alpha CD115S User guide

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Installation and Servicing

Instructions

Alpha CD90S and 115S

Wall Mounted, Fan Assisted, Gas Fired, High Efficiency

Condensing System Boilers

For Technical help or for Service call ...

ALPHA HELPLINE Tel: 0844 8718764

website:www.alpha-innovation.co.uk

Nepicar House, London Road,

Wrotham Heath, Sevenoaks,

Kent TN15 7RS

0051

For use with Natural Gas or Propane Gas (LPG)

Leave these instructions with the User

CONTENTS

1 Introduction ....................................... 2

2 Technical data ................................... 3

3 General boiler information .................. 7

4 Installation ......................................... 14

5 Commissioning ................................. 18

7 Wiring diagram .................................. 27

8 Fault finding ...................................... 28

9 Short parts list ................................... 30

10 Benchmark Checklist ......................... 31

11 Service record ................................... 32

6 Routine servicing ............................... 23

1 INTRODUCTION

The Alpha CD90S and 115S are wall mounted high efficiency condensing, fan assisted system boilers. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve.

These are system boilers providing heating only for sealed central heating systems. However, they may be used with an open central heating system if required - refer to Section 3.8.

The boilers are supplied with type B23 flue configuration (open chamber and forced draught) but can be changed to type C (room sealed) by using a conversion kit.

The boilers are fitted with a pump, 4 bar pressure relief valve and pressure gauge fully assembled and tested. They are designed for use with a fully pumped, sealed and pressurised central heating system. If used with an open system refer to Section 3.8.

The CD90S boiler is suitable for central heating loads of between 22.5 and 90 kW (85 985 and 307 092 Btu/h). The CD115S boiler is suitable for central heating loads of between 28.8 and 109 kw (98 269 and 371 923 Btu/h). The boilers can be supplied for use with Natural gas or Propane Gas (LPG).

Note: There are a number of additional controls and accessories available for use with the boilers to enable cascade and zone installations to be used. Further information is available from Alpha Therm Ltd.

IMPORTANT

It is the law that all gas appliances are installed by a competent person, ie Gas Safe 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 5295 Code of practice foe ventilation principles and designing for natural ventilation BS 5854 Code of practice for flues and flue structures in buildings BS 5978 Safety and performance of gas fired hot water boilers of rated inputs between 70 kW and 1.8 MW BS 6644 Specification for installation of gas fired hot water boilers of rated inputs between 70 kW and 1.8 MW BS 6700 Specification for design, installation, testing and maintenance of services supplying hot water for domestic use

within buildings and their curtilages. BS 6981 Installation of low pressure gas pipework of up to 28 mm in domestic premises BS 7074 Application selection and installation of expansion vessels and ancillary equipment for sealed water systems

Part 1 Code of practice for domestic heating and hot water

Part 2 Code of practice for low and medium temperature hot water system BS 7593 Code of Practice for treatment of water in heating systems BS 7671 Requirements for electrical installations, IEE Wiring Regulations BS EN 12828 Design for water based heating systems DOE Chimney heights, Third edition of the Clean Air Act Memorandum IGE/UP/1 Soundness testing and purging of industrial and commercial gas installations IGE/UP/1A Soundness testing and purging of small low pressure industrial and commercial natural gas installations IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises IGE/UP/10 Installation of gas appliances in industrial and commercial premises

Part 1 Flued appliances IM/11 Flues for commercial and industrial gas fired boilers

Reference should be made to DEFRA document 'Guide to condensing boiler installation assessment procedures for dwellings'.

Alpha CD90S/115S - Contents/Introduction

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 IPX5D, ie degree of protection against moisture. This appliance contains no asbestos and no substances have been used in the construction process that contravene the

COSHH Regulations (Control of Substances Hazardous to Health). 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 Checklist has been completed after the boiler has been installed and

commissioned.

2. It is the law that all boiler installations are registered by the installer through the Gas Safe Gas Work Notification Scheme.

3. The boiler must only be used with the flue components supplied with the boiler.

Propane Gas (LPG) - In addition to the regulations and requirements stated, the boiler must be installed in accordance with BS 5482:1 - The Installation of Propane Burning Appliances in Permanent Dwellings.

2 TECHNICAL DATA

2.1 PERFORMANCE

NATURAL GAS (CAT: I2H 2H - G20 - 20 mbar)

Alpha CD90S

Central Heating

Heat Input (H

)kW

(Gross) Btu/h

Heat Input (Hi)kW

(Net) Btu/h

Heat Output (Hs condensing) kW

(50°C/30°C) Btu/h

Heat Output (Hi non-condensing) kW

(80°C/60°C) Btu/h

Fan Speed rpm

Gas Rate m³/h

ft³/h

MAX.

92.8

316 634

90.0

307 080

97.8

333 700

88.4

301 621

5 900

8.9

297

MIN.

23.4

79 841

22.5

76 770

24.9

85 000

22.0

75 064

1 750

2.3

PROPANE GAS (CAT I3P 3P - G31 - 37 mbar)

Alpha CD90S

Central Heating

Heat Input (H

)kW

(Gross) Btu/h

Heat Input (Hi)kW

(Net) Btu/h

Heat Output (Hs condensing) kW

(50°C/30°C) Btu/h

Heat Output (Hi non-condensing) kW

(80°C/60°C) Btu/h

Fan Speed rpm

Gas Rate m³/h

ft³/h

MAX.

92.8

31 634

90.0

307 080

95.4

333 700

88.4

301 621

5 900

3.5

117

MIN.

23.4

79 841

22.5

76 770

24.3

85 000

22.0

75 064

1 750

0.9

Alpha CD115S

Central Heating

Heat Input (H

)kW

(Gross) Btu/h

Heat Input (Hi)kW

(Net) Btu/h

Heat Output (Hs condensing) kW

(50°C/30°C) Btu/h

Heat Output (Hi non-condensing) kW

(80°C/60°C) Btu/h

Fan Speed rpm

Gas Rate m³/h

ft³/h

MAX.

110.7

37 771

109.0

371 908

120.5

411 200

109.2

372 590

5 800

10.6

355

100 313

98 256

111 200

98 948

Alpha CD115S

Central Heating

Heat Input (H

)kW

(Gross) Btu/h

Heat Input (Hi)kW

(Net) Btu/h

Heat Output (Hs condensing) kW

(50°C/30°C) Btu/h

Heat Output (Hi non-condensing) kW

(80°C/60°C) Btu/h

Fan Speed rpm

Gas Rate m³/h

ft³/h

MAX.

110.7

37 771

109.0

371 908

120.5

411 200

109.2

372 590

5 700

4.2

14.0

100 313

98 256

111 200

98 948

MIN.

29.4

28.8

32.6

29.0

1 750

2.8

MIN.

29.4

28.8

32.6

29.0

1 750

1.1

36.7

Note: The above appliances are fully modulating and are not range rated.

Alpha CD90S/115S - Technical Data

2.2 SYSTEM

2.3 COMPONENTS

Central Heating (Sealed System)

Max. Working System Pressure

Min. System Pressure

Max. System temperature

Pressure Relief Valve Setting

Flow Connection

Return Connection

Relief Valve Connection

Recommended System Pressure (cold)

CH Water Temp. (Approx. max.)

2.4 ELECTRICAL

Supply

External Fuse

Power Consumption CD90S

CD115S

Internal Fuse - Main Terminal

PCB Fuse F1

PCB Fuse F3

Electrode Spark Gap

Electrical Enclosure Degree of Moisture Protection

3.5 bar

0.5 bar

85°C

4 bar (58.8 PSI)

1½" BSP

¾" BSP

1.0 bar

85°C (185°F)

230/240 V ~ 50 Hz

3 A

370 W

390 W

F2A

T2A

T4A

3 to 4 mm

IPX5D

Burner

Main Heat Exchanger

Main Burner Injector CD90S NG

CD115S NG

CD90S LPG

CD115S LPG

Concentric Flue Outer Duct

Concentric Flue Inner Duct

Open Flue Single Flue Pipe

2.5 INSTALLATION

Min. Clearances for Servicing Top

(from casing) Bottom

Sides

Front

Flue Diameter Open Flue

Concentric Flue

Flue Protruding Outside Open Flue

Concentric Flue

Hole For Flue Assy. Open Flue

Concentric Flue

Lift Weight CD90S

CD115S

Stainless steel

12.0 mm

14.0 mm

8.8 mm

10.8 mm

125 mm dia.

80 mm dia.

350 mm

10 mm

450 mm

80 mm

125 mm

80 mm

125 mm

100 mm dia.

127 mm dia.

63 kg

68 kg

2.6 FLUE LENGTHS - See also Section 3.4

Open Flue 80 mm single pipe - B23

Maximum Horizontal

Maximum Vertical

90° bend is equivalent to

45° bend is equivalent to

Concentric 80/125 mm room sealed

Maximum Horizontal

Maximum Vertical

90° bend is equivalent to

45° bend is equivalent to

CD90S

17 m

2.1 m

1.3 m

CD90S

10 m

12 m

1.9 m

1.4 m

CD115S

14 m

2.1 m

1.3 m

CD115S

1.9 m

1.4 m

2.8 PERFORMANCE DATA

%CO2 content (± 0.2%)

Min

9.10

8.95

Natural Gas

CH Max

9.30

9.45

Boiler model

CD90S

CD115S

7 m

8 m

(LPG) Propane Gas

Min

10.2

10.3

2.7 GENERAL

Case Dimensions Height

Width

Depth

Gas Connection CD90S

CD115S

Water Content CD90S

CD115S

CH Max

10.7

1010 mm

600 mm

610 mm

3/4 "

1 "

9.5 L

11.0 L

Alpha CD90S/115S - Technical Data

2.9 AVAILABLE PUMP HEAD FOR CENTRAL HEATING

A = CD90S - Available head with pump at maximum speed B = CD90S - Available head with pump at speed two C = CD115S - Available head with pump at maximum speed D = CD115S - Available head with pump at speed two

Total Head

(m water)

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000

2.10 ELECTRICAL CONNECTIONS

Note: This Appliance Must Be Earthed

230V ~ 50Hz

Fused at 3A

External Pump

Max 1A

(Optional)

External sensor

(Optional)

Flow Rate (l/h)

Fig. 1

DHW

temp sensor

(Optional)

Zone

manager

(Optional)

37A38

Room

thermostat

(Optional)

LINK

Diverter valve

motor

(Optional)

Summer switch

(Optional)

Analog

input 0 - 10 Volt (Optional)

Fuse F2A

X85

PQN

230/240 V ~ 50 Hz only Maximum 24 V connection only

GJ MORHF E TS KVUY Z

Note: Do not connect 230/240 V ~ 50 Hz

Fig. 2

Alpha CD90S/115S - Technical Data

X86

2.11 BOILER SCHEMATIC

Flow

1 Tundish

2 Pressure relief valve (4 bar)

3 Drain point

4 Primary pressure switch

5 Gas valve

6 Fan

7 Injector

8 Air inlet pipe

9 Ignition electrodes

10 Combustion chamber cover

11 Heat exchanger

12 Flue hood

13 Air inlet sampling point

14 Flue sampling point

Gas

Condensate

discharge

Return

15 Automatic air vent

16 Primary flow temperature sensor

17 Primary return temperature sensor

18 Overheat thermostat

19 Flue overheat thermostat

20 Burner

21 Flame sensing electrode

22 Venturi

23 Venturi positive point (P2)

24 Pump

25 Condensate trap

Alpha CD90S/115S - Technical Data

Fig. 3

3 GENERAL BOILER INFORMATION

3.1 GAS SUPPLY

Natural Gas:

The Alpha CD90S boiler requires a gas rate of 8.9 m³/h (297 ft³/h). The Alpha CD115S boiler requires a gas rate of 10.6 m³/h (355 ft³/h).

Propane Gas (LPG):

The Alpha CD90S boiler requires a gas rate of 7.17 kg/h or 14 litres/h of liquid gas. The Alpha CD115S boiler requires a gas rate of 8.76 kg/h or 17.2 litres/h of liquid gas.

The local Propane Gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas.

The meter and supply pipes must be capable of delivering this quantity of gas in addition to the demand from any other appliances. The boiler requires at least a 35 mm gas supply pipe and ensure the inlet supply pressure is at least 20 mbar for Natural Gas or 37 mbar for Propane Gas (LPG).

The complete installation, including the meter, must be tested for gas tightness 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

Note: 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 mm² (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).

3.3 AIR SUPPLY

Open flued (Type B23 flue)

Alpha CD90S and CD115S boilers leave the factory with 'B23' type configuration (open chamber and forced draught single flue pipe) and receive the air for combustion from openings in the rear of the boiler, therefore air supply for combustion and ventilation must be provided in accordance with BS6644.

Note: Where a boiler installation is to operate in summer months (e.g. DHW) additional ventilation requirements are required if operating more than 50% of the time (refer to BS 6644).

Room sealed (Type C flue)

If the boilers are converted to a 'C' type configuration (sealed chamber and forced draught - concentric flue pipe) as described in Section 3.4 only air for ventilation is required.

A minimum of 2 cm² free area per kW of net heat input at both high and low level is required for boiler rooms. For enclosures refer to BS 6644.

The minimum clearances for servicing must always be maintained.

Alpha CD90S/115S - General Boiler Information

3.4 FLUE SYSTEM

The flue system must be installed in accordance with BS 5854, BS 6644, IM/11.

For horizontal flues ensure the flue assembly slopes downwards towards the boiler by a minimum of 25 - 30 mm per metre of flue.

It is recommended that horizontal and vertical flue assemblies should be supported approximately every 1.5 m with access provided to the joints.

Alpha CD90S and CD115S boilers leave the factory with 'B23' type flue configuration (open chamber and forced draught single flue pipe). To change the configuration to 'C' type (sealed chamber and forced draught - concentric flue pipe), remove the 80 mm dia. adapter, the bracket and gasket from the top of the boiler and fit the concentric flue adaptor, see Section 4.5.

Note: 1. Under no circumstances must the flue length (including allowances for extra bends) exceed the maximum flue

lengths stated for each type of flue.

2. Failure to use the correct Alpha flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe.

Seals for flue elements - If lubrication of components (already performed by the manufacturer) is not sufficient, remove the residual lubricant using a dry cloth, then to ease fitting apply a small amount of common or industrial talc to the seal.

Ensure that the seals are correctly located in the elbows and extensions as shown in Fig. 4.

Seal Seal

Fig. 4

Flue components are available as follows:-

Open flue - 80 mm dia. single pipe

Horizontal terminal kit 80 mm dia. (includes 1 m straight with terminal, one 90° bend and two collars)

Vertical terminal kit 80 mm dia.

Extension pipe 1 m x 80 mm dia.

90° bend 80 mm dia.

45° bend 80 mm dia.

Concentric flue - 80/125 mm dia.

Horizontal terminal kit 80/125 mm dia. (includes 1 m straight with terminal, one 90° bend, two collars and adaptor)

Vertical terminal kit 80/125 mm dia. (includes adaptor)

Extension kit 1 m x 80/125 mm dia.

90° bend 80/125 mm dia.

45° bend 80/125 mm dia.

Alpha CD90S/115S - General Boiler Information

3.4.1 Horizontal Flue Options

L max

Open flue: 80 mm dia. single pipe

Lmax = 14.9 m (CD90S), 11.9 (CD115S)

Concentric flue: 80/125 mm dia.

Lmax = 8.1 m (CD90S), 5.1 m (CD115S)

L max

Open flue: 80 mm dia. single pipe Lmax = 17 m (CD90S), 14 m (CD115S) 90° bend is equivalent to 2.1 m of flue length 45° bend is equivalent to 1.3 m of flue length

Concentric flue: 80/125 mm dia. Lmax = 10 m (CD90S), 7 m (CD115S) 90° bend is equivalent to 1.9 m of flue length 45° bend is equivalent to 1.4 m of flue length

L max

Open flue: 80 mm dia. single pipe

Lmax = 14.4 m (CD90S), 11.4 m (CD115S)

Concentric flue: 80/125 mm dia.

Lmax = 7.2 m (CD90S), 4.2 m (CD115S)

3.4.2 Vertical Flue Options

Open flue: 80 mm dia. single pipe

Hmax = 17 m (CD90S), 14 m (CD115S)

Concentric flue: 80/125 mm dia.

Hmax = 12 m (CD90S), 8 m (CD115S)

Not less than

300 mm

Not less than

300 mm

Fig. 5 - Horizontal flues

Open flue: 80 mm dia. single pipe

Concentric flue: 80/125 mm dia.

Not less than

300 mm

Not less than

300 mm

Hmax = 14.4 m (CD90S), 11.4 m (CD115S)

Hmax = 9.2 m (CD90S), 5.2 m (CD115S)

Fig. 6 - Vertical flues

Alpha CD90S/115S - General Boiler Information

3.5 FLUE TERMINAL LOCATION - Fig. 7

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. 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.

Boundary

A Directly below an opening, air brick, windows, etc.

B Below gutters, soil pipes or drain pipes

C Below eaves

D Below balconies

E From a vertical drain pipe or soil pipe

F From an internal or external corner

G Above ground, roof or balcony level

H From a surface or boundary facing the terminal

I From a terminal facing the terminal

J Above an opening, air brick, window etc.

K Vertically from a terminal on the same wall

L Horizontally from a terminal on the same wall

M Horizontally from an opening, air brick, window etc.

N Minimum protrusion through a roof

O From a vertical obstruction

P From an openable window

Q From an adjacent vertical terminal

Min. distance (mm)Terminal position

300 mm (See Note 1)

Note: A terminal must not be sited under a car port roof

300 (See Note 1)

75 (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

600 mm

Fig. 7

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 can be extended beyond gutters, pipes, eaves, balconies etc. by upto 500 mm. If the flue is extended more than 500 mm outside, it should be boxed and insulated.

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 6644.

Alpha CD90S/115S - General Boiler Information

Propane Gas (LPG): Installation pipes, cylinders and pressure regulators should be fitted in accordance with BS 5482:1.

Bulk tank installation must comply with the requirements of the Home Office code of practice for the storage of liquefied petroleum gas at fixed installations. The boiler must not be installed in a room or internal space below ground level, e.g. in a basement or cellar, except where at least one side is open to ground level.

3.7 FROST PROTECTION

The boiler is fitted with a frost thermostat that activates the pump and burner when the system water temperature in the boiler falls below 3°C.

The electrical supply to the boiler must be left on for the thermostat to operate and the selector switch must be set to ON .

3.8 CENTRAL HEATING SYSTEM - Fig. 8

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 85°C. 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 graph for guidelines (see Fig. 1).

To ensure the boiler heat exchanger is protected from contamination, we strongly recommend the use of a barrier heat exchanger when installing these boilers. Barrier heat exchangers are available from Alpha Therm Ltd..

If the boiler is to be used with an open central heating system refer to Fig. 8 and use a barrier heat exchanger (i.e. separates the boiler primary circuit from the open heating circuit).

Sealed system volume - An expansion vessel is not incorporated into the boiler. An expansion vessel must be fitted in the position shown in Fig. 8. To check correct operation of the expansion vessel the system pressure should not be more than 3.5 bar when the system is at maximum operating temperature (for further guidance refer to BS 7074:1), For example an 8 litre expansion vessel is suitable for a sealed system of 80 litres.

The boiler is supplied with the following components built in:Pressure relief valve - complying with BS 6759 and set to operate at 4 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. By-pass - The boiler has no built-in by-pass, therefore an automatic by-pass is required for the system.

Note: A drain tap should be installed at the lowest point of the heating circuit and beneath the appliance.

Heating flow

System drain tap

Fig. 8

Make up vessel (sealed system only)

Boiler

Heating return

Return

Automatic air vent

Return

Flow

Fit pump if Barrier heat exchanger used

Static head of system

Expansion vessel (sealed system only)

Double check valve assy. (sealed system only)

Filling point (sealed system only)

Barrier heat exchanger used on open or old/dirty systems

Heating flow

Heating return

Drain tap

Installation on a low temperature heating system.

The boiler can directly feed a low temperature system, varying the maximum delivery temperature of the boiler and setting a value of between 20 and 85°C. To vary the boiler maximum delivery temperature, modify the boiler maximum delivery temperature of parameter No. 4 as described in Section 5.7 and Table 3.

In this mode it is advisable to include a safety limit thermostat set at 55°C in series with the boiler circulating pump. The thermostat must be positioned in the system flow pipe at more than 2 metres from the boiler.

Alpha CD90S/115S - General Boiler Information

3.9 FILLING THE SEALED CENTRAL HEATING SYSTEM - Figs. 9

The system design pressure (cold) should be set to 1.0 bar. This pressure is equivalent to a static head (see Fig. 8) 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 Fig. 9. The position for connecting an automatic make-up vessel is indicated in Fig. 8. A double check valve assembly must be used.

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. 9. 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 4 bar.

Drain taps (to BS 2879) must be used to allow the system to be completely drained.

Heating circuit

return

Stop valve

temporarily connected

Hose

unions

Filling loop

Double check

valve assembly

Test cock

Stop valve

Mains water supply

Fig. 9

3.10 FLUSHING THE HEATING SYSTEM

It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha CD50S or CD70S boiler. Failure to do so will invalidate the warranty. If this is difficult because the system is old/dirty refer to Section 3.8, Fig. 8 gives consideration to using a barrier heat exchanger.

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 CD90S or CD115S boilers. Further information can be obtained from Fernox (Tel: 0179 9521133) or Sentinel (Tel: 0151 4209563).

The system should be flushed in accordance with BS 7593 . 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.

2. 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.

Alpha CD90S/115S - General Boiler Information

3.11 DISPOSAL OF CONDENSATE

Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha CD90S or CD115S boilers and reference should be made to BS 6644 for the requirements on the disposal of condensate.

The boilers incorporate a condensate trap, therefore no additional trap is required.

The condensate should ideally be discharged internally into an internal waste pipe 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. 10 and 11.

Note: All pipework must have a continuous fall (see Figs. 10 and 11) 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.

Use waterproof pipework insulation

Plastic pipe

in very exposed positions

Ensure pipe is adequately supported

Minimum gradient 2½°

Fig. 10 - External gully

22mm termination from boiler

500 mm min.

100mm plastic tube

Bottom of tube sealed

Soakaway depth 400mm filled with limestone chippings

Cement mortar sealing

Open end of pipe diverted into gully below grid but above water level

2½ fall

25mm

Ground level (either/or)

300mm

Two rows of 3 x 12mm holes at 25mm centres, 50mm from the bottom of the tube. Holes to face away from house.

Fig. 11 - External soakaway

Alpha CD90S/115S - General Boiler Information

4 INSTALLATION

4.1 UNPACKING

1. The basic boiler is supplied in a single box, containing the following:-

Cased boiler with:-

Mounting hooks and wall plugs Tundish for pressure relief valve outlet Condensate discharge pipe Gas service cock - 3/4" BSP (CD90S) or 1" BSP (CD115S) Literature pack and Wall template

Other parts of the flue system are supplied in separate packs as ordered.

2. Unpack boiler and remove the loose items.

4.2 DIMENSIONS and CONNECTIONS- Fig. 12

300 300

80 Dia.

140

1086

Heating flow B

Pressure relief valve discharge C

Condensate drain

Heating return B

1010

Gas D

982

905

105

170

300

445

495

600

Fig. 12

4.3 PREPARE THE WALL - Fig. 13

1. Decide upon the position of the boiler taking into account the clearances required for servicing (refer to Section 2.5) and the flue terminal position.

2. Tape the template to the wall (ensure it is level and the right way up). Mark the position of the two holes for the boiler mounting hooks, and the centres of the flow, return, gas and discharge connections.

3. Drill the fixing holes (12 mm dia.) to accept the No.12 plugs supplied. Screw the boiler mounting hooks fully into the plugs.

4. Cut suitable holes in the wall/roof 100 mm dia for open flue 80 mm dia. pipe or 127 mm dia. for concentric flue. Use the centre line positions given on the flue template.

5. Lift the boiler and locate it on the mounting hooks.

Note: When handling or lifting always use safe techniques - keep your back straight, bend your knees, don't twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible. Where possible transport the boiler using a sack truck or other suitable trolley. Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary.

134

253

B C

315

340

Centre line for horizontal concentric flue

Centre line for horizontal open flue

610

170 mm

Centre line for vertical flues

MINIMUMTOP CLEARANCE 350 mm

BOILERMOUNTING HOOKFIXING HOLE

TOPOF CASING

WITHCOVER

MINIMUMSIDE

CLEARANCE10 mm

BOTTOMOF CASING

HEATING

SAFETY

FLOW

VALVE

(11/2"BSP)

(3/4"BSP)

MINIMUMBOTTOM CLEARANCE 250 mm WITHOUTHYDRAULIC OPTIONAL KIT

FORUSE WITH ALPHA CD50 - 70S

Fig. 13

Alpha

BOILERMOUNTING HOOKFIXING HOLE

GAS

(28mm)

MINIMUMSIDE

CLEARANCE10 mm

HEATING RETURN (11/2"BSP)

200 mm

Alpha CD90S/115S - Installation

4.4 CONNECT THE PIPEWORK - Fig. 12

1. Thoroughly flush out all the water pipework. Refer to Section 3.10.

2. Connect the system flow and return pipework to the boiler using suitable isolating valves. 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.

3. Connect the 22 mm condensate trap drain pipe to the condensate discharge pipe using the clip supplied. Ensure that the condensate discharge pipe is as required in Section 3.11. Pour at least 0.5 litre of water into the flue duct, as shown in Fig. 14, and check the condensate discharge pipe for soundness

4. Ensure that all the valves are closed and do not turn on the water or gas supplies at this stage.

Fig. 14

4.5 'B23' TYPE SINGLE PIPE 80 mm FLUE KITS

Vertical kit - see Figs. 15 and 16, and refer to Section 3.4.

Fig. 17 shows the vertical flue kit parts.

To assemble the kit to the boiler - Slide the flue pipe down through the roof seal and place the seal over the flue duct. Push the flue duct into the flue socket on top of the boiler up to the stop. Ensure the seal is pushed in position against the ceiling.

The maximum vertical length (without bends) for flue pipe is 17 m (CD90S) or 14 m (CD115S) (see Figs. 15 and 16).

To install extensions or other flue components, proceed as follows: fit the male end of the pipe or elbow up to the stop on the female socket (with lip seals) of the previously installed component, this will ensure a secure fit and seal of the joints. Ensure all joints have the seal located correctly and the tape supplied is applied around each joint to ensure the flue ducts cannot be pulled apart.

It is recommended that the flue should be supported approximately every 1.5 m with access provided to the joints.

430 mm minimum

Seal

Flue pipe

Seal

Ver

tical terminal

Maximum length 17 m (CD90S) 14 m (CD115S)

Fig. 15 Fig. 16

Horizontal through the wall kit - see Figs. 17 and 18, and refer to Section 3.4.

Fig. 17 shows the horizontal through the wall kit parts.

To assemble the kit to the boiler - Fit the male end of the flue elbow into central flue outlet on the top of the boiler to the stop. Place the outer seal over the flue duct and slide it throught the wall from the outside. Place the inner seal over the flue duct then insert the duct into the elbow up to the stop. Slide the seals along the duct to seal it to the inside and outside of the wall.

To install extensions or other flue components, proceed as follows: fit the male end (smooth) of the pipe or elbow up to the stop on the female socket (with lip seals) of the previously installed component, this will ensure a secure fit and seal of the joints.

Extensions for flue kit - The maximum vertical/horizontal straight length (without flue bend) is 17 m (CD90S) or 14 m (CD115S) (refer to Section 3.4).

Note: To prevent condensate lying in the flue pipe, slope the pipe towards the boilers with a minimum slope of 2.5° - 3° (25 - 30 mm per metre). When installing the extensions, a wall/ceiling mounted clamp must be installed every 1.5 metres.

Alpha CD90S/115S - Installation

Flue pipe

Flue elbow

Fig. 17

Inner seal

Outer seal

100 mm

160 mm

80 mm

Note: Ensure the flue slopes downwards towards the boiler by a minimum of 25 to 30 mm per metre (2.5° to 3°)

Fig. 18

4.6 'C' TYPE CONCENTRIC FLUE KITS

Convert the boiler from the factory supplied 'B23' type configuration to 'C' type, i.e. room sealed concentric flue by removing the 80 mm dia. adaptor and four screws securing the fixing plate and gasket from the top of the boiler.

Horizontal through the wall concentric flue kit - see Figs. 19 and 20.

Fig. 19 shows the flue kit parts that need to be fitted to the boiler to ensure the room sealed concentric flue can be used.

To assemble the kit to the boiler - Fit the adapter into the central flue outlet on the top of the boiler up to the stop. Slide the square gasket over the adapter up to the groove, then fix it to the cover by means of the previously removed fixing plate and four screws. Fit the male end of the flue elbow up to the stop on the adapter. Place the outer seal over the concentric flue pipe and slide it throught the wall from the outside. Place the inner seal over the concentric flue pipe then insert the pipe into the elbow up to the stop. Slide the seals along the duct to seal it to the inside and outside of the wall.

To install extensions or other flue components, proceed as follows: fit the male end (smooth) of the concentric pipe or concentric elbow up to the stop on the female socket (with lip seals) of the previously installed component, this will ensure a secure fit and seal of the joints.

Extensions for horizontal kit - The horizontal kit can be extended up to a maximum horizontal distance of 10 m (CD90S) or 14 m (CD115S) (Fig. 20), including the flue terminal and excluding the flue bend on the boiler (refer to Section 3.4).

Note: To prevent condensate lying in the flue pipe, slope the pipe towards the boilers with a minimum slope of 3° (25 - 30 mm per metre). When installing the extensions, a wall/ceiling mounted clamp must be installed every 1.5 metres.

Flue elbow

Fixing plate

Square gasket

Adaptor

Concentric flue pipe

Fig. 19

Inner seal

Outer seal

136 mm

190 mm

Alpha CD90S/115S - Installation

Maximum 10 m (CD90S), 7 m (CD115S)

9820 mm (CD90S), 6820 mm (CD115S)

Inner seal

Note: Ensure the flue slopes downwards towards the boiler by a minimum of 25 to 30 mm per metre (2.5° - 3°)

Fig. 20

180 mm

Outer seal

4.7 CONNECT THE MAINS SUPPLY - Fig. 2

1. Remove the four screws securing the plastic top cover so that it can be lifted slightly at the front edge.

2. Remove the two fixing screws (one each side at the bottom) securing the case front panel (refer to Fig. 23). Pull the bottom of the panel outwards while pushing up at the same time and remove the panel then remove the two screws securing the control panel and lower the panel to gain access to the terminal block. Refer to Technical Data, Section 2.10 for connection details.

3. 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: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. Do not switch on the electrical supply at this stage.

4. If any external control, i.e. room thermostat etc. is to be fitted, refer to Fig. 2.

Note: All external control connections are less than 24 volts.

Do not connect 230/240 volts to any of the terminals G to Z on the X86 terminal block or to the X84 terminal block.

5. Ensure that there is sufficient free cable to allow the control panel to be raised and lowered then tighten the cable clamp screws.

6. Leave the control panel open until commissioning procedures have been completed.

7. Carry out electrical system checks - Short circuit, Polarity, Earth continuity and Resistance to earth with a suitable multimeter.

Alpha CD90S/115S - Installation

5 COMMISSIONING

When commissioning the boiler, ensure the Benchmark Checklist is completed.

5.1 FILL THE SYSTEM

1. The boiler is fitted with an automatic air vent positioned as shown in Fig. 3, ensure that the vent is always open.

2. Open any central heating flow and return valves.

3. Open the fill point valve on the filling loop until water is heard to flow.

4. To remove the air - Vent each radiator in turn, starting with the lowest in the system.

5. 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.

6. Check the operation of the pressure relief valve (see Fig. 3) 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.

7. 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. If the system has been over pressurised water may be released from the system by manually operating the drain point (see Fig. 3) until the system design pressure is obtained. The system design pressure (cold) should be between 0.75 and 1.25 bar.

Refer to Sections 3.9 and 3.10. Filling and Flushing the system.

5.2 TEST FOR GAS TIGHTNESS AND PURGE THE SUPPLY

1. With the boiler gas service cock closed. Pressure test the gas supply and inlet pipework connection to the boiler gas service cock for tightness in accordance with BS 6891.

2. Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 21). Ensure the gas supply is on and open the boiler service cock to purge in accordance with BS

6891.

3. Retighten the test point screw and test for gas tightness. Close the boiler gas service cock.

P3 Outlet gas pressure test point

Outlet flow regulator

Inlet gas pressure test point

Off-set adjustment screw

Fig. 21

5.3 BOILER CONTROLS - Fig. 22

On/Off switch

RESET

MODE

STEP

STORE

Alpha

Pressure gaugeDisplay panel

Fig. 22

5.4 INITIAL LIGHTING - Refer to Fig. 22

1. Ensure that the gas and electrical supplies to the boiler are off and that any heating flow and return valves are open.

2. Turn on the gas and electrical supplies to the boiler.

3. Ensure any external controls are calling for heat.

4. Set the On/Off 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 CD90S/115S - Commissioning

5.5 BOILER DISPLAY PANEL AND FUNCTION MODES

The boiler display panel (see Fig. 22), is composed of a 4-character display and 6 keys. By using these keys it is possible to adjust the boiler as it would be by using traditional selector switches and knobs.

Table 1 gives the function of each key.

RESET

MODE

STEP

STORE

Manual reset for possible boiler block

Display menu selection key

Selection of parameter to be displayed or edited

Data and storage confirmation key

Increase set value

Decrease set value

Table 1

When the boiler is operating, the 4-figure display indicates the mode code (by means of the first 2 figures on the left) and the boiler flow temperature (by means of the other two figures on the right).

For example if these values are shown on the display it means that the boiler is operating in

03 60

The boiler function modes are given in Table 2:

heating mode with a flow temperature of 60°C.

Mode code

9 (flashing)

Mode description

Stand - by, no operation demand

Pre-ventilation

Burner ignition

Burner lit (system heating)

Burner lit (domestic hot water)

Fan check

Burner off, requested temperature reached

Pump over-run in system heating mode

Pump over-run in domestic hot water mode

Burner off for one of the reasons given in Table 8 in Section 8

3 - way valve check

Table 2

5.6 BOILER FUNCTIONING PARAMETERS

PARAMETER Mode - Press the MODE key once to enter Parameter mode. In this mode the preset operational values

can be changed. The first two figures indicate the parameter number, the last two give the setting value. To change the boiler settings proceed as follows:

1. Press the MODE key once to enter parameter mode, using the STEP key select the parameter to be changed.

2. Change the value using the + or - keys, press the STORE key to store the new value.

3. Press MODE to make the new value effective.

Parameters that can be modified are given in Table 3.

Parameter Factory set

Domestic hot water setting value *

Domestic hot water functioning mode

Heating function mode

Max. heating flow temperature

Description

* Only active with hot water function enabled when external accessories are fitted.

Lower limit value Upper limit value New value

20°C

0 = disabled

1 = enabled

2 = disabled + continuous pump

3 = enabled + continuous pump

0 = disabled

1 = enabled

2 = disabled + continuous pump

3 = enabled + continuous pump

20°C

70°C

85°C

20°C

85°C

Table 3

Alpha CD90S/115S - Commissioning

Parameter 1: Allows domestic hot water temperature to be set if controlled with NTC probe.

Parameter 2: Allows domestic hot water production to be activated or cut out. With factory settings domestic hot water

production is cut out.

Parameter 3: Allows system heating function (Summer) to be cut out, or enabled (Winter). With factory settings system

heating is on.

Parameter 4: Allows heating flow temperature to be set. If the external temperature probe is connected to the boiler, the

electronics automatically determine the ideal system water temperature. This parameter represents the maximum temperature that the system delivery water can reach.

INFO Mode - Press the MODE key twice to enter INFO mode. In this mode the instantaneous operational values can be displayed and checked, but without making changes. The first two figures indicate the step number; the last two give the setting value.

For example if these values are shown on the display it means that the boiler is operating in

02 40

heating mode with a return temperature of 40°C.

Step

7, 8, 9

Visulisation

Flow temperature

Return temperature

Not active (Domestic temp., if domestic circuit probe is present)

Not active (External temp., if probe is installed)

Flow temperature set point

Temperature gradients (cannot be modified)

Flame current value

Value

Value in °C

-36 (value in °C)

Value in °C

°C/S

µA

Table 4

5.7 BOILER FUNCTIONING PARAMETERS

Tables 5 and 6 gives the boiler adjustment parameters with factory settings. To modify the parameters reserved for the Installer, it is necessary to enter an access code, which can be supplied on request.

To enter the code:

1. Press the MODE and STEP keys at the same time for 2 seconds; the display will show the wording CODE and subsequently a random number on the last two digits.

2. Change the value by operating the + or - keys until reaching the correct code.

3. Press the STORE key to confirm.

Possible settings for the Installer and User (without entering an access code)

Parameter

Description

Domestic hot water set point value

Domestic hot water functioning mode

Central heating functioning mode

Max, central heating flow temperature

Lower limit value

20°C

0 = disabled

1 = enabled

2 = disabled + continuous pump

3 = enabled + continuous pump

0 = disabled

1 = enabled

2 = disabled + continuous pump

3 = enabled + continuous pump

20°C

Upper limit value

70°C

85°C

Factory set

20°C

85°C

New value

Alpha CD90S/115S - Installation

Table 5

Parameter

Settings accessible by the Installer only

Description

Minimum heating flow temperature

Lower external temperature limit

Upper external temperature limit

Antifreeze temperature

External probe reading correction

Max. secondary heating circuit temperature

Min. secondary heating circuit temperature

Secondary heating circuit temp hysteresis

Min. tempearature set point value

Booster time

Flow temp compensation with ambient temp

Temp increase rel to DHW set point

Max fan rpm in heating mode (x100)

Max fan rpm in heating mode (units)

Max fan rpm in DHW mode (x100)

Max fan rpm in DHW mode (units)

Min fan rpm in heating mode (x100)

Min fan rpm in heating mode (units)

Fan rpm during ignition (x100)

Fan rpm during stabilisation period (x100)

Stabilisation period

Heating mode ramp up

Pump overrun at end of heating cycle

Pump overrun at end of DHW cycle

Hysteresis modulation with heating ON

Hysteresis modulation with heating OFF

Hysteresis modulation with DHW ON

Hysteresis modulation with DHW OFF

Hysteresis measurement with DHW ON

Hysteresis measurement with DHW OFF

Heating mode timer

DHW timer

DHW heating mode transition timer

Max time with DHW prioritised

Cascade address

Control type for heating installation

Type of DHW installation

Manual fan speed

PWM signal level for pump

Lower limit value

15°C

-30°C

15°C

-30°C

-5°C

Not active

0 = Off

1°C

0 = no booster

1 minute

0°C

15 CD90S

17 CD115S

15 CD90S

17 CD115S

12 CD90S

15 CD115S

12 CD90S

18 CD115S

0 = 10

1 minute

0 seconds

0°C

-5°C

0°C

-5°C

0 = phase with burner on

30 = phase with burner off 10 s

0 min

Not active

00 = ambient temp stat

01 = external probe

02 = 0 - 10 V power

03 = 0 - 10 V temperature

00 = instantaneous with probe

01 = instantaneous no probe

02 = Boiler with probe

03 = Boiler without probe

1 = Off

Upper limit value

60°C

10°C

25°C

10°C

5°C

60°C

30 minutes

80°C

30°C

60 CD90S

65 CD115S

38 CD90S

65 CD115S

60 CD90S

65 CD115S

38 CD90S

38 CD115S

900

99 minutes

300 seconds

20°C

10°C

30°C

300 seconds

120 min

100%

Factory set

20°C

-5°C

20°C

0°C

15°C

59 CD90S

59 CD115S

38 CD90S

38 CD115S

17 CD90S

17 CD115S

16 CD90S

20 CD115S

0°C

5°C

0°C

5°C

0°C

180

0 min

-1

Not active

New value

Table 6

Alpha CD90S/115S - Installation

Parameter

Description

PWM signal level for pump

PWM hysteresis

PWM pump high/low level

Low/Off and pump cycle

Min rpm for pressure switch (x100)

Min temp for boiler maintain function

Ramp up for HTG or HTG + DHW function

Pre-ignition time

Lower limit value

1°C

x0 = Off

x1 = On

0x = Normal heating pump cycle

0x = Normal DHW pump cycle

0°C

0 (heating only)

Not active

Upper limit value

10°C

255

80°C

1 (HTG + DHW)

Factory set

Not active

0°C

New value

Table 6 -

continued

5.8 FINAL COMMISSIONING

1. 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, Section 2.2).

2. Turn off the boiler.

4. Thoroughly flush out the water pipework (refer to Section 3.10).

5. Re-pressurise the system as described in Section 5.1.

5.9 FINAL ASSEMBLY

1. Raise and secure the control panel, replace the front cover and secure in position with the screws removed and secure the plastic top cover in position using the screws previously removed.

2. If the boiler is to be left in service with the User, set any external controls to the User's requirements.

3. If the boiler is not to be handed over immediately, close the boiler gas service cock and switch off the electrical supply.

4. If there is any possibility of the boiler being left during frost conditions, then the boiler and system should be drained. It is recommended that a label is attached to the boiler drawing attention to the fact that the system has been drained.

5. Complete the details of the installation in the Benchmark Checklist on page 31.

5.10 USER INFORMATION

The User must be advised (and demonstrate if necessary) of the following important points:-

1. How to light and turn off the boiler and how to operate any external 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 Gas Safe registered personnel.

4. Ensure that the boiler controls 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, i.e. the On/Off switch must be set to ON.

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 on page 31 has been completed after the boiler has been installed and commissioned.

Note: It may require that the installation is registered by the installer through the Gas Safe Work Notification Scheme.

12. Leave these Installation and Servicing instructions with the User for use on future calls.

Alpha CD90S/115S - Commissioning

6 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. Gas Safe 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 right hand of the base plate.

Always test for gas tightness after servicing any gas carrying components.

Always carry out electrical system checks i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter after servicing.

Notes: 1. Prior to servicing, it is recommended that a flue gas analyser is used to measure the performance of the boiler

(refer to Fig. 3 or 4 for the position of the flue sampling point). If the CO/CO2 ratio measured is greater than

0.003 or when other checks and comments from the customer have indicated that there may be problems, cleaning of the heat exchanger will be necessary. All Sections 6.1, 6.2, 6.3 and 6.4 must be carried out. Repeat the flue gas analyser test after reassembling the boiler and check that the CO/CO2 ratio is less than

0.003.

2. If the CO/CO2 ratio measured is less than 0.003 and other checks and comments from the customer suggest there are no problems then only Section 6.1 and Section 6.2 paragraphs 1, 2 and 3 need to be carried out to allow a visual check of the components within the combustion chamber.

3. If a flue gas analyser is not available, then all Sections 6.1, 6.2, 6.3 and 6.4 must be carried out.

6.1 IMPORTANT NOTES PRIOR TO SERVICING

1. Check the flue terminal outside and ensure it is not blocked.

2. Run the boiler and check the operation of its controls.

3. Refer to Fig. 3 or 4 for location of flue sampling point.

4. Ensure that all system connections and fittings are sound.

5. Refill, vent and re-pressurise the system as necessary. (Refer to Commissioning, Section 5.1). If the system pressure exceeds 3.5 bar when operating at maximum temperature, the heating expansion vessel should be checked and re-pressurised, if necessary. Note: Check the expansion vessel charge only when the system pressure is zero.

6. Check that the condensate trap drain pipe is connected and all joints are sound.

7. Record details of the service in the Service Record Section on page 32.

6.2 CASING REMOVAL - Fig. 23

If required, the casing can be completely removed as follows:

1. Remove the bottom cover plate by removing its four fixing screws.

2. Remove the two screws (item 1) securing the bottom of the casing front panel (item 5).

3. Remove the screws (item 7) at the top of the cover (item 6).

4. Pull the bottom of the casing front panel outwards while pushing upwards at the same time to remove it from the boiler.

5. Remove the two screws (item 2), each side, securing the side panels to the front support bracket.

6. Remove the screws (item 3) at the bottom side of the boiler securing the bottom of the side panel (item 4), then push upwards in order to remove the side panel.

Note: If only the front panel is to be removed, remove the four screws securing the plastic top cover so that it can be lifted slightly at the front edge. Remove the two fixing screws (item 1) (one each side at the bottom) securing the case front panel. Pull the bottom of the panel outwards while pushing up at the same time and remove the panel

Alpha CD90S/115S - Routine Servicing

Fig. 23 - Case removal

6.3 PREPARE FOR SERVICING - Fig. 23 and 24

1. Ensure the electrical supply is isolated and the gas supply is off.

2. Remove the complete case or just the front panel as described in Section 6.2.

4. Disconnect the gas supply pipe union from the burner manifold.

5. Remove the two screws securing the fan assembly to the combustion chamber front.

6. Remove the pressure tube.

7. Disconnect the electrode lead from the spark electrode and the in-line connector to the flame sensing electrode.

8. Remove the six nuts and washers securing the combustion chamber front assembly and remove the assembly.

Alpha CD90S/115S - Routine Servicing

1 Tundish

2 Burner

3 Flue temperature sensor

4 Flue hood

5 Condensing heat exchanger

6 Air intake pipe

7 Ignition electrode

8 Primary flow NTC

9 Primary return NTC

10 Venturi housing

11 Venturi

12 Injector

13 Fan

14 Transformer

15 Condensate drain trap

16 Pressure switch

17 Safety valve 4 bar

18 PCB

19 Condensate drain pipe

20 Sample points (A - air, F - flue gas)

21 Automatic air vent

22 Combustion chamber front cover

23 Overheat thermostat

24 Ignition sensor

25 Pump

26 Gas valve

Fig. 24

Alpha CD90S/115S - Routine Servicing

6.4 CLEANING THE BOILER

1. Remove any deposits from heat exchanger using a suitable soft brush. Do not use a brush with metallic bristles.

2. Check the condition of the combustion chamber insulation panels.

3. 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 injector.

4. 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.

5. Unscrew and replace the injector should it appear damaged.

6. Remove the four screws securing the burner 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.

7. Check the condition of the electrodes.

9. Check the spark gap, positioning and height of the electrodes. Refer to Fig. 25.

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.

Burner

Electrode gap 3-4mm

Combustion chamber front assembly

Ignition electrodes

Front panel insulation

Burner to electrode gap 16 mm

Flame sensing electrode

Fig. 25

6.5 RE-ASSEMBLE THE BOILER

1. 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. Replace the combustion chamber front assembly, ensuring it is correctly located.

3. Ensure the electrode lead is connected.

4. Re-connect the gas pipe to the manifold, test the connections for gas tightness and re-commission, Sections 5.2 and

5.4.

5. Place the case or front case panel in position and secure in position with the screws previously removed, see Section 6.2.

7. Check the operation of the boiler.

8. Return all controls to their original settings.

Alpha CD90S/115S - Routine Servicing

7 WIRING DIAGRAM

Optional controls - Note: maximum 24 volt only. Do not connect 230/240 volts

Gas valve

Pump

Display

Return

temperature sensor

Heating flow

temperature sensor

Overheat

thermostat

Flue overheat

thermostat

System pressure

switch

Fan

External

probe

Diverter

valve

motor

Cascade

regulator

DHW

temperature

sensor

Room

thermostat

Summer

switch

External pump

Max 1 A

Ignition electrodes

Supply

230/240 V ~ 50 HZ Fused at 2 A

Selector

Fuse

F 2 A

Transformer

Flame sensing

electrode

NOTE: to apply an external

room thermostat, connect it

to the terminals F & E

removing the link.

Br Brown Bk Black Bl Blue R Red Or Orange G/Y Green/Yellow W White GY Grey P Purple W/Bl White/Blue W/Br White/Brown

X85

X84

X86

Flue

temperature sensor

Alpha CD90S/115S - Wiring Diagram

8 FAULT FINDING

Boiler error codes that may appear on the right hand side of the boiler display panel when a fault shuts down the boiler. The code will be displayed with either the letter 'E' or 'b' on the left hand side. 'E' codes require a manual reset, 'b' codes will automatically reset.

Code 'E'

E 00

E 02

E 03

E05 E06 E11

E13 E14 E15

E16 E17 E44 E60

E 04

E 07

E 12

E 18

E 19

E 24

E 25

E 26

E 28

E 29

E 30

E 31

E 32

E 33

E 36

E 37

E 38

E 52

E 65

E114

E118

FUSE

Solution

Check flame sensing electrode and wiring

Check PCB

Check gas supply

Check electrode position

Check flame sensing signal is greater than 6µA

Check gas supply

Check electrical connections

Check PCB

Check electrical connections

Check PCB fuses

Check primary flow thermostat

Check flue thermostat

Check water circulation

Check for air in the system

Check water circulation

Check for air in the system

Check water circulation

Check for air in the system

Check water circulation

Check for air in the system

Check for system leaks

Re-pressurise the system 0.75 - 1.25 bar

Check fan

Check fuse F3

Check fan

Check fuse F3

Check electrical connections

Check PCB

Check water circulation

Check for air in the system

Check NTC resistance

Check fan

Check flue

Check air inlet pipework

Check water circulation

Check for air in the system

Check fan

Check flue

Check air inlet pipework

Check correct address setting on PCB

Check gas supply

Check gas supply pressure

Check gas supply pipework

Change fuse

Alpha CD90S/115S - Fault Finding

Table 7

Examples of boiler error codes

This example of a manual reset fault means that the boiler has ignition failure. To eliminate the

E 02

failure press the RESET button on the boiler control panel (see Fig. 24).

This example of an automatic reset fault means that the temperature difference between the

6 30

system flow and return is more than 40°C. The boiler will automatically reset when the anomaly disappears.

Code 'b'

b 18

b 19

b 24

b 25

b 26

b 28

b 29

b 30

b 33

b 38

b 65

b118

Description

System flow temperature over 92°C

System return temperature over 87°C

Inverted flow and return sensors

Increase of the system flow temperature too quick

No water/insufficient water pressure

Fan breakdown (no Hall signal)

Fan fault

Temperature difference between system flow greater than 40°C

DHW sensor anomaly (short circuit)

DHW sensor anomaly (open)

Fan start stand-by (insufficient air flow rate)

Ionisation current loss during burner ignition (after 3 attempts

becomes 'E 02' error ignition failure)

Table 8

Solution

Check the circulation of water in the system

Check sensor position

Check the circulation of water in the system

Check the system pressure is correct

Set the system pressure to between 1 and 1.2 bar

Check for any system leaks

Check the fan

Check the fan fuse 'F3'

Check the PCB

Check the fan

Check the fan fuse 'F3'

Check the PCB

Check the circulation of water in the system

Check/replace DHW sensor

Check fan functioning

Check presence of gas and electricity supply

Check the gas supply pressure

Alpha CD90S/115S - Fault Finding

9 SHORT PARTS LIST

Description

Main PCB

Display PCB

Control panel flap

Control panel - CD90S

Control panel - CD115S

Pressure gauge

Transformer

Flame sensor

Flame sensor lead

Ignition electrode

Combustion chamber cover - CD90S

Combustion chamber cover - CD115S

Burner - CD90S

Burner - CD115S

Injector Nat Gas - CD90S

Injector Nat Gas - CD115S

Injector LPG - CD90S

Injector LPG - CD115S

Fan

Flexible air inlet pipe

Primary Heat exchanger - CD90S

Primary heat exchanger - CD115S

Plastic flue manifold

Primary NTC

Pump

Automatic air vent

Primary pressure switch

Gas valve

Expansion relief valve

Overheat thermostsat

Flue NTC

Pipe, pump to heat exchanger - CD90S

Pipe, pump to heat exchanger - CD115S

Pipe, heat exchanger to manifold - CD90S

Pipe, heat exchanger to manifold - CD115S

Pipe, gas valve to burner manifold - CD90S

Pipe, gas valve to burner manifold - CD115S

LH side panel

RH side panel

Tundish

Pipe, tundish adapter

Flue connection flange

Condensate trap

Condensate drain pipe

Hydraulic seal kit

Heat exchanger seal kit

Gas circuit seal kit

Flue manifold seal kit

Qty.

Alpha Pt. No.

1.025819

1.019405

1.018884

1.029148

1.029197

1.015807

1.025780

1.028852

3.019870

1.028702

1.024139

1.028675

1.028343

1.028277

1.028828

1.029229

1.028946

1.029230

1.028674

1.028689

1.026338

1.028253

3.020422

1.023435

1.028715

1.2295

1.018320

1.028678

1.018879

1.016870

1.028832

1.028707

1.028692

1.028706

1.028691

1.028688

1.028681

2.014072

2.014071

1.018870

1.011654

1.028682

1.028679

1.028680

3.021582

3.021583

3.021580

3.021581

Alpha CD90S/115S - Short Parts List

10 CHECKLIST

Ensure the following is completed after the boiler has been installed and commissioned:-

BOILER SERIAL No. ......................................................... NOTIFICATION No. ..........................................................

CONTROLS

Time & temperature control to heating

Time & temperature control to hot water

Heating zone valves

Hot water zone valves

Thermostatic radiator valves

Automatic by-pass to system

FOR ALL BOILERS CONFIRM THE FOLLOWING:

The system has been flushed in accordance with the boiler manufacturer's instructions? Yes No

The system cleaner used ....................................................................................................................

The inhibitor used ................................................................................................................................

FOR CENTRAL HEATING MODE, MEASURE AND RECORD THE FOLLOWING:

Gas rate m³/hr ft³/hr

Burner operating differential pressure (if applicable) N/A mbar

Central heating flow temperature °C

Central heating return temperature °C

FOR COMBINATION BOILERS ONLY

Has a water scale reducer been fitted? Yes No

What type of scale reducer has been fitted? ......................................................................................

To comply with the Building Regulations, each section must have a tick in one or other of the boxes

room t/stat & programmer/timer

cylinder t/stat & programmer/timer

Fitted

Programmable roomstat

Combi boiler

Not required

FOR DOMESTIC HOT WATER MODE, MEASURE AND RECORD THE FOLLOWING:

Gas rate m³/hr ft³/hr

Maximum burner operating differential pressure (if applicable) N/A mbar

Cold water inlet temperature °C

Hot water outlet temperature °C

Water flow rate 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 Yes

The appliance and associated equipment has been installed and commissioned in accordance with the manufacturer's instructions Yes

If required by the manufacturer, have you recorded a CO/CO2 ratio reading N/A Yes CO/CO2 ratio

The operation of the appliance and system controls have been demonstrated to the customer Yes

The manufacturer's literature has been left with the customer Yes

COMMISSIONING ENG'S NAME:

Print ...................................................................... CORGI ID No. ..................................................

Sign ...................................................................... Date .................................................................

Alpha CD90S/115S - Benchmark Checklist

11 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. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

SERVICE 3: Date .......................................................................

Engineers Name .........................................................................

Company Name ..........................................................................

Telephone No. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

SERVICE 2: Date .......................................................................

Engineers Name .........................................................................

Company Name ..........................................................................

Telephone No. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

SERVICE 4: Date .......................................................................

Engineers Name .........................................................................

Company Name ..........................................................................

Telephone No. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

SERVICE 5: Date .......................................................................

Engineers Name .........................................................................

Company Name ..........................................................................

Telephone No. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

SERVICE 7: Date .......................................................................

Engineers Name .........................................................................

Company Name ..........................................................................

Telephone No. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

SERVICE 9: Date .......................................................................

Engineers Name .........................................................................

Company Name ..........................................................................

Telephone No. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

SERVICE 6: Date .......................................................................

Engineers Name .........................................................................

Company Name ..........................................................................

Telephone No. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

SERVICE 8: Date .......................................................................

Engineers Name .........................................................................

Company Name ..........................................................................

Telephone No. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

SERVICE 10: Date .....................................................................

Engineers Name .........................................................................

Company Name ..........................................................................

Telephone No. .............................................................................

Gas Safe ID card serial No. .......................................................

Comments ...................................................................................

.....................................................................................................

Signature .....................................................................................

Alpha Therm Limited. Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS

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 2010.

Tel: 0844 8718764

email: info@alpha-innovation.co.uk website:www.alpha-innovation.co.uk

Manual compiled and designed by Publications 2000 - Tel: (01670) 356211 03/10/D243

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Frequently Asked Questions

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