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Alpha HE25 Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing boiler range
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Installation and Servicing

Alpha HE25 and HE33
Wall Mounted, Fan Assisted, Room Sealed, Gas Fired,
High Efficiency Condensing Boiler Range
Leave these instructions with the User
Instructions
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
British Gas
Service Listed
Alpha HE25
Alpha HE33
For use with Natural Gas only
G.C. No. 47 532 41
G.C. No. 47 532 43

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Summary of Contents for Alpha Alpha HE25

  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha HE25 and HE33 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,...

  • 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 HE25 boiler and for the Alpha HE33 boiler - 33.2 kW (113 300 Btu/h), providing 13.2 litres/min with a temperature rise of 35°C.

  • Page 3: Technical Data

    16.7 20.0 68 200 13.3 22.0 75 000 15.0 14.5 49 500 10.0 20.0 68 200 13.3 This information is based on 20°C system design temperature difference. Refer to Section 3.7, System Volume. Alpha HE25 and HE33 - Technical Data...
  • Page 4 The CD Vertical Flue terminal assembly is equivalent to 1 m of flue length. ELECTRICAL CONNECTIONS 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 5 Main burner Drain point Automatic by-pass Condensing heat exchanger Pressure relief valve Condensate trap Room sealed chamber Primary pressure switch Flue limit thermostat Air pressure switch Ignition electrodes Main heat exchanger Fig. 2 Alpha HE25 and HE33 - Technical Data...

  • Page 6: 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 7 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 HE25 and HE33 - General Boiler Information...
  • Page 8 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 9 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 10 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 11 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 HE25 and HE33 - General Boiler Information...

  • Page 12: 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 HE25 and HE33 - Installation...
  • Page 13 D - Cold water mains inlet (15 mm) E - Heating return (22 mm) F - Pressure relief valve (15 mm) G - Heating drain point Condensate trap H - Cold water inlet filter I - Condensate discharge pipe Fig. 13 Alpha HE25 and HE33 - Installation...
  • Page 14 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 15 (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 16 The main terminal block can be removed by pulling it off the pins to give easy access to the terminals. Do not switch on the electrical supply at this stage. Alpha HE25 and HE33 - Installation...
  • Page 17 Insert the clock into the opening and secure in place with the screws supplied - do not overtighten the screws. IMPORTANT - Only use an Alpha single channel clock. Do not fit a two channel clock to an HE25 or HE33 i).

  • Page 18: Commissioning

    Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 23). 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 HE25 and HE33 - Commissioning...
  • Page 19 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 page 39 of this manual and the Benchmark log book. Alpha HE25 and HE33 - Commissioning...
  • Page 20 11. Ensure the Benchmark Checklist in Section 12, page 39, 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 HE25 and HE33 - Commissioning...
  • Page 21 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 HE25 and HE33 - Boiler Operation...

  • Page 22: Routine Servicing

    Condensing heat exchanger Fan assembly Primary temperature sensor Air pressure Overheat switch thermostat Room sealed panel (six Combustion fixing screws) chamber front cover (four fixing screws) Viewing window Fig. 24 Alpha HE25 and HE33 - Routine Servicing...

  • Page 23: Boiler Operation

    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 HE25 and HE33 - Routine Servicing...

  • Page 24: 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 HE25 and HE33 - Component Replacement...
  • Page 25 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 HE25 and HE33 - Component Replacement...

  • Page 26: Diverter Valve Motor

    Remove the diverter valve motor head by unplugging its electrical connection and removing the retaining clip from the back of the motor. Withdraw the motor forwards from the valve body. Re-assemble in reverse order with a new motor. Alpha HE25 and HE33 - Component Replacement...

  • Page 27: Primary Temperature Sensor

    Remove the two screws securing the left hand side panel. Slide out the side panel, then prise out the top of the rear insulation panel and lift it up and out of the boiler. Fit new panels and re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, Section 5.1). Alpha HE25 and HE33 - Component Replacement...
  • Page 28 Connect the plug to the new head. 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 HE25 and HE33 - Component Replacement...

  • Page 29: Dhw Heat Exchanger

    10. Lift the assembly up slightly and pull the diverter valve to the right and off the automatic by-pass. 11. Re-assemble in reverse order using new seals and washers. 12. Refill and pressurise the system. (Refer to Commissioning, Section 5.1). Alpha HE25 and HE33 - Component Replacement...
  • Page 30 Remove the screw securing the trap to the bottom of the boiler casing and lift out the trap. Fit the new trap in reverse order. Note: Fill the new trap with water once installed. Alpha HE25 and HE33 - Component Replacement...

  • Page 31: Wiring Diagrams

    REMOVE LINK FROM TERMINALS 1 & 2 Or - Orange AND CONNECT 230/240 V SWITCHED LIVE TO - Purple TERMINAL1. - Green G/Y - Green/Yellow A FROST THERMOSTAT IS INCORPORATED - White WITHIN THE MAIN PCB Gy - Grey Alpha HE25 and HE33 - Wiring Diagrams...
  • Page 32 Gas Valve Modulating Coil DHW Temperature Sensor Primary Temperature Sensor Note: Main Terminal Block TO CONNECT EXTERNAL CONTROL REMOVE LINK FROM TERMINALS 1 AND 2 AND CONNECT 230/240 V SWITCHED LIVE TO TERMINAL 1. Alpha HE25 and HE33 - Wiring Diagrams...

  • Page 33: Fault Finding

    Check gas valve adjustment Go to section ' ', page 35 set temperature is reached Pump continues to run for Burner goes out Fan stops after 30 seconds 3 minutes Operation sequence successful Alpha HE25 and HE33 - Fault Finding...
  • Page 34 Close DHW tap Go to section ' ', page 35 adjustment DHW flow switch DHW switch fault senses no flow Burner goes out Pump stops Fan stops after 30 seconds Operation sequence successful Alpha HE25 and HE33 - Fault Finding...
  • Page 35 Max. burner press. approx. 9 V DC, Min. burner press. approx. 2 V DC modulates Replace PCB Zero V DC across terminals 20 and 21 Modulating coil faulty 24 V DC across cold resistance Replace gas valve terminals 20 and 21 approx. 45 ohm Alpha HE25 and HE33 - Fault Finding...

  • Page 36: Condensing Heat Exchanger

    24 V DC at PCB across Continuity across primary Check switch and switch M4 connector terminal 13 pressure switch terminals connection for blockages and M6 connector terminal 20 Replace PCB Replace primary pressure switch Alpha HE25 and HE33 - Fault Finding...
  • Page 37 M16 diverter valve connector Check all electrical Terminals Replace diverter valve PCB connections are correct DHW demand 0 Volts 230 Volts 230 Volts CH demand 230 Volts 230 Volts 0 Volts Replace diverter valve motor Alpha HE25 and HE33 - Fault Finding...

  • Page 38: Short Parts List

    H50-474 Combustion chamber insulation panel set - HE25 3.016448 H28-387 H28-388 Combustion chamber insulation panel set - HE33 3.016449 Fig. 24 Condensing heat exchanger H28-389 3.015063 Fig. 13 Condensate trap 3.017281 H50-476 Alpha HE25 and HE33 - Short Parts List...

  • Page 39: 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 HE25 and HE33 - Benchmark Checklist...

  • Page 40: 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 2007. Tel: 0870 3001964 email: info@alphatherm.co.uk Part No. 1.026216 website: www.alpha-boilers.com...

This manual is also suitable for:

He33

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