KyungDong KDB-101GOM+ User manual

GOM+ 표준형-영문
33
1. Safety Warnings ------------------------- 34
2. Safe and Correct Installation ---------------- 35
3. Boiler Size and Function Guide -------------- 39
4. Electricity Line Construction ---------------- 41
5. Gas Pipe Construction -------------------- 42
6. Heating and Hot Water Pipe Construction ------ 44
7. Intake/Exhaust Flue Construction------------- 47
8. Thermostat Installation Construction ---------- 59
9. Wiring Diagram ------------------------- 60
10. Specifications --------------------------62
※ This Installation Manual can be modified without any prior notice for
product quality improvement purposes.
Contents

GOM+ 표준형-영문
34
Safety Warnings
The cautions issued by this user’s manual include critical information for the safety
while using the product. When the user fails to adhere to the following requirements
can cause death, serious damages, and a great property loss.
For safety, according to the level of danger, we have indicated by ‘Danger’,
‘Warning’, ‘Caution’ and the definitions for these terms are as follows :
1) The definitions 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 more care for safety when using the product.
Please read and understand this installation manual completely for safe use of this
product.
When disposing of the product, it must be done through the installer.
1

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Safe and Correct Installation
▣ After installation is completed, user’s(installation) manual must be to
the user.
Please check the type of gas supplied at the
installation location and the electrical lines
before installation.
y Do not use any other type of gas than the one
indicated on the boiler lower right hand corner
rating plate. If such other type of gas is used, this
may cause fire or explosion due to improper
combustion.
y Supply power for the boiler is 220V 50/60Hz that if
the supplied power is lower or higher than the
usages power then this may cause a fire, lessen
the boiler functions, and shorten boiler use life.
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 as
gasoline, kerosene, benzene, or glue.
2
Before Installatio
n
Selection of Installation

GOM+ 표준형-영문
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When using a indoor space that is not an
exclusively boiler room, please install the
required inflow/outflow type (FF).
y There is a danger of Carbon Monoxide (CO) gas
poisoning when installing the unit in an indoor
space not exclusively for the boiler where it should
be installed in air close type (FF).
Please check to make sure that the location
has sufficient space to prevent fire and the
walls and ceiling are safe against fire.
y The unit should be installed near a non-
combustible wall.(if combustible wall then install a
heat-proof panels.)
y The side of the unit 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 install the unit in a boiler room away
from the effects of rain or wind.
y Any rain or rain may cause improper combustion
causing exhaust fume poisoning.
Please do not install the unit in a location
where there is high humidity such as
bathroom and other closed spaces.
y Due to lack of oxygen causing improper
combustion leading to CO poisoning.
y
Also, this may cause malfunction in a unit early.

GOM+ 표준형-영문
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Please do not install the unit above any
combusting appliances or near any air
conditioning units.
y This may cause improper combustion causing CO
poisoning.
Please do not install the unit in a location
where there are any corrosive materials
such as ammonia, chlorine, sulfur, and acids.
y Boiler will be damaged quicker and cause
improper combustion leading to CO poisoning.
y Install the unit by maintaining at least 600mm space between any electricity facilities.
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) at
boiler installation.
Recommendations

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y Since about 35~45kg of weight will be placed, the installation wall should be
reinforced if it lacks the capacity to endure such weight.
y Unit weight is specified in the product 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. If it has to be installed outdoors then place sufficient guarding materials
such as aluminum to prevent any affects of wind on the combustion and prevent
any snow or rain from getting into the unit. Also, insulation must be done to
prevent any freezing.
Product Installation

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Boiler Size and Function Guide
 Pressure Gauge : Indicates the pressure inside the heating pipes. In case the pressure falls
below 49kPa(0.5kgf/cm2), open the water replenishing valve to auto-
matically refill the water to 49~147kPa (0.5~1.5kgf/cm2).
 Water Drain : For a vacation or not at home for a prolonged period of time, to guard
against freezing, the water 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 pipes to
improve heating efficiency. When there is a problem with heating,
remove the clip and clean the filter. (see page 24)
3
KDB-101/131/161/201/251/301GOM+

GOM+ 표준형-영문
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y All pipes should be inspected for leaks after assembly is
completed to prevent any defects or leaks.
y All pipes other than the gas pipes should be insulated for
prevention against freezing after assembly is completed.
y When connecting the pipes, after fixing the connetions
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 level
- 25,000~35,000
kcal/h : Over 5 level
Standard Piping Diagra
m

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Electricity Line Construction
Please complete construction of the electric
line to fit the product power supply.
y The electricity for the boiler should be 220V
(230V) 50/60Hz. If the supply is higher or lower
than the required voltage, it may cause a fire,
reduce the boiler performance, or decrease use
life of the boiler.
y Please adhere to the following related national/local standards or rules when
starting the construction for 220V(230V) power supply, connection, and cable.
y In the area of 220V(230V), when the power outlet contact is not proper, you are
required to complete a contact construction.
y In the area of 110V, the contact construction is required if individual transformer is
done to increase up to 220V(230V).
y Please install an outlet exclusively for the boiler. The power outlet must be installed
in a location at least 300mm from the boiler.
Proper Construction of Electrical Lines
4

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Gas Pipe Construction
Gas pipe construction must be done by gas dealer or gas pipe installation dealer.
1 The diameter of the gas pipes for this
unit is 15A(PT 1/2″) or 20A(PT 3/4″)
for each model.
See specifications in this manual(P63
∼66)
2 Gas pipes should be metal flexible
pipes that were approved by metal
pipe or gas part inspection testing.
When using LP gas, do not install the
fuse cork and a middle gas shut-off
valve must be installed.(installing fuse
cork can cause 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 gas waste and
normal operation may be hindered.
4 Boiler gas pipe should be directly
connected to the main pipe and do
not connect it along with other gas
appliances.
5 In the connection part, use a nut to
tighten the section that can be
attached and detached.
5

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After gas pipe construction, a gas leak
check must be done.
y In case of gas leak, it may cause an explosion
that induces serious bodily harm or property
damage.
Please complete the gas pipe construction
after checking the required gas for the unit.
y If you use gas other than the one specified in the
boiler lower right hand rating plate, it may cause
incomplete combustion that can cause a fire or an
explosive ignition.
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 pipe or copper alloy ＋ insulator, XLPE pipe ＋ insulator
Hot Water Pipe Copper or copper alloy ＋ insulator, XLPE pipe ＋ insulator
Gas meter, at least 3 level for below 20,000kcal/h and at least 5 level
for over 25,000kcal/h.
Pipe Material

GOM+ 표준형-영문
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Heating and Hot Water Pipe Construction
Do not add anti-freezing liquids to the
heating pipes.
y This may shorten use life of the unit and cause
malfunctions.
After completely cleaning out the pipes,
then complete pipe construction.
y Any contaminant inside the pipes may reduce the
heating and hot water efficiency as well as cause
malfunctions.
Any exposed pipes must be insulated with
insulation material.
y There may be 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 excessive force to connect the pipes
or it may cause a leak due to damages to the
external parts.
Distributor must be non-corrosive material.
Do not use aluminum, carbon steel pipes, and cast iron material since they are easily corroded.
6

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y The contact diameter of the water supply pipes of this unit is 15A (PT 1/2”).
y In the entrance of the water supply, install water supply middle valve.
y To use this unit [{product operation water pressure＋hot water pipe loss flow (when water
flows)}＋safety factor] it may be necessary to retain more than enough water pressure.
(space 29.4kPa{0.3kgf/cm2} or more.)
y When sending hot water to the second floor, more than 98kPa{1kgf/cm2}(when water
flows) of water pressure is necessary.
y In the region where the water pressure is low, please install a pressure pump on the water
supply pipe.(except, when in use, please use a pump that is not affected by the capacity.)
y Before connecting the water supply pipe and the unit, open the water supply valve to
remove any excesses and sand from the pipes.
y When the water pressure is over 980kPa(10kgf/cm2) then install a pressure reducer valve.
y The contact diameter of the hot water pipe of this unit is 15A (PT 1/2″).
y Hot water pipe should be as short as possible.
y Water supply and hot water 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 20A (PT 3/4˝).
y The diameters of the supply pipe and the circulation pipe should be the same.
y The pipe length should be as short as possible and any curvature or connections should be
minimized.
y Connect a hose to the overflow hose connection hole to drain the water to the sewage.
y When connecting to the radiator, please install manual or automatic air vent on the top of
the radiator to prevent any collection of air or steam inside.
y In case of any renovation/repair installation of the coal or oil boilers, please clean the pipes
before connecting the unit to the pipe.
y For freezing guard, the exposed pipes must be insulated with insulation material.
y For Air Open Type model, the boiler and the heating pipes must be installed on the same
floor.
y When the heating pipe is installed on the floor above the boiler (first floor), Air Closed Type
model should be installed.
y For distributor, less than 5 holes must be over 36 mm and more than 6 holes must use over
44mm of diameters.
After pipe construction is completed, you must check for leaks.
Hot Water Pipe Constructio
n
Water Supply Constructio
n
Heating Pipe Constructio
n

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y If unit is connected to the pipe and the pipe is not completely full of water, plug the
power cord and in case of much bubbles inside the pipes, if you start the freezing
guard function with less than sufficient number of pipes then this may cause the unit
to rotate without operating normally, overheating the pump or induce malfunctions.
Thus, make sure to release the air inside the pipes and check the water level.
y Pipes must be completely insulated.
y Please do necessary measures to ensure freezing guard in locations where it is
extremely cold such as covering the exposed pipes with insulation heater. (It is also
proper to insulate by constructing the pipes next to the heating pipes.)
y If any freezing may occur, condensed water discharge hose must be completely
insulated with insulation material.
y When not using the boiler for a long time, completely drain the unit of water to
prevent freezing and close the gas shut-off valve and unplug the unit.
y The exposed parts must be protected from freezing by covering with 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 hot water pipes to the boiler joint, please
remove any iron shavings that were produced during the pipe construction or any
contaminants inside the pipes. (Complete Cleaning of the Pipes)
y Please do not use any well water for heating. If it is unavoidable that you must use
well water then please remove any contaminants from the pipes.
y Do not connect to the pipes (particularly the metal pipes) that were used for coal or
oil boilers if at all possible. (This may cause malfunction or shorten its use life.) If
unavoidable, please remove any contaminants from the pipes.
y Any contaminants inside the pipes reduce heating and hot water efficiency and
causes malfunctions.
y Please completely remove any air from each of the pipes.
Recommendations
Freezing Guard

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Intake /Exhaust Flue Construction
y Please use only the flue approved by our company with the gas boiler manufactured or
sold by our company.
y If any malfunction or accidents occur by using flue that was not approved by our
company, our company will not be held responsible.
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.
Intake or exhaust flue should be installed in
a location where there is a good ventilation to
the outside and there is no seepage of
exhaust gas into the inside of the house.
y It is possible to cause incomplete combustion due
to lack of oxygen and presence of exhaust gas
and exhaust gas seepage may cause Carbon
Monoxide poisoning.
7

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Please install supply ventilation and
ventilation.
y Lack of ventilation may cause incomplete
combustion due to oxygen shortage and if
the ventilation fan malfunctions, incomplete
combustion may result and exhaust gas may
seep into the inside causing carbon
monoxide poisoning.
Please install in a boiler room exclusively
for the boiler.
y If not installed in boiler room exclusively for
the boiler, there is a possible exhaust gas
poisoning in case of exhaust gas leak.
y In an exclusive boiler room, do not install any
ventilation fan.
Please install in a remote location where
there is no affects from snow or rain
and strong winds.
y If icicles form from the evaporation due to
the exhaust gas during the winter months,
they may fall causing physical or property
damage.
Forced Exhaust (FE) Type Pipe Constructio
n

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In the tunnel portion where the pipe goes
through the wall, it must be completely
airtight in order to prevent any exhaust gas
from re-entering inside.
y If the exhaust gas enters inside, it may cause
exhaust gas poisoning.
The connection portion of the exhaust pipe
must be completely airtight.
y In case of leaks, exhaust gas leakage may cause
carbon monoxide poisoning.
You must use a flue (exhaust flue) that was
approved by local codes (latest edition) or
other official testing administrative offices.
y Using unapproved flues (exhaust pipe) may cause
exhaust gas poisoning due to exhaust gas leaks.
The flat portion of the flue should be
installed downward at about 5°angle to
prevent any reverse flow of the condensed
water or rain water into the boiler and turn
it downward toward the ground at 45°∼
90°angle.
y If condensed water or rain water reenter the
boiler, cause of the incomplete combustion, boiler
function reduction and shorten its use life.

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■ The total length of the exhaust flue should be 3m or less, the curvature must be 2 or less.
■ The exhaust flue should be over φ75, φ80 or more depending on capacity. (see P62, 63)
■ Be careful not to allow the middles of the exhaust flue to become constricted and the curvature
must be constructed so that the diameter of the curvature is as large as possible.
 The material of the exhaust gas should
be stainless steel (27 types) or heatproof
and non-corrosive metal materials.
 When the exhaust gas goes through
combustible wall, or ceiling, cover with at
least 20mm of non-combustible materials
and keep at least 50mm of space. Also,
in case of going through the ceiling,
please install a lamp overhead.
 Exhaust flue must be installed independents
and natural exhaust flue or other fuel (coal,
kerosene) heaters should not be used at the
same time.
 Intake flue should be installed in a location
with good ventilation such as outside
and in a place where the exhaust gas
does not enter from the exhaust flue.
(※ If intake and exhaust processes are
not complete, this may cause incomplete
combustion due to lack of oxygen.)
Warning
Please do not install in an airtight location
such as a bathroom. This may cause
suffocation due to lack of oxygen.
Forced Exhaust Flue Construction
(
FE)

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y Please make a hole in the wall to allow the outside air to directly come in contact with the
top ventilation or bottom air intake flues.
y Intake flue or ventilation’s effective cross-section must be greater than the cross section
of the exhaust flue.
Open Area (cm²)
Effective Cross
Section
Plastic Lattice
(Open Ratio 0.5)
Wood Lattice
(Open Ratio 0.3)
Perforated metal sheeting
(Open Rate 0.3) Unit
Area Over 50 Over 100 Over 125 Over 170 cm2
Diameter Over φ80 Over φ115 Over φ130 Over φ150 mm
y If the space between the top of the exhaust flue and the outside wall is heatproof, the space
should be at least 300mm.
Within 600mm of the top of the exhaust flue,
there should be no openings such as a
window.
y If exhaust gas enters inside of the house, it may
cause exhaust gas poisoning.

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y When installing the exhaust flue inside the ceiling hidden from view then the connection
part should be structured so as to prevent any exhaust gas leaks and covered with
heatproof material other than metal.
y The connection part must be sealed with plaster tapes.
y For inspection repair of the exhaust flue in nearly dark locations, please install a lamp
for inspection.
y The connection part of the exhaust flue must be inserted with “O-ring” then pushed in
sufficiently to make it airtight and check for any exhaust gas leaks.
y In case of extending the exhaust flue, one hanger for maximum 900mm of pipe to
stabilize it completely. (when over 1m)
y If the pipe is not installed properly, the product will not operate properly. It can also
cause injuries or damages. Thus, follow this instruction and complete a proper
installation according to the national or local standards.