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INSTALLATION MANUAL
RESIDENTIAL GAS FURNACE
WITH ECM MOTOR
MODELS:
TP8C/TPLC*MP, YP8C/YPLC*MP,
CP8C/CPLC*MP, LP8C/LPLC*MP
(80% Modulating Multi-position / Low NOx)
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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
Downflow Installation - Gas Valve Rotation . . . . . . . . . . . . . . . . . . . . 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
Upflow/Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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 . . . . . . . . . . . . . . . . . . . . . . . . . 12
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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.
LIST OF SECTIONS
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 22
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 29
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 30
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 30
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LIST OF FIGURES
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 13
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 14
Thermostat - Variable Speed or PSC Modulating Furnace . . . . . . . 15
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 16
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 17
Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . 18
Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
to the Burner Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . 21
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LIST OF TABLES
Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . 20
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Blower Performance CFM - Any Position . . . . . . . . . . . . . . . . . . . . . 27
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.
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.
EFFICIENCY
RATING
CERTIFIED
ISO 9001
Certified Quality
Management System
368262-UIM-B-1008
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Table of Contents
Related Manuals for Johnson Controls Unitary Products TP8C/TPLC MP Series
Summary of Contents for Johnson Controls Unitary Products TP8C/TPLC MP Series
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Page 1: Table Of Contents
INSTALLATION MANUAL RESIDENTIAL GAS FURNACE WITH ECM MOTOR MODELS: EFFICIENCY RATING CERTIFIED TP8C/TPLC*MP, YP8C/YPLC*MP, ISO 9001 CP8C/CPLC*MP, LP8C/LPLC*MP Certified Quality Management System (80% Modulating Multi-position / Low NOx) LIST OF SECTIONS SAFETY ......... . . 1 START-UP AND ADJUSTMENTS . - Page 2 When working on heating equipment, observe precau- operating conditions including ignition, input rate, temperature tions in the manuals and on the labels attached to the unit and rise and venting, according to the manufacturer’s instructions. other safety precautions that may apply. Johnson Controls Unitary Products...
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Page 3: Safety
In some instances these instructions exceed certain local codes and ordinances, especially those who have not kept up with changing residential and non-HUD modular home construction practices. These instructions are required as a minimum for a safe installation. Johnson Controls Unitary Products... -
Page 4: Unit Clearances To Combustibles
1. Special floor base or air conditioning coil required for use on combustible floor. 2. Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of the furnace jacket and building joists, studs or framing. Johnson Controls Unitary Products... -
Page 5: Ductwork
If the ducts are undersized, the result will be high duct static pres- sures and/or high temperature rises which can result in a heat exchanger OVERHEATING CONDITION. This condition can result in premature heat exchanger failure, which can result in personal injury, property damage, or death. Johnson Controls Unitary Products... -
Page 6: Combustible Floor Base Accessory
It must not be installed on its back. blower shelf, and the third support should be at the return end of the fur- nace. Maintain a 6” minimum clearance between the front of the fur- nace and the support rods or straps. Johnson Controls Unitary Products... -
Page 7: Typical Suspended Furnace / Crawl Space Installation
This access cover shall be attached in such a manner as to prevent leaks. UPFLOW DOWNFLOW FIGURE 8: Vertical Applications (Typical) Johnson Controls Unitary Products... -
Page 8: Coil Flange
12. Gas Furnace Place the ductwork over the coil casing flange and secure. Check for air leakage between the furnace and coil casing and seal appropriately. FIGURE 13: Horizontal Left or Right application (Right Shown) Johnson Controls Unitary Products... -
Page 9: Filters
Some accessories such as electronic air cleaners and pleated media may require a larger side opening. Follow the instructions supplied with that accessory for side opening requirements. Do not cut the opening larger than the dimensions shown in Figure 14. Johnson Controls Unitary Products... -
Page 10: Gas Piping
1/2 psig (3.5 kPa). Gas piping may be connected from either side of the furnace using any of the gas pipe entry on both sides of the furnace. Refer to Figure 14. Johnson Controls Unitary Products... -
Page 11: Electrical Power
Field wiring to the unit must be grounded. Electric wires that are field Use copper conductors only. installed shall conform to the temperature limitation for 63°F (35°C) rise wire when installed in accordance with instructions. Refer to Table 6 in these instructions for specific furnace electrical data. Johnson Controls Unitary Products... -
Page 12: Electrical Wiring
The power connection leads and wiring box may be relocated to the 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. Johnson Controls Unitary Products... -
Page 13: Thermostat Chart - Single Stage Air Conditioner - Variable Speed Or Psc Modulating Furnace
“YES” if humidistat is to be used. is not necessary Part Number: Part Numbers: S1-2HU16700124 SAP = Legacy FIGURE 19: Thermostat Chart - Single Stage Air Conditioner – Variable Speed or PSC Modulating Furnace Johnson Controls Unitary Products... -
Page 14: Thermostat Chart - Two Stage Air Conditioner - Variable Speed Or Psc Modulating Furnace
Multistage Conventional Thermostat Installer Setup 15-Compressor Protection -must be set to 5 Part Numbers: Part Number: SAP = Legacy S1-2HU16700124 FIGURE 20: Thermostat Chart - Two Stage Air Conditioner – Variable Speed or PSC Modulating Furnace Johnson Controls Unitary Products... -
Page 15: Thermostat Chart - Two Stage Air Conditioner With Single Stage Thermostat - Variable Speed Or Psc Modulating Furnace
Part Number: Part Numbers: S1-2HU16700124 SAP = Legacy FIGURE 21: Thermostat Chart - Two Stage Air Conditioner with Single Stage Thermostat – Variable Speed or PSC Modulating Furnace Johnson Controls Unitary Products... -
Page 16: Thermostat Chart - Single Stage Heat Pump - Variable Speed Or Psc Modulating Furnace
Menu must be set to Pump OFF Part Numbers: Part Number: Part Numbers: SAP = Legacy S1-2HU16700124 SAP = Legacy 67297 = 031-01975 FIGURE 22: Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace Johnson Controls Unitary Products... -
Page 17: Thermostat Chart - Single Stage Heat Pump - Variable Speed Or Psc Modulating Furnace
Part Number: Part Numbers: SAP = Legacy S1-2HU16700124 SAP = Legacy 126768 = 031-09137 18395 = 031-01996 340512 = 031-09178 FIGURE 23: Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace Johnson Controls Unitary Products... -
Page 18: Thermostat Chart - Two Stage Heat Pump - Variable Speed Or Psc Modulating Furnace
18395 = 031-01996 Kit- must be set to 1 340512 = 031-09178 Heat Pump Control is Controlling Heat Pump Backup Heat FIGURE 24: Thermostat Chart - Two Stage Heat Pump – Variable Speed or PSC Modulating Furnace Johnson Controls Unitary Products... -
Page 19: Vent System
National Fuel Gas Code or in Canada, the B-149 Installation Codes. Johnson Controls Unitary Products... -
Page 20: Estimated Free Area
Appliance 1 Appliance 2 Total Input + 30,000 = (130,000 ÷ 4,000) = 32.5 Sq. In. Vertical 100,000 Appliance 1 Appliance 2 Total Input + 30,000 = (130,000 ÷ 2,000) = 65 Sq. In. Horizontal 100,000 Johnson Controls Unitary Products... -
Page 21: Outside And Ambient Combustion Air
Carbon Monoxide or an unsafe condition to occur. Not less than the sum of all vent connectors in the confined space. Johnson Controls Unitary Products... -
Page 22: Start-Up And Adjustments
1/2 PSI (3.45 kPa). The furnace must be isolated from the gas supply piping system by closing the equipment shutoff valve during any pressure testing of the gas supply system. Johnson Controls Unitary Products... - Page 23 NOTE: DO NOT set manifold pressure less than 3.2 in wc or more than 3.8 in wc for natural gas at sea level. If manifold pressure is outside this range, change main burner orifices. Johnson Controls Unitary Products...
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Page 24: Gas Rate (Cu Ft/Hr) At Full Input
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 1500 1385 1286 1200 1125 1059 1000 Johnson Controls Unitary Products... -
Page 25: Gas Valve
10.0" w.c. (2.49 kPa) ature rise), move the jumper to the -10 position. If less air is desired Propane (LP) Gas (Min) 2.5" w.c. (0.62 kPa) (higher temperature rise), move the jumper to the +10 position. Johnson Controls Unitary Products... -
Page 26: Furnace Control Board
Humidifier Terminals Terminals Zoning Jumper Heat Pump Jumper Cooling Speed Jumper Humidistat Jumper Continuous Fan Speed Jumper Test Button Last Diagnostic Error Voltage Light Terminals Button FIGURE 29: Furnace Control Board Johnson Controls Unitary Products... -
Page 27: Blower Performance Cfm - Any Position
NOTE: At some settings, LOW COOL airflow may be lower that what is required to operate an airflow switch on certain models of electronic air cleaners. Con- sult the instructions for the electronic air cleaner for further details. Johnson Controls Unitary Products... -
Page 28: Safety Controls
Do not rely upon the interlock switch as a main power dis- connect. Blower and burner must never be operated without the blower panel in place. Johnson Controls Unitary Products... -
Page 29: Normal Operation And Diagnostics
Low flame signal control lockout point is One Amber Flash - Normal operation with call for cooling. 0.1 microamps DC (µa) Two Amber Flashes - Normal operation with call for heat. Johnson Controls Unitary Products... -
Page 30: Replacement Parts List
3. Customer Service contact information. a. 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... -
Page 31: Wiring Diagram
368262-UIM-B-1008 SECTION XI: WIRING DIAGRAM FIGURE 30: Wiring Diagram Johnson Controls Unitary Products... - Page 32 Subject to change without notice. Printed in U.S.A. 368262-UIM-B-1008 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 368262-UIM-A-0508 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...