Fondital BALI RTFS Series Installation and operating instructions

BALI RTFS
IST 03 C 080 - 01
INSTALLATION
OPERATION AND MAINTENANCE
CE 49BN3788
GB

1
Dear Customer,
Thank you for choosing and buying one of our boilers. Please read these instructions carefully in order to
install, operate, and maintain this equipment properly.

This INSTRUCTION BOOKLET is an
integral and essential part of this pro-
duct and must be handed to the user
by the installer for safekeeping and
consultation when necessary. This
instruction booklet is to be handed
over with the equipment should it be
sold or transferred.
The boiler must only be used for
the purposes that are expressly
foreseen. Any other use is to be
considered improper and therefo-
re dangerous.
The installation must be carried out in
compliance with current standards
and following the manufacturer’s
instructions contained in this booklet.
Incorrect installation may result in
harm to people, animals, and/or pro-
perty, and the manufacturer accepts
no responsibility for such damage.
The unit must be installed in a
room that is sufficiently well venti-
lated, in compliance with current
standards and laws.
FONDITAL does not accept any con-
tractual or extra-contractual responsi-
bility for any damage caused due to
errors in installation or operation, or
resulting from failure to follow the
instructions below.
Before installing this equipment make
sure that the technical data for the
unit meet the requirements for its pro-
per use in the plant.
Also check that the equipment is
complete and that it has not been
damaged in transit or during hand-
ling. Do not install any equipment that
is clearly damaged and/or defective.
For all equipment with optional extras
or kits (including electrical items),
only original accessories must be
used.
When installing the equipment do not
throw the packing away. All the mate-
rials can be recycled and must be
taken to specific separated collection
areas.
Keep the packing out of reach of chil-
dren, as, by its very nature, it may
constitute a source of danger.
Should the equipment break down
and/or function defectively, switch it
off and do not attempt to repair it
yourself. Call in only qualified per-
sonnel.
Any repairs to this product must be
made using only original spare parts.
Failure to comply with the above may
compromise the safety of the equip-
ment and expose people, animals,
and property to danger.
The owner is obliged to have routi-
ne maintenance carried out on the
equipment once a year, as indica-
ted in the programme given in the
relevant section of this booklet, in
order to ensure that it works effi-
ciently and correctly.
Where the equipment is not to be
used for an extensive period of time,
disconnect it from the electrical
power supply and shut the fuel stop-
cock.
Where there is a danger of freezing,
add antifreeze. Draining the system
is not recommended as this may
damage the overall system. For this
purpose use non-freeze products
specifically made for multi-metal hea-
ting equipment.
IMPORTANT
For equipment powered by gas fuel, if
the smell of gas is sensed in the area,
proceed as follows:
- Do not activate any electrical
switches or start any electrical
equipment.
- Do not light any flames and do
not smoke.
- Shut the central gas stopcock.
- Open all doors and windows.
- Contact a Service Centre, quali-
fied installer, or the gas supply
company.
Using naked flames to check for
gas leaks is completely forbidden.
2
GENERAL NOTES FOR THE USER AND THE INSTALLER
WARNING
This BALI unit is built for installation in the destination
Country specified on the technical data plate.
Installation in any country other than that indicated
may pose a danger to people, animals, or property.

Warnings pag. 1
General Notes for the Installer, Maintenance Technician and User pag. 2
1 Instructions for the User pag. 4
1.1 Control Panel pag. 4
1.2 Operating the Boiler pag. 5
1.2.1 Starting Up pag. 5
1.2.2 Burner Cut-Out pag. 5
1.2.3 Cut-Out Excess Temperature pag. 5
1.3 Maintenance pag. 5
1.4 Notes for the User pag. 5
2 Technical Characteristics and Dimensions pag. 6
2.1 Technical Characteristics pag. 6
2.2 Dimensions pag. 7
2.3 Operating Data pag. 8
3 Instructions for the Installer pag. 9
3.1 Installation Standards pag. 9
3.2 Installation pag. 9
3.2.1 Packing pag. 9
3.2.2 Choosing the installation position for the boiler pag. 9
3.2.3 Installing the Boiler pag. 9
3.2.4 Ventilation of Boiler Rooms pag. 9
3.2.5 Smoke stack system pag. 9
3.2.6 On site measurement of combustion performance pag. 11
3.2.7 Connecting to the gas mains pag. 11
3.2.8 Connecting to the electricity power supply pag. 12
3.2.9 Plumbing Connections pag. 12
3.2.10 Installation of original kits pag. 12
3.3 Filling the system pag. 12
3.4 Starting the Boiler pag. 12
3.4.1 Preliminary Checks pag. 12
3.4.2 Starting Up and Switching Off pag. 12
3.5 Wiring Diagrams pag. 13
3.6. Gas Transformation pag. 14
3.6.2 Change over from natural gas to LPG pag. 14
3.6.1 Change over from LPG to natural gas pag. 14
4 Maintenance pag. 14
3
INDICE

General Lit Switch (Green) (1)
When the switch is in the 0 position
the boiler is switched off and the
switch is not lit.
When the switch is in the I position
the boiler is switched on and the
switch is lit.
Reset Button (2)
When the reset button is pressed
the boiler is restarted.
Temperature adjustment for the
heating water (3)
This knob is used to set the tempe-
rature for the water in the heating
system. It can be set between a
minimum of 45°C and a maximum of
85°C.
Heating Function LED (Yellow) (4)
This LED indicates that the system
is calling for heating.
Excess Temperature Cut-Out LED
(Red) (5)
This light indicates that the cut-out
connected to the safety thermostat
has tripped due to malfunctioning. It
must be reset manually.
Burner cut-out LED (Red) (6)
This light indicates that the burner
safety device has tripped due to a
malfunction.
Burner operation LED (Yellow) (7)
This light indicates that the burner is
operating.
Thermometer/Pressure Gauge (8)
The thermometer/pressure gauge’s
function is to display the temperatu-
re and pressure of the water in the
boiler.
Manual excess temperature cut-
out reset (9)
The thermostat reset button can be
accessed by removing the protective
cover. The safety thermostat is used
to protect the boiler in case of a fault.
1. INSTRUCTIONS FOR THE USER
1.1 CONTROL PANEL
4
1. General switch with line light (Green)
2. Reset Button
3. Temperature adjustment for the heating water
4. Heating Pump operation light (Yellow)
5. Excess Temperature Cut-Out LED (Red)
6. Burner cut-out LED
7. Burner operation LED (Yellow)
8. Thermometer
9. Safety thermostat-reset manually.
fig. 1

1.2 Operating the Boiler (Fig. 1)
1.2.1 Switching On
•Open the fuel stopcock.
•Switch the boiler’s main switch 1to
the ON position (the switch lights up).
•Turn the heating water temperatu-
re adjustment knob 3to set the tem-
perature required for the heating
system.
•Set the ambient temperature using
the ambient thermostat (where fitted).
•When the heating system calls for
heat the heating request light 4
comes on.
•When the burner is operating, the
burner operation light 7comes on.
Please Note: When igniting the bur-
ner after the boiler has been out of
use for a long period of time, espe-
cially in the case of LPG boilers,
there may be airlocks in the pipes.
The boiler’s burner may cut-out a
few times. Restart the burner using
the reset button (see the paragraphs
that follow).
1.2.2 Burner Cut-Out
When any functioning faults arise
the boiler’s burner cuts out automa-
tically. The cut-out light (6) comes
on. Should this happen proceed as
follows:
•First check the fuel supply, make
sure that the gas stopcock is open
and that the gas mains have gas in
them by lighting a cooking ring in the
kitchen for example.
•Having checked the fuel supply
reset the burner by pushing the
reset button 2on the control panel: if
the equipment does not restart and
cuts out again, after trying three
times contact an authorised Service
Centre or qualified personnel to
carry out maintenance.
If the burner cuts out frequently this
is a sign that there is an ongoing
operating fault. Contact qualified
personnel or an authorised Service
Centre for maintenance.
1.2.3 Excess Temperature Cut-Out
Should the red cut-out light indica-
ting excess temperature 5 come on,
this means that the safety thermo-
stat cut-out has tripped and must be
reset manually. This is due to an
operating fault and an authorised
Service Centre or qualified person-
nel must be contacted for mainte-
nance.
1.2.4 Cut-Out due to a fault in the
smoke flue and/or the air intake
Should any conditions occur that
give rise to a fault in the functioning
of the air intake and flue pipes, the
boiler goes into stand-by mode.
It remains in this mode until correct
operating conditions are reinstated.
WARNING
To solve this problem qualified
personnel must be called in or an
authorised Service Centre must
be contacted to carry out mainte-
nance work on the equipment.
1.3 Maintenance
The user is obliged to have routine
maintenance done on the boiler and
the burner once a year.
Correct maintenance of the boiler
allows it to work under the best con-
ditions, protects the environment,
and makes the equipment fully safe
for people, animals, or property.
The boiler must be maintained by
qualified personnel.
The user may only clean the
bodywork on the boiler, and this
must be done using products for
cleaning furniture.
Do not use water!
1.4 Notes for the User
The user is not authorised to
remove the bodywork on the boi-
ler and to work on parts inside.
NOBODY, INCLUDING QUALIFIED
PERSONNEL, IS AUTHORISED TO
MODIFY THE BOILER.
Qualified personnel may install spe-
cific original kits on the boiler.
FONDITAL accepts no responsi-
bility for damage to people, ani-
mals, or property that may arise
due to tampering or incorrect
work done on the boiler.
The heating system can be effecti-
vely protected against icing by using
specific non-freeze products that are
suitable for multi-metal systems.
Do not use non-freeze products
for car engines, and check the
effectiveness of the product used
over time.
This boiler is fitted with a thermome-
ter to allow you to check the water
temperature.
5

The BALI RTFS is a boiler with a
high performance heat-exchange
casing that works with gas burners
at atmospheric pressure. The follo-
wing models are available:
BALI RTFS E 18 with a thermal
power rating of 18 kW.
BALI RTFS E 24 with a thermal
power rating of 24 kW.
BALI RTFS E 32 with a thermal
power rating of 32 kW.
BALI RTFS E 36 with a thermal
power rating of 36.5 kW.
BALI boilers can be supplied in a PV
version, which means that they have
a circulation pump and an 8 lit.
expansion tank.
BALI boilers meet the essential
requirements laid down in EEC
Directives for this product and Gas
Directive 93/396/EEC dated 29th
June 1990,
Performance Directive 92/42/EEC
dated 21st May 1992.
EMC Directive 89/336/EEC dated
3rd May 1989, as amended by
Directive 92/31/EEC dated 28th April
1992,
European Community Low Voltage
Directive 73/23/EEC dated 19th
February 1973, as amended by
Directive 93/68/EEC dated 22nd July
1993, and is fitted with all the safety
devices called for in the current stan-
dards for this type of product.
The main technical characteristics of
the BALI boiler are listed below.
•High-performance cast iron heat
exchanger.
•Insulation in glass wool with thick
aluminized paper (50 mm).
•Bodywork in electrically galvani-
sed steel plating, epoxy-polyester
powder coated.
•Lit main switch.
•LED indications for: power on,
heating pump operating, burner ope-
rating, excess temperature cut-out,
burner cut-out.
•Heating temperature selector
(45/85°C).
•Safety limit thermostat (110°C).
•Smoke pressure switch
•Thermometer/Pressure Gauge
•System drain stopcock.
•Electrical system with printed elec-
tric circuit.
•Provision for electrical connection
for a heating pump.
•Provision for an electrical collec-
tion for a safety pressure switch to
guard against insufficient water.
•Provision for connecting up a card
for managing a remote boiler (optio-
nal kit).
•Provision for connecting up a cli-
matic unit (optional kit).
•Provision for connecting up a card
for managing three heating areas
(optional kit).
•8 lit expansion tank (for PV
models).
•Single-speed circulation unit (for
PV models).
2. TECHNICAL CHARACTERISTICS AND DIMENSIONS
2.1 Technical Characteristics
6

GAS
G 1/2”
G 1/2”
G 1/2”
G 1/2”
RETURN
G 1”
G 1”
G 1”
G 1”
FEED
G 1”
G 1”
G 1”
G 1”
Model
RTFS E 18
RTFS E 24
RTFS E 32
RTFS E 36
L
510
510
610
610
2.2 Dimensions
7
fig. 2

See notes, Page 10
24
26,6
90,2
89,23
2,2
0,2
7,6
3
125
10
520
4
45 - 85
230/50
50
4
7,6
120/130
55
3
2,4
2 x 0,27
11,0
2,81
9,8
120/130
55
3
1,50
1 x 0,5
26
2,1
MODELS
RTFS E 18 RTFS E 24 RTFS E 32 RTFS E 36
18
20
89,8
88,53
2,5
0,2
7,7
3
125
10
400
4
45 - 85
230/50
50
4
5,7
120/130
42
3
2,1
2 x 0,27
9,5
2,11
7,2
120/130
42
3
1,25
1 x 0,5
27
1,6
32
34,4
93,1
92,08
1,9
0,2
5
4
160
13,4
690
4
45 - 85
230/50
60
4
8,3
110/120
67
3
2,9
2 x 0,27
9,5
3,64
9,7
120/130
67
3
1,7
1 x 0,5
25,5
2,7
36,5
39,2
93,1
92,14
1,5
0,2
5,4
4
160
13,4
780
4
45 - 85
230/50
60
4
8,2
120/130
76
3
2,9
2 x 0,27
12,0
4,15
11,1
120/130
76
3
1,8
1 x 0,5
26
3,1
49BN3788
II2H3+
C12, C32, C42, C52, C82
kW
kW
%
%
%
%
%
N°
Kg
l
l/h
bar
°C
V-Hz
W
A
%
°C
Kg/h
N°
mm
mm
mbar
Stm3/h
mm
%
°C
Kg/h
N°
mm
mm
mbar
kg/h
EC Performance Class
EC PIN
Category
Type
Thermal Power
Thermal Capacity
Performance at nominal load
Performance at reduced load (30%)
Maintenance losses T=50
Flue losses with burner extinguished
Flue losses with burner ignited
N°heat exchange elements
Net weight
Water content
Minimum water flow
Maximum operating pressure
Working Temperature
Electrical Power Supply
Electrical Power
Fuses on Power Supply
Natural gas G20
CO2 value
Smoke temperature
Smoke mass flow
Number of main burner nozzles
Diameter of main burner nozzles
Diameter of main pilot nozzle
Gas pressure at burner
Gas Flow (15°C / 1013 mbar).
Diaphragm
Gas G30
CO2 value
Smoke temperature
Smoke mass flow
Number of main burner nozzles
Diameter of main burner nozzles
Diameter of main pilot nozzle
Gas pressure at burner
Gas Flow (15°C / 1013 mbar).
2.3 Operating Data
8
★★ ★★ ★★★ ★★★

3.1 Installation Standards
This BALI boiler must be installed in
compliance with current laws and
standards, which are taken as being
an integral part of this booklet.
3.2 Installation
3.2.1 Packing
BALI boilers are supplied packed in
a strong cardboard box on a wooden
pallet. On removing the cardboard
box make sure that the boiler is
complete.
The packing materials can be recy-
cled. Dispose of them via specific
waste collection points.
Keep the packing out of reach of
children, as, by its very nature, it
may constitute a source of danger.
FONDITAL accepts no responsi-
bility for damage to people, ani-
mals, or property due to failure to
observe the instruction above.
The pack contains a packet in which
you will find:
a)The installation, operation, and
maintenance manual.
b)The guarantee certificate.
c) The booklet for the plant or unit,
depending on the model.
3.2.2 Choosing the installation
position for the boiler
The following must be taken into
account when choosing where to
install the boiler:
•It is advisable to leave at least 50
cm on each side of the boiler to faci-
litate future maintenance.
•Do not install in damp or dusty
rooms.
•The boiler room must not be
accessible to outsiders, children, or
animals.
3.2.3 Installing the Boiler
Before connecting the boiler to the
piping for the hot water and heating
systems, clean the piping carefully
to eliminate any metal residue left
during working and welding, and
any oil or grease that may be left
and that could damage the boiler or
alter the way it works if it reaches
the boiler.
NB: Do not use solvents as these
could damage the components.
FONDITAL accepts no responsibi-
lity for damage to people, animals,
or property due to failure to observe
the instructions above.
To install the boiler proceed as follows:
•Unscrew the four screws that
attach the brackets that connect the
boiler to the timber pallet (Fig. 3)
•Remove the boiler from the pallet
without damaging it.
•Put spacers between the floor and
the boiler’s feet if necessary, to
make the installation stable.
•Connect the boiler to the system’s
feed and return pipes.
•Remember that the plumbing
system must include all the safety and
control elements required in terms of
current standards (safety valve, water
pressure switch, heat discharge valve,
pressure gauge, etc.).
•Connect the boiler up to the air
intake and flue pipes.
•Connect the ambient thermostat,
the heating pump, and the heating
water pressure switch to the electri-
cal system.
•Connect up the electricity supply.
3.2.4 Ventilation of Boiler Rooms
BALI RTFS boilers have airtight
combustion chambers.
It is obligatory that the boiler be
installed in an adequate room in
terms of the current standard,
which is taken as an integral part
of this booklet.
3.2.5 Smoke discharge and com-
bustion-supporting air intake
system
BALI boilers have a coupling for a
flue pipe and another coupling for a
combustion-supporting air intake,
both of which are suitable for con-
necting up to 80 mm diameter pipes.
The smoke ducts from the boiler are
to be connected to a smoke flue for-
med as indicated in current stan-
dards, which are taken as being
an integral part of this booklet.
Type C12
This boiler is designed to be con-
nected up to horizontal flue and
intake terminals, connected to the
outside air by means of a coaxial
pipe or double pipes.
The distance between the air intake
pipe and the smoke flue pipe must
be at least 250 mm and both termi-
nals are to be positioned within a
square with 500 mm sides.
• Air intake/smoke flue coaxial pipe,
diameter 60/100 mm.
Configuration allowed:
N°1 flanged stub pipe
N°3 metres coaxial pipe
N°1 intake/flue terminal.
Notes:
- Reduce the maximum length by 1
metre for each 90°bend.
- Reduce the maximum length by 0,5
metres for each 45°bend.
- Models RTFS 18 and RTFS 24:for
installations with an equivalent length
of less than 1 metre, install a 75 mm
diaphragm.
- Model RTFS 32: for all installations,
install a 78 mm diaphragm.
- RTFS 36 models: for installations
with an equivalent length of less than
1 metre, install a 78 mm diaphragm.
•Air intake/smoke flue double 80
mm diameter piping
Configuration allowed:
N°2 flanged stub pipes
N°19 metres of air intake piping
N°19 metres of smoke flue piping
N°1 air intake terminal
N°1 smoke flue terminal
3. INSTRUCTIONS FOR THE INSTALLER
9
fig. 3

Notes:
- Reduce the maximum length by 1
metre for each 90°bend.
- Reduce the maximum length by 0,5
metres for each 45°bend.
- Models RTFS 18 and RTFS 24:for
installations with an equivalent length
of less than 2+2 metres, install a 42
mm diaphragm on the air intake.
- Models RTFS 32 and RTFS 36:for
installations with an equivalent length
of less than 9+9 metres, install a 40
mm diaphragm on the air intake.
Type C32
This boiler is designed to be connec-
ted up to vertical flue and intake termi-
nals, connected to the outside air by
means of a coaxial pipe or double
pipes.
The distance between the air intake
pipe and the smoke flue pipe must be
at least 250 mm and both terminals
are to be positioned within a square
with 500 mm sides.
•Air intake/smoke flue coaxial pipe,
diameter 60/100 mm.
Configuration allowed:
N°1 flanged stub pipe
N°4 metres coaxial pipe
N°1 roofed intake/flue terminal.
Notes:
- Reduce the maximum length by 1
metre for each 90°bend.
- Reduce the maximum length by 0,5
metres for each 45°bend.
•Air intake / smoke flue double 80
mm diameter piping
Configuration allowed:
N°2 flanged stub pipes
N°19 metres of air intake piping
N°19 metres of smoke flue piping
N°1 air intake terminal
N°1 smoke flue terminal
Notes:
- Reduce the maximum length by 1
metre for each 90°bend.
- Reduce the maximum length by 0,5
metres for each 45°bend.
- Models RTFS 18 and RTFS 24:for
installations with an equivalent length
of less than 2+2 metres, install a 42
mm diaphragm on the air intake.
- Models RTFS 32 and RTFS 36:for
installations with an equivalent length
of less than 9+9 metres, install a 40
mm diaphragm on the air intake.
Type C42
This boiler is designed to be connec-
ted up to a collective smoke flue
system made up of two pipes, one for
the combustion-supporting air intake
and the other for the removing the
smoke produced by combustion, by
means of a coaxial pipe or double
pipes.
The distance between the air intake
pipe and the smoke flue pipe must be
at least 250 mm and both terminals
are to be positioned within a square
with 500 mm sides.
The smoke flue is to comply with cur-
rent standards.
•Air intake/smoke flue double 80
mm diameter piping
Configuration allowed:
N°2 flanged stub pipes
N°2 metres of air intake piping
N°2 metres of smoke flue piping
Notes:
- Reduce the maximum length by 1
metre for each 90°bend.
- Reduce the maximum length by 0,5
metres for each 45°bend.
- Models RTFS 18 and RTFS 24:
install a 42 mm diaphragm on the air
intake.
- Model RTFS 32 and RTFS 36: install
a 40 mm diaphragm on the air intake.
Type C52
This boiler is designed to be connec-
ted up to separate flue and combu-
stion-supporting air intake pipes.
These pipes may open out into
areas at differing pressures.
The two terminals may not be posi-
tioned on opposite sides.
•Air intake/smoke flue double 80
mm diameter piping
Roof-mounted flue pipe
Configuration allowed:
N°2 flanged stub pipes
N°1 metre of air intake piping
N°30 metres of smoke flue piping
N°1 air intake terminal
N°1 roof-mounted smoke flue terminal
Notes:
- 1 metre of air intake piping is
equivalent to 2 metres of vertical
smoke flue piping.
- Reduce the maximum length by 1
metre for each 90°bend.
- Reduce the maximum length by
0,5 metres for each 45°bend.
- Models RTFS 18 and RTFS 24: for
installations with an equivalent verti-
cal flue pipe length of less than 18
metres, install a 40 mm diaphragm
on the air intake.
- Model RTFS 32 and RTFS 36:for
installations with an equivalent verti-
cal flue pipe length of less than 4
metres, install a 42 mm diaphragm
on the air intake.
Wall-mounted flue pipe
Configuration allowed:
N°2 flanged stub pipes
N°19 metres of air intake piping
N°19 metres of smoke flue piping
N°1 air intake terminal
N°1 smoke flue terminal
Notes:
- 1,6 metres of air intake piping is
equivalent to 1 metres of horizon-
tal smoke flue piping.
- Reduce the maximum length by 1
metre for each 90°bend.
- Reduce the maximum length by
0,5 metres for each 45°bend.
- Models RTFS 18 and RTFS 24:for
installations with an equivalent
length of less than 9+9 metres,
install a 40 mm diaphragm on the air
intake.
10

- Model RTFS 32 and RTFS 36:for
installations with an equivalent
length of less than 2+2 metres,
install a 42 mm diaphragm on the air
intake.
Type C82
This boiler is designed to be con-
nected to a terminal for taking in
combustion-supporting air and an
individual or collective smoke flue.
The smoke flue is to comply with
current standards.
•Air intake/smoke flue double 80
mm diameter piping
Configuration allowed for maximum
distance:
N°2 flanged stub pipes
N°4 metres of air intake piping
N°1 metre of smoke flue piping
N°1 air intake terminal
Notes:
- 1,6 metres of air intake piping is
equivalent to 1 metre of horizon-
tal smoke flue piping.
- Reduce the maximum length by 1
metre for each 90°bend.
- Reduce the maximum length by
0,5 metres for each 45°bend.
- Models RTFS 18 and RTFS 24:
install a 42 mm diaphragm on the air
intake.
- Model RTFS 32 and RTFS 36:
install a 40 mm diaphragm on the air
intake.
3.2.6 On site measurement of
combustion performance
To determine combustion perfor-
mance the following measurements
must be taken:
•The temperature of the combu-
stion-supporting air.
•The temperature of the smoke and
the percentage of CO2in samples
drawn from the hole provided for this
purpose in the smoke duct.
Taking the specific measure-
ments with the boiler running at
normal load.
3.2.7 Connecting to the gas mains
The gas supply pipe is to have a
cross-section that is equal to or
greater than that on the burner.
Installation standards must be com-
plied with and are taken as being an
integral part of this booklet.
Remember that before putting an
internal gas distribution system
into service, before it is connec-
ted to the meter, it must be chec-
ked for leaks.
If any part of the system is inac-
cessible the leak test must be car-
ried out before the pipes are
covered up.
The leak test must not be carried
out using combustible gas. Use
air or nitrogen for this purpose.
Once there is gas in the pipes,
checking for leaks using a naked
flame is forbidden.
Use the products made for this
purpose that are available on the
market.
3.2.8 Connecting to the electricity
power supply
BALI boilers have a terminal board for
connecting up a three-pole power
supply cable, and a suitable cable
clamp to prevent it being torn out.
This boiler must be connected to a
230V-50Hz electrical power supply.
When forming the connection
respect the phase/neutral polarity.
Installation standards must be com-
plied with and are taken as being an
integral part of this booklet.
A two-pole switch must be fitted
upstream of the boiler to allow all
maintenance work to be carried out
in complete safety.
The power supply to the boiler must
be fitted with a differential magnetic-
thermal trip-switch of a suitable trip-
ping power.
The electrical power supply must be
safely earthed.
This basic safety requirement must
be checked. In case of doubt, call in
professionally qualified personnel to
check the electrical system carefully.
FONDITAL accepts no responsi-
bility whatsoever for any damage
caused due to failure to earth the
system. Piping for gas, plumbing,
or heating systems are not suita-
ble for earthing this system.
3.2.9 Plumbing Connections
Before installation the system
should be cleaned in order to remo-
ve the impurities that may come
from the components as far as pos-
sible, as these could damage the cir-
culation or heat exchange units.
The heating feed and return pipes
must be connected up to the respec-
tive couplings on the boiler.
When sizing the piping for the hea-
ting system, bear in mind the load
losses caused by radiators, thermo-
static valves, radiator gate valves,
and the configuration of the system
itself.
3.2.10 Installation of original kits
FONDITAL provides original kits for
installing clock programmers, cards
for managing a remote boiler, and
for installing a heat-regulating unit.
These original kits are to be installed
in compliance with the instructions
supplied with them.
3.3 Filling the system
Once all the connections in the
system have been completed, the
heating circuit can be filled.
This must be carried out carefully,
and in the following steps:
•Open the bleeding valves on the
radiators and make sure that the
vent valve installed in the boiler
room is working.
•Gradually open the relevant stop-
cock to fill the system and make
sure that all automatic air vents
installed in the system are working
properly.
•Close the vent valve as soon as
water comes out of it.
•Use the pressure gauge installed
in the boiler room to check when the
pressure reaches 0,8 / 1 bar.
•Shut the filling stopcock and bleed
any air out again using the bleeding
valves on the radiators.
11

•Having started the boiler and
brought the system up to its working
temperature, stop the pump and
repeat the air bleeding operations.
•Allow the system to cool and return
the water pressure to 0,8 / 1 bar.
WARNING
The UNI CTI 8065/89 standard –
Treatment of water in domestic hea-
ting systems –determines and defi-
nes the chemical and chemical-
physical characteristics of the water
used in domestic heating systems,
and especially, “… in order to optimi-
se performance and safety, to pre-
serve these conditions over time, to
ensure long-lasting regular operation
of auxiliary equipment as well, and to
minimise energy consumption, the-
reby integrating current laws and
standards …”.
In this regard specific products must
be used that are suitable for multi-
metal plants.
Note: The boiler is fitted with a
drain stopcock at the front of the
unit that can be used to empty the
system.
3.4 Starting the Boiler
3.4.1 Preliminary Checks
Before starting the boiler it is best to
check that:
•The smoke flue has been installed
in compliance with instructions.
When the boiler is running no pro-
ducts generated by combustion
are to leak from any gaskets.
•The boiler power supply is 230 V –
50 Hz.
•The system is properly filled with
water (pressure on the water gauge
0,8 / 1 bar).
•All stopcocks in the system’s
piping are open.
•The fuel supply stopcock is open.
•There are no gas leaks.
•The external main switch is on.
•The boiler’s safety valve is not
blocked.
•There are no water leaks.
To speed up and facilitate igniting the
boiler for the first time, bleed the air
out of the gas piping using the gas
pressure valve socket.
Close the pressure socket carefully
after bleeding the system.
3.4.2 Starting Up and Switching Off
For starting up and switching off the
boiler, follow the “User’s Instructions”.
12

13
IG: Main Switch (marked “on/off”
on the printed circuit).
R: Heating thermostat (marked
“Tr”on the printed circuit).
Lon: Power on indication
TS: Safety Thermostat
L3: Heating circulation unit indica-
tion
Fu1: Protection fuse F4A 250V
L4: Burner ON indication
BC: Flame check
L5: Safety thermostat indication
P1: Burner reset button
L6: Burner cut-out indication
PC: Heating circulation unit
MT: Motor timer (optional) [marker
“TIMER”on the printed circuit]
VG: Gas valve
TM: Contact Timer (optional) [mar-
ked “TIMER”on the printed cir-
cuit]
PZ: Ignition spark unit
PA: Water pressure switch (optio-
nal) [marked with the pressure
switch symbol on the
printed circuit]
EA: Ignition electrode
MN: Minimum thermostat (optional)
[marked “Tm”on the printed
circuit]
ER: Flame detection electrode
TA: Ambient thermostat
PR: Circulation pump
BR: Ignition card connection
PCB1:Printed Circuit Board
a = Blue
br = Brown
g = Grey
p = Pink
v = Violet
bl = Dark Blue
bk = Black
gn = Green
r = Red
y = Yellow
w = White
ygn = Yellow/Green
o = Orange
fig. 5
BALI RTFS E
BALI RTFS E
fig. 4
3.5 Wirings diagrams

14
3.6 Gas Transformation
Changing a boiler over from natural
gas to LPG and vice versa is only to
be carried out by qualified personnel.
To check the setting values for the
nozzles and gas supply pressure, use
a pressure gauge connected to the
pressure sockets on the valves.
3.6.1 Change over from natural gas
to LPG
Proceed as follows:
•Remove the natural gas nozzle from
the pilot burner after having unscrewed
the nut that holds the olive and vent the
gas supply pipe to the pilot burner.
•Position the LPG nozzle checking
that it is as indicated in the technical
data table, and after repositioning the
gas supply pipe tighten the nut that
secures the olive.
•Remove the natural gas nozzle on
the main burner and fit the LPG nozz-
le, checking that this is as indicated in
the technical data table.
•Unscrew the pressure regulating cap
on the gas valve and tighten the pres-
sure regulating screw all the way.
•Screw the pressure regulating cap
back on and seal it (using paint or a
self-adhesive label, for example).
•Check the gas circuit for leaks, espe-
cially the points that were disconnected.
•Affix the self-adhesive label provided
that indicates the type of gas and pres-
sure for which the equipment is set.
3.6.2 Change over from LPG to
natural gas
Proceed as follows:
•Remove the LPG nozzle from the
pilot burner after having unscrewed the
nut that holds the olive and vent the
gas supply pipe to the pilot burner.
•Position the natural gas nozzle chec-
king that it is as indicated in the techni-
cal data table, and after repositioning
the gas supply pipe tighten the nut that
secures the olive.
•Remove the LPG nozzle on the main
burner and fit the natural gas nozzle,
checking that this is as indicated in the
technical data table.
•Unscrew the pressure regulating cap
on the gas valve and unscrew the
pressure regulating screws so that the
pressure at the outlet is as specified in
the technical data table.
•Screw the pressure regulating cap
back on and seal it (using paint or a
self-adhesive label, for example).
•Check the gas circuit for leaks,
especially the points that were dis-
connected.
•Affix the self-adhesive label provided
that indicates the type of gas and pres-
sure for which the equipment is set.
4. MAINTENANCE
In order to ensure that the equip-
ment is efficient and that it functions
correctly, maintenance must be car-
ried out annually, based on the pro-
gramme laid out below:
It is obligatory for all maintenance
(and repair) operations to be car-
ried out by qualified personnel.
Before starting any maintenance
work that involves replacing com-
ponents and/or cleaning the insi-
de of the boiler, disconnect the
equipment from the electrical
power supply.
Maintenance programme
Routine maintenance must include
the following checks:
- Check of the general integrity of
the boiler.
- Checking the gas supply to the
boiler for leaks.
- Checking ignition of the boiler.
- Checking the boiler’s combustion
parameters by analysing the smoke
(this check is done every two years
if the boiler is installed on its own.
Where the boiler is installed in a
cascading system, this check is run
annually).
- Checking the integrity, good state
of preservation, and leak test on the
smoke flue.
- Checking the integrity of safety
devices on the boiler in general.
- Checking for water leaks and
rusting on the boiler’s couplings.
- Checking the efficiency of the
system’s safety valve.
The following cleaning is to be
done (with the boiler cold):
- General internal cleanliness of the
boiler.
- Cleanliness of the burner and
resetting of the same as necessary.
- Cleanliness of the smoke side of
the heat exchanger. This can be
done using swabs and vacuum clea-
ners to remove soot deposits on the
sides and fins used for exchanging
heat.
Alternatively specific chemical pro-
ducts can be used in compliance
with the instructions for use of the
same.
Do not use inflammable products
such as petrol, solvents or any
other such material to clean the
heat exchanger.
When working on the boiler for
the first time, check.
The declaration of conformity for the
plant.
- The plant handbook.
Also check:
- The suitability of the boiler room.
- The ventilation openings in the
room.
- The smoke evacuation flues, and
the diameters and lengths of these.
- That the boiler has been correctly
installed as per the instructions in
this booklet.
If the equipment is not able to
work correctly, or where it poses
any danger to people, animals or
property, inform the person
responsible for the plant and
draw up a statement in this
regard.

FONDITAL F.I.N.V. Spa
25078 VESTONE (Brescia) Italia - Via Mocenigo, 123
Tel. [phone] - Fax [phone]
e mail: f[email protected] - expor[email protected]
www.fondital.it
Fondital reserves the right to make any changes it deems necessary without notice.
Fondital Advertising Office IST 03 C 080 - 01 Giugno 2003 (06/2003)