Installation and Servicing Instructions Alpha 500E Wall Mounted, Fan Assisted, Room Sealed, Gas Fired Combination Boiler with Unvented Hot Water Storage For Technical help or for Service call ... ALPHA HELPLINE Tel: (01322) 669443 Goldsel Road, Swanley, Kent BR8 8EX Fax: (01322) 615017 *HEJEID /=I Service Listed Alpha 500E G.C. No. 47 532 07 0051 For use with Natural Gas only Leave these instructions with the User Building Regulations Certificate No.
CONTENTS 1 2 3 4 5 6 Introduction ....................................... 2 Technical data ................................... 3 General boiler information .................. 6 Installation ......................................... 12 Commissioning ................................. 17 Boiler operation ................................. 19 1 7 8 9 10 11 12 Routine servicing ............................... 20 Component replacement ................... 22 Wiring diagrams ................................
2 2.1 TECHNICAL DATA PERFORMANCE - NATURAL GAS (Cat I2H ) Central Heating Heat Input kW (Gross) Heat Output (modulating) Btu/h kW 117 700 45 000 28.0 10.4 Burner Pressure Btu/h mbar 95 550 10.8 35 500 1.9 in wg mbar 4.32 11.5 0.76 2.6 Gas Rate in wg m³/h 4.6 3.25 1.04 1.24 CH Water Temp. (Approx.) ft³/h °C 114.8 82 43.9 30 180 86 Settings Room sealed chamber panel fitted Room sealed chamber panel removed °F 2.2 MAX. 34.5 MIN. 13.2 SYSTEM 82°C 3 bar (44 PSI) Max.
2.7 FLUE LENGTHS Flue length = 0.75 m (not including the terminal, which is supplied with the boiler) Note: Additional flues (of the same length) are available. Length of Flue Required:Rear Flue = wall thickness +115 mm Side Flue = wall thickness + distance between wall and side of boiler + X mm (L/H side X = 380, R/H side X = 130) Vertical Flue = distance from top of boiler side panel to required roof position minus 1 m for vertical terminal assembly Maximum flue length = 4 m horizontal or 4 m vertical.
2.10 BOILER SCHEMATIC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Gas Service Cock Heating On/Off Valve Gas Valve Pressure Gauge Pump and Air Separator Primary Return Temperature Sensor Differential Water Flow Switch Adjustable By-Pass Flow restrictor 3-Port Diverter Valve Primary Flow temperature Sensor Overheat Thermostat C.H. Pressure Relief Valve Auto Air Vent Main Burner Main Heat Exchanger Fan Air pressure Switch 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
3 3.1 GENERAL BOILER INFORMATION GAS SUPPLY The boiler requires a gas rate of 3.25 m³/h (114.8 ft³/h). The meter and supply pipes must be capable of delivering this quantity of gas in addition to the demand from any other appliances in the house. The boiler requires at least a 22 mm gas supply pipe. The complete installation, including the meter, must be tested for gas soundness and purged as described in BS 6891. 3.
HORIZONTAL FLUE OPTIONS Lmax = 4 metres, For L/H side flue X = 380, for R/H side flue X = 130 L = B + C + X mm L = B + C + E + X mm B C B C RHS LHS E Front Front B F E C L = B + E + F + X mm + (90° bend = 1 metre) B L = B + C + X mm + (2 x 45° bends = 1 metre) VERTICAL FLUE OPTIONS Hmax = 4 metres Not less than 300 mm Not less than 300 mm Not less than 450 mm Not less than 450 mm H H Fig.
3.5 FLUE TERMINAL LOCATION - Fig. 4 Fig. 4 Terminal position Min. distance A Directly below an opening, air brick, windows, etc.
3.7 CENTRAL HEATING SYSTEM - Fig. 5 The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798. The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. Refer to the pump performance table for guidelines.
3.9 DOMESTIC HOT WATER SYSTEM The mains water supply must be first connected to the components detailed in section 3.10 before the boiler. No valves must be fitted between these components and the boiler. The incoming mains water pressure to the boiler is regulated to 3.5 bar by the pressure reducing valve supplied in the unvented package. However, all taps and mixing valves used with the hot water system must be suitable for operating at a pressure of up to 8 bar.
The discharge pipework from the tundish:1. Shall fall continuously through its length. 2. Shall be of a heat resistant material, e.g. metal. 3. Shall not be fitted with any valves or taps. 4. Shall discharge to a safe visible position, e.g. onto the surface of an external wall or into a gulley. 5. Shall have a minimum of 300 mm straight pipework directly from the tundish.
4 4.1 1. INSTALLATION UNPACKING The boxes required when the boiler is installed with a horizontal flue are as follows:Box 1 Cased boiler Water and gas valves plus washers Water fittings Mounting bracket plus screws and wall plugs Flue terminal and wall sealing plate plus 2 screws and mastic Literature pack and Wall template Box 2 90° flue bend with clamp (not required for vertical flue) Box 3 0.
4.4 FIT THE BOILER - Refer to Fig. 11 1. Lift the boiler and locate it on the mounting bracket. 2. Adjust the position of the boiler, as necessary. Fit the bottom screws to secure the boiler in position. 4.5 FIT THE UNVENTED KIT (BOX 4) - Fig 12 1. Unpack Box 4 and check the contents. 2. Locate the expansion vessel mounting bracket in a suitable position as close to the boiler as possible and secure in position with the screws and wall plugs provided. 3.
A - Hot water outlet (15 mm) B - Cold water inlet (15 mm) C - Heating return (22 mm) D - Heating flow (22 mm) E - Gas inlet (22 mm) I G F - Heating pressure relief valve (15 mm) G - Heating return filter and drain point H H - Adjustable heating by-pass I - Drain point for DHW storage J - Flow restrictor housing J 20 23 118 100 A 110 B 100 C 55 D 55 F 62 E Fig. 13 4.7 1. FIT THE FLUE - Figs. 14, 15 The following procedure applies to both rear or side exit flue.
Inner flue duct length Outer air duct length 15 115 72 Outer duct clamp and seal 20 Inner duct clamp 90° bend 120 40 Terminal Sealing plate (optional) BOILER SIDE 60 Note: For horizontal flue ensure there is a slight downward slope towards terminal. Note: 40 mm gap between boiler 90° bend and outer air duct 160 Fig.
8. Place the inner flue duct back into the outer duct. Use the inner duct supports to centralise the duct in the outer duct. 9. Fit the flue assembly as described in the previous section. Due to the size of the flue clamps the flue must be fitted from inside the building. 10. It may be necessary to support the flue with suitable brackets (every metre) when flue lengths approaching the maximum are used. 4.9 CONNECT THE MAINS SUPPLY - Fig. 16 1.
5 COMMISSIONING When commissioning the boiler, ensure the Benchmark Log Book is completed. 5.1 FILL THE SYSTEM 1. The boiler is fitted with an automatic air vent positioned on the pump (see Fig. 2). The vent is fitted with a non-sealing cap. 2. Open the central heating flow and return valves (spindle flats in-line with valve) (see Fig. 13). 3. Open the fill point valve on the filling loop until water is heard to flow. 4.
5.4 INITIAL LIGHTING - Refer to Fig. 18 Note: Remove the protective plastic coating from the boiler painted panels before lighting. 1. Ensure that the gas and electrical supplies to the boiler are off, the selector switch is set to '0' and the central heating flow and return valves are open. 2. Turn on the gas and electrical supplies to the boiler. 3. Ensure all external controls are calling for heat.
5.8 USER INFORMATION The User must be advised (and demonstrated if necessary) of the following important points:1. How to light and turn off the boiler and how to operate the system controls. 2. The importance of annual servicing of the boiler to ensure safe and efficient operation. 3. That any servicing or replacement of parts must only be carried out by CORGI registered personnel. 4. Ensure that the boiler controls and room thermostat (if fitted) are set to the User's requirements. 5.
6.5 INDICATOR NEONS When illuminated, the following conditions apply:Warning light (continuously on) - blocked flue or fan fault, contact your Service Engineer. Overheat thermostat has operated - press white reset button (see Fig. 18) to reset. Electrical supply to the boiler is on. Boiler is supplying hot water. Boiler is supplying central heating. ) is illuminated it indicates that the burner has failed to light - Press the red reset button When the red reset button ( (see Fig.
Front casing screws Room sealed chamber panel screws Combustion chamber front cover Ignition electrodes Bottom casing panel screws Control panel screws Fig. 20 7.3 CLEANING THE BOILER 1. Remove any deposits from heat exchanger using a suitable soft brush. Do not use a brush with metallic bristles. 2. Check the condition of the combustion chamber insulation panels. Any damaged panels must be replaced. (Refer to Component Replacement, section 8.23). 3.
8 COMPONENT REPLACEMENT It is the law that any service work must be carried out by a competent person, i.e. CORGI registered personnel. Warning: Before replacing any boiler components, set the selector switch to 0, 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).
8.5 1. 2. 8.6 MAIN BURNER Remove the burner assembly as described in Routine Servicing, section 7.2. Flame sensing electrode 11 to 12 mm BURNER INJECTORS Remove the burner assembly as described in Routine Servicing, section 7.2. 2. Remove the two screws securing the burner to the injector manifold and remove the burner. Securing screws Fig. 21 3. Unscrew the damaged injector and screw in a replacement. 4. Re-assemble as described in Routine Servicing, section 7.4. FAN - Fig. 23 1.
8.10 GAS VALVE - Fig. 26 1. Gain access as in section 8.1. 2. Remove the two screws securing the bottom panel and lift out the panel. 3. Disconnect the coil wires and pressure tube from the gas valve. 4. Loosen the screw (see Fig. 26) securing the solenoid plug and disconnect the plug. 5. Remove the four manifold screws from beneath the boiler. 6. Disconnect the burner manifold union within the room sealed chamber and remove the four screws securing the manifold to the gas valve. 7.
Ignition PCB Ignition electrode leads Main PCB Neon PCB Earthing terminals Reset switch Securing screws Pressure gauge Relay PCB Fig. 27 8.17 RESET SWITCH - Fig. 27 1. Gain access as described in section 8.1. 2. Disconnect the wiring from the switch. 3. Remove the five screws securing the complete control box to the control panel. 4. Depress the switch retaining lugs and withdraw the switch from the front of the control box. 5.
8.22 MAIN HEAT EXCHANGER - Refer to Fig. 23 1. Drain the boiler heating circuit as described in section 8.2. 2. Remove the four screws securing the combustion chamber front cover and remove the cover. 3. Remove the fan assembly as described in section 8.7. 4. Remove the two screws securing the flue hood and lift out the flue hood. 5. Remove the two screws securing the heat exchanger and remove by pulling it towards the front, being careful not to damage the combustion chamber insulation. 6.
Hot water storage sensor Overheat thermostat Differential water flow switch Primary return sensor Automatic air vent Cable clamps Pump Primary flow sensor Diverter valve Fig. 29 Complete pump 1. Unscrew the automatic air vent from the pump outlet. 2. Disconnect the pump unions and withdraw the pump, remove the wiring cover and disconnect the wiring. 3. Connect the wiring as described above, ensure that pump is set to maximum and re-assemble using new sealing washers. 4.
8.32 DIFFERENTIAL WATER FLOW SWITCH - Refer to Fig. 29 1. Drain the boiler heating circuit as described in section 8.2. 2. Disconnect the flow switch unions and remove the switch. 3. Remove the screws securing the plastic cover and disconnect the wiring from the microswitch. 4. Re-assemble in reverse order using the new seals supplied. 5. Refill and pressurise the system. (Refer to Commissioning, section 5.1). 8.33 DHW TEMPERATURE/PRESSURE RELIEF VALVE - Refer to Fig. 2 1.
9 9.
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10 FAULT FINDING 10.1 CARRY OUT INITIAL FAULT FINDING CHECKS 1. Check that gas, water and electrical supplies are available at the boiler. i.e. Inlet gas pressure = 20 mbar, Electrical supply = 230/240 V ~ 50 Hz, CH water system pressurised to 1 - 1.5 bar 2. Carry out electrical system checks, i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter. Note: These checks must be repeated after any servicing or fault finding. 3.
10.3 DOMESTIC HOT WATER - Follow operational sequence (DHW storage at ambient temperature i.e. cold) Turn selector to neon illuminated NO Go to section ' A ', page 33 YES Turn thermostat to max. neon illuminated NO YES Pump runs, i.e. primary water NO to DHW store heat exchanger PCB - M1 connector, is 2V DC across terminals 49, 52 YES Replace neon PCB NO Replace main PCB Go to section ' B ', page 33 YES Differential flow switch operated NO neon illuminated YES Fan runs at max.
10.4 FAULT FINDING SOLUTION SECTIONS A to L A 1. Main terminals L and N NO 2. Main terminal fuse 3. 4. B C Replace neon PCB 240 V at:NO Main PCB - M11 connector, neon NO is 2V DC across terminals illuminated 46, 49 Replace fuse Both sides of suppressor NO Replace suppressor PCB - M4 connector, terminals 10, 11 NO NO Check wiring Replace main PCB 240 V at:YES If pump jammed, release NO 1. Pump 2. Main PCB - M9 connector, terminals 20, 21 1. CH system pressure 1.0 bar 2.
G YES Burner output modulates H Modulating coil faulty cold resistance approx. 40 ohm Check and correct:1. Main PCB - CM3, plug is connected to MET, i.e. Natural Gas 2. Main PCB - CM4, the RLA plug is connected to OFF NO YES Volts across modulating coil and at Main PCB - M5 connector across terminals 31, 32 NO Max. burner press. approx. 10 V DC Min. burner press. approx. 1.5 V DC Check and correct:240V at Main PCB - M8 connector, 1.
11 SHORT PARTS LIST Reference Description Qty. Alpha Pt. No. British Gas GC No. Fig. 2, item 15 Burner assembly and seal 1 5630310A 343 750 Fig. 2, item 16 Main injector 1.18 mm Primary heat exchanger and seals 18 1 5202820 5622181A 385 830 343 751 Fig. 2, item 21 Fig. 2, item 3 DHW storage cylinder and seals Gas valve - Honeywell VK4105A1027 1 1 5632750A 5644680 343 752 E02 286 Fig. 26 Fig.
12 SERVICE HISTORY DETAILS OF BOILER INSTALLATION Date of Installation: ...................................................................... Name of Installer: ......................................................................... Address: ...................................................................................... .................................................................................................... ...............................................................................
