Granby KLR-100 Einrichtungshandbuch

OIL FIRED LOBOY FURNACE - 85% + EFF

LR-100

LR-200

LF-100

KLF

-200

KLR-100 & 200 KLF-100 KLF-200

Please read the manual in its entirety before beginning installation. This

manual must be kept with the boiler for future reference. For maintenance

or question, please refer to your installer – contractor directly.

18-06-2017 G2017-E1 Rev.I

Installation, Operation and Service

Manual

INSTALLATIONS MUST MEET ALL LOCAL AND CODES THAT MAY

DIFFER FROM THIS

TABLE OF

CONTENTS

1.0 IMPORTANT SAFETY ADVICE 2

2.0 PRODUCT INFORMATION 3

3.0 FURNACE INSTALLATION 7

4.0 ACCESSORIES INSTALLATION 9

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 (ST9103A1028) 17

6.3 (ST9103A1028) CONTROL BOARD SEQUENCE 18

6.4 SERVICING – FAN TIMER (ST9103A1028) 19

7.0 SERVICE 21

8.0 ELECTRICAL / WIRING DIAGRAMS 24

HEATING & COOLING – RIELLO BURNER 24

HEATING & COOLING – BECKETT BURNER 25

HEATING ONLY (2 WIRES THERMOSTAT) 27

9.0 EXPLODED PARTS VIEW 28

KLR-100 28

KLR-200 30

KLF-100 (Coming soon, please call your Granby representative) ---

KLF-200 32

10. START-UP TEST RESULTS 34

! !

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 TAMPER WITH THE FURNACE OR CONTROLS, CALL A QUALIFIED BURNER

TECHNICIAN.

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.

!! ! ! !!!KLR!!!!!!!!!!!!KLF!

! !

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

BURNER TUBE INSERTION

Riello and Beckett 2-1/2” (63 mm)

AIR/BLOWER DATA

Maximum external static pressure 0.5” WC

Maximum cooling unit capacity KLR-100, up to 3.0 tons.

KLR-200, up to 5.0 tons.

KLF-100, up to 3.0 tons

KLF-200, up to 5.0 tons.

Maximum air temperature rise 85°F

High Limit temperature 185°F

MOTOR/BLOWER

KLR-100: 1/2 hp 4 Speed PSC / G10-8 DD or 1/2 hp 5 speed ECM / G10-8 DD

KLR-200: 3/4 hp 4 Speed PSC / GT12-10 DD or 3/4 hp ECM 5 speed / GT12-10 DD

KLF-100: 1/2 hp 4 Speed PSC / G10-8 DD or 1/2 hp ECM 5 speed / G10-8 DD

KLF-200: 3/4 hp 4 Speed PSC / GT12-10 DD or 3/4 hp ECM 5 speed / GT12-10 DD

FAN/HIGH LIMIT CONTROL

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

FLUE-PIPE CONNECTION

5” breech

CLEANOUTS

Rear breech cover & burner opening (KLR) or Front breech & burner opening (KLF)

THERMOSTAT

Any wall thermostat

Thermostat adjustment as per thermostat manufacturer installation.

FUEL

Not heavier than No. 2 furnace oil.

ELECTRICAL – 120 Volts, 1PH-60 Hz, 15 amps. circuit protection, USA circuit protection 20 amps.

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-100 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”

(51 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”

(51 mm)

PLENUM DIMENSIONS (KLF-100)

Cold air return

(A)

18” x 20-3/4”

(457 x 527 mm)

Hot air supply

(B)

18” x 21-3/4”

(457 x 552 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

Plenum spacing

(B)

(C)

20” x 24”

2”

(508 x 610 mm)

(51 mm)

B C A B C A

KLR KLF

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

Depth

49-1/8”

(1248 mm)

Depth

53-1/2”

(1,359 mm)

Height

33”

(838 mm)

Height

29-3/8”

(746 mm)

Width

21-1/2”

(546 mm)

Width

21-1/2”

(546 mm)

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

Depth

55-1/8”

(1400 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)

KLR KLF-100 KLF-200

KLR-100 - DIMENSIONS

Dimensions are in inches

KLR-200 – DIMENSIONS

Dimensions are in inches

KLF-100 - 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 CAN/CSA B139 and NFPA 31 in the USA.

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: CAN/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 CAN/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.

PRESENCE OF CONDENSATION

IN THE CHIMNEY OR FLUE PIPE

Presence of condensation in your chimney or flue pipe is not normal, all

necessary precautions should be taken to prevent condensation build-up in the

flue pipe and inside the chimney. Make sure that the chimney size is according

to the tables in CAN/CSA B139 / NFPA 31.

Note: Base temperature — the temperature of the flue gases at the base of

the chimney flue, measured within the vent at the base tee or vent connector

thimble, with the barometric damper shut, after the appliance flue-gas

temperature has stabilized.

10!

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® CERTIFIED.

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.

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 CAN/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.

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