Alpha Pro Tec 48NX Design, Installation And Servicing Instructions
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Alpha Pro Tec 48NX Design, Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing combination boiler
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Installation and Servicing
Instructions
Pro Tec 48NX and 68NX
Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing Combination Boiler
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
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  • Page 1 Installation and Servicing Instructions Pro Tec 48NX and 68NX Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing Combination Boiler For Technical help or for Service call ... ALPHA HELPLINE Tel: 0344 871 8764 website: www.alpha-innovation.co.uk Nepicar House, London Road,...

  • Page 2: Table Of Contents

    1.18 Wiring diagram - two direct heating zones - DHW pump - open therm thermostat ................30 1.19 Wiring diagram with high power remote control .............................31 1.20 Wiring diagram BUS-Cascade connection ...............................32 1.21 Alpha flue systems ......................................33 1.22 Equivalent lengths of flue system components............................34 1.23 Cap removal for concentric kit installation ..............................35 1.24 Concentric horizontal kit installation ................................35...
  • Page 3 Instructions for use and maintenance ............................. 53 General recommendations ..................................53 2.2 Cleaning and maintenance ..................................54 2.3 Control panel ........................................55 Using the appliance ......................................56 2.5 Weekly schedule ......................................58 2.6 Eco ..........................................58 Holidays .........................................59 2.8 User menu ........................................60 Fault and anomaly signals ....................................69 2.10 Appliance switch-off ....................................73 2.11 Restore central heating system pressure ..............................73 2.12 Draining the system .....................................73...

  • Page 4: General Recommendations

    Read the instructions provided with the product carefully to ensure proper installation. • This instructions manual provides technical information for installing Alpha products. As for the other issues related to the installation of products (e.g. safety at the workplace, environmental protection, accident prevention), it is necessary to comply with the provisions of the standards in force and the principles of good practice.

  • Page 5: Safety Symbols Used

    safETy symbols UsED GENEral HazarD Strictly follow all of the indications next to the pictogram. Failure to follow the indications can generate hazard situations resulting in possible harm to the health of the operator and user in general, and/or property damage. ElEcTrIcal HazarD Strictly follow all of the indications next to the pictogram.

  • Page 6: Unit Installation

    Installation must be carried out according to regulation standards, current legislation and in compliance with local technical regulations and the required technical procedures. The place of installation of the appliance and relative Alpha accessories must have suitable features (technical and structural), such as to allow for (always in safe, efficient and comfortable conditions): - installation (according to the provisions of technical legislation and technical regulations);...
  • Page 7 Fig. 1 It is forbidden to install appliances removed from other systems. The manufacturer declines all liability in the event of damage caused by appliances removed from other systems or for any non-conformities with such equipment. Check the environmental operating conditions of all parts relevant to installation, referring to the values shown in the technical data table in this booklet.
  • Page 8 Before installing the appliance, ensure that it is delivered in perfect condition; if in doubt, contact the supplier immediately. Packing materials (staples, nails, plastic bags, polystyrene foam, etc.) constitute a hazard and must be kept out of the reach of children.
  • Page 9 risk of damage due to corrosion caused by unsuitable combustion air and environment. Spray, solvents, chlorine-based detergents, paints, glue, ammonium compounds, powders and similar cause product and flue duct corrosion. Check that combustion air power supply is free from chlorine, sulphur, powders, etc. Make sure that no chemical substances are stored in the place of installation.

  • Page 10: Handling The Appliance

    HaNDlING THE aPPlIaNcE aTTENTIoN: the casing sides are not load-bearing, so in order to move the appliance, it is necessary to take it from the rear and front as shown in the fig. 2 and not from the side. Fig. 2 DaTa NamEPlaTE PosITIoN Key (Fig.

  • Page 11: Main Dimensions

    maIN DImENsIoNs Key (Fig. 4): - Air intake - Electrical connection - Gas supply - System return - System flow - Condensate drain (minimum in- ternal diameter Ø 13 mm) Fig. 4 Height Width Depth (mm) (mm) (mm) 851 (985) Connections SYSTEM 3/4"...

  • Page 12: Position Of The Appliances

    PosITIoN of THE aPPlIaNcEs The installation of appliances powered with gas with a greater density than 0.8 (l.P.G.) is only allowed in places above ground level, also communicating with places that are on the ground. In both cases the walkway must not have hollows or depressions such to create gas pockets that determine dangerous conditions.

  • Page 13: Antifreeze Protection

    - The materials used for the central heating circuit of Alpha appliances resist propylene glycol based antifreeze liquids (if the mixtures are prepared perfectly).

  • Page 14: Other Antifreeze Functions (Optionals)

    oTHEr aNTIfrEEzE fUNcTIoNs (oPTIoNals) Depending on the system implemented and thus on the optional kits fitted, other Antifreeze functions may be available. External probe (optional) If the external probe is present, the appliance's pump or other pumps if installed (Pump, Zone 1 pump, Zone 2 pump, System pump), is activated when the external temperature measured by the probe drops below the temperature set in the parameter "System settings/ Additional antifreeze protections/Outside temperature pump activation"...

  • Page 15: Gas Connection

    1.10 Gas coNNEcTIoN Our appliances are built to work with natural gas (G Z50, G27), LPG and mixtures of methane and hydrogen up to 20% in volume (20%H2NG). Power supply pipes must be the same as or larger than the appliance fitting. Before connecting the gas line, carefully clean inside all the fuel feed system pipes to remove any residue that could impair appliance efficiency.

  • Page 16: Hydraulic Connection

    1.11 HyDraUlIc coNNEcTIoN In order not to void the condensation module warranty, before making the device connections, carefully clean the heating system (pipes, radiators, etc.). A treatment of the heating and water system water is required, in compliance with the technical standards in force, in order to protect the system and the appliance from deposits (e.g.
  • Page 17 If the system-side flow sensor is used, Boiler supply temperature is limited by the maximum permissible temperature (95°C). To avoid the risk of exceeding the optimal temperature of operation in low temperature, due to external causes (e.g.: incorrect adjustment, prolonged non-use of the system, etc.), you must insert in series with the supply voltage of the boiler, a special safety kit (optional) consisting of a thermostat (with adjustable temperature, depending on the characteristics of the system).

  • Page 18: Electrical Connection

    1.12 ElEcTrIcal coNNEcTIoN The electrical system must be built in compliance with technical standards and all legislation in force. The appliance has an IPX5D protection degree; electrical safety of the appliance is achieved only when it is connected properly to an efficient earthing system, as specified by current safety standards.
  • Page 19 opening rear control panel cover for access to the low power and high power connection boards (figs. 7 and 8) In order to access the electrical connection boards, it is necessary to dismantle the front casing and follow the instructions below: 1.
  • Page 20 Key (Fig. 9): - Power supply cable Fig. 9...

  • Page 21: Commands For Heat Adjustment (Optional)

    1.13 commaNDs for HEaT aDjUsTmENT (oPTIoNal) The device is prepared for the application of the cascade and zone regulator, the zone manager, the remote control for single high-power boilers, on/off thermostats, commercial Opentherm modulators and the external probe. These components are available as separate kits to the boiler and are supplied on request. Carefully read the user and assembly instructions contained in the accessory kit.
  • Page 22 • constant setpoint The CH demand is generated permanently on both heating zones (it is not mandatory to configure both pumps of the two zones). Inputs OT1 and OT2 (in this case), can be used as setpoint reduction (open contact). With closed contact, the setpoint used is given by the parameters "Zone 1 CH setpoint"...
  • Page 23 The device connected to the BMS must only be controlled by it and not by other modes (Opentherm, 0-10V, Cascade and zone regulator, room thermostat, CH and DHW demand type parameter). If the BMS must be integrated into an existing home automation system or other than the Alpha system manager, Alpha technical must be contacted for the configuration of the correct parameters.
  • Page 24 By setting the parameter "CH Request type" within "HYDRAULIC SETTINGS" it is possible to configure the input by choosing the operating mode between "0-10 V Temperature control" and "0-10 V Power control" . By setting this parameter, both in temperature and in Power, the CH demand is subject to priority in DHW, deactivation CH Demand, Decreasing slope (function) and Minimum time.
  • Page 25 • oTc climate curve - cH1 (zone 1 cH) TM (°C) TE (°C) Fig. 11 The graph in Fig. 11 is made by the outside temperatures for minimum CH (+18 °C) with the Zone 1 minimum CH setpoint (+20 °C) and the outside temperatures for maximum CH (-10 °C) with the maximum Zone 1 CH setpoint (+85 °C).

  • Page 26: Hydraulic Settings

    1.14 HyDraUlIc sETTINGs system sensor Two heating zones (one of which can be mixed) and a DHW storage tank can be managed. relay settings See also Relay settings in chapter Maintenance. Using the configurable relays, the hydraulic diagrams shown on the following pages can be realised. These relays can be used to activate zone pumps, system pump, DHW pump, 3-way DHW valve, mixing valve, fault signal and Burner on.

  • Page 27: Notes And Tables In Common Of Wiring Diagrams

    1.15 NoTEs aND TablEs IN commoN of WIrING DIaGrams The notes and tables below apply to all diagrams in this section. For low-temperature zones, insert a safety thermostat in series with the relevant zone pump. Remove the X40 link in case of connection: * cascade and zone regulator * 0-10V * BMS...

  • Page 28: Hydraulic Diagram - One Direct Zone - One Mixed Zone - Dhw Pump

    1.16 HyDraUlIc DIaGram - oNE DIrEcT zoNE - oNE mIXED zoNE - DHW PUmP Fig.13 Key (Fig. 13): - Minimum pressure switch with manual reset - Safety thermostat - Generator - Storage tank unit feeding pump - External probe - Non return valve - Manifold/mixer - External storage tank unit - Slurry collection system filter...

  • Page 29: Wiring Diagram - One Direct Zone - One Mixed Zone - Dhw Pump

    1.17 WIrING DIaGram - oNE DIrEcT zoNE - oNE mIXED zoNE - DHW PUmP Further notes on this diagram can be found in Para. 1.15. As a hydraulic diagram, please refer to Fig. 13. TA/2 TA/1 Link Fig. 14 Key (Fig. 14): Parameter configuration table A37 - Connection sheet (loads) "HyDraUlIc sETTINGs"...

  • Page 30: Wiring Diagram - Two Direct Heating Zones - Dhw Pump - Open Therm Thermostat

    1.18 WIrING DIaGram - TWo DIrEcT HEaTING zoNEs - DHW PUmP - oPENTHErm THErmosTaTs Further notes on this diagram can be found in Para. 1.15. As a hydraulic diagram, please refer to Fig. 13. Fig. 15 Key (Fig. 15): Parameter configuration table A37 - Connection sheet (loads) "HyDraUlIc sETTINGs"...

  • Page 31: Wiring Diagram With High Power Remote Control

    1.19 WIrING DIaGram WITH HIGH PoWEr rEmoTE coNTrol cascaDE maNaGEr/zoNE coNTrollEr Key (Fig. 17): A25 - CLIP-IN (optional) A38 - Connection card (signals) - Room thermostat (optional) - Cable type: J-Y(St)Y 2x2x0,6. Maximum permitted length: 50 m - Address 0 Fig.

  • Page 32: Wiring Diagram Bus-Cascade Connection

    1.20 WIrING DIaGram bUs-sImPlE cascaDE coNNEcTIoN ≤ 2 m ≤ 2 m...

  • Page 33: Alpha Flue Systems

    1.21 alPHa flUE sysTEms Alpha supplies various solutions separately from the appliances regarding the installation of air intake terminals and flue extraction, which are fundamental for appliance operation. Type c configuration, sealed chamber and fan assisted Extension pipes and concentric elbows push-fittings.

  • Page 34: Equivalent Lengths Of Flue System Components

    1.22 EqUIvalENT lENGTHs of alPHa flUE sysTEm comPoNENTs. Equivalent length TyPE of DUcT to 1 m of pipe pipe Ø 80/125 Concentric pipe 80/125 Ø m 1 m 1,0 90° concentric bend 80/125 Ø m 1,5 Concentric bend 45° Ø 80/125 m 1,0 Terminal complete with concentric horizontal intake-exhaust Ø...

  • Page 35: Cap Removal For Concentric Kit Installation

    1.23 caP rEmoval for coNcENTrIc kIT INsTallaTIoN In order to be able to install the concentric kits, it is necessary to remove the factory fitted cap on the concentric intake. Key (Fig. 19): - Screw - Concentric intake cap Fig. 19 1.24 coNcENTrIc HorIzoNTal kIT INsTallaTIoN Type c configuration, sealed chamber and fan assisted The position of the terminal (in terms of distances from openings, overlooking buildings, decking, etc.) must be set up in compliance...
  • Page 36 Horizontal intake/exhaust kits –Ø 80/125 assembly (fig. 20) 1. Remove the Ø 125 cap on the concentric intake, with its gasket (Fig. 19) by unscrewing the fixing screw. 2. Engage the bend (1) with the male (smooth) side up to the end stop of the flue flange of the appliance; 3.

  • Page 37: Concentric Vertical Kit Installation

    1.25 coNcENTrIc vErTIcal kIT INsTallaTIoN Type c configuration, sealed chamber and fan assisted Concentric vertical intake and exhaust kit. This vertical terminal is connected directly to the outside of the building for air intake and flue gas exhaust. The vertical kit with aluminium tile enables installation on terraces and roofs with a maximum slope of 45% (approx 25°) and the height between the terminal cap and half-shell (260 mm) must always be respected.

  • Page 38: Intake Stub Pipe Kit Installation For Type B Configurations

    1.26 INTakE sTUb PIPE kIT INsTallaTIoN for TyPE b coNfIGUraTIoNs Installation of the intake stub pipe kit (fig. 24) 1. Unscrew the screws (1) securing the Ø 80 suction cap; 2. Remove the factory-assembled suction cap (2); 3. Place the gasket (5) of the stub pipe kit on the newly freed intake hole; 4.

  • Page 39: Separator Kit Installation

    1.27 sEParaTor kIT INsTallaTIoN Type c configuration, sealed chamber and fan assisted separator kit Ø 80/80 This kit allows air to come in from outside the building and the exhaust to exit from the chimney, flue or intubated duct through divided flue exhaust and air intake pipes.
  • Page 40 Extensions for separator kit Ø 80/80 (l = maximum length) To aid in the removal of possible condensate forming in the exhaust pipe, tilt the pipes towards the appliance with a minimum slope of 5% (Fig.27). Please note the type of installation C must be done with a natural draught flue.

  • Page 41: Ducting Of Flues Or Technical Slots

    Ducting requires ducts declared to be suitable for the purpose by the manufacturer, following the installation and user instructions, provided by the manufacturer and the requirements of the regulations in force. - When using flexible flue liner contact Alpha technical for advice.

  • Page 42: Maximum Flue Length

    1.29 maXImUm flUE lENGTH Pro Tec 48NX Type Installation Pro Tec 48 NX L = Maximum length (m) 80/125mm C13 (horizontal+curve) C33 (vertical) C43 - C53 - C83 (split) 80/80mm B23 - B23p - B33 - B53 - B53p Ø 80mm C9 C93 (Ø80/125 1b+1m Ø80 1b)

  • Page 43: Flue Gas Exhaust With Cascade Appliances

    The boilers installed in cascade composed of any number between 2 and 5 boilers, can be manifolded to a unique flue exhaust pipe, which flows into a single chimney. Alpha supplies an appropriate and original flue exhaust system separately to the appliances. 1.31 WaTEr TrEaTmENT PlaNT fIllING As already mentioned in the previous Pararaphs, a treatment of the thermal and domestic system water (when paired with a storage tank unit) is required, in compliance with the local standards in force.

  • Page 44: System Filling

    1.32 sysTEm fIllING Once the device is connected, proceed with filling the system. Filling is performed at low speed to ensure release of air bubbles in the water via the appliance and central heating system vents. The appliance has a built-in automatic vent valve and a manual one on the condensing module (Para. 1.69). Check if the cap is loose.

  • Page 45: Simple Cascade

    1.35 sImPlE cascaDE By connecting two or more boilers electrically via BUS, a simple cascade can be configured. Make the BUS connection as shown in the diagram (Fig. 18). A system flow sensor is required in this configuration, see relevant example installation wiring diagrams in the cascade booklet. If the system flow sensor fails, the system will still function but with reduced performance.

  • Page 46: Autodetection

    1.36 aUToDETEcTIoN This function makes it possible to detect and associate appliances in cascade in the case of simple cascade installation. It also serves to assign the role of Master and Slave to devices in simple cascade or, to revert to a single configuration from simple cascade. Ensure that the communication BUS for simple cascade has been connected as in the diagram in Fig.

  • Page 47: Heating Zones

    1.38 HEaTING zoNEs Using the appliance's P.C.B., two separate zones can be managed in CH mode, and one of these can be mixed. The system flow probe is required and, in the case of the mixed zone, the low temperature flow probe is also required. When using the system-side flow sensor and hydraulic separator, the flow temperature of the unit (or units in the case of simple cascade) is limited by the maximum permissible temperature (95°C).

  • Page 48: Anti-Legionella

    1.41 aNTI-lEGIoNElla The menu "Antilegionella" is present if the parameter "DHW request type" is set as "Sensor". The function must be enabled by the 'Function' parameter and the temperature read by the DHW probe must be lower than the setpoint parameter (anti-legionella) to be activated.

  • Page 49: Circulation Pump

    'Minimum pump speed' and 'Pump start speed' parameters should be set at 100 %. In domestic hot water mode, the circulator pump always runs at full speed. Pump lED Pro Tec 48NX - LED off: circulator not powered - flashing green LED: circulator powered, but stopped - steady green LED: circulator active - flashing red LED (temporary error): pump is making attempts to unblock;...
  • Page 50 Pro Tec 68NX - LED off: circulator not powered - fixed green LED: circulator powered or running - flashing red LED (temporary error): pump is making attempts to unblock; overload; pump driven by external flow; overtemperature; overvoltage; undervoltage - fixed red LED (permanent error): pump blocked (unblock the rotor mechanically - de-energise for approx. 30 seconds in order to reset the pump's internal error);...

  • Page 51: Kits Available On Request

    A wide range of accessories is available for the Pro Tec NX range to meet all different installation needs. Check the complete list of kits available and which can be combined with the product, contact Alpha technical for more details.

  • Page 52: Main Components

    1.47 maIN comPoNENTs Fig. 33 Key (Fig. 33): - Concentric intake cap Ø 125 - Intake closing cap Ø 80 - P.C.B. - Flange with sample points - High power connection board - Flue probe - Low power connection board - Heat exchanger safety thermofuse - Drain fitting - Condensation module...

  • Page 53: Instructions For Use And Maintenance

    INsTrUcTIoNs for UsE aND maINTENaNcE GENEral rEcommENDaTIoNs Never expose the wall-mounted appliance to direct vapours from a hob. (only single installation ofPro Tec NX boiler) The device can be used by children at least 8 years old as well as by persons with reduced physical, sensory or mental capabilities, or lack of experience or required knowledge, provided that they are under surveillance, or after they have been instructed relating to the safe use and have understood the potential dangers.

  • Page 54: Cleaning And Maintenance

    In the event of malfunctions, faults or incorrect operation, turn the appliance off and contact an authorised company (e.g. the Alpha Technical Helpline, which have specifically trained staff and original spare parts). Do not attempt to modify or repair the appliance alone.

  • Page 55: Control Panel

    2.3 coNTrol PaNEl Fig. 34 Key (Fig. 34): - Indicates the central heating setpoint temperature - Main switch - Central heating mode enabled - Multifunction display (main screen) - Indicates burner on and relative output scale - Sliding door - Hourly heating programming active mode (ON, OFF, ECO) of - Function keys central heating schedule - Instrument pressure gauge...

  • Page 56: Using The Appliance

    UsING THE aPPlIaNcE Before ignition, make sure that the system is full of water, checking that the pressure gauge (Fig. 34) indicates a base value at which the system has been designed and calculated and however not less than 0.5 bar. –...
  • Page 57 CENTRAL HEATING Outside temperature Outside temperature for CH off 85°C Zone 1 CH setpoint Zone 1 Offset 35°C 0°C Zone 2 CH setpoint Zone 2 Offset 0°C Outside temperature 30°C Zone 1 CH ECO setpoint reduction 5°C Zone 2 CH ECO setpoint reduction To confirm To confirm To select...

  • Page 58: Weekly Schedule

    2.5 WEEkly scHEDUlE Time programming allows you to define the operating times of the device. Two independent programmes are available, one for CH and one for DHW. To activate programming, you must enter the menus CENTRAL HEATING" and DOMESTIC HOT WATER" and under the parameter "Enable/disable scheduler"...

  • Page 59: Holidays

    - Zone 1 CH ECO setpoint reduction; - Zone 2 CH ECO setpoint reduction; - ECO shutdown hysteresis CH Zone 1; - ECO shutdown hysteresis CH Zone 2. The parameter for the function "ECO" in DHW is as follows: - ECO setpoint reduction. If parameters "ECO shutdown hysteresis CH Zone 1"...

  • Page 60: User Menu

    2.8 UsEr mENU Press the “MENU” button to access a list of variables that enable you to customise use of the system. Hereunder is a list of available menus: mENU menu item Description USER Allows selection of the user menu TECHNICIAN Allows selection of the technical menu (access allowed via password for Service only) UsEr mENU...
  • Page 61 restore customised menu item Description range Default settings value Sets the temperature that will be subtracted from the actual setpoint for heating zone 1 when the "ECO" mode is activated. Zone 1 CH ECO setpoint 0 ÷ 50 If the parameter "CH Request type is set to reduction (°C) (°C)
  • Page 62 UsEr mENU/cENTral HEaTING/oUTDoor TEmPEraTUrE restore customised menu item Description range Default settings value Defines the external air temperature at which Outside temperature for CH 7 ÷ 25 the heating request is disabled (even if the (°C) room thermostat demand is active). This is the offset value to be added on zone 1 to Zone 1 Offset -15 ÷...
  • Page 63 When Thermostat is set in Technician menu/HYDRAULIC SETTINGS/DHW request type, the table below will look like this: UsEr mENU/HolIDay/HolIDay moDE restore customised menu item Description range Default settings value Sets the zone 1 heating setpoint when Zone 1 "Holiday mode" is active minimum If the parameter "Zone 1 CH setpoint"...
  • Page 64 When Sensor is set in Technician menu/HYDRAULIC SETTINGS/DHW request type, the table below will look like this: UsEr mENU/HolIDay/HolIDay moDE restore customised menu item Description range Default settings value Sets the zone 1 heating setpoint when Zone 1 "Holiday mode" is active. minimum If the parameter "Zone 1 CH setpoint"...
  • Page 65 UsEr mENU/sETTINGs/UsEr INTErfacE restore customised menu item Description range Default settings value English Italian Bulgarian Czech Greek French Flemish Polish Portuguese Select language Allows the selection of the desired language. English Slovak Spanish Romanian Russian Slovenian German Turkish Ukrainian Hungarian Imperial Allows selection of the unit of measurement Measurement units...
  • Page 66 UsEr mENU/DIaGNosTIcs/boIlEr sTaTE menu item Description Antifreeze protection Displayed when Antifreeze mode is active. Anti legionella Displayed when '' A nti legionella'' is active. CH Demand Displayed when "CH Demand" is active. CH Postpump Displayed at the end of "CH Demand" and during the pump post-circulation phase. CH - Primary circuit Displayed when the setpoint is reached and the burner is switched off during “CH Demand”.
  • Page 67 UsEr mENU/DIaGNosTIcs/sysTEm INformaTIoN menu item Description Flame current* Value in µA. Actual fan speed Real-time fan speed (rpm). Requested fan speed Fan setpoint (rpm). Modulation level * Effective burner output value (%). Boiler setpoint* Temperature value calculated by the system (°C). CH setpoint Required temperature value during heating (°C).
  • Page 68 UsEr mENU/DIaGNosTIcs/fIrmWarE rElEasE menu item Description Display Views the display board firmware version. Main board Displays the P.C.B. firmware version. UsEr mENU/maINTENaNcE menu item Description Service information Displays the telephone number of the service centre. Service due date Date of next maintenance (see error code 102).

  • Page 69: Fault And Anomaly Signals

    An error is detected on the main circuit board and the main board fault supply to the device. device does not start. (2) (1) (1) If the shutdown or fault persists, contact alpha Technical. (2) If normal operating conditions are restored, the appliance re-starts without having to be reset.
  • Page 70 Press the OK (Reset) button (1) fault. be necessary to wait 3 minutes for the error to be detected). (1) If the shutdown or fault persists, contact alpha Technical. (2) If normal operating conditions are restored, the appliance re-starts without having to be reset.
  • Page 71 (heating of the system is not independent mode until guaranteed). communication is restored). (2) (1) (1) If the shutdown or fault persists, contact alpha Technical. (2) If normal operating conditions are restored, the appliance re-starts without having to be reset.
  • Page 72 Slave receives no communication from the boiler Master. This error will only appear on the display of the Slave devices (2) (1) (1) If the shutdown or fault persists, contact alpha Technical. (2) If normal operating conditions are restored, the appliance re-starts without having to be reset.

  • Page 73: Appliance Switch-Off

    Authorised After-Sales Technical from the menu "TECHNICIAN". Assistance Centre). (1) If the shutdown or fault persists, contact alpha Technical. (2) If normal operating conditions are restored, the appliance re-starts without having to be reset. 2.10 aPPlIaNcE sWITcH-off Switch the appliance off by putting it in “off” mode, disconnect the main switch outside of the appliance and close the gas cock upstream of the appliance.

  • Page 74: Antifreeze Protection

    2.13 aNTIfrEEzE ProTEcTIoN The appliance has an antifreeze function that switches the burner on automatically when the temperature drops below 9°C (standard protection to minimum temperature of -5°C). In order to guarantee the integrity of the appliance and the domestic hot water heating system in areas where the temperature drops below zero, we recommend protecting the central heating system using anti-freeze liquid .

  • Page 75: Instructions For Maintenance And Initial Check

    These will also compromise the product’s compliance, and the said product may no longer be valid and fail to meet the current regulations. in regard to the above, only use original Alpha spare parts when replacing components. If additional documentation needs to be consulted for extraordinary maintenance, contact the Authorised After-Sales Service.

  • Page 76: Initial Check

    INITIal cHEck commissioning the appliance requires you to: - Ensure that the type of gas used corresponds to the appliance settings (the type of gas appears on the display on first electrical power supply, on the data nameplate or, with the display already on, with the following sequence: MENU - Information - Ok); - Check connection to a 230V-50Hz power mains, correct L-N polarity and the earthing connection;...

  • Page 77: Yearly Appliance Check And Maintenance

    yEarly aPPlIaNcE cHEck aND maINTENaNcE The following checks and maintenance should be performed once a year to ensure operation, safety and efficiency of the appliance over time. - Clean the flue side of the heat exchanger. - Clean the main burner. - Check the correct positioning, integrity and cleanliness of the detection and ignition electrode;...
  • Page 78 Pro Tec 48NX Gas type to nominal q. to minimum q. G20 Nat. Gas 9,2 (9,1 ÷ 9,6) 8,7 (8,6 ÷ 9,1) G31 LPG 10,3 (10,2 ÷ 10,6) 9,6 (9,3 ÷ 9,7) Gas type at Nominal q. at minimum q.

  • Page 79: Hydraulic Diagram

    HyDraUlIc DIaGram 17 18 Fig. 41 Key (Fig. 41): - Heat-exchanger safety thermostat (manual reset) - Overheating safety thermostat - Draining funnel on view - System return regulation probe - Device emptying cock - System flow regulation probe - · 4 bar safety valve - Detection electrode - Flow manifold - Burner...

  • Page 80: Wiring Diagram

    WIrING DIaGram Fig. 42...
  • Page 81 Key (Fig. 42): Key (Fig. 42): - Circuit board - 230 Vac 50Hz Power supply - Display board - Testing/iXTool (Bus microm) - CLIP-IN (Optional - part No.1.037171) - External reset (Optional) - Cascade and zone regulator - Bus openTherm 1 - Connection sheet (loads) - Bus openTherm 2 - Connection card (signals)
  • Page 82 maximum loads on relays of boards a2 and a4 Multifunction Voltage Current cosφ From factory relay settings, K70 Programmable relays do not relays perform any K70-A2/K70-A3 230 Vac < 0.1 A ≥ 0,6 functions. K70-A4/K70-A5 K70-A1 Insert an optional Potential-free external relay to Run/fault signal contact (230 Vac...

  • Page 83: Troubleshooting

    TroUblEsHooTING Trouble Possible causes solutions Caused by leakage from gas circuit smell of gas Check sealing efficiency of gas intake circuit. pipelines. Check the presence of pressure in the network and that the gas adduction repeated ignition blocks No gas. cock is open.

  • Page 84: Technical Menu

    TEcHNIcal mENU Press the “MENU” button to access a list of variables that enable you to customise use of the system. Hereunder is a list of available menus: mENU menu item Description USER Allows selection of the user menu TECHNICIAN Allows selection of the technical menu (access allowed via password for Service only) To access the technical menu, enter the password '123' using the '+' and '-' buttons, pressing 'OK' with each entered digit.
  • Page 85 TEcHNIcIaN mENU/HyDraUlIc sETTINGs/rElay sETTINGs restore value menu item Description range Default settings customized K70-A1 Relay not used Booster pump K70-A2 Zone 1 pump K70-A3 Zone 2 pump K70-A4 System pump DHW pump System fault 3-way valve CH Each relay has a dedicated K70-A5 3-way valve DHW parameter to determine its...
  • Page 86 TEcHNIcIaN mENU/HyDraUlIc sETTINGs/mIX zoNE restore value menu item Description range Default settings customized Selects the mixed heating zone (mixing valve, Mix zone selection* sensor). Only one heating zone can be 1 ÷ 2 equipped with a mixing valve. Running time of the mixing valve. 1 ÷...
  • Page 87 TEcHNIcIaN mENU/HyDraUlIc sETTINGs/cH rEqUEsT TyPE restore value menu item Description range Default settings customized Room thermostat OTC They allow the selection of Room thermostat OTC Room thermostat setpoint different CH demands Room thermostat setpoint Room Only OTC according to the type of Only OTC thermostat installation:...
  • Page 88 TEcHNIcIaN mENU/HyDraUlIc sETTINGs/3-Way valvE restore value menu item Description range Default settings customized 3-way valve selection: Motorized (Motorised diverter valve) Motorized Spring return (Diverter valve with spring ÷ 3-way valve selection return) Motorized Spring **non tradotto**1**non tradotto**16**non return tradotto**1**non tradotto**26**non tradotto** Defines the time during which the 'electric' valve is energised to switch the position from...
  • Page 89 TEcHNIcIaN mENU/cH sETTINGs/TEmPEraTUrEs restore customised menu item Description range Default settings value Zone 1 maximum CH 15 ÷ 90 Set the "Zone 1 maximum CH setpoint. setpoint (°C) (°C) ÷ Zone 1 minimum CH Zone 1 Set the "Zone 1 minimum CH setpoint". setpoint maximum (°C)
  • Page 90 TEcHNIcIaN mENU/cH sETTINGs/TEmPEraTUrEs restore customised menu item Description range Default settings value Sets the temperature that will be subtracted from the actual setpoint for heating zone 1 when the "ECO" mode is activated. Zone 1 CH ECO setpoint If the parameter "CH Request type " is set to 0 ÷...
  • Page 91 TEcHNIcIaN mENU/cH sETTINGs/TEmPEraTUrEs restore customised menu item Description range Default settings value If set other than 0 and when the "ECO" mode is active, the CH demand is inhibited when the calculated setpoint is lower than the temperature set on the zone 2 CH setpoint. The request is unlocked if the calculated ECO shutdown hysteresis 0 ÷...
  • Page 92 TEcHNIcIaN mENU/cH sETTINGs/ovErTEmPEraTUrE restore customised menu item Description range Default settings value Each time the burner is switched on and 0 ÷ 10 Overtemperature timer* during the time set by the parameter (min) (min) "Overtemperature timer", the burner is switched off at a temperature value increased Overtemperature hysteresis 0 ÷...
  • Page 93 TEcHNIcIaN mENU/cH sETTINGs/TImING sETTING restore customised menu item Description range Default settings value 0 ÷ -20 Post pump time [min] Set the heating pump delay time (min) (min) Set the anti-cycle timer (minimum time 0 ÷ 15 Anticycling timer between boiler switch-off and next switch- (min) (min) The boiler output is adjusted so that the...
  • Page 94 When Thermostat is set in Technician menu/HYDRAULIC SETTINGS/DHW request type, the table below will look like this: TEcHNIcIaN mENU/DomEsTIc HoT WaTEr/TEmPEraTUrEs restore customised menu item Description range Default settings value Storage temperature Sets the flow temperature during the 35 ÷ 87 setpoint "Domestic hot water"...
  • Page 95 TEcHNIcIaN mENU/DomEsTIc HoT WaTEr/TImING sETTING restore customised menu item Description range Default settings value 0 ÷ 59 Post pump time [sec] Set the "DHW Postpump" time in seconds. Set the time for "DHW Postpump" in 0 ÷ 30 Post pump time [min] minutes.
  • Page 96 TEcHNIcIaN mENU/sysTEm sETTINGs Fan parameters Pump parameters Delta T parameters Boiler antifreeze protection Additional antifreeze protections Decreasing slope User interface settings Anti-humidity settings Modbus parameters 10. Maintenance TEcHNIcIaN mENU/sysTEm sETTINGs/faN ParamETErs restore customised menu item Description range Default settings value See table 750-6750 Para.
  • Page 97 TEcHNIcIaN mENU/sysTEm sETTINGs/PUmP ParamETErs Default restore customised menu item Description range appliance settings value Disabled Disabled = pump feedback is not used Feedback ÷ Enabled Enabled = pump feedback is used Enabled PWM = the pump feedback signal is a PWM based signal selectable between Wilo and Grundfos Feedback signal type...
  • Page 98 TEcHNIcIaN mENU/sysTEm sETTINGs/aDDITIoNal aNTIfrEEzE ProTEcTIoNs restore customised menu item Description range Default settings value Defines the antifreeze activation threshold. Antifreeze activation This threshold is monitored by the (system) 2 ÷ 20 temperature sensor (if present) in order to protect the (°C) (°C) system.
  • Page 99 TEcHNIcIaN mENU/sysTEm sETTINGs/moDbUs ParamETErs restore customised menu item Description range Default settings value Allows the assignment of the Modbus slave Address 1 ÷ 247 address. 1200 2400 4800 Baudrate Modbus transmission rate. 9600 9600 19200 38400 The first digit (8 fixed value) defines the number of bits per byte.
  • Page 100 TEcHNIcIaN mENU/maNUal TEsT menu item Description Activates "Function" "Chimney sweep" for single boiler or for one or more boilers if simple Chimney sweep cascade installation (for more details, see Para. 3.11). Check the "Function" associated with the relay previously set in "Technician menu/ HYDRAULIC SETTINGS/Relay settings".

  • Page 101: Programming

    TEcHNIcIaN mENU/cascaDE Settings Single burner power Autodetect Parameter synchronization The parameter ' A utodetect' is also used by the individual device (Para. 1.36). Although the remaining parameters are also present on the individual boiler, they can be set when the appliance is part of a cascade installation. For setting and explanation of parameters, please refer to the cascade booklet.

  • Page 102: Converting The Appliance To Other Types Of Gas

    coNvErTING THE aPPlIaNcE To oTHEr TyPEs of Gas The gas conversion operation must be carried out by an authorised company (e.g. Authorised Technical Assistance Service). The pressure testers used for calibration should be perfectly closed and there should be no leaks from the gas circuit.

  • Page 103: Co Regulation

    sIT 848 Gas valve Key (Fig. 43): - Gas valve inlet pressure point - Gas valve outlet pressure point - Off/Set adjustment screw - Pressure regulator connection (PR) - Outlet gas flow rate adjuster Fig 43 after 10 years from the date of manufacture, replace the gas valve. 3.10 co rEGUlaTIoN To have an exact value of CO...

  • Page 104: Chimney Sweep

    3.11 cHImNEy sWEEP This function, which can be activated at Technician menu/Manual test, allows the technician to check combustion parameters. The operating temperature is limited by the parameters "Zone 1 CH setpoint" and "Zone 2 CH setpoint". If the system-side flow sensor is used, the above two parameters limit the temperature on the hydraulic circuit where the system-side flow sensor is installed.

  • Page 105: Antifreeze

    3.15 aNTIfrEEzE The antifreeze is also active when the appliance is in standby mode or when CH and/or DHW is disabled. radiators The appliance is equipped with a function that starts the burner if the system flow water is below 9°C. The burner is switched off when the system flow water reaches approximately 35°C.

  • Page 106: Assembling The Manifold On The Condensation Module

    3.17 assEmblING THE maNIfolD oN THE coNDENsaTIoN moDUlE The maximum tightening force in assembling the manifold (2) on the condensation module (3) must be 5 Nm. Every time the manifold is opened, the condition and integrity of the ceramic fibres must be verified and replaced, if necessary.

  • Page 107: Casing Removal

    3.18 casING rEmoval To facilitate appliance maintenance the casing can be completely removed as follows: front (fig.49) 1. Loosen the two screws (a). 2. Pull the front casing (b) towards you. 3. Push the front casing upwards, releasing it from the upper pins (c). 4.
  • Page 108 sides (figs. 49, 50) 5. Tilt the control panel (e) towards you. 6. Unscrew the four screws (f) in order to remove the lower grid (g). 7. Unscrew the four screws (h). 8. Remove the side panels (i) by opening them slightly outwards and then lifting them first upwards and then pulling them towards you, so that they disengage from the rear seats (Ref.
  • Page 109 sealed chamber cover (fig. 51) 9. Unscrew the eight screws (l). 10. Swing the airtight chamber cover (m) towards yourself so that it can be removed from the two rebated screws at the top of the frame and released. Fig. 51...

  • Page 110: Technical Data

    The power data in the table has been obtained with intake-exhaust pipe measuring 0.5 m in length. Gas flow rates refer to net calorific value below a temperature of 15°C and at a pressure of 1013 mbar. Pro Tec 48NX NaT. Gas...

  • Page 111: Combustion Parameters

    20% (referring to the gas distributed in the network), all calibration operations of the device must refer to the O values of the gas G20 given in the following tables. Pro Tec 48NX Gas type NaT. Gas (G20)

  • Page 112: Technical Data Table

    4.3 TEcHNIcal DaTa TablE Pro Tec 48NX Pro Tec 68NX Central heating nominal heat input 51,0 69,9 Minimum heat input PoCentral heating nominal heat input 49,3 72,0 with 20%H2NG gas Minimum heat input with 20%H2NG gas Central heating nominal heat output...

  • Page 113: Data Nameplate And Indelible Nameplate Key

    DaTa NamEPlaTE aND INDElIblE NamEPlaTE kEy Cod.Md. Sr N° Type Qnw/Qn min Qnw/Qn max Pn min Pn max NOx Class CONDENSING Fig. 52 The technical data are provided on the data plate on the appliance. Model Cod. Md. Model code Sr N°...

  • Page 114: Technical Parameters For Combination Boilers (In Compliance With Regulation 813/2013)

    4.5 TEcHNIcal ParamETErs for combINaTIoN boIlErs (IN comPlIaNcE WITH rEGUlaTIoN 813/2013) The efficiencies and NO values in the following tables refer to the gross calorific value. model Pro Tec 48NX Condensing Boiler Low temperature boiler Boiler type B1 Co-generation appliance for central heating...
  • Page 115 model Pro Tec 68NX Condensing Boiler Low temperature boiler Boiler type B1 Co-generation appliance for central heating Mixed heating appliance Nominal heat output Seasonal energy efficiency of central heating η For central heating only and combination boilers: useful heat output At nominal heat output in high temperature mode (*) 68,2 At 30% of nominal heat output in a low temperature mode (**)

  • Page 116: Product Fiche (In Compliance With Regulation 811/2013)

    ProDUcT fIcHE (IN comPlIaNcE WITH rEGUlaTIoN 811/2013) Pro Tec 48NX Pro Tec 68NX Pro Tec 68 NX Pro Tec 48 NX Fig. 54 Fig. 55 Pro Tec 48NX Parameter value Annual energy consumption for the central heating mode (QHE) Seasonal space heating energy efficiency (ηs)

  • Page 117: Parameters For Filling In The Package Charts

    ParamETErs for fIllING IN THE PackaGE cHarTs If an assembly is to be made from this device, use the assembly sheets shown in (Fig. 58 and 59). For the correct compilation, insert into the appropriate spaces (as shown in the facsimile package charts (Figs. 56 and 57) the values set out in the tables "Parameters for compiling package chart"...
  • Page 118 facsimile for filling in the domestic hot water production system package chart ‘I’ Solar contribution From the board of the solar device Auxiliary electricity ( 1.1 x ‘I’ 10 % ) ‘II’ ‘III’ - ‘I’ average climate conditions < 27 % ≥...
  • Page 119 Parameters for filling in the central heating chart Parameter Pro Tec 48NX Pro Tec 68 mX "I" "II" "III" 0,54 0,37 "IV" 0,21 0,14 * 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.
  • Page 120 Parameters for filling in the DHW package chart Parameter Pro Tec 48NX Pro Tec 68NX "I" "II" "III" * to be determined according to Regulation 811/2013 and transient calculation methods as per Notice of the European Community no. 207/2014. Domestic hot water production system package chart.
  • Page 121 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 122 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 123 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 124 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.
  • Page 128 These instructions have been carefully prepared but we reserve the right to Sevenoaks, Kent TN15 7RS alter the specification at any time in the interest of product improvement. © Alpha Therm Limited 2023. Tel: 0344 8718764 email: info@alpha-innovation.co.uk Part No. 1.048051 rev. ST.007674/000 website:www.alpha-innovation.co.uk...

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