Protherm Bear 50 KLZ Installation guide
Contents
1. 9 OL 91S WHZHlOHd paeoq E i 2108098 uoniub yue 1 l dd 1 T tY dl AOL euuiluo WY 99975 Lj TTHMABNOH feimjongsiedn anen Kaul N Jeued yun eux SX LX vX EX IS Sec 2 96 seb uojsnquog ZTA 09 Ov oc 0 19110q jo e21129 3 312. 27 Boiler 9 Electrical connection of boiler 28 Protection functions 10 Converting to different fuel 29 Service and maintenance 11 Electrical wiring diagram 31 Warranty and warranty conditions 12 Technical specifications 13 Connection dimensions 15 Schematic diagram of boiler 16 Introduction 1 The boiler and all the associated equipment must be installed and used in accordance with the installation design all the corresponding valid legal prescriptions and technical norms and with the manufacturer s instructions 2 The boiler may be installed only in an environment for which it is designed 3 After installation the boiler may be put into operation by an authorised service organisation only 4 The boiler complies with the prescriptions valid in the Slovak Republic When used in the conditions of other countries any applicable deviations must be identified and addressed 5 In the event of a defect call the manufacturers service organisation any unauthorised intervention may damage the boiler and possibly also associated equipment 6 The service technician putting the boiler into operation for the first time is obliged to familiarise the user with the safety eleme
3. using the screw C the left limit position is set to minimum output anticlockwise the dial D on the automatic device is used to set 55 mm of water column for natural gas 130 mm of water column for propane After completing setting switch the boiler off remove the U manometer tube and slightly tighten the closing screw at the measurement point Screw the metal cover plug back on Put the boiler into operation and perform a tightness test of the measurement points on the gas armature 26 First heating The first heating is a short sharp operation of the boiler after its initial connection to the heating system Setthe boiler control elements operational controls room control unit so as to attain the highest possible heating water temperature in the system and at the same time the smallest possible number of shutdowns of the boiler Maintain the entire system boiler and heating system in these conditions until it is stabilised i e the temperature becomes constant also on the at the furthest distance from the boiler and for at least one hour more The boiler is shut down Record the pressure value on the boiler Once more carefully de aerate the system and subsequently pressurise to the recorded value Finally the system is allowed to cool During the drop in temperature check that there is not also simultaneously a marked pressure drop In the case of such a pressure drop check for leakages
4. for thrust exhaust of combustion gases 3 PROTHERM room control unit for regulation of boiler on the basis of temperature in referential room 20 Preparing for boiler installation Boiler equipment The boiler PROTHERM 20 30 40 50 KLZ comprises the following parts cast iron boiler body with thermal insulation burner plate including gas path and starting equipment combustion gas catcher with thrust breaker hydraulic construction boiler casing with control panel hot water tank Cast iron boiler body This is composed of elements and serves simultaneously as a combustion chamber including combustion gas paths and a water space including water paths The elements are lateral right and left and central of one type The connection of the elements creates the boiler body with the relevant size both of the combustion chamber and the water space The assembled boiler body is connected to a hydraulic construction and insulated against heat loss and radiation It is also fitted with clips for fitting the sensors of the thermostats and thermometer and clips on legs serving for connection with the boiler construction in which the tank is placed Burner plate This is fitted with a gas pipe section its own burner pipes and a starting device According to size which corresponds to the size of the boiler body it holds 2 to 4 burner pipes and the entire gas path The gas pa
5. In this phase of setting the expansion vessel changes in pressure are imperceptible and it is necessary to proceed very carefully since the water is practically impossible to pressurise and even in the case of reduction of the pressure effect its volume 24 will be practically unchanged So when throw takes place during relaxation of the pressure from the equalizing gas part and the pressure watershed of the sought working point is exceeded and the water volume in the system is not changed the gas part can be simply re pressurised and pressure relaxation in seeking the pressure watershed can be repeated more carefully The tightness of the valve of the expansion vessel is not absolutely constant if the pressure in the system drops this may be caused not only by a water leakage but also by a reduction of the pressure effect of the equalizing gas part of the expansion vessel on the water part upon topping up the system pressure by inlet of water the gas part may then shrink in volume which reduces the overall expansion capability of the expansion vessel as against its nominal state For this reason it is never possible to resolve setting of the expansion vessel only by simple pressurising of the equalizing gas part in operation with a longer duration with absolute certainty or even in the shortest operation if water has been charged into the system Setting of the hot water expansion vessel resides only in its press
6. according to STN 33 2000 7 701 Fig 7 The boilers are designed to run with heating water compliant with STN 07 7401 above all this water must not under any circumstances be acidic i e its pH factor must be greater than 7 and must have a minimal carbonate hardness The requirements for utility water properties are defined in STN 83 0616 for drinking water STN 75 7111 If the water has a combined calcium and magnesium concentration greater than 1 8 mmol l it is useful to implement other non chemical measures against incrustation e g use of magnetic water treatment combined with a desludging device In the case of clogging of the system with dirt from the heating system or incrusta tion sediments or problems caused by other clogging e g clogging of the heat exchanger pump defects are not covered by the boiler s warranty Upon installation and operation of the boiler it is prohibited in the sense of STN 92 0300 for objects classified according to STN 73 0823 to be placed at a distance of less than 100 mm in the case of materials which are not easily flammable flammable with difficulty or medium flammable 200 mm in the case of easily flammable materials e g chipboard polyurethane polystyrene polyethylene sponge PVC synthetic fibres cellulose materials asphalt strip rubber and others Important The surface temperature of the upper parts of the boiler particularly the side walls and the co
7. button fig 1 position 6 If the emergency shutdown recurs after a short time again or if the boiler cannot be unblocked by pressing the RESET button call an authorised service organisation Shutting the boiler down The boiler can be shut down for shorter periods by switching off the main switch If the boiler is to remain shut down for a longer period of time also remove the flexible power cord plug from the socket and close the gas inlet to the boiler If there is no danger of the boiler freezing water can be left in the boiler in the opposite case it is necessary to discharge the water from the boiler and from the system If the arrangement of the heating System enables this upon disassembly of the boiler discharge water only from the boiler and leave water in the system so as to avert danger of corrosion Boiler control connection is cancelled and the room control unit is connected The boiler is Using the boiler without a room control unit When running in this mode the boiler maintains the selected heating water temperature No room control unit is connected the terminals for its connection must be mutually interconnected standard factory setting Setting procedure turn the main switch to the ON position e set the required heating water temperature on the control panel Using the boiler with a room control unit The boiler maintains the selected heating water temperature Switching of the termi
8. of heating system and filling the heating system It is necessary to set the temperature of the emergency thermostat according to the type of implementation of the heating system open or closed For open systems the emergency temperature is set to 95 C for closed systems 105 C Setting of the heating water expansion vessel pressure in its gas equalizing section begins before filling it is necessary to add extra pressure e g by 50 kPa 0 5 bar above the expected resulting water pressure in the system This ensures that the equalizing volume is as large as possible and that this will be used as such in further operation The system is then filled and preliminary pressured by cold water to the required pressure according to the pressure gauge on the boiler in this manner the remaining water part of the expansion vessel is filled and filling is closed In this state the overpressure is gradually relaxed from the equalizing part the pressure in this is monitored by a pneumometer Relaxing of the pressure continues as long as the equalizing part is harder than the water part pressure on the pneumometer is higher than on the pressure gauge on the boiler Only when both monitored values become very close very carefully continue relaxing the equalizing part so that the both values become equal and both begin to drop this is the watershed where the sought largest equalizing volume is set for the given working point
9. rectify them and repeat the first heating Service additional modes Setting attenuation in heating The parameter A appears on the display and the diode flashes in the upper left hand corner This parameter is used to set the attenuation in the heating system which depends on the timer switch In this setting the attenuation interval is identical to the attenuation interval for heating the hot water tank up to the required temperature i e during this interval the set heating water value drops by the value of this parameter The required parameter is selected using the A button and subsequently confirmed with the MODE button which at the same time transfers the boiler into the next mode Values of parameter u1 no attenuation 2 attenuation by 3 C attenuation by 6 C u4 attenuation by 9 C u5 attenuation by 12 C u6 attenuation by 15 C u7 attenuation by 18 C u8 attenuation by 21 C u9 attenuation by 24 C u max attenuation boiler shut down according to setting of timer switch Running pump The parameter t 5 appears on the display and the diode flashes in the upper left hand corner In this mode the t parameter is set to the heating water temperature at which the heating water pump is started i e the pump is switched on when the temperature set using the t parameter is reached The required parameter is selected usin
10. takes place on the basis of constant comparison of the actually attained values with the values requested set by the user this regulation is proportional i e in the case of a larger difference of compared values the boiler works with a higher output and vice versa Protection against freezing When the temperature of the heating water drops below 8 C the boiler is automatically started and heats the heating water Protection of hot water tank against freezing When the hot water in the tank drops below 8 C the boiler is automatically started and heats the tank This function is active only in the case that heating of the hot water in the tank is switched off Pump protection There is a possibility of blockage of the pump due to sedimentation of sludge in its bearings when the pump is idle for a 10 tank the boiler automatically switches to the mode of heating the hot water in the tank After heating the hot water to the required temperature the boiler is automatically switched to the regime of heating the heating water into the system and continues in the heating system Setting boiler output The factory setting of the boiler is to maximum output In case of necessity it is possible to adjust the output of the boiler according to requirement with regard to the properties of the boiler In the case of heating the hot water in the tank up to the required temperature the boiler always works at full output Impor
11. 6 10 Backflow valve for HeW circuit 11 Backflow valve for HOW circuit 12 Gas inlet 13 Heating water outlet 14 Boiler body 15 Heating water inlet 16 Hot water tank 17 Hot water outlet 18 Connection of HoW circulation 19 Hot water cold water inlet 20 Filling and discharge 21 Burner plate 22 Gas valve with ignition automatic 23 Hinged frontal cover 24 Set for installation on HoW inlet 25 Expansion vessel for HoW circuit Installation instructions Introduction The PROTHERM Bear 20 30 40 50 KLZ boiler is compatible with common types of hot water heating systems and heating radiators Important The PROTHERM boilers must be put into operation only by authorised organisations according to Czech Bureau of Occupational Safety and Czech Safety Inspectorate Notice No 21 1979 in the wording of Public Notice No 554 1990 Coll The boiler must be put into operation and warranty and post warranty service must be performed by the manufacturer s contracted service organisation which meets the above specified requirements The boiler is designed to work in a normal AA5 AB5 environment according to STN 33 2000 3 and STN 33 2000 5 51 i e within a temperature range of 5 to 40 C and humidity depending on temperature up to maximum 85 The 20 30 40 50 KLZ boiler must not be installed in zones 0 1 and 2 i e in rooms with a bath tub in bathrooms washing rooms and showers
12. DCS is activated and the boiler switched off inflow of gas into the boiler is shut off Power failure Power failure will turn the boiler off When power supply is restored the boiler will automatically restart itself without losing any of the operating parameters settings If an error code appears on the display after electrical power supply restoration Service and maintenance Maintenance of boiler by user According to requirement the boiler casing is cleaned without removing the upper cover Cleaning is performed when the boiler is disconnected from the electrical power supply by switching off the mains switch and removing the power cord plug from the socket If the surface of the boiler is damp it can be switched back on only after it has dried It is necessary to check the water pressure in the heating systems once in a while and if necessary top up the water Water can be added into the heating system after the boiler has cooled to less than 40 C measured by the thermometer on the boiler Failure to abide by this condition may result in leakage or cracks caused by unblock the boiler using the RESET button Note The boiler may be blocked as a consequence of overheating caused by the pump being switched off as a result of power failure Rectify this fault by pressing the RESET button on the boiler control panel If the fault persist call an authorised service Safety valve The boiler is equipped with a saf
13. a numerical value this means that the boiler is not in priority hot water heating mode but is only warming the heating water into the system Selecting Setup mode Setting hot water temperature Press the MODE button the diode in the upper left hand corner of the display flashes and the diode inthe lower right hand corner is lit Use the A button to set the required temperature of hot water in the tank The setting range of hot water values is 40 44 48 52 56 60 64 68 70 C On setting the parameter the boiler warms only the heating water into the heating system By pressing the MODE button the selected value is saved into the memory and the mode for setting the heating water temperature appears on the display Note Switch between the display of the current temperature of the heating water and the temperature of the hot water in the tank using the A button Other values on display Without regard to displaying the temperature of the hot water and temperature on the heating water one of the following statuses is signalised by means of the diode in the lower right hand corner diode not burning diode flashing requirement for burning from tank requirement for additional heating of hot water in tank diode lit requirement for burning from room control unit lit no requirement for Displaying heating water pressure Pressure of heating water in the boiler is displayed constantly on
14. ars which compiles with STN 07 7401 this water must not under any circumstances be acidic i e its pH factor must be 7 and must have a minimal carbonate hardness With regard to their properties which are unsuitable for operation of the boiler use of antifreeze compounds is not recommended This primarily concerns reduction of heat transmission large scale expansion ageing and damage to rubber elements If no other possibility exists for reliably preventing freezing of the heating system within the specific conditions failure to meet any of the functional parameters or any defects of the boiler as a consequence of use of antifreeze compounds cannot be covered by the boiler warranty The boiler may be used also in systems with an open expansion vessel In such a case itis necessary to ensure an additional check upon installation and if applicable also adjustment of the factory setting of the emergency thermostat temperature see point 3 4 It is necessary to set the expansion vessel with regard to the system in the sense of STN 06 0830 this ensures that the heating System itself is secured up to a total volume of 180 litres of water against quick pressure fluctuations and undesirable stress on all its elements during operation In cases where the total quantity of heating water in the closed system exceeds 1801 it is essential to include a second expansion vessel in the system This vessel must have an identical
15. ater in the hot water tank to maintain temperature The length of the attenuation interval is set by the cogs on the perimeter of the clock rotor The interval is set to where the cogs face outwards see diagram There may be more than one interval i e there may be a number of attenuations per day Error codes No flame F1 Thissignals automatic irreversible blocking of the automatic ignition and closure of the gas valve i e LOSS OF FLAME This blocking occurs always in the mode when the gas valve is open and no feedback signal about the presence of the flame is sent The boiler is switched off and cannot be started This fault however may be caused by intervention with the safety elements emergency thermostat and combustion gas thermostat Press the RESET button fig 1 position 6 to unblock the fault If the fault persists call an authorised service Sensor error F2 This signals a fault of the heating water sensor or a drop in temperature of the heating water below 3 C The boiler is switched off and cannot be started Call an authorised service Boiler overheated F3 This signals a heating water temperature higher than 95 C The boiler is shut down and restarts itself automatically after the water has cooled Sensor error F4 This signals a fault of the hot water sensor Heating of the hot water tank is blocked whilst the mode of heating int
16. boiler any handling by children persons under influence of intoxicating substances non certified persons etc must be prevented In practice situations may arise in which the following essential measures must be adopted preventthe boilerfrom even accidentally being switched on while conducting inspections or working on the combustion gases flue route or gas and water distribution pipes by disconnecting the boiler from electrical power supply also by other means than only using the main switch e g by pulling the power cord plug out of the power socket e shut the boiler down every time when there are any even temporary flammable or explosive fumes present in the area from which combustion air is supplied to the boiler e g from paint when painting laying and spraying molten substances from gas leaks etc if it is necessary to drain water from the boiler or from the whole system the water must not be dangerously hot in the case of a water leak from the boilers heat exchanger or when the exchanger is clogged up with ice do not attempt to start up the boiler until normal operating conditions have been restored when a gas leak has been detected the gas supply has failed or in the case of suspicion that this has occurred shut the boiler down turn the gas supply off and call the gas board or a service organisation e g TPG 800 01 Operating instructions Contro
17. cated outside preferably at half the height of the building or of the heated zone at least 2 5 m above the ground If equithermal regulation is predominantly intended to control heating according to the required comfortable temperature the sensor is placed on the same side of the building as the windows of the heated rooms if this cannot be secured then it is placed on the north western side If equithermal regulation is predominantly intended to optimise the quantity of heat the sensor is always placed on the coldest most often north side of the building The sensor is connected to the boiler by a two core cable with a cross section of copper conductors of at least 0 5 and a length of maximum 30 m between boiler and sensor i e total 60 m of conductor measured from boiler to sensor and back to boiler This cable must not run concurrently with other electrical wiring and areas with more powerful electrical machinery e g welding machines Diagram of connection of external elements Terminals for connecting outdoor sensor Room control unit Select this BOILER connection only if you want to connect Power cable a room control unit ithout pl wi out plug Connection of external control unit not part of delivery Main power connection 230V Converting to different fuel If it is necessary to convert to a different cooling rods must be removed typ
18. culation piping the length of heating may be perceptibly increased by this or at the same time also by inefficient insulation of the piping of the circulation circuit The pump for hot water circulation is not controlled from the boiler and must meet the hygiene requirements If there are special requirements for relocation of the boiler e g prevention of damage to covers limited passage profile etc it is possible to partially disassemble the boiler from the assembled state in which it is delivered It is necessary to maintain a sufficient space around the boiler in order to ensure that handling of the boiler and its accompanying equipment during installation and operation can be performed safely 19 Delivery completeness Content of boiler delivery Content of delivery PROTHERM Bear 20 30 40 50 KLZ boilers are supplied completely assembled and functionally tested Associated armatures safety valve and backflow clack valve are enclosed with the boiler for equipment for the hot water inlet as well as a set of adjustable legs The delivery includes Fig 8 1 The boiler 2 Operation and Installation Guide 3 Service Book 4 List of service centres 5 Warranty Certificate Special delivery On request the following selected accessories can be ordered 1 Outdoor sensor for equithermal control order no 4180 2 Ventilator superstructure PROTHERM POLO TURBO
19. e of fuel natural gas to propane and 5 Re mounting of burner vice versa the boiler is reconstructed in 6 Setting of prescribed gas pressure to the following manner This reconstruction designated boiler output see chapter may be performed exclusively by a service Preparing and starting the boiler authorised by the manufacturer Together with setting the prescribed gas The following are performed pressure for the designated boiler output T the following are performed 1 Disassembly of burner from boiler 2 Replacement of all burner jets with upon change from natural gas to propane setting of SOFT LITE to MAX fastest others according to type of fuel opening of gas valve 3 Replacement of burner tubes with others upon change from propane to natural m eus bs Rr iMd gas setting of SOFT LITE to MIN atura gas 19 slowest opening of gas valve propane the cooling rods including SOFT LITE is located on the foot of clamps are mounted on the burner tubes three rods on each tube The rod in the axis of the combined ignition electrode is shortened by approx 35 mm Upon change from propane to natural gas the the body on the side of gas outlet from the valve has a dark plastic plug with bayonet hook turning and removal of plug must be performed without use of force 29 otherwise this could cause damage tearing of SOFT LITE The red rotating knob undern
20. eath the plug has an arrow which if turned in the direction of gas flow is at the value MAX ifturned against the direction of gas flow is at the value MIN 7 Checking of the tightness of connections of the gas path and subsequent safety measures the type of fuel for which the boiler is now designated is indicated on the boiler in an appropriate manner change date and person performing changearerecordedinthe accompanying technical documentation of the boiler Important In the case of reconstruction 30 only original parts supplied by the manufacturer or person authorised by the manufacturer are used Reconstruction may be performed only by a qualified technician In changing the type of fuel it is essential to respect the requirements for construction of the screw connections on the gas piping inside the boiler i e to seal them with material appropriate for assembly and corresponding effects of the given type of fuel for natural gas e g plumbing hemp infused with varnish linseed oil etc for propane butane e g plumbing hemp infused with spirit cements produced either from lamp black type HERMETIC or shellac with an admixture of washed graphite The setting of all elements is secured e g by a drop of paint Josues J9 EM JOH Josues Joopjno 5 JOSUSS 195 adon
21. ential to furnish the boiler with a non flammable thermally insulating underlay which overlaps the ground dimensions of the boiler by at least 100 mm For passage of a boiler with case it is necessary to meet the condition that the doors have a width of at least 65 cm Adjustable legs Before connection of the boiler to the heating system install the adjustable legs onto the boiler clamps for improved stability and balancing of the boiler The instruction guide is included in the packaging Installing the boiler In the case of service interventions into the boiler it is unconditionally necessary whenever the boiler is collected to the electrical power source even when the mains switch of the boiler is off to abide by the safety prescriptions for operation and work on electrical equipment provision of norm STN 34 3100 The boiler casing can be disassembled The frontal section is secured by spring clamps in the upper corners of the casing The frontal wall can be folded down by pulling on the upper corner the upper side is folded from the back in an upwards direction after the removal of two screws The remaining parts of the casing are attached with self drilling screws to the boiler chassis The individual parts of the casing are connected to the electrical installation of the boiler by protective conductors Exercise especial caution in transport handling of the boiler with regard to the height of the centre of grav
22. ety valve with an opening pressure of 3 bar DO NOT TOUCH THE SAFETY VALVE Whenever the safety valve starts releasing heating water switch off the boiler disconnect if from the electrical power supply and call a service organisation If the heating system repeatedly loses pressure consult your service organisation Important All the mentioned electronic protection functions are enabled only when the boiler is connected to power supply the power cord plug is inserted into a power socket and the main switch is in the ON position I stress in the block of the boiler In the case of gas leakage it is necessary to shut down the boiler close the gas valve and call a service organisation Protection against legionella It is recommended to that the hot water in the tank is either heated constantly to a temperature of 65 C or that the temperature of heating the hot water is increased at regular intervals to 70 C in order to eliminate the possibility of the spread of Legionella pneumophila bacteria or other types of bacteria 11 Professional maintenance of boiler Once per year preferably before the beginning of the heating season we recommend that the boiler is checked and Set by a service organisation This check is not covered by the boilers warranty The specific tasks to be performed are specified in the Service Book This mostly concerns tasks such as checking the function and state of the burner checking and set
23. ft X Press the MODE button until the parameter P appears on the display At the same time the diode in the upper left hand corner flashes Using the A button set the required curve P1 P9 and subsequently confirm selection by pressing the MODE button Value shift of individual curves P1 posun o 15 C P2 posun o 9 C P3 posun o 6 C P4 posun o 3 C P5 posun o 3 C P6 posun o 6 C P7 posun o 9 C P8 posun 0 15 C P9 posun o 21 C P no shift Curve slope OFF Wit EGSEGEITEGES i E4 4 60 E 50 40 30 20 10 0 10 20 30 Parallel curve shift 10 10 20 30 Cut The required temperature of the heating water according to the curve set in advance is reduced P1 to P4 or increased P5 to P9 by the set value or remains without shift P 9 5 E KS 5 2 5 10 0 10 20 30 10 o 10 20 30 lc Cc Valid only for connection of outdoor sensor Timer switch The timer switch serves for setting attenuation of heating the hot water in the tank i e during the interval of the set attenuation the boiler does not heat the w
24. g the A button and subsequently confirmed with the MODE button which at the same time transfers the boiler into the next mode Values of t parameter t1 40 C 12 45 C 13 48 C t4 50 C 15 52 C 16 54 C 17 56 C 18 58 C 19 60 C t automatic setting of heating water temperature according to current required temperature Starting output of boiler The parameter Pd appears on the display and the diode flashes in the upper left hand corner In this mode the starting output of the boiler is set as follows n maximum starting output The required parameter is selected using the A button and subsequently confirmed with the MODE button which at the same time transfers the boiler into the next mode 27 Electrical connection of boiler The boiler is connected to power supply by a three core flexible cord with a plug A fixed socket through which the boiler is connected to power mains must comply with the provisions of STN 33 2000 4 46 This must always have a protective earth contact pin reliably connected by a PE or PEN wire yellow and green The boiler must be always connected to the protection wire earth through its power cord and must be always installed in such a manner that the socket and plug are accessible Use of adapters extension cords etc is not permitted Important Preparation of the socket and connection of the room control unit which
25. he vessel in an appropriate place of the hot water distribution system Important There must not be any stoppers or obstacles to the flow of water through the piping between the tank and the safety valve combined armature and between the tank and the expansion vessel for the utility water In order to ensure that no water leaks from the safety valve after installation of the high pressure vessel the resulting working pressure of the vessel must be 10 to 30 kPa 0 1 to 0 3 bar lower than the opening pressure of the valve Theboilerpipeconnection pieces primarily for gas must not be subjected to any forces from the pipe system of the heating System or gas inlet This requires precise adherence to the dimensions of the end pieces of the connection pipes vertically as well as in terms of the distance from the wall and the mutual distance between the individual inlets and outlets During reconstructions in unfavourable building dispositions etc it is possible to connect the boiler to the heating System and gas mains by means of flexible elements hoses but only those which are designed for this purpose Flexible components should be as short as possible must be protected against mechanical and chemical loads and 23 damage and must be replaced with new ones before the end of their useful life or before their reliability to meet their nominal parameters as stated by their manufacturers is diminished Properties
26. iod of time we recommend that you close the gas supply and disconnect the boiler from the electricity network This recommendation applies in conjunction with the general conditions stipulated in this Operation and Installation Guide 13 At the end of its useful life the boiler or its parts must be disposed of ecologically in a manner which avoids causing any harm to the environment 14 The manufacturer is not liable for and provides no warranty for damages caused by the failure to abide by theconditions stipulated in this Operation and Installation Guide prescriptions and norms proper installation and procedures conditions stated in the Warranty Certificate and the Service Book 15 If the boiler is delivered to the user by the technician who also installs the boiler this technician is also obliged to present to the user all the accompanying documentation for the boiler in particular operation the Operation guide Service Book etc If the boiler is not put into operation the original packaging of the boiler must be available for the potential further transport thereof Safety of equipment and people According to the findings of the SZ Brno National Testing Institute the boiler as well as all its optional accessories complies with the requirements of European Directive 90 396 EEC on gas fuelled appliances and European Directive 92 42 EEC on efficiency the European Directive 2006 95 EC on e
27. ity The end pieces for connection are on the rear side of the boiler see Fig 5 Connection dimensions of boiler It is necessary to install a backflow clack valve and safety valve on the hot water inlet to the boiler The clack valve combined in a single armature is supplied together with the boiler The valve compensates for the volume expansion of the utility water during heating and is thus constantly active and it is recommended that water escaping from this is drained by a permanently installed drainage pipe into the waste water conduit It is necessary for the water to have a smooth passage of drainage without any possibility of accumulation of the drained water In the case of a higher pressure of the inlet utility water then 600 kPa 6 bar it is necessary to use a reduction valve before inlet into the boiler Before the combined armature in the flow direction of the utility water it is desirable to install also a stopper which is not included in the boiler delivery The combined armature is always installed however water leakage from the safety valve in the armature may be resolved by installing an expansion tank for utility water This concerns a high pressure but not heating expansion vessel which must have a nominal volume of at least 3 litres and nominal pressure of 600 kPa 6 bar It must be placed behind the combined armature in the flow direction of the water either in front of or behind t
28. lectrical means of operation for use in certain voltage ranges and the European Directive 89 336 EEC on electromagnetic compatibility The appliance is also approved according to the European norms EN 677 EN 625 EN 60335 01 EN 50165 EN 55014 EN 61000 3 2 and EN 61000 3 3 In order to operate and handle the boiler in accordance with the purpose for which itis designed in actual conditions of use hereafter referred to only as use it is necessary to abide also by additional conditions the most essential of which i e those which must not be omitted are found in the following regulatory documents in the design area STN 06 0310 and STN 06 0830 in the fire safety area STN 92 0300 for installation and fitting and repairs STN EN 1755 or STN 38 6460 as applicable STN 38 6462 Decree no 48 1982 Coll as amended by the later prescriptions and the binding occupational health regulations in time of running and operation STN 38 6405 in the area of discharge of combustion gases and air inflow STN EN 483 company material catalogue of dual piping for discharge of combustion gases and inflow of combustion air designated for type C gas appliances i e in closed TURBO version In addition to the above mentioned documents it is necessary when using the boiler to proceed in accordance with this Operation and Installation Guide and the accompanying boiler manufacturers documentation During use ofthe
29. ls and signals SN SML 111144444 N Main switch The main switch Fig 1 Position 7 is used to switch the boiler on or off The main switch is situated on the right side of the boiler control panel Caution The boiler must be put into operation and switched on for the first time by an authorised service organisation Control panel On the boilers control panel you can monitor current values and setthe required parameters The control panel has the following control elements Fig 1 1 Timer switch sets attenuation of tank heating and attenuation of heating water 2 MODE button transition into setting mode 3 Display panel 4 4 button 5 Pressure gauge displays pressure of heating water 6 RESET button to unblock errors 7 Main switch switches boiler on and off Selecting Read mode Displaying heating water temperature After turning the boiler on by pressing the main switch the current temperature of the hot water will appear on the display Displaying hot water temperature After pressing pu the button the temperature of the heating water in the tank will appear on the display In this display the diode is lit in the upper left hand corner which indicates the value of the current hot water temperature in the tank If the parameter appears on the display instead of
30. m h 3 3 kg h 5 2 m h 3 8 kg h Heating Max operating pressure Min operating pressure Recommended operating pressure Temperature range Water volume in boiler Hot water Max supply pressure Adjustable temperature range Hot water tank capacity Hot water flow Di according to STN EN 625 I min Electrical data Voltage Inp t MAX ins W Prot cover Current Exhaust of combustion gases method Flue diameter Combustion gas temperature Combustion flow mass Min required stable chimney thrust Pa Noise level 1 m from the boiler at height of 1 5 m dB Dimensions height width depth mm 1385 505 892 Weight without water 14 Connection dimensions of boiler 20 30 40 50 KLZ TYPE a b 9 od j C Lt A hot water input 3 4 B hot water circulation 3 4 C hot water output 3 4 D heating water input 1 E heating water output 1 F gas input 3 4 15 Schematic diagram of boiler 1 Control panel 2 POLO TURBO superstructure 3 Combustion gas collector 4 Automatic bleeding valve 5 Safety valve 6 Pump for HoW heating circuit 7 Combustion exhaust safety valve 8 Pump for HeW circuit 9 Expansion vessel for HeW circuit 1
31. nals to the room control unit switched on and off according to the internal temperature of the room in which the room control unit is installed This room must not have thermostatic valves installed on heating radiators Important On the control panel it is necessary to set the heating water temperature temperature of the water in the system which will be capable of covering thermal losses of the building even at low outdoor temperatures Note Use control units recommended and supplied by the PROTHERM company which are designated and tested for the given type of boiler In the case of use of other regulators we do not guarantee the correct and full functioning of the boiler Operation of boiler with equithermal control The boiler regulates the heating water temperature on the basis of outdoor temperature changes In the case of this type of regulation it is necessary to set the equithermal curve according to the required heating water temperature It is also necessary to attach an outdoor temperature sensor The procedure for setting equithermal curves is outlined on page 6 of this manual Important The room control unit and outdoor temperature sensor must be connected only by an authorised service Note During all types of boiler regulation heating of the hot water in the tank always has priority i e when a command for heating the hot water is sent from the Protection functions Continuous output modulation This
32. nts ofthe boiler theircharacteristics and with the relevant required response of the user with the fundamental parts of the boiler and manner of use of the boiler If this technician is also delivering the boiler he she must ensure that the original packaging of the boiler is available for potential further transport thereof until the moment of launch into operation 7 Check whether the delivery is complete 8 Check whether the model and type supplied corresponds to the type required for use i e check whether the data relating the boiler settings stated on the plate correspond with the data relating to the local network supplying fuel gas to the place of installation or have this performed by a professional technician who shall install the boiler or put it into operation 9 Whenever you are not sufficiently certain of how to control the boiler seek out and study all the corresponding instructions in this Operation and Installation Guide carefully and proceed accordingly 10 Never remove or damage any markings and signs on the boiler Also store the original packaging of the boiler in an undamaged condition for potential further transport in the case that the boiler is not put into operation 11 When performing any repairs only original parts may be used It is prohibited to make any changes to the boiler s internal installation or to interfere with this in any way 12 When shutting the boiler down for a longer per
33. o the system is not affected by this fault Outdoor sensor error F5 This signals a fault of the outdoor temperature sensor when equithermal boiler regulation is set The boiler continues unlimited in its activity but the heating water temperature is regulated according to the value set on the boiler see Setting heating water temperature page 5 If the boiler is not in equithermal regulation mode this fault does not occur Starting up and shutting down boiler Starting up the boiler Important Putting the boilerinto operation and starting it up for the first time must be performed by an authorised service only If you wish to start the boiler up after it has been put into operation make sure that 1 the boiler is connected to the electrical power supply 2 all stop valves heating water hot water gas underneath the boiler are opened 3 the heating water pressure is lower than indicated on the pressure gauge red adjustable hand water in boiler must be cold Turn the main switch Fig 1 position 7 to the ON position 1 The boiler is ignited and heats the hot water in the tank After this has been heated the boiler heats the water in the heating system if the heating water temperature is set and a command for heating is sent from the regulator In the event of a safety boiler shutdown an error code appears on the control panel see Error codes page 8 Unblock the boiler by pressing the RESET
34. of piping with a pair of pumps backflow clack valves and safety elements i e with an expansion vessel for the hot water circuit with nominal content of 10 a safety valve for the hot water circuit with nominal opening pressure of 3 bar and automatic de aeration by valve The hydraulic construction also includes end pieces for connection of the boiler 21 Casing This is composed of covers firmly attached to the back wall and side plates a detachable frontal wall and detachable upper part The upper part contains a horizontal control panel and a vertical control panel beneath the upper edge of the detachable frontal wall Hot water tank This is a cylindrical vessel containing spiral piping The heating water passes through the piping and heats the utility water in the vessel The tank is enamelled inside and has a magnesium electrode for protection against corrosion The external thermal casing of the tank is composed of polystyrene foam with reflexive foil on the surface Hot water tank expansion vessel The boiler is equipped with an expansion vessel for the hot water tank with a volume of 4 litres 22 Placing of boiler The boiler is fitted on a construction base i e a platform or pedestal The platform must have at least a regular load capacity and must not be slippery The surrounding area may be cleaned only in a dry manner e g by vacuuming If the platform is made of flammable material it is ess
35. requires intervention with the boilers internal wiring must be always connected by a qualified electrician in accordance with Public Notice No 50 1978 Likewise servicing of the electro technical part must be performed by only a person with the above qualification Before performing any works on the electro technical part the boiler must be disconnected from the power supply by removing the power cord plug from the power socket The main part of the boiler is secured by a tube fuse T1 6A 250 V which is located on the control panel of the boiler For control of the boiler using a room control room unit only a zero potential output room control unit may be used i e a unit which convey no foreign voltage to the boiler The room control unit must be connected to the boiler by a two core cable The recommended copper wire cross section is 0 5 to 1 5 sq mm The room control unit connection cables must not run concurrently with power wires or cables 28 The terminal for connection of the room control units is equipped from the factory with a jumper andis located in the electrical box of the boiler Before connection of the room regulator it is necessary to remove the jumper on the terminal In all other cases the jumper is left If the boiler is to be operated in the continuous control mode according to outside temperature i e equithermal regulation an outdoor temperature sensor is attached to it This sensor is lo
36. s of the customer Setting gas pressure Output is set using the regulating elements on the combined gas armature see illustration of gas armature pressure is measured using the U manometer against atmosphere 1 measurement point of gas pressure on inflow to armature 2 measurement point of gas pressure on outflow from armature A cover plug B setting internal screw of maximum C setting screw of minimum D electrical setting of minimum 25 Before commencing setting when the boiler is switched off plug of electrical power cord is removed from socket it is necessary to detach the covering metal plug A relax the closing screw of the measurement point 2 of outflow gas pressure and slide on the tube of the U manometer screw not removed Maximum output The boiler is put into operation and left to work during hot water consumption at maximum output The course of measurement should not be interrupted by switching off the boiler e g by reaching the maximum hot water temperature or heating water temperature etc By turning the plastic screw B the gas pressure is set to maximum output by turning it clockwise gas pressure is increased 125 mm of water column for natural gas 270 mm of water column for propane Reduced output Measurement is performed upon soft start after the boiler is switched on in heating mode this state persists for max 100 seconds
37. same construction i e it must be closed with a membrane The resultant value of the water pressure in the system when cold is constantly indicated by the red adjustable hand of the boiler pressure gauge If the pressure drops beneath such an indicated value it is necessary to seek and rectify any leakages orto de aerate the system more effectively or both If pressure drops repeatedly and the entire system is effectively sealed and properly de aerated this most probably represents a fault in the expansion vessel and it is essential to call an authorised technician to rectify this fault Upon filling of the hot water tank it is necessary to open the inflow and outflow from the tank and allow the water to flow out until it is entirely clear and without air bubbles Before final assembly of the boiler it is necessary to flush the distribution pipes of the heating system several times with pressurised water In older used systems this must be performed against the flow direction of the heating water Note is recommended to mount a sludge trap in front of the boiler i e on the piping with return heating water The construction of this trap should enable emptying at regular intervals without the necessity of discharging a large volume of heating water The sludge trap may be combined with a filter a filter with a sieve alone is not sufficient protection In the case of clogging of the boiler with dirt from the heating sy
38. stem these problems or problems caused by other clogging are not covered by the boiler s warranty The filter and sludge trap must be checked and cleaned regularly The requirements for utility water properties are defined in STN 83 0616 for drinking water STN 75 7111 If the water has a combined calcium and magnesium concentration greater than 1 8 mmol l it is useful to implement other non chemical measures against incrustation e g use of magnetic or electrostatic field The tank must not be exposed to the effects of higher pressures than the maximum operational pressure direct effects of fire or temperatures higher than ordinary working and climatic conditions impact collision force on the tank vessel shakes and vibrations with the exception of manifestations during actual operation i e circulation of heating water and filling of utility water If the hot water issue points cocks are located very far from the boiler it is possible to connect further piping creating a circuit with constantly flowing hot water between the boiler and cocks hot water circulation circuit A hot water outlet is used for the piping from the boiler to the cocks the return piping from the cocks to the boiler is connected to the circulation outlet With the introduction of hot water circulation there is no discharge of cold water from the cock The hot water supply is increased by the volume of the cir
39. tant Change of setting of boiler output must be performed only by an authorised technician longer period of time Switch the pump on for a short time when it has been in the room continuously for 24 hours Running down of pump After the boiler is switched off by the room control unit the pump continues to ensure circulation of water in the heating system for approximately 1 minute only in heating mode Anti cycling After the boiler has been shut down in heating mode it cannot be restarted sooner than 1 minute after shutdown and the temperature of the heating water drops by 8 C Note This does not apply when the boiler has been switched off by the room control unit Protection against overheating The pump is switched on always when the temperature of the heating water is higher than was set by the user or if the temperature of the heating water is higher than 85 C The boiler is switched off when the temperature of the heating water is higher than 90 C fault F3 Running pump depending on heating water temperature The boiler enables setting running of the pump after a certain selected temperature has been reached This function can be set only by an authorised service technician Chimney draught control system The boiler is equipped with a Chimney draught control system CDCS Upon an accumulation of combustion gases in the boiler i e in the case of insufficient discharge of combustion gases the C
40. tective function and for this reason replacement thereof cannot be included within the warranty Technical specifications 20 30 KLZ Bear 20 KLZ Category Version Ignition Max thermal input Min thermal input Max thermal output Min thermal output Efficiency Gas pressure Supply pressure Jet diameter Gas consumption Bear 30 KLZ 2 65 1 7 Q MAX cies hr eer rr hri 2 0 m h 1 6 kg h 3 0 m h 2 0 kg h Heating Max operating pressure Min operating pressure Recommended operating pressure Temperature range Water volume in boiler Hot water Max supply pressure Adjustable temperature range Hot water tank capacity Hot water flow Di according to STN EN 625 I min Electrical data Voltage V Hz Input W Prot cover Current Exhaust of combustion gases method Flue diameter Combustion gas temperature Combustion flow mass Min required stable chimney thrust Noise level 1 m from the boiler at height of 1 5 m dB Dimensions height width depth mm Weight without water 13 Technical specifications 40 50 KLZ Bear 40 KLZ Bear 50 KLZ Category Version Ignition G20 G31 Max thermal input Min thermal input Max thermal output 44 41 2 Min thermal output Efficiency 90 92 89 91 Gas pressure Supply pressure 18 30 Jet diameter 2 65 1 7 2 65 1 7 Gas consumption aE E EE T 4 1
41. th is formed by a pipe section of the gas connector which ends with an inlet into the combined gas armature The combined gas armature regulates gas inflow into the boiler depending on the required and attained operational states of the system i e of the boiler and heating system together the outlet from this is the section of the gas piping of the burner plate finished with 2 to 4 jets one on each burner pipe The burner is started by an electrical spark An automatic control device is used to start and maintain running which is connected directly with the combined gas armature manufactured by the same company to form a single unit which also reduces all requirements for mutual interconnection Combustion gas catcher This is a plate cover which contains the CDCS thermostat it is connected directly to the thrust breaker and finished beyond this with the combustion gas collector of the boiler for connection of exhaust flue The CDCS chimney draught control system is based on monitoring the temperature of combustion gases on exhaust from the boiler in the case of accumulation of these gases in the boiler i e insufficient exhaust it is activated and switches off the boiler closes the gas inlet into the burner The combustion gas catcher is fitted with a detachable cleaning jacket which is accessible after removal of the upper part of the boiler casing upper cover Hydraulic construction This is a system
42. the analogue pressure gauge fig 1 position 5 Setting heating water temperature In the heating water t setting mode the diode in the upper left hand corner of the flashes and the diode in the lower right hand corner is not lit Use the button to set the required temperature of heating water into the system The setting range of heating water values is 45 50 55 60 65 70 75 80 85 C On setting the parameter the boiler warms only the hot water in the tank the boiler works in summer mode By pressing the MODE button the selected value is saved into the memory Equithermal mode Setting the equithermal mode i e selection of the equithermal curve slope and parallel shift of the curve is possible only in the case that an outdoor sensor is attached to the boiler Note If no outdoor sensor is attached the boiler will not enable the user to transfer to setting mode E and P Setting curve slope zi Press the MODE T3 button until the parameter E appears on the display At the same time the diode in the upper left hand corner flashes Using the A button set the required curve E1 E9 and subsequently confirm selection by pressing the MODE button In the case of selecting the parameter E the equithermal mode is switched off The required output temperature of the heating water from the boiler has a value according to the outside temperature and the relevant set curve Fig 2 Parallel curve shi
43. ting output checking the tightness of connections of the flue conduit checking the boiler exchanger checking the hot water tank and checking the state of the magnesium electrode In this it is particularly important to verify the functional capability of the safety valve andalso verify the activity ofthe emergency and combustion exhaust thermostat This check is performed upon every service intervention on these elements We recommend that the state of the magnesium electrode is checked within six months of putting the boiler into operation Deterioration of the electrode depends on the composition and hardness of the water Longer time intervals for checking are stipulated by a professional service according to the degree of deterioration following the first check If 6096 of the electrode has been used up and the time interval is to remain same the electrode Warranty and warranty conditions The PROTHERM Bear 20 30 40 50 KLZ is covered by the warranty defined in the Warranty Certificate the Service Book and by other conditions specified in this Operation Guide and Installation Guide chapters Introduction and Boiler installation 12 must be replaced with a new one The tank must not be operated with a depleted electrode The overall warranty of the boiler does not cover defects caused by corrosion in the case of a depleted magnesium electrode Note The depletion of the magnesium electrode rod ensues from its pro
44. urising before filling utility water into the boiler and distribution System to the resulting working pressure After fillingthe heating system de aeration and setting the pressure expansion vessel if this is used the resulting pressure of the heating water in the system when cold is indicated by the red adjustable hand of the boiler pressure gauge Operating the boiler Preparing and starting the boiler Check the water pressure on the boiler pressure gauge By opening the gas cock gas is inlet into the boiler Connect the plug of the flexible power cord into the Socket and press the mains button The heating and hot water are set to approx Ve of their volume In the first additional mode we select automatic setting of the heating water temperature for running of the pump for subsequent actual operation this is adjusted further as applicable The boiler ignites and heats the hot water After this heating the boiler heats in the heating system During the running of the boiler check the gas tightness of all connections of the gas path in the boiler e g using a foam Regulating gas armature forming solution It is necessary to rectify any determined leakages and repeat the check At the end of preparing and starting the boiler check and if necessary adjust the output of the boiler with regard to the heating system by setting the gas pressure on the outlet of the gas armature and set this according to the requirement
45. ver may exceed the ambient temperature by up to 50 C A minimum manipulation free space maintained around the immediate vicinity of the boiler must be sufficient for a person to work on it safely with bare hands and with common hand tools we recommend a minimum distance of 300 mm on all sides and min 600 mm in front of the boiler The boiler is designed for combustion gases to be discharged via a chimney inlet with a minimum stabilised thrust of 2 Pa The boiler is connected to the chimney inlet by a flue for the boilers PROTHERM 20 30 KLZ with 130 mm for the type PROTHERM 40 KLZ with 150 mm and for the type PROTHERM 50 KLZ with 180 mm Important It is prohibited to place any objects restricting the combustion gas flow inside the flue e g various types of heat exchangers to utilise their residual heat The combustion gas exhaust flue is not part of the boiler accessories Construction of the combustion gas exhaust flue as well as that of the chimney must comply with the requirements of STN 06 1610 and STN 73 4210 Compliance with the principles specified by these norms will prevent undesirable phenomena from occurring such as excessive cooling of the combustion gases penetration of dampness into masonry and fluctuations in the chimney thrust and thus prevent undesirable effects on the functioning of the boiler The boiler takes combustion air from the space in which it is installed The minimum si
46. www protherm eu Protherm spol s r o Pplk Pljusta 45 909 01 Skalica Slovakia Tel 421 34 6966 101 Fax 421 34 6966 111 Your service organisation EN xxxx 01 v 3 2 2007 Bear Operation and Installation Guide 20 30 40 50 KLZ mm Stationary cast iron boiler Output range 17 44 5 kW mm Continuous output modulation ntegrated 110 hot water tank Bear 20 30 40 50 KLZ The boiler s Serial no is shown on the plate which is attached to the rear side of the control panel The control panel is accessible after removing the front cover In the section Operating Instructions you will find description of the boiler s main functions and guidelines on how to handle the boiler safely The section Installation Instructions is for skilled workers only Table of contents Introduction itecto teres 2 OPERATING INSTRUCTIONS INSTALLATION INSTRUCTIONS Controls and signals 4 InttOdctlOn eric eere taces 17 Selecting Read mode 5 Delivery completeness 20 Selecting Setup mode 5 Preparing for boiler installation 21 Schematic diagram of boiler control 7 Installing the boiler 23 8 Operating the 25 Starting up and shutting down boiler 9 Service
47. ze of such a space requires that there is 0 8 cu m of free space per 1 kW of boiler output and in addition it must be possible to ventilate the space directly If direct ventilation is not possible 2 cu m of free space is required for each 1 kW of boiler output For discharge of combustion gases from PROTHERM 20 30 40 50 KLZ boilers it is possible also to use the supplementary device superstructure PROTHERM PT 20 30 40 POLO TURBO which ensures the forced discharge of combustion gases It enables the operation of cast iron boilers in cases where it is not possible to use regular discharge of combustion gases into a chimney The superstructure is designed for direct connection to the combustion gas collector The outlet of combustion gases from the superstructure 18 is adapted for connection of single shell exhaust piping up to a length of 10 equivalent metres 1 equivalent metre 1 metre of even section or 1 90 joint Mounting the superstructure onto the boiler and putting into operation may be performed only by an authorised organisation according to Public Notice of the Slovak Bureau of Occupational Safety no 74 1996 Coll It is essential to abide by the safety prescriptions during service interventions into the superstructure when this is connected to an electrical power source even when the mains switch is off The boiler is constructed for operation with heating water up to an overpressure of 400 kPa 4 b
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Protherm Bear 50 KLZ Installation guide