Wall hung combination boiler PROTHERM 100EC USER, INSTALLATION, AND SERVICING INSTRUCTIONS 4728 THIS IS A CAT II2H3+ APPLIANCE Technical Advice & After Sales Service 01773 828100
Protherm 100EC 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. Users’ Instructions Introduction ............................................................................................................................ 2 Controls and lighting .....................................................
USERS INSTRUCTIONS The Protherm 100EC 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.
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.
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.
INSTALLATION INSTRUCTIONS INTRODUCTION The Protherm 100EC 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 Natural gas (G20) to G30/G31 Modification must only be carried out by a suitably qualified engineer.
TECHNICAL DATA CE Certification .............................................. n° ............................................................... 49AU2915 Class .......................................................................................................................................... II2H3+ Type ........................................................................................................................................ C12, C32 Gas type .............................................
DIMENSIONS AND PRESSURE AVAILABLE Diagram 2 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 Diagram 3 7
BOILER SCHEMATIC 1 – Air pressure switch 2 – Fan 3 – Combustion chamber 4 – Heat exchanger 5 – Burner 6 – Gas valve 7 – Expansion vessel 8 – Pump 9 – Water flow sensor 10 – Safety valve 11 – Heating return 12 – Domestic cold water inlet 13 – Gas inlet 14 – DHW thermistor 15 – DHW outlet 16 – Automatic by-pass 17 – Heating flow 18 – Drain point 19 – Water pressure sensor 20 – 3-way valve 21 – Actuator 22 – Domestic heat exchanger 23 – CH temperature sensor 24 – High limit thermostat Diagram 4 8
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 diagram 5 below: Diagram 5 Minimum dimensions (in mm) for the positioning of flue terminals a b c d e f g h i l m n Under a window . . . . . . . . . . .
HEATING SYSTEM DESIGN The Protherm 100EC 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.
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.
BOILER TEMPLATE Boiler connections A Heating flow B Hot water outlet C Gas connection D Cold water mains inlet E Heating return F Safety valve discharge connection Diagram 7 12
HORIZONTAL FLUE INSTALLATION A B C D E F G I J K Air inlet pipe Terminal Seal and clamp Elbow Gasket Screws External rubber sealing collar Internal plastic collar ‘O’ rings Spacer (see diagram 9) • • • • • • • Fit gasket (E) onto underside of flue elbow (D). Diagram 8 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.
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.
FLUE CONFIGURATIONS Diagram 11 15
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.
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.
• 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. • Shut down boiler. • Remove pressure gauge, tighten up carefully test point screw and check for gas soundness. Setting the central heating output The central heating output must be set in accordance with the system requirements.
SERVICING INSTRUCTIONS 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. It is the law that any servicing is carried out by a competent person. ROUTINE CLEANING AND INSPECTION • • • Operate boiler and check for any faults that need to be put right.
REPLACEMENT OF PARTS To gain access to the boiler components, proceed as follows: • Isolate boiler from electrical supply. • Remove outer case, if necessary sealed chamber cover, combustion chamber cover and side covers, see “Routine cleaning and inspection”. • Gently squeeze metal clip securing the control panel box, lift it up and hinge down. To replace fan • Disconnect power supply and earth leads to fan. • Supporting fan, unscrew and remove two screws securing fan to front of flue hood, see diagram 18.
To replace pump Drain down heating circuit only of boiler as follows: • From below boiler, close isolating valves on flow and return connections to boiler. • Open boiler drain valve on left hand side of hydraulic block. Note: It is not necessary to drain down entire heating circuit to carry out this work. Simplification: for simpler work remove gas valve module and right side cover. • Disconnect pump cable. • Remove 2 clips fixing pump, see diagram 20. • Unscrew 2 screws securing the pump to boiler bottom.
To replace heating water thermistor • Locate thermistor (b) clipped onto flow pipe to left hand side of sealed chamber below overheat thermostat, see diagram 22. • Unclip thermistor from pipe. • Pull off electrical connections from thermistor. • Fit replacement thermistor in reverse order to removal. Note: No heat sink compound is required. The polarity of the connections is not important.
SCHEMATIC WIRING DIAGRAM Diagram 25 23
FAULT FINDING Before fault finding, make sure that: - All gas cocks are open and there is an inlet gas pressure of 20 mbar (G 20). - The heating system pressure is at least 1 bar. - There is a permanent mains supply to the boiler. - The fuses on the PCB are intact. - All external controls are correctly wired and calling for heat. WARNING: Always isolate the boiler from the electrical supply before carrying out any electrical replacement work. Always check for gas soundness after any service work.
Air pressure switch failure: If the fan and the pump is running but the boiler doesn’t light, check the air pressure switch. Blown fuses: If the main switch is on and display does not light check the FUSE 1 (T1.6A), see diagram 23. The pump, the fan and the ignition module don’t work. Warning message: If the pressure in CH system drops to 0.8 bar the LED on the Bar button starts to flash. This give you information that CH pressure is on the low limit and must be pressurised.
PROTHERM 100EC – CONVERSION TO LPG Note: Conversion must only be carried out by a competent person • Isolate boiler from the gas and electrical supplies. • Remove boiler casing, sealed chamber and combustion chamber cover as described in Installation/Servicing Instructions. • Disconnect flame sense electrode. • Disconnect ignition lead at gas valve module. • Disconnect ignition earth lead. • Undo nuts securing gas supply pipe between burner and gas valve and remove pipe.
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