KyungDong KDB-181KCA Installation Manual Download

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k c a - 영 문

1. Safety Warnings ----------------------------------------------------- 34

2. Safe and Correct Installation-------------------------------------- 35

3. Boiler Size and Function Guide---------------------------------- 40

4. Electricity Line Construction -------------------------------------- 43

5. Gas Pipe Construction --------------------------------------------- 44

6. Heating and Hot Water Pipe Construction -------------------- 65

7. Intake/Exhaust Flue Construction------------------------------- 72

8. Thermostat Installation Construction --------------------------- 84

9. Wiring Diagram------------------------------------------------------- 85

10. Display Interface -----------------------------------------------------86

11. Change of Gas -------------------------------------------------------89

12. Other Function and Adjustments -------------------------------92

13. Working Mode -------------------------------------------------------97

14. Maintenance --------------------------------------------------------100

15. Specifications --------------------------------------------------------101

※

This Installation Manual can be modified without any prior notice for

product quality improvement purposes.

Contents

Summary of Contents for KDB-181KCA

Page 1: ...tWater Pipe Construction 65 7 Intake Exhaust Flue Construction 72 8 Thermostat Installation Construction 84 9 Wiring Diagram 85 10 Display Interface 86 11 Change of Gas 89 12 Other Function andAdjustments 92 13 Working Mode 97 14 Maintenance 100 15 Specifications 101 This Installation Manual can be modified without any prior notice for product quality improvement purposes Contents ...

Page 2: ...nitions of the symbols indicated on the product and installation manual are as follows This symbol indicates Caution for bodily injury under particular conditions This symbol indicates Stop for possible bodily injury or property damage This symbol indicates a Must follow sign 2 Since the specified warnings and cautions in the installation manual are not all the cautions for using the product use m...

Page 3: ...d according to the manufacturer s instruction and by qualified personnel skilled in the specific sector as foreseen by the law Incorrect installation can cause damage or physical injury and the manufacturer declines all liability for failure to observe instruction and standards In particular maintenance must be performed by qualified personnel In this case an Authorized Manufacturer Service Centre...

Page 4: ...type of gas is used this may cause fireorexplosionduetoimproper combustion When installing the unit read the following items and install it according to designated method safely and correctly Please do not install in a location where there are flammable materials There is a danger of a fire if you install this unit near any dangerous flammable materials such as gasoline kerosene benzene or glue Be...

Page 5: ...a non combustible wall if combustible wall then install a heat proof panels The side of the unit should be at least 150mm away from any inflammables If right and left walls are non combustibles then the unit should be at least 45mm from the walls Heatproof panels insulating plate should be at least 3mm of metal or other non combustible materials The top of the exhaust pipe should be at least 150mm...

Page 6: ...s Boiler will be damaged quicker and cause improper combustion leading to CO poisoning Install the unit by maintaining at least 600mm space between any electricity facility Do not install near any location where there are many traffic of people Do not install near any stairs or emergency exit Ensure sufficient space for product inspection and repair For repair and inspection the front of the unit ...

Page 7: ...ht Fix the unit on the wall firmly to prevent any shaking during its operation to prevent any noise it is best to use buffer material such as rubber Gas boiler is for indoor use only and should not be installed outside such as a veranda If it has to be installed outdoors then place sufficient guarding materials such as aluminum to prevent any affects of wind on the combustion and prevent any snow ...

Page 8: ...k c a 영 문 40 BoilerSizeandFunctionGuide BoilerSchematic 3 ...

Page 9: ...he heating function by removing the contaminants inside the heating pipes using an inside filter When heating is not done properly removetheclipandcleanthefilter seepage 35 Heating Water Filter Strainer Filter is built in to catch any contaminants inside the heating pipes to improve heating efficiency When there is a problem with heating remove theclip andclean thefilter see page 35 Condensed wate...

Page 10: ...e pipes after fixing the connections using the spanner etc connectitto the pipes Distributor Specifications Lessthan 5holes Inner diameter ofover 36mm Over 6holes Inner diameter ofover 44mm Distributor material Please use non Corrosive material Donotuse aluminum carbon steelpipes castiron materials since theyare easilycorroded GasMeter Specifications 20 000 kcal h orless Over 3 level 25 000 35 000...

Page 11: ...n effective and efficient earth system as specified in the current safety standard The boiler is designed with IPX4d protection rating The power cable must be laid as shown in the figures For safety reason please take the earth cable at least 2 cm longer than the Line and Neutral cable In the event of power cable replacement please contact a qualified electrical technicians At the end of any cable...

Page 12: ...e connected to a clean contact of a room thermostat Please remove the jump from the terminal block N 3 and 4 and connect the cable coming from the free contact of the room thermostat The boiler is designed to be connected to an external probe sensor for external environmental temperature checking Please connect it to the terminal block N 5 and 6 as showed in the figure The boiler is designed to be...

Page 13: ...ork can cause malfunctions 3 When using LP gas use caution of the following items LP gas governor should be household low pressure governor thatisproperforgasusageindicated LP gas container should be 50kg and use two or more containers connect a twin valve to supply gas from the two containers simultaneously In case the container capacity is small evaporation capacity is small that it may cause ga...

Page 14: ...gnition When using a gas container place the container in the cool shady place away from direct sunlight in the outdoors and fix the container properly to prevent tipping An explosion may occur Pipematerialshouldadhere totheKSstandards Gas Pipe Carbon steel pipe for pipe usage copper or copper alloy pipe metal flexible pipe approved by gas component part inspection testing Heating Pipe Copper pipe...

Page 15: ...y be freezing during the winter months Since hot water cannot be used in case of supply water pipe freezes and when there is insufficient water inside the heating pipes the water cannot be replenished making normal operation of the boiler impossible When completing the pipe connection construction it should be done after tightening the boiler pipe adaptor with a tool such as a spanner Do not use e...

Page 16: ...ex pipes Please maintain at least 1 200 1 300 upward incline for proper drainage Please connect the pipes in a way to avoid any collection of air inside the pipes The contact diameter of the heating pipes of this unit is 20A PT 3 4 The diameters of the supply pipe and the circulation pipe should be the same The pipe length should be as short as possible and any curvature or connections should be m...

Page 17: ...the siphon exit at the bottom of the boiler and the end of the release hose must be connected to the sewage or the water conduit When using a separate release hose use vinyl or plastic hose with more than 13 mm in diameter The siphon inside the boiler must be always full of water and if there is no water fill it with water through the exhaust duct Condensed water should not be used for drinking wa...

Page 18: ...k c a 영 문 50 AvailableHeadtotheSystem ...

Page 19: ...k c a 영 문 51 ...

Page 20: ... be protected from freezing by covering with at lease 25mm of insulation material Colder locations it should be at least 50mm General Cautionary Items in Pipe Construction Each connection part must be tightened with union or nut Water supply pipe hot water pipe heating pipe distributor and check valve must be insulated to prevent freezing Pipe materials must be national or local standard materials...

Page 21: ...be done according to the instructions given If the intake and exhaust flue construction is done improperly there is a possibility of exhaust gas poisoning and shorten the use life of the product Intake or exhaust flue should be installed in a location where there is the good ventilation to the outside and there is no seepage of exhaust gas into the inside of the house It is possible to cause incom...

Page 22: ...ase install so that the intake side or the exhaust side of the supply exhaust pipes are not inside of the wall If the intake exhaust openings are inside of the wall there are may be incomplete combustion due to lack of oxygen causing Carbon Monoxide poisoning Please install so that the rain cover protection is placed in the upper side If the cover is not correctly placed the rain can enter in to t...

Page 23: ...d flue system and following the producer s instruction it s possible to prevent any discharge of condensate away from the wall and avoid reenter of rain in to the flue system The flue system has to be installed in view The flue system have to be installed in view for a easy control and in order to avoid that any kind of exhaust leak may spread through the hided ...

Page 24: ... For the choice of the correct dimension of the holes of ventilation please follows the national and the local laws and standards For B33 installation type intake or exhaust flue should be installed in a location where there is a good ventilation from the outside and there is no seepage of exhaust gas into the inside of the house Please follows the instruction supplied in the following paragraph I...

Page 25: ...se follow carefully the following instructions Each concentric flue system kit includes an adapter as showed in the figure that permits to connect the boiler to the flue system Take care about the correct position of the components and of the seals as showed in the figure ForcedDraughtBalancedFlueConstruction TypeC13 C33 C43 C53 C63 C83 FlueAdapterforConcentricFlueSystem ...

Page 26: ...apter as showed in the figure that permits to connect the boiler to the flue system Take care about the correct position of the components and of the seals as showed in the figure FlueAdapterforSeparateFlueSystem Horizontalconcentricfluesystem60 100mm TypeC13 ...

Page 27: ...k c a 영 문 59 Horizontalconcentricfluesystem60 100mm TypeC43 Verticalconcentricfluesystem60 100mm TypeC33 ...

Page 28: ...not 3 80m but not more than 2 50m If it s necessary to insert two 45 bends in the 60 100 vertical flue system type C33 the total high that the vertical flue system may reach is not 5 00m but not more than 3 50m In order to considered C13 type the terminals for the air intake and for the exhaust outlet have to be included in a square of 50cm It is also possible to install the terminal at a longer d...

Page 29: ...ct like for example plastic bag or other devices during the painting of the external side of the wall that may force the exhausts to return in to the air duct On the contrary it exist the concrete risk of explosion of the sealed chamber of the boiler Horizontalseparatefluesystem80 80mm TypeC83 Horizontalseparatefluesystem80 80mm TypeB33 ...

Page 30: ...ssary to insert some concentric bends please consider that each of them has a resistance corresponding to the following linear length Then if it s necessary for example to insert others N 2 90 bend in the flue system type C53 the total length that the flue system may reach is not 33 70m but not more than 29 30m Horizontal Verticalseparatefluesystem80 80mm TypeC53 Calculationofthemaximumlengthwitht...

Page 31: ...ear window E 400 From a near air opening F 600 From a discharge tube G 300 From a building corner H 300 From a recess I 300 From the ground or other floor L 2 500 Between two terminal in vertical M 1 500 Between two terminal in horizontal N 1 000 From a facing wall without any air opening or any other terminal in a radius of 3m O 2 000 From a facing wall with air opening or other terminal in a rad...

Page 32: ...n sufficiently pushing it through Please check for any exhaust gas leaks When the exhaust flue goes through the combustible wall including the flue it should be insulated with over 20mm of incombustible material and keep at least 50mm from any combustible materials In the exhaust flue or exhaust elbow connection portion insert its proper sealing gasket and connect it so that it does not disconnect...

Page 33: ...installation location should be at least 1 2 1 5m from the floor where there is plenty of ventilation Do not install in a location where it is close to the common door where there is cold draft where there is direct sunlight where achild may reach it Examples of Installation location thermostat InstallationLocation 8 ...

Page 34: ...k c a 영 문 66 WiringDiagram WiringConnectingDiagram 9 ...

Page 35: ...ee External Temperature KFactor Pressing together with the near one for more 2sec the boiler reset from thelockout condition Lockout Symbol Indicates the boiler is in lockout mode condition Heating Water Pressure Symbol Pressing for less less than 0 5sec on the inquiry Push button this symbol appears and the display shows the heating waterpressure K Factor Symbol Fixed External temperature probe s...

Page 36: ...er short circuit signal E15 Main supply frequency error 50Hz E16 Lockout for high limit switch Lock out for chimney thermostat intervention E20 High Limit Switch or Chimney Limit Switch intervention during a stand by condition E21 Tension falling of the main supply during last 24 hours When the boiler is in working mode pressing the button and the left side button contemporaneously for at least 10...

Page 37: ...ic hot water temperature C digits 3rd Central heating temperature C digits 4th External temperature 1 C digits 5th K factor 1 digits 6th Fan speed rpmx10 digits 7th Tension falling during last 24 hours E21 if exist Return to the standard visualization 1 The external temperature and the K factor are shown if the external sensor is present A complete explanation of the user procedure is written in t...

Page 38: ...fice 5 55 24 5 6 80 28 0 5 95 25 5 6 70 29 0 G25 Ø nozzle Ø orifice 6 30 24 5 7 90 28 0 6 75 25 5 8 05 29 0 G27 Ø nozzle Ø orifice 6 65 24 5 8 40 28 0 7 00 25 5 8 20 29 0 G30 Ø nozzle Ø orifice 3 65 22 0 4 20 24 5 3 95 23 0 4 40 25 5 G31 Ø nozzle Ø orifice 4 25 24 5 5 15 28 0 4 55 25 5 5 15 29 0 Insert the probe of the combustion analyzer in to the exhaust proving device of the flue system Check t...

Page 39: ... 53 6 6 2 94 6 6 3 00 6 6 1 88 6 3 1 86 201KCA MIN 9 741 11 3 11 5 1 5 1 22 1 6 1 42 1 6 1 44 1 6 0 91 1 6 0 89 MAX 24 383 28 4 29 2 8 8 3 09 8 9 3 59 8 9 3 67 9 5 2 30 8 9 2 27 251KCA MIN 9 796 11 4 11 6 1 5 1 23 1 5 1 43 1 5 1 46 1 5 0 91 1 5 0 90 MAX 29 083 33 8 34 9 6 9 3 69 6 9 4 30 7 0 4 38 7 9 2 75 6 9 2 71 301KCA MIN 12 765 14 8 15 1 1 4 1 60 1 4 1 86 1 4 1 90 1 4 1 19 1 4 1 17 Pressure to...

Page 40: ...sed There are not leakages from the gas circuit By the deep switch N 1 and N 2 located in to the Electric Board it s possible to select the correct fan speed suitable for the boiler according to the above table This regulation is done in the factory by the manufacturer But anyway if some doubt exist about the correct setting please check the dip switch setting following this scheme DIP 1 DIP2 BOIL...

Page 41: ...on output up to the correct value reading the ignition in the combustion chamber The adjustment may be done changing the fan speed from 2 800 to 3 800 rpm the display will show the right digits changing from 28 to 38 The boiler has a function that permit to the pump to run after each burner switching off for certain period of time from 0 to 2 000 seconds in order to have a uniform temperature insi...

Page 42: ...is adjustable as follows Press the and the left button and for at lest 10 sec up the digits start to blink Press the button in the left side up to the number 2 appears in the left digit A number included between 0 to 99 appears in the right digits Press in the right side in order to arrange theAFCF up to the value desired The number included between 0 to 99 appearing in the right digits represent ...

Page 43: ... electrical short circuit the burner ignition is still avoided and the error code E13 is shown If the primary temperature probe failure occurs interruption and short circuit the burner switch off and the fault code is displayed E05 E06 If a DHW temperature probe failure occurs interruption and short circuit the DHW service is avoided and the fault code is displayed E07 E08 The DHW temperature prob...

Page 44: ...w the heating temperature in blinking mode Boiler forced to the ignition input Starting from the previous condition press the button palce on the right side of the display the number 01 appears in the right side digits Press the button one more time in the right side the number 02 appears in the right side digits The burner is now set to the ignition input After few seconds the two digits in the r...

Page 45: ...able and the pump runs for the Ch overrun time Anti freezing function keeps operating in each working mode also OFF mode If the boiler is in the lock out condition only the pump is activated After 24 hours of inactivity the pump is energized for 30 sec in order to prevent the block After 24 hours of inactivity the 3 way valve is energized for 10 sec in order to prevent the block If a request occur...

Page 46: ... Thermostat Air Vent Heating Strainer Pump Siphon Orifice Fan Mix Chamber Burner Ignition Flame Dectection Rod NTC Sensor Safety Thermostat Three Way Valve DHW H E Gas Valve DHW Flow S W DHW NTC Sensor 1 2 3 4 5 6 Copper H E 1 2 3 4 5 6 7 7 Heating Water Supply Heating Supply Pump STS H E Three Way Valve Heat Supply Room Heating Heating Coil Radiator Heating Return Heating Strainer Air Intake Air ...

Page 47: ...3 way valve relay is switched off This mode allow to use an external tank storage with the thermostat and an external 3 way valve When the thermostat close the contact the boiler starts the 3 way valve is moved to CH position and the circulator and the fan are energized After checking the precense of primary flow and the fan reaches the ingnition speed the burner control working is enabled Passed ...

Page 48: ...oint is reached the rising rump is stopped and the control passes to the modulating mode to achieve the central heating set point In case of the temperature exceed the temperature set in CH mode the burner switch off and the anti fast cycling timer is loaded The burner restart when the primary temperature falls under the temperature set in CH mode and if the anti fast cycling time is finished The ...

Page 49: ...n the pressure gauge Checking of the correct activation of the detection control system its activation must be shorter than 5 seconds Watertight of the boiler heating and domestic hot water production circuit no leakage or water oxidation have to appear around the coupling Visual Checking that the outlet of the pressure relive valve is not blocked Checking that the expansion vessel charge after ha...

Page 50: ...7 20 204 20 204 20 204 30 306 37 377 20 204 20 204 20 204 30 306 37 377 Purpose HeatingandDomesticHotWaterProduction HeatingWaterCirculationMethod AirCloseType MaxHeatingWaterPressure bar 3 0 MaxHeatingTemperature 85 AdjustableTemperatureHeating 30 50 40 80 TotalVolumeExpansionTank L 7 0 10 0 ExpansionTankPreCharge bar 1 0 DomesticHotWaterOutput kW kcal h 20 9 10 0 17 962 8 596 23 3 11 3 20 000 9 ...

Page 51: ...k c a 영 문 83 MEMO ...

Page 52: ...k c a 영 문 84 MEMO ...

Page 53: ...mer Damage Types Repair Exchange Within one year from the date of installation of the unit Leaks in the unit manufacturer defect Hot water or heating problems Defective components ignition device or thermostat Noise Free Unit Free Within 3 months of the date of installation of the unit Damages external Free Unit Free Damages compensation regulation after warranty expiration Same as above Charge Ch...

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