Alpha FlowSmart 25, FlowSmart 50 Installation and Servicing Instructions
Installation and Servicing
Instructions
Alpha FlowSmart 25 and 50
Hot Water System incorporating a Flue Gas Heat
Recovery Device, Primary Store and an Alpha CD
Condensing Combination Boiler
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Building Regulations Approved
Certificate No. ETC12908
Zenex SuperFlow Technology
Patent Protected No. 2420174
Other Patents Pending
Leave these instructions with the User
CONTENTS
1 Introduction ....................................... 2
2 Technical data................................... 3
3 General information........................... 5
4 Installation......................................... 8
5 Commissioning ................................. 10
6 Routine inspection............................. 11
7 Short parts list ................................... 11
8 Inspection history .............................. 12
1 INTRODUCTION
The Alpha FlowSmart system is a domestic hot water system designed to provide a high level of performance more
efficiently.
The combination boiler will provide both central heating and domestic hot water at mains pressure.
The complete FlowSmart package consists of an Alpha CD35C condensing combination boiler, GasSaver, primary
storage cylinder (25 or 50 litre), expansion vessel and fittings kit. A cylinder thermostat and a 'Y' or 'S' plan control
system kit will also be required for the installation (not supplied).
IMPORTANT
The Alpha FlowSmart system must be installed as detailed in these instructions. The boiler and GasSaver must be
installed in accordance with the installation instructions supplied with them. Failure to do so will negate the warranty
supplied with this unit.
The FlowSmart system has been approved to the relevant requirements of the Building Regulations for primary hot water
storage systems and to the UK Water Regulations.
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
Failure to install any part of the FlowSmart system 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. Alpha CD condensing flue components must be used when the GasSaver is used with an Alpha CD boiler.
2. It is essential that the primary system is thoroughly cleaned and flushed when fitting the FlowSmart system.
All cleaning agent must be removed and inhibitor added to the system - failure to do so will invalidate the warranty.
Alpha FlowSmart 25 and 50 - Contents/Introduction
2
2 TECHNICAL DA T A
2.1 GENERAL
Cylinder External Dimensions 25 L
50 L
Outer Case
Cylinder Insulation Material
Cylinder Insulation Thickness
Standing Energy Loss of Cylinder 25 L
50 L
2.2 DHW SYSTEM
Maximum Inlet Water Pressure
Minimum Inlet Water Pressure
Maximum Water Flow Rate
Minimum Water Flow rate
Outlet Water Temperature (approx. max.)
FlowSmart Cylinder
Mains Water Inlet Pipe Connection
Mains Water Outlet Pipe Connection
Coil Material
DHW Coil Water Capacity 25 L
50L
Secondary Circulation Connections 50L only
Secondary Circulation Coil Capacity 50L only
345 mm Dia. x H530 mm
470 mm Dia. x H650 mm
Steel - White paint
PUR foam
50 mm
0.6 kW/24hr (0.8 Watts/litre)
1.1 kW/24hr (0.8 Watts/litre)
*5 bar
0.2 bar
18 l/min
2.5 l/min
62°C
3/4" BSP to 15 mm (fitting supplied)
3/4" BSP to 15 mm (fitting supplied)
Copper
2 L
3.5 L
3/4" BSP
0.28 L
* Note: If inlet water
pressure is above 5
bar a pressure
reducing valve must
be fitted
2.3 PRIMARY SYSTEM
Maximum Working Pressure
Minimum System Pressure
Maximum System Temperature (approx.)
Boiler Pressure relief Valve Setting
Boiler Exp. Vessel (pre-charge press.)
Recommended System Pressure (cold)
FlowSmart Cylinder
Flow and Return Connections
Cylinder Material
Cylinder Capacity 25 L
50 L
Plugged Connection (immersion heater if required)
3/4" BSP to 22 mm (fittings supplied)
2.4 COMPONENTS
Blending Valve Setting (boiler inlet) - Required temperature setting
Blending Valve Connections
Additional Primary System Expansion Vessel Capacity
Connection
Pre-Charge Pressure
2.5 bar
0.5 bar
82°C
3 bar
8 L at 0.8 bar
1.0 bar
Mild Steel
24 L
50 L
1 1/4" BSP
30°C
15 mm
5 L
1/2" BSP
1 bar
Alpha FlowSmart 25 and 50 - Technical Data
3
2.5 INSTALLATION
Minimum Clearances for Servicing Top
(Refer to Fig. 1) Drain Point Side only
Lifting Weight (empty) 25 L
50 L
Weight (full) including DHW and Primary Circuit 25 L
50 L
* 150 mm
100 mm
16 kg
29 kg
42 kg
82 kg
2.6 FLOWSMART CYLINDER LOCATION and CONNECTIONS
* Note: If an immersion heater is fitted,
sufficient top clearance must be
allowed to enable the immersion
heater to be replaced
*
Minimum
clearances
150 mm
470 mm Dia.
50 L
100 mm 100 mm
E
G
D
F
38 mm
650 mm
C
B
A
Minimum
*
clearances
Drain PointDrain Point
150 mm
345 mm Dia.
25 L
E
D
38 mm
530 mm
C
B
A
Connections - 50 L Connections - 25 L
- Mains Water Inlet 3/4" BSP (Blue collar)
A
- Hot Water Outlet 3/4" BSP (Red collar)
B
- Primary Return 3/4" BSP(Black collar)
C
- Primary Flow 3/4" BSP (Black collar)
D
- Secondary Circulation 3/4" BSP (White collar)
E
- Secondary Circulation 3/4" BSP (White collar)
F
- Plugged Immersion Heater Connection 11/4" BSP
G
2.7 ELECTRICAL CONNECTIONS
Remove link to connect
external control
2
1
Earth
(Green/Yellow Wire)
Neutral
NL
Permanent Live
Fuse
F2A
Alpha FlowSmart 25 and 50 - Technical Data
4
- Always fit fast blow 2A
- Mains Water Inlet 3/4" BSP (Blue collar)
A
- Hot Water Outlet 3/4" BSP (Red collar)
B
- Primary Return 3/4" BSP (Black collar)
C
- Primary Flow 3/4" BSP (Black collar)
D
- Plugged Immersion Heater Connection 11/4" BSP
E
Fig. 1
230/240V Switched Live from S or Y plan wiring junction box
(Blue Wire)
(Brown Wire)
230/240V ~ 50Hz
Fuse supply 3A
Fig. 2 - Boiler terminal block
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