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Alpha Boilers SY9-24 Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired system boiler
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Installation and Servicing
Instructions
Alpha SY9-24
Wall Mounted, Fan Assisted, Room Sealed, Gas Fired
System Boiler
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001 964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Service Listed
Alpha SY9-24
G.C. No. 41 532 01
For use with Natural Gas only
Leave these instructions with the User

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Summary of Contents for Alpha Boilers SY9-24

  • Page 1 Installation and Servicing Instructions Alpha SY9-24 Wall Mounted, Fan Assisted, Room Sealed, Gas Fired System Boiler For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001 964 Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS...

  • Page 2: Table Of Contents

    12 Service history ........31 INTRODUCTION The Alpha SY9-24 boiler is a wall mounted, fan assisted room-sealed system boiler. The burner is lit electronically and the heat output is controlled by a modulating gas valve. The boiler, provides central heating, and is designed for use with a fully pumped, sealed and pressurised heating system using only Natural Gas.

  • Page 3: Technical Data

    (from casing) Bottom 250 mm Sides 5 mm Front 450 mm Flue Terminal Size 100 mm Dia. Flue Terminal Protruding 145 mm Hole Size Required For Flue Assy. 110 mm Dia. Lift Weight 38 kg Alpha SY9-24 - Technical Data...
  • Page 4 40 000 16.7 5.65 18.5 31 700 5.45 17.9 This information is based on 17°C and 20°C system design temperature difference. ELECTRICAL CONNECTIONS Note: This Appliance Must Be Earthed Fig. 1 - Boiler terminal block Alpha SY9-24 - Technical Data...
  • Page 5 Room sealed chamber Flame sensing electrode Flue sampling point Air pressure switch Gas service cock Flue hood Primary pressure switch Overheat thermostat On/off valve (2 off) Expansion vessel Automatic by-pass Automatic air vent Fig. 2 Alpha SY9-24 - Technical Data...

  • Page 6: General Boiler Information

    2. Under no circumstances must the flue length (including allowances for extra bends) exceed 4 metres. 3. Failure to use Alpha flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe. Alpha SY9-24 - General Boiler Information...
  • Page 7 L = B + E + F + 185 mm + (90° bend = 1 metre) L = B + C + 185 mm + (2 x 45° bends = 1 metre) VERTICAL FLUE OPTIONS Fig. 3 Alpha SY9-24 - General Boiler Information...
  • Page 8 The boiler may be installed in a cupboard or compartment, provided it is correctly designed for that purpose, i.e. complies with the Building Regulations and the requirements of BS 6798. Alpha SY9-24 - General Boiler Information...
  • Page 9 Heating circuit return Feed cistern to be water return Stop located above highest Stop supply Stop valve point in the system valve valve Test cock Test cock Filling loop temporarily connected Fig. 6 Fig. 7 Alpha SY9-24 - General Boiler Information...

  • Page 10: Installation

    Using the screws supplied, fit the mounting bracket. Top pipe connections - Preform the pipework at the back of the boiler before hanging the boiler, see Fig. 10, and secure in the clips provided. Alpha SY9-24 - Installation...
  • Page 11 Ensure that all the valves are closed (spindle flats at right angles to valve) and do not turn on the water or gas supplies at this stage. A - Heating flow (22 mm) B - Heating return (22 mm) C - Gas inlet (22 mm) D - Pressure relief valve (15 mm) E - Heating drain point 212.5 47.5 Fig. 11 Alpha SY9-24 - Installation...
  • Page 12 If fitting the collar externally, ensure it does not restrict any of the openings of the flue terminal. Fig. 12 - Rear flue Alpha SY9-24 - Installation...
  • Page 13 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. Alpha SY9-24 - Installation...
  • Page 14 Ensure that there is sufficient free cable to allow the control panel to be raised and lowered then tighten the cable clamp screws. Leave the control panel open until commissioning procedures have been completed. Carry out electrical system checks - Short circuit, Polarity, Earth continuity and Resistance to earth with a suitable multimeter. Alpha SY9-24 - Installation...

  • Page 15: Commissioning

    Set the selector switch to ON. The pump will start, the fan will start; once the pressure switch is proved, the main gas valve solenoid will open allowing the main burner to light from the ignition electrodes. Alpha SY9-24 - Commissioning...
  • Page 16 Hand the User's instructions and the Benchmark Log Book to the User. 10. Leave these Installation and Servicing instructions with the User for use on future calls. 11. Inform the User that the boiler bottom tray has the facility to store the instructions and log book. Alpha SY9-24 - Commissioning...

  • Page 17: Boiler Operation

    A and B Flashing on and off at the same time - Blocked flue or fan fault. A and B Flashing on and off alternatively - System pressure is very low and re-pressurisation is required. A Illuminated continuously and B flashing - Pump fault or restricted flow. Alpha SY9-24 - Boiler Operation...

  • Page 18: Routine Servicing

    Disconnect the electrode leads from the electrodes and the in-line connector to the flame sensing electrode. Remove the four screws securing the burner and withdraw it out of the boiler. Take care not to damage the side insulation panels. Fig. 17 Alpha SY9-24 - Routine Servicing...

  • Page 19: Component Replacement

    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 is secured. Secure with five screws - do not overtighten. Alpha SY9-24 - Routine Servicing/Component Replacement...
  • Page 20 Connect the wiring to the new switch. The polarity of the wires is not important. Secure the new switch in position and connect the pressure sensing tube to the connection nearest the front. Re-assemble in reverse order. Alpha SY9-24 - Component Replacement...
  • Page 21 Fit the new assembly and re-assemble in reverse order. Light the boiler and test for gas soundness. (Refer to Commissioning, section 5.4). Fig. 20 Complete re-assembly as described in Routine Servicing, section 7.4 paragraphs 5 to 9. Alpha SY9-24 - Component Replacement...
  • Page 22 Fit a new panel and re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha SY9-24 - Component Replacement...
  • Page 23 Disconnect the wiring from the pressure switch. Unscrew the switch from the primary flow pipe. Using the new washer supplied, re-assemble in reverse order. When connecting the wiring to the new switch the polarity of the wires is not important. Alpha SY9-24 - Component Replacement...
  • Page 24 When replacing the vessel, ensure that the connection is towards the front of the boiler and re-assemble in reverse order using new seals as necessary. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha SY9-24 - Component Replacement...

  • Page 25: Wiring Diagrams

    WIRING DIAGRAMS ILLUSTRATED WIRING DIAGRAM Alpha SY9-24 - Wiring Diagrams...
  • Page 26 FUNCTIONAL FLOW WIRING DIAGRAM Alpha SY9-24 - Wiring Diagrams...

  • Page 27: Fault Finding

    Check that the gas and water pipework has been connected to the correct connections on the boiler and all valves are open. However, before any servicing or replacement of parts ensure the gas and electrical supplies are isolated. 10.2 CENTRAL HEATING - Follow operational sequence Alpha SY9-24 - Fault Finding...
  • Page 28 10.3 FAULT FINDING SOLUTION SECTIONS A to F Alpha SY9-24 - Fault Finding...
  • Page 29 10.4 FAULT FINDING SOLUTION SECTIONS G to J Alpha SY9-24 - Fault Finding...

  • Page 30: Short Parts List

    Fig. 2, item 16 Flame sensing electrode 1.010645 E57-714 Ignition electrode lead 3.013212 E65-195 Flame sensing electrode lead 3.013213 E57-717 Fig. 2, item 21 By-pass assembly 3.013801 E65-222 Combustion chamber insulation panel set 3.013838 E74-960 Alpha SY9-24 - Short Parts List...

  • Page 31: Service History

    DETAILS OF BOILER SERVICE HISTORY Date of Service Details of Service Service Engineer .................................................................................................................................................................................................................................................................................................................................................................... Alpha SY9-24 - Service History...
  • Page 32 Alpha Therm Limited. Nepicar House, London Road, Wrotham Heath, These instructions have been carefully prepared but we reserve the right to Sevenoaks, Kent TN15 7RS alter the specification at any time in the interest of product improvement. Tel: 0870 3001964 ©...

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