Page 1: Table Of Contents
820SA/821SA VARIABLE- -SPEED ECM, INDUCED- -COMBUSTION, SINGLE- -STAGE, 4- -WAY MULTIPOISE NON- -CONDENSING GAS FURNACE Installation, Start- -up, Operating and Service and Maintenance Instructions Series A SAFETY CONSIDERATIONS ......
Page 2 A190045 ACCESSORY FILTER TOP AND VENT FURNACE SIZE MEDIA CABINET OUTLET BOTTOM FLUE BOTTOM CONNECTION SHIP WT. CABINET COLLAR SIZE WIDTH WIDTH INLET WIDTH LB (KG) SIZE 17--- 1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 120 (54) 16 (406) 48045V17 48070V17...
Page 3: Safety Considerations
SAFETY CONSIDERATIONS to identify hazards which may result in minor personal injury or product and property damage. NOTE is used to highlight WARNING suggestions which will result in enhanced installation, reliability, or operation. 1. Use only with type of gas approved for this furnace. Refer FIRE, EXPLOSION, ELECTRICAL SHOCK, AND to the furnace rating plate.
Page 4: Electrostatic Discharge (Esd) Precautions Procedure
ELECTROSTATIC DISCHARGE (ESD) person’s hand during grounding will be satisfactorily dis- charged. PRECAUTIONS PROCEDURE 3. After touching the chassis, you may proceed to service the CAUTION control or connecting wires as long as you do nothing to recharge your body with static electricity (for example; DO NOT move or shuffle your feet, do not touch un- FURNACE RELIABILITY HAZARD grounded objects, etc.).
Page 5: Introduction
INTRODUCTION CODES AND STANDARDS Follow all national and local codes and standards in addition This 4- -way multipoise Category I fan- -assisted furnace is CSA (formerly A.G.A. and C.G.A.) design- -certified. A Category I to these instructions. The installation must comply with fan- -assisted furnace is an appliance equipped with an integral regulations of the serving gas supplier, local building, heating, mechanical means to either draw or force products of combustion...
Page 6: Location
LOCATION All fuel- -burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative GENERAL pressure in the equipment room or space. A positive seal must be This multipoise furnace is shipped in packaged configuration. made between the furnace cabinet and the return- -air duct to Some assembly and modifications are required when used in any prevent pulling air from the burner area and from draft safeguard...
Page 7: Air For Combustion And Ventilation
CAUTION CAUTION PERSONAL INJURY AND/OR PROPERTY FURNACE CORROSION HAZARD DAMAGE HAZARD Failure to follow this caution may result in furnace damage. Improper use or installation of this furnace may result in Air for combustion must not be contaminated by halogen premature furnace component failure.
Page 8: Outdoor Combustion Air Method
outdoors or spaces (crawl or attic) that freely communicate with Spaces having at least 50 cubic feet per 1,000 Btuh the outdoors. may use the INDOOR COMBUSTION AIR, STAN- Indoor Combustion AirE NFPA & AGA DARD or KNOWN AIR INFILTRATION Standard and Known- -Air- -Infiltration Rate Methods METHOD.
Page 9: Combination Of Indoor And Outdoor Air
dimension of air openings shall be at least 3 in. (80 b. Doors and openable windows are weatherstripped and mm). (See Fig. 8.) c. Other openings are caulked or sealed. These include c. Combining space on different floor levels. The vol- joints around window and door frames, between sole umes of spaces on different floor levels shall be con- plates and floors, between wall- -ceiling joints, between...
Page 10: Installation
INSTALLATION NOTE: Bottom closure must be used when leveling legs are used. It may be necessary to remove and reinstall bottom closure UPFLOW INSTALLATION panel to install leveling legs. To remove bottom closure panel, see Bottom Return Air Inlet Item 1 in Bottom Return Air Inlet section in Step 1 above. These furnaces are shipped with bottom closure panel installed in To install leveling legs: bottom return- -air opening.
Page 11: Suspended Furnace Support
can be hung from floor joists, rafters or trusses or installed on a 2. Rotate bottom filler panel downward to release holding non- -combustible platform, blocks, bricks or pad. tabs. Suspended Furnace Support 3. Remove bottom closure panel. 4. Reinstall bottom filler panel and screws. The furnace may be supported under each end with threaded rod, angle iron or metal plumber’s strap as shown.
Page 12: Filter Arrangement
Table 3 – Opening Dimensions - - In. (mm) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Upflow Applications on Combustible or Noncombustible 12- -11/16 21- -5/8 13- -5/16 22- -1/4 Flooring (subbase not required) (322) (549) (338) (565) Downflow Applications on Noncombustible Flooring 12- -9/16 13- -3/16 19- -5/8...
Page 13 The supply- -air duct must be connected to ONLY the furnace supply- -air duct must be connected to ONLY the furnace supply supply- -outlet- -air duct flanges or air conditioning coil casing outlet or air conditioning coil casing (when used). When installed (when used).
Page 14 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).
Page 15 A190270 Fig. 18 - - Upflow Return Air Configurations and Restrictions A190271 Fig. 19 - - Downflow Return Air Configurations and Restrictions A02162 Fig. 20 - - Horizontal Return Air Configurations and Restrictions...
Page 16 Table 4 – Air Delivery - - CFM (With Filter)* COOLING4 AND HEATING AIR DELIVERY - - CFM (Bottom Return5 With Filter) (SW1- - 5 and SW2- - 2 set to OFF, except as indicated. See Notes 1 and 2.) Unit Size: 48045V17 Clg/CF Switch settings External Static Pressure (ESP)
Page 17 Table 4 - - Air Delivery - - CFM (With Filter)* (CONTINUED) COOLING4 AND HEATING AIR DELIVERY - - CFM (Bottom Return5 With Filter) (SW1- - 5 and SW2- - 2 set to OFF, except as indicated. See Notes 1 and 2.) Unit Size: Clg/CF Switch settings External Static Pressure (ESP)
Page 18 Table 4 - - Air Delivery - - CFM (With Filter)* (CONTINUED) COOLING4 AND HEATING AIR DELIVERY - - CFM (Bottom Return5 With Filter) (SW1- - 5 and SW2- - 2 set to OFF, except as indicated. See Notes 1 and 2.) Unit Size: Clg/CF Switch settings External Static Pressure (ESP)
Page 19: Gas Piping
NOTES: Table 4 - - Air Delivery 1. Nominal 350 CFM/ton cooling airflow is delivered with SW1-5 and SW2-2 set to OFF. Set both SW1-5 and SW2-2 to ON for +7% airflow (nominal 370 CFM/ton). Set SW1-5 to ON and SW2-2 to OFF for +15% airflow (nominal 400 CFM/ton). Set SW2-2 to ON and SW1-5 to OFF for -7% airflow (nominal 325 CFM/ton).
Page 20: Electrical Connection
Table 5 – Maximum Capacity of Pipe If pressure exceeds 0.5 psig (14- -In. W.C.), gas supply pipe must be disconnected from furnace and capped before and during NOMINAL LENGTH OF PIPE --- FT (M) INTERNAL supply pipe pressure test. If test pressure is equal to or less than IRON PIPE DIA.
Page 21 CAUTION WARNING ELECTRICAL SHOCK HAZARD FURNACE MAY NOT OPERATE HAZARD Failure to follow this warning could result in personal Failure to follow this caution may result in intermittent injury or death. furnace operation. Blower access panel door switch opens 115- -v power to Furnace control must be grounded for proper operation or control.
Page 22 J- -Box Relocation 5. Pull furnace power wires out of 1/2- -in. (12 mm) diameter hole in J- -Box. Do not loosen wires from strain- -relief NOTE: If factory location of J- -Box is acceptable, go to next wire- -tie on outside of J- -Box. section (ELECTRICAL CONNECTION to J- -Box).
Page 23: Accessories
BX Cable Installation in Furnace J- -Box replacement is required, use ONLY a 3- -amp. fuse of identical size. 1. Remove cover from J- -Box. ACCESSORIES 2. Route BX cable into 7/8- -in. (22 mm) diameter hole in J- -Box. 1.
Page 24 A190207 Fig. 26 - - Variable Speed ECM Blower Motor...
Page 25: Venting
A12223 Fig. 27 - - Thermostat Wiring Diagrams NOTES FOR THERMOSTAT WIRING DIAGRAMS 1. Heat pump MUST have a high pressure switch for HYBRID HEATr dual fuel applications. 2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure. 3.
Page 26 Vent system or vent connectors may need to be resized. Vent WARNING systems or vent connectors must be sized to approach minimum size as determined using appropriate table found in the current edition of NFGC. CARBON MONOXIDE POISONING HAZARD General Venting Requirements Failure to follow the steps outlined below for each Follow all safety codes for proper vent sizing and installation appliance connected to the venting system being placed into...
Page 27 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 Crown Rebuild condition: crown. Missing mortar or brick? Is chimney property lined with clay tile liner? Repair Reline...
Page 28 Masonry Chimney Requirement Relining with a listed metal liner or Type- -B vent is considered to be a vent- -in- -a- -chase. NOTE: These furnaces are CSA design- -certified for use in If a metal liner or Type- -B vent is used to line a chimney, no other exterior tile- -lined masonry chimneys with a factory accessory appliance shall be vented into the annular space between the Chimney Adapter Kit.
Page 29 Table 8 – Minimum Allowable Input Rating of The vent connector can exit the furnace through one of five locations on the casing. Space- -Heating Appliance in Thousands of Btuh per Hour CAUTION INTERNAL AREA OF CHIMNEY VENT HEIGHT SQ. IN. (SQ. MM) FT.
Page 30 SEE NOTES: 1,2,4,5,7,8,9 SEE NOTES: 1,2,3,4,7,8,9 on the page following on the pages following these figures these figures A03211 A03209 Fig. 32 - - Downflow Application - - Vent Elbow Up Fig. 30 - - Upflow Application - - Vent Elbow Right SEE NOTES: 1,2,4,5,6,7,8,9,10 SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures...
Page 31 SEE NOTES: 1,2,4,7,8,9 on the page following these figures A03218 Fig. 37 - - Horizontal Right Application - - Vent Elbow Right SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures. A03212 Fig. 34 - - Downflow Application - - Vent Elbow Up then Right SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A03215...
Page 32 SEE NOTES: 1,2,4,5,7,8,9 SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A02068 Fig. 41 - - Horizontal Right Application- -Vent Elbow Left A03219 Fig. 40 - - Horizontal Right Application - - Vent Elbow Left then Up VENTING NOTES FOR FIG. 29 - - 41 1.
Page 33: Start- -Up, Adjustment, And Safety Check
START- - UP, ADJUSTMENT, AND SAFETY CHECK General WARNING FIRE HAZARD Failure to follow this warning could result in personal injury, death or property damage. This furnace is equipped with manual reset limit switches in the gas control area. The switches open and shut off power to BURNER ORIFICE the gas valve, if a flame rollout or overheating condition...
Page 34: Service Label
Component test feature will not operate if any thermostat signal is WARNING present at the control. Refer to service label attached to furnace or See Fig. 45. ELECTRICAL SHOCK HAZARD Component test sequence is as follows: Failure to follow this warning could result in personal a.
Page 35: Adjustments
A190272 Fig. 46 - - Furnace Setup Switch Description 1. Default A/C when A/C switches are in OFF position. 2. Default Low stage A/C airflow when CF switches are in OFF position. A190273 Fig. 47 - - Airflow Selection (based on 350 CFM/TON) for A/C (SW2- -6, 7, 8) and *CF (SW2- -3, 4, 5) Adjustments rating plate.
Page 36 a. Obtain average yearly gas heat value (at installed alti- g. Remove regulator seal cap and turn regulator adjusting tude) from local gas supplier. screw counterclockwise (out) to decrease input rate of clockwise (in) to increase input rate. b. Obtain average yearly gas specific gravity from local gas supplier.
Page 37 (3.) Return and supply ducts for excessive restrictions 7. Adjust blower off delay The blower off delay has 4 ad- causing static pressures greater than 0.50- -In. W.C. justable settings from 90 sec to 180 sec. The blower off delay jumpers are located on the furnace control board. (4.) Ensure Comfort/Efficiency SW 1- -4 on furnace con- (See Fig.
Page 38 Table 11 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate A10180...
Page 39 Table 11 - - Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (CONT) A10180A...
Page 40: Check Safety Controls
Check Safety Controls 2. Verify that blower OFF- -DELAY time is selected as desired. The flame sensor, gas valve, and pressure switch were all checked 3. Verify that blower and burner access doors are properly in the Start- -up procedure section as part of normal operation. installed.
Page 41 b. Remove outer access door. CAUTION c. Look into blower access door sight glass for current LED status. ELECTRICAL OPERATION HAZARD d. Remove blower access door. Failure to follow this caution may result in improper NOTE: The Status Codes cannot be retrieved by disconnecting furnace operation or failure of furnace.
Page 42: Wiring Diagram
A190274 Fig. 48 - - Wiring Diagram CARE AND MAINTENANCE For continuing high performance and to minimize possible furnace failure, periodic maintenance must be performed on this WARNING furnace. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract. FIRE OR EXPLOSION HAZARD WARNING Failure to follow this warning could result in personal...
Page 43 7. Replace filter cabinet door. WARNING 8. Turn on electrical supply to furnace. Blower Motor and Wheel CARBON MONOXIDE POISONING AND FIRE WARNING HAZARD Failure to follow this warning could result in personal ELECTRICAL SHOCK HAZARD injury, death and/or property damage. Failure to follow this warning could result in personal Never operate furnace without a filter or with filter access door removed.
Page 44 d. Remove bolts holding motor to blower housing and combustion air, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken slide motor out of wheel (40+/- -10 in.- -lb. when re- to correct the problem. assembling).
Page 45: Sequence Of Operation
a. Remove metal screw fitting from wire brush to allow f. Hot surface igniter. insertion into cable. g. Flame- -sensing electrode. b. Insert the twisted wire end of brush into end of spring h. Flame rollout switches. cable, and crimp tight with crimping tool or crimp by 14.
Page 46 d. Flame- -Proving- - When the burner flame is proved at minutes) which is permitted before switching to high- -cooling. If the power is interrupted, the stored history is erased and the the flame- -proving sensor electrode FSE, the furnace furnace control CPU will select low- -cooling for up to 20 minutes control CPU begins the blower- -ON delay period and and then energize the air conditioning relay ACR to energize the...
Page 47: Troubleshooting
plies to operation with a Thermidistat. The exceptions are 5. Heat pump listed below: See Fig. 27 for thermostat connections. When installed with a heat pump, the furnace control auto- a. Low cooling- -When the R- -to- -G- -and- -Y1 circuit is matically changes the timing sequence to avoid long blow- closed and there is a demand for dehumidification, the er off times during demand defrost cycles.
Page 48 A190024 Fig. 52 - - Troubleshooting Guide...
Page 49 A05032 Fig. 52 - - Troubleshooting Guide (Continued)
Page 50: Parts Replacement Information Guide
PARTS REPLACEMENT INFORMATION GUIDE CASING GROUP GAS CONTROL GROUP Outer door Manifold Blower door Burner assembly Top filler plate Orifice Bottom filler plate Flame sensor Bottom enclosure Hot surface igniter Gas valve ELECTRICAL GROUP Manual reset limit switches Control bracket Burner support assembly Junction box HEAT EXCHANGER GROUP...

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