Daikin DPS012, DPS015, DPS004, DPS016, DPS018 Installation And Maintenance Manual

...

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

3–6 tons

16–28 tons

Shown with Energy Recovery

7–15 tons

Shown with Energy Recovery

Table of ConTenTs

Introduction.............................................3

General Information .....................................3

Unit Nameplate......................................... 3

Hazard Identication Information ...........................3

Mechanical Installation ...................................4

Installer Responsibilities..................................4

Receiving Inspection ....................................4

Service Clearance ......................................4

Ventilation Clearance ....................................4

Overhead Clearance ....................................6

Roof Curb Assembly and Installation ........................6

Rigging and Handling ................................... 10

Unit Piping - Condensate Drain Connection.................. 12

Damper Assemblies ....................................12

Cabinet Weather Protection ..............................13

Installing Ductwork .....................................13

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Pre-Construction ......................................15

Refrigeration System ....................................19

Piping System ........................................19

DPS 003–015 Component Description .....................21

DPS 016–028 Ton Component Description ..................27

VFD Compressor Operation – DPS 016–028 ................29

Variable Speed Scroll Compressor.........................33

Optional Modulating Hot Gas Reheat....................... 36

Modulating Hot Gas Reheat ............................. 36

Optional Electric Heat ...................................39

Electric Heater Design ..................................39

Optional Gas Heat ......................................40

Daikin Tubular Heater Series .............................40

Gas Furnace Design ...................................40

Gas Heating Capacity Data ..............................41

DPS 003–015 Sequence of Operation ...................... 48

DPS 016–028 Sequence of Operation .....................49

Start-Up Procedures.................................... 50

Operating Procedures ..................................51

DPS 003–015 (only) Ignition Control Module for

Staged Gas Furnace ...................................52

DPS 003–015 (only) Ignition Control Module for

Modulating Gas Furnace ................................53

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

Troubleshooting .......................................54

VB-1200 Trouble Shooting Guide..........................54

DPS 016–028 Gas Furnace Ignition Troubleshooting ..........60

Optional Hot Water Heat .................................65

Hot Water Heater Design ................................65

Optional Energy Recovery Wheel..........................66

System Description ....................................66

Optional Outdoor Air Monitor .............................69

Thermal Dispersion Airow Measurement Technology..........69

ECM Motor.............................................74

Table of ConTenTs

Unit Options ...........................................76

Economizer Enthalpy Control.............................76

External Time Clock ....................................76

Exhaust Fan Option ....................................76

Proof-of-Airow and Dirty Filter Switch...................... 76

Duct High Pressure Limit ................................76

Convenience Receptacle (Field Powered) ................... 77

Convenience Receptacle (Unit Powered) ...................77

Wiring Diagrams........................................78

Sequence of Operation ..................................90

Operating States ......................................90

Mechanical Cooling .................................... 91

Economizer ..........................................91

Preparing the Unit for Start Up ............................92

Pre-Start of Unit .......................................92

Spring Isolated Fans ...................................92

Servicing Control Panel Components ......................93

Power-Up ............................................93

Fan Start-Up..........................................93

Check, Test and Start Procedures .........................94

Economizer Start-Up ...................................94

Compressor Start-Up ...................................94

Set Up for Optimum Control .............................. 95

Air Balancing .......................................95

Energy Recovery Wheel................................. 96

Final Control Settings ...................................97

Final Control Settings ................................... 97

Maintaining Control Parameter Records ....................97

Maintenance ...........................................98

Performing Service Maintenance ..........................98

Planned Maintenance................................... 98

Unit Storage ..........................................98

Periodic Service and Maintenance.........................99

Refrigerant Charge....................................100

Servicing Refrigerant Sensors or Switches ............... 101

Servicing Optional Electric Heater .................... 101

Servicing the Compressor Ground Fault Interrupter ..........101

Phase Voltage Monitor (PVM) ...........................101

Cleaning Option E Coated Coils .........................102

Service and Warranty Procedures ........................103

Replacement Parts....................................103

Scroll Compressor ....................................103

In-Warranty Return Material Procedure ....................103

Warranty Registration Form.............................104

Quality Assurance Survey Report ........................108

Appendix – Keypad/Display Menu Structure................ 11 0

IM 1125-7 • REBEL ROOFTOPS 2 www.DaikinApplied.com

General Information

This manual provides general information about the “A” vintage Daikin Rebel Commercial Packaged Rooftop Unit, model DPS. In addition to an overall description of the unit, it includes mechanical and electrical installation procedures, commissioning procedures, sequence of operation information, and maintenance instructions.

The MicroTech® III rooftop unit controller is equipped on “A” vintage rooftop units. For a detailed description of the MicroTech III components, input/output congurations, eld wiring options and requirements, and service procedures,

see OM 1141. For operation and information on using and

programming the MicroTech III unit controller, refer to the

appropriate operation manual (see Table 1).

For a description of operation and information on using the keypad to view data and set parameters, refer to the appropriate program-specic operation manual (see Table 1).

InTroduCTIon

Unit Nameplate

The unit nameplate is located on the outside of the main control box door. It includes the unit model number, serial number, electrical characteristics, and refrigerant charge.

Hazard Identication Information

DANGER

Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.

WARNING

Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.

InTroduCTIon

Table 1: Program Specic Unit Operation Literature

Rooftop unit control conguration

BACnet IP Comm Module IM 916

BACnet® Integration IM 917

LonWorks® Integration IM 918

DPS Unit Controller Discharge

Air Control (VAV or CAV)

Space Comfort Control (SCC)

Rebel Quick Start Guide OM 1164

Manual

bulletin number

OM 1141

Nomenclature (DPS 003–028)

DPS – 010 – A H H G 4

Daikin Packaged System

Nominal capacity

003 = 3 tons 016 = 16 tons

004 = 4 tons 018 = 18 tons

005 = 5 tons 020 = 20 tons

006 = 6 tons 025 = 25 tons

007 = 7.5 tons 028 = 28 tons

010 = 10 tons

012 = 12 tons

015 = 15 tons

CAUTION

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

Line voltage

2 = 208 volt power supply

3 = 230 volt power supply

4 = 460 volt power supply

5 = 575 volt power supply

Heat medium

Y = None (cooling only)

G = Natural gas heat

E = Electric heat

W = Hot water heat

Design vintage

A = Vintage 1

Cooling efciency

H = High (exceeds ASHRAE 92)

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Unit style

C = Cooling only

H = Heat pump

M = Cooling-only microchannel

Installer Responsibilities

MeChanICal InsTallaTIon

Service Clearance

CAUTION

Sharp edges on sheet metal and fasteners can cause personal injury. This equipment must be installed, operated, and serviced only by an experienced installation company and fully trained personnel.

The installation of this equipment shall be in accordance with the regulations of authorities having jurisdiction and all applicable codes. It is the responsibility of the installer to determine and follow the applicable codes.

Receiving Inspection

When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates and cartons have been received. If the unit has become dirty

during shipment (winter road chemicals are of particular concern), clean it when received.

All units should be carefully inspected for damage when received. Report all shipping damage to the carrier and le a claim. In most cases, equipment is shipped F.O.B. factory and claims for freight damage should be led by the consignee.

Before unloading the unit, check the unit nameplate to make sure the voltage complies with the power supply available.

CAUTION

Location. Care should be taken for the installation

location to minimize snow drifts on the outdoor coil.

Allow service clearances as approximately indicated in Figure

1. Also, Daikin recommends providing a roof walkway to the

rooftop unit as well as along each side of the unit that provides access to most controls and serviceable components.

Refer to NEC and local for minimum clearances around the unit and control panel.

Ventilation Clearance

Below are minimum ventilation clearance recommendations. The system designer must consider each application and provide adequate ventilation. If this is not done, the unit may not perform properly.

Unit(s) Surrounded by a Screen or a Fence:

1. The bottom of the screen or fence should be at least 1 ft. (305 mm) above the roof surface.

2. The distance between the unit and a screen or fence should be as described in Figure 1.

3. The distance between any two units within a screen or fence should be at least 120" (3048 mm).

Unit(s) Surrounded by Solid Walls:

1. If there are walls on one or two adjacent sides of the unit, the walls may be any height. If there are walls on more than two adjacent sides of the unit, the walls should not be higher than the unit.

2. The distance between the unit and the wall should be at least 96" (2438 mm) on all sides of the unit.

3. The distance between any two units within the walls should be at least 120" (3048 mm).

Do not locate outside air intakes near sources of contaminated air.

If the unit is installed where windy conditions are common, install wind screens around the unit, maintaining the clearances specied (see Figure 1). This is particularly important to maintain adequate head pressure control when mechanical cooling is required at low outdoor air temperatures.

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Figure 1: Service Clearances

MeChanICal InsTallaTIon

Small Cabinet 003—006

Filter

Access

60.00

(1524 mm)

Plenum Discharge,

Electric Heat &

Supply Fan Access

Large Cabinet 016—028

Exhaust

Fan Access

Outdoor Air

Control

Panel

Access

Hood

50.00

(1270 mm)

48.00

(1219 mm)

21.00 (533 mm)

Gas

59.2"

(1504 mm)

36.00

(914 mm)

Medium Cabinet 007—015

Filter

Access

60.00

(1524 mm)

Supply Fan

Access

Exhaust

Fan Access

Outdoor Air

Control

Panel

Access

Hood

50.00

(1270 mm)

48.00

(1219 mm)

17.00 (431 mm)

Gas

59.2"

(1504 mm)

36.00

914 mm)

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MeChanICal InsTallaTIon

Overhead Clearance

1. Unit(s) surrounded by screens or solid walls must have no overhead obstructions over any part of the unit. For heat pump models overhead obstructions could allow the formation of dangerous ice cycles.

2. The area above the condenser must be unobstructed in all installations to allow vertical air discharge.

3. The following restrictions must be observed for overhead obstructions above the air handler section:

a. There must be no overhead obstructions above the

furnace ue, or within 9" (229 mm) of the ue box.

b. Overhead obstructions must be no less than 96"

(2438 mm) above the top of the unit.

c. There must be no overhead obstructions in the areas

above the outside air and exhaust dampers that are farther than 24" (610 mm) from the side of the unit.

Roof Curb Assembly and Installation

WARNING

Mold can cause personal injury. Some materials such

as gypsum wall board can promote mold growth when damp. Such materials must be protected from moisture that can enter units during maintenance or normal

operation.

Locate the roof curb and unit on a portion of the roof that can support the weight of the unit. The unit must be supported to prevent bending or twisting of the machine.

If building construction allows sound and vibration into the occupied space, locate the unit over a non-critical area. It is the responsibility of the system designer to make adequate provisions for noise and vibration in the occupied space.

Install the curb and unit level to allow the condensate drain to ow properly and allow service access doors to open and close without binding.

The gasketed top surface of the curb seals against the unit when it is set on the curb. These anges must not support the total weight of the duct work. See Installing Ductwork on

page 13 for details on duct connections. It is critical that

the condensate drain side of the unit be no higher than the

opposite side.

Assembly Instructions

Assembly of a typical roof curb is shown in Figure 2, Figure 3

on page 8 and Figure 4 on page 9.

1. Set curbing parts A thru G per dimensions shown over roof opening or on a level surface. Note location of supply air opening. Check alignment of all mating screw holes.

2. Screw curbing parts together using fasteners provided. Leave all screws loose until curb is checked to be square.

3. Square entire curbing assembly and securely tighten all screws.

4. Position curb assembly over roof openings. Curb must be level within 0.25 inches from side to side and 1.50 inches over its length. Check that top surface of curb is at with no bowing or sagging.

5. Weld curb assembly in place. Caulk all seams watertight. Remove backing from 0.25 × 1.50 wide gasket and apply to surfaces shown by crosshatching.

6. Check that electrical connections are coordinated.

IM 1125-7 • REBEL ROOFTOPS 6 www.DaikinApplied.com

Figure 2: Roof Curb Assembly (DPS 003—006)1

DPS 003–006 Roofcurb with ERW Certi ed Drawing

McQuay International certi es that its equipment will conform to this drawing and McQuay’s published speci cations, subject to its published warranty. Purchaser must determine that the equipment is  t and suf cient for the job speci cations. No change to this drawing may be made

Model: DPS

Date:

Unit Tag:

Units: Sheet: __ of __

DPS 003–006 Roofcurb with ERW Certi ed Drawing

Model: DPS

Date:

Unit Tag:

Units: Sheet: __ of __

Curb Detail

A–A

2"×4"

Nailer

A A

2.0"

Typ.

14.0"

24.0"

4.0"

3.9

28.55 Inside

9.69

Inside

28.69 Inside

44.38

Inside

76.0

Inside

19.1

9.5

Inside

18.5

Supply

Opening

Return

Opening

Electrical

Entrance

47.05

2.0

3.9

6.4

LEFT SIDE

28.69

INSIDE

MeChanICal InsTallaTIon

BACK SIDE

9.84

INSIDE

SUPPLY AIR

RETURN AIR

28.76

INSIDE

61.50

RIGHT SIDE

FRONT SIDE

44.24

9.64

INSIDE

NOTE: 1. Check submittal drawing for gas/water/electrical/supply/return air opening

Horizontal above the roof gas connection only

Standard Roof Curb – Small Cabinet

2.0

9.5

Inside

19.1

Return

Opening

44.38 Inside

Supply

Opening

28.55 Inside

Roof Curb for ERW – Small Cabinet

57.5

Inside

3.9

6.4

Electrical Entrance

3.9

28.69 Inside

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9.69

Inside

A A

Curb Detail

14.0"

24.0"

A–A

2.0"

Typ.

4.0"

2"×4"

Nailer

Figure 3: Roof Curb Assembly (DPS 007–015)1

DPS 007–012 Roofcurb with ERW Certi ed Drawing

Model: DPS

Date:

Unit Tag:

Units: Sheet: __ of __

DPS 007–012 Roofcurb with ERW Certi ed Drawing

Model: DPS

Date:

Unit Tag:

Units: Sheet: __ of __

Curb Detail

A–A

2"×4"

Nailer

A A

2.0"

Typ.

4.0"

14.0"

24.0"

34.88 Inside

48.38 Inside

101.5 Inside

13.5

Inside

30.5

Inside

Supply

Opening

Return

Opening

Electrical Entrance

20.0

24.25

2.0

3.4

6.9

8.8

MeChanICal InsTallaTIon

LEFT SIDE

BACK SIDE

SUPPLY

AIR

RETURN

AIR

FRONT SIDE

RIGHT SIDE

NOTE: 1. Check submittal drawing for gas/water/electrical/supply/return air opening

Horizontal above the roof gas connection only

Standard Roof Curb – Medium Cabinet

2.0

30.5

Inside

Supply

Opening

Electrical Entrance

8.8

6.9

3.4

Roof Curb for ERW – Medium Cabinet

81.5

Inside

IM 1125-7 • REBEL ROOFTOPS 8 www.DaikinApplied.com

24.25

13.5

Inside

34.88 Inside

Return

Opening

48.38 Inside

A A

Curb Detail

14.0"

24.0"

A–A

2.0" Typ.

4.0"

2"×4"

Nailer

Figure 4: Roof Curb Assembly (DPS 016–028)1

LEFT SIDE

RETURN

AIR

SUPPLY

AIR

MeChanICal InsTallaTIon

BACK SIDE

RIGHT SIDE

FRONT SIDE

NOTE: 1. Check submittal drawing for gas/water/electrical/supply/return air opening

2. Horizontal above the roof gas connection only

3. All dimensions in inches

Standard Roof Curb – Large Cabinet

Roof Curb for ERW – Large Cabinet

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Rigging and Handling

WARNING

Only trained and qualified personnel should be allowed to rig loads or operate load rated cranes and/or hoist assemblies. Do not use a forklift to lift or maneuver the unit. Failure to use a load rated crane or hoist assembly to lift or maneuver the unit can cause severe personal injury and property damage.

WARNING

Use all lifting points. Improper lifting can cause property damage, severe personal injury, or death.

CAUTION

Lifting points may not be symmetrical to the center of gravity of the unit. Ballast or unequal cable lengths

may be required.

Figure 5: Rigging Label 003–015

LIFT ONLY AS SHOWN

USE SPREADER BAR

REMOVE THE FORKLIFT

CHANNELS BEFORE SETTING THE UNIT ON THE ROOF CURB

Figure 6: Rigging Label 016–028

LIFT ONLY AS SHOWN

MeChanICal InsTallaTIon

CAUTION

Unit is equipped with fork slot reenforcement pieces. These need to be removed before unit is set on the curb.

Rigging holes for shackles are integral on the unit base. Use

four independent lines, securing one end of a line to a unit base lifting point and the other end of the line to an associated spreader bar lifting point. Figure 5 and Figure 6

are examples of instruction labels shipped with each unit.

Use spreader bars to prevent damage to the unit cabinet. Avoid twisting or uneven lifting of the unit. The cable length from the bracket to the hook should always be longer than the distance between the outer lifting points.

If the unit is stored at the construction site for an intermediate period, take these additional precautions:

1. Support the unit well along the length of the base rail.

2. Level the unit (no twists or uneven ground surface).

3. Provide proper drainage around the unit to prevent

ooding of the equipment.

4. Provide adequate protection from vandalism, mechanical contact, etc.

5. Securely close the doors.

6. Cover the supply and return air openings.

USE SPREADER BAR

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MeChanICal InsTallaTIon

Table 2: Physical Data—Unit Weights DPS 003 through 028

Model

003 004 005 006 007 010 012 015

Weight (lbs.)

Base Weight

1000 1000 1025 1058 1600 1600 1600 1763

Heat pump 1030 1030 1058 1058 1660 1660 1660 1823

Electric Heat 45 45 45 45 100 100 100 100 Hot Water 2 Row 11 11 11 16.5 30 30 30 30 Hot Water 1 Row 32 32 32 20 31 31 31 31

Gas Heat 75 75 63 93 186 186 186 186

Hot Gas Re-heat 8 8 12 12 28 31 31 31 Economizer 163 163 163 163 308 308 308 308 High capacity coil 105 105 105 105 215 215 215 215

Energy Wheel Weight Adds (lbs.)

100% OA 160 160 160 160 300 300 300 300 Mixed Air 175 175 175 175 250 250 250 250

1. Includes standard cooling coil

Small Cabinet Medium Cabinet

Model

Base Weight (in lbs.) 2,465 2,575 2,700

Heat Pump — — — — —

Electric Heat 228

1-row 60

Hot Water Heat

Gas Heat

Hot Gas Reheat 30

Economizer 500

ERW – Small 350

ERW – Large 400

Indoor Fan

Indoor Fan Motors

Exhaust Fan 250

2-row 100

3-row 140

016 018 020 025 028

300 175

450 225

600 275

16" 100

20" 150

24" 260

1 36

1.5 41

2 40

3 69

5 84

7.5 11 5

10 128

15 211

20 225

Large Cabinet

Size 3–15 Fan Weights (lbs.)

12 (in) 87 14 (in) 91 16 (in) 115 18 (in) 87 20 (in) 91 22 (in) 115

Curb Weights (lbs.) 14" 24"

003—006 156 230 007—015 200 295 016—028 566 657

Table 3: Refrigerant Charge

Unit Size

3 10.5 12.9 12.0 14.4

4 11.1 13.5 12.6 15.0

5 15.3 18.2 16.8 19.7

6 15.3 18.2 16.8 19.7

7.5 11.0 17.3 26.0 31.2

10 34.0 39.8 40.0 45.8

12 34.0 39.8 40.0 45.8

15 37.0 43.8 42.0 47.8

16 37.0

18 37.0

20 37.0

25 35.5

28 35.5

Cooling Model Heat Pump Model

Standard Unit

w/ MHGRH

Standard Unit

Consult Factory

Standard Unit

w/ MHGRH

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Static Pressure (P)

Actuator

MeChanICal InsTallaTIon

Unit Piping - Condensate Drain Connection

WARNING

Drain pans must be cleaned periodically. Material in uncleaned drain pans can cause disease. Cleaning

should be performed by qualified personnel.

The unit is provided with a condensate drain connection, a 3/4" male NPT for 003–015 units and a 1" male NPT for 016–028 units. For proper drainage, level the unit and drain pan side to side and install a P-trap.

Figure 7 shows the layout of the condensate drain connection.

The distance from the drain pan outlet to the horizontal run of the P-trap should be a distance of twice the static pressure in the drain pan.

Example: If the static pressure as measured in the drain pan is 1.5", then the distance between the drain outlet and the horizontal run should be 3".

Draining condensate directly onto the roof may be acceptable; refer to local codes. Provide a small drip pad of stone, mortar, wood, or metal to protect the roof against possible damage.

If condensate is piped into the building drainage system, pitch the drain line away from the unit a minimum of 1/8" per foot. The drain line must penetrate the roof external to the unit. Refer to local codes for additional requirements. Sealed drain lines require venting to provide proper condensate ow.

Periodically clean to prevent microbial growth/algae buildup from plugging the drain and causing the drain pan to overow. Clean drain pans to prevent the spread of disease. Cleaning should be performed by qualied personnel.

Damper Assemblies

The optional damper assemblies described in this section are ordered with factory-installed actuators and linkages. The following sections describe the operation and linkage adjustment of the factory option.

Figure 8: Damper Assembly

Linkage

Figure 7: Condensate Drain Connection

at the Drain Pan

Economizer Dampers

As the single actuator modulates, the outside air dampers open, the return air dampers close, and the exhaust air exits the unit through the gravity relief dampers.

The economizer comes with manually adjustable linkage (Figure

8). The damper is set so that the crank-arm moves through

a 90-degree angle to bring the economizer dampers from full open to full close. Mechanical stops are placed in the crank-arm mounting bracket. Do not remove stops. Driving the crank-arm past the stops results in damage to the linkage or damper.

Outdoor Air Dampers (0% to 30%)

These dampers are intended to remain at a xed position during unit operation, providing fresh air quantities from 0 to 30% of the total system airow, depending on the damper setting.

The damper position may be set at the unit controller keypad

(refer to OM 1141 for further detail). During unit operation, the

damper is driven to the position set at the unit controller. During the OFF cycle, the damper is automatically closed.

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MeChanICal InsTallaTIon

Cabinet Weather Protection

CAUTION

Transportation, rigging, or maintenance can damage

the unit’s weather seal. Periodically inspect the unit for leakage. Standing moisture can promote microbial growth, disease, or damage to the equipment and building.

This unit ships from the factory with fully gasketed access doors and cabinet caulking to provide weather resistant operation. After the unit is set in place, inspect all door gaskets for shipping damage and replace if necessary.

Protect the unit from overhead runoff from overhangs or other such structures.

Installing Ductwork

WARNING

Mold can cause personal injury. Materials such as

gypsum wall board can promote mold growth when damp. Such materials must be protected from moisture that can enter units during maintenance or normal

operation.

On vertical-supply/vertical-return units, if a Daikin roof curb is not used, the installing contractor should make an airtight connection by attaching eld fabricated duct collars to the bottom surface of the unit’s duct opening. Do not support the total weight of the duct work from the unit.

Use exible connections between the unit and ductwork to avoid transmission of vibration from the unit to the structure.

To minimize losses and sound transmission, design duct work per ASHRAE and SMACNA recommendations.

Where return air ducts are not required, connect a sound absorbing T or L section to the unit return to reduce noise transmission to the occupied space.

Ductwork exposed to outdoor conditions must be built in accordance with ASHRAE and SMACNA recommendations and local building codes.

Table 4: AHRI CFM Ratings

Unit Size AHRI Rated CFM Unit Size AHRI Rated CFM

3 1140 15 4690

4 1550 16 Consult Factory

5 1810 18 Consult Factory

6 2310 20 7315

7.5 2885 25 8180

10 3850 28 8200

12 4620

Installing Duct Static Pressure Sensor Taps

For all VAV units, duct static pressure taps must be eld installed and connected to the static pressure sensor 1 (SPS1) in the unit. Sensor SPS1 is standard on VAV units and is located in the main control panel.

Carefully locate and install the duct static pressure sensing tap. Improperly locating or installing the sensing tap causes unsatisfactory operation of the entire variable air volume system. Below are pressure tap location and installation recommendations. The installation must comply with local code

requirements.

1. Install a tee tting with a leak-tight removable cap in each

tube near the sensor tting. This facilitates connecting a manometer or pressure gauge if testing is required.

2. Use different colored tubing for the duct pressure (HI) and reference pressure (LO) taps, or tag the tubes. Daikin recommends 3/16" ID tubing.

3. Locate the duct pressure (HI) tap near the end of a long duct to ensure that all terminal box take-offs along the run have adequate static pressure.

4. Locate the duct tap in a nonturbulent ow area of the duct. Keep it several duct diameters away from take-off points, bends, neckdowns, attenuators, vanes, or other irregularities.

5. Use a static pressure tip (Dwyer A302 or equivalent) or the bare end of the plastic tubing for the duct tap. (If the duct is lined inside, use a static pressure tip device.)

6. Install the duct tap so that it senses only static pressure (not velocity pressure). If a bare tube end is used, it must be smooth, square (not cut at an angle) and perpendicular to the airstream (see Figure 10).

7. Locate the reference pressure (LO) tap near the duct pressure tap within the building. If the tap is not connected to the sensor, unsatisfactory operation will result.

8. Route the tubes through the curb and feed them into the unit through the knockout in the bottom of the control

panel (see Figure 9). Connect the tubes to appropriate

barbed ttings (on SPS1) in the control panel. (Fittings are sized to accept 3/16" ID tubing.)

Figure 9: Typical Wiring Chase, Size 007–015 shown

Field

Wiring

Block

Behind

Panel

Utility

Chase

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MeChanICal InsTallaTIon

Figure 10: Duct Static Pressure Sensing Tubing Installation

Condenser Sec tion

Roof

Ductwork (RemoteLocation)

Tubing Extends Through Approx.3/16"

SPS1

LO Line

HI Line

Remote Sense Po int

To Sensor LO Input

Main ControlPanel

To Sensor HI Input

PressureSensing Tubing

Rubber Grommet

Installing Building Static Pressure Sensor Taps

CAUTION

Fragile sensor fittings. If you must remove tubing

from a pressure sensor fitting, use care. Do not use excessive force or wrench the tubing back and forth to remove or the fitting can break off and damage sensor.

If a unit has building static pressure control capability, you must eld install and connect static pressure taps to the static pressure sensor SPS2 in the unit. This sensor is located at the bottom of the main control panel next to SPS1.

Carefully locate and install the two static pressure sensing taps. Improper location or installation of the sensor taps causes unsatisfactory operation. Below are pressure tap location and installation recommendations for both building envelope and lab, or “space within a space” pressure control applications. The installation must comply with local code requirements.

3. Locate the building tap so it is not inuenced by any source of moving air (velocity pressure). These sources may include air diffusers or outside doors.

4. Route the building tap tube through the curb and feed it into the unit through the knockout in the bottom of the control panel (refer to Figure 9). Connect the 3/16" ID tube to the (high) tting for sensor SPS2.

5. Locate the reference pressure (low) tap on the roof. Keep it away from the condenser fans, walls, or anything else that may cause air turbulence. Mount it high enough above the roof so it is not affected by snow. Not connecting the reference tap to the sensor results in unsatisfactory operation.

6. Use an outdoor static pressure tip (Dwyer A306 or equivalent) to minimize the adverse effects of wind. Place some type of screen over the sensor to keep out insects. Loosely packed cotton works well.

7. Route the outdoor tap tube out of the main control panel through a small eld-cut opening in the upright. Seal the penetration to prevent water from entering. Connect the 3/16" ID tube to the (low) tting for sensor SPS2.

Discharge Air Temperature Sensor

The discharge air temperature sensor must be installed in the discharge air duct, downstream of the rooftop unit. Locate the sensor in a location that closely approximates the average duct temperature. To avoid the effects of radiation, the sensor should not be in the line-of-sight of a gas furnace or electric heater. Generally, locate sensor in the center of a duct wall, 5′ – 10′ from unit opening to allow for air mixing. Do not mount down stream of VAV boxes or other dampers.

Installation: Drill 7/8" diameter hole in duct, insert sensor probe and secure plate to duct with 2 – #10 screws. Be sure to apply gasket or silicone sealant to back of mounting plate prior to screwing plate to the duct to create an air-tight seal.

Figure 11: Discharge Air Temperature Sensor Installation

Building Pressurization Applications

1. Install a tee tting with a leak-tight removable cap in each tube near the sensor tting. This facilitates connecting a manometer or pressure gauge if testing is required.

2. Locate the building pressure (high) tap in the area that requires the closest control. Typically, this is a ground level oor that has doors to the outside.

IM 1125-7 • REBEL ROOFTOPS 14 www.DaikinApplied.com

DANGER

Hazardous voltage. Can cause severe injury or death.

Disconnect electric power before servicing equipment. More than one disconnect may be required to deenergize the unit.

WARNING

Provide proper line voltage and phase balance.

Improper line voltage or excessive phase imbalance constitutes product abuse. It can cause severe damage to the unit’s electrical components.

WARNING

Electrical shock hazard. Can cause severe injury or death.

Connect only low voltage NEC Class II circuits to terminal block TB2.

DANGER

Overheating or failure of the gas supply to shut off can cause equipment damage, severe personal injury or death. Turn off the manual gas valve to the appliance before

shutting off the electrical supply.

eleCTrICal InsTallaTIon

Pre-Construction

The Rebel unit comes equipped with a Microtech III controller and can be used for sites that are still under construction. The following conditions must be met.

1. Ductwork has to be installed. The fan proving switch and furnace might not run correctly without the specied external static pressure

2. Filters must be installed.

3. Follow furnace commissioning instructions found in the

furnace section.

4. After substantial completion of the construction process the unit is to be thoroughly cleaned. Special attention should be paid to the indoor DX coil and the furnace. Filters should be changed

5. Furnace operation, rate, and temperature rise should be re-veried. See instructions found in the furnace section.

Lab Pressurization Applications

1. Install a “T” tting with a leak-tight removable cap in each tube near the sensor tting. This facilitates connecting a manometer or pressure gauge if testing is required.

2. Use different colored tubing for the controlled space pressure (high) and reference pressure (low) taps, or tag the tubes.

3. Regardless whether the controlled space is positive or negative with respect to its reference, locate the high pressure tap in the controlled space (the setpoint can be set between -0.2" and 0.2" wc).

4. Locate the reference pressure (low) tap in the area surrounding the controlled space. Not locating the reference tap to the sensor results in unsatisfactory

operation.

5. Locate both taps so they are not inuenced by any source

of moving air (velocity pressure). These sources may include air diffusers or doors between the high and low

pressure areas.

6. Route the building tap tube between the curb and the

supply duct and feed it into the unit through the knockout in the bottom of the control panel.

7. Connect the tube to the (high) tting for sensor SPS2.

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Electrostatic Discharge (ESD)

Disconnect Power to the Rebel Rooftop Unit prior to inspecting and/or repairing.

When inspecting/repairing Rebel Rooftop units the technician or building owner must take precautions to ground themselves to the unit. This will prevent them from damaging the circuit boards mounted inside the inverter box and main control panel.

Electrostatic Discharge (ESD) can damage components in a manner that is not always readably detectable. A static potential can easily be generated on a person that reaches 25 kVolts. If this potential is discharged into one of the unit’s circuit boards it can degrade part of the current carrying conductors inside. This is the conceptual equivalent of reducing 16 gage wires to 18. The component will still operate initially, but will have a much shorter life span due to overheating of the conductor.

In order to prevent ESD from the technician to the unit they must both be at the same potential. First the technician must ground themselves to the unit; this can be achieved by touching any galvanized (not painted) section of the unit. The unit’s base rail and refrigerant piping are both reliable options. The next step is to attach a grounded wrist or ankle strap to the copper tubing. This grounding strap must have direct contact with the technician’s skin. Once this has been done the technician is free to work on electrical components in side the unit.

Although ESD is partially dependent on humidity, at levels above 50% it is a greatly reduced risk, good practices should always be observed.

All Units

Wiring must comply with all applicable codes and ordinances. The warranty is voided if wiring is not in accordance with these specications.

According to the National Electrical Code, a disconnecting means shall be located within sight of and readily accessible from the air conditioning equipment. The unit can be ordered with an optional factory mounted disconnect switch. This switch is not fused. Power leads must be over-current protected at the point of distribution. The maximum rated overcurrent protection device (MROPD) value appears on the unit nameplate.

All units are provided with internal power wiring for single point power connection. The power block or an optional disconnect switch is located within the main control panel. Field power leads are brought into the unit through knockouts in the bottom of the main control panel (see Figure 9 and also Table 5). Refer to the unit nameplate to determine the number of power connections.

NOTE: To wire entry points, refer to certied drawings for

dimensions.

Table 5: Recommended Field Power Wiring

Ampacity (MCA)

20 1 14 75

25 1 12 75

35 1 10 75

50 1 8 75

65 1 6 75

85 1 4 75

100 1 3 75

115 1 2 75

130 1 1 75

150 1 1/0 75

175 1 2/0 75

200 1 3/0 75

230 1 4/0 75

255 1 250 75

NOTE:

1. All wire sizes assu me separ ate conduit for ea ch set of pa rallel c onduc tors.

2. All wi re sizes based on NEC Table 310-16 for 75°C THW wire (copper). Cana dian elect rical c ode wire ampacities may vary.

3. All wi re sizes as sume no vo ltage dr op for short power leads .

Number of Power

Wires Per Phase

Wire Gauge

Insulation

Temperature

Rating (°C)

IM 1125-7 • REBEL ROOFTOPS 16 www.DaikinApplied.com

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WARNING

Provide proper line voltage and phase balance.

Improper line voltage or excessive phase imbalance constitutes product abuse. It can cause severe damage to the unit’s electrical components.

WARNING

Electrical shock hazard. Can cause severe injury or death.

Connect only low voltage NEC Class II circuits to terminal block TB2.

DANGER

Overheating or failure of the gas supply to shut off can cause equipment damage, severe personal injury or death. Turn off the manual gas valve to the appliance before

shutting off the electrical supply.

The preferred entrance for power cables is through the bottom knockouts provided on the unit. If a side entrance is the only option, a hole may be drilled in the stationary upright.

The minimum circuit ampacity (MCA) is shown on the unit

nameplate. Refer to Table 5 for the recommended number of

power wires.

Copper wire is required for all conductors. Size wires in accordance with the ampacity tables in Article 310 of the

National Electrical Code. If long wires are required, it may be

necessary to increase the wire size to prevent excessive voltage drop. Wires should be sized for a maximum of 3% voltage drop. Supply voltage must not vary by more than 10% of nameplate. Phase voltage imbalance must not exceed 2%. (Calculate the average voltage of the three legs. The leg with voltage deviating the farthest from the average value must not be more than 2% away.) Contact the local power company for correction of improper voltage or phase imbalance.

The power source to the unit must be a balanced 3-phase power supply, meaning that the voltage and impedance to the line is matched. Under normal conditions, a balanced power supply will result in balanced current phase-to-phase. Unbalanced voltage and/or current (such as provided with an "Open Delta" conguration), is likely to result in nuisance alarms, premature failure of components and it will void equipment warranty.

A ground lug is provided in the control panel. Size the grounding conductor in accordance with Table 250-95 of the National Electrical Code.

In compliance with the National Electrical Code, a 115 V factory mounted service receptacle outlet is provided. This outlet must be powered by a eld connected 15 A, 115 V power supply. Leads are brought into the unit through the bottom of the main control panel.

Field Control Wiring

The Rebel rooftop units are available with the following eld control connections:

• Space sensor.

• Space sensor with setpoint adjustment.

• Fan operation output.

• VAV box output.

• Remote alarm output.

• External discharge air temperature reset.

• Outdoor air damper minimum position adjustment.

Descriptions of these eld connections are included in the MicroTech III Unit Controller Manual (OM 1141).

Start-up and service of this equipment must be performed by trained and experienced technicians. It is highly

recommended that the initial start-up and future service be performed by Daikin trained technicians who are familiar with working on live equipment. A representative of the owner or the operator of the equipment should be present during start-up to receive instructions in the operation, care and adjustment of the unit.

Before Start-Up

1. Notify inspectors or representatives who may be required to be present during start-up of gas fuel equipment. These could include the gas utility company, city gas inspectors, heating inspectors, etc.

2. Review the equipment and service literature and become familiar with the location and purpose of the furnace controls. Determine where the gas and power can be turned off at the unit and before the unit.

3. Determine that power is connected to the unit and available.

4. Determine that the gas piping, meter, and service regulator

have been installed, tested, and meet the equipment

requirements.

5. Determine that proper instruments will be available for the

start-up. A proper start-up requires the following: voltmeter, manometer or gauges with ranges for both manifold pressure and inlet gas pressure.

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Table 6: 003–015 Electric Heat Data

kW Voltage Amps kW Voltage Amps

208 16.7

NOTE: 1. Maximum temperature rise equals 60ºF

230 15.1 230 90.4

475 7.3 475 43.8

575 6.0 575 36.1

208 33.3

230 30.1 230 135.6

475 14.6 475 65.6

575 12.0 575 54.2

208 50.0

230 45.2 230 N/A

475 21.9 475 87.5

575 18.1 575 72.3

208 83.3

230 75.3

475 36.5

575 30.1

208 99.9

208 149.9

208 N/A

Table 7: DPS 016–028 Electric Heat Data

KW Voltage Amps KW Voltage Amps

208 83.4

230 75.4 230 226.2

460 37.7 460 113.1

575 30.2 575 90.5

208 125.1

230 113.1 230 301.6

460 56.5 460 150.8

575 45.2 575 120.6

208 166.7

230 150.8 230 377.0

460 75.4 460 188.5

575 60.3 575 150.8

120

150

208 250.1

208 333.5

208 416.9

Table 8: Amp Draw Data

Unit Size

(Tons)

3 7.7 7.0 3.5 — 45% 0.0 0.0 0.0 —

4 10.0 9.0 4.5 — 55% 0.0 0.0 0.0 — 0.0 0.0 0.0 — 1 0.9 0.8 0.4

5 11.9 10.8 5.4 — 68% 0.0 0.0 0.0 — 0.0 0.0 0.0 — 1 2.0 1.8 0.9

6 15.0 13.6 6.8 — 89% 0.0 0.0 0.0 — 0.0 0.0 0.0 — 1 2.0 1.8 0.9

7.5 11.9 10.8 5.4 — 68% 8.6 7.8 3.9 — 67.5 73.7 37.1 — 2 2.0 1.8 0.9

10 10.0 9.0 4.5 — 59% 17.5 15.8 7.9 — 93.1 84.2 42.1 — 2 2.0 1.8 0.9

12 15.0 13.6 6.8 — 89% 17.5 15.8 7.9 — 93.1 84.2 42.1 — 2 2.0 1.8 0.9

15 28.3 25.6 12.8 — 100% 17.5 15.8 7.9 — 93.1 84.2 42.1 — 2 2.0 1.8 0.9

16 47.0 42.5 22.9 20.5 — 0 0 0 0

18 47.0 42.5 22.9 20.5 — 0 0 0 0 1 8.0 8.0 4.0

20 47.0 42.5 22.9 20.5 — 0 0 0 0 1 8.0 8.0 4.0

25 47.0 42.5 22.9 20.5 — 39.1 35.4 18.6 15.4 1 8.0 8.0 4.0

28 47.0 42.5 22.9 20.5 — 39.1 35.4 18.6 15.4 1 8.0 8.0 4.0

NOTE: The inverte r compr esor is c ontro lled to have a s oft start and a n LRA <1.0

Horse

Power

NOTE: DPS 0 07–015 575 V Amp Draws: Compressor s and moto rs will b e run of f a 575 to 460V transformer. Motors will be nameplated at 46 0V.

Compressor 1 - Variable Compressor 2 - Fixed Compressor 1 Compressor 2

208 230 460 575 [%] 208 230 460 575 208 230 460 575 208 230 460 575

Supply Fan FLA (DPS 003–015) Exhaust Fan FLA (DPS 003–028) Supply Fan FLA (016–028)

208 230 460 kW 208 230 460 kW 208 230 460 575

1.3 3.1 2.8 1.4 1.0 3.1 2.8 1.4 1.0 — — — —

2.3 5 4.6 2.3 1.7 5 4.6 2.3 1.7 — — — — 3 — — — — — — — — 9.9 9.0 4.5 3.4 4 8.8 7.4 4.0 3.0 8.8 7.4 4.0 3.0 — — — —

5 — — — — — — — — 16.1 14.0 7.0 5.3

7.5 — — — — — — — — 25.0 21.6 10.8 8.2

8 13.5 12.2 6.1 6.0 — — — — — — — —

10 — — — — — — — — 33.0 28.0 14.0 11.0

15 — — — — — — — — 44.8 40.6 20.3 16.2

20 — — — — — — — — 61.0 50.0 25.0 20.0

EAF FL A are per motor. Some D PS 016– 028 units have (2) EAFs a nd motor s.

Compressor RLA Compressor LRA

0.0 0.0 0.0 — 1 0.9 0.8 0.4

See Note

Voltage Voltage Voltage

Condenser Fan

FLA Each

Qty 208 230 460Voltage Voltage Voltage Voltage

1 8.0 8.0 4.0

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Piping System

The Rebel piping system varies signicantly between the multiple possible congurations; heat pump, cooling only, and modulating hot gas reheat. In spite of this multiplicity there are some consistent characteristics. All units have a single circuit with a single or tandem compressor. All units use an electronic expansion valve (EVI) and a start-up by pass solenoid valve (SVB).

Figure 12: Typical Refrigeration Circuit for Cooling Only Unit with Modulating Hot Gas Reheat (DPS 007–015 shown)

refrIgeraTIon sysTeM

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Figure 13: Typical Refrigeration Circuit for Heat Pump Unit with Modulating Hot Gas Reheat (DPS 007–015 shown)

Item Description

EVI

EVO

CV Check Valve, size 3-15 only

REC Refrigerant Receiver

IDF Indoor fan

ODF Outdoor fan

COMP1 Inverter compressor

COMP3

SVB Bypass solenoid valve

RHV Reheat step valve

SVR Receiver solenoid valve

CHV Condenser step valve

OVI

4WV 4-way heat pump valve

OS Oil separator, size 3-15 only

Indoor coil electronic expansion valve

Outdoor coil electronic expansion valve

Fixed speed compressor (7½ thru 15 ton and 25-28 only)

Outdoor electronic expansion valve

IM 1125-7 • REBEL ROOFTOPS 20 www.DaikinApplied.com

DPS 003–015 Component Description

refrIgeraTIon sysTeM

Variable Speed Compressor

A variable speed compressor (COMP1) is used on all DPS(H) 003–015. On small cabinet units (3–6 Tons) the variable speed compressor will be the only one present. On medium cabinet units (7–15 Tons) the variable speed compressor will be on the left. The discharge of the variable speed compressor is located on the side and the suction is located on the top.

These pipes can also be identied by recalling that suction lines will always be larger than discharge lines. The side discharge design is used to create a positively pressurized crank case that returns oil to the scroll set even during low turn down conditions.

Figure 14: Compressor Suction and Discharge on Medium Cabinet (7.5T) Heat Pump (DPH)

Compressor Suction Line

Compressor Discharge Line

Receiver

Only Rebel Heat Pump units will have a receiver. Different volumes of refrigerant are required inside the system during Mechanical Cooling (or defrost) and Mechanical Heating. This is the results of the charge in operating temperatures in Cooling and Heating Mode. The receiver stores the excess refrigerant upstream, in Cooling Mode, of the Indoor Expansion Valve (EVI). Three refrigerant lines connect to the receiver.

In cooling mode the refrigerant leaves (Cooling Mode) the receiver from the bottom connection on its way to the Indoor Expansion Valve (EVI). The refrigerant enters the receiver by the middle connection from the Outdoor Expansion Valve (EVO). The top connection is linked to the Receiver Solenoid Valve (SVR) and is used to bleed refrigerant vapor out of the top of the vessel during the change over from Mechanical Heating to Cooling Mode (or defrost).

In heating mode the refrigerant ow path will be reversed and will enter the receiver at the bottom connection on its way from EVI. The refrigerant will leave the receiver from the middle connection towards EVO. The top connection will always be a vapor bleed connected to SVR regardless of the units operating mode.

Figure 16: Receiver on Medium Cabinet (7.5T) Heat Pump (DPH)

Fixed Speed Compressor (7–15 Only)

The xed speed compressor (COMP3) is used on all medium cabinet (7–15 Ton), DPS, units. This compressor will always be located on the right and like the variable speed has the suction line on the top of the dome entering the scrolls and a discharge exiting from the side of the shell.

Figure 15: Compressor Tandem on Medium Cabinet

Variable Speed

Compressor

(COMP 1)

Fixed Speed Compressor

(COMP 3)

“Vapor Bleed”

leading to SVR

Entering Receiver from Outdoor Coil

(Cooling Mode)

Leaving Receiver

to EVI

(Cooling Mode)

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Oil Separator

All DPS(H) 003–015 units will have an oil separator on the discharge line of the compressor. This device will remove oil from the compressor discharge gas and return it to the compressor suction line. The oil separator has three lines entering it. The connection on the side of the compressor is where the discharge gas enters. The hot gas continues on to the Outdoor Coil from the connection on the top of the separator. On the bottom is a small drain through which the oil returns after separation to the compressor suction. The refrigerant and oil path through the separator will not change depending on Heating or Cooling Mode.

Figure 17: Oil Separator

Hot Gas

Entering

Outdoor Coil

Check Valve

All DPS 003–015 will have check valves on each of the compressor discharge lines. On medium cabinet units (7–15 Tons), two valves, one on each compressor, prevent recirculation of refrigerant during part load conditions. On small cabinet units (3–6 Tons) a single check valve prevents migration of refrigerant into the scrolls during off cycles.

Figure 19: Discharge Line Check Valves on Large Cabinet (7.5T) Heat Pump (DPH)

Y-Joint connecting

COMP1 and COMP2

Discharge

CAUTION!

Correct Orientation

Must Be Observed

Discharge Gas

from Compressor

Oil Drain into

Compressor

Suction Line

Figure 18: Secondary Oil Separator

Secondary

Oil Separator

Direction of

Compressor

Discharge Gas

IM 1125-7 • REBEL ROOFTOPS 22 www.DaikinApplied.com

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High Pressure Switch

All Rebel Units will have a high pressure switch on each compressor. Medium cabinet units (7–15 Tons) will have an HP1 switch on the variable speed compressor (COMP1) and a HP3 on the xed speed compressor (COMP3). These switches are normally closed devices that are brazed directly to the refrigerant piping. When the pressure at the switch exceeds 580 PSIG the switch will open. This opening will interrupt the control signal to the variable compressor drive or de-energize the contactor coil on the xed speed compressor, both acts will shut down the compressors and generate an alarm at the MicroTech III keypad.

Figure 20: High Pressure Switch

High Pressure Switch

(HP1)

Four-Way Valve

The Four-Way Valve (4WV) also known as a Reversing Valve is a component only used on Heat Pumps. This device is used to direct the discharge gas from the compressor into the outdoor coil (Heating Mode) or indoor coil (Cooing Mode). This device is defaulted to cooling and when un-energized will direct the discharge gas into the outdoor coil.

Figure 22: Four-Way Valve

Compressor Discharge Gas

Cooling Mode: Suction Vapor from Indoor Coil

Suction Vapor

to Compressor

Heating Mode: Discharge Gas to Indoor Coil

Refrigerant Screen

During manufacturing, service, and repair there is always the potential for debris to accidentally enter the sealed refrigeration system. Filter screens are positioned around the refrigerant circuit to prevent any possible debris from entering critical components; expansion valves, compressors, etc. These screens are not bi-direction and must be installed in a specic direction if replaced. Please be aware that these screens are not desiccant lters and provide no moisture protection for compromised systems.

Figure 21: Refrigerant Screen

Refrigerant Screen

Cooling Mode: Discharge Gas to Outdoor Coil

Heating Mode: Suction Vapor from Outdoor Coil

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By-Pass Solenoid Valve

The By-Pass Solenoid Valve (SVB) is used to “short-circuit” the high pressure compressor discharge to the low pressure suction side during start-up. This increases compressor longevity by minimizing starting torque and inrush current.

Figure 23: By-pass Solenoid Valve

Short Circuit between

High Pressure Discharge

and Low Pressure Suction

By-Pass

Solenoid

Valve

Indoor Expansion Valve

The Indoor Expansion Valve (EVI) is a 12 VDC stepper motor driven valve, used in heating and cooling mode. In cooling mode EVI is used to expand the refrigerant entering the Indoor Coil, operating as an evaporator, in much the same way as a TXV on a conventional air conditioner. In heating mode the EVI can operate in two different modes, congurable at the keypad.

When congured for Standard during heating mode the EVI will modulate to fully open and remain in this position. When congured for heating mode the EVI will modulate to maintain the Subcooling Set-Point.

Figure 25: Indoor Expansion Valve

Indoor

Refrigerant Temperature Sensor (IRT)

Indoor

Expansion

Valve (EVI)

Receiver Solenoid Valve

The Receiver Solenoid Valve (SVR) is used to “bleed off” refrigerant vapor from the top of the Receiver during pump down or the transition between mechanical heating and defrost. Cooling only units will not have this component, only

Heat Pumps .

Figure 24: Receiver Solenoid Valve

Receiver Solenoid

Valve (EVI)

Vapor Bleed

from top of

Receiver to

Compressor

Suction

Outdoor Expansion Valve

The Outdoor Expansion Valve (EVO) is a 12 VDC stepper motor driven valve, used in heating and cooling mode. Cooling only units will not have this component, only Heat Pumps. In heating mode the EVO is used to expand the refrigerant entering the Outdoor Coil, which is now and evaporator, in much the same way as a TXV on a conventional air conditioner. In Cooling Mode the EVO can operate in two different modes, congurable at the keypad. When congured for Standard during Cooling Mode the EVO will modulate to fully open and remain in this position. When congured for Cooling Mode the EVO will modulate to maintain the Subcooling Set-Point.

IM 1125-7 • REBEL ROOFTOPS 24 www.DaikinApplied.com

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Suction Pressure Transducer

The Suction Pressure Transducer (PTS) is a refrigerant pressure sensor that screws onto a Schrader tting on the suction line of the compressor deck. On single compressor units (3–6T) this sensor is located on the suction line. On tandem, two compressor units (7–15T), the PTS is located upstream of the joint suction.

This sensor is used to ensure that the compressor does not leave the operating envelope and is used to regulate the super heat leaving the indoor coil and entering the compressor.

Discharge Pressure Transducer

The Discharge Pressure Transducer (PTD) is a refrigerant pressure sensor that screws onto a Schrader tting on the discharge line of the compressor system. On single compressor units (3–6T) this sensor is located on the discharge line. On tandem, two compressor units (7–15T), the PTD is located down stream of the joint discharge.

This sensor is used to ensure that the compressor does not leave the operating envelope and is used to regulate the outdoor fan speed and maintain head pressure.

Discharge Refrigerant Temperature

All Rebel units will have a Discharge Refrigerant Temperature Sensor (DRT1 / DRT3) on the discharge line of each compressor. This sensor is attached the piping with a metal clip and wrapped in insulation. The purpose of this device is to increase compressor life by preventing it from running outside of the operating envelope.

Outdoor Refrigerant Temperature

Only Rebel Heat Pumps units will have an Outdoor Refrigerant Temperature Sensor (ORT). This sensor is used in Cooling Mode when ClgEVOmethod is set to control subcooling. This sensor is attached to the refrigerant piping upstream (Cooling Mode) of the Outdoor Expansion Valve (EVO).

Figure 26: Outdoor Expansion Valve

Outdoor Expansion

Valve (EVI)

Outdoor

Refrigerant

Temperature

Sensor (ORT)

Defrost Temperature Sensor

Only Rebel Heat Pump, DPH, units will have a Defrost Temperature Sensor (DFT). This sensor is used in Heating Mode and Defrost Mode to determine the amount of frost accumulated on the Outdoor Coil.

Suction Refrigerant Temperature

All Rebel units will have a Suction Refrigerant Temperature Sensor (SRT). This sensor is located on the suction line. Unlike DRT1 or 3 there is only one SRT for tandem compressor units. This sensor is used to determine the suction super heat entering the compressor and is the control input for the EVI in cooling mode (EVO in heating mode).

Indoor Refrigerant Temperature

Only Rebel Heat Pump units will have an Indoor Refrigerant Temperature Sensor (IRT). This sensor is used in Heating Mode when htgEVImethod is set to control subcooling. This sensor is attached to the refrigerant piping downstream (Cooling Mode) of the Indoor Expansion Valve (EVI).

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Heating

The unit’s heating mode of operation is determined by the control temperature and the heating setpoint temperature. The unit enters the heating mode of operation by comparing the control temperature to the heating setpoint.

The control temperature can be either the return temperature or the space temperature.

The return temperature is typically used for VAV units and the space temperature is typically used for CAV units.

The unit goes into the heating mode of operation when the control temperature (return or space temperature) is below the heating setpoint by more than ½ the deadband.

For example, a standard air conditioning unit with supplemental gas, electric, or hot water heat with a heating setpoint of 68.0ºF and a deadband of 1.0ºF would enter heating mode if the control temperature reached 67.4ºF. When this takes place, the heating mode of operation will begin and the 1st Stage of heating operation will start.

Heat Pump

(DPS 003 –015 ton)

The heating mode of operations will be slightly different for heat pump units. It is the manufacturer’s recommendation that all Rebel heat pump units be purchased with supplemental gas, electric, or hot water heat. When the control temperature drops below the heating setpoint by half the deadband the unit will energize the four way valve and initiate mechanical heating.

On heat pumps mechanical heating is the primary source of heat and will always be the unit’s rst attempt to meet the application’s load. After start-up the variable compressor will ramp up to meet the DAT Setpoint. If the mechanical heating capacity at the ambient conditions is capable of meeting the building load the variable speed compressor will stabilize at some value below its maximum speed. If the heat pump’s capacity is insufcient at the ambient conditions the supplemental (gas, electric, hot water) heat will be enabled and gradually ramp/stage on to make up the capacity shortage. If the combined capacity of the heat pump’s mechanical and supplemental heating is greater than the building load the supplemental supply will ramp/stage down. The unit will always seek to operate with mechanical heating as much as possible.

Periodically during heating operations the unit will need to enter defrost to remove frost build up from the outdoor coil. During defrost mechanical heating will be unavailable and the supplemental heat will ramp/stage up to meet the DAT set-point.

Defrost

(DPS 003 –015 ton)

Defrost is a temporary and infrequent period during normal heating operations on Rebel heat pumps. The purpose of defrost is to remove frost that has built up on the outdoor coil during mechanical heating. In heating mode the outdoor coil acts as an evaporator to “pull” heat out of the ambient air. As a result the surface temperature of the outdoor coil is below the ambient temperature and depending on conditions maybe below freezing. During prolonged mechanical heating while the surface temperature of the outdoor coil is below 32ºF frost will form.

The defrost operation is similar to mechanical cooling. In defrost the four way valve will de-energize and the hot gas from the compressor will be forced into the outdoor coil, rejecting heating to the ambient, and melting any frost formed on the coil. To speed up the melting process during a defrost cycle the OA damper will close and the outdoor fan will de-energize. During this period the supplemental (gas, electric, hot water) heat will ramp/stage up to maintain the unit’s DAT Setpoint.

Rebel heat pump unit’s have demand based defrost control and will operate in defrost only as long as necessary to remove frost from the outdoor coil.

Charging

Rebel units have advanced charge management systems that obsolete many common techniques for determining over or under charged conditions. The charge management system means that super heat and subcooling values will oat to achieve the peak real time energy efciency possible at current operating conditions (building load and ambient temperature). Rebel units also use electronic expansion valves that can not be adjusted manually. Refrigerant should never be added or removed from the system based on the desire to achieve an arbitrary subcooling value. It will always be Daikin's recommendation that unit’s suspected of being over/under charged have all of their refrigerant removed, leak tested with nitrogen, and then re-charged based on the unit name plate.

Table 9: Refrigerant Charge

Unit Size

3C 10.5 12.9 12.0 14.4

3M 6.6 11.3

4C 11.1 13.5 12.6 15.0

4M 6.5 11.3

5 15.3 18.2 16.8 19.7

6 15.3 18.2 16.8 19.7

7.5 11.1 17.8 26.0 31.2

10 20.0 25.8 40.0 45.8

12 20.0 25.8 40.0 45.8

15 24.4 30.2 46.0 51.8

3C & 4C with n tube outdoor coils 3M & 4M with micro-channel outdoor coils

Cooling Model Heat Pump Model

Standard Unit

w/ MHGRH

Standard Unit

w/ MHGRH

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DPS 016–028 Ton Component Description

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Variable Speed Compressor

A variable speed compressor (COMP1) is used on all DPS 016-028. On DPS 16–20 ton units, the variable speed compressor will be the only one present, and be on the right. The discharge of the variable speed compressor is located on the top and the suction is located on the side.

These pipes can also be identied by recalling that suction lines will always be larger than discharge lines. The side suction design is used to cool the motor with cold refrigerant.

Figure 27: Compressor Suction and Discharge on DPS 025–028 units

Figure 28: High Pressure Switch

High Pressure Switch

Refrigerant Screen

Fixed Speed Compressor (DPS 025–028 Only)

This compressor will always be located on the left and like the variable speed has the suction line on the side of the dome entering the scrolls and a discharge exiting from the top of the shell.

High Pressure Switch

All Rebel Units will have a high pressure switch on each compressor. HP1 switch is on the variable speed compressor (COMP1) and HP3 is on the xed speed compressor (COMP3). These switches are normally closed devices that are brazed directly to the refrigerant piping. When the pressure at the switch exceeds 580 PSIG the switch will open. This opening will interrupt the control signal to the variable compressor drive or de-energize the contactor coil on the xed speed compressor, Both acts will shut down the compressors and generate an alarm at the MicroTech III keypad.

Figure 29: Refrigerant Screen

Refrigerant Screen

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Indoor Expansion Valve

The Indoor Expansion Valve (EVI) is a 12 VDC stepper motor driven valve. In cooling mode EVI is used to control the superheat and expand the refrigerant entering the Indoor Coil, operating as an evaporator, in much the same way as a TXV on a conventional air conditioner.

Figure 30: Indoor Expansion Valve

Indoor

Expansion

Valve

Easy

Expansion

Valve

Access

Panel

Suction Pressure Transducer

The Suction Pressure Transducer (PTS) is a refrigerant pressure sensor that screws onto a Schrader tting on the suction line of the compressor deck. On single compressor units (DPS 016–020) this sensor is located on the suction line. On tandem, two compressor units (DPS 025–028), the PTS is located upstream of the joint suction.

This sensor is used to ensure that the compressor does not leave the operating envelope and is used to regulate the super heat leaving the indoor coil and entering the compressor.

Discharge Pressure Transducer

The Discharge Pressure Transducer (PTD) is a refrigerant pressure sensor that screws onto a Schrader tting on the discharge line of the compressor system. On single compressor units (DPS 016–020) this sensor is located on the discharge line. On tandem, two compressor units (DPS 025–

028), the PTD is located downstream of the joint discharge.

This sensor is used to ensure that the compressor does not leave the operating envelope and is used to regulate the outdoor fan speed and maintain head pressure.

Discharge Refrigerant Temperature

All Rebel units will have a Discharge Refrigerant Temperature Sensor (DRT1/DRT3) on the discharge line of each compressor. This sensor is attached the piping with a metal clip and wrapped in insulation. The purpose of this device is to increase compressor life by preventing it from running outside of the operating envelope.

Suction Refrigerant Temperature

Bypass Solenoid

The bypass solenoid (SVB) is used to “short circuit” the high pressure compressor discharge to the low pressure suction side during startup. This increases compressor life by reducing the startup torque and inrush current.

IM 1125-7 • REBEL ROOFTOPS 28 www.DaikinApplied.com

VFD Compressor Operation – DPS 016–028

VFD compressor modulation is controlled by a Mobus® signal from the unit controller. The minimum VFD compressor speed is 25 rps (1500 rpm) and the maximum VFD compressor speed is 100 rps (6000 rpm), but the minimum and maximum limits per unit may vary depending on operating conditions and unit

model size.

The VFD compressor is a 4 pole motor design that operates off a frequency signal from the VFD between 50Hz and 200Hz.

At Start-up the VFD compressor will automatically ramp up to 50 rps for rst 10 seconds for lubrication requirements.

Crankcase heating for VFD Compressor is performed by the VFD via DC-holding current through the motor windings.

VFD compressor modulation is additionally monitored and adjusted in order to maintain operation within the approved compressor operating envelope.

Table 10: VFD Compressor Modulation Ranges

VFD Modulation Range

VFD Max rps

DPS Unit

Model

016 25 rps/0 Vdc 60 rps/4.0 V 90 rps/6.0 V

018 25 rps/0 Vdc 100 rps/8.7 V 100 rps/10.0 V

020 25 rps/0 Vdc 100 rps/8.7 V 100 rps/10.0 V

025 25 rps/0 Vdc 85 rps/8.0 V 100 rps/10.0 V

028 25 rps/0 Vdc 85 rps/8.0 V 100 rps/10.0 V

* High and Low Oil Boost are explained on page 30

VFD Min rps/

VFD Min V

VFD and Fixed

Comp(s) ON

1 Fixed ON

VFD1Max rps/

VFD1MaxV

VFD Comp Only

VFDMax rps/

VFDMaxV

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DPS Size 025 & 028, Two Compressor Units

If the VFD compressor were to become inoperative, the unit can continue to operate on the remaining xed speed compressor until the unit can be serviced.

When the VFD compressor is at its maximum speed and more capacity is required, a xed speed compressor is started while the VFD compressor is reduced to minimum speed at which point it resumes modulating to maintain the discharge temperature. When the VFD compressor is at its minimum speed and less capacity is required, a xed speed compressor is turned OFF while the VFD compressor is increased to maximum speed at which point it resumes modulating to maintain discharge temperature.

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VFD Compressor Control

Control of the VFD compressor is accomplished with a digital output enable signal and a 0-10VDC analog modulating control signal.

General VFD Compressor Start Sequence

On a call for VFD compressor operation the VFD enable output is energized (on) and the 0-10VDC analog control signal is set to 3.33VDC (50 rps) for 10 seconds. During this 10 second initial period the VFD compressor’s internal logic ramps the compressor to 50 rps to insure compressor startup oil lubrication. After 10 seconds the VFD compressor control signal begins modulation to maintain the cooling discharge set point.

Compressor Stage Up Transition (DPS 025 & 028 Only)

When the VFD compressor has been operating at maximum capacity for the cooling stage time period and there is a call for more cooling capacity the following transition sequence is followed when staging up.

During the xed compressor stage UP sequence, the VFD compressor speed is reduced to its minimum, as a xed speed compressor is turned on. Note that the VFD compressor speed range is extended for these staging points to assure smooth transition and to minimize capacity gaps. Typically, the VFD compressor is overdriven (higher speed than normal full load rating speed) before staging up the xed compressor. The VFD is held at minimum speed for 30 seconds before normal

modulation resumes.

Compressor Stage Down Transition (DPS 025 & 028 Only)

When the VFD compressor has been operating at minimum capacity for the cooling stage time period and there is a call for less capacity the following transition sequence is followed when staging down.

During the xed speed compressor stage DOWN sequence, the VFD compressor speed is increased to maximum speed (which varies with unit size and number of operating xed compressors) as the xed speed compressor is turned off. Note that the VFD compressor speed range has been extended for these staging points to assure smooth transition and to minimize capacity gaps. Typically, the VFD compressor will be overdriven (higher speed than normal full load rating speed) when staging down the xed compressor.

Dehumidication Transition During Cooling State

When dehumidication operation becomes active while the unit is in the Cooling operating state, The VFD compressor is ramped to its maximum capacity. If the VFD capacity at this point is already above 75% of its full modulation a xed compressor is also turned on. The compressors are held at this capacity for 1 minute before normal modulation resumes, to maintain leaving coil temperature (LCT).

• VFD compressor will load up completely before starting any xed speed compressors to achieve LCT of 45F (default) with the VFD compressor option. LCT may be set between 45F to 52F.

• If reheat signal is at 100% for 10 minutes and the unit is unable to raise the DAT to desired point, the controller will stage off the xed compressor and modulate the VFD compressor speed to achieve the DAT set point.

Oil Balance/Boost Operational Sequence

When a low oil level is indicated in the VFD compressor sump, the unit switches to either an oil balance or oil boost state. The VFD compressor speed is increased during these modes to promote the return of refrigerant oil to the VFD compressor.

To avoid short cycling of the oil balance/boost sequence, no action is taken until a low oil indication has been present for 5 consecutive run minutes.

The unit determines whether to enter the oil balance or oil boost mode based on the running conditions when a low oil indication is experienced. The balance mode is only used when a VFD compressor is part of a tandem compressor set. The balance mode is usually entered rst, and is utilized to move oil from the xed speed compressor to the VFD compressor. If this mode fails to resolve the low oil indication issue, the unit will then go into the boost mode. The boost mode is utilized to return oil from the refrigerant system to the compressors. VFD compressors that are not part of a tandem compressor arrangement will skip the balance mode and only utilize the

boost mode.

The balance mode will be entered if the VFD compressor is part of a tandem compressor arrangement and the xed speed compressor is running, and there is a low oil indication. Upon entering the oil balance mode the xed speed compressor is turned off and the VFD compressor speed is increased to the oil boost value shown in Table 9 on page 26. The VFD compressor runs at this condition until the optical oil sensor veries that oil is present for 3 continuous minutes. Unit Controller default is set for a 10 minute max balance.

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Daikin DPS012, DPS015, DPS004, DPS016, DPS018 Installation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual