Table of Contents
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Installation and Servicing
Instructions
Alpha HE CB25/33 and HE SY25
Wall Mounted, Fan Assisted, Room Sealed, Gas Fired,
High Efficiency Condensing Boiler Range
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Service Listed
Alpha HE CB25 G.C. No. 47 532 25
Alpha HE CB33 G.C. No. 47 532 26
Alpha HE SY25 G.C. No. 47 532 07
For use with Natural Gas only
Leave these instructions with the User
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Table of Contents
Related Manuals for Alpha Alpha HE CB25
Summary of Contents for Alpha Alpha HE CB25
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Page 1: Installation And Servicing
Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS Service Listed Alpha HE CB25 G.C. No. 47 532 25 Alpha HE CB33 G.C. No. 47 532 26 Alpha HE SY25 G.C. No. 47 532 07 For use with Natural Gas only... -
Page 2: Table Of Contents
The maximum output available for domestic hot water is 25.0 kW (85 300 Btu/h), capable of providing 9.9 litres/min with a temperature rise of 35°C for the Alpha HE CB25 boiler and for the Alpha HE CB33 boiler - 33.2 kW (113 300 Btu/h), providing 13.2 litres/min with a temperature rise of 35°C. -
Page 3: Technical Data
Return Connection 22 mm HE CB33 0.35 L Relief Valve Connection 15 mm Outlet Water Temp. (Approx. max.) 62°C (144°F) Recommended System Pressure (cold) 1.0 bar CH Water Temp. (Approx. max.) 82°C (180°F) Alpha HE CB25/33, SY25 - Technical Data... - Page 4 16.7 20.0 68 200 22.0 75 000 13.3 15.0 14.5 49 500 20.0 68 200 10.0 13.3 This information is based on 20°C system design temperature difference. Refer to Section 3.7, System Volume. Alpha HE CB25/33, SY25 - Technical Data...
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Page 5: Electrical Connections
Alpha HE CB25/33 only Note: This Appliance Must Be Earthed An optional integral single channel Clock kit is available if required. Note: Only use the Alpha single channel clock. Do not fit any two channel clocks. Brown Blue Used... - Page 6 Overheat thermostat Filling loop Primary heat exchanger Flame sensing electrode Mains inlet on/off valve Room sealed chamber Condensate trap Filter Pressure tube Automatic air vent Flow regulator Pump Gas service cock Fig. 2a Alpha HE CB25/33, SY25 - Technical Data...
- Page 7 Primary heat exchanger Primary temperature sensor Isolating valve Room sealed chamber Overheat thermostat Isolating valve Pressure tube Flame sensing electrode Gas service cock Condensate trap Air pressure switch Automatic air vent Fig. 2b Alpha HE CB25/33, SY25 - Technical Data...
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Page 8: General Boiler Information
3. If the flue is more than 0.5 m, the restrictor must be removed from the boiler flue adaptor (see Fig. 19, 4. Failure to use Alpha CD flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe. - Page 9 L = B + E + F + 230 mm + (90° bend = 1.3 metre) L = B + C + 230 mm + (2 x 45° bends = 1.8 metre) VERTICAL FLUE OPTIONS Fig. 3 Alpha HE CB25/33, SY25 - General Boiler Information...
- Page 10 However, If the terminal is fitted less than 2.1 m above a surface where there is no public access, the terminal must be protected by a terminal guard. A suitable guard is available from Alpha Therm Ltd. BOILER LOCATION The boiler is not suitable for external installation, unless it is installed within a purpose designed weatherproof building.
- Page 11 System volume - The expansion vessel incorporated into the boiler is suitable for a sealed heating system with a maximum water content of 80 litres (18 gal). For guidance on water contents contact Alpha Therm Ltd. for Technical Data Sheet 15.
- Page 12 3.10 DISPOSAL OF CONDENSATE Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha HE boilers, and reference should be made to BS 6798:2000 for the requirements on the disposal of condensate.
- Page 13 Before the mains water supply pipe is connected to the boiler, it should be thoroughly flushed out to avoid the danger of dirt or foreign matter entering the boiler. Alpha HE CB25/33, SY25 - General Boiler Information...
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Page 14: 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. 12, and secure in the clips provided. Alpha HE CB25/33, SY25 - Installation... - Page 15 G - Heating drain point H - Cold water inlet filter I - Condensate discharge pipe 47.5 47.5 " ! " " " ! " ! " ! " ! " Fig. 13a - HE CB25/33 Alpha HE CB25/33, SY25 - Installation...
- Page 16 FIT THE FLUE - Figs. 14, 15 The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only. The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below.
- Page 17 Comments Up to maximum:- 2.83 m 2.77 m Alpha CD 750 mm or 1000 mm flue extension (Part No. 6.2000750 or 6.2000150) is required to extend the range of telescopic flue. Refer to Section 4.7 paragraph 2 for instructions on how to extend the flue.
- Page 18 (use a 127 mm core drill). The size of the hole provides sufficient clearance for the clamps on the flue extension to pass through the hole. Determine the overall flue length as described in Section 4.6, paragraph 2 to determine the number of Alpha CD 750/1000 mm flue extensions required.
- Page 19 Insert the clock into the opening and secure in place with the screws supplied - do not overtighten the screws. 4a. HE CB25/33: IMPORTANT - Only use an Alpha single channel clock. Do not fit a two channel clock to an HE CB25/33 i).
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Page 20: Commissioning
Ensure that the condensate trap has been filled with water. Refer to Section 4.5, paragraph 4. BOILER CONTROLS - Fig. 22a or Fig. 22b Fig. 22a - Alpha HE CB25/33 Fig. 22b - Alpha HE SY25 Alpha HE CB25/33, SY25 - Commissioning... - Page 21 Turn off the boiler. Thoroughly flush out the water pipework (refer to Section 3.9). HE CB25/33 only - Clean the mains water inlet filter (see Fig. 13). Re-pressurise the system as described in Section 5.1. Alpha HE CB25/33, SY25 - Commissioning...
- Page 22 11. Ensure the Benchmark Checklist in Section 12, page 43, has been completed after the boiler has been installed and commissioned. 12. Leave these Installation and Servicing instructions with the User for use on future calls Alpha HE CB25/33, SY25 - Commissioning...
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Page 23: 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 HE CB25/33, SY25 - Boiler Operation... -
Page 24: Routine Servicing
Condensing heat exchanger Fan assembly Primary temperature sensor Air pressure Overheat switch thermostat Combustion Room sealed chamber front panel (four Combustion cover fixing screws) chamber front cover (five fixing screws) Viewing window Fig. 24 Alpha HE CB25/33, SY25 - Routine Servicing... - Page 25 Place the front case panel in position as shown in Fig. 24 and secure in position. Raise the control panel and secure in position with the two screws provided. Check the operation of the boiler. (Refer to Boiler Operation, Section 6). Return all controls to their original settings. Alpha HE CB25/33, SY25 - Routine Servicing...
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Page 26: Component Replacement
Re-assemble Replace the burner, ensuring it is located correctly. Replace the combustion chamber front cover, ensuring it is correctly located. Complete re-assembly as described in Routine Servicing, Section 7.4 paragraphs 4 to 9. Alpha HE CB25/33, SY25 - Component Replacement... - Page 27 Disconnect the inline connector from the thermostat. Using a 17 mm spanner unscrew the thermostat from the rear of the heat exchanger and disconnect the wiring from the thermostat. Fit a new limit thermostat and re-assemble in reverse order. Alpha HE CB25/33, SY25 - Component Replacement...
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Page 28: Dhw Flow Switch
Remove the switch from the diverter valve by pulling or prising it upwards from the valve body. Disconnect the inline wiring connector. Re-assemble in reverse order with a new switch. Ensure that the switch is located correctly. Alpha HE CB25/33, SY25 - Component Replacement... - Page 29 Depress the two lugs on the pressure gauge and push it out of the control panel. Fit the new gauge using a new washer on the manifold connection if necessary. Refill and pressurise the system. (Refer to Commissioning, Section 5.1). Fig. 29 Alpha HE CB25/33, SY25 - Component Replacement...
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Page 30: Primary 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 HE CB25/33, SY25 - Component Replacement... -
Page 31: Dhw Heat Exchanger
Unscrew (not necessary to remove) the two screws securing the DHW flow valve to the diverter valve and withdraw the valve. When re-assembling, push the new valve into position, holding it in, while tightening the fixing screws. Re-assemble in reverse order. Alpha HE CB25/33, SY25 - Component Replacement... - Page 32 Remove the clip from the tube at the top of the trap. Disconnect the outlet drain connection. Lift the trap out and re-assemble with a new condensate trap. Note: Before fitting the new trap, pour 100 cc of water into the trap. Alpha HE CB25/33, SY25 - Component Replacement...
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Page 33: Wiring Diagrams
WIRING DIAGRAMS HE CB25/33 ILLUSTRATED WIRING DIAGRAM Alpha HE CB25/33, SY25 - Wiring Diagrams... - Page 34 HE SY25 ILLUSTRATED WIRING DIAGRAM Alpha HE CB25/33, SY25 - Wiring Diagrams...
- Page 35 HE CB25/33 FUNCTIONAL FLOW WIRING DIAGRAM Alpha HE CB25/33, SY25 - Wiring Diagrams...
- Page 36 HE SY25 FUNCTIONAL FLOW WIRING DIAGRAM Alpha HE CB25/33, SY25 - Wiring Diagrams...
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Page 37: 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 HE CB25/33, SY25 - Fault Finding... - Page 38 10.3 DOMESTIC HOT WATER (HE CB25/33 only) - Follow operational sequence Alpha HE CB25/33, SY25 - Fault Finding...
- Page 39 10.4 FAULT FINDING SOLUTIONS A to F Alpha HE CB25/33, SY25 - Fault Finding...
- Page 40 10.5 FAULT FINDING SOLUTION SECTIONS G to J Alpha HE CB25/33, SY25 - Fault Finding...
- Page 41 10.6 FAULT FINDING SOLUTION SECTIONS K to L Alpha HE CB25/33, SY25 - Fault Finding...
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Page 42: Short Parts List
Combustion chamber insulation panel set - HE CB25, SY25 3.016448 H28-387 Combustion chamber insulation panel set - HE CB33 3.016449 H28-388 Condensing heat exchanger 3.015063 H28-389 Fig. 13 Condensate trap 1.021805 H28-390 Alpha HE CB25/33, SY25 - Short Parts List... -
Page 43: Benchmark Checklist
The operation of the appliance and system controls have been demonstrated to the customer The manufacturer's literature has been left with the customer COMMISSIONING ENG'S NAME: Print ..............CORGI ID No........... Sign ..............Date ..............Alpha HE CB25/33, SY25 - Benchmark Checklist... -
Page 44: Service Record
These instructions have been carefully prepared but we reserve the right to Nepicar House, London Road, Wrotham Heath, alter the specification at any time in the interest of product improvement. Sevenoaks, Kent TN15 7RS © Alpha Therm Limited 2005. Tel: 0870 3001964 email: info@alphatherm.co.uk website: www.alpha-boilers.com Part No.