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Alpha 240XP Installation And Servicing Instructions

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

Alpha 240XP and 240XE
Wall Mounted, Fan Assisted, Room Sealed, Gas Fired
0051
Instructions
Combination Boilers
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Alpha 240XP
Alpha 240XE
For use with Natural Gas only
Leave these instructions with the User
Service Listed
G.C. No. 47 532 10
G.C. No. 47 532 11

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  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha 240XP and 240XE 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

    12 Service history ........44 INTRODUCTION The Alpha 'X' Range of boilers are wall mounted, fan assisted room-sealed combination boilers. Heat output is controlled by a modulating gas valve. The boilers, providing both central heating and domestic hot water at mains pressure, are 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 240XP and 240XE - Technical Data...
  • Page 4 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 240XP and 240XE - Technical Data...
  • Page 5 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 240XP and 240XE - Technical Data...
  • Page 6 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. 3 Alpha 240XP and 240XE - Technical Data...

  • Page 7: 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 240XP and 240XE - General Boiler Information...
  • Page 8 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. 4 Alpha 240XP and 240XE - General Boiler Information...
  • Page 9 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 240XP and 240XE - General Boiler Information...
  • Page 10 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 11: 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. 35). An optional kit is available from Alpha Therm Ltd., Goldsel Road, Swanley, Kent BR8 8EX.
  • Page 12 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 240XP and 240XE - Installation...
  • Page 13 13. Pull the outer duct towards the bend. Check that the flue terminal protrudes 120 mm out of the wall, then position the seal equally over the joint between the bend and the outer duct. Dismantle the clamp, position it over the seal and secure in position. 14. Make good the inside and outside walls. Alpha 240XP and 240XE - Installation...
  • Page 14 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 240XP and 240XE - Installation...
  • Page 15 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 240XP and 240XE - Installation...

  • Page 16: Commissioning

    Open valves. Close when needle is in green band. (If in doubt, see User Instructions). Disconnect loop. (Contact your installer if in doubt). Clock Central Domestic Selector (if fitted) Heating Hot Water Switch Thermostat Thermostat Fig. 16 Alpha 240XP and 240XE - Commissioning...
  • Page 17 Alpha 240XP boiler. CHECK THE BURNER PRESSURES - Fig. 17 Turn the boiler off.

  • Page 18: Boiler Operation

    3 minutes. If the CH sensor has not registered the pre-set temperature but the room thermostat is satisfied the burner is turned off, the fan stops (the fan drops to low speed on the Alpha 240XP) and the pump continues to run for five minutes.

  • Page 19: Routine Servicing

    OVERHEAT THERMOSTAT When this thermostat operates on the Alpha 240XP the pilot is turned off and will have to be relit. When it operates on the Alpha 240XE the boiler will not operate and the red button on the overheat thermostat must be pressed to reset it.
  • Page 20 Alpha 240XE - Disconnect the electrode leads from the electrodes. Alpha 240XP - Disconnect the thermocouple and pilot supply from the gas valve. Remove the two screws securing the pilot assembly to the burner. Remove the pilot shield and withdraw the complete pilot assembly.

  • Page 21: Component Replacement

    Alpha 240XE - Ensure the electrode leads are connected and the seals are in position in the bottom of the inner case. Alpha 240XP - Refit the pilot assembly and pilot shield to the burner. Ensure the ignition lead is still connected and the seal is in position in the bottom of the inner case.
  • Page 22 Electrode Pilot injector Fig. 19 IGNITION LEAD (Alpha 240XP only) - Refer to Fig. 28 Gain access as in section 8.1. Disconnect the lead from the electrode. Disconnect the lead from the ignition PCB, noting its position (see Fig. 28).
  • Page 23 Re-assemble with a new burner as described in Routine Servicing, section 7.4. BURNER INJECTORS Remove the burner as described in Routine Servicing, section 7.2. Unscrew the damaged injector and screw in a replacement. Re-assemble as described in Routine Servicing, section 7.4. Alpha 240XP and 240XE - Component Replacement...
  • Page 24 Gain access as in section 8.1. Alpha 240XP - Disconnect the thermocouple from the gas valve and withdraw the overheat thermostat lead. Unscrew the other overheat thermostat lead from the back of the gas valve - accessible from the boiler base.
  • Page 25 8.12 GAS VALVE (Alpha 240XP only) - Fig. 24 Burner manifold union Pilot supply Gain access as in section 8.1. Disconnect the thermocouple, pilot supply and Thermocouple overheat thermostat leads from the gas valve. Disconnect the wiring and pressure tube from the...
  • Page 26 8.15 IGNITION MICROSWITCH ASSEMBLY (Alpha 240XP only) - Fig. 26 Gain access as in section 8.1. Remove the screw securing the light grey cover around the gas control knob. Remove the screw securing the microswitch assembly to the valve (access from beneath the boiler).
  • Page 27 8.21 IGNITION PCB (Alpha 240XP only) - Refer to Fig. 28 Gain access as described in section 8.1. Remove the two fixing screws and disconnect the wiring. Refer to Fig. 28, connect the wiring to the new PCB and re-assemble in reverse order.
  • Page 28 3 and 4, (or as per the instructions supplied with the clock). Fig. 31 Re-assemble in reverse order. Refer to the User's instructions and the boiler's control cover to set the clock. Alpha 240XP and 240XE - Component Replacement...
  • Page 29 Alpha 240XE - Connect the fan wiring, blue to terminal 1 and brown to terminal 2. Alpha 240XP - Connect the fan wiring, blue to terminal 'MIN', brown to terminal 'MAX' and black to terminal 'COM'. Ensure the pressure tubes are connected correctly - refer to Fig. 21, and that the bottom of the combustion chamber cover is located in the burner.
  • Page 30 Using the new seals supplied in the manifolds, re-assemble in reverse order. 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). Alpha 240XP and 240XE - Component Replacement...
  • Page 31 Disconnect the two small flow sensing pipes from the R/H manifold. 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). Alpha 240XP and 240XE - Component Replacement...
  • Page 32 Pressure gauge DHW flow sensor Re-assemble in reverse order using the new microswitch assy. seals supplied. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Fig. 38 Alpha 240XP and 240XE - Component Replacement...
  • Page 33 8.42 DHW EXPANSION DEVICE (if fitted) - Refer to Fig. 35 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 240XP and 240XE - Component Replacement...

  • Page 34: Wiring Diagrams

    WIRING DIAGRAMS Alpha 240XP ILLUSTRATED WIRING DIAGRAM - Alpha 240XP and 240XE - Wiring Diagrams...
  • Page 35 Alpha 240XE ILLUSTRATED WIRING DIAGRAM - Alpha 240XP and 240XE - Wiring Diagrams...
  • Page 36 Alpha 240XP FUNCTIONAL FLOW WIRING DIAGRAM - Alpha 240XP and 240XE - Wiring Diagrams...
  • Page 37 Alpha 240XE FUNCTIONAL FLOW WIRING DIAGRAM - Alpha 240XP and 240XE - Wiring Diagrams...

  • Page 38: Fault Finding

    Ensure all external controls are calling for heat and check all external and internal fuses. Before any servicing or replacement of parts ensure the gas and electrical supplies are isolated. 10.2 LIGHTING PILOT (Alpha 240XP only) - Follow operational sequence Replace main PCB...
  • Page 39 Diverter valve spindle to CH system. assy. faulty DHW flow switch released (off) YES (240XE only) Fan stops Burner goes out Pump stops Fan reduces to slow speed YES (240XP only) Operation sequence successful Alpha 240XP and 240XE - Fault Finding...
  • Page 40 ', page 42 set temperature is reached YES (240XE only) Fan stops Pump continues to run for Burner goes out 5 minutes Fan reduces to slow speed YES (240XP only) Operation sequence successful Alpha 240XP and 240XE - Fault Finding...
  • Page 41 (resistance reduces with increase in temp.) illuminated Press red reset button Replace sensor 240V at ignition PCB across M1 connector, terminal D and Replace main PCB M2 connector, terminal F Replace reset switch Replace ignition PCB Alpha 240XP and 240XE - Fault Finding...
  • Page 42 1 and 33 terminal 1 terminal 33 Check external controls Continuity across Wiring between clock are calling for heat and PCB is correct clock terminals 3 and 4 Internal clock calling Replace clock for heat Alpha 240XP and 240XE - Fault Finding...

  • Page 43: Short Parts List

    5625660 343 575 Fig. 20 Electrode 8420930 343 432 Fig. 20 Electrode lead 8417441 343 576 Fig. 28 Ignition PCB 5643341 E01 724 Fig. 26 Ignition microswitch and cable 5645050 E01 725 Alpha 240XP and 240XE - Short Parts List...

  • Page 44: 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 1997. Sevenoaks, Kent TN15 7RS email: info@alphatherm.co.uk website: www.alpha-innovation.co.uk Part No.

This manual is also suitable for:

240xe

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