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Alpha CD18S Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing system boiler range
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Installation and Servicing

Alpha CD18S/24S/30S
Wall Mounted, Fan Assisted, Room Sealed, Gas Fired,
High Efficiency Condensing System Boiler Range
Instructions
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Alpha CD18S
Alpha CD24S
Alpha CD30S
For use with Natural Gas only
Leave these instructions with the User
Service Listed
G.C. No. 41 532 06
G.C. No. 41 532 02
G.C. No. 41 532 08

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  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha CD18S/24S/30S Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing System Boiler Range For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001964 Nepicar House, London Road, Wrotham Heath, Sevenoaks,...

  • Page 2: Table Of Contents

    13 Service record ........36 INTRODUCTION The Alpha CD18S, 24S and 30S are high efficiency condensing, wall mounted, fan assisted, room-sealed system boilers. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve.

  • Page 3: Technical Data

    15 mm External Fuse Recommended System Pressure (cold) 1.0 bar Power Consumption CD18/24 130 W CH Water Temp. (Approx. max.) 82°C (180°F) CD30 140 W Internal Fuse F2 A Electrode Spark Gap 3 - 4 mm Alpha CD18S/24S/30S - Technical Data...
  • Page 4 Note: This Appliance Must Be Earthed An optional integral two channel Clock kit (Part No. 6.1000220) is available if required. Note: Only use the Alpha two channel clock. Do not fit any single channel clocks. Fuse - Always fit fast blow 2 A...

  • Page 5: Boiler Schematic

    Cyclone separator Venturi Drain point Condensate trap Main burner Pressure relief valve Primary/condensing heat exchanger Primary pressure switch Room sealed chamber Ignition electrodes Flame sensing electrode Pressure differential test points Venturi negative point Fig. 2 Alpha CD18S/24S/30S - Technical Data...

  • Page 6: General Boiler Information

    2. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally and only 15 metres vertically. 3. Failure to use Alpha CD flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe.
  • Page 7 L = B + E + F + 230 mm + (90° bend = 1.3 metre) L = B + C + 230 mm + (2 x 45° bends = 1.8 metre) VERTICAL FLUE OPTIONS Fig. 3 Alpha CD18S/24S/30S - General Boiler Information...
  • Page 8 However, If the terminal is fitted less than 2.1 m above a surface where there is no public access, the terminal must be protected by a terminal guard. A suitable guard is available from Alpha Therm Ltd. BOILER LOCATION The boiler is not suitable for external installation unless it is installed within a purpose designed weatherproof building.
  • Page 9 Heating circuit water Feed cistern to be Stop return Stop supply located above highest valve valve Stop point in the system Test cock valve Test cock Filling loop temporarily connected Fig. 6 Fig. 7 Alpha CD18S/24S/30S - General Boiler Information...
  • Page 10 FLUSHING THE HEATING SYSTEM It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha CD boiler. Failure to do so will invalidate the warranty. The primary condensing heat exchanger is constructed in stainless steel and therefore is compatible with most materials used in a heating system.
  • Page 11 Fig. 8 - External gully Fig. 9 - External soakaway Alpha CD18S/24S/30S - General Boiler Information...

  • Page 12: Installation

    Using the screws supplied, fit the mounting Fig. 11 bracket. Top pipe connections - Preform the pipework at the back of the boiler before hanging the boiler, see Fig. 12, and secure in the clips provided. Alpha CD18S/24S/30S - Installation...
  • Page 13 Heating return C - Heating return (22 mm) valve D - Pressure relief valve (15 mm) Condensate E - Heating drain point trap F - Condensate discharge pipe G - Cyclone drain point 47.5 212.5 Fig. 13 Alpha CD18S/24S/30S - Installation...
  • Page 14 FIT THE FLUE - Figs. 14, 15 The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only. The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below.
  • Page 15 (use a 127 mm core drill). The size of the hole provides sufficient clearance for the clamps on the flue extension to pass through the hole. Determine the overall flue length as described in Section 4.6, paragraph 2 to determine the number of Alpha CD 750/1000 mm flue extensions required.
  • Page 16 The main terminal block can be removed by pulling it off the pins to give easy access to the terminals. Fig. 20 Do not switch on the electrical supply at this stage. Alpha CD18S/24S/30S - Installation...
  • Page 17 Ensure the electrical supply to the boiler is isolated. IMPORTANT - Only use an Alpha two channel clock. Do not fit a single channel clock. Remove the two screws securing the clock cover at the rear of the control panel.

  • Page 18: Commissioning

    Set the boiler selector switch to 'ON'. 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. Alpha CD18S/24S/30S - Commissioning...
  • Page 19 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 35. Alpha CD18S/24S/30S - Commissioning...
  • Page 20 11. Ensure the Benchmark Checklist in Section 12 on page 35 has been completed after the boiler has been installed and commissioned. 12. Leave these Installation and Servicing instructions with the User for use on future calls. Alpha CD18S/24S/30S - Commissioning...

  • Page 21: Boiler Operation

    A and B Flashing on and off alternately - 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 CD18S/24S/30S - Boiler Operation...

  • Page 22: Routine Servicing

    Six nuts and washers Gas pipe securing combustion union chamber front assembly Viewing window Room sealed panel fixing screws Pressure tube connections assembly Fan assembly fixing screws Ignition generator Condensate trap Fig. 25 Alpha CD18S/24S/30S - Routine Servicing...
  • Page 23 Place the front case panel in position as shown in Fig. 25 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 CD18S/24S/30S - Routine Servicing...

  • Page 24: Component Replacement

    Gain access behind the room sealed chamber panel as described in Section 8.1. Undo the gas inlet union to the combustion chamber front to gain access. Unscrew the damaged injector and screw in a replacement. Re-assemble in reverse order. Alpha CD18S/24S/30S - Component Replacement...
  • Page 25 Light the boiler and test for gas soundness. (Refer to Commissioning, Section 5.4) and the instructions supplied with the replacement valve for adjustment of the valve. 10. Complete re-assembly as described in Routine Servicing, Section 7.4 Fig. 28 paragraphs 5 to 9. Alpha CD18S/24S/30S - Component Replacement...
  • Page 26 Fig. 29 8.15 CLOCK (if fitted) - Refer to Fig. 21 Note: For replacement only use an Alpha two channel clock. Do not fit a single channel clock. 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.
  • Page 27 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). Automatic air vent Pump Primary pressure switch Pressure relief valve Pressure gauge Fig. 31 Alpha CD18S/24S/30S - Component Replacement...
  • Page 28 Disconnect the top and drain connection of the condensate trap. Lift the trap out and re-assemble with a new condensate trap. Note: Before fitting the new trap, pour 100 cc of water into the trap. Alpha CD18S/24S/30S - Component Replacement...

  • Page 29: Wiring Diagrams

    WIRING DIAGRAMS ILLUSTRATED WIRING DIAGRAM Alpha CD18S/24S/30S - Wiring Diagrams...
  • Page 30 FUNCTIONAL FLOW WIRING DIAGRAM Alpha CD18S/24S/30S - Wiring Diagrams...

  • Page 31: Fault Finding

    Check that the gas and water pipework has been connected to the correct connections on the boiler and all valves are open. However, before any servicing or replacement of parts ensure the gas and electrical supplies are isolated. 10.2 CENTRAL HEATING - Follow operational sequence Alpha CD18S/24S/30S - Fault Finding...
  • Page 32 10.2 FAULT FINDING SOLUTIONS A to E Alpha CD18S/24S/30S - Fault Finding...
  • Page 33 10.3 FAULT FINDING SOLUTIONS F to K Alpha CD18S/24S/30S - Fault Finding...

  • Page 34: Short Parts List

    Fig. 28 Flame sensing electrode and lead - CD30 1.019293 E96-572 Fig. 2A,2B, item 26/27 By-pass assembly 3.012801 E65-498 Fig. 27 Combustion chamber insulation panel front 1.014732 E94-420 Fig. 25 Condensate trap 1.011844 H01-874 Alpha CD18S/24S/30S - Short Parts List...

  • Page 35: Benchmark Checklist

    The operation of the appliance and system controls have been demonstrated to the customer The manufacturer's literature has been left with the customer COMMISSIONING ENG'S NAME: Print ..............CORGI ID No........... Sign ..............Date ..............Alpha CD18S/24S/30S - Service History...

  • Page 36: Service Record

    These instructions have been carefully prepared but we reserve the right to Nepicar House, London Road, Wrotham Heath, alter the specification at any time in the interest of product improvement. Sevenoaks, Kent TN15 7RS © Alpha Therm Limited 2005. Tel: 0870 3001964 email: info@alphatherm.co.uk website: www.alpha-boilers.com Part No.

This manual is also suitable for:

Cd24sCd30s

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