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1. LCD display is lit ar temperature is displayed 6 oD eco a co During first ignition you can run the fan in manual mode By pressing fan manual button you can lt at minimum level to help the fire become alive in short time Fan operation mode setting You can set the speed of the fan manually at 5 steps or you can leave fan in AUTO mode in that speed is modulated by the electronic board in accordance with boiler set and actual temperature When control panel is switched on fan will automatically work in the last mode left By pressing FA buttons manual or auto you can select in which mode fan will operate Fan in manual mode When this button is pressed fan will continously work at selected constat sp If pressed once Fan will be ON and speed will be minimum Twice 2nd stage Third 3rd stage Four times 4th stage Five times Maximum speed Six times Fan will be OFF again Fan in auto mode When this button is pressed other mode is cancelled and fan starts to operate mode in respect with boiler outlet temperature by the help of written software Boiler outlet water temperature setting C alt You can set desired boiler outlet water temp 1 Press MENU button once 2 The icon which points the setting parame J outlet water If you press MENU button once again thermostat setting will be over and the menu swtiches to the n sub menu Control panel leaves the MENU mode if you wait for 10 seco
2. R 1 1 Connection for delivery safety line dg R Connection for return safety line dd _ R Safety heat exchanger connection R 11 Filling draining connection R 1 Grille design o o Cast External dimensions Height H H1 Width W1 w2 Length L1 mm L2 Flue outlet diameter C 8 Electrical supply CT 232 V Fueltype Cid 3t Requested fuel parameters Maximum wate Maximum cross sec Average calorific value Flue gas mass flow Fueltype Maximum fuel charge Combustion period at max load 5 te Requested fuel parameters Maximum wate Average size betv Average calorific value Flue gas mass flow CT 55 F CT 70 F 48 000 55 000 60 000 70 000 360 108 4 1 134 0 410 124 4 9 165 0 co 450 480 480 O N N O O1 A80 X 305 three pass orced ital control panel for primary air 9 90 JO mended 1 1 4 1 1 4 Iron 1180 OINI ROT GO C El BRIO 0 Ol O11 CO O1 870 1030 1170 ar content 20 tion 10 cm x 10 cm 17 000 20 000 kJ kg ar content 15 veen 30 to 60 mm 26 000 30 000 kJ kg
3. RY Safety heat exchanger connection RE Filling draining connection RE Grile desin Castro External dimensions Height H Electrical suppl Power consumption Maximum water content 20 Maximum cross section 10 cm x 10 cm Average calorific value 17 000 20 000 kJ kg Maximum fuel charge O kW a a so Combustion period at max load h 5 to 8 Requested fuel parameters Maximum water content 15 Average size between 30 to 60 mm Average calorific value 26 000 30 000 kJ kg Fluegasmassflow gl 495 636 777 wo PAGE 3 __________________ INSTALLATION OF HEATING SYSTEM Handling the product Caltherm is a heavy product and care should be taken when carrying the boiler to the room where it is going to be installed The total weight of each boiler is indicated in Technical data section Carrying equipments of product must be of enough capacity to support that weight Room selection Caltherm boiler must be installed in an individual boiler room particularly organized for heating The boiler room should be of enough volume for installation firing and maintenance of the boiler There should be enough fresh air circulation for combustion the chimney design must ensure an dequate draught for related boiler type and must comply with construction criteria given further in this manual and in mandatory regulations Your boiler must never be installed in open spaces or balconies in spaces occupied by people l
4. a minimum speed and a maximum default or re set speed by the user Fan is automatically s when desired boiler outlet temperature is reached If boiler outlet temperature falls below 40 C electronic board keeps on operating fan as long as a pre is elapsed If boiler temperature does not exceed 40 C again during this safety time then control pane there is no fuel in combustion chamber and fan will be swtiched off After this safety time if boiler outlet temperature is over 40 C again for any reason fan will be switche However we recommend that you should reset the control panel by pressinG ON OFF button ONCE Default value for safety time is 45 minutes But you can re adjust this safety time between 5 minutes t by 5 minutes intervals To re adjust safety time 1 Press MENU button three times 2 The icon which points the settin 3 You can increase or decrease tl between 5 and 90 minutes pressin Pump control Pump will operate as long as boiler outlet temperature is above 40 C Pump is always kept switched c boiler temperature is below 40 C in order to prevent condensation and save energy Control panel do allow re set on pump start temperature Night sleep mode adjustments You can use night mode if you do not need to warm the radiators and if you will not stop the boiler per this feature you can have a small fire bed in combustion chamber and you do not have to start up the very beginning In this mode fan is switced
5. in order to slowdown the combustion Likewise you can leave flue gas damper half closed at any time you want to slow combustion such as at night mode When fan is switched off by control panel there is no air entrance to combustion chamber thanks to auto shut off air damper installed inside the fan adaptor on front lower door Control panel has following features 1 Displays 1 1 Actual boiler temperature 1 2 Set boiler temperature 1 3 Fan operation mode and speed 1 4 Circulation pump status 1 5 Boiler operation function manual auto ECO Night mode 1 6 Warning and failure indications 1 7 Set parameters in sub menus 2 Allows adjustment of following parameters in MENU mode 2 1 Boiler set temperature between 50 to 90 C with 2 C intervals 2 2 Fan speed in manual mode 2 3 Maximum fan speed in auto mode if needed 2 4 Fan safe over run working time 2 5 Night mode stop and run time re set if needed 3 Controls 3 1 Boiler temperature according to set value 3 2 Auto operation of CH pump 3 3 Auto operation of pump 3 4 Modulation of fan speed for optimum efficiency in FAN AUTO mode 3 5 Room thermostat option 3 6 External burner preferably as pellet burner ON OFF control 4 Safety features 4 1 If boiler temperature reaches up to 100 C for any reason fan is shut off CH pump is kept in operation Panel warns the user by an audible buzzer alarm If boiler temperature falls below 95 C again buzzer alarms switche
6. just fired it is quite normal for water vapour in flue gases to condense Condensation rarely creates a problem for the boiler as it will stop when boiler becomes hot However the boiler should not be operated in fully condensing mode When you open loading door if chamber walls are wet it means that there is condensation in flue gases Continuous condensation does not only creates massive sooth on combustion chamber heating surfaces but also has effect on boiler lifetime For this reason we recommend you to set desired boiler outlet temperature not less than 60 C at all times Design parameters for open expansion tank Expansion tank protects the hydraulic curcuit from excessive temperatures by allowing free volume for expanding water and keeping the water pressure from exceeding the static pressure Expansion tank may be built in rectangular prism or cylindirical shape may be installed in horizontal or vertical position in the system Safety lines between boiler and expansion tank should be installed by an increasing slope up to tank Following scheme shows the maximum vertical distances between safety lines and boiler The size of expansion tank can easily be calculated regarding the total expanding water contained in whole system If the total volume of water in the system is Vs the volume of expanison tank should be SR Vg 8 Vs 100 in liters l In more practical way just using the nominal heat output of boiler Qk in terms o
7. 10 a P G M BY PASS WA A o m gt k J gt SAFETY VALVE a MAINS SUPPLY WATER gt x STRAINER VALVE N SAFETY VALVE TA REGULUS JBV l v FLEXIBLE HOSE ay L g E Be I F NN EXPANSION TANK DRAIN SAFETY HEAT SAFETY VALVE Sl EXCHANGER Wie i STRAINER VALVE PS sic 4 Finally attach cold water supply line to inlet port of safety valve amd drain the other port of the safety heat exchanger If the boiler water temperature exceeds 95 oC thermostat of the safety valve lets cold sanitary water flows through the serpantine of the safety heat exchanger Serpantine with cold water circulating inside cools down the boiler water temperature When the boiler temperature decreases below the safe degree safety valve shuts the cold sanitary water circulation and the boiler goes back to normal operation AN The valves on the sanitary connections of safety heat exchanger must always be kept open Caltherm can only be used with origial safety heat exchanger kit which is tested and approved for each boiler model Cold water must never be delivered directly to boiler inlet in order to solve overheating porblems as this will result in serious damage on boiler body That application will end the warranty of the boiler Install a safety valve whose relief pressure is maximum 2 5 bar Refer to following table when sizing the AN safety valve Boiler model CT 35F CT 45F CT 55F CT 70F Safety valv
8. ON and OFF in respect with a pre set duration so that it will only operate t minimum flame in the combustion chamber According to factory set values when this mode is activa 120 seconds and stops for 20 minutes You can re set this time intervals within the MENU To re set ON and OFF time intervals 1 Press MENU button four times 1 Press MENU button again 2 The icon which points the setting parameter will blink 2 The icon which points the settin 3 You can increase or decrease the OFF time 3 You can increase or decrease tl between 10 and 40 minutes pressing the buttons between 60 and 240 seconds pres on right or left side of the MENU button on right or left side of the MENU b Slowdown the combustion You can slowdown the combustion by 1 Decreasing set value of boiler outler temperature or switch control panel to ECO mode 2 Closing flue damper on smokehood to half closed or fully closed position in case low fire be You can combine the steps of 1 and 2 or if you do not want to warm your room you can set the contro mode ECO mode eco You can use ECO mode to shift boiler outlet temperature down to 50 C if you do not need to much he instead of decreasing set temperature on the menu If you want to leave ECO mode and go back to standard operation just press ECO button once again NIGHT mode If you want to activate NIGHT mode just press NIGHT mode button on the control panel When this m fan is switched to manual mo
9. again Warning on fuels Different fuels require different fresh air volumes for combustion That is why control panel has some the fan speed for the fuel types used for boiler For example if you use wood logs as a fuel boiler will air than it needs for combustion of black coal and lignite Fuels must comply with the specifications given in the technical data section The manufacturer will n responsible for the problems due to lack of fuel specifications use of fuels not suggested for this boile Lack of chimney draugt If there is lack on chimney draught or there is no draught at the chimney such as badly built uninsula you may face combustion problems no fire excessive smoke condensation due to cold flue gasses we strictly recommend you to have your chimney controlled by an expert and fix any irregularity features to adapt require less ot be held ited blocked etc _In this case HEALTH AND SAFETY INFORMATION Control of substances hazardous to user health HEALTH AND SAFETY INFORMATION For the type of material and where used in Caltherm boiler refer to the following chart 1 PAINTS General purpose black undercoat High temperature black coating Powder coating 2 INSULATION AND SEALS Rock wool insulation board Glass wool insulation board aluminum backed Fibre glass rope and tape Ceramic fibre board CFC free polyurethane spray foam Refractory brick Asbestos products 3 ADHESIVES High tempe
10. arder is not at right position insert it at the top flue passage as shown in the following picture draw the retarder backwards fully until it hits the chamber rear wall 3 Place the flue separator as shown in the following picture at right hand side Flue separator position is very imprortant as it blocks flue gasses reaching out to chimney without swepping all boiler heating surfaces 4 Fix the front door handles using M8 setscrews supplied with the boiler 5 Loose the two self tapping screws that fix top panel to rear panel and take top panel from its housing to continue with installation of control panel and its accessories Control panel has three sets of wiring for different equipments and sensors Pass those three wiring sets through corresponding holes cut on the top panel as seen in the following pictures 6 Loose one of self tapping screws that fix left hand side panel to front upper panel and draw the wiring to the fan routing it around boiler insulation board and passing it through the space for fan plug cut on bottom level of left hand side panel Brown L PHASE Blue N NEUTRAL YELLOW E EARTH 7 Attach isolated terminals of fan wiring to the female plug supplied together with the boiler package Make sure that you are connecting the right wire to the right terminal on female plug Follow the matching given in above picture 8 Fix female plug for fan wiring to the left hand sid
11. at Product Welded steel body solid fuel boilers for hot water production Brand Caldera Models CT 17 CT 25 CT 35 CT 45 CT 55 CT 70 To which this declaration relates is in conformity with the following standards Harmonized normative EN 303 5 of April 2001 on Heating boilers for solid fuels hand and automatically stocked nominal heat output up to 300 kW And following directives Council Directive 97 23 EEC of 29 May 1997 on the approximation of the laws of the Member States relating to pressure equipments Council Directive 89 106 EEC of 21 December 1988 on the approximation of laws regulations and administrative provisions of the Member States relating to construction products We declare that we are going to supply the documentation of each product including data labels safety precautions and warnings installation and final user instructions in the language of the destination country This declaration will become invalid in case the product has been subject to any modification without prior notice to the manufacturer 2009 August 25th Bursa Turkey TR F Murat Gedik Technical Director CT39 F CT 45 F Fuels Efficiency S a 80 Watercontent tt 80 vo Combustion ch dimensions Height 475 Width Length Q AC Flue circulation Horizontal Draught Fan f Temperature control Fan speed modulation by a dig 50 t 1 40 recon 9 2 Water flow return connections D
12. caldera HEATING GROUP Installation and User Manual for boiler series Caltherm Models CT 35F to OF 02 2012 v4 Thank you for purchasing Caltherm solid fuel boiler Please read this manual carefully before installation and operation of your product and keep it during the whole operation life Do not touch or interfere any part of the product other than those allowed The installation maintenance and service of this boiler requires skilled technicians For the installation of the boiler and proper room selection installation of water circuit chimney design this manual and mandatory regulations must be considered Caltherm is a welded steel boiler for solid fuel firing which is constructed in three pass horizontal flue gas circulation principle It is designed for hot water heating systems should not be used for direct sanitary water supply Caltherm can hold high amount of fuel thanks to its big volume of combustion chamber Due to high volume and well contributed size in flue gas passages and high effecting heating surface Caltherm boiler fires your fuel with very high water efficiency saving on your fuel cost The boiler is constructed with reliable materials at high thicknesses required by related European normative resulting with long operation life Caltherm boiler can be used either in forced or natural water circulation systems thanks to its large waterways inside the boiler and medium sized delivery and return co
13. d continue to set larger and larger pieces on top until the fuel exceeds the 1 3 level of the filling chamber Ensure that chimney damper is open Then light the newspaper at the bottom For air entrance leave the lower front door open for a while After first ignition turn on the control panel by pressing ON OFF button Follow the instructions in the next chapter given for control panel Close the front lower door The fire should be well established within approximately 15 minutes then filling chamber can be loaded completely but check to make sure that the firelighters have not been extinguished Keep the fire going always keep a flame on your fire a smoking or smoldering fire is a cold and inefficient fire and also produces pollutants and creosote tar in the chimney Never let the boiler water temperature reach high values sharply with leaving control panel switched off In this case instant cold water delivey to hot boiler may result in cracks on boiler body due to high thermal energy Chimney flue gas damper Your boiler has fan assisted combustion Air for combustion is forced to enter the combustion room As the speed of the fan is controlled and modulated by control panel the boiler itself adjust the air flow However you can use the flap or Flue damper half open Flue damper Flue damper open_Z 3 closed SS If flue circulation to chimney is too fast you can half close the flue gas damper
14. de at the third speed level As described above we recommend you to a mode specially during night times when you do not need to heat up the radiators If you want to leave NIGHT mode and go back to standard operation just press NIGHT button once a A clear contact to switch pellet burner ON and OFF in respect with desired outlet temperature is supp control panel The burner will operate according to its own software when switched ON Pellet burner is installed on lower front door of the boliler You do not have to remove the combustion the left hand side of the boiler You can activate pellet burner just by pressing the EXT BURNER buttc panel then the boiler will operate according to pellet fuel To switch back to operation with wood or cc FAN MANUEL of FAN AUTO buttons If you fire wood or coal we recommend you to remove pellet burner from the front door to prevent any damage on the burner Safety shut offs If boiler temperature reaches up to 100 C for any reason fan is shut off CH pump is kept in operatior user by high temperature icon on LCD an audible buzzer alarm If boiler temperature falls below 95 C switches off boiler switches back to its normal operation If boiler temperature reaches 110 C it means that there is a problem on control panel s PCB or senso an additional bi metal safet limiter stops the boiler operation for an external safety This bi metal therr on the boiler hot water outlet pipe under the top panel of the boi
15. e panel by self tapping screw as shown in the following pictures 9 Fit 4 pieces of M6 x 20 setscrews through the flange holes of fan inlet adaptor on the left hand side seramic paper fan gasket onto those setscrews Fit fan with position shown in the following picture an with 4 pieces M6 nuts Attach the male power plug of the fan to the female plug on the left hand side f Note Installation position of the fan is very important as it has its own air flap integrated on the body follow the instruction above carefully Fan has also another flap on inlet side to limit air entrance to far this flap if you need further air flow control during combustion Never let this flap positioned fully close Notes for wiring Wiring type Identification at the end of the wir Attach one of d secure it anel Therefore 1 body Use d a 10 Insert NTC sensor into the pocket between the outlet pipe and connection pipe to safety line to open expansion tank Attach two ends of wiring to bi metal thermostat onto the two terminals on the thermostat as seen on right hand side 10 Draw wiring to mains and heating circuit pump through cable clips and secure the cable and clips together on the side panel of the boiler as shown on the following picture 11 Finally fix control panel to top panel of the boiler with supplied M5 setscrews Then re position the top panel into its original place and secure it Note If you
16. e size 1 2 1 2 3 4 3 4 N Install a manometer and follow the hydraulic circuit pressure When the boiler is cold water pressure should be 1 1 5 bars Warning on water level in system After first water make up in the system minimum water level must be marked on hydrometer for open vented circuits minimum water pressure level must be marked on manometer for pressurized circuits Water level or pressure should be checked daily and water should added to circuit if they are below the minimum value Warning on corrosion protection in system Your boiler is quite a strong design against corrosion However all metal surfaces in whole heating circuit should be protected against corrosion like piping and radiators The oxygen in heating water will cause rust and then material loss on iron based metal surfaces by means of oxidation o During the first water make up oxygen must be fully discharged from the system Generally oxidation will not be a problem if all measures are taken into account furing first water make up Oxidation will take place because of fresh water addition to the system during operation of the boiler The main reasons are as follows 1 In case of open vented systems oxygen will be added as expansion tank is open to atmosphere That is why open expansion tank sizes its position in the system safety connections to and from are very important and instructions given in this manual for open vented systems should be
17. e supplied with the kit between outlet port of safety valve and one of ports of safety valve in respect with the flow direction shown on valve body 4 Finally attach cold water supply line to inlet port of safety valve and drain the other port of the safety heat exchanger FORBIDDEN POSITION Notes on electrical wiring The boiler is fed with 220 V A regulator must be used in installations where the power supply is below 205 V or above 230 V Control panel should be connected to a wall plug with an efficient ground system which is placed not far more than 50 cm to boiler with a circuit breaker which has at least 3 mm gap between contacts For this reason if a new electrical installation is required 3x1 5 TTR cables must be used All electrical installations must be carried out by authorized persons in accordance with mandatory regulations and codes of practise AN THIS APPLIANCE MUST BE EARTHED OPERATING INSTRUCTIONS Pre firing checks Before the first operation of boiler right after installation the hydraulic circuit must be ready for operation To fill an open vented circuit the valve on start level line from expansion tank is opened and the circuit is filled with main supply water During filling the system all valves and accessories on the lines must be checked for leakage Filling is is stopped when water from start level line is observed closing the valve on this line Right after that the hydraulic pressure is mar
18. em in other words they come in the first place where corrosion starts That is why following precautions should be added to those given above for a new boiler in an old system 1 If the old system has an open expension tank this may be converted to pressurized system with all necessary safety measures 2 The old system must be fully washed up from all substitutes and particules contained on the surfaces 3 An air separator with manual vent should be installed at the heighest level of the circuit Chimney connection Caltherm boiler must be connected to an individual chimney that will provide at least the minimum draught requested The flue canal between the boiler and the chimney should be insulated using a glass wool material The flue canal to chimney and chimney must be made of steel or an equivalent material that can be used at temperatures around 400 C All connections on the flue system must be sealed in order to perform a good combustion and efficiency The flue canal must be connected to the chimney using the shortest way and in accordance with the dimensions given in the following scheme Horizontal connections and equipments that will increase the pressure loss such as elbows should be avoided A vertical single steel piping should not be used as a chimney H d min Chimney must be made of one internal and one external Aug m T surface External surface may be made of steel or brick po im For internal surface sta
19. f kW the volume of expansion tank can be caluculated as SV Deliver safety line SR Return safety line Vg 2 15 Qk in liters Sizing safety lines between boiler and open expansion tank Size of the safety line for delivery doy 154 1 5 Q mm Size of the safety line for return doy 15 0 mm where Qk is the boiler output in kW Pressurised hydraulic circuit Caltherm boiler can be installed in a pressurised heating system if following scheme is referred with addition of the safety heat exchanger kit which is supplied as a separate accessory Safety heat exchanger set includes the following items 1 Safety heat exchanger copper serpantine integrated with port for safety valve assembly 2 Safety valve 3 Flexible hose To install the safety heat exchanger system 1 Remove 1 1 2 tap from the safety cooling loop connection at the back of the boiler 1 Install the safety heat exchanger into the 1 1 2 port on upper right hand side at the back of the boiler After the installation 1 2 female outlet which is going to be used for safety valve installation should be positioned at the top 2 Install the Regulus JBV 1 safety valve into 1 2 port 3 Attach the flexible connection hose supplied with the kit between outlet port of safety valve and one of ports of safety valve in respect with the flow direction shown on safety valve body XA AIR COCK a gt a annunnaannannan Er gt 3 CIRCULATION PUMP
20. followed carefully Pressurized heating system is therefore much more resistant to corrosion Pressurized system can be preferred but the optional safety kit against over heating must be utilized within the system 2 Leak points in a system will cause oxygen to be absorbed inside the heating water For this reason minimum water pressure in a pressurized heating circuit must be above atmospheric pressure Besides pressure level should always be checked periodically Precautions for new installations System should be sized and designed accordingly in order to minimize fresh water addition Make sure that no part of the system is made of material that is permeable to gases The original system filling water and any topping up water must always be filtered using synthetic or metal mesh filters with a filtration rating of no less than 50 microns to prevent sludge from forming and triggering deposit induced corrosion Minimum water pressure in a pressurized heating circuit must always be kept above atmospheric pressure Precautions for a new boiler installed in an old system In old systems used for a long time a protective coating black magnetite has been built on all metal surfaces contact with water This coating protects the system agains further corrosion When a mew boiler is installed in such an old system new parts with clean metal surfaces particularly boiler surfaces will inevitably become sacrificial anode for the entire heating syst
21. gulations before feeding into the system to prevent corrosion inside the heating circuit and the boiler Front doors of the boiler should be checked for properly closing Fibre glass ropes must be replaced if necessary Check the condition of refractory inside the front door If it is damaged you will have higher surface temperatures on front doors In this case the refractory should be replaced to save energy and prevent further crack Check if there is flue gas leakage from the chimney connections of the boiler and have it fixed if necessary Check wiring to control panel and wiring from control panel to heating circuit pump and fan Check gasket in front of the fan Check gasket behind the rear cleaning cover Check primary air inlet diverter behind the fan assembly flange Remove any deposits which may block the air flow into combustion chamber Check the heat transfer surfaces of the boiler The soot formation will change according to fuel type you use and the combustion air amount So if you feel that the outlet water temperature can not reach the usual values with the same conditions heating surfaces therefore should be cleaned Cleaning of boiler Before cleaning the boiler switch off the control panel and other electrical appliances in boiler room off Detach the control panel electrical supply from the mains To clean the boiler Remove flue separator behind the upper loading door Remove flue gas retarder from 3
22. have a pressurised heating circuit with cloesd expansion tank tap the two pipes intended to open expansion tank at the inlet and outlet side Safety heat exchanger optional The safety heat exchanger is used to save the boiler in case of overheating In case of electrical cutot defect etc the boiler water temperature can be overheated If the boiler water temperature exceeds 9 thermostat of the safety valve lets cold sanitary water flows through the serpantine of the safety heat e Serpantine with cold water circulating inside cools down the boiler water temperature When the boile decreases below the safe degree safety valve shuts the cold sanitary water circulation and the boiler to normal operation It is best to purchase the safety kit together with the boiler and install during the boiler assembly as tr the labour for assembly However safety kit can also be installed on an old Caltherm boiler in use AA M YA Bi metal safety limiter to connect it pump gt C axchanger r temperature goes back is will ease o For installation of safety kit refer to following instructions 1 Install the safety heat exchanger into the 1 1 2 port on upper right hand side at the back of the boiler After the installation 1 2 which is going to be used for safety valve installation should be positioned at the top 2 Install the Regulus JBV 1 safety valve into 1 2 port 3 Attach the flexible connection hos
23. hecked regularly and any leakages corrected in order to keep system water make up to a minimum because excessive make up will lead to salt deposits forming in the boiler waterways causing local overheating and damage to the boiler body Make sure that your installer applies the recommendations given further in this manual in order to protect either old and new installations from limescale Particularly if the boiler is going to be installed in an old heating system the system should washed away and cleaned from any particules before Caltherm is attached Caltherm should be installed directly onto a smooth level floor of non combustible material It is recommended that the SS o TECHNICAL DATA Fuels AI NN kcal h 30 000 35 000 40 000 45 000 48 000 55 000 60 000 70 000 Efficiency gt o a so Efficien Se ee E a Warr omen yg a Combustion chamber volume ame 1050 1240 740 160 HA Combustion ch dimensions mm 475 450 420 480 480 ma 5 765 Fuel loading clearance upper door mmxmm 420x250 480X305 Maximum fuelloadingheight mm OO Flue circulation Horizontal three pass Draught Fan forced S O Temperature control Fan speed modulation by a digital control panel for primary air__ Safety systemactivatedat CH Maximum operating pressure ba Water flow return connections D R 1 ar iw iww Connection for delivery safety line dg RL Connection for return safety line dd
24. ike kitchen living room bathroom bedroom in spaces where there are explosive and combustible materials The boiler room should have air ventillation holes through outside to let fresh air in One air ventillation hole must be built maximum 40 cm below the level of room ceiling the other must be built maximum 50 cm above the floor level These ventillation holes should always be kept open The upper hole should be at least 40x40 cm in size the lower hole at least 30x30 cm All hydraulic and electrical circuits must be arranged by authorized staff in accordance with mandatory regulations specified by legal organizations Solid fuels should be stored by keeping minimum 800 mm distance from the boiler We recommend you to keep the solid fuel in another room Caltherm boiler should be installed on a concrete plinth made of a fireproof material For minimum sizes of the plinth following table should be referred Model CT 35F CT45F CT55F CT 70F Plinth height mm Plinth width mm 580 640 Plinth length mm 650 750 750 900 Clearances around boiler At least the following clearances should be achieved around the boiler O 100 cm 60 cm 40 cm Circulation pump We recommend to build a forced water circulation system accompanied with a sufficient pump To size the pump refer the boiler water side resistance level given in Technical data section taking the other resistances created by the hydraulic circ
25. inless steel chimney elements should L a be preferred against corrosion The space between internal we DB eee and external surfaces of the chimney should be insulated to m mi prevent condensation in flue gasses n 1 At the lowest level of chimney there should be a cleaning Hy cover which is made of steel and sealed for any leakage l l The length of flue canal between the boiler and the chimney should not exceed 1 4 height of chimney n m m m i 1 y I FI CLEANING rrr COVER Port Li The size of flue canal and chimney should not be less than the size of the boiler flue gas outlet connection For the total height and the minimum internal diameter of the chimney following diagram should be referred in respect with boiler output power if otherwise stated in mandatory regulations CT ae E E 3 E E ETE at diameter aa Boler output kw 10 20 30 liaii of chimney m The heighest level of chimney outside should be in accordance with the dimensions given in following sketch so as to minimize the harmful effect of flue gasses on ambient and to improve draught in chimney ASSEMBLY INSTRUCTIONS Follow the instructions to finish the assembly of boiler accessories supplied together with the boiler 1 Out of the box your boiler has the configuration as shown on the picture at right hand side 2 First check the condition of flue gas retarder at the 3rd passage of the boiler If the ret
26. ked on screen of the hydrometer This will make re filling operations during heating season much easier just feeding the system with fresh water until the hydraulic pressure on screen reaches the pre marked value Before every firing make sure that Boiler and circuit are filled with water and the hydraulic pressure is in the required range All valves on the line except by pass lines and start leve line are in open position There is enough draught in chimney There is electricity in front of the control panel inlet Panel is in STAND BY mode To fill a pressurised circuit feed the fresh water from main supply line using either the filling drilling tap connection on the boiler rear sectiion or the feeding line constructed within the circuit To purge the air contained in the system use air relief valves on the hydraulic circuit on the radiators and also spring pressure relief valve at boiler hot water outlet Firing AN Do not turn on the control panel during the ignition period leave it in STAND BY mode Set the Kindling Place firestarters crumpled newspaper 3 or 4 sheets balled up fairly tightly on the grate of the boiler Place small kindling over the paper or starter The more dry small kindling you have the easier and better the fire will start Crisscross the kindling so there is plenty of air space in between each piece Wood that is packed too tight will not burn properly Set larger wood on top of the kindling an
27. ler If boiler temperature is above 110 OFF but pump is kept ON in order to protect the system against very high temperatures El failure cc LCD In this case we recommend you to call for a service agent to check the control panel and its ass The bi metal thermostat is of manual reset type and therefore it must be manually reset right after the Then the control panel is reset by pressing ON OFF button once Failure codes and indicators code E1 Bi metal safety limiter stopped the boiler High temperature warning code E2 NTC sensor fail No fuel warning Turning off the panel Control panel is turned off by pressing ON OFF button Never turn off the control panel when there is chamber Before opening the front door for fuel addition in combustion chamber we recommend you t fan by pressing FAN CONTROL button After closing the front door switch on the fan again After each combustion period before loading combustion chamber and ignition the contro panel must be reset by pressing ON OFF button Room thermostat You can install a room thermostat between the short cut terminals of room thermostat contact outboard the control panel If you do not use a room thermostat leave this wire bridge as it is When requested room temperature by room thermostat is reached Fan and pump are switched off In the meantime if boiler temperature exceeds 75 C pump will start and be in operation until boiler temperature is below 70 C
28. nds without pressing any butt to normal operation Short cut for thermostat setting You can just press or buttons to set the desired boiler outlet wi temperature without entering the MENU A N Boiler outlet temperature can be set between 50 C to 90 C with 2 C intervals Fan maximum speed setting for FAN AUTO mode only You can set the maximum speed of the fan if you choose fan operation mode as auto as described il previous page Control panel allows you to set the maximum speed in fan modulation mode If you fee is too much for your chimney installation and fuel to be loaded then you may decrease the maximum fan In this case fan will be operated between minimum speed and the maximum new speed you set will help the boiler save on fuel consumption To re set the maximum speed of fan 1 Press MENU button twice 2 The icon which points the setting paramete 3 You can increase or decrease the new max between 3 and 5 pressing the buttons on right MENU button If you press MENU button once again thermostat setting will be over and the menu swtiches to the n sub menu Control panel leaves the MENU mode if you wait for 10 seconds without pressing any butt to normal operation Auto fan switch off feature Quek When power is turned on by ON OFF button of control panel fan will automatically start no matter whi temperature is Then fan will be operated according to your adjustments that is modulated by electro between
29. nnections You can fire different solid fuels whose specifications are given further in this manual As calorific values of solid fuel types differ from each other the output power of the boiler will vary between a maximum and a minimum range specified Delivery term Caltherm boiler is delivered as fully assembled in one wooden box 1 Boiler Fully assembled doors attached insulation wrapped external jackets installed data label attached 2 Accessories Control panel fan flue gas retarder user manual cleaning brush and fuel shaker arm are delived in the combustion chamber of boiler Optional accessory A safety heat exchanger kit is delivered upon special request This kit holds a copper heat exchanger against excessive heat accumulation inside the boiler a safety valve to activate the heating system at high water temperatures and auxillary accessories for installation Whether the hydraulic circuit is open vented or pressurised this safety heat exchanger system should be utilized within the system for meeting the regulations of related European standard for this product as well as the safety of whole heating installation and the boiler itself A In case of pressurised hydraulic circuit the safety heat exchanger kit MUST be installed for safety reasons Safety warnings Electrical installation of this boiler must be completed in accordance with mandatory regulations and codes of practice regarding the instructions given in this man
30. nt for the combustion Flue gases 1 There could be a little gas release from the front side of the boiler when the front loading door is opened Never breathe this gas flow 2 When adding solid fuel when there is active fire bed inside the combustion chamber protect your hands and face If needed wear protective gloves Firing fuel 1 Do not take the firing fuel out from the combustion chamber while it is still burning 2 Do not try to put the firing fuel off using water or any other liquids 3 Do not leave the front doors and fire door open when there is fire inside the combustion chamber 4 To slow down or stop the fire close air inlets and flue outlets 5 Your boiler can only be fired with the solid fuels whose characteristics have been given in Technical data section Never use any other solid fuel that would be harmfull for boiler section design any liquid or gaseous fuels MAINTENANCE AND CLEANING Regular maintenance by qualified staff strictly in accordance with the manufacturers instructions is essential for the efficient operation of system Periodic inspections Check the water level or pressure either in open vented or pressurised systems The hydrometer must be marked after first filling of the boiler So water level can be checked regularly If the water level or pressure is under the level of static pressure or the system set up a water make up is needed The make up water should be softened according the local re
31. r at points as close as possible to boiler using the shortest possible vertical way between expansion tank and boiler If the circulation pump is installed on return line and the head of pump at maimum speed is h the h vertical distance given in above scheme must be achieved within the system design h being the vertical distance bet ween the top radiator of the circuit and bottom level of open expansion tank If h is not achieved in such system there will be air suction on radiators at heighest level of circuit In this case the pump must be installed on delivery line from boiler A hydrometer must be installed on the delivery line to monitor the pressure level and to check if there is any leakage The hydrometer should be purchased separately and should be installed at the same level with the boiler outlet A by pass line should be installed between inlet and outlet connections of circulation pump in order to allow maximum water delivery when circulation pump is switched off and there is fuel fired in boiler particularly during sudden electricty cuts off N The optional safety heat exchanger kit is highly recommended to be used with the boiler even in the case of open vented systems to protect the boiler and the whole heating circuit against excessive heat accumulation For installation of this kit please refer to the next section _ o When water temperature in hydraulic circuit is relatively low particularly when solid fuel is
32. rature adhesive compound Fire cement Gas jointing compound NOT APPLICABLE Boiler body All jackets NOT APPLICABLE Boiler body Front door Front door Rear cleaning cover NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE Front door NOT APPLICABLE NOT APPLICABLE Specific data sheets are available on request from CALDERA for those materials but the following material handling and first aid procedures should in all cases be observed Paints sealants ceramic fibre boards 1 These materials contain organic solvents and should be used in a well ventillated area away from naked flames 2 Do not allow to come into contact with the skin eyes inhale or swallow 3 Use barrier cream or gloves to protect the skin and goggles to protect the eyes from accidental contact 4 Small quantities can be removed from clothes or skin with a proprietary paint remover or hand cleaning prdouct 5 If inhaled remove sufferer into fresh air if swallowed clean mouth with and drink fresh water but do not induce vomitting 6 If in the eye irrigate the eye with clean water and seek medical attention Sharp edges Care should be taken when handling sheet metal panels that do not have safety or folded edges Lifting boiler body Care should be taken when lifting boiler body as they can weigh up to a few hundred kilograms and CALDERA can confirm the weight of each individual boiler if required Thermal insulation 1 Avoid contact with skin e
33. rd flue gas passage Clean all heating surfaces using the brush supplied with the boiler Clean the air inlet passages of the bottom grate using fule shaker arm Collect all soot deposits inside the ash tray and the smokehood Remove the disposals Maintenance Before each heating season we would recommend you to call for the contracted service agent to check the boiler heating system electrical connections and chimney conditions Do not attempt to carry any maintenance work without getting help from qualified people Safety heat exchanger The valves on the sanitary connections of safety heat exchanger must always be kept open Caltherm can only be used with origial safety heat exchanger kit which is tested and approved for each boiler model Cold water must never be delivered directly to boiler inlet in order to solve overheating porblems as this will result in serious damage on boiler body That application will end the warranty of the boiler o kaldera Isitma Sistemleri San ve Tic Ltd Sti C a a e Pa Org San Bolg Demirciler Sitesi 75 Yil Cd D Blok No 10 11 HEATING GROUP Bursa Turkiye TR 90 224 243 14 90 www caldera heating com c DECLARATION OF CONFORMITY We Kaldera Is tma Sistemleri Sanayi ve Ticaret Limited Sirketi located at Organize Sanayi B lgesi Demirciler Sitesi 75 Y l Caddesi D Blok No 10 11 Bursa Turkey TR herewith declare under our sole responsibility th
34. s off boiler switches back to its normal operation 4 2 External bi metal termostat for additional safety which is activated if boiler temperature is over 110 C This bi metal thermostat is of manual reset type due to European regulations 4 3 High current protection fuse cut outboard on rear panel of the control box 4 4 All settings are stored in the memory of electronic board even in case of electricty cut off 5 Energy saving functions 5 1 Circulation pump is switched off below boiler temperatures of 40 C This will also protect the boiler against excessive condensation 5 2 Fan speed modulation in respect with desired boiler temperature saves energy and fuel 5 3 ECO mode automatically shifts set boiler temperature down to 50 C and saves fuel 5 4 NIGHT mode keeps the boiler in minimum flame without stopping during the times when there is no need for high temperatures This will save too much energy and there will no need re fire the boiler in the morning STAND BY MODE When mains is attached to control panel has following view in STAND BY mode OPERATION MODE You can leave boiler control panel in STAND BY mode during fuel loading in combustion chamber and first ignition When there is fire in combustion chamber control panel must be switiched on immediatley For setting and usage of control panel please refer to following chapters Turning on the panel By presssing ON OFF button for three seconds control panel is switched on
35. ual by authorized installator A THIS APPLIANCE MUST BE EARTHED Caltherm boiler must be connected to an appropriate chimney whose construction complies with the instructions given further in this manual and mandatory regulations The chimney must perform the requested draft values for related boiler model Your boiler should not be fired unless the chimney connection is made and there is enough draft for combustion Any irregular electricity installations in boiler room should be replaced Always allow enough amount of fresh air in the boiler room Refer to the instructions for room arrangement Do not install the boiler in a space shared or used by people or in a place with direct openings to a living room The boiler must be installed in an open vented hydraulic circuit unless the hydraulic circuit is equipped with safety heat exchanger kit according to the directions given further in this manual Do not feed cold water directly to the boiler overheated by any reason This may resutl in noise production in the system and or permanent damage on boiler body Do not drain water in hydraulic circuit unless in case of maintenance or risk of freezing Do not fire boiler with front doors open In case operation with fan never open front doors without switching the fan off The system design must provide water flow rates commensurate with boiler output and the temperature difference between flow and return should not exceed 20 C Water levels should be c
36. uit into account Refer to the system diagrams given further in this manual to find the right position of the pump wtithin the hydraulic circuit Your boiler automatically switches the pump on and off according the program stored in its PCB That is why heating circuit pump must be driven by the control panel Wiring to the pump is supplied within control panel with indications So attach this wire to terminals of the heating circuit pump The pump will automatically start when boiler outlet water exceeds 40 C and will automatically swtich off when temperature falls below 40 C This feature will help prevent boiler from condensation in flue Rules for hydraulic circuit Open vented hydraulic circuit Caltherm boilers are preferred to be installed in a hydraulic circuit with an open type expansion tank in accordance with the following schemes The circulation pump may be installed on eitjer delivery or return line of the boiler E y 5 o rl LI oO am Max 25 m Hl SAFETY LINE FOR DELIVERY SR SAFETY LINE FOR RETURN SW OVER FLOW LINE S START LEYEL LINE CHECK VALYE LF gt gt MAIN SUPPLY Pre UNE DRAINING VALVE Ya Open type expansion tank must be installed at the heighest level of whole hydraulic system No globe valves must be installed on delivery and return safety lines between boiler and expansion tank Safety lines should be attached to inlet and outlet lines of boile
37. yes or inhaling dust 2 If cutting insulation then do so in a well ventillated area using gloves to protect the hands goggles to protect the eyes and a disposable dust mask 3 If a skin reaction or eye irritation is experienced then discontinue working with the material and seek medical advice Devices under pressure 1 Avoid contact with the parts of heating system under pressure during operation of boiler These dangerous parts are such that Boiler body Boiler inlet and outlet lines Safety lines Pressure relief devices installed on heating system 2 Never attempt to drain water from heating system when the boiler is being operated 3 Never feed the boiler directly with cold water to cool it down for any reason when the boiler is hot o High temperature surfaces Avoid contact with parts and surfaces having high temparutares which will be hazardous for human such as Boiler front doors Fire door movable door behind lower front door Water delivery and return lines even if isolated safety lines Smokehood Connection between flue outlet and chimney Circulator pumps expansion vessels Boiler room 1 Ensure that the boiler room has an easy access to outside in case of danger in heating system 2 Do not leave the solid fuels and auxillary substances chips paper etc to ignite the boiler with the distance less than 800 mm from the boiler 3 Do not cover the fresh air openings of the boiler room as it is very importa

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