Protherm 40 Instructions For Use Installation And Servicing
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Protherm 40 Instructions For Use Installation And Servicing

Protherm 40 Instructions For Use Installation And Servicing

Fanned flue boiler
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Installation and Servicing
PROTHERM
40 - 50 CI
G.C. No. 41-047-53
Cat I
Fanned Flue Boiler
Reference in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
For Ireland the rules in force must be used.
The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration
Card. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety
(Installation and Use) Regulations, be handed to the user on completion of the installation.
Thank you for installing a new PROTHERM appliance in your home.
The appliance is manufactured to the very highest standard so we are pleased to offer our customers' a
In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
All replacement parts
All labour charges
All call-out charges
One Contact Local Service
Instructions for Use
To b e l e f t w i t h t h e u s e r
2H
Guarantee Registration
Comprehensive First Year Guarantee.
return as soon as possible.
Service number 01773 828100.
REGISTER YOUR APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
221973A.10.01

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  • Page 1 (Installation and Use) Regulations, be handed to the user on completion of the installation. Guarantee Registration Thank you for installing a new PROTHERM appliance in your home. The appliance is manufactured to the very highest standard so we are pleased to offer our customers' a Comprehensive First Year Guarantee.

  • Page 2: Important Information

    Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 3 Boilers Installed in a Compartment or safe and economical use of your boiler. Cupboard The Protherm CI series are fanned flue boilers designed to If the boiler is installed in a compartment or cupboard do not provide central heating and indirect domestic hot water.
  • Page 4 Instructions for Use Boiler Electrical Supply The pressure gauge should show at least 0.7bar, anything less than this figure could indicate a leak and you MUST contact your WARNING. This boiler must be earthed. installation/servicing company. The boiler must only be connected to a 230V~50Hz supply If there is any doubt about the boiler being full of water consult protected by a 3A fuse.

  • Page 5: General Data

    1 General Data WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) SIDE ELEVATION FRONT ELEVATION Diagram 1.1 Important Notice This boiler is for use only on G20 gas. The manufacturer’s instructions, supplied. This boiler can be used on open vented or sealed water The Gas Safety (Installation and Use) Regulations, The Building systems.
  • Page 6 1 General Data 1.9 Drain 1.3 Range Rating This boiler is range rated and may be adjusted to suit individual System system requirements. A drain tap must be provided at the lowest points of the system See table 2 and diagram 1.3 for ratings and settings. which will allow the entire system, boiler and hot water cylinder The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is be drained.
  • Page 7 1 General Data 1.10 Safety Valve A safety valve need not be fitted to an open vented system. 1.11 Location This boiler is not suitable for outdoor installation. This boiler may be installed in any room, although particular attention is drawn to the requirements of the current issue of BS7671 with respect to the installation of a boiler in a room containing a bath or shower.
  • Page 8 2 Flue and Ventilation Note. Detailed recommendations for flue are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

  • Page 9: Water Systems

    3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 3.1 Frost Protection 1000 If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 10 3 Water Systems FLOW OPEN VENTED FULLY PUMPED WATER SYSTEM RETURN RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT 22mm 22mm VENT PIPES 22mm (MIN.) 450mm PIPES MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION CISTERN 1150mm MIN. 22mm VENT & 15mm COLD FEED PUMP TO BE FITTED IN ACCORDANCE WITH BS 5449...

  • Page 11: Pressure Gauge

    3 Water Systems 3 LITRES (0.66 gals) MAKE-UP BOTTLE RELEASE (if required) POINT AUTO VENT NON-RETURN VALVE FILLING POINT IF REQUIRED 22mm (min) BY-PASS WITH LOCKSHIELD VALVE FLOW CIRCULATING SAFETY PUMP VALVE RETURN PRESSURE GAUGE DRAIN COCK (Make-up BOILER alternatives) EXPANSION VESSEL Diagram 3.5...

  • Page 12: Flue And Appliance Preparation 4

    4 Flue and Appliance Preparation STANDARD FLUE PACK SIDE FLUE REAR FLUE FLUE LENGTH FLUE LENGTH MAX 570mm (std) MAX 570mm (std) 31mm 15mm 15mm SCREW SCREW & TAPE & TAPE Note: Outer casing, mounting brackets & boiler details removed for clarity STANDARD FLUE PACK &...
  • Page 13 4 Flue and Appliance Preparation NOTE : Make sure that the ductings do not slope down towards the boiler. 4.1 Flue Position and Length 115mm Determine flue application, length and terminal position before MINIMUM BOILER starting. HOLE CENTRE LINE Refer to diagram 4.1. 4.2 Flue Preparation All flue assemblies are designed for internal installation, given 90mm...
  • Page 14 This item should be used to support the flue at the top of each floor joist and The kits shown in diagram 4.4, enable the Protherm to be fitted provide a fire stop feature. Spacer lugs fitted to the underside with the flue configurations shown in diagram 4.6.
  • Page 15 4 Flue and Appliance Preparation Ceiling Plate - Two Piece - Part No. 208593 Manufactured in galvanised steel and should be used on the underside of floor joists where the flue passes through the floor or roof in a non vertical plane. This item is supplied without spacer lugs and should be nailed or screwed to the underside of the joists.
  • Page 16 4 Flue and Appliance Preparation VERTICAL FLUE DIAGONAL and VERTICAL FLUE HORIZONTAL and VERTICAL FLUE VERTICAL FLUE KIT 458115 VERTICAL FLUE KIT 458115 VERTICAL FLUE KIT 458115 1M EXTENSION KIT 230484 (as reqd.) 1M EXTENSION KIT 230484 (as reqd.) 1M EXTENSION KIT 230484 (as reqd.) °...
  • Page 17 4 Flue and Appliance Preparation Push flue duct & air duct STEP 4 onto flue bend (45 or 90 STEP 3 drill and screw then seal STEP 6 FLUE BEND Push flue bend (45 or 90 with tape provided. (90˚ or 45˚) onto flue duct or boiler end Push flue duct standard flue, drill and screw...

  • Page 18: Boiler Installation 5

    5 Boiler Installation 5.1 Boiler Preparation Open the carton, check the items supplied against the boiler CONTROLS pack contents list on the carton flap. COVER With the boiler still in in the bottom tray slide the controls cover upwards and remove, see diagram 5.1. Remove the front cover by undoing the wing nut, nut and washer, lift the front cover off, see diagram 5.1.

  • Page 19: Boiler Installation

    5 Boiler Installation 5.5 Gas Connection 5.8 Gravity Domestic Hot Water Systems Make the gas connection to the Rc in gas service cock, see Fit the yellow link cable, supplied in the fittings pack, between diagram 6.1. terminal K1 and K2, see diagram 5.7. Check for leaks using a suitable leak detection fluid.
  • Page 20 5 Boiler Installation 5.11 Testing Checks to ensure electrical safety must be carried out by a competent person. After installation of the system, preliminary electrical system checks as below should be carried out. 1. Test insulation resistance to earth. 2. Test continuity and short circuit of all cables, 3.

  • Page 21: Commissioning 6

    6 Commissioning Please ensure the “Benchmark” logbook is completed and left OVERHEAT SAFETY with the user. CUT-OFF 6.1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 22 6 Commissioning 6.4 Testing - Electrical Turn the boiler thermostat knob fully clockwise to the maximum setting, which is about 82 C (180 F), neon 2 will light. The lighting sequence is automatic as follows: The fan operates The spark ignition operates neon 3 will light The pilot solenoid opens The pilot burner lights...
  • Page 23 6 Commissioning 6.6 Testing - Open Vented System Allow the system to reach maximum working temperature and SEAL examine for water leaks. There should be no undue noise in the system and no pumping SIDE SEAL over of water or entry of air at the open vent above the feed and expansion cistern.

  • Page 24: Servicing 8

    7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the imposes a duty of care on all persons who let out any property boiler, heating system and domestic hot water system. containing a gas appliance. Advise the user, that to ensure the continued efficient and safe It is the Law that servicing is carried out by a competent person.

  • Page 25: Table

    8 Servicing Remove the wing nut from the burner support bracket, see SECURING NUT AND diagram 8.5. SHAKEPROOF WASHER Remove the main burner from the main injector at the rear. Raise the burner up and forwards, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly.

  • Page 26: Fault Finding

    9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 27 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated, for fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 28 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 29 9 Fault Finding bk BLACK or ORANGE bk BLACK or ORANGE br BROWN w WHITE br BROWN w WHITE BLUE BLUE PURPLE y YELLOW PURLPLE YELLOW Red Link must be fitted between SL and 9. RED LINK LINK SPARK ELECTRODE PUMP SPARK ELECTRODE...
  • Page 30 9 Fault Finding KEY: GRAVITY DOMESTIC - BLUE HOT WATER AND bk - BLACK PUMPED CENTRAL - BROWN HEATING g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE SWITCH CHASSIS CHASSIS EARTH EARTH SEQUENCE Yellow link fitted to bridge out the...
  • Page 31 9 Fault Finding KEY: FULLY PUMPED - BLUE OPEN VENTED bk - BLACK OR SEALED - BROWN WATER SYSTEM g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE Remove red link between SWITCH 9 and SL when fitting a time control etc (If no switch is fitted,...

  • Page 32: Replacement Of Parts

    10 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT SHAKEPROOF Before replacing any parts isolate the boiler from the electrical WASHERS AND supply and turn the gas supply off at the gas service cock, SCREWS indicator slot should be vertical.
  • Page 33 10 Replacement of Parts ELECTRICAL PLUGS PHIAL RETAINING BOILER BRACKET SECURING THERMOSTAT SCREW ELECTRICAL CONNECTION OVERHEAT NO.3 "YELLOW" CABLE CUTOFF DEVICE PHIAL CHASSIS EARTH CONNECTION SUPPORT SECURING EARTH POST (4) SCREW (2) SPLIT CONNECTION IGNITION MAIN LEAD TERMINAL STRIP PLASTIC RETAINING CLIP FLUE HOOD...
  • Page 34 10 Replacement of Parts 10.9 Main Burner Remove the main burner as Section 8.3. 10.10 Main Injector RESTRICTOR Remove the main burner as Section 8.3. Remove the main injector as Section 8.4. PILOT PIPE 10.11 Insulation - 10.4 & 10.5. TUBING NUT Combustion Chamber Front Remove the retaining screw then the insulation.
  • Page 35 10 Replacement of Parts SIDE INSULATION MICA WINDOW OPENING (INSIDE FACE OF THE BOILER FRONT COVER) PEEL OFF SELF ADHESIVE BACKING ALUMINIUM FOIL PAPER GASKET Diagram 10.6 CLEAR AIR PRESSURE SWITCH TUBES SECURING SCREWS REAR INSULATION Diagram 10.5 PRESSURE SWITCH ELECTRICAL CONNECTIONS CONTROL...

  • Page 36: Spare Parts

    11 Spare Parts 11.1 Part Identification The key number on the diagram and the list will help to identify the part. 11.2 Ordering When ordering any spare parts please quote the number and description from the list together with the model name and serial number. If ordering from Britsh Gas also quote the GC number of the appliance and part.

This manual is also suitable for:

50 ci40 ci

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