58PHA/PHX Performance Boost 80 4---Way Multipoise Induced---Combustion Gas Furnace Input Capacities: 45,000 thru 135,000 Btuh Installation, Start---up, Operating and Service and Maintenance Instructions Series 100/A SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND MAINTENANCE PROCEDURES . . . . . . .
(733mm) 28-7/8" (664mm) 26-1/8" (FLUE COLLAR) (641mm) 25-1/4" 5-15/16" (135mm) (22mm) 7/8" DIA ACCESSORY 22-9/16" (573mm) A JUNCTION BOX LOCATION D F 13/16" (21mm) 4-13/16" (122mm) 2-7/16" (62mm) 1-5/16" (33mm) 1-1/8" (29mm) 13/16" (21mm) 19" (483mm) OUTLET 1/2" DIA. K.O.THERMOSTAT WIRE ENTRY (13mm) 1-3/4" DIA.RIGHT HAND GAS ENTRY (44mm) 8-9/16" (217mm) 1/2" (13 mm) DIA.
8. 9. Recognize safety information. This is the safety--alert symbol . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death.
58PHA A08471 Fig. 2 -- Clearances to Combustibles CODES AND STANDARDS Safety Follow all national and local codes and standards in addition to these instructions. The installation must comply with regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.
CANADA: CAN/CSA--B149.1--05 Parts 4, 5, and 6 Appendices A, B, E, and H. Electrical Connections S Max 85ºF/ 29ºC S US: National Electrical Code (NEC) ANSI/NFPA 70--2008. S CANADA: Canadian Electrical Code CSA C22.1. Venting S US: NFGC NFPA 54 / ANSI Z223.1--2006; Chapters 12 and 13. S CANADA: CAN/CSA--B149.1--05 Part 8 and Appendix C. Min 60ºF / 16ºC A02055 ! Fig. 3 -- Return Air Temperature General Installation S FURNACE RELIABILITY HAZARD US: Current edition of the NFGC and the NFPA 90B.
THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. 58PHA THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS LOCATED TO THE LEFT OF THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED TO THE RIGHT. THE BLOWER IS LOCATED ABOVE THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED DOWNWARD A02097 Fig. 4 -- Multipoise Orientations 6.
S Masonry acid washing materials All fuel--burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return--air duct to prevent pulling air from the burner area and from draft safeguard opening.
Table 3 – Minimum Space volumes for 100% combustion, Ventilation, and Dilution from Indoors OTHER THAN FAN---ASSISTED TOTAL (1,000’S BTUH GAS INPUT RATE ACH* 30 40 FAN---ASSISTED TOTAL (1,000’S BTUH GAS INPUT RATE) 50 44 66 88 110 132 Space Volume (ft.3) 0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 0.
a. One opening MUST commence within 12--in. (300 mm) of the ceiling and the second opening MUST commence within 12--in. (300 mm) of the floor. b. Size openings and ducts per Fig. 7 and Table 2. c. TWO HORIZONTAL DUCTS require 1 square inch of free area per 2,000 Btuh (1,100 mm2/kW) of combined input for all gas appliances in the space per Fig. 7 and Table 2. d.
CIRCULATING AIR DUCTS INTERIOR HEATED SPACE A02098 Fig. 9 -- Removing Bottom Closure Panel b. Outdoor opening size reduction Factor is 1 minus the Ratio in a. above. c. Minimum size of Outdoor openings shall be the size required in Outdoor Combustion Air Method above multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3 in. (80 mm). VENT THROUGH ROOF CLEARANCE IN FRONT OF COMBUSTION AIR OPENINGS SHALL BE AT LEAST 3 IN. 58PHA of at least 2 in.
5/ 16″ (8mm) (8mm) 5/ 16″ 1 3/4″ (44mm) A PLENUM OPENING 1 3/4″ (44mm) D B FLOOR OPENING (8mm) 5/16″ C 58PHA (8mm) 5/ 16″ (44mm) 1 (44mm) 3/ 4″ 1 3/ 4″ A89014 A96283 Fig. 10 -- Leveling Legs Fig. 11 -- Floor and Plenum Opening Dimensions 4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement. 5. Reinstall bottom closure panel if removed.
FURNACE APPROVED COIL ASSEMBLY OR COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM 58PHA FLOOR OPENING A08556 Fig.
Table 4 – Opening Dimensions -- In.
3. Remove bottom closure panel. 4. Reinstall bottom filler panel and screws. Side Return Air Inlet Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when side return air inlet(s) is used without a bottom return air inlet. Not all horizontal furnaces are approved for side return air connections. (See Fig. 20).
UPFLOW DOWNFLOW HORIZONTAL 90° 90° YES 120° MIN YES YES 120° MIN YES 120° MIN NO NO YES 58PHA YES NO A02020 Fig. 14 -- Duct Flanges " (6mm) THREADED ROD 4 REQ. 1/4 OUTER DOOR ASSEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 x 3/4" (19mm) SCREWS TYPICAL FOR 2 SUPPORTS 8" (203mm) MIN FOR DOOR REMOVAL 1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm) ANGLE IRON OR UNI-STRUT MAY BE USED (2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS REQ. PER ROD A05027 Fig.
58PHA METHOD 2 USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES. METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM). A03176 Fig.
Return Air Connections WARNING FIRE OR EXPLOSION HAZARD FIRE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Failure to follow this warning could cause personal injury, death and/or property damage. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance.
Table 5 – Air Delivery -- CFM (With Filter)* UNIT SIZE RETURN---AIR SUPPLY Bottom or Side(s) 070---16 / 048070 Bottom or Side(s) 090---16 / 048090 Bottom or Side(s) 110---20 / 060110 Bottom or Side(s) 58PHA 045---08/ 024045 135---20 / 060135 Bottom or Side(s) SPEED 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 0.1 1185 920 735 820 650 1625 1405 1240 1190 1035 1845 1590 1365 1225 1100 2255 1600 1945 1420 1280 2295 1725 1910 1630 1430 0.
58PHA A02075 Fig. 18 -- Upflow Return Air Configurations and Restrictions A02163 Fig.
58PHA A02162 Fig. 20 -- Horizontal Return Air Configurations and Restrictions 2” (51mm) Street Elbow A08551 Fig.
Table 7 – Electrical Data FURNACE MODEL VOLTS--HERTZ--PHASE 045--- 08 / 024045 070--- 16 / 048070 090--- 16 / 048090 110--- 20 / 060110 135--- 20 / 060135 115--- 60--- 1 115--- 60--- 1 115--- 60--- 1 115--- 60--- 1 115--- 60--- 1 OPERATING VOLTAGE* (VOLTS) MAX MIN 127 104 127 104 127 104 127 104 127 104 MAX UNIT (AMPS) UNIT AMPACITY# (AMPS) MAX WIRE LENGTH} FT. (M) MAX FUSE/ CKT BKR{ (AMPS) MIN WIRE GAGE 8.1 9.5 10.3 13.1 13.1 10.9 12.6 13.4 16.9 16.
! CAUTION FURNACE MAY NOT OPERATE Failure to follow this caution may result in intermittent furnace operation. 58PHA Furnace control must be grounded for proper operation or else control will lock out. Control must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw. 115--V WIRING Verify that the voltage, frequency, and phase correspond to that specified on unit rating plate.
A03221 Fig. 23 -- Field--Supplied Electrical Box on Furnace Casing POWER CORD INSTALLATION IN FURNACE J--BOX NOTE: Power cords must be able to handle the electrical requirements listed in Table 7. Refer to power cord manufacturer’s listings. 1. Remove cover from J--Box. 2. Route listed power cord through 7/8--in. (22 mm) diameter hole in J--Box. 3. Secure power cord to J--Box bracket with a strain relief bushing or a connector approved for the type of cord used. 4.
BLOWER OFF-DELAY TWINNING AND/OR COMPONENT TEST TERMINAL 24-V THERMOSTAT TERMINALS HUMIDIFIER TERMINAL (24-VAC 0.5 AMP. MAX) 3-AMP FUSE 58PHA LED OPERATION & DIAGNOSTIC LIGHT HEAT TRANSFORMER 24-VAC CONNECTIONS COOL BLOWER SPEED SELECTION TERMINALS FAN SPARE 2 SPARE 1 PL1-LOW VOLTAGE DRAIN HARNESS CONNECTOR 115-VAC (L2) NEUTRAL CONNECTIONS EAC-1 TERMINAL (115-VAC 1.0 AMP. MAX.) 115-VAC (L1) NEUTRAL CONNECTIONS PL2-HOT SURFACE IGNITER & INDUCER MOTOR CONNECTOR A08063 Fig.
WARNING 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 monoxide 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. Seal any unused openings in venting system. 2.
58PHA See notes 2,5,7, and 10 on the page following these figures. See notes 1, 2, 4, 6, 7, 9, 10 and 12 on the page following these figures. A04215 A04217 Fig. 26 -- Single--Stage Furnace with Single--Speed Air Conditioner Fig. 28 -- Single--Stage Furnace with Single--Speed Heat Pump (Dual Fuel) See notes 2,5,8, and 10 on the page following these figures. See notes 1, 2, 3, 4, 6, 8, 9, 10 and 12 on the page following these figures. A04216 A04218 Fig.
HUMIDFIER (24VAC) See notes 1, 2, 4, 11, 12, and 13 on the page following these figures. See notes 1, 2, 3, 4, 11, 12, and 14 on the page following these figures. A04220 A04219 Fig. 31 -- Dual Fuel Thermostat with Single--Stage Furnace and Two--Speed Heat Pump Fig. 30 -- Dual Fuel Thermostat with Single--Stage Furnace and Single--Speed Heat Pump See note 2 on the page following these figures. HUMIDFIER (24VAC) A04221 Fig.
58PHA Canada (and U.S.A.)--This furnace is permitted to be vented into a clay tile--lined masonry chimney that is exposed to the outdoors below the roof line, provided: 1. Vent connector is Type--B double--wall, and 2. This furnace is common vented with at least 1 draft hoodequipped appliance, and 3. The combined appliance input rating is less than the maximum capacity given in Table A, and 4.
CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211 Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian installation Code CSA-B149.1 in Canada. Crown condition: Missing mortar or brick? Rebuild crown. Yes No No 58PHA Is chimney property lined with clay tile liner? Yes Is liner and top seal in good condition? No Repair liner or top seal or reline chimney as necessary.
58PHA To prevent condensation in the furnace and vent system, the following precautions must be observed: 1. The return--air temperature must be at least 60_F (16_C)db except for brief periods of time during warm--up from setback at no lower than 55_F (13_C) db or during initial start--up from a standby condition. 2. Adjust the gas input rate per the installation instructions. Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system.
58PHA SEE NOTES: 1,2,4,7,8,9 on the page following these figures SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures A03208 A03210 Fig. 34 -- Upflow Application--Vent Elbow Up Fig. 36 -- Downflow Application--Vent Elbow Up then Left SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures SEE NOTES: 1,2,3,4,7,8,9 on the pages following these figures A03211 A03209 Fig. 37 -- Downflow Application--Vent Elbow Up Fig.
58PHA SEE NOTES: 1,2,4,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,6,7,8,9 on the page following these figures A03207 A03213 Fig. 38 -- Downflow Application--Vent Elbow Left then Up Fig. 40 -- Horizontal Left Application--Vent Elbow Left SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures. A03212 A03214 Fig. 39 -- Downflow Application--Vent Elbow Up then Right Fig.
SEE NOTES: 1,2,4,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A03219 SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures Fig. 44 -- Horizontal Right Application--Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A03215 A03216 Fig. 43 -- Horizontal Left Application--Vent Elbow Up Fig. 45 -- Horizontal Left Application--Vent Elbow Right SEE NOTES: 1,2,4,5,7,8,9 A02068 Fig.
58PHA Venting Notes for Figures 34--46 1. For common vent, vent connector sizing and vent material: United States----use the NFGC Canada----use the CAN/CSA--B149.1--05 2. Immediately increase to 5--inch (127 mm) or 6--inch (152 mm) vent connector outside furnace casing when 5--inch (127 mm) vent connector is required, refer to Note 1 above. 3.
58PHA A04128 A04130 Fig. 48 -- Rounded End of Knockout Fig. 50 -- Hammer and Screwdriver Used for Knockout A04129 A04131 Fig. 49 -- Knockout Pulled Loose Fig.
START--UP, ADJUSTMENT, AND SAFETY CHECK ! General ELECTRICAL SHOCK HAZARD ! Failure to follow this warning could result in personal injury, or death. WARNING Blower access door switch opens 115--v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes. FIRE HAZARD Failure to follow this warning could result in personal injury, death and/or property damage.
adjustment tables. All models in all positions, except Low NOx models in downflow or horizontal positions, use Table 13 (22,000 Btuh/Burner). Low NOx models in the downflow or horizontal positions must use Table 14 (21,000 Btuh/Burner). See input listed on rating plate. a. Obtain average yearly gas heat value (at installed altitude) from local gas supplier. b. Obtain average yearly gas specific gravity from local gas supplier. c. Find installation altitude in Table 13 or 14. d.
58PHA c. Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow. d. Refer to Table 12 for cubic ft. of gas per hr. e. Multiply gas rate (cu ft./hr) by heating value (Btuh/cu ft.) to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct input is achieved.
Table 11 – Speed Selection COLOR Gray Yellow Blue Orange Red SPEED 5 4 3 2 1* THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.) AS SHIPPED COOL SPARE HEAT SPARE CONT FAN HOOK-AROUND AMMETER * Continuous---blower speed---as shipped default ! R Y W G CAUTION FURNACE OVERHEATING HAZARD Failure to follow this caution may result in reduced furnace life. Recheck temperature rise. It must be within limits specified on the rating plate.
Table 12 – Gas Rate (Cu Ft./Hr.) 58PHA SECONDS FOR 1 REVOLUTION 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 SIZE OF TEST DIAL 1 Cu Ft. 360 327 300 277 257 240 225 212 200 189 180 171 164 157 150 144 138 133 129 124 120 116 113 109 106 103 100 97 95 92 90 88 86 84 82 80 78 76 75 73 2 Cu Ft. 5 Cu Ft.
58PHA Table 13 – Orifice Size* and Manifold Pressure (In.
58PHA Table 13 -- Orifice Size* and Manifold Pressure (In.
! WARNING FIRE, INJURY, OR DEATH HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. The ability to properly perform maintenance on this equipment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User’s Manual.
58PHA Table 14 – Orifice Size* And Manifold Pressure (In.
58PHA Table 14-- Orifice Size* And Manifold Pressure (In. wc) For Gas Input Rate (CONT) A08221A SERVICE If status code recall is needed, briefly remove then reconnect one main limit wire to display stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. After status code recall is completed component test will occur. LED CODE STATUS CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.
CARE AND MAINTENANCE ! WARNING FIRE OR EXPLOSION HAZARD 58PHA Failure to follow this warning could result in personal injury, death and/or property damage. Never store anything on, near, or in contact with the furnace, such as: 1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning tools. 2. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.
! CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in shortened heat exchanger life. Heating fan speed(s) MUST be adjusted to provide proper air temperature rise as specified on the rating plate. Recommended operation is at the midpoint of the rise range or slightly above. Refer to “SET TEMPERATURE RISE” under START--UP, ADJUSTMENT, and SAFETY CHECK. NOTE: Refer to Table 11 for motor speed lead relocation if leads were not identified before disconnection. 17.
58PHA them thoroughly. A heavy build--up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size or damaged manifold orifice( s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem. If it becomes necessary to clean the heat exchangers because of dust or corrosion, proceed as follows: 1. Turn OFF gas and electrical power to furnace. 2.
A91252 Fig. 58 -- Cleaning Heat Exchanger Cell 15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field--supplied, corrosion--resistant, sheet metal screws located 180_ apart. 16. Replace blower access door only, if it was removed. 17. Set thermostat above room temperature and check furnace for proper operation. 18. Verify blower airflow and speed changes between heating and cooling. 19. Check for gas leaks. 20. Replace outer access door.
58PHA 2. Cooling Mode The thermostat “calls for cooling.” a. Single--Speed Cooling (See Fig. 25 -- 32 for thermostat connections) The thermostat closes the R--to--G--and--Y circuits. The R--to-- Y circuit starts the outdoor unit, and the R--to--G--and--Y/Y2 circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC--1 is energized with 115 vac when the blower motor BLWM is operating. When the thermostat is satisfied, the R--to--G--and--Y circuits are opened.
turn on the blower motor BLWM at HEAT speed, and begin a heating cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HEAT speed. When theWinput signal disappears, the furnace control begins a normal inducer post--purge period and the blower switches to COOL speed after a 3 second delay.
58PHA A08176 Fig.
Fig. 60 -- Troubleshooting Guide A02106A 53 Go to section below for the status code that was flashed. Determine status code.
A05032 Copyright 2008 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 11/08 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 54 Catalog No: 58PHA ---03SI Replaces: 58PHA--02SI 24 SECONDARY VOLTAGE FUSE IS OPEN Check for: - Short circuit in secondary voltage (24V) wiring including thermostat leads. Disconnect thermostat leads to isolate short circuit.