240XP-240XE Installation.pdf

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: (01322) 669443

Goldsel Road,

Swanley, Kent BR8 8EX

Fax: (01322) 615017

Service Listed

Alpha 240XP

G.C. No. 47 532 10

Alpha 240XE

G.C. No. 47 532 11

0051

For use with Natural Gas only

Leave these instructions with the User

CONTENTS

Introduction ....................................... 2

Routine servicing ............................... 19

Technical data ................................... 3

Component replacement ................... 21

General boiler information .................. 7

Wiring diagrams ................................ 34

Installation ......................................... 11

Fault finding ...................................... 38

Commissioning ................................. 16

Short parts list ................................... 43

Boiler operation ................................. 18

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 .

The boilers are supplied with a pump, diverter valve, pressure relief valve, expansion vessel and pressure gauge fully

assembled and tested.

As supplied, the Alpha 240XP and 240XE boilers will automatically modulate to provide central heating outputs between 9.3

and 23.3 kW (31 700 and 79 500 Btu/h).

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.

IMPORTANT

It is the law that all gas appliances are installed by a competent person, ie CORGI registered personnel, in accordance with

the following recommendations:-

Gas Safety (Installation and Use) Regulations

All relevant Building Regulations issued by the Department of the Environment

Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department

Local Water Bye Laws

Health & Safety Document No. 635 (The Electricity At Work Regulations 1989)

The installation should also be in accordance with the following British Standard Codes of Practice:-

BS 5440:1:1990 Flues

BS 5449:1990 Forced circulation hot water systems

BS 5546:1990 Installation of hot water supplies for domestic purposes

BS 6700:1987 Design, installation, testing and maintenance of services supplying water

BS 6798:1987 Installation of gas fired hot water boilers

BS 6891:1989 Gas installation

BS 7593:1992 Code of Practice for treatment of water in heating systems

BS 7671:1992 Requirements for electrical installations, IEE Wiring Regulations

If installation is in a timber framed building, refer to the British Gas publication 'Guide for Gas Installations in Timber Frame

Housing' reference DM2.

This appliance meets the requirements of IP44, ie degree of protection against moisture.

Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety to ensure that the

law is complied with.

Manufacturer's instructions must NOT be taken in anyway as over-riding statutory obligations.

Alpha 240XP and 240XE - Contents/Introduction

TECHNICAL DATA

2.1

PERFORMANCE - NATURAL GAS

Central Heating

Heat Input

MAX.

28.63

97 700

23.3

79 500

9.6

3.84

10.6

4.24

2.74

96.76

MIN.

11.76

40 150

9.3

31 700

1.1

0.44

2.1

0.84

1.13

39.9

Domestic Hot Water

Heat Input

MAX.

28.63

97 700

23.3

79 500

9.6

3.84

10.6

4.24

2.74

96.76

9.5

2.1

MIN.

11.76

40 150

9.3

31 700

1.1

0.44

2.1

0.84

1.13

39.9

(Gross)

Btu/h

(Gross)

Btu/h

Heat Output (modulating)

Btu/h

Output to Water (modulating)

Btu/h

mbar

Burner Pressure

Room sealed chamber

panel fitted

Room sealed chamber

panel fitted

in wg

mbar

in wg

mbar

in wg

Settings

Room sealed chamber

panel removed

Room sealed chamber

panel removed

Gas Rate

m³/h

ft³/h

Gas Rate

m³/h

ft³/h

Flow Rate at 35°C Rise

L/min

G.P.M.

2.2

SYSTEM

Domestic Hot Water

Max. Mains Inlet Water Pressure

Min. Mains Water Pressure

Min. DHW Flow Rate

Mains Inlet Connection

DHW Outlet Connection

DHW Water Content

Outlet Water Temp. (Approx. max.) °C

°F

Central Heating (Sealed System)

Max. System Pressure

Min. System Pressure

Max. System temperature

Pressure Relief Valve Setting

Expansion Vessel Size (pre-charge press.)

Flow Connection

Return Connection

Relief Valve Connection

Recommended System Pressure (cold)

CH Water Temp. (Approx. max.)

3 bar

0.5 bar

82°C

3 bar (44 PSI)

8 L at 0.8 bar

22 mm

15 mm

1.0 bar

180

8 bar

0.2 bar

2.5 l/min

15 mm

0.17 L

144

°C

°F

2.3

COMPONENTS

2.4

INSTALLATION

Burner (15 blade)

Main Heat exchanger

DHW Heat Exchanger

Main Burner Injectors

Pilot Injector

Stainless steel

Copper

Stainless Steel

1.18 mm

0.27 mm

Epoxy coated

Aluminium

Min. Clearances for Servicing

Top

Bottom

Sides

Front

220 mm

250 mm

5 mm

450 mm

100 mm Dia.

115 mm

107 mm Dia.

39 kg

(240XP only)

Flue Terminal Size

Flue Terminal Protruding

Hole Size Required For Flue Assy.

Lift Weight

Flue - Outer Duct

Flue - Inner Duct

Alpha 240XP and 240XE - Technical Data

2.5

GENERAL

2.6

ELECTRICAL

Dimensions

Height

Width

Depth

900 mm

450 mm

360 mm

22 mm

1.7 L

100 mm

60 mm

Supply

External Fuse

Power Consumption

Internal Fuse

Electrode Spark Gap 240XP

240XE

Thermocouple (240XP only):-

min. closed circuit output

230/240 V ~ 50 Hz

3 A

170 W

F2 A

5 mm

3.0 to 3.5 mm

Gas Connection

Primary Water Content

Air Duct Diameter

Flue Duct Diameter

10 mV

2.7

FLUE LENGTHS

Flue length = 0.75 m (not including the terminal, which is supplied with the boiler)

Note: Additional flues (of the same length) are available.

Length of Flue Required:-

Rear Flue = wall thickness +150 mm

Side Flue = wall thickness + distance between wall and side of boiler + 185 mm

Vertical Flue = distance from top of boiler side panel to required roof position minus 1 m for vertical terminal assembly

Maximum flue length = 4 m

Each additional 90° Bend is equivalent to 1 m of flue length

Each 45° Bend is equivalent to 0.5 m of flue length

The Vertical Flue terminal assembly is equivalent to 1 m of flue length

2.8

AVAILABLE PUMP HEAD FOR CENTRAL HEATING

Pressure loss across boiler

Output

Available pump head

Flow rate

Btu/h

17°C

20°C

17°C

20°C

17°C

20°C

metres

feet

metres

feet

metres

litre/min

18.10

14.80

gal/min

4.00

3.27

litre/min

15.10

12.60

gal/min

3.32

2.78

feet

7.4

metres

2.33

3.00

feet

7.7

9.8

2.95

3.45

3.75

9.7

11.3

12.3

2.50

2.20

2.00

8.2

7.2

6.6

2.25

2.00

1.75

23.3

17.58

79 500

60 000

6.6

5.7

4.9

4.4

12.36

9.89

7.84

2.72

2.18

1.73

10.50

8.40

6.70

2.32

1.85

1.47

14.65

11.63

9.3

50 000

40 000

31 700

3.45

3.85

4.20

11.3

12.6

13.8

4.05

4.35

13.3

14.3

1.70

1.45

5.6

4.8

1.50

1.35

This information is based on 17°C and 20°C system design temperature difference.

2.9 ELECTRICAL CONNECTIONS

Note: This Appliance Must Be Earthed

An optional integral Clock kit is available if required.

Not

Used

Black

Wire

Black

Wire

Brown

Wire

Blue

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

BOILER SCHEMATIC - Alpha 240XP

2.10

Pressure gauge

Gas service cock

Mains inlet on/off valve and filter

Diverter valve assy.

DHW flow valve

Primary flow valve

Differential pressure sensor

Automatic by-pass

DHW heat exchanger

DHW expansion device (if fitted)

Drain point

Pressure relief valve

DHW flow valve microswitch

Primary flow valve microswitch

Pump and air separator

Automatic air vent

DHW temperature sensor

Primary temperature sensor

Overheat thermostat

Expansion vessel

Gas valve

Main burner injector

Main burner

Pilot burner

Thermocouple

Main heat exchanger

Flue hood

Fan

Air pressure switch

Positive pressure point

Negative pressure point

Flue adaptor

Flue sample point

Room sealed chamber

On/off valve

On/off valve and filter

Heating

Flow

Domestic

Hot Water

Outlet

Gas

Cold Mains

Water Inlet

Heating

Return

Fig. 2

Alpha 240XP and 240XE - Technical Data

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