KEER ECLIPSE MAX User manual

ECLIPSE
HIGH EFFICIENCY OIL-FIRED FURNACE
MAX
EVO
CLASSIC AIR
Installation, Operation and
Maintenance Manual
INSTALLATIONS MUST MEET ALL LOCAL AND FEDERAL
CODES THAT MAY DIFFER FROM THIS MANUAL
Please read this complete manual before beginning installation. These instructions must be
kept with the furnace for future reference.
CERTIFIED TO: CAN/CSA Std. B140.0 & Std. B140.4
CONFORMS TO: UL 727
KERR ENERGY SYSTEMS
PO Box 637
12118 Hwy 209
Parrsboro Nova Scotia Canada
B0M 1S0
www.KerrEnergySystems.com

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TABLE OF CONTENTS
1.0HomeownerInformation 3
1.1Introduction 3
1.2AirFilters 3
1.3 Regular Maintenance 3
1.4Warnings 3
1.5DirectVent 3
1.6 Shutting Furnace Down 3
1.7 Restarting Furnace 4
2.0Installation 4
2.1Important 4
2.2Caution 4
2.3 Installation Codes 4
2.4 Field Convertible Breech 5
2.5 Placement & Venting 5
2.6 MAX/EVO AC/Auxiliary Sensor Installation 6
2.7Assemble&InstallBurner 7
2.8 Changing Nozzle 7
2.9 Set Burner for Efficient Operation 8
2.10 Classic Air Blower Settings 8
2.11 Air Conditioning 9
2.12 Humidifier 9
2.13 Thermostat Anticipator Setting 9
2.14 Blocked Vent Switch 9
2.15 Fan Control 10
2.16 Off Cycle Air Circulation 10
2.17 MAX Blower Operation 11
3.0 Burner Specifications 12
4.0 Oil Tank & Piping 13
5.0 Blower Removal 13
6.0 General Specifications 14
7.0 Classic Air Comfort Adjustments 15
8.0 Trouble Shooting Guide 16
8.1 MAX/EVO LED Indicators 17

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9.0 Appendix
Figure – 1 Burner Insertion
Figure – 2 Blower Removal
Figure – 3 Tank & Piping
Figure – 4 Classic Air Wiring Diagram
Figure – 5 EVO Wiring Diagram
Figure – 6 MAX (9300i) Diagram
Figure – 7 Front Breech Dimensions
Figure – 8 Rear Breech Dimensions
Figure – 9 Front Breech Exploded Parts
Figure – 10 Rear Breech Exploded Parts
Table – 1 Front Breech Classic Air Parts List
Table – 2 Front Breech EVO Parts List
Table – 3 Front Breech MAX Parts List
Table – 4 Rear Breech Classic Air Parts List
Table – 5 Rear Breech EVO Parts List
Table – 6 Rear Breech MAX Parts List
Keep this manual in a safe place for future reference.
Follow manual carefully for the correct way to install and operate this appliance.
Do not operate this appliance until operating instructions have been read and fully understood.
SAVE THESE INSTRUCTIONS

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1.0 HOMEOWNER INFORMATION
1.1 INTRODUCTION
Please read and understand this manual before installing, operating or maintaining the
furnace. To ensure you have a clear understanding of the operating procedures of the
appliance please take the time to read section 1.0 HOMEOWNER INFORMATION, of this
manual. If you have any questions, your Kerr dealer will be happy to answer them for you.
1.2 AIR FILTERS
To maintain furnace performance and safety, replace dirty filters as required or at least once
every heating season. Use new approved disposable filters of the same size and type, or
clean permanent filters according to manufacturer’s instructions. Replace the filters or clean
the filters more often if dusty conditions exist. Dirty, clogged or wrongly sized filters will impair
the furnace performance and may cause the furnace to shut down or overheat.
1.3 REGULAR MAINTENANCE
Check complete operation at least once a year. In Canada see B139, Section 14,
Maintenance, for recommended servicing procedure. Heat exchanger ducts are accessed
through breech access panel at front of unit. Replace stainless steel baffles after cleaning.
Clean flue pipes on a regular basis. Replace flue pipes if there is any sign of corrosion or
other problems. Cerafelt (1/4”) gaskets may have to be replaced.
1.4 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 drainings or any oil containing gasoline.
1.5 DIRECT VENT
It is the responsibility of the homeowner to ensure that the area around the Direct 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.
1.6 SHUTTING FURNACE DOWN
POWER OFF Turn off main power switch.
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.

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1.7 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 switch 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.
2.0 INSTALLATION
2.1 IMPORTANT
This manual contains instructional and operational information for the Eclipse Classic Air,
EVO and MAX units. Read the instructions thoroughly before installing furnace or starting
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. Ensure that the two piece ceramic target wall is correctly placed at the
back of the heat exchanger if using a Beckett burner.
2.2 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 OR ANY OTHER APPLIANCE.
2.3 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 B139 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/NFPA 70 National Electrical Code.
CSA C22.1 Canadian Electrical Code.
ANSI/NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances.
Certified to CSA and UL requirements. Use only nozzles and settings shown on the operating
decal. Use approved fittings, tubing, fuel tank, oil shut off valves etc. The latest versions of
the above codes, which have been approved for use in the location of the installation, must be
used.

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2.4 FIELD CONVERTIBLE BREECH
The Eclipse is designed to have a field reversible breech. The breech is reversible from front
to rear (or vice versa) by switching the breech pipe and cover plate. The Eclipse Conversion
Kit is available at your Kerr dealer. Conversion from rear breech to front breech, # KMO-KA-
0110-00. Conversion from front breech to rear breech, # KMO-KA-0120-00.
2.5 PLACEMENT & VENTING
Furnace installation shall conform to the required installation code for oil-fired equipment (USA:
NFPA 31, Canada: CSA B139).
FLOOR SUPPORT NON-COMBUSTIBLE – If required, support furnace on a Kerr Appliance
Stand (available at your Kerr dealer) or 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. Use approved fitting through a wall. Vent/flue
pipes MUST NOT pass through a ceiling. Maximum flue gas
temperature is 575°F.
WALL VENTING This Furnace is approved for Kerr Direct Vent.
COMBUSTION & Install openings and ductwork to the furnace room providing fresh outside
VENTILATION AIR 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. See the furnace operating decal. Not applicable for Direct
Vent.
DRAFT Use approved draft control supplied for 5” pipe. Use two draft controls
on strong draft chimneys. Set specified draft pressure to -0.04” wc. Not
applicable to Direct Vent installations.
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 6.0 GENERAL SPECIFICATIONS.
LOCATION Install the furnace close to chimney or vent and central to ductwork.

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ADD-ON Any furnace can only have one additional appliance added to the ductwork. Other
items which do not drastically reduce the air flow are allowed.
2.6 MAX/EVO AC/AUXILIARY SENSOR INSTALLATION
Mandatory for MAX series furnaces when equipped with an A/C coil. Optional for EVO series
furnaces when equipped with an A/C coil, defaults to full speed on A/C if not installed.
AC/Auxiliary sensor kit contents:
AC/ Auxiliary sensor mounted in sensor box with 86” of sensor cable.
Three (3) mounting screws.
Four (4) cable clamps and clamp screws
Mounting the AC/auxiliary sensor
a) Disconnect the POWER from the furnace.
b) Find a location in the plenum down-stream of the air conditioning coil or auxiliary heating
unit to mount the AC/auxiliary temperature sensor. This location should be centrally
located in the air stream of the plenum and far enough from the A/C coil or heat source,
so that the auxiliary sensor senses an even temperature from the coil. On a wood furnace
the sensor should be located approximately 10” above the cabinet and centrally on the
side of the plenum. Also make sure that the cable from the AC/auxiliary sensor will
reach back to the wiring channel on the furnace and that the cable can be routed to
avoid contact with any extremely hot surfaces (i.e. flue pipe).
c) In the plenum location chosen, drill a 7/8” hole or construct a hole large enough to insert
the AC/auxiliary sensor into the plenum. The sensor probe should not touch the plenum
metal when the box is mounted to the plenum.
d) Remove the cover from the sensor box. Using the three screws provided mount the
sensor box to the plenum through the three pilot holes in the sensor box. IMPORTANT:
Ensure that the SENSOR ORIENTATION is correct with the AIRFLOW arrow. See sensor
mount in sensor box.
e) Place the cover back on the sensor box.
f) Remove the cover from the wiring channel on the furnace.
g) Locate the 5/8” hole with the black plug on the wiring channel and remove the plug. (Plug
can be discarded).
h) Fit the end of the sensor cable through the 5/8” hole and make the cable connection to
the auxiliary sensor female plug on the circuit board (note plug release tab orientation).
i) Press the strain relief bushing on the auxiliary sensor cable in to the 5/8” hole.
j) Replace the wiring channel cover.
k) Reconnect the power to the system and test the system. When the power is reconnected
this RESETS the circuit board to recognize that the sensor is connected.

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With the AC/auxiliary sensor properly connected, on a call for air conditioning there is a 15
second time delay for the blower to come on slowly and the blower speed will modulate
according to the plenum temperature.
2.7 ASSEMBLE & INSTALL BURNER
ASSEMBLE Check burner model is correct for furnace rating required. Assemble as
per burner manufacturer’s instructions.
SET END CONE Riello – set turbulator as per furnace operating decal. Beckett – see
Burner Manufacturers 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.
TARGET WALL If the furnace is equipped with a Beckett burner use the two piece
ceramic target wall included in the burner packaging. Install target wall
through burner opening ensuring that the target wall is positioned so that
it sits tightly against the back of the heat exchanger. The target wall
must be installed so that it sits on the bottom of the primary heat
exchanger.
ELECTRODES See burner manufacturer’s instructions for correct setting.
INSERTION See section 6.0 GENERAL SPECIFICATIONS or Figure – 1.
LENGTH
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
WIRING Refer to wiring label and Figure – 4, 5 or 6 (depending on which unit is
being installed) for correct burner connections.
Beckett Burners – Beckett burners must have the igniters wired to
operate constantly while the burner motor is running. This is referred to
as intermittent ignition in the Beckett manual.
.
THERMOSTAT Connect the thermostat terminals.
DO NOT start the oil burner until installation is complete and all cleanout covers are securely in
place.
2.8 CHANGING NOZZLE
NOZZLE CHANGE If a new nozzle of a different size is installed, change the heating blower
speed according to the sections 3.0 BURNER SPECIFICATIONS or
operating decal.

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2.9 SET BURNER FOR EFFICIENT OPERATION
SET END CONE Use turbulator settings in section 3.0 BURNER SPECIFICATIONS and
operating decal as a guide to set turbulator, particularly for nozzle
changes.
PUMP PRESSURE Refer to section 3.0 BURNER SPECIFICATIONS or operating decal.
AIR SETTING Use air settings in section 3.0 BURNER SPECIFICATIONS and
operating decal as a guide to set air damper.
SAMPLING HOLE On smoke/vent pipe, between appliance breech and draft control,
punch or drill a 1/4” round opening. Direct Vents have a sampling port
located on the breech connecting adaptor.
DRAFT PRESSURE Using an accurate draft meter; adjust the draft control to obtain -0.04”
wc draft pressure at the breech sampling hole. Use two barometric
dampers if necessary. Not applicable to Direct Vent.
BURNER SETTING Set the burner to give a stable symmetrical flame. After 15 minutes of
normal operation, check SMOKE for zero trace reading and measure
CO2. Readjust the burner controls as required. When the burner is
set, lock the adjustments with the locking nuts.
EFFICIENCY Always leave burner set with CO2reading about 1% lower than the
peak CO2efficiency achieved with a zero to trace smoke (e.g. a zero to
trace reading of 12.5% CO2should be set back 1% to 11.5%). This
gives better allowance for fuel and draft variations and maintains a
better seasonal efficiency. When the burner is set, lock the
adjustments with the locking nuts.
FLAME CHECK Look through view port to check the flame after setting the burner. If
the flame is not clean and symmetrical, reset the burner or replace the
nozzle.
DO NOT START BURNER UNTIL ALL FITTINGS AND COVERS ARE IN PLACE.
2.10 CLASSIC AIR BLOWER SETTING
Ensure power is off when adjusting blower setting. For heating, use the blower speeds
shown on the furnace specifications to give a rise of 70 – 85°F. The #4 Lo blower speed can
be used for air circulation when neither heating nor cooling are required. Set blower speeds to
match the installation requirements.

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2.11 AIR CONDITIONING
An air conditioning coil may be installed on the supply side only. Coils installed on the return
side will cause condensation on the heat exchanger; this will shorten the heat exchanger life
and may cause products of combustion to enter the house. The bottom of the drain pan must
be at least 10” above the top of the heat exchanger. Wire as per Figure – 4. Height of the
coil above the heat exchanger shall be no less than 10” (254 mm).
*See A/C coil Manufacturers Requirements
CLASSIC AIR MODELS
Air conditioning models include a fan centre relay wired to run the blower at #1 Hi speed when
the cooling cycle is operating. For normal operation, select “AUTO” on the thermostat. When
“FAN ON” is selected the blower runs constantly at the cooling speed. See section 2.16
CLASSIC AIR OFF CYCLE AIR CIRCULATION. For air conditioning, the blower on #1 speed
will provide 1200 CFM at 0.50 in. wc static pressure.
MAX/EVO MODELS
IMPORTANT – MAX/EVO models that make use of the AC/auxiliary Sensor for better
dehumidification MUST have a Thermal Expansion (TX) Valve incorporated into the A/C piping
system. Most evaporator manufactures have the option of supplying the thermal expansion
valve built right in to the evaporator. If there is not a thermal expansion valve on the evaporator
then a thermal expansion valve kit MUST be properly installed in the evaporator system to
ensure proper operation of the A/C system.
2.12 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.
2.13 THERMOSTAT ANTICIPATOR SETTING
The thermostat anticipator setting is only applicable to the non-electronic type of thermostat.
Electronic thermostats do not have an anticipator setting. All Classic Air burners use 0.2
amps. The MAX/EVO control requires 0.1 amps as a thermostat anticipator setting. Check
that the thermostat anticipator setting matches the primary control circuit current draw. This
setting affects the thermostat’s response to the control.
2.14 BLOCKED VENT SWITCH
Furnaces installed on a chimney (i.e. not Direct Vent or Power Vent) require a blocked vent
shut-off system when installed in Canada. 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.

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2.15 FAN CONTROL
CLASSIC AIR FAN CONTROL
Limit 200°F – Factory set
Fan On 130°F
Fan Off 100°F
MAX/EVO FAN CONTROL
Standard Mode EVO only
High Limit 180°F (Resets at 120°F)
Fan On (Heat) 130°F
Fan Off (Heat) 90°F
Fan On (Cool) 15-second delay
Fan Off (Cool) 45-second delay
Variable Speed Mode
High Limit 180°F (Resets at 120°F)
Fan On (Heat) Varies to maintain 145°F
Fan Off (Heat) 90°F
Fan On (Cool) *Varies to maintain 48°F with the Auxiliary Sensor installed
Fan Off (Cool) 65°F
*If no Auxiliary Sensor is installed than the cooling cycle will act as in the standard mode.
2.16 OFF CYCLE AIR CIRCULATION
#4 LO SPEED All Classic Air models have the #4 Lo speed switch for optional constant air
circulation during the furnace off cycle.
“FAN ON” When “FAN ON” is selected on the thermostat of a Classic Air furnace, the
blower will run constantly at the #1 Hi speed providing heat, cooling or neither
as selected.
EVO/MAX Air circulation can be operated from the thermostat. Blower will run on low
speed.

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2.17 MAX BLOWER OPERATION
The MAX furnace has an advanced control that performs all of the safety and control functions.
There are two temperature sensors. One comes installed in the furnace and the AC/auxiliary
temperature sensor is installed after the A coil or auxiliary heating device. The control will
automatically handle two stage air conditioning and auxiliary heat such as electric plenum
heaters or heat pumps. The control will automatically modulate the blower for optimal airflow
regardless of the mode of operation. In heating mode the blower will modulate to maintain a
constant plenum temperature. In cooling mode the blower will modulate to attain the best
dehumidification performance even with two stage compressors. The control logic is detailed
below.

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3.0 BURNER SPECIFICATIONS
CLASSIC AIR
Model Burner Input Nozzle Pump
(psi) Air Setting Turbulator Output Heating CFM@ Blower Speed
USGPH L/h Btu/h Btu/h kW 0.2"wc 0.5"wc 0.2"wc 0.5"wc
KMR(F)-E1-0095-03 Riello 40 F3
0.61 2.32 85,400 0.50 60W 150 2.7 0.5 73,000 21 1084 873 4 Lo 4 Lo
0.73 2.78 102,200 0.60 60W 150 3.3 1.0 87,000 25 1084 1113 4 Lo 2 MHi
0.80 3.04 112,000 0.65 60W 150 3.8 1.2 95,000 28 1198 1200 3 MLo 1 Hi
KMR(F)-G3-0095-03 Beckett AFG
PA 402
0.59 2.24 82,600 0.50 70B 140 6.5** 70,000 21 1084 873 4 Lo 4 Lo
0.71 2.70 99,400 0.60 70B 140 6.5 84,000 25 1084 1113 4 Lo 2 MHi
0.77 2.93 107,800 0.65 70B 140 7.5 92,000 27 1198 1200 3 MLo 1 Hi
Direct Vent
KMR(F)-V1-0095-03 Riello 40 BF3
0.61 2.32 85,400 0.50 80W 150 3.6 1.0 73,000 21 1084 997 4 Lo 3 MLo
0.73 2.78 102,200 0.60 80W 150 4.0 1.5 87,000 25 1084 1200 4 Lo 1 Hi
0.80 3.04 112,000 0.65 70W 150 4.8 2.0 95,000 28 1198 1200 3 MLo 1 Hi
KMR(F)-D2-0095-03 Beckett AFG
PA 404*
0.59 2.24 82,600 0.50 70B 140 45** *** 70,000 21 1084 997 4 Lo 3 MLo
0.71 2.70 99,400 0.60 70B 140 55 *** 84,000 25 1084 1200 4 Lo 1 Hi
0.77 2.93 107,800 0.65 70B 140 67 *** 92,000 27 1198 1200 3 MLo 1 Hi
*Post Purge factory set to two minutes. **Low Firing Rate Baffle required.
***Use Air Boot Restrictor Plate.
EVO
*Post Purge factory set to two minutes. **Low Firing Rate Baffle required.
***Use Air Boot Restrictor Plate. ****Approximately 90 Btu/h CFM.
MAX
Model Burner Input Nozzle Pump
(psi) Air Setting Turbulator Output Heating
USGPH L/H Btu/h Btu/h kW CFM
KMR(F)-E1-0095-E3 Riello 40 F3 0.61 2.32 85,400 0.50 60W 150 2.7 0.5 73,000 21 810*
0.73 2.78 102,200 0.60 60W 150 3.3 1.0 87,000 25 970*
0.80 3.04 112,000 0.65 60W 150 3.8 1.2 95,000 28 1055*
Direct Vent
KMR(F)-V1-0095-E3 Riello 40 BF3 0.61 2.32 85,400 0.50 80W 150 3.6 1.0 73,000 21 810* 0.73 2.78 102,200 0.60 80W 150 4.0 1.5 87,000 25 970*
0.80 3.04 112,000 0.65 70W 150 4.8 2.0 95,000 28 1055*
*Approximately 90 Btu/h CFM.
The turbulator and air settings found on this page should be used as a guide.
Model Burner Input Nozzle Pump
(psi) Air Setting Turbulator Output Heating
USGPH L/h Btu/h Btu/h kW CFM****
KMR(F)-E1-0095-F3 Riello 40 F3 0.61 2.32 85,400 0.50 60W 150 2.7 0.5 73,000 21 810****
0.73 2.78 102,200 0.60 60W 150 3.3 1.0 87,000 25 970****
0.80 3.04 112,000 0.65 60W 150 3.8 1.2 95,000 28 1055****
KMR(F)-G3-0095-F3 Beckett AFG PA
402
0.59 2.24 82,600 0.50 70B 140 6.5/0.0** *** 70,000 21 780****
0.71 2.70 99,400 0.60 70B 140 6.5/0.0 *** 84,000 25 930****
0.77 2.93 107,800 0.65 70B 140 7.5/0.0 *** 92,000 27 1020****
Direct Vent
KMR(F)-V1-0095-F3 Riello 40
BF3
0.61 2.32 85,400 0.50 80W 150 3.6 1.0 73,000 21 810****
0.73 2.78 102,200 0.60 80W 150 4.0 1.5 87,000 25 970****
0.80 3.04 112,000 0.65 70W 150 4.8 2.0 95,000 28 1055****
KMR(F)-D2-0095-F3 Beckett AFG PA
404*
0.59 2.24 82,600 0.50 70B 140 4.5** *** 70,000 21 780****
0.71 2.70 99,400 0.60 70B 140 55 *** 84,000 25 930****
0.77 2.93 107,800 0.65 70B 140 67 *** 92,000 27 1020****

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4.0 OIL TANK & PIPING
Tank installation must conform to local requirements.
Install according to the applicable code. Minimize number of connections in suction line and
make all connections as tight as possible. 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 in Figure – 3 are recommended. Optional tank gauge protectors and
outlet protectors are available at your local Kerr dealer. Further information is available at
www.KerrEnergySystems.com.
ONE PIPE SYSTEM Where the tank 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 single line is unsuitable, use double line or see your Kerr
dealer for special oil line fittings.
5.0 BLOWER REMOVAL
Kerr furnaces have a blower sealing system, which is designed to be tight and rattle free.
Refer to Figure – 2. Use a reversing drill with 1/4” hex drive for the sheet metal screws.
1. Shut off oil and power to furnace.
2. Open blower compartment.
3. Disconnect the wiring to the blower motor.
4. Remove the #8 (1/4”) hex drive sheet metal screws securing the blower side to the divider
panel.
5. Remove the rear 5/16” blower mount nuts.
6. Lift the blower straight up, keeping it level to avoid jamming on the blower mounting bolts
and center panel. Shift the blower out of the furnace.
Secure casing insulation with aluminum foil tape to ease blower re-installation. Replace the
blower assembly using the reverse procedure. Ensure wiring and ground wire is correctly
reconnected.

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6.0 GENERAL SPECIFICATIONS
CLEARANCE TO COMBUSTIBLES
Top 1” (25 mm)
Front 24” (610 mm)
Rear 24” (610 mm)
Side – Non Access 2” (51 mm)
Side – Access 24” (610 mm)
Flue Pipe 9” (229 mm)
Floor Non-combustible
DRAFT PRESSURE
Breech draft pressure -0.04” wc
Overfire draft pressure -0.01” wc
(Not Applicable to Direct Vent Units)
BURNER INSERTION (overall)
Riello 40F3 & BF3 - Beckett PA402 & 404 2 1/2” (63 mm)
AIR/BLOWER DATA
External static – Non A/C 0.2” wc
External static – A/C 0.5” wc
Cooling 3 tons
Maximum air temperature rise 85°F
High Limit, max design outlet temp 200°F
Thermostat anticipator 0.2 amps (Classic Air)
0.1 amps (EVO)
1/3 hp #1 speed @ 0.50 in. wc static pressure 1200 CFM (Classic Air &EVO)
1/2 hp @ 0.50 in. wc static pressure 1200 CFM (MAX)
MOTOR/BLOWER
Classic Air 1/3 hp 4 Speed/GT 10 DD
EVO 1/3 hp 4 Speed/GT 10 DD
MAX 1/2 hp ECM/GT10 DD
FAN/HIGH LIMIT CONTROL
Classic Air Fan and Limit Control
EVO EVO Control Board (Variable or Non-Variable)
MAX MAX Control Board (Variable)
FAN CENTRE RELAY – Classic Air models only
Honeywell R8285A1048
White Rodgers 8A05A-101
DIMENSIONS
Depth 46 7/8” (1191 mm)
Height 29 3/8” (746 mm)
Width 19 3/8” (492 mm)

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PLENUM DIMENSIONS
Cold air return 18 x 20 3/4” (457 x 527 mm)
Hot air supply 18 x 21 3/4” (457 x 552 mm)
Plenum spacing 1 3/8” (35 mm)
A/C COIL LOCATION
Minimum height above the heat exchanger 10” (254 mm)
See A/C Coil Manufactures Requirements
OPENING HEIGHTS – from base
Burner c/l 10” (254 mm)
Smoke pipe c/l 22 1/2” (572 mm)
SMOKE/VENT PIPE
5” Chimney
4” Direct Vent
CLEANOUTS
Front Covers & Burner Opening
AIR FILTERS 16” x 20” x 1”
THERMOSTAT
Classic Air Any thermostat
EVO Any thermostat
MAX Any 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.
7.0 CLASSIC AIR COMFORT ADJUSTMENTS
oOutlet air is initially too warm or too cold - adjust the fan on setting.
oOutlet air consistently too warm or too cold - change the blower motor speed to give the
specified air temperature rise (70 - 85°F).
oBlower motor shuts off and the oil burner keeps going - the “FAN ON” setting is set too
low or the inlet air is below 50°F.
oOutlet air gets too warm and burner shuts down - increase air by changing the blower
motor speed to give the specified temperature rise (70 - 85°F).
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” time higher or lower.

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8.0 TROUBLE SHOOTING GUIDE
Unless otherwise specified, the following applies to all units.
Furnace will not start
Tripped blocked vent switch Clear vent, reset switch.
Tripped breaker Determine cause, reset breaker.
Blown fuse Replace fuse.
No oil Check tank for leaks and call oil supplier.
Sooty flame
Wrong pump pressure Increase or decrease pressure to correct setting.
Dirty nozzle Replace nozzle.
Improper burner setting See section 3.0 BURNER SPECIFICATIONS.
Barometric draft wrong Adjust barometric regulator for -0.04” wc draft pressure at
breech.
Oil burner keeps turning off
Dirty air filter Change air filter.
Restricted air supply/return Check all air return/supply registers.
Limit control Check ductwork for blockage.
Motor over heating Check motor speed is correct for nozzle on furnace label
settings.
Dirty nozzle Call technician to replace nozzle.
Using too much oil
Oil leak in line or tank Check tightness of fittings. Inspect tank and replace if
necessary.
Draft regulator set high Adjust regulator for -0.04” wc draft pressure at breech.
Nozzle too large Replace nozzle to lower input.
Burner reset cuts out
No oil Call oil supplier.
Frozen oil line Call technician or oil supplier.
Dirty oil filter Replace filter.
Dirty nozzle, smoky fire Replace nozzle, adjust burner air.
Faulty oil pump Have pump replaced, adjust burner air.
Faulty or dirty electrodes Have technician clean or replace.
Flame blowing off of burner On the Beckett burner have igniters wired for intermittent
ignition (run constantly with the motor).
Warm air registers blowing cold air
Basement cooling ducts Insulate and seal ductwork to maintain duct temperature.
Ducts running through Change or insulate ductwork.
unheated spaces
Low speed switch is on Switch off blower low speed (Classic Air).
“FAN OFF” set low Fan control – Set “FAN OFF” higher (Classic Air).
Motor speed set too high Reset motor speed to slow blower (Classic Air).
All rooms at different temperatures
Supply air not regulated Adjust warm air regulators to suit each room.
Return air not regulated Check for sufficient return air.

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Warm air registers blowing too hot
Blower running slow Speed blower up (Classic Air).
Return air restricted Open up return air ductwork to ensure adequate airflow.
Nozzle too large Lower nozzle size to suit ductwork.
Noisy operation
Loose blower wheel Tighten wheel set screw or replace.
Blower wheel hitting housing Center wheel in housing.
Damaged motor bearings Replace blower motor.
Faulty oil pump Repair or replace oil pump. Reset to correct pressure.
Air leak in oil line Tighten all connections.
Vacuum too high on pump Check pump vacuum. Check filters and pump screen.
8.1 MAX/EVO LED INDICATORS
Refer to decal on inside of wiring box cover.
GREEN LED (Status)
Slow Green Standby.
Fast Green B1-B2 Energized.
Solid Green System Fault.
In this case the Red LED will flash a number of times to indicate probable cause.
1. Disconnect power
2. Correct error
3. Re-connect power
RED (Diagnostic)
On Power Up of system, the RED LED will flash. If there is a problem detected the system
will try two times to diagnose and correct the problem (approx. 80 seconds). If problem
persists RED LED error code will flash.
RED 3 Flashes Heat/Aux Sensor Trouble
a) Ensure sensor or Jumper Plug (9300i only) is fully plugged into connector.
b) Otherwise, Replace Sensor or Jumper Plug (9300i only).
RED 4 Flashes B1 Output Trouble
a) Check for wiring error.
b) Otherwise replace control.
RED 5 Flashes System Trouble
a) Replace control.

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SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
FOR MOST RECENT UPDATES PLEASE VISIT www.KerrEnergySystems.com.
The following form MUST be completed for the warranty to be valid.
Installed by:
Address:
Telephone: Date:
START UP TEST RESULTS
Nozzle: Pressure:
Air: Turbulator:
CO2: Smoke Number:
Breech Draft: Stack Temperature:
TestPerformedBy:
Staple Printout Here: Staple Smoke Spot Here: