Lennox G1D91BT, G1D93BT, CG90TB Installation Instructions Manual
INSTALLATION INSTRUCTIONS
G1D91BT, CG90TB, & G1D93BT
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 ............................................ 21
OPERATION ........................................ 22
MAINTENANCE ................................... 24
TABLE OF CONTENTS
CONTROL SYSTEM DIAGNOSTICS .. 25
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.
REPAIR PARTS ................................... 25
WIRING DIAGRAMS............................ 27
Manufactured By
A.A.C.
A Lennox International Company
421 Monroe Street
Bellevue, OH 44811
*47860A005*
IMPORTANT
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.
# 47860A005 Page 1
SAFETY
The following is a list of safety rules and precautions that
must be followed when installing this furnace.
WARNING
In the State of Massachusetts:
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 specifically for the detection of leaks to check all connections, as specified in Gas Supply and Piping
beginning on page 18 of these instructions.
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.
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
24 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 18 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.
# 47860A005Page 2
INSTALLATION
Location
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.
G1D91BT, G1D93BT, and CG90TB furnaces may be installed
as upflow or horizontal furnaces. When installed horizontally, the installer must install a sheet metal screw to retain
the upper door as shown in Figure 1.
Never install any furnace on its back.
Horizontal Installations
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 system must not be exposed to temperatures under 32°F. The
condensate system must be insulated if exposed to temperatures under 32°F. Use of heat
tape is permissible provided the rate temperature of the tape does not exceed 155°F.
All models are suitable for closet or utility room installation.
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.
Figure 1
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.
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.
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.
# 47860A005 Page 3
G1D91BT, G1D93BT, and CG90TB models installed in the
horizontal position are approved for attic installations. If the
furnace is to be installed in an attic or other insulated
space, it must be kept free and clear of insulating
materials.
To avoid property damage caused by condensate drain
blockage, install a field-fabricated auxiliary drain pan with
a separate drain line to the outside under the entire
furnace and drain system. Install according to local codes.
Clearances
WARNING
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.
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 for the minimum clearances to combustibles required for construction and proper unit operation.
Where servicing clearances are greater than clearances
to combustibles, servicing clearances take precedence.
G1D91BT, G1D93BT, and CG90TB models may be installed on wood flooring but shall not be installed directly
on carpeting, tile, or any other combustible material.
Minimum Clearances to
Combustibles
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Table 1
Combustion and Ventilation Air
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.
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 appliances within the enclosure. If horizontal combustion ducts
are run, 1 square inch per 2000 BTU/HR is required.
# 47860A005Page 4
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
Canada, see CSA B149.1, Natural Gas and Propane
Installation Codes (latest edition).
operation. All venting must be in accordance with the codes
having jurisdiction in the area and these instructions.
G1D91BT, G1D93BT, and CG90TB models 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 2) is supplied with this
furnace and can be found in the plastic bag containing these
Installation Instructions and the User’s Information Manual.
This inlet restrictor plate must be used in all installations
using inside air for combustion (non-direct vent).
To install the inlet restrictor plate:
1. Install the restrictor plate in the inlet pipe collar in the
top panel of the furnace.
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
2. Insert a 3" section of PVC pipe (field supplied) into the
collar. Use high temperature RTV sealant to attach
PVC pipe to collar.
3. Attach a 90° elbow (field supplied) to the PVC pipe.
Use high temperature RTV sealant to attach elbow to
PVC pipe.
Two different sized inlet restrictor plates are supplied with
the furnace (2" and 3"). Use the proper restrictor plate for
the furnace model.
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.
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.
Therefore, this furnace requires special venting considerations and the instructions must be followed to insure proper
# 47860A005 Page 5
Figure 2
Also included in the plastic bag containing the inlet air
restriction plate is a flue pipe screen (see Figure 2). 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.
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.
Piping and Fitting Specifications
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For either type of installation (direct or non-direct vent),
special venting considerations must be followed. Refer to
the proper section in pages 10 – 14 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).
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
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Table 2
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.
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
cement is recommended. Metal or plastic strapping may be
used for vent pipe hangers.
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.
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.
# 47860A005Page 6
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 3). Refer to the instructions included with
the concentric vent kit for installation specifics.
Concentric Vent Kit Dimensions
Figure 3
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 4. 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.
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 – 14
for the unit model and type of installation.
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
Vent Tables
(numbers in inches unless specified otherwise)
Minimum Pipe Diameter
40,000 – 80,000 BTU/HR Models
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06
07
08
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01
02
03
04
05
06
NR = Not Recommended
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other equipment. See Figures 5 and 6 on pages 8 and 9 for
additional information on where the horizontal vent terminal
can and cannot terminate.
For horizontal venting in situations where clearance to
floor joists is limited, see Horizontal Venting – Low
Clearance Installations on page 14.
# 47860A005 Page 7
Sidewall Vent Terminal Clearances (Direct Vented Furnaces)
V
Vent Terminal
Air Supply Inlet
X
Area Where Terminal Is
Not Permitted
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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
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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 5
# 47860A005Page 8
Sidewall Vent Terminal Clearances (Non-Direct Vented Furnaces)
V
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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.
# 47860A005 Page 9
telniylppusrialacinahcemaotecnaraelC )m38.1(teef6
detacolyawevirddevaproklawedisdevapevobaecnaraelC
ynoclabro,kced,hcrop,adnarevrednuecnaraelC )mc03(sehcni21*
‡
Permitted only if veranda, porch, deck, or balcony is fully open on a
†
)m31.2(teef7)m31.2(teef7
‡
01nihtiwfievoba)mc19(teef3
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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 6
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