Alpha CD50S, CD70S Installation and Servicing Instructions

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Page 1

Installation and Servicing

Instructions

Alpha CD50S and 70S

W all Mounted, Fan Assisted, Gas Fired, High Efficiency

Condensing System Boilers

For Technical help or for Service call ...

ALPHA HELPLINE

Tel: 0870 3001964

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

Page 2

CONTENTS

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

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

3 General boiler information..................8

4 Installation......................................... 15

5 Commissioning ................................. 19

7 Wiring diagram.................................. 29

8 Fault finding ...................................... 30

9 Short parts list ................................... 31

10 Benchmark Checklist ........................ 32

11 Service record ................................... 33

6 Routine servicing............................... 24

1 INTRODUCTION

The Alpha CD50S and 70S 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 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 CD50S boiler is suitable for central heating loads of between 10 and 53.8 kW (34 121 and 183 700 Btu/h). The CD70S boiler is suitable for central heating loads of between 18.1 and 72.8 kw (61 800 and 248 600 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 CORGI registered personnel, in accordance with the following recommendations:-

Current Gas Safety (Installation and Use) Regulations All current Building Regulations issued by the Department of the Environment, i.e. Approved Document L1. Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department UK Water Regulations/Byelaws (Scotland) Health & Safety Document No. 635 (The Electricity At Work Regulations 1989) The installation should also be in accordance with the following British Standard Codes of Practice:-

BS 5440:1:2000 Flues BS 5449:1990 Forced circulation hot water systems BS 5546:2000 Installation of hot water supplies for domestic purposes BS 6700:1997 Design, installation, testing and maintenance of services supplying water BS 6798:2000 Installation of gas fired hot water boilers BS 6891:1998 Gas installation BS 7593:1992 Code of Practice for treatment of water in heating systems BS 7671:2001 Requirements for electrical installations, IEE Wiring Regulations

Reference should be made to DEFRA document 'Guide to condensing boiler installation assessment procedures for dwellings'. If installation is in a timber framed building, refer to the Institute of Gas Engineers document IGE/UP/7. This appliance meets the requirements of 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 CORGI 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.

Alpha CD50S/70S - Contents/Introduction

Page 3

2 TECHNICAL DA T A

2.1 PERFORMANCE

NATURAL GAS (CAT: I2H 2H - G20 - 20 mbar) Alpha CD50S

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.

56.4

192 400

50.8

173 300

53.8

183 700

50.0

170 600

5 180

5.37

189.6

MIN.

11.5

39 250

10.4

35 500

11.1

37 800

10.0

34 120

1 280

1.10

38.8

PROPANE GAS (CAT I3P 3P - G31 - 37 mbar) Alpha CD50S

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.

56.4

192 400

50.8

173 300

53.8

183 700

50.0

170 600

5 200

2.15

75.9

MIN.

11.5

39 250

10.4

35 500

11.1

37 800

10.0

34 120

1 250

0.44

15.5

Alpha CD70S

Central Heating

Heat Input (H

)kW

(Gross) Btu/h Heat Input (Hi)kW (Net) Btu/h Heat Output (Hs condensing) k W (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.

77.5

264 300

69.8

238 200

72.8

248 600

67.9

231 700

5 240

7.4

261.2

70 060

63 120

67 100

61 800

Alpha CD70S

Central Heating

Heat Input (H

)kW

(Gross) Btu/h Heat Input (Hi)kW (Net) Btu/h Heat Output (Hs condensing) k W (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.

77.5

264 300

69.8

238 200

72.8

248 600

67.9

231 700

5 240

2.96

104.5

70 060

63 120

67 100

61 800

MIN.

20.5

18.5

19.7

18.1

1 400

1.96

69.2

MIN.

20.5

18.5

19.7

18.1

1 450

0.78

27.7

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

2.2 SYSTEM

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.)

3.5 bar

0.5 bar 82°C

4 bar (58.8 PSI)

1½" BSP 1½" BSP

¾" BSP

1.0 bar

82°C (180°F)

Alpha CD50S/70S - Technical Data

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2.3 COMPONENTS 2.4 ELECTRICAL

Burner Main Heat Exchanger Main Burner Injector CD50S NG

CD70S NG CD50S LPG

CD70S 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 CD50S

CD70S

Stainless steel Stainless steel

7.85 mm

13.0 mm

5.7 mm

7.8 mm

125 mm dia.

80 mm dia. 80 mm dia.

350 mm 250 mm

10 mm

450 mm

80 mm

125 mm

80 mm

180 mm 100 mm dia. 127 mm dia.

63 kg 68 kg

Supply External Fuse Power Consumption Internal Fuse - Main Terminal PCB Fuse F1 PCB Fuse F3 Electrode Spark Gap

Electrical Enclosure Degree of Moisture Protection

2.6 GENERAL

Case Dimensions Height

Width

Depth Gas Connection Water Content CD50S

CD70S

230/240 V ~ 50 Hz

3 A

180 W

F2A T2A T4A

3 to 4 mm

IPX5D

950 mm 600 mm 525 mm

28 mm

3.7 L

4.0 L

2.7 PERFORMANCE DATA

Boiler model

CD50S CD70S

Natural Gas Efficiency

Min

9.25

9.00

%CO2 content (± 0.2%) Sedbuk rating

(LPG) Propane Gas

CH Max

9.30

9.25

Min

10.1

9.7

CH Max

10.6

10.5

band

A A

NOx class

5 5

Alpha CD50S/70S - Technical Data

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2.8 FLUE LENGTHS - See also Section 3.4

Open flue - Maximum horizontal or vertical flue with single 80 mm dia. open flue is 30 metre

90° bend is equivalent to 2.1 m of flue length 45° bend is equivalent to 1.3 m of flue length Vertical terminal is equivalent to 3 m of flue length

Concentric flue - Maximum horizontal flue is 14 metre, maximum vertical flue is 18 metre

90° bend is equivalent to 1.9 m of flue length 45° bend is equivalent to 1.4 m of flue length Vertical terminal is equivalent to 3.4 m of flue length

Notes: 1. Ensure all flues slope downwards towards the boiler by a minimum of 25 to 30 mm per metre of flue.

2. It is recommended that horizontal and vertical flue assemblies should be supported approximately every 1.5 m

with access provided to the joints.

2.9 AVAILABLE PUMP HEAD FOR CENTRAL HEATING

A = CD50S - Available head with pump at maximum speed B = CD50S - Available head with pump at speed two C = CD70S - Available head with pump at maximum speed D = CD70S - Available head with pump at speed two

TOTAL HEAD

(M water)

200 400 600 800 10001200 14001600 1800 20002200 2400 2600 2800 3000 32000

2.10 ELECTRICAL CONNECTIONS

Note: This Appliance Must Be Earthed

External Pump

Max 1A

(Optional)

Fuse F2A

230V ~ 50Hz

Fused at 3A

PQN

FLOW RATE (litre/h)

Fig. 1

External sensor

(Optional)

Zone

manager

(Optional)

37A38

temp sensor

(Optional)

DHW

thermostat

Room

(Optional)

LINK

Diverter valve

motor

(Optional)

Summer switch

(Optional)

X85

GJ MOR HF E TS KVUY Z

Analog

input 0 - 10 Volt (Optional)

X86

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

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

Fig. 2

Alpha CD50S/70S - Technical Data

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2.11 BOILER SCHEMATIC - CD50S

16 17

1 Tundish 2 Pressure relief valve (4 bar) 3 Drain point 4 Primary pressure switch 5 Flow manifold 6 Condensate trap 7 Gas valve 8 Air inlet pipe 9 Fan 10 Injector 11 Flame sensing electrode 12 Combustion chamber cover 13 Heat exchanger 14 Flue overheat thermostat

ReturnGasFlow Condensate

discharge

15 Flue hood 16 Air inlet sampling point 17 Flue sampling point 18 Primary flow temperature sensor 19 Air vent - manual 20 Primary return temperature sensor 21 Overheat thermostat 22 Ignition electrodes 23 Burner 24 Venturi positive point (P1) 25 Venturi 26 Automatic air vent 27 Pump

Alpha CD50S/70S - Technical Data

Fig. 3 - CD50S

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2.12 BOILER SCHEMATIC - CD70S

15 16

1 Tundish 2 Pressure relief valve (4 bar) 3 Drain point 4 Primary pressure switch 5 Flow manifold 6 Gas valve 7 Fan 8 Injector 9 Air inlet pipe 10 Ignition electrodes 11 Combustion chamber cover 12 Hear exchanger 13 Flue overheat thermostat

ReturnGasFlow Condensate

discharge

14 Flue hood 15 Air inlet sampling point 16 Flue sampling point 17 Automatic air vent 18 Primary flow temperature sensor 19 Primary return temperature sensor 20 Overheat thermostat 21 Burner 22 Flame sensing electrode 23 Venturi 24 Venturi positive point (P1) 25 Pump 26 Condensate trap

Fig. 4 - CD70S

Alpha CD50S/70S - Technical Data

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3 GENERAL BOILER INFORMATION

3.1 GAS SUPPLY

Natural Gas:

The Alpha CD50S boiler requires a gas rate of 5.37 m³/h (189.6 ft³/h). The Alpha CD70S boiler requires a gas rate of 7.4 m³/h (261.2 ft³/h).

Propane Gas (LPG):

The Alpha CD50S boiler requires a gas rate of 3.94 kg/h (8.4 lb/h) or 7.6 litres/h of liquid gas. The Alpha CD70S boiler requires a gas rate of 5.42 kg/h (11.6 lb/h) or 10.4 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 28 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 CD50S and CD70S 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 BS5440:2.

1. If the boiler is installed in a room - The room must have a permanent air vent either direct to the outside air or to an adjacent room which itself has a permanent air vent to the outside air. The minimum effective air vent(s) required is:

Alpha CD50S: 220 cm² Alpha CD70S 315 cm²

2. If the boiler is installed in a cupboard or compartment - Permanent air vents are required in the cupboard or compartment, one at high level and one at low level, either direct to the outside air or to a room. Both the high and low level air vents must communicate with the same room or must be on the same wall to outside air. The minimum effective areas required are given in Table 1.

Where the cupboard or compartment is ventilated to a room, the room itself must have an effective air vent direct to outside air of minimum effective area as given above in paragraph 1.

Boiler model Vents to outside air

Vents into a room

High level Low level High level Low level

CD50S 255 cm² 510 cm² 510 cm²

1020 cm²

CD70S 350 cm² 700 cm² 700 cm²

1400 cm²

Table 1

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.

1. If the boiler is installed in a room - No air vents are required in the room in which the boiler is installed.

2. If the boiler is installed in a cupboard or compartment - Permanent air vents for ventilation are required in the

cupboard or compartment, one at high level and one at low level, either direct to the outside air or to a room. Both the high and low level air vents must communicate with the same room or must be on the same wall to outside air. Both the high and low level vent must each have a free area as follows. The free area of each vent may be halved if the ventilation is provided directly from outside.

Alpha CD50S: 510 cm² Alpha CD70S 700 cm²

The minimum clearances for servicing must always be maintained.

Alpha CD50S/70S - General Boiler Information

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3.4 FLUE SYSTEM

The flue system must be installed in accordance with BS 5440:1. 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 CD50S and CD70S 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. 5.

Seal Seal

Fig. 5

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 CD50S/70S - General Boiler Information

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3.4.1 Horizontal Flue Options

L max

Open flue: 80 mm dia. single pipe Lmax = 30 m 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 = 14 m 90° bend is equivalent to 1.9 m of flue length 45° bend is equivalent to 1.4 m of flue length

Open flue: 80 mm dia. single pipe Lmax = 27.9 m Concentric flue: 80/125 mm dia. Lmax = 12.1 m

3.4.2 Vertical Flue Options

Not less than

300 mm

Not less than

300 mm

L max

Open flue: 80 mm dia. single pipe Lmax = 27.4 m Concentric flue: 80/125 mm dia. Lmax = 11.2 m

Fig. 6 - Horizontal flues

Not less than

300 mm

Not less than

300 mm

Open flue: 80 mm dia. single pipe Hmax = 30 m Concentric flue: 80/125 mm dia. Hmax = 18 m

Alpha CD50S/70S - General Boiler Information

Open flue: 80 mm dia. single pipe Hmax = 27.4 m Concentric flue: 80/125 mm dia. Hmax = 15.2 m

Fig. 7 - Vertical flues

Page 11

3.5 FLUE TERMINAL LOCATION - Fig. 8

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) 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

300 mm 300 mm 600 mm 600 mm

Fig. 8

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 6798.

Alpha CD50S/70S - General Boiler Information

Page 12

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. 9

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 82°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).

However, if the boiler is to be used with an open central heating system refer to Fig. 9 and use a barrier heat exchanger (i.e. separates the boiler primary circuit from the open heating circuit). This will also ensure the boiler heat exchanger is protected from an old/dirty system.

Sealed system volume - An expansion vessel is not incorporated into the boiler. An expansion vessel must be fitted in the position shown in Fig. 9. 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. 9

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 5.8 and Table 6.

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 CD50S/70S - General Boiler Information

Page 13

3.9 FILLING THE SEALED CENTRAL HEATING SYSTEM - Figs. 10, 11

The system design pressure (cold) should be set to 1.0 bar. This pressure is equivalent to a static head (see Fig. 9) of

10.2 metres of water. Provision should be made to replace water lost from the system. This can be by manual or automatic means, as shown in

Figs. 10 and 11. The position for connecting an automatic make-up vessel is indicated in Fig. 9. A double check valve assembly must be used, as shown in Fig. 11.

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. 10. 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.

Mains water supply

Feed cistern to be located above highest point in the system

Heating circuit

return

Stop valve

temporarily connected

Hose

unions

Filling loop

Double check

valve assembly

Test cock

Stop valve

Mains water supply

Heating circuit

return

Double check

valve assembly

Test cock

Overflow

Stop valve

Fig. 10 Fig. 11

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. 9 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 CD50S or CD70S 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 and BS 5449. The following procedures are recommended:

1. Installing onto a new system:a.Fill the system, vent at high points, at pump and radiators. b. Check for leaks. c.Rapidly drain the system. d. If required, chemically clean the system as instructed by the recommended cleaner manufacturer.

Note: Ensure that the system is flushed to remove any remains of the cleaner.

e. If chemical cleaner is not used to clean the system:-

i) Refill the system. ii) Switch on the boiler and allow the system to heat up to the normal operating temperature. iii) Rapidly drain the system while the water is still hot.

iv) Refill the system. f. As required, add the recommended inhibitor to the system as instructed by the inhibitor manufacturer. g. Recheck for leaks.

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 CD50S/70S - General Boiler Information

Page 14

3.11 DISPOSAL OF CONDENSATE

Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha CD50S or CD70S boilers and reference should be made to BS 6798: 2000 for the requirements on the disposal of condensate.

The boilers incorporate a condensate trap which has a seal of 75 mm, therefore no additional trap is required. The condensate should ideally be discharged internally into an internal waste pipe (washing machine/sink waste) or soil

pipe to avoid the possible risk of freezing. The pipework must be in 22 mm pipe. External pipe runs should be avoided, but if it is necessary, the pipework should be at least 32 mm and protected from

the risk of freezing with a waterproof insulation and the length should be kept to a maximum of 3 m. Termination should be into an external gulley or soakaway as shown in Figs. 12 and 13.

Note: All pipework must have a continuous fall (see Figs. 12 and 13) 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. 12 - 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.

Alpha CD50S/70S - General Boiler Information

Fig. 13 - External soakaway

Page 15

4 INST ALLATION

4.1 UNPACKING

1. The basic boiler is supplied in a single box, containing the following:Cased boiler supplied with water connections and washers

Mounting hooks and wall plugs Tundish for pressure relief valve outlet Condensate discharge pipe Gas service cock and 28 mm connection tail Literature pack and Wall template

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

2. Unpack boiler and remove the loose items.

4.2 DIMENSIONS and CONNECTIONS- Fig. 14

1010

Heating flow B

Pressure relief valve discharge C

Gas A

Heating return B

950

905

105

300

170

300

Alpha CD70S

495

600

Fig. 14

300

23280 Dia.

220

285

525

4.3 PREPARE THE WALL - Fig. 15

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) and mark the position of the two holes for the boiler mounting hooks.

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.

Centre line for horizontal concentric flue

170 mm

Centre line for horizontal open flue

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

Alpha

GAS

(28mm)

Fig. 15

Alpha CD50S/70S - Installation

BOILERMOUNTING HOOKFIXING HOLE

MINIMUMSIDE

CLEARANCE10 mm

HEATING RETURN (11/2"BSP)

200 mm

Page 16

4.4 CONNECT THE PIPEWORK - Fig. 14

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. 16, 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. 16

4.5 'B23' TYPE SINGLE PIPE 80 mm FLUE KITS

Vertical kit - see Fig. 17 and 18, 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 30 metres (see Fig. 17 and 18) 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

Vertical terminal

Maximum length 30 m

Fig. 17 Fig. 18

Horizontal through the wall kit - see Fig. 19 and 20, and refer to Section 3.4.

Fig. 19 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 30 metres (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 CD50S/70S - Installation

Page 17

Flue elbow

Flue pipe

Fig. 19

Inner seal

Outer seal

170 mm

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

100 mm

80 mm

Fig. 20

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 Fig. 21 and 22.

Fig. 21 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 14 metres (Fig. 22), 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.

200 mm

136 mm

Flue elbow

Fixing plate

Square gasket

Adapter

Inner seal

Outer seal

Concentric flue pipe

Fig. 21

Maximum 14000 mm

13820 mm

Inner seal

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

180 mm

Outer seal

Fig. 22

Alpha CD50S/70S - Installation

Page 18

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. 25). 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 CD50S/70S - Installation

Page 19

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. The CD50S also has a manual air vent (see Fig. 3)

2. Open the 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 or 4) 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 or 4) 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. 23). 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.

Outlet gas pressure test point

Outlet flow regulator

Off-set adjusment screw

Inlet gas pressure test point

Fig. 23

5.3 BOILER CONTROLS - Fig. 24

On/Off switch

RESET

MODE

STEP

STORE

Alpha

Pressure gaugeDisplay panel

Fig. 24

5.4 INITIAL LIGHTING - Refer to Fig. 24

1. Ensure that the gas and electrical supplies to the boiler are off and that the 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 CD50S/70S - Commissioning

Page 20

5.5 BOILER DISPLAY PANEL AND FUNCTION MODES

The boiler display panel (see Fig. 24, 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 2 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 2

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 3:

heating mode with a flow temperature of 60°C.

Mode code

0 1 2 3 4 5 6 7 8 9 (flashing) A

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 3 - way valve check

Table 3

5.6 BOILER FUNCTIONING PARAMETERS - Refer to Fig. 22

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 4

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

Alpha CD50S/70S - Commissioning

Table 4

Page 21

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

1 2 3 4 6

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 Value in °C

70 (value in °C)

-37 (value in °C) Value in °C

°C/S

µA

Table 5

5.7 BOILER FUNCTIONING PARAMETERS

Tables 6 and 7 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

1 2

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 0

85°C

New value

Table 6

Alpha CD50S/70S - Installation

Page 22

Parameter

10 11 12 13 14 15 16 17 18

20 21 22

23 24 25 26

27 28 29

30 31 32

33 34 35 36 37 38 39 40 41 42

43 44 45

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 Not active Not active 0 = Off 1°C 0 = no booster 1 minute 0°C 0 15

0 15 0 12

0 21 12

0 0 0 = 10 1 minute 0 seconds 0°C 0°C

-5°C 0°C 0°C

-5°C 0 0 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 0% 1

Upper limit value

60°C 10°C 25°C 10°C 5°C

60°C

30 minutes

80°C 30°C 60

99 38 99 60

99 27 38

900 15 99 minutes

300 seconds 20°C 10°C 30°C 30°C 30°C 30°C 300 seconds 300 seconds

120 min

100%

Factory set

20°C

-5°C 20°C 0°C 0°C

0°C

0°C 15°C CD50S=52 CD70S=53 0 38 0 CD50S=13 CD70S=15 0 23 CD50S=16 CD70S=17 06 2 3

60 0°C 5°C 0°C 5°C 5°C 0°C 180 0 0

0 min

-1

Not active

New value

Alpha CD50S/70S - Installation

Table 7

Page 23

Parameter

49 50 51 52 53

54 55 56 57

Description

PWM signal level for pump 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

10 15 1°C 16 x0 = Off x1 = On 0x = Normal heating pump cycle 0x = Normal DHW pump cycle 5 0°C 0 (heating only) Not active

Upper limit value

50 50 10°C 255

70 80°C 1 (HTG + DHW)

Factory set

Not active Not active Not active Not active 00

5 0°C 0

New value

Table 7 - 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 32.

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 CORGI 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 32 has been completed after the boiler has been installed and commissioned.

Note: It is a requirement that the installation is registered by the installer through the CORGI Gas Work Notification Scheme.

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

Alpha CD50S/70S - Commissioning

Page 24

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. CORGI registered personnel. Warning: Before servicing the boiler, isolate the electrical supply and close the boiler gas service cock. Allow the boiler to

cool. The data label is positioned on the inside of the 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 33.

6.2 CASING REMOVAL - Fig. 25

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 CD12S/20S/28S - Routine Servicing

Page 25

Fig. 25 - Case removal (CD70S shown)

6.3 PREPARE FOR SERVICING - Fig. 26 or 27

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 ignition generator 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 CD12S/20S/28S - Routine Servicing

Page 26

1 PCB 2 Delivery manifold 3 System pressure switch 4 Air intake pipe 5 Fan 6 Injecter 7 Venturi 8 Ignition sensor 9 Combustion chamber front cover 10 Venturi housing 11 Condensing heat exchanger 12 Test points (air A) - (flue F) 13 Flue hood 14 Primary return NTC

Alpha CD12S/20S/28S - Routine Servicing

15 Flue thermostat 16 Manual air vent 17 Primary flow NTC 18 Overheat thermostat 19 Ignition electrodes 20 Burner 21 Transformer 22 Automatic air vent 23 Pump 24 Condensate trap 25 Gas valve 26 Safety valve 4 bar 27 Tundish

Fig. 26 CD50S

Page 27

1 Tundish 2 Burner 3 Flue hood 4 Flue overheat thermostat 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 Condensate trap

15 System pressure switch 16 Flow manifold 17 Safety valve 4 bar 18 PCB 19 Condensate drain pipe 20 Test points (air A) - (flue F) 21 Automatic air vent 22 Combustion chamber front cover 23 Overheat thermostat 24 Ignition sensor 25 Transformer 26 Pump 27 Gas valve

Fig. 27 CD70S

Alpha CD12S/20S/28S - Routine Servicing

Page 28

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. 28.

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. 28

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 CD50S/70S - Routine Servicing

Page 29

7 WIRING DIAGRAM

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

External

probe

Cascade regulator

DHW

temperature

sensor

thermostat

Room

Diverter

valve

motor

thermostat

Summer

switch

Overheat

Flue overheat

thermostat

System pressure

switch

Pump

230/240 V ~ 50 HZ Fused at 2 A

Fuse

F 2 A

Gas valve

Supply

External pump

X85

Selector

Max 1 A

X86

CD70S only

Fan

X84

temperature sensor

Return

Heating flow

Display

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

Transformer

Flame sensing

electrode

Fig. 29

Ignition electrodes

Alpha CD50S/70S - Wiring Diagram

Page 30

8 F AULT 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

05 06 11 13 14 15

16 17 44 60

04 07 12

31 32 33 36 37 38 65

114 118

FUSE

Description

Flame sensor fault detected

Ignition failure

Gas valve supply error Internal fault (electronics)

Burner lock-out (electrical fault) Gas valve relay fault Overheat safety thermostat operated

Primary flow temperature too high

Primary return temperature too high

Return temp. higher than flow temp. by more than 10°C after 180 sec

Rapid primary flow temperature increase

Insufficient water pressure

Fan fault (no Hall signal)

Fan fault

Temperature difference between system flow and return too high

Primary flow temperature sensor fault (short circuited) Primary return temperature sensor fault (short circuited) Domestic temperature sensor fault (short circuited) System flow sensor fault (open) System return sensor fault (open) Domestic circuit sensor fault (open) Fan fault (insufficient air)

Invalid cascade signal Loss of ionisation current during ignition of burner (after 3 attempts fault becomes error 02)

24 V fuse blown (T 4A)

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 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 NTC resistance Check NTC resistance Check NTC resistance Check NTC resistance Check NTC resistance 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

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.

Alpha CD50S/70S - Fault Finding

Table 8

Page 31

9 SHORT PARTS LIST

Description

Main PCB Display PCB Control panel flap Control panel - CD50S Control panel - CD70S Pressure gauge Transformer Flame sensor Flame sensor lead Ignition electrodes and lead Combustion chamber cover - CD50S Combustion chamber cover - CD70S Burner - CD50S Burner - CD70S Injector Nat Gas - CD50S Injector Nat Gas - CD70S Injector LPG - CD50S Injector LPG - CD70S Fan - CD50S Fan - CD70S Flexible air inlet pipe - CD50S Flexible air ilnet pipe - CD70S Primary Heat exchanger _ CD50S Primary heat exchanger - CD70S Plastic flue manifold - CD50S Plastic flue manifold - CD70S Primary NTC Pump - CD50S Pump - CD70S Automatic air vent - CD50S Automatic air vent - CD70S Primary pressure switch Gas valve - CD50S Gas valve - CD70S Expansion relief valve Flow manifold Overheat thermostsat Flue thermostat - CD50S Flue thermostat - CD70S Pipe, pump to heat exchanger - CD50S Pipe, pump to heat exchanger - CD70S Pipe, heat exchanger to manifold - CD50S Pipe, heat exchanger to manifold - CD70S Pipe, gas valve to burner manifold - CD50S Pipe, gas valve to burner manifold - CD70S LH side panel RH side panel Flow/return adapter 1 1/2" Tundish Pipe, tundish adapter

Qty.

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Alpha Pt. No.

1.025819

1.019405

1.018884

1.027173

1.027180

1.015807

1.025780

1.026474

3.019870

3.019718

1.025506

1.024139

1.017499

1.025333

1.019802

1.025283

1.019818

1.026051

1.021206

1.023299

1.019313

1.024266

1.022167

1.024241

3.017115

3.017475

1.023435

1.021532

1.024234

1.019735

1.2295

1.021715

1.019556

1.024263

1.018879

1.024184

1.016870

1.012067

1.021356

1.025017

1.024282

1.027141

1.024289

1.018784

1.024264

2.012075

2.012074

3.019369

1.018870

1.011654

Alpha CD50S/70S - Short Parts List

Page 32

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 Fitted Fitted Fitted

Programmable roomstat

Combi boiler

Not required Not required

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/CO 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...................................................

ratio reading N/A Yes CO/CO2 ratio

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

Alpha CD50S/70S - Benchmark Checklist

Page 33

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

CORGI ID card serial No. ...........................................................

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

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

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

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

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

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

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

CORGI ID card serial No. ...........................................................

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

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

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

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

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

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

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

CORGI ID card serial No. ...........................................................

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

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

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

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

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

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

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

CORGI ID card serial No. ...........................................................

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

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

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

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

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

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

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

CORGI ID card serial No. ...........................................................

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

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

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

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

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

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

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

CORGI ID card serial No. ...........................................................

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

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

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

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

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

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

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

CORGI ID card serial No. ...........................................................

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

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

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

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

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

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

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

CORGI ID card serial No. ...........................................................

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

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

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

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

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

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

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

CORGI ID card serial No. ...........................................................

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

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

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

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

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

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

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

CORGI ID card serial No. ...........................................................

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

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

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

Alpha CD50S/70S - Service Record

Page 34

Page 35

Page 36

Alpha Therm Limited. Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS Tel: 0870 3001964

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 2008.

email: [email protected] website:www.alpha-innovation.co.uk

Manual compiled and designed by Publications 2000 - Tel: (01670) 356211 06/08/D222

Part No. 1.027175