Granby KHM-1/090, KHM-2/140 Installation, Operation And Service Manual

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Page 1

Installation, Operation and

Service Manual

KHM

85% + EFFICIENCY

OIL FIRED HI-BOY FURNACE

KHM-1 / 090 KHM-2 / 140

INSTALLATIONS MUST MEET ALL LOCAL AND FEDERAL

SERIES

CODES THAT MAY DIFFER FROM THIS MANUAL

KHM-1 / 090 Illustration

Please read the manual in its entirety before beginning installation.

This manual must be kept with the furnace for future reference.

GRANBY FURNACES INC.

PO Box 637 12118 Hwy 209 Parrsboro Nova Scotia Canada B0M 1S0 902-254-2543

www.granbyindustries.com

11-09-2012 G2012-E2 Rev. C

Page 2

TABLE OF

CONTENTS

1.0 IMPORTANT SAFETY ADVICE 2

2.0 PRODUCT INFORMATION

3.0 FURNACE INSTALLATION

4.0 ACCESSORY INSTALLATION

5.0 BURNER INSTALLATION AND SPECIFICATIONS 13

5.1 ASSEMBLY & INSTALLATION OF BURNER 13

5.2 SET BURNER FOR EFFICIENT OPERATION 14

5.3 TECHNICAL INFORMATION 16

6.0 FURNACE OPERATION AND SETTINGS 17

6.1 BLOWER SETTING 17

6.2 FAN TIMER CONTROL BOARD (ST9103 A 1028) 18

6.3 ST9103 A 1028 CONTROL BOARD SEQUENCE 19

6.4 SERVICING – FAN TIMER (ST9103 A 1028) 20

7.0 SERVICE 22

8.0 ELECTRICAL / WIRING DIAGRAMS 25

RIELLO WIRING DIAGRAM 25

BECKETT WIRING DIAGRAM 26

9.0 EXPLODED PARTS VIEW 28 KHM-1 / 90 28

KHM-2 / 140 30

10. START-UP TEST RESULTS 32

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1.0 IMPORTANT SAFETY ADVICE

Please read and understand this manual before installing, operating or servicing the furnace. To ensure you have a clear understanding of the operating procedures of the

appliance please take the time to read the IMPORTANT SAFETY ADVICE section of this manual.

WARNINGS

NEVER burn garbage or paper in the unit. NEVER store combustible material around it. DO NOT attempt to start burner when excess oil has accumulated, when unit is full of vapour

or when heat exchanger is very hot.

DO NOT use gasoline, crankcase drainings or any oil containing gasoline.

CAUTION

DO NOT START THE BURNER UNTIL ALL FITTINGS, COVERS AND DOORS ARE IN

PLACE. DO NOT TAMPER WITH THE FURNACE OR CONTROLS, CALL A QUALIFIED BURNER TECHNICIAN. DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPOURS AND LIQUIDS IN THE VICINITY OF THIS UNIT OR ANY OTHER APPLIANCE.

DANGER

Do not use this furnace as a construction heater. Use of this furnace as a construction heater exposes it to abnormal conditions, contaminated combustion air and lack of air filtering. Failure to follow this warning can lead to premature furnace failure which could result in a fire hazard and/or bodily harm and/or materials damages.

IMPORTANT

This manual contains instructional and operational information for the KHM OIL-FIRED FURNACE. Read the instructions thoroughly before installing furnace or starting the burner. Consult local authorities about your local FIRE SAFETY REGULATIONS. All installations must be in accordance with local state or provincial codes. Improper installation will result in voiding of warranty.

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2.0 PRODUCT INFORMATION

CLEARANCE (minimum) TO COMBUSTIBLES UPFLOW POSITION

Top & Sides of Supply Plenum 1” (25 mm) Front (Maintenance) 24” (610 mm) Rear 0” (0 mm) First Side 0” (0 mm) Other Side 0” (0 mm) Flue Pipe 9” (229 mm) Floor Combustible

DOWNFLOW POSITION

Top 2” (51 mm) Bottom and Sides - Plenum 1” (25 mm) Rear 0” (0 mm) First Side 0” (0 mm) Other Side 0” (0 mm) Front (Maintenance) 24” (610 mm) Flue Pipe 9” (229 mm) Floor (with Down flow base) Combustible

HORIZONTAL POSITION

Top 2” (51 mm) Bottom and Sides - Plenum 1” (25 mm) Rear 1” (25 mm) First Side 1” (25 mm) Other Side 1” (25 mm) Front (Maintenance) 24” (610 mm) Flue Pipe 9” (229 mm) Floor 2” (51 mm)

DRAFT PRESSURE

Breech draft pressure -0.01” wc minimum AIR/BLOWER DATA

External static – Non A/C 0.2” wc External static – A/C 0.5” wc Maximum cooling 3.0 tons… KHM-1 / 090

5.0 tons… KHM-2 /140 Maximum air temperature rise See page 16 and 33 High Limit, max design outlet temp 185°F Thermostat anticipator 0.2 amps

MOTOR/BLOWER

KHM-1 / 090: 1/2 hp 4 Speed / G10-8 DD or 1/2 hp ECM / G10-8 KHM-2 / 140: 3/4 hp 4 Speed / GT12-10DD or 3/4 hp ECM / GT12-10

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FAN/HIGH LIMIT CONTROL

Honeywell ST9103 Fan Center & Thermo-Disk (7” stem) DIMENSIONS (KHM-1 / 090)

Depth 26” (660 mm) Height 46 1/4” (1175 mm) Width 21 7/16” (545 mm)

DIMENSIONS (KHM-2 / 140) Depth 30” (762 mm) Height 49 7/8” (1267 mm) Width 21 7/16” (545 mm)

PLENUM DIMENSIONS (KHM-1 / 090) Cold air return (A) 18” x 18” (457 x 457 mm) Hot air supply (B) 20” x 20” (508 x 508 mm)

PLENUM DIMENSIONS (KHM-2 / 140)

Cold air return (A) 23” x 18” (584 x 457 mm) Hot air supply (B) 24” x 20” (610 x 508 mm)

AIR FILTERS KHM-1 / 090 20” x 20” x 2” non-pleated UL approved KHM-2 / 140 25” x 20” x 2” non-pleated UL approved

A/C COIL LOCATION

Minimum height above the heat exchanger 6” (152 mm)

See A/C Coil Manufactures Requirements SMOKE-PIPE CONNECTION

5” Chimney or direct vent DVS Granby kit CLEANOUTS

Front Cover & Burner Opening

THERMOSTAT

Any thermostat

FUEL

Not heavier than No. 2 furnace oil. ELECTRICAL – 120 Volts, 60 Hz

Canada Less than 12 amps. USA 13.3 amps, circuit protection 20 amps.

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KHM-1 / 090 - DIMENSIONS

Dimensions are in inches

KHM-2 / 140 - DIMENSIONS

Dimensions are in inches

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3.0 FURNACE INSTALLATION

OIL TANK & PIPING

Tank installation must conform to local requirements.

Install according to the applicable code such as CSA B139 and NFPA 31. Minimize the number of connections in suction line and make all connections as tight as possible. Use a pipe joint compound suitable for oil on all pipe threads. To reduce possibility of air leaks, tighten stem packing gland nut on any valves installed in the suction line. Also, be sure the oil filter is tight, as filter gaskets often shrink. Check for kinks in the oil lines as well as for possible air pockets and for loose connections. Two filters as shown below are recommended. Optional tank gauge protectors and outlet protectors are available at your local dealer.

ONE PIPE SYSTEM Where the tank is above the burner and when the oil flows by

TWO PIPES SYSTEM When a single line is unsuitable, use a double line system or see

gravity to the oil pump, a single-stage fuel unit with a single oil line to the pump may be used.

your dealer for special oil line fittings. Install by-pass plug on burner fuel unit as specified in the burner manual.

Oil Tank and Piping

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PLACEMENT & VENTING

Furnace installation shall conform to the required installation code for oil-fired equipment (USA: NFPA 31, Canada: CSA B139).

FLOOR SUPPORT COMBUSTIBLE – If required, support furnace on five (5) concrete

blocks. Make sure the center of the furnace base is supported. Approved for installation on combustible floors in the upflow position and downflow position (with the optional sub-base). Not approved for installation on combustible floor in horizontal applications. For horizontal applications, use railing type support (not supplied) to keep the furnace in position. Make sure that all clearances are respected.

CHIMNEY/VENT Connect the furnace to a chimney/vent system of size and condition

required by the NFPA 31 (USA) or CSA B139 (Canada) code. Furnace is approved for factory built chimney type “L” vents. Breech is certified for 5” vent pipe. Keep vent/flue pipe as short as possible with a minimum upward slope of ¼’’ per foot. Vent/flue pipes MUST NOT pass through a ceiling. Maximum flue gas temperature is 575°F.

CONDENSATION If you have condensation in your chimney, make sure that the

chimney size is according to the tables in CSA B139 / NFPA 31. The temperature at the entrance of the chimney can be increased by insulating the flue-pipe between the furnace and the chimney base. If this is not sufficient, consider cutting or removing some flue baffles in the furnace. BE AWARE THAT REMOVING BAFFLES REDUCES THE UNIT EFFICIENCY AND A MODIFIED UNIT IS NO LONGER ENERGY STAR APPROVED.

COMBUSTION &

Install openings and ductwork to the furnace room providing fresh

VENTILATION AIR outside combustion and circulation air for cooling the furnace casing, as

installation code requires (USA NFPA 31, Canada CSA B139). If installed in a closed room, provide two free air ventilation openings of at least 8” x 12” (96 sq. in.) free flow area near ceiling and floor. Oil burners must have sufficient air to allow vent systems to operate properly.

DRAFT Use approved draft control supplied for 5” pipe. Set specified draft

minimum pressure of -0.01” wc.

ELECTRICAL Wire according to the National Electrical Code (Canadian Electrical

Code in Canada) or local codes. Use a separately fused #12 electrical line directly from the service panel to the furnace junction box. Install a manual shut-off switch at the door or stairway to furnace room so furnace can be shut off remotely.

CLEARANCES Before placing unit, review installation clearances as shown on furnace

operating decal or section PRODUCT INFORMATIONS.

LOCATION Install the furnace close to chimney and central to ductwork.

Page 9

WARM AIR

Filter

used to ensure these clearances.

MULTI-POSITION CONFIGURATIONS

UPFLOW INSTALLATION DOWNFLOW INSTALLATION

AIR RETURN

The return air opening can be located on left side or on the right side of the unit. After installing the filter rack supplied with the unit we recommend installing the blower door before handling the unit.

HORIZONTAL INSTALLATION

Downflow Sub-base

WARM AIR

When the unit is installed in downflow configuration on a combustible floor, the clearance from combustible material must be respected. The downflow sub-base CAB-A0-0045-00 (for KHM-1/090) or CAB-A0-0046-00 (for KHM-2/140) can be

AIR RETURN

When the unit is installed in the horizontal configuration on a combustible floor with a choice of right or left air outlet, the clearance of (2’’) from combustible material must be taken into consideration.

The burner must always be installed facing upwards regardless of the

For complete clearance information to combustibles, see PRODUCT

configuration installation.

INFORMATION, page 3.

AIR RETURN

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4.0 ACCESSORY INSTALLATION

BLOCKED VENT SWITCH (BVSO) FOR CANADIAN APPLICATION ONLY

Oil-fired appliances installed in Canada require a blocked vent switch system when installed on a chimney. A safety switch is included with the furnace to perform this function. It is the installer’s responsibility to install the switch in accordance with the instructions provided. Not applicable for Direct Vent systems. Field Controls Model: WMO-1 (Manual Reset)

Switch Operation

Blocked vent switches are flue gas safety devices for detecting spillage of flue gases due to a blocked flue or inadequate draft. After detecting a problem, the switch de-energizes the system’s burner control.

NEVER reset the switch unless the cause of the blockage has been corrected. Installation (Figure 1)

1) Drill a 5/8” hole in to the flue vent pipe near the appliance breech connection.

2) This hole must be before the draft regulator, vertically or horizontally.

3) Remove one of the securing nuts from the threaded tube of the safety switch.

4) Tighten the other securing nut onto the pipe as far as possible.

5) Insert the threaded tube end into the pierced hole of the flue vent pipe.

6) Install the securing nut on the safety switch tube, which protrudes into the flue vent pipe. Tighten the nut securely.

Figure 1-

Illustration from the instruction

Figure 2- BVSO wiring diagram

manual of Field Controls

Wiring Instructions (BVSO) Caution: Disconnect the electrical power when wiring the unit.

Wire the blocked vent switch in accordance with The National Electrical Code and applicable local codes. Wire the safety switch (BVSO) in series with the thermostat and the fan timer relay control (Figure 2).

Page 11

System Test Procedure (BVSO)

1) With the power re-established, block the chimney or vent pipe downstream of the switch.

2) Adjust the thermostat to call for heat.

3) Once the heating system has started the blocked vent switch should shut down the burner within 10 minutes or sooner.

4) Once the system has cooled, the blocked vent switch can manually be reset.

5) This procedure should be tested a second time.

6) After testing the blocked vent switch the chimney should be cleared of obstruction and the heating system should be tested over a long run cycle.

If the block vent switch shuts down the system, check to ensure there is enough draft in the chimney and venting pipes.

AIR CONDITIONING

An air conditioning coil may be installed on the supply side only. Coils installed on the return side will cause

condensation on the heat exchanger; this will shorten the heat exchanger life and may cause products of combustion to enter the house. Wire as per wiring label and diagram. Height of

the coil above the unit supply shall be at least 4” (102 mm).

4 inch

minimum

See A/C coil Manufacturers Requirements. To check the AC coil total air flow resistance, see procedure at page 33.

HUMIDIFIER

If a humidifier is installed ensure that no water can drip or run from it into the furnace. This would cause deterioration and void the furnace warranty.

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rack

Spacer

holder

door

AIR FILTER RACK INSTALLATION

The air filter rack is shipped uninstalled inside the furnace. This way the owner can install it in the position that he wants. There are 3 possible locations to install the air filter rack which are: bottom left side, bottom right side and under the furnace. Follow the instructions below to install the air filter support properly.

Step 1: Slide air filter spacer inside the outside filter rack. Step 2: Screw in the 4 screws to hold these two parts together.

4 X

Bend must be

facing out

Outside filter

Air filter

Step 3: Slide filter holder door and filter door. Step 4: Use the 2 remaining screws to maintain the filter door in place.

2 X

Door

Filter

Page 13

Step 5: Remove the 4 knockouts on the panel (left side, right side or base panel) where you

want to install the air filter

Step 6: Cut the panel between the 4 knockouts.

Step 7: Using 8 screws ,install the air filter rack on the furnace. Step 8: Slide the air filter inside the air filter rack

8 X

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5.0 BURNER INSTALLATION AND SPECIFICATIONS

5.1 ASSEMBLY & INSTALLATION OF BURNER

ASSEMBLE Check burner model is correct for furnace rating required. Assemble as

per burner manufacturer’s instructions.

SELECT NOZZLE Select oil input, nozzle and burner configuration as shown on furnace

operating decal.

INSTALL NOZZLE Install selected nozzle, check for clean seating and tighten in nozzle

adaptor.

ELECTRODES See burner manufacturer’s instructions for correct setting. INSERTION See figure below.

LENGTH

PUMP BY-PASS For one pipe system factory setting (no PLUG plug).

WIRING Refer to wiring diagram for correct

burner connections (see page 25 or 26).

THERMOSTAT Connect the thermostat wires to the fan

timer control board (ST9103).

Page 15

5.2 SET BURNER FOR EFFICIENT OPERATION

BURNER SETTINGS Use burner settings in the table on page 16 or operating decal as a

guide to set burner, particularly for nozzle change. Those settings are only starting points for the adjustments and are not meant as final settings.

On Beckett AFG burner, make sure the correct retention head and static disk are installed on the burner for the desired firing rate. The head is held in place by two (2) screws at the end of the burner blast tube. In the burner model in the table of page 16, the head is always after the AFG designation and the static disk after the head. For example, the AFG L2 3 3/8 means an AFG chassis burner with a L2 head and a static disk of 3 3/8.

PUMP PRESSURE Refer to the table on page 16 or operating decal.

AIR SETTING Use air settings on page 16 as a guide to set air adjustment. Those

settings are only starting points for the adjustments and are not meant as final settings.

DRAFT REGULATOR The draft regulator should be installed at least three (3) flue pipe

diameters from breeching or elbow of the furnace.

SAMPLING HOLE On smoke/vent pipe, drill a 3/8” round opening. The hole should be at

least two (2) flue pipe diameter from breeching or elbow of the furnace.

Page 16

DRAFT PRESSURE Using an accurate draft meter; adjust the draft control to obtain - 0.01”

wc minimum draft pressure at the breech sampling hole. The draft regulator’s adjustments should be made after furnace has been running under heating mode for at least five (5) minutes minimum.

COMBUSTION TEST All your tests must be done with the burner cover on (Riello)

COMBUSTION After 10 minutes of normal operation, take a smoke test and adjust SETTING/ the burner to obtain a reading of “1” on the smoke scale. Take a CO2 EFFICIENCY test and note the result.

To reach the maximum smoke test value, a 10 full slow steady pump action is required.

Open the air band adjustment on the burner to reduce your CO2 lecture by 1%.

To reach the maximum CO2 test value, a 18 full slow steady pump action is required.

You now have a perfect “slight trace” of smoke.

Relation between % of CO2 and O

(%) O

13.5 2.6 15.0

13.0 3.3 20.0

12.5 4.0 25.0

12.0 4.6 30.0

11.5 5.3 35.0

11.0 6.0 40.0

(%) Excess Air (%)

Page 17

5.3 TECHNICAL INFORMATION

Riello Burner

Ene

rgy Star Approved

(%)

875

850 1150

1050

LO 775 750 1060

1010

KHM Series

KHM-1 / 090 KHM-2 / 140

F3 F5

Unit Model Firing Rate (USGPH) Input (BTU/h) Output (BTU/h) Nozzle Pump Pressure (psi) Turbulator Setting Air Gate Adjustment

AFUE (%)

KHM-E1-*067-

0.55 0.65 0.75 0.90 1.05 1.15 77,000 91,000 105,000 126,000 147,000 161,000 67,000 79,000 91,000 109,000 126,000 139,000

0.40 70A 0.60 70W 0.65 70W 0.75 80W 0.85 70W 1.00 70W 190 145 145 145 165 145

0 0 0 0 1 2

1.75 2 2.35 2 2.25 2.25

YES YES YES YES YES YES

86.50 86.80 86.30 87.50 86.60 86.90

KHM-E1-*079-

KHM-E1-*091-

KHM-E3-*109-

KHM-E3-*127-

KHM-E3-*139-

Beckett Burner AFG L2 3-3/8 AFG F3 2-3/4

Unit Model

KHM-G2-*066-

Firing Rate (USGPH) 0.55 0.65 0.75 0.85 1.00 1.10 Input (BTU/h) 77,000 91,000 105,000 119,000 140,000 154,000 Output (BTU/h) 66,000 78,000 90,000 102,000 119,000 132,000 Nozzle 0.50 60W 0.60 60W 0.65 60W 0.75 70B 0.85 70B 1.00 70B Low Firing Rate Baffle YES YES YES YES YES YES Pump Pressure (psi) 145 145 145 145 145 145 Air Band (Gross) 1 1 1 1 2 2 Air Shutter (Fine) 4 6,5 8 7 6 10 Energy Star Approved YES YES YES YES YES YES AFUE (%)

86.80 86.60 86.00 86.70 86.50 86.40

12.5 13.5 13.7 12.5 13.5 13.5

General Information PSC motor info

Temperature Rise (°F) 40 – 70 40 – 70 50 – 80 40 – 70 40 – 70 50 – 05 Blower Speed Blower Speed

Energy Star ECM motor (0.2’’ wc to 0.5’’ wc static pressure)

Temperature Rise (°F) 50-80 55-85 60-85 52-85 55-85 55-85 Blower Speed M-LOW M-LOW MEDIUM M-LOW MEDIUM M-HIGH

(0.2’’ wc)

(0.5” wc)

M-LOW M-HIGH M-HIGH M-LOW M-HIGH M-HIGH

M-HIGH M-HIGH HIGH M-HIGH HIGH HIGH

KHM-G2-*078-

KHM-G2-*090-

KLHMG2-*102-

KHM-G2-*119-

KHM-G2-*132-

Static Pressure at 0.2'' WC / 0.5'' WC

Blower PSC 1/2 hp PSC 3/4 hp

Speed 0.2" wc 0.5" wc 0.2" wc 0.5" wc

MHI 1250 1170 1940 1875 MED --- --- --- --MLO 1100 1075 1710 1650

HI 1375 1275 2120 2030

(*) In the Unit Model number, is specific information of the product for administration only

Blower ECM 1/2 hp ECM 3/4 hp

Speed 0.2" wc 0.5" wc 0.2" wc 0.5" wc

HI 1300 1230 2000 1910

MHI 1225 1160 1900 1835 MED 1140 1050 1690 1660 MLO 1025 980 1610 1575

Page 18

6.0 FURNACE OPERATION AND SETTINGS

SHUTTING FURNACE DOWN

POWER OFF Turn off main power breaker or disconnect. FUEL OFF Shut off manual fuel supply valve.

Always keep manual fuel supply valve shut off if the burner is shut down for an extended period of time.

RESTARTING FURNACE

Follow this procedure before restarting a unit that has been shut down for an extended period of time.

INSPECTION Have the furnace/system serviced and inspected by a qualified technician. FUEL Turn on fuel supply and check that there are no leaks. POWER Turn on power and check that the furnace starts and operates as usual. OPERATION If the furnace/system fails to operate or operates in an unusual manner, call

your service technician. If the burner fails to operate at any time, call a qualified burner technician.

6.1 BLOWER SETTING

Ensure power is off when adjusting blower setting. For heating, use the blower speeds

shown on the furnace specifications to give a temperature rise according to tables on page 16. The Lo blower speed can be used for air circulation when neither heating nor cooling are required. Set blower speeds to match the installation requirements.

THERMOSTAT ANTICIPATOR SETTING

Adjust to thermostat manufacturer’s instruction.

FAN & LIMIT CONTROL

Limit 185°F (Factory set) Fan On 45 seconds after burner stats Fan Off Adjustable on fan control board (see page18)

Page 19

6.2 FAN TIMER CONTROL BOARD (ST9103A 1028)

o “FAN OFF” Dip Switches adjustment

Dip Switches

COMFORT ADJUSTMENTS

o Outlet air consistently too warm or too cold - change the blower motor speed to give the

specified air temperature rise.

o Outlet air gets too warm and burner shuts down - increase air by changing the blower

motor speed to give the specified temperature rise.

o Outlet air is too cold or too warm at the end of the heating cycle after the burner has turned

off - adjust the “FAN OFF” dip switch on electronic fan center. Refer to the next figure.

“FAN OFF” Dip Switch

OFF CYCLE AIR CIRCULATION

LOW SPEED All KHM models have the low speed switch for optional constant air

circulation during the furnace off cycle.

“FAN ON” When “FAN ON” is selected on the thermostat, the blower will run constantly

at the blower speed selected on the heating terminal. This is the equivalent of jumping terminals R and G on the ST9103 board.

Page 20

6.3 ST9103A 1028 CONTROL BOARD SEQUENCE

ST9103 Heating Sequence

1) Thermostat calls for Heat.

2) Burner starts

3) Blower starts after 45 seconds

4) Burner shuts down after call for heat is satisfied

5) Blower stops according to adjusted (FAN OFF) Dip switch selection

ST9103 Cooling Sequence

1) Thermostat calls for cooling

2) Blower starts immediately

3) Cooling unit starts

4) Blower stops immediately after cooling demand is satisfied

5) Cooling unit stops

Honeywell ST9103A 1028 Electronic Board

Page 21

Step

Possible Cause

Check

out procedure

Corrective action

on electronic fan control

Check breaker main power switch

electronic fan control.

Check for bad connection

Change Transformer

Yes

- Move to next step

Yes

- Move to next step

Warning: Make sure the quick connect cable is fully inserted on the board

Yes

- Move to step # 5

Failure on the limit control circuit

Temperature too high

6.4 SERVICING - FAN TIMER ST9103A 1028

Trouble shooting the electronic board ST 9103

Before trouble shooting

the board,

check for the 5 amp. fuse

For accurate trouble shooting, follow

step by step the Trouble Shooting Chart.

1 Incoming supply

2 Transformer

Electronic Fan

control

Limit Control

No Heat

Check for 120 Volts between terminal S2 and 3

Check for 120 Volts between terminal S3 and 4 on

Check for 24 Volts between terminal X and C on electronic fan control Check for 24 Volts between R and C Check for 24 Volts between terminal W and C

Check for 120 Volts on each terminal of the two limits

Check for 120 Volts coming from the main plug-in of the electronic fan control to the limit control

Check for 120 Volts coming out of the limit control

Yes - Move to next step

No -

Yes - Move to next step

No -

Yes - Move to next step

No -

No - Change the electronic board No - Check thermostat and wiring

Yes - Move to step # 5

No - Move to next step

Yes - Move to next step

No - Change the electronic fan control

No -

. . Bad limit control

Page 22

Yes

- Move to next s

tep

Blower

Step Possible Cause

5 A

5 B

Riello burner

application

Beckett Burner

application

Check-out procedure Corrective action

No Heat

Check for 120 Volts on the black wire, contact (COM) on the Riello burner relay kit.

Check if oil primary control is on reset

Check for continuity between the two wires yellow and violet on the Riello burner relay kit

Check for 120 Volts on the contact (No) of the Riello burner relay kit

Check for 120 volts on the orange wire coming to the burner (L)

Check for 120 Volts on the black wire terminal strip (mid terminal)

Check if oil primary control is on Reset

Check for continuity between the two wires black and gray (TT) on primary control

Yes - Move to next step

No - Back to step # 4 or check for bad connection

Yes - Press reset button

No - Move to the next step

Yes - Move to next step

No - Change the electronic fan control

Yes - Move to next step

No - Change the Riello burner relay kit

Yes - Failure on the burner

No - Change the electronic fan control No - Back to step # 4 or check bad

connection

Yes - Press reset button

No - Move to the next step

Yes - Move to next step

No - Change the electronic fan control

Low speed Check if the constant low speed switch is ON

Check for 120 Volts coming from the electronic fan control to the primary control (black wire)

Check for 120 Volts coming from the primary control (orange wire) to the transformer, motor and the electronic board

Check for 120 Volts at the ''CONT'' terminal on the electronic fan control

Check for 120 Volts on both side of the constant low speed switch

Yes - Move to next step

No - Change the electronic board

Yes - Failure on the burner

No - Change the primary control

Yes - Move to next step

No - Change the electronic fan control

Yes - Check ''LOW'' speed on the blower motor

No - Change the switch

Page 23

Compressor ON

Humidifier failure

Step Possible Cause Check-out procedure Corrective action

No Cooling

Step Possible Cause Check-out procedure Corrective action

Blower . High speed

Check for 24 Volts between G and C on electronic fan control

Check for 120 Volts at the ''COOL'' terminal of the electronic fan control

Yes - Move to next step

No - Check thermostat and wiring; if it's OK, then change the electronic fan control

Yes - Check ''COOL'' speed on the blower motor

No - Change the electronic fan control

Electronic air filter and Humidifier

Check for 24 volts between

8 Condensing unit

9 Electronic air filter

terminal Y and C on the electronic fan control

Check for 120 Volts on terminal ''EAC'' of the electronic fan control (thermostat must call a Heat, Cool or Fan ON demand

Yes -

No - Check thermostat and wiring

Yes - Electronic filter failure

No - Change the electronic fan control

Check for 120 Volts on

10 Humidifier

terminal ''HUM'' of the electronic fan control (burner must be energized)

Yes -

No - Change the electronic fan control

7.0 SERVICE

REGULAR MAINTENANCE

Check complete operation at least once a year. In Canada see B139, (Maintenance), in United States see NFPA 31, for recommended servicing procedure. Clean flue pipes on a regular basis. Replace flue pipes if there is any sign of corrosion or other problems. Gaskets should be checked and may have to be replaced.

Page 24

Step 3:

Remove the burner

Step

CHANGING NOZZLE

It is recommended that the nozzle be replaced once a year. If a new nozzle of a different size is installed, change the blower speed according to section BURNER INSTALLATION AND

SPECIFICATIONS (see table at page 14) or operating decal as required

CLEANING HEAT EXCHANGER

Heat exchanger must be inspected every heating season. Refer to instructions and pictures below.

Remove the breech plate

Remove the baffles and clean the round tubes if needed (use a 2’’ diameter brush)

Clean the transitions tubes if needed

Clean the combustion chamber if needed

AIR FILTERS

To maintain furnace performance and safety, replace dirty filters as required or at least once every heating season or as required. Use new approved disposable filters of the same size and type. Dirty, clogged or wrong sized filters will impair the furnace performance and may cause the furnace to shut down or overheat

Page 25

BLOWER REMOVAL

This furnace has a blower sealing system, which is designed to be tight and rattle free. Refer to the instructions and pictures below.

1) Shut off oil and power to furnace.

2) Remove the two (2) screws securing the blower door (Figure

1).

3) Open blower compartment (Figure 2).

4) Disconnect the wiring to the blower motor.

5) Remove the screw securing the blower side to the separating panel (Figure 3).

6) Slide the blower toward you and get the blower out of the furnace (Figure 4).

Figure 1 Figure 2

Figure 3 Figure 4

Page 26

8.0 ELECTRICAL / WIRING DIAGRAMS

Page 27

Transforming the electric box for a Beckett burner application, see page 27

GeniSys control schematic with the ST9103 Board

Page 28

Electric box with a Beckett burner application

Transforming the factory assembly Riello electric box

STEP 1 : Locate and disconnect the 2-pin Molex connector.

STEP 2 : Connect the 2-pin connector to the 2-pin harness

provided in the Beckett burner box.

STEP 3 : Connect the 2 wires (black and grey) of the 2-pin harness to the TW and TR connection on the GeniSys primary control

to a Beckett electric box

Page 29

9.0 EXPLODED PARTS VIEW

KHM-1 / 090 – Exploded Parts View

Page 30

KHM-1 / 090 – Part List

ITEM PART NUMBER

1 CAB-A0-0019-00 Left Panel Assembly 1 2 CAB-A0-0020-00 Right Panel Assembly 1 3 CAB-A0-0018-00 Rear Panel Assembly 1 4 CAB-A0-0016-00 Blower Panel Assembly 1 5 CAB-A0-0021-00 Front Panel Assembly 1 6 CAB-A0-0022-00 20’’ x 20’’ Filter Holder Assembly 1 7 CAB-P0-0045-00 Base Panel 1 8 CAB-P0-0052-00 Front Door Panel 1

9 CAB-P0-0051-00 Blower Door Panel 1 10 3HN-00-PULL-00 Handle Flush Pocket Pull 1 11 HEX-A0-0009-00 Heat Exchanger Assembly 1 12 HEX-P0-0064-00 Pipe Baffle Hi-Boy 7 13 ELB-A0-0006-00 Electrical Box Assembly - Hi-Boy Model 1

DESCRIPTION QTY

14 ELB-P0-0014-00 Cover Electric Box - Hi-Boy Model 1 15 4CB-00-FAN0-00 ST9103A1028 Electronic Board 1 16 4RY-00-24V0-00 Relay AE04001 24VAC Form C SPDT 24V 1 17 4TF-00-40VA-00 Transformer HTC-01A0BB01 40 VA 1 18 FAN-A0-0002-00 Fan Motor Assembly KLR-090 PSC Motor 1 19 FAN-A0-0002-01 Fan Motor Assembly KLR-090 ECM Motor 1 20 3BU-10-08DD-00 Blower 10'' x 8'' Direct Drive (G10-8DD) 1 21 3BM-50-4SDD-01 Motor Blower 1/2 HP Direct Drive 4SP EMERSON 1 22 4CA-00-705M-00 Capacitor 7.5 µF 370VAC 70C 60 Hz 1 23 3BM-50-ECM0-02 Motor Blower 1/2 HP ECM Ecotech EMERSON 1 24 1SB-00-BUMR-00 Bracket Motor Mounting Direct Drive Blower 1 25 3AF-02-2020-01 Filter Air 20" x 20" x 2" Non-Pleated (Strata Type) 1 26 INS-P0-0015-00 Low-Boy Rear Insulation 2 27 HEX-A0-0013-00 Front Collector Assembly 1 28 CAB-P0-0121-00 Front Flue Collar 1 29 4SD-00-0185-00 Control Limit Snap Disc (185°) Au to Reset (L185-40F)

2 30 INS-P0-0017-00 Burner's Flange Insulation 1 31 3SG-0P-1030-5A Glass Sight Clear 1" NPT Hex With THD Seal 1 32 INS-P0-0018-00 Sight Glass Insulation 1

Page 31

KHM-2 / 140 – Exploded Parts View

Page 32

KHM-2 / 140 – Part List

ITEM PART NUMBER

1 CAB-A0-0027-00 Left Panel Assembly 1 2 CAB-A0-0028-00 Right Panel Assembly 1 3 CAB-A0-0026-00 Rear Panel Assembly 1 4 CAB-A0-0024-00 Blower Panel Assembly 1 5 CAB-A0-0029-00 Front Panel Assembly 1 6 CAB-A0-0030-00 20’’ x 25’’ Filter Holder Assembly 1 7 CAB-P0-0061-00 Base Panel 1 8 CAB-P0-0065-00 Front Door Panel 1

9 CAB-P0-0051-00 Blower Door Panel 1 10 3HN-00-PULL-00 Handle Flush Pocket Pull 1 11 HEX-A0-0011-00 Heat Exchanger Assembly 1 12 HEX-P0-0064-00 Pipe Baffle Hi-Boy 11 13 ELB-A0-0006-00 Electrical Box Assembly - Hi-Boy Model 1 14 ELB-P0-0014-00 Cover Electric Box - Hi-Boy Model 1 15 4CB-00-FAN0-00 ST9103A1028 Electronic Board 1

DESCRIPTION QTY

16 4RY-00-24V0-00 Relay AE04001 24VAC Form C SPDT 24V 1 17 4TF-00-40VA-00 Transformer HTC-01A0BB01 40 VA 1 18 FAN-A0-0001-00 Fan Motor Assembly KHM-140 PSC Motor 1 19 FAN-A0-0001-01 Fan Motor Assembly KHM-140 ECM Motor 1 20 3BU-12-00DD-00 Blower 12'' Direct Drive (GT12-10DD) 1 21 3BM-75-4SDD-01 Motor Blower 3/4 HP Direct Drive 4SP EMERSON 1 22 1SB-00-BUMR-00 Bracket Motor Mounting Direct Drive Blower 1 23 4CA-00-156M-2B Capacitor 15 µF 370VAC 70C 60 Hz 1 24 3BM-75-4SDD-02 Motor Blower 3/4 HP ECM Ecotech EMERSON 1 25 3AF-02-2025-01 Filter Air 20" x 25" x 2" Non-Pleated (Strata Type) 1 26 INS-P0-0020-00 Hi-Boy Front Insulation 2 27 HEX-A0-0010-00 Front Collector Assembly 1 28 CAB-P0-0121-00 Front Flue Collar 1 29 4SD-00-0185-00 Control Limit Snap Disc (185°) Au to Reset (L185-40F) 2 30 INS-P0-0017-00 Burner's Flange Insulation 1 31 3SG-0P-1030-5A Glass Sight Clear 1" NPT Hex With THD Seal 1 32 INS-P0-0018-00 Sight Glass Insulation 1

Page 33

10. START-UP TEST RESULTS

Model: Serial Number: Unit configuration: Upflow____ Downflow_____ Horizontal left_____ Horizontal right_____

Date of installation: Installer (name & address):

START-UP TEST RESULTS

Size of unit (Btu/h): Nozzle: Oil Pressure (psi):

Chimney____________ Direct vent system (DVS) ____________

Burner adjustments: RIELLO F3___ RIELLO F5___ BECKETT AFG L2___ BECKETT AFG F3____

Turbulator: ______ Air band: ______ Air Gate: ________ Air shutter______

Smoke result: #0 TRACE #1 Combustion Results:

CO2 % Chimney draft: “ W.C. Ambient temperature: °F Gross flue temperature: °F Temperature rise: °F (see page 33) External total static pressure: “ W.C. (see page 33) A/C Coil total resistance: “ W.C. (see page 33)

Page 34

TEST PROCEDURES

External Total Static Pressure Reading A/C Coil Total Resistance Reading

Supply Pressure (Ps) + Return Pressure (Pr)

Coil Pressure (Pc) - Supply Pressure (Ps)

Temperature Rise Reading ***

Supply Temp. (Ts) - Return Temp. (Tr)

*** Probe must not be in direct sight of heat exchanger.

Page 35

Granby Furnaces Inc. manufactures a full line of oil-fired furnaces in its 70,000 square feet facility. Granby products are sold across Canada and the United States through a distribution network.

Our team of engineers, designers and technicians continually research and develop products to go beyond the demanding specifications of today’s certifications.

Thank you

Thank you for choosing Granby

Thank you Thank you

for choosing Granby....

for choosing Granbyfor choosing Granby