Alpha InTec2 20SE Installation And Servicing Instruction
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Alpha InTec2 20SE Installation And Servicing Instruction

Wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing system boiler
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Installation and Servicing
InTec² 20SE and 30SE
Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing System Boiler
0051
These instructions have been carefully prepared but we reserve the right
to alter the specification at any time in the interest of product improvement.
© Alpha Therm Limited 2015.
Instructions
For Technical help or for Service call ...
ALPHA HELPLINE Tel: 0844 871 8764
website: www.alpha-innovation.co.uk
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Alpha InTec² 20SE
Alpha InTec² 30SE
Set for use with Natural Gas
Leave these instructions with the User
G.C. No. 41 532 28
G.C. No. 41 532 29
Part No. 1.035664 rev. ST.001835/000
0515/D347

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Summary of Contents for Alpha InTec2 20SE

  • Page 1 InTec² 20SE and 30SE Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing System Boiler For Technical help or for Service call ... ALPHA HELPLINE Tel: 0844 871 8764 website: www.alpha-innovation.co.uk Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS Alpha InTec²...
  • Page 2 Benchmark 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 - 0844 871 8760 Technical Helpline - 0844 871 8764 Alpha InTec² 20SE and 30SE - Benchmark Scheme...

  • Page 3: Table Of Contents

    2. It is the law that all domestic boiler installations are registered by the installer through the Gas Safe Notification Scheme. 3. The boiler must only be used with Alpha CD condensing flue components. Propane Gas (LPG) - In addition to the regulations and requirements stated, the boiler must be installed in accordance with BS 5482:1 - The Installation of Propane Burning Appliances in Permanent Dwellings.

  • Page 4: Technical Data

    CH output % (±1%) 10.7 10.7 at minimum output % (±1%) 10.0 10.0 at medium output (ignition) % (±1%) 10.6 10.6 Note: OtherTechnical data is the same as NG data. Alpha InTec² 20SE and 30SE - Technical Data...
  • Page 5 If necessary, the by-pass can be adjusted to the system requirements from minimum (by-pass closed) to maximum (by-pass open). Adjust using a flat head screwdriver, turn clockwise to open the by-pass, and anticlockwise to close. Alpha InTec² 20SE and 30SE - Technical Data...
  • Page 6 2.4.2 Pump Power Consumption Speed 9 Speed 5 1000 1200 1400 1600 Flow rate (l/h) C + D = Pump power consumption with by-pass opened. D = Pump power consumption with by-pass closed. Fig. 2.2 Alpha InTec² 20SE and 30SE - Technical Data...
  • Page 7 ELECTRICAL CONNECTIONS Note: This Appliance Must Be Earthed Optional integral two channel controls are available if required. Note: Only use the Alpha two channel controls. Do not fit any single channel controls. Remove link to connect clock Programmer clock X1 on PCB...
  • Page 8 6 - Ignition/detection electrode 13 - Return thermostat 20 - Safety valve 7 - Air test point (pressure point -) 14 - Automatic air vent 21 - Safety valve indicator Fig. 2.4 Alpha InTec² 20SE and 30SE - Technical Data...

  • Page 9: General Boiler Information

    3. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally and only 14 metres vertically. 4. Failure to use Alpha flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe.
  • Page 10 L = A + (2 x 45° bends = 1.8 metre) Fig. 3.1 VERTICAL FLUE OPTIONS Not less than 300 mm Not less than 300 mm Hmax = 14 m Hmax = 12.2 m (14 m - 1.8 m) Fig. 3.2 Alpha InTec² 20SE and 30SE - General Boiler Information...
  • Page 11 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 InTec² 20SE and 30SE - General Boiler Information...
  • Page 12 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 InTec² 20SE and 30SE - General Boiler Information...
  • Page 13 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. 3.6 Alpha InTec² 20SE and 30SE - General Boiler Information...
  • Page 14 FLUSHING THE HEATING SYSTEM It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha boiler. Failure to do so will invalidate the warranty. The primary condensing heat exchanger is constructed in aluminium and therefore is compatible with most materials used in a heating system.
  • Page 15 Optional Condensate Trace Heating Kit Use waterproof An optional Alpha trace heating kit is also available pipework insulation to prevent the condensate from freezing. in very exposed positions Plastic pipe The control of this kit works with a unique patented...

  • Page 16: Installation

    Condensate discharge pipe Literature pack and Wall template A suitable Alpha flue system must be selected to use with the boiler. Notes: a. All flues must be suitable for Alpha condensing boilers. b. CD 750 mm and 1000 mm flue extensions are available, if required.
  • Page 17 Condensate discharge pipe Heating drain point A - Gas inlet - Yellow (22 mm) C - Heating return - (22 mm) D - Heating flow - (22 mm) Bottom cover plate Fig. 4.4 Alpha InTec² 20SE and 30SE - Installation...
  • Page 18 FIT THE FLUE - Figs. 4.5 and 4.6 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 19 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. 4.10 Alpha InTec² 20SE and 30SE - Installation...
  • Page 20 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 4.6, paragraph 2 to determine the number of Alpha CD 750 or 1000 mm flue extensions required.
  • Page 21 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. 4.12 Alpha InTec² 20SE and 30SE - Installation...
  • Page 22 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 InTec² boiler maximum equivalent flue length must not exceed 12 metres. Alpha InTec² 20SE and 30SE - Installation...
  • Page 23 With enhanced boiler control, the unit further increases boiler and system efficiency. Alternatively standard programmable room thermostats or mechanical and digital boiler clocks are available. Note: Only use a Climatic or suitable single channel Alpha controller. Do not fit a two channel controller. Connecting Controls Remove the control panel cover as described in Section 4.10, if it has not already been removed.
  • Page 24 Notes: 1. The temperature of the radiators will vary depending on the outside temperature; the required room temperature will still be maintained by the room thermostat. 2. The weather compensation sensor can only be used on an InTec² SE boiler when the Alpha diverter valve kit is used, otherwise the DHW temperature will be affected.

  • Page 25: Commissioning

    18 Functioning with external temperature Information button power scale probe active (optional) Domestic hot water temperature 11 Operating in summer mode (with Alpha 19 Boiler connected to remote control selector switch (with Alpha diverter kit diverter kit only) (optional) only)
  • Page 26 E72 shown on the display. The air flow check function will operate for 15 minutes, alternatively disconnect the boiler electrical supply or press the standby button for 8 seconds to exit the function early. Alpha InTec² 20SE and 30SE - Commissioning...
  • Page 27 The primary flow temperature will be displayed (item 14 in Fig. 5.1) when operating in heating or hot water. Note: If a weather compensation sensor is fitted (can only be fitted when the Alpha diverter kit is fitted) a gradient value of 1 to 9 is displayed (see Fig.
  • Page 28 Thoroughly flush out the water pipework (refer to Section 3.9). Refill and re-pressurise the system as described in Section 5.1. Add the correct level of inhibitor to the system as detailed in the instructions supplied with the inhibitor. Alpha InTec² 20SE and 30SE - Commissioning...
  • Page 29 °C Central heating set point temperature °C Domestic hot water set point temperature °C External weather compensation sensor temperature (value flashes if negative) (Alpha diverter kit fitted) °C Not used Heating return temperature °C Fault history - by rotating the CH knob (item 6 in Fig. 5.1) in this menu the last five faults will be displayed...
  • Page 30 If the flow temperatures are getting up to maximum operating temperature during the procedure it is possible to open a hot tap and turn the controls to heating and hot water demand. Note: In this mode only the boiler flow sensor controls the maximum temperature. Alpha InTec² 20SE and 30SE - Commissioning...
  • Page 31 Defines the boiler boiler as InTec 20SE Defines the boiler boiler as InTec 30SE Note: Only use the parameter relating to the boiler installed. When changed 'E62' will be displayed and full calibration is required. Alpha InTec² 20SE and 30SE - Commissioning...
  • Page 32 4 = Secondary zone control (volt free switching across 57 & 58 on relay PCB contacts) 5 = Heat pump function with dedicated controls 6 = Alpha Trace heating cable enabled 7 = When boiler pump active Relay 3 Boiler functions/configurations when optional relay PCB is fitted...
  • Page 33 Defines the maximum flow temperature set point (t0 + 5) + 85 °C temperature DHW thermostat Establishes the switch-off method in DHW mode (if Alpha diverter 0 - 3 valve kit fitted) depending on the cylinder temperature Cylinder heating on Cylinder temp.

  • Page 34: Routine Servicing

    Run the boiler and check the operation of its controls. Ensure that all system connections and fittings are sound. Remake any joints and check the tightness of any fittings that may be leaking. Alpha InTec² 20SE and 30SE - Routine Servicing...
  • Page 35 Loosen the two screws 'D'. Pull the front panel 'E' slightly towards you. Release front 'E' from pins 'F' pulling it towards you while pushing it upwards at the same time. Fig. 6.2 Alpha InTec² 20SE and 30SE - Routine Servicing...
  • Page 36 (view 'A' in Fig. 6.4) Lower the panel out and away from the top cover. View A Fig. 6.4 Alpha InTec² 20SE and 30SE - Routine Servicing...
  • Page 37 Unscrew the flue sampling point cap and remove the complete fitting from the top of the case. Disconnect the flue sensor wires and remove the lower retaining screw on the flue manifold assembly. Pull down the flue manifold assembly and withdraw the complete assembly. Alpha InTec² 20SE and 30SE - Routine Servicing...
  • Page 38 12. Carry out a full calibration procedure (refer to Section 5.13) if the burner and electrode have been cleaned or replaced. 13. Check the operation of the boiler. (Refer to Sections 5.5 and 5.6). 14. Return all controls to their original settings. Alpha InTec² 20SE and 30SE - Routine Servicing...

  • Page 39: Component Replacement

    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 40 Gain access to the PCB as described in Section 7.8. Lift out and remove the fuse. Fit a 3.15 AF fuse as a replacement. PCB fuse Re-assemble in reverse order. Pressure gauge Fig. 7.2 Alpha InTec² 20SE and 30SE - Component Replacement...
  • Page 41 Turn the automatic air vent anticlockwise and lift it out. Insert the new air vent using a new washer and turn it clockwise to lock it in position. Refill and pressurise the system. (Refer to Commissioning, Section 5.1). Alpha InTec² 20SE and 30SE - Component Replacement...
  • Page 42 It is important to clean the trap every time the trap is removed to flush out any deposits from the collection bowl. Note: Partially fill the trap before replacing. Alpha InTec² 20SE and 30SE - Component Replacement...
  • Page 43 Remove the bottom fixing screw and withdraw the vessel taking care not to spill any water into other boiler components. Re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, Section 5.1). 7.19 ALPHA CONTROLS (if fitted) Refer to section 4.11 on the connection options for boiler controls. Alpha InTec² 20SE and 30SE - Component Replacement...

  • Page 44: Wiring Diagram

    Climatic Control NTC sensor (optional) room thermostat (optional) (optional) When an Alpha Climatic control is connected to terminals 41 and 44 remove the links between terminal blocks 1 and 2 Colour Code Component identification Bk ..Black A19 ..Removable memory Bl ..Blue B1 ....Flow sensor...

  • Page 45: Error Codes And Fault Finding

    Where an error code is displayed use the following tables to identify the fault and possible causes. ERROR CODES AND FAULT FINDING If any fault or anomaly persists, contact Alpha Heating Innovation Technical Helpline. The history of errors can be viewed in the 'INFO' menu - d9...
  • Page 46 Check the inlet gas pressure is correct and carry out a full calibration process as described in Section 5.13 If the fault persists replace gas valve Alpha InTec² 20SE and 30SE - Error Codes and Fault Finding...
  • Page 47 Reading out of range Sensor or parameter setting out of range Check the flow and DHW sensor resistance is within range Check the parameters are correctly set for boiler model Alpha InTec² 20SE and 30SE - Error Codes and Fault Finding...

  • Page 48: Short Parts List

    1.037816 Clip - Flow/return pipe to heat exchanger 1.026763 Clip - Gas pipe connections 1.020393 Boiler wall bracket 2.015350 Boiler connection kit 3.025335 Boiler accessory box complete 3.025336 Wall template 1.035155 Alpha InTec² 20SE and 30SE - Short Parts List...
  • Page 49 Alpha InTec² 20SE and 30SE - This Page Intenionally Blank...

  • Page 50: 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 51 (AFC) hot water function (AFC) Seasonal room heating yield (ηs) 92 % Seasonal room heating yield (ηs) 92 % Domestic hot water production yield (ηwh) Domestic hot water production yield (ηwh) Alpha InTec² 20SE and 30SE - Energy Classification...
  • Page 52 Alpha InTec² 20SE and 30SE - Energy Classification...
  • Page 53 * 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 InTec² 20SE and 30SE - Energy Classification...
  • Page 54 11.7 PARAMETERS FOR FILLING IN DHW PACKAGE ASSEMBLY CHART Parameter InTec² 20SE InTec 30SE ‘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 InTec² 20SE and 30SE - Energy Classification...
  • Page 55 Alpha InTec² 20SE and 30SE - Energy Classification...

  • Page 56: Benchmark Checklist

    GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty.

  • Page 57: Service Record

    SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s specifed spare part when replacing controls.

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