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Alpha Boilers Alpha 500E Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired combination boiler with unvented hot water storage
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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
Service Listed
Alpha 500E
G.C. No. 47 532 07
Building Regulations
0051
Certificate No. ETC 00795
For use with Natural Gas only
Leave these instructions with the User

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  • Page 1: Installation And Servicing

    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...

  • Page 2: Table Of Contents

    12 Service history ........36 INTRODUCTION The Alpha 500E boiler is a wall mounted, fan assisted room-sealed combination boiler, incorporating a 54 litre unvented hot water storage cylinder. Heat output is controlled by a modulating gas valve, with fully automatic direct burner ignition.

  • Page 3: Technical Data

    450 mm Power Consumption 190 W Gas Connection 22 mm Internal Fuse F2 A Primary Water Content 3.2 L Electrode Spark Gap 2.0 to 3.5 mm Air Duct Diameter 100 mm Flue Duct Diameter 60 mm Alpha 500E - Technical Data...
  • Page 4 Blue Used Wire Wire Wire Wire Internal Clock Terminals WARNING 1. Ensure wires are connected correctly 2. Only fit the Alpha recommended clock. Other clocks could cause damage. Clock connections Boiler terminal block Fig. 1 Alpha 500E - Technical Data...

  • Page 5: Boiler Schematic

    14. Auto Air Vent 32. Negative Pressure point 15. Main Burner 33. Flue Adaptor 16. Main Heat Exchanger 34. Flue Sample Point 17. Fan 35. Room Sealed Chamber 18. Air pressure Switch 36. Expansion Relief Valve Fig. 2 Alpha 500E - Technical Data...

  • Page 6: General Boiler Information

    3. Under no circumstances must the flue length (including allowances for extra bends) exceed the maximum recommended length. 4. Failure to use Alpha flue components with the boiler will invalidate the boilers CE approval, warranty and may be unsafe. Alpha 500E - General Boiler Information...
  • Page 7 L = B + C + X mm + (2 x 45° bends = 1 metre) VERTICAL FLUE OPTIONS = 4 metres Not less than Not less than 300 mm 300 mm Not less than Not less than 450 mm 450 mm Fig. 3 Alpha 500E - General Boiler Information...
  • Page 8 The boiler may be installed in a cupboard or compartment, provided it is correctly designed and sufficiently ventilated for that purpose and that the requirements of BS 6798 and BS 5440:2 are complied with. Alpha 500E - General Boiler Information...
  • Page 9 Heating circuit water return Feed cistern to be return supply Stop located above highest Stop valve point in the system valve Test cock Test cock Filling loop temporarily connected Fig. 6 Fig. 7 Alpha 500E - General Boiler Information...
  • Page 10 (i.e. no elbows or bends) or bend 22 mm up to 9 m 0.8 m G½ 15 mm 28 mm up to 18 m 1.0 m 35 mm up to 27 m 1.4 m Alpha 500E - General Boiler Information...
  • Page 11 Asphalt, roofing felt and non-metallic rainwater goods may be damaged by such discharges. TERMINATION INTO A HOPPER Tundish 300 mm minimum Type 'A' air gap End of pipe to be clearly visible Fig. 9 Alpha 500E - General Boiler Information...

  • Page 12: Installation

    Cut the 110 mm diameter hole in the wall for the flue. Bottom Drill the fixing holes (8 mm dia.) to accept the plugs fixing holes supplied. Using the washers supplied with the screws, Template Boiler fit the mounting bracket. outline Fig. 11 Alpha 500E - Installation...
  • Page 13 This pipework must be installed as recommended in Unvented Hot Water Storage System, section 3.10. 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. Alpha 500E - Installation...
  • Page 14 14. Make good the inside and outside walls. The flue sealing collar could be used for making good either the outside or inside by locating it over the outer duct of the flue and pushing it tight against the wall. If fitting the collar externally, ensure it does not restrict any of the openings of the flue terminal. Alpha 500E - Installation...
  • Page 15 Ensure that all cuts are square and burr free. Fit the flue terminal to the outer duct by inserting it into the end with two holes. Align the holes and secure with the two screws provided. Alpha 500E - Installation...
  • Page 16 Black wires to terminals 3 and 4, Brown to terminal 2 and Blue to terminal 1, (or as per the instructions supplied with the clock). Ensure wiring is correct. Leave the control panel open until commissioning procedures have been completed. Clock Control panel Terminal without clock fitted Fig. 17 Alpha 500E - Installation...

  • Page 17: Commissioning

    Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 19). Ensure the gas supply is on and open the boiler service cock to purge in accordance with BS 6891. Retighten the test point screw and test for gas soundness. Close the boiler gas service cock. Alpha 500E - Commissioning...
  • Page 18 (Refer to Component Replacement, section 8.2). It is recommended that a label is attached to the boiler drawing attention to the fact that the system has been drained. Complete the details of the installation on the back page of this manual. Alpha 500E - Commissioning...

  • Page 19: Boiler Operation

    30°C. PUMP If the electrical supply neon is illuminated and the boiler has not operated for 24 hours for heating or hot water, the pump will operate automatically for five minutes every 24 hours. Alpha 500E - Commissioning/Boiler Operation...

  • Page 20: Routine Servicing

    Disconnect the main burner's union and withdraw the burner out of the boiler. During removal of the burner, disconnect the flame sensing electrode lead and take care not to damage the side insulation panels. Alpha 500E - Boiler Operation/Routine Servicing...
  • Page 21 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. Check the operation of the boiler. (Refer to Boiler Operation, section 6). Return all controls to their original settings. Alpha 500E - Routine Servicing...

  • Page 22: Component Replacement

    Disconnect the lead from the ignition PCB, noting its position (see Fig. 27). Fit the new lead ensuring it passes through the grommets in the control panel cover and base of the combustion chamber. Re-assemble in reverse order. Alpha 500E - Component Replacement...
  • Page 23 Disconnect the wiring from the thermostat. thermostat Remove the two fixing screws and remove the thermostat from the primary flow pipe. Primary Fit the new thermostat and re-assemble in reverse order. flow pipe Fig. 25 Alpha 500E - Component Replacement...
  • Page 24 Re-assemble in reverse order. 8.16 RELAY PCB - Fig. 27 Gain access as described in section 8.1. Disconnect the wiring connector from the PCB. Remove the fixing screw and remove the board. Re-assemble in reverse order. Alpha 500E - Component Replacement...
  • Page 25 Blue to terminal 1, Brown to terminal 2 and Black wires to terminals 3 and 4, (or as per the instructions supplied with the clock). Re-assemble in reverse order. Refer to the User's instructions and the boiler's control cover to set the clock. Alpha 500E - Component Replacement...
  • Page 26 Connect the wiring to the new head as follows:- Brown to L, Blue to N, Green/yellow to Ensure the pump is set to maximum (3) and re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha 500E - Component Replacement...
  • Page 27 Remove the nut and washers securing the vessel to the hot water storage cylinder and lift the vessel out of the boiler. Re-assemble in reverse order using the new seal supplied. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha 500E - Component Replacement...
  • Page 28 Close the mains water supply valve and ensure that all hot water taps are closed. Release the pressure from the hot water circuit. Unscrew the cartridge from the valve body. Clean or replace the cartridge and re-assemble in reverse order. Refill and pressurise the hot water circuit by opening the mains water supply valve. Alpha 500E - Component Replacement...

  • Page 29: Wiring Diagrams

    G/Y - Green/Yellow EXTERNAL CONTROL (240V SWITCHING) - Blue - White 2) A FROST THERMOSTAT IS INCORPORATED - Red Gy - Grey WITHIN MAIN PCB - Yellow 3) LINK BETWEEN TERMINALS 55 & 56 MUST BE CONNECTED Alpha 500E - Wiring Diagrams...
  • Page 30 FUNCTIONAL FLOW WIRING DIAGRAM NOTES: DENOTES MAIN TERMINAL BLOCK 2) A FROST THERMOSTAT IS INCORPORATED WITHIN MAIN PCB 3) LINK BETWEEN TERMINALS 55 & 56 MUST BE CONNECTED Alpha 500E - Wiring Diagrams...

  • Page 31: Fault Finding

    ', page 34 alight after 10 seconds Burner output modulates until Go to section ' ', page 34 set temperature is reached Pump continues to run for Fan stops Burner goes out 3 minutes Operation sequence successful Alpha 500E - Fault Finding...
  • Page 32 DHW stat. is reached the DHW thermostat neon illuminates neon off DHW tap is opened Pump continues to run Burner goes out Fan stops for 3 minutes Operation sequence successful Alpha 500E - Fault Finding...
  • Page 33 PCB - M2 connector, Replace gas valve terminals I, H Red reset button Press red reset button illuminated 240V at ignition PCB across Replace reset switch M1 connector, terminal D and M2 connector, terminal F Replace ignition PCB Alpha 500E - Fault Finding...
  • Page 34 54 connector, terminal 30 connector, terminal 30 Check external controls Continuity across Wiring between clock are calling for heat clock terminals 3 and 4 and PCB is correct Internal clock calling Replace clock for heat Alpha 500E - Fault Finding...

  • Page 35: Short Parts List

    Insulation panel set (combustion chamber) 5635480 343 757 Fig. 29 Automatic air vent and seals 5625830A 343 578 Fig. 27 Relay PCB 5631550 343 718 Fig. 2, item 4 Pressure gauge 8922220 385 839 Alpha 500E - Short Parts List...

  • Page 36: Service History

    12 SERVICE HISTORY DETAILS OF BOILER INSTALLATION Date of Installation: ..............Name of Installer: ................. Address: ..............................................................................Postcode: ..................Telephone No: ................Boiler Serial Number: ..............(see data label on inside of left hand case panel) DETAILS OF BOILER SERVICE HISTORY Date of Service Details of Service Service Engineer...

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