Alpha Boilers Alpha C23 Installation And Servicing Instructions Download

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Installation and Servicing

Instructions

Alpha C23/27

Range of Wall Mounted, Fan Assisted, Room Sealed,

Gas Fired Combination Boilers

Nepicar House, London Road,

Wrotham Heath, Sevenoaks,

Kent TN15 7RS

For Technical help or for Service call ...

ALPHA HELPLINE

Tel: 0870 3001964

*HEJEID/=I

Service Listed

For use with Natural Gas only

Leave these instructions with the User

Alpha C23

G.C. No. 47 532 22

Alpha C27

G.C. No. 47 532 23

Summary of Contents for Alpha C23

Page 1: ...ired Combination Boilers Nepicar House London Road Wrotham Heath Sevenoaks Kent TN15 7RS For Technical help or for Service call ALPHA HELPLINE Tel 0870 3001964 HEJEID I Service Listed For use with Natural Gas only Leave these instructions with the User Alpha C23 G C No 47 532 22 Alpha C27 G C No 47 532 23 ...

Page 2: ...installed by a competent person ie CORGI registered personnel in accordance with the following recommendations Current Gas Safety Installation and Use Regulations All current Building Regulations issued by the Department of the Environment i e Approved Document L1 Building Standards Scotland Consolidation Regulations issued by the Scottish Development Department UK Water Regulations Byelaws Scotla...

Page 3: ...in wg Gas Rate m h ft h Flow Rate at 35 C Rise L min G P M Room sealed chamber panel fitted MAX 33 0 112 600 27 0 92 100 11 3 4 52 3 14 110 9 11 0 2 42 MIN 14 3 48 800 8 1 27 600 1 21 0 48 1 03 36 4 Domestic Hot Water Heat Input kW Gross Btu h Output to Water modulating kW Btu h Burner Pressure mbar Settings in wg Gas Rate m h ft h Flow Rate at 35 C Rise L min G P M Room sealed chamber panel fitte...

Page 4: ... to 0 5 m of flue length The Vertical Flue terminal assembly is equivalent to 1 m of flue length 2 8 AVAILABLE PUMP HEAD FOR CENTRAL HEATING gal min 3 7 2 8 2 3 1 8 1 5 Btu h 79 500 60 000 50 000 40 000 31 700 kW 23 3 17 58 14 65 11 63 9 3 metres 1 4 2 8 3 5 4 1 4 95 feet 4 6 9 2 11 5 13 5 14 6 Output Available pump head metres 2 2 3 4 3 8 4 35 4 65 feet 7 2 11 2 12 5 14 3 15 26 metres 2 5 1 9 1 2...

Page 5: ...er 10 Fan 11 Air pressure switch 12 Flue hood 13 Overheat thermostat 14 Expansion vessel 15 Automatic air vent Fig 2 16 Pump 17 Drain point 18 Pressure relief valve 19 Primary pressure switch 20 Ignition electrode front 21 Flame sensing electrode rear 22 DHW temperature sensor 23 Flue sampling point 24 Gas service cock 25 Mains inlet on off valve 26 On off valve 2 off 27 Automatic by pass ...

Page 6: ...es for servicing must always be maintained Note A cupboard or compartment used to enclose the boiler must be designed and constructed specifically for the purpose i e comply with the Building Regulations 3 4 FLUE SYSTEM Fig 3 The flue system must be installed in accordance with BS 5440 1 For horizontal flues ensure there is a slight downward slope towards the terminal Flue components are available...

Page 7: ...TAL FLUE OPTIONS Lmax 3 metres L B C E 185 mm Alpha C23 27 General Boiler Information L B C 185 mm C B E C B E B F B C L B E F 185 mm 90 bend 1 metre L B C 185 mm 2 x 45 bends 1 metre Fig 3 VERTICAL FLUE OPTIONS ...

Page 8: ...le have access the terminal must be protected by a terminal guard A suitable guard is available from Tower Flue Components Ltd Vale Rise Tonbridge Kent TN9 1TB 3 6 BOILER LOCATION The boiler is not suitable for external installation The boiler must be installed on a flat vertical wall which is capable of supporting the weight of the boiler The boiler can be fitted to or adjacent to a wall comprisi...

Page 9: ... Mains water supply Stop valve Test cock Double check valve assembly Overflow Heating circuit return Fig 6 Fig 7 3 8 FILLING THE CENTRAL HEATING SYSTEM Figs 6 7 The system design pressure cold should be set to 1 0 bar This pressure is equivalent to a static head see Fig 5 of 10 2 metres of water Provision should be made to replace water lost from the system This can be by manual or automatic means...

Page 10: ... and burner to operate is 2 0 litres min The incoming mains water pressure should be between 0 2 and 8 bar to ensure efficient operation If the pressure is above 7 bar a pressure reducing valve must be fitted To ensure economic use the pipe runs between the boiler and taps should be in 15 mm copper pipe and be as short as possible Where possible the pipework should be insulated to reduce heat loss...

Page 11: ...27 Installation Fig 10 Fig 9 4 4 FIT THE BOILER Refer to Fig 10 1 Lift the boiler and locate it on the mounting bracket 2 Fit the bottom screws to secure the boiler in position 4 5 CONNECT THE PIPEWORK Fig 11 1 Thoroughly flush out all the water pipework 2 The valves fittings have been factory fitted however check that all the connections underneath the boiler have been tightened especially the un...

Page 12: ...he collar completely passes through the wall Then pull the flue assembly back into the correct position Visually check that the collar is sealing the outside wall and that it is not restricting any of the openings of the flue terminal 10 Position the seal and clamp two screws supplied with the bend over the boiler flue adaptor Fit the bend and rotate to the correct position then secure in position...

Page 13: ...flue duct length finished wall thickness 172 mm Side flue Outer air duct length finished wall thickness the distance from the inside wall to the side of the boiler 145 mm Inner flue duct length finished wall thickness the distance from the inside wall to the side of the boiler 182 mm 5 When measuring the outer duct measure from the end of the tube as shown in Figs 12 and 13 6 Cut both the inner an...

Page 14: ...erminal block cover and remove the link between terminals 1 and 2 Pass the cable through the cable clamp and connect it to terminals 1 and 2 Replace the terminal block cover Refer to section 2 9 4 Replace the terminal block ensuring it is located correctly on the plastic pins and replace the cover 5 Ensure that there is sufficient free cable to allow the control panel to be raised and lowered then...

Page 15: ... the exposed spindle about half a turn then replace the cap 6 Check the operation of the pressure relief valve see Fig 2 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 7 Continue to fill the system until the pressure gauge indicates 1 0 bar Close the fill point valve and c...

Page 16: ...ner pressure test point screw on the gas valve and connect a pressure gauge Allow the boiler to run for 10 minutes and check the burner pressures Hot water mode 1 Settheselectorswitchto DHWonly andfullyopenahotwatertap 2 The burner will light at the ignition rate and the burner pressure will increase to maximum 3 Gradually close the hot tap and check that the burner pressure decreases to its minim...

Page 17: ...trols the operating times of the central heating not domestic hot water DHW is available continuously Domestic hot water supply always takes priority over central heating If a demand for hot water is required during a central heating period the boiler will automatically switch to the hot water mode until the demand is satisfied This interruption in the central heating is only when the demand for h...

Page 18: ...intervals The frequency of servicing will depend upon the particular installation conditions and usage but in general once per year should be adequate It is the law that any service work must be carried out by a competent person i e CORGI registered personnel Warning Before servicing the boiler isolate the electrical supply and close the boiler gas service cock Allow the boiler to cool The data la...

Page 19: ...jector that appears damaged 6 Clean the top of the burner with a soft brush and check that the flame ports are clear Blockages may be removed with a stiffer brush Tap the burner open end down to remove any deposits from inside 7 Check the condition of the electrodes 9 Check the spark gap positioning and height of the electrodes see Fig 19 10 Check that the fan impeller is clean and free to rotate ...

Page 20: ...se the central heating flow and return valves see Fig 11 Connect a suitable pipe to the drain point see Fig 2 and route it to a suitable container Open the drain point 2 Hot water circuit Close the mains water inlet valve see Fig 11 Open any hot tap below the level of the boiler to allow as much draining as possible Note Some water will remain in the components and care must be taken when removing...

Page 21: ...e and test the boiler as described in Routine Servicing section 7 4 paragraphs 5 to 9 8 8 AIR PRESSURE SWITCH Fig 20 1 Gain access to the combustion chamber as in section 8 1 2 Disconnect the pressure sensing tube 3 Remove the fixing screw and disconnect the wiring 4 Connect the wiring to the new switch The polarity of the wires is not important 5 Secure the new switch in position and connect the ...

Page 22: ... the boiler take care not to damage the manifold sealing washer and lift out the valve assembly 7 Fit the new assembly and re assemble in reverse order 8 Light the boiler and test for gas soundness Refer to Commissioning section 5 4 9 Complete re assembly as described in Routine Servicing section 7 4 paragraphs 5 to 9 8 11 VIEWING WINDOW 1 Gain access behind the casing as in section 8 1 2 Remove t...

Page 23: ...r at the rear of the control panel 3 Disconnect the wiring from the clock 4 Remove the clock retaining screws and withdraw the clock from the control panel 5 Fit the new clock and connect the wires as follows Blue to terminal 1 Brown to terminal 2 and Red wires to terminals 3 and 4 or as per the instructions supplied with the clock 6 Re assemble in reverse order Refer to the User s instructions an...

Page 24: ...rcuit for primary sensor or hot water circuit for DHW sensor as described in section 8 2 2 Primary Sensor The primary sensor is positioned on the right hand side of the heat exchanger see Fig 20 Disconnect the wiring and unscrew the sensor Re assemble in reverse order with a new sensor and sealing washer 2a DHW Sensor Close the mains cold water inlet valve and open the lowest hot water tap to drai...

Page 25: ...ch 3 Unscrew the switch from the primary flow pipe 4 Using the new washer supplied re assemble in reverse order When connecting the wiring to the new switch the polarity of the wires is not important 8 23 PRESSURE RELIEF VALVE Fig 25 1 Gain access behind the casing and drain the boiler heating circuit as described in sections 8 1 and 8 2 2 Remove the four screws securing the bottom tray and remove...

Page 26: ...hich case an additional vessel should be fitted external to the boiler in the central heating return pipe as close to the boiler as possible see Fig 5 1 Gain access behind the casing and drain the boiler heating circuit as described in sections 8 1 and 8 2 2 Disconnect the pipe from the pump inlet manifold and expansion vessel 3 Remove the four screws securing the top support plate 4 Lift the expa...

Page 27: ...27 9 1 ILLUSTRATED WIRING DIAGRAM Alpha C23 27 Wiring Diagrams 9 WIRING DIAGRAMS ...

Page 28: ...28 Alpha C23 27 Wiring Diagrams 9 2 FUNCTIONAL FLOW WIRING DIAGRAM ...

Page 29: ...Continuity Resistance to Earth Short Circuit and Polarity with a suitable meter Note These checks must be repeated after any servicing or fault finding 3 Ensure all external controls are calling for heat and check all external and internal fuses 4 Check that the gas and water pipework has been connected to the correct connections on the boiler and all valves are open However before any servicing o...

Page 30: ...30 Alpha C23 27 Fault Finding 10 3 DOMESTIC HOT WATER Follow operational sequence ...

Page 31: ...31 Alpha C23 27 Fault Finding 10 4 FAULT FINDING SOLUTIONS A to F ...

Page 32: ...32 Alpha C23 27 Fault Finding 10 5 FAULT FINDING SOLUTION SECTIONS G to L ...

Page 33: ...ion panel set C23 Combustion chamber insulation panel set C27 Description British Gas GC No E57 720 H06 131 E57 733 E57 733 H06 195 H06 146 E57 665 E57 666 H06 201 H06 205 H06 214 E76 320 H06 219 H06 220 H06 221 E76 317 E76 378 E57 700 E57 702 E57 703 E57 709 E57 710 H06 222 E57 714 H06 223 E57 717 E65 498 H06 224 H06 225 Alpha Pt No 1 015368 1 019850 1 4270 1 4270 1 015417 1 019349 1 015803 1 015...

Page 34: ...ETAILS OF BOILER INSTALLATION Date of Installation Name of Installer Address Postcode Telephone No Boiler Serial Number see data label on inside of left hand case panel DETAILS OF BOILER SERVICE HISTORY Date of Service Details of Service Service Engineer ...

Page 35: ...35 Alpha C23 27 ...

Page 36: ...s 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 2003 Alpha Therm Limited NepicarHouse LondonRoad WrothamHeath Sevenoaks Kent TN15 7RS Tel 0870 3001964 email info alphatherm co uk website www alpha boilers com ...

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