Technical data

21
7.4 RE-ASSEMBLE THE BOILER
1. Replace the burner, ensuring it is located correctly over the injectors and the four locating pins (two each side).
2. Replace the combustion chamber front cover, ensuring the bottom is correctly located in the burner.
3. Alpha 240XE - Ensure the electrode leads are connected and the seals are in position in the bottom of the inner case.
Alpha 240XP - 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. Reconnect the pilot supply and thermocouple
4. Test the connections for gas soundness and check the burner pressures. (Refer to Commissioning, sections 5.4 and 5.5).
5. Ensure that the room sealed chamber panel seal is intact and in position, replace the panel and secure it in position with
the screws previously removed.
6. Raise the control panel and secure in position with the screws previously removed.
7. Place the front casing in position over the boiler ensuring the bottom tags are located behind the control panel and secure
in position at the top using the screws previously removed.
8. Check the operation of the boiler. (Refer to Boiler Operation, section 6).
9. Return all controls to their original settings.
Alpha 240XP and 240XE - Routine Servicing/Component Replacement
It is the law that any service work must be carried out by a competent person, ie CORGI registered personnel.
Warning: Before replacing any boiler components, isolate the electrical supply and close the boiler gas service cock. Allow the
boiler to cool.
Always test for gas soundness after replacing any gas carrying components or disturbing any gas connections.
Check the operation of the boiler. (Refer to Boiler Operation, section 6).
Ensure that all the controls are returned to their original settings.
The replacement of components in sections 8.3 to 8.21 does not require draining of the boiler.
8.1 GENERAL ACCESS - Fig. 17
Ensure the electrical supply is isolated and the gas supply is off.
Remove the two screws securing the top of the front casing. Lift the cover up slightly and remove.
1. If access is required behind the control panel - Remove the two fixing screws (one each side) securing the control panel.
Raise the complete control panel slightly, hinging it forward at the same time.
Alpha 240XP - When replacing the control panel, ensure that the gas control locates correctly over the black cap on the
gas valve knob.
2. To gain access to the combustion chamber - Remove the four screws securing the room sealed chamber panel and
remove the panel, taking care not to damage the seal. When replacing the panel, ensure the seal is intact and in position.
3. To gain access to the control panel components - Remove the five screws securing the rear cover and carefully raise
the cover from the front. When replacing the cover, ensure no wires are trapped and all wiring grommets are in position.
Secure with five screws - do not overtighten.
8.2 DRAINING THE BOILER - Refer to Figs. 2 or 3, 11
Isolate the electricity supply and close the boiler gas service cock (see Fig. 11). Allow the boiler to cool.
Remove the two screws securing the top of the front casing. Lift the cover up slightly and remove.
Remove the two fixing screws (one each side) securing the control panel. Raise the complete control panel slightly, hinging it
forward at the same time.
1. Heating circuit
Close the central heating flow and return valves (see Fig. 11).
Connect a suitable pipe to the drain point (see Fig. 2 or 3) and route it to a suitable container. Open the drain tap.
2. Hot water circuit
Close the mains water inlet valve (see Fig. 11).
Open any hot tap below the level of the boiler to allow as much draining as possible.
Note: Some water will remain in the components and care must be taken when removing them.
8 COMPONENT REPLACEMENT