Alpha Boilers SY9-24 User guide

Installation and Servicing

Instructions

Alpha SY9-24

Wall Mounted, Fan Assisted, Room Sealed, Gas Fired

System Boiler

Alpha SY9-24 G.C. No. 41 532 01

Service Listed

For use with Natural Gas only

Leave these instructions with the User

Nepicar House, London Road,

Wrotham Heath, Sevenoaks,

Kent TN15 7RS

For Technical help or for Service call ...

ALPHA HELPLINE

Tel: 0870 3001 964

2Alpha SY9-24 - Contents/Introduction

CONTENTS

1 Introduction ....................................... 2

2 Technical data................................... 3

3 Generalboilerinformation.................. 6

4 Installation......................................... 10

5 Commissioning ................................. 15

6 Boileroperation ................................. 17

7 Routine servicing............................... 18

8 Componentreplacement ................... 19

9 Wiringdiagrams ................................ 25

10 Faultfinding ...................................... 27

11 Short parts list ................................... 30

12 Service history .................................. 31

The Alpha SY9-24 boiler is a wall mounted, fan assisted room-sealed system boiler. The burner is lit electronically and the

heat output is controlled by a modulating gas valve.

The boiler, provides central heating, and is designed for use with a fully pumped, sealed and pressurised heating system using

only Natural Gas.

The boiler is supplied with a pump, pressure relief valve, expansion vessel and pressure gauge fully assembled and tested.

As supplied, the Alpha SY9-24 boiler will automatically modulate to provide central heating outputs between 9.3 and 23.3 kW

(31 700 and 79 500 Btu/h).

IMPORTANT

It is the law that all gas appliances are installed by a competent person, ie CORGI registered personnel, in accordance with

the following recommendations:-

Current Gas Safety (Installation and Use) Regulations

All current Building Regulations issued by the Department of the Environment i.e. Approved Document L1

Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department

Health & Safety Document No. 635 (The Electricity At Work Regulations 1989)

The installation should also be in accordance with the following British Standard Codes of Practice:-

BS 5440:1:2000 Flues

BS 5449:1990 Forced circulation hot water systems

BS 6798:2000 Installation of gas fired hot water boilers

BS 6891:1989 Gas installation

BS 7593:1992 Code of Practice for treatment of water in heating systems

BS 7671:2001 Requirements for electrical installations, IEE Wiring Regulations

If installation is in a timber framed building, refer to the Institute of Gas Engineers document IGE/UP/7.

This appliance meets the requirements of IPX4D, ie degree of protection against moisture.

Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety to ensure that the

law is complied with.

Manufacturer's instructions must NOT be taken in anyway as over-riding statutory obligations.

Note: Ensure that the Benchmark Log Book has been completed after the boiler has been installed and commissioned.

1 INTRODUCTION

2.1 PERFORMANCE - NATURAL GAS

2 TECHNICAL DATA

Alpha SY9-24 - Technical Data

Min. Clearances for Servicing Top

(from casing) Bottom

Sides

Front

Flue Terminal Size

Flue Terminal Protruding

Hole Size Required For Flue Assy.

Lift Weight

2.4 INSTALLATION

220 mm

250 mm

5 mm

450 mm

100 mm Dia.

145 mm

110 mm Dia.

38 kg

MAX.

28.4

96 900

23.3

79 500

10.7

4.28

2.71

95.70

MIN.

12.1

41 300

9.3

31 700

2.2

0.9

1.16

40.96

Room sealed chamber

panel fitted

Central Heating

Heat Input kW

(Gross) Btu/h

Heat Output (modulating) kW

Btu/h

Burner Pressure mbar

Settings in wg

Gas Rate m³/h

ft³/h

Burner

Main Heat exchanger

Main Burner Injectors

Flue - Outer Duct

Flue - Inner Duct

Stainless steel

Copper

1.30 mm (x12)

White

Aluminium

2.3 COMPONENTS

Central Heating (Sealed System)

Max. Working System Pressure

Min. System Pressure

Max. System temperature

Pressure Relief Valve Setting

Expansion Vessel Size (pre-charge press.)

Flow Connection

Return Connection

Relief Valve Connection

Recommended System Pressure (cold)

CH Water Temp. (Approx. max.)

2.5 bar

0.5 bar

82°C

3 bar (44 PSI)

8 L at 0.8 bar

22 mm

15 mm

1.0 bar

82°C (180°F)

2.2 SYSTEM

4Alpha SY9-24 - Technical Data

Fig. 1 - Boiler terminal block

720 mm

450 mm

330 mm

22 mm

1.6 L

100 mm

60 mm

Case Dimensions Height

(without bottom tray) Width

Depth

Gas Connection

Primary Water Content

Air Duct Diameter

Flue Duct Diameter

2.5 GENERAL 2.6 ELECTRICAL

Supply

External Fuse

Power Consumption

Internal Fuse

Electrode Spark Gap

230/240 V ~ 50 Hz

3 A

170 W

F2 A

2 to 4 mm

2.7 FLUE LENGTHS

Flue length = 0.75 m (not including the terminal, which is supplied with the boiler)

Note: Additional flues (of the same length) are available.

Length of Flue Required:-

Rear Flue = wall thickness + 175 mm

Side Flue = wall thickness + distance between wall and side of boiler + 185 mm

Vertical Flue = distance from top of boiler side panel to required roof position minus 1 m for vertical terminal assembly

Maximum flue length = 4 m

Each additional 90° Bend is equivalent to 1 m of flue length

Each 45° Bend is equivalent to 0.5 m of flue length

The Vertical Flue terminal assembly is equivalent to 1 m of flue length

2.8 AVAILABLE PUMP HEAD FOR CENTRAL HEATING

gal/min

3.7

2.8

2.3

1.8

1.5

Btu/h

79 500

60 000

50 000

40 000

31 700

23.3

17.58

14.65

11.63

9.3

metres

2.4

3.8

4.5

5.1

5.45

feet

7.9

12.5

14.8

16.7

17.9

Output Available pump head

metres

3.2

4.4

4.8

5.35

5.65

feet

10.5

14.4

15.8

17.5

18.5

metres

2.5

1.9

1.25

0.8

0.5

feet

8.2

6.2

4.1

2.6

1.6

metres

2.3

1.3

0.95

0.65

0.4

feet

7.5

4.3

3.1

2.1

1.3

Pressure loss across boiler

gal/min

4.3

3.3

2.7

2.2

1.7

litre/min

16.7

12.6

10.5

8.3

6.7

17°C 20°C litre/min

19.6

14.8

12.3

9.8

7.8

17°C 20°C 17°C 20°C

Flow rate

This information is based on 17°C and 20°C system design temperature difference.

2.9 ELECTRICAL CONNECTIONS

Note: This Appliance Must Be Earthed

2.10 BOILER SCHEMATIC

Alpha SY9-24 - Technical Data

1 - Gas valve

2 - Primary temperature sensor

3 - Main burner

4 - Main heat exchanger

5 - Room sealed chamber

6 - Fan

7 - Air pressure switch

8 - Flue hood

9 - Overheat thermostat

10 - Expansion vessel

11 - Automatic air vent

Fig. 2

12 - Pump

13 - Drain point

14 - Pressure relief valve

15 - Ignition electrodes

16 - Flame sensing electrode

17 - Flue sampling point

18 - Gas service cock

19 - Primary pressure switch

20 - On/off valve (2 off)

21 - Automatic by-pass

3.1 GAS SUPPLY

The Alpha SY24 boiler requires a gas rate of 2.71 m³/h (95.7 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. The boiler requires at least a 22 mm gas supply pipe.

The complete installation, including the meter, must be tested for gas soundness and purged as described in BS 6891.

3.2 ELECTRICAL SUPPLY

The boiler requires a 230/240 V ~ 50 Hz mains supply, fused at 3 A

The boiler must be earthed.

There must only be one common isolator, providing complete electrical isolation, for the boiler and any external controls.

This boiler has been fitted with a supply cable, however, if it is necessary to fit a cable use PVC insulated cable not less than

0.75 mm² (24 x 0.2 mm) to BS 6500 Table 16. The boiler should be connected to a fused three pin plug and unswitched

shuttered socket outlet (both complying with BS 1363), or a fused double pole switch with a contact separation of at least 3 mm

in both poles.

Wiring external to the boiler must be in accordance with the current IEE Wiring Regulations (BS 7671).

Note: If a room thermostat is fitted, it must be suitable for 230/240 V switching.

3.3 AIR SUPPLY

The boiler does not require any air vents for cooling in the room in which it is installed or when installed in a cupboard or

compartment. The minimum clearances for servicing must always 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.

3.4 FLUE SYSTEM - Fig. 3

The flue system must be installed in accordance with BS 5440:1.

For horizontal flues ensure there is a slight downward slope towards the terminal.

Flue components are available as follows:-

Top easy-flue 500 mm (includes 90° bend), refer to separate instructions

0.75 m flue

90° bend

45° bend

Vertical flue terminal assembly. Refer to the separate installation instructions supplied with the assembly.

A Twin Pipe Flue system is available for use with all the boilers in the range. Refer to the separate instructions for details.

The following methods determine the correct length of flue required.

For rear exit flue L = B + 175 mm

For side exit flue L = B + C + 185 mm (min. side clearance required is 5 mm)

For vertical flue L = H minus 1000 mm for vertical terminal assembly

Where L = Required flue length

B = Finished wall thickness

C = Distance from the inside wall to the side of the boiler

H = Distance from top of boiler side panel to roof position

Note: 1. If an extra 90° bend is used, this reduces the maximum flue length by 1 m. Each 45° bend used reduces the maximum

flue length by 500 mm.

2. Under no circumstances must the flue length (including allowances for extra bends) exceed 4 metres.

3. FailuretouseAlphafluecomponentswiththeboilerwillinvalidatetheboilersCEapproval,guaranteeandmaybeunsafe.

3 GENERAL BOILER INFORMATION

Alpha SY9-24 - General Boiler Information

HORIZONTAL FLUE OPTIONS - Lmax = 4 metres

L = B + C + E + 185 mm

Alpha SY9-24 - General Boiler Information

L = B + C + 185 mm

L = B + E + F + 185 mm + (90° bend = 1 metre)

L = B + C + 185 mm + (2 x 45° bends = 1 metre)

Fig. 3

VERTICAL FLUE OPTIONS

3.5 FLUE TERMINAL LOCATION - Fig. 4

A Directly below an opening, air brick, windows, etc.

B Below gutters, soil pipes or drain pipes

C Below eaves

D Below balconies or car port roof

E From a vertical drain pipe or soil pipe

F From an internal or external corner

G Above ground, roof or balcony level

H From a surface facing the terminal

I From a terminal facing the terminal

J From an opening in the car port (e.g. door, window) into dwelling

K Vertically from a terminal on the same wall

L Horizontally from a terminal on the same wall

M Horizontally from an opening, air brick, window, etc.

300 mm

75 mm

25 mm

300 mm

600 mm

1200 mm

1500 mm

300 mm

Min. distance

Terminal position

Fig. 4

The flue terminal must be exposed to the external air and the position must allow the free passage of air across it at all times.

In certain weather conditions the terminal may emit a plume of steam. Avoid positioning the terminal where this may cause a nuisance.

If the terminal is fitted within 850 mm of a plastic or painted gutter or 450 mm of painted eaves or 300 mm of a plastic car port

roof, an aluminium shield at least 1 m long should be fitted to the underside of the gutter or painted surface. If the terminal is

fitted less than 2 m above a surface to which people have access, the terminal must be protected by a terminal guard.

A suitable guard is available from:

Tower Flue Components Ltd., Vale Rise, Tonbridge, Kent TN9 1TB

3.6 BOILER LOCATION

The boiler is not suitable for external installation.

The boiler must be installed on a flat vertical wall which is capable of supporting the weight of the boiler. The boiler can be fitted

to or adjacent to a wall comprising of a combustible 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 British Gas publication 'Guide for

Gas Installations in Timber Frame Housing', reference DM2.

The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the

current IEE Wiring (BS7671) Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in

Scotland, with respect to the installation of the boiler in a room or internal space containing a bath or shower. Where a room-

sealed boiler is installed in a room containing a bath or shower, it must not be possible for a person using the bath or shower

to touch any electrical switch or boiler control utilising mains electricity.

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 SY9-24 - General Boiler Information

3.7 CENTRAL HEATING SYSTEM - Fig. 5

The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798.

The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump head, expansion

vessel size, mean radiator temperature, etc must all be taken into account. Refer to the pump performance table for guidelines.

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.

Above 80 litres, consideration should be given to fitting an additional expansion vessel fitted in the position shown in Fig. 5. To

check correct operation of the expansion vessel(s) the system pressure should not be more than 2.5 bar when the system is at

maximum operating temperature (for further guidance refer to BS 7074:1).

The boiler is supplied with the following components built in:-

Pressure relief valve - complying with BS 6759 and set to operate at 3 bar. The discharge pipe must be routed clear of the

boiler, in such a manner that it can be seen, but cannot cause injury to persons or property.

Pressure gauge - To indicate the system pressure to be maintained.

Expansion vessel - Conforming to BS 4814 with a capacity of 8 litres and pre-charged to a pressure of 0.8 bar.

By-pass - The boiler incorporates a by-pass. However, where all radiators are fitted with thermostatic radiator valves it is

recommended a system by-pass, preferably automatic, is fitted.

Alpha SY9-24 - General Boiler Information

3.8 FILLING THE CENTRAL HEATING SYSTEM - Figs. 6, 7

Thesystemdesignpressure (cold) shouldbesetto1.0bar. Thispressure isequivalent toa statichead(seeFig.5)of 10.2metres ofwater.

Provision should be made to replace water lost from the system. This can be by manual or automatic means, as shown in Figs.

6 and 7. The position for connecting an automatic make-up vessel is indicated in Fig. 5. A double check valve assembly must

be used, as shown in Fig. 7.

Filling of the system must be carried out in a manner approved by the local Water Undertaking. Where allowed, the system may

be filled via a temporary connection as shown in Fig. 6. After filling, always disconnect the flexible hose of the filling loop.

All fittings used in the system must be able to withstand pressures up to 3 bar.

Drain taps (to BS 2879) must be used to allow the system to be completely drained.

The heating system should be thoroughly flushed before the boiler is connected and again after the first heating.

If it is required to add inhibitor to the system, refer to Alpha Therm Ltd. for guidance.

Refer to BS 5449 and BS 6798 for further information.

Note: A drain tap should be installed at the lowest

point of the heating circuit and beneath the appliance.

System

drain tap

Static head of system

Make up vessel

Additional expansion

vessel (if required)

Automatic

air vent

Boiler

casing

Heating flow

Heatingreturn

Filling point

Double check valve assy.

Note: If required, an automatic by-pass is

preferred.

Heating

by-pass

(If required)

Fig. 5

Feed cistern to be

located above highest

point in the system

Mains

water

supply

Stop

valve

Test cock

Double check

valve assembly

Overflow

Heating circuit

return

Fig. 6 Fig. 7

Filling loop

temporarily connected

Heating circuit

return Mains

water

supply

Stop

valve

Hose

unions

Stop

valve

Double check

valve assembly

Test cock

Fig. 9

Alpha SY9-24 - Installation

4 INSTALLATION

4.1 UNPACKING

1. The boxes required when the boiler is installed with a horizontal flue are as follows:-

Box 1 Cased boiler fitted with water and gas valves, union bends and washers

Mounting bracket plus screws and wall plugs

Flue terminal and flue sealing collar plus 2 screws

Literature pack and Wall template

Box 2 90° flue bend (not required for vertical flue)

Box 3 0.75 m flue (for side and rear flue) with two clamps and inner duct support

Note: If an Easy flue 500 mm is ordered, this will be supplied instead of boxes 2 and 3.

2. Unpack boiler and remove the loose items packs, i.e. mounting bracket, flue terminal and collar.

Note: The boiler can be stood in an upright position supported by the bottom tray, (to allow this, the union bends have

been turned upwards so that they do not protrude beneath the bottom tray - check this before standing the boiler on the

bottom tray).

4.2 CLEARANCES REQUIRED - Fig. 8

Fig. 8

4.3 PREPARE THE WALL - Figs. 9, 10

1. Decide upon the position of the boiler taking 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 boiler mounting bracket and bottom fixings. If

rear exit flue is used, mark the position of the hole

for the flue.

3. Side exit flue - Continue the horizontal centre line of

the flue across the wall to the side wall, then along the

sidewall215mm(ensurethelinesarehorizontal).This

willgivethepositionofthecentreoftheholefortheflue.

4. Cut the 110 mm diameter hole (or use a 107 mm

core drill) in the wall for the flue.

Note: For internal fitting of the flue, using the flue

sealing collar supplied, cut a 127 mm dia. flue hole

using a 127 mm core drill.

5. Drill the fixing holes (10 mm dia.) to accept the No.10

plugs supplied. Using the screws supplied, fit the

mounting bracket.

6. Top pipe connections - Preform the pipework at the back of the boiler before hanging the boiler, see Fig. 10, and secure in

the clips provided.

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