Protherm 60 Instructions For Use Manual

Manual is about: Fanned flue boiler

Summary of 60

  • Page 1

    Supplied by www.Heating spares.Co tel. 0161 620 6677 9269 one contact local service customer services: tel: (01773) 828100 fax: (01773) 828070 221974a.10.01 all replacement parts all labour charges all call-out charges thank you for installing a new protherm appliance in your home. The appliance is ...

  • Page 2: Important Information

    Supplied by www.Heating spares.Co tel. 0161 620 6677 2 221974a testing and certification this boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from hepworth heating ltd. Any alteration no...

  • Page 3: Instructions For Use

    Supplied by www.Heating spares.Co tel. 0161 620 6677 3 221974a 9270 diagram 1 9364 controls cover data & serial number label viewing window setting point control thermostat knob gas service cock (shown off) it is the law that any servicing is carried out by a competent person. To obtain service, ple...

  • Page 4: Instructions For Use

    Supplied by www.Heating spares.Co tel. 0161 620 6677 4 221974a 500mm from a permanent fixture 6mm 6mm front view 6mm 6mm 6mm 160mm 65mm diagram 2 cleaning warning. This appliance contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges. C...

  • Page 5: 1 General Data

    Supplied by www.Heating spares.Co tel. 0161 620 6677 5 221974a c l return pumped pumped flow c l water connections 22mm copper pipe gas connections rc 1 / 2 ( 1 / 2 in. Bspt) side elevation front elevation a 80 b 300 c 100 d 75 e 700 f 124 g 130 h 400 j 60 k 162 l 110 m 142 n 90 b a d l k n j g f e ...

  • Page 6: 1 General Data

    Supplied by www.Heating spares.Co tel. 0161 620 6677 6 221974a 53 kg (117 lb) 47 kg (103lb) 3.35 litre (0.74 gallon) rc 1 / 2 in. 71w internal fuse f1 & f2 (f1a) 2x22mm copper pipes from top of case 230v~50hz, fused 3a bottom right hand side of case 1 general data table 2. Range rating approx. M 3 /...

  • Page 7: 1 General Data

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 221974a diagram 1.2 500mm from a permanent fixture 6mm 6mm front view 6mm 6mm 6mm 160mm 65mm 1 general data 1.10 safety valve a safety valve need not be fitted to an open vented system. 1.11 location this boiler is not suitable for outdoor insta...

  • Page 8: 2 Flue And Ventilation

    Supplied by www.Heating spares.Co tel. 0161 620 6677 8 221974a 2 flue and ventilation a a f g e a g g g b,c b,c f f k k k c g l l diagram 2.1 minimum siting dimensions for fanned flue terminals position a directly below, above or horizontally to an opening, air brick, opening windows, air vent or an...

  • Page 9: 3 Water Systems

    Supplied by www.Heating spares.Co tel. 0161 620 6677 9 221974a 1000 750 500 250 0 0 5 10 15 20 25 30 flow rate (litres/minute) water pressure loss (mm head of water) 9154 design flow rate 30.6 l /min diagram 3.1 3 water systems the installation of the boiler must comply with the requirements of the ...

  • Page 10: 3 Water Systems

    Supplied by www.Heating spares.Co tel. 0161 620 6677 10 221974a 3 water systems diagram 3.2 9155 feed and expansion cistern 22mm vent (min.) 15mm (minimum) cold feed open vented fully pumped water system recommended relationship between pump cold feed and vent 450mm min. Height 1150mm min. Return fl...

  • Page 11: 3 Water Systems

    Supplied by www.Heating spares.Co tel. 0161 620 6677 11 221974a method 1 method 2 method 3 supply stop valve supply pipe hose unions servicing valve temporary hose heating system heating system temporary hose hose unions servicing valve supply pipe supply stop valve double check valve assembly heati...

  • Page 12

    Supplied by www.Heating spares.Co tel. 0161 620 6677 12 221974a diagram 4.1 4 flue and appliance preparation rear flue side flue 15mm note: outer casing, mounting brackets & boiler details removed for clarity note: 1 metre extension kits can be joined together, but the total flue system must not exc...

  • Page 13

    Supplied by www.Heating spares.Co tel. 0161 620 6677 13 221974a note : make sure that the ductings do not slope down towards the boiler. 4.1 flue position and length determine flue application, length and terminal position before starting. Refer to diagram 4.1. 4.2 flue preparation all flue assembli...

  • Page 14

    Supplied by www.Heating spares.Co tel. 0161 620 6677 14 221974a 4 flue and appliance preparation 4.8 easi-vent vertical flue terminal general the kits shown in diagram 4.4, enable the protherm to be fitted with the flue configurations shown in diagram 4.6. For other accessories, see diagram 4.5. Onl...

  • Page 15

    Supplied by www.Heating spares.Co tel. 0161 620 6677 15 221974a 4 flue and appliance preparation firestop plate (pt.No.208592) adjustable wall band (pt.No.208594) ceiling collar (pt.No.208590) ceiling plate (pt.No.208593) support assembly (pt.No.208591) 7122 diagram 4.5 ceiling plate - two piece - p...

  • Page 16

    Supplied by www.Heating spares.Co tel. 0161 620 6677 16 221974a 4 flue and appliance preparation 4.11 installation warning in the interests of safety and performance, it is essential that the vertical flue system is fitted in strict accordancewith these instructions. Installation details with due co...

  • Page 17

    Supplied by www.Heating spares.Co tel. 0161 620 6677 17 221974a 4 flue and appliance preparation step 1 step 2 step 4 step 3 diagram 4.9 push flue duct & air duct into flue spigot and lock into position by turning clockwise. Step 6 step 5 slide flue duct & air duct together, mark, drill, screw and s...

  • Page 18: 5 Boiler Installation

    Supplied by www.Heating spares.Co tel. 0161 620 6677 18 221974a 5 boiler installation diagram 5.1 controls cover front cover shakeproof washer 9202 nut 5.1 boiler preparation open the carton, check the items supplied against the boiler pack contents list on the carton flap. With the boiler still in ...

  • Page 19: 5 Boiler Installation

    Supplied by www.Heating spares.Co tel. 0161 620 6677 19 221974a 5 boiler installation diagram 5.2 securing screws (2) 5.3 water circulation system complete the water connections to the boiler. Fill, vent and flush the system. Check for any water leaks and put right. 5.4 safety valve discharge fit a ...

  • Page 20: 5 Boiler Installation

    Supplied by www.Heating spares.Co tel. 0161 620 6677 20 221974a diagram 5.6 3310 make sure that the supply cable and all external cables are secured and away from hot surfaces. 5.10 testing checks to ensure electrical safety must be carried out by a competent person. After installation of the system...

  • Page 21: 6 Commissioning

    Supplied by www.Heating spares.Co tel. 0161 620 6677 21 221974a 6 commissioning diagram 6.2 9364 4108 diagram 6.1 please ensure the “benchmark” logbook is completed and left with the user. 6.1 all systems commissioning should be carried out by a competent person in accordance with the current issue ...

  • Page 22: 6 Commissioning

    Supplied by www.Heating spares.Co tel. 0161 620 6677 22 221974a 6 commissioning diagram 6.3 diagram 6.4 note: pilot shield removed for clarity spark gap 2 to 4mm 10 to 20mm flame length 9136 viewing window securing screw (4) 4146 4139 fit the combustion chamber front. Note: make sure it fits under l...

  • Page 23: 6 Commissioning

    Supplied by www.Heating spares.Co tel. 0161 620 6677 23 221974a 6 commissioning diagram 6.5 diagram 6.6 controls cover wing nut washer top seal side seal note: make sure of correct engagement nut 9274 9270 turn the control thermostat knob fully anticlockwise to “o”. Remove the pressure gauge from th...

  • Page 24: 7 Instructions to The User

    Supplied by www.Heating spares.Co tel. 0161 620 6677 24 221974a 7 instructions to the user diagram 8.1 diagram 8.2 baffle (8 off) flue connecting elbow flue duct extension top turret flue ducting 9139 9803 8 servicing instruct and demonstrate the safe and efficient operation of the boiler, heating s...

  • Page 25: 8 Servicing

    Supplied by www.Heating spares.Co tel. 0161 620 6677 25 221974a 8 servicing diagram 8.5 diagram 8.6 diagram 8.7 securing screw main burner injector pilot burner spring clip electrode pilot injector 4112 4111 4143 8.3 main burner disconnect the pilot pipe union connector and pilot burner, securing nu...

  • Page 26: 9 Fault Finding

    Supplied by www.Heating spares.Co tel. 0161 620 6677 26 221974a diagram 9.1 9 fault finding neon indicators neon indicators - an aid to fault finding the neon indicators are an aid to fault finding only. Failure of any of the neon indicators does not warrant the replacement of an otherwise satisfact...

  • Page 27: 9 Fault Finding

    Supplied by www.Heating spares.Co tel. 0161 620 6677 27 221974a diagram 9.2 9 fault finding is neon 1 lit? Yes yes is neon 2 lit? Yes no correct power supply problem. No yes is there 230v~ between 3 on thermostat and n ? Replace thermostat. No yes no is neon 3 lit? Is there 230v~ between "n/c" on ai...

  • Page 28: 9 Fault Finding

    Supplied by www.Heating spares.Co tel. 0161 620 6677 28 221974a 9 fault finding does pump continue to run after sl is interrupted? Yes does pump stop after several minutes? System satisfactory. Faulty pcb. Replace no yes yes no no does the pump run when sl is applied ? Pump overrun operation for ful...

  • Page 29: 9 Fault Finding

    Supplied by www.Heating spares.Co tel. 0161 620 6677 29 221974a 9 fault finding fuse f1 & f2 (f1a) air pressure switch connections spark electrode o/h cutoff control stat fan air pressure switch pilot solenoid main solenoid n n n n n n n (n/o) (c) (n/c) l 2 3 n n b w br y y y r b r bk b y br b b bk ...

  • Page 30: 9 Fault Finding

    Supplied by www.Heating spares.Co tel. 0161 620 6677 30 221974a 9 fault finding diagram 9.5 r fully pumped open vented or sealed water system key: b - blue bk - black br - brown g/y - green/yellow or - orange r - red y - yellow w - white p - purple fan multi-functional control electrode plug air pre...

  • Page 31: 10 Replacement of Parts

    Supplied by www.Heating spares.Co tel. 0161 620 6677 31 221974a 10 replacement of parts control thermostat control knob electrical connections yellow 2 & 3 split grommet retaining clip locknut electrical connections shakeproof washers and screws 5755 diagram 10.1 10 replacement of parts note. Replac...

  • Page 32: 10 Replacement of Parts

    Supplied by www.Heating spares.Co tel. 0161 620 6677 32 221974a 10 replacement of parts 10.4 control board (pcb) - diagram 102a release the control box, refer to section 5.6. Disconnect the three electrical plugs and ignition lead. Release the cables from the plastic retaining clip, then disconnect ...

  • Page 33: 10 Replacement of Parts

    Supplied by www.Heating spares.Co tel. 0161 620 6677 33 221974a 10 replacement of parts 10.7 multifunctional control - diagram 10.3 disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control, take care as there is a restrictor on the pilot pipe. Disconnect the electrical...

  • Page 34: 10 Replacement of Parts

    Supplied by www.Heating spares.Co tel. 0161 620 6677 34 221974a diagram 10.4 diagram 10.6 red clear air pressure switch tubes securing screws air pressure switch electrical connections control box front insulation retaining screw side insulation rear insulation 4118 4122 10 replacement of parts diag...

  • Page 35: 11 Spare Parts

    Supplied by www.Heating spares.Co tel. 0161 620 6677 35 221974a 11 spare parts key no. Part no. Description gc part no. 1 800442 multifunctional control 278 021 2 208040 “o” ring 334 592 3 205710 injector 278 024 4 203432 pilot burner 278 023 5 801236 mica window and gasket 6 800421 fan assembly 278...

  • Page 36: 11 Spare Parts

    Supplied by www.Heating spares.Co tel. 0161 620 6677 36 221974a because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 11 spare parts diagram 11.1 4 6 2 1 10 5 7 8 11 3 13 15 9216 14 9.