Alpha E-Tec 25R, Installation And Servicing Instructions

Page 1: ... 7RS For Technical help or for Service call ALPHA HELPLINE Tel 0344 871 8764 website www alpha innovation co uk Set for use with Natural Gas Leave these instructions with the User These instructions have been carefully prepared but we reserve the right to alter the specification at any time in the interest of product improvement Alpha Therm Limited 2018 Part No 1 041526 rev ST 003864 000 1118 D389...

Page 2: ...ort product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Handoverthemanufacturer sinstructions includingtheBenchmarkChecklist tothecustomeronco...

Page 3: ... 2009 Specification for Installation gas fired boilers up to 70 kW BS 6891 2005 A2 2008 Installation of low pressure Gas Pipework IGEM UP 2 Installation of pipework IGEM UP 4 Commissioning of gas fired plant IGE UP 10 Installation of Flued gas appliances IGEM UP 16 Design for natural gas installations IGE UP 1 and 1B Strength Testing and tightness testing Natural Gas Installations Reference should...

Page 4: ...th terminal connection point READ AND UNDERSTAND THE INSTRUCTIONS Read and understand the appliance s instructions before performing any operation carefully following the indications provided RECOVERABLE OR RECYCLABLE MATERIAL INFORMATION Indicates useful tips or additional information SAFETY GLOVES SAFETY GOGGLES SAFETY FOOTWEAR The user must not dispose of the appliance at the end of its service...

Page 5: ... rate at max output m h Gas supply pressure mbar Max CH temperature Set point C Gas burner injector diameter mm Dry NOx weight net calorific value mg kWh Dry NOx ppm NOx Class Factory set CO2 CO2 at maximum CH output CO2 at maximum DHW output CO2 at minimum output CO max ppm Maximum CO CO2 Ratio SAP SEDBUK seasonality efficiency 2005 SAP SEDBUK seasonality efficiency 2009 ErP Seasonal space heatin...

Page 6: ...nal CD 90 Bend is equivalent to 1 3 m of flue length Each CD 45 Bend is equivalent to 0 9 m of flue length The CD Vertical Flue terminal assembly is equivalent to 1 m of flue length 3 3 PHYSICAL DATA Boiler flow and return connections mm Gas connection diameter mm Boiler dimensions Height mm Width mm Depth mm Clearances for servicing Bottom mm Top horizontal flue mm Top vertical flue mm Sides mm F...

Page 7: ...are available if required Note Only use the Alpha two channel controls Do not fit any single channel controls Fig 3 1 shows the Internal two channel clock option for S or Y plan Alternatively bring a Switched Live from external controls to terminal 1 DO Not connect an Alpha Climatic control when the proprogrammer clock is connected 3 5 ELECTRICAL CONNECTIONS Fig 3 1 3 6 DATA BADGE ANNOTATION Md Sr...

Page 8: ...ve 8 Overheat thermostat 9 Ignition sensing electrode 10 Air supply pipe 11 Flue temperature sensor and thermal fuse 12 Flue test point pressure point 13 Air test point pressure point 14 Condensing heat exchanger 15 Burner 16 Primary return sensor 17 Venturi 18 Fan 19 Drain valve Gas Condensate discharge Primary Heating return Primary Heating flow 1 2 3 4 5 6 7 8 9 10 11 12 17 19 16 18 15 14 13 ...

Page 9: ...s be maintained Note A cupboard or compartment used to enclose the boiler must be designed and constructed specifically for the purpose i e comply with the Building Regulations 4 4 FLUE SYSTEM Figs 4 1 4 2 The flue system must be installed in accordance with BS 5440 1 When using a horizontal flue kit ensure that the flue outer duct is installed horizontally please note that the flue inner duct alr...

Page 10: ... Boiler Information L A B 90 bend 1 3 metre L A 2 x 45 bends 1 8 metre Fig 4 2 VERTICAL FLUE OPTIONS Hmax 14 m Hmax 12 2 m 14 m 1 8 m 12 m B A A B A HORIZONTAL FLUE OPTIONS Lmax 12 metres Not less than 300 mm H Not less than 300 mm H Fig 4 1 ...

Page 11: ...e position must allow the free passage of air across it at all times 8 The flue terminal must be positioned where products of combustion will freely disperse and not cause a nuisance 9 Where a terminal is sited below 2 m from the ground or floor level the terminal must be protected by a terminal guard In these situations consideration should also be given to prevent nuisance plume and fumes in are...

Page 12: ...bustible material without the need for a special thermal insulation barrier If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineers Guide for Gas Installations in Timber Frame Housing reference IGE UP 7 The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the c...

Page 13: ...ituated at a maximum height of 27 m above the boiler The cold feed must be 15 mm minimum size The vent should be 22 mm in size rise continuously and be unrestricted It is important that the relative positions of the pump cold feed and open vents are as shown in Fig 4 5 The domestict hot water cylinder must be of the fully indirect coil type Boiler 150mm max 1000mm min height Feed and expansion tan...

Page 14: ...avoid the possible risk of freezing The pipework must be in 22 mm pipe minimum External pipe runs should be avoided but if it is necessary the pipework should be protected from the risk of freezing with waterproof insulation and the length should be kept to a maximum of 3 m and the condensate pipework should be increased to a minimum of 32 mm diameter Termination should be into an external gulley ...

Page 15: ...tely supported Plastic pipe minimum 32 mm Minimum gradient 2 Fig 4 10 External soakaway Ground level either or 22mm termination from boiler increase to 32 mm if external 2 fall O 25mm 300mm Two rows of 3 x 12mm holes at 25mm centres 50mm from the bottom of the tube Holes to face away from house Cement mortar sealing 100mm plastic tube Bottom of tube sealed Soakaway depth 400mm filled with limeston...

Page 16: ...ble Alpha flue system must be selected to use with the boiler Notes a All flues must be suitable for Alpha condensing boilers b CD 750 mm and 1000 mm flue extensions are available if required Damaged products must not be used 2 Unpack boiler and remove the loose items packs and mounting bracket Note The boiler can be stood in an upright position only while the valves and union bends are not fitted...

Page 17: ...m pipework to the union fittings on the top of the boiler see Fig 5 4 Note When soldering bends ensure they are not connected to the valves otherwise the internal seals may be damaged One metre of copper pipe must be fitted to the boiler before connecting to any plastic pipework conforming to BS 7291 4 Connect the flexible condensate pipe to the rubber connector as shown in Fig 5 4 Using the adapt...

Page 18: ...ss 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 the outside black flue sealing collar onto the outer duct of the flue immediately before the terminal grille onto the location provided Push the flue assembly through the 130 mm flue hole so that the collar completely passes through the wall Then pull the fl...

Page 19: ...d the inside wall by pushing the inside flue sealing collar up to the wall The hole around the flue can be made good using the flue sealing collars supplied or using a suitable sealant cement if required Fig 5 8 Fitting the flue from inside Check collar is sealing the wall and it is not restricting any openings of the flue terminal 130 mm Fig 5 9 Rear flue Allow 20 mm 30 mm Do not cut past this po...

Page 20: ...all flue length as described in Section 5 6 paragraph 2 to determine the number of Alpha CD 750 or 1000 mm flue extensions required 4 Assemble the flue extensions together by locating the inner duct into the seal joint and secure each extension together with the extension clamps supplied three screws Ensure that the clamps are positioned centrally over the joints Note If it is required to cut an e...

Page 21: ...ecuring the terminal and remove the terminal by pulling it from the flue assembly Remove the screw 2 in Fig 5 12 securing the terminal end section and remove the end section from the terminal ii Locate a 93 Plume Management bend into the flue assembly and rotate it to the direction required iii Connect to the 93 bend the required Plume Management components as detailed and refer to Fig 5 13 Notes ...

Page 22: ... Flue Ensure there is a slope of approximately 3 back towards the Easy Flue Fig 5 13 Note The equivalent horizontal flue assembly length the equivalent plume management length PM length must not exceed the maximum flue length stated for each boiler i e E Tec boilers the maximum equivalent flue length must not exceed 12 metres Note 1 Ensure each joint is secured with the screw supplied 2 Ensure the...

Page 23: ...ock ensuring it is located correctly on the plastic pins and replace the cover 5 Ensure that there is sufficient free cable to allow the control panel to be raised and lowered then tighten the cable clamp screws 6 Leave the control panel open until commissioning procedures have been completed 7 Carryoutelectricalsystemchecks Shortcircuit Polarity EarthcontinuityandResistancetoearthwithasuitablemul...

Page 24: ...al blocks 1 and 2 5 Replace the control panel cover in reverse order Note Ensure all wires and connections are secured safely before replacing covers External Sensor Weather compensation feature The weather compensation sensor can only be used on an E Tec R boiler when the Alpha Diverter Kit part No 6 5500048 or the DHW relay kit part No 3 029422 are used otherwise the DHW temperature will be affe...

Page 25: ...3 3 With the Alpha Diverter kit fitted the optional weather compensation feature can be used to control the central heating flow temperature weather compensation sensor Part number 3 022383 Automatic by pass valve Boiler 150mm max 1000mm min height Feed and expansion tank Vent 22mm min Cold feed 15mm min Pump DHW storage cylinder Alpha diverter valve with cylinder sensor 450mm min height Heating c...

Page 26: ... screw on the gas valve see Fig 6 2 and purge in accordance with BS 6891 3 Retighten the test point screw and test for gas tightness Close the boiler gas service cock 1 On Off Standby button 2 Summer Winter button 3 Reset button 4 Information button 5 Domestic hot water temperature control knob with Alpha diverter kit or DHW relay fitted 6 Central heating water temperature control knob 7 N A 8 DHW...

Page 27: ...ater cylinder heating the boiler goes to standby function Each time the burner ignites the flame present symbol is displayed together with the relative strength of the flame output power 7 Operation with Climatic control Optional If the Climatic control is connected Apha Diverter Kit required the symbol will appear on the display The boiler regulation parameters can be set via the Climatic control...

Page 28: ...ombustion levels of the boiler when the installation is completed must be measured and recorded The air gas ratio of the boiler has been factory set and should not require adjusting during commissioning If adjustment is recommended or required the engineer must be competent to carry out this work See Fig 6 3 for analyser test point If the boiler requires adjusting or setting to operate on LPG furt...

Page 29: ...n for the thermostat to operate i e the boiler must be set to standby 6 Explain to the User that in certain weather conditions the flue terminal will emit a plume of steam i e water vapour This is safe and quite normal 7 Show the User the position of the condensate discharge pipes 8 Leave the instructions with the User 9 Ensure the Benchmark Checklist at the back of these instructions has been com...

Page 30: ...ensate trap is pre filled If the flow temperatures are getting up to maximum operating temperature during the procedure it is possible to open a hot tap and turn the controls to heating and hot water demand to lose the heat Attention the CO2 checks must be carried out with the case fitted while the gas valve adjustments must be carried out with the front case removed Calibration of the minimum CO2...

Page 31: ...xit the parameter menu Note When setting the parameters on a new PCB set the values starting at the lowest parameter first Alpha E Tec 25R Commissioning DHW control knob CH control knob RESET INFO RESET BOOST bar C x100rpm Button A Button B Button C Button D Fig 6 4 ID Parameter Description Range 0 60 600s 10 sec steps 0 84 840s 10 sec steps 0 60 600s 10 sec steps 0 2 0 1 The boiler has electronic...

Page 32: ...s Ignition phase no of fan revs CH set point min temperature CH set point max temperature External sensor S0 S1 S2 S3 S4 S5 S6 S7 Default NG 14 LPG 13 NG 60 LPG 57 NG 14 LPG 13 NG 53 LPG 49 28 25 80 0 ID Parameter Description Range 0 0 0 1 0 0 0 0 1 0 1 Not used on this model This parameter value is fixed on 0 Not used on this model This parameter value is fixed on 0 The external pump can function...

Page 33: ...e with the analyser manufacturers requirements 3 Competence can be demonstrated by satisfactory completion of the CPA1ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Combustion check Connect the flue gas analyser to the flue gas sampling point as shown in Fig 6 3 Notes 1 Prior to servicing it is recommended that a flue gas...

Page 34: ...ce in the Service Record at the back of these instructions 7 2 PREPARE FOR SERVICING Fig 7 1 and 7 2 1 Ensure the electrical supply is isolated and the gas supply is off 2 Remove the screw at the top centre of the front panel then lift it up and remove the panel Release the two screws securing the control panel and lower the panel 3 Remove the seven screws securing the room sealed chamber panel an...

Page 35: ...changer This is to ensure the condensate trap is full of water before operating the boiler 2 Replace the combustion chamber front assembly ensuring it is correctly located and secure with the four 10 mm nuts previously removed Replace seals if necessary 3 Ensure the injector is in position in the gas valve outlet and re connect the gas pipe securing it in position with the spring clips previously ...

Page 36: ...at thermostat 8 Boiler drain points 9 Gas injector 10 Gas valve 11 Condensate trap 12 Test points air A flue F 13 Flue temperature sensor and thermal fuse 14 Four fixing nuts for item 15 15 Combustion chamber front assembly 16 Primary heat exchanger 17 Venturi 18 Primary return temperature sensor 19 Spark generator A F 1 6 10 11 5 9 3 7 8 12 13 16 17 18 14 15 2 4 19 ...

Page 37: ...gnition lead from the electrode 2 Remove the cap screws securing the electrode to the front of the combustion chamber using a 3 mm allen key and carefully withdraw the electrode 3 Fit the new electrode assembly with a new gasket and re assemble in reverse order 4 Test the boiler check the ignition and test the combustion as described in Section 7 8 4 MAIN BURNER 1 Remove the complete burner fan ai...

Page 38: ...lectrical plug from the gas valve 2 Remove the gas pipe retaining clip and remove the pipe 3 Disconnect the gas valve union beneath the boiler 4 Remove the two screws from beneath the boiler disconnect the gas valve pressure tube and lift out the valve assembly 5 Unscrew the brass union from the top of the gas valve and transfer it to the new gas valve using a new washer 6 Fit the new assembly and...

Page 39: ...bustion as described in Section 6 8 12 PRIMARY TEMPERATURE SENSORS Fig 7 4 Gain access to the boiler as described in Sections 8 1 1 Unplug the wiring and unclip the sensor from the flow or return pipe as required Re assemble in reverse order with a new sensor onto the conductive paste ensuring good contact between the pipe and sensor 8 13 COMBUSTION CHAMBER INSULATION 1 Remove the complete burner ...

Page 40: ... connections E4 B1 B5 B4 Y1 E3 M G3 When an Alpha Climatic control is connected to terminals 41 and 44 remove the links between terminal blocks 1 and 2 Remove link to connect 230 V room thermostat Mains Supply 230 V 50 Hz 230 V Room thermostat optional External pump optional 230 Vac Max 1 A Programmer clock optional Remove link to connect clock Bk Bl Br Gy W Heating CH1 DHW OFF DHW ON CH2 CH ON Co...

Page 41: ...B Resistor R14 on plug X14 Refer to wiring diagram Engineers function activated by pressing the reset button for 8 seconds Refer to fault history codes INFO menu d9 Cylinder sensor wiring connections Cylinder sensor faulty Check fan wiring connections Fan fault PCB fault Check electrode and lead PCB fault Return sensor wire connections Return sensor faulty Check for jammed control panel buttons Ch...

Page 42: ...ing pressure Check flame sensing electrode and lead Check spark generator and lead Check for flue gas recirculation Check adjust the gas valve settings Check adjust the fan speed settings Check gas supply working pressure Check flame sensing electrode and lead Check spark generator and lead Check for flue gas recirculation Check adjust the gas valve settings Check adjust the fan speed settings Che...

Page 43: ...1489 Flue turret assembly 3 029728 Flue sampling point cap 3 026794 Primary heat exchanger 3 027697 Burner 1 040669 Burner gasket 1 025910 Gas valve 1 039944 Fan with gasket 3 029726 Complete heat exchanger seal kit 3 027772 Gas pipe to fan manifold 1 041050 Gas pipe O ring 1 037816 Clip Flow return pipe to heat exchanger 1 026763 Clip Gas pipe connections 1 020393 Boiler wall bracket 2 015350 Boi...

Page 44: ...output and low temperature regime P1 8 0 kW At 30 of rated heat output and low temperature regime η1 97 5 Auxiliary electricity consumption Other items At full load elmax 0 027 kW Standby heat loss Pstby 0 009 kW At part load elmin 0 016 kW Ignition burner power consumption Pign 0 000 kW In standby mode PSB 0 006 kW Emissions of nitrogen oxides NOX 32 mg kWh For combination heaters Declared load p...

Page 45: ...he domestic hot water function AEC Yearly fuel consumption for the domestic hot water function AFC Seasonal room heating yield ηs 92 Domestic hot water production yield ηwh 12 2 PRODUCT DATA SHEET IN COMPLIANCE WITH REGULATION 811 2013 Alpha E Tec 25R Energy Classification A A B C D E F G A A 24 kW 54 dB 2015 811 2013 InTec 25R ...

Page 46: ...oss in the distribution system and the dimensioning of the products in relation to building size and characteristics Seasonal space heating energy efficiency of package Seasonal space heating energy efficiency class of package Solar contribution From fiche of solar device Class I 1 Class II 2 Class III 1 5 Class IV 2 Class V 3 Class VI 4 Class VII 3 5 Class VIII 5 2 3 Seasonal space heating energy...

Page 47: ...ce installed in a building as the efficiency is influenced by further factors such as heat loss in the distribution system and the dimensioning of the products in relation to building size and characteristics Seasonal space heating energy efficiency of package Seasonal space heating energy efficiency class of package Solar contribution From fiche of solar device 2 3 ______ x 0 1 _____ x _______ 0 ...

Page 48: ...34 35 36 36 37 38 40 39 50 55 60 65 75 80 85 100 115 123 131 130 150 160 170 163 188 200 213 M L XL XXL 3 2 3 2 The energy efficiency of the package of products provided for in this fiche may not correspond to its actual energy efficiency once installed in a building as the efficiency is influenced by further factors such as heat loss in the distribution system and the dimensioning of the products...

Page 49: ... III I Auxiliary electricity 3 G F E D C B A A A A 27 27 27 28 27 27 27 28 30 30 30 32 33 34 35 36 36 37 38 40 39 50 55 60 65 75 80 85 100 115 123 131 130 150 160 170 163 188 200 213 M L XL XXL 3 2 3 2 The energy efficiency of the package of products provided for in this fiche may not correspond to its actual energy efficiency once installed in a building as the efficiency is influenced by further...

Page 50: ...ure and record Gas rate m hr OR ft hr Burner operating pressure if applicable mbar OR Gas inlet pressure mbar Central heating fow temperature C Central heating return temperature C COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes and if required by the manufacturer has a water scale reducer been ftted Yes No What type of scale reducer has been ftted DOME...

Page 51: ...egister No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 04 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 05 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Wher...

Page 52: ...doors and windows Contact the National Gas Emergency Service immediately on 0800 111 999 8 ELECTRICAL SUPPLY The boiler requires a 230 240 V 50 Hz supply fused at 3 A To connect a plug The colour of the wires in the mains lead of the boiler may not correspond with the coloured markings identifying the terminals in your plug In this case proceed as follows The wire coloured green and yellow must be...

Page 53: ...iances correctly could lead to prosecution It is in your interest and that of safety to ensure compliance with the law The manufacturer s instructions must not be taken in any way as over riding statutory obligations The Benchmark Checklist must be fully completed by the installer on installation of the boiler The Benchmark Checklist is shown in back of the Installation and Servicing instructions ...

Page 54: ...s on the temperature of the water leaving the boiler to the radiators will be displayed If an external weather compensation sensor is fitted indicated by the symbol item 18 in Fig 1 in the display it will automatically vary the temperature of the water in the radiators and on mild day the radiators will not feel as hot as on a cold day this is normal and not a fault with the boiler or heating circ...

Page 55: ...cted to the boiler terminals features are still active and frost protection enabled Off In this mode there is electrical power to the boiler but the boiler will not function in any condition On In this mode the boiler can be switched between Summer or Winter settings by pressing the button 2 see Fig 1 The boiler can be used by children at least 8 years old as well as by persons with reduced physic...

Page 56: ...ks Kent TN15 7RS For Technical help or for Service call ALPHA HELPLINE Tel 0344 871 8764 website www alpha innovation co uk Set for use with Natural Gas Leave these instructions with the User These instructions have been carefully prepared but we reserve the right to alter the specification at any time in the interest of product improvement Alpha Therm Limited 2018 ...