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Alpha Alpha CD24, Installation And Servicing Instructions

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Installation and Servicing

Instructions

Alpha CD24/32

Range of Wall Mounted, Fan Assisted, Room Sealed,

Gas Fired, High Efficiency Condensing Boilers

Goldsel Road,

Swanley, Kent BR8 8EX

Fax: (01322) 615017

For Technical help or for Service call ...

ALPHA HELPLINE

Tel: (01322) 669443

Alpha CD24C

G.C. No. 47 532 19

Alpha CD24S

G.C. No. 41 532 02

Alpha CD32C

G.C. No. 47 532 21

*HEJEID/=I

Service Listed

For use with Natural Gas only

Leave these instructions with the User

Summary of Contents for Alpha CD24

Page 1: ...cy Condensing Boilers Goldsel Road Swanley Kent BR8 8EX Fax 01322 615017 For Technical help or for Service call ALPHA HELPLINE Tel 01322 669443 Alpha CD24C G C No 47 532 19 Alpha CD24S G C No 41 532 0...

Page 2: ...rise of 35 C 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 Inst...

Page 3: ...ng 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 Va...

Page 4: ...flue length 12 m Maximum vertical flue length including terminal is 15 m Each additional 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...

Page 5: ...led chamber 10 Fan 11 Pressure differential test points Fig 2A 12 Flue hood 13 Overheat thermostat 14 Expansion vessel 15 Automatic air vent 16 Pump 17 Drain point 18 Pressure relief valve 19 Primary...

Page 6: ...8 Pressure relief valve 19 Primary pressure switch 20 Ignition electrodes 21 Flame sensing electrode 22 DHW temperature sensor 23 Flue sampling point Alpha CD24 32 Technical Data 24 Gas service cock 2...

Page 7: ...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 m...

Page 8: ...FLUE OPTIONS Lmax 12 metres L B C E 230 mm Alpha CD24 32 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...

Page 9: ...tted 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 you local boiler merchant 3 6 BOILER LOCATION The b...

Page 10: ...or solid matter etc from the system Alpha CD24 32 General Boiler Information Feed cistern to be located above highest point in the system Mains water supply Stop valve Test cock Double check valve as...

Page 11: ...eaks 2 Installing onto an existing system clean the system 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 opera...

Page 12: ...oss All taps and mixing valves used with the hot water system must be suitable for operating at a mains pressure of up to 8 bar Showers A shower may be used with the boiler if required If a loose or f...

Page 13: ...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...

Page 14: ...dering to the boiler union bends ensure the bends are not connected to the valves otherwise the internal seals may be damaged 3 Connect the system pipework to the boiler Note Do not forget that the pr...

Page 15: ...t 22 mm D Cold water mains inlet 15 mm E Heating return 22 mm F Pressure relief valve 15 mm G Heating drain point H Cold water inlet filter I Condensate discharge pipe J Cyclone drain point Note Disco...

Page 16: ...aling the outside wall and that it is not restricting any of the openings of the flue terminal 5 Position the seal and clamp two screws supplied over the bend Fit the bend to the boiler and rotate to...

Page 17: ...nger than 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...

Page 18: ...as required Note If flue sealing collars are being used 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 th...

Page 19: ...7 Carry out electrical system checks Short circuit Polarity Earth continuity and Resistance to earth with a suitable multimeter 4 9 FIT THE CLOCK KIT CD24C and CD32C only Fig 21 Ensure the electrical...

Page 20: ...pe from the system check that this is actually happening 7 Continue to fill the system until the pressure gauge indicates 1 0 bar Close the fill point valve and check the system for water soundness re...

Page 21: ...tart the fan will start and the main gas valve solenoid will open allowing the main burner to light 5 5 CHECK THE BURNER PRESSURES Fig 24 Turn the boiler off Loosen the burner pressure test point scre...

Page 22: ...on to the fact that the system has been drained 5 Complete the details of the installation on the back page of this manual and the Benchmark log book 5 8 USER INFORMATION The User must be advised and...

Page 23: ...the boiler from operating 6 2 DOMESTIC HOT WATER MODE CD24C and CD32C only When a demand for hot water by opening a hot tap etc is sensed by the flow switch the pump starts and the burner lights incr...

Page 24: ...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 clockwis...

Page 25: ...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 in...

Page 26: ...cure with five screws do not overtighten 8 2 DRAINING THE BOILER Refer to Figs 2A 2B or 13 Isolate the electricity supply and close the boiler gas service cock see Fig 13 Allow the boiler to cool 1 He...

Page 27: ...section 8 1 2 Disconnect the wiring from the overheat thermostat 3 Unscrew and remove the overheat thermostat from the heat exchanger 4 Fit the new overheat thermostat taking care not to cross thread...

Page 28: ...nections 5 Light the boiler and adjust the PCB as described in the instructions supplied with the replacement PCB Alpha CD24 32 Component Replacement Fig 30 Fig 31 CD24C and CD32C only 8 15 DHW FLOW S...

Page 29: ...surise the system Refer to Commissioning section 5 1 8 18 COMBUSTION CHAMBER INSULATION Gain access to the combustion chamber as described in section 8 1 Front insulation see Fig 27 1 Remove the elect...

Page 30: ...cket head screws securing the pump head to the body Withdraw the head remove the wiring cover and disconnect the wiring 2 Connect the wiring to the new head as follows Brown to L Blue to N Green yello...

Page 31: ...Release the screws shown in Fig 31 and raise the valve slightly to disengage it from the manifold then lift it out of the boiler 5 Re assemble in reverse order using the new seals supplied 6 Refill a...

Page 32: ...Refer to Commissioning section 5 1 8 31 CONDENSATE TRAP Fig 12 1 Gain access behind the casing and drain the trap as described in sections 8 1 and 7 3 paragraph 10 2 Disconnect the top and drain conn...

Page 33: ...e Sensor G G Fuse F2A Link Supply 230 240V 50Hz Fused at 3A 2 2 1 1 N L X6 X9 S3 S1 S2 X10 X8 L N X16 X7 X1 Main PCB CH SET DHW SET FUSE 315 mAT CH CAP MAX CAP X11 X12 X4 H1 Green LED H4 Yellow LED H3...

Page 34: ...se F2A Link Supply 230 240V 50Hz Fused at 3A 2 2 1 1 N L X6 X9 S3 S1 S2 X10 X8 L N X16 X7 X1 Main PCB CH SET DHW SET FUSE 315 mAT CH CAP MAX CAP X11 X12 X4 H1 Green LED H4 Yellow LED H3 Red LED H2 Red...

Page 35: ...34 33 3 55 2 24 49 26 51 25 50 22 47 23 48 27 21 46 Clock Optional 1 2 3 4 Pump Fan Gas Valve Primary Temperature Sensor DHW Switch Primary Pressure Switch NO COM Overheat Thermostat Spark Generator F...

Page 36: ...45 38 13 43 39 14 34 33 3 55 2 24 49 26 51 25 50 22 47 23 48 27 21 46 1 2 3 4 Pump Fan Gas Valve Primary Temperature Sensor Primary Pressure Switch NO COM Overheat Thermostat Spark Generator Flue Lim...

Page 37: ...age 37 A YES YES BUT Pump runs and fan runs Go to section page 38 I YES Go to section page 37 D Burner output modulates until set temperature is reached Burner goes out NO YES Operation sequence succe...

Page 38: ...ter 50 seconds YES Operation sequence successful Pump stops YES Go to section page 37 D YES CH system pressure too low Re pressurise to 1 0 bar Flue or faulty fan Primary DHW temperature sensor fault...

Page 39: ...k pressure tubes are connected Replace PCB C DHW Primary temp sensor faulty Cold resistance approx 12 14 k ohms resistance reduces with increase in temp i e when hot resistance is approximately 3 k oh...

Page 40: ...locked heat exchanger pipework or pump not circulating water NO YES 240V at internal clock terminals 1 and 2 I 240V at PCB X1 connector terminals 55 and N 240V at PCB X1 connector terminals 34 and N W...

Page 41: ...No E94 407 E96 565 E94 409 E96 566 E94 408 E96 567 E57 739 E96 568 E94 410 E57 666 E94 411 E96 569 E76 320 E65 154 E96 570 E57 751 E94 412 E94 413 E94 414 E94 415 E76 317 E76 378 E96 571 E94 416 E57 7...

Page 42: ...ate of Installation Name of Installer Address Postcode Telephone No Boiler Serial Number see data label on inside of left hand case panel DETAILS OF BOILER SERVICE HISTORY Date of Service Details of S...

Page 43: ...43...

Page 44: ...d Swanley Kent BR8 8EX Tel 01322 669443 Fax 01322 615017 email info alphatherm co uk website www alpha boilers com Part No 1 019479 These instructions have been carefully prepared but we reserve the r...

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