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Fondital ITACA KC 24 Installation, Use And Maintenance Manual Download Page 92

Malfunctions, possible causes and solutions

92

7.  Malfunctions, possible causes and solutions

7.1  Troubleshooting

BOILER STA-

TUS

MALFUNCTION

PROBABLE CAUSE

USER'S TASKS

QUALIFIED PERSON-

NEL'S TASKS

E01*

Burner does not ignite.

Gas supply failure.

Check gas supply.

Check gas supply cock or gas network safety valve 

intervention.

Gas valve is discon-

nected.

Contact qualified person

-

nel

Reconnect it.

Gas valve is faulty.

Contact qualified person

-

nel

Replace it.

The board is faulty.

Contact qualified person

-

nel

Replace it.

Burner does not ignite: no 

spark.

Ignition relay is faulty.

Contact qualified person

-

nel

Replace the electrode.

Ignition transformer is 

faulty

Contact qualified person

-

nel

Replace the ignition tran-

sformer.

Electronic board does not 

ignite. It is faulty.

Contact qualified person

-

nel

Replace electronic board.

Burner ignites for a few 

seconds and goes off.

Electronic board does 

not detect flame: inverted 

phase and neutral.

Contact qualified person

-

nel

Verify correct neutral and 

phase connection.

Detection electrode cable 

is interrupted.

Contact qualified person

-

nel

Reconnect or replace 

wire.

Detection electrode is 

faulty.

Contact qualified person

-

nel

Replace the electrode.

Electronic board does not 

detect flame: it is faulty.

Contact qualified person

-

nel

Replace electronic board.

Ignition heat input setting 

is too low.

Contact qualified person

-

nel

Increase it.

Minimum heat input is not 

set correctly.

Contact qualified person

-

nel

Check burner setting.

E02*

Flow temperature excee-

ded the max. allowed 

value.

Circulation pump is faulty.

Contact qualified person

-

nel

Replace it.

Circulation pump is 

seized.

Contact qualified person

-

nel

Check pump electrical 

connection.

E03*

Flue thermostat trigge-

ring.

Poor flue draught.

Contact qualified person

-

nel

Check air intake or flue 

gas venting system and 

vent grilles in the boiler 

room.

Flue vent / air intake duct 

is obstructed.

Contact qualified person

-

nel

Check for any duct ob-

struction, and eliminate.

Flue gas thermostat is 

faulty.

Contact qualified person

-

nel

Replace it.

Summary of Contents for ITACA KC 24

Page 1: ...It is compulsory to read this manual before proceeding with the boiler installation use and maintenance operations This boiler is intended for production of hot technical water only For heating of re...

Page 2: ...bin symbol indicated on the boiler and on the package means that the boiler at the time of its decommissionig must be collected and disposed of separately from other waste see Decom missioning disasse...

Page 3: ...legislation in force is forbid den DANGER This boiler must be installed according to the manufacturer s instructions given in this manual Incorrect installation may cause injury to persons and or anim...

Page 4: ...e instructions above 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 dam...

Page 5: ...ll prevailing law require ments and trained to properly carry out these operations In the event of long periods of inactivity of the boiler disconnect it from the electrical power mains and close the...

Page 6: ...the boiler 2 Turn the master switch installed ahead of the boiler ON the boiler display turns on 3 If you do not wish to activate the CH function press the button until displaying the symbol only the...

Page 7: ...2 Choosing where to install the boiler 42 3 3 Positioning the boiler 42 3 4 Installing the boiler 44 3 5 Boiler room ventilation 44 3 6 Air intake and flue gas venting system 45 3 7 Checking combusti...

Page 8: ...8 7 Malfunctions possible causes and solutions 92 7 1 Troubleshooting 92...

Page 9: ...g 24 Thermoregulation curves 59 Fig 25 Available head KC KR KRB 12 68 Fig 26 Available head KC KR KRB 24 69 Fig 27 Available head KC KR KRB 28 69 Fig 28 Available head KC KR KRB 32 70 Fig 29 Wiring di...

Page 10: ...mbustion specifications KC KR KRB 28 39 Tab 11 Combustion specifications KC KR KRB 32 39 Tab 12 Additional specifications 39 Tab 13 ERP and Labelling data KC 40 Tab 14 ERP and Labelling data KR KRB 41...

Page 11: ...programme for temperature zones and manual programme selection C Time and ambient temperature setting D Set the domestic hot water DHW E Set the heating water and the CH settings F Alarm reset and ba...

Page 12: ...d with the sun and the moon 9 Display of current time fan revolutions Not used 10 Indicates if the unit is in time slot programming mode Not used 11 Manual mode operation Manual mode setting 12 Displa...

Page 13: ...indication Not used 25 During parameter editing the wrench symbol stays on until the set datum is confirmed Not used 26 Lit flame indication Not used 1 2 Interpreting boiler status from display indica...

Page 14: ...WINTER mode or CH ONLY CH function active The flow water temperature is displayed WINTER CENTRAL HEATING ONLY Boiler switch in SUMMER or WINTER mode External water heater enabled DHW temperature is di...

Page 15: ...temperature Press button DHW to select the desi red DHW temperature During selection icon will flash In the phase in which the icon is flashing only the buttons to adjust the temperatu re are enabled...

Page 16: ...n OFF press OK button to enable it 1 Comfort function enabled 2 Press OK 3 Comfort function disabled 1 6 Time setting 1 To set time minutes and day of the week press 2 Flashing values can be edited by...

Page 17: ...tures cannot be set Day temperature is identified by the symbol while night tempera ture by the symbol The day temperature is active when bars are on while night tempe rature is active when bars are o...

Page 18: ...mme 1 Press to access the manual programme setting mode 2 Press OK to confirm 3 Press to go back to the star ting page namely to quit the fun ction 1 9 Automatic programme setting The selection of aut...

Page 19: ...ns to move inside the different times of the day 10 To program other days of the week or to program zone 2 and water hea ter press 11 You will go back to the starting page Whatever part of the program...

Page 20: ...perature or solar valve temperature displaying if the water heater probe or solar valve probe are installed on additional solar board Tab 1 Displayable parameters with info button 1 12 Failures that c...

Page 21: ...this procedure the boiler might still experience some starting difficulties and shut down once or twice Press the RESET button to restore boiler operation 1 14 2 CH function To set the water temperat...

Page 22: ...14 4 Comfort function model KC only The COMFORT function keeps the plate heat exchanger hot to minimise the waiting time for the production of DHW Enable COMFORT function by pressing the corresponding...

Page 23: ...operate even if the boiler shuts down During the water heater anti freeze operation the temperature detected by the flow probe is constantly checked and in case it reaches 60 C the burner is switched...

Page 24: ...shown For optimal curve adjustment a position close to 20 C is recommended For further details on cruising temperature operation refer to paragraph Installation of the optional external probe and sli...

Page 25: ...the boiler by interrupting the gas supply to the boiler and the LCD will display the code In this case contact a Service Centre or a qualified service engineer to carry out the maintenance 1 15 3 Shu...

Page 26: ...will be signalled by the symbol appearing on the display If the automatic filling occurs correctly the display shows the standard screen If automatic filling is not correctly carried out error E08 wil...

Page 27: ...tion is constantly monitored and in case of malfunction the burner goes off the code E40 flashes on the display This mode is maintained until the fan recovers normal working parameters If the boiler d...

Page 28: ...aracteristics IPX5D electrically protected control panel Integrated modulating electronic safety board Electronic start up with built in igniter and ionisation flame detection Stainless steel fully pr...

Page 29: ...ossibility to select the heating range standard or reduced Ignition flame propagation function CH thermostat timer 240 seconds adjustable Heating pump post circulation function in CH freeze protection...

Page 30: ...imensions KC model R RS M SI C G F RC Fig 3 Model KC dimensions RUGIADA PLUS N CDX RUGIADA PLUS NB CDX M CH system flow 3 4 C DHW outlet 1 2 G Gas inlet 1 2 F Cold water inlet 1 2 RC Filler cock R CH...

Page 31: ...es and dimensions 31 KR model R RS M SI G F Fig 4 Model KR dimensions RUGIADA PLUS N CDX RUGIADA PLUS NB CDX M CH system flow 3 4 G Gas inlet 1 2 F Cold water inlet 1 2 R CH system return 3 4 RS Syste...

Page 32: ...el R RS M SI MB G RB Fig 5 Model KRB dimensions RUGIADA PLUS N CDX RUGIADA PLUS NB CDX M CH system flow 3 4 MB Water heater secondary flow 1 2 G Gas inlet 1 2 RB Water heater secundary return 1 2 R CH...

Page 33: ...e 7 Air intake duct 8 Flue gas venting duct 9 Flue gas analysis ports 10 Flue gas thermostat on venting duct 11 Flue gas probe on heat exchanger 12 Ignition detection electrode 13 Expansion vessel 14...

Page 34: ...erature twin probe 4 Modulating fan 5 Main condensing heat exchanger 6 Air purging device 7 Air intake duct 8 Flue gas venting duct 9 Flue gas analysis ports 10 Flue gas thermostat on venting duct 11...

Page 35: ...gas valve 3 Flow temperature twin probe 4 Modulating fan 5 Main condensing heat exchanger 6 Air purging device 7 Air intake duct 8 Flue gas venting duct 9 Flue gas analysis ports 10 Flue gas thermosta...

Page 36: ...Flue CO2 value Max output 1 Flue CO2 value Min output Natural gas G20 20 3 70 9 0 0 3 9 3 0 3 Propane Gas G31 37 3 00 10 0 0 3 10 0 0 3 Tab 3 Adjustment specifications KC KR KRB 24 Fuel Gas mains pres...

Page 37: ...w rate T 25K l min 10 6 16 1 18 6 19 4 DHW specific flow rate T 30K l min 8 8 13 4 15 5 16 2 Qualification of domestic hot water EN 13203 1 Electric power supply voltage frequency V Hz 230 50 230 50 2...

Page 38: ...e frequency V Hz 230 50 230 50 230 50 230 50 Power mains supply fuse A 3 15 3 15 3 15 3 15 Maximum power consumption W 88 97 101 106 Pump absorption W 50 50 50 50 Electric protection rating IP X5D X5D...

Page 39: ...6 13 Casing heat loss with burner off 0 20 Flue system heat loss with burner on 2 26 1 89 Flue system mass capacity g s 13 93 1 47 Flue temp air temp C 60 45 Heat output efficiency rating 60 80 C 96...

Page 40: ...ctricity consumption In standby mode PSB kW 0 003 0 003 0 003 0 003 Standby heat loss Pstby kW 0 064 0 049 0 054 0 059 Ignition burner power consumption Pign kW 0 000 0 000 0 000 0 000 Annual energy c...

Page 41: ...e regime 1 95 5 96 7 96 7 97 8 Auxiliary electricity consumption At full load elmax kW 0 020 0 036 0 036 0 038 Auxiliary electricity consumption At part load elmin kW 0 013 0 015 0 013 0 017 Auxiliary...

Page 42: ...be taken into account when choosing where to install the boiler indications contained in paragraph Air intake and flue gas venting system on page 45 and its sub paragraphs check the wall for sturdines...

Page 43: ...ap rece P vod studen vody Hidegv z csatlakoz s So uk su giri R Ritorno impianto riscaldamento Retorno instalaci n calefacci n Retour instal lation Powr t systemu ogrzewania Retorno do sistema de aquec...

Page 44: ...12 mm holes in the wall to accommodate the boiler bracket wall blocks If necessary provide holes in the wall to allow air intake and or flue gas venting ducts to pass through it Secure the supporting...

Page 45: ...with split air intake and flue gas venting ducts in the case of passages through flammable walls apply fire proof insulating material around the flue gas venting pipe DANGER The boiler is equipped wi...

Page 46: ...ne of the two flue gas closing plugs C from the boiler top cover eliminating any seal residues Fix the adhesive gasket under the flange connection for air intake system B The gasket must adhere comple...

Page 47: ...sate collection and conveying to the condensate drain system Fig 12 Installation examples KEY A Air intake S Flue gas vent Condensate Rain To install pipes bends terminals and other accessories for ai...

Page 48: ...dheres to the wall Any pipes bends or other components must not be inserted at the passage through the wall A A Fig 14 Wall mounted terminal installation Tile for pitched roofs The tile for pitched ro...

Page 49: ...cap of the tile for roofs B and fix it with the screw supplied Keep the distance indicated in the figure between the rainproof collar and the terminal Check that the flue is in a vertical position and...

Page 50: ...ed within a square measuring 500 x 500 mm The boiler is to be equipped with a fan mounted before the combustion chamber heat exchanger Type C43 C43X Boiler intended for connection to collective chimne...

Page 51: ...missible length by 1 5 meters The air intake duct is to be tilted down by 1 toward its exit in order to avoid rain water to enter it The flow resistance of the first elbow shall not be taken into acco...

Page 52: ...to be reduced by 0 5 meter The roof vent terminal reduces maximum permissible length by 1 5 meters KC 28 KR 28 KRB 28 Minimum permissible length of vertical coaxial pipes is 1 meter Maximum permissibl...

Page 53: ...lbow 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 b...

Page 54: ...nd KC KR KRB 28 20 m for models KC KR KRB 32 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...

Page 55: ...ue in Hz the fan current speed and the lit flame on symbol if burner is on As soon as the DHW key is released again the display will show fan current rpm value flow temperature system pressure the lit...

Page 56: ...ely sized gasket A made from suitable material see Fig 22 Connection to gas mains The boiler gas inlet coupling is NOT suitable for hemp teflon tape or similarly made gaskets A Fig 22 Connection to ga...

Page 57: ...is always advisable when water supplied to the boiler is more than 20 F hard Water supplied by commonly marketed water softeners due to PH level induced in water may not be compatible with some compon...

Page 58: ...nt thermostat contacts must be properly sized in compliance with a load of 5 mA at 24 Vdc The ambient thermostat cables must be connected to terminals 1 and 2 of the electronic board see par Wiring di...

Page 59: ...fter this time value is stored and display standard operation will be restored The figure shows the curves for a fictitious ambient temperature of 20 C Parameter P10 allows selecting the curve value s...

Page 60: ...o TSP parameters on page 62 P17 1 P57 1 P61 3 The ambient probe automatically modifies the CH flow temperature in relation to Measured ambient temperature Selected ambient temperature Through boiler p...

Page 61: ...rol connector is protected against inverted polarity and the connections may be inverted WARNING Do not connect the remote control to mains electrical power 230 V 50 Hz The remote control wiring must...

Page 62: ...TSP4 Fan speed at burner maximum output TSP5 250 Hz According to the model 12 kW natural gas 182 12 kW propane 177 24 kW Natural gas 197 24 kW Propane 192 28 kW natural gas 205 28 kW propane 200 32 kW...

Page 63: ...ntial OFF 0 0 1 0 C 0 0 C only with connected ambient probe P52 SA1 ambient probe triggering differential ON 1 0 0 1 C 0 5 C only with connected ambient probe P53 Ambient probe SA1 correction range 5...

Page 64: ...C only with zone board connected P66 Selection of zone 3 curve 0 3 0 6 only with two zone boards connected P67 Zone 3 set point fictitious temp 15 35 C 20 C only with two zone boards connected P70 Se...

Page 65: ...abled 1 enabled with P18 1 only Tab 19 Solar parameter with P17 2 or with supplementary board Parameter Settable values Default values Notes P80 Multifunction relay forcing 0 1 0 0 standard function 1...

Page 66: ...one 4 flow temperature only with three zone boards connected optional P42 DHW plate exchanger temperature only for KC models P43 Boiler return temperature P44 Water heater temperature KR KRB models Co...

Page 67: ...ure gauge is used to read pressure inside the heating circuit WARNING As for water treating in the domestic heating systems in order to optimise efficiency and safety ensure a long life trouble free o...

Page 68: ...ystem delivery and return T fixed at a value set in the boiler super technical parameters 2 Fixed speed operation In the fixed speed operating mode circulation pump speed remains constant at the value...

Page 69: ...Instructions for the installer 69 Fig 26 Available head KC KR KRB 24 Fig 27 Available head KC KR KRB 28...

Page 70: ...nstaller 70 Fig 28 Available head KC KR KRB 32 Q Flow rate l h H Available head mbar Minimum curve that can be used in systems without hydraulic separator Minimum curve that can be used in systems wit...

Page 71: ...u GND IN OUT X4 X3 X5 FL CN_L CN_I CN_M CN_A CN_H CN_E CN_C CN_D SF SR1 SR2 E SRT SS rd wh bk Conn_F Conn_E Conn_C Conn_B Conn_A Conn_D bu bn bn bu bu bn bu bn bn bu ygn ygn ygn 1 2 3 X6 CN_J bu bn rd...

Page 72: ...viating valve E ignition flame detection electrode V brushless fan ACC1 ignition transformer CN_A CN_M Load signal connectors X2 X7 ground connectors Connections performed by the installer 1 2 TA2 amb...

Page 73: ...mbient thermostat Terminals 1 2 Terminals 21 22 23 0KITSOLC07 Terminals 11 12 Terminals 5 6 Solar collector tempe rature probe Solar water heater temperature probe Terminals 9 10 OUTDOOR TEMPE RATURE...

Page 74: ...Terminals 3 4 Terminals 5 6 SOLAR DEVIATING VALVE Solar water heater temperature probe Terminals 9 10 OUTDOOR TEMPE RATURE PROBE Terminals 21 22 23 Domestic water system Fig 32 Wiring diagram for natu...

Page 75: ..._M CN_A CN_E CN_C CN_D SF SR1 SR2 E SRT rd wh bk Conn_F Conn_E Conn_C Conn_B Conn_A Conn_D bu bn bu bn bn bu ygn ygn ygn CN_J rd pk wh bk rd pk wh bk or pk wh bk or pk wh bk bn bn bu bu bn bn bu bu 0S...

Page 76: ...l connectors X2 X7 ground connectors Connections performed by the installer 1 2 TA2 ambient thermostat 2 3 4 OT or TA1 Remote Control or ambient thermostat 5 6 SEXT external probe 10K Ohm B 3977 at 25...

Page 77: ...t thermostat Terminals 1 2 Terminals 24 25 Terminals 7 8 Terminals 11 12 Terminals 5 6 BOILER WATER HEATER PROBE Solar water heater temperature probe Terminals 9 10 OUTDOOR TEMPE RATURE PROBE Terminal...

Page 78: ...bn bu X4 X3 X5 CN_L CN_I CN_M CN_A CN_H CN_E CN_C CN_D SF SR1 SR2 E SRT rd wh bk Conn_F Conn_E Conn_C Conn_B Conn_A Conn_D bu bn bu bn bn bu ygn ygn ygn CN_J rd pk wh bk rd pk wh bk or pk wh bk or pk...

Page 79: ...ushless fan ACC1 ignition transformer CN_A CN_M Load signal connectors X2 X7 ground connectors Connections performed by the installer 1 2 TA2 ambient thermostat 2 3 4 OT or TA1 Remote Control or ambie...

Page 80: ...0 9 Water heater cooling function This function consists in cooling water heater down to the temperature value set by the user by transferring excess heat from the boiler to the solar collector With t...

Page 81: ...ting diagrams The control panel features a multifunction relay to be set through the parameter P17 TSP17 Solenoid valve with limit swich Solenoid valve coupled to Remote Control Fig 38 Relay with remo...

Page 82: ...20 12 Relationship between temperature and nominal resistance of all NTC probes B 3435 T C 0 2 4 6 8 0 27203 24979 22959 21122 19451 10 17928 16539 15271 14113 13054 20 12084 11196 10382 9634 8948 30...

Page 83: ...n wrench loosen the two mixer nozzles see Fig 43 Mixer plastic body Screw the new nozzles for propane listed in Tab 25 Diameter of nozzles diaphragms mm taking care to drive them fully home without ti...

Page 84: ...y for KC KR KRB 32 versions remove the 7 2 mm diaphragm on the outlet of the gas valve WARNING In case the nozzle idles when reaching the bottom of the nozzle threaded seat it means that the thread is...

Page 85: ...the installer 85 E F G F Fig 43 Mixer plastic body G G H I Fig 44 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...

Page 86: ...ng output adjustment Minimum heating output adjustment Set boiler min output operation by keeping DHW button pressed until the value corresponding to fan min speed for the output and boiler gas is dis...

Page 87: ...type is correct for the boiler calibration convert the boiler to the available gas when necessary this operation must only be performed by qualified technical personnel the gas supply cock is open th...

Page 88: ...r and network gas supply for leakage Check gas supply pressure to boiler Check boiler ignition sequence Check boiler combustion parameters by flue gas analysis Check the condition and seal integrity o...

Page 89: ...valve pressure taps must be checked Flame electronic control board It is mandatory to set up the electronic board according to the boiler model based on the instructions supplied together with the va...

Page 90: ...changing the ignition electrodes and or inspection glass all affected seals must be changed and sealing checked and ensured Hydraulic components In case of operations involving removing and or changi...

Page 91: ...ce in the count ry of installation Gas boilers are classified as domestic appliances and must be disposed of in the same way as washing machines dish washers and tumble dryers R2 WEEE waste The disass...

Page 92: ...rted phase and neutral Contact qualified person nel Verify correct neutral and phase connection Detection electrode cable is interrupted Contact qualified person nel Reconnect or replace wire Detectio...

Page 93: ...ue probe is electrically disconnected Contact qualified person nel Reconnect it Flue probe is faulty Contact qualified person nel Replace it E08 Automatic filling procedu re failure System pressure is...

Page 94: ...Reconnect it Remote control faulty Contact qualified person nel Replace it Boiler board is faulty Contact qualified person nel Replace it E35 Safety Thermostat trigge ring to protect the mixed zone 2...

Page 95: ...er is disconnected Contact qualified person nel Reconnect it Pressure transducer is faulty Contact qualified person nel Replace it E49 The interface does not work The interface is faulty Contact quali...

Page 96: ...he interface disconnect boiler from power mains E99 The max number of resets from the Remote Control has been rea ched The user has reached the max number of reset table values from the Remote Control...

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Page 100: ...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 alte ring the basic characteristics of th...

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