Protherm 100 e
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 ............................................................................................................. 2
Draining and filling ................................................................................................................ 3
Heating safety valve ............................................................................................................. 3
Servicing/maintenance ......................................................................................................... 3
Cleaning ............................................................................................................................... 3
Boiler casing ......................................................................................................................... 3
Installation Instructions
Introduction ........................................................................................................................... 4
Technical data ...................................................................................................................... 5
Dimensions ........................................................................................................................... 6
Pump capacity ...................................................................................................................... 6
Boiler schematic ................................................................................................................... 7
Installation section ................................................................................................................ 8
Terminal positions ................................................................................................................. 8
Heating and hot water system design ................................................................................... 9
Boiler installation ................................................................................................................ 10
Horizontal flue installation ................................................................................................... 12
Vertical flue installation ....................................................................................................... 13
Flue configurations ............................................................................................................. 14
Electrical connection ........................................................................................................... 15
Commissioning ................................................................................................................... 16
Servicing Instructions
Routine cleaning and inspection ......................................................................................... 18
Replacement of parts ......................................................................................................... 19
Schematic wiring diagram ................................................................................................... 22
Fault finding ........................................................................................................................ 23
Conversion to LPG ............................................................................................................. 24
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.
1
USERS INSTRUCTIONS
The Protherm 100 e 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 shown on the pressure gauge is less than 1 bar 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 behind the drop down front door. The controls on this panel allow the boiler to be
started, shut down, controlled and monitored during use, see diagram 1.
Diagram 1
Controls
1 - Timeclock
2 - Pressure gauge
3 - Hot water temperature control
4 - Heating temperature control
2
5 - Summer/Winter switch
6 - Reset button
7 - Mains On/Off switch
8 - Digital display
Make sure that:
• The boiler is connected to the electrical supply.
• The boiler gas service cock is open.
• The pressure gauge reads between 1 and 2 bar.
The boiler is now ready to start.
To start the boiler
• Place switch (7) in the On position “I”
• Place switch (5) in the desired Summer
or Winter
position
To stop the boiler
Place switch (7) to the Off position “O”.
If the boiler is to be out of operation for a long period, turn off the gas service cock.
Setting to ‘Summer’ mode (Hot water only)
Place switch (5) in the Summer position
Setting to ‘Winter’ mode (Heating and hot water)
Place switch (5) to the Winter position
Adjust the heating temperature control (4) to the desired temperature.
Adjust the domestic hot water control (3) to the desired hot water temperature. 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 always has priority over central heating.
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 (6).
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.
Note: If there is persistent loss of system pressure, you must consult your Installer/Service Provider.
If the pressure shown on the pressure gauge is less than 1 bar the system must be filled immediately.
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.
3
INSTALLATION INSTRUCTIONS
Introduction
The Protherm 100 e 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 . . . . . . . 92321165
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 nearest 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’.
4
TECHNICAL DATA
Protherm 100 e
CE Certification . . . . . . . . . . . . . . . . . . . . . . . . n° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 AU 2915
Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II2H3+
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C12,C32
Gas type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G20 . . . . . . G30 . . . . . . . . G31
Max. Heat Input . . . . . . . . . . . . . . . . . . . . . . . . kW . . . . . . . . . . . . . . . . . 30.5 . . . . . . 30.5 . . . . . . . . 30.5
Min. Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . kW . . . . . . . . . . . . . . . . . 12.1 . . . . . . 12.1 . . . . . . . . 12.1
Max. Heat Output . . . . . . . . . . . . . . . . . . . . . . . kW . . . . . . . . . . . . . . . . . 27.4 . . . . . . 27.4 . . . . . . . . 27.4
Min. Heat Output . . . . . . . . . . . . . . . . . . . . . . . kW . . . . . . . . . . . . . . . . . 10.0 . . . . . . 10.0 . . . . . . . . 10.0
GAS SUPPLY PRESSURE
Burner pressure . . . . . . . . . . . . . . . . . . . . . . . mbar . . . . . . . . . . . . . 2.1 – 15.0 . . 3.8 – 28.8 . 4.1 – 36.7
Nominal pressure . . . . . . . . . . . . . . . . . . . . . . mbar . . . . . . . . . . . . . . . . 20 . . . . . . . . 29 . . . . . . . . . . 37
Injectors diameter . . . . . . . . . . . . . . . . . . . . . ∅ mm . . . . . . . . . . . . . . . . 1.2 . . . . . . . 0.73 . . . . . . . . 0.73
GAS CONSUMPTION
Qmax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m3/h . . . . . . . . . . . . . . . . . 3.2 . . . . . . . . 1.1 . . . . . . . . . . 1.4
Qmin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m3/h . . . . . . . . . . . . . . . . . 1.3 . . . . . . . . 0.5 . . . . . . . . . . 0.6
Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m3/h . . . . . . . . . . . . . . . . . 135 . . . . . . . 135 . . . . . . . . 135
EFFICIENCY
Nominal efficiency . . . . . . . . . . . . . . . . . . . . . . % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89,8
Efficiency at 30% load . . . . . . . . . . . . . . . . . . . % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86,7
HEATING
Temperature range . . . . . . . . . . . . . . . . . . . . . . °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 85
Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Expansion vessel pressure . . . . . . . . . . . . . . . bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Max. working pressure . . . . . . . . . . . . . . . . . . . bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Max. system temperature . . . . . . . . . . . . . . . . . °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Max. system capacity . . . . . . . . . . . . . . . . . . . . . l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
HOT WATER
Flow rate at 30°C temperature rise . . . . . . . . l/min
Flow rate at 35°C temperature rise . . . . . . . . l/min
Min. water flow . . . . . . . . . . . . . . . . . . . . . . . . l/min
Max. supply pressure . . . . . . . . . . . . . . . . . . . . bar
Min. supply pressure . . . . . . . . . . . . . . . . . . . . bar
Temperature range . . . . . . . . . . . . . . . . . . . . . . °C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
.......................................... 2
........................................... 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 – 60
ELECTRICAL DATA
Voltage/frequency . . . . . . . . . . . . . . . . . . . . . V/Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~230/50
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Level of protection . . . . . . . . . . . . . . . . . . . . . . IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 44
DIMENSIONS
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 880
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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 – 3
Vertical flue length min/max . . . . . . . . . . . . . . . m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 – 11,5
HEAT OUTPUT
kW . . Btu/hr
10 . . . 34 120
11 . . . 37 532
12 . . . 40 944
13 . . . 44 356
14 . . . 47 768
15 . . . 51 180
16 . . . 54 592
17 . . . 58 004
18 . . . 61 416
19 . . . 64 828
G20
. . . . mbar
. . . . 2.1
. . . . 2.5
. . . . 3.0
. . . . 3.6
. . . . 4.2
. . . . 4.8
. . . . 5.4
. . . . 6.2
. . . . 6.8
. . . . 7.5
PRESSURE
G30
G31
. . mbar . . . mbar
. . . . 3.8 . . . . . 4.1
. . . . 4.6 . . . . . 5.2
. . . . 5.5 . . . . . 6.4
. . . . 6.6 . . . . . 7.8
. . . . 7.7 . . . . . 9.2
. . . . 9.0 . . . . 10.9
. . . . 10.3 . . . 12.6
. . . . 11.7 . . . 14.5
. . . . 13.2 . . . 16.4
. . . . 14.7 . . . 18.3
HEAT OUTPUT
kW . . Btu/hr
20 . . . 68 240
21 . . . 71 652
22 . . . 75 064
23 . . . 78 478
24 . . . 81 888
25 . . . 85 300
26 . . . 88 712
27 . . . 92 124
27.4 . . 93 489
G20
. . . . mbar
. . . . 8.2
. . . . 9.0
. . . . 9.8
. . . 10.7
. . . 11.6
. . . 12.6
. . . 13.6
. . . 14.7
. . . 15.0
PRESSURE
G30
. . mbar . . .
. . . . 16.2 . . .
. . . . 17.7 . . .
. . . . 19.3 . . .
. . . . 21.0 . . .
. . . . 22.7 . . .
. . . . 24.5 . . .
. . . . 26.2 . . .
. . . . 28.1 . . .
. . . . 28.8 . . .
G31
mbar
20.3
22.3
24.4
26.6
28.9
31.2
33.5
35.8
36.7
5
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)
Diagram 3
6
5 – Heating return (pipe diameter 22 mm)
6 – Wall
7 – Wall fixings
8 – Outer cover
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
Diagram 4
7
INSTALLATION SECTION
Clearances
The boiler can be installed with the following clearances:
25 mm either side of the boiler
50 mm to the front of the boiler
300 mm below the boiler
200 mm above the boiler
The above clearances are minimum clearances, consideration must be given to allow adequate space for servicing.
The recommended servicing clearances are:
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
8
Under a window . . . . . . . . . . . . . . . . . . . . . . . . 300
Under an air vent . . . . . . . . . . . . . . . . . . . . . . . 300
Under a gutter . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Under a balcony . . . . . . . . . . . . . . . . . . . . . . . . 300
From an adjacent window . . . . . . . . . . . . . . . . . 300
From an adjacent air vent . . . . . . . . . . . . . . . . . 300
From vertical drain pipes or soil pipes . . . . . . . . 75
From an external corner of the building . . . . . . 300
From an internal corner of the building . . . . . . . 300
From the ground or from another floor . . . . . . . 300
Between two terminals vertically . . . . . . . . . . 1500
Between two terminals horizontally . . . . . . . . . 300
Heating system design
The Protherm 100 e 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 130 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.
A suitable WRC approved filling loop must be fitted to enable correct filling of the system.
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.
Boiler connections
A
B
C
D
E
F
Heating flow
Hot water outlet
Gas connection
Cold water mains inlet
Heating return
Safety valve discharge connection
Diagram 6
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 color washers belong to hot water system connections.
9
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 (8 in wg).
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 requirements 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 contaminents 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).
• 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.
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.
Note:
Remove the plastic caps from the boiler connections prior to connecting boiler to the pipework.
10
BOILER TEMPLATE
Boiler connections
A
B
C
D
E
F
Heating flow
Hot water outlet
Gas connection
Cold water mains inlet
Heating return
Safety valve discharge connection
Diagram 7
11
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).
Carefully insert ‘O’ ring (J) into upper and lower parts of inner elbow.
Diagram 8
Place spacer (K) (supplied with boiler) onto top of boiler.
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 3 m.
• 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
Flue extension kit
90° bend kit
45° bend kit
85090
85091
85092
85093
Diagram 9
Standart top
outlet flue
90 degree
elbow
Extension pipe
12
Standart top
outlet flue
Vertical flue installation
•
•
•
•
•
•
•
•
•
Fit gasket (E) onto underside of vertical adaptor (O).
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.
Fit the terminal (L) onto roof ensuring flashing makes a watertight joint.
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 5 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).
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)
Vertical flue terminal (brick)
Pitched roof flashing
Flat roof flashing
Flue extension pipe
90° bend kit
45° bend kit
85103
85104
85105
85107
85099
85101
85102
Diagram 10
13
FLUE CONFIGURATIONS
Diagram 11
14
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 INTERRUPT THE MAINS SUPPLY TO THE BOILER WITH A TIME SWITCH OR PROGRAMMER.
The Protherm 100 e is delivered with 1metre mains supply lead ready connected.
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 LINKED TOGETHER (as supplied).
If a room thermostat is required, it must be connected as shown below and the link must be removed.
ANY ROOM THERMOSTAT USED MUST BE OF THE VOLTAGE FREE TYPE.
Diagram 12
WARNING: ON NO ACCOUNT MUST ANY ELECTRICAL VOLTAGE BE APPLIED TO
EITHER OF THE TERMINALS OF THE 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.
15
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 screws securing front
panel at upper corners, remove front panel by pulling forwards and off.
Disconnect earth wire from front panel.
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
• Open isolating valves (A, E and D) see diagram 6 and cap on automatic air vent on top of pump, see diagram 19.
• Fill system by opening system filling loop until a pressure of between 1 and 2 bar is shown on the boiler pressure gauge.
• Bleed each radiator until a continuous jet of water is obtained.
• Do not close automatic air vent cap.
• Open various hot water taps to bleed hot water circuit.
• Make sure that pressure gauge reads between 1 and 2 bar.
Re-pressure as necessary.
Diagram 13
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
• Set boiler to run in central heating as described in ‘Users Instructions’.
• Set heating temperature control to maximum temperature and check that any external 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 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 of 1 bar is indicated on the pressure
gauge 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. 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 test point screw and check for gas soundness.
16
Setting the central heating output
The central heating output must be set in accordance with the system requirements. To adjust the burner
pressure, proceed as follows, referring to the tables listed in ‘Technical Data’:
Gain access to the PCB as follows:
• Unclip the two plastic clips securing the lower control
panel to the boiler side panels and hinge down.
• Unscrew and remove screws securing plastic PCB
cover to rear of lower control panel and remove cover.
• Set the ‘summer/winter’ switch to the ‘winter’ position
• Light the burner and check the gas pressure at pressure test point ‘2’, see diagram 13
• Adjust the pressure using potentiometer TR1 on the
PCB, see diagram 14.
Note: Do not adjust any of the other potentiometers.
• Refit PCB cover.
Diagram 14
Safety devices
Air flow rate safety device
If an obstruction, even partial, of the flue occurs, the built in safety system of the boiler will turn the boiler OFF. The
boiler will be ready to operate when the fault has been cleared.
In case of power supply failure
The boiler no longer operates. As soon as power is restored, the boiler will be automatically restarted. If the boiler
does not restart, the overheat device may need resetting.
Overheat safety
In the event of overheating, the overheat safety device causes safety shutdown of the boiler. The digital display will
show error code F1. To reset, press the reset button on the safety device, (a), see diagram 23.
Diagram 15
Summer/winter
switch
RESET
switch
On/off
switch
Important notice
A central heating system cannot operate satisfactorily unless it is properly filled with
water and unless the air initially contained in the pipework system 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.
To reset the boiler (other than for overheating) use the reset button on the fascia, see diagram 15.
The Protherm 100 e boiler has a built-in frost protection device that protects the boiler during freezing conditions.
Should the temperature within the central heating circuit of the boiler fall below 10 °C, the pump will switch on
providing the electrical supply has been left connected. If the temperature falls below 8 °C, then the burner will
operate until the water temperature increases to 25 °C. Should the electrical supply have been disconnected and
the boiler/system has frozen, the boiler will not start up until the boiler/system has been cleared.
17
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.
• Isolate boiler from the gas and electrical supplies.
• On completion check all gas carrying parts for soundness with leak detection fluid.
Remove boiler casing as follows:
Outer casing
• Undo screws securing the casing at upper corners and remove outer casing by pulling forwards and off.
• Disconnect earth lead from outer casing.
Sealed chamber
• Unclip two clips holding sealed chamber cover to boiler and lift it up and off, see diagram 16.
Diagram 16
Cleaning the burner
• Unscrew and remove 6 screws securing combustion chamber cover and remove cover.
• Disconnect flame sense electrode at burner.
• Disconnect ignition lead at gas valve module.
• Disconnect ignition earth lead.
• Undo nuts (A) securing gas supply pipe between burner and gas valve and remove pipe, see diagram 17.
Note: The washer between the burner and burner gas supply must be kept to use on reasembly.
• Unscrew 4 screws (B) securing burner to base of sealed chamber.
• Pull main burner up and forward out of boiler.
• Examine and clean burner as necessary.
Note: DO NOT use a wire or sharp instrument on the holes.
Heat exchanger
• Locate the heat exchanger inside the sealed chamber.
• Gain acces to heat exchanger by removing fan and flue hood.
• Examine heat exchanger for any blockages or build up of deposits.
• Clean heat exchanger with soft brush or vacuum cleaner.
Reassembly of parts removed for servicing
All parts are replaced in reverse order to removal.
Flue system
• Check externally to make sure that flue is not blocked
• Inspect flue system to make sure that all fittings are secure.
Operation of fan
• Switch on electrical supply and turn on gas.
• Set selector switch to ‘Winter’
position.
• Remove sealed chamber cover.
• Light burner by operating external controls (if fitted) to call for heat.
• Check that fan operates when burner lights and stops when it goes out.
18
Diagram 17
Replacement of parts
To gain access to the boiler components, proceed as follows:
• Isolate boiler from electrical supply.
• Remove outer case by grasping and gently pulling forwards.
• Supporting sealed chamber cover, unclip two clips securing cover to sealed chamber and lift off cover.
• Gently squeeze the two moulded plastic clips securing the lower front panel to the side panels; the lower front
panel will now 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.
• Gently ease fan forwards and out of boiler.
• Fit replacement fan in reverse order to removal making sure
that mounting plate engages correctly onto flue hood
Important: Ensure that fan outlet is correctly fitted into flue elbow
at top of boiler.
To replace air pressure switch
• Locate air pressure switch in upper left hand corner of
sealed chamber.
• Pull off clear plastic tube from base of switch.
• Remove electrical connections from switch.
• Unscrew and remove two screws securing switch to upper panel and remove switch
– (or unclip air pressure switch from plastic holder – depends on type of switch used).
• Fit electrical connections to replacement switch as follows:
One to the microswitch connection marked ‘NO 2’
One to the microswitch connection marked ‘COM 3’
• Fit replacement switch in reverse order to removal.
Important: Refit clear plastic tube as follows:
Tube from tapping point of flue hood to switch point ‘P 2 -’
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.
• Undo screw A and remove pump electrical connection cover, see
diagram 19.
• Unscrew electrical connections and disconnect pump cable.
• Supporting pump, unscrew pump connection nuts at top and rear of
pump. Remove pump by lifting forward and out of boiler.
• Fit replacement pump in reverse order to removal.
• Open isolating valves on flow and return connections,
• Refill, vent and pressurise boiler. Check for leaks.
To replace gas valve module
• Locate gas valve module attached to side of gas valve,
Diagram 19
A
see diagram 20.
• Unscrew screw (a) securing cover onto gas valve module.
• Remove cover and disconnect multi-plug from module.
• Disconnect ignition and flame sense leads from module and withdraw module from gas valve.
• Fit replacement module in reverse order to removal.
• Reconnect ignition and flame sense leads, the connections are uniquely sized to ensure correct replacement.
• Refit cover ensuring all sealing grommets are correctly located in module body.
19
To replace gas valve
• Ensure that gas supply is turned off at gas cock.
• Remove gas valve module as described previously.
• Undo nuts securing gas supply pipe between burner and
gas valve and remove pipe, taking care not to lose sealing washers, see diagram 21.
• Remove gas inlet connection to boiler.
• Unscrew four screws securing gas inlet flange and gas
valve to its mounting bracket.
• Remove gas valve by lifting upwards and out of boiler.
• Fit replacement gas valve in reverse order to removal.
To replace burner
• Remove burner as described in ‘Cleaning the burner’.
• Fit replacement burner in reverse order to removal.
To replace domestic heat exchanger
• Drain down heating circuit of boiler as described previously.
Drain down hot water circuit of boiler as follows:
• From below boiler, close cold water inlet isolating valve.
• Open a hot tap to drain hot water circuit.
• Supporting the domestic heat exchanger, undo connections and turn heat exchanger until vertical.
• Manouvre heat exchanger up and forwards out of boiler, see diagram 22.
• Fit replacement heat exchanger in reverse order to removal, ensuring seals are correctly positioned in hydraulic block.
• Open isolating valves on flow and return connections,
refill, vent and pressurise boiler. Check for leaks
• Open cold water isolating valve. Check for leaks.
Diagram 20
To replace overheat thermostat
Important: Isolate boiler from electrical supply before this
Diagram 21
Diagram 22
To replace pressure gauge
• Drain boiler as described in ‘To replace pump’.
• Unscrew pressure gauge capillary pipe nut on right hand side of hydraulic block.
• Unclip pressure gauge and pull out of lower front panel.
• Fit replacement pressure gauge in reverse order to removal.
20
operation - connections to overheat thermostat are mains voltage.
• Locate overheat thermostat (a) to left hand side of sealed chamber above
thermistor, see diagram 23.
To gain access to the thermostat, proceed as follows:
• Unscrew and remove two screws securing the lower grille on the left bottom of the boiler.
• Unscrew and remove two screws securing the left side cover.
• Remove the left side cover by pulling forward and aside.
• Unclip overheat thermostat from pipe.
• Pull off electrical connections from thermostat.
• Fit replacement overheat thermostat in reverse order to removal.
Note: No heat sink compound is required. The polarity of the connections is
not important.
To replace thermistor
• Locate thermistor (b) clipped onto flow pipe to left hand side of sealed
chamber below overheat thermostat, see diagram 23.
• 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.
Diagram 23
To replace printed circuit board (PCB)
• From behind lower control panel, unscrew and remove six screws securing
PCB cover to panel.
• Pull off five molex type electrical plugs from PCB.
• Remove screws securing PCB to panel and lift out PCB.
• Fit replacement PCB in reverse order to removal, ensuring that domestic
hot water and central heating temperature control spindles engage properly
into PCB.
• Potentiometers on PCB and user controls need to be set to max. before fitting.
To replace timeclock
• Remove PCB cover as described in ‘To replace PCB’
• Disconnect clock electrical connections from PCB. Unclench and remove
plastic clips securing timeclock to lower front panel.
• Remove timeclock from panel.
• Fit replacement timeclock in reverse order to removal.
To replace heat exchanger
• Drain down heating circuit of boiler only as described previously.
• Remove sealed and combustion chamber covers as described
previously.
• Unscrew screws securing lower grille.
• Unscrew and remove screws securing left and right side covers.
• Remove both side covers by pulling forward and aside.
• Pull off spring clips securing heat exchanger pipes to heat exchanger.
• Manoeuvre heat exchanger pipes down to disengage from heat
exchanger.
• Remove heat exchanger by sliding forward and out of boiler.
• Fit replacement heat exchanger in reverse order to removal.
• Open isolating valves on flow and return connections, refill, vent and pressurise boiler. Check for leaks.
Diagram 24
Diagram 25
21
22
Diagram 26
SCHEMATIC WIRING DIAGRAM
FAULT FINDING
Before fault finding, make sure that:
• All gas cocks are open and there is an inlet gas pressure of 20 mbar.
• The heating system pressure is at least 1 bar.
• There is a permanent mains supply to the boiler.
• The fuse on the PCB is 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.
Digital display shows:
– CHW temperature (no decimal point displayed)
– DHW temperature (decimal point lights)
– diagnostic error messages
As soon as the mains switch is on the display shows for a very short time the version of software used. It has no
importance for boiler operation.
Diagnostic error messages
In the event of a fault, the following diagnostic error messages will be displayed.
Message Fault
Action
Comments
F0
Flow rate sensor failure
Loss of system water
Air lock in boiler.
Pump failure
Check sensor
Refill system-check for leaks
Bleed boiler and system
Check the pump
Pump runs for one minute
Pump runs for one minute
Pump runs for one minute
F1
No flame detected
Check flame sense electrode
Check ignition electrode
Check ignition unit on gas valve
Check fan operation
Reset overheat thermostat
Boiler shuts down and
pump runs if there is CH
or DHW demand
Central heating thermistor failure
or
CH water temperature below 3 °C
Check flow thermistor
Boiler shuts down
F3
Heat exchanger blockage
Check main heat exchanger
Check domestic heat exchanger
Boiler shuts down and
pump runs
F4
Domestic hot water
thermistor faulty
Check thermistor/leads
Domestic hot water is
available but poor
Overheating
F2
Check if system is not frozen
Flashing decimal point when DHW temperature is displayed
This indicates that the domestic heat exchanger may be partially or fully blocked, the pump may be running too
slowly or the central heating flow rate is too low.
23
Protherm 100 e - Conversion to LPG
• Isolate boiler from the gas and electrical supplies.
• Remove boiler casing 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.
• Unscrew two screws securing burner to base of
sealed chamber.
• Pull main burner up and forward out of boiler.
Note: The washer between the burner and burner gas
supply must be kept to use in reassembly.
• Fit new burner with marked injector diameter
∅ 0,73 mm to the boiler in reverse order to removal.
• Readjust the gas valve.
Gas Valve Adjustment
To adjust the minimum and maximum settings, proceed as follows:
• Gain access to the rear of the controls housing
• Remove the PCB cover
• Connect a manometer to the burner pressure test point (2) on the gas valve
• Turn potentiometer TR1, on the PCB, fully anti-clockwise
• Start boiler in Central Heating mode
• Adjust the gas valve minimum pressure Pmin using screw (C) on gas valve. Turn clockwise to increase,
anti-clockwise to decrease.
• Turn potentiometer TR1, on the PCB, fully clockwise
• Start boiler in Domestic Hot Water mode
• Adjust gas valve maximum pressure Pmax using screw (B). Turn clockwise to increase, anti-clockwise
to decrease
Note: It is first necessary to remove cover (A) to gain access to screw (B)
• If necessary, run boiler in Central Heating mode and adjust the range rating to suit the size of the heating system using potentiometer TR1. Refer to commissioning in Installation/Servicing Instructions
• Disconnect manometer and check for gas soundness
• Replace all covers in reverse order to removal
G20 (20 mbar)
G30 (30 mbar)
G31 (37 mbar)
Inj. diam
∅ 1,20 mm
∅ 0,73 mm
∅ 0,73 mm
Pmin
2 mbar
4 mbar
4 mbar
Pmax
15 mbar
29 mbar
36 mbar
A - Cover
B - Maximum adjustment screw
C - Minimum adjustment screw
1 - Inlet pressure testpoint
2 - Burner pressure testpoint
Combined gas armature Honeywell CVI-M
24
Wall hung combination boiler
PROTHERM 100 e
USER, INSTALLATION, AND
SERVICING INSTRUCTIONS
THIS IS A CAT II2H3+ APPLIANCE
Technical Advice & After Sales Service
01773 828100
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