Protherm 80E Manual

THIS IS A CAT II2H3+ APPLIANCE
USER, INSTALLATION, AND
SERVICING INSTRUCTIONS
Wall hung combination boiler
PROTHERM 80E
Technical Advice & After Sales Service
01773 828100
4723

1
Protherm 80E
Users’ Instructions
Introduction ............................................................................................................................ 2
Controls and lighting .............................................................................................................. 2
Draining and filling .................................................................................................................. 4
Heating safety valve .............................................................................................................. 4
Servicing/maintenance ........................................................................................................... 4
Cleaning ................................................................................................................................. 4
Boiler casing .......................................................................................................................... 4
Installation Instructions
Introduction ............................................................................................................................ 5
Technical data ........................................................................................................................ 6
Dimensions ............................................................................................................................ 7
Pressure available ................................................................................................................. 7
Boiler schematic .................................................................................................................... 8
Installation section ................................................................................................................. 9
Terminal positions .................................................................................................................. 9
Heating and hot water system design .................................................................................. 10
Boiler installation ................................................................................................................ 11
Boiler template ..................................................................................................................... 12
Telescopic horizontal flue installation ................................................................................... 13
Classic horizontal flue installation ........................................................................................ 15
Vertical flue installation ........................................................................................................ 16
Flue configurations............................................................................................................... 17
Electrical connection ............................................................................................................ 18
Commissioning .................................................................................................................... 19
Servicing Instructions
Routine cleaning and inspection ........................................................................................... 21
Replacement of parts........................................................................................................... 22
Schematic wiring diagram .................................................................................................... 25
Fault finding ......................................................................................................................... 26
Conversion to LPG...............................................................................................................28
Mandatory warning for CE countries
WARNING, these appliances were designed, approved and inspected to meet the
requirements of the English market.The identification plate located on the inside of the
appliance certifies the origin where the product was manufactured and the country
for which it is intended.
If you see any exception to this rule, please contact your nearest stockist.
Thank you in advance for your assistance.
Note: The boiler serial number is marked on the data label attached to the fascia behind the front panel. Refer
to the ‘Introduction’ section for a description of the basic functions of the boiler. The ‘User’ section describes
how to safely operate the boiler.

2
Diagram 1
USERS INSTRUCTIONS
The Protherm 80E is a wall mounted combination boiler providing central heating and instantaneous domestic hot
water.
These instructions should be carefully followed for the safe and economical use of your boiler.
Gas leak or fault
If a gas leak or fault exists or is suspected, turn the boiler and gas supply off and consult the local gas company
or your Installer/Service provider.
In case of power supply failure
The boiler no longer operates.
As soon as power supply is restored, the boiler will restart automatically.
In case of loss of water in the system
CAUTION: The boiler is installed as part of a sealed system which must only be drained and filled by a competent
person.
If the pressure LED diod (2) flashes the pressure in CH system is less than 0.8 bar and the system must be filled
up immediately.
Important notice: A central heating system cannot operate satisfactorily unless it is properly filled with water and
unless the air initially contained in the piping systems has been properly bled off. If these conditions are not
satisfied, air noise will occur within the system and the boiler may fail to operate.
Air in the heating system
Persistent air in the heating system may indicate leaks in the system or corrosion taking place. Call your Installer
/Service provider.
Overheating safety
In the event of problem, the overheat safety device causes safety shutdown of the boiler. If this happens, call
your Installer/Service provider.
CONTROLS AND LIGHTING
The control panel is located at the lower front of the boiler casing.The controls on this panel allow the boiler to be
started, shut down, controlled and monitored during use, see diagram 1.
Controls:
1 – mains on/off switch 7 – pressure button
2 – system pressure LED 8 – reset button
3 – central heating LED 9 – decrease button
4 – domestic hot water LED 10 – mode button
5 – timeclock 11 – display
6 – increase button

3
The following information is displayed:
• Actual heating temperature (°C) - LED (3) lights on
displayed during standby
• Actual domestic hot water temperature (°C) - LED (4) lights
displayed during hot water demand
• System pressure (bar) – LED (2) lights
for 25 sec after Bar button is pressed
• Diagnostic messages – displayed letter F and numbers from 0 to 4
Make sure that:
• The boiler is connected to the electrical supply.
• The boiler gas service cock is open.
• The CH system is filled up and pressurized between 1 and 2 bar.
The boiler is now ready to start.
To start the boiler
Switch on the mains switch (display will light up). The version of the software used is displayed for 2 sec.
To stop the boiler
Switch off the mains switch (display will go out).
If the boiler is to be out of operation for a long period, turn off the gas service cock.
Boiler setting
All parameters are adjustable by means of 3 buttons, pushing the RESET button
restarts the boiler.
Note: Buttons must be pressed in the middle.
Domestic hot water setting
• Press Mode button until LEDs (4) flash.
• Using buttons (6) and (9) set the desired hot water temperature.
Setting steps: 40, 42, 45, 48, 50, 52, 55, 58, 60 °C
• Set ´– –´ if hot water is not required.
• Press Mode button to save new setting.
Heating setting / summer mode setting
• Press Mode button until LED (3) flashes.
• Using buttons (6) and (9) set the desired heating temperature.
Setting steps: 45, 50, 55, 60, 65, 70, 75, 80, 85 °C
• Set ´– –´ if only hot water is required (summer mode).
• Press Mode button to save new setting.
The heating will operate according to the requirements of the timeclock and/or room
thermostat if fitted or, will operate according to the system requirements. Domestic
hot water (DHW) always has priority over central heating (CH).
Note: All new settings are stored by pressing MODE button. If MODE button is not
pressed for 20 sec the display reverts to standby mode and old settings are
retained.
Helpfull hint
If you get confused and wish to start again, switch boiler off, press and hold button (9) and switch boiler on by
main switch. The boiler will revert to the internal factory set programme (heating temperature 80 °C, hot water
temperature 50 °C, maximum heat output).

4
Timeclock
The boiler can be switched on and off automatically by the built-in timeclock. To set the timeclock, proceed as
follows: (refering to diagram 1).
Press in the tappets corresponding to the time you want the boiler to be on.
For example if you want the boiler to be on between 7 AM and 9 AM, push in all the tappets between 7 and 9.
Set the times you want the boiler to be on for the rest of the day in the same way.
Note: The timeclock setting is in 24 hour format. Therefore, if you want the boiler to come on at 2 PM you must
push in the tappets at 14.
To set the correct time rotate the clock by hand until the current time is indicated by the arrow at the top of the
clock.
To operate the boiler according to your selected times, place the grey lever to the position.
To have the boiler permanently ‘ON’, place the grey lever to the ‘I’ position.
To have the boiler permanently ‘OFF’, place the grey lever to the ‘0’ position.
Safety lockout
In the event of a safety lockout, the digital display will show ‘F1’.
Reset boiler by pressing the RESET button.
IMPORTANT: If safety lockout occurs frequently, or if any other fault is indicated, contact your Installer/Service
Provider.
DRAINING AND FILLING
CAUTION: The boiler is installed as part of a sealed system which must only be drained and filled by a competent
person.
If the pressure drops to 0.8 bar the pressure LED on the Bar button starts to flash.The boiler will continue to work,
but the LED warns that pressure in the CH system is on the low limit and CH system must be filled. To fill the
system, open the tap on the filling loop below the boiler. Press the Bar button to read the system pressure.When
the pressure is between 1 and 2 bar, close the tap.
Note: If there is persistent loss of system pressure, you must consult your Installer/Service Provider.
HEATING SAFETY VALVE
CAUTION: A safety valve with a discharge pipe is fitted to this boiler.
The valve MUST NOT BE TOUCHED except by a competent person. If the valve discharges at any time, switch
the boiler off and isolate it from the electrical supply. Contact your Installer/Service Provider.
SERVICING / MAINTENANCE
To ensure the continued efficient and safe operation of the boiler, it is recommended that it is checked and
serviced at regular intervals.The frequency of servicing will depend upon the installation conditions and usage
but, in general, once a year should be enough.
CLEANING
The boiler casing can be cleaned with a damp cloth followed by a dry cloth to polish.
Do not use abrasive or solvent cleaners.
BOILER CASING
CAUTION: Do not remove or adjust the casing in any way, as incorrect fitting may result in faulty operation.
If in doubt, contact your Installer/Service Provider.

5
INSTALLATION INSTRUCTIONS
INTRODUCTION
The Protherm 80E is a wall mounted combination boiler providing central heating and instantaneous domestic hot
water.
The boiler is of the II2H3+ category for use with Natural gas (G20) as distributed in the United Kingdom, or with Butane
or Propane gas (G30/G31) with the appropriate conversion kit.
Conversion kit:
Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . Part No.
Natural gas (G20) to G30/G31 . . . . . . . . . . . 99800933
Modification must only be carried out by a suitably qualified engineer.
Boilers burning LPG or similar gases MUST NOT be fitted in basements or below ground level.
These instructions should be carefully followed for the safe and economical use of your boiler.
The boiler has a fan assisted, balanced, flue which both discharges the product of combustion to, and draws the
combustion air from the outside of the building.
Accessories
A range of accessories are available including, vertical flue components. For further information, contact you near-
est stockist.
Gas Safety (Installation and Use) Regulations
In the interests and that of gas safety, it is the law that ALL gas appliances are installed and serviced in by
a competent person in accordance with the above regulations.
Gas leak or fault
If a gas leak or fault exists or is suspected, turn the boiler and gas supply off and consult the local gas company or
your Installer/Service Provider.
Boiler controls
The control panel, located at the lower front of the boiler, allows the boiler to be started, shut down, controlled and
monitored during use, refer to ‘Users Instructions’.

6
TECHNICAL DATA
CE Certification .............................................. n° ............................................................ 0063BL3573
Class .......................................................................................................................................... II2H3+
Type ........................................................................................................................................ C12, C32
Gas type ....................................................................................... G20...............G30 ................. G31
Max. / min. heat input .................................... kW ..................... 25.8/11.4.......25.8/11.4 ..... 25.8/11.4
Max. / min. heat output ................................. kW ...................... 23.0/9.4 ....... 23.0/9.4 ........23.0/9.4
EFFICIENCY (PCI)
Nominal efficiency .......................................... % ........................................................................... 81
Efficiency at 30% load .................................... % ........................................................................... 76
HEATING
Temperature range ......................................... °C .................................................................... 45 – 85
Expansion vessel ............................................. l ............................................................................. 5
Expansion vessel pressure ........................... bar ............................................................................. 1
Max. working pressure .................................. bar ............................................................................. 3
Max. system temperature .............................. °C ........................................................................... 85
Max. system capacity ....................................... l ........................................................................... 70
HOTWATER
Flow rate at 30°C temperature rise .............. l/min ........................................................................ 11.2
Flow rate at 35°C temperature rise .............. l/min .......................................................................... 9.6
Min. water flow ............................................ l/min ............................................................................. 2
Max. / min. supply pressure .......................... bar ........................................................................ 6 / 1
Temperature range ......................................... °C .................................................................... 40 – 60
ELECTRICAL DATA
Voltage / frequency .................................... V/Hz ................................................................ ~230 / 50
Current ............................................................. A .......................................................................... 0.6
Power .............................................................. W ..........................................................................135
Level of protection .......................................... IP ....................................................................... IP 44
DIMENSIONS
Width / height / depth ................................... mm ....................................................... 410 / 740 / 320
Weight ........................................................... kg ........................................................................... 35
CONNECTIONS
Heating flow / return ..................................... mm ........................................................................... 22
Domestic water inlet / outlet ......................... mm ........................................................................... 15
Gas .............................................................. mm ........................................................................... 22
Flue products outlet / air inlet ∅ ..................... mm ....................................... horiz. 60/100, vert. 80/125
Horizontal flue length min. – max. ................... m .................................................................... 0.3 – 4
Vertical flue length min. – max. ....................... m .................................................................... 0.5 – 9
GAS SUPPLY PRESSURE
Burner pressure ......................................... mbar ............ 3 – 15.7 ........... 5.3 – 27.5 .............7 – 35.6
Nominal pressure ....................................... mbar .................20 ..................... 29 ........................... 37
Injectors diameter .................................... ∅mm ............... 1.07 .................. 0.68 ...................... 0.68
GAS CONSUMPTION
Q max / Q min ............................................ m3/h ............ 2.7 / 1.2 ......... 1.9 / 0.9 kg/h... 1.9 / 0.8 kg/h
Air flow ........................................................ m3/h ................ 100 ................... 100 ......................... 100

7
Diagram 2
Diagram 3
1 – Heating flow (pipe diameter 22 mm)
2 – Hot water outlet (pipe diameter 15 mm)
3 – Gas inlet (pipe diameter 22 mm)
4 – Cold water mains inlet (pipe diameter 15 mm)
5 – Heating return (pipe diameter 22 mm)
6 – Wall
7 – Wall fixings
8 – Outer cover
DIMENSIONS AND PRESSURE AVAILABLE

8
Diagram 4
BOILER SCHEMATIC
1 – Air pressure switch
2 – Fan
3 – Heat exchanger
4 – Burner
5 – Gas valve
6 – Expansion vessel
7 – Pump
8 – Water flow sensor
9 – Pressure gauge connection
10 – By-pass pipe
11 – Safety valve
12 – Heating return
13 – Domestic cold water inlet
14 – Gas inlet
15 – DHW thermistor
16 – DHW outlet
17 – Automatic by-pass
18 – Heating flow
19 – Drain
20 – Microswitch
21 – Loss of water pressure switch
22 – 3-way valve
23 – Differential valve
24 – Microswitch
25 – Secondary heat exchanger
26 – CH temperature sensor
27 – High limit thermostat

9
INSTALLATION SECTION
Clearances
To allow for servicing, the boiler should be installed with the following clearances:
50 mm either side of the boiler
600 mm to the front of the boiler
300 mm below the boiler
200 mm above the boiler
TERMINAL POSITION
The minimum acceptable spacings from the terminal to obstructions and ventilation openings are shown in dia-
gram 5 below:
Diagram 5
Minimum dimensions (in mm) for the positioning of flue terminals
a Under a window . . . . . . . . . . . . . . . . . . . . . . . . . 300
b Under an air vent . . . . . . . . . . . . . . . . . . . . . . . 300
c Under a gutter . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
d Under a balcony . . . . . . . . . . . . . . . . . . . . . . . . 300
e From an adjacent window . . . . . . . . . . . . . . . . . 300
f From an adjacent air vent . . . . . . . . . . . . . . . . . 300
g From vertical drain pipes or soil pipes . . . . . . . . . 75
h From an external corner of the building . . . . . . . 300
i From an internal corner of the building. . . . . . . . 300
l From the ground or from another floor . . . . . . . . 300
m Between two terminals vertically . . . . . . . . . . . 1500
n Between two terminals horizontally . . . . . . . . . . 300

10
HEATING SYSTEM DESIGN
The Protherm 80E is compatible with any type of sealed system installation, i.e. radiators, fan convectors etc.
Pipe sectional areas shall be determined in accordance with normal practices, using the pump curve, refer to
‘Technical Data’. The distribution system shall be calculated in accordance with the output requirements of the
actual system, not the maximum output of the boiler. However, provision shall be made to ensure sufficient flow so
that the temperature difference between the flow and return pipes is less than or equal to 20 °C.The minimum flow
is 500 l/h.
The piping system shall be routed so as to avoid any air pockets and facilitate permanent venting of the installation.
Bleed fittings shall be provided at every high point of the system and on all radiators.
The total volume of water permitted for the heating system depends, amongst other things, on the static head in the
cold condition. The expansion vessel on the boiler is pressurised at 1 bar (corresponding to a static head of 10 m
wg.) and allows a maximum system volume of 100 litres for an average temperature of 75 °C and a maximum
service pressure of 3 bar. This pressure setting can be modified at commissioning stage if the static head differs.
Provision shall be made for a drain valve at the lowest point of the system.
Thermostatic radiator valves are permitted, however, not all radiators must be fitted with this type of valve and
particularly where the room thermostat is fitted.
In all cases, it is ESSENTIAL that the system be thoroughly flushed prior to installing the new boiler.
Domestic hot water system design
Copper tubing or plastic Hep2O may be used for the domestic hot water system. Unnecessary pressure losses
should be avoided. The domestic hot water supply pressure must be between 1 and 6 bar. If the pressure exceeds
6 bar, a pressure reducing valve must be fitted. In known hard water areas, it is recommended that a suitable scale
reducing device is fitted to the cold water supply to the boiler.
Diagram 6
Boiler connections
AHeating flow
BHot water outlet
CGas connection
DCold water mains inlet
EHeating return
FSafety valve discharge connection
Heating system connections
- Pipe diameter 22 mm.
Hot water system connections
- Pipe diameter 15 mm.
Gas connection
- Pipe diameter 22 mm.
Safety valve discharge connection
- Pipe diameter 22 mm.
Note: White colored washers must be used for the hot water system connections.

11
Safety valve discharge
WARNING: It must not discharge above an entrance or window or any type of public access area.
Connect the safety valve discharge pipe to the valve, the discharge must be extended using not less than 15 mm
o.d. pipe, to discharge in a visible position outside the building, facing downward, preferably over a drain.The pipe
must have a continuous fall and be routed to a position so that any discharge of water, possibly boiling or steam,
cannot create any danger to persons, damage to property or external electrical components and wiring.Tighten all
pipe connection joints.
Gas connection
The supply from the governed meter must be of adequate size to provide a constant inlet working pressure of 20
mbar for Natural gas (28 – 30 mbar for Butane or 37 mbar for Propane).
To avoid low pressure problems, it is recommended that the supply is taken to the boiler using 22 mm pipe as far
as possible.
On completion, the gas installation must be tested using the pressure drop method and purged in accordance with
the current issue of BS6891.
Gas Safety (Installation and Use) Regulations
In your interests and that of gas safety, it is the law that ALL gas appliances are installed and serviced by
a competent person in accordance with the above regulations.
Statutory requirements
The installation of this boiler must be carried out by a competent person in accordance with the relevant require-
ments of the current issue of:
The Gas Safety (Installation and Use) Regulations
The Building Regulations
The local water company Bylaws
The Building Standards Regulations (Scotland)
The Health and Safety at Work Act
Sheet metal parts
WARNING: When installing or servicing this boiler, care should be taken when handling the edges of sheet metal
parts to avoid the possibility of personal injury.
Installing the boiler
Prior to installing the boiler, the system must be thoroughly flushed to eliminate any foreign bodies and contami-
nents such as filings, solder, particles, oil, grease etc.
Note: Solvent products could cause damage to the system.
BOILER INSTALLATION
To install the boiler, proceed as follows:
• Allowing sufficient clearances for servicing/repair, place the template on the wall (see diagram 7).
Note: The boiler can be installed only on the closed wall.
• Determine the position of the flue hole and drill hole for flue, preferably using a 120 mm core drill.
• Drill two 10 mm holes for the wallplugs supplied.
• Screw fixing screws supplied into wallplugs, leave proud by approx. 10 mm.
Note: Boiler fixing holes are keyhole type slots at the top of the boiler to allow easy hanging of boiler.
• Remove template.
• Hang the boiler on the screws and tighten screws.
Note: As a option the hanging bracket can be used.Two screws are sufficient for fixing of the hanging bracket.
Hanging bracket fixing screws have to be fully tight before the boiler is hung on.
Pipework connections
• Remove plastic caps from boiler connections.
• Connect the central heating pipework connections and isolating cocks as shown on diagram 6.
• Connect the domestic cold water inlet connection and isolating cock.
• Connect the hot water outlet connection.
• Connect the safety valve discharge pipe.
• Finally, connect the gas connection and isolating cock.

12
Diagram 7
BOILER TEMPLATE
Boiler connections
AHeating flow
BHot water outlet
CGas connection
DCold water mains inlet
E Heating return
FSafety valve discharge connection

13
TELESCOPIC HORIZONTAL FLUE INSTALLATION
Flue Systems
StandardTop Outlet Flue Pack Pt. No. 230483
1 Metre Extension Kit Pt. No. 230484
45° Flue Bend Pack Pt. No. 230485
90° Flue Bend Pack Pt. No. 230486
Flue Position and Length
• Determine flue application, length and terminal position be-
fore starting. Refer to diagram a2.
• Place spacer (K) (supplied with boiler) onto top of boiler (see
diagram 9).
• If you are using a Flue Bend, please follow the instructions
supplied with the kit.
Note: For each 90° flue bend fitted, reduce overall flue length by
1 m. For each 45° flue bend fitted, reduce overall flue length
by 1/2 m.
• To make a neat finish to the flue outlet a flue collar kit, part
No. 443286, with instructions, is available, see diagram a1.
Flue Assembly
• Extend the telescopic flue to the required length, making sure that the minimum overlap is no less than
25 mm, and that the flue terminal projects 15 mm minimum beyond wall face, see diagram a2.
• Carefully drill though air duct pilot hole and secure with self tapping screw provided in fittings pack, see diagram a2.
• Seal the joint with tape provided.
• If the flue system requires the addition of flue extension kits, drill, seal and secure them with the self tapping
screw and tape provided.
Note: Should any one of the flue sections require cutting to obtain desired flue system length, cut at the end
opposite the expanded end.
• If the boiler is not to be fitted for some time cover the hole in wall.
Top Outlet Side or Rear Flue Fixing
Make good the area around the flue inside and outside after installation of the boiler.
Flue Positioning
• Push the flue assembly into and through the hole such that it is within the wall, and does not stick out into the
room. Do not push the flue assembly too far into the hole as it has to be pulled back into the boiler and secured.

14
SKCAPEULF
MUMINIM
LLAW
SSENKCIHT
MUMINIM
EULF
HTGNEL
MUMIXAM
EULF
HTGNEL
MORFECNATSIDMUMIXAM
GNITNUOMRELIOB
LANRETXEOTECAF
"B"ECAFLLAW
OTGNISACRELIOB
LLAWLANRETXE
"A"ECAF
.DTSPOT
RAER
EDIS
57
57
061
061
075
075
584
—
—
564
.DTXEPOT
RAER
EDIS
57
57
061
061
048
048
557
—
—
537

15
CLASSIC HORIZONTAL FLUE
INSTALLATION
AAir inlet pipe
BTerminal
CSeal and clamp
DElbow
EGasket
FScrews
GExternal rubber sealing collar
IInternal plastic collar
J‘O’rings
KSpacer (see diagram 9)
•Fit gasket (E) onto underside of flue elbow (D).
•Carefully insert ‘O’ring (J) into upper and lower parts of inner elbow.
•Place spacer (K) (supplied with boiler) onto top of boiler (see diagram 9).
•Fit elbow onto spacer ensuring elbow inner connection locates correctly onto fan outlet.
•Fit external rubber sealing collar (G) onto air inlet pipe (A).
•Fit flue through hole in wall and pull up so that external collar (G) is flush against outside wall.
•Fit seal and clamp (C) to flue and assemble into elbow (D) making sure that both inner and outer pipes are
sealed properly.
Note: Maximum horizontal length with no bends is 4 m. For horizontal flue lengths up to 1 m the restrictor must
be left in the fan outlet, see diagram 9. For horizontal flue lengths between 1 and 4 m, remove the restrictor (R).
•Tighten up clamp using screws provided.
Note: Should it be necessary to cut the flue, always cut equal amounts from both inner and outer pipes.
Always cut the end furthest from the terminal.
For each 90°flue bend fitted, reduce overall flue length by 1 m.
For each 45°flue bend fitted, reduce overall flue length by 1/2 m.
Horizontal flue kit 85090
Flue extension kit 85091
90°concentric bend kit 85092
45°concentric bend kit 85093
Diagram 8
Diagram 9
Standart top
outlet flue
90°elbow
Extension
pipe
Standart top
outlet flue

16
Diagram 10
VERTICAL FLUE INSTALLATION
•Fit gasket (E) onto underside of vertical adaptor (O) –see diagram 10.
•Carefully insert ‘O’ring (J) into vertical adaptor inner spigot.
•Place spacer (K) on the top of boiler.
•Fit vertical adaptor (O) onto spacer (K) ensuring adaptor inner connection locates correctly onto fan outlet.
•For flat roof installation, fit flat roof flashing collar (part no. 85107)
•Fit extension pipes (M) as required.
•For pitch roof installation, fit pitch roof flashing (part no. 85105).
•Fit flue terminal (L) onto roof ensuring flashing makes a watertight joint.
Note: Maximum vertical height with no bends is 9 m.
Should it be necessary to cut the flue, always cut equal amounts from both inner and outer pipes.
Connect condensate trap (supplied) to vertical flue adaptor when flue length exceeds 3 m.
Connect 15 mm plastic pipe (not supplied) to a suitable drain.
For vertical flue lengths up to 4 m the restrictor must be left in the fan outlet, see diagram 9.
For vertical flue lengths between 4 and 9 m, remove the restrictor (R).
For each 90°flue bend fitted, reduce overall flue height by 1 m.
For each 45°flue bend fitted, reduce overall flue height by 1/2 m.
Vertical flue terminal (black) 85103
Vertical flue terminal (brick) 85104
Pitched roof flashing 85105
Flat roof flashing 85107
Flue extension pipe 85099
90°concentric bend kit 85101
45°concentric bend kit 85102

17
FLUE CONFIGURATIONS
Diagram 11

18
ELECTRICAL CONNECTION
Warning: This boiler must be earthed.
All system components must be of an approved type.
Connection of the whole electrical system and any heating system controls to the electrical supply must be through
a common isolator.
Isolation should preferably be by a double pole switched fuse spur box having a minimum contact separation of
3 mm on each pole.The fused spur box should be readily accessible and preferably adjacent to the boiler. It should
be identified as to its use.
A fused three pin plug and shuttered socket outlet may be used instead of the fused spur box, provided that:
a) They are not used in a room containing a bath or shower.
b) Both the plug and socket comply with the current issue of BS1363.
The mains electrical supply must be maintained at all times in order to provide domestic hot water and frost
protection.
It is recommended that a room thermostat is fitted.
Thermostatic radiator valves may be installed in addition to the room thermostat.
Note: For further information, see The Building Regulations 1991 - Conservation of fuel and power - 1995 edition -
Appendix G, table 4b.
DO NOT INTERRUPTTHE MAINS SUPPLYTOTHE BOILER WITH A TIME SWITCH OR PROGRAMMER.
The Protherm 80E is delivered with 1metre mains supply lead ready connected.
The electrical supply cable is the original spare part and must be replaced only by original supply cable for Protherm
80E boiler.
External controls
The boiler will work for heating AS DELIVERED without a room thermostat fitted provided the two wires on the
integral external controls connection REMAIN LINKEDTOGETHER (as supplied). If a room thermostat is required,
it must be connected as shown below and the link must be removed.
ANY ROOMTHERMOSTAT USED MUST BE OF THE VOLTAGE FREE TYPE.
WARNING: ON NO ACCOUNT MUST ANY ELECTRICAL VOLTAGE BE APPLIED TO EITHER OFTHE TERMI-
NALS OFTHE EXTERNAL CONTROLS CONNECTION
WARNING: This boiler must be wired in accordance with these instructions. Any fault arising from incorrect wiring
cannot be put right under the terms of the guarantee.
Diagram 12

19
COMMISSIONING
The commissioning and first firing of the boiler must only be carried
out by a competent person.
To gain access to the inside of the boiler undo screw securing front panel at
the boiler bottom, remove front panel by pulling forwards, lifting it up and off.
Note –upper edge of front casing is fixed to the boiler by means of 2 pins.
Gas installation
It is recommended that any air is purged from the supply at the gas inlet test
point on the gas valve, see diagram 13.
1- Inlet test point
2- Outlet test point
Filling the system
•Check that the gas meter tap is closed.
•Conect boiler to electrical supply.
•Place switch (1) diagram 1 to possition ‘I’. F0 is displayed and the
pump runs for about one minute.
•Press the BAR button, see diagram 1.Value of system pressure (0.0)
is displayed and LED (2) –see diagram 1 –lights.
Note: The pressure is displayed for about 25 sec. After this time the display comes back to
the standby mode.The pressure can be displayed after pressing Bar push button again.
•Open isolating valves (A, Eand D) see diagram 6.
•Undo, but not remove, cap on automatic air vent on the top of the pump.
•Fill system by opening system filling loop until a pressure of between 1 and 2 bar is shown on the display.
•Bleed each radiator until a continuous jet of water is obtained.
•Do not retighten automatic air vent cap.
•Open various hot water taps to bleed hot water circuit.
•Make sure that pressure is between 1 and 2 bar. Re-pressure as necessary.
Important: When venting air from boiler, do not touch the schrader valve on the expansion vessel, it is NOT a vent.
Starting the boiler
Before starting the boiler check that:
–The gas meter tap is open.
–The boiler gas service cock is open.
–The water isolating cocks are open.
–The boiler is connected to the electrical supply.
First starting up
•Place main switch (1) diagram 1 to position ‘I’.
•Set maximum heating water temperature (85°C), as described in ‘Users Instructions’and check that any exter-
nal controls, if fitted, are calling for heat.
•Allow the temperature to rise to the maximum value, with all radiator valves open. Air contained in the water of
central heating system will be automatically released through the automatic air vent. Air trapped at the hightest
point of the system must be released by bleeding the radiators.
On reaching maximum temperature, the boiler should be turned off and the system drained as rapidly as possible
whilst still hot.
•Refill system to a pressure at least of 1 bar and vent as before.
•Restart boiler and operate until a maximum temperature is reached. Shut down boiler and vent air from heating
system. If necessary, top up heating system and make sure that a pressure at least of 1 bar is indicated on the
display when system is COLD.
Gas pressures
•Shut down boiler.
•Undo screw on gas inlet test point ‘1’on gas valve, see diagram 13.
•Connect a suitable pressure gauge.
•Start boiler as described in ‘Users Instructions’.
•Check that there is a constant pressure of 20 mbar for Natural gas (28 –30 mbar for Butane or 37 mbar for
Propane). If the pressure is insufficient, it is necessary to check the gas supply/pipework and correct any fault.
Diagram 13