KD Gemini
HIGH EFFICIENCY OIL-FIRED FURNACE
Installation, Operation and
Maintenance Manual
INSTALLATIONS MUST MEET ALL LOCAL AND FEDERAL
CODES THAT MAY DIFFER FROM THIS MANUAL
Please read this complete manual before beginning installation.
These instructions must be kept with the furnace for future reference.
CERTIFIED TO: CAN/CSA Std. B140.0 & Std. B140.4
CONFORMS TO: UL 727
c/o Parrsboro Metal Fabricators Ltd.
12118 Hwy 209
PO Box 637
Parrsboro, Nova Scotia, Canada
B0M 1S0
www.kerrheating.com
KD GEMINI – INSTALLATION/OPERATION MANUAL
Table of Contents
1.0 Introduction 2
2.0 Homeowner Information 2
2.1 Air Filters 2
2.2 Regular Maintenance 2
2.3 Warnings 2
2.4 Direct Vent 2
2.5 Shutting Furnace Down 3
2.6 Restarting Furnace 3
3.0 Installation 4
3.1 Important 4
3.2 Caution 4
3.3 Installation Codes 4
3.4 Placement, Venting & Ventilation 5
3.5 Installation 5
3.6 Assemble & Install Burner 6
3.7 Changing Nozzle 6
3.8 Set Up Burner For Efficient Operation 7
3.9 Blower Settings 8
3.10 Cooling – AC Models 8
3.11 Humidifier 8
3.12 Thermostat Anticipator Setting 8
3.13 Blocked Vent Switch 8
3.14 Fan Control 9
3.15 Off Cycle Air Circulation 9
4.0 Comfort Adjustments 9
5.0 Regular Maintenance & Cleaning 10
6.0 Oil Tanks & Piping 10
7.0 Blower Removal 11
8.0 Burner Specifications 11
9.0 General Specifications 12
10.0 Trouble Shooting Guide 13
11.0 Appendix
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KD GEMINI – INSTALLATION/OPERATION MANUAL
1.0 INTRODUCTION
Please read and understand this manual before installing, operating or
maintaining the furnace. The KD Gemini is engineered to provide rapid warm up,
giving you better room temperature control, dependable service and peace of mind.
This appliance features an insulated cabinet, which greatly reduces operating noise. To
ensure you have a clear understanding of the operating procedures of this appliance
please take the time to read Section 2, “HOMEOWNER INFORMATION”, of this
manual. If you have any questions, your KERR dealer will be happy to answer them for
you.
2.0 HOMEOWNER INFORMATION
2.1 AIR FILTERS
To maintain furnace performance and safety, replace dirty filters as required or at least
once every heating season. Use new approved disposable filters of the same size and
type, or clean permanent filters according to manufacturer’s instructions. Replace the
filters or clean the filters more often if dusty conditions exist. Dirty, clogged or wrongly
sized filters will impair the furnace performance and may cause the furnace to shut
down or overheat.
2.2 REGULAR MAINTENANCE
Have a qualified technician check complete furnace operation at least once a year.
2.3 WARNINGS
NEVER BURN GARBAGE OR PAPER IN THE UNIT AND 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 COMBUSTION CHAMBER IS VERY
HOT.
DO NOT USE GASOLINE, CRANKCASE DRAININGS OR ANY OIL CONTAINING
GASOLINE.
2.4 DIRECT VENT
It is the responsibility of the homeowner to ensure that the area around the Direct Vent
terminal and air intake is free of snow, ice, and debris. The vent terminal should be
checked during heavy snowstorms to ensure proper operation.
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KD GEMINI – INSTALLATION/OPERATION MANUAL
2.5 SHUTTING FURNACE DOWN
POWER OFF Turn off main power switch.
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.
2.6 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.
CHECK Furnace/system has not been tampered with.
FUEL ON & Turn on fuel supply and check that there are no leaks.
CHECK
POWER ON Turn on power switch and check that the furnace starts and operates
& CHECK as usual.
CHECK If the furnace/system fails to operate or operates in an unusual
manner, call your service technician.
OPERATION If the burner fails to operate at any time, call a qualified burner
technician.
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KD GEMINI – INSTALLATION/OPERATION MANUAL
3.0 INSTALLATION
3.1 IMPORTANT
Read this installation manual thoroughly before installing furnace or starting 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.
3.2 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 OR ANY OTHER APPLIANCE.
3.3 INSTALLATION CODES
INSTALLATION MUST COMPLY WITH THE REQUIREMENTS OF AUTHORITIES
HAVING JURISDICTION. All local and national codes governing the installation of oil
burning equipment, wiring, and venting must be followed. Use only nozzles and
settings shown on the operating decal. Use approved fittings, tubing, fuel tank, oil shut
off valves, etc. Some of the applicable codes are:
CAN/CSA B139 Installation Code for Oil Burning Equipment.
NFPA 31 Installation Code for Oil Burning Equipment.
ANSI/NFPA 90B Warm Air Heating and Air Conditioning Systems.
ANSI/NFPA 70 National Electrical Code.
CSA C22.1 Canadian Electrical Code.
ANSI/NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances.
The latest versions of the above codes that have been approved for use in the location
of the installation must be used.
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KD GEMINI – INSTALLATION/OPERATION MANUAL
3.4 PLACEMENT, VENTING & VENTILATION
Furnace installation shall conform to the required installation code for oil-fired
equipment (USA: NFPA 31, Canada: CSA B139).
FLOOR SUPPORT If required, support furnace on 5 concrete blocks. Make sure the
NON-COMBUSTIBLE center of the furnace base is supported. For a furnace installed on
a combustible floor, a fire-resistant heat shield, which satisfies the
requirements of the authorities having jurisdiction, must be placed
between the furnace base pan and the floor to create a noncombustible base. The floor must be strong enough to carry the
weight.
CLEARANCES Before placing unit, review installation clearances as shown on
furnace operating decal or “GENERAL SPECIFICATIONS”.
LOCATION Install the furnace close to chimney or vent and central to
ductwork.
CHIMNEY/VENT Connect the furnace to a chimney/vent system of size and
condition required by the installation code. THIS FURNACE IS
APPROVED FOR FACTORY BUILT CHIMNEY TYPE “A” OR
TYPE “L” VENT. See operating decal for approved vent/flue pipe
sizes. Maximum flue gas temperature is 575°F.
THROUGH-THE- This Furnace is approved for Kerr Direct Vent.
WALL-VENTING
COMBUSTION & Install openings and ductwork to the furnace room to provide fresh
VENTILATION AIR outside combustion air and circulation air for cooling the furnace
casing as installation code requires (USA: NFPA31, Canada: CSA
B139). If installed in a closed room, provide two free air ventilation
openings of least 170sq. in. each free flow area near ceiling and
floor. Oil burners must have sufficient air to allow vent systems to
operate properly. See furnace operating decal. Not applicable to
Direct Vent installation.
3.5 INSTALLATION
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.
VENT PIPE See NFPA 31 (USA) or CSA B139 (Canada) code. Breech is
certified for 5” vent pipe. Keep vent/flue pipe as short as possible
with min. 1/4” per foot upward slope. Use approved fitting through
a wall. Vent/flue pipe MUST NOT pass through a ceiling
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DRAFT CONTROL Use approved draft control supplied for 5” pipe. Use two draft
controls on strong draft chimneys. Set specified draft pressure to
-0.04” wc. Not applicable to Direct Vent installations.
3.6 ASSEMBLE & INSTALL BURNER
ASSEMBLE Check burner model is correct for furnace rating required.
BURNER Assemble as per burner manufacturer’s instructions.
SET END CONE Riello – Set turbulator as per furnace operating decal.
Beckett – See Burner Manufactures Instructions.
SELECT NOZZLE Select oil input, nozzle required and burner configuration as shown
on furnace operating decal.
INSTALL NOZZLE Install selected nozzle, check for clean seating and tighten in
nozzle adaptor.
CHECK See burner manufacturer’s instructions for correct setting.
ELECTRODES
INSERTION See “GENERAL SPECIFICATIONS” or diagram (Figure – 1).
LENGTH
MOUNT BURNER Tighten top nut first so burner tips down slightly. The burner is
always installed in an upright position by four nuts.
PUMP BY-PASS For one pipe system factory setting (no plug).
PLUG
WIRING Refer to wiring diagram or wiring decal for correct burner
connections. Riello series burners use the Riello LT-1 thermostat
relay or Honeywell R8038 relay.
THERMOSTAT Connect thermostat terminals.
DO NOT start the oil burner until installation is complete and all cleanout covers are
secured in place.
3.7 CHANGING NOZZLE
NOZZLE If a new nozzle of a different size is installed, change the heating
CHANGE blower speed according to the “BURNER SPECIFICATIONS” or
operating decal.
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KD GEMINI – INSTALLATION/OPERATION MANUAL
3.8 SET BURNER FOR EFFICIENT OPERATION
SET END CONE Set turbulator to operating decal settings.
Particularly if you change nozzles.
PUMP PRESSURE Refer to “BURNER SPECIFICATIONS” or operating decal.
BURNER AIR Set air damper as settings on operating decal.
SAMPLING HOLE On smoke/vent pipe, between appliance breech and draft
control, punch or drill a 1/4” round opening.
Direct Vents have a sampling port located on the breach
connecting adaptor.
DRAFT PRESSURE Using an accurate draft meter, adjust the draft control to obtain -
0.04” wc draft pressure at the breech sampling hole. Use two
barometric dampers if necessary.
Not applicable to Direct Vent.
BURNER SETTING Set the burner to give a stable symmetrical flame. After 15
minutes of normal operation, check SMOKE for #0 – trace
reading and measure CO
required. When the burner is set, lock the adjustments with the
locking nuts
EFFICIENCY Always leave burner set with CO2 reading about 1% lower than
the peak CO2 efficiency achieved with a #0 – trace smoke (e.g.
a #0 – trace reading of 12.5% CO2 should be set back 1% to
11.5%). This gives better allowance for fuel and draft variations
and maintains a better seasonal efficiency. When the burner is
set, lock the adjustments with the locking nuts.
FLAME CHECK Look through view port to check the flame after setting the
burner. If the flame is not clean and symmetrical, reset the
burner or replace the nozzle, only use nozzle types specified in
“BURNER SPECIFICATIONS” or operating decal.
Always set flame with proper draft, smoke and CO
DO NOT START BURNER UNTIL ALL FITTINGS AND COVERS ARE IN PLACE.
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Re-adjust the burner controls as
2.
measurements.
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KD GEMINI – INSTALLATION/OPERATION MANUAL
3.9 BLOWER SETTINGS
Ensure power is off when adjusting blower setting. For heating, use the blower
speeds shown on the furnace specifications to give a rise of 70 - 85°F. The #4 Lo
blower speed can be used for air circulation when neither heating nor cooling are
required. Set blower speeds to match the installation requirement.
3.10 COOLING – A/C MODELS
Air Conditioning models include a fan centre relay wired to run the blower at #1 Hi
speed when the cooling cycle is operating. For normal operation, select “AUTO” on the
T87F thermostat. When “FAN ON” is selected the blower runs constantly at the cooling
speed. See “OFF CYCLE AIR CIRCULATION”. For air conditioning, the blower on #1
speed will provide 1300 CFM at 0.50 in. wc static pressure. Height of the coil above
the heat exchanger shall be no less than 4” (100 mm).
3.11 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.
3.12 THERMOSTAT ANTICIPATOR SETTING
Thermostat anticipator setting should be 0.2 amps for any burner. Check that the
thermostat anticipator setting matches the primary control circuit current draw. This
setting affects the thermostat’s response to the control.
3.13 BLOCKED VENT SWITCH
ONLY APPLICABLE IN CANADA
NOT APPLICABLE FOR DIRECT VENT SYSTEMS
SWITCH The blocked vent switches are flue gas spillage safety devices. They
OPERATION detect spillage of flue gas products due to a blocked flue system or
inadequate draft. The switch senses the spillage of hot flue gases and
de-energizes the system’s burner control. NEVER reset the blocked
vent switch, unless the cause of the blockage has been corrected.
INSTALLATION
1. Pierce a 5/8” hole into the flue vent pipe near the appliance breech connection.
2. This hole must be at least 10” before the draft regulator, top vertical or horizontal.
3. Remove one of the securing nuts from the threaded tube of the safety switch.
4. Tighten the other securing nut onto the pipe as far as possible.
5. Insert the threaded tube end into the pierced hole of the flue vent pipe.
6. Install the securing nut on the safety switch tube, which protrudes into the flue
vent pipe. “Tighten the nut securely.
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UNIT WIRING Caution: Disconnect the electrical power when wiring the unit.
INSTRUCTIONS Wire the blocked vent switch in accordance with The National
Electrical Code and applicable local codes. Wire the safety switch in
series with the burner limit control or aquastat. See the appliancewiring diagram in the manual or wiring label. Route the wiring with an
accepted wiring enclosure in accordance with The National Electrical
Code and applicable local codes.
SYSTEM TEST PROCEDURE
1. With the power re-established, block the chimney or vent pipe down stream 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 tested on a long burn cycle.
7. If the block vent switch shuts down the system check to ensure there is enough
draft in the chimney and venting pipes.
3.14 FAN CONTROL
LIMIT 200°F - Factory set
FAN ON 130°F
FAN OFF 100°F
3.15 OFF CYCLE AIR CIRCULATION
#4 LO SPEED All furnace models have the #4 Lo speed switch for optional constant
off cycle air circulation.
“FAN ON” When “FAN ON” is selected on the T87F thermostat, the blower will
OVER-RIDES run constantly at the #1 Hi speed providing heat, cooling or neither
#4 Lo as selected.
4.0 COMFORT ADJUSTMENTS
o Outlet air is initially too warm or too cold - adjust the fan on setting.
o Outlet air consistently too warm or too cold - change the blower motor speed to
give the specified air temperature rise (70 - 85°F).
o Blower motor shuts off and the oil burner keeps going - the “FAN ON” setting is
set too low or the inlet air is below 50°F.
o Outlet air gets too warm and burner shuts down - increase air by changing the
blower motor speed to give the specified temperature rise (70 - 85°F).
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” time higher or lower.
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5.0 REGULAR MAINTENANCE & CLEANING
Check complete operation at least once a year. Heat exchanger can be accessed for
cleaning through the breech cleanout cover and burner opening. Clean flue pipes on a
regular basis. Replace flue pipes if there is any sign of corrosion or other problem.
Cerafelt (1/4”) gaskets may have to be replaced on cleanout cover.
6.0 OIL TANKS & PIPING
Tank installation must conform to local requirements.
Install according to the applicable code. Minimize number of connections in suction line
and make all connections as tight as possible. Use a pipe joint compound suitable for
oil on all pipe threads. To reduce possibility of air leaks, tighten stem packing gland nut
on any valves installed in the suction line. Also, be sure the oil filter is tight, as filter
gaskets often shrink. Check for kinks in the oil lines as well as for possible air pockets
and for loose connections. Two filters as shown below are recommended. Further
information is available at www.kerrheating.com.
ONE PIPE SYSTEM Where the tank 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 single line is unsuitable, use double line or see your
KERR dealer for special oil line fittings.
See your KERR dealer for information on tank systems.
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KD GEMINI – INSTALLATION/OPERATION MANUAL
7.0 BLOWER REMOVAL
Kerr furnaces have a blower sealing system, which is designed to be tight and rattle free
(Figure - 2). Use a reversing drill with 1/4” hex drive for the sheet metal screws.
1. Shut off oil and power to furnace.
2. Open blower compartment and if necessary remove lower rear filter support.
3. Disconnect wiring to blower motor.
4. Remove the #8 (1/4”) hex drive sheet metal screws securing the blower sides to
the divider panel.
5. Remove the rear 5/16” blower mount nuts.
6. Lift the blower straight up, keeping it level to avoid jamming on the blower mount
bolts and center panel. Shift the blower out of the furnace.
Secure casing insulation with aluminum foil tape to ease blower re-installation. Replace
the blower assembly using the reverse procedure. Ensure wiring and ground wire are
correctly reconnected.
8.0 BURNER SPECIFICATIONS
Model Burner
Input Pump Output
USGPH L/h
Nozzle
(psi)
Air
Setting
Turbulator
Btu/h kW 0.2"wc 0.5"wc 0.2"wc 0.5"wc
Heating
cfm@
Blower
Speed
0.75 2.84 0.60 60B 3.5 0.0 88,000 26 850 950 4 3
KDF(R)E-
115(A3)
KDF(R)E-
130(A3)
KDF(R)E-140
KDF(R)G-
115(A3)
KDF(R)V-
095(A3)
KDF(R)V-
110(A3)
KDF(R)V-
130
Riello 40 F3
Riello 40 F5
Beckett AFG
PA#402
Riello 40
BF3**
Riello 40
BF5**
0.92 3.48 0.75 60W
1.00 3.81 0.75 60W 175 5.0 1.5 116,000 34 1080 1300 3 1
1.10 3.48 0.85 60B 170 3.2 2.0 128,000 37 1520 1300 1 1
1.10 3.48 0.85 60B 170 3.2 2.0 128,000 37 1520 1
1.22 2.78 1.00 60B 150 3.5 2.0 140,000 41 1520 1
0.59 3.48 0.50 60B 8.0/0.0* 70,000 21 850 740 4 4
0.71 0.60 60B 6.0/1.0* 84,000 25 850 950 4 3
0.77 0.65 60B 7.5/1.0* 90,000 26 850 950 4 3
0.89 0.75 60B 6.5/0.0 105,000 31 1080 1200 3 2
1.01 3.94 0.85 60B
0.75 3.48 0.60 70B 7.0 0.0 88,000 26 1080 1200 3 2
0.80 3.94 0.65 60ARD
0.92 2.69 0.75 70B 4.2 1.5 108,000 32 1330 1300 2 1
1.04 3.36 0.85 60W
150
5.0 1.5 105,000 31 1080 1200 3 2
140
9.0/1.0 117,000 34 1330 1300 2 1
150
6.5 3.0 94,000 28 1080 1200 3 2
150
5.2 2.0 122,000 36 1520 1
* Low firing rate baffle required ** Direct Vent BF3 and BF5 - 4” Vent
Use Delavan nozzles. Use turbulator and air settings as a guide. Set flame to #0
smoke before CO2 test. When there is a discrepancy between the inform ation from the
burner manufacturer and Kerr Heating Products, the Kerr data shall be used.
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KD GEMINI – INSTALLATION/OPERATION MANUAL
9.0 GENERAL SPECIFICATIONS
CLEARANCE TO COMBUSTIBLES
Top 1” (25 mm)
Front 24” (610 mm)
Rear - Access 24” (610 mm)
Side - Non-Access 6” (152 mm)
Side - Access 24” (610 mm)
Flue Pipe 9” (229 mm)
Floor Non-combustible
DRAFT PRESSURE
Breech draft pressure -0.04” wc
Overfire draft pressure -0.01 to 0.02” wc
(Not Applicable to Direct Vent Units)
BURNER INSERTION (overall)
Riello 40F3 & BF3 - Beckett PA402 & 404 2 1/2” (63 mm)
AIR/BLOWER DATA
External static - Non - AC 0.2” wc
External static - AC 0.5” wc
Cooling Air Flow 3 tons
Maximum air temperature rise 85°F
Fan Control 130°F ON, 100°F OFF
High Limit, max design outlet temp 200°F
1/3 hp #1 speed @ 0.50 static 1300 CFM
MOTOR/BLOWER
All Models - 1/3 hp 4 speed/GT 10 DD
FAN/HIGH LIMIT CONTROL
Honeywell L6064A1003 11” or equal
FAN CENTRE RELAY – AC models only
Honeywell R8405A1001/B1009, R8239A1003 or equivalent
DIMENSIONS
Overall Depth 50 5/8” (1286 mm)
Depth 46 3/4” (1187 mm)
Height 44 1/2” (1130 mm)
Width 22 1/8” (562 mm)
PLENUM DIMENSIONS
Cold air return 19 x 20 1/2” (483 x 521 mm)
Hot air supply 23 3/4 x 20 1/2” (603 x 521 mm)
Plenum spacing 1 3/8” (35 mm)
AC COIL LOCATION
Minimum height above the heat exchanger 4” (100 mm)
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KD GEMINI – INSTALLATION/OPERATION MANUAL
OPENING HEIGHTS from floor
Burner c/l 11 5/8” (295 mm)
Smoke pipe c/l 39 3/16” (995 mm)
SMOKE/VENT PIPE CONNECTIONS
5” Chimney
4” Direct Vent
CLEANOUTS
View port, Front Cleanout, Smoke pipe and Burner opening
AIR FILTERS 20” x 24” x 1”
FUEL not heavier than No. 2 furnace oil.
ELECTRICAL 120 Volts, 60 Hz
Canada Less than 12 amps.
USA 13.3 amp, circuit protection 20 amps.
This furnace has been tested to and meets the requirements of B212-93 Seasonal
Energy Utilization Efficiencies of Oil-Fired Furnaces & Boilers & the Energy-Efficient
Appliances Act of 1991.
Certified for use with Type “A” or Type “L” vent – maximum flue gas temperature 575°F.
Certified for use with Kerr Direct Vent.
Certified for use with Kerr KPV-SS1C through-the-wall mechanical vent system.
10.0 TROUBLE SHOOTING GUIDE
Furnace will not start
Tripped blocked vent switch Clear vent, reset switch.
Tripped breaker Determine cause, reset breaker.
Blown fuse Replace fuse.
No oil Check tank for leaks and call oil supplier.
Oil burner keeps turning off
Dirty air filter Change air filter.
Restricted air supply/return Check all air return/supply registers.
Limit control Check ductwork for blockage.
Motor over heating Check motor speed for correct nozzle on furnace
label settings.
Dirty nozzle Call technician to replace nozzle.
Sooty flame
Wrong pump pressure Increase or decrease pressure to correct setting.
Dirty nozzle Replace nozzle.
Improper burner setting See “BURNER SPECIFICATIONS”.
Barometric draft wrong Adjust barometric regulator for -0.04” wc draft
pressure at breech.
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KD GEMINI – INSTALLATION/OPERATION MANUAL
Using too much oil
Oil leak in line or tank Check fittings for tightness. Inspect tank and replace
if necessary.
Draft regulator set high Adjust regulator for -0.04” wc draft pressure at
breech.
Nozzle too large Replace nozzle to lower input.
Burner reset cuts out
No oil Call oil supplier.
Frozen oil line Call technician or oil supplier.
Dirty oil filter Replace filter.
Dirty nozzle, smoky fire Replace nozzle, adjust burner air.
Faulty oil pump Have pump replaced, adjust burner air.
Faulty or dirty electrodes Have technician clean or replace.
Warm air register blowing cold air
Basement cooling ducts Insulate and seal ductwork to maintain duct
temperature.
Ducts running through Change or insulate ductwork.
Unheated spaces
Low speed switch is on Switch off blower low speed.
“FAN OFF” set low Fan control – Set “FAN OFF” higher.
Motor speed set too high Reset motor speed to slow blower.
Warm air registers blowing too hot
Blower running slow Speed blower up.
Return air restricted Open up return air ductwork to ensure adequate
airflow.
Nozzle too large Lower nozzle size to suit ductwork.
All rooms at different temperatures
Supply air not regulated Adjust warm air regulators to suit each room.
Return air not regulated Check for sufficient return air.
Noisy operation
Loose blower wheel Tighten wheel set screw or replace.
Blower wheel hitting housing Center wheel in housing.
Damaged motor bearings Replace blower motor.
Faulty oil pump Repair or replace oil pump. Reset to correct pressure.
Air leak in oil line Tighten all connections.
Vacuum too high on pump Check pump vacuum. Check filters and pump
screen.
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KD GEMINI – INSTALLATION/OPERATION MANUAL
____________________________________________________________________________
Installed by: ____________________________________________________________________________________________
Address: _______________________________________________________________________________________________
Telephone: ____________________________________ Date: __________________________________________________
START UP TEST RESULTS
Nozzle: ________________________________________ Pressure: _______________________________________________
Air: ____________________________________________ Turbulator: ______________________________________________
CO2: ___________________________________________ Smoke Number: __________________________________________
Breech Draft: ____________________________________ Stack Temperature: _______________________________________
Test Performed By: ________________________________________________________________________________________
Staple Printout Here: Staple Smoke Spot Here:
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KDF Gemini Oil Fired Furnace
Order No. Item No. Part Description
3SG-0P-1030-5A KDF-1 Sight Glass
KD0-CB-023A-00 KDF-2 Wiring Channel
KD0-CB-023B-00 KDF-3 Wiring Channel Cover
KD0-HE-0050-00 KDF-4 Sight Glass Flange Assembly
4FL-00-A100-3B KDF-5 Fan/High Limit Control L6064A1003B
K00-HE-0100-00 KDF-6 Smoke Pipe Flange Assembly K4C/K6/KD
KD0-CB-025A-00 KDF-7A Side Panel Assembly (Left)
KD0-CB-025B-00 KDF-7B Side Panel Assembly (Right)
KD0-CB-029B-00 KDF-8 Baffle
KD0-CB-0300-00 KDF-9 Front Panel Assembly
K00-CB-0019-00 KDF-10 Base Pan Assembly KD/KC
KDF-HE-0000-00 KDF-11 Heat Exchanger Assembly
K00-CB-0022-00 KDF-12 Bridge (Top Divider) KD/KC
KDF-CB-0500-00 KDF-13 Center Panel Assembly
K00-CB-0400-00 KDF-14A Filter Frame Assembly
K00-CB-0025-00 KDF-15 Rear Cabinet Top KD/KC
KD0-CB-0020-00 KDF-16 Blower Door
3BU-10-00DD-00 KDF-17 Delhi GT10 DD Blower
4CA-00-505M-23 KDF-18A Motor Run Capacitor - 5 micro farad (Not Shown)
3BM-33-4SDD-00 KDF-19A Motor 1/3 G.E. 5KCP39KGT192S (Not Shown)
K00-BM-1033-50 KDF-20A Blower Motor Assembly (1/3 HP) KD/KC/KM
K00-HE-0020-00 KDF-21 Sight Glass Flange Gasket
K00-HE-0020-00 KDF-22 Smoke Pipe Flange Gasket
3HN-00-PULL-00 KDF-23 Blower Door Handle
4RY-00-A105-5B KDF-24 Riello R8038A1055B Switching Relay
KDF-25 24 Volt Internal Switching Relay
3BN-BF-3SBT-00 KDF-26 BF3 Riello Burner (Short) Direct Vent
3BN-BF-5SBT-00 KDF-27 BF5 Riello Burner (Short) Direct Vent
3BN-0F-3SBT-00 KDF-28 40F3 Riello Burner (Short)
3BN-0F-5SBT-00 KDF-29 40F5 Riello Burner (Short)
3BN-00-PA40-20 KDF-30 AFG Beckett Burner PA 402
June-06
KDR Gemini Oil Fired Furnace
Order No. Item No. Part Description
3SG-0P-1030-5A KDR-1 Sight Glass
K00-CB-023A-00 KDR-2 Wiring Channel
K00-CB-023B-00 KDR-3 Wiring Channel Cover
K00-HE-0050-00 KDR-4 Sight Glass Flange Assembly
4FL-00-A100-3B KDR-5 Fan/High Limit Control L6064A1003B
K00-HE-0155-00 KDR-6 K4/KD/K6 Flange (Blank)
K00-CB-025A-00 KDR-7A Side Panel Assembly (Left) KDF/KDR
KD0-CB-025B-00 KDR-7B Side Panel Assembly (Right) KDF/KDR
KD0-CB-029B-00 KDR-8 Baffle
KD0-CB-0300-00 KDR-9 Front Panel Assembly
K00-CB-0019-00 KDR-10 Base Pan Assembly KD/KC
KDR-HE-0000-00 KDR-11 Heat Exchanger Assembly
K00-CB-0022-00 KDR-12 Bridge (Top Divider) KD/KC
KDR-CB-0500-00 KDR-13 Center Panel Assembly
KD0-CB-0400-00 KDR-14A Filter Frame Assembly
K00-CB-0024-00 KDR-15 Rear Cabinet Top
KD0-CB-0020-00 KDR-16 Blower Door
K00-CB-0103-00 KDR-17 5" Flue Pipe Collar
3BU-10-00DD-00 KDR-18 Delhi GT10 DD Blower
4CA-00-505M-23 KDR-19A Motor Run Capacitor - 5 micro farad (Not Shown)
3BM-33-4SDD-00 KDR-20A Motor 1/3 G.E. 5KCP39KGT192S (Not Shown)
K00-BM-1033-50 KDR-21 Blower Motor Assembly (1/3 HP)
K00-HE-0020-00 KDR-23 Sight Glass Flange Gasket
K00-HE-0020-00 KDR-24 Front Cleanout Cover Gasket
3HN-00-PULL-00 KDR-25 Blower Door Handle
4RY-00-A105-5B KDR-26 Riello R8038A1055B Switching Relay
KDR-27 24 Volt Internal Switching Relay
3BN-BF-3SBT-00 KDR-28 BF3 Riello Burner (Short)
3BN-BF-5SBT-00 KDR-29 BF5 Riello Burner (Short)
3BN-0F-3SBT-00 KDR-30 40F3 Riello Burner (Short)
3BN-0F-5SBT-00 KDR-31 40F5 Riello Burner (Short)
3BN-00-PA40-20 KDR-32 AFG Beckett Burner PA 402
June-06
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