tahiti dual hc - hr - Portsdean Technical

TAHITI DUAL
HC - HR
GB
High quality
Italian product
Gas fired wall Mounted condensing boiler
Tahiti Dual 24 - 32 kW Combi (HC)
Tahiti Dual 24 - 32 kW Regular (HR)
MADE IN ITALY
INSTALLATION,
USE AND MAINTENANCE
Natural Gas
Fondital Tahiti Dual HC 24 kW Line Combi (HC)
G.C.N° 47 309 04
Fondital Tahiti Dual HR 24 kW Line Regular (HR)
G.C.N° 47 309 05
Fondital Tahiti Dual HC 32 kW Line Combi (HC)
G.C.N° xx xxx xx
Fondital Tahiti Dual HR 32 kW Line Regular (HR)
G.C.N° xx xxx xx
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the
correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by
competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to
demonstrate compliance with Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice
which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.
Dear Customer,
Thank You for choosing and buying one of our boilers.
Please read these instructions carefully in order to properly install, operate, and maintain the equipment.
1. General information for fitters, maintenance technicians and users
1.1.General warnings
This INSTRUCTION MANUAL, which is an integral and indispensable part of the product, must be handed over to the user by the installer and must be kept in a safe place for future reference. The manual must accompany the boiler should it be sold or its possession
transferred. Following to the boiler installation, the fitter is to advise the user about boiler operation and its safety devices. This Manual
must be left along with the Benchmark commissioning booklet with the boiler as Regulation 29 of the HSC Gas safety (installation and
use) Regulations 1998.
This boiler is designed for connection to a domestic heating or hot water system.
Any other use is deemed as improper and as such dangerous. Under no circumstances will the manufacturer be held
responsible for damage or injury to persons or animals caused by errors in the installation and/or use of the appliance, or through non-compliance with current local and national standards and/or the manufacturer’s instructions.
The boiler must be installed by qualified personnel, in compliance with applicable laws and standards and according to the
manufacturer’s instructions given in this manual.
In GB, the installation must be carried out by a Registered Installer. To check for authorised qualified engineers please contact
CORGI 01256 372400. It must be carried out in accordance with the relevant requirements of the:
•
•
•
•
Gas Safety Regulations;
The appropriate Building Regulations either The Building Regulation, The Building Regulations (Scotland), Building Regulations (Northern Ireland);
The Water Fittings Regulations or Water Bylaws in Scotland;
The current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be made to the relevant British Standards Code of Practice.
In IE, the installation must be carried out by a competent Person and installed in accordance with the current edition of I.E. 813
“Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for electrical
installations.
The commissioning of the boiler and any subsequent works carried out on the appliance must be effected by an appropriately qualified
technician or an approved Fondital Helpline Service Centre.
Damage and/or injury caused by incorrect installation or use and/or damage and/or injury due to non-observance of the manufacturer’s
instructions shall relieve the manufacturer from any and all contractual and extra-contractual liability.
Before installing the boiler, check that the technical data correspond to the requirements for its correct use in the system.
Check that the boiler is intact and it has not been damaged during transport and handling: do not install equipment which is damaged
and/or faulty. In case of doubt, do not attempt to use the product but refer to the supplier. Packing materials (cardboard box, wooden
crate, nails, staples, plastic bags, polystyrene, etc.) must not be left within reach of children in that these items represent a potential
hazard and must be disposed of in a responsible manner.
Do not obstruct the air intake or flue exhaust grills and terminals.
Only manufacturer approved and supplied accessories or optional kits (including electric ones) are to be installed.
Properly dispose of the packaging as all the materials can be recycled. The packaging must therefore be sent to specific waste
management sites.
In the event of failure and/or malfunction, shut down the system. Do not interfere with or attempt any repairs. Call for professionally
qualified technical assistance only. Fondital helpline UK 08700 34 8820.
Any warranty repairs to the appliance must be carried out exclusively by the manufacturer’s authorised service centre using original
spare parts. Non-observance of the above requirements may affect the safety of the boilers and endanger people, animals and property.
The manufacturer, in order to guarantee efficient and correct functioning of the equipment, recommends the boiler to be serviced and
repaired by an authorized Service Centre which is best trained for the purpose.
Before carrying out any cleaning or maintenance operations, disconnect the appliance from the mains electricity supply by switching off
at the main switch and/or any other isolating device.
Routine boiler maintenance is to be performed according to the schedule indicated in the relevant section of this manual. Appropriate boiler maintenance ensures efficient operation, environment preservation, and safety for people, animals and objects.
In the event of long periods of inactivity of the boiler, disconnect it from power mains and close the gas tap. Warning!
When power mains are disconnected, boiler electronic anti-freeze function will not be operative.
Should there be a risk of freezing, add anti-freeze: it is not advisable to empty the system as this may result in damage; use specific
anti-freeze products suitable for multi-metal heating systems.
Should you smell gas:
- do not turn on or off electric switches and do not turn on electric appliances;
- do not ignite flames and do not smoke;
- close the main gas tap;
- open doors and windows;
- contact a Service Centre, a qualified installer or the gas supply company.
Never use flames to detect gas leaks.
The boiler is designed for installation in the country indicated on the technical data plate: installation in any other country may be source of danger for people, animals and objects.
NATIONAL GRID GAS EMERGENCY 0800 111 999
The “operating instructions” of this manual must be read carefully as it provides information on the operating and the operating limits of
the appliance.
This appliance must be used exclusively in an un-vented central heating system.
The warnings contained in this chapter have been written for the appliance user, the installer and the service engineer.
1.2.
Product conformity
FONDITAL S.p.a. declare that all its products are manufactured to a high specification and in compliace with the relevant standards.
All FONDITAL boilers are CE certified and possess technical and functional characteristics that comply with the following standards:
UNI EN 297 for GAS-FIRED CENTRAL HEATING BOILERS TYPE B OF NOMINAL HEAT INPUT ≤ 70 kW
EN 483 for GAS-FIRED CENTRAL HEATING BOILERS TYPE C OF NOMINAL HEAT INPUT ≤ 70 kW
UNI EN 677 for GAS-Fired CENTRAL HEATING BOILERS. SPECIFIC REQUIREMENTS FOR CONDENSING BOILERS WITH NOMINAL
HEAT INPUT ≤ 70 kW
Gas fired boilers also comply with the following directives:
GAS APPLIANCES DIRECTIVE 90/396 CEE for CE compliance
LOW VOLTAGE DIRECTIVE 2006/95 CE
BOILER EFFICIENCY DIRECTIVE 92/42 CE
ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 89/336 CE
The materials used such a copper, brass, stainless steel, etc. form a compact, homogeneous, highly functional unit that is easy to install
and simple to operate. In its simplicity, the wall-mounted appliance is equipped with all the appropriate accessories required to make it a
fully independent boiler capable of satisfying domestic hot water production and central heating needs. All boilers are fully inspected and
are accompanied by a quality certificate, signed by the inspector, and a guarantee certificate. This manual must be kept in a safe place
and must accompany the boiler at all times.
FONDITAL S.p.a. will not be held responsible for any misinterpretation of this manual resulting from the inaccurate translation of
same.
FONDITAL S.p.a. will not be held responsible for the consequences in the case of non observance of the instructions contained
in this manual or in the case where actions not specifically described herein are undertaken.
FONDITAL S.p.a. declare that no substances harmful to health are contained in the appliance or used during appliance
manufacture and have not used or intend to use any of the following substances in the manufacture of Fondital heating
products:
- Asbestos
- Mercury
- CFC’s
It is a condition of the manufacturers warranty that the Benchmark Commissioning Checklist is fully
completed and left with the appliance.
CONTEST
1.General information for fitters, maintenance technicians and users
1.1.General warnings
1.2.Product conformity
2.Instructions for the user
2.1 Control panel
2.2 Operating the boiler
2.2.1.Switching on 2.2.2.CH function
2.2.3.DHW function
2.2.4. ANTI-FREEZE function
2.2.5.PUMP AND THREE-WAY VALVE ANTI-SEIZE FUNCTION
2.2.6.External probe operation (optional equipment)
2.3.Boiler lockout
2.3.1.Burner lockout
2.3.2.Shut-down due to overheating
2.3.3.Shut-down due to inadequate air/flue gas draught
2.3.4.Shut-down due to low water pressure
2.3.5.Shut-down due to temperature probe malfunction
2.4.Maintenance
2.5.Notes for the user
3.Technical characteristics and dimensions
3.1.Dimensions
3.2.Layout
3.3.Operating data
3.4.General characteristics
4.Instructions for the fitter
4.1.Reference standard
4.2.System details
4.2.1.Central heating circuit
4.2.2.Filling the central heating system
4.2.3.Domestic hot water circuit
4.3. Site requirements
4.3.1. Choosing where to install the boiler
4.3.2.Positioning the boiler
4.3.3.Boiler room ventilation
4.3.4.Flue
4.4. Installation (authorised personnel)
4.4.1.Packaging
4.4.2.Installing the boiler
4.4.3.Gas main connection
4.4.4.Hydraulic connections
4.4.5.Adjustable by-pass
4.5. Flue options
4.5.1.Air intake/flue gas discharge system
4.5.2.Configuration of air/flue system pipes
4.5.3.Ø 100/60 mm air/flue gas coaxial duct system
4.5.4.Ø 80 mm air/flue gas split duct system
4.5.5.Electrical supply connection
4.5.6.Room thermostat connection (optional equipment)
4.5.7.External temperature probe installation (optional equipment) and “sliding temperature” operation
4.5.8.Installation of the OPENTHERM remote control (optional equipment only for HR model)
4.5.9. Loading the system
4.6. Burner adjustment
5.Commissioning
5.1. Commissioning the boiler
5.2. Setting the timer
5.3. Checking
5.4. Switching on and switching off
6.Servicing
6.1. General warnings
6.2. Boiler inspection
6.3. Servicing schedule
6.4. Analysis of combustion parameters
6.5. Testing combustion efficiency
6.5.1.“Chimney sweep” function
6.5.2.Measurements
6.6. Wiring diagram
6.7 Hydraulic loss
7.Spare part list
8.Troubleshooting
Benchmark Commissioning checklist
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2. Instructions for the user
Fondital is a licensed member of the Benchmark Scheme which aims to improve the standards of installation and commissioning of
domestic heating and hot water systems in the UK and to encourage regular servicing to optimise safety, efficiency and performance.
Benchmark is managed and promoted by the Heating and Hotwater Industry Council.
For more information visit www.centralheating.co.uk
Please ensure that the installer has fully completed the Benchmark Checklist on the inside back pages of the installation instructions
supplied with the product and that you have signed it to say that you have received a full and clear explanation of its operation. The
installer is legally required to complete a commissioning checklist as a means of complying with the appropriate Building Regulations
(England and Wales).
All installations must be notified to Local Area Building Control either directly or through a Competent Persons Scheme. A Building Regulations Compliace Certificate will then be issued to the customer who should, on receipt, write the Notification Number on the Benchmark Checklist.
This product should be serviced regularly to optimise its safety, efficiency and performance. The service engineer should complete the
relevant Service Record on the Benchmark Checklist after each service.
The Benchmark Checklist may be required in the event of any warranty work and as supporting documentation relating to home improvements in the optional documents section of the Home Information Pack.
2.1. Control panel
1
2
3 4
5
6 7
8
9
10
11
12
pic. 1
1. Power mains connection light (green)
This light indicates that the power supply to the boiler is on.
2. Indicator light (red)
When this light is on, it means the temperature of the water in the heating system is between 25°C and 35°C.
When this light is flashing, it means the boiler has shut down due to a malfunction.
3. Indicator light (red)
When this light is on, it means the temperature of the water in the heating system is between 36°C and 45°C. When this light is flashing,
it means the boiler’s safety thermostat has shut the boiler down.
4. Indicator light (red)
When this light is on, it means the temperature of the water in the heating system is between 46°C and 55°C.
When this light is flashing, it means there is a fault in the air intake and/or flue discharge piping.
5. Indicator light (red)
When this light is on, it means the temperature of the water in the heating system is between 56°C and 65°C.
When this light is flashing, it means the burner has shut down.
6. Indicator light (red)
When this light is on, it means the temperature of the water in the heating system is between 66°C and 75°C.
When this light is flashing, it means the water pressure in the boiler is too low.
7. Indicator light (red)
When this light is on, it means the temperature of the water in the heating system is between 76°C and 85°C.
When this light is flashing, it means the CH temperature is above 85°C.
8. Indicator light (yellow)
When this light is on, it means the flame is present on the burner.
When this light is flashing, it means the boiler has shut down due to a malfunction.
9. Boiler mode
When the knob is in the OFF position the boiler is in stand-by mode.
When the knob is in the SUMMER position
, the boiler supplies DHW only.
When the knob is in the WINTER position
, the boiler supplies both CH and DHW.
When the knob is in the ANTI-FREEZE position
, only the boiler anti-freeze function is active.
When the knob is turned to the RESET position and back
, the boiler resumes operation.
10. DHW temperature regulator
This knob is used to set the DHW temperature within the range 35 - 57°C
WARNING
The boiler has a special built-in regulator that limits DHW flow up to 10 litres per minute. In addition to the DHW temperature set on this
regulator, the DHW temperature also depends on the amount of water requested by the user and the supply temperature.
11. CH temperature adjustment
This knob is used to set the temperature of the water in the heating system. The setting range is 35 - 78°C.
12. Time clock
The time clock is for central heating control only. The clock is provided with a selector switch with three positions:
a)
b)
c)
Position “I” CONSTANT: in this position, the clock circuit is always closed (switch on), therefore the boiler will constantly on and will only shut off upon the request of the room thermostat (if installed) or the heating thermostat;
Position “O” HEATING OFF: in this position, the clock circuit is always open (switch off) and the boiler will therefore never igniter for heating, Domestic hot water will operate on demand;
“Central” position PROGRAMMING ACTIVE: in this position, the programming set by the user is active.
Using the three position switch the timer will allow either constant operation, timed operation or central heating off. Move the switch bottom by sliding to the desired position.
The time clock is provided with 72 switches, each of which cover a time interval of 20 minutes (three per hour).
Tapped position
ON
When a rider is switched from the outside (on setting) to the inside of the clock border (off setting),
the circuit is open (switch off) for a period of 20 minutes and then the boiler stops.
OFF
For set the time of day, turn the timer outer bezel clockwise, to align the pointer with the correct
time to the nearest 20 minutes. Do not at any time attempt to turn the bezel anti-clockwise.
For set the timed heating program, decide which times of the day the central heating is required.
The heating will operate when the green tappets are set to the outer edge of the bezel.
To ensure the heating stays OFF set the required tappets inwards towards the centre of the bezel.
COLOUR DISPLAY ACCORDING TO BOILER STATUS
Regular working
LIGHT 1
LIGHT 2
LIGHT 3
LIGHT 4
LIGHT 5
LIGHT 6
LIGHT 7
LIGHT 8
Power connected to boiler
GREEN
n/a
n/a
n/a
n/a
n/a
n/a
n/a
Burner on
GREEN
n/a
n/a
n/a
n/a
n/a
n/a
YELLOW
CH temperature < 25°C
GREEN
OFF
OFF
OFF
OFF
OFF
OFF
n/a
26°C < CH temperature < 35°C
GREEN
RED
OFF
OFF
OFF
OFF
OFF
n/a
36°C < CH temperature < 45°C
GREEN
OFF
RED
OFF
OFF
OFF
OFF
n/a
46°C < CH temperature < 55°C
GREEN
OFF
OFF
RED
OFF
OFF
OFF
n/a
56°C < CH temperature < 65°C
GREEN
OFF
OFF
OFF
RED
OFF
OFF
n/a
66°C < CH temperature < 75°C
GREEN
OFF
OFF
OFF
OFF
RED
OFF
n/a
76°C < CH temperature < 85°C
GREEN
OFF
OFF
OFF
OFF
OFF
RED
n/a
LIGHT 4
LIGHT 5 LIGHT 6
Table 1 - Colour displayed by Light in relation to boiler operation status
Malfunctions
LIGHT 1 LIGHT 2 LIGHT 3
LIGHT 7
LIGHT 8
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Safety thermostat shutdown
GREEN
OFF
RED L
OFF
OFF
OFF
OFF
OFF
Air/flue gas pressure switch
shutdown
GREEN
OFF
OFF
RED L
OFF
OFF
OFF
OFF
Shutdown due to flame absence
GREEN
OFF
OFF
OFF
RED L
OFF
OFF
OFF
Water pressure switch shutdown
GREEN
OFF
OFF
OFF
OFF
RED L
OFF
OFF
Gas valve alarm
GREEN
OFF
RED L
OFF
OFF
OFF
OFF
YELLOW L
Water temperature switch alarm (>85°C)
GREEN
OFF
OFF
OFF
OFF
OFF
RED L
OFF
DHW flow probe alarm
GREEN
RED L
OFF
OFF
OFF
OFF
OFF
OFF
CH flow probe alarm
GREEN
RED L
OFF
OFF
OFF
OFF
OFF
YELLOW L
External cylinder probe alarm
GREEN
RED LA
OFF
OFF
OFF
OFF
OFF
YELLOW LA
Remote control malfunction
GREEN
OFF
OFF
RED L
OFF
OFF
OFF
YELLOW L
Power is missing
Table 2- Colour displayed by Light in relation to boiler malfunction status
KEY TO ACRONY
OFF
RED L RED LA RED n/a LIGHT off
LIGHT on, displaying the colour shown on the table
LIGHT or lights flashing, displaying the colour shown on the table
LIGHTS flashing, displaying in sequence the colours shown on the table
LIGHT status not relevant
2.2. Operating the boiler
2.2.1. Switching on
These instructions presuppose that the boiler has been installed by an authorized fitter, started up for the first time and set up for correct operation.
• Open the gas stop cock.
• Connect the boiler to the mains power supply (LIGHT 1 on the control panel comes on).
• Choose boiler mode by operating the “OFF/SUMMER/WINTER/ANTI-FREEZE” selector (9).
• Turn the CH temperature adjustment knob (11) to set the temperature required for the heating system.
• Turn the DHW temperature knob (10) to set the temperature required for the DHW (HC).
• Set desired room temperature by means of the room thermostat in the premises (when available).
WARNING: If the boiler is not used for a long time, particularly if it runs on LPG, ignition may be difficult.
Before operating the boiler, switch on another gas-powered device (e.g. kitchen range or oven). Be aware that even if this
procedure is followed, the boiler may still experience some starting difficulties and shut down once or twice.
Reset the boiler by operating knob
(9), then turn the knob back to the required position. Allow three minutes between each
attempt to re-light the boiler.
2.2.2. CH function
Use the regulation knob (11, pic. 1) to set the temperature in the central heating system.
The temperature setting range is 35-78°C (from the counter-clockwise limit position to the time limit position).
The CH temperature can be read from lights 2÷7 (pic. 1) on the control panel.
To prevent frequent ignition and switching off in heating mode, the boiler has a 4-minute waiting time between subsequent ignitions.
If the water temperature in the system fall below 40°C, waiting procedure is aborted and the boiler re-ignites (Antifast function).
2.2.3. DHW function
The domestic hot water supply function is active on model HC, and on model HR with an (optional) external water heater. This function
always has priority over central heating water.
For model HC, the temperature setting range is 35-57°C (from the counter-clockwise limit position to the time limit of regulation knob 10).
For model HR with an (optional) external water heater with an NTC probe (10 kΩ @ ß=3435; refer to the water heater specifications), the
temperature setting range is 35-57°C (from the counter-clockwise limit position to the time limit of regulation knob 10).
For model HR with an (optional) external water heater with thermostat probe, the desired DHW temperature must be set on the water
heater (refer to the attached instructions). Regulation knob 10 has no effect on this configuration.
The boiler is fitted with a flow-limiting device that allows a maximum DHW flow of 10 litres per minute.
The DHW flow rate depends on the boiler’s thermal capacity and the mains water supply temperature, and can be calculated from the
following formula:
K
l = DHW liter per minute = -------∆
T
K represents:
349 (HC 24)
434 (HC 32)
ΔT = DHW temperature – mains water supply temperature.
E.g. In model HC 24, if the mains water supply temperature is 8°C and DHW is required at 38°C, the value of ΔT is:
ΔT = 38°C – 8°C = 30°C
and DHW litres (l per minute) available at the required temperature of 38°C is
I = 349 / 30 = 11.7 [litres per minute - mixed water to the tap].
2.2.4. ANTI-FREEZE FUNCTION
This boiler is fitted with an anti-freeze protection system, which works when the following functions are activated: SUMMER, WINTER
and ANTI-FREEZE.
The anti-freeze function only protects the boiler, not the whole heating system. The heating system must be protected using a room thermostat, although this is disabled when the selector is set to the ANTI-FREEZE or OFF mode.
Therefore, if you want to protect both the boiler and the system, turn to WINTER mode on selector 9.
When the heating water temperature sensor detects a water temperature of 5°C, the boiler switches on and stays on at its minimum
thermal power until the temperature reaches 30°C or 15 minutes have elapsed. The pump continues to operate even if the boiler shuts
down.
In model HC, anti-freeze function also protects the DHW circuit.
When the DHW temperature sensor detects a temperature of 5°C, the boiler switches on and stays on at its minimum thermal power
until the temperature reaches 10°C or 15 minutes have elapsed (the deviating valve is in the DHW position). The pump continues to
operate even if the boiler shuts down.
In boilers with an external heater for the supply of domestic hot water, which have a thermostat-type temperature sensor, the anti-freeze
function does NOT protect the water heater. It can be protected by setting the boiler to Summer
or Winter
, or by setting a
value above 0°C on the water heater thermostat.
In CH boilers with an external water heater for the supply of domestic hot water, which have an NTC temperature sensor (10 kΩ @
ß=3435; refer to the boiler specifications), the anti-freeze function protects the water heater as well.
When the external cylinder temperature sensor detects a water temperature of 5°C, the boiler switches on and stays on at its minimum
thermal power until the temperature of the water in the external cylinder reaches 10°C or 15 minutes have elapsed. The pump continues
to operate even if the boiler shuts down.
The CH system can be protected effectively against freezing by means of specific anti-freeze additives suitable for use in multi-metal
systems.
Do not use car engine anti-freeze products, and periodically check the effectiveness of the anti-freeze product.
2.2.5.
PUMP AND THREE-WAY VALVE ANTI-SEIZE FUNCTION
Where the boiler is to remain inactive and:
- no. 9 selector is not set to the OFF position;
- boiler is not disconnected from electric main power supply;
the circulation pump (for all models) and three-way valve (HC model), are operated for 30 second every 24 hours in order to prevent the
components from seizing.
2.2.6.
External probe operation (optional equipment)
The boiler can be equipped with an (optional) external temperature probe, by means of which the boiler adjusts the CH water
temperature according to the outdoor temperature, in other words, increasing the CH water temperature when the outdoor temperature
decreases, and vice-versa. This increases energy-saving operation (this boiler mode is called “sliding temperature operation”).
10
The boiler microprocessor program determines CH water temperature variations.
When an external temperature probe is connected to the boiler, the CH water temperature adjusting knob (11, pic. 1) loses its function
and becomes a room temperature control device.
When knob 11 is turned fully counter-clockwise, the room temperature setting is 15°C; when set to 9 o’clock, the temperature is 18°C;
when set to 12 o’clock, the temperature is 25°C; when set to 3 o’clock the temperature is 32°C; when it is turned fully clockwise the
temperature is 35°C.
For the best curve setting, it is advisable to set the temperature at around 20°C.
Picture 2 shows the curves for a room temperature of 20°C. As this value is increased via the regulation knob 11, the curves move
upwards. With this setting, if for example you select the curve corresponding to coefficient 1, with an outdoor temperature of -4°C, the
flow temperature will be 50°C.
Refer to subsection 4.5.7 for detailed sliding temperature operation.
CH flow temperature (°C)
100
2,5
2
80
1,5
1,25
1
60
40
20
20
16
12
pic. 2
8
-4
0
4
-8
External temperature (°C)
-12
Thermoregulation curves
coefficient
3
-16
2.3.Boiler lockout
If a malfunction occurs, the boiler automatically shuts down.
Refer to tables 1 and 2 for boiler status.
In order to determine the probable causes of the malfunction, refer to section 8 - Troubleshooting - at the end of this manual (in addition
to tables 1 and 2).
Follow the procedure described for the type of shut-down.
2.3.1. Burner lockout
When the burner shuts down because the flame has gone out, light 5 (red) starts flashing. If this happens, proceed as follows.
• Check that the gas stopcock is open, and make sure the gas main is actually providing service by lighting a gas-powered kitchen
appliance such as a kitchen range or oven.
• Once the presence of gas has been verified, reset the burner by turning knob 9
to the RESET position for 2 seconds, and then
to the desired operating mode. If the boiler does not shut down, and you have performed the reset procedures three times, contact an
authorized Service Centre or a qualified service engineer.
Should frequent burner shut-down occur, a recurrent malfunction may be present. Contact an authorized Service Centre or a qualified
service engineer.
2.3.2. Shut-down due to overheating
When the CH water gets too hot, the boiler shuts down, and light 3 (red) starts flashing. If this happens, contact an authorized Service
Centre or a qualified service engineer.
Should the above happen contact the Fondital helpline UK or CORGI registered engineer with appropriate competence for service.
2.3.3. Shut-down due to inadequate air/flue gas draught
If the burner shuts down due to a malfunction of the air intake and/or flue discharge piping, light 4 starts to flash.
Should the above happen contact the Fondital helpline UK or CORGI registered engineer with appropriate competence for service.
11
2.3.4. Shut-down due to low water pressure
If red shout-down light 6 comes on, it indicates low water pressure and intervention of the low water pressure switch.
The following situation may occur: the water pressure gauge (pic.3) indicates a pressure value lower than 1 bar.
Follow the loading procedure as below described:
- open the loading tap upstream the boiler to fill the system with water;
- keep the loading tap open until the water pressure gauge reads 1÷1.3 bar;
- close the loading tap;
- reset the burner by turning knob 9 to the RESET position for 2 seconds, and then to the desired operating mode.
Should the boiler shut down again, contact the Fondital helpline UK or CORGI registered engineer with appropriate competence for
service.
Water pressure gauge
pic. 3
Once the loading procedure is completed, properly close the loading tap. Should the tap not be appropriately closed, as pressure increases, CH system safety valve may open and water flow out.
2.3.5.
Shut-down due to temperature probe malfunction
If the burner shuts down due to temperature probe malfunction, the following lights start to flash:
• Red light no. 2 and yellow light no. 8 when CH probe malfunction occurs.
• Red light no. 2 when DHW probe malfunction occurs.
• Red light no. 2 and yellow light no. 8 (flashing alternately) for external cylinder probe (model HR with external boiler and NTC
temperature probe).
Should the boiler not re-start and still remain in the above status, contact the Fondital helpline UK or CORGI registered engineer with
appropriate competence for service.
2.4.
Maintenance
Routine boiler maintenance must be provided according to the applicable laws in the country of installation and following the instructions
given in the relevant section in this manual. Correct maintenance ensures that the boiler operates efficiently, is environmentally friendly,
and is not a danger to people, animals or property.
By law, only qualified personnel are allowed to service the boiler.
The Manufacturer recommends that Customers contact an authorized Service Centre for maintenance and repairs.
For maintenance interventions, refer to section 6 – Maintenance.
The external boiler housing must only be cleaned with standard household cleaning products.
Do not use water!
2.5.
Notes for the user
The user may only access boiler parts that can be reached without using any technical equipment or tools. The user is not authorized to remove the boiler housing or touch any of the internal parts.
No one, including qualified service engineers, is authorized to modify the boiler.
The manufacturer can not be held liable for damage to people, animals, or property due to tampering or improper work done to the
boiler.
If the boiler remains inactive and the power supply disconnected for a long time, the pump may not operate.
Pump servicing includes removing the boiler housing and accessing the internal parts of the boiler, so this must only be done by
a qualified service engineer.
Pump blockage can be avoided by adding to the water filming additives suitable for multi-metal systems.
12
3. Technical characteristics and dimensions
The boiler is equipped with an atmospheric burner. All versions are equipped with electronic ignition and ionization flame control.
The following models of boiler are available:
-
-
-
-
HC 24: sealed chamber and forced draught, electronic ignition and instant DHW supply (25.5 kW);
HR 24: sealed chamber and forced draught, electronic ignition, CH supply only (25.5 kW);
HC 32: sealed chamber and forced draught, electronic ignition and instant DHW supply (31.5 kW);
HR 32: sealed chamber and forced draught, electronic ignition, CH supply only (31.5 kW);
The boilers meet local applicable Directives enforced in the country of destination, which is stated on their data plate.
Boiler installation in a different country from specified may endanger people, animals and objects.
The main technical characteristics of the boilers are listed below:
Construction characteristics
-
-
-
-
-
-
-
-
-
IPX4D electrically protected control panel
Integrated, modulating electronic safety board
Electronic ignition via separated transformer and
ionization flame detection
Stainless steel multi-gas atmospheric burner
Modulating gas valve with double shutter
Mono-thermal, high efficiency, composite and stainless steel heat exchanger with air purging device
Stainless steel DHW heat exchanger (only HC)
Motorized deviating valve (only HC)
Three-speed pump with air purging device
-
-
-
-
-
-
-
-
-
Safety flow-switch, preventing operation with low water pressure in the CH system
8 litre expansion vessel
DHW priority flow switch (only HC)
10 litres/min DHW flow limiting device (only HC)
Integrated, automatic by-pass
Boiler filling and draining taps
CH (all models) and DHW (only HC) temperature probes
Safety limit thermostat
Flue pressure switch
-
-
-
Leds indicating water temperature
Water pressure gauge
CH temperature switch (35-78 °C)
-
-
-
-
-
-
-
-
-
-
-
-
Flame propagation function during ignition
CH max heat output adjusting trimmer
Ignition heat output adjusting trimmer
Timer-controlled room thermostat (240 seconds when CH flow temperature >40°C)
Pump over run function in CH, anti-freeze or chimney sweep mode (180 seconds)
Pump over run function in DHW (30 seconds)
CH temperature post-circulation function: >85°C:30 seconds
Safety post-circulation function (ON: 95°C; OFF: 90°C)
Pump and deviating valve anti-locking function (180 seconds operation after 24 hours of boiler inactivity)
Can be connected to a room thermostat (optional)
Can be connected to an external temperature probe (optional supplied by the Manufacturer)
Can be connected to a cylinder timer connection (only for model HR equipped with external cylinder and NTC
temperature probe).
User interface
-
-
RESET, STAND-BY, SUMMER/WINTER, SUMMER and
ANTI-FREEZE function selector
DHW temperature switch for model HC and HR equipped with external cylinder and NTC temperature probe (35-75 °C)
Operating characteristics
-
-
-
-
-
-
-
-
CH mode electronic flame modulation, timer controlled flame rising ramp (50 seconds)
DHW mode electronic flame modulation, timer controlled flame
rising ramp (for models HC and HR equipped with external cylinder and NTC temperature probe)
DHW priority function
CH flow anti-freeze function: ON at 5 °C; OFF at 30 °C or after 15 minutes operation when CH water > 5 °C
DHW anti-freeze function: ON at 5 °C; OFF at 10 °C or after 15 minutes operation when DHW temperature > 5°C; (for
models HC and HR equipped with external cylinder and NTC temperature probe)
External boiler anti-freeze function (HR + external cylinder equipped with NTC probe): ON at 5 °C; OFF at 10 °C or after 15 minutes operation when external cylinder water
temperature > 5 °C
Timer controlled “chimney sweep” function: 15 minutes
“Anti-Legionnaires’ disease function (only for model HR equipped with external cylinder and NTC temperature probe)
13
750
3.1. Dimensions
325
450
DHW
CWI
140
225
SV
175
F
G
R
138
177
S
SI
43
56
98
75
98
80
RS
Bottom view
pic. 4
14
S
F
G
SI
DHW
Condensate drain
CH system flow
Gas intake
Inspection trap plug
DHW hot water draw off (HC model only)
Top view
CWI
SV
R
RS
Cold water inlet (HC model only)
3-bar safety valve drain cock
CH system return
Drain cock
3.2. Layout
HR MODEL
15
14
16
13
12
17
11
10
9
8
18
19
1. Condensate drain
2. Modulating gas valve
3. CH temperatura probe
4. Burner nozzles
5. Flame detection electrode
6. Safety thermostat
7. Heat exchanger
8. Sealed combustion chamber
9. Flue gas extraction fan
10. Flue gas pressure test point
7
11. Flue gas pressure safety switch
6
12. Flue gas pressure micro switch
13. Condensate detection probe
14. Safety thermostat
15. Air intake/flue gas pipe
16. Flue gas recoverer
17. Flue gas pressure test point
18. Expansion vessel filling tap
19. Expansion vessel
20
20
5
21
4
22
3
2
23
24
1
25
20. Ignition electrode
21. Air purging device
22. Pump
23. Water pressure switch
24. 3-bar safety valve
25. Unloading tap
pic. 5
HC MODEL
18
17
16
15
19
14
13
12
11
10
9
20
21
8
7
6
5
4
22
22
23
24
3
25
31
2
1
30
32
26
27
28
29
pic. 6
G
S
1. Condensate drain
2. DHW temperature probe
3. Modulating gas valve
4. CH temperature probe
5. Burner nozzles
6. Burner
7. Flame detection electrode
8. Safety thermostat
9. Heat exchanger
10. Sealed combustion chamber
11. Flue gas extraction fan
12. Flue gas pressure test point
13. Flue gas pressure safety switch
14. Flue gas pressure micro switch
15. Condensate detection probe
16. Flue gas recoverer
17. Safety thermostat
18. Air intake/flue gas intake
19. Flue gas pressure test point
20. Expansion vessel filling tap
21. Expansion vessel
22. Ignition electrode
23. Air purging device
24. Pump
25. Water pressure switch
26. Safety valve
27. DHW flow limiting device (max 10 litre/minute)
28. Flow switch
29. Mains water inlet filter
30. Adjustable by-pass
31. Three way valve
32. Secondary plate heat exchanger
15
3.3.
Operating data
Burner pressures must be verified after a three minute boiler operation time.
HC 24 / HR 24
Heat
input
[kW]
Function
Heat
output
50-30°C
[kW]
Heat
output
80-60°C
[kW]
Mains gas
pressure
[mbar]
Nozzle diameter
[mm]
Burner pressure
[mbar]
min
max
min
max
min
max
min
max
Methane gas G20
11.5
25.5
10.7
24.4
11.4
26.4
20
1.25
2.90
13.2
Butane gas G30
11.5
25.5
10.7
24.4
11.4
26.4
28-30
0.77
5.74
27.7
Propane gas G31
11.5
25.5
10.7
24.4
11.4
26.4
37
0,77
6,5
29,5
Table 3 - Calibration data for HC 24 and HR 24
Hot water supply ΔT 45°C = 7.8 l/min
Hot water supply ΔT 40°C = 8.7 l/min
Hot water supply ΔT 35°C = 10.0 l/min
Hot water supply ΔT 30°C = 11.7 l/min *
Hot water supply ΔT 25°C = 14.0 l/min *
*Note: mixed water to the tap
HC 32 / HR 32
Heat
input
[kW]
Function
Heat
output
50-30°C
[kW]
Heat
output
80-60°C
[kW]
Mains gas
pressure
[mbar]
Nozzle diameter
[mm]
Burner pressure
[mbar]
min
max
min
max
min
max
min
max
Methane gas G20
12.0
31.5
11.2
30.3
12.0
32.7
20
1.25
2.90
13.2
Butane gas G30
12.0
31.5
11.2
30.3
12.0
32.7
28-30
0.76
4.7
29.0
Propane gas G31
12.0
31.5
11.2
30.3
12.0
32.7
37
0,76
6,5
29,5
Table 4 - Calibration data for HC 32 and HR 32
Hot water supply ΔT 45°C = 9.6 l/min
Hot water supply ΔT 40°C = 10.9 l/min
Hot water supply ΔT 35°C = 12.4 l/min
3.4.
General characteristics
Category
Burner nozzles
Minimum CH flow rate
Minimum CH pressure
Maximum CH pressure
Minimum DHW pressure
Maximum DHW pressure
DHW specific capacity ( Δt 30°C)
Electrical power supply - voltage / frequency
Power mains supply fuse
Maximum power consumption
Net weight
Natural gas consumption(*)
Butane gas consumption
Propane gas consumption
Maximum CH working temperature
Maximum DHW working temperature
Total capacity of expansion vessel
Maximum recommended CH system capacity
Table 5 - General data for each model
(*) Value referred to 15 °C - 1013 mbar
16
Hot water supply ΔT 30°C = 14.5 l/min *
Hot water supply ΔT 25°C = 17.4 l/min *
*Note: mixed water to the tap
no.
l/h
bar
bar
bar
bar
l/min
V ~ Hz
A
W
kg
m3/h
Kg/h
Kg/h
°C
°C
l
l
HC 24
II2H3+
12
500
0.5
3
0.5
8
11.8
230 ~ 50
2
142
43.3
2.698
2.008
1.977
78+5
57+5
8
100
HR 24
II2H3+
12
500
0.5
3
230 ~ 50
2
142
41.0
2.698
2.008
1.977
78+5
57+5
8
100
HC 32
II2H3+
15
500
0.5
3
0.5
8
15.0
230 ~ 50
2
177
44.5
3.333
2.480
2.442
78+5
57+5
8
100
HR 32
II2H3+
15
500
0.5
3
230 ~ 50
2
177
41.9
3.333
2.480
2.442
78+5
57+5
8
100
HC 24 / HR 24
Boiler casing heat loss with burner on
Flue system heat loss with burner on
Flue system mass capacity
Flue temp. – air temp.
CO2 (gas G20)
CO2 (gas G30)
Boiler efficiency rate (80-60 °C) (Net)
Boiler efficiency rate (50-30 °C) (Net)
Boiler efficiency at 30 % of the load (Net)
Efficiency rating (according to 92/42/CE)
SEDBUK classification HC 24 kW
SEDBUK classification HR 24 kW
NOx emission class
Table 6 - HC 24 - HR 24 model combustion rates
%
%
g/s
°C
%
%
%
%
%
-
HC 32 / HR 32
Boiler casing heat loss with burner on
Flue system heat loss with burner on
Flue system mass capacity
Flue temp. – air temp.
CO2 (gas G20)
CO2 (gas G30)
Boiler efficiency rate (80-60 °C) (Net)
Boiler efficiency rate (50-30 °C) (Net)
Boiler efficiency at 30 % of the load (Net)
Efficiency rating (according to 92/42/CE)
SEDBUK classification HC 32 kW
SEDBUK classification HR 32 kW
NOx emission class
Table 7 - HC 32 - HR 32 model combustion rates
%
%
g/s
°C
%
%
%
%
%
-
Max. heat output
1.71
2.39
13.5
47.9
7.5
9.1
95.8
103.4
-
Min. heat output
2.06
4.74
14.3
45.4
3.0
3.6
93.2
99.4
-
30% heat output
100.9
B (86.5 %)
B (86.6 %)
3
Max. heat output
1.31
2.59
16.7
54.9
7.6
9.0
96.1
103.8
-
Min. heat output
0.66
5.94
16.7
50.6
2.6
3.0
93.4
99.8
-
30% heat output
100.0
B (86.2 %)
B (86.3 %)
3
4.Instructions for the fitter
This is an II2H3+ category boiler and must be installed in compliance with laws and standards enforced in the country of installation,
which are here considered as entirely transcribed.
4.1.
Reference standard
In GB, the installation must be carried out by a CORGI Registered Installer. To check for authorised qualified engineers please contact
CORGI 01256-372400. It must be carried out in accordance with the relevant requirements of the:
- Gas Safety Regulations;
- The appropriate Building Regulations either The Building Regulation, The Building Regulations (Scotland), Building Regulations (Northern Ireland);
- The Water Fittings Regulations or Water Bylaws in Scotland;
- The current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be made to the relevant British Standards Code of Practice.
The following list is the full lists of codes of practice and British Standards that engineers should work to in the UK.
It is law in the UK that a competent person installs all gas-burning appliances. Please ensure that the installer is a class of person approved for the time being by the Heath and Safety Executive for the purpose of carrying out this work. An approved engineer should be
registered to an approved scheme i.e. CORGI 01256-372400.
In GB, the following Codes of Practice apply:
BS 5440: Part 1 2000 - Flues
BS 5440: Part 2 2000 - Air Supply
BS 5446: Installation of hot water supplies for domestic purposes (1st, 2nd and 3rd family gases)
BS 5449: 1990 Forced circulation hot water systems
BS 6700: 1987 - Installation of cold water supplies for domestic purposes (1st, 2nd and 3rd family gases)
BS 6798: 2000 Specification for installation of gas-fired boilers of rated input not exceeding 70 kW net
BS 6891: Specification for installation of low pressure gas pipe work of up to 28 mm (R!) in domestic premises (2nd family gas)
BS 7074: Expansion Vessels and ancillary equipment for sealed water systems
BS 7593: 1992 Code of practice for treatment of water in domestic hot water central heating systems
BS 7671: 2001 IEE wiring regulations.
17
This appliance meets the requirements of:
- UNI EN 677 for GAS-FIRED CENTRAL HEATING BOILERS. SPECIFIC REQUIREMENTS FOR CONDENSING BOILERS WITH
NOMINAL HEAT INPUT ≤ 70 kW,
- IPX4D rating for electrical appliances,
- EMC DIRECTIVE 89/336 CE,
- LVD DIRECTIVE 2006/95 CE,
- BOILER EFFICIENCY DIRECTIVE 92/42 CE
Failure to install a gas appliance correctly and in accordance with the above norms could lead to prosecution. It is in the interest of the
installer and safety that the law is complied with.
The manufacturers instructions form an integral part of the installation and should be left with the appliance but do not over ride in anyway statutory obligations.
4.2.
System details
4.2.1. Central heating circuit
The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798. The
system should be designed to operate with flow temperatures of up to 78 °C. When designing the system, the pump head, expansion
vessel size, mean radiator temperature, ect. must all be taken into account. Refer to the pump performance table for guidelines.
System volume: the expansion vessel incorporated into the boiler is suitable for a sealed heating system. The boiler is supplied with the
following components built in:
Pressure relief valve: set to operate at 3 bars. The outlet connection of the boiler safety valve must terminate to atmosphere in accordance with current regulations. The manufacturer will not be held responsible for flooding caused by the operation of the safety valve in
the case of system overpressure.
Pressure gauge: to indicates the system pressure to be maintained.
Expansion vessel: capacity of 8 litres.
By-pass: The boiler incorporates an automatic by-pass.
All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler
noise and circulation problems.
All systems must be thoroughly drained and flushed out. System additives - corrosion inhibitors and flushing agents/descalers should
comply to BS7593 requirements. It is important to check the inhibitor concentration after installation, system modification and at every
service in accordance with the manufacturer’s instructions.
4.2.2.
Filling the central heating system
The system design pressure (cold) should be set to 1,5 bar. This pressure is equivalent to a static head of 15,4 metres of water. Provision
should be made to replace water lost from the system. This can be by manual or automatic means as shown in Pics. 7 and 8. A double
check valve assembly must be used as show in pic 8.
Filling of the system must be carried out in a manner approved by the local Water Undertaking. Where allowed the system may be filled
via a temporary connection as shown in pic 7. After filling, always disconnect the flexible hose of the filling loop. All fittings used in the
system must be able to withstand pressures up to 3 bar. Drain taps must be used to allow the system to be completely drained.
In order to prevent scaling or deposits in the primary heat exchanger, the mains supply water to the
heating circuit must be treated according to the requirements of standard.
This treatment is indispensable in the case where the circuit is frequently topped-up or when the system is often either partially or fully drained.
Mains water
supply
CH return
Hose unions
Additional
stop valve
Temporary hose
(disconnect after filling)
pic. 7
18
Double check valve
assembly
(note direction of flow)
Overflow
Heating
circuit
return
pic. 8
Double
check valve
assembly
Test
cock
Stop
valve
Mains
water
supply
Feed cistern to be
located above
highest point in
the system
4.2.3.
Domestic Hot Water Circuit
All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations.
Your attention is drawn for GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide.
4.3.
Site requirements
4.3.1.
Choosing where to install the boiler
The following must be taken into account when choosing where to install the boiler:
-
-
-
-
Approved document L1 + L2 government guidelines.
Check the wall is strong enough to support the weight of the boiler.
Do not fit the boiler above any equipment that may affect operation (kitchen appliances that emit steam or greasy vapour, washing machines, etc.).
Do not install natural draught boilers in corrosive or very dusty atmosphere areas, such as hairdressing salons or laundries as this would greatly reduce the boiler’s lifespan.
4.3.2.
Positioning the boiler
Each boiler is supplied with a paper template (pic. 10), within its packaging,
allowing arrangement of CH pipe system, DHW pipe system, gas supply pipe
system and air intake/flue gas discharge system before actually installing the
boiler.
The template is made of heavy-duty paper, it is to be affixed to the wall where
the boiler is to be mounted using a carpenter’s level.
It provides all the indications required to drill the boiler fixing holes to the wall,
procedure which is done using two screws and wall plugs.
The lower area of the template displays where to mark the exact point at which
the couplings are to be positioned for boiler connection to the gas supply pipe,
water mains supply pipe, DHW flow pipe, CH flow and return pipes.
The upper area of the template displays where air intake and flue gas ducts are
to be positioned.
The manufacturer recommends leaving a space all round the boiler during
installation as follows:
- at least 2,5 cm on the right and left;
- at least 25 cm above and below.
This facilitates service operations on the boiler, e.g. maintenance and repair
interventions (pic. 9).
25 cm
2,5 cm
2,5 cm
pic. 9
2,5 cm
25 cm
Since the temperature of the walls on which the boiler is mounted and external temperature of coaxial air/flue gas
system do not exceed 60 °C, no minimum distance from flammable walls is to be accounted for.
Boilers with split pipe flue system: in presence of flammable walls and flue gas ducts through such walls, ensure air gap of 15 mm between wall and flue gas ducts.
19
DHW
CWI
R
F
G
S
Domestic hot water
Cold water inlet
CH system return
Gas
Condensate drain
S
G
pic. 10
20
F
DHW
CWI
R
4.3.3.
Boiler room ventilation
The boiler has sealed combustion chamber. Combustion air is not drawn from boiler room therefore specific recommendations need not
to be applied concerning the boiler room or openings and ventilation provided to the boiler room.
It is mandatory to install the boiler in an adequate room following laws and standards applicable in the country of installation, which are considered as fully transcribed in this manual.
4.3.4.
Flue
The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendations are given in
BS 5440 Part 1. If the terminal discharges onto a pathway or passageway, check that combustion products will not cause a nuisance
and that the terminal will not obstruct the passageway. If a terminal is less than 2 metres above a balcony, above ground or above a flat
roof to which people have access, then a suitable terminal guard must be provided.
TERMINAL POSITION WITH MINIMUM DISTANCE (mm)
Aa Directly below an opening, air brick, opening windows, etc.
300
Ba Above an opening, air brick, opening window etc.
300
Ca Horizontally to an opening, air brick, opening window etc.
300
D
Below gutters, soil pipes or drain pipes
25
E
Below eaves.
25
F
Below balconies or car port roof.
25
G From a vertical drain pipe or soil pipe.
25
H From an internal or external corner.
25
I
300
Above ground, roof or balcony level.
J From a surface or boundary line facing a terminal.
600
K
From a terminal facing a terminal (Horizontal flue).
1200
From a terminal facing a terminal (Vertical flue).
600
L From an opening in carport (e.g. door, window) into the dwelling.
1200
M Vertically from a terminal on the same wall.
1500
N Horizontally from a terminal on the same wall.
300
R From adjacent wall to flue (vertical only).
300
S From an adjacent opening window (vertical only).
1000
T Adjacent to windows or openings on pitched and flat roofs
600
U Below windows or openings on pitched roofs
2000
a In addition, the terminal should be no nearer than 150 mm to an
opening in the building fabric formed for the purpose of accommodating
a built-in element such as a window frame. See BS 5440 Pt. 1.
T
J,K
U
N
R
I
M
C
I
I
F
D
E
A
S
I
F
J,K
B
L
G
A
A
H
H
I
pic. 11
Likely flue positions requiring
a flue terminal guard
21
4.4.
Installation (authorised personnel)
Accessories and spare parts for installation and service procedures are to be supplied by the
Manufacturer. Should non original accessories and spare parts be employed, boiler proper performance is not guaranteed.
4.4.1.
Packaging
Boiler is shipped in a sturdy cardboard box. Remove boiler from cardboard box and check its integrity.
The packing materials can be recycled and should be disposed of at an appropriate waste collection site. Keep packaging out of reach
of children, as it may be dangerous.
The manufacturer shall not be held responsible for harm to people and/or animals, and/or damage to property due to failure in following
the above mentioned instructions.
Packaging includes:
- copper pipe kit for boiler connection to the gas mains, to the CH system (HC and HR) and DHW system (HC) (pic.12);
- four shutoff valves: one for gas, one for heating flow, one for heating return and one for cold water supply (pic.12);
- a bag containing:
a) boiler installation, use and maintenance manual;
b) boiler wall mounting template (pic. 10);
c) metal plate for fixing the boiler to the wall;
d) two screws and wall plugs for fixing the metal plate to the wall;
e) one closing caps with gaskets.
f) benchmark commissioning booklet.
g) air intake diaphragm.
pic.12
4.4.2. Installing the boiler
Before connecting the boiler to the CH and DHW systems, clean the pipes carefully. Prior to operating a NEW system, eliminate any metallic leftover during manufacturing and welding process, and any oil or grease deposits, which might get into the boiler and damage it or affect operation. Prior to operating an UPGRADED system (addition of radiators, boiler replacement, etc.), clean it thoroughly to remove all sludge and foreign particles. Clean the system using a
non-acid product available on the market. Do not use solvents as they could damage the components of the system. In the (new or upgraded) central heating system, it is always advisable to add to the water, in a suitable concentration, a corrosion inhibiting product for use in multi-metal systems to produce a protective film on internal metal surfaces. The
Manufacturer can not be held liable for injury to people or animals or damage to property resulting from failure to follow the above instructions.
Proceed as follows to install the boiler:
• Fix the template (pic. 10) onto the wall.
• Drill two 12 mm Ø holes in the wall to accommodate the boiler bracket wall plugs.
• Arrange air intake/flue gas system in the wall as needed.
• Secure the boiler bracket to the wall using the wall plugs supplied.
• Position the gas supply fitting (G), the mains water fitting (F), the DHW flow fitting (C, only in model HC), the CH flow fitting (M) and the
CH return fitting (R) as shown on the template (refer to the lower part).
• Provide a disposal system for relieving the 3-bar safety valve.
• Hang the boiler on the bracket fixed onto the wall.
• Connect the boiler to the mains pipes using the kit supplied with the boiler (refer to subsections 4.4.3. and 4.4.4.).
• Connect the boiler to the air intake and flue gas exhaust system (refer to subsections 4.5.1; 4.5.2; 4.5.3 and 4.5.4).
• Connect the power supply, room thermostat (optional) and other accessories (refer to subsections 4.5.5; 4.5.6 and 4.5.7).
4.4.3. Gas main connection
The gas installation should be in accordance with the relevant standards. In GB this is BS 6891.
Gas supply pipe cross-section must be equal or greater than boiler gas pipe.
Cross-section gas pipe size calculation depends on its length, layout pattern, gas flow rate. Gas pipe size is to be dimensioned
accordingly.
Comply with installation standards BS 6891 enforced in the installation country which are considered as fully
transcribed in this booklet.
Remember that before operating an indoor gas distribution system and before connecting it to a meter, it must be checked for leaks.
Adhere to the following leak test instructions:
- leak test is to be carried out before pipes are covered;
- leak test is not to be carried out employing flammable gas: use air or nitrogen for this purpose;
- when gas is already in the pipes supplying the boiler, leak testing by naked flame is forbidden, use specific products available on the market.
22
To prevent the main exchanger pipes from getting clogged with any material accumulated in the system it is
necessary to install a filter which can be inspected (Y-shaped type) with Ø 0.4mm-mesh span, on the heating return pipe, before the boiler (part of hydraulic kit) like our accessory 0KITFILT00 (pic.13)
pic. 13
When connecting the boiler to gas supply network, install an appropriately sized and made gasket (pic. 14).
The boiler gas inlet thread configuration is not appropriate for hemp, plastic tape or similarly made gaskets.
Gasket
pic.14
4.4.4.
Hydraulic connections
Prior to installing the boiler, the hydraulic system is to be cleaned in order to remove impurities; they could be present in system components and damage the pump and the heat exchanger (refer to 4.4.2 paragraph).
CENTRAL HEATING
76
CH flow and CH return pipes must be connected to the relevant 3/4” F and R couplings on the boiler (pic. 4).
When calculating the cross section of CH system pipes, bear in mind load losses induced by radiators, thermostatic valves, radiator gate
valves, and the configuration of the system itself.
It is advisable to convey the discharge flow of boiler safety valve to the sewer system. Should the above precaution not be implemented and the safety valve be activated, boiler room flooding may occur.
Manufacturer shall not be held responsible for any damage resulting as failure in observing the above mentioned
technical precaution.
DOMESTIC HOT WATER (only for HC model)
DHW flow and water mains inlet pipes are to be connected to the relevant 1/2” CWI and DHW couplings on the boiler (pic. 4).
Hardness of water supplied to the boiler may increase the plate heat exchanger cleaning/replacement frequency.
All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations.
Depending on hardness level of the water supplied, it might be necessary installing a suitable water treatment device for domestic use and in compliance with applicable laws and standards.
Water treatment is always advisable when water supplied to the boiler is more than 20°F hard.
Water treated by commonly marketed water softeners, due to PH level induced in water, may not be compatible with some components in system.
CONDENSATE DRAIN
Comply with condensate drain laws and standards applicable in the country of installation and which are considered herein integrally
transcribed.
When the law is not stating differently, the condensate produced by combustion, is to be routed (via the condensate drain S in pic. 4)
through a discharge system connected to the domestic sewer, which due to its basicity, counteracts flue gas condensate acidity.
In order to avoid domestic sewer odour to reach the premises, it is advisable to install an appropriate device between the discharge
system and the domestic sewer.
The condensate drain system and the domestic discharge system is to be made of adequate condensate resistant material.
Manufacturer shall not be held responsible for any damage to people, animals or objects, resulting as failure in observing the above
mentioned technical precaution.
23
Boiler
Boiler
Termination to an internal soil and
vent pipe
Sink
50 mm
per met
re of pip
e run
2,5° Min
imum fa
ll
External termination via internal discharge
branch
e.g. sink waste - downstream
50 mm p
er metre
of pipe ru
n
2,5° Min
imum fa
ll
Pipe must terminate
above water level but
below surrounding
surface
450 mm min
Termination to a drain or gully
Boiler
Pipe must terminate above
water level but below
surrounding surface
50 mm
per met
re of pip
e run
2,5° Min
imum fa
ll
Termination to a purpose made soakaway
Boiler
500 mm min
50 mm
per metr
e of pipe
run
2,5° Min
imum fa
ll
Holes in the soak-away
must face away from the
building
FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE
OPERATION OF THE BOILER
The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre)
along the entire run.
1. The condensate outlet will accept 21.5 mm (3/4 in) plastic overflow pipe which should generally discharge internally into the house
hold drainage system. If this is not possible, discharge into an outside drain is acceptable.
2. Ensure the discharge of condensate complies with any national or local regulations in force.
BS 6798:2000 & Part H1 of the Building Regulations give further guidance.
3. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP.
4. Metal pipework is NOT suitable for use in condensate discharge systems.
5. The pipe should be a minimum of 21.5 mm diameter and must be supported using suitably spaced clips to prevent sagging.
6. It is advisable to keep the condensate pipe internal.
7. External runs greater than 3 metres or runs in cold areas should use 32 mm waste pipe.
8. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run.
9. In all cases discharge pipe must be installed to aid disposal of the condensate. To reduce the risk of condensate being trapped, as
few bends and fittings as possible should be used.
10. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil
pipes or waste pipes are subjected to internal pressure fluctuations when WC’s are flushed or sinks emptied then back-pressure may
force water out of the boiler trap and cause appliance lockout.
Examples are shown of the following methods of termination:
i) to an internal soil & vent pipe
ii) via an internal discharge branch (e.g. sink waste)
iii) to a drain or gully
iv) to a purpose made soakaway
24
4.4.5.
Adjustable by-pass
The boiler is equipped by an adjustable by-pass. By-pass operation can be inhibited.
Pic. 15A shows an adjusting by-pass screw set for by-pass operation preclusion.
Pic. 15B shows an adjusting by-pass screw set for by-pass operation.
The boiler is supplied with by-pass set to closed by-pass.
Closed
By-pass
Open
By-pass
pic.15 A
pic.15 B
4.5.
Flue options
4.5.1.
Air intake / flue gas discharge system
As far as flue gas discharge into the atmosphere and air intake / flue gas discharge systems are concerned, comply with laws enforced
in the country of installation, which are considered as fully transcribed in this manual.
In accordance with BS 5440 Part 1 and BS 5440 Part 2 the boiler is equipped with safety devices checking correct flue gas exhaustion. Should an air/flue gas system malfunction occur, the safety devices shut down the boiler and flashing red light 4.
It is strictly forbidden to tamper with and/or prevent operation of such safety devices.
Should the boiler repeatedly shut down, it is necessary to have air/flue gas system ducts inspected, as they might be obstructed or inadequate to flue gas discharge into the atmosphere.
In air intake/flue gas discharge systems, specific, manufacturer approved, condensate acid-resistant systems for condensing boiler are to be used.
Flue gas discharge pipes are to be installed tilted toward the boiler so that condensate runs in the direction of the combustion chamber, which is designed for condensate collection and drainage.
Should the above procedure not be possible to be implemented, it is necessary to install, in condensate stagnation areas, devices designed for condensate collection and conveying to the condensate drain system.
It is necessary to avoid formation of condensate stagnation areas in the flue gas discharge system, with the exception of the condensate drain siphon eventually connected to the discharge system itself.
The manufacture shall not be held liable for damage resulting in incorrect installation, use, modification of the equipment or non-observance of instructions provided by the manufacturer or applicable installation standards involving the product.
pic. 16
LEGENDA
A Air intake - S Flue gas discharge -
Condensate -
Rain
25
Type
C12
Type
B22
4.5.2.
Configuration of air/flue system pipes
Types: B22, C12, C32, C42, C52, C82
Type
C32
B22
This boiler is intended for connection to an
existing flue system either inside or outside the boiler
room. Combustion air is drawn straight from the boiler
room itself and flue gas is conveyed to the outside. The
boiler must not be fitted with an anti-wind gust system;
it must be equipped with a fan mounted after the
combustion chamber.
C12
This boiler is intended for connection to horizontal flue
gas and air-intake pipes connected
to the outside by means of coaxial or split pipes. The
distance between the air intake pipe and the flue gas
pipe must be at least 250 mm and both terminals must
be positioned in a 500mm-side square area.
Type
C42
C32
This boiler is intended for connection to vertical flue gas
and air-intake pipes connected to the outside by means
of coaxial or split pipes. The distance between the air
intake pipe and the flue gas pipe must be at least 250
mm and both terminals must be positioned in a
500mm-side square area.
C42
This boiler is intended for connection to a common
chimney pipe system that includes two pipes, one for
the air intake and the other for flue gas discharge. These
pipes may be coaxial or split. The flue gas chimney
system must comply with current standards.
Type
C52
C52
Boiler with separate pipes for air intake and flue gas. Air
and flue gas may have different discharge pressures. Air
and flue gas terminals must not face each other from
opposite walls.
C82
This boiler is intended to be connected to a combustion
air-intake terminal and to a single flue gas
terminal or to a common chimney.
The flue gas chimney system must comply with current
standards.
26
Type
C82
In order to ensure that the appliance functions correctly and efficiently, the flue connection between the boiler and the flue terminal must be made using original components specifically designed for condensing boilers.
Traditional flue components cannot be used for conveying exhaust fumes from condensing boilers, nor vice versa.
It is recommended that:
-
for the exhaust discharge duct, the entire length of the flue slopes upwards towards the exterior in order to facilitate the flow of condensate back to the combustion chamber, which has been specifically designed to collect and drain the acidic condensate;
-
for the air intake, the entire length of the duct slopes upwards towards the boiler to prevent the entry of rainwater, dust or foreign bodies into the pipe;
in the case where a horizontal coaxial system is installed, the coaxial terminal must be positioned horizontally in that the exhaust duct
has been specifically designed with the required slope (Ø 60) and the air intake (Ø 100) has been suitably protected against the weather.
4.5.3. Ø 100/60 mm air/flue gas coaxial duct system
Type C12
The minimum permissible length of horizontal coaxial pipes is 0.5 metre, not including the first elbow connected to the boiler.
The maximum permissible length of horizontal coaxial pipes is 5 metres for HC-HR 24 and 4 metres for HC-HR 32, not including the first
elbow connected to the boiler. For each additional elbow, the maximum permissible length must be reduced by 1 metre.
In addition, the pipe must have a 1% slope to prevent rainwater entering it.
Choosing the applicable diaphragm supplied with the boiler (pic. 17)
HR 24 and HC 24
HC 32 and HC 32
Pipe length (m)
Air intake diaphragm
(mm)
Pipe length (m)
Air intake diaphragm
(mm)
0,5≤ L ≤ 2
80
0,5≤ L ≤ 2
87
2≤L≤5
82
2≤L≤4
-
* excluding the first elbow connected to the boiler
* excluding the first elbow connected to the boiler
0CONDASP01
,5 M TO
FROM 0
AIR INTAKE DIAPHRAGM
5M
NEOPRENE
GASKET
SEALING
CAP
NEOPRENE
GASKET
Supplied with the boiler
pic.17
Type C32
The minimum permissible length of vertical coaxial pipes is 0,5 metre, equal to the length of the chimney.
The maximum permissible length of vertical coaxial pipes is 5 metres for HC-HR 24 and 4 metres for HC-HR 32, including the terminal.
For each additional elbow, the maximum permissible length must be reduced by 1 metre.
Choosing the applicable diaphragm supplied with the boiler (pic. 17)
27
HR 24 and HC 24
HC 32 and HR 32
Pipe length (m)
Air intake diaphragm
(mm)
Pipe length (m)
Air intake diaphragm
(mm)
0.5≤ L ≤ 2
80
0,5≤ L ≤ 2
87
2≤L≤5
82
2≤L≤4
-
The boiler is equipped with a device for controlling the emissions of the products of combustion. If the flue gas and/or combustion air intake system fails, the device sets the equipment in the safety configuration (subsection 2.3.3).
750
107
Ø100
175
450
325
pic.18
These pictures are merely an indication. For installation of optional fittings please refer to the instruction enclosed to the same fittings.
4.5.4.
Ø 80 mm air/flue gas split duct system
The below data are referred to air intake/flue gas discharge system, implemented with original, rigid and smooth ducts, delivered by the manufacturer.
0KITSDOP01
Neoprene
gasket
Diaphragm
Neoprene
gasket
pic. 19
28
Installation types C12- C32- C42- C52- C82
HR-HC 24 and HR-HC 32
AIR INTAKE
STUB
PIPE
For installations with separate air intake and
flue gas discharge pipes the split base kit (code
0KITSDOP01) must be used. The kit consists of the
following components (pic. 20):
• no. 1 Ø 80 mm female stub pipe with flange for
connection to the flue gas discharge pipe (flue gas
deflector included);
• no. 1 Ø 80 mm female stub pipe with flange for
connection to the air intake pipe;
• no. 1 standard air deflector;
• no. 2 air intake diaphragm (43 and 52 mm);
• fixing screws and seals.
NEOPRENE
GASKET
FLUE GAS
DISCHARGE
STUB PIPE
DIAPHRAGM
NEOPRENE
GASKET
AIR
DEFLECTOR
pic.20
Air intake
The minimum length of the air intake pipe is 0.5 metre.
Each wide-radius 90° elbow (R=D) installed on the air intake pipe is equal to 1 m linear length.
Each narrow-radius 90° elbow (R<D) installed on the air intake pipe is equal to 1 m linear length.
The load loss of the air intake terminal is not to be taken into consideration.
A standard air deflector MUST be installed.
Flue gas system
Each wide-radius 90° elbow (R=D) installed on the flue pipe is equal to 1.5 m linear length.
Each narrow-radius 90° elbow (R<D) installed on the flue pipe is equal to 1 m linear length.
HC 24 and HR 24
Pipe length (m)
HC 32 and HR 32
∆p (Pa)
Air intake diaphragm
(mm)
Pipe length (m)
0.5 ≤ L ≤ 28,5
1 ≤ L ≤ 50
43
28,5 ≤ L ≤ 57
50 ≤ L ≤102
-
* excluding the first elbow connected to the boiler
∆p (Pa)
Air intake diaphragm
(mm)
0.5 ≤ L ≤ 14,5
1 ≤ L ≤ 25
52
14,5 ≤ L ≤ 29
25 ≤ L ≤51
-
* excluding the first elbow connected to the boiler
A flue pressure switch is fitted to the boiler. It controls the flue gas discharge flow rate. If the flue gas discharge and/or air intake system malfunctions, the device shuts down the boiler to prevent unsafe operation (see subsection 2.3.3).
The following are merely an indication. For installation of optional fittings please refer to the instruction enclosed to the same fittings.
175
140
225
80
750
80
Ø 80
225
450
pic.21
325
pic.22
29
Configuration of Ø 80 mm flue gas discharge
and air intake pipes
Example no. 1 (pic. 23)
Primary air intake and flue gas discharge through two opposing outside walls.
Example no. 2 (pic. 24)
Primary air intake through outside wall and flue gas discharge through
outside wall behind the boiler.
Example no. 3 (pic. 25)
Primary air intake through outside wall and flue gas discharge through
the same wall.
Example no. 4 (pic. 26)
Primary air intake through outside wall and flue gas discharge through
the same wall behind the boiler.
Example no. 5 (pic. 27)
Primary air intake through outside wall and flue gas discharge through
the roof.
These pictures are merely an indication.
pic.23
pic.24
pic.25
pic.26
pic.27
30
4.5.5.
Electrical supply connection
The boiler is supplied with a three-poled power cable, already connected to the electronic board and it is provided with an anti-rupture
firming clamp.
The boiler is to be connected to a 230V~50Hz electrical power supply.
When connecting the boiler to power mains, follow correct phase/neutral polarity sequence.
Installation standards BS7671 IEE WIRING REGS must be complied with and are which are considered herein integrally transcribed.
An easy accessible two-poled switch is to be installed externally to the boiler, in an easy to reach position. The switch minimum distance
between contacts is to be 3 mm.
The switch is to allow power supply interruption in order to safely perform maintenance and service procedures.
Power supply to the boiler is to be fitted with a differential magnetic-thermal automatic switch of appropriate shut-down capacity.
Electrical power supply is to be appropriately earthed.
The above mentioned safety measure is to be verified. When in doubt, ask a qualified technician to thoroughly check the power network.
DO NOT:
• touch the electrical connections with wet hands
• put any electrical cables under stress
• leave the electrical components exposed to weather conditions
Check and inspect the cable supplied with the boiler do not use if this cable is damaged. The boiler should be
connected in line with the requirements of the IEE electrical regulations and should only be connected by a competent person.
The manufacturer shall not be held responsible for any damage due to failure in grounding the system: gas, hydraulic, or CH system pipes are not suitable for grounding power networks.
4.5.6.
Room thermostat connection (optional equipment)
The boiler can be connected to a room thermostat (not supplied with the boiler).
Room thermostat contacts must be properly sized for 5 mA at 24 V D.C.
The room thermostat must be connected to the terminal block shown in pic. 39, after removal of the jumper which is delivered as standard fitting to the boiler.
Room thermostat wiring must not be grouped together with power mains supply cables.
4.5.7.
External temperature probe installation (optional equipment) and “sliding temperature” operation
The boiler can be connected to an external temperature probe (optional equipment), which adjusts CH flow temperature for temperature
compensation operation (pic. 28).
The manufacturer supplies 0SONDAES01: external probe for direct connection to the boiler.
pic.28
31
Only original external temperature probes supplied by the manufacturer must be used.
If non-original external temperature probes are used, correct operation of the boiler cannot be guaranteed.
External temperature probe connection is to be performed by means of a double insulated wire, its minimum cross-section is to be 0.35
sq.mm.
External temperature probe is to be connected to M8 position of the boiler printed circuit board (pic. 29).
External temperature probe wiring is NOT to be grouped together with power mains supply cables.
pic.29
External temperature probe is to be installed on an outside wall facing north/north-east, in a position protected from atmospheric agents.
Do not install in window area, next to ventilation openings, or heat sources.
The external temperature probe automatically modifies CH flow temperature in relation to:
- sensed outdoor temperature;
- selected thermoregulation curve;
- selected virtual room temperature.
The thermoregulation curve is selected via trimmer
.
It is important for trimmer
to be set to a value of 1-3 (pics. 30).
The virtual room temperature is set via adjuster 11 (pic. 1), which, when the external temperature probe is installed, loses its capability to
set CH flow temperature (see subsection 2.2.6.).
1 2
0 3
pic.30
32
CH flow temperature (°C)
2
80
1,5
1,25
1
60
40
20
20
pic.31
4.5.8.
2,5
16
12
8
-4
0
4
-8
External temperature (°C)
-12
Thermoregulation curves
coefficient
3
100
-16
Installation of the OpenTherm remote control (optional equipment only for HR model)
The boiler can be connected to an OpenTherm remote control, an optional only for HR model supplied by the manufacturer.
The remote control must be installed by a suitably qualified person.
Only original remote controls supplied by the manufacturer must be used.
If non-original remote controls are used, correct operation of the boiler cannot be guaranteed.
For installation instructions, refer to the booklet accompanying the remote control.
Precautions to take when installing the remote control:
• The remote control cables must NOT be routed together with power cables: otherwise the disturbance would cause the remote
control to malfunction.
• Position the remote control on a wall inside the building, about 1,5 metres from the floor, in a suitable position for measuring the environmental temperature.
• Do not install in alcoves, behind doors or curtains, near sources of heat, or exposed to sunlight, draughts or spray.
4.5.9.
Loading the system
Once all boiler connections have been completed, CH system can be filled.
This procedure is to be cautiously carried out, following each below indicated step:
- Open the air purging valves on all radiators and verify the boiler automatic valve operation.
- Gradually open the filling loop to fill the system up, checking that all automatic air purging valves installed in the system properly work.
- Close all radiator air purging valves as soon as water starts coming out.
- Check boiler water pressure gauge for pressure to reach 1-1.3 bars reading.
- Shut the filling loop and bleed any air out again by opening all air purging valves on radiators.
- Start the boiler and, as soon as the system reaches working temperature, stop the boiler and pump and repeat the air purging
procedures.
- Allow the system to cool and restore water pressure to 1-1.3 bars.
WARNING
As far as domestic heating systems treatment of water is concerned, in order to optimize performance and safety, to preserve
these conditions over time, to ensure long-lasting regular operation of auxiliary equipment as well, and to minimize energy
consumption, thereby integrating current local laws and standards it is advisable to use specific products that are suitable for
multi-metal plants.
WARNING
The safety fluid flow meter will not allow the burner to be started when CH water flow is too low. CH system water pressure is
not to be below 1 bar; restore proper value as needed via the filling loop. The procedure is to be carried out while water in the
system is cold.
Boiler pressure gauge displays water pressure in the CH system.
WARNING
After long boiler inactivity, its pump may be stuck. Before operating the boiler, follow the below indicated pump clearing
procedure:
- unscrew the protective bolt, located in the center front section of pump motor;
- put a screwdriver into the opening and manually rotate the circulation unit shaft clockwise;
- once the pump is reliased, screw back on the protection bolt and check for water leaks.
When the pump protective bolt is removed, some water may flow out. Before re-installing the boiler external housing, verify all
internal surfaces to be dry.
33
4.6. Burner adjustment
A) Max power adjustment
• Check the gas supply pressure (refer to tables 3 and 4)
• Remove the plastic cap (С, pic. 32), which is positioned on top on the modulating coil and protects the gas valve pressure adjusting nut and screw.
• Connect a manometer to V test point in pic. 33.
• Adjust the screw (maxR, pic. 34) to MAX by rotating fully clockwise.
• Select WINTER boiler operation on switch 9 (pic. 1).
• Start the boiler in “chimney sweep” mode (subsection 6.5.1.).
• Turn (external) nut К clockwise to increase nozzle pressure or vice versa (pic. 35).
• In LPG-fuelled boilers, turn the brass nut К fully clockwise.
B) Min power adjustment
• Disconnect the electrical wiring from the modulation coil (М, pic. 33).
• Turn the burner on and check MIN pressure according to tables 3 and 4.
• To adjust the pressure, hold nut К still using a 100 mm tool, and turn screw W clockwise to increase or counter-clockwise to decrease the gas pressure (pic. 35).
• Re-connect the electrical wiring to the modulation coil.
C) Final settings
• Turn the Pacc screw (pic. 34) to the middle set point, exit “chimney sweep” mode (subsection 6.5.1.)
and make sure the burner works correctly and silently. If necessary, increase or decrease ignition
power via the Pacc adjuster (clockwise to increase, counter-clockwise to decrease).
• Re-check the min and max gas valve pressure values.
• Adjust as necessary.
• Fit on plastic protective cap C.
• Close gas pressure check valves.
• Check for gas leaks.
C
pic. 32 - Gas valve modulation coil
V
M
pic. 33 - Pressure test point
Pacc
maxR
pic. 34 - Control panel setting
W
K
pic. 35 - Gas valve adjustment
34
5.
Commissioning
5.1. Commissioning the boiler
It is recommended to carry out the following:
- reference should be made to BS 5449 Section 5 when commissioning the boiler;
- open the mains water supply to the boiler;
- open all hot water taps to purge the DHW system;
- ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler;
- the system must be flushed in accordance with BS 7593 and the flushing agent manufacturers instructions;
- pressurise the system to 1.5 bar then close and disconnect the filling loop;
- turn the gas supply on and purge according to BS 6891 “Domestic Gas Installations”;
- test for gas soundness;
- turning either of the temperature control knobs will set the relevant temperature. When the knob is turned the display will alter and show the selected temperature. After a few seconds the display reverts to show the current boiler temperature.
At the time of commissioning, complete all relevant sections of the Benchmark Checklist located on the inside back pages of
this document.
5.2.
Setting the timer
The Electro-Mechanical Timer allows the central heating system to be set every 20 minutes. Using the three position switch the timer will
allow either constant operation, timed operation or central heating off. Move the switch button by sliding to the desired position.
There are three position switch:
Constant (Top position): The heating will be on constantly irrespective of the position of the tappets. The heating will be controlled by
the main thermostat on the appliance and/or any external controls.
Timed (Central position): The heating will operate according to the position of the tappets and be controlled as above.
Off (Bottom position): No central heating. Domestic hot water will operate on demand.
To set the time of day
Turn the timer outer bezel clockwise, to align the pointer with the correct time to the nearest 20 minutes. Do not at any time attempt to
turn the bezel anti-clockwise.
To set the timed heating program
Decide which times of the day the central heating is required. The heating will operate when the green tappets are set to the outer edge
of the bezel. To ensure the heating stays OFF set the required tappets inwards towards the centre of the bezel. Each tappet represents
20 minutes.
5.3.
Checking
Before testing the boiler, it is recommended to carry out the following checks:
- compliance of flue gas discharge ducts and terminal installation according to instructions: when the boiler is operating no
products generated by combustion are to leak from any gasket;
- power mains supply to boiler is 230 V ~ 50 Hz;
- the system is correctly filled (water pressure gauge is to display 1 - 1.3 bar);
- all stopcocks in the system piping are to be open;
- gas type is to be in accordance to boiler specifications: convert the boiler to the available gas type; the procedure is to be performed by technically qualified personnel;
- gas supply stopcock is to be open;
- no gas leaks are to be detected;
- electric power switch, external to the boiler is to be on;
- boiler 3 bar safety valve is not to be blocked and correctly terminated;
- the condensate trap must drain correctly and is correctly terminated;
- water leaks are not to be detected;
- pump is not to be stuck;
- a gas rate measurement may now be made. (see tables 3, 4, 5)
Should the boiler not be installed in compliance with current laws and standards, inform the installer and do not test the boiler.
WARNING
The boiler is equipped with a pump with three speeds, corresponding to the residual head to the system (refer to subsection
3.4.)
The boiler is delivered with the pump set to third speed.
When changing speed to the pump, in accordance with the flow rate required by the boiler (ensured by the primary flow switch)
and the system characteristics, verify that all the conditions relative to the system itself (such as closing of one or more zones in
the CH system or closing of thermostatic valves) are respected.
5.4.
Switching on and switching off
For boiler switching on and switching off procedure follow § 1. Instructions for the User.
35
6.
SERVICING
6.1.
General Warnings
Before carrying out any type of maintenance operation, disconnect the appliance from the mains electricity supply and close the gas valve.
In order to guarantee the long life of the appliance and in accordance with the current gas safety regulations, only use original spare parts.
The frequency of the boiler maintenance must comply with current law and, nevertheless, should be carried out once a year.
6.2.
Boiler inspection
Maintenance and repair procedures are strictly to be carried out by professionally qualified personnel.
The manufacturer recommends Customers to contact the Fondital Helpline UK for all maintenance and repairs, which are best
trained for the purpose.
Appropriate boiler maintenance ensures efficient operation, preservation of the environment, and safety for people, animals and
objects.
Maintenance operations must be carried out at least once a year.
6.3.
Before carrying out any maintenance involving replacement of components and/or cleaning inside parts of the boiler, switch off the power supply to the boiler.
Servicing schedule
The routine maintenance schedule must include the following checks:
- General integrity of the boiler.
- Boiler and gas supply pipework for tightness.
- Gas supply pressure to boiler.
- Boiler ignition.
- Minimum and maximum gas pressures to boiler nozzles.
- Flue gas system integrity, good state of preservation, and absence of leaks.
- Flue system integrity, good state of preservation, and leak test.
- Air pressure switch operation.
- Efficiency of boiler safety devices in general.
- Absence of water leaks and oxidized areas on boiler couplings.
- Efficiency of the system’s safety valve.
- Expansion vessel loading pressure (1±0,2 bar).
- Safety flow switch efficiency preventing low water pressure operation.
- Condensate discharge through the trap.
Cleaning operations:
- General boiler internal areas.
- Gas nozzle.
- Air intake and flue gas exhaust system.
- Flue side of the heat exchanger.
- Siphon and condensate discharge pipes.
When operating the boiler for the first time, also check:
- Boiler room suitability.
- Duct diameter and length in the flue gas system.
- Boiler installation in accordance to this “Installation use and maintenance” manual instructions.
Should the boiler not correctly operate, while not creating any danger to people, animals or property, inform the Fondital helpline UK both verbally and in writing.
After servicing, complete the relevant Service Interval Record section of the Benchmark Checklist located on the inside back
pages of this document.
6.4.
Analysis of combustion parameters
The boiler combustion parameters must be checked in accordance with legal requirements to determine the efficiency and the emission
of pollutants.
36
6.5.
Testing combustion efficiency
6.5.1.
“Chimney sweep” function
The boiler has a “chimney sweep” function, used to test its efficiency and adjust burner performance.
The boiler comes with the chimney-sweep function, which must be used to measure combustion efficiency and regulate the burner.
To activate the chimney-sweep function, you need to open the front panel to access the controls. To do this, follow the sequence below:
• unscrew two of the four screws securing the panel (right or left, pic. 36) and open it, but without removing it from the boiler;
• remove the control panel template by widening the right and left hooks and pulling it outwards (pic. 36).
The control panel is like shown in pic. 37.
pic.36
Turn knob 9 (pic. 1) to WINTER and the room thermostat (if there is one) to ON.
While the boiler is operating, press the button
for a few seconds (pic. 37). The boiler will turn off and then resume the ignition sequence, starting again at the max power. Maximum boiler power output
max is as much as set point
max (pic. 37).
The “Chimney sweep” function remains active for 15 minutes. To deactivate this function, turn selector 9 to any position other than
WINTER.
P6
pic.37
6.5.2
Measurements
Coaxial pipe system
Proceed as follow to verify combustion performance.
- Measure air intake through hole 2 (A, picture 38)
- Measure flue gas and CO2 temperature through hole 1 (A, picture 38)
Allow the boiler to react working temperature before taking the readings.
Split pipe system
Proceed as follow to verify combustion performance.
- Measure air intake through hole 1 (B, picture 38)
- Measure flue gas and CO2 temperature through hole 2 (B, picture 38)
Allow the boiler to react working temperature before taking the readings.
SPA
maxR
A
1
2
FLUE GAS
AIR
B
2
1
pic.38
37
DK
C
bk
NC
P
bk
12 3 4
NO
bk
P1
R1
bl
SR
12 3 4 5 67 8
1
r
w
2
3 4
R
12 3 4 5 67 8
r
only HR
r
bk
r
bl
SS
only HC
bl
only HC
bl
P
NO
DK
NC
C
12 3 4
only HC
gn
38
gn
pic.39
F
bk
FL
bk
6.6.
Wiring diagram
r
bk
Chart to pic. 30 acronyms
F1BIT: Bi-thermal heat exchanger boiler
F2PIA: Mono-thermal heat exchanger boiler
F3RIS: CH only boiler
F4BOL: System boiler
F5MIC: Micro-reservoir boiler
F6MAC: “ACQUA PREMIUM” boiler (encased installation)
M3-M8-M9: Power Supply connector,
outdoor probe, TA
M16: Connector for tele-metering
M2-M15: Service connector
E.RIV: Detection electrode
E.ACC: Ignition electrode
P: Pump
V: Fan
MVD: Three-way valve motor
DK: Water pressure switch
SR: CH probe 10K Ohm B=3435
SE: Outdoor temperature probe 0SONDAES01
10K Ohm B=3977 (optional)
SS: DHW probe 10K Ohm B=3435
TA: Room thermostat (optional)
CM1 - CM2: Boiler type selection jumper
FL: DHW flow switch
VG: Gas valve
TL: Limit thermostat
PV: Fan pressure switch
TIMER: Electromechanical day timer
TF: Flue gas leak detection thermostat
P1: CH flow temperature potentiometer
P2: DHW temperature potentiometer
P3: Boiler selection
P4: Maximum CH output adjusting potentiometer
P5: Ignition power adjusting potentiometer
P6: Thermoregulation curve adjuster
K1: “Chimney sweep” function key
Relation between temperature (°C) and nominal resistance (Ohm) of CH probe SR and DHW probe SS
T (°C)
0
2
4
6
8
0
27203
24979
22959
21122
19451
10
17928
16539
15271
14113
13054
20
12084
11196
10382
9634
8948
30
8317
7736
7202
6709
6254
40
5835
5448
5090
4758
4452
50
4168
3904
3660
3433
3222
60
3026
2844
2674
2516
2369
70
2232
2104
1984
1872
1767
80
1670
1578
1492
1412
1336
90
1266
1199
1137
1079
1023
Table 8 - Correlation “temperature - nominal resistance” of temperature probes
6.7
Hydraulic loss
Head available mbar
V3
V2
V1
Flow rate l/h
V1 Speed I (min)
V2 Speed II
V3 Speed III (max)
39
7
Spare part list
11
HC model
12
10
13
20
18
16
21
22
19
14
17
32
15
35
23
31
33
30
32
29
26
24
34
36
25
27
28
2
1
37
3
4
5
6
7
38
8
9
41
40
39
44
42
pic. 40
40
43
HR model
11
12
10
13
20
18
21
14
15
19
17
35
23
33
32
34
36
24
27
28
25
37
2
38
1
41
40
3
4
5
6
7
39
42
45
8
pic. 41
9
41
Item
Code
1
6ISOLRIC00
2
3
4
5
No. of pieces per pack
Complet panel insulation
1
6PANLACM00
Wall-hung boiler side panel
1
6PRESSOS04
Air pressure switch (24 Kw)
1
6PRESSOS05
Air pressure switch (32 Kw)
1
6CANDELA00
Igniter plug
3
6BRUMMET03
Methane 12-ramp gas burner 24
1
6BRUMGPL03
LPG 12-ramp gas burner 24
1
6BRUMMET11
Methane 15-ramp gas burner 32
1
6BRUMGPL11
LPG 15-ramp gas burner 32
1
0TRASMET04
Methane conversion kit dual HC-HR 24 line
12
0TRASGPL03
LPG conversion kit dual HC-HR 24 line
12
0TRASMET12
Methane conversion kit dual HC-HR 32 line
15
0TRASGPL11
LPG conversion kit dual HC-HR 32 line
15
Complet panel insulation
1
6PANLACM00
Wall-hung boiler side panel
1
8
6YTRAACC00
Ignition transformer
1
9
6PANFRCM06
Dual Line front panel
1
10
6CAMCORC00
Combustion chamber for wall-hung boilers
1
6VENTILA15
Fan (24 Kw)
1
6VENTILA16
Fan (32 Kw)
1
12
6CAPFURC01
Fume hood
1
13
6SETISRC00
Fume hood insulation
1
6
6ISOLRIC00
7
11
14
6SIFRACO02
Condensate trap
1
15
6FASCMOL00
Spring retainer diameter 24
1
16
6CORPVAL04
Condensing three-way valve unit
1
17
6YBOBINA00
Gas valve coil
1
18
6YTERSIC00
Safety thermostat 95 °C
3
19
6SCAMMON08
Heat exchanger HC
1
20
6TERMSIC05
Safety thermostat 105 °C
3
21
6RECUFUM00
Flue gas recoverer
1
6SCAMPIA01
Plate heat exchanger (24 Kw)
1
22
42
Description
6SCAMPIA05
Plate heat exchanger (32 Kw)
1
23
6CIRCOLA07
Circulating pump
1
24
6RUBISCA01
Boiler drain cock unit
1
25
6GRIDIR00
Hydraulic unit for heating return circuit
1
26
6GRURIRC00
Heat exchanger connector unit
1
27
6VALSIBA11
3 bar safety valve
1
28
6PRESSAC00
Water pressure switch
1
29
6FLUSSOS00
Flow meter switch
1
30
6REGOFLU00
Flow regulator
1
31
6PROATTT00
Actuator programmer
1
32
6SONDNTC01
NTC immersion probe 10 Kohm
3
33
6VALVGAS11
Gas valve
1
34
6TUBFLEX02
Hose
1
35
6MOLSUVC00
Expansion vessel supporting spring
2
36
6VASOESP10
8-litre expansion vessel
1
37
6SCHEMOD14
Modulating board
1
Box for control panel housing
1
Pressure gauge
1
38
6SCAELPA02
39
6MANOMET08
Item
Code
40
6ORINNMA00
Description
No. of pieces per pack
Pressure gauge o-ring seal
10
41
6GUIPPCM04
Boiler control panel light guide
1
42
6MANOPOL04
Knob
3
43
6TIMERGB00
Timer
1
44
6CORTIME00
Timer Fixing Frame
1
45
6TAPTIME00
Timer plug
1
Table 9 - Spare part list
43
8. Troubleshooting
BOILER STATUS
MALFUNCTION
Burner does not ignite.
Burner does not ignite: no spark.
The boiler has shut down, and red
light 5 is flashing.
Turn selector 9 to RESET position to
resume boiler operation.
Burner ignites for a few seconds
and goes off.
Condensate is not discharged.
Flue pressure switch not
operating
The boiler has shut down and red
light 4 is flashing.
Turn selector 9 to RESET position to
resume boiler operation.
Boiler safety thermostat has shut
boiler down
The boiler has shut down and red
light 3 is flashing.
Turn selector 9 to RESET position to
resume boiler operation.
Boiler safety thermostat has shut
boiler down
Insufficient water pressure
The boiler has shut down and red
light 6 is flashing.
Reset boiler by restoring correct
water pressure.
44
PROBABLE CAUSE
SOLUTION
Gas supply failure.
Check gas pressure.
Check mains gas safety valve.
Gas valve has disconnected
Reconnect gas valve
Gas valve is faulty.
Replace it.
PCB is faulty
Replace it.
Spark electrode is faulty.
Replace it.
Ignition transformer is faulty.
Replace ignition transformer
PCB is faulty.
Replace PCB
Burner ignites for a few seconds and
goes off.
Verify correct neutral and phase
connections.
Flame detection electrode wire is
disconnected or faulty.
Connect flame detection electrode
wire or replace it
Detection electrode is faulty.
Replace electrode
PCB does not detect flame
Replace PCB
P ACC ignition value setpoint is too
low.
Adjust P ACC ignition value set point
Min. heat input is not set correctly.
Check burner adjustment
Condensate drain is clogged.
Check the condensate drain
The trap is full.
Check the condensate trap and
boiler drain
Flue pressure switch is faulty
Check flue pressure switch and
replace if necessary
Silicon pipes are disconnected or
faulty
Reconnect or replace silicone pipes
Insufficient air intake or flue gas
discharge
Check air/flue gas pipes: unclog or
replace as required
Fan is faulty
Replace it.
PCB is faulty
Replace it.
Insufficient air intake or flue gas
discharge
Check air/flue gas pipes: unclog or
replace as required
CH water does not flow: pipes might
be clogged, thermostatic valves
Check CH system.
might be shut, system stopcocks
might be closed.
Pump is stuck or faulty.
Check the pump.
Possible water leaks.
Check system for leaks.
Pressure switch is disconnected
Reconnect it.
Water pressure switch is faulty.
Replace it.
BOILER STATUS
MALFUNCTION
PROBABLE CAUSE
SOLUTION
CH probe is disconnected
Reconnect it.
CH probe is faulty.
Replace it.
DHW probe disconnected.
Reconnect it.
DHW probe faulty.
Replace it.
CH probe is not operational.
The boiler has shut down, red light 2
and yellow light 8 are flashing.
Boiler will automatically resume
operation when the problem has
been solved.
DHW probe is not operational.
Model HC.
The boiler has shut down and red
light 2 is flashing.
Boiler will automatically resume
operation when the problem has
been solved.
Boiler is not providing DHW
DHW flow meter is not operational.
Model HC
Insufficient system pressure or
capacity
Check DHW system.
Check DHW flow meter filter.
Flow meter sensors is disconnected
Replace or reconnect it.
or faulty.
Flow meter is stuck.
Replace it.
45
GAS Boiler SyStem CommiSSioNiNG CHeCKliSt
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
Customer Name
Telephone Number
Address
Boiler Make and Model
Boiler Serial Number
Commissioned by (print name)
CORGI ID Number
Company Name
Telephone Number
Company Address
Commissioning Date
To be completed by the customer on receipt of a Building Regulations Compliance Certificate*:
Building Regulations Notification Number (if applicable)
CONTROLS Tick the appropriate boxes
Time and Temperature Control to Heating
Room Thermostat and
Programmer/Timer
Programmable
Room Thermostat
Time and Temperature Control to Hot Water
Load/Weather
Compensation
Optimum Start
Control
Cylinder Thermostat and Programmer/Timer
Combination Boiler
Heating Zone Valves
Fitted
Not Required
Hot Water Zone Valves
Fitted
Not Required
Thermostatic Radiator Valves
Fitted
Not Required
Automatic Bypass to System
Fitted
Not Required
Boiler Interlock
Provided
ALL SYSTEMS
The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions
Yes
What system cleaner was used?
What inhibitor was used?
litres
Quantity
CENTRAL HEATING MODE Measure and Record:
Gas Rate
m3/hr
OR
Burner Operating Pressure (if applicable)
mbar
OR
ft3/hr
Gas Inlet Pressure
mbar
Central Heating Flow Temperature
°C
Central Heating Return Temperature
°C
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)?
Yes
No
If yes, has a water scale reducer been fitted?
Yes
No
What type of scale reducer has been fitted?
DOMESTIC HOT WATER MODE Measure and Record:
Gas Rate
m3/hr
OR
Burner Operating Pressure (at maximum rate)
mbar
OR
ft3/hr
Gas Inlet Pressure (at maximum rate)
mbar
°C
Cold Water Inlet Temperature
Hot water has been checked at all outlets
Yes
°C
Temperature
l/min
Water Flow Rate
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798
Yes
ALL INSTALLATIONS
If required by the manufacturer, record the following
CO2
%
OR
CO
ppm
The heating and hot water system complies with the appropriate Building Regulations
OR CO/CO2 Ratio
Yes
The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions
Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer
Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer
Yes
Commissioning Engineer’s Signature
Customer’s Signature
(To confirm satisfactory demonstration and receipt of manufacturer’s literature)
*All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.
A Building Regulations Compliance Certificate will then be issued to the customer.
46
©Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed.
Service Provider
Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s
instructions.
Always use the manufacturer’s specified spare part when replacing controls.
SERVICE 1
SERVICE 2
Date
Energy Efficiency Checklist completed?
Yes
No
Date
Energy Efficiency Checklist completed?
Engineer Name
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
SERVICE 3
SERVICE 4
Date
Energy Efficiency Checklist completed?
Yes
No
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
SERVICE 6
Date
Energy Efficiency Checklist completed?
Yes
No
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
SERVICE 8
Date
Energy Efficiency Checklist completed?
Yes
No
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
Yes
No
Yes
No
Yes
No
SERVICE 10 Date
Date
Energy Efficiency Checklist completed?
No
Date
Energy Efficiency Checklist completed?
Engineer Name
SERVICE 9
Yes
Date
Engineer Name
SERVICE 7
No
Date
Engineer Name
SERVICE 5
Yes
Yes
No
Energy Efficiency Checklist completed?
Engineer Name
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
47
48
49
50
51
Fondital S.p.A.
25078 VESTONE (Brescia) Italia - Via Mocenigo, 123
Tel. 0365/878.31 - Fax 0365/596.257
e mail: fondital@fondital.it - www.fondital.it
Fondital UK (Service Centre)
P.O. Box 159 - Fareham
Hants - PO17 6WX
e mail: admin@fondital.co.uk
The manufacturer reserves the right to implement any necessary and/or useful
variation to products, without modifying fundamental characteristics.
Uff. Pubblicità Fondital IST 03 C xxx - 01 Gennaio 2008 (01/2008)
Fondital UK Helpline 08700 34 88 20