Alpha Alpha Plus DH Units Leitfaden

Instructions for Installation

Alpha Plus DH Units for Domestic Hot Water

and Low Pressure Central Heating

Alpha Therm Ltd

Nepicar House

London Rd

Wrotham Heath

Kent

TN15 7RS

Leave these instructions with the User

1/ INTRODUCTION

The Alpha Plus district heating units are hydraulic units designed for various

heating applications within individual domestic dwellings served by a district heating

scheme. The units are:-

(i) Domestic Hot Water Unit – Model DHW (Part No 6.3000100)

This unit provides instantaneous hot water indirectly from a district heating

circuit via a plate heat exchanger. The main components are pre-assembled

mounted on a back panel. Isolation valves and strainer are supplied with wall

fixings and thermostat sensor.

(ii) Low Pressure Central Heating Unit – Model LPCH (Part No 6.3000300)

This unit is to be used in conjunction with the unit DHW and provides central

heating to the dwelling indirectly from the district heating circuit via a plate

heat exchanger. It incorporates all the necessary components i.e. pump,

expansion vessel, safety valve, pressure gauge, filling loop, pressure switch

etc required to provide a sealed central heating system with a maximum

working pressure of 2.5 bar (Refer diagrams)

Note: Differential pressure control valves and an automatic by-pass valve for

fitting to the district heating circuit are not provided in the above units and

need to be supplied by the installer.

An optional outer cover (Part no 6.3000400) enclosing the main components of the DHW

or LPCH unit is available, if required.

The above district heating units comply with the following requirements:

Electrical requirements of BS EN60335 – 1

EMC requirements of BS EN55014 – 2, BS EN50081 – 1, BS EN61000 - 3 - 2 / 3

UK Water Regulations / Byelaws (Scotland)

Northern Ireland Water Regulations

IMPORTANT

The installation should be in accordance with the following British Standards and requirements:

All current Dept of Environment Building Regulations , i.e. Approved Document L1

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

UK Water Regulations/Byelaws (Scotland)

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

BS 5449: 1990 Forced circulation hot water system

BS 5546: 2000 Installation of hot water supplied for domestic purposes

BS 6700: 1997 Design, installation, testing and maintenance of services supplying water

BS 7983: 1992 Code of Practice for treatment of water in heating systems

BS 7671: 2001 Requirements for electrical installations, IEE Wiring Regulations

Note: Manufacturer’s instructions must NOT be taken in any way as over-riding statutory

obligations

2/ TECHNICAL DATA

2.1 District Heating Circuit

Max Working Pressure 8 bar

Min Working Pressure 1 bar

Max Flow Temperature 95°C

Max Differential Pressure 4 bar

Flow connection 22mm

Return connection 22mm

2.2 Secondary Circuit (Domestic Hot Water)

Max Working Pressure 8 bar

Min Working Pressure 0.2 bar

Heat Output to water (approx) 20 to 28kW

DH circuit flow rate reqd for max output 15 to 20 l/min

Max Flow Rate at 35°C rise (approx) 12 l/min

Min required Flow Rate 2.5 l/min

Adjustable Outlet temperature up to 60°C

Max Outlet Temperature (approx) 62°C

Mains inlet connection 15mm

DHW outlet connection 15mm

2.3 Low Pressure Central Heating (Sealed System)

Max. working system pressure 2.5 bar

Min System Pressure 0.5 bar

Max System temperature 85°C

Safety Valve setting 3 bar

Expansion Vessel Size (pre-charge press)8 L @ 0.8 bar

Flow Connection 22mm

Return Connection 22mm

Relief valve discharge connection 15mm

Recommended System Pressure (Cold) 1.0 bar

2.3 Components

DHW Heat Exchanger Stainless Steel 23 plate

CH Heat Exchanger Stainless Steel 14 plate

Hot Water Thermostatic Valve Brass body with removable t/sensor

CH/DHW on/off 2-way Valve Brass body with removable actuator

DHW Flow Switch with Strainer Nylon with ½” Brass connection

Strainer for DH and CH Brass 22mm comp with S/S filter

DH/CH Isolation Valves Brass 22mm comp.

Cold Water Inlet Valve Brass 15mm comp

Pump with AAV & Separator Grundfoss 15/60

LP Pressure Switch Set 0.5 bar switching

Expansion Vessel 8 litre charge to 1 bar

Pressure Relief Valve/Gauge Set 3 bar

2.4 Electrical

Supply – 230/240V – 50 Hz

External fuse - 3 A

Power Consumption – 116W

Important – Ensure terminal block 2 (supplied with LPCH unit) is fitted within the DHW

control box, if not already fitted

2.5 Installation

Dimensions of each assembled Unit Height 500mm

(Including Cover) Width 300mm

Depth 220mm

Min clearances required Top 5mm

Bottom 200mm

Sides 5mm

Front 450mm

Assembled weight of Units DHW 7.4kg

LPCH 8kg

2.6 Schematic Diagram

3/ OPERATION

Domestic hot water is available continuously and always takes priority over central

heating. If a demand for hot water is required during a central heating period the

controls will automatically switch to the hot water mode until the demand is

satisfied. This interruption in the central heating is only when the demand for hot

water is present and should not be noticed by the User.

3.1 Domestic Hot Water mode

When there is a demand for hot water the flow switch operates and the DHW valve

is opened via a relay. District heating water is circulated to the DHW heat

exchanger thus heating the incoming mains water. The hot water is maintained at

the set temperature by the hot water thermostatic valve regulating the district

heating water flow to the heat exchanger. When the flow switch senses that hot

water is no longer required the DHW valve closes.

3.2 Low Pressure Central Heating

If there is a call for heating from an external control the CH valve opens and district

heating water is circulated to the CH heat exchanger. The pump will start and

circulate the central heating water to the dwelling’s radiators via the heat

exchanger. When there is no demand for heating the CH valve will close and the

pump will stop. If there is a demand for hot water the CH valve will close and not be

allowed to open until the hot water demand has been satisfied.

Note: If the pressure in the central heating system falls below 0.5 bar the pressure

switch will operate and stop the pump from running until the system has been re-

pressurised above 0.5 bar

4/ INSTALLATION

4.1 Unpacking

(1) The contents of each box is as follows:

DHW Box - Assembled unit panel mounted with heat exchanger,

flow switch, DHW valve, HW thermostatic valve, control

box and pipework

Thermostat and sensor

Thermostat sensor fixing kit, screws and wall plugs

Two 22mm isolation valves, strainer, 15mm Isolation valve

LPCH Box - Assembled unit panel mounted with heat exchanger, pump

with AAV and separator, CH valve, pressure switch and

pipework

Four 22mm isolation valves, strainer, screws, wall plugs

Terminal block 2

(2) Unpack and remove loose items

4.2 Unit Location

(1) The unit is not suitable for external installation. It must be installed vertically on

a flat vertical wall which is capable of supporting its weight.

(2) Decide upon the position of the unit taking into consideration the clearances

required (Refer Sect 2.5)

(3) Refer to diagram below for the layout and location of the two units:

4.3 Fit the DHW Unit

(1) Drill four fixing holes (5mm dia) through the back panel of the unit to accept

the No. 8 screws supplied.

(2) Hold the unit on the wall in the required position ensuring it is level and mark the

position of the fixing holes. Then drill the fixing holes (6mm dia) in the wall to

accept the No.8 wall plugs.

(3) Using the screws supplied secure the unit to the wall.

4.4 Fit the Thermostat and Sensor (Refer Diagram 4.2.3)

(1) Unscrew the plastic cap on the HW thermostatic valve body and remove.

(2) If applicable, remove the pocket from the capillary tube sensor and discard.

Then locate the thermostat onto the valve body by tightening the loose nut by

hand onto the thread of the body.

(3) With care unwind the capillary tube and position the sensor onto the location

provided on the outlet pipe from the heat exchanger.

(4) Secure the sensor in position using the tape supplied. Then locate the

insulation supplied around the sensor and secure with the two straps provided.

4.5 Connect the Pipework (Refer Diagram 4.2.3)

(1) Thoroughly flush out ALL the system pipework.

Note: An automatic system by-pass must always be fitted.

(2) Connect the 15mm isolating valve to the cold inlet pipe of the unit and then

connect the domestic hot water pipework.

(3) Using a ‘T’ connection, Connect the DH flow and return of the DHW unit and fit

the LPCH unit in the position shown in the diagram 4.2.3 and as detailed in

section 4.2 and 4.3.

Note: Ensure the LPCH unit is located within 300mm of the DHW unit. This will

allow the cables to be directly connected into the unit’s control box.

(4) Fit the 22mm strainers supplied to the DH flow pipe and to the CH return pipe.

Ensure the strainers are always fitted after the valves so that isolation allows

cleaning of the filter (Refer diagram 2.6)

4.6 Fit the Sealed System Kit

(1) Assemble the components of the sealed system kit as shown in the instruction

supplied in it’s box. Note: Check the expansion vessel has been charged to 1

bar before connection to the system.

(2) Using the 22mm ‘T’ connector and 22mm to 15mm reducer supplied connect

the kit to the CH system, preferably on the return to the pump.

Note: The pressure relief valve discharge pipe must be routed to a drain in such a

manner that it may be seen, but cannot cause injury to persons or property.

4.7 Fit Terminal Block 2, If Not Already Fitted (Supplied with the LPCH unit)

(1) Gain access to the DHW terminal block by releasing the 4 screws securing the

control box cover.

(2) Connect the terminal block 2 to terminal block 1 as follows (Refer diagram 2.4):

Brown wire to terminal 6, Blue wire to terminal 3, Green/Yellow wire to earth.

(3) Locate terminal block 2 into the control box as shown in diagram 4.10.6

4.8 Connect the CH Valve Electrical Cable (Refer Sect 2.4)

(1) Gain access to the DHW terminal block by releasing the 4 screws securing

the control box cover.

(2) Pass the CH valve’s electrical cable through a cable clamp and connect the

wires to terminal block’s 1 and 2 as follows (Refer diagram 2.4);

Brown to terminal 7, Black to terminal 9, Blue to terminal 3, Grey to terminal 13,

Orange to terminal 12, White wire not used ensure to terminate it safely.

(3) Tighten the cable clamp by hand until the cable is secured.

4.9 Connect the CH Pump electrical cable

(1) Pass the CH pump’s electrical cable through a cable clamp and connect the

wires to the terminal block 2 as follows (refer diagram 2.4);

Brown to pump ‘L’ (no11), Blue to pump ‘N’ (no10), Green/Yellow to pump earth

(2) Tighten the cable by hand until the cable is secured.

4.10 Connect the LP Pressure Switch

(1) Pass the LP pressure switch cable through a cable clamp and connect the wires

to terminal block 2 as follows (refer diagram 2.4):

Brown wire to terminal 13, Blue wire to terminal 11

(2) Tighten the cable by hand until the cable is secured.

4.10 Connect the Electrical Supply (Refer Sect 2.4)

The Unit requires a 230/240V ~ 50Hz mains supply, fused at 3A

The Unit must be earthed.

There must be only one common isolator, providing complete electrical isolation, for

the Unit and any external controls.

Using PVC insulated cable not less than 0.75mm²(24 x 0.2mm) to BS6500 Table 16,

the Unit should be connected to a fused three pin plug and unswitched shuttered

socket outlet (both complying with BS1363), or a fused double pole switch with a

contact separation of at least 3mm in both poles.

Wiring external to the Unit must be in accordance with the current IEE Wiring

Regulations (BS7671).

NOTE:If external controls are fitted, they MUST be suitable for 230/240V

switching and MUST be single pole, 2 way / Changeover switching

The procedure is as follows:

(1) Gain access to the terminal block as in 4.7.1.

(2) Pass the mains supply cable through the cable clamp and connect as follows:-

Brown to L, Blue to N and Green/Yellow to earth. Ensure correct polarity.

Note: Ensure that the length of the earth wire is such that if the supply cable

is pulled out of its clamp the live and neutral wires become taut before

the earth wire.

(3) If an external control i.e. room thermostat or external clock is to be fitted,

remove the link between terminals 8 and 9. Pass the cable through the cable

clamp and connect to terminals 8 & 9 using terminal 9 as switched live.

(4) Ensure there is sufficient free cable to allow the control box cover to be

removed giving easy access to the main terminal block, then tighten the cable

clamps by hand.

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