Saturn KDB - 161 GOM, KDB - 251 GOM, KDB - 201 GOM, KDB - 301 GOM User Manual

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KDB-GOM

Series

- 1 -

1. Specifications of the KDB-GOM series

1.1 Kyungdong Boiler Product Features and Functions

1.2 Specifications

2. Operating Types/Constructions/Schematic Diagram

2.1 Operating Types

2.2 Constructions of the Boiler

2.3 Schematic Diagram of Operating

3. Equipment Protection and Personal Safety

4. Specifications and Functions of the Major Components

4.1 Main Heat Exchanger

4.2 Fan Assembly

4.3 Circulation Pump

4.4 Modulating Gas Control Valve

4.5 3-Way Valve

4.6 Expansion Tank

4.7 Air Pressure Switch

4.8 Hot Water Flow Sensor

4.9 High Limit Sensor(Bimetal Type)

4.10 High Limit Fuse(Fuse Type)

4.11 Heating Temperature Sensor

4.12 Ignition Transformer

4.13 Power Transformer

4.14 Domestic Hot Water Heat Exchanger

4.15 Burner Assembly

4.16 Nozzle Holder Assembly

4.17 Wiring Diagram

4.18 Main Controller

Technical Information

KDB-GOM

Series

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THE KDB -GOM

THE KDB -GOMTHE KDB -GOM

THE KDB -GOM

KYUNGDONG BOILER’S VARIABLE-CAPACITY-MULTI-PURPOSE

82%+ HYDRONIC HEATING SYSTEM

How does it work?

The KDB-GOM provides 2 different heating functions that operate independently from the same boiler. One mode provides space heating water to heat the home. The other mode provides a continuous circuit of hot water for domestic use eg, bath, laundry, etc. Both circuits are separate and operate at different temperature ranges.

The space-heating water is controlled by the FR-5 thermostat. A special thermostat has been provided that enables the user to either set the room temperature required of set the heating water temperature. In some cases this thermostat may not be suitable for multi-system applications. (The installing contractor will make this determination and install suitable alternative controls.

The domestic hot-water is controlled by the user. Because the KDB-GOM is a multi-purpose design, it can provide hot water on demand, there is no storage tank to hold hot water, when there is no use for it. The KDB-GOM will only produce hot water when you use it : instantaneous. The modulating gas burner allows water to heat up as evenly as it is being used. The KDB-GOM will continue to heat the water until the source or sources are shut off. This on-demand-use also helps to prevent water being held in the boiler for long periods of time.

IMPORTANT:

A thermostatic mixing valve should be installed on the domestic water supply pipe to control the supply water temperature and prevent any possibility of scalding.

Domestic hot water priority

The GOM prioritizes bath water over space-heating water and will immediately stop producing space-heating water the moment a hot water valve is opened anywhere in the home. Once the valve has been turned off, the boiler will return to the home-heating function again.

The seal-combustion process

The KDB-GOM is designed with a special sealed-combustion venting process. Both sides of the combustion process (inlet oxygen and outlet carbon monoxide) are isolated from each other and are totally sealed-off from the air supply within the home. This reduces drafts, caused by infiltration, by as much as 82% making the KDB-GOM one of the safest, most comfortable and clean-burning boilers in the world.

1. Specifications of the KDB-GOM series

1. 1 KyungDong GOM Product Features and Functions

A. Continuous Hot Water

Its On Demand! KyungDong Boiler makes running-out-of-hot-water obsolete.

B. Everything Built-in

Installs in half the time. We tried to think of all the parts and accessories you’ll need (plus a few you might have

forgotten) and built them into this multi-purpose hydronic heating system. You’ll spend less time driving to all the supply

houses.

KDB-GOM

Series

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C. Baked-in Beauty

The high quality porcelain finish is bake on and keeps the exterior looking new and lustrous for years to come.

D. System Timer

Save energy during times the home is unoccupied. Just set and activate the timer and leave. The unit turns off for pre-programmed intervals until you return.

E. Room Thermostat FR-5

Convenient and accurate, large digital display is easier to read, easier to use. Our new room thermostat gives the consumer digital control over several heating function.

F. Performance Indicator

With the use of the FR-5 electronic room thermostat, the (LED) will conveniently display the current operating condition of the unit such as temperature of heating water, room temperature, normal operation, etc.

G. Continuous-Discharge Ignition(C.D.I.)

Direct ignition design requires no wasteful pilot burner and offers fuel savings.

H. Combustion Safety Protection

If the unit fails to ignite after the “ON” switch is pressed, or if the flame is extinguished due to a gas shortage, the flame sensor will shut down the unit.

I. Always Balanced Operation

Despite fluctuating wind conditions, changes in atmospheric pressure and other external disturbances, the

variable-speed combustion blower provides steady performance.

J. Exhaust Safety Protection

While operating, the exhaust-discharge fan is continuously monitored. The units will be immediately stopped to prevent fumes from entering the home if the wind gusts become excessive or if the flue exhaust has been clogged.

K. Smart Re-Start

Should the unit’s flame fail due to strong winds or temporary low gas pressure, the unit will automatically restart. In cold weather climates, manual resets could cause freeze damage.

L. Safety Protection during Power Outages

When the power fails, the gas is automatically shut down and the units are stopped.

M. Automatic Fill & Refill

If for any reason the water level in the system drops to an unsafe level, makeup water will automatically fill to the appropriate levels.

N. Automatic Air Bleed

Each unit has 2 built-in air bleed devices. One is manual and used for quick fill and venting convenience; the other is air-activated and operates and automatically.

O. Removal of Impurities

Each unit come equipped with a built-in, clearable, heavy duty, particulate water filter for trapping impurities and preventing the clogging of pipes. This is a maintenance item.

P. Air-Ratio Controller

Air ratio is monitored, adjusted and controlled prior to and during each operating cycle and will automatically adjust the combustion rate. The air-ratio controller guarding against unsafe operating conditions also senses excessive gusts of wind filling the flue system.

Q. Proportional Temperature Control

This control is designed to continually analyze water flow and usage while maintaining the outgoing water at a constant, even temperature.

KDB-GOM

Series

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1.2 Specifications

GAS WALL-MOUNT

FRONT

View

Full, Dual Function Heating Design.

Natural and Propane Gas M odels.

Pow er-Vent, 2-Pipe C ombustion Process.

Modulating Gas for Precis ion Tem peratures.

REA R

Built-in Circulation Pump Assembly .

View

Built-in Ex pans ion Tank. Quiet, Vibration-Free Operation.

Built-in Freez e Protection.

Digitally Controlled, Full-Logic T hermostat.

Funct ion

SIDE Vi

CENTR AL HEATING WATER

(LEFT

)

Const ructi on of Heat Exchanger

Heat Output (kcal/hr)

6,400

~ 16,

000

8,000

~ 20,

000

10,000

~ 25,

000

12,000

~ 30,

000

Max.Effici ency (%) 82 82 83 84

(wall)

Temperature Setting Range (℃)

Maxim um Working Pressur e (kgf/cm2) Pre- Charged Ex pansion Tank (l iter ) 6.5 6.5 8.5 8.5

Circulation Pump

Freeze Protection Device

DOMESTIC HOT WATER

Heat Output (kcal/hr)

6,400

~ 16,

000

8,000

~ 20,

000

10,000

~ 25,

000

12,000

~ 30,

000

Max.Temperature Setting (℃)

Conti nuous DHW product ion

△T = 25 ℃

(liter )

10.7 13.3 16.7 20.0

Conti nuous DHW product ion △T = 33 ℃ (liter )

8 10.0 12.5 15.0

Conti nuous DHW product ion △T = 40 ℃ (liter )

6.7 8.3 10.4 12.5

Conti nuous DHW product ion △T = 50 ℃ (liter )

5.3 6.7 8.3 10.0

SIDE Vi

Maxim um Working Pressur e (kgf/cm2)

(RIGHT)

OTHER DATA

Gas Type

Gas Consumption - LP (kg/hr)

1.58

1.98 2.48 2.97

(wall ) Gas Consumption (natural gas) (kcal/hr ) 19,000 23,700 29,700 35,600

Gas Inlet Supply Pressur e (natural: kPa) ( min - max)

Manifold Pressure (kPa) 0.16 ~ 0.92 0.16 ~ 0.96 0.25 ~ 0.94 0.14 ~ 0.96

Usage ( Heating & H ot Water )

Water Storage Capacity (liter) 0.7 0.7 0.8 0.8

Power (volts/cycle)

Power Consumption (watts)

Ignition

NOx Emi ssions

(Ref:0%, O2 in flue gas natural gas, ppm)

E F G D

Temp. of Exhaust Gas (℃)

WEIGHT AN D DIMENSIONS

Net Weight (l bs) 31 31 39 39

BOTTOM

A Physi cal Dimensions: Hei ght (mm) 630.0 630.0 685.0 685.0

View

B Wi dth (mm) 485 485 525 525 C Depth (mm) 235 235 250 250

D C onnection: Gas Inlet 15A, 1/2" 15A, 1/2" 20A, 3/4" 20A, 3/4" E C onnection: Heating Water Supply/Return

F C onnection: Domestic H ot Water Supply/Return

(front) G C onnection: Primary Power (AC220V-50Hz)

H F lue Diameter (Intake / Exhaust) (mm)

TOP

Specif ication s s ubject to c hange with out prior not if ication

View ( wall )

- 2865 PELLISSIER PLACE - W HITTIER, CA 90601 - (562) 463-0880

15A, 1/2"

70 / 75

28 (l ess than)

150 (l ess than)

20A, 3/4"

Dual

AC 220V- 50Hz

120 ~ 160

ELECT RONIC

17.5

Liquefied Petroleum ( L.P.) or Natural Gas

0.98 ~ 2.45

40 ~ 80

Self Pr imi ng

Ther mis tor

MODEL NUMBER

Combo Boiler

Stainl ess Steel / Copper

161 GOM 201 GOM 251 GOM 301 GOM

w ith 1-Year on Parts.

KYUNGDONG BOILER SPECIFICATIONS

C on trols Bo th Water F unction s Separ ately .

On-Demand Hot Water Delivery.

Com pact, Space-sav ing Design.

Limited Warranty on Heat Exc hanger

---- KEY FEATURES

Prov ides Hi-Temp Water for Heating the Home.

Pr ov ide s Hot Wate r fo r B athing & Wa s hing.

KDB - 161 / 201 / 251 / 301 GOM

Residential Gas Hydronic Heating System

GAS FIRED, WALL-MOUNT ED, MULT I-PURPOSE, HYDRONIC HEATING SYS T EMS

MODEL RAN GE : 16, 000 ~ 30,000 kcal/hr

 



KDB-GOM

Series

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2. Operating Types/Constructions/Schematic Diagram

2.1 Operating Types

Item Specification

Installation

Wall Mount Type

Flue Type

Both Use FF and FE

Usage

Both Use Heating and Domestic Water (Single Pipe, 2 Waterways)

Water Supply for

Heating

Maintain normally at a constant water pressure by pressure reducing valve

(Auto / Manual)

Control Method

Proportional Control Method by MICOM

Heat Exchanger Type

Single Dry Type (131/161/201GOM) and Single Wet Type (251/301/351GOM)

Combustion Method

Air Intake Method by Semi-Bunsen Burner

Gas Flow Control

Current Proportional Control Method by Thermistor

Heat Exchange

Method of Hot Water

y Heat Exchange Method : Indirect Heat Exchange by Secondary Heat Exchanger y Heat Exchange Type : Plate Formed Brazing Heat Exchange y Heat Exchange Circuit : Parallel Circuit

Ignition Method

Continuous Discharge, Direct Ignition Method

Heating

Domestic Water

Changeover

Heating Priority, Changeover to Domestic Water Circuit by 3-way Valve

Domestic Water Signal

Detect Flow by Flow Switch

y Motor : Condenser Type y Casing : Engineering Plastic

Circulator Pump

y Impeller and Shaft Coupled : Magnetic Type

Expansion Tank

y Type : Expansion Tank y Volume:6.5Liter(161/201GOM), 8.5Liter(251/301GOM)

Pressure Reducing /

Flow Limiting Control

and Water Hammering

Prevention

Control Pressure Reduction/Flow Limit and Prevent Water Hammering by Diaphragm

KDB-GOM

Series

- 6 -

2.2 Constructions of the Boiler

■

Model : KDB

Model : KDB Model : KDB

Model : KDB – 251 / 301 GO M

251 / 301 G OM 251 / 301 G OM

251 / 301 G OM

■

Model : KDB – 161 / 201GOM

KDB-GOM

Series

- 7 -

2.3 Schematic Diagram of Operating

2.3.1 Schematic Diagram at the Heating Water Supply

High Limit Fuse

Fan Assembly

Heating Temperature

Sensor

Hot Water Flow Switch

Modulating Gas Control Valve

Expansion Tank

Air Pressure Switch

Nozzle Holder Assembly

Burner Assembly

Flame Detector

Electrode

High Limit Sensor

②

Main Heat Exchanger

Exhaust Duct

③

3-Way Valve

Gas Inlet

Domestic Water Outlet

Tap Water Inlet

⑥

Heating Return

④

Heating Supply

⑦

Heating Strainer

①

Circulator Pump

Flue Exhaust

Heating Flow Sensor

Combustion Air Inlet

Domestic Water

Heat Exchanger

①

Circulator Pump → ② Main Heat Exchanger → ③ 3-Way Valve → ④ Heating Supply

⑦

Heating Strainer → ⑥ Heating Return → ⑤ Room Heating(Heating Coil, Radiator)

KDB-GOM

Series

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2.3.2 Controls of the Heating Temperature

2.3.2.1 When the heating water temperature is selected

- Setting Temperature: 40 ~ 80

℃

- To stop the run, turns the “HEATING WATER TEMP.” dial to “OFF” position.

2.3.2.2 When the heating is controlled by the room temperature

- Setting Temperature: 10 ~ 40

℃

- To stop the run, turns the “ROOM TEMP.” dial to “OFF” position.

2.3.2.3 When the heating with the repetition time (TIMER)

- The timer sets the stop time between 0 to 4-hours.

- Press the “TIMER” button, the boiler runs for 20minutes and stops for the time set by the timer.

- The temperature of the heating water is automatically set at 80 ℃ and the temperature indicator displays the room temperature.

※

If the range of control has been exceeded due to the change in the set temperature or to abrupt change in

flow, the set temperature will be reached through the proportional control with the delay of 30±3 seconds. If 83 ℃ is exceeded, the delay of 30±3 seconds will not be performed.

Control Range

Setting Temperature,

“T” set

ON OFF

Over 78

℃

63±2.0

℃

83±2.0

℃

70 ~ 77

℃

“T” set – (14±2.0)

℃

“T” set – (6±2.0)

℃

60 ~ 69

℃

“T” set – (12±2.0)

℃

“T” set – (6±2.0)

℃

50 ~ 59

℃

“T” set – (10±2.0)

℃

“T” set – (5±2.0)

℃

Below 49

℃

“T” set – (10±2.0)

℃

“T” set – (5±2.0)

℃

KDB-GOM

Series

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2.3.3 Schematic Diagram at the Domestic Water Supply

Fan Assembly

Heating Temperature

Sensor

②

Hot Water Flow Switch

Modulating Gas Control Valve

ⓐ

Expansion Tank

Air Pressure Switch

Nozzle Holder Assembly

Burner Assembly

Flame Detector

Electrode

High Limit Sensor

ⓒ

Main Heat Exchanger

High Limit Fuse

Exhaust Duct

ⓓ

3-Way Valve

Gas Inlet

Domestic Water Outlet

Tap Water Inlet

Heating Return

Heating Supply

Heating Strainer

ⓑ

Circulator Pump

Flue Exhaust

Heating Flow Sensor

Combustion Air Inlet

③

Domestic Water

Heat Exchanger

③

Domestic Water

Heat Exchanger

Domestic Water Line

Heating Water Line

ⓒ

Main Heat Exchanger

④

Domestic

Water Outlet

②

Hot Water

Flow Switch

①

Tap Water Inlet

ⓓ

3-Way Valve

ⓑ

Circulator Pump

ⓐ

Expansion Tank

KDB-GOM

Series

- 10 -

2.3.4 Controls of the Domestic Water Temperature

2.3.4.1 Possible use of hot water in heating/not-at-home mode and hot water exclusive mode, according to the flow volume detection of the hot water sensor.

2.3.4.2 Indirect control of the hot water temperature based on the heating water temperature.

2.3.4.3 Control at 80℃ when using hot water during heating.

2.3.4.4 Control at 70℃ when not-at-home or hot water exclusive mode

2.3.4.5 Stand by after hot water use

y when stopped after hot water use, the fan does not perform post purge and maintain the ON status for 90 seconds.

y the pump stops after the post purge (60 seconds)

y when using hot water again and after the hot water sensor detects the flow volume

pre-ignition Æ fuel supply Æ flame detection Æ post-ignition

y return to the before-hot-water-use status 90 seconds after the use of hot water.

2.3.4.6 Combustion in progress while in stand-by for hot water (90 seconds) or after 12 seconds of the post purge time ( while in heating mode after the hot water sensor if “OFF”). Hot water stand-by time in progress separately.

3. Equipment Protection and Personal Safety

A. Ignition Failure

If the ignition fails, the gas supply is automatically cut off. An error code will appear as a flashing 2-digit code on the room

thermostat(models FR-5 only). The error codes are discussed in the troubleshooting section of the installation manual.

B. Flame Detection

If the fails and/or the re-ignition attempt fails, the gas supply is automatically cut off. An error code will appear on the room

thermostat(models FR-5 only).

C. Power Interruption

When the power is restored after a power failure, the boiler will automatically start and return to normal

operation(Manual reset is not required).

D. Excessive Air Pressure

Occasionally an excessive gust of wind from outside may be forced into the flue pipe. The air-ratio control module

will detect these strong back-drafts. To prevent any products of combustion from re-entering the building through the open flue, the gas supply will be automatically cut off. An error code will appear on the room thermostat(models FR5 only).

E. Explosive Re-ignition Protection

Abrupt, noisy startups and backfires are prevented by means of soft ignition, a trademark of our air-ratio control module.

F. Overheat Protection

Any overheating of the burners or heat exchanger will automatically shut down the supply of gas to the burners.

An error code will appear on the room thermostat(models FR-5 only).

G. Low Water-Level Safety

Water levels in the heating pipes are continuously monitored to prevent the boiler from operating if there is no

water or a restricted flow through the piping. The boiler will automatically shut down and an error code will appear on the room thermostat(models FR-5 only).

KDB-GOM

Series

- 11 -

H. Automatic Water Fill

Should the water level in the system drop too low, a sensor will automatically activate the re-fill circuit.

I. Freeze Protection

During the heating season, a sensor inside the boiler will automatically detect and initiate safe heating cycles to prevent internal

equipment damage from occurring should freezing temperatures surround the boiler.

Note !

- When there is no gas supply available, the circulating pump will automatically start up to guard the pipes from freezing (available only in boilers equipped with a circulation pump).

J. Gas Pressure Control

To prevent internal damage from rupture, each boiler is protected from occasional surges in gas pressure by a regulating governor

device located in the gas valve.

K. Short-Circuit Protection

Any short-circuits occurring inside the boiler’s electrical circuit will immediately ‘blow’ the internal glass fuse(s) and automatically cut off the gas supply.

L. Lightening Protection

Each boiler is specially grounded inside and out to protect against lightening strikes.

M. Combustion air flow control

When the combustion airflow is disrupted due to a defective, obstructed or an abnormal back-pressure of the flue, the combustion is shut off safely.

N. Thermostat Control Failure

Should the thermostat fail to function properly, as a safeguard, the boiler’s gas supply will be automatically shut down.

KDB-GOM

Series

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4. Specifications and Functions of the Major Components

4.1 Main Heat Exchanger

Item

161GOM 201GOM 251GOM 301GOM

Typ e

Single Dry Type Single Wet Type

Structure

Copper Fin＋Copper pipe Brazing

Function

- For use of heating and hot water, absorb generated heat from main burner and then transmit it to heating pipe and hot water heat exchanger.

Number of Heat Fin

72 Fin 80 Fin 106 Fin 112 Fin

Material & Dimension

- Copper Pipe:C1220T-H(φ15.88).

- Heat Fin:C1220P-1/4H(t=0.4)

Heat Exchange Method

Instantaneous Method

KDB – 251 / 301 GOM

KDB – 161/201GOM

KDB-GOM

Series

- 13 -

4.2 Fan Assembly

Item

161GOM 201GOM 251/301GOM

Fan Type

Phase Controlled Air Intake Fan

Motor Type

Shading Coil Induction Motor Condenser Induction Motor

Blower Dimension

(mm)

100 X 40L X 45 Fin

134 X 40L X 60 Fin

Function

- Supply air needed for combustion and exhaust the remained gas before and after combustion in order to prevent explosion in advance.

Bell Mouth(mm)

70 -

Rated Voltage

AC 220V, 50Hz

Power Consumption

Max.: 36.4 W, Min.: 14.0 W Max.: 75 W, Min.: 30 W

Casing

ALDC12

Blower

AL 5052

Material

Venture

ALDC12

KDB – 161 / 201GOM

KDB – 251 / 301GOM

KDB-GOM

Series

- 14 -

4.3 Circulation Pump

Item

All GOM models

Pump Type

Magnet Type

Motor Type

Single Phase, 2 Pole Induction Motor

Function

- Transmit the absorbed heat from main heat exchanger to heating pipe by circulating heating water when use heating.

- Transmit the absorbed heat from main heat exchanger to hot water heat

exchanger by circulating heating water inside of boiler when use hot water.

Maximum Pump Head

10M(at 0 gal/ min )

Rated Voltage

AC 220V, 50Hz

Power Consumption

90 W

Condenser Capacity

2.5

㎌

Weight

2.45 kg

KDB-GOM

Series

- 15 -

4.4 Modulating Gas Control Valve

Item

All GOM models

Model No.

UP 33 –06 (TIME CO.)

Rated Voltage

AC 220V, 50 / 60Hz

Power Consumption

8 W

Function

y Controls the flow of gas supply by the current value received from main

controller.

y Cut off the gas to prevent danger by the signal of sensor when happen troubles

caused by improper combustion.

Magnet Valve Proportional Valve

Schematic Diagram

SV1

(UV3)

SV2

(UV3)

(UP2)

(SV1)

(SV2)

(PV)

Secondary pressure

Adjust Screw

Gas flow diagram

KDB-GOM

Series

- 16 -

4.5 3-Way Valve

Item

All GOM models

Rated Voltage

AC 220V, 50 / 60Hz

Power Consumption

3 W

Body Material

NYLON 66

Function

- Block the passage of heating water by the flow detection in flow switch and flow heating water into the hot water heat exchanger when use hot water, and lead to exchanging the heat of hot water with heating water in the hot water heat exchanger. (When stop using hot water, the water passage is changed over to the way of heating pipe automatically.)

Heating → Hot Water 10 ± 2 sec

Operating Time

Hot Water → Heating 10 ± 2 sec

Wire Identification

y RED : Heating, y BLUE : Hot Water y BLACK : Common

Model

Motor Speed

2.5 ~ 3 RPM

Direction of Motor

Rotation

CCW

KDB-GOM

Series

- 17 -

4.6 Expansion Tank

NO. Part Name Material Remarks

1 Body SBHG1 , 2.0t

2 Bracket SBHG1 , 2.0t

3 Diaphragm BUTYL , 2.0t

4 Nipple S10C , PF3/8”

Item KDB – 161 / 201GOM KDB – 251 / 301GOM

Vol um e

6.5 Liter 8.5 Liter

Body Material

SBHG 1

Charging Gas

Nitrogen

Charging Pressure

1.0 kg/cm2 (14.2 psig)

Function

y Vent the generated air in the heating pipe.

y Absorbs pressure generated in the pipe by the expansion of heating water due to

increasing temperature of heating water.

y Maintain the water volume in the boiler at a constant by low water level sensor.

Nitrogen gas

Charging point

KDB-GOM

Series

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4.7 Air Pressure Switch

Item All GOM Model

Electric Rating

0.1A –125V AC, 0.1A –30V DC (Micro Switch)

Typ e

Differential Pressure Type (Vertical Type), Normal Close Type

Body Material

Nylon 66 (GF 30%)

Function

- Stop the combustion safely and automatically by monitoring the high pressure or the adverse wind in the flue.

Contact Arrangement

ON more than 2.0 mmH2O

ON / OFF Operating

Pressure

OFF 7.0 ± 2 mmH

Reference

- Normal Close Type : The contact is always connected, and if the wind

pressure switch is operated by adverse pressure, this contact is opened and stop the combustion in the boiler.

P3 (COM)

P1 (NC)

P2 (NO)

KDB-GOM

Series

- 19 -

4.8 Hot Water Flow Switch

Item All GOM models

Body Material

Nylon 66 (GF 30%)

ON 2.3 ± 0.3 liter / min

Operating Flow

OFF 1.5 ± 0.5 liter / min

Installation Type

Horizontal Installation

Function

- When use hot water, detect the flow of hot water and transmit the signal to controller, and operate 3-way valve to usable hot water.

- Reduce the pressure of discharging hot water in case of high water pressure area (water supply pressure : more than 1.5 kgf/㎠) and maintain the optimum condition of hot water use through flow limited by reduced pressure.

Reducing Pressure

Capability

P1 : 0.3 ～ 10 kgf/

㎠

→ P2 : 0.3

～

3.0 kgf/

㎠

Contact Rating

10 VA (W)

Maximum Contact Current

AC, DC 0.5A

Contact Resistance

less than 300 m

Ω

수동󰼿물보충

KDB-GOM

Series

- 20 -

4.9 High Limit Sensor (Bimetal Type)

Function

- When the bimetal plate in the high limit sensor detects the increase in the heating water temperature or in causing surface temperature, it is transformed to move the shaft and to let the contact “OFF”

- The “OFF” signal from the high limit sensor is sent to the controllers so that the check lamp on the room thermostat comes “ON” and the failure code NO. 16 is displayed on the temperature indication. When the running is resumed, only the check lamp is kept “ON”.

- In case of reduced discharge of combustion exhaust or overheat of heat

exchangers, the high limit sensor automatically cut off the gas control valve to close it when the send the sensed the temperature of the heat exchanger reaches 95 ℃ or higher. The check lamp on the room thermostat is lit and failure code NO. 1 is indicated on the indication panel.

Model MS-1, Manual Reset

Type Bimetal Type

Operating Temp. 95

℃

Structure

Recovery Temp.

℃

Voltage Rating 125 ~ 250 V

Electric Rating

Current Rating 15 A

[Automatic, MS-1]

KDB-GOM

Series

- 21 -

4.10 High Limit Fuse (Fuse Type)

Function

- In case of abnormal overheat of heat exchanger, the temperature of sensor

part will be more than 195 ℃, high limit fuse will cut off the power of modulating gas control valve to close the modulating gas control valve and secure the safety.

- Check lamp will on in the room thermostat and failure code # 03 will be

indicated.

Type Fuse Type

Structure

Operation Temp. OFF point: 195

℃

Electric Rating

Resistance

61.1 Ω at 20

℃

KDB-GOM

Series

- 22 -

4.11 Heating Temperature Sensor

Item All GOM models

Model No.

DKS - 902ET - 330C

Resistance

R50 = 3.485 ㏀ ± 3%

B Constant

R0 / R100 = 3449 K ± 1%

Thermal Radiation Constant

0.7

mW /

℃

Thermal Time Constant

Within 10 seconds

Function

- Detect the temperature of heating water and transmit the signal to main controller. The main controller controls the flow of air / gas needed for achieving and maintaining the setting temperature.

KDB-GOM

Series

- 23 -

4.12 Ignition Transformer

Function

- Electric energy provides high voltage and current to the main burner for ignition of gas.

Primary Rating AC 220 V , 50 / 60 Hz

Secondary Rating 19 kVo-p±2

Power Requirement

Secondary Current

7 mA±2

Casing Non-Combustible ABS

Structure

Cable Silicon

KDB-GOM

Series

- 24 -

4.13 Power Transformer

Function

- Supply the power source to boiler.

Input Rating AC 220 V , 50 / 60 Hz

AC 220 V # 8-BLACK, # 9-GRY

AC 34.0 V # 2-RED, # 6-RED

AC 18.4 V # 1-ORANGE, # 5-BLUE

Power Requirement

Output Rating

AC 12.0 V # 4-WHITE, # 7-BROWN

Casing Non-Combustible ABS

Structure

Cable Silicon

KDB-GOM

Series

- 25 -

4.14 Domestic Hot Water Heat Exchanger

Item

161GOM 201GOM 251GOM 301GOM

Material

STS 304

Capacity

10 Pieces 12 Pieces 16 Pieces 18 Pieces

Function

- When use hot water, supply the heating water heated in main heat exchanger to hot water heat exchanger and heat-exchange water (water supply) with heating water supplied in hot water heat exchanger to be usable hot water.

Domestic Water

Outlet

Heating Supply

Tap Water

Inlet

Heating Return

KDB-GOM

Series

- 26 -

4.15 Burner Assembly

Item

161 / 201GOM 251 / 301GOM

Quantity of Secondary Nozzle

10 EA 15 EA

Material of Secondary Nozzle

ALSTAR

Slit (Flame Holder) Material

STS 430

Front Bracket

SBHG 1

Rear Bracket

STS 430

Function

- Supply heat sources by mixing and combusting the supplied gas and air.

KDB-GOM

Series

- 27 -

4.16 Nozzle Holder Assembly

Item

161GOM 201GOM 251GOM 301GOM

Quantity of Primary Nozzle

10 EA 15 EA

Material of Primary Nozzle

C3602 BD

Material of Nozzle Holder

A6063S

LNG

1.33

1.46

1.37

1.50

Diameter of

Nozzle(mm)

LPG

0.92

1.06

0.95

1.06

Function

- Supply gas needed for combustion according to demands.

Secondary gas pressure measuring hole

KDB-GOM

Series

- 28 -

.17 Wiring Diagram

NO Function NO Function

1, 3

Gas Valve 1

7, 12

Ignition Transformer

2, 3

Gas Valve 2

8, 12

3-Way Hot Water

4, 11

AC 220V

9,13

3-Way Heating

5, 6

Circulation Pump

Ground

NO Function NO Function

1, 11

Water Filling

9, 20

Room Thermostat

2, 12

Fan

3, 13

Control Voltage

RPM Power Sourc e

RPM Input

5, 15

Heating Temp.

Sensor

RPM Ground

6 16

Flame Detector

7, 20

Air Pressure

Switch

Heating Flow Sensor

8, 20

Hot Water

Flow Switch

18, 19

Overheat

NO Function NO Function

1,5

AC 20V

4,7

AC 12V

2,6

AC 40V

8,9

AC 220V

AC 200V

4.17.3.3 21 Pin Wiring Connecting Diagram

4.17.3.2 9 Pin Wiring Connecting Diagram

4.17.3.1 13 Pin Wiring Connecting Diagram

4.17.3 Wiring Connecting Diagram

4.17.1 Fault repair codes (room thermostat, FR-5)

NO ON OFF

Trial Run Normal

Forced Max.

Combustion

Normal

Forced Min.

Combustion

Normal

FE FF

L.P. Gas Natural Gas

Close-Air Type Open Tank System

50 Hz 60 Hz

161GOM 201GOM 251GOM 301GOM

OFF OFF ON OFF

ON ON OFF OFF

ON OFF ON ON

4.17.2 DIP S/W Setting on Main Controller

FND

No.

Problems FND

No.

Problems

Overheat

Air pressure failure

Low water level

Water level detection failure

Ignition failure

Flame failure in combustion

Flame sensor (Lower gas pressure)

Heating water switch failure

Heating sensor wire disconnected

Gas alarm(optional)

Short circuit of heating sensor

MICOM failure

Hot water sensor wire disconnected

Mechanical overheat

Short circuit of hot water sensor

DIP switch setting error

Fan R.P.M. failure

KDB-GOM

Series

- 29 -

4.17.3 Wiring Diagram

WHT : WHITE ORG : ORANGE

AC34V

AC220V

AC18.4V

IGNITION TRANS

LEGEND

GRY : GRAY

RED : RED

BLK : BLACK

BLK

2)BRN: Secondary valve

2)BLK: Currency

. .

Modulation

YEL : YELLOW BLU : BLUE

1)BLU : Primary valve

TIME UP 33-06

GAS VALVE

BLU

BLK

EV 1

BLU

RED

. .

BRN

EV 2

HIGH LIMIT FUSE

2)BLK,BLU : HOT WATER

1)BLK,RED : HEATING WATER THREE WAY VALVE

. .

GRN

RED BLK

BLU

EARTH

AIR PRESSURE

: DC 5V : DC 5V

SWITCH

INPUT SIGNAL

HEATING FLOW

SWITCH

INPUT SIGNAL

: DC 20V

THERMOSTAT

INPUT SIGNAL

ROOM

: DC 5V

HOT WATER

FLOW SWITCH

INPUT SIGNAL

WHT

RED

SUPPLY POWER

BLK

WHT

FUSE , 3A - 2EA

PUMP

POWER TRANSFORMER

1)WHT : AC 5V

BLK

INPUT SIGNAL

: AC 200V

3)BLK : Ground

2)RED : DC 12V

FLAME

DETECTOR

EARTH

SUPERVISION

FAN ROTATION

BLK

RED

BLK

: DC 20V

YELYEL

GRN

PREVENTION

INPUT SIGNAL

OVERHEAT

SKYSKY

BLUBLU

ORG

BLK

RED

GRY

AC220V

: DC 5V

TEMPERATURE

HEATING WATER

INPUT SIGNAL

WHT

FAN

RED

BLK

BLU

RED

BLU

: DC 5 - 20V

F 50

176

99 4 F

Hrs

140

104

ORGORG

ALARM WIRE

INPUT SIGNAL

GAS LEAKAGE

BLK

RED

( - )

(+)

[13 PIN]

GRN : GREEN

BRN : BROWN

[9 PIN]

[21 PIN]

BLU

AC18.4V

RED

BRN

YEL

WHT

AC34V

AC12V

AC200V

AC12V

KDB-GOM SERIES WIRING DIAGRAM

AC220V, 50/60Hz

220VAC 50Hz

AC220V, 50Hz

AC 220V, 50/60Hz

Operating Temp. : 156

KDB-GOM

Series

- 30 -

4.18 Main Controller

Voltage , Frequency AC 220V , 50 / 60 Hz

Voltage Range +10% to –15%

Ambient Temp. -15℃ to 70

℃

Electric Spec.

Ambient Humidity 45 – 90 %

Structure

Casing ABS

Model

KDC – 208-1M

4.18.1 DIP switch setting on main controller

4.18.2 Functions of Main Controllers

4.18.2.1 Pre-Purge

When the boiler operates, the function is to operate blower (fan) first and exhaust the remained air in the combustion

chamber before combustion starts, in order to prevent from immoderate ignition. Pre-Purge time is by achieving the fan’s

light-up RPM ± 200 rpm with more time than 4 ± 1 seconds.

4.18.2.2 Pre-Ignition

After Pre-Purge, the function is to operate ignition transformer previously in order to light up easily before supplying the fuel (gas) for combustion. Pre-Ignition time is from ON time of ignition transformer till ON time of fuel supply device (gas valve 2).

DIP Switch adjust part

Max. adjust screw for secondary gas pressure

NO ON OFF

Trial Run Normal

Forced Max. Combustion

Normal

Forced Min.

Combustion

Normal

FE FF

L.P. Gas Natural Gas

Close-Air Type Open Tank System

50 Hz 60 Hz

161GOM 201GOM 251GOM 301GOM

OFF OFF ON OFF

ON ON OFF OFF

ON OFF ON ON

KDB-GOM

Series

- 31 -

1 ± 1 second

4.18.2.3 Post- Ignition

The function is to keeps operation of ignition transformer until flame detector monitors and combustion flame is stable after fuel supplied and ignited. Post-Ignition time is from the time of fuel supply till OFF time of ignition transformer.

4 ± 2 seconds

4.18.2.4 Post-Purge

The function is to exhaust the remained gas of combustion after flame extinguished when boiler stops. Post-Purge time is from OFF time of fuel supply device till OFF time of fan.

Blower : 20 ± 2 seconds / Pump : 60 ± 6 seconds

4.18.2.5 Safety Shut-Off (No Light-Up)

The function is to stops fuel supply for safety when the flame signal isn’t detected even though boiler’s blower is operated, and Pre-Purge, Pre-Ignition done and fuel supplied. Safety shut-off time is from ON time of fuel supply device till OFF time of fuel supply. At that time, ignition transformer is also OFF.

3 ± 1 seconds

4.18.2.6 Boiler Stopping by Safety Shut-Off

If fuel supply and ignition transformer is OFF by the function of safety shut-off, the restarting operation repeats (operation of Pre-Purge, Pre-Ignition, Fuel supply, Flame detection, etc by a series of control sequence) and counts their cycle. If the number of safety shut-off is 3 times in series, transmits ignition trouble signal to the temperature

controller and fan is OFF after Post–Purge done. (Only if water temperature in the pipe is more than 80 ± 2.0

℃

, fan and

pump operate.)

4.18.2.7 Misfire (Flame Extinction or No Flame Detection) During Combustion

When misfire is monitored during combustion, stops fuel supply and performs the ignition operation by re-starting function (Pre-Purge, Pre-Ignition, Fuel supply, Flame detection, etc by a series of control sequence) and counts their cycle. If the number of fire loss is 10 times, fuel supply device is OFF and transmits the misfire signal to temperature controller, and

then fan is OFF after Post-Purge done. (Only if water temperature in the pipe is more than 80 ± 2.0

℃

, fan and pump

operate.)

4.18.2.8 Flame Detection during Pre-Purge (The Early Pseudo Flame)

When monitored flame signal during Pre-Purge time, stops to be progress even though Pre-Purge done, and transmits

the pseudo flame signal to temperature controller after checking continuously for 3 ± 1 seconds. Post-Purge performs in

series, and release automatically when pseudo flame is disappeared and then is returned the function as before. (Only if circulation pump operate continuously until release the pseudo flame.)

4.18.2.9 Combustion Stop / Flame Detection during Standby (The Last Pseudo Flame)

When extinguishes by stopping fuel supply and performs Post-Purge, transmits the pseudo flame signal to the temperature controller if flame isn’t extinguish actually or the flame signal is monitored during waiting combustion and isn’t

disappear within 3 ± 1 seconds. Post-Purge performs in series, and release automatically when pseudo flame is

disappeared and then is returned the function as before. (Only if circulation pump operate continuously until release the pseudo flame.)

4.18.2.10 Low Water Level, Normal Water Level

When the power of boiler is ON, monitors always water level from low water level and normal water level sensor. If monitors low water level that water is not enough in the boiler, the boiler stops running. Auto water filling valve is ON and filling a boiler with water after pump is OFF, and transmits low water level signal to the temperature controller. (If the boiler is filled with water by normal water level, the signal is released automatically and returned the status as before.) Closed air type boiler doesn’t use normal level sensor and the heating water flow switch is attached on the low water level sensor. If

pump operates and heating water flow switch is ON within 6 ± 1 seconds, consider normal water level, and if heating

water flow switch is not ON, transmit abnormal status signal to temperature controller and pump is OFF and then

maintain this condition until restarting. (Only if water temperature in the pipe is more than 80 ± 2.0

℃

, fan operate.)

KDB-GOM

Series

- 32 -

4.18.2.11 Water Level Sensor Trouble (Opened Air Type)

If monitors water level that there are water at the normal water level sensor and no water at the low water level sensor, consider the trouble of normal water level sensor or low water level sensor, and operates immediately a serial of operation

as same condition of low water level. (Only if water temperature in the pipe is more than 80 ± 2.0

℃

, fan operate.)

4.18.2.12 Heating Temperature Sensor Trouble

If finds the trouble of disconnection / short-circuit by checking heating temperature sensor as long as the power of boiler is ON, the boiler is stopped (The burner stops and the pump / blower operate continuously, and stop the pump / blower

after temperature sensor is returned to normal and check water temperature to be less than 80 ± 2.0

℃

in the pipe.) and

the failure status of sensor is indicated in temperature controller.

4.18.2.13 Combustion Indication

Combustion indication in the temperature controller displays by the presence of flame signal. (Not by the presence of fuel supply)

4.18.2.14 Air Pressure Switch

Air pressure switch is always ON regardless of blower. When air pressure is excessive, aind pressure switch is OFF and the boiler is stopped and the abnormal status of air pressure is transmitted to the temperature controller. Blower operates continuously and release automatically when return to normal state. (Only if water temperature in the pipe is

more than 80 ± 2.0

℃

, pump operates. The abnormality of RPM isn’t monitored in the abnormal status of wind pressure.)

4.18.2.15 Gas Leakage Alarm

When the gas leakage signal is input from outside, the boiler is stopped and blower operates to ventilate air. When the gas leakage signal is released, the abnormal status is disappeared automatically and then returns to the status as before.

(Only if water temperature in the pipe is more than 80 ± 2.0

℃

, pump / blower operate.)

4.18.2.16 Pump Trouble

Water level control method of the closed air type boiler is decided by the input presence of flow switch within 6 ± 1 seconds after pump is ON. When there is no signal of flow switch within 3 ± 1 seconds, delay Pre-Purge by 6 ± 1 seconds. When the signal is, operate normally. If flow switch is ON continuously more than 15 ± 3 seconds before pump

operates, consider the trouble of pump or flow switch and transmit abnormal status to the temperature controller. Pump is OFF and maintains this status until re-operate the temperature controller. (Only if water temperature in the pipe is more

than 80 ± 2.0

℃

, fan operate.)

4.18.2.17 Time Multiple Function When Control Heating

When heating combustion operates continuously at a steady heating value by heating command of the temperature controller, calculate average heating value and is converted into running time / stop time according to heating value. And then maintain the stopping state (same as outdoor state) for regular time after running combustion for regular time. If changed heating command or setting temperature in the temperature controller or operated hot water combustion, etc except heating function within heating running time or forced stop time, the time should be always initialized. (Only in hot water combustion, it doesn’t stop function.)

4.18.2.18 MICOM Trouble

As the part of deciding trouble inside of the controller, considers that there is trouble of MICOM when external AC power of 50/60Hz isn’t monitored, stops all output and transmits trouble status to the temperature controller and then

maintains the current state until re-operate the temperature controller. (If water temperature in the pipe is more than 80 ±

2.0℃, pump operate.)

4.18.2.19 Heating Control when Hot Water Use

Proportional control uses the indirect control method of hot water temperature by heating water temperature and hot water temperature is as follows.

In case of FR-5 use, water temperature in the pipe is 80℃ when choose heating, and is set 70℃ when choose

outgoing and hot water .

4.18.2.20 Heating Temperature Control

The temperature of heating water at the discharge may be set in the range of 30~80±4.0℃ at the room thermostat. If the temperature of the heating water is lower than 83℃, the ratio control(PID) will be performed in accordance with the specified procedures.

If the range of control has been exceeded due to the change in the set temperature or to abrupt change in flow, the set temperature will be reached through the proportional control with the delay of 300±15 seconds.(If 83±4.0℃ is exceeded, the delay of 30±3 seconds will not be performed.)

KDB-GOM

Series

- 33 -

ON/OFF Control Range

Set Temperatures (“T” set)

ON OFF

℃

“T” set - (18±2)

℃

“T” set - (5±2)

℃

70 ~ 77

℃

“T” set - (14±2)

℃

“T” set - (7±2)

℃

60 ~ 69

℃

“T” set - (12±2)

℃

“T” set - (6±2)

℃

50 ~ 59

℃

“T” set - (10±2)

℃

“T” set - (5±2)

℃

40 ~ 49

℃

“T” set - (8±2)

℃

“T” set - (4±2)

℃

30 ~ 39

℃

“T” set - (6±2)

℃

“T” set - (3±2)

℃

If the combustion is delayed due to the temperature increase as above, the pump will be continuously run and the resumption of combustion will be delayed for 300±30 seconds. (If the combustion stops at 85℃, the forced delay of 300 seconds will not be executed.)

If other functions than the heating, such as a different function or change in the set temperature, is performed during the heating time or forced stop time, the time should be changed to the initial value.(In the case of heating domestic hot water supply, the boiler will not be stopped.)

4.18.2.21 Re-Use Standby after Use Domestic Hot Water

When hot water flow switch is OFF by stopping use of hot water, fuel supply stop. Fan doesn’t perform Post-Purge

caused by stopping fuel supply and maintains ON status for 90 ± 9 seconds. If hot water flow switch is ON within this time, performs pre-Ignition, fuel supply, flame detection, and Post-Ignition. And return the status as before when expires 90 ± 9

seconds after using hot water.

Only if the heating signal is input in the temperature controller during hot water standby (90 ± 9 seconds) or after hot

flow switch is OFF, turn immediately to heating. At this time, combustion should start always from the beginning after

combustion is OFF, and Post-Purge time is 15 ± 3 seconds and hot water standby time progress separately.

4.18.2.22 Freezing Prevention

When heating water temperature is lowered less than 10 ± 2.0℃, circulation pump operates for 30 ± 2 seconds by the interval of one hour. If circulated water temperature is lowered less than 6 ± 2.0

℃

, operates circulation pump and starts

combustion for freezing prevention after output of freezing running in temperature controller. When the heating water

temperature is more than 21 ± 2.0

℃

, the circulation pump and combustion stop.

4.18.2.23 The Number of Fan Rotation Trouble

The RPM signal monitors after running fan and the related status is indicated in the temperature controller as follows.

- After reaching within ignition rpm ± 200rpm during ignition, ignition is started by controlling gas valve. If it doesn’t reach

within 13 ± 2 seconds, consider as one time failure of ignition. When re-ignition is performed and it doesn’t reach for 3 times in series within 13 ± 2 seconds, stop the ignition. After perform purge for 15 ± 2 seconds, start re-ignition again.

(Only if repeats for 10 times of the above operation and doesn’t ignite, consider as the number of rotation trouble.)

- If ignite normally and progress the combustion, initialize the count of above operation.

- If the number of rotation maintains less than 400 ± 200rpm or more than 3200 ± 200rpm for 12 ± 1 seconds during

normal combustion, consider as the RPM trouble.

- When the RPM trouble is happens by the above mention, re-check trouble of blower for 30 ± 3 seconds after indicating

first the trouble status in the temperature controller. If decide as normal status (1000 ± 200rpm), release it automatically

and return to normal status.

4.18.2.24 Bimetal (Mechanical Type) Overheat Control

When overheat signal is monitored continuously for 1 ± 1 second from mechanical overheat sensor during combustion

and stopping, transmits bimetal overheat status to the temperature controller and safety shut-off performs. Fan and

circulation pump operate continuously and stop when heating water temperature is less than 80 ± 2.0

℃

4.18.2.25 DIP Switch Setting Trouble

The voltage of wind pressure switch is always monitored during combustion and stopping of the boiler, and it is compared with current setting of DIP switch. When finds trouble, indicates trouble status in the temperature controller and stops combustion. (Only if set normal status, release automatically.)

KDB-GOM

Series

- 34 -

4.18.2.26 Test Operation Function

- It is priority of the set function of DIP switch.

- Pump operates for 2 hours. In case of open type, operate continuously after auto water filling when low water level is happens.

- If releases test operation by manipulating DIP switch in standby status after performing test operation and sets again, initializes test operation function and starts test operation.

- When low water level (pseudo flame) happens in case of closed air type, releasing automatically by the interval of one minute and progresses continuously.

- When flow switch is ON in case of closed air type, stops pump and checks trouble.

- When DIP switch sets test operation, the power lamp flickers by repetition of ON for 1 second and OFF for 1 second.

4.18.2.27 Forced Maximum / Minimum Combustion Function

- When change-over switch sets to forced Max or forced Min, combusts by the set Max or Min according to the capacity

of the boiler after normal ignition. (PID control doesn’t.)

- When DIP switch sets for both forced Max and Min at the same time, combusts by forced Min.

- During combustion of forced Max / Min, operation of stopping time isn’t performed.

- If the test operation is ON in status of forced Max/Min operation, the function of forced Max / Min operation isn’t work.

4.18.2.28 Fault repair codes(room thermostat, FR-5)

FND No. Problems FND No. Problems

Overheat

Air pressure failure

Low water level

Water level detection failure

Ignition failure

Flame failure in combustion

Flame sensor (Lower gas pressure)

Heating water switch failure

Heating sensor wire disconnected

Gas alarm(optional)

Short circuit of heating sensor

MICOM failure

Hot water sensor wire disconnected

Mechanical overheat

Short circuit of hot water sensor

DIP switch setting error

Fan R.P.M. failure

4.18.2.29 Current Proportional Range Compensation

- Maximum current change by adjusting variable resistor for maximum current compensation.

- Current compensation range can be variable more than ± 20mA of maximum current.

4.18.4.30 The Others

- Heating flow switch is used to monitor water level of closure type (closed air type).

- Power lamp is always lit in the condition of power ON and flickers by the repetition of ON for 0.5 second and OFF for 0.5 second in the abnormal condition.

4.18.2.31 Secondary Gas Pressure according to Capacity of Boiler (mmAq)

Model High Load Low Load

NG 104 20

KDB – 161 GOM

LP 170 20

NG 104 20

KDB – 201 GOM

LP 150 30

NG 104 20

KDB – 251 GOM

LP 165 38

NG 106 20

KDB – 301 GOM

LP 156 30

KDB-GOM

Series

- 35 -

1. Precautions before installation

1.1 Shipping from factory

1.2 Choosing the best location

1.3 Methods of installation

1.4 Check the kind of gas

1.5 Precautions for installation

2. Identifying the components of the boiler

3. Installation of water piping

4. Installation of the flue

4.1 PVC Venting Method

4.2

Flue pipes used for Standard Flue Kit models

5. Gas piping connections

6. Installation of the room thermostat

6.1 Choosing the Best Location

6.2 Installation

II.

Installation of Boiler & Accessory

KDB-GOM

Series

- 36 -

■

WARRANTY WILL BE CONSIDERED VOID IF THIS EQUIPMENT IS INSTALLED BY ANYONE OTHER THAN A

QUALIFI ED, TRAINE D AND L ICEN SED ( WHERE APPLICABL E ) HE ATING TECHNICIAN.

■

KYUNGDONG BOILER CORPORATION IS NOT RESPONSIBLE FOR PROBLEMS OR DAMAGE CAUSED BY IMPROPER

INSTALLATION IN CONSISTENT WITH THIS M ANUAL.

■

THE IN STALLING CO NTRACTOR M UST I NSTRUCT THE OWNE R ON THE FU LL OPERATION OF THIS PRODUCT.

■

THE INSTAL LI NG CON TRACTO R M UST GI VE THE OWNE R THE APPO RPR IATE WARRANTY CERTIFICATE AFTER

THE IN STAL LATIO N H AS BEE N CO MP LETE D.

1. Precautions before installation

1.1 Shipping from factory

The units are released from our facility specially packaged to prevent handling damage and contamination in transit. Dropping or throwing the boilers or moving them while outside of their shipping container may cause damage or internal contamination by any moisture remaining after testing. Do not stand the boilers up by resting on the connections piping.

1.2 Choosing the best location

■

Never locate the unit outdoors,

Such as an open porch or patio or exposed to the wind, rain snow and cold temperature. Special consideration must be given to where the venting will terminate outdoors.

■

Do not locate the unit in an equipment room that has an exhaust fan.

■

Install the unit securely on any non-combustible wall that is capable of supporting the 40 kg weight of this

equipment.

■

Maintain an 150mm clearance to the left and right of unit including 150mm clearance in front of the unit for safety

inspections and future access.

■

Do not install unit in an underground or semi-underground location unless using the model FF or designated

concentric flue kit for KDB-GOM models.

■

When installing the unit, consideration must be given to the proper location. The location selected should be as

close to the vent pipe termination outside the building, and as centralized with the water piping system as possible.

■

A minimum clearance of 100mm must be allowed for access to replaceable parts such as the thermostats, drain

valve and relief valve.

■

As the gas boiler is to be installed indoors, they shall not be installed outdoors, such as in the porch.

■

Do not install boiler on combustible wall in a high humidity location.

There is a risk in using fuel burning appliances in rooms or areas where gasoline, other flammable liquids or engine driven equipment or vehicles are stored, operate or repaired. Flammable vapors are heavy and travel along the floor and may be ignited by the igniter or main burner flames causing fire or explosion. Some local codes permit operation of gas appliances if installed 18-inches or more above the floor. This may reduce the risk if location in such an area cannot be avoided. Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the boiler. Open containers of flammable material should not be stored or used in the same room with the boiler.

1.3 Methods of installation

■

The units must be firmly secured on the wall, which can sufficiently hold the unit weight.

■

Exhaust vent pipe has a maximum length of 5.0M with up to 3-90° elbow. Vent pipe must be angle 2-3° toward

the boiler to return condensate.

■

The units should be grounded to prevent electric shock.

1.4 Check the kind of gas

■

Check if the gas indicated on the rating plate is being used. If not, change the nozzle

by consulting the service center or dealers.

KDB-GOM

Series

- 37 -

CONVERSION OF THIS APPLIANCE FROM NATURAL GAS TO PROPANE OR PROPANE TO NATURAL GAS CAN ONLY BE PERFORMED by a QUALIFIED TECHNICIAN.

1.5 Precautions for installation

■

Piping for heating and hot water should be cleaned before connecting to the unit.

Lime scale accumulation can reduce the life of the equipment, reduce efficiency and waste fuel. Boiler failure due to lime or scale buildup voids the warranty.

Check the metal tag on the relief valve and compare it to the heater’s rating plate. The pressure rating of the relief valve must not exceed the working pressure shown on the rating plate of the heater. In addition, the hourly heat capacity rated temperature discharge capacity of the relief valve shall not be less than the input rating of the heater. NO VALVE

IS TO BE PLACED BETWEEN THE RELIEF VALVE AND TANK. DO NOT PLUG THE RELIEF VALVE.

The drain line connected to this valve must not contain a reducing coupling or other restriction and must terminate near a suitable drain to prevent water damage during valve operation. The drain line shall be installed in a manner to allow complete drainage of both the valve and line. DO NOT THREAD, PLUG OR CAP THE END OF THE DRAIN

LINE.

■

The boiler needs a large quantity of air for combustion, the specified vent must be

installed. Incomplete combustion will occur and prevent normal operation of the boiler.

For safe operation, an ample supply of air must be provided for proper combustion and ventilation in accordance with the national fuel gas code or applicable provisions of the local building codes (latest editions). An insufficient supply of air may result in a yellow, luminous burner flame, carboning or sooting of the finned heat exchanger, or create a risk of asphyxiation. Do not obstruct the flow of combustion and ventilation air.

NEVER OPERATE THE HEATER UNLESS IT IS VENTED TO THE OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF IMPROPER OPERATION, FIRE, EXPLOSION OR ASPHYXIATION.

■

The boiler should be at least 600mm away from electric appliances.

The boiler is set up for AC 220V, 50/60Hz.

The flow of combustion air to the boiler must not be obstructed.

The boiler area must be kept clear and free from combustible materials, gasoline and other flammable vapors and liquids.

■

Flue made of stainless steel.

■

To facilitate the discharge of exhaust gas, the flue

should be installed with fewest possible bents and curves. The flue should have a diameter larger than that of the flue of the boiler.

■

Do not place flammable item near the boiler.

Never place combustibles such as vinyl bags, match, thinner, etc on boiler.

Read first before connection to power supply

Low Voltage (Thermostat Wire)

Orange

Blk

Red

Black

White

Green

Low Voltage (for optional gas alarm)

Gray Wire (to live voltage)

More than 600mm

Only for AC220V, 50Hz

KDB-GOM

Series

- 38 -

2. Identifying the components of the boiler

■

Model : KDB – 251 / 301GOM

■

Model : KDB – 161 / 201GOM

KDB-GOM

Series

- 39 -

3. Installation of water piping

■

The piping materials used should meet local codes and industry standards.

■

Piping must be cleaned and flushed-out before installation.

■

Do not apply torch heat within 300mm of the bottom connections of the unit.

■

Perform all solder connections at a safe distance from the (brass) male

connectors below the unit. Allow fittings to cool, before attaching to unit. Use only approved coupling unions with

O-rings to attach field piping to unit.

■

The ‘heating’ pipe should be 3/4" and of type-L copper. Never use aluminum, plastic, or galvanized steel piping.

■

The pipe size used for supply heating water should be the same size used for the return heating water.

■

Use only copper piping with lead-free solder for the domestic water side.

■

Since the expansion tank has already been installed in the unit, no separate tank is required.

■

The size of the domestic hot water pipe should be 1/2" diameter.

■

The length of piping should be as short as possible and the piping should have minimal number of bends and

connections.

■

Use only ball type isolating valves. Do not use gate valves.

■

Never leave the heating pipes disconnected while operating the unit as a boiler. This will cause damage to the

heat exchanger and void the manufacturers warranty.

■

All piping should be insulated.

■

After making the piping connections, check for gas or water leaks.

■

If the water supply pressure is 10 kgf/cm² or higher, install the reduction valve on the water supply piping.

■

If the water supply pressure is 0.3 kgf/cm² or lower, install a pressurizing pump.

KDB-GOM

Series

- 40 -

A THERMOSTATIC MIXING VALVE MUST BE ADDED TO THIS SYSTEM TO PREVENT SCALDING. IF YOU CANNOT FIND A MIXING VALVE LOCALLY, PLEASE CONTACT YOUR QUIETSIDE DEALER OR LOCAL SPECIALITY PLUMBING SUPPLIER.

Mixing type valve:

- Controls the desired hot water temperature and ensures constant hot water temperature in the faucets

- Ensures safety through the built-in anti-burn/scald safeguard. Limits the deposits and accumulation of scale.

- Includes built-in wire mesh filters and check valves for long and trouble-free operation.

Fig. Schematic of piping installation

There is a risk in using fuel burning appliances in rooms or areas where gasoline, other flammable liquids or engine driven equipment or vehicles are stored, operated or repaired. Flammable vapors are heavy and travel along the floor and may be ignited by the igniter or main burner flames causing fire or explosion. Some local codes permit operation of gas appliances if installed 5.0M or more above the floor. This may reduce the risk if location in such an area cannot be avoided. Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the boiler. Open containers of flammable material should not be stored or used in the same room with the boiler.

DO NOT INSTALL THIS BOILER DIRECTLY ON A CARPETED FLOOR. A FIRE HAZARD MAY RESULT. INSTEAD THE BOILER MUST BE PLACED ON A METAL OR WOOD PANEL EXTENDING BEYOND THE FULL WIDTH AND DEPTH BY AT LEAST 75mm IN ANY DIRECTION. IF THE HEATER IS INSTALLED IN A CARPETED ALCOVE OR CLOSET, THE ENTIRE FLOOR SHOULD BE COVERED BY THE PANEL.

99 F

113

104

ROOM TEMP.

140 F

OFF

MAX

122

131 86

KDB-GOM

Series

- 41 -

4. Installation of the flue

4.1 PVC Venting Method

■

The KDB-GOM Series boiler may be vented using 75mm schedule-40 venting materials.

■

Cut all lengths of pipe cleanly maintaining a 90-degree square edge. Use long radius elbows whenever possible.

■

Use only the type of adhesive recommended by the stainless pipe manufacturer.

■

Keep an uphill slant from boiler to the outside to ensure that all condensed water inside the pipe will return back to

the boiler.

■

Do not place the outdoor termination kit in an area where discharge gasses will be directed towards evergreen

shrubbery.

■

Assemble the flue using the following illustration as a guide. Your installation may vary slightly from the illustration

shown below.

Use the optional Vent Termination Kit for venting the KDB-GOM boiler to outside area.

Use the optional Vent Termination Kit for venting the KDB-GOM boiler to outside area.Use the optional Vent Termination Kit for venting the KDB-GOM boiler to outside area.

Use the optional Vent Termination Kit for venting the KDB-GOM boiler to outside area.

- Standard : The Stainless Steel Concentric Flue Kit for KDB-GOM models.

“A” : 75

㎜×

㎜×㎜×

㎜×

1.0m LENGTH STAINLESS FLUE PIPE

“B” : 75

㎜×

㎜×㎜×

㎜×

0.5m LENGTH STAINLESS FLUE PIPE

“C” : 75

㎜×

㎜×㎜×

㎜×

90-DEG. STAINLESS ELBOW

Shown : 75

㎜㎜㎜㎜

″″″″

) Stainless Venting.

“C”

“A” or “B”

(Maximum Allowable

Flue Length = 5 m)

Min. 250㎜ (10″)

Vent Termination Kit

Exhaust

Intake Air

Min. 600㎜ (2 ft) from ground

(Note! - Install the vent termination kit in an area away from plants,

people and

animals)

φ75㎜

″″″″

)

Type 304

stainless steel

only

NOTE

ⅰ) Intake Air : φ75㎜ (3

″″″″

) stainless steel.

ⅱ) Exhaust : φ75㎜ (3

″″″″

) Stainless steel. ⅲ) Maximum three 90° elbows. ⅳ) Slant flue pipe 2-3° away from boiler to outside, to drain condensate.

Ground

KDB-GOM

BOILER

“C”

To Dr a i n

Install Horizontal Drip

Te e

If Required

KDB-GOM

Series

- 42 -

4.2 Flue pipes used for STS exhaust flue kit

■

When the flue duct (including extension) passes through a combustible wall or ceiling with combustible materials,

it should be insulated with 25mm or thicker insulation and then set apart from the wall or materials by 50mm or more. When it passes through the ceiling, include an opening for inspection of the flue.

■

If the air supply duct is separated from the flue duct, the total length of the flue duct should be 3.0 M or less and

with 2 or less elbows.

■

The connection of the air supply hose must be sealed by the wire clamp to prevent any air loss. In the connection

of the flue duct and the flue elbow, In O-ring must be inserted to prevent leakage.

■

Do not use any aluminum duct as an extension. Use extension duct sets or elbows available through your

kyungdong distributor.

■

The flue duct which carries combustion waste gas should be firmly secured by the clamp so that it will not loosen

due to vibration. The parts where the band clamp is not used should be sealed with aluminum tape.

In the event the exhaust pipe passes through a combustible wall or an combustible ceiling, insulate it with

nonflammable materials of 25mm thick or more and locate 50mm or more away from any combustible materials.

In addition, install a check port if flue passes through the ceiling.

Tie up a joint of the air intake hose with the wire clamp so as not produce a loss of an intake air, insert an O-ring in a

joint of the exhaust pipe and exhaust elbow so that the exhaust gas won’t leak.

Fix the exhaust pipe with the band clamp and screws so as not to pull due to shock. Make sure to wrap any pipe joint

not using a band clamp with aluminum tape.

Fig. Schematic of Standard Flue kit Installation

Ceiling

Seal opening to ensure that burne

waste gas does not enter the room.

In the event the intake hose is to

long, cut the shortest length as possible and connect it.

Nonflammabl e wall

150 or more

250or more

500 or more

Install the horizont al part of flue downwards(120mm) so that the condense d water from the flue or rain doesn’t enter into the boiler.

Install the flue in a place where there are no any obstacle

within 1.5M away from the flue.

Install the flue ensu ring no that it cannot be blocked by sno

falling from the roof eaves.

Install the flue in a place in a location opening exist within 500 m

from the flue so that exhaust gas can’t re circul ator in to the building.

Install the flue at least 600mm above the ground.

Unit : mm

KDB-GOM

Series

- 43 -

5. Gas piping connections

■

The heating water supply piping should be 3/4". An isolation (ball-type) valve should be installed before the piping is

connected to the units.

■

Black iron piping or 3/4" flexible connector (approved by the local authorities for gas) should be used for gas piping.

■

Do not use Teflon tape for gas pipe connections.

■

Install a gas drip leg at the unit.

■

Gas piping should be kept at the required distance away from any electric lines and the main service panel(check

with local authorities).

Items Distance (mm)

1. Distance from electric lines 150

2. Distance from electric heaters and electric panels 600

3. Distance from flue pipes and outlets 300

■

Install the ball valve(cut-off valve) before connecting the gas piping to the unit (Allow space for the lever’s full

movement, install valve as close to the units as possible).

■

After the gas pipe has been completed, all connections must be checked with soapy water.

Note!

- Do not test for gas leaks by pumping air-pressure into the line without first disconnecting the gas line to the unit. Pressuring the unit will void the manufacturers warranty. Releasing this pressure into the unit will cause immediate and severe damage to the gas valve and its internal pressure regulating device and could result in property damage and/or personal injury.

6. Installation of the room thermostat

6.1 Choosing the Best Location

■

Never locate the thermostat near or above a heat producing source(lamp, TV, fireplace, radiator, direct sunlight,

etc.).

■

Never locate in areas with drafts(stairwells, vestibules, foyers, against an outside/exterior wall, etc.).

■

Never locate in a room, which will be shut-off from the other living areas of the home.

■

On multi-story homes, locate thermostat on the ground floor.

■

Install at a height of about 1.2M to 1.5M above the floor.

■

Keep out of reach from children.

6.2 Installation

1. Remove the back plate from the FR-5 thermostat by grasping the faceplate with one hand and sliding the back plate downward with the other hand.

2. Pull the thermostat wire through the back plate.

3. Connect 2(orange colored/stranded) wires from unit to the 2 screws located on the FR-5 thermostat.

Consult with your gas provider to determine the proper diameter of gas pipe. This will vary due to input capacity, the number of elbows and length of pipe.

[On Hollow Plaster or Drywall]

[On Recessed Outlet]

KDB-GOM

Series

- 44 -

4. Mount the back plate to the wall using either of the above techniques(depending on the construction of the wall). Recheck all connections both inside the unit and at the thermostat. Be careful not to pinch the control wires. Pinched or shorted wires will prevent the system from operating. Do not over tighten wire nut connecting wires together.

5. Use countersunk type screws.

CAREFULLY TIGHTEN THE 2 SCREWS WHEN CONNECTING THE WIRES. DO NOT APPLY EXCESSIVE FORCE. IF THE INSULATION OF THE WIRES IS DAMAGED OR IF THE TERMINALS ARE ON POOR CONTACT, THE ROOM THERMOSTAT WILL NOT WORK PROPERLY. BE CAREFUL TO PROTECT THE INSULATION OF THE WIRES.

[Wiring FR-5 Thermostat]

DC 20V

FR-5 Thermostat

2 Orange Wires

Main Controller

AC 220V, 50/60Hz Grounded Power Supply to Boiler

Boiler

KDB-GOM

Series

- 45 -

1. Checkup after installation

2. Checking for gas and water leaks

3. Checks before trial operation

4. Trial operation

4.1 Trial operation quick-fill

4.2 Procedure of trial operation

5. Routine maintenance

6. Troubleshooting

6.1 Troubleshooting - Error Codes

6.2 Troubleshooting - Occurs

III.

Trial operation & Checkup

KDB-GOM

Series

- 46 -

1. Checkup after installation

1) Check the flammability and rigidity of floor & wall materials. Ensure that all-minimum clearances to walls, ceilings, overhangs, etc. have been met.

2) Freeze Prevention Device

The units must be wired-in to AC 220 volt electrical circuit once they have been connected to water piping and the

circuit has been filled with water. If the freeze prevention circuit starts due to a low-water condition, the pump will begin running on “air” and cause premature failure and will void the warranty on the pump.

Check to see if the unit is properly connected and the piping is insulated properly.

If the insulation has worn off or is not fitted, the risk of freezing of piping and severe damage to the unit is

considerable. Thoroughly check the piping insulation and replace where necessary.

■

Measures to prevent fire must be taken and check that flue ducts are installed in compliance with the instructions?

2. Checking for gas and water leaks

■

Are there any water leaks in the heating and domestic hot water piping?

■

Are there any gas leaks in the gas piping?

3. Checks before trial operation

■

Type of gas being supplied(the one indicated on the rating plate of the units)

■

When the type of gas does not match the one specified on the unit rating plate, modification and re-adjusting will be required(Consult your heating dealer or a qualified technician with the gas utility company).

■

Test for leakage at all gas piping connections.

■

Inspect for proper operation of gas alarm system.

■

AC 220 volts 15 Amp. dedicated circuit with approved grounded connection.

■

Heating and hot water pipes must be properly installed and in compliance with the standard installation methods and local code requirements. CAUTION! : Any air remaining in the heat exchanger piping will cause rapid corrosion

in the unit.

■

Completely vent the air at this time.

■

Check DIP switch setting against the factory settings shown on the control board diagram.

■

Connect room thermostat and check all wiring connections at control, at molex connectors in unit and at main circuit panel.

KDB-GOM

Series

- 47 -

4. Trial operation

4.1 Trial operation quick-fill

STEP 1 Fill water by means of auto water filling system.

STEP 2 DIP switch setting #1 to on.

STEP 3 Run the pump for 2hours.

STEP 4 After trial operation, manipulate DIP switches in the stand-by condition to the stop the trial operation and re-

set the switches.

STEP 5 The low water level will be automatically deactivated at 1-minute intervals.

STEP 6 If the flow switch is “ON”, stop the pump and check for any errors.

STEP 7 If DIP switches are set for trial operation, the power lamp will flicker : 1-second “ON” and 1-second “OFF”.

■

After the installation, connect the unit to an AC 220V, 50/60Hz outlet with the intermediate valve in the water

supply line open and turn the water heater “ON”. The auto water fill will start.

■

When the temperature sensor terminal is disconnected, the fans and pumps are continuously run to purge air in

the piping.

4.2 Procedure of trial operation

STEP 1 Open the water valve & fill the system.

STEP 2 Fill the units with water by means of the automatic water filling system and wait until the pressure in the

heating pipe reaches the maximum pressure(max. pressure through water filling valve). (Air in the heating water pipe will cause quick corrosion in the unit. Take the time to completely remove air before proceeding to the next step.

STEP 3 Wait until the water fill is completed.

STEP 4 Check the unit and turn the unit to “ON” at the room thermostat.

STEP 5 If the CHECK lamp is illuminated, note the error code and follow the steps required according to the

troubleshooting guide. After the corrections or adjustments have been made, restart the unit. Disconnecting and reconnecting the power may be required to restart the unit.

STEP 6 In case of water pipe leaks, turn off power to unit. Shut off all isolation valves. Inspect O-ring connections and

replace if necessary. Check to be sure all fastening clips are securely in place before opening the isolation valves.

■

Turn the boiler to “POWER” at the room thermostat.

■

If the CHECK lamp is illuminated, note the error code and follow the troubleshooting guide. After the require or

adjustments have been made, restart the unit. Disconnecting and reconnecting the power may be required to restart the boiler(at power button “POWER”).

■

In case of leaks water pipes, turn off power to unit. Shut off all isolation valves. Inspect O-ring connections and

replace if necessary. Check all fastening clips are securely in place before opening the isolation valves.

KDB-GOM

Series

- 48 -

No. Checking Items Measures

Prior to inspection and maintenance.

Close the gas shut-off valve, or turn off power to the unit.

Check for leaks in gas piping & connections with soapy water.

Repair the leak.

Emergency measures for a gas leak.

1) Close the gas shut – off valve.

2) Prohibit the use of any device which may cause gas to ignite or explode such as matches, lighters, or turnin g switches on or off.

3) Ventilate the indoor space.

4) Contact the gas supplier or call the fire department

or 911.

Check for obstructions in air intake and exhaust (flue) pipe.

Stop the unit and immediately contact the installer or service company.

Check for lack of heating water. (Low volume or flow of water supplied to tub or faucets)

Check the pressure of the incoming water supply (If the pressure is lower than the minimum hot water pressure, install a separate pressurizing pump).

Check for external contamination. Stop the unit and clean with neutral detergent.

Precautions for restart after prolonged shutdown. (Typical for vacation homes)

Check if condensate trap is filled to mark. If add water fill to mark.

Check for clogging of the strainers at the heating inlet or hot water inlet.

Clean strainer(s). If clogged it may be ‘advisable to’ flush system completely

Abnormal noise during the operation. Stop the unit and contact your dealer.

Drainage of condensed water. (KDB-KC model only)

Siphon should always be filled with water to the top of the container. The condensed water drainage should be connected to the sewer. Never drain to areas prone to freezing temperatures. Siphon should be cleaned annually.

5. Routine maintenance

KDB-GOM

Series

- 49 -

6. Troubleshooting

6.1 Troubleshooting - Error Codes

Error Code Cause Troubleshooting

01 / Overheat



Clogged / Reduce flow in heating system



Circulating pump failure



Check strainer clean



Check system for air rate



Check pump for operation –220V AC = 1 Amp

02 / Low Water Level



No water in system / Pump failure



No make up water supply



Water fill valve failure



Check system / Check pump



Check system



Check system 5V DC- input signal

03 / Ignition Failure



Check ignition transformer



Check high limit switch / fuse



No gas supply



Air pressure switch tripped



Input 220V AC



N/C contacts



Check gas connection



Check gas valve



Check tube for connection



Check flue for blockage

04 / Flame Sensor



Low gas pressure



Fan failure / Airflow pressure switch



Check gas valve 220V AC



Check gas pressure



Check fan for operation



Check switch, flue for obstruction

05 / Heating Sensor Wire Disconnected



Check molex connection



Re - connect

06 / Heating Sensor Short Circuit



Sensor failure



Check voltage Pin #15&5 on 21Pin connector,

main controller 5V DC

07 / Hot Water Sensor Wire Disconnected



Check molex connection



Re - connect

08 / Hot Water Sensor Short Circuit



Sensor failure



Check voltage Pin #19&8 on 21Pin connector,

main controller 5V DC

09 / Fan RPM Failure



Fan failure



Check speed control



Check fan for operation. Input voltage 7 – 40V

DC. Red-Black wires

10 / Air Pressure Switch Failure



Fan failure



Air flow switch failure



Blocked flue



Excessive wind gusts



Check fan for operation



Check tube connection



Check voltage 5V DC



Check flue for blockage



Check flue termination - relocate 11 / Water level Detection Failure



Check water fill valve



Voltage 5V DC

12 / Flame Failure



Low gas pressure



Fan failure / Air flow sensor



Blocked flue



Check gas pressure



Check gas valve



Check fan for operation



Check tube on air flow sensor



Check air flow sensor – 5V DC



Check flue for obstruction

13 / Heating Water Switch Failure



Faulty switch



Check voltage – 5V DC on Pin #10 on 13 pin and

Pin #17 on 21 pin connectors

14 / Gas Alarm (Optional)



Check if connected (Red / Black wire)



Re – connect



Check gas supply



Check voltage 5 – 20V DC

15 / MICOM Failure



Check connection from t-stat to unit



Replace t-stat or micom controller

16 / Mechanical Overheat



Pump motor overheat



Fan motor overheat



Check for pump operation 220V AC, approx 1A

(dependent on flow rate)



Check fan for operation



Check rotation

17 / DIP Switch Setting



Incorrect settings



Check setting especially

KDB-GOM

Series

- 50 -

6.2 Troubleshooting - Occurs

■

IF ANY FAILURE OCCURS, CHECK THE FOLLOW INGS BEFORE CONTACTING A SERVICE OR A DEALER.

■

IF THE CHECK LAMP COMES “ON” AND THE FAILURE CODE IS DISPLAYED, TAKE PROPER ACTIONS AND THEN

RESTART THE UNIT.

(RE-PLUG IN THE UNIT OR TURN THE UNIT “ON” FEW MINUTES AFTER THE CHECK LAMP HAS COME

“ON”)

■

IF SUCH PROCEDURE DOES NOT WORK, CONTACT THE NEAREST SERVICE CENTER.

■

CERTAIN NON HAZARDOUS FAILURES WILL SHUT DOWN THE UNIT, BUT WILL NOT ILLUMINATE CHECK

LIGHT. PRESS ON/OFF BUTTON TO OBTAIN ERROR CODE.

Symptoms Causes Troubleshooting

▶

Blown fuse

▶

Replace new fuse

▶

Power failure

▶

Wait until the power restores

▶

No indication on the water temperature indicator

▶

Repair the plug

▶

Room temperature is higher than the set temperature

▶

Increase the set temperature at the room

thermostat

▶

Set temperature at the unit thermostat is low

▶

Increase the set temperature at the

thermostat

▶

Temperature is indicated but the unit does not work

▶

“02” is indicated on the temperature indicator

▶

No water in the heating pipe

▶

Water filling valve failure

▶

No tap water supply

▶

Fill the heating water

▶

Contact the service center

The unit does not work

▶

“01” is indicated on the temperature indicator

▶

Clogged heating pipe

▶

Circulation pump failure

▶

Check for any clogging in the heating pipe. If the pipe is clogged, contact the unit installer

▶

Clean the heating strainer

▶

Check the circulation pump

※

After removing the cause, press the

“POWER” button again

▶

Low or no gas pressure

▶

Contact for service

▶

No flame detection

▶

Contact for service

▶

Intermediate valve closed

▶

Open the valve

▶

When the unit is started, the ignition fails and the check lamp comes “ON”

▶

No ignition

▶

Contact for service

▶

Air pressure switch tube

disconnected

▶

Connect the tube

▶

Incorrect installation of flue

▶

Correct the wrong installation

▶

Ignition fails and the exhaust fan runs continuously

▶

Clogged flue exhaust pipe

▶

Check the smoke stack

▶

Closed valve on the heating line or

clogged pipe(Heating water)

▶

Check the heating pipe(strainer)

▶

Air in the heating pipe

▶

Purge the air from the piping

▶

Circulation pump does not work

▶

Contact for service

▶

he unit runs properly but heat

performance id poor

▶

Leak in heating pipe

▶

Fix the leak

▶

Low water pressure

▶

Install a pressurizing pump

▶

Circulation pump does not work

▶

Contact for service

▶

he unit runs normally but hot water is

not supplied

▶

Defective 3-way valve

▶

Contact for service

▶

Pressure falls

▶

Leakage in piping

▶

Contact for service

▶

installation of flue duct

▶

Contact for service

▶

Loud noise during the ignition and combustion

▶

Clogged flue pipe(s)

▶

Contact for service

▶

Clogged hot water line

▶

Clean the strainer at the inlet of the hot

water flow switch

▶

Hot water supply stops

▶

Defective hot water flow switch

▶

Contact for service

KDB-GOM

Series

- 51 -

1. Conversion Kit Contents

2. Parts & Tools Required

3. Conversion Procedure

IV.

Fuel Conversion Method

KDB-GOM

Series

- 52 -

MODEL :

KDB – 161 / 201 / 251 / 301GOM – LNG , LPG

Kyun gDong, GO M Series

Kyun gDong, GO M SeriesKyun gDong, GO M Series

Kyun gDong, GO M Series

G as Conversion

G as ConversionG as Conversion

G as Conversion

Installation Man ual

Installation Man ualInstallation Man ual

Installation Man ual

1. Conversion Kit Contents

2. Required Parts & Tools

- Conversion Kit : Correct Kit for Model # and Capacity. Refer to

Table 1

- Tool : Screwdriver

- Gauge : Gas Pressure Gauge(eg: manometer)

This conversion kit is to be installed by a qualified installer/service technician in accordance with the

KyungDong Boiler instructions and all local code requirements.

Failure to follow all instructions in proper order can cause severe personal injury or death. The qualified technician performing this work assumes responsibility for this conversion.

DO NOT TAMPER WITH NOZZLE SIZE. CHANGING OR MODIFYING IN ANY WAY CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

-110*10*3t,1EA

Nozzle Holder Packing

-100*10*3t,1EA

:for Nozzle Holder

-17.5*2.7t,1EA :for Gas Valve

:for Burner Cover

-324*10*2t,1EA

-305*10*2t,1EA

-130*10*2t,2EA

Ceramic Packing

Manual

O-Ring

:for Nozzle Holder

Nozzle Holder

:for Nozzle Holder,Gas Valve

Gas Conversion Info. Sticker

(Only 075/095W1)

(Only 120/140W1)

-M4*12L,2EA

Bolt

-4*12L,2EA

KDB-GOM

Series

- 53 -

Shut off the gas supply & power.

Change Nozzle Assembly.

[Table 1] Instructions apply to the following conversion kits:

Natural Gas

ÆÆÆÆ

Propane Gas

Boiler Model

Conversion Kit, #

Nozzle Size (

㎜㎜㎜㎜

)

KDB – 161GOM, L NG 161GOM LPKT Ø 0.92

KDB – 201GOM, LNG 201GOM LPKT Ø 1.06

KDB – 251GOM, LNG 251GOM LPKT Ø 0.95

KDB – 301GOM, LNG 301GOM LPKT Ø 1.06

Refer to the following instructions,

To convent the boiler fuel type.

STEP 1.

STEP 1.STEP 1.

STEP 1.

STEP 2.

STEP 2.STEP 2.

STEP 2.

3. Conversion Procedure

2.1 KDB – 161 / 201 GOM

1) Remove 11 screws holding front cover to heat exchanger. Disconnect thermal fuse. Do not forget 2 screws on top of heat exchanger.

2) Remove front cover, be careful with sealing gasket.

3) Remove bracket holding igniter transformer to gas nozzle assembly. Disconnect igniter wires and ignition sensor.

4) Remove 4 screws holding nozzle assembly. Remove nozzle assembly from unit.

5) Replace nozzle assembly with new assembly from L.P kit. Do not forget to install new O-ring.

6) Replace 4 screws: Tip : Install assembly into gas valve first, and install screw on RHS of assembly first.

7) Replace front cover and thermal fuse mount. Reconnect fuse. Seal front cover with high temp. silicone seal ( not supplied ).

8) Replace igniter transformer bracket and reconnect igniter and sensor.

2.2 KDB – 251 / 301 GOM

1) Remove igniter wires and ignition sensor wire. Remove ignition transformer, disconnect wires at molex plug.

2) Remove 12 screws holding front plate to the combustion chamber.

3) Remove front plate from the combustion chamber, be careful with the sealing gasket.

4) Remove 4 screws holding the nozzle assembly. Remove nozzle assembly from the unit.

5) Replace nozzle assembly with new assembly provided in the L.P kit. Do not forget to install the O-ring.

6) Install assembly in gas valve first then secure with screw in assembly RHS first.

7) Replace cover, be careful not to strip screws. Use a high temp. silicone sealant to seal cover (not supplied).

8) Replace igniter transformer, igniter wires and ignition sensor wire.

KDB-GOM

Series

- 54 -

Switch DIP switch #5 (“B”) on the main controller to the new settings

Table 2

■

L.P. Gas

: DIP switch # 5 "ON"

■ Natural Gas : DIP switch # 5 "OFF"

[Fig. 1] Procedure of gas conversion

[Table 2] DIP switch setting on the main controller

[Table 3] Gas modulating valve head(

㎜㎜㎜㎜

No ON OFF

Trial operation Normal

Forced Max. Combustion Normal

Forced Min. Combustion Normal

F. E F. F

L.P Gas Natural Gas

Sealed combustion Open Combustion

50 Hz 60 Hz

Gas Modulating head Pressure , mmH

₂₂₂₂

O(inch W.C.)

Max. Load Min. Load

Front PanelONFront Panel

OFF

Front PanelONFront Panel

OFF

KDB-161GOM-NG Natural Gas 100 (3.94) 104 (4.10) 16 (0.63) 18 (0.71)

1.33 (0.052)

161GOM-LP L.P. Gas 170 (6.70) 174 (6.86) 26 (1.02) 28 (1.10)

0.92 (0.036)

KDB-201GOM-NG Natural Gas 104 (4.10) 108 (4.26) 16 (0.63) 18 (0.71)

1.46 (0.057)

201GOM-LP L.P. Gas 150 (5.91) 154 (6.07) 26 (1.02) 28 (1.10)

1.06 (0.041)

KDB-251GOM-NG Natural Gas 104 (4.10) 110 (4.34) 20 (0.79) 22 (0.87)

1.37 (0.053)

251GOM-LP L.P. Gas 164 (6.46) 170 (6.70) 24 (0.95) 26 (1.02)

0.95 (0.037)

KDB-301GOM-NG Natural Gas 106 (4.18) 116 (4.57) 20 (0.79) 22 (0.87)

1.50 (0.059)

301GOM-LP L.P. Gas 156 (6.15) 166 (6.54) 28 (1.10) 30 (1.18)

1.06 (0.041)

- Key -

①Igniter wire & Ignition sensor ③Ignition Transformer

②

Combustion chamber ④Nozzle Assembly

STEP 3.

STEP 3.STEP 3.

STEP 3.

KDB-GOM

Series

- 55 -

Set offset of the gas control valve.

1) Shut off the power.

2) Switch DIP switch #3 on the main controller to ON, It will make the unit run at Min. load (forced Min. combustion mode).

3) Connect the gas pressure gauge hose to the gas pressure check nipple ("C").

4) Restore the power and supply gas.

Caution!

Check any gas leak with soapy water.

If error code #17 is displayed on the panel of the room controller, check on DIP switch #3 setting.

5) Close all the water inlet valves. Then, set the Min. load gas pressure Refer to

Table 3.

Turn the adjusting screw("D") counterclockwise and ΔP will go up, turn clockwise ΔP will go down.

※

Check for abnormal combustion noise if this occurs:

Check STEP 4. gas leak and close the water inlet valve again.

Check STEP 2. nozzle holder assembly fitness.

※

Check for abnormal burning noise if this occurs:

Check STEP 4. gas leak and close the water inlet valve again. Check STEP 2. nozzle holder assembly fitness.

6) After procedure is complete shut off power supply.

7) Set the DIP switch #3 to off, back to normal.

8) Set DIP switch #2 on, it will make the unit run at Max. load (forced Max. combustion mode).

9) Restore the power again and supply the gas.

If error code #17 is displayed on the panel of the room controller, check DIP switch #3 setting.

10) Close all the water inlet valves. Then, set the Max. load gas pressure refer to

Table 3

Turn the adjusting screw("A") clockwise and ΔP will go up, turn counterclockwise ΔP will go down.

※

Check for abnormal combustion noise if this occurs:

Check STEP 4. gas leak and close the water inlet valve again.

Check STEP 2. nozzle holder assembly fitness.

※

Check for abnormal burning noise if this occurs: Check STEP 4. gas leak and close the water inlet valve again. Check STEP 2. nozzle holder assembly fitness.

11) After procedure is complete shut off power supply.

12) Set the DIP switch #2 off, back to normal operation mode.

Final check.

Supply power to run the boiler, and check for any abnormal noise or check lamp on the room controller. When the check lamp is on and an error code is displayed on the room controller panel

, Refer to service

manual.

STEP 4.

STEP 4.STEP 4.

STEP 4.

CAUTION

CAUTIONCAUTION

CAUTION::::

If an abnormal combustion or burning noise is heard, Check the nozzle holder assembly is correct one for the boiler & gas and try

STEP 4

STEP 4STEP 4

STEP 4

again

STEP 5.

STEP 5.STEP 5.

STEP 5.

KDB-GOM

Series

- 56 -

1. Failure code #02, Low Water Level

2. Failure code #03, Ignition Failure

3. Failure code #04, Pseudo Flame

4. Failure code #05, Disconnection of the heating sensor

5. Failure code #06, Short circuit of the heating sensor

6. Failure code #09, Abnormal RPM

7. Failure code #10, Air Pressure Failure

8. Failure code #12, Flame Failure in Combustion

9. Failure code #13, Heating Flow Sensor Failure

10. Failure code #14, Gas Alarm (Optional)

11. Failure code #15, MICOM Failure

12. Failure code #16, Mechanical Overheat

13. Failure code #17, DIP Switch Setting Error

14. Others – 1, 2, 3, 4 and 5

Troubleshooting

KDB-GOM

Series

- 57 -

1 # 02 Failure Low water level

No Symptoms and Causes Solutions Reference

The heating flow sensor has to be ON within 3 seconds after the power supply. If it is still OFF after 3 seconds, the failure code # 02 will be displayed.

1) Heating valve (Splitter) is closed. - Open the splitter valve

<Fig. 1>

2) Heating water is lacking. - Adjust the heating pressure gauge between

0.5~1.5kg

/cm2 (49 ~147 kPa)

<Fig. 2>

3) Too much air in the heating line. - Remove air from the heating line.

4) The circulation pump is working but there is not enough RPM or the impeller is damaged.

- Check the resistance of the circulation pump coils terminal. 0 level is normal. If it shows infinite level the coil is short-circuited and the circulation pump has to be replaced.

<Fig. 3>

5) There is no point of contact in the heating flow sensor.(close model)

- When the boiler is running and the heating flow sensor point of contact is normal, the resistance should be 0. if it shows an infinite level it is defective and has to be replaced.

- Reconnect the boiler earth wire.

<Fig. 4>

Check valve is open

Splitter valve

<Fig. 1>

<Fig. 4>

Circulation pump

<Fig. 3>

Heating flow sensor

kgf/

㎠

(kPa)

0.5

(49)

1.5

(147)

Heating Pressure gauge

<Fig. 2>

easure

resistance

KDB-GOM

Series

- 58 -

2 - 1 # 03 Failure Ignition failure

No Symptoms and Causes Solutions Reference

Failure code # 03 indicates ignition failure of the combustion device

In case there is no combustion and failure code # 03 is displayed

1) Gas supply is not normal. [Supply pressure standard]

- LNG : 200

50 100

−

mmH2O

- LPG : 280±50 mmH

- Check supply pressure and call the gas company if not normal.

<Fig. 1>

- Check power supply from the controller to the ignition transformer.

- If there is no power supply, replace the main controller.

<Fig. 2>

- If there is power supply but the ignition transformer is not working properly, check for coil short circuit. If the resistance shows an infinite level, it is defective and needs to be replaced.

<Fig. 2>

2) Ignition transformer is not working.

- The secondary voltage should be 19.5kV and if it comes out weak, the ignition transformer has to be replaced.

3) Space between electrodes and discharge.

- Check whether crevice between electrodes is 2~3mm and adjust accordingly.

- Check whether the electrodes are not banded in a direction.

<Fig. 3>

<Fig. 1>

<Fig. 2> <Fig. 3>

Gas Inlet Connection

Supply Pressure Measure Hole

Blue

Main Controller

Ignition Transformer

Electrode Assembly

Electrode Crevice

2~3 mm

KDB-GOM

Series

- 59 -

그림

그림그림

그림

2 - 2 # 03 Failure Ignition failure

No Symptoms and causes Solutions Reference

- Check for a crack in the electrode insulator and replace the electrode if found.

<Fig. 1>

- Check whether the high limit fuse is short circuited through resistance measurement. If it shows an infinite level, it is defective and needs to be replaced.

<Fig. 2>

4) No power supply to the modulating gas control valve.

- Check for power supply (AC 220V) from the transformer to the modulating gas control valve. If there is no power supply, replace the transformer.

- If the symptoms remain after performing the check up described above, then replace the controller.

<Fig. 3>

5) There is power supply to the modulating gas control valve but it is still not working.

- Check whether the modulating gas control valve coil is short-circuited. If the resistance measurement shows an infinite level, replace the modulating gas control valve.

<Fig. 4>

6) There is power supply to the modulating gas control valve and the coil is not damaged but still there is no ignition.

- The internal diaphragm of the gas control valve is defective. Replace the gas control valve.

- Using the water manometer, check the first and second head pressure (refer to gas pressure chart of GOM technical documents, and adjust the first and second pressure.

<Fig. 4>

<Fig. 1>

<Fig. 4>

Electrode Assembly

Insulator damage

<Fig. 2>

High Limit Fuse

Measure resistance

<Fig. 3>

Power Transformer

BLK

Check AC 220V

Modulating Gas Control Valve

Nozzle Holder Assembly

Secondary Pressure Measuring Hole

KDB-GOM

Series

- 60 -

2 - 3 # 03 Failure Ignition failure

No Symptoms and causes Solutions Reference

- Check the connection of the flame sensor on the electrode.

- Reconnect the flame sensor on the electrode.

- If problem persists, replace electrode assembly.

<Fig. 1>

2 Combustion is working and failure code

# 03 is displayed.

- Check for power supply (AC 200V) from the power transformer to the flame sensor. If not, replace the power transformer.

※

Voltage Supply Chart

<Fig. 2>

<Fig. 1>

<Fig. 2>

Power Transformer

Check AC 200V

Electrode Assembly

Check flame rod Wire connection

No Vol ta ge Check Points

3 200V Flame rod

1, 5 20V Controller circuitry

4, 7 12V Water level detection

2, 6 40V

Modulating gas control

Solenoid valve

8, 9 220V

Modulating gas control

valve ON/OFF

KDB-GOM

Series

- 61 -

3 # 04 Failure Pseudo flame

No Symptoms and causes Solutions Reference

What’s a pseudo flame?

Combustion takes place normally but a flame is detected in the combustion area before the modulating gas control valve starts operating inducing the boiler to stop its operation.

1 The boiler operation is stopped and

power is supplied to the modulating gas control valve.

- If power is supplied then the controller is defective. Replace the controller.

<Fig. 1>

2 There is no power supply but there are

small flames in the combustion area when the boiler stops operation.

- There is a problem with the diaphragm inside the gas control valve. Replace the gas control valve.

- If the symptoms remain after performing the check up described above, then the controller is defective and has to be replaced.

<Fig. 2>

<Fig. 1>

<Fig. 2>

Modulating Gas Control Valve

Main Controller

Internal diaphragm

KDB-GOM

Series

- 62 -

4 # 05 Failure Disconnection of the heating temp. sensor

No Symptoms and causes Solutions Reference

Failure code # 05 is displayed when the heating sensor is short circuited or disconnected.

1 Bad connection between the heating

temp. sensor and the harness connecting the controller.

- Reconnect the connecting harness terminal.

<Fig. 1>

2 The heating temp. sensor is short-

circuited therefore unable to detect.

- The heating temp. sensor is defective and has to be replaced.

- If there is nothing wrong with the above, the main controller is defective and has to be replaced.

<Fig. 1>

Main Controller

Check connection

Heating Temperatur

Sensor

KDB-GOM

Series

- 63 -

5 # 06 Failure Short circuit of the heating temp. sensor

No Symptoms and causes Solutions Reference

Failure code # 06 is displayed when the heating temp. sensor shows a temperature greater than 120℃, interpreting it as a short circuit of the heating sensor. A bad heat circulation or a mechanical deficiency may abruptly increase the temperature.

1 When the circulation pump does not

work.

- Check for the short circuit of the circulation pump coil. Measure the resistance and if it displays infinite level (0 level is normal) the coil is short-circuited and the circulation pump has to be replaced.

<Fig. 1>

- Check whether the 3-way valve coil is short circuited. Measure the resistance and if it displays infinite level (“0” level is normal) the coil is short-circuited and the 3-way valve has to be replaced. Check whether the ball inside the 3-way valve has fallen and if it did replace the 3-way valve.

<Fig. 2>

2 In case the ball falls down when the 3-

way valve is on the hot water side, the hot water flow switch will also always be on the hot water side. Therefore, since the heating water is not circulating, the temperature goes up abruptly when the boiler starts operation.

- Check the point of contact of the hot water flow switch when the boiler is idle. If it shows a resistance of infinite level it is normal but if it shows “0” it is defective and the hot water flow switch has to be replaced.

- If the symptoms remain after performing the check up described above, then replace the heating temp. Sensor and the main controller.

<Fig. 3>

<Fig. 1>

<Fig. 2>

<Fig. 3>

Measure resistance

Circulation Pump

Hot Water Flow Switch

3-Way Valve

Check whether ball has fallen

Measure resistance

KDB-GOM

Series

- 64 -

6 # 09 Failure Abnormal RPM

No Symptoms and Causes Solutions Reference

1 Fan unit RPM is too slow. - Replace the fan unit.

<Fig. 1>

2 The fan does not rotate. - Check whether the fan unit coil is short-

circuited. Measure the resistance and if it displays infinite level (“0” level is normal) the coil is short-circuited and the fan unit has to be replaced.

3 The fan RPM check board (phase control

sensor) is out or defective.

- If the phase control sensor is out, reassemble it. If the check board is defective, replace the fan unit.

4 The connection of the connector terminal

is defective.

- Reassemble the connector terminal.

- If the symptoms remain after performing the above, replace the controller.

<Fig. 1>

Phase control sensor

Measure resistance

Fan Assembly

KDB-GOM

Series

- 65 -

7 # 10 Failure Air pressure failure

No Symptoms and Causes Solutions Reference

The KDB-GOM boiler air pressure switch always operates at the ON position of contact B and displays failure code # 10 in case of back pressure or back fire.

1 The diaphragm inside the air pressure

switch is defective and the contact is OFF.

- Check the resistance of the air pressure switch terminal when the boiler is idle and if it shows an infinite level (“0” is normal), it is defective and the air pressure switch has to be replaced.

<Fig. 1>

2 The installation and the position of the flue

is not appropriate.

- Correct the flue due the formation of a wind pressure zone.

- Check whether the connector terminal is well assembled and reconnect.

If the symptoms remain after checking the

above, replace the main controller.

<Fig. 1>

Air Pressure Switch

KDB-GOM

Series

- 66 -

8 - 1 # 12 Failure Flame failure in combustion

No Symptoms and Causes Solutions Reference

Flame failure in combustion occurs when the flame disappears during combustion 10 times consecutively.

Check gas supply pressure

LNG: 100 ~ 250 mmAq.,

LPG: 230 ~ 330

mmAq

- Check whether LPG is empty when gas pressure is low and if it is replace with a new full container.

<Fig. 1>

- In cold seasons, the gas container may not supply gas normally. Warm up the container first.

- LPG hose may be too long (more than 3 m) or have fold down. Replace the hose or shorten it.

- The gas meter may be defective. Contact the gas company for replacement.

<Fig. 2>

1 Gas supply pressure is not right.

- Gas initial supply pressure of 200 mmAq may fall down under 100 mmAq after combustion. In that case contact the gas company.

KyungDong

<Fig. 1>

<Fig. 2>

L.P. Gas Container

Gas Meter

KDB-GOM

Series

- 67 -

8 - 2 # 12 Failure Flame failure in combustion

No Symptoms and Causes Solutions Reference

2 Gas meter capacity is insufficient. - Boiler capacity is 30,000 kcal/h (34.9 kW) and in

case the gas meter is third class gas supply may not be smooth. Contact the gas company for replacement. (refer to Chart 2)

<Fig. 1>

3 Flame rod is too close to the burner. - Adjust crevice between Flame rod.

<Fig. 2>

- Replace modulating gas control valve

- If symptoms remain after the check up above, replace the controller.

<Fig. 3>

※

Chart 2

Gas meter class per usage capacity

(unit: kcal/hr)

Boiler capacity Gas range Tot al Meter class

10,000~25,000 7,500 17,500~32,500 third

30,000~40,000 7,500 37,500~47,500 fifth

4 Modulating gas control valve does not

adjust gas volume.

※

gas range 1hole : 2,500 kcal/h

pace between flame sensor

2~3mm with the burner

Electrode Assembly

Kyungdong

<Fig. 1>

<Fig. 2>

<Fig. 3>

Gas Meter

Modulating Gas Control Valve

KDB-GOM

Series

- 68 -

9 # 13 Failure Heating flow sensor failure

No Symptoms and Causes Solutions Reference

Heating flow sensor failure occurs only in close air system boiler.

1 Heating flow sensor is ON although the

pump is not operating.

- Measure the resistance of the heating flow sensor. When the circulation pump is not working resistance should indicate infinity and zero when it is working. If there is no change according to the pump movement, clean the heating flow sensor or replace it.

<Fig. 1>

Heating Flow Sensor

Measure resistance

KDB-GOM

Series

- 69 -

10 # 14 Failure Gas alarm

No Symptoms and Causes Solutions Reference

After the installation of the gas alarm (optional feature), gas leak is detected and alarm goes off.

1 There is no gas leak and failure code # 14

is displayed.

- Gas alarm is defective and has to be replaced.

<Fig. 1>

Gas Alarm(Optional)

KDB-GOM

Series

- 70 -

11 # 15 Failure MICOM failure

No Symptoms and Causes Solutions Reference

1 MICOM controller failure. - Replace the controller when displayed failure

code # 15.

<Fig. 1>

Main Controller

KDB-GOM

Series

- 71 -

12 # 16 Failure Mechanical overheat

No Symptoms and Causes Solutions Reference

When the high limit sensor (98℃) located on the upper right pipe of the main heat exchanger starts operation.

1 The heating valve is shut down and the

temperature abruptly goes up.

- Open the splitter valve if it is closed.

<Fig. 1>

2 The hot water sensor in ON and the 3-

way valve shuts off the heating side.

- Separate the hot water flow switch jack and if the 3-way valve goes back to its initial position, the hot water flow switch is defective and has to be replaced.

<Fig. 2>

3 The high limit sensor is defective and

failure code # 16 is displayed when the boiler does not operate.

- Replace the high limit sensor.

- If the symptoms remain after checking the above, replace the main controller.

<Fig. 3>

Terminal separation

<Fig. 1>

<Fig. 2>

<Fig. 3>

Splitter Valve

Hot Water Flow Switch

High Limit Sensor

KDB-GOM

Series

- 72 -

13 # 17 Failure DIP switch setting error

No Symptoms and Causes Solutions Reference

The DIP switch located on the upper part of the controller has not been set according to capacity.

1 Failure code #17 is displayed although

the controller DIP switch has been set according to capacity.

- The controller is defective and has to be replaced.

<Fig. 1>

Main Controller

NO 161GOM 201GOM 251GOM 301GOM

OFF OFF ON OFF

ON ON OFF OFF

ON OFF ON ON

NO ON OFF

Run Normal

Forced maximum

Combustion

Normal

Forced minimum

Combustion

Normal

FE FF

L.P. gas Natural gas

Close air type Open tank type

50 Hz 60 Hz

Check DIP switch setting

KDB-GOM

Series

- 73 -

14 - 1 Others Failure

Boiler is operating normally but water overflows toward the expansion tank

No Symptoms and Causes Solutions Reference

- There are many impurities in the heating water of the heating pipeline and in the water pipeline that are stuck on the water filling valve solenoid diaphragm and water slowly flows in. replace and clean the solenoid.

<Fig. 1>

1 The water fill valve is defective and

cannot stop water and heating water.

- Especially, in case the splitter material is aluminum, corrosion is fast and there is formation of much impurities. Replace with a splitter in copper or stainless steel.

<Fig. 2>

2 Water overflows due to an internal sinking

of the hot water heat exchanger.

- If water still overflows after the checking above, it is an internal sinking of the hot water heat exchanger and the hot water heat exchanger has to be replaced.

Flue󰼿EXhaust

Combustion󰼿Air󰼿Inlet

Domestic󰼿Water󰼿Outlet

Gas󰼿Inlet Tap󰼿Water󰼿Inlet

<Fig. 1>

<Fig. 2>

Check hating pipeline condition

Check splitter valve’s material

Water filling valve

Internal diaphragm

KDB-GOM

Series

- 74 -

14 - 2 Others Failure

Heating is working but domestic water comes out cold or does not come out at all.

No Symptoms and Causes Solutions Reference

First, set the room thermostat to the domestic water position and open the domestic water tap.

1 The operating lamp does not light up. - The operating lamp does not light up because

the hot water flow switch is defective. Replace it.

<Fig. 1>

2 It is operating but domestic water

does not come out.

- Open the domestic water tap and measure the resistance of the hot water flow switch terminal. If it shows “0” it is normal, if it shows infinite it is defective.

<Fig. 2>

3 The operating lamp is working but the

heating pipeline is not warm and domestic water does not come out.

- Replace the 3-way valve if the heating pipeline is warm, meaning the transition to heating water supply mode has not been done due to a failure of the 3-way valve.(check whether the coil is short circuited and the ball damaged)

- In case there is no heat exchange in the domestic water heat exchanger, touch the heat exchanger. One side is very hot and the other side cold. Replace the domestic water heat exchanger.

- If symptoms remain after the checking above, it may be a problem of hot water supply capacity from the boiler. Check it out.

<Fig. 3>

4 In case hot water does not come out

during operation, tap inlet and domestic water outlet pipes are switched, and domestic water does not come out because hot water flow switch is not working.

- Check the piping of the switched tap water inlet and domestic water outlet.

<Fig. 2>

<Fig. 3>

Supply

<Fig. 1>

Room thermostat, FR-5

Operating lamp

Return

Domestic Water Outlet

Tap Water Inlet

Hot Water Flow Switch

Measure resistance

KDB-GOM

Series

- 75 -

14 - 3 Others Failure

Domestic water comes out but heating is not working

No Symptoms and Causes Solutions Reference

1 The splitter valve is shut down. - Open the splitter valve.

2 Too much air inside the boiler and the

pipeline.

- Remove the air from the boiler and the pipeline.

3 Hot water is always ON because the 3-

way valve is defective.

- Replace the hot water flow switch.

- The 3-way valve is defective and shuts down the heating. Replace the 3-way valve.

<Fig. 1>

4 There are many impurities in the heating

strainer and there is no heating circulation.

- Clean the strainer by removing the clip below the heating strainer.

<Fig. 2>

5 The heating pipeline is obstructed and

the heating water does not circulate.

- Clean the heating pipeline.

(contact the manufacturer)

6 Combustion is normal but the water

temperature goes up late and slowly.

- If the secondary gas supply pressure is insufficient, adjust it according to capacity using the water manometer.

- The heating area may be too big for the boiler capacity. Check the area and the capacity volume.

<Fig. 1>

<Fig. 2>

Check contact point

Hot Water Flow Switch

Heating Strainer

KDB-GOM

Series

- 76 -

14 - 4 Others Failure Boiler power lamp indicator does not light up

No Symptoms and Causes Solutions Reference

- Test whether 220V electricity comes out from the wall outlet.

<Fig. 1>

- Check whether the boiler internal fuse is shortcircuited.

<Fig. 2>

1 Boiler power lamp indicator does not light

up.

- Test the fuse resistance. If 0 it is normal, if infinite the fuse is short-circuited and has to be replaced.

2 The boiler power plug is in, hot water is

open, the boiler is operating and hot water does not come out.

- Check whether the room thermostat wire is short-circuited.

<Fig. 1>

<Fig. 2>

KDB-GOM

Series

- 77 -

14 - 5 Others Failure Too much noise

No Symptoms and Causes Solutions Reference

1 Too many ignition noise during ignition. - There is too much gas during the initial ignition.

Adjust the primary gas pressure according to regulations.

2 Ignition noise due to delayed ignition. - Space between electrodes is too close or too

far away. Adjust the space (2~3mm) between them.

- Replace the ignition transformer if it discharges.

<Fig. 1>

3 Noise during combustion. - The flue bends and length may be above

regulations (3 elbow 5.0m) and in case of a FF flue the airtight chamber may be damaged causing a flow of waste gas to the suction area. Check the flue and replace if needed.

<Fig. 2>

4 Boiling noise. - Boiling noise may occur when the heating

water temperature goes beyond a certain point due to uncleanness of the heating water or a defect in the welding of the main heat exchanger brazing. Clean the heating water and replace the main heat exchanger.

<Fig. 3>

<Fig. 1>

<Fig. 2>

<Fig. 3>

Crevice between electrode

2~3 mm

(Schem e of the

air intake hose is omitted)

Nail

Band Clamp

Screw

KDB-GOM

Series

- 78 -

1. Room Thermostat, FR-5

2. Main Controller

3. Modulating Gas Control Valve

4. Fan Assembly

5. Circulation Pump

6. Expansion Tank

7. Air Pressure Switch

8. 3-Way Valve

9. Heating Strainer

10. Ignition Transformer

11. Electrode Assembly

12. High Limit Sensor

13. High Limit Fuse

14. Hot Water Flow Switch

15. Domestic Water Heat Exchanger

16. Main Heat Exchanger

17. Power Transformer

VI. Procedure of disassembly/assembly

KDB-GOM

Series

- 79 -

No 1 Part name Room thermostat

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Separate the room thermostat by pulling up from the bracket.

③

Take the two screws connected with the thermostat wire off.

④

Separate the wire from the room thermostat.

Assembly

①

Connect the replaced wire to the thermostat by screwing the two screws.

②

Pull down the thermostat inside the bracket.

③

Plug the boiler into the electric outlet.

Caution

1. Don’t force disassembly.

2. After replacement, check the thermostat during boiler operation.

Room thermostat, FR-5

KDB-GOM

Series

- 80 -

No 2 Part name Main controller

Replacement steps

Disassembly

①

unplug the boiler from the electric outlet.

②

open the external cover of the boiler.

③

separate the harness terminal from the controller.

④

take off the two screws fixing the controller to the external base.

⑤

separate the controller from the boiler.

Assembly

①

fix the replacement controller to the external base.

②

screw the two screws fixing the controller to the external base.

③

connect the harness terminal to the controller.

④

close the external cover of the boiler.

⑤

plug the boiler to the electric outlet.

Caution

Check the connection of the harness terminal thoroughly.

④

⑤

KDB-GOM

Series

- 81 -

No 3 Part name Modulating gas control valve

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet and open the external cover.

②

Close the main gas valve installed on the gas supply pipe outside the boiler.

③

Loosen the flexible part connected to the gas inlet connection using manual tools (monkey spanner/group joint

plier).

④

Separate the four electric inlet wires connected to the gas control valve.

⑤

Separate the six wires connected to the gas control valve (4 ON-OFF valve, 2 proportional control valves ).

⑥

Separate the gas control valve and the nozzle by unscrewing the two screws connecting them.

⑦

Separate the board holding the ignition transformer and the air pressure switch from the nozzle by unscrewing

one screw.

⑧

Separate the gas control valve from the boiler.

Assembly

①

Fix the gas control valve to the external base.

②

Screw the four screws fixing the gas control valve to the external base.

③

Screw the two screws connecting the nozzle and the gas control valve (*check for the existence or

nonexistence of O-ring when connecting).

④

Assemble the parts making sure there is no gas leak.

⑤

Open the main gas valve.

⑥

Connect the six wires of the gas control valve correctly.

⑦

Fix the board holding the ignition transformer and the air pressure switch to the nozzle by screwing one screw.

⑧

Plug the boiler to the electric outlet.

Caution

1. Check whether the gas pipe connecting O-ring is correctly assembled.

2. Make sure not to switch the color of the connection terminals.

3. Perform a gas leak test using soap foam after assembly.

⑧

⑦

⑥

④

KDB-GOM

Series

- 82 -

No 4 Part name Fan assembly

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the external cover.

③

Separate the board holding the ignition transformer and the air pressure switch from the nozzle by removing

one screw.

④

Separate the hose connecting the fan and the air pressure switch.

⑤

Separate the wire and jack of the fan unit power line and the RPM detector line.

⑥

Take off the two screws fixing the fan unit.

⑦

Separate the fan unit from the boiler.

Assembly

①

Fix the fan unit to the boiler.

②

Screw the two screws fixing the fan unit.

③

Connect the jack of the fan unit power line and the RPM detector line.

④

Assemble the air pressure switch connecting hose.

⑤

Fix the board holding the ignition transformer and the air pressure switch to the nozzle by screwing one screw.

⑥

Close the external cover.

⑦

Plug the boiler to the electric outlet.

Caution

1. Make sure there is no shaking.

2. Check for unnecessary noise.

3. Make sure all the wires, including the phase controller wire, are correctly connected.

⑦

⑥

③

KDB-GOM

Series

- 83 -

No 5 Part name Circulation pump

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Release the heating water inside the boiler by opening the safety valve below the circulator pump.

④

Separate the circulator motor power jack.

⑤

Separate the circulation inlet hose and the circulator motor by pulling down the clip connecting them.

⑥ Take off heati n g ret urn p ipe and heat in g fl ow s wit ch. ⑦

Take off the four screws fixing the circulator pump to the front cover(downside).

⑧

Separate the circulator pump from the boiler.

Assembly

①

Fix the circulator pump to the boiler.

②

Screw the four screws fixing the circulator pump to the front cover.

③

Connect the circulation inlet hose and the circulator pump by pulling up the clip connecting them.

④

Connect the circulator pump power line jack and check the safety valve is closed.

⑤ Connect the heating flow switch and heating return pipe in the pump outlet. ⑥

Plug into the electric outlet and check for water leakage after water replenishment.

⑦

Close the front cover.

⑧

Plug the boiler into the electric outlet.

Caution

1. Make sure the O-ring is connected correctly.

2. After assembly, check for water leakage.

3. After assembly, make sure there is no noise due to vibrations or other causes.

③

⑤

⑥

KDB-GOM

Series

- 84 -

No 6 Part name Expansion tank

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Release the circulation pipe clip.

④

Release the circulation pipe.

⑤

Remove the nut for heating water filling pipe.

⑥

Release the nut for circulation pipe connecting the expansion tank and the various parts.

⑦

Separate the expansion tank by removing the two screws fixing its front cover.

Assembly

①

Screw the two screws fixing the expansion tank to the front cover.

②

Tighten the nut for circulation pipe connecting the expansion tank and the various parts.

③

Connect the circulation pipe connected to circulation inlet hose and insert the clip.

④

Connect the power cord, check for water leak after replenishing water, and if everything is fine, close the front

cover.

⑤

Plug the boiler into the electric outlet.

Caution

1. Check for water leak after assembly.

2. Check whether the sensor wire is correctly connected.

④

③

⑤

⑥

⑦

KDB-GOM

Series

- 85 -

No 7 Part name Air pressure switch

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Separate the two wires (yellow) connected to the air pressure switch.

④

Separate the air pressure switch by removing one screw from the board holding it.

⑤

Separate the air pressure switch connecting hose.

Assembly

①

Fix the air pressure switch to the board by screwing one screw.

②

Connect the two wires to the air pressure switch.

③

Assemble the hose connecting the air pressure switch.

④

Close the front cover.

⑤

Plug the boiler into the electric outlet.

Caution

1. Make sure there is no shaking after assembly.

2. Make sure the connecting jack is correctly assembled.

④

KDB-GOM

Series

- 86 -

No 8 Part name 3-way valve

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Release the heating water inside the boiler by unscrewing the safety valve below the circulator pump.

④

Separate the 3-way valve wire jack.

⑤

Separate the 3-way valve housing and head by removing the 4 screws on the lower part of the 3-way valve.

Assembly

①

Fix the 3-way valve to the 3-way valve housing.

②

Fix the 3-way valve head by screwing the 4 screws.

③

Connect the 3-way valve wire jack.

④

Screw the drain screw below the circulator pump.

⑤

Plug the boiler to the electric outlet and after water replenishment, check for water leak.

⑥

If everything is fine, close the front cover.

⑦

Plug the boiler into the electric outlet.

Caution

1. Make sure there is no water leak after assembly.

2. Check the jack connection.

④

KDB-GOM

Series

- 87 -

No 9 Part name Heating strainer

Replacement steps

Disassembly

①

󰼿Unplug the boiler from the electric outlet.

②

󰼿Open the front cover.

③

󰼿Release the heating water inside the boiler by unscrewing the drain screw below the circulator pump.

④

󰼿Separate the strainer by separating the

ㄷ

shaped lock.

⑤

󰼿Separate the hot water heat exchanger from the strainer by removing the connecting clip.

⑥

󰼿Separate the expansion tank from the strainer by removing the connecting connection.

Assembly

①

󰼿Fix the strainer to the boiler.

②

󰼿Fix the hot water heat exchanger by inserting the connecting clip.

③

󰼿Fix the expansion tank and the strainer by inserting the connecting connection.

④

󰼿Fix the strainer by screwing the 3 screws under the front cover (check the packing status between the strainer

and return inlet connection).

⑤

󰼿Fix the strainer and the

ㄷ

shaped lock.

⑥

󰼿Screw the drain screw under the circulator pump.

⑦

󰼿Unplug the power cord and after water replenishment, check for water leak

⑧

󰼿If everything is fine, close the front cover.

⑨

󰼿Plug the boiler into the electric outlet.

Caution

Check for water leak after assembly.

KDB-GOM

Series

- 88 -

No 10 Part name Ignition transformer

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Separate the two high voltage cables of the ignition transformer connected to the electrode from the electrode.

④

Separate the ignition transformer power cord jack.

⑤

Separate the ignition transformer by unscrewing the two screws.

Assembly

①

Screw the two screws fixing the ignition transformer.

②

Connect the ignition transformer power cord jack.

③

Connect the ignition transformer’s two high voltage cords to the electrode.

④

Close the boiler’s front cover.

⑤

Plug the boiler into the electric outlet.

Caution

1. Make sure fixation is done correctly.

2. Check the connection of the connection jack.

⑤

KDB-GOM

Series

- 89 -

No 11 Part name Electrode assembly

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Separate the ignition transformer’s two high voltage cords connected to the electrode from the flame sensor

wire.

④

Unscrew the two screws fixing the electrode.

⑤

Separate the electrode from the boiler

Assembly

①

Fix the electrode to the boiler.

②

Fix the electrode by screwing the two screws

③

Connect the ignition transformer’s two high voltage cords and the flame sensor wire to the electrode.

④

Close the front cover of the boiler.

⑤

Plug the boiler into the electric outlet.

Caution

1. Check whether the fixation is correctly done and spark production is good.

2. Make sure the connecting jack is correctly connected.

④

⑤

KDB-GOM

Series

- 90 -

No 12 Part name High limit sensor

Replacement steps

Disassembly

①

Unplug the boiler form the electric outlet.

②

Open the front cover.

③

Separate the overheating prevention device’s two terminals (red).

④

Remove the clip fixing the overheating prevention device ( or unscrew the two screws ).

⑤

Separate the overheating prevention device.

Assembly

①

Fix the overheating prevention device by inserting the clip (or screw the two screws ).

②

Connect the overheating prevention device wire.

③

Close the front cover.

④

Plug the boiler into the electric outlet.

Caution

1. Make sure fixation is done correctly.

2. Make sure the connecting jack is assembled correctly.

⑤

④

KDB-GOM

Series

- 91 -

No 13 Part name High limit fuse

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Separate the high limit fuse wire jack.

④

Separate the high limit fuse unit by unscrewing one screw fixing it.

Assembly

①

Fix the high limit fuse unit by screwing one screw fixing it.

②

Connect the high limit fuse wire jack.

③

Plug the power cord into the electric outlet and check its operation.

④

If everything is fine, close the front cover.

⑤

Plug the boiler power cord into the electric outlet.

Caution

1. Check fixation is done without any shaking.

2. Make sure the connecting jack is assembled correctly.

④

KDB-GOM

Series

- 92 -

No 14 Part name Hot water flow switch

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Close the water pipeline.

④

Separate the board holding the ignition transformer and the air pressure switch.

⑤

Separate the fan unit.

⑥

Separate the pin connecting the hot water sensor and the hot water heat exchanger and the pin connecting the

hot water inlet and the connection.

⑦

Separate the hot water sensor.

⑧

Separate the water valve by taking out the hot water sensor and removing the connecting pin from the water

valve.

Assembly

①

Fix the water valve to the hot water sensor and insert the connecting pin.

②

Insert the connecting pin into the hot water sensor.

③

Fix the fan unit.

④

Fix the board holding the ignition transformer and the air pressure switch.

⑤

Open the water and check for water leak.

⑥

Plugs the power cords into the outlet check the operation. if everything is fine, close the front cover.

⑦

Plug the boiler into the outlet.

Caution

1. Check for water leak after assembly.

2. Make sure the connecting jack is assembled correctly.

3. Make sure the O-ring is assembled correctly.

④

⑥

⑦

⑧

KDB-GOM

Series

- 93 -

No 15 Part name Domestic water heat exchanger

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Span the front cover .

③

Close the water valve.

④

Release the heating water by unscrewing the drain screw below the circulator pump.

⑤

Separate the fan unit.

⑥

Separate the board holding the ignition transformer and the air pressure switch.

⑦

Separate the hot water sensor.

⑧

Remove the 2 screws below the front cover fixing the hot water outlet of the hot water heat exchanger.

⑨

Separate the 2 pins connecting the hot water heat exchanger and the strainer, the hot water heat exchanger

and the expansion tank.

⑩

Separate the hot water heat exchanger from the boiler.

Assembly

①

Connect the hot water heat exchanger to the hot water outlet from outside.

②

Fix the hot water heat exchanger to the boiler.

③

Fix the hot water outlet of the hot water heat exchanger by screwing the 2 screws.

④

Insert the pipe clip at the connecting points.

⑤

Fix the board holding the ignition transformer and the air pressure switch.

⑥

Open the water, plug in the power cord, replenish water and check for water leak and if everything is fine, close

the front cover.

⑦ Plug the boiler into the electric outlet.

Caution

1. Check for water leak after assembly.

2. Make sure the O-ring is assembled correctly.

⑥

④

⑤

⑨

⑩

⑧

KDB-GOM

Series

- 94 -

No 16-1 Part name Main heat exchanger - 1

Replacement steps

Disassembl

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Release the heating water by unscrewing the drain screw below the circulator pump and release the heating

water from the splitter.

④

Separate the board holding the air pressure switch and the ignition transformer by removing one screw.

⑤

Separate the front cover of the main heat exchanger by removing the 9 screws in the front and the 2 screws on

the top.

⑥

Separate the gas pipe between the gas control valve and the nozzle.

⑦

Separate the fan unit according to the manual.

⑧

Remove the plastic hose band connecting the expansion tank and the main heat exchanger.

⑨

Separate the high limit fuse according to the manual.

⑩

Separate the overheating prevention device wire.

⑪

Remove the hot water temperature sensor.

⑫

Remove the 2 screws at the bottom, the screw on the left and the one on the right, fixing the main heat

exchanger to the front cover.

⑬

Separate the main heat exchanger from the boiler.

⑭

Separate the exhaust gas notice plate from the main heat exchanger by removing the 6 screws on the top.

⑮

Remove the 4 screws fixing the main heat exchanger and separate the main heat exchanger from its front

cover.

⑭

⑫

⑬

⑧

⑪

⑦

⑤

⑨

⑥

④

KDB-GOM

Series

- 95 -

No 16-2 Part name Main heat exchanger - 2

Replacement steps

Assembly

①

Fix the main heat exchanger to the front cover by screwing the 4 screws.

②

Fix the gas exhaust notice plate to the main heat exchanger by screwing the 6 screws.

③

Fix the main heat exchanger to the boiler by screwing the 4 screws on its front cover..

④

Insert the plastic hose connecting the expansion tank and put the band on.

⑤

Fix the hot water sensor.

⑥

Fix the high limit fuse.

⑦

Connect the 2 wires of the overheating prevention device.

⑧

Assemble the fan unit.

⑨

Connect the nozzle.

⑩

Connect the ignition transformer and the air pressure switch.

⑪

Plug in the power cord and check for water leak during operation. If everything is fine, close the front cover.

⑫

Plug in the boiler power cord into the outlet.

Caution

1. Check for water leak after assembly.

2. Check whether all bolts and nuts have been assembled.

3. Check for any shaking while in operation.

KDB-GOM

Series

- 96 -

No 17 Part name Power transformer

Replacement steps

Disassembly

①

Unplug the boiler from the electric outlet.

②

Open the front cover.

③

Separate the harness jack connecting the power transformer and the controller.

④

Unscrew the 2 screws fixing the power transformer and separate it from the boiler.

Assembly

①

Fix the power transformer to the boiler by screwing the 2 screws.

②

Put the power transformer harness jack into the controller.

③

Plug the power cord into the outlet and check its operation. If everything is fine, close the front cover.

④

Plug the boiler power cord into the outlet.

Caution

Make sure the connecting jack is connected properly.

④

KDB-GOM

Series

- 97 -

1. Exploded Views

2. Part List of each Sections

2.1 Front Cover & Cabinet Section

2.2 Main Heat Exchanger Section

2.3 Heating Water Section

2.4 Domestic Hot Water Section

2.5 Gas Supply Section

VII.

Part List

- 98 -

All GOM(3 kgf/cm )

128

48 49 50

46 47

35 36

31 32 33

EGI

ALCOT

ALDC

1 1 1

1 1

ALDC

ALCOT

TIME UP33-06

Silicone

SBHG1

1 1

NYLON66

Galvanium

EPDM

1 1 1

φ8×φ5×620L

L356×φ17×φ25

161/201GOM

All GOM(CS-0125W)

20 21 22

18 19

7 8

3 4 5

STS304

All GOM(φ25×φ17×4T)

161GOM(10P),201G OM(12P)

C1220T

C3771BE

EPDM

C1220T

C3771BE

NYLON66

C3771BE

NYLON66

STS304

1 1 1

1 1

All GOM, 20A(3/4")

161/201GOM

All GOM, 15A(1/2")

NYLON66

EPDM

C3771BE

EPDM

ABS

SBHG1

1 1

All GOM

L394×φ17×φ25

All GOM, 20A(3/4")

All GOM, AC 220V 50/60Hz

All GOM(0~4 kgf/cm )

161/201GOM

1.2T×250×90×16(WH/SKK)

SCP1

1 1

All GOM

161/201GOM

54 55

CR CR

1 1

NO.

PART NAME

MATERIAL Q'TY DESCRIPTION

ROOM THERMOSTAT(FR-5)

Front Cover Cabinet Base Bracket, Top Base Bracket, Bottom Combustion Air Vent Plate Flue Exhaust Combustion Air Vent Expansion Tank Heating Pressure Gauge Power Transformer Main Controller Heating Temperature Sensor Hose, Supply 3-Way Valve Connection, Heating Supply Hose, Domestic Water Supply Pipe, Supply Domestic Water Heat Exchanger Pipe, Domestic Water Outlet Connection, Domestic Water Outl et Hot Water Flow Switch Connection, Tap Water Inlet Pipe, Water Filling Pipe, Circulation Hose, Pump Inlet Strainer, Heating Connection, Heating Return Safety Valve Circulator Pump Heating Flow Sensor Hose, Return Exhaust Duct Main Heat Exchanger Ass'y High Limit Sensor Burner Ass'y Automatic Air-vent Manual Air-vent Hose, Drain 2nd Air Guide Plate 1st Air Guide Plate Combustion Chamber Ass'y Electrode Ass'y Fan Plate Fan Ass'y Combustion Chamber Cover Ass'y Flame Observation Port High Limit Fuse Nozzle Holder Ass'y Modulating Gas Control Valve Connection, Gas Inlet Bracket, Ignition Transformer Air Pressure Switch Ignition Transformer Packing, Fan Ass'y Packing, Nozzle Holder Ass'y

KDB-161/201GOM, EXPLODED VIEW

All GOM All GOM All GOM

All GOM

All GOM All GOM

All GOM

실내온도난방수온도

반복시간

난방수온도

확인

실내온도

420

온수전용

FR-5

운전

전원

161/201GOM

ON:98°C, OFF:70°C

161/201GOM

All GOM

All GOM, 1/8"PT

161/201GOM

All GOM

161/201GOM

All GOM All GOM

161GOM(φ62), 201GOM(φ70)

161/201GOM

All GOM

All GOM(195°C)

161(N,φ1.33), 201(N, φ1.46)

161/201GOM, 15A( 1/2")

All GOM All GOM All GOM All GOM All GOM

- 99 -

NYLON66

Pipe, Domestic Water Outlet

ALDC

Nozzle Holder Ass'y

실내온도난방수온도 반복시간

Packing, Fan Ass'y Packing, Nozzle Holder Ass'y

Combustion Chamber Cover Ass'y

Ignition Transformer

Electrode Ass'y Fan Plate

52 53

49 50

ROOM THERMOSTAT(FR-5)

확인

난방수온도

온수전용

실내온도

운전

FR-5

전원

ALCOT

1 1

φ8×φ5×720L

L277×φ17×φ25

TIME UP33-06

133

Air Pressure Switch Manual Air-vent Auto Air-vent

High Limit Fuse Main Heat Exchanger Ass'y

Combustion Chamber Ass'y

Modulating Gas Control Valve Connection, Gas Inlet

2nd Air Guide Plate 1st Air Guide Plate

High Limit Sensor

Fan Ass'y

45 46

Burner Ass'y

42 43

38 39

Exhaust Duct

35 36

SBHG1

ALDC

ALCOT

1 1

Galvanium

1 1

Connection, Domestic Water Outlet Hot Water Flow Switch Connec tion, Tap Water Inlet Pipe, Water Filling Pipe, Circulation Hose, Pump Inlet Strainer, Heating Connection, Heating Return

Circulator Pump Heating Flow Sensor

Hose, Return Hose, Drain

31 32

Safety Valve

24 25

C3771BE

EPDM

NYLON66

Silicone

1 1

C3771BE NYLON66 C3771BE

C1220T

EPDM

C1220T

1 1

3511

DESCRIPTION

L484×φ17×φ25

Combustion Air Vent Plate

Combustion Air Vent Expansion T ank Heating Pressure Gauge Power Transformer Main Controller Heating Temperature Sensor Hose, Supply

Connection, Heating Supply Hose, Dom estic Water Supply

Domestic Water Heat Exchanger

Pipe, Supply

17 18

3-Way Valve

12 13

10 11

Flue Exhaust

6 7

EPDM

C3771BE

EPDM

NYLON66

STS304

C3771BE

1 1

SBHG1

STS304

1 1

PART NAME

Base Bracket, Top Base Bracket, Bottom

Front Cover Cabinet

3 4

NO.

MATERIAL

SCP1 SCP1 SCP1 SCP1

1 1

Q'TY

KDB-251/301GOM, EXPLODED VIEW

251/301GOM

251/301GOM (E MBO)

1.2T×250×90×16 All GOM All GOM All GOM All GOM

251/301GOM

All GOM(0~4 kgf/cm )

All GOM, AC 220V 50/60Hz

All GOM All GOM

All GOM

All GOM, 20A(3/4")

All GOM All GOM

251GOM(16P), 301GOM(18P)

All GOM

All GOM, 15A(1/2")

251/301GOM

All GOM

All GOM(φ25×φ17×4T)

All GOM

All GOM, 20A(3/4") All GOM(3 kgf/cm )

All GOM All GOM

All GOM

All GOM, 1/8"PT

All GOM

251/301GOM

All GOM(195°C)

251/301GOM

MS-1P, 95 °C, Automatic

251/301GOM, 20A(3/4")

251/301GOM 251/301GOM

All GOM

251/301GOM 251/301GOM

251(N, φ1.37), 301(N, φ1.50)

All GOM

251/301GOM 251/301GOM

All GOM All GOM All GOM

- 100 -

Heat󰼿Source Set󰼿Temperature

Base

OFF

Rad

Fcl

MAX

Cast

OFF

4 0

normal

Room Thermosat

FR - 5

◈ Front Cover & Cabinet Section(1)

A/S Part List(Ⅰ) : KDB-161/201GOM, LNG

NO Part Name Part Code Q'ty Material Remarks

1 Room Thermostat C21005075A 1 All GOM, FR-5 2 Front Cover C21701278A 1 SCP1 KDB-161/201GOM 3 Pressure Gauge Sticker C22008023A 1 PC All GOM, 64×64×0.4T 4 Rock Ring, Cover C21701095A 2 STS304 KDB-161/201GOM, 1.0T

Cabinet C21701320A 1 SCP1 KDB-161/201GOM

Bolt C21336012A 25 MSWR3/FZ D4×10L

Base Bracket, Top C21701034B 1 SHP1 All GOM, 16×90×250×1.2T

Tapping Screw C21336011A 3 MSWR3/FZ D4×8L

Base Bracket, Bottom C21701211A 1 SHP1 All GOM

Tapping Screw C21336011A 3 MSWR3/FZ D4×8L Expansion Tank C22601010A 1 KDB-161/201GOM Tapping Screw C21336004A 2 MSWR3/FZ D5×10L

Combustion Air Vent Plate C21701217A 1 PP All GOM

Tapping Screw C21336011A 3 MSWR3/FZ D4×8L

Flue Exhaust C21701215C 1 STS304 All GOM

Tapping Screw C21336011A 3 MSWR3/FZ D4×8L

Combustion Air Vent C21701216A 1 PP All GOM

Tapping Screw C21336011A 3 MSWR3/FZ D4×8L

Heating Pressure Gauge C20405004B 1 ABS All GOM

Tapping Screw C21336011A 2 MSWR3/FZ D4×8L

13 Rock Ring, Cabinet C21701093A 2 STS304 KDB-161/201GOM, 0.8T

Power Trans former C20701060A 1 A ll GOM

Tapping Screw C21336011A 2 MSWR3/FZ D4×8L

Main Controller C21014104D 1 All GOM, KDC-208-1M

Tapping Screw C21336001A 2 MSWR3/FZ D4×10L 16 Harness (Wires) A ssembly C21405126C 1 KDB-161/201GOM 17 Glass Fuse C21744027A 2 A ll GOM, 250V 3A 18 Pow er Cord C21405142A 1 All GOM

Saturn KDB - 161 GOM, KDB - 251 GOM, KDB - 201 GOM, KDB - 301 GOM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual