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Alpha Pro Tec 90 Installation And Servicing Instructions

Wall mounted, fan assisted, gas fired, high efficiency condensing system boilers
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Installation and Servicing

Instructions
Alpha Pro Tec 50, 70, 90 and 115
Wall Mounted, Fan Assisted, Gas Fired, High Efficiency
Condensing System Boilers
For Technical help or for Service call ...
ALPHA HELPLINE
Tel: 0870 3001964
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
0051
For use with Natural Gas or Propane Gas (LPG)
Leave these instructions with the User

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  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha Pro Tec 50, 70, 90 and 115 Wall Mounted, Fan Assisted, Gas Fired, High Efficiency Condensing System Boilers For Technical help or for Service call ... ALPHA HELPLINE Tel: 0870 3001964 Nepicar House, London Road,...
  • 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 Pro Tec - Benchmark Scheme...

  • Page 3: Table Of Contents

    Service record ........47 INTRODUCTION The Alpha Pro Tec range are wall mounted high efficiency condensing, fan assisted system boilers. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve. These are system boilers providing heating only for sealed central heating systems. However, they may be used with an open central heating system if required - refer to Section 3.8.

  • Page 4: General Data

    28 mm Boiler dimensions Height 1038 1038 1038 Width Depth Clearances for servicing Bottom Top (horizontal flue) Top (vertical flue) Sides Front Boiler dry lift weight Boiler operating weight (full of water) approx. Water content litre Alpha Pro Tec - Data...
  • Page 5 Flue temperature (nominal) °C at maximum output (factory set) 10.6 10.6 10.6 10.7 at minimum output (factory set) 10.1 10.0 10.0 10.3 CO (nominal) at 0% O CO weight (nominal) mg/kWh Dry NOX weighted mg/kWh Alpha Pro Tec - Data...
  • Page 6 3. These dimensions only apply for flue parts supplied by Alpha. Cascade flue options are also available, please contact Alpha for further details. AVAILABLE PUMP HEAD The Pro Tec boilers are fitted with a 3 speed pump. The boiler does not operate correctly with the pump set at the slowest speed.
  • Page 7 3200 3600 4000 4400 Flow rate (l/h) Fig. 2.2 Pro Tec 90 11.0 10.0 Head (m water) 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 Flow rate (l/h) Fig. 2.3 Alpha Pro Tec - Data...

  • Page 8: Electrical Connections

    220 V ~ 50 Hz 220/240 V R1 R2 A1 A2 S1 S2 OT1OT2 Alarm free contact Max. 1 A 220/240 V Open Therm External reset 220/240 V Zone manager Analog (optional) input 0 - 10 V Fig. 2.5 Alpha Pro Tec - Data...
  • Page 9 Primary return temperature sensor Manifold cover Flame sensing electrode Ignition electrode Primary flow sensor Combustion chamber cover Air inlet pipe Heat exchanger Burner Heat exchanger automatic air vent Venturi Flue sensor Automatic air vent Thermofuse Pump Fig. 2.6 Alpha Pro Tec - Data...
  • Page 10 Overheat thermostat (manual reset) Flue sensor Injector Burner Air inlet pipe Thermofuse Flame sensing electrode Ignition electrode Combustion chamber cover Manifold cover Heat exchanger Venturi Flue hood Pump Air sampling point Condensate trap Fig. 2.7 Alpha Pro Tec - Data...

  • Page 11: General Boiler Information

    Open flued (Type B23 flue) Alpha Pro Tec boilers leave the factory with 'B23' type configuration (open chamber and forced draught - single flue pipe) and receive the air for combustion from openings in the rear of the boiler, therefore air supply for combustion and ventilation must be provided in accordance with BS 5440:2 (for domestic installations with a net input less than 70 kW) or BS 6644 (for commercial installations with a net input over 70 Kw).
  • Page 12 90° bend is equivalent to 1.9 m of flue length 80 mm Open flue 30 m 28 m 14 m 8.5 m 45° bend is equivalent to 1.4 m of flue length Fig. 3.1 Alpha Pro Tec - General Boiler Information...
  • Page 13 8.5 m Fig. 3.2 FLUE TERMINATION The Alpha ProTec range of boilers can be individually flued using either 80 mm open flue configuration or 80/125 mm concentric flue. Multiple boilers can be individually flued or cascade flue kits are also available.
  • Page 14 Provision should be made to replace water lost from the system. This can be by manual or automatic means, as shown in Figs. 3.4 and 3.5. The position for connecting an automatic make-up vessel is indicated in Fig. 3.3. A double check valve assembly must be used, as shown in Fig. 3.5. Alpha Pro Tec - General Boiler Information...
  • Page 15 3.10 FLUSHING THE HEATING SYSTEM It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha Pro Tec boiler. Failure to do so will invalidate the warranty. If this is difficult because the system is old/dirty refer to Section 3.8, Fig. 3.3 gives consideration to using a barrier heat exchanger.
  • Page 16 3.11 DISPOSAL OF CONDENSATE Provision must be made for the safe disposal of condensate produced by Alpha Pro Tec boilers and reference should be made to BS 6798: 2000 for the requirements on the disposal of condensate. The boilers incorporate a condensate trap which has a seal greater than 75 mm, therefore no additional trap is required.

  • Page 17: Installation

    DIMENSIONS and CONNECTIONS- Fig. 14 4.2.1 Pro Tec 50 80 Dia. E - Electrical connection G - Gas supply HR - Heating return HF - Heating flow CD - Condensate drain SV - Safety valve outlet (tundish) Fig. 4.1 Alpha Pro Tec - Installation...
  • Page 18 Where possible transport the boiler using a sack truck or other suitable trolley. MINIMUM BOTTOM CLEARANCE 250 mm Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as Fig. 4.3 necessary. Alpha Pro Tec - Installation...
  • Page 19 Note: To prevent condensate lying in the flue pipe, slope the pipe towards the boilers with a minimum slope of 2.5° - 3° (25 - 30 mm per metre). When installing the extensions, a wall/ceiling mounted clamp must be installed at least every 1.5 metres. Alpha Pro Tec - Installation...
  • Page 20 Note: To prevent condensate lying in the flue pipe, slope the pipe towards the boilers with a minimum slope of 3° (25 - 30 mm per metre). When installing the extensions, a wall/ceiling mounted clamp must be installed every 1.5 metres. Inner seal Flue elbow Outer seal Fixing plate Square gasket Concentric flue pipe Adapter Fig. 4.9 Alpha Pro Tec - Installation...
  • Page 21 Ensure that there is sufficient free cable to allow the control panel to be raised and lowered then tighten the cable clamp screws. Leave the control panel open until commissioning procedures have been completed. Carry out electrical system checks - Short circuit, Polarity, Earth continuity and Resistance to earth with a suitable multimeter. Alpha Pro Tec - Installation...
  • Page 22 Fig. 4.11 Alpha Pro Tec - Installation...

  • Page 23: Commissioning And Using The Boiler

    To remove the air - Vent each radiator in turn, starting with the lowest in the system. Note: The Pro Tec 50 model must be vented using the manual air vent on the top left of the heat exchanger (see Fig. 6.2).
  • Page 24 Allow the boiler to run and heat the circuit, checking for leaks and correct circulation, testing any secondary circuits and zone controls for correct operation. During operation gas working pressure and gas rate checks can be conducted using the engineering function. Refer to Section 5.9. Alpha Pro Tec - Commissioning...
  • Page 25 RESET Fig. 5.7 In the standby mode the boiler is still switched on but not active, maintaining the anti-freeze function. To turn it back on simply press button 'B'. RESET Fig. 5.8 Alpha Pro Tec - Commissioning...
  • Page 26 External sensor temperature reading (if installed) °C / °F Not used Flow temperature requested by system in heating °C / °F Flow temperature requested by system in DHW °C / °F Not used Not used Not used Alpha Pro Tec - Commissioning...
  • Page 27 Note: It is a requirement that the installation is registered by the installer through the Gas Safe Gas Work Notification Scheme. 12. Leave these Installation and Servicing instructions with the User for use on future calls. Alpha Pro Tec - Commissioning...

  • Page 28: Routine Servicing

    2. The expansion vessel must be the correct size for the system. Check that the condensate trap drain pipe is connected and all joints are sound. Record details of the service in the Service Record Section at the back of this manual. Alpha Pro Tec - Routine Servicing...
  • Page 29 (view 'A' in Fig. 6.1) Lower the panel out and away from the top cover. Note: If only the front panel is to be removed, remove as described in Section 4.7, paragraph 1. View A Fig. 6.1 (Pro Tec 50 shown) Alpha Pro Tec - Routine Servicing...
  • Page 30 Ignition electrodes Front panel insulation Fig. 6.2 - Pro Tec 50 Fig. 6.3 - Pro Tec 70, 90, 115 RE-ASSEMBLE THE BOILER Important: Before replacing the combustion chamber front assembly, pour at least 200 cc of water into the coils of the heat exchanger.
  • Page 31 Ignition unit Condensate trap Ignition electrode Flow manifold Flue sensor Safety valve 4 bar Automatic air vent Gas cock Test points (air A) - (flue F) Tundish Flue hood manifold Fig. 6.4 Pro Tec 50 Alpha Pro Tec - Routine Servicing...
  • Page 32 Condensing heat exchanger Flow manifold Flue hood manifold Safety valve 4 bar Air intake pipe Ignition unit Test points (air A) - (flue F) Overheat thermostat (manual reset) Fig. 6.5 Pro Tec 70, 90, 115 Alpha Pro Tec - Routine Servicing...

  • Page 33: Wiring Diagram

    WIRING DIAGRAM Pro Tec 50 model only Pro Tec 70, 90, 115 models only Low Voltage 220 Vac 50 Hz Interface Plug Br Br Low Voltage Pk Pk Terminal E F J G H R S2 1 2 3 4 5...

  • Page 34: Fault Finding

    Check flow sensor connections and damaged wires. Sensor measures a temperature outside normal working range. Check sensor resistance values. 0A37 Insufficient system flow - (Pro Tec 50 model only). Check the system for circulation and restrictions. Check the boiler flow meter connections. 0A43 Return sensor short circuit.
  • Page 35 Check electrical socket connections. Check external power supply. 0E37 Insufficient system flow - (Pro Tec 50 model only). Check the system for circulation and restrictions. Insufficient system pressure - (Pro Tec 70, 90, 115 models). Check system pressure and gauge.

  • Page 36: Programming The Boiler Pcb

    The boiler is supplied with the PCB configuration set according to the boiler model, however it is possible to adjust certain parameters according to the boiler and system configuration. Note: These parameters should only be adjusted by an approved Alpha engineer or Agent. To access the programming menu, press and hold buttons 'B' and 'C' simultaneously.
  • Page 37 128 - 256 = °F - Btu/h Not used Not used Not used Not used Temp. sampling time Time between temp. sampling intervals. Note: Do not adjust this 1 - 10 sec parameter. Alpha Pro Tec - Programming the Boiler PCB...

  • Page 38: Performance Data

    2740 18.0 2580 1.31 2500 16.0 1.78 2250 14.0 1.57 2320 1.15 12.0 1.35 2060 0.99 1990 1.14 1790 0.83 1730 10.0 0.67 1460 0.92 1520 0.69 1240 0.51 1190 0.58 1100 0.43 1050 Alpha Pro Tec - Performance Data...
  • Page 39 1.70 2.10 2190 1.54 2060 19.0 2020 1.38 1900 17.0 1.88 1.22 1730 15.0 1.66 1860 1.44 1690 1.06 1570 13.0 1520 0.90 1410 11.0 1.22 0.74 1250 1.00 1350 1100 0.80 1200 0.59 Alpha Pro Tec - Performance Data...
  • Page 40 2340 2.16 2200 27.0 2.94 2020 24.0 2.62 2140 1.92 21.0 2.30 1950 1.68 1840 1760 1.45 1670 18.0 1.97 1.21 1490 15.0 1.64 1570 1320 12.0 1.32 1390 0.97 0.99 1200 0.73 1150 Alpha Pro Tec - Performance Data...
  • Page 41 2.16 1950 27.0 2.95 1.92 1800 24.0 2.62 1860 1650 21.0 2.30 1710 1.69 1.97 1560 1.45 1500 18.0 1.21 1350 15.0 1.64 1400 1200 12.0 1.32 1250 0.97 1.21 1200 0.89 1150 11.0 Alpha Pro Tec - Performance Data...

  • Page 42: Cascade System Installation

    11 CASCADE SYSTEM INSTALLATION Alpha Pro Tec - Cascade System Installation...

  • Page 43: Short Parts List

    1.035731 Fan - Pro Tec 90 1.034142 Fan - Pro Tec 115 1.036711 Flexible air intake pipe - Pro Tec 50 1.036647 Flexible air intake pipe - Pro Tec 70, 90, 115 1.035180 Flue hood manifold - Pro Tec 50 3.023386...
  • Page 44 Alpha Pro Tec - Blank Page...
  • Page 45 Alpha Pro Tec - Blank Page...

  • Page 46: 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 47: 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.
  • Page 48 These instructions have been carefully prepared but we reserve the right to Nepicar House, London Road, Wrotham Heath, alter the specification at any time in the interest of product improvement. Sevenoaks, Kent TN15 7RS © Alpha Therm Limited 2014. Tel: 0870 3001964 email: info@alphatherm.co.uk website:www.alpha-innovation.co.uk 1..037322 rev.

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