Granby KLR-100 Guida all'installazione

Installation, Operation and

Service Manual

KLR / KLF series

85% + EFFICIENCY

OIL FIRED

LOWBOY FURNACE

KLR-100

KLR-200

KLF-200

KLR-100

KLF-200

Illustration

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

09-05-2013

G2012-E1 Rev.E

TABLE OF CONTENTS

1.0 IMPORTANT SAFETY ADVICE 2

2.0 PRODUCT INFORMATION

3.0 FURNACE INSTALLATION

4.0 ACCESSORIES INSTALLATION

5.0 BURNER INSTALLATION AND SPECIFICATIONS 11

5.1 ASSEMBLY & INSTALLATION OF BURNER 11

5.2 SET BURNER FOR EFFICIENT OPERATION 12

5.3 KLR TECHNICAL INFORMATION 14

5.4 KLF TECHNICAL INFORMATION 15

6.0 FURNACE OPERATION AND SETTINGS 16

6.1 BLOWER SETTING 16

6.2 FAN TIMER CONTROL BOARD (ST9103 A 1028) 17

6.3 (ST9103 A 1028) CONTROL BOARD SEQUENCE 18

6.4 SERVICING – FAN TIMER (ST9103 A 1028) 19

7.0 SERVICE 21

8.0 ELECTRICAL / WIRING DIAGRAMS 24

RIELLO WIRING DIAGRAM 24

BECKETT WIRING DIAGRAM 25

9.0 EXPLODED PARTS VIEW 27

KLR-100 27

KLR-200 29

KLF-200 31

10. START-UP TEST RESULTS 33

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.

NEVER store combustible material around it.

DO NOT attempt to start burner when excess oil has accumulated, when unit is full of vapour

or when heat exchanger is very hot.

DO NOT use gasoline, crankcase draining’s or any oil containing gasoline.

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 KLR / KLF OIL-FIRED

FURNACE. Read the instructions thoroughly before installing furnace or starting the burner.

Consult local authorities about your local FIRE SAFETY REGULATIONS. All installations

must be in accordance with local state or provincial codes. Improper installation will result in

voiding of warranty.

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)

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... KLR-100

5.0 tons… KLR-200

5.0 tons… KLF-200

Maximum air temperature rise See pages 14 (KLR), 15(KLF) and 34

High Limit temperature 185°F

Thermostat anticipator 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

FAN/HIGH LIMIT CONTROL

Honeywell ST9103A1028 Fan Center & Thermo-Disk (7” stem)

THERMOSTAT

Any wall thermostat

FUEL

Not heavier than No. 2 furnace oil.

ELECTRICAL – 120 Volts, 60 Hz

Canada Less than 12 amps.

USA 13.3 amps, circuit protection 20 amps.

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” x 20” x 2” (2X) non pleated UL approved

PLENUM DIMENSIONS (KLR-100)

Cold air return (A) 20” x 20” (508 x 508 mm)

Hot air supply (B) 20” x 20” (508 x 508 mm)

Plenum spacing (C) 2-1/8” (54 mm)

PLENUM DIMENSIONS (KLR-200)

Cold air return (A) 20” x 22” (508 x 559 mm)

Hot air supply (B) 20” x 24” (508 x 610 mm)

Plenum spacing (C) 2-1/8” (54 mm)

PLENUM DIMENSIONS (KLF-200)

Cold air return (A) 20” x 20” (508 x 508 mm)

Hot air supply (B) 20” x 24” (508 x 610 mm)

Plenum spacing (C) 2” (51 mm)

KLR KLF

B C A C

B A

DIMENSIONS (KLR-100) DIMENSIONS (KLF-200)

Depth 49-1/8” (1248 mm) Depth 52-5/8” (1337 mm)

Height 33” (838 mm) Height 35-1/8” (892 mm)

Width 21-1/2” (546 mm) Width 21-1/2” (546 mm)

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

KLR-200 – DIMENSIONS

Dimensions are in inches

KLF-200 – DIMENSIONS

Dimensions are in inches

3.0 FURNACE INSTALLATION

OIL TANK & PIPING

Tank installation must conform to local requirements.

Install according to the applicable code such as 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. To reduce possibility of air leaks, tighten stem packing

gland nut on any valves installed in the suction line. Also, be sure the oil filter is tight, as filter

gaskets often shrink. Check for kinks in the oil lines as well as for possible air pockets and for

loose connections. Two filters as shown below are recommended. Optional tank gauge

protectors and outlet protectors are available at your local dealer.

ONE PIPE SYSTEM Where the tank outlet is above the burner and when the oil flows by

gravity to the oil pump, a single-stage fuel unit with a single oil line

to the pump may be used.

TWO PIPE SYSTEM When a single line is not suitable, use double line or contact your

dealer for special oil line fittings. Install by-pass plug on burner fuel

pump as specified in the burner manual.

REAR FLUE FURNACE ILLUSTRATION

Oil Tank and Piping

PLACEMENT & VENTING

Furnace installation shall conform to the required installation code for oil-fired equipment (USA:

NFPA 31, Canada: CSA B139).

FLOOR SUPPORT COMBUSTIBLE – If required, support furnace on five (5) concrete

blocks. Make sure the center of the furnace base is supported. For a

furnace installed on a combustible floor, consult the applicable code and

authorities having jurisdiction on this application. The floor must support

the weight.

CHIMNEY/VENT Connect the furnace to a chimney/vent system of size and condition

required by the NFPA 31 (USA) or CSA B139 (Canada) code. Furnace

is approved for factory built chimney type “L” vents. Breech is certified

for 5” vent pipe. Keep vent/flue pipe as short as possible with min. 1/4”

per foot upward slope. Vent/flue pipes MUST NOT pass through a

ceiling. Maximum flue gas temperature is 575°F.

CONDENSATION If you have condensation in your chimney, make sure that the

chimney size is according to the tables in CSA B139 / NFPA 31.

The temperature at the base of the chimney can be increased by

insulating the flue-pipe between the furnace and the chimney base.

If this is not sufficient, consider cutting or removing some flue

baffles in the furnace. BE AWARE THAT REMOVING BAFFLES

REDUCES THE UNIT’S EFFICIENCY AND A MODIFIED UNIT IS NO

LONGER ENERGY STAR APPROVED.

COMBUSTION &

Install openings and ductwork to the furnace room providing fresh out-

VENTILATION AIR side combustion and circulation air for cooling the furnace casing, as

installation code requires (USA NFPA 31, Canada CSA B139). If

installed in a closed room, provide two free air ventilation openings of at

least 8” x 12” (96 sq. in.) free flow area near ceiling and floor. Oil

burners must have sufficient air to allow vent systems to operate

properly.

BREECH DRAFT Use approved draft control supplied for 5” pipe. Set draft pressure of the

flue to -0.01” wc.

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.

CLEARANCES Before placing unit, review installation clearances as shown on furnace

operating decal or section PRODUCT INFORMATION (page 3).

LOCATION Install the furnace close to chimney and central to ductwork.

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 from the instruction

Figure 2 - BVSO wiring diagram

manual of Field Controls

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).

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