Granby KLR-100, KLF-200, KLR-200 Installation, Operation And Service Manual

Installation, Operation and

Service Manual

KLR / KLF series

85% + EFFICIENCY
OIL FIRED

LOWBOY FURNACE

KLR-100
KLR-200
KLF-200

KLR-100
Illustration

INSTALLATIONS MUST MEET ALL LOCAL AND FEDERAL

CODES THAT MAY DIFFER FROM THIS MANUAL

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

09-05-2013

KLF-200

G2012-E1 Rev.E

TABLE OF CONTENTS

1.0 IMPORTANT SAFETY ADVICE 2

2.0 PRODUCT INFORMATION

3.0 FURNACE INSTALLATION

4.0 ACCESSORIES INSTALLATION

5.0 BURNER INSTALLATION AND SPECIFICATIONS 11

5.1 ASSEMBLY & INSTALLATION OF BURNER 11

5.2 SET BURNER FOR EFFICIENT OPERATION 12

5.3 KLR TECHNICAL INFORMATION 14

5.4 KLF TECHNICAL INFORMATION 15

6.0 FURNACE OPERATION AND SETTINGS 16

6.1 BLOWER SETTING 16

6.2 FAN TIMER CONTROL BOARD (ST9103 A 1028) 17

6.3 (ST9103 A 1028) CONTROL BOARD SEQUENCE 18

6.4 SERVICING – FAN TIMER (ST9103 A 1028) 19

7.0 SERVICE 21

8.0 ELECTRICAL / WIRING DIAGRAMS 24

RIELLO WIRING DIAGRAM 24
BECKETT WIRING DIAGRAM 25

9.0 EXPLODED PARTS VIEW 27
KLR-100 27
KLR-200 29
KLF-200 31

10. START-UP TEST RESULTS 33

3

7

9

1

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 unit
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 draining’s 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 material damage.

IMPORTANT

This manual contains instructional and operational information for the KLR / KLF 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.

2

2.0 PRODUCT INFORMATION

CLEARANCE (minimum) TO COMBUSTIBLES

Top of Supply Plenum 1” (25 mm)
Front (Maintenance) 24” (610 mm)
Rear (Maintenance) 24” (610 mm)
Side – Non-Access 1” (25 mm)
Side – Access maintenance 24” (610 mm)
Flue Pipe 9” (229 mm)
Floor (Can be installed directly on combustible or non-combustible)

DRAFT PRESSURE

Breech draft pressure -0.01” wc minimum

AIR/BLOWER DATA
Maximum external static pressure 0.5” wc
Maximum cooling unit capacity 3.0 tons... KLR-100

5.0 tons… KLR-200

5.0 tons… KLF-200
Maximum air temperature rise See pages 14 (KLR), 15(KLF) and 34
High Limit temperature 185°F
Thermostat anticipator See thermostat instructions

MOTOR/BLOWER

KLR-100: 1/2 hp 4 Speed / G10-8 DD or 1/2 hp ECM / G10-8
KLR-200: 3/4 hp 4 Speed / GT12-10DD or 3/4 hp ECM / GT12-10

KLF-200: 3/4 hp 4 Speed / GT12-10DD or 3/4 hp ECM / GT12-10
1/2 hp ECM /GT12-10 with a firing rate of 0.75 USGPH

FAN/HIGH LIMIT CONTROL

Honeywell ST9103A1028 Fan Center & Thermo-Disk (7” stem)

THERMOSTAT

Any wall 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.

3

FLUE-PIPE CONNECTION
5” Chimney or Direct Vent DVS Granby kit

CLEANOUTS

Rear Cover & Burner Opening

AIR FILTERS
KLR-100 20” x 20” x 2” non pleated UL approved
KLR-200 15” x 20” x 2” & 20” x 20” x 2” non pleated UL approved
KLF-200 15” x 20” x 2” (2X) non pleated UL approved

PLENUM DIMENSIONS (KLR-100)

Cold air return (A) 20” x 20” (508 x 508 mm)
Hot air supply (B) 20” x 20” (508 x 508 mm)
Plenum spacing (C) 2-1/8” (54 mm)

PLENUM DIMENSIONS (KLR-200)
Cold air return (A) 20” x 22” (508 x 559 mm)
Hot air supply (B) 20” x 24” (508 x 610 mm)
Plenum spacing (C) 2-1/8” (54 mm)

PLENUM DIMENSIONS (KLF-200)
Cold air return (A) 20” x 20” (508 x 508 mm)
Hot air supply (B) 20” x 24” (508 x 610 mm)
Plenum spacing (C) 2” (51 mm)

B

C

A

B

C

A

KLR KLF

4

DIMENSIONS (KLR-100) DIMENSIONS (KLF-200)

Depth 49-1/8” (1248 mm) Depth 52-5/8” (1337 mm)
Height 33” (838 mm) Height 35-1/8” (892 mm)
Width 21-1/2” (546 mm) Width 21-1/2” (546 mm)

DIMENSIONS (KLR-200)
Depth 55-1/8” (1400 mm)
Height 33” (838 mm)
Width 21-1/2” (546 mm)

KLR-100 - DIMENSIONS

Dimensions are in inches

5

KLR-200 – DIMENSIONS

Dimensions are in inches

KLF-200 – DIMENSIONS

Dimensions are in inches

6

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 number of
connections in suction line and make all connections air tight. 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 outlet is above the burner and when the oil flows by

TWO PIPE SYSTEM When a single line is not suitable, use double line or contact your

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

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

REAR FLUE FURNACE ILLUSTRATION

Oil Tank and Piping

7

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. For a
furnace installed on a combustible floor, consult the applicable code and
authorities having jurisdiction on this application. The floor must support
the weight.

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 min. 1/4”
per foot upward slope. 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 base 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’S EFFICIENCY AND A MODIFIED UNIT IS NO
LONGER ENERGY STAR APPROVED.

COMBUSTION &

Install openings and ductwork to the furnace room providing fresh out-

VENTILATION AIR side 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.

BREECH DRAFT Use approved draft control supplied for 5” pipe. Set draft pressure of the

flue to -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 INFORMATION (page 3).

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

8

4.0 ACCESSORIES 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

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 (Figure 1).

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).

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).

9

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

4 inch

minimum

KLR KLF
See A/C coil Manufacturers Requirements.

To check the AC coil total air flow resistance, see procedure at page 34.

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.

10

5.0 BURNER INSTALLATION AND SPECIFICATIONS

5.1 ASSEMBLY & INSTALLATION OF BURNER

ASSEMBLY Check that the 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

MOUNT BURNER Tighten top nut first so burner tips down

slightly. The burner is always installed in
an upright position by four (4) nuts.

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

WIRING Refer to wiring diagram for correct burner

connections (see page 24 or 25).

THERMOSTAT Connect the thermostat wires to the fan

timer control board (ST9103).

11

5.2 SET BURNER FOR EFFICIENT OPERATION

BURNER SETTING Use burner settings in the table on page 14 (KLR) and 15 (KLF) or

operating decal as a guide to set burner, particularly for nozzle
changes. 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 screws at the end of the burner blast tube.
From the burner technical information table on page 14 (KLR) and 15
(KLF), 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 14 (KLR) and 15 (KLF) or operating decal.

AIR SETTING Use air settings on page 14 (KLR) and 15 (KLF) 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 3 flue pipe diameter

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 2 flue pipe diameter from breeching or elbow of the furnace.

FRONT FLUE FURNACE ILLUSTRATION

12

DRAFT PRESSURE Using an accurate draft meter; adjust the draft control to obtain a

minimum of -0.01” wc 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 5 minutes.

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%.

CO2 test can be done mechanically or electronically

(18 full slow steady
pump action)

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

Relation between % of CO2 and O

2

CO

(%) O

2

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 (%)

2

13

5.3 KLR TECHNICAL INFORMATION

CO

2

(%)

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

LO

875

850 1150

1050

LO 775 750 1

060 1010

KLR Series

Riello Burner

Unit Model
Firing Rate (USGPH) 0.55 0.65 0.75 0.90 1.05 1.15
Input (BTU/h) 77,000 91,000 105,000 126,000 147,000 161,000
Output (BTU/h) 67,000 79,000 91,000 109,000 126,000 139,000
Nozzle 0.40 70A 0.60 70W 0.65 70W 0.75 80W 0.85 70W 1.00 70W
Pump Pr.
Pump Pr.
Turbulator Setting 0 0 0 0 1 2
Air Gate Adjustment 1.75 2 2.35 2 2.25 2.25
Energy Star Approved YES YES YES YES YES YES

AFUE (%)

2 pipes sys. (psi)
1 pipe sys. (psi)

KLR-100 KLR-200

F3 F5

KLR-E1-*067-03 KLR-E1-*079-03 KLR-E1-*091-03 KLR-E3-*109-05 KLR-E3-*127-05 KLR-E3-*139-05

190 145 145 145 165 145
190 165 165 165 175 165

86.80 87.00 86.20 88.00 87.40 86.80

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

Unit Model
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 NO NO NO YES YES YES
Pump Pressure (psi) 145 145 145 145 145 145
Air Band (Gross) N/A N/A N/A 1 2 2
Air Shutter (Fine) 4 5.5 7 7 6 10
Energy Star Approved YES YES YES YES YES YES

AFUE (%)

KLR-G2-*066-03 KLR-G2-*078-03 KLR-G2-*090-03 KLR-G2-*102-05 KLR-G2-*119-05 KLR-G2-*132-05

87.00 87.10 86.30 87.50 87.20 86.50

12.5 13.5 13.5 12.5 13.5 13.5

General Information
PSC motor info

Temperature Rise (°F) 55 – 85 55 – 85 55 – 85 55 – 85 55 – 85 55 – 85
Blower Speed
Blower Speed

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

Temperature Rise (°F) 40-70 45-75 55-85 55-85 55-85 60-85
Blower Speed M-LOW M-LOW M-LOW 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

Blower PSC 1/2 hp PSC 3/4 hp

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

HI 1375 1275 2120 2030

MHI 1250 1170 1940 1875

MED --- --- --- ---

MLO 1100 1075 1710 1650

(*) 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

14

5.4 KLF TECHNICAL INFORMATION

Pump Pr

.

CO212.5

13.5

13.5

12.5

KLF Series

Riello Burner

Unit Model
Firing Rate (USGPH)
Input (BTU/h)
Output (BTU/h)
Nozzle

2 pipes sys. (psi)

Pump Pr. 1
Turbulator Setting
Air Gate Adjustment
Energy Star Approved
AFUE (%)

pipe sys. (psi)

KLF-200

F5

KLF-E3-*093-03 KLF-E3-*102-05 KLF-E3-*119-05 KLF-E3-*132-05

0.75 0.85 1.00 1.10

105,000 119,000 140,000 154,000

93,000 102,000 119,000 132,000

0.65 70W 0.75 70W 0.85 70W 1.00 70W
145 145 165 145
165 165 175 165

0 0 1 2

1.75 2 2.25 2.25
YES YES YES YES

88.60 87.50 87.30 86.50

Beckett Burner AFG F3 2-3/4

Unit Model
Firing Rate (USGPH) 0.75 0.85 1.00 1.10
Input (BTU/h) 105,000 119,000 140,000 154,000
Output (BTU/h) 93,000 102,000 119,000 132,000
Nozzle 0.65 70W 0.75 70B 0.85 70B 1.00 70W
Low Firing Rate Baffle YES YES YES YES
Pump Pressure (psi) 145 145 145 145
Air Band (Gross) 0 1 2 2
Air Shutter (Fine) 4 7 6 10
Energy Star Approved YES YES YES YES

AFUE (%)

KLF-G2-*093-03 KLF-G2-*102-03 KLF-G2-*119-03 KLF-G2-*132-05

87.50 86.60 86.30 86.30

General Information
PSC motor info

Temperature Rise (°F) 55 - 85 55 - 85 55 - 85 55 - 85
Blower Speed
Blower Speed

(0.2’’ wc)

(0.5” wc)

M-LOW M-HIGH HIGH HIGH

M-LOW M-HIGH M-HIGH HIGH

Energy Star ECM motor (0,2'' wc to 0,5'' static pressure)

Temperature Rise (°F) 45-75 52-80 55-85 55-85
Blower Speed M-LOW M-LOW MEDIUM MED-HI

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

Blower PSC 3/4 hp

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

HI 2120 2030 1300 1230 2000 1910

MHI 1940 1875 1225 1160 1900 1835
MED - - 1140 1050 1690 1660
MLO 1710 1650 1025 980 1610 1575

LO 1150 1050 775 750 1060 1010

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

ECM 1/2 hp

ECM 3/4 hp

15

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 the technical
information tables on page 14 (KLR) and 15 (KLF). The Lo blower speed can be used for air
circulation when heating or cooling are not required. Set blower speeds to match the
installation requirements.

FAN & LIMIT CONTROL

Limit 185°F – Factory set
Fan On 45 seconds after the burner starts
Fan Off Adjustable on board (see page 17)

THERMOSTAT ANTICIPATOR SETTING

Adjust to thermostat manufacturer’s instruction.

16

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 fan timer control board. Refer to the next
figure.

“FAN OFF” Dip Switch

Dip Switch adjustment (90 seconds) on all unit input

Except for Beckett burner 0.55 nozzle

60 seconds adjustment

OFF CYCLE AIR CIRCULATION (Factory settings)

LO SPEED All KLR / KLF models have the Lo 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.

17

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

KLF

KLR

18

on electronic fan control

power switch

electronic fan control.

Check for bad connection

Change Transformer

Yes

- Move t

o step # 5

Failure on the limit control circuit

Temperature too high

6.4 Servicing - Fan Timer ST9103A 1028
Trouble shooting the Honeywell electronic board ST9103

Before trouble shooting

the board,

check for the 5 amp. fuse

For accurate trouble shooting, follow step by step the Trouble Shooting Chart.

Step Possible Cause Check-out procedure Corrective action

1 Incoming supply

2 Transformer

3

4

Electronic Fan

control

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

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

Yes - Move to next step

No - Check breaker main

Yes - Move to next step

No -

Yes - Move to next step

No -

Yes - Move to next step

No - Change the electronic board

Yes - Move to next step

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

Check for 120 Volts coming
out of the limit control

No -

.
. Bad limit control

19

Yes

- Press reset button

, check by

-

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 burner activation
relay

Check if oil primary control
is on reset

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

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

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

Check for 120 Volts on
terminal strip (COM) of the
burner activation relay

Check if oil primary control
is on Reset and by-pass on
(TT)

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

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 burner activation relay

Yes - Failure on the burner

No - Change the electronic fan control

Yes - Move to next step

No - Back to step # 4 or check bad
connection

pass on (TT)

No - Move to the next step

Yes - Move to next step

No - Change the electronic fan control

6

Blower

.

Low speed
Check if the
constant low
speed switch is
ON

Check for 120 Volts on the
contact (NO) on the burner
activation relay

Check for 120 Volts on the
orange wire coming to the
burner

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 burner activation relay

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

20

Humidifier failure

Step Possible Cause Check-out procedure Corrective action

No Cooling

7

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 - Compressor ON

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
Unites 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.

21

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) Open blower compartment.

3) For KLF furnace only, remove air filter.

4) Disconnect the wiring to the blower motor.

5) Remove the four (4) wing nuts securing the blower side to the base panel bracket.

Wing Nuts

Wing Nuts

KLR KLF

6) Slide the blower toward you and then lift the blower straight up. Shift the blower out of the
furnace.

KLR KLF

Put back the blower assembly using the reverse procedure. Ensure wiring and ground wires
are correctly reconnected.

AIR FILTERS

To maintain furnace performance and safety, replace dirty filters 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.

22

Step 1:

Remove breech plate

Step 2:

Remove ba

ffles

Step 3:

Step 4:

Remove burner

Step 5:

Step 1:

Step

4

:

Step

3

:

Step

5:

Step

2

:

(use a 2’’ diameter brush)

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 or operating decal as required.

CLEANING HEAT EXCHANGER

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

KLR HEAT EXCHANGER

Clean the round tubes, if
needed (use a 2’’
diameter brush)

Clean combustion
chamber, if needed

KLF HEAT EXCHANGER

Remove burner

Clean combustion chamber, if needed

Remove breech plate

Remove the baffles and clean
the round tubes, if needed

23

8.0 ELECTRICAL / WIRING DIAGRAMS

24

25

GeniSys control schematic with the ST9103 Board

26

9.0 EXPLODED PARTS VIEW

KLR-100 – Exploded Parts View

27

KLR-100 – Part List

ITEM PART NUMBER DESCRIPTION QTY

1 CAB-A0-0007-00 Front Panel Assembly 1
2 CAB-A0-0005-00 Right Panel Assembly 1
3 CAB-A0-0004-00 Left Panel Assembly 1
4 CAB-A0-0006-00 Divider Panel Assembly 1
5 CAB-A0-0011-00 Base Panel Assembly 1
6 CAB-P0-0080-00 Top Rear Panel 1
7 CAB-P0-0013-00 Blower Door Panel 1
8 CAB-P0-0014-00 Upper Divider 1

9 CAB-P0-0015-00 Divider's Filler Gasket Bracket 1
10 3HN-00-PULL-00 Handle Flush Pocket Pull 1
11 HEX-A0-0001-00 Heat Exchanger Assembly 1
12 HEX-P0-0053-00 Pipe Baffle Low-Boy 5
13 INS-P0-0001-00 Divider Filler Gasket - 5 Holes 1
14 ELB-A0-0008-00 Electrical Assembly - Low-Boy Model 1
15 ELB-P0-0018-00 Cover Electrical Box - Low-Boy Model 1
16 4CB-00-FAN0-00 ST9103A1028 Electronic Board 1
17 4TF-00-40VA-00 Transformer HTC-01A0BB01 40VA 1
18 4RY-00-24V0-00 Relay AE04001 24VAC Form C SPDT 24V 1
19 HEX-A0-0012-00 Rear Collector Assembly 1
20 FAN-A0-0002-00 Fan Motor Assembly KLR-100 PSC Motor 1
21 FAN-A0-0002-01 Fan Motor Assembly KLR-100 ECM Motor 1
22 3BU-10-08DD-00 Blower 10'' x 8'' Direct Drive (G10-8DD) 1
23 3BM-50-4SDD-01 Motor Blower 1/2 HP Direct Drive 4SP EMERSON 1
24 4CA-00-705M-00 Capacitor 7.5 µF 370VAC 70C 60 Hz 1
25 3BM-50-ECM0-02 Motor Blower 1/2 HP ECM Ecotech EMERSON 1
26 1SB-00-BUMR-00 Bracket Motor Mounting Direct Drive Blower
27 INS-P0-0015-00 Low-Boy Rear Insulation 2
28 3AF-02-2020-01 Filter Air 20'' x 20'' x 2'' Non-Pleated (Strata Type) 1
29 INS-P0-0017-00 Burner's Flange Insulation 1
30 4SD-00-0185-00 Control Limit Snap Disc (185°) Auto Reset (L185-30F) 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

1

28

KLR-200 – Exploded Parts View

29

ITEM PART NUMBER

1 CAB-A0-0007-00 Front Panel Assembly 1
2 CAB-A0-0012-00 Base Panel Assembly 1
3 CAB-A0-0009-00 Right Panel Assembly 1
4 CAB-A0-0008-00 Left Panel Assembly 1
5 CAB-A0-0010-00 Divider Panel Assembly 1
6 CAB-P0-0080-00 Top Rear Panel 1
7 CAB-P0-0013-00 Blower Door Panel 1
8 CAB-P0-0014-00 Upper Divider 1

9 CAB-P0-0015-00 Divider's Filler Gasket Bracket 1
10 3HN-00-PULL-00 Handle Flush Pocket Pull 1
11 HEX-A0-0003-00 Heat Exchanger Assembly 1
12 HEX-P0-0053-00 Pipe Baffle Low-Boy 7
13 INS-P0-0008-00 Divider Filler Gasket - 7 Holes 1
14 ELB-A0-0008-00 Electrical Assembly - Low-Boy Model 1
15 ELB-P0-0018-00 Cover Electrical Box - Low-Boy Model 1
16 4CB-00-FAN0-00 ST9103A1028 Electronic Board 1
17 4TF-00-40VA-00 Transformer HTC-01A0BB01 40VA 1
18 4RY-00-24V0-00 Relay AE04001 24VAC Form C SPDT 24V 1
19 HEX-A0-0012-00 Rear Collector Assembly 1
20 FAN-A0-0001-00 Fan Motor Assembly KLR-200 PSC Motor 1
21 FAN-A0-0001-01 Fan Motor Assembly KLR-200 ECM Motor 1
22 3BU-12-00DD-00 Blower 12'' Direct Drive (GT12-10DD) 1
23 3BM-75-4SDD-01 Motor Blower 3/4 HP Direct Drive 4SP EMERSON 1
24 4CA-00-156M-2B Capacitor 15 µF 370VAC 70C 60 Hz 1
25 3BM-75-4SDD-02 Motor Blower 3/4 HP ECM Ecotech EMERSON 1
26 1SB-00-BUMR-00 Bracket Motor Mounting Direct Drive Blower 1
27 INS-P0-0015-00 Low-Boy Rear Insulation 2
28 3AF-02-2020-01 Filter Air 20'' x 20'' x 2'' Non-Pleated (Strata Type) 1
29 3AF-02-1520-01 Filter Air 15'' x 20'' x 2'' Non-Pleated (Strata Type) 1
30 4SD-00-0185-00 Control Limit Snap Disc (185°) Auto Reset (L185-30F) 1
31 INS-P0-0017-00 Burner's Flange Insulation 1
32 3SG-0P-1030-5A Glass Sight Clear 1'' NPT Hex With THD Seal 1
33 INS-P0-0018-00 Sight Glass Insulation 1

KLR-200 – Part List

DESCRIPTION QTY

30

KLF-200 – Exploded Parts View

31

KLF-200 – Part List

ITEM PART NUMBER

1 CAB-A0-0049-00 Front Panel Assembly 1

2 CAB-A0-0052-00 Base Panel Assembly 1

3 CAB-A0-0051-00 Right Panel Assembly 1

4 CAB-A0-0050-00 Left Panel Assembly 1

5 CAB-A0-0053-00 Divider Panel Assembly 1

6 CAB-P0-0164-00 Top Rear Panel 1

7 3HN-00-PULL-00 Handle Flush Pocket Pull 1

8 CAB-P0-0013-00 Blower Door Panel 1

9 ELB-A0-0018-00 Electrical Box Assembly 1

10 CAB-P0-0128-00 Cover Electrical Box 1
11 4TF-00-40VA-00 Transformer HTC-01A0BB01 40VA 1
12 4RY-00-24V0-00 Relay AE04001 24VAC Form C SPDT 24V 1
13 4CB-00-FAN0-00 ST9103A1028 Electronic Board 1
14 3AF-02-1520-01 Filter Air 15'' x 20'' x 2'' Non-Pleated (Strata Type) 2
15 HEX-A0-0011-00 Heat Exchanger Assembly 1
16 HEX-P0-0064-00 Pipe Baffle Hi-Boy 11
17 INS-P0-0018-00 Sight Glass Insulation 1
18 INS-P0-0017-00 Burner's Flange Insulation 1
19 3SG-0P-1030-5A Glass Sight Clear 1'' NPT Hex With THD Seal 1
20 4SD-00-0185-00 Control Limit Snap Disc (185°) Auto Reset (L185-30F) 1
21 INS-P0-0020-00 Hi-Boy Front Insulation 2
22 HEX-A0-0010-00 Front Collector Assembly 1
23 CAB-P0-0156-00 Front Door Panel 1
24 FAN-A0-0001-00 Fan Motor Assembly KLR-200 PSC Motor 1
25 FAN-A0-0001-01 Fan Motor Assembly KLR-200 ECM Motor 1
26 FAN-A0-0006-00 Fan Motor Assembly KLF-200 PSC Motor 1
27 FAN-A0-0006-01 Fan Motor Assembly KLF-200 ECM Motor 1
28 3BU-12-00DD-00 Blower 12'' Direct Drive (GT12-10DD) 1
29 4CA-00-156M-2B Capacitor 15 µF 370VAC 70C 60 Hz 1
30 3BM-75-4SDD-01 Motor Blower 3/4 HP Direct Drive 4SP EMERSON 1
31 3BM-75-4SDD-02 Motor Blower 3/4 HP ECM Ecotech EMERSON 1
32 1SB-00-BUMR-00 Bracket Motor Mounting Direct Drive Blower 1
33 3BM-50-4SDD-01 Motor Blower 1/2 HP Direct Drive 4SP EMERSON 1
34 3BM-50-ECM0-02 Motor Blower 1/2 HP ECM Ecotech EMERSON 1

DESCRIPTION QTY

32

10. START-UP TEST RESULTS

Model: Serial Number:
Lowboy KLR________ Lowboy KLF_______
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___BF3___RIELLO F5___BF5___ BECKETT AFG-LII___ Beckett AFG-F3___

Turbulator: _____ Air band:_______
Air Gate: ________ Air shutter: ______

Smoke result: #0 TRACE #1
Combustion Results:
Chimney draft: “ W.C.
Ambient temperature: °F
Gross flue temperature: °F
Temperature rise: °F (see page 34)
External total static pressure: “ W.C. (see page 34)
A/C Coil total resistance: “ W.C. (see page 34)

CO2 %

33

TEST PROCEDURES

Pr

Ps

Pc

Ps

External Total Static Pressure Reading

Total Static Pressure = Supply Pressure (Ps) + Return Pressure (Pr)

Pr

A/C Coil Total Resistance Reading

A/C coil total resistance = Coil Pressure (Pc) - Supply Pressure (Ps)

Temperature Rise Reading ***

Temperature rise = Supply Temp. (Ts) - Return Temp. (Tr)

Tr Ts

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

34

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 choosis

Thank youThank you

for choosis

for choosisfor choosis

35