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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