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Alpha C23 Installation And Servicing Instructions

Range of wall mounted, fan assisted, room sealed, gas fired combination boilers
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Installation and Servicing

Range of Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired Combination Boilers
Instructions
Alpha C23/27
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Alpha C23
Alpha C27
For use with Natural Gas only
Leave these instructions with the User
Service Listed
G.C. No. 47 532 22
G.C. No. 47 532 23

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Summary of Contents for Alpha Alpha C23

  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha C23/27 Range of Wall Mounted, Fan Assisted, Room Sealed, Gas Fired Combination Boilers For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001964 Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS...

  • Page 2: Table Of Contents

    The maximum output available for domestic hot water is 23.3 kW (79 500 Btu/h), capable of providing 9.5 litres/min with a temperature rise of 35°C for the Alpha C23 boiler, and 27.0 kW (92 200 Btu/h), capable of providing 11.0 litres/min with a temperature rise of 35°C for the Alpha C27 boiler.

  • Page 3: Technical Data

    Flue - Outer Duct White Flue Terminal Size 100 mm Dia. Flue - Inner Duct Aluminium Flue Terminal Protruding 145 mm Hole Size Required For Flue Assy. 110 mm Dia. Lift Weight 36 kg 37 kg Alpha C23/27 - Technical Data...
  • Page 4 Blue Used Wire Wire Wire Wire Internal Clock Terminals WARNING 1. Ensure wires are connected correctly 2. Only fit the Alpha recommended clock. Other clocks could cause damage. Clock connections Boiler terminal block Fig. 1 Alpha C23/27 - Technical Data...
  • Page 5 Room sealed chamber DHW temperature sensor Flue sampling point Air pressure switch Gas service cock Flue hood Mains inlet on/off valve Overheat thermostat On/off valve (2 off) Expansion vessel Automatic by-pass Automatic air vent Fig. 2 Alpha C23/27 - Technical Data...

  • Page 6: General Boiler Information

    GAS SUPPLY The Alpha C23 boiler requires a gas rate of 2.71 m³/h (95.7 ft³/h) and the Alpha C27 a gas rate of 3.14 m³/h (110.9 ft³/h). The meter and supply pipes must be capable of delivering this quantity of gas in addition to the demand from any other appliances in the house.
  • Page 7 L = B + E + F + 185 mm + (90° bend = 1 metre) L = B + C + 185 mm + (2 x 45° bends = 1 metre) VERTICAL FLUE OPTIONS Fig. 3 Alpha C23/27 - General Boiler Information...
  • Page 8 The boiler may be installed in a cupboard or compartment, provided it is correctly designed for that purpose, i.e. complies with the Building Regulations and the requirements of BS 6798. Alpha C23/27 - General Boiler Information...
  • Page 9 System volume - The expansion vessel incorporated into the boiler is suitable for a sealed heating system with a maximum water content of 80 litres (18 gal). For guidance on water contents contact Alpha Therm Ltd. for Technical Data Sheet 15.

  • Page 10: Installation

    Note: The boiler can be stood in an upright position supported by the bottom tray, (to allow this, the union bends have been turned upwards so that they do not protrude beneath the bottom tray - check this before standing the boiler on the bottom tray). CLEARANCES REQUIRED - Fig. 8 Fig. 8 Alpha C23/27 - General Boiler Information/Installation...
  • Page 11 Ensure that all the valves are closed (spindle flats at right angles to valve) and do not turn on the water or gas supplies at this stage. Alpha C23/27 - Installation...
  • Page 12 14. Make good the inside and outside walls. The flue sealing collar could be used for making good either the outside or inside by locating it over the outer duct of the flue and pushing it tight against the wall. If fitting the collar externally, ensure it does not restrict any of the openings of the flue terminal. Alpha C23/27 - Installation...
  • Page 13 Fit the flue assembly as described in the previous section. Due to the size of the flue clamps the flue must be fitted from inside the building. 10. It may be necessary to support the flue with suitable brackets (every metre) when flue lengths approaching the maximum are used. Fig. 12 - Rear flue Alpha C23/27 - Installation...
  • Page 14 Blue wire to terminal 1, Brown wire to terminal 2 and Red wires to terminals 3 and 4, (or as per the instructions supplied with the clock). Ensure wiring is correct. Replace the clock cover. Do not overtighten the fixing screws. Leave the control panel open until commissioning procedures have been completed. Alpha C23/27 - Installation...

  • Page 15: Commissioning

    Refer to sections 3.7 and 3.8. System volume and Filling the system. Open the mains water inlet valve (see Fig. 11). Turn on all hot water taps and allow water to flow until no air is present. Turn off taps. BOILER CONTROLS - Fig. 16 Fig. 16 Alpha C23/27 - Commissioning...
  • Page 16 Turn off the boiler. Thoroughly flush out the water pipework and with no pressure in the boiler heating circuit. Clean the mains water inlet filter (see Fig. 11). Re-pressurise the system as described in section 5.1. Alpha C23/27 - Commissioning...

  • Page 17: Boiler Operation

    In both modes the fan operates at full speed before the burner lights, remaining at that speed until the demand is satisfied. When the burner is turned off, the fan will continue to run for 20 seconds approximately if the selector is set for hot water only. Alpha C23/27 - Commissioning/Boiler Operation...

  • Page 18: Routine Servicing

    2. The expansion vessel pressure test point is accessible from the top and rear of the boiler. Record details of the service in the Service History section on page 34 of this manual and in the Benchmark Log Book. Alpha C23/27 - Boiler Operation/Routine Servicing...
  • Page 19 Place the front case panel in position as shown in Fig. 18 and secure in position. Raise the control panel and secure in position with the two screws provided. Check the operation of the boiler. (Refer to Boiler Operation, section 6). Return all controls to their original settings. Alpha C23/27 - Routine Servicing...

  • Page 20: Component Replacement

    Fit the new electrode, ensuring it is positioned correctly and the spark gap is correct (see Fig. 19). Re-assemble Replace the burner, ensuring it is located correctly. Replace the combustion chamber front cover, ensuring it is correctly located. Complete re-assembly as described in Routine Servicing, section 7.4 paragraphs 4 to 9. Alpha C23/27 - Component Replacement...
  • Page 21 Gain access to the combustion chamber as in section 8.1. Disconnect the wiring from the overheat thermostat. Remove the spring clip and remove the overheat thermostat from the heat exchanger. Fit the new overheat thermostat and re-assemble in reverse order. Alpha C23/27 - Component Replacement...
  • Page 22 Gain access behind the casing as in section 8.1. Remove the rubber window frame and remove the damaged glass. Re-assemble in reverse order with a new glass. Ensure the rubber frame is located correctly in the front panel. Alpha C23/27 - Component Replacement...
  • Page 23 Fit the pipes to the new heat exchanger, ensuring new washers are used. Ensure the heat exchanger is correctly located. Re-assemble in reverse order. 10. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha C23/27 - Component Replacement...
  • Page 24 Connect the wiring to the new head as follows:- Brown to L, Blue to N, Green/yellow to Ensure the pump is set to maximum (3) and re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha C23/27 - Component Replacement...
  • Page 25 Remove the four screws securing the bottom tray and remove the tray. Disconnect the pressure relief valve outlet fitting. Release the screw retaining the pressure relief valve and pull out the valve. Re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha C23/27 - Component Replacement...
  • Page 26 When replacing the vessel, ensure that the connection is towards the front of the boiler and re-assemble in reverse order using new seals as necessary. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha C23/27 - Component Replacement...

  • Page 27: Wiring Diagrams

    WIRING DIAGRAMS ILLUSTRATED WIRING DIAGRAM Alpha C23/27 - Wiring Diagrams...
  • Page 28 FUNCTIONAL FLOW WIRING DIAGRAM Alpha C23/27 - Wiring Diagrams...

  • Page 29: Fault Finding

    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 or replacement of parts ensure the gas and electrical supplies are isolated. 10.2 CENTRAL HEATING - Follow operational sequence Alpha C23/27 - Fault Finding...
  • Page 30 10.3 DOMESTIC HOT WATER - Follow operational sequence Alpha C23/27 - Fault Finding...
  • Page 31 10.4 FAULT FINDING SOLUTIONS A to F Alpha C23/27 - Fault Finding...
  • Page 32 10.5 FAULT FINDING SOLUTION SECTIONS G to L Alpha C23/27 - Fault Finding...

  • Page 33: Short Parts List

    Ignition electrode lead 3.015165 H06-223 Flame sensing electrode lead 3.013213 E57-717 Fig. 2, item 27 E65-498 By-pass assembly 3.012801 Combustion chamber insulation panel set (C23) H06-224 3.015220 H06-225 Combustion chamber insulation panel set (C27) 3.015221 Alpha C23/27 - Short Parts List...

  • Page 34: Service History

    DETAILS OF BOILER SERVICE HISTORY Date of Service Details of Service Service Engineer .................................................................................................................................................................................................................................................................................................................................................................... Alpha C23/27 - Service History...
  • Page 35 Alpha C23/27...
  • Page 36 These instructions have been carefully prepared but we reserve the right to Nepicar House, London Road, Wrotham Heath, alter the specification at any time in the interest of product improvement. Sevenoaks, Kent TN15 7RS © Alpha Therm Limited 2003. Tel: 0870 3001 964 email: info@alphatherm.co.uk website: www.alpha-innovation.co.uk Part No.

This manual is also suitable for:

C27

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