Granby KLC-088 User manual

Installation, Operation and
Service Manual
KLC
Condensing Unit
95% + EFFICIENCY
OIL FIRED
LOWBOY FURNACE
Model KLC- 088
CONFORTO CHE
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 11-12-2012 G2012-E3 Rev.C

1
TABLE OF CONTENTS
1.0 IMPORTANT SAFETY ADVICE 2
2.0 PRODUCT INFORMATION 3
3.0 FURNACE INSTALLATION 5
3.1 PLACEMENT & VENTING 6
3.2 INSTALLATION CODES 7
3.3 INSTALLATION 7
3.4 VENTING OPTIONS 8
4.0 ACCESSORIES INSTALLATION 10
5.0 BURNER INSTALLATION AND SPECIFICATIONS 11
5.1 ASSEMBLY & INSTALLATION OF THE BURNER 11
5.2 SET BURNER FOR EFFICIENT OPERATION 12
5.3 TECHNICAL INFORMATION 14
6.0 FURNACE OPERATION AND SETTINGS 15
6.1 BLOWER SETTING 15
6.2 FAN TIMER CONTROL BOARD (ST9103 A 1028) 16
6.3 (ST9103 A 1028) CONTROL BOARD SEQUENCE 17
6.4 SERVICING – FAN TIMER (ST9103 A 1028) 18
6.5 FLUE AND FRESH AIR PIPE SERVICING 20
7.0 SERVICE AND MAINTENANCE 21
7.1 CLEANING HEAT EXCHANGER 21
7.2 BLOWER REMOVA L 22
8.0 ELECTRICAL / WIRING DIAGRAM 23
9.0 EXPLODED PARTS VIEW 24
10. START-UP TEST RESULTS 26

2
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. 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.
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.
NOTE: DO NOT INSTALL IN SPACE WHERE TEMPERATURE DROPS BELOW 32
o
F (0
o
C)
FREEZING POINT. CONDENSATE WILL FREEZE AND WILL DAMAGE UNIT.
IMPORTANT
This manual contains instructional and operational information for the KLC 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.

3
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)
Vent Pipe 0” (0 mm)
Floor (Can be installed directly on combustible or non-combustible)
AIR/BLOWER DATA
Maximum external static pressure 0.5” wc
Maximum cooling unit capacity 3.0 tons.
Maximum air temperature rise See pages 14 and 27
High Limit temperature 215°F
Thermostat anticipator See thermostat instructions
MOTOR/BLOWER
KLC-088: 1/2 hp ECM / GT12-10
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.
VENT PIPE CONNECTION
3’’ IPEX 636
CONDENSATE DRAIN
PLASTIC HOSE ½’’ diameter
CLEANOUTS
Rear Cover & Burner Opening

4
AIR FILTER
KLC-086 2 x 12” x 20” x 2” non pleated UL approved
PLENUM DIMENSIONS KLC-088 CONFORTO
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) 3” (76 mm)
KLC-088 - DIMENSIONS
Dimensions are in inches

5
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
See page 8
for vent
options
installation.

6
3.1 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.
VENT Connect the furnace to the vent system of size and condition required by
the NFPA 31 (USA) or CSA B139 (Canada) code. Furnace is approved
for factory built venting material ‘’IPEX 636’’ PVC. Breech is certified for
3” vent pipe. Keep vent/flue pipe as short as possible with min. 1/4” per
foot upward slope
.
WARNING BE AWARE THAT REMOVING BAFFLES REDUCES THE UNIT’S
EFFICIENCY AND INCREASE THE OUTLET TEMPERATURE. A
MODIFIED UNIT IS NO LONGER ENERGY STAR APPROVED.
THIS COULD RESULT IN FIRE HAZARD AND/OR OTHER
HAZARDOUS CONDITIONS THAT MAY LEAD TO BODILY HARM.
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. If balance flue burner his used, combustion air must be duct to
the outside as per instructions.
ELECTRICAL Wire according to the National Electrical Code (Canadian or USA) 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).
BLOWER DOOR
Do not operate without blower door properly installed. This could result in
fire hazard and/or hazardous conditions that may lead to bodily harm.

7
3.2 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 B 139 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/NFPA70 National Electrical Code
CSA C 22.1 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.
3.3 INSTALLATION
VENT PIPE See NFPA 31 (USA) or CSA B139 (Canada) code. Breech is certified for
3’’ ULC S636 PVC vent pipe in Canada and PVC schedule 40 pipe rated
for 65
o
C (149
o
F) in the United States. Keep vent/flue pipe as short as
possible.
RETURN AIR Ensure that the furnace return air temperature to the unit is not lower than
50
o
F (10
o
C)
3.4 VENTING
The KLC 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 schedule 40 pipe rated for 65
o
C (149
o
F) in the United States.
IPEX System 636 in 3 inch diameter is recommended for the KLC. 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 horizontal equivalent length allowed
is 80 feet. Each 90
o
elbow accounts for 8 feet. As an example if the system has 5 elbows, 40
linear feet of vent can be used. The vent is connected to the furnace using the supplied
neoprene coupling.

8
VENTING OPTIONS INSTALLATION
TWO PIPES SYSTEM COAXIAL SYSTEM
VERTICAL ONE PIPE SYSTEM
Single opening of 4’’1/2+
BF3
Riello burner approved
Two small openings of 3’’1/2+
BF3 Riello burner approved
Especially for retrofit installation
Easy to fit one pipe in 7”x7” chimney tile
Avoid wall opening
No clearance restriction
Perfect where there is no access to external
wall in the mechanical room
F3 Riello burner approved

9
WALL TERMINAL INSTALLATION REQUIREMENTS
In Canada
Refer to the CSA B139 Code for the placement of the vent termination
In United States
Refer to the NFPA31 Code for the placement of the vent termination
COAXIAL WALL CLEARANCE TWO PIPES WALL CLEARANCE
All piping must be on same wall
0utlet termination clearance above grade and roof overhang
Check flue and combustion air pipes for any leak
VENT TERMINATION WARNING
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.

10
4.0 ACCESSORIES INSTALLATION
AIR CONDITIONING SYSTEM
OUTSIDE CONDENSER UNIT INSIDE EVAPORATOR COIL
An air conditioning evaporator coil may be installed on the supply side only. Coils installed
on the return side will cause damage on the unit; this will shorten the unit life and may cause
products of combustion to enter the house. Wire as per wiring label and diagram. Height of
the coil above the unit supply shall be at least 4” (102 mm).
See A/C coil Manufacturers
Requirements.
To check the AC coil total air flow
resistance, see procedure at page
27.
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.

11
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.
INSTALL NOZZLE Install selected nozzle, check for clean seating and tighten in nozzle
adaptor.
ELECTRODES See burner manufacturer’s instructions for correct setting
INSERTION
MOUNT BURNER Tighten top nut first so burner tips down
slightly. The burner is always installed in
an upright position by four (4) nuts.
PUMP BY-PASS For one pipe system factory setting (no
PLUG plug).
PRESSURE TUBE BF3 BURNER – 2 PIPES (IPEX) VENTING
THE PRESSURE TUBE MUST BE CONNECTED ON THE
APPROPRIATE LOCATION (TOP RIGHT) ON THE BURNER
CASING.
F3 BURNER – 1 PIPE (IPEX) VERTICAL VENTING
THE PRESSURE TUBE MUST BE CUT AT THE EXIT OF THE
ELECTRICAL BOX. IT SHOULD MEASURE ATMOSPHERIC
PRESSURE.
WIRING Refer to wiring diagram for correct burner
connections (see page 23).
THERMOSTAT Connect the thermostat wires to the fan
timer control board (ST9103).

12
5.2 SET BURNER FOR EFFICIENT OPERATION
BURNER SETTING Use burner settings in the table on page 14 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.
PUMP PRESSURE Refer to the table on page 14 or operating decal.
AIR SETTING Use air settings on page 14 as a guide to set air adjustment. Those
settings are only starting points for the adjustments and are not
meant as final settings.
SAMPLING HOLE A sample hole is required for the burner set-up. Drill 3/8’’ diameter
hole on top of the vent pipe and use the supplied test port plug to seal
after burner setup.
Rear Flue Furnace illustration
COMBUSTION TEST
: All your tests must be done with the burner cover on
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
2 measurements.
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 Stac Temperature AFUE
Usgph %
ο
οο
ο
F %
0,50 11.5 98 TO 108 95,4
0,60
12
.5
109 TO 115
95,4
See
page 8
for
venting
options.
Sampling Hole

13
COMBUSTION After 10 minutes of normal operation, take a smoke test and adjust
SETTING/ the burner to obtain a reading of “1” on the smoke scale.
EFFICIENCY
.
Take a CO2test and note the result. Open the air band on the burner to reduce
your CO2lecture by 1.5%.
You now have a perfect “ 0 ” of smoke.
Relation between % of CO
2
and O
2
CO
2
(%) O
2
(%) Excess Air (%)
13.5 2.6 15.0
13.0 3.3 20.0
12.5 4.0 25.0
12.0 4.6 30.0
11.5 5.3 35.0
11.0 6.0 40.0
To reach the maximum
smoke test value, a 10 full
slow steady pump action is
required.
To reach the maximum
CO2 test value, a 18 full
slow steady pump action is
required.

14
5.3 TECHNICAL INFORMATION
KLC- 088 Two pipes system One pipe system
Riello Burner BF3 Riello F3 Riello
Uni
t Model
KLC-V1-*073-03 KLC-V1-*088-03 KLC-E1-*073-03 KLC-E1-*088-03
Firing Rate (USGPH) 0.55 0.65 0.55 0.65
Input (BTU/h) 77,000 91,000 77,000 91,000
Output (BTU/h) 74,000 87,000 74,000 87,000
Nozzle 0.50 70W 0.60 70W 0.50 70W 0.60 70W
Pump Pressure (psi) 145 145 145 145
Turbulator Setting 0 0 0 0
Air Gate Adjustment 3.75 4.50 2.50 3.25
Energy Star Approved YES YES YES YES
AFUE (%) 95.8 95.8 95.8 95.8
CO 2 (%) 11.5 12.5 11.5 12.5
General Information
Energy Star
ECM motor
(0.2’’ wc to 0.5’’wc
)
Temperature Rise (°F) 52-85 58-85 52-85 58-85
Blower Speed MEDIUM MEDIUM MEDIUM MEDIUM
Static Pressure
Blower ECM 1/2 hp
Speed 0.2" wc 0.5" wc
HI 1300 1230
MHI 1225 1160
MED 1140 1050
MLO
1025
980
LO 775 750
Approved Vent
Model Vent configuration Combustion Air Maximum vent length Vent
KLC-V1-*073-03
IPEX Concentric
and IPEX 2 pipes system
Outside 80 equivalent horizontal feet 3"
KLC-V1-*088-03
IPEX Concentric
and IPEX 2 pipes system
Outside 80 equivalent horizontal feet 3"
KLC-E1-*073-03
IPEX Vertical Vent Inside
50 equiv. horizontal feet +
Vertical vent 3"
KLC-E1-*088-03
IPEX Vertical Vent Inside
50 equiv. horizontal feet +
Vertical vent 3"
(*) In the Unit Model number, is specific information of
the product for administration onl .

15
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.
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.
FUEL Turn on fuel supply and check that there are no leaks.
POWER Turn on power 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.
6.1 BLOWER SETTING
Ensure power is off when adjusting blower setting. For heating, use the blower speeds
shown on the furnace specifications to give a temperature rise according to the technical
information tables on page 14. The Lo blower speed can be used for air circulation when
heating or cooling are not required. Set blower speeds to match the installation requirements.
FAN & LIMIT CONTROL
Limit 215°F – Factory set
Fan On 45 seconds after the burner starts
Fan Off Adjustable on board (see page 16)
THERMOSTAT ANTICIPATOR SETTING
Adjust to thermostat manufacturer’s instruction

16
6.2 FAN TIMER CONTROL BOARD (ST9103A 1028)
o“FAN OFF” Dip Switches adjustment
COMFORT ADJUSTMENTS
oOutlet air consistently too warm or too cold - change the blower motor speed to give the
specified air temperature rise.
oOutlet air gets too warm and burner shuts down - increase air by changing the blower
motor speed to give the specified temperature rise.
oOutlet air is too cold or too warm at the end of the heating cycle after the burner has
turned off - adjust the “FAN OFF” dip switch on fan timer control board. Refer to the next
figure.
“FAN OFF” Dip Switch
Dip Switch adjustment (90 seconds) on all input
OFF CYCLE AIR CIRCULATION (Factory settings)
LO SPEED All KLC models have the Lo speed switch for optional constant air circulation
during the furnace off cycle.
“FAN ON” When “FAN ON” is selected on the thermostat, the blower will run constantly
at the blower speed selected on the heating terminal. This is the equivalent of
jumping terminals R and G on the ST9103 board.
Dip Switches

17
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
3) Cooling unit starts
4) Blower stops immediately after cooling demand is satisfied
5) Cooling unit stops
Honeywell ST9103A 1028 Electronic Board

18
6.4 SERVICING - FAN TIMER ST9103A1028
Trouble shooting the Honeywell
electronic board ST 9103
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
1 Incoming supply
Check for 120 Volts
between terminal S2 and 3
on e
lectronic fan control
Yes - Move to next step
No -
Check breaker main power switch
2 Transformer
Check for 120 Volts between
terminal S3 and 4 on electronic
fan control.
Check for 24 Volts between
terminal X and C on electronic
fan control
Yes - Move to next step
No -
Check for bad connection
Yes - Move to next step
No -
Change Transformer
3 Electronic Fan
control
Check for 24 Volts between R
and C
Yes - Move to next step
No - Change the electronic board
Check for 24 Volts between
terminal W and C
Yes - Move to next step
No - Check thermostat and wiring
4 Warning: Make sure the quick connect cable is fully inserted on the board
Limit Control
Check for 120 Volts on each
terminal of the two limits Yes - Move to step # 5
No - Move to next step
Check for 120 Volts coming
from the main plug-in of the
electronic fan control to the
limit control
Yes - Move to next step
No - Change the electronic fan control
Check for 120 Volts coming
out of the limit control
Yes
-
Move to step # 5
No -
Failure on the limit control circuit
. Temperature too high
. Bad limit control

19
Step Possible Cause Check-out procedure Corrective action
No Heat
5 Riello burner
Check for 120 Volts on the
black wire, contact (COM) on
the Riello burner relay kit.
Yes - Move to next step
No - Back to step # 4 or check for bad
connection
Check if oil primary control is
on reset
Yes - Press reset button
No - Move to the next step
Check for continuity between
the two wires yellow and
violet on the Riello burner
relay kit
Yes - Move to next step
No - Change the electronic fan
control
Check for 120 Volts on the
contact (No) of the Riello
burner relay kit
Yes - Move to next step
No -
Change the Riello burner relay kit
Check for 120 Volts on
terminal # 1 of the bypass
timer relay. (15sec.)
Yes - Move to next step
No - Change the relay, check for 120v.
on pressure switch terminals.
Check for 120 volts on the
orange wire coming to the
burner (L)
Yes - Failure on the burner
No - Change the electronic fan control
6
Blower
. Low speed
Check if the
constant low
speed switch is
ON
Check for 120 Volts at the
''CONT'' terminal on the
electronic fan control
Yes - Move to next step
No - Change the electronic fan
control
Check for 120 Volts on both
side of the constant low
speed switch
Yes - Check ''LOW'' speed on the
blower motor
No - Change the switch
. High speed
(wait for the
seconds delay
''DIP'' switch
adjustments on
the board)
Check for 120 Volts at the ''
Heat'' terminal of the
electronic fan control
Yes - Check ''HEAT'' speed on the
blower motor
No - Change the electronic fan control
No Cooling
7
Blower .
High speed
Check for 24 Volts between
G and C on electronic fan
control
Yes - Move to next step
No - Check thermostat and wiring; if it's
OK, then change the electronic fan
control
Check for 120 Volts at the
''COOL'' terminal of the
electronic fan control
Yes - Check ''COOL'' speed on the
blower motor
No - Change the electronic fan control