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1. Hot Water Monday End ooo 0 12 24 OK Cs C __ C m lt lt There 3 operating ranges for each day of the week When you have selected one of the programmes press the F key corresponding to OK to confirm 1 5 Antifreeze function Monday End 09 00 16 00 16 30 19 00 Standard 20 30 21 30 OK The system comes with an antifreeze protection system When the external probe reads a temperature below 0 C default value possible adjustable range 15 C to 5 C the system switches on and runs until the nominal temperature is reached The nominal temperature varies with the value read by the external probe the nominal fictitious room temperature default value 5 C and the selected heating curve When the manifold probe reads a temperature below 5 C default value the system activates and runs until a temperature of 20 C is reached When the heating water temperature sensor reads a temperature of 5 C the boiler switches on at minimum heat output until the water heating temperature rises to 30 C or 15 minutes have elapsed If the boiler shuts down the pump continues to operate The heating system can also be protected effectively from frost by using specific antifreeze products suitable for multi metal systems Periodically check the effectiveness of the additive Do not use vehicle antifreeze products 13
2. 1 5 70 1 0 60 2 50 4 0 8 Q 40 _ T 4 0 6 E 2 0 4 3 30 5 0 2 20 10 4 0 t t 20 16 12 8 4 0 4 8 12 16 20 24 28 32 36 40 Outside temperature C The curves shown above which refer to an room temperature of 20 are always limited by the maximum and minimum values of the operating range 3 3 Filling the system When all the boiler connections have been completed the CH system can be filled with water This must be done with caution following these steps in sequence Open the air relief valve on all the radiators and check the efficiency of the automatic boiler valve Gradually open the boiler external filling tap and check that any automatic air relief valves work efficiently Close the relief valves as soon as water starts to come out Check the water pressure on the pressure gauge of the header module it has to be 1 5 bar Close the filling device and bleed all the valves on the radiators to remove any residual air Start the boilers and as soon as the system reaches the working temperature stop the pump and repeat the air bleeding procedure Allow the system to cool down then restore water pressure to 1 5 bar IMPORTANT As regards treating water in domestic heating systems it is advisable to use specific products that are suitable for multi metal systems in order to optimize performance and safety preserve these conditions ov
3. 4 5 AT AB A9 A10 A12 6 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 La Ob m Q G T6 3H 1 2 Vaal vw L CAN 50Hz 000 M M I 18 H Bus GND 230V 2s 7 T 19 2 2 NIN N L1 L1 101102 82 T1 T2 T3 21 2 1 The thermoregulation curve is selected on the control unit To set the heating curve press the HOME button to call up the main menu Use the knob to scroll through the menu Press the F key corresponding to USER Main Menu End Display C User m e Time Progr CC After entering the User submenu press the F key corresponding to HEAT CIRC 1 Gam End Ss Installation C Hot Water __ Heat Circ 1 CC 4 34 From the HEAT CIRC 1 submenu press the F key corresponding to HEAT CURVE Heat Circ 1 los End c T reduction 50 C T absence 150 C Heat Curve 2 0 c Turn the knob clockwise or anticlockwise to set the temperature curve then press the F key corresponding to OK Heat Curve End 2 0 Favourite Standard OK 100 3 0 2 5 2 0 90 80
4. IST 03 C 438 02 CO e o 5 INSTALLATION USE AND MAINTENANCE fondital Dear Customer Thank you for choosing and buying one of our boilers Please read these instructions carefully They will enable you to install operate and service the appliance properly Any maintenance and repairs must be carried out by fully qualified engineers who carry the appropriate competency for this equipment General information for fitters maintenance technicians and users This INSTRUCTION MANUAL which is an integral and indispensable part of the product must be handed over to the user by the installer and must be kept in a safe place for future reference The manual must accompany the boiler should it be sold or its possession transferred Following to the boiler installation the fitter is to advise the user about boiler operation and its safety devices This boiler is designed for connection to a domestic heating or hot water system Any other use is deemed as improper and as such dangerous Under no circumstances will the manufacturer be held responsible for damage or injury to persons or animals caused by errors in the installation and or use of the appliance or through non compliance with current local and national standards and or the manufacturer s instructions The boiler must be installed by qualified personnel in compliance with applicable laws and standards and according
5. system must be filled with water pressure reading on water gauge 1 5 bar Any stopcocks on the pipes must be open gas supplied to the boiler must be of the type for which the boiler is designed If necessary convert the boiler following the instructions in 5 3 7 Adapting to other gases and regulating the burner This operation must be carried out by a qualified service engineer gas supply stopcock must be open There must be no gas leaks The master power switch before the boiler must be on boiler safety valve must not be blocked There must be no water leaks The pump must not be blocked The condensate trap installed on the boiler must discharge condensate correctly and not be clogged Itis delivered with the circulation pump on the third speed setting If you wish to set a different speed taking account of the water circulation requirements in the boiler controlled by the water pressure switch and the resistance properties of the system check boiler operation under all the conditions dictated by the features of the system e g closure of one or more heating zones or thermostat controlled valves The boiler is equipped with a three speed circulation pump corresponding to three different residual heads 3 4 2 Switching on and off To switch the boiler on and off refer to the User Instructions 36 inet Standard control cab 3 5 ay ur mous s
6. L _10 B RO gt We M4 8 M31 m26 49 50 51 52 lC TOL nec 53 54 55 TS 5657 58 H2 M32 M33 KKAB Hp cox TD 100 2 CLAMP 28 32 3 2 11 Connecting the control cabinet to the boilers The control cabinet comes with corrugated cables for connection to the boiler Each cable is marked by a number The boiler to which cable 1 is connected is recognised by the control unit as boiler 1 Connecting a cable to a boiler involves accessing the inside of the electrical box To do this proceed as follows unscrew two of the four screws securing the case either the two on the right and two on the left open the case remove the mask from the control panel by pressing on the hooks on the right and left and pulling outwards unscrew the three screws securing the box to the base of the boiler Connect terminal M3 and the earth wire to the boiler board and terminal M6 to the OSCHEREMOO board as shown in pic 18 Proceed as follows when replacing the electronic board of any boiler Connect the OCREMOTOO5 Remote Control not supplied with the boiler to terminal M6 of the OSCHEREMOO board Press the key to switch the Remote Control to OFF Press s 1 and hold them down until TSP is displayed Press 6 to confirm The display reads TSPO Turn knob e to select TSP1 Press 62 to modify the value the value associated with thi
7. LW D Den 19 AIN A ZHOS 9EAO C 39 Key to symbols F2PIA Mono thermal Aqua Premium boiler F3RIS CH only boiler F4BOI boiler with water heater F5MIC micro storage boiler F6MAC encased Aqua Premium boiler M3 M8 M9 Outdoor probe power connector M16 telemetering connector M2 M15 service connectors E RIV detection electrode E ACC ignition electrode P pump V brushless fan MVD three way valve motor 1 2 flue gas thermostat protecting flue gas system and heat exchanger TR ACC ignition transformer SR 10K Ohm CH probe 3435 SE OSONDAESO external probe 10K Ohm 3977 optional boiler probe to be connected to the boiler board SS 10K Ohm 3435 DHW probe max length 3 metres 40 TA ambient thermostat optional CM1 CM2 jumpers for selecting the type of boiler FL DHW flow switch FLP Safety flow switch for low water in the primary circuit CH VG gas valve TL limit thermostat P1 upgrading of flow temperature regulation P2 upgrading of DHW temperature regulation P3 boiler selector P4 upgrading of maximum heat output P6 thermoregulation curve regulation K1 chimney sweep selection button B external water heater with probe remove R1 BM120 separat
8. Power supply voltage frequency V Hz 230 50 Maximum input power 491 537 583 959 1005 1051 1097 Index of protection IP X4D Table 5 General specifications If the boiler is connected to a separate water heater with NTC probe 10 8 3435 Value referred to 15 C 1013 mbar KR 340 KR360 KR390 KR420 KR450 KR480 KR 510 Category II2H3P II2H3P II2H3P II2H3P II2H3P II2H3P II2H3P CH minimum pressure bar 0 5 0 5 0 5 0 5 0 5 0 5 0 5 CH maximum pressure bar 4 4 4 4 4 4 4 CH maximum working temperature C 83 83 83 83 83 83 83 DHW maximum working temperature C 62 62 62 62 62 62 62 Methane gas consumption at max flow m h 35 979 38 095 41 270 44 444 47 619 50 794 53 968 Power supply voltage frequency Hz 230 50 Maximum input power 1143 1473 1519 1565 1611 1657 1703 Index of protection IP X4D X4D X4D X4D X4D Table 6 General specifications If the boiler is connected to a separate water heater with NTC probe 10 8 3435 Value referred to 15 C 1013 mbar 21 KR110 KR 140 170 KR220 KR250 KR280 KR 310 Casing heat loss with burner on Pmax 96 0 46 0 36 0 30 0 46 0 41 0 36 0 33 Casing heat loss with burner on Pmin 96 0 83 0 89
9. The following measurements must be made to determine combustion efficiency measure combustion air taken from opening 1 pic 15 measure flue gas temperature and CO from opening 2 pic 15 The boiler must be working at a steady rate about ten minutes after entering the chimney sweep mode KR 85 The boiler is not equipped with a tower allowing for connection of the air intake and flue gas discharge pipes In this case combustion air flue gas temperature and CO are measured at the openings for the accessory pipes or as close as possible to the air intake and flue gas discharge points on the boiler 3 2 9 Connecting to the gas mains The cross section of the pipe depends on the length of the pipe the layout pattern and the gas flow rate This means the pipe must be sized accordingly Gas connections must comply with the applicable rules and regulations in the country of installation which are intended as an integral part of this handbook Please note that before activating an indoor gas supply system and before connecting it to a meter it must be checked for ZN tightness If any part of the system is not visible the gas leak test must be performed before the pipe is covered The test must NOT be performed with combustible gas Use air or nitrogen If gas is present in the piping do not use a naked flame to look for leaks Use a specific product available on the market When connecting the boi
10. and leak test State of the thermostat on the flue gas stack State of combustion fans State of the Hall sensors General integrity of the boilers safety devices Integrity state of preservation and seal of the flue gas discharge pipes Boiler safety valve efficiency Expansion vessels pressure Efficiency of water minimum differential switches Correct discharge of condensates through the condensate drains installed on each separate boiler Cleaning operations Inside of the boiler e Burner Gas nozzles Air intake and flue gas discharge circuit Heat exchanger Condensate discharge ducts Drain siphons for discharge of condensate Checks to perform when using the boiler for the first time User manual Suitability of the boiler room Flue gas discharge pipes diameters and lengths Boiler installation in accordance with the instructions in this manual If the boiler does not work properly or if it poses a danger to people animals or property inform the system supervisor and compile a report In case of electronic board failure any attempt to repair is forbidden It is advisable to carefully protect the electronic board from any dripping water that could damage the internal circuits 5 2 Combustion analysis The boiler combustion parameter check to assess efficiency and polluting emissions must be performed in accordance with the applicable laws and regulations 6
11. 0 92 0 93 Casing heat loss with burner off 96 0 48 0 39 0 41 0 43 0 45 0 47 0 48 Chimney heat loss with burner on Pmax 96 2 20 2 08 2 11 2 14 2 16 2 18 2 20 Chimney heat loss with burner on Pmin 96 1 79 1 87 1 85 1 83 1 81 1 80 1 79 Flue gas system mass flow rate Pmax 9 5 154 8 164 2 177 8 191 4 205 0 218 6 2322 Flue gas system mass flow rate Pmin 9 5 9 60 6 60 6 60 6 60 6 60 6 60 9 60 Flue gas air temperature Pmax C 47 00 44 71 45 31 45 82 46 27 46 66 47 00 Flue gas air temperature Pmin C 36 00 38 29 37 69 37 18 36 73 36 34 36 00 Available pumping head Pmax Pa 90 0 163 0 163 0 163 0 163 0 163 0 163 0 Available pumping head Pmin Pa 8 0 8 0 8 0 8 0 8 0 8 0 8 0 Maximum heat output efficiency rating 60 80 C 97 3 97 3 97 3 97 3 97 3 97 3 97 3 Maximum heat output efficiency rating 30 50 C 106 4 106 9 106 8 106 7 106 6 106 5 106 4 Minimum heat output efficiency rating 60 80 C 97 3 97 1 97 1 97 2 97 2 97 3 97 3 Minimum heat output efficiency rating 30 50 C 107 7 108 0 108 0 107 9 107 8 107 8 107 7 30 heat output efficiency rating 108 5 108 8 108 8 108 7 108 6 108 6 108 5 Flue gas collector diameter mm 160 200 200 200 200 200 200 Efficiency rating according to 92 42 CEE NO emission class 5 Table 8 Combustion data 22 2 7 Pumping head Available head mbar 8 8 200 100 KR 55 ss atus w o D CM 500 Pump speed min Pump speed II Pump spe
12. ON Off Time master Off Off Plant select HS1 Type 03 06 modulating boiler HS 1 BUS 00 01 HS2 Type 00 00 Storage HS2 00 00 Buffer 00 00 Cool Operation Off Off F15 Function 00 00 Sensor Sens 5k Sens 5k Cascade control values 1 Press the HOME button to access the control unit main menu Turn the knob to scroll through the main menu Press the F key corresponding to EXPERT Main menu End Time date C Service __ Expert CS 2 From the technical submenu press the F key corresponding to the CASCADE line Ee End r Configuration C Heat source __ m lt Enter the following recommended values in the cascade submenu Description Set value Mandatory value detected HSS Capacity Stage 00 kW Enter thermal output for each boiler 4 BUS Scan Off Off min Mod Cascade 00 00 DHW HS 00 00 Control Deviation Desired Output Switch value Block Time Max T Module 90 C 90 C Dyn Upward 100 K 100 K Dyn Downward 100 K 100 K Reset time 50 50 Modulation max 80 15 qa Modulation min 30 15 Min Mod HS 3096 1596 Modulat DHW 8096 8096 Sequence 1 12345678 12345678 Sequence 2 87654321 87654321 Sequ change 0 hours 0 hours Block time 00 min 00 min 29 3 2 8 Testing combustion effi
13. be open There must be no gas leaks The main power switch must be on boiler safety valve must not be blocked There must be no water leaks The pump must not be blocked condensate trap installed on the boiler is discharging condensate correctly and is not stuck N If the boiler is not installed in accordance with the applicable laws and regulations inform the system supervisor and do not test the boiler 4 2 Switching on and off Refer to the User Instructions for details of how to switch the boiler on and off 42 5 Maintenance Maintenance and repairs must be carried out by a fully qualified technician The user is strongly advised to have the boiler serviced and repaired by one of the Manufacturer s fully qualified Service Centres Correct maintenance of the boiler will allow it to work efficiently without harming the environment and in complete safety 5 1 Maintenance schedule Routine maintenance must be performed once a year Before carrying out any maintenance work involving the replacement of components or internal cleaning of the boiler disconnect the boiler from the mains Routine maintenance must include a series of checks and cleaning operations Checks General integrity of the boilers Boiler and gas supply leaks Boiler gas supply pressure Minimum and maximum gas pressures to boiler nozzles Boilers ignition Flue system integrity good state of preservation
14. is in CH mode c Boiler shutdown indicator This comes on when there is a malfunction that cannot be reset via the boiler funtion selector 2 pic 1 The problem must be solved before the boiler can be restarted d Burner shutdown indicator This comes on when the burner shutdown device activates due to a malfunction r To restart the boiler turn the boiler selector 2 pic 1 to the RESET position X for a few seconds and then back to the desired position e Flame indicator This comes on when the burner flame is present f Chimney sweep function indicator for fitter only This flashes when the chimney sweep function is activated The flow water temperature and the number of fan revs are shown alternatively in this case symbol g is also shown g Number of fan revs for fitter only When the chimney sweep function is activated symbol f flashes and flow water temperature and number of fan revs are shown alternatively in this case the correspondent symbol is also shown 1 3 Boiler status LCD operation Normal operation Boiler selector on OFF Boiler selector on Antifreeze Boiler selector on WINTER EE Hr No function active AE The flow water temperature is displayed Boiler selector on WINTER ILLE LLL 1 W CH function active n The flow water temperature is displayed Table 1 Boiler Status Message Display with normal operation Malfunction Boiler not powered on 4 2 Boiler lockout d
15. malfunction page 16 1 8 9 Alarm due to control unit wrong connection page 16 1 8 10 Alarm due to manifold probe malfunction 1 8 11 Alarm due to external probe malfunction 1 9 Maintenance 1 10 Notes for the user 2 Technical features and dimensions 2 1 Technicalifeat res ak u M 2 2 Dimensionsand couplinads eet 2 3 Main components for the KR 55 2 4 Main components for the KR 85 2 5 E OH 2 6 General characteristics 2 7 Pumping head 3 Instructions for the fitter 3 1 Installation standards y MIN c occ CK ce E ME MN ERE 3 2 1 Packaging edet cte ehe bebe eade etnies aqa pasaq asa EAA cH a qaqa CHR en 3 2 2 Choosing where to install the boiler 4 3 2 2 1 Height of the installation area ertt 3 2 3 Ait vents in the iristallation area ter ecd 3 2 4 Positioning the boiler 3 2 5 Antifreeze protection 3 2 6 Installing the boiler a S a wQ pa ueteres 3 2 6 1 Fixing the control unit to the wall 3 2 7 Contro
16. nea e d Combustion fan not working automatically when the cause of shutdown has been removed Fan faulty Replace it The control unit is off on the The wire connecting the boiler to boiler LCD the symbol Ais the control unit is disconnected displayed and code E22 flashes Communication with the Operation is resumed external control unit impossible automatically when the cause of shutdown has been removed Control unit faulty Replace it The following problems relate to the system s control unit COMMUNICATION ERRORS ERROR DESCRIPTION E90 Address 0 and 1 in BUS BUS 0 and 1 codes cannot be used simultaneously E91 BUS address occupied The set BUS code is already used by another appliance E 200 Boiler 1 communication error E 201 Boiler 2 communication error E 202 Boiler 3 communication error E 203 Boiler 4 communication error E 204 Boiler 5 communication error E 205 Boiler 6 communication error E 206 Boiler 7 communication error E 207 Boiler 8 communication error INTERNAL ERRORS ERROR DESCRIPTION E81 EEPROM error The non valid value has been replaced by the standard value Check the parameter values PROBE ERRORS ERROR DESCRIPTION E 69 F5 boiler 2 flow probe E70 F11 boiler 1 flow probe multi purpose probe 1 E71 F1 buffer below probe E72 F3 buffer above probe E75 F9 external probe E76 F6 tank probe E78 F8 boiler probe manifold probe cascade E 80 boiler 1 ambient probe F2 buffer at the centre of th
17. parts No one including qualified personnel is authorised to modify the boiler The manufacturer cannot be held liable for damage or injury due to tampering of the boiler or improper intervention If the boilers remain inactive and the power supply is switched off for a long time it may be necessary to reset the pumps This involves removing the casing and accessing internal parts so it must only be carried out by suitably qualified personnel Pump failure can be avoided by adding proprietary central heating system additives 16 27 Technical features and dimensions 2 1 Technical features The boilers are equipped with a fully pre mixed gas burner electronic ignition and ionization flame sensing device The heat generators are built using the following boilers in various output combinations KR 55 condensing boiler with sealed chamber and forced draught supplying CH water 55kW KR 85 condensing boiler with sealed chamber and forced draught supplying CH water 85kW Each of these boilers is defined as a thermal module Each combination corresponds to a different thermal output of the modular heating genera tor The following combinations of outputs were selected 110 140 170 220 250 280 310 340 360 390 420 450 480 510 kW The boilers meet applicable laws in force in the country of destination which is stated on the rating plate If the boiler is installed in a country other than the one specified it may be dang
18. temperature press the HOME button to call up the main menu Use the knob to scroll through the menu Press the F key corresponding to USER Main Menu 01 Display User Time Progr End After entering the User submenu press the F key corresponding to HOT WATER User 01 Installation Hot Water Heat Circ 1 End 11 In the Hot Water submenu you can enter 3 different temperatures Press the F key corresponding to T DHW 1 des Hot Water End 1 x hot water Off 9 T DHW 1 des 60 0 C lt T DHW 2 des 60 0 C Turn the knob clockwise or anticlockwise to set the temperature then press the F key corresponding to OK T DHW 1 des End 60 0 C Favorite Standard OK Setting the heating programme time programme 1 To set the heating programme press the HOME button to call up the main menu Use the knob to scroll through the menu Press the F key corresponding to TIME PROGR Main Menu E Display C m User Time Progr CSS s After entering the Time Progr submenu press the F key corresponding to HEATCIRCUIT 1 PRG 1 ume Program End Heatcircuit 1 Prg 1 CS Heatcircuit 1 Prg 2 e heatcircuit 2 Prg 1 CC Turn the knob in the Heat Circuit 1 Prg 1 submenu to
19. unit the boiler shutdown symbol is displayed on the boiler and code E22 flashes ACCE Contact a Service Centre or a qualified service engineer 1 8 10 Alarm due to manifold probe malfunction If the manifold probe malfunctions code E78 is displayed on the control unit Contact a Service Centre or a qualified service engineer 1 8 11 Alarm due to external probe malfunction If the external temperature probe malfunctions on the control unit display code E75 is shown The boiler continues to operate but the sliding temperature function is disabled Contact a Service Centre or a qualified service engineer 1 9 Maintenance The boiler must be serviced periodically as indicated in the relevant section of this manual Correct maintenance of the boiler will allow it to work efficiently without harming the environment and in complete safety Maintenance and repairs must be performed by qualified personnel The user is strongly advised to have the boiler serviced and repaired by a fully qualified Service Centre Refer to section 5 for Maintenance instructions The end user may clean the case of the appliance using a proprietary cleaning solution applied to the cloth not directly to the boiler surface Do not use water 1 10 Notes for the user The user may only access parts of the boiler that can be reached without using special equipment or tools The user is not authorised to remove the boiler casing or to operate on any internal
20. 0 93 0 83 0 86 0 89 0 91 Casing heat loss with burner off 96 0 36 0 43 0 48 0 36 0 40 0 43 0 46 Chimney heat loss with burner on Pmax 96 2 04 2 14 2 20 2 04 2 09 2 14 2 17 Chimney heat loss with burner on Pmin 96 1 89 1 83 1 79 1 89 1 86 1 83 1 81 Flue gas system mass flow rate Pmax 9 5 50 20 63 80 77 40 100 4 114 0 127 6 141 2 Flue gas system mass flow rate Pmin 9 5 6 60 6 60 9 60 6 60 6 60 6 60 6 60 Flue gas air temperature Pmax C 44 00 45 82 47 00 44 00 45 02 45 82 46 47 Flue gas air temperature Pmin C 39 00 37 18 36 00 39 00 37 98 37 18 36 53 Available pumping head Pmax Pa 90 0 90 0 90 0 90 0 90 0 90 0 90 0 Available pumping head Pmin Pa 8 0 8 0 8 0 8 0 8 0 8 0 8 0 Maximum heat output efficiency rating 60 80 C 97 3 97 3 97 3 97 3 97 3 97 3 97 3 Maximum heat output efficiency rating 30 50 C 107 0 106 7 106 4 107 0 106 9 106 7 106 6 Minimum heat output efficiency rating 60 80 C 97 0 97 2 97 3 97 0 97 1 97 2 97 2 Minimum heat output efficiency rating 30 50 C 108 1 107 9 107 7 108 1 108 0 107 9 107 8 30 heat output efficiency rating 108 9 108 7 108 5 108 9 108 8 108 7 108 6 Flue gas collector diameter mm 160 160 160 160 160 160 160 Efficiency rating according to 92 42 CEE NO emission class 5 5 Table 7 Combustion data KR340 KR360 KR390 KR420 KR450 KR480 KR 510 Casing heat loss with burner on Pmax 96 0 30 0 42 0 39 0 36 0 34 0 32 0 30 Casing heat loss with burner on Pmin 96 0 93 0 85 0 87 0 89 0 91
21. 52 MODUL E SPA Le PACC SAN RISC 33 3 2 12 Connecting to the external probe and sliding temperature operation The boiler can be connected to an external temperature probe for sliding temperature operation Only original external temperature probes supplied by the manufacturer must be used If non original external temperature probes are used correct operation of the boiler cannot be guaranteed The external temperature probe must be connected by means of a double insulated wire minimum cross section 0 35 sq mm The probe must be connected to terminals 1 F9 GND of the control unit pic 19 The temperature probe cables must NOT be sheathed together with power cables The temperature probe must be installed on an outside wall facing north or north east in a position protected from atmospheric agents Do not install near a window ventilation openings or sources of heat The external temperature probe automatically modifies the CH flow temperature in relation to the outdoor temperature measured the thermoregulation curve selected the calculated room temperature selected ejas m 107 2 1 FBR E neb LZ AeH amv mH 31 aese 8 2 3112 wora Pri 4 2 19113 14 tira Prio 489 I 4 42 nri mz 60 7 13 Fi7 FBR 13 IMP L4 D oo gt BUS e t _ a um 1 2
22. If the heating system is fitted with optional external heater for DHW production fitted with a NTC temperature sensor 5 kO please refer to the heater technical characteristics when the heater temperature sensor detects a temperature of 7 C the boiler switches on and stays on at its minimum thermal power until the temperature of the water in the heater reaches 9 C If the heating system is fitted with optional external heater for DHW production fitted with a thermostat type temperature sensor the antifreeze function DOES NOT protect the water heater If the boiler shuts down the water heater will not be protected against freezing 1 6 PUMP ANTI SEIZE function If the boiler remains inactive the control unit is not on standby the system is NOT electrically disconnected from the mains the boiler circulation pumps are activated for a short period every 24 hours to prevent them from shutting down 1 7 Operation with an external probe The boiler can be connected to an external temperature probe optional When the external temperature has been measured the boiler automatically regulates the CH water temperature increasing it when the outside temperature drops and decreasing it when it rises which improves comfort and saves fuel this is referred to as sliding temperature operation The CH water temperature varies according to a program in the boiler s microprocessor Figure 4 shows the curves for a calculated room temperat
23. Troubleshooting The following problems apply to all the individual boilers included in the cascade In addition to being shown on the LCD display of the boilers they are also displayed by the control unit BOILER STATUS PROBLEM POSSIBLE CAUSE SOLUTION The boiler has locked out The symbol X is displayed and code E01 flashes Turn selector 2 to RESET to resume boiler operation Burner does not ignite Gas supply failure Check gas pressure Check that the gas valve opens or whether any system safety valves have cut in Gas valve disconnected Reconnect it Gas valve faulty Replace it PCB faulty Replace it Burner does not ignite spark not generated Ignition electrode faulty Replace the ignition electrode Ignition transformer faulty Replace the ignition transformer PCB faulty Replace the PCB Burner ignites for a few seconds and then goes off PCB does not detect the flame phase and neutral connections are inverted Verify correct neutral and phase connections to the power mains Flame detection electrode wire faulty Reconnect or replace the wire Flame detection electrode faulty Replace the electrode PCB does not detect flame Replace the PCB Ignition value setpoint too low Increase value setpoint Min heat input not set correctly Check burner setting The boiler has locked out The symbol X is displayed and code E03
24. area must be equipped with one or more permanent ventilation openings on the external walls Protection of the vents is allowed with metal grids or nets and or finned trusses on the condition that they do not reduce the net area of ventilation The air vents must be built and located so as to avoid the formation of gas pockets whatever the shape of the cover 26 3 2 4 Positioning the boiler For positioning the wall structure keep in mind the CH connections flow M and return connection to the gas mains G connection to the condensate drain S connections to the air intake and flue gas discharge pipes according to the dimensions shown in pic 5 3 2 5 Antifreeze protection The boiler is equipped as standard with an antifreeze function which operates the pump and the burner upon the occurrence of the following situations If the external sensor detects a temperature below 0 C Default value within the range 15 C to 5 C the module switches on up to the nominal temperature The nominal temperature varies depending on the outdoor measured by the outdoor probe from the theoretical room temperature 5 C by default and from the selected heating curve If the manifold sensor detects a temperature below 5 the default the module switches on up to reaching a temperature of 20 C on the manifold If the the flow probes on individual boilers detect a temperature below 5 C those boilers switch o
25. ciency 3 2 8 1 Chimney sweep function The boiler has a chimney sweep function to be used when testing combustion efficiency and regulating the burner To activate this function open the front part of the casing for access to the controls To do this proceed as follows Unscrew two of the four screws securing the casing either those on the left or those on the right Open the casing Remove the control panel cover by pulling the hooks on either side outwards and pulling the cover towards you pic 12 The control panel layout is shown in pic 13 With selector 2 pic 1 on WINTER the room thermostat if there is one ON and the boiler in operation press the chimney sweep button pic 13 with a small screwdriver for five seconds The boiler turns off performs the ignition sequence and runs at a preset stable heat output corresponding to the maximum one set with button Wimax pic 13 The chimney sweep function operates for 15 minutes To exit chimney sweep mode turn selector 2 to any position other than WINTER and then to the desired setting 30 3 2 8 2 Measurement procedure KR 55 The boiler is equipped with a tower allowing for connection of the air intake and flue gas discharge pipes figs 14 and 15 The tower comes with two openings for direct access to the combustion air and flue gas pipes pic 15 Remove the caps A from these openings pic 14 before measurements
26. display the set operating ranges for each day of the week If you wish to change the operating range for a particular day press the OK button on the screen for that day Heatcircuit 1 Prg 1 Monday End OK 4 There are 3 operating ranges for each day of the week When you have selected one of the programmes press the F key corresponding to OK to confirm Monday End 09 00 16 00 16 30 19 00 Standard 20 30 21 30 OK 12 Setting the water heater programme DHW programme To set the water heater programme press the HOME button to call up the main menu Use the knob to scroll through the menu Press the F key corresponding to TIME PROGR In the Time Progr submenu turn the knob to display HOT WATER Main Menu 01 Display User Time Progr End Time Program 01 Heatcircuit 1 Prg 1 Heatcircuit 1 Prg 2 heatcircuit 2 Prg 1 End Press the F key corresponding to Hot Water Time Program 04 Heatcircuit 2 Prog 2 Hot Water Circulation Time End Cm pem 3 C mS Turn the knob in the Hot Water submenu to display the set operating ranges for each day of the week If you wish to change the operating range for a particular day press the F key corresponding to the OK button on the screen for that day
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28. e probe E 83 boiler 2 ambient probe F15 swimming pool probe water heater 3 E135 F12 water heater probe multi purpose probe 2 E 136 F13 PT1000 boiler 2 manifold 2 multi purpose probe 3 E137 F14 PT1000 manifold 1 multi purpose probe 4 45 46 47 OLIBMUEN30 fondital Fondital S p A 25079 VOBARNO Brescia Italy Via Cerreto 40 Tel 39 0365 878 31 Fax 39 0365 878 304 e mail info fondital it www fondital com The manufacturer reserves the right to modify the products as it deems necessary and useful without affecting their basic features Uff Pubblicita Fondital IST 03 C 438 02 Luglio 2014 07 2014
29. e table 4 See table 4 KR 280 280 14 1 2724 15 7 298 4 2 pcs 55kW 2 pcs 85kW See table 4 See table 4 KR 310 310 14 1 301 6 15 7 330 0 1 pc 55kW 3 pcs 85kW See table 4 See table4 KR 340 340 20 3 330 8 22 6 361 6 4 pcs 85kW See table 4 See table 4 KR 360 360 14 1 350 2 15 7 384 4 5 pcs 55kW 1 pc 85kW See table 4 See table 4 KR 390 390 14 1 379 4 15 7 416 0 4 pcs 55kW 2 pcs 85kW See table 4 See table 4 KR 420 420 14 1 408 6 15 7 447 6 3 pcs 55kW 3 pcs 85kW See table 4 See table 4 KR 450 450 14 1 437 8 15 7 479 2 2 pcs 55kW 4 pcs 85kW See table 4 See table 4 KR 480 480 14 1 467 0 15 7 510 8 1 pc 55kW 5 pcs 85kW See table 4 See table 4 KR 510 510 20 3 496 2 22 6 542 4 6 pcs 85kW See table 4 See table 4 Table 3 Calibration data Diaphragm Flue gas diameter o mm KR 55 G20 8 2 9 KR 85 G20 10 3 9 Table 4 Gas system specifications 2 6 General characteristics KR 110 KR140 KR 170 KR220 KR250 KR280 KR310 Category II2H3P II2H3P II2H3P II2H3P II2H3P II2H3P II2H3P CH minimum pressure bar 0 5 0 5 0 5 0 5 0 5 0 5 0 5 CH maximum pressure bar 4 4 4 4 4 4 4 CH maximum working temperature 83 83 83 83 83 83 83 DHW maximum working temperature C 62 62 62 62 62 62 62 Methane gas consumption at max flow m h 11 64 14 815 17 989 23 280 26 455 29 630 32 804
30. e ua doe page 43 5 2 Combustion analysis sonurinn pa aap aaa e Uere page 43 6 Troubleshooting euge en page 44 1 User instructions There are three types of control cabinet 1 Standard control cabinet for controlling the system from the control unit with no external communication 3 cman EE e E E I TEE 4 Q J Opentherm 1 Boiler 2 CoCo OT CAN interface module 3 Control unit 5 CanBUS L m E Op N i i i i i 4 d olo e Opentherm 1 Boiler 2 CoCo OT CAN interface module 3 PC Active module 4 Control unit 5 Null modem serial cable D 6 PC 3 Control cabinet with a GSM modem for controlling the system via a remote PC CanBUS O i 3 a i i i 5 0 1 Boiler 2 CoCo OT CAN interface module Opentherm 3 PC Active module 4 Control unit 5 Serial cable 6 GSM modem 7 Antenna 8 PC 1 1 1 Boiler cont
31. e water heater with bulb thermostat remove P1 TIMER DHW timer remove P1 if the TIMER is mounted P1 TIMER jumper DHW priority R1 10KOhm resistance REMOTE CONTROL optional CT optional telephone sequence switch for remote boiler activation 3 7 Adapting to other gases and regulating the burner This boiler is built to run on the type of gas specified on the order which is shown on the packaging and on the boiler rating plate PAN If you wish to switch to another type of gas this must be done by a qualified technician using the accessories supplied by the manufacturer He will make the necessary modifications and adjustments to ensure efficient operation of the boiler KR 55 KR 85 Fuel type Diaphragm diameter mm Fuel type Diaphragm diameter mm Methane gas G20 82 Methane gas G20 10 3 Propane gas G31 5 9 Propane gas G31 7 9 3 7 1 Switching from METHANE to PROPANE Open the front panel of the boiler For model KR 55 unscrew the outlet connection to the gas valve A in pic 27 For model KR 85 unscrew the connecting pipe between the gas valve and the fan D in pic 25 Replace the existing diaphragm with one for PROPANE see table below Make the reconnection A in pic 27 for KR 55 and D in pic 25 for KR 85 Refer to 8 3 7 3 3 7 2 Switching from PROPANE to Open the front panel of the boiler For model KR 55 unscrew the outle
32. ed III max SS lt 1000 1500 2000 2500 Flow rate I h Available head mbar V1 V2 500 1000 1500 Pump speed min Pump speed ll Pump speed III max LLLI m m ul m i A m y 4 lt 4 7 2000 2500 23000 3500 4000 4500 Flow rate I h 23 Heat generator components HEADER MODULE o o A 1 Hydraulic separator 7 Ventilation chimney 2 Flanged piping 8 Expansion vessel of the unit 3 Gas manifold 9 Condensation drain pipes and for system water 4 Hydraulic manifolds from the safety valve 5 Flue gas discharge module 1 6 Flue gas discharge module 2 The header module houses the hydraulic separator and all the safety accessories header module be supplied with hydraulic separator right or left depending the installation site 24 EXPANSION MODULE 1 Hydraulic manifolds 5 Condensation drain pipes and for system water 2 Flue gas discharge module 1 from the safety valve 3 Chimney Ventilation 6 Expansion vessel of the unit 4 Flue gas discharge module 2 expansion modules cannot be provided separately from the header module 25 3 Instructions for the fitter 3 1 Installation standards This is an II2H3P category boile
33. eoJb5 e uejsip e 195 si ioq eu JI A00S 00 ww bs L gt S38IM NOISN3L TVNIWON AOSZ OSt uurbs 671 S34IM NOISN3L Do OL aunjesadwia WOOY 9NDIHOM TVIMALVW DNILYTNSNI cua e ECS bt Dan u3dWnf IVHLIOSN 35 NOIIOSNNOO HHL deny aur q jno pales aq pales 0 3iwu3N3o in 8TVzSONIOO 37 Boiler wiring diagrams 3 6 __ 11V8 3NOZ Y 4 f 4 OM Ji CLA nay ree i 145 HI 1xas 849SrEeT LALIN 32 8LGOWSHOSO nw E EE ed 0009 13H9S0 6N 2 9 SLA YN M SS ZH0S ATW A 38 5 A TLN 0 Sveet LN 5220 565 n LN 9d d DI w Sd NOZ wt S N m z IRE DAVIDIS acssreet 35 fe 2 8 Or y be nene e zn SLA YN LW
34. er time ensure regular operation of auxiliary equipment as well and minimize energy consumption in compliance with the applicable laws and standards Compliance with this standard is a legal requirement Use specific products suitable for multi metal systems WARNING The low water safety pressure switch will prevent the burner from starting up when the water pressure is below 0 4 0 6 bar A pressure of 1 5 bar is recommended in the CH system If necessary open the external filling tap This must be done with the system cold The pressure gauge on the control panel shows the water pressure in the system WARNING If the boiler is not used for a long time the pump may not work Before starting up the boiler perform the following procedure to make sure that the pump works Unscrew the protection bolt in the centre of the pump motor Insert the tip of a screwdriver in the hole and turn the pump shaft clockwise Then screw the protection bolt back in and check for water leaks When the protection bolt is removed some water may flow out Dry off any wet surfaces before remounting the boiler casing 3 4 Starting the boiler 3 4 1 Preliminary checks Before starting the boiler perform the following checks flue gas exhaust pipe and terminal must be installed as instructed When the boiler is running no combustion products must leak from any of the seals boiler must be supplied at 230 V 50 Hz
35. erous for people animals and objects The main technical features of the boilers are listed below Construction features IPX4D electrically protected control panel Integrated electronic safety and modulation board Electronic ignition via separate igniter and ionization flame detection Stainless steel fully pre mixed burners Stainless steel mono thermal high efficiency heat exchangers with deaerator Twin shutter modulating gas valves with constant air gas ratio Electronically controlled modulating flue gas discharge fans Three speed pumps with built in deaerators Air separator with deaerator Differential pressure switches fitted in the single boiler units preventing incorrect water circulation in the CH system Hydraulic separator CH temperature probe Safety thermostat Flue gas thermostats External temperature probe manifold probe water heater probe optional Rack for wall installation User interface each boiler Liquid crystal display showing that boiler operating status LCD display integrated in the system s control unit to show the system s operation Mode selector RESET OFF WINTER Water pressure gauge Operating features Electronic flame modulation in CH mode with timer controlled rising ramp 50 seconds Flow antifreeze function ON at 5 C OFF at 30 C or after 15 minutes of operation if CH temperature gt 5 C Water heater antifre
36. eze function if the boiler is connected to a separate water heater ON at 5 C OFF at 10 C or after 15 minutes of operation Timer controlled chimney sweep function 15 minutes Ignition flame propagation function Timer controlled ambient thermostat 240 seconds with flow temperature gt 40 C Pump post circulation function in CH antifreeze and chimney sweep modes e Post ventilation safety function ON at 95 C OFF at 90 C Pump anti seize function 180 second operation after 24 hours of boiler inactivity Provision for connection to a room thermostat optional Provision for operation with an external probe 17 2 2 Dimensions and couplings 630 T SS mam e N 9 rre AA 5 7 P 2 MAT xj ias 3645 1 3811 DESCRIPTION COUPLINGS M Flow DN 80 PN 6 R Return DN 80 PN 6 G Gas DN 50 PN 6 SC Condensate drain 050 55 Purge drain G11 2F Main components for the KR 55 20 11 13 21 17 14 1 Control panel 12 Gasvalve 2 Heat exchanger 13 Safety thermostat 3 Flue gas fan 14 Circulating pump 4 Air separator 15 Deaerator on air separator 5 Deaerator on heat exchanger 16 Ignition electrode 6 CH temperature probe 17 Detection elect
37. flashes Turn selector 2 to RESET to resume One of the boiler safety thermostats has cut in Difficult draught at chimney Check the chimney and ambient air suction grids boiler operation Flue gas thermostat faulty Replace it CH water does not flow pipes might be clogged thermostatic The boiler has locked out The iaht Desh Check the CH system symbol X is displayed code Boiler safety thermostat has 4 E02 flashes d y stopcocks might be closed Turn selector 2 to RESET to resume lt boiler operation Pump blocked or faulty Check the pump The boiler has locked out The symbol Ais displayed and code E10 flashes Operation is resumed as soon as the CH plant pressure is restored Insufficient water in the system Possible water leaks Check the system for leaks Main flow switch disconnected Reconnect it Main flow switch faulty Replace it The boiler has locked out The symbol Ais displayed and code E05 flashes Operation is resumed automatically when the cause of shutdown has been removed CH probe not working CH probe disconnected Reconnect it CH probe faulty Replace it 44 BOILER STATUS PROBLEM POSSIBLE CAUSE SOLUTION The boiler does not work properly The symbol Ais displayed and Fan disconnected Reconnect it
38. he equipment the manufacturer recommends that the boiler be serviced and repaired by a qualified Service Centre Routine boiler maintenance is to be performed according to the schedule indicated in the relevant section of this manual Appropriate boiler maintenance ensures efficient operation environment preservation and safety for people animals and objects Incorrect or irregular maintenance can cause a hazard for people animals and property In the event of long periods of inactivity of the boiler disconnect it from power mains and close the gas tap Warning When power mains are disconnected boiler electronic antifreeze function will not be operative Should there be a risk of freezing add antifreeze use specific antifreeze products suitable for multi metal heating systems It is not advisable to empty the system as this may result in damage N Should you smell gas do not turn on or off electric switches and do not turn on electric appliances do not ignite flames and do not smoke close the main gas tap open doors and windows contact a Service Centre a qualified installer or the gas supply company Never use flames to detect gas leaks The boiler is designed for installation in the country indicated the technical data plate installation in any other country may be source of danger for people animals and objects The Manufacturer cannot be held contractually or extra contractually liable in the event of fail
39. l unit setting 3 2 8 Testing combustion efflciency 3 2 8 1 Chimney sweep function 3 2 8 2 Measurement procedure 3 2 9 Connecting to the gas mains 3 2 10 Connecting the control cabinet to the power mains 3 2 11 Connection the control cabinet to the boilers page 33 3 2 12 Connecting to the external probe and sliding temperature operation page 34 3 3 ettet a eee retento page 36 3 4 Starting the boiler page 36 3 4 1 Preliminary checks page 36 3 422 Switchihig On and Off u uu tritt page 36 3 5 5 EC 37 3 6 Boiler wiring diagrams page 38 3 7 Adapting to other gases and regulating the burner u a page 41 Switching from METHANE to PROPANE Zulu Reese eee apte UE Ree G page 41 37 2 Switching from PROPANE to METHANE L II L vane W and acl eser ee eet ebbe eee eee grece page 41 37 3 Regulating ua eLis ERTELE SEEREN SARA Stasis page 41 4 Commissioning the boiler page 42 4 1 Preliminary checks 4 2 Switching on and off page 42 So MaIRtenance u u page 43 Bile Maintenance schedule tte eet iR e e e uW a ei
40. ler to the gas supply fitting an appropriately sized seal made of suitable material MUST be used pic 16 Hemp Teflon tape or the like are NOT SUITABLE for use with gas fittings Seal 31 3 2 10 Connecting the control cabinet to the power mains The control cabinet comes with three pole power cable one end of which must be connected to the OCIRCSTA16 interconnection board as shown in pic 17 and secured by a clamping system The boiler must be connected to a 230V 50Hz mains supply When connecting the boiler keep to the correct phase neutral polarity sequence The installation must comply with the applicable laws in the country of installation which are intended as an integral part of this handbook An easy access double pole switch with at least 3mm between the contacts must be installed before the boiler to enable the power supply to be cut off so that maintenance can be performed in complete safety The power supply to the boiler must be protected by a differential magnetic thermal automatic switch of appropriate shut down capacity The mains supply must be appropriately earthed This is a vital safety requirement When in doubt have the electrical system checked thoroughly by a qualified electrician The Manufacturer shall not be held liable for damage or injury resulting from failure to earth the system properly Gas water and CH pipes must NOT be used as the primary earth source Me5 17
41. me the burner shutdown symbol is displayed and code 01 flashes ZELI This code also appears on the control unit display If this happens proceed as follows check that the gas cock is open and light a kitchen gas ring for example to check the gas supply if the gas supply is normal turn selector 2 pic 1 to the reset position X for a few seconds then back to the WINTER position if after three attempts the burner still fails to ignite contact a Service Centre or a qualified service engineer In this case operation of the cascade system is guaranteed bypassing the boiler that has shut down When the problem has been solved the boiler rejoins the cascade system If the burner locks out frequently there is a recurring malfunction so contact a Service Centre or a qualified service engineer 1 8 2 Lockout due to overheating If the flow water temperature is too high the 55 kW boiler will lock out The burner lockout symbol is display ed and code E02 flashes This code also appears on the control unit display Contact a Service Centre or a qualified service engineer l Fr r3 IN 1 8 3 Lockout due to air intake flue gas discharge system malfunction model 55 only If the air intake flue gas discharge system malfunctions the 55 kW boiler locks out The burner lockout symbol sEm is displayed X and code E03 flue gas thermostat operation flashes This code also appears on the control unit E Ra as displa
42. n until reaching a temperature of 30 C or after 15 minutes of operation The antifreeze operation is assured only if the boiler is connected to the gas and electric supply the boiler is constantly powered e the boiler is not locked out due to a failure in switching on In a case where gas supply is lacking or the boiler goes off due to a failure in switching on the device can reach the freezing point To avoid this risk it is necessary to protect the heating system from freezing by adding an antifreeze liquid in compliance with the manufacturer s instructions 3 2 6 Installing the boiler The whole system must be cleaned thoroughly before the boiler is connected to the pipes in the central heating system Before starting up a NEW system clean it thoroughly to remove any metal residues from the construction or welding process and any oil or grease present as this could get into the boiler and damage it Before starting up a MODERNIZED system additional radiators replacement of the boiler etc clean it thoroughly to remove any sludge and foreign bodies To do this use appropriate non acidic products that can be bought on the market Do not use solvents as they would damage the components In any new or modernized heating system specific anticorrosion products for multi metal systems must be added to the water in the correct concentration This will form a protective film on the internal metal surfaces The Manufacture
43. ny position other than WINTER and then to the desired position Value of carbon dioxide in the flue gas Fuel CO rates Methane gas 8 8 9 2 Propane gas 9 8 10 2 Table 9 CO rates 41 KR 85 Gas valve 22 Ee 4 Commissioning the boiler 4 1 Preliminary checks Before testing the boiler it is advisable to check that installation complies with the current regulations flue gas exhaust pipe and terminal must be installed as instructed When the boiler is running no combustion products must leak from any of the gaskets Supply power to the boiler must be 230 V 50 Hz system must be filled with water pressure reading on water gauge 1 5 bar All the stopcocks on the pipes must be open gas supplied to the boiler must be of the type for which the boiler is designed If necessary convert the boiler following the instructions subsection 3 7 ADAPTATION TO OTHER GASES AND BURNER ADJUSTMENT This operation must be carried out by a qualified service engineer gas supply stopcock must
44. o the same to set the minutes Time Return gt OK lt lt Now enter the date by turning the knob To set the day month and year press the F key corresponding to gt then turn the knob until you reach the desired value Then press the bottom F key OK to confirm Date Return 1 Jan 09 gt OK Once you have entered all the parameters press the HOME button 10 Setting the room temperature To set the room temperature press the HOME button to call up the main menu Use the knob to scroll through the menu Press the F key corresponding to USER Main Menu 01 Display User Time Progr End After entering the User submenu press the F key corresponding to HEAT CIRCUIT 1 User 01 Installation Hot Water Heat Circ 1 End In the HEAT CIRCUIT 1 submenu you can enter 3 different temperatures Press the F key corresponding to T Room Des 1 HeatCircuit 1 01 Operation T Room Des 1 T Room Des 2 End 20 0 C 20 0 C Turn the knob clockwise or anticlockwise to set the temperature then press the F key corresponding to OK T Room Des 1 20 0 C End Favorite Standard OK Setting the hot water temperature To set the hot water
45. r and it must be installed in compliance with the laws and regulations in force in the country of installation 3 2 Installation Accessories and spare parts for installation and service procedures must be supplied by the Manufacturer Correct heating system performance cannot be guaranteed if non original accessories and spare parts are used 3 2 1 Packagings Each individual boiler the hydraulic part of the header module and any expansion modules rack optional and electrical panel are all supplied in individual cardboard boxes All the packaging materials can be recycled and should be disposed of accordingly Keep the packaging out of the reach of children as it may cause a hazard The Manufacturer cannot be held liable for damage or injury caused by failure to comply with the above instructions Contents of the box this manual manufacturer s certification of hydraulic test flue gas check valves 3 2 2 Choosing where to install the boilers The boilers must be installed in areas used exclusively for heating installations The boilers must in every case be installed so that they will not be exposed to shocks or tampering 3 2 2 1 Height of the installation area The height of the installation area must meet the following minimum dimensions depending on the overall heat output Not above 116 kW 2 00 m Above 116 kW to 350 kW 2 30 m Above 350 kW and up to 580 kW 2 60 m 3 2 3 Air vents in the installation area The
46. r cannot be held liable for damage or injury caused by failure to comply with the above instructions In any type of system it is important to mount an inspectable filter type Y with 0 4 mm mesh in the return line to the boiler 3 2 6 1 Fixing the control unit to the wall REAR of the ELECTRIC CABINET Mount the 4 brackets supplied to the electric cabinet using the 8 M6 screws 27 2 Fasten the electric cabinet to the wall using appropriate hardware anchor 3 2 7 Control unit setting When starting up the system for the first time it is advisable to set the control unit according to the following instructions System configuration 1 Press the HOME button to access the main menu of the control unit Scroll through the main menu by turning the knob Press the F key corresponding to the EXPERT line Main menu E Time date C Service __ Expert C lt 2 From the technical submenu press the F key corresponding to the CONFIGURATION line a End Ss Configuration CSS Heat source gt Cascade Cs Enter the following recommended values in the configuration submenu 28 Description Set value Mandatory value Change code 0000 0000 BUS ID 1 01 01 BUS ID 2 02 02 BUS Termination ON Off eBUS supply
47. rode 7 Flue gas thermostat 18 Air gas mixer 8 Inspection plug on condensate trap 19 Air flue gas test intake 9 Condensate drain pipe 20 Air flue gas suction tower 10 Pre mixing burner 21 Water pressure switch 11 Differential water pressure switch 2 4 Main components for the KR 85 1 Control panel 12 Gasvalve 2 Heat exchanger 13 Safety thermostat 3 Flue gas fan 14 Circulating pump 4 Air separator 15 Deaertator on air separator 5 Deaerator on heat exchanger 16 Ignition electrode 6 CH temperature probe 17 Detection electrode 7 Flue gas thermostat 18 Air gas mixer 8 Inspection plug on condensate trap 19 Air flue gas suction tower 9 Condensate drain pipe 20 Water pressure switch 10 Pre mixing burner 11 Differential water pressure switch 20 2 5 Operating data Burner pressures must be verified after a three minute boiler operation time The figures refer to the G20 methane gas with feed pressure at 20 mbar CH CH Max CH output output Diaphragm Model input TS ET Heat the Pd FIG 425 kW Ikw kW single boiler immi 90 min max min max KR 110 110 14 1 107 0 15 7 117 6 2 pcs 55kW See table 4 See table 4 KR 140 140 14 1 136 2 15 7 149 2 1 pc 55kW 1 pc 85kW See table 4 See table 4 KR 170 170 20 3 165 4 22 6 180 8 2 pcs 85kW See table 4 See table 4 KR 220 220 14 1 214 15 7 235 2 4 pcs 55kW See table 4 See table 4 KR 250 250 14 1 243 2 157 266 8 3 pcs 55kW 1 pc 85kW Se
48. rol panel If boilers are connected to the control unit certain features of the control panel are disabled 1 2 3 4 5 1 Liquid crystal display LCD The LCD displays the boiler status and operating data pic 1 2 Boiler function selector With the selector on RESET X the boiler restarts after activation of the burner shutdown device lockout With the selector on OFF the boiler is in stand by mode heating function is disabled The SUMMER F position has no influence on the boiler operation With the selector on WINTER Wg the boiler is ready for providing hot water for the CH system The Antifreeze he position doesn t affect boiler operation Place the boiler selector in WINTER mode position AN For proper operation of the boiler set the selector to WINTER mode position 3 DHW temperature regulator This regulator is not active The domestic hot water must be regulated on the system s control unit and not on each single boiler 4 CH water temperature regulator This regulator is not active The heating water must be regulated on the system s control unit and not on each single boiler 5 Water pressure gauge This shows the pressure of the water in the CH system 1 2 Boiler LCD 9 a Alphanumeric indicator This shows the following CH flow water temperature CHtemperature setting boiler status boiler diagnostics b Central heating indicator This comes on when the boiler
49. s parameter starts to flash Turn knob 62 to modify the value and enter 196 for 55kW boilers and 202 for 85kW boilers Press 603 to record the value Turn knob 6 to select TSP2 Press e to modify the value the value associated with this parameter starts to flash Turn knob amp 9 to modify the value and enter 61 for 55kW boilers and 59 for 85kW boilers Press 682 to record the value Turn knob 6 to select TSP3 Press e to modify the value the value associated with this parameter starts to flash Turn knob 6 to modify the value and enter 90 for 55kW and 105 for 85kW boilers Press amp to record the value Turn knob 62 to select TSP4 Press to modify the value the value associated with this parameter starts to flash Turn knob e to modify the value and enter 100 Press e to record the value Turn knob 69 to select TSP7 Press e to modify the value the value associated with this parameter starts to flash Turn knob 62 to set the value to 0 Press 602 to record the value Press to exit the configuration mode When you have done disconnect the Remote Control Then connect the wire from the control unit to terminal M6 as shown in pic 18 These instructions refer to a single boiler so the whole procedure must repeated for each boiler of the system M18L 1 M17 M1 M14 M15 EKE ER esses le M8 M9 2 3 12345678 a7 ZONE BATT OSCHEMOD18 M11 GPL
50. sure of 1 5 bar Contact a Service Centre or a qualified service engineer 2 With flashing code E26 contact a Service Centre or a qualified service engineer 1 8 6 Lockout for fan malfunction SE 11 AL t Fan operation is constantly monitored and in case of a malfunction it goes off the boiler lockout symbol is displayed and code E17 flashes This mode is maintained until the fan recovers normal working parameters If the boiler should not start and remain in this mode contact a Service Centre or a qualified service engineer 15 1 8 7 Alarm due to a boiler temperature probe malfunction If the burner locks out due to malfunction of the temperature probe the following flashing code will appear on the boiler s and the controller s LCD displays E05 CH probe the boiler does not work Contact a Service Centre or a qualified service engineer 1 8 7 Alarm due to water heater external probe malfunction If the water heater probe malfunctions code E76 appears on the control unit display In this case the system operates in heating mode only If the system is connected to an external water heater with a temperature thermostat any failure to the thermostat is not detected by the boiler electronics Contact a Service Centre or a qualified service engineer 1 8 9 Alarm due to control unit wrong connection The control unit recognizes whether or not there are any boilers If the n qu not receive any information from the control
51. t connection to the gas valve A in pic 27 For model KR 85 unscrew the connecting pipe between the gas valve and the fan D in pic 25 Replace the existing diaphragm with one for METHANE see table below Make the reconnection A in pic 27 for KR 55 and D in 25 for KR 85 Refer to 8 3 7 3 3 7 3 Regulating the burner Setting maximum heat output Turn the maximum heat output regulator Wmax pic 13 to MAXIMUM fully clockwise Maximum heat output setting is displayed on the LCD as a percentage of the boiler s maximum available value position selector 2 pic 1 to WINTER Check that the ambient thermostat optional is set to ON Activate the chimney sweep mode Adjust CO in flue gas by turning the ratio regulator B pic 26 for KR 85 and 27 for KR 85 and make sure it is within the limits of Table 9 Operate the boiler on chimney sweep mode and move to the following paragraph Minimum heat output regulation Minimum heat output regulation Rotate the regulator Wimax pic 13 fully anticlockwise to set the maximum heat output to MINIMUM The display shows the desired maximum heat output as a percentage of the boiler s maximum available heat output Regulate the CO in flue gas by turning the offset regulator C pic 27 for KR 55 and pic 26 for KR 85 and make sure it is within the limits of Table 3 To terminate the chimney sweep operating mode set knob 2 pic 1 to a
52. to the manufacturer s instructions given in this manual Before installing the boiler check that the technical data corresponds to the requirements for its correct use in the system Check that the boiler is intact and it has not been damaged during transport and handling do not install equipment which is damaged and or faulty In case of doubt do not attempt to use the product but refer to the supplier Only manufacturer approved and supplied parts or optional kits including electric ones must be used for all repairs to the boiler Packing materials cardboard box wooden crate nails staples plastic bags polystyrene etc must not be left within reach of children as these items represent a potential hazard and must be disposed of in a responsible manner Properly dispose of the packaging as all the materials can be recycled The packaging must therefore be sent to specific waste management sites In the event of failure and or malfunction shut down the system Do not interfere with or attempt any repairs Call for professionally qualified technical assistance only Failure to comply with the above requirements may affect the safety of the boiler and endanger people animals and property Before carrying out any cleaning or maintenance operations disconnect the appliance from the mains electricity supply by switching off at the main switch and or any other isolating device 4 In order to guarantee efficient and correct operation of t
53. ue to flame absence F LI t Boiler lockout due to safety thermostat activation TT Boiler lockout due to flue gas thermostat activation gt N i Enc Failure of the CH flow probe ALLIZ Low primary fluid circulation alarm E Faz pump ON flow switch OPEN AL LI Low primary fluid circulation alarm pump OFF flow switch CLOSED ALL gt Fan failure iE Failure of the connection to the Control Unit lt Table 2 Boiler status Message display with malfunction 1 4 Control unit The control unit is located inside the control cabinet 26 May 05 10 00 4 6 7 HOME BUTTON T HS 1 Standby l Mon F KEYS d 0 12 24 1 5 56 8 C 4 LINE 1 LINE 2 I LINE Heating 7 4 KNOB Control elements KNOB used to enter a setting or parameter HOME BUTTON gives access to the main menu F KEYS to select the setting parameter shown on a particular display line Display LINE 1 day date and time LINE 2 heating based on the time programme LINE 3 boiler 1 temperature LINE 4 operating mode on the left current situation on the right 1 2 1 Operating modes When the control cabinet has been installed by a qualified fitter the boiler has been started up for the first time and the control cabinet is ready for correct operation the operating mode m
54. ure of 20 If the value is increased or decreased via knob 4 the curve shifts up and down respectively by the same amount 100 3 0 2 5 20 90 80 r_ e _ 15 70 z 1 0 v 60 5 5 a 50 0 8 E 0 6 8 40 0 4 30 0 2 20 10 0 t t 20 16 12 8 4 0 4 8 12 16 20 24 28 32 36 40 Outside temperature C With this setting for example if you select the curve corresponding to parameter 1 and the outdoor temperature is 4 C the flow temperature will be 50 For details on sliding temperature operation mode refer to 8 3 2 12 Only original external probes supplied by the manufacturer must be used If non original external probes are used correct operation of the boiler and the probe cannot be guaranteed 14 1 8 Heating system lockout The heating system locks out automatically if a malfunction occurs Refer to Tables 1 and 2 to identify the boiler operating mode Refer to Table 2 and section 6 to identify possible causes of the shutdown The troubleshooting section is at the end of this manual Below is a list of possible causes of the shutdown and the procedure to follow in each case 1 8 1 Boiler burner lockout If the burner locks out as there is no fla
55. ure to comply with the above TABLE OF CONTENTS General information for fitters maintenance technician and user page 3 T User Instructions uuu page 5 TT Boil ereontrolpanel y tt u a uq Awa ee Waaa iwan u aa qawa aq pend page 6 1 2 Boiler LCD i 7 1 3 tiitrites ai titie SEREEN EEES PEO EESE EENT E ESTE page 8 1 4 Controlu ituu n 9 1 5 Antifreeze function 1 6 Pump anti seize er ette B tret page 14 1 7 Operatio with an exter al probe u u u rochers nasa page 14 1 8 Heating system lockout 1 8 1 Boiler burner lockout 1 8 2 1 qn aa ee Qasa Se Mae e BOR Re pce usaba page 15 1 8 3 Lockout due to air flue gas system malfunction 1 8 4 Lockout due hot melt fuse operation page 15 1 8 5 Lockout due to a water circulation malfunction page 15 1 8 6 Lockout for fan malfunction page 15 1 8 7 Alarm due to boiler temperature probe malfunction page 16 1 8 8 Alarm due to water heater temperature probe
56. ust be set on the control unit 1 Standby the heating and hot water function is disabled only antifreeze function is active 2 Automatic 1 heating is enabled according to time programme 1 hot water is enabled according to the DHW programme 3 Automatic2 heating is enabled according to time programme 2 the DHW programme is enabled 4 Summer the system only operates to produce hot water according to the DHW programme if connected to an external hot water system 5 Heat the boiler is set to heat for 24 hours at temperature 1 the DHW programme is enabled 6 Reduce the boiler is set to heat for 24 hours at reduced temperature the DHW programme is enabled 7 Assist for fitter only for controlling the cascade manually To set an operating mode press the bottom F key corresponding to line 4 and select the desired function on the knob Control unit first start up The following is displayed when the control unit is switched on for the first time Press the F key corresponding to the OK line Ende Installation OK Turn the knob to enter the desired language then press the bottom F key to confirm Sprache Zur ck English Standard OK lt _ Now enter the time by turning the knob To set the hour press the F key corresponding to gt then turn the knob until you reach the desired value Then press the bottom F key OK to confirm D
57. y Contact a Service Centre or a qualified service engineer 1 8 4 Lock out due to hot melt fuse operation model 85 only If the air intake flue gas discharge system malfunctions the 85 kW boiler locks out The burner lockout symbol is displayed X and code E03 hot melt fuse operation flashes This code also appears on the control unit display Contact a Service Centre or a qualified service engineer 1 8 5 Lockout due to a water circulation malfunction If the pressure or water circulation in the heating system are incorrect the boilers lock out The boiler lockout symbol is displayed and codes E10 or E26 flash according to the malfunction gt m lt AL tL With code E10 flashing there can be two different situations a the pressure gauge 5 pic 1 shows a pressure lower than 1 bar Proceed as follows to restore the correct water pressure Turn the external filling tap anticlockwise to allow water to enter the boiler Keep the tap open until the pressure gauge shows a value of 1 5 bar Turn the tap clockwise to close it Wait a minute until the malfunction disappears from the display If the boiler still fails to operate contact a Service Centre or a qualified service engineer Make sure you close the external filling tap carefully after filling If you do not when the pressure increases the safety valve may activate and discharge F TI lt xEgE b the pressure gauge 5 pic 1 shows a pres

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