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Alpha CB50 Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired combination boiler with unvented hot water storage (from boiler serial no. 27b32500001)
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Installation and Servicing

Instructions
Alpha CB50
Wall Mounted, Fan Assisted, Room Sealed, Gas Fired
Combination Boiler with Unvented Hot Water Storage
(From Boiler Serial No. 27B32500001)
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
British Gas G.C. No. 47 532 18
For use with Natural Gas only
Leave these instructions with the User

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Summary of Contents for Alpha Alpha CB50

  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha CB50 Wall Mounted, Fan Assisted, Room Sealed, Gas Fired Combination Boiler with Unvented Hot Water Storage (From Boiler Serial No. 27B32500001) For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001964 Nepicar House, London Road,...

  • Page 2: Table Of Contents

    12 Service history ........36 INTRODUCTION The Alpha CB50 boiler is a wall mounted, fan assisted room-sealed combination boiler, incorporating a 57 litre unvented hot water storage cylinder. Heat output is controlled by a modulating gas valve, with fully automatic direct burner ignition.

  • Page 3: Technical Data

    450 mm Power Consumption 190 W Gas Connection 22 mm Internal Fuse F2 A Primary Water Content 3.2 L Electrode Spark Gap 2.0 to 4.0 mm Air Duct Diameter 100 mm Flue Duct Diameter 60 mm Alpha CB50 - Technical Data...
  • Page 4 Blue Used Wire Wire Wire Wire Internal Clock Terminals WARNING 1. Ensure wires are connected correctly 2. Only fit the Alpha recommended clock. Other clocks could cause damage. Clock connections Boiler terminal block Fig. 1 Alpha CB50 - Technical Data...
  • Page 5 32. Flue Sample Point 15. Main Burner 33. DHW Expansion Relief Valve 16. Main Heat Exchanger 34. Mains Inlet Valve 17. Fan 35. DHW Drain Point 18. Air pressure Switch 36. Mains Inlet Filter Fig. 2 Alpha CB50 - Technical Data...

  • Page 6: General Boiler Information

    3. Under no circumstances must the flue length (including allowances for extra bends) exceed the maximum recommended length. 4. Failure to use Alpha flue components with the boiler will invalidate the boilers CE approval, warranty and may be unsafe. Alpha CB50 - General Boiler Information...
  • Page 7 L = B + E + F + X mm + (90° bend = 1 metre) L = B + C + X mm + (2 x 45° bends = 1 metre) VERTICAL FLUE OPTIONS = 4 metres Fig. 3 Alpha CB50 - General Boiler Information...
  • Page 8 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 CB50 - General Boiler Information...
  • Page 9 System volume - The expansion vessel incorporated into the boiler is suitable for a sealed heating system with a maximum water content of 80 litres (18 gal). For guidance on water contents contact Alpha Therm Ltd. for Technical Data Sheet 15.
  • Page 10 The stored water temperature is adjustable to a maximum of 65°C. In hard water areas this should avoid possible scale build-up, although it is still advisable to reduce the DHW thermostat setting in such areas. However, if descaling is necessary contact Alpha Therm Ltd.
  • Page 11 Therefore the maximum permitted length equates to 18 - 4 = 14 m End of pipe to be As the actual length is 7 m, a 28 mm (D2) copper pipe will be satisfactory. clearly visible Fig. 9 Alpha CB50 - General Boiler Information...

  • Page 12: Installation

    127 mm diameter flue hole using a 127 mm core drill. Template Boiler Drill the fixing holes (10 mm dia.) to accept the outline No. 10 plugs supplied. Using the screws supplied, fit the mounting bracket. Fig. 11 Alpha CB50 - Installation...
  • Page 13 Mark the outer air duct to match the length given above, measure from the end of the tube as shown in Figs. 13 and 14. Mark the inner flue duct to match the length given above. Alpha CB50 - Installation...
  • Page 14 Inner flue duct length = finished wall thickness + the distance from the inside wall to the side of the boiler + b mm. Note: L/H side a = 100, b = 137. R/H side a = 340, b = 377. Fig. 13 - Rear flue Alpha CB50 - Installation...
  • Page 15 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 CB50 - Installation...
  • Page 16 Blue wire to terminal 1, Brown wire to terminal 2 and Red wires to terminals 3 and 4, (or as per the instructions supplied with the clock). Ensure wiring is correct. Replace the clock cover. Do not overtighten the fixing screws. Leave the control panel open until commissioning procedures have been completed. Clock cover Rear of control panel Fig. 16 Alpha CB50 - Installation...

  • Page 17: Commissioning

    Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 18). Ensure the gas supply is on and open the boiler service cock to purge in accordance with BS 6891. Retighten the test point screw and test for gas soundness. Close the boiler gas service cock. Alpha CB50 - Commissioning...
  • Page 18 (Refer to Component Replacement, section 8.2). It is recommended that a label is attached to the boiler drawing attention to the fact that the system has been drained. Complete the details of the installation on the back page of this manual. Alpha CB50 - Commissioning...

  • Page 19: Boiler Operation

    8°C, providing the electrical supply is on. The boiler will operate until the water temperature in the system reaches approximately 40°C. PUMP If the electrical supply is on and the boiler has not operated for 24 hours for heating or hot water, the pump will operate automatically for five minutes every 24 hours. Alpha CB50 - Commissioning/Boiler Operation...

  • Page 20: Routine Servicing

    Remove the two screws securing the top of the combustion chamber front cover and remove the upper section. Take care not to damage the insulation on the inside of the front cover. Disconnect the flame sensing electode lead plug. Alpha CB50 - Boiler Operation/Routine Servicing...
  • Page 21 Place the front casing in position over the boiler and secure in position at the bottom using the screws previously removed. Check the operation of the boiler. (Refer to Boiler Operation, section 6). Return all controls to their original settings. Alpha CB50 - Routine Servicing...

  • Page 22: Component Replacement

    Connect the main burner's union nut and tighten. Reconnect the flame sensing lead plug. Replace the combustion chamber front cover, take care not to damage the insulation panels. Complete re-assembly as described in Routine Servicing, section 7.4 paragraphs 3 to 9. Alpha CB50 - Component Replacement...
  • Page 23 Connect the wiring to terminals 1 and 3 on the new switch (polarity is not important), and reconnect the pressure tubes as previously connected, i.e. fan connection to P2. Secure the new switch in position. Re-assemble in reverse order. Alpha CB50 - Component Replacement...
  • Page 24 Gain access to the control panel as described in section 8.1. Disconnect all the wiring connectors from the PCB. Remove the fixing screw and carefully remove the PCB. Re-assemble in reverse order. Refer to the wiring diagram in section 9 for connections. Alpha CB50 - Component Replacement...
  • Page 25 To replace the rear and side panels, remove the heat exchanger as described in section 8.17 and slide out the insulation panels. Fit a new panel and re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha CB50 - Component Replacement...
  • Page 26 Unscrew the automatic air vent from the pump outlet. Connect the wiring as described above, ensure that pump is set to maximum and re-assemble using new sealing washers. Refill and pressurise the system. (Refer to Commissioning, section 5.1). Alpha CB50 - Component Replacement...
  • Page 27 Partially drain the hot water circuit, so that the water in the hot water storage cylinder is below the relief valve connection, as described in section 8.2. Remove the valve from the storage cylinder. Re-assemble in reverse order. Refill the storage cylinder by opening the mains water supply valve and opening a hot water tap. Alpha CB50 - Component Replacement...
  • Page 28 Close the mains water supply valve and ensure that all hot water taps are closed. Release the pressure from the hot water circuit. Disconnect the two flow regulator unions and remove the valve from the boiler. Re-assemble in reverse order using new washers. Alpha CB50 - Component Replacement...

  • Page 29: Wiring Diagrams

    WIRING DIAGRAMS ILLUSTRATED WIRING DIAGRAM Alpha CB50 - Wiring Diagrams...
  • Page 30 FUNCTIONAL FLOW WIRING DIAGRAM Alpha CB50 - Wiring Diagrams...

  • Page 31: Fault Finding

    Check that the gas and water pipework has been connected to the correct connections on the boiler and all valves are open. However, before any servicing or replacement of parts ensure the gas and electrical supplies are isolated. 10.2 CENTRAL HEATING - Follow operational sequence Alpha CB50 - Fault Finding...
  • Page 32 10.3 DOMESTIC HOT WATER - Follow operational sequence Alpha CB50 - Fault Finding...
  • Page 33 10.4 FAULT FINDING SOLUTIONS A to F Alpha CB50 - Fault Finding...
  • Page 34 10.5 FAULT FINDING SOLUTION SECTIONS G to L Alpha CB50 - Fault Finding...

  • Page 35: Short Parts List

    CH pressure relief valve - 3 bar 1.011126 E57-703 Insulation panel set (combustion chamber) 3.014390 E85-139 Fig. 25 Automatic air vent 1.010771 E57-709 Fig. 2, item 8 By-pass assembly 3.013081 E65-222 Fig. 24 Pressure gauge 1.016151 E57-710 Alpha CB50 - Short Parts List...

  • Page 36: Service History

    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 2005. Tel: 0870 3001964 email: info@alphatherm.co.uk website: www.alpha-boilers.com Part No.

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