ALPHA70 CAST IRON SECTIONAL OIL, GAS & DUAL FUEL BOILERS SINGLE UNIT OUTPUTS 295kW - 640kW I N S T R U C T I O N S F O R A S S E M B LY / INSTALLATION, SERVICING & OPERATION
ALPHA 700 contents page section 3 . . . . . . . . . . .1.0 2.0 General Notes Product Description 4 . . . . . . . . . . .3.0 Key Points 5 . . . . . . . . . . .4.0 5.0 Specification for Alpha 700 Delivery 6 . . . . . . . . . . .6.0 7.0 Single Boiler Dimensional Data/Clearances Installation Requirements 7 . . . . . . . . . . .8.0 9.0 10.0 Air Supply & Ventilation Boiler Base Clearances 8 . . . . . . . . . .11.0 Technical Data 9 . . . . . . . . . .12.0 13.
ALPHA 700 1.0 general notes These instructions are intended to assist the installer, commissioning engineer, maintenance engineer and user with the assembly, installation maintenance and operation of the Alpha 700 Series Cast Iron Sectional Boilers and must be read in conjunction with the instructions supplied with the burner. Please read this manual fully before commencing the installation of the boiler. This manual must be handed to the appliance user following completion of the installation.
ALPHA 700 3.0 key points conformity with standards All Alpha 700 series boilers are designed and manufactured in accordance with the requirements of EN 303.1 and are supplied with burners certified to the relevant standards. Alpha 700 series boilers are CE approved and conform to all relevant standards and requirements. 68AR139 quality Alpha 700 burners are manufactured under a quality system in accordance with Quality Assurance ISO 9001.
ALPHA 700 4.0 specification for Alpha 700 The three pass heat exchanger is constructed using high carbon content corrosion resistant cast iron sections with turbo rotational flue passes and polygonal profile combustion chamber. The assembled body is connected together using biconical nipples and full length tie rods. Gas tight sealing of the sections, one to another, is achieved using ceramic fibre rope bedded into channels in the casting faces.
ALPHA 700 6.
ALPHA 700 8.0 air supply & ventilation An adequate supply of fresh air for combustion and ventilation of the boiler house must be supplied in accordance with BS6644/BS5410 as appropriate. The air supply should be achieved using: a) Natural ventilation with low level and high level openings. b) Using a fan to supply air to a low level opening with natural discharge through a high level opening. c) Using a fan to supply air to a low level opening and a fan to extract air at a high level opening.
ALPHA 700 11.0 technical data Boiler Model Max Heat Output to Water Alpha 700 300 380 425 470 510 555 600 640 kW 295.3 338.4 381.4 424.4 467.4 510.4 553.5 596.5 639.5 Btu/h x 1000 1007.5 1154.6 1301.3 1448.0 1594.7 1741.4 1888.5 2035.2 2181.9 kW 327.8 375.5 423.3 471.0 518.8 566.5 614.3 662.0 709.8 Btu/h x 1000 1118.4 1281.2 1444.2 1607.0 1770.1 1932.8 2095.9 2258.7 2421.8 Water Content L UK Gal 272 59.8 302 66.4 332 73.0 362 79.63 392 86.22 422 92.
ALPHA 700 12.0 system schematic using reverse/return It is important to ensure that for all Alpha single and multi-boiler installations, the system should be designed to provide an even flow of water through each boiler when the burner is firing, and that this flow rate is not less than the minimum flow rate shown for each size of boiler in the technical data.
ALPHA 700 14.0 minimum water flow rate The minimum water flow rate must be provided at all times either via the main system pump/s or via shunt pumps. The boiler and burner must be interlocked to the pumps and the burner must be prevented from firing in the event of water flow failure. In the case of multiple boilers with individual shunt pumps, it is important to install non return valves upstream of the return connection to avoid parasitic flows between boilers. See diagram opposite.
ALPHA 700 17.
ALPHA 700 Standard Boiler Control Panel Electrical Diagram D G Boiler Pump (if required) 4 E N J K 3 2 2nd Stage External Control Power supply 240V-50 Hz x7 B S T T Phase Neutral 1st Stage / on-off External Control Satety Interlock contacts Burner Connection Plugs 1 N L 1 8 7 6 5 Burner Cables Casing Panel L1 N T8 T7 T6 B5 F H A1 A X Y B4 S3 T2 T1 N L N x4 T T T B B Y Y/G Y/G O R Y BK R W BW W R BW GY G 3 1 1 B R 2 ZP ZB ZT 3 2 TR1 BK W TR2 O TS BK O G
ALPHA 700 18.0 boiler installation general Alpha 700 series boilers are supplied in kit form on-site assembly. Special boiler assembly tools are required to assemble the boiler heat exchanger. (Boiler assembly tools are available for purchase or hire from MHS Boilers). 18.1 health & safety Care should be taken when handling or moving the boiler parts as they are extremely heavy and fragile. Ensure sufficient persons are available to move and handle the parts. Protective footwear and gloves must be worn.
ALPHA 700 18.2.5 Insert boiler assembly tools into upper and lower waterway ports and (following specific tool usage instructions) compress boiler sections together with even tightening of upper and lower tools to avoid that section castings are stressed on an angle. Sections should be compressed together until opposing faces touch at 2 points. Remove the tools.
ALPHA 700 18.2.11 Ensure 2 piece rigid ceramic fibre target wall is correctly assembled into rear combustion chamber access way. See Fig 6. a) taking one piece of (the 2 piece) target wall which has the rearmost overlap and inserting it into the boiler through the rear access way. Temporarily retain in place using one of the vertical support beams and lightly affix using retaining nut. b) Carefully insert remaining piece of target wall and position the remaining vertical support beam.
ALPHA 700 18.2.12 insulation and jacket assembly 16 1. Apply the insulation jacket (1) as shown in fig 7 and join by using springs (2) supplied (see fig 8). 2. Mount the four vertical casing support struts (3), (ensuring that the longer profile is installed at the top). Fix onto the front section by means of M10 x 97mm nuts (4) and onto rear section by means of M10 x 85mm nuts (5). See figs 7 and 9. 3.
ALPHA 700 3 1 3 6 Top 257mm 7 7 224mm Bottom Casing support strut vertical 6 fig.7 fig.9 9 3 1 2 1 6 3 8 5 4 4 5 6 fig.8 21 16 20 17 15 22 11 17 16 15 23 12 10 14 13 19 18 fig.
ALPHA 700 19.0 system connections 19.1 gas connection (where appropriate) Specific detail on the gas connection is provided by the burner manufacturer. The gas installation pipework should be installed in accordance with the requirements of IGE/UP/2 and be tested and purged in accordance with the requirements of IGE/UP/1. 19.
ALPHA 700 20.0 mounting the burner The supplied burner must be securely mounted to the front of the boiler via the mounting plate provided and following the instructions supplied with the burner. The maximum length of the burner blast tube must not exceed 220mm.
ALPHA 700 23.0 initial lighting The initial lighting should be carried out by a competent engineer. Follow closely the specific instructions supplied by the burner manufacturer. a) Ensure electrical supply to the boiler and the ON/OFF switch on the control panel are OFF. b) Ensure fuel and water supplies are turned ON and check for soundness the fuel carrying components of the burner. c) Make initial pre-settings to burner in accordance with the burner manufacturers instructions.
ALPHA 700 25.0 boiler servicing WARNING Make sure that the fuel supply is turned OFF and that the electricity supply is turned off and disconnected before attempting to service the appliance. Check all fuel carrying components for soundness after servicing boiler. Servicing must be carried out by a qualified engineer and where applicable, a qualified electrician. Servicing must be carried out on a regular basis with periods not exceeding 6 months for oil firing and 12 months for gas firing.
ALPHA 700 26.0 to turn on the appliance 26.1 26.2 26.3 26.4 26.5 26.6 26.7 Ensure electricity supply to appliance is turned on. Ensure fuel supply to appliance is turned on. Ensure external controls (if fitted) are turned on and calling for heat. Ensure system circulation pumps are running. Set control thermostat “A” and “B” to desired settings. If there is a boiler pump connected switch on at “D” . See fig.13. Turn on burner at switch “E”. See fig.13. Burner should now ignite.
ALPHA 700 28.0 fault finding FAULT POSSIBLE CAUSE REMEDY Boiler/Burner does not operate. Power supply turned off. Refer to section 26. External controls turned off. Refer to section 26. Boiler already hot or control thermostats set too low. Allow boiler to cool or re-set control thermostats to higher setting. System water not circulating. Investigate/check pumps and reset limit thermostat. Control thermostats defective/out of calibration. Replace thermostats and reset limit thermostat.
ALPHA 700 29.0 boiler log ON COMPLETION PLEASE LEAVE WITH APPLIANCE FOR FUTURE REFERENCE AND LOG BOOK RECORDS Installer Address CORGI Reg No. Report No: Pre-Commissioning Check Sheet PRE - COMMISSIONING CHECKS Customer’s Address Site Address Tel No. Tel No. Date of Commissioning Engineer’s Name (Print) Contract No.
ALPHA 700 ON COMPLETION PLEASE LEAVE WITH APPLIANCE FOR FUTURE REFERENCE AND LOG BOOK RECORDS Installer Address CORGI Reg No. Report No: Commissioning Report Customer’s Address Site Address Tel No. Tel No. Date of Commissioning Engineer’s Name (Print) Contract No.
ALPHA 700 30.
7 1 ALPHA 4 10 6 8 9 UT O 21 LOC ER K N 11 15 3 HOURS RUN 2 STAGE H IG H/L OW ST 2 AT 23 17 25 15 0000000h 2 C ON TROL STA 1 T 0000000h HOURS RUN 1 STAGE 5 T E 22 AT R HE ES R E RHEA VE T O 1 24 4 18 l 60 O 40 l N O WER O O 20 BOILER TEMPERATURE 16 14 P BU R Flow Connection Spool Piece TEST FUSE °C 15 19 20 13 7 12 6 8 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Key No.
ALPHA70 QW/6/99 A member of the Modular Heating Group Plc 35 Nobel Square, Burnt Mills Industrial Estate, Basildon, Essex SS13 1LT Tel: 01268 591010 Fax: 01268 728202 http://www.modular-heating-group.co.uk This publication is issued subject to alteration or withdrawal without notice. The illustrations and specifications are not binding in detail. All offers and sales are subject to the Company's current terms and conditions of sale.
