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Alpha 240X Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired combination boiler
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Installation and Servicing

Instructions
Alpha 240X
Wall Mounted, Fan Assisted, Room Sealed, Gas Fired

Combination Boiler

For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Service Listed
Alpha 240X
G.C. No. 47 532 13
0051
For use with Natural Gas only
Leave these instructions with the User

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Summary of Contents for Alpha Alpha 240X

  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha 240X Wall Mounted, Fan Assisted, Room Sealed, Gas Fired Combination Boiler For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001964 Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS Service Listed Alpha 240X G.C.

  • Page 2: Table Of Contents

    12 Service history ........36 INTRODUCTION The Alpha 240X boiler is a wall mounted, fan assisted room-sealed combination boiler. Heat output is controlled by a modulating gas valve and it uses a permanent pilot for lighting the burner. The boiler, providing both central heating and domestic hot water at mains pressure, is designed for use with a fully pumped, sealed and pressurised heating system using only Natural Gas.

  • Page 3: Technical Data

    Flue Terminal Size 100 mm Dia. Flue - Outer Duct Epoxy coated Flue Terminal Protruding 115 mm Flue - Inner Duct Aluminium Hole Size Required For Flue Assy. 107 mm Dia. Lift Weight 39 kg Alpha 240X - 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 240X - Technical Data...
  • Page 5 32 - Flue adaptor 33 - Flue sample point 34 - Room sealed chamber 35 - On/off valve 36 - On/off valve and filter Heating Domestic Cold Mains Heating Flow Hot Water Water Inlet Return Outlet Fig. 2 Alpha 240X - Technical Data...

  • Page 6: General Boiler Information

    2. Under no circumstances must the flue length (including allowances for extra bends) exceed 4 metres. 3. Failure to use Alpha flue components with the boiler will invalidate the boilers CE approval, warranty and may be unsafe. Alpha 240X - General Boiler Information...
  • Page 7 L = B + C + 185 mm + (2 x 45° bends = 1 metre) VERTICAL FLUE OPTIONS = 4 metres = 3 metres Not less than Not less than 300 mm 300 mm Not less than Not less than 450 mm 450 mm Fig. 3 Alpha 240X - 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 240X - General Boiler Information...
  • Page 9 The heating system should be thoroughly flushed before the boiler is connected and again after the first heating. If it is required to add inhibitor to the system, refer to Alpha Therm Ltd. for guidance. Refer to BS 5449 and BS 6798 for further information.

  • Page 10: Installation

    Note: The boiler has been provided with the facility for fitting an expansion device, i.e. shock arrestor or expansion vessel in the DHW circuit (see Fig. 32). An optional kit is available from Alpha Therm Ltd., Goldsel Road, Swanley, Kent BR8 8EX.
  • 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 240X - 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 240X - Installation...
  • Page 13 Cut both the inner and outer ducts to length. Note: Do not cut the outer duct end with the two holes, these are for securing the terminal. Ensure that all cuts are square and burr free. Alpha 240X - Installation...
  • Page 14 Re-assemble in reverse order. When replacing the rear cover, ensure no wires are trapped and all wiring grommets are in position. Do not overtighten the fixing screws. Leave the control panel open until commissioning procedures have been completed. Clock Control panel Clock fitted in position Terminal without clock fitted Fig. 15 Alpha 240X - Installation...

  • Page 15: Commissioning

    Ensure all external controls are calling for heat. If the optional Clock is fitted, refer to the User's instructions, set the time and ensure the Clock is in an 'on' mode. Set the hot water and central heating temperature selectors to maximum. Alpha 240X - Commissioning...
  • Page 16 (Refer to Component Replacement, section 8.2). It is recommended that a label is attached to the boiler drawing attention to the fact that the system has been drained. Complete the details of the installation on the back page of this manual. Alpha 240X - 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. Alpha 240X - Commissioning/Boiler Operation...

  • Page 18: Routine Servicing

    Withdraw the main burner out of the boiler. Take care not to damage the side insulation panels. Front casing screws Room sealed Combustion chamber chamber front cover panel screws Pilot assembly Thermocouple and pilot supply Control panel screws Fig. 18 Alpha 240X - Routine Servicing...

  • Page 19: Component Replacement

    To gain access to the control panel components - Remove the five screws securing the rear cover and carefully raise the cover from the front. When replacing the cover, ensure no wires are trapped and all wiring grommets are in position. Secure with five screws - do not overtighten. Alpha 240X - Routine Servicing/Component Replacement...
  • Page 20 Fit the new lead ensuring it passes through the grommets in the control panel cover and base of the combustion chamber. Re-assemble in reverse order. MAIN BURNER Remove the burner as described in Routine Servicing, section 7.2. Re-assemble with a new burner as described in Routine Servicing, section 7.4. Alpha 240X - Routine Servicing/Component Replacement...
  • Page 21 Thermostat lead accessible from the boiler base. connections Remove the two fixing screws and remove the overheat thermostat from the CH flow pipe. Fit the new overheat thermostat and re-assemble in reverse order. Fig. 22 Alpha 240X - Component Replacement...
  • Page 22 Lift out the fuse holder and remove the fuse. Fit a fast blow 2 A fuse as a replacement, ensuring that the holder snaps into position. Re-assemble in reverse order, ensuring the terminal block is located correctly on the plastic pin. Alpha 240X - Component Replacement...
  • Page 23 Blue to terminal 1, Brown to terminal 2 and Black wires to terminals 3 and 4, (or as per the instructions supplied with the clock). Re-assemble in reverse order. Refer to the User's instructions and the boiler's control cover to set the clock. Alpha 240X - Component Replacement...
  • Page 24 Fit the new gauge using a new washer on the diverter valve connection if necessary. Refill and pressurise the system. (Refer to Pressure gauge sensor Commissioning, section 5.1). Pressure gauge Fig. 29 Alpha 240X - Component Replacement...
  • Page 25 Note: Ensure the heat exchanger is fitted the right way up - see label on heat exchanger. Refill and pressurise the system. (Refer to Commissioning, section 5.1). DHW heat exchanger DHW heat exchanger securing screws Fig. 31 Alpha 240X - Component Replacement...
  • Page 26 Unscrew and remove the end fitting containing the filter/restrictor. Replace or clean components as necessary and re-assemble in reverse order. Refill and pressurise the system (if necessary). (Refer to Commissioning, section 5.1). Restrictor Differential Filter pressure sensor Fig. 33 Alpha 240X - Component Replacement...
  • Page 27 DHW flow valve When re-assembling, push the new valve into securing screws position, holding it in, while tightening the fixing screws. Re-assemble in reverse order. DHW flow microswitch assy. Fig. 36 Alpha 240X - Component Replacement...
  • Page 28 8.37 DHW EXPANSION DEVICE (if fitted) - Refer to Fig. 32 Drain the boiler hot water circuit as described in section 8.2. Unscrew the device from its fitting. Fit the replacement using a new seal. Re-assemble in reverse order. Alpha 240X - Component Replacement...

  • Page 29: Wiring Diagrams

    Br - Brown Bk - Black Bl - Blue - Red NOTE: REMOVE LINK FROM - Yellow TERMINALS 1 & 2 TO CONNECT - Green EXTERNAL CONTROL (240V SWITCHING) G/Y - Green/Yellow W - White Alpha 240X - Wiring Diagrams...
  • Page 30 Air Pressure Switch Flow Switch Clock (Optional) Primary Temperature Sensor Ignition PCB Main PCB MAXR Primary Flow Switch Ignition Microswitch Gas Valve Modulating Coil Gas Valve Thermocouple Overheat Thermostat Note: Main Terminal Block Thermo-Electric Valve Alpha 240X - Wiring Diagrams...

  • Page 31: Fault Finding

    Thermocouple Replace Connections Hold in gas valve control for output = 10 mV min thermocouple approx. 15 - 20 seconds, then release. Pilot stays alight Continuity across Replace overheat thermostat overheat thermostat Operation sequence successful Alpha 240X - Fault Finding...
  • Page 32 DHW flow valve senses no flow. Primary water diverted Diverter valve spindle assy. faulty to CH system. DHW flow switch released (off) Burner goes out Fan reduces to slow speed Pump stops Operation sequence successful Alpha 240X - Fault Finding...
  • Page 33 Go to section ' ', page 34 Burner output modulates until Go to section ' ', page 34 set temperature is reached Pump stops Burner goes out Fan reduces to slow speed Operation sequence successful Alpha 240X - Fault Finding...
  • Page 34 Check external controls 240V across main PCB Continuity across Wiring between clock are calling for heat terminals 4 and N clock terminals 3 and 4 and PCB is correct Internal clock calling for heat Replace clock Alpha 240X - Fault Finding...

  • Page 35: Short Parts List

    Electrode 8420930 343 432 Fig. 19 Electrode lead 8417441 343 576 Fig. 25 Ignition PCB 5645600 E05 235 Fig. 24 Ignition microswitch and cable 5645050 E01 725 Fig. 26 Selector switch 8630320 E05 236 Alpha 240X - Short Parts List...

  • Page 36: Service History

    These instructions have been carefully prepared but we reserve the right to Alpha Therm Limited. alter the specification at any time in the interest of product improvement. Nepicar House, London Road, Wrotham Heath © Alpha Therm Limited 1999. Sevenoaks, Kent TN15 7RS email: info@alphatherm.co.uk website: www.alpha-innovation.co.uk Part No.

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