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INSTALLATION MANUAL
MODULATING ECM
RESIDENTIAL GAS FURNACE
MODELS:
TPLC*C, YPLC*C, CPLC*C, LPLC*C
(80% AFUE Multi-position / Low NOx)
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 23
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horizontal Application (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 7
Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vertical Applications (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Horizontal Right Application (Typical) . . . . . . . . . . . . . . . . . . . . . . . . 8
Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Furnace Control Board - Communications Connections . . . . . . . . . 12
Modulating Furnace with Communicating AC or HP . . . . . . . . . . . . 13
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 8
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . . . . 9
High Altitude Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 11
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
These high efficiency, compact units employ induced combustion, reli-
able hot surface ignition and high heat transfer aluminized tubular heat
exchangers. The units are factory shipped for installation in upflow or
horizontal applications and may be converted for downflow applica-
tions.
These furnaces are designed for residential installation in a basement,
closet, alcove, attic, recreation room or garage and are also ideal for
commercial applications. All units are factory assembled, wired and
tested to assure safe dependable and economical installation and oper-
ation.
These units are Category I listed and may be common vented with
another gas appliance as allowed by the National Fuel Gas Code.
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
LIST OF SECTIONS
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . . . . . 30
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . 31
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LIST OF FIGURES
Thermostat and non-Communicating AC . . . . . . . . . . . . . . . . . . . . . 13
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 14
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 15
Thermostat - Variable Speed or PSC Modulating Furnace . . . . . . . 16
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 17
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 18
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 19
Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Casing to the Burner Compartment . . . . . . . . . . . . . . . . . . . . . . . . . 21
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . 22
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
LIST OF TABLES
Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Blower Performance CFM - Any Position . . . . . . . . . . . . . . . . . . . . . 28
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance
can cause injury or property damage. Failure to carefully read and
follow all instructions in this manual can result in furnace mal-
function, death, personal injury and/or property damage. Only a
qualified contractor, installer or service agency should install this
product.
987158-UIM-B-1013
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Table of Contents
Related Manuals for York TPLCC
Summary of Contents for York TPLCC
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Page 1: Table Of Contents
INSTALLATION MANUAL MODULATING ECM RESIDENTIAL GAS FURNACE MODELS: TPLC*C, YPLC*C, CPLC*C, LPLC*C (80% AFUE Multi-position / Low NOx) LIST OF SECTIONS SAFETY ..........1 SAFETY CONTROLS . - Page 2 987158-UIM-B-1013 SPECIFIC SAFETY RULES AND PRECAUTIONS 12.When moving or handling this furnace prior to installation, always leave the doors on the furnace to provide support and to prevent 1. Only Natural gas or Propane (LP) gas are approved for use with this damage or warping of the cabinet.
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Page 3: Safety
987158-UIM-B-1013 COMBUSTION AIR QUALITY CODES AND STANDARDS (LIST OF CONTAMINANTS) Follow all national, local codes and standards in addition to this installa- The furnace requires OUTDOOR AIR for combustion when the furnace tion manual. The installation must comply with regulations of the serv- is located in any of the following environments. - Page 4 987158-UIM-B-1013 INSPECTION FOR FURNACES INSTALLED IN THE COMMON- As soon as a unit is received, it should be inspected for possible dam- WEALTH OF MASSACHUSETTS ONLY age during transit. If damage is evident, the extent of the damage For all side wall horizontally vented gas fueled equipment installed in should be noted on the carrier’s freight bill.
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Page 5: Ductwork
987158-UIM-B-1013 SECTION II: DUCTWORK DUCT FLANGES DUCTWORK GENERAL INFORMATION Four flanges are provided to attach ductwork to the furnace. These flanges are rotated down for shipment. In order to use the flanges, The duct system’s design and installation must: remove the screw holding an individual flange, rotate the flange so it is 1. -
Page 6: Combustible Floor Base Accessory
987158-UIM-B-1013 DOWNFLOW DUCT CONNECTORS All downflow installations must use a suitable duct connector approved by the furnace manufacturer for use with this furnace. The duct connec- This furnace may be installed in a horizontal position on either side as tors are designed to be connected to the rectangular duct under the shown above. -
Page 7: Coil Flange
987158-UIM-B-1013 SUSPENDED FURNACE / CRAWL SPACE INSTALLATION The furnace can be hung from floor joists or installed on suitable blocks or pads. Blocks or pad installations shall provide adequate height to ensure that the unit will not be subject to water damage. Units may also be suspended from rafters or floor joists using rods, pipe angle supports or straps. -
Page 8: Horizontal Right Application (Typical)
987158-UIM-B-1013 ALTERNATE FLANGE LOCATION (Used for downflow or horizontal left (Min) installations) Flexible Duct Collar Field Fabricated FACTORY Ductwork Do not drill FLANGE or Screw LOCATION this flange Upflow (Used for upflow or horizontal Coil right installations) Upflow FIGURE 8: Coil Flange Furnace FURNACE ASSEMBLY - MC SERIES COILS ONLY Alternate... -
Page 9: Filters
987158-UIM-B-1013 RIGHT SIDE LEFT SIDE FRONT Vent Connection Electrical Outlet Entry Vent Electrical Connection Entry Outlet Gas Pipe Gas Pipe Entry Entry 33” 23” Thermostat Thermostat Wiring Wiring 14” 28.5” 1” 1.5” 29.5” (For Cladded door add appoximately an additional .75”) 4”... -
Page 10: Gas Piping
987158-UIM-B-1013 Downflow Filters Main Inlet On/Off Regulator Downflow furnaces typically are installed with the filters located above Pressure Switch Adjustment the furnace, extending into the return air plenum or duct. Any branch duct (rectangular or round duct) attached to the plenum must attach to the vertical plenum above the filter height. -
Page 11: Electrical Power
987158-UIM-B-1013 The factory gas orifice sizes are based on a gas heating value of which shows “#43”. You should change from the factory #45 orifices to 1030 BTU/Cu.ft., so if your gas value is significantly higher or larger #43 orifices, which will bring the input rate back up to approxi- lower than that, it may be necessary to change to smaller or larger mately 76,000 BTU/H, which is what it should be for that furnace at gas orifices. -
Page 12: Furnace Control Board - Communications Connections
987158-UIM-B-1013 SUPPLY VOLTAGE CONNECTIONS The power connection leads and wiring box may be relocated to the Junction left side of the furnace. Remove the screws and cut wire tie holding excess wiring. Reposition on the left side of the furnace and fasten using holes provided. -
Page 13: Modulating Furnace With Communicating Ac Or Hp
987158-UIM-B-1013 CONTROL WIRING USING COMMUNICATING When connecting the Communicating Control (wall thermostat) and fur- CONTROLS nace control to a non-communicating outdoor A/C or heat pump, use the wiring diagram in Figure 20. The thermostat and furnace will be con- Use the wiring diagram below to connect the furnace control, Communi- nected exactly as shown above, but the conventional 24 volt R, C and cating Control (wall thermostat) and communicating outdoor unit. -
Page 14: Thermostat Chart - Single Stage Air Conditioner - Variable Speed Or Psc Modulating Furnace
987158-UIM-B-1013 For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available online at www.upgnet.com in the Product Catalog Section. ID MODELS 73/& <3/& &3/& THERMOSTAT /3/& SINGLE STAGE MODULATING SINGLE STAGE *PP11C70224 FURNACE AIR CONDITIONER CONDITIONER MODULATING FURNACE CONTROL... -
Page 15: Thermostat Chart - Two Stage Air Conditioner - Variable Speed Or Psc Modulating Furnace
987158-UIM-B-1013 ID MODELS 73/& <3/& &3/& THERMOSTAT THERMOSTAT /3/& TWO STAGE MODULATING *DN22U00124 *PP32U70124 FURNACE CONDITIONER MODULATING FURNACE CONTROL 24 – Volt Common 24 – Volt Common 24 – Volt Common 24 – Volt Common Single First Stage Compressor First Stage Compressor First Stage Compressor Stage Compressor 24 –... -
Page 16: Thermostat Chart - Two Stage Air Conditioner With Single Stage Thermostat - Variable Speed Or Psc Modulating Furnace
987158-UIM-B-1013 ID MODELS 73/& <3/& &3/& THERMOSTAT /3/& TWO STAGE MODULATING *PP11C70224 FURNACE CONDITIONER MODULATING FURNACE CONTROL 24 – Volt Common 24 – Volt Common Single Full Stage Compressor First Stage Compressor Stage Compressor 24 – Volt Hot 24 – Volt Hot 24 –... -
Page 17: Thermostat Chart - Single Stage Heat Pump - Variable Speed Or Psc Modulating Furnace
987158-UIM-B-1013 ID MODELS OD MODELS TP9C *HGD *HJR YP9C *HJD CP9C *HGF THERMOSTAT THERMOSTAT THERMOSTAT LP9C *HJF *BP21H50124 *BN21H00124 MODULATING SINGLE STAGE *DN22U00124 *DP32H70124 *DP21H40124 FURNACE HEAT PUMP *DN21H00124 MODULATING DEMAND DEFROST FURNACE CONTROL CONTROL 24 – Volt Common 24 – Volt Common 24 –... -
Page 18: Thermostat Chart - Single Stage Heat Pump - Variable Speed Or Psc Modulating Furnace
987158-UIM-B-1013 ID MODELS OD MODELS TP9C YP9C CP9C THERMOSTAT THERMOSTAT THERMOSTAT LP9C *BP21H50124 *BN21H00124 MODULATING SINGLE STAGE *DN22U00124 *DP32H70124 *DP21H40124 FURNACE HEAT PUMP *DN21H00124 YORKGUARD VI MODULATING CONTROL FURNACE CONTROL 24 – Volt Common 24 – Volt Common 24 – Volt Common 24 –... -
Page 19: Thermostat Chart - Two Stage Heat Pump - Variable Speed Or Psc Modulating Furnace
987158-UIM-B-1013 ID MODELS OD MODELS THERMOSTAT THERMOSTAT *DN22H00124 MODULATING TWO STAGE *PP32U70124 *DP22U70124 FURNACE HEAT PUMP YORKGUARD VI MODULATING CONTROL FURNACE CONTROL 24 – Volt Common 24 – Volt Common 24 – Volt Common 24 – Volt Common Single Single First Stage Compressor First Stage Compressor Stage Compressor... -
Page 20: Vent System
987158-UIM-B-1013 SECTION VI: VENT SYSTEM ACCESSORY CONNECTIONS The furnace control will allow power-switching control of various acces- VENT CONNECTIONS sories. Figure 27 shows the furnace as it is shipped from the factory. To convert ELECTRONIC AIR CLEANER CONNECTION to a horizontal or downflow position, remove the four screws that secure Two 1/4”... -
Page 21: Combustion Airflow Path Through The Furnace Casing To The Burner Compartment
987158-UIM-B-1013 FAN-ASSISTED COMBUSTION SYSTEM Combustion Air Source From Outdoors This appliance is equipped with an integral mechanical means to draw The blocking effects of louvers, grilles and screens must be given con- products of combustion through the heat exchanger. sideration in calculating free area. If the free area of a specific louver or grille is not known, refer to Table 7, to estimate free area. -
Page 22: Outside And Ambient Combustion Air
987158-UIM-B-1013 Vent Vent Vent Gable Gable Vent Vent Ventilated Ventilated Attic Attic Optional Top Above Inlet (a) Top Above Insulation Insulation Outlet Soffit Air (a) Soffit Vent Outlet Outlet Vent Air (b) Air (a) Water Heater Water Water Inlet Heater Inlet Heater Inlet... - Page 23 987158-UIM-B-1013 CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon- monxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: 1.
- Page 24 987158-UIM-B-1013 SETUP TEST MODE NOTICE During normal operation, the furnace input rate can vary between 50% and 100% of full nameplate input, making it difficult to check for proper DO NOT set manifold pressure less than 3.2 in wc or more than 3.8 in operation.
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Page 25: Gas Rate (Cu Ft/Hr) At Full Input
987158-UIM-B-1013 Table 10: Gas Rate (CU FT/HR) at Full Input Size of Test Dial Size of Test Dial Seconds For Seconds For 1 Revolution 1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft 1800 1636... -
Page 26: Inlet Gas Pressure Range
987158-UIM-B-1013 ADJUSTMENT OF MANIFOLD GAS PRESSURE Main Inlet On/Off Inlet and manifold gas pressure may be measured by connecting the Regulator Pressure Switch Adjustment “U” tube manometer to the gas valve with a piece of tubing. Follow the appropriate section in the instructions below. Refer to Figure 30 for a drawing of the locations of the pressure ports on the gas valve. -
Page 27: Furnace Control Board
987158-UIM-B-1013 ADJUSTMENT OF FAN CONTROL SETTINGS Continuous Fan Operation - The airflow delivered by the furnace dur- ing continuous fan operation can be adjusted as desired. This is done Cooling - The airflow delivered by the furnace during cooling operation my moving the control fan jumper on the control board to give the can be adjusted to match the cooling capacity of the A/C condensing desired airflow. -
Page 28: Blower Performance Cfm - Any Position
987158-UIM-B-1013 Table 13: Blower Performance CFM - Any Position High / Low Speed Cooling CFM 060A12 080B12 Jumper Settings Hi Cool Lo Cool Hi Cool Lo Cool COOL Jumper ADJ Jumper 1340 1290 1125 1065 1225 1165 1050 1100 1050 High / Low Speed Cooling CFM 080C16 100C16... -
Page 29: Safety Controls
987158-UIM-B-1013 ROLLOUT SWITCH CONTROLS Delay Taps Selection These controls are mounted on the burner assembly. If the temperature The set of jumper pins on the control board labeled “DELAY” are used in the burner area exceeds its set point, the ignition control and the gas to set the delay profiles for the furnace. -
Page 30: Normal Operation And Diagnostics
987158-UIM-B-1013 SECTION IX: NORMAL OPERATION AND Three Amber flashes - Normal operation, burner is on at end of heat- DIAGNOSTICS ing cycle after wall thermostat has been satisfied. Four Amber Flashes - Heating capacity is reduced due to restriction in NORMAL OPERATION SEQUENCE the circulating air system. -
Page 31: Replacement Parts List
Click on the “Brand Links” button b. Click on the “Customer Service” button • You can contact us by mail. Just send a written request to: Johnson Controls Unitary Products Consumer Relations 5005 York Drive Norman, OK 73069 Johnson Controls Unitary Products... -
Page 32: Wiring Diagram
987158-UIM-B-1013 SECTION XI: WIRING DIAGRAM CAUTION Wiring Diagram 80+% Modulating Furnace With ECM Motor OPEN ALL DISCONNECTS BEFORE SERVICING THIS UNIT 115VAC NEUT. 115VAC LINE PRECAUTION DOOR SWITCH OUVREZ LES DISJONCTEURS AVANT PF (NOT USED ON 1/2 HP MOTORS) DE PROCEDER AVEC LE SERVICE VALVE 120VAC NEUTRAL... -
Page 33: Start Up Sheet
987158-UIM-B-1013 SECTION XII: START UP SHEET 33" 80% AFUE (ECM/PSC) Modulating Gas Furnace Start Up Sheet Proper furnace start up is critical to customer comfort and equipment longevity Start-Up Date Technician Performing Start-Up Installing Contractor Name Owner Information Name Address City State or Province Zip or Postal Code... - Page 34 Explain thermostat use and programming (if applicable) to owner Additional Job Detail Subject to change without notice. Published in U.S.A. 987158-UIM-B-1013 Copyright © 2013 by Johnson Controls, Inc. All rights reserved. Supersedes: 987158-UIM-A-0313 York International Corp. 5005 York Drive Norman, OK 73069...