Related Manuals for Alpha ARES 440 Tec
Summary of Contents for Alpha ARES 440 Tec
- Page 1 ARES Tec ARES 440 Tec Installation and Servicing Instructions ARES 550 Tec ARES 660 Tec ARES 770 Tec ARES 900 Tec Floor standing, high output, modular condensing boilers Leave these instructions with the Building Manager...
- Page 2 Alpha ARES Tec 440 - 900...
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Page 3: Table Of Contents
Nozzles - pressures..............43 3.10 Hydraulic system filter ...............21 3.26 Emergency and safety operations ..........45 3.11 Determining the primary circuit pump or boiler pump ..22 3.27 First ignition ................46 3.12 Valves ....................22 Inspections and maintenance ..........47 Alpha ARES Tec 440 - 900... -
Page 4: General Information
CoMpLIANT uSE of ThE AppLIANCE Alpha ARES Tec appliance was built to current standards in place. Nevertheless, following improper use the safety and life of the user or other people may be exposed to danger, i.e. damage to the appliance or other objects. -
Page 5: Safety Warnings
The heating unit must be installed so as to avoid it from freezing and exposing the controls to temperatures below -15°C and over +40°C. The heating unit must be protected by: • Insulating the water and condensate pipes. • Adopting specific anti-freeze products in the water system. Alpha ARES Tec 440 - 900... -
Page 6: Regulations For Installation
Also observe the standards regarding the heating control unit, construction regulations and requirements on combustion heating in the country of installation. The Alpha ARES Tec boiler is a gas category II heating unit. 2h3p The appliance must be installed, commissioned and subject to The appliance must be installed in accordance with the instructions maintenance in accordance with all current regulations in force. -
Page 7: Water Treatment
Sentinel are acceptable for use with AresTec boilers. further information can be obtained from fernox (Tel: 01799 521133) or Sentinel (Tel: 01928 588330) Alpha ARES Tec 440 - 900... -
Page 8: General Warnings
General information GENERAL wARNINGS Any repairs to the products must be carried out by authorised Alpha personnel only, using original spare parts only. Failure to observe the above can jeopardise the safety of the appliance and will void the The instruction manual is an integral and essential part of the product warranty. -
Page 9: Technical Data And Dimensions
3.21) circulate the flow to the various circuits. The return water • Single temperature control sensors for the combined modules on enters the hydraulic separator, to start the cycle again. the flow and return manifolds. Alpha ARES Tec 440 - 900... -
Page 10: View Of Main Components
Return RIGHT side (as supplied) - LEFT side rear side of the boiler. Gas pipe RIGHT side (as supplied) - LEFT side The rear cover (previously removed) must be put back on the right side of the boiler. Alpha ARES Tec 440 - 900... -
Page 11: Dimensions
1448 1448 1448 1448 Width 'W' 1087 1355 1355 1623 1623 Width 'W1' 1039 1307 1307 1575 1575 Depth Attachment sizes Gas fitting 'G' System flow 'F' System return 'R' Flue fitting Condensate drain Alpha ARES Tec 440 - 900... -
Page 12: Operating Data / General Data
1252 (***) Degree of protection Consumption in stand-by (*) Room Temperature = 20°C (**) See 'NOZZLES - PRESSURES' table, Section 3.24. (***) The IP X5D degree of protection is obtained with the lid lowered. Alpha ARES Tec 440 - 900... -
Page 13: Instructions For Installation
Ensure that the flue has an adequate draught, that it is not blocked, and that there are no flues from other appliances connected to it. Only once these checks have been carried out can the boiler be connected to the flue. Alpha ARES Tec 440 - 900... -
Page 14: Packaging
• Plate and cable clamp for power output. Alpha will not be held liable in case of damage caused • A cardboard box containing: to people, animals or property due to failure to observe • Flanges. -
Page 15: Removing The Boiler From The Pallet And Fitting The Feet
Do not turn upside dow Do not expose to rain Fragile Do not expose to sunlight Do not store at stacked temperature: lower than - 5 ° C / 23 °F more than 50 °C / 122 °F Alpha ARES Tec 440 - 900... -
Page 16: Positioning The Boiler
70 kW and 1.8 MW, referring to BS 6644 and IGE/UP/10. A > 400 mm B > 400 mm C = 100 mm D = 500 mm Trap E = 600 mm Observe the minimum clearances required to perform normal maintenance and cleaning operations. Alpha ARES Tec 440 - 900... -
Page 17: Connecting The Boiler
'o' rings - Fitted in the first and last element of the flow manifold 18 mm internal dia. (A), 27 mm internal dia. (B). Gaskets - Fitted on all of the other elements (C). Alpha ARES Tec 440 - 900... -
Page 18: Gas Connection
EXAMpLE of GAS SuppLy SySTEM INSIDE BOILER OUTSIDE BOILER PLANT ROOM PLANT ROOM 1 - Isolation valve 2 - Gas solenoid valve 3 - Appliance isolation valve 4 - Test and purge point Alpha ARES Tec 440 - 900... -
Page 19: System Flow And Return Pipe Connection
Do not use solvents to wash the system, as they might damage the system and/or its components. failure to observe the instructions in this manual can cause damage to people, animals and property, for which the manufacturer will not be held liable. Alpha ARES Tec 440 - 900... -
Page 20: Additional Safety, Protection And Control Devices
Install a vessel with a capacity, Control devices. determined by an authorised designer. 13 (pressure gauge - not supplied by Alpha) with (12) damper pipe and (11) pressure gauge valve: it indicates the current pressure in Safety devices. -
Page 21: Hydraulic Separator
• Hydraulic decoupling between the two hydraulic circulation rings. • Balancing the circuits. Primary Boiler Circuit Secondary System Circuit hydraulic system filter F = 100 mm ( 4") nominal diameter 100 mm (4") nominal diameter R = 100 mm (4") nominal diameter Alpha ARES Tec 440 - 900... -
Page 22: Determining The Primary Circuit Pump Or Boiler Pump
The resistance curve on the water side of the boiler is represented in the table provided below. Alpha provides a series of primary rings complete with an accurately The pump is not an integral part of the boiler. sized pump, if alternative solutions are being used, the boiler pump... -
Page 23: Complete Optional Kits
Instructions for the installer 3.13 CoMpLETE opTIoNAL kITS Safety kits including pump and plate exchanger. Safety kits including pump and hydraulic separator. External covering kit for plate exchanger kit. External covering kit for hydraulic separator. Alpha ARES Tec 440 - 900... -
Page 24: Condensate Drain
If you do not want to or are able to create a plinth, it is possible to install the boiler on the floor and set up the trap at a depth of 100 mm. Alpha ARES Tec 440 - 900... -
Page 25: Connecting The Flue
1 metre of the boiler. To install the test point (supplied), drill a 21 mm hole in the flue pipe, and fit the test point following the sequence shown below. Ø21 mm Alpha ARES Tec 440 - 900... - Page 26 25 m Diameter 315 mm 1040 NoTE: 1213 The diagram above provides rough values only. The 1386 flue must be designed by a qualified professional in compliance with legislation and technical standard in force. Alpha ARES Tec 440 - 900...
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Page 27: Electrical Connections
• The appliance may not be used by children or unskilled individuals. TGC Terminal board (rear view) GCI Terminal board (rear view) DL1 DL2 Neutral connection (N) rear side Mains connection (view A) View A FL - Flow switch connections 24 V 230 V Alpha ARES Tec 440 - 900... -
Page 28: 230/240 V Electrical Supply Connection
230 V Safety devices Mains supply 230 V Relay Mains supply 230 V If the safety devices operate, the modulating pump continues to operate at the minimum speed in order to decrease the high temperature. Alpha ARES Tec 440 - 900... -
Page 29: Connection Diagram
SUPPLIED Flow switch Terminal block below Modulating pump boiler circuit board interface board Relay IF-EXT. Min. 0 - 10 V External sensor N L1 L1 A1 A2 A3 A4 A5 A8 A9 A10 A11 Alpha ARES Tec 440 - 900... -
Page 30: Safety Group Safety Connection (Supplied With Modulating Pump)
A1 A2 A3 A4 A5 A8 A9 A10 A11 on/off thermostat connection. On/O On/O SUPPLIED Zone 2 Zone 1 On/Off contact N L1 L1 A1 A2 A3 A4 A5 A8 A9 A1 0 A 11 Alpha ARES Tec 440 - 900... -
Page 31: Modulating Room Thermostats Connection
N L1 L1 A1 A2 A3 A4 A5 A8 A9 A10 A11 Modulating zone manager connection. SUPPLIED Zone 1 Zone 2 N L1 L1 A1 A2 A3 A4 A5 A8 A9 A1 0 A 11 Alpha ARES Tec 440 - 900... -
Page 32: Practical Connection Diagram
PF ...... Flue pressure switch 230/240 V ~ 50 Hz TRA.ACC 1 - 8 ..Ignition transformer PG ...... Gas pressure switch VM 1 - 8 ....Modulating fan SL ...... Condensate level sensor Alpha ARES Tec 440 - 900... - Page 33 Module 4 Module 5 Module 6 Module 7 Module 8 (setting 0) (setting 1) (setting 2) (setting 3) (setting 4) (setting 5) (setting 6) (setting 7) PCB module address selector setting on each module Alpha ARES Tec 440 - 900...
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Page 34: Connections And Management Diagram
: Mixing valve heating circuit 2 OPEN : Mixing valve heating circuit 2 CLOSED Terminal VI Terminal IV : Mixing valve heating circuit 1 OPEN /multifunction relay : Mixing valve heating circuit 1 CLOSED/multifunction relay Multifunction relay Multifunction relay Alpha ARES Tec 440 - 900... - Page 35 (*) ( - ) Modulating pump control 0-10 V ( - ) Remote eBUS Alarm signal ( + ) (external cascade manager) Modbus - B Pump control manifold circuit PLC / Modbus - A Alpha ARES Tec 440 - 900...
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Page 36: Examples Of Installation (Functional Diagram And Description Of Connections)
(4) Manifold pump (1) flow sensor heating circuit 1 Storage (10) flow sensor earth heating circuit 1 cylinder * This sensor need not be used External sensor Safety group Hydraulic Flow separator Return Filter Manifold pump Alpha ARES Tec 440 - 900... - Page 37 (1) Mixing valve heating circuit 1 OPEN (2) Mixing valve heating circuit 1 CLOSED (5) Storage tank recirculation pump (4) Manifold pump Storage cylinder External sensor Safety group Hydraulic Flow separator Return Filter Manifold pump Alpha ARES Tec 440 - 900...
- Page 38 Blue circuit 2 circuit 1 Blue CH pump Storage CH pump circuit 2 cylinder circuit 1 Diverter valve 2 Storage Diverter General electrical pump valve 1 control panel Relay A1 A2 A3 A4 A5 Alpha ARES Tec 440 - 900...
- Page 39 Relay A10 A11 Connections to solar systems require changing a number of setting parameters. Refer to the TGC controller manual - Expert field →Level SoLAR / Mf → Mf 4 fuNCTIoN = "23" Alpha ARES Tec 440 - 900...
- Page 40 Bus ID HS = _ _ _ _ sensor KF-boiler global ow sensor External cascade manager For any other system applications not included in these instructions, contact the Alpha Helpline 0844 871 8764. * Consult the TGC controller manual supplied. Alpha ARES Tec 440 - 900...
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Page 41: System Filling And Draining
This may damage gaskets and cause noise to develop during operation. Alpha will not be held liable in case of damage caused to people, animals or property due to failure to observe the above. Once all of the system connections have been made, it is possible to fill the circuit. -
Page 42: Check And Adjust The Co Values
(left and right). Hinge out the control panel 'A' slightly and lower the assembly 'C'. Temporarily secure the assembly 'C' in place using two M4 screws and washers 'D' (supplied in the documentation bag). Alpha ARES Tec 440 - 900... -
Page 43: Nozzles - Pressures
Fan speed (rpm) levels (%) Type of pressure size Diaphragm ignition IG Min. Max. Min. Max. (mbar) (mm) ARES Tec Nat. gas 1760 6000 440 - 900 (G20) Propane 1760 6000 10.2 10.4 (G31) Alpha ARES Tec 440 - 900... - Page 44 5 Bring entry 'HS 01' to 00% to turn off the last module that has stayed 6 Bring entry 'HS 01' to 100% for the definitive combustion analysis, Fig. 2 to be noted down in the control unit handbook. Alpha ARES Tec 440 - 900...
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Page 45: Emergency And Safety Operations
NoTE: The emergency function only switches the burners on in the boiler at 50% output and 70°C flow temperature. All system loads, including the manifold pump, must be controlled manually. Alpha ARES Tec 440 - 900... -
Page 46: First Ignition
Gas Safe The individual in charge of the system must be instructed in the use registered engineer. Alpha will not be held liable in and operation of the heating system, in particular: case of damage caused to people, animals or property • Supply the Building manager with the 'THE BUILDING... -
Page 47: Inspections And Maintenance
INSpECTIoNS AND Instructions for inspection and maintenance. MAINTENANCE only original Alpha spare parts must be used to ensure a long life for all of the functions of your appliance, and to avoid changing the conditions of Inspection and maintenance carried out at regular the approved standard product. - Page 48 • Remove all the casing panels. • Remove the rear, front and side fixing screws. • Turn the required screw to lift the cover. • Remove the two cover fixing screws. • Remove the panel. Alpha ARES Tec 440 - 900...
- Page 49 • Remove the nuts 'A' from each element (13 mm socket and ring spanner as shown above). • Unhook the fan chamber clamping spring (right/left side). • Disconnect the red silicone tubes. • Remove the fan chamber. Alpha ARES Tec 440 - 900...
- Page 50 • Lift the burner block slightly and unscrew the two screws (one each side) using a 5 mm hex key, until you reach holes 'C', to hinge the burner block. • Disconnect the gas fittings from the gas manifold using a 36 mm spanner. Alpha ARES Tec 440 - 900...
- Page 51 • Perform a combustion analysis and check the parameters. • Inspect the flue outlet pipe and the flue. • Ensure that all of the previously opened gas pressure points are closed. Compressed air Alpha ARES Tec 440 - 900...
- Page 52 Note: Correct periodic maintenance is highly recommended. www.alpha-innovation.co.uk For Technical help or for Service call the Alpha Helpline or use the following e-mail: info@alpha-innovation.co.uk Alpha helpline 0844 871 8764 Alpha Therm Limited Nepicar house, London Road,...
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