CD50.pdf

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

Nepicar House, London Road,

Wrotham Heath, Sevenoaks,

Kent TN15 7RS

Service Listed

Alpha CD50

G.C. No. 47 532 24

For use with Natural Gas only

Leave these instructions with the User

CONTENTS

Introduction ....................................... 2

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

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

Component replacement ................... 26

General boiler information .................. 7

Wiring diagrams ................................ 33

Installation ......................................... 14

Fault Finding ..................................... 35

Commissioning ................................. 20

Short parts list ................................... 39

Boiler operation ................................. 23

Service history .................................. 40

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.

The boiler, providing both central heating and domestic hot water at mains pressure, is designed for use with a fully pumped,

sealed and pressurised heating system using only Natural Gas .

The boiler is supplied with a pump, diverter valve, pressure relief valve, expansion vessel and pressure gauge fully assembled

and tested.

As supplied, the boiler will automatically modulate to provide central heating outputs between 6.3 and 29.7 kW (21 500 and

101 430 Btu/h).

The maximum output available for domestic hot water is 32.0 kW (109 200 Btu/h) and provides hot water at temperatures of up

to 65°C and flow rates of up to 18 litres/min (4 gal/min).

IMPORTANT

This boiler has been approved to the Building Regulations for unvented hot water storage systems and the Local Authority

must be notified of the intention to install. Therefore the installation must be carried out by a person competent to install

unvented hot water systems.

It is the law that all gas appliances are installed by a competent person, ie CORGI registered personnel, in accordance with

the following recommendations:-

Gas Safety (Installation and Use) Regulations 1984 (as amended)

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

Local Water Bye Laws

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

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 IPX4D, ie degree of protection against moisture.

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 Log Book has been completed after the boiler has been installed and commissioned.

2. Ensure that the appliance has been supplied with an Alpha CD flue system.

Alpha CD50 - Contents/Introduction

TECHNICAL DATA

2.1

PERFORMANCE - NATURAL GAS

Central Heating

Heat Input (H s ) kW

(Gross) Btu/h

Heat Input (H i ) kW

(Net) Btu/h

Heat Output (H s condensing) kW

(50°C/30°C) Btu/h

Heat Output (H i non-condensing) kW

(80°C/60°C)

MAX.

31.0

105 770

28.0

95 230

29.7

101 430

27.6

94 130

2.91

1.16

2.95

104.1

MIN.

7.4

25 360

6.6

22 830

7.0

23 980

6.5

21 500

0.27

0.11

0.71

25.1

Domestic Hot Water

Heat Input (H s )

MAX.

36.1

123 190

32.6

110 910

32.0

109 200

3.70

1.48

3.44

121.4

18.0

4.0

149

MIN.

7.4

25 360

6.6

22 830

6.3

21 500

0.27

0.11

0.71

25.1

1.0

0.22

(Gross)

Btu/h

Heat Input (H i )

(Net)

Btu/h

Output to Water (H s )

(modulating)

Btu/h

Differential Burner

mbar

Room sealed

chamber panel

fitted

Btu/h

Pressure

in wg

Differential Burner

mbar

Gas Rate

m³/h

ft³/h

Room sealed

chamber panel

fitted

Pressure

in wg

Gas Rate

m³/h

ft³/h

Flow Rate

L/min

G.P.M.

Outlet Water Temp. (Approx.)

°C

°F

Time to raise water store by 50°C

Reheat time for 70% of store

7 minutes

3 minutes

5 minutes

(boiler ON)

(boiler OFF)

2.2

SYSTEM

Central Heating (Sealed System)

Max. Working System Pressure

Min. System Pressure

Max. System temperature

Pressure Relief Valve Setting

Expansion Vessel Size (pre-charge press.)

Flow Connection

Return Connection

Relief Valve Connection

Recommended System Pressure (cold)

CH Water Temp. (Approx. max.)

Domestic Hot Water

Max. Hot Water Working Pressure

Max. Mains Inlet Pressure (inlet of pressure reducing valve)

Min. Mains Water Pressure

Mains Inlet Connection

DHW Outlet Connection

DHW Water Storage

Expansion Vessel Size (pre-charge press.)

Pressure Reducing Valve Setting

Temperature and Pressure Relief Valve

Expansion Relief Valve Setting

2.5 bar

0.5 bar

82°C

3 bar (44 PSI)

8 L at 0.8 bar

22 mm

15 mm

1.0 bar

82°C (180°F)

5.5 bar

12 bar

0.1 bar

15 mm

52 L

4 L at 2.5 bar

2.5 bar

90°C/7 bar

6 bar

2.3

COMPONENTS

2.4

ELECTRICAL

Burner

Main Heat Exchanger

DHW Storage Cylinder

Main Burner Injector

Flue - Outer Duct

Flue - Inner Duct

Stainless steel

Stainless Steel

6.6 mm

White

Plastic

Supply

External Fuse

Power Consumption

Internal Fuse

Electrode Spark Gap

230/240 V ~ 50 Hz

3 A

140 W

F2 A

3 - 4 mm

2.5

INSTALLATION

2.6

GENERAL

Min. Clearances for Servicing

Top

220 mm

250 mm

10 mm

450 mm

100 mm Dia.

100 mm

110 mm Dia.

70 kg

130 kg

Case Dimensions

Height

Width

Depth

900 mm

600 mm

450 mm

22 mm

3.2 L

100 mm

60 mm

(from casing)

Bottom

Sides

Front

Gas Connection

Primary Water Content

Air Duct Diameter

Flue Duct Diameter

Flue Terminal Size

Flue Terminal Protruding

Hole Size Required For Flue Assy.

Lift Weight

Weight Full and Operational

Alpha CD50 - Technical Data

2.7 FLUE LENGTHS

CD Easy-Flue 500 mm with terminal and 90° bend. A CD Easy-Flue 1000 mm with terminal and 90° bend is also available.

CD 750 mm flue extensions are available.

Length of Flue Required:-

Rear Flue = wall thickness + 170 mm (includes terminal)

Side Flue = wall thickness + distance between wall and side of boiler + 230 mm (includes terminal)

Vertical Flue = distance from top of boiler side panel to required roof position minus 1 m for vertical terminal assembly

Maximum horizontal flue length = 12 m.

Maximum vertical flue length including terminal is 15 m.

Each additional CD 90° Bend is equivalent to 1.3 m of flue length.

Each CD 45° Bend is equivalent to 0.9 m of flue length.

The CD Vertical Flue terminal assembly is equivalent to 1 m of flue length.

2.8

AVAILABLE PUMP HEAD FOR CENTRAL HEATING

Output (50/30°C)

Available pump head

Flow rate

Btu/h

20°C

metres

2.3

3.5

feet

7.6

11.6

litre/min

16.6

gal/min

3.7

25.40

18.70

15.60

12.35

86 700

64 000

53 000

42 200

12.6

10.5

8.3

3.2

2.8

2.3

1.8

0.7

3.8

4.0

4.6

12.6

13.2

15.2

5.30

18 100

This information is based on 20°C system design temperature difference.

Note: For outputs upto 30 kW refer to section 3.7.

2.9 ELECTRICAL CONNECTIONS

Note: This Appliance Must Be Earthed

An optional integral Clock kit is available if required.

Not

Used

Red

Wire

Red

Wire

Brown

Wire

Blue

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 CD50 - Technical Data

2.10

BOILER SCHEMATIC

Flue sampling point

Automatic air vent

CH Pressure Relief Valve

Flue thermostat

Pump

DHW Expansion Vessel

Injector

Drain point

DHW Storage Temperature Sensor

Gas valve

Pressure gauge

DHW Temperature/Pressure Relief Valve

Primary temperature sensor

Primary pressure switch

Storage Cylinder

Venturi

Ignition electrodes

Secondary Heat Exchanger

Main burner

Flame sensing electrode

DHW Drain Point

Primary/condensing heat exchanger

Venturi negative point

DHW Expansion Relief Valve

Room sealed chamber

Venturi positive point

Mains Inlet Filter

Fan

Gas service cock

Check Valve

Pressure differential test points

On/off valve (2 off)

Mains Inlet Valve

Flue hood

Automatic by-pass

Pressure Reducing Valve with Filter

Overheat thermostat

Cyclone separator

Automatic Flow Regulator

CH Expansion vessel

Condensate trap

Tundish

Diverter Valve

Fig. 2

Alpha CD50 - Technical Data

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