Installation, Operation and
Service Manual
GEMINI 3T & 5T / ECLIPSE 3T
80% + EFFICIENCY
GAS FIRED LOWBOY FURNACE
KLR- FRONT KLR- REAR KLR- REAR KLF- FRONT
GEMINI 3T & 5T ECLIPSE 3T
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 04-07-2015 G2014-E7 Rev. A
1
TABLE OF CONTENTS
Gemini & Eclipse
Gas
1.0 IMPORTANT SAFETY ADVICE 3
2.0 PRODUCT INFORMATION 5
3.0 FURNACE INSTALLATION 8
4.0 ACCESSORIES INSTALLATION 15
5.0 BURNER INSTALLATION AND SPECIFICATIONS 17
5.1 ASSEMBLY & INSTALLATION OF BURNER 17
5.2 GAS-FIRED FURNACE LIGHTING INSTRUCTIONS 18
5.3 TECHNICAL INFORMATION / SET-UP 19
6.0 FURNACE OPERATION AND SETTINGS 21
6.1 BLOWER SETTING 21
6.2 FAN TIMER CONTROL BOARD (ST9103 A 1028) 22
6.3 (ST9103 A 1028) CONTROL BOARD SEQUENCE 23
6.4 SERVICING – FAN TIMER (ST9103 A 1028) 24
7.0 SERVICE 26
8.0 ELECTRICAL / WIRING DIAGRAM 30
HEATING & COOLING – RIELLO BURNER 30
HEATING ONLY (2 WIRES THREMOSTAT 31
9.0 START-UP TEST RESULTS 32
10,0 TEST PROCEDURES 33
2
NOTE: THE BURNER INSTRUCTION MANUAL AND THE
BURNER USER’S INFORMATION MANUAL ARE
CONSIDERED PART OF THIS MANUAL AND THEIR
INSTRUCTIONS MUST BE FOLLOWED EXCEPT WHEN
SPECIFICALLY MENTIONNED IN THIS MANUAL.
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result, causing property
damage, personal injury or death.
- Do not store or use gasoline or other
flammable vapors or liquid in the vicinity of
this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
o Do not try to light the appliance,
o Do not touch any electrical switch; do not
use any phone in your building,
o Immediately call your gas supplier from an
outside phone. Follow the gas supplier’s
instructions,
o If you cannot reach your gas supplier, call
the fire department.
- Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
3
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.
• Use only with Natural gas or Propane gas. Refer to the furnace rating plate.
• Install this furnace only in a location and position as specified in Section 3 of
these instructions.
• Provide adequate combustion and ventilation air to the furnace space as
specified in Section 3 of these instructions.
WARNING
FIRE OR EXPLOSION HAZARD
Never test for gas leaks with an open flame. Use a commercially available soap
solution made specifically for the detection of leaks to check all connections, as
specified in Section 5 of these instructions.
• Always install furnace to operate within the furnace’s intended temperature-rise
range with a duct system that has an external static pressure within the allowable
range, as specified in Section 5 of these instructions. See furnace rating plate.
• When a furnace is installed so that supply ducts carry air circulated by the
furnace to areas outside the space containing the furnace, the return air shall also
be handled by duct(s) sealed to the furnace casing and terminating outside the
space containing the furnace.
• This gas-fired furnace is not intended for installation in a residential garage.
• This furnace is not factory approved for installation at altitude higher than 2000
feet.
• Excessive exposure to contaminated combustion air will result in safety and
performance related problems.
o Sample List of Contaminants to be Avoided
The recommended source of combustion air is to use the outdoor air
supply. However, the use of indoor air in most applications is
acceptable except as follows:
• 1. If the furnace is installed in a confined space it is
recommended that the necessary combustion air come from
the outdoors by way of attic, crawl space, air duct, or direct
opening.
• 2. If outdoor combustion air is used, there must be no
exposure to the installations or substances listed in “3” below.
• 3. The following types of installation may require OUTDOOR
AIR for combustion, due to chemical exposures:
o - Commercial buildings
o - Buildings with indoor pools
o - Furnaces installed in laundry rooms
4
o - Furnaces installed in hobby or craft rooms
o - Furnaces installed near chemical storage areas
o Exposure to the following substances in the combustion
air supply may also require OUTDOOR AIR for
combustion:
- Permanent wave solutions
- Chlorinated waxes and cleaners
- Chlorine based swimming pool chemicals
- Water softening chemicals
- De-icing salts or chemicals
- Carbon tetrachloride
- Halogen type refrigerants
- Cleaning solvents (such as perchloroethylene)
- Printing inks, paint removers, varnishes, etc.
- Hydrochloric acid
- Cements and glues
- Antistatic fabric softeners for clothes dryers
- Masonry acid washing materials
WARNINGS
NEVER burn garbage or paper in the unit.
NEVER store combustible material around it.
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 GEMINI 3T & 5T/
ECLIPSE 3T OIL-FIRED FRONT / REAR 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.
THE INSTALLATION OF YOUR GAS-FIRED FURNACE MUST CONFORM TO THE
REQUIREMENT OF THE AUTHORITY HAVING JURISDICTION OR IN THE ABSENCE
OF SUCH REQUIREMENTS, TO THE NATIONAL FUEL GAS CODE ANDSI Z223.1/NFPA
54 AND/OR NATIONAL GAS AND PROPANE INSTALLATION CODE CAN/CSA B149.1
.
5
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)
Furnaces for indoor installation on combustible flooring shall not be installed directly
on carpeting, tile or other combustible material other than wood flooring.
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 & 5.0 Tons
Maximum air temperature rise See pages 19,20 and 33
High Limit temperature 185°F
Thermostat anticipator See thermostat instructions
MOTOR/BLOWER
Gemini 3T / Eclipse 3T: 1/2 hp 4 Speed / G10-8 DD or 1/2 hp ECM / G10-8
Gemini 5T: ¾ hp / G12-10 DD or ¾ hp ECM / G12-10 DD
FAN/HIGH LIMIT CONTROL
Honeywell ST9103A1028 Fan Center & Thermo-Disk (7” stem)
THERMOSTAT
Any wall thermostat
ELECTRICAL – 120 Volts, 60 Hz
Canada Less than 12 amps. circuit protection 15 amps.
USA 13.3 amps, circuit protection 20 amps.
FLUE-PIPE CONNECTION
5” Chimney
AIR FILTERS
Gemini 3T / Eclipse 3T : 20” x 20” x 2” non pleated UL approved
Gemini 5T Rear: 20” x 20” x 2” & 15” x 20” non pleated UL approved
Gemini 5T Front: Two 15” x 20” non pleated UL approved
6
PLENUM (GEMINI 3T & 5T) REAR / FRONT
Cold air return 19” x 20” (483 x 508 mm)
Hot air supply 23-7/8” x 20” (606 x 508 mm)
Plenum spacing 3T: 1-3/4” (45mm)
5T: 2-3/4” (70mm)
GEMINI 3T/5T FRONT (KLF)
GEMINI 3T/5T REAR (KLR)
7
PLENUM (ECLIPSE 3T) REAR / FRONT
Cold air return 18” x 20-3/4” (457 x 527 mm)
Hot air supply 18” x 21-3/4” (457 x 552 mm)
Plenum spacing 2” (50mm)
ECLIPSE 3T FRONT (KLF)
ECLIPSE 3T REAR (KLR)
8
3.0 FURNACE INSTALLATION
GAS PIPING
Gas piping must conform to local requirements.
Install according to the applicable code such as NATIONAL FUEL GAS CODE ANDSI
Z223.1/NFPA 54 AND/OR NATIONAL GAS AND PROPANE INSTALLATION CODE
CAN/CSA B149.1.
The gas piping must be installed between the gas meter and the combination gas valve
(located upstream of the Riello gas burner on the furnace. The gas valve has a knob acting as
a shut-off valve to stop gas flow. It is recommended to install a manual shut-off valve upstream
of the gas valve to facilitate service of the gas valve. The gas valve also has pressure tapping
for inlet pressure as well as outlet pressure. The outlet pressure of the gas valve is also
referred as manifold pressure in this manual.
If local codes allow the use of a flexible gas appliance connector, always use a new
listed connector. Do not use a connector which has previously serviced another gas
appliance
WARNING:
• Connect from the gas supply to the burner combination gas valve inlet using new, clean
black iron pipe and malleable iron fittings only. Do not use copper, brass, cast iron or
galvanized pipe or fittings.
• Provide support for gas piping. Do not rest weight of piping on burner gas valve.
• Apply pipe dope sparingly at all joints. Use only pipe dope listed for use with propane
gas. Do not use pipe sealing tape. In doubt consult CSA B149.1 or NFPA 54 or the
authorities having jurisdiction.
• Do not hold gas valve with a pipe wrench. Use crescent wrench or other smooth jawed
device. Do not over-tighten.
• Failure to comply with above could result in severe personal injury, death or
substantial property damage.
1. If possible, install a new gas line directly from the gas meter. If you are using an existing
gas line, verify it is clean and in good condition and verify it is large enough to handle the
load of all connected appliances. See the table below for guidance on pipe sizes.
2. When branching from a common gas line, do not tap from the bottom or horizontal sections,
only from the side or top.
3. Install a main manual shutoff valve, sediment trap a
nd ground joint union near the burner
combination gas valve connection as shown below.
9
GAS SUPPLY PRESSURE
• Maximum supply pressure: 13 inches W.C.
• Minimum supply pressure: 7” inches W.C.
•
WARNING:
• Do not expose the combination gas valve to gas pressures in excess of 14” W.C. The
valve has a safety mechanism that interrupt the flow of gas over 14” W.C. In any event
higher pressure could damage the valve seat, resulting in potentially hazardous
conditions. When pressure testing at higher pressures, disconnect burner from gas line
before testing.
10
• If the gas supply pressure can exceed 14 inches of water column at any time, you must
install a lockup type gas pressure regulator in the gas supply piping, ahead of the main
manual gas valve on the burner.
• The furnace and its gas connections must be leak tested before placing the boiler in
operation.
• Enough combustion air should be provided to the gas-fired furnace in accordance with
the section “Air for combustion and ventilation” of the National Fuel Gas Code ANSI
Z223.1/NFPA 54 or clause 8,2, 8,3 or 8.4 of Natural gas and Propane installation code
CAN/CSA B149.1, or applicable provisions of the local building codes.
TEST AND PURGE GAS LINE
1. Read warning above.
2. Pressure test and purge the line. Pressure testing should be done by the gas supplier or
utility, following all applicable codes.
11
PLACEMENT & VENTING
THE INSTALLATION OF YOUR GAS-FIRED FURNACE MUST CONFORM TO
THE REQUIREMENT OF THE AUTHORITY HAVING JURISDICTION OR IN
THE ABSENCE OF SUCH REQUIREMENTS, TO THE NATIONAL FUEL GAS
CODE ANDSI Z223.1/NFPA 54 AND/OR NATIONAL GAS AND PROPANE
INSTALLATION CODE CAN/CSA B149.1.
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 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 480°F.
ADDITIONAL CHIMNEY INFORMATIONS
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected to the venting
system being placed into operation could result in carbon monoxide poisoning or
death.
When an existing furnace is removed from a common venting system, the common venting
system is likely to be too large for proper venting of the appliances connected to it. At the time
of removal of the existing furnace, the following steps shall be followed with EACH appliance
remaining connected to the common venting system, while the other appliances remaining
connected to the common venting system are not in operation:
1. Seal any unused openings in the venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine
there is no blockage or restriction, leakage, corrosion and other deficiencies which could
cause an unsafe operation.
3. Insofar as is practical, close all building doors and windows and all doors between the
space in which the appliances remaining connected to the common venting system are
located and other spaces of the building. Turn on clothes dryer and any appliance not
connected to the common venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate
a summer exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust
thermostat operation so appliance will operate continuously.
12
5. Test for spillage at the draft regulator outlet / draft hood opening after 5 minutes of main
burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar,
or pipe.
6. After it has been determined that each appliance remaining connected to the common
venting system properly vents when tested as outlined above, return doors, windows
exhaust fans, fireplace dampers and any other gas-burning appliance to their previous
condition of use.
7. Any improper operation of the common venting system should be corrected so the
installation conforms with the National fuel gas code ANSI Z223.1/NFPA 54 and/or the
Natural gas and propane installation code CAN/CSA B149.1. When resizing any portion
of the common venting system, the common venting system should be resized to
approach the minimum size as determined by the appropriate tables in chapter 13 of the
National fuel gas code ANSI Z223.1/NFPA 54 and/or the Natural gas and propane
installation code CAN/CSA B149.1.
• Vent installations shall be in accordance with Part 10, Venting of Equipment, and
Part 13, Sizing of Category I Venting Systems, CSA B199.1, of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 , and/or Section 7, Venting Systems and Air
Supply for Appliances, and Appendix C, Vent Sizing Tables for Category I Natural
Gas and Propane Appliances, of the Natural Gas and Propane Installation Code,
CSA B149.1, the local building codes, furnace and the vent manufacturer’s
instructions.
• Multistory common venting is not permitted for the KLR/KLF gas fired furnaces.
• KLR/KLF gas fired furnaces MUST be vented vertically.
• The furnace shall be connected to a factory built chimney or vent complying with
a recognized standard, or a masonry or concrete chimney lined with a lining
material acceptable to the authority having jurisdiction. Venting into an unlined
masonry chimney or concrete chimney is prohibited.
For furnaces for connection to gas vent or chimneys such as the KLR/KLF furnace, vent
installation must be in accordance with “Venting of equipment” of the National fuel gas code
ANSI Z223.1/NFPA 54 or “Venting systems and air supply for appliances” of the Natural gas
and propane installation code CAN/CSA B149.1, or applicable provisions of the local building
codes.
Vent connectors serving appliances vented by natural draft shall not be connected into any
portion of mechanical draft system operating under positive pressure.
Use of cellular core PVC (ASTM F*891), cellular core CPVC or Radel (Polyphenolsulfone) in
venting systems shall be prohibited.
Connecting non-metallic vent pipe and fittings with thermal insulation shall be prohibited.
13
Horizontal portions of the venting system shall be supported to prevent sagging by installing
support every 36 inches. The horizontal runs must be sloping upwards not less than ¼ inch per
foot from the boiler to the chimney connector.
A furnace shall not be connected to a chimney flue serving a separate appliance designed to
burn solid fuel.
Provisions for adequate combustion and ventilation air shall be in accordance with one of the
following:
1. Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 ,
2. Sections 7.2, 7.3 or 7.4 of Natural Gas and Propane Installation Code, CSA B149.1 ,
3. Applicable provisions of the local building code.
CONDENSATION If you have condensation in your chimney, make sure that the
chimney size is according to the tables in THE NATIONAL FUEL
GAS CODE ANDSI Z223.1/NFPA 54 AND/OR NATIONAL GAS AND
PROPANE INSTALLATION CODE CAN/CSA B149.1. 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.
CHIMNEY VENT 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.
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. 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. Gas burners must have sufficient air to allow vent
systems to operate properly.
14
DRAFT Use approved DOUBLE ACTING draft control supplied for 5” pipe. Set
specified draft minimum pressure of -0.01” wc. THE CHIMNEY MUST
BE EQUIPPED WITH A DOUBLE ACTING DRAFT REGULATOR.
FAILURE TO COMPLY WITH THIS MAY RESULT IN IMPROPER
OPERATION LEADING TO POTENTIAL DANGEROUS OPERATION
OF UNIT AND INJURIES TO PERSON AND LOSS OF LIFE.
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.
The furnace must be electrically grounded in accordance with local
codes or, in the absence of local codes, with the National Electrical
Code, ANSI/NFPA 70, and/or the Canadian Electrical Code , CSA
C22.1, Part 1, if an external electrical source is utilized
The wiring shall conform with the temperature limitations of 63°F
(35°C) rise.
The furnace shall be installed so the electrical components are
protected from water.
CLEARANCES Before placing unit, review installation clearances as shown on furnace
operating decal or section PRODUCT INFORMATION (page 5).
LOCATION Install the furnace close to chimney and central to ductwork.
15
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 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).
16
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) for the
ECLIPSE and 0’’ for the GEMINI.
00
KLF KLR KLR KLF
GEMINI 3T/5T ECLIPSE 3T
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.
0’’
4 inch
17
5.0 BURNER INSTALLATION AND SPECIFICATIONS
5.1 ASSEMBLY & INSTALLATION OF BURNER
CONSULT THE BURNER INSTRUCTION MANUAL THAT IS INCLUDED IN THE BURNER
BOX. In case of differences between the instructions on the burner instruction manual
and this manual, the furnace instruction manual (this manual) must be followed. The
instructions in the gas burner instruction manuals are detailed mounting, wiring,
adjusting, testing and maintenance instructions that are specific to the burner used
(Riello or Carlin). The specific adjustments for the furnace are detailed in the following
pages. As a general guideline:
1) Use the burner instruction manual for general instructions.
2) Use this manual for specific instructions (such as for example, the initial air gate
adjustment for a specific size of furnace with a specific burner).
• RIELLO GAS BURNERS
o In the Section “Setting the burner”, disregard the table and use the initial
adjustments detailed for the appropriate unit with Riello burner in the section 5.2
of this manual below.
o In the section “Air gate adjustment”, disregard the table and use the information
in section 5.2 below.
o In the section “Combustion head settings”, disregard the table and use the
information in section 5.2 below.
o In the section “Manifold pressures”, disregard the table and use the information in
section 5.2 below.
o Disregard the “Pressure working chart” and the “Combustion chamber size”
sections as those sections apply only for conversion burners.
COMBUSTION CHECKS
All combustion checks must be performed with an instrument capable of reading at least CO2,
CO and temperature.
• RIELLO GAS BURNERS
o Natural Gas Maximum CO2 is 10%
o Propane Gas Maximum CO2 is 12%
o Maximum Air free PPM reading of CO is 200.
o If any of these readings exceed the values above, adjust the air gate to increase
the air intake to the burner.
AFTER PLACING THE FURNACE IN OPERATION, THE IGNITION SYSTEM MUST BE
TESTED. THE METHOD OF TESTING IS AS FOLLOWS:
• Place the furnace in operation, by raising the thermostat, and observe a normal
ignition of the burner.
• Lower the thermostat. This should shut off the burner.
• Close the manual shut-off gas valve that is upstream of the gas control.
• Place the furnace in operation again, by raising the thermostat.
• After a trial for ignition period, the burner control should go in lockout mode. A light
on the red button on the burner ignition control will indicate this.
18
• To restart the furnace, open again the manual gas shut-off valve that you closed a few
steps back..
• Press the red button on the ignition control. The burner should then retry its ignition and
light the burner. If this sequence is not respected, consult the burner manual
5.2 GAS-FIRED FURNACE LIGHTING INTRUCTIONS
19
5.3 TECHNICAL INFORMATION / SET-UP
KLR/KLF Series
(KLR) ECLIPSE 3T / GEMINI 3T REAR (KLF) ECLIPSE 3T / GEMINI 3T FRONT
Riello Burner
G-120 Gas G-120 Gas
Unit Model
KLR-E1-*087-03 (N/P) KLF-E1-*087-03 (N/P)
Input (BTU/h) 105,000 105,000
Output (BTU/h) 87,000 87,000
Manifold Pressure 3.7’’ W.C. Natural / 4.0’’ W.C. Propane 3.7’’ W.C. Natural / 4.0’’ W.C. Propane
Orifice size B5 Natural / B16 Propane B5 Natural / B16 Propane
Max. Inlet Pressure 11’’ W.C. Natural / 13’’ W.C. Propane 11’’ W.C. Natural / 13’’ W.C. Propane
Min. Inlet Pressure 7’’ W.C. 7’’ W.C.
Comb. Head Setting 3.0 3.0
Air Gate Adjustment 2.5 2.5
Desired CO2 (%) 9.3% Natural / 11.0% Propane 9.3% Natural / 11.0% Propane
Efficiency (%)
83.50 83.50
General Information
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-LOW M-LOW M-LOW M-LOW M-LOW
Blower Speed (0.5” wc)
M-HIGH M-HIGH HIGH M-HIGH HIGH HIGH
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 M-LOW M-LOW
Static Pressure at 0.2'' WC / 0.5'' WC
(PSC MOTOR / ECM MOTOR)
Blower speed / CFM
Blower
GEMINI 3T (REAR)
PSC
GEMINI 3T (REAR)
ECM
Blower
GEMINI 3T (FRONT)
PSC
GEMINI 3T (FRONT)
ECM
Speed 0.2" wc 0.5" wc 0.2" wc 0.5" wc
Speed 0.2" wc 0.5" wc 0.2" wc 0.5" wc
HI 1500 1300 1500 1300
HI 1500 1300 1500 1300
MHI 1300 1200 1300 1200
MHI 1350 1300 1350 1300
MED --- --- 1200 1100
MED --- --- 1275 1200
MLO 1100 1000 1100 1000
MLO 1200 1100 1200 1100
LO
875
850
775
750
LO 875 850
775 775
Blower
ECLIPSE 3T (REAR)
PSC
ECLIPSE 3T (REAR)
ECM
Blower
ECLIPSE 3T (FRONT)
PSC
ECLIPSE 3T (FRONT)
ECM
Speed 0.2" wc 0.5" wc 0.2" wc 0.5" wc
Speed 0.2" wc 0.5" wc 0.2" wc 0.5" wc
HI 1400 1250 1400 1250
HI 1400 1250 1400 1250
MHI 1300 1200 1325 1225
MHI 1300 1200 1325 1225
MED --- --- 1275 1200
MED --- --- 1275 1200
MLO 1200 1150 1200 1125
MLO 1200 1150 1200 1125
LO
875
850 775
750
LO
875
850 775 750
20
KLR/KLF Series
GEMINI 5T REAR GEMINI 5T FRONT
Riello Burner
G-200 Gas G-200 Gas
Unit Model
KLR-E3-*131-05 (N/P) KLF-E3-*131-05 (N/P)
Input (BTU/h) 155,000 155,000
Output (BTU/h)
131,000
131,000
Manifold Pre
ssure
4.5’’ W.C. Natural /3.8’’ W.C. Propane
4.5’’ W.C. Natural /3.8’’ W.C. Propane
Orifice Size B5 Natural / B16 Propane B5 Natural / B16 Propane
Max. Inlet Pressure
11’’ W.C. Natural / 13’’ W.C. Propane
11’’ W.C. Natural / 13’’ W.C. Propane
Min. Inle
t Pressure
7’’ W.C.
7’’ W.C.
Comb. Head Setting 3.0 3.0
Air Gate Adjustment
2.5 2.5 Desired CO2 (%)
9,8% Natural / 11.6% Propane
9,8% Natural / 11.6% Propane
Efficiency (%)
83.50 83.50
General Information
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 HIGH HIGH M-HIGH HIGH HIGH
Energy Star ECM motor (0.2’’ wc to 0.5’’ wc static pressure)
Temperature Rise (°F) 55-85 55-85 60-85 55-85 55-85 60-85
Blower Speed M-LOW MEDIUM M-HIGH M-LOW MEDIUM M-HIGH
Static Pressure at 0.2'' WC / 0.5'' WC
(PSC MOTOR / ECM MOTOR)
Blower speed / CFM
Blower
GEMINI 5T (REAR)
PSC
GEMINI 5T (REAR)
ECM
Blower
GEMINI 5T (FRONT)
PSC
GEMINI 5T (FRONT)
ECM
Speed 0.2" wc 0.5" wc 0.2" wc 0.5" wc
Speed 0.2" wc 0.5" wc 0.2" wc 0.5" wc
HI 1900 1800 2000 1910
HI 1900 1800 2000 1910
MHI 1800 1700 1900 1385
MHI 1800 1700 1900 1385
MED --- --- 1690 1660
MED --- --- 1690 1660
MLO 1550 1450 1610 1575
MLO 1550 1450 1610 1575
LO 1050
1000 1060
1010
LO
875 1050
1000
1010
21
6.0 FURNACE OPERATION AND SETTINGS
SHUTTING FURNACE DOWN
POWER OFF Turn off main power breaker or disconnect.
FUEL OFF Shut off manual gas supply valve.
Always keep manual gas 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 gas 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 to
obtain a temperature rise of 75 degrees F. 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
FAN & LIMIT CONTROL
Limit 185°F – Factory set
Fan On 45 seconds after the burner starts
Fan Off Adjustable on board (see page 22)
THERMOSTAT ANTICIPATOR SETTING
Adjust to thermostat manufacturer’s instruction.
22
6.2 FAN TIMER CONTROL BOARD (ST9103A 1028)
o “FAN OFF” Dip Switches adjustment
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
OFF CYCLE AIR CIRCULATION (Factory settings)
LO SPEED All GEMINI and ECLIPSE 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.
Dip Switches
23
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 find in the electric box of each unit,
ECLIPSE / GEMINI
THERMOSTAT
Connect the thermostat wires
to the fan timer control board (ST9103).
24
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
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
Yes - Move to next step
No - Change the electronic board
Check for 24 Volts between
terminal W and C
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
Yes - Move to step # 5
No - Move to next step
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 - 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
25
Step Possible Cause
Check-out procedure Corrective action
No Heat
5
Riello burner
application
Check for 120 Volts on the
black wire, contact (COM)
on the burner activation
relay
Yes - Move to next step
No - Back to step # 4 or check for bad
connection
Check if oil primary control
is on reset
Yes - Press reset button
No - Move to the next step
Check for continuity
between the two wires
yellow and violet on the
burner activation relay
Yes - Move to next step
No - Change the electronic fan control
Check for 120 Volts on the
contact (No) of the burner
activation relay
Yes - Move to next step
No - Change the burner activation relay
Check for 120 volts on the
orange wire coming to the
burner (L)
Yes - Failure on the burner
No - Change the electronic fan control
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
Yes - Move to next step
No - Change the electronic fan control
Check for 120 Volts on both
side of the constant low
speed switch
Yes - Check ''LOW'' speed on the
blower motor
No - Change the switch
(No) Cooling / Heating
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
Heating speed
(45 sec. delay)
Check for 120 Volts at the
''HEAT'' terminal of the
electronic fan control
Yes - Check ''HEAT'' speed on the
b
lower motor
No - Change the electronic fan control
26
Step Possible Cause Check-out procedure Corrective action
Electronic air filter and Humidifier
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
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
7.0 SERVICE
WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in dangerous
operation, serious injury, death or property damage.
Improper servicing could result in dangerous operation, serious
injury, death or property damage.
• Before servicing, disconnect all electrical power to furnace.
• When servicing controls, label all wires prior to disconnecting.
Reconnect wires correctly.
• Verify proper operation after servicing.
REGULAR MAINTENANCE
Check complete operation at least once a year. In Canada see B139, (Maintenance), 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.
27
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) Remove air filter for easy maitenance.
4) Disconnect the wiring to the blower motor.
5) Remove the four (4) wing nuts securing the blower side to the base panel bracket.
6) Slide the blower toward you and then lift the blower straight up. Shift the blower out of the
furnace.
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.
Wing Nuts
28
CLEANING HEAT EXCHANGER
Heat exchanger must be inspected every heating season. Refer to instructions and pictures
below.
GEMINI 3T/5T AND ECLIPSE 3T ( REAR) HEAT EXCHANGER
ECLIPSE 3T REAR ILLUSTRATION
(SAME STEPS for the GEMINI)
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------
GEMINI 3T/5T AND ECLIPSE 3T (FRONT) HEAT EXCHANGER
ECLIPSE 3T FRONT ILLUSTRATION
(SAME STEPS for the GEMINI)
Step 1:
Remove breech plate
Step 2:
Remove baffles
Step 3:
Clean the round tubes, if
needed (use a 2’’
diameter brush)
Step 4:
Remove burner
Step 5:
Clean combustion
chamber, if needed
Step 1:
Remove breech plate
Step 4:
Clean the transitions tubes if needed
Step 3:
Remove burner
St
ep 5:
Clean combustion chamber, if needed
Step 2:
Remove the baffles and clean
the round tubes, if needed
(use a 2’’ diameter brush)
Control
box in
front
29
BURNER CLEANING NOTES
Your burner manufacturer has supplied instructions for servicing and
maintenance should be performed as instructed.
Riello 40 G120 Gas Burner
Carlin EZGas PRO Burner Burner
PERFORM COMBUSTION TEST
Perform an annual combustion check on the gas burner.
Electronic
combustion
tester
30
8.0 ELECTRICAL / WIRING DIAGRAMS
HEATING & COOLING
Connection for Carlin
Burner, check the
Carlin burner
instruction manual
31
HEATING ONLY (2 WIRES THERMOSTAT)
Connection for Carlin
Burner, check the
Carlin burner
instruction manual
Riello burner
electrical
connection,
see page 30
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):
Input: Manifold Pressure:
Chimney__________ DVSystem__________
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)
33
TEST PROCEDURES
External Total Static Pressure Reading
Total Static Pressure = Supply Pressure (Ps) + Return Pressure (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)
*** Probe must not be in direct sight of heat exchanger.
Pr
Tr Ts
Pr
Ps
Pc
Ps
34
Kerr products manufactured by Granby Furnaces Inc. offer a full
line of furnaces and boilers built proudly in Parrsboro, NovaScotia, Canada at its 70,000 square feet facility. Kerr products are
sold across Canada through a wide 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 youThank you
Thank you for
forfor
for choosing Ke
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