Fondital Tahiti Condensing 24 kW Combi (KC), Installation, Use And Maintenance Manual

Page 1: ...INSTALLATION USE AND MAINTENANCE TAHITI CONDENSING GB Gas fired wall Mounted condensing boiler Tahiti Condensing 24 28 32 kW Combi KC Tahiti Condensing 24 28 32 kW Regular KR High quality Italian product MADE IN ITALY ...

Page 2: ...re 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 Ins...

Page 3: ... 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 ...

Page 4: ...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 wh...

Page 5: ...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...

Page 6: ...4 2 System details pag 25 4 2 1 Central heating circuit pag 25 4 2 2 Filling the central heating system pag 25 4 2 3 Domestic hot water circuit pag 25 4 3 Site requirements pag 26 4 3 1 Choosing where to install the boiler pag 26 4 3 2 Positioning the boiler pag 26 4 3 3 Boiler room ventilation pag 28 4 3 4 Flue pag 28 4 4 Installation authorised personnel pag 29 4 4 1 Packaging pag 29 4 4 2 Insta...

Page 7: ...n 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 do mestic hot water s...

Page 8: ...his case the symbol m comes on simultaneously i Thermoregulation indicator for fitter only This comes on when the thermoregulation curve is set l Virtual ambient temperature indicator When an external probe is installed this indicator flashes when the virtual ambient temperature is set on regulator 4 pic 1 m Fan rev counter for fitter only When the chimney sweeper function is activated the symbol ...

Page 9: ...nction active The boiler water temperature is displayed only for model KR with an optional external boiler Table 1 BOILER STATUS LCD in normal operation Malfunction No electric power Flame absence shutdown Safety thermostat shutdown Flue gas thermostat shutdown Flow primary temperature sensor alarm DHW temperature sensor alarm Only for KC model Water tank temperature sensor alarm Only for model KR...

Page 10: ...mmed to have an anti cycling time between subse quent 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 4 5 6 paragraph anti cycling procedure is aborted and boiler re ignited 2 4 3 DHW function Turn the regulator 3 pic 1 to set the domestic hot water temperature DHW opera...

Page 11: ...n through no 2 knob 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 freeze function protects the domestic hot water system as well When domestic hot wat...

Page 12: ... Boiler microprocessor program determines CH water temperature variations When an external temperature probe is connected to the boiler CH water temperature adjusting knob no 4 pic 1 loses its function and becomes a virtual room temperature adjusting device During temperature setting the virtual ambient temperature symbol flashes and the temperature setting is displayed When no 4 knob is turned fu...

Page 13: ...dequate air flue gas draught Should the boiler shut down due to air intake and or flue gas discharge ducts malfunction the burner shutdown symbol is displayed and code E03 flashes intervention of flue gas thermostats Should the above happen contact the Fondital helpline UK or CORGI registered engineer with appropriate competence for service 2 5 4 Shut down due to incorrect fluid circulation Should...

Page 14: ...unction is deactivated The temperature of the CH water is regulated according to the position of regulator 4 pic 1 which in this case loses its function as a virtual ambient temperature regulator see 2 4 6 Contact the Fondital helpline UK 08700 34 88 20 or CORGI registered engineer with appropriate competence for service 2 6 Maintenance Have the boiler routinely serviced following the schedule des...

Page 15: ...ng device 13 liter min KC 24 14 liter min KC 28 16 liter min KC 32 Boiler mode selector OFF RESET WINTER SUMMER ANTI FREEZE CH temperature adjusting switch 20 78 C standard range or 20 45 C reduced range DHW temperature adjusting switch KC 35 57 C CH water pressure gauge Liquid crystal display LCD showing the boiler operating status CH mode electronic flame modulation timer controlled flame rising...

Page 16: ...ug F CH system flow DHW Domestic hot water draw off KC model only CWI Cold water inlet KC model only SV 3 bar safety valve drain cock R CH system return RS Drain cock Bottom view Top view 139 5 135 148 90 90 77 325 750 450 138 177 56 98 75 98 80 71 43 46 G F CWI R S DHW SI SV RS ...

Page 17: ...nt Circulation pump Gas valve 3 bar safety valve Electronic ignition circuit board Water pressure switch Domestic cold water flow switch d h w sensor d h w heat exchanger Condensate drain trap Electric van Safety thermostat Heating sensor Ignition electrode Burner unit Primary fluid flow meter pic 6 ...

Page 18: ...with filter 24 Secondary plate exchanger 25 DHW probe 26 Automatic by pass 27 Motorized 3 way valve S Condensate drain G Gas intake F CH system flow DHW DHW flow CWI 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 pu...

Page 19: ...ax CH input kW CH output 80 60 C kW CH output 50 30 C kW DHW output kW Gas mains pressure mbar Diaphragm Ø mm Flue gas CO2 min max min max min max Methane gas G20 31 4 8 7 30 63 9 6 33 2 9 6 35 4 20 8 4 8 8 9 1 Propane gas G31 31 4 8 7 30 63 9 6 33 2 9 6 35 4 37 6 0 9 8 10 1 Table 5 KC 32 model adjustment rates Hot water supply ΔT 45 C 11 3 l min Hot water supply ΔT 40 C 12 7 l min Hot water suppl...

Page 20: ...ut Casing heat loss with burner on 1 4 2 1 Casing heat loss with burner off 0 2 Chimney heat loss with burner on 2 6 2 2 Flue gas system mass flow rate g s 12 4 3 1 Flue gas temp air temp C 67 49 Maximum heat output efficiency rating Net 60 80 C 97 5 Maximum heat output efficiency rating Net 30 50 C 104 8 Minimum heat output efficiency rating Net 60 80 C 95 7 Minimum heat output efficiency rating ...

Page 21: ...5 145 Electric protection rating IP X4D X4D X4D Net weight kg 37 5 38 2 39 0 Methane gas consumption at maximum CH input ft3 h 88 6 97 9 117 4 Propane gas consumption at maximum CH input ft3 h 34 3 37 9 45 4 Maximum CH working temperature C 83 83 83 Total capacity of expansion vessel l 10 10 10 Maximum recommended CH system capacity l 200 200 200 Table 13 KR model general specifications Value refe...

Page 22: ...ing to 92 42 CE SEDBUK classification A 90 1 NOx emission class 5 Table 15 KR 28 model combustion rates KR 32 Max heat output Min heat output 30 heat output Casing heat loss with burner on 0 6 1 6 Casing heat loss with burner off 0 2 Chimney heat loss with burner on 2 4 2 1 Flue gas system mass flow rate g s 15 7 4 1 Flue gas temp air temp C 54 51 Maximum heat output efficiency rating Net 60 80 C ...

Page 23: ...d III max 600 500 400 300 200 100 0 0 200 400 600 800 1000 KC KR 24 model Flow rate l h Head available mbar KC KR 28 model Flow rate l h Head available mbar 600 500 400 300 200 100 0 0 200 400 600 800 1000 KC KR 32 model Flow rate l h Head available mbar V1 V2 V3 ...

Page 24: ...ved 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 Specific...

Page 25: ...tallation 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 Provi sion should be made to replace water lost from the system This can be by manual or automatic means as shown in Pics 10 and 11...

Page 26: ...l 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 dis...

Page 27: ...27 G F DHW CWI R S Domestic hot water Cold water inlet CH system return Gas Condensate drain DHW CWI R F G S G F DHW CWI R S pic 13 ...

Page 28: ...g 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 Above ground roof or balcony level 300 J From a surface or boundary line facin...

Page 29: ...and DHW circuits clean the pipes carefully in accordance with BS 7593 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 slu...

Page 30: ...ensioned 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 tes...

Page 31: ... the condensate produced by combustion is to be routed via the condensate drain S in pic 5 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 s...

Page 32: ...ion 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 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 transcr...

Page 33: ...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 combust...

Page 34: ...efore 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 pip...

Page 35: ...h 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 i...

Page 36: ... 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 ...

Page 37: ...d 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 Selecting central heating output range CH water temperature adjusting choice depends...

Page 38: ...at wiring must not be grouped together with power mains supply cables 4 5 8 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 25 Only original external temperature probes supplied by the manufacturer ...

Page 39: ...ed outdoor temperature selected thermoregulation curve selected virtual room temperature The thermoregulation curve is selected via the thermoregulation trimmer in pic 27 During setting the thermoregulation symbol flashes and the value is displayed The thermoregulation trimmer position selects CH operation temperature range in relation to the following values The virtual room temperature is set vi...

Page 40: ...ation 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 th...

Page 41: ...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 Chec...

Page 42: ... for tightness 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 pr...

Page 43: ...n pic 30 for at least 10 seconds the boiler turns off and resumes the ignition sequence again to the maxi mum heat output corresponding to max trimmer setting pic 30 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 2 selector to any position other than WINTER for a 10 seconds and then to the desired p...

Page 44: ...e 2 Note 2 only in KR equipped by external cylinder with NTC probe and temperature regulation on the boiler See note 1 Note 1 only in KR equipped by external cylinder with NTC probe and temperature regulation on the boiler Only KC model Only KC model Only KC model pic 32 6 5 Wiring diagram ...

Page 45: ...arge system and exchanger TR ACC ignition transformer SR CH probe 10k Ohm ß 3435 TIMER CH electromechanical day timer SS DHW probe 10k Ohm B 3435 three meter max length CM1 CM2 boiler type selection jumpers FL DHW flow switch FLP flow switch preventing low water pressure operation CH DK Water pressure switch VG gas valve TL limit thermostat P1 CH flow temperature potentiometer P2 DHW temperature p...

Page 46: ...46 7 Spare part list pic 33 KC model ...

Page 47: ...47 pic 34 KR model ...

Page 48: ...7 Tripple lipped seal 1 15 6VENTILA11 Ventilator 1 16 6YTRAACC00 Ignition transformer 1 17 6CIRCOLA07 Circulating pump 1 18 6FILTRIT00 Return filter CH 3 19 6SCAMPIA06 26 plate heat exchanger only KC model 1 20 6ORSCAPI00 Plate heat exchanger o ring seal only KC model 10 21 6CORPVAL02 Condensing 3 way valve unit only KC model 1 22 6PROATTT00 Actuator programmer only KC model 1 23 6BASFLUS01 Heatin...

Page 49: ...e boiler has shut down The symbol is displayed and code E03 flashes Turn selector 2 to RESET to resume boiler operation One of the boiler safety thermo stat has shut boiler down Difficult draught at chimney Check the chimney and ambient air suction grilles Flue gas thermostat faulty Replace it The boiler has shut down The symbol is displayed and code E02 flashes Turn selector 2 to RESET to resume ...

Page 50: ... Storage tank probe faulty Replace it The boiler does not work in DHW mode DHW flow switch does not cut in Model KC System pressure or flow rate too low Check DHW system Check flow meter filter Flow meter sensors disconnected or faulty Replace or reconnect it Flow meter stuck Replace it The boiler does not work properly the symbol is displayed and code E17 flashes Operation is resumed automaticall...

Page 51: ...Yes ALL INSTALLATIONS If required by the manufacturer record the following CO2 OR CO ppm OR CO CO2 Ratio The heating and hot water system complies with the appropriate Building Regulations 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 un...

Page 52: ...s Signature SERVICE 7 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE 9 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE 2 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number CORGI ...

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Page 56: ...mail fondital fondital it www fondital it 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 COD 0xxxxxxx00 Fondital UK Helpline 08700 34 88 20 ...