Download SERVICE MANUAL

SERVICE MANUAL
STATIONARY STORAGE WATER HEATERS
CLASS-I
KGS15W6P-GDE,KGS15W6M-GDE,
KGS25W6P-GDE, KGS25W6M-GDE
CLASS-II
KGS15W5P , KGS15W5M
KGS25W5P, KGS25W5M
Please read this manual carefully to diagnose trouble correctly before offering service.
Record model name & serial number of the machine. Please quote this information when you require service.
INDEX
SR. NO
DESCRIPTION
PAGE NO
01
PRODUCT SPECIFICATIONS
02-03
02
MAIN PARTS, THEIR FUNCTIONS & SPECIFICATIONS
04
03
TROUBLE SHOOTING
05
04
EXPLODED VIEW
06-07
05
SERVICE SPARE PARTS LIST
08-10
SERVICE MANUAL
01
PRODUCT SPECIFICATIONS
* At Kenstar improvement is continuous process, specification may
change without any notice.
SERVICE MANUAL
02
PRODUCT SPECIFICATIONS
* At Kenstar improvement is continuous process, specification may
change without any notice.
SERVICE MANUAL
03
MAIN PARTS, THEIR FUNCTIONS & SPECIFICATIONS
CLASS-I &II
Outer body
OUTLET PIPE
INNER TANK
INLET PIPE
SG INSULATION/PUF
THERMAL CUT OUT POCKET
HEATING ELEMENT
THERMOSTAT POCKET
FUSIBLE PLUG
INLET PIPE
PRESSURE RELEASE VALVE(for Class-II only)
VACCUUM RELEASE VALVE
(for Class-II only)
NEON LAMP
SERVICE MANUAL
MULTI FUNCTION VALVE( for Class-I only)
04
TROUBLE SHOOTING
S. NO. DEFECTS
POSSIBLE ACTION
ACTION TAKEN
1
GREEN LAMP
NOT GLOWING
MAY BE DUE TO THE DEFFECT OF
LAMP & THERMOSTAT CHECK BOTH.
REPLACE THE DEFECTIVE
PARTS
2
ONLY RED LAMP
GLOWS
THERMOSTAT NOT WORKING
REPLACE THE THERMOSTAT
3
SPARKING INSIDE
THE WATER HEATER
THIS HAPPEN DUE TO THE LOOSE ELECTRIC
CONNECTION AT HEATING ELEMENT
TIGHTEN THE ELECTRIC
CONNECTIONS THEN START THE
WATER HEATER.
LEAKAGE
FIRST CHECK THE APPARATUS PLATE AT
HEATING ELEMENT, GASKET & MAIN GASKET
THEN CHECK THE WATER TANK.
IF THERE IS LEAKAGE
CHANGE RESPECTIVE ONE
NO HOT WATER
IF GREEN LIGHT GLOWS & NO HOT
WATER IT MEANS ELEMENT PROBLEM.
REPLACE THE HEATING
ELEMENT
4
5
6
7
SERVICE MANUAL
05
EXPLODED VIEW
SHOWCASE
PUF CLAMPING RING
FRONT COVER
ELEMENT
ELEMENT GASKET
ASSLY PLATE
MAIN GASKET
SS TANK
POWER PLUG
METAL BODY
THERMOSTAT
THERMAL CUT-OUT
FRONT BEADING
INLET PIPE
OUTLET PIPE
UPPER PUF
BACK COVER
LOWER PUF
PUF CLAMPING
RING
CLAMPING
CLAMPING PAD
CLAMPING
NUT BOLT
SERVICE MANUAL : METAL BODY
REAR BEADING
06
EXPLODED VIEW
UPPER SHOWCASE
FRONT COVER
THERMOSTAT
INLET PIPE
THERMAL CUT-OUT
HEATING ELEMENT
L-GAURD
UPPER PUF
GASKET
LOWER SHOWCASE
ASSLY PLATE
POWER PLUG
SS TANK
ASSLY PLATE GASKET
REAR COVER
CRCA CLAMP
CRCA CLAMP
CLAMP PAD
CLAMPING NUT BOLT
TANK
CLAMPING
RING
LOWER PUF
SERVICE MANUAL : PLASTICS BODY
07
Spare Part List
KGT03W1P WATER HEATER,3L INSTANT,KGT03W1P
1100046036
1100046037
1100046038
1100046039
1300007383
1300007384
1300007385
MAIN BODY-3LTR,ABS,KGT03W1P
CLAMP,LEG,KGT03W1P
TANK,SS 304,1 LTR,KGT03W1P
INSTRUCTION MANUAL,KGT03W1P
BOX,PACKAGING,5PLY,INNER,PRINTD,KGT03W1P
BUFFER THERMOCOL,KGT03W1P
BOX,PACKAGING,5 PLY,OUTER,KGT03W1P
K GT 03W1P WATER HEATER,1L INSTAN T,K GT01W1P
1100046066
1100046067
1100046068
1100046069
1100046070
1100046071
1100046072
1100046073
1100046074
1100046075
1100046076
1100046077
1100046078
1100046079
1100046080
1100046081
1100046082
1100046083
MAIN BODY,ABS,KGT01W1P
CLAMP,LEG,KGT01W 1P
TAN K,SS 304,1 LT R,KGT01W 1P
PLAT E,APPARAT US,BRASS,2.1MM,KGT 01W1P
PIPE,THERM OSTAT 7",COPPER ,KGT01W 1P
PIPE,CU T OUT 7",COPPER,KGT01W1P
PIPE,OUTER 4 ",IN+OUT,BRASS,KGT01W 1P
PIPE,U & I,BRASS,23 ",KGT01W 1P
NOZZLE,BR ASS,KGT01W 1P
PIPE,OUTSIDE,FU SABLE,PVC,KGT01W 1P
WASH ER ,FIBER ,R UBBER,KGT01W 1P
REDUCER,BRASS,KGT01W 1P
VALVE,SAFETY,BRASS,KGT01W 1P
ROD,WELD IN G,COPPER,KGT 01W1P
THERMOSTAT, 11" / 7",KGT01W 1P
THERMAL CU T OU T 7",KGT01W1P
CABLE,PVC ,EXTER NAL,48/20,KGT01W 1P
WIRE,PVC,INTERNAL,48/20,KGT01W 1P
SERVICE MANUAL
1100046084
1100046085
1100046086
1100046087
1100046088
1100046089
1100046090
1100046091
1100046092
1100046093
1100046094
1100046095
1100046096
1100046097
1100046098
1100046099
1100046100
1100046101
1100046102
1100046103
1100046104
1100046105
1100046106
1100046107
1100046108
1100046109
1100046110
1100046111
1100046112
1300007398
1300007399
1300007400
NEON LAMP,RED,KGT01W1P
NEON LAMP,GREEN,KGT01W 1P
ELEM EN T,HEATING,3 KW,KGT01W1P
SLEEVE,FIBRE GLASS,KGT01W1P
THIMBLES,SMALL,KGT01W 1P
THIMBLES,BIG,6MM,KGT01W1P
BOLT,6 x 25,M S,KGT01W1P
WASH ER ,M 6,KGT01W1P
WASH ER ,SPRING,M 6,KGT 01W1P
NUT,6 M M,MS,KGT01W 1P
SC REW ,6 X 16,SS,KGT01W1P
BOLT,H EX,M6 X8,SS,KGT01W 1P
STU D,SS,M6 x 18,KGT01W1P
WASH ER ,SS,M 6,KGT01W1P
NUT,HEX,M 6,SS,KGT01W1P
WASH ER ,SPRING,,SS,KGT01W1P
GASKET,127 M M,EPDM ,R UBBER,KGT01W 1P
PIPE,PVC ,1/2",THREAD ,KGT01W 1P
CAP,PVC,KGT01W1P
CLIP,CORD,KGT01W1P
GR OM MET,CORD,KGT01W1P
ELEM EN T,EPDM,RU BBER,KGT01W 1P
GLASS,WOOL,KGT 01W1P
STICKER,LOGO,KGT01W1P
STICKER,TRANSFER ANT ,JACUZ I,KGT 01W1P
STICKER,ISI,AL FOIL,KGT01W 1P
STICKER,SPECIFIC ATION,AL FOIL,KGT01W1P
STICKER,BU BBLES,KGT01W 1P
IN STR UCTION MANUAL,KGT01W1P
CARTON,IN NER,PRINT D,5PLY,KGT01W 1P
BU FFER TH ER MOCOL,KGT 01W1P
CARTON,OU TER ,5 PLY,KGT01W1P
08
Spare Part List
KGS15W4P WATER HEATER,15L,4*,JACUZZI,KGS15W4P
KGS15W4M WATER HEATERE,15L,4*,HOT SPRING,KGS15W4
1100046040
1100046121
1100046122
1100046123
1100046124
1100046125
1100046126
1100046127
1100046128
1100046129
1100046130
1100046131
1100046132
1100046133
1100046134
1100046135
1100046136
1100046137
1100046138
1300007386
1300007387
1300007388
1300007389
1100046139
1100046140
1100046141
1100046142
1100046143
MAIN BODY-15LTR,ABS,KGS15W4P
CLAMP,LEG,KGS15W4P
TANK,SS 304,15 LTR,KGS15W4P
PLATE,APPARATUS,BRASS,2.3MM,KGS15W4P
PIPE,THERMOSTAT 11",COPPER,KGS15W4P
PIPE,CUT OUT 11",COPPER,KGS15W4P
PIPE,U & I,BRASS,4 SOOT ",KGS15W4P
NOZZLE,BRASS, 2 SOOT, KGS15W4P
VALVE,VACUUM RELEASE, KGS15W4P
THERMOSTAT,11", KGS15W4P
THERMAL CUT OUT ,11 INCH, KGS15W4P
MAINS CORD,PVC,3CORE,32/20,KGS15W4P
WIRE,PVC, 1 CORE, 32/20,KGS15W4P
ELEMENT,HEATING,2 KW,KGS15W4P
SCREW 6x13 SS, KGS15W4P
SCREW 6x95 SS, KGS15W4P
SCREW 4x12 SS, KGS15W4P
PUFF,INSULATION, KGS15W4P
INSTRUCTION MANUAL,KGS15W4P
BOX,PACKAGING,5PLY,PRINTED,KGS15W4P
BUFFER THERMOCOL,KGS15W4P
BOX,PACKAGING,5PLY,PRINTD,KGS15W4M
BUFFER THERMOCOL,KGS15W4M
SERVICE MANUAL
MAIN BODY-15LTR,C.R.C.A.,KGS15W4M
COVER END,CRC,12.5in,KGS15W4M
BRACKET,LEG CLAMP,CRC,KGS15W4M
PUFF,INSULATION,KGS15W4M
INSTRUCTION MANUAL,KGS15W4M
KGS25W4P WATER HEATER,25L,4*,JACUZZI,KGS25W4P
1100046144
1100046145
1100046146
1100046147
1100046148
1100046149
1100046150
1300007410
1300007411
MAIN BODY-25 LTR,ABS,KGS25W4P
CLAMP,LEG,KGS25W4P
TANK,SS 304,25 LTR,KGS25W4P
PIPE,U & I,BRASS,4 SOOT ",KGS25W4P
NOZZLE,BRASS, 2 SOOT, KGS25W4P
PUFF,INSULATION,KGS25W4P
INSTRUCTION MANUAL,KGS25W4P
BOX,PACKAGING,5PLY,PRINTD,KGS25W4P
BUFFER THERMOCOL,KGS25W4P
KGS25W4M WATER HEATERE,25L,4*,HOT SPRING,KGS25W4M
1100046151
1100046152
1100046153
1100046154
1100046155
1300007412
1300007413
MAIN BODY-25LTR,C.R.C.A.,KGS25W4M
COVER END,WITH COV SH,12.5",KGS25W4M
BRACKET,LEG CLAMP,CRC,KGS25W4M
PUFF,INSULATION, KGS25W4M
INSTRUCTION MANUAL,KGS25W4M
BOX,PACKAGING,5PLY,PRINTD,KGS25W4M
BUFFER THERMOCOL,KGS25W4M
09
Spare Part List : Only for Class-1 model.
M at eria l C od e
1 1 00 06 58 6 2
1 1 00 06 58 6 3
1 1 00 06 58 6 4
1 1 00 06 58 6 5
1 1 00 06 58 6 6
1 1 00 06 58 6 7
1 1 00 06 58 6 8
1 1 00 06 58 6 9
1 1 00 06 58 7 0
1 1 00 06 59 1 1
1 1 00 06 59 1 2
1 1 00 06 59 1 3
1 1 00 06 59 1 4
1 1 00 06 59 1 5
1 1 00 06 59 1 6
11 0 00 65 91 7
D ESC R
TA N K,SS,K GS 15 W 6 M - G DE /K GS 15 W 6 P -G D E
TA N K,SS,K GS 25 W 6 M - G DE /K GS 25 W 6 P -G D E
AP AR A TU S P L ATE , K GS 25 W 6 P -G D E,15 -2 5L -P /M
M FV , KG S2 5W 6 P- G DE , 1 5- 25 L- P/ M
K N O B SE T,EX TER N A ,KG S2 5W 6 P- G DE ,1 5 -25 L -P /M
ISI, KG S2 5W 6 P- G DE , AL L M O DE L
STIC K ER B E E,KG S1 5W 6 P- G DE
STIC K ER B E E,KG S1 5W 6 M -G D E
STIC K ER B E E,KG S2 5W 6 P- G DE
STIC K ER B E E,KG S2 5W 6 M -G D E
P LA TE R ATIN G , K G S25 W 6P -G D E
P LA TE R ATIN G , K G S15 W 6P -G D E
P LA TE R ATIN G , K G S25 W 6M -G D E
P LA TE R ATIN G ,KG S1 5W 6 M -G D E
M A N U AL , K GS1 5 W 6 P -G D E
Pl an t
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
S00 1
STIC K ER C L ASS- 1, K G S15 W 6P -G D E
S00 1
SERVICE MANUAL
10