Saturn KDB - 301 GOM User Manual

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

Saturn KDB - 301 GOM Specifications

General

Brand	Saturn
Model	KDB - 301 GOM
Category	Boiler
Language	English

Summary

I. Technical Information

1. Specifications of the KDB-GOM series

Overview of the KDB-GOM series specifications, including features and data.

1.1 KyungDong Boiler Product Features and Functions

Detailed overview of the boiler's unique features and operational capabilities.

1.2 Specifications

Technical specifications and performance data for the KDB-GOM series boilers.

2. Operating Types, Constructions, and Schematic Diagram

Information on boiler operating modes, construction details, and operational diagrams.

2.1 Operating Types

Description of the different operating modes and configurations of the boiler.

2.2 Constructions of the Boiler

Details on the internal and external construction of the KDB-GOM boiler.

2.3 Schematic Diagram of Operating

Diagrams illustrating the operational flow of the boiler's heating and water systems, including controls.

3. Equipment Protection and Personal Safety

Critical safety features and measures to protect equipment and users.

4. Specifications and Functions of the Major Components

Detailed specifications and functional descriptions of key boiler components.

4.1 Main Heat Exchanger

Information on the main heat exchanger's specifications and function.

4.2 Fan Assembly

Details on the fan assembly's specifications, function, and construction.

4.3 Circulation Pump

Specifications and operational details of the circulation pump.

4.4 Modulating Gas Control Valve

Specifications and function of the modulating gas control valve.

4.5 3-Way Valve

Specifications and operational characteristics of the 3-way valve.

4.6 Expansion Tank

Specifications and function of the expansion tank.

4.7 Air Pressure Switch

Details on the air pressure switch's function and specifications.

4.8 Hot Water Flow Switch

Specifications and function of the hot water flow switch.

4.9 High Limit Sensor (Bimetal Type)

Information on the high limit sensor's specifications and safety function.

4.10 High Limit Fuse (Fuse Type)

Specifications and function of the high limit fuse.

4.11 Heating Temperature Sensor

Details on the heating temperature sensor's specifications and role.

4.12 Ignition Transformer

Specifications and function of the ignition transformer.

4.13 Power Transformer

Specifications and role of the power transformer.

4.14 Domestic Hot Water Heat Exchanger

Specifications and function of the domestic hot water heat exchanger.

4.15 Burner Assembly

Details on the burner assembly's specifications and function.

4.16 Nozzle Holder Assembly

Specifications and function of the nozzle holder assembly.

4.17 Wiring Diagram

Diagrams and information related to the boiler's wiring, fault codes, and controller settings.

4.18 Main Controller

Details on the main controller's specifications, functions, settings, and operational modes.

II. Installation of Boiler & Accessory

1. Precautions before installation

Essential safety and preparation guidelines before installing the boiler unit.

1.1 Shipping from factory

Guidelines for handling and transporting the boiler unit from the factory.

1.2 Choosing the best location

Criteria for selecting an optimal and safe installation location for the boiler.

1.3 Methods of installation

Step-by-step instructions and best practices for physically installing the boiler.

1.4 Check the kind of gas

Verification procedure for the type of gas supply to ensure correct boiler operation.

1.5 Precautions for installation

Critical safety warnings and important considerations during the boiler installation process.

2. Identifying the components of the boiler

Visual guide to locate and identify all major parts and components of the boiler.

3. Installation of water piping

Detailed instructions for connecting and installing the water piping system for the boiler.

4. Installation of the flue

Guidelines for correctly installing the flue system for safe exhaust gas removal.

4.1 PVC Venting Method

Specific instructions for installing the boiler using PVC venting materials.

4.2 Flue pipes used for Standard Flue Kit models

Information on the standard flue kit components and their installation.

5. Gas piping connections

Procedures for safely connecting the gas supply lines to the boiler.

6. Installation of the room thermostat

Steps for installing the room thermostat to control the heating system.

6.1 Choosing the Best Location

Guidelines for selecting the optimal placement for the room thermostat.

6.2 Installation

Step-by-step instructions for mounting and wiring the room thermostat.

III. Trial operation & Checkup

1. Checkup after installation

Final checks to perform after the boiler installation is complete.

2. Checking for gas and water leaks

Procedures to detect and identify any gas or water leaks in the system.

3. Checks before trial operation

Pre-operation checks to ensure the boiler is ready for the initial test run.

4. Trial operation

Steps for performing the initial startup and testing of the boiler system.

4.1 Trial operation quick-fill

Method for quickly filling the system with water during the trial operation.

4.2 Procedure of trial operation

Detailed sequence of steps for conducting a successful trial operation.

5. Routine maintenance

Recommended schedule and tasks for regular maintenance of the boiler.

6. Troubleshooting

Guidance for diagnosing and resolving common issues with the boiler system.

6.1 Troubleshooting - Error Codes

Explanations of error codes and solutions for boiler malfunctions.

6.2 Troubleshooting - Occurs

Troubleshooting common symptoms and their corresponding causes and remedies.

IV. Fuel Conversion Method

1. Conversion Kit Contents

List of items included in the fuel conversion kit for the boiler.

2. Parts & Tools Required

Necessary parts and tools needed for performing the fuel conversion process.

3. Conversion Procedure

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

2.1 KDB – 161 / 201 GOM

Fuel conversion procedure specific to KDB-161 and KDB-201 GOM models.

2.2 KDB – 251 / 301 GOM

Fuel conversion procedure specific to KDB-251 and KDB-301 GOM models.

V. Troubleshooting

1. Failure code #02, Low Water Level

Troubleshooting steps for low water level error code #02.

2. Failure code #03, Ignition Failure

Troubleshooting steps for ignition failure error code #03.

3. Failure code #04, Pseudo Flame

Troubleshooting steps for pseudo flame error code #04.

4. Failure code #05, Disconnection of the heating sensor

Troubleshooting steps for heating sensor disconnection error code #05.

5. Failure code #06, Short circuit of the heating sensor

Troubleshooting steps for heating sensor short circuit error code #06.

6. Failure code #09, Abnormal RPM

Troubleshooting steps for abnormal RPM error code #09.

7. Failure code #10, Air Pressure Failure

Troubleshooting steps for air pressure failure error code #10.

8. Failure code #12, Flame Failure in Combustion

Troubleshooting steps for flame failure in combustion error code #12.

9. Failure code #13, Heating Flow Sensor Failure

Troubleshooting steps for heating flow sensor failure error code #13.

10. Failure code #14, Gas Alarm (Optional)

Troubleshooting steps for gas alarm error code #14.

11. Failure code #15, MICOM Failure

Troubleshooting steps for MICOM failure error code #15.

12. Failure code #16, Mechanical Overheat

Troubleshooting steps for mechanical overheat error code #16.

13. Failure code #17, DIP Switch Setting Error

Troubleshooting steps for DIP switch setting error code #17.

14. Others – 1, 2, 3, 4 and 5

Troubleshooting for other unspecified failure codes or issues.

VI. Procedure of disassembly/assembly

1. Room Thermostat, FR-5

Steps for disassembling and assembling the FR-5 room thermostat.

2. Main Controller

Steps for disassembling and assembling the main controller unit.

3. Modulating Gas Control Valve

Steps for disassembling and assembling the modulating gas control valve.

4. Fan Assembly

Steps for disassembling and assembling the fan assembly.

5. Circulation Pump

Steps for disassembling and assembling the circulation pump.

6. Expansion Tank

Steps for disassembling and assembling the expansion tank.

7. Air Pressure Switch

Steps for disassembling and assembling the air pressure switch.

8. 3-Way Valve

Steps for disassembling and assembling the 3-way valve.

9. Heating Strainer

Steps for disassembling and assembling the heating strainer.

10. Ignition Transformer

Steps for disassembling and assembling the ignition transformer.

11. Electrode Assembly

Steps for disassembling and assembling the electrode assembly.

12. High Limit Sensor

Steps for disassembling and assembling the high limit sensor.

13. High Limit Fuse

Steps for disassembling and assembling the high limit fuse.

14. Hot Water Flow Switch

Steps for disassembling and assembling the hot water flow switch.

15. Domestic Water Heat Exchanger

Steps for disassembling and assembling the domestic water heat exchanger.

16. Main Heat Exchanger

Steps for disassembling and assembling the main heat exchanger.

17. Power Transformer

Steps for disassembling and assembling the power transformer.

VII. Part List

1. Exploded Views

Visual diagrams showing the arrangement of all boiler components.

2. Part List of each Sections

Detailed list of parts categorized by their respective sections within the boiler.

2.1 Front Cover & Cabinet Section

List of parts for the front cover and cabinet of the boiler.

2.2 Main Heat Exchanger Section

List of parts related to the main heat exchanger assembly.

2.3 Heating Water Section

List of parts for the heating water circulation system.

2.4 Domestic Hot Water Section

List of parts for the domestic hot water supply system.

2.5 Gas Supply Section

List of parts associated with the gas supply and control system.