E.C.A. Proteus Premix Series Operation instructions

PROTEUS PREMIX
CONDENSING BOILER
PROTEUS PREMIX PPR 14/20/24/28/30/35 HM/HCH/HST
INSTALLATION AND USER'S
OPERATING INSTRUCTIONS

INTRODUCTION
1 - INTRODUCTION .................................................................................................................................. 3
2- GUARANTEE AND SERVICE .................................................................................................................. 3
3- DEFINITIONS OF SYMBOLS .................................................................................................................. 3
4- SAFETY RULES AND WARNINGS .......................................................................................................... 4
5- PRODUCT............................................................................................................................................. 5
5.1- General Specifications.................................................................................................................. 5
5.2- Notations of Product.................................................................................................................... 5
5.3- Detailed View and List of Components ........................................................................................ 6
5.4- Technical Specifications ............................................................................................................... 9
5.5- Electrical Drawing....................................................................................................................... 12
6.BOILER PACKAGING........................................................................................................................... 13
7.FLUES ................................................................................................................................................. 14
7.1- Flue Sizes .................................................................................................................................... 14
7.2- Flue Types................................................................................................................................... 14
7.3- Distances for Placement of Flues ............................................................................................... 15
8-INSTALLATION ................................................................................................................................... 16
8.1- Selection of Installation Location of Device ............................................................................... 16
8.2- Independent Operation from Ambient Air (Type C).................................................................. 17
8.3- Mounting the Boiler ................................................................................................................... 17
9 - CONNECTIONS.................................................................................................................................. 18
9.1- Condensate Discharge Connection ............................................................................................ 18
9.2- Gas and Water Connections....................................................................................................... 19
9.3- Electrical Connection.................................................................................................................. 20
9.4- Room Thermostat ...................................................................................................................... 21
9.5- Outdoor Sensor .......................................................................................................................... 22
9.6- Room Thermostat and Outer Air Sensor Connection ................................................................ 23
9.7- Controller Connection................................................................................................................ 23
10-COMMISSIONING, USE AND TURNING OFF THEBOILER ................................................................ 24
11-CONTROL PANEL .............................................................................................................................. 25
12-GAS CONVERSION ........................................................................................................................... 28
13-ERROR CODES VE DESCRIPTIONS .................................................................................................... 28
14-USEFULL INFORMATION ON PRODUCT........................................................................................... 31
15-ANNEXES ......................................................................................................................................... 33
16-
WALL MOUNTING TEMPLATE…………………………………………………………………………………………………….. 34
2

1 – INTRODUCTION
First of all, we would like to thank you for choosing E.C.A brand.
E.C.A. Proteus Premix condensing boilers have been designed for an efficient, safe and comfortable central
heating and hot water requirement. The Proteus Premix condensing boilers can possibly use natural gas or LPG
according to the desired fuel preference.
HM Model: It is designed for both Central Heating (CH) and Domestic Hot Water (DHW).
HCH Model: It is designed for Central Heating (CH).
HST Model: It is designed for both Central Heating (CH) and Domestic Hot Water (DHW). Boiler connection must
be used for Domestic HotWater (DHW) requirement.
The assembly and usage information of 14/20/24/28/30/35 kW Proteus Premix condensing boilers are available
in this manual. Detailed information have been provided in the guide regarding the technical specifications of the
devices, selection of the boiler location, fitting its water, gas, flue and electric supply connections, gas
conversion, maintenance information and resolution of possible failures. Please carefully read the manual in
order to benefit from all the features of your device.
Keep all the documents provided by your device in order to refer when required.
2- GUARANTEE AND SERVICE
• The appliance has guarantee period against faulty workmanship or material in condition that the instructions
and precautions in this manual must be obeyed. The service operations and general maintenance must be
carried out only qualified person.
• The warranty certificate must be registered by Service in the installation day.
• Your appliance needs not any repairs if operated according to this manual. For assistance for additional
information, consult qualified person, installer or gas supplier.
3- DEFINITIONS OF SYMBOLS
The following symbols have been placed at required points in the text in order to draw attention to significant
points regarding the usage and assembly of the device. The meanings of the symbols have been specified below.
Indicates that the situation that can only be interfered by qualified person.
Explanations containing information that should be considered by the user.
CAUTION:It means that you may suffer from material damage or slight
personal injury.
DANGER: It means that you may suffer from sever personal injury.
3

4- SAFETY RULES AND WARNINGS
4.1- Safety Instructions
When a gas leak is found or suspected;
•Turn off the gas valve of the boiler and the valves of all other devices operating with gas.
•Shut off the stove, oven and similar appliances to put their flame out.
•Do not light matches, lighter etc, and stub out your cigarette.
•Ventilate the environment by opening doors and windows.
•Do not ever touch the buttons and plugs of your electrical appliances.
•Turn off the gas valves in the apartment and building entrance.
•Do not use the phones at places where the 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 materials such as water, foam away from electrical connections during operations such as cleaning,
gas leak test etc.
•Do not lay the LPG container down
•Do not block air vents, openings made in the walls of the room which provide fresh air to the installation
room.
4.2- Water Systems & Gas Supply Line
•Before installation of the boiler, the water systems (CH & DHW circuit) and gas supply line must be
completed in accordance with the relevant regulations and standards by user.
4.3- Gas Type Conversion
•The appliances should be purchased depending on operating gas type. In case of a demanding gas type
conversion, this is made with charge.
•Gas type conversion should be performed by the authorized service. Gas leak test should be made after
the conversion operation.
•The self-adhesive conversion label must br placed on the boiler after gas type conversion.
4.4- 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 should not be positioned having direct contact to steam, detergent or gases.
•Any change of flue position must not be made without consulting qualified person.
•Sunlight can cause color change on the exterior of your device over time.
•The device must be installed in indoor spaces under normal conditions. However, it can be operated in
a suitable cabinet in places such as garage, open balcony. Please consult E.C.A for proper cabine
sizes.
•If device is located in an unheated area, it should be connected to mains, switched on, and pressure of
installation should be within operation range so that freeze protection would be activated. Even if device
is OFF position, freeze protection stays activated.
4.5- 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 pressure (bar) and
electricity supply voltage 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.
CAUTION: The 2-amp bipolar fuse with a minimum contact opening of 3 mm must be used
in the electrical connection of the boiler.
4

4.6 - Usage and Maintenance
•Read carefully instructions and precautions in this manual against wrong usage which causes unsafe
conditions.
•The boiler should be checked and serviced for general maintenance once a year. Maintenance and
service operations must be carried out only qualified person.
•Only a damp clothshould be used for cleaning the outersurfaceof the boiler and then the surfaces should
be dried completely. Do not use chemical substances or solutions which cause rust and scratches in your
appliances.
CAUTION: This device is not intended to be used by persons with physical, sensory or mental
disabilities (even children) or persons with inadequate experience and knowledge, unless the
person responsible for the safety of the device provides supervision and management of the
use of the device. Children must be kept under surveillance to ensure that they do not play
with the device. Cleaning and user maintenance should not be done by unattended children.
CAUTION: This device is not intended for use by persons (including children) who are low
physical or sensory and mental capacity and inexperienced persons without informing and
supervising the use of the device by responsible persons. Ensure that children do not play
with the appliance.
CAUTION:If device is used incorrectly or for other than its intended use, it may present a life
hazard and may cause material damage to the product and its surroundings.
5- PRODUCT
5.1- General Specifications
Control panel is ergonomic and easy to use. The Proteus Premix condensing combi boiler with elegant plastic
control panel and advanced LCD screen provides ease of use and service. On aLCD display with black instrument
panel; you can see the operating state icons, heating circuit and operating water adjustment values, the fault /
failure codes and the heating water pressure. With the safety systems available in your device, safety of both you
and your device are fully ensured.
These safety systems;
•Flame Failure Safety System
•Boiler Over-Heat Safety System (95 ° C)
•DHW (Domestic Hot Water) Over-Heat System (71 ° C)
•High Water Pressure Protection System (3 bar)
•Low Water Pressure Protection System (0.4 bar)
•Low Voltage Protection System(170 VAC)
•Thermal Accumalation Protection System (with by-pass circuit and ‘’pump over-run’’)
•Frost Protection System for both CH and DHW circuit)
•Domestic Hot Water Flow Control (only for HM Model)
•Pump Anti-sticking Function
•3 Way Valve Anti-sticking Function (except HCH Model)
•Automatic Air Vent
•Expansion Vessel (8 liters)
•Warning System for Siphon Blockage
•Protection System Against Penetration of Water Through Flue
•Maintenance Reminder Function (Yearly)
•Anti-legioner Protection (only for HST Model)
5.2- Notations of Product
5

5.3- Detailed View and List of Components
Figure 1.1
1- Main Exchanger
2- Silencer
3- Venturi
4- Fan
5- Motorized Valve
6- Condensing Water Hose
7- Outlet Manifold
8- 3 Bar Safety Valve
9- Pressure Sensor
10- Siphon
11- Plated Heat Exchanger
12- Gas Valve
13- Return Manifold
14- Pump
15- Flexible Connection Hose
16- Expansion Tank (8liters)
17- Rainwater Hose
18- Rainwater Collection Reservoir
19- Ignition Electrode
20- Temperature Sensor for Supply
Water
21- Temperature Sensor for Return
Water
22- Turbine
23- Flue Gas Sensor
18 17
8
7
6
5
4
3
2
16
1
11 12 13
14
15
9 10
19
20
21
22
23
5.3.1- HM Model
Figure 1.2
6

18 17
8
7
6
5
4
3
2
15
16
1
11 12
13
14
9 10
19
20
22
21
Figure 2.1
5.3.2- HST Model
Figure 2.2
1- Main Exchanger
2- Silencer
3- Venturi
4- Fan
5- 3 Way Valve
6- Condensing Water Hose
7- Outlet Manifold
8- 3 Bar Safety Valve
9- Pressure Sensor
10- Siphon
11- Gas Valve
12- Return Manifold
13- Pump
14- Flexible Connection Hose
15- Expansion Tank (8liters)
16- Expansion Tank Holder Bracket
17- Rainwater Hose
18- Rainwater Collection Reservoir
19- Ignition Electrode
20- Inlet Temperature Sensor
21- Outlet Temperature Sensor
22- Flue Gas Sensor
BOILER Boiler return
Boiler outlet
CH return
CH outlet
7

17 16
8
7
6
4
3
2
15
1
11 12
13
14
9
10
1- Main Exchanger
2- Silencer
3- Venturi
4- Fan
5- Flue Gas Sensor
6- Condensing Water Hose
7- Outlet Manifold
8- 3 Bar Safety Valve
9- Pressure Sensor
10- Siphon
11- Gas Valve
12- Return Manifold
13- Pump
14- Flexible Connection Hose
15- Expension Vessel(8L)
16- Rainwater Hose
17- Rainwater Collection Reservoir
18- Ignition Electrode
19- Temperature Sensor for Supply Water
20- Temperature Sensor for Return Water
18
20
5
19
Figure 3.1
5.3.3- HCH Model
Figure 3.2
CH outlet
CH return
8

5.4- Technical Specifications
9

10

5.5- Electrical Drawing
Figure 4
*Boiler sensor in
HST model
* Except of
HCH Model
*Only HM
Model
11

6. BOILER PACKAGING
CAUTION: Attention must be paid to warning on packaging regarding handling and
storage.
-The device is delivered with a cartonboard with dimensions of 735 x 345 x 490 (HxWxD) mm, supported by
upper and lower styrofoams.
Figure 5
-Parts required for installation of the device (wall bracket, 5 gaskets for HM and HCH and 6 gaskets for HST
water and gas connections, 3 anchors and 3 fixing screws) are placed on the top styrofoam.
-The hermetic flue set is delivered in a carton box separate from the unit. The standard hermetic flue set (Ø
60/100 or Ø80/125) consists of the following components (Figure 6).
Figure 6
Mounting bracket
12

2. Exhaust Gas Tap
7. Flange Gaskets
3. Air Inlet Tap
8. Flue Exhaust Terminal
4. Sealing Gasket Ø60 or Ø80
9. Inner Wall Connection Flange
5. Sealing Gasket Ø 100 or Ø125
10. Outer Wall Connection Flange (EPDM)
Table 2
7. FLUES
7.1- Flue Sizes
Flue gas connections between the boiler and the flue terminal must be made using original components specially
designed for the condensing boiler to ensure that the device operates efficiently and correctly.
Flue gas pipes and fittings of non-condensing boilers can not be used for exhausting gases from condensing
boilers. In the horizontal concentric flues, the exhaust gas pipe (the inner pipe) facing outwards should be inclined
upward and the fresh air pipe (outer pipe) should be inclined downward. When the original flue set is installed
parallel to the ground, the exhaust gas pipe is automatically inclined upwards.
Equivalent length for each 900 elbow: 1 m
Equivalent length for each 450 elbow: 0.5 m
7.2- Flue Types
Figure 7
1. 90° C Elbow 6. Flange Screws
13

7.3- Distances for Placement of Flues
Figure 8
POSITION DISTANCE (cm) POSITION DISTANCE (cm)
A-Below a windows 60 G- Next to vertical or horizontal pipe 60
B- Below an air vent 60 H- Below the distance grille from the outside
of the building 30
C- Below rain channel 30 I- Distance from the inner corner of the
building100
D- Under the balcony 30 L- From the ground or from the floor 180
E- Next to a window 40 M- Vertical distance of two flue outlets 150
F- Next to an air grill 60 N- Horizontal distance of two flue outlets 100
Table 3
14

8- INSTALLATION
8.1- Selection of Installation Location of Device
The boiler must be installed in accordance with gas safety regulations and relevant standards. Additionally, the
clearance around the boiler should be as shown in fig 4. In order to make service, maintenance and usage
easier.
Figure 9:Itshows the minimum distances required from the top and sides of the device (Dimensions given
in mm).
The installation must comply with the following minimum distances so that servicing and maintenance of the
boiler can be performed correctly. The position of the boiler must be checked against technical requirements.
Figure 9
-Do not install your boilers in locations that will be exposed to direct sunlight.
Sunlight can cause color change on the exterior of your device over time.
-Ambient temperature of device's installation location should be between 5
-350C.
-The device can be used at altitudes up to 2000 m above sea level.
-There is no need to remove side panels in the combi boiler service
operations. Minimum 50 mm clearances are given taking into consideration
the share of possible side panel sheet changes.
-Since the outside temperature of the device does not rise above 85 ° C at the maximum heating power,
no special protective measures are required against the combustible construction materials and
components.
15

8.2- Independent Operation from Ambient Air (Type C)
DANGER: For room sealed operation, the boiler location and air/flue terminal
position must obey national and local requirements, gas safety regulations and
relevant standards.
-Type C (hermetic) devices are not suitable for outdoor installations. These devices should be installed inside the
building.
-In case of gas leakage, it is necessary to vent the installation room according to national and local requirements,
although the room sealed operation boilers are independent of room volume and ventilation.
DANGER: 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 minimumacceptable dimensions fromthe terminal to obstructions an ventilation openings must obey national
and local requirements.
-All horizontally fitted ducts (air/flue) should be fitted 2° or 3° upwards incline to allow condensate water drain to
the boiler.
-The flue ducts are always wet.
-Under cold or excessive humid weather conditions the water vapor inside the waste
gas may condensate while leaving the flue.
8.3- Mounting the Boiler
Having determined the boiler location,
• The points of lock screws of wall bracket and assembly bracket are marked byusing the assembly template
inside installation and user’s operating instructions of the device (pages 34-35-36). The mounting bracket
isan optional part.
• After drilling the marked points, wall assembly bracket and assembly bracket are fixed on the wall by the dowel
and lock screws which are inside the packaging of the device.
• Finally, the boiler is hanged on the wall by placing the assembly bracket on the back side of the boiler on the
mounting bracket assembled on the wall.
16

Figure 10
9 - CONNECTIONS
9.1- Condensate Discharge Connection
•All condensing boilers generate condensing discharge. The amount of the
condensate water depends on the working conditions of your appliance. This can
be up to 1.7 litres condensate water an hour.
•The condensation water must be connected to a drain with the help of a plastic hose which is connected to the
end of siphon. The use of standard discharge hose is recommended for connection to the drain. The addition of
1 cable connection on the hose should be made for fixing.
•If drain hose will be connected to drain outside of the building, insulation should be provided to prevent freeze of
hose.
•The condensate discharge hose and interconnection parts must be made of plastic material.
•All horizontal parts must be connected at a slight 2° or 3° downwards incline to ensure to a good flow.
Figure 11
17

-Water and gas supply connections between the boiler and the mounting bracket can be fixed with the optional
pipes and the nipples as shown in Figure 12.
a) CH flow ¾ ‘’ (hot)
b) DHW outlet ½ ‘’ (hot)
c) Gas inlet ¾’’
d) DHW inlet ½ ‘’ (cold)
e) CH return ¾’’ (cold)
-A suitable valve should be mounted on the gas inlet and CH &
DHW water circuit. In addition, a water filter should be mounted
on CH (3/4”) return and DHW (1/2”) inlet.
-A plastic pipe should be fixed the outlet tap of the three bar
relief valve and the pipe should be connected to the drain line.
-The connection between the appliance and gas supply must
be made with a flexible pipe.
-National and local requirements should be take into
consideration.
Figure 12
9.2.2- HCH Model
a b C d
a) CH flow ¾ ‘’ (hot)
b) Water filling line1/2"
c) Gas inlet ¾’’
d) CH return ¾’’ (cold)
Figure 13
9.2- Gas and Water Connections
9.2.1- HM Model
18

9.3- Electrical Connection
Electrical installation should be made according to the national and local instructions. The boiler must
be earthed and a standard 230 V AC – 50 Hz supply is required.
CAUTION: Disconnect power supply to prevent electrical shock before
connecting the electrical supply.
CAUTION: If the supply cord is damaged, it must be replaced by the
manufacture, its service agent or similarly qualified person in order to avoid a
hazard.
CAUTION: The 2-amp bipolar fuse with a minimum contact opening of 3 mm
must be used in the electrical connection of the boiler.
CAUTION: The cable diameter (including insulation) of the electrical installation
to be installed must be at least 14 mm and the pipe diameter used must be at
least 16 mm.
9.2.2- HST Model
a) CH flow ¾‘’ (hot)
b) Boiler supply water (hot)
c) Gas inlet ¾’’
d) Boiler return (cold)
e) Installation Filling Line ½ ‘’
f) CH return ¾’’ (cold)
a b C d e
f
Figure 14
19

9.4- Room Thermostat
Optional room thermostats compatible with your device can be used to control heating system.
Figure 15
E.C.A. On/Off Room
Thermostat
T6360
7006901312
E.C.A. Digital Room Modulated,
Programmable
LAGO FB OT
7006902518
E.C.A. Smart Room
Thermostat
T6360
7006907531
E.C.A. Digital Room Thermostat
No Wire,Programmable
CM 727
7006902046
E.C.A. Digital Room Thermostat
DT90
70069020502
E.C.A. On/Off No Wire Room Thermostat
7006907522
E.C.A. On/Off No Wire Room Thermostat
7006907519
E.C.A. Programmable Digital
Room Thermostat
CM707
7006901313
No Wire
7006901501
20