Alpha 41 532 03 Installation And Servicing Instructions Download

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Alpha CD 13R (NG)

G.C. No. 41 532 05

Alpha CD 18R (NG)

G.C. No. 41 532 03

Alpha CD 24R (NG)

G.C. No. 41 532 04

Alpha CD 13R (LPG)

G.C. No. 41 532 11

Alpha CD 18R (LPG)

G.C. No. 41 532 09

Alpha CD 24R (LPG)

G.C. No. 41 532 10

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 2015.

Part No. 1.038436 ST.001941/000

0615/D352

Installation and Servicing

Instructions

Alpha CD 13R,18R and 24R

Wall Mounted, Fan Assisted, Room Sealed, Gas Fired,

High Efficiency Condensing Regular Boiler Range

British Gas

Service Listed

Nepicar House, London Road,

Wrotham Heath, Sevenoaks,

Kent TN15 7RS

For Technical help or for Service call ...

ALPHA HELPLINE Tel: 0844 871 8764

website: www.alpha-innovation.co.uk

Summary of Contents for 41 532 03

Page 1: ...we reserve the right to alter the specification at any time in the interest of product improvement Alpha Therm Limited 2015 Part No 1 038436 ST 001941 000 0615 D352 Installation and Servicing Instructions Alpha CD 13R 18R and 24R Wall Mounted Fan Assisted Room Sealed Gas Fired High Efficiency Condensing Regular Boiler Range British Gas Service Listed Nepicar House London Road Wrotham Heath Sevenoa...

Page 2: ...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 tothecustomeroncompletionofaninstallation Obtain the customer s signa...

Page 3: ...rence should be made to DEFRA document Guide to condensing boiler installation assessment procedures for dwellings 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 i e degree of protection against moisture This appliance contains no asbestos and no substances have been used in the construction pr...

Page 4: ...asonality efficiency 2005 SAP SEDBUK seasonality efficiency 2009 Max primary system pressure bar Min primary system pressure bar Recommended system pressure Cold bar Electrical power consumption Max Watts Electrical power consumption Standby Watts 2 TECHNICAL DATA Alpha CD13R 18R 24R Technical Data 26 6 24 0 25 6 23 5 6 5 2 54 20 82 5 25 0 6 1 45 5 9 2 9 0 27 200 0 003 90 3 88 6 2 5 0 5 1 0 55 6 2...

Page 5: ...110 28 29 12 14 60 100 22 22 15 600 390 305 100 235 150 5 450 110 27 28 12 14 60 100 CD 13R CD 18R CD 24R 13 8 12 4 13 1 12 1 5 4 0 48 37 82 4 0 0 5 2 0 10 6 9 8 0 003 CD 13R CD 18R CD 24R 20 4 18 4 19 6 18 0 5 4 0 72 37 82 4 0 0 5 4 22 10 6 9 8 0 003 26 6 24 0 25 6 23 5 6 5 0 44 37 82 4 0 0 6 6 4 10 6 9 8 0 003 Heat input gross CH kW Heat input net CH kW Heat output condensing 50 30 C CH kW Heat ...

Page 6: ...Clock connections 2 6 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 channel clock Other clocks could cause damage WARNING 1 2 3 4 5 Internal 2 Chann...

Page 7: ...Room sealed chamber 10 Fan 11 Pressure differential test points Fig 2 3 12 Flue hood 13 Overheat thermostat 14 Primary flow temperature sensor 15 Drain point 16 Ignition electrodes 17 Flame sensing electrode 18 Venturi negative point 19 Venturi positive point 20 Gas service cock 21 Condensate trap Gas Condensate discharge Primary Heating return Primary Heating flow 20 4 1 10 21 11 2 14 16 3 12 8 7...

Page 8: ...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 towards the boiler Flue components are available as follows CD Easy Flue 500 mm includes 90 b...

Page 9: ...s L B C E 200 mm Alpha CD13R 18R 24R General Boiler Information L B C 200 mm L B E F 200 mm 90 bend 1 3 metre L B C 200 mm 2 x 45 bends 1 8 metre Fig 2 4 VERTICAL FLUE OPTIONS Not less than 300 mm H Not less than 300 mm H C B E C B E B F C B ...

Page 10: ...e reduced to 25 mm without effecting the performance of the boiler However to ensure the condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferable 3 These clearances may be reduced to 25 mm without effecting the performance of the boiler However to ensure the condensate plume does not affect adjacent surfaces the terminal can be extended beyond gutters pipes eaves balc...

Page 11: ...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 p...

Page 12: ... 150mm max 1000mm min height Feed and expansion tank Vent 22mm min Cold feed 15mm min Pump DHW storage cylinder Mid position 3 port valve Automatic by pass valve Balancing valve 450mm min height 3 8 FILLING THE OPEN VENTED CENTRAL HEATING SYSTEM A minimum head of 1 m is required between the boiler pump and the feed and expansion tank The boiler must be supplied from an unrestricted water supply ta...

Page 13: ...nce with their manufacturers instructions Only products from Fernox and Sentinel are acceptable for use with the Alpha CD boilers Further information can be obtained from Fernox Tel 0870 8700362 or Sentinel Tel 0151 4209563 The system should be flushed in accordance with BS 7593 and BS 5449 The following procedures are recommended 1 Installing onto a new system a Fill the system vent at high point...

Page 14: ... 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 Alternatively the condensate pipework could be increased to a minimum of 32 mm diameter without the requirement to insulate the pipework Termination should be into an external gulley or soakaway as shown in Figs 2 11 ...

Page 15: ...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 side wall 160 m...

Page 16: ...onnections underneath the boiler have been tightened Note When soldering to the boiler union bend ensure the bend is not connected to the valve otherwise the internal seals may be damaged 3 Connect the system pipework to the boiler Note Ensure the flow and return pipes are correctly connected to the boiler Refer to Fig 4 4 4 Connect the 22 mm condensate trap drain pipe to the condensate discharge ...

Page 17: ... 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 flue assembly back into the correct position Visually check that the collar is sealing the outside wall and that it is not restricting any of the openings of the flue terminal Fig 4...

Page 18: ...o 6 2000750 or 6 2001050 is required to extend the range of telescopic flue Refer to Section 4 7 paragraph 2 for instructions on how to extend the flue Note A 130 mm flue hole 127 mm core drill is required in the wall Within the standard Easy Flue 1000 mm Part No 6 2001010 telescopic range Discard the first telescopic section of the Easy Flue 1000 mm i e not with terminal and cut to the required l...

Page 19: ...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 the TOP of the flue ...

Page 20: ...nagement 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 4 11 Notes 1 The wall support brackets must be used to secure the Plume Management pipework to the wall and prevent disconnection of the 93 bend from the flue assembly or any other component 2 Each joint must be secured with o...

Page 21: ...nal end section from CD Easy Flue PM length C 4 x 93 bend 5 2 m C Terminal end section from CD Easy Flue Ensure there is a slope of approximately 3 back towards the Easy Flue Fig 4 12 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 Alpha Intec boiler maximum equivalent flue lengt...

Page 22: ...pump is always connected to the boiler terminal block 4 Replace the terminal block 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 Carryoutelectrical system...

Page 23: ...ness in accordance with BS 6891 2 Loosen the gas inlet pressure test point screw on the gas valve see Fig 5 3 Ensure the gas supply is on and open the boiler service cock to purge in accordance with BS 6891 3 Retighten the test point screw and test for gas soundness Close the boiler gas service cock 5 4 INITIAL LIGHTING Refer to Fig 5 1 1 Ensure that the gas and electrical supplies to the boiler a...

Page 24: ...itch off the electrical supply 4 If there is any possibility of the boiler being left during frost conditions then the boiler and system should be drained refer to Section 8 2 It is recommended that a label is attached to the boiler drawing attention to the fact that the system has been drained 5 Complete the details of the installation in the Benchmark Checklist on page 33 5 8 USER INFORMATION Th...

Page 25: ... operate until the water temperature in the system reaches approximately 40 C 6 4 PUMP If the electrical supply is on and the boiler has not operated for 24 hours for heating or hot water the external pump will operate automatically for five minutes every 24 hours 6 5 INDICATOR NEONS When neons A red B red C yellow D green are illuminated the following conditions apply Neon D Illuminated continuou...

Page 26: ...ry 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 5 2 Notes 1 Prior to servicing it is recommended that a flue gas analyser is used to measure the performance of the boiler refer to Fig 5 2 for the position ...

Page 27: ... soft brush if necessary Do not use a brush with metallic bristles as this might damage the injector 4 Remove any deposits from the heat exchanger coils This can be done by suction or water sprayed onto the coils Ensure all electrical components are protected from water Any water used to clean the heat exchanger will drain to the condensate trap 5 Unscrew and replace the injector if it appears dam...

Page 28: ...ctions 5 4 and 5 5 5 Ensure that the room sealed chamber panel seal is intact and in position replace the panel ensuring it has been located correctly and secure it in position with the screws previously removed 6 Raise the control panel and secure in position with the two screws provided 7 Replace the front case panel and secure in position 8 Check the operation of the boiler Refer to Boiler Oper...

Page 29: ...nel has been located correctly 8 2 DRAINING THE BOILER Refer to Figs 2 3 or 7 1 1 Isolate the electricity supply and close the boiler gas service cock see Fig 4 4 Allow the boiler to cool 2 Gain access as described in Section 8 1 Connect a hose to the drain valve located in the flow pipe just above the heat exchanger see Fig 7 1 and route it to a suitable container Open the drain valve Note Water ...

Page 30: ...oom sealed chamber panel as described in 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 it and re assemble in reverse order 8 10 FLUE THERMOSTAT Fig 8 1 1 Gain access behind the room sealed chamber panel as described in Section 8 1 2 Remove the tw...

Page 31: ...er at the rear of the control panel 3 Disconnect the wiring from the clock 4 Remove the clock retaining screws and withdraw the clock from the control panel 5 Fit the new 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 assembl...

Page 32: ...rs are the same 1 Gain access as described in Section 8 1 and drain as described in Section 8 2 2 Remove the screw securing the air inlet tube and remove 3 The primary sensors are positioned on the right hand side of the heat exchanger see Fig 8 1 flow at the front and return at the rear Disconnect the wiring and unscrew the sensor using a 13 mm A F socket spanner access to the return sensor will ...

Page 33: ...X7 X1 FUSE 315 mAT X11 X12 X4 Br Bl 29 30 31 32 Bk R Br Br Br W Gy Bl Bl Bl Br Bl G G G G Or R R Pk Pk P Gy Pk Pk Gy P Or W Bl Bk Br Primary Flow Temperature Sensor R R Primary Return Temperature Sensor Fan Flame Sensing Electrode Flue Limit Thermostat Overheat Thermostat Or Bk Bk W R W Gy Spark Generator Ignition Electrodes 40 36 35 11 41 37 12 42 18 44 19 45 38 13 43 39 14 34 33 3 55 2 24 49 26 ...

Page 34: ...ure Sensor Overheat Thermostat Spark Generator Optional 2 Channel Clock Flue Limit Thermostat Fuse F2A 1 2 3 4 L N 230 240V 50Hz Fuse 3A Remove link to connect external control N Note Main Terminal Block N L L Transformer N N TO CONNECT EXTERNAL CONTROL REMOVE LINK FROM TERMINALS 1 AND 2 AND CONNECT 230 240 V SWITCHED LIVE TO TERMINAL 1 240 Vac 24 Vac H1 H4 H3 H2 Green LED Yellow LED Red LED Red L...

Page 35: ...ner output modulates until set temperature is reached Burner goes out NO YES Operation sequence successful Pump continues to run until temperature reduces to set temperature YES Go to section page 36 D Fan stops after 50 seconds Check gas valve adjustment Primary temperature sensor faulty NO NO Neon B illuminated cont Neon A flashing Neon A and B flashing at the same time Neon A flashing Go to sec...

Page 36: ...and purged Check pressure tubes are connected Replace PCB C 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 ohms Check and correct connections wiring at temperature sensors and PCB 2 1 YES YES Check resistance throughout the range from cold to hot Primary return temperature sensor faulty i e no hea...

Page 37: ...37 Alpha CD13R 18R 24R Fault Finding 10 3 FAULT FINDING SOLUTIONS F to I ...

Page 38: ...electrode and lead Combustion chamber insulation panel front Condensate trap Description British Gas GC No H28 392 E94 407 H28 393 H28 394 H28 395 H28 396 H28 397 E94 413 E94 414 E94 415 E76 317 E76 378 E96 571 H28 398 E94 417 E94 418 E96 572 E94 420 Alpha Pt No 1 021877 1 013172 1 022472 1 022709 1 021521 1 019725 1 018808 1 021206 1 027267 1 023071 1 018162 1 012477 1 015970 1 6098 1 013931 1 01...

Page 39: ...ers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature Model s CD 18R Condensing boiler YES Low temperature boiler NO B1 boiler NO Cogeneration space heater NO Equipped with a supplementary heater NO Combination heater NO Item Symbol Value Unit Item Symbol Value Unit Rated heat output Pn 18 kW Seasonal space heating energy efficiency ηs 90 For boiler space heaters ...

Page 40: ...ther items At full load elmax 0 040 kW Standby heat loss Pstby 0 090 kW At part load elmin 0 023 kW Ignition burner power consumption Pign 0 000 kW In standby mode PSB 0 007 kW Emissions of nitrogen oxides NOX 29 mg kWh For combination heaters Declared load profile Water heating energy efficiency ηWH Daily electricity consumption Qelec kWh Daily fuel consumption Qfuel kWh Contact details Alpha The...

Page 41: ... AFC Seasonal room heating yield ηs 90 Domestic hot water production yield ηwh Parameter Value Yearly energy consumption for the hea ting function QHE 74 3 GJ Yearly electricity consumption for the domestic hot water function AEC Yearly fuel consumption for the domestic hot water function AFC Seasonal room heating yield ηs 91 Domestic hot water production yield ηwh CD 18R CD 24R A A B C D E F G A ...

Page 42: ...s 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 a...

Page 43: ...ding 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 5 x O 0 5 x 4 5 6 7 4 ...

Page 44: ...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 in...

Page 45: ... II 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 furt...

Page 46: ...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 47: ...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 48: ...4 Alpha CD13R 18R 24R ...

Page 49: ...he law that all gas appliances are installed and serviced by a competent person i e Gas Safe registered personnel Failure to install or service appliances 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 ful...

Page 50: ... is restored 4 CLEANING Use only a damp cloth and mild detergent to clean the boiler outer casing Do not use abrasive cleaners 5 SERVICING To maintain efficient and safe operation of your boiler routine annual servicing is essential For advice on servicing contact The Alpha Helpline 0844 871 8764 Refer to Fig 1 for boiler controls 1 Ensure the following a Electrical supply to the boiler is off b A...

Page 51: ...has operated Rotate selector switch to the reset position 3 to reset If this continues to happen contact yor Service Engineer B Illuminated continuously Burner has failed to light Rotate selector switch to the reset position 3 and the ignition sequence will restart after a delay of about 30 seconds A and B Flashing on and off at the same time Blocked flue or fan fault contact your Service Engineer...

Page 52: ...epared but we reserve the right to alter the specification at any time in the interest of product improvement Alpha Therm Limited 2015 Part No 1 038436 ST 001941 000 0615 D352 User Instructions Alpha CD 13R 18R and 24R Wall Mounted Fan Assisted Room Sealed Gas Fired High Efficiency Condensing Regular Boiler Range British Gas Service Listed Nepicar House London Road Wrotham Heath Sevenoaks Kent TN1...

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