Navien KDB-735GTD, KDB-535GTS, KDB-535GTG, KDB-535GPS, KDB-735GTS Installation Manual
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Medium-sized gas boiler
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1. Precautions for safety--------------------------------------30
2. Outside drawing of the boiler ----------------------------31
3. Safe and correct installation method --------------------34
4. Electric wiring installation --------------------------------37
5. Gas piping installation-------------------------------------39
6. Heating and hot water piping installation --------------41
7. Exhaust / Intake vent installation ------------------------47
8. Temperature controller installation ---------------------- 52
9. Check points for test operation---------------------------53
10. Electric wiring diagram --------------------------------- 55
11. Specifications------------------------------------------------56
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This installation manual is subject to change without notice for quality improvement.
Table of
contents
Medium-sized gas boiler
30
Precautions for safety
The instructions provided in this installation manual include important
information for safe use of this product. Failure of complying with
those instructions may result in death, severe injury, or tremendous loss
of property.
The instructions for safe use are classified into ‘Danger’, ‘Warning’,
‘Caution’
by the degree of danger, which respectively contains the
following meaning.
Violation of instructions may cause a seriously dangerous
situation such as death or a severe injury
Violation of instructions may cause a potentially dangerous
situation such as death or severe injury.
Violation of instructions may cause a potentially dangerous
situation such as a light or half-serious injury.
Violation of instructions may cause a situation such as a
property loss, product malfunction, or deteriorated performance.
1) The symbols provided in the product and the installation manual contains the
following meaning.
This symbol implies that “precautions” shall be taken against a possibility of a
personal injury under a specific condition.
This symbol implies that a “prohibition” shall be made against a possibility
of a personal injury or a property loss under a specific condition.
This symbol implies that the instructions shall be complied with.
2) The warnings and cautions specified in the installation manual do not include all
the possible safety precautions to be taken for using the product. Consequently,
utmost care shall be taken for safety during use of the product.
1
Medium-sized gas boiler
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Outside drawing of the boiler
Model no.:
KDB-535GTD, GTS, GTG
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The sizes in the blank “( )” are applied to the model no..
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A dedicated boiler (GTS, GTG) is not supplied with the hot water inlet and outlet on the rear of
the boiler.
Model no.:
KDB-535GPD, GPS
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The sizes in the blank “( )” are applied to the model no.
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A dedicated boiler (GPS) is not supplied with the hot water inlet and outlet on the rear of the
boiler.
2
Medium-sized gas boiler
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Model no.:
KDB-735GTD, GTS, GTG
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The sizes in the blank “( )” are applied to the model no..
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A dedicated boiler (GTS, GTG) is not supplied with the hot water inlet and outlet on the rear of
the boiler.
Model no.:
KDB-735GPD, GPS
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The sizes in the blank “( )” are applied to the model no.
※
A dedicated boiler (GPS) is not supplied with the hot water inlet and outlet on the rear of the
boiler.
Medium-sized gas boiler
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Model no.:
KDB-1035GPD, GPS, GPG
1535GPD, GPS, GPG
2035GPD, GPS, GPG
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The sizes in the blank “( )” are applied to the model no. 1535, and those in the bracket “[ ]” are to the
model no. 2035GPD, GPS, GPG.
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A dedicated boiler (GPS, GPG) is not supplied with the hot water inlet and outlet on the rear of the
boiler.
Medium-sized gas boiler
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Safe and correct installation method
After completion of installation, be sure to return the user’s (installation) manual to the user.
Be sure to check the gas to be used in the
installation place, prior to installation.
Use of the gas, other than the one specified on the
name plate on the front of the boiler, may result
in a fire or explosion.
Be sure to check the power supply gas to be
used in the installation place, prior to
installation.
The power supply, if higher or lower than the one
specified on the front of the boiler, may cause a fire.
After reading the following instructions, install the product in a safe and correct way as
specified in the instructions.
Never install the boiler in a place with
inflammable objects.
Highly inflammable materials, such as volatile
oil or alcohol, may cause a fire during ignition of
the boiler.
Install the boiler in a boiler room free froml
the impact of rain and wind.
Incomplete combustions, resulting from rain and
wind, may eventually lead to a carbon oxide
poisoning.
3
Before installation
Selection of the installation place
Medium-sized gas boiler
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Never install the boiler in a moist or enclosed
place such as a bathroom, a toilet.
Incomplete combustion, caused by oxygen
deficiency, may lead to a carbon oxide poisoning.
Installation in the above place may also cause
earlier product malfunctions.
Never install the product with corrosive gas
such as ammonia, chlorine, sulfur, acids.
Corrosive gas may damage the boiler and cause
incomplete combustion, eventually leading to a
carbon oxide poisoning.
Never install the boiler in the following areas.
Do not install the boiler near the electric equipment.
Do not install the boiler in an uneven or unstable place.
Do not install the boiler in a place with highly combustible materials.
Do not install the boiler in a place inadequate for safe gas piping installation.
Do not install the boiler in a place with special chemical agents
(generating combustible or corrosive gas).
Do not install the boiler in a place where it is difficult to get access to the
stairway or the exit for escaping.
Do not install the boiler in a place which is not well drained.
Do not install the boiler below the shelf with unstable objects.
Do not install the boiler in a place where it is difficult to conduct
maintenance of the boiler after installation.
Do not install the boiler in a place with noise and air pollution.
Do not install the boiler in a place where the wind generated from a vent, a
range, and a hood have an impact on the air intake and exhaust.
Do not install the boiler in a place which is not well-ventilated.
Do not install the boiler in a place with strong wind.
Do not install the boiler in a place where it is difficult to install the
chimney pipe (chimney).
Be sure to install the boiler in a sufficient place for check up and repair of
the boiler.
A space of more than 1m shall be provided in front of the boiler, in order to
perform maintenance and checks.
Other considerations
Medium-sized gas boiler
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Install the boiler on the surface with a structure capable of enduring the load of the boiler (weight). (Refer to the
specifications presented in the user’s manual.)
Install the boiler in a horizontal, upright position so that the boiler does not lean toward one side.
Installation shall be made for the front side of the boiler to face forward.
Install the boiler to be fixed on the floor, in order to prevent vibration during operation.
Sufficient light shall be provided with the boiler room in order to help to observe the boiler equipment by sight
and offer the after-sales service for the equipment.
Be sure to install the boiler in the dedicated boiler room. (The boiler room shall be designed so that the gas
emitted from the boiler does not flow into the living room, and the wall between the boiler room and the
living room shall be made of the fireproof materials, except for the entrance / exit door.)
The dedicated boiler room shall not be equipped with the ventilating fan which causes the negative pressure (the
pressure lower than the atmosphere pressure).
The dedicated boiler room shall not be equipped with the exhaust duct of the gas range (hood) which leads to air
flowing in and out of the living room and the kitchen.
Installation of the boiler shall not be made nearby the place for storage and treatment of the combustible or
inflammable objects. A sufficient space shall be provided for boiler installation as presented in the following
figure, in order to perform the control, combustion, check-ups and repair of the boiler.
The top of the boiler body shall be kept at least 1.2m away from the structures such as the ceiling and the piping.
The boiler body shall be kept at least 450mm away from other structures such as the wall and the piping on the side of the
boiler.
The front of the boiler shall be kept more than 1m away from the structures in front of the wall.
The boiler shall be kept away from the nearby combustible objects, as illustrated in
the following figure.
Appropriate facilities such as the casing shall be equipped with the boiler to prevent the rain from permeating into
the boiler.
The waterproof treatment shall be applied to the exposed insulation materials or lagging.
Proper measures shall be taken to protect the water pipe outside the boiler from getting frozen.
Proper measures shall be taken for boiler combustion to be protected against snow, rain and wind.
Precautions for boiler installation in a dedicated boiler room
Boiler installation method
Precautions for installation of the boiler in the outdoors
Medium-sized gas boiler
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Electric wiring installation
The electric wiring installation shall be
performed to comply with the power supply of
the product.
The power supply, if higher or lower than the one
specified on the name plate on the front of the
boiler, may cause a fire.
Do not connect the power supply to the boiler until the
electric wiring installation is completed.
With the power supply on, the electricity flowing through the
boiler may cause an electric shock.
Install the power outlet in a place free from the
impact of rain and moisture.
Electric leakage, possibly resulting from rain and
moisture, may cause a fire.
4
Medium-sized gas boiler
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Never make a ground connection to the lightning
rods and the gas pipe.
Ground connection to the lightning rod may result in a boiler
malfunction.
Ground connection to the gas pipe may result in an explosive
accident.
Be sure to use the magnet switch for connection of the
circulation pump with more than 1.5kW.
The boiler may malfunction, without the magnet switch.
Install the electric wiring as presented in the electric wiring drawing in the installation manual.
Install the dedicated power outlet for the boiler, with a length of less than the effective length of
the power cord. Installation shall be made for the power outlet not to get in contact with the drain
valve of the boiler.
Use the power outlet with a cover attached, and install the outlet at more than 300m above
ground level.
If the power outlet is not provided with a cover, install the outlet in a place free from the impact
of rain or moisture, or in the waterproof box or the indoor distribution box.
Never install a switch onto the power cord, nor use the power outlet with a switch attached. (The
boiler does not operate, when the switch is set at off.)
A ground connection shall be installed, if not, on the side of the power outlet.
The wires of the room temperature controller shall be connected through the insulation pipe with
a thickness of more than 4mm. The insulation pipe shall be installed and concealed with an
upper gradient toward the indoors.
The wires of the circulation pump, connected to the controller, shall not be
short-circuited.
Correct electric wiring installation
Medium-sized gas boiler
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Gas piping installation
Be sure to perform the gas leak test after gas pipe
installation, replacement of the burner, or the
supply pressure or head pressure test.
Retention of the leaked gas, combined with static electricity or
spark, may cause a fire
In preparaion for the unexpected gas leak, be sure
to install the gas leak alarm device and the gas
breaker in the boiler room.
Retention of the leaked gas, combined with static electricity
or spark, may cause a fire
Be sure to check the gas to be used for the product
prior to gas piping installation.
Use of the gas, other than the one specified on the name plate
on the front of the boiler, may cause incomplete combustion,
eventually leading to a fire or explosive ignition.
Install the gas holder, if used, in the well-ventilated
outdoor without above ground high voltage power
line. The gas holder shall be fixed not to fall down
on the ground.
If the gas holder falls down or gets in contact with the high
voltage power line, an explosive accident may occur.
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