alpha InTec 12S User guide

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User's

0051

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

British Gas

Service Listed

For use with Natural Gas or Propane Gas (AS SUPPLIED)

Leave these instructions with the User

Please read these instructions carefully before operating your boiler.

1 INTRODUCTION

The Alpha InTec range of high efﬁciency condensing boilers incorporate the latest technology in boiler design. With improved burner efﬁciency and reduced electrical consumption together with high quality and reliability.

The boiler output will automatically adjust according to the requirements of the system.

The InTec range are designed to work with most central heating controls however we recommend the Alpha two channel versions of built in clock or Comfort RF external thermostat programmer.

Alternatively with the use of the Alpha system diverter kit the enhanced Alpha Climatic boiler energy manager can be used to increase comfort and efﬁciency. When using the Climatic control unit the efﬁciency can be further enhanced with the use of the outside sensor to enable the boiler's built in weather compensation feature.

The boilers will provide both central heating and hot water when required according to the times and temperatures set by the controls ﬁtted. Hot water cylinder heating will take priority over heating. Simultaneous heating and hot water can be achieved when using a mid position Y-plan valve or S-plan system.

2 OPERATING THE BOILER

The boiler controls are located on the control panel located behind a drop down ﬂap.

5 6

RESET

°C

bar

x100rpm

BOOST

INFO

1.5

0.5

CORRECT PRESSURE

WHEN COLD

721

2.5 3

bar

3.5

8 9 10

RESET

BOOST

11 12

°C

bar

x100rpm

151617181920

1 On-Off/Standby button 2 Summer/Winter button 3 Reset button 4 Information button 5* Domestic hot water temperature

selector switch

6 Central heating water temperature

selector switch 7 Heating system pressure gauge 8* DHW mode active

9 Boiler locked does not require reset via

“RESET” button

10 Flame present symbol and relative

power scale 11* Operating in summer mode 12 Operating in winter mode 13 Central heating mode active 14 Temperature indicator, boiler info and

error codes 15 Boiler in Stand-by mode

16 Presence of external connected devices 17 Solar function active 18 Functioning with external temperature

probe active (optional)

19 Boiler connected to remote control

(optional) 20 Not used on this model 21 Optional boiler controls (if ﬁtted)

* The summer hot water mode and hot water temperature selector switch will only function when using the Alpha System Diverter kit in conjunction with a hot water cylinder. When using a standard Y or S plan system the boiler must be left in winter mode and only the Heating thermostat used.

Fig. 1

Make sure the heating system is ﬁlled and the needle on the pressure gauge (item 7 in Fig. 1) is in the green band. If incorrect refer to Section 4.

Switch the boiler on at the mains supply socket switch. The boiler will automatically go through a system purging operation for 8 minutes; this is indicated by a count down on the display starting from 96. During this operation the pump will turn on and off to help remove any air that may be trapped in the heating system. If the boiler has already been commissioned by the installer then this operation can be terminated by pressing the reset button (item 3 in Fig. 1).

Note: It is important to allow this purging operation to function when the boiler has been initially installed to remove all the air from the system.

After this purging operation the boiler will be in 'Standby' or 'On' mode.

By pressing the On-Off button (item 1 in Fig. 1) the Standby or On mode can be selected, or press and hold the On-Off button for eight seconds to turn the boiler off.

Standby - In this mode the boiler will not provide hot water or central heating, but frost protection and pump circulation features are still active.

Off - In this mode there is electrical power to the boiler but the boiler will not function in any condition.

Alpha InTec S

On - In this mode the boiler can be switched between 'Summer' or 'Winter' settings by pressing the Summer/Winter button

9 8

5 4

(item 2 in Fig. 1).

Press the Summer/Winter button (item 2 in Fig. 1) to select either heating and hot water or hot water only. If an InTec S boiler is used with a conventional Y-plan, the boiler must be set to winter mode to provide heat to the hot water cylinder.

3 HEATING AND HOT WATER TEMPERATURE

Summer setting - This function can only be used if the boiler is ﬁtted with an Alpha System kit allowing control of the

hot water cylinder using the boiler controls. This has the added advantage of allowing you to independently control the temperature of the heating hot water and the cylinder hot water. In this mode the boiler will only supply hot water to the cylinder when the temperature of the cylinder water is below that set by the hot water selector switch (item 5 in Fig. 1). When heating the hot water cylinder the central heating will not function even if requested by any controls. The desired hot water cylinder temperature can be set using the hot water selector switch.

Winter setting - In this mode the boiler will operate to requests for both heating and hot water. For a system ﬁtted with a standard Y or S plan the boiler should always be left in the winter mode. The boiler will always prioritise hot water when requested by external controls. The heating will activate depending on the request from any external controls ﬁtted. The LCD display will then display the actual temperature of the water leaving the boiler when operating to provide heating or hot water.

Note: When using a standard Y or S plan system the central heating selector switch (item 6 in Fig. 1) must be set above the cylinder thermostat value.

External weather compensation probe (only for use with the Alpha system diverter kit) - The temperature of the

central heating water can be adjusted by turning the central heating selector switch (item 6 in Fig. 1). When the heating is on the temperature of the water leaving the boiler to the radiators will be displayed.

If an external weather compensation probe is ﬁtted, indicated by the automatically vary the temperature of the water in the radiators and on mild day the radiators will not feel as hot as on a cold day, this is normal and not a fault with the boiler or heating circuit. The room temperature will still be maintained as set by the room thermostat.

When an external weather probe is ﬁtted, the central heating selector switch (item 6 in Fig. 1) will no longer adjust the ﬂow temperature in °C, instead the display will show a scale of 1 to 9. Each number corresponds to a line on the graph in Fig 2 i.e. line 6 will give a ﬂow temperature of 60°C when the external temperature is 10°C.

Note: This is the temperature of the water supplied to the radiators and not the desired room temperature. The time and temperature will still be maintained according to the setting of the room thermostat.

symbol (item 18 in Fig. 1) in the display, it will

85 (50)

60 (40)

25 (25)

Flow temperature (°C)

27 15

External temperature (°C)

-510 0 -10 -1520

Setting 1 to 9 as selected using the central heating selector switch

Flow temperature in brackets ie. 25 to 50°C range when boiler is used with a low temperature system such as under floor heating

Fig. 2 - External weather compensation probe ﬁtted

4 FILL AND PRESSURISE THE SYSTEM

InTec S models should have a ﬁlling loop ﬁtted by the installer located in the pipework close to the boiler.

Do not attempt to ﬁll or pressurise the system while the system is hot - wait for it to cool.

The ﬁlling loop will have two tap connections at either end of the ﬁlling loop. These taps should normally be in the closed position 90° to the tap housing.

Alpha InTec S

To ﬁll or pressurise the system open one tap fully by turning it 90° anticlockwise in line with the tap housing. The second tap should be opened a quarter of a turn and the water will start to reﬁll the system (water should be heard ﬁlling the system). You should see the pressure gauge (item 7 in Fig. 1) rise back up into the green area on the pressure gauge between 1 bar and 1.5 bar pressure.

Once the pressure gauge is in the green area turn the taps back to the off position and the water will stop ﬁlling the system.

If you happen to ﬁll the system too much and the pressure gauge is over the green area, just bleed water from a radiator until the pressure on the gauge goes down into the green area.

5 INFORMATION MENU

By pressing the info button (item 4 in Fig. 1) the information menu is accessed this will then show the information according to the table below.

Info Menu

(d - preﬁx)

Information

Flame signal

Central heating water temperature leaving the boiler

Domestic hot water cylinder temperature (only if Alpha System diverter valve kit ﬁtted)

Central heating set point temperature

Domestic hot water set point temperature (only if Alpha System diverter valve kit ﬁtted)

External weather compensation probe temperature (value ﬂashes if negative)

Not used

Fault history - by rotating the CH knob (item 6 in Fig. 1) in this menu the last ﬁve faults will be displayed

Units

Shown

mA x 10 (approx)

°C

Error code

6 FROST PROTECTION

The boiler has a built in frost protection function to protect the boiler (only) from freezing. If water within the boiler falls below 4°C the boiler will ﬁre in heating mode and raise the temperature of the heating water (in the boiler only) to 30°C.

For this function to be active the gas and electricity supplies to the boiler must be turned on and the boiler be in either 'Standby' or 'On' mode.

Further protection for the mains water supply and heating circuit must be provided separately.

If Alpha external controls are ﬁtted, a frost protection setting is incorporated into the room thermostat activating the central heating when the temperature falls below 5°C.

7 CONDENSATE DRAINAGE

High efﬁciency (condensing) boilers remove more useful heat from the combustion gases, resulting in additional water vapour which is collected within the boiler (as condensate) and run to a suitable drainage point via the condensate drainage pipe.

If the condensate drain pipe runs outside it should be ﬁtted with increased diameter pipe and be suitably lagged to reduce the risk from freezing.

In situations where there are likely to be extremes of temperature or wind-chill the use of a proprietary trace-heating system for external condensate drainage pipework, incorporating an external frost thermostat, should be considered.

Alpha InTec S

8 OPERATIONAL FAULTS

The InTec range of boilers are ﬁtted with a fault code display feature.

If a fault occurs a fault code will be displayed in the LCD display screen (item 14 in Fig. 1), indicated with an alternating ﬂashing E followed by the fault code. A list of fault codes are given in the table below.

In the event of a fault occurring ﬁrstly check that the gas and electricity supplies are on and that any external controls ﬁtted are set and working correctly.

Press the reset button (item 3 in Fig. 1) on the control panel to restart the boiler if the fault occurs again, make a note of the fault code and contact your installer or Alpha technical Helpline for further advice.

Error

code

Fault Fault description Possible causes

Ignition failure

Overheat boiler lock out

High ﬂue thermostat temperature

Gas valve electrical connection fault

Flame not detected during ignition sequence

Overheat thermostat or thermal fuse has operated

Flue thermostat intervention (ﬂue temperature over 113°C)

Gas valve wiring circuit fault detected

Gas supply Check pressure tubes Ignition electrode gap Flame sensor electrode gap Ignition generator or lead Flame sensor electrode lead Gas valve setting Gas valve PCB

Pump or ﬂow problem Blocked heat exchanger Air in heat exchanger Overheat thermostat Thermal fuse (if open circuit then replace

primary heat exchanger)

Blocked or restricted primary ﬂow Heat exchanger air ﬂow blocked Flue restriction Flue sensor fault

Gas valve lead connection fault Faulty gas valve Faulty PCB

Heating ﬂow sensor fault

DHW sensor fault (InTec C, X, GS only)

Maximum number of resets

Primary system pressure low

Cylinder sensor fault (InTec S and FlowSmart only)

Internal wiring error

Incorrect ﬂow sensor resistance value

DHW sensor resistance value is incorrect

Maximum number of resets reached (5)

Primary pressure switch has operated

Incorrect cylinder sensor resistance

Incorrect wiring conﬁguration detected

Flow sensor wire connections Flow sensor faulty

DHW sensor wiring connection DHW sensor faulty

Refer to fault history codes (INFO menu d9)

Check expansion vessel pressure (1 bar) Leak in system Expansion relief valve operated Primary pressure switch

Cylinder sensor wiring connections Cylinder sensor faulty

Check internal wiring connections to PCB Combination boiler DHW sensor X4 System boiler link X14 Refer to wiring diagram

Alpha InTec S

Error code

Fault Fault description Possible causes

Fan fault

Flame sensing fault

Control panel button fault

Overheat lock out

Insufﬁcient primary ﬂow

Flue sensor fault

Fan wiring fault or fan faulty

False ﬂame detection Flame detected but gas valve is not open

Control panel button stuck in the on position

Rapid temperature rise of ﬂue sensor

Rapid temperature rise of primary sensor

Flue sensor resistance out of range

Check fan wiring connections Fan fault PCB fault

Check ﬂame sensing electrode and lead PCB fault

Check for jammed control panel buttons Check for jammed PCB buttons

Air in heat exchanger Blocked or restricted primary ﬂow Heat exchanger air ﬂow blocked Flue restriction Flue sensor fault Pump fault Boiler or heating circuit valve closed

Blocked or restricted primary ﬂow Air in heat exchanger Boiler or heating circuit valve closed Pump fault Primary ﬂow sensor fault

Check sensor wiring connection Flue sensor faulty

Loss of communication with external control (Alpha Climatic)

Low supply voltage

Loss of ﬂame rectiﬁcation

Safety lock out

External sensor intervention

Loss of connection between the boiler and Alpha Climatic control unit

Insufﬁcient supply voltage to operate boiler

Flame detected but signal is lost. Ignition reattempts after fan purge

Repeated loss of ﬂame signal during operation (shown as E38 in the fault code history in the INFO menu)

The boiler has attempted to ﬁre repeatedly for the maximum time limit

No continuity of external sensor circuit

Remote control or receiver connection wiring Remote control or receiver

Check mains power supply

Check ﬂame sensing electrode and lead Check for ﬂue gas recirculation Check/adjust the gas valve settings Check/adjust the fan speed settings

Check gas supply/working pressure Check ﬂame sensing electrode and lead Check for ﬂue gas recirculation Check/adjust the gas valve settings Check/adjust the fan speed settings

Check external control (room thermostat) requests Rapid on/off hot tap requests

Check external sensor and cable are not damaged or wet Check continuity of external sensor and circuit Check connection at X19 on PCB and sensor connecting block

Reduced burner output

Alpha InTec S

Flue thermostat has sensed high ﬂue gas temperature (110°C) and reduced the burner

output to prevent damage. If the temperature continues to rise the boiler will lock out and E03 will be displayed

Air in heat exchanger Restricted primary ﬂow Heat exchanger air ﬂow blocked Flue restriction Flue sensor fault Pump fault

9 IMPORTANT NOTES

1. BOILER LOCATION

Always ensure the following clearances are available around the casing of the boiler:-

Top: (horizontal ﬂue) 235 mm, Top: (vertical ﬂue) 150 mm, Bottom: 150 mm, Bottom: (with Jig) 250 mm,

Each side: 5 mm, Front: 450 mm

Do not store any other articles in a cupboard containing the boiler and never place any clothing or combustible material on or near the boiler or ﬂue pipe.

2. FLUE TERMINAL

The terminal on the outside wall must not be allowed to be obstructed. If it is damaged, in any way, turn the boiler off and contact your Service Engineer.

Note: The Alpha InTec boilers are high efﬁciency condensing boilers and when operating vapour will be emitted from the terminal. This is safe and quite normal.

3. MAINS FAILURE

In the event of an electrical supply failure the boiler will not operate. When the supply is restored, the boiler will return to normal operation. Remember to reset any controls, if ﬁtted, when the supply is restored. If the mains water supply fails, there will be no hot water from the taps. The boiler will continue to provide central heating.

4. ADDITIONAL BATHROOM FITTINGS

Any equipment such as mixing valves, showers, bidets etc. must be designed to operate at mains water pressure. Contact your plumbing merchant or installer for advice when considering purchasing such items.

5. CLEANING

Use only a damp cloth and mild detergent to clean the boiler outer casing. Do not use abrasive cleaners.

6. SERVICING

To maintain efﬁcient and safe operation of your boiler, routine annual servicing is essential. For advice on servicing contact:- The Alpha Helpline: 0844 871 8764.

7. GAS LEAK

If a fault or gas leak is suspected, turn off the gas supply. Do not touch any electrical switches, do not smoke and extinguish all naked ﬂames. Contact your local Gas Region immediately on 0800 111 999.

8. ELECTRICAL SUPPLY

The boiler requires a 230/240 V ~ 50 Hz supply, fused at 3 A if a 13 A 3-pin plug is used or a 5 A fuse if any other type of plug is used.

To connect a plug:-

The colour of the wires in the mains lead of the boiler may not correspond with the coloured markings identifying the terminals in your plug. In this case proceed as follows:-

The wire coloured green and yellow must be connected to the terminal in the plug that is marked with the letter E, or by the earth symbol The blue wire must be connected to the terminal which is marked with either the letter N or coloured black. The brown wire must be connected to the terminal which is marked with the letter L or coloured red.

THE APPLIANCE MUST BE EARTHED.

, or coloured green or green and yellow.

10 GAS SAFETY REGULATIONS

Current Gas Safety (Installation and Use) Regulations:-

It is the law that all gas appliances are installed and serviced by a competent person, i.e. Gas Safe registered personnel. Failure to install or service appliances correctly could lead to prosecution. It is in your interest and that of safety to ensure compliance with the law. The manufacturer's instructions must not be taken in any way as over-riding statutory obligations.

The Benchmark Checklist must be fully completed by the installer on installation of the boiler. The Benchmark Checklist is shown in back of the Installation and Servicing instructions. All Gas Safe registered installers carry a Gas Safe ID card and have a registration number. Both should be recorded in the Checklist. You can check your installer is Gas Safe registered by calling Gas Safe on 0800 408 5500.

Alpha InTec S

11 OPTIONAL BOILER CONTROLS (if ﬁtted)

There is a range of controls available from Alpha to operate your boiler. In addition to the items listed below the Alpha InTec boilers are compatible with most controls available on the market. However to get the most comfort and efﬁciency from your boiler we recommend the Alpha Climatic controls with enhanced remote boiler functions and efﬁciency control.

Please refer to the instructions provided with the controls for further information on their setting and use.

Available Alpha controls:

7 day digital heating clock- two channel (boiler mounted) ..........................................................................Part No.6.1000220

Alpha Comfort 7 day wireless programmable room thermostat - two channel (boiler mounted receiver) ..Part No.3.022142

*Alpha Climatic wired programmable boiler energy manager (boiler mounted) ......................................... Part No. 3.022144

*Alpha Climatic wireless programmable boiler energy manager (boiler mounted receiver) .......................Part No. 3.022143

*External weather compensation probe......................................................................................................Part No. 3.022383

Alpha System diverter valve kit ..................................................................................................................Part No. 3.022382

Optional boiler controlled condensate trace heating kit ..............................................................................Part No. 6.5500000

* These controls can only be used in conjunction with the Alpha System diverter valve kit.

Alpha Therm Limited. Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS Tel: 0844 871 8764

These instructions have been carefully prepared but we reserve the right to alter the speciﬁcation at any time in the interest of product improvement. © Alpha Therm Limited 2011.

email: info@alpha-innovation.co.uk website: www.alpha-innovation.co.uk

Instructions compiled and designed by Publications 2000 - Tel: 01670 356211 05/11/D272

Part No. 1.030786 Rev 15.035285/000

alpha InTec 12S User guide

Specifications and Main Features

Frequently Asked Questions

User Manual