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INSTALLATION INSTRUCTIONS
High Efficiency 90+ Condensing Gas Furnace
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
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.
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 edi-
tion) 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.
# 47860A005
G1D91BT, CG90TB, & G1D93BT
WARNING
TABLE OF CONTENTS
SAFETY ................................................. 2
INSTALLATION ...................................... 3
START-UP ............................................ 21
OPERATION ........................................ 22
MAINTENANCE ................................... 24
REPAIR PARTS ................................... 25
WIRING DIAGRAMS............................ 27
A Lennox International Company
*47860A005*
IMPORTANT
Manufactured By
A.A.C.
421 Monroe Street
Bellevue, OH 44811
Page 1
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Summary of Contents for Lennox G1D91BT
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Page 1: Table Of Contents
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 informa- tion, consult a qualified installer, service agency, or the gas supplier. -
Page 2: Safety
SAFETY WARNING The following is a list of safety rules and precautions that In the State of Massachusetts: must be followed when installing this furnace. This product must be installed by a licensed 1. Use only with the type of gas approved for this furnace. -
Page 3: Installation
155°F. G1D91BT, G1D93BT, and CG90TB furnaces may be installed as upflow or horizontal furnaces. When installed horizon- tally, the installer must install a sheet metal screw to retain the upper door as shown in Figure 1. - Page 4 G1D91BT, G1D93BT, and CG90TB models installed in the horizontal position are approved for attic installations. If the WARNING furnace is to be installed in an attic or other insulated Insufficient combustion air can cause head- space, it must be kept free and clear of insulating materials.
- Page 5 Excessive exposure to contaminated combustion air will result in safety and performance related problems. The G1D91BT, G1D93BT, and CG90TB models can be installed recommended source of combustion air is outdoor air. as either direct vent or non-direct vent units. A direct vent...
- Page 6 WARNING Piping and Fitting Specifications If at any time in the future the installation of t t i 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.
- Page 7 Concentric Vent Kit Vent Tables A concentric vent kit (model ACVK2) is available for use (numbers in inches unless specified otherwise) when installing this furnace as a direct vent furnace and the Minimum Pipe Diameter air intake and vent pipe are to be run through the same hole, 40,000 –...
- Page 8 Sidewall Vent Terminal Clearances (Direct Vented Furnaces) Vent Terminal Air Supply Inlet Area Where Terminal Is Not Permitted a i l < a i l < a i l > a i l > < < a i l > a i l >...
- Page 9 Sidewall Vent Terminal Clearances (Non-Direct Vented Furnaces) Vent Terminal Air Supply Inlet Area Where Terminal Is Not Permitted a i l < a i l > < a i l > y l t i t r a l i t i f f h t i l a t...
- Page 10 Upflow Direct Vent Installation furnace, at a minimum pitch of 1/4" per foot of run, to prevent accumulation of condensate. An inlet air restrictor plate (see Figure 2 on page 5) is supplied with this furnace and can be found in the plastic bag containing Do not cement air intake into the connector on burner these Installation Instructions and the User’s Information Manual.
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Page 11: Horizontal Venting
Upflow Non-Direct Vent Installation Upflow Non-Direct Vent An inlet air restrictor plate (see Figure 2 on page 5) is Vertical Venting 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. -
Page 12: Vertical Venting
these areas, moisture in the flue gases may condense and Do not cement air intake into the connector on burner freeze on the air intake if this height is reduced. In milder box. Use high temperature RTV silicone sealant so climates, this may be reduced to a minimum of 6". - Page 13 Prime the trap system by slowly pouring 1 cup of water down For horizontal venting, refer to Figure 13. For vertical venting, the vent pipe. On initial start-up of the unit, some of the refer to Figure 14. The vent pipe on horizontal runs must water used to prime the trap system may run down into the slope upward, away from the furnace, at a minimum pitch of combustion blower and cause noise.
- Page 14 Horizontal Venting – Low Clearance Installations can result in spillage of flue products into the living space, the formation of condensate, leakage, etc. See the WARNING Vent pipe on horizontal runs must slope upward, away from box below for proper test procedure. the furnace, at a minimum pitch of 1/4"...
- Page 15 Condensate Disposal Installation Tilt Unit Forward The condensate drain should be routed directly to a locally acceptable disposal area. The condensate drain line 1/4" Max should not be run directly to the outdoors especially in colder climates where temperatures may cause the condensate to freeze in the drain line.
- Page 16 4. Connect a length of 3/4" PVC pipe (3' minimum) to the trap assembly (see Figure 21). Tilt Unit Forward 5. Install 3/4" tee (supplied) as shown in Figure 21. " 1/4 Max. Completing Condensate Drain Installation Figure 22 Insert Plugs 3/4"...
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Page 17: Upflow Installation
Condensate Drain Trap Installation – Completing Condensate Tight Clearance Below Unit Drain Installation " 3/4 Tee " 3/8 Vinyl Hose (supplied) Be sure to avoid double-trapping the vinyl hose. Hose must be installed as shown. Figure 25 6. From the tee, connect the drain to disposal area. The top of the tee must be left open for proper condensate Do not install trap assembly any farther than 10"... - Page 18 Horizontal Installation Circulating Air Supply The unit is shipped from the manufacturer with a black When the furnace is installed so that the supply ducts hose connected to the pressure switch. The other end of carry air circulated by the furnace to areas outside the the hose must be connected to the external drain trap.
- Page 19 Gas supply piping should be installed in accordance with The furnace must be isolated from the gas supply piping local codes and the regulations of the utility. Piping must be system by closing the individual manual shutoff valve of adequate size to prevent undue pressure drop. Consult during any pressure testing of the gas supply piping the local utility or gas supplier for complete details on special system at test pressure equal to or less than 1/2 psig...
- Page 20 Filters are not supplied with CG90TB series furnaces but and “NEUTRAL”) must be observed to ensure that their use if required. G1D91BT and G1D93BT furnaces come safety controls provide the protection intended. with a filter rack and cleanable 16" x 25" x 1/2" filter. (Models...
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Page 21: Start-Up
START-UP Minimum Filter Requirements Lighting Instructions For Your Safety, Read Before Operating f r i WARNING If you do not follow these instructions exactly, a fire or explosion may result causing prop- erty damage, personal injury, or loss of life. These furnaces are equipped with an ignition device which automatically lights the burners. -
Page 22: Operation
3. Move the gas control knob to the “ON” position. Use shuts off after a 15-second post-purge delay. The circulating only your hand to turn the gas control knob; never use air blower will continue to operate until the user-selectable tools. - Page 23 Primary Limit Control Gas input must never exceed the value shown on the furnace rating plate. The furnace is equipped for rated This is a normally closed control that opens if abnormally input at manifold pressures of 3.5" W.C. for natural gas or high circulating air temperatures occur.
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Page 24: Maintenance
and Table 4. Typical manifold set point for installations at MAINTENANCE altitudes from 0 to 4500 feet above sea level is 10.0" W.C. Temperature Rise WARNING ELECTRICAL SHOCK, FIRE, Check the temperature rise and, if necessary, adjust blower speed to maintain temperature rise within the range shown OR EXPLOSION HAZARD on the unit rating plate. -
Page 25: Control System Diagnostics
The furnace has a built-in, self-diagnostic capability. If a Main Burners system problem occurs, a fault code is shown by an LED Light the burners and allow to operate for a few minutes to on the control board. The control continuously monitors its establish normal burning conditions. - Page 26 Blower motor capacitor Burner Group Gas manifold Main burner orifices Main burners Accessories ALPKT572 Natural Gas to Propane Conversion Kit (G1D91BT and CG90TB) ALPKT574 Natural Gas to Propane Conversion Kit (G1D93BT) AFILTHA7 Single Side Filter Frame Kit AFILT524 Side Return Filter Kit...
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Page 27: Wiring Diagrams
Connection Diagram P/N 45198-006 Figure 35 # 47860A005 Page 27... - Page 28 Schematic Diagram P/N 45198-006 Figure 36 Page 28 # 47860A005...
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