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OIL FIRED LOBOY FURNACE -
85% + EFFICIENCY
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K
LR-100
K
LR-200
K
LF-100
KLF
-200
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KLR-100 & 200 KLF-100 KLF-200
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Please read the manual in its entirety before beginning installation. This
manual must be kept with the boiler for future reference. For maintenance
or question, please refer to your installer – contractor directly.
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18-06-2017 G2017-E1 Rev.I
Installation, Operation and
Service
Manual
INSTALLATIONS MUST MEET ALL LOCAL AND CODES THAT MAY
DIFFER FROM THIS
Page 2
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TABLE OF
CONTENTS
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1.0 IMPORTANT SAFETY ADVICE 2
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2.0 PRODUCT INFORMATION 3
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3.0 FURNACE INSTALLATION 7
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4.0 ACCESSORIES INSTALLATION 9
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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
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6.0 FURNACE OPERATION AND SETTINGS 16
6.1 BLOWER SETTING 16
6.2 FAN TIMER CONTROL BOARD (ST9103A1028) 17
6.3 (ST9103A10
28) CONTROL BOARD SEQUENCE 18
6.4 SERVICING – FAN TIMER (ST9103A1028) 19
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7.0 SERVICE 21
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8.0 ELECTRICAL / WIRING DIAGRAMS 24
HEATING & COOLING – RIELLO BURNER 24
HEATING & COOLING – BECKETT BURNER 25
HEATING ONLY (2 WIRES THERMOSTAT) 27
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9.0 EXPLODED PARTS VIEW 28
KLR-100 28
KLR-200 30
KLF-100
(Coming soon, please call your Granby representative) ---
KLF-200 32
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10. START-UP TEST RESULTS 34
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1.0 IMPORTANT SAFETY ADVICE
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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.
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WARNINGS
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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.
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CAUTION
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DO NOT TAMPER WITH THE FURNACE OR CONTROLS, CALL A QUALIFIED BURNER
TECHNICIAN.
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DANGER
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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.
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IMPORTANT
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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.
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2.0 PRODUCT INFORMATION
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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
BURNER TUBE INSERTION
Riello and Beckett 2-1/2” (63 mm)
AIR/BLOWER DATA
Maximum external static pressure 0.5” WC
Maximum cooling unit capacity KLR-100, up to 3.0 tons.
KLR-200, up to 5.0 tons.
KLF-100, up to 3.0 tons
KLF-200, up to 5.0 tons.
Maximum air temperature rise 85°F
High Limit temperature 185°F
MOTOR/BLOWER
KLR-100: 1/2 hp 4 Speed PSC / G10-8 DD or 1/2 hp 5 speed ECM / G10-8 DD
KLR-200: 3/4 hp 4 Speed PSC / GT12-10 DD or 3/4 hp ECM 5 speed / GT12-10 DD
KLF-100: 1/2 hp 4 Speed PSC / G10-8 DD or 1/2 hp ECM 5 speed / G10-8 DD
KLF-200: 3/4 hp 4 Speed PSC / GT12-10 DD or 3/4 hp ECM 5 speed / GT12-10 DD
FAN/HIGH LIMIT CONTROL
Honeywell ST9103A1028 Fan Center & Thermo-Disk (7” stem)
FLUE-PIPE CONNECTION
5” breech
CLEANOUTS
Rear breech cover & burner opening (KLR) or Front breech & burner opening (KLF)
THERMOSTAT
Any wall thermostat
Thermostat adjustment as per thermostat manufacturer installation.
Page 5
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FUEL
Not heavier than No. 2 furnace oil.
ELECTRICAL – 120 Volts, 1PH-60 Hz, 15 amps. circuit protection, USA circuit protection 20 amps.
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-100 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”
(51 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”
(51 mm)
PLENUM DIMENSIONS (KLF-100)
Cold air return
(A)
18” x 20-3/4”
(457 x 527 mm)
Hot air supply
(B)
18” x 21-3/4”
(457 x 552 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
Plenum spacing
(B)
(C)
20” x 24”
2”
(508 x 610 mm)
(51 mm)
B C A B C A
KLR KLF
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KLR KLF
DIMENSIONS (KLR-100) DIMENSIONS (KLF-100))
Depth
49-1/8”
(1248 mm)
Depth
53-1/2”
(1,359 mm)
Height
33”
(838 mm)
Height
29-3/8”
(746 mm)
Width
21-1/2”
(546 mm)
Width
21-1/2”
(546 mm)
DIMENSIONS (KLR-200) DIMENSIONS (KLF-200)
Depth
55-1/8”
(1400 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)
KLR KLF-100 KLF-200
KLR-100 - DIMENSIONS
Dimensions are in inches
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KLR-200 – DIMENSIONS
Dimensions are in inches
KLF-100 - DIMENSIONS
Dimensions are in inches
Page 8
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KLF-200 – DIMENSIONS
Dimensions are in inches
3.0 FURNACE INSTALLATION
OIL TANK & PIPING
Tank installation must conform to local requirements.
Install according to the applicable code such as CAN/CSA B139 and NFPA 31 in the USA.
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 gravity
to the oil pump, a single-stage fuel unit with a single oil line to the pump
may be used.
TWO PIPE SYSTEM When a single line is not suitable, use double line or contact your dealer
for special oil line fittings. Install by-pass plug on burner fuel pump as
specified in the burner manual.
Page 9
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REAR FLUE FURNACE ILLUSTRATION
Oil Tank and Piping
PLACEMENT & VENTING
Furnace installation shall conform to the required installation code for oil-fired equipment
(USA: NFPA 31, Canada: CAN/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 CAN/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.
PRESENCE OF CONDENSATION
IN THE CHIMNEY OR FLUE PIPE
Presence of condensation in your chimney or flue pipe is not normal, all
necessary precautions should be taken to prevent condensation build-up in the
flue pipe and inside the chimney. Make sure that the chimney size is according
to the tables in CAN/CSA B139 / NFPA 31.
Note: Base temperature — the temperature of the flue gases at the base of
the chimney flue, measured within the vent at the base tee or vent connector
thimble, with the barometric damper shut, after the appliance flue-gas
temperature has stabilized.
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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® CERTIFIED.
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.
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 CAN/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.
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Appliance(s) located in a large space
Combustion air and additional ventilation from outdoor
The opening shall have a total free-flow area of not less than 4,4 cm2/kW (1 po2/5000 BTU/h) of the
total input rating for the appliance(s) located in a large space.
12’’ higher than ground level
and snow forecast.!
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Appliance(s) located in a limited space
Combustion air from outdoors by infiltration and ventilation from inside the building
The opening shall have a total free-flow area of not less than 4,4 cm2/kW (1 po2/5000 BTU/h) of the
total input rating for the appliance(s) located in a limited space.
Each ventilation opening through the inside wall (venting opening of the combustion air and
ventilation opening) shall have a free-flow area of not less than 22 cm2/kW (1 po2/1000 BTU/h) of
the input rating of the appliance(s) located in the limited space.
4.0 ACCESSORIES INSTALLATION
BLOCKED VENT SWITCH (BVSO)
(FOR CANADIAN INSTALLATION 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)
12’’ higher than ground level
and snow forecast.!
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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 Granby Industries Figure 2 - BVSO wiring diagram
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).
System Test Procedure (BVSO)
1. 1)With the power re-established, block the chimney or vent pipe downstream of the switch.
2. 2)Adjust the thermostat to call for heat.
3. 3)Once the heating system has started the blocked vent switch should shut down the burner
within 10 minutes or sooner.
4. 4)Once the system has cooled, the blocked vent switch can manually be reset.
5. 5)This procedure should be tested a second time.
6. 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.
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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).
See A/C coil Manufacturers Requirements.
To check the AC coil total air flow resistance, see procedure at page 39
4 inches minimum 4 inches
minimum
KLR KLF
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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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 Tighten top nut first so burner tips down slightly. The burner
MOUNT 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 28, 29 or 31).
THERMOSTAT Connect the thermostat wires to the fan timer
control board (ST9103).
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5.2 SET BURNER FOR EFFICIENT OPERATION
BURNER SETTING Use burner settings in the table on page 18 (KLR) and 19 (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 18 (KLR) and 19 (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 18 (KLR) and 19 (KLF) or operating decal.
AIR SETTING Use air settings on page 18-19 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 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
2 flue pipe diameters from breeching or elbow of the furnace.
FRONT FLUE FURNACE ILLUSTRATION
Page 17
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COMBUSTION TEST
All your tests must be done with the burner cover on
ADJUSTMENTS After 10 minutes of normal operation, adjust the breech draft with the
barometric control to obtain a value of -0.01’’ WC, after proceed to take
a smoke test and adjust
the burner to obtain a reading of “1” on the smoke
scale. Take a CO
2
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, activate
18 full
slow steady pump action.
OR do an electronical CO2 test
§ Re adjust
§ You now have a small “slight trace” of smoke.
Relation between % of CO
2
and O
2
CO
2
(%)
O
2
(%)
Excess Air (%)
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
Page 18
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5.3 KLR TECHNICAL INFORMATION / BURNER AND BLOWER
KLR Series
KLR-100
KLR-200
Riello Burner
F3
F5
Unit Model
KLR-E1-*067-03
KLR-E1-*079-03
KLR-E1-*091-03
KLR-E3-*109-05
KLR-E3-*127-05
KLR-E3-*139-05
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. 2 pipes sys. (psi)
190
145
145
145
165
145
Pump Pr. 1 pipe sys. (psi)
190
165
165
165
175
165
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 (%)
86.80
87.00
86.20
88.00
87.40
86.80
Beckett Burner
AFG LII (3-3/8 Static disc)
AFG F3 (2-3/4 Static disc)
Unit model
KLR-G2-*066-03
KLR-G2-*078-03
KLR-G2-*090-03
KLR-G2-*102-05
KLR-G2-*119-05
KLR-G2-*132-05
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 (%)
87.00
87.10
86.30
87.50
87.20
86.50
CO2 (%)
12.5
13.5
13.5
12.5
13.5
13.5
PSC motor info
Temperature Rise (°F)
55 – 85
55 – 85
55 – 85
55 – 85
55 – 85
55 – 85
Blower Speed (0.2’’
WC)
M-LOW
M-HIGH
M-HIGH
M-LOW
M-HIGH
M-HIGH
Blower Speed (0.5” WC)
M-HIGH
M-HIGH
HIGH
M-HIGH
HIGH
HIGH
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
Static Pressure at 0.2'' WC / 0.5'' WC
Blower Speed
PSC 1/2 hp
PSC 3/4 hp
!
Blower Speed
ECM 1/2 hp
ECM 3/4 hp
0.2" WC
0.5" WC
0.2" WC
0.5" WC
!
0.2" WC
0.5" WC
0.2" WC
0.5" WC
HIGH
1375
1275
2120
2030 !HIGH
1300
1230
2000
1910
M-HIGH
1250
1170
1940
1875 !M-HIGH
1225
1160
1900
1835
MEDIUM
---
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---
--- !MEDIUM
1140
1050
1690
1660
M-LOW
1100
1075
1710
1650 !M-LOW
1025
980
1610
1575
LOW
875!
850!
1150!
1050!
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LOW
775
750
1060
1010
(*) For administration only.
Page 19
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19!
5.4 KLF TECHNICAL INFORMATION / BLOWER AND BURNER
KLF Series!
KLF-100
KLF-200
Riello Burner
F3
F5
Unit Model
KLF-E1-*067-03
KLF-E1-*079-03
KLF-E1-*091-03
KLF-E3-*102-05
KLF-E3-*119-05
KLF-E3-*132-05
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)
67,000
79,000
91,000
102,000
119,000
132,000
Nozzle
0.40 - 70A
0.60 - 70W
0.65 - 70W
0.75 - 70W
0.85 - 70W
1.00 - 70W
Pump Pr. 2 pipes sys. (psi)
190
145
145
145
165
145
Pump Pr. 1 pipe sys. (psi)
190
165
165
165
175
165
Turbulator Setting
0 0 0 0 1
2
Air Gate
1.75
2
2.35 2 2.25
2.25
Energy Star® Certified
YES
YES
YES
YES
YES
YES
AFUE (%)
86.80
86.80
86.30
87.50
87.30
86.50
Beckett Burner
AFG LII (3-3/8 Static disc)
AFG F3 (2-3/4 Static disc)
Unit Model
KLF-G2-*066-03
KLF-G2-*078-03
KLF-G2-*090-03
KLF-G2-*102-03
KLF-G2-*119-03
KLF-G2-*132-05
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® Certified
YES
YES
YES
YES
YES
YES
AFUE (%)
86.80
86.60
86.00
86.60
86.30
86.30
CO2 (%)
12.5
13.5
13.7
13.5
13.5
12.5
PSC motor info
Temperature Rise (°F)
40 - 70
40 - 70
50 - 80
55 – 85
55 – 85
55 – 85
Blower Speed (0.2’’ WC)
M-LOW
M-HIGH
M-HIGH
M-LOW
HIGH
HIGH
Blower Speed (0.5” WC)
M-HIGH
M-HIGH
HIGH
M-HIGH
M-HIGH
HIGH
ECM Motor (0.2’’ WC. to 0.5’’WC static pressure)
Temperature Rise(°F)
40 - 70
40 - 70
50- 80
52-80
55-85
55-85
Blower Speed
M-LOW
M-HIGH
HIGH
M-LOW
MEDIUM
M-HIGH
Static Pressure at 0.2'' WC / 0.5''WC
!!!!!
!
Blower
Speed
PSC 1/2 hp
PSC 3/4 hp
!
Blower
Speed
ECM 1/2 hp
ECM 3/4 hp
0.2" WC
0.5" WC
0.2" WC
0.5" WC
!
0.2" WC
0.5" WC
0.2" WC
0.5" WC
HIGH
1400
1250
2120
2030
!
HIGH
1400
1250
2000
1910
M-HIGH
1300
1200
1940
1875
!
M-HIGH
1325
1225
1900
1835
MEDIUM
---
---
---
---
!
MEDIUM
1275
1200
1690
1660
M-LOW
1200
1150
1710
1650
!
M-LOW
1200
1125
1610
1575
LOW
875
850
1150
1050
!
LOW
775
750
1060
1010
(*) For administration only.
Page 20
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!
20!
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.
RESTARTING FURNACE
Follow this procedure before restarting a unit that has been shut down for an extended period.
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 18 (KLR) and 19 (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 ST9103 board (see page 18)
6.2 FAN TIMER CONTROL BOARD (ST9103A1028)
o “FAN OFF” Dip Switches adjustment
Dip Switches
Page 21
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21!
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.
6.3 ST9103A1028 CONTROL BOARD
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
ST9103A1028 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
Page 22
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22!
Position of the ST9103A1028 Electronic Board
KLR-100 and 200
KLF-100
KLF-200
Page 23
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23!
6.4 SERVICING - FAN TIMER ST9103A1028
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 Char
t
.
Step
Possible Cause
Check-out procedure
Corrective action
No Heat
1
Incoming supply
Check for 120 Volts
between terminal S2 and
3 on electronic fan control
Yes - Move to next step
No - Check breaker main power
switch
2
Transformer
Check for 120 Volts
between terminal S3 and 4
on electronic fan control.
Check for 24 Volts
between terminal X and C
on electronic fan control
Yes - Move to next step
No - Check for bad connection
Yes - Move to next step
No - Change Transformer
3
Electronic Fan
control
Check for 24 Volts between
R and C
Check for 24 Volts
between terminal W and C
Yes - Move to next step
No - Change the electronic board
Yes - Move to next step
No - Check thermostat and wiring
4
Warning: Make sure the quick connect cable is fully inserted on the board
Limit Control
Check for 120 Volts on
each terminal of the high
limit
Check for 120 Volts coming
from the main plug-in of the
electronic fan control to the
limit control
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
Yes - Move to step # 5
No - Failure on the limit control circuit
. Temperature too high
. Bad limit control
Page 24
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24!
Step
Possible Cause
Check-out procedure
Corrective action
No Heat
5
Riello burner
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)
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
Beckett Burner
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
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
Yes - Move to next step
No - Back to step # 4 or check bad
connection
Yes - Press reset button, check
by- pass on (TT)
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 primary control
Page 25
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!
25!
Step
Possible Cause
Check-out procedure
Corrective action
6
Blower
. Low speed
Check if the
constant low
speed switch is
ON
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 fan control
Yes - Check ''LOW'' speed on
the blower motor
No - Change the switch
No Cooling
7
Blower .
High speed
Cooling 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
No Cooling
8
Condensing unit
Check for 24 volts between
terminal Y and C on the
electronic fan control
Yes - Compressor ON
No - Check thermostat and wiring
Electronic air filter and Humidifier
9
Electronic air filter
Check for 120 Volts on
terminal ''EAC'' of the
electronic fan control
(thermostat must call a
Heat, Cool or Fan ON
demand
Yes - Electronic filter failure
No - Change the electronic fan
control
10
Humidifier
Check for 120 Volts on
terminal ''HUM'' of the
electronic fan control
(burner must be
energized)
Yes - Humidifier failure
No - Change the electronic fan
control
Page 26
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!
26!
7.0 SERVICE / MAINTENANCE
REGULAR MAINTENANCE
Check complete operation at least once a year. In Canada see CAN/B139, (Maintenance),
in United States refer to 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 replace.
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.
KLR HEAT EXCHANGER
KLF HEAT EXCHANGER
Step Remove
breech
Step Clean the round
tubes, needed (use an
diameter
Step Remove
Step
Remove
Step
Clean
chamber, if
Step
Remove breech
Step Remove the baffles and
the round tubes, if
(use a 2’’ diameter
Step
Remove
Step 4: Remove
Step
Clean combustion
chamber, if
Page 27
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!
27!
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.
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.
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.
Nuts!
Nuts!
Page 28
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!
28!
8.0 ELECTRICAL WIRING
DIAGRAMS
HEATING & COOLING
KLR ⁄ KLF RIELLO
Page 29
!
!
29!
HEATING & COOLING
For!more!informations,!
see!next!page!
Page 30
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!
30!
GeniSys control schematic with the ST9103 Board
Page 31
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!
31!
HEATING ONLY RIELLO / BECKETT
Page 32
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!
32!
9.0 EXPLODED PARTS VIEW
KLR-100
-
EXPLODED PARTS VIEW
View
Detoit A
View
DetailC
Detail C
Fan-A0-0002-01
ECM Motor
Page 33
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!
33!
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
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
INS-P0-0017-00
Burner's Flange Insulation
1
30
4SD-00-0185-00
Control Limit Snap Disc (185°) Au to Reset (L185-
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 34
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!
34!
KLR-200 - EXPLODED PARTS VIEW
Detail A
ELB-A0-0008-00
Electric box
Page 35
!
!
35!
KLR-200 – Part List
ITEM
PART NUMBER
DESCRIPTION
QTY
1
CAB-A0-0007-
Front Panel Assembly
1
2
CAB-A0-0012-
Base Panel Assembly
1
3
CAB-A0-0009-
Right Panel Assembly
1
4
CAB-A0-0008-
Left Panel Assembly
1 5 CAB-A0-0010-
Divider Panel Assembly
1
6
CAB-P0-0080-
Top Rear Panel
1
7
CAB-P0-0013-
Blower Door Panel
1 8 CAB-P0-0014-
Upper Divider
1 9 CAB-P0-0015-
Divider's Filler Gasket Bracket
1
10
3HN-00-PULL-
Handle Flush Pocket Pull
1
11
HEX-A0-0003-
Heat Exchanger Assembly
1
12
HEX-P0-0053-
Pipe Baffle Low-Boy
7
13
INS-P0-0008-00
Divider Filler Gasket - 7 Holes
1
14
ELB-A0-0008-
Electrical Assembly - Low-Boy Model
1
15
ELB-P0-0018-
Cover Electrical Box - Low-Boy Model
1
16
4CB-00-FAN0-
ST9103A1028 Electronic Board
1
17
4TF-00-40VA-
Transformer HTC-01A0BB01 40VA
1
18
4RY-00-24V0-
Relay AE04001 24VAC Form C SPDT 24V
1
19
HEX-A0-0012-
Rear Collector Assembly
1
20
FAN-A0-0001-
Fan Motor Assembly KLR-200 PSC Motor
1
21
FAN-A0-0001-
Fan Motor Assembly KLR-200 ECM Motor
1
22
3BU-12-00DD-
Blower 12'' Direct Drive (GT12-10DD)
1
23
3BM-75-4SDD-
Motor Blower 3/4 HP Direct Drive 4SP EMERSON
1
24
4CA-00-156M-
Capacitor 15 µF 370VAC 70C 60 Hz
1
25
3BM-75-4SDD-
Motor Blower 3/4 HP ECM Ecotech EMERSON
1
26
1SB-00-BUMR-
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°) Au to Reset (L185-
1
31
INS-P0-0017-00
Burner's Flange Insulation
1
32
3SG-0P-1030-
Glass Sight Clear 1'' NPT Hex With THD Seal
1
33
INS-P0-0018-00
Sight Glass Insulation
1
Page 36
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!
36!
KLF-200-
Exploded Parts View
14
Detail B Detail C Detail D Detail E
FAN-A0-0001-00 FAN-A0-0001-01 FAN-A0-0006-00 FAN-A0-0006-01
Motor PSC 3⁄4 HP Motor ECM 3⁄4 HP Motor PSC 1⁄2 HP Motor ECM 1⁄2 HP
Page 37
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!
37!
KLF-200 – Part List
ITEM
PART NUMBER
DESCRIPTION
QTY
1
CAB-A0-0049-
Front Panel Assembly
1
2
CAB-A0-0052-
Base Panel Assembly
1
3
CAB-A0-0051-
Right Panel Assembly
1 4 CAB-A0-0050-
Left Panel Assembly
1 5 CAB-A0-0053-
Divider Panel Assembly
1 6 CAB-P0-0164-
Top Rear Panel
1
7
3HN-00-PULL-
Handle Flush Pocket Pull
1
8
CAB-P0-0013-
Blower Door Panel
1
9
ELB-A0-0018-
Electrical Box Assembly
1
10
CAB-P0-0128-
Cover Electrical Box
1
11
4TF-00-40VA-
Transformer HTC-01A0BB01 40VA
1
12
4RY-00-24V0-
Relay AE04001 24VAC Form C SPDT 24V
1
13
4CB-00-FAN0-
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-
Heat Exchanger Assembly
1
16
HEX-P0-0064-
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-
Glass Sight Clear 1'' NPT Hex With THD Seal
1
20
4SD-00-0185-00
Control Limit Snap Disc (185°) Au to Reset (L185-
1
21
INS-P0-0020-00
Hi-Boy Front Insulation
2
22
HEX-A0-0010-
Front Collector Assembly
1
23
CAB-P0-0156-
Front Door Panel
1
24
FAN-A0-0001-
Fan Motor Assembly KLR-200 PSC Motor
1
25
FAN-A0-0001-
Fan Motor Assembly KLR-200 ECM Motor
1
26
FAN-A0-0006-
Fan Motor Assembly KLF-200 PSC Motor
1
27
FAN-A0-0006-
Fan Motor Assembly KLF-200 ECM Motor
1
28
3BU-12-00DD-
Blower 12'' Direct Drive (GT12-10DD)
1
29
4CA-00-156M-
Capacitor 15 µF 370VAC 70C 60 Hz
1
30
3BM-75-4SDD-
Motor Blower 3/4 HP Direct Drive 4SP EMERSON
1
31
3BM-75-4SDD-
Motor Blower 3/4 HP ECM Ecotech EMERSON
1
32
1SB-00-BUMR-
Bracket Motor Mounting Direct Drive Blower
1
33
3BM-50-4SDD-
Motor Blower 1/2 HP Direct Drive 4SP EMERSON
1
34
3BM-50-ECM0-
Motor Blower 1/2 HP ECM Ecotech EMERSON
1
Page 38
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!
38!
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 F3 ____
Turbulator: Air Gate:
Air band: _ _ 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 39)
External total static pressure: “ W.C. (see page 39)
A/C Coil total resistance: (see page 39)
Page 39
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!
39!
TEST PROCEDURES
External Total Static Pressure Reading
Total Static Pressure = Supply Pressure (Ps) + Return Pressure (Pr)
Pr
Ps
A/C Coil Total Resistance Reading
A/C coil total resistance = Coil Pressure (Pc) - Supply Pressure (Ps)
Ps
Pr
Pc
Temperature Rise Reading ***
Temperature rise = Supply Temp. (Ts) - Return Temp. (Tr)
Tr Ts
*** Probe must not be in direct sight of heat exchanger.
Page 40
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40!
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.
GRANBY FURNACES INC.
CP 637
12118 Hwy 209
Parrsboro, Nova Scotia, Canada
B0M 1S0
www.granbyindustries.com
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Thank you for choosing Granby
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