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INSTALLATION INSTRUCTIONS
G1D80BT, G1D80BR, G2D80BT, & G2D80BR
Improper installation, adjustment, alteration, service, or maintenance can cause
injury or property damage. Refer to this manual. For assistance or additional infor-
mation, consult a qualified installer, service agency, or the gas supplier.
WARNING
Do not store combustible materials, includ-
ing 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.
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 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.
# 45465J004
80% Gas Furnace
WARNING
IMPORTANT
TABLE OF CONTENTS
INSTALLATION....................................... 2
START-UP ............................................ 18
OPERATION ........................................ 19
MAINTENANCE ................................... 22
REPAIR PARTS .................................... 23
WIRING DIAGRAMS ............................ 25
Manufactured By
A.A.C.
A Lennox International Company
421 Monroe Street
Bellevue, OH 44811
*45465J004*
Page 1
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Summary of Contents for Lennox G1D80BT
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Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS G1D80BT, G1D80BR, G2D80BT, & G2D80BR 80% Gas Furnace WARNING Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional infor- mation, consult a qualified installer, service agency, or the gas supplier. -
Page 2: Important Safety Information
G1D80BT and G2D80BT models may be installed as upflow furnaces or horizontal furnaces. G1D80BR and G2D80BR models may be installed as counterflow (downflow) furnaces or horizontal furnaces. -
Page 3: Minimum Clearances To Combustibles
Figure 2. Where servicing clearances are greater than clearances to combustibles, servicing clearances take precedence. G1D80BT, G2D80BT, and horizontally installed G1D80BR and G2D80BR models may be installed on wood flooring, but shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring. - Page 4 the combustion air and ventilating air must enter and leave CAUTION the space through two permanent openings of equal area (see Figure 3). One opening shall be located within 12" of Do not use the furnace as a heater in a the ceiling and the other within 12"...
- Page 5 Equipment in Confined Space Equipment in Confined Space All Air from Outside All Air from Outside (Inlet Air from Crawl Space and (All Air Through Horizontal Ducts) Outlet Air to Ventilated Attic) Chimney or Chimney or Gas Vent Gas Vent Water Heater Ventilation Louvers (Each end of attic)
- Page 6 certified as a direct vent using outside air for combustion or it can use air from inside the structure. See Figures 14 – 16 Inlet Air Restrictor Plate Placement on page 11 for optional outside combustion air applications. The furnace is shipped with the air inlet pipe terminated to the top panel for either inside or outside combustion air.
- Page 7 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 8 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 9 Vertical Venting (Using Inside Air for Combustion) Vent Through Ceiling 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”...
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Page 10: Masonry Chimney Venting
Masonry Chimney Venting Factory-Built Chimney Venting Liner Factory-Built Chimney Cleanout Masonry Chimney Cleanout Figure 12 Figure 13 Do not cement air intake into the connector on burner 12. Where local experience indicates that condensate box. Use high temperature RTV silicone sealant so may be a problem, the vent shall be constructed to intake pipe can be removed if service is required. - Page 11 Typical Installation Optional Outside Air Vertical Vent with Outdoor Fresh Air 16” Min. Gable Vent Max. 65’* 24” Max. Approved Vent 6” Min. System Keep inlet away from Joist and Insulation obstructions PVC Inlet 12” Min. and maximum Pipe snow level See Chart Soffit Vents...
- Page 12 Upflow Installations ANSI Z223.1/NFPA 54 (latest edition) and/or the CSA B149.1, Natural Gas and Propane Installa- G1D80BT and G2D80BT series furnaces can be installed tion Codes. as upflow units with either a side or bottom air return. For 9. After it has been determined that each appliance...
- Page 13 A filter rack and cleanable 16" x 25" x 1/2" filter are recess into the floor joists and the base should rest on supplied with each G1D80BT and G2D80BT furnace. all four outside flanges. (Models designed for more than 1600 CFM nominal air delivery include two of each.) The filter rack is to be...
- Page 14 4. Install the filter(s) in the rack(s), mesh side of filter Minimum Filter Requirements towards furnace. Filter Rack Installation f r i Filter Rack Mounting Hole Screw Filter Rack Front of Cabinet Corner Embossments Figure 19 1. The Airflow Descriptor is the two digits following the “D”...
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Page 15: Insert Location
Gas Connection Insert Manual Location Gas Valve 1/8" NPT Plugged Union Tapping Drip Leg Upflow/Counterflow Installation Figure 21 Manual Gas Valve 1/8" NPT Plugged Gas supply piping should be installed in accordance with Horizontal Union Tapping Installation local codes and the regulations of the utility. Piping must be of adequate size to prevent undue pressure drop. - Page 16 Electrical Wiring 10 minutes). The furnace will start on 1 stage heat and stay at 1 stage heat for the duration of the selected time before switching to 2 stage heat. WARNING W1 on the control board must be connected to W1 on the Risk of electrical shock.
- Page 17 (see Figure 23) from the NONE position to either the 5 or 10 minute setting. G1D80BR and G1D80BT Models – To twin two G1D80BR Connect rest of wiring as shown in Figure 24 or Figure...
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Page 18: Start-Up
START-UP 3. Move the gas control knob to the “ON” position. Use only your hand to turn the gas control knob. Never use Lighting Instructions tools. If the knob will not turn by hand, don’t try to repair it; call a qualified service technician. Force or For Your Safety, Read Before Operating attempted repair may result in a fire or explosion. -
Page 19: Operation
OPERATION delay, the control energizes the cooling fan speed. If the fan is already energized, it remains running and does not de- Sequence of Operation (G1D80BR and G1D80BT energize for the 1-second cooling fan “on” delay. Models) The call for cooling has priority over continuous fan... - Page 20 continues to run according until the selected blower “off” can be caused by a restricted heat exchanger causing main delay time (factory shipped at 120 seconds) ends. burner flame to “roll out” into vestibule area or burner box. In the event the unit loses ignition, the control will attempt This switch must be manually reset by pushing the button to recycle up to five times before it goes into a 1-hour on top to restore furnace operation.
- Page 21 Gas input must never exceed the value shown on the furnace rating plate. G1D80BR and G1D80BT units are 2. Set low-fire (1 stage) setting by turning hex adjust- equipped for rated input at manifold pressures of 3.5"...
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Page 22: Maintenance
MAINTENANCE Manifold Pressure vs. Altitude G1D80BR and G1D80BT Models WARNING ELECTRICAL SHOCK, FIRE, i t l OR EXPLOSION HAZARD ) . t Failure to follow the safety warnings exactly t f / t f / could result in dangerous operation, serious injury, death, or property damage. -
Page 23: Repair Parts
Side Return Filter Kit (upflow models) AFILT525 Return Filter Kit (counterflow models) Figure 27 AFILT529 Bottom Return Filter Kit ATWIN579 Twinning Kit (G1D80BR and G1D80BT models only) AFOSL443 Fossil Fuel Kit ABASE512 Combustible Floor Base (17.5" cabinets) ABASE568 Combustible Floor Base (21.0" cabinets) ABASE569 Combustible Floor Base (24.5"... -
Page 24: Control System Diagnostics
The flash codes are presented in Tables 5 and 6. Failure Codes – Red LED Table 6 G1D80BR and G1D80BT Models connection diagrams on page 25 and 27). When the pushbutton switch is pressed and released, the control flashes the stored fault codes. The most recent fault code is flashed first;... -
Page 25: Wiring Diagrams
G1D80BT, G1D80BR Connection Diagram P/N 45198-006 Figure 28 # 45465J004 Page 25... - Page 26 G1D80BT, G1D80BR Schematic Diagram P/N 45198-006 Figure 29 Page 26 # 45465J004...
- Page 27 INDUCED FLAME HOT SURFACE PRESSURE DRAFT ROLLOUT PRESSURE PRESSURE SWITCH SENSOR IGNITER SWITCH BLOWER SWITCH SWITCH (DRAIN) (IF USED) ROLLOUT (HIGH) GAS VALVE (LOW) (IF USED) SWITCH C HI WHT/BLK 2-PIN CONNECTOR MAIN LIMIT RED/BLK 120/1/60 NEUTRAL GROUND NOTE 3 INTERLOCK SWITCH TRANSFORMER...
- Page 28 G2D80BT, G2D80BR Wiring Schematic P/N 45604-005 Figure 31 Page 28 # 45465J004...
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