Alpha Alpha CD18S Installation And Servicing Instructions Download Page 34

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11 SHORT PARTS LIST

Alpha CD18S/24S/30S - Short Parts List

Reference

Burner - CD18/24

Burner - CD30

Main injector 5.0 mm - CD18/24

Main injector 6.6 mm - CD30

Primary heat exchanger - CD18/24

Primary heat exchanger - CD30

Gas valve - Honeywell VK4115V

Pump

Fan assembly - CD18/24

Fan assembly - CD30

Primary pressure switch

PCB

Flue thermostat

Ignition generator

Transformer

Temperature sensor

Fuse F2A

PCB fuse F315mA

Overheat thermostat

Expansion vessel 8 Litre

Pressure relief valve 3 bar

Automatic air vent

Pressure gauge

Ignition electrode and lead

Ignition electrode

Flame sensing electrode and lead - CD18/24

Flame sensing electrode and lead - CD30

By-pass assembly

Combustion chamber insulation panel front

Condensate trap

Description

British Gas GC No.

E94-407

E96-565

E94-409

E96-566

E94-408

E96-567

E94-410

E57-666

E94-411

E96-569

E76-320

E94-412

E94-413

E94-414

E94-415

E76-317

E76-378

E96-571

E94-416

E57-702

E57-703

E57-709

E57-710

E94-417

E94-418

E94-419

E96-572

E65-498

E94-420

H01-874

Alpha Pt. No.

1.013172

1.018956

1.011848

1.019247

1.018030

1.018593

1.011846

1.015610

1.010659

1.016623

1.017496

1.017788

1.012067

1.018162

1.012477

1.015970

1.6098

1.013931

1.018031

1.015394

1.011126

1.010771

1.016151

3.013626

1.016779

1.018163

1.019293

3.012801

1.014732

1.011844

Qty.

Fig. 27

Fig. 2A/2B, item 6/31

Fig. 2B, item 31

Fig. 32

Fig. 24

Fig. 33

Fig. 28

Fig. 33

Fig. 30

Fig. 28

Figs. 34 and 28

Fig. 20

Fig. 30

Fig. 28

Fig. 2A,2B, item 14

Fig. 33

Fig. 28

Fig. 2A,2B, item 26/27

Fig. 27

Fig. 25

Summary of Contents for Alpha CD18S

Page 1: ... System Boiler Range Nepicar House London Road Wrotham Heath Sevenoaks Kent TN15 7RS For Technical help or for Service call ALPHA HELPLINE Tel 0870 3001964 Alpha CD18S G C No 41 532 06 Alpha CD24S G C No 41 532 02 Alpha CD30S G C No 41 532 08 HEJEID I Service Listed For use with Natural Gas only Leave these instructions with the User ...

Page 2: ... 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 544...

Page 3: ...em 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 22 mm 15 mm 1 0 bar 82 C 180 F Alpha CDS models Alpha CD24S Alpha CD30S MAX 26 4 90 100 24 0 82 000 25 4 86 700 23 5 81 135 5 78 2 30 2 54 89 7 M...

Page 4: ...Alpha CD18S 24S 30S Technical Data L N 1 2 F2A 3 4 Fig 1 Boiler terminal block Clock connections 2 9 ELECTRICAL CONNECTIONS Note This Appliance Must Be Earthed An optional integral two channel Clock kit Part No 6 1000220 is available if required Note Only use the Alpha two channel clock Do not fit any single channel clocks 1 Ensure wires are connected correctly 2 Only fit the Alpha recommended 2 c...

Page 5: ...ealed chamber 10 Fan 11 Pressure differential test points Fig 2 12 Flue hood 13 Overheat thermostat 14 Expansion vessel 15 Automatic air vent 16 Pump 17 Drain point 18 Pressure relief valve 19 Primary pressure switch 20 Ignition electrodes 21 Flame sensing electrode 22 Venturi negative point 23 Venturi positive point 24 Gas service cock 25 On off valve 2 off 26 Automatic by pass 27 Cyclone separat...

Page 6: ...mum 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 the flue assembly is horizontal and the inner duct is sloping downwards...

Page 7: ...UE OPTIONS Lmax 12 metres L B C E 230 mm Alpha CD18S 24S 30S General Boiler Information L B C 230 mm C B E C B E B F B C L B E F 230 mm 90 bend 1 3 metre L B C 230 mm 2 x 45 bends 1 8 metre Fig 3 VERTICAL FLUE OPTIONS ...

Page 8: ... 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 requirem...

Page 9: ...e This is a device fitted in the heating return within the boiler to remove any foreign or solid matter etc from the system Alpha CD18S 24S 30S General Boiler Information 3 8 FILLING THE CENTRAL HEATING SYSTEM Figs 6 7 The system design pressure cold should be set to 1 0 bar This pressure is equivalent to a static head see Fig 5 of 10 2 metres of water Provision should be made to replace water los...

Page 10: ...tem before fitting the new boiler a If the old boiler is still working i Switch on the boiler and allow the system to heat up to the normal operating temperature ii Rapidly drain the system while the water is still hot iii Refill and chemically clean the system as instructed by the recommended cleaner manufacturer iv Ensure the system is flushed to remove any remains of the cleaner v Fit the new b...

Page 11: ...11 Alpha CD18S 24S 30S General Boiler Information Fig 9 External soakaway Fig 8 External gully ...

Page 12: ...ALL Figs 11 12 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 th...

Page 13: ...ged 3 Connect the system pipework to the boiler Note Do not forget that the pressure relief valve discharge pipe must be routed clear of the boiler to a drain in such a manner that it may be seen but cannot cause injury to persons or property 4 Connect the 22 mm condensate trap drain pipe to the condensate discharge pipe Ensure that the condensate discharge pipe is as required in Section 3 10 Pour...

Page 14: ... clamp ensuring the seal is located centrally over both the bend and boiler adaptor 6 Fit the inside flue sealing collar over the Easy Flue Fit the outside flue sealing collar onto the flue immediately before the terminal grille onto the location provided 7 Slide the clamp three screws over the outer duct and pull the flue assembly towards the bend locating the inner duct into the seal joint on th...

Page 15: ...han the outer duct 5 Adjust the telescopic section of the Easy Flue to the required length and secure the Easy Flue with the sealing tape supplied Fit the Easy Flue to the extensions by locating the inner duct into the seal joint and secure with the clamp three screws ensuring it is located centrally over the joint 6 Mark the end of the flue assembly TOP where it is connected to the boiler so that...

Page 16: ...to make good the inside wall then they will need to be fitted before assembling the flue 4 8 CONNECT THE MAINS SUPPLY Fig 20 1 Gain access to the boiler terminal block by releasing the two fixing screws one each side securing the control panel and lowering the panel Refer to Technical Data Section 2 9 for connection details 2 Note This boiler has been fitted with a mains supply cable However if it...

Page 17: ...tem checks Short circuit Polarity Earth continuity and Resistance to earth with a suitable multimeter 4 9 FITTING AN INTERNAL CLOCK KIT Optional Fig 21 Ensure the electrical supply to the boiler is isolated IMPORTANT Only use an Alpha two channel clock Do not fit a single channel clock 1 Remove the two screws securing the clock cover at the rear of the control panel 2 Remove and discard the clock ...

Page 18: ...til the system design pressure is obtained The system design pressure cold should be between 0 75 and 1 25 bar Refer to Sections 3 7 and 3 8 System volume Flushing and Filling the system 8 Open the mains water inlet valve see Fig 13 Turn on all hot water taps and allow water to flow until no air is present Turn off taps 9 Ensure that the condensate trap has been filled with water Refer to Section ...

Page 19: ...6 FINAL COMMISSIONING 1 Allow the heating system to heat up then balance the system to achieve the necessary temperature difference across the heating flow and return pipes at the boiler and check the system volume and pressure Refer to Technical Data Sections 2 2 and 2 8 2 Turn off the boiler 3 Thoroughly flush out the water pipework refer to Section 3 9 and with no pressure in the boiler heating...

Page 20: ...supply is on and the boiler has not operated for 24 hours for heating or hot water the pump will automatically operate for 5 minutes 7 Explain to the User that an internal frost thermostat is fitted in the boiler and that the electrical supply to the boiler must be left on for the thermostat to operate 8 Explain to the User that in certain weather conditions the terminal will emit a plume of steam...

Page 21: ...st thermostat which automatically turns on the boiler and pump if the water in the boiler falls below 8 C providing the electrical supply is on and the selector switch is set to position 1 or position 2 The boiler will operate until the water temperature in the system reaches approximately 40 C 6 3 PUMP If the electrical supply is on and the boiler has not operated for 24 hours for heating or hot ...

Page 22: ...nd fittings are sound Remake any joints and check the tightness of any fittings that may be leaking 5 It is recommended that the operation of the safety valve is checked by turning the head anti clockwise until it clicks The click is the safety valve lifting off its seat allowing water to escape from the system check that this is actually happening 6 Refill vent and re pressurise the system as nec...

Page 23: ...ews securing the burner see Fig 26 and remove the burner Clean the burner with a soft brush and check that the flame ports are clear Blockages may be removed with a stiffer brush Tap the burner open end down to remove any deposits from inside 7 Check the condition of the electrodes 9 Check the spark gap positioning and height of the electrodes See Fig 26 10 Unscrew the condensate trap drain cap Cl...

Page 24: ...ure no wires are trapped and all wiring is secured Secure with five screws do not overtighten 8 2 DRAINING THE BOILER Refer to Figs 2 or 13 Isolate the electricity supply and close the boiler gas service cock see Fig 13 Allow the boiler to cool 1 Heating circuit Close the central heating flow and return valves see Fig 13 Connect a suitable pipe to the drain point see Fig 2 and route it to a suitab...

Page 25: ...ew and remove the overheat thermostat from the heat exchanger 4 Fit the new overheat thermostat taking care not to cross thread it and re assemble in reverse order 8 10 FLUE THERMOSTAT Fig 27 1 Gain access behind the room sealed chamber panel as described in Section 8 1 2 Remove the thermostat from the spring clip at the top rear of the heat exchanger 3 Disconnect the wiring 4 Fit the new thermost...

Page 26: ...move the clock retaining screws and withdraw the clock from the control panel 5 Fit the new two channel clock and connect the wires as follows Brown wire to terminal 1 Blue wire to terminal 2 Black wire to terminal 3 Grey wire to terminal 4 and White wire to terminal 5 or as per the instructions supplied with the clock 6 Re assemble in reverse order Refer to the instructions supplied with the cloc...

Page 27: ...pressure gauge sensor and withdraw the sensor 3 Depress the two lugs on the pressure gauge and push it out of the control panel 4 Fit the new gauge using a new washer on the manifold connection if necessary 5 Refill and pressurise the system Refer to Commissioning Section 5 1 8 19 PRIMARY TEMPERATURE SENSOR Refer to Fig 27 1 Gain access as described in Section 8 1 behind the room sealed chamber pa...

Page 28: ...ct the pressure relief valve outlet fitting 3 Release the screw retaining the pressure relief valve and pull out the valve 4 Re assemble in reverse order 5 Refill and pressurise the system Refer to Commissioning Section 5 1 8 24 EXPANSION VESSEL Fig 12 Note If there is less than 450 mm clearance above the boiler or a rear exit flue is used it is not possible to replace the vessel in which case an ...

Page 29: ...29 9 1 ILLUSTRATED WIRING DIAGRAM Alpha CD18S 24S 30S Wiring Diagrams 9 WIRING DIAGRAMS ...

Page 30: ...30 Alpha CD18S 24S 30S Wiring Diagrams 9 2 FUNCTIONAL FLOW WIRING DIAGRAM ...

Page 31: ... Earth Short Circuit and Polarity with a suitable meter Note These checks must be repeated after any servicing or fault finding 3 Ensure all external controls are calling for heat and check all external and internal fuses 4 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 e...

Page 32: ...32 10 2 FAULT FINDING SOLUTIONS A to E Alpha CD18S 24S 30S Fault Finding ...

Page 33: ...33 Alpha CD18S 24S 30S Fault Finding 10 3 FAULT FINDING SOLUTIONS F to K ...

Page 34: ... Condensate trap Description British Gas GC No E94 407 E96 565 E94 409 E96 566 E94 408 E96 567 E94 410 E57 666 E94 411 E96 569 E76 320 E94 412 E94 413 E94 414 E94 415 E76 317 E76 378 E96 571 E94 416 E57 702 E57 703 E57 709 E57 710 E94 417 E94 418 E94 419 E96 572 E65 498 E94 420 H01 874 Alpha Pt No 1 013172 1 018956 1 011848 1 019247 1 018030 1 018593 1 011846 1 015610 1 010659 1 016623 1 017496 1 ...

Page 35: ...e reducer has been fitted FOR DOMESTIC HOT WATER MODE MEASURE AND RECORD THE FOLLOWING Gas rate m hr ft hr Maximum burner operating pressure if applicable N A mbar Cold water inlet temperature C Hot water outlet temperature C Water flow rate lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING The condensate drain has been installed in accordance with the manufacturer s instructions Yes FOR A...

Page 36: ...when replacing all controls SERVICE 1 Date Engineers Name Company Name Telephone No CORGI ID card serial No Comments Signature SERVICE 2 Date Engineers Name Company Name Telephone No CORGI ID card serial No Comments Signature SERVICE 3 Date Engineers Name Company Name Telephone No CORGI ID card serial No Comments Signature SERVICE 4 Date Engineers Name Company Name Telephone No CORGI ID card seria...

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