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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
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Table of Contents
Related Manuals for Alpha CD90S
Summary of Contents for Alpha CD90S
- Page 1 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,...
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Page 2: Table Of Contents
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). -
Page 3: Technical Data
98 948 Fan Speed 5 900 1 750 Fan Speed 5 700 1 750 Gas Rate m³/h Gas Rate m³/h ft³/h ft³/h 14.0 36.7 Note: The above appliances are fully modulating and are not range rated. Alpha CD90S/115S - Technical Data... - Page 4 Stainless steel Max. Working System Pressure 3.5 bar Main Heat Exchanger Stainless steel Min. System Pressure 0.5 bar Main Burner Injector CD90S NG 12.0 mm Max. System temperature 85°C CD115S NG 14.0 mm Pressure Relief Valve Setting 4 bar (58.8 PSI) CD90S LPG 8.8 mm...
- Page 5 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...
- Page 6 Flue overheat thermostat Burner Injector Flame sensing electrode Air inlet pipe Venturi Ignition electrodes Venturi positive point (P2) Combustion chamber cover Pump Heat exchanger Condensate trap Flue hood Air inlet sampling point Flue sampling point Fig. 3 Alpha CD90S/115S - Technical Data...
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Page 7: General Boiler Information
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. - Page 8 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.
- Page 9 3.4.1 Horizontal Flue Options L max 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.
- Page 10 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 Fig.
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Page 11: Flow 2
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). - Page 12 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.
- Page 13 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.
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Page 14: Installation
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. - Page 15 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).
- Page 16 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).
- Page 17 Ensure that there is sufficient free cable to allow the control panel to be raised and lowered then tighten the cable clamp screws. Leave the control panel open until commissioning procedures have been completed. Carry out electrical system checks - Short circuit, Polarity, Earth continuity and Resistance to earth with a suitable multimeter. Alpha CD90S/115S - Installation...
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Page 18: Commissioning
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... - Page 19 1 = enabled 2 = disabled + continuous pump 3 = enabled + continuous pump Max. heating flow temperature 20°C 85°C 85°C * Only active with hot water function enabled when external accessories are fitted. Table 3 Alpha CD90S/115S - Commissioning...
- Page 20 3 = enabled + continuous pump Central heating functioning mode 0 = disabled 1 = enabled 2 = disabled + continuous pump 3 = enabled + continuous pump Max, central heating flow temperature 20°C 85°C 85°C Table 5 Alpha CD90S/115S - Installation...
- Page 21 00 = instantaneous with probe 01 = instantaneous no probe 02 = Boiler with probe 03 = Boiler without probe Manual fan speed 1 = Off 100% PWM signal level for pump Not active Table 6 Alpha CD90S/115S - Installation...
- Page 22 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...
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Page 23: Routine Servicing
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... - Page 24 Remove the pressure tube. Disconnect the electrode lead from the spark electrode and the in-line connector to the flame sensing electrode. Remove the six nuts and washers securing the combustion chamber front assembly and remove the assembly. Alpha CD90S/115S - Routine Servicing...
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Page 25: Gas Valve
Sample points (A - air, F - flue gas) Primary flow NTC Automatic air vent Primary return NTC Combustion chamber front cover Venturi housing Overheat thermostat Venturi Ignition sensor Injector Pump Gas valve Fig. 24 Alpha CD90S/115S - Routine Servicing... -
Page 26: Ignition Electrodes
5.4. Place the case or front case panel in position and secure in position with the screws previously removed, see Section 6.2. Check the operation of the boiler. Return all controls to their original settings. Alpha CD90S/115S - Routine Servicing... -
Page 27: Wiring Diagram
NOTE: to apply an external room thermostat, connect it to the terminals F & E removing the link. Brown Black Blue Orange Green/Yellow White Grey Flame sensing Purple Ignition electrodes electrode W/Bl White/Blue W/Br White/Brown Transformer Alpha CD90S/115S - Wiring Diagram... -
Page 28: Fault Finding
Check for air in the system E 65 Check fan Check flue Check air inlet pipework E114 Check correct address setting on PCB E118 Check gas supply Check gas supply pressure Check gas supply pipework FUSE Change fuse Table 7 Alpha CD90S/115S - Fault Finding... - Page 29 Fan start stand-by (insufficient air flow rate) Check fan functioning b118 Ionisation current loss during burner ignition (after 3 attempts Check presence of gas and electricity supply becomes 'E 02' error ignition failure) Check the gas supply pressure Table 8 Alpha CD90S/115S - Fault Finding...
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Page 30: Short Parts List
Pipe, pump to heat exchanger - CD115S 1.028692 Pipe, heat exchanger to manifold - CD90S 1.028706 Pipe, heat exchanger to manifold - CD115S 1.028691 Pipe, gas valve to burner manifold - CD90S 1.028688 Pipe, gas valve to burner manifold - CD115S 1.028681 LH side panel 2.014072 RH side panel 2.014071... -
Page 31: Benchmark Checklist
The operation of the appliance and system controls have been demonstrated to the customer The manufacturer's literature has been left with the customer COMMISSIONING ENG'S NAME: Print ..............CORGI ID No........... Sign ..............Date ..............Alpha CD90S/115S - Benchmark Checklist... -
Page 32: 11 Service Record
These instructions have been carefully prepared but we reserve the right to Nepicar House, London Road, Wrotham Heath, alter the specification at any time in the interest of product improvement. Sevenoaks, Kent TN15 7RS © Alpha Therm Limited 2010. Tel: 0844 8718764 email: info@alpha-innovation.co.uk website:www.alpha-innovation.co.uk...
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