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Installation Instructions for DR96SC &
DD96SC Ultra Low NOx Variable Speed Gas
Furnace
(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.
ATTENTION INSTALLING PERSONNEL
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.
R
ECOGNIZE THIS SYMBOL
AS A SAFETY PRECAUTION
NOTE: Please contact your distributor or our website listed below
for the applicable Specification Sheet referred to in this manual.
Our continuing commitment to quality products may mean a change in specifications without notice.
IOD-2042
04/2024
Installer: Affix all manuals
adjacent to the unit.
©2024
19001 Kermier Rd., Waller, TX 77484
www.daikincomfort.com
INSTALLATION INSTRUCTIONS
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 CAPABILITIES, 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.
DO NOT BYPASS SAFETY DEVICES
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 410-A OR R-32 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.
WARNING
WARNING
WARNING
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Summary of Contents for Daikin DR96SC
- Page 1 INSTALLATION INSTRUCTIONS Installation Instructions for DR96SC & WARNING DD96SC Ultra Low NOx Variable Speed Gas Furnace 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.
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Page 2: Table Of Contents
CONTENTS This device, which was assembled by Daikin Comfort Technologies Manufacturing, L.P., contains a component that is classified as an Safety Considerations ..........3 intentional radiator. This intentional radiator has been certified by the Product Application ............5 FCC: FCC ID QOQBGM111. And this international radiator has an Location Requirements &... -
Page 3: Safety Considerations
Combustion products must be discharged to the outdoors. WARNING Connect this furnace to an approved vent system only, as specified in VENT/FLUE PIPE & COMBUSTION AIR PIPE section of this manual. Changes or modifications not expressly approved by the par- ty responsible for compliance could void the user’s authori- ty to operate the equipment. - Page 4 WARNING If the information in these instructions is not followed exactly, a fire or explosion 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 5: Shipping Inspection
Shipping Inspection 4. Discharge your body to ground before removing a All units are securely packed in shipping containers new control from its container. Follow steps 1 through tested according to International Safe Transit Association 3 if installing the control on a furnace. Return any old specifications. -
Page 6: Location Requirements & Considerations
• Direct vent (dual pipe) central forced air furnace CSA International in which all combustion air supplied directly to the 8501 East Pleasant Valley Road furnace burners through a special air intake system Independence, OH 44131-5516 outlined in these instructions. NOTE: Meeting the following conditions is The rated heating capacity of the furnace should be greater a requirement when using this furnace as a... -
Page 7: Clearances And Accessibility
Permanent wave solutions precedence over clearances from the enclosure Chlorinated waxes or cleaners where accessibility clearances are greater. Chlorine-based swimming pool chemicals Carbon tetrachloride DR96SC/DD96SC MINIMUM CLEARANCES Water softening chemicals TO COMBUSTIBLE MATERIALS (INCHES) Swimming pool chemicals POSITION* SIDES REAR... -
Page 8: Combustion & Ventilation Air Requirements
Existing Furnace Removal Consult the instructions packaged with the thermostat for The following vent testing procedure is reproduced from mounting instructions and further precautions. the American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47, COMBUSTION & VENTILATION AIR CSA-2.3 latest edition Section 1.23.1. -
Page 9: Horizontal Applications & Considerations
HORIZONTAL APPLICATIONS & CONSIDERATIONS When installing a furnace horizontally, additional consideration must be given to the following: Furnace Suspension If suspending the furnace from rafters or joists, use 3/8” threaded rod and 2”x2”x1/8” angle iron as shown in the following diagram. The length of rod will depend on the application and the clearances necessary. -
Page 10: High Altitude Installation
Leveling “combustion air” pipe. This furnace is dual certified and may be installed as a Leveling ensures proper condensate drainage from the non-direct vent (single pipe) or direct vent (dual pipe) heat exchanger. For proper flue pipe drainage, the furnace appliance. -
Page 11: Installation
runs of piping must be supported every three to five VENTING MATERIAL REQUIREMENTS feet. Condensation within the furnace secondary heat ASTM STANDARD exchanger and in the vent pipe is a normal occurrence. SCHEDULE 40 PIPE D1785 Vent pipe must be installed to maintain a minimum 1/4 inch SDR 21 or 26 PIPE D2241 per foot downward slope toward the furnace to return... -
Page 12: Pipe Sizing
Figure 4 NOT ACCEPTABLE NO TRANSITION ON HORIZONTAL PLANE, THIS CREATES A WATER TRAP AND RESTRICTS FLUE GASES Figure 5 Precautions must be taken to prevent condensate from freezing inside the vent pipe. All vent piping exposed to Increased Clearance Configuration freezing temperatures must be insulated with 1/2”... - Page 13 drain tube free-draining to proper condensate disposal location. A loop in the drain tube can serve as a trap. The unused RF000142 drain fitting should be capped. A field supplied tee installed in the vent and/or intake pipe is also an acceptable method of capturing condensation.
- Page 14 2. Insert the 3” cabinet plug from the drain bag assembly in the unused combustion air hole. 3. Drill a pilot hole at the cabinet dimple (size dictated by knockout tool used). 4. Use a knockout tool to create a 3” diameter hole. 5.
- Page 15 Figure 12 Horizontal vent pipe terminations should be as shown in TEE (OPTIONAL) the following figures. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and COMBUSTION AIR INTAKE 12”...
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Page 16: Vent/Intake Terminations For Installation Of Multiple Direct Vent Furnaces
12" MIN. 90° ELBOWS VENT/FLUE TEE ( OPTIONAL) 45° ELBOW TURNED DOWN or 90° ELBOW TURNED DOWN 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL Combustion Air Intake may also be snorkeled to obtain 12” min ground clearance. Horizontal Termination (Single Pipe) Alternate Vent Termination Above Anticipated Snow Level Above Highest Anticipated Snow Level (Dual Pipe) -
Page 17: Concentric Vent Termination
Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups. • The drain trap supplied with the furnace must be 10”MIN used. 24”MAX •... -
Page 18: General Drain Information
General Drain Information All furnace models come with a factory installed drain trap. For vertical installations, the trap will remain in the factory position. All furnace models installed horizontally require the trap to be relocated. Many drain hoses have a built-in grommet which will provide a cabinet seal when installed. - Page 19 Front Cover Hose #6 Hose #11 Hose #2 Pressure Switch Hose #11 Hose #5 Tube Location Figure 26 Figure 27 NOTE: Horizontal Drain Kit 0270F05404 needed for Horizontal Installation with Left Side Down horizontal installations. Minimum 5 ½” clearance is required for the drain trap beneath the furnace.
- Page 20 13. Use two silver clamps and secure the hoses to drain 10. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through...
- Page 21 end of hose #9 into the cabinet front drain hole and secure on collector box drain port with a silver clamp. 6. Mate the drain trap inlets to the hoses and secure with silver clamps. 7. Line up the trap mounting holes with the pre-drilled holes in the furnace and secure with 2 screws removed in step 2.
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Page 22: Electrical Connections
115 Volt Line Connections Hose #4 Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be NEC Class 1, and must comply with all applicable codes. -
Page 23: Junction Box Relocation
Junction Box Relocation Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a left side electrical connection. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the left side prior to making electrical connections. - Page 24 control a single-stage AC outdoor unit and a single-stage notifies the user. Software updates are classified gas furnace. The control board does not accommodate an as either optional or mandatory and installed by using the phone application. Ensure installation O wire thermostat input (reversing valve signal). If using a heat pump, set up the thermostat, as stated above.
- Page 25 needs replacement. INDOOR BOARD TERMINAL CONNECTIONS EXTREMELY IMPORTANT: For two-stage gas heating, the system only needs a single W input. Internal algorithms will control the staging of the gas furnace automatically based on the single W input. For non-communicating outdoor unit 24 VAC wiring, see instructions below.
- Page 26 NOTE: For two-stage non-communicating outdoor Indoor units, the system will stage airflow automatically Board Terminal for low stage operation. 24 VAC 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 27: Auxiliary Alarm Switch
terminal when dehumidification is required, set the control instructions). board “dHL” (Dehum Logic) menu setting to “HI” using the 3. If the thermostat is capable of providing a continuous pushbuttons or CoolCloud HVAC phone application. If the fan call (G signal) during accessory operation: humidistat opens on humidity rise or the thermostat de- Make sure to connect the thermostat G terminal to the energizes this terminal when dehumidification is required,... - Page 28 100% CFM Figure 48 • Profile D (4) ramps up to 50% demand for 1/2 minute, then ramps to 85% of the full cooling demand for 7 1/2 minutes. Once elapsed, the motor runs at 100% capacity for the remainder of the cycle, and provides a post-cycle OFF delay at 50% airflow.
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Page 29: R-32 Features
cabinet. Once the R-32 sensor stops detecting a leak, the fan will continue to run for 5 minutes. After the 5 minutes, if there are no other alarms or faults, the control will de-energize the R-32 FEATURES optional ventilation and alarm outputs and then go back to the original operating mode per the thermostat. -
Page 30: Gas Supply And Piping
GAS SUPPLY AND PIPING 54, National Fuel Gas Code for proper purging methods. In Canada, follow approved purging methods in CAN/CSA B149.1-15. CAUTION Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, To prevent unreliable operation or equipment damage, the gas manifold pressure must be as specified on the unit or other approved method. - Page 31 required, specific gravity of the gas, and length of the run. Natural Gas Capacity of Pipe The gas line installation must comply with local codes, or In Cubic Feet of Gas Per Hour (CFH) in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1 Length of Nominal Black Pipe Size...
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Page 32: Gas Piping Checks
A semi-rigid connector to the gas piping can be used Manual Shut Off Valve Alternate (upstream from outside the cabinet per local codes. ½” NPT pipe and Union ground joint pipe union) fittings are required. Model requires one 90 degree elbow, Location one 2”... -
Page 33: Circulating Air & Filters
WARNING To determine total external duct static pressure, proceed as follows: 1. With clean filters in the furnace, use a manometer to If the gas furnace is installed in a basement, an excavat- ed area or confined space, it is strongly recommended to measure the static pressure of the return duct at the contact a certified contractor to install a gas detecting inlet of the furnace (Negative Pressure). -
Page 34: Bottom Return Air Opening [Upflow Models]
Bottom Return Air Opening [Upflow Models] Filters - Read This Section Before Installing The The bottom return air opening on upflow models utilizes Return Air Duct work a “lance and cut” method to remove sheet metal from the Filters must be used with this furnace. Discuss filter duct opening in the base pan. -
Page 35: Horizontal Installations
AIR FLOW Regulator Cover Screw SIDE RETURN EXTERNAL FILTER RACK KIT (EITHER SIDE) 10.0 Mode White-Rodgers Model 36J22Y-204 Connected to Manometer Figure 56 Possible Upright Upflow NOTE: If measuring gas pressure at the drip leg, a Figure 55 field-supplied hose barb fitting must be installed Horizontal Installations prior to making the hose connection. -
Page 36: Gas Manifold Pressure Measurement And Adjustment
decrease pressure. Replace regulator cover screw. 9. Turn off all electrical power and gas supply to the system. 10. Remove the manometer hose from the hose barb fitting or outlet pressure tap. 11. Replace outlet pressure tap: White-Rodgers 36J22 valve: Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum). -
Page 37: Operational Checks Safety Circuit Description
OPERATIONAL CHECKS 4. Turn ON gas to and relight all other appliances turned off in step 1. Be certain that all appliances SAFETY CIRCUIT DESCRIPTION are functioning properly and that all pilot burners (if applicable) are operating. CAUTION Temperature Rise Air temperature rise is the temperature differench between To avoid personal injury or death, do not remove internal supply and return air. -
Page 38: Troubleshooting
Pressure Switches The pressure switches are normally open (closed during Improper filter maintenance is the most common cause of operation) negative air pressure activated switches. They inadequate heating or cooling performance. Filters should monitor the airflow (combustion air and flue products) be cleaned (permanent) or replaced (disposable) every two through the heat exchanger via pressure taps located on months or as required. -
Page 39: Before Leaving An Installation
Condensate Trap and Drain System (Qualified Servicer Only) Annually inspect the drain tubes, drain trap, and field- supplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary. Flame Sensor (Qualified Servicer Only) Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. -
Page 40: Menu Options
MENU OPTIONS Menu Description Menu Description Display Display Aux (condensate switch enabled) tF Gas Heat Airflow Trim (default = 0%) Enable or disable inverter boost operation. (Compressor speed may increase when M aximum Compressor Run Time Between Defrost Cycles (default t this feature is on) (inverter only) = 120 minutes) -
Page 41: Status Codes
STATUS CODES Display Description of System Status Compressor Cooling, Low Stage (non-communicating units) Compressor Cooling, High Stage (non-communicating units) Compressor Heat, Low Stage (non-communicating units) Compressor Heat, High Stage (non-communicating units) Compressor Cooling, Single-Stage (single stage non-comm. units) Compressor Cooling, Low Stage (communicating units) Compressor Cooling, High Stage (communicating units) Dehumidification Constant Fan... -
Page 42: Troubleshooting Chart
TROUBLESHOOTING CHART Symptom Fault Description Corrective Actions LED Status Check filters for blockage, clean filters or remove obstruction Furnace operates at reduced Check ductwork for blockage, remove obstruction performance or operates on E Airflow is lower than demanded and verify all registers are fully open low stage when high stage is expected Verify ductwork is appropriately sized for system,... - Page 43 TROUBLESHOOTING CHART Symptom Fault Description Corrective Actions LED Status Locate and correct gas interruption Check front cover pressure switch operation and verify proper drainage (hose, wiring, contact Furnace lockout due to an excessive operation), correct if necessary Replace or realign number of ignition “retries”...
- Page 44 TROUBLESHOOTING CHART Symptom Fault Description Corrective Actions LED Status Polarity of 115 volt AC is reversed Correct polarity, check and correct wiring if necessary Furnace fails to operate Poor unit ground Verify proper ground, correct if necessary Gas valve is not energized when it should Check Wiring in gas valve circuit EE...
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Page 45: Wiring Diagrams
WIRING DIAGRAMS DR96SC*** upflow 115 VAC/ 1 Ø /60 HZ POWER SUPPLY WITH ID BLOWER OVERCURRENT PRESSURE SWITCH PROTECTION DEVICE SURFACE WARNING:DISCONNECT IGNITER POWER BEFORE SERVICING. WIRING 2 CIRCUIT TO UNIT MUST BE CONNECTOR COLLECTOR BOX PROPERLY POLARIZED DISCONNECT PRESSURE SWITCH AND GROUNDED. - Page 46 WIRING DIAGRAMS DD96SC*** Downflow 115 VAC/ 1 Ø /60 HZ ID BLOWER POWER SUPPLY WITH PRESSURE SWITCH OVERCURRENT PROTECTION DEVICE SURFACE WARNING:DISCONNECT IGNITER POWER BEFORE SERVICING. WIRING 2 CIRCUIT TO UNIT MUST BE PROPERLY POLARIZED CONNECTOR DISCONNECT AND GROUNDED. COLLECTOR BOX PRESSURE SWITCH VALVE WIRE...
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Page 47: 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 48: Customer Feedback
CUSTOMER FEEDBACK Daikin Comfort Technologies 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.
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