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Alpha CB24 Installation And Servicing Instructions

Range of wall mounted, fan assisted, room sealed, gas fired combination boilers
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Installation and Servicing

Range of Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired Combination Boilers
Instructions
Alpha CB24/28
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001 964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Alpha CB24X
Alpha CB24
Alpha CB28
Alpha CB28X
For use with Natural Gas only
Leave these instructions with the User
Service Listed
G.C. No. 47 532 14
G.C. No. 47 532 15
G.C. No. 47 532 16
G.C. No. 47 532 17

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  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha CB24/28 Range of Wall Mounted, Fan Assisted, Room Sealed, Gas Fired Combination Boilers For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001 964 Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS...

  • Page 2: Table Of Contents

    The maximum output available for domestic hot water is 23.3 kW (79 500 Btu/h), capable of providing 9.5 litres/min with a temperature rise of 35°C for the Alpha CB24 boilers, and 28.0 kW (95 500 Btu/h), capable of providing 11.4 litres/min with a temperature rise of 35°C for the Alpha CB28 boilers.

  • Page 3: Technical Data

    100 mm Dia. Flue - Outer Duct White Flue Terminal Protruding 145 mm Flue - Inner Duct Aluminium Hole Size Required For Flue Assy. 110 mm Dia. Lift Weight 24/24X 41 kg 28/28X 42 kg Alpha CB24/28 - 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 CB24/28 - Technical Data...

  • Page 5: Boiler Schematic

    Room sealed chamber Gas service cock Mains inlet on/off valve Air pressure switch On/off valve (2 off) Flue hood Automatic by-pass (N/A to 24X/28X) Overheat thermostat Cyclone separator (N/A to 24X/28X) Expansion vessel Fig. 2 Alpha CB24/28 - Technical Data...

  • Page 6: General Boiler Information

    GENERAL BOILER INFORMATION GAS SUPPLY The Alpha CB24 and CB24X boilers require a gas rate of 2.71 m³/h (95.7 ft³/h) and the Alpha CB28 and CB28X a gas rate of 3.25 m³/h (114.8 ft³/h). The meter and supply pipes must be capable of delivering this quantity of gas in addition to the demand from any other appliances in the house.
  • Page 7 L = B + E + F + 185 mm + (90° bend = 1 metre) L = B + C + 185 mm + (2 x 45° bends = 1 metre) VERTICAL FLUE OPTIONS Fig. 3 Alpha CB24/28 - General Boiler Information...
  • Page 8 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 CB24/28 - General Boiler Information...
  • Page 9 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 10: Installation

    Note: The boiler can be stood in an upright position supported by the bottom tray, (to allow this, the union bends have been turned upwards so that they do not protrude beneath the bottom tray - check this before standing the boiler on the bottom tray). CLEARANCES REQUIRED - Fig. 8 Fig. 8 Alpha CB24/28 - General Boiler Information/Installation...
  • Page 11 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 CB24/28 - Installation...
  • Page 12 Alpha CB24 and CB28 Note: Disconnect the filling loop after Filling loop filling the central heating system. A - Heating flow (22 mm) Seasonality valve B - Hot water outlet (15 mm) C - Gas inlet (22 mm) D - Cold water mains inlet (15 mm)
  • Page 13 Fit the flue assembly as described in the previous section. Due to the size of the flue clamps the flue must be fitted from inside the building. 10. It may be necessary to support the flue with suitable brackets (every metre) when flue lengths approaching the maximum are used. Fig. 12 - Rear flue Alpha CB24/28 - Installation...
  • Page 14 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. Alpha CB24/28 - Installation...

  • Page 15: Commissioning

    Refer to sections 3.7 and 3.8. System volume and Filling the system. Open the mains water inlet valve (see Fig. 11). Turn on all hot water taps and allow water to flow until no air is present. Turn off taps. BOILER CONTROLS - Fig. 16 Fig. 16 Alpha CB24/28 - Commissioning...
  • Page 16 Raise the control panel and secure in position with the screws provided. If the boiler is to be left in service with the User, set the controls, clock (if fitted, see User's Operating manual) and room thermostat (if fitted) to the User's requirements. Alpha CB24/28 - Commissioning...

  • Page 17: Boiler Operation

    In both modes the fan operates at full speed before the burner lights, remaining at that speed until the demand is satisfied. When the burner is turned off, the fan will continue to run for 20 seconds and the pump will stop immediately if the selector is set for hot water only. Alpha CB24/28 - Commissioning/Boiler Operation...

  • Page 18: Routine Servicing

    2. The expansion vessel pressure test point is accessible from the top and rear of the boiler. Record details of the service in the Service History section on page 34 of this manual and in the Benchmark Log Book. Alpha CB24/28 - Boiler Operation/Routine Servicing...
  • Page 19 Place the front case panel in position as shown in Fig. 18 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 CB24/28 - Routine Servicing...

  • Page 20: Component Replacement

    Fit the new electrode, ensuring both are positioned correctly and the spark gap is correct (see Fig. 19). Re-assemble Replace the burner, ensuring it is located correctly. Replace the combustion chamber front cover, ensuring it is correctly located. Complete re-assembly as described in Routine Servicing, section 7.4 paragraphs 4 to 9. Alpha CB24/28 - Component Replacement...
  • Page 21 Gain access to the combustion chamber as in section 8.1. Disconnect the wiring from the overheat thermostat. Remove the two fixing screws and remove the overheat thermostat from the heat exchanger. Fit the new overheat thermostat and re-assemble in reverse order. Alpha CB24/28 - Component Replacement...
  • Page 22 Gain access behind the casing as in section 8.1. Remove the rubber window frame and remove the damaged glass. Re-assemble in reverse order with a new glass. Ensure the rubber frame is located correctly in the front panel. Alpha CB24/28 - Component Replacement...
  • Page 23 Fit the flow and return pipes to the new heat exchanger, ensuring the new 'O' rings are in position in the flanges. Lubricating the 'O' rings with a soap solution will aid assembly. Ensure the heat exchanger is correctly located. Re-assemble in reverse order. 10. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha CB24/28 - Component Replacement...
  • Page 24 Connect the wiring to the new head as follows:- Brown to L, Blue to N, Green/yellow to Ensure the pump is set to maximum (3) and re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha CB24/28 - Component Replacement...
  • Page 25 Note: Be careful not to allow water to drip onto any electrical components. Using the new washers supplied, re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Fig. 26 Alpha CB24/28 - Component Replacement...
  • Page 26 Gain access behind the casing and drain the boiler heating circuit as described in sections 8.1 and 8.2. Disconnect the unions from the cyclone and re-assemble with a new cyclone. Pressurise the system. (Refer to Commissioning, section 5.1). Alpha CB24/28 - Component Replacement...

  • Page 27: Wiring Diagrams

    WIRING DIAGRAMS ILLUSTRATED WIRING DIAGRAM Alpha CB24/28 - Wiring Diagrams...
  • Page 28 FUNCTIONAL FLOW WIRING DIAGRAM Alpha CB24/28 - Wiring Diagrams...

  • Page 29: Fault Finding

    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 ensure the gas and electrical supplies are isolated. 10.2 CENTRAL HEATING - Follow operational sequence Alpha CB24/28 - Fault Finding...
  • Page 30 10.3 DOMESTIC HOT WATER - Follow operational sequence Alpha CB24/28 - Fault Finding...
  • Page 31 10.4 FAULT FINDING SOLUTIONS A to F Alpha CB24/28 - Fault Finding...
  • Page 32 10.5 FAULT FINDING SOLUTION SECTIONS G to L Alpha CB24/28 - Fault Finding...

  • Page 33: Short Parts List

    3.013213 Fig. 27 Diverter valve assembly E57-773 3.012752 Fig. 2, item 27 By-pass assembly 3.012801 E65-498 Combustion chamber insulation panel set (CB24, CB24X) 3.013838 E74-960 Combustion chamber insulation panel set (CB28, CB28X) 3.013839 E74-961 Alpha CB24/28 - Short Parts List...

  • Page 34: Service History

    DETAILS OF BOILER SERVICE HISTORY Date of Service Details of Service Service Engineer .................................................................................................................................................................................................................................................................................................................................................................... Alpha CB24/28 - Service History...
  • Page 35 Alpha CB24/28...
  • Page 36 These instructions have been carefully prepared but we reserve the right to Sevenoaks, Kent TN15 7RS alter the specification at any time in the interest of product improvement. Tel: 0870 3001964 © Alpha Therm Limited 2003. email: info@alphatherm.co.uk website: www.alpha-innovation.co.uk Part No. 1.017292...

This manual is also suitable for:

Cb28Cb24xCb28x

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