ProTerm RAY 9-24K Operating instructions

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User and installation instructions for direct heating
electric boiler
RAY 9 - 24K
y

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Operation and installation instructions
1.Introduction................................................................................................................................................2
1.1.Qualityassurance equipment and personal safety....................................................................2
2.Boilercharacteristicsandequipment.........................................................................................................3
2.1.Characteristics...........................................................................................................................3
2.2.Boilerequipment........................................................................................................................3
3.Controlandsignalling................................................................................................................................ 4
4.Conditionsforinstallationand operation................................................................................................... 5
5.Boilerconnection dimensions and pump characteristics...........................................................................6
6.Mountingandplacement of the boiler....................................................................................................... 7
6.1.Wiring........................................................................................................................................ 7
6.2.Cascadecontrol.........................................................................................................................8
7.Operations.................................................................................................................................................8
8.Maintenance..............................................................................................................................................9
9.Completepartssupply...............................................................................................................................9
10.Warrantyandwarrantyconditions...........................................................................................................9
11.Transportandstorage..............................................................................................................................
9
12.Technicalparameters............................................................................................................................. 10
13.Boilerwiringdiagram...............................................................................................................................11
13.1. Wiring diagram of two boilers connected to cascade.............................................................. 12
14.Interconnection the electric boiler with a DHWtank................................................................................12

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DEAR CUSTOMER
Youhavejust become the owner ofadirectheatingelectric boiler which was designedforcentralheatingsystems
with a user friendly regulation option for thermal comfort.
PROTHERM wants your electric boiler to serve you at a high level of efficiency. In order for it to do so, it is
necessary to adhere to certain principles when installing and operating the boiler. Therefore we would ask you to
carefully read the operating instructions and put them into use during operation.
We believe that our PROTHERM electric boiler will bring about optimal thermal comfort and result in a truly
pleasantenvironment.
We would ask you to pay close attention to the following important points:
1.Theboilerandallrelated equipment must be installed and made use of in accordance with the design, all relevant
valid regulations and technical standards and according to the manufacturer’s directions.
2. The boiler can only be installed in an environment it has been designed for.
3.Theinstallationandinitiation(orlaterrestarting)ofoperationcan be only undertaken by a professional individual,
authorised by the manufacturer.
4.Please,referto a professional authorized by the manufacturer in case offailure– unprofessional intervention can
lead to damage to the boiler (or – eventually – to the related equipment)!!
5. Check if all parts have been supplied.
6. Check,if the supplied boiler type corresponds with the type required for use.
7. When uncertain about boiler operation, please, do not neglect to look up and study all relevant information
located in the operating instructions and carry out everything in accordance with them.
8. Do not remove or damage any labels or written notices on the boiler.
9. The boiler complies with the following standards: CSN EN 60335 – 1: 1997 CSN EN 50081 – 1:1994, CSN EN
55014-1:1995,CSNEN61000-3-2+A12:1997,CSNEN61000-3-3:1997CSNEN 55 014-2:1998, CSN EN 06
1008:1997.
10. At the end of its service life the boiler and its parts should be treated with respect to the environment.
1. INTRODUCTION
In accordance with development trends in the area of electric boilers, PROTHERM company has introduced
electric direct heating boilers of the REJNOK series, produced in 9, 12, 15, 18, 21 and 24 kW versions.
This boiler has a high utility value, i.e. it is well equipped, which makes it independent of the heating system
equipment. Through the use of a simple control panel it is possible to adjust the boiler operation according to the
conditions of the given building.
1.1. QUALITY ASSURANCE OF EQUIPMENT AND PERSONAL SAFETY
Inadditiontotherequirementsoftheabovementioneddocuments,itisnecessarytoadhere to these instructions
andthe accompanyingmanufacturer’sdocumentationofthe boilerwhileusingthisboiler. Alsoessentialis intervention
by children, intoxicated persons, irresponsible persons, etc.
The manufacturer’s products conform to the standards of the examined type through maintaining technological
discipline through its quality control system in accordance with the ISO 9001 standard.
Aconstanthighlevelofcarefortheproductandtheuser(i.e.oninstallation,placingintooperation,acquaintance
with usage, setting and regulation in accordance with local conditions, during the warranty and after warranty
period) is provided by a network of contract partner companies with qualifications in correspondence.

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2. BOILER CHARACTERISTIC AND EQUIPMENT
2.1. CHARACTERISTICS
PROTHERMelectricboilersaredesigned for usage in heating warm-water systems with forced water circulation.
They serve as heaters of heating water, which is then pumped and distributed through central and level heating
systems to heating bodies.
Theelectricboilerhasa function of sequential on/off switching of power at intervals of maximum 6 kWwith10-70
seconds delay according to the boiler output, so that undesirable impulses in the mains are eliminated on the
electric boiler switch-off and switch-on. The circulation pump only works when it is necessary, thereby saving
energyandreducingmechanicalwear.Thepumpstaysinoperationfor2minutes after the electric boiler switch-off,
so that warm water remaining in the boiler body and distribution system after switch-off can be utilized.
Theelectric boiler is mounted into a steel casewith a front panel integrated with sidepanels attached to the back
panelwith screws. Theheatingwater inlet andoutletare at thebottomof the boileraswell as anelectricalconnection.
The REJNOK series boilers are designed for mounting on a wall.
In order to achieve higher output, the electric boilers can be cascade-connected, and controlled by only one
temperature controller connected to the primary electric boiler.
Operating diagram of the electric boiler (Diagram 1)
1. a heating coil
2. a container / heat exchanger
3. insulation
4. a deaerating valve
5. the circulation pump
6. heating flow
7. heating return
8. an integrated hydroblock
9. a safety valve
10. a pressure sensor
11. an expansion tank
2.2. Boiler equipment
The electric boiler is equipped with a cylindrical heat
exchangerwithheatingelements,ahydroblockconsistingof
anintegratedcirculationpump,apressuresensorand asafety
valve.
The signalling and power control panel consists of an
integrated thermometer and a pressure meter, an operating
thermostat,thefirst,second andthirdoutputlevelLED diodes,
the second and third output level switches, general remote
control LED diode and LED diode indicating mains and
eventual overheating of the boiler.
The internal control and safety segment consists of an
electronicswitchingblock with a contactor forgeneralremote
signal control and an emergency thermostat.
Thereisa built-in 10l expansion tank forthecompensation
ofthethermalexpansivityeffectofheatingwaterin thesystem.
TS
1
2
3
4
5
6
7
8
9
10
11
Diagram 1

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3. Control and signalling
The electric boiler is designed for unmanned operation. After switching on of the main power supply switch there
is a green signal light lit on the control panel (see the picture of the control panel) signalling, that the electric boiler
is connected to the mains. The white general remote control LED diode signalizes, that the contactor controlled by
thegeneralremotecontrol is switched on and also signalizes if there is aninterruptionof the lower tariff of the direct
heating rate. the LED diode is on when the lower tariff is active.
Control panel (Diagram 2)
1. Indicator of boiler water pressure
2. Indicator of heating water temperature
3. Indication of general remote control mode
4. Output level switchControl
5. Wheel of the boiler operating thermostat
6. Indication of boiler connection to the mains
7. Indication of 1st – 3rd output level
8. Indication of boiler overheating and boiler water pressure decrease
Two switches located in the lower part of the control panel allow the user to
choose the output levels
according to the next table:
Output range (kW) 9 12 15 18 21 24
I 00661212
I+II 369121518
I+III 662121818
I+II+III 9 12 15 18 21 24
LitLEDdiodesIIandIII above switches signalize that switches are turned on
and that the appropriate heating elements inside the electric boiler are heating. LED diode I signalizes that the first
outputlevelisswitchedonand alsosignalizesthemomentwhentheboilerisswitched on/offby theindoor temperature
controller or by a boiler thermostat, when the ripple control is switched on. If there are two or more electric boilers
working in a cascade connection, the second electric boiler always turns on with a delay after switch-on of the
bottom switch of the preceding boiler. Along with the boiler thermostat, the maximum heating water temperature
can be set, heated in the electric boiler. The boiler thermostat has to be set in accordance with the mounting
company instructions, because the maximum heating water temperature depends on the type of heating system
(floor heating, fitting of thermostatic heads, heating of hot water). Please set the indoor temperature controller
according to the user instructions. When using classical central heating with heating bodies and with an indoor
temperature controller it is necessary to set the boiler thermostat to a higher temperature - e.g. to 80 °C. Do not
however be suprised that the water in the heating system will not reach that temperature. The indoor temperature
controllerwill stabilize the water temperatureon a level necessary for reaching the required indoor air temperature.
Bysettingtheboilerthermostattoahighertemperature,preventionoftheswitch-offoftheelectricboilerisachieved
when the set temperature of the water is too low so as to not influence indoor temperature room regulation. The
boiler operating thermostat has a limiting function when control is executed in this way.
Output preset value depends on heat loss in your flat or house, on external temperature, on required indoor
temperature,orifyou use your electric boiler also for the heating of hot water.Fulloutputoperation at temperatures
around or above 0°C will not cause damage to the electric boiler.
When heating two flats it is necessary to set output so as to be sufficient for covering losses for both flats.
Theelectricboilerisequipped with a safety thermal cut-out – safety thermostat and pressuresensor for securing
of safe operation. The safety thermostat will shut down the boiler irreversibly when the water exceeds the critical
temperature (100 °C). This will be signalized by a yellow signal light. When a reaction of this kind does not occur,
callaserviceengineerimmediatelyinorderto detect the true cause, repair the boiler and put it into operation again.
Annotation: no any time itśmust be a warranty revision.
Never try to repair the boiler yourself! This situation is rare and will not be encountered on a regular basis. The
pressuresensorprevents the boiler switch-on if there is a leakage ofwaterfrom the heating system and if the water
pressuredropsbelow0,8Bar, so that the heating elements are protected from damage in case ofoperationwithout
Diagram 2
HDO
1
2
3
4
5
6
7

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water in the system. A pressure drop is also signalized by a yellow signal light. The type of failure can be identified
according to the integrated pressure meter/thermometer reading.
Inordertoachievemaximumoperationefficiency(minimalized electricitycosts) itis necessarytoaddanappropriate
regulating mechanism to your heating system, which maintains the required temperature when you are at home
and will lower the indoor temperature automatically at night or when nobody is at home.
4. Conditions for installation and operation
The connection for electric heating is subject to approval by a local distribution company. An applicant has to
seek preliminary approval with an option for connection to a higher electric input and has to apply for a direct
heating rate for flats.
Wheninstallingnewcentralheatingorreconstructing an old one, we recommend professional carrying out of the
project so as to ensure an economical and failure-free system.
Theelectricboiler can be connected to the heating systemonlybyacompetentheating engineer. The connection
to the mains and the electric wiring can only be done by a professional qualified in accordance .
The electric boilers are designed for permanent connection to fixed mains. A switch has to be integrated into the
boilerfixedmainsasa main switch and the gap of its disconnected contacts has to be bigger than 3 mmatallpoles.
It is necessary to choose a suitable place for the electric boiler, counting on a certain amount of space in front of
theboiler,necessaryforhandlingaswellas under the boiler for connection of inlet and outlet heating system piping.
Minimum distances between the electric boiler and a proof check are demonstrated on a Diagram 3.
Provisionofwarrantyisconditionedbyprofessionalinstallation
carried out by an authorized service company! Therefore please
contact our contract partners who will help you in acquiring
necessary technical data, will connect your boiler professionally
and will also advise you in questions of operation of your electric
heating.
After installationyou should ask a competent employee of the
company which carried out the installation to demonstrate how
the system functions and train you in working with the boiler. A
competent worker has to certify the electric boiler warranty
certificate after putting the boiler into operation.
The electric equipment of the boiler is designed for handling
with no need for electrotechnical qualification. The handler is
allowed to manipulate only with those control elements specified
in these usage instructions, eventually specified by a service
company. The handler is not allowed to change the wiring.
Itisnecessarythatthereis pressurewater forfillingofthesystem
and also the possibility for drainage of the system in the place
where the electric boiler will be installed. It is also necessary that
there is a straight wall in the room (the electric boiler is mounted
on the wall).
The electric boiler is designed for operation in a standard environment (i.e. temperatures from +5 to +40 °C,
humidity up to 85% depending on temperature).
The boiler must not be installed in bathrooms, wash-rooms and shower-rooms . It should also not be installed if
there is the possibility that the water stream will reach the boiler (e.g. in public baths, bath-rooms and showers,
located in schools, factories, sport clubs, other public facilities, etc.).
When the boiler is installed in permitted zones, there must be protection against electric shock in accordance with
the same standard.
min 700 mm
HDO
min 50 mm min 50 mm
min 500 mm
min 800 mm
Diagram 3

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5. Boiler connection dimensions and pump characteristics
Boiler connection description
1. a cable bushings
2. filling / draining 1/2”
3. a heating water inlet 3/4”
4. overflow of a safety valve
5. a heating water outlet 3/4”
12
3
45
350
277
200
136
410
240
38
rear view
bottom view

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6. Mounting and placement of the boiler
Themounting rail (is included) is recommended for mounting the boiler onthe wall see
Diagram6.First fixtherailonthewall. On this rail hang the heater unit with the pump and
accessories. The boiler casing is removable and is fixed to the rear panel with screws. It
isnecessarybeforemountingtofind a place where the boiler can be serviced without any
obstructions.
If the boiler is installed to an open system the heating water column must produce a
pressure of min. 1bar.
In heating systems fitted with thermostatic heads, water circulation can be completely
closed, and it is necessary to mount a by-pass leading through one heating body, which
is not fitted with thermostatic heads or to use another by-pass.
The use of non-freezing mixtures is not recommended due to their properties which
arenotsuitablefor boileroperation–particularlyreductionofheat transfer,highexpansivity,
aging, damage to rubber parts. If there is no other possibility of reliable prevention of
freezing of the heating system, then non-fulfilment of some functional parameters or
eventualboilerfailurecausedby usage of non-freezing mixtures can not be included as a
area of warranty.
Prior to the final mounting of the boiler it is necessary to flush the boiler distribution system several times with
pressure water. Older, already used systems should be flushed in the direction which is opposite to the direction of
the heating water. In new systems all heating bodies should be flushed with pressure water to remove preserving
agents.
Placement of a sediment catcher before the boiler is recommended (i.e. to the return heating water piping). The
sediment catcher should allow regular draining without having to drain a lot of heating water. The sediment catcher
can be combined with a filter. A filter itself with a sieve, however, is not sufficient for protection.
The warranty does not apply to clogging of the boiler by heating system contaminants and to failures caused by
such a clogging.
Note: The filter and the sediment catcher must be checked and cleaned regularly.
Before a filling the heating system of water is a requirement to check a pressure in an expansion tank. An
additional completion of the pressure from among 1-1,3 bar is made if necessary.
6.1. Wiring
The user has to arrange a power electric connection with a main switch for heating, protection, and other
adjustments of the house wiring including its initial revision and application for electricity supply.
Bushingsformainsconnection, connectionofaspatialcontroller,ageneral remotecontrol,oracascadeconnection
Diagram 6
0200 400 600 800 1000 1200 1400 1600 1800
0
10
20
30
40
50
60
2000
Available pressure (kPa) between heating supply and return lines
Flow rate through heating system (l/hod)
(10kPa = 1 m WG)
Available pressure (kPa)

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arelocatedinthelowerleftcornerofthebearingframe(frontalview).Wealsomountan external protective terminal
(brass M6 screw).
Thepainthastoberemovedfromthesurfacearoundthescrewinsidethecaseandonitsoutersidebeforefitting
of the protective terminal. We connect a protective conductor ended with a cable lug under the head of the screw
inside the case. On the outer side we tighten a brass nut with a fan-shaped washer. The second nut is used for
connection of the external protective conductor.
Simple and also more complicated regulation elements such as programmable indoor temperature controllers
(daily or weekly programme) are available at the PROTHERM electrical boilers company and through its contract
partners. For proper operation of PROTHERM electric boilers it is necessary to install controllers with zero output
voltage.The required currentcarryingcapacity of outputcontactsof the controlleris230V /0,1A.Indoor temperature
controllers with zero potential output are connected to RT terminals.
6.2. Cascade control
Iftheoutputofthe boiler does not cover the heat loss of the building, there is a possibilitytoconnectanotherheat
source to boilers of the 21 and 24 series. To enable so-called cascade control connect K 1 and K 2 terminals of the
controlling boiler with the PR 1 and PR 2 terminals of the controlled boiler. If there is a need for cascade control,
ensuredby the spatial thermostat,weconnectits control terminalswiththePR 1 and PR2terminalsof the controlling
boiler.
7. Operations
Afterconnectionoftheelectricboilertotheheatingsystem(accordingtolocal conditions) the system is filled with
softwater andthe tightness of the entire system ischeckedsimultaneously.Additionalsealingis made if necessary.
Aftercompleting installation, the operatingthermostatfunctionischecked along with the thermalcut-off,pressure
switch and control elements on the panel.
Note: Before the initial start-up of the boiler it is necessary to set the boiler operating thermostat to the minimum
level, due to undesirable air intake. After the switch-on of the main switch of the boiler (the green signal light is lit)
and after checking the active function of the general remote control turn the operating thermostat of the boiler until
the LED diode of the first output level is lit. Subsequently, turn the operating thermostat back to the minimum level.
This will activate the after-running function of the pump with a duration of 2 minutes. It is recommended to repeat
this two times.
If the orange signal light is on, then the boiler has probably overheated or there was a water pressure drop in the
boiler. In the first case a professional service engineer should check the emergency thermostat above the control
panel, see pic. 7.The emergency thermostat is irreversible, so the failure has to be deblocked by a deblocking
button (a). In the second case there was a water pressure drop in
the boiler. This can be only solved by filling the system with water,
untilthewaterpressure rises above 1 bar. The orange signal light is
then switched off.
Beforeananycheckintoaninsidepartoftheelectric boilerrelevant
to parts which are in a contact with a water or a wiring itśnecessary
to fill following conditions:
-to switch off the boiler by means of the room thermostat or
the operating thermostat
-to wait for c. 2 minutes
-to disconnect the boiler from off the pernament input
connection of mains (a circuit breaker)
-to close valves under the boiler (inlet, outlet)
-to drain a water from the boiler (drain cock)
After a finish of the control or a possible revision check before the
repeated switching of the electric boiler to the mains, if the water
doesn´t issue out of the boiler.
Diagram 7

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8. Maintenance
Theelectricboilerdoesnotrequiremaintenance.Itisrecommended, however, that a service company check the
boiler once a year, preferably before the heating period (this is not included in the warranty). The skilled control
should to tighten all the electric and water connections, to clear a pump, a safety and a deaeraling valve, to check
safety components and in ending globally to attest a correct function of the boiler.
The water pressure has to be checked regularly, when using the boiler in a closed heating system with an
expansion pressure tank. If the overpressure in a cold system drops under the level marked by the installation
company, it is necessary to carry out a professional revision of the system. Itśinvalid at a first heating and by
subsequently operating time, when e.g. an air is evolved from a system. There itśnecessary the system to fill with
water in accordance with a standard. When using an open heating system, it is necessary to check the water level
in the expansion tank and refill the lost water.
9. Complete supply of parts
The electric boiler is supplied in an assembled state. The connecting wires for the electric boiler and connecting
wires for the indoor temperature controller are not included in the supply of parts.
The complete supply consists of these components and documentation:
- the electric boiler in an assembled state
- mounting rail (screws +dowels)
- external protective terminal
- a cable bushings
- user and installation instructions for the PROTHERM electric boiler
- warranty certificate
- quality certificate and complete supply of parts
- list of contract partners
10. Warranty and warranty conditions
The warranty is valid for the PROTHERM electric boiler in accordance to the certificate of warranty and the
herein written conditions.
11. Transport and storage
The electric boiler is transported and stored in its original package – strong force application should be avoided,
as well as shocks and the boiler should not be turned over to a position, in which it can slip out from the package.
Standardconditionshavetobeensuredforstorage(anon-aggressiveanddust-freeenvironment,atemperature
from 5 to 50 °C, air humidity up to 75 %, prevention of biological impacts, shocks and vibrations).

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12. Technical parameters
Voltage............................................................................V.........................3 x 400 + N + PE, 50 Hz
Max.current(24kW)................................................... A........................3 x 36 A
Powerinput*............................................................. kW.....................9, 12, 15, 18, 21, 24
Expansiontank.......................................................... l..........................10l
Min.operatingboiler overpressure................................ kPa....................80
Max.operatingboiler overpressure............................... kPa....................300
Electricprotection.......................................................................................IP 40
Heatingwaterconection.............................................................................G 3/4“
Filling/drainingopening.............................................................................. G 1/2“
Dimensions:
height...............................................................................mm.................... 745
width............................................................................... mm.................... 410
depth.............................................................................. mm.................... 240
weight(withoutwater)..................................................... kg...................... 34
Efficiency.........................................................................%........................99,5
Max. operating temperature of the heating water........... °C.......................85
Max. delivery of the circulation pump..............................kPa................... 50
Recommended operating overpressure of the boiler......kPa....................100 - 170
Recommended circuit breakers valves and cross-sectional area of power
supply cable
type of Protherm boiler K (kW) circuit breaker value (A) Cross-sectional area of Cu
power supply cable (mm 2)
9 16 1,5
12 25 2,5
15 25 2,5
18 35 4
21 35 4
24 50 6

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13. Boiler wiring diagram
TS – pressure switch 0,8 Bar
HT – over heat thermostat 100°C
PT – operating thermostat max. 85°C
PR1,PR2 – room thermostat 230 V / 0,1 A
HDO – ripple control
S-HDO – RC contactor
K1,K2 – cascade output (only 21 kW and 24 kW)

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13.1. Wiring diagram of two boilers connected to cascade
TS – pressure switch 0,8 Bar
HT – over heat thermostat 100°C
PT – operating thermostat max. 85°C
PR1,PR2 – room thermostat 230 V / 0,1 A
HDO – ripple control
S-HDO – RC contactor
K1,K2 – cascade output (only 21 kW and 24 kW)
14. Interconnection the electric boiler with DHW tank
The electric boiler PROTHERM can be to add to non-direct DHW
tank PROTHERM of series B60Z, B100MS, B100Z, B200S and B200Z.
For a correct communication between the boiler and the DHW tank itś
necessary to fill following conditions which relate to a pic. on the page No.
13.
Assembly conditions:
- to a distribution a heating water into a heating system or into DHW itś
necessarytousea 3-way motor valve with donkey-switching contact (3/4”
valve with a exterior screw - No. in a order 2046, 1” valve with a interior
screw – No. in a order 2045)
- contacts of a room thermostat (PR) are played to donkey-contact W1
and W2 of the 3-way motor valve
- the room thermostat will be connect between a contact of a thermostat
of the DHW tank TB2 and a contact of a supply phase of the 3-way valve
motor
cascade
connection
PR
boiler
DHW tank

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external wiring
- toassurance acorrectfunctionof apreparationDHW itśnecessaryfilltheswitching relaywithfollowing parameters:
switching contact current above 0,5 A / switching voltage 0-230 V, control voltage 230 AC
- at the interconnection the electric boiler with the DHW tank itśalways necessary made it in accordance with
conditions in user and installation instructions
TS – pressure switch 0,8 Bar
HT – the emergency thermostat 100°C
PT – the operating thermostat max. 85°C
PR1, PR2 – the room thermostat 230 V / 0,1 A
HDO – ripple control (RC)
S-HDO – RC contactor
K1, K2 – cascade (only 21 kW and 24 kW)
R – switching relay
TC, TB1, TB2 – thermostat contacts of DHW tank