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Alpha CD24 Installation And Servicing Instructions

Range of wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing boilers
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Installation and Servicing
Range of Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing Boilers
Instructions
Alpha CD24/32
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: (01322) 669443
Goldsel Road,
Swanley, Kent BR8 8EX
Fax: (01322) 615017
*HEJEID/=I
Alpha CD24C
Alpha CD24S
Alpha CD32C
For use with Natural Gas only
Leave these instructions with the User
Service Listed
G.C. No. 47 532 19
G.C. No. 41 532 02
G.C. No. 47 532 21

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Summary of Contents for Alpha CD24

  • Page 1 Installation and Servicing Instructions Alpha CD24/32 Range of Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing Boilers For Technical help or for Service call ... ALPHA HELPLINE Tel: (01322) 669443 Goldsel Road, Swanley, Kent BR8 8EX Fax: (01322) 615017...

  • Page 2: Table Of Contents

    The maximum output available for domestic hot water is 24.2 kW (82 600 Btu/h), capable of providing 9.6 litres/min with a temperature rise of 35°C for the Alpha CD24C boiler and for the Alpha CD32C boiler - 32 kW (109 200 Btu/h), providing 13.2 litres/min with a temperature rise of 35°C.

  • Page 3: Technical Data

    Flue - Outer Duct White Flue Terminal Protruding 100 mm Flue - Inner Duct Plastic Hole Size Required For Flue Assy. 110 mm Dia. Lift Weight CD24C 49 kg CD24S 46 kg CD32C 51 kg Alpha CD24/32 - Technical Data...
  • Page 4 Blue Used Wire Wire Wire Wire Internal Clock Terminals WARNING 1. Ensure wires are connected correctly 2. Only fit the Alpha recommended clock. Other clocks could cause damage. Clock connections Boiler terminal block Fig. 1 Alpha CD24/32 - Technical Data...
  • Page 5 Cyclone separator Venturi Drain point Condensate trap Main burner Pressure relief valve Primary/condensing heat exchanger Primary pressure switch Room sealed chamber Ignition electrodes Flame sensing electrode Pressure differential test points Venturi negative point Fig. 2A Alpha CD24/32 - Technical Data...
  • Page 6 32 - Venturi negative point 10 - Fan 22 - DHW temperature sensor 33 - Venturi positive point 11 - Pressure differential test points 23 - Flue sampling point 34 - Flue thermostat 12 - Flue hood Fig. 2B Alpha CD24/32 - Technical Data...

  • Page 7: General Boiler Information

    2. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally and only 15 metres vertically. 3. Failure to use Alpha CD flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe.
  • Page 8 L = B + E + F + 230 mm + (90° bend = 1.3 metre) L = B + C + 230 mm + (2 x 45° bends = 1.8 metre) VERTICAL FLUE OPTIONS Fig. 3 Alpha CD24/32 - General Boiler Information...
  • Page 9 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 CD24/32 - General Boiler Information...
  • Page 10 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.
  • Page 11 FLUSHING THE HEATING SYSTEM It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha CD boiler. Failure to do so will invalidate the warranty. The primary and condensing heat exchanger is constructed in stainless steel and therefore is compatible with most materials used in a heating system.
  • Page 12 A supply of direct mains fed hot and cold water is permitted provided the appliance is of the over- rim flushing type. Before the mains water supply pipe is connected to the boiler, it should be thoroughly flushed out to avoid the danger of dirt or foreign matter entering the boiler. Alpha CD24/32 - General Boiler Information...

  • Page 13: Installation

    Using the screws supplied, fit the mounting bracket. Top pipe connections - Preform the pipework at the back of the boiler before hanging the boiler, see Fig. 12, and secure in the clips provided. Alpha CD24/32 - Installation...
  • Page 14 Pour at least 0.5 litre of water into the flue duct, as shown in Fig. 12, and check the condensate discharge pipe for soundness. Ensure that all the valves are closed (spindle flats at right angles to valve) and do not turn on the water or gas supplies at this stage. Alpha CD24/32 - Installation...
  • Page 15 FIT THE FLUE - Figs. 14, 15 The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only. The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below.
  • Page 16 Note: Check the flue terminal protrudes 100 mm out of the wall and the inner duct of the terminal is positioned correctly (see Fig. 18). Make good the inside wall by pushing the inside flue sealing collar upto the wall. Alpha CD24/32 - Installation...
  • Page 17 (use a 127 mm core drill). The size of the hole provides sufficient clearance for the clamps on the flue extension to pass through the hole. Determine the overall flue length as described in section 4.6, paragraph 2 to determine the number of Alpha CD 750 mm flue extensions required.
  • Page 18 The main terminal block can be removed by pulling it Fig. 20 off the pins to give easy access to the terminals. Do not switch on the electrical supply at this stage. Alpha CD24/32 - Installation...
  • Page 19 Blue wire to terminal 1, Brown wire to terminal 2 and Red wires to terminals 3 and 4, (or as per the instructions supplied with the clock). Ensure wiring is correct. Replace the clock cover. Do not overtighten the fixing screws. Leave the control panel open until commissioning procedures have been completed. Fig. 21 Alpha CD24/32 - Installation...

  • Page 20: Commissioning

    Selector Switch Pressure Gauge Heating Thermostat Indicator Domestic Clock (if fitted) Neons Hot Water Thermostat RESET SELECTOR THERMOSTAT THERMOSTAT Fig. 22 - Alpha CD24C and CD32C System Central Selector Switch Pressure Gauge Heating Thermostat Indicator Frost Neons Thermostat position FROST RESET...
  • Page 21 The burner will light at the ignition rate and will increase to the factory pre-set maximum output after 1 minute. Turn off the boiler. Disconnect the pressure gauge and tighten the test point screw. Test for gas soundness using suitable leak detection fluid. Note: Refer to Technical Data, section 2.1 for burner pressure settings. Alpha CD24/32 - Commissioning...
  • Page 22 Show the User the position of the pressure relief valve and condensate discharge pipes. 10. Hand the User's instructions and the Benchmark Log Book to the User. 11. Leave these Installation and Servicing instructions with the User for use on future calls. Alpha CD24/32 - Commissioning...

  • Page 23: Boiler Operation

    A and B Flashing on and off at the same time - Blocked flue or fan fault. A and B Flashing on and off alternatively - System pressure is very low and re-pressurisation is required. Alpha CD24/32 - Boiler Operation...

  • Page 24: Routine Servicing

    Combustion chamber front assembly Six nuts and washers Gas pipe securing combustion union chamber front assembly Viewing window Room sealed panel fixing screws Pressure tube connections assembly Fan assembly fixing screws Ignition generator Fig. 26 Alpha CD24/32 - Routine Servicing...
  • Page 25 Place the front case panel in position as shown in Fig. 26 and secure in position. Raise the control panel and secure in position with the two screws provided. Check the operation of the boiler. (Refer to Boiler Operation, section 6). Return all controls to their original settings. Alpha CD24/32 - Routine Servicing...

  • Page 26: Component Replacement

    Gain access behind the room sealed chamber panel as described in section 8.1. Undo the gas inlet union to the combustion chamber front to gain access. Unscrew the damaged injector and screw in a replacement. Re-assemble in reverse order. Alpha CD24/32 - Component Replacement...
  • Page 27 Light the boiler and test for gas soundness. (Refer to Commissioning, section 5.4) and the instructions supplied with the replacement valve for adjustment of the valve. Fig. 29 10. Complete re-assembly as described in Routine Servicing, section 7.4 paragraphs 5 to 9. Alpha CD24/32 - Component Replacement...
  • Page 28 Blue to terminal 1, Brown to terminal 2 and Red wires to terminals 3 and 4, (or as per the instructions supplied with the clock). Re-assemble in reverse order. Refer to the User's instructions and the boiler's control cover to set the clock. Alpha CD24/32 - Component Replacement...
  • Page 29 Fit the new gauge using a new washer on the manifold connection if necessary. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Automatic air vent Pump Primary pressure switch Pressure relief valve Pressure gauge Fig. 33 Alpha CD24/32 - Component Replacement...
  • Page 30 Remove the four screws securing the bottom tray and remove the tray. Disconnect the pressure relief valve outlet fitting. Release the screw retaining the pressure relief valve and pull out the valve. Re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha CD24/32 - Component Replacement...
  • Page 31 When replacing the vessel, ensure that the connection is towards the front of the boiler and re-assemble in reverse order using new seals as necessary. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha CD24/32 - Component Replacement...
  • Page 32 Note: CD24C and CD32C - If access is difficult, remove the DHW heat exchanger as described in section 8.25. Lift the trap out and re-assemble with a new condensate trap. Note: Before fitting the new trap, pour 100 cc of water into the trap. Alpha CD24/32 - Component Replacement...

  • Page 33: Wiring Diagrams

    REMOVE LINK FROM TERMINALS 1 & 2 - Green AND CONNECT 230/240 V SWITCHED LIVE TO G/Y - Green/Yellow TERMINAL1. - White Gy - Grey A FROST THERMOSTAT IS INCORPORATED Pk - Pink WITHIN THE MAIN PCB - Purple Alpha CD24/32 - Wiring Diagrams...
  • Page 34 REMOVE LINK FROM TERMINALS 1 & 2 - Green AND CONNECT 230/240 V SWITCHED LIVE TO G/Y - Green/Yellow TERMINAL1. - White Gy - Grey A FROST THERMOSTAT IS INCORPORATED Pk - Pink WITHIN THE MAIN PCB - Purple Alpha CD24/32 - Wiring Diagrams...
  • Page 35 Temperature Sensor Primary Temperature Sensor DHW Switch Primary Pressure Switch Transformer Note: Main Terminal Block TO CONNECT EXTERNAL CONTROL REMOVE LINK FROM TERMINALS 1 AND 2 AND CONNECT 240 V SWITCHED LIVE TO TERMINAL 1. Alpha CD24/32 - Wiring Diagrams...
  • Page 36 Red LED MAX CAP Pump Primary Temperature Sensor Primary Pressure Switch Transformer Note: Main Terminal Block TO CONNECT EXTERNAL CONTROL REMOVE LINK FROM TERMINALS 1 AND 2 AND CONNECT 240 V SWITCHED LIVE TO TERMINAL 1. Alpha CD24/32 - Wiring Diagrams...

  • Page 37: Fault Finding

    Check gas valve adjustment Go to section ' ', page 37 set temperature is reached Pump continues to run until temperature Burner goes out Fan stops after 50 seconds reduces to set temperature Operation sequence successful Alpha CD24/32 - Fault Finding...
  • Page 38 DHW flow valve senses no flow. Primary water diverted Diverter valve/DHW switch fault to CH system. DHW flow switch released (off) Burner goes out Pump stops Fan stops after 50 seconds Operation sequence successful Alpha CD24/32 - Fault Finding...
  • Page 39 Replace PCB Check pressure tubes are connected Ensure gas is on and purged Gas at burner PCB - X7 connector, Adjust gas valve Replace gas valve is 240 V across terminals 26, 27 Replace PCB Alpha CD24/32 - Fault Finding...
  • Page 40 PCB - X8 connector, Replace PCB switch at inline connector terminals 46, 47 Diverter valve Replace DHW switch spindle operating DHW flow valve Replace diaphragm diaphragm damaged Diverter valve Replace diverter valve spindle assy. fault Alpha CD24/32 - Fault Finding...

  • Page 41: Short Parts List

    Ignition electrode and lead 3.013626 E94-417 Fig. 28 Ignition electrode 1.016779 E94-418 Fig. 28 Flame sensing electrode and lead - CD24 1.018163 E94-419 Fig. 28 Flame sensing electrode and lead - CD32 1.019293 E96-572 Fig. 31 and 35 Diverter valve assembly - CD24C/CD32C 3.012752...

  • Page 42: Service History

    DETAILS OF BOILER SERVICE HISTORY Date of Service Details of Service Service Engineer .................................................................................................................................................................................................................................................................................................................................................................... Alpha CD24/32 - Service History...
  • Page 44 These instructions have been carefully prepared but we reserve the right to Goldsel Road, Swanley, Kent BR8 8EX alter the specification at any time in the interest of product improvement. © Alpha Therm Limited 2003. Tel: (01322) 669443 Fax: (01322) 615017 email: info@alphatherm.co.uk...

This manual is also suitable for:

Cd32

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