Alpha InTec 40GS2 Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing combination boiler with a passive flue gas heat recovery device

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Installation and Servicing

Alpha InTec 40GS2

Wall Mounted, Fan Assisted, Room Sealed,

Gas Fired, High Efficiency Condensing Combination Boiler

with a Passive Flue Gas Heat Recovery Device

These instructions have been carefully prepared but we reserve the right

to alter the specification at any time in the interest of product improvement.

Instructions

For Technical help or for Service call ...

ALPHA HELPLINE Tel: 0344 871 8764

website: www.alpha-innovation.co.uk

Nepicar House, London Road,

Wrotham Heath, Sevenoaks,

Kent TN15 7RS

Alpha InTec 40GS2 (NG) G.C. No. 47 532 51

Set for use with Natural Gas

Leave these instructions with the User

Part No. 1.044210 ST.004691/000

02/20/D406

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Page 1 Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS Alpha InTec 40GS2 (NG) G.C. No. 47 532 51 Set for use with Natural Gas Leave these instructions with the User Part No. 1.044210 ST.004691/000 These instructions have been carefully prepared but we reserve the right to alter the specification at any time in the interest of product improvement.
Page 2 Service Interval Record and left with the householder. www.centralheating.co.uk Useful contact details: Gas Safe Register - 0800 408 5577 - www.gassaferegister.co.uk Alpha Heating Innovation: General Sales Enquiries - 0344 871 8760 Technical Helpline - 0344 871 8764 Alpha InTec 40GS2 - Benchmark Scheme...
Page 3: Table Of Contents
Service record ........53 INTRODUCTION The Alpha InTec range of high efficiency condensing boilers are wall mounted, fan assisted room-sealed combination boilers. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve. These are combination boilers providing both central heating and domestic hot water at mains pressure.
Page 4: Safety Symbols And Information
The user must not dispose of the appliance at the end of its service life as municipal waste, but send it to appropriate collection centres. PERSONAL PROTECTIVE EQUIPMENT SAFETY GLOVES SAFETY GOGGLES SAFETY FOOTWEAR Alpha InTec 40GS2 - Safety Symbols and Information...
Page 5 The boiler is supplied with a 'Special X' type electrical connection with a PVC <HAR> H05VV-F 3 x 0.75 cable without a plug. If the power cable is damaged or replaced, it must be replaced with a cable supplied by Alpha or authorized After-Sale Technical Service.
Page 6: Technical Data
Electrical power consumption - Standby Watts Max. temperature of combustion products °C Max. flue overheating temperature °C Ambient operating temperature °C -5 to +50 Category II 2H3P Type of installation C13, C33, C43, C53, C63 Alpha InTec 40GS2 - Technical Data...
Page 7 During normal operation the green LED (2) is on and the four yellow LEDs (3) indicate the power level according to the following table: Pump LEDs Power consumption 0 - 25 % 25 - 50 % 50 - 75 % 75 - 100 % Alpha InTec 40GS2 - Technical Data...
Page 8 Pump function modes - To see the current operation mode press button (1) once. The circulator has various built-in operation modes, however the operation mode should be selected according to the boiler model. InTec 40GS2 the default setting is constant curve speed 4. The table below shows the possible mode settings.
Page 9 ELECTRICAL CONNECTIONS 230 V ~ 50 Hz CONNECTIONS LOW VOLTAGE CONNECTIONS ONLY (optional Climatic or RF Climatic control) Remove the link between 1 and 2 if the optional Alpha Climatic control or 230 V room thermostat is used. Room FlowSmart External...
Page 10 22 - Primary temperature sensor 34 - Automatic by-pass 11 - Venturi 23 - Overheat thermostats 12 - N/A 24 - Ignition electrodes Note: The schematic diagram does not necessarily indicate the physical position of components Alpha InTec 40GS2 - Technical Data...
Page 11: General Boiler Information
2. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally and only 14 metres vertically. 3. Failure to use Alpha flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe.
Page 12 VERTICAL FLUE OPTIONS Not less than 300 mm Not less than 300 mm Not less than 300 mm Not less than 300 mm Hmax = 10 m Hmax = 8.2 m Fig. 4.1 Alpha InTec 40GS2 - General Boiler Information...
Page 13 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. Alpha InTec 40GS2 - General Boiler Information...
Page 14 Building Regulations and the requirements of BS 6798. If required the boiler gas and water pipework can be run up the wall behind the boiler. Refer to the wall mounting template for positions. Alpha InTec 40GS2 - General Boiler Information...
Page 15 Drain taps (to BS 2879) must be used to allow the system to be completely drained. Hose unions Double check valve assembly Heating circuit Mains return water Stop Stop supply valve valve Test cock Filling loop temporarily connected Fig. 4.5 Alpha InTec 40GS2 - General Boiler Information...
Page 16 DISPOSAL OF CONDENSATE Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha InTec boilers and reference should be made to BS 6798 for the requirements on the disposal of condensate.
Page 17 Two rows of 3 x 12mm holes at 25mm centres, 50mm from the bottom Soakaway depth 400mm of the tube. Holes to face filled with limestone chippings away from house. Fig. 4.7 - External soakaway Alpha InTec 40GS2 - General Boiler Information...
Page 18: Installation
130 mm dia. flue hole using a 127 mm core drill. Drill the fixing holes (10 mm dia.) to accept the No.10 plugs Template supplied. Using the screws supplied, fit the mounting bracket. Outline of Fig. 5.2 boiler Alpha InTec 40GS2 - Installation...
Page 19 Ensure that all the valves are closed (spindle flats at right angles to valve) and do not turn on the water or gas supplies at this stage. Fig. 5.4 Alpha InTec 40GS2 - Installation...
Page 20 FIT THE FLUE - Figs. 5.5 and 5.6 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 21 Note: Ensure that all cuts are square and free from burrs. Once assembled with the components pushed home, the flue is fully sealed. Allow 20 mm 30 mm Do not cut past this point Fig. 5.10 Alpha InTec 40GS2 - Installation...
Page 22 Use the template (supplied with the boiler) to mark the required flue position, ensure the slope towards the boiler is correct. Determine the overall flue length as described in Section 5.6, paragraph 2 to determine the number of Alpha CD 750 or 1000 mm flue extensions required.
Page 23 Plume Management 45° bend 60 mm dia. (each 45° bend equivalent to 0.9 m flue length) Plume Management 1000 mm extension 60 mm dia. (equivalent to 1 m flue length) 60 mm dia. wall bracket Fig. 5.12 Alpha InTec 40GS2 - Installation...
Page 24 Note: The equivalent horizontal flue assembly length + the equivalent plume management length (PM length) must not exceed the maximum flue length stated for each boiler, i.e. Alpha InTec GS boiler maximum equivalent flue length must not exceed 8 metres. Alpha InTec 40GS2 - Installation...
Page 25 Ensure the electrical supply to the boiler is isolated. Important: Only use the Alpha single channel controls. Do not fit any two channel controls. Remove the three screws securing the terminal block cover at the rear of the control panel.
Page 26: Commissioning
Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 6.2) and purge in accordance with BS 6891. Retighten the test point screw and test for gas tightness. Close the boiler gas service cock. Alpha InTec 40GS2 - Commissioning...
Page 27 If the selector is set for hot water only - The burner is turned off, the fan will continue to run for 50 seconds and the pump will stop immediately. In both modes the fan modulates according to the output required. Alpha InTec 40GS2 - Commissioning...
Page 28 (Refer to Technical Data, Sections 3.1). Turn off the boiler. Thoroughly flush out the water pipework (refer to Section 4.9). Clean the mains water inlet filter (see Fig. 5.3). Re-pressurise the system as described in Section 6.1. Alpha InTec 40GS2 - Commissioning...
Page 29 Mains inlet temperature or FlowSmart cylinder temperature (if sensor fitted) °C Not used Fault history - by rotating the CH knob (item 6 in Fig. 5.1) in this menu the last five faults will be displayed Error code Alpha InTec 40GS2 - Commissioning...
Page 30: Routine Servicing
Run the boiler and check the operation of its controls. Refer to Fig. 7.1 for location of flue sampling point. Ensure that all system connections and fittings are sound. Remake any joints and check the tightness of any fittings that may be leaking. Alpha InTec 40GS2 - Routine Servicing...
Page 31 Disconnect the electrode lead from the ignition generator and the in-line connector to the flame sensing electrode. Remove the four nuts and washers and four screws securing the combustion chamber front assembly and remove the assembly. Alpha InTec 40GS2 - Routine Servicing...
Page 32 To ensure correct and safe operation of the appliance, it is essential that any worn or failed components are replaced with only genuine Alpha spare parts. Use of non-genuine Alpha spares could invalidate your warranty and may pose a potential safety hazard.
Page 33: Component Replacement
Remove the burner assembly as described in Routine Servicing, Section 7.2. Remove the four screws securing the burner to the combustion chamber front assembly. Re-assemble with a new burner as described in Routine Servicing, Section 7.4. Alpha InTec 40GS2 - Component Replacement...
Page 34 Gain access behind the front panel as described in Section 8.1. Disconnect the wiring. Using a 13 mm spanner, turn the sensor 90° anti-clockwise and withdraw it from the heat exchanger. Fit the new sensor and re-assemble in reverse order. Alpha InTec 40GS2 - Component Replacement...
Page 35 Withdraw the motor forwards from the valve body. Re-assemble in reverse order with a new motor. DHW temperature sensor Retaining clip Diverter valve motor and Condensate trap assembly DHW Flow switch Flow switch bottom fixing screw Fig. 8.3 Alpha InTec 40GS2 - Component Replacement...
Page 36 8.13 ALPHA CONTROLS (if fitted) - Fig. 5.15 Note: For replacement only use an Alpha single channel control. Do not fit a two channel control. Gain access behind the control panel as described in Section 8.1. Remove the three screws securing the terminal block cover at the rear of the panel.
Page 37 Fit the new gauge using a new 'O' ring on the connection if necessary. Refill and pressurise the system. (Refer to Commissioning, Section 6.1). Primary pressure switch Pressure gauge sensor position Automatic air vent Pump Pressure relief valve Drain point Pressure gauge Fig. 8.5 Alpha InTec 40GS2 - Component Replacement...
Page 38 Re-assemble in reverse order making sure that the printing on the heat exchanger is at the top when fitted and that the seals are in position in the manifold. Refill and pressurise the system. (Refer to Commissioning, Section 6.1). Alpha InTec 40GS2 - Component Replacement...
Page 39 12. The GasSaver should be filled with water through the inner flue duct. This should be done by removing the flue connection on the top of the boiler and pouring 6 litres of water into the centre flue duct. See Fig. 5.4. Alpha InTec 40GS2 - Component Replacement...
Page 40: Wiring Diagrams
CH SET Gy Grey Remove the link between terminal block connections 1 and 2 if the 12 34 5 6 optional Alpha Climatic control or Alpha controls (optional) 230 V room thermostat is used. Transformer Alpha InTec 40GS2 - Wiring Diagrams...
Page 41 (15 - 20 V DC) Transformer FlowSmart Sensor (optional) Note: Main Terminal Block PCB Connection Gas Valve To connect external controls remove link from terminals 1 and 2 and connect 230 V switched live to terminal 1. Alpha InTec 40GS2 - Wiring Diagrams...
Page 42: Error Codes And Fault Finding
Check internal wiring connections to PCB Combination boiler DHW sensor X4 System boiler link X14 Refer to wiring diagram Fan fault Fan wiring fault or fan faulty Check fan wiring connections Fan fault PCB fault Alpha InTec 40GS2 - Error Codes and Fault Finding...
Page 43 Climatic RF Error between the communication of the Batteries require replacing communication fault Climatic transmitter and boiler receiver Distance between boiler and climatic control too great Interference Object blocking signal (metallic) Alpha InTec 40GS2 - Error Codes and Fault Finding...
Page 44: Short Parts List
Air/flue system seal kit 3.022655 Flue turret 1.029067 Drip tray/flue connection 1.031235 Mixing valve 1.031246 GasSaver complete assemby 3.027753 Brass inlet manifold with flow regulator 3.021927 Flow regulator (blue) - 16 litre 1.032415 Relay board 3.022464 Alpha InTec 40GS2 - Short Parts List...
Page 45: Energy Classification
Contact details Alpha Therm Ltd., Nepicar House, Wrotham Heath, Kent. TN15 7RS (*) High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet. (**) Low temperature means for condensing boilers 30°C, for low-temperature boilers 37°C and for other heaters 50°C return temperature.
Page 46 Alpha InTec 40GS2 - Energy Classification...
Page 47 12.3 FACSIMILE FOR FILLING IN DOMESTIC HOT WATER PRODUCTION SYSTEM ASSEMBLY CHART Water heating energy efficiency of combination heater ‘I’ Declared load profile: Solar contribution From fiche of solar device Auxiliary electricity ( 1.1 x ‘I’ 10 % ) ‘II’ ‘III’...
Page 48 12.4 PRODUCT DATA SHEET (IN COMPLIANCE WITH REGULATION 811/2013) InTec 40GS2 punto soluzioni srl InTec 40 GS2 "!! Parameter value Yearly energy consumption for the hea- 88 GJ ting function (QHE) Yearly electricity consumption for the 55 kWh domestic hot water function (AEC)
Page 49 * To be established by means of table 5 of Regulation 811/2013 in case of “assembly” including a heat pump to integrate the boiler. In this case the boiler must be considered as the main appliance of the assembly. Alpha InTec 40GS2 - Energy Classification Alpha InTec 40GS2 - Energy Classification...
Page 50 12.7 PARAMETERS FOR FILLING IN DHW PACKAGE ASSEMBLY CHART Parameter InTec 40GS2 ‘I’ ‘II’ ‘III’ * To be determined according to Regulation 811/2014 and transient calculation methods as per Notice of the European Community no. 207/2014. Alpha InTec 40GS2 - Energy Classification...
Page 51 Alpha InTec 40GS2 - Page intentionally Blank...
Page 52: Benchmark Checklist
GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water system complies with the appropriate Building Regulations? Optional: Building Regulations Notiﬁcation Number (if applicable): Time, temperature control and boiler interlock provided for central heating and hot water Boiler Plus requirements (tick the appropriate box(s))
Page 53: Service Record
SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’...
Page 54 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’...
Page 55 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers speciﬁed spare parts.

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