Carrier start-up and Installation And Operating Instructions Manual Download

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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

. . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CODES AND STANDARDS

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Safety

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General Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion and Ventilation Air

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Duct Systems

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Acoustical Lining and Fibrous Glass Duct

. . . . . . . . . . . . .

Gas Piping and Gas Pipe Pressure Testing

. . . . . . . . . . . . .

Electrical Connections

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Venting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTROSTATIC DISCHARGE PRECAUTIONS

PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upflow Installation

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Downflow Installation

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Horizontal Installation

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Filter Arrangement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Ducts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Piping

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115--V Wiring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

START--UP, ADJUSTMENT, AND SAFETY CHECK

. . . . .

General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start--up Procedures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Safety Controls

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Checklist

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SERVICE AND MAINTENANCE PROCEDURES

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Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Care and Maintenance

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Sequence of Operation

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Wiring Diagrams

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

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ama

REGISTERED

ISO 9001:2000

CERTIFIED

NOTE

: Read the entire instruction manual before starting the

installation.
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1--2006

, with permission of National Fire Protection

Association, Quincy, MA 02269 and American Gas Association,
Washington DC 20001. This reprinted material is not the

complete and official position of the NFPA or ANSI on the

referenced subject, which is represented only by the standard in
its entirety.

Summary of Contents for start-up and

Page 1: ... 13 Filter Arrangement 14 Air Ducts 14 Gas Piping 17 115 V Wiring 22 START UP ADJUSTMENT AND SAFETY CHECK 36 General 36 Start up Procedures 36 Adjustments 36 Check Safety Controls 39 Checklist 40 SERVICE AND MAINTENANCE PROCEDURES 43 Introduction 43 Care and Maintenance 46 Sequence of Operation 49 Wiring Diagrams 51 Troubleshooting 51 ama REGISTERED ISO 9001 2000 CERTIFIED NOTE Read the entire ins...

Page 2: ...2 11 16 322 9 5 16 237 4 102 114 52 16 406 070 16 048070 17 1 2 445 15 7 8 403 16 406 11 9 16 294 4 102 136 62 16 406 090 16 048090 21 533 19 3 8 492 19 1 2 495 13 5 16 338 4 102 150 68 20 508 110 20 060110 21 533 19 3 8 492 19 1 2 495 13 5 16 338 4 102 162 73 20 508 135 20 060135 24 1 2 622 22 7 8 581 23 584 15 1 16 383 4 102 173 78 24 610 5 in or 6 in 127 or 152 mm vent connector may be required...

Page 3: ...e space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace See Air Ducts section 8 A gas fired furnace for installation in a residential garage must be installed as specified in the warning box in the Location section 9 The furnace may be used for construction heat provided that the furnace ins...

Page 4: ...f local codes the installation must comply with the national codes listed below and all authorities having jurisdiction In the United States and Canada follow all codes and standards for the following Safety S USA National Fuel Gas Code NFGC NFPA 54 2006 ANSI Z223 1 2006 and the Installation Stan dards Warm Air Heating and Air Conditioning Sys tems ANSI NFPA 90B S CANADA CSA B149 1 05 National Sta...

Page 5: ... Z223 1 2006 Chapters 12 and 13 S CANADA CAN CSA B149 1 05 Part 8 and Appendix C ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause premature furnace component failure Electrostatic discharge can affect electronic components Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installati...

Page 6: ...leaning Always comply with minimum fire protection clearances shown on the furnace clearance to combustible label The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures S Commercial buildings S Buildings with indoor pools S Laundry rooms S Hobby or craft rooms and S Chemical storage areas CARBON MONOXIDE POISONING HAZARD Failure to follow this...

Page 7: ... It also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is maintained between 55_F 13_C and 80_F 27_C with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions Th...

Page 8: ...h means to prevent operation of either unit unless the damper is in the full heat or full cool position AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion ventilation and dilution air must be provided in accordance with S U S installations Section 9 3 of the NFGC NFPA54 ANSI Z223 1 2006 Air for Combustion and Ventilation and applicable provisions of the local building codes WARN...

Page 9: ...tilation and dilution of flue gases The furnace combustion air supply must be provided in accordance with this instruction manual WARNING The Standard Method 1 The space has no less volume than 50 cubic feet per 1 000 Btuh of the maximum input ratings for all gas appliances installed in the space and 2 The air infiltration rate is not known to be less than 0 40 air changes per hour ACH The Known A...

Page 10: ...sly and 3 Outdoor openings shall be sized as follows a Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method below 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 multipliedbyredu...

Page 11: ...ecommended that the perforated supply air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory supplied cased coil or coil box To remove the supply air duct flange use wide duct pliers or hand seamers to bend flange back and forth until it breaks off Be careful of sharp edges See Fig 14 Bottom Return Air Inlet These furnaces are shipped with botto...

Page 12: ...12 APPROVED COIL ASSEMBLY OR COIL BOX FURNACE SHEET METAL PLENUM FLOOR OPENING COMBUSTIBLE FLOORING A08556 Fig 13 Furnace Plenum and Coil Assembly or Coil Box Installed on a Combustible Floor 58PHA ...

Page 13: ...ty damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace WARNING The furnace can be installed horizontally in an attic or crawl space on either the left hand LH or right hand RH side The furnace can be hung from floor joists rafters or truss...

Page 14: ...d and sealed to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in 25 mm clearance from combustible materials to supply air ductwork for a distance of 36 in 914 mm horizontally from the furnace See NFPA 90B or local code for further requirements Ductwork Acoustical Treatment NOTE Metal duct systems that do not have a 90 degree elbow and 10 ft 3 ...

Page 15: ... THREADED ROD 4 REQ SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 8 x3 4 19mm SCREWS TYPICAL FOR 2 SUPPORTS 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 8 203mm MIN FOR DOOR REMOVAL OUTER DOOR ASSEMBLY A05027 Fig 15 Horizontal Unit Suspension 58PHA ...

Page 16: ...Suspension with Straps 30 IN 762mm MIN WORK AREA 6 MIN TYPE B VENT 17 3 4 22 SHEET METAL SEDIMENT TRAP EQUIPMENT MANUAL SHUT OFF GAS VALVE LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING GAS ENTRY 17 3 4 451mm OVERALL 4 3 4 121mm UNDER DOOR 1 25mm UNDER FURNACE EXTEND OUT 12 305mm FROM FACE OF D...

Page 17: ...extend a minimum of 2 in 51 mm outside the furnace WARNING Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S the CAN CSA B149 1 05 in Canada Installations must be made in accordance with all authorities having jurisdiction If possible the gas supply line should be a separate line running directly from meter to furnace NOTE In the s...

Page 18: ...ded 3 4 in 19 mm washable filter media such as contained in factory authorized accessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available external static pressure Indicates unstable operating conditions Table 6 Maximum Capacity of Pipe NOMINAL IRON PIPE INTERNAL DIAMETER LENGTH OF PIPE FT M SIZE IN mm In mm 10 20 30 40 50 1 2 13 0 622 16 175...

Page 19: ...19 A02075 Fig 18 Upflow Return Air Configurations and Restrictions A02163 Fig 19 Downflow Return Air Configurations and Restrictions 58PHA ...

Page 20: ...20 A02162 Fig 20 Horizontal Return Air Configurations and Restrictions 2 51mm Street Elbow A08551 Fig 21 Burner and Manifold 58PHA ...

Page 21: ...ent ELECTRICAL CONNECTIONS ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access panel door switch opens 115 v power to control No component operation can occur Do not bypass or close switch with panel removed WARNING See Fig 25 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical connections for ...

Page 22: ...Step 1 5 Route J Box wires within furnace away from sharp edges rotating parts and hot surfaces ELECTRICAL CONNECTION TO J BOX Field Supplied Electrical Box on Furnace J Box Bracket See Fig 23 1 Remove cover from furnace J Box 2 Attach electrical box to furnace J Box bracket with at least two field supplied screws through holes in electrical box into holes in bracket Use blunt nose screws that wil...

Page 23: ...t is required use ONLY a 3 amp fuse of identical size ACCESSORIES 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using 1 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC 1 and EAC 2 The terminals are rated for 115 VAC 1 0 amps maximum and are energized during blower motor operation See Fig 24 2 Humi...

Page 24: ...AUXILIARY J BOX 24 V TERMINAL BLOCK THREE WIRE HEATING ONLY FIVE WIRE NOTE 1 NOTE 2 FIELD SUPPLIED DISCONNECT CONDENSING UNIT TWO WIRE FURNACE C O N T R O L R G COM W C R G Y GND GND FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING 208 230 OR 460 V THREE PHASE 208 230 V SINGLE PHASE BLOWER DOOR SWITCH WHT BLK WHT BLK NOTES Connect Y terminal in furnace as s...

Page 25: ...nce with ANSI Z21 47 2006 CSA 2 3 2006 and operate with a non positive vent static pressure to minimize the potential for vent gas leakage Category I furnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in the venting system These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliance...

Page 26: ...owing these figures A04216 Fig 27 Single Stage Furnace with Two Speed Air Condi tioner See notes 1 2 4 6 7 9 10 and 12 on the page following these figures A04217 Fig 28 Single Stage Furnace with Single Speed Heat Pump Dual Fuel See notes 1 2 3 4 6 8 9 10 and 12 on the page following these figures A04218 Fig 29 Single Stage Furnace with Two Speed heat Pump Dual Fuel 58PHA ...

Page 27: ... installations This is factory default 5 Dip switch No 1 on Thermidistat should be set in ON position for heat pump installations 6 Dip switch No 2 on Thermidistat should be set in OFF position for single speed compressor operation This is factory default 7 Dip switch No 2 on Thermidistat should be set in ON position for two speed compressor operation 8 Configuration Option No 10 Dual Fuel Selecti...

Page 28: ...erior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors NFPA AGA Table 8 Combined Appliance Maximum Input Rating in Thousands of BTUH per Hour VENT HEIGHT FT M INTERNAL AREA OF CHIMNEY IN2 MM2 12 7741 19 12258 28 18064 38 24516 6 1 8 74 119 178 257 8 2 4 80 130 193 279 10 3 0 84 138 207 299 15 4 5 NR 152 233 334 20 6 0 NR NR 250 368 30 9 1 NR NR NR 404 Table 9 Minimum A...

Page 29: ...n cleanout Mortar tile metal vent fuel oil residue Is liner and top seal in good condition Is chimney property lined with clay tile liner Crown condition Missing mortar or brick Rebuild crown Yes Yes No No No Reline Yes Repair Yes Yes Yes No No Remove mortar and tile debris Remove metal vent or liner No No No No Yes Yes Suitable Suitable Not Suitable Line chimney with property sized listed flexibl...

Page 30: ...sing If flue extension is used fasten the flue extension to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180_ apart Fasten the vent connector to the flue extension with at least two field supplied corrosion resistant sheet metal screws located 180_ apart 2 Vent the furnace with the appropriate connector as shown in Fig 34 46 CUT HAZARD Failure to f...

Page 31: ...7 8 9 on the pages following these figures A03209 Fig 35 Upflow Application Vent Elbow Right SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures A03210 Fig 36 Downflow Application Vent Elbow Up then Left SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Fig 37 Downflow Application Vent Elbow Up 58PHA ...

Page 32: ...8 9 on the page following these figures A03212 Fig 39 Downflow Application Vent Elbow Up then Right SEE NOTES 1 2 4 7 8 9 on the page following these figures A03213 Fig 40 Horizontal Left Application Vent Elbow Left SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03214 Fig 41 Horizontal Left Application Vent Elbow Right then Up 58PHA ...

Page 33: ...15 Fig 43 Horizontal Left Application Vent Elbow Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03219 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 A03216 Fig 45 Horizontal Left Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 A02068 Fig 46 Horizontal Right Application Vent Elbow Left 58PHA ...

Page 34: ...a min vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external to the furnace 6 Accessory Downflow Vent Guard Kit KGAVG0101DFG required in downflow installations with lower vent configuration 7 Chimney Adapter Kit may be required for exterior masonry chimney applications Refer to Chimney Adapter Kit KGACA02014FC or KGACA02015FC for sizing and compl...

Page 35: ...35 A04128 Fig 48 Rounded End of Knockout A04129 Fig 49 Knockout Pulled Loose A04130 Fig 50 Hammer and Screwdriver Used for Knockout A04131 Fig 51 Remove Knockout with Hammer 58PHA ...

Page 36: ...rned on See Fig 24 ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death 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 WARNING NOTE The furnace control allows all components except the gas valve to be run for short ...

Page 37: ...right then up Fig 41 132 000 5 127 7 2 Horizontal Left Vent elbow right Fig 42 132 000 5 127 7 2 NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 4 in 102 mm inside casing or vent guard Including 4 in 102 mm vent section s Table 10 Altitude Derate Multiplier for U S A ALTITUDE FT M PERCENT OF DERATE DERATE MULTIPLIER FACTOR 0 2000 0 610 0 1 00 2001 3000 ...

Page 38: ...rmometer readings stabilize subtract return air temperaturefromsupply air temperatureto determineair temperature rise NOTE Blower access door must be installed for proper temperature rise measurement NOTE If the temperature rise is outside this range first check 1 Gas input for heating operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing static...

Page 39: ...tion during this test cause must be determined and corrected a Run furnace for at least 5 minutes b Gradually block off return air with a piece of cardboard or sheet metal until the limit trips c Unblock return air to permit normal circulation d Burners will re light when furnace cools down 2 Check draft safeguard switch The purpose of this control is to cause the safe shutdown of the furnace duri...

Page 40: ...48 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 3...

Page 41: ...41 Table 13 Orifice Size and Manifold Pressure In wc for Gas Input Rate A08220 58PHA ...

Page 42: ...42 Table 13 Orifice Size and Manifold Pressure In wc for Gas Input Rate CONT A08220A 58PHA ...

Page 43: ...he furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 24 Any shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse The control LED w...

Page 44: ...44 Table 14 Orifice Size And Manifold Pressure In wc For Gas Input Rate A08221 58PHA ...

Page 45: ...or before initiating status code recall After status code recall is completed component test will occur 327596 101 REV B 31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open longer than five minutes inducer shuts off for 15 minutes before retry Check for Excessive wind Proper vent sizing Defective inducer motor Low inducer voltage 115VAC Defective pressure switch Inadequate combustion air supply D...

Page 46: ... service agency 5 Inspect the vent pipe vent system before each heating season for rust corrosion water leakage sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified service agency 6 Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner Perform any service or maintenance to the accessories as recommended in the accessory instr...

Page 47: ...wer housing and set screw contacts the flat portion of the motor shaft Loosen set screw on blower wheel and reposition if necessary 14 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 15 Reinstall blower assembly in furnace 16 Reinstall control box assembly in furnace UNIT DAMAGE HAZARD Failure to follow this caution may result in shortened heat exchanger life Hea...

Page 48: ... rifle cleaning brush 36 in 914 mm long 1 4 6 mm diameter steel spring cable a variable speed reversible electric drill and vacuum cleaner clean cells as follows a Remove metal screw fitting from wire brush to allow insertion into cable b Insert the twisted wire end of brush into end of spring cable and crimp tight with crimping tool or crimp by striking with ball peen hammer TIGHTNESS IS VERY IMP...

Page 49: ...former TRAN inducer motor IDM blower motor BLWM hot surface igniter HSI and gas valve GV 1 Heating See Fig 25 for thermostat connections The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check verifies the pressure switch contacts PRS are open and starts the inducer motor IDM a Inducer Prepurge Period As the inducer motor IDM comesuptospeed thepressu...

Page 50: ...R to G and Y Y2 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blower speed from COOL to HEAT for a maximum of 10 minutes before reverting back to COOL speed If there is still a demand for dehumidification after 20 minutes the furnace control CPU will drop the blower speed back to HEAT speed This alternating 10 minute cycle will continue as...

Page 51: ...nd Y Y2 and G R to W and Y1 and Y Y2 or R to W and Y1 and Y Y2 and G circuits are energized the furnace control CPU will switch to or 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...

Page 52: ...52 A08176 Fig 59 Wiring Diagram 58PHA ...

Page 53: ...t sequence The inducer will start and run for the entire component test The HSI blower motor FAN speed AMBER LED boards only HEAT speed and COOL speed will run for 10 15 seconds each Gas valve and humidifier will not be turned on Was there a previous status code other than 11 Is door switch closed Is there 115V going to switch Replace door switch Replace transformer Does the control respond to W Y...

Page 54: ...t sensed during the trial for ignition period the control will repeat the ignition sequence 3 more times before lockout 14 occurs If flame signal is lost during the blower on delay period blower will come on for the selected blower off delay Check the following items first before proceeding to the next step Gas valve turned off Manual shut off valve Green Yellow wire MUST be connected to furnace s...

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Carrier start-up and, Installation And Operating Instructions Manual

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