KyungDong KDB-131GOM, Installation Manual

Page 1: ...t Water Pipe Construction 46 7 Intake Exhaust Flue Construction 50 8 Thermostat Installation Construction 64 9 Wiring Diagram 65 10 Display Interface 66 11 Change of gas 69 12 Other functions and Adjustments 72 13 Working Mode 75 14 Maintenance 77 15 Specifications 78 This Installation Manual can be modified without any prior notice for product quality improvement purposes Contents ...

Page 2: ...finitions of the symbols indicated on the product and installation manual are as follows This symbol indicates Caution for bodily injury under particular conditions This symbol indicates Stop for possible bodily injury or property damage This symbol indicates a Must follow sign 2 Since the specified warnings and cautions in the installation manual are not all the cautions for using the product use...

Page 3: ...nd according to the manufacturer s instruction and by qualified personnel skilled in the specific sector as foreseen by the law Incorrect installation can cause damage or physical injury and the manufacturer declines all liability for failure to observe instruction and standards In particular maintenance must be performed by qualified personnel In this case an Authorized Manufacturer Service Centr...

Page 4: ... explosion due to improper combustion Check for power supply Please check whether the boiler is filled properly When installing the unit read the following items and install it according to designated method safely and correctly Please do not install in a location where there are flammable materials y There is a danger of a fire if you install this unit near any dangerous flammable materials such ...

Page 5: ...t should be at least 150mm away from any inflammables y If right and left walls are non combustibles then the unit should be at least 45mm from the walls y Heatproof panels insulating plate should be at least 3mm of metal or other non combustible materials y The top of the exhaust pipe should be at least 150mm from the ceiling y There is a danger of a fire if the above terms are not adhered Please...

Page 6: ...he unit by maintaining at least 600mm space between any electricity facility y Do not install near any location where there are many traffic of people y Do not install near any stairs or emergency exit y Ensure sufficient space for product inspection and repair y For repair and inspection the front of the unit should have at least 600mm of space Please should be prepare water discharge hole Device...

Page 7: ...specification chart of this manual y When installing the unit use the anchor bolt for firm installation to bear the unit weight y Fix the unit on the wall firmly to prevent any shaking during its operation to prevent any noise it is best to use buffer material such as rubber y Gas boiler is for indoor use only and should not be installed outside such as a veranda Product Installation Method ...

Page 8: ...G O M 영 문 38 Boiler Size and Function Guide KDB 131 161 201GOM KDB 251GOM BOILER SCHEMATIC 3 ...

Page 9: ...excreted through this part Pressure Relief Valve When there is excessive pressure inside the heating pipes it automatically excretes the water inside the boiler to maintain optimal pressure level In case of long absence from home to guard against freezing the water inside the boiler should be drained Heating Water Filter Strainer Filter is built in to catch any contaminants inside the heating pipe...

Page 10: ... is excreted through this part Pressure Relief Valve When there is excessive pressure inside the heating pipes it automatically excretes the water inside the boiler to maintain optimal pressure level In case of long absence from home to guard against freezing the water inside the boiler should be drained Heating Water Filter Strainer Filter is built in to catch any contaminants inside the heating ...

Page 11: ...pipes after fixing the connections using the spanner etc connect it to the pipes y Distributor Specifications Less than 5 holes Inner diameter of over 36mm Over 6 holes Inner diameter of over 44mm y Distributor material Please use non Corrosive material Do not use aluminum carbon steel pipes cast iron materials since they are easily corroded y Gas Meter Specifications 20 000 kcal h or less Over 3 ...

Page 12: ...to an effective and efficient earth system as specified in the current safety standard y The boiler is designed with IPX4d protection rating y The power cable must be laid as shown in the figures y For safety reason please take the heart cable at least 2cm longer than the Line and Neutral cable y In the event of power cable replacement please contact a qualified electrical technicians y At the end...

Page 13: ...r side of PCB Room thermostat connection External probe sensor connection y The boiler is designed to be connected to a room thermostat y Please remove the jump from the connectors and connect the cable coming from the free contact of the room thermostat y The boiler is designed to be connected to an external probe sensor for external temperature checking y Please connect it to the proper contact ...

Page 14: ...use malfunctions 3 When using LP gas use caution of the following items y LP gas governor should be house hold low pressure governor that is proper for gas usage indicated y LP gas container should be 50kg and use two or more containers connect a twin valve to supply gas from the two containers simultaneously In case the container capacity is small evaporation capacity is small that it may cause g...

Page 15: ...tion When using a gas container place the container in the cool shady place away from direct sunlight in the outdoors and fix the container properly to prevent tipping y An explosion may occur Pipe material should adhere to the KS standards Gas Pipe Carbon steel pipe for pipe usage copper or copper alloy pipe metal flexible pipe approved by gas component part inspection testing Heating Pipe Copper...

Page 16: ... freezing during the winter months y Since hot water cannot be used in case of supply water pipe freezes and when there is insufficient water inside the heating pipes the water cannot be replenished making normal operation of the boiler impossible When completing the pipe connection construction it should be done after tightening the boiler pipe adaptor with a tool such as a spanner y Do not use e...

Page 17: ...r pipe should all be insulated y Please do not use allophone metals if possible and avoid any complex pipes y Please maintain at least 1 200 1 300 upward incline for proper drainage y Please connect the pipes in a way to avoid any collection of air inside the pipes y The contact diameter of the heating pipes of this unit is 3 4 y The diameters of the supply pipe and the circulation pipe should be ...

Page 18: ...G O M 영 문 48 y GOM boilers are supplied with built in circulating pump The available head to the system are showed in the following diagrams Available Head to the System ...

Page 19: ...at lease 25mm of insulation material Colder locations it should be at least 50mm General Cautionary Items in Pipe Construction y Each connection part must be tightened with union or nut y Water supply pipe hot water pipe heating pipe distributor and check valve must be insulated to prevent freezing y Pipe materials must be national or local standard materials y Before connecting the heating and ho...

Page 20: ...sing unapproved flues exhaust flue may cause exhaust gas poisoning due to exhaust gas leaks The exhaust and intake flue construction must be done according to the instructions given y If the intake and exhaust flue construction is done improperly there is a possibility of exhaust gas poisoning and shorten the use life of the product In the tunnel portion where the pipe goes through the wall it mus...

Page 21: ...vent any discharge of the condensate away from the wall y Using proper approved flue system and following the producer s instruction it s possible to prevent any discharge of condensate away from the wall and avoid reenter of rain in the flue system The flue system has to be installed in view y The flue system have to be installed in view for a easy control and in order to avoid that any kind of e...

Page 22: ...For B33 installation type intake or exhaust flue should be installed in a location where there is a good ventilation from the outside and there is no seepage of exhaust gas into the inside of the house y Please follows the instruction supplied in the following paragraph y It is possible to cause incomplete combustion due to lack of oxygen and presence of exhaust gas and exhaust gas seepage may cau...

Page 23: ...een The boiler and the flue system as swoed in the following drafts Diaphram For the Concentric Fluse System adapter Diaphram For the Separate Flue System Adapter y For the choise of the correct diaphragme please look at the schemes related to each drawing in the following solutions y Please pay attenction to the fact that 131GOM 161GOM boilers with a very short length of separate flue system need...

Page 24: ... 00m Between 2 00m 2 88m Diaphragm φ 48mm φ 52mm without The MAXIMUM LENGTH of this configuration is 2 88m CHOICE OF THE DIAPHRAGM Flue system length Up to 0 75m Between 0 75m 2 00m Between 2 00m 2 88m Diaphragm φ48mm φ52mm without Horizontal concentric flue system 60 100mm Type C13 Horizontal concentric flue system 60 100mm Type C43 ...

Page 25: ...without Pay attention The chimney has to to protrude at least 350 mm from the base look at the figure The MAXIMUM LENGTH of this configuration is 3 60m CHOICE OF THE DIAPHRAGM Flue system length Up to 1 60m Between 1 60m 2 60m Between 2 60m 3 60m Diaphragm φ48 mm φ 52 mm without Horizontal concentric flue system 80 125mm Type C13 Vertical concentric flue system 60 100mm Type C33 ...

Page 26: ...AXIMUM LENGTH of this configuration is 6 70m CHOICE OF THE DIAPHRAGM Flue system length Up to 1 30m Between 1 30m 4 00m Between 4 00m 6 70m Diaphragm φ48mm φ48mm without Vertical concentric flue system 80 125mm Type C33 ...

Page 27: ...e system type C13 the total length that the horizontale flue system may reach is not 2 88m but not more than 2 28m y If it s necessary to insert two 45 bends in the 80 125 vertical flue system type C33 the total high that the vertical flue system may reach is not 6 70m but not more than 4 70m Choice of the Correct Diaphragme with the Bends Included in the Flue System y If some bend is included in ...

Page 28: ...t a longer distance than this or on a different wall y In order to avoid the look out of the boiler it s forbidden to istall the intake and the outlet of the flue system on the wall placed to the opposite side of the house y With the above C13 flue system type 80 80 separate and 60 100 concentric please NEVER close the terminal part with any object like for exampple plastic bag or other devices du...

Page 29: ...φ48mm φ52mm Without 201GOM 251GOM φ48mm φ52mm Without The TOTAL MAXIMUM LENGTH 1 2 of this configuration is 23 90m CHOICE OF THE DIAPHRAGM Flue system length Up to 5 00m Between 5 00m 12 70m Between 12 70m 18 30m Between 18 30m 23 90m 131GOM 161GOM φ41mm φ48mm φ52mm Without 201GOM 251GOM φ48mm φ52mm Without Horizontal separate flue system 80 80mm Type C83 Horizontal Vertical separate flue system 8...

Page 30: ...sary to insert N 2 90 bends in the flue system type C53 the total length that the flue system may reach is not 23 90m but not more than 19 50mm y If some bend is included in the flue system the total length for the evaluation of the correct diaphragm has to be calculated adding the reduction of length showed in the above schemes y For example if the boiler is a KDB 161GOM combined with a flue syst...

Page 31: ...3 90m 131GOM 161GOM φ41mm φ48mm φ52mm Without 201GOM 251GOM φ48mm φ52mm Without For both these two arguments please follows the instructions contained in the previous paragraph Horizontal separate flue system 80 80mm Type B33 Calculation of the maximum length with the single bends included in the flue system Choice of the correct diaphragme with the bends included in the flue system ...

Page 32: ...rom a near window E 400 From a near air opening F 600 From a discharge tube G 300 From a building corner H 300 From a recess I 300 From the ground or other floor L 2 500 Between two terminal in vertical M 1 500 Between two terminal in horizontal N 1 000 From a facing wall without any air opening or any other terminal in a radius of 3m O 2 000 From a facing wall with air opening or other terminal i...

Page 33: ...n sufficiently pushing it through Please check for any exhaust gas leaks y When the exhaust flue goes through the combustible wall including the flue it should be insulated with over 20mm of incombustible material and keep at least 50mm from any combustible materials y In the exhaust flue or exhaust elbow connection portion insert its proper sealing gasket and connect it so that it does not discon...

Page 34: ...nstallation location should be at least 1 2 1 5m from the floor where there is plenty of ventilation Do not install in a location where it is close to the common door where there is cold draft where there is direct sunlight where a child may reach it Examples of Installation location thermostat Installation Location 8 ...

Page 35: ...G O M 영 문 65 Wiring Diagram 9 Wiring Connecting Diagram ...

Page 36: ...G O M 영 문 66 Display Interface 10 s burner is switched on ...

Page 37: ...09 Fan failure E10 Air pressure switch failure E13 Primary flow switch failure Pump OFF and Flow switch ON E15 Main supply frequency error E16 Lockout for high limit switch y When the boiler is in working mode ON pressing the button for less than 0 5 seconds it s possible to look on the display at the following parameters in sequence No Parameter Display 1 Domestic hot water temperature C digits 2...

Page 38: ...o set some parameters as follows y A complete explanation of the serviceman menu procedure is written in the following chapters No Parameter Range Default 0 Ignition capacity 0 100 50 1 Central heating max capacity 0 100 100 2 Pump overrun 0 100 50 3 Anti fast cycling timer 0 100 50 4 Not used 0 100 5 Type of gas 0 Natural Gas 1 LPG 6 Gas curve correction 0 10 5 Serviceman menu Synthesis ...

Page 39: ...essure gauge to the gas probe 1 in order to measure the burner gas pressure screw out a couple of turn the inside screw y Remove the transparent plastic cup 2 y With the modulator powered to the maximum for example opening the DHW tap to the maximum screw or unscrew the brazing screw 3 with a 10mm spanner up to the burner gas pressure reach the value specified in the table y WARNING y For the boil...

Page 40: ...ht digits y Press in the right side in order to change the number read in the right digits arranging in this way the slow injection gas burner pressure step to the correct value The gas burner pressure to reach is written in the below tables Adjust the electronic board PCB from the current max heating output to the new one if necessary look at the paragraph adjustment of the heating capacity Take ...

Page 41: ... 14 0 3 6 1 63 10 1 1 21 13 0 1 19 3 9 1 89 3 9 2 23 4 1 1 93 10000 11 6 2 8 1 36 7 2 1 02 9 4 1 00 3 0 1 59 3 0 1 87 3 1 1 62 8495 9 9 2 3 1 16 5 4 0 87 7 1 0 85 2 5 1 35 2 6 1 59 2 6 1 38 KDB 161 GOM Output Natural Gas G20 Butane G30 Propane G31 G25 GZ350 G27 Kcal h kW Nozzles Press mbar Gar Flow Rate m3 h Nozzles Press mbar Gas Flow Rate kg h Nozzles Press mbar Gas Flow Rate kg h Nozzles Press ...

Page 42: ... as follows Press the and the left button and for at lest 10 sec up the digits start to blink Press the button in the left side up to the number 2 appears in the left digit A number included between 0 to 99 appears in the right digits Press in the right side in order to arrange the overrun period time up to the value desired The number included between 0 to 99 appearing in the right digits represe...

Page 43: ...e the relation between the power capacity and the fan speed in order to reduce the quantity of air during the ignition stage Press the and the left button and for at lest 10 sec up the digits start to blink Press the button in the left side up to the number 6 appears in the left digit The number 5 appears in the right digits The boiler in normally set in the 5 position this is the reference condit...

Page 44: ...hanger overcome 100 the error code E16 appears on the display up to this temperature comes down under 65 and the pump continue to run If during this time a request of injection occurs the boiler falls in a lock out condition and stay in that condition up to the reset of the boiler In order to reset the boiler is necessary to remove the cause of the overheating and to wait up to the temperature goe...

Page 45: ...m the room thermostat under the condition the boiler is set in winter condition y If the room thermostat is not connected the CH mode phase begins a soon as the boiler is set in winter condition y The 3 way valve relay is switched on CH position the circulator and the fan are energized and after checking the air pressure switch the burner control working is enabled y Passed the ignition burn capac...

Page 46: ...with the boiler in OFF position y If the temperature detected by the primary temperature sensor falls down under antifreeze thermostat ON the pump is activated and the burner starts keeping the minimum capacity till the temperature reaches antifreeze thermostat OFF y At this temperature the anti freezing function is disabled and the pump runs for the CH overrun time y Anti freeze function keeps op...

Page 47: ...the pressure gauge Checking of the correct activation of the detection control system its activation must be shorter than 10 seconds Watertight of the boiler heating and domestic hot water production circuit no leakage or water oxidation have to appear around the coupling Visual Checking that the outlet of the pressure relive valve is not blocked Checking that the expansion vessel charge after hav...

Page 48: ...ater Output kW kcal h 15 3 6 7 13 177 5 727 18 7 8 1 16 058 7 000 23 6 9 9 20 271 8 495 29 3 12 4 25 180 10 680 Min Dynamic Dom Hot Water Pressure bar 0 2 Min Domestic Hot Water Flow Rate ℓ min 2 3 Max Domestic Hot Water Pressure bar 17 5 Specific Domestic Hot Water Rate T 30 C ℓ min 7 3 8 9 11 3 14 0 Other Domestic Hot Water Rate T 25 C ℓ min 8 8 10 7 13 6 16 8 Other Domestic Hot Water Rate T 40 ...

Page 49: ...ow Rate ℓ min 2 3 Max Domestic Hot Water Pressure bar 17 5 Specific Domestic Hot Water Rate T 30 C ℓ min 11 6 Other Domestic Hot Water Rate T 25 C ℓ min 13 9 Other Domestic Hot Water Rate T 40 C ℓ min 8 7 Electrical Supply V Hz 230 V 50 Hz Nominal Absorption A 0 9 Power consumption W 160 Fan Power Absorption W 67 Pump Power Absorption W 84 Electrical Protection IPX4D Installation Type Wall Mountin...

Page 50: ...G O M 영 문 80 MEMO ...

Page 51: ...amage Types Repair Exchange Within one year from the date of installation of the unit y Leaks in the unit manufacturer defect y Hot water or heating problems y Defective components ignition device or thermostat y Noise Free Unit Free Within 3 months of the date of installation of the unit y Damages external Free Unit Free Damages compensation regulation after warranty expiration y Same as above Ch...