Lenoxx G1D91BU User manual

506305-01 Page 1 of 36Issue 0938
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TABLE OF CONTENTS
SAFETY ...............................................................2
INSTALLATION ....................................................3
START-UP..........................................................26
OPERATION ......................................................27
MAINTENANCE .................................................30
REPAIR PARTS..................................................31
CONTROL SYSTEM DIAGNOSTICS.................32
WIRING DIAGRAMS..........................................33
INSTALLATION INSTRUCTIONS
G1D91BU, G1D91BT, G1D93BU, G1D93BT & G1D93BC
High Efficiency 90+ Condensing Gas Furnace
With System Sentry™ Control System
Manufactured By
Allied Air Enterprises Inc.
A Lennox International Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
*506305-01*
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/NFPANo.70(latestedition)intheUnitedStates;CSAB149.1(latestedition)NaturalGasandPropaneInstallation
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
shouldbeconsultedbeforeinstallationismade. Suchapplicableregulationsorrequirementstakeprecedenceoverthegeneral
instructions in this manual.
WARNING
This furnace is not approved for installation in a mobile
home. Do not install this furnace in a mobile home.
Installationinamobilehomecould result in actions that
couldcausepropertydamage,personalinjury,ordeath.
WARNING
Donotstorecombustiblematerials,includinggasolineand
otherflammablevaporsandliquids,nearthefurnace,vent
pipe, or warm air ducts. The homeowner should be
cautioned that the furnace area must not be used as a
broomclosetorforanyotherstoragepurposes. Suchuses
may result in actions that could cause property damage,
personalinjury, or death.
WARNING
Improperinstallation,adjustment,alteration,service,ormaintenancecan cause injuryorpropertydamage.
Refer to this manual. For assistance or additional information, consult a qualified installer, service
agency, or the gas supplier.
WARNING

506305-01Page 2 of 36 Issue 0938
The following is a list of safety rules and precautions that
must be followed when installing this furnace.
1. Useonlywiththetypeofgasapprovedforthisfurnace.
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
VentilationAir section on page 4 of these instructions.
4. Adequateclearancemustbeprovided aroundthevent-
airintaketerminalsasspecifiedintheVenting section
beginning on page 5 of these instructions.
5. Combustion products must be discharged outdoors.
Connect this furnace to an approved vent system only,
asspecifiedintheVentingsectionbeginningonpage5
of these instructions.
6. Never test for gas leaks with an open flame. Use a
commerciallyavailablesoapsolutionmadespecifically
for the detection of leaks to check all connections, as
specified in Gas Supply and Piping beginning on
page 22 of these instructions.
IMPORTANT SAFETY INFORMATION
7. 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 28 of these instructions. See furnace rating
plate.
8. 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 CirculatingAir Supply on page 22
of these instructions.
9. A gas-fired furnace for installation in a residential
garagemustbe installedasspecified in the Location
section on page 3 of these instructions.
10. The furnace is permitted to be used for temporary
heatingofbuildingsorstructuresunderconstructionas
specified in the Location section beginning on page 3
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 lever-
type gas shutoffs are used, they shall be T-handle
type.

506305-01 Page 3 of 36Issue 0938
INSTALLATION
Theseinstructions must beplaced on ornear the furnacein
a conspicuous place.
The furnace design is certified by CSA International as a
Category IV furnace in compliance with the latest edition of
American National Standard Z21.47/CSA Standard 2.3 for
Gas-Fired Central Furnaces, for operation with natural gas
or propane. Consult the rating plate on the furnace for gas
type before installing.
The maximum hourly heat loss of space shall be calculated
in accordance with the procedure described in the current
manuals of Air Conditioning Contractors of America, or by
any other recognized method which is suitable for local
conditions, provided the results obtained are in substantial
agreementwith,and not lessthan, those obtainedusingthe
procedure described in the manuals.
G1D91BU and G1D93BU models shall be installed only as
upflow furnaces. G1D93BC models shall be installed only
as counterflow (downflow) furnaces.
G1D91BTandG1D93BTmodelsmaybeinstalledasupflow
orhorizontalright to leftorleftto rightairflowfurnaces. When
installed horizontally, the installer must install a sheet metal
screw to retain the upper door as shown in Figure 1.
Never install any furnace on its back.
To avoid property damage caused by condensate drain
blockage, install a field-fabricated auxiliary drain pan with a
separate drain line to the outside under the entire furnace
and drain system. Install according to local codes.
All models are suitable for closet or utility room installation.
Thefurnaceissuitableforinstallationinbuildings constructed
on-site. The furnace should be centralized in respect to the
heat distribution system as much as practicable. When
installedinautility room, the doorshould be wideenough to
allow the largest part of the furnace to enter, or permit the
replacement of another appliance, such as a water heater.
Agas-firedfurnace for installationinaresidential garage must
beinstalledsotheburner(s)andtheignitionsourcearelocated
not less than 18" above the floor. The furnace is to be located
or protected to avoid physical damage by vehicles.
Thisfurnaceisnotrecommendedtobeusedasaconstruction
heater during any phase of construction. Very low return air
temperatures, harmful vapors, and operation of the unit with
clogged or misplaced filters will damage the unit.
Thefurnacemaybe usedforheatingofbuildingsorstructures
under construction, if the following conditions are met:
• Theventsystemmustbepermanentlyinstalledperthese
installationinstructions.
• Aroom thermostat must control the furnace. The use of
fixedjumpers that will provide continuous heating is not
allowed.
• The return air duct must be provided and sealed to the
furnace.
Inspection of Shipment
This furnace is shipped in one package, completely
assembled and wired. The thermostat is shipped in a
separate carton when ordered.
Upon receipt of equipment, carefully inspect it for possible
shippingdamage. If damage is found,it should benoted on
the carrier’s freight bill. Damage claims should be filed with
thecarrier immediately. Claimsof shortagesshould be filed
with the seller within 5 days.
Location
Toprovideproperoperationandsatisfactoryperformance,care
must be taken in choosing the location for this furnace. The
atmosphere in which the furnace operates must be free of
contaminants such as chlorides and sulfates.
Thefurnace must be installedsothat electrical components
are protected from water. Unit must be level for proper
condensatedrainage.
The condensate drain on this furnace is incorporated
within the furnace and must be primed before start-up.
The condensate system must not be exposed to
temperatures under 32°F. Use of heat tape is
permissible provided the rate temperature of the tape
does not exceed 155°F.
WARNING
Horizontal Installations
Figure 1
HORIZONTAL RIGHT TO
LEFT AIRFLOW SHOWN

506305-01Page 4 of 36 Issue 0938
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.” Whenafurnaceisinstalled in an unconfined space
in a building, it can be assumed that the infiltration will be
sufficienttosupplythe required air. Ifthefurnaceisinstalled
in a ventilated attic or crawl space, it is assumed that the
infiltration is sufficient to supply the required air. However,
inabuildingofunusuallytightconstruction,additionaloutdoor
air should be provided.
• Return air temperature range between 60°F and 80°F
must be maintained.
• Air filters must be installed in the system and must be
maintained during construction.
• Air filters must be replaced upon construction completion.
• Theinput rate and temperature rise must be set per the
furnace rating plate.
• Onehundredpercent(100%)outdoorairmustbeprovided
for combustion air requirements during construction.
Temporary ducting may supply outdoor air to the furnace.
Do not connect duct directly to the furnace. Size the
temporary duct following the instructions provided on this
page in the Combustion and Ventilation Air section
regarding confined space with air from outside.
• The furnace heat exchanger, components, duct system,
airfilters,andevaporatorcoilsmustbethoroughlycleaned
following final construction cleanup.
• Allfurnaceoperatingconditions(includingignition,input
rate, temperature rise, and venting) must be verified
according to these installation instructions.
If the furnace is to be installed in an attic or other insulated
space,itmust be kept free and clear of insulating materials.
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.
Refer toTable1fortheminimumclearancesto combustibles
required for construction and proper unit operation.
Accessibility clearances must take precedence over fire
protection clearances.
G1D91BU,G1D91BT,G1D93BUandG1D93BTmodelsmay
be installed on wood flooring but shall not be installed directly
on carpeting, tile, or any other combustible material.
G1D93BC counterflow models are certified for installation
on combustible flooring provided a special base assembly
is used. (Refer to the Duct Connection – Counterflow
Models section on page 22 for more information on using
the special base assembly.)
When a counterflow unit is installed on a combustible floor,
1"clearancemust be provided betweenthesupply duct and
the floor.
Combustion and Ventilation Air
Adequate provisions for combustion air and ventilation of
furnace must be made. Refer to Section 5.3, “Air for
CombustionandVentilation,”oftheNationalFuelGasCode,
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.
Insufficient combustion air can cause headaches,
nausea,dizziness,orasphyxiation. Whenconsidering
combustionair requirements,enough air must alsobe
provided to meet the needs of all fuel-burning
appliances and exhaust fans.
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.
WARNING
Table 1
Minimum Clearances to Combustibles

506305-01 Page 5 of 36Issue 0938
Confined Space
Aconfined 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.”
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.
If the furnace is installed in a space within a building of tight
construction, makeup air must be supplied from outdoors. In
this case, one opening shall be within 12" of the ceiling and
one opening within 12" of the floor. If combustion ducts are
vertical, each opening shall have a free area of 1 square inch
per 4000 BTU/HR of the total input rating of all appliances
withintheenclosure. Ifhorizontalcombustionductsarerun,1
square inch per 2000 BTU/HR is required.
Contaminated Combustion Air
Excessiveexposuretocontaminatedcombustionairwillresult
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 come
fromtheoutdoorsbyway ofanattic,crawlspace,airduct,
or direct opening.
2. Ifindoorcombustionairisused,theremustbenoexposure
to the substances listed in item 5.
3. All provisions for indoor combustion air must meet the
requirementsforcombustion air indicated in theNational
Fuel Gas Code,ANSI Z223.1/NFPA54 (latest edition),
and/orany applicable local codes. In Canada, see CSA
B149.1, Natural Gas and Propane Installation Codes
(latest edition).
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
• Carbontetrachloride
• Halogen-typerefrigerants
• 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
The high efficiency of this furnace is accomplished by the
removal of both sensible and latent heat from the flue gases.
The removal of latent heat results in the condensation of
moisture in the flue gases. This condensation occurs in the
secondaryheatexchanger andintheventsystem.Therefore,
this furnace requires special venting considerations and the
instructions must be followed to insure proper operation. All
venting must be in accordance with the codes having
jurisdiction in the area and these instructions.
G1D91BU,G1D91BT, G1D93BU, G1D93BTandG1D93BC
models can be installed as either direct vent or non-direct
vent units. Adirect vent (two pipe) installation requires that
alltheairnecessaryforcombustionbesuppliedfromoutside
the dwelling through an air intake pipe. A non-direct vent
(one pipe) installation uses air from inside the dwelling for
combustion.
The furnace is shipped with the air inlet pipe terminated to the
top panel for either inside or outside combustion air. An inlet
air restrictor plate (see Figure 2) is supplied with this furnace
andcanbefoundintheplasticbagcontainingtheseInstallation
Instructions and the User’s Information Manual. The inlet
restrictorplatemustbeusedinallinstallationsusinginside
air for combustion (non-direct vent).
Figure 2
Inlet Air Restrictor Plate
The inlet air restrictor plate must be
installed in all installations using inside
air for combustion (non-direct vent).
The flue pipe screen should be
installed at the termination of the flue
pipe in all installations.
Flue Pipe Screen

506305-01Page 6 of 36 Issue 0938
When a furnace is installed as direct vent, provisions for
ventilation air should follow the same requirements as if
installed as non-direct vent. Proper ventilation air is
necessary to maintain furnace component temperatures
within acceptable limits.
Allventspassingthroughfloors,ceilings, and walls must be
installed in accordance with National Fuel Gas Code,ANSI
Z223.1/NFPA54 (latest edition).
Thelengthof fluepipeexposedtooutdoorconditionsshould
be kept to a minimum. When the installation requires more
than 3 feet of flue pipe be exposed to outdoor conditions,
insulating the exposed flue pipe with 1/2” Armaflex or
equivalent is recommended. In climates with design
temperatures below zero degrees (F), 3/4” Armaflex or
equivalent is recommended.
Materials
All pipe, fittings, primer, and solvent cement must conform
withAmericanNationalStandard Institute and theAmerican
Society for Testing and Materials (ANSI/ASTM) standards.
The solvent shall be free flowing and contain no lumps,
undissolved particles, or any foreign matter that adversely
affects the joint strength or chemical resistance of the
The inlet restrictor plate must be installed in the air inlet in
one of three ways:
• Restrictor plate in inlet collar: Install the restrictor plate
in the inlet pipe collar in the top panel of the furnace.
Insert a 3" to 36" section of PVC pipe (field supplied)
into the collar. Use high temperature RTV sealant to
attach PVC pipe to collar. A90° elbow (field supplied)
may be attached to the PVC pipe, but the elbow is not
required. Use high temperature RTV sealant to attach
elbow to PVC pipe (if applicable).
• Restrictor plate in inlet pipe: Insert a 3" to 36" section of
PVC pipe (field supplied) into the collar. Use high
temperature RTV sealant to attach PVC pipe to collar.
Install the restrictor plate in the end of the inlet pipe just
installed. Attach either a field-supplied coupler or 90°
elbow to the end of the PVC pipe to keep the restrictor
plate in place. Use high temperature RTV sealant to
attach the coupler or elbow to PVC pipe.
• Restrictor plate in elbow: Insert a 3" to 36" section of
PVC pipe (field supplied) into the collar. Use high
temperature RTV sealant to attach PVC pipe to collar.
Attach a 90° elbow (field supplied) to the PVC pipe. Use
hightemperatureRTVsealanttoattachelbowtoPVCpipe.
Install the restrictor plate into the elbow.
Two different sized inlet restrictor plates are supplied with the
furnace (2" and 3"). Use the proper restrictor plate for the
furnace model.
If at any time in the future the installation of this furnace
is changed to require outside fresh air for combustion,
theinlet 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.
WARNING
Also included in the plastic bag containing the inlet air
restriction plate is a flue pipe screen (see Figure 2). In all
installations,thisscreensouldbeinstalledat thetermination
of the flue pipe and is designed to keep objects out of the
flue pipe.
For either type of installation (direct or non-direct vent),
special venting considerations must be followed. Refer to
the proper section in pages 11 – 17 for the type of furnace
and venting being installed.
Theventingsystemmustbesupportedwithmountingstraps
to prevent any weight load from being applied to the vent
blower. Horizontal vent pipe must be supported every 5'
and vertical pipe should be supported every 10' to prevent
sagging and provide rigid support. Table 2
Piping and Fitting Specifications
Piping & Fitting
Material
ASTM
Specification
Schedule 40 PVC
(Pipe) D1785
Schedule 40 PVC
(Cellular Core Pipe) F891
Schedule 40 PVC
(Fittings) D2466
SDR-26 CPVC
(Pipe)
D2241
Schedule 40 ABS
(Pipe) D1527
Schedule 40 ABS
(Fittings) D2468
Schedule 40 & 80 CPVC
(Pipe) F441
ABS-DWV
Drain Waste & Vent
(Pipe & Fittings)
D2661
PVC-DWV
Drain Waste & Vent
(Pipe & Fittings)
D2665
F442
SDR-26
(Pipe)
Schedule 40 ABS
Cellular Core
DWV (Pipe)
F628
F438
Schedule 40 & 80 CPVC
(Fittings)

506305-01 Page 7 of 36Issue 0938
Preferredfittings are DWV styleor long sweep. Seal all joints
gas tight with appropriate cement. In areas where vent and
airintakepipesareexposedto abnormalstressoraresubject
to damage, schedule 80 pipe should be used.
Category IV Furnace Limitations
This furnace shall not be connected to any Type B, BW, or L
ventorventconnectorandshallnotbeconnectedtoanyportion
of a factory-built or masonry chimney. This furnace is not to
be common vented with any other appliance. The vent
pipe must not be connected to a chimney flue serving a
separate appliance designed to burn solid fuel.
Concentric Vent Kit
cement. The cement shall show no gelation, stratification,
or separation that cannot be removed by stirring.
Refer to Table 2 for approved piping and fitting materials.
Canadian Applications Only: PVC pipe, fittings, primer
and solvent cement used to vent this applicance must be
certifiedtoULCS636andsuppliedby a single manufacturer
as part of an approved venting system. In addition, the first
three feet of vent pipe from the furnace flue collar must be
accessibleforinspection. Models that may beinstalledasa
horizontal furnace include a horizontal drain kit. In Canada
this drain kit must be replaced by a locally available IPEX
Drain Kit # 196014. For Local IPEX Canadian Customer
Service Center and Kit abailability call IPEX at 1-866-473-
9462.
The primers and solvents used must also meet ASTM
specifications. PVCprimer is specified inASTMF656. Use
PVC solvent as specified inASTM D2564 andABS solvent
cementasspecifiedASTMD2235. Lowtemperaturesolvent
cement is recommended. Metal or plastic strapping may
be used for vent pipe hangers.
WhenmakingABSjoints,piecescanbepreparedwithaclean
dryclothtocleaninsidesocketsurfaceoffittingandmaleend
of pipe to depth of socket. Refer to procedure specified in
ASTM D3138. When joining ABS to PVC materials, use
transitionsolvent.
Figure 3
Concentric Vent Kit Dimensions
Aconcentric vent kit (seeAccessories section on page 31 for
correct kit) is available for use when installing this furnace as
adirectventfurnace andtheairintakeand ventpipearetobe
run through the same hole, whether horizontally through the
wall or vertically through the roof (see Figure 3). Refer to the
instructionsincludedwiththeconcentricventkitforinstallation
specifics.
Vent Pipe Size and Length
Theventpipe and air intakepipe(indirectvent installations)
should be sized in accordance with the information found in
theappropriatetableinFigure4. One90°elbow isequivalent
to 5' of pipe. Two 45° elbows are equivalent to one 90°
elbow. The minimum length certifiedforusewiththisfurnace
is 5' and one elbow, not including the vent and air intake
terminals.
In the event that the pipe length is in between the lengths
listed in the table, use the next larger length listed. For
example, if a length of pipe needed to install the furnace is
27', use the diameter values for the 30' row in the tables.
For direct vent installations, if the vent and air intake pipe
arenotequalin lengthandnumberofelbows,thendetermine
the minimum pipe diameter for both the vent and air intake.
If the results indicate different diameters, use the larger of
the two for both the vent and air intake. Under no
circumstances should the vent and air intake pipe size
be different in diameter. For installation details, refer to
the appropriate section in pages 11 – 17 for the unit model
and type of installation.
High Altitude Installation: 2” pipe not recommended at
altitudeabove4,000feet. 3”pipe required for altitude above
5,000 feet.
Horizontal Venting
The vent for this appliance shall not terminate over public
walkways; or near soffit vents or crawl space vents or other
areaswherecondensateorvaporcouldcreateanuisance or
hazardorcausepropertydamage;orwherecondensatevapor
couldcausedamageorcouldbedetrimentalto the operation
of regulators, relief valves, or other equipment.
See Figures 5 and 6 on pages 9 and 10 for additional
information on where the horizontal vent terminal can and
cannot terminate.
For Massachusetts Installations: The installation must
comply with Massachusetts 248 CMR 5.08 Modifications to
sections of NFPA-54, Chapter10. (See pages 35 and 36 )

506305-01Page 8 of 36 Issue 0938
Figure 4
Vent Tables *
(numbers in inches unless specified otherwise)
Minimum Pipe Diameter
45,000 – 75,000 BTU/HR Models
NR = Not Recommended
* 2” not recommended at altitude above 4,000 feet
3” required for altitude above 5,000 feet
Minimum Pipe Diameter
112,000 – 125,000 BTU/HR Models
Minimum Pipe Diameter
90,000 – 100,000 BTU/HR Models
0123456789
222222222
2222222
2
3333
33333
Vent Pipe
Length
(ft.)
Number of 90° Elbows
5
10
20
30
40
50
60
70
80
90
1.5 1.5
1.5
22222222
2.5
2222222
22
2.5 2.5 2.5
2.5 2.5 2.5 2.5 2.5
22 2 22
32.5 2.5 2.5 2.5 2.5 2.5 2.5
3
3
3
2.5
2
2
2.5 2.5 2.5 2.5 2.5
2.52.52.5
2.52.5
2.5
2.5
2.5
2.52.5
3333 3
NR
NR NR
NR NR NR
0123456789
222
222
222 333
333333
3333
33
Vent Pipe
Length
(ft.)
Number of 90° Elbows
5
10
20
30
40
50
60
70
80
90
3
3
33 3
3 3 3
333
3 3 333
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
2.5 2.5
NR
NR
NR
2
NR
2
22222
22222
2
2
NR NR NR
NR NR NR NR NR
NR NR
NRNR
NR
NR NR NR NR NR NR NR
NR
0123456789
.
3
33
Vent Pipe
Length
(ft.)
Number of 90° Elbows
5
10
20
30
40
50
60
NR
2.5
3
3
33
3
3
3
NR
NR
NR
NR
NR NR NR NR NR NR NR NR
NR
NRNR
NR
NR
NR
NR NR NR
NR NR
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
2.52.52.5
2.5
2.5 2.5 2.5 2.5 2.5
2.52.5
2.52.52.5
2.5
2.5
2.52.5

506305-01 Page 9 of 36Issue 0938
Figure 5
Sidewall Vent Terminal Clearances (Direct Vented Furnaces)
1In accordance with the current CSA B149.1, Natural Gas and
Propane Installation Code
2In accordance with the current ANSI Z223.1/NFPA 54, National
Fuel Gas Code
†A vent shall not terminate directly above a sidewalk or paved
driveway that is located between two single family dwellings and
serves both dwellings.
‡Permitted only if veranda, porch, deck, or balcony is fully open on a
minimum of two sides beneath the floor.
* For clearances not specified in ANSI Z223.1/NFPA 54 or CSA
B149.1, the following statement shall be included:
“Clearance in accordance with local installation codes and the
requirements of the gas supplier and the manufacturer’s installation
instructions.”
V
X
Vent Terminal
Air Supply Inlet
Area Where Terminal Is
Not Permitted
A ** Minimum 12” (30 cm) above grade or
12” (30 cm) above average snow accumulation.

506305-01Page 10 of 36 Issue 0938
Figure 6
Sidewall Vent Terminal Clearances (Non-Direct Vented Furnaces)
1In accordance with the current CSA B149.1, Natural Gas and
Propane Installation Code
2In accordance with the current ANSI Z223.1/NFPA 54, National
Fuel Gas Code
†A vent shall not terminate directly above a sidewalk or paved
driveway that is located between two single family dwellings and
serves both dwellings.
‡Permitted only if veranda, porch, deck, or balcony is fully open on a
minimum of two sides beneath the floor.
* For clearances not specified in ANSI Z223.1/NFPA 54 or CSA
B149.1, the following statement shall be included:
“Clearance in accordance with local installation codes and the
requirements of the gas supplier and the manufacturer’s installation
instructions.”
A ** Minimum 12” (30 cm) above grade or
12” (30 cm) above average snow accumulation.
V
X
Vent Terminal
Air Supply Inlet
Area Where Terminal Is
Not Permitted

506305-01 Page 11 of 36Issue 0938
Do not cement air intake into the connector on burner
box. Use high temperature RTV silicone sealant so
intake pipe can be removed if service is required.
Inhorizontalventingapplications,theventand air intake
pipe must be installed on the same side of the house
within the parameters shown in Figure 7.
Prime the trap system by slowly pouring 1 cup of water down
the vent pipe. On initial start-up of the unit, some of the
water used to prime the trap system may run down into the
combustion blower and cause noise.
G1D91BU, G1D91BT, G1D93BU and G1D93BT Upflow
Models – Direct Vent Installation
Aninletairrestrictorplate(seeFigure2onpage5)issuppliedwith
this furnace and can be found in the plastic bag containing these
InstallationInstructionsandtheUser’sInformationManual. This
restrictor plate is to be used only in non-direct vent
applications. Seepages5and6formoreinformationoninstalling
therestrictor plate in non-directvent applications.
The flue pipe screen (see Figure 2 on page 5) should be
installed at the termination of the flue pipe and is designed to
keepobjects out of the flue pipe. An additional screen should
notbeplacedintheintaketermination. Ifascreenisinstalled,
the air intake may freeze shut.
For horizontal venting, refer to Figure 7. For vertical venting,
refer to Figure 8. It is permissible to run the vent vertically
through the roof and terminate it as shown in Figure 8, and
to run the combustion air intake pipe horizontally through a
side wall and terminate as shown in Figure 7. The vent pipe
onhorizontalrunsmustslopeupward,awayfromthefurnace,
at a minimum pitch of 1/4" per foot of run, to prevent
accumulation of condensate.
Figure 7
Upflow Direct Vent – Horizontal Venting
(G1D91BU, G1D91BT, G1D93BU & G1D93BT Only)
* Maintaining a vertical separation
between the flue outlet and the
air intake of at least 18” is highly
recommended to minimize the
chance of flue gases
recirculating and freezing in the
air intake pipe. This distance
may be reduced in milder
climates or where wind is
unlikely to blow flue products to
the intake pipe, but should not
be less than 6”.
THIS PIECE
IS OPTIONAL.
INTAKE PIPE
FLUE PIPE
3” MIN. - 48” MAX.
Overhead View
Upflow Direct Vent – Vertical Venting
(G1D91BU, G1D91BT, G1D93BU & G1D93BT Only)
Figure 8

506305-01Page 12 of 36 Issue 0938
G1D91BU, G1D91BT, G1D93BU & G1D93BT Upflow
Models – Non-Direct Vent Installation
Aninletairrestrictorplate(seeFigure2on page5)is 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. See pages 5 and 6
for more information on installing the restrictor plate in non-direct
ventapplications.
Two inlet airrestrictor plates are supplied with each furnace
– a 2" plate and a 3" plate. Use the proper restrictor plate
for the furnace model.
The flue pipe screen (see Figure 2 on page 5) should be
installed at the termination of the flue pipe and is designed
to keep objects out of the flue pipe.
Forhorizontalventing, refer to Figure 9. For verticalventing,
refer to Figure 10. The vent pipe on horizontal runs must
slope upward, away from the furnace, at a minimum pitch of
1/4" per foot of run, to prevent accumulation of condensate.
Primethetrapsystembyslowlypouring1cupofwaterdown
the vent pipe. On initial start-up of the unit, some of the
water used to prime the trap system may run down into the
combustion blower and cause noise.
Figure 9
Upflow Non-Direct Vent Horizontal Venting
(G1D91BU, G1D91BT, G1D93BU & G1D93BT Only)
(CLOSED) DRAINHOLE
THRU.
59.69/56.64
"
"
THE VENT SYSTEM OF
THE FURNACE MUST BE
SELF-SUPPORTING AND
MUST NOT APPLY ANY
WEIGHT LOAD TO THE
COMBUSTION BLOWER.
Upflow Non-Direct Vent Vertical Venting
(G1D91BU, G1D91BT, G1D93BU & G1D93BT Only)
Figure 10
(CLOSED) DRAINHOLE
THRU.
59.69/56.64
"

506305-01 Page 13 of 36Issue 0938
Do not cement air inlet pipe. Use high temperature RTV
silicone sealant so inlet pipe can be removed if service
is required.
Inhorizontalventingapplications,theventand air intake
pipe must be installed on the same side of the house
within the parameters shown in Figure 11.
Prime the trap system by slowly pouring 1 cup of water down
the vent pipe. On initial start-up of the unit, some of the
water used to prime the trap system may run down into the
combustion blower and cause noise.
G1D93BC Counterflow Models – Direct Vent Installation
Aninletairrestrictorplate(seeFigure2onpage5)issuppliedwith
this furnace and can be found in the plastic bag containing these
InstallationInstructionsandtheUser’sInformationManual. This
restrictor plate is to be used only in non-direct vent
applications.Seepages5and6formoreinformationoninstalling
therestrictor plate in non-directvent applications.
The flue pipe screen (see Figure 2 on page 5) should be
installed at the termination of the flue pipe and is designed to
keepobjects out of the flue pipe. An additional screen should
notbeplacedintheintaketermination. Ifascreenisinstalled,
the air intake may freeze shut.
Forhorizontalventing,refertoFigure11. Forverticalventing,
refer to Figure 12. It is permissible to run the vent vertically
throughthe roof and terminateit as shownin Figure 12, and
to run the combustion air intake pipe horizontally through a
side wall and terminate as shown in Figure 11. The vent
pipe on horizontal runs must slope upward, away from the
furnace,ataminimum pitch of 1/4" per foot of run, toprevent
accumulation of condensate.
Counterflow Direct Vent Horizontal Venting
(G1D93BC Only)
Figure 11
* Maintaining a vertical separation
between the flue outlet and the
air intake of at least 18” is highly
recommended to minimize the
chance of flue gases
recirculating and freezing in the
air intake pipe. This distance
may be reduced in milder
climates or where wind is
unlikely to blow flue products to
the intake pipe, but should not
be less than 6”.
THIS PIECE
IS OPTIONAL.
INTAKE PIPE
FLUE PIPE
3” MIN. - 48” MAX.
Overhead View
Figure 12
Counterflow Direct Vent – Vertical Venting
(G1D93BC Only)

506305-01Page 14 of 36 Issue 0938
G1D93BC Counterflow Models – Non-Direct Vent
Installation
Aninletairrestrictorplate(seeFigure2on page5)is 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. See pages 5 and 6
for more information on installing the restrictor plate in non-
direct vent applications.
Two inlet airrestrictor plates are supplied with each furnace
-a 2” plate and a 3” plate. Use the proper restrictorplate for
the furnace model.
The flue pipe screen (see Figure 2 on page 5) should be
installed at the termination of the flue pipe and is designed
to keep objects out of the flue pipe.
Forhorizontalventing,refertoFigure 13. Forverticalventing,
refer to Figure 14. The vent pipe on horizontal runs must
slopeupward, away from thefurnace, at a minimumpitch of
1/4"per foot of run, to prevent accumulation ofcondensate.
Primethetrapsystembyslowlypouring1cupofwaterdown
theventpipe.Oninitialstart-upoftheunit,someofthewater
used to prime the trap system may run down into the
combustion blower and cause noise.
G1D91BT & G1D93BT Horizontal Models-Direct Vent
Installation
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
theseInstallationInstructionsandtheUser’sInformationManual.
This restrictor plate is to be used only in non-direct vent
applications. See pages 5 and 6 for more information on
installing the restrictor plate in non-direct vent applications.
The flue pipe screen (see Figure 2 on page 5) should be
installed at the termination of the flue pipe and is designed to
keepobjectsoutof the flue pipe. An additional screen should
notbeplacedintheintaketermination. Ifascreenisinstalled,
the air intake may freeze shut.
Maintaining a vertical separation between the flue outlet and
theairintakeofatleast18”ishighlyrecommendedtominimize
thechanceoffluegassesre-circulatingandfreezingintheair
intake pipe. The 18” separation is shown for horizontal
installations in Figure 15. This distance may be reduced in
milderclimatesorwherewindisunlikelytoblowflueproducts
to the intake pipe, but should not be less than 6”.
Figure 13
Counterflow Non-Direct Vent Horizontal Venting
(G1D93BC Only)
(CLOSED)
DRA N HOLE
THRU.
59.69/56.64
"
"
"
Figure 14
Counterflow Non-Direct Vent Vertical Venting
(G1D93BC Only)
"
(CLOSED)
DRAINHOLE
THRU.
59.69/56.64
"

506305-01 Page 15 of 36Issue 0938
Forhorizontalventing,refertoFigure 15. Forverticalventing,
refer to Figure 16. It is permissible to run the vent vertically
throughthe roof and terminateit as shownin Figure 16, and
to run the combustion air intake pipe horizontally through a
side wall and terminate as shown in Figure 15. The vent
pipe on horizontal runs must slope upward, away from the
furnace, at a minimum pitch of 1/4" per foot of run, to prevent
accumulation of condensate.
Do not cement air intake into the connector on burner
box. Use high temperature RTV silicone sealant so
intake pipe can be removed if service is required.
Inhorizontalventingapplications,theventand air intake
pipe must be installed on the same side of the house
within the parameters shown in Figure 15.
Figure 16
Horizontal Direct Vent – Vertical Venting
(G1D91BT & G1D93BT Only)
Airflow Left to Right
* Canadian Installations: See “Canadian Applications Only” on page 7
Airflow Right to Left
Figure 15
Horizontal Direct Vent – Horizontal Venting
(G1D91BT & G1D93BT Only)
* Canadian installations: See “Canadian Applications Only” on page 7
THIS PIECE
IS OPTIONAL.
INTAKE PIPE
FLUE PIPE
3” MIN. - 48” MAX.
Overhead View
Airflow Right to Left
Airflow Left to Right

506305-01Page 16 of 36 Issue 0938
For horizontalventing,refertoFigure17. Forverticalventing,
refer to Figure 18. The vent pipe on horizontal runs must
slope upward, away from the furnace, at a minimum pitch of
1/4" per foot of run, to prevent accumulation of condensate.
Primethetrapsystembyslowlypouring1cupofwaterdown
the vent pipe. On initial start-up of the unit, some of the
water used to prime the trap system may run down into the
combustion blower and cause noise.
Figure 18
Figure 17
Horizontal Non-Direct Vent – Horizontal Venting
(G1D91BT & G1D93BT Only)
* Canadian Installations: See “Canadian Applications Only” on page 7.
Airflow Right to Left
Airflow Left to Right
Horizontal Non-Direct Vent – Vertical Venting
(G1D91BT & G1D93BT Only)
* Canadian Installations: See “Canadian Applications Only” on page 7.
Airflow Left to Right
Airflow Right to Left
Prime the trap system by slowly pouring 1 cup of water down
the vent pipe. On initial start-up of the unit, some of the
water used to prime the trap system may run down into the
combustion blower and cause noise.
G1D91BT & G1D93BT Horizontal Models - Non-Direct
Vent Installation
Aninletairrestrictorplate(seeFigure2on page5)is supplied
with this furnace and can be found in the plastic bag
containingtheseInstallationInstructions. Thisrestrictorplate
is to be used only in non-direct vent applications. Place the
restrictor plate into the inlet collar, insert 3” section of PVC
pipe(fieldsupplied), then attach a 90°elbow (field supplied)
to the PVC pipe in all non-direct vent installations (see
Figures 17 and 18).
Two inlet airrestrictor plates are supplied with each furnace
– a 2" plate and a 3" plate. Use the proper restrictor plate
for the furnace model.
The flue pipe screen (see Figure 2 on page 5) should be
installed at the termination of the flue pipe and is designed
to keep objects out of the flue pipe.

506305-01 Page 17 of 36Issue 0938
G1D91BT & G1D93BT Horizontal Models-Horizontal
Venting – Low Clearance Installations
Vent pipe on horizontal runs must slope upward, away from
the furnace, at a minimum pitch of 1/4" per foot of run, to
preventaccumulationofcondensate.Incertainhorizontal,left-
to-right airflow applications, the furnace’s close proximity to
thefloorjoistsabovetheunit maymakeitdifficulttoobtainthe
required pitch/slope. Figure 19 and 20 show the accepted
vent practice to obtain proper pitch/slope back to furnace for
proper drainage. For direct vent applications, see Figure 19.
For non-direct applications, see Figure 20.
Inallapplications,minimum clearancestocombustiblesmust
be observed (as shown in Table 1 on page 4) as well as all
other required clearances shown in Figures 15 and 17 on
pages 15 and 16.
Existing Venting Systems
Whenanexistingfurnaceis removedorreplaced,theoriginal
venting system may no longer be sized to properly vent the
attachedappliances. Animproperlysizedventingsystemcan
result in spillage of flue products into the living space, the
formation of condensate, leakage, etc. See the WARNING
box below for proper test procedure.
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placedinto operation couldresult in carbon monoxide
poisoning or death.
Thefollowingstepsshallbefollowedforeachappliance
connected to the venting system being placed into
operation, while all other appliances connected to the
common venting system are not in operation:
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper size
andhorizontalpitch,asrequiredintheNationalFuel
GasCode,ANSI Z223.1/NFPA54(latestedition)or
the CSA B149.1, Natural Gas and Propane
Installation Codes and these instructions.
Determine that there is no blockage or restriction,
leakage,corrosion,orotherdeficiencieswhichcould
cause an unsafe condition.
3. As far as practical, close all building doors and
windows between the space in which the
appliance(s) connected to the venting system are
located and other spaces in the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any
exhaust fans, such as range hoods and bathroom
exhausts,sotheyareoperatingatmaximumspeed.
Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the unit
beinginspectedinoperation. Adjustthethermostat
so appliance is operating continuously.
7. Test for spillage from draft hood equipped
appliances at the draft hood relief opening after 5
minutes of main burner operation. Use the flame
of a match or candle.
8. If improper venting is observed during any of the
abovetests,theventingsystemmustbecorrected
in accordance with the National Fuel Gas Code,
ANSI Z223.1/NFPA54 (latest edition) and/or the
CSAB149.1,NaturalGasandPropaneInstallation
Codes.
9. After it has been determined that each appliance
remaining connected to the venting system
properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers, and any other gas-fired burning
appliance to their previous conditions of use.
CARBON MONOXIDE POISONING HAZARD
WARNING
Figure 19
Horizontal Direct Vent – Horizontal Venting
Low Clearance Installation
* Canadian Installations: See “Canadian Applications Only” on page 7.
Figure 20
Horizontal Non-Direct Vent – Horizontal Venting
Low Clearance Installation
* Canadian Installations: See “Canadian Applications Only” on page 7.

506305-01Page 18 of 36 Issue 0938
Condensate Disposal Installation
The condensate drain should be routed directly to a locally
acceptabledisposalarea. Thecondensatedrainlineshould
not be run directly to the outdoors especially in colder
climateswhere temperatures may cause the condensate to
freeze in the drain line.
In horizontal installations where clearance beneath the unit
islimited, analternate methodfor condensate disposal trap
installationmaybeused(seeHorizontalInstallation–Tight
Clearance Below Unit on page 20).
Upflow or Counterflow Installation
Install the condensate drain line to the unit as follows. The
condensate can be drained from either the right or left side
of the furnace. Install the 1/2" NPT x 3/4" PVC adapter
(supplied)inthedrainonthe side that the draining will occur.
Installtheplasticpipeplug opposite ofthe drain. Using 3/4"
PVCpipe,makea connection from theadapterjust installed
to extend just outside the unit. Install a 3/4" PVC tee as
shown in Figure 21. From the tee, install the drain to the
disposalarea.Thetopoftheteemust be leftopenforproper
condensatedrainage.
Horizontal Installation – Right to Left Airflow
Furnacemust be mountedsuch that theside through which
thecondensatewill drain is elevateda minimum of 9"above
a surface such as a floor.
Install unit at a slight pitch forward (see Figure 22).
1. Relocate the 1/2" NPT plug installed on the flue pan to
one side of the internal trap assembly (as shown in
Figure 23).
2. Connect the 1/2" NPT plug (supplied) to the opposite
sideofthe internal trap assembly fromthe plug installed
in Step 1.
3. Inserttrapassembly(supplied) into flue pan(seeFigure
24).
Figure 21
Condensate Disposal
Upflow or Counter-Flow Models
THRU.
59.69/56.64
1/2” NPT PLUG
(SUPPLIED) 1/2” NPT x 3/4”PVC ADAPTER
(SUPPLIED)
3/4” PVC
TEE MUST REMAIN
OPEN
3/4” PVC
Figure 22
Tilt Unit Forward
Figure 24
Install Trap Assembly
Figure 23
Insert Plugs

506305-01 Page 19 of 36Issue 0938
6. Fromthetee,connectthedrain to disposalarea. Thetop
of the tee must be left open for proper condensate
drainage. The open end of the tee must be oriented so
that condensate does not run out of the opening.
7. Remove 72" vinyl hose supplied with unit and cut in half.
Connectoneendofthevinylhosetothe3/8"barbedfitting
of the 2" x 2" x 1/2" tee in vent and the other end to the
3/8” barbed fitting on the drain trap assembly.
Horizontal Installation – Left to Right Airflow
Furnacemust be mountedsuch that theside through which
thecondensatewill drain is elevateda minimum of 9"above
a surface such as a floor.
Install unit at a slight pitch forward (see Figure 26).
1. Relocate 1/2" NPT plug installed on flue pan to one side
of the internal trap assembly (as shown in Figure 27).
2. Connect the 1/2" NPT plug (supplied) to the opposite
sideofthe internal trap assembly fromthe plug installed
in Step 1.
3. Inserttrapassembly(supplied) into flue pan(seeFigure
28).
4. Connect a length of 3/4" PVC pipe (3' minimum) to the
trap assembly (see Figure 29).
4. Connect a length of 3/4" PVC pipe (3' minimum) to the
trap assembly (see Figure 25).
5. Install 3/4" tee (supplied) as shown in Figure 25.
5. Install 3/4" tee (supplied) as shown in Figure 29.
Figure 28
Install Trap Assembly
Completing Condensate
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
Figure 26
Tilt Unit Forward
Figure 27
Insert Plugs

506305-01Page 20 of 36 Issue 0938
6. From the tee, connect the drain to disposal area. The
top of the tee must be left open for proper condensate
drainage. The open end of the tee must be oriented so
that condensate does not run out of the opening.
7. Connectoneendof72"vinylhose(supplied)to3/8"barbed
fitting of the 2" x 2" x 1/2" tee in vent and the other end to
3/8" barbed fitting on drain trap assembly.
Horizontal Installation – Tight Clearance Below Unit
Incertainhorizontalinstallations,clearancebetween unit and
drain pan beneath unit may be limited. In these applications,
an alternate method may be used to install the condensate
drain trap assembly. Using two 90° elbows (field supplied),
bring condensate trap out to side of unit beyond drain pan
(seeFigure30). Aftertrapassemblyhasbeenattachedusing
this method, follow proper instructions on the previous pages
for completing condensate drain installation.
Drain Pressure Switch Connection
(for G1D91BT and G1D93BTmulti-position units only. The
G1D91BU/G1D93BU dedicated upflow and G1D93BC
dedicated counterflow units do not require a drain switch).
Upflow Installation
The G1D91BT and G1D93BT units are shipped from the
manufacturerwith a black hosehaving one end connected to
the 0.10” drain pressure switch and the other end shipped
loose. FOR UPFLOW INSTALLATIONS the loose end is to
beconnectedtothe capped teeinthehoseassemblyleading
from the primary pressure switch to the inducer. Remove
and discard the plastic cap from the tee and connect the
hose from the 0.10” drain pressure switch to the tee. (See
Figure 31.)
Figure 29
Completing Condensate
Drain Installation
Be sure to avoid double-trapping the vinyl hose.
Hose must be installed as shown.
To avoid property damage caused by condensate drain
blockage,installa field-fabricatedauxiliarydrainpanwith
aseparatedrainlinetotheoutsideundertheentirefurnace
and drain system, including open vent tees.
CAUTION
Figure 30
Condensate Drain Trap Installation – Tight Clearance Below Unit
Drain Pan
Two 3/4" 90° Elbows
1/2" NPT x 1/2" PVC
Adapter and Trap Assembly
(supplied)
End View
Field-Supplied Fittings
IMPORTANT: If vent tee is not located over the
auxiliary drain pan, it must be extended over the
pan with an elbow facing down to prevent
overflow in the event of a blocked drain. The
elbow must be installed downward over the
auxiliary pan to prevent wicking back down the
condensate line.
Do not install trap assembly any farther than 10" from unit. The pressure switch and vent
hoses must be able to reach the barbed fittings on the trap assembly.
NOTE: Vent tee to avoid
vapor lock. If connecting
to waste drain pipe, a
second trap must be
installed downstream.