Daikin Rebel Applied DPSA Installation and operation manual

Installation and Start-up Manual IM 1287-4
Group: Applied Air Handling
Part Number: IM 1287
Date: April 2022
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 ...............................8
Condenser and Compressor Piping ..................12
VFD Inverter Box ................................14
Controlled Component Locations . . . . . . . . . . . . . . . . . . . . 16
Control Panel ...................................17
Installation.......................................20
Unit Installation ..................................20
Receiving Inspection..............................20
Service Clearance..............................20
Ventilation Clearance ...........................21
Overhead Clearance ............................22
Roof Curb Assembly and Installation .................23
Full Condenser Floor Sealing .......................26
Post and Rail Mounting............................28
Rigging and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shipping Splits ..................................30
Reassembly of Shipping Splits ....................30
Reassembly Procedure..........................30
Reconnecting Power and Control Wire ..............36
Unit Piping......................................36
Condensate Drain Connection ....................36
Hot Water or Hot Water Integral Face and Bypass .....37
Steam Coil or Steam Integral Face and Bypass Coil ...39
Damper Assemblies ..............................42
Economizer Dampers ...........................42
Intake Hood Damper (0% to 30% outside air).........42
Exhaust Hood Assembly .........................43
.....44
 ..............44
 ...................46
Installing Ductwork ...............................48
Installing Duct Pressure Taps .......................48
󰀨 ..............................49
󰀨 .....................49
󰀨...................49
Top Discharge...................................50
Side Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installing Building Static Pressure Sensor Taps .........51
Installing Discharge Air Temperature Sensor .........51
Unit Wiring ......................................52
Field Power Wiring ...............................52
Field Control Wiring ..............................55
Field Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Unit Operation....................................58
Preparing Unit for Operation........................58
Power-up.....................................58
Start Up Operating State.........................58
Recirculating Operating State .....................58
Fan Only .....................................58
Fan Operation .................................58
Economizer Operation...........................58
Compressor Operation ..........................59
External Time Clock ............................59
VAV Box Signal/Fan Operation Signal ..............59
Fan Operation .................................59
.......................59
MHGRH Control & Arrangement ...................60
MLSCRH+MHGRH Control & Arrangement ..........61
.................................61
Steam Supply Line Connection ...................62
VAV Box Output................................63
Entering Fan Temperature Sensor .................64
Duct High Pressure Limit.........................64
Variable Frequency Drive Operation ................64
Convenience Receptacle/Section Lights.............64
Propeller Exhaust Fan Option .....................64
Fan Prestarting Checks..........................65
Fan Maintenance...............................65
Damper Counterbalance Adjustment ...............65
Ultraviolet Lights Option .........................65
Convenience Receptacle/Section Lights.............66
Check, Test and Start Procedures..................66
Servicing High Voltage Control Panel Components ....66
Initial Manual Mode Start-Up......................67
OA Damper Start-up ............................67
Cooling/Heating Start up .........................68
Economizer/OA Damper Start-up ..................68
Fixed Speed Compressor Startup..................68
Expansion Valve Superheat Adjustment
(Thermal Expansion Valve) .......................70
Heating System Startup .........................70
Maintaining Control Parameter Records .............72
Using the Keypad/Display ........................72
Navigation Mode ...............................73

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Edit Mode ....................................73
Smoke and Fire Protection .......................74
MicroTech®4 Remote User Interface .................76
Features .....................................76
MicroTech 4 Field Installed Sensors . . . . . . . . . . . . . . . . 77
Space Temperature Sensors......................77
DDC Space Sensors ............................77
Communicating Network Space Sensors ............77
Keypad and Display Menu Structure .................78
Unit Maintenance .................................84
Servicing Control Panel Components.................84
Example Wiring Diagram ..........................85
Planned Maintenance .............................97
Unit Storage ..................................98
Restart.......................................99
Daikin Electric Heater Modules.....................100
Electric Heater General Information ...............100
Installation ...................................102
Startup......................................102
Operation....................................102
Maintenance .................................102
Electric Heater Step Controller .....................104
Stage Sequencing.............................104
Vernier Operation .............................104
Set-Up........................................105
Step Controller Troubleshooting ....................106
Electric Heater Wiring Diagrams ..................107
Daikin Tubular Gas Heater Series ..................111
Packaged Gas Heater Module ...................111
General Gas Furnace Information.................112
Gas Furnace Sequence of Operation . . . . . . . . . . . . . . 112
Electric Furnace Sequence of Operation ...........115
Refrigeration Only Controls (ROC) ..................117
ROC Analog Staging ...........................117
ROC SCR Gas Staging.........................121
Unit Location and Clearances ...................126
DPSA Gas Furnace Capacity Data ................127
Ventilation and Flue Pipe Requirements ............129
Gas Piping Requirements ......................130
Field Gas Piping ..............................131
Altitude Conversion ............................132
Gas Conversion...............................132
Condensate Management ......................133
Operations...................................133
Operating Procedures .........................134
Burner and Gas Manifold Pressure Adjustment
Instructions ..................................138
Maxitrol EXA Star Controller ......................139
Connections .................................139
Valve Setting .................................139
High Fire Setting - Button #1.....................139
Low Fire Setting - Button #2 .....................139
Service .....................................140
VB1285 BPP Split Manifold Modulating Control ........141
Sequence of Operation .........................141
VB1287 BPP 2-Stage and 2-Stage Split Control .......142
Sequence of Operation .........................142
Furnace Wiring Diagrams .........................143

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This manual provides installation information about the Rebel
Applied rooftop unit - model DPSA. 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
Rebel Applied- model
DPSA
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 (Chlorinated Polyvinyl Chloride) piping in chilled water
systems. In the event the pipe is exposed to POE (Polyester) 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
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
Figure 2: DPSA 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
󰀩
󰀩
󰀩
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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Figure 4: ECM Fan Array Identication
ϭD ϮDϭD
ϭD ϮD
ϯDϰD
ϭyϭϭyϮ
ϮyϮ
EŽƚĞƐ
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ŝŶƚŚĞϰdžϰĂƌƌĂLJĨĂŶϭ^ǁŝůůďĞĐŽŶƚƌŽůůĞĚďLJϭDĂŶĚϮ^ǁŝůůďĞĐŽŶƚƌŽůůĞĚďLJϮD
ϯ ŚĂŶŐĞĚĨƌŽŵϰŵŽĚďƵƐĂĚĚƌĞƐƐĞƐƚŽϵĂĚĚƌĞƐƐĞƐŽŶϰϮϵϮϬĂŶĚĐŚĂŶŐĞĚƚŚĞĨĂŶ
ŝĚĞŶƚŝĨŝĐĂƚŝŽŶŽĨƚŚĞƐůĂǀĞĨĂŶƐĨƌŽŵΘƚŽ^

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Refrigeration Piping
This section presents the unit refrigeration piping diagrams for

Figure 5: Schematic, Standard Circuit
Figure 6: Schematic, Hot Gas Bypass Circuit

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Figure 7: Schematic, MHGRH Circuit
Figure 8: Schematic, LSCRH Circuit 1

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Figure 9: Schematic, LSCRH Circuit 2
Figure 10: Low Ambient Circuit Schematic

Speedtrol (Variable speed fans) down to 25F
Speedtrol (Variable speed fans) + Splitter solenoid down to -10F

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Figure 11: Variable Speed Cooling Circuit Diagram

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Condenser and Compressor Piping
Figure 12: 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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Figure 13: Condenser and Compressor Piping (Inverter Compressors)
Figure 14: Inverter Compressor Piping Detail

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
Figure 15: VFD Inverter Box Refrigerant Connections, Front
Figure 16: VFD Inverter Box Refrigerant Connections, Back

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Figure 17: VFD Inverter Box Components

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Controlled Component Locations
Figure 18 shows basic control and component locations within
a typical unit
Figure 18: 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

󰀨
Figure 19: Control Panel Locations
Figure 20: 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 21: Typical Low Voltage Control Panel
Figure 22: Typical Return Control Panel (with Prop Exhaust Fan VFD)

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Figure 23: Typical Return Control Panel (without Prop Exhaust Fan VFD)
Figure 24: Typical Return Control Panel (with Energy Recovery Wheel)

IM 1287-4 • REBEL APPLIED ROOFTOP 20 www.DaikinApplied.com
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Unit Installation
WARNING
Sharp edges on sheet metal and fasteners can cause personal injury.
Please wear appropriate personal protective equipment (PPE) 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
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claim. In most cases, equipment is shipped F.O.B. factory and
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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 25 or Figure
26. Figure 25 denotes clearances required if large component
replacement would be completed through side access doors.
Figure 26 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 25: 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