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Alpha InTec 12SNG Installation And Servicing Instructions

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

Alpha InTec 12S, 18S, 28S
Range of Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing System Boilers
For use with Natural Gas or Propane Gas (AS SUPPLIED)
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 InTec 12S (NG)
Alpha InTec 18S (NG)
Alpha InTec 28S (NG)
Alpha InTec 12S (LPG)
Alpha InTec 18S (LPG)
Alpha InTec 28S (LPG)
0051
Leave these instructions with the User
G.C. No. 41 532 22
G.C. No. 41 532 23
G.C. No. 41 532 24
G.C. No. 41 532 25
G.C. No. 41 532 26
G.C. No. 41 532 27

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Summary of Contents for Alpha Alpha InTec 12SNG

  • Page 1: Installation And Servicing

    Installation and Servicing Instructions Alpha InTec 12S, 18S, 28S Range of Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing System Boilers 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...

  • Page 2: Introduction

    Give a full and clear explanation/demonstration of the product or system and its operation to the customer. • Hand over the manufacturer's instructions, including the Benchmark Checklist, to the customer on completion of an installation. • Obtain the customer's signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of manufacturer's instructions.

  • Page 3: Table Of Contents

    Manufacturer's instructions must NOT be taken in anyway as over-riding statutory obligations. Notes: 1. Ensure that the Benchmark Checklist has been completed after the boiler has been installed and commissioned. 2. It is the law that all boiler installations are registered by the installer through the Gas Safe Gas Work Notification Scheme.

  • Page 4: Technical Data

    TECHNICAL DATA TECHNICAL PERFORMANCE DATA - NATURAL GAS (Cat I2H 2H - G20 20 mbar) InTec 12S InTec 18S InTec 28S Heat input gross - CH 13.6 20.6 31.5 Heat input net - CH 12.3 18.6 28.4 Heat output condensing (50/30°C) - CH 13.2 30.7 Heat output non condensing (80/60°C) CH kW...
  • Page 5 TECHNICAL PERFORMANCE DATA - PROPANE GAS (Cat I3P 3P - G31 - 37 mbar) InTec 12S InTec 18S InTec 28S Heat input gross - CH 13.6 20.6 31.5 Heat input net - CH 12.3 18.6 28.4 Heat output condensing (50/30°C) - CH 30.7 Heat output non condensing (80/60°C) CH kW 12.0...

  • Page 6: Technical Data

    FLUE LENGTHS CD Easy-Flue 500 mm with terminal and 90° bend. A CD Easy-Flue 1000 mm with terminal and 90° bend is also available. CD 750 mm and 1000 mm flue extensions are available. Length of Flue Required:- Rear Flue = wall thickness + 160 mm (includes terminal).

  • Page 7: Boiler Schematic

    BOILER SCHEMATIC Primary Heating return Condensate Primary Heating flow discharge 1 - Heat exchanger thermal fuse 11 - Expansion vessel 21 - On/off valve (2 off) 2 - Gas valve 12 - Automatic air vent 22 - Automatic by-pass 3 - Primary temperature sensor 13 - Pump 23 - Cyclone separator (if applicable) 4 - Main burner...

  • Page 8: General Boiler Information

    GENERAL BOILER INFORMATION GAS SUPPLY The meter and supply pipes must be capable of delivering the required quantity of gas in addition to the demand from any other appliances in the house. Refer to Technical performance data in Section 2.1 and 2.2. The complete installation, including the meter, must be tested for gas tightness and purged as described in BS 6891.
  • Page 9 HORIZONTAL FLUE OPTIONS - L = 12 metres (245 mm length includes terminal) L = B + C + 245 mm L = B + C + E + 245 mm L = B + E + F + 245 mm + (90° bend = 1.3 metre) (add 45 mm to 'F' if a jig is used) L = B + C + 245 mm + (2 x 45°...
  • Page 10 FLUE TERMINAL LOCATION - Figs. 4 and 5 Boundary Fig. 4 Terminal position Min. distance (mm) Directly below an opening, air brick, windows, etc. (See Note 1) Below gutters, soil pipes or drain pipes (See Note 3) C Below eaves (See Note 3) D Below balconies (See Note 3)

  • Page 11: Boiler Location

    Proximity of flue duct outlets to boundaries The flue duct shall be sited so that it is at least 600 mm (see Fig. 5) from the boundary line when facing it and at least 300 mm from the boundary line when running parallel to it. Boundary Boundary 600 mm...
  • Page 12 CENTRAL HEATING SYSTEM - Fig. 6 The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS EN 12828 and BS 6798. The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc.
  • Page 13 FLUSHING THE HEATING SYSTEM It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha InTec boiler. Failure to do so will invalidate the warranty. The primary condensing heat exchanger is constructed in stainless steel and therefore is compatible with most materials used in a heating system.
  • Page 14 If the external temperature drops below 2°C and the boiler is on, the relay PCB is operated and voltage is supplied to the trace heating wire causing it to heat up and prevent the condensate from freezing. When the outside temperature rises to 4°C or the boiler pump stops, the trace heater is switched off.

  • Page 15: Installation

    INSTALLATION UNPACKING The boxes required when the boiler is installed with a horizontal flue are as follows:- Box 1......Cased boiler fitted with water and gas valves, union bends and washers Mounting bracket plus screws and wall plugs Condensate discharge pipe Literature pack and Wall template Box 2 .........CD Easy-Flue 500 mm or CD Easy-Flue 1000 mm.
  • Page 16 Cut the 110 mm diameter hole (or use a 107 mm core drill) in the wall for the flue. Notes: 1. Ensure the hole is horizontal. 2. For internal fitting of the flue, using the flue sealing collar supplied, cut a 130 mm dia. flue hole using a 127 mm core drill.
  • Page 17 Note: Disconnect the filling loop after filling the central heating system. Heating return A - Heating flow (22 mm) valves Condensate B - Gas inlet (15 mm - 12S, 18S) Heating flow trap valve (22 mm - 28S) C - Heating return (22 mm) Heating drain point D - Pressure relief valve (15 mm)
  • Page 18 Check collar is sealing the wall and it is not restricting any openings of the flue terminal 130 mm Fig. 17 - Fitting the flue from inside Position the seal and clamp (two screws) supplied, over the bend. Fit the bend to the boiler and rotate to the correct position. Secure in position using the seal and clamp, ensuring the seal is located centrally over both the bend and boiler adaptor.
  • Page 19 EXTENDING THE FLUE - Fig. 20 Note: The flue assembly length must not exceed the maximum length stated, including the equivalent lengths of any extensions, bends etc. used for plume management components. CD boilers must not exceed the maximum of an equivalent horizontal flue length of 12 m.
  • Page 20 10. Secure the flue assembly to the bend with the clamp ensuring it is positioned centrally over the joint, ensuring the 'TOP' marked on the outer duct is positioned at the top. Note: Check the flue terminal protrudes 120 mm out of the wall and that the inner duct of the terminal is positioned correctly, i.e.
  • Page 21 Terminal end section from CD Easy-Flue Terminal end section from CD Easy-Flue Min. 400 mm Terminal end section from CD Easy-Flue PM length = C + (2 x 93° bend = 2.6 m) + (2 x 45° bends = 1.8 m) Ensure there is a slope of approximately Flue sealing collar 3°...
  • Page 22 4.10 CONNECT THE MAINS SUPPLY - Fig. 23 Terminal block cover Grommets Gain access to the boiler terminal block by releasing the two fixing screws (one each side) securing the control panel and lowering the panel. Refer to Technical Data, Section 2.6 for connection details.
  • Page 23 4.12 OPTIONAL ALPHA SYSTEM DIVERTER KIT The Alpha Diverter valve kit operates as a hot water priority valve meaning if the heating is on and there is a hot water demand the valve will divert the primary hot water to the cylinder until the cylinder sensor is satisfied. The heating will be held off during this period so it is recommended that a high recovery cylinder is used.

  • Page 24: Commissioning

    COMMISSIONING When commissioning the boiler, ensure the Benchmark Checklist is completed. FILL THE SYSTEM The boiler is fitted with an automatic air vent positioned on the pump (see Fig. 2), ensure that the vent is always open. Open the central heating flow and return valves (vertical slot in-line with valve) (see Fig. 13).
  • Page 25 INITIAL LIGHTING - Refer to Fig. 26 Before turning on the gas and electrical supplies check the heating system is filled to the correct pressure. Refer to Section 5.1 Fill the System. The pressure gauge on the right of the control panel indicates the heating system pressure. When the boiler is cold the needle should be within the green band.
  • Page 26 (refer to Section 7.2). It is recommended that a label is attached to the boiler drawing attention to the fact that the system has been drained. Complete the details of the installation in the Benchmark Checklist at the back of these instructions. Alpha InTec S - Commissioning...
  • Page 27 Show the User the position of the pressure relief valve and condensate discharge pipes. 10. Hand the User's instructions to the User. 11. Ensure the Benchmark Checklist at the back of these instructions has been completed after the boiler has been installed and commissioned.

  • Page 28: Routine Servicing

    ROUTINE SERVICING To ensure efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year should be adequate.

  • Page 29: Component Replacement

    Front case locating pins Four nuts and washers and Manual air vent Flue gas four screws securing combustion sampling point chamber front assembly Combustion chamber front assembly Viewing window Flame sensing Air supply pipe electrode Expansion vessel Air supply pipe test/fill point fixing screw Gas pipe union...
  • Page 30 Burner Front panel insulation Burner to electrode gap 6 mm Combustion chamber front assembly Flame sensing electrode Electrode gap 3 - 4 mm Ignition electrodes Fig. 30 RE-ASSEMBLE THE BOILER Replace the burner, ensuring it is located correctly and secure it in position using the four screws previously removed. Important: Before replacing the combustion chamber front assembly, pour at least 200 cc of water into the coils of the heat exchanger.

  • Page 31: Component Replacement

    COMPONENT REPLACEMENT It is the law that any service work must be carried out by a competent person, i.e. Gas Safe registered personnel. Warning: Before replacing any boiler components, isolate the electrical supply and close the boiler gas service cock. Allow the boiler to cool.
  • Page 32 FAN - Fig. 29 Gain access behind the room sealed chamber as described in Section 7.1. Remove the two screws securing the air supply pipe (see Fig. 29) and remove the pipe. Unplug the fan plug and remove the two screws securing the fan to the combustion chamber front (see Fig. 29). Withdraw the fan to the right of the boiler - this can be made easier if the right hand side panel is removed.
  • Page 33 7.10 GAS VALVE - Fig. 31 Note: The replacement of the gas valve or PCB must be carried out by a Gas Safe registered engineer with the use of a flue analyser. Gain access behind the front casing as in Section 7.1. Disconnect the positive pressure tube from the gas valve.
  • Page 34 7.15 CONDENSATE TRAP - Fig. 13 Gain access behind the front casing as described in Section 7.1. Disconnect the top and drain connection of the condensate trap. Place a container under the boiler and unscrew the bowl at the bottom of the trap, see Fig. 13. Some water will spill from the trap.
  • Page 35 Primary pressure switch Pressure gauge sensor position Automatic air vent Pump Pressure relief valve Drain point Condensate trap Pressure gauge Fig. 34 7.21 AUTOMATIC AIR VENT - Fig. 34 Gain access behind the front casing and drain the boiler heating circuit as described in Sections 7.1 and 7.2. 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.
  • Page 36 7.25 EXPANSION VESSEL - Fig. 31 Gain access behind the front casing and drain the boiler heating circuit as described in Sections 8.1 and 8.2. Disconnect the pipe from the expansion vessel. Remove the screw securing the top support bracket. Lift the expansion vessel out of the boiler.

  • Page 37: Wiring Diagrams

    WIRING DIAGRAMS ILLUSTRATED WIRING DIAGRAM 230 V electrical connections Low voltage electrical connections System Heat Alpha Boiler Pressure Exchanger Room 3-way Valve Storage Tank Climatic Control Pump Switch Link Temperature Thermal thermostat (optional) (optional) Probe Fuse (optional) Ignition (optional) Supply Electrodes Flue External...
  • Page 38 FUNCTIONAL FLOW WIRING DIAGRAM Remove link to Fuse 3.15 AF connect Alpha control (on PCB) 230/240V ~ 50Hz Fuse 3A Alpha Control (Optional) Remove link to connect external control Pump Cylinder Diverter Valve Motor (optional) Spark Generator External Sensor (optional) Flame Sensing Climatic Control (low voltage) Electrode...

  • Page 39: Carry Out Initial Fault Finding Checks

    ERROR CODES AND FAULT FINDING CARRY OUT INITIAL FAULT FINDING CHECKS Check that gas, electrical and water supplies are available at the boiler. i.e. Inlet gas pressure = 20 mbar - Electrical supply = 230/240 V ~ 50 Hz CH water system pressurised to between 0.75 and 1.25 bar Carry out electrical system checks, i.e.
  • Page 40 Error Fault Fault description Possible causes code Flame sensing fault False flame detection Check flame sensing electrode and lead Flame detected but gas valve is not open PCB fault Control panel button Control panel button stuck in the on position Check for jammed control panel buttons fault Check for jammed PCB buttons...

  • Page 41: 10 Short Parts List

    10 SHORT PARTS LIST Reference Description Qty. Alpha Pt. No. British Gas GC No. Spark generator 1.018162 Pressure gauge 1.023551 Condensate trap assembly 3.017281 Flue sensor 1.024296 Overheat thermostat 1.025797 Flame sensing electrode 1.032007 Flue turret (12S - 18S) 1.030636 Flue turret (28S) 1.030738 Ignition electrode...

  • Page 42: Benchmark Checklist

    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. This does not affect the customer’s statutory rights.

  • Page 43: 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 44 Alpha Therm Limited. 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 2013. Tel: 0844 871 8764 email: info@alpha-innovation.co.uk website: www.alpha-innovation.co.uk...

This manual is also suitable for:

Intec 12s lpgIntec 18s ngIntec 18s lpgIntec 28s lpgIntec 28s ng

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