Beijer Ref KIRBYAIR COMPACT Installation and maintenance instructions
KIRBYAIRTM COMPACT
High-EciencyGasFurnace
Installation & Service Instructions
Exclusively distributed by
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Contents
1.0. Installation Instructions 3
1.1. General 3
1.2. Models 3
1.3. General Requirements 4
1.4. Location 5
1.5. Clearances 5
1.6. General Installation 6
1.7. Roof Space Installation 6
1.8. Under Floor Installation 7
1.9. External Installation 7
1.10. Fluing 7
1.11. Gas Piping 8
1.12. Power Connections 8
1.13. Room Thermostat 9
1.14. Duct Connections 9
1.15. Warm Air Ducting 9
1.16. Return Air Ducting 9
1.17. Outlet Registers 10
1.18. Filters 10
1.19 Add-On Cooling 10
1.20. System Balancing 10
1.21. Fan Adjustment 10
1.22. Installation Notes 10
1.23. Pre Commissioning Checklist 11
1.24. Commissioning Procedure 11
1.25. Minimum Number of Vent Openings 12
1.26. Abnormal Operation 12
1.27. Warnings 12
1.28. Maintenance 12
1.29. Final Checks 13
2.0. Service Instructions 15
2.1. Removal of Covers 15
2.2. Diagnostic Conditions 16
2.3. Overheat Switches 16
2.4. Replacement of the Flame Sensor and / or Ignitor 17
2.5. Pressure Switch 17
2.6. Electronic Control Board (PCB) 17
2.7. Gas Valve 17
2.8. Combustion Fan 18
2.9. Supply Air / Ventilation Motor Fan 18
2.10. Heat Exchanger 18
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1.0. Installation Instructions
1.1. General
The KirbyAir™ Compact range of gas furnaces are designed as a single stage, non-condensing central gas ducted
heating unit. Throughout the installation and service instructions, reference is made to the general aspect of the unit
with dimensions indicated in Figures 1 and 2 noted in Table 2.
As shown in Figures 1 and 2 the access service panel, where the gas, power and thermostat are connected, is located
at the front of the unit. With respect to the front access the rear side contains the fan box (as seen in Figures 1 and
panels of the front section. The front section behind the service panel contains access to the Printed Circuit Board
(PCB) controls, the gas burner, combustion fan, and the gas valve. The gas inlet connection is given at the front lower
section. Access to the fan wheel and motor is achieved on the far-right hand side.
1.2. Models
These installation and service instructions cover the following range of KirbyAir™ Compact internal and external gas
furnaces:
Figures 1 and 2: General Aspects
A
B
C
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Table 1: Specications
Model Unit KG4-165 KG4-200 KG4-265 KG4-315
Heat Input MJ/h 64 80 102 120
Heat Output kW 16.5 19.5 26.5 31.5
Air Flow L/Sec 470 630 770 940
Electrical Power V/Hz/Ph 240/50/1 240/50/1 240/50/1 240/50/1
Thermostat Control V 24 24 24 24
Maximum Add-On Cooling kW 8 11 14 18
Energy Star Rating Stars 4.5 4.7 4.7 4.8
Table 2: Dimensions
1.3. General Requirements
The installation of this appliance must conform to the following requirements:
1. These installation and service instructions
2. AS/NZS 5601
3.
4. Local building regulations
5. Local electrical supply authority regulations
6. Fitment of dedicated circuit breakers in the power line of the unit in the meter box
Model Unit KG4-165 KG4-200 KG4-265 KG4-315
A - Width mm 360 432 585 585
B - Depth mm 1165 1180 1180 1180
C - Height mm 450 450 450 450
Return Duct Connections mm 300 350 400 400
Supply Duct Connections mm 300 350 400 400
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1.4. Location
to the building (for external models), with connection to a warm air heating duct system.
Although the location is generally predetermined, please check with the owner or builder for detailed installation
plans. If a location has not yet been decided, consideration must be given to the following:
1. The location must provide adequate structural support; space for service access; and clearances for return and
supply air duct connections.
2. Care should be taken to locate the unit and ductwork so that the supply air does not short circuit to the return air.
3. Proper electrical supply must be available.
4. Proper gas supply must be available.
5. Clearances must be provided.
6. Enough partition with insulation and cushioning for noise dampening between the unit and the living space.
1.5. Clearances
The following clearances must be provided for installation:
• 600mm at the front and sides of the unit to allow for servicing
• 600mm wide walkway for servicing from the access point in accordance with AS/NZS 5601
• 100mm above the lid of the unit
Please refer to Figure 3 for clearances.
NOTE: Ducting must not intrude on these clearances for servicing, except for connections.
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KIRBYAIRTM COMPACT
Figure 3: Minimum Installation Clearances
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1.6. General Installation
The following sequence of installation steps is suggested. Reference is also made to the Final Installation Checklist.
NOTE: Always ensure appropriate manual handling and safety procedures are adhered to throughout installation.
The KirbyAir™ Compact is tted with handles at each end to assist manual handling.
1.
and stable position. For on ground installation, an appropriate concrete slab of the same size is recommended
to be used under the unit.
2. Make electrical power connections with a light above available within 1000mm of the front access panel of the
unit with a switch next to it.
3.
4. Connect all ductwork after 1500mm straight duct lengths for return and supply from the unit. Failure to comply
with ductwork requirements may impact performance and void warranty.
5.
6.
7. Connect a thermostat using 24V appropriate gauge wiring connections.
8. Power up the unit.
9. Start and check the system for the given nominal gas pressure at the gas valve outlet for operation.
10. Balance the air pressure in all the vents and explain the thermostat operation to the user. Advise on any servicing
1.7. Roof Space Installation
1. The area in the roof space must be capable of supporting the additional load of the appliance. The unit base rails
2.
using a normal ladder or steps.
3. A walkway must be provided between the access point to the roof space and the unit. This walkway must be
4. Permanent lighting must be provided at the unit, with the switch located at the point of entry to the roof space.
5.
unit. A minimum clearance of 100mm between the top of the appliance and any combustible material must be
maintained.
6. Ensure that any ceiling insulation material is kept clear of the appliance by a minimum of 100mm.
7. This is a non-condensing furnace in which there is no condensate discharge to be terminated.
KIRBYAIRTM COMPACT
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1.8. Under Floor Installation
The
1.
extend from the access opening to the appliance, and around the appliance.
2. Where minimum clearances exist as above, the unit shall be located within 2000mm of the access opening.
3. Where greater clearances than above exist, the unit may be installed at any distance from the access opening
4.
maintained.
5. The unit is to stand on a level concrete base of at least 50mm thickness, and provision must be made to drain
away any seepage or ground water so that water can not come into contact with the unit.
6. Fixed electrical lighting must be provided at the unit, with the switch located adjacent to the access opening.
1.9. External Installation
Every
provided separately). Before installing the unit, use a concrete slab to put the unit on, high enough from the ground
level to ensure that rain and storm water do not enter the cabinet.
1.10. Fluing
required for each
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1.11. Gas Piping
NOTE: A licensed professional must install the gas piping.
An AGA approved appliance isolating cock must be installed close to the unit. Gas piping material and size must be
in accordance with AS/NZS 5601. The gas connection must be tested for any leakage.
DO NOT USE AN OPEN FLAME OR OTHER SOURCE OF IGNITION FOR LEAK TESTING.
Figure 4 illustrates a typical gas valve showing the location of the gas inlet and outlet and the pressure testing point.
1.12. Power Connections
wiring diagram should be found on the front panel of the unit. The 10 ampere general purpose outlet is required to
be positioned within 1500mm of the unit. Wiring shall be in accordance with the local supply authority regulations.
Ensure that polarity of the power outlet is correct, as shown in Figure 5.
A suitable electrical light is to be provided near the unit to assist with servicing and the switch placed adjacent to the
access opening.
KIRBYAIRTM COMPACT
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Figure 4: Gas Valve Connections
Figure 5: Power Point Connection Polarity
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1.13. Room Thermostat
The KirbyAir™ Compact is run with either a manual or programmable room thermostat. The thermostat should be
room air circulation, normally near the return air intake. It should not be installed on an outside wall or where it is
exposed to direct sunlight, heat sources, draughts, or other conditions, which could adversely affect its operation.
Generally, the hallways/walkways, living or dining room is a suitable location, provided there are no cooking facilities
or refrigeration appliances on the opposite wall facing the thermostat. Mount the thermostat and route the 24-volt
control wiring from the thermostat to the heater unit. Connect the terminals labeled “R” and “W” on the thermostat to
the screw type terminals labeled “R” and “W”, respectively, on the PCB connection strip. Ensure that the hole through
the wall for wiring to the thermostat is sealed to prevent draughts from affecting the thermostat. The control wiring
that passes into the heater should use a cable gland for safe harnessing the wiring on to the PCB. This gland should
the thermostat please refer to the separate thermostat instructions used with the unit.
1.14. Duct Connections
All return air and the supply air duct connecting collars are circular. Refer to Table 2 for dimensions. Two starting
collars are provided with each unit. It is very important to the satisfactory functioning of the installation that the duct
system be properly sized, installed, and pressure-balanced.
1.15. Warm Air Ducting
From the outlet/supply air duct connection of the unit, install adequately sized ductwork to the outlet/supply air
registers. Flexible ducting should be used where noise transfer may be a problem particularly at the duct connection
ductwork be insulated, especially where it runs through an unheated space. The supply air connection should be
fastened directly to the structure. Care should be taken to ensure that all ducting is free from internal obstructions,
free of leaks and adequately supported. Likewise ducting should not be caved in, crushed, or slack in any manner.
1.16. Return Air Ducting
A return air duct must be provided and should draw air from a central location within the house. The maximum
recommended duct length is 6000mm. This ducting may be installed to either or both of the return air connections
found on the left and right hand rear sides of the unit. In instances where the unit is drawing air from a building
cavity make certain that it is fully sealed. This ensures that outside air is not drawn into the system, which will affect
into the heater.
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1.17. Outlet Registers
Suitable outlet registers/diffusers must be provided in all areas being heated.
1.18. Filters
30%.
NOTE: Filters are not permitted on the supply air vents under any conditions.
1.19. Add-On Cooling
Where either presently or in the future any KirbyAir™ Compact unit may be installed with the correct indoor refrigerated
coil section, it should be installed at least 1500mm downstream of the supply air duct connection.
1.20. System Balancing
the duct layout.
1.21. Fan Adjustment
The fan is preset during manufacturing to operate at a designed speed. The fan speed should not be changed
without the expressed authorisation of the manufacturers.
1.22. Installation Notes
1. A 30-second delay is given to run the fan from the ignition taking place.
2. The fan speed is factory-set so that discharge air temperature does not exceed 60 degrees
3.
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1.23. Pre Commissioning Checklist
• Have all the gas lines been checked for leaks?
• Is the fan motor correctly wired?
• Is the thermostat correctly wired for polarity for W*G*R, and wiring harnessed?
• Filters are clean and in place with the correct size of the return air grille?
• Outlet registers/diffusers and return air grille are open?
•
• Gas is open, power is on, and thermostat is one with preset temperature higher than the room temperature?
1.24. Commissioning Procedure
1. Check the burner pressure setting. The correct pressure for natural gas is 0.87 kPa for all models.
2. Ignite the unit by setting the room thermostat to call for heat by raising the set point above the current room
temperature.
3.
the dampers to achieve design air quantities. Maximum air delivery temperature at the outlets should not exceed
an average of 50 degrees C. Maximum air delivery temperature at the supply air connection should not exceed
60 degrees C, or 55 degrees C for extra air models. If this requirement is not met the duct pressure balancing
must be performed.
4.
air grille.
5. Turn the room thermostat to the ‘OFF’ position. The room air fan should stop after a period of approximately
50-seconds.
6.
sealed. If so, this condition must be corrected.
NOTE: The user must be instructed on how to correctly operate the system.
number of registers open otherwise the unit will cut out on the high temperature limit.
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1.25. Minimum Number of Vent Openings
The following minimum number or more vents should always remain open:
KG4-165 3
KG4-200 4
KG4-265 5
KG4-315 6
In case of less than above number of vents are open, or there is a power failure, the unit may over heat and short-
cycle, or go to lockout mode and the high temperature manual overheat limit switch may activate, and may require
human intervention to reset. When more vents are opened and or power is restored the over heat auto-reset high
temperature limit will automatically reset but the thermostat may have to be turned down and up again to re-set and
re-start the system.
1.26. Abnormal Operation
Should any of the following circumstances occur, cease using the unit and contact your installer or gas authority
immediately:
• Smell of gas fumes; unusual odours, smoke or fumes from outlet registers.
• Excessive or unusual noise emanating from the unit.
1.27. Warnings
Advise the user of the following issues:
• Do not place articles on or against the unit.
•
• Do not spray aerosols in the vicinity of the unit while it is in operation.
•
•
1.28. Maintenance
Advise the user
levels. The frequency at which cleaning or replacement occurs depends on the hours of operation and the local
environment.
KIRBYAIRTM COMPACT
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1.29. Final Checks
• Have all the parts of the unit been inspected for any damage due to transport?
• Has a suitable location been selected?
• Have electrical power connections been made according to all relevant standards?
• Has the gas piping been connected according to the relevant standards?
• Has the electrical control wiring been connected to the unit in accordance with the instructions?
• Has the gas inlet pressure to the unit been set correctly?
• Has all the required ductwork been installed properly with air balancing?
• Have all the relevant regulatory bodies been advised of the installation?
• Has the user been provided with a copy of the operating instructions and instructed on how the system operates
with the connected thermostat?
• Has the user been advised of the unit’s servicing requirements?
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Figure 6: Dimensions (Refer to Table 2)
Table 2: Dimensions
Model Unit KG4-165 KG4-200 KG4-265 KG4-315
A - Width mm 360 432 585 585
B - Depth mm 1165 1180 1180 1180
C - Height mm 450 450 450 450
Return Duct Connections mm 300 350 400 400
Supply Duct Connections mm 300 350 400 400
A
B
C
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2.0. Service Instructions
NOTE: Please switch off the power and shut the gas cock before touching the appliance for service. Open the
service panel as per instructions provided in this manual to service or replace any part of component of the unit.
2.1. Removal of Covers
All KirbyAir™ Compact units may be serviced from the front panel without needing to remove the lid or rear section
panels. Side panels may be removed by undoing the outer screws on the panels.
1. Ignitor can be accessed from left bottom side of the burner. Undo the two screws using a star screw driver and
the ignitor may be removed for replacement.
2. Flame sensor can be removed from the front right corner of the burner upper panel by undoing two screws.
3. Burner can be removed by opening the front upper access panel. In order to take the injector manifold out,
remove both end brackets on the manifold fastened on the burner front, and a bracket on the base of the unit.
This will allow changes to the burners, injectors and gas valve.
4. Gas valve can be accessed by opening the front lower panel. Remove the manifold side brackets and take out
the injector manifold. Undo the gas valve and replace if needed.
WARNING
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE
PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. INSTALLATION AND SERVICE MUST BE
PERFORMED BY A LICENSED PROFESSIONAL INSTALLER OR SERVICE AGENCY.
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2.2. Diagnostic Conditions
access panel and observe the green indicator light to diagnose the fault.
2 Flashes System lock out due to failure to detect or sustain ame.
•
burner port.
4 Flashes High limit or manual overheat switch opened.
• Wait until the auto limit closes, or is manually cut off.
• Check for obstructions in the duct and open more registers.
• Reset the manual switch and attempt ignition from the thermostat.
5 Flashes Flame sensed and gas valve not energised.
• Check the gas valve
Steady Light Internal failure.
• Microcontroller failure and power on self check
Should the unit continue to fail to operate, contact your installer or Kirby HVAC&R.
2.3. Overheat Switches
• 1x left of the fan with access from the return air spigot
• 1x right of the fan with access from the return air spigot
• 1x in the middle of the heat exchanger panel below the burner, above a manually resettable over-temperature
switch
Temperature ratings are provided in Table 3.
KIRBYAIRTM COMPACT
Model KG4-165 KG4-200 KG4-265 KG4-315
Automatic 3x A 60°C 3x A 80°C 3x A 80°C 3x A 80°C
Manual 1x M 80°C 1x M 90°C 1x M 90°C 1x M 90°C
Table 3: Temperature Ratings
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2.4. Replacement of the Flame Sensor and/or Ignitor
burner top panel. The ignitor is located below the burner bottom. Open the two screws and pull down the ignitor
for replacement. Ensure the ignitor lead of the replacement part is sleeved with a high voltage suppression lead.
Ensure the gap between the electrode tips is not tampered with.
2.5. Pressure Switch
Ensure the air pressure tube is connected at both ends and with grey inlet of the switch and the spade connections
To remove the pressure switch, disconnect the air pressure tube, gently remove the two wiring connections, and
remove the screws on the top and bottom, replacing it. Position and harness it in the same manner which it was
originally installed and connect the air pressure tube back to the grey inlet with two wire spades reconnected.
2.6. Electronic Control Board (PCB)
The control board is protected by a 3 amp purple fuse located next to the transformer outlet with 24V connections.
The fuse may be replaced by gently removing using long nose pliers. If the PCB is not showing power through the
When replacing the PCB, use the back spacers to position it correctly on the base and reconnect the wiring as per
the wiring diagram.
2.7. Gas Valve
To replace the gas valve, shut the isolating gas cock and remove the access panel. Remove the gas manifold by
undoing the side brackets on the burner and the base. Pull out gently the gas manifold with the gas valve. Using
two spanners, undo the gas valve and replace it with the new one using the gas sealant on the threaded inlet outlet
connections. Reposition the gas valve with manifold on the burner inlets one-by-one. Fasten the two side brackets
are made as per the wiring diagram. Start the unit and ensure there is no gas leak. Replace the access panel and
harness it properly with all screws.
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2.8. Combustion Fan
the sealant around the box, and remove it. Replace the combustion fan and refasten the mounting plate with four
2.9. Supply Air / Ventilation Motor Fan
The supply air fan motor is mounted with a centrifugal forward curved wheel attached to it. Access to the motor
is located on the far right hand side. Ensure the power is switched off from the GPO before accessing the motor.
Remove the panel and access the motor. The motor is mounted with three nuts and bolts on a bracket fastened on
the ring of the inner side panel of the housing. Remove these bolts and the ring around it. Remove the opposite
side panel to access the wheel attached to the shaft and undo the grub screw to remove the wheel. If the wheel is
undamaged, replace motor using the same wheel. Once the motor has been replaced, ensure the wiring is connected
as per the wiring diagram and the connection to the safety switches in the fan box are not disturbed and are correctly
repositioned, and the fan bracket is tightly fastened on the ring and the ring on the panel.
2.10. Heat Exchanger
The heat exchanger sits in the middle of the unit and is integrated to the burner facing panel from the top end to the
bottom end and is harnessed onto the base of the unit. Remove the heat exchanger by undoing the screws on the
base, outer lid, inner lid and burner box. Finally, undo the screws on the base and remove its sealing and take the
heat exchanger out. Replace the heat exchanger, seal it off on the base and then fasten with the same size screws.
KIRBYAIRTM COMPACT
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Figure 7: Wiring Diagram with Ignition Module
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Exclusively distributed by
KIRBYCOMPACTGASFURNACE_IS1_1903
The contents of this brochure are copyright protected and may not be reproduced in any form without the written consent of Kirby HVAC&R (T/A Heatcraft).
Recommendations and advice regarding the use of the products described in this publication are to be taken as a guide only and are given without liability on the
part of the company or its employees. As Kirby HVAC&R continually improves its product range and processes,
publication. The purchaser should independently determine the suitability of the product for the intended use and application and that the product complies with
economic loss) however arising which results from any errors or omissions in the information contained in this publication or arising from the use or application of
the information contained herein.
® and ™ Registered Trade Mark and Trade Mark of Kirby HVAC&R Pty Ltd (T/A Heatcraft)
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KIRBYCOMPACTGASFURNACE_IS1_2004 - KirbyAir Compact Installation & Service Instructions.indd 20KIRBYCOMPACTGASFURNACE_IS1_2004 - KirbyAir Compact Installation & Service Instructions.indd 20 7/04/2020 12:23:08 PM7/04/2020 12:23:08 PM
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