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Lennox G1D91BU User Manual

Lennox G1D91BU
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INSTALLATION INSTRUCTIONS
G1D91BU, G1D93BC, G1D93BU, CG90CB, & CG90UB
High Efficiency 90+ Condensing Gas Furnace
Manufactured By
A.A.C.
A Lennox International Company
421 Monroe Street
Bellevue, OH 44811
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.
IMPORTANT
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.
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.
WARNING
TABLE OF CONTENTS
SAFETY ................................................. 2
INSTALLATION....................................... 3
START-UP ............................................ 19
OPERATION ........................................ 20
MAINTENANCE ................................... 23
REPAIR PARTS .................................... 24
CONTROL SYSTEM DIAGNOSTICS .. 25
WIRING DIAGRAMS ............................ 26
®
®
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Lennox G1D91BU Specifications

General IconGeneral
BrandLennox
ModelG1D91BU
CategoryFurnace
LanguageEnglish

Summary

Installation Instructions Overview

High Efficiency Condensing Gas Furnace Models

Overview of the high-efficiency condensing gas furnace models covered.

Critical Installation Safety Warnings

Critical warnings about installation, adjustment, alteration, service, or maintenance.

Furnace Safety Precautions

General Installation Safety Rules

Essential safety rules and precautions to follow during furnace installation.

Massachusetts Specific Installation Requirements

Special installation requirements for furnaces in the State of Massachusetts.

Furnace Installation Site Selection

Approved Furnace Location Criteria

Guidance on selecting an appropriate and safe location for furnace installation.

Construction Site and Combustible Material Hazards

Precautions regarding installation in buildings under construction and combustible materials.

Furnace Installation Clearance Requirements

Specifies required clearances around the furnace for safe operation and servicing.

Combustion and Ventilation Air Supply

Unconfined Space Airflow Requirements

Guidelines for supplying combustion and ventilation air in unconfined spaces.

Confined Space Airflow Requirements

Guidelines for supplying combustion and ventilation air in confined spaces.

Risks of Contaminated Combustion Air

Discusses risks and recommendations for combustion air quality.

Venting System Installation Guidelines

High Efficiency Furnace Venting Requirements

Explains high-efficiency venting and requirements for direct/non-direct vent.

Inlet Air Restrictor and Flue Pipe Screen Installation

Details the installation of inlet air restrictor plates and flue pipe screens.

Piping and Venting Materials Specifications

Approved Materials for Vent and Air Piping

Lists approved materials for vent and air intake piping systems.

Category IV Furnace Venting System Limitations

Specifies limitations for connecting Category IV furnaces to venting systems.

Vent Pipe Sizing and Length Calculation

Provides guidance on selecting appropriate vent pipe size based on length and elbows.

Vent Pipe Sizing Tables and Horizontal Venting

Minimum Vent Pipe Diameter Charts

Tables detailing minimum vent pipe diameter requirements for different BTU/HR models and elbows.

Horizontal Vent Termination Safety Considerations

Notes on vent termination locations and potential hazards in horizontal venting.

Sidewall Vent Terminal Clearances (Direct Vent)

Direct Vent Terminal Clearance Requirements

Specifies minimum clearances for direct vent terminals in Canadian and US installations.

Sidewall Vent Terminal Clearances (Non-Direct Vent)

Non-Direct Vent Terminal Clearance Requirements

Specifies minimum clearances for non-direct vent terminals in Canadian and US installations.

Upflow Direct Vent Installation Guide

Upflow Direct Vent Horizontal Venting Procedure

Installation details for horizontal direct venting of upflow models.

Upflow Direct Vent Vertical Venting Procedure

Installation details for vertical direct venting of upflow models.

Upflow Non-Direct Vent Installation Guide

Upflow Non-Direct Vent Horizontal Venting Procedure

Installation details for horizontal non-direct venting of upflow models.

Upflow Non-Direct Vent Vertical Venting Procedure

Installation details for vertical non-direct venting of upflow models.

Counterflow Direct Vent Installation Guide

Counterflow Direct Vent Horizontal Venting Procedure

Installation details for horizontal direct venting of counterflow models.

Counterflow Direct Vent Vertical Venting Procedure

Installation details for vertical direct venting of counterflow models.

Counterflow Non-Direct Vent Installation Guide

Counterflow Non-Direct Vent Horizontal Venting Procedure

Installation details for horizontal non-direct venting of counterflow models.

Counterflow Non-Direct Vent Vertical Venting Procedure

Installation details for vertical non-direct venting of counterflow models.

Venting System Maintenance and Safety

Existing Venting System Replacement Considerations

Advice on replacing existing venting systems with new furnaces.

Condensate Disposal System Installation

Instructions for installing the condensate drain line and disposal system.

Carbon Monoxide Poisoning Hazard Warning

Critical safety warning regarding improper venting and carbon monoxide.

Airflow, Ducting, and Gas Supply

Circulating Air Supply for Ducted Systems

Guidelines for return air ducting when the furnace supplies air to remote areas.

Counterflow Model Combustible Floor Duct Connection

Instructions for connecting ducts for counterflow models on combustible flooring.

Initial Gas Supply and Piping Requirements

General requirements for gas supply piping installation and conversion.

Gas Piping Installation and Safety

Gas Supply Piping Standards and Practices

Details on gas piping installation in accordance with local codes and utility regulations.

Gas Piping Connection Diagram and Components

Illustrates the gas piping connection points and components.

Fire or Explosion Hazard Warning during Gas Work

Critical safety warning regarding fire or explosion hazards during gas piping.

Electrical Wiring and Filter Installation

Electrical Safety and Wiring Practices

Safety precautions and wiring guidelines for electrical connections.

Filter Rack Installation Procedure

Instructions for installing the filter rack on upflow models.

Furnace Filter Requirements Overview

Information on furnace filters and their installation for various models.

Furnace Accessories and Control Connections

Minimum Filter Requirements Table

Specifies minimum filter sizes and quantities based on airflow.

Electronic Air Cleaner and Humidifier Connections

Details connections for electronic air cleaners and humidifiers.

Twinning and Thermostat Installation Guidance

Information on twinning furnaces and thermostat installation.

Furnace Start-Up and Shutdown Procedures

Lighting Instructions and Gas Leak Safety Protocols

Critical safety instructions for lighting and what to do if gas is detected.

Step-by-Step Furnace Start-Up Process

Step-by-step procedure for starting the furnace operation.

Step-by-Step Furnace Shutdown Process

Step-by-step procedure for safely shutting down the furnace.

Furnace Operation and Control System Overview

Sequence of Operation for Heating, Fan, and Cooling

Describes the furnace's operational sequence for heating, fan, and cooling modes.

Key Furnace Control Components Explained

Explains the function of key control components like pressure and limit switches.

Gas Input and Temperature Adjustment Procedures

Checking and Adjusting Furnace Gas Input

Procedures for measuring and adjusting gas input to the furnace.

Adjusting Blower Speed for Temperature Rise

How to adjust blower speed to maintain the correct temperature rise.

Furnace Operation at High Altitudes

Guidelines for operating the furnace at high altitudes.

Manifold Pressure and Altitude Correlation

Manifold Pressure vs. Altitude Data Table

Provides manifold pressure settings for natural gas and propane at various altitudes.

Routine Furnace Maintenance Tasks

General Maintenance Safety Precautions

Essential safety precautions before performing any maintenance tasks.

Furnace Filter Inspection and Cleaning

Recommendations for checking and maintaining furnace air filters.

Main Burner Flame Inspection and Cleaning

How to inspect main burner flames for proper operation and appearance.

Condensate Drain System Maintenance

Guidance on checking and maintaining the condensate drain system.

Furnace Repair Parts and Accessories

List of Available Repair Parts by Component Group

Lists available replacement parts categorized by functional groups.

Furnace Accessory Kit Options and Usage

Details available accessory kits for conversion, filters, and twinning.

Control System Diagnostics and Fault Codes

Initial Troubleshooting Visual Checks

Initial visual checks to perform before troubleshooting system issues.

Understanding Control Board Failure Codes

Explains fault codes indicated by the control board's LED for diagnostics.

Managing Fault Code History

How to view and clear the stored fault code history on the control board.

Furnace Electrical Wiring Diagrams

Furnace Electrical Connection Diagram Details

Illustrates the electrical connection points and wiring for the furnace.

Furnace Electrical Schematic Diagram

Detailed Furnace Electrical Schematic

Provides a detailed schematic of the furnace's electrical system and components.

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