Alpha InTec 12S (NG) Installation And Servicing Instructions
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Alpha InTec 12S (NG) Installation And Servicing Instructions

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Installation and Servicing

Alpha InTec 12S, 18S, 28S
Range of Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficien y 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 InTec 12S (NG)

  • Page 1: Installation And Servicing

    Alpha InTec 12S, 18S, 28S Range of Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficien y 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,...

  • Page 2: Introduction

    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 InTec S - Benchmark Scheme...

  • Page 3: Table Of Contents

    Service record ........43 INTRODUCTION The Alpha InTec range of high efficiency condensing boilers are all mounted, fan assisted room-sealed 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.

  • Page 4: Technical Data

    Min. primary system pressure Recommended system pressure - Cold System pressure relief valve setting Expansion vessel size litres Expansion vessel charge pressure Electrical power consumption - Max. Watts Electrical power consumption - Standby Watts Alpha InTec S - Technical Data...
  • Page 5 Boiler operating weight (full of water) approx. Max. total flue lengt Horizontal Max. total flue length Vertical Flue system diameter 60/100 60/100 60/100 Factory fitted Filling loop Factory fitte Seasonality valve GasSaver compatible Solar compatible Alpha InTec S - Technical Data...

  • Page 6: Electrical Connections

    Note: This Appliance Must Be Earthed Remove the link between 1 and 2 if the Remove the resistor between terminal block optional Alpha Climatic control or 230 V Optional integral two channel controls are connections 8 and 9 to connect optional room thermostat is used.

  • Page 7: Boiler Schematic

    18 - Flame sensing electrode 28 - Venturi negative point 9 - Flue hood 19 - Flue sampling point 29 - Flue temperature sensor 10 - Overheat thermostat 20 - Gas service cock Fig. 2 Alpha InTec S - Technical Data...

  • Page 8: General Boiler Information

    2. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally and 14 metres vertically. 3. Failure to use Alpha CD flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe.
  • Page 9 VERTICAL FLUE OPTIONS Not less than 300 mm Not less than 300 mm Not less than 300 mm Not less than 300 mm Hmax = 15 m Hmax = 13.2 m Fig. 3 Alpha InTec S - General Boiler Information...
  • Page 10 However, If the terminal is fitted less than 2 m ab ve a surface where there is no public access, the terminal must be protected by a terminal guard. A suitable guard is available from Alpha Therm Ltd. Alpha InTec S - General Boiler Information...
  • Page 11 The boiler may be installed in a cupboard or compartment, provided it is correctly designed for that purpose, i.e. complies with the Building Regulations and the requirements of BS 6798. Alpha InTec S - General Boiler Information...
  • Page 12 Drain taps (to BS 2879) must be used to allow the system to be completely drained. Hose Double check unions valve assembly Heating circuit Mains return water Stop Stop supply valve valve Test cock Filling loop temporarily connected Fig. 7 Alpha InTec S - General Boiler Information...
  • 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 Two rows of 3 x 12mm holes at 25mm centres, 50mm from the bottom Soakaway depth 400mm of the tube. Holes to face filled with limestone chippings away from house. Fig. 9 - External soakaway Alpha InTec S - General Boiler Information...

  • Page 15: Installation

    140 mm, 185 mm if the wall jig is used (ensure the lines are horizontal). Template This will give the position of the centre of the Fig. 11 hole for the flu . Alpha InTec S - Installation...
  • Page 16 B - Gas inlet (15 mm - 12S, 18S) Heating flow (22 mm - 28S) valve C - Heating return (22 mm) D - Pressure relief valve (15 mm) Heating drain Condensate point discharge pipe Fig. 13a - Without wall jig Alpha InTec S - Installation...
  • Page 17 FIT THE FLUE - Figs. 14, 15 The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side xit flue - ho izontally only. The CD Easy-Flues are suitable for use in the flue length anges shown in the tables below.
  • Page 18 Note: Ensure that all cuts are square and free from burrs. Once assembled with the components pushed home, the flue is fully sealed Allow 20 mm 30 mm Do not cut past this point Fig. 19 Alpha InTec S - Installation...
  • Page 19 Use the template (supplied with the boiler) to mark the required flue position, ensure the slope towards the boiler is correct. Determine the overall flue length as desc ibed in Section 4.6, paragraph 2 to determine the number of Alpha CD 750 or 1000 mm flue xtensions required.
  • Page 20 Plume Management 45° bend 60 mm dia. (each 45° bend equivalent to 0.9 m flue length Plume Management 1000 mm extension 60 mm dia. (equivalent to 1 m flue length 60 mm dia. wall bracket Fig. 21 Alpha InTec S - Installation...
  • Page 21 Note: The equivalent horizontal flue assem ly length + the equivalent plume management length (PM length) must not exceed the maximum flue length stated or each boiler, i.e. Alpha Intec boiler maximum equivalent flue length ust not exceed 12 metres.
  • Page 22 Ensure the electrical supply to the boiler is isolated. IMPORTANT - Only use an Alpha two channel clock. Do not fit a single hannel clock. Remove the three screws securing the terminal block cover at the rear of the control panel.
  • 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

    14 Temperature indicator, boiler info and 21 Optional boiler controls (if fitted Heating system pressure gauge error codes DHW mode active (Alpha System kit fitted) 15 Boiler in Stand-by mode Fig. 26 TEST FOR GAS TIGHTNESS AND PURGE THE SUPPLY With the boiler connected, pressure test the gas supply and inlet pipework connected to the boiler for tightness in accordance with BS 6891.
  • Page 25 Fig. 26) when operating in heating or to heat the DHW cylinder. Note: If a weather compensation probe is fitted (can only be fitted when the Alpha D erter valve kit is fitted) a radient value of 1 to 9 is displayed when adjusting the central heating temperature selector switch. This is because the boiler output is modulated according to outside temperature.
  • 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 °C Domestic hot water set point temperature °C Weather compensation probe temperature (value flashes if negati e) - Alpha Diverter valve kit fitte °C Not used Fault history - by rotating the CH knob (item 6 in Fig. 25) in this menu the last fi e faults will be displayed...

  • Page 28: Routine Servicing

    2. The expansion vessel pressure test point is accessible from inside the boiler at the front. Check that the condensate trap drain pipe is connected and all joints are sound. Record details of the service in the Service Record at the back of these instructions. Alpha InTec S - Routine Servicing...
  • Page 29 Note: Before removing the cap, ensure that the water released from the trap can be contained to avoid spillage. The trap will contain no more than 200 cc of condensate water. Replace the drain cap. Alpha InTec S - Routine Servicing...
  • Page 30 To ensure correct and safe operation of the appliance, it is essential that any worn or failed components are replaced with only genuine Alpha spare parts. Use of non-genuine Alpha spares could invalidate your warranty and may pose a potential safety hazard.

  • Page 31: Component Replacement

    Gain access to the room sealed chamber as described in Section 7.1. Undo the gas inlet union to the combustion chamber front to gain access. Unscrew the damaged injector and screw in a replacement. Re-assemble in reverse order. Alpha InTec S - Component Replacement...
  • Page 32 Gain access behind the front panel as described in Section 7.1. Disconnect the wiring. Using a 13 mm spanner, turn the sensor 90° anti-clockwise and withdraw it from the heat exchanger. Fit the new sensor and re-assemble in reverse order. Alpha InTec S - Component Replacement...
  • Page 33 Light the boiler and adjust the PCB as described in the instructions supplied with the replacement PCB. 7.13 ALPHA CONTROLS (if fitted) - Fig 24 Note: For replacement only use an Alpha two channel control. Do not fit a single hannel control. Gain access behind the control panel as described in Section 7.1.
  • Page 34 The primary temperature sensor is positioned on the bottom left hand side of the heat exchanger fl w pipe, see Fig. 31. Disconnect the wiring and unscrew the sensor. Re-assemble in reverse order with a new sensor and sealing washer. Alpha InTec S - Component Replacement...
  • Page 35 Remove the two screws securing the expansion relief valve and the left hand DHW manifold securing screw. Withdraw the retaining clip from the valve and pull the valve from the pump housing. Re-assemble in reverse order. Refill and pressu ise the system. (Refer to Commissioning, Section 5.1). Alpha InTec S - Component Replacement...
  • Page 36 When replacing the vessel, ensure that the connection is towards the left of the boiler and re-assemble in reverse order using new seals as necessary. Refill and pressu ise the system. (Refer to Commissioning, Section 5.1). Alpha InTec S - Component Replacement...

  • Page 37: Wiring Diagrams

    230 V room thermostat is used. 12 34 5 6 Remove the resistor between Transformer Alpha controls (optional) terminal block connections 8 and 9 and connect the optional tank temperature probe in its place. Alpha InTec S - Wiring Diagrams...
  • Page 38 (15 - 20 V DC) Transformer Cylinder temp. Sensor (optional) Note: Main Terminal Block Gas Valve PCB Connection To connect external controls remove link from terminals 1 and 2 and connect 240 V switched live to terminal 1. Alpha InTec S - Wiring Diagrams...

  • Page 39: Error Codes And Fault Findin

    Check internal wiring connections to PCB Combination boiler DHW sensor X4 System boiler link X14 Refer to wiring diagram Fan fault Fan wiring fault or fan faulty Check fan wiring connections Fan fault PCB fault Alpha InTec S - Fault Finding...
  • Page 40 Flue sensor fault Pump fault Climatic RF Error between the communication of the Batteries require replacing communication fault Climatic transmitter and boiler receiver Distance between boiler and climatic control too great Interference Object blocking signal (metallic) Alpha InTec S - Fault Finding...

  • Page 41: 10 Short Parts List

    Fan (28S) 1.029719 Flue turret (12S - 18S) 3.022544 Flue turret (28S) 3.022546 Complete boiler seal kit 3.022652 Hydraulic circuit seal kit 3.022653 Primary H/E seal kit 3.022654 Air/flue system seal ki 3.022655 Alpha InTec S - Short Parts List...

  • Page 42: 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 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 These instructions have been carefully prepared but we reserve the right to Nepicar House, London Road,Wrotham Heath, 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 Part No.

This manual is also suitable for:

Intec 18s (ng)Intec 28s (ng)Intec 28s (lpg)Intec 12s (lpg)Intec 18s (lpg)

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