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Alpha Boilers SY24 User Manual

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Installation and Servicing
Instructions
Alpha SY24
Wall Mounted, Fan Assisted, Room Sealed, Gas Fired
System Boiler
Goldsel Road,
Swanley, Kent BR8 8EX
Fax: (01322) 615017
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: (01322) 669443
Alpha SY24 G.C. No. 41 532 01
*HEJEID/=I
Service Listed
For use with Natural Gas only
Leave these instructions with the User
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Alpha Boilers SY24 Specifications

General IconGeneral
MountingWall-mounted
Central Heating Output24kW
Domestic Hot Water Output24kW
ErP RatingA
Max Working Pressure3 bar
Warranty5 years
Fuel TypeGas
Central Heating Flow Temperature Range30°C - 80°C
Dimensions (H x W x D)700 x 400 mm

Summary

Introduction

Technical Data

Performance - Natural Gas

Details of heat input, output, burner pressure and gas rate.

System

Specifications for the central heating sealed system.

Components

List of main boiler components and materials.

Installation

Required clearances and dimensions for installation.

General

General dimensions, gas connection, water content and duct diameters.

Electrical

Electrical supply voltage, fuse ratings, and power consumption.

Flue Lengths

Guidelines and calculations for flue system lengths.

Available Pump Head for Central Heating

Data on pump head, flow rate, and pressure loss for heating.

Electrical Connections

Diagram and notes for boiler electrical connections.

Boiler Schematic

Diagram showing the layout and identification of boiler components.

General Boiler Information

Gas Supply

Requirements for gas supply, pipe size, and testing.

Electrical Supply

Mains supply voltage, fuse rating, earthing, and cable requirements.

Air Supply

Information regarding room ventilation and clearances.

Flue System

Installation requirements and lengths for the flue system.

Flue Terminal Location

Guidelines for positioning the flue terminal to ensure safety and performance.

Boiler Location

Requirements for boiler placement and installation environment.

Central Heating System

Design and components of the sealed central heating system.

Filling the Central Heating System

Procedure for filling and pressurising the heating system.

Installation

Unpacking

Contents of the boiler packaging and unpacking instructions.

Clearances Required

Minimum clearances around the boiler for servicing and installation.

Prepare the Wall

Steps for preparing the wall for boiler mounting and flue entry.

Fit the Boiler

Instructions for mounting the boiler onto the bracket.

Connect the Pipework

Procedure for connecting the heating and gas pipework to the boiler.

Fit the Flue

Instructions for fitting the flue system, including cutting and assembly.

Fit a Flue Extension

Procedure for fitting flue extensions and calculating lengths.

Connect the Mains Supply

Steps for connecting the boiler to the electrical mains supply.

Commissioning

Fill the System

Procedure for filling and venting the heating system.

Boiler Controls

Overview and identification of the boiler's control panel features.

Test for Gas Soundness and Purge the Supply

Steps for testing gas connections and purging the supply.

Initial Lighting

Procedure for the initial lighting and operation of the boiler.

Check the Burner Pressures

Procedure for checking and verifying burner pressures.

Final Commissioning

Steps for completing the commissioning process.

Final Assembly

Reassembling the boiler after commissioning.

User Information

Key information to provide to the end-user.

Boiler Operation

Central Heating

How the boiler operates for central heating.

Frost Thermostat

Operation of the frost protection thermostat.

Pump

Information on the automatic pump operation.

Indicator Neons

Explanation of the status indicator lights.

Routine Servicing

Important Notes Prior to Servicing

Key checks and warnings before performing service.

Prepare for Servicing

Steps to access and prepare the boiler for servicing.

Cleaning the Boiler

Procedure for cleaning internal boiler components.

Re-assemble the Boiler

Steps for reassembling the boiler after cleaning.

Component Replacement

General Access

How to gain access to different boiler components.

Draining the Boiler

Procedure for draining the boiler for maintenance or replacement.

Ignition Electrode Lead

Procedure for replacing the ignition electrode lead.

Electrodes

Procedure for replacing ignition and flame sensing electrodes.

Main Burner

Procedure for replacing the main burner assembly.

Burner Injectors

Procedure for replacing burner injectors.

Fan

Procedure for replacing the fan assembly.

Air Pressure Switch

Procedure for replacing the air pressure switch.

Overheat Thermostat

Procedure for replacing the overheat thermostat.

Gas Valve

Procedure for replacing the gas valve assembly.

Viewing Window

Procedure for replacing the viewing window glass.

Internal Fuse

Procedure for replacing the internal fuse.

PCB

Procedure for replacing the Printed Circuit Board (PCB).

Heat Exchanger

Procedure for replacing the heat exchanger.

Combustion Chamber Insulation

Procedure for replacing combustion chamber insulation panels.

Pressure Gauge

Procedure for replacing the pressure gauge.

Primary Temperature Sensor

Procedure for replacing the primary temperature sensor.

Automatic Air Vent

Procedure for replacing the automatic air vent.

Pump

Procedure for replacing the pump or pump head.

Primary Pressure Switch

Procedure for replacing the primary pressure switch.

Pressure Relief Valve

Procedure for replacing the pressure relief valve.

Expansion Vessel

Procedure for replacing the expansion vessel.

Wiring Diagrams

Illustrated Wiring Diagram

Diagram showing the physical layout of boiler wiring.

Functional Flow Wiring Diagram

Diagram showing the functional flow of electrical connections.

Fault Finding

Carry Out Initial Fault Finding Checks

Basic checks to perform before detailed fault diagnosis.

Central Heating - Follow Operational Sequence

Flowchart for diagnosing central heating faults.

Fault Finding Solution Sections A to F

Detailed troubleshooting solutions for specific fault conditions.

Fault Finding Solution Sections G to J

Further troubleshooting solutions for specific fault conditions.

Short Parts List

Service History

Description

User Controls

Boiler Controls

Central Heating Thermostat

Control for the central heating water temperature.

Selector Switch

Switch for turning the boiler on/off and resetting.

Pressure Gauge

Indicator for central heating system pressure.

Indicator Neons

Explanation of the status indicator lights.

Overheat Thermostat

Function of the overheat safety thermostat.

Pressure Relief Valve

Information about the pressure relief valve discharge.

Frost Thermostat

Operation of the built-in frost thermostat.

Lighting Instructions

Important Notes

Boiler Location

Required clearances for boiler installation.

Flue Terminal

Importance of keeping the flue terminal unobstructed.

Mains Failure

Boiler behavior during and after electrical supply interruptions.

Cleaning

Instructions for cleaning the boiler casing.

Servicing

Importance and contact for routine annual servicing.

Gas Leak

Procedure to follow in case of a suspected gas leak.

Electrical Supply

Gas Safety Regulations

Fault Finding for the User