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I. Technical Information

1.1 Kyungdong Boiler Product Features and Functions

2.1 Operating Types

4.8 Hot Water Flow Sensor

4.9 High Limit Sensor(Bimetal Type)

4.10 High Limit Fuse(Fuse Type)

— 1 —

KDB-GOM

Series

• Page 1
  KDB-GOM Series I. Technical Information 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.
• Page 2
  KDB-GOM Series 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.
• Page 3
  KDB-GOM Series 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.

• Page 4: Specifications

  KDB-GOM Series 1.2 Specifications GAS WALL-MOUNT KDB — 161 / 201 / 251 / 301 GOM Residential Gas Hydronic Heating System FRONT View MODEL RANGE : 16,000 ~ 30,000 kcal/hr GAS FIRED, WALL-MOUNTED, MULTI-PURPOSE, HYDRONIC HEATING SYSTEMS —- KEY FEATURES Full, Dual Function Heating Design.
• Page 5
  KDB-GOM Series 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 Maintain normally at a constant water pressure by pressure reducing valve Heating (Auto / Manual) Control Method…
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  KDB-GOM Series 2.2 Constructions of the Boiler Model : KDB – 161 / 201GOM – — 6 -…

• Page 7: Schematic Diagram At Heating Water Supply

  KDB-GOM Series 2.3 Schematic Diagram of Operating 2.3.1 Schematic Diagram at the Heating Water Supply Flue Exhaust Combustion Air Inlet Exhaust Duct High Limit Fuse Main Heat Exchanger Expansion Tank High Limit Sensor Heating Temperature Flame Detector Sensor Electrode Burner Assembly Nozzle Holder Assembly Fan Assembly Air Pressure Switch…

• Page 8
  KDB-GOM Series 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.”…
• Page 9
  KDB-GOM Series 2.3.3 Schematic Diagram at the Domestic Water Supply Flue Exhaust Combustion Air Inlet Exhaust Duct High Limit Fuse Main Heat Exchanger Expansion Tank High Limit Sensor Heating Temperature Flame Detector Sensor Electrode Burner Assembly Nozzle Holder Assembly Fan Assembly Air Pressure Switch 3-Way Valve Modulating…
• Page 10
  KDB-GOM Series 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.
• Page 11
  KDB-GOM Series 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.
• Page 12
  KDB-GOM Series 4. Specifications and Functions of the Major Components 4.1 Main Heat Exchanger KDB – 161/201GOM KDB – 251 / 301 GOM 161GOM 201GOM 251GOM 301GOM Item Type Single Dry Type Single Wet Type Structure Copper Fin Copper pipe Brazing — For use of heating and hot water, absorb generated heat from main burner and Function then transmit it to heating pipe and hot water heat exchanger.
• Page 13
  KDB-GOM Series 4.2 Fan Assembly KDB – 161 / 201GOM KDB – 251 / 301GOM 161GOM 201GOM 251/301GOM Item Phase Controlled Air Intake Fan Fan Type Motor Type Shading Coil Induction Motor Condenser Induction Motor Blower Dimension 100 X 40L X 45 Fin 134 X 40L X 60 Fin (mm) — Supply air needed for combustion and exhaust the remained gas before and after…
• Page 14
  KDB-GOM Series 4.3 Circulation Pump All GOM models Item Pump Type Magnet Type Motor Type Single Phase, 2 Pole Induction Motor — Transmit the absorbed heat from main heat exchanger to heating pipe by circulating heating water when use heating. Function — Transmit the absorbed heat from main heat exchanger to hot water heat exchanger by circulating heating water inside of boiler when use hot water.
• Page 15
  KDB-GOM Series 4.4 Modulating Gas Control Valve Secondary pressure Adjust Screw Gas flow diagram All GOM models Item Model No. UP 33 –06 (TIME CO.) Rated Voltage AC 220V, 50 / 60Hz Power Consumption Controls the flow of gas supply by the current value received from main controller.
• Page 16
  KDB-GOM Series 4.5 3-Way Valve All GOM models Item Rated Voltage AC 220V, 50 / 60Hz Power Consumption NYLON 66 Body Material — 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 Function exchanging the heat of hot water with heating water in the hot water heat exchanger.
• Page 17
  KDB-GOM Series 4.6 Expansion Tank Nitrogen gas Charging point Part Name Material Remarks Body SBHG1 , 2.0t Bracket SBHG1 , 2.0t Diaphragm BUTYL , 2.0t Nipple S10C , PF3/8” Item KDB – 161 / 201GOM KDB – 251 / 301GOM Volume 6.5 Liter 8.5 Liter…
• Page 18
  KDB-GOM Series 4.7 Air Pressure Switch Item All GOM Model Electric Rating 0.1A –125V AC, 0.1A –30V DC (Micro Switch) Differential Pressure Type (Vertical Type), Normal Close Type Type Body Material Nylon 66 (GF 30%) — Stop the combustion safely and automatically by monitoring the high pressure Function or the adverse wind in the flue.
• Page 19
  KDB-GOM Series 4.8 Hot Water Flow Switch Item All GOM models Body Material Nylon 66 (GF 30%) 2.3 ± 0.3 liter / min Operating Flow 1.5 ± 0.5 liter / min Installation Type Horizontal Installation — 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.
• Page 20
  KDB-GOM Series 4.9 High Limit Sensor (Bimetal Type) [Automatic, MS-1] — 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”…
• Page 21
  KDB-GOM Series 4.10 High Limit Fuse (Fuse Type) — 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 Function secure the safety.
• Page 22
  KDB-GOM Series 4.11 Heating Temperature Sensor Item All GOM models DKS — 902ET — 330C Model No. ± 3% R50 = 3.485 Resistance R0 / R100 = 3449 K ± 1% B Constant Thermal Radiation Constant mW / Within 10 seconds Thermal Time Constant — Detect the temperature of heating water and transmit the signal to main controller.
• Page 23
  KDB-GOM Series 4.12 Ignition Transformer — Electric energy provides high voltage and current to the main burner for Function ignition of gas. Primary Rating AC 220 V , 50 / 60 Hz Power Requirement Secondary Rating 19 kVo-p 2 Secondary Current 7 mA 2 Casing Non-Combustible ABS…
• Page 24
  KDB-GOM Series 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 Power Requirement AC 34.0 V # 2-RED, # 6-RED Output Rating AC 18.4 V # 1-ORANGE, # 5-BLUE AC 12.0 V…
• Page 25
  KDB-GOM Series 4.14 Domestic Hot Water Heat Exchanger Tap Water Domestic Water Inlet Outlet Heating Heating Supply Return 161GOM 201GOM 251GOM 301GOM Item Material STS 304 Capacity 10 Pieces 12 Pieces 16 Pieces 18 Pieces — When use hot water, supply the heating water heated in main heat exchanger to hot water Function heat exchanger and heat-exchange water (water supply) with heating water supplied in hot water heat exchanger to be usable hot water.
• Page 26
  KDB-GOM Series 4.15 Burner Assembly 161 / 201GOM 251 / 301GOM Item 10 EA 15 EA Quantity of Secondary Nozzle Material of Secondary Nozzle ALSTAR Slit (Flame Holder) Material STS 430 Front Bracket SBHG 1 Rear Bracket STS 430 — Supply heat sources by mixing and combusting the supplied gas and Function air.
• Page 27
  KDB-GOM Series 4.16 Nozzle Holder Assembly Secondary gas pressure measuring hole 161GOM 201GOM 251GOM 301GOM Item Quantity of Primary Nozzle 10 EA 15 EA Material of Primary Nozzle C3602 BD Material of Nozzle Holder A6063S 1.33 1.46 1.37 1.50 Diameter of Nozzle(mm) 0.92 1.06…
• Page 28
  KDB-GOM Series 4.17 Wiring Diagram 4.17.1 Fault repair codes (room thermostat, FR-5) 4.17.2 DIP S/W Setting on Main Controller Problems Problems Overheat Air pressure failure Trial Run Normal Forced Max. Normal Low water level Water level detection failure Combustion Forced Min. Normal Ignition failure Flame failure in combustion…

• Page 29: Wiring Diagram

  KDB-GOM Series 4.17.3 Wiring Diagram KDB-GOM SERIES WIRING DIAGRAM LEGEND WHT : WHITE BRN : BROWN BLK : BLACK YEL : YELLOW ORG : ORANGE GRN : GREEN RED : RED BLU : BLUE GRY : GRAY — 29 -…

• Page 30
  KDB-GOM Series 4.18 Main Controller DIP Switch adjust part Max. adjust screw for secondary gas pressure Voltage , Frequency AC 220V , 50 / 60 Hz Voltage Range +10% to –15% Electric Spec. Ambient Temp. to 70 Ambient Humidity 45 – 90 % Structure Casing Model…
• Page 31
  KDB-GOM Series 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 ±…
• Page 32
  KDB-GOM Series 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.
• Page 33
  KDB-GOM Series ON/OFF Control Range Set Temperatures (“T” set) “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”…
• Page 34
  KDB-GOM Series 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.
• Page 35
  KDB-GOM Series II. Installation of Boiler & Accessory 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.
• Page 36
  KDB-GOM Series 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.
• Page 37
  KDB-GOM Series 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.
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  KDB-GOM Series 2. Identifying the components of the boiler Model : KDB – 161 / 201GOM Model : KDB – 251 / 301GOM — 38 -…
• Page 39
  KDB-GOM Series 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.
• Page 40
  KDB-GOM Series 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.
• Page 41
  KDB-GOM Series 4. Installation of the flue — Standard : The Stainless Steel Concentric Flue Kit for KDB-GOM models. 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.
• Page 42
  KDB-GOM Series 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.
• Page 43
  KDB-GOM Series 5. Gas piping connections 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. 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.
• Page 44
  KDB-GOM Series 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.

• Page 45: Troubleshooting

  KDB-GOM Series III. Trial operation & Checkup 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 — 45 -…

• Page 46: Checkup After Installation

  KDB-GOM Series 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.

• Page 47: Trial Operation Quick-Fill

  KDB-GOM Series 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.

• Page 48: Routine Maintenance

  KDB-GOM Series 5. Routine maintenance Checking Items Measures Close the gas shut-off valve, or turn off power to the Prior to inspection and maintenance. unit. Check for leaks in gas piping & connections Repair the leak. with soapy water. 1) Close the gas shut – off valve. Emergency measures for a gas leak.

• Page 49: Troubleshooting — Error Codes

  KDB-GOM Series 6. Troubleshooting 6.1 Troubleshooting — Error Codes Error Code Cause Troubleshooting Clogged / Reduce flow in heating system Check strainer clean Circulating pump failure Check system for air rate 01 / Overheat Check pump for operation –220V AC = 1 Amp No water in system / Pump failure Check system / Check pump No make up water supply…

• Page 50: Troubleshooting — Occurs

  KDB-GOM Series 6.2 Troubleshooting — Occurs IF ANY FAILURE OCCURS, CHECK THE FOLLOWINGS 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”…

• Page 51
  KDB-GOM Series IV. Fuel Conversion Method 1. Conversion Kit Contents 2. Parts & Tools Required 3. Conversion Procedure — 51 -…
• Page 52
  KDB-GOM Series MODEL : KDB – 161 / 201 / 251 / 301GOM – LNG , LPG 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.
• Page 53
  KDB-GOM Series [Table 1] Instructions apply to the following conversion kits: Natural Gas Propane Gas Conversion Kit, # Boiler Model Nozzle Size ( ) KDB – 161GOM, L NG 161GOM LPKT Ø 0.92 KDB – 201GOM, LNG 201GOM LPKT Ø 1.06 KDB –…
• Page 54
  KDB-GOM Series 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 — Key — Igniter wire &…
• Page 55
  KDB-GOM Series 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.
• Page 56
  KDB-GOM Series V. Troubleshooting 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.
• Page 57
  KDB-GOM Series # 02 Failure Low water level Splitter valve Measure (49) (147) resistance kgf/ Check valve is open (kPa) Circulation pump Heating Pressure gauge Heating flow sensor <Fig. 4> <Fig. 1> <Fig. 2> <Fig. 3> Symptoms and Causes Solutions Reference The heating flow sensor has to be ON within 3 seconds after the power supply.
• Page 58
  KDB-GOM Series 2 — 1 # 03 Failure Ignition failure Electrode Crevice 2~3 mm Blue Ignition Transformer Supply Pressure Gas Inlet Main Controller Measure Hole Electrode Connection Assembly <Fig. 1> <Fig. 2> <Fig. 3> 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…
• Page 59
  KDB-GOM Series 2 — 2 # 03 Failure Ignition failure Electrode Measure resistance Assembly Nozzle Holder Assembly Insulator damage High Limit Fuse <Fig. 2> <Fig. 2> <Fig. 1> Secondary Pressure Measuring Hole Modulating Gas Control Valve BLK BLK Check AC 220V Power Transformer <Fig.
• Page 60
  KDB-GOM Series 2 — 3 # 03 Failure Ignition failure Power Transformer Check AC 200V Check flame rod Wire connection Electrode Assembly <Fig. 2> <Fig. 1> Symptoms and causes Solutions Reference Combustion is working and failure code — Check the connection of the flame sensor on <Fig.
• Page 61
  KDB-GOM Series # 04 Failure Pseudo flame Internal diaphragm Modulating Gas Control Valve Main Controller <Fig. 2> <Fig. 1> 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.
• Page 62
  KDB-GOM Series # 05 Failure Disconnection of the heating temp. sensor Heating Temperature Sensor Check connection Main Controller <Fig. 1> Symptoms and causes Solutions Reference Failure code # 05 is displayed when the heating sensor is short circuited or disconnected. <Fig.
• Page 63
  KDB-GOM Series # 06 Failure Short circuit of the heating temp. sensor Measure resistance Measure resistance Measure resistance Check whether ball has fallen Circulation Pump 3-Way Valve Hot Water Flow Switch <Fig. 3> <Fig. 2> <Fig. 1> Symptoms and causes Solutions Reference Failure code # 06 is displayed when the…
• Page 64
  KDB-GOM Series # 09 Failure Abnormal RPM Measure resistance Phase control sensor Fan Assembly <Fig. 1> Symptoms and Causes Solutions Reference Fan unit RPM is too slow. — Replace the fan unit. <Fig. 1> The fan does not rotate. — Check whether the fan unit coil is short- circuited.
• Page 65
  KDB-GOM Series # 10 Failure Air pressure failure Air Pressure Switch <Fig. 1> 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. The diaphragm inside the air pressure — Check the resistance of the air pressure switch <Fig.
• Page 66
  KDB-GOM Series 8 — 1 # 12 Failure Flame failure in combustion L.P . Gas Container KyungDong Gas Meter <Fig. 1> <Fig. 2> Symptoms and Causes Solutions Reference Flame failure in combustion occurs when the flame disappears during combustion 10 times consecutively. Gas supply pressure is not right.
• Page 67
  KDB-GOM Series 8 — 2 # 12 Failure Flame failure in combustion Kyungdong Space between flame sensor 2~3mm with the burner Gas Meter Electrode Assembly Modulating Gas Control Valve <Fig. 2> <Fig. 1> <Fig. 3> Symptoms and Causes Solutions Reference Gas meter capacity is insufficient.
• Page 68
  KDB-GOM Series # 13 Failure Heating flow sensor failure Measure resistance Heating Flow Sensor <Fig. 1> Symptoms and Causes Solutions Reference Heating flow sensor failure occurs only in close air system boiler. <Fig. 1> Heating flow sensor is ON although the — Measure the resistance of the heating flow pump is not operating.
• Page 69
  KDB-GOM Series # 14 Failure Gas alarm Gas Alarm(Optional) <Fig. 1> Symptoms and Causes Solutions Reference After the installation of the gas alarm (optional feature), gas leak is detected and alarm goes off. There is no gas leak and failure code # 14 — Gas alarm is defective and has to be <Fig.
• Page 70
  KDB-GOM Series # 15 Failure MICOM failure Main Controller <Fig. 1> Symptoms and Causes Solutions Reference MICOM controller failure. — Replace the controller when displayed failure <Fig. 1> code # 15. — 70 -…
• Page 71
  KDB-GOM Series # 16 Failure Mechanical overheat Terminal separation Splitter Valve Hot Water Flow Switch High Limit Sensor <Fig. 1> <Fig. 2> <Fig. 3> Symptoms and Causes Solutions Reference When the high limit sensor (98 ) located on the upper right pipe of the main heat exchanger starts operation.
• Page 72
  KDB-GOM Series # 17 Failure DIP switch setting error Normal Forced maximum Normal Combustion Forced minimum Normal Combustion Check DIP switch setting L.P . gas Natural gas Close air type Open tank type 50 Hz 60 Hz 161GOM 201GOM 251GOM 301GOM Main Controller <Fig.
• Page 73
  KDB-GOM Series Boiler is operating normally but water overflows 14 — 1 Others Failure toward the expansion tank Internal Check splitter valve’s material diaphragm Water filling valve Check hating pipeline condition <Fig. 2> <Fig. 1> Symptoms and Causes Solutions Reference The water fill valve is defective and — There are many impurities in the heating water <Fig.
• Page 74
  KDB-GOM Series Heating is working but domestic water comes 14 — 2 Others Failure out cold or does not come out at all. Room thermostat, FR-5 Measure resistance Operating lamp Supply Domestic Water Outlet Tap Water Inlet Return Hot Water Flow Switch <Fig.
• Page 75
  KDB-GOM Series Domestic water comes out but heating is not 14 — 3 Others Failure working Check contact point Heating Strainer Hot Water Flow Switch <Fig. 2> <Fig. 1> Symptoms and Causes Solutions Reference The splitter valve is shut down. — Open the splitter valve.
• Page 76
  KDB-GOM Series 14 — 4 Others Failure Boiler power lamp indicator does not light up <Fig. 1> <Fig. 2> Symptoms and Causes Solutions Reference Boiler power lamp indicator does not light — Test whether 220V electricity comes out from <Fig. 1> the wall outlet.
• Page 77
  KDB-GOM Series 14 — 5 Others Failure Too much noise Nai l Crevice between electrode 2~3 mm Band Cl a mp Band Cl a mp Screw (Scheme of the air i n take hose i s omi t ted) <Fig. 2> <Fig.
• Page 78
  KDB-GOM Series VI. Procedure of disassembly/assembly 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.
• Page 79
  KDB-GOM Series Part name Room thermostat Room thermostat, FR-5 Replacement steps Unplug the boiler from the electric outlet. Separate the room thermostat by pulling up from the bracket. Take the two screws connected with the thermostat wire off. Separate the wire from the room thermostat. Connect the replaced wire to the thermostat by screwing the two screws.
• Page 80
  KDB-GOM Series Part name Main controller Replacement steps unplug the boiler from the electric outlet. open the external cover of the boiler. separate the harness terminal from the controller. take off the two screws fixing the controller to the external base. separate the controller from the boiler.
• Page 81
  KDB-GOM Series Part name Modulating gas control valve Replacement steps Unplug the boiler from the electric outlet and open the external cover. Close the main gas valve installed on the gas supply pipe outside the boiler. Loosen the flexible part connected to the gas inlet connection using manual tools (monkey spanner/group joint plier).
• Page 82
  KDB-GOM Series Part name Fan assembly Replacement steps Unplug the boiler from the electric outlet. Open the external cover. Separate the board holding the ignition transformer and the air pressure switch from the nozzle by removing one screw. Separate the hose connecting the fan and the air pressure switch. Separate the wire and jack of the fan unit power line and the RPM detector line.
• Page 83
  KDB-GOM Series Part name Circulation pump Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Release the heating water inside the boiler by opening the safety valve below the circulator pump. Separate the circulator motor power jack. Separate the circulation inlet hose and the circulator motor by pulling down the clip connecting them.
• Page 84
  KDB-GOM Series Part name Expansion tank Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Release the circulation pipe clip. Release the circulation pipe. Remove the nut for heating water filling pipe. Release the nut for circulation pipe connecting the expansion tank and the various parts. Separate the expansion tank by removing the two screws fixing its front cover.
• Page 85
  KDB-GOM Series Part name Air pressure switch Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Separate the two wires (yellow) connected to the air pressure switch. Separate the air pressure switch by removing one screw from the board holding it. Separate the air pressure switch connecting hose.
• Page 86
  KDB-GOM Series Part name 3-way valve Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Release the heating water inside the boiler by unscrewing the safety valve below the circulator pump. Separate the 3-way valve wire jack. Separate the 3-way valve housing and head by removing the 4 screws on the lower part of the 3-way valve.
• Page 87
  KDB-GOM Series Part name Heating strainer Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Release the heating water inside the boiler by unscrewing the drain screw below the circulator pump. Separate the strainer by separating the shaped lock.
• Page 88
  KDB-GOM Series Part name Ignition transformer Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Separate the two high voltage cables of the ignition transformer connected to the electrode from the electrode. Separate the ignition transformer power cord jack. Separate the ignition transformer by unscrewing the two screws.
• Page 89
  KDB-GOM Series Part name Electrode assembly Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Separate the ignition transformer’s two high voltage cords connected to the electrode from the flame sensor wire. Unscrew the two screws fixing the electrode. Separate the electrode from the boiler Fix the electrode to the boiler.
• Page 90
  KDB-GOM Series Part name High limit sensor Replacement steps Unplug the boiler form the electric outlet. Open the front cover. Separate the overheating prevention device’s two terminals (red). Remove the clip fixing the overheating prevention device ( or unscrew the two screws ). Separate the overheating prevention device.
• Page 91
  KDB-GOM Series Part name High limit fuse Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Separate the high limit fuse wire jack. Separate the high limit fuse unit by unscrewing one screw fixing it. Fix the high limit fuse unit by screwing one screw fixing it. Connect the high limit fuse wire jack.
• Page 92
  KDB-GOM Series Part name Hot water flow switch Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Close the water pipeline. Separate the board holding the ignition transformer and the air pressure switch. Separate the fan unit. 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.
• Page 93
  KDB-GOM Series Part name Domestic water heat exchanger Replacement steps Unplug the boiler from the electric outlet. Span the front cover . Close the water valve. Release the heating water by unscrewing the drain screw below the circulator pump. Separate the fan unit. Separate the board holding the ignition transformer and the air pressure switch.
• Page 94
  KDB-GOM Series 16-1 Part name Main heat exchanger — 1 Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Release the heating water by unscrewing the drain screw below the circulator pump and release the heating water from the splitter.
• Page 95
  KDB-GOM Series 16-2 Part name Main heat exchanger — 2 Replacement steps Fix the main heat exchanger to the front cover by screwing the 4 screws. Fix the gas exhaust notice plate to the main heat exchanger by screwing the 6 screws. Fix the main heat exchanger to the boiler by screwing the 4 screws on its front cover..
• Page 96
  KDB-GOM Series Part name Power transformer Replacement steps Unplug the boiler from the electric outlet. Open the front cover. Separate the harness jack connecting the power transformer and the controller. Unscrew the 2 screws fixing the power transformer and separate it from the boiler. Fix the power transformer to the boiler by screwing the 2 screws.

• Page 97: Exploded Views

  KDB-GOM Series VII. Part List 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 — 97 -…

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  Part Nam e Part Code Q’ty Material Rem arks Room Thermostat C21005075A All GOM, FR-5 Front Cover C21701278A SCP1 KDB-161/201GOM Pressure Gauge Sticker C22008023A All GOM, 64×64×0.4T Rock Ring, Cover C21701095A STS304 KDB-161/201GOM, 1.0T Cabinet C21701320A SCP1 KDB-161/201GOM Bolt C21336012A MSWR3/FZ D4×10L Base Bracket, Top…
• Page 101
  Part Nam e Part Code Q’ty Material Rem arks Room Thermostat C21005075A All GOM, FR-5, Ver1.1 Front Cover C21701280B SCP1 KDB-251/301GOM Pressure Gauge Sticker C22008023A All GOM, 64×64×0.4T Rock Ring, Cover C21701296A STS304 KDB-251/301GOM, 1.2T Cabinet C21701279B SCP1 KDB-251/301GOM Bolt C21336012A MSWR3/FZ D4×10L…
• Page 102
  Part Nam e Part Code Q’ty Material Rem arks C21703158A KDB-161GOM Main Heat Exchanger Assembly C21703159A KDB-201GOM Heating Temperature Sensor C21007029A All GOM C21336007A MSWR3/FZ D4×6L Automatic Air Vent C20307013A All GOM Pipe Clip C21374024A STS304 24×32×1T Manual Air Vent C20301010A All GOM High Limit Sensor…
• Page 103
  Part Nam e Part Code Q’ty Material Rem arks C21703160C KDB-251GOM Main Heat Exchanger C21703161C KDB-301GOM Exhaust Duct C21703141A KDB-251/301GOM Tapping Screw C21336011A MSWR3/FZ D4×8L Drain Hose C21606034A SILICONE KDB-251/301GOM, 8× 5×720L Automatic Air Vent C20307013A All GOM Pipe Clip C21374024A STS304 24×32×1T…
• Page 104
  Part Nam e Part Code Q’ty Material Rem arks Circulation Pump Assembly C20501017A All GOM Pressure Relief Valve C20307014C All GOM Heating Flow Sensor C21213011A NY66 All GOM, 20 Pipe Clip C21374009B STS304 27×34×1T C40308017A KDB-161/201GOM Heating Return Pipe C40308018A KDB-251/301GOM Pipe Clip C21374024A…
• Page 105
  Part Nam e Part Code Q’ty Material Rem arks C21703128A STS304 KDB-161GOM C21703129A STS304 KDB-201GOM Domestic Water Heat Exchanger C21703144A STS304 KDB-251GOM C21703145A STS304 KDB-301GOM Clip(Domestic Heat Exchanger) C21374014A STS304 1.8T Domestic Water Outlet Pipe C21808013A All GOM O-ring C21610036A P15×2.4T Domestic Water Outlet Connection C21708307B…
• Page 106
  Part Nam e Part Code Q’ty Material Rem arks Part Nam e Part Code Q’ty Material Rem arks C21707219A ALDC KDB-251GOM, 1.37 C21707273A ALDC KDB-161GOM, 1.33 Nozzle Holder Assembly Nozzle Holder Assembly C21707221A ALDC KDB-301GOM, 1.50 C21707275A ALDC KDB-201GOM, 1.46 Tapping Screw C2133011A MSWR3/FZ…