Kiturami TURBO-21 Manual

Model
┃┃┃┃┃
* TURBO - 25 (29.1 kW)
* TURBO - 30 (34.9 kW)
* TURBO - 17 (19.8 kW)
* TURBO - 21 (24.4 kW)
Technical information and Installation Servicing Instructions
TURBO Oil Boiler.....................................
boiler……………..
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CONTENTS
1) overall view
1 -1. General information ************************************** 3
2) Product description
2 - 1. Boiler Specification ************************************** 4
2 - 2. Product dimensions ************************************** 5
2 - 3. Burner Specification ************************************** 6
3) Installation
3 - 1. Standard chimney installation ************************************** 9
3 - 2. Standard heating & hot water installation ************************************** 11
3 - 3. Standard gas connection installation ************************************** 14
3 - 4. Burner connection spec ************************************** 15
3 - 5. connecting Electricity ************************************** 16
4) Main part spec
4 - 1. Gear pump
**************************************
17
4 - 2. Electronic pump
**************************************
17
4 - 3. Ignition transformer
**************************************
19
4 - 4. Connector
**************************************
19
4 - 5. Ignition bar
**************************************
20
4 - 4. Adjustment and gas conversion ************************************** 21
5) Burner direction for assembly
5 - 1. Burner part exploded view ************************************** 22
6) Teat working
6 - 1. Check list before switching - on ************************************** 24
7) Direction
For
assembly
7 - 1. Boiler part exploded view ************************************** 25
7 - 2. Part name ************************************** 26
8) Maintenance guide
8 - 1. Assembly of Burner ************************************** 27
8 - 2. Assembly of Temp. and Overheating Sensors ************************************** 28
8 - 3. How to clean Heat exchanger's Exhaust tube ************************************** 29
9) Function of the controller
9 - 1. Main controller part mane ************************************** 30
9 - 2. Room control part mane (CTR-5700 plus) ************************************** 31
9 - 3. Room control LED panel ************************************** 32
10) Troubleshooting guide (error code)
10 - 1. Finding failure ************************************** 33
11) Technical Data Table ************************************** 34
10) Memo ************************************** 35
11) Warranty ************************************** 36
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1. overall view
These instructions are suitable for TURBO Series standing Oil boiler;
Do not forget this instruction.
To ensure the correct installation, commissioning and servicing of domestic central heating system.
1. High efficient Heat Exchanger
It's a boiler with high efficiency and low noise, which exchanges the heat efficiently and has a tolerance to the
strong headwind in winter.
2. Electronic Automatic Control Device (Korea Patent No.17570)
Electronic Automatic Control Device(CTC) judges the operation status of boiler and controls it. CTC is the high-tech controller with
the program for self-diagnosis function, automatic control function, Hot water-only mode, Sleep mode and Out of house mode.
3. Cutting edge self-diagnosis System
It has the various and convenient fuel-saving mode such as Outgoing, Bath and Sleep mode, and is equipped with the safety devices
including a flame sensor and a temperature sensor. It's a safe boiler with the cutting edge technology.
4. Turbo Cyclone Burner (Korea Patent No.101040)
Kiturami Turbo Cyclone Burner burns combusted air secondarily with a special metal plate heated up to 800℃ like a turbo engine
of an automobile. It's different from general burner which burns injected fuel from nozzle in the air. It's eco-friendly and acquires
NT(Net Technology). Turbo Cyclone Burner guarantees environment-friendliness, safety and long-life.
It's a hydraulic spray type burner, which can use the oil or the diesel variously, and adapt to solidified oil under sub-zero Temp.
and combustion conditions change
5. Slim design for easy installation
It's easy to transport and install in a small space by the optimal design with the cutting edge 3-dimentional design technique.
1 - 1 General Information
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2. Product description
Model : TURBO Oil Boiler
TURBO-25
166
MODEL TURBO-17 TURBO-21 TURBO-30
STAINLESS BAND
350
220 V/50Hz
2 - 1 Boiler Specification
150
DIMENSION (Wx Dx H)
POWER SOURCE
365 x 650 x 890
FLUE
Room Control
WEIGHT (kg)
HEATING AREA (㎡)
FUEL TYPE
113 140
325 x 602 x 815
INSTALLATION TYPE FE
220160
Light Oil
200
CH SUPPLY
Ignition transformer
BURNER
Heat exchanger
DHW COIL
Damper Ring
Bottom COVER
Main controller
CH RETURN
Temperature
sensor
OIL FILTER
CASE
TOP COVER
TOTAL
CONTROL
COMPUTER
OIL
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▶
TURBO
-
17 , 21 , 25 , 30
A : Flue Connector B: CH Supply C: CH Return D: Drain
E : DHW inlet
F: DHW outlet
▶ Dimension of Boiler mm
▶ Pipe Size mm
A B C DE F
80 32 32 32 15 15
80 32 32 32 15 15
80 32 32 32 15 15
80 32 32 32 15 15
※ CH supply pipe is on the upper section as shown in Figure.
602
815
650
REMARK
603
H
890
TURBO - 17
TURBO - 30
325
L
MODEL
W
325
TURBO - 21
TURBO - 25
2 - 2 Product dimensions
815
TURBO - 30
365
TURBO - 25
890
MODEL
365
TURBO - 17
650
TURBO - 21
B
A
Temperature sensor
MAIN Controller
Peep hole
C
Burner
D
Photo sensor
Air damper
Ignition
transformer
E
F
Low water sensor
electronic
pump
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* BURNER MODEL : TURBO - 17 (19.8kW) , TURBO - 21 (24.4kW)
TURBO - 25 (29.0kW) , TURBO - 30 (34.9kW)
NO NO NO
123
456
789
Remark
※ Features of Turbo Cyclone Burner
Kiturami Turbo Cyclone Burner burns combusted
air secondarily with a special metal plate heated
up to 800℃ like a turbo engine of an automobile,
considerably reducing fuel costs and exhausts.
Ignition transformer
Air Damper Burner Tube
Burner Body
NAME
Oil filter
2 - 3 Burner Specification
Gear Pump typeElectronic Pump type
NAME
Photo sensor
Burner Gasket
Electronic, Gear Pump
Motor cover
NAME
입체 형 소용돌이 스테빌라이저
특수금속 (FCH2)
NOZZLE
9
6
8
1
8
2
2
3
4
5
4
6
9
5
Cyclone stabilizer
Special metal
(FCH2)
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* Dimension of Electronic Pump type Burner
mm
*
Dimension of Gear Pump type Burner
Gear Pump type Electronic Pump type
Gear Pump type
Gear Pump type
Gear Pump type
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* Dimension of Electronic Pump type Burner Flange
m
m
* Dimension of Gear Pump type Burner Flange
m
m
A B
115
172TURBO-35
TURBO-25 143.5 115 172
115143.5
TURBO-21
143.5
CMODEL
172
143.5
115
172
A
143.5
115
B C
172TURBO-21
TURBO-17
MODEL
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3. Installation
▶ Installing flue in case of no existing flue
1. As shown in Figure 1-1, install stainless flue outside and then install
air intake vent and exhaust gas vent for boiler room.
2. Cover the Flue and the surface of the wall with the nonflammable
material to prevent fire or damage by high temperature of exhaust gas.
3. Install the flue part connected with exhaust hood should be installed
longer than 50cm, which prevents condensate from flowing into the
inside of boiler.
4. Install the condensate drain at "A" region to prevent the condensate,
generated in the outer flue, from flowing into the inside of boiler.
▶ Installing flue in case of existing flue
1. Check the air leakage at the joint between outer flue and inner flue,
and seal the joint with the nonflammable material.
2. Install air intake vent at the bottom and exhaust gas vent at the top.
3. Keep the distance more than 200mm between the outer flue and the inner
flue's end, which smoothes the emission of exhaust gas.
4. Install the condensate drain to discharge the condensate, generated
in the outer flue.
3-1 Standard chimney installation
BURNE
R
DRAI
N
AIR SUPPLY
cleaning
NONFLAMMABLES
AIR
VEN
T
NONFLAMMABLE
CLEANING and
CONDENSATE
DRAIN HOLE
AIR VENT
under
under
15cm under
45cm under
50cm under
200cm under
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▶ Installing the Boiler
1. Do not install the boiler in tighty shut area without ventilation or in bathroom
with a lot of moisture. It may cause the critical lack of oxygen or imperfect
combustion.
2. Install the boiler horizontally and solidly on the nonflammables such as
concrete or bricks which can withstand the weight.
3. Do not install the boiler in open veranda or outdoor for the frost protection.
4. Place the boiler in the area with enough space to check and repair it.
5. Use a plug acceptable only for the boiler.
6. Install the boiler 50mm higher than the floor.
▶ Cautions in installing Flue
1. The highest part of flue should be out of wind pressure belt and
not be influenced by rain and wind.
2. When there is a high building or an obstacle within 1M around the flue,
the flue should be Min. 1M higher than the high building.
3. If the flue is placed in a wind pressure belt, the efficiency of the boiler
is getting lower because the imperfect combustion causes soot, and
that leads to safety shut down function, which means the boiler does
not work well.
AIR
SUPPLY
NON-FLAMMABLES
AIR PRESSURE
BELT
CLEANING
HOLE
1m under
1m under
1m under
chimney
1m
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※ " A " height + pump pressure = less than the pump head pressure 35m
▶ Cautions in installing the pipe
1. Be sure to install a Air vent or Auto Air vent at the top of the pipes.
2. This product is for the working pressure 3.5kgf/㎠ of cold water supply. Therefore, Install the pipe
in accordance with 3.5kgf/㎠
3. Don't install any valve such as a pressure reducing valve and a check valve at the water supplement
and the drain pipe.
※ Caution against the damage to the boiler due to user's negligence
4. Please install an open type expansion tank or the nitrogen tank(closed type) and a safety valve,
appropriate to the capacity of the boiler to prevent the damage by the thermal expansion pressure.
5. If the boiler is directly connected to the water supply pipe, it may be damaged due to the high pressure
of water supply. Therefore, be sure to install a pressure reducing valve and a check valve.
※ Keep the pressure of the cold water supply within 0.6 - 1.kgf/㎠ to use the hot water sufficiently.
3 - 2 Standard heating & hot water installation
DHW
Outlet
DHW inlet
CH Return
Circulation pump
CH Supply
Drain hole
* Heating coil
* radiator
* FCU
expansion
tank
Water tank
Over flow
Emission pipe is more than 20A
safety valve is more than 3.5kgf/㎠
20A
Install the safety and Auto air valve.
보일러 물 보충관
min 1.5m
By pass pipe
CH Supply
Herder
CH Return
Header
Water supplement
pipe
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3-2-1 Installing Downward piping type
3-2-2 Installing Downward piping type (Diagram of Total Piping)
expansion tank
chimney
Boiler
circulation pump
Heating return Heating supply
Over flow pipe
DHW outlet
DHW inlet
Cool water inlet
pipe
Over flow
Heating
header
expansion tank
Over flow
* radiator
DHW outlet
Heating return
Heating supply
DHW inlet
Bath
* Heating coil
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3-2-3 Installing Upward piping type
3-2-4 Installing Upward piping type (Diagram of Total Piping)
Heating supply
circulation
pump
Heating return
DHW outlet
Pipe preventing
the natural circulation
DHW inlet
VALVE
Over flow pipe
DHW inlet
control valve
Boiler
chimney
Auto Air
vent
expansion tank (2 nd) Heating Coil
(1 st) Heating Coil
Over flow
Heating
header
circulation
pump
Drain
chimney
급수파이프
Water supplement pipe
Pipe preventing
the natural circulation
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Oil supply pipe
-. When installing the Oil tank higher than Burner.
(Upward type)
① KITURAMI burner is equipped the special filter,
which protects gear pump and motor.
When install the Oil tank higher than Burner, follow
below instructions.
② The P should be lower than 4m to protect the
Pump retainer.
③ Oil pressure from the pump should be less than
0.4bar/30cmHg.
④ As for Downward type Oil supply pipe, refer to below
Figure and instructions.
H = Height from pump
L = Total length of Oil supply pipe
Values in the right table is for the Copper pipe of 8mm
and 10mm, which can be substituted with the steel pipe
of 1/4" , 3/8".
-. When installing the Oil tank lower than Burner. (Downward type)
※ Caution : Surely check whether the return line is open or not. In case of operation of burner with it open,
the retainer in pump will be damaged.
① Install the oil pipe, if possible, with the copper pipe,
and check the air infiltration clearly.
② Place the both tips of return pipe and supply pipe
at the same position.
H = Height from pump
L = Total length of Oil supply pipe
Values in the right table is for the Copper pipe of 8mm
and 10mm, which can be substituted with the steel pipe
of 1/4" , 3/8".
3 - 3 Standard oil pipe installation
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3 - 4 Oil Burner connection spec
▶ How to connect the Oil pipe (only gear pump equipped boiler)
1) When the Oil tank is located higher than the Gear Pump : single piping, multy piping
2) When the Oil tank is located lower than the Gear Pump : multy piping
* Connect the Pipe from the lower part of oil tank, to gear pump's IN, and the Pipe from the upper part of oil tank
to gear pump's OUT.
* If the height difference between the bottoms of oil tank and gear pump, is more than 3m, gear pump doesn't work.
※ Gear pump equipped boiler should use the diesel.
▶ How to connect the Oil pipe (only electronic pump equipped boiler)
1) If the Oil tank is located lower than the electronic pump, the boiler
can't operate normally. Be sure to install the Oil tank higher.
2) Oil pipe should be installed as single piping.
※ Electronic pump equipped boiler can use diesel, oil and heating oil.
2. Water connection
1). The illustration shows the connections for the water and gas attachments of the boiler. See valves configuration
2). Check that the maximum water mains pressure does not exceed 3bar; if it does, a pressure reducing valve must be
installed.
3). For measuring of the pipes and of the heating bodies in the heating system, the residual head value should be calculated
as a function of the requested flow rate, in accordance with the valves shown in the circulation pump graph
3. Drain connection
1). Extend the hose from the safety valve and connect the drain hole.
※ Caution ; Do not store any wettable things under the boiler or near the drain hole.
②
⑥
Rubber Oil Hose
Hose Band
Electronic Pump
Oil Filter
①
③ ⑤ ⑦ ⑨
④⑧
NO
Oil Tank connecting Nipple
Part name
⑩
Oil Hose extending Nipple
GEAR PUMP
Oil tank
check valve
oil filter
GEAR PUMP
Oil tank
oil filter
Oil tank
ELECTRONIC PUMP
oil filter
Water-gas
Separator
Approx. 6m Approx. 4m
Approx. 6m
Water-gas
Separator
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3-5-1 Connecting Wires
※ This appliance is designed on AC 220V ~ 230V/ 50Hz.
This work of connecting wires is required by a qualified electrician.
1. Make sure that the earth connection is required for safety uses from any electric leakage or short-circuit.
2. Make sure that the connecting electricity - for example, connecting power and cable, wiring, earthing, etc - should
comply with the regulation.
3. If this appliance is not earthed by power plug, ensure to earth separately, by minimum 30cm inserted in the
ground. Note not to connect gas pipe, telephone wire and lightning conductor(rod) in order to avoid any
accident from lightning, surge, or the gas accident.
4. Make sure that the socket outlet is apart by over 30 cm from the appliance.
5. The power outlet has to have at least the minimum clearance of 30mm from the gas boiler
6. The grounding point need to be buried at least 30cm
3 - 5 Connecting Electricity
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4. MAIN PART SPEC
4 - 1 GEAR PUMP
① Pressure of pump
-. 10 bar : Adjusted pressure out of factory
-. 12 bar : Change the pressure when the burner ignites at a low temperature.
② Structure of pump (based on DANFOSS pump)
③ Gear pump work SYSTEM
4 - 2 ELECTRONIC PUMP
W x L x H = 60mm x 67mm x 89mm
Power
connector
Oil outlet
Outlet pressure
adjusting screw
Air outlet
Oil filter
connector
Adjusting Pressure
Cylinder Port
Inlet (Φ 1/4")
Outlet (Φ 1/4")
Nozzle Connection (Φ 1/8")
Pressure Gauge Connection (Φ
1/8")
Vacuum Gauge Connection (Φ
1/8")
Oil Filter Replacement
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④ How to adjust the Air damper (manual)
1. After loosening screw A, adjust B by hand.
2. After adjusting B to the desired number , fasten the screw A.
3. The number D is bigger, the air flow is more.
※ After checking the combustion status, adjust the air damper
appropriately. In case of excessive or deficient air flow, imperfect
combustion may occur.
⑤ How to adjust the Air damper (automatic)
1. Loosen the 1st Air control KNOB by turning it counterclockwise.
2. Adjust the position of the Adjusting KNOB by rotating it
counterclockwise (close) or clockwise (open).
3. After adjusting, fasten Adjusting KNOB by turning clockwise.
→ Adjusting method of 2nd Air control KNOB is identical to
1st Air control KNOB.
→ Adjusted new location is applied after reactivation.
※ Air adjusting damper controls the 1st air inlet and the 2nd air inlet by the motor with the electronic control.
It can inhale the exact amount of air to prevent a gas explosion at the initial ignition.
⑥ How to adjust the Air damper of Electronic Pump type Burner (Manual)
1. Loosen the Air control KNOB by turning it counterclockwise.
2. On Burner's operating, the more the knob is turned counterclockwise,
the less the amount of air is.
3. On Burner's operating, the more the knob is turned clockwise,
the more the amount of air is.
4. After adjusting for the perfect combustion, fasten Adjusting KNOB
by turning clockwise.
1st Air
control
2nd Air
control
2nd Air control
KNOB
(
댐퍼조절
KNOB)
1st Air control KNOB
(댐퍼조절 KNOB)
D
Air adjusting
damper
(KNOB)
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4 - 3 IGNITION TRANSFORMER
① SPEC (KI-G50)
② Name and Dimension
(mm)
4 - 4 CONNECTOR
123
456
789
2
D
1
Electronic pump
IGNITION TRANSFORMER
60
105
16.5kV (0 ∽
+
10%)
FAN
FAN
Power Supply
AC 220V ±15%(50Hz)
V
ALUE
C
PHOTO SENSOR
5
Power connector
fuse Box
4
3
*
I
TEM
V
ALUE
20 W
Allowable Temp.
15kHz (Min)
Power Consumption
(-10℃ +70℃)
33 mA (Min)
Output Current
Current
Consumption
220 mA (Max)
Output Frequency
high tension WIRE
170
6A (
instant
)
Fuse Rating
70
A
B
Ignition bar cap
9pin connector
PHOTO SENSOR
I
TEM
POWER
Electronic pump
Fan Preheater
Electronic pump Power (220V)
fuse
fuse
fuse
Photo sensor
Ground
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4 - 5 IGNITION BAR
▶ SPECIFICATION
▶ Name and Dimension
60
70
26
3.5
24 3
11
14
▶ How to adjust the location of ignition rod
1. Ignition rod carries 16.5k voltage. Before adjusting,
plug off the power cord.
2. Don't adjust it at your discretion, it has been adjusted
minutely out of factory.
3. If necessary, adjust the ignition rod as shown Figure.
4. Epoxy material protects electrode rod and prevent
electrical short. Lots of soot may cause the inter
mittent ignition fault or ignition delay by electrical
discharges. Therefore, check the soot and epoxy damage.
▶ TIME CHART
◈ Normal combustion ◈ Abnormal combustion
C2
Thermal Resistance
10
14
- 10
15
Ωcm
DIMENSION (mm)
Withstanding voltage
NAME
190 ℃
Epoxy
F
E4
B
TURBO-21
18 KV/mm
Electrode rod
Connection hole
H
ardness
97 M
ITEM
5.3
VALUE
196 s
e
c
D
A
D
ielectric Constant
ITEM
VALUE
Insulation Resistance
Ignition rod
A
RC Resistance
1
TURBO-17
Ignition transformer
Connection nipple
ALARM
FAN
I/G Transformer
Ignition bar
Nozzle adapter
Nozzle
stabilizer
Electronic pump
Flame sensing
ALARM
FAN
I/G Transformer
Electronic pump
Flame sensing
sec sec
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