E.C.A. Fortius Service Manual Download

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24 kW Open Flued Gas Combination Boiler (bithermic type)

24 kW Room Sealed Fan Assisted Gas Combination Boiler (bithermic type)
24 kW Room Sealed Fan Assisted Gas Combination Boiler (monothermic type)
28 kW Room Sealed Fan Assisted Gas Combination Boiler (monothermic type)

SERVICE MANUAL

Summary of Contents for Fortius

Page 1: ...bithermic type 24 kW Room Sealed Fan Assisted Gas Combination Boiler bithermic type 24 kW Room Sealed Fan Assisted Gas Combination Boiler monothermic type 28 kW Room Sealed Fan Assisted Gas Combinatio...

Page 2: ...y Systems Technical Data Main Components Operating Functions GAS TYPE CONVERSION Gas Pressure Adjustments Replacement Of The Burner Injectors Jumper Adjustment ADJUSTMENTS Service Setting Mode Chimney...

Page 3: ...ith by pass circuit and pump over run Frost Protection System The appliance must be on stand by mode to activate frost protection system Pump Anti sieze Function 3 Way Anti sieze Function in monotherm...

Page 4: ...3 40 80 230V AC 50Hz 105 8 750x454x340 33 7 II 2H 3 C12x C32 Natural gas LPG 8 4 24 19 2 9 2 26 2 21 2 73 0 96 2 08 20 28 37 3 10 t 34 0 3 10 35 60 0 8 3 40 80 230V AC 50Hz 150 8 750x454x340 39 8 II 2...

Page 5: ...ar Pressure Relief Valve 9 c Discharge Tap c Discharge Tap 10 d Filling Tap d Filling Tap 11 e Water Pres Sensor e Water Pres Sensor 12 f Water Flow Sensor f Water Flow Sensor 13 14 DHW NTC Sensor Sur...

Page 6: ...ling Tap 11 e Water Pres Sensor e Water Pres Sensor 12 f Water Flow Sensor f Water Flow Sensor 13 g Plate Heat Exchanger 12 plate g Plate Heat Exchanger 14 plate 14 h DHW NTC Sensor Direct Immersion h...

Page 7: ...The main board provides all the functionality and safety of the boiler The board was cased by a plastic casing which was mounted on the gas valve The functionality of the board is provided with 2 mic...

Page 8: ...Wiring Diagrams 7 fig 1a...

Page 9: ...8 fig 1b...

Page 10: ...9 fig 1c...

Page 11: ...valve output 230 Vrac 50mA Diferantial air pressure switch input 12 Vdc 100 kOhm Limit thermostat input 5 Vdc 100 kOhm Water pressure switch input 12 Vdc 100 kOhm Water flow sensor input output 12 4 V...

Page 12: ...8 sec Pump over run time A for DHW Monothermic Winter mode Monothermic Summer mode 3 way electric valve Bithermic Winter mode Bithermic Summer mode B for CH Winter mode Summer mode 3 sec 5 sec 3 sec T...

Page 13: ...it thermostat CLOSE temperature 75 C TTB sensor limit temperature in the first 90 sec 100 C TTB sensor limit temperature after the 90 sec 70 95 C GAS VALVE 2 Gas valve controls and modulates the gas f...

Page 14: ...d in 24 kW boilers while 15 blade burners are used in 28 kW boilers Some of the common specifications of these two burners are shown in the table below Table 6 Burner Injector nozzle diameter for natu...

Page 15: ...inlet and one water outlet and only the central heating circuit is heated In monothermic types domestic hot water circuit is heated by a second exchanger plate heat exchanger In both heat exchangers...

Page 16: ...pump pressure relief valve 3 bar discharge tap filling tap water pressure switch and water flow sensor on it The monothermic hydroblock has pump pressure relief valve 3 bar discharge tap filling tap w...

Page 17: ...fig 5a Bithermic Hydroblock 1 Outlet manifold 2 Inlet manifold 3 By pass pipe 4 Water flow sensor 5 Filling tap 6 Gasket G3 4 G1 2 7 Hall effect sensor 16...

Page 18: ...Monothermic Hydroblock 1 3 way electric valve 2 Inlet manifold 3 By pass pipe 4 Water flow sensor 5 Filling tap 6 Valve motor 7 Valve motor clip 8 Hall effect sensor 9 Bolt 10 Oring 11 By pass pipe c...

Page 19: ...s located on the hydroblock and has 3 speed stages The pump has expansion vessel and termomanometer connections and also an automatic air vent on it fig 6 Pump Table 8 Pump Maximum Power 85 W Speed St...

Page 20: ...on the inlet manifold in monothermic types Table 10 Discharge Tap Hydroblock connection G External thread FILLING TAP 9 The filling tap is for filling the central heating circuit using the domestic w...

Page 21: ...late Heat Exchanger Hydroblock connection Bolts 2 pieces Plate heat exchanger water inlet outlet onnections O rings 4 pieces fig 10 Plate Heat Exchanger WATER FLOW SENSOR 12 The water flow sensor meas...

Page 22: ...rface mounted sensors for domestic water and direct immersion sensors for central heating Only direct immersion NTC sensors are used in monothermic types In bithermic models the surface mounted temper...

Page 23: ...95 0 2 7 125 346 4 2 6 The sensitivity is the percentage change in resistance of the sensing element per o C temperature change at the specified temperature 3 WAY ELECTR C VALVE 14 3 Way electric valv...

Page 24: ...nabling the boiler to operate again after the reset In bithermic types limit thermostat is mounted on the heat exchanger with a metal clip while in monothermic types it is mounted using two screws fig...

Page 25: ...air pressure switch is connected to terminals 1 and 3 2 not connected Table 16 Differential Air Pressure Switch Interior diameter of silicon hose to fan 5 mm Interior diameter of silicon hose to comb...

Page 26: ...5714 4 7 20 12493 4 5 25 10000 4 4 30 8056 4 3 35 6530 4 2 40 5327 4 0 45 4370 3 9 50 3603 3 8 55 2986 3 6 60 2488 3 6 65 2083 3 5 70 1752 3 4 75 1480 3 3 80 1255 3 3 85 1070 3 3 90 915 3 2 95 787 3 1...

Page 27: ...displays the water temperature and water pressure of the central heating circuit IGNITION ELECTRODE 21 The burner is ignited by a spark between two ignition electrodes One of the electrodes is earthe...

Page 28: ...or Conditions like sensor faults or over temperature The priority of the modes of functions is as follows 1 Fault Error Condition 2 Service Settings Mode 3 DHW Mode 4 CH Mode 5 Frost Protection 6 Stan...

Page 29: ...hot water tap and open it again b In Bithermic types if the boiler is in summer mode the burner will switch OFF and to reactivate DHW mode again it is necessary to close the hot water tap and open it...

Page 30: ...nsor detects temperature less then 6 C CH mode is activated burner starts As long as frost protection conditions last till water temperature reaches 30 C the burner operates in minimum capacity When t...

Page 31: ...od of time 10 min If the boiler is switched to summer mode when CH mode is active pump over run time is 5 sec Pump Anti Seize Function 5 The pump may be blocked if not used for a long period of time T...

Page 32: ...ed on the lower edge to remove the front panel Undo the 2 screws which are located on the corners of the control panel Pull the control panel outwards to reach the gas valve Maximum operating pressure...

Page 33: ...o remove the combustion body cover in room sealed fan assisted boiler Undo the 4 screws which fasten the manifold to the burner to remove the burner Fix the suitable burner injectors according to type...

Page 34: ...type conversion GAS LEAK TEST Apply a rich soap and water solution to the surface of all pipe connections Bubbles indicate a gas leak In case of gas leak tighten the pipe connection Check the pipe con...

Page 35: ...oiler parameters Level 3 L3 is setting mode to set some boiler parameters Level 4 L4 is fault history and permits to read the last 8 error codes While in service level LED L7 is on fig 20 Service leve...

Page 36: ...button progressively to reach some parameters detailed in Table 23 The parameters are set by means of the CH potentiometer P1 The parameters can be increased by turning the CH potentiometer clockwise...

Page 37: ...ow rate ltr min can be adjusted as F1 ON 3 OFF 2 5 or F2 ON 3 5 OFF 3 DHW Delay Time In order to avoid water hammer effect in DHW mode DHW delay time can be adjusted as d2 1 sec or it can be adjusted...

Page 38: ...Mode 1 11 Pump control mode P2 Mode 2 P2 12 Modulation start point T F R if return sensor existing o C 10 30 20 Level 4 fault history 3 Press PB3 service push button 4 times and see L 4 on the 7 segme...

Page 39: ...ed by pressing the push button again more than 3 seconds and less than 5 seconds fig 21c If chimney sweep mode is started in stand by mode the system goes back to stand by mode after the deactivation...

Page 40: ...nk OFF fast blink fig 22b Turn the CH potentiometer the maximum position LED L8 and L9 start blinking to indicate that maximum running is being selected fig 22c The appliance operates in max load with...

Page 41: ...call qualified service While in lockout conditions LED L2 will turn on b Blocking conditions Circuit break in flue safety device NTC Short circuit in flue safety device NTC Flue safety device NTC shut...

Page 42: ...r temperature failure E 3 Flow temperature too high t 1 Circuit break in CH flow sensor NTC t 3 Short circuit in CH flow sensor NTC t 3 Circuit break in DHW sensor NTC t 5 Short circuit in DHW sensor...

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E.C.A. Fortius, Service Manual

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