ACV Alfa G Manuel du propriétaire

INSTALLATION, OPERATING

AND SERVICING INSTRUCTIONS

ALFA Gaz

G/GP

Dual application gas boiler

with atmospheric burner

ACV reserves the right to modality the technical specifications and components of its products without prior notice. 664Y0800

05/11/2002

1.1 INTENDED USERS OF THESE INSTRUCTIONS

These instructions are intended for:

- the specifying engineer

- the installation engineer

- the user

- servicing technicians

1.2 SYMBOLS

The following symbols are used in these instructions:

Essential instruction for operating the system

correctly.

Essential instruction for personal safety and

environmental protection.

Danger of electrocution.

Risk of burns.

1.3 APPLICABLE STANDARDS

The products have received the “EC” certificate in accordance with the

standards prevailing in different countries (European Directives

90/42/EEC, “efficiency”, 90/396/EEC “gas appliances”). These

products have also received the Belgian “HR+” mark.

1 INTRODUCTION 2

1.1 Intended users of these instructions 2

1.2 Symbols 2

1.3 Applicable standards 2

1.4 Warnings 2

2 INSTALLATION 3

2.1 Boiler room 3

2.2 Connections 3

2.3 Electrical connection 5

3 STARTUP 6

3.1 Filling the heating and hot water circuits 6

3.2 Atmospheric burner troubleshooting 6

4 SERVICING 6

4.1 Recommendation 6

4.2 Servicing the gas boiler 6

4.3 Servicing the safety devices 6

4.4 Servicing the burner 7

4.5 Emptying the boiler 7

4.6 Spare parts 7

5 DESCRIPTION 8

5.1 Overview 8

5.2 Description of operation 8

5.3 Design features 8

6 TECHNICAL SPECIFICATION 9

6.1 Effective dimensions 9

6.2 Maximum operating conditions 9

6.3 Domestic hot water performance 10

6.4 Boiler performances 10

6.5 Atmospheric burner 10

7 USER GUIDE 12

7.1 Using the boiler 12

7.2 Boiler room 13

1.4 WARNINGS

These instructions are an integral part of the equipment to which they

refer and must be supplied to the user.

The product must be installed and serviced by qualified engineers, in

compliance with the prevailing standards.

ACV accepts no liability for any damage resulting from incorrect

installation or from the use of components or fittings not specified by

ACV.

Failure to observe instructions regarding tests and test

procedures can result in personal injury or pollution

risks.

Note:

ACV reserves the right to modify the technical specifications and

components of its products without prior notice.

INDEX 1 INTRODUCTION

2.1 BOILER ROOM

2.1.1 ACCESSIBILITY

The boiler room must be large enough to allow good access to boiler.

The following minimum distances (mm) are required around the boiler:

- front 500 - sides 100

- rear 150 - above 700

2.1.2 VENTILATION

The boiler room must be fitted with top and bottom vents according to

the table below or current regulations.

2.1.3 BASE

The base on which the boiler rests must be made of non-combustible

materials.

2.2 CONNECTION

2.2.1 CHIMNEY CONNECTION

The boiler can be connected to a suitable flue or to the chimney by a

metal pipe rising at an angle from the boiler to the chimney. It must be

easy to remove to give access to the flue pipes when servicing the boiler.

IMPORTANT

Boilers must be installed by a qualified engineer, in

accordance with the prevailing local standards and

regulations.

2.2.2 CENTRAL HEATING CONNECTION

2.2.2.1 Examples of basic circuit configurations

The drain valve and safety valve must be connected to the waste

water system in accordance with current regulations.

1. 3-way manual motorisable mixer valve

2. Safety valve pre-set to 3 bar with pressure gauge

3. Circulator

4. Non-return valve

5. System filling valve

6. Expansion tank

7. Room thermostat

8. ACV 13 controller (see controller kit page 5)

9. Central heating isolating valve

10. Drain valve

Fig. 2: Configuration with circulator controlled

by a room thermostat

2 INSTALLATION

Fig. 3: Configuration with motor driven mixer valve

Fig. 1: Boiler room ventilation and chimney connection

A. Top vent

B. Bottom vent

C. Chimney height

D. Chimney diameter

ALFA G ALFA GP

Ventilation

Min. fresh air requierement m3/h 82,8 82,8

Top vent (A) dm21,5 1,5

Bottom vent (B) dm21,5 1,5

Chimney

C = 5 m Ø min. D mm 130 130

C = 10 m Ø min. D mm 130 130

C = 15 m Ø min. D mm 130 130

2.2.2.2 ACV circulation kit

ACV offers an optional pre-assembled circulation kit comprising:

- a circulator.

- a 3-way manual motorisable valve.

- connecting pipes including a second optional circuit.

- two isolating valves.

- adapters for mounting expansion tank, safety valve and filling

valve to right or left.

2.2.2.3 Discharge

The drain valve and safety valve must be connected to the waste

water system in accordance with current regulations.

2.2.3 DOMESTIC HOT WATER CONNECTION

2.2.3.1 Pressure reducer

If the water mains pressure is greater than 6 bar, a pressure

reducer calibrated to 4.5 bar must be fitted.

2.2.3.2 Safety unit

The tank safety unit must be ACV approved and calibrated to 7 bar.

The valve discharge must be connected to the waste water

system in accordance with current regulations.

2.2.3.3 Hot water expansion tank

Installing a hot water expansion tank avoids any risk of pressure

surges due to water-hammer.

2.2.3.4 Hot water circulation

If the tank is situated a long way from the point of use, then

installing a closed return circuit can provide a faster supply of

hot water always available.

2.2.3.5 Description

1. Safety unit

2. Pressure reducer

3. Thermostatic mixing valve

4. Hot water circulator

5. Non-return valve

6. Hot water expansion tank

7. Inlet valve

8. Draw-off valve

9. Bleed valve

IMPORTANT

As a safety measure against burns, we strongly advise

installing a thermostatic mixing valve (recommended

temperature: 60° C).

Optional fittings available

2 INSTALLATION

Fig. 5a: Configuration without thermostatic mixing valve

Fig. 5b: Configuration with thermostatic mixing valve

Fig. 4: ACV circulation kit assembly

Safty unit Ø 3/4”

Pressure reducer Ø 3/4”

Thermostatic mixer Ø 3/4”

Hot water expansion tank 5 litres

Wiring diagram of ACV controller kits (fig. 7)

2 INSTALLATION

2.3 ELECTRICAL CONNECTION

2.3.1 POWER SUPPLY

The boiler operates with a 230 V - 50 Hz single phase supply.

An isolator switch with 6 A fuses must be fitted outside the boiler to

allow power to be shut off during servicing and before any repairs are

carried out on the boiler.

2.3.2 COMPLIANCE

Boiler installation must comply with the prevailing local standards and

legislation.

2.3.3 SAFETY

The stainless steel tank must be earthed separately.

2.3.4 BURNER ELECTRICAL CONNECTION

The burner is supplied with power by a 3-core cable.

1. Boiler thermostat (60/90° C)

2. On/off switch

3. Summer/winter selector

4. Thermometer

5. Flue spillage thermostat (TTB)

6. Safety thermostat (103° C max.)

7. Plug (power and control)

8. Room thermostat

9. Heating pump connection

10. To gas valve

Fig. 8: Control panel

The power to the boiler must be switched off before any

work is carried out. Fig. 9: Boiler wiring diagram

M. Brown

O. Orange

N. Black

B. Blue

R. Red

T. Green-yellow

NT1 T2

230V-50 Hz

20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

bl n/z br

SQK 349

QAAD50

(QAAD70) QAC32 QAD22

P1 B5 B9 B3 B2

P1Y1Y2NB5B9B3B2

B2. Water temperature detector

B9. Outside temperature detector

B5. Analogue/digital room thermostat

P1. Central heating pump

Y1/Y2/N. Mixer valve (SQK349)

bl. Blue N

n/z. Black Y2

br. Brown Y1

230V / 50 Hz

ALIMENTATION

230V

Fig. 6a: kit 1

Fig. 6b: kit 2

2.2.4 CONTROLLER KITS

KIT 1: ACV 13.00 / Basic

Basic kit for regulating flow temperature according to

weather conditions.

It comprises: temperature regulator with analogue timer,

water temperature detector (-30/130° C), outside temperature

detector (-30/50° C), 230V - 3 spindle servomotor SQY 31

and intermediate socket.

KIT 1: ACV 13.00 / Standard

Basic kit for regulating flow temperature according to

weather conditions.

It comprises: temperature regulator with analogue timer,

water temperature detector (-30/130° C), outside temperature

detector (-30/50° C), 230V - 3 spindle servomotor SQY 349

and intermediate socket.

3.1 FILLING THE HEATING AND HOT

WATER CIRCUITS

1. Fill the domestic hot water circuit and bring it up to pressure.

IMPORTANT

The hot water tank must be pressurised before the

heating circuit is filled.

2. Fill the heating circuit taking care not to exceed the 2 bar pressure

limit.

3. Vent the air from the top of the boiler.

4. After venting the air from the system, bring the pressure up to the

static head plus 0.5 bar: 1.5 bar = 10 m – 2 bar = 15 m.

5. Check the power connection, the boiler room ventilation, and

ensure that there are no leaks in the flue gas discharge pipes.

6. Set the thermostat (1) to between 60 and 90° C.

3 START-UP 4 SERVICING

Fig. 10: Control panel

7. Set the Summer/Winter selector (3) to the desired position.

8. Switch the on/off switch (2) to the ON position.

9. Check the gas supply pressure on starting up.

3.2 BURNER TROUBLESHOOTING

Refer to the servicing and troubleshooting instructions for the burner.

Before servicing or repairs, switch off the power at the

mains switch fitted in the boiler room by the electrician.

4.1 RECOMMENDATION

ACV recommends that boilers should be serviced at least once a year.

The burner must be serviced and tested by a competent engineer.

4.2 SERVICING THE GAS BOILER

1- Switch off the power at the mains switch outside the boiler and

close the gas tap.

2 - Set the on/off switch on the control panel to the OFF position.

3 - Release and remove the chimney flue (1) to free the top of the

boiler.

4 - Remove the jacket top (2) and lift off the flue reducer (3).

5 - Remove the baffles (4) from the flue pipes (5) for cleaning. Replace

them if in poor condition.

6 - Unscrew the burner chamber plate (6).

7 - Brush the flue pipes (5).

8 - Clean the burner chamber (7) and the burner (8).

9 - Check that the insulation on the burner chamber plate (6) is in

good condition.

1. Chimney flue

2. Jacket top

3. Chimney flue reducer

4. Baffles

5. Flue pipes

6. Burner chamber plate

7. Burner chamber

8. Burner

Fig. 11: Main components.

4.3 SERVICING THE SAFETY DEVICES

- Check that all thermostats and safety devices are working properly:

boiler thermostat, cut-off thermostat and manual reset safety

thermostat.

- Test the safety valves on the central heating and hot water circuits.

4.4 SERVICING THE BURNER

- Check and clean the burner and ignition electrode.

- Check that the safety components are working properly.

4.5 EMPTYING THE BOILER

4.5.1 EMPTYING THE PRIMARY CIRCUIT (central heating):

1. Switch off the power to the boiler at the mains switch installed by

the electrician.

2. Close the isolating valves (1) of the boiler system.

3. Connect a hose to the drain valve (2).

Ensure that it is attached properly.

4. Open the drain valve and let the hot water drain out.

5. When the boiler is empty, return the isolating and safety valves to

their initial positions.

4.5.2 EMPTYING THE HOT WATER TANK:

1. Switch off the mains power to the boiler at the external switch

installed by the electrician.

2. Relieve the pressure in the primary circuit.

3. Close valves (A) and (B).

4. Open valves (C) and (D) (first C then D).

5. Let the water drain away.

6. After emptying, return the valves to their initial positions.

For the tank to be emptied, valve (C) must be situated at

ground level.

4.6 SPARE PARTS

Refer to the specific document available from ACV or your distributor.

4 SERVICING

Fig. 12a: Emptying the primary circuit

Fig. 12b: Emptying the hot water circuit

5.3 DESIGN FEATURES

5.3.1 OUTER BODY

The outer body containing the primary fluid is made of STW 22 steel.

5.3.2 TANK-IN-TANK TYPE EXCHANGER ACCUMULATOR

The ring-shaped inner tank with its large heating surface for producing

domestic hot water is built of Chrome/Nickel 18/10 stainless steel. It is

corrugated over its full height by an exclusive production process and

entirely by argon arc welded by the TIG (Tungsten Inert Gas) method.

5.3.3 COMBUSTION GAS CIRCUIT

The combustion gas circuit is protected by cold galvanisation. The

combustion gas circuit comprises:

5.3.3.1 Flue pipes

Depending on output, ALFA Gas models contain 4 or 8 steel flue

pipes with an internal diameter of 64 mm. Each pipe is fitted with

a baffle of special steel designed to improve heat exchange and

reduce flue gas temperature.

5.3.3.2 Combustion chamber

The combustion chamber on ALFA Gas models is water cooled.

5.3.4 INSULATION

The boiler body is fully insulated by rigid polyurethane foam with a high

thermal insulation coefficient, sprayed on without the use of CFCs.

5.3.5 JACKET

The boiler is covered by a steel jacket which has been scoured and

phosphated before being stove enamelled at 220° C.

5.3.6 BURNER

ALFA Gas boilers are fitted with an atmospheric burner with electric

ignition.

5.3.7 CONTROL PANEL (Fig. 14)

1 - Thermostat adjustable between 60 and 90° C

2 - On/off switch

3 - Summer/winter selector

4 - Thermometer

Fig. 14: Control panel

5.1 OVERVIEW

• Dual application boiler (central heating and domestic hot water).

• Designed for connection to a chimney or suitable flue.

• TANK-IN-TANK indirect storage type domestic hot water production.

• Fittings for connecting the circulation kit to feed the heating circuit

(available as an option).

• Control panel with setting thermostat (60/90 °C), on/off switch,

Summer/Winter selector, thermometer, warning lamp and burner

reset button.

• Flue gas anti-backdraught safety device.

• Delivered complete with atmospheric type burner.

• ALFA G for natural gas, with rated output of 20.3 kW.

• ALFA GP for propane, with rated output of 23.5 kW.

5 DESCRIPTION

Fig. 13: Ballon inox sanitaire

5.2 DESCRIPTION OF OPERATION

5.2.1 THE TANK-IN-TANK CONCEPT

The ALFA Gas series differs from traditional hot water producers

because of its ring-shaped tank immersed in the primary fluid contained

in the outer body. When there is a demand for hot water from the central

heating system or the domestic hot water system, the thermostat starts

the burner. The combustion gases quickly heat up the primary fluid,

creating a natural circulation around the tank.

5.2.2 DOMESTIC HOT WATER HEATED INDIRECTLY

This circulation facilitates heat exchange between the primary fluid and

the domestic water, which takes place all over the tank surface. The

corrugations on the inner and outer shells of the ring-shaped tank

further boost the area of heat exchange and speed up the heating

process of the domestic water.

5.2.3 EASY SETTING AND SAFETY ASSURED

With a single command, the water temperature of both the primary circuit

and the hot water circuit is set by the adjustable thermostat situated on

the tank in the primary circuit. A manually reset safety thermostat shuts

off the burner if the temperature reaches 103° C.

Boiler components Fig. 15

1. Chimney flue

2. Domestic hot water outlet

3. Central heating return

4. Central heating flow pipe

5. Inner ring-shaped domestic hot water tank

6. Sprayed-on polyurethane foam insulation

7. Flue pipes

8. Baffles

9. External body containing central heating circuit

10. Burner chamber disk

11. Boiler drain

12. Combustion chamber

13. Boiler base

14. Burner flame holder

15. Burner chamber cap

16. Burner chamber door

17. Thermometer / boiler thermostat bulb

18. Front

19. Control thermostat 60/90 °C

20. Manual reset safety thermostat 103 °C

21. Casing top

22. Domestic cold water flow pipe

23. Flue spillage thermostat (TTB)

24. Chimney reducing adapter

5 DESCRIPTION

6 TECHNICAL SPECIFICATION

6.1 EFFECTIVE DIMENSIONS

The units are delivered fully assembled, tested and packed on a timber

base with shockproof edges and protected by heat-shrunk plastic film.

On reception and after unpacking, check the equipment for damage.

For transport purposes, refer to the weights and dimensions given

opposite.

6.2 MAXIMUM OPERATING CONDITIONS

Maximum service pressure (tank full of water)

- Primary circuit: 3 bar

- Secondary circuit: 10 bar

Test pressure (tank full of water)

- Primary circuit: 4.5 bar

- Secondary circuit: 13 bar

Operating temperature

- Maximum temperature: 90° C

569

200

160

542

125

Fig. 16: Effective dimensions

Dimensions

ALFA G ALFA GP

1363 1363

130 130

685 685

390 390

143 143

ALFA G ALFA GP

Gas G20 - 20 mbar - I E2+ - I 2E LL

Burner pressure mbar 9,8 -

Flow rate m3/h 2,43 -

Gas G31 - 37/50 mbar - I 3P

Burner pressure mbar - 21,2

Flow rate m3/h - 0,94

Injector Ø 1/100 mm 450 3x160

6.5 ATMOSPHERIC BURNER

6 TECHNICAL SPECIFICATION

6.3 DOMESTIC HOT WATER PERFORMANCE

6.4 BOILER PERFORMANCES

Domestic hot water performances ALFA G ALFA GP

Operating at 80° C

Peak delivery at 40° C (6T = 30° C) litres/10’ 170 170

Peak delivery at 40° C (6T = 30° C) litres/60’ 653 665

Continuous delivery 40° C (6T = 30° C) litres/h 579 594

Operating at 80° C

Initial heating time minutes 24 24

After draw-off of 140 l at 45° C minutes 17 16,5

Results obtained without a thermostatic mixing valve and with water supply at 10° C

ALFA G ALFA GP

Input kW 23 23,5

Output kW 20,3 20,7

Combustion efficiency %90,7 91,3

Maintenance loss at 60° C as % of rate value %11

Mass rate of combustion products g/sec. 18 19

Average CO2%8,5 9,5

Total capacity litres 99 99

Primary circuit capacity litres 56 56

Heating connection Ø1” 1”

Hot water connection Ø3/4” 3/4”

Hot water tank heat exchange surface m21,42 1,42

Weight empty Kg

143

Chimney connection B11 BS B11 BS

BE - FR AT - DK - ES - GB - IT - PT - IE - SE BE - FR - ES - GB - IE - PT NL LU - DE

I E2+ I 2H I 3P I 2L I 2ELL

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