Fondital FORMENTERA KC 24 User manual

INSTRUCTIONMANUAL
FAMILY: Wall-mounted
condensing boilers
GROUP: Instantaneous with
forced draught
MODELS: Formentera
Condensing
VERSIONS: For indoor
installation
CODE: AST 14 C 257/00
______________________________________________
1st edition, February 2013
ENGLISH

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2 AST 14 C 257/00
Contents
SECTION 01
TECHNICAL FEATURES
1.1 – Models
1.2 – Overall Dimensions
1.3 – Technical Data ___________________Page 04
SECTION 02
TOUCH-SCREEN CONTROL PANEL AND DIAGNOSTICS
2.1 – User Interface
2.2 – LCD
2.3 – Boiler Status and Error Codes ___________________Page 10
SECTION 03
PLUMBINGDIAGRAMS AND COMPONENTS
3.1 – Plumbing diagrams
3.2 – Plumbing assembly
3.3 – Primary condensing exchanger
3.4 – Pre-mix burner
3.5 – Fan unit and gas valve
3.6 – Flue gas venting and condensate drain system ___________________Page 17
SECTION 04
GAS SETTING AND PARAMETERS
4.1 – Gas valve setting
4.2 – Chimney-sweep function
4.3 – Gas conversion
4.4 – Parameters ___________________Page 33
SECTION 05
OPERATING LOGIC
5.1 – Main general characteristics ___________________Page 44
SECTION 06
ELECTRICAL SYSTEM
6.1 – Electronic board
6.2 – Outer terminal box electrical connections
6.3 – Wiring diagram ___________________Page 76
SECTION 07
VENT DUCTSAND PIPES
7.1 – 100/60 Co-axial air/vent ducts
7.2 – 125/80 Co-axial air/cent ducts
7.3 – 80/80 Split air/vent ducts
7.4 – Split vent ducts 60
___________________Page 79
TROUBLE-SHOOTING CHART
__________________Page 85

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3 AST 14 C 257/00

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4 AST 14 C 257/00
SECTION 1
TECHNICAL FEATURES
1.1 MODELS
FORMENTERA Condensing KC 24 - 28 – 32
FORMENTERA Condensing KR 24 - 28 - 32
KEY TO SYMBOLS:
K: condensing
C: combined
R : heating-only
MAIN FEATURES:
•FORMENTERA Condensing KC 24 – 28 - 32:
combined instantaneous condensing boiler for indoor installation, with DHW+heating, sealed
chamber, forced draught, mono-thermal with plate exchanger
•FORMENTERA Condensing KR 24 – 28 - 32:
•heating-only condensingboiler for indoor installation, sealedchamber,forced draught,mono-
thermal
1.2 OVERALL DIMENSIONS
Height H = 750 mm
Width L = 420 mm
Depth P = 315 mm

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5 AST 14 C 257/00
Front view Side view
View from below View from above
GGas inlet (1/2”)
MHeating systemflow (3/4”)
RCH return (3/4”)
AF Cold waterinlet (1/2”)
ACS Hot water outlet (1/2”)
M ACS G AF
R

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6 AST 14 C 257/00
INSTALLATION DIAGRAM

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7 AST 14 C 257/00
1.3 TECHNICAL DATA
General Features
KC-KR 24 KC-KR 28 KC-KR 32
Operating parameters
Category II2H3P
Burnernozzles no. 2
Minimum CHcircuitflowrate l/h 400 600
Maximumand minimumCHpressure ba
r
3
-
0.5
Maximumand minimumDHWcircuitpressure ba
r
6
-
0.5
DHW specificflowrateût30°C l/min 13.5 15.5 16.2
Double flowprobeinterventiontemperatureOFF °C 105
Double flowprobeinterventiontemperatureON °C 90
Fluegasthermostatintervention temperature °C 105
Standard heatingregulationrang
e
°C 20
-
78
Maximumstandard operatingtemperature °C 78+5
Reduced heatingregulationrange °C 20
-
45
Maximumreducedoperating temperature °C 45+2
DHW regulationrange °C 35
-
57
MaximumDHWoperatingtemperature °C 57+5
Nominal expansion ves
s
el capacity l 10
Maximumrecommended system capacity(**) l 200
Nominalratings
PowerSupply:Voltage/Frequency V – Hz 230-50
Mainssupplyfuse A 2
Electrical cabinetprotection IP X5D
Max.inputpower
W
121
Inputpoweronstandby
W
2.4
Overalldimensionsandconnections
Height mm 750
Width mm 420
Depth mm 315
Gasconnection
-
G
½
Flowand return connection - G ¾
Cold waterandDHW/tankheaterconnection - G ½
Netweight kg 30.5 32 38
Consumption
Natural gasconsumption (*) m
3
/h 2.51 2.80 3.22
Propane gasconsumption(*) kg/h 1.84 2.05 2.36
Operatingfeatures
Type ofignition
-
Electronic
Flamesurveillanc
e
-
Ionisation
Type ofdetection
-
No phase
-
neutral polarisation
DHW production
-
Instantaneou
s
(*) Value relatedto 15°C-1013mbar
(**) Maximum watertemperatureat83°Cwithvessel preloaded at1bar

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8 AST 14 C 257/00
Design data and stacksize KC-KR 24
Max. heat
output Min. output 30% load
Casing heatlosswithburnerof
f
%0.28
-
Casing heatlosswithburneron % 0.97 6.49
-
Fluesystem heatlosswithburneron % 2.62 2.09 -
Flue(natural gas)massflowrate g/
s
12.43 1.33
-
Fluegas/ airtemperatur
e
°C 61 33
-
Residual pressureavailable Pa 130 1.56 -
CO2(natural gas) content
s
%9.0 9.3
-
CO2(propane) content
s
% 10.0 10.0
-
Useful thermal output(60/80°C) % 96.7 91.4 -
Useful thermal output(30/50°C) % 105.1 104.9 106.5
Efficiencyrating(according to92/42/EC)
-
使使使使
Nox emissionclass
-
5
KC-KR 28
Max. heat
output Min. output 30% load
Casing heatlosswithburneroff % 0.25 -
Casing heatlosswithburneron % 1.40 5.70
-
Fluesystem heatlosswithburneron % 2.40 2.00
-
Flue(natural gas)massflowrate g/s 13.93 1.47 -
Fluegas/ airtemperatur
e
°C 60 45
-
Residual pressureavailable Pa 170 2.0
-
CO2(natural gas) contents % 9.0 9.3 -
CO2(propane) content
s
% 10.0 10.3
-
Useful thermal output(60/80°C) % 96.4 92.3
-
Useful thermal output(30/50°C) % 105.5 104.5 107.0
Efficiencyrating(according to92/42/EC) - 使使使使
Nox emissionclass
-
5
KC-KR 32
Max. heat
output Min. output 30% load
Casing heatlosswithburnerof
f
%0.22
-
Casing heatlosswithburneron % 0.99 5.06 -
Fluesystem heatlosswithburneron % 2.61 2.04
-
Flue(natural gas)massflow
r
ate g/
s
15.81 1.87
-
Fluegas/ airtemperature °C 60 40.5 -
Residual pressureavailable Pa 183 3.5
-
CO2(natural gas) content
s
%9.0 9.3
-
CO2(propane) content
s
% 10.0 10.0
-
Useful thermal output(60/80°C) % 96.8 92.9 -
Useful thermal output(30/50°C) % 106.2 104.8 108.3
Efficiencyrating(according to92/42/EC)
-
使使使使
Nox emissionclass - 5

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9 AST 14 C 257/00
Settings
KC-KR 24
Max heat
input MIN-MAX heat output Gas mains inlet pressure No. of nozzles Diameter nozzles MIN-MAX CO2value
(
k
W) (
k
W) (mbar) (mm) (%) +/
-
0.1
G20
natural gas 23.7 2.7 – 22.9 (60-80°C)
3.2 – 24.9 (30-50°C)
3.0 – 27.4 (DHW))
20 2 3.7 9.3-9.0
G31
propane gas 23.7 37 2 3.0 10.0-10.0
KC-KR 28
Max heat
input MIN-MAX heat output Gas mains inlet pressure No. of nozzles Diameter nozzles MIN-MAX CO2value
(
k
W) (
k
W) (mbar) (mm) (%)
G20
natural gas 26.4 3.0 – 25.4 (60-80°C)
3.58 – 27.9 (30-50°C)
3.0 – 29.2 (DHW))
20 2 4.0 9.3-9.0
G31
propane gas 26.4 37 2 3.3 10.3-10.0
KC-KR 32
Max heat
input MIN-MAX heat output Gas mains inletpressure No. of nozzles
Diamete
r
nozzles
MIN-MAX
CO2value
(
k
W) (
k
W) (mbar) (mm) (%)
G20
natural gas 30.4 3.9 – 29.4 (60-80°C)
4.4 – 32.3 (30-50°C)
3.9 – 33.4 (DHW))
20 2 4.45 9.3-9.0
G31
propane gas 30.4 37
2 +
diaphragm
Ø 7.2 3.55 10.0-10.0

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10 AST 14 C 257/00
SECTION 2
TOUCH-SCREEN CONTROL PANEL AND DIAGNOSTICS
2.1 USER INTERFACE
1. LCD
The LCD shows the boiler status and operating details (see
below).
2. DHW temperature setting
This button is used to regulate (increase or decrease) the DHW
temperature, within a range of 35°C to 57°C.
3. Boiler resetting
Press thisbutton toresume boileroperationafterashutdown (onlywithresettable failures), orreturn to the
home page when selecting the parameters.
4. Request for information and parameter confirmation
Press thisbutton to scroll throughsome display-onlyparametersin sequence,andtoconfirm the settingsof
the modified parameters.
5. Boiler operating mode selection
Press thisbutton to set one of the following functions:
SUMMER : Boiler on DHW only.
WINTER : Boiler on both CH and DHW.
CENTRAL HEATING ONLY : Boiler on CH mode only.
STANDBY OFF: boiler in standby: CH and DHW functionsdisabled.
6. Heating water temperature regulation
Thisbuttonisused to regulatethewatertemperaturein the CH system from 20°C to 45°C (reduced range)
or 78°C(standard range).Withan external probe however,thefictitioustemperaturecanbe regulated (refer
to the temperature regulation section).
1
2
3
4
5
6
Important: Touch the button area to access the various
settings. This activates backlighting (keys + LCD) and
access to the various functions. To guide the user, only
active buttons are backlit.
One minute after the last button has been touched, the
interface is disabled and the light sw itches off.
N.B. Backlighting has three separate settings (parameter
P78): 0 = standard, 1 = LCD alw ays ON, 2 = LCD +
buttons alw ays ON (default P78=0):

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11 AST 14 C 257/00
2.2 LIQUID CRYSTAL DISPLAY (LCD)
Symbol Description
Boiler operating mode indicator
These iconsindicate the current operating mode:
SUMMER: only the icon comes on
SUMMER and WINTER: both icons come on
CENTRAL HEATING ONLY: only the icon comeson
STANDBY: OFF comes on
DHW indicator
It comeson when the boiler isin the DHW mode.
Itflasheswhen the DHW temperature isregulatedvia button2 (see above).
CH indicator
It comeson when the boiler isè in the heating mode.
ItflasheswhenCH temperature isregulatedvia button 6 (seeabove).
Fictitious ambient temperature indicator
When anexternal probe isinstalled,thisindicatorflasheswhen the fictitious
ambient temperature isset via button 6 (see above).
Alphanumeric indicator
Alphanumeric digitsindicating:
- flow temperature on heating mode
- CH regulation temperature
- DHW temperature on DHW mode
- DHW regulation temperature
- parameter display
- boiler status
- boiler diagnostics.
Degrees centigrade indicator
Itisdisplayedsimultaneouslywiththealphanumeric indicator, it showsthe
value in degreescentigrade.
Solar indicator
It switches on when the solar pump activation function or solar valve
(depending on the type of system installed) isactivated.

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12 AST 14 C 257/00
Fan rpm indicator
Itswitcheson,togetherwiththerelevantsymbol when thechimney-sweep
function isactivated. Itindicatesthe fan rpm alternativelywiththe flow
temperature.
SUPE
R
-TECHNICAL parameter indicator
When displayed simultaneouslywiththeparameterdisplayindicator, it
indicatesthesuper-technicalparametersprogramming mode.Entera
password todisplayormodifytheseparameters.
Installation parameter indicator
When displayed simultaneously with the parameter display indicator, it
indicatesthe parameterprogramming mode.
Parameter display indicator
Depending on the operating mode, this indicates (numerically) the
parameter number or the system pressure or the burner heat output
percentage.
Pressure indicator
When displayed simultaneously with the parameter display indicator, it
indicatesthe system pressure only, with the boiler awaiting a request.
Percentage indicator
When displayed simultaneously with the parameter display indicator, it
indicatesthepercentage ofthe heatoutputoftheboilerfollowinga request.
Flame indicator
It comeson when the flame isdetected on the burner.
Chimney-sweep function indicator
It flashes when this function is activated (reset button pressed for three
seconds) and stays on until this function is active. The alphanumeric
indicator showsthe fan rpm, while the parameter display indicator shows
the flow temperature.
Parameter configuration indicator
When programming a parameter, this button indicatesthe possibility of
modifying the associated parameter.
2.3 BOILER STATUS AND ERRORCODES
Normal operation
Boiler in STANDBY mode.
Only the systempressureis displayed.
Boiler in SUMMER or WINTER mode.
No function active.
The flow temperature and the systempressurearedisplayed.

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13 AST 14 C 257/00
Boiler in SUMMER mode.
DHW function active withflame lit.
The DHW temperature and the burner output percentage are
displayed.
Boiler in SUMMER or WINTER mode.
DHW function active withflame lit.
The DHW temperature and the burner output percentage are
displayed.
Boiler in SUMMER or WINTER mode.
Heating function activew ithflame lit.
The flow temperature and the burner output percentage are displayed.
Boiler in WINTER mode.
Heating function activew ithflame lit.
The flow temperature and the burner output percentage are displayed.
Malfunctioning – user-resettableand auto-resettable faults
The displayindicates thefailurewiththe associatederrorcode(seetable below). Some of
the faults can be reset (r) merelybypressing the reset button.Others are permanent,and
can be reset (f) onlywhen the faulthas been cleared:
Important. With auto-resettable faults, the LCD remains backlit
with the error message and code flashing. With user-resettable
faults, the error code remains fixed and the reset button
activates to allow the boiler to be reset.
In either case, w hen the fault has been eliminated, all the
buttons light up, and the interface is disabled after one minute
(w ithout pressing any button).

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14 AST 14 C 257/00
Boiler shutdow ndue to flame absence (r)
Boiler shutdow ndue to double flow probeintervention (r)
Boiler shutdow ndue to flue gas thermostat intervention (r)
Boiler shutdow ndue to low systempressure(f)
Boiler shutdow ndue to flow probefault (f)
Boiler shutdow ndue to DHW probe fault (f)
Boiler shutdow ndue to flue gas probe fault (f)
System pressuretoo high
Boiler shutdow ndue to failure of the tank heater probe
Boiler shutdow ndue to return probe fault (f)
External probe fault(f)
Solar collector probe (SCS) fault (f)
Solar valveprobe (SVS) fault (f)
Solar tank heater probe (SBS) fault (f)
Remote control connection fault (f)
Mixed zone 2 safety thermostat intervention (f)
Failure on flow probeof mixed zone 2 (f)

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15 AST 14 C 257/00
Failure on flow probeof mixed zone 3 (f)
Failure on flow probeof mixed zone 4 (f)
Boiler shutdow ndue to fanfault (r)
No communication betweenperipherals: additional interface
or board (a)
Plumbing configuration not allowed
Zone configuration error (remotecontrol andambientthermostat)
Pressure transducer fault (f)
Communication error betw eenthe main board and the
interfaceboard.
Shutdowndue to safety circuithardw arefailure
Incompatibility betw eenboiler board and interfaceboard
Boiler shutdow ndue to ûT max deviation error (r)
Shutdowndue to heating fluid circulation malfunction* (r) or (f)
Shutdowndue to heating fluid circulation malfunction* (r) or (f)
Shutdowndue to heating fluid circulation malfunction* (r) or (f)
Shutdowndue to heating fluid circulation malfunction* (r) or (f)

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16 AST 14 C 257/00
Flow probe o returnprobe > 120 C°(a)
Shutdowndue to max. flow derivativethresholdexceeded (r)
Shutdowndue to max. returnderivative threshold exceeded
(r)
Power reduction due to high flue gas temperature* (f)
Maximum number of remote resetattempts reached
* Errors E81, 82, 83, 84 and 88 are not displayed in real time. They are recorded on the shutdow n
counter under super-technical parameters (P01 to P05).
Important. They can be viewed on the display by setting super-technical parameter P90 to 1.
(f) = flow (r) =return
Malfunctions - errorsresettableby the technical serviceonly
Particularlyseriousshutdowns(see table below) required the intervention ofthe technical
service.
Press thereset andboilermodebuttons simultaneously.The spanner icon will appear,to
tell you that you can resetthe boiler bypressing the reset button.
Flue gas temperature low er thanthe return T
Maximum flue gas threshold exceeded
Alarm due to maximum flue gas derivative threshold
exceeded

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17 AST 14 C 257/00
SECTION 3
PLUMBING DIAGRAMS AND COMPONENTS
3.1 PLUMBING DIAGRAMS
KC
1. Condensate drain trap 20. 3-bar safety valve
2. Modulating gas valve 21. Discharge tap
3. Heating temperature sensor 1 22. Pressure transducer
4. Heating temperature sensor 2 23. 13-14 l/minflow-limitingdevice
5. Modulating fan 24. Fillingtap
6. Return temperature sensor 25. Coldwater flow meter with filter
7. Primary condensing exchanger 26. Secondary plate exchanger
9. De-aerator 27. DHW temperature sensor
10. Combustion airintake system 28. Automatic bypass
11. Fluegas vent system 29. Motorised 3-way valve
12. Fluegas sampling points
13. Fluegas thermostat on vent duct
14. Fluegas probe on exchanger SCondensate drain
15. Ignition/detection electrode MHeating system flow
16. Expansion vessel CDHW outflow
17. Fan control sensor GGas intake
18. De-aerator FColdwater inlet
19. Circulation pump RHeating system return

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18 AST 14 C 257/00
KR
1. Condensate drain trap 15. Return temperature sensor
2. Modulating gas valve 16. 3-bar safety valve
3. Heating temperature sensor 1 17. Pressure transducer
4. Modulating fan 18. De-aerator
5. Primary condensing exchanger 19. Circulation pump
6. De-aerator 20. Discharge tap
7. Combustion airintake system 21. Automatic bypass
8. Fluegas vent system
9. Fluegas sampling points
10 Fluegas thermostat on vent duct SCondensate drain
11. Fluegas probe on exchanger MHeating system flow
12. Ignition/detection electrode GGas intake
13. Expansion vessel FColdwater inlet
14. Fan control sensor RHeating system return

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19 AST 14 C 257/00
3.2 PLUMBING ASSEMBLY
MOTORISED THREE-WAY VALVE (Version KC only)
The boiler uses a three-way valve to divert the water flow from one pipe to another.The
valve conveys the primary circuit water to the secondary exchanger, where heat is
transferred to the DHW.
The valve consists of a brass main body, a cartridge made of composite material (35%
glass-reinforced nylon),and an electricmotor (actuator) to operate the internal shutter.
The secondary exchanger is connected by means of the three-way valve to another
thermopolymerassemblythatconnects thecoldwater inletpipe to the restof the plumbing
assembly.
The stainlesssteelplateheatexchanger consists of26 plates for all versions (24,28 and
32kW versions).
When a DHW request is received, the cold water from the mains passes through the
flowstat and causes the boiler to operate in the DHWmode.The three-wayvalve diverts
hotwater fromthe primaryheatexchanger to the secondaryone, which transfers the heat
to the water .
N.B. The home position of the three-way valve is the DHWposition.
Electric
motor
Water from primar
y
exchanger
T
o the plate
heat
exchanger
Flow
ELEC TRIC MO TO
R
CONNECTIONS
1 Line 1
Heating
2 Neutral
DHW
3 Line 2

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20 AST 14 C 257/00
Three-wayvalve view:
The boiler is fitted with an automatic bypass and a non-return valve, with an opening
threshold of 400 mbar. In the event of system load losses due to intervention of the
thermostatic valve,the bypass ensures a minimum flow inside the primaryexchanger.
Its job is to prevent the primary condensing heatexchangerfrom overheating caused by
low or no water circulation.
COLD WATE
R
DHW
Bypass pipe with
non-return valve
3-WA
Y
VALVE
FLOW RETURN
Pressure
transducer
3 bar
safetyvalve
Expansion vessel
connection
SHUTTE
R
THERMOPOLYMER
CARTRIDGE
3-WAY VALVESTATUS
DHW
Shutter pointingup
Actuatorpiston home
Heating
Shutter pointingdown
Actuatorpiston thrust
ACTUATO
R