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Alpha CD24C Installation And Servicing Instructions

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

Alpha CD24C/32C
Range of Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing Combination Boilers
Instructions
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Alpha CD24C
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. 47 532 21

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Summary of Contents for Alpha Alpha CD24C

  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha CD24C/32C Range of Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing Combination Boilers For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001964 Nepicar House, London Road, Wrotham Heath, Sevenoaks,...

  • 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

    130 W Main Burner Injector CD24 5.0 mm CD32 140 W CD32 6.6 mm Internal Fuse F2 A Flue - Outer Duct White Electrode Spark Gap 3 - 4 mm Flue - Inner Duct Plastic Alpha CD24C/32C - Technical Data...
  • Page 4 Note: For outputs upto 28 kW refer to Section 3.7. ELECTRICAL CONNECTIONS Note: This Appliance Must Be Earthed An optional integral single channel Clock kit is available if required. Note: Only use the Alpha single channel clock. Do not fit any two channel clocks. Brown Blue Used...

  • Page 5: Boiler Schematic

    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 CD24C/32C - Technical Data...

  • Page 6: 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 7 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 CD24C/32C - General Boiler Information...
  • Page 8 However, If the terminal is fitted less than 2.1 m above a surface where there is no public access, the terminal must be protected by a terminal guard. A suitable guard is available from Alpha Therm Ltd. BOILER LOCATION The boiler is not suitable for external installation unless it is installed within a purpose designed weatherproof building.
  • Page 9 Heating circuit water Feed cistern to be Stop return Stop supply located above highest valve valve Stop point in the system Test cock valve Test cock Filling loop temporarily connected Fig. 6 Fig. 7 Alpha CD24C/32C - General Boiler Information...
  • Page 10 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 condensing heat exchanger is constructed in stainless steel and therefore is compatible with most materials used in a heating system.
  • Page 11 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 CD24C/32C - General Boiler Information...

  • Page 12: 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 CD24C/32C - Installation...
  • Page 13 E - Heating return (22 mm) F - Pressure relief valve (15 mm) Condensate trap G - Heating drain point H - Cold water inlet filter I - Condensate discharge pipe J - Cyclone drain point 47.5 47.5 Fig. 13 Alpha CD24C/32C - Installation...
  • Page 14 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 15 (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 750/1000 mm flue extensions required.
  • Page 16 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 CD24C/32C - Installation...
  • Page 17 FIT THE CLOCK KIT - Fig. 21 Ensure the electrical supply to the boiler is isolated. Important: Only use an Alpha single channel clock. Do not fit a two channel clock. Remove the two screws securing the clock cover at the rear of the control panel.

  • Page 18: Commissioning

    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. Ensure that the condensate trap has been filled with water. Refer to Section 4.5, paragraph 4. BOILER CONTROLS - Fig. 22 Fig. 22 Alpha CD24C/32C - Commissioning...
  • Page 19 Turn off the boiler. Disconnect the pressure gauge and tighten the test point screws. Test for gas soundness using suitable leak detection fluid. Note: Refer to Technical Data, Section 2.1 for the required differential burner pressures. Differential Burner pressure Fig. 24 Alpha CD24C/32C - Commissioning...
  • Page 20 11. Ensure the Benchmark Checklist in Section 12 on page 38 has been completed after the boiler has been installed and commissioned. 12. Leave these Installation and Servicing instructions with the User for use on future calls. Alpha CD24C/32C - Commissioning...

  • Page 21: Boiler Operation

    A and B Flashing on and off alternatively - System pressure is very low and re-pressurisation is required. A Flashing and B Illuminated continuously - Pump fault or restricted flow. Note: Do not hold the selector switch in the reset position (3) for more than 2 to 3 seconds. Alpha CD24C/32C - Boiler Operation...

  • Page 22: 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 CD24C/32C - Routine Servicing...
  • Page 23 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 CD24C/32C - Routine Servicing...

  • Page 24: 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 CD24C/32C - Component Replacement...
  • Page 25 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 CD24C/32C - Component Replacement...
  • Page 26 Re-assemble in reverse order with a new switch. Ensure that the switch is located correctly. 8.16 CLOCK (if fitted) - Refer to Fig. 21 Note: For replacement only use an Alpha single channel clock. Do not fit a two channel clock. Gain access behind the control panel as described in Section 8.1.
  • Page 27 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 CD24C/32C - Component Replacement...
  • Page 28 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 CD24C/32C - Component Replacement...
  • Page 29 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 CD24C/32C - Component Replacement...
  • Page 30 Note: 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 CD24C/32C - Component Replacement...

  • Page 31: 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 CD24C/32C - Wiring Diagrams...
  • Page 32 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 CD24C/32C - Wiring Diagrams...

  • Page 33: 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 CD24C/32C - Fault Finding...
  • Page 34 10.3 DOMESTIC HOT WATER- Follow operational sequence Alpha CD24C/32C - Fault Finding...
  • Page 35 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 CD24C/32C - Fault Finding...
  • Page 36 Replace PCB PCB - X8 connector, 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 CD24C/32C - Fault Finding...

  • Page 37: Short Parts List

    E96-572 Fig. 31 and 35 Diverter valve assembly 3.012752 E57-773 Fig. 2, item 27 By-pass assembly 3.012801 E65-498 Fig. 27 Combustion chamber insulation panel front 1.014732 E94-420 Fig. 2, item 29 Condensate trap 1.018192 Alpha CD24C/32C - Short Parts List...

  • Page 38: Benchmark Checklist

    The operation of the appliance and system controls have been demonstrated to the customer The manufacturer's literature has been left with the customer COMMISSIONING ENG'S NAME: Print ..............CORGI ID No........... Sign ..............Date ..............Alpha CD24C/32C - Benchmark Checklist...

  • Page 39: 13 Service Record

    Engineers Name ................. Company Name ................Company Name ................Telephone No................Telephone No................CORGI ID card serial No............CORGI ID card serial No............Comments ................... Comments ..........................................................Signature ..................Signature ..................Alpha CD24C/32C - Service Record...
  • Page 40 These instructions have been carefully prepared but we reserve the right to Nepicar House, London Road, Wrotham Heath, alter the specification at any time in the interest of product improvement. Sevenoaks, Kent TN15 7RS © Alpha Therm Limited 2005. Tel: 0870 3001964 email: info@alphatherm.co.uk website: www.alpha-boilers.com Part No.

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Cd32c

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