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. Failure to use Alpha CD flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe. Page 8 However, If the terminal is fitted less than 2. A suitable guard is available from Alpha Therm Ltd. 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.
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Burner lights but neon C illuminated 1. Check and correct if pressure tubes are connected and not blocked 2. If ignition can be called a small explosion then check wiring to ignition generator 3.
Boiler operation The boiler operating mode is controlled by the selector switch on the facia panel. DHW is capable of constantly controlling hot water domestic system. The whole boilers operation is designed to provide priority to domestic hot water supply over the central heating.
At this time and when air pressure switch will light the burner, fan will start to run at its full speed. The burner is suppose to adjust to provide the system demand. The moment that demanded temperature is reached, burner will switch off.
Normally fan would continue to run for more seconds, and then minimum 3 minutes will pass bufore burner is allowed to re-light. After tap is closed the boiler will immediately change back to providing CH. Whenever the is no water flow recognized by the flow switch,burner will turn off and the boiler immediately goes back to the central heating mode.
Parts replacement Warning! Wait till the boiler cools down. Take a note of what fuel is suppose to be used label on the inside of case side panel. Ensure the electrical supply is isolated and the gas supply is off. Allow the boiler to cool. Remove front panel from the boiler as shown on the picture below.
In some instances you will need to remove side panels by first unfixing bottom screws and only then lifting it upwards and forwards. In order to gain access to the chamber of combustion — remove all the screws connecting the sealed chamber panel should be 4. Move panel to the side, pay attention not to scratch, break the seal. Look at the picture below Attention: When replacing the panel, ensure the seal is intact and that the panel has been located correctly, especially on the sides.
Secure with five screws — do not over-tighten. Re-assemble in reverse order Draining the boiler Replacement of most of the parts will require draining the boiler. To properly drain the boiler follow steps below 1. Connect a suitable pipe to the drain point and route it to a suitable container. Open the drain point. For Hot water circuit- close the mains water inlet valve as shown on the picture obove. Open any hot tap below the level of the boiler to allow as much draining as possible. Attention: small amount of water will remain in the components and care must be taken when removing them.
Ignition electrode replacement 2. Gain General Access. Gain access to the combustion chamber 3. Disconnect the lead from the electrode 4. Disconnect the lead from the PCB as described on the picture below.
Note all positions 5. Re-assemble in reverse order. General electrodes replacement 1. Isolate the appliance 2. Remove all the screws should be 4 connecting the cover of the combustion chamber and put it aside 4. Disconnect the leads from the electrodes. Remove the grommet in the bottom of the chamber, disconnect the flamesensing electrode in-line connector and withdraw the lead 5. Take out the main burner from the body of the boiler.
Pay attention not to scratch or damabe insulation panels on the sides 6. Rear flame sensing electrode -unscrew all the screws connecting flame sensing electrode and take electrode out.
Put the new electrode in, verify if it is correctly positioned and that the gap is correct as shown on the picture below Attention! Fit the in-line connector to the lead by pushing it into the connector after the burner has been fitted. Put the new electrode in, verify if it is correctly positioned and that the spark gap is correct as shown on the picture below. Replace the burner, ensuring it is located correctly. Re-assemble the front cover of the combustion chamber, making sure it is properly located.
Fan replacement 2. Disconnect the fan wiring 4. Remove the three screws securing the fan to the flue hood. Fit the new fan and re-assemble in reverse order Attention! Re-assemble in reverse order and test the boiler Air pressure switch replacement 2. The pressure sensing tube should be disconnected 4.
Connect the wiring to the new switch. The polarity of the wires is not important 6. Secure the new switch in position and connect the pressure sensing tube to the connection nearest the front 7.
Overheat thermostat replacement 2. All applicable wiring from the overheat thermostat should be disconnected 4. Remove the spring clip and remove the overheat thermostat from the heat exchanger 5.
Fit the new overheat thermostat 6. Gas valve replacement 2. Unfix the screw should be one as described on the picture below. The plug needs to be disconnected and electrical plug needs to be secured. The gas inlet pipe union should be disconnected from the burner manifold 6.
Pay attention not to scratch or damage washer of the sealing manifold. After this lift out the valve assembly 8. Fit the new one 9. Pay attention to lighting the boiler and testing for gas soundness. Viewing window replacement 2. Remove the rubber window frame and remove the damaged glass 4. Re-assemble in reverse order with a new glass. Ensure the rubber frame is located correctly in the front panel. Internal fuse replacement 1. The fuse is located in the boiler terminal block 3.
PCB replacement 2. All PCB wiring connectors should be disconnected 4. Re-assemble in reverse order DHW flow switch replacement 2. Disconnect the wiring from the flow switch 4. Disconnect the two unions and remove the switch. Using a new washer reassemble in reverse order. Clock replacement optional part 1. Disconnect the wiring from the clock 5. Take out all the remaining clock screws and take the clock out from the control panel. Connect the wires following below logic:- terminal 1- blue, terminal 2- brown and , terminals 3 and 4- red wires.
Primary heat exchanger 1. Remove the overheat thermostat and the CH temperature sensor 5. Remove the plate. All unions should be two connecting return pipes and exchanger should be disconnected 7. Remove the the heat exchanger from the pipes move it upward , gently take it out of the boiler 8.
Remove the pipes from the heat exchanger by releasing the four union connections. New washers should be used when fitting the pipes into the new exchanger heat. Pay attention so that heat exchanger is properly located. Refill and re-pressure the system. Combustion chamber insulation replacement 2. Side out the front panel 4.
To replace the rear and side panels remove the heat exchanger.
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