KyungDong KDB-161GOM User manual

GOM -영문
31
1. Safety Warnings ------------------------------- 32
2. Safe and Correct Installation -------------------- 33
3. Boiler Size and Function Guide------------------ 38
4. Electricity Line Construction--------------------- 42
5. Gas Pipe Construction-------------------------- 44
6. Heating and Hot 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

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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.
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Safe and Correct Installation
This instruction booklet is considered an integral part of the product and must
be delivered to the user together with the appliance.
It must follows the appliance also in every passage of property.
Store the booklet in a safe place and read it carefully before using the appliance
as it contains important information to ensure safe installation, operation and
maintenance.
This appliance must be installed following the National and the Local law and
standard in force.
Installation and maintenance must be performed according to National and
Local standard in force and 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 Centre represent a guarantee
of professional and qualified services.
The appliance must be used according to the applications as specified in the
design.
Any other use has to be considered improper and therefore hazardous.
The manufacturer declines all contractual or not-contractual responsibility for
damages caused by incorrect installation and incorrect operation and failure to
observe the relative instructions.
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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.
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.
yThere is a danger of a fire if you install this unit
near any dangerous flammable materials such as
gasoline, kerosene, benzene, or glue.
Before Installation
Selection of Installation Location

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When the boiler takes air from the place
where it is installed, be sure that the opening
ventilation are open.
yAny malfunction in the ventilation may cause
improper combustion that may lead to Carbon
Monoxide(CO) gas poisoning, a fire, or shorten
product use life.
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.
yThe top of the exhaust pipe should be at least 150mm from the ceiling.
yThere 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.
For B33 Type of installation, Please do not
install the unit above any combusting
appliances or near any air conditioning units.
yThis may cause improper combustion causing CO
poisoning.

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Please do not install the unit in a location
where there are any corrosive materials
such as ammonia, chlorine, sulfur, and acids.
yBoiler 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 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) 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.
Product Installation Method

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Boiler Size and Function Guide
KDB-131/161/201GOM
KDB-251GOM
BOILER SCHEMATIC
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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 automatically 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 21).
KDB-131/161/201 GOM

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 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 21)
KDB-251 GOM

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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 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 level
- 25,000kcal/h : Over 5 level
Standard Piping Diagram

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Electricity Line Construction
230V~50Hz Electrical connection
y The boiler has to be connected to the electrical
installation by an “X” type power cable without plug.
y The power cable must be connected to a 230V~
50Hz main supply with correct sequence Line-
Neutral-Heart.
y The main power supply must be also equipped
with a multi-pole circuit switch, with a contact
opening gap of at least 3mm.
y The electrical safety of the unit is guaranteed
when correctly connected 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 of any cable installation or substitution,
please, squeeze the press cable in the boiler.
y For the main power supply of the boiler, never
use plugs, adapters, multiple sockets or extension
leads.
CAUTION
Boiler pipes must never be used to heart the
electrical or the telephone lines.
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Fuse substitution
y In the event of mains fuse replacement on the
PCB, please use a 2A quick blow fuse.
y Please switch-off the main switch upstream the
boiler.
y Take away the plastic box containing the main
PCB.
y Open the cover of the plastic box.
y Look and substitute the fuse in the upper 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 of the
connector in the boiler as showed in the figure.
y Finally squeeze the press cable in the boiler.

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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.
2 Gas pipes must be metal 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 must be directly
connected to the main pipe and do
not connect it along with other gas
appliances.
CAUTION
In every case for gas pipe construc-
tion, please, follows National and
Local laws and roles.
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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

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Heating and Hot Water Pipe Construction
Do not add anti freezing liquid 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.
Every 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.
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y The contact diameter of the water supply pipes of this unit is 1/2″.
y In the entrance of the water supply, install water supply middle valve.
y To use this unit it’s always necessary to have more than 0.5 bar inlet pressure for the filling
of the installation and for domestic hot water production too.
y When sending hot water to the second floor, more than 1.0 bar (1kgf/cm2) 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 10 bar (10kgf/cm2) install a pressure reducer valve.
y The contact diameter of the hot water pipe of this unit is 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 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 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 distributor, less than 5 holes must be over 36 mm and more than 6 holes must use
over 44mm of diameters.
Hot Water Pipe Construction
Water Supply Construction
Heating Pipe Construction

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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

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After pipe construction is completed, you must check for leaks.
y If unit is connected to the pipe and the pipe is not completely full of water, this may
cause the pump to rotate without operating normally, overheating the pump or
inducing malfunctions. Thus, make sure to remove 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
hard 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.
You must use a flue (exhaust flue) that was
approved by our company.
y Using 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 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.
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