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Alpha Boilers HE CB25 Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing boiler
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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
*HEJEID/=I
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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Summary of Contents for Alpha Boilers HE CB25

  • Page 1: Installation And Servicing

    Wrotham Heath, Sevenoaks, Kent TN15 7RS *HEJEID/=I 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...

  • Page 2: Table Of Contents

    They are designed for use with a fully pumped, sealed and pressurised central heating system using only Natural gas. The HE CB25 and HE SY25 boilers are suitable for central heating loads of between 14.5 and 25.0 kW (49 500 and 85 300 Btu/h).

  • 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 13.3 22.0 75 000 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...
  • Page 5 2. Only fit the Alpha recommended single channel clock. Other clocks could cause damage. Clock connections Boiler terminal block - HE CB25/33 only Fig. 1a b. Alpha HE SY25 only Note: This Appliance Must Be Earthed An optional integral two channel Clock kit (Part No. 6.1000220) is available if required.
  • 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...

  • Page 8: General Boiler Information

    GENERAL BOILER INFORMATION GAS SUPPLY The Alpha HE CB25 and HE SY25 boilers require a gas rate of 2.61 m³/h (92.1 ft³/h). The Alpha HE CB33 boiler requires a gas rate of 3.49 m³/h (123.2 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.
  • 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 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 HE CB25/33, SY25 - General Boiler Information...
  • Page 11 Feed cistern to be Stop return Stop supply located above highest valve valve Stop point in the system Test cock valve Test cock Filling loop temporarily connected Fig. 6 Fig. 7 Alpha HE CB25/33, SY25 - General Boiler Information...
  • Page 12 (copper or steel is not suitable). It should be noted that the connection of a condensate pipe to a drain may be subject to local building control requirements. Alpha HE CB25/33, SY25 - General Boiler Information...
  • 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...

  • 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 Lift the boiler and locate it on the mounting bracket. Fit the bottom screws to secure the boiler in position. Fig. 12 CONNECT THE PIPEWORK - Fig. 13a (HE CB25/33) or Fig. 13b (HE SY25) Thoroughly flush out all the water pipework. Refer to Section 3.9.
  • Page 16 Position the seal and clamp (two screws) supplied, over the bend. Fit the bend to the boiler and rotate to the correct position. Secure in position using the seal and clamp, ensuring the seal is located centrally over both the bend and boiler adaptor. Alpha HE CB25/33, SY25 - Installation...
  • Page 17 280 mm and 520 mm 220 mm and 460 mm Within standard Easy-Flue 500 mm (Part No. 6.2000500) telescopic range. Less than:- 280 mm 220 mm Terminal may protrude somewhat from the outside wall. Alpha HE CB25/33, SY25 - Installation...
  • Page 18 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 HE CB25/33, SY25 - Installation...
  • 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).

  • 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 Central heating mode Set the selector switch to (DHW and CH) for the HE CB25/33 or 'ON' for the HE SY25. The burner will light at the ignition rate and will increase to the factory pre-set maximum output after 1 minute.
  • 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...

  • Page 23: Boiler Operation

    Note: If the system pressure is very low, the primary pressure switch will prevent the boiler from operating. HE CB25/33 only - If there is a demand for DHW during the 3 minute burner delay, the boiler will operate to provide DHW until the tap is closed;...

  • 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...

  • 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...

  • Page 28: Dhw Flow Switch

    Fig. 27 Fig. 28 - HE CB25/33 only 8.15 DHW FLOW SWITCH (HE CB25/33 only) - Fig. 28 Gain access behind the casing as described in Section 8.1. Remove the switch from the diverter valve by pulling or prising it upwards from the valve body. Disconnect the inline wiring connector.

  • Page 29: Combustion Chamber Insulation

    8.16 CLOCK (if fitted) - Refer to Fig. 21 Note: When replacing a clock, only use a single channel clock for the HE CB25/33 and a two channel clock for the HE SY25 boiler. Refer to Section 2.9 and 4.9.

  • Page 30: Primary Pressure Switch

    Re-assemble in reverse order with a new sensor and sealing washer. 2a. DHW Sensor (HE CB25/33 only) - Close the mains cold water inlet valve and open the lowest hot water tap to drain the DHW system.

  • Page 31: Dhw Heat Exchanger

    Re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, Section 5.1). 8.26 DHW HEAT EXCHANGER (HE CB25/33 only) - Refer to Fig. 31 Gain access behind the casing and drain the boiler heating and hot water circuits as described in Sections 8.1 and 8.2.

  • Page 32: Expansion Vessel

    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...

  • 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...

  • 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...

  • Page 42: Short Parts List

    Fig. 32 Diverter valve assembly 3.012752 E57-773 Fig. 2, item 27 By-pass assembly 3.012801 E65-498 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.

  • 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

    13 SERVICE RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record below. Service Provider: Before cpmpleting the appropriate Service Interval Record below, please ensure you have carried out the service as described in this instruction manual.

This manual is also suitable for:

He sy25He cb33

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