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MAUI KR 115-280 installation, use and maintenance...
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Dear Customer, We wish to thank you for choosing our condensing device, a technologically advanced and high quality product, which will ensure you high energy efficiency and very low emissions. Our environmentally friendly products will satisfy your comfort needs at very low operating costs.
SAFETY WARNINGS AND STANDARDS • After unpacking, make sure the supplied items are intact and complete. In case of non-compliances, contact the Dealer. • The device must be installed by qualified personnel, in compliance with the national and local prevailing laws as well as with the instructions given in the manual supplied along with the device.
DESCRIPTION maui KR 115-280 aluminium thermal units are heat condensing generators, designed for room heating, and, if combined with a storage-type water heater, also for the production of domestic hot water. They are made up of: - an aluminium body having a low water content and a high exchange surface to maximize energy efficiency and heat output; - a stainless steel and fully pre-mixed micro-flame burner, allowing high modulation ratios, combustion stability and low emissions (NOx Class = 5);...
IDENTIFICATION The device is identified through: - the Rating Plate applied to the casing. WaRninG • Tampered, removed or missing rating plate - or any other event preventing a clear identification of the product - will make any installation and/or maintenance work extremely difficult.
SYSTEM PUMP Choose a pump suitable for the hydraulic resistance of the thermal unit and the system. The diagram shows the curves of the thermal unit flow resistance. 1300 1200 1100 1000 Flow (m It is recommended to strictly comply with the flow rates given in the table and with the instructions below. maui KR 115-280 descRiPtion 4.72...
CONTROL PANEL Warning light - shutdown due to activation of safety devices User interface with display Main switch with light signalling Main fuse (10A) Manual reset safety thermostat Fpc1 Primary pump fuse 1 (6.3A) Fpc1 Fpbl Water heater pump fuse (6.3A) Fpbl Fpc2 Primary pump fuse 2 (6.3A) Fpc2 Fpcs Cascade pump fuse (6.3A) Fpcs - 11...
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maui KR 115-280 menu Lunedi, 24. Settembre 2012 09.37 disPlaY sYmBol descRiPtion D.h.W. OPERATING MODE CENTRAL HEATiNG Ext.temp. DETECTED TEMPERATURE CH REQUEsT ENABLED ExTERNAL PROBE FLOW TEMPERATURE BOiLER WATER CURRENTLY DETECTED PRESSURE Lunedi, 24. Settembre 2012 SET DATE DHW REQUEsT ENABLED 09.37 SET TIME staRt scReen Function description display on/stand-BY stand-BY: Stops the device, blocking the device keys.
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Function description display oPeRatinG mode summeR: DhW production only Ext.temp. ON OFF Lunedi, 24. Settembre 2012 09.37 WinteR: Ch only or Ch and DhW Ext.temp. Ext.temp. Monday, 24. September 2012 Monday, 24. September 2012 09.37 09.37 none: neither Ch, nor DhW. Antifreeze or "Manual test" function active Ext.temp.
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Function description display HolidaY Holiday start Holiday end 20 / 10 30 / 10 Sets the holiday start and end dates and the DhW and 2012 2012 Ch water delivery temperature values for this interval to con rm to con rm User menu User menu Scrolls up screen lines...
UPON RECEIvING ThE PRODUCT maui devices are delivered in a single package placed on a wooden pallet and protected by cardboard and a wooden cage. in the plastic envelope (A) inside the packing you will find: - the installation, use and maintenance manual - the certificate of guarantee with the barcode labels - the hydraulic test certificate - the spare part catalogue WaRninGs...
hANDLING After unpacking the device, handle it as described below: - Remove the front panel (1) to ease the seizing and handling operations. - insert two 1" pipes (2) in the specific holes or slide the fork- lift under (3) the packed device. - Lift and handle the device. WaRninGs • ALWAYs use accident-prevention protections. • in case of manual handling, do not exceed the maximum weight lifted per person. INSTALLATION ROOM The installation room must always comply with the Technical Rules and the prevailing Laws. it must feature suitably sized aeration openings.
NEW INSTALLATION OR REPLACEMENT OF ANOThER DEvICE Follow these instructions when installing the device on old systems or systems to be updated: - in case you are using an existing flue pipe, make sure that it is suitable for the new condensing device, that it has been calculated and manufactured in compliance with the Standards, that it is as straight as possible, sealed, insulated and that it has no obstructions or narrowings.
WaRninGs • iT is FORBiDDEN to soften the water according to the principle of ion exchange. • Never fill the system with distilled or demineralized water as it will severely corrode the aluminium heat exchanger. Use softened water for filling and top-ups to reduce the total hardness. Moreover, the water must be conditioned to keep the ph within the defined range in order to prevent corrosion. • Keep a log of the amount of filling and top-up water, of the water quality checks and of the water treatment checks. •...
BLOCK DIAGRAMS example 1: System flow cH only systems System return example 2: System flow system used for heating and for the production of dHW with water heater downstream the hydraulic separator System return - 20...
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WaRninGs • In case DhW is produced by the water heater pump located on the flow collector, use boiler pump 2 as the system's pump (without mix valve). This allows controlling the operation of these two pumps with priority or in parallel, to prevent the temperature in the Ch circuit from rising.
ELECTRICAL CONNECTIONS maui devices must be connected as described below. The connections must be carried out by the installation technician or by qualified personnel. To access the terminal box (MC): - Remove the front panel (1). - insert the cables in the specific tearproof cable glands (2) located on the terminal box (MC) and run them through the pipe (3) placed inside the casing. Upon completing the connections, refit the front panel (1).
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connections FoR oPeRation in cH and dHW PRoduction mode WitH WateR HeateR PumP and BoileR PumP 2 (sYstem PumP)(example no. 2 on page 20) 44 43 44 43 0-10V PRmax Kit with safety 0-10V devices PRmax General Kit with safety Switch devices General...
WaRninGs It is compulsory: • to use a line isolator omnipolar magnetic breaker, compliant with the EN Standards. • To connect L (Phase) - N (Neutral). • NOT to use cables having a cross-section smaller than 1 mm • To ensure that the grounding conductor is at least 2 cm longer than the L (Phase) - N (Neutral) cables. • For any electrical work please refer to the wiring diagrams in this manual. •...
GAS CONNECTION Connection of maui KR 115-280 devices to the gas supply must be carried out in compliance with the prevailing installation standards. maui KR 115-280 Hydraulic connections Gas supply 1” 1/2 Ø 1088 1088 1088 Prior to executing the connections, make sure that: - The gas is of the type for which the device has been designed - The piping is thoroughly clean and free from processing residuals.
FLUE GAS vENT AND COMBUSTION AIR INTAKE maui KR 115-280 dimensions Øi (internal) Øi Øi “B-tYPe” installations WaRninGs • maui KR 115-280 devices feature a flue gas vent probe which will immediately stop device operation if flue gas temperature rises in an abnormal way. •...
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“c-tYPe” installations maui devices are approved for the "C43, C53, C63 and C83” types of installation and iT is COMPULsORY to fit them with flue gas system ducts and combustion air intake ducts compliant with said types of installation. WARNINGS • In case of installations of “C53” type, the intake and discharge terminals can not be installed on walls opposite the building. in case ducts and outlets from another manufacturer are used (c63-type), they must be approved.
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upon delivery, the thermal unit is in the B23 configuration. To draw air from the outside it is necessary to connect a plastic pipe with diameter 100 to the intake outlet of the device. To suck air from the outside it is necessary to connect a plastic tube (d. 100) to the device intake terminal keeping in mind that such duct must not feature a flow resistance higher than the value specified in the table below. Gas supply and flue gas vent should be in an area having the same pressure.
CONDENSATE DRAIN WaRninGs • the condensate drain duct must be tight and have dimensions suitable for the trap. moreover it must not have any narrowing or reduction of the “i” tilting, which should be ≥ to 3%. • condensate must be drained in accordance with the Prevailing national or local standards. •...
SYSTEM FILLING AND EMPTYING maui 115-280 devices ARE NOT equipped with a system filler cock. It is therefore necessary to arrange a suitable filling system which shall be located in the position most convenient to the installer. As an indication, the picture shows a possible connection point for the system filling unit (Ci).
MENU NAvIGATION AND STRUCTURE navigation procedure The device default factory configuration is STAND-BY. To navigate through menu screens use the keys as indicated in the diagram below. MENU User menu Ext.temp. USER OFF OFF 1. HEATING data NAViGATiON 2. DOMESTIC HOT WATER screen TECHNICIAN 3.
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user menu navigation MENU User menu USER 1. HEATING NAVIGATION 2. DOMESTIC HOT WATER TREE TECHNICIAN 3. HOLIDAY 4. MAINTENANCE 5. SETTINGS 6. DIAGNOSTICS to con rm User menu 1. HEATING 2. DOMESTIC HOT WATER 3. HOLIDAY 4. MAINTENANCE 5. SETTINGS 6.
Factory useR menu Keys sub-menu Keys lines Keys value Range 5. sETTINGs 1. Select language English / Italiano Italiano English / Italiano Fahrenheit / 2. Select unit Fahrenheit / Celsius Celsius Celsius 3. Set date ---> ---> day / month / year 4.
menu line line title meaning ref. 5. sETTINGs Language Language selection (English or Italian) Unit of measurement Unit of measurement selection (Celsius or Fahrenheit) Set date Current date setting of modification Set time 12 or 24 hour format selection - Current time setting or editing Restore factory settings Restores factory settings 6.
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Factory tecHnical menu Keys sub-menu Keys lines Keys value Range 1. ADvANCED CH sETTINGs 1. Maximum power 100% 100% 0 ÷ 100% 1. CH power set 2. Minimum power 0% 0 ÷ 100% 1. Absolute maximum temperature 90°C 20 ÷ 95°C 2.
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Factory tecHnical menu Keys sub-menu Keys lines Keys value Range 3. sYsTEM sETTINGs 1.Ignition power 0÷100% 2. Delay siphon check 0÷60s Pump and 3-way 3.Number of boiler pump Double pump valve / Double pump 4.Pump speed max 100% 15÷100% 5.Pump speed min 15÷100% 1.Boiler parameters 6.Antilegionella...
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Factory tecHnical Keys sub-menu Keys sub-menu Keys lines Keys Range value menu 5. usER sETTINGs 1.Temperature setting 75°C 20 ÷ 90°C range 1.Temperature setting range 2.External switch-off OFF / 7 ÷ 25°C temperature 1.Ch 2.ECO setpoint reduction ---> ---> 50°C 0 ÷...
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tecHnical Factory sub-menu sub-menu lines Range Keys Keys Keys Keys menu value 7.FACTORY sETTINGs To restore factory settings ---> 8. boiler type 1. 60kW ---> 1. G20 2. 100kW ---> 3. 115kW 1. Wall hung boiler ---> 1. 60kW ---> 2.
meaninG oF tecHnical menu items menu line line title meaning ref. 1. CH 1.1.1. Maximum output Maximum cascade pump speed 1.1.2. Minimum output Minimum cascade pump speed 1.2.1 Maximum absolute temperature Setting of the maximum flow temperature that can be tolerated by the device 1.2.2 Maximum set temperature Setting of the maximum flow temperature corresponding to the minimum external temperature...
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menu line line title meaning ref. 3.1.4 Maximum pump speed (Primary) boiler pump maximum speed 3.1.5 Minimum pump speed (Primary) boiler pump minimum speed 3.1.6 Anti-legionella Anti-legionella function enabling or disabling 3.1.7 Boiler body protection Boiler body protection with probe - enabling or disabling 3.1.8 Boiler body delta Setting of flow temperature increase, above which the boiler body temperature sets a fault...
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menu line line title meaning ref. 6. CAsCADE 6.1.1 Cascade module delay Time interval between the ignition of different boilers 6.1.2 Minimum modulation head output Minimum available cascade output 6.1.3 Individual burner heat output Maximum heat output of an individual burner 6.1.4 DHW boilers Number of boilers allocated to DHW...
COMMISSIONING PReliminaRY actiVities By default, when delivered from the factory, maui 115-280 thermal units are: - set for operating with G20 (natural gas), however they can also work with G31 (propane) - with the device in stand-by mode - in "none" operating mode; both CH and DHW requests are inhibited. This prevents the boiler from starting when it is supplied with power Ext.temp.
useR inteRFace setuP FRom tecHnical menu This procedure allows checking or changing the LANGUAGE and UNIT OF MEASUREMENT in use and to set the current date and time. Key to press Description Display MENU to view the MENU screen USER Ext.temp. OFF OFF TECHNICIAN to enter the TECHNiCAL MENU that requires a PASSWORD data To enter PAssWORD "231":...
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Key to press Description Display to select "2. Unit of measurement" User interface settings Select units 1. Select language Fahrenheit 2. Select units Celsius to confirm and access the selected line 3. Set date 4. Set time to edit the desired unit of measurement to con rm to con rm to confirm your selection and go back to line "2. Unit of measurement"...
Key to press Description Display User interface settings Selection format to select "4. set time" 1. Select language 24 hours 2. Select units 12 hours 3. Set date 4. Set time to confirm and access the selected line to con rm to con rm Set time to change time format in use 10 : 05...
Gas cHanGe By default, the thermal unit is preset for G20 when delivered from the factory. To use it with LPG, proceed as follows. Key to press Description Display MENU to view the MENU screen USER Ext.temp. OFF OFF TECHNICIAN to enter the TECHNiCAL MENU that requires a PASSWORD data To enter PAssWORD "231": Technician menu 2 TIMES Insert code to set the first digit "2" 2 3 1 to confirm and move to second digit To select to con rm to set the second digit "3"...
Key to press Description Display Restores factory data to select the heat output corresponding to the device 1. 115kW model 2. 150kW 3. 200kW Please wait 4. 240kW 5. 280kW to confirm your selection and go back to the START screen to con rm to con rm...
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Key to press Description Display To enter PAssWORD "231": Technician menu Insert code to set the first digit "2" 2 TIMES 2 3 1 to confirm and move to second digit To select to con rm to set the second digit "3" 3 TIMES to confirm and move to third digit Technician menu 1.
In case of a malfunction, the device performs a safety shutdown or a safety stop, based on the type of fault/malfunction that occurred, which is shown on the device display. Error message safety shutdown The table below lists the faults/malfunctions that cause a Safety Shutdown. Probe open health ERROR 33 To restore normal operating conditions:...
Visualization on display meaning The flue gas probe detected a temperature Flue gas sensor - open circuit Fault 46 outside the allowed range (probe circuit open) Water pressure switch Fault 47 The water pressure switch is not connected or is faulty Gas Pressure Fault 76 Gas Pressure Low (pressure switch circuit open) Trap fault Fault 77 The trap probe detects an excessive pressure Fault 80 Ret. temp. > Flow temp. Sensor temperature difference test in progress. Fault 81 A negative outcome will generate Fault 15.
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In case they do not match, gradually turn the MAX gas setting screw located on the gas valve until correct combustion values can be detected on the analyser. maui 115 / 150 gas valve maui KR 200-280 gas valve - Press the key to decrease heat output to 0% (see section “MANUAL TEsT FUNCTION” on page 47). This brings the thermal unit to work at its minimum Gas Flow Rate.
exteRnal PRoBe and climate cuRVe When operation requires the use of the external probe (sliding temperature), the MAXIMUM and MiNiMUM FLOW temperatures must be set, as well as the ExTERNAL temperature range, so as to allow the device to determine the climate curve that corresponds to the entered settings. Follow the procedure below: - Access the Technical menu (see page 34) - Access “1. CH” and proceed to line "2. CH temperature" (see page 35) - Press and check the current values...
0..10V inPut cHecK IMPORTANT PREMISES When an external regulator with 0÷10 V signal for heat output control is used, the system must feature, on device flow, an additional temperature probe connected to the external regulator. IF it is not present, this must be installed. DEViCE sETTiNGs With these settings, the device heat output / temperature is managed directly via the 0÷10 V signal, as follows: - Access the Technical menu (see page 34) - Access “1. CH” and proceed to line "6. Request type" (see page 35) - Then select “0-10 V [%] signal”...
ReQuest tYPe According to the device selection (Heating parameter 1.6), the following table shows the priority based on the ambient thermostat and Timer setting conditions. Heating external probe ambient thermostat 0-10 V (heat output or temperature) The thermal unit follows the time setting, respecting the ON, ECO and OFF phases: The thermal unit if = OFF => Request follows the time setting, disabled, thermal unit in respecting the ON, ECO stand-by;...
TIMER SETTING IT is possible to program specific time slots (periods of time) during which the thermal unit has to work if there is a heat request, and time slots during which the thermal unit remains off or in ECO operating mode in case an external probe is present. The maximum number of programmable time slots is 6 within 24 hours. Each time slot must be identified by a start time (ON) and an end time (OFF). The minimum programming time range is half an hour. Key to press Description Display MENU to view the MENU screen USER Ext.temp. OFF OFF TECHNICIAN to enter the USER MENU data to select "1. CH" User menu Heating 1. HEATING 1. DHW setpoint 2. DHW SETTING 2.
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Key to press Description Display Scheduler set Monday Friday 1. --:-- - --:-- -- to select an individual day or a group of days of the 5. Friday 2. --:-- - --:-- -- 6. Saturday week 3. --:-- - --:-- -- 7.
TEMPORARY SWITChING OFF AND hOLIDAY TIME PROGRAMMING This function allows setting the thermal unit operation to reduced capacity during temporary absences, week-ends, holidays and restoring full capacity automatically after a set period of time. WaRninGs • During any holiday periods the device's gas and power supplies must be on to ensure correct operation. The Ch and/or DhW production delivery temperatures must be set by following the procedure below: Key to press Description...
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Key to press Description Display to select "2. DHW temperature" to confirm and access the selected line to con rm Boiler t. setpoint 1. CH holiday setpoint 2. DHW holiday setpoint to set the desired value (for water heaters with probe only) (*) to con rm to con rm to confirm set value and go back to line "2. DHW temperature" Holiday start maui KR 115 to return to start screen 20 / 10 2012...
After cleaning, remove/extract the residues from the condensate collection tank, by opening the inspection door and clean the condensate trap as well. iF in douBt, contact Fondital. Removing the panelling - Open and remove the front (1), side (2) and top (3) panels. - 59...
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- Use a tube-brush, or any other suitable tool, to clean the exchanger lines. A tool (metal blade 12) suitable for the mechanical cleaning of the flue gas lines can be supplied by Fondital as an optional - After cleaning, check the condition of the seals (6) and replace them if necessary.
Disassembling and replacing the electrodes WaRninGs • When disassembling the electrodes, pay the utmost attention not to damage the seals (18) and (19). Replace them if damaged. - Loosen the retaining screws of the electrode unit (20), slide it out and check that it is in a good condition. it is advisable to replace it considering the frequent ignitions of the device.
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Fault cause solution - Air in the system - Bleed system The generator temperature is correct but - Unseize pump the heating systems are cold - System pump - Replace pump - System safety valve - Check calibration or efficiency - Check filling pressure Frequent triggering of system safety valve - System pressure...
CONTROL PANEL Warning light - shutdown due to activation of safety devices User interface with display Main switch with light signalling Main fuse (10A) Manual reset safety thermostat menu Lunedi, 24. Settembre 2012 09.37 disPlaY sYmBol descRiPtion D.h.W. OPERATING MODE CENTRAL HEATiNG Ext.temp. DETECTED TEMPERATURE CH REQUEsT ExTERNAL PROBE...
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Function description display on/stand-BY stand-BY: Stops the device, blocking the device keys. Ext.temp. OFF OFF on: Starts the device, unblocking the device keys. data data oPeRatinG mode summeR: DhW production only Ext.temp. ON OFF Lunedi, 24. Settembre 2012 09.37 WinteR: Ch only or Ch and DhW Ext.temp.
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Function description display HolidaY Holiday start Holiday end 20 / 10 30 / 10 Sets the holiday start and end dates and the DhW 2012 2012 and Ch water delivery temperature values for this interval to con rm to con rm User menu User menu Scrolls up screen lines...
IGNITION AND sWITCHING OFF Commissioning of the device must be carried out by the Technical service personnel; after that the device can run automatically. The person in charge of the system can turn the device on and off as follows: - Power the thermal unit by turning the system (iG) and the device (lp) main switches to “ON”. - The display will show the stand-by screen. - Press to enable device keypad. Ext.temp.
MAINTENANCE We wish to point out that the PERsON iN CHARGE OF THE THERMAL sYsTEM is COMPELLED by Law to have the ROUTiNE MAINTENANCE and the MEASURING OF ThE COMBUSTION EFFICIENCY carried out. These operations should be carried out only by QUALiFiED PERsONNEL The Technical Service is available to perform this important law obligation.
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0LIBBCEN00 Fondital s.p.a. 25079 VOBARNO (Brescia) italy - Via Cerreto, 40 Tel. +39 0365/878.31 - 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 640 - 01 Ottobre 2014 (10/2014)
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