E.C.A. Fortius User manual

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

CONTENTS
PRODUCT
Product Notation
Safety 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 Sweep Push-Button PB4
FAULT & FAILURE
1

PRODUCT
Product Notation
Table 1
Notation Description
FO 24 BB Fortius 24 kW Open Flued Gas Combination Boiler (bithermic type)
FO 24 HB Fortius 24 kW Room Sealed Fan Assisted Gas Combination Boiler (bithermic type)
FO 24 HM Fortius 24 kW Room Sealed Fan Assisted Gas Combination Boiler (monothermic type)
FO 28 HM Fortius 28 kW Room Sealed Fan Assisted Gas Combination Boiler (monothermic type)
Safety Systems
The safety systems in appliance provide entire safety for user and appliance. The safety systems are:
¾Flue Gas Safety System
¾Flame Failure Safety System
¾Over-heat Safety System (105 0C)
¾DHW (Domestic Hot Water) Over-heat Safety System (75 0C)
¾CH (Central Heating) Over-heat Safety System (95 0C)
¾High Water Pressure Protection System (3 bar)
¾Low Water Pressure Protection System (0,8 bar)
¾Low Voltage Protection System (185 VAC)
¾Thermal Accumalation Protection System (with by-pass circuit and “pump over-run”)
¾Frost Protection System (The appliance must be on stand-by mode to activate frost protection
system)
¾Pump Anti-sieze Function
¾3 Way Anti-sieze Function (in monothermic types)
¾Automatic Air Vent
¾Expansion Vessel
¾DHW safety stop function
Technical Data
Fortius 24 kW open flued gas combination boiler (FO 24 BB) is B type boiler (DIN EN 297). B
type boilers have an open combustion chamber. Combustion air is provided from the installation
room and products of combustion is discharged by means of approved flue ducts connections and a
chimney. Therefore, they are named as room air dependent gas appliances.
Fortius 24 / 28 kW room sealed fan assisted gas combination boilers (FO 24 HB, FO 24 HM, FO
28 HM) are C type boilers (DIN 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.
2

3
Table 2 FO 24 BB FO 24 HB FO 24 HM FO 28 HM Unit
Gas Category*
Boiler Type
Type of gas
Performances
Pmin, Min. Heat Output
Pmaks, Max. Heat Output
P%80, Heat Output
Qmin, Min. Thermal Load
Qmaks, Max. Thermal Load
Q%80, Thermal Load
Gas Consumption**
Natural Gas (Max. Load)
Natural Gas (Min. Load)
LPG
Gas Supply Pressure
Natural Gas
LPG
Domestic Hot Water
Min. Flow Rate For Activating***
Max. Flow Rate
Min. Operating Pressure
Max. Operating Pressure
Set Temperature Range
Central Heating
Min. Operating Pressure
Max. Operating Pressure
Set Temperature Range
General
Electrical Supply
Electrical Power Consumption
Expansion Vessel
Dimensions (HxWxL)
Weight (Net)
II 2H 3+
B 11 BS
Natural gas
LPG
8,4
24
19,2
9,3
26,6
21,3
2,77
0,97
2,08
20
28 / 37
3
10 (∆t=34)
0,3
10
35-60
0,8
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 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
40,8
II 2H 3+
C12x, C32
Natural gas
LPG
9,8
28
22,4
10,7
30,6
24,5
3,19
1,12
2,39
20
28 / 37
3
12 (∆t=33)
0,3
10
35-60
0,8
3
40-80
230V AC- 50Hz
150
8
750x454x340
41,3
kW
kW
kW
kW
kW
kW
m3/h
m3/h
kg/h
mbar
mbar
ltr/min
ltr/min
bar
bar
oC
bar
bar
oC
V AC/Hz
watt
ltr
mm
kg
**For gas consumption calculation ; Natural gas: Hu=9,59 kWh/m3
LPG: Hu=12,793 kWh/kg
*** DHW ON flow rate can be adjustable as 3 ltr/min (default) or 3,5 ltr/min.
*the following gas categories can also be used
FO 24 BB FO 24 HB FO 24 HM FO 28 HM
Gas Categories II 2H 3B/P
II 2E 3B/P
II 2H 3B/P
II 2E 3B/P
II 2H 3B/P
II 2E 3B/P
II 2H 3B/P
II 2E 3B/P

Main Components
Table 3a
FO 24 BB FO 24 HB
1 Microcontroller Board
Bitermic (Main Board)
Microcontroller Board
Bitermic (Main Board)
2 User Interface User Interface
3 Gas Valve Gas Valve
4 Burner (13 blade) Burner (13 blade)
5 24 kW Heat Exchanger
(bithermic)
24 kW Heat Exchanger
(bithermic)
6 Hydroblock (bithermic) Hydroblock (bithermic)
7 a) Pump a) Pump
8 b) 3 Bar Pressure
Relief Valve
b) 3 Bar 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
(Surface Mount)
DHW NTC Sensor
(Surface Mount)
15 CH NTC Sensor
(Direct Immersion)
CH NTC Sensor
(Direct Immersion)
16 - -
17 Limit Thermostat Limit Thermostat
18 Expansion Vessel Expansion Vessel
19 - Air Pressure Switch
20 TTB Sensor -
21 - Fan
22 Manometer Manometer
23 Ignition Electrode Ignition Electrode
24 Ionization Electrode Ionization Electrode
25 - Concentric Air/Flue Kit
26 Timer Timer
4

5
Table 3b
FO 24 HM FO 28 HM
1 Microcontroller Board
Monotermic (Main Board)
Microcontroller Board
Monotermic (Main Board)
2 User Interface User Interface
3 Gas Valve Gas Valve
4 Burner (13 blade) Burner (15 blade)
5 24 kW Heat Exchanger
(monothermic)
28 kW Heat Exchanger
(monothermic)
6 Hydroblock (monothermic) Hydroblock (monothermic)
7 a) Pump a) Pump
8 b) 3 Bar Pressure
Relief Valve
b) 3 Bar 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 g) Plate Heat Exchanger
(12 plate)
g) Plate Heat Exchanger
(14 plate)
14 h) DHW NTC Sensor
(Direct Immersion)
h) DHW NTC Sensor
(Direct Immersion)
15 ı) CH NTC Sensor
(Direct Immersion)
ı) CH NTC Sensor
(Direct Immersion)
16 j) 3 Way Electrical
Valve
j) 3 Way Electrical
Valve
17 Limit Thermostat Limit Thermostat
18 Expansion Vessel Expansion Vessel
19 Air Pressure Switch Air Pressure Switch
20 - -
21 Fan Fan
22 Manometer Manometer
23 Ignition Electrode Ignition Electrode
24 Ionization Electrode Ionization Electrode
25 Concentric Air/Flue Kit Concentric Air/Flue Kit
26 Timer Timer

MICROCONTROLLER BOARD (MAIN BOARD)
1
The main board operates on 230 VAC, 50 Hz and drives gas valve, fan, pump and (in monothermic
types) 3 way electric valve. Dynamic air pressure test takes place before every ignition cycle. Limit
thermostat ensures extra safety level. Flame in the burner is checked regularly.
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 microcontrollers (low voltage and high voltage microcontroller).
The board can be divided in 2 part: low voltage side and high voltage side. Both side have a
microcontroller. There is continuous communication between microcontrollers. Numerous data is
sent from one side to the another for check and comparison.
6

Wiring Diagrams
7
fig. 1a

8
fig. 1b

9
fig. 1c

10
Tablo 4 Technical and Functional Specifications
General
Power supply range: 230 Vac -15% +10%
Power supply frequency: 50 Hz ± % 2
Power consumption: 5 VA
Max. admitted humidity: 90% @ 40 °C (non condensing)
Working temperature range: -20 °C … 60 °C
Electrical rating
Fusing: 2A
Fan output: 230 Vac 0.8 A maks, cosϕ≤0.6
Pump output: 230 Vac 0.8 A maks, cosϕ≤0.6
3-Way valve output (1): 230 Vac 0.8 A maks, cosϕ≤0.6
3-Way valve output (2): 230 Vac 0.8 A maks, cosϕ≤0.6
Total output: 2A
Gas 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 Vdc, 10 mA max.
Sensors input:
- CH sensor
- DHW sensor
- TTB sensor
10 kOhm NTC
Communication input: “0” p 0,8 Vdc
“1” + 2 … 24 Vdc (10 Ohm)
Communication output: 24 V and 10 mA max.
User interface connectors
High voltage spark: 2,8 x 0,5 mm spade terminal (2 pieces)
Flame sensing: 4,8 x 0,5 mm spade terminal
Mains connector: 10 pole Molex Minifit (male)
Low voltage connectors: 16 and 6 pole Molex Microfit (male)
Flame sensing
Response time ON: < 0,2 sec
Response time OFF: < 1 sec

Tablo 4 Technical and Functional Specifications
Timing
Pre purge time: 0 sec
Waiting time: 0 sec
Pre ignition time: 2 sec
Safety time: 7 sec
Number of retrials: 5
Flame failure response time: 1 sec
Post ignition time: 0,4 sec
Post purge time: 0,8 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
TCH > 75 °C: 1 sec
TCH < 75 °C: 0 sec
10 min
5 sec
Pump anti-seize run time:
A) Bithermic type
B) Monothermic type
5 sec
5 sec
CH anti-cycling time: 3 min (0 min … 15 min)
TTB error waiting time: 15 min
Chimney sweep run time: 20 min
Timing tolerance: ± 5%
11

Tablo 4 Technical and Functional Specifications
Other Specifications
Nr. of electrodes: 2 for flame ignition and one for detection
Flame sensing cable and spark cable: max. 0,5 m
External components (except heat demand): max 0,5 m
Remote reset: max. of 5 reset in 15 minutes
CH water SET temperature range: 40 °C … 80 °C
CH water OFF temperature: CH water SET temperature + 10 °C
CH water ON temperature: CH water SET temperature
DHW water SET temperature range : 35 °C … 60 °C
DHW water OFF safety temperature: 75 °C
DHW ON Flow rate : 3,0 lt/min
DHW OFF Flow rate : 2,5 lt/min
Frost protection level 1 ON temperature: 8 °C (pump runs)
Frost protection level 1 OFF temperature: 10 °C (pump is OFF)
Frost protection level 2 ON temperature: 6 °C (burner runs)
Frost protection level 2 OFF temperature: 30 °C (burner is OFF)
Limit thermostat OPEN temperature: 105 °C
Limit 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 flow to the burner. It consists of two valves: The first one
is the on/off safety valve and the second one is the main (modulation) valve which enables safety
and modulated gas control. Maximum and minimum operating pressures can be adjusted
mechanically on the gas valve. Maximum outlet pressure can be adjusted with the adjustment screw
of the maximum pressure regulator. Minimum outlet pressure can be adjusted with the mechanical
minimum adjustment screw (see Gas pressure adjustment, page 30).
Table 5 Gas Valve 24 kW Models 28 kW Models
Max. pressure setting (factory default) 11,2 11,3
Natural Gas
(mbar) Min. pressure setting (factory default) 1,3 1,2
Max. pressure setting (factory default) 28 / 35 28 / 35
LPG
(mbar) Min. pressure setting (factory default) 3,3 / 4,1 3,4 / 4,2
Gas inlet & outlet connections G ¾”
(External thread)
G ¾”
(External thread)
12

13
fig. 2 Gas Valve
BURNER
3
The gas coming from the gas valve is fired in the burner. 13 blade burners are used 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 natural gas ∅1,25 mm
Injector (nozzle) diameter for LPG ∅0,75 mm
Gas inlet connection G ¾” (External thread)
fig. 3 Burner

HEAT EXCHANGER
4
Heat exchanger is the component which enables transferring the energy produced by the burning of
the gas to the water circuit. Different heat exchangers are used in bithermic (24 kW) and
monothermic (24 / 28 kW) models. In bithermic heat exchangers which have two water inlets and
two water outlets, both central heating and domestic hot water circuits are heated. In monothermic
types, the exchanger has only one water 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, there is a manual air vent on central heating inlet.
Table 7 Heat Exchanger
Bithermic heat exchanger (24 kW)
Central heating inlet & outlet connections G ¾” (External thread)
Domestic hot water inlet & outlet connections G ½” (External thread)
Monothermic heat exchanger (24 kW)
Water inlet & outlet connections G ¾” (External thread)
Monothermic heat exchanger (28 kW)
Water inlet & outlet connections G ¾” (External thread)
fig. 4a Bithermic Heat Exchanger
14

fig. 4b Monothermic Heat Exchanger
HYDROBLOCK
5
Two different types of hydroblocks are used in bithermic and monothermic types. Hydroblock
consists of different components depending on the boiler model. The bithermic hydroblock has
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, water pressure switch, plate heat-exchanger, water flow sensor, domestic hot water
(DHW) sensor, central heating (CH) sensor and 3 way electric valve on it. On both hydroblocks,
inlet and outlet manifolds are connected by a by-pass pipe.
15

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

fig. 5b 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 clip
17

PUMP
6
Pump enables the central heating water circulation in monothermic and bithermic types. Also in
monothermic types, it enables heating the domestic water passing through the plate heat-exchanger
by causing the central heating water short circuit circulation.
Pump is 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 Stages 3
Hydroblock connection (pump water inlet) Rapid connection (O-ring)
Pump water outlet connection G ¾” (External thread)
Termomanometer connection Rapid connection (O-ring)
Expansion vessel connection Rapid connection (O-ring)
fig. 7 Pump’s Characteristic Curve (Height & Flow)
18

PRESSURE RELIEF VALVE (3 BAR)
7
Pressure relief valve (3 bar) protects the central heating circuit and the appliance against increasing
pressure. When the pressure in the central heating circuit is over 3 bars, the relief valve functions
and decreases the pressure (the outlet tap of the 3 bar relief valve should be connected to the drain
line with a plastic hose). The pressure relief valve is on the hydroblock, on the central heating
return.
Table 9 Pressure relief valve
Hydroblock connection Rapid connection (O-ring)
Water discharge pipe connection G ½”
fig. 8 Pressure Relief Valve
DISCHARGE TAP
8
The discharge tap is used for removing the water in the central heating circuit. It is on the outlet
manifold in bithermic types while it is on the inlet manifold in monothermic types.
Table 10 Discharge Tap
Hydroblock connection G ¼” (External thread)
FILLING TAP
9
The filling tap is for filling the central heating circuit using the domestic water line. It is integrated
on the inlet manifold of the hydroblock.
WATER PRESSURE SWITCH
10
Water pressure switch prevents the operation of the appliance in low water pressure. If the water
pressure in the central heating circuit is below 0.8 bar, the water pressure switch goes OFF and the
signal sent from the water pressure switch to the main board prevents the boiler operation. When
the pressure is above 1 bar, the boiler goes back to normal operation. The water pressure switch is
on the outlet manifold of the hydroblock, on the central heating flow.
The electric circuit connection of the water pressure switch is COM and CO terminals (NC not
connected).
TABLE 11 Water Pressure Switch
Hydroblock connection G ¼” (External thread)
19