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ALPHA700

MHS Boilers ALPHA700 470, ALPHA700 300, ALPHA700 510, ALPHA700 555, ALPHA700 600 Instructions For Assembly And Installation

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CAST IRON SECTIONAL
OIL, GAS & DUAL FUEL BOILERS
SINGLE UNIT OUTPUTS 295kW - 640kW
INSTRUCTIONS FOR ASSEMBLY/
INSTALLATION, SERVICING & OPERATION
ALPHA700
2
contents
page section
3
. . . . . . . . . . .
1.0
General Notes
2.0
Product Description
4
. . . . . . . . . . .
3.0
Key Points
5
. . . . . . . . . . .
4.0
Specification for Alpha 700
5.0
Delivery
6
. . . . . . . . . . .
6.0
Single Boiler Dimensional Data/Clearances
7.0
Installation Requirements
7
. . . . . . . . . . .
8.0
Air Supply & Ventilation
9.0
Boiler Base
10.0
Clearances
8
. . . . . . . . . .
11.0
Technical Data
9
. . . . . . . . . .
12.0
System Schematic Using Reverse/Return
13.0
System Schematic Using Diverter Valves
10
. . . . . . . . .
14.0
Minimum Water Flow Rate
15.0
Circulating Water
16.0
Flue Systems
11
. . . . . . . . .
17.0
Control Panel
12
. . . . . . . . .
17.0
Standard Boiler Control Panel Electrical Diagram
13-17
. . . . . . .
18.0
Boiler Installation
18
. . . . . . . . .
19.0
System Connections
19
. . . . . . . . .
20.0
Mounting The Burner
21.0
Controls
22.0
Commissioning Procedures
20
. . . . . . . . .
23.0
Initial Lighting
24.0
Adjustment & Safety Checks
21
. . . . . . . . .
25.0
Boiler Servicing
22
. . . . . . . . .
26.0
To Turn On The Appliance
27.0
To Turn Off The Appliance
23
. . . . . . . . .
28.0
Fault Finding
24-25
. . . . . . .
29.0
Boiler Log
26
. . . . . . . . .
30.0
Service Repair Record Sheet
27
. . . . . . . . .
31.0
Spare Parts
3
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.
If the Alpha 700 boiler is to be gas fired, then the installer must be deemed to be competent in the relevant areas of gas work involved and be Corgi Registered for those areas.
2.0 product
description
The Alpha 700 Series of cast iron boilers are engineered to the highest standards of design and production quality, performance and reliability.
The range comprises nine models offering LTHW outputs from 295 to 640 kW. Each boiler is supplied with a matched Natural gas, LPG, Oil or Dual Fuel Burner.
The boilers are supplied in kit form for on-site assembly, thus allowing greater ease of handling and reduced difficulties where plant room access is restricted.
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.
quality
Alpha 700 burners are manufactured under a quality system in accordance with Quality Assurance ISO 9001.
high output
The boiler heat exchanger has been designed around the turbo rotation principle of turbulent flow of flue gases through the flueways giving excellent heat transfer properties. The Alpha 700 series provides outputs from 295kW to 640kW, with the use of 8 through to 16 sections.
fuel options
Each boiler is supplied with a perfectly matched power flame burner. The user has freedom to choose from natural gas, LPG or class D oil. With a quick burner changeover, or with the use of a dual fuel burner, there is no need to be locked into any single fuel, allowing the use of the most economical fuel.
reduced emissions
The combustion chamber and flueways are of large volume and this, coupled with the principle of flue gas flow employed and power flame combustion, significantly reduces un-burnt particles and harmful oxides, protecting the environment from higher levels of damaging pollution.
built to last
The exceptional corrosion resistant properties of the casting material in conjunction with the unique polygonal profile of the combustion chamber combine to create a boiler body that will withstand the rigours of heavy duty. The combustion chamber walls are designed to allow convex flexing, giving the inherent strength of resistance to mechanical and thermal movement.
reduced maintenance
The turbo rotational passage of the flue gases through the generous sized flueways ensures low potential for fouling with combustion deposits. In addition, the entire front of the boiler body is a hinged access door providing easy and generous access for cleaning and inspection, reducing maintenance time.
low standby losses
The use of burners with fully closing air inlet dampers, and a high standard of insulation, keeps standby and maintenance losses to a minimum within the range 0.3 to 0.5%, conserving energy and reducing plant room temperatures.
guarantee
Heat exchanger carries a five year guarantee against material or manufacturing defect.
68AR139
4
5
4.0 specification
for Alpha700
5.0 delivery
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.
The rear of the combustion chamber includes an anchored ceramic target wall. The combustion chamber is fully water cooled and is spaced generously above floor level to ensure low boiler house floor temperatures. The boiler is suitable for a maximum flow temperature of 95°C and a maximum working pressure of 5.5 bar.
combustion chamber door
The combustion chamber door covers the entire front of the boiler body, providing uncompromised access to the combustion chamber and horizontal flueways, allowing total front cleaning with the robust cleaning tools provided. The door is hinged on both left and right hand sides giving freedom of choice for handed opening without the need to move hinge positions. The door is heavily insulated with dense ceramic fibre panels which reduces heat loss and thermal inertia.
insulation
The boiler body is insulated on all faces with a dense fibre-backed insulating blanket of 100mm thickness.
casing
Each boiler is provided with a high quality rigidly attached stove enamelled casing.
control panel
Each boiler is supplied with a fully pre-wired top mounted control pod which incorporates high and low fire control thermostats, manual reset high limit thermostat, water temperature thermometer, burner on/off switch, pump on/off switch, high limit thermostat test button, high and low fire hours run counters, fascia mounted fuse holder and lamps to indicate low fire, high fire, power on, high limit trip and burner lockout. As an option, volt free contacts may be included to relay status information to a BMS or similar remote monitoring panels.
item 1 Pallet(s) of boiler sections complete with accessories. item 2 Pack of tie rods. item 3 Carton containing casing and insulation. item 4 Selected burner and burner accessories. item 5 Carton containing control panel.
6
6.0 single boiler
dimensional data/clearances
7.0 installation
requirements
The Alpha 700 series boilers must be installed in accordance with (as appropriate) the requirement of the Building Regulations, Health and Safety Executive Regulation PM5, IEE Regulations, Gas Safety (Installation and Use) Regulation, National Water Bylaws, Clean Air Act Memorandum on Chimney Heights and any Insurance Company requirements.
codes of practice
BS 6880 Code of Practice for low temperature hot water heating systems for output greater
than 45kW, Parts 1, 2 and 3: 1988.
BS 5410 Part 2: 1978 - Code of Practice for oil firing installations of 44kW and above output
for space heating, hot water and steam supply purposes.
BS 6644 1991 - Specification for installation of gas fired hot water boilers of rated inputs
between 60kW and 2MW.
IGE/UP/2 Gas Installation pipework, boosters and compressors on industrial and commercial
premises.
CISBE Guide Reference sections B7, B11 and B13. LPG When boilers are fired with LPG, it is recommended that gas leakage detection
equipment is installed at low level, near the boiler or boilers.
Models Alpha 700 A - Overall Length - mm B - Casing Length - mm C - Section Length - mm D - Flue Outlet Size - mm Flow & Return Connection
300 1515 1360 1030
300
DN100
340 1650 1495 1165
300
DN100
380 1785 1630 1300
300
DN100
425 1920 1765 1435
300
DN100
470 2055 1900 1570
300
DN100
510 2190 2035 1705
300
DN100
555 2325 2170 1840
300
DN100
600 2460 2305 1975
300
DN100
640 2595 2440 2110
300
DN100
B
1600
1765
C
1020
530
555
Dimensions in millimetres
102
1135
165
430
A
1410
ø D
7
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. Where natural ventilation is used, suitable permanent openings connected directly to the outside air must
be provided. The openings should be fitted with grilles that cannot be easily blocked or flooded. The free area of the grilles should be as follows:-
LOW LEVEL (inlet) 540cm2plus 4.5cm2per kW in excess of 60kW of total rated input. HIGH LEVEL (outlet) 270cm2plus 2.25cm2per kW in excess of 60kW of total rated input.
10.0 clearances
The dimensions shown below are required for proper access for assembly and maintenance. There is no requirement for clearance above the boiler.
Alpha boilers should be installed on a level fireproof plinth with a minimum height of 100mm. The plinth must be capable of supporting the weight of the boiler/s when they are filled with water. The front of the plinth can be level with, but not extend beyond, the front of the boiler casing. Depending on the make of burner selected, dual fuel applications may require a higher plinth. Details will be provided on request.
plinth details
B
A
≈10cms
Plinth must be level and trowelled smooth.
300 136 112
340 150 112
380 163 112
425 177 112
470 190 112
510 204 112
555 217 112
600 231 112
640 244 112
Alpha 700
A cm B cm
Model
300 340 380 425 470 510 555 600 640
Gas 580 580 580 580 580 580 840 840 840
Oil 470 470 470 470 470 470 680 680 680
Dual Fuel
610 610 770 770 770 770 920 920 920
Dimension X in mm
1000 min
1000X
450 min
X + 200
(450 min)
9.0 boiler base
8
* Connection Flanges C/W gaskets supplied
11.0 technical
data
300
295.3
1007.5
327.8
1118.4
272
59.8
7.03
4.68
3.51
120
60 30
3.51
95
5.5
79.75
34.01
7.48
463.2
16,357
225
33.57
1185.5
432.9
15,288
210
20.0
8.0
0 - 3.0
0 - 0.12
DN100
300
11.81
1505 1777
10
8
340
338.4
1154.6
375.5
1281.2
302
66.4
8.05
5.37
4.02
155
80 38
4.02
95
5.5
79.75
38.96
8.57
530.7
18,741
225
38.45
1358.0
495.8
17,511
210
20.0
8.0
0 - 3.0
0 - 0.12
DN100
300
11.81
1655 1957
10
9
380
381.4
1301.3
423.3
1444.2
332
73.0
9.08
6.05
4.54
200 100
50
4.54
95
5.5
79.75
43.92
9.66
598.2
21,125
225
43.35
1530.9
559.0
19,742
210
20.0
8.0
0 - 3.0
0 - 0.12
DN100
300
11.81
1805 2137
10
10
425
424.4
1448.0
471.0
1607.0
362
79.63
10.1
6.73
5.05
250 125
62
5.05
95
5.5
79.75
48.87
10.75
665.7
23,509
225
48.23
1703.4
622.0
21,965
210
20.0
8.0
0 - 3.0
0 - 0.12
DN100
300
11.81
1955 2317
10
11
470
467.4
1594.7
518.8
1770.1
392
86.22
11.1
7.41
5.56
300 150
75
5.56
95
5.5
79.75
53.82
11.83
733.1
25,890
225
53.13
1876.3
685.1
24,197
210
20.0
8.0
0 - 3.0
0 - 0.12
DN100
300
11.81
2105 2497
11
12
510
510.4
1741.4
566.5
1932.8
422
92.8
12.1
8.1
6.07
360 180
90
6.07
95
5.5
79.75
58.77
12.92
800.5
28,272
225
58.01
2048.9
749.2
26,460
210
20.0
8.0
0 - 3.0
0 - 0.12
DN100
300
11.81
2255 2677
13
13
555
553.5
1888.5
614.3
2095.9
452
99.4
13.1
8.78
6.58
420 210 105
6.58
95
5.5
79.75
63.73
14.01
868.1
30,658
225
62.91
2221.7
811.3
28,651
210
20.0
8.0
0 - 3.0
0 - 0.12
DN100
300
11.81
2405 2857
15
14
600
596.5
2035.2
662.0
2258.7
482
106.0
14.2
9.46
7.10
490 245 122
7.10
95
5.5
79.75
68.68
15.10
935.5
33,036
225
67.79
2394.3
874.25 30,873
210
20.0
8.0
0 - 3.0
0 - 0.12
DN100
300
11.81
2555 3037
20
15
640
639.5
2181.9
709.8
2421.8
512
112.6
15.2
10.15
7.61
560 280 140
7.61
95
5.5
79.75
73.64
16.19
1003.1 35,425
225
72.69
2567.1
937.4
33,105
210
20.0
8.0
0 - 3.0
0 - 0.12
DN100
300
11.81
2705 3217
25
16
Boiler Model Alpha 700
Max Heat
kW
Output to Water
Btu/h x 1000
Max Heat
kW
Input (Nett)
Btu/h x 1000
Water L Content UK Gal
Design ∆t10°C Flow Rate ∆t15°C L/sec ∆t20°C
Waterside ∆t10°C Pressure drop ∆t15°C mm wg ∆t20°C
Minimum Flow For
L/sec
Shunt Re circulation
Maximum Flow
°C
Temperature
Maximum
Bar
Working
psig
Pressure
Input Rate L/h 35SRI Oil UK Gal/h
Approx Flue
m
3
/h
Gas Volume at
ft
3
/h
NTP Oil Fired
Approx Flue Gas
°C
Temp Oil Fired
Input Rate m
3
/h
Nat Gas ft
3
/h
Approx Flue
m
3
/h
Gas Volume at
ft
3
/h
NTP Gas Fired
Approx Flue Gas
°C
Temp Gas Fired
Minimum Nat
m bar
Gas Inlet
in wg
Pressure to Burner
Draught
mm wg
Required at
in wg
Boiler Flue Outlet
Water Flow Return Conn's *
Flue Conn's
mm in
Weight of Boiler Empty (Kg) Full
Combustion Chamber mm wg Resistance
Electrical
Dual Fuel
Supply (Burner)
Oil or Gas
No. of Sections
415v 3 Phase220/240v 1ph
220/240v 1ph 415v 3 Phase
9
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.
On multi-boiler installations, even flow can be achieved by connecting the boilers to the water flow and return pipework using a reverse return method of connection.
This will provide an even water flow through each boiler and ensure that the pressure loss across any number of boilers is never greater than that for a single boiler plus adjacent pipework losses.
Constant Temp. Circuit
Primary
Circulating
Pump
3-Way Vent Valve
Gate Valv e
Boiler
No.1
No.2
No.3
Water
Sensor
Zone
Controls
Thermometer
Open Vent
Safety Valve
Boiler Sequence Controller
Zone 2
Zone 1
Mixing Valve
It is desirable to prohibit flow of water through a non firing boiler in a multiple boiler bank. One such way is to install divertor valves and boiler bypass as shown below.
If this option is to be followed, then overrun timers must be incorporated into the control scheme to allow any latent heat contained within the boilers to be scrubbed off before by-passing a boiler via the operation of the divertor valve.
13.0 system schematic
using diverter valves
Constant Temp. Circuit
Primary Circulating Pump
3-Way Vent Valve
Diverter Valve
Boiler
No.1
No.2
No.3
Water Sensor
Zone
Controls
Thermometer
Open Vent
Safety Valve
Boiler Sequence
Controller
Zone 2
Zone 1
Mixing Valve
Isolating Valves
Gate Valve
Balancing
Valv e
10
14.0 minimum
water flow rate
15.0 circulating
water
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 boilers must always be installed on closed systems, whether they are of open vented or sealed and pressurised type. All systems should be thoroughly cleaned prior to the installation of the boiler and the system water must be treated to prevent the deposition of scale or sludge in the boiler waterways. The system water must be of a sufficient quality to maintain the following requirements:
● pH between 7.5 and 8.5
● maximum hardness between 8 and 12 grammes of calcium carbonate per 100 litres of water.
16.0 flue
systems
The diameter of the flue pipe used must not be less than the diameter of the flue connection on the boiler. Due consideration must be given to the requirements of the Clean Air Act Memorandum on Chimney Heights (3rd Edition) when designing flue systems and selecting terminal positions. Detailed guidance and recommendations for flue design are given in BS6644 and British Gas Publication IM11. Similar guidance for oil fired appliances may be found in BS5410 Part 3.
Any brick built chimney used must be swept clean, cleared of any obstructions and where not internally coated with an impervious barrier, must be lined with a suitable liner and insulated as necessary.
The chimney must be designed to provide the negative draught requirement as detailed in the technical data section of this publication. Where the generated draught exceeds the maximum figure quoted, then gas fired installations can be fitted with a draught stabiliser.
Exposed, prefabricated flue systems should be adequately insulated to maintain flue gas buoyancy and reduce condensation.
Flue terminals should have minimum resistance and terminals such as GLC and GC1 types are not considered suitable.
Flue pipe routes should allow for the shortest possible horizontal run to the main vertical chimney. The use of tight radius bends and square tees should be avoided.
For detailed guidance, assistance and quotations on flue systems, contact MHS Boilers Flue Department.
Non Return Valves
11
17.0 control
panel
ALPHA
BOILER TEMPERATURE
HOURS RUN
1 STAGE
HOURS RUN
2 STAGE
O
V
E
R
H
E
A
T
R
E
S
E
T
H
I
G
H
/
L
O
W
S
T
A
T
O
V
E
R
H
E
A
T
B
U
R
N
E
R
L
O
C
K
O
U
T
12
C
O
N
T
R
O
L
S
T
A
T
P
O
W
E
R
O
N
F
U
S
E
TEST
0000000
h
0000000
h
l
O
l
O
°C
20 40 60
A 2nd stage control thermostat H Water temperature thermometer B 1st stage control thermostat I Overheat trip lamp C High limit thermostat reset button J 1st stage hours run counter D Pump control switch K 2nd stage hours run counter E Burner on/off switch L 1st stage operating indicator lamp F High limit thermostat test switch M 2nd stage operating indicator lamp G Fuse holder N Burner lockout indicator lamp
key to components
IH
B
L
CEF
G
DA
MNJK
12
Index
CH1 1st Stage hours run meter CH2 2nd Stage hours run meter F1 6,3 AT protection fuse TR1 1st Stage control thermostat TR2 2nd Stage control thermostat TS Limit thermostat VM1 1st Stage indicator lamp VM2 2nd Stage indicator lamp VMT Power "ON" light VSB Burner lockout lamp VSC Boiler overheat lamp ZB Burner ON/OFF switch ZP Pump switch ZT T est s witch
Important: Maximum current that can s witched per output is
2A (cos. o ,7) which corresponds to an output of about 400W . Provide a contractor relay for an y output above that v alue.
Cable Colour Identification
R Red O Orange GY Gray Y Y ello w BK Black V Violet G Green B Blue W White BW Brown Y/G Y ellow/Green
Blue wire: N Neutral Y ellow/Green: Earth
Remove link D - G and install volt free contact to achiev e remote external on/off control
Remove link x-y and install volt free contact to achiev e remote high / low control - As appropriate and for high / low burners only.
Y/G
O
R
B
BK
Y
Y
R
W
R
O
O
BK
BK
BK
B
B
B
1
2
3
3
1
2
BW G
B
B
G
G
WB
B
BW
W
GY
W
BK
R
Y/G
DG ENJK LN FHA1A X Y B4 S3 T2 T1 N L1 N T8 T7T6B5
B
4
x7 x4
S
3T 2T 1N L 1
T
8T 7T 6
B
5
Burner Cables
Casing
Panel
ZTZBZP
TSTR2TR1
CH1
VSB VM1 VM2 VSC VMT F1
CH2
Satety Interlock contacts
Phase
Neutral
Boiler Pump (if required)
2nd Stage
External Control
1st Stage / on-off
External Control
Power supply
240V-50 Hz
Burner Connection Plugs
hh
Notes:
Standard Boiler Control Panel Electrical Diagram
13
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
18.2 boiler
assembly
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. Be aware that individual boiler sections weigh approximately 150 Kg each.
18.2.1 assembling boiler body
Ensure nipples and nipple seatings are clean and free from any surface rusting. Lightly clean as necessary using steel wool or emery cloth.
To aid the assembly of the boiler body it is suggested to consider to position the boiler on 2Nr flat strips of steel (min 100mm wide) this will allow the section to move more easily into the final mounted position (see fig. 1).
18.2.2
Insert woven glass fibre sealing rope into deep groove around the periphery of one side of each section.
18.2.3
Position and support the rear section of the boiler.
Lightly coat the nipples and nipple seatings with Linseed oil jointing compound or red lead jointing compound and insert nipples into seatings.
It is important to ensure that the nipples are carefully and accurately centred.
Lightly drive nipples home using a mallet and a block of wood (see fig 1.). Do not use a hammer on the nipples.
Ensure any splintered wood is removed from the sections and nipple bores as the boiler is progressively built.
18.2.4
Clean and lightly coat the nipple seatings of an intermediate section with jointing compound and offer up to the rear section (see fig 2.). Carefully engage the nipples into the seatings and temporarily secure the sections one to another by hammering using a mallet and a block of wood.
fig.1
fig.2
14
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.
If using MHS Alpha 700 Compact Assembly Tools, insert tools as shown in figs 3 and 4 and ensure proper and even bearing of tools on the hubs of the waterway ports. Compress the sections together by alternate tightening of the upper and lower tools paying attention to keep the sections parallel. Continue until opposing faces touch at 2 points.
Remove the tools.
18.2.6
Continue to assemble the boiler body until all of the intermediate sections plus the front section have been applied, following generally and repeating the procedures described in 18.2.3 to 18.2.5.
18.2.7
Fit the 4Nr tie rod assemblies to the assembled boiler body at top and bottom, left and right hand along the length of the body adjacent to the waterway ports.
Tighten the tie rods to maintain the close coupling of the sections one to another, but do not over tighten. The purpose of the tie rods is to hold the boiler body in an assembled manner and not to add compression.
18.2.8
Check position of boiler body and if necessary, ease into final required position.
18.2.9
Fit top and bottom front water closure blanks using gaskets and fixings provided.
Fit temporary “test” blanks to rear flow and return connections and filling/draining test tee arrangement to drain cock port at rear lower left hand side of rear section.
Fill and hydraulically test boiler (venting air whilst filling from slackened upper test blank).
Maximum test pressure must not exceed 8.25 bar.
Following a successful hydraulic test; drain boiler whilst admitting air through slackened upper test blank.
When boiler is fully drained, remove test blanks and attach flanged flow connector pipe spool piece which includes instrument pockets.
18.2.10
As appropriate, fit flue gas way baffle plates (A) vertically across the outside of the rear section exhaust ports and retain by interference by the flue connection hood. See fig 5.
Boiler Model Baffle plate width (w) mm.
Alpha 700/300 105
Alpha 700/340 65
Alpha 700/380 65
Alpha 700/425 65
Alpha 700/470 65
Alpha 700/510 No baffles required
Alpha 700/555 No baffles required
Alpha 700/600 No baffles required
Alpha 700/640 No baffles required
fig.3
fig.5
fig.4
A
W
15
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.
c) Carefully remove retaining nut fitted in (a) above, and install locking piece and locate onto target
wall fixing studs passing through the vertical support beams, ensuring “U” section faces in towards target wall and acts to steady and retain the vertical beams.
d) Fit and tighten firmly (but do not over tighten) securing nuts onto target wall fixing studs.
e) Carefully place into position the secondary mill board panel. (not shown)
f) Ensure ceramic fibre rope seal is correctly positioned in channel around the rear access way.
g) Close rear access way with the steel cover panel and secure using nuts provided.
WARNING !!!
Under no circumstances must the boiler be put into service without a complete and correctly fitted target
wall assembly being in place.
Alpha 700 Series
Boilers
View of rear access way with steel cover panel and secondary millboard insulation panel removed to show correctly assembled arrangement.
View from rear of boiler.
fig.6
Ceramic Target Wall (2 piece)
Locking piece installed with “U” section between vertical beams
Ceramic Fibre Rope Seal
Vertical support beams. Must be installed with return folded edge facing towards boiler
16
18.2.12 insulation and jacket assembly
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. Mount each of the four horizontal casing support channels (6) (as shown in fig 1) and fasten them each by using M8 x 20 bolts. (Note: Horizontal profiles on boilers 510-640 are made in two parts which have to be joined using 4 screws M5 as supplied). See figs 7 and 8.
4. Apply the front (8) and rear (9) insulation panels. See fig 8.
5. Fix the front side panels (10 and 11) by sliding under bottom horizontal and lifting over top horizontal. Fasten panels to front section by M10 x 12 (12) upper fixings and M10 x 78 (13) lower fixings. Fix self tapping screw (14) to bottom horizontal. See fig 10.
6. Fit casing intermediate side panels (15) onto horizontal profiles. (Note: Only fitted to boilers 425-640). See fig 10.
7. Fit casing rear side panels onto horizontal profiles and fasten onto rear section by using M10 x 12 (17). Fasten bottom of casing to bottom profile using self-tapping screw. (14). See fig 10.
8. Fit lower front casing (18) and fasten by using M10 x 12 (19) supplied. See fig 10.
9. Unpack boiler control panel and remove upper shell by unscrewing 3 x retaining screws. Carefully uncoil limit/control/thermometer capillaries and pass through grommet located at the base of the control panel. Pass limit/control/thermometer capillaries along with burner control cable, through cut-out in top panel. Fasten control panel to top panel by using self-tapping screws (supplied). Replace upper shell.
10. Fit front top casing panel (20), fit limit/control/thermometer phials into instrument pockets located on the flow pipe spool piece.
11. Fit rear top panel (21), see fig 10.
12. Route burner cables through most appropriate aperture in side casing front leading edge and close apertures with plates provided.
13. Fit front section insulation slab (22) inside upper front casing (23). See fig 10.
14. Fit upper front casing (23) (front top panel will have to be lifted slightly to enable fitting of front upper panel). See fig 10.
17
fig.7
fig.9
fig.8
3 1 3 6
7
7
257mm
224mm
6
9 3 1 2 1 6 3 8
4
4
6
5
5
Top
Bottom
Casing support strut vertical
fig.10
21
20
22
11
15
16
17
17
16
15
10
14
19
18
12
13
23
18
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.
19.2 oil connection (where appropriate)
The supply of oil to the appliance must be installed strictly in accordance with BS5410: Part 2: 1978 and observing the instructions supplied by the burner manufacturer.
19.3 flue connection
A flue pipe of suitable material must be connected to the flue connection at the rear of the boiler. (see fig.11) The flue pipe must be adequately supported to avoid that the weight of the flue system is bearing upon the boiler. The connection of the flue pipe to the boiler must be gas tight and include provision for disconnection. The purpose of the flue pipe is to safely, properly and fully evacuate the products of combustion to outside of the building and must be properly designed - see section 16.
19.4 water connections
All Alpha 700 series boilers are provided with flow and return connections on the rear of the back section. (see fig.12) DN100 Mating flanges for welding are supplied complete with bolts and gaskets.
When making the flow connection, ensure flow connection spool piece complete with thermostat pockets is attached directly to the boiler using gasket and fixings provided and system connection is made to the spool piece.
A drain tapping (3/4 “ BSP-F) is provided adjacent to the return connection. (see fig.12) The installer should connect a short length of pipe terminating in an accessible position with a plugged/capped full bore drain valve.
19.5 electrical connection
The boiler should be connected (as shown in section
17) using heat resisting cable tested to 160°C and suitable for a working temperature of 70°C. The boiler should be connected using flexible multistand cables being routed via the purpose provided grommeted cable entries at the rear face of the side casing panels. Cables should be routed on the outside of the insulating blanket and into the control panel via the opening base of the control panel.
Note:
Where a particular burner requires a 3 phase power supply, this should be taken via a suitable isolator directly to the burner.
Also, where a particular burner requires a 3 phase power supply, a single phase supply plus neutral and earth must still be connected into the boiler control panel.
Electrical installation must be in accordance with the current edition IEE Regulations.
WARNING:
This appliance MUST BE EARTHED.
fig.11
flue connection
flow connection
drain tapping
return connection
fig.12
19
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.
If it is necessary to pare away the ceramic fibre insulation of the burner door to allow burner blast tube entry, then this should be done carefully using a hacksaw blade or similar and ensuring that the blast tube is a snug fit through the hole in the door insulation. If the hole is oversized then the gap around the blast tube should be packed with ceramic fibre wool from the combustion chamber side of the door.
If required, a cooling air line may be connected between the burner air test point and the connection on the combustion chamber viewing window carrier using silicon rubber or similar tubing. This will provide a cooling to the sight glass and assist in keeping it clean.
21.0 controls
Each boiler is supplied with boiler high fire and low fire control thermostats, manual reset on/off switch and high limit test switch.
Whilst the following devices are not supplied, the boiler is designed to be compatible for use with the following ancillary controls:
1. Time Clock/ Programmer 4. Sequence Control Panel
2. Room Thermostat 5. Compensating Equipment
3. Frost Protection Thermostat 6. Optimum Start/Stop Equipment
22.0 commissioning
procedures
22.1 electrical installation
Ensure that the electrical supply installation and burner electrical connection has been checked for earth continuity and adequate fuse protection by a qualified engineer.
22.2 gas/oil installation (fuel installation)
Ensure that the whole of the fuel installation is inspected and tested for soundness and purged in accordance with the relevant BS.
22.3 water circulation system
The whole of the system should be thoroughly flushed out with cold water, without the pump in position. Ensure that all valves are open.
With the pump fitted, the system should be filled.
Vent all heat emitters, high pipework, clear airlocks, and check for water soundness.
22.4 flues
Make a general check of the flue system ensuring that draught is negative and stable, the flue is clear and all joints are correctly sealed. Ensure also that the flue terminal is correctly positioned.
22.5 boiler
Check that boiler components are in position and correctly fitted, check boiler internal wiring is undamaged, all connections including burner are properly made.
Light the boiler following as necessary specific instructions supplied with the burner.
20
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.
d) Turn ON power supply.
e) Turn up control thermostats and ensure that any ancillary controls are calling for heat.
f) Switch ON the ON/OFF switch on the boiler control panel and the burner should now ignite.
24.0 adjustment
and safety checks
final commissioning checks and settings
a) Check for soundness of all fuel carrying components of the burner.
b) Make final adjustments/settings of the burner in accordance with the burner manufacturers
instructions. Ensure the burner flame does not impinge on the combustion chamber walls and is will distributed in the combustion chamber.
c) Carry out flue gas analysis/efficiency checks and make any trimming adjustments of the burner
manufacturers instructions. Ensure that all checks and adjustments are made after burner has been operating for at least 5 minutes.
d) When the combustion is properly set, turn OFF the ON/OFF switch and remove all test
instruments.
Replace all test points. Turn ON the ON/OFF switch and check all test points for soundness.
e) Check that there is no leakage of products of combustion from the flue joints.
f) Allow water to warm up and check all test points for soundness.
g) Check operation of boiler high limit thermostat by holding in test button on control panel.
h) Ensure burner goes to “lockout” by turning off fuel supply.
i) Check system for water soundness and then whilst still hot, turn off system and rapidly drain. Clean
any filters/strainers. The system should then be refilled and water treatment added.
Vent system and clear air locks. Re-set controls and re-fire boiler. Examine system for water soundness.
j) Instruct user on the safe and efficient use of the boiler and controls and hand over all instructions.
k) Advise the user on any frost precautions.
l) Advise the user, that for continued efficient and safe operation of the boiler it is important that
adequate regular servicing is carried out and water treatment is maintained.
21
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.
Consider your own safety and the safety of others when carrying out servicing. Health and Safety at Work Acts refers.
It is recommended that protective gloves, eye protection and face mask are used as necessary.
If fuel connections must be broken to facilitate boiler cleaning, then the fuel supply must be securely capped or plugged.
a) Switch off electricity supply and turn off fuel supply.
b) disconnect as necessary (referring to the burner manufacturers
instructions) electricity and fuel connections to the burner.
c) Remove burner door securing nuts and hinge open boiler door.
d) Inspect the ceramic back protection target wall and replace if deteriorated.
e) Thoroughly brush through all flueways and combustion chamber. Use a vacuum cleaner to assist.
Take care not to damage ceramic back protection target wall.
f) With the use of a vacuum cleaner, clean away any deposits in the cast flue smoke hood at the rear
of the boiler by access through the clean out ports in the hood.
g) Clean and service burner in accordance with the manufacturers instructions.
h) Examine the boiler door ceramic rope seal and replace if deteriorated.
i) Close and secure boiler door.
j) Re-make any disturbed connections to the boiler or burner.
k) Check condition of cables and thermostat capillaries within boiler casing and replace any cable that
show signs of hardening or cracking of the outer insulation.
l) Turn on fuel supply and check all fuel carrying components and joints for soundness.
m) Check flue joints for integrity.
n) Check system for signs of leakage and take corrective action as necessary.
o) Check ventilation provision to boiler house to ensure any ducts/grilles are of the correct area and
are clean and clear
p) Recommission boiler in accordance with relevant sections of commissioning and lighting
instructions. Check all fuel carrying joints for soundness.
q) Reset all controls to normal.
22
26.0 to turn on
the appliance
26.1 Ensure electricity supply to appliance is turned on.
26.2 Ensure fuel supply to appliance is turned on.
26.3 Ensure external controls (if fitted) are turned on and calling for heat.
26.4 Ensure system circulation pumps are running.
26.5 Set control thermostat “A” and “B” to desired settings.
26.6 If there is a boiler pump connected switch on at “D” . See fig.13.
26.7 Turn on burner at switch “E”. See fig.13. Burner should now ignite.
ALPHA
BOILER TEMPERATURE
HOURS RUN
1 STAGE
HOURS RUN
2 STAGE
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0000000
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20 40 60
A 2nd stage control thermostat H Water temperature thermometer B 1st stage control thermostat I Overheat trip lamp C High limit thermostat reset button J 1st stage hours run counter D Pump control switch K 2nd stage hours run counter E Burner on/off switch L 1st stage operating indicator lamp F High limit thermostat test switch M 2nd stage operating indicator lamp G Fuse holder N Burner lockout indicator lamp
key to components
IH
B
L
CEF
G
DA
MNJK
27.0 to turn off
the appliance
27.1 For short periods
27.1.1 Turn off switch “E”. See fig.13.
27.2
For long periods.
27.2.1 Turn off switch “E”. See fig.13.
27.2.2 Turn off switch “D”. See fig.13.
27.2.3 Turn off external controls.
27.2.4 Turn off fuel supplies.
27.2.5 Turn off electricity supply.
27.2.6 If there is the risk of frost, then boiler and system should be drained.
fig.13
23
FAULT POSSIBLE CAUSE REMEDY
Boiler/Burner does Power supply turned off. Refer to section 26.
not operate.
External controls turned off. Refer to section 26.
Boiler already hot or Allow boiler to cool control thermostats set or re-set control too low. thermostats to higher
setting.
Overheat lamp System water not Investigate/check
illuminated and circulating. pumps and reset
boiler non-operational limit thermostat.
Control thermostats Replace thermostats defective/out of and reset limit calibration. thermostat.
Limit thermostat Replace limit defective/out of thermostat. calibration.
Burner locks out. Fuel supply turned off. Investigate - turn on
fuel supply.
Defect in burner or Refer to burner burner maladjusted. manufacturers
instructions.
Burner very noisy/ Burner maladjustment. Check and adjust burner.
flame unstable.
Problem with flue. Investigate and rectify flue
anomaly.
28.0 fault
finding
24
29.0 boiler log
ON COMPLETION PLEASE LEAVE WITH APPLIANCE FOR FUTURE REFERENCE AND LOG BOOK RECORDS
Installer Address Customer’s Address Site Address
CORGI Reg No.
Report No:
Pre-Commissioning
Check Sheet
Tel No.
Date of Commissioning
Contract No.
Tel No.
Engineer’s Name (Print)
PRE - COMMISSIONING CHECKS FLUE SYSTEM CHECK LISTYES NO N/A
YES NO N/A
YES NO N/A
YES NO N/A
YES NO N/A
Local gas meter fitted Manufacturer
Flue Type
Conventional
Fan assisted
Fan dilution system
Forston fan dilution system
Monodraught system Plant room door
interlocked
Flue header diameter
Stack diameter
Approximate overall height
Draught stabilisers fitted
Dampers fitted
Fan assisted ventilation
Fan interlocked checked
Cold fill flexible hose removed
Anti-Gravity loop fitted
Lockshield valve fitted to loop
Air vent fitted to loop Lockshield & drain cock fitted to
vessel
PRESSURISATION CHECK LIST
GAS BOOSTER CHECK LIST
System fuel service cock installed
System fuel service cock accessible
Fuel pipework clean, sound & purged
Fuel available at boiler Electrical supply fused, isolated &
earthed Local isolation available
External controls operational
Flue system clear & functional Plant room ventilation to relevant
standard
System filled, pumps operational & isolating valves open
Boilers clean & clear
BOILER SYSTEM CHECK LIST
pipe connections as per manual Water isolating valves fitted to each
boiler
Water flow proving switch fitted
Interlock checked
Water shut-off valve fitted
Interlock checked
Shunt pump fitted
Interlock checked
Pump overrun facility available
Pressure relief valve fitted
SRV lift pressure
System pressure
ENGINEER’S NOTES:
SHEET No. OF
System return temperature below 100ºc
Electrical supply fused, isolated & earthed
Electrical supply fused, isolated & earthed
3-Phase supply including neutral connected
Electrical supply uninterrupted
Electrical supply uninterrupted
Pressure switch fitted
Pressure switch - setting mbar
Gas supply pressure mbar
Isolation valves fitted
ENGINEER’S SIGNATURE
CLIENT REP (PRINT)
CLIENT REP (SIGNATURE)
25
Installer Address Customer’s Address Site Address
CORGI Reg No.
Report No:
Commissioning
Report
Tel No.
Date of Commissioning
Contract No.
Tel No.
Engineer’s Name (Print)
Boiler model type:
Boiler serial no:
Burner model type:
Burner operation:
Burner serial no:
Burner status:
Gas manifold pressure
Gas manifold pressure - single boiler firing
Gas manifold pressure - all boilers firing
Gas head pressure
Gas rate
Oil rate
C0
2
0
2
C0
Smoke Number
Fan Pressure
Air pressure switch setting
Flue gas temperature
Flue draught max & min firing conditions
Ambient temperature
Combustion chamber pressure
Water flow temperature
Water return temperature
Head setting
Damper setting
Nozzle make
Nozzle angle
Nozzle capacity
Gas inlet pressure switch setting
Control stat operation checked & set to
Hi/Low stat operation checked & set to
Limit stat operation checked & set to
Lockout & safety functions checked
Soundness of internal gas/oil pipework checked
Water level operation proved Yes No N/A
on/off
Low fire High fire Low fire High fire Low fire High fire
high/low
modulatin
g
ENGINEER’S NOTES:
ENGINEER’S SIGNATURE
CLIENT REP (PRINT)
CLIENT REP (SIGNATURE)
mbar
mbar
mbar
mbar
m
3
/hr
bar
%
%
ppm
mbar
mbar
mbar
ºC
ºC
mbar
ºC
ºC
%
º
mbar
ºC
ºC
ºC
Yes No N /A Ye s N o N /A
SHEET No. OF
ADDITIONAL DETAILS
Specific fuel type
Burner electrical supply
Control panel option kit fitted
ON COMPLETION PLEASE LEAVE WITH APPLIANCE FOR FUTURE REFERENCE AND LOG BOOK RECORDS
26
Date work carried out:
Order No:
Hours run on meter reading:
Work carried out:
Replacement oil nozzle make:
Static gas pressure:
C0
2
:
Flue gas temperature: Ambient temperature:
Control stat setting: Water and other safety interlocks proved:
Signature:
Telephone No:
Engineer’s Name:
Company Name:
Pilot probe signal: Low fire flame signal: Hi fire flame signal:
Gas burner manifold pressure:
Gas inlet pressure (single boiler firing):
ITEMS BELOW TO BE CHECKED AGAINST INITIAL COMMISSIONING FIGURES
Angle:
Capacity:
Contract No:
Boiler Serial No:
Burner Serial No:
30.0 service/repair record sheet
C0:
Flue draught:
Gas Inlet Pressure (all boilers firing):
Date work carried out:
Order No:
Hours run on meter reading:
Work carried out:
Replacement oil nozzle make:
Static gas pressure:
C0
2
:
Flue gas temperature: Ambient temperature:
Control stat setting: Water and other safety interlocks proved:
Signature:
Telephone No:
Engineer’s Name:
Company Name:
Pilot probe signal: Low fire flame signal: Hi fire flame signal:
Gas burner manifold pressure:
Gas inlet pressure (single boiler firing):
ITEMS BELOW TO BE CHECKED AGAINST INITIAL COMMISSIONING FIGURES
Angle:
Capacity:
Contract No:
Boiler Serial No:
Burner Serial No:
C0:
Flue draught:
Gas Inlet Pressure (all boilers firing):
27
31.0 spare parts
Key No. Description Code
1 Front Section 200086
2 Intermediate Section 200254
3 Back Section 200413
4 Insulated Door 200501
5 Biconical Nipple D,126 210020
6 Back Plate 213080
7 Burner Plate 213082
8 Smoke Hood 214316
9 Bracket Back Refractory Brick 236313
10 Back Plate Insulation 250495
11 Back Refactory Brick 251765
12 Boiler Brush Alpha 700/300-640 470309
13 Sight Glass 470410
14 Fibreglass Rope D.20 849101
15 Fibreglass Rope D.12 849110
16 Orange Lamp 450414
17 Green Lamp 450415
18 On/Off Switch 460038
19 Combination Pump & Test Switch 460039
20 Boiler Water Thermometer 460098
21 Control Thermostat 460145
22 Limit Thermostat 460159
23 Hours Run Meter 460482
24 Thermostat Pocket 270196
25 Red Lamp 450411
1
7 6 9 11 3 15 5 1 15 7 6
410815 2
Flow Connection Spool Piece
24
14 4 13 12 8 3
25
17
23
16
20
21 22 18 19
E
S
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F
°C
N
O
20 40 60
R
E
W
1 STAGE
HOURS RUN
2 STAGE
HOURS RUN
BOILER TEMPERATURE
h
0000000
h
0000000
O
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12
TEST
l
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ALPHA
QW/6/99
ALPHA700
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.
35 Nobel Square, Burnt Mills Industrial Estate, Basildon, Essex SS13 1LT Tel: 01268 591010 Fax: 01268 728202
http://www.modular-heating-group.co.uk
A member of the Modular Heating Group Plc
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