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Saturn KDB - 201 GOM User Manual

Saturn KDB - 201 GOM
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KDB-GOM
Series
- 1 -
1. Specifications of the KDB-GOM series
1.1 Kyungdong Boiler Product Features and Functions
1.2 Specifications
2. Operating Types/Constructions/Schematic Diagram
2.1 Operating Types
2.2 Constructions of the Boiler
2.3 Schematic Diagram of Operating
3. Equipment Protection and Personal Safety
4. Specifications and Functions of the Major Components
4.1 Main Heat Exchanger
4.2 Fan Assembly
4.3 Circulation Pump
4.4 Modulating Gas Control Valve
4.5 3-Way Valve
4.6 Expansion Tank
4.7 Air Pressure Switch
4.8 Hot Water Flow Sensor
4.9 High Limit Sensor(Bimetal Type)
4.10 High Limit Fuse(Fuse Type)
4.11 Heating Temperature Sensor
4.12 Ignition Transformer
4.13 Power Transformer
4.14 Domestic Hot Water Heat Exchanger
4.15 Burner Assembly
4.16 Nozzle Holder Assembly
4.17 Wiring Diagram
4.18 Main Controller
I.
Technical Information

Table of Contents

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Saturn KDB - 201 GOM Specifications

General IconGeneral
BrandSaturn
ModelKDB - 201 GOM
CategoryBoiler
LanguageEnglish

Summary

1. KDB-GOM Series Specifications

1.1 KyungDong Boiler Product Features

Details KyungDong Boiler product features including continuous hot water and built-in components.

Domestic Hot Water Priority

Explanation of the boiler's priority for domestic hot water over space heating.

Seal-Combustion Process

Description of the sealed-combustion venting process for safety and efficiency.

1.2 Technical Specifications

Key Features Overview

Highlights of the KDB-GOM series, including heating and hot water capabilities.

2. Operating Types, Constructions, and Schematic Diagrams

2.1 Operating Types

Details on the different operating modes and installation types of the boiler.

2.2 Boiler Constructions

Model: KDB – 251 / 301GOM Construction Diagram

Diagram showing the construction layout for KDB-251 and 301GOM models.

Model: KDB – 161 / 201GOM Construction Diagram

Diagram showing the construction layout for KDB-161 and 201GOM models.

2.3 Operating Schematic Diagrams

2.3.1 Heating Water Supply Schematic

Schematic illustrating the flow of water for the heating system within the boiler.

2.3.2 Heating Temperature Controls

Heating Water Temperature Selection

Instructions for setting heating water temperature directly via dial.

Room Temperature Control Method

Instructions for controlling heating based on room temperature settings.

Timer Function for Heating

Instructions for using the timer function for heating cycles.

2.3.3 Domestic Water Supply Schematic

Domestic Water Line Diagram

Diagram showing the components and flow for domestic hot water supply.

Heating Water Line Diagram

Diagram illustrating the path of water for the heating system.

2.3.4 Domestic Water Temperature Controls

Hot Water Usage Modes and Controls

Controls for domestic hot water usage in different heating modes.

Indirect Temperature Control Logic

How domestic hot water temperature is indirectly controlled by heating water temp.

Hot Water Temperature Settings

Setting for domestic hot water temperature during heating operation.

Standby After Hot Water Use

Procedure for boiler operation after domestic hot water usage.

3. Equipment Protection and Personal Safety

Ignition and Flame Safety

Procedures for ignition failure, flame detection, and safety shutdown.

Power and Environmental Safety

Boiler behavior during power interruptions and air pressure events.

Operational Safety Features

Overheat, low water, and re-ignition safety mechanisms.

4. Major Component Specifications and Functions

4.1 Main Heat Exchanger

Details on the main heat exchanger type, structure, and function.

4.2 Fan Assembly

Fan Type and Specifications

Specifications for the fan type, motor, and blower dimensions.

Fan Assembly Function

Explains the function of the fan assembly in combustion and exhaust.

4.3 Circulation Pump

Circulation Pump Type and Motor

Specifies the type of circulation pump and its motor details.

Circulation Pump Function

Describes the function of the circulation pump in heat transfer.

4.4 Modulating Gas Control Valve

Gas Control Valve Model and Function

Identifies the model number and explains the function of the gas control valve.

4.5 3-Way Valve

3-Way Valve Function and Operation Time

Describes the function and operating times of the 3-way valve.

4.6 Expansion Tank

Expansion Tank Function

Explains the function of the expansion tank in managing water pressure.

4.7 Air Pressure Switch

Air Pressure Switch Function and Reference

Describes the function and reference information for the air pressure switch.

4.8 Hot Water Flow Switch

Hot Water Flow Switch Function

Details the function of the hot water flow switch in detecting flow.

4.9 High Limit Sensor (Bimetal Type)

High Limit Sensor Function

Explains how the high limit sensor detects overheating and shuts down the boiler.

4.10 High Limit Fuse (Fuse Type)

High Limit Fuse Function

Describes the function of the high limit fuse in overcurrent protection.

4.11 Heating Temperature Sensor

Heating Temperature Sensor Function

Explains the role of the heating temperature sensor in controlling combustion.

4.12 Ignition Transformer

Ignition Transformer Function

Details how the ignition transformer provides high voltage for ignition.

4.13 Power Transformer

Power Transformer Function

Explains the function of the power transformer in supplying power to the boiler.

4.14 Domestic Hot Water Heat Exchanger

Domestic Hot Water Heat Exchanger Function

Describes the function of the domestic hot water heat exchanger.

4.15 Burner Assembly

Burner Assembly Function

Explains the function of the burner assembly in mixing gas and air.

4.16 Nozzle Holder Assembly

Nozzle Holder Assembly Function

Describes the function of the nozzle holder assembly for gas supply.

4.17 Wiring Diagram

4.17.1 Fault Repair Codes

List of fault repair codes displayed on the room thermostat.

4.17.2 DIP Switch Setting on Main Controller

DIP switch settings for different operating modes and models.

4.17.3 Wiring Connecting Diagram

Diagrams showing wiring connections for different pin configurations.

4.18 Main Controller

4.18.1 DIP Switch Setting on Main Controller

Details on setting the DIP switches on the main controller.

4.18.2 Functions of Main Controllers

Explains various functions and operational sequences of the main controller.

II. Boiler Installation and Accessories

1. Precautions Before Installation

Important considerations and warnings before starting boiler installation.

2. Identifying Boiler Components

Guide to identifying the different components of the boiler unit.

3. Water Piping Installation

Instructions for installing the water piping system for the boiler.

4. Flue Installation

Guidelines for installing the flue system for exhaust gases.

5. Gas Piping Connections

Instructions for making safe and correct gas piping connections.

6. Room Thermostat Installation

Steps for installing the room thermostat, including location and wiring.

III. Trial Operation and Checkup

1. Post-Installation Checkup

Procedures for checking the boiler after installation.

2. Gas and Water Leak Checks

Steps to check for gas and water leaks in the system.

3. Pre-Trial Operation Checks

Pre-trial operation checks, including gas type and electrical connections.

4. Trial Operation Procedures

Procedures for conducting the initial trial operation of the boiler.

5. Routine Maintenance

Guidelines for regular maintenance of the boiler.

6. Troubleshooting Common Issues

Section dedicated to diagnosing and resolving boiler issues.

IV. Fuel Conversion Method

1. Conversion Kit Contents

List of items included in the fuel conversion kit.

2. Required Parts & Tools

List of parts and tools needed for fuel conversion.

3. Conversion Procedure Steps

Step-by-step instructions for converting the boiler's fuel type.

V. Troubleshooting Specific Failures

1. Failure Code #02: Low Water Level

Troubleshooting steps for low water level failure code #02.

2. Failure Code #03: Ignition Failure

Troubleshooting steps for ignition failure code #03.

3. Failure Code #04: Pseudo Flame

Troubleshooting steps for pseudo flame failure code #04.

4. Failure Code #05: Heating Sensor Disconnection

Troubleshooting for heating sensor disconnection failure code #05.

5. Failure Code #06: Heating Sensor Short Circuit

Troubleshooting for heating sensor short circuit failure code #06.

6. Failure Code #09: Abnormal RPM

Troubleshooting for abnormal fan RPM failure code #09.

7. Failure Code #10: Air Pressure Failure

Troubleshooting for air pressure failure code #10.

8. Failure Code #12: Flame Failure in Combustion

Troubleshooting for flame failure in combustion code #12.

9. Failure Code #13: Heating Flow Sensor Failure

Troubleshooting for heating flow sensor failure code #13.

10. Failure Code #14: Gas Alarm (Optional)

Troubleshooting for gas alarm failure code #14.

11. Failure Code #15: MICOM Failure

Troubleshooting for MICOM controller failure code #15.

12. Failure Code #16: Mechanical Overheat

Troubleshooting for mechanical overheat failure code #16.

13. Failure Code #17: DIP Switch Setting Error

Troubleshooting for DIP switch setting error code #17.

14. Other Failure Codes

Troubleshooting for other miscellaneous failure codes.

VI. Disassembly and Assembly Procedures

1. Room Thermostat (FR-5)

Procedure for disassembling and assembling the room thermostat.

2. Main Controller

Procedure for disassembling and assembling the main controller.

3. Modulating Gas Control Valve

Procedure for disassembling and assembling the modulating gas control valve.

4. Fan Assembly

Procedure for disassembling and assembling the fan assembly.

5. Circulation Pump

Procedure for disassembling and assembling the circulation pump.

6. Expansion Tank

Procedure for disassembling and assembling the expansion tank.

7. Air Pressure Switch

Procedure for disassembling and assembling the air pressure switch.

8. 3-Way Valve

Procedure for disassembling and assembling the 3-way valve.

9. Heating Strainer

Procedure for disassembling and assembling the heating strainer.

10. Ignition Transformer

Procedure for disassembling and assembling the ignition transformer.

11. Electrode Assembly

Procedure for disassembling and assembling the electrode assembly.

12. High Limit Sensor

Procedure for disassembling and assembling the high limit sensor.

13. High Limit Fuse

Procedure for disassembling and assembling the high limit fuse.

14. Hot Water Flow Switch

Procedure for disassembling and assembling the hot water flow switch.

15. Domestic Water Heat Exchanger

Procedure for disassembling and assembling the domestic water heat exchanger.

16. Main Heat Exchanger

Procedure for disassembling and assembling the main heat exchanger.

17. Power Transformer

Procedure for disassembling and assembling the power transformer.

VII. Part List

1. Exploded Views

Diagrams showing exploded views of boiler components.

2. Part List by Section

Detailed part lists categorized by boiler sections.

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