Lennox G1D91BU User manual

# 45466K003 Page 1

INSTALLATION INSTRUCTIONS

G1D91BU, G1D93BC, G1D93BU, CG90CB, & CG90UB

High Efficiency 90+ Condensing Gas Furnace

Manufactured By

A.A.C.

A Lennox International Company

421 Monroe Street

Bellevue, OH 44811

The installation of the furnace, wiring, warm air ducts, venting, etc. must conform to the requirements of the

National Fire Protection Association; the National Fuel Gas Code, ANSI Z223.1/NFPA No. 54 (latest edition)

and the National Electrical Code, ANSI/NFPA No. 70 (latest edition) in the United States; CSA B149.1

(latest edition) Natural Gas and Propane Installation Codes and the Canadian Electrical Code Part 1, CSA

22.1 (latest edition) in Canada; and any state or provincial laws, local ordinances (including plumbing or

wastewater codes), or local gas utility requirements. Local authorities having jurisdiction should be con-

sulted before installation is made. Such applicable regulations or requirements take precedence over the

general instructions in this manual.

IMPORTANT

Do not store combustible materials, including

gasoline and other flammable vapors and

liquids, near the furnace, vent pipe, or warm

air ducts. The homeowner should be cau-

tioned that the furnace area must not be

used as a broom closet or for any other

storage purposes. Such uses may result in

actions that could cause property damage,

personal injury, or death.

WARNING

This furnace is not approved for installation in

a mobile home. Do not install this furnace in a

mobile home. Installation in a mobile home

could result in actions that could cause prop-

erty damage, personal injury, or death.

WARNING

Improper installation, adjustment, alteration, service, or maintenance can cause

injury or property damage. Refer to this manual. For assistance or additional informa-

tion, consult a qualified installer, service agency, or the gas supplier.

WARNING

TABLE OF CONTENTS

SAFETY ................................................. 2

INSTALLATION....................................... 3

START-UP ............................................ 19

OPERATION ........................................ 20

MAINTENANCE ................................... 23

REPAIR PARTS .................................... 24

CONTROL SYSTEM DIAGNOSTICS .. 25

WIRING DIAGRAMS ............................ 26

# 45466K003Page 2

SAFETY

The following is a list of safety rules and precautions that

must be followed when installing 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 the Location section on page 3 of these

instructions.

3. Provide adequate combustion and ventilation air to the

furnace space as specified in the Combustion and

Ventilation Air section on page 4 of these instructions.

4. Adequate clearance must be provided around the

vent-air intake terminals as specified in the Venting

section beginning on page 5 of these instructions.

5. Combustion products must be discharged outdoors.

Connect this furnace to an approved vent system only,

as specified in the Venting section beginning on page 5

of these instructions.

6. Never test for gas leaks with an open flame. Use a

commercially available soap solution made specifi-

cally for the detection of leaks to check all connec-

tions, as specified in Gas Supply and Piping

beginning on page 15 of these instructions.

7. Always install furnace to operate within the furnace’s

intended temperature-rise range with a duct system

which has an external static pressure within the

allowable range, as specified in Temperature Rise

on page 21 of these instructions. See furnace rating

plate.

8. When a 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 duct(s) sealed to the furnace casing

and terminating outside the space containing the

furnace. See Circulating Air Supply on page 15 of

these instructions.

9. A gas-fired furnace for installation in a residential

garage must be installed as specified in the Location

section on page 3 of these instructions.

10. The furnace is not to be used for temporary heating of

buildings or structures under construction as specified

in the Location section on page 3 of these instructions.

In the State of Massachusetts:

This product must be installed by a licensed

Plumber or Gas Fitter. When flexible connec-

tors are used, the maximum length shall not

exceed 36". When lever-type gas shutoffs are

used, they shall be T-handle type.

WARNING

# 45466K003 Page 3

INSTALLATION

These instructions must be placed on or near the

furnace in a conspicuous place.

The furnace design is certified by CSA International as a

Category IV furnace in compliance with the latest edition

of American National Standard Z21.47/CSA Standard 2.3

for Gas-Fired Central Furnaces, for operation with natural

gas or propane. Consult the rating plate on the furnace for

gas type before installing.

The maximum hourly heat loss of space shall be calcu-

lated in accordance with the procedure described in the

current manuals of Air Conditioning Contractors of

America, or by any other recognized method which is

suitable for local conditions, provided the results obtained

are in substantial agreement with, and not less than, those

obtained using the procedure described in the manuals.

G1D91BU, G1D93BU, and CG90UB models shall be

installed only as upflow furnaces. G1D93BC and

CG90CB models shall be installed only as counterflow

(downflow) furnaces.

Inspection of Shipment

This furnace is shipped in one package, completely

assembled and wired. The thermostat is shipped in a

separate carton when ordered.

Upon receipt of equipment, carefully inspect it for possible

shipping damage. If damage is found, it should be noted

on the carrier’s freight bill. Damage claims should be filed

with the carrier immediately. Claims of shortages should

be filed with the seller within 5 days.

Location

To provide proper operation and satisfactory performance,

care must be taken in choosing the location for this furnace.

The atmosphere in which the furnace operates must be free

of contaminants such as chlorides and sulfates.

The furnace must be installed so that electrical compo-

nents are protected from water. Unit must be level for

proper condensate drainage.

All models are suitable for closet or utility room installation.

The furnace is suitable for installation in buildings con-

structed on-site. The furnace should be centralized in

respect to the heat distribution system as much as

practicable. When installed in a utility room, the door

should be wide enough to allow the largest part of the

furnace to enter, or permit the replacement of another

appliance, such as a water heater.

A gas-fired furnace for installation in a residential garage

must be installed so the burner(s) and the ignition source

are located not less than 18" above the floor. The furnace

is to be located or protected to avoid physical damage by

vehicles.

If the furnace is to be installed in an attic or other

insulated space, it must be kept free and clear of

insulating materials.

Clearances

All servicing and cleaning of the furnace can be performed

from the front. If installed in a closet or utility room, provide

18" clearance in front for service if the door to the room is

not in line with the front of the furnace.

Refer to Table 1 on page 4 for the minimum clearances to

combustibles required for construction and proper unit

operation.

Accessibility clearances must take precedence over

fire protection clearances.

Upflow models (G1D91BU, G1D93BU, & CG90UB) may be

installed on wood flooring but shall not be installed directly

on carpeting, tile, or any other combustible material.

Counterflow models (G1D93BC & CG90CB) are certified

for installation on combustible flooring provided a special

base assembly is used. (Refer to the Duct Connection –

The condensate drain on this furnace is

incorporated within the furnace and must be

primed before start-up. The condensate

system must not be exposed to tempera-

tures under 32°F. Use of heat tape is per-

missible provided the rate temperature of the

tape does not exceed 155°F.

CAUTION

Do not use the furnace as a heater in a

building under construction. The furnace can

be severely damaged due to the abnormal

environment caused by construction. Chlo-

rides from sources such as paint, stain, or

varnish; tile and counter cements; adhesives;

and foam insulation are abundant in a struc-

ture under construction and can be highly

corrosive. Low return air temperature can

cause condensation in the furnace and other

damage that can shorten the life of the unit.

CAUTION

# 45466K003Page 4

Unconfined Space

An unconfined space is defined as “a space whose

volume is more than 50 cubic feet per 1000 BTU per hour

of the combined input rating of all appliances installed in

that space.”When a furnace is installed in an unconfined

space in a building, it can be assumed that the infiltration

will be sufficient to supply the required air. If the furnace is

installed in a ventilated attic or crawl space, it is assumed

that the infiltration is sufficient to supply the required air.

However, in a building of unusually tight construction,

additional outdoor air should be provided.

Confined Space

A confined space is defined as “a space whose volume is

less than 50 cubic feet per 1000 BTU per hour of the

combined input rating of all appliances installed in that

space.”

If the furnace is installed in a confined space within the

building and combustion air is taken from a heated space,

the combustion air and ventilating air must enter and leave

the space through two permanent openings of equal area.

One opening shall be located within 12" of the ceiling and

the other within 12" of the floor, each having a free area of

1 square inch per 1000 BTU/HR of total input rating of all

appliances within the space and not less than 100 square

inches each.

If the furnace is installed in a space within a building of tight

construction, makeup air must be supplied from outdoors. In

this case, one opening shall be within 12" of the ceiling and

one opening within 12" of the floor. If combustion ducts are

vertical, each opening shall have a free area of 1 square

inch per 4000 BTU/HR of the total input rating of all appli-

ances within the enclosure. If horizontal combustion ducts

are run, 1 square inch per 2000 BTU/HR is required.

Contaminated Combustion Air

Excessive exposure to contaminated combustion air will

result in safety and performance related problems. The

recommended source of combustion air is outdoor air.

However, the use of indoor air in most applications is

acceptable if the following guidelines are followed:

1. If the furnace is installed in a confined space, it is

recommended that the necessary combustion air come

from the outdoors by way of an attic, crawl space, air

duct, or direct opening.

2. If indoor combustion air is used, there must be no

exposure to the substances listed in item 5.

3. All provisions for indoor combustion air must meet the

requirements for combustion air indicated in the

National Fuel Gas Code, ANSI Z223.1/NFPA 54

(latest edition), and/or any applicable local codes. In

Adequate provisions for combustion air and ventilation of

furnace must be made. Refer to Section 5.3, “Air for

Combustion and Ventilation,”of the National Fuel Gas

Code, ANSI Z223.1/NFPA54 (latest edition), Sections 7.2,

7.3, or 7.4 of CSA B149.1 Natural Gas and Propane

Installation Codes (latest editions), or applicable provi-

sions of the local building codes.

Counterflow Models section on page 15 for more

information on using the special base assembly.)

When a counterflow unit is installed on a combustible

floor, 1" clearance must be provided between the supply

duct and the floor.

Combustion and Ventilation Air

Table 1

Minimum Clearances to Combustibles

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Insufficient combustion air can cause head-

aches, nausea, dizziness, or asphyxiation.

When considering combustion air require-

ments, enough air must also be provided to

meet the needs of all fuel-burning appliances

and exhaust fans.

WARNING

Air openings in the front of the furnace must

be kept free of obstructions. Any obstruction

may cause improper operation that can result

in a fire hazard or carbon monoxide injury.

WARNING

# 45466K003 Page 5

Canada, see CSA B149.1, Natural Gas and Propane

Installation Codes (latest edition).

4. The following types of installation may require outdoor

air for combustion, due to chemical exposures:

•Commercial buildings

•Buildings with indoor pools

•Furnaces installed in laundry rooms

•Furnaces installed in hobby or craft rooms

•Furnaces installed near chemical storage areas

5. Exposure to the following substances in the combustion

air supply may 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, varnishes, etc.

•Cements and glues

•Antistatic fabric softeners for clothes dryers

•Masonry acid washing materials

•Chlorinated laundry products

•Hydrochloric acid

Venting

The high efficiency of this furnace is accomplished by the

removal of both sensible and latent heat from the flue gases.

The removal of latent heat results in the condensation of

moisture in the flue gases. This condensation occurs in the

secondary heat exchanger and in the vent system. There-

fore, this furnace requires special venting considerations

and the instructions must be followed to insure proper

operation. All venting must be in accordance with the codes

having jurisdiction in the area and these instructions.

Upflow models G1D91BU, G1D93BU, and CG90UB and

counterflow models G1D93BC and CG90CB can be

installed as either direct vent or non-direct vent units. A

direct vent (two pipe) installation requires that all the air

necessary for combustion be supplied from outside the

dwelling through an air intake pipe. A non-direct vent (one

pipe) installation uses air from inside the dwelling for

combustion.

The furnace is shipped with the air inlet pipe terminated to

the top panel for either inside or outside combustion air. An

inlet air restrictor plate (see Figure 1) is supplied with this

furnace and can be found in the plastic bag containing these

Installation Instructions and the User’s Information Manual.

For installations using inside air for combustion (non-direct

vent), attach a 90°elbow (not supplied) to the inlet coupler

and install the restrictor plate inside the elbow (see Figures

8 and 9 on page 11 or Figures 13 and 14 on page 13).

If at any time in the future the installation of

this furnace is changed to require outside

fresh air for combustion, the inlet air restrictor

plate must be removed. Failure to remove the

inlet air restrictor could cause improper

operation that can result in a fire hazard or

carbon monoxide injury.

WARNING

Also included in the plastic bag containing the inlet air

restriction plate is a flue pipe screen (see Figure 1). In all

installations, this screen should be installed at the termi-

nation of the flue pipe and is designed to keep objects out

of the flue pipe.

For either type of installation (direct or non-direct vent),

special venting considerations must be followed. Refer to

the proper section in pages 10 –13 for the type of furnace

and venting being installed.

The venting system must be supported with mounting

straps to prevent any weight load from being applied to the

vent blower. Horizontal vent pipe must be supported every

5' and vertical pipe should be supported every 10' to

prevent sagging and provide rigid support.

When a furnace is installed as direct vent, provisions for

ventilation air should follow the same requirements as if

installed as non-direct vent. Proper ventilation air is

necessary to maintain furnace component temperatures

within acceptable limits.

All vents passing through floors, ceilings, and walls must

be installed in accordance with National Fuel Gas Code,

ANSI Z223.1/NFPA 54 (latest edition).

Inlet Air Restrictor Plate

Flue Pipe Screen

The inlet air restrictor plate

must be installed in all

installations using inside air

for combustion (non-direct

vent).

The flue pipe screen

should be installed at the

termination of the flue pipe

in all installations.

Figure 1

# 45466K003Page 6

Category IV Furnace Limitations

This furnace shall not be connected to any Type B, BW, or

L vent or vent connector and shall not be connected to

any portion of a factory-built or masonry chimney. This

furnace is not to be common vented with any other

appliance. The vent pipe must not be connected to a

chimney flue serving a separate appliance designed

to burn solid fuel.

Vent Pipe Size and Length

The vent pipe and air intake pipe (in direct vent installa-

tions) should be sized in accordance with the information

found in the appropriate table in Figure 3. One 90°elbow

is equivalent to 5' of pipe. Two 45°elbows are equivalent

to one 90°elbow. The minimum length certified for use

with this furnace is 5' and one elbow, not including the

vent and air intake terminals.

In the event that the pipe length is in between the lengths

listed in the table, use the next larger length listed. For

example, if a length of pipe needed to install the furnace is

27', use the diameter values for the 30' row in the tables.

In all applications where the flue pipe is run through

an unconditioned space, 1/2"Armaflex or equivalent

must be used over the pipe. In extreme cold climates,

3/4"Armaflex is recommended.

Materials

All pipe, fittings, primer, and solvent cement must conform

with American National Standard Institute and the Ameri-

can Society for Testing and Materials (ANSI/ASTM)

standards. The solvent shall be free flowing and contain

no lumps, undissolved particles, or any foreign matter that

adversely affects the joint strength or chemical resistance

of the cement. The cement shall show no gelation, stratifi-

cation, or separation that cannot be removed by stirring.

Refer to Table 2 for approved piping and fitting materials.

cement is recommended. Metal or plastic strapping may be

used for vent pipe hangers.

When making ABS joints, pieces can be prepared with a

cleaner. When joining ABS to PVC materials, use PVC

solvent cement as specified in ASTM D3138.

Preferred fittings are DWV style or long sweep. Seal all joints

gas tight with appropriate cement. In areas where vent and

air intake pipes are exposed to abnormal stress or are

subject to damage, schedule 80 pipe should be used.

Concentric Vent Kit

A concentric vent kit (model ACVK2) is available for use

when installing this furnace as a direct vent furnace and the

air intake and vent pipe are to be run through the same hole,

whether horizontally through the wall or vertically through the

roof (see Figure 2). Refer to the instructions included with

the concentric vent kit for installation specifics.

Table 2

Piping and Fitting Specifications

The primers and solvents used must also meet ASTM

specifications. PVC primer is specified in ASTM F656. Use

PVC solvent as specified in ASTM D2564 and ABS solvent

cement as specified ASTM D2235. Low temperature solvent

Figure 2

Nominal

Pipe Size

3.5"

18" 5"

11"

Concentric Vent Kit Dimensions

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# 45466K003 Page 7

Horizontal Venting

The vent for this appliance shall not terminate over public

walkways; or near soffit vents or crawl space vents or

other areas where condensate or vapor could create a

nuisance or hazard or cause property damage; or where

condensate vapor could cause damage or could be

detrimental to the operation of regulators, relief valves, or

other equipment.

See Figures 4 and 5 on pages 8 and 9 for additional

information on where the horizontal vent terminal can and

cannot terminate.

For direct vent installations, if the vent and air intake pipe

are not equal in length and number of elbows, then

determine the minimum pipe diameter for both the vent

and air intake. If the results indicate different diameters,

use the larger of the two for both the vent and air intake.

Under no circumstances should the vent and air

intake pipe size be different in diameter. For installation

details, refer to the appropriate section in pages 10 –13

for the unit model and type of installation.

Figure 3

Vent Tables

(numbers in inches unless specified otherwise)

Minimum Pipe Diameter

40,000 – 80,000 BTU/HR Models

NR = Not Recommended

Minimum Pipe Diameter

112,000 – 125,000 BTU/HR Models

Minimum Pipe Diameter

90,000 – 100,000 BTU/HR Models

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# 45466K003Page 8 Figure 4

Sidewall Vent Terminal Clearances (Direct Vented Furnaces)

1In accordance with the current CSA B149.1, Natural Gas and

Propane Installation Code

2In accordance with the current ANSI Z2223.1/NFPA 54, National

Fuel Gas Code

†A vent shall not terminate directly above a sidewalk or paved

driveway that is located between two single family dwellings and

serves both dwellings.

‡Permitted only if veranda, porch, deck, or balcony is fully open on a

minimum of two sides beneath the floor.

* For clearances not specified in ANSI Z2223.1/NFPA 54 or CSA

B149.1, the following statement shall be included:

“Clearance in accordance with local installation codes and the

requirements of the gas supplier and the manufacturer’s installation

instructions.”

†

‡

Vent Terminal

Air Supply Inlet

Area Where Terminal Is

Not Permitted

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# 45466K003 Page 9

Figure 5

Sidewall Vent Terminal Clearances (Non-Direct Vented Furnaces)

1In accordance with the current CSA B149.1, Natural Gas and

Propane Installation Code

2In accordance with the current ANSI Z2223.1/NFPA 54, National

Fuel Gas Code

†A vent shall not terminate directly above a sidewalk or paved

driveway that is located between two single family dwellings and

serves both dwellings.

‡Permitted only if veranda, porch, deck, or balcony is fully open on a

minimum of two sides beneath the floor.

* For clearances not specified in ANSI Z2223.1/NFPA 54 or CSA

B149.1, the following statement shall be included:

“Clearance in accordance with local installation codes and the

requirements of the gas supplier and the manufacturer’s installation

instructions.”

†

‡

Vent Terminal

Air Supply Inlet

Area Where Terminal Is

Not Permitted

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# 45466K003Page 10

Figure 6

Upflow Direct Vent – Horizontal Venting

(Models G1D91BU, G1D93BU,

& CG90UB Only)

* The 18" dimension is the minimum

recommended height for extremely

cold areas. In these areas,

moisture in the flue gases may

condense and freeze on the air

intake if this height is reduced. In

milder climates, this may be

reduced to a minimum of 6".

Height may be increased as

needed provided total length is not

exceeded.

(CLOSED)

DRAINHOLE

THRU.

59.69/56.64

THE VENT SYSTEM OF

THE FURNACE MUST

BE SELF-SUPPORTING

AND

MUST NOT APPLY ANY

WEIGHT LOAD TO THE

COMBUSTION

BLOWER.

CAUTION

FLUE PIPE

THIS PIECE

IS OPTIONAL.

AIR INTAKE PIPE

18” *

RUN PITCH = 1/4”

PER FOOT MIN.

SEE TABLE FOR

PROPER PIPE SIZE.

HEIGHT TO PROVIDE

12” CLEARANCE TO

MAX. SNOW LEVEL.

AIR INTAKE PIPE 6”

CONDENSATE

COLLAR

DO NOT INSTALL THE

RESTRICTOR PLATES IN

ANY DIRECT VENT

APPLICATIONS.

IMPORTANT

slope upward, away from the furnace, at a minimum pitch of

1/4" per foot of run, to prevent accumulation of condensate.

Do not cement air intake into the connector on burner

box. Use high temperature RTV silicone sealant so

intake pipe can be removed if service is required.

For proper operation, the vent and air intake pipe

must be installed in the same pressure zone. There-

fore, in horizontal venting applications they must be

on the same side of the house within the parameters

shown in Figure 6.

On initial start-up of the unit, some of the water used to

prime the trap system may run down into the combustion

blower and cause noise.

Upflow Models G1D91BU, G1D93BU, & CG90UB

Direct Vent Installation

An inlet air restrictor plate (see Figure 1 on page 5) is supplied

with this furnace and can be found in the plastic bag containing

these Installation Instructions and the User’s Information

Manual. This restrictor plate is to be used only in non-direct

vent applications. See the non-direct venting sections on

pages 11 and 13 for more information on installing the restrictor

plate in non-direct vent applications.

The flue pipe screen (see Figure 1 on page 5) should be

installed at the termination of the flue pipe and is designed

to keep objects out of the flue pipe. An additional screen

should not be placed in the intake termination. If a screen

is installed, the air intake may freeze shut.

Prime the trap system by slowly pouring 1 cup of water

down the vent pipe.

For horizontal venting, refer to Figure 6. For vertical venting,

refer to Figure 7. The vent pipe on horizontal runs must

THIS PIECE

IS OPTIONAL.

INTAKE PIPE

FLUE PIPE

3” MIN. - 48” MAX.

Overhead View

Upflow Direct Vent – Vertical Venting

(Models G1D91BU, G1D93BU,

& CG90UB Only)

Figure 7

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