Protherm 60 User manual

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221974A.10.01
All replacement parts
All labour charges
All call-out charges
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.
In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and
return as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Service number 01773 828100.
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
Guarantee Registration
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.
To beleftwiththeuser
❏
✔
❏
✔
❏
✔
Instructions for Use
Installation and Servicing
G.C. No. 41-047-66
REGISTER YOUR APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
60 - 80 CI
Cat I2H
PROTHERM

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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.
CE Mark
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed to meet the
requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels.
Type test for purposes of Regulatioon 5 certified by: Notified body 0086.
Product/productioncertifiedby: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within
certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.
INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health.
CERAMIC FIBRE/INSULATION PADS.
Thesecancauseirritationtoskin,eyesandtherespiratorytract.Ifyouhaveahistoryofskincomplaintyoumaybesusceptibletoirritation.Highdust
levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands
before eating, drinking or going to the lavatory. If you do suffer irritation of the eyes or severe irritation to the skin seek medical attention.
THERMOSTATS
These contain very small amounts of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does not cause a
problem, but in case of skin contact, wash with cold water. If swallowed drink plenty of water and seek medical attention.
CUT-OFF DEVICES
These contain activated charcoal and a very small amount of chlorodifluormethane in the sealed phial and capillary. If broken, under normal
circumstances the fluid does not cause a problem. If there is irritation to the eyes or skin then seek medical attention.
SPARE PARTS
REMEMBER, When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performancespecificationthatwerequire. DonotusereconditionedorcopypartsthathavenotbeenclearlyauthorisedbyHepworth
Heating Ltd.
Important Information
Introduction 3
Lighting the Boiler 4
General Data 1 5
Flue & Ventilation 2 8
Water Systems 3 9
Flue and Appliance Preparation 4 12
Boiler Installation 5 18
Commissioning 6 21
Instructions to User 7 24
Servicing 8 24
Fault Finding 9 26
Replacement Parts 10 31
Spare Parts 11 35
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS

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9270
Diagram 1
9364
CONTROLS COVER
DATA &
SERIAL
NUMBER
LABEL
VIEWING WINDOW
SETTING POINT
CONTROL
THERMOSTAT
KNOB GAS SERVICE
COCK (Shown
Off)
It is the law that any servicing is carried out by a competent
person.
Toobtainservice,pleasecallyourinstallerorHeatcallusingthe
telephone number given on the controls tray.
Please be advised that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boilerLogbook. YoucancheckyourinstallerisCORGIregistered
by calling CORGI direct on :- 01256 372300.
Boiler Clearances
If fixtures are positioned close to the boiler space must be left
asshownindiagram2. Atleastaminimumclearanceof500mm
must be left in front of the boiler to allow for servicing.
Boilers Installed in a Compartment or
Cupboard
If the boiler is installed in a compartment or cupboard do not
obstruct any ventilation openings.
Do not use the compartment or cupboard for storage.
Instructions for Use
Introduction
WARNING. Itisimportantthatthecase(notthecontrolscover)
is not disturbed or removed other than for servicing by a
competent person.
Pleaseread these instructions and followthemcarefullyfor the
safe and economical use of your boiler.
The Protherm CI series are fanned flue boilers designed to
provide central heating and indirect domestic hot water.
The boiler is fully automatic in operation having only one user
control, the control thermostat
The Gas Safety (Installation and Use)
Regulations
In your interest and that of gas safety it is the law that ALL gas
appliances are installed by a competent person in accordance
with the above regulations.
Gas Leak or Fault
If a gas leak or fault exists or is suspected, the boiler must be
turned off, including the electrical supply and must not be used
until the fault has been put right.
Advice/helpshouldbeobtainedfrom yourinstallation/servicing
company or the local gas undertaking.
Electrical Supply Failure
Failure of the electrical supply will cause the burner to go out.
Should this occur, operation of the appliance will normally
resume after the electrical supply is restored.
If the boiler does not relight after an electrical supply failure the
overheat safety cutoff device may need resetting, remove the
controls cover and press the reset button, refer to diagram 1.
Overheat Safety Cutoff
If the overheat safety cutoff device operates on any other
occasionthananelectricalsupplyfailure,presstheresetbutton
asin“ElectricalSupplyFailure”. Iftheoverheatoperatesagain,
turn the appliance off and contact your installation/servicing
company.
Maintenance
To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.
If this appliance is installed in a rented property there is a duty
or care imposed on the owner of the property by the current
issue of The Gas Safety (Installation and Use) Regulations,
Section 35.

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500mm FROM A PERMANENT
FIXTURE
6mm 6mm
FRONT
VIEW
6mm 6mm
6mm
160mm
65mm
Diagram 2
Cleaning
WARNING. Thisappliancecontainsmetalparts(components)
and care should be taken when handling and cleaning, with
particular regard to edges.
Clean the casing occasionally by wiping it over with a damp
cloth or dry polishing duster.
Do not use an abrasive cleaner.
Boiler Electrical Supply
WARNING. This boiler must be earthed.
The boiler must only be connected to a 230V~50Hz supply
protected by a 3A fuse.
All wiring must be in accordance with the current issue of
BS7671.
Wiring to the boiler must be PVC insulated type to the current
issueofBS6500Table16,notlessthan0.75mm2(24/0.20mm).
The colours of three core flexible cable are:
Brown - live, Blue - neutral,
Green/yellow - earth.
As the markings on your plug may not correspond with these
colours continue as follows:
The cable coloured blue must be connected to the terminal
marked “N” or black.
The cable coloured brown must be connected to the terminal
marked “L” or red.
The cable coloured green/yellow must be connected to the
terminal marked “E”, or green or the earth symbol .
To Light the Boiler
WARNING. Sealed Systems
A sealed water system must be filled and pressurised by a
competent person.
Onlylighttheboilerwhenyouaresurethatthesystemhasbeen
filled and pressurised.
Thepressure gauge should showatleast0.7bar,anything less
thanthisfigurecouldindicatealeakandyouMUSTcontactyour
installation/servicing company.
If there is any doubt about the boiler being full of water consult
your installation/servicing company.
ALL SYSTEMS.
Turn the electrical supply on to the boiler and check that all
remote controls are calling for heat.
To Turn the Boiler On
Open the controls cover door, by pulling it forward and down,
see diagram 1.
Turn the control thermostat knob clockwise to any position
between MIN and MAX. The maximum temperature setting is
about 82oC (180oF), see diagram 1.
The boiler lighting operation is now automatic as follows.
The fan operates, followed by an ignition spark until the pilot is
lit. When the pilot is alight the ignition system switches off and
the main burner lights. The flames can be seen through the
viewing window, see diagram 1.
The main burner will remain alight until switched off by the
control thermostat or any remote control.
If the boiler is switched OFF, by hand, wait at least 30 seconds
before switching on again.
When the boiler switches off, both the pilot and main burner go
out.
The automatic lighting sequence will operate again when heat
is required.
Shut the controls cover.
It should be noted that this is a fan flue appliance and fan
operation may be heard.
To Turn the Boiler Off
Forshortperiods,turnthecontrolthermostatknobanti-clockwise
to “O” Off. To relight, turn the control thermostat knob to any
position between “MIN” and “MAX”.
For longer periods, turn the control thermostat knob fully anti-
clockwise to “O” Off and switch off the electrical supply to the
boiler.
To relight follow the lighting sequence given above.
Protection Against Freezing.
If the boiler is to be out of use for any long period of time during
severeweatherconditionswerecommendthatthewholeofthe
system, including the boiler, be drained off to avoid the risk of
freezingup. Makesurethat,iffitted,theimmersionheaterinthe
cylinder is switched off.
For the position of the serial number, see diagram 1.
Instructions for Use
9271

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5221974A
C
L
RETURN PUMPED PUMPED FLOW
C
L
WATER CONNECTIONS
22mm COPPER PIPE
GAS CONNECTIONS
RC
1
/ 2 (
1
/ 2 in. BSPT)
SIDE ELEVATION FRONT ELEVATION
A
80
B
300
C
100
D
75
E
700
F
124
G
130
H
400
J
60
K
162
L
110
M
142
N
90
B
A
D
LK
N
J
G
F
E
M
C
R
H
1 General Data
Diagram 1.1
Important Notice
This boiler is for use only on G20 gas.
This boiler can be used on open vented or sealed water
systems.
When used on an open vented system domestic hot water can
only be provided by a pumped primary circulation.
Wherever possible, all material, appliances and components
used shall comply with requirements of applicable British
Standards.
Where no British Standards exist, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
Sheet Metal Parts
WARNING. Wheninstalling orservicingthis boilercareshould
betakenwhenhandlingsheetmetalparts,toavoidanypossibility
of personal injury.
1.1 Statutory Requirements
Theinstallationoftheboilermustbecarriedoutbyacompetent
person in accordance with the relevant requirements of the
current issue of:-
The manufacturer’s instructions, supplied.
TheGasSafety(InstallationandUse)Regulations,TheBuilding
Regulations, Local Water Company Byelaws, The Health and
Safety at Work Act, Control of Substances Hazardous to
Health, The Electricity at Work Regulations and any local
regulations which may apply.
Detailedrecommendationsarecontainedinthecurrentissueof
the following British Standards and Codes of Practice:-
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593,
BS7671.
Manufacturer’s instructions must not be taken as overriding
statutory requirements
9273

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53 kg (117 lb)
47 kg (103lb)
3.35 litre (0.74 gallon)
Rc 1/2in.
71W
Internal fuse F1 & F2 (F1A)
2x22mm copper pipes from
top of case
230V~50Hz, fused 3A
Bottom right hand side of case
1 General Data
TABLE 2.
RANGE RATING
APPROX. m3/h
GAS
RATE ft3/h
Min. Medium Max.
2.1 2.4 2.7
74 86 97
DATA TABLE 1.
TOTAL DRY
WEIGHT
(Including
Terminal)
LIFT
WEIGHT
WATER
CONTENT
GAS
CONNECTION
ELECTRICITY
RATING
WATER
CONNECTION
ELECTRICITY
SUPPLY
DATA LABEL
BURNER INJECTOR MARKING: 205710
BURNER INJECTOR SIZE: 4.0 mm
PILOT INJECTOR MARKING: 7218
1.2 Data
See Table 1 and diagram 1.1.
All dimensions are given in millimetres (except as noted).
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
78.1%.
ThevalueisusedintheUKGovernment’sStandardAssessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.
1.3 Range Rating
Thisboiler is range ratedandmaybe adjusted to suitindividual
system requirements.
See Table 2 and diagram 1.3 for ratings and settings.
1.4 B.S.I. Certification
Thisboileriscertificatedtothe currentissueofBritishStandard
6332 Part 1, invoking the current issue of BS5258 Part 1 for
performance and safety. It is, therefore, important that no
alteration is made to this boiler without permission, in writing,
from Hepworth Heating Ltd.
Any alteration that is not approved by Hepworth Heating Ltd.,
could invalidate the B.S.I. Certification of the boiler, warranty
and could infringe the current issue of the Statutory
Requirements.
1.5 Gas Supply
The gas installation shall be in accordance with the current
issue of BS6891.
The supply from the governed meter must be of adequate size
toprovideasteadyinletworkingpressureof20mbar(8inwg)at
the boiler.
Oncompletion test the gas installationforsoundnessusing the
pressure drop method and suitable leak detection fluid, purge
in accordance with the above standard.
1.6 Electrical Supply
WARNING. This boiler must be earthed.
All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
and any applicable local regulations.
Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be fused
3A, maximum. This method of connection must be by a fused
doublepoleisolatingswitch,withaminimumcontactseparation
of3mm onbothpoles. The switchshouldbe readilyaccessible
and preferably adjacent to the appliance. It should supply the
appliance only and be easily identifiable as so doing.
Alternatively, an unswitched shuttered socket outlet and 3A
fused 3 pin plug, both to the current issue of BS1363 may be
usedprovidedthattheyarenotusedinaroomcontainingabath
or shower.
WiringtotheboilermustbetothecurrentissueofBS6500Table
16, not less than 0.75mm2(24/0.20mm).
1.7 Contents of Packaging
The boiler is delivered in one pack, refer to Section 4.1 for
contents.
1.8 Water System
This boiler may be fitted to an open vented or a sealed water
system.
TABLE 3. COMPARTMENT AIR VENTS
VENTILATION HIGH LEVEL LOW LEVEL
REQUIREMENTS VENT AREA VENT AREA
VENTILATION
FROM ROOM
OR SPACE
VENTILATION
FROM
OUTSIDE
cm2in2cm2in2
264 41 264 41
132 21 132 21
1.9 Drain
System
A drain tap must be provided at the lowest points of the system
which will allow the entire system, boiler and hot water cylinder
be drained.
Draining taps should be to the current issue of BS2879.
Boiler
Adrainingpointisfittedatthebottomrighthandsideoftheheat
exchanger.
Cover controls to avoid water damage.
If required remove the combustion chamber front cover to
improve access.

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Diagram 1.2
500mm FROM A PERMANENT
FIXTURE
6mm 6mm
FRONT
VIEW
6mm 6mm
6mm
160mm
65mm
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. The electrical provisions of the
Building Standards (Scotland) apply to such installations in
Scotland.
The boiler must be mounted on a flat wall which is sufficiently
robust to take its total weight.
Theboiler maybefitted toawall madeofcombustible material.
1.12 Boiler Clearances
Refer to diagram 1.2.
This boiler must be positioned so that at least the minimum
operational and servicing clearances are provided.
Additional clearances may be required for installation.
Iffixtures are positioned next to theboiler they should be made
removable for access to pipework.
At least a minimum of 500mm clearance must be left in front of
the boiler for servicing, see diagram 1.2.
1.13 Room Ventilation
The boiler is room sealed and does not require the room or
space containing it to have permanent air vents.
1.14 Boilers in a Compartment
Wheretheinstallationoftheboilerwillbeinanunusualposition,
special requirements are needed, the current issue of BS6798
gives detailed guidance on these requirements.
A compartment used to enclose the boiler must be designed
and constructed specifically for this purpose. An existing
cupboard or compartment modified for the purpose may be
used. Details of essential requirements for cupboard or
compartment design are given in the current issue of BS6798.
The doorway opening should be of sufficient size to allow for
easy removal of the boiler.
Where the boiler is fitted in a cupboard or compartment,
permanenthighandlowlevelventilationmustbeprovided. The
minimum ventilation areas required are given in Table 3.
1.15 Timber Frame Building
If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
documentIGE/UP/7/1998. Ifindoubtseekadvicefromthelocal
gas undertaking or Hepworth Heating Ltd.
1.16 Heating System Controls
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.
Note: For further information, see The Building Regulations
1991-Conservationoffuelandpower,1995edition -Appendix
G, table 4b.
MINIMUM CLEARANCES FROM WALLS
CEILING, FLOOR, CUPBOARD, WORKTOPS,
AND INFLAMMABLE MATERIALS
9271
Diagram 1.3
9804

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2 Flue andVentilation
A
A
FGEA
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
Diagram 2.1
MINIMUM SITING DIMENSIONS
FOR FANNED FLUE
TERMINALS POSITION
ADIRECTLY BELOW, ABOVE OR
HORIZONTALLY TO AN OPENING,
AIR BRICK, OPENING WINDOWS,
AIR VENT OR ANY OTHER
VENTILATION OPENING. 300
BBELOW GUTTER, DRAIN/SOIL PIPE 75
CBELOW EAVES 200
DBELOW A BALCONY OR CAR PORT 200
EFROM VERTICAL DRAIN PIPES AND
SOIL PIPES 75
FFROM EXTERNAL CORNERS 300
GABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
HFROM A SURFACE FACING THE
TERMINAL 600
IFACING TERMINALS 1200
JFROM OPENING (DOOR/WINDOW) IN
CAR PORT INTO DWELLING 1200
KVERTICAL FROM A TERMINAL 1500
LHORIZONTALLY FROM A TERMINAL 300
MFROM INTERNAL CORNERS 25
MINIMUM
SPACING
in mm
0103M
Under Car Port etc.
H,I
JD
F
K
M
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
fromobstructions, 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.
Car ports or similar extensions of a roof only, or a roof and one
wall,requirespecialconsiderationwithrespecttoanyopenings,
doors, vents or windows under the roof. Care is required to
protect the roof if it is made of plastic sheeting. If the car port
consists of a roof and two or more walls, seek advice from the
local gas company before installing the boiler.
If the terminal is fitted within 600mm below plastic guttering or
painted soffitanaluminiumshield1500mmlongshouldbefitted
immediately beneath the guttering or eaves. If the terminal is
fittedwithin450mmbelowpaintedeavesorapaintedgutter,an
aluminium shield 750mm long should be fitted immediately
beneath the guttering or eaves.
2.2 Terminal Guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide
aminimumof50mmclearancefromanypartoftheterminaland
be central over the terminal.
A suitable guard, reference Type “K3”, can be obtained from:
Tower Flue Components Ltd
Morley Road
Tonbridge
Kent
TN9 1RA
2.3 Flue Options
Standard Top Outlet Flue Pack - Pt. No. 230483, supplied with
boiler.
1 Metre Extension Kit - Pt. No. 230484.
A flue system up to 3 metres in length can be made by
connecting 1 metre extension kits together.
Optional Wall Liner Kit - Pt. No. 900862.
45°Flue Bend Pack - Pt. No. 230485.
90°Flue Bend Pack - Pt. No. 230486.
Vertical Flue Kit - Pt. No. 458115.
2.4 Vertical Balanced Flue System
IMPORTANT NOTE : See Section 4.8 Easi-Vent Vertical Flue
Terminal, for Installation requirements and fitting instructions.
0161M

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1000
750
500
250
0051015 20 25 30
Flow rate (litres/minute)
Water pressure loss
(mm head of water)
9154
Design Flow Rate
30.6
L /min
Diagram 3.1
3Water Systems
Theinstallationoftheboilermustcomplywiththerequirements
of the current issue of BS6798.
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
ofBS5422.Itisrecommendedthatafrostprotectionthermostat
be fitted.
3.2 Pump
The pump, with integral valves, should be fitted in the heating
flow pipework from the boiler, it should be set to produce a
temperature difference of 11oC (20oF) between the flow and
return, with the boiler thermostat set at “MAX”, which is about
82oC (180oF).
The pressure loss of the boiler can be found from diagram 3.1.
High resistance microbore systems may require a higher duty
pump.
3.3 Bypass - Fully Pumped and Sealed Water
System
A bypass is usually unnecessary on systems using a 3 port
diverter valve since one port will remain in the open position at
all times. This allows satisfactory operation of the pump
overrun.
Howeverifthermostaticradiatorvalvesarefittedtoallradiators
or two port valves are used a bypass is required.
The bypass connection must be at least 2.5 metres away from
the boiler.
Theflow through the boiler must notbeallowedtofall such that
thereisatemperaturedifferencegreaterthan20oCbetweenthe
flow and return.
3.4 Water System
Foran openventedsystem theboilermust besuppliedfroman
unrestricted water supply taken from a feed and expansion
cisternfittedatamaximumheightof27metresabovetheboiler.
The cold feed must be 15mm minimum size.
It is important that the relative positions of the pump, cold feed
and open vent are as shown in diagram 3.2.
Theunrestrictedopenventfromtheboilermustrisecontinuously
to discharge over the feed and expansion cistern.
3.5 Domestic Hot Water System
General. Thedomestichotwaterservicemustbeinaccordance
withthecurrentissueofBS5546,referalsotothecurrentissue
of BS6700.
3.6 Cylinder
Forallsystemssupplying domestic hot water the cylinder must
be indirect. It is recommended that the cylinder be fitted with
some form of temperature control.
3.7 Fully Pumped Domestic Hot Water
The connection for this type of system MUST be as shown in
diagram 3.2 and 3.3.
3.8 Inhibitor
Attention is drawn to the current issue of BS5449 and BS7593
on the use of inhibitors in central heating systems.
Ifaninhibitoristobeused,contactamanufacturerorHepworth
Heating Ltd., for their recommendations as to the best product
to use.
When installing in an existing system take special care to drain
theentiresystem,includingradiators,thenthoroughlycleaning
outbeforeinstallingtheboilerwhetherornotaddinganinhibitor.
3.9 Sealed Water Systems
Theinstallationshouldcomplywiththeappropriaterequirements
ofthecurrentissueofBS4841, BS5449, BS6759, BS6798 and
BS7074 Part 1 and 2, see diagram 3.4 for suggested layout.
3.10 Safety Valve
A safety valve must be fitted to a sealed water system.
It shall be preset, nonadjustable with a lift pressure of 3bar,
incorporating seating of a resilient material, a test device and a
connection for drain.
The drain from the safety valve must be routed clear of any
electrical fittings and positioned so that any discharge can be
seen.
PRESSURE LOSS
FF BOILER

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221974A
3Water Systems
Diagram 3.2
9155
FEED AND
EXPANSION
CISTERN
22mm VENT
(MIN.)
15mm (MINIMUM)
COLD FEED
OPEN VENTED FULLY PUMPED WATER SYSTEM
RECOMMENDED RELATIONSHIP BETWEEN
PUMP COLD FEED AND VENT
450mm
MIN.
HEIGHT
1150mm
MIN.
RETURN FLOW
CYLINDER
PUMP
HEATING
150mm
MAX.
BOILER
IF REQUIRED
22mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
FLOW
RET.
Diagram 3.3
1metre Min.
27 metres
Max.
22mm VENT & 15mm COLD FEED
TO BE FITTED IN ACCORDANCE
WITH BS 5449
INDIRECT
CYLINDER ALTERNATIVE
SYSTEM
CONTROL
VALVES
HEATING
SYSTEM
PUMP
FULLY PUMPED CIRCULATION
SYSTEM (DIAGRAMMATIC)
9157
IF REQUIRED
BYPASS 22mm
MIN WITH
LOCKSHIELD
VALVE
28mm
PIPES
RETURN FLOW
9156
1metre Min.
27 metres
Max.
22mm FOR COMBINED FEED & VENT
TO BE FITTED IN ACCORDANCE
WITH BS 5449
INDIRECT
CYLINDER
ALTERNATIVE
SYSTEM
CONTROL
VALVES
HEATING
SYSTEM
PUMP
FULLY PUMPED CIRCULATION
BYPASS (DIAGRAMMATIC)
9158
IF REQUIRED
BYPASS 22mm
MIN WITH
LOCKSHIELD
VALVE
3.11 Expansion Vessel
A diaphragm type expansion vessel, conforming to the current
issue of BS4814 (see also BS7404 Part 1 and 2) must be
connected at a point close to the inlet side of the circulating
pump, see diagram 3.4 unless laid down differently by the
manufacturer.
The expansion vessel volume depends upon the total water
systemvolume and theinitialsystem design pressure. Forany
systeman accuratecalculationof thevesselsize isgivenin the
current issue of BS7074 Part 1.
Example. For an initial system design pressure of 0.7bar the
minimum total vessel volume required is 0.063xTotal System
volume.
Note. A higher initial design pressure requires a larger volume
expansion vessel.
Guidance on vessel sizing is also given in the current issue of
BS5449 and BS7074 Part 1.
Thechargepressuremustnotbelessthanthestaticheadofthe
system, that is, the height of the highest point of the system
above the expansion vessel.
The water content of the boiler is given in Data Table 1.
3.12 Pressure Gauge
A pressure gauge with a set pointer and covering at least the
range 0 to 4bar (0 to 60lb/in2) shall be permanently fitted to the
system in a position where it can be seen when filling the
system.
22 X 28
UNION
CONNECTION

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11 221974A
METHOD 1
METHOD 2
METHOD 3
SUPPLY STOP
VALVE
SUPPLY
PIPE
HOSE
UNIONS SERVICING
VALVE
TEMPORARY
HOSE
HEATING
SYSTEM
HEATING
SYSTEM
TEMPORARY
HOSE
HOSE
UNIONS SERVICING
VALVE
SUPPLY
PIPE
SUPPLY STOP
VALVE
DOUBLE CHECK
VALVE ASSEMBLY
HEATING
SYSTEM
SERVICING
VALVE
SUPPLY
STOP VALVE
SUPPLY
PIPE
HOSE
UNIONS DOUBLE CHECK
VALVE ASSEMBLY
OVERFLOW
CISTERN
COMBINED
CHECK VALVE
AND VACUUM
BREAKER
PRESSURE
REDUCING
VALVE
0051M
Diagram 3.4
3 LITRES (0.66 gals)
MAKE-UP BOTTLE
(if required)
NON-RETURN
VALVE
AUTO
AIR
VENT
FLOW
DRAIN
COCK
BOILER
SAFETY
VALVE
(Make-up
alternatives) EXPANSION
VESSEL
PRESSURE
GAUGE
CIRCULATING
PUMP
FILLING POINT
AIR
RELEASE
POINT
HEATING CIRCUIT
IF REQUIRED
22mm (min)
BY-PASS WITH
LOCKSHIELD
VALVE
RETURN
9159
3Water Systems
Diagram 3.5
3.13 Domestic Hot Water Cylinder
SINGLEFEEDINDIRECTCYLINDERSARENOTSUITABLE.
Thedomestichotwatercylindermustbeoftheindirectcoiltype.
It must be suitable for working at a gauge pressure of 0.35bar
above the safety valve setting.
3.14 Domestic Hot Water System - Unvented
Wherea storage system willnothavea vent to atmospherethe
installation must comply with Building Regulations and local
WaterCompanyBye-laws,seealsothecurrentissueofBS6700.
If fitting into an existing system the local authority must also be
advised.
3.15 Filling a Sealed Water System
Provisionforfillingthesystematlowlevelmustbemade. Three
methodsareshownindiagram3.5. Theremustbenopermanent
connection to the mains water supply, even through a non-
return valve.
3.16 Water Makeup
Provision must be made for replacing water lost from the
system. A make up vessel mounted above the highest point of
the system and connected through a non-return valve to the
system on the return side of either the hot water cylinder or
heating system, see diagram 3.4.
Alternativelyprovisionformakeupcanbemadebyafillingloop.

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221974A
Diagram 4.1
4 Flue and Appliance Preparation
REAR FLUE
SIDE FLUE
15mm
Note: Outer casing, mounting brackets & boiler details removed for clarity
Note: 1 metre extension kits can be joined together, but the total flue system must not exceed 3 metres.
Note: Outer casing, mounting brackets & boiler details removed for clarity
SCREW
& TAPE
9370
FLUE LENGTH
MAX 570mm (std) FLUE LENGTH
MAX 570mm (std)
15mm
SCREW
& TAPE
STANDARD FLUE PACK
'X'
SIDE FLUE
SCREW
& TAPE
STANDARD FLUE PACK & 1 METRE EXTENSION KIT
FLUE LENGTH
Total must not excede 3m MAX.
15mm
SCREW
& TAPE
'X'
'Y'
31mm
STANDARD
REAR
SIDE R.H.
SIDE L.H.
MINIMUM
WALL
THICKNESS
MINIMUM
FLUE
LENGTH
MAXIMUM
FLUE
LENGTH
"Y"
BOILER MOUNTING FACE
TO EXTERNALWALL FACE
"X"
BOILER CASINGTO
EXTERNALWALL FACE
MAXIMUM DISTANCE FROM
128
93
273
527
-
-
-
555
372
75
75
75
570
570
570
-
-- - 2988 2808
75
75 3000 3000
FLUE
PACKS
NOTE :
FLUE & AIR DUCT CUTTING
THE DUCTS WILL REQUIRE CUTTING FOR FLUE LENGTHS LESSTHAN 280mm.
THE DUCTS CAN BE CUT FLUSH BUT MUST HAVE AN OVERLAP OF 50mm.
STANDARD
SIDE R.H.
SIDE L.H.
PLUS 1 METRE
EXTENSION KITS

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13 221974A
NOTE:Makesurethattheductingsdonotslopedowntowards
the boiler.
4.1 Flue Position and Length
Determine flue application, length and terminal position before
starting.
Refer to diagram 4.1.
4.2 Flue Preparation
All flue assemblies are designed for internal installation, given
that there is sufficient clearances opposite to the flue for the
installation of the flue.
If there is insufficient clearance the flue can be installed from
outside.
For a wall thickness of over 300mm the external flue hole will
need to be made good from the outside.
4.3 Top and Side Flue Application
Select the boiler location and flue application, with due regard
to the terminal position, see diagram 2.1.
Takethetemplatefromtheboilerpackandtemporarilyposition
it on the wall, making sure that the minimum clearances are
maintained, see diagram 4.2.
Mark the centre line position of the flue, as diagram 4.2.
For a side flue, extend centre line of flue to L.H. or R.H. corner.
Mark the position of the centre of the flue and boiler, as
diagram 4.2.
4.4 Flue Hole Cutting
Having marked out the flue centre cut a hole for the flue using,
preferably, a 115mm minimum core drill.
4.5 Wall Mounting Bracket
Repositionthetemplate,makingsureofdimensionalalignment
with the flue hole.
Marktheboilerfixingpointsandmountingbracketposition,see
diagram 4.3.
Drill holes and plug, to suit No. 12x2in wood screws, fit the
screwsallowingsufficientclearance,about5mm,toallowboiler
to be hung.
Secure the mounting bracket to the wall with two No.12x2in
wood screws and plugs, see diagram 4.3.
4.6 Flue Duct
Extend the telescopic flue to the required length, making sure
thattheminimumoverlapisnolessthan25mm,andthattheflue
terminalprojects15mmminmumbeyondwallface,seediagram
4.1.
Carefully drill though air duct pilot hole and secure with self
tapping screw provided in fittings pack, see diagram 4.1.
Seal the joint with the tape provided.
Iftheboilerisnottobe fitted for some time cover the hole in the
wall.
4.7 Top, Side Flue Fixing
Make sure that the ductings do not slope down towards the
boiler.
Make good the area around the flue inside and outside after
installation of the boiler.
4 Flue and Appliance Preparation
SIDE FLUE
145mm
115mm
MINIMUM
HOLE BOILER
CENTRE LINE
FLUE
CENTRE LINE
90mm
TOP BOILER
MOUNTING
POINT
BOTTOM BRACKET
MOUNTING POINT
Diagram 4.2
9288
Diagram 4.3
9210
FLUE
CENTRE LINE
BOILER
MOUNTING
BRACKET
BOILER
CENTRE LINE
5mm

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14
221974A
4 Flue and Appliance Preparation
4.8 Easi-Vent Vertical Flue Terminal
General
Thekits shown in diagram 4.4, enablethe Protherm to be fitted
with the flue configurations shown in diagram 4.6.
For other accessories, see diagram 4.5.
Only proprietary parts supplied by Hepworth Heating Ltd.
should be used.
4.9 Accessories
Ceiling Collar - Part No. 208590
Used if required as a ceiling trim immediately below the ceiling
to make a neat installation.
Fixings are required to hold ceiling collar in position.
FITTINGS PACK
AIR DUCT
FLUE DUCT
FITTINGS
PACK
TOP FLUE
TRANSITION DUCT
TERMINAL ASSEMBLY
AIR/FLUE
DUCT ASSEMBLY
FLUE SPIGOT
EASI-VENT
ADAPTOR
RING
TAPE (FITTINGS
PACK SUPPLIED
WITH BOILER)
4 SCREWS
(FITTINGS PACK
SUPPLIED WITH
BOILER)
45oFLUE BEND KIT Pt No. 230485
VERTICAL FLUE PACK Pt No. 458115
1M EXTENSION KIT Pt No. 230484
7527
90o FLUE BEND KIT Pt No. 230486
7529
7528
FITTINGS PACK
FITTINGS PACK
(DISCARD)
Diagram 4.4
Support Assembly - Part No. 208591
Manufactured in galvanised steel and incorporates a fire stop
platewithfittedspacerlugsandsupportcollar. Thisitemshould
be used to support the flue at the top of each floor joist and
provide a fire stop feature. Spacer lugs fitted to the underside
oftheplateensuresthataclearanceismaintainedbetweenthe
inner liner of the flue and any combustible materials. The
supportcollarwhichissituatedonthetopoftheplateshouldbe
securely fixed around the flue by tightening the nut and bolt
fasteners provided. The plate should be nailed or screwed to
the ceiling joists.
Fire Stop Plate - Part No. 208592
Manufactured in galvanised steel and fitted with spacer lugs
whichensure that a clearance is maintained between the inner
liner of the flue and any combustible materials. The fire stop
plate should be fitted to the underside of the ceiling joists by
sliding over the flue and nailed or screwed to the joists. This
item can act as a dust plate and should be used when the flue
systempassesthroughnoncombustiblefloorssuchasconcrete.

Supplied By www.heating spares.co Tel. [phone]
15 221974A
4 Flue and Appliance Preparation
FIRESTOP PLATE
(Pt.No.208592)
ADJUSTABLE WALL BAND
(Pt.No.208594)
CEILING COLLAR
(Pt.No.208590)
CEILING PLATE
(Pt.No.208593)
SUPPORT ASSEMBLY
(Pt.No.208591)
7122
Diagram 4.5
Ceiling Plate - Two Piece - Part No. 208593
Manufactured in galvanised steel and should be used on the
undersideof 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.
Adjustable Wall Band - Part No. 208594
The wall bracket is supplied in two parts - an aluminium band
whichfitstightlyaroundthe outsideof theflue anda galvanised
“T”bracketwhichissecuredtoawallorbatten. Thisitemisused
where the flue is positioned up to 280mm from a wall or point.
4.10 Flue Terminal Position
Caution
If the flue is to pass through or near combustible material it
shouldbefittedinaccordancewith thecurrent issueofBS5440
Part 1, which requires a minimum clearance of 25mm from the
flue duct.
The minimum clearance from the air duct is 5mm.
The terminal should be positioned so as to cause the least
problem with the dispersal of the products of combustion and
any “pluming” that can occur.
Iftheterminalisfittedlessthan500mmbelowplasticguttersor
less than 500mm below painted eaves or any other painted
surfacethenanaluminiumshieldatleast1metrelongshouldbe
fitted immediately beneath the guttering or eaves.
Minimum distances for flue to walls and roof positions are
shown in diagram 4.6.
Failure to comply with these instructions could result in a
potentially dangerous installation and loss of boiler efficiency.
General guidance only can be found in the current issue of
BS5440 Part 1.
If in doubt consult Heatcall.
;
;
y
y
;;yy
;
;
y
y
;y
PITCHED ROOF WITH STRUCTURE
5712
Diagram 4.6
300mm
350mm
MINIMUM DIMENSIONS
FLAT ROOF INTERNAL CORNER
400mm
300mm
300mm

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221974A
4 Flue and Appliance Preparation
4.11 Installation
Warning
In the interests of safety and performance, it is essential that the
vertical flue system is fitted in strict accordancewith these
instructions.
Installation Details
With due consideration to flue terminal position, choose the flue
application required, shown in diagram 4.7.
The use of weather and storm collars is preferred and can be
bought locally.
The suggested flashings are :-
RiteVent or Selkirk along with their appropriate storm collar if
required.
Flue Installation and Terminal Assembly
Measure then cut the selected flue arrangement as required
ensuring an overlap of 25mm AIR DUCT and 50mm FLUE
DUCT.
Make sure that all flue pipes, joints and bends are properly
secured and tight, see diagram 4.9 for details.
Fit the split/spacing ring supplied in kit, inside the flue terminal.
Locateflueterminalinpositionontopofflueduct.Drillandsecure
with 2 no. 8 x 3/8in. self-tapping screws, see diagram 4.10.
ROOF TERMINAL PITCHED ROOF (Slate orTile)
ROOF TERMINAL FLAT ROOF
5711
VERTICAL
FLUE
TERMINAL
KIT
VERTICAL
FLUE
TERMINAL
KIT
WEATHER
COLLAR
WEATHER
COLLAR
Diagram 4.8
STORM
COLLAR
STORM
COLLAR
3m
VERTICAL FLUE KIT 458115
"X" MAX. FLUE LENGTH
X + Y + Z = THE MAXIMUM STRAIGHT "FLUE LENGTH" DOES NOT INCLUDE THE ELBOWS.
Diagram 4.7
"X"
HORIZONTAL and VERTICAL FLUE
VERTICAL FLUE KIT 458115
1M EXTENSION KIT 230484 (as reqd.)
FLUE BEND KIT 90°230486 (2 reqd.)
"X"
C
L
FLUE
L
CBOILER
"Z"
MAX
1m
"Y"
DIAGONAL and VERTICAL FLUE
90
X+Y+Z MAX. FLUE LENGTH X+Y+Z MAX. FLUE LENGTH
1.5m 2.0m
VERTICAL FLUE KIT 458115
1M EXTENSION KIT 230484 (as reqd.)
FLUE BEND KIT 45°230485 (2 reqd.)
"X"
"Z"
"X" MIN. FLUE LENGTH MINIMUM
FLUE
LENGTH
500mm X60mm A 500mm YZERO B RH 192mm
Z500mm / LH 15mm
FRONT VIEW
FRONT VIEW FRONT VIEW
1M EXTENSION KIT 230484 (as reqd.)
MINIMUM
INSTALLATION
CLEARANCE
X60mm A 500mm
YZERO B RH 58mm
Z500mm / LH N/A
VERTICAL FLUE
9551
NOTE: An Inline Adaptor Pt. No. 230488 with a flue length of 100mm can be used.
MINIMUM
INSTALLATION
CLEARANCE
MINIMUM
FLUE
LENGTH
"B"
"A" "A"
"Y"
RH 192
LH 15

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4 Flue and Appliance Preparation
STEP 1
STEP 2
STEP 4
STEP 3
Diagram 4.9
Push flue duct & air duct
into flue spigot and lock into
position by turning clockwise.
STEP 6
STEP 5
Slide flue duct & air duct
together, mark, drill, screw
and seal with tape
provided.
Push flue bend (45oor 90o)
onto flue duct or boiler end
standard flue, drill and screw
then seal with tape provided.
Push flue duct & air duct
onto flue bend (45oor 90o),
drill and screw then seal
with tape provided.
Push flue bend (45oor 90o)
onto flue duct & air duct, drill
and screw then seal with tape
provided.
FLUE BEND
(90˚ or 45˚)
SECURING
SCREW (2)
SECURING
SCREW (2)
Push flue duct
& air duct
onto flue bend
(45oor 90o),
drill and screw
then seal with
tape provided.
SECURING
SCREW (2)
FLUE BEND
(90˚ or 45˚)
SECURING
SCREW (4)
AIR/FLUE DUCT
ASSEMBLY
7382
FLUE DUCT SPIGOT
Secure to boiler with screws provided
in the boiler fittings pack. No. 8 x 3/8in.
3mm
TOP FLUE
TRANSITION DUCT
(DISCARD)
Diagram 4.10
FLUE
DUCT
No. 8 x 3/8in.
3mm
AIR
DUCT
TERMINAL
EASI-VENT
ADAPTOR
RING
7390
4416
Pitched and Flat Roof
Fit Weather and Storm Collar onto air duct/terminal assembly,
see diagram 4.8.
Makesurethe weathercollariscorrectlypositionedandsealed
for the roof type.
Fit the flue adaptor into flue terminal and connect to air duct.
After the flue terminal is fitted, fit an appropiate wall band.
Makesurethataweatherproofsealismadeinaccordancewith
good building practice.

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221974A
5 Boiler Installation
Diagram 5.1
CONTROLS
COVER
FRONT
COVER
SHAKEPROOF
WASHER
9202
NUT
5.1 Boiler Preparation
Open the carton, check the items supplied against the boiler
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.
Place controls cover and front cover to one side until required.
Fitsuitable compression fittings to therequiredtappingson the
boiler.
Disconnect the air pressure tubes, see diagram 8.1.
Remove the blue and red electrical connections from the fan,
see diagram 8.1.
Remove the front right hand flue hood securing screw and
slacken off the front left hand one, see diagram 8.3.
Remove fan and flue hood assembly from boiler by drawing
assembly forward, place to one side until required.
5.2 Mounting the boiler
Lift the boiler into position ensuring first that the bottom of the
boiler is hooked on to the boiler mounting bracket and then
engagethe two keyhole slots, located ontopoftheboiler, on to
the securing screws. Tighten the two securing screws, see
diagram 5.2
Note: Installations where the flue exits to the left of the boiler,
complete the water connections to the boiler before fitting the
flue.
From the fittings pack, place top turret gasket in position on
boiler flue opening, see diagram 5.3
Takingcarenottodamagethegasket,securethetopturretwith
flue assembly to the boiler with four self-tap screws, see
diagram 5.3.
From the fittings pack, fit flue duct extension assembly into the
top turret flue ducting and loosely fit jubilee clip on elbow of the
flue duct extension, see diagram 5.4.
Refitfanandfluehoodassembly,ensuringthatthefluehoodfits
in the flue hood retaining clamps and engage the fan into the
elbow of flue duct extension, see diagram 8.3
Tightenup lefthandfluehood securingscrew,replacethe right
hand one and tighten, see diagram 8.3.
Secure fan to elbow of flue duct extension by tightening up
jubilee clip, see diagram 5.4.
WING
NUT
9270

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19 221974A
5 Boiler Installation
Diagram 5.2
SECURING
SCREWS (2)
5.3 Water Circulation System
Complete the water connections to the boiler.
Fill, vent and flush the system.
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
outside the building so that any discharge can be seen but will
notcauseinjurytopersons,damagetopropertyoranyelectrical
installation.
5.5 Gas Connection
Make the gas connection to the Rc1/2in gas service cock, see
diagram 6.1.
Check for leaks using a suitable leak detection fluid.
5.6 Control Box Removal
Removetheelectricalcontrolboxsecuringscrews,seediagram
5.5. Slide the box forwards and release, hook it onto the lip
bracket at the front, see diagram 5.5.
Diagram 5.4
TOP TURRET
FLUE DUCTING
9139
Diagram 5.3
TOP
TURRET
9203
GASKET
SCREWS
(4)
TOP TURRET
FLUE OUTLET
FLUE
DUCT
EXTENSION
FLUE DUCT
EXTENSION
5mm
BOILER
MOUNTING
BRACKET
9283
JUBILEE
CLIP

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20
221974A
Diagram 5.6
3310
Make sure that the supply cable and all external cables are
secured and away from hot surfaces.
5.10 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. Test the polarity of the mains.
The installer is requested to advise and give guidance to the
user on the controls scheme used with the boiler.
Remove red link between 9 & SL when fitting
a time control etc (if no switch is fitted, link will
make the circulation pump run constantly).
IGNITION
LEAD
PUMP
CABLE
CABLE
CLAMPS
MAINS
CABLE
5 Boiler Installation
5.7 Electrical Connection
WARNING. This boiler must be earthed.
Take care not to damage any internal wiring and capillaries.
Takeplasticcableretainingclip,fromthelooseitemspack,peel
offthebackingpaperandpositionitinasuitableplacetosecure
the incoming cable.
Using heat resistant (to 85oC) cable of at least 0.75mm2(24/
0.2mm)tothecurrentissueofBS6500 Table16 andof suitable
length, thread through cable clamps, secure into the plastic
clipsandconnecttoappropriateterminals,seediagram5.6and
9.5.
Standard colours are, brown - live (L), blue - neutral (N) and
green and yellow - earth (E).
The mains cable outer insulation must not be cut back external
to the cable clamp.
Make sure the cable is suitably secured.
Whenmakingconnections,makesurethattheearthconductor
ismadeofagreaterlengththanthecurrentcarryingconductors,
so that if the cable is strained the earth conductor would be the
last to become disconnected.
5.8 Pump Connection
The pump must be connected directly to the control box, as
shown in diagram 5.6 threading the cable through the cable
clamp in the side of the control box.
5.9 External Controls
Anyexternalcontrolsmustonlybewiredtointerrupttheredlink
between terminals SL and 9.
9368
FIXING SCREWS
LIP BRACKET
4620
Diagram 5.5