Fondital TAHITI CONDENSING KR32 Installation, Use And Maintenance Manual
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IST 03 C 234 - 01
TAHITI
CONDENSING
GB
INSTALLATION
USE AND MAINTENANCE
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.
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General information for fitters, maintenance technicians and users
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 boiler must be used for the purposes for which it has been intended.
Any other use shall be considered incorrect and therefore dangerous.
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. Incorrect installation may cause injury to persons and/or animals and damage to property. The manufacturer shall not be held liable for any such injury and/or damage.
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.
Do not obstruct the air suction openings.
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.
Keep the packaging out of the reach of children as it may represent a source hazard.
In the event of failure and/or faulty functioning, switch off the boiler. Do not attempt to make repairs: contact qualified technicians.
Manufacturer approved and supplied parts must be used for all repairs to the boiler.
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.
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-frost function will not be operative.
Should there be a risk of freezing, add anti-frost: it is not advisable to empty the system as this may result in damage; use specific antifrost products suitable for multi-metal heating systems.
IMPORTANT
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.
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CONTENTS
Warnings
General information for the installer, maintenance technician and user
1. Instructions for the User
1.1. Control panel
1.2. Operating the boiler
1.2.1. Switching on
1.2.2. Operation
1.2.3. External temperature probe operation (optional equipment)
1.3. Boiler shutdown
1.3.1. Burner shut-down
1.3.2. Shut-down due to overheating
1.3.3. Shut-down due to incorrect fluid circulation
1.3.4. Shut-down due to inadequate air/flue gas draught (flue gas shutdown)
1.3.5. Shut-down due to fan malfunction
1.3.6. Flow alarm
1.3.7. Alarm due to failure of temperature probes
1.3.8. Alarm due to remote control malfunction
1.4. Maintenance
1.5. Notes for the user
2. Technical characteristics and dimensions
2.1. Technical characteristics
2.2. Dimensions
2.3. Hydraulic layouts
2.4. Operating data
2.5. General characteristics
3. Instructions for the fitter
3.1. Installation standards
3.2. Installation
3.2.1. Packaging
3.2.2. Choosing where to install the boiler
3.2.3. Positioning the boiler
3.2.4. Installing the boiler
3.2.5. Boiler room ventilation
3.2.6. Air/flue gas system
3.2.6.1. Air/flue gas system duct configuration
3.2.6.2. 100/60 mm and 125/80 mm air/flue gas coaxial duct system
3.2.6.3. 80 mm air/flue gas split duct system
3.2.7. Testing combustion efficiency
3.2.7.1. “Chimney sweep” function
3.2.7.2. Measurements
3.2.8. Gas main connection
3.2.9. Hydraulic connections
3.2.10. Power main connection
3.2.11. Selecting central heating output range
3.2.12. Room thermostat connection (optional equipment)
3.2.13. Open Therm remote control installation and operation procedure (optional equipment)
3.2.14. External temperature probe installation (optional equipment) and “sliding temperature” operation
3.2.15. Phone operation device installation (optional equipment)
3.3. Loading the system
3.4. Starting the boiler
3.4.1. Preliminary checks
3.4.2. Switching on and switching off
3.5. Electric diagram
3.6. Adaptation to other gases and burner adjustment
4. Testing the boiler
4.1. Preliminary checks
4.2. Switching on and switching off
5. Maintenance
6. Troubleshooting page 25 page 26 page 26 page 27 page 27 page 28 page 28 page 29 page 30 page 30 page 31 page 31 page 31 page 32 page 33 page 35 page 35 page 35 page 35 page 17 page 19 page 19 page 19 page 19 page 19 page 20 page 20 page 21 page 21 page 22 page 23 page 24 page 24 page 24 page 2 page 3 page 6 page 6 page 8 page 8 page 8 page 9 page 10 page 10 page 10 page 10 page 11 page 11 page 11 page 11 page 11 page 11 page 11 page 12 page 12 page 14 page 15 page 16 page 36
PICTURE INDEX pic. 1 - Control panel pic. 2 - Loading tap pic. 3 - Dimensions pic. 4 - KC model hydraulic layout pic. 5 - KR model hydraulic layout pic. 6 - Installation template pic. 7 - Installation of the seal with filter pic. 8 - Installation examples of air intake /flue gas discharge pipes pic. 9 - Air intake and flue gas discharge coaxial pipe system pic. 10 - Dimensions for connection to air intake and flue gas discharge coaxial pipe system pic. 11 - Air intake and flue gas discharge split pipe system pic. 12 - Dimensions for connection to air intake and flue gas discharge split pipe system pic. 13 - “Chimney sweep” function pic. 14 - Air intake and flue gas discharge tower pic. 15 - Openings for combustion efficiency measurement pic. 16 - Gas mains connection pic. 17 - Open Therm remote control installation pic. 18 - Correlation between P6 trimmer position and thermoregulation curves pic. 19 - Central heating curves in external probe operation pic. 20 - System head curves pic. 21 - Electric layout pic. 22 - Adaptation to other gas types pic. 23 - Gas valve adjustment
CHART INDEX
No. 1 chart - Correlation between LED SIGNALLING – BOILER STATUS when boiler is in operation
No. 2 chart - Correlation between LED SIGNALLING – BOILER STATUS when boiler is malfunctioning
No. 3 chart - KC 24 model adjustment rates
No. 4 chart - KC 32 model adjustment rates
No. 5 chart - KR 24 model adjustment rates
No. 6 chart - KR 32 model adjustment rates
No. 7 chart - KC model general specifications
No. 8 chart - KC 24 model combustion rates
No. 9 chart - KC 32 model combustion rates
No. 10 chart - KR model general specifications
No. 11 chart - KR 24 model combustion rates
No. 12 chart - KR 32 model combustion rates
No. 13 chart - Burner re-ignition temperatures
No. 14 chart - Limits to be set for TSP parameters and default values in relation to boiler type (TSP0)
No. 15 chart - TSP chart of parameters which can be displayed (they cannot be adjusted via remote control)
No. 16 chart - Correlation “temperature – nominal resistance” of temperature probes
No. 17 chart - CO
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rates page 17 page 18 page 18 page 18 page 27 page 28 page 28 page 33 page 34 page 7 page 7 page 16 page 16 page 16 page 16 page 17 page 17
5 page 6 page 10 page 14 page 15 page 15 page 20 page 21 page 21 page 23 page 23 page 24 page 24 page 25 page 25 page 25 page 26 page 28 page 29 page 29 page 31 page 32 page 34 page 34
1. Instructions for the user
1.1. Control panel pic. 1 - Control panel
1. Power LED (green)
The LED indicates that electric power is being supplied to the boiler.
2. Signal LED (red)
When the LED is on and fixed, it signals central water temperature is in the range between 26°C and 35°C.
When the LED is on and blinking, it signals an operation malfunction (see no. 2 chart on page 7).
3. Signal LED (red)
When the LED is on and fixed, it signals central water temperature is in the range between 36°C and 45°C.
When the LED is on and blinking, it signals an operation malfunction (see no. 2 chart on page 7).
4. Signal LED (red)
When the LED is on and fixed, it signals central water temperature is in the range between 46°C and 55°C.
When the LED is on and blinking, it signals an operation malfunction (see no. 2 chart on page 7).
5. Signal LED (red)
When the LED is on and fixed, it signals central water temperature is in the range between 56°C and 65°C.
When the LED is on and blinking, it signals an operation malfunction (see no. 2 chart on page 7).
6. Signal LED (red)
When the LED is on and fixed, it signals central water temperature is in the range between 66°C and 75°C.
When the LED is on and blinking, it signals an operation malfunction (see no. 2 chart on page 7).
7. Signal LED (red)
When the LED is on and fixed, it signals central water temperature is in the range between 76°C and 85°C.
When the LED is on and blinking, it signals an operation malfunction (see no. 2 chart on page 7).
8. Signal LED (yellow)
When the LED is on and fixed, it signals flame presence on burner.
When the LED is on and blinking, it signals an operation malfunction (see no. 2 chart on page 7).
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9. Boiler operation mode selector
When the selector is set to OFF, the boiler is in stand-by.
When the selector is positioned to WINTER , the boiler is ready to operate both in central heating and domestic hot water supply modes (in KR models, domestic hot water supply mode is activated only when the boiler is connected to an external cylinder).
When the selector is positioned to SUMMER , the boiler is ready to operate in domestic hot water supply mode (in KR models, domestic hot water supply mode is activated only when the boiler is connected to an external cylinder).
When the selector is positioned to ANTI-FROST only the antifrost function is active.
When the selector is positioned to RESET , the boiler is re-activated after a shutdown.
10. Domestic hot water temperature adjusting knob
The knob is adjusts domestic hot water temperature between a minimum of 35°C and a maximum of 57°C.
WARNING
In KC model, a special adjusting device is installed, which limits domestic hot water flow rate to 13 liter per minute (KC
24), and to 16 liter per minute (KC 32). Domestic hot water temperature supplied, depends on no. 10 adjusting device, on the quantity requested by the user and on water mains supply temperature.
11. CH temperature adjustment
The knob is adjusts central heating water temperature between a minimum of 20°C and a maximum of 78°C.
12. Water pressure gauge
Water pressure gauge indicates water pressure in the heating system.
CORRELATION BETWEEN LED SIGNALLING – BOILER STATUS
Normal boiler operation LED 1 LED 2 LED 3 LED 4 LED 5
Boiler powered on
Flame presence
CH water temp. ≤ 25°C
26°C < CH water temp. ≤ 35°C
36°C < CH water temp. ≤ 45°C
46°C < CH water temp. ≤ 55°C
56°C < CH water temp. ≤ 65°C
66°C < CH water temp. ≤ 75°C
76°C < CH water temp. ≤ 85°C
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN n/a n/a
OFF
RED
OFF
OFF
OFF
OFF
OFF n/a n/a
OFF
OFF
RED
OFF
OFF
OFF
OFF n/a n/a
OFF
OFF
OFF
RED
OFF
OFF
OFF
No. 1 chart – Correlation between LED SIGNALLING – BOILER STATUS when boiler is operating n/a n/a
OFF
OFF
OFF
OFF
RED
OFF
OFF
LED 6 n/a n/a
OFF
OFF
OFF
OFF
OFF
RED
OFF
LED 7 n/a n/a
OFF
OFF
OFF
OFF
OFF
OFF
RED
Malfunction
No electric power
Safety thermostat shutdown
Flue gas thermostat shutdown
Flame absence shutdown
Fluid circulation shutdown
Fan shutdown
Flow alarm (>85°C)
DHW probe alarm
Flow probe alarm
Water tank probe alarm
Faulty remote control connection
LED 1
OFF
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
LED 2
OFF
OFF
OFF
OFF
OFF
OFF
OFF
RED L
RED L
RED LA
OFF
LED 3
OFF
RED L
OFF
OFF
OFF
RED L
OFF
OFF
OFF
OFF
OFF
LED 4
OFF
OFF
RED L
OFF
OFF
OFF
OFF
OFF
OFF
OFF
RED L
LED 5
OFF
OFF
OFF
RED L
OFF
OFF
OFF
OFF
OFF
OFF
OFF
No. 2 chart – Correlation between LED SIGNALLING – BOILER STATUS when boiler is malfunctioning
LED 6
OFF
OFF
OFF
OFF
RED L
OFF
OFF
OFF
OFF
OFF
OFF
Key chart to acronyms
OFF LED off
RED
RED L
RED LA n/a
LED on and fixed (colored as indicated in the chart)
LED or LEDs blinking simultaneously (colored as indicated in the chart)
LEDs blinking alternatively (colored as indicated in the chart)
LED status is not relevant
LED 7 LED 8
OFF OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
RED L
OFF
OFF
YELLOW L n/a
OFF
YELLOW L
OFF YELLOW LA
OFF YELLOW L
LED 8 n/a
YELLOW n/a n/a n/a n/a n/a n/a n/a
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1.2. Operating the boiler
1.2.1. Switching on
The following procedure is to be implemented only after the boiler is installed and tested by a qualified fitter.
• Open the gas stop cock;
• turn ON the power switch external to the boiler (no. 1 LED turns on);
• select boiler operation mode via no. 9 selector (pic. 1);
• set desired CH temperature via no. 11 knob (pic. 1);
• In KC model, set desired domestic hot water temperature via no. 10 knob (pic. 1); In KR model equipped with external cylinder, set desired domestic hot water temperature directly on the external cylinder (see its instruction manual);
• Set desired room temperature by means of the room thermostat in the premises (when available).
When the flame on the burner turns on, no. 8 yellow LED turns on.
WARNING
Should the boiler be left inactive for a long time, particularly when boiler is LPG fired, ignition might be difficult.
Before starting the boiler switch on another gas powered device (e.g. kitchen range).
Beware that even by following this procedure, the boiler might still experience some starting difficulties and shut down once or twice. Resume boiler operation by turning no. 9 knob to the reset position for two seconds and back to the desired position.
1.2.2. Operation
CENTRAL HEATING
Set desired CH water temperature via no. 11 knob (pic. 1);
CH water temperature adjusting range depends on selected operation range:
- standard range : from 20°C to 78°C (from full counter-clockwise position to full clockwise position);
- reduced range : from 20°C to 45°C (from full counter-clockwise position to full clockwise position).
Operation range choice is to be selected by the fitter or an authorized Service Centre (see 3.2.11. paragraph).
Instantaneous central heating water temperature is displayed on the control board via no. 2 through no. 7 LED’s (pic. 1).
To prevent frequent ignition and switching off in central heating mode, boiler is programmed to have a waiting time between subsequent ignitions which depends on the selected operating range.
- standard range : 4 minutes;
- reduced range : 2 minutes.
Should water temperature in the system fall below the default value (see 3.2.11. paragraph), waiting time procedure is aborted and boiler re-ignited.
DOMESTIC HOT WATER
Domestic hot water supply is activated in KC model and KR model equipped with an external cylinder (optional equipment). Such function always has priority over CH water supply.
In KC model, set desired domestic hot water temperature via no. 10 knob (pic.1). It can be adjusted within a 35°C to 57°C range (from full counter-clockwise position to full clockwise position);
In KR model equipped with external cylinder (optional equipment), set desired domestic hot water temperature directly on the external cylinder (see its instruction manual); no. 10 knob is not functional in this model operation.
WARNING
In KC model, a special adjusting device is installed, which limits domestic hot water flow rate to 13 liter per minute (KC 24), and to 16 liter per minute (KC 32). Domestic hot water temperature supplied depends on no. 10 adjusting device, on the quantity requested by the user and on water mains supply temperature.
In KC model, DHW liter per minute flow depends on the boiler’s thermal capacity and water mains supply temperature, according to the following formula:
K l = DHW liter per min. = --------
∆T
K represents:
- 401 in KC 24 model
- 507 in KC 32 model
∆t = DHW temperature – water mains supply temperature
E.g. in KC 24 model, when water mains supply temperature is 8°C and DHW is required to be 38°C, in order to have a shower, the value of ∆t is:
∆t = 38 °C – 8 °C = 30 °C and DHW liters (l per minute) available at the required temperature of 38°C are:
I = 401/30 = 13,4 [liter per minute] (mixed water at the tap)
In contrast, in KR model equipped with an external cylinder (optional equipment), available DHW flow depends on the cylinder capacity.
In KR model with external cylinder (optional equipment), every 15 days, the anti-Legionella function is activated; it consists in heating up the cylinder to 65°C for 30 minutes, regardless of boiler mode setting.
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ANTI-FROST
The boiler is equipped with anti-frost function, which is active in SUMMER/WINTER/ANTI-FROST modes.
When central heating water temperature sensor detects a water temperature of 5°C, the boiler is switched on and stays on at minimum heat output until central heating water temperature reaches 30°C or 15 minutes have elapsed.
Should boiler shut down, pump operation is still granted.
In KC model, anti-frost function protects the domestic hot water system as well.
When domestic hot water probe detects a temperature of 5°C, the boiler ignites and stays on at minimum heat output until domestic hot water temperature reaches 10°C or 15 minutes have elapsed (the deviating valve is set to domestic hot water position).
Should boiler shut down, pump operation is still granted.
In CH only boilers equipped with a DHW supply external cylinder, anti-frost function protects the cylinder as well. The function is active only for cylinders equipped with β =3435 type NTC probe (refer to cylinder technical data).
When cylinder water temperature probe detects a water temperature of 5°C, the boiler is switched on and stays on at minimum heat output until cylinder water temperature reaches 10°C or 15 minutes have elapsed (the deviating valve is set to domestic hot water position).
Should the boiler shut down, pump operation is granted.
Anti-frost function protects the boiler only and not the whole central heating system.
Central heating system is to be protected by means of an ambient thermostat, although this is disabled when the boiler is set to the anti-frost and OFF modes. Should anti-frost protection be necessary for the boiler and CH system, select winter position through no. 9 knob.
CH system can be effectively protected from freezing by means of specific anti-freezing addictives suitable in multi-metal systems.
Do not use automotive anti-frost products, and periodically check anti-frost product effectiveness.
PUMP AND DEVIATING VALVE ANTI-BLOCKING 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 (KC and KR) and three-way valve (KC), are operated for 3 minutes every 24 hours in order to prevent blockage.
1.2.3. External probe operation (optional equipment)
The boiler can be equipped with an external temperature probe (optional equipment), through which the boiler adjusts CH water temperature according to outdoor temperature, in other words, increasing CH water temperature when outdoor temperature decreases and vice-versa, providing increased energy saving operation (such boiler mode is called “sliding temperature operation”) .
Boiler microprocessor program determines CH water temperature variations.
When an external temperature probe is connected to the boiler, CH water temperature adjusting knob, no.
11 (pic. 1), loses its function and becomes a fictitious room temperature adjusting device.
When no. 11 knob is turned fully counter-clockwise, selected room temperature is 15°C; when set to 9:00 hours selected room temperature is 18°C; when set to 12:00 hours selected room temperature is 25°C; when set to 3:00 hours selected room temperature is 32°C; when is turned fully clockwise selected room temperature is 35°C;
For best curve setting, it is advisable a position close to 20°C.
Refer to 3.2.14. paragraph for detailed sliding temperature operation.
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1.3. Boiler shut-down
Should any malfunction occur, boiler automatically shuts down.
Refer to no. 1 and no. 2 charts (on page 7) for boiler status detection.
In order to detect the probable malfunction causes, see, in addition to no. 2 chart, no. 7 “Troubleshooting” paragraph at the end of the manual, as well.
Follow the described procedure with respect to the type of shut-down.
1.3.1. Burner shut-down
When the burner shuts down due to flame extinguishing, no. 5 LED (red) starts flashing. Should this happen proceed as follows:
- check the gas stopcock to be open, and gas network is actually providing service, by lighting a gas powered kitchen appliance such as a kitchen range or oven.
- once gas presence is verified, reset the burner by turning no. 9 knob (pic. 1) to the reset position for 2 seconds, and then to the desired mode position: should the boiler not start shut down, and after performing three reset procedures, contact an authorized Service
Centre or qualified personnel for service.
Should frequent burner shut down occur, a recurrent malfunction might be present: contact an authorized Service Centre or qualified personnel for service.
1.3.2. Shut-down due to overheating
When CH flow water overheats the boiler is shut down, no. 3 LED (red) starts flashing.
Should the above happen contact an authorized Service centre or qualified personnel for service.
1.3.3. Shut-down due to incorrect fluid circulation
Should CH water circulation not be adequate, the primary flow switch intervenes, the boiler is shut-down, and no. 6 LED (red) starts flashing.
The following 2 instances may have occurred: a) no. 12 water pressure gauge (pic. 1) indicates a pressure value lower than 1 bar; in this instance follow the loading procedure as below described:
- turn the loading tap (pic. 2) counter-clockwise in order to allow water inlet;
- keep the loading tap open until the water pressure gauge reads 1-1.3 bar;
- close the loading tap by turning it clockwise;
- reset the burner by turning no. 9 knob to the reset position for 2 seconds, and then to the desired mode position.
Should the boiler shut down again, contact an authorized Service Centre or qualified personnel for service.
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.
b) no. 12 water pressure gauge (pic. 1) indicates a correct pressure value (1-1.3 bar); in this instance contact an authorized Service Centre or qualified personnel for service.
LOADING TAP
10 pic. 2 - Loading tap
1.3.4. Shut-down due to inadequate air/flue gas draught
Should the boiler shut down due to air intake and/or flue gas discharge ducts malfunction, no. 4 LED (pic. 1) starts flashing. Should that happen, contact an authorized Service Centre or qualified personnel for service.
1.3.5. Shut-down due to fan malfunction
Fan operation is constantly monitored and in case of malfunction the burner is turned off and no. 3 and no. 8 LEDs (pic. 1) start flashing simultaneously.
The above status continues until correct fan operation is restored.
Should the boiler not re-start and still remain in the above status, contact an authorized Service Centre or qualified personnel for service.
1.3.6. Flow alarm
Should flow temperature rise above 85°C, no. 7 LED (pic. 1) start flashing and the burner is turned off.
Normal boiler operation will be restored once flow temperature decreases below 85°C.
1.3.7. Alarm due to failure of temperature probes
Should the temperature probes malfunction, the following LEDs turn on:
- no. 2 and no. 8 LEDs start flashing simultaneously when flow probe malfunction occur;
- no. 2 LED start flashing when DHW probe malfunction occur (KC);
- no. 2 and no. 8 LEDs start alternatively flashing when external cylinder probe malfunction occur (KR equipped with external cylinder).
Contact an authorized Service Centre or qualified personnel for service.
1.3.8. Alarm due to remote control malfunction
Should the boiler receive incorrect information from the OpenTherm remote control (optional equipment), or should it not receive any
(due to remote control malfunctioning, or incorrect connection between the boiler and the remote control), no. 2 and no. 8 LEDs start flashing simultaneously.
Contact an authorized Service Centre or qualified personnel for service.
1.4. Maintenance
Have the boiler routinely serviced, following the schedule described in the relevant section of this manual.
Appropriate boiler maintenance ensures efficient operation, environment preservation, and safety for people, animals and objects.
Qualified personnel only are to service the boiler.
Manufacturer recommends Customers to contact authorized Service Centre for maintenance and repairs; they are best qualified to implement such procedures.
1.5. Notes for the user
The user may only access boiler parts that can be reached without using technical equipment and/or tools: the user is not authorized to remove boiler casing and operate on any internal part.
No one, including qualified personnel, is authorized to modify the boiler.
The manufacturer shall not be held responsible for damage to people, animals, or property due to tampering or improper intervention to the boiler.
Should the boiler be left inactive for a long time and power main supply disconnected, the pump might need to be un-blocked.
Such servicing includes boiler casing removal and access to boiler internal parts, therefore only qualified personnel may perform it.
Pump blockage may be avoided by adding filming additives suitable for multi-metal systems to water.
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2. Technical characteristics and dimensions
2.1. Technical characteristics
The boiler is equipped with a fully pre-mixed gas burner. The following models are available:
KC : condensing boiler with sealed chamber and forced draught, supplying CH water and instant DHW;
KR : condensing boiler with sealed chamber and forced draught, supplying CH water;
Both models are available in the following heat outputs:
KC 24 and KR 24 = 23.7 kW.
KC 32 and KR 32 = 31.4 kW.
Both models are equipped with electronic ignition and ionization flame sensing device.
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:
Manufacturing characteristics
- IPX4D electrically protected control panel
- Integrated, modulating electronic safety board
- Electronic ignition via separated igniter and ionization flame detection
- Stainless steel, fully pre-mixed burner
- Mono-thermal, high efficiency, composite and stainless steel heat exchanger with air purging device
- Twin shutter, modulating gas valve with constant air/gas ratio
- Modulating, electronically managed flue gas discharge fan
- Three-speed pump with air purging device
- Safety flow-switch, preventing operation with low water pressure in the CH system
- CH temperature probe (KC and KR) and DHW (KC)
- Safety limit thermostat
- Flue gas thermostats
- Integrated, automatic by-pass
- 10 liter expansion vessel
- System loading and draining taps
- Stainless steel plate DHW heat exchanger (KC)
- Motorized deviating valve (KC)
- DHW priority flow switch (KC)
- DHW flow limiting device; 13 liter/min (KC 24), 16 liter/min (KC 32)
User interface
- Boiler mode selector: OFF, RESET, WINTER, SUMMER, ANTI-FROST
- CH temperature adjusting switch: 20/78°C (standard range), or 20/45°C (reduced range)
- DHW temperature adjusting switch (KC): 35/57°C.
- Led displayed CH water temperature
- CH water pressure gauge
- Light emitting diodes indicating:
• power main supply connection;
• flame detection;
• burner shut-down due to flame extinguishing;
• burner shut-down due to overheating;
• burner shut-down due to flue gas pressure switch intervention;
• burner shut-down due to inadequate CH water circulation;
• burner shut-down due to fan malfunction;
• malfunction of temperature probes;
• remote control faulty connection.
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Operating characteristics
- CH mode electronic flame modulation, timer controlled flame rising ramp (50 seconds)
- DHW mode electronic flame modulation (KC and KR with external cylinder)
- DHW priority function (KC and KR with external cylinder)
- Flow anti-frost function: ON at 5°C; OFF at 30°C or after 15 minutes operation when CH water > 5°C
- DHW anti-frost function (KC): ON at 5°C; OFF at 10°C or after 15 minutes operation when DHW temperature > 5°C
- External cylinder anti-frost function (KR + 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-Legionella function (KR equipped with optional external cylinder)
- Maximum CH input adjusting trimmer
- Ignition heat input adjusting trimmer
- CH water temperature range adjusting device: standard or reduced
- Ignition flame spread function
- Timer controlled CH thermostat: 240 seconds standard range, 120 seconds reduced range
- Post-circulation function in CH mode, anti-frost and chimney sweep mode: 180 seconds
- Post-circulation function in DHW supply mode (KC and KR with external cylinder): 30 seconds
- Post-circulation function for CH temperature > 85°C: 30 seconds
- Post ventilation function following operation: 10 seconds
- Post ventilation function for CH temperature > 95°C
- Pump (KC and KR) and deviating valve (KC) anti-blocking function: 180 seconds operation after 24 hours of non operation
- Ready for connection to a room thermostat
- Ready for connection to an external probe (manufacturer delivered optional equipment)
- Ready for connection to an OpenTherm remote control (manufacturer delivered equipment)
- Ready for serving different zones
13
2.2. Dimensions
Bottom view
14 pic. 3 - Dimensions
Top view
S Condensate drain
F Water mains intake
G Gas intake
SI Inspection trap plug
M CH system flow
C DHW flow (KC model only)
SV 3-bar safety valve drain cock
RC Filling tap
R CH system return
RS Drain cock
2.3. Hydraulic layouts
4
3
6
5
8
7
3
11
10
9
2
1
28 27 26 25 24 pic. 4 - KC model hydraulic layout
4
3
6
5
8
7
3
11
10
9
2
1
23 pic. 5 - KR model hydraulic layout
18
19
20
21
22
23
12
13
14
15
16
17
18
19
20
21
22
12
13
14
15
16
17
1. Condensate drain siphon
2. Modulating gas valve
3. Safety thermostat
4. CH temperature probe
5. Modulating fan
6. Primary fluid flow meter
7. Primary condensing exchanger
8. Ignition electrode
9. Air purging device
10. Combustion air intake system
11. Flue gas discharge system
12. Flue gas analysis ports
13. Flue gas thermostat on discharge duct
14. Flue gas thermostat on exchanger
15. Flame sensing electrode
16. Expansion vessel
17. Fan management probe
18. Air purging device
19. Pump
20. 3 bar safety valve
21. Unloading tap
22. Flow limiting device
23. Loading tap
24. Domestic cold water flow meter with filter
25. Secondary plate exchanger
26. DHW probe
27. Automatic by-pass
28. Motorized 3-way valve
S Condensate drain
G Gas intake
M CH system flow
C DHW flow
F Water mains intake
R CH system return
1. Condensate drain siphon
2. Modulating gas valve
3. Safety thermostat
4. CH temperature probe
5. Modulating fan
6. Primary fluid flow meter
7. Primary condensing exchanger
8. Ignition electrode
9. Air purging device
10. Combustion air intake system
11. Flue gas discharge system
12. Flue gas analysis ports
13. Flue gas thermostat on discharge duct
14. Flue gas thermostat on exchanger
15. Flame sensing electrode
16. Expansion vessel
17. Fan management probe
18. Air purging device
19. Pump
20. 3 bar safety valve
21. Unloading tap
22. Loading tap
23. Automatic by-pass
S Condensate drain
G Gas intake
M CH system flow
F Water mains intake
R CH system return
15
2.4. Operating data
Burner pressures must be verified after a three minute boiler operation time
Function
Max. CH input
(kW)
Methane Gas G20
Propane Gas G31
23.7
23.7
No. 3 chart – KC 24 model adjustment rates min
6.5
6.5
CH output
(80-60°C)
[kW] max
22.7
22.7
KC 24 min
7.3
7.3
CH output
(50-30°C)
[kW] max
24.8
24.8
min
7.3
7.3
DHW output
(kW) max
28.0
28.0
Gas mains pressure
(mbar)
20
37
Hot water supply ∆T 45°C = 8.9 l/min
Hot water supply ∆T 40°C = 10 l/min
Hot water supply ∆T 35°C = 11.5 l/min
Hot water supply ∆T 30°C = 13.4 l/min *
Hot water supply ∆T 25°C = 16.1 l/min *
*Note: mixed water to the tap
Function
Max. CH input
(kW)
Methane Gas G20
Propane Gas G31
31.4
31.4
No. 4 chart – KC 32 model adjustment rates min
8.7
8.7
CH output
(80-60°C)
[kW] max
30.5
30.5
Hot water supply ∆T 45°C = 11.3 l/min
Hot water supply ∆T 40°C = 12.7 l/min
Hot water supply ∆T 35°C = 14.5 l/min
Hot water supply ∆T 30°C = 16.9 l/min *
Hot water supply ∆T 25°C = 20.3 l/min *
*Note: mixed water to the tap
Function
Methane Gas G20
Propane Gas G31
Max. CH input
(kW)
23.7
23.7
No. 5 chart – KR 24 model adjustment rates
KC 32 min
9.6
9.6
CH output
(50-30°C)
[kW] max
33.2
33.2
min
9.6
9.6
DHW output
(kW) min
6.5
6.5
CH output
(80-60°C)
[kW] max
22.7
22.7
KR 24 min
7.3
7.3
CH output
(50-30°C)
[kW] max
24.8
24.8
max
35.4
35.4
Function
Methane Gas G20
Propane Gas G31
Max. CH input
(kW)
31.4
31.4
No. 6 chart – KR 32 model adjustment rates min
8.7
8.7
CH output
(80-60°C)
[kW] max
30.5
30.5
KR 32 min
9.6
9.6
CH output
(50-30°C)
[kW] max
33.2
33.2
Gas mains
20
37
20
37 pressure
(mbar)
20
37
Gas mains pressure
(mbar)
Gas mains pressure
(mbar)
Flue gas
CO
[%]
8.8 ÷ 9.1
9.8 ÷ 10.1
8.8 ÷ 9.1
9.8 ÷ 10.1
Flue gas
CO
2
[%]
2
Flue gas
CO
[%]
Flue gas
CO
[%]
2
2
8.8 ÷ 9.1
9.8 ÷ 10.1
8.8 ÷ 9.1
9.8 ÷ 10.1
16
2.5. General characteristics
KC MODEL
Equipment category
Minimum CH system pressure
Maximum CH system pressure
Minimum DHW system pressure
Maximum DHW system pressure
DHW specific flow rate (∆t 30 °C)
Electric power supply – voltage / frequency
Power mains supply fuse
Maximum power consumption
Electric protection rating
Net weight
Methane gas consumption at maximum CH input (*)
Propane gas consumption at maximum CH input
Maximum CH working temperature
Maximum DHW working temperature
Total capacity of expansion vessel
Maximum recommended CH system capacity (**)
No. 7 chart – KC model general specifications
(*) Value referred to 15°C - 1013 mbar
(**) Maximum water temperature 83°C, expansion vessel pressure 1 bar
KC 24
Casing heat loss with burner on
Casing heat loss with burner off
Chimney heat loss with burner on
Flue gas system mass flow rate
Flue gas temp. – air temp
Maximum heat output efficiency rating (60/80°C)
Maximum heat output efficiency rating (30/50°C)
Minimum heat output efficiency rating (30/50°C)
30% heat output efficiency rating
Efficiency rating (according to 92/42/CEE)
NO x
emission class
No. 8 chart – KC 24 model combustion rates
KC 32
Casing heat loss with burner on
Casing heat loss with burner off
Chimney heat loss with burner on
Flue gas system mass flow rate
Flue gas temp. – air temp
Maximum heat output efficiency rating (60/80°C)
Maximum heat output efficiency rating (30/50°C)
Minimum heat output efficiency rating (30/50°C)
30% heat output efficiency rating
Efficiency rating (according to 92/42/CEE)
NO x
emission class
No. 9 chart – KC 32 model combustion rates bar bar bar bar m
-
3
°C
°C l l
/h kg/h
KC 24
II2H3P II2H3P
0.5
3
0.5
8
2.51
1.84
83
62
10
200
KC 32
0.5
3
0.5
8 l/min 13.4
16.9
V - Hz 230 - 50 230 - 50
A
W
2
145
2
145
IP kg
X4D
38.5
X4D
40.0
3.32
2.44
83
62
10
200
%
%
% g/s
°C
%
%
%
%
-
-
Max. heat output
1.4
0.2
2.6
12.4
67
96.0
104.8
-
-
Min. heat output
2.1
0.2
2.2
3.1
49
-
-
106.9
-
5
30% heat output
-
-
-
-
-
-
-
-
109.1
g/s
°C
%
%
%
%
%
-
-
%
%
Max. heat output
0.6
0.2
2.4
15.7
54
96.6
105.4
-
-
Min. heat output
1.6
0.2
2.1
4.1
51
-
-
106.3
-
5
30% heat output
-
-
-
-
-
-
-
-
108.7
17
KR MODEL
Equipment category
Minimum CH system pressure
Maximum CH system pressure
Electric power supply – voltage / frequency
Fuse
Maximum power consumption
Electric protection rating
Net weight
Methane gas consumption at maximum CH input (*)
Propane gas consumption at maximum CH input
Maximum CH working temperature
Total capacity of expansion vessel
Maximum recommended CH system capacity (**)
No. 10 chart – KR model general specifications
(*) Value referred to 15°C - 1013 mbar
(**) Maximum water temperature 83°C, expansion vessel pressure 1 bar
KR 24
Casing heat loss with burner on
Casing heat loss with burner off
Chimney heat loss with burner on
Flue gas system mass flow rate
Flue gas temp. – air temp
Maximum heat output efficiency rating (60/80°C)
Maximum heat output efficiency rating (30/50°C)
Minimum heat output efficiency rating (30/50°C)
30% heat output efficiency rating
Efficiency rating (according to 92/42/CEE)
NO x
emission class
No. 11 chart – KR 24 model combustion rates
KR 32
Casing heat loss with burner on
Casing heat loss with burner off
Chimney heat loss with burner on
Flue gas system mass flow rate
Flue gas temp. – air temp
Maximum heat output efficiency rating (60/80°C)
Maximum heat output efficiency rating (30/50°C)
Minimum heat output efficiency rating (30/50°C)
30% heat output efficiency rating
Efficiency rating (according to 92/42/CEE)
NO x
emission class
No. 12 chart – KR 32 model combustion rates
bar bar
V - Hz m
A
W
IP kg
3 l l
/h kg/h
°C
KR 24
II2H3P
0.5
3
230 - 50
2
145
X4D
37.5
2.51
1.84
83
10
200
%
%
% g/s
°C
%
%
%
%
-
-
Max. heat output
1.4
0.2
2.6
12.4
67
96.0
104.8
-
-
Min. heat output
2.1
0.2
2.2
3.1
49
-
-
106.9
-
5
30% heat output
-
-
-
-
-
-
-
-
109.1
°C
%
%
%
%
%
% g/s
%
-
-
Max. heat output
0.6
0.2
2.4
15.7
54
96.6
105.4
-
-
Min. heat output
1.6
0.2
2.1
4.1
51
-
-
106.3
-
5
30% heat output
-
-
-
-
-
-
-
-
108.7
KR 32
II2H3P
0.5
3
230 - 50
2
145
X4D
39.0
3.32
2.44
83
10
200
18
3. Instructions for the fitter
3.1. Installation standards
This is an II2H3P category boiler and must be installed in compliance with laws and standards enforced in the country of installation, which are herein considered as entirely transcribed.
3.2. Installation
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.
3.2.1. Packaging
Boiler is shipped in a sturdy cardboard box.
Remove boiler from cardboard box and check its integrity.
The packing materials can be recycled. Disposal of must be managed via appropriate waste collection sites.
Keep packaging out of reach of children, as it may be dangerous.
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 (KC and KR) and DHW system (KC);
- wall hanging bracket;
- a bag containing: a) boiler installation, use and maintenance manual.
b) boiler wall mounting template (pic. 6).
c) metal plate for fixing the boiler to the wall.
d) two screws and wall plugs for fixing the metal plate to the wall.
3.2.2. Choosing where to install the boiler
The following must be taken into account when choosing where to install the boiler:
- 3.2.6. “Air intake /flue gas discharge system” paragraph instructions;
- check the wall for sturdiness, avoiding weak areas;
- do not hang the boiler above any equipment which may prejudice proper operation (steam and greasy vapor emitting kitchen appliances, washing machines, etc.).
19
3.2.3. Positioning the boiler
Each boiler is supplied with a paper template (pic. 6), 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.
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 proper insulation between wall and flue gas ducts
3.2.4. Installing the boiler
Before connecting the boiler to CH and DHW networks, clean the pipes carefully.
Prior to operate a NEW system eliminate any metallic leftover during manufacturing and welding process, and any oil or grease deposits, which might reach the boiler and damage it or alter its operation.
Prior to operate a MODERNIZED system (addition of radiators, boiler replacement, etc.), clean it throughout so as to remove possible sludge and foreign particles.
In order to clean the system, employ non acid product available on the market. Do not use solvents as they could damage system components.
Furthermore, in the central heating system (either new or modernized), it is always advisable to add to water, with adequate concentration, suitable products inhibiting corrosion in multi-metal systems, which produce a protective film on internal metal surfaces.
Manufacturer shall not be held responsible in case of harm to people and/or animals, or property damage due to failure in adhering to the above stated instructions.
For all kinds of heating plants, it is necessary to install the seal with filter (supplied with the boiler) on the return duct, as shown in pic. 7.
Should boiler be mounted in an existing system, install a filter which can be inspected (Y-shaped type) with
Ø 0.4mm-mesh span, on return pipe before the boiler.
pic. 6 - Installation template
In order to install the boiler proceed as follows:
- affix the template (pic. 6) to the wall;
- drill two 12 mm Ø holes in the wall to accommodate the boiler support bracket wall plugs;
- arrange air intake/flue gas system path in the wall as needed;
- secure boiler support bracket to the wall by means of the wall plugs supplied with the boiler;
- position gas supply network coupling (G), water mains supply coupling
Seal with filter
(F), DHW flow coupling (C, only in KC model), CH flow coupling (M), and
CH return coupling (R), and condensate drain coupling (S), as shown on the template (refer to its lower area );
- position the boiler to the supporting bracket on the wall; pic. 7 - Installation of the seal with filter
- connect the boiler to network pipes by means of the coupling kit supplied with the boiler (refer to 3.2.9. paragraph);
- connect the boiler to pipe for condensate discharge (refer to 3.2.9. paragraph);
- connect the boiler to the air intake and flue gas exhaust system (refer to 3.2.6. paragraph);
- connect electric power supply, ambient thermostat (when available) and other available accessories (refer to the following paragraphs).
20
3.2.5. 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.
3.2.6. 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.
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 no. 4 or no. 3 and no. 8 LEDs start flashing (see no. 2 chart).
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 nonobservance of instructions provided by the manufacturer or applicable installation standards involving the product.
Installation examples
Chart to acronyms:
A Air intake - S Flue gas discharge - Condensate - Rain pic. 8 – Installation examples of air intake/flue gas discharge pipes
21
3.2.6.1. Air/flue gas system duct configuration
Type B23
Boiler intended for connection to an existing flue system external to the boiler room. Combustion air is taken directly from the boiler room itself while flue gas is conveyed to the outside.
The boiler is not to be fitted by anti-wind gust device; it has to be equipped by a fan mounted before the combustion chamber/heat exchanger.
Type B53
Boiler intended for connection, via an independent duct, to the flue gas discharge terminal. Air intake combustion air is taken directly from the boiler room itself while flue gas is conveyed to the outside.
The boiler is not to be fitted by anti-wind gust device; it has to be equipped by a fan mounted before the combustion chamber/heat exchanger.
Type C13
Boiler intended for connection to horizontal outlet and intake ducts connected to the outside by means of coaxial or split ducts.
The distance between the air intake duct and the flue gas outlet duct is to be a minimum of 250 mm, and both terminals are to be positioned within a squared area having 500 mm sides.
The boiler is to be equipped by a fan mounted before the combustion chamber/heat exchanger.
Type C33
Boiler intended for connection to vertical outlet and intake ducts connected to the outside by means of coaxial or split ducts.
The distance between air intake duct and flue gas flue duct is to be a minimum of 250 mm, and both ends are to be positioned within a squared area having 500 mm sides.
The boiler is to be equipped by a fan mounted before the combustion chamber/heat exchanger.
Type C43
Boiler intended for connection to collective chimney pipe system that includes two ducts, air intake and flue gas exhaustion. These ducts may be coaxial or split.
The flue gas chimney system must comply with current standards.
The boiler is to be equipped by a fan mounted before the combustion chamber/heat exchanger.
Type C53
Boiler with separate pipes for air intake and flue gas.
Air and flue gas may be have different exhaustion pressure. Air and flue gas terminals may not face each other from opposite walls.
The boiler is to be equipped by a fan mounted before the combustion chamber/heat exchanger.
Type C83
Boiler intended to be connected to combustion air terminal and to a single flue gas terminal or collective chimney.
Flue gas chimney must comply with current standards.
The boiler is to be equipped by a fan mounted before the combustion chamber/heat exchanger.
22
3.2.6.2. Ø 100/60 mm and Ø 125/80 mm air/flue gas coaxial duct system
Type C13
KC 24 and KR 24
Minimum permissible length of horizontal coaxial pipes is 1 meter, without accounting for the first elbow connected to the boiler.
Maximum permissible length of Ø 100/60 mm horizontal coaxial pipes is 9.5 meter not including the first elbow connected to the boiler.
Maximum permissible length of Ø 125/80 mm horizontal coaxial pipes is 14.5 meter not including the first elbow connected to the boiler.
For each additional 1 meter straight pipe maximum permissible length is to be reduced by 1 meter.
For each additional 90° elbow, maximum permissible length is to be reduced by 1 meter.
For each additional 45° elbow, maximum permissible length is to be reduced by 0.5 meter.
The wall terminal reduces maximum permissible length by 1.5 meters.
The air intake duct is to be tilted by 1% toward its exit, in order to avoid rain water to enter it.
KC 32 and KR 32
Minimum permissible length of horizontal coaxial pipes is 1 meter, without accounting for the first elbow connected to the boiler.
Maximum permissible length of Ø 100/60 mm horizontal coaxial pipes is 6.5 meter not including the first elbow connected to the boiler.
Maximum permissible length of Ø 125/80 mm horizontal coaxial pipes is 11.5 meter not including the first elbow connected to the boiler.
For each additional 1 meter of straight pipe maximum permissible length is to be reduced by 1 meter.
For each additional 90° elbow, maximum permissible length is to be reduced by 1 meter.
For each additional 45° elbow, maximum permissible length is to be reduced by 0.5 meter.
The wall terminal reduces maximum permissible length by 1.5 meters.
The air intake duct is to be tilted by 1% toward its exit, in order to avoid rain water to enter it.
Type C33
KC 24 and KR 24
Minimum permissible length of vertical coaxial pipes is 1 meter.
Maximum permissible length of Ø 100/60 mm vertical coaxial pipes is 9.5 meters.
Maximum permissible length of Ø 125/80 mm vertical coaxial pipes is 14.5 meters.
For each additional 1 meter of straight pipe maximum permissible length is to be reduced by 1 meter.
For each additional 90° elbow, maximum permissible length is to be reduced by 1 meter.
For each additional 45° elbow, maximum permissible length is to be reduced by 0.5 meter.
The roof terminal reduces maximum permissible length by 1.5 meters.
KC 32 and KR 32
Minimum permissible length of vertical coaxial pipes is 1 meter.
Maximum permissible length of Ø 100/60 mm vertical coaxial pipes is 6.5 meters.
Maximum permissible length of Ø 125/80 mm vertical coaxial pipes is 11.5 meters.
For each additional 1 meter of straight pipe maximum permissible length is to be reduced by 1 meter.
For each additional 90° elbow, maximum permissible length is to be reduced by 1 meter.
For each additional 45° elbow, maximum permissible length is to be reduced by 0.5 meter.
The roof terminal reduces maximum permissible length by 1.5 meters.
The above data are referred to air intake/flue gas discharge system, implemented with original, rigid and smooth ducts, delivered by the manufacturer.
Sealing cap
Neoprene seal
Sealing
cap
Neoprene seal pic. 9 - Air intake and flue gas discharge coaxial pipe system
450
330 pic. 10 - Dimensions for connection to air intake and flue gas discharge coaxial pipe system
23
3.2.6.3. Ø 80 mm air/flue gas split duct system
Installation types C43 – C53 – C83
Minimum permissible length of air intake pipe is 1 meter.
Minimum permissible length of flue gas discharge pipe is 1 meter.
Maximum permissible length of air intake/flue gas discharge pipes is 120 meters (combined length of air intake and flue gas discharge pipe length).
For each additional 1 meter of straight pipe maximum permissible length is to be reduced by 1 meter.
For each additional 90° elbow, maximum permissible length is to be reduced by 1.5 meter.
For each additional 45° elbow, maximum permissible length is to be reduced by 1 meter.
The condensate trap reduces maximum permissible length by 1.5 meters.
The roof terminal reduces maximum permissible length by 1.5 meters.
The wall terminal reduces maximum permissible length by 1 meter.
The above data are referred to air intake/flue gas discharge system, implemented with original, rigid and smooth ducts, delivered by the manufacturer.
Sealing cap
148
229,5
139,5 fl 80
Neoprene seal
Neoprene seal pic. 11 - Air intake and flue gas discharge split pipe system
450 330 pic. 12 - Dimensions for connection to air intake and flue gas discharge split pipe system
3.2.7. Testing combustion efficiency
3.2.7.1. “Chimney sweep” function
The boiler is equipped with “chimney sweep” function, to be used when testing combustion efficiency, and in order to adjust the burner.
When no. 9 selector (pic. 1) is positioned to WINTER, and ambient thermostat (if available) to ON, while the boiler is operating, press SPA button (pic. 13) for at least 10 seconds; the boiler turns off and resumes the ignition sequence again to the maximum heat output corresponding to maxR trimmer setting (pic. 13), which allows for adjustment of maximum CH output.
“Chimney sweep” function operates for 15 minutes. In order to exit the “chimney sweep” function, set no. 9 selector to any position other than WINTER.
24
3.2.7.2. Measurements
The boiler is equipped with a tower allowing for air intake/flue gas discharge duct connection (pic. 14 and pic. 15). The tower is designed with two pre-arranged openings directly accessing air and flue gas ducts (pic. 15).
Remove cap A from the pre-arranged openings on the tower, before starting combustion checking procedure (pic. 14).
In order to verify combustion performance the following measurements must be implemented:
- assess combustion air from no. 1 opening (pic. 15).
- assess flue gas temperature and CO
2
from no. 2 opening (pic. 15).
Allow boiler to reach working temperature before performing any measurement.
pic. 13 –“Chimney sweep” function
P6 SPA maxR
A pic. 14 - Air intake and flue gas discharge tower
1 2 pic. 15 - Openings for combustion efficiency measurement
25
3.2.8. Gas main connection
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 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.
When connecting the boiler to gas supply network, install an appropriately sized and made gasket (pic. 16).
The boiler gas inlet thread configuration is not appropriate for hemp, plastic tape or similarly made gaskets.
GASKET pic. 16 - Gas mains connection
3.2.9. 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.
CENTRAL HEATING
CH flow and CH return pipes must be connected to the relevant 3/4” M and R couplings on the boiler (pic. 6).
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
DHW flow and water mains inlet pipes are to be connected to the relevant 1/2” C and F couplings on the boiler (pic. 6).
Hardness of water supplied to the boiler may increase the plate heat exchanger cleaning/replacement frequency.
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.
26
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. 3) 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 odor 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.
3.2.10. Power main 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 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.
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.
3.2.11. Selecting central heating output range
CH water temperature adjusting choice depends on selected operation range:
- standard range : from 20°C to 78°C (from full counter-clockwise position to full clockwise position);
- reduced range : from 20°C to 45°C (from full counter-clockwise position to full clockwise position).
Act on P6 trimmer (pic. 13) in order to choose the operation range, as per the following instruction:
- standard range : turn P6 trimmer fully clockwise;
- reduced range : turn P6 trimmer fully counter-clockwise.
When the external probe is installed, P6 trimmer function varies (see paragraph 3.2.14).
Central heating output range selection, alter the waiting time between ignition sequences, preventing frequent ignition and switching off of the boiler, when in CH mode.
- standard range : 4 minutes;
- reduced range : 2 minutes.
Should water temperature in the system fall below a determined value (no. 13 chart), waiting time procedure is aborted and the boiler re-ignited.
Selected range
Standard range
Set-point > 55°C
Set-point ≤ 55°C
Reduced range
Regardless of set-point
No. 13 chart – Burner re-ignition temperatures
< 40°C
Tset-point – Tflow > 15°C
< 20°C
Re-ignition temperature
Operation range selection is to be implemented by a fitter or an authorized Service Centre.
27
3.2.12. Room thermostat connection (optional equipment)
The boiler can be connected to a room thermostat (not supplied with the boiler). Room thermostat contacts are to be connected to M9 position of the boiler printed circuit board (pic. 21), 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.
3.2.13. Open Therm remote control installation and operation procedure (optional equipment)
The boiler can be connected to an Open Therm remote control (optional equipment).
Installation is to adhere to the following procedure:
- install 0SCHEREM00 printed circuit board, included in the Remote Control Kit (which is necessary for connection of the remote control to the boiler), following the instructions described in the kit itself;
- position the remote control on a wall inside the premises, far from heat sources or draughts;
- separate, by means of a screwdriver, the rear part of the housing (grey) from the front one (white) and secure, by means of openings A
(pic. 17) the rear part to the wall;
- hook up the remote control to the boiler, connecting no. 1 and no. 2 positions of the remote control (pic. 17) to the terminal board
OPENTH M6 of code 0SCHEREM00 printed circuit board (see pic. 20 electric layout). The connection of BUS is protected against false polarity, that means the connections can be switched;
• employ two wired electric line for the connection, and with the following characteristics:
• maximum length: 40 meters;
• maximum impedance: 2 x 4Ω/m;
• interlaced or sheathed wires can be installed in order to avoid disturbances;
• remote control wires are not to be routed together with electric supply cables;
- now, should the external probe or the phone operation device not be in need to be installed, close the remote control housing, otherwise, follow the instructions described in the following paragraphs.
The remote control is not to be connected to a 230V electrical power supply.
pic. 17 - Open Therm remote control installation
Refer to the manual included in the remote control Open Therm kit, in order to program it.
A series of parameters, called TSP, reserved to qualified personnel (no. 14 and no. 15 charts), can be read and set through the remote control.
TPS0 parameter sets default data chart and restores all original values, cancelling all preceding modifications on single parameters.
When the value of a single parameter is detected to be wrong, its value is restored from the default data chart.
When a parameter is tried to be set to a value out of the allowed range, the new value is rejected and the existing one is kept.
Parameter
Range of values to be set default values by
TSP0 = 1 - KC/KR 24
TSP0
Equipment type and default data chart
TSP1
Fan speed at burner max. output (DHW)
TSP2
Fan speed at burner min. output (DHW and CH)
TSP3
Fan speed at burner ignition and spread
TSP4
CH max. output upper limit, adjustable via P4 trimmer
1 - 3
120 ÷ 250 Hz
(3600 ÷ 7500 rpm)
30 ÷ 120 Hz
(900 ÷ 3600 rpm)
30 ÷ 160 Hz
(900 ÷ 4800 rpm)
10 ÷ 100%
1
181 Hz
(5430rpm)
53 Hz
(1590rpm)
67 Hz
(2010rpm)
84%
No. 14 chart – Limits to be set for TSP parameters and default values in relation to boiler type (TSP0) default values by
TSP0 = 3 - KC/KR 32
3
193 Hz
(5790 rpm)
56 Hz
(1680 rpm)
67 Hz
(2010 rpm)
90 %
Parameter Minimum limit Maximum limit
TSP5
P6 trimmer position
TSP6
Fictitious temperature set via adjuster 11
(only when external probe is installed)
0
(thermoregulation curve = 0.0)
15°C
255
(thermoregulation curve = 3.0)
35°C
No. 15 chart – TSP chart of parameters which can be displayed (these parameters cannot be adjusted via remote control)
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3.2.14. 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 sliding temperature operation.
The manufacturer supplies two probe models:
- 0KSONEST00: external probe for connection to the remote control;
- 0SONDAES01: external probe for direct connection to the boiler;
When the Open Therm remote control is employed, it is advisable to install the external probe for connection to the remote control, code 0KSONEST00.
For boiler trouble-free operation of the boiler use external probes supplied by the Manufacturer only.
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 code 0KSONEST00 is to be connected to no. 5 and no. 6 positions on the remote control (pic. 17).
External temperature probe code 0SONDAES01 is to be connected to M8 position of the boiler printed circuit board (pic. 21).
External temperature probe wiring is NOT to be grouped together with power mains supply cables.
External temperature probe is to be installed on an outside wall facing north/north-east.
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 fictitious room temperature.
The thermoregulation curve is selected via P6 trimmer (pics. no. 18 and no. 19), which value can be read as TSP5 parameter in the TE-
CHNICAL menu on the remote control (when installed):
Relation between read value and thermoregulation curves coefficients: coefficient = read value/84.67
In addition, P6 trimmer position selects CH operation temperature range in relation to the following values:
TSP5 parameter values which select the reduced range
Coefficients corresponding to the thermoregulation curves
TSP5 parameter values which select the standard range
Coefficients corresponding to the thermoregulation curves
0 ÷ 75
0.0 ÷ 0.8
76 ÷ 255
1.0 ÷ 3.0
The fictitious room temperature is set via adjuster 11 (pic. 1), which, when the external temperature probe is installed, looses its capability to set CH flow temperature (see 1.2.3. paragraph) and which value can be read as TSP6 parameter in the TECHNICAL menu on the remote control (when installed).
0
1 2
3
1 2
0 3 pic. 18 - Correlation between P6 trimmer position and thermoregulation curves
Outdoor temperature °C pic. 19 - Central heating curves in operation with external probe
29
Above shown curves, relative to a 20°C desired room temperature, are always limited between minimum and maximum value of Ch operation temperature range. When 20°C fictitious room temperature is changed (via adjuster 11), all curves move correspondingly.
3.2.15. Phone operation device installation (optional equipment)
The boiler can be connected to a phone operation device (not provided with the boiler), allowing for CH mode activation via phone.
The phone operation device is to be connected to no. 3 and no. 4 positions on the remote control (pic. 17).
Phone operation device specifications are enclosed in the manual enclosed in its packaging.
3.3. 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 relevant loading tap to fill the system up (pic. 2), 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 boiler loading tap 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 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
Safety low water pressure switch will not allow the burner to be started when water flow is below 200 liter/minute.
CH system water pressure is not to be below 1 bar; restore proper value as needed via the provided loading tap (pic. 2).
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 blocked. Before operating the boiler, follow the below indicated pump unblocking 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 unblocking operation is completed, 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.
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3.4. Starting the boiler
3.4.1. Preliminary checks
Before starting the boiler it is necessary to perform the following checks:
- flue gas exhaust pipe and terminal are installed as instructed: when the boiler is running no products generated by combustion are to leak from any gasket;
- electric power supplied to the boiler is to be 230 V – 50 Hz;
- the system is properly filled with water (pressure reading on water pressure gauge is to be 1 – 1.3 bar);
- all system pipes stopcocks are open.
- the gas type supplied to the boiler corresponds to that for which the boiler is set: convert the boiler to the available gas type (see 3.6. section Adaptation to other gases and burner adjustment); the procedure is to be performed by technically qualified personnel;
- the gas supply stopcock is open;
- there are no gas leaks ;
- the power main switch external to the boiler is on;
- the boiler 3 bar safety valve is not blocked;
- there are no water leaks;
- the pump is not blocked.
WARNING
The boiler is equipped with a pump with three speeds corresponding to the residual head to the system according to the curves in pic. 20.
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.
400
300
200
600
500
100
0
0 200 400
Portata (l/h)
600
Flow rate (l/h)
800 1000
600
300
200
500
400
100
0
0 pic. 20 - System head curves
3.4.2. Switching on and switching off
200 400
Portata (l/h)
600
Flow rate (l/h)
800
For boiler switching on and switching off procedure follow § 1. “ Instructions for the User ”.
1000
Velocità 3
Speed 2
31
3.5. Wiring diagram
32 pic. 21 - Electric layout
CHART TO PIC. 21 ACRONYMS
F2 PIA: mono-thermal heat exchanger boiler
F3 RIS: CH only boiler
F4 BOL: system boiler
F5 MIC: micro-reservoir boiler
F6 MAC: “AQUA PREMIUM “ boiler
M3-M8-M9: power Supply connector, outdoor probe TA
M16: connector for tele-metering
M2-M15: service connectors
E.RIV:
E.ACC: detection electrode ignition electrode
P:
V: pump brushless fan
MVD: three-way valve motor
TF1 – TF2: flue gas thermostat protecting discharge system and exchanger
TR.ACC: ignition transformer
SR:
TA:
CH probe 10k Ohm B = 3435 ambient thermostat (option)
CM1-CM2: boiler type selection jumpers
FL: DHW flow switch
SS:
FLP:
VG:
SE:
SE:
TL:
P1:
P2:
P3:
P4:
P6:
K1: external temperature probe
0SONDAES01 10k Ohm B = 3977
(Option) boiler probe to be connected to the boiler electronic board when no remote control is installed external temperature probe
0SONDAES02 type KYT (Option): to be connected to the remote control when remote control
(option) is installed
DHW probe 10k Ohm B = 3435 three meter max length flow switch preventing low water pressure operation (CH) gas valve limit thermostat
CH flow temperature potentiometer
DHW temperature potentiometer boiler selector maximum CH output adjusting potentiometer thermoregulation curve adjuster
“chimney sweep” function key
B: probe equipped external water tank
(remove R1)
BM120: external water tank equipped with bulb probe thermostat (remove P1)
TIMER:
P1:
R1:
DHW programmer (remove P1 when timer is installed)
TIMER jumper – DHW priority
10k Ohm resistance
S: bulb probe thermostat
COMANDO REMOTO:
REMOTE CONTROL (option)
0CREMOTO03: Open therm remote control
0SCHEREM00: interface board for remote
control
0SONDAES02: outdoor probe to be installed
with remote control (option)
CT (option): phone operation device
Relation between temperature (°C) and nominal resistance (Ohm) of CH probe SR and DHW probe SS.
T (°C) 0 2 4
0
10
20
30
40
27203
17928
12084
8317
5835
24979
16539
11196
7736
5448
22959
15271
10382
7202
5090
50
60
70
4168
3026
2232
3904
2844
2104
3660
2674
1984
80
90
1670
1266
1578
1199
No. 16 chart - Correlation “ temperature - nominal resistance” of temperature probes
1492
1137
6
21122
14113
9634
6709
4758
3433
2516
1872
1412
1079
8
19451
13054
8948
6254
4452
3222
2369
1767
1336
1023
3.6. Adaptation to other gases and burner adjustment
The boilers are manufactured for the gas type specified upon order.
WARNING
Adaptations after delivery are to be strictly implemented by qualified personnel, employing manufactured supplied accessories and implementing the modifications and adjustments for the necessary boiler setting up.
Adapting the boiler from METHANE to PROPANE
- unscrew the outlet connection to the gas valve (A in pic. 22);
- replace the diaphragm in the relevant seating, with the one for PROPANE;
- re-connect the outlet connection to the gas valve (A in pic. 22);
- see A) and B) points.
Adapting the boiler from PROPANE to METHANE
- unscrew the outlet connection to the gas valve (A in pic. 22);
- replace the diaphragm in the relevant seating, with the one for METHANE;
- re-connect the outlet connection to the gas valve (A in pic. 22);
- see A) and B) points.
A) Maximum heating output adjustment
- set heating output adjuster maxR (pic. 13) to maximum (turn it fully clockwise after removing the protective cap);
- position selector 9 (pic. 1) to WINTER;
- verify the room thermostat (when available) to be set to ON;
- start “chimney sweep” boiler mode (see paragraph 3.2.7.1);
- adjust CO
2
in flue gas by turning ratio adjuster B (pic. 23) and verify CO
2
value to be within the range stated in no. 17 chart;
- allow boiler to keep operating in chimney sweep mode and go to point B;
33
B) Minimum heating output adjustment
- set heating output adjuster maxR (pic. 13) to minimum (turn it fully counter-clockwise after removing the protective cap);
- adjust CO
2
in flue gas by turning offset adjuster C (pic. 23) and verify CO
2
to be within the range stated in no. 17 chart;
- exit chimney sweep mode by setting selector 9 (pic. 1) to any position other than WINTER;
Fuel
Methane
Propane
No. 17 chart – CO
2
rates
CO
2
8.8 ÷ 9.1
9.8 ÷ 10.1
A pic. 22 - Adaptation to other gas types
C
34 pic. 23 - Gas valve adjustment
B
4. Testing the boiler
4.1. Preliminary checks
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 loaded (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 (see 3.6. section “ Adaptation to other gases and burner adjustment ”); 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;
- water leaks are not to be detected;
- pump is not to be blocked.
Should the boiler not be installed in compliance with current laws and standards, inform the system supervisor and do not test the boiler.
4.2. Switching on and switching off
For boiler switching on and switching off procedure follow § 1. “ Instructions for the User ”.
5. Maintenance
Have the boiler periodically serviced in compliance with standards applicable in the country of installation.
Appropriate heating unit maintenance ensures efficient operation, environment preservation, and safety for people, animals and objects.
Maintenance and repair procedures are strictly to be carried out by qualified personnel.
The manufacturer recommends Customers to contact an authorized Service Centre for all maintenance and repairs, which are best trained for the purpose.
Before implementing any maintenance involving replacement of components and/or cleaning of internal boiler parts, disconnect electrical power supply to the boiler.
Maintenance schedule
Routine maintenance schedule must include: the following checks:
- general integrity of the boiler;
- boiler and network gas supply leakage;
- gas supply pressure to boiler;
- boiler ignition sequence;
- boiler combustion parameters by analysis of flue gas;
- flue gas system integrity, good state of preservation, and absence of leaks;
- combustion fan correct operation;,
- general integrity of boiler safety devices;
- absence of water leaks and oxidized areas on boiler couplings;
- efficiency of the system safety valve;
- expansion vessel loading pressure;
- safety flow switch efficiency preventing low water pressure operation.
the following cleaning is to be performed:
- general boiler internal areas;
- gas nozzles;
- air intake and flue gas exhaust system;
- heat exchanger;
- siphon and condensate discharge pipes.
When operating for the very first time to the boiler, 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 system supervisor both verbally and in writing.
35
6. Troubleshooting
BOILER STATUS
The boiler has shut down, and no. 5 led
(red) is flashing.
Turn selector 9 to reset position in order to resume boiler operation
MALFUNCTION
Burner does not ignite
Burner does not ignite: no spark
PROBABLE CAUSE
Gas supply failure
Gas valve is disconnected
Gas valve is faulty
PCB is faulty
Spark electrode is faulty
Ignition transformer is faulty
SOLUTION
Check gas pressure.
Check gas stopcocks to be open and gas network safety valve intervention.
Reconnect it
Replace it
Replace it
Replace the electrode
Replace ignition transformer
PCB does not ignite: it is faulty Replace PCB
PCB does not detect flame: inverted phase and neutral
Verify correct neutral and phase connections
Flame detection electrode wire is disconnected or faulty
Connect flame detection electrode wire or replace it
Burner ignites for a few seconds and goes off
Detection electrode is faulty Replace electrode
PCB does not detect flame: it is faulty
Ignition heat output value set point is too low
Replace PCB
Increase it
The boiler has shut down and no. 4 LED
(red) is flashing.
Turn selector 9 to reset position in order to resume boiler operation
Minimum heat input is not set correctly
Flue gas thermostats are faulty
Flue gas thermostats are not consenting to operation
Inadequate air intake or flue gas discharge flow
Fan is not correctly operating
PCB is faulty
Check burner adjustment
Check flue gas thermostats: replace them if faulty
Check air intake/flue gas discharge ducts: clean or replace
Check fan
Replace it
The boiler is not operating, no. 3 LED
(red) is flashing.
Boiler will resume operation when selector 9 is brought to reset position and CH water temperature goes back to normal parameters
Boiler safety thermostat has intervened
CH water does not flow: pipes might be clogged, thermostatic valves might be shut, system stopcocks might be closed
Check CH system
Pump is stuck or faulty Check the pump
Flow probe sends faulty signals Check flow probe
The boiler is not operating, no. 7 LED
(red) is flashing.
Boiler will automatically resume operation as soon as malfunction ends
Flow water temperature has exceeded
85°C
The boiler is not operating, no. 6 LED
(red) is flashing.
Boiler will resume operation as soon as
CH water flow is restored
CH water does not flows
Check the pump
Inadequate water flow in the system
Insufficient water in CH system
CH system is leaking
Primary flow switch is disconnected
Primary flow switch does not intervene: it is faulty
Fan is not correctly connected
Check CH system
Load CH system
Check CH system
Reconnect it
Replace it
Check the fan
The boiler is not operating, no. 3 (red) and no. 8 (yellow) LEDs are simultaneously flashing.
Boiler will automatically resume operation as soon as malfunction ends
Fan is not correctly operating
The boiler is not operating, no. 2 (red) and no. 8 (yellow) LED are simultaneously flashing.
Boiler will automatically resume operation as soon as malfunction ends
Flow probe is not operating
No. 2 LED (red) is flashing.
Boiler will automatically resume operation as soon as malfunction ends
DHW probe is not operating
Fan is faulty
Flow probe is disconnected
Flow probe is faulty
DHW probe is disconnected
DHW probe is faulty
Replace it
Reconnect it
Replace it
Reconnect it
Replace it
36
BOILER STATUS MALFUNCTION
No. 2 (red) and no. 8 (yellow) LEDs are alternatively flashing (in KR boilers with external cylinder equipped by NTC probe).
Boiler will automatically resume operation as soon as malfunction ends
Cylinder probe is not operating
No. 4 (red) and no. 8 (yellow) LEDs are simultaneously flashing.
Boiler will automatically resume operation as soon as malfunction ends
The boiler is not receiving data from remote control
Boiler is not operating in DHW mode (KC)
DHW flow switch is not operating
PROBABLE CAUSE
Flow probe is disconnected Reconnect it
SOLUTION
Flow probe is faulty Replace it
Remote control connection is interrupted Check connections of remote control
Remote control is faulty Replace remote control
The system has inadequate pressure or flow rate
Check DHW system
Check flow switch filter
Flow switch sensor is faulty or disconnected
Flow switch is blocked
Replace it or reconnect it
Replace it
37
38
39
COD. 0LIBMUEN10
40
Fondital S.p.A.
2507 9 V OBARNO (Brescia) Italy - Via Cerreto , 40
Tel. +39 0365 878 31 - Fax +39 0365 878 576 e mail: [email protected] - www.fondital.it
The manufacturer reserves the right to modify the data contained herein at any time without notice.
Uff. Pubblicità Fondital IST 03 C 234 - 01 Gennaio 2007 (01/2007)

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