E.C.A. Proteus Plus Operation instructions

PLUS
23,3 kW RoomSealed Fan Assisted Gas CombinationBoiler (monothermic type)
INSTALLATIONAND USER’S OPERATING
INSTRUCTIONS

...-- .I CONTENTS
PREFACE
GUARANTEE
& SERVICE
SYMBOLS' DEFINITIONS
SAFETY INSTRUCTIONS AND WARNINGS
PRODUCT
General Specifications
Product Notation
Technical Data
L J BOILER PACKAGING
INSTALLATION
SelectionOf The Boiler Location
Mounting The Boiler
CONNECTIONS
Flue Connection
Gas Supply
& Water Systems
Electricity Supply
BOILER
START-UP
Final Checks And Operations Before Boiler Start-up
Control
Panel
Operating The Boiler
Timer
GAS TYPE CONVERSION
Gas Pressure Adjustments
Replacement Of The Burner Injectors
Jumper Adjusment
FAULT & FAILURE FINDING
MAINTENANCE
STANDARDS AND REGULATIONS
APPENDIX
2

PREFACE
Proteus Plus 23,3 kW room sealed fan assisted gas combination boilers have been designed for
providing efficient, safe and comfortable central heating (CH) and domestic hot water (DHW). The
boilers are supplied for use with either natural gas or LPG.
This manual contains installation and user’s operating instructions. The detailed information about
technical data, selection of the boiler location, fitting the connections (water systems, gas supply, flue
connection and electricity supply), gas type conversion, maintenance and fault & failure finding are
placed in your manual. Please read the instructions carefully for operating the boiler a long time
period and to maximize benefit from the boiler specifications.
Please keep all your documents safe.
GUARANTEE & SERVICE
The appliance has guarantee period against faulty workmanship or material in condition that the
instructions and precautions in this manual must be obeyed. The service operations and general
maintenance must be carried out only by qualified person.
The warranty certificate must be registered by Service in the installation day.
Your appliance need not any repairs if operated according to this manual. For assistance
additional information, consult qualified person, installer or gas supplier.
or
SYMBOLS’DEFINITIONS
The symbols have been placed on particular points to make some instructions more noticeable. The
symbols’definitions are described as follows:

- CAUTION: Property damage and/or non-severe injury can happen.

- WARNING: Severe injury or death can happen.

: The important explanations to be considered by users.

: The situations that can only be interfered by qualified person.
2

SAFETY INSTRUCTIONSAND PRECAUTIONS
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety. Children should be supervised to ensure that they do
not play with the appliance.
Safety Instructions
When a gas leak is found or suspected:
- Turn off the gas valve of the boiler and other appliances which operate with gas.
- Shut off the oven, cooker and similar appliances to put their flame out.
- Do not light match, lighter etc. and put cigarette out.
- Allow fresh air into the room by opening doors and windows.
- Do not touch the electrical appliances’switches and plugs.
- Turn off gas supply at the gas meter.
- Do not use telephones in the environment where a gas leak is suspected.
- Call your qualified person as soon as possible.
Do not place and use flammable and explosive liquid or materials around the boiler.
Keep soap and water solution away from electrical connections during cleaning, gas leak test etc.
Do not block air vents, openings made in the walls of the room, which provide fresh air to the
installation room.
Do not lay the LPG container down.
Water Systems & Gas Supply Line
Before installation of the boiler, the water systems (CH and DHW circuit) and gas supply line
must be completed in accordance with the relevant regulations and standarts by user.
Gas Type Conversion
The appliance should be purchased depending on operating gas type. In case of a demanding gas
type conversion, this is made with charge.
Gas type conversion from LPG to natural gas or from natural gas to LPG must be carry out only by
qualified person. After gas type conversion, gas leak test must be performed by qualified person.
Maximum pressure regulator must be sealed and the self-adhesive conversion label must be placed
on the boiler after gas type conversion.
Installation
The boiler must be installed in accordance with national and local requirements, gas safety
regulations, relevant standarts and this manual by qualified installer.
The appliance should be mounted against a closed wall.
The appliance must be positioned so that the plug is accessible.
The appliance should not be positioned having a direct contact to steam or gases.
Anychange of flue position must not be made without consulting qualified person.
3
4
3
2
1

Boiler Start-up
Boiler start-up must be performed certainly by qualified person.
Gas type (natural gas/LPG), gas supply pressure (mbar), maximum DHW operating water presure
(bar) and electricity supply voltage (V) data which are detailed on the information plate must be
suitable with mains supply conditions. This is checked by qualified person.
After boiler start-up, you should request information about operating the boiler and safety
precautions from qualified person.
Operating The Boiler And Maintenance
Read carefully instructions and precautions in this manuel against wrong usage which causes
unsafe conditions.
The boiler should be checked and serviced for general maintenance once a year. Maintenance and
service operations must be carried out only by qualified person.
Only a damp cloth should be used for cleaning the outer surface of the boiler and then the surfaces
should be dried completely. Do not use chemical subtances or solutions which cause rust and
scratches in your appliance.
PRODUCT
General Specifications
ProteusPlus 23,3 kW room sealed fan assisted gas combination boilers are for providing central
heating and domestic hot water. The boilers are supplied for use with either natural gas or LPG.
Boiler has space saving design which provides easy servicing and maintenance. It has also a elegant
appearance with compact dimensions (720x400x330 mm).
Control panel has been designed ergonomically to provide user friendliness. The display panel has a
yellow backlight LCD display and error led. Operating modes, actual and setpoint Central Heating
& Domestic Hot Water temperatures. manometer and timer-(optional) are on the conrol panel, boiler
functions and fault/error conditions can be seen on the LCD display .
Microcontroller board (main board) provides all the functionality and safety of the boiler. The
controller drives gas valve, fan, pump and 3-way valve. Flame modulation can be seen through the
observation glass on the front panel.
CAUTION: Do not directly contact the observation glass while observing the flame
modulation to avoid burning injury.
Burner, is made of stainless steel, withstands thermal stress. Burner performs silently and provides
efficient and clean combustion as a result of the homogeneous dispersion of gas. Combustion chamber
has ideal dimensions for burner and perfect insulation of heat and has been designed to provide loss of
low heat, high efficiency and low emission of gas. These specifications of burner and combustion
chamber provide energy saving and minimum noise level.
Pump has an automatic air vent and 3 operation mode. The boiler has ‘pump over-run’behaviour so
that pump continues to run for a certain time after ending of CH or DHW heat demand to prevent
from thermal accumulation in water circuit.
Heat exchanger is made of copper and designed for thermal shock absorbing. It has long life, high
productivityand is non-calcerous as well.
4
6
5

Plate heat exchanger makes hot water more efficient in monothermic types.
The safety systems in your appliance provide entire safety for you and your appliance. The safety
systems are:













Flue Gas Safety System
Flame Failure Safety System
Over-heat Safety System (105 0C)
DHW (Domestic Hot Water) Over-heat Safety System (71 0C)
High Water Pressure Protection System (3 bar)
Low Water Pressure Protection System (0,6 bar)
Low Voltage Protection System (165 VAC)
Thermal Accumalation Protection System (with by-pass circuit and “pump over-run”)
Frost Protection System (The appliance must be on stand-by mode to activate frost protection system)
Pump Anti-sieze Function
3 Way Anti-sieze Function (in monothermic types)
Automatic Air Vent
Expansion Vessel (7lt)
Product Notation
Table 1
Technical Data
Proteus Plus 23,3 kW room sealed fan assisted gas combination boiler is a C type boiler (EN 483).
C type boilers have a sealed combustion chamber. Required fresh air for combustion is provided
independently from the installation room by concentric air/flue ducts and products of combustion can
be also discharged
appliances.
by
the
same
air/flue
ducts.
Therefore,
they are
named
as air
independent
gas
5
Notation
D e s criptio n
PRP 24 HM
Proteus Plus 23,3 kW Room Sealed Fan Assisted Gas Combination Boiler (monothermic type)

kW
kW
kW
m3/h
oC
oC
watt
kg
For gas consumption calculation ; Natural gas: Hu=9,59 kWh/m3
LPG: Hu=12,793 kWh/kg
*the following gas categories can also be used
6
PRP 24 HM
Gas Categories
II 2H
3B/P
II 2E
3B/P
II 2E+
3+
Table 2.2
PRP 24 HM
Unit
Gas Category *
Boiler Type
Type of gas
Performances
Pmin, Min. Heat Output
Pmaks, Max. Heat Output
P%80, Heat Output
Qmin, Min. Thermal Load
Qmaks, Max. Thermal Load
Q%80, Thermal Load
Gas Consumption
Natural Gas (Max. Load)
Natural Gas (Min. Load)
LPG
Gas Supply Pressure
Natural Gas
LPG
Domestic Hot Water
Min. Flow Rate For Activating
Max. Flow Rate
Min. Operating Pressure
Max. Operating Pressure
Set Temperature Range
Central Heating
Min. Operating Pressure
Max. Operating Pressure
Set Temperature Range
General
Electrical Supply
Electrical Power Consumption
Expansion Vessel
Insulation Class
Dimensions (HxWxL)
Weight (Net)
NOx
II 2H
3B/P
C12x C32x C42x C
52x
Natural gas
LPG
8,2
23,3
18,7
9,2
25,6
20,5
2,67
0,96
2,00
20
28 / 37
3
10 (t=33,4)
0,3 / 30
10 / 1
35-64
0,6
3
40-80
230V AC- 50Hz
95
8
IPX4D
720x400x330
35
2
kW
kW
kW
m
3
/h
kg/h
mbar
mbar
ltr/min
ltr/min
bar / kPa
bar/ MPa
bar
bar
V AC / Hz
ltr
mm

D
Wi r i ng Di agram
PRP
24HM
I
Ill
f
El
12
1
15
L_,
II
C N S
.
8
E::::::::l
c::::::::J
CN1
4
.
.
..
T
N
F
22
1
2
3
4
5
MA I N BOARD SUPPLY CABLE
ELECTR I C 3 WAY VALVE
GASVALVE
FAN
PUMP
9 OUTS DE TEMPERATURE SENSOR ( Opti o nal )
10 DHW FLOW SE N S OR
11 DHW TEMPERATURE S E NSOR
12 D I FFERE N TIA L A R PRESSURE SWITCH
13 LIM I T THERMO ST A T
14 WATER PRESSURE SWIT C H
15 CH TEMPERATURE S E NSOR
16 TIMER ( O p t o i na l )
17 TIMER SUPP L Y
18
19
20
21
22
23
24
TERM I NAL
GAS VALVE MODULATOR
ROOM THERMOSTAT ( Opti ona l )
TERM N A L
COMMU N I C ATION CABLE
DHW TEMPERATURECONTROL P OTE NTIOMETER
CH TEMPERATURE C ONTROL PO TE N T IOMETER
6 I GNmO N ELEC T RODE
7 I ON I ZATION EL . ECTRODE
8 FUSE 2A
25 STATUS PO T ENTIOMETER
26 ERROR LEO
27 LCD D SPLAY
...:I
27
. 2
0
23 24 25
CN1
•
11
1 s
=
: _
=
- : _
=
-
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==- ;Kj
-- , ®16
21
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17
19
20
5
4
-
1
0
CN9
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9

fig. 1
BOILER PACKAGING
CAUTION: The instructions on the boiler package should be considered during
transportation and storage.
- The product is covered with a cardboard box of which dimensions are 867x 470x400 mm (HxWxL)
and supported byupper and lower styrofoams (fig. 2a).
a)
b)
fig. 2
The required parts (Wall bracket, 5 pieces gasket for water and gas connections and screews)
for installation of the boiler is put into the upper styrofoam (fig. 2b). The other parts which seen in
the
fig.2b are optional. The optional parts are:
a) Mounting bracket
b) CH connecting pipes (3/4’’, 2 pieces)
c) DHW connecting pipes (1/2’’, 2 pieces)
d) Gas supply pipe (3/4’’, 1 piece)
e) Nipples (1/2’’, 2 pieces –3/4’’, 3 pieces) which are held with spring clips.
h) 4 pieces ½” gasket, 6 pieces ¾” gasket for water and gas connections.
8

- For room sealed fan assisted operation,
apart
from the
boiler
package,
concentric
air/flue
kit
(60/100) is given with a cardboard box.
Air/flue kit consists of the following
parts:
a) Flat sealing ring
b) Flange
c) 900 Concentric elbow
d) Screws
e) Fixing Collar
f) Sealing ring, EPDM
g) Concentric Terminal (100mm)
h) Inner and outer flanges, EPDM, 2 pieces
fig. 3
9

INSTALLATION
Selection Of The Boiler Location
The boiler must be installed in accordance with gas safety regulations and relevant standards.
Additionally, the clearances around the boiler should be as shown in fig. 4 in order to make service,
maintenance and usage easier.
Fig. 4 indicates minumum clearances from the ceiling and the sides.
a)
b)
fig. 4
WARNING: The appliance must be positioned so that the plug is accessible.
- The appliance should be mounted against a closed wall.
- The outer surface of the boiler do not exceed 85 oC in maximum running mode so do not take
additional precautions againts constructional materials (combustible materials).
10

Room Sealed Fan Assisted Operation
WARNING: For room sealed fan assisted appliance, the boiler location and air/flue
terminal position must obey national and local requirements, gas
safety regulations and relevant standarts.
The room sealed fan assisted boiler is not suitable for external installation. It should be
within in the building.
- In case of gas leakage, it is necessary to vent the installation room according to national and local
requirements, although the room sealed fan assisted boilers are independent of room volume and
ventilation.
WARNING: Do not block the air vents which provide fresh air to the installation room.
The air/flue terminal must be exposed to the external air and allow free passage of air cross it
at all times.
- The minumum acceptable dimensions from the terminal to obstructions and ventilation openings
must obey national and local requirements.
- The air/flue ducts should be fitted at a slight % 10 or 20 downwards incline to prevent any water or
condensation from entering the boiler.
Mounting The Boiler
Having determined the boiler location,
- Use the paper template to mark out the positions of the fixing holes of wall and mounting brackets.
- Drill the wall and fix the wall bracket to the wall with the 3 screws, then also the mounting bracket
with the 2 screws.
- Hang the boiler up on the wall bracket.
a)
b)
11

fig. 7
CONNECTIONS
Flue Connection
3 different types of air/flue system can be designed for 23,3 kW room sealed fanned
assisted
boilers:
a) The air/flue system is designed by horizontal concentric ducts.
b) The air/flue system is designed bytwo separate ducts.
c) The air/flue system is designed by vertical concentric ducts.
: The air/flue kit, given with your room sealed fan assisted appliance,
is only suitable for horizontal air/flue design. For the other types,
you should order required accessories from qualified service.
Connection by horizontal concentric ducts
- 900 Concentric elbow can be mounted on the boiler in different positions (fig. 9).
Air/flue kit parts is mounted as shown in fig. 10.
- Stick the flat sealing ring (96,3/128 mm) on the elbow.
- Fix the sealing ring (60 mm) to interior joint of the elbow –fan outlet.
- Fix the sealing ring (60 mm) to interior joint of the elbow –tube (L=860 mm).
- Fix the sealing ring (100mm) to interior joint of the elbow –tube (L=860 mm).
- Screw the 900 elbow to the boiler with 4 screws.
:The air/flue ducts should be fitted at a slight % 10 or 20 downwards
incline to prevent any water or condensation from entering the boiler.
12
a

fig. 9
Room Sealed Fan Assisted Operation
fig. 10
If the air/flue kit length is insufficient, additional flue
accessories qualified service. Do not use any other type / brand name of
flue parts.
should
be
ordered
through
- Horizontal air/flue kit accessories (fig 11):
a) Concentric extension, L=500 mm, 60/100 mm
Concentric extension, L=1000 mm, 60/100 mm
b) 900 Concentric elbow, 60/100 mm
c) 450 Concentric elbow, 60/100 mm
a)
b)
c)
fig. 11
13

Room Sealed Fan Assisted Operation
The total length of horizontal air/flue system must not exceed 3 m. Furthermore, each extra
900
concentric elbow or two pieces of 450 concentric elbow decreases the maximum length 1m
(fig. 12). The maximum number of 900 elbow to be used is 3.
a)
b)
c)
fig. 12
14

Room Sealed Fan Assisted Operation
Mounting the restrictor:
The restrictor should be mounted on the fan outlet according to the length of the air/flue connection to
provide efficient combustion and suitable combustion products.
Table 3
(mm)
fig. 13
15
Product
Elbow
L (m)
Lmax (m)
restrictor
PRP 24 HM
1x90
0
≤ 1
3
47
1x90
0
1< ≤ 2
49
0
1x90
2< ≤ 3
-
2x90
0
≤ 1
2
49
2x90
0
1< ≤ 2
-
3x90
0
≤ 1
1
-

Room Sealed Fan Assisted Operation
Connection by two separate ducts
Maximum length of the air ducts and flue ducts are seen in Table 4. The air ducts and flue
ducts must be parallel (fig. 15).
- The twin air/flue kit and its accessories (fig. 14):
a) The twin air/flue kit
b) Extension, L=500 mm, 80 mm
Extension, L=1000 mm, 80 mm
c) 900 elbow, 80 mm
d) 450 elbow, 80 mm
a)
b)
c)
d)
fig. 14
fig. 15
16
b

Room Sealed Fan Assisted Operation
Table 4
(mm)
Connection by vertical concentric ducts
Vertical flue connection can be designed by 60/100 mm or 80/125 mm concentric ducts.
The total length is 3 m for 60/100 mm vertical air/flue system and 8 m for 80/125 mm vertical
air/flue system. Furthermore, each extra 900 concentric elbow or two pieces of 450 concentric elbow
decreases the maximum length 1 m (fig. 17).
- Vertical air/flue kit (60/100) accessories (fig. 16):
a) Concentric vertical connector, 60/100 mm
b) 900 Concentric elbow, 60/100 mm
c) Concentric extension, L=500 mm, 60/100 mm
Concentric extension, L=1000 mm, 60/100 mm
d) Pitched roof flashing
e) Concentric vertical top, 60/100 mm
f) 450 Concentric elbow, 60/100 mm
fig. 16
17
c
Product
Elbow
Lmax (m)
restrictor
PRP 24 HM
0
1x90
4
42
2x900
3
42

Room Sealed Fan Assisted Operation
Table 5 The restrictors for 60/100 mm concentric ducts
(mm)
In the use of 80/125 mm concentric ducts,
- up to 2 m length, the same restrictors (shown in Table 5) should be used
- between 2m and 8m, no restrictor should be used.
a)
b)
c)
Sample connections by 60/100 mm vertical concentric ducts
fig. 17
18
Product
Elbow
L (m)
Lmax (m)
restrictor
PRP 24 HM
1x90
0
≤ 1
3
47
1x90
0
1< ≤ 2
49
0
1x90
2< ≤ 3
-
2x90
0
≤ 1
2
49
2x90
0
1< ≤ 2
-
3x90
0
≤ 1
1
-

Gas Supply & Water Systems (Optional)
- Water & gas connections between the boiler and the mounting bracket can be fixed with the optional
pipes and the nipples as shown in fig. 18.
1\!Iounting Bracket
Nipp le (3 / 4"
t
b
t
c
t
e
t
d
a
fig. 18
a) CH flow 3/4"
b) DHW outlet 1/2"
c) Gas inlet 3/4"
d) DHW inlet 1/2"
e) CH return 3/4"
- A Suitable valve should be mounted on the gas inlet and CH - DHW water circuits. I n addition, a
water fiher should be mounted on CH (3/4") return and DHW (1/2") inlet.
- A plastic hose should be ftxed the outlet tap of the 3 bar relief valve and the hose should be
connected to the drain line.
- The connection between the appliance and gas supply must be made with a flexible pipe.
19