Benchmark Alpha InTec 24X Installation And Servicing Instructions
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Benchmark Alpha InTec 24X Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired, high efficieny condensing combination boilers
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Installation and Servicing

26C, 30C, 34C and 24X, 28X
Range of Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficien y Condensing Combination Boilers
Alpha InTec 24X (NG)
Alpha InTec 28X (NG)
Alpha InTec 26C (NG)
Alpha InTec 30C (NG)
Alpha InTec 34C (NG)
0051
For use with Natural Gas or Propane Gas (AS SUPPLIED)
Instructions
Alpha InTec
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
G.C. No. 47 532 45
G.C. No. 47 532 46
G.C. No. 47 532 47
G.C. No. 47 532 48
G.C. No. 47 532 49
Leave these instructions with the User
Alpha InTec 24X (LPG)
G.C. No. 47 532 52
Alpha InTec 28X (LPG)
G.C. No. 47 532 53
Alpha InTec 26C (LPG)
G.C. No. 47 532 54
Alpha InTec 30C (LPG)
G.C. No. 47 532 55
Alpha InTec 34C (LPG)
G.C. No. 47 532 56

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Summary of Contents for Benchmark Alpha InTec 24X

  • Page 1: Installation And Servicing

    ALPHA HELPLINE Tel: 0844 871 8764 website: www.alpha-innovation.co.uk Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS Alpha InTec 24X (NG) G.C. No. 47 532 45 Alpha InTec 24X (LPG) G.C. No. 47 532 52 Alpha InTec 28X (NG) G.C.
  • Page 2 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 confi m 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 26C InTec 30C InTec 34C InTec 24X InTec 28X Heat input gross - DHW 29.7 32.7 37.9 27.5 31.4 Heat input gross - CH 27.1 31.5 20.6...
  • Page 5 TECHNICAL PERFORMANCE DATA - PROPANE GAS (Cat I3P 3P - G31 - 37 mbar) InTec 26C InTec 30C InTec 34C InTec 24X InTec 28X Heat input gross - DHW 29.7 32.7 37.9 27.5 31.4 Heat input gross - CH 20.6 27.1 31.5 20.6...

  • Page 6: Electrical Connections

    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 xtensions are available. Length of Flue Required:- Rear Flue = wall thickness + 160 mm (includes terminal).

  • Page 7: Boiler Schematic

    BOILER SCHEMATIC Domestic Primary hot water Heating outlet return Condensate Cold mains Primary discharge water inlet Heating flow 1 - Heat exchanger thermal fuse 14 - Expansion vessel 27 - Automatic by-pass 2 - DHW fl w switch, filter and flow regulator 15 - Automatic air vent 28 - Cyclone separator (if applicable) 3 - Diverter valve...

  • 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 Proximity of flue duct outlets to boundarie 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 fl w 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 I ec 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 Use waterproof pipework insulation in very exposed Plastic pipe positions Ensure pipe is adequately supported Open end of pipe diverted into gully below grid but above water level Minimum gradient 2½° Fig. 8 - External gully 22mm termination from boiler, increase to 32 mm if external Cement mortar sealing 500 mm min.

  • Page 15: Installation

    INSTALLATION UNPACKING The boxes required when the boiler is installed with a horizontal flue are as ollows:- Box 1......Cased boiler fitted with ater 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 flu . 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 Seasonality valve Condensate discharge pipe Cold water Cold water Filling loop taps Condensate trap inlet filter inlet filter Filling Heating return Heating return loop valves valves Heating flow Heating flow Condensate valve valve trap Heating drain Heating drain point point Cyclone drain Cyclone drain Condensate...
  • 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 f om inside Position the smaller Easy-Flue 40 mm clamp (with seal) supplied, over the bend. Fit the bend to the boiler and rotate to the correct position.
  • Page 19 EXTENDING THE FLUE - Fig. 20 Note: The flue assem ly length must not exceed the maximum length stated, including the equivalent lengths of any extensions, bends etc. used for plume management components. InTec boilers must not exceed the maximum of an equivalent horizontal flue length of 12 m When the flue length required is more than the maxi um stated in Section 4.6, paragraph 1, refer to the table below and Figs 14 and 15.
  • Page 20 10. Secure the flue assem ly 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 te minal 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 Note: 1. Ensure each joint is secured with the screw Min. supplied. 400 mm 2. Ensure there is always a slight slope towards the CD Easy-Flue so that there is no part of the pipework where condensate will collect.
  • Page 22 4.10 CONNECT THE MAINS SUPPLY - Fig. 23 Terminal block cover Gain access to the boiler terminal block by releasing the Grommets 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: Commissioning

    COMMISSIONING When commissioning the boiler, ensure the Benchmark Checklist at the back of these instructions is completed. FILL THE SYSTEM The boiler is fitted with an automatic air ent positioned on the pump (see Fig. 34), ensure that the vent is always open.
  • Page 24 INITIAL LIGHTING - Refer to Fig. 25 Before turning on the gas and electrical supplies check the heating system is filled to the correct pressur . 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 25 Frost Thermostat The boiler incorporates a built in frost thermostat which automatically turns on the boiler and pump if the water in the boiler falls below 4°C, providing the electrical supply is on and the boiler is in standby mode. The boiler will operate until the water temperature in the boiler reaches 42°C.
  • Page 26 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 27: Routine Servicing

    ROUTINE SERVICING To ensure efficient ope ation 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 28 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 29 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. 29 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 30: 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 31 FAN - Fig. 28 Gain access behind the room sealed chamber as described in Section 7.1. Remove the two screws securing the air supply pipe (see Fig. 28) and remove the pipe. Unplug the fan plug and remove the two screws securing the fan to the combustion chamber front (see Fig. 28). Withdraw the fan to the right of the boiler - this can be made easier if the right hand side panel is removed.
  • Page 32 7.10 GAS VALVE - Fig. 30 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 33 7.14 ALPHA CONTROLS (if fitted) - Fig 24 Note: For replacement only use an Alpha single channel control. Do not fit a t o channel control. Gain access behind the control panel as described in Section 7.1. Remove the three screws securing the terminal block cover at the rear of the panel. Disconnect the wiring from the control.
  • Page 34 7.20 DHW FLOW SWITCH - Fig. 32 Gain access behind the front casing as described in Section 7.1. Isolate the mains water supply and open all hot taps to drain any water from the boiler. Disconnect the wires from the switch. Undo the union nut and remove the fixing scr w from the bottom of the switch.
  • Page 35 7.23 PRIMARY TEMPERATURE SENSOR - Fig. 30 Gain access as described in Section 7.1 and drain the heating circuit described in Section 7.2. Disconnect the wiring and unscrew the sensor. Re-assemble in reverse order with a new sensor and sealing washer. Refill and pressu ise the system.
  • Page 36 7.29 MAINS WATER INLET FILTER - Fig. 13 The mains water inlet filter is located in the body of the DHW flow switch. Refer to Section 7.17 to remove the fl w switch. The filter can be rem ved using a small screwdriver. Clean the filter and re-assem le in reverse order.

  • Page 37: Wiring Diagrams

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

  • Page 39: Error Codes And Fault Findin

    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 - DHW fl w rate is more than 2.5 litre/min Carry out electrical system checks, i.e.
  • Page 40 Error Fault Fault description Possible causes code Flame sensing fault False flame detectio Check flame sensing electrode and lea 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 Diverter valve cartridge assembly 3.020380 Seasonality valve 3.017106 12 L fl w regulator (red - 24X) 1.020412 Pressure gauge 1.023551 Condensate trap assembly 3.017281 Flue sensor 1.024296...

  • 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. Nepicar House, London Road,Wrotham Heath, These instructions have been carefully prepared but we reserve the right to alter the specification at a y 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:

Alpha intec 34cAlpha intec 28xAlpha intec 26cAlpha intec 30c

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