Table of Contents
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Installation, Operation and
KLR / KLF series
85% + EFFICIENCY
OIL FIRED
LOWBOY FURNACE
KLR-100
KLR-200
KLF-200
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
Service Manual
KLR-100
09-05-2013
KLF-200
Illustration
G2012-E1 Rev.E
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Summary of Contents for Granby KLR-100
- Page 1 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...
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Page 2: Table Of Contents
6.2 FAN TIMER CONTROL BOARD (ST9103 A 1028) 6.3 (ST9103 A 1028) CONTROL BOARD SEQUENCE 6.4 SERVICING – FAN TIMER (ST9103 A 1028) SERVICE ELECTRICAL / WIRING DIAGRAMS RIELLO WIRING DIAGRAM BECKETT WIRING DIAGRAM EXPLODED PARTS VIEW KLR-100 KLR-200 KLF-200 START-UP TEST RESULTS... -
Page 3: Important Safety Advice
1.0 IMPORTANT SAFETY ADVICE Please read and understand this manual before installing, operating or servicing the furnace. To ensure you have a clear understanding of the operating procedures of the unit please take the time to read the IMPORTANT SAFETY ADVICE section of this manual. WARNINGS NEVER burn garbage or paper in the unit. -
Page 4: Product Information
See thermostat instructions MOTOR/BLOWER KLR-100: 1/2 hp 4 Speed / G10-8 DD or 1/2 hp ECM / G10-8 KLR-200: 3/4 hp 4 Speed / GT12-10DD or 3/4 hp ECM / GT12-10 KLF-200: 3/4 hp 4 Speed / GT12-10DD or 3/4 hp ECM / GT12-10 1/2 hp ECM /GT12-10 with a firing rate of 0.75 USGPH... - Page 5 FLUE-PIPE CONNECTION 5” Chimney or Direct Vent DVS Granby kit CLEANOUTS Rear Cover & Burner Opening AIR FILTERS KLR-100 20” x 20” x 2” non pleated UL approved KLR-200 15” x 20” x 2” & 20” x 20” x 2” non pleated UL approved KLF-200 15”...
- Page 6 52-5/8” (1337 mm) Height 33” (838 mm) Height 35-1/8” (892 mm) Width 21-1/2” (546 mm) Width 21-1/2” (546 mm) DIMENSIONS (KLR-200) Depth 55-1/8” (1400 mm) Height 33” (838 mm) Width 21-1/2” (546 mm) KLR-100 - DIMENSIONS Dimensions are in inches...
- Page 7 KLR-200 – DIMENSIONS Dimensions are in inches KLF-200 – DIMENSIONS Dimensions are in inches...
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Page 8: Furnace Installation
3.0 FURNACE INSTALLATION OIL TANK & PIPING Tank installation must conform to local requirements. Install according to the applicable code such as CSA B139 and NFPA 31. Minimize number of connections in suction line and make all connections air tight. Use a pipe joint compound suitable for oil on all pipe threads. - Page 9 PLACEMENT & VENTING Furnace installation shall conform to the required installation code for oil-fired equipment (USA: NFPA 31, Canada: CSA B139). FLOOR SUPPORT COMBUSTIBLE – If required, support furnace on five (5) concrete blocks. Make sure the center of the furnace base is supported. For a furnace installed on a combustible floor, consult the applicable code and authorities having jurisdiction on this application.
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Page 10: Accessories Installation
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. - Page 11 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.
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Page 12: Burner Installation And Specifications
5.0 BURNER INSTALLATION AND SPECIFICATIONS 5.1 ASSEMBLY & INSTALLATION OF BURNER ASSEMBLY Check that the burner model is correct for furnace rating required. Assemble as per burner manufacturer’s instructions. SELECT NOZZLE Select oil input, nozzle and burner configuration as shown on furnace operating decal. -
Page 13: Set Burner For Efficient Operation
5.2 SET BURNER FOR EFFICIENT OPERATION BURNER SETTING Use burner settings in the table on page 14 (KLR) and 15 (KLF) or operating decal as a guide to set burner, particularly for nozzle changes. Those settings are only starting points for the adjustments and are not meant as final settings. - Page 14 DRAFT PRESSURE Using an accurate draft meter; adjust the draft control to obtain a minimum of -0.01” wc draft pressure at the breech sampling hole. The draft regulator’s adjustments should be made after furnace has been running under heating mode for at least 5 minutes. COMBUSTION TEST All your tests must be done with the burner cover on (Riello) COMBUSTION...
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Page 15: Klr Technical Information
5.3 KLR TECHNICAL INFORMATION KLR Series KLR-100 KLR-200 Riello Burner Unit Model KLR-E1-*067-03 KLR-E1-*079-03 KLR-E1-*091-03 KLR-E3-*109-05 KLR-E3-*127-05 KLR-E3-*139-05 Firing Rate (USGPH) 0.55 0.65 0.75 0.90 1.05 1.15 Input (BTU/h) 77,000 91,000 105,000 126,000 147,000 161,000 Output (BTU/h) 67,000 79,000 91,000... -
Page 16: Klf Technical Information
5.4 KLF TECHNICAL INFORMATION KLF Series KLF-200 Riello Burner KLF-E3-*093-03 KLF-E3-*102-05 KLF-E3-*119-05 KLF-E3-*132-05 Unit Model 0.75 0.85 1.00 1.10 Firing Rate (USGPH) 105,000 119,000 140,000 154,000 Input (BTU/h) 93,000 102,000 119,000 132,000 Output (BTU/h) 0.65 70W 0.75 70W 0.85 70W 1.00 70W Nozzle Pump Pr. -
Page 17: Furnace Operation And Settings
6.0 FURNACE OPERATION AND SETTINGS SHUTTING FURNACE DOWN POWER OFF Turn off main power breaker or disconnect. FUEL OFF Shut off manual fuel supply valve. Always keep manual fuel supply valve shut off if the burner is shut down for an extended period of time. -
Page 18: Fan Timer Control Board (St9103A 1028)
6.2 FAN TIMER CONTROL BOARD (ST9103A 1028) o “FAN OFF” Dip Switches adjustment Dip Switches COMFORT ADJUSTMENTS o Outlet air consistently too warm or too cold - change the blower motor speed to give the specified air temperature rise. o Outlet air gets too warm and burner shuts down - increase air by changing the blower motor speed to give the specified temperature rise. -
Page 19: St9103A 1028 Control Board Sequence
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... -
Page 20: Servicing - Fan Timer St9103A 1028
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... - Page 21 Step Possible Cause Check-out procedure Corrective action No Heat Check for 120 Volts on the Yes - Move to next step Riello burner black wire, contact (COM) No - Back to step # 4 or check for bad application on the burner activation connection relay Check if oil primary control...
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Page 22: Service
Step Possible Cause Check-out procedure Corrective action No Cooling Yes - Move to next step Check for 24 Volts between G Blower No - Check thermostat and wiring; if it's and C on electronic fan High speed OK, then change the electronic fan control control Yes - Check ''COOL'' speed on the... - Page 23 BLOWER REMOVAL This furnace has a blower sealing system, which is designed to be tight and rattle free. Refer to the instructions and pictures below. 1) Shut off oil and power to furnace. 2) Open blower compartment. 3) For KLF furnace only, remove air filter. 4) Disconnect the wiring to the blower motor.
- Page 24 CHANGING NOZZLE It is recommended that the nozzle be replaced once a year. If a new nozzle of a different size is installed, change the blower speed according to section BURNER INSTALLATION AND SPECIFICATIONS or operating decal as required. CLEANING HEAT EXCHANGER Heat exchanger must be inspected every heating season.
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Page 25: Electrical / Wiring Diagrams
8.0 ELECTRICAL / WIRING DIAGRAMS... - Page 27 GeniSys control schematic with the ST9103 Board...
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Page 28: Exploded Parts View
9.0 EXPLODED PARTS VIEW KLR-100 – Exploded Parts View... - Page 29 Transformer HTC-01A0BB01 40VA 4RY-00-24V0-00 Relay AE04001 24VAC Form C SPDT 24V HEX-A0-0012-00 Rear Collector Assembly FAN-A0-0002-00 Fan Motor Assembly KLR-100 PSC Motor FAN-A0-0002-01 Fan Motor Assembly KLR-100 ECM Motor 3BU-10-08DD-00 Blower 10'' x 8'' Direct Drive (G10-8DD) 3BM-50-4SDD-01 Motor Blower 1/2 HP Direct Drive 4SP EMERSON 4CA-00-705M-00 Capacitor 7.5 µF 370VAC 70C 60 Hz...
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Page 30: Klr-200
KLR-200 – Exploded Parts View... - Page 31 KLR-200 – Part List ITEM PART NUMBER DESCRIPTION CAB-A0-0007-00 Front Panel Assembly CAB-A0-0012-00 Base Panel Assembly CAB-A0-0009-00 Right Panel Assembly CAB-A0-0008-00 Left Panel Assembly CAB-A0-0010-00 Divider Panel Assembly CAB-P0-0080-00 Top Rear Panel CAB-P0-0013-00 Blower Door Panel CAB-P0-0014-00 Upper Divider CAB-P0-0015-00 Divider's Filler Gasket Bracket 3HN-00-PULL-00 Handle Flush Pocket Pull HEX-A0-0003-00...
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Page 32: Klf-200
KLF-200 – Exploded Parts View... - Page 33 KLF-200 – Part List ITEM PART NUMBER DESCRIPTION CAB-A0-0049-00 Front Panel Assembly CAB-A0-0052-00 Base Panel Assembly CAB-A0-0051-00 Right Panel Assembly CAB-A0-0050-00 Left Panel Assembly CAB-A0-0053-00 Divider Panel Assembly CAB-P0-0164-00 Top Rear Panel 3HN-00-PULL-00 Handle Flush Pocket Pull CAB-P0-0013-00 Blower Door Panel ELB-A0-0018-00 Electrical Box Assembly CAB-P0-0128-00...
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Page 34: Start-Up Test Results
10. START-UP TEST RESULTS Model: Serial Number: Lowboy KLR________ Lowboy KLF_______ Date of installation: Installer (name & address): START-UP TEST RESULTS Size of unit (Btu/h): Nozzle: Oil Pressure (psi): Chimney__________ Direct vent system (DVS) _______________ Burner adjustments: RIELLO F3___BF3___RIELLO F5___BF5___ BECKETT AFG-LII___ Beckett AFG-F3___ Turbulator: _____ Air band:_______... - Page 35 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.
- Page 36 Granby Furnaces Inc. manufactures a full line of oil-fired furnaces in its 70,000 square feet facility. Granby products are sold across Canada and the United States through a distribution network. Our team of engineers, designers and technicians continually research and develop products to go beyond the demanding specifications of today’s certifications.
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