KyungDong KDB-181KCA User manual

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1. Safety Warnings ----------------------------------------------------- 34
2. Safe and Correct Installation-------------------------------------- 35
3. Boiler Size and Function Guide---------------------------------- 4
4. Electricity Line Construction -------------------------------------- 43
5. Gas Pipe Construction --------------------------------------------- 44
6. Heating and Hot Water Pipe Construction-------------------- 65
7. Intake/Exhaust Flue Construction------------------------------- 72
8. Thermostat Installation Construction ---------------------------84
9. Wiring Diagram------------------------------------------------------- 85
1 . Display Interface -----------------------------------------------------86
11. Change of Gas -------------------------------------------------------89
12. Other Function and Adjustments -------------------------------92
13. Working Mode -------------------------------------------------------97
14. Maintenance --------------------------------------------------------1
15. Specifications --------------------------------------------------------1 1
※ 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.
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.
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.
 There 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.
Any 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.
The unit should be installed near a non-combustible wall.(if combustible wall then install a
heat-proof panels.)
The side of the unit should be at least 15 mm away from any inflammables.
If right and left walls are non-combustibles then the unit should be at least 45mm from the walls.
Heatproof panels (insulating plate should be at least 3mm of metal or other non-combustible
materials.
The top of the exhaust pipe should be at least 15 mm from the ceiling.
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.
Any rain or rain may cause improper combustion
causing exhaust fume poisoning.

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For B33 Type of installation. Please do not install
the unit above any combusting appliance or near
any air conditioning units.
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.
Boiler will be damaged quicker and cause
improper combustion leading to CO poisoning.
 Install the unit by maintaining at least 6 mm space between any electricity facility.
 Do not install near any location where there are many traffic of people.
 Do not install near any stairs or emergency exit.
 Ensure sufficient space for product inspection and repair.
 For repair and inspection, the front of the unit should have at least 6 mm of space.
Please should be prepare water discharge hole (Device) at boiler installation.
Recommendations

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Since about 35~45kg of weight will be placed, the installation wall should be reinforced
if it lacks the capacity to endure such weight.
Unit weight is specified in the product specification chart of this manual.
When installing the unit, use the anchor bolt for firm installation to bear the unit weight.
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.)
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 Method

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Boiler Size and Function Guide
Boiler Schematic
3

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 Condensed Water Discharge : Location where the condensed water is discharged (connect the
discharge hose).
 Water Drain : Location where the water inside the boiler is discharged to prevent
freezing in case of there is overflow of water or in case of long-term
outing.
 Heating Water Filter(Strainer) : Improve the heating function by removing the contaminants inside the
heating pipes using an inside filter. When heating is not done properly,
remove the clip and clean the filter. (see page 35)
 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 35)
 Condensed water exit : Any condensed water is excreted from this part. (connect the draining hose.
see page 59)
KDB-181/2 1/251/3 1KCA

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 All pipes should be inspected for leaks after assembly is
completed to prevent any defects or leaks.
 All pipes other than the gas pipes should be insulated for
prevention against freezing after assembly is completed.
 When connecting the pipes, after fixing the connections using
the spanner, etc., connect it to the pipes.
 Distributor Specifications
- Less than 5 holes : Inner diameter of over 36mm
- Over 6 holes : Inner diameter of over 44mm
 Distributor material
- Please use non-Corrosive material
- Do not use aluminum, carbon steel pipes, cast iron materials
since they are easily corroded.
 Gas Meter Specifications
- 2 , kcal/h or less : Over 3 level
- 25, ~35, kcal/h : Over 5 level
Standard Piping Diagram

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Electricity Line Construction
Electrical connection .
The Boiler has to be connected to the electrical
installation by an “X” type power cable without plug.
The power cable must be connected to a 23 V~5 Hz
main supply correct sequence Line-Neutral-Heart.
The main power supply must be also equipped with a
multi-pole circuit switch, with a contact opening gap of
al least 3 mm.
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.
The boiler is designed with IPX4d protection rating.
The power cable must be laid as shown in the figures.
For safety reason, please take the earth cable at least
2 cm longer than the Line and Neutral cable.
In the event of power cable replacement, please
contact a qualified electrical technicians.
At the end of any cable installation or substitution,
please squeeze the press cable in the boiler.
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 earth the electrical
or telephone lines.
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Fuse substitution
• In the event of mains fuse replacement on the PCB, please use a 2A quick blow fuse.
• Please switch-off the main switch upstream the boiler.
• Take away the plastic box containing the main PCB.
• Open the cover of the plastic box.
• Look and substitute the fuse in the upper side of PCB.
Room thermostat connection
External probe sensor connection
External tank storage thermostat connection
• The boiler is designed to be connected to a
clean contact of a room thermostat. Please
remove the jump from the terminal block N°
3 and 4 and connect the cable coming from
the free contact of the room thermostat.
• The boiler is designed to be connected to
an external probe sensor for external
environmental temperature checking.
Please, connect it to the terminal block N°5
and 6 as showed in the figure.
• The boiler is designed to be connected to a
free contact of an external storage tank
thermostat. Please, connect it to the
terminal block N°1 and 2 as showed in the
figure.
CAUTION
The voltage of this connection is 23 V
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 2 A(PT 3/4”) for
each model. See specification in this
manual
2 Gas pipes must 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 :
LP gas governor should be
household low pressure governor
that is proper for gas usage indicated.
 LP gas container should be 5 kg 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 pipes connection,
please follows National and Local laws and
roles.
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After gas pipe construction, a gas leak check
must be done.
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.
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.
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 2 , kcal/h and at least 5 level for over
25, kcal/h.
Pipe Material

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Heating and Hot Water Pipe Construction
Do not add anti-freezing liquid to the heating
pipes.
This may shorten use life of the unit and cause
malfunctions.
After completely cleaning out the pipes, then
complete pipe construction.
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.
There may be freezing during the winter months.
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.
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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The contact diameter of the water supply pipes of this unit is 15A (PT 1/2”).
In the entrance of the water supply, install water supply middle valve.
To use this unit it’s always necessary to have more than ,5 bar inlet pressure for the filling of
the installation and for domestic hot water production too.
When sending hot water to the second floor, more than 98kPa {1, bar / 1, kgf/cm
2
} water
pressure is necessary.
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.)
Before connecting the water supply pipe and the unit, open the water supply valve to remove
any excesses and sand from the pipes.
 When the water pressure is over 98 kPa (1 kgf/cm
2
) then install a pressure reducer valve.
 The contact diameter of the hot water pipe of this unit is 15A (PT 1/2″).
 Hot water pipe should be as short as possible.
 Water supply and hot water pipe should all be insulated.
 Please do not use allophone metals if possible and avoid any complex pipes.
 Please maintain at least 1/2 ~1/3 upward incline for proper drainage.
 Please connect the pipes in a way to avoid any collection of air inside the pipes.
The contact diameter of the heating pipes of this unit is 2 A (PT 3/4˝).
The diameters of the supply pipe and the circulation pipe should be the same.
The pipe length should be as short as possible and any curvature or connections should be
minimized.
Connect a hose to the overflow hose connection hole to drain the water to the sewage.
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.
In case of any renovation / repair installation of the coal or oil boilers, please clean the pipes
before connecting the unit to the pipe.
For freezing guard, the exposed pipes must be insulated with insulation material.
 For Air Open Type model, the boiler and the heating pipes must be installed on the same floor.
When the heating pipe is installed on the floor above the boiler (first floor), Air Closed Type
model should be installed.
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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After pipe construction is completed, you must check for leaks.
When modifying the central heating system apartment to individual heating, since there is
possible flood due to excessive water storage and air residuals in the pipes with the existing
pipes, complete a contaminant cleaning and air release from within the heating pipes and if
the pipes are old, make sure you replace the heating pipes.
When installing condensed water discharge hoses, make sure the pipes where they can
be frozen must be insulated.
Condensing boiler needs a release device since condensation occurs inside the boiler.
Connect the included condensed water discharge hose to the siphon exit at the bottom of
the boiler and the end of the release hose must be connected to the sewage or the water
conduit.
When using a separate release hose, use vinyl or plastic hose with more than 13 mm in
diameter.
The siphon inside the boiler must be always full of water and if there is no water, fill it with
water through the exhaust duct.
Condensed water should not be used for drinking water.
In case of a blockage due to contaminants inside the siphon, the condensed water cannot
be released and the boiler goes in lock-out condition. Thus, please clean out the siphon at
least once a year. (Cleaning Method : removed the clip the cup in the bottom side of the
siphon.
Be careful because of the siphon is full of condense. Then, please collect condensate
water with a basin under the siphon
Condensed Water Discharge
Gas Boiler KCA Model

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Available Head to the System

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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.
Pipes must be completely insulated.
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.)
If any freezing may occur, condensed water discharge hose must be completely insulated
with insulation material.
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.
The exposed parts must be protected from freezing by covering with at lease 25mm of
insulation material. (Colder locations it should be at least 5 mm.)
<General Cautionary Items in Pipe Construction>
Each connection part must be tightened with union or nut.
Water supply pipe, hot water pipe, heating pipe, distributor, and check valve must be
insulated to prevent freezing.
Pipe materials must be national or local standard materials.
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)
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.
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.
 Any contaminants inside the pipes reduce heating and hot water efficiency and causes
malfunctions.
 Please completely remove any air from each of the pipes.
Recommendations
Anti-Freezing Guard