Saturn KDB - 161 GOM Manual Download Page 45

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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

Summary of Contents for KDB - 161 GOM

Page 1: ...ns 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 H...

Page 2: ...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 domest...

Page 3: ...s 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 Shoul...

Page 4: ...fold Pressure kPa 0 16 0 92 0 16 0 96 0 25 0 94 0 14 0 96 Usage Heating Hot Water Water Storage Capacity liter 0 7 0 7 0 8 0 8 Power volts cycle Power Consumption watts Ignition NOx Emissions Ref 0 O2...

Page 5: ...ethod 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...

Page 6: ...KDB GOM Series 6 2 2 Constructions of the Boiler Model KDB Model KDB Model KDB Model KDB 251 301 GOM 251 301 GOM 251 301 GOM 251 301 GOM Model KDB 161 201GOM...

Page 7: ...zle Holder Assembly Burner Assembly Flame Detector Electrode High Limit Sensor Main Heat Exchanger Exhaust Duct 3 Way Valve Gas Inlet Domestic Water Outlet Tap Water Inlet Heating Return Heating Suppl...

Page 8: ...button the boiler runs for 20 minutes 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 temperatur...

Page 9: ...gh 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...

Page 10: ...m thermostat modelsFR 5only Theerrorcodesarediscussedinthetroubleshootingsectionoftheinstallationmanual B Flame Detection If the fails and or the re ignition attempt fails the gas supply is automatica...

Page 11: ...ol Topreventinternaldamagefromrupture eachboilerisprotectedfromoccasionalsurgesingaspressurebyaregulatinggovernor devicelocatedinthegasvalve K Short Circuit Protection Any short circuits occurring ins...

Page 12: ...e 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 7...

Page 13: ...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 Mout...

Page 14: ...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...

Page 15: ...n 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...

Page 16: ...he 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 ov...

Page 17: ...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 b...

Page 18: ...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 mm...

Page 19: ...r 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...

Page 20: ...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 s...

Page 21: ...art 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 thermost...

Page 22: ...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...

Page 23: ...tion 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 Ca...

Page 24: ...on 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 Cas...

Page 25: ...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 su...

Page 26: ...01GOM 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...

Page 27: ...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 ne...

Page 28: ...iring Connecting Diagram 4 17 1 Fault repair codes room thermostat FR 5 NO ON OFF 1 TrialRun Normal 2 ForcedMax Combustion Normal 3 ForcedMin Combustion Normal 4 FE FF 5 L P Gas NaturalGas 6 Close Air...

Page 29: ...FUSE 3A 2EA PUMP POWER TRANSFORMER 1 WHT AC 5V BLK BLK INPUT SIGNAL AC 200V 3 BLK Ground 2 RED DC 12V FLAME DETECTOR EARTH SUPERVISION FAN ROTATION BLK RED BLK DC 20V YEL YEL GRN PREVENTION INPUT SIGN...

Page 30: ...ition 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...

Page 31: ...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 pr...

Page 32: ...en 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 temperat...

Page 33: ...r 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...

Page 34: ...st 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 01 Overhe...

Page 35: ...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...

Page 36: ...signated concentricfluekitforKDB GOMmodels 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...

Page 37: ...pecified vent must be installed Incomplete combustion will occur and prevent normal operation of the boiler Forsafeoperation anamplesupplyofairmustbeprovidedforpropercombustionandventilationinaccordan...

Page 38: ...KDB GOM Series 38 2 Identifying the components of the boiler Model KDB 251 301GOM Model KDB 161 201GOM...

Page 39: ...urn 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...

Page 40: ...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...

Page 41: ...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...

Page 42: ...gh 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 po...

Page 43: ...nit 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 p...

Page 44: ...rom operating Do not over tighten wire nut connecting wires together 5 Use countersunk type screws CAREFULLY TIGHTEN THE 2 SCREWSWHEN CONNECTING THE WIRES DO NOT APPLY EXCESSIVE FORCE IF THE INSULATIO...

Page 45: ...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...

Page 46: ...tions 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 be...

Page 47: ...x 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...

Page 48: ...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 6 Check for external contamination S...

Page 49: ...8 HotWater 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...

Page 50: ...ting 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 f...

Page 51: ...KDB GOM Series 51 1 Conversion Kit Contents 2 Parts Tools Required 3 Conversion Procedure IV Fuel Conversion Method...

Page 52: ...hnician 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...

Page 53: ...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 th...

Page 54: ...ontPanel ON FrontPanel OFF FrontPanel ON FrontPanel 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...

Page 55: ...he 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 al...

Page 56: ...ort 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 F...

Page 57: ...mp 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 circuite...

Page 58: ...n 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...

Page 59: ...ower 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...

Page 60: ...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...

Page 61: ...pplied 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 ar...

Page 62: ...n 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...

Page 63: ...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 w...

Page 64: ...el 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...

Page 65: ...d 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 b...

Page 66: ...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...

Page 67: ...urner 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 un...

Page 68: ...er 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 zer...

Page 69: ...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 defect...

Page 70: ...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 Fig 1 Main Controller...

Page 71: ...er 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 a...

Page 72: ...isplayed although the controller DIP switch has been set according to capacity The controller is defective and has to be replaced Fig 1 Fig 1 Main Controller NO 161GOM 201GOM 251GOM 301GOM 8 OFF OFF O...

Page 73: ...op 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...

Page 74: ...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...

Page 75: ...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 pipelin...

Page 76: ...Check whether the boiler internal fuse is short circuited 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...

Page 77: ...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 are...

Page 78: ...culation 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...

Page 79: ...ke the two screws connected with the thermostat wire off Separate the wire from the room thermostat Assembly Connect the replaced wire to the thermostat by screwing the two screws Pull down the thermo...

Page 80: ...off the two screws fixing the controller to the external base separate the controller from the boiler Assembly fix the replacement controller to the external base screw the two screws fixing the contr...

Page 81: ...sformer and the air pressure switch from the nozzle by unscrewing one screw Separate the gas control valve from the boiler Assembly Fix the gas control valve to the external base Screw the four screws...

Page 82: ...e off the two screws fixing the fan unit Separate the fan unit from the boiler Assembly Fix the fan unit to the boiler Screw the two screws fixing the fan unit Connect the jack of the fan unit power l...

Page 83: ...the circulator pump from the boiler Assembly Fix the circulator pump to the boiler Screw the four screws fixing the circulator pump to the front cover Connect the circulation inlet hose and the circu...

Page 84: ...tank by removing the two screws fixing its front cover Assembly Screw the two screws fixing the expansion tank to the front cover Tighten the nut for circulation pipe connecting the expansion tank and...

Page 85: ...h by removing one screw from the board holding it Separate the air pressure switch connecting hose Assembly Fix the air pressure switch to the board by screwing one screw Connect the two wires to the...

Page 86: ...ad by removing the 4 screws on the lower part of the 3 way valve Assembly Fix the 3 way valve to the 3 way valve housing Fix the 3 way valve head by screwing the 4 screws Connect the 3 way valve wire...

Page 87: ...ng the connecting connection Assembly Fix the strainer to the boiler Fix the hot water heat exchanger by inserting the connecting clip Fix the expansion tank and the strainer by inserting the connecti...

Page 88: ...parate the ignition transformer power cord jack Separate the ignition transformer by unscrewing the two screws Assembly Screw the two screws fixing the ignition transformer Connect the ignition transf...

Page 89: ...wo screws fixing the electrode Separate the electrode from the boiler Assembly Fix the electrode to the boiler Fix the electrode by screwing the two screws Connect the ignition transformer s two high...

Page 90: ...clip fixing the overheating prevention device or unscrew the two screws Separate the overheating prevention device Assembly Fix the overheating prevention device by inserting the clip or screw the two...

Page 91: ...by unscrewing one screw fixing it Assembly Fix the high limit fuse unit by screwing one screw fixing it Connect the high limit fuse wire jack Plug the power cord into the electric outlet and check it...

Page 92: ...ate the water valve by taking out the hot water sensor and removing the connecting pin from the water valve Assembly Fix the water valve to the hot water sensor and insert the connecting pin Insert th...

Page 93: ...ater heat exchanger and the strainer the hot water heat exchanger and the expansion tank Separate the hot water heat exchanger from the boiler Assembly Connect the hot water heat exchanger to the hot...

Page 94: ...pipe between the gas control valve and the nozzle Separate the fan unit according to the manual Remove the plastic hose band connecting the expansion tank and the main heat exchanger Separate the high...

Page 95: ...nnecting the expansion tank and put the band on Fix the hot water sensor Fix the high limit fuse Connect the 2 wires of the overheating prevention device Assemble the fan unit Connect the nozzle Conne...

Page 96: ...Unscrew the 2 screws fixing the power transformer and separate it from the boiler Assembly Fix the power transformer to the boiler by screwing the 2 screws Put the power transformer harness jack into...

Page 97: ...ies 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...

Page 98: ...ansion 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...

Page 99: ...BE EPDM NYLON66 Silicone 1 1 1 1 1 1 C3771BE NYLON66 C3771BE C1220T EPDM C1220T 1 1 1 1 1 1 4 2 35 11 33 34 3 5 7 6 32 38 12 39 37 44 43 42 36 DESCRIPTION L484 17 25 Combustion Air Vent Plate Combusti...

Page 100: ...A 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 Tappi...

Page 101: ...1A 3 MSWR3 FZ D4 8L Expansion Tank C22601011A 1 KDB 251 301GOM 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 Fl...

Page 102: ...rode Assembly C21809040B 1 KDB 161 201GOM Electrode Bracket C21703162A 1 All GOM Tapping Screw C21336011A 2 MSWR3 FZ D4 8L 10 Hig Limit Fuse C21007028A 1 All GOM Tapping Screw C21336011A 1 MSWR3 FZ D4...

Page 103: ...FZ D4 8L Burner Assembly C25103088A 1 KDB 251 301GOM Tapping Screw C21336011A 2 MSWR3 FZ D4 8L Electrode Assembly C21809054B 1 KDB 251 301GOM Electrode Bracket C21703162A 1 All GOM Tapping Screw C2133...

Page 104: ...4024A 1 STS304 24 32 1T O ring C21603038A 1 EPDM 28 34 3T C21708336A 1 C1220T KDB 161 201GOM C21708339A 1 C1220T KDB 251 301GOM Bolt C21336012A 2 MSWR3 FZ D4 10L C21708338A 1 C1220T KDB 161 201GOM C21...

Page 105: ...Round Head C21305019A 2 S10C M4 12L 6 Domestic Water Flow Sw itch C21213016B 1 NY66 All GOM 7 Tap Water Inlet Connection C21708308B 1 C3771BE All GOM 8 Clip Domestic Water Flow S W C21374015A 1 STS304...

Page 106: ...pping Screw C2133011A 2 MSWR3 FZ D4 8L 6 Modulating Gas Control Valve C30109017A 1 All GOM TIMEUP33 06 7 O ring C21602065A 1 NBR 17 5 2 7T Gas Inlet Connection C21708304C 1 ALDC KDB 161 201GOM Bolt Ro...

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Saturn KDB - 161 GOM, Manual

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