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Instructions for Use and Installation of Cast-Iron Boilers
PROTHERM 20(30,40,50,60) KLO
"BEAR" Version
Protherm s r.o.(ltd)
Pplk. Pljušta 45
909 01 Skalica
Slovak Republic
Supplied By www.heating spares.co Tel. 0161 620 6677
Instructions for Use
1. Boiler Characteristics
2. Boiler Accessories..........................................................................................................5
3. Boiler A
4. Desc
5. Boi
6. Boiler Maintenance...................................................................................................... 12
7. Safety of Life and Property
8. Warranty ...................................................................................................................... 13
9. Complete D
10. Transportation and Storage..........................................................................................14
ssembly.............................................................................................................7
ription of Controls................................................................................................ 10
ler Operation........................................................................................................... 11
elivery
..................................................................................................... 2
.......................................................................................... 13
....................................................................................................... 13
Service Instructions
3. Boiler Assembly........................................................................................................... 15
4. Description of Controls ................................................................................................ 16
5. Boiler Operation........................................................................................................... 16
6. Boiler Maintenance...................................................................................................... 17
Technical Parameters...........................................................................................................20
List of Figures
Fig. 1 Basic and Connection Dimensions...............................................................................
Fig. 2 Boiler Working Diagram..............................................................................................8
Horizontal Control Panel..........................................................................................
Fig. 3a
Fig. 3b Vertical Control Panel.............................................................................................. 11
ig. 4a Electric Wiring Diagram of PRO
F
Fig. 4b Electric Wiring Diagram of PROTHE
Fig. 5a Regulation elements of "SIT 843" combined gas armature...................................... 19
Fig. 5b Re
gulation elements of "SIT 840 SIGMA" combined gas armature
THERM 60 KLO ................................................. 18
RM 20, 30, 40, 50 KLO ............................... 18
........................ 19
4
10
Definitions
These Instructions indicate Warning, Caution and Comment to emphasise information or instructions we consider important. The
indications are used along the following rules:
Caution:
l Comment: Information or instructions that can simplify or facilitate maintenance, or important parts of the text
Warning: Information or instructions that may result in hazardous situations if not followed.
Information or instructions that may damage equipment or its parts if not followed.
that should be emphasised.
1
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Dear Customer,
You have become an owner of a cast-iron PROTHERM KLO boiler, for natural gas or LPG. We believe it will serve you to your
full satisfaction – certain minimum requirements must be fulfilled to that end. That is why we are asking you to study and follow
these instructions carefully.
Please, keep the following rules in mind:
1. The boiler and all ac
regulations and the manufacturer's instructions.
2. The boiler can only be installed in the type
Boiler Installation below).
3. Only service centres authorised by the manufacturer are allowed to put the
4. In case of defects, call a service centre authorised by the manufacturer – incompetent intervention can damage the boiler
(and/or the accessories)!
5. The service centre's em
boiler, its parts and operation.
6. Check to make sure the supplied boiler type complies with the expected manner of use.
7. If you feel uncertain about any activities related to the boiler operation, look up and study all relevant information in
these instructions, and follow the recommended procedure.
8. Do not remove or damage any labels or markings on th
9. The boiler complies with all Czech applicable regulations. If it is to be used in another country, deviations in the
regulations have to be identified and resolved.
10. When the life cycle of the boiler, or its parts, has expired, they should be disposed of in an environmentally friendly
manner.
cessories must be installed and used in compliance with the design, the applicable laws, technical
of environment for which it is designed, and which is properly ventilated (cf.
boiler into operation after installation.
ployee who will initiate the boiler operation after the installation shall instruct the user about he
e boiler.
1. Boiler Characteristics
The boiler is designed for heating up HCW (heating-circuit water) and, in combination with an external reservoir, for heating up
DHW (domestic hot water). The types in this series have codes PROTHERM 60 KLO, 50 KLO, 40 KLO, 30 KLO, 20 KLO,
both for natural gas and LPG.
st
The types are distinguished by power output (1
Code
Natural gas LPG Natural gas LPG
20 KLO
30 KLO
40 KLO
50 KLO
60 KLO
Switching between the stages (only for 20, 30, 40, 50 KLO) is done by the user (notation: one or two flames) on the control panel.
The HCW pump is thermostat-controlled – it is activated when the HCW temperature gets to
the heating-up time is reduced after a prolonged break in operation.
The boiler is able to "work in cooperation" with en external DHW reservoir. The standard equipment m
connect necessary electrical cables from the "cooperating" equipment to the boiler's terminal board.
Proper DHW function requires an 80- to 200-litre reservoir, with a thermostat and a switch
Rated output
st
1
stage [kW]
17 16 11.9 11.2
26 24.5 18.2 17.2
35 33 24.5 23
44.5 42 31 29
49.5 48 – –
stage – full power, 2nd stage – reduced power), as shown in the table below:
Reduced output
2nd stage [kW]
the value set on the thermostat. Thus
akes it possible to simply
ing contact.
2
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It is an absolute necessity, for combined heaters (HCW+DHW), to exclude bringing "foreign" voltage to the boiler –
i.e., the thermostat contacts must be separated from the heater's internal electrical components.
The DHW reservoir is heated by a separate circuit, controlled b
equipped with an electric switching contact (applicable only to 20, 30, 40, 50 KLO), which is connected if the valve's motor is not
active (gets no voltage).
The boiler's manufacturer supplies both DHW reservoirs (100, 150, 200 l) and suitable three-way
y a three-way distributing (not mixing!!!) valve. The valve must be
distribution valves.
l DHW heating takes preference over the heating circuit – in other words, the heating circuit water is only heated up after the
DHW has reached the required temperature. Hence, if you set the DHW temperature to unusually high values (more than 5060°C), the heat-up time is too long and heating of the house/flat may be erratic. The same applies to setting the boiler to a
too low power output or a too low value of the HCW temperature.
The boiler can only be used for the purposes specified in these instructions.
3
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TYPE A B C
D
∅
20 335 180 600 130
30 420 222 600 130
40 505 265 600 150
50 590 307 620 180
60 675 350 620 180
Fig. 1 Basic and Connection Dimensions
1. Control panel;
2. HCW pressure measuring point;
3. HCW temperature measuring point;
4. Boiler cast-iron body;
5. Combined gas armature;
6. Water filling and discharging;
7. Burner plate (distribution to nozzles);
8. Ionisation electrode;
9. Compound ignition electrode;
10. Flue-gas outlet;
11. Draft damper;
12. Safety therm
13. Outgoing HCW;
14. Gas supply;
15. Incomi
ostat;
ng HCW.
4
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2. Boiler Accessories
A PROTHERM KLO boiler consists of the following parts:
1. Cast-iron boiler body with thermal insulation and water-connection pipes;
2. Burner plate, including gas supply and ignition part;
3. Flue-gas duct, with draft dampener and SKKT thermostat;
4. Boiler casing, control panel, and terminal board;
5. Boiler body base.
Cast-iron boiler body cons
chamber (including the water ways). There are side elements ("Left" and "right") and middle (of one type). The elements are put
together to create a body of the corresponding size (of both the combustion and water chambers). A completed body is equipped
with water pipes for connection of water, insulated to prevent heat radiation, and provided with fixtures for thermostat sensors and
on the legs, fixtures for mounting on the base.
Burner plate is equipped with part of gas piping, burner tubes, and ignition equipment. Depending on the boiler (and body) size,
it includes between 2 to 6 burner tubes and the gas pipe, which leads to the combined gas armature. This in turn regulates gas
supply to the boiler, depending on the required and actual parameters (i.e., the state of the boiler and the heating circuit); the gas
pipe leading out of the armature is part of the burner plate, with 2 to 6 nozzles, (one per each burner tube). Gas is ignited by an
electric spark.
Flue-gas duct contains a draft dampener and flue-gas outlet (to
cleaning cover, which is accessible after the top casing panel of the boiler is removed.
The SKKT chimney-draft control system monitors flue-gas temperature in the duct. If the draft
and the thermostat inserted in the duct will switch off the boiler (shut down gas supply to the boiler).
Boiler casing consists of covers, fixed back wall and
control panel is situated at the upper part of the boiler.
Boiler body base consists of two brackets connected to the bottom of the body
with holes for bars (approx. 1/2"), which make handling of the boiler possible without a pallet, if a sufficient number of people are
available.
The base also includes reflexive sheet, which substantially reduces heating of the floor under the boiler. The reflexive sheet is
inserted from the side into the base brackets, exactly under the cast-iron body; its bent edges must be directed downwards along
the brackets.
ists of elem
ents and serves as a combustion chamber (including the flue-gas outlet) and water
which the flue duct is connected). It is equipped with a removable
is worsened, the temperature rises,
side panels, removable front panel and removable top casing panel. The
, supporting the casing weight. It is also provided
5
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6
1
8
17
Extension “polo-turbo”
(They are not an equipment
of standard boiler)
12
3
4
5
6
7
8
1
15
1. Control panel;
2. Cleaning cover;
3. Chimney flange;
4. Flue gas duct with dr
5. SKKT
6. Outgoing HCW;
7. Gas supply;
8. Cast-iron elements;
9. In
10. Combustion chamber;
11. Secondary
12. Atmospheric-pressure burner;
13. Primary-air supply;
14. Burner nozzles;
15. Combined gas armature;
16. Automatic ignition equipment;
17. Boiler casing;
18. Space fo
chimney-draft control system;
comi
ng HCW;
-air supply
r sensors of thermo
9
10
Fig. 2 Boiler Working Diagram
aft dampener;
;
meter plus operational and emergency thermostats.
6
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