BLADES LCS BLADE TWIN PLUS TPWH60 Installation & Service Manual Download Page 3

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Blade 60 & 80 Twin Plus Water Heater Manual July 2020

Contents Page

1.0

INTRODUCTION

2.0

WATER HEATER TECHNICAL DATA

3.0

WATER HEATER SCHEMATIC LAYOUT

4-5

4.0

INSTALLATION REQUIREMENTS

5.0

EQUIPMENT DETAILS

7-11

6.0

BASE PLANS & FIXING DETAILS

7.0

SPLIT ASSEMBLY INSTRUCTIONS

8.0

GENERAL SERVICES REQUIREMENTS

9.0

MAINTENANCE & SERVICING CLEANCES

10.0

INSTALLATION SCHEMATIC

11.0

CONVERSION TO SPACE HEATING DETAILS

12.0

ROUTINE SERVICING

13.0

WIRING DIAGRAM

14.0

SHORT PARTS LIST

15.0

COMMISSIONING DETAILS

21-22

SERVICE RECORDS

23-26

NOTES

APPENDIX “A” ALPHA BOILER MANUAL

APPENDIX “B” DAB PUMP MANUAL

Summary of Contents for BLADE TWIN PLUS TPWH60

Page 1: ...500 litre storage cylinder INCLUDES ALPHA E Tec 20S 30S and 35S Boiler manual BLADES LOW CARBON SYSTEMS Ltd 4 Valhalla Industrial Estate Holsworthy Devon EX22 6HN For Technical help or Service call 01566 770799 For use with Natural Gas or Propane Gas LPG Leave these instructions with the User ...

Page 2: ......

Page 3: ...11 6 0 BASE PLANS FIXING DETAILS 12 7 0 SPLIT ASSEMBLY INSTRUCTIONS 13 8 0 GENERAL SERVICES REQUIREMENTS 14 9 0 MAINTENANCE SERVICING CLEANCES 15 10 0 INSTALLATION SCHEMATIC 16 11 0 CONVERSION TO SPACE HEATING DETAILS 17 12 0 ROUTINE SERVICING 18 13 0 WIRING DIAGRAM 19 14 0 SHORT PARTS LIST 20 15 0 COMMISSIONING DETAILS 21 22 SERVICE RECORDS 23 26 NOTES 27 APPENDIX A ALPHA BOILER MANUAL APPENDIX B...

Page 4: ...ue Gas Heat Recovery Devices PFGHRD which usesthenormally wastedlatentheatwithintheflue exhaustgases Theseareconnectedtotheboiler via the boiler flue spigot The recovered energy from the Passive Flue Gas Heat Recovery Devices is used to pre heat the cold feed to the DHW cylinder this increases the overall system efficiency of this unit to 97 It should be noted on this boiler the PFGHRD can be used...

Page 5: ...r TPWH60 TPWH140 DOMESTIC HOT WATER PERFORMANCE Heat up from cold 10 C 500 litre 29 08 min 23min ELECTRICAL TPWH60 TPWH80 Supply Main Water Heater V 50Hz 230 240V 230 240V Supply Main Immersion heater V 50Hz 230 240V 230 240V External Fuse Water Heater 3 A 3 A External fuse Immersion heater 13A 13A Power Consumption DHW pump 75 W 75 W Power Consumption Pressurisation unit 50W 50W DENOTES Pressuris...

Page 6: ...4 Blade 60 80 Twin Plus Water Heater Manual July 2020 3 0 BLADE WATER HEATER SCHEMATIC LAYOUT ...

Page 7: ...Blade 60 80 Twin Plus Water Heater Manual July 2020 5 3 1 SCHEMATIC LEGEND ...

Page 8: ...ater are fully raised The stabilising feet are located on each wheel mount and can be raised using a suitable flat headed spanner from below 4 2 4 Unbolt and remove all shipping brackets WARNING once the shipping brackets have been removed and the stabilising feet raised the unit will become mobile from this point until it is immobilised again The Water Heater should be physically restrained at al...

Page 9: ...lded stainless steel and approved for mains pressure or gravity systems and come complete with ERP compliant high density insulation and solid external powder coated finish They come in a standard size of 500 litres other sizes are available as special orders details on request SEE BENCHMARK MAINTENANCE requirements within this document which must be completed when serviced to maintain the warrant...

Page 10: ...A2 2 Blinks TRIP loss of motor control may be caused by incorrect parameters blocked rotor disconnected phase disconnected motor 3 Blinks SHORT CIRCUIT short circuit on phases or between phase and earth 4 Blinks OVERRUN software fault 5 Blinks SAFETY safety module error may be caused by a sudden overcurrent or other hardware faults of the board 5 3 PLATE HEAT EXCHANGER The plate heat exchanger is ...

Page 11: ...Wednesday Thursday Friday Saturday 8 Select day or day blockas required and press Ybutton to confirm 9 Press the button this will select the programme 01 OFF press Y to confirm 10 Follow 4 to 7 above to set the 01 OFF programme day or day block must be the same as programme ON 11 If no more programmes are required press the N button to exit 12 If more programmes are required follow 3 above 13 To c...

Page 12: ...inder switching on the water heating when the temperature falls below the thermostat setting and switching it off once this set temperature has been reached The water heating will not work if a time switch or programmer has switched it off The cylinder thermostat will have a temperature scale marked on it and it can be adjusted to the chosen temperature then left to do its job The thermostat must ...

Page 13: ...r temperature and the weekly boost will immediately start and recur every 1 7 days depending on the user set position at the same time Adjusting and Resetting the Cylinder Thermostat Adjust the dial to show the desired hot water temperature on the display between 25 C to 65 C The lower the temperature the less chance of scalding and the more energy saving The Cylinder temperature will be factory s...

Page 14: ...12 Blade 60 80 Twin Plus Water Heater Manual July 2020 6 0 BASE PLANS TPWH100 AND TPWH140 Frame Levelling and Immobisation Detail all Models Frame Fixing Bracket for all Models 5 2 FIXING DETAILS ...

Page 15: ...lade frame is in the required location on a flat surface immobilize the whole frame by lowering the eight levelling feet provided Assembly Procedure Once the three sections of the frame are in their final location the two sections of frame should be position adjacent to each other and frame bolt holes and pipes should be aligned using the levelling feet Securely bolt the two halves of the frame to...

Page 16: ... if required 8 1 7 For sealed heating and domestic water services the correct size expansion vessel must be installed to protect the system from the excess pressure created by waterexpansion 8 1 8 All pumps within Water Heater should be vented during commissioning via vent screw on front of pumps 8 1 9 Automatic air release valves must be installed at the high point on the system where necessary 8...

Page 17: ...Blade 60 80 Twin Plus Water Heater Manual July 2020 15 9 0 MAINTENANCE AND SERVICING CLEARANCES ...

Page 18: ...16 Blade 60 80 Twin Plus Water Heater Manual July 2020 10 0 INSTALLATION SCHEMATIC LAYOUT ...

Page 19: ...e 60 80 Twin Plus Water Heater Manual July 2020 17 11 0 CONVERSION TO SPACE HEATING DETAILS The Water Heater can be supplied factory converted and configured to supply both DHW and space heating on request ...

Page 20: ...f1 yearintervalstomaintaintheWaterHeaterwarranties 1 DHWcylindercheckoperationoftheP TRV 2 ExpansionVesselcoldandhotoperating pressurestobechecked 3 CheckincomingwaterMainpressure To maintain the boiler and Water Heater guarantee all the above actions must be carried out including those shown in section 6 in the BOILER MANUAL in Appendix A and recorded in the Service Record at the back of this man...

Page 21: ...Blade 60 80 Twin Plus Water Heater Manual July 2020 19 13 0 WIRING DIAGRAM ...

Page 22: ...ge Cylinder 1 B1 60 TPWH1 3 B1 80 TPWH1 3 300L DHW Storage Cylinder 1 B1 60 TPWH1 4 B1 80 TPWH1 4 Frame 1 B1 60 TPWH1 5 B1 80 TPWH1 5 Electric control box 1 B1 60 TPWH1 6 B1 80 TPWH1 6 Switched Fuse Spur 1 B1 60 TPWH1 7 B1 80 TPWH1 7 DHW Time clock 1 B1 60 TPWH1 8 B1 80 TPWH1 8 Immersion Heater 1 B1 60 TPWH1 9 B1 80 TPWH1 9 Cylinder Stat 1 B1 60 TPWH1 10 B1 80 TPWH1 10 500L DHW Storage Cylinder 1 ...

Page 23: ...sioned at theaboveaddress The system design is in line with current best practice and the system is installed in such a manner as to comply with the relevant Gas Safety and Building Regulations and with all legal requirements All notifiable works have been carried out by suitably qualified personnel and have been notified to the relevant authorities Signed Print Name Date ofCommissioning Declarati...

Page 24: ...charged Bar 1 5 bar 12 Heating Expansion Vessel Capacity Litre Litres 13 Domestic Expansion Vessel Fitted charged Bar Bar 14 Domestic Expansion Vessel Capacity Litre Litre 15 DHW Temperature Sensors Secured Tick Yes 16 Operation of Pressure Relief Valve Heating Tick 3 0 bar 17 Operation of Pressure Relief Valve DHW Cylinder Tick Yes 18 Heating Pumps Vented and Working Tick Yes 19 DHW Pumps Vented ...

Page 25: ...e where possible CO ppm CO2 Comments ANCILLARY EQUIPMENT Visual check of all components TICK TO CONFIRM Test cylinder P TPRV Operation TICK TO CONFIRM Check cylinder expansion vessel pressure which should be set at 0 2 bar below system operation pressure record pressure Bar Clean filter on Combination inlet group TICK TO CONFIRM Signature Service 01 Date Engineer Name Company Name Telephone No Gas...

Page 26: ...e where possible CO ppm CO2 Comments ANCILLARY EQUIPMENT Visual check of all components TICK TO CONFIRM Test cylinder P TPRV Operation TICK TO CONFIRM Check cylinder expansion vessel pressure which should be set at 0 2 bar below system operation pressure record pressure Bar Clean filter on Combination inlet group TICK TO CONFIRM Signature Service 05 Date Engineer Name Company Name Telephone No Gas...

Page 27: ...te where possible CO ppm CO2 Comments ANCILLARY EQUIPMENT Visual check of all components TICK TO CONFIRM Test cylinder P TPRV Operation TICK TO CONFIRM Check cylinder expansion vessel pressure which should be set at 0 2 bar below system operation pressure record pressure Bar Clean filter on Combination inlet group TICK TO CONFIRM Signature Service 9 Date Engineer Name Company Name Telephone No Gas...

Page 28: ...e where possible CO ppm CO2 Comments ANCILLARY EQUIPMENT Visual check of all components TICK TO CONFIRM Test cylinder P TPRV Operation TICK TO CONFIRM Check cylinder expansion vessel pressure which should be set at 0 2 bar below system operation pressure record pressure Bar Clean filter on Combination inlet group TICK TO CONFIRM Signature Service 13 Date Engineer Name Company Name Telephone No Gas...

Page 29: ...Blade 60 80 Twin Plus Water Heater Manual July 2020 27 Notes ...

Page 30: ...APPENDIX A ALPHA BOILER MANUAL ...

Page 31: ...ALPHA HELPLINE Tel 0344 871 8764 website www alpha innovation co uk Set for use with Natural Gas Leave these instructions with the User These instructions have been carefully prepared but we reserve the right to alter the specification at any time in the interest of product improvement Alpha Therm Limited 2020 Part No 1 043049 rev ST 004615 001 0220 D409 Alpha E Tec 20S G C No 41 532 47 Alpha E Te...

Page 32: ...ed Report product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Handoverthemanufacturer sinstructions includingtheBenchmarkChecklist tothecustom...

Page 33: ...es and Ventilation BS 5546 2010 Specification for Water Heating Appliances BS 6798 2009 Specification for Installation gas fired boilers up to 70 kW BS 6891 2005 A2 2008 Installation of low pressure Gas Pipework IGEM UP 2 Installation of pipework IGEM UP 4 Commissioning of gas fired plant IGE UP 10 Installation of Flued gas appliances IGEM UP 16 Design for natural gas installations IGE UP 1 and 1B...

Page 34: ...n point READ AND UNDERSTAND THE INSTRUCTIONS Read and understand the appliance s instructions before performing any operation carefully following the indications provided RECOVERABLE OR RECYCLABLE MATERIAL INFORMATION Indicates useful tips or additional information SAFETY GLOVES SAFETY GOGGLES SAFETY FOOTWEAR The user must not dispose of the appliance at the end of its service life as municipal wa...

Page 35: ...boiler and any external controls Wiring external to the boiler must be in accordance with the current IEE Wiring Regulations BS 7671 Note If a room thermostat is fitted it must be suitable for 230 V switching If the boiler is locked out and an error code is shown on the display the RESET button can be pressed to try and clear the fault If the fault still occurs after pressing the RESET button then...

Page 36: ...temperature Set point C Gas burner injector diameter mm Dry NOx weight net calorific value mg kWh Dry NOx ppm NOx Class Factory set CO2 CO2 at maximum CH output CO2 at maximum DHW output CO2 at minimum output CO max ppm Maximum CO CO2 Ratio SAP SEDBUK seasonality efficiency 2005 SAP SEDBUK seasonality efficiency 2009 ErP Seasonal space heating efficiency Max primary system pressure bar MPa Min pri...

Page 37: ...functioning modes of the pump are available Proportional Fixed and Constant T Proportional The pump speed is controlled automatically in order to give a proportional pump head the pump speed varies based on the heat output supplied by the burner the greater the heat output the higher the pump speed See parameter A3 in Section 6 13 It is possible to adjust the pump speed range in the boiler paramet...

Page 38: ...ass closed dotted area A B Head available with by pass closed B Head available with by pass open C D Power consumed by the pump with by pass open dotted area D Power consumed by the pump with by pass closed dotted area Pump electrical consumption W 0 10 20 30 40 50 60 70 Flow rate l h 200 600 1000 1400 800 1200 1600 400 0 0 1 2 3 4 5 6 7 Head m water Pump electrical consumption W 0 10 20 30 40 50 ...

Page 39: ...ig 3 3 3 5 3 E Tec Plus 35S Available Pump Head and Power Consumption A B Head available with by pass closed B Head available with by pass open C D Power consumed by the pump with by pass open dotted area D Power consumed by the pump with by pass closed dotted area Speed 9 Speed 9 Speed 5 C D B A Alpha E Tec S 20 30 and 35 Technical Data ...

Page 40: ... CONDENSING Condensing boiler NOTE Technical data is provided on the boiler data label and in Section 3 1 If the boiler is used for heating only a single channel control can be fitted Fit the clock or receiver as normal and connect a link between terminals A and 3 on the boiler J2 on PCB J2 on PCB J1 on PCB X4 on PCB Colour Code Bk Black Bl Blue Br Brown G Green Gy Grey G Y Green Yellow Or Orange ...

Page 41: ...1 Air supply pipe 12 Flue temperature sensor 13 Flue test point pressure point 14 Air test point pressure point 15 Burner 16 Primary return sensor 17 Fan 18 Automatic air vent 19 Boiler pump 20 Primary pressure switch 21 By pass 22 Drain point 23 Safety valve indicator 24 Heating return isolation valve 25 Heating flow isolation valve Gas Condensate discharge and expansion relief Primary Heating re...

Page 42: ...Horizontal and vertical flue assemblies should be supported every metre with access provided to the joints All joints between flue sections should be connected using the clamps provided It is not required to add additional screws through the clamps and into the flue sections Additional flue components are available as follows CD EasyFlue 500 mm telescopic terminal Part No 6 12000510 CD EasyFlue 10...

Page 43: ...eneral Boiler Information L A B 90 bend 1 3 metre L A 2 x 45 bends 1 8 metre Fig 4 2 VERTICAL FLUE OPTIONS Hmax 14 m Hmax 12 2 m 14 m 1 8 m 12 m B A A B A HORIZONTAL FLUE OPTIONS Lmax 12 metres Not less than 300 mm H Not less than 300 mm H Fig 4 1 ...

Page 44: ...tion must allow the free passage of air across it at all times 8 The flue terminal must be positioned where products of combustion will freely disperse and not cause a nuisance 9 Where a terminal is sited below 2 m from the ground or floor level the terminal must be protected by a terminal guard In these situations consideration should also be given to prevent nuisance plume and fumes in areas suc...

Page 45: ...ble material without the need for a special thermal insulation barrier If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineers Guide for Gas Installations in Timber Frame Housing reference IGE UP 7 The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the curren...

Page 46: ... By pass The boiler incorporates an automatic by pass an automatic by pass is required for the system when zone valves are used 4 7 FILLING THE CENTRAL HEATING SYSTEM Fig 4 6 The system design pressure cold should be set to 1 0 bar This pressure is equivalent to a static head see Fig 4 5 of 10 2 metres of water Provision must be made for filling the system This is done by the use of a filling loop...

Page 47: ...operation 4 9 DISPOSAL OF CONDENSATE Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha boilers and reference should be made to BS 6798 for the requirements on the disposal of condensate The boilers incorporate a condensate trap which has a seal of greater than 75 mm therefore no additional trap is required The condensate should ideally be discharged...

Page 48: ...mm termination from boiler increase to 32 mm if external 2 fall O 25mm 300mm Two rows of 3 x 12mm holes at 25mm centres 50mm from the bottom of the tube Holes to face away from house Cement mortar sealing 100mm plastic tube Bottom of tube sealed Soakaway depth 400mm filled with limestone chippings 500 mm min ...

Page 49: ...ng bracket 5 INSTALLATION Fig 5 1 Alpha E Tec S 20 30 and 35 Installation 5 1 UNPACKING 1 The boiler carton also contains the following Connection kit union bends washers and valves Mounting bracket plus screws and wall plugs Condensate discharge pipe Literature pack and Wall template A suitable Alpha flue system must be selected to use with the boiler Notes a All flues must be suitable for Alpha ...

Page 50: ... system pipework to the union fittings on the valves just fitted Note When soldering bends ensure they are not connected to the valves otherwise the internal seals may be damaged One metre of copper pipe must be fitted to the boiler before connecting to any plastic pipework conforming to BS 7291 4 Connect the flexible condensate pipe to the rubber connector as shown in Fig 5 4 Using the adaptor su...

Page 51: ...g the telescopic section 4 Pass the flue assembly through the wall from inside or outside Note Internal fitting If there is no access to make good the outside wall locate the outside black flue sealing collar onto the outer duct of the flue immediately before the terminal grille onto the location provided Push the flue assembly through the 130 mm flue hole so that the collar completely passes thro...

Page 52: ...ll by pushing the inside flue sealing collar up to the wall The hole around the flue can be made good using the flue sealing collars supplied or using a suitable sealant cement if required Fig 5 8 Fitting the flue from inside Check collar is sealing the wall and it is not restricting any openings of the flue terminal 130 mm Fig 5 9 Rear flue Allow 20 mm 30 mm Do not cut past this point Fig 5 10 5 ...

Page 53: ...ion ensure the slope towards the boiler is correct 3 Determine the overall flue length as described in Section 5 6 paragraph 2 to determine the number of Alpha CD 750 or 1000 mm flue extensions required 4 Assemble the flue extensions together by locating the inner duct into the seal joint and secure each extension together with the extension clamps supplied three screws Ensure that the clamps are ...

Page 54: ...5 12 securing the terminal and remove the terminal by pulling it from the flue assembly Remove the screw 2 in Fig 5 12 securing the terminal end section and remove the end section from the terminal ii Locate a 93 Plume Management bend into the flue assembly and rotate it to the direction required iii Connect to the 93 bend the required Plume Management components as detailed and refer to Fig 5 13 ...

Page 55: ... Easy Flue Ensure there is a slope of approximately 3 back towards the Easy Flue Fig 5 13 Note The equivalent horizontal flue assembly length the equivalent plume management length PM length must not exceed the maximum flue length stated for each boiler i e E Tec boilers the maximum equivalent flue length must not exceed 12 metres Note 1 Ensure each joint is secured with the screw supplied 2 Ensur...

Page 56: ...1 FITTING BOILER CONTROLS It is recommended that Alpha controls are used with the boiler to maintain efficient and correct operation of the boiler Please note that using controls that are not supplied or recommended by Alpha may invalidate the boiler warranty and may not control the boiler correctly Alpha offer a number of controls options from simple in built mechanical timers to remote wireless ...

Page 57: ...r to operate with alternative control type 1 External Sensor Weather compensation feature The weather compensation sensor can only be used on an E Tec S boiler when the Alpha Diverter Kit part No 6 5500048 is used otherwise the DHW temperature will be affected The E Tec S boilers have a built in weather compensation feature which is automatically activated when the external sensor is fitted Part N...

Page 58: ...ndependantly set using the two thermostat knobs on the boiler control panel or the control dials on the Alpha Climatic control unit if fitted Diverter kit Part number 6 5500048 Climatic Control Unit Wired Part number 3 022144 Climatic Control Unit RF Part number 3 022143 Remove the Cylinder Resistor R8 when connectiong the Cylinder Sensor to terminals 38 and 48 See Figs 3 3 and 5 20 Check that Par...

Page 59: ...until water is heard to flow see Section 4 7 4 To remove the air Vent each radiator in turn starting with the lowest in the system 5 Check the operation of the safety valve see Fig 7 6 by turning the head anti clockwise until it clicks The click is the valve lifting off its seat allowing water to escape from the system check that this is actually happening 6 Continue to fill the system until the p...

Page 60: ...5 11 6 From this moment the boiler functions automatically With no demand for heat central heating or domestic hot water production the boiler goes to standby function Each time the burner ignites the flame present symbol is displayed together with the relative strength of the flame output power 7 Operation with Climatic control Optional If the Climatic control is connected Apha Diverter Kit requi...

Page 61: ...hermostats should be considered Pump Cycle If the electrical supply is on and the boiler has not operated for 24 hours in heating or hot water the pump will operate automatically for thirty seconds every 24 hours 6 6 checking the combustion chimney sweep mode As part of the Benchmark Checklist procedure the combustion levels of the boiler when the installation is completed must be measured and rec...

Page 62: ...d if necessary of the following important points 1 How to light and turn off the boiler and how to operate the system controls 2 The importance of annual servicing of the boiler to ensure safe and efficient operation and maintain the boiler guarantee 3 That any servicing or replacement of parts must only be carried out by a Gas Safe registered engineer 4 Ensure that the boiler controls and room th...

Page 63: ...low Fan speed during current operation Flue sensor reading Calculated flow temperature Screed heat function hours operated Toggles between safety software version functional software version Not used Not used Service reminder function number of months remaining Units Shown µA C C C C C C Error code Speed level l h 100 rpm 100 C C h n a months 6 11 CONVERTING THE BOILER TO OPERATE ON LPG If the boi...

Page 64: ...er the chimney sweep mode with no DHW demand use the DHW down button to set the output to minimum 0 Insert the analyser probe into the flue test point Fig 6 3 and check that the CO2 value is as specified in Section 3 1 otherwise adjust the screw Fig 6 2 To increase the CO2 value turn the adjustment screw in a clockwise direction and vice versa to decrease Calibration of the maximum CO2 nominal DHW...

Page 65: ... mode button for more than 1 second to store the parameter value Confirmation is given by the numbers 88 which appear for 2 seconds To access the programming menu press and hold the RESET and INFO buttons at the same time for 5 seconds the display will show two flashing dashes next enter the password 69 to access the programming menu Once in the menu you can scroll through the four submenus P t A ...

Page 66: ...enabled 6 When boiler pump active 7 Alpha Trace heating cable enabled 8 Not used 9 Not used The boiler pump can function in two ways 0 Intermittent The pump is controlled according to the heating request of a room thermostat or remote control 1 Continuous In Winter mode the pump runs continuously If the reading of the external sensor is not correct it is possible to adjust the reading to correlate...

Page 67: ...gh The display is always lit with high intensity LCD display setting Summer mode 0 The display is always off 1 Displays the flow temperature during operation and off when no request Winter mode 0 The display shows the set value of the CH selector 1 The display shows the flow temperature during operation and the set value with no request The switch off temperature of the flow is increased by the se...

Page 68: ...ordance with the analyser manufacturers requirements 3 Competence can be demonstrated by satisfactory completion of the CPA1ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Combustion check Connect the flue gas analyser to the flue gas sampling point as shown in Fig 6 3 Notes 1 Prior to servicing it is recommended that a fl...

Page 69: ...zero 2 The expansion vessel pressure test point is accessible from on top at the top left side 5 Check that the condensate trap drain pipe is connected and all joints are sound 6 Record details of the service in the Service Record at the back of these instructions 7 2 CASING REMOVAL Figs 7 1 7 2 7 3 and 7 4 To facilitate boiler servicing and maintenance the casing can be completely removed as foll...

Page 70: ...e panels Fig 7 4 8 Remove the screws H securing the side panel I Lift the side panel and pull it forwards unhooking it from the rear panel view A in Fig 7 4 Lower the panel out and away from the top cover Note The side panels require no sealing strip as the front case insulation forms the room seal Fig 7 3 Fig 7 4 6 7 G G 6 6 6 A A A H A View A I H A A I H 8 H 8 8 ...

Page 71: ...y are in good condition remove any oxide deposits using a fine abrasive paper If it is necessary to replace the electrode assembly ensure a new gasket is used 3 Check that the fan is clean and rotates freely Carefully clean the impellor with a soft bristle brush if necessary 7 5 CLEANING THE HEAT EXCHANGER with the condensate trap in place 1 Remove any deposits from the heat exchanger coils using ...

Page 72: ...s valve 11 Boiler drain point 12 Safety valve operation indicator 13 Test points air A flue F 14 Flue temperature sensor 15 Four fixing nuts for item 16 16 Combustion chamber front assembly 17 Primary heat exchanger 18 Venturi 19 Primary return temperature sensor 20 Primary pressure switch 21 Automatic air vent 22 Boiler pump 23 3 bar safety valve 24 By pass A F 2 7 11 6 10 12 1 4 8 9 13 14 17 18 ...

Page 73: ... pipe 6 Re fit the ignition lead to the electrode 7 Check all the connections are sound and re commission Sections 6 3 and 6 8 8 Raise the control panel and clip into place 9 Check that the insulation on the back of the case front panel is intact and in position it also acts as a case seal then place the panel in position over the top pins and secure with the two screws previously removed 10 Refit...

Page 74: ... combustion chamber using a 3 mm allen key and carefully withdraw the electrode 3 Fit the new electrode assembly with a new gasket and re assemble in reverse order 4 Test the boiler check the ignition and test the combustion as described in Section 7 8 4 MAIN BURNER 1 Remove the complete burner fan air inlet assembly as described in Routine Servicing Section 7 3 2 Open the three spring clips see F...

Page 75: ... flue analyser Isolate the boiler gas supply and gain access as described in Section 8 1 1 Disconnect the electrical plug from the gas valve 2 Remove the gas pipe retaining clip and remove the pipe 3 Disconnect the gas valve union beneath the boiler 4 Remove the two screws from beneath the boiler disconnect the gas valve pressure tube and lift out the valve assembly 5 Unscrew the brass union from ...

Page 76: ...sconnect it from the bottom bracket and withdraw it from the boiler 9 Refit the flue temperature sensor 10 Reassemble in reverse order using the lubricant supplied with the heat exchanger kit Note Lubricating the seals with soap and water will aid assembly 11 Refill boiler pressurise the system and visually inspect for leaks 12 Test the boiler check the ignition and test the combustion as describe...

Page 77: ...ch the polarity of the wires is not important 8 17 SAFETY VALVE Fig 7 6 Gain access and drain the boiler heating circuit as described in Sections 8 1 and 8 2 1 Disconnect the clear plastic tube from the pressure relief valve 2 Remove the retaining clip securing the expansion relief valve and pull the valve forwards to remove 3 Re assemble in reverse order 4 Refill and pressurise the system Refer t...

Page 78: ...3 X2 X3 X1 X6 X5 1 6 1 5 4 1 7 1 4 1 XF1 T2 Bl Br Bk J1 3 1 Bl R Br Bk Y Br Bk R Y Y Or Or P P B1 B5 B10 R W R W S5 Or Or G Y G Y G Y Remove link to connect 230 V room thermostat When an Alpha Climatic control is connected to terminals 41 and 44 remove the links between terminal blocks 1 and 2 B4 R Or Y Bk Or Y Mains Supply 230 V 50 Hz Br Bl G Y 44 40 41 38 39 38 48 For testing only Bk R Chassis e...

Page 79: ...sor wire connections or sensor faulty Check parameter A6 set to 1 Refer to fault history codes INFO menu d9 Check expansion vessel pressure 1 bar Leak in system Expansion relief valve operated Primary pressure switch Check cylinder sensor wiring connections Faulty sensor Check the settings of the A family parameters Check fan wiring connections Fan fault PCB fault Check flame sensing electrode and...

Page 80: ...rical pump fault Restricted CH flow due to air or a circuit restriction Possible failure of one or both sensors Possible failure of one or both sensors Check sensor wiring and connections Check sensor resistance Remote control or receiver connection wiring Distance or interference of RF signal Remote control or receiver fault Check batteries if using RF controller Check mains power supply Check fo...

Page 81: ...y to be read To permanently reset the error Sr E97 1 Enter the parameter menu using the password 69 See Section 6 13 2 Parameter P6 will show 0 3 Set P6 to any value above zero save by pressing the mode button and wait for 88 to be displayed as confirmation 4 Then set P6 to 0 save by pressing the mode button and wait for 88 to be displayed as confirmation 5 Now set the parameter P6 at the number o...

Page 82: ...pling point cap Complete boiler seal kit Hydraulic circuit seal kit Complete heat exchanger seal kit Gas pipe to fan manifold Gas pipe O ring Clip Flow return pipe to heat exchanger Clip Gas pipe connections Boiler wall bracket Boiler connection kit Boiler accessory box complete Wall template Burner front insulation panel 20 30 Burner front insulation panel 35 Flue sensor Rear combustion insulatio...

Page 83: ...tlet Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature Model s E Tec 30S Condensing boiler YES Low temperature boiler NO B1 boiler NO Cogeneration space heater NO Equipped with a supplementary heater NO Combination heater NO Item Symbol Value Unit Item Symbol Value Unit Rated heat output Pn 28 kW Seasonal space heating ...

Page 84: ...tby 0 055 kW At part load elmin 0 007 kW Ignition burner power consumption Pign 0 000 kW In standby mode PSB 0 002 kW Emissions of nitrogen oxides NOX 34 mg kWh For combination heaters Declared load profile Water heating energy efficiency ηWH Daily electricity consumption Qelec kWh Daily fuel consumption Qfuel kWh Contact details Alpha Therm Ltd Nepicar House Wrotham Heath Kent TN15 7RS High tempe...

Page 85: ... the distribution system and the dimensioning of the products in relation to building size and characteristics Seasonal space heating energy efficiency of package Seasonal space heating energy efficiency class of package Solar contribution From fiche of solar device Class I 1 Class II 2 Class III 1 5 Class IV 2 Class V 3 Class VI 4 Class VII 3 5 Class VIII 5 2 3 Seasonal space heating energy affic...

Page 86: ... x II III I Auxiliary electricity 3 G F E D C B A A A A 27 27 27 28 27 27 27 28 30 30 30 32 33 34 35 36 36 37 38 40 39 50 55 60 65 75 80 85 100 115 123 131 130 150 160 170 163 188 200 213 M L XL XXL 3 2 3 2 The energy efficiency of the package of products provided for in this fiche may not correspond to its actual energy efficiency once installed in a building as the efficiency is influenced by fu...

Page 87: ... 3 ______ x 0 1 _____ x _______ 0 5 x O 0 5 x 4 5 6 7 4 5 Collector size in m2 Tank volume in m3 Collector efficiency in Tank rating A 0 95 A 0 91 B 0 86 C 0 83 D G 0 81 ____ x ____ x x 0 9 x 100 x G F E D C B A A A A 30 30 34 36 75 82 90 98 125 150 7 50 x ______ ____ 12 5 Room heating system assembly chart Class I 1 Class II 2 Class III 1 5 Class IV 2 Class V 3 Class VI 4 Class VII 3 5 Class VIII...

Page 88: ...5 36 36 37 38 40 39 50 55 60 65 75 80 85 100 115 123 131 130 150 160 170 163 188 200 213 M L XL XXL 3 2 3 2 The energy efficiency of the package of products provided for in this fiche may not correspond to its actual energy efficiency once installed in a building as the efficiency is influenced by further factors such as heat loss in the distribution system and the dimensioning of the products in ...

Page 89: ...59 Alpha E Tec S 20 30 and 35 Page intentionally Blank ...

Page 90: ...ers complete DHW mode gas rate m3 hr or ft3 hr Central heating output left at factory settings Yes No If no what is the maximum central heating output selected kW Dynamic gas inlet pressure mbar Central heating flow temperature C Central heating return temperature C System correctly balanced rebalanced Yes COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No Water ...

Page 91: ...l service in accordance with the manufacturers instructions and BS 7593 It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non water facing component SERVICE INTERIM WORK ON BOILER delete as appropriate Date Engineer name Company name Telephone No Gas Safe registration No Max rate CO ppm CO CO CO Min rate CO ppm CO...

Page 92: ...l service in accordance with the manufacturers instructions and BS 7593 It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non water facing component SERVICE INTERIM WORK ON BOILER delete as appropriate Date Engineer name Company name Telephone No Gas Safe registration No Max rate CO ppm CO CO CO Min rate CO ppm CO...

Page 93: ...l service in accordance with the manufacturers instructions and BS 7593 It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non water facing component SERVICE INTERIM WORK ON BOILER delete as appropriate Date Engineer name Company name Telephone No Gas Safe registration No Max rate CO ppm CO CO CO Min rate CO ppm CO...

Page 94: ...eration Remember to reset any controls if fitted when the supply is restored If the mains water supply fails there will be no hot water from the taps The boiler will continue to provide central heating 4 ADDITIONAL BATHROOM FITTINGS Any equipment such as mixing valves showers bidets etc must be designed to operate at mains water pressure Contact your plumbing merchant or installer for advice when ...

Page 95: ...ystem for external condensate drainage pipework incorporating an external frost thermostat should be considered 7 GAS SAFETY REGULATIONS Current Gas Safety Installation and Use Regulations It is the law that all gas appliances are installed and serviced by a competent person i e Gas Safe registered personnel Failure to install or service appliances correctly could lead to prosecution It is in your...

Page 96: ...perature will still be maintained as set by the room thermostat When an external weather sensor is fitted the central heating selector buttons items 6 and 7 in Fig 1 will no longer adjust the flow temperature in C instead the display will show a scale of 1 to 9 Each number corresponds to a line on the graph in Fig 2 i e line 6 will give a flow temperature of 60 C when the external temperature is 1...

Page 97: ...this mode the boiler can be switched between Summer or Winter settings by pressing the Mode button item 1 in Fig 1 Fig 1 If the boiler is locked out and an error code is shown on the display the RESET button can be pressed to try and clear the fault If the fault still occurs after pressing RESET then contact an approved engineer or Alpha service support department The boiler can be used by childre...

Page 98: ...ired High Efficiency Condensing System Boiler Nepicar House London Road Wrotham Heath Sevenoaks Kent TN15 7RS For Technical help or for Service call ALPHA HELPLINE Tel 0344 871 8764 website www alpha innovation co uk Set for use with Natural Gas Leave these instructions with the User ...

Page 99: ...Blade 60 80 Twin Plus Water Heater Manual July 2020 29 APPENDIX B DAB PUMP MANUAL ...

Page 100: ...11 1 1 Regulation with Proportional Differential Pressure 42 11 1 2 Regulation with Constant Differential Pressure 43 11 1 3 Regulation with constant curve 43 12 CONTROL PANEL 44 12 1 Elements on the Display 44 12 2 Graphic Display 44 13 FACTORY SETTINGS 47 14 TYPES OF ALARM 47 15 MAINTENANCE 47 16 DISPOSAL 47 17 DIMENSIONs 48 18 PERFORMANCE CURVES 50 INDEX OF FIGURES Figure 1 Pumped liquids warni...

Page 101: ...ble 2 Technical data 32 Table 3 Maximum head Hmax and maximum flow rate Qmax of EVOSTA2 EVOSTA3 circulators 33 Table 4 Mounting the Evosta3 connector 39 Table 5 Mounting the Evosta2 connector 40 Table 6 Pump operating modes 46 Table 7 Types of Alarm 47 ...

Page 102: ...sed by children under 8 years old or by persons with reduced physical sensory or mental capacities or who lack experience or knowledge unless they are under supervision or after they have received instructions concerning the safe use of the appliance and the understanding of the dangers involved Children must not play with the appliance Ensure that the product has not suffered any damage during tr...

Page 103: ...ent a complete range of circulators These installation and operating instructions describe EVOSTA2 and EVOSTA3 models The type of model is indicated on the pack and on the identification plate The table below shows the EVOSTA2 and EVOSTA3 models with built in functions and features Functions features EVOSTA 2 EVOSTA 3 Proportional pressure Constant pressure Constant curve Dry running protection Au...

Page 104: ...d against Overloads Lack of phase Excess temperature Over voltage and under voltage 6 TECHNICAL DATA Supply voltage 1x230 V 10 50 60 Hz Absorbed power See electrical data plate Maximum current See electrical data plate Grade of protection IPX5 Protection class F TF Class TF 110 Motor protector No external motor protector is needed Maximum environment temperature 40 ºC Liquid temperature 10 ºC 110 ...

Page 105: ...irculator use lifting devices with the aid of the pallet supplied with it if contemplated 7 3 Weight The adhesive plate on the packaging indicates the total weight of the circulator 8 INSTALLATION Carefully follow the advice in this chapter to carry out correct electrical hydraulic and mechanical installation Always switch off the mains power supply before working on the electrical or mechanical p...

Page 106: ...s 8 2 User Interface Position Always install the EVOSTA2 EVOSTA3 circulator with the motor shaft in a horizontal position Install the electronic control device in a vertical position Figure 3 Assembly position The circulator may be installed in heating and conditioning systems on either the delivery pipe or the return pipe the arrow marked on the pump body indicates the direction of flow Install t...

Page 107: ... the circulating water It is recommended that the addition of antifreeze where necessary should not exceed 30 In the event of heat insulation use the special kit if provided and ensure that the condensate draining holes in the motor casing are not closed or partly blocked In the case of maintenance always use a set of new gaskets Never insulate the electronic control device 8 2 1 Positioning of th...

Page 108: ... to maintain the grade of IP protection and to allow the user a more convenient interaction with the graphic interface Before rotating the circulator ensure that it has been completely drained To rotate the EVOSTA2 EVOSTA3 circulator proceed as follows 1 Remove the 4 fixing screws of the circulator head 2 Rotate the motor casing with the electronic control device through 90 degrees clockwise or co...

Page 109: ...8 4 Non return valve If the system is equipped with a non return valve ensure that the minimum pressure of the circulator is always higher than the valve closing pressure 8 5 Insulating the pump body only for Evosta3 Figure 7 Insulating the pump body It is possible to reduce the loss of heat from the EVOSTA3 pump by insulating the pump body with the insulating shells supplied with the pump See fig...

Page 110: ...d mains connections are admissible The appliance must be earthed IEC 536 class 1 NEC and other applicable standards THE SYSTEM MUST BE CORRECTLY AND SAFELY EARTHED It is advised to install a correctly dimensioned differential switch to protect the system type class A with adjustable leakage current selective The automatic differential switch must be marked with the following symbols The circulator...

Page 111: ...nector on the cable Strip the wires as indicated in the figure Connect the wires to the terminal board respecting the phase neutral and earth Illustratio n Phase 4 5 Action Insert the wired terminal board in the cable gland securing it with the side clips Screw on the locking nut Connect the wired connector to the pump securing it with the rear hook Illustratio n Table 4 Mounting the Evosta3 conne...

Page 112: ... the cable gland Screw on the locking nut Connect the wired connector to the pump and tighten the retaining screw Illustration 10 START Table 5 Mounting the Evosta2 connector All the starting operations must be performed with the cover of the EVOSTA2 EVOSTA3 control panel closed Start the system only when all the electrical and hydraulic connections have been completed Avoid running the circulator...

Page 113: ...ENGLISH 41 It is dangerous to touch the circulator DANGER OF SCALDING ...

Page 114: ...ssible to modify the operating modes to adapt better to the plant requirements see par 12 10 1 Degassing the pump Figure 8 Venting of the pump 10 2 Automatic Degassing Automatic degassing occurs only for the Evosta3 pump Hold down the Mode key for 3 and the function starts 1 minute at maximum speed then it passes to the set mode Figure 9 Automatic venting of the pump Always vent the pump before st...

Page 115: ...lating mode the differential pressure is reduced or increased as the demand for water decreases or increases The Hs set point may be set from the display Regulation indicated for Heating and conditioning plants with high load losses Plants with secondary differential pressure regulator Primary circuits with high load losses Domestic water recirculating systems with thermostatic valves on the risin...

Page 116: ...splay Regulation indicated for Heating and conditioning plants with low load losses Single pipe systems with thermostatic valves Plants with natural circulation Primary circuits with low load losses Domestic water recirculating systems with thermostatic valves on the rising columns In this regulating mode the circulator works on characteristic curves at a constant speed Regulation indicated for he...

Page 117: ...ion in Watt the flow rate in m3 h the head in metres and the set curve 3 Key for selecting the pump setting 4 Luminous segments indicating the set curve 12 2 Graphic Display 12 2 1 Luminous segments indicating the pump setting The pump presents nine setting options that can be selected with the key The pump settings are indicated by six luminous segments on the display 12 2 2 Key for selecting the...

Page 118: ...he display switches off and only the operating mode LED remains lit If the selection key is pressed within 10 the display performs 6 viewing cycles then goes into stand by If the key is pressed again within 10 the display performs 11 more viewing cycles to allow a greater reading time Height of the selected curve 1 2 3 Instantaneous power absorption in Watt Instantaneous head in m Instantaneous fl...

Page 119: ...e curve with proportional pressure PP2 3 Higher curve with proportional pressure PP3 4 Lower curve with constant pressure CP1 5 Intermediate curve with constant pressure CP2 6 Higher curve with constant pressure CP3 7 Lower constant curve I 8 Intermediate constant curve II 9 Higher constant curve III Table 6 Pump operating modes ...

Page 120: ...NCE Table 7 Types of Alarm Cleaning and maintenance activities must not be carried out by children under 8 years of age without supervision by a qualified adult Before starting any work on the system before starting to look for faults it is necessary to disconnect the power supply to the pump take the plug out of the socket and read the use and maintenance instructions 16 DISPOSAL This product or ...

Page 121: ...2 40 70 80 130 1 2 M230 50 60 130 65 65 135 36 99 1 94 Ø91 142 96 EVOSTA2 40 70 80 130 1 M230 50 60 130 65 65 135 36 99 1 1 2 94 Ø91 142 96 EVOSTA2 40 70 80 180 1 M230 50 60 180 90 90 135 36 99 1 1 2 94 Ø91 142 96 EVOSTA2 40 70 80 180 1 1 4 M230 50 60 180 90 90 135 36 99 2 94 Ø91 142 96 ...

Page 122: ... 60 157 78 5 65 130 144 45 99 1 110 Ø91 153 107 5 EVOSTA3 40 60 80 130 1 M230 50 60 157 78 5 65 130 144 45 99 1 1 2 110 Ø91 153 107 5 EVOSTA3 40 60 80 180 1 M230 50 60 157 78 5 90 180 144 45 99 1 1 2 110 Ø91 153 107 5 EVOSTA3 40 60 80 180 1 1 4 M230 50 60 157 78 5 90 180 144 45 99 2 110 Ø91 153 107 5 ...

Page 123: ...ENGLISH 51 18 PERFORMANCE CURVES EVOSTA2 40 70 XXX ...

Page 124: ...ENGLISH 52 EVOSTA2 80 XXX ...

Page 125: ...ENGLISH 53 EVOSTA3 40 XXX ...

Page 126: ...ENGLISH 54 EVOSTA3 60 XXX ...

Page 127: ...ENGLISH 55 EVOSTA3 80 XXX ...

Page 128: ...BLADES LOW CARBON SYSTEMS Ltd 4 Valhalla Industrial Estate Holsworthy Devon EX22 6HN For Technical help or Service call 01566 770799 info bladeslcs co uk www bladeslcs co uk ...

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BLADES LCS BLADE TWIN PLUS TPWH60, Installation & Service Manual

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