THE HEATING BOX. Model KD-HBO100 & KD-HBC100. * KD-HB100 (Open-Loop System) * KD-HBC100 (Close-Loop System)

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1 THE HEATING BOX Model KD-HBO100 & KD-HBC100 * KD-HB100 (Open-Loop System) * KD-HBC100 (Close-Loop System) Automatic Hot Water Management System A Combination System for Domestic Water and Space Heating

2 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 CLEARANCE REQUIREMENTS THE HEATING BOX AS A PRIMARY LOOP APPLICATIONS DOMESTIC HOT WATER SUPPLY IN-FLOOR RADIANT FLOOR HEATING SYSTEM FAN-ASSISTED HYDRO HEATING SYSTEM SNOW MELTING SYSTEM SPA WATER HEATING SYSTEM WIRING IN-FLOOR RADIANT FLOOR/BASEBOARD HEATING SYSTEM FAN-ASSISTED HYDRO HEAITNG SYSTEM OPERATION IMPORTANT SET-UP INSTRUCTIONS DOMESTIC HOT WATER SUPPLY SPACE HEATING FREEZING PROTECTION PUMP EXERCISE LADDER DIAGRAM DESIGN REFERENCE FOR HEAT LOSS CALCULATION TROUBLESHOOTING GUIDE PARTS LISTS MODEL KD-HBO100 OPEN LOOP SYSTEM PARTS DIAGRAMS MODEL KD-HBO100 OPEN LOOP SYSTEM PARTS LIST MODEL KD-HBC100 CLOSE LOOP SYSTEM PARTS DIAGRAMS MODEL KD-HBC100 CLOSE LOOP SYSTEM PARTS LIST LIMITED WARRANTY

3 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 professional service technician following national building code, national electric code and all applicable local codes. Improper installation and/or operation and/or installed by unqualified person, the warranty will be voided by the manufacturer. Please refer to the warranty section on page 26. Please follow each manufacturer s installation instructions for different appliances for your other applications used conjunction with our product such as space heating systems and water heating systems. Be sure your appliance is properly installed in accordance with local codes and the provided installation instructions. Do not touch the system with wet hands. Do not pour water directly to the system for any purpose. Electric shock may occur and serious body and/or property damages can result. Water temperatures above 125 F (50 C) can cause severe burns or death from scalding. 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. 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. 3

4 Thank you for purchasing the Heating Box Model KD-HBO100/KD-HBC100. This Heating Box provides 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 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 heating system) and fan assisted hydronic space heating system without interrupting domestic hot water supply and that means no more temperature fluctuations. Please read the installation manual completely before attempting installation. Understand how the system operates and installation recommendations before beginning installation. Most of the questions that you will have will be answered in the manual. If you have any questions, please review the installation manual or contact manufacturer directly at 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. Description Picture Quantity Manual 1 Bracket 1 4

5 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 5

6 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. WARNING 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. 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 such as living areas. For ease of installation, top of the system should be installed at eye level and/or bottom of the system should be no less than 3 feet off from the floor. Allow 6 off set above the heat source for air to escape from the system. 6

7 1. To mount on the fire rated wall, locate wood or metal studs to properly hold the weight of the unit. 2. Drill a single screw hole for at least 2 ; it should be for 16 OC. Insert and tighten the screw and hang the unit by the upper wall mounting bracket. 3. Determine the positions for remaining four screws (two for the top bracket and two for the bottom), and remove the unit to drill holes. 4. Hang the unit again by the first screw, and then insert and tighten the remaining four screws. 5. Make sure the unit is installed securely so that it will not fall or move due to vibration or earthquakes. 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 To Water Heater Outlet needs to be connected to the Hot Water Connection of the heat source. Connect the City Water Supply Line to the piping labeled To City Water and Domestic Hot Water Supply Line to Hot Water Supply. From the space heating appliance, connect its Inlet to the Heating Box s 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. Provides filling ports/valves for water or/and Glycol mix working fluid and easy accessible location for closed loop model KD-HBC100. 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 flush the entire system from the Heating Box to the water heater and your radiant or hydronic heat application. 7

8 To City water To water heater Outlet To Space heat Return (OUT) 120 VAC Hot water supply To Space heat supply (IN) To water heater Inlet Model KD-HBO100 8

9 To City water To Space heat Return (OUT) 120 VAC To water heater Outlet To Space heat supply (IN) To water heater Inlet Hot water supply Model KD-HBC100 9

10 Make sure all electrical power is turned off before filling water to the system. Close all domestic hot water faucets. Open main cold water supply valve and purge valve slowly. If water leaks from the purging valve, close the valve immediately. Before connecting the electrical wires, strongly recommend to do water leaking test with/without a pressurizing pipe system. When the system tests with pressurized air, the test pressure should not exceed 50 PSI. Before testing, check the pressure relief valve and see if it is in the test pressure range. The shut off valve to the expansion tank must be closed to prevent damages to it. After the test, open the shut off valve to the expansion tank. 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. WARNING The expansion tank comes pre-pressurized at 50 PSI (4 Kgf/Cm 2 ). If necessary, adjust the pressure in the expansion tank to the anticipated system operating pressure. * Maintain clearances in accordance with local installation codes and other appliances. 10

11 If separate secondary circulator has to be used in the system, the secondary circulator can be connected to the External Pump Port from the control box of the Heating Box to properly relay its power as an independent circuit (activating Port, dip switch No. 5 must be ON position). When room thermostat is ON, secondary circulator is also ON 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 primary loop temperature falls below 5 F from the default set temperature, the primary circulator will start operating again to maintain the default set temperature range. Radiant Heating Manifold There are many applications you can apply with the Heating Box including radiant infloor, radiant baseboard, hydronic air handlers, snow melting system and more. The Heating Box always prioritizes domestic hot water supply in operations. The Heating Box has a built-in priority switch to prioritize domestic hot water supply. For an example when it detects a demand from the domestic side while the unit is operating for the space heating side, it quickly switches over from the space heating mode to the domestic heating side by stopping a pump and/or a fan for the air handler until domestic hot water demand stops. 11

12 Recommended application specifications: 1. ½ PEX or other comparable products with max 9 space and 150~350 feet tube length per loop ~ 1.25 GPM in each loop in depend on loop length and 6~8 Maximum loop per each Heating Box F temperature drop in each loop recommended 4. Recommended size of space is about 2000 sq ft maximum with most tankless water heaters 5. Recommended heat source (water heater) temperature is 158 F and radiant heating supply temperature sets between 100 ~130 F depend on applications. 6. In cold weather, it is possible that areas of the slab may be below freezing even temporary heat is being provided. The system should not be filled and purged until it is ready to have the system start circulating with the heat source in operation applying heat to the slab Radiant Heating Manifold Water heater set temperatures: 140, 160, 180 F Radiant heating supply temperatures: 120 F 12

13 Recommended application specifications: ~ 5 GPM flow rate ~ 35 F temperature drop at 140 F hot water supply to the air handler 3. Maximum 5 ton air handler for 2000 sq ft space with most tankless water heaters Fan Coil Water heater set temperature: 140, 160, 180 F Hydro heating supply temperature: 140 F 13

14 Snow Melting System s format and specifications are very similar to other heating applications. As a working media, Glycol (propylene or ethylene glycol) can be used and recommended to mix with water in this system. Recommended application specifications: 1. ½ PEX or other comparable products with maximum 9 space ~ 250 feet tube length per loop ~ 1.25 GPM in each loop depend on the loop length 4. 6 ~ 8 Maximum loop F temperature drop in each loop recommended 6. Recommended size of space is about 2000 sq ft maximum for most tankless water heaters 7. Recommended heat source (water heater) temperature is 180 F and radiant heating supply temperature sets between 100 ~130 F depend on the application. 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. 14

15 In Spa Heating Application, the Heating Box connect to the proper supply inlet and return 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. Bromidanted water can be used in the spa, but not encourage the use of Chlorinated water in the spa. 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. From the bottom of Heating Box, connect the 120 VAC, 60Hz hot wire (Black), neutral (White) and ground (Green) wires to the marked terminals with minimum 14 AWG. 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. 15

16 ROOM THERMOSTAT (with Battery) ROOM THERMOSTAT (without Battery) SWITCH MOVE TO OFF POSITION OFF ON SWITCH MOVE TO ON POSITION OFF ON 16

17 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 setting temperature. Also, its computer board monitors water movement and temperatures for both heat source and space heating to make steady and optimum performances. The Heating Box can operate with any water heating systems offer in the market. The unit recommends the incoming water temperature from the heat source to be above 167 F. After setting the temperature from the heat source, it needs to be entered into the computer board of the Heating Box for a proper control of each application. You need to set the temperature of the heat source into the computer board of the Heating Box so it 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 Heating s return temperature and Dip Switches. 17

18 Whether the Heating Box is in stand by mode or space heating mode, domestic hot water supply mode is the priority. The whole system of Heating Box does act like a water heater. When you open a hot water tap, city water passes through the Heating Box to a water heater and produced hot water passes through the Heating Box to supply domestic hot water as you demand. The Heating Box monitors incoming hot water temperature from the water heater to make sure hot water temperature is in its setting range. The Heating Box has a built-in thermostatic mixing valve to set the domestic hot water supply temperature. The factory set is at 110 F for domestic hot water supply and the Heating Box tries maintain the set temperature if incoming hot water from the water heater is above the thermostatic mixing valve setting. Domestic hot water temperature can be easily adjusted at the mixing valve. 18

19 Domestic Hot water temperature adjustment mixing valve WARNING Over 122 F (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 120 F. 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 maximum temperature setting of the mixing valve, the valve fully opens and will allow the heat source temperature directly in to the space heating side. Space Heating Supply Temperature adjustment 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. 19

20 The Heating Box offers two different freezing protection systems. One continuously check incoming city water temperature and when its temperature reaches below 6 C (42 F), the Heating Box s pump will turn on automatically until the temperature of inside water pipe reaches to 20 C (68 F). It runs for about two minute. Pump will run pump exercises for about 30 seconds at the point of non-usage in the period of 24 hours. 20

21 This section gives a general idea to design a space heating system; it can vary system to system and case by case. Initial step in any heating system design is to determine the heating requirements (same as heat loss ) of each individual room or area. More accurate heat loss calculation is to assure the potential of maximum energy savings and to achieve maximum level of comfortness. By using the conventional heat loss calculations for radiant heating design can result to over size the system. As an example, when desired room temperature is 65 F ~ 70 F and ambient temperature is -10 F at seasonal low temperature, following resistance to heat flow values can be used for basic heat loss calculations in each construction site. * More detail heat loss data can be collected from the heating design software and heating design engineers. 21

22 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 ½ PEX pipe. Also the typical pipe lengths are from 150 to 450 in each loop where pipe lengths can be calculated (in each loop, heating area times by 1.3). For an example, if heating area is 200 square feet, pipe lengths are approximately 260. Finally calculating the each loop requires flow rate divides by the total required heat output (BTU/Hour) by 500 times the design T of the system. A design T of 28 F is considered optimum for on-demand tankless water heaters. 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 you re your heating design engineer for more accuracy of your heating system design. 22

23 Problem Water not hot enough Check The set temp of the heat source and the heating box s mixing valve Little or no heat from the fan coil or radiant heating The heat source on Connections could ve been reversed The heat source is undersized for the space heating system The Heating Box doesn t response when a room thermostat is ON Wire and the power supply of the room thermostat Wrong connection between the room thermostat & the air handler Pump keeps turn ON & OFF Check room thermostat Domestic hot water line is leaking Water temp fluctuates The set temp of the heat source is too low The Heating Box s pump is circulating during the cooling cycle Heating and cooling wire on the room thermostat could ve been reversed or/and two different wires are shorted Domestic hot water line is leaking Pump noise System may have not purged air completely T & P or pressure relief valve on water heater weeps In the Heating Box, the expansion tank s manual ball valve might have closed Valve may be malfunction 23

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28 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 KD- HBC100 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, customer s sole and exclusive remedy shall be, at KyungDong s 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 KyungDong s 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 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. 28