Alpha Boilers Alpha 500E Installation And Servicing Instructions Download Page 1

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Installation and Servicing

Instructions

For use with Natural Gas only

Leave these instructions with the User

Alpha 500E

Wall Mounted, Fan Assisted, Room Sealed, Gas Fired

Combination Boiler with Unvented Hot Water Storage

Alpha 500E

G.C. No. 47 532 07

*HEJEID/=I

Service Listed

0051

Goldsel Road,

Swanley, Kent BR8 8EX

Fax: (01322) 615017

For Technical help or for Service call ...

ALPHA HELPLINE

Tel: (01322) 669443

Building Regulations

Certificate No. ETC 00795

Summary of Contents for Alpha 500E

Page 1: ...ll Mounted Fan Assisted Room Sealed Gas Fired Combination Boiler with Unvented Hot Water Storage Alpha 500E G C No 47 532 07 HEJEID I Service Listed 0051 Goldsel Road Swanley Kent BR8 8EX Fax 01322 61...

Page 2: ...with the following recommendations Gas Safety Installation and Use Regulations 1984 as amended All relevant Building Regulations issued by the Department of the Environment Building Standards Scotlan...

Page 3: ...ansion Vessel Size pre charge press Flow Connection Return Connection Relief Valve Connection Recommended System Pressure cold 2 5 bar 0 5 bar 82 C 3 bar 44 PSI 7 5 L at 0 8 bar 22 mm 22 mm 15 mm 1 0...

Page 4: ...00 60 000 50 000 40 000 35 495 metres 1 0 2 2 3 6 4 2 4 8 5 0 feet 3 28 7 22 11 8 13 7 15 7 16 4 Output Available pump head metres 2 1 3 4 4 2 4 6 5 1 5 3 feet 6 9 11 1 13 7 15 1 16 7 17 3 metres 3 5...

Page 5: ...ressure Relief Valve 14 Auto Air Vent 15 Main Burner 16 Main Heat Exchanger 17 Fan 18 Air pressure Switch 19 Unvented Kit 20 C H Expansion Vessel 21 Storage Cylinder 22 Temperature Pressure Relief Val...

Page 6: ...w at least 75 mm clearance between the front of the boiler and the door for air movement 3 4 FLUE SYSTEM Fig 3 The flue system must be installed in accordance with BS 5440 1 The flue assembly supplied...

Page 7: ...H side flue X 380 for R H side flue X 130 VERTICAL FLUE OPTIONS Hmax 4 metres L B E F X mm 90 bend 1 metre L B C X mm 2 x 45 bends 1 metre L B C E X mm L B C X mm Front Front RHS LHS C B E C B E B F B...

Page 8: ...erence DM2 Theboilermaybeinstalledinanyroomorinternalspace althoughparticularattentionisdrawntotherequirementsofthecurrentIEEWiring Regulations and in Scotland the electrical provisions of the Buildin...

Page 9: ...he system design pressure cold should be set to 1 0 bar This pressure is equivalent to the maximum static head see Fig 5 of 10 2 metres of water Provision should be made to replace water lost from the...

Page 10: ...ENTED HOT WATER STORAGE SYSTEM To comply with the Building Regulations for unvented hot water storage it is required that the components detailed in Fig 8 are fitted before the mains cold water inlet...

Page 11: ...discharges from safety devices may not be apparent i e in dwellings occupied by blind infirm or disabled people consideration should be given to the installation of an electronically operated device t...

Page 12: ...ing into account the clearances required for servicing and the flue terminal position 2 Tape the template to the wall ensure it is level and the right way up and mark the position of the holes for the...

Page 13: ...3 9 4 6 CONNECT THE PIPEWORK Fig 13 1 Thoroughly flush out all the water pipework Ensure that all the plastic caps are removed from the boiler connections 2 Secure all the valves fittings to the boile...

Page 14: ...into the outer duct 9 Pass the flue assembly through the wall from inside or outside Note Internal fitting If there is no access to make good the outside wall locate and secure the flue sealing colla...

Page 15: ...de wall to the side of the boiler a mm Inner flue duct length finished wall thickness the distance from the inside wall to the side of the boiler b mm Note L H side a 300 b 377 R H side a 50 b 127 5 W...

Page 16: ...f an external control i e room thermostat or external clock is to be fitted remove the terminal block cover and remove the link between terminals 1 and 2 Pass the cable through the cable clamp through...

Page 17: ...ssary Disconnect the filling loop from the mains supply Water may be released from the system by manually venting a radiator until the system design pressure is obtained The system design pressure col...

Page 18: ...H thermostat to maximum 2 The burner will light at the factory pre set maximum output 3 Set the selector switch to 0 to turn off the boiler Disconnect the pressure gauge and tighten the test point scr...

Page 19: ...here is a call for central heating the diverter valve is operated the pump will start to circulate the primary heating water operating the flow switch The fan will run at full speed once the air press...

Page 20: ...tually happening 6 Refill vent and re pressurise the system as necessary Refer to Commissioning section 5 1 7 If the boiler is in a cupboard or compartment ensure that the ventilation openings are ade...

Page 21: ...HE BOILER 1 Replace the burner ensuring it is located correctly onto the side panels and that the leads to the flame sensing and ignition electrodes are connected Connect the main burner s union nut a...

Page 22: ...lightly and remove Remove the two fixing screws one each side securing the control panel and hinge it forward 1 Heating circuit refer to Fig 13 Close the central heating flow and return valves and dra...

Page 23: ...e to terminal 1 and brown to terminal 2 Ensure the pressure tubes are connected correctly red tube to clear tube to marked on the fan outlet as shown in Fig 23 and that the bottom of the combustion ch...

Page 24: ...indow frame and remove the damaged glass and gasket 3 Re assemble in reverse order with a new glass and gasket Ensure the gasket is next to the inner case front panel 8 13 INTERNAL FUSE Refer to Fig 1...

Page 25: ...Fig 28 1 Gain access as described in section 8 1 2 Withdraw the suppressor from the control panel cover 3 Disconnect the wiring and re assemble with a new suppressor Connect the wiring as follows Main...

Page 26: ...nsure the pressure tubes are connected correctly refer to Fig 23 6 Refill and pressurise the system Refer to Commissioning section 5 1 8 24 PRESSURE GAUGE 1 Gain access as described in section 8 1 2 D...

Page 27: ...w seals supplied 7 Refill and pressurise the system Refer to Commissioning section 5 1 8 29 HEATING RETURN FILTER Refer to Fig 13 1 Drain the boiler heating circuit as described in section 8 2 2 Unscr...

Page 28: ...ckplate Pull the cylinder forward and out of the boiler 10 Re assemble in reverse order using the new seals supplied 11 Refill and pressurise the heating and hot water circuits Refer to Commissioning...

Page 29: ...agrams NOTES 1 REMOVE LINK FROM TERMINALS 1 2 TO CONNECT EXTERNAL CONTROL 240V SWITCHING 2 A FROST THERMOSTAT IS INCORPORATED WITHIN MAIN PCB 3 LINK BETWEEN TERMINALS 55 56 MUST BE CONNECTED Br Brown...

Page 30: ...0 9 2 FUNCTIONAL FLOW WIRING DIAGRAM Alpha 500E Wiring Diagrams NOTES 1 DENOTES MAIN TERMINAL BLOCK 2 A FROST THERMOSTAT IS INCORPORATED WITHIN MAIN PCB 3 LINK BETWEEN TERMINALS 55 56 MUST BE CONNECTE...

Page 31: ...alling for heat Has DHW demand been satisfied 240 V across main terminal block terminals 1 and N YES Replace relay PCB Relay energised and contacts closed i e continuity between terminals 14 15 on PCB...

Page 32: ...illuminated Air pressure switch proved neon stays off neon illuminated YES NO Go to section page 33 E Burner output modulates after approx 3 mins from max until storage temp set by DHW stat is reache...

Page 33: ...CB Main PCB M7 connector is 240 V across terminals 4 5 Fan jammed or faulty winding i e cold resistance 45 ohm YES Replace fan Press red reset button 240V at gas valve and across ignition PCB M2 conne...

Page 34: ...ng electrode and lead connections 2 Electrode position Flame current should be Maximum burner pressure 3 5 mA approx Minimum burner pressure 1 5 mA approx I Replace ignition PCB Replace flame sensing...

Page 35: ...Grundfos UPS 15 60 AO and seals Pump head replacement UPS 15 60 and seals Fan assembly SEL type RL108 4200 A55 Air pressure switch Honeywell C6065F1100 Differential water flow switch and seals Diverte...

Page 36: ...STORY Manual compiled and designed by Publications 2000 Tel 01670 356211 Alpha Therm Limited Goldsel Road Swanley Kent BR8 8EX Tel 01322 669443 Fax 01322 615017 Part No 920 308 1 These instructions ha...

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