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KyungDong KDB-181KCA Installation Manual

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k c a - 영 문
Contents
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
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.
33

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  • Page 1: Table Of Contents

    k c a - 영 문 Contents 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.

  • Page 2: Safety Warnings

    k c a - 영 문 Safety Warnings The cautions issued by this user’s manual include critical information for the safety while using the product. When the user fails to adhere to the following requirements can cause death, serious damages, and a great property loss. ‘Danger’, For safety, according to the level of danger, we have indicated by ‘Warning’, ‘Caution’...

  • Page 3: Safe And Correct Installation

    k c a - 영 문 Safe and Correct Installation This instruction booklet is considered an integral part of the product and must be delivered to the user together with the appliance. It must follows the appliance also in every passage of property. Store the booklet in a safe place and read it carefully before using the appliance as it contains important information to ensure safe installation, operation and maintenance.
  • Page 4 k c a - 영 문 Before Installation Please check the type of gas supplied at the installation location and the electrical lines before installation. Do not use any other type of gas than the one indicated on the boiler lower right hand corner rating plate.
  • Page 5 k c a - 영 문 When the boiler takes air from the place where it is installed, be sure that the opening ventilation are open. Any malfunction in the ventilation may cause improper combustion that may lead to Carbon Monoxide (CO) gas poisoning, a fire, or shorten product use life.
  • Page 6 k c a - 영 문 For B33 Type of installation. Please do not install the unit above any combusting appliance or near any air conditioning units. This may cause improper combustion causing CO poisoning. Please do not install the unit in a location where there are any corrosive materials such as ammonia, chlorine, sulfur, and acids.
  • Page 7 k c a - 영 문 Product Installation Method Since about 35~45kg of weight will be placed, the installation wall should be reinforced if it lacks the capacity to endure such weight. Unit weight is specified in the product specification chart of this manual. When installing the unit, use the anchor bolt for firm installation to bear the unit weight.

  • Page 8: Boiler Size And Function Guide

    k c a - 영 문 Boiler Size and Function Guide Boiler Schematic...
  • Page 9 k c a - 영 문 KDB-181/201/251/301KCA Condensed Water Discharge : Location where the condensed water is discharged (connect the discharge hose). Water Drain : Location where the water inside the boiler is discharged to prevent freezing in case of there is overflow of water or in case of long-term outing.
  • Page 10 k c a - 영 문 Standard Piping Diagram All pipes should be inspected for leaks after assembly is Distributor Specifications completed to prevent any defects or leaks. - Less than 5 holes : Inner diameter of over 36mm - Over 6 holes : Inner diameter of over 44mm All pipes other than the gas pipes should be insulated for Distributor material...

  • Page 11: Electricity Line Construction

    k c a - 영 문 Electricity Line Construction Electrical connection The Boiler has to be connected to the electrical installation by an “X” type power cable without plug. The power cable must be connected to a 230V~50Hz main supply correct sequence Line-Neutral-Heart. The main power supply must be also equipped with a multi-pole circuit switch, with a contact opening gap of al least 3 mm.
  • Page 12 k c a - 영 문 Fuse substitution • In the event of mains fuse replacement on the PCB, please use a 2A quick blow fuse. • Please switch-off the main switch upstream the boiler. • Take away the plastic box containing the main PCB. •...

  • Page 13: Gas Pipe Construction

    k c a - 영 문 Gas Pipe Construction Gas pipe construction must be done by gas dealer or gas pipe installation dealer. The diameter of the gas pipes for this LP gas container should be 50kg and unit is 15A (PT 1/2″) or 20A(PT 3/4”) for use two or more containers.
  • Page 14 k c a - 영 문 After gas pipe construction, a gas leak check must be done. In case of gas leak, it may cause an explosion that induces serious bodily harm or property damage. Please complete the gas pipe construction after checking the required gas for the unit.

  • Page 15: Heating And Hot Water Pipe Construction

    k c a - 영 문 Heating and Hot Water Pipe Construction Do not add anti-freezing liquid to the heating pipes. This may shorten use life of the unit and cause malfunctions. After completely cleaning out the pipes, then complete pipe construction. Any contaminant inside the pipes may reduce the heating and hot water efficiency as well as cause malfunctions.
  • Page 16 k c a - 영 문 Water Supply Construction The contact diameter of the water supply pipes of this unit is 15A (PT 1/2”). In the entrance of the water supply, install water supply middle valve. To use this unit it’s always necessary to have more than 0,5 bar inlet pressure for the filling of the installation and for domestic hot water production too.
  • Page 17 k c a - 영 문 After pipe construction is completed, you must check for leaks. When modifying the central heating system apartment to individual heating, since there is possible flood due to excessive water storage and air residuals in the pipes with the existing pipes, complete a contaminant cleaning and air release from within the heating pipes and if the pipes are old, make sure you replace the heating pipes.
  • Page 18 k c a - 영 문 Available Head to the System...
  • Page 19 k c a - 영 문...
  • Page 20 k c a - 영 문 Anti-Freezing Guard If unit is connected to the pipe and the pipe is not completely full of water, plug the power cord and in case of much bubbles inside the pipes, if you start the freezing guard function with less than sufficient number of pipes then this may cause the unit to rotate without operating normally, overheating the pump or induce malfunctions.

  • Page 21: Intake/Exhaust Flue Construction

    k c a - 영 문 Intake / Exhaust Flue Construction Please use only the flue approved by our company with the gas boiler manufactured or sold by our company. If any malfunction or accidents occur by using flue that was not approved by our company, our company will not be held responsible.
  • Page 22 k c a - 영 문 In the tunnel portion where the pipe goes through the wall, it must be completely airtight in order to prevent any exhaust gas from re-entering inside. If the exhaust gas enters inside, it may cause gas poisoning.
  • Page 23 k c a - 영 문 The flat portion of the flue should be installed upward at about 3° to prevent any discharge of the condensate away from the wall. Using proper, approved 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.
  • Page 24 k c a - 영 문 Forced Exhaust(FE) Type Pipe Construction, Type B33 Please install supply ventilation ventilation. Lack of ventilation may cause incomplete combustion due to oxygen shortage and if the ventilation malfunctions, incomplete combustion may result and exhaust gas may seep into the inside causing carbon monoxide poisoning.
  • Page 25 k c a - 영 문 Forced Draught Balanced Flue Construction Type C13 – C33 – C43 – C53 – C63 – C83 KCA Family boilers may installed with many different flue type system ; B33 – C13 – C33 – C43 – C53 – C63 – C83 For the installation of the different kind of flue system, please follow carefully the following instructions.
  • Page 26 k c a - 영 문 Flue Adapter for Separate Flue System Each separate 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.
  • Page 27 k c a - 영 문 Horizontal concentric flue system 60/100mm – Type C43 Vertical concentric flue system 60/100mm – Type C33...
  • Page 28 k c a - 영 문 Calculation of the maximum length with the concentric bend included in the flue system These flue systems may be oriented in all the possible directions: front, back, right and left hand. They may also include some special components, like the concentric bends, in order to reach some particular position.
  • Page 29 k c a - 영 문 With the above C13 flue system type (80/80 separate and 60/100 concentric) please NEVER close the terminal part with any object (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.
  • Page 30 k c a - 영 문 Horizontal/Vertical separate flue system 80/80 mm – Type C53 Calculation of the maximum length with the concentric bend included in the flue system These flue systems may be oriented in all the possible directions: front, back, right and left hand. They may also include some special components, like the concentric bends, in order to reach some particular position.
  • Page 31 k c a - 영 문 Calculation of the maximum length with the concentric bend included in the flue system For this arguments, please, follows the instructions contained in the previous paragraph. Position of the terminal for the exhausts The terminals for the exhaust have to respect certain minimum distances from the elements of the building as showed in the following prospect.
  • Page 32 k c a - 영 문 Cautions for Installation Intake/exhaust flue must be placed on the wall that connects to the outside. There should be no dangerous materials or obstructions near intake/exhaust flue. The wall where intake/exhaust flue are placed should be incombustible interior material. The connection part of the exhaust flue must be airtight by inserting its proper sealing gasket ;...

  • Page 33: Thermostat Installation Construction

    k c a - 영 문 Thermostat Installation Construction Installation Location Install on a wall where the heating occurs such as the bedroom. The installation location should be at least 1.2 ~ 1.5m from the floor where there is plenty of ventilation.

  • Page 34: Wiring Diagram

    k c a - 영 문 Wiring Diagram Wiring Connecting Diagram...
  • Page 35 k c a - 영 문 Wiring Diagram ℃ Symbol Domestic Hot Water Central Heating Digit Burner Indicate the current (DHW) Production (CH) Symbol Symbol Fixed ; the digit show a temperature. temperature. Fixed ; Boiler in CH Indicate the burner Symbol Missing ;...
  • Page 36 k c a - 영 문 Fault Codes The most important fault are detected by the PCB and showed trough the display interface. When a fault occur, the digits start to blink. The left digit shows the E letter (As Error Code). The 2 and 3 right digits show one of the following numbers :...
  • Page 37 k c a - 영 문 User menu (Synthesis) When the boiler is in working mode ON, pressing the button for less than 0.5 seconds it’s possible to look, on the display, at the following parameters in sequence : Parameter Display Heating water pressure digits...

  • Page 38: Change Of Gas

    k c a - 영 문 Change of Gas Gas Type Conversion If it’s necessary to convert the boiler for different type of gas than what specified on the data plate, the specific “gas kit conversion” must be requested for a quick and easy conversion. Conversion of the gas type must be done by a very skilled engineer authorized by the manufacturer.
  • Page 39 k c a - 영 문 • Take care over all about, the CO level to the min. output, if it’s not correct, adjust it turning the screw located in to the gas valve. Turning the right CO level will increase. After this adjustment, check one more time the CO level to the MAX output.
  • Page 40 k c a - 영 문 Checking after gas type conversion After ensuring the correct gas conversion with specified nozzles, orifices and checking the correct CO level, please ensure that : • There is no flame return in the combustion chamber •...

  • Page 41: Other Function And Adjustments

    k c a - 영 문 Other functions and Adjustments Adjustment of ignition capacity The ignition capacity of the boiler is adjusted in the factory at the reference level corresponding to 3,300 rpm of the fan speed. If necessary, for example in order to reduce some noise during the ignition stage, it’s possible to adjust this value from the MAX corresponding to 3,800 rpm to a MIN corresponding to 2,800 rpm.
  • Page 42 k c a - 영 문 Adjustment of DHW Pump Overrun The boiler has a function that permit to the pump to run, after each burner switch-off for Domestic Hot Water Production, for certain period of time (from 0 to 30 seconds) in order to have no risk of lockout for overheating of the heat exchanger.
  • Page 43 k c a - 영 문 Primary Flow and Primary Pressure Checking Primary water pressure is continuously checked; curing stand-by and during running condition. If the water pressure is or goes under 0,5 bar, the boiler is stopped and the fault code E10 appears on the display.
  • Page 44 k c a - 영 문 Frequency Supply Error If the electrical supply is different from what the PCB is set, the boiler doesn’t start and error code E15 appears on the display. Serviceman Function The boiler has a function that permit to force the boiler to run in Central Heating condition for 15 minutes without any gas modulation, in the following different coditions: max input, ignition input, minimum input.
  • Page 45 k c a - 영 문 Fan Control The control board devices the fan and read the fan speed by a signal coming from the fan (feed back). At each burner ignition request, the burner control sequence is enabled after that the fan reaches the correct ignition fan speed.

  • Page 46: Working Mode

    k c a - 영 문 Working Mode * Schematic Diagram for heating Operating Mode Air Intake Air Intake Orifice Expansion Tank Nozzle Exhaust Duct Mix Chamber Burner Ignition&Flame Dectection Rod NTC Sensor Copper H/E Safety Thermostat STS H/E Exhaust Safety Thermostat Three Way Valve DHW H/E Air Vent...
  • Page 47 k c a - 영 문 Domestic Hot Water (DHW) Production – Instantaneous Mode When the DHW flows, the DHW flow switch close the contact and the DHW Production mode begins. The pump switch on (if it was off), the fan is energized and, after checking the primary circuit water flow and the fan speed suitable for a correct burner ignition, the burner control is enabled.
  • Page 48 k c a - 영 문 Central Heating (CH) Mode The CH Mode phase begins when the heating demand comes from the room thermostat; under the condition the boiler is set in “winter” condition. If the room thermostat is not connected the CH mode phase begins a soon as the boiler is set in “winter”...

  • Page 49: Maintenance

    k c a - 영 문 Maintenance Yearly appliance check and maintenance The followings checks and maintenance activity should be performed at least one time per year : • Cleaning of the flue side of the heat exchanger • Cleaning of the burner •...

  • Page 50: Specifications

    - 영 문 Specifications Techni c al Speci f i c ation Model KDB-181KCA KDB-201KCA KDB-251KCA KDB-301KCA 21,4 ~ 10,2 23,9 ~ 11,5 29,2 ~ 11,6 34,9 ~ 15,1 Heating Input (Max-Min) (kcal/h) (18.404 ~ 8.772) (20.555 ~ 9,889) (25.111 ~ 9.976)
  • Page 51 k c a - 영 문 MEMO...
  • Page 52 k c a - 영 문 MEMO...
  • Page 53 ④ What are the costs of repair and benefits? For repairs, present the warrant to the Kyungdong Boiler service personnel when he or she visits your home for repairs to receive either free or charged repair benefits.

This manual is also suitable for:

Kdb-201kcaKdb-251kcaKdb-301kca

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