Alpha CD50 Installation And Servicing Instructions
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Alpha CD50 Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired, high efficiency, condensing combination boiler with unvented hot water storage
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Installation and Servicing

Instructions
Alpha CD50
Wall Mounted, Fan Assisted, Room Sealed, Gas Fired,
High Efficiency, Condensing Combination Boiler with
Unvented Hot Water Storage
For Technical help or for Service call ...
ALPHA HELPLINE Tel: 0870 3001964
website:www.alpha-innovation.co.uk
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
British Gas
Service Listed
Alpha CD50
G.C. No. 47 532 24
For use with Natural Gas only
Leave these instructions with the User

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  • Page 1: Installation And Servicing

    Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency, Condensing Combination Boiler with Unvented Hot Water Storage For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001964 website:www.alpha-innovation.co.uk Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS...

  • Page 2: Table Of Contents

    INTRODUCTION The Alpha CD50 is a wall mounted, high efficiency, fan assisted, room-sealed, condensing combination boiler - incorporating a 52 litre unvented hot water storage cylinder. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve.

  • Page 3: Technical Data

    3.2 L Flue Terminal Protruding 100 mm Air Duct Diameter 100 mm Hole Size Required For Flue Assy. 110 mm Dia. Flue Duct Diameter 60 mm Lift Weight 70 kg Weight Full and Operational 130 kg Alpha CD50 - Technical Data...
  • Page 4 Note: For outputs upto 28 kW refer to Section 3.7. ELECTRICAL CONNECTIONS Note: This Appliance Must Be Earthed An optional integral single channel Clock kit is available if required. Note: Only use the Alpha single channel clock. Do not fit any two channel clocks. Brown Blue Used...

  • Page 5: Boiler Schematic

    12 Flue hood 26 Automatic by-pass 40 Pressure Reducing Valve with Filter 13 Overheat thermostat 27 Cyclone separator 41 Automatic Flow Regulator 14 CH Expansion vessel 28 Condensate trap 42 Tundish 43 Diverter Valve Fig. 2 Alpha CD50 - Technical Data...
  • Page 6 2. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally and only 15 metres vertically. 3. Failure to use Alpha CD flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe.

  • Page 7: General Boiler Information

    L = B + C + X + (2 x 45° bends = 1.8 metre) VERTICAL FLUE OPTIONS Not less than 300 mm Not less than 300 mm Not less than 300 mm Not less than 300 mm = 15 metres = 13.2 metres Fig. 3 Alpha CD50 - General Boiler Information...
  • Page 8 However, If the terminal is fitted less than 2 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. For further information refer to BS 5440 Pt1:2008.
  • Page 9 Heating circuit water Feed cistern to be Stop return Stop supply located above highest valve valve Stop point in the system Test cock valve Test cock Filling loop temporarily connected Fig. 6 Fig. 7 Alpha CD50 - General Boiler Information...
  • Page 10 FLUSHING THE HEATING SYSTEM It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha CD boiler. Failure to do so will invalidate the warranty. The primary condensing heat exchanger is constructed in stainless steel and therefore is compatible with most materials used in a heating system.
  • Page 11 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 12 5. Shall have a minimum of 300 mm straight pipework directly from the tundish. Note: Where children may play or otherwise come into contact with discharges, a wire cage or similar guard must be positioned to prevent contact whilst maintaining visibility. Alpha CD50 - General Boiler Information...
  • Page 13 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. 11 Alpha CD50 - General Boiler Information...

  • Page 14: Installation

    Drill the fixing holes (10 mm dia.) to accept the No.10 plugs Template Fig. 13 Boiler supplied. Using the screws supplied, fit the mounting outline bracket. FIT THE BOILER - Refer to Fig. 13 Lift the boiler and locate it on the mounting bracket. Alpha CD50 - Installation...
  • Page 15 J - Cold water inlet filter K - Check valve L - Automatic flow regulator valve M - Temperature/pressure relief valve discharge pipe N - Condensate discharge pipe O - Condensate trap P - Cyclone Fig. 15 Alpha CD50 - Installation...
  • Page 16 FIT THE FLUE - Figs. 16, 17 The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only. The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below.
  • Page 17 (use a 127 mm core drill). The size of the hole provides sufficient clearance for the clamps on the flue extension to pass through the hole. Determine the overall flue length as described in Section 4.6, paragraph 2 to determine the number of Alpha CD 750/1000 mm flue extensions required.
  • Page 18 Note: Ensure the flue extension slopes 325 mm Boiler front downwards towards the boiler by a minimum of 25 - 30 mm per metre Flue length (L) 180 mm 420 mm Fig. 21 - Side flue Alpha CD50 - Installation...
  • Page 19 FIT THE CLOCK KIT - Fig. 23 Ensure the electrical supply to the boiler is isolated. Important: Only use an Alpha single channel clock. Do not fit a two channel clock. Remove the two screws securing the clock cover at the rear of the control panel.

  • Page 20: Commissioning

    Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 26). 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 CD50 - Commissioning...
  • Page 21 If the inlet gas pressure is not 20 mbar, either the pipework is too small or the gas supply to the house is insufficient, in which case contact your gas supplier. If the differential burner pressures are still incorrect contact Alpha.
  • Page 22 11. Ensure the Benchmark Checklist in Section 12 on page 40 has been completed after the boiler has been installed and commissioned. 12. Leave these Installation and Servicing instructions with the User for use on future calls. Alpha CD50 - Commissioning...

  • Page 23: Boiler Operation

    A and B Flashing on and off alternately - System pressure is very low and re-pressurisation is required. A Flashing and B Illuminated continuously - Pump fault or restricted flow. Note: Do not hold the selector switch in the reset position (3) for more than 2 to 3 seconds. Alpha CD50 - Boiler Operation...

  • Page 24: Routine Servicing

    Gas pipe Expansion vessel union support strap Viewing window Room sealed Pressure tube panel fixing connections screws and assembly clips Fan assembly Ignition generator fixing screws Fig. 27 Alpha CD50 - Routine Servicing...
  • Page 25 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 CD50 - Routine Servicing...

  • Page 26: Component Replacement

    Gain access behind the room sealed chamber panel as described in Section 8.1. Undo the gas inlet union to the combustion chamber front to gain access. Unscrew the damaged injector and screw in a replacement. Re-assemble in reverse order. Alpha CD50 - Component Replacement...
  • Page 27 Light the boiler and test for gas soundness. (Refer to Commissioning, Section 5.4) and the instructions supplied with the replacement valve for Fig. 30 adjustment of the valve. 10. Complete re-assembly as described in Routine Servicing, Section 7.4 paragraphs 5 to 9. Alpha CD50 - Component Replacement...
  • Page 28 Fig. 31 8.16 CLOCK (if fitted) - Refer to Fig. 23 Note: For replacement only use an Alpha single channel clock. Do not fit a two channel clock. Gain access behind the control panel as described in Section 8.1. Remove the two screws securing the clock cover at the rear of the control panel.
  • Page 29 Refill and pressurise the system. (Refer to Commissioning, Section 5.1). Store temperature sensor Automatic air vent DHW expansion vessel Pump Primary pressure switch Pressure gauge sensor behind Pressure relief valve diverter valve Pressure gauge Fig. 33 Alpha CD50 - Component Replacement...
  • Page 30 Disconnect the relief valve outlet fitting. Undo the screw screws securing the relief valve and pull out the valve. Re-assemble in reverse order using a new 'O' ring seal. Fig. 34 Refill and pressurise the system. (Refer to Commissioning, Section 5.1). Alpha CD50 - Component Replacement...
  • Page 31 Close the mains water supply valve and ensure that all hot water taps are closed. Release the pressure from the hot water circuit. Unscrew the cartridge from the valve body. Clean or replace the filter/cartridge and re-assemble in reverse order. Refill and pressurise the hot water circuit by opening the mains water supply valve. Alpha CD50 - Component Replacement...
  • Page 32 Disconnect the top and drain connection of the condensate trap. Lift the trap out and re-assemble with a new condensate trap. Note: Before fitting the new trap, pour 100 cc of water into the trap. Alpha CD50 - Component Replacement...

  • Page 33: Wiring Diagrams

    REMOVE LINK FROM TERMINALS 1 & 2 - Green AND CONNECT 230/240 V SWITCHED LIVE TO G/Y - Green/Yellow TERMINAL1. - White Gy - Grey A FROST THERMOSTAT IS INCORPORATED Pk - Pink WITHIN THE MAIN PCB - Purple Alpha CD50 - Wiring Diagrams...
  • Page 34 Red LED Pump Temperature Sensor Primary Temperature Sensor Primary Pressure Switch Transformer Note: Main Terminal Block TO CONNECT EXTERNAL CONTROL REMOVE LINK FROM TERMINALS 1 AND 2 AND CONNECT 240 V SWITCHED LIVE TO TERMINAL 1. Alpha CD50 - Wiring Diagrams...

  • Page 35: Fault Finding

    Check gas valve adjustment Go to section ' ', page 37 set temperature is reached Pump continues to run until Burner goes out Fan stops after 50 seconds temperature reduces to set temperature Operation sequence successful Alpha CD50 - Fault Finding...
  • Page 36 10.3 DOMESTIC HOT WATER - Follow operational sequence Alpha CD50 - Fault Finding...
  • Page 37 10.4 FAULT FINDING SOLUTIONS A to E Alpha CD50 - Fault Finding...
  • Page 38 10.5 FAULT FINDING SOLUTIONS F to L Alpha CD50 - Fault Finding...

  • Page 39: Short Parts List

    Ignition electrode and lead 3.013626 E94-417 Fig. 29 Ignition electrode 1.016779 E94-418 Fig. 29 Flame sensing electrode and lead 1.019293 E96-572 Fig. 28 Combustion chamber insulation panel front 1.014732 E94-420 Fig. 2 Condensate trap 1.018192 Alpha CD50 - Short Parts List...

  • Page 40: Benchmark Checklist

    CHECKLIST Ensure the following is completed after the boiler has been installed and commissioned:- BOILER SERIAL No............NOTIFICATION No............CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes Time &...

  • Page 41: Service Record

    13 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.
  • Page 44 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 2008. Tel: 0870 3001964 email: info@alphatherm.co.uk website:www.alpha-innovation.co.uk Part No.

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