Fondital ITACA KB 24 Installation, Use And Maintenance Manual
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Fondital ITACA KB 24 Installation, Use And Maintenance Manual

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ITACA KB
24 - 32
INSTALLATION, USE AND MAINTENANCE
EN
Translation of the
original instructions (in
Italian)

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  • Page 1 ITACA KB 24 - 32 INSTALLATION, USE AND MAINTENANCE Translation of the original instructions (in Italian)
  • Page 2 Dear Sirs, thank You for choosing and buying one of our products. Please read these instructions carefully in order to properly install, operate, and maintain the product. WARNING • We inform users that: • Boilers shall be installed by an authorised company under the requirements set forth by the prevailing rules, in full compliance with the prevailing regulations and standards.
  • Page 3 General notes for installing and maintenance technicians, and users This instruction manual is an integral and essential part of the product. It shall be supplied by the installer to the user who shall keep it carefully to consult it whenever necessary. This document shall be supplied together with the equipment in case the latter is sold or transferred to others.
  • Page 4 DANGER With gas fired boilers, take the following measures if 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 cock. •...

  • Page 5: Rapid Operating Instructions

    Rapid operating instructions The following instructions will help you to switch the boiler on quickly and regulate it for immediate use. WARNING It is presumed that the boiler has been installed by a qualified installer, it has been commissioned and is ready to operate correctly. If any accessories have been fitted on the boiler, these instructions will not cover them.

  • Page 6: Table Of Contents

    Instructions for the user ............Control panel .......................................
  • Page 7 Decommissioning, disassembly and disposal ........Malfunctions, possible causes and solutions .
  • Page 8 Fig. 1 Control panel ......................Fig.
  • Page 9 Tab. 1 Displayable parameters with info button ................. Tab.

  • Page 10: Instructions For The User

    1. Instructions for the user Control panel Fig. 1 Control panel A. Temperature selection (day/night) and information recall. B. Weekly programme for temperature zones and manual programme selection. C. Time and ambient temperature setting. D. Set the domestic hot water (DHW +/-). E.
  • Page 11 Ref. Symbol Steady on Flashing Indication of "parameter" inside the Not used parameter menu Displaying of the number of parameters, or of the system pressure, Not used or of the burner power percentage Lit flame indication Not used Indication of the temperatures and values of fault and shutdown Not used parameters...
  • Page 12 Ref. Symbol Steady on Flashing Displaying of the fictitious Not used ambient temperature set-point Indication of the centigrade Not used degrees During parameter setting, the 'wrench' symbol stays on until Not used the value is confirmed. Indication of system pressure Not used measurement unit Percentage indication...

  • Page 13: Interpreting Boiler Status From Display Indications

    Interpreting boiler status from display indications 1.2.1 Normal operation Boiler switch in OFF mode. Boiler switch in SUMMER or WINTER mode or CH ONLY. No active function. The flow temperature and the heating system pressure are displayed. SUMMER WINTER CENTRAL HEATING ONLY Boiler switch in SUMMER or WINTER mode.

  • Page 14: Selecting The Operating Mode

    Selecting the operating mode Whenever key is pressed, the "SUMMER”, “WINTER” , “CH ONLY”, “OFF” modes are enabled in sequence. At this stage, all buttons are enabled. "OFF" operating status When the "OFF" mode is enabled, no function is active. "SUMMER"...

  • Page 15: Comfort Function Enable/Disable

    Comfort function enable/disable This function always keeps the water heater warm, without considering the programming of water heater heating time (see par. Programming mode for heating and water heater on page 21). When the "COMFORT" icon is on, the function is enabled. When it is off the function is disabled and the boiler follows the set water heater hour programming (see par.

  • Page 16: Adjusting Heating And Dhw Temperature

    Adjusting heating and DHW temperature Press button +/- DHW to select the desired DHW temperature. During selection, icon will flash. In the phase in which the icon is flashing, only the buttons to adjust the temperature are enabled. As soon as button is released, icon will continue flashing for approx. 3 seconds, and temperature value will flash as well.

  • Page 17: Time Setting

    Time setting To set time, minutes and day of the week, press Flashing values can be edited by pressing CH +/- buttons. The first value to be modified is "HOURS". Press OK to confirm the edited values and shift to next parameter. The second value to be modified is "MINUTES". Flashing values can be edited by pressing CH +/- buttons.

  • Page 18: Day Temperature" And "Night Temperature" Setting

    "Day temperature" and "night temperature" setting When one or more ambient probes are connected to boiler electronic board, two levels of desired ambient temperatures can be set. Boiler will manage the heating request based on the set temperatures, as follows. If no ambient probe is connected to the boiler, temperatures cannot be set.

  • Page 19: Automatic" Programme Setting

    Press CH +/- buttons to edit "night temperature" values. Press OK to confirm the edited values and quit the setting mode. "Automatic" programme setting The selection of "automatic" mode, identified by symbol , allows boiler to enable heating of both zones in "day temperature" or "night temperature", based on the programming envisaged for zone 1 and zone 2.

  • Page 20: Manual" Programme Setting

    "Manual" programme setting The "manual" mode selection indicated with symbol , allows activating the heating function, 24 hours a day, in both zones at the "day temperature", disabling at the same time zone 1 and zone 2 programming. External water heater, if there is one, is heated according to the specific programme. Press to access the manual programme setting mode.

  • Page 21: Programming Mode For Heating And Water Heater

    1.10 Programming mode for heating and water heater To access zone 1 heating programme displaying or editing, press button twice. The display shows zone 1 symbol flashing, sun or moon symbols, bars on or off, respectively , at 00:00.Clock lights display the programming connected to day 1 (Monday) and 00:00 bar is flashing. Press OK to access zone programming function."PROG"...

  • Page 22: Parameter Display

    1.11 Parameter display Press to scroll the different parameter values. You can quit this function at any time by simply pressing the button. To find the meaning of all parameters, see TSP parameters on page 58. Par. DESCRIPTION P30 - TSP30 external temperature displayed (if an external probe is installed).

  • Page 23: Boiler Operation

    1.14 Boiler operation 1.14.1 Switching on DANGER It is presumed that the boiler has been installed by a qualified installer, it has been commissioned and is ready to operate correctly. • Open the gas shut-off cock. • Turn the master switch installed ahead of the boiler to ON. •...
  • Page 24 1.14.3 DHW function The boiler is equipped with a stainless steel water heater with 45 litres single coil. DHW production function may be enabled by the user in two ways: • setting a water heater hour programming on the boiler (see par. Programming mode for heating and water heater on page 21); •...
  • Page 25 1.14.6.1 Ambient probe freeze protection function If the boiler board is OFF, or DHW ONLY, and the ambient probes detect a temperature below 5°C, a heating request to heat the probe- controlled room is launched. The heating function ends when the probe ambient temperature reading reaches +6°C. 1.14.6.2 Flow freeze protection function When the heating water temperature sensor detects a water temperature of +5 °C, the boiler switches on and stays on at its minimum heat output until the temperature reaches +30 °C or 15 minutes have elapsed.

  • Page 26: Boiler Shut-Down

    1.14.9 Operation with (optional) remote control The boiler can also be connected to a Remote Control (optional - not compulsory, supplied by the manufacturer) so as to manage several boiler parameters, such as: • boiler status selection. • ambient temperature selection. •...
  • Page 27 1.15.3 Shut-down due to low water pressure If "shutdown due to insufficient pressure in system" error E04 starts flashing (indicating safety water pressure switch triggering), fill the system by opening the filler cock as shown in Fig. 2 Filler cock.E04 error is displayed when system pressure drops below 0.4 bar and error will be automatically reset as soon as system pressure reaches 1.0 bar.
  • Page 28 1.15.6 Alarm due to (optional) Remote Control connection malfunction The boiler recognises whether or not there is a Remote Control (optional, not compulsory). If the boiler does not receive information from the Remote Control after the Remote Control itself is connected, the boiler attempts to re- establish communication for 60 seconds, after which the fault code E31 is shown on the remote control display.

  • Page 29: Maintenance

    1.16 Maintenance WARNING The boiler must be serviced periodically as indicated in the relevant section of this manual. Appropriate boiler maintenance ensures efficient operation, environment preservation, and safety for people, animals and objects. Boilers must be maintained by qualified personnel only, under the requirements set forth by the prevailing rules. WARNING The user may only clean the external casing of the boiler, employing common household products.

  • Page 30: Technical Features And Dimensions

    2. Technical features and dimensions Technical features The boiler is equipped with a fully pre-mixed gas burner. The following model is available: • KB: condensing boiler with sealed chamber and forced draught, supplying CH water and domestic hot water through integrated water heater.
  • Page 31 2.1.3 Operating features • CH electronic flame modulation with timer-controlled rising ramp (60 seconds, adjustable). • Electronic flame modulation in DHW mode. • DHW function priority. • Flow freeze protection function: ON 5°C; OFF 30°C or after 15 minutes of operation if CH temperature > 5 °C. •...

  • Page 32: Dimensions

    Dimensions 61 88 Fig. 3 Dimensions CH system flow (3/4”) Cold water inlet (1/2") Gas inlet (1/2”) DHW outlet (1/2”) CH system return (3/4”) DHW recirculation inlet (1/2") Filler cock DHW drain cock CH discharge cock Condensate drain and safety valves Technical features and dimensions...

  • Page 33: Key Components

    Key components Fig. 4 Key components Condensate trap 14. Air intake and flue gas venting duct Motorised 3-way valve 15. Flue gas temperature sensor on exchanger Modulating gas valve 16. Magnesium anode Pressure transducer 17. Coil air bleed valve 3-bar safety valve (CH) 18.

  • Page 34: Boiler Layouts

    Boiler layouts Fig. 5 Hydraulic diagram Condensate trap Condensate drain Modulating gas valve Gas inlet Flow temperature twin probe CH system flow Combustion fan CH system return Heat exchanger DHW outlet Deaerator on exchanger Cold water inlet Air intake duct Flue gas venting duct Flue gas analysis ports 10.

  • Page 35: Operating Data

    Operating data Burner pressures reported in the following page must be verified after the boiler has been operating for 3 minutes. Gas category: II2H3P Gas mains pressure Diaphragm diameter Fuel Nozzle [mm] Flue CO2 value [%] [mbar] [mm] Natural gas G20 9.0 ÷...

  • Page 36: General Characteristics

    General characteristics Description KB 24 KB 32 CH nominal heat input 23,7 30,4 CH minimum heat input Maximum heat output (80-60°C) - CH 22,8 29,4 Minimum heat output (80-60°C) - CH Maximum heat output (50-30°C) - CH 25,0 32,2 Minimum heat output (50-30°C) - CH Minimum CH system pressure Maximum CH system pressure DHW maximum heat input...
  • Page 37 Description Max. output Min. output 30% load Casing heat loss with burner on 1,13 6,54 Casing heat loss with burner off 0,30 Flue system heat loss with burner on 2,67 2,06 Flue system mass capacity 12,43 1,33 Flue gas temperature - Air temperature °C Heat efficiency (80-60°C) 96,2...

  • Page 38: Erp And Labelling Data

    Annual electricity consumption Annual fuel consumption Contact details: FONDITAL S.p.A. - Via Cerreto, 40 I-25079 VOBARNO (Brescia) Italia - Italy (*) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet. (**) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).
  • Page 39 Annual electricity consumption Annual fuel consumption Contact details: FONDITAL S.p.A. - Via Cerreto, 40 I-25079 VOBARNO (Brescia) Italia - Italy (*) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet. (**) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).

  • Page 40: Instructions For The Installer

    3. Instructions for the installer Installation standards This boiler must be installed in compliance with the laws and standards in force in the country of installation, which are herein considered as entirely transcribed. To find out about the gas category and technical specifications, refer to operation data and general features specified in the previous pages. DANGER Accessories and spare parts for installation and service procedures are to be supplied by the Manufacturer.

  • Page 41: Choosing Where To Install The Boiler

    Choosing where to install the boiler The following must be taken into account when choosing where to install the boiler: • indications contained in paragraph Air intake and flue gas venting system on page and its sub-paragraphs. • check the wall for sturdiness, avoiding weak areas. •...
  • Page 42 Fig. 6 Paper template Instructions for the installer...

  • Page 43: Installing The Boiler

    Installing the boiler DANGER Before connecting the boiler to CH and DHW networks, clean the pipes carefully. Before commissioning a NEW system, clean it to remove any metal chips due to machining and welding, and any oil and grease that might negatively affect boiler operation or even damage it in case they get inside it.

  • Page 44: Boiler Room Ventilation

    Boiler room ventilation The boiler has sealed combustion chamber. Combustion air is not drawn from boiler room, therefore no specific recommendations need to be applied concerning the boiler room or openings and ventilation provided to the boiler room. DANGER the boiler must be installed in a room that is compliant with the legislation and standards in force in the country of installation, which are herein considered as entirely transcribed.
  • Page 45 Fig. 8 Installation examples Air intake Flue gas vent Condensate Rain Instructions for the installer...
  • Page 46 3.6.1 Possible configuration of air intake and flue gas venting ducts 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 with anti-wind gust device;...
  • Page 47 3.6.2 Ø 100/60 mm and Ø 125/80 mm air/flue gas coaxial duct system WARNING The information given above is with reference to air intake/flue gas venting ducts made from smooth, rigid pipes approved and supplied by the manufacturer. C13 installation type KB 24 •...
  • Page 48 C33 installation type KB 24 • Minimum permissible length of vertical coaxial pipes is 1 meter. • Maximum permissible length of Ø 100/60 mm vertical coaxial pipes is 10 meters. • Maximum permissible length of Ø 125/80 mm vertical coaxial pipes is 14.5 meters. •...
  • Page 49 3.6.3 Air intake and flue gas venting via 80 mm split pipes Installation types C43 - C53 - C83 KB 24 • Minimum permissible length of air intake pipe is 1 meter. • Minimum permissible length of flue gas venting pipe is 1 meter. •...
  • Page 50 Fig. 11 Type C43 - C53 - C83 split ducts A. Gasket 61 88 Fig. 12 Type C43 - C53 - C83 split pipes dimensione Instructions for the installer...

  • Page 51: Checking Combustion Efficiency

    Checking combustion efficiency 3.7.1 Flue cleaning function • The boiler features a flue cleaning function which must be used to measure combustion efficiency during operation and to adjust the burner. • To enable the flue cleaning function, press the key and keep it pressed for 3 seconds. •...

  • Page 52: Connection To Gas Mains

    Connection to gas mains Cross-section gas pipe size must be chosen depending on its length, layout pattern, gas flow rate. Gas supply pipe cross-section must be equal or greater than boiler gas pipe. DANGER Comply with installation standards enforced in the country where the boiler is installed which are considered as fully transcribed in this booklet.
  • Page 53 3.9.2 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 water heater. The cold water inlet and the DHW outlet must be connected to the respective 1/2” connectors C and F on the boiler (see Fig. 6 Paper template). Hardness of water supplied to the boiler may increase the plate heat exchanger cleaning/replacement intervals.

  • Page 54: Connection To Electrical Mains

    3.10 Connection to electrical mains The boiler is supplied with a three-poled power cable, already connected to the electronic board and it is provided with a safety clamp. The boiler is to be connected to a 230V-50Hz electrical power supply. When connecting it to power mains, follow correct phase / neutral polarity sequence.

  • Page 55: Installation And Operation With Open Therm Remote Control (Optional)

    3.12 Installation and operation with Open Therm Remote Control (optional) WARNING Only use original Remote Control Units supplied by the manufacturer. The correct operation of the Remote Control itself and of the boiler is not guaranteed if non original Remote Control units not supplied by the manufacturer are used.
  • Page 56 3.12.1 Installation of the (optional) external probe and sliding temperature operation The boiler can be connected to an (optional) external temperature probe (optional, provided by the manufacturer) for sliding temperature operation. WARNING Only original external temperature probes supplied by the manufacturer must be used. If non-original external temperature probes are used, correct operation of the boiler and external probe cannot be guaranteed.
  • Page 57 The figure shows the curves for a fictitious ambient temperature of 20°C.Parameter P10 allows selecting the curve value shown (see Fig. 16 Thermoregulation curves). If fictitious ambient temperature value is edited on boiler display, the curves shift up or down, respectively, by the same amount. With a fictitious ambient temperature setting of 20°C, for example, if you select the curve corresponding to parameter 1 and the outdoor temperature is - 4°C, the CH flow temperature will be 50°C.

  • Page 58: Tsp Parameters

    3.13 TSP parameters The boiler operation is controlled by several parameters. To change the parameters, press at the same time for 3 seconds. Scroll through the parameters by pressing CH +/- buttons. Set onto the required one and press symbol turns on to indicate that you can edit the parameter value. The parameter value can be edited using CH +/- buttons.
  • Page 59 Parameter Settable Default values Notes values P39 Set point of zone 4 flow temperature only with three zone boards connected P40 Current zone 4 flow temperature only with three zone boards connected P43 Boiler return temperature P44 Water heater temperature P45 Flue gas temperature P49 Ambient probe SA1 temperature only with connected ambient probe...

  • Page 60: Filling The System

    Parameter Settable values Default values Notes P78 Interface back-lighting 0 = standard; 1 = LCD always on 0 ÷ 2 switching on 2 = LCD and keys always on 0 = standard function; 1 = relay P80 Multifunction relay forcing 0 ÷...

  • Page 61: Starting Up The Boiler

    3.15 Starting up the boiler 3.15.1 Preliminary checks Before starting the boiler, check that: • the flue gas venting duct and the relative terminal are installed in conformity with the instructions: when the boiler is working there must be no leakage of combustion by-products from any of the gaskets. •...

  • Page 62: Available Head

    3.16 Available head The boiler is equipped with a high-efficiency circulation pump with variable speed. Circulation pump speed is automatically managed by the electronics, according to the settings of boiler parameters. It is possible to choose between two pump working modes: 1.

  • Page 63: Wiring Diagram

    3.17 Wiring diagram OT o TA1 n.a. n.c. 230V a.c 485A 485B Conn_D Conn_F SF SR1 SR2 CN_J Conn_E CN_C CN_C CN_E CN_E Conn_C CN_H CN_H CN_B Conn_B CN_J CN_A CN_A CN_D CN_D 0SCHEMOD27 CN_M Conn_A ACC1 CN_L CN_L CN_I X7 X6 X5 X4 X3 X2 CN_M CN_I...
  • Page 64 Internal connections DK : ....pressure transducer SBC : ... . . water heater NTC probe 10k Ohm at 25°C B=3435 SRT :.
  • Page 65 3.17.2 Multifunction relay setting diagrams The control panel features a multifunction relay, to be set through the parameter P17-TSP17 Solenoid valve, coupled to Remote Control Solenoid valve with limit swich Fig. 21 Relay with remote control and TA2 Solenoid valve, coupled to Remote Control Solenoid valve with limit swich...
  • Page 66 CIRCULATION PUMP, coupled to Remote Control Fig. 23 Relay with remote request (P17=1) CIRCULATION PUMP, coupled to ambient thermostat (TA) Fig. 24 Relay with TA2 request (P17 = 3) Instructions for the installer...
  • Page 67 REMOTE CONTROL OR BOILER INTERFACE (NOT BOTH) Fig. 25 Relay with alarm alert (P17 = 0) DIAGRAM PARAMETER SETTING (SOLAR PLANT EXCLUDED) Error signalling relay Relay controlled by TA1 or by the Remote Control Relay controlled by TA2 or by the interface Tab.

  • Page 68: Adaptation To Other Gas Types And Burner Adjustment

    3.18 Adaptation to other gas types and burner adjustment WARNING This boiler is built to run on the type of gas specified on the order, which is shown on the packaging and on the boiler rating plate. Any later transformation is to be exclusively carried out by qualified personnel, using manufacturer designed accessories and following the procedure and adjustment instructions for an accurate boiler setting-up.
  • Page 69 3.18.2 Switching from PROPANE to NATURAL GAS • Disconnect the boiler from the electric power supply. • Remove boiler outer front panel. • Loosen the three screws securing combustion chamber front panel to frame, then remove panel. • Loosen the screw securing intake pipe to mixer, and remove pipe (see Fig. 26 Intake pipe). •...
  • Page 70 Fig. 26 Intake pipe Fig. 27 Mixer Fig. 28 Mixer plastic body Fig. 29 Assembling direction A. Gas valve B. Mixer C. Air intake D. Gas pipe E. O-ring F. Nozzles G. Venturi to mixer retaining screws H. Gas fitting I.
  • Page 71 3.18.3 Edit parameter P0-TSP0 and ON at the same time for three seconds. Press Scroll through the parameters by pressing CH +/- buttons. As soon as you reach the one to be modified, press The wrench symbol turns on and indicates you can edit the parameter value. The parameter value can be edited using CH +/- buttons.
  • Page 72 Fig. 30 Adjusting CO2 value Fuel CO2 value (%) 24 kW Methane 9,0 - 9,3 24 kW Propane 32 kW Methane 9,0 - 9,3 32 kW Propane Tab. 14 Flue CO2 content Model Natural gas Propane 24 kW 3,70 3,00 32 kW 4,45 3.55 + diaphragm Ø...

  • Page 73: Testing The Boiler

    4. Testing the boiler Preliminary checks Before testing the boiler, it is recommended to check the following: • the flue gas venting duct and the relative terminal are installed in conformity with the instructions: there must be no leakage of combustion by-products from any of the gaskets.

  • Page 74: Maintenance

    5. Maintenance WARNING Any maintenance (and repair) work must only be carried out by qualified personnel. The user is strongly advised to have the product serviced and repaired by a service centre or qualified personnel. Appropriate boiler maintenance ensures efficient operation, environment preservation, and safety for people, animals and objects. The boiler must be serviced at least once every year.
  • Page 75 6. Decommissioning, disassembly and disposal Warning If you decide to definitively decommission the boiler, have decommissioning, disassembly and disposal procedures carried out by qualified personnel, only. The user is not authorised to carry out such operations. Decommissioning, disassembly and disposal operations must be performed with boiler cold and disconnected from gas and power mains. The materials the boiler is made of can all be recycled.

  • Page 76: Troubleshooting

    7. Malfunctions, possible causes and solutions Troubleshooting BOILER STATUS MALFUNCTION PROBABLE CAUSE USER'S TASKS QUALIFIED PERSONNEL'S TASKS Check gas supply. Gas supply failure. Check gas supply cock or gas network safety valve intervention. Gas valve is disconnected. Contact qualified personnel Reconnect it.
  • Page 77 BOILER STATUS MALFUNCTION PROBABLE CAUSE USER'S TASKS QUALIFIED PERSONNEL'S TASKS Flow probe is electrically Contact qualified personnel Reconnect it. disconnected. E05** CH probe failure Flow probe faulty. Contact qualified personnel Replace it. Flue probe is electrically Contact qualified personnel Reconnect it. disconnected.
  • Page 78 BOILER STATUS MALFUNCTION PROBABLE CAUSE USER'S TASKS QUALIFIED PERSONNEL'S TASKS Check that the P17 and P18 Wrong boiler board or solar parameter set values match Hydraulic system setting error. Contact qualified personnel board setting parameters. with those specified on the reference tables.
  • Page 80 Fax +39 0365/878.304 e mail: info@fondital.it www.fondital.com The manufacturer reserves the right to modify his/her products as deemed necessary, without altering the basic characteristics of the products themselves. Uff. Pubblicità Fondital IST 03 C 845 - 01 Luglio 2015 (07/2014)

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