Lennox G1N80BU, GIN80BT, GIN80BR, CG80UB, CG80RB Installation Instructions Manual
...
INSTALLATION INSTRUCTIONS
®
G1N80BU, GIN80BR, GIN80BT, CG80UB, CG80RB, & CG80TB
80% Gas-Fired 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.
W ARNING
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 ...................................... 2
START-UP ............................................ 14
OPERATION ........................................ 15
MAINTENANCE................................... 16
T ABLE OF CONTENTS
CONTROL SYSTEM DIAGNOSTICS .. 18
W ARNING
REPAIR PARTS ................................... 18
This furnace is not approved for installation in
a mobile home. Do not install this furnace in a
WIRING DIAGRAMS ............................ 19
mobile home. Installation in a mobile home
could result in actions that could cause property damage, personal injury, or death.
A Lennox International Company
Manufactured By
A.A.C.
421 Monroe Street
Bellevue, OH 44811
®
IMPORT ANT
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.
# 45464K003 Page 1
IMPORT ANT SAFETY INFORMATION
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 beginning on page 4 of
these instructions.
4. Combustion products must be discharged outdoors.
Connect this furnace to an approved vent system
only, as specified in Venting beginning on page 6 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 Supply and Piping
beginning on page 12 of these instructions.
6. 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 16 of these instructions. See furnace rating
plate.
7. 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 8
of these instructions.
8. A gas-fired furnace for installation in a residential
garage must be installed as specified in the Loca-
tion section on page 3 of these instructions.
9. The furnace is not to be used for temporary heating of
buildings or structures under construction as specified
on page 4 of these instructions.
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 levertype gas shutoffs are used, they shall be T-handle
type.
INSTALLATION
These instructions must be placed on or near the
furnace in a conspicuous place.
This furnace is design certified by CSA International as a
Category I furnace using air from inside the structure for
combustion. The combustion system is fan-assisted, which
means it is equipped with an integral mechanical means to
draw products of combustion through the heat exchanger.
G1N80BT and CG80TB models may be installed as upflow
or horizontal furnaces. G1N80BR and CG80RB models
may be installed as counterflow (downflow) or horizontal
furnaces. When installed horizontally, the installer must
install a sheet metal screw to retain the upper door as
shown in Figure 1.
G1N80BU and CG80UB models must be installed only as
upflow furnaces.
Never install any furnace on its back.
Horizontal Installations
Figure 1
# 45464K003Page 2
Inspection of Shipment
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This furnace is shipped in one package, completely
assembled and wired. The thermostat is shipped in a
separate carton when ordered.
Minimum Clearances to Combustibles
(all measurements in inches)
Upflow and Counterflow Installations
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.
Check the rating plate for correct model number, type of
gas, and input.
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.
All models are suitable for installation at reduced clearances to combustibles as noted in the tables in Figure 2.
Where servicing clearances are greater than clearances to
combustibles, servicing clearances take precedence.
G1N80BU, G1N80BT, CG80UB, and CG80TB models, and
horizontally installed G1N80BR and CG80RB models may
be installed on wood flooring, but shall not be installed
directly on carpeting, tile, or other combustible material
other than wood flooring.
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Horizontal Installations
(G1N80BR and CG80RB models)
Horizontal Installations
(G1N80BT and CG80TB models)
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G1N80BR and CG80RB models installed as counterflow
(downflow) units may be installed on combustible flooring
provided a special combustible floor base is used. Refer to
the Counterflow (Downflow) Installations section begin-
ning on page 10 for more information on using the special
base assembly.
Location
All models are suitable for closet or utility room installation.
The furnace must be installed so that electrical components are protected from water.
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.
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.
# 45464K003 Page 3
1
May be 2" when Type B-1 vent pipe is used.
2
May be 1" when Type B-1 vent pipe is used.
3
Where values greater than 0 are shown, may be 0"
when Type B-1 vent pipe is used.
Figure 2
G1N80BR, G1N80BT, CG80RB, and CG80TB 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. When a furnace is
installed in conjunction with an evaporator coil in an
attic or above a finished ceiling where condensate
overflow could result in property damage, a drain
pan should be provided under the units as specified
by most local building codes.
G1N80BR, G1N80BT, CG80RB, and CG80TB models may
be installed as suspended units in the horizontal position.
These furnaces are not designed for direct attachment of
suspension rods to the furnace casing.
However, in a building of unusually tight construction,
additional outdoor air should be provided.
Confined Space
The suspending means must be field fabricated, and
should consist of two “cradles” made by attaching two rods
to a length of angle iron or suitable gage steel. Locate the
cradles so that they are as close as possible to the ends
of the furnace (this will provide access for removal of
major components such as the blower assembly). Provide
enough clearance between the suspension rods and the
furnace to allow removal of access panels.
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.
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.”
Confined Space Installation/Air from Inside Structure
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 (see Figure 3).
Equipment in Confined Space
All Air From Inside
Chimney or
Gas Vent
Water
Heater
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.
Openings
Furnace
Note: Each opening shall have a free area of at least one square
inch per 1000 BTU per hour of the total input rating of all
equipment in the enclosure, but not less than 100 square
inches.
Figure 3
Confined Space Installation/Air from Outside Structure
If air from outside is brought in for combustion, the confined
space shall be provided with two permanent openings. One
opening shall be within 12" of the ceiling and one opening
within 12" of the floor. Several methods can be used to bring
the outside air in through these openings. The openings
shall open directly or by ducts with the outdoors, through
spaces (crawl space or attic) that freely open to the outdoors, or indirectly through vertical ducts (see Figures 4 and
5). If any of these methods are used, 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.
# 45464K003Page 4
Equipment in Confined Space
All Air from Out side
(Inlet Air from Crawl Sp ace and
Outlet Air to V entilated Attic)
Equipment in Confined Space
All Air from Out side
(All Air Through Horizontal Ducts)
Chimney or
Gas Vent
Furnace
Ventilation
Louvers
(For unheated
crawl space)
Note: The inlet and outlet air opening shall each have a free area of
at least one square inch per 4000 BTU per hour of the total
input rating of all equipment in the enclosure.
Ventilation Louvers
(Each end of attic)
Outlet
Air
Inlet
Air
Water
Heater
Figure 4
Equipment in Confined Space
All Air from Out side
(All Air Through V entilated Attic)
Chimney or
Gas Vent
Outlet Air
Furnace
Ventilation Louvers
(Each end of attic)
Inlet Air
(Ends 12”
above bottom)
Water
Heater
Chimney or
Gas Vent
Water Heater
Outlet Air
Furnace
Inlet Air
Note: Each air duct opening shall have a free area of at least one
square inch per 2000 BTU per hour of the total input rating of
all equipment in the enclosure. If the equipment room is
located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free
area of at least one square inch per 4000 BTU per hour of the
total input rating of all other equipment in the enclosure.
Figure 6
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).
Note: The inlet and outlet air opening shall each have a free area of
at least one square inch per 4000 BTU per hour of the total
input rating of all equipment in the enclosure.
Figure 5
Another option is to use horizontal combustion ducts (see
Figure 6). 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
# 45464K003 Page 5
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
This furnace has a fan-assisted combustion system
designed for vertical venting into a suitable chimney or
listed gas vent, and is classified as a Category I furnace
as shipped from the factory.
If this furnace is used to replace an existing furnace,
it is possible that the existing venting system is not
suitable for venting this furnace. Furthermore, the
existing venting system may have to be modified to
properly vent any other gas appliance, such as a water
heater, that remains connected to it. Carefully read the
Vertical Venting, Sidewall Venting, and Existing Vent
Systems sections that follow to determine proper venting
practices for the installation.
vent connector is permissible only in conditioned
space. Use Doublewall Type B vent pipe through
unconditioned space such as attics and crawl
spaces. The vent material used should be in accor-
dance with the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 (latest edition) or the CSA B149.1, Natural
Gas and Propane Installation Codes and local codes.
Fan-assisted combustion system Category I furnaces
shall not be vented into single wall metal vents.
4. The vent connector must have an upward slope toward
the chimney on all horizontal runs of at least 1/4" per
foot of horizontal run and should be supported by a
sheet metal strap. The vent pipe connection must be
secured to the induced draft blower outlet. A single
screw is sufficient. On G1N80BR and CG80RB models,
a hole in the door hook will allow access to the blower
outlet without removing the door hook.
5. All vents passing through floors, ceilings, and walls
must be firestopped according to the requirements of
the National Fuel Gas Code (see Figure 7).
Installation shall be in accordance with Parts 7 and 11 of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (latest
edition) and/or Section 7 and Appendix B of the CSA
B149.1, Natural Gas and Propane Installation Codes
(latest edition); local building codes; vent manufacturer
instructions; and these instructions.
IMPORT ANT
For 100K, 125K, and 150K BTUH input models,
the minimum vent connector diameter is 5". The
transition from 4" diameter flue outlet to 5"
diameter pipe must be made at the flue outlet.
Vertical Venting
Category I furnaces must be vented vertically or nearly
vertically. Common venting and multistory venting are
permitted when done in accordance with applicable codes,
such as local and national codes.
The venting system should be designed in accordance with
the “FAN” columns in the venting tables in the latest editions
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the
CSA B149.1, Natural Gas and Propane Installation Codes.
Vent Through Ceiling
Vent Through Floor
V ent Through W all
1. Consult local building codes for installation requirements.
2. The vent connector should be as short as possible with
the least number of elbows and angles to do the job.
3. It is recommended a minimum of 26 gauge galvanized
flue pipe be used. Use of single-wall vent pipe for the
Figure 7
# 45464K003Page 6
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