Protherm 60 Instructions For Use Manual
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Protherm 60 Instructions For Use Manual

Protherm 60 Instructions For Use Manual

Fanned flue boiler
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Installation and Servicing

PROTHERM
60 - 80 CI
G.C. No. 41-047-66
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
Supplied By www.heating spares.co Tel. 0161 620 6677

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
221974A.10.01

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  • Page 1: Instructions For Use

    (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 The Protherm CI series are fanned flue boilers designed to All CORGI Registered Installers carry a CORGI ID card, and provide central heating and indirect domestic hot water.
  • Page 4 Instructions for Use Cleaning To Light the Boiler WARNING. This appliance contains metal parts (components) WARNING. Sealed Systems and care should be taken when handling and cleaning, with A sealed water system must be filled and pressurised by a particular regard to edges. competent person.

  • Page 5: General Data

    1 General Data WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) SIDE ELEVATION FRONT ELEVATION Diagram 1.1 1.1 Statutory Requirements Important Notice This boiler is for use only on G20 gas. The installation of the boiler must be carried out by a competent person in accordance with the relevant requirements of the This boiler can be used on open vented or sealed water current issue of:-...
  • Page 6 1 General Data 1.2 Data 1.9 Drain See Table 1 and diagram 1.1. System All dimensions are given in millimetres (except as noted). A drain tap must be provided at the lowest points of the system The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is which will allow the entire system, boiler and hot water cylinder 78.1%.
  • 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 500mm FROM A PERMANENT BS7671 with respect to the installation of a boiler in a room FIXTURE...
  • 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. 1000 3.1 Frost Protection 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 28mm PIPES 22mm VENT (MIN.) 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED 22 X 28 FEED AND UNION EXPANSION CISTERN CONNECTION 1150mm MIN.

  • Page 11: Domestic Hot Water Cylinder

    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 3.4...

  • Page 12: Flue And Appliance Preparation

    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 90mm All flue assemblies are designed for internal installation, given...
  • Page 14 General plate with fitted spacer lugs and support collar. This item should The kits shown in diagram 4.4, enable the Protherm to be fitted be used to support the flue at the top of each floor joist and 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 HORIZONTAL and VERTICAL FLUE DIAGONAL 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 Boiler Installation 5.1 Boiler Preparation FRONT Open the carton, check the items supplied against the boiler COVER pack contents list on the carton flap. 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 5 Boiler Installation 5.3 Water Circulation System Complete the water connections to the boiler. Fill, vent and flush the system. SCREWS Check for any water leaks and put right. 5.4 Safety Valve Discharge Fit a suitable discharge pipe to the safety valve and route it to GASKET outside the building so that any discharge can be seen but will not cause injury to persons, damage to property or any electrical...
  • Page 20 5 Boiler Installation Make sure that the supply cable and all external cables are 5.7 Electrical Connection secured and away from hot surfaces. WARNING. This boiler must be earthed. 5.10 Testing Take care not to damage any internal wiring and capillaries. Checks to ensure electrical safety must be carried out by a Take plastic cable retaining clip, from the loose items pack, peel off the backing paper and position it in a suitable place to secure...
  • Page 21 6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. OVERHEAT 6.1 All Systems SAFETY CUT-OFF 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 Fit the combustion chamber front. Note: Make sure it fits under lip of flue hood. Reconnect the ignition lead to the PCB. Stick the self adhesive arrow indicator to the data label, against the rating that the boiler is going to be set to, for future reference. The arrow is in the loose items pack.
  • Page 23 6 Commissioning Turn the control thermostat knob fully anticlockwise to “O”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. When the control thermostat is turned to the “Off” position, by SIDE hand, wait at least 30 seconds before turning “On”...

  • Page 24: Instructions To The User

    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 8 Servicing 8.3 Main Burner 8.6 Operational Checks Disconnect the pilot pipe union connector and pilot burner, After completing a service and before fitting the case, check securing nut and shakeproof washer together with the pilot condition of the case seal and renew if necessary. shield.

  • 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 br BROWN w WHITE BLUE PURLPLE YELLOW LINK PUMP SPARK ELECTRODE O/H CUTOFF FUSE F1 & F2 (F1A) CONTROL STAT (N/O) PRESSURE SWITCH (N/C) PILOT SOLENOID MAIN SOLENOID Remove red link between 9 and SL when fitting a time control etc (if no switch is fitted, link will make the circulation pump run constantly) AIR PRESSURE SWITCH CONNECTIONS...
  • Page 30 9 Fault Finding KEY: FULLY PUMPED OPEN - BLUE VENTED OR SEALED bk - BLACK WATER SYSTEM - BROWN g/y - GREEN/YELLOW - ORANGE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE - PURPLE PRESSURE SWITCH ELECTRODE PLUG CHASSIS CHASSIS EARTH EARTH Remove red link between 9 and SL when fitting a time control etc (If no switch is fitted, link...

  • Page 31: Replacement Of Parts

    10 Replacement of Parts 10 Replacement of Parts CONTROL THERMOSTAT Note. Replacement of parts must only be carried out by a SHAKEPROOF competent person. WASHERS AND Before replacing any parts isolate the boiler from the electrical SCREWS supply and turn the gas supply off at the gas service cock, indicator slot should be vertical.
  • Page 32 10 Replacement of Parts OVERHEAT CUTOFF DEVICE BOILER PHIAL THERMOSTAT ELECTRICAL PLUGS ELECTRICAL CONNECTION PHIAL RETAINING NO.3"YELLOW" BRACKET SECURING CABLE SCREW OVERHEAT CUTOFF ELECTRICAL CONNECTION "WHITE" CABLE CHASSIS EARTH CONNECTION SPLIT SUPPORT IGNITION POST (4) LEAD MAIN TERMINAL STRIP SECURING SCREW (2) ELECTRICAL FLUE HOOD...
  • Page 33 10 Replacement of Parts 10.7 Multifunctional Control - diagram 10.3 Disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control, take care as there is a restrictor on the pilot pipe. RESTRICTOR Disconnect the electrical plug. Support the multifunctional control, remove the four extended screws from the flanged connections at the left and right hand PILOT PIPE side.
  • Page 34 10 Replacement of Parts MICA WINDOW OPENING (INSIDE FACE OF THE BOILER RETAINING FRONT COVER) SCREW PEEL OFF SELF ADHESIVE BACKING ALUMINIUM FOIL PAPER GASKET Diagram 10.5 CLEAR AIR PRESSURE FRONT INSULATION SWITCH TUBES SECURING SCREWS SIDE INSULATION PRESSURE SWITCH ELECTRICAL CONNECTIONS CONTROL...

  • Page 35: 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.
  • Page 36 11 Spare Parts Diagram 11.1 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221974A Supplied By www.heating spares.co Tel. 0161 620 6677...

This manual is also suitable for:

60 ci

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