Daikin RCS 015D, RCS 140D Installation And Maintenance Manual
Installation and Maintenance Manual IM 893-10
Group: Applied Air Systems
Part Number: IM 893
Date: July 2017
RoofPak® Singlezone Heating and Cooling Units
RPS/RDT/RFS/RCS 015D—140D
with MicroTech® III Unit Controller and Refrigerant R-410A
Table of ConTenTs
Introduction .................................3
Unit Nameplate ............................3
Compressor Nameplate .....................3
Gas Burner Nameplate ......................3
Hazard Identication Information ..............3
Unit Description ............................4
Refrigeration Piping ........................6
Control Locations ..........................7
Control Panel .............................8
Controls, Settings and Functions ..............15
FanTrol .................................16
Condenser Fan Arrangement ................18
Mechanical Installation .......................19
Receiving Inspection .......................19
Unit Clearances ...........................19
Roof Curb Assembly and Installation ..........21
Post and Rail Mounting .....................24
Rigging and Handling.......................24
Charging the System ......................33
Unit Piping ...............................35
Damper Assemblies .......................37
Cabinet Weather Protection .................39
Installing Ductwork ........................39
Electrical Installation .........................42
Field Power Wiring ........................42
Preparing Unit for Operation ..................46
Preparing Unit for Operation .................46
Sequences of Operation ......................49
MicroTech III Controller Operation ..............51
Using the Keypad/Display ...................51
Wiring Diagrams ............................53
Unit Options ................................75
Table of ConTenTs
Control Actuators ..........................75
Modulating Hot Gas Reheat .................77
Smoke and Fire Protection ..................80
Field Output Signals .......................82
DesignFlow™ Outdoor Air Damper Option ......86
Propeller Exhaust Fan Option ................89
Ultraviolet Lights Option ....................92
MicroTech III Remote User Interface ..........94
VFD Compressor Operation .................96
Variable Speed Scroll Compressor ...........101
Check, Test, and Start .......................104
Economizer Start-up ......................105
Compressor Startup ......................106
Heating System Startup ...................108
Air Balancing ............................108
Drive Belt Alignments......................109
Final Control Settings .......................113
Keypad/Display Menu Structure ...............114
Maintenance ...............................127
Servicing Control Panel Components .........127
Planned Maintenance .....................127
Unit Storage ............................128
Scroll Compressor Piping ..................134
Refrigerant Charge .......................136
Control Panel Components .................139
Replacement Parts List ......................144
Service and Warranty Procedure ..............145
Limited Product Warranty ....................147
Rooftop Equipment Warranty Registration Form . 148
Quality Assurance Survey Report .............151
IM 893-10 • ROOFPAK SINGLEZONE UNITS 2 www.DaikinApplied.com
InTroduCTIon
This manual provides general information about the “D” vintage
Daikin RoofPak applied rooftop unit, models RPS, RDT, RFS
and RCS. 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. For further information on the
optional forced draft gas-red furnace, refer to IM 684 or
IM 685.
The MicroTech III applied rooftop unit controller is available
on “D” vintage applied rooftop units. For a detailed description
of the MicroTech III components, input/output congurations,
eld wiring and information on using and programming the
MicroTech III unit controller, refer to OM 920.
For a description of operation and information on using
the keypad to view data and set parameters, refer to the
appropriate program-specic operation manual (see Figure 1).
Table 1: Program Specic Rooftop Unit Literature
Rooftop unit control conguration Operation manual number
Daikin 208 -460 V OM 844
VFDs
Daikin 575 V OM 895
Non-Daikin See vendor manuals
Unit Nameplate
The unit nameplate is located on the outside lower right
corner on the main control box door. It includes the unit
model number, serial number, unit part number, electrical
characteristics, and refrigerant charge.
InTroduCTIon
Compressor Nameplate
On units that utilize the tandem compressor design, each
compressor includes an individual nameplate along with a
nameplate identifying the tandem compressors.
On units that utilize the trio compressor design, each
compressor includes an individual nameplate. There is no
nameplate identifying the trio compressors.
Gas Burner Nameplate
On units that include gas heat, the nameplate is located on the
lower right corner on the main control box door. It includes the
burner model number, minimum/maximum input, maximum
temperature rise, and minimum CFM.
Hazard Identication 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.
CAUTION
Cautions indicate potentially hazardous situations, which can
result in personal injury or equipment damage if not avoided
Figure 1: Nomenclature
RoofPak
Unit conguration
DT = Draw-through
P = Heating, mechanical cooling
F = Heating, future mechanical cooling
C = Condensing section only
Singlezone unit
Nominal capacity (tons)
Design vintage
DX coil
L = Large face area
S = Standard face area
RCS / R DT / RFS / R P S 070 D L A S 5
DX coil
4 = 12 fpi, 4-row or 10 fpi, 5-row
5 = 12 fpi, 5-row or 10 fpi, 6 row
6 = 12 fpi, 6 row
Y = Other
VFD
S = SAF VFD
Y = No VFD
V = SAF & Compressor VFD
Heating medium
A = Natural gas
E = Electric
S = Steam
W = Hot water
Y = None (cooling only)
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Unit Description
Typical Component Locations
Figure 2 shows an RPS/RDT/RFS/RCS unit. Figure 3 shows
a typical RPS unit with the locations of the major components.
Figure 4 shows a typical RDT unit with the locations of the
major components. These gures are for general information
only. See the project’s certied submittals for actual specic
dimensions and locations.
Figure 2: RPS/RDT/RFS/RCS Unit
InTroduCTIon
RPS/RDT
Figure 3: Typical Component Locations—RPS Units
1.5" NPT Drain
Condenser
control panel
(RCS only)
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Figure 4: Component Locations—RDT Units
InTroduCTIon
1.5 NPT drain
www.DaikinApplied.com 5 IM 893-10 • ROOFPAK SINGLEZONE UNITS
Refrigeration Piping
B
A
J
D
L
K
N
M
H F I
E
P
P
O
A Compressor (1, 2, or 3 per circuit) †
B Discharge line †
C Condenser coil †
D Evaporator coil *
E Manual charging/evacuation valve †
F Filter-drier †
H Sightglass †
I Liquid line *†
J Suction line *†
K Thermal expansion valve *
L Distributor *
M Drop solenoid valve *
N Hot gas bypass valves (optional) *
O Hot Gas bypass piping (optional) *†
P Manual shutoff valve (optional)
Q Condenser Coil Splitter Solenoid Valve**
*Supplied on RFS units
**Variable Speed Inverter Compressor Unit Only
†Supplied on RCS units
Q
C
This section presents the unit refrigeration piping diagrams for
the various available congurations.
Figure 5: Circuit Schematic
InTroduCTIon
Figure 6: Condenser Piping, Scroll Compressors, 2 to 3 Compressors per Circuit are Provided (6 Compressors* Shown)
* Unit with Fixed-Speed Compressors shown
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Control Locations
(optional)
)
(
SC11, 12
(optional)
Figure 7 (RPS Units) and Figure 8 (RDT Units) Additional
information is included in Table 2 on page 15 and show the
locations of the various control components mounted the wiring
diagram legend, which is included in wiring throughout the unit.
Figure 7: Control Locations—RPS units
Comp*
FS1
SD2
optional)
Return air
economizer
C19
RAT
Filter
section
Supply
fan
section
LT11
S11,
REC11
(optional)
section
OAE
OAT
ACT3
ACT6 (optional)
RAE (opti onal)
Heat
S10, R EC10
PC5
DX
section
LT10
See Control Panel on page 8 for the Wiring Diagrams on
page 51. locations of control components mounted in control
panels.
VFD
Discharge
plenum
section
HL22
(optional)
OOE*
section
SD1
SV11*
VM1
(optional)
Condensor
PC7
EFT
(optional)
(optional)
* Only for VFD Compressor Units
DAT
(optional)
(optional)
C11, 12
(optional)
ACT5 (optional)
SV9, SV10*
HTR1-2, HTR3-4 (optional
InTroduCTIon
Figure 8: Control Locations—RDT Units
SC11, 21
DAT
(optional)
C11, 21
(optional)
SV9, SV10*
HTR1-2, U1/U2
HTR3-4 (optional)
Comp*
VFD
Supply fan
discharge
plenum
RAE
C9
ACT3
ACT6
(optional)
section
PC5
OAE
OAT
Heat
section
DX
section
Filt er
section
Economizer
return air
C19, 20
(optional)
RAT
LT11 (optional)
S11, REC11
SD2
(optional)
OOE*
Condenser
SV11*
section
LT10 (optional)
S10, REC10 (optional)
SD1 (optional)
VM1
(optional)
FS1
(optional)
* Only for VFD Compressor Units
www.DaikinApplied.com 7 IM 893-10 • ROOFPAK SINGLEZONE UNITS
Control Panel
P
The unit control panels and their locations are shown in the
from these gures depending on the particular unit options.
following gures. These gures show a typical unit See Wiring
Diagrams on page 51 for the legend and conguration.
Specic unit congurations may differ slightly component
description.
Figure 9: Control Panel Locations
OOE*
SV11*
InTroduCTIon
rop exhaust/ return fan
* Located on the opposite side of the RPS Condensing Unit Control Panel
Comp*
VFD
IM 893-10 • ROOFPAK SINGLEZONE UNITS 8 www.DaikinApplied.com
Figure 10: Typical Main Control Panel, 045D to 075D, 460 Volt
InTroduCTIon
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Figure 11: Typical Main Control Panel, 080D to 140D, 460 Volt
InTroduCTIon
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InTroduCTIon
Figure 12: Typical Gas Heat Panel, 1000 MBh (High TD) Figure 13: Typical Prop Exhaust Panel, 3 Fans, 460 Volt
IT
R22
TD10
M51 M52 M53
TB11
AS
R20
R23 R21
LS2
LS1
AFD20 GND
Figure 14: VFD Bypass Panel, 40 HP, 460 Volt
S3
FSG
FSG Time
www.DaikinApplied.com 11 IM 893-10 • ROOFPAK SINGLEZONE UNITS
Figure 15: RCS Control Panel with MicroTech III, RPS 045D to 079D
Figure 16: RCS Control Panel with MicroTech III, RPS 080D to 140D
InTroduCTIon
IM 893-10 • ROOFPAK SINGLEZONE UNITS 12 www.DaikinApplied.com
InTroduCTIon
Figure 17: Electric Heat Panel, Sizes 045D to 79D
FB31FB32FB33
M31M32M33
H53
TB11
M42
FB41FB42FB43
M41M43
GLG3
Figure 19: Electric Heat Panel, Sizes 080D to 140D
FB31FB32FB33
M31M32M33
FB34FB44
M34M44
FB41FB42FB43
M41M42M43
H53
TB11
DS3
Figure 18: VFD Compressor Panel, SIzes 016D–074D
Fan
(M3)
TB14
R38
R40
VFD 2
Fan
(M4)
LCP
(Local
Control
Panel)
GLG3
DS3
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Figure 20: Harness Plug Connector Detail
RATS OATSDATS
FP1 OPEN1EPTS
AFD10 AFD20
SV12 SV56
ACT3 OPEN2
OAE PC7PC5
HL22 OPEN3
InTroduCTIon
GSHT1 GSHT2
SD1 SD2
DFRH DFLH OPEN4
COMP1 COMP2
COMP3 COMP4
COMP6COMP5
LT11LT10
LT OP1 LT OP2
IM 893-10 • ROOFPAK SINGLEZONE UNITS 14 www.DaikinApplied.com
InTroduCTIon
Controls, Settings and Functions
Table 2: Controls, Settings, and Functions
Symbol Description Function Reset Location Setting Range Differential Part No.
CS1 & 2
CDS 2 Discharge Thermostat Refrigerant temperature N/A Compressor N/A N/A N/A 910150290
DAT
DHL Duct high limit switch
EFT
FP1, 2 Frost protection
FS1 Freezestat
HP1, 2 High pressure control
LP1, 2 Low pressure control
MCB Main control board Processes input information N/A Main control box N/A N/A N/A 060006101
MF3, 4 Cooling fan Ventilate VFD box N/A VFD box N/A N/A N/A 910147046
MP1–6
OAE
OAT
OOS Optical Oil Sensor Sense oil level N/A Compressor sump N/A N/A N/A 910150291
PC5 Dirty lter switch Senses lter pressure drop Auto First lter section As required
PC6 Dirty lter switch Senses lter pressure drop Auto Final lter section As required
PC7 Airow proving switch
PT1, 2 Pressure transducer Sense high side pressure N/A Condenser panel N/A 0–700 psig N/A 910153045
RAE
RAT
SD1
SD2
SPS1
SPS2
S1 System switch
S7 ON-OFF-AUTO switch Used to manually switch unit N/A Main control box N/A N/A N/A —
SV1-2 Drop solenoid
SV9, 10 Splitter solenoid valve Control refrigerant ow N/A Condenser Normally open
SV11 OIV injection solenoid Direct oil in compressor N/A Compressor Normally closed N/A
Switch (toggle),
refrigerant circuit
Discharge air
temperature sensor
Entering fan air
temperature sensor
Compressor motor
protector
Enthalpy control
(electromechanical)
Enthalpy control
(electronic)
Outside air
temperature sensor
Return air enthalpy
sensor
Return air temperature
sensor
Smoke detector,
supply air
Smoke detector,
return air
Static pressure sensor
duct #1
Static pressure sensor
duct #2
Static pressure sensor:
building (space)
pressure
Shuts off compressor
control circuits manually
Senses discharge air
temperature
Prevents excessive VAV
duct pressures; shuts fan
OFF
Senses entering fan air
temperature
Senses DX coil temperature
for frost protection
Shuts fans OFF, opens
heating valve, and closes
outdoor damper if low
air temperature at coil is
detected
Stops compressor when
refrigerant discharge
pressure is too high
Stops compressor when
suction pressure is too low
Senses motor winding
temperature, shuts
compressor OFF on high
temperature
Returns outside air dampers
to minimum position when
enthalpy is too high
Returns outside air dampers
to minimum position when
outside air enthalpy is
higher than return air
enthalpy (use RAE)
Senses outside air
temperature
Senses supply fan pressure
to prove airow
Used to compare return
air enthalpy to outside air
enthalpy (used with OAE)
Senses return air
temperature
Initiates unit shutdown if
smoke is detected
Initiates unit shutdown if
smoke is detected
Converts static pressure
signals to voltage signals
Converts static pressure
signals to voltage signals
Converts static pressure
signals to voltage signals
Shuts off entire control
circuit (except crankcase
heaters)
Shuts liquid line when
compressor is OFF
N/A Main control panel N/A N/A N/A 01355000
N/A
Auto Main control panel
N/A Inlet of supply fan N/A N/A N/A 060004705
Auto DX coil
Auto Heating section
Manual
(relay
latched)
Auto Condenser panel See page 115 N/A
Auto at 3400
ohms
Auto
Auto
N/A N/A N/A N/A N/A 060004705
Auto Supply fan section
N/A Economizer section N/A N/A N/A 049262202
N/A Return air section N/A N/A N/A 060004705
Manual
Manual Return air section N/A N/A N/A 04925001
N/A Main control box N/A
N/A Main control bo N/A
N/A Main control box N/A
N/A Main control box N/A N/A N/A 001355000
N/A
Discharge air
section
Condenser panel See page 115 N/A 150 psi 403585001
Compressor
junction box
Economizer
section
Economizer section
Fully CW past “D”
(when used with
RAE)
Discharge air
section
Discharge air
section
N/A N/A N/A 060004705
3.5ʺ w.c
(871.8 Pa)
30° +/-6° open 45°
+/- 6° close
38°F (3°C)
or as required
9 K–18 K ohms 700 ohms cold N/A 044691509
“B” or as required A–D
A–D N/A N/A 049262201
0.10ʺ w.c.
(25 Pa)
N/A N/A N/A 04925001
N/A N/A N/A 049266502
0.05–5.0ʺ w.c.
(12.5–1245.4 Pa)
N/A 15° 113073401
35°F–45°F
(2°C–7°C)
0.05-5ʺ w.c.
(12.5–1245.4 Pa)
0.05-5ʺ w.c.
(12.5–1245.4 Pa)
0.05-5ʺ w.c.
(12.5–1245.4 Pa)
0–5ʺ w.c. (0–1245.4
Pa) 1–6 V (dc) out
0–5ʺ w.c. (0–1245.4
Pa) 1–6 V (dc) out
-025–0.25ʺ w.c.
(-62.3–62.3 Pa)
1–5 V (dc) out
Open at 350 psig
Close at 250 psig
0.05ʺ w.c.
(12.5 Pa), xed
12°F
(7°C), xed
50 psi low ambient
option/
70 psi standard
Temperature: 3.5°F
(2°C) Humidity: 5%
xed
0.05ʺ w.c.
(12.5 Pa)
0.05ʺ w.c.
(12.5 Pa)
0.05ʺ w.c.
(12.5 Pa), xed
N/A 049545007
N/A 049545007
N/A 049545006
N/A —
Activated above
50 rps
065493801
065830001
910139364
030706702
065493801
065493801
060015801
910150289
www.DaikinApplied.com 15 IM 893-10 • ROOFPAK SINGLEZONE UNITS
FanTrol
The FanTrol, provided on all units, is a method of head
pressure control that automatically cycles the condenser fans
in response to ambient air temperature. This feature maintains
head pressure and allows the unit to run at low ambient air
temperatures.
RPS/RDT and RCS units have two independent refrigerant
circuits with one to four condenser fans being controlled
independently by the ambient air temperature of each circuit.
See the following sections for sequence of operation for
condenser fans with FanTrol.
FanTrol does not apply to units with VFD compressors.
InTroduCTIon
Table 3: R-410A FanTrol Setpoints in °F with
MicroTech III Controls.
Unit
Size
015 70 5
016 75 5
020 70 5
021 75 5
025 60 5
026 70 5
030 75 5
031 75 5
035 70 5
040 65 5
042 65 5
045 65 5
050 65 5
051 70 5
061 60 5
063 70 5
068 70 5
070 75 5 90 35
071 75 5 90 35
075 65 5 85 5 90 35
079 65 5 80 5 90 35
080 75 5 90 35
081 75 5 90 35
085 70 5 90 35
090 60 5 85 5 90 35
091 60 5 85 5 90 35
100 60 5 85 5 90 35
101 60 5 85 5 90 35
105 50 5 80 5 90 35
110 65 5 90 5 90 35
120 65 5 85 5 90 35
125 65 5 85 5 90 35
130 60 5 85 5 90 35
140 55 5 80 5 90 35
a. D07 = TC12
b. D08 = TC14
c. PC13/23 Cut in = 450 psig (125 degree sat.), xed
Cut out = 275 psig (90 degree sat.), xed
D07a D08b PC13/PC23c
Setpoint Differential Setpoint Differential Setpoint Differential
Degrees Farenheit
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Table 4: R-410A Fan Cycling Setpoints in °F with No Controls
RPS, RCS, RDT, RPR Control ID
015 TC12 65 70 5 TC12 Controls 1 Fan
016 TC12 70 75 5 TC12 Controls 1 Fan
020 TC12 65 70 5 TC12 Controls 1 Fan
021 TC12 70 75 5 TC12 Controls 1 Fan
025 TC12 55 60 5 TC12 Controls 1 Fan
026 TC12 65 70 5 TC12 Controls 1 Fan
030 TC12 70 75 5 TC12 Controls 1 Fan
031 TC12 70 75 5 TC12 Controls 1 Fan
035 TC12 65 70 5 TC12 Controls 1 Fan
040 TC12 60 65 5 TC12 Controls 1 Fan
042 TC12 60 65 5 TC12 Controls 1 Fan
045 TC12 60 65 5 TC12 Controls 1 Fan
050 TC12 60 65 5 TC12 Controls 1 Fan
051 TC12 65 70 5 TC12 Controls 1 Fan
061 TC12 55 60 5 TC12 Controls 1 Fan
063 TC12 65 70 5 TC12 Controls 1 Fan
068 TC12 65 70 5 TC12 Controls 1 Fan
070
071
075
079
080
081
085
090
091
100
101
105
110
120
125
130
140
* PC13/23Cut in = 450 psig (125 degree sat.), Fixedcut out = 275 psig (90 degree sat.), Fixed
TC12 65 70 5 TC12 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 65 70 5 TC12 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 60 65 5 TC12 Controls 1 Fan
TC14 80 85 5 TC14 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 65 65 5 TC12 Controls 1 Fan
TC14 75 80 5 TC14 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 70 75 5 TC12 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 70 75 5 TC12 Controls 1 Fan
PC13/PC23 90 12 35 PC13/PC23 Controls 1 Fan*
TC12 65 70 5 TC12 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 55 60 5 TC12 Controls 1 Fan
TC14 80 85 5 TC14 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 55 60 5 TC12 Controls 1 Fan
TC14 80 85 5 TC14 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 55 60 5 TC12 Controls 1 Fan
TC14 80 85 5 TC14 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 55 60 5 TC12 Controls 1 Fan
TC14 80 85 5 TC14 Controls 1 Fan
PC13/PC23 90 125 3 PC13/PC23 Controls 1 Fan*
TC12 45 50 5 TC12 Controls 1 Fan
TC14 75 80 5 TC14 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 60 65 5 TC12 Controls 1 Fan
TC14 85 90 5 TC14 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 60 65 5 TC12 Controls 1 Fan
TC14 80 85 5 TC14 Controls 1 Fans
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 60 65 5 TC12 Controls 1 Fan
TC14 80 85 5 TC14 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 55 60 5 TC12 Controls 1 Fan
TC14 80 85 5 TC14 Controls 1 Fan
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
TC12 50 55 5 TC12 Controls 1 Fan
TC14 75 80 5 TC14 Controls 2 Fans
PC13/PC23 90 125 35 PC13/PC23 Controls 1 Fan*
Cut Out Cut In Differential
InTroduCTIon
Degrees °F Notes
www.DaikinApplied.com 17 IM 893-10 • ROOFPAK SINGLEZONE UNITS
Condenser Fan Arrangement
Table 5 shows the condenser fan numbering conventions and
locations for each unit size.
Table 5: Condenser Fan Arrangement
Unit size Refrigerant circuit Arrangement Unit size Refrigerant circuit Arrangement
015, 016, 025, 026,
020, 021
1
2
074
1
2
InTroduCTIon
030, 031, 035, 042
045
050, 051
061, 063, 068
070, 071, 080, 081
1
075, 079, 090, 091
2
1
100, 101
2
1
110
2
1
120
2
1
125
2
130, 140
1
2
1
2
1
2
1
2
1
2
1
2
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MeChanICal InsTallaTIon
110D - 140D 38"
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.
NOTE: Low head pressure may lead to poor, erratic refrigerant
feed control at the thermostatic expansion valve. The
units have automatic control of the condenser fans
which should provide adequate head pressure control
down to 50°F (10°C) provided the unit is not exposed to
windy conditions. The system designer is responsible
for assuring the condensing section is not exposed to
excessive wind or air recirculation.
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.
MeChanICal InsTallaTIon
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.
Unit Clearances
Service Clearance
Allow service clearance approximately as indicated in Figure
21. Also, Daikin recommends providing a roof walkway to
the rooftop unit as well as along at least the two sides of the
unit that provide access to most controls and serviceable
components.
Figure 21: Service Clearances
*
*Condenser coil replacement is simplified
if the following temporary access clearance
can be arranged:
015D - 025D 61"
030D - 062D 83"
070D - 100D 106"
www.DaikinApplied.com 19 IM 893-10 • ROOFPAK SINGLEZONE UNITS
Ventilation Clearance
maximum
box,
Below are minimum ventilation clearance recommendations.
The system designer must consider each application and
provide adequate ventilation. If this is not done, the unit will 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 Service Clearance on page
19. See also Figure 21.
3. The distance between any two units within a screen or
fence should be at least 120ʺ (3048 mm).
MeChanICal InsTallaTIon
Do not locate outside air intakes near exhaust vents or other
sources of contaminated air.
If the unit is installed where windy conditions are common,
install wind screens around the unit, maintaining the
clearances specied (see Figure 21). This is particularly
important to prevent blowing snow from entering outside air
intake and to maintain adequate head pressure control when
mechanical cooling is required at low outdoor air temperatures.
For pad-mounted units, it is recommended that the condenser
section be lifted a minimum of 12ʺ off the ground for proper
underside ventilation. This clearance allows for proper airow,
optimal condenser performance and to prevent any minor
reductions in performance.
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 96ʺ (2438 mm) on all sides of the unit.
3. The distance between any two units within the walls
should be at least 120ʺ (3048 mm).
Figure 22: Overhead Clearance
Overhead
canopy
Overhead Clearance
1. Unit(s) surrounded by screens or solid walls must have
no overhead obstructions over any part of the unit.
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 (see Figure
22):
a. There must be no overhead obstructions above the
furnace ue, or within 9ʺ (229 mm) of the ue box.
b. Overhead obstructions must be no less than 96ʺ
(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 24ʺ (610 mm) from the side of
the unit.
9" (229 mm)
24" (610 mm)
maximum
96" (2438 mm)
minimum,
top of unit to
permanent
overhead
obstruction
Flue box
24" (610 mm)
minimum to flue
typical all sides
IM 893-10 • ROOFPAK SINGLEZONE UNITS 20 www.DaikinApplied.com
Roof Curb Assembly and Installation
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.
Integral supply and return air duct anges are provided with
the RPS/RFS roof curb, allowing connection of duct work to the
curb before the unit is set. The gasketed top surface of the duct
anges seals against the unit when it is set on the curb.
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.
MeChanICal InsTallaTIon
These anges must not support the total weight of the
ductwork. See Installing Ductwork on page 39 for details on
duct connections. It is critical that the condensate drain side of
the unit be no higher than the opposite side.
Assembly of a typical RPS/RDT roof curb is shown in Figure
24. Parts A through K are common to all units having bottom
supply and return openings. Depending on the unit length,
Parts L and M may be included with the roof curb kit to create
the correct overall curb length.
RCS Assembly instructions
Figure 23 shows the assembly of the RCS roof curb.
1. Set curbing parts (A) in place making sure that the
orientation complies with the assembly instructions.
Check alignment of all mating bolt holes.
2. Bolt curbing parts together using fasteners provided.
3. Curb must be level from side to side and over its length.
4. Weld curbing in place. Caulk all seams watertight and
insulate between channels.
5. Flash curbing into roof as shown in Detail C.
Figure 23: RCS Roof Curb Assembly
(INSIDE)
015D - 025D = 52.00
030D - 068D = 64.00
070D - 105D = 83.00
110D - 140D = 120.00
(INSIDE)
See DETAIL A
www.DaikinApplied.com 21 IM 893-10 • ROOFPAK SINGLEZONE UNITS
RPS/RDT Assembly instructions (Figure 24)
1. Set curbing parts A through K per dimensions shown
over roof opening or on a level surface. Note location of
return and supply air openings.
2. If applicable, set other curbing parts (D, L, M, etc.) in
place making sure that the orientation complies with the
assembly instructions. Check alignment of all mating bolt
holes. See Detail A.
3. Bolt curbing parts together using fasteners provided.
Tighten all bolts nger tight.
4. Square entire curbing assembly and securely tighten all
bolts.
5. Position curb assembly over roof openings. Curb must
be level from side to side and over its length. Check that
top surface of the curb is at with no bowing or sagging.
Figure 24: RPS/RFS Roof Curb Assembly
MeChanICal InsTallaTIon
6. Weld curbing in place. Caulk all seams watertight.
Remove backing from 0.25ʺ (6 mm) thick × 1.50ʺ (38
mm) wide gasketing and apply to surfaces shown by
cross-hatching.
7. Flash curbing into roof as shown in Detail B.
8. Parts E and F are not required on units with no return
shaft within the curb perimeter.
9. Parts G and H are not required on units with no supply
shaft within the curb perimeter.
10. Be sure that electrical connections are coordinated (see
Figure 25).
IM 893-10 • ROOFPAK SINGLEZONE UNITS 22 www.DaikinApplied.com
Table 6: RPS/RFS Roof Curb Assembly Dimensions
9.7
y
Unit size Return Fan
2 × 15ʺ FC
015 – 042
045 – 079 All units 38.0 (965) 87.0 (2210)
080 – 140 All units 62.0 (1575) 87.0 (2210)
Unit size Z W
015, 020, 025 53.6 (1361)
015D – 025D
030 56.2 (1427)
030D
035, 040 57.3 (1455)
035D – 040D
045, 050, 062, 068 61.0 (1594)
045D – 075D
010, 021, 026, 031, 042, 051, 061, 070-080, 085, 090, 100, 105 74.0 (1880)
080D – 090D
081, 091, 101, 110-140 99.0 (2514)
100D – 140D
Note: These dimensions do not apply to units with energy recovery wheels.
30ʺ AF 30 (762) 76 (1930)
40ʺ AF 36 (914) 78 (1981)
None 24 (610) 82 (2083)
MeChanICal InsTallaTIon
X Y
in. (mm) in. (mm)
24 (610) 82 (2083)
—
—
—
—
—
—
—
20 (508)
—
20 (508)
—
20 (508)
—
28.0 (711)
—
38.0 (965)
—
46.0 (1168)
Figure 25: Typical Power Wire Entrance, Curb View (RPS/RFS 045D to 140D shown, See Project Certied Drawings)
C
D
B
A
RA
OPNG
A
D
2 Typ
4 Typ
0.9 Dia.
A
K.O.
Unit length minus 6.4
3.4
See Detail A
12.1
5.1
20.0
SA
OPNG
6.8
1.5
76.0
RPS onl
7.5
3.0 Dia.
K.O.
Detail A
4.3
3.1
2.1
2.0
4.6
4.8
www.DaikinApplied.com 23 IM 893-10 • ROOFPAK SINGLEZONE UNITS
MeChanICal InsTallaTIon
Lift only as indicated
cable lengths may be required.
Post and Rail Mounting
CAUTION
The unit must be level side to side and over the entire length.
Equipment damage can result if the unit is not level.
When mounting by post and rail, run the structural support the
full length of the unit. Locate the structural member at the base
of the unit as shown in Figure 26, assuring the I-beam is well
supported by the structural member.
If resilient material is placed between the unit and the rail,insert
a heavy steel plate between the unit and the resilient material
to distribute the load. Seal cabinet penetrations (electrical,
piping, etc.) properly to protect against moisture and weather.
Figure 26: Post and Rail Mounting
A
MAX. MAX.
B
* Beam ca n extend benea th unit no m ore th an 5" to allow adequat e space
for duct connecti ons and elect rical en try.
Table 7: Post and Rail Mounting Dimensions
Unit Size 15–42 45–140
A
B — 93"–94" 97"
Condensing Unit 99"
Air Handler 94"
99"
Rigging and Handling
CAUTION
Use all lifting points. Improper lifting can cause severe
personal injury and property damage.
CAUTION
Lifting points may not be symmetrical to the center of gravity
of the unit. Ballast or unequal cable lengths maybe required.
Lifting brackets with 2ʺ (51 mm) diameter holes are provided
on the sides of the unit.
Use spreader bars, 96ʺ to 100ʺ (2438 to 2540 mm) wide 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. If there are isolation dampers, make sure they are properly
installed and fully closed to prevent the entry of animals
and debris through the supply and return air openings.
7. Cover the supply and return air openings on units without
isolation dampers.
Figure 27 shows an example of the rigging instruction label
shipped with each unit.
Figure 27: Rigging and Handling Instruction Label
IM 893-10 • ROOFPAK SINGLEZONE UNITS 24 www.DaikinApplied.com
Unit has either four or six lifting points (four-point shown below).
Rigging cables must be at least as long as distance “A”
Spreader bars
required
A
Caution: Lifting points may not
be symmetrical to center of
gravity of unit. Balast or unequal
Lifting Points
Refer to Figure 28 and Figure 29 and the following calculations
to determine whether a four or six point lift is required.
X = distance from the entering air end of the unit (or shipping
section) to the rst lifting lug in the direction of air ow.
For all unit or shipping sections with outdoor air/return air
options, X = 48ʺ
For shippings sections without outdoor air/return air
options, X= 0
Y = distance from condenser or leaving air end of unit to the
last lifting lug.
For all units or shipping sections with condensers use the
following:
Unit Size Y
015, 020, 025 13.9
030, 035, 040 25.6
016, 021, 026, 031, 042,
050, 062, 068
051, 063, 070, 071, 075, 079,
080, 085, 090, 100, 105
081, 091, 101, 110-140 38.0
36.5
30.0
MeChanICal InsTallaTIon
Figure 28: RPS/RDT Lifting Points
4 Lifting Points
(not required
on 015-042)
A
For all units or shipping sections without condensers, Y = 0.
Installation
Z = total base rail length of the units.
NOTE: Z excludes hoods and overhung parts extending past
base rails of the unit.
A = Z - X - Y
If A < 288ʺ, 4-point lift is sufcient
If A > 288ʺ, 6-point lift is required
B = distance from rst lifting lug to middle lifting lug on units
with 6-point lift.
B = A / 2 +/- 48ʺ
NOTE: Middle lifting lug may be installed on either side of the
midpoint to avoid interference with condensate drains.
RDT 045D–140D: B Min. = 72” (1829 mm)
RPS 080D–105D: B Min: = 96” (2348 mm)
RPS 110D–140D: B Min: = 120” (3048 mm)
Figure 29: RCS or Condenser Factory Split at Condenser
B
Unit Size B
015, 020, 025 59” (1448mm)
016, 021, 026-080, 085, 090, 100, 105 81” (2362mm)
081, 091, 101, 110-140 115” (2870mm)
www.DaikinApplied.com 25 IM 893-10 • ROOFPAK SINGLEZONE UNITS
MeChanICal InsTallaTIon
4 Lifting Points
Remove plywood and retaining
Save screws for reassembly.
Figure 30: RPS Factory Split at Supply Fan Section
Z
B
Z
045D–068D:BMin. = 72 (1829 mm)
070D–105D:BMin. = 96 (2438 mm)
110D–140D:BMin. = 120 (3048 mm)
Reassembly of Split Units
Although RoofPak units typically ship from the factory as
complete units, they may be split at the factory in one of two
possible congurations; see (1) “RPS Factory Split at Fan”,
Figure 31 and (2) “RFS/RCS Permanent Split Systems” on
page 29.
RPS Factory Split at Fan
The RPS unit is factory split at the fan section and ships as two
pieces, split at the supply fan bulkhead, to recouple together on
the roof. Like the RPS/RDT unit factory split at the condenser,
this conguration is ordered if shipping length or weight
limitation prevents a packaged RPS/RDT from being ordered.
Splitting at the fan has the advantage of leaving all factory
refrigerant piping intact so eld evacuation and charging is not
required. Detailed instructions are on page 29 to page 28.
A single nameplate is attached to the air handler section and
power is fed to both sections through the main control box, as
in a non-split RPS/RDT unit.
Field reassembly of an RPS/RDT unit that has shipped split
at the fan takes place in three phases: (1) setting the sections
(2) mechanically recoupling the cabinet, and (3) reconnecting
power and control wiring.
Phase I. Set sections (Figure 30)
1. Remove top cap and save for Step 3.
2. Remove screws on fan panel, leaving retainer clips in
place to secure bulkhead. Save screws for Phase II,
Step 5.
3. Remove plywood and retaining angles from unit and
discard.
4. Carefully lower both sections of unit (fan end and
discharge end) into place, making sure the roof curb
engages the recesses in the unit base.
Figure 31: Set Sections - Steps 1-4, RPS Factory Split at Supply Fan
Remove top cap and
save for reassembly.
angles from unit and discard.
Discharge end of unit
Fan end of unit
Remove screws on fan panel,
leaving retainer clips in place.
IM 893-10 • ROOFPAK SINGLEZONE UNITS 26 www.DaikinApplied.com
Phase II. Reassemble cabinet (Figure 31)
1. Reinstall top cap removed in Phase I, Step 1.
2. Caulk (watertight) ends of splice cap.
3. Caulk (watertight) vertical seam.
4. Install #10 screws (provided).
5. Install screws (0.25–20 × 0.75) removed in Phase I,
Step 2
6. Install splice cover (provided).
Figure 32: Reassemble Cabinet
MeChanICal InsTallaTIon
Reinstall top cap
saved in step 1
Caulk ends
of splice cap
Splice cover,
provided
See detail
Caulk
vertical
seam
Install screws
(.25 to 20 × .75)
saved from step 1
#10 screws,
provided
Nut clip-on,
provided
www.DaikinApplied.com 27 IM 893-10 • ROOFPAK SINGLEZONE UNITS
Phase III. Reconnect Power and Control Wiring
CAUTION
Connect the power block correctly and maintain proper
phasing. Improper installation can cause severe equipment
damage.
MeChanICal InsTallaTIon
Figure 33: Electrical Connections/Cover Installation
If applicable, install as shown
with provided fasteners.
The DX coil/condenser section contains power and control
harnesses that have their excess length in the blank or heat
section, which normally is immediately downstream of the fan.
Once the sections are physically reconnected, the ends of
the power harness are fed back through the unit base into the
junction box, per the unit’s electrical schematics.
1. Make electrical connections and reinstall inner raceway
cover as shown in Figure 33.
2. When power wire reconnection is complete, reinstall the
inner raceway cover in the blank or heat section. Figure
33 shows a typical installation of the raceway cover.
3. Run the control harnesses by removing the external
raceway covers on either side of the unit split.
4. Remove the excess harness length from the external
raceway on the DX side of the split; then route along the
raceway through the bushed hole in the fan section and
into the junction box where control wiring terminal blocks
are provided for reconnection.
5. Make all electrical connections per the unit’s electrical
schematics.
6. Reinstall the external raceway covers after routing of the
control wires is complete.
7. Draw through cooling coils only. Reconnect refrigerant
piping. These refrigerant circuits for these units are
shipped with a holding charge only. Figure 34 illustrates
what the installer sees at the shipping split
a. To bridge the gap and connect the piping, remove
the refrigerant piping caps and add ttings and
copper tubing, as required.
b. Evacuate and charge the unit. See page 31 for
further details.
After routing wires,
install inner raceway
cover (see step 6).
Figure 34: Refrigerant Lines
Capped
refrigerant
lines
3.72 ref.
(94 mm)
IM 893-10 • ROOFPAK SINGLEZONE UNITS 28 www.DaikinApplied.com
RFS/RCS Permanent Split Systems†
The RFS air handler section and RCS condenser section ship
as two separate units. This conguration is ordered when the
condenser is intended to remain separated by a short distance
from the air handler because of space or structural constraints.
On all units, refrigerant piping is terminated near the exterior
of the cabinet for convenient eld piping between the RCS
and RFS units, and all necessary refrigeration components
are provided (except the eld-installed hot gas bypass valve).
Detailed instructions are on page 31 to page 34.
The hot gas bypass valve should be located as close to the
RCS as possible to minimize refrigerant from accumulating in
the HGBP piping. Units with a VFD compressor option do not
require HGBP as the compressor is capable of modulating.
Minimize pipe bends (especially those that accumulate
refrigerant) as much as possible. Connect the pressure
sensing tap to the suction line.
Piping Recommendations
All eld piping, wiring, and procedures must be performed
in accordance with ASHRAE, EPA, and industry standards.
Proper refrigerant piping can make the difference between a
reliable system and an inefcient, problematic system.
The primary concerns related to piping are refrigerant pressure
drop, a solid liquid feed to the expansion valves, continuous oil
return and properly sized refrigerant specialties.
Insulate the suction line to reduce excessive superheat
buildup. Insulate the liquid line, where located in areas above
ambient temperature, to prevent loss of subcooling and
consequent liquid ashing.
The recommended source for refrigerant piping techniques and
sizing is the Daikin AG31-011 Refrigerant Piping Design Guide.
Although conicting piping recommendations can be found in
different sources, Daikin offers the following recommendations
for these controversial issues.
The use of double risers for vertical gas risers is generally not
required and should be used only as a last resort to maintain
the minimum refrigerant ow to carry oil up the vertical risers.
Slightly downsizing the vertical riser is a preferable option to
providing double risers.
Slope the refrigerant lines ½" to 1ʺ per 10 feet of horizontal run
in the direction of refrigerant ow to assist oil return.
Pressure drops in the refrigerant lines should be maintained
at or below the ASHRAE recommendations and line lengths
should be made as short as possible. Exceeding these
recommendations will decrease performance and could impact
reliability.
Small traps should be provided at the base of each major
vertical gas riser to assist in the collection of oil. If vertical
risers exceed more than 25 feet, install a small trap at the
midpoint and at a maximum of 20 foot intervals.
MeChanICal InsTallaTIon
Use caution in sizing the liquid line in applications where
the evaporator is above the outdoor section. The weight of
the liquid refrigerant in the vertical column will decrease the
pressure at the top of the riser (approximately 0.5 psi per foot
of vertical rise) allowing some of the refrigerant to ash to a
gas. Adequate refrigerant subcooling is needed at the outdoor
section to prevent large volumes of refrigerant gas at the
expansion valve.
The piping systems should always extend above the highest
component in the refrigeration system before dropping down
to make the nal refrigerant connections to components. This
practice will hinder the draining of condensed refrigerant to the
lower component when normal shutdown procedures do not
occur (such as a power failure).
NOTE: Do not run refrigerant lines underground.
1. Use type K or L clean copper tubing. Thoroughly clean or
braze all joints with high temperature solder. Make sure
nitrogen is owing through the tubes while brazing to
minimize the formation of oxide contaminants.
2. Base piping sizes on temperature/pressure limitations
as recommended in the following paragraphs. Under no
circumstances should pipe size be based strictly upon
coil or condensing unit piping connection size.
3. To determine the minimum tonnage required to carry
oil up suction risers of various sizes, check the vertical
suction risers using Table 8.
4. Size the liquid line for a pressure drop not to exceed
the pressure equivalent of 2°F (1°C), 6 psi (41.4 kPa)
saturated temperature. The lter drier, solenoid, and
sight glass ship loose with each RFS unit.
Table 8: Minimum Tonnage (R-410A) to Carry Oil Up
Suction Riser at 40°F Saturated Suction
Line size O.D. Minimum tonnage
1-1/8ʺ 2.0
1-3/8ʺ 3.5
1-5/8ʺ 5.4
2-1/8ʺ 11.2
2-5/8ʺ 19.5
*3-1/8ʺ 30.5
* Daikin’s largest suction connection is 2-5/8ʺ and is generally sufcient.
† Not available on variable speed inverter compressor units.
www.DaikinApplied.com 29 IM 893-10 • ROOFPAK SINGLEZONE UNITS
Piping Connections, RFS/RCS Units
Figure 35: Refrigerant Piping Connection Locations Example
MeChanICal InsTallaTIon
E
F
A
B
C
DD
EF
A
B
C
Table 9: 015D – 140D Connection Sizes and Locations*
Dimension Component Circuit
A Liquid line #1/#2 Ckt.1 & 2 16.7 12.9 12.0 13.5 11.2 20.8
B HGBP line #1/#2 Ckt.1 & 2 24.0 25.4 25.9 25.9 28.1 25.9
C Suction line #1/#2 Ckt.1 & 2 32.7 29.3 29.4 32.3 32.3 32.4
D Liquid line #1/#2 Ckt.1 & 2 8.38 8.38 8.38 8.38 8.38 8.38
E HGBP line #1/#2 Ckt.1 & 2 6.02 6.02 6.02 6.02 6.02 6.02
F Suction line #1/#2 Ckt.1 & 2 6.62 6.62 6.62 6.62 6.62 6.62
015D - 026D 030D - 042D 045D - 068D 070D - 079D 080D - 105D 110D - 140D
Piping Dimension (inches)
Table 10: 015D – 140D Piping Diameter*
Component Circuit
Liquid line #1/#2 Ckt.1 & 2 5/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8
HGBP line #1/#2 Ckt.1 & 2 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8
Suction line #1/#2 Ckt.1 & 2 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8
Component Circuit
Liquid line #1/#2 Ckt.1 & 2 7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8
HGBP line #1/#2 Ckt.1& 2 7/8 7/8 7/8 7/8 7/ 7/8 7/8 7/8 7/8 7/8 7/8
Suction line #1/#2 Ckt.1& 2 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8
015D -
016D
070D -
071D
020D -
021D
075D -
079D
025D -
026D
080D -
081D
030D -
031D
085D
Piping Diameter (inches)
035D 042D 045D
Piping Diameter (inches)
090D -
091D
100D -
101D
105D 110D 120D 125D 140D
050D -
051D
061D 063D 068D
* For xed speed compressors only
IM 893-10 • ROOFPAK SINGLEZONE UNITS 30 www.DaikinApplied.com
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