Fondital ITACA KC 24 Quick setup guide

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1 AST 14 C 120/00
INFORMATION MANUAL
FAMILY: Wall-hung boilers
UNIT: Instantaneous natural and
forced draught and only
heating
MODELS: Tahiti Condensing
Pictor Condensing
VERSIONS: Indoor
CODE: AST 14C120/00
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1st Edition, Giugno 2007

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2 AST 14 C 120/00
Index
NOTES ___________________Page 03
CHAPTER 01
TECHNICAL FEATURES 1.1 – Models
1.2 – Overall sizes
1.3 – Control panel
1.4 – Dimensions for installation
1.5 – Technical data ___________________Page 06
CHAPTER 02
FUNCTIONAL LAYOUTS 2.1 – Hydraulic layouts
2.2 – Condensation siphon
2.3 – Hydraulic unit
2.4 – Primary condensation heat exchanger
2.5 – Pre-aerated burner
2.6 – Gas unit ___________________Page 14
CHAPTER 03
ADJUSTMENTS 3.1 – Transformations
3.2 – Calibration of the SIT 848 gas valve
3.3 – Chimney sweep function ___________________Page 31
CHAPTER 04
FUNCTIONING LOGIC AND DIAGNOSTICS
4.1 – Circuit board for management of the condensing boilers ___________________Page 33
CHAPTER 05
DISCHARGES AND PIPING 5.1 – KC - KR ___________________Page 50

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3 AST 14 C 120/00
NOTES
CONDENSATION
The condensing boilers as of today, represent the most technologically advanced offer
available on the market for domestic heating and the production of hot water.
A solution that satisfies environmental protection requirements thanks to the emission of
particularly reduced pollutants of this product.
The condensing boilers have greater combustion efficiency to that of traditional boilers with
consequent energy saving and a reduction of combustion consumption.
These generators, that initially present themselves to the client has top of the range
products and therefore more expensive than traditional boilers, allow to realise effective
savings and therefore repay the extra cost, if however they are introduced into an ad hoc
plant.
The formation of condensation is therefore testimony of the correct functioning of a
condensation generator.
The recovery of latent heat of condensation, which takes place by cooling the fumes more
and taking them to a temperature lower to that of the dew point, obviously allows energy
recovery and, as a consequence, an increase of the combustion efficiency.
Energy that is otherwise lost is recovered in this way (540 kcal for every kg of
condensation produced). The condensation is however acid and therefore the boiler is
created using especially studied technological materials.
Useful definitions
Sensible heat: the amount of heat that causes the temperature variation of a body
without modifying its physical state.
Latent heat: the amount of heat that causes the variation of the state of the body
without modifying the temperature.
Gross Calorific Value (GCV): heat released by the combustion of 1 Nm3 of gas
when all of the water is assumed taken back to the liquid state in the combustion
products, so recovering latent heat. International symbol: Hs
(G20 : Hs=37.78 Mj/m3)
Net Calorific Value (NCV): heat released by the combustion of 1 Nm3 of gas when all
of the water is assumed to be in the vapour state in the combustion products.
International symbol Hi (G20 : Hi=34.02Mj/ m3)
Combustion is the phenomenon obtained when a mixture of oxygen and combustible
is taken to a given temperature. It is an exothermic reaction, which means that heat is
released.
The combustion of methane creates steam and carbon dioxide that are released with
the combustion products. The fumes produced by a boiler are in reality a mixture of
flue gases and steam.

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4 AST 14 C 120/00
Why and how do condensing boilers produce condensation?
As known, during a combustion process of methane, as well as the production of heat, a
determined quantity of carbon dioxide and steam are obtained. Everything is, in an analytic
manner expressed in the following reaction:
HEATOHCOCH
+
+
→+ 2224 202
(methane + oxygen -->carbon dioxide + steam + heat)
In a traditional generator, the fumes emitted into the atmosphere inevitably contain a
quantity of energy that is destined to be dispersed. This energy is determined by the high
temperature of the fumes emitted, which are expelled at over 100°C.
The reasons for which this energy is dispersed in traditional appliances are due to the fact
that a reduction in temperature of the fumes (with consequent recovery of sensible heat,
1% of combustion efficiency gained every 20°C recovered from the fumes) would prevent
the natural ascending motion implemented by the difference in temperature between the
fumes and the external air (natural draught of the flue). Their further cooling (with
consequent recovery of latent heat of condensation) would lead to the formation of acid
condensation (pH 3-5), surely dangerous for the components used in the construction of a
traditional type generator (with primary heat exchanger in copper).
The construction features of the modern condensation generators, generally realised using
noble materials (stainless steel), determine the correct functioning of the appliances
without altering the features during the course of the activity period.
To use the heat that is produced in the chemical reaction of combustion between methane
and oxygen, as already explained previously, the fumes must be cooled in order to recover
the heat held and transfer it to the plant.
In order to do this, the fumes must be cooled below the “dew point”. While the temperature
of the fumes remains above the “dew point”, by cooling the fumes only the “sensible heat”
is recovered.
When the temperature falls below the “dew point” (about 55-56°C in normal methane
combustion), a part of the steam contained in the fumes “condenses” releasing further
latent heat.
How not to condensate.
Until a few years ago the condensation calories of the steam generated in combustion
were considered irretrievable, so much as to define a “net calorific value”.
Today, appliances and components are available that allow this operation. Attention,
however, must be paid when designing “condensation plants” as it is not sufficient just to
install “condensation generators” (which can simply condensate if they are put in the right
conditions) but the system must be designed, built and run in a way that the return
temperature of the water to the boiler and the power supplied by the generator remain
constant at the minimum values possible, compatibility with the requirements of the
service.
The use of the panels as heating elements is often presented as a warranty of the
attainment of a “low temperature” plant, therefore optimal use of the condensing boilers;
this however, is not always true.
It is possible to build a panel plant that does not produce even a drop of condensation if
the plant is not studied correctly.

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5 AST 14 C 120/00
Reference regulations.
The fact that yield exceeds 100% derives
from the fact that the European Community
Regulations prescribe, for all boilers, to
calculate efficiency by referring to the net
calorific value, which does not consider the
condensation heat of steam; this method
allows to compare the efficiency of
condensing boilers and traditional boilers on
the same basis.
European Efficiency Directive 92/42/CEE,
enforced in Italy by Presidential Decree
660/96
With methane, the theoretical latent heat that
can be recovered is equal to 11%.
The UNI11071 (July 2003) Reference
Regulation supplies clear and detailed rules
for the installation and maintenance of a
plant interlocked to a condensation
generator or similar, with a nominal heat
input that does not exceed 35 kW.
Finally, the next publication of the CIG E01.08.929.0 Regulation project will cover the field of plants
with potentiality greater than 35 kW, covering a current Regulation “vacuum” and also making
application of condensation generators in this ambit clear.
What does the regulation say.
Definition of condensation appliance or similar (art. 3.1).
The Regulation defines condensation appliances similar to those appliances for which, when
running regularly, in all or some functioning conditions and/or installation of the plant, the
Manufacturer envisions the formation of condensation of the combustion products not only inside
the appliance but also in the combustion products evacuation in amounts such to request their
conveying and/or disposal.
Condensation discharge system (art. 5).
In all cases, the condensation appliances or similar, as previously defined, must always be
connected to a domestic waste disposal plant. It is important that the attachment of the
condensation discharge pipe is realised in a way to prevent the escape and return of the unburned
residues or emission into the environment or the drain system. To obtain this, a siphon must be
used (inside the appliance and/or interlocked to the fumes discharge system) constructed in a way
to prevent the escape of gaseous combustion products into the environment or the drain system.
Regarding the set-up, the Regulation prescribes that the condensation cannot be used by the
utility; they must have flow without leaks, must not have constrictions that prevent regular
discharge and cannot undergo the eventual freezing of the fluid (condensation).
For the regular flow, the Regulation envisions a slope or inclination of the discharge plant greater
than 3%. In all cases, stagnation of the condensation must be prevented with exception to that
present inside the discharge siphon inside the combustion products evacuation system.
N.B. The connection plant of the condensation discharge to the disposal plant of domestic waste is
not part of the gas plant (art. 5 paragraph 5.1).
-Treatment of the condensation:
The Regulation considers the noteworthy quantity of waste water produced in domestic uses (180
litres pro-capite), well-known for its high basicity, which allows to effectively dilute the acid
condensation produced by the appliances or similar and therefore, declares the possibility to
discharge the condensation into the drain system directly. This is because of the alteration of
the pH due to mixture of the domestic waste (power less than 35 kW it can be practically ignored).

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6 AST 14 C 120/00
CHAP. 1
TECHNICAL FEATURES
1.1 MODELS
TAHITI-PICTOR CONDENSING KC 24 – 32
TAHITI-PICTOR CONDENSING KR 24 – 32
KEY:
C: combined
R: only heating
K: condensation
MAIN FEATURES:
TAHITI-PICTOR condensing KC 24-32: condensing boiler combined instantaneous, waterproof chamber,
forced draught, stainless steel composite heat exchanger, pre-aeration burner, modulating fan, 3-speed
circulator with degaser, fifth class NOx emission;
TAHITI-PICTOR condensing KR 24-32: condensing boiler only heating, waterproof chamber, forced draught,
stainless steel composite heat exchanger, pre-aeration burner, modulating fan, 3-speed circulator with
degasser, fifth class NOx emission;
1.2 OVERALL SIZES
Height H = 750 mm
Width L = 450 mm
Depth P = 330 mm

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7 AST 14 C 120/00
1.3 CONTROL PANEL
1 Line bulb (green)
2-7 Indication bulbs (red)
8 Indication bulb (green)
9 Boiler state – release boiler selector switch
10 Domestic hot water temperature adjuster
11 Heating water temperature adjuster
12 Water manometer
13 Aqua Premium system activation button
The indication bulbs 1-8 can indicate two different situations: information in the case of
normal functioning of the boiler or self-diagnostics in the case of anomaly or blocking of
the boiler.
INFORMATION LIGHTS IN NORMAL BOILER FUNCTIONING
2 3 4 5 6 7
Condition Red Red Red Red Red Red
Delivery temperature 20° or lower OFF OFF OFF OFF OFF OFF
Delivery temperature 30° ON OFF OFF OFF OFF OFF
Delivery temperature 40° OFF ON OFF OFF OFF OFF
Delivery temperature 50° OFF OFF ON OFF OFF OFF
Delivery temperature 60° OFF OFF OFF ON OFF OFF
Delivery temperature 70° OFF OFF OFF OFF ON OFF
Delivery temperature 80° OFF OFF OFF OFF OFF ON
Delivery temperature 90° or higher OFF OFF OFF OFF OFF
ON L
Key:
OFF - LED off
ON - LED on with fixed light
ON L - LED on with flashing light

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8 AST 14 C 120/00
SELF-DIAGNOSTIC WARNING LIGHTS IN THE CASE OF ANOMALY OR BOILER BLOCKING
1 2 3 4 5 6 7 8 Remote
code
Condition Green Red Red Red Red Red Red Yellow
Flame control block X OFF OFF OFF ON L OFF OFF OFF E01
Safety thermostat block X OFF ON L OFF OFF OFF OFF OFF E02
Fumes thermostat block X OFF OFF ON L OFF OFF OFF OFF E03
Fluid circulation block X OFF OFF OFF OFF ON L OFF OFF E04
Delivery probe fault X ON L OFF OFF OFF OFF OFF ON L E05
Domestic hot water probe fault X ON L OFF OFF OFF OFF OFF OFF E06
Boiler probe fault X ON LA OFF OFF OFF OFF OFF ON LA E12
Return probe fault X OFF ON LA OFF OFF OFF OFF ON LA E15
Fan/hall fault X OFF ON L OFF OFF OFF OFF ON L
Remote connection fault X OFF OFF ON L OFF OFF OFF ON L
Delivery temperature >>90°C X OFF OFF OFF OFF OFF ON L X
Flame presence X X X X X X X ON
Line presence ON X X X X X X X
Key:
OFF - LED off
ON - LED on with fixed light
ON L - LED on with flashing light
ON LA - LED on with alternating flashing light
1.4 DIMENSIONS FOR INSTALLATION

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9 AST 14 C 120/00
DIMENSIONS AND OVERALL SIZES KC
Key:
S: Condensation discharge
G: Gas inlet (G1/2”)
M: Heating plant delivery (G3/4”)
C: Domestic hot water outlet (G1/2”)
F: Cold water inlet (G1/2”)
R: Heating plant return (G3/4”)

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10 AST 14 C 120/00
DIMENSIONS AND OVERALL SIZES KR
Key:
S: Condensation discharge
G: Gas inlet (G1/2”)
M: Heating plant delivery (G3/4”)
F: Cold water inlet (G1/2”)
R: Heating plant return (G3/4”)

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11 AST 14 C 120/00
1.5 TECHNICAL DATA
NOMINAL DATA
MODEL
KC 24 KR 24 KC 32 KR 32
NOMINAL HEAT INPUT (QN) KW 23.7 23.7 31.4 31.4
NOMINAL HEAT INPUT (80 - 60°C) (PN) KW 22.7 22.7 30.5 30.5
NOMINAL HEAT INPUT (50 - 30°C) KW 24.8 24.8 33.2 33.2
REDUCED HEAT INPUT (QR) KW 6.8 6.8 9.1 9.1
REDUCED HEAT INPUT (80 - 60°C) (PR) KW 6.5 6.5 8.7 8.7
REDUCED HEAT INPUT (50 - 30°C) (PR) KW 7.3 7.3 9.6 9.6
YIELD AT 100% (80 - 60°C) % 96.0 96.0 96.6 96.6
YIELD AT 100% (50 - 30°C) % 104.8 104.8 105.4 105.4
YIELD AT 30 % % 109.1 109.1 108.7 108.7
YIELD AT REDUCED INPUT (80 - 60°C) % 95.7 95.7 96.3 96.3
YIELD AT REDUCED INPUT (50 - 30°C) % 106.9 106.9 106.3 106.3
HEATING TEMPERATURE ADJUSTMENT FIELD °C 20 ÷
78
20 -
78
20 ÷
78
20 -
78
MAXIMUM HEATING TEMPERATURE °C 78 + 5 78 + 5 78 + 5 78 + 5
HEATING WATER MAXIMUM PRESSURE (PMS) BAR 3 3 3 3
NOMINAL HEAT INPUT DHW (QNS) KW 27.2 --- 34.5 ---
NOMINAL HEAT INPUT DHW (QNS) KW 28.0 --- 35.4 ---
REDUCED HEAT INPUT DHW (QRS) KW 6.8 --- 9.1 ---
DISCHARGE INTENSITY (D) ∆T 30K L/MIN 13.5 --- 16.5 ---
DOMESTIC HOT WATER DHW MAX. PRESSURE BAR 8 --- 8 ---
DOMESTIC HOT WATER DHW ADJUSTMENT FIELD °C 35 ÷
57 --- 35 ÷
57
DOMESTIC HOT WATER MAX. TEMPERATURE °C 57 + 5 --- 57 + 5
HEIGHT MM 750 750 750 750
WIDTH MM 450 450 450 450
DEPTH MM 330 330 330 330
WEIGHT KG 38.5 37.5 40 39
GAS CONNECTION --- G1/2 G1/2 G1/2 G1/2
HEATING CONNECTIONS --- G3/4 G3/4 G3/4 G3/4
DOMESTIC HOT WATER CONNECTIONS --- G1/2 --- G1/2 ---
NOX CLASS (ACCORDING TO EN 483) 5 5 5 5
DOMESTIC HOT WATER QUALIFICATION EN 13203  ---  ---
POWER SUPPLY VOLTAGE V 230 230 230 230
FREQUENCY HZ 50 50 50 50
ELECTRICAL POWER W 145 145 145 145
LEVEL OF PROTECTION AGAINST HUMIDITY AND
PENETRATION OF WATER --- IPX4D IPX4D IPX4D IPX4D

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12 AST 14 C 120/00
GAS CATEGORY
COUNTRY OF DESTINATION CATEGORY TYPE OF GAS SUPPLY RESSURE
(mbar)
ITALY II2H3P G20 - G31 20 – 37
AT – CH II2H3P G20 - G31 20 – 50
DE II2ELL3/P G20-G25 / G31 20/20 – 50
NL II2L3P G25 - G31 25 – 30
FR II2Er3P G20/G25 - G31 20/25 – 37
DK – EE – FI – LV – LT – CZ – SK
– SI – SE - NO II2H3P G20 - G31 20 – 30
BE IE(R)B - I3P G20/G25 - G31 20/25 – 37
EE – GB – GR – IE – LV – LT –
PT – ES – CH II2H3P G20 - G31 20 – 37
LU I2E G20 20
PL II2ELwLs3P G20/GZ41,5/GZ350 –
G31 20/20/13 – 36
HU II2HS3P G20/G25.1 – G31 25/25 – 30
CY - IS - MT I3P G31 37
Tahiti/Pictor Condensing KC/KR 24
GAS CIRCUIT
FAMILY GAS NUMBER OF JETS TO THE BURNER DIAPHRAGM BURNER JET CO2
mm mm %
2Lw GZ41,5 1 10.0 10.8 8.8
2Ls GZ350 1 --- 10.8 8.6
2L G25 1 9.2 10.8 8.8
2LL G25 1 9.2 10.8 8.8
2HS G25.1 1 10.0 10.8 10.3
2HS G20 1 7.2 10.8 9.0
2H G20 1 7.2 10.8 9.0
2Er G20 1 9.2 10.8 9.0
2E(R)B G20 1 7.2 10.8 9.0
3P G31 1 5.3 10.8 10.0

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13 AST 14 C 120/00
Tahiti/Pictor Condensing KC/KR 32
GAS CIRCUIT
FAMILY GAS
NUMBER OF
JETS TO THE
BURNER DIAPHRAGM BURNER JET CO2
N° mm mm %
2Lw GZ41,5 1 12.0 10.8 8.8
2Ls GZ350 1 --- 10.8 8.6
2L G25 1 10.7 10.8 8.8
2LL G25 1 10.7 10.8 8.8
2HS G25.1 1 12.0 10.8 10.3
2HS G20 1 8.4 10.8 9.0
2H G20 1 8.4 10.8 9.0
2Er G20 1 10.7 10.8 9.0
2E(R)B G20 1 8.4 10.8 9.0
3P G31 1 6.0 10.8 10.0
FAN CALIBRATION
PARAMETER KC/KR 24 KC/KR 32
Vmax DHW [Hz] 181 193
Vmin DHW [Hz] 53 56
Vacc [Hz] 67 67
Vlimite % CH [%] 84 90
Designer data
KC/KR 24 KC/KR 32
Pmax – Heat. Pmin Pmax – Heat. Pmin
Leaks through the Shell
with Burner Functioning % 1.4 2.1 0.6 1.6
Leaks through the Shell
with Burner Off % 0.2 0.2
Leaks through the Flue
with Burner Functioning % 2.6 2.2 2.4 2.1
Leaks through the Flue
with Burner Off % --- ---
Performance Label 4 STARS 4 STARS
Flue Dimensioning
KC/KR 24 KC/KR 32
Pmax – San. Pmin Pmax – San. Pmin
CO2% {See Gas
Table}
{ See Gas
Table }
{ See Gas
Table }
{ See Gas
Table }
Tfumes – Tair °C 67 49 54 51
Fumes mass flow g/s 12.4 3.1 15.,7 4.1
Available Residual
Pressure Pa 127 8 204 15

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14 AST 14 C 120/00
CHAP. 2
FUNCTIONAL LAYOUTS
2.1HYDRAULIC LAYOUTS
Condensing KC

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15 AST 14 C 120/00
Condensing KR

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16 AST 14 C 120/00
Details of the hydraulic circuit:
This boiler has two flow switches: as well as the one for domestic hot water, there is
another one positioned on the delivery pipe of the heating circuit (see n° 6 in previous
figures). This flow switch intervenes when the flow of fluid inside the heat exchanger is
lower than 500 l/h for versions at 24 kw, 650 litres/h for the versions at 32 kw), and blocks
ignition of the burner until adequate circulation inside the heat exchanger is re-established.
The intervention of the heating flow switch (primary) could indicate that the heat exchanger
is blocked (primary or domestic hot water), or a fault with the pump. The intervention of
this flow meter is less probable in the case of plant problems as the boiler has an internal
By-pass that opens when the pressure in the plant is greater than 4 metres, assuring the
circulation of at least 400 litres of fluid within the boiler. The boiler has an internal siphon,
which evacuates the condensation produced making sure that the combustion products do
not come into contact with the environment.
FLOW SWITCHES
Primary flow switch
Domestic hot water flow switch
Flow adjuster:
-flow adjuster 13 l/min
(mod. 24kW)
code: 0REGFLU04
- flow adjuster 16 l/min
(mod. 32kW)
code: 0REGFLU06
Intervention flow:
- 500 l/h (24 Kw version)
- 650 l/h (32 kW version)

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17 AST 14 C 120/00
CONDENSATION
Condensation coming from
the main heat exchanger
2.2 CONDENSATION SYPHON
The siphon is integrated into the boiler; it must not be filled because it is a siphon with
float. It can be cleaned without opening the air chamber, by means of a cap facing
outwards. The siphon prevents combustion products from entering the condensation
discharge plants and therefore successively into the drain system.
Functioning of the condensation recovery device:
The float closes the condensation opening (fig. A). The float frees the opening as soon as
the device fills with condensation (fig. B). The condensation fills the second chamber up to
the level of the discharge pipe taking the condensation out of the boiler (fig. C).
The plant and the connection to the discharge pipe must be realised using materials
suitable to resist thermal and chemical stress. Stainless and plastic materials are
considered suitable.
N.B The choice and positioning of the siphon determine the correct functioning of the
boiler in total safety. It is not possible to extract and re-locate the siphon in a different
position, as the appliance is type-approved in its complexity.
Any modifications to the system would make the boiler no longer type-approved, with
liability of the operator that tampered with the device.
Condensation
discharge
Cap for cleaning

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18 AST 14 C 120/00
2.3HYDRAULIC UNIT
MOTORISED THREE-WAY VALVE
The boiler uses a 3-wat valve to vary the distribution of the water (secondary heat
exchanger side or plant heating side).
It is formed by a valve body without adjustable by-pass and by an electric motor (actuator).
The secondary heat exchanger is fixed, by means of the 3-way valve and a connection piece that joins the
cold water arrival pipe, the by-pass pipe, the heating return pipe and the discharge pipe, to the rest of the
hydraulic unit. For all models the heat exchanger is made up of 26 stainless steel plates.
On the request for domestic hot water, the cold water coming from the domestic hot water distribution system
passes through the flow switch taking the boiler to “domestic” functioning. At this point the 3-way valve
deviates the hot water coming from the primary heat exchanger to the secondary one in a way that it gives
its heat to the domestic water, heating it.
Electric motor
Water inlet from the heat
exchanger
Exit towards
the plate heat
exchanger
Delivery
PLATE HEAT
EXCHANGER
LOADING TAP
DELIVERY ELECTRIC
MOTOR
A.C.S.
Cold water inlet
By-pass
connection
pipe
Heating water
outlet
Heating water
inlet

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19 AST 14 C 120/00
As it can be seen in the following images, the boiler ha san automatic internal by-pass. If
leaks occur in the loading plant, which are caused by the intervention of the thermostatic
valves, the by-pass guarantees minimum flow inside the primary heat exchanger.
The by-pass therefore protects the condensing primary heat exchanger from over-
temperatures due to the bad or lack of circulation of the water.
The end block of the circulation pump has a 3-
position selector switch that acts on the rotation
speed of the motor and consequently on the flow
rate towards the plant.
3 BAR SAFETY
VALVE
MANOMETERCOLD WATER
A.C.S
BY-PASS
3-WAY VALVE
Speed
selector
switch

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20 AST 14 C 120/00
RESIDUAL PRESSURE OF THE KC-KR 32 BOILER
RESIDUAL PRESSURE OF THE KC-KR 24 BOILER