PARADIGM
HIGH EFFICIENCY OIL-FIRED
CONDENSING 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, & UL 727
KERR ENERGY SYSTEMS
PO Box 637
12118 HWY 209
Parrsboro Nova Scotia Canada
B0M 1S0
www.KerrEnergySystems.com
PARADIGM – INSTALLATION/OPERATION MANUAL
TABLE OF CONTENTS
1.0 Homeowner Information 3
1.1 Introduction 3
1.2 Air Filters 3
1.3 Regular Maintenance 3
1.4 Warnings 3
1.5 Exhaust Vent Termination 3
1.6 Shutting Furnace Down 4
1.7 Restarting Furnace 4
2.0 Installation
2.1 Important 4
2.2 Caution 4
2.3 Installation Codes 5
2.4 Installation 5
2.5 Venting 5
2.5.1 Requirements for Canada 7
2.5.2 Requirements for the United States 8
2.6 Assemble & Install Burner 8
2.7 Furnace Control 9
2.8 Control Error Codes 10
2.9 Auxiliary Temperature Sensor Installation 10
2.10 Set Burner for Efficient Operation 12
2.11 Humidifier 12
2.12 Thermostat Anticipator Setting 13
2.13 Blocked Vent Shut-off System 13
2.14 Air Conditioning 13
2.15 Condensate Neutralizer 13
2.16 Combustion Air 13
3.0 Blower Removal 13
4.0 Oil Tanks & Piping 14
5.0 Burner Specifications 14
6.0 Cleaning Instructions 15
7.0 General Specifications 15
8.0 Trouble Shooting Guide 17
9.0 Annual Maintenance 18
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10.0 Appendix
Figure – 1 Burner Insertion
Figure – 2 Blower Removal
Figure – 3 Oil Tank & Piping
Figure – 4 Wiring Diagram
Figure – 5 Installation Requirements
Figure – 6 Sealing the Burner
Figure – 7 Complete Assembly
Figure – 8 Heat Exchanger Assembly
Figure – 9 Left Side Assembly
Figure – 10 Right Side Assembly
Figure – 11 Wire Channel Assembly
Figure – 12 Combustion Chamber Assembly
Figure – 13 Center Panel Assembly
Keep this manual in a safe place for future reference.
Follow manual carefully for the correct way to install and operate this unit.
Do not operate this furnace until operating instructions have been read and fully understood.
SAVE THESE INSTRUCTIONS FOR REFERENCE
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PARADIGM – INSTALLATION/OPERATION MANUAL
1.0 HOMEOWNER INFORMATION
1.1 INTRODUCTION
Please read and understand this manual before installing, operating or maintaining the
furnace. This furnace is equipped with an electronically commutated motor (ECM) for the main
circulation blower. The ECM will significantly reduce the electrical power consumption and will
enhance home comfort. To ensure you have a clear understanding of the operating
procedures of this furnace please take the time to read section 1.0 HOMEOWNER
INFORMATION of this manual.
1.2 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 filter
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. The air filter
bracket can be mounted with the door facing out from either side or rear of the furnace. The
filter size can be found in section 7.0 GENERAL SPECIFICATIONS.
1.3 REGULAR MAINTENANCE
Have a qualified technician check complete furnace operation at least once a year. In Canada
see B139, Section 14, Maintenance, for recommended servicing procedure. Heat exchanger
ducts are accessed through the burner support plate, the front secondary cleanouts and the
rear collector. Replace stainless steel gas baffles after cleaning.
1.4 WARNINGS
NEVER:
o Burn garbage or paper in the furnace
o Store combustible material around the appliance
o Use gasoline, crankcase drainings or any oil containing gasoline
o Store items within required clearances of the furnace, see section 7.0 GENERAL
SPECIFICATIONS for proper clearances to combustibles
o Tamper with the furnace controls – call your service technician
o Deprive the furnace of air for ventilation, never allow the return air registers to become
blocked or obstructed
o Allow the furnace to be subject to freezing conditions unless the furnace has been
serviced and prepared by a qualified service technician for these conditions. Condensate
conditioner cartridge may rupture.
1.5 EXHAUST VENT TERMINATION
It is the responsibility of the homeowner to ensure that the area around the 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. Also ensure that the combustion air supply to the
burner is not obstructed.
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1.6 SHUTTING FURNACE DOWN
In case of emergency it is important to know where the emergency power isolation switch is
located.
POWER OFF Turn off main power switch.
FUEL OFF Shut off manual fuel supply valve.
It is important to contact a service technician before shutting the furnace down for an extended
period of time.
Always keep manual fuel supply valve shut off if the burner is shut down for an extended
period of time.
1.7 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.
Ensure that the furnace/system has not been tampered with.
FUEL Turn on fuel supply and check that there are no leaks.
POWER Turn on power switch 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.
DO NOT ATTEMPT TO START BURNER WHEN EXCESS OIL HAS ACCUMULATED, WHEN
UNIT IS FULL OF VAPOUR, OR WHEN HEAT EXCHANGER IS VERY HOT.
2.0 INSTALLATION
2.1 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.
2.2 CAUTION
DO NOT:
o Start the burner until all fittings, covers and doors are in place.
o Tamper with the furnace or controls – call a qualified burner technician.
o Store or use gasoline or other flammable vapours and liquids in the vicinity of this or any
other appliance.
o Start the burner unless the blower access door is secured in place.
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PARADIGM – INSTALLATION/OPERATION MANUAL
2.3 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. 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.
2.4 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 3”
ULC S636 PVC vent pipe in Canada or PVC/CPVC schedule 40 pipe rated
for 140°F in the United States. Keep vent/flue pipe as short as possible.
BREECH The Paradigm is rear breech only.
RETURN AIR Ensure that the furnace return air temperature does not go below 50°F
(10°C).
2.5 VENTING
The Kerr Paradigm condensing furnace can be vented vertically through the roof or
horizontally through the wall. The low stack temperature allows the use of PVC vent. The
approved vent is vent meeting ULC S636 standard in Canada or PVC/CPVC schedule 40 pipe
rated for 140°F in the United States. IPEX System 636 in 3 inch diameter is recommended
for the Paradigm. The Installation Methods to be used are detailed in the manual available at:
http://www.ipexinc.com. An online Solvent Cementing Course is also available at that site.
The minimum vent linear length is 5 feet. The maximum equivalent length allowed after the
condensate trap is 80 feet. Each 90° elbow accounts for 8 feet. As an example if the system
has 5 elbows after the condensate trap, 40 lineal feet of vent can be used.
The vent is connected to the furnace using the supplied neoprene coupling. This coupling
attaches directly to the plastic collector. The furnace connection with the condensate trap is
shown in the figure below. The reducing tee and 1/2” connection are supplied. The supplied
tubing is connected to the condensate neutralizer.
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PARADIGM – INSTALLATION/OPERATION MANUAL
ENSURE THAT ENOUGH ROOM IS LEFT TO REMOVE THE AIR FILTER IF REAR FILTER
DOOR LOCATION IS SELECTED.
A second neoprene pipe coupling (Clamp-All) is supplied that can be inserted in the vent to
enable a section of the vent to be removed for furnace cleaning. It is better to have the second
neoprene pipe coupling inserted on a vertical rise to easily accommodate the removal of the
vent section.
Ensure that the vent slopes back to the furnace.
TERMINATION The IPEX System 636 PVC Concentric Vent Kit (termination), 196006 and
the Termination Vent Screen, 196051 is supplied with the furnace. The
parts of the termination, with the exception of the conical exterior end,
must be glued together after they are fitted for the wall installation. The
conical exterior end can be glued in place after the termination is installed
in the wall. The termination screen should be installed in the outside of the
termination as a friction fit. Removal of the screen may be necessary in
the future for cleaning purposes.
SIDEWALL VENT The sidewall vent must be installed in accordance with the appropriate
installation code.
CONDENSATE
The Paradigm Condensing Furnace comes with two hoses attached to the
DRAIN back left hand side.
The bottom clear plastic hose is to be connected to the vent tee. It allows
condensate from the vent tee to travel to the input side of the condensate
neutralizer. This hose has a furnace label “From Vent Tee to Condensate
Neutralizer”. The vent tee and the furnace collector drain connect to the
bottom of the neutralizer canister with a tee connection. The condensate
fills the neutralizer canister rising up and draining out the top.
The top plastic tube is the drain from the neutralizer, the decal next to the
port says “From Condensate Neutralizer to Drain”. This is the conditioned
condensate which should be drained to the waste water system.
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2.5.1 REQUIREMENTS FOR CANADA (Figure – 5)
In Canada, based on CSA B139 placement of the vent must ensure that it shall not
terminate:
a) Directly above a paved sidewalk or a paved driveway that is located between two
buildings and that serves both buildings.
b) Less than 2.13 m (7 ft) above any paved sidewalk or any paved driveway (Dimension
“A”).
c) Within 1.8 m (6 ft) of a window, door or mechanical air supply inlet to any building
including soffit openings (Dimension “B”).
d) Above a gas meter/regulator assembly within 1 m (3 ft) of the vertical centerline of the
regulator on a horizontal plane perpendicular to the regulator.
e) Within 1.8 (6 ft) of any gas s ervice regulator vent outlet or within 1 m (3 ft) of an oil tank
vent or an oil tank-fill inlet (Dimension “C”).
f) Less than 0.3 m (1 ft) above grade level (Dimension “D”).
Note: The vent should terminate 0.3 m (1 ft) above the anticipated snow level for the
location.
g) Within 1.8 (6 ft) of any combustion air inlet, unless the furnace is otherwise certified
(Dimension “F”).
Note: When exhaust equipment is not operating it can inadvertently provide a passage for
fumes or products of combustion to leak into a building.
h) With 1.8 m (6 ft) of the property line.
i) Underneath a veranda, porch or deck.
j) So that the flue gases are directed at combustible material or any opening of surrounding
buildings that are within 1.8 m (6 ft).
k) Less than 1 m (3 ft) from an inside corner of an L shaped structure (Dimension “A”).
l) So that the bottom of the vent termination opening is less than 0.3 m (1 ft) above any
surface that may support snow, ice, or debris; and
m) So that the flue gases are directed towards brickwork, siding or other construction, in
such a manner that may cause damage from heat or condensate from the flue gases.
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PARADIGM – INSTALLATION/OPERATION MANUAL
2.5.2 REQUIREMENTS FOR THE UNITED STATES (Figure – 5)
Based on NFPA31 Code
1. The exit terminal of the system shall not be less than 7 ft (2.1 m) above grade when
located adjacent to public walkways (Dimension “A”).
2. The flue gas outlet of an appliance shall terminate at least 4 ft (1.2 m) below, 4 ft (1.2 m)
horizontally from, or 1 ft (0.3 m) above any door, window, or gravity air inlet of the
structure (Dimension “B”).
3. The air inlet and the flue gas outlet shall terminate at least 5 ft (1.6 m) from the vent outlet
of a supply tank (Dimension “C”).
4. The outlet also shall terminate at least 1 ft (0.3 m) above grade (Dimension “D”).
5. The flue gas outlet of a furnace shall terminate at least 3 ft (0.9 m) from an inside corner
of an L shaped structure (Dimension “E”).
6. The venting system shall terminate at least 3 ft (0.9m) above any forced air inlet that is
within 10 ft (3.1 m) of the termination point (Dimension “F”).
Exception No. 1: This requirement shall not apply where the inlet is a combustion air intake
for a sidewall vent appliance.
Exception No. 2: This Requirement shall not apply to the separation distance between the
circulating air inlet and the vent discharge of a listed outdoor appliance.
7. The flue gas outlet of a furnace shall terminate at least 1 ft (0.3 m) above any door,
window, or gravity air inlet of the structure.
8. The flue gas outlet of the furnace shall terminate at least 1 ft (0.3 m) from the soffit of the
roof of the structure.
9. The combustion air inlet and flue gas outlet of the sidewall vent furnace shall terminate in
the same plane and in the same ambient pressure zone when they terminate in the
sidewall of the structure.
2.6 ASSEMBLE & INSTALL BURNER
ASSEMBLE BURNER Check burner model is correct for furnace rating required.
Assemble as per burner manufacturer’s instructions.
SET END CONE Set turbulator as per furnace operating decal.
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 ELECTRODES See burner instructions for correct setting.
INSERTION LENGTH 3 1/2” (89 mm). Refer to Figure – 1.
SEAL FLANGE Apply 1/4” bead of heat resistant sealant. Refer to Figure – 7.
MOUNT BURNER Tighten top nut first so burner tips down slightly. The burner is
always installed in an upright position by four nuts.
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PARADIGM – INSTALLATION/OPERATION MANUAL
PUMP BY-PASS PLUG For one pipe system factory setting (no plug).
COMPLETE WIRING Refer to wiring diagram or furnace label for burner connections.
POST PURGE Set the post purge timing; it should be set around two minutes. On
the Riello burner the post purge is set at minimum, 10 seconds. One
quarter turn on the dial will set it to about 2-1/2 minutes.
THERMOSTAT Connect thermostat directly to the labeled thermostat terminals on
control board.
DO NOT START BURNER UNTIL ALL FITTINGS AND COVERS ARE IN PLACE.
2.7 FURNACE CONTROL
The Kerr Paradigm condensing furnace has an advanced control that performs all of the safety
and control functions. There are two temperature sensors. One comes installed in the furnace
and the auxiliary temperature sensor is installed after the A coil or auxiliary heating device. The
control will automatically handle two stage air conditioning and auxiliary heat such as electric
plenum heaters or heat pumps. The control will automatically modulate the blower for optimal
airflow regardless of the mode of operation. In heating mode the blower will modulate to
maintain a constant plenum temperature. In cooling mode the blower will modulate to attain the
best dehumidification performance even with two stage compressors. The control logic is
detailed below.
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PARADIGM – INSTALLATION/OPERATION MANUAL
2.8 CONTROL ERROR CODES
GREEN LED (Status)
Slow Green Standby.
Fast Green B1-B2 Energized.
Solid Green System Fault.
In this case the Red LED will flash a number of times to indicate probable cause.
1. Disconnect power
2. Correct error
3. Re-connect power
RED (Diagnostic)
On Power Up of system, the RED LED will flash. If there is a problem detected the system
will try two times to diagnose and correct the problem (approx. 80 seconds). If problem
persists RED LED error code will flash.
RED 3 Flashes Heat/Aux Sensor Trouble
a) Ensure sensor or Jumper Plug is fully plugged into connector
b) Otherwise, Replace Sensor or Jumper Plug
RED 4 Flashes B1 Output Trouble
a) Check for wiring error
b) Otherwise replace control
RED 5 Flashes System Trouble
a) Replace control
Refer to decal on inside of wiring box cover.
2.9 AUXILIARY TEMPERATURE SENSOR INSTALLATION
The auxiliary sensor is required for systems with air conditioning coils or for systems using
auxiliary forms of heat. The control board is supplied with a jumper on the Cool Sensor
terminal. This jumper must be removed when the auxiliary sensor is used. Note that the control
will not work if there is not sensor or jumper on the Cool Sensor terminal.
Paradigm Condensing Furnace comes with a jumper plug on the “AUX SENSOR” board
connection. To get the auxiliary temperature sensor to become active when using an
alternative source of heat, the “G” line on the 9300i control must be triggered. To trigger the
“G” line on the 9300i a dry contact switch (relay) must be used to make contact between the
“R” (24V supply) and “G” (24V common) terminal screws on the 9300i. The dry contact switch
(relay) is to be activated by the alternate heating source when it is in operation or requires the
blower to come on. This only applies to an alternate heating source; a cooling coil uses the “Y”
terminals to activate the temperature sensor.
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PARADIGM – INSTALLATION/OPERATION MANUAL
Auxiliary sensor kit contents:
Auxiliary sensor mounted in sensor box with 86” of sensor cable.
Three (3) mounting screws.
Four (4) cable clamps and clamp screws.
Mounting the auxiliary sensor
a) Disconnect the POWER from the furnace.
b) Find a location in the plenum down-stream of the air conditioning coil or auxiliary heating
unit to mount the auxiliary temperature sensor. This location should be centrally located in
the air stream of the plenum and far enough from the A/C coil or heat source, so that the
auxiliary sensor senses an even temperature from the coil. On a wood furnace the
sensor should be located as high up the supply plenum as possible. The minimum height
of 10” above the cabinet and centrally on the side of the plenum. Also make sure that
the cable from the auxiliary sensor will reach back to the wiring channel on the
furnace and that the cable can be routed to avoid contact with any extremely hot
surfaces (i.e. flue pipe).
c) In the plenum location chosen, drill a 7/8” hole or construct a hole large eno ugh to insert
the auxiliary sensor into the plenum. The sensor probe should not touch the plenum metal
when the box is mounted to the plenum.
d) Remove the cover from the sensor box. Using the three screws provided mount the
sensor box to the plenum through the three pilot holes in the sensor box. IMPORTANT:
Ensure that the SENSOR ORIENTATION is correct with the AIRFLOW arrow. See sensor
mount in sensor box.
e) Place the cover back on the sensor box.
f) Remove the cover from the wiring channel on the furnace.
g) Locate the 5/8” hole with the black plug on the wiring channel and remove the plug. (Plug
can be discarded).
h) Fit the end of the sensor cable through the 5/8” hole and make the cable connection to
the auxiliary sensor female plug on the circuit board (note plug release tab orientation).
i) Press the strain relief bushing on the auxiliary sensor cable in to the 5/8” hole.
j) Replace the wiring channel cover.
k) Reconnect the power to the system and test the system. When the power is reconnected
this RESETS the circuit board to recognize that the sensor is connected.
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2.10 SET BURNER FOR EFFICIENT OPERATION
SET END CONE Use turbulator settings in section 5.0 BURNER SPECIFICATIONS and
operating decal as a guide to set turbulator, particularly for nozzle
changes.
PUMP PRESSURE 150 psi.
AIR SETTING Use air settings in section 5.0 BURNER SPECIFICATIONS and
operating decal as a guide to set air damper.
SAMPLING HOLE A sampling hole is required for the burner setup. Drill a 3/8” diameter
hole on top of the vent pipe and use the supplied test port plug to seal
after burner setup.
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
Readjust the burner controls as required.
2
EFFICIENCY Always leave burner set with CO
reading about 1% of CO
2
lower than
2
the peak efficiency achieved with a #0 - trace smoke (e.g. a #0 – trace
reading of 12.5% CO
should be set back 1% to 11.5%). This gives
2
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.
ANALYZER Use an electronic gas analyzer for setup and record information on the
furnace setup decal. Failure to do so may void warranty. Always set
flame with proper draft, smoke and CO
measurements.
2
NOTE: Some electronic gas analyzers do not account for recovery
of latent heat and give low efficiency readings. Use the table
below to determine the AFUE.
Nozzle Size CO2 Concentration
Stack
Temperature
AFUE
USgph % °F %
0.4 12.5 98 95.7
0.5 12 100 95.4
0.6 12.5 102 94.5
2.11 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. Maintain humidifier regularly as
required by the humidifier manufacturer.
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2.12 THERMOSTAT ANTICIPATOR SETTING
If the thermostat has an anticipator it should be set at 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. The Paradigm is compatible with any quality
thermostat.
2.13 BLOCKED VENT SHUT-OFF SYSTEM
The Paradigm furnace is equipped with both a thermal and a pressure blocked vent switch.
These devices require manual reset after shutdown. When either switch is tripped a qualified
technician must be called to determine the root cause of the problem and to reset the switches.
The thermal switch is accessed through the air filter opening. Remove the filter and reach
down on the left side of the furnace. The pressure switch is reset by pushing the reset button
on the rear left side of the furnace.
2.14 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 that will shorten the heat exchanger life
and may cause products of combustion to enter the house. Ensure that the coil is compatible
with an oil-fired furnace. The bottom of the drain pan must be at least 6 inches (152 mm)
above the top of the cabinet or follow the coil manufacturer’s recommendations.
2.15 CONDENSATE NEUTRALIZER
The neutralizer canister must be replaced once per year or for every 600 USG (2300L) of oil
used in the furnace. The condensate from the furnace is slightly acidic with a pH of about 4; a
neutral fluid would have a pH of 7. If the condensate is not conditioned, damage could result in
waste water handling system which would result in expensive repairs. A replacement
neutralizer cartridge can be acquired from your local Kerr dealer.
2.16 COMBUSTION AIR
The Paradigm Condensing Furnace is designed to operate with combustion air from outside
the house. The incoming air should be fed to the burner using 3” diameter PVC/CPVC pipe or
and reducing if necessary, to a smaller size only at the burner. The pipe bringing in the
combustion air should not be insulated. For the Riello burner use a 4” to 3” galvanized vent
reducer. The 3” end on the burner and a 3” PVC coupling or elbow in the 4” end of the reducer.
The 3” vent pipe can be run from the elbow or coupling to the termination.
3.0 BLOWER REMOVAL
The blower is accessed by removing the lower rear panel. There are four 1/4” Tek screws and
two carriage bolts holding the blower in place. The pressure switch bracket and condensate
conditioner must be removed first. Remove the bolts and then remove the blower. Replace the
blower assembly using the reverse procedure. DO NOT start the oil burner until installation is
complete and all covers are secured in place. Refer to Figure – 2.
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4.0 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 in Figure – 3 are recommended. The filter before the burner must be a 10
Micron or better. Optional tank gauge protectors and outlet protectors are available at your
local Kerr dealer.
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, us e double line or see your Kerr dealer
for special oil line fittings.
5.0 BURNER SPECIFICATIONS
Model Burner
KPR-V1-0100-E4 Riello 40 BF3
Input
USGPH L/h Btu/h Btu/h kW
0.49 1.85 68,600 0.40 60W
0.61 2.31 85,400 0.50 60W 4.0 1.5 83,600 24
0.73 2.76 102,200 0.60 60W 4.8 2.0 98,000 29
Nozzle
Pump
Air Setting Turbulator
(psi)
3.2 1.0 66,500 19
150
Use Delavan nozzles. Set flame to #0-1 smoke before CO
test. The information provided by
2
the manufacturer of this furnace supersedes any information provided by any other party
including the manufacturer of the burner.
Output
The turbulator & air
settings found on this
page should be used
as a guide.
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PARADIGM – INSTALLATION/OPERATION MANUAL
6.0 CLEANING INSTRUCTIONS
1) Turn off the power to the furnace.
2) Remove the section of breeching between the two neoprene pipe couplings which
includes the vent condensate trap.
3) Remove the blower door and upper back panel.
4) Disconnect the two tubes connected to the top and bottom of the rear plastic collector.
5) Remove the rear plastic collector, which is held by twelve 1/4” nuts (7/16 socket).
6) Remove the baffles and clean the tubes with a brush. A 1” dia. nylon brush is best.
7) Ensure that the gasket on the rear collector is not damaged, if it is then replace it with
Kerr Part # 3GK-18-COLL-00. Replace the baffles and rear collector, reattach the tubes to
the plastic collector.
8) Replace the rear panels and venting section. Ensure venting section is properly secured
to prevent flue gases from leaking into the house. Reconnect vent condensate trap
house.
9) Remove the cabinet cleanout cover on the front above the burner. This cover is held in
place by keyhole openings in the cover which are over screws in the cabinet front. Just lift
the cove up to remove cover.
10) Remove the two cleanout covers to the secondary heat exchanger. These are each held
by two 1/4” nuts (7/16 wrench). With these panels removed use a crevice tool or brush to
clean the secondary channels (MasterCraft 27” crevice tool #304352).
11) Inspect the cleanout cover gaskets and replace if degraded before reinstalling the covers
(gasket material 1/8” ceramic paper). Replace the cabinet panel also.
12) Remove the burner. Vacuum any debris from the bottom of the primary drum.
IMPORTANT – TAKE CARE NOT TO DAMGE THE CERAMIC CHAMBER.
13) Replace the burner.
14) Return power to the furnac e and check for proper operation.
7.0 GENERAL SPECIFICATIONS
CLEARANCE TO COMBUSTIBLES
Top 1” (25 mm)
Front 24” (610 mm)
Rear 24” (610 mm)
Side – Non-Access 6” (152 mm)
Side – Access 24” (610 mm)
Flue Pipe 0“ (0 mm)
Floor Non-Combustible
DRAFT PRESSURE
Breech draft pressure -0.04” wc
Overfire draft pressure -0.01” wc
BURNER INSERTION (From Gasket to End Cone)
Riello BF3 3 1/2” (89 mm)
Paradigm
15 Jun 10
PARADIGM – INSTALLATION/OPERATION MANUAL
AIR/BLOWER DATA
External static – Non – A/C 0.2” wc
External static – A/C 0.5” wc
Cooling 4 tons
Maximum air temperature rise 85°F
High Limit, max design outlet temp 180°F
MOTOR/BLOWER
1 hp GE ECM/GT12DD
PLENUM DIMENSIONS
Cold air return 18 1/8” x 18 1/8” (460 x 460 mm)
Hot air supply 21 13/16” x 20 7/8” (554 x 530 mm)
Height to plenum 36 13/16” (supply) (935 mm)
39 13/16” (return) (1011 mm)
A/C COIL LOCATION
Minimum height above the cabinet 6” (152 mm)
See A/C coil Manufacturer’s Requirements
OPENING HEIGHTS from floor
Burner c/l 14 3/4” (375 mm)
Smoke pipe c/l 24 1/2” (622 mm)
DIMENSIONS
Depth 45 1/2” (1156 mm)
Height 39 13/16” (1011 mm)
Width 23” (584 mm)
Shipping Weight 398 lb (180 kg)
SMOKE/VENT PIPE 3” IPEX System 636
CLEANOUTS
Front Covers & Burner Opening
AIR FILTERS (All Models) Pleated 20” x 20” x 2”
THERMOSTAT (Digital)
Honeywell Focus Pro 5000 or similar
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.
Paradigm
16 Jun 10
PARADIGM – INSTALLATION/OPERATION MANUAL
8.0 TROUBLESHOOTING GUIDE
Furnace will not start
Tripped thermal/pressure switch Call service technician for switch reset.
Tripped breaker Determine cause, reset breaker.
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 duct work for blockage.
Dirty nozzle Call service technician to replace nozzle.
Sooty flame
Wrong pump pressure Increase or decrease pressure to correct setting.
Dirty nozzle Replace nozzle.
Improper burner setting See section 5.0 BURNER SPECIFICATIONS.
Using too much oil
Oil leak in line or tank Check fittings for tightness. Inspect tank and replace if
necessary.
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 registers blowing cold air
Basement cooling ducts Insulate and seal ductwork to maintain duct temperature.
Ducts running through Change or insulate ductwork.
unheated spaces
Warm air registers blowing too hot
Return air restricted Open up return air ductwork to ensure adequate airflow.
Nozzle too large Lower nozzle size to suit duct work.
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.
Paradigm
17 Jun 10
PARADIGM – INSTALLATION/OPERATION MANUAL
9.0 ANNUAL MAINTENANCE
Maintenance is to be performed at least once a year only by a qualified contractor recognized
by the authority having jurisdiction. Maintenance performed by any other party will void the
warranty.
The following maintenance routines are specific to the Paradigm furnace and must be
performed in conjunction with all other maintenance routines listed in Clauses 14.2 to 14.5 of
the CSA B139, Installation Code for Oil-Burning Equipment.
Burner
Refer to section 5.0 BURNER SPECIFICATION of the Manual.
o Verify that the fuel pump pressure is set to the correct pressure and adjust as required.
o Check for after drip and sharp fuel cutoff and replace automatic cut-off valve if necessary.
o Check and inspect electrodes and porcelain holders and clean or replace if necessary.
o Replace nozzle with a new one of the exact type listed for the output requirements.
o Clean turbulator and nozzle assembly, verify that the turbulator setting matches the
nozzle being used and adjust as required.
Furnace
o Inspect chamber and replace if necessary.
o Clean furnace as described in section 6.0 CLEANING INSTRUCTIONS.
o Replace air filter with the same size and type.
o Replace the condensate conditioner.
o Initiate a call for heat and observe through the sight glass that there is flame.
o After five minutes of burner operation (steady state) measure the smoke density and
adjust the burner air setting as required to obtain a zero to trace reading.
o Measure the CO2 and adjust the air setting slightly to obtain between 11.5 and 12 %.
o If, while monitoring the CO2 on start up, you witness changes in the % reading while the
blower ramps up, this may indicate a heat exchanger or gasket leak. Further testing may
be required to verify this.
o Measure the flue gas temperature through the hole in the vent pipe and verify that it is in
the range between 90 to 120°F.
o Disconnect the black wire from the C2 terminal of the low voltage section of the printed
circuit board. Initiate a call for heat and ensure that the limit shuts the burner off.
Reconnect the black wire initiate a call for heat and verify that the burner and furnace
cycle properly.
Paradigm
18 Jun 10
PARADIGM – INSTALLATION/OPERATION MANUAL
SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
FOR MOST RECENT UPDATES PLEASE VISIT www.KerrEnergySystems.com.
The following form MUST be completed for the warranty to be valid.
Installed by:
Address:
Telephone: Date:
START UP TEST RESULTS
Nozzle:
Air:
CO
Stack Temperature:
Test Performed By:
Staple Printout Here: Staple Smoke Spot Here:
Pressure:
Turbulator:
: Smoke Number:
2
Paradigm
19 Jun 10
9
2
10
1112
4
5
6
3
1714
13
8
16
ITEM
NO.
PART NUMBER
DESCRIPTION
Def
ault/
QTY.
1
KPR036
BASE PAN
1
2
KPRSUB006
LEFT SIDE PANEL ASSY
1
3
KPRSUB007
RIGHT SIDE PANEL ASSY
1
4
KPRSUB005
CENTER PANEL ASSY
1
5
KPR037
REAR BOX
1
6
KPR057
REAR PANEL
1
7
KPR040
LOWER FRONT PANEL
1
8
KPR041
TOP FRONT PANEL
1
9
KPR046
CABINET CLEANOUT
COVER
1
10
KPRSUB012
HEAT EX ASSY
1
11
KPR042
TOP DIVIDER
1
ITEM
NO.
PART NUMBER
DESCRIPTION
Def
ault/
QTY.
12
KPRSUB001
FILTER FRAME ASSY
1
13
STD149
CLEANOUT COVER
2
14
KPRSUB013
WIRE CHANNEL ASSEMBLY
1
15
std118 - 119
SENSOR BOX ASSY
1
16
KPR054
REAR EDGE
1
PARADIGM COMPLETE ASSEMBLY
KPR_2 AUG2409
FIGURE - 7
2
7
3
5
6
4
1 8101291011
ITEM
NO.
PART NUMBER
DESCRIPTION
QTY.
1
KPRSUB010
PRIMARY & SECONDARY
HEAT EXCHANGER
1
2
3GK-18-EXCH-00
GASKET CONDENSING
HEAT EXCHANGER 1/4" HT
SILICONE FOAM 2PC
1
3
KPRSUB011
TERTIARY HEAT EX
1
4
3GK-18-COLL-00
GASKET CONDENSING
COLLECTOR 3/16" HT
NEOPRENE
1
5
3HC-12-COLL-00
COLLECTOR HEAT
EXCHANGER PLASTIC
HMWPE 3" PIPE OUTLET
1
ITEM
NO.
PART NUMBER
DESCRIPTION
QTY.
6
KPR017
BACKING PLATE
1
7
KPR016
SNAP DISC CLIP
1
8
Default
CARRIAGE BOLT
12
9
HBOLT 0.3125-
18x1x0.875-N
6
10
Preferred Narrow
FW 0.3125
18
11
HNUT 0.3750-16-
D-N
6
12
HNUT 0.2500-20-
D-N
12
PARADIGM HEAT EXCHANGER ASSEMBLY
KPRSUB012_2 AUG1009
FIGURE - 8
4
2
8
7
5
6
1
3
9
ITEM
NO.
PART NUMBER
DESCRIPTION
QTY.
1
KPR051
LEFT SIDE PANEL
1
2
KPR052
LEFT SIDE BAFFLE
1
3
KPR043
LEFT INSIDE PANEL
1
4
KPR056
TERTIARY BAFFLES
1
5
KPR047
CONDENSATE CONDITIONER BRACKET
1
6
KPR048
CONDENSATE CONDITIONER CLMP
1
7
KPR049
PRESSURE SWITCH BRACKET
1
8
KPRSUB004
LEFT CORNER BAFFLE ASSY
1
9
KPR060
TOP SIDE INSULATION RETAINER
1
PARADIGM LEFT SIDE ASSEMBLY
KPRSUB006 AUG 1109
FIGURE - 9
5
3
2
6
4
1 7
ITEM
NO.
PART NUMBER
DESCRIPTION
QTY.
1
KPR050
RIGHT SIDE PANEL
1
2
KPR053
RIGHT SIDE BAFFLE
1
3
KPR060
TOP SIDE INSULATION RETAINER
1
4
KPR044
RIGHT INSIDE PANEL
1
5
KPR056
TERTIARY BAFFLES
1
6
KPRSUB003
RIGHT CORNER BAFFLE ASSY
1
7
KPRSUB002
INTERNAL WIRE CHANNEL ASSY
1
PARADIGM RIGHT SIDE PANEL ASSEMBLY
KPRSUB007 AUG 110
9
FIGURE - 10
1
5
2
3
4
ITEM
NO.
PART NUMBER
DESCRIPTION
QTY.
1
STD144
KPM WIRE CHANNEL
1
2
STD114
TRANSFORMER MOUNTING BR.
1
3
STD145
CHOKE BRACKET
1
4
STD143
WIRE CHANNEL COVER
1
5
STD113
CIRCUIT BOARD MOUNTING BR.
1
PARADIGM WIRE CHANNEL ASSEMBLY
KPRSUB13 AUG2409
FIGURE - 11
2 3
1
4 5 6
6 7
ITEM
NO.
PART NUMBER
DESCRIPTION
QTY
1
KPR025
BURNER PLATE ASSEMBLY
1
2
3CC-00-CHAM-02
CHAMBER COMBUSTION FURNACE
190mm ID 254mm OD 381mm LG
1
3
KPR024
CHAMBER SUPPORT TRIANGLE
1
4
HFBOLT 0.3125-18x1x1-N
3
5
HNUT 0.3125-18-D-N
3
6
Regular FW 0.375
7
7
HNUT 0.3750-16-D-N
4
PARADIGM COMBUSTION CHAMBER ASSEMBLY
KPRSUB008 AUG 2509
FIGURE - 12
2
1
3
ITEM
NO.
PART NUMBER
DESCRIPTION
QTY.
1
KPR038
CENTER PANEL BOTTOM
1
2
KPR039
CENTER PANEL TOP
1
3
KPR055
CENTER PANEL BAFFLE
1
PARADIGM CENTER PANEL ASSEMBLY
KPRSUB005 AUG 2509
FIGURE - 13
Table - 1
Parts listed below are not shown in previous assembly figures
KPR Paradigm MAX Oil-Fired Condensing Furnace
Order No. Item No. Part Description
4TF-00-25V0-00 KPR-1
4CB-00-TEMP-01 KPR-2
4SW-00-RA90-10 KPR-3
4CB-00-ECML-00 KPR-4
3SG-0P-1030-5A KPR-5
3BU-12-00DD-00 KPR-6
1SB-00-BUMR-00 KPR-7
4CO-00-6673-GE KPR-8
3BM-10-ECM0-02 KPR-9
9MF-25-NYL2-00 KPR-10
4SW-03-PRSS-00 KPR-11
3PV-03-SCRN-02 KPR-12
3PV-03-CVKT-02 KPR-13
3PV-15-RBUS-01 KPR-14
3PV-03-RTEE-02 KPR-15
1MF-CP-0300-40 KPR-16
K00-KC-NEUT-2G KPR-17 Tube Acidic Condensate Neutralizing 2 GPH 3/8" NPT JM-2
4SD-00-0130-00
KPR-18
Transformer 120/24 VAC 40VA AT41A1012B
Sensor Air Temperature Heating
Switch Rocker SP/ST 20amp Marked
Control Furnace Limit MAX 9300i REV 4.1B
Glass Sight Clear 1" NPT Hex with THD Seal
Blower 12" Forward Curved Direct Drive Blower (GT12-10DD)
Bracket Motor Mounting Direct Drive Blower
Coil Inductor Choke 2.1 mH 120 VAC 12A #6673GE
Motor Blower 1 HP ECM
Fitting Hose Barb adapter Thruwall 1/4" Tube x 1/4" NPT NYLON
Switch Pressure Proving 2" wc SPST NC Manual Reset
Vent Termination Screen System 636 PVC-FGV
Kit Concentric Vent System 636 PVC-FGV
Vent Bushing RD 1-1/2" Pipe x 1/2" Barb System 636 PVC-FGV
Vent Tee Reducing 3" x 1-1/2" Pipe System 636 PVC-FGV
Coupling Pipe Low-Pressure 3" Neoprene/Stainless
Control Limit Snap Disc 130 F Manual Reset 36TX16
Please have serial number & date of manufacture ready when ordering parts
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