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Daikin DPS012 User Manual

Daikin DPS012
122 pages
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3–6 tons
7–15 tons
Shown with Energy Recovery
16–28 tons
Shown with Energy Recovery
Installation and Maintenance Manual IM 1125-7
Group: Applied Air Systems
Part Number: IM 1125
Date: November 2015
Rebel
Commercial Packaged
Rooftop Systems
Heating and Cooling
Models DPS003 – 028A
R-410A Refrigerant
MicroTech
®
III Unit Controller
Energy Recovery Wheel

Table of Contents

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Daikin DPS012 Specifications

General IconGeneral
BrandDaikin
ModelDPS012
CategoryAir Conditioner
LanguageEnglish

Summary

Introduction

Hazard Identification Information

Explains the meaning of DANGER, WARNING, and CAUTION notices used in the manual.

Mechanical Installation

Installer Responsibilities

Outlines the responsibilities of the installer regarding safety and code compliance for equipment installation.

Roof Curb Assembly and Installation

Provides instructions for assembling and installing the roof curb, including warnings about mold and ensuring proper levelness.

Rigging and Handling

Provides safety warnings and instructions for rigging and handling the unit, emphasizing the use of proper lifting points and spreader bars.

Installing Ductwork

Provides guidance on installing ductwork, including airtight connections, flexible connections, and sound transmission considerations.

Installing Duct Static Pressure Sensor Taps

Explains the procedure for field installing duct static pressure sensor taps for VAV units to ensure proper system operation.

Installing Building Static Pressure Sensor Taps

Details how to install static pressure taps for building pressurization control applications, emphasizing proper location and installation.

Electrical Installation

Lab Pressurization Applications

Provides installation recommendations for static pressure taps in laboratory pressurization applications.

Electrostatic Discharge (ESD)

Explains precautions to take to prevent ESD damage to electronic components, including grounding procedures.

Technician Training Recommendation

Emphasizes that start-up and service must be done by trained technicians and recommends owner/operator presence.

Before Start-Up

Lists pre-start-up checks and requirements, including notifying inspectors, reviewing literature, and verifying power and gas supply.

Refrigeration System

Four-Way Valve

Describes the Four-Way Valve (4WV) or Reversing Valve used in heat pumps to direct refrigerant flow for heating and cooling modes.

Outdoor Expansion Valve

Describes the Outdoor Expansion Valve (EVO) operation in heating and cooling modes, used for refrigerant expansion in the outdoor coil.

Defrost (DPS 003–015 ton)

Details the defrost operation on heat pumps, its purpose, mechanism, and the role of supplemental heat.

Charging

Discusses advanced charge management systems, electronic expansion valves, and the procedure for refrigerant charging or removal.

High Pressure Switch

Explains the high pressure switch function on each compressor, its pressure limit, and how it interrupts control signals.

Indoor Expansion Valve

Details the Indoor Expansion Valve (EVI) operation in cooling mode, controlling superheat and expanding refrigerant.

Suction Pressure Transducer

Explains the Suction Pressure Transducer (PTS) function in monitoring compressor operating envelope and regulating suction superheat.

Discharge Pressure Transducer

Details the Discharge Pressure Transducer (PTD) function in monitoring compressor operating envelope and regulating outdoor fan speed.

VFD Compressor Operation – DPS 016–028

Details VFD compressor modulation control, start-up sequence, and operating ranges based on unit model.

VFD Compressor Control

Describes VFD compressor control via digital output enable and analog modulating signal, including start sequence.

Oil Balance/Boost Operational Sequence

Explains the unit's sequence for monitoring and restoring oil level in the VFD compressor sump.

VFD Compressor Protection Unloading Control

Outlines modulating control functions that protect the VFD compressor from damage under abnormal conditions like high pressure.

High Pressure Unloading Control

Details the VFD compressor's upper discharge pressure limit and the speed reduction/lockout procedures.

High Discharge Line Temperature Unloading Control

Explains the function of the discharge temperature sensor and the VFD compressor speed reduction/shutdown procedures.

Low/High Discharge Superheat

Describes how the unit monitors and adjusts VFD compressor speed based on discharge superheat levels.

VFD Compressor Emergency Stop Control

Details the VFD compressor emergency stop control activation, conditions, and lockout procedures.

Variable Speed Scroll Compressor

Discusses the benefits and applications of variable speed scroll compressors for energy efficiency and precise control.

Optical Oil Level Sensor

Describes the optical oil sensor used to monitor oil level in the VFD compressor sump and its role in oil boost sequences.

Variable Frequency Drive for VFD Compressor

Details the VFD compressor, its factory programming, compatibility, and control setup.

Optional Modulating Hot Gas Reheat

Modulating Hot Gas Reheat

Explains the reheat coil option, its components, and how hot gas is routed to control discharge air temperature during dehumidification.

Control & Arrangement

Details the control and arrangement for MHGRH, including PI loop for valves, compressor staging, and communication with reheat valves.

Optional Electric Heat

Electric Heater Design

Describes the design of the electric heat option, including heating coil, DDC staging control, and safety switches.

Optional Gas Heat

Daikin Tubular Heater Series Package Heater Module

Introduces the Daikin Tubular Heater Series, its certifications, and installation warnings.

Gas Furnace Design

Explains the gas furnace design, including heat exchanger types, safety switches, and clearance requirements.

Installation

Provides important installation notes regarding gas supply, technician qualifications, and safety warnings.

Auxiliary Limit Switch Function

Explains the function of the auxiliary limit switch, its manual reset, and its location in different cabinet types.

Gas Piping Routing Into Unit

Details gas piping routing into the unit, including on-the-roof piping, support requirements, and regulator sizing.

DPS 016–028 Gas Pipe Manifold Pressure Adjustment

Provides detailed procedures for adjusting gas pipe manifold pressure for two-stage and modulating furnaces.

DPS 003–015 Sequence of Operation

Details the sequence of operation for staged and modulating gas furnace controls in DPS 003–015 units.

DPS 016–028 Sequence of Operation

Details the sequence of operation for staged and modulating gas furnace controls in DPS 016–028 units.

Start-Up Procedures

Outlines responsibilities and preliminary checks for unit start-up, emphasizing safety and technician qualifications.

Operating Procedures

Provides step-by-step instructions for operating the gas furnace, including safety warnings and turning off gas.

Turning OFF Gas to the Appliance

Details the procedure for safely turning off gas to the appliance before servicing.

Maintenance

Provides guidance on planned maintenance, typical service intervals, and specific tasks for burner controls and components.

DPS 003–015 (only) Ignition Control Module for Staged Gas Furnace

Explains the typical electrical schematic and LED diagnostics for staged gas furnaces.

Ignition Control Module LED Diagnostics

Lists LED indicators and their corresponding fault conditions for diagnosing staged gas furnace issues.

DPS 003–015 (only) Ignition Control Module for Modulating Gas Furnace

Details the typical electrical schematic with sensors for modulating gas furnaces.

DPS 003–015 (only) Gas Furnace Ignition and Control Troubleshooting

Covers variable furnace controller functions and troubleshooting using the VB-1200 guide.

Modulating Furnace Diagnostics

Explains the self-diagnostic capabilities of the Rebel furnace control and how LEDs indicate system state and faults.

VB-1200 Trouble Shooting Guide

Provides information on furnace ID plug and normal furnace operation displays for troubleshooting.

Functional Alerts — DPS 003–015 only

Lists functional alerts, their descriptions, possible causes, and solutions for DPS 003–015 furnaces.

Functional Alerts — DPS 003–015 only (Continued)

Continues the list of functional alerts, possible causes, and solutions for DPS 003–015 furnaces.

Lockout Errors — DPS 003–015 only

Lists lockout errors, their descriptions, possible causes, and solutions for DPS 003–015 furnaces.

Lockout Errors — DPS 003–015 only (Continued)

Continues the list of lockout errors, possible causes, and solutions for DPS 003–015 furnaces.

DPS 016–028 Gas Furnace Ignition Troubleshooting

Provides troubleshooting for ignition control on DPS 016–028 staged gas furnaces using the UTEC 1016 Ignition Board.

Modulating Control LED Status Indicator

Lists LED status indicators for modulating control, indicating system status and operational modes.

Typical 2 Stage Control Gas Furnace, 300 MBH — DPS 016–028 shown

Shows the electrical schematic for a 2-stage control gas furnace, 300 MBH, DPS 016–028.

Typical 2 Stage Control Gas Furnace, 450/600 MBH — DPS 016–028 shown

Presents the electrical schematic for a 2-stage control gas furnace, 450/600 MBH, DPS 016–028.

Typical 4 Stage Control Gas Furnace, 300/450/600 MBH — DPS 016–028 shown

Displays the electrical schematic for a 4-stage control gas furnace, 300/450/600 MBH, DPS 016–028.

Typical Modulating Control Gas Furnace, 300/450/600 MBH — DPS 016–028 shown

Shows the electrical schematic for a modulating control gas furnace, 300/450/600 MBH, DPS 016–028.

Optional Hot Water Heat

Hot Water Heater Design

Describes the design considerations for hot water coils, including freeze prevention and coil configurations.

Optional Energy Recovery Wheel

Frost Protection Option

Details the factory-installed frost protection options available for the enthalpy wheel, including defrost control.

Constant Speed Frost Prevention

Describes the constant speed frost prevention method, jogging the wheel to avoid frosting.

Variable Speed Frost Prevention

Explains the variable speed frost prevention method, slowing the wheel to avoid frosting.

Optional Outdoor Air Monitor

Thermal Dispersion Airflow Measurement Technology

Describes thermal dispersion technology and its application in measuring airflow rate and air temperature accurately.

General Troubleshooting

Provides a table for troubleshooting common issues with the transmitter, including LCD display problems and signal fluctuations.

Transmitter Troubleshooting

Lists potential causes and remedies for communication issues between the transmitter and the host control system.

ECM Motor

ECM Smoke Purge or Ventilation Override

Describes how the MicroTech III controller performs ventilation override for smoke purge and how to set the maximum vent speed.

Wiring Diagrams

Typical CAV_VAV 208-230 VAC Wiring (1 of 4) — DPS 003–006 shown

Presents the first part of the typical wiring diagram for CAV/VAV units, 208-230 VAC, DPS 003–006.

Typical CAV_VAV 208-230 VAC Wiring (2 of 4) — DPS 003–006 shown

Shows the second part of the wiring diagram, detailing sensors, control modules, and various components.

Typical CAV_VAV 208-230 VAC Wiring (3 of 4) — DPS 003–006 shown

Continues the wiring diagram, illustrating compressor circuits, heating elements, and fan connections.

Typical CAV_VAV 208-230 VAC Wiring (4 of 4) — DPS 003–006 shown

Completes the wiring diagram, including terminal block details and a wiring legend.

Typical CAV_VAV 460 VAC Wiring (1 of 4) — DPS 003–006 shown

Presents the first part of the wiring diagram for CAV/VAV units, 460 VAC, DPS 003–006.

Typical CAV_VAV 460 VAC Wiring (2 of 4) — DPS 003–006 shown

Shows the second part of the wiring diagram for 460 VAC units, detailing sensors and control modules.

Typical CAV_VAV 460 VAC Wiring (3 of 4) — DPS 003–006 shown

Continues the wiring diagram for 460 VAC units, illustrating compressor circuits, heating elements, and fan connections.

Typical CAV_VAV 460 VAC Wiring (4 of 4) — DPS 003–006 shown

Completes the wiring diagram for 460 VAC units, including terminal block details and a wiring legend.

Typical 575 Volt Wiring (1 of 4) — DPS 007–015 shown with 460 to 575 Transformer

Presents the first part of the wiring diagram for 575 VAC units, including transformer connections.

Sequence of Operation

Preparing the Unit for Start Up

Check, Test and Start Procedures

Compressor Start-Up

Provides instructions for preparing for and starting the compressor, including crankcase heater operation and troubleshooting compressor cycling.

Set Up for Optimum Control

Details how to calibrate the outdoor air sensor and set up discharge/suction superheat for optimum control.

Final Control Settings

Maintenance

Performing Service Maintenance

Emphasizes that service must be performed by qualified personnel and provides important warnings.

Planned Maintenance

Outlines routine preventive maintenance tasks, including blower checks, coil cleaning, filter replacement, and safety control checks.

Refrigerant Charge

Explains how refrigerant charge affects unit configuration and efficiency, and the importance of using correct oil types.

Re-charging the unit

Details the procedure for evacuating and recharging the unit, including vacuum requirements and charging by weight.

Service and Warranty Procedures

Warranty Registration Form

Furnace Check, Test, & Start

Checklist for furnace gas pressure, high limit control, flame failure shutoff, airswitch, and main gas valve.

Quality Assurance Survey Report

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