Lennox G1D91BU, G1D93BU, CG90CB, CG90UB, G1D93BC Installation Instructions Manual
INSTALLATION INSTRUCTIONS
G1D91BU, G1D93BC, G1D93BU, CG90CB, & CG90UB
High Efficiency 90+ Condensing Gas Furnace
WARNING
Improper installation, adjustment, alteration, service, or maintenance can cause
injury or property damage. Refer to this manual. For assistance or additional information, consult a qualified installer, service agency, or the gas supplier.
WARNING
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 cautioned 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.
SAFETY ................................................. 2
INSTALLATION....................................... 3
START-UP ............................................ 19
OPERATION ........................................ 20
MAINTENANCE ................................... 23
TABLE OF CONTENTS
REPAIR PARTS .................................... 24
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 property damage, personal injury, or death.
®
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 consulted before installation is made. Such applicable regulations or requirements take precedence over the
general instructions in this manual.
®
IMPORTANT
CONTROL SYSTEM DIAGNOSTICS .. 25
WIRING DIAGRAMS ............................ 26
Manufactured By
A.A.C.
A Lennox International Company
421 Monroe Street
Bellevue, OH 44811
# 45466K003 Page 1
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.
WARNING
In the State of Massachusetts:
This product must be installed by a licensed
Plumber or Gas Fitter. When flexible connectors are used, the maximum length shall not
exceed 36". When lever-type gas shutoffs are
used, they shall be T-handle type.
6. 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 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.
# 45466K003Page 2
INSTALLATION
All models are suitable for closet or utility room 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 calculated 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
The furnace is suitable for installation in buildings constructed 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.
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. Chlorides from sources such as paint, stain, or
varnish; tile and counter cements; adhesives;
and foam insulation are abundant in a structure 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.
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 components are protected from water. Unit must be level for
proper condensate drainage.
CAUTION
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 temperatures under 32°F. Use of heat tape is per-
missible provided the rate temperature of the
tape does not exceed 155°F.
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 –
# 45466K003 Page 3
Unconfined Space
Minimum Clearances to Combustibles
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Table 1
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
WARNING
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.
Insufficient combustion air can cause headaches, nausea, dizziness, or asphyxiation.
When considering combustion air requirements, enough air must also be provided to
meet the needs of all fuel-burning appliances
and exhaust fans.
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 provisions of the local building codes.
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.
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 appliances 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
# 45466K003Page 4
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
Inlet Air Restrictor Plate
The inlet air restrictor plate
must be installed in all
installations using inside air
for combustion (non-direct
vent).
Flue Pipe Screen
The flue pipe screen
should be installed at the
termination of the flue pipe
in all installations.
Figure 1
WARNING
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.
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. Therefore, 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).
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 termination 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).
# 45466K003 Page 5
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
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.
All pipe, fittings, primer, and solvent cement must conform
with American National Standard Institute and the American 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, stratification, or separation that cannot be removed by stirring.
Refer to Table 2 for approved piping and fitting materials.
Piping and Fitting Specifications
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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.
Concentric Vent Kit Dimensions
1"
5"
2"
Nominal
Pipe Size
11"
3.5"
18"
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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
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 installations) 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.
# 45466K003Page 6
Horizontal Venting
Vent Tables
(numbers in inches unless specified otherwise)
Minimum Pipe Diameter
40,000 – 80,000 BTU/HR Models
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5
01
02
03
04
05
06
07
08
09
5
01
02
03
04
05
06
07
08
09
5.15.1 22222222
5.1 2 2 2 2 2 2 2 2 2
222222222 5.2
2 2 2 2 2 2 2 5.2 5.2 5.2
22222 5.25.25.25.25.2
2 2 5.2 5.2 5.2 5.2 5.2 5.2 5.2 3
25.25.25.25.25.25.2 333
5.2 5.2 5.2 5.2 5.2 3 3 3 3 RN
5.25.25.2 33333 RNRN
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Minimum Pipe Diameter
90,000 – 100,000 BTU/HR Models
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2 2 2 5.2 5.2 5.2 5.2 3 3 3
22 5.25.25.2 33333
5.2 5.2 5.2 3 3 3 3 3 3 RN
5.2 333333 RNRNRN
3 3 3 3 3 RN RN RN RN RN
333 RNRNRNRNRNRNRN
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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.
Minimum Pipe Diameter
112,000 – 125,000 BTU/HR Models
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0 1 2 3 4 5 6 7 8 9
).tf(
5
01
02
03
04
05
06
NR = Not Recommended
5.25.25.25.25.25.25.25.25.25.2
5.2 5.2 5.2 5.2 5.2 5.2 5.2 5.2 5.2 3
5.25.25.25.25.25.25.233RN
5.2 5.2 5.2 5.2 5.2 3 3 RN RN RN
5.25.25.25.23RNRNRNRNRN
5.2 3 3 RN RN RN RN RN RN RN
33 RNRNRNRNRNRNRNRN
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Figure 3
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.
# 45466K003 Page 7
Sidewall Vent Terminal Clearances (Direct Vented Furnaces)
V
Vent Terminal
Air Supply Inlet
X
Area Where Terminal Is
Not Permitted
1
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In accordance with the current CSA B149.1, Natural Gas and
Propane Installation Code
2
In 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.
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“Clearance in accordance with local installation codes and the
requirements of the gas supplier and the manufacturer’s installation
instructions.”
Figure 4
# 45466K003Page 8
Sidewall Vent Terminal Clearances (Non-Direct Vented Furnaces)
V
X
Area Where Terminal Is
Not Permitted
Vent Terminal
Air Supply Inlet
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1
In accordance with the current CSA B149.1, Natural Gas and
Propane Installation Code
2
In 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.
# 45466K003 Page 9
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‡
Permitted only if veranda, porch, deck, or balcony is fully open on a
†
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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.”
Figure 5
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