Trane UX2B060A9362A, UX2D120A9602A, DX2B060A9362A, DX2B080A9422A, DX2C100A9482A Installer's Manual

IIIIII IIIIIIIIIIIIII IIIIIIII

1 8- CD1 9 D8- 1 5

Upflow / Horizontal & Downflow / Horizontal,

Gas-Fired, Direct Vent, 2-Stage Condensing

Furnaces with Variable Speed Inducer

*UX2B060A9362A *UX2B080A9422A *UX2C100A9482A
*UX2D120A9602A *DX2B060A9362A *DX2B080A9422A
*DX2C100A9482A *DX2D120A9602A

*__Firstlettermay be"A" or "T"

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

IMPORTANT -- This Document is customer property and is to remain with this unit.

Please return to service information pack upon completion of work.

*UX2 *DX2

DOWNFLOW

A!R

A/R

FLOW

UPFLOW

AIR

FLOW

UPFLOW/HORIZONTAL LEFT

DOWNFLOW/HORIZONTAL RIGHT

/

\

/ _

FLOW

FLOW

\

i °

A341624P03

Installer's Guide

SAFETY SECTION

The following safety practices and precautions must be
followed during the installation, servicing, and operation of

this furnace.

1. Use only with the type of gas approved for this furnace.
Refer to the furnace rating plate.

2. Install this furnace only in a location and position as
specified in "Location and Clearances" (page 3), of these

instructions.

3. Provide adequate combustion and ventilation air to the
furnace space as specified in "Air for Combustion and

Ventilation" (pages 7-8), of these instructions.

4. Combustion products must be discharged outdoors.
Connect this furnace to an approved vent system only, as

specified in the "Venting" section (pages 13-23), of these
instructions.

5. Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically
for the detection of leaks to check all connections, as

specified in "Gas Piping" (page 31), of these instructions.

6. Always install the furnace to operate within the furnace's
intended temperature-rise range with a duct system

which has an external static pressure within the allow-
able range, as specified on the unit rating plate. Airflow

with temperature rise for cfm versus static is shown in
the Service Facts accompanying this furnace.

7. When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space

containing the furnace, the return air shall also be
handled by a duct(s) sealed to the furnace casing and

terminating outside the space containing the furnace.

8. A gas-fired furnace for installation in a residential
garage must be installed as specified in "Location and

Clearances" section (page 3), of these instructions.

9. The furnace may be used for temporary heating of
buildings or structures under construction only when the

following conditions have been met:
a. The furnace venting system must be complete and

installed per manufacturer's instructions.

b. The furnace is controlled only by a room thermostat

(no field jumpers).

c. The furnace return air duct must be complete and

sealed to the furnace and clean air filters are in place.

d. The furnace input rate and temperature rise must be

verified to be within nameplate marking.

e. 100% of the furnace combustion air requirement must

come from outside the structure.

f. The furnace return air temperature range is between

55 and 80 degrees Fahrenheit.

g. Clean the furnace, duct work, and components upon

substantial completion of the construction process,
and verify furnace operating conditions including

ignition, input rate, temperature rise and venting,
according to the manufacturer's instructions.

10. This product must be gas piped by a Licensed Plumber or
Gas Fitter in the Commonwealth of Massachusetts.

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 the venting system.

2.

Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 or the CAN/CGA B149
Installation Codes and these instructions. Determine

that there is no blockage or restriction, leakage,

corrosion and other deficiencies which could cause an
unsafe condition.

3.

As far as practical, close all building doors and
windows and all doors between the space in which the
appliance(s) connected to the venting system are

located and other deficiencies which could cause an
unsafe condition.

4. Close fireplace dampers.

5.

Turn on clothes dryers and any appliance not

connected to the venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they are operating at maximum speed. Do not operate

a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.

7.

If improper venting is observed during any of the above

tests, the venting system must be corrected in

accordance with the National Fuel Gas Code,
ANSI Z221.1/NFPA 54 and/or CAN/CGA B149

Installation Codes.

8.

After it has been determined that each appliance
connected to the venting system properly vents where

tested as outlined above, return doors, windows,

exhaust fans, fireplace dampers and any other gas-fired
burning appliance to their previous conditions of use.

Safety signal words are used to designate a degree or level
of seriousness associated with a particular hazard. The

signal words for safety markings are DANGER, WARNING,
and CAUTION.

a. DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.
This signal word is limited to the most extreme situations.

b. WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

c. CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate

To prevent shortening its service life, the furnace should
not be used as a "Construction Heater" during the finishing

phases of construction until the requirements listed in item
9, a-g of the safety section of this publication have been

met. Condensate in the presence of chlorides and fluo-
rides from paint, varnish, stains, adhesives, cleaning

compounds, and cement create a corrosive condition which
may cause rapid deterioration of the heat exchanger.

© 2008 Trane All Rights Reserved 18-CD1 9D8-1 5

FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in

serious injury, death or property damage.

Improper servicing could result in dangerous operation,

serious injury, death, or property damage.

Installer's Guide

GENERAL

The manufacturer assumes no responsibility for equipment
installed in violation of any code or regulation.

It is recommended that Manual J of the Air Conditioning
Contractors Association (ACCA) or A.R.I. 230 be followed in
estimating heating requirements. When estimating heating
requirements for installation at Altitudes above 2000 ft.,
remember the gas input must be reduced (See GAS INPUT

ADJUSTMENT).

Material in this shipment has been inspected at the
factory and released to the transportation agency
without known damage. Inspect exterior of carton for
evidence of rough handling in shipment. Unpack
carefully after moving equipment to approximate
location. If damage to contents is found, report the
damage immediately to the delivering agency.

Codes and local utility requirements governing the installa-
tion of gas fired equipment, wiring, plumbing, and flue
connections must be adhered to. In the absence of local codes,

the installation must conform with latest edition of the
National Fuel Gas Code ANSI Z223.1 • National Installation

Code, CAN/CGA B149.1. The latest code may be obtained
from the American Gas Association Laboratories, 400 N.
Capitol St. NW, Washington D.C. 20001. 1-800-699-9277 or

www.aga.org
These furnaces have been classified as CATEGORY IV

furnaces in accordance with latest edition of ANSI Z21.47
standards ° CAN/CGA 2.3. Category IV furnaces operate

with positive vent static pressure and with a flue loss less
than 17 percent. These conditions require special venting
systems, which must be gas tight and water tight. These
Category IV Direct Vent furnaces are approved for installa-
tion in Manufactured/Mobile housing when used with

BAYMFGH001A.

LOCATION AND CLEARANCES

The location of the furnace is normally selected by the
architect, the builder, or the installer. However, before the
furnace is moved into place, be sure to consider the following
requirements:

1. Is the location selected as near the chimney or vent and
as centralized for heat distribution as practical?

2. Do all clearances between the furnace and enclosure
equal or exceed the minimums stated in Clearance Table
on the Outline Drawings.

3. Is there sufficient space for servicing the furnace and
other equipment? A minimum of 24 inches front accessi-

bility to the furnace must be provided. Any access door

or panel must permit removal of the largest component.

4. Are there at least 3 inches of clearance between the
furnace combustion air openings in the front panel and
any closed panel or door provided?

5. Are the ventilation and combustion air openings large
enough and will they remain unobstructed? If outside
air is used, are the openings set above the highest snow

accumulation level? (See the Air for Combustion and

Ventilation section.)

6. Allow sufficient height in supply plenum above the
furnace to provide for cooling coil installation, if the
cooling coil is not installed at the time of this furnace

installation.

7. A furnace shall be installed so electrical components are
protected from water.

8. If the furnace is installed in a residential garage, it
must be installed so that the burners, and the ignition

18-CD19D8-15 3

Contents

Installation Instructions

General
Location and Clearances

Outline Drawings
Upflow Installation

Downflow Installations
Air For Combustion and Ventilation

Duct Connections
Return Air Filters
General Venting
Venting Materials

Vent Tables
Horizontal Venting Through Wall

Venting Through the Roof
Venting Routed Through a Masonry Chimney

Downward Venting
Condensate Drain Instructions

Field Wiring Diagrams
Electrical Connections

Gas Piping
Combustion and Input Check
High Altitude Derate

Start-up and Adjustment

Preliminary Inspections
Lighting Instructions

Sequence of Operation
Control and Safety Switch Adjustments

Abnormal Conditions

IFC Error Flash Codes

Fault Code Recovery

source are located not less than 18 inches above the floor
and the furnace must be located or protected to avoid

physical damage from vehicles.

IMPORTANT:

The furnace must be installed level The only allowable variation

would be slightly to the left and/or forward in upflow installations
or slightly toward the front in horizontal installations. This is
necessary for proper condensate drainage.

Do not install the furnace in a corrosive or contaminated
atmosphere. Failure to follow this warning could result in

early equipment failure.

Do not install the furnace directly on carpeting, tile or other
combustible material other than wood flooring. For vertical
downflow application, subbase (BAYBASE205) must be
used between the furnace and combustible flooring. When

the downflow furnace is installed vertically with a cased

coil, a subbase is not required.

4_

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-,-- 5/8" 4- I/ilJ

OUTLET t°_

AIR /._

OUTSIDEAIR

7/8" HOLE_

ELECTRICALLY.... _ ,

SUPPLY ,_._ .... _1

1/78" x 7/8"_

SLOT KNOCKOUT

CONDENSATE DRAIN

(HORIZONTAL)

I-I/8" KNOCKOUT-

CONDENSATE DRAIN

I-5/16"--=-

,l-m..

01_0

23-3/4"

-i

DIM "D"

_1

3/4,,_-

3/4" --_

--,_ 28- I /2" -_,.

INLET I • I

AIR "

I_ 24- I/32" _-J L 3-7/32"

DIM "B"

_---r_2"FLUE CONNECT

SEE NOTES I & 2

"E"

"'--4-1/16"

*UX2 UPFLOW / HORIZONTAL OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

',1-3-15/16"

"--2-1/16"

-¢1-1/2" GAS

SUPPLY

"-2-1/8"

__T

I -7/8 22-

--__20-1/4"

5 "

18-

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;0-5/8"

/4" I

IZONTAL APPLICATION

IS SIDE ONLY)

I/2"_

40"

o

DIM "A" ---,'-

-,- I/2"

Model

DIM "A" DIM "B" DIM "C" DIM "D" DIM "E" DIM "F"

(See Note 1 & 2)

*UX2B060A9362A

17-1/2" 2-1/4" 16-1/4" 16" 7-1/2" 2"

*UX2B080A9422A

*UX2C100A9482A 21" 2-1/2" 19-3/4" 19-1/2" 9" 3"
*UX2D120A9602A 24-1/2" 2-15/16" 23-1/4" 23" 10" 3"

* Prefix May Be "A" or "T" Notes:

1. *UX2D120A9602A Requires 3" Diameter Vent Pipe.
*UX2C100A9482A Requires 2-1/2" or 3" Diameter Vent Pipe.

2. Diameter of Vent Pipe may be limited to 2-1/2" or 3" on some
models at different altitudes. Refer to the Vent Length Table for
proper application.

7/8" KNOCKOUT
ELECTRICAL
SUPPLY

(ALTERNATE)

-_1-1/2" KNOCKOUT
GAS SUPPLY

(ALTERNATE)

I/8" KNOCKOUT

DRAIN

(ALTERNATE)

MINIMUMCLEARANCETO

COMBUSTIBLE MATERIALS

SIDES O IN.
REAR 0 IN.
FRONT 3 IN,
TOP I IN.
FLUE 0 IN.

HORIZONTAL(FLUE
BSCHARGEON THE LEFTI

ALCOVE

SIDES

RIGHT O IN

LEFT O IN
REAR 6 IN
FRONT 18 IN
TOP I IN,
FLUE 0 IN,

CLOSET

SIDES

RIGHT I IN

LEFT I IN
REAR 3 IN
FRONT 3 IN
TOP I IN

FLUE 0 IN,

From Dwg. 21C341884 Rev. 1

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DIM "D"

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3/4

o_ a,,6,_.... j i 7 _,,4"

*DX2 DOWNFLOW / HORIZONTAL OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

From Dwg. 21C341885 Rev. 1

,; llOlR z.N '. t,,_l C,\I ON

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2-i ,'8 ........."-

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DIM "A" ,.-.-

23/i6"

Model

DIM "A" DIM "B" DIM "C" DIM "D"

(See Note 1)

*DX2BO60A9362A

17-1/2" 2-1/4" 16-1/4" 16"

*DX2BO80A9422A

*DX2C100A9482A 21" 2-1/2" 19-3/4" 19-1/2"
*DX2D120A9602A 24-1/2" 2-15/16" 23-1/4" 23"

Prefix May Be "A" or "T" Notes:

1. Diameter of Vent Pipe may be limited
to 2-1/2" or 3" on some models at
different altitudes. Refer to the Vent
Length Table for proper application.

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MINIMUM CLEARANCE TO
COMBUSTIBLE MATERIALS

DOWNFLOW

SIDES 0
REAR 0
I ROi' I 3 ',
O[ N
i I b E 0 N

HORIZONTAL (FLUE
DISCHARGE ON THE LEFT)

ALCOVE

SIDES

RI iT 0 \

REAR 6 _N
iRON[ 18 N

-OR N
FlU 0 \

CLOSET

SIDES

[EFT ;N
REAR _N
FRONT _N
lOP iN
FI U_ i N

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Installer's Guide

UPFLOW INSTALLATION

Standoffs and screws (See Figure 1) are included with the
cased coils for attachment to the furnace. There are clear-

ance alignment holes near the bottom of the coil wrapper.
Drill screws are used to engage the furnace top flanges. The
standoff is inserted into the cabinet alignment hole. The drill
screws are inserted through the standoffs then screwed into
the furnace flange. The coil is always placed downstream of

the furnace airflow.

STANDOFFS (4) DRILL SCREWS (4)

J

FOR VERTICAL

- SCREWS
(BOTH BIDES)

STANDOFFS

(BOTH SIDES)

DOWNFLOW INSTALLATIONS

(_ CABINET SIDE CABINET SIDE

SUB-BASE SUB-BASE

FLANGE FLANGE

(BENT UP) (BENT UP)

DUCT

Do not install the furnace directly on carpeting, tile or other
combustible material other than wood flooring. For
vertical downflow application, subbase (BAYBASE205)

must be used between the furnace and combustible
flooring. When the downflow furnace is installed vertically

with a cased coil, a subbase is not required.

Required floor opening: (DOWNFLOW)

See Figure 3 and Table I

TABLE 1

CABINET RETURN FLOOROPENING PLENUM OPENING

WIDTH DUCT WIDTH "A.... B.... C.... D"

14-1/2" 13-1/4" 13-5/8" 20-1/8" 12-5/8" 19-3/8"
17-1/2" 16-1/4" 16-5/8" 20-1/8" 15-5/8" 19-3/8"

21" 19-3/4" 20-1/8" 20-1/8" 19-1/8" 19-3/8"

24-1/2" 23-1/4" 23-5/8" 20-1/8" 22-5/8" 19-3/8"

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used in
the horizontal position. It is always recommended that an
auxiliary drain pan be installed under a horizontally in-
stalled evaporator coil or 90% gas furnace. Connect the
auxiliary drain line to a separate drain line (no trap is

needed in this line).
Three brackets (with screws) are included with downflow

furnaces for installation to stabilize and secure the furnace
and TXC cased coil in the horizontal position. See Fig-

ure 4.

©

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

IMPORTANT:
The 2/4TXC cased coil must be placed downstream of the

furnace. In horizontal installations, the apex of the coil
may point either toward or away from the furnace. See

the 2/4TXC coil Installer's Guide for more details.

The cased coil is secured to the furnace and both the furnace
and the cased coil must be properly supported. The brackets

mount using the rear screws on the coil case and use the
screws provided to secure the bracket to the furnace. The
remaining bracket is placed as close to center as possible
(horizontally) between the coil case front and the furnace

bottom channel (for downflow/horizontal furnace). Use four of
the screws provided to secure the bracket. The upflow furnace,

converted to horizontal, aligns and attaches the TXC coil as in
Figure 1. However, the coil requires additional support.

The furnace may be installed in an attic or crawl space in the
horizontal position by placing the furnace on the left side (as
viewed from the front in the vertical position). The horizontal
furnace installation in an attic should be on a service plat-
form large enough to allow for proper clearances on all sides
and service access to the front of the furnace (See Figure 5 &
Clearance Tables, pages 4-5). Line contact is only permis-
sible between lines formed by intersections of the top and two
sides of the furnace casing and building joists, studs, or
framing.

The furnace may be placed horizontally in a crawl space on a
pad or other noncombustible material which will raise the
unit for sufficient protection from moisture.

@

UPFLOW/ I

HORIZONTAL I

SHOWN WITH
DIRECT VENT

18-CD19D8-15

Installer's Guide

®

[--

50 CU. FT. OR MORE

UNCONFINED

The furnace must be supported at both ends and the
middle when installed horizontally. The furnace must

also be elevated approximately 4-6 inches to allow

clearance for the condensate drain to exit the cabinet in

the horizontal position.

The horizontal furnace may also be suspended from the joists
using 3/8" all-thread rods with pieces of angle iron under-

neath the furnace to form a hanging rack at both ends and
the midpoint. The rods need to be of sufficient length to

allow for proper clearances from combustible materials. The
angle iron needs to be at least 32" in length to allow for

access to service panels.

AIR FOR COMBUSTION AND VENTILATION

If these furnaces are installed in a nondirect vent capacity
then the adequate flow of combustion and ventilating air
must not be obstructed from reaching the furnace. Air
openings provided for combustion air must be kept free of

obstructions which restrict the flow of air. Airflow restric-
tions affect the efficiency and safe operation of the furnace.

Keep this in mind should you choose to remodel or change
the area which contains your furnace. Furnaces must have a
free flow of air for proper performance.

Provisions for combustion and ventilation air shall be made
in accordance with latest edition of Section 5.3, Air for
Combustion and Ventilation, of the National Fuel Gas Code,

ANSI Z223.1 -- CAN/CGA B 149.1 or applicable provisions of

the local building codes. Special conditions created by
mechanical exhausting of air and fireplaces must be con-
sidered to avoid unsatisfactory furnace operation.

OUTSIDE AIR IS RECOMMENDED

The use of indoor air for most applications is acceptable,
unless there is the presence of corrosive chemicals or
contamination. Certain types of installation will require

the use of outside air for combustion.
The following types of installations will require use of

OUTDOOR AIR for combustion, due to chemical exposures:

* Commercial buildings
* Buildings with indoor pools
* Furnaces installed in "confined" laundry rooms
* Furnaces installed in "confined" hobby or craft rooms
* Furnaces installed near chemical storage areas.

Exposure to the following substances in the combustion air
supply will also require OUTDOOR AIR for combustion:

* Permanent wave solutions
* Chlorinated waxes and cleaners

* Chlorine based swimming pool chemicals
* Water softening chemicals
* Deicing salts or chemicals

* Carbon Tetrachloride
* Halogen type refrigerants

* Cleaning solvents (such as perchloroethylene)
* Printing inks, paint removers, varnish, etc.
* Hydrochloric acid
* Cements and glues
* Antistatic fabric softeners for clothes dryers
* Masonry acid washing materials

18-CD19D8-15 7

.....\ /

Furnace locations may be in a "confined space" or an
"unconfined space".

Unconfined space is defined in Figure 6. These spaces may
have adequate air by infiltration to provide air for combustion
and ventilation. Buildings with tight construction (for
example, weather stripping, heavily insulated, caulked, vapor

barrier, etc.), may need additional air to be provided as

described for confined space.
Confined spaces are installations with less than 50 cu. ft. of

space per 1000 BTU/hr input from all equipment installed.

Air for combustion and ventilation requirements can be

supplied from inside the building as in Figure 9 or from the
outdoors, as in Figure 10.

Q MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE WITH 8 FT. CEILING

MAXIMUM BTUH MINIMUM AREA IN SQUARE FEET

INPUT RATING OF UNCONFINED SPACE

60,000 375

80,000 500
100,000 625
120,000 875

® -I

m

m FURNAOF

CONFINED

SPACE

1.

All air from inside the building as in Figure 9: The

confined space shall be provided with two permanent
openings communicating directly with an additional

room(s) of sufficient volume so that the combined volume
of all spaces meets the criteria for an unconfined space.

The total input of all gas utilization equipment installed
in the combined space shall be considered in making this
determination. Refer to Table 2 for minimum open areas
requirements.

2.

All air from outdoors as in Figure 10: The confined space

shall be provided with two permanent openings, one
commencing within 12 inches of the top and one com-
mencing within 12 inches of the bottom of the enclosure.
The openings shall communicate directly, or by ducts,
with the outdoors or spaces (crawl or attic) that freely
communicate with the outdoors. Refer to Table 2, for
minimum open areas requirements.

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

60,000
80,000

100,000
120,000

From

Inside

LESS THAN 50 CU. FT.
PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

TABLE 2

Air

lOO
lOO

lOO
12o

Air From Outside

Vertical

Duct

15
20

25
30

Horizontal

Duct

30
40

50
60

iiiiiiiiiiii

Installer's Guide

®

CONFINED SPACE
AIR FROM INSIDE BUILDING

CONFINED
SPACE

_J

®

CONFINED SPACE
AIR FROM OUTDOORS

L

CONFINED-
SPACE

CONFINED SPACE k
AIR FROM VENTILATED ATTIC/CRAWL SPACE

_ ATTIC LOUVERS

CONFINED - AIR
SPACE

ALTERNATE INLET

INLET A_R _ AIR DUCT

PERMANENT
OPENINGS

,UTLET

DOORS

DUCT CONNECTIONS

Air duct systems should be installed in accordance with
standards for air conditioning systems, National Fire Protec-
tion Association Pamphlet No. 90. They should be sized in
accordance with ACCA Manual D or whichever is applicable.

Central furnaces, when used in connection with cooling units,
shall be installed in parallel or on the upstream side of the
cooling coil to avoid condensation in the heat exchanger. With
a parallel flow arrangement, the dampers or other means used
to control flow of air shall be adequate to prevent chilled air
from entering the furnace, and if manually operated, must be
equipped with means to prevent operation of either unit
unless the damper is in full heat or cool position.

On any job, flexible connections of nonflammable material may
be used for return air and discharge connections to prevent
transmission of vibration. Though these units have been
specifically designed for quiet, vibration free operation, air ducts
can act as sounding boards and could, if poorly instMled,
amplify the slightest vibration to the annoyance level.

When the furnace is located in a utility room adjacent to the
living area, the system should be carefully designed with
returns to minimize noise transmission through the return
air grille. Although these furnaces are designed with large
blowers operating at moderate speeds, any blower moving a
high volume of air will produce audible noise which could be
objectionable when the unit is located very close to a living

area. It is often advisable to route the return air ducts under
the floor or through the attic. Such design permits the

installation of air return remote from the living area (i.e.
central hall).

When the furnace is installed so that the supply ducts carry
air circulated by the furnace to areas outside the space
containing the furnace, the return air shall also be handled
by a duct(s) sealed to the furnace and terminating outside
the space containing the furnace.

RETURN AIR DUCT SYSTEMS

Where there is no complete return duct system, the
return connection must be run full size from the

furnace to a location outside the utility room, base-
ment, attic, or crawl space.

Do Not install return air through the back of the furnace

cabinet.
Do Not install return air through the side of the furnace

cabinet on horizontal applications.

NOTE:
Minimum return air temperature is 55 ° F.

CONFINED SPACE
AIR FROM VENTILATED ATTIC

CONFINED-
SPACE

INLET
AIR DUCT

8 18-CD19D8-15

:LOUVERS

TO OUTDOORS

All return air duct systems should provide for installation of
return air filters.

1. Set the furnace in place.

2. For upflow side return installations, remove the insula-
tion around the opening in the blower compartment.

3. The side panels of the upflow furnace include locating
notches that are used as guides for cutting an opening
for return air, refer to Figure 11 and the outline
drawing on page 4 for duct connection dimensions for

various furnaces.

NOTE:
On upflow 5 ton airflow models, if the airflow requirement

exceeds 1800 CFM, these models will require return air
openings and filters on both sides; OR 1side and the
bottom; OR just the bottom.

Installer's Guide

4. Ifa 3/4" flange is to be used for attaching the air inlet duct,
add to cut where indicated by dotted lines in Figure 11.

Cut corners diagonally and bend outward to form flange.

5. If flanges are not required, and a filter frame is installed,
cut between locating notches (Figure 11).

6. The bottom panel of the upflow furnace must be re-
moved for bottom return air. Remove the filter and lay

the furnace on its back. Remove the two 1/4" hex screws
securing the bottom front channel to the cabinet. Lower

the front edge of the bottom front channel and pull
forward to remove the channel. The bottom return air

panel will now easily slide out of the cabinet. Reinstall
the bottom front channel and filter for upflow bottom

return installations.

7. The filter retainer is factory supplied for upflow bottom
return. Use the filter retainer on side or bottom if filter

is to be used within the furnace cabinet on upflow only
installations.

8. The horizontal installation of the upflow furnace

requires an external filter section. Do NOT use the
bottom return filter within the furnace. Filter kits
are available for horizontal applications.

9. Connect duct work to furnace. See Outline Drawing for
supply and return duct size and location. Flexible duct
connectors are recommended to connect both supply and
return air ducts to the furnace. If only the front of the
furnace is accessible, it is recommended that both supply
and return air plenums are removable.

NOTE:
On upflow 5 ton airflow models, if the airflow requirement

exceeds 1800 CFM, these models will require return air
openings and filters on both sides; OR 1 side and the
bottom; OR just the bottom.

The upflow furnace blower door has a hinge at the bottom
which allows the door to tilt forward for filter replacement
without the door being removed (See Figure 12). The furnace
filter in the bottom or side configuration can be removed by
simply turning the two latches on the blower door and tilting

the door forward.

The filter rails are spring loaded for automatic adjustment to
allow standard size, locally obtainable replacement filters.

The filter rack itself slides to adjust to the required width
needed for bottom or side return (See Figure 13).

BOTTOM FILTER RACK INSTALLATION

With the filter removed, the filter rack is compressed and

then inserted into the bottom of the furnace. The retaining
screw/pin on each side inserts into engagement holes at the

bottom of the furnace cabinet side.

RETURN AIR FILTERS (NOT SUPPLIED)

TYPICAL UPFLOW RETURN AIR FILTER
INSTALLATIONS

Filters are not factory supplied for these furnaces. These
furnaces require high velocity type air filters. The filters may

be located within the furnace blower compartment for
UPFLOW furnaces in either a BOTTOM or SIDE (left side or

right side) return air inlet. Some filters may need to be
trimmed for side or bottom filter use.

TABLE 3

MODELS CABINET FILTER

NUMBERS WIDTH QTY & SIZE

*UX2B060A9362A
*UX2B080A9422A

*UX2C100A9482A 21" 1 - 20" X 25" X 1"
*UX2D120A9602A 24-1/2" 1 - 24" X 25" X 1"

* Firstletter may be "A" or "T"

** NOTE - On 5 ton airflow models, if the airflow requirementexceeds

1800CFM, these models will require return air openings andfilters

on bothsides; OR 1sideand the bottom;OR just the bottom.

®

LOCATING *_
VIDED FOR SIDE

NOTCHES PRO-

RETURN CUTOUT

UPFLOW FURNACE ONLY

17-1/2" 1- 17"X25"X 1"

I

-,. I/-

I

q

4..

J

j CUT OUT FOR

SIDE FILTER

I

*- I

Blower Door Hinge and Bottom Filter Rack Installation

®

FILTER

RACK
RAILS

'_ SPRINGS

AUTOMATIC

ADJUSTMENT

RETAINING

PIN

(Both Sides)

*SEE OUTLINE DRAWING _ of Furnace

"_ ,_ RONT

18-CD19D8-15 9

Optional Filter Rack Accessory Kit - BAYRACK960A

Installer's Guide

",.: ..... ..

_ _ BOTTOM ENGAGEMENT

BlowerDeck _ II Furnace "

Engagement II • " II Cabinet

Filter Rack

Retaining

Screw/Pin Filter

Rack

iiiiiiiiiiii

iiii II _ II Side

ENGAGEMENT

HOLE DETAIL

(Typical both sides

and blower deck) BLOWER EngagementHole

OPTIONAL FILTER RACK INSTALLATION FOR SIDE RE-
TURN AIR ON UPFLOW FURNACES (Left or Right)

If side air return is desired, it is necessary to move the filter
rack from the bottom of the furnace and reinstall it on the

side. The following instructions should be used:

a. Open or remove the blower door.

b. Remove the filter.

c. Compress the filter rack to disengage the retaining

d. Leave the bottom panel in place.
e. After the side cutout is made following the directions

f. Reinstall the furnace filter on the side inserting the

!'" '_" I1..... 11 _lnstallation With_)_Bottom Return

pins/screws from the furnace sides and slide the filter
rack out.

in the "Return Air Duct Connections" section on
pages 8 and 9, compress the filter rack and reinstall

in the side of the furnace. Confirm that the upper
retaining pin/screw locks into the engagement hole in
the blower deck and the lower pin/screw rests against
the side of the bottom panel. See Figures 15-19.

chamfer end first.

Engagement Hole

For Filter Rack

For Filter Rack

Installation With

Side Return

Furnace

Cabi net .,.,,)_

Side

Retaining Rack

Screw/Pin Assembly

SIDE

CUTOUT

\

®

Furnace

Cabinet

Side

Filter

Rack

RETAINING

PIN -_

Bottom Panel

Furnace
Blower
Deck

F

EngagementHole
ForFilter Rack

InstallationWith
BottomReturn

10 18-CD19D8-15

Filter Rack
Retaining

Screw/Pin

(Bo_[__,

III J/ FILTER BOTTOM
I I.] JJ RACK PANEL

[[I // RAILS INSTALLED
I[ V/zJ Typical Upflow Left Side Return Filter

L_z/Rack Installation

Optional Filter Rack Accessory Kit - BAYRACK960A

Typical Upflow Right Side Return Filter Rack Installation

O

Installer's Guide

BLOWER DOOR/HINGE REMOVAL

If clearance or other problems create a problem in using the
tilting door, the blower door hinge may be removed without
creating any problems with the seal of the furnace. To remove
the blower door, tilt the door forward 2 to 3 inches and pull up.
To remove the tilt feature, simply remove the lower hinge as
shown in Figure 22. The bottom of the blower door will catch
in the bottom of the furnace front channel for door replacement.

CHAMFER

END OF

FILTER GOES

INTO FILTER
RACK FIRST

RETURN AIR FILTERS FOR UPFLOW FURNACE IN
HORIZONTAL CONFIGURATION

When the Upflow Furnace is installed in the horizontal

configuration, the return air filters must be installed exterior
to the cabinet. Remote filter grilles may be used for home-
owner convenience or the filters may be installed in the duct
work upstream of the furnace. See Figure 21.

f_

Door Hinge Removed

ALTERNATE UPFLOW FILTER CLIP / BRACKET
INSTALLATION (KIT09224)

1. Determine the location to be used. The furnace cabinet
has dimples for location of the alternate furnace clips

(Side return only). Pre-drill clearance holes with a 3/16"
drill. Bottom return holes are pre-drilled.

2. Install the clips in front and rear of the desired location
using the screws provided. The filter clip with the leaf
spring mounts in the rear of the cabinet.

ALTERNATE FILTER
CLIPS LOCATION

TYPICAL RETURN AIR FILTER INSTALLATION IN

UPFLOW MODEL IN HORIZONTAL POSITION

18-CD19D8-15 11

FILTER CLIP - KIT09224

Installer's Guide

iiiiiiiiiiii

INSTALLING THE FILTER

The filter may need to be cut to fit the unit depending on the
location of the return air filter.

A score line and the words "CUT HERE" are located on the
end of the filter. If your application requires cutting the

filter, do so as indicted by the score mark.

UNIT

SIZE

17-1/2"

21"

24-1/2"

TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER
INSTALLATIONS

Two filters are factory supplied for each downflow furnace.
These furnaces require high velocity type air filters. Down-

flow furnace filters must be located outside the furnace
cabinet. Typical installations are shown in Figure 24.

Tables 5 and 6 provide information for installation of the
filter retaining brackets shipped with downflow furnaces.

@

Optional

BAYFLTR206

Door Kit

BOTTOM

DO NOT CUT
DO NOT CUT

DO NOT CUT

RETURN AIR

SIDE

DO NOT CUT

CUT ON LINE
CUT ON LINE

TABLE 4

MODELS CABINET FILTER

NUMBERS WIDTH QTY & SIZE

*DX060R936

*DX080R942

*DX100R948 21" 2 - 16" X 20" X 1"
*DX120R960 24-1/2" 2 - 16" X 20" X 1"

*First letter may be "A" or "T"

LOCATING FILTER RETAINER BRACKETS IN

CABINET RETURNDUCT DIMENSION DIMENSION BRACKET

WIDTH WIDTH "A .... B" LOCATION*

17-1/2" 16-1/4" 15" 14" 14-3/8"

21" 19-3/4" 19-1/2" 14" 13-1/8"

24-1/2" 23-1/4" 22" 14" 13-5/8"

* LOCATION DIMENSION IS FROM END OF DUCT AGAINST THE FURNACE TO THE

SCREW HOLES FOR THE BRACKET.

BOptiyFLnTRI06

17-1/2" 2 - 14" X 20" X 1"

TABLE 5

DUCTWORK

FILTER

p.

Airflow

DOWNFLOW

/ ow% ow;

TABLE 6

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL AND DOWNFLOW/HORIZONTAL FURNACES

UNIT LOCATION

FURNACE SURFACE

SIDES 0" 1" 0"

BACK 0" 3" 6"

TOP 1" 1" 1"

FRONT 3" 3" 18"

VENT 0" 0" 0"

NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

12 18-CD19D8-15

VERTICAL HORIZONTAL HORIZONTAL

CLOSET CLOSET ALCOVE / ATTIC