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G1D91BU, G1D91BT, G1D93BU, G1D93BT & G1D93BC
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 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.
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.
506305-01
INSTALLATION INSTRUCTIONS
With System Sentry™ Control System
Save these instructions for future reference
WARNING
SAFETY ............................................................... 2
INSTALLATION .................................................... 3
START-UP .......................................................... 26
OPERATION ...................................................... 27
MAINTENANCE ................................................. 30
REPAIR PARTS .................................................. 31
CONTROL SYSTEM DIAGNOSTICS ................. 32
WIRING DIAGRAMS .......................................... 33
A Lennox International Inc. Company
WARNING
Issue 0938
TABLE OF CONTENTS
Manufactured By
Allied Air Enterprises Inc.
215 Metropolitan Drive
West Columbia, SC 29170
*506305-01*
Page 1 of 36
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Summary of Contents for Lenoxx G1D91BU
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Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS G1D91BU, G1D91BT, G1D93BU, G1D93BT & G1D93BC High Efficiency 90+ Condensing Gas Furnace With System Sentry™ Control System Save these instructions for future reference 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. -
Page 2: Safety
IMPORTANT SAFETY INFORMATION The following is a list of safety rules and precautions that 7. Always install furnace to operate within the furnace’s must be followed when installing this furnace. intended temperature-rise range with a duct system which has an external static pressure within the 1. -
Page 3: Installation
155°F. procedure described in the manuals. To avoid property damage caused by condensate drain G1D91BU and G1D93BU models shall be installed only as blockage, install a field-fabricated auxiliary drain pan with a upflow furnaces. G1D93BC models shall be installed only separate drain line to the outside under the entire furnace as counterflow (downflow) furnaces. - Page 4 • Return air temperature range between 60°F and 80°F G1D91BU, G1D91BT, G1D93BU and G1D93BT models may must be maintained. be installed on wood flooring but shall not be installed directly on carpeting, tile, or any other combustible material. • Air filters must be installed in the system and must be maintained during construction.
- Page 5 However, the use of indoor air in most applications is acceptable if the following guidelines are followed: G1D91BU, G1D91BT, G1D93BU, G1D93BT and G1D93BC models can be installed as either direct vent or non-direct 1. If the furnace is installed in a confined space, it is vent units.
- Page 6 The inlet restrictor plate must be installed in the air inlet in When a furnace is installed as direct vent, provisions for one of three ways: ventilation air should follow the same requirements as if installed as non-direct vent. Proper ventilation air is •...
- Page 7 cement. The cement shall show no gelation, stratification, A concentric vent kit (see Accessories section on page 31 for or separation that cannot be removed by stirring. correct kit) is available for use when installing this furnace as a direct vent furnace and the air intake and vent pipe are to be Refer to Table 2 for approved piping and fitting materials.
- Page 8 Vent Tables * (numbers in inches unless specified otherwise) Minimum Pipe Diameter 45,000 – 75,000 BTU/HR Models Vent Pipe Number of 90° Elbows Length (ft.) 1.5 1.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 NR NR NR NR NR...
- Page 9 Sidewall Vent Terminal Clearances (Direct Vented Furnaces) A ** Minimum 12” (30 cm) above grade or 12” (30 cm) above average snow accumulation. Vent Terminal Air Supply Inlet Area Where Terminal Is Not Permitted In accordance with the current CSA B149.1, Natural Gas and ‡...
- Page 10 Sidewall Vent Terminal Clearances (Non-Direct Vented Furnaces) A ** Minimum 12” (30 cm) above grade or 12” (30 cm) above average snow accumulation. Vent Terminal Air Supply Inlet Area Where Terminal Is Not Permitted In accordance with the current CSA B149.1, Natural Gas and ‡...
- Page 11 G1D91BU, G1D91BT, G1D93BU and G1D93BT Upflow Do not cement air intake into the connector on burner Models – Direct Vent Installation box. Use high temperature RTV silicone sealant so An inlet air restrictor plate (see Figure 2 on page 5) is supplied with intake pipe can be removed if service is required.
- Page 12 G1D91BU, G1D91BT, G1D93BU & G1D93BT Upflow Models – Non-Direct Vent Installation Upflow Non-Direct Vent Vertical Venting An inlet air restrictor plate (see Figure 2 on page 5) is supplied (G1D91BU, G1D91BT, G1D93BU & G1D93BT Only) with this furnace and can be found in the plastic bag containing these Installation Instructions and the User’s...
- Page 13 G1D93BC Counterflow Models – Direct Vent Installation Do not cement air inlet pipe. Use high temperature RTV An inlet air restrictor plate (see Figure 2 on page 5) is supplied with silicone sealant so inlet pipe can be removed if service this furnace and can be found in the plastic bag containing these is required.
- Page 14 G1D93BC Counterflow Models – Non-Direct Vent Counterflow Non-Direct Vent Vertical Venting Installation (G1D93BC Only) 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 these Installation Instructions and the User’s Information Manual.
- Page 15 For horizontal venting, refer to Figure 15. For vertical venting, Do not cement air intake into the connector on burner refer to Figure 16. It is permissible to run the vent vertically box. Use high temperature RTV silicone sealant so through the roof and terminate it as shown in Figure 16, and intake pipe can be removed if service is required.
- Page 16 Prime the trap system by slowly pouring 1 cup of water down For horizontal venting, refer to Figure 17. For vertical venting, the vent pipe. On initial start-up of the unit, some of the refer to Figure 18. 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 17 G1D91BT & G1D93BT Horizontal Models-Horizontal result in spillage of flue products into the living space, the Venting – Low Clearance Installations 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 18 Condensate Disposal Installation The condensate drain should be routed directly to a locally Tilt Unit Forward acceptable disposal area. The condensate drain line 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 19 4. Connect a length of 3/4" PVC pipe (3' minimum) to the Tilt Unit Forward trap assembly (see Figure 25). 5. Install 3/4" tee (supplied) as shown in Figure 25. Completing Condensate Drain Installation Figure 26 Insert Plugs 3/4" Tee 3/8"...
- Page 20 Drain Pressure Switch Connection Figure 29 (for G1D91BT and G1D93BT multi-position units only. The G1D91BU/G1D93BU dedicated upflow and G1D93BC dedicated counterflow units do not require a drain switch). 6. From the tee, connect the drain to disposal area. The top of the tee must be left open for proper condensate drainage.
- Page 21 Pressure Switch Connection Pressure Switch Connection Horizontal Installation – R to L Airflow Upflow Installation Figure 32 Figure 31 Pressure Switch Connection Horizontal Installation – L to R Airflow Be sure that the pressure switch hose does not form a trap to hold condensation that could form from the flue gas.
- Page 22 Circulating Air Supply When the furnace is installed so that the supply ducts carry Combustible Floor Installation air circulated by the furnace to areas outside the space (G1D93BC Counterflow Models Only) containing the furnace, the return air shall be handled by a duct or ducts sealed to the furnace casing and terminated outside the space containing the furnace.
- Page 23 Gas supply piping should be installed in accordance with local Gas Piping Connection codes and the regulations of the utility. Piping must be of adequate size to prevent undue pressure drop. Consult the Manual Gas Valve local utility or gas supplier for complete details on special 1/8"...
- Page 24 Table 3. Filters are not supplied with G1D93BC series furnaces. Other filter accessories are also available from the G1D91BU, G1D91BT, G1D93BT AND G1D93BU Upflow manufacturer including a full line of indoor air quality Models products.
- Page 25 Thermostat Filter Rack Installation Install a room thermostat according to the instructions furnished with it. Select a location on an inside wall that is Filter Rack Mounting Hole not subject to drafts, direct sunshine, or other heat sources. The initial heat anticipator setting should be equal to the Screw total current draw of the control circuit.
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Page 26: Start-Up
START-UP To Start Furnace: Lighting Instructions CAUTION For Your Safety, Read Before Operating Be sure the manual gas control has been in the “OFF” position for at least 5 minutes before starting the unit. Do not attempt to manually light the burners. WARNING If you do not follow these instructions exactly, a fire or 1. -
Page 27: Operation
After a 1-second cooling “on” delay, the control energizes the cooling fan speed. If the fan is already G1D91BU and G1D93BU upflow models do not include an energized, it remains running and does not de-energize for auxiliary limit control. - Page 28 is operating correctly. natural gas and 13" W.C. for propane. Integrated Ignition/Blower Control Board Gas input must never exceed the value shown on the furnace The integrated ignition/blower control board operates all rating plate. The furnace is equipped for rated input at functions of the furnace and any accessories connected to it.
- Page 29 High Altitude In both the United States and Canada, this furnace is approved for operation at altitudes from 0 to 4500 feet above sea level without any required modifications. From 4500 to 7500 feet, the gas manifold pressure needs to be adjusted according to the information shown in Table 4 on page 29.
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Page 30: Maintenance
MAINTENANCE Burners Light the burners and allow to operate for a few minutes to establish normal burning conditions. Observe the burner flames. Compare this observation to Figure 39 to determine if WARNING proper flame adjustment is present. Flame should be ELECTRICAL SHOCK, FIRE, predominantly blue in color and strong in appearance. -
Page 31: Repair Parts
ACCESSORIES ALPKT572 Natural Gas to Propane Conversion Kit The following repair parts are available from the local (G1D91BU & G1D91BT) distributor. When ordering parts, include the complete furnace model number and serial number which are printed ALPKT574 Natural Gas to Propane Conversion Kit on the rating plate located on the furnace. -
Page 32: Control System Diagnostics
SYSTEM SENTRY™ CONTROL DIAGNOSTICS Failure Codes Troubleshooting The following visual checks should be made before troubleshooting: 1. Check to see that the power to the furnace and the integrated ignition/blower control board is on. 2. The manual shutoff valves in the gas line to the furnace must be open. -
Page 33: Wiring Diagrams
LINE VOLTAGE - FACTORY HOT SURFACE LINE VOLTAGE - FIELD IGNITOR LOW VOLTAGE - FACTORY LOW VOLTAGE - FIELD INTERLOCK SWITCH CIRCULATION BLOWER WHT (NEUT) RED (LO) ORN (MED/LO) BLU (MED) YEL (MED/HI) BLK (HIGH) INDUCED NOT ON ALL MODELS DRAFT BLOWER BLK/WHT STRIPE... - Page 34 Schematic Diagram P/N 45198-006 Figure 41 Page 34 of 36 Issue 0938 506305-01...
- Page 35 FOR MASSACHUSETTS ONLY IMPORTANT For Side Wall Horizonal Venting The installation must comply with 248 CMR 5.08 Modifications to sections of NFPA-54, Chapter 10 as listed below. * “a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be...
- Page 36 ** “c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include: 1.
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