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Alpha Style20OF Installation, Commissioning And Servicing Instructions

Wall mounted, gas fired combination boiler
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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
Models covered by these instructions
Style20OF
WALL MOUNTED, GAS FIRED COMBINATION BOILER FOR USE WITH NATURAL GAS ONLY
Gas Safety (Installation and use) Regulations 1984:- It is the law that all gas appliances are installed by a competent person, in accordance with the
above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure compliance
with the law.
The installation of this appliance must be in accordance with the relevant requirements of the Gas Safety (Installation and use). 'Current' IEE Wiring
Regulations, local building regulations and bye laws of the local water undertaking. It should be in accordance also with the relevant
recommendations of the following British Standards and Codes of Practice: BS.5449:1:1977, BS.5546:1:1979, BS.5440:1:1990, BS.5440:2:1989, BS
6798:1987, BS.6891:1988 and BG.DM2
Manufacturer's instructions must NOT be taken in any way as over-riding statutory obligations
These instructions have been carefully prepared but we reserve the right to alter the specification at any time in the interest of product improvement.
CONTENTS
INTRODUCTION
1.
2.
3.
4.
Technical Data - Tables 1 and 2
Available Pump Heads - Table 3
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
4.
5.
1.
2.
External Wiring of Heating Controls. Clock - Room Thermostat - Frost Thermostat -
3.
Fig. 5
(47-532-05)

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  • Page 1: Table Of Contents

    INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS Models covered by these instructions Style20OF (47-532-05) WALL MOUNTED, GAS FIRED COMBINATION BOILER FOR USE WITH NATURAL GAS ONLY Gas Safety (Installation and use) Regulations 1984:- It is the law that all gas appliances are installed by a competent person, in accordance with the above regulations.

  • Page 2: General Specification Details

    Appliance Wiring Diagram - Fig. 6 Appliance Functional Flow Diagram - Fig. 7 INSTALLATION OF THE APPLIANCE Fixing Templates - Hardware Supplied Fixing the Wall Mounting Plate Dimensional Relationship Between Appliance and Wall Face - Wall Mounting Requirements - Assembly of Upper Cross Bar - Fig. 9 Making Service Connections, from the System to the Wall Plate Hanging the Boiler on the Wall Plate and Making Service Connections to the Boiler Commissioning the Appliance.

  • Page 3: Electrical Supply

    Thermostatic radiator valves may be used providing either a 22 mm by pass, with lockshield balancing valve, is fitted to ensure a minimum flow rate through the boiler of 9.86 l/m (2.17 gpm) when all radiator valves are closed, OR a single uncontrolled radiator with a minimum catalogue emission of 1.2 kW (4,100 Btu/h) is fitted.

  • Page 4: Installation Instructions

    The inlet Pressure test point is located on the gas valve (Refer to Fig. 13.1) Table 2 (Refer to Fig. 1) Table 3 AVAILABLE PUMP HEADS FOR HEATING SYSTEM MINIMUM SYSTEM PRESSURE LOSS THROUGH BOILER HEATING OUTPUT HEADS FLOW RATE FLOW-RETURN CONNECTIONS (Btu/h) METRES (FEET) LITRES/MIN.

  • Page 5: Location Of Boiler

    The meter outlet governor should ensure a nominal dynamic pressure of 20 mbar (8 in. wg). The complete installation including the meter must be tested for gas soundness and purged in accordance with the recommendations made in BS.6891. NOTE: Both the user and the manufacturer rely upon the installer, whose job is to install the boiler and connect it to a correctly designed heating system.

  • Page 6: Air Supply - Table

    4 Air Supply Air for combustion and ventilation must be provided in accordance with BS 5440:2. The appliance should not be installed in a room containing a bath or shower, bedrooms and bed sitting rooms. 1 If the appliance is installed in a room, the room must have a permanent air vent with a minimum effective area no less than 104 cm (16 in ).
  • Page 7 Fig. 2.ii...

  • Page 9: Requirements For Sealed Systems

    REQUIREMENTS FOR SEALED SYSTEMS 1 General The appliance is suitable for sealed central heating systems only. IMPORTANT: SEALED SYSTEMS MAY BE FILLED, COMMISSIONED OR DRAINED BY A COMPETENT PERSON ONLY. The istallation shall comply with the recommendations made in BS 6798 and BS 5449:1. Refer to Table 2 for information relating to flow and return pipework.

  • Page 10: Filling And Venting The System

    Vessel charge and initial system pressure 7.3 14.5 21.8 Total water content of system using 71 (1.54 gal) capacity expansion gal 18.5 14.0 vessel supplied with appliance For systems having a larger .0833 .109 .156 capacity MULTIPLY the TOTAL system capacity in litres (gallons) by the factor to obtain the TOTAL MINIMUM expansion vessel capacity required litres (gallons)

  • Page 11: System Checks - Fig

    8 System Checks Existing systems must be thoroughly cleaned using a suitable chemical cleaner. Ensure the system is thoroughly flushed out with cold water prior to filling up to 1.5 bar (21.8 psi) (green area). Clear all air and check for water soundness.

  • Page 12: Domestic Hot Water Supply To The Boiler And Other Appliances

    DOMESTIC HOT WATER SUPPLY TO THE BOILER AND OTHER APPLIANCES 1 General The following information is for guidance only. Contact the local Water Undertaking for specific information and requirements before fitting the appliances referred to below. The appliance is intended for connection to a mains water supply at a maximum pressure of 8 bar (116 psi). DO NOT use at a higher mains pressure. If necessary fit a water pressure reducing valve.

  • Page 13: Appliance Wiring Diagram - Fig

    3 External Wiring of Heating Controls. Clock - Room Thermostat - Frost Fig. 5. Fig. 6. APPLIANCE WIRING DIAGRAM...
  • Page 14 Fig. 7. APLIANCE FUNCTIONAL FLOW DIAGRAM...

  • Page 15: Installation Of The Appliance

    INSTALLATION OF THE APPLIANCE Thermostat 1 Fixing Templates-Hardware Supplied Unpack the hardware carton and check its contents against the list below. ONE Wall mounting plate assembly complete with:...

  • Page 16: Fixing The Wall Mounting Plate

    Papertemplates; 3/4″ heating flow isolation valve and safety valve assembly; 3/4″ heating return isolation valve; 1/2″ domestic mains inlet isolation valve; ONE plastic bag containing gas cock with flanges straight pipe section / half union; gas supply union elbow and pipe support clip. ONE small plastic bag containing ‘o’...
  • Page 17 Fig. 9. DIMENSIONAL RELATIONSHIP BETWEEN APPLIANCE AND WALL FACE WALL MOUNTING REQUIREMENTS...

  • Page 18: Making Service Connections From The System To The Wall Plate

    3 Making Service Connections from the System to the Wall Plate Refer to Fig.8...

  • Page 19: Hanging The Boiler On The Wall Plate And Making Service Connections To The Boiler

    Remove ALL OF THE POLYTHENE CAPS protecting the screw threads of the fittings mounted on the boiler. The layout of the services and their position is given in Fig. 8. Note that the: HEATING FLOW AND RETURN SOCKETS ARE 22 mm COPPER; GAS SUPPLY SOCKET IS 22 mm COPPER;...

  • Page 20: Commissioning The Appliance

    5 Commissioning the Appliance 1. The complete gas installation, including the meter MUST be purged and tested for gas soundness in accordance with BS 6891:1988. 2. Isolate the electrical supply. 3. Turn off the gas supply at the appliance service cock (Fig.
  • Page 21 4. Loosen the burner setting pressure test point screw (Fig. 13.1) and attach a pressure gauge. Set any external controls to call for heat. Fig. 12.1 Fig. 12.2 5. Using a screwdriver, carefully prise off the heating thermostat control knob (Fig.
  • Page 22 e) If adjustment is required, using a 10 mm blade screwdriver, adjust the spindle A, Fig. 13.2 (counter clockwise to decrease). The prescribed pressure must not be exceeded. f) Turn the hot water tap off and on a few times and ensure that the pressure indicated remains correct. g) Isolate the electrical supply.
  • Page 23 Fig. 13.3. 6 Checking Operation of the Central Heating / Domestic Hot Water Services and Safety Valve 1 Set the control thermostat to OFF and the service selector knob to central heating and domestic hot water. Depress and release the ON/OFF button.
  • Page 24 IF A BYPASS IS NOT REQUIRED: ie. an uncontrolled radiator of minimum catalogue rating 1.2 kW (4,100 Btu/h) is fitted, proceed to Section 6.7 below. Provided the heating system has been designed to take account of the AVAILABLE PUMP HEAD FOR HEATING SYSTEMS - Table 3 - page 5, the pump energy should ensure a temperature difference across the boiler flow and return pipes of 17 °C (30.6°F) maximum.

  • Page 25: Servicing The Appliance

    If further advice or assistance is required relating to servicing contact Argos Building and Heating Supplies Ltd. SERVICING THE APPLIANCE 1 Annual Servicing - Routine Inspection and Cleaning To ensure continued efficient operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general once per year should be adequate.

  • Page 26: Servicing Of Components

    c) Ensure the gas supply is turned OFF at the gas cock. When service work has been completed gas soundness should always be checked using gas soundness fluid. Recommission the appliance in accordance with the procedure detailed under Installation of the Appliance - Section 3 Tools to Undertake Servicing The following tools will assist in servicing and replacing all appliance components.
  • Page 27 Reassemble in reverse order. Push both the electrode and thermocouple fully home into their respective retaining sockets before tightening the union connectors. Ensure the pilot injector is replaced correctly when refitting the aluminium pilot pipe. Finally refer to Fig. 13.1 and check the correct dimensional relationship exists between the individual components.
  • Page 28 6 Cleaning the heat exchanger (Fig. Examine the heat exchanger carefully. If necessary clean the fins using a suitable brush from above and below. TAKE CARE NOT TO DAMAGE THE COMBUSTION CHAMBER INSULATION. Any debris which has fallen down into the base of the boiler body should now be removed together with the cover over the gas manifold connection before reassembly.

  • Page 29: Replacement Of Component Parts

    Reassemble in reverse order using new O ring seals at the pipe entry points. NOTE: When assembling the main diaphragm the circular indentation points to the rear of the pressurestat. 5 Replacement of Component Parts NOTE: COMPONENT PARTS SHOULD BE REPLACED BY A COMPETENT PERSON ONLY IMPORTANT: ISOLATE THE MAINS ELECTRICAL SUPPLY AT THE WALL SOCKET OR SWITCH BEFORE ATTEMPTING TO REPLACE COMPONENT PARTS.

  • Page 30: Replacement Of Thermocouple; Electrode Lead; Electrode; Pilot Injector; Pilot Burner

    (e) Central Heating expansion vessel (f) Safety valve (g) Domestic Hot Water expansion vessel (h) Pressure gauge (j) Heat exchanger 5.1. Remove the white outer casing by unscrewing the pozipan head screws located on the top and lifting and pulling the casing forward. a) Remove the combustion chamber front panel (Fig.
  • Page 31 Remove the pilot injector. Fit a new pilot injector and reassemble in reverse order. Check the pilot pipe connections for gas soundness using leakage detection fluid. Refer Section 5.3 B(d) - and Fig. 13.1. f) Replacement of main burner Refer to Remove the pilot burner assembly (5.2a) Remove the burner (4.
  • Page 32 Fig. 21. Fig. 22. Fig. 23a. CONTROL BOX ELECTRICAL SUPPLY CONNECTOR NOTE: On/off switches are marked clearly ‘L’ and ‘N’ and must be replaced in the position shown in Fig. 22 after replacing the push on connectors. Replace the switch as follows: Refit the push on connectors as shown in Fig.

  • Page 33: Replacement Of Piezo Spark Generator

    Fig. 23b. CONTROL BOX EARTH CONNECTIONS b) Suppressor replacement Remove the suppressor from its retaining clip on the left hand side of the control box by sliding forward. Remove the earth wire connected to the suppressor from the brass earthing post at the rear of the control box. Several earth wire connections are made to the earthing post.
  • Page 34 Note the thermostat capillary route from the thermostat body to the phial. Remove the three insulated connectors from the push on connections on the thermostat body (Fig. 24). Remove the two pozidrive screws on the front face of the control box, attaching the thermostat body. Withdraw the capillary tube and phial from behind the control box and gas valve.

  • Page 35: Replacement Of Overheat Thermostat

    When renewing the thermostat ensure the capillary tube is not kinked or tangled with other components. Route it behind the gas valve. REASSEMBLE IN REVERSE ORDER. After completing refitment of the safety or domestic hot water thermostat, ENSURE the insulated connectors are secure and in the correct position (Fig.

  • Page 36: Replacement Of Gas Valve

    NOTE: Take care to ensure the ECO leads are securely fixed behind and on top of the gas valve. A sachet of heat sink compound is provided with the replacement thermostat, which MUST be smeared on the face of the thermostat mounting plate. 5.5 REPLACEMENT OF THE GAS VALVE CHECK THE GAS SUPPLY IS TURNED OFF AT THE SERVICE COCK BEFORE PROCEEDING.
  • Page 37 Refer to Fig. 34. The combustion chamber front panel insulation should now be removed and replaced as shown. When the new insulation pad is fitted correctly there will be a gap of about 12 mm at each end. (f) Reassemble the appliance in reverse and undertake gas soundness checks. 5.7 REPLACEMENT OF COMPONENTS REQUIRING ISOLATION OF THE APPLIANCE FROM THE CENTRAL HEATING (PRIMARY) AND DOMESTIC HOT WATER (SECONDARY) CIRCUITS AND DRAINING OF THE BOILER In order to remove certain component it will be necessary to drain down the appliance.
  • Page 38 b (i) Replacement of Euramo Gold Star / Grundfos 15/60 Circulating Pump - complete First remove the appliance control panel. NOTE: Before pulling the front panel off the supporting side panels, release the union connector attaching the pressure gauge capillary tube to the appliance return pipe - just below the circulating pump.
  • Page 39 Fig. 33. Observe, when releasing the union, there are TWO remaining union connections to the same fitting. They are the water flow switch sensing pipe (RHS) and the connecting pipe from the expansion vessel (REAR). A 6″ adjustable spanner may be used to release them. Remove the safety thermostat phial from its pocket.

  • Page 40: Replacement Of Domestic Hot Water Heat Exchanger

    Unscrew the TWO M5 hexagon head screws indicated ‘A’ using an 8 mm spanner and/or a screwdriver, sufficiently to allow the retaining plate to be pulled upwards and released. Put the plate to one side. Note the plate is held in position within slots at the front and rear. Remove the pozidrive screw retaining the plastic cover over the electrical connections to the pump.
  • Page 41 Fig. 36. Fig. 37.a...
  • Page 42 Fig. 37.b Remove the plates, complete with screws by means of the small extension lug at the top of each plate. Remove the limit thermostat from the boiler flow pipe by releasing the two pozidrive screws fixing the limit thermostat body to the flow pipe mounting plate.
  • Page 43 The ‘O’ ring seals made at the point where each pipe enters the base of the domestic hot water heat exchanger can now be broken by pulling each end forward slightly. Remove the boiler flow pipe by disconnecting the already released union at the boiler heat exchanger. Fig.
  • Page 44 Pull the RIGHT HAND pipe up, out of its retaining hole in the pressure stat. Pull the other end of the pipe out of its retaining hole in the base of the domestic hot water heat exchanger. This will release the pipe. Push the remaining pipe slightly and remove the TWO M5 pozidrive screws attaching the microswitch cover assembly to the top of the pressure stat.

  • Page 45: Diverter Valve

    Unscrew the M5 pozidrive screw fixing the RIGHT HAND retaining plate to the base of the domestic hot water heat exchanger. Refer Fig. Remove the plate, complete with screw. Refer to Fig. 39 and note the FOUR M5 hexagon head fixing screws ‘B’ ‘C’ fixing the assembly to the main control support plate. Using an 8 mm spanner or screwdriver remove the two M5 hexagon head screws ‘B’...
  • Page 46 Check that the electrical supply to the appliance is turned OFF at the isolation switch and that any clock or heating controls fitted are in the OFF position. Turn OFF the gas service cock. (Fig. Locate the black plastic cover over the terminal block into which the electrical supply to the appliance is wired. (Fig.
  • Page 47 Replace the vessel - AND SEALING WASHER. Before opening the isolation valves and refilling the system - REFER TO PAGE 8 - REQUIREMENTS FOR SEALED SYSTEMS - SECTIONS 7 Fig. h) Replacement of pressure gauge After draining down the boiler in accordance with the procedure under Section 5.9, identify the pressure gauge at the right hand end of the control panel.
  • Page 48 Fig. 44. Fig. 45.A Fig. 45.B...

  • Page 49: Fault Finding

    FAULT FINDING CHART...

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