TC1005CN DD96TC1205DN Table 4 Termination Locations... - Page 14 WARNING WARNING Edges of sheet metal holes may be sharp. Use gloves as a The rubber elbow is not designed to support a load. When precaution when removing hole plugs. the rubber elbow is mounted externally to the furnace cabinet, extreme care must be taken to adequately support field-supplied vent/flue piping, as damage can result in leaks causing bodily injury or death due to exposure to flue gases, including carbon monoxide.
- Page 15 Vent & combustion air pipes may terminate vertically through a roof, or horizontally through an outside wall. The combustion air intake and vent pipe can be terminated in two different pressure zones. The intake pipe can be terminated on one side of the building, while the flue vent can be terminated on another side of the building or through the roof.
- Page 16 10”- 24” 6” MAX 6” MAX 4” MIN 4” MIN 12" MIN. TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL Standard Horizontal Terminations (Dual Pipe) 12" MIN. TO GRADE OR Figure 15 HIGHEST ANTICIPATED SNOW LEVEL DOWN VENTING UPFLOW MODEL FURNACES ONLY Standard Horizontal Vent Termination (Dual Pipe) Figure 18 Use alternate vent...
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Page 17: Vent/Intake Terminations For Installation Of Multiple Direct Vent Furnaces
If more than one direct vent furnace is to be installed horizontally through a common side wall, maintain the clearances as in the following figure. Always terminate all VENT/FLUE exhaust vent outlets at the same elevation and always terminate all air intakes at the same elevation. Concentric Vent Termination Refer to the directions provided with the Concentric Vent DISTANCE BETWEEN... -
Page 18: Approved Carbon Monoxide Detectors
a. In the event that the side wall horizontally d. MANUFACTURER REQUIREMENTS - GAS vented gas fueled equipment is installed in a EQUIPMENT VENTING SYSTEM NOT crawl space or an attic, the hard wired carbon PROVIDED. When the manufacturer of a monoxide detector with alarm and battery back- Product Approved side wall horizontally up may be installed on the next adjacent floor... -
Page 19: Upflow Model Installed Vertically
The condensate must be collected in the furnace drain trap Upflow Model Installed Vertically and routed to an appropriate drain location in compliance The trap and factory installed hoses remain as shipped. with local and national codes. The furnace drain may exit either the right or left side of the furnace cabinet. -
Page 20: Drain Exiting Left Side
Drain Exiting Left Side 7. Use two silver clamps and secure the hoses to drain 1. Install the 45 degree pipe / hose drain coupling from trap. The trap outlet faces the front of the furnace. the outside of the cabinet (barbed end goes in the Secure the trap to the cabinet using two screws cabinet) through the hole in the left side of the cabinet removed in step 2 by inserting the two screws through... -
Page 21: Counterflow Model Installed Vertically
10. Connect hose #6 & hose #5 using 100º elbow and 9. Install the non-grommet end of hose #11 from outside secure with two red clamps the cabinet in the upper drain hole. Install on collector 11. (Draining the Collector Box) Remove cap from left box and secure with a silver clamp. - Page 22 Drain Exiting Right Side Counterflow Model Installed Horizontally with Right Side Down Minimum 5 ½” clearance is required for the drain trap beneath the furnace. NOTE: For horizontal installations, some of the required hoses are found in the factory-installed hose assemblies. Remove the hose clamps to obtain the respective hoses needed for installation, and install per the following directions.
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Page 23: R-32 Information
Counterflow Model Installed Horizontally 14. Connect the 4” straight section of hose #4 to the 100º with Left Side Down elbow and the PVC pipe and secure with red clamps. 15. Connect the hoses to the trap inlets and secure * Also see Front Cover Pressure Switch Tube Location on page 10. -
Page 24: Gas Supply And Piping
Furnace Start up INLET GAS SUPPLY PRESSURE During furnace start up, the furnace control will identify the Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c. connected R-32 sensor and will start monitoring the sensor Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c. communication. -
Page 25: Propane Gas Conversion
The high altitude, kit will provide the proper design certified input rate within the specified altitude range. WARNING Do not derate the furnace by adjusting the manifold To avoid possible unsatisfactory operation of equipment damage due to underfiring or equipment, use the proper size pressure to a lower pressure than specified on the furnace of natural/propane gas piping needed when running pipe from rating plate. - Page 26 • Install a 1/8” NPT pipe plug fitting, accessible for test Manual Shut Off Valve Alternate Manifold Burners (upstream from Gas Line gage connection, immediately upstream of the gas ground joint Location supply connection to the furnace. pipe union) • Always use a back-up wrench when making the connection to the gas valve to keep it from turning.
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Page 27: Gas Piping Checks
Manual Shut Off Valve (upstream from 5 to 15 PSIG ground joint First Stage (20 PSIG Max.) pipe union) Regulator Continuous 11" W.C. 200 PSIG Second Stage Maximum Regulator Propane Gas Installation (Typ.) Figure 39 A gas detecting warning system is the only reliable way to detect a propane gas leak. -
Page 28: Checking Duct Static
Install the duct system in accordance with Standards of For example: Difference is .4 the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B. A closed return duct system must be used, with the return duct connected to the furnace. -
Page 29: Horizontal Installations
Filters - Read This Section Before Installing SUPPLY The Return Air Duct CUT USING TIN SNIPS CUTAWAY OF DUCTWORK TO EXPOSE COIL DIGITAL MANOMETER SCRIBE LINES OUTLINING DUCT FLANGES Dual Flange Cut Outs . RETURN Figure 41 Mode Filters must be used with this furnace. Discuss filter maintenance with the building owner. - Page 30 Clean Comfort™ brand MERV 11 air cleaners have 5¼” media filters and are available in the following configurations. Consult your distributor for information on our complete line of IAQ Clean Comfort™ products. Model Minimum Recommended Filter Size^ DR96TC0403BN* 1 - 16 X 25 Side or Bo�om DR96TC0603BN* 1 - 16 X 25 Side or Bo�om Figure 46...
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Page 31: Electrical Connections
ELECTRICAL CONNECTIONS Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side electrical WARNING connection with the junction box located inside the burner compartment (blower compartment for downflows). - Page 32 CoolCloud™ HVAC Phone Application stages including dual fuel operation based on these inputs. Actual screens may look different based on the mobile Any single-stage 24VAC thermostat can be used. For device being used. proper operation the thermostat must be setup to control a single-stage AC outdoor unit and to control a single stage gas furnace.
- Page 33 NOTE: When new versions of Bluetooth Quick Start Guide For Non-Communicating Communication Software and Furnace Control Outdoor Units Software are available, the phone application EXTREMELY IMPORTANT: For two-stage gas notifies the user. Software updates are classified heating, the system only needs a single W input. as either optional or mandatory and installed by Internal algorithms will control staging of the using the phone application.
- Page 34 INDOOR BOARD TERMINAL CONNECTIONS 24 VAC Heat Pump Thermostat Optional Optional Optional Non-Communicating Single Stage Heat Pump Figure 56 INDOOR BOARD TERMINAL CONNECTIONS Two Stage 24 VAC 4. Go to the tonnage units menu (ton) and select the Heat Pump Thermostat tonnage value that corresponds to the desired airflow for the outdoor unit.
- Page 35 Indoor NOTE: For two stage non-communicating outdoor units, system will stage airflow automatically for Board Terminal 24 VAC low stage operation. Connections Thermostat Tonnage Tonnage Tonnage Tonnage Airflow Airflow Airflow Airflow Selection Selection Selection Selection 1440 1960 1480 2000 1000 1520 2040 1040...
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Page 36: Auxiliary Alarm Switch
Dehumidification NOTE: After scrolling to the desired option Dehumidification allows the furnace’s circulator blower to within a menu, that option may be flashing on the operate at a reduced speed during a combined thermostat 7-segment displays. This indicates the option has not been officially selected. - Page 37 Ramping Profiles • Profile B (2) ramps up to full cooling demand airflow The variable-speed circulator offers four different ramping by first stepping up to 50% of the full demand for profiles. These profiles may be used to enhance cooling 30 seconds.
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Page 38: Field-Installed Accessories
• Profile C (3) ramps up to 85% of the full cooling • All field wiring must conform to applicable codes. demand airflow and operates there for approximately • If it is necessary for the installer to supply additional 7 1/2 minutes. The motor then steps up to the full line voltage wiring to the inside of the furnace, the demand airflow. -
Page 39: Furnace Startup
Drain Trap Priming Gas Supply Pressure Measurement The drain trap MUST be primed prior to furnace startup. To prime, fill both sides of the drain trap with water. This ensures proper furnace drainage upon startup and prohibits the possibility of flue gases escaping through the drain system. -
Page 40: Gas Manifold Pressure Measurement And Adjustment
NOTE: If using the inlet pressure tap on the White- Rodgers 36J54 gas valve, then use the 36G/J Valve Pressure Check Kit, Part No. 0151K00000S. 3. Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line. -
Page 41: Temperature Rise
3. If the 1/2 cu. ft. dial was used, multiply your number by two. EXAMPLE: If it takes 23 seconds to complete one revolution of the 1/2 ft. dial (23 x 2 = 46). SUPPLY This tells us that at this rate, it would take 46 seconds to consume one cu. -
Page 42: Normal Sequence Of Operation
NORMAL SEQUENCE OF OPERATION • Circulator blower continues running for the selected heat off delay period. The blower speed during this period depends on the last heat call provided by the Power Up thermostat. If the last call for heat was a call for low The normal power up sequence is as follows: heat, the air circulator motor will run on low heat •... -
Page 43: Rollout Limit
Auxiliary Limit 1. Disconnect all power to the furnace. Do not touch The auxiliary limit controls are located on or near the the integrated control module or any wire connected circulator blower and monitors blower compartment to the control prior to discharging your body’s temperatures. -
Page 44: Maintenance
MAINTENANCE The bearings in the induced draft blower and circulator Annual Inspection blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check WARNING motor windings for accumulation of dust which may cause overheating. Clean as necessary. To avoid electrical shock, injury or death, Condensate Trap and Drain System disconnect electrical power before... -
Page 45: Menu Options
MENU OPTIONS Menu Description Menu Description Display Display Percentage of high stage gas heating airflow to run Aux (condensate switch enabled) SE during low St Enable or disable inverter boost operation. stage gas heat operation. (default = 70%) (compressor speed may increase when this feature is St Gas Heat Airflow Trim (default = 0%) t... -
Page 46: Status Codes
MENU OPTIONS STATUS CODES Menu Description Description of System Status Display Display Menu is enabled if the CFS menu is set to 6. Select the Compressor Cooling, Low Stage (non-communicating target time the system will attempt to satisfy the ... -
Page 47: Troubleshooting Chart
TROUBLESHOOTING CHART Symptom Fault Description Corrective Actions Status Populate shared data set using CoolCloud Furnace fails to operate Equipment lacks shared data HVAC App Normal operation Normal operation None Furnace fails to operate No 115 power to furnace or no 24 volt power to Restore high voltage power to furnace and integrated control module. - Page 48 TROUBLESHOOTING CHART Symptom Fault Description Corrective Actions Status Check filters for blockage, clean filters or remove obstruction. Check ductwork for blockage and verify all Furnace operates at reduced registers are fully open. performance or operates on low Airflow is lower than demanded ...
- Page 49 TROUBLESHOOTING CHART Symptom Fault Description Corrective Actions Status NOTE: Allow time as the control may take up to 90 seconds to detect sensors. Verify that the sensor probe is plugged in all the way. Verify that the sensor probe connector is Supply air temperature reading not Supply Air Temperature Sensor Circuit is Open properly crimped.
- Page 50 TROUBLESHOOTING CHART Symptom Fault Description Corrective Actions Status 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 number of ignition “retries” (3 total). Replace or realign igniter.
- Page 51 TROUBLESHOOTING CHART Symptom Fault Descrip�on Correc�ve Ac�ons Status Check and correct wiring from integrated control module to igniter Problem with igniter circuit Diagnose and replace shorted igniter as needed Improperly connected or shorted igniter Furnace fails to operate Verify and correct unit ground wiring if needed Poor unit ground Igniter relay fault on integrated control module Check igniter output from control, replace if necessary...
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Page 52: Wiring Diagram
WIRING DIAGRAM JUNCTION BOX Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. -
Page 53: 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 Static Pressure IN. - Page 54 THIS PAGE INTENTIONALLY LEFT BLANK...
- Page 55 THIS PAGE INTENTIONALLY LEFT BLANK...
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Page 56: Customer Feedback
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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