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Automatic Hot Water Management System A Combination System for Domestic Water and Space Heating
Table Contents
SAFETY INSTRUCTIONS ........................................................................... 3 INTRODUCTION ...................................................................................... 4 INSPECT SHIPMENT ......................................................................... 4 SPECIFICATIONS ...................................................................................... 5 INSTALLATION ......................................................................................... 6 INSTALLATION LOCATION .............................................................. 6 INSTALLING THE HEATING BOX....................................................... 7 PIPING CONNECTIONS .................................................................... 7 WATER FILLING AND PURGING SYSTEM ......................................... 10 CLEARANCE REQUIREMENTS ......................................................... 10 THE HEATING BOX AS A PRIMARY LOOP........................................ 11 APPLICATIONS ....................................................................................... 11 DOMESTIC HOT WATER SUPPLY .................................................... 11 IN-FLOOR RADIANT FLOOR HEATING SYSTEM............................... 12 FAN-ASSISTED HYDRO HEATING SYSTEM...................................... 13 SNOW MELTING SYSTEM ............................................................... 14 SPA WATER HEATING SYSTEM ....................................................... 15 WIRING .................................................................................................. 15 IN-FLOOR RADIANT FLOOR/BASEBOARD HEATING SYSTEM ......... 16 FAN-ASSISTED HYDRO HEAITNG SYSTEM...................................... 16 OPERATION............................................................................................ 17 IMPORTANT SET-UP INSTRUCTIONS ............................................. 17 DOMESTIC HOT WATER SUPPLY ................................................... 18 SPACE HEATING ........................................................................... 19 FREEZING PROTECTION ................................................................ 20 PUMP EXERCISE............................................................................. 20 LADDER DIAGRAM.................................................................................. 20 DESIGN REFERENCE FOR HEAT LOSS CALCULATION ...................... 21 TROUBLESHOOTING GUIDE..................................................................... 23 PARTS LISTS ........................................................................................... 24 MODEL KD-HBO100 OPEN LOOP SYSTEM PARTS DIAGRAMS ......... 24 MODEL KD-HBO100 OPEN LOOP SYSTEM PARTS LIST ................... 25 MODEL KD-HBC100 CLOSE LOOP SYSTEM PARTS DIAGRAMS ........ 26 MODEL KD-HBC100 CLOSE LOOP SYSTEM PARTS LIST .................. 27 LIMITED WARRANTY............................................................................... 28
KyungDong America, Inc. reserves the right to change specifications and/or designs without prior notice in anytime and without incurring obligations.
Please check specifications of the Heating Box to make sure it is right for your application. Please keep this manual in safe place for future reference. The Heating Box must be installed and serviced by a licensed contractors or/and a code and all applicable local codes. Improper installation and/or operation and/or Please refer to the warranty section on page 26. professional service technician following national building code, national electric installed by unqualified person, the warranty will be voided by the manufacturer. Please follow each manufacturers installation instructions for different appliances for your other applications used conjunction with our product such as space heating systems and water heating systems. provided installation instructions. Be sure your appliance is properly installed in accordance with local codes and the
Do not touch the system with wet hands. Do not pour water directly to the system for any purpose. Electric shock may occur Water temperatures above 125 F (50 C) can cause severe burns or death from Do not store or use gasoline or other flammable vapors or liquids or other combustible materials in the vicinity of this or any other appliances. To do so may result in an explosion or fire. scalding. and serious body and/or property damages can result.
This is the safety alert symbol. Recognize this symbol as an indication of Important Safety Information! This symbol alerts you to potential hazards that can kill or hurt you and others.
Introduction Introduction
Thank you for purchasing the Heating Box Model KD-HBO100/KD-HBC100. Heating Box provides a combination system ( heat potable water and space ) with just This one heat source in convenience of simple installation. The unit consist with a high head distribution in domestic hot water. The Heating Box can be used with conventional tank type water heaters, on-demand tankless water heaters or any hot water heating systems as a heat source. The Heating Box can be associated with applications like in-floor space heating system (radiant domestic hot water supply and that means no more temperature fluctuations. Please read the installation manual completely before attempting installation. Understand Most of the questions that you will have will be answered in the manual. If you have any 519-8794. Please make sure to fill out your product warranty card and return the original form to KyungDong America, Inc. within 30 days of purchase. Important to Owner: These instructions should be carefully read and kept near product, for future reference. While these instructions are addressed primarily to the installer, useful maintenance information is included. As expressed in product warranty, KyungDong America, Inc. will not be billed for any structural damage due to failure to follow these installation requirements. how the system operates and installation recommendations before beginning installation. questions, please review the installation manual or contact manufacturer directly at 800-
bronze constructed pump to circulate water and built-in priority device for more effective
heating system) and fan assisted hydronic space heating system without interrupting
Inspect Shipment
Description Picture Quantity
Manual
Bracket
Specifications
Air Separator Thermostatic Mixing valve for Heating Heating Box Controller 3-Way Valve Expansion Tank Circulating Pump Priority switch with check valve Manual ball valve for expansion tank Thermostatic Mixing valve for Domestic Hot Water
Model KD-HBO100
Space heating side Air Separator Pressure Gage Heat source side Air Separator Heating Box Controller Thermostatic Mixing valve for space heating Expansion Tank Flat Heat Exchanger(two) Check valve Space heating side Circulating Pump Heat source side Circulating Pump Thermostatic Mixing valve for Domestic Hot Water Domestic Hot Water Priority switch
Model KD-HBC100
Model KD-HBO100 Open system Minimum Flow Rate (activate priority device) Minimum Water Pressure Hot and Cold Water Connections Heat Source Supply & Return Space Heating Supply & Return Flat Heat Exchanger (BTU/Hour) each Expansion Tank Electricity Physical Size (W x H x D) 0.5 GPM 7 PSI 3/4" NPT 3/4" NPT 3/4" NPT Not Applicable 1.8 Gallons 120VAC, 60 Hz, Max. 5A, Normal 2A 15 x 25 x 10
Model KD-HBC100 Close system 0.5 GPM 7 PSI 3/4" NPT 3/4" NPT 1 NPT 80,000 Btu/Hour Each, Total 160,000 BTU/Hour 1.8 Gallons 120 VAC,60 Hz, Max 10A, Normal 4A 20 x 28 x 10
Installation
The Heating Box Model KD-HBO100 is an open-loop system. If your application requires a close-loop system, you can add an extra heat exchanger in between systems to separate potable and space heating water; otherwise you can use the close-loop system, the Heating Box Model KD-HBC100.
The hot water coil or all radiant water lines must be purged of air before the hot water pump can be energized. Failure to purge the water system of air can result in damage to the pump.
WARNING
Installation Location
Locate the unit near the heat source and the space heating appliance such as in-floor radiant heating manifolds or a hydro space heating air handler. Extra care should be taken to avoid placing the product near noise sensitive location For ease of installation, top of the system should be installed at eye level and/or Allow 6 off set above the heat source for air to escape from the system. bottom of the system should be no less than 3 feet off from the floor. such as living areas.
Piping Connections
Verify that matched pairs of supply and return pipes are connected to the appropriate outlets and inlet to the Heating Box. From the Heating Box, the piping labeled To Water Heater Inlet needs to be
connected to the Cold Water Connection of the heat source and the piping labeled
Domestic Hot Water Supply Line to Hot Water Supply. From the space heating appliance, connect its Inlet to the Heating Boxs piping labeled To Space heat supply (IN) and connect its Return Line to the piping labeled
To Space heat Return (OUT). Refer below figure for the Radiant Heating Manifold.
Connect the City Water Supply Line to the piping labeled To City Water and
heat source.
To Water Heater Outlet needs to be connected to the Hot Water Connection of the
Provides filling ports/valves for water or/and Glycol mix working fluid and easy We suggest that you use pipe unions for all connections to the Heating Box for easy maintenance (use pipe isolators such as Webstone or equivalent product). You can or hydronic heat application. flush the entire system from the Heating Box to the water heater and your radiant accessible location for closed loop model KD-HBC100.
To City water
Model KD-HBO100
To City water
120 VAC
Model KD-HBC100
tank must be closed to prevent damages to it. After the test, open the shut off valve Turn on the power to both the unit and the thermostat for heating. The Heating Box will start circulate water. Please check the purging valve to see whether there is any air left in the system. Above steps should be repeated until there is no air left inside the piping system.
The expansion tank comes pre-pressurized at 50 PSI (4 Kgf/Cm2). If necessary, adjust the pressure in the expansion tank to the anticipated system operating pressure.
WARNING
Clearance Requirements
Piping Side Front (Maintenance Space) Back Non Piping Side 12 24 1 (Bracket included) 1
* Maintain clearances in accordance with local installation codes and other appliances.
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properly relay its power as an independent circuit (activating Port, dip switch No. 5 must
continuously. The control relay activates the primary circulator until it turns off the heating mode. When primary loop temperature gets close to the default set temperature, primary loop circulator will stop and the secondary circulator will continue to operate. When circulator will start operating again to maintain the default set temperature range.
primary loop temperature falls below 5F from the default set temperature, the primary
Applications
There are many applications you can apply with the Heating Box including radiant infloor, radiant baseboard, hydronic air handlers, snow melting system and more.
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4. Recommended size of space is about 2000 sq ft maximum with most tankless water heaters 5. Recommended heat source (water heater) temperature is 158F and radiant heating supply 6. In cold weather, it is possible that areas of the slab may be below freezing even temporary the system start circulating with the heat source in operation applying heat to the slab temperature sets between 100 ~130 F depend on applications.
heat is being provided. The system should not be filled and purged until it is ready to have
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Fan Coil
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6. Recommended size of space is about 2000 sq ft maximum for most tankless water 7. Recommended heat source (water heater) temperature is 180 F and radiant 8. On cold weather start up, that areas of the slab may be below freezing even temporary heat being provided. The system should use propylene glycol mix not be filled and purged until it is ready to have the system circulating with the heat source in operation applying heat to the slab. heating supply temperature sets between 100 ~130 F depend on the application.
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outlet to maintain safe and steady spa water temperature of maximum 105 F. You can lower the temperature by adjusting the thermostatic mixing valve on the heating side. the spa. Bromidanted water can be used in the spa, but not encourage the use of Chlorinated water in
Wiring
The unit must be in OFF position before connecting the electrical wires. Make sure the circuit breaker on the distribution panel is OFF or GFI (ON/OFF switch) in Heating Box is OFF.
(White) and ground (Green) wires to the marked terminals with minimum 14 AWG.
From the bottom of Heating Box, connect the 120 VAC, 60Hz hot wire (Black), neutral
When Room Thermostat needs external 24 VAC power, Heating Box controller provide 24 VAC power to your convenience.
Please follow wiring diagram for 24 VAC for either radiant or snow melt application.
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OFF
ON
OFF
ON
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Operation
This Heating Box is designed to make a combination system (heat potable water and space) with just one heat source in convenience of simple installation. The unit consist with a high head bronze constructed pump to circulate water and built-in priority device for more effective distribution in domestic hot water. The Heating Box will make sure there will be no interruption to your domestic hot water even when the heating box is
distributing its hot water to the space heating side. It supports domestic side fully as soon as it detects a demand from the domestic side and once the domestic hot water demand is done, it switches back to the space heating side until the room temperature reaches at its for both heat source and space heating to make steady and optimum performances. setting temperature. Also, its computer board monitors water movement and temperatures
The Heating Box can operate with any water heating systems offer in the market. The After setting the temperature from the heat source, it needs to be entered into the set the temperature of the heat source into the computer board of the Heating Box so it
unit recommends the incoming water temperature from the heat source to be above 167 F. computer board of the Heating Box for a proper control of each application. You need to control and distribute hot water to each application more effectively. In order to set the temperature, use dip switches and they are located on the front of controller in the Heating Box. For heat source temperature between 158 F 167 F, leave the dip switch settings at the factory default setting which is 158 F.
* Above picture shows Space Heatings return temperature and Dip Switches.
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4 5 6 7 8
CLOSE TYPE OPEN TYPE EXTRA PUMP ON EXTRA PUMP OFF CELSIUS() FAHRENHEIT() EXTRA POWER ON EXTRA POWER OFF
supply mode is the priority. The whole system of Heating Box does act like a water heater.
temperature. The factory set is at 110 F for domestic hot water supply and the Heating
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WARNING
Over 122F (50 C) water temperature is dangerous to human body and it cause scalds and burns resulting in serious personal injury and/or death. Typical factory set temperature for domestic hot water is 120F.
Space Heating
Whether using radiant heating or hydronic fan coil heating, simply turn on the room thermostat. The Heating Box controller will turn on the circulating pump and the heat source will supply hot water to the space heating appliance. The Heating Box has a built in thermostatic mixing valve to adjust space heating water temperature. Space heating water temperature is typically recommended at 120 F for a radiant space heating and above 140 F for a fan coil space heating. The Heating Box continuously monitors the temperature of space heating and returning water temperatures. The temperature range of the mixing valve on space heating side is from 86 F (30 C) to 140 F+ (60 C+). At the heat source temperature directly in to the space heating side. maximum temperature setting of the mixing valve, the valve fully opens and will allow the
In the process of initial set up for a radiant heating or a fan coil space heating, LED from the control board will show each temperature read so you can easily identify and adjust flow rates and temperature drops.
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Freezing Protection
The Heating Box offers two different freezing protection systems. One continuously check Heating Boxs pump will turn on automatically until the temperature of inside water pipe reaches to 20C (68F). It runs for about two minute. incoming city water temperature and when its temperature reaches below 6C (42F), the
Pump Exercise
Pump will run pump exercises for about 30 seconds at the point of non-usage in the period of 24 hours.
Ladder Diagram
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is -10 F at seasonal low temperature, following resistance to heat flow values can be used
* More detail heat loss data can be collected from the heating design software and heating design engineers.
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From above table, factor in areas as square feet to figure out heat loss calculation (or required heat calculation and unit for the heat requirement is BTU/hr in each section.
Pipe spacing in a radiant floor heating installation can directly affect the heat output.
The
commonly recommended pipe spacing is 8 ~ 9 with PEX pipe. Also the typical pipe loop, heating area times by 1.3). For an example, if heating area is 200 square feet, pipe lengths are approximately 260.
lengths are from 150 to 450 in each loop where pipe lengths can be calculated (in each
Finally calculating the each loop requires flow rate divides by the total required heat considered optimum for on-demand tankless water heaters. output (BTU/Hour) by 500 times the design T of the system. A design T of 28 F is
Required heat output (BTU/Hr) each loop Flow Rate = 500 X T This is very rough formula to design a radiant heating system, please consult youre your heating design engineer for more accuracy of your heating system design.
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Troubleshooting Guide
Problem Check
The set temp of the heat source and the heating boxs mixing valve The heat source on
Connections couldve been reversed The heat source is undersized for the space heating system
Wire and the power supply of the room thermostat the air handler
Pump keeps turn ON & OFF Water temp fluctuates The Heating Boxs pump is circulating during the cooling cycle
Check room thermostat Domestic hot water line is leaking The set temp of the heat source is too low Heating and cooling wire on the room thermostat couldve been reversed or/and two different wires are shorted Domestic hot water line is leaking System may have not purged air completely In the Heating Box, the expansion tanks manual ball valve might have closed Valve may be malfunction
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Parts Lists
Model KD-HBO100 Open Loop System Parts Diagrams
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Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Description Expansion Tank Base Bracket 3-Way Valve To water heater IN connection Controller Controller Bracket Thermostatic Mixing valve Manual Drain Port Air Separator Air Separator body To Space heating return line Base frame To Space heating supply line Pump Bracket Pump Flange Circulation pump To Space heating Return (OUT) Expansion Tank pipe (Right) To Space heating Supply (IN) Pump gasket To City water pipe line To water heater OUT connection Domestic priority switch Expansion tank pipe (left) Expansion tank manual valve To City water connection
Part No. 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
Description To Domestic hot supply connect Pipe clamp Electric junction box Pipe isolator clamp Case Front cover Air separator clip Bottom bracket GFI Case clamp Front cover clamp hook Drain hose Pump holder bolt Pump holder nut Packing gasket Packing gasket O-ring O-ring O-ring Wire holder packing Gasket Gasket Gasket Pipe connector holder screws Screws Screws
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Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Description Case Front cover Expansion Tank Controller Controller Bracket Circulation pump Pump gasket Pump Flange Pump Bracket Pump holder bolt Pump holder nut Thermostatic Mixing valve Flat Heat Exchanger GFI Pressure Gage Base Bracket Domestic priority switch Check Valve Air Separator Manual Drain Port Air Separator body (space heat) Air Separator body (heat source) Air separator clip Air separator clip To Space heating supply line To Space heating supply line To Space heating Supply (IN) To Space heating Return (OUT) To City water pipe line To City water connection To Water Heater IN Pipe line To water heater IN connection
Part No. 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
Description To Water heater OUT pipe line To water heater OUT connection Domestic hot supply pipe line Domestic hot supply pipe line To Domestic hot supply connect Expansion Tank pipe Sealing Rubber Sealing Rubber Base frame Base frame Bottom bracket Drain hose Wire holder packing Electric junction box Pipe clamp Pipe isolator clamp Pipe clamp Pipe isolator clamp Case clamp hook Front cover clamp hook O-ring Gasket O-ring Gasket O-ring Pipe connector holder O-ring Pipe connector holder Rivet Packing gasket Packing gasket Screws Screws Screws
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Limited Warranty
Heating Box Limited Warranty Coverage KyungDong America, Inc. (KyungDong) warrants to the original purchaser of a Heating Box Model KD-HBO100 and Model KDHBC100 unit installed in its original installation location in North America in accordance with all state, local and federal codes that the heating box will be free from defects in workmanship and materials, under normal use, for five (5) years from the original purchase date. The warranty registration card must be completed and mailed to KyungDong to establish your installation date. What is Not Covered under this Limited Warranty? This warranty excludes: external causes (i.e. accidents and Acts of God), abuse, misuse, alterations, or problems with electrical power or water supply pressure, problems caused by water freezing in unit or piping; failure to follow product instructions or failure to perform preventive maintenance; usage not in accordance with product instructions or use in conjunction with unapproved device(s); improper installation or installation in an area with corrosive atmosphere; damage resulting from use with well water and water with high pH and/or hardness levels; and improper sizing. Exclusive Remedies Should a covered defect occur during the warranty period and customer notifies Kyung Dong, customers sole and exclusive remedy shall be, at KyungDongs sole option and expense, to repair or replace the heating box. Replacement products or parts may be new or reconditioned or comparable versions of the defective item and are subject to the same limitations and exclusions for the remainder of the original warranty period. Customer will be response for all other costs incurred including but not limited to labor cost, service fees, shipping, delivery, and handling of the replacement part or unit, cost for permits or materials necessary for the repair, or incidental costs resulting from damage external to the unit resulting from the defect. Warranties Exclusive To the full extent allowable by law, the foregoing warranties and remedies are exclusive and in lieu of all other warranties, terms or conditions, express or implied, including warranties of merchantability, fitness for a particular purpose, correspondence with description, and non-infringement, all of which are expressly disclaimed by KyungDong and its suppliers. Limitation of Liability Neither KyungDong nor its suppliers shall be liable for incidental, consequential, indirect, special, or punitive damages of any kind, or other financial loss arising out of or in connection with the sale or use of the heating box, whether based in contract, tort (including negligence) or any other theory, even if KyungDong had been advised of the possibility of such damages. The entire liability of KyungDong shall be limited to replacement or repair, at KyungDongs sole option. Disclaimer Some states or provinces do not allow the exclusion or limitation of implied warranties or the limitation of incidental or consequential damages for certain products supplied to consumers or the limitation of liability for personal injury, so the above limitations and exclusions may not apply to you. When implied warranties may not be excluded in their entirety, they will be limited to the duration of the applicable written warranty. This warranty gives you specific legal rights and you may have other rights that may vary depending on local law. Governing Law This Limited Warranty shall be governed by the laws of the State of California, U.S.A., and by the laws of the United States, excluding their conflicts of laws principles. The United Nations Convention on Contracts for the International Sale of Goods is hereby excluded in its entirety from application to this Limited Warranty. How to Obtain Warranty Service To obtain warranty service for the heating box, you may contact KyungDong by calling 1-800-519-8794. Please be prepared to provide: (1) proof of original purchase, i.e. receipt or invoice (2) your name, address, telephone numbers; (3) model and serial number of the product; and (4) explanation of the problem.
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