E.C.A. CA 24 BB Operation instructions

E. C. A:
cal ora
//""""
24 kW Open Flued Gas Combination Boiler (bithermic type)
24kW
Open Flued Gas Combination Boiler (monothermic 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)
INSTALLATION AND USER•s
OPERATING INSTRUCTIONS
L E.CA
•
~~ -
(~

2
CONTENTS
- PREFACE
- GUARANTEE & SERVICE
- SYMBOLS' DEFINITIONS
- SAFETY INSTRUCTIONS AND WARNINGS
- PRODUCT
• General Specifications
• Product Notation
• Technical Data
-
BOILER PACKAGING
- INSTALLATION
• Selection Of The Boiler Location
• Mounting
The Boiler
-
CONNECTIONS
• Flue Connection
• Gas Supply & Water
Systems
• Electricity Supply
-
BOILER START-UP
• Final Checks And Operations Before Boiler Start-up
• Control Panel
• Operating
The Boiler
•
Timer
- GAS TYPE CONVERSION
• Gas Pressure Adjustments
• Replacement Of
The Burner Injectors
• JumperAdjusment
-
FAULT & FAILURE FINDING
- MAINTENANCE
- STANDARDS AND REGULATIONS
- APPENDIX

- INTRODUCTION
- PREFACE
Colora 24 kW open flued gas combination boilers and 24/28 kW room sealed fan assisted
gas combination boilers have
been designed for providing efficient, safe and comfortable
central heating
(CH) and domestic hot water (DHW). The boilers are supplied for use with either
natural gas or LPG.
This manual contains installation and user's operating instructions. The detailed information
about technical data, selection of the boiler location, fitting the connections (water systems ,
gas supply, flue connection
and electricity supply), gas type conversion, maintenance and
fault &failure finding are placed in your manual. Please read the instructions carefully for
operating the boiler a long time period and to maximize benefit from the boilerspecifications.
Please keep all your documents safe.
-GUARANTEE &SERVICE
). The appliance has guarantee period against faulty workmanship or material in condition
thatthe instructions
and precautions in this manual must be obeyed. The service operations
and general maintenance must be carried out only by qualified person.
).
The warranty certificate must be registered by Service in the installation day.
). Your appliance need not any repairs if operated according to this manual. For assistance
or additional information, consult qualified person, installer or gas supplier.
-SYMBOLS' DEFINITIONS
The symbols have been placed on particular points to make some instructions more
noticeable.
The symbols' definitions are described as follows:
~ Information
- CAUTION: Property damage and/or non-severe injurycan
happen.
-WARNING: Severe injury
or death can happen.
: The importantexplanations to
be considered by users.
: The situations that can only
be interfered by qualified
person.
3

- SAFETY INSTRUCTIONS AND PRECAUTIONS
• SafetyInstructions
When a gas
leak is found or suspected:
- Turn off tfle gas valve of the boirer and other appliances which operate with gas.
-Shut off the oven, cooker
and similar appliances to put their flame out.
-Do not light match, lighter etc. and put cigarette out.
-Allow
fresh air into the room by opening doors and windows.
-Do nottouch the electrical appliances' switches
and plugs.
-
Turn off gas supply at the gas meter.
-Do not
use telephones in the environment where a gas leak is suspected.
-Call your qualified person as soon as possible.
~ Do not place and use flammable and explosive liquid or materials around the boiler.
~ Keep soap and water solution away from electrical connections during cleaning, gas leak
test etc.
~ Do not block air vents, openings made in the walls of the room, which provide fresh air to
the installation room.
~ Do not lay the LPG container down.
~ Open flued gas combination boilers are equipped with combustion products discharge
safety
device (TTB sensor). Combustion products discharge safety device shall not be put out
of operation.
In case of the replacement of the defective safety devices, only the original
parts
may be used.
• Water Systems & Gas SupplyUne
~ Before installation of the boiler, the water systems (CH and DHW circuit) and gas supply line
must
be completed in accordance with the relevant regulations and standarts by user.
• Gas Type Conversion
~ The appliance should be purchased depending on operating gas type. In case of a
demanding gas type conversion, this is made with charge.
~ Gas type conversion from LPG to natural gas or from natural gas to LPG must be carry out
only
by qualified person. After gas type conversion, gas leak test must be performed by qualified
person.
~ Maximum pressure regulator must be sealed and the self-adhesive conversion label must be
placed on the boiler after gas type conversion.
•Installation
~ The boiler must be installed in accordance with national and local requirements, gas safety
regulations, relevant standarts
and this manual by qualified installer.
~The appliance should be mounted against a closed wall.
~ The appliance must be positioned so that the plug is accessible.
~ The appliance should not be positioned having a direct contact to steam or gases.
~ Any change of flue position must not be made without consulting qualified person.
~ The flue ducts must be fitted to a approved chimney for open flue boilers.
• Boiler Start-up
~ Boiler start-up must be performed certainly by qualified person.
~ Gas type (natural gaS/LPG), gas supply pressure (mbar), maximum DHW operating water
presure (bar)
and electricity supply voltage M data which are detailed on the information
plate must
be suitable with mains supply conditions. This is checked by qualified person.
~ After boiler start-up, you should request information about operating the boiler and safety
precautions from qualified person.
• Operating The Boiler And Maintenance
~ Read carefully instructions and precautions in this manuel against wrong usage which causes
unsafe conditions.
~The boilershould be checked and serviced for general maintenanceoncea year. Maintenance
and service operations must be carried out only by qualified person.
~ Only a damp cloth should be used for cleaning the outer surface of the boiler and then the
surfaces should
be dried completely. Do not use chemical subtances or solutions which cause
rust and scratches in your appliance.
4

-PRODUCT
• GeneralSpecifications
Colora 24 kW open flued gas combination boilers and 24 I 28 kW room sealed fan assisted
gas combination boilers are for providing central heating
and domestic hotwater. The boilers
are supplied for
use with either natural gas or LPG.
Boiler has space saving design which provides easy servicing and maintenance. It has also
a elegant
appearance with compact dimensions (750x454x340 mm) and round edges.
Control panel has been designed ergonomically. Whilst push-buttons, CH & DHW temperature
control potentiometers, thermomanometer
and timer (optional) are under its plastic cover,
boiler functions
and fault/error conditions can be seen via LEDs signal without opening the
cover.
Microcontroller
board (main board) provides all the functionality and safety of the boiler. The
controller drives gas valve, fan, pump and (in monothermic types) 3-way valve. The board is
cased by a plastic casing, which is mounted on the gas valve. Flame in the burner is checked
regularly. Flame modulation
can be seen through the observation glass on the front panel.
A CAUTION: Do not directly contact the observation glass
~ whileobservingthe flame modulation to avoidburninginjury.
Burner, is made of stainless steel, withstands thermal stress. Burner performs silently and provides
efficient
and clean combustion as a result ofthe homogeneous dispersion of gas. Combustion
chamber has ideal dimensions for burner
and perfectinsulation of heat and has been designed
to provide loss of low heat, high efficiency and low emission of gas. These specifications of
burner and combustion chamber provide energy saving and minimum noise level.
Pump has an automatic airvent and 3 operation mode. The boiler has 'pump over-run' behaviour
so that pump continues to run for a certain time after ending of CH or DHW heat demand to
prevent from thermal accumulation
in water circuit.
Heat exchanger
is made of copper and designed for thermal shockabsorbing. It has long life,
high productivity
and is non-calcerous as well.
Plate heat exchanger makes hot water more efficient in monothermic types.
The safety systems in your appliance provide entire safety for you and your appliance. The
safety systems are:
~ Flue Gas Safety System
~ Flame Failure Safety System
~Over-heat Safety System (1 05°C)
~ DHW (Domestic Hot Water) Over-heat Safety System (75°C)
~ CH (Central Heating) Over-heat Safety System (95°C)
~ High Water Pressure Protection System (3 bar)
~ Low Water Pressure Protection System (0,8 bar)
~ Low Voltage Protection System (185 VAC)
~ Thermal Accumalation Protection System (with 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 WayAnti-sieze Function (in monothermic types)
~ Automatic Air Vent
~ Expansion Vessel
5

• ProductNotation
Table 1
Notation Description
CA24 BB
Colora 24 kW Open Flued Gas Combination Boiler (bithermic type)
CA24 BM Colora 24kW Open Flued Gas Combination Boiler (monothermic type)
CA24 HB Colora 24 IN/ Room Sealed Fan Assisted Gas Combination Boiler (bilhermic type)
CA24HM Colora 24 IN/ Room Sealed Fan Assisted GasCombination Boiler (monothermic type)
CA28HM Colora 28 IN/ Room Sealed Fan Assisted GasCombination Boiler (monothermic type)
• Technical Data
Colora 24 kW open flued gas combination boiler (CA 24 BB) is a Btype boiler (EN 297). Btype
boilers have
an open combustion chamber. Combustion air is provided from the installation
room
and products ofcombustion is discharged by means of approved flue ducts connections
and a chimney. Therefore, they are named as room air dependent gas appliances.
Colora 24/28 kW room sealed fan assisted gas combination boilers (CA 24 HB, CA 24 HM,
CA 28 HM) is a C type boiler (EN 483). C type boilers have a sealed combustion chamber.
Required
fresh air for combustion is provided independently from the installation room by
concentric air/flue ducts and products of combustion can be also discharged by the same
air/flue ducts. Therefore, they are
named as air independent gas appliances.
6
Table2
C4.24BB
C4.24BM C4.24HB
C4.24HM
Gas Category *
112H31W 1121131¥' 112H31W
Boiler Type
Bn BS c1 2x. c32x c1 2x. c32x
Type of gas
GaznakJel Gazrduel GaznakJel
Plcpcre Plcpcre Plcpcre
Alri»naJCES
Pmin, Min. Heat Output
8,4 8,4 8,4
Pmal<s, Max. Heat Output
24 24 24
P%80, Heat Output
19,2 19,2 19,2
Qmin, Min. Thermal Load
9,3 9,2 9,2
Qmal<s,
Max. Thermal Load
2M
26,2 26,2
Q%80, Thermal Load
21,3 21 21
GasConsurplion
Natural Gas (Max. Load)
2,77 2,73 2,73
Natural Gas (Min. Load)
0,97 0,96 0,96
LPG
2,08 2,08 2,08
Gas~~
Natural Gas
2005 20'25 20'25
LPG
28137 28137 28137
lJotrleB:Hot.IM*r
Min. Flow Rate For Activating
3 3 3
Max. Flow Rate
1~t=34) 1Q:At=34) 1Q:At=34)
Min.
Operating Pressure 0,3 0,3 0,3
Max. Operating Pressure 10 10 10
Set
Temperature Range
35(:£) 35(:£) 35(:£)
CenlrallletiDJg
Min. Operating Pressure
0,8 0,8 0,8
Max. Operating Pressure 3 3 3
Set Temperature Range 4()..8() 4()..8() 4()..8()
General
Electrical Supply
23CW PC -50 Hz 23CW PC- 50 Hz 23CW PC -50 Hz
Electrical Power Consumption
105 150 150
Expansion Vessel 8 8 8
Dimensions (HxWxL)
7S0rA54lc340 7S0rA54lc340 7S0rA54lc340
Weight (Net) 33,7 39,8
40,8
For gas consumption calculation; Natural gas: Hu=9,59 kWh/m
3
LPG: Hu=l2,793 kWh/kg
C4.28HM Unit
112H31W
c12x. C32x
Gazrduel
Plcpcre
9,8 kW
28 kW
22,4 kW
10,7
kW
30,6 kW
24,5 kW
3,19
m3Jh
1,12
m3/h
2,39 l<glh
20'25
mbar
28137
mbar
3 11/mln
12(At=33) It/min
0,3
bar
10 bar
35(:£)
"C
0,8 bar
3 bar
4()..8()
"C
23CW PC -50 Hz
VAC/HZ
150 waH
8 It
7S0rA54lc340 mm
41,3
kg

5 6 7 "
CA24 BB
.-----G
230VAC
31 32
20 3
~-~~-~
33
11
44 43 42 41
0 0 0 0
::Dl
Ill
,...
47 46
~
121 121
''I I I • 15
!._
17
49
0
G~ 48
G
MAIN BOARD SUPPLY CABLE 11 TTB TEMP. SENSOR
31 ROOM THERMOSTAT (OPTIONAL) 45 RESET BUTTON
3 PUMP 12 DHW SENSOR 32 TIMER (OPTIONAL) 46 PB3 SERVICE BUTTON
5 IONIZATION ELECTRODE 13 CH SENSOR 33 TERMINAL
(4 POLES) 47 PB4 CHIMNEY.SWEEP BUTTON
6 IGNITION ELECTRODE (EARTH} 14 SHORT CIRCUIT 34 TIMER SUPPLY (OPTIONAL} 48
CH TEMP. CONTROL POTENTIOMETER
7 IGNITION ELECTRODE 15
WATER FLOW SENSOR 41 LED L3 49 DHWTEMP. CONTROL POTENTIOMETER
8 ON/OFF SWITCH 16
WATER PRESSURE SWITCH 42 LED L4
9 FUSE2A 17 LIMIT THERMOSTAT 43 LED L8
10 TERMINAL WITH FUSE
20GASVALVE 44 LED L7

5 6 7
20
MAIN BOARD SUPPLY CABLE
2
FAN
3 PUMP
5 IONIZATION ELECTRODE
6 IGNITION ELECTRODE (EARTH)
7 IGNITION ELECTRODE
8 ON/OFF SWITCH
9 FUSE2A
CA24 HB
~--G
8 ~ 9
Vl I 1 23DVAC !Ill l~~~
2
31
10
32
~-lr_-5
''I I I • 15
L
-17
10 TERMINAL WITH FUSE 20 GAS VALVE
33
11
0
11 10k RESISTOR 31 ROOM THERMOSTAT (OPTIONAL)
12 DHW SENSOR 32 TIMER (OPTIONAL)
13 CH SENSOR 33 TERMINAL (4 POLES)
14 DIFFERENTIAL AIR PRES. SWITCH 34 TIMER SUPPLY (OPTIONAL)
15 WATER FLOW SENSOR
41 LED L3
16 WATER PRESSURE SWITCH
17 LIMIT THERMOSTAT
42 LED L4
43 LED L6
49
G
44 43 42 41
0 0 0 0
47 46
121 121
48
G
4500
121
I Oo
44 LED L7
45 RESET BUTTON
46 PB3 SERVICE BUTTON
47 PB4 CHIMNEY-SWEEP BUTTON
~
~
48 CH TEMP. CONTROL POTENTIOMETER
49 DHW TEMP. CONTROL POTENTIOMETER
CD

CA 24 BM

-BOILER PACKAGING
CAUTION: The instructions on the boilerpackage should be
consideredduring transportation and storage.
-The product is covered with a cardboard box of which dimensions are 867x522x422
(HxWxl) mm and supported by upper and lower styrofoams (fig. 2a).
a) b)
fig.2
- The required parts (Wall bracket, 5 pieces gasket for water and gas connections and
screews) for installation of the boiler is put into the upper styrofoam (fig. 2b). The other parts
which seen in the fig.2b are optional. The optional parts are:
a) Mounting
bracket
b) CH connecting pipes (3/4", 2 pieces)
c) DHW connecting pipes (1/2", 2 pieces)
d) Gas supply
pipe (3/4", 1 piece)
e) Nipples (1/2", 2 pieces- 3/4", 3 pieces) which are held with spring clips.
h) 4 pieces W gasket, 6 pieces %" gasket for water and gas connections.
10

11

-INSTALLATION
• Selection Of The Boiler Location
The boiler must be installed in accordance with gas safety regulations and relevant standards.
Additionally, the clearances around the boiler should
be as shown in fig. 4 in order to make
service, maintenance
and usage easier.
Fig. 4 indicates minumum clearances from the ceiling and the sides.
12
E
E
0
Ill
I'
fig.4
WARNING: The appliance must be positioned so that the plug is
accessible.
- The appliance should be mountedagainst a closedwall.
- The outersurface of the boiler do not exceed85°C in maximum running modeso do not
take additionalprecautions againts constructionalmaterials (combustible materials).

WARNING: For open flue boilers, theboilerlocation and flue gas discharge
connections must obey national and local requirements, gas safety
regulations
and relevantstandarts.
+Open flue appliances must not be installed in a bedroom, bedsitting room, bathroom or
in a room containing a bath or shower and also the installation room must not contain
inflammable or explosive liquid or materials.
The boiler should not be installed in rooms with
high level
of dust or humidity.
+ General requirements for the installation room
of open flue boilers:
-The installation room must have 1 m3 volume for
each 1 kW heat output. Therefore, The
installation room must have 24 m3 volume for boilers of 24 kW heat output (fig. Sa). Also, a
permanent air vent connected to external air with cross-section area
of 150 cm
2
is required.
-
If volume of the room is less than 1m3 /k.W that means the volume is less than 24 m3 for boilers
of 24 kW heat output, 2 additional permanent air vents connected to adjacent room with
cross-section areas
of 150 cm
2 are required, one
at high level and one at low level. The
adjacent room must not be a bathroom, bedsitting room or bedroom. The total volume of the
installation room
and the adjacent room must be 24 m3 as well. The additional airvents should
be on the same wall (fig. Sb).
WARNING: Do not block the air vents which provide fresh air to
the installation room.
a) Volume of installation room ~ 1m3 /k.W
b) Volume of room represented by 1::; 1m3/kW
Total volume of rooms 1 and 2 ~1 m3/kW
(installation room
is represented by 1)
(adjacent room is represented by 2)
fig.S
13

• Flue gas discharge connections:
- The boiler should be located on the wall as near as possible to the existing chimney and the
total horizontal length
of the flue ducts must not exceed the maximum length approved by
gas company regulations.
-The minimum distance between elbow
and top of the boiler should be 39 mm.
-
The flue duct should be fitted at a slight % 3° upwards incline to the chimney inlet in such a
waythat the cross-section area of the chimney must not
be narrowed (fig. 6).
WRONG RIGHT
fig.6
ELBOW 90°
EXTENSION
Lmin=39mm
-The materail of the flue duct can be made of stainless steel sheet, enamelled steel sheet or
approved materials
and the diameter of the flue duct must be suitable to the hood outlet.
-The flue ducts must not
be taken through bedroom, bedsitting room, bathroom or a room
containing inflammable or explosive materials or liquids.
-
The flue ducts must not be closer than 20 em to combustible materials.
AWARNING: Open Ruedgas combination boilersare
equipped with combustion
products discharge safetydevice (IT8 sensor). Do not interfere with the
combustion products discharge safetydevice.
~The flue ducts must be fitted to a approved chimney.
-
The minumum effectual chimney length is 4 m.
-The chimney must be checked and swept.
14

A WARNING:
For room sealed fan assistedappliance, the boilerlocation and
air/flue terminal position must obey national and localrequirements,gas safety
regulations
and relevantstandarts.
~ The room sealed fan assisted boiler is notsuitable for external installation. It should be within
in the building.
-
In case of gas leakage, it is necessaryto vent the installation room according to national and
local requirements, although the room sealed fan assisted boilers are independent of room
volume
and ventilation.
A WARNING: Do not block the air vents which provide fresh air to
~ the installation room.
~ The air/flue terminal must be exposed to the external air and allow free passage of air cross
it
at all times.
-
The minumum acceptable dimensions from the terminal to obstructions and ventilation
openings must
obey national and local requirements.
-
The air/flue ducts should be fitted at a slight % 10 or 20 downwards incline to prevent any
water or condensation from entering the boiler.
• Mounting The Boiler
Having determined the boiler location,
-
Use the paper template to markout the positions of the fixing holes of wall and mounting
brackets.
-
Drill the wall and fix the wall bracket to the wall with the 3 screws, then also the mounting
bracketwith the 2 screws.
-Hang the boiler up on the wall bracket.
E
E
~
fig.7
15

16
-CONNECTIONS
• Flue Conaedioa
.. 3 ditlhent types of air/flue system can be deaiglmd fOr 23,3 kW momsealed 6mned aasisted
boilers:
a) Theair/8ue systemis desigDed by horizontal concent:rit ducts.
b) The air/flue systemis desiped by two separate ducts.
c)Theair/flue ayatem is desigaed byvertical concentric clw:ts.
: De tlir/jlru ldt, givf!ll willf ytiiR' IYHRfl 6ellle4 fa asrictetl t1pJ1IWu:e,
is onq gir«"fe fur lulrizlmtlllllir/jble daig& Fortileoilier(Wier,
yt~ll dttlll4 ortlo rq~~lre4 tuWDDria fro• (JIIIIIJfle4 8m1lce.
[!] Collaectioa by hodzoatal coaceatlie duds
- 90° Ccmceullic elbowcan be mowrted on the boil.e:r indifferentpositions (fig. 9).
Air/fluekitpartsillmounted aa shown in fig. 10.
-Stick the :flat sealing riDg (•96,3/128 mm) onthe elbow.
-Fix
the sealillg riDg ( +60 mm) to illteriorjoilrt of the elbow- fim outlet.
-Fix
the sealillg riDg ( +60 mm) to illteriorjoilrt of the elbow- tube (L=860 mm).
-Fix the s~ riDg (+lOOmm) tointerior joiDt oftheelbow-tube (1..=860 mm).
-Screwthe90 elbow to the boilerwith4 screws.
:De tlir/jllle hclll •luJul4u jitla tit" B1fPt " 11 or 2' tlowmwJrtls
laclllfe tiJ prnMt ay wtltn or ctnuletiSfltltm fro• eMerittgtilebolkr.

Room Sealed Fan Assisted Operation
fig. tO
+ If the air/flue kit length is insufficient, additional flue accessories should be ordered through
qualified service.
Do notuse any othertype I brandname of flue parts.
-Horizontalair/flue kitaccessories (fig 11):
a) Concentric extension, L=500 mm,
4>60/1 00 mm
Concentric extension,
L=lOOO mm, lj)60/100 mm
b) 90° Concentric elbow, 4>60/100 mm
c) 45° Concentric elbow, lj)60/100 mm
----
@
a) b)
fig. 11
c)
17

);> The total length Of hOrizontal air/fluesystem must not exceed 3 m. Furthermore, each extra
90" concentric elbow or two pieces of 45° concentric elbow decreases the maximum length
1m (fig. 12).The maximum number of 90" elbow to be used is 3
Lmax=3m
a)
b) Lmax=Ll+L2
~2m
I
~
-tttl
L1
Lmax=Ll+L2+L3 ~ 2 m
C)
18

~ Connection by two separate ducts
+ Maximum length of the air ducts and flue ducts are seen in Table 4. The air ducts and
flue ducts must be parallel (fig. 15).
- The twin air/flue kit and its accessories (fig. 14) :
a) The twin air/flue kit
b) Extension,
l=500 mm, 080 mm
Extension,
l= 1000 mm, 080 mm
c) 900 elbow,
080 mm
d) 450 elbow, 080 mm
a)
b)
20
fig. 14
c)
(J~
lmax
d)
&
'I