Daikin Rebel Applied DPSA Installation and operation manual

Installation and Start-up Manual IM 1287
Group: Applied Air Handling
Part Number: IM 1287
Date: January 2020
Rebel Applied™Packaged Rooftop
Heating and Cooling
Models DPSA
30 to 52 Tons
R-410A Refrigerant

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Introduction..................................4
Nameplate Information ........................4
Unit Nameplate ............................4
Compressor Nameplate ......................4
Gas Burner Nameplate ......................4
Electric Heater Nameplate ....................4
Hazardous Information Messages ...............4
Unit Description..............................5
Refrigeration Piping...........................7
Controlled Component Locations ...............10
Control Panel ..............................11
Installation..................................14
Unit Installation .............................14
Receiving Inspection .........................14
Unit Clearances.............................14
Service Clearance .........................14
Ventilation Clearance .......................15
Overhead Clearance .......................16
Roof Curb Assembly and Installation ............17
Post and Rail Mounting .......................21
Rigging and Handling ........................21
Unit Piping.................................23
Condensate Drain Connection................23
Hot Water Coil Piping.......................23
Steam Coil Piping .........................25
Damper Assemblies .........................27
Economizer Dampers ......................27
Intake Hood Damper (0% to 30% outside air) ....27
Exhaust Hood Assembly ....................28
Installing Ductwork ..........................29
Installing Duct Pressure Taps ..................29
Installing Building Static Pressure Sensor Taps ....30
Installing Discharge Air Temperature Sensor.....30
Unit Wiring .................................31
Field Power Wiring ..........................31
Field Control Wiring..........................34
Field Output Signals .........................36
Unit Operation...............................37
Preparing Unit for Operation ...................37
Power-up ................................37
Start Up Operating State ....................37
Recirculating Operating State ................37
Fan Only ................................37
Fan Operation ............................37
Economizer Operation ......................37
Fixed Speed Compressor Operation ...........38
External Time Clock ........................38
VAV Box Signal/Fan Operation Signal ..........38
Fan Operation ............................38
VAV Box Output ...........................38
Entering Fan Temperature Sensor.............39
Duct High Pressure Limit ....................39
Variable Frequency Drive Operation ...........39
Convenience Receptacle/Section Lights ........39
Propeller Exhaust Fan Option ................39
Fan Prestarting Checks .....................40
Fan Maintenance ..........................40
Damper Counterbalance Adjustment ...........40
Ultraviolet Lights Option.....................40
Convenience Receptacle/Section Lights ........41
Check, Test and Start Procedures .............41
Servicing High Voltage Control Panel Components..
41
Initial Manual Mode Start-Up .................42
OA Damper Start-up .......................42
Cooling/Heating Start up ....................43
Economizer/OA Damper Start-up .............43
Fixed Speed Compressor Startup .............43
Expansion Valve Superheat Adjustment
(Thermal Expansion Valve) ..................45
Heating System Startup .....................45
Air Balancing .............................46
Maintaining Control Parameter Records ........47
Using the Keypad/Display ...................47
Navigation Mode ..........................49
Edit Mode................................49
Smoke and Fire Protection ..................49
MicroTech®4 Remote User Interface ............51
Features.................................51
MicroTech 4 Field Installed Sensors ...........52
Space Temperature Sensors . . . . . . . . . . . . . . . . . 52

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DDC Space Sensors .......................52
Communicating Network Space Sensors .......53
Keypad and Display Menu Structure.............54
Unit Maintenance ............................60
Servicing Control Panel Components ............60
Example Wiring Diagram .....................61
Planned Maintenance ........................71
Unit Storage ..............................72
Restart ..................................73
Daikin Electric Heater Modules .................74
Electric Heater General Information ...........74
Installation ...............................76
Startup ..................................76
Operation ................................76
Maintenance .............................76
Electric Heater Wiring Diagrams ..............79
Daikin Tubular Gas Heater Series...............83
Packaged Gas Heater Module................83
General Gas Furnace Information .............83
Unit Location and Clearances ................84
DPSA Gas Furnace Capacity Data ............85
Ventilation and Flue Pipe Requirements ........87
Gas Piping Requirements ...................88
Field Gas Piping...........................89
Altitude Conversion ........................90
Gas Conversion ...........................90
Condensate Management ...................91
Operations ...............................91
Operating Procedures ......................92
Burner and Gas Manifold Pressure Adjustment
Instructions...............................95
Maxitrol EXA Star Controller ..................96
Connections ..............................96
Valve Setting .............................96
High Fire Setting - Button #1 .................96
Low Fire Setting - Button #2 .................96
Service ..................................97
Maintenance .............................97
VB1285 BPP Split Manifold Modulating Control . . . . 98
Sequence of Operation .....................98
VB1287 BPP 2-Stage and 2-Stage Split Control....99
Sequence of Operation .....................99
Furnace Wiring Diagrams ....................100
Rooftop Equipment Warranty Registration Form . 108
Warranty Exclusion .......................108
In-Warranty Return Material Procedure .........108
North America ...........................108
Exceptions ..............................109
Assistance ..............................109
Sole Remedy ............................109
Rooftop Equipment Warranty Registration Form . 110
Quality Assurance Survey Form ...............116

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This manual provides installation information about the Rebel
Applied Daikin rooftop unit, DPSA models. In addition to an
overall description of the unit, it includes mechanical and
electrical installation and start-up procedures. For operations
and/or maintenance procedures, see OM 1288
Table 1: Program Specic Rooftop Unit Literature
Product Manual Title Manual Number
Daikin, Rebel Applied
DPSA units
Unit Installation and
Start Up IM 1287
Unit Operations and
Maintenance OM 1288
Non-Daikin See vendor manuals
Nameplate Information
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.
Compressor Nameplate
On units that utilize the tandem compressor design, each
compressor includes an individual nameplate.
Gas Burner Nameplate
On units that include gas heat, the cabinet furnace nameplate
is located next to the furnace access door. It includes the gas
pressures, minimum/maximum input, maximum temperature
rise, and minimum CFM. The furnace rating plate is included
on the furnace; this includes the burner model number.
Electric Heater Nameplate
On units that include electric heat, the cabinet electric heater
nameplate is located next to the electric heater access door.
The electric heater rating plate is included on the electric
heater; this includes the electric heater model number.
Hazardous Information Messages
CAUTION
Caution indicates potentially hazardous situations which can result in injury,
death, and property damage if not avoided.
WARNING
Warning (sign) indicate potentially hazardous situations which can result in
property damage, severe personal injury, or death if not avoided.
WARNING
Warning indicates potentially hazardous situations for PVC (Polyvinyl
Chloride) and CPVC (Clorinated Polyvinyl Chloride) piping in chilled water
systems. In the event the pipe is exposed to POE (Polyolester) oil used
in the refrigerant system, the pipe can be chemically damaged and pipe
failure can occur.
DANGER
Danger (Danger lightning sign) indicates a hazardous situation which will
result in death or serious injury if not avoided.
DANGER
Danger (Danger gas sign) indicates a hazardous gas situation which will
result in death or serious injury if not avoided.
NOTICE
Notices give important information concerning a process, procedure,
special handling or equipment attributes.

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Figure 1: Nomenclature
Unit Description
Figure 2 shows a typical DPSA unit. Figure 3 shows a typical
DPSA unit with the locations of the major components. These
gures are for general information only. See the project’s
certied submittals for actual specic dimensions and locations.
Figure 2: DPS-A Unit, Typical
D PS A 050 A 4 B S
Daikin Rebel
Packaged DX Cooling System
PS = Packaged DX Cooling
AH = Air Handler
FS = Permanent Split System
Applied
Unit Size
B00 = B cabinet, no cooling coil
B24 = B cabinet, 24 ft2coil
B29 = B cabinet 29 ft2coil
B34 = B cabinet 34 ft2coil
031 = 31 ton
035 = 35 ton
040 = 40 ton
050 = 50 ton
052 = 52 ton
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0 = No cooling, heat only
C = Chilled water coil
S = Standard e󰀩ciency air-cooled DX
H = High e󰀩ciency air-cooled DX
P = Premium e󰀩ciency air-cooled DX
Cabinet Size
B = B cabinet (31 – 52 tons)
Voltage
2 = 208V
3 = 230V
4 = 460V
5 = 575V
Vintage

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Figure 3: Typical Component Locations—DPS-A Units
Top View
Side View
Bottom Return Air Opening
Bottom Discharge Air
Opening
Condensate Connection 1.5” NPT
Outside/Return Air Dampers
(Economizer Dampers)
Exhaust
Hood
Return Air Fan
Filter
Evaporator
Coil
Supply Air
Fan
Heat Section (Natural Gas,
Oil, Steam, Hot Water,
Electric)
Main Control Panel
Condenser Fan
Condenser Coils
(Circuit 1)
Condenser Coils
(Circuit 2)
Low Voltage Control
Panel
Outdoor Air
Hood

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Refrigeration Piping
This section presents the unit refrigeration piping diagrams for
the various available congurations.
Figure 4: Schematic, Standard Circuit
Figure 5: Schematic, Hot Gas Bypass Circuit

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Figure 6: Schematic, MHGRH Circuit
Figure 7: Low Ambient Circuit Schematic
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Speedtrol (Variable speed fans) down to 25F
Speedtrol (Variable speed fans) + Splitter solenoid down to -10F

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Figure 8: Condenser Piping, Compressors, 1 to 2 Compressors per Circuit are Provided*
Splitter Solenoid
(optional)
Comp 1
Comp 3
Comp 2
Comp 4
To DX
Coil
Filter Dryer (replaceable core optional)
shown)
Ckt 1
Ckt 2
Liquid Line Sight Glass
Suction Shut-off Valve (optional)
Hot gas Bypass
Valves and Liquid
Line solenoids
(not shown)
Optional Refrigerant
Temperature and Pressure
Transducers
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Controlled Component Locations
Figure 9 shows basic control and component locations within a
typical unit
Figure 9: Control and Component Locations
Return Air Dampers
(Economizer Dampers)
Energy
Recovery VFD
Exhaust
Fans
Outdoor Temp
and/or humidity
Return Temp
And/Or Humidity
Sensors
Supply Fans
Condenser
Fans
Outside Air
Damper
Refrigerant Pressure
Sensors/Switches
Furnace
Low
Voltage
Control
Box
(MT4)
Leaving Coil
Temperature
Energy Wheel
Control Box
Hot Water Coil
Valve
Furnace
Controller
Discharge Air
Temp. (DAT)
Service
ports
Energy Wheel
Outdoor Air Pre Heater
Exhaust Wheel
Temperature
Sensor
Leaving Wheel
Temp. Sensor
Discharge Air Temp.
Sensor (Field Installed)

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Control Panel
The unit control panels and their locations are shown in the
following gures. These gures show a typical unit.
Specic unit congurations may di󰀨er.
Figure 10: Control Panel Locations
Figure 11: Typical Main Control Panel
Main Control Panel
(includes gas heat
controls if applicable)
Low Voltage
Control
Panel
Energy Wheel /Electric
Pre heater Control
Panel (if applicable)
Return
Control
Panel
Electric Heat
Control Panel (if
applicable)

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Figure 12: Typical Low Voltage Control Panel
Figure 13: Typical Return Control Panel (with Prop Exhaust Fan VFD)

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Figure 14: Typical Return Control Panel (without Prop Exhaust Fan VFD)
Figure 15: Typical Return Control Panel (with Energy Recovery Wheel)

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Unit Installation
WARNING
Sharp edges on sheet metal and fasteners can can cause personal injury.
Please wear appropriate person protective equipment such as gloves,
protective clothing, footwear, eye protection, etc. 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.
NOTICE
Unit/equipment must be installed in a location that is not accessible to the
general public.
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.
Remove all shipping protection prior to installation
Unit Clearances
Service Clearance
Allow service clearance as indicated in Figure 16 or Figure
17. Figure 16 denotes clearances required if large component
replacement would be completed through side access doors.
Figure 17 denotes clearances needed if large component
replacement would be completed from the top of the unit (with
a crane) after removing roof panels. 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 16: Service Clearances (Scenario A)
60”
72”
60”
60”
96”
Return
Section
Filter section
Supply Fan Section
To roof
access
location
Recommended
roof walkway
Heat Section
Condenser Section

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Figure 17: Service Clearances (Scenario B)
Ventilation Clearance
Figure 18 denotes 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 Figure 16.
3. The distance between any two units within a screen or
fence should be at least 120ʺ (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 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).
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 specied (Figure 16). 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 o󰀨 the ground for proper
underside ventilation. This clearance allows for proper airow,
optimal condenser performance and to prevent any minor
reductions in performance.
48”
48”
48”
72”
To roof
access
location
Recommended
roof walkway
96”
Return
Section
Filter section
Supply Fan Section
Heat Section
Condenser Section

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Overhead Clearance
1. If clearances from Scenario B (Figure 17) are applied to
the installation, then unit must not have any overhead
obstructions over any part of the unit.
2. If unit is surrounded by solid walls or screens, then unit
must not have any overhead obstructions over any part
of the unit.
3. The area above the condenser must be unobstructed in
all installations to allow vertical air discharge.
4. The following restrictions must be observed for overhead
obstructions above the air handler section where ground
clearances noted in scenario A are applied (i.e. if
Figure 16 is applicable, then Figure 18 shows allowable
overhead canopy) :
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 intake and exhaust
dampers that are farther than 24ʺ (610 mm) from
the side of the unit.
Figure 18: Overhead Clearance
24”
max
24”
max
Furnace flue (if
applicable)
No overhead
obstructions allowed
within 9”
24”
max
96” minimum from top
of unit to permanent
overhead construction
Overhead Canopy

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Roof Curb Assembly and Installation
WARNING
Mold can cause serious illness and property damage. 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.
Integral supply and return air duct anges are provided with the
DPSA 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.
These anges must not support the total weight of the
ductwork. It is critical that the condensate drain side of the
unit be no higher than the opposite side. Assembly of a typical
DPSA roof curb is shown in Figure 19.
Curb Assembly instructions
1. Set curbing parts in accordance with assembly
instructions provided with unit. Take careful note of the
location of return and supply air openings, Figure 19.
2. If applicable, set other curbing parts in place making
sure that the orientation complies with the assembly
instructions. Check alignment of all mating bolt holes.
See Figure 21, 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.
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 Figure 21, Detail A.
8. Be Sure that electrical connection are coordinated (see
Figure 23)
Figure 19: Standard Roof Curb Assembly
Condenser
Section Support
(if applicable)
A
B
C
D
J
K
P
E
L
M

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Figure 20: B – Full Perimeter Roof Curb Assembly
Figure 21: Detail Views
A
B
C
D
J
K
E
L
M
1. Unit Base
2. Curb Gasketing
3. 2x4 Nailer Strip
4. Galvanized Curb
5. Cant Strip (not furnished)
6. Roofing Material (not furnished)
7. Rigid Insulation (not furnished)
8. Counterflashing (not furnished)
9. Flashing (not furnished)
Detail A
Detail B
Note: height of perimeter curb and
condensing section support are not equal

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Table 2: Rebel Applied Roof Curb Assembly Dimensions,
Return Congurations
Unit
Size
Return
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A B C D E
in. (mm) in.
(mm)
in.
(mm) in. (mm) in. (mm)
B
Cabinet
None
3.70
(93.9)
36
(914.4)
3.70
(93.9)
82.0
(2082.8)
55.75
(1416)
Standard
Return Fans
O󰀨set Return
Fans
Prop Exhaust
High Static
Exhaust
30.86
(783.8)
Energy Wheel 56.86
(1444.2)
Table 3: Rebel Applied Roof Curb Assembly Dimensions,
Supply Congurations
Unit
size
Supply
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J K L M P
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
B
Cabinet
Standard
Discharge
4.03
(102.4)
24.75
(628.6)
1.5
(38.1)
70.5
(1791)
55.75
(1416)
Short Out of
Air Stream
52.03
(1322)
Long Out of
Air Stream
76.03
(1931)
Figure 22: Rebel Applied Plenum Curb Application

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The base of the unit has structural steel between the oor
of the unit and the curb sealing surface. For plenum curb
applications, exta insulation and sealing is required. Consult
the factory before application with a plenum curb. Refer to
Figure 22.
Figure 23: Typical Power Wire Entrance, Curb View, See Project Certied Drawings
Power Wire Entrance (route
wires up from bottom, and route
through provided patch plate)