Alpha InTec 12S (LPG), Installation And Servicing Instructions

Page 1: ...7RS For Technical help or for Service call ALPHA HELPLINE Tel 0844 871 8764 website www alpha innovation co uk Alpha InTec 12S NG G C No 41 532 22 Alpha InTec 18S NG G C No 41 532 23 Alpha InTec 28S NG G C No 41 532 24 Alpha InTec 12S LPG G C No 41 532 25 Alpha InTec 18S LPG G C No 41 532 26 Alpha InTec 28S LPG G C No 41 532 27 For use with Natural Gas or Propane Gas AS SUPPLIED Leave these instru...

Page 2: ...t product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Handoverthemanufacturer sinstructions includingtheBenchmarkChecklist tothecustomeroncomp...

Page 3: ...d commissioning of water based heating systems Reference should be made to DEFRA document Guide to condensing boiler installation assessment procedures for dwellings 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 i e degree of protection against moisture This appliance contains no asbestos and ...

Page 4: ...CH mbar Dry NOx weight mg kWh Dry NOx PPM NOx Class Factory set CO2 0 25 CO2 at maximum CH output CO2 at minimum CH output CO weight nominal mg kWh CO max ppm Maximum CO CO2 Ratio SAP SEDBUK seasonality efficiency 200 SAP SEDBUK seasonality efficiency 200 Max primary system pressure bar Min primary system pressure bar Recommended system pressure Cold bar System pressure relief valve setting bar Ex...

Page 5: ... Yes Yes 22 22 15 22 720 440 300 150 250 235 150 5 450 110 39 41 12 14 60 100 No No Yes Yes 22 22 15 15 720 440 300 150 250 235 150 5 450 110 35 37 12 14 60 100 No No Yes Yes InTec 12S InTec 18S InTec 28S 13 6 12 3 13 12 0 2 0 1 9 37 82 2 8 0 27 6 95 10 8 10 4 0 003 InTec 12S InTec 18S InTec 28S 20 6 18 6 20 18 3 3 2 2 8 37 82 3 8 0 19 5 27 10 5 9 7 0 003 31 5 28 4 30 7 27 6 7 2 4 3 37 82 5 8 0 24...

Page 6: ...ock Alpha Diverter valve connection optional Remove the link between 1 and 2 if the optional Alpha Climatic control or 230 V room thermostat is used 2 4 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 and 1000 mm flue xtensions are available Length of Flue Required Rear Flue wall thickness 160 mm includes termi...

Page 7: ...ssure relief valve 16 Primary pressure switch 17 Ignition electrodes 18 Flame sensing electrode 19 Flue sampling point 20 Gas service cock 21 On off valve 2 off 22 Automatic by pass 23 Cyclone separator if applicable 24 Condensate trap 25 Injector 26 Venturi 27 Venturi positive point 28 Venturi negative point 29 Flue temperature sensor Gas Condensate discharge Primary Heating return Primary Heatin...

Page 8: ...ards the boiler for condensate to run back towards the boiler When additional flue xtensions are used ensure the flue slopes d wnwards towards the boiler by a minimum of 25 30 mm per metre of flu It is recommended that horizontal flue assemblies should be supported approximately every 1 5 m with access provided to the joints Flue components are available as follows CD Easy Flue 500 mm includes 90 ...

Page 9: ...245 mm 90 bend 1 3 metre add 45 mm to F if a jig is used L B C 245 mm 2 x 45 bends 1 8 metre Fig 3 VERTICAL FLUE OPTIONS HORIZONTAL FLUE OPTIONS Lmax 12 metres 245 mm length includes terminal Hmax 15 m Hmax 13 2 m Not less than 300 mm H Not less than 300 mm Not less than 300 mm H Not less than 300 mm ...

Page 10: ...uced to 25 mm without effecting the performance of the boiler However to ensure the condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferable 3 These clearances may be reduced to 25 mm without effecting the performance of the boiler However to ensure the condensate plume does not affect adjacent surfaces the terminal can be extended beyond gutters pipes eaves balconies...

Page 11: ...the installation of the boiler in a room or internal space containing a bath or shower Where a room sealed boiler is installed in a room containing a bath or shower it must not be possible for a person using the bath or shower to touch any electrical switch or boiler control utilising mains electricity The boiler may be installed in a cupboard or compartment provided it is correctly designed for t...

Page 12: ...matic by pass therefore an automatic by pass is not required for the system Cyclone if applicable This is a device fitted in the heating retu n within the optional Premier Pack wall jig to remove any foreign or solid matter etc from the system 3 8 FILLING THE CENTRAL HEATING SYSTEM Fig 7 The system design pressure cold should be set to 1 0 bar This pressure is equivalent to a static head see Fig 6...

Page 13: ...recommended cleaner manufacturer iv Ensure the system is flushed to rem ve any remains of the cleaner v Fit the new boiler b If the old boiler is not working i Drain the system ii Remove the old boiler iii Flush the system through iv Fit the new boiler v Refill and chemically clean the system as inst ucted by the recommended cleaner manufacturer vi Ensure the system is flushed to rem ve any remain...

Page 14: ...entres 50mm from the bottom of the tube Holes to face away from house Cement mortar sealing 100mm plastic tube Bottom of tube sealed Soakaway depth 400mm filled with limestone chippings 500 mm min If the external temperature drops below 2 C and the boiler is on the relay PCB is operated and voltage is supplied to the trace heating wire causing it to heat up and prevent the condensate from freezing...

Page 15: ...0 mm hole to be cut for side exit flue 145 mm 4 1 UNPACKING 1 The boxes required when the boiler is installed with a horizontal flue are as ollows Box 1 Cased boiler fitted with ater and gas valves union bends and washers Mounting bracket plus screws and wall plugs Condensate discharge pipe Literature pack and Wall template Box 2 CD Easy Flue 500 mm or CD Easy Flue 1000 mm Both include 90 bend and...

Page 16: ...th the boiler have been tightened especially the union bends Note If applicable the heating union bends supplied with the wall jig have been designed to enable the heating pipes to be routed from above and or below using the same fitting Note When soldering to the boiler union bends ensure the bends are not connected to the valves otherwise the internal seals may be damaged 3 Connect the system pi...

Page 17: ... heating system 3 Adjust the telescopic section of the flue to the distance L ensu ing that the two labels marked TOP are aligned then seal and secure the joint between the ducts with the sealing tape supplied Note Always ensure that the two sections overlap by at least 25 mm when extending to the maximum length 4 Pass the flue assem ly through the wall from inside or outside Note Internal fitting...

Page 18: ... the outer duct and pull the flue assem ly towards the bend locating the inner duct into the seal joint on the bend Ensure the labels marked TOP are positioned at the top before securing the flue assembly to the bend with the clamp three screws located centrally over the joint Note Check the flue te minal protrudes 90 mm out of the wall and the inner duct of the terminal is positioned correctly se...

Page 19: ...ates the seal joint Ensure the inner duct end without the seal joint is cut so that it is 20 mm longer than the outer duct Ensure that all cuts are square and free from burrs Once assembled with the components pushed home the flue is fully sealed 5 Adjust the telescopic section of the Easy Flue to the required length and secure the Easy Flue with the sealing tape supplied Fit the Easy Flue to the ...

Page 20: ...o the terminal from outside i Remove the screws 1 in Fig 21 securing the terminal and remove the terminal by pulling it from the flue assem ly Remove the screw 2 in Fig 21 securing the terminal end section and remove the end section from the terminal ii Locate a 93 Plume Management bend into the flue assem ly and rotate it to the direction required iii Connect to the 93 bend the required Plume Man...

Page 21: ...al end section from CD Easy Flue PM length C 4 x 93 bend 5 2 m C Terminal end section from CD Easy Flue Ensure there is a slope of approximately 3 back towards the Easy Flue Fig 22 Note The equivalent horizontal flue assem ly length the equivalent plume management length PM length must not exceed the maximum flue length stated or each boiler i e Alpha Intec boiler maximum equivalent flue length us...

Page 22: ... that there is sufficient free cable to allow the control panel to be raised and lowered then tighten the cable clamp screws 6 Leave the control panel open until commissioning procedures have been completed 7 Carryoutelectricalsystemchecks Short circuit Polarity Earth continuity and Resistance to earth with a suitable multimeter 4 11 FIT ALPHA CONTROLS standard 240 V clock option Fig 24 Ensure the...

Page 23: ...The kit comprises of a diverter valve and cylinder sensor Installing the kit is simplified due to the direct wi ing of the diverter valve and cylinder sensor to the boiler connector block and the option of an RF or direct wired Climatic Programmable Boiler Energy Manager should be used to control hot water and heating see Section 8 Wiring Diagrams When using this kit the hot water cylinder tempera...

Page 24: ...ressure is obtained The system design pressure cold should be between 0 75 and 1 25 bar Refer to Sections 3 8 and 3 9 Filling and Flushing the system 9 Ensure that the condensate trap has been filled with ater Refer to Section 4 5 paragraph 4 5 2 BOILER CONTROLS Fig 26 5 3 TEST FOR GAS TIGHTNESS AND PURGE THE SUPPLY 1 With the boiler connected pressure test the gas supply and inlet pipework connec...

Page 25: ...al primary fl w temperature item 14 in Fig 26 when operating in heating or to heat the DHW cylinder Note If a weather compensation probe is fitted can only be fitted when the Alpha D erter valve kit is fitted a radient value of 1 to 9 is displayed when adjusting the central heating temperature selector switch This is because the boiler output is modulated according to outside temperature Refer to ...

Page 26: ...olume and pressure Refer to Technical Data Sections 2 1 2 2 and 2 3 2 Turn off the boiler 4 Thoroughly flush out the water pipework refer to Section 3 9 and with no pressure in the boiler heating circuit empty the cyclone if applicable at it s drain point see Fig 13 of any debris 5 Re pressurise the system as described in Section 5 1 5 8 FINAL ASSEMBLY 1 Raise the control panel and secure in posit...

Page 27: ... normal 9 Show the User the position of the pressure relief valve and condensate discharge pipes 10 Hand the User s instructions to the User 11 Ensure the Benchmark Checklist at the back of these instructions has been completed after the boiler has been installed and commissioned Note It is a requirement that the installation is registered by the installer through the Gas Safe Gas Work Notificatio...

Page 28: ... sampling point as s wn in Fig 28 Notes 1 Prior to servicing it is recommended that a flue gas analyser is used to measure the per ormance of the boiler refer to Fig 28 for the position of the flue sampling point If the CO CO2 ratio measured is greater than 0 003 or when other checks and comments from the customer have indicated that there may be problems cleaning of the heat exchanger will be nec...

Page 29: ...might damage the injector 4 Remove any deposits from the heat exchanger coils This can be done by suction or water sprayed onto the coils Ensure all electrical components are protected from water Any water used to clean the heat exchanger will drain to the condensate trap 5 Unscrew and replace the injector should it appear damaged 6 Remove the four screws securing the burner see Fig 30 and remove ...

Page 30: ...e connections for gas tightness and re commission Sections 5 3 and 5 7 5 Place the front case panel in position and secure in position with the four screws previously removed see Fig 30 6 Raise the control panel and secure in position with the two screws provided 7 Check the operation of the boiler Refer to Sections 5 4 and 5 5 8 Return all controls to their original settings To ensure correct and...

Page 31: ...s do not overtighten 7 2 DRAINING THE BOILER Figs 2 13 Isolate the electricity supply and close the boiler gas service cock see Fig 13 Allow the boiler to cool Heating circuit Close the central heating fl w and return valves see Fig 13 Connect a suitable pipe to the drain point see Figs 13 and 34 and route it to a suitable container Open the drain point Note Some water will remain in the component...

Page 32: ...ove the pipe 3 Disconnect all the wires from the ignition generator 4 Loosen the two screws securing the generator slide it downwards to remove 4 Slide the new generator in position tighten the screws and re connect the wires 5 Re assemble in reverse order 7 8 OVERHEAT THERMOSTAT Fig 31 1 Gain access behind the front panel as described in Section 7 1 2 Disconnect the wiring from the overheat therm...

Page 33: ...draw the board from the switch spindles 4 Re assemble in reverse order Refer to the wiring diagram in Section 8 1 for connections 5 Light the boiler and adjust the PCB as described in the instructions supplied with the replacement PCB 7 13 ALPHA CONTROLS if fitted Fig 24 Note For replacement only use an Alpha two channel control Do not fit a single hannel control 1 Gain access behind the control p...

Page 34: ...sor and thermal fuse See Fig 31 4 Disconnect the condensate drain pipe by pulling its rubber connector from the heat exchanger 5 Remove the screws securing the ignition generator bracket disconnect the earth lead and remove the ignition generator 6 Unplug the fan and remove it from the boiler 7 Remove the heating fl w and return pipe retaining clips from the primary heat exchanger and pull the pip...

Page 35: ...Y PRESSURE SWITCH Fig 34 1 Gain access behind the front casing and drain the boiler heating circuit as described in Sections 7 1 and 7 2 2 Disconnect the wiring from the pressure switch 3 Withdraw the retaining clip on the left side of the switch and lift the switch upwards to remove 4 Insert a new switch and re assemble in reverse order When connecting the wiring to the new switch the polarity of...

Page 36: ...and 8 2 2 Disconnect the pipe from the expansion vessel 3 Remove the screw securing the top support bracket 4 Lift the expansion vessel out of the boiler 5 When replacing the vessel ensure that the connection is towards the left of the boiler and re assemble in reverse order using new seals as necessary 6 Refill and pressu ise the system Refer to Commissioning Section 5 1 ...

Page 37: ...y 2 1 Colour Code Br Brown Bk Black Bl Blue R Red Or Orange G Green G Y Green Yellow W White Gy Grey Remove the link between terminal block connections 1 and 2 if the optional Alpha Climatic control or 230 V room thermostat is used X21 X26 50 5152 53 54 55 56 57 58 Relay Board optional X20 X16 X4 2 4 4 2 5 1 1 5 3 3 X12 4 2 3 6 5 1 7 X18 4 2 3 6 5 1 7 8 X14 4 2 3 6 5 1 7 8 9 10 11 X7 4 2 3 6 5 1 X...

Page 38: ...4 2 3 6 5 1 7 8 9 10 11 X7 4 2 3 6 5 1 X17 3 5 4 1 2 6 X19 2 1 X3 L N 3 4 X10 X9 X11 X15 1 1 2 2 3 3 Fuse 3 15 AF Transformer DHW SET CH SET B A X5 123456 X8 1 X6 R2 N Spark Generator N Climatic Control low voltage optional X3 L X3 4 X16 1 X3 N X9 2 2 PCB Note Main Terminal Block PCB Connection To connect external controls remove link from terminals 1 and 2 and connect 240 V switched live to termi...

Page 39: ...er Blocked or restricted primary fl w Heat exchanger air fl w blocked Flue restriction Flue sensor fault Gas valve lead connection fault Faulty gas valve Faulty PCB Flow sensor wire connections Flow sensor faulty DHW sensor wiring connection DHW sensor faulty Refer to fault history codes INFO menu d9 Check expansion vessel pressure 1 bar Leak in system Expansion relief valve operated Primary press...

Page 40: ...nger air fl w blocked Flue restriction Flue sensor fault Pump fault Batteries require replacing Distance between boiler and climatic control too great Interference Object blocking signal metallic False flame detectio Flame detected but gas valve is not open Control panel button stuck in the on position Rapid temperature rise of flue senso Rapid temperature rise of primary sensor Flue sensor resist...

Page 41: ...Flame sensing electrode Flue turret 12S 18S Flue turret 28S Ignition electrode Pump head Flue turret foam seal Primary heat exchanger 12S Primary heat exchanger 18S Primary heat exchanger 28S Burner 12S Burner 18S Burner 28S Pressure switch PCB Condensate trap bowl Primary NTC sensor Injector 3 7 mm 12S NG Injector 5 1 mm 18S NG Injector 2 8 mm 12S LPG Injector 3 8 mm 18S LPG Injector 5 8 mm 28S L...

Page 42: ...ure and record Gas rate m hr OR ft hr Burner operating pressure if applicable mbar OR Gas inlet pressure mbar Central heating fow temperature C Central heating return temperature C COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes and if required by the manufacturer has a water scale reducer been ftted Yes No What type of scale reducer has been ftted DOME...

Page 43: ...egister No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 04 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 05 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Wher...

Page 44: ...ut we reserve the right to alter the specification at a y time in the interest of product improvement Alpha Therm Limited 2013 Alpha Therm Limited NepicarHouse LondonRoad WrothamHeath Sevenoaks Kent TN15 7RS Tel 0844 871 8764 email info alpha innovation co uk website www alpha innovation co uk Part No 1 030769 Rev 15 035282 000 ...