Protherm Bear 20 KLZ, Bear 40 KLZ, Bear 30 KLZ, Bear 50 KLZ Operation And Installation Manual

Output range 17 – 44.5 kW

Continuous output modulation

Integrated 110 l hot water tank

Bear

EN

version

xxxx_01 - v.3 2/2007

Operation and

Installation Guide

20, 30, 40, 50 KLZ

Protherm spol. s r.o.
Pplk. Pľjušťa 45
909 01 Skalica, Slovakia
Tel.: [phone]
Fax: [phone]

www.protherm.eu

Your service organisation:

Stationary cast iron boiler

1

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 fi nd 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.

Obsah

Table of contents

Introduction ........................................... 2

OPERATING INSTRUCTIONS

Controls and signals ............................. 4

Selecting Read mode ........................... 5

Selecting Setup mode .......................... 5

Schematic diagram of boiler control ..... 7

Error codes ........................................... 8

Starting up and shutting down boiler .... 9

Boiler control ......................................... 9

Protection functions ............................. 10

Service and maintenance .................... 11

Warranty and warranty conditions ....... 12

Technical specifi cations ....................... 13

Connection dimensions ....................... 15

Schematic diagram of boiler ................ 16

INSTALLATION INSTRUCTIONS

Introduction .......................................... 17

Delivery completeness ........................ 20

Preparing for boiler installation ............ 21

Installing the boiler ............................... 23

Operating the boiler ............................. 25

Service modes ..................................... 27

Electrical connection of boiler .............. 28

Converting to different fuel .................. 29

Electrical wiring diagram..................... 31

2

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 identifi ed
and addressed.

5. In the event of a defect call the
manufacturer’s 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 fi rst time is obliged
to familiarise the user with the safety
elements of the boiler, their characteristics
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 suffi ciently 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 period 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:

• the conditions stipulated in this Operation
and Installation Guide;

• prescriptions and norms;

• proper installation and operation
procedures;

• conditions stated in the Warranty
Certifi cate 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

Introduction

3

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 fi ndings of the SZÚ
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
effi ciency, the European Directive
2006/95/EC on electrical 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
it is 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 fi re safety area: STN 92 0300;

- for installation and fi tting (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 infl ow STN EN 483,
company material – “catalogue of dual
piping for discharge of combustion gases
and infl ow 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
manufacturer’s documentation. During
use of the boiler any handling by children,
persons under the infl uence of
intoxicating substances, non-certifi ed
persons, etc. must be prevented.

In practice situations may arise in which
the following essential measures must be
adopted:

• prevent the boiler from (even accidentally)
being switched on while conducting
inspections or working on the combustion
gases fl ue 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);

• shut the boiler down every time when
there are any (even temporary)
fl ammable 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
boiler’s 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 or
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

4

Operating instructions

Operating instructions

Controls and signals

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 fi rst time
by an authorised service organisation!

Control panel

On the boiler’s control panel you can
monitor current values and set the required
parameters.

Fig. 1

124

3

5

6

7

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

button.

5

Pressure gauge – displays pressure of

heating water.

6

RESET button – to unblock errors.

7

Main switch – switches boiler on and

off.

5

Selecting Read mode

Selecting Setup mode

Setting hot water temperature

Press the MODE
button – the diode in
the upper left-hand
corner of the display
fl ashes and the diode
in the lower right-hand
corner is lit. Use the

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.

Setting heating water temperature

In the heating water
setting mode, the
diode in the upper
left-hand corner of
the fl ashes 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.

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
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 left­hand corner, which indicates the value of
the current hot water temperature in the
tank. If the parameter “--“ appears on the
display instead of 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.

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 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 lit – no requirement for
burning

• diode fl ashing – requirement for burning
from tank (requirement for additional
heating of hot water in tank)

• diode lit – requirement for burning from
room control unit

Displaying heating water pressure

Pressure of heating water in the boiler
is displayed constantly on the analogue
pressure gauge (fi g 1, position 5).

6

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

Press the MODE
button until the
parameter E appears
on the display. At
the same time the

diode in the upper
left-hand corner fl ashes. Using the
button set the required curve E1 – E9
and subsequently confi rm 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 shift

Press the MODE

button until the

parameter P appears

on the display. At the

same time the diode

in the upper left-hand
corner fl ashes. Using the

button set the
required curve P1 – P9 and subsequently
confi rm 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 o +15 °C
P9 - posun o +21 °C
P− - no shift

Fig. 2

Curve slope

Fig. 3

Parallel curve shift

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-).

7

Valid only for connection of outdoor sensor

Fig. 4

Schematic diagram of boiler control

8

Error codes

No flame – F1

This signals 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 fl ame 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 (fi g. 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 into 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.

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
water 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.

9

Starting up the boiler

Important:

Putting the boiler into operation
and starting it up for the fi rst 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 (I). 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
button (fi g 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
fl exible 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.

Starting up and shutting down boiler

Boiler control

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;

• 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 terminals to the room control unit

connection is cancelled and the room
control unit is connected. The boiler is
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.