Installation and Servicing Instructions: Alpha CD24C/32C

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, Kent TN15 7RS
*HEJEID/=I
Service Listed
Alpha CD24C Alpha CD32C
G.C. No. 47 532 19 G.C. No. 47 532 21
For use with Natural Gas only
Leave these instructions with the User
CONTENTS
1 2 3 4 5 6 7 Introduction ....................................... 2 Technical data ................................... 3 General boiler information .................. 6 Installation ......................................... 12 Commissioning ................................. 18 Boiler operation ................................. 21 Routine servicing ............................... 22 8 9 10 11 12 13 Component replacement ................... 24 Wiring diagrams ................................ 31 Fault finding ...................................... 33 Short parts list ................................... 37 Benchmark Checklist ......................... 38 Service record ................................... 39
INTRODUCTION
The Alpha CD range of high efficiency condensing boilers are wall mounted, fan assisted room-sealed combination boilers. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve. The CD24C and CD32C are combination boilers providing both central heating and domestic hot water at mains pressure. The boilers are supplied with a pump, pressure relief valve, expansion vessel and pressure gauge fully assembled and tested. They are designed for use with a fully pumped, sealed and pressurised central heating system using only Natural gas. The CD24C is suitable for central heating loads of between 4.7 and 25.4 kW (16 018 and 86 700 Btu/h). The CD32C boiler is suitable for central heating loads of between 6.5 and 29.8 kw (22 200 and 101 700 Btu/h). 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 35C 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 35C. 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 (Installation and Use) Regulations All current Building Regulations issued by the Department of the Environment, i.e. Approved Document L1. Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department UK Water Regulations/Byelaws (Scotland) Health & Safety Document No. 635 (The Electricity At Work Regulations 1989) The installation should also be in accordance with the following British Standard Codes of Practice:BS 5440:1:2000 BS 5449:1990 BS 5546:2000 BS 6700:1997 BS 6798:2000 BS 6891:1998 BS 7593:1992 BS 7671:2001 Flues Forced circulation hot water systems Installation of hot water supplies for domestic purposes Design, installation, testing and maintenance of services supplying water Installation of gas fired hot water boilers Gas installation Code of Practice for treatment of water in heating systems Requirements for electrical installations, IEE Wiring Regulations
Reference 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, ie degree of protection against moisture. Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety to ensure that the law is complied with. Manufacturer's instructions must NOT be taken in anyway as over-riding statutory obligations. Notes: 1. Ensure that the Benchmark Log Book has been completed after the boiler has been installed and commissioned. 2. The boiler must only be used with Alpha CD condensing flue components.
Alpha CD24C/32C - Contents/Introduction
TECHNICAL DATA
2.1 PERFORMANCE - NATURAL GAS (CAT: I2H 2H - G20 - 20 mbar) Alpha CD24C Alpha CD24C
Central Heating Heat Input (Hs) (Gross) Heat Input (Hi) (Net) Heat Output (Hs condensing) (50C/30C) kW Btu/h kW Btu/h kW Btu/h MAX. 26.4 90 100 24.0 82 000 25.4 86 700 23.5 81 135 5.78 2.30 2.54 89.7 MIN. 5.5 18 800 5.0 17 100 5.3 18 100 4.7 16 018 0.35 0.14 0.53 18.7 Domestic Hot Water Heat Input (Hs) (Gross) Heat Input (Hi) (Net) Output to Water (Hs) (modulating) Differential Burner Pressure Gas Rate Flow Rate at 35C Rise
Room sealed chamber panel fitted
MAX. kW Btu/h kW Btu/h kW Btu/h mbar in wg m/h ft/h L/min gal/min

gal/min
MIN. 5.5 18 800 5.0 17 100 4.97 17 000 0.35 0.14 0.53 18.7 9.6
26.4 90 100 24.0 82 000 24.20 82 600 5.78 2.3 2.54 89.7
Heat Output (Hi non-condensing) kW (80C/60C) Btu/h Differential Burner Pressure Gas Rate
mbar in wg m/h ft/h
Specific Flow Rate (D) at 30C Rise L/min
2.2 11.2 2.5
Alpha CD32C
Central Heating Heat Input (Hs) (Gross) Heat Input (Hi) (Net) Heat Output (Hs condensing) (50C/30C) kW Btu/h kW Btu/h kW Btu/h MAX. MIN. 31.1 7.3 106 100 24 900 28.0 95 550 6.6 22 500
(Flow rate @ 30K to EN625)
Alpha CD32C
Domestic Hot Water Heat Input (Hs) (Gross) Heat Input (Hi) (Net) Output to Water (Hs) (modulating) Differential Burner Pressure Gas Rate Flow Rate at 35C Rise
kW Btu/h kW Btu/h kW Btu/h mbar in wg m/h ft/h L/min gal/min
MAX. 36.2
MIN. 7.3
123 500 24 900 32.6 6.6 111 300 22 500 32.0 6.6 109 200 22 500 4.27 0.39 1.71 0.16 3.45 121.8 13.2 2.9 15.4 3.9 0.69 24.4
29.8 7.0 101 700 23 900 28.0 95 500 3.33 1.33 2.98 105.2 6.5 22 200 0.39 0.16 0.69 24.4
Heat Output (Hi non-condensing) kW (80C/60C) Btu/h Differential Burner Pressure Gas Rate
mbar in wg m/h ft/h
2.2 SYSTEM Alpha CD24C

Central Heating (Sealed System) Max. Working System Pressure Min. System Pressure Max. System temperature Pressure Relief Valve Setting 2.5 bar 0.5 bar 82C 3 bar (44 PSI)
Specific Flow Rate (D) at 30C Rise L/min (Flow rate @ 30K to EN625) gal/min
Alpha CD24C and CD32C

Domestic Hot Water Max. Mains Inlet Water Pressure Min. Mains Water Pressure Min. DHW Flow Rate Mains Inlet Connection DHW Outlet Connection DHW Water Content CD24C 8 bar 0.2 bar 2.5 l/min 15 mm 15 mm 0.2 L
Expansion Vessel Size (pre-charge press.) 8 L at 0.8 bar Flow Connection 22 mm Return Connection Relief Valve Connection Recommended System Pressure (cold) CH Water Temp. (Approx. max.) 22 mm 15 mm 1.0 bar 82C (180F)
CD32C 0.3 L Outlet Water Temp. (Approx. max.) 62C (144F)
2.3
COMPONENTS
Stainless steel Stainless steel CD24 CD32 Stainless Steel 5.0 mm 6.6 mm White Plastic
2.4
ELECTRICAL
230/240 V ~ 50 Hz 3A CD24 CD32 130 W 140 W F2 A 3 - 4 mm
Burner Main Heat exchanger DHW Heat Exchanger Main Burner Injector Flue - Outer Duct Flue - Inner Duct
Supply External Fuse Power Consumption Internal Fuse Electrode Spark Gap
Alpha CD24C/32C - Technical Data
2.5
INSTALLATION
Top Bottom Sides Front 220 mm 250 mm 5 mm 450 mm 100 mm Dia. 100 mm 110 mm Dia. 49 kg 51 kg
2.6
GENERAL
Height Width Depth (CD24) Depth (CD32) 850 mm 450 mm 345 mm 380 mm 22 mm 2.5 L 3.0 L 100 mm 60 mm
Min. Clearances for Servicing (from casing)
Case Dimensions
Flue Terminal Size Flue Terminal Protruding Hole Size Required For Flue Assy. Lift Weight CD24C CD32C
Gas Connection Primary Water Content Air Duct Diameter Flue Duct Diameter CD24 CD32
2.7
FLUE LENGTHS
CD Easy-Flue 500 mm with terminal and 90 bend. A CD Easy-Flue 1000 mm with terminal and 90 bend is also available. CD 750 mm and 1000 mm flue extensions are available. Length of Flue Required:Rear Flue = wall thickness + 170 mm (includes terminal) Side Flue = wall thickness + distance between wall and side of boiler + 230 mm (includes terminal) Vertical Flue = distance from top of boiler side panel to required roof position minus 1 m for vertical terminal assembly Maximum horizontal 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 Vertical Flue terminal assembly is equivalent to 1 m of flue length.
2.8
kW
AVAILABLE PUMP HEAD FOR CENTRAL HEATING

Flow rate 20C feet 7.6 11.6 12.6 13.2 15.2 litre/min 16.6 12.6 10.5 8.3 3.2 gal/min 3.7 2.8 2.3 1.8 0.7 Btu/h metres 20C
Output (50/30C) Available pump head
25.40 18.70 15.60 12.35 5.30
86 700 64 000 53 000 42 200 18 100
2.3 3.5 3.8 4.0 4.6
This information is based on 20C system design temperature difference. Note: For outputs upto 28 kW refer to Section 3.7.
2.9
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.
Not Used
Red Wire
Red Brown Blue Wire Wire Wire
4 3 2 1 Internal Clock Terminals
WARNING
1. Ensure wires are connected correctly 2. Only fit the Alpha recommended clock. Other clocks could cause damage.
Clock connections
Fig. 1
Boiler terminal block
2.10 BOILER SCHEMATIC
1 - Flow regulator 2 - DHW flow switch 3 - Diverter valve and DHW flow valve 4 - Gas valve 5 - Primary temperature sensor 6 - DHW heat exchanger 7 - Main burner 8 - Primary/condensing heat exchanger 9 - Room sealed chamber 10 - Fan 11 - Pressure differential test points 12 - Flue hood
13 - Overheat thermostat 14 - Expansion vessel 15 - Automatic air vent 16 - Pump 17 - Drain point 18 - Pressure relief valve 19 - Primary pressure switch 20 - Ignition electrodes 21 - Flame sensing electrode 22 - DHW temperature sensor 23 - Flue sampling point
24 - Gas service cock 25 - Mains inlet on/off valve 26 - On/off valve (2 off) 27 - Automatic by-pass 28 - Cyclone separator 29 - Condensate trap 30 - Injector 31 - Venturi 32 - Venturi negative point 33 - Venturi positive point 34 - Flue thermostat
Fig. 2B
3
3.1
GENERAL BOILER INFORMATION

GAS SUPPLY
The Alpha CD24C boiler requires a gas rate of 2.54 m/h (89.7 ft/h). The Alpha CD32C boiler requires a gas rate of 3.45 m/h (121.8 ft/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. The boiler requires at least a 22 mm gas supply pipe. The complete installation, including the meter, must be tested for gas soundness and purged as described in BS 6891.
3.2
ELECTRICAL SUPPLY
The boiler requires a 230/240 V ~ 50 Hz mains supply, fused at 3 A The boiler must be earthed. There must only be one common isolator, providing complete electrical isolation, for the boiler and any external controls. This boiler has been fitted with a supply cable, however, if it is necessary to fit a cable use PVC insulated cable not less than 0.75 mm (24 x 0.2 mm) to BS 6500 Table 16. The boiler should be connected to a fused three pin plug and unswitched shuttered socket outlet (both complying with BS 1363), or a fused double pole switch with a contact separation of at least 3 mm in both poles. Wiring external to the boiler must be in accordance with the current IEE Wiring Regulations (BS 7671). Note: If a room thermostat is fitted, it must be suitable for 230/240 V switching.
3.3
AIR SUPPLY
The boiler does not require any air vents for cooling in the room in which it is installed or when installed in a cupboard or compartment. The minimum clearances for servicing must always be maintained. 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 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 bend and terminal) - Part No. 6.2000500. CD Easy-Flue 1000 mm (includes 90 bend and terminal) - Part No. 6.2001000. CD 750 mm flue extension - Part No. 6.2000750. CD 1000 mm flue extension - Part No. 6.2001050 CD 90 bend - Part No. 6.2000590. CD 45 bend - Part No. 6.2000545. CD Vertical flue terminal assembly. Refer to the separate installation instructions supplied with the assembly. The following methods determine the correct length of flue required. For rear exit flue (including terminal) L = B + 170 mm For side exit flue (including terminal) L = B + C + 230 mm (min. side clearance required is 5 mm) For vertical flue L = H minus 1000 mm for vertical terminal assembly Where L = Required flue length B = Finished wall thickness C = Distance from the inside wall to the side of the boiler H = Distance from top of boiler side panel to roof position Note: 1. If an extra 90 bend is used, this reduces the maximum flue length by 1.3 m. Each 45 bend used reduces the maximum flue length by 0.9 m. 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.
Alpha CD24C/32C - General Boiler Information
HORIZONTAL FLUE OPTIONS - Lmax = 12 metres
L = B + C + 230 mm
L = B + C + E + 230 mm
B F
E C L = B + E + F + 230 mm + (90 bend = 1.3 metre) B L = B + C + 230 mm + (2 x 45 bends = 1.8 metre)
VERTICAL FLUE OPTIONS
Fig. 3
3.5
FLUE TERMINAL LOCATION - Fig. 4
Fig. 4
Terminal position A B C D E F H I J K L Directly below an opening, air brick, windows, etc. Below gutters, soil pipes or drain pipes Below eaves Below balconies From a vertical drain pipe or soil pipe From an internal or external corner From a surface facing the terminal From a terminal facing the terminal Above an opening, air brick, window etc. Vertically from a terminal on the same wall Horizontally from a terminal on the same wall Min. distance (mm) 300 (See Note 1) 75 (See Note 3) 200 (See Note 3) 200 (See Note 3) 150 (See Note 3) 300 (See Note 2) 300 600 (See Note 4) 1200 mm 300 (See Note 1) 1500 mm 300 mm
G Above ground, roof or balcony level
M Horizontally from an opening, air brick, window etc. 300 mm (See Note 1)
Note: A terminal must not be sited under a car port roof Note: In certain weather conditions the terminal will emit a plume of steam. If possible avoid positioning the terminal where this may cause a nuisance, i.e. positions A, D, G, H, J or M. The flue terminal must be exposed to the external air and the position must allow the free passage of air across it at all times. If the terminal is fitted within 850 mm of a plastic or painted gutter or 450 mm of painted eaves, an aluminium shield at least 1 m long should be fitted to the underside of the gutter or painted surface. A terminal must not be sited below 2.1 m where people have access to, such as public footpaths, access routes, patios etc. 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.
Notes: 1. In addition, the terminal should not be nearer than 150 mm to the framework of an opening into the buiding, i.e. a window surround or door surround. 2. This clearance may be 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 should be extended beyond gutters, pipes, eaves, balconies etc. 4. To reduce the possibility of nuisance to neighbouring buildings etc. it is recommended the terminal shouild not be less than 2500 mm from car parking spaces, building boundary walls, fences etc.
3.6
BOILER LOCATION
The boiler is not suitable for external installation unless it is installed within a purpose designed weatherproof building. The boiler must be installed on a flat vertical wall which is capable of supporting the weight of the boiler. The boiler can be fitted to or adjacent to a wall comprising of a combustible material without the need for a special thermal insulation barrier. If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with the Institute of Gas Engineers 'Guide for Gas Installations in Timber Frame Housing', reference IGE/UP/7. The boiler may be installed in any room or internal 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 roomsealed boiler is installed in a room containing a bath or shower, it must not be possible for a person using the bath or shower to touch any electrical switch or boiler control utilising mains electricity. 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.
3.7
CENTRAL HEATING SYSTEM - Fig. 5
The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798. The system should be designed to operate with flow temperatures of up to 82C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. Refer to the pump performance table for guidelines. 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). Above 80 litres, consideration should be given to fitting an additional expansion vessel fitted in the position shown in Fig. 5. To check correct operation of the expansion vessel(s) the system pressure should not be more than 2.5 bar when the system is at maximum operating temperature (for further guidance refer to BS 7074:1). The boiler is supplied with the following components built in:Pressure relief valve - complying with BS 6759 and set to operate at 3 bar. The discharge pipe must be routed clear of the boiler and terminated in such a manner that it can be seen, but cannot cause injury to persons or property. Pressure gauge - To indicate the system pressure to be maintained. Expansion vessel - Conforming to BS 4814 with a capacity of 8 litres and pre-charged to a pressure of 0.8 bar. By-pass - The boiler incorporates a by-pass, however where all radiators are fitted with thermostatic radiator valves it is recommended a system by-pass, preferably automatic is fitted. Cyclone - This is a device fitted in the heating return within the boiler to remove any foreign or solid matter etc. from the system.
Make up vessel
Static head of system

Automatic air vent
Boiler casing
Additional expansion vessel (if required) Double check valve assy.
Heating by-pass (If required)
Note: if required, an automatic by-pass is preferred.

Heating flow
Filling point
DHW outlet Mains water inlet

Heating return
Note: A drain tap should be installed at the lowest point of the heating circuit and beneath the appliance.
System drain tap
Note: If the mains is fitted with water meter, check valves or loose jumper stop cock, then a DHW expansion device must be fitted.
Fig. 5
3.8
FILLING THE CENTRAL HEATING SYSTEM - Figs. 6, 7
The system design pressure (cold) should be set to 1.0 bar. This pressure is equivalent to a static head (see Fig. 5) of 10.2 metres of water. Provision should be made to replace water lost from the system. This can be by manual or automatic means, as shown in Figs. 6 and 7. The position for connecting an automatic make-up vessel is indicated in Fig. 5. A double check valve assembly must be used, as shown in Fig. 7. Filling of the system must be carried out in a manner approved by the local Water Undertaking. Where allowed, the system may be filled via a temporary connection as shown in Fig. 6. After filling, always disconnect the flexible hose of the filling loop. All fittings used in the system must be able to withstand pressures up to 3 bar. Drain taps (to BS 2879) must be used to allow the system to be completely drained.
Overflow Hose unions Heating circuit return Stop valve Test cock Filling loop temporarily connected Test cock Double check valve assembly Stop valve Mains water supply
Mains water supply
Heating circuit return
Double check valve assembly Feed cistern to be located above highest point in the system
Stop valve
Fig. 6
Fig. 7
3.9
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. If a cleaning agent and inhibitor are used, they must be applied in accordance 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: 0179 9521133) or Sentinel (Tel: 0151 4209563). Although the Cyclone is fitted in the heating return on the boiler, the heating system should still be thoroughly flushed as detailed below. The Cyclone collection point should be emptied via the drain point (see Fig. 11) after flushing has been completed. 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 points, at pump and radiators. b. Check for leaks. c. Rapidly drain the system. d. If required, chemically clean the system as instructed by the recommended cleaner manufacturer. Note: Ensure that the system is flushed to remove any remains of the cleaner. e. If chemical cleaner is not used to clean the system:i) Refill the system. ii) Switch on the boiler and allow the system to heat up to the normal operating temperature. iii) Rapidly drain the system while the water is still hot. iv) Refill the system. f. As required, add the recommended inhibitor to the system as instructed by the inhibitor manufacturer. g. Recheck for leaks. 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 operating temperature. ii) Rapidly drain the system while the water is still hot. iii) Refill and chemically clean the system as instructed by the recommended cleaner manufacturer. iv) Ensure the system is flushed to remove any remains of the cleaner. v) Fit the new boiler. b. If the old boiler is not working:i) Rapidly drain the system. ii) Remove the old boiler. iii) Flush the system through. iv) Fit the new boiler. v) Refill and chemically clean the system as instructed by the recommended cleaner manufacturer. vi) Ensure the system is flushed to remove any remains of the cleaner. c. As required, add the recommended inhibitor to the system as instructed by the inhibitor manufacturer. d. Check for leaks.
2.
3.10 DISPOSAL OF CONDENSATE

Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha CD boilers and reference should be made to BS 6798: 2000 for the requirements on the disposal of condensate. The boilers incorporate a condensate trap which has a seal of 75 mm, therefore no additional trap is required. The condensate should ideally be discharged internally into an internal waste pipe (washing machine/sink waste) or soil pipe to avoid the possible risk of freezing. The pipework must be in 22 mm pipe. External pipe runs should be avoided, but if it is necessary, the pipework should be at least 32 mm and protected from the risk of freezing with a waterproof insulation and the length should be kept to a maximum of 3 m. Termination should be into an external gulley or soakaway as shown in Figs. 8 and 9. Note: All pipework must have a continuous fall (see Figs. 8 and 9) from the boiler and must be of an acid resistant material such as plastic waste pipe. (copper or steel is not suitable). It should be noted that the connection of a condensate pipe to a drain may be subject to local building control requirements.
10
Fig. 8 - External gully
Fig. 9 - External soakaway
3.11 DOMESTIC HOT WATER SYSTEM

The minimum flow rate needed for the flow switch and burner to operate is 2.0 litres/min. The incoming mains water pressure should be between 0.2 and 8 bar to ensure efficient operation. If the pressure is above 7 bar a pressure reducing valve must be fitted. To ensure economic use, the pipe runs between the boiler and taps should be in 15 mm copper pipe and be as short as possible. Where possible the pipework should be insulated to reduce heat loss. 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 flexible head type shower is used it may require the fitting of a double check valve, to comply with Water Bye Law 17. Bidets - No anti-syphonage arrangements are necessary, provided the outlets are shrouded and it is not possible to attach a temporary hand held spray. A supply of direct mains fed hot and cold water is permitted provided the appliance is of the overrim 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.
11
4
4.1
1.
INSTALLATION
UNPACKING
The boxes required when the boiler is installed with a horizontal flue are as follows:Box 1 Cased boiler fitted with water and gas valves, filling loop, union bends and washers Mounting bracket plus screws and wall plugs Literature pack and Wall template CD Easy-Flue 500 mm or CD Easy-Flue 1000 mm. Both include 90 bend and horizontal flue terminal Note: NOT required for vertical flue a. All flues must be suitable for CD condensing boilers. b. CD 750 mm and 1000 mm flue extensions are available, if required.
Box 2 Notes: 2.
Unpack boiler and remove the loose items packs and mounting bracket. Note: The boiler can be stood in an upright position, (to allow this, the union bends have been turned upwards so that they do not protrude beneath the bottom - check this before standing the boiler upright).
4.2
CLEARANCES REQUIRED - Fig. 10
A = 345 mm for CD24 A = 380 mm for CD32
Fig. 10
4.3
1.
PREPARE THE WALL - Figs. 11, 12

Decide upon the position of the boiler taking into account the clearances required for servicing and the flue terminal position. 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. Side exit flue - Continue the horizontal centre line of the flue across the wall to the side wall, then along the side wall 165 mm (ensure the lines are horizontal). This will give the position of the centre of the hole for the flue. Cut the 110 mm diameter hole (or use a 107 mm core drill) in the wall for the flue. Notes: a. Ensure the hole is horizontal. b. For internal fitting of the flue, using the flue sealing collar supplied, cut a 130 mm dia. flue hole using a 127 mm core drill. Drill the fixing holes (10 mm dia.) to accept the No.10 plugs supplied. Using the screws supplied, fit the mounting bracket.
2.
3.
4.
5.
Fig. 11
6.
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.
12
Alpha CD24C/32C - Installation
4.4
1.
FIT THE BOILER - Refer to Fig. 11

Lift the boiler and locate it on the mounting bracket. Fit the bottom screws to secure the boiler in position.
Fig. 12
4.5
1. 2.
CONNECT THE PIPEWORK - Fig. 13

Thoroughly flush out all the water pipework. Refer to Section 3.9. The valves/fittings have been factory fitted, however, check that all the connections underneath the boiler have been tightened, especially the union bends. The heating union bends have been designed to enable the heating pipes to be routed from above and/or below using the same fitting. Note: When soldering to the boiler union bends, ensure the bends are not connected to the valves, otherwise the internal seals may be damaged. Connect the system pipework to the boiler. Note: Do not forget that the pressure relief valve discharge pipe must be routed clear of the boiler to a drain in such a manner that it may be seen, but cannot cause injury to persons or property. Connect the 22 mm condensate trap drain pipe to the condensate discharge pipe. Ensure that the condensate discharge pipe is as required in Section 3.10. 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.
3.
4.
5.
Note: Disconnect the filling loop after filling the central heating system. A - Heating flow (22 mm) B - Hot water outlet (15 mm) C - Gas inlet (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
Filling loop Cyclone J Heating return valve Condensate trap 20

47.5 47.5
H I
23
70 C
70 B
95 D
95 F
70 E A
50
Fig. 13
13
4.6
1.
FIT THE FLUE - Figs. 14, 15

The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below. Note: Where the length is less than the minimum or more than the maximum, refer to Section 4.7.
The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only.
CD Easy-Flue 500 mm 1000 mm
B (mm) Max 520 915 Min 280 675
CD Easy-Flue B + C (mm) 500 mm 1000 mm Max 460 855 Min 220 615
Fig. 14
2. Determine the overall length (L) of flue required, (see Fig. 16) as follows:Rear flue Side flue L = wall thickness (B) + 170 mm
Fig. 15
L = wall thickness (B) + distance between boiler and wall (C) + 230 mm
Fig. 16
3. 4. Adjust the telescopic section of the flue to the distance 'L', ensuring that the two labels marked 'TOP' are aligned, then seal and secure the joint between the ducts with the sealing tape supplied. Pass the flue assembly through the wall (from inside or outside). Note: Internal fitting - If there is no access to make good the outside wall, locate the flue sealing collar 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. 17 - Fitting the flue from inside

5. 6. 7. Position the seal and clamp (two screws) supplied, over the bend. Fit the bend to the boiler and rotate to the correct position. Secure in position using the seal and clamp, ensuring the seal is located centrally over both the bend and boiler adaptor. Fit the inside flue sealing collar over the Easy-Flue. Fit the outside flue sealing collar onto the flue immediately before the terminal grille onto the location provided. Slide the clamp (three screws) over the outer duct and pull the flue assembly towards the bend, locating the inner duct into the seal joint on the bend. Ensure the labels marked 'TOP' are positioned at the top before securing the flue assembly to the bend with the clamp (three screws) located centrally over the joint. 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). 8. Make good the inside wall by pushing the inside flue sealing collar upto the wall. Alpha CD24C/32C - Installation
14
Fig. 18 - Rear flue
4.7
1.
EXTENDING THE FLUE - Fig. 19

When the flue length required is more than the maximum or less than the minimum stated in Section 4.6, paragraph 1, refer to the table below.
Note: The maximum horizontal flue assembly length must not exceed a length of 12 metres.
Flue Length
Rear Flue (B)
Side Flue (B + C) 11.77 m
Comments Alpha CD 750 mm or 1000 mm flue extension (Part No. 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. 6.20001000) telescopic range. Use an Easy-Flue 1000 mm (Part No. 6.20001000) and the terminal may protrude somewhat from the outside wall. Within standard Easy-Flue 500 mm (Part No. 6.2000500) telescopic range. Terminal may protrude somewhat from the outside wall.
Up to maximum:- 11.83 m
Between:Between:-
675 mm and 915 mm 520 mm and 675 mm
615 mm and 855 mm 460 mm and 615 mm
Between:Less than:-
280 mm and 520 mm 280 mm
220 mm and 460 mm 220 mm
2.
Use the template (supplied with the boiler) to mark the required flue position and cut a 130 mm diameter hole for the flue (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. Assemble the flue extensions together by locating the inner duct into the seal joint and secure each extension together with the clamps supplied (three screws). Ensure that the clamps are positioned centrally over the joints. Note: If it is required to cut an extension, DO NOT cut the end of the inner duct that incorporates the seal joint. Ensure the inner duct end without the seal joint is cut so that it is 15 mm longer than the outer duct.
3. 4.
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 the inner duct into the seal joint and secure with the clamp (three screws), ensuring it is located centrally over the joint. Mark the end of the flue assembly 'TOP' where it is connected to the boiler,so that the 'TOP' of the flue terminal is aligned with the 'TOP' at the boiler end of the flue assembly. Pass the complete flue assembly through the wall.
6. 7.
15
8.
Position the seal and clamp (two screws) supplied, over the bend. Fit the bend to the boiler and rotate to the correct position and secure in position using the seal and clamp, ensuring that the seal is positioned centrally over both the bend and adaptor. Slide the clamp (three screws) over the outer duct and pull the flue assembly towards the bend, locating the inner duct into the seal joint on the bend.
9.
10. Secure the flue assembly to the bend with the clamp (three screws) ensuring it is positioned centrally over the joint, ensuring the 'TOP' marked on the outer duct is positioned at the top. Note: Check the flue terminal protrudes 100 mm out of the wall and that the inner duct of the terminal is positioned correctly, i.e. the inner duct within the terminal is at the top. See Fig. 19. 11. Make good the outside wall by fitting a flue sealing collar onto the location provided immediately behind the flue terminal grille. Make good the inside wall 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.
Fig. 19 - Side flue
4.8
1.
CONNECT THE MAINS SUPPLY - Fig. 20

Gain access to the boiler terminal block by releasing the two fixing screws (one each side) securing the control panel and lowering the panel. Refer to Technical Data, Section 2.9 for connection details. Note: This boiler has been fitted with a mains supply cable. However, if it is necessary to fit an alternative supply cable, ensure the cable clamp that has been fitted is removed and connect as follows:Remove the two screws securing the terminal block cover from the back of the control box (see Fig. 20). Pass the mains supply cable through the cable clamp and connect as follows:- Brown to L, Blue to N and Green/Yellow to . Ensure correct polarity. Note: Ensure that the length of the earth wire is such that if the supply cable is pulled out of its clamp the live and neutral wires become taut before the earth wire. The main terminal block can be removed by pulling it off the pins to give easy access to the terminals. Do not switch on the electrical supply at this stage.
2.
Fig. 20
16
3.
If an external control, i.e. room thermostat or external clock is to be fitted, remove the terminal block cover and remove the link between terminals 1 and 2. Pass the cable through the cable clamp and connect it to terminals 1 and 2. Replace the terminal block cover. (Refer to Section 2.9). Replace the terminal block, ensuring it is located correctly on the plastic pins and replace the cover. Ensure that there is sufficient free cable to allow the control panel to be raised and lowered then tighten the cable clamp screws. Leave the control panel open until commissioning procedures have been completed. Carry out electrical system checks - Short circuit, Polarity, Earth continuity and Resistance to earth with a suitable multimeter.
4. 5. 6. 7.
4.9
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. 1. 2. 3. 4. Remove the two screws securing the clock cover at the rear of the control panel. Remove and discard the clock blanking panel. Insert the clock into the opening and secure in place with the screws supplied. Disconnect the clock wiring from the terminal block and connect it to the clock as follows: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.
5. 6.
Fig. 21
17
COMMISSIONING
When commissioning the boiler, ensure the Benchmark Checklist is completed.
5.1
1. 2. 3. 4. 5. 6. 7.
FILL THE SYSTEM

The boiler is fitted with an automatic air vent positioned on the pump (see Fig. 2). The vent is always open and has no sealing cap. Open the central heating flow and return valves (slot in-line with valve) (see Fig. 13). Open the fill point valve on the filling loop until water is heard to flow. To aid venting, the boiler drain point (see Fig. 2) may be opened until water flows out. Close the drain point as soon as water appears. To remove the air - Vent each radiator in turn, starting with the lowest in the system. It is important that the pump is properly vented to avoid it running dry and damaging its bearings. Unscrew and remove the cap from the centre of the pump. Using a suitable screwdriver rotate the exposed spindle about half a turn, then replace the cap. Check the operation of the pressure relief valve (see Fig. 2) by turning the head anti-clockwise until it clicks. The click is the valve lifting off its seat allowing water to escape from the system - check that this is actually happening. 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, rectifying where necessary. Disconnect the filling loop from the mains supply. Water may be released from the system by manually operating the drain point (see Fig. 2) until the system design pressure is obtained. The system design pressure (cold) should be between 0.75 and 1.25 bar. Refer to Sections 3.7 and 3.8. System volume, Flushing and Filling the system. 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.
8. 9.
5.2
BOILER CONTROLS - Fig. 22
Fig. 22
18
Alpha CD24C/32C - Commissioning
5.3
1. 2. 3.
TEST FOR GAS SOUNDNESS AND PURGE THE SUPPLY

With the boiler gas service cock closed (slot at right angles to valve). Pressure test the gas supply and inlet pipework connection to the boiler gas service cock for soundness in accordance with BS 6891. Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 23). Ensure the gas supply is on and open the boiler service cock to purge in accordance with BS 6891. Retighten the test point screw and test for gas soundness. Close the boiler gas service cock.
5.4
1. 2. 3. 4. 5. 6.
INITIAL LIGHTING - Refer to Fig. 22

Ensure that the gas and electrical supplies to the boiler are off and that the mains water inlet valve and the central heating flow and return valves are open. Turn on the gas and electrical supplies to the boiler. Ensure all external controls are calling for heat. If the optional Clock is fitted, refer to the User's instructions, set the time and ensure the Clock is in an 'on' mode. Set the hot water and central heating thermostats to maximum. (DHW only). Open a hot water tap, the main burner will light and the boiler will provide hot Set the selector switch to water. Close the tap and the burner will go out. Set the selector switch to (CH and DHW). The boiler will now run in the central heating mode. The pump will start, the fan will start and the main gas valve solenoid will open allowing the main burner to light.
5.5
CHECK THE BURNER PRESSURES - Figs. 23, 24
Turn the boiler off. Remove the two pressure test point screws at the top of the boiler and connect a differential pressure gauge to P1 and P2 as shown in Fig 24. Allow the boiler to run for 10 minutes and check the differential burner pressures. Hot water mode 1. 2. 3. Set the selector switch to (DHW only) and fully open a hot water tap. The burner will light at the ignition rate and the burner pressure will increase to maximum. Gradually close the hot tap and check that the burner pressure decreases to its minimum. Fully open the tap and check that the burner pressure increases. Close the tap and check that the burner goes off. Note: The burner pressure settings have been factory set and do not require adjusting. If incorrect, check that the inlet gas pressure is 20 mbar. If the inlet gas pressure is not 20 mbar, either the pipework is too small or the gas supply to the house is insufficient, in which case contact your gas supplier. Set the selector switch to (DHW and CH).
Central heating mode 1. 2. 3. 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 screws.
Fig. 23
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
19
5.6
1.
FINAL COMMISSIONING
Allow the heating system to heat up, then balance the system to achieve the necessary temperature difference across the heating flow and return pipes at the boiler and check the system volume and pressure. (Refer to Technical Data, Sections 2.2 and 2.8). Turn off the boiler. Thoroughly flush out the water pipework (refer to Section 3.9) and with no pressure in the boiler heating circuit, empty the cyclone at it's drain point (see Fig. 13) of any debris. Clean the mains water inlet filter (see Fig. 13). Re-pressurise the system as described in Section 5.1.
2. 3. 4.
5.7
1. 2. 3. 4. 5.
FINAL ASSEMBLY
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. If the boiler is not to be handed over immediately, close the boiler gas service cock and switch off the electrical supply. 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. Complete the details of the installation in the Benchmark Checklist on page 38.
5.8
USER INFORMATION
The User must be advised (and demonstrated if necessary) of the following important points:1. How to light and turn off the boiler and how to operate the system controls. 2. The importance of annual servicing of the boiler to ensure safe and efficient operation. 3. That any servicing or replacement of parts must only be carried out by CORGI registered personnel. 4. Ensure that the boiler controls and room thermostat (if fitted) are set to the User's requirements. 5. Tell the User about the sealed system pressure. 6. Tell the User that if the electrical supply is on and the boiler has not operated for 24 hours for heating or hot water, the pump will automatically operate for 5 minutes. 7. Explain to the User that an internal frost thermostat is fitted in the boiler, and that the electrical supply to the boiler must be left on for the thermostat to operate. 8. Explain to the User that in certain weather conditions the terminal will emit a plume of steam, i.e. water vapour. This is safe and quite normal. 9. Show the User the position of the pressure relief valve and condensate discharge pipes. 10. Hand the User's instructions to the User. 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.
20
BOILER OPERATION
The boiler operating mode is controlled by the selector switch on the facia panel. When set to , the boiler will only operate in the Domestic Hot Water mode. When set to , it will operate in the Domestic Hot Water and Central Heating mode. Note: The clock (if fitted) only controls the operating times of the central heating, not domestic hot water - DHW is available continuously. Domestic hot water supply always takes priority over central heating. If a demand for hot water is required during a central heating period, the boiler will automatically switch to the hot water mode until the demand is satisfied. This interruption in the central heating is only when the demand for hot water is present and should not be noticed by the User.
6.1
CENTRAL HEATING MODE
If there is a call for heat, the pump will start to circulate the central heating water. The fan will run and the pre-mix burner will light. The burner output then automatically adjusts to suit the system demand; as the temperature of the water in the boiler approaches that set by the adjustable temperature thermostat, the burner output is reduced. When the set temperature is reached, the burner is turned off. The fan continues to run for 50 seconds and the pump continues to run until the temperature within the boiler reduces to the set temperature before allowing the burner to relight. If the primary sensor has not registered the pre-set temperature but the room thermostat is satisfied the burner is turned off. The fan continues to run for 50 seconds and the pump continues to run for 60 seconds. In this instance there is no delay before the burner will relight. If there is a demand for DHW during the burner delay, the boiler will operate to provide DHW until the tap is closed; the boiler will then immediately revert to provide CH if there is a demand. Note: If the system pressure is very low, the primary pressure switch will prevent the boiler from operating.
6.2
DOMESTIC HOT WATER MODE
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, increasing immediately to its maximum output. Water in the boiler is then diverted from the central heating system to the domestic hot water heat exchanger, heating the incoming mains water. The burner output is varied to maintain the temperature of the hot water as that set by the adjustable temperature selector. When the flow switch senses that hot water is no longer required the burner is turned off and the boiler immediately returns to the central heating mode. When the burner is turned off, the fan will continue to run for 50 seconds and the pump will stop immediately if the selector is set for hot water only. In both modes the fan modulates according to the output required.
6.3
FROST THERMOSTAT
The boiler incorporates a built in frost thermostat which automatically turns on the boiler and pump if the water in the boiler falls below 8C, providing the electrical supply is on and the selector switch is set to position 1 ( ) or position 2 ( ). The boiler will operate until the water temperature in the system reaches approximately 40C.
6.4
PUMP
If the electrical supply is on and the boiler has not operated for 24 hours for heating or hot water, the pump will operate automatically for five minutes every 24 hours.
6.5
INDICATOR NEONS
Neon D C A B B
When neons A (red), B (red), C (yellow), D (green) are illuminated, the following conditions apply:Illuminated continuously - Electricity supply to the boiler is on. Illuminated continuously - Burner is alight. Flashing on and off - Temperature sensor fault. Flashing on and off - Overheat thermostat has operated. Rotate selector switch to the reset position (3) to reset. 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. 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
21
ROUTINE SERVICING
To ensure efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year should be adequate. It is the law that any service work must be carried out by a competent person, i.e. CORGI registered personnel. Warning: Before servicing the boiler, isolate the electrical supply and close the boiler gas service cock. Allow the boiler to cool. The data label is positioned on the inside of the left hand side panel. Always test for gas soundness after servicing any gas carrying components. Always carry out electrical system checks i.e. Eart Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter after servicing.
7.1
1. 2. 3. 4. 5. 6.
IMPORTANT NOTES PRIOR TO SERVICING

Check the flue terminal outside and ensure it is not blocked. Run the boiler and check the operation of its controls. Refer to Fig. 2 for location of flue sampling point. Ensure that all system connections and fittings are sound. Remake any joints and check the tightness of any fittings that may be leaking. It is recommended that the operation of the safety valve is checked by turning the head anti-clockwise until it clicks. The click is the safety valve lifting off its seat allowing water to escape from the system - check that this is actually happening. Refill, vent and re-pressurise the system as necessary. (Refer to Commissioning, Section 5.1). If the system pressure exceeds 2.5 bar when operating at maximum temperature, the heating expansion vessel should be checked and re-pressurised, if necessary. Note: 1. Check the expansion vessel charge only when the system pressure is zero. 2. The expansion vessel pressure test point is accessible from the top and rear of the boiler.
7. 8.
Check that the condensate trap drain pipe is connected and all joints are sound. Record details of the service in the Service Record Section on page 39.
Combustion chamber front assembly Gas pipe union Viewing window Room sealed panel fixing screws Fan assembly Fan assembly fixing screws Ignition generator Six nuts and washers securing combustion chamber front assembly
Pressure tube connections
Fig. 26
22
Alpha CD24C/32C - Routine Servicing
7.2
1. 2. 3. 4.
PREPARE FOR SERVICING - Fig. 26

Ensure the electrical supply is isolated and the gas supply is off. Unscrew the two screws securing the control panel and lower the panel. Lift the case front panel upwards slightly and pull it forwards to remove it from the boiler. Remove the four screws, or for the CD32C, release the four clips securing the room sealed chamber panel and remove the panel, taking care not to damage the seal. Disconnect the gas supply pipe union. Remove the two screws securing the fan assembly to the combustion chamber front. Remove the two pressure tubes, noting their positions. Disconnect the electrode lead from the ignition generator and the in-line connector to the flame sensing electrode. Remove the six nuts and washers securing the combustion chamber front assembly and remove the assembly.
Ignition electrodes Front insulation panel Gap 3 - 4 mm Flame sensing electrode Burner Gap 11 mm (CD32C 17 mm)
Combustion chamber front assembly
5. 6. 7. 8.
9.
Fig. 27
7.3
1. 2. 3.
CLEANING THE BOILER

Remove any deposits from heat exchanger using a suitable soft brush. Do not use a brush with metallic bristles. Check the condition of the combustion chamber insulation panels. Any damaged panels must be replaced. (Refer to Component Replacement, Section 8.18). Check the condition of the burner injector on the combustion chamber front assembly, carefully clean them with a soft brush if necessary. Do not use a brush with metallic bristles as this might damage the injectors. 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. Unscrew and replace any injector that appears damaged. Remove the four screws securing the burner (see Fig. 27) and 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 inside. Check the condition of the electrodes. Check the spark gap, positioning and height of the electrodes. See Fig. 27.
4.
5. 6.
7. 9.
10. Unscrew the condensate trap drain cap to remove any deposits. Note: Before removing the cap, ensure that the water released from the trap can be contained to avoid spillage. The trap will contain no more than 200 cc of condensate water. Replace the drain cap.
7.4
1.
RE-ASSEMBLE THE BOILER

Replace the burner, ensuring it is located correctly and secure it in position using the four screws previously removed. Important: Before replacing the combustion chamber front assembly, pour at least 200 cc of water into the coils of the heat exchanger. This is to ensure the condensate trap is full of water before operating the boiler.
2. 3. 4. 5. 6. 7. 8. 9.
Replace the combustion chamber front assembly, ensuring it is correctly located. Ensure the electrode lead is connected and the seal is in position in the bottom of the room sealed chamber. Test the connections for gas soundness and re-commission, Sections 5.4 and 5.5. Ensure that the room sealed chamber panel seal is intact and in position, replace the panel ensuring it has been located correctly (especially on the sides) and secure it in position with the screws previously removed. 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
23
COMPONENT REPLACEMENT
It is the law that any service work must be carried out by a competent person, i.e. CORGI registered personnel. Warning: Before replacing any boiler components, isolate the electrical supply and close the boiler gas service cock. Allow the boiler to cool. Always test for gas soundness after replacing any gas carrying components or disturbing any gas connections. Always carry out electrical system checks i.e. Eart Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter after servicing. Check the operation of the boiler. (Refer to Boiler Operation, Section 6). Ensure that all the controls are returned to their original settings. The replacement of components in Sections 8.3 to 8.16 does not require draining of the boiler.
8.1
1. 2. 3.
GENERAL ACCESS - Fig. 26

If access is required behind the control panel - Release the two fixing screws (one each side) securing the control panel and lower the panel. To gain access behind the casing - Lift the case front panel upwards slightly and pull it forwards to remove it from the boiler (see Fig. 26). If required, remove the side panels by removing the bottom fixing screw and lifting forwards and upwards. To gain access behind the room sealed chamber panel - Remove the four screws, or in the case of the CD32C release the four clips, securing the room sealed chamber panel and remove the panel, taking care not to damage the seal. Note: When replacing the panel, ensure the seal is intact and that the panel has been located correctly, especially on the sides. To gain access to the control panel components - Remove the five screws securing the rear cover and carefully raise the cover from the front. When replacing the cover, ensure no wires are trapped and all wiring is secured. Secure with five screws - do not overtighten.
Ensure the electrical supply is isolated and the gas supply is off.
4.
8.2
1.
DRAINING THE BOILER - Refer to Figs. 2, 13

Heating circuit Close the central heating flow and return valves (see Fig. 13). Connect a suitable pipe to the drain point (see Fig.2) and route it to a suitable container. Open the drain point.
Isolate the electricity supply and close the boiler gas service cock (see Fig. 13). Allow the boiler to cool.
2.
Hot water circuit Close the mains water inlet valve (see Fig. 13). Open any hot tap below the level of the boiler to allow as much draining as possible. Note: Some water will remain in the components and care must be taken when removing them.
8.3
1.
ELECTRODES - See Fig. 27

Ignition electrode and lead Disconnect the lead from the ignition generator, noting its position. Remove the two screws securing the electrode to the front of the combustion chamber and carefully withdraw the electrode.
Gain access behind the room sealed chamber panel as in Section 8.1.
2.
Flame sensing electrode and lead Remove the grommet in the bottom of the chamber, disconnect the flame sensing electrode in-line connector and withdraw the lead. Remove the two screws securing the electrode to the front of the combustion chamber and carefully withdraw the electrode.
3.
Ignition electrode Remove the two screws securing the electrode to the front of the combustion chamber and carefully withdraw the electrode.
Re-assemble in reverse order
8.4
1. 2. 3.
MAIN BURNER - Fig. 27

Remove the burner assembly as described in Routine Servicing, Section 7.2. Remove the four screws securing the burner to the combustion chamber front assembly. Re-assemble with a new burner as described in Routine Servicing, Section 7.4.
8.5
1. 2. 3. 4.
BURNER INJECTORS - Fig. 26

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
24
8.6
1. 2. 3. 4.
FAN - Fig. 28
Gain access behind the room sealed chamber panel as described in Section 8.1. For the CD32C, also remove the combustion chamber front assembly as described in Section 7.2. Disconnect the fan wiring. Remove the inlet and outlet flanges from the fan. Fit the new fan and re-assemble in reverse order. Ensure that the pressure tubes are connected correctly. Re-assemble and test the boiler as described in Routine Servicing, Section 7.4 paragraphs 5 to 9.
Flue thermostat
8.7
1. 2. 3. 4. 5.
IGNITION GENERATOR - Fig. 28

Gain access behind the room sealed chamber panel as described in Section 8.1. Disconnect all the wiring from the ignition generator. Remove the two screws securing the generator and remove. Secure the new generator in position and reconnect the wiring. Re-assemble in reverse order.
Primary temperature sensor Overheat thermostat
Ignition electrodes
Flame sensing electrode
8.8
1.
TRANSFORMER - Fig. 28
Gain access behind the room sealed chamber panel as described in Section 8.1. For the CD32C, also remove the fan as described in Section 8.6. Remove the two screws securing the transformer and remove the transformer. Disconnect all of the wiring noting their position. Fit the new transformer and re-assemble in reverse order.
Fan assembly Ignition generator Transformer
2. 3. 4.
Fig. 28
8.9
1. 2. 3. 4.
OVERHEAT THERMOSTAT - Fig. 28

Gain access behind the room sealed chamber panel as described in Section 8.1. Disconnect the wiring from the overheat thermostat. Unscrew and remove the overheat thermostat from the heat exchanger. Fit the new overheat thermostat taking care not to cross thread it and re-assemble in reverse order.
8.10 FLUE THERMOSTAT - Fig. 28

1. 2. 3. 4. Gain access behind the room sealed chamber panel as described in Section 8.1. Remove the thermostat from the spring clip at the top rear of the heat exchanger. Disconnect the wiring. Fit the new thermostat and re-assemble in reverse order.
8.11 GAS VALVE - Fig. 29

1. 2. 3. 4. 5. 6. 7. 8. 9. Gain access behind the casing as in Section 8.1. Disconnect the positive pressure tube from the gas valve. Loosen the one screw (see Fig. 25) securing the electrical plug and disconnect the plug. Disconnect the burner manifold union and the gas inlet pipe union. Remove the two manifold screws from beneath the boiler. Push the valve towards the rear of the boiler and lift out the valve assembly. Remove the inlet and outlet flanges and fit them to the new valve. Fit the new assembly and re-assemble in reverse order. 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
25
8.12 VIEWING WINDOW - Fig. 26

1. 2. 3. 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.
8.13 TERMINAL BLOCK FUSE - Refer to Fig. 20

The fuse is located in the boiler terminal block. 1. 2. 3. Gain access as described in Installation, Section 4.8. Lift out the fuse holder and remove the fuse. Fit a fast blow 2 A fuse as a replacement, ensuring that the holder snaps into position. Re-assemble in reverse order, ensuring the terminal block is located correctly on the plastic pins.
8.14 PCB - Fig. 30

1. 2. 3. 4. 5. Gain access behind the control panel as described in Section 8.1. Disconnect all the wiring connectors from the PCB. Remove the five fixing screws and carefully withdraw the board from the switch spindles. Re-assemble in reverse order. Refer to the wiring diagram in Section 9.1 for connections. Light the boiler and adjust the PCB as described in the instructions supplied with the replacement PCB.
Fig. 30
Fig. 31
8.15 DHW FLOW SWITCH - Fig. 31

1. 2. Gain access behind the casing as described in Section 8.1. Remove the switch from the diverter valve by pulling or prising it upwards from the valve body. Disconnect the inline wiring connector. 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. 1. 2. 3. 4. 5. 6. Gain access behind the control panel as described in Section 8.1. Remove the two screws securing the clock cover at the rear of the control panel. Disconnect the wiring from the clock. Remove the clock retaining screws and withdraw the clock from the control panel. Fit the new clock, and connect the wires as follows: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.
26
Alpha CD24C/32C - Component Replacement
8.17 PRIMARY HEAT EXCHANGER - See Fig. 32

1. Gain access behind the room sealed chamber panel as described in Section 8.1 and drain the boiler heating circuit as described in Sections 8.1 and 8.2. Disconnect the gas inlet union from the combustion chamber front. Remove the two screws and six nuts and washers securing the combustion chamber front burner assembly and remove. Remove the overheat thermostat (Section 8.9), flue thermostat (Section 8.10) and the primary temperature sensor (Section 8.20). Disconnect the condensate drain union. Remove the two clips from the heat exchanger flow and return pipes and disconnect the unions at the pump and diverter valve (if applicable). Remove the four screws securing the heat exchanger retaining brackets. Lift up the heat exchanger off the pipes and remove it by carefully withdrawing it out of the boiler. Re-assemble in reverse order, ensuring that new seals are used. Lubricating the seals with the grease supplied will aid assembly.
2. 3. 4. 5. 6.
7. 8. 9.
Fig. 32
10. Refill and pressurise 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. 2. 3. 1. 2. 3. Remove the electrodes from the combustion chamber front as described in Section 8.3. Remove the four screws securing the burner. Carefully remove the insulation. Remove the combustion chamber front/burner assembly. Remove the centre screw retaining the insulation. Carefully remove the insulation, suction applied to the centre of the insulation will aid this.
Back insulation - see Fig. 32
Fit a new panel and re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
8.19 PRESSURE GAUGE - Fig. 33

1. 2. 3. 4. 5. Gain access behind the casing and drain the boiler heating circuit as described in Sections 8.1 and 8.2. Remove the nut securing the pressure gauge sensor and withdraw the sensor. Depress the two lugs on the pressure gauge and push it out of the control panel. 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
Primary pressure switch
Pump Pressure relief valve
Pressure gauge
Fig. 33
27
8.20 TEMPERATURE SENSORS - Refer to Fig. 28 and 34

Note that both sensors are the same. 1. Gain access as described in Section 8.1 (behind the casing for the DHW sensor or behind the room sealed chamber panel for the primary temperature sensor) and drain (heating circuit for primary sensor or hot water circuit for DHW sensor) as described in Section 8.2. Primary Sensor - The primary sensor is positioned on the right hand side of the heat exchanger, see Fig. 28. Disconnect the wiring and unscrew the sensor. Re-assemble in reverse order with a new sensor and sealing washer.
2.
2a. DHW Sensor - Close the mains cold water inlet valve and open the lowest hot water tap to drain the DHW system. Disconnect the wiring and unscrew the sensor from the hot water outlet pipe from the DHW plate heatexchanger, see Fig 34. Re-assemble in reverse order with a new sensor, replacing the sealing washer if necessary.
8.21 AUTOMATIC AIR VENT - Fig. 33

1. 2. 3. Gain access behind the casing and drain the boiler heating circuit as described in Sections 8.1 and 8.2. Unscrew the automatic air vent from the pump outlet. Fit a new one using a new 'O' ring. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
8.22 PUMP - Refer to Fig. 33

Gain access behind the casing and drain the boiler heating circuit as described in Sections 8.1 and 8.2. Pump head 1. 2. Remove the four socket head screws securing the pump head to the body. Withdraw the head, remove the wiring cover and disconnect the wiring. 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). Remove the pump head as described above. Unscrew the automatic air vent from the pump outlet. Disconnect the pump unions and withdraw the pump body. Connect the wiring as described above, ensure that pump is set to maximum and re-assemble using new sealing washers. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
3. 1. 2. 3. 4. 5.
Complete pump
8.23 PRIMARY PRESSURE SWITCH - Fig. 33

1. 2. 3. 4. Gain access behind the casing and drain the boiler heating circuit as described in Sections 8.1 and 8.2. Disconnect the wiring from the pressure switch. Unscrew the switch from the primary flow pipe. Using the new washer supplied, re-assemble in reverse order. When connecting the wiring to the new switch the polarity of the wires is not important.
8.24 PRESSURE RELIEF VALVE - Fig. 33

1. 2. 3. 4. 5. Gain access behind the casing and drain the boiler heating circuit as described in Sections 8.1 and 8.2. 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).
28
8.25 DHW HEAT EXCHANGER - Refer to Fig. 34

1. 2. Gain access behind the casing and drain the boiler heating and hot water circuits as described in Sections 8.1 and 8.2. Disconnect the three union nuts to the heat exchanger and remove heat exchanger by lifting it upwards from the rear right hand side 'O' ring seal connection. 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).
DHW sensor DHW heat exchanger
3. 4.
8.26 MAINS WATER INLET FILTER - Fig. 13

1. 2. 3. Drain the boiler hot water circuit as described in Section 8.2. Withdraw the filter after disconnecting the unions between the inlet valve and boiler (item H in Fig. 13). Clean or replace and re-assemble in reverse order.
Union nuts
Fig. 34
8.27 DIVERTER VALVE ASSEMBLY - Figs. 31 and 35

1. 2. 3. 4. 5. 6. Gain access behind the casing and drain the boiler heating and hot water circuits as described in Sections 8.1 and 8.2. Remove the domestic hot water heat exchanger and flow switch assemblies from the diverter valve as described in Sections 8.23 and 8.15. Disconnect the union connections from the diverter valve. 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. Re-assemble in reverse order using the new seals supplied. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
8.28 DHW FLOW VALVE - Fig. 35

1. 2. 3. 4. Remove the diverter valve as described in Section 8.27. Unscrew (not necessary to remove) the two screws securing the DHW flow valve to the diverter valve and withdraw the valve. When re-assembling, push the new valve into position, holding it in, while tightening the fixing screws. Re-assemble in reverse order.
8.29 EXPANSION VESSEL - Fig. 12

Note: If there is less than 450 mm clearance above the boiler or a rear exit flue is used, it is not possible to replace the vessel, in which case an additional vessel should be fitted external to the boiler in the central heating return pipe, as close to the boiler as possible (see Fig. 5). 1. 2. 3. 4. 5. 6. Gain access behind the casing and drain the boiler heating circuit as described in Sections 8.1 and 8.2. Disconnect the pipe from the pump inlet manifold and expansion vessel. Remove the four screws securing the top support plate. Lift the expansion vessel out of the boiler. 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).
Fig. 35
29
8.30 CYCLONE - Fig. 13

1. 2. 3. 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).
8.31 CONDENSATE TRAP - Fig. 12

1. 2. 3. Gain access behind the casing and drain the trap as described in Sections 8.1 and 7.3, paragraph 10. Disconnect the top and drain connection of the condensate trap. 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.
30
9
9.1
WIRING DIAGRAMS
ILLUSTRATED WIRING DIAGRAM
(Optional) Clock
R R Br Bl
5 4 3 2 1
Overheat Thermostat Spark Generator Flue Limit Thermostat

12
Bk W R
Or Bk Gy
Supply 230/240V-50Hz Fused at 3A

Link
Fan
Fuse F2A L N 1 2 G/Y
Bk Bl R
Flame Sensing Electrode

W
Ignition Electrodes
W R Or
Br R Bl
Br
Bk Gy
Br Bl
Or W Bl Bk Br
X1 33 34 3 55 2 FUSE 315 mAT L N

11 12 13 14 X4
P
X16
X7 21 22 23 24 25 26 27
29 30 31 32
18 19 X6
Br Bl
Gy
Main PCB
DHW SET CH CAP CH SET S1 S2
X12 35 36 37 38 39
Green LED Yellow LED Red LED Red LED H1 H4 H3 H2
Gas Valve
40 41 42 43 X11
X10 MAX CAP
S3
Pk Pk R R
X9 44 45
Or Or
46 47 48 49 50 51 X8
Br Bl G G
Br Bl
G G
DHW Temperature Sensor

Pk Pk P Gy Or Or
COM
240 Vac
24 Vac
R
Bl Br
Pump Primary Temperature Sensor
NO
Transformer
Primary Pressure Switch
DHW Switch
Br Bk Bl R Or G G/Y W Gy Pk P
- Brown - Black - Blue - Red - Orange - Green - Green/Yellow - White - Grey - Pink - Purple
NOTE:
TO CONNECT EXTERNAL CONTROL REMOVE LINK FROM TERMINALS 1 & 2 AND CONNECT 230/240 V SWITCHED LIVE TO TERMINAL1. A FROST THERMOSTAT IS INCORPORATED WITHIN THE MAIN PCB
Alpha CD24C/32C - Wiring Diagrams
31
9.2
FUNCTIONAL FLOW WIRING DIAGRAM
230/240V ~ 50Hz Fuse 3A
Fuse F2A
L L
1 2 3 4
Remove link to connect external control
1 2
Clock (Optional)
N
Fan
Spark Generator
Overheat Thermostat
Flue Limit Thermostat
Gas Valve
X1 33 34 3 55 2 L N
18 19 X6
X16
X7 21 22 23 24 25 26 27
29 30 31 32
FUSE 315 mAT
11 12 13 14 X4
Main PCB
X12 35 36 37 38 39
Green LED Yellow LED Red LED Red LED H1 H4 H3 H2
DHW SET
CH CAP
CH SET S1 S2
40 41 42 43 X11
X10 MAX CAP
S3
X9 44 45
46 47 48 49 50 51 X8
Pump
N
DHW Temperature Sensor
Primary Temperature Sensor
240 Vac
24 Vac
COM
NO
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.
32
Alpha CD24C/32C - Wiring Diagrams
10 FAULT FINDING
10.1 CARRY OUT INITIAL FAULT FINDING CHECKS
1. Check that gas, water and electrical supplies are available at the boiler. i.e. Inlet gas pressure = 20 mbar Electrical supply = 230/240 V ~ 50 Hz CH water system pressurised to between 0.75 and 1.25 bar DHW flow rate is more than 2.5 litre/min Carry out electrical system checks, i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter. Note: These checks must be repeated after any servicing or fault finding. Ensure all external controls are calling for heat and check all external and internal fuses. Check that the gas and water pipework has been connected to the correct connections on the boiler and all valves are open.
2. 3. 4.
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
33
10.3 DOMESTIC HOT WATER- Follow operational sequence
34
10.4 FAULT FINDING SOLUTIONS A to E
240 V ac at:1. Main terminals L and N NO 2. Main terminal fuse 3. 4. NO Check electrical supply Replace fuse NO Check wiring Neon D illuminated contiuously NO NO Is 240 V ac across PCB X4 connector terminals 11,12 YES YES Is 26 V ac across PCB X11 connector terminals 40,41 NO Replace transformer Replace PCB Neon D NO illuminated continuously Replace PCB
PCB - X1 connector, terminals 55, N PCB fuse NO Replace fuse
Replace PCB
B C
240 V ac at:1. 2. Pump YES NO If pump jammed, release NO Replace PCB Replace pump
PCB - X6 connector, terminals 18, 19
1.
Check and correct connections/wiring at sensor and PCB
DHW temperature sensor faulty YES i.e. heating OK. Hot water operates but does not modulate Check resistance throughout the range from cold to hot
2.
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 ohms)
Replace sensor
Primary temperature sensor faulty i.e. no heating or hot water
YES
1. Check and correct:1. Electrical connections 2. Restriction in flue Neon A and B flashing at the same time YES 2. Fan connections correct at fan and PCB connector X12 PCB connector, is 36 V dc across terminals 39 and 37 or 38 NO YES 3. Fan runs at maximum speed YES (BUT)
YES
Is dc volts at PCB, X12 connector:YES across terminals 35 and 37 - 34 V dc across terminals 36 and 37 - 4 V dc NO
Replace fan
Replace PCB YES
Fan jammed or faulty winding
Replace fan Replace PCB
Check pressure tubes are connected NO Gas at burner Ensure gas is on and purged
PCB - X7 connector, is 240 V across terminals 26, 27 NO Replace PCB
YES
Adjust gas valve
NO
Replace gas valve
35
10.5 FAULT FINDING SOLUTIONS F to K
Check and correct:1. Ignition electrodes and leads 2. Electrode connections 3. Spark gap and position 4. Connections at ignition generator and PCB connector X7 YES Is spark generator (T2) making a clicking noise NO PCB, X7 connector is 200V ac YES across terminals 22, 23 during ignition NO Replace PCB Replace ignition generator
G H
Check and correct:YES 1. Check polarity of electrical supply 2. Flame sensing electrode and lead connections 3. Electrode position 4. Blockage of pressure tubes
Replace PCB
Allow to cool. NO Continuity across thermostat terminals YES
Replace overheat thermostat
Air in main heat exchanger, blocked heat exchanger/pipework or pump not circulating water
YES
Vent air, clear blockage
Replace pump
240V at internal clock terminals 1 and 2 YES
NO
240V at PCB - X1 connector, terminals 55 and N
YES
Wiring between clock and PCB is correct YES 240V at PCB - X1 connector, terminals 34 and N NO
Continuity across clock terminals 3 and 4 NO Internal clock calling for heat
YES
Wiring between clock YES and PCB is correct
Check external controls are calling for heat
YES
Replace clock
J K
Continuity across primary YES pressure switch terminals NO
36 V DC at PCB across NO X9 connector terminal 45 and X8 connector terminal 46
Replace PCB
Replace primary pressure switch
Continuity across DHW YES switch at inline connector NO Diverter valve spindle operating NO YES
36 V DC between PCB - X8 connector, terminals 46, 47
NO
Replace PCB
Replace DHW switch
YES DHW flow valve diaphragm damaged NO Diverter valve spindle assy. fault YES
Replace diaphragm
Replace diverter valve
36
11 SHORT PARTS LIST
Reference Fig. 27 Fig. 27 Fig. 2, item 30 Fig. 2, item 30 Fig. 32 Fig. 32 Fig. 34 Fig. 34 Fig. 24 Fig. 33 Fig. 28 Fig. 28 Fig. 33 Fig. 2, item 1 Fig. 2, item 1 Fig. 31 Fig. 30 Fig. 28 Fig. 28 Fig. 28 Figs. 34 and 28 Fig. 20 Fig. 30 Fig. 28 Fig. 2, item 14 Fig. 33 Fig. 33 Fig. 33 Fig. 28 Fig. 28 Fig. 28 Fig. 28 Fig. 31 and 35 Fig. 2, item 27 Fig. 27 Fig. 2, item 29
Description Burner - CD24 Burner - CD32 Main injector 5.0 mm - CD24 Main injector 6.6 mm - CD32 Primary heat exchanger - CD24 Primary heat exchanger - CD32 DHW heat exchanger - CD24C DHW heat exchanger - CD32C Gas valve - Honeywell VK4115V Pump Fan assembly - CD24 Fan assembly - CD32 Primary pressure switch DHW flow regulator - CD24C DHW flow regulator - CD32C DHW flow switch PCB Flue thermostat 100C Ignition generator Transformer Temperature sensor Fuse F2A PCB fuse F315mA Overheat thermostat 100C Expansion vessel 8 Litre Pressure relief valve 3 bar Automatic air vent Pressure gauge Ignition electrode and lead Ignition electrode Flame sensing electrode and lead - CD24 Flame sensing electrode and lead - CD32 Diverter valve assembly By-pass assembly Combustion chamber insulation panel front Condensate trap
Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Alpha Pt. No. British Gas GC No. 1.013172 1.018956 1.011848 1.019247 1.018030 1.018593 1.015957 1.018597 1.011846 1.015610 1.010659 1.021206 1.018320 1.011128 1.019465 3.013211 1.017788 1.012067 1.018162 1.012477 1.021762 1.6098 1.013931 1.012067 1.015394 1.011126 1.010771 1.016151 3.013626 1.016779 1.018163 1.019293 3.012752 3.012801 1.014732 1.018192 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 E57-702 E57-703 E57-709 E57-710 E94-417 E94-418 E94-419 E96-572 E57-773 E65-498 E94-420
Alpha CD24C/32C - Short Parts List
37
12
CHECKLIST
Ensure the following is completed after the boiler has been installed and commissioned:BOILER SERIAL No. ......................................................... NOTIFICATION No. ..........................................................
CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes Time & temperature control to heating room t/stat & programmer/timer Programmable roomstat Time & temperature control to hot water cylinder t/stat & programmer/timer Combi boiler Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted Automatic by-pass to system Not required Fitted
FOR ALL BOILERS CONFIRM THE FOLLOWING: The system has been flushed in accordance with the boiler manufacturer's instructions? Yes The system cleaner used .................................................................................................................... The inhibitor used ................................................................................................................................
No
FOR CENTRAL HEATING MODE, MEASURE AND RECORD THE FOLLOWING: Gas rate Burner operating pressure (if applicable) Central heating flow temperature Central heating return temperature
m/hr N/A
ft/hr mbar C C
FOR COMBINATION BOILERS ONLY Has a water scale reducer been fitted? Yes What type of scale reducer has been fitted? ......................................................................................
No
FOR DOMESTIC HOT WATER MODE, MEASURE AND RECORD THE FOLLOWING: Gas rate Maximum burner operating pressure (if applicable) Cold water inlet temperature Hot water outlet temperature Water flow rate
m/hr N/A
ft/hr mbar C C lts/min
FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING: The condensate drain has been installed in accordance with the manufacturer's instructions?
Yes
FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING: The heating and hot water system complies with current Building Regulations The appliance and associated equipment has been installed and commissioned in accordance with the manufacturer's instructions If required by the manufacturer, have you recorded a CO/CO2 ratio reading N/A The operation of the appliance and system controls have been demonstrated to the customer The manufacturer's literature has been left with the customer
Yes Yes Yes CO/CO2 ratio Yes Yes
COMMISSIONING ENG'S NAME:

Print ...................................................................... CORGI ID No. .................................................. Sign ...................................................................... Date .................................................................
38
Alpha CD24C/32C - Benchmark Checklist
13 SERVICE RECORD
It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record below. Service Provider: Before cpmpleting the appropriate Service Interval Record below, please ensure you have carried out the service as described in this instruction manual. Always use the manufacturer's specified spare parts when replacing all controls.
SERVICE 1: Date ....................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature ..................................................................................... SERVICE 3: Date ....................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature ..................................................................................... SERVICE 5: Date ....................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature ..................................................................................... SERVICE 7: Date ....................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature ..................................................................................... SERVICE 9: Date ....................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature ..................................................................................... SERVICE 2: Date ....................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature ..................................................................................... SERVICE 4: Date ....................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature ..................................................................................... SERVICE 6: Date ....................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature ..................................................................................... SERVICE 8: Date ....................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature ..................................................................................... SERVICE 10: Date ..................................................................... Engineers Name ......................................................................... Company Name .......................................................................... Telephone No. ............................................................................. CORGI ID card serial No. ........................................................... Comments ................................................................................... ..................................................................................................... Signature .....................................................................................
Alpha CD24C/32C - Service Record
39
Alpha Therm Limited. Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS Tel: 0870 3001964 email: info@alphatherm.co.uk website: www.alpha-boilers.com
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 2005.
Part No. 1.023382 Rev 15.021101/000

10/05/D191
Manual compiled and designed by Publications 2000 - Tel: (01670) 356211

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Installation and Servicing Instructions

Alpha CD24C Alpha CD32C

G.C. No. 47 532 19 G.C. No. 47 532 21

For use with Natural Gas only

Leave these instructions with the User

Alpha CD24C/32C - Contents/Introduction

MAX. kW Btu/h kW Btu/h kW Btu/h mbar in wg m/h ft/h L/min gal/min

mbar in wg m/h ft/h

Specific Flow Rate (D) at 30C Rise L/min

2.2 11.2 2.5

(Flow rate @ 30K to EN625)

kW Btu/h kW Btu/h kW Btu/h mbar in wg m/h ft/h L/min gal/min

mbar in wg m/h ft/h

2.2 SYSTEM Alpha CD24C

Alpha CD24C and CD32C

CD32C 0.3 L Outlet Water Temp. (Approx. max.) 62C (144F)

Alpha CD24C/32C - Technical Data

Min. Clearances for Servicing (from casing)

AVAILABLE PUMP HEAD FOR CENTRAL HEATING

Output (50/30C) Available pump head

25.40 18.70 15.60 12.35 5.30

86 700 64 000 53 000 42 200 18 100

2.3 3.5 3.8 4.0 4.6

Red Brown Blue Wire Wire Wire

4 3 2 1 Internal Clock Terminals

Boiler terminal block

Alpha CD24C/32C - Technical Data

2.10 BOILER SCHEMATIC

GENERAL BOILER INFORMATION

FLUE SYSTEM - Fig. 3

Alpha CD24C/32C - General Boiler Information

HORIZONTAL FLUE OPTIONS - Lmax = 12 metres

E C L = B + E + F + 230 mm + (90 bend = 1.3 metre) B L = B + C + 230 mm + (2 x 45 bends = 1.8 metre)

VERTICAL FLUE OPTIONS

Alpha CD24C/32C - General Boiler Information

FLUE TERMINAL LOCATION - Fig. 4

G Above ground, roof or balcony level

Alpha CD24C/32C - General Boiler Information

CENTRAL HEATING SYSTEM - Fig. 5

Static head of system

Additional expansion vessel (if required) Double check valve assy.

Heating by-pass (If required)

Note: if required, an automatic by-pass is preferred.

DHW outlet Mains water inlet

System drain tap

FILLING THE CENTRAL HEATING SYSTEM - Figs. 6, 7

Mains water supply

Heating circuit return

Alpha CD24C/32C - General Boiler Information

FLUSHING THE HEATING SYSTEM

3.10 DISPOSAL OF CONDENSATE

Alpha CD24C/32C - General Boiler Information

Fig. 8 - External gully

Fig. 9 - External soakaway

3.11 DOMESTIC HOT WATER SYSTEM

Alpha CD24C/32C - General Boiler Information

CLEARANCES REQUIRED - Fig. 10

A = 345 mm for CD24 A = 380 mm for CD32

PREPARE THE WALL - Figs. 11, 12