Alpha 240 Installation And Servicing Instructions

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

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Function manual (2 pages)

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Page 1: Installation And Servicing
Installation and Servicing Instructions Alpha 240/280 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: Introduction
As supplied, the Alpha 240E and 240P boilers will automatically modulate to provide central heating outputs between 9.3 and 23.3 kW (31 700 and 79 500 Btu/h). The Alpha 280E and 280P boilers will provide central heating outputs between 9.3 and 28.0 kW (31 700 and 95 500 Btu/h).
Page 3: Technical Data
0.27 mm Flue Terminal Protruding 115 mm Flue - Outer Duct Epoxy coated Hole Size Required For Flue Assy. 107 mm Dia. Flue - Inner Duct Aluminium Lift Weight 240E/P 39 kg 280E/P 40 kg Alpha 240/280 - 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 240/280 - 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 240/280 - Technical Data...
Page 6 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. 3 Alpha 240/280 - Technical Data...
Page 7: General Boiler Information
GENERAL BOILER INFORMATION GAS SUPPLY The Alpha 240E and 240P boilers require a gas rate of 2.74 m³/h (96.76 ft³/h) and the Alpha 280E and 280P a gas rate of 3.25 m³/h (114.8 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 8 L = B + C + 185 mm + (2 x 45° bends = 1 metre) VERTICAL FLUE OPTIONS Not less than = 4 metres = 3 metres Not less than 300 mm 300 mm Not less than Not less than 450 mm 450 mm Fig. 4 Alpha 240/280 - 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 240/280 - General Boiler Information...
Page 10 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 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 240/280 - Installation...
Page 13 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 240/280 - Installation...
Page 14 2. If the flue is more than 1 m, the restrictor must be removed from the flue adaptor (see Fig. 13), by removing the screw and lifting out the restrictor. The Alpha 280E and 280P are not fitted with a restrictor.
Page 15 Replace 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 Terminal without clock fitted Fig. 15 Alpha 240/280 - Installation...
Page 16: Commissioning
THERMOSTAT SELECTOR Central Domestic Selector Indicator System Heating Hot Water Switch Control Neons Pressure Thermostat Thermostat Gauge Burner Alpha 240E and Alpha 280E Viewing Window Clock (if fitted) RESET THERMOSTAT THERMOSTAT SELECTOR System Pressure RESET Gauge White Indicator Central Domestic...
Page 17 Alpha 240P and 280P boilers. Inlet gas pressure test point CHECK THE BURNER PRESSURES - Fig.
Page 18: Boiler Operation
When the set temperature is reached, the burner is turned off and the fan stops (the fan drops to low speed on the Alpha 240P and 280P). The pump continues to run for five minutes to remove residual heat build up in the boiler.
Page 19: Routine Servicing
Warning light (continuously on) - blocked flue or fan fault, contact your Service Engineer. Overheat thermostat has operated - press white reset button (see Fig. 16) to reset (not applicable to the Alpha 240Pand 280P). Electrical supply to the boiler is on.
Page 20 Alpha 240E and 280E - Disconnect the electrode leads from the electrodes. Alpha 240P and 280P - 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
Replace the combustion chamber front cover, ensuring the bottom is correctly located in the burner. Alpha 240E and 280E - Ensure the electrode leads are connected and the seals are in position in the bottom of the inner case. Alpha 240P and 280P - 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 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. IGNITION ELECTRODE LEAD (Alpha 240E and 280E only) - Refer to Fig. 27 Gain access as in section 8.1.
Page 23 ELECTRODES (Alpha 240E and 280E only) - Fig. 20 Gain access as in section 8.1. Remove the five screws securing the combustion chamber front cover and remove the cover. Disconnect the leads from the electrodes. Withdraw the main burner out of the boiler. Take care not to damage the side insulation panels.
Page 24 Alpha 240E and 280E - Disconnect the wiring from the overheat thermostat. Alpha 240P and 280P - 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 240P and 280P only) - Fig. 24 Burner manifold union Gain access as in section 8.1. Pilot supply Disconnect the thermocouple, pilot supply and overheat thermostat leads from the gas valve. Thermocouple Disconnect the wiring and pressure tube from the Overheat gas valve.
Page 26 8.15 IGNITION MICROSWITCH ASSEMBLY (Alpha 240P and 280P only) - Figs. 26 and 28 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 boiler base).
Page 27 8.22 IGNITION PCB (Alpha 240P and 280P 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 screw 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 240/280 - Component Replacement...
Page 29 Alpha 240E and 280E - Connect the fan wiring, blue to terminal 1 and brown to terminal 2. Alpha 240P and 280P - Connect the fan wiring, blue to terminal 4, brown to terminal 3 and black to terminal 1.
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 240/280 - 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 240/280 - 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 240/280 - Component Replacement...
Page 33 8.44 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 240/280 - Component Replacement...
Page 34: Wiring Diagrams
WIRING DIAGRAMS Alpha 240P and 280P ILLUSTRATED WIRING DIAGRAM - Alpha 240/280 - Wiring Diagrams...
Page 35 Alpha 240E and 280E ILLUSTRATED WIRING DIAGRAM - Alpha 240/280 - Wiring Diagrams...
Page 36 Alpha 240P and 280P FUNCTIONAL FLOW WIRING DIAGRAM - Alpha 240/280 - Wiring Diagrams...
Page 37 Alpha 240E and 280E FUNCTIONAL FLOW WIRING DIAGRAM - Alpha 240/280 - 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 240P and 280P only) - Follow operational sequence Replace main PCB...
Page 39 Primary water diverted Diverter valve spindle assy. faulty to CH system. DHW flow switch released (off) YES (240E/280E) Fan stops Burner goes out Pump stops Fan reduces to slow speed YES (240P/280P) Operation sequence successful Alpha 240/280 - Fault Finding...
Page 40 Go to section ' ', page 42 set temperature is reached YES (240E/280E) Fan stops Pump continues to run for Burner goes out 5 minutes Fan reduces to slow speed YES (240P/280P) Operation sequence successful Alpha 240/280 - 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 240/280 - Fault Finding...
Page 42 1 connector, terminal 52 connector, terminal 52 Check external controls Continuity across Wiring between clock are calling for heat clock terminals 3 and 4 and PCB is correct Internal clock calling Replace clock for heat Alpha 240/280 - Fault Finding...
Page 43: Short Parts List
343 574 Fig. 20 Thermocouple 5625660 343 575 Fig. 20 Electrode 8420930 343 432 Fig. 20 Electrode lead 8417441 343 576 Fig. 28 Ignition PCB 5643341 EO1-724 Fig. 26 Ignition microswitch and cable 5645050 EO1-725 Alpha 240/280 - 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 2000. Sevenoaks, Kent TN15 7RS email: info@alphatherm.co.uk website: www.alpha-innovation.co.uk Part No.

This manual is also suitable for:

Alpha 280 240p 280p 240e 280e