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Johnson Controls CP8C/CPLC*MP manual

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Table of contents for the manual

  • Page 1

    368262-UIM-B-1008 EFFICIENCY RATING CERTIFIED ISO 9001 Certified Quality Management System 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) INSTALLATION MANUAL LIST OF SECTIONS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 2

    368262-UIM-B-1008 2 Johnson Controls Unitary Products SPECIFIC SAFETY RULES AND PRECAUTIONS 1. Only Natural gas or Propane (LP) ga s are approved for use with this furnace. 2. Install this furnace only in a location and position as specified in these instructions. 3. A gas-fired furnace for installation in a residential garage must be installed as [...]

  • Page 3

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 3 COMBUSTION AIR QU ALITY (LIST OF CONT AMINANTS) The furnace requires OUTDOO R AIR for combustion when the furnace is located in any of the following environments. • Restricted Environments • Commercial buildings • Buildings with indoor pools • Furnaces installed in laundry rooms • Fur[...]

  • Page 4

    368262-UIM-B-1008 4 Johnson Controls Unitary Products INSPECTION As soon as a unit is received, it should be inspected for possible dam- age during transit. If damage is evident, the extent of the damage should be noted on the carrier ’s freight bill. A sep arate reque st for inspection by the carrier ’s agent should be made in writing. Also, b[...]

  • Page 5

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 5 SECTION II: DUCTWORK DUCTWORK GENERAL INFORMA TION The duct system’s design and installation must: 1. Handle an air volume appropriate for the served space and within the operating parameters of the furnace specifications. 2. Be installed in accordance of National Fire Protection Association [...]

  • Page 6

    368262-UIM-B-1008 6 Johnson Controls Unitary Products DOWNFL OW DUCT CONNECT ORS All downflow installations must us e a suitable duct connector approved by the furnace manufacturer for use with this furnace. The duct connec- tors are designed to be connected to the rectangular duct under the floor and sealed. Refer to the instructions supplied with[...]

  • Page 7

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 7 All six suspension points must be level to ensure proper and quiet fur- nace operation. When suspe nding the furnace, use a secure platform constructed of plywood or other build ing materials secured to the floor or ceiling joists. Refer to Figure 1 1 for details and additional informa- tion. W[...]

  • Page 8

    368262-UIM-B-1008 8 Johnson Controls Unitary Products FURNACE ASSEMBL Y - MC & FC SERIE S COILS These coils are factory shipped for installation in either upflow or down- flow applications with no conversion. Position the coil casing over or under the furnace opening as shown in Figure 8 after configuring coil flanges as required see “Coil Fl[...]

  • Page 9

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 9 SECTION III: FIL TERS FIL TER INST ALLA TION All applications require the use of a field installed filter . All filters and mounting provision must be field supplied. Filters must be installed external to the furnace cabinet. DO NOT attempt to install filters inside the furnace. NOTES: 1. Air v[...]

  • Page 10

    368262-UIM-B-1008 10 Johnson Controls Unitary Products HORIZONT AL APPLICA TION Horizontal Filters Any branch duct (rectangular or r ound duct) attached to the plenum must attach to the vertical plenum before the filter . The use of straps and / or supports is required to support the weight of the external filte r box. Downflow Filt ers Downflow fu[...]

  • Page 11

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 11 GAS CONVERSION FOR PROP ANE (LP) This furnace is constructed at the facto ry for natural gas-fired operation, but may be converted to operate on propane (LP) gas by using a fac- tory-supplied LP conversi on kit which includes a LP gas valve. Follow the instructions supplied with the LP kit. HI[...]

  • Page 12

    368262-UIM-B-1008 12 Johnson Controls Unitary Products Annual Fuel Utilizat ion Efficiency (AFUE) numbers a re determined in accordance with DOE T est procedures. Wire size and over current protection must comply wi th t he National Electrical Code (NFP A-70-latest edition) and all local code s. SUPPL Y VOL T AGE CONNECTIONS 1. Provide a power supp[...]

  • Page 13

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 13 For additional connection diagrams fo r all UPG equipment refer to “Low V oltage System Wiring” document available online at www . upgnet.com in the Product Catalog Section. FIGURE 19: Thermostat Chart - Single S tage Air Conditioner – V ariable S peed or PSC Modula ting Furnace HM1 Humi[...]

  • Page 14

    368262-UIM-B-1008 14 Johnson Controls Unitary Products FIGURE 20: Thermostat Chart - T wo S tage Air Conditioner – V ariable S peed or PSC Modulatin g Furnace C 24 – Volt Comm on Y1 First Stage Co mp ressor Y2 Second St age Compre ssor G Fan *PP32U70124 THERMOSTAT AUX Auxiliary Hea t R 24 – Volt Hot (Heat XFMR) R 24 – Volt Hot (Cool XFMR) C[...]

  • Page 15

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 15 FIGURE 21: Thermostat Chart - T wo S tage Air Conditioner with Single S t age Thermostat – V ariable S peed or PSC Modulating Furnace HM1 Humidistat Y Full Stage Compressor G Fan *PP11C70224 THERMOSTAT RH 24 – Vo lt Hot (Heat XFMR) RC 24 – Volt Hot (Cool XFMR) W Full Stage Heat Clipping [...]

  • Page 16

    368262-UIM-B-1008 16 Johnson Controls Unitary Products FIGURE 22: Thermostat Chart - Single S tage Heat Pump – V ariable S peed or PSC Modulating Furnace C 24 – Volt Common R 24 – Volt Hot Y1 First Stage Co mp ressor O Reversing Valve Energized in Cool L Malfunction Ligh t G Fan *DP32H70124 THERMOSTAT W1 Second St age Aux. Hea t E Emergency H[...]

  • Page 17

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 17 FIGURE 23: Thermostat Chart - Single S tage Heat Pump – V ariable S peed or PSC Modulating Furnace C 24 – Volt Comm on R 24 – Volt Hot Y1 First Stage Comp ressor O Reversing Valve Energized in Cool L Malfunction Ligh t G Fan *DP32H70124 THERMOSTAT W1 Second St a ge Aux. Hea t E Emergency[...]

  • Page 18

    368262-UIM-B-1008 18 Johnson Controls Unitary Products FIGURE 24: Thermostat Chart - T wo S tage Heat Pump – V ariable S peed or PSC Modulating Furnace O Reversing Valve Energized in Co ol C 24 – Vo lt Common R 24 – Volt Hot W1 OUT First Stage Heat W2 OUT Second Stage Heat Y2 OUT Second Stage Compressor Y1 Single Stage Compressor X/L Malfunct[...]

  • Page 19

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 19 ACCESSOR Y CONNECTIONS The furnace control will allow power- sw itching control of various acces- sories. ELECTRONIC AIR CLEANER CONNECTION T wo 1/4” (0.64 cm) spade terminals (EAC and NEUTRAL) for electronic air cleaner connections are located on the control board. The te rminals provide 1 [...]

  • Page 20

    368262-UIM-B-1008 20 Johnson Controls Unitary Products F AN-ASSISTED COMBUSTION SY STEM This appliance is equipped with an integral mechanical means to draw products of combustion through the heat exchanger . Ambient Combustion Air Supply This type installation will draw the air required for combustion from within the space surrounding the applianc[...]

  • Page 21

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 21 Air Supply Openings and Duct s 1. An opening may be used in lieu of a duct to provide the outside air supply to an appliance unless othe rwise permitted by the authority having jurisdiction. The opening shall be located within 12” (30.5 cm) horizontally from, the burner level of the applianc[...]

  • Page 22

    368262-UIM-B-1008 22 Johnson Controls Unitary Products SECTION VII: S T ART -UP AND ADJUSTMENTS NOTE: In order that this furnace will operate properly , it is required that all of the startup procedures in this section be followed. NOx SCREEN REMO V AL (Lo-NOx Models Only) If the furnace is equipped with NOx screens and is to be used with LP (propa[...]

  • Page 23

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 23 SETUP TEST MODE During normal operation, the furnace input rate can vary bet ween 50% and 100% of full nameplate input, making it difficult to check for proper operation. T o help with the furnace startup process, the control has a TEST MODE available that allows t he furn ace input rate to st[...]

  • Page 24

    368262-UIM-B-1008 24 Johnson Controls Unitary Products T ab le 10: Gas Rate (CU FT/HR) at Full Inpu t Seconds For 1 Revolution Size of T est Dial Seconds For 1 Revolution Size of T est Dial 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft 10 360 720 1800 55 65 131 327 1 1 327 655 1636 56 64 129 321 12 300 600 1500 57 63 126 316 13 277 555 1385 58 62[...]

  • Page 25

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 25 ADJUSTMENT OF MANI FOLD GAS PRESSURE * The gas line pressure MUST BE • 7” W .C. (1.74 kP A) for Natural Gas • 1 1” W .C. (2.74 kP A) for Propane (LP) Gas in order to obtain the BTU input specified on the rating plate and/or the nominal manifold pressure specifi ed in these instructions[...]

  • Page 26

    368262-UIM-B-1008 26 Johnson Controls Unitary Products ADJUSTMENT OF F AN CONTROL SETTINGS Cooling - The airflow delivered by the furnace during cooling operation can be adjusted to match the cooli ng capacity of the A/C condensing unit. This is done by moving the COOL and ADJ jumper on the control board to give the desired airflow. The COOL jumper[...]

  • Page 27

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 27 All CFM’s ar e shown at 0.5” w .c. external static pressure.These un its have variable speed motors that automatically adjust to p rovide constant CFM from 0.0” to 0.6” w .c. st ati c pressure. From 0.6” to 1.0” static pressu re , CFM is reduced by 2% per 0.1” increase in static.[...]

  • Page 28

    368262-UIM-B-1008 28 Johnson Controls Unitary Products Delay T aps Selection The set of jumper pins on the control board labeled "DELA Y" are used to set the delay profiles for the fu rnace. These can be chosen so as to maximize the comfort and sound levels for various regions of the coun - try . Ta p A is the default profile. It provides[...]

  • Page 29

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 29 SECTION IX: NORMAL OPERA TION AND DIAGNO STICS NORMAL OPERA TION SEQUENCE The furnace control calculates the optimum firing rate each time the wall thermostat R and W contact s close or open (at the beginning and at the end of each call for heat) based on information from the thermo- stat and [...]

  • Page 30

    368262-UIM-B-1008 30 Johnson Controls Unitary Products DIAGNOSTIC F AUL T CODE STORA GE AND RETRIEV AL The control in this furnace is equipped with memory that will store up to five error codes to allow a serv ice technician to diagnose problems more easily . This memory will be ret ained even if power to the furnace is lost. Only a qualified servi[...]

  • Page 31

    368262-UIM-B-1008 Johnson Controls Unitary Produ cts 31 SECTION XI: WI RING DIAGRAM FIGURE 30: Wiring Diagram[...]

  • 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 Contro ls Unitary Produc t s 5005 Y o rk Drive Norman, OK 73069[...]