alpha Intec 2 20SE, Intec 2 26CE, Intec 2 30CE, Intec 2 30SE, Intec 2 35SE User guide
Installation and Servicing
0051
Instructions
InTec² 26CE, 30CE and 35CE
Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing Combination Boiler
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 InTec² 26CE G.C. No. 47 532 66
Alpha InTec² 30CE G.C. No. 47 532 67
Alpha InTec² 35CE G.C. No. 47 532 68
Set for use with Natural Gas
Leave these instructions with the User
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 2015.
Part No. 1.035665 ST.001836/000
0415/D346
BENCHMARK SCHEME
To comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be installed in accordance with the
manufacturer’s instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Checklist at the back of these instructions
Code of Practice
For the installation, commissioning and servicing of domestic heating and hot water products.
Benchmark places responsibilities on both manufacturers and installers*. The purpose is to ensure that customers** are
provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with
the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building
Regulations. Installers are required to carry out work in accordance with the following:
Standards of Work
• Be competent and qualified to undertake the work required.
• Install, commission, service and use products in accordance with the manufacturer's instructions provided.
• Ensure that where there is responsibility for design work, the installation is correctly sized and fit for purpose.
• Meet the requirements of the appropriate Building Regulations. Where this involves notifiable work be a member of a
Competent Persons Scheme or confirm that the customer has notified Local Authority Control (LABC), prior to work
commencing.
• Complete all relevant sections of the Benchmark Checklist/Service Record when carrying out commissioning or
servicing of a product or system.
• Ensure that the product or system is left in a safe condition and, where possible, in good working order.
• Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing work.
• Refer to the manufacturer's helpline where assistance is needed.
• Report product faults and concerns to the manufacturer in a timely manner.
Customer Service
• Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request.
• 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.
• Advise the customer that regular product servicing is needed, in line with manufacturers' recommendations, to ensure
that safety and efficiency is maintained.
• Respond promptly to calls from a customer following completion of their work, providing advice and assistance by
phone and, if necessary, visiting the customer.
• Rectify any installation problems at no cost to the customer during the installer's guarantee period.
* The use of the word "installer" is not limited to installation itself and covers those carrying out installation, commissioning and/or servicing of heating and hot water
products, or the use of supporting products (such as water treatment or test equipment).
** Customer includes householders, landlords and tenants.
Benchmark Commissioning and Servicing Section
It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and
the data fields on the commissioning checklist completed in full.
To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one
month of the installation.
To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe
registered engineer who has been trained on the boiler installed. The service details should be
recorded on the 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 InTec² 26E, 30CE and 35CE - Benchmark Scheme
2
CONTENTS
1 Introduction ........................................3
2 Technical data ...................................4
3 General boiler information .................9
4 Installation ......................................... 16
5 Commissioning ..................................25
6 Routine servicing ...............................34
8 Wiring diagram .................................. 45
9 Error codes and fault finding..............47
10 Short parts list ...................................50
11 Energy classification ..........................51
Benchmark Checklist .........................58
Service Record ..................................59
7 Component replacement ...................39
1 INTRODUCTION
The InTec² 26CE, 30CE and 35CE are wall mounted, room sealed, fan assisted, high efficiency, condensing boilers. The
burner is lit electronically and the heat output is controlled by a modulating fan and gas valve.
The InTec² 26CE, 30CE and 35CE are combination boilers providing both central heating and domestic hot water at mains
pressure.
The boiler is supplied with a pump, pressure relief valve, expansion vessel and pressure gauge fully assembled and tested. It
is designed for use with a fully pumped, sealed and pressurised central heating system.
IMPORTANT
Failure to install and commission this appliance in compliance with the manufacturer's instructions may invalidate the warranty.
It is the law that all gas appliances are installed by a competent person, ie Gas Safe registered personnel, in accordance
with the following recommendations:-
Current Gas Safety (Installation and Use) Regulations
All current Building Regulations issued by the Department of the Environment, i.e. Approved Document L26.
Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department
UK Water Regulations/Byelaws (Scotland)
Health & Safety Document No. 635 (The Electricity At Work Regulations 1989)
The installation should also be in accordance with the following British Standard Codes of Practice:-
BS 5440-1: 2008 ........................Flueing and Ventilation Requirements
BS 5440-2: 2009 ........................Installation and Maintenance of Flues and Ventilation
BS 5546: 2010 ...........................Specification for Water Heating Appliances
BS 6798: 2009 ...........................Specification for Installation gas fired boilers up to 70 kW
BS 6891: 2005 + A2: 2008 .........Installation of low pressure Gas Pipework
IGEM/UP/2 ...............................Installation of pipework
IGEM/UP/4 ................................Commissioning of gas fired plant
IGE/UP/10 .................................Installation of Flued gas appliances
IGEM/UP/16 ..............................Design for natural gas installations
IGE/UP/1 and 1A .......................Strength Testing and tightness testing Natural Gas Installations
Reference should also be made to any other standards and requirements relating to the installation depending on the location
and use.
Reference should be made to DEFRA document 'Guide to condensing boiler installation assessment procedures for dwellings'.
If installation is in a timber framed building, refer to the Institute of Gas Engineers document IGE/UP/7.
This appliance meets the requirements of IPX5D, ie degree of protection against moisture.
This appliance contains no asbestos and no substances have been used in the construction process that contravene the
COSHH Regulations (Control of Substances Hazardous to Health).
Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety to ensure that
the law is complied with.
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 domestic boiler installations are registered by the installer through the Gas Safe Notification
Scheme.
3. The boiler must only be used with Alpha CD condensing flue components.
Propane Gas (LPG) - In addition to the regulations and requirements stated, the boiler must be installed in accordance with
BS 5482:1 - The Installation of Propane Burning Appliances in Permanent Dwellings.
Alpha InTec² 26E, 30CE and 35CE - Contents/Introduction
3
2 TECHNICAL DATA
2.1 TECHNICAL PERFORMANCE DATA - NATURAL GAS (Cat I2H 2H - G20 20 mbar)
Heat input gross - DHW kW
Heat input gross - CH kW
Heat input net - DHW kW
Heat input net - CH kW
Heat output condensing (50/30°C) - CH kW
Heat output non condensing (80/60°C) CH kW
Heat output min. - CH kW
Heat output nominal - DHW kW
Gas rate at max. output m³/h
Gas supply pressure mbar
Max. CH temperature - Set point °C
Gas burner injector diameter mm
DHW flow rate at 35°C rise l/min
DHW flow rate at 30°C rise - EN13203-1 l/min
Dry NOx weight mg/kWh
Dry NOx ppm
NOx Class
Factory set CO
CO
at maximum CH output %
2
CO
at maximum DHW output %
2
CO
at minimum output %
2
CO
at medium output (ignition) %
2
(± 0.8%)
2
CO weight (nominal) mg/kWh
CO (max) ppm
Maximum CO/CO
Ratio
2
SAP/SEDBUK seasonality efficiency 2005 %
SAP/SEDBUK seasonality efficiency 2009 %
ErP DHW efficiency %
Max. primary system pressure bar
Min. primary system pressure bar
Recommended system pressure - Cold bar
System pressure relief valve setting bar
Expansion vessel size litres
Expansion vessel charge pressure bar
Electrical power consumption - Max. Watts
Electrical power consumption - Standby Watts
InTec² 26CE
29.6
22.8
26.7
20.5
21.3
20
2.8
26
2.83
20
85
6.15
10.7
12.5
18
11
5
9.1
9.2
9.0
9.0
21
200
0.003
90.1
88.9
74 (M)
2.5
0.5
1.0
3.0
8.0
1.0
90
6
InTec² 30CE
31.9
27.3
28.7
24.6
25.5
24
2.8
28
3.04
20
85
6.15
11.7
13.7
18
11
5
9.1
9.2
9.0
9.0
21
200
0.003
90
88.8
74 (M)
2.5
0.5
1.0
3.0
8.0
1.0
95
6
InTec² 35CE
38.7
31.9
34.9
28.7
29.8
28
3.5
34
3.69
20
85
6.15
14.4
16.8
20
12
5
9.2
9.5
9.0
9.0
21
200
0.003
90.1
88.9
85 (XL)
2.5
0.5
1.0
3.0
8.0
1.0
105
6
2.1 TECHNICAL PERFORMANCE DATA - LPG - PROPANE GAS (Cat I3P 3P - G31 37 mbar)
InTec² 26CE InTec² 30CE
Heat input gross - DHW kW
Heat input gross - CH kW
Gas supply pressure mbar
CO
at maximum CH output % (±1%)
2
CO
at maximum DHW output % (±1%)
2
CO
at minimum output % (±1%)
2
CO
at medium output (ignition) % (±1%)
2
Note: OtherTechnical data is the same as NG data.
Alpha InTec² 26E, 30CE and 35CE - Technical Data
4
29
22.3
37
10.8
10.2
10.0
10.7
31.2
26.7
37
10.7
10.2
10
10.7
InTec² 35CE
37.9
31.2
37
10.8
10.5
10
10
2.2 PHYSICAL DATA
Boiler flow and return connections mm
DHW inlet (cold) DHW outlet (hot) connections mm
Gas connection diameter mm
Boiler dimensions Height mm
Width mm
Depth mm
Clearances for servicing Bottom mm
Bottom (with jig) mm
Top (horizontal flue) mm
Top (vertical flue) mm
Sides mm
Front mm
Recommended hole size for flue pipe mm
Recommended hole size for instalation from inside the building mm
Boiler dry lift weight kg
Boiler operating weight (full of water) approx. kg
Max. total flue length Horizontal m
Max. total flue length Vertical m
Flue system diameter mm
22
15
22
712
440
276
150
250
235
150
5
450
110
130
33.4
35.8
12
14
60/100
2.3 FLUE LENGTHS
A 500 mm or 1000 mm Easy-Flue terminal kit with 90° bend or horizontal terminal is available.
CD 750 mm and 1000 mm flue extensions are available.
Length of Flue Required:-
Rear Flue = wall thickness + 180 mm (includes terminal).
Side Flue = wall thickness + distance between wall and side of boiler + 265 mm (includes terminal)
Vertical Flue = distance from top of boiler side panel to required roof position minus 1000 mm for vertical terminal assembly
Maximum horizontal flue length = 12 m.
Maximum vertical flue length including terminal is 14 m.
Each additional CD 90° Bend is equivalent to 1.3 m of flue length.
Each CD 45° Bend is equivalent to 0.9 m of flue length.
The CD Vertical Flue terminal assembly is equivalent to 1 m of flue length.
Note: For flue lengths over 4.5 m the 'F0' parameter should be changed - See Section 5.4.
2.4 PUMP
The boiler is equipped with a variable speed low power consumption pump.
During the DHW mode, the pump always runs at the maximum speed.
During the CH mode, different functioning modes of the pump are available.
AUTO - CONSTANT
and return according to the
Parameter A5 adjusts the
Note: A constant
AUTO - PROPORTIONAL: If
pump head, the pump speed varies based on the heat output supplied by the burner - the greater the heat output the higher the
pump speed. It is possible to adjust the pump speed range in the boiler parameter menu. Parameter A3 adjusts the maximum
speed between values 5 to 9 and parameter A4 the minimum between 5 and the maximum setting (A3).
FIXED - If parameters 'A3' and 'A4' are set to the same value, the pump runs at the constant speed level set.
Note: For correct operation of the boiler, do not set values lower than the minimum value indicated above (i.e. lower than 5).
Pump release - After a prolonged period of inactivity, the pump might stick, and it may be necessary to turn the motor shaft
using a screwdriver. Take great care during this operation to avoid damage to the motor.
By-pass Regulation (part. 24 Fig. 1-30) - The boiler leaves the factory with the by-pass open.
If necessary, the by-pass can be adjusted to the system requirements from minimum (by-pass closed) to maximum (by-pass
open). Adjust using a flat head screwdriver, turn clockwise to open the by-pass, and anticlockwise to close.
ΔT (Default): The pump speed is controlled automatically to keep a constant ΔT between heating flow
ΔT set (default value 15°C). It is possible to adjust the ΔT value in the boiler parameter menu.
ΔT between 5 and 25°C.
ΔT may not be achievable depending on the heating system design and size.
ΔT = 0°C (parameter A5), the pump speed is controlled automatically in order to give a proportional
Alpha InTec² 26E, 30CE and 35CE - Technical Data
5
1600
1600
2.4.1 Available Pump Head
7
6
5
4
3
Head (m water)
2
1
0
A + B = Head available to the system with by-pass closed.
B = Head available to the system by-pass opened.
Speed 9
A
B
Speed 5
200 600 1000 1400800 1200
4000
Flow rate (l/h)
2.4.2 Pump Power Consumption
70
60
50
40
30
20
Pump electrical consumption (W)
10
0
200 600 1000 1400800 1200
Fig. 2.1
Speed 9
C
D
Speed 5
4000
Flow rate (l/h)
C + D = Pump power consumption with by-pass opened.
D = Pump power consumption with by-pass closed.
Alpha InTec² 26E, 30CE and 35CE - Technical Data
6
Fig. 2.2
2.5 ELECTRICAL CONNECTIONS
Relay board
(optional)
Remove link to
connect clock
Mains Supply
220 V ~ 50 Hz
Remove link to connect
220 V room thermostat
Room
thermostat
(optional)
Alpha
Climatic Control
(optional)
When an Alpha Climatic control is connected to terminals 41 and 44
remove the links between terminal blocks 1 and 2
X70
B4
B9
3
1
2
4
R
Bl
Br
R
R
Br
Bl
Bk
Bl
Br
R Br
Or
G
Bl Bk Br W G
Y
Y
G/Y
G/Y
Br
Bl
G/Y
L
N
A
B
1
2
21
40
414441 14
15
38 39 38 48
X5 on PCB
X1 on PCB
X1 on PCB
X4 and X9 on PCB
Colour Code
Bk Black
Bl Blue
Br Brown
G Green
Gy Grey
G/Y Green/Yellow
Or Orange
R Red
V Violet
W White
Y Yellow
X70 Low temperature circuit thermostat
B4 External sensor
B9 DHW inlet sensor (as standard)
Note: This Appliance Must Be Earthed
Optional integral single channel controls are available if required.
Note: Only use the Alpha single channel controls. Do not fit any two channel controls.
Programmer clock
(optional)
X20
X21
50 51 52 53 54 55 56 5758
X26
Fig. 2.3
2.6 DATA BADGE ANNOTATION
NOTE: Technical data is provided on the boiler data / wiring label and in Section 2.1.
nw/Qn max.
Q
PMW
Md
Sr N
Type
Q
PMS
NO
o
nw/Qn min.
x Class
Md.............................Model
Cod. Md ....................Model code
o
Sr N
.........................Serial number
CHK ..........................Check
Cod. PIN ...................PIN code
Type ..........................Type of installation (ref. CEN TR 1749)
Q
nw min. .....................DHW minimum heat input
Q
n min. .......................CH minimum heat input
Q
nw max. ....................DHW maximum heat input
Q
n max. ......................CH maximum heat input
Cod. Md
Cod. PIN
P
n min.
D
n max.
P
TM
CONDENSING
n min. .......................Minimum heat output
P
P
n max. .......................Maximum heat output
PMS ..........................Maximum system pressure
PMW .........................Maximum DHW pressure
D ...............................Specific flow rate
TM ............................Maximum operating
temperature
NO
x Class .................NOx Class
CONDENSING .........Condensing boiler
Alpha InTec² 26E, 30CE and 35CE - Technical Data
7
2.7 BOILER SCHEMATIC
F(+) A(-)
13
12
11
10
14
15
16
17
9
8
7
6
5
4
3
18
19
20
21
22
23
24
2
1
1 - Gas valve
2 - Cold water filter
3 - DHW flow regulator
4 - Mains inlet sensor
5 - DHW sensor
6 - DHW heat exchanger
7 - Expansion vessel
8 - Primary heat exchanger
9 - Air/gas mixer
Gas
Domestic
hot water
outlet
Cold mains
water inlet
Primary
Heating
return
Primary
Heating flow
Condensate discharge
and expansion relief
10 - Fan
11 - Ignition/detection electrode
12 - Air test point (pressure point -)
13 - Flue test point (pressure point +)
14 - Flue temperature sensor
15 - Manual air vent
16 - Primary temperature sensor
17 - Overheat thermostat
18 - Return thermostat
25
26
27
19 - Automatic air vent
20 - Pump
21 - Primary pressure switch
22 - Diverter valve
23 - Automatic bypass
24 - Drain point
25 - Safety valve indicator
26 - Safety valve
27 - Safety valve indicator
Alpha InTec² 26E, 30CE and 35CE - Technical Data
8
Fig. 2.4
3 GENERAL BOILER INFORMATION
3.1 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.
3.2 ELECTRICAL SUPPLY
The boiler requires a 230/240 V ~ 50 Hz mains supply, fused at 3 A
The boiler must be earthed.
There must only be one common isolator, providing complete electrical isolation, for the boiler and any external controls.
This boiler has been fitted with a supply cable, however, if it is necessary to fit a cable use PVC insulated cable not less than
0.75 mm² (24 x 0.2 mm) to BS 6500 Table 16. The boiler should be connected to a fused three pin plug and unswitched shuttered
socket outlet (both complying with BS 1363), or a fused double pole switch with a contact separation of at least 3 mm in both poles.
Wiring external to the boiler must be in accordance with the current IEE Wiring Regulations (BS 7671).
Note: If a room thermostat is fitted, it must be suitable for 230/240 V switching.
3.3 AIR SUPPLY
The boiler does not require any air vents for cooling in the room in which it is installed or when installed in a cupboard or
compartment. The minimum clearances for servicing must always be maintained.
Note: A cupboard or compartment used to enclose the boiler must be designed and constructed specifically for the purpose,
i.e. comply with the Building Regulations.
3.4 FLUE SYSTEM - Fig. 3
The flue system must be installed in accordance with BS 5440:1.
When using the horizontal flue kit supplied ensure that the flue outer duct is installed horizontally (please note that the flue
inner duct already has a pre-determined slope towards the boiler for condensate to run back towards the boiler).
When additional flue extensions are used, ensure the flue slopes downwards towards the boiler by a minimum of 25 - 30 mm
per metre of flue.
Horizontal and vertical flue assemblies should be supported approximately every 1.5 m with access provided to the joints.
Flue components are available as follows:-
CD 750 mm flue extension - Part No. 6.2000750.
CD 1000 mm flue extension - Part No. 6.2001050.
CD 100 mm flue support brackets (pack of 5) - Part No. 6.1000355.
CD 90° bend - Part No. 6.2000590.
CD 45° bend - Part No. 6.2000545.
CD Vertical flue terminal kit - Part No. 6.2000520. Refer to the separate installation instructions supplied with the kit.
Note: 1. If an extra 90° bend is used, this reduces the maximum flue length by 1.3 m. Each 45° bend used reduces the
maximum flue length by 0.9 m.
2. For flue lengths over 4.5 m the 'F0' parameter should be changed - See Section 5.4.
3. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally
and only 14 metres vertically.
4. Failure to use Alpha flue components with the boiler will invalidate the boilers CE approval, guarantee and may be
unsafe.
Alpha InTec² 26E, 30CE and 35CE - General Boiler Information
9
12 m
B
A
A
B
A
HORIZONTAL FLUE OPTIONS - Lmax - 12 metres
Not less than
300 mm
H
L = A + B = 12m max.
L = A + B + (90° bend = 1.3 metre)
VERTICAL FLUE OPTIONS
L = A + (2 x 45° bends = 1.8 metre)
Fig. 3.1
Not less than
300 mm
H
Hmax = 14 m Hmax = 12.2 m (14 m - 1.8 m)
Fig. 3.2
Alpha InTec² 26E, 30CE and 35CE - General Boiler Information
10
3.5 FLUE TERMINAL LOCATION - Figs. 3.3 and 3.4
J
D
G
H I
Q
Boundary
O
P
N
A Directly below an opening, air brick, windows, etc.
B Below gutters, soil pipes or drain pipes
C Below eaves
D Below balconies
E From a vertical drain pipe or soil pipe
F From an internal or external corner
G Above ground, roof or balcony level
H From a surface or boundary facing the terminal
I From a terminal facing the terminal
J Above an opening, air brick, window etc.
K Vertically from a terminal on the same wall
L Horizontally from a terminal on the same wall
M Horizontally from an opening, air brick, window etc.
N Minimum protrusion through a roof
O From a vertical obstruction
P From an openable window
Q From an adjacent vertical terminal
Min. distance (mm)Terminal position
(See Note 1)
300
75 (See Note 3)
200 (See Note 3)
200 (See Note 3)
150 (See Note 3)
300 (See Note 2)
300
600
(See Note 4)
1200 mm
300
(See Note 1)
1500 mm
300 mm
300 mm
(See Note 1)
300 mm
300 mm
600 mm
600 mm
Fig. 3.3
Notes:
1. In addition, the terminal should not be nearer than 150 mm to the framework of an opening into the building, i.e. a
window surround or door surround.
2. This clearance may be reduced to 25 mm without effecting the performance of the boiler. However, to ensure the
condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferable.
3. These clearances may be reduced to 25 mm without effecting the performance of the boiler. However, to ensure the
condensate plume does not affect adjacent surfaces the terminal can be extended beyond gutters, pipes, eaves,
balconies etc. by upto 500 mm. If the flue is extended more than 500 mm outside, it should be boxed and insulated.
4. To reduce the possibility of nuisance to neighbouring buildings etc. it is recommended the terminal should not be less
than 2500 mm from car parking spaces, building boundary walls, fences etc.
5. A terminal must not be sited under a car port roof.
6. In certain weather conditions the terminal will emit a plume of steam. If possible avoid positioning the terminal where
this may cause a nuisance, i.e. positions A, D, G, H, J or M.
7. The flue terminal must be exposed to the external air and the position must allow the free passage of air across it at all times.
8. A terminal must not be sited below 2 m where people have access to, such as public footpaths, access routes, patios
etc. However, If the terminal is fitted less than 2 m above 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 InTec² 26E, 30CE and 35CE - General Boiler Information
11
Proximity of flue duct outlets to boundaries
The flue duct shall be sited so that it is at least 600 mm (see Fig. 3.4) from the boundary line when facing it and at least 300
mm from the boundary line when running parallel to it.
Boundary
Building
Terminal facing the boundary
Boundary
Building
Terminal at an angle to the boundary
Terminal
300 mm
600 mm
600 mm
Terminal
Fig. 3.4
Boundary
Building
Terminal parallel to the boundary
Adjacent building
Boundary
Building
Terminal facing an opening
in adjacent building
Terminal
300 mm
Terminal
Window
2000 mm
3.6 BOILER LOCATION
The boiler is not suitable for external installation unless it is installed within a purpose designed weatherproof building.
The boiler must be installed on a flat vertical wall which is capable of supporting the weight of the boiler. The boiler can be fitted
to or adjacent to a wall comprising of a combustible material without the need for a special thermal insulation barrier.
If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with the Institute of Gas Engineers
'Guide for Gas Installations in Timber Frame Housing', reference IGE/UP/7.
The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the
current IEE Wiring (BS 7671) Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in
Scotland, with respect to the installation of the boiler in a room or internal space containing a bath or shower. Where a roomsealed boiler is installed in a room containing a bath or shower, it must not be possible for a person using the bath or shower
to touch any electrical switch or boiler control utilising mains electricity.
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 InTec² 26E, 30CE and 35CE - General Boiler Information
12
3.7 CENTRAL HEATING SYSTEM - Fig. 3.5
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 90°C. When designing the system, the pump
head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. Refer to the pump performance
table for guidelines.
System volume - The expansion vessel incorporated into the boiler is suitable for a sealed heating system with a maximum
water content of 80 litres (18 gal). Above 80 litres, consideration should be given to fitting an additional expansion vessel
fitted in the position shown in Fig. 3.5. To check correct operation of the expansion vessel(s) the system pressure should not
be more than 2.5 bar when the system is at maximum operating temperature (for further guidance refer to BS 7074:1).
The boiler is supplied with the following components built in:-
Pressure gauge - To indicate the system pressure to be maintained.
Expansion vessel - Conforming to BS 4814 with a capacity of 8 litres and pre-charged to a pressure of 1.0 bar.
By-pass - The boiler incorporates an automatic by-pass, therefore an automatic by-pass is not required for the system.
Static head of system
Note: A drain tap should be installed at the lowest point
of the heating circuit and beneath the appliance.
Boiler
casing
Heating
flow
Heating return
System
drain tap
Automatic
air vent
Note: If the mains is fitted with water
meter, check valves or loose jumper
stop cock, then a DHW expansion
device must be fitted.
Additional expansion
vessel (if required)
Filling point
DHW outlet
Mains water inlet
Fig. 3.5
3.8 FILLING THE CENTRAL HEATING SYSTEM - Fig. 3.6
The system design pressure (cold) should be set to 1.0 bar. This pressure is equivalent to a static head (see Fig. 3.5) of 10.2
metres of water.
The InTec² CE models have an integrated filling loop provided with the boiler connection group.
Fill the system using the two small black control valves opening one first and using the second to control the flow into the
system.
When the system is filled and vented to the correct pressure close both control valve taps. The temporary connection can
then be undone and slides back to disconnect the loop.
Drain valves (to BS 2879) must be fitted in the heating system to allow the system to be fully drained.
Filling control valves
Sliding temporary connection
Fig. 3.6
Alpha InTec² 26E, 30CE and 35CE - General Boiler Information
13
3.9 FLUSHING THE HEATING SYSTEM
It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha boiler. Failure to do so
will invalidate the warranty.
The primary condensing heat exchanger is constructed in aluminium and therefore is compatible with most materials used in
a heating system.
Cleaning agents and inhibitors must be applied in accordance with their manufacturers instructions. Suitably approved
products for cleaning and treatment must be used.
The system should be flushed in accordance with BS 7593 and BS EN 14336. The following procedures are recommended:
1. Installing onto a new system: a. Fill the system, vent at high points, at pump, primary heat exchanger and radiators.
b. Check for leaks.
c. Drain the system.
d. Chemically clean the system as instructed by the recommended cleaner manufacturer.
Note: Ensure that the system is flushed to remove any remains of the cleaner.
e. If chemical cleaner is not used to clean the system: i) Refill the system.
ii) Switch on the boiler and allow the system to heat up to the normal operating temperature.
iii) Switch off the boiler and drain the system while the water is still hot.
iv) Refill the system and check for leaks.
f. Add the inhibitor to the system as instructed by the inhibitor manufacturer instructions.
2. Installing onto an existing system, clean the system before fitting the new boiler: a. If the old boiler is still working: i) Switch on the boiler and allow the system to heat up to the normal operating temperature.
ii) Switch off the boiler and drain the system while the water is still hot.
iii) Refill and chemically clean the system as instructed by the cleaner manufacturer instructions.
iv) Ensure the system is flushed to remove any remains of the cleaner.
v) Fit the new boiler.
b. If the old boiler is not working: i) Drain the system.
ii) Remove the old boiler.
iii) Flush the system through.
iv) Fit the new boiler.
v) Refill and chemically clean the system as instructed by the cleaner manufacturer instructions.
vi) Ensure the system is flushed to remove any remains of the cleaner and check for leaks.
c. Add the inhibitor to the system as instructed by the inhibitor manufacturer instructions.
The system inhibitor level must be maintained at the correct concentration. The PH of the system water must be between 6.5
and 8.5 or the appliance guarantee will be invalidated.
The system must not be filled with softened water.
3.10 DISPOSAL OF CONDENSATE
Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha boilers and reference
should be made to BS 6798 for the requirements on the disposal of condensate.
The boilers incorporate a condensate trap which has a seal of greater than 75 mm, therefore no additional trap is required.
The condensate should ideally be discharged internally into an internal waste pipe (washing machine/sink waste) or soil pipe
to avoid the possible risk of freezing. The pipework must be in 22 mm pipe (minimum).
External pipe runs should be avoided, but if it is necessary, the pipework should be protected from the risk of freezing with
waterproof insulation and the length should be kept to a maximum of 3 m and the condensate pipework should be increased
to a minimum of 32 mm diameter. Termination should be into an external gulley or soakaway as shown in Figs. 3.7 and 3.8.
Note: All pipework must have a continuous fall (see Figs. 3.7 and 3.8) from the boiler and must be of an acid resistant
material such as plastic waste pipe. (copper or steel is not suitable).
The condensate pipe is combined with the expansion relief discharge. The flexible condensate hose supplied meets the
requirements for use with both condensate and expansion relief. This should be connected to a suitable waste pipe and
fittings with approval for hot and cold water, i.e. BS EN1451-1PP Waste piping, BS EN1455-1 ABS piping or BS EN 1566-1
MUPVC piping.
The condensate and discharge should be connected to a drain for sewage and foul waste or a dedicated soak away with
neutraliser added.
It should be noted that the connection of a condensate pipe to a drain may be subject to local building control requirements.
Alpha InTec² 26E, 30CE and 35CE - General Boiler Information
14
Optional Condensate Trace Heating Kit
adequately supported
An optional Alpha trace heating kit is also available
to prevent the condensate from freezing.
The control of this kit works with a unique patented
design using the boiler PCB to control the trace
heating. The outside weather probe measures the
Plastic pipe
(minimum 32 mm)
Use waterproof
pipework insulation
in very exposed
positions
Ensure pipe is
external temperature, activating the trace heating
cable only when the boiler is in operation and
producing condensate. This feature together with
the latest technology variable resistance heating
cable ensures only a small amount of electrical
energy is used.
If the external temperature drops below 2°C
Open end of pipe
diverted into gully
below grid but above
water level
and the boiler is on, the relay PCB is operated
and voltage is supplied to the trace heating wire
Minimum gradient 2½°
causing it to heat up and prevent the condensate
from freezing. When the outside temperature rises
Fig. 3.7 - External gully
to 4°C or the boiler pump stops, the trace heater
is switched off. The connection of the outside weather probe supplied with this kit also enables the weather compensation
feature on the boiler.
22mm termination from boiler, increase to 32 mm if external
Cement mortar sealing
500 mm min.
O
2½ fall
Ground level (either/or)
25mm
100mm plastic tube
Bottom of tube sealed
Soakaway depth 400mm
filled with limestone chippings
300mm
Two rows of 3 x 12mm
holes at 25mm centres,
50mm from the bottom
of the tube. Holes to face
away from house.
Fig. 3.8 - External soakaway
3.11 DOMESTIC HOT WATER SYSTEM
The minimum flow rate needed for the flow switch and burner to operate is 1.5 litres/min.
If the incoming mains water pressure is above 5 bar a pressure reducing valve must be fitted.
If the mains supply is fitted with a water meter, check valves or loose jumper stop cock, then a DHW expansion device must
be fitted.
Following Part L Building Regulations, where the mains water hardness exceeds 200 parts per million, provision should be
made to treat the feed water to the hot water circuit of combination boilers to reduce the rate of accumulation of limescale.
To ensure economic use, the pipe runs between the boiler and taps should be in 15 mm copper pipe and be as short as
possible. Where possible the pipework should be insulated to reduce heat loss.
All taps and mixing valves used with the hot water system must be suitable for operating at a mains pressure of up to 8 bar.
Showers - A shower may be used with the boiler if required.
If a loose or flexible head type shower is used it may require the fitting of a double check valve, to comply with Water Bye Law 17.
Bidets - No anti-syphonage arrangements are necessary, provided the outlets are shrouded and it is not possible to attach
a temporary hand held spray. A supply of direct mains fed hot and cold water is permitted provided the appliance is of the
over-rim flushing type.
Before the mains water supply pipe is connected to the boiler, it should be thoroughly flushed out to avoid the danger of dirt
or foreign matter entering the boiler.
Alpha InTec² 26E, 30CE and 35CE - General Boiler Information
15
4 INSTALLATION
712 mm
Minimum
clearance
of 450 mm
from front
of boiler
276 mm
440 mm5 mm
5 mm
150 mm
235 mm - Can be reduced to
150 mm when using a
vertical flue
4.1 UNPACKING
1. The boiler carton also contains the following:-
Connection kit (bottom cover plate, union bends, washers and valves)
Mounting bracket plus screws and wall plugs
Condensate discharge pipe
Literature pack and Wall template
A suitable Alpha flue system must be selected to use with the boiler.
Notes: a. All flues must be suitable for Alpha condensing boilers.
b. CD 750 mm and 1000 mm flue extensions are available, if required.
2. Unpack boiler and remove the loose items, packs and mounting bracket.
Note: The boiler can be stood in an upright position (only while the valves and union bends are not fitted).
It is recommended that two persons lift the boiler.
4.2 CLEARANCES REQUIRED - Fig. 4.1
Minimum clearances
Fig. 4.1
4.3 PREPARE THE WALL - Fig. 4.2
1. Decide upon the position of the boiler taking into account the
clearances required for servicing and the flue terminal position.
2. Tape the template to the wall (ensure it is level and the right
way up) and mark the position of the holes for the boiler
mounting bracket. If rear exit flue is used, mark the position of
the hole for the flue.
3. Side exit flue - Continue the horizontal centre line of the flue
across the wall to the side wall, then along the side wall 135 mm
(ensure the lines are horizontal). This will give the position of the
centre of the hole for the flue.
4. 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
5. Drill the fixing holes (10 mm dia.) to accept the No.10 plugs
supplied. Using the screws supplied, fit the mounting bracket.
collar supplied, cut a 130 mm dia. flue hole using a
127 mm core drill.
Rear exit hole
110 mm dia.
=
Ensure line is level
=
Fig. 4.2
143 mm
Fixing holes
if mounting
bracket used
Fixing holes
if wall jig used
Outline of
boiler
Template
135 mm
Position of
110 mm hole
to be cut for
side exit flue
Alpha InTec² 26E, 30CE and 35CE - Installation
16
4.4 FIT THE BOILER - Refer to Figs. 4.2 and 4.3
Pour water into flue duct
Lift the boiler and locate it on the mounting bracket - the boiler should be lifted
by two persons.
Note: When handling or lifting always use safe techniques - keep your back
straight, bend your knees, don't twist - move your feet, avoid bending forwards
and sideways and keep the load as close to your body as possible.
Where possible transport the boiler using a sack truck or other suitable trolley.
Always grip the boiler firmly, and before lifting feel where the weight is concentrated
to establish the centre of gravity, repositioning yourself as necessary.
Location for
wall mounting
bracket on
rear of boiler
4.5 CONNECT THE PIPEWORK - Fig. 4.4
1. Thoroughly flush out all the water pipework. Refer to Section 3.9.
2. Fit the valves to the boiler connections as shown in Fig. 4.4 - note the
colours of the operating levers.
When fitting the filling loop keep it assembled (as supplied) and adjust
the width (on the sliding connection) to match the distance between the
cold mains inlet and heating return valves. Tighten the nuts, keeping the
valves aligned, in order to allow the connection pipe to slide.
3. Connect the system pipework to the union fittings on the valves just fitted.
Note: When soldering bends, ensure they are not connected to the valves, otherwise the internal seals may be
damaged.
One metre of copper pipe must be fitted to the boiler before connecting to any plastic pipework.
4. Connect the flexible condensate pipe to the rubber connector as shown in Fig. 4.4. Using the adaptor supplied, connect
the flexible pipe to the condensate drain.
Ensure that the condensate discharge pipe is as required in Section 3.10.
5. Ensure that all the valves are closed (operating lever at right angle to valve) and do not turn on the water or gas supplies
at this stage.
Cold water inlet (black), filter and restrictor
Fig. 4.3 - rear of boiler
Hot water outlet
Gas service cock (yellow)
Electrical connection
Condensate discharge pipe
Bottom cover plate
65 70 457095 95
A B C
Safety valve operation indicator
Filling loop assembly
Heating return valve
Heating flow valve
Heating drain point
D
E
A - Gas inlet - Yellow (22 mm)
B - DHW outlet elbow (15 mm)
C - Cold water inlet - Black (15 mm)
D - Heating return - (22 mm)
E - Heating flow - (22 mm)
Fig. 4.4
Alpha InTec² 26E, 30CE and 35CE - Installation
17
4.6 FIT THE FLUE - Figs. 4.5 and 4.6
The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only.
1. The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below.
Note: Where the length is less than the minimum or more than the maximum, refer to Section 4.7.
(B + C)
B (mm)
Max
530
975
Min
305
765
Side Flue
(B)
Rear Flue
CD Easy-Flue
500 mm
1000 mm
Note: Add 45 mm to
dimension B if the wall jig is
used.
Fig. 4.5 Fig. 4.6
2. Determine the overall length (L) of flue required, (see Fig. 4.7) as follows:-
Rear flue L = wall thickness (B) + 60 mm (105 mm if the wall jig is used)
Side flue L = wall thickness (B) + distance between boiler and wall (C) + 145 mm
L
Seal Joint with Tape
CD Easy-Flue
500 mm
1000 mm
B + C (mm)
Max
Min
440
215
885
675
Fig. 4.7
3. Adjust the telescopic section of the flue to the distance ‘L’, ensuring that the two labels marked ‘TOP’ are aligned, then
seal and secure the joint between the ducts with the sealing tape supplied.
Note: Always ensure that there is a minimum overlap of 25 mm when fully extending the telescopic section.
4. Pass the flue assembly through the wall (from inside or outside).
Note: Internal fitting - If there is no access to make good the outside wall, locate the outside (black) flue sealing collar
onto the outer duct of the flue immediately before the terminal grille onto the location provided. Push the flue assembly
through the 130 mm flue hole, so that the collar completely passes through the wall. Then pull the flue assembly back into
the correct position. Visually check that the collar is sealing the outside wall and that it is not restricting any of the openings
of the flue terminal.
Alpha InTec² 26E, 30CE and 35CE - Installation
18
Fig. 4.8 - Fitting the flue from inside
Check collar is sealing
the wall and it is not
restricting any openings
of the flue terminal
130 mm
5. 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. Secure in position using the clamp. Ensure the clamp is located centrally over both the bend and
boiler adaptor.
6. Fit the inside (white) flue sealing collar over the Easy-Flue. If it was not previously fitted, fit the outside (black) flue
sealing collar onto the flue immediately before the terminal grille onto the location provided.
7. Slide the larger Easy-Flue 45 mm clamp over the outer duct and pull the flue assembly towards the bend, locating the
inner duct into the seal joint on the bend. Ensure the labels marked 'TOP' are positioned at the top before securing the
flue assembly to the bend with the clamp (three screws) located centrally over the joint.
Note: Check the flue terminal protrudes 120 mm out of the wall and the inner duct of the terminal is positioned correctly
(see Fig. 4.9).
8. Make good the inside wall by pushing the inside flue sealing collar upto the wall.
The hole around the flue can be made good using the flue sealing collars supplied or using a suitable sealant/cement if
required.
Ensure the inner duct within
the terminal is at the top.
The inner duct must
Note:
be positioned to slope towards
the boiler
Flue sealing collar
Inner duct seal
120
20
Terminal
65
Note: Ensure the outer flue duct is horizontal
CD Easy-Flue
40 (85 if wall jig used)
Inner duct
Easy-Flue 45 mm clamp
Elbow seal joint
90° bend
Easy-Flue
40 mm clamp
and seal
Side of boiler
135 (180 if wall jig used)
Fig. 4.9 - Rear flue
4.7 REDUCING THE FLUE - Fig. 19
When the flue length required is less than the minimum stated in Section 4.6, paragraph 1, refer to Fig. 4.10.
Discard the first telescopic section (not the section with the terminal) of the Easy-Flue 1000 mm or 500 mm and cut to the
required length.
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. 4.10
Alpha InTec² 26E, 30CE and 35CE - Installation
19
4.8 EXTENDING THE FLUE - Fig. 4.11
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. InTec boilers must not exceed the maximum of an
equivalent horizontal flue length of 12 m.
1. When the flue length required is more than the maximum stated in Section 4.6, paragraph 1, refer to the table below
and Figs 4.5 and 4.6.
Rear Flue length (B)
Up to maximum:-
11.890 m
(Subtract 45 mm if the
wall jig is used)
Side Flue length (B + C)
Up to maximum:-
11.805 m
Comments
Alpha CD 750 mm flue extension (Part No. 6.2000750) or 1000 mm extension
(Part No. 6.2001050) is required to extend the range of telescopic flue.
Refer to Section 4.8 for instructions on how to extend the flue.
Note: A 130 mm flue hole (127 mm core drill) may be required in the wall.
This is when the extended flue is passed through the wall.
Additional support brackets are required when extending the flue. These are available from Alpha, Part No. 6.1000355.
2. Use the template (supplied with the boiler) to mark the required flue position, ensure the slope towards the boiler is correct.
3. Determine the overall flue length as described in Section 4.6, paragraph 2 to determine the number of Alpha CD 750 or
1000 mm flue extensions required.
4. Assemble the flue extensions together by locating the inner duct into the seal joint and secure each extension together
with the extension clamps supplied (three screws). Ensure that the clamps are positioned centrally over the joints.
Note: If it is required to cut an extension, DO NOT cut the end of the inner duct that incorporates the seal joint. Ensure
the inner duct end without the seal joint is cut so that it is 20 mm longer than the outer duct.
Ensure that all cuts are square and free from burrs.
Once assembled with the components pushed home, the flue is fully sealed.
5. Adjust the telescopic section of the Easy-Flue to the required length and secure the Easy-Flue with the sealing tape
supplied. Fit the Easy-Flue to the extensions by locating the inner duct into the seal joint and secure with the clamp
(three screws), ensuring it is located centrally over the joint.
6. Mark the end of the flue assembly 'TOP' where it is connected to the boiler, so that the 'TOP' of the flue terminal is
aligned with the 'TOP' at the boiler end of the flue assembly.
7. Pass the complete flue assembly through the wall.
8. 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 and secure in position. Ensure the seal is located centrally over both the bend and boiler adaptor. If
the inside sealing collar (white) is being used to make good the inside wall, then it will need to be fitted before assembling
the flue.
9. Slide the larger Easy-Flue 45 mm clamp (two screws) over the outer duct and pull the flue assembly towards the bend,
locating the inner duct into the seal joint on the bend.
Ensure the inner duct within the terminal is at the top.
The inner duct must be positioned to slope towards the boilerNote:
Terminal
Flue sealing
collar
20
120
20
Alpha InTec² 26E, 30CE and 35CE - Installation
CD Easy-Flue
Ensure outer flue duct of Easy-Flue is horizontal
Inner seal joint
Flue length (L)
Fig. 4.11 - Side flue
Extension clamp
Inner seal joint
CD Flue extension
Ensure the flue extension slopes
downwards towards the boiler by a
minimum of 25 - 30 mm per metre
Easy-Flue 45 mm clamp
90° bend
Easy-Flue
40 mm clamp
and seal
125
220
Seal joint
45
Front of boiler
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. the inner duct within the terminal is at the top. See Fig. 4.11.
11. Make good the outside wall by fitting the outside sealing collar (black) onto the location provided immediately behind the
flue terminal grille. Make good the inside wall using the inside sealing collar (white) if required.
4.9. FIT PLUME MANAGEMENT COMPONENTS - (OPTIONAL)
The following procedures detail the options for management of the exhaust flue gas/plume emitted from the terminal.
a. The terminal supplied with the Easy-Flue can be altered to divert exhaust flue gas/plume at an angle.
This can be achieved by simply turning the end section of the terminal to the desired angle.
b. The CD Easy-Flue can be converted to allow the inner flue duct to be extended so as to position the terminal in an area
where the exhaust flue gas/plume will not cause a nuisance. This can be done before or after installation of the flue,
providing there is access to the terminal from outside.
i. Remove the screws (1 in Fig. 4.12) securing the terminal and remove the terminal by pulling it from the flue assembly.
Remove the screw (2 in Fig. 4.12) securing the terminal end section and remove the end section from the terminal.
ii. Locate a 93° Plume Management bend into the flue assembly and rotate it to the direction required.
iii. Connect to the 93° bend the required Plume Management components as detailed and refer to Fig. 4.13.
Notes:
1. The wall support brackets must be used to secure the Plume Management pipework to the wall and
prevent disconnection of the 93° bend from the flue assembly or any other component.
2. Each joint must be secured with one of the screws provided to prevent accidental disconnection.
3. Ensure there is always a slight slope towards the flue assembly fitted in the wall and there is no part
of the plume management pipework where condensate/rain will collect and cause a blockage or any
restriction.
iv. Terminate the Plume Management pipework by fitting the terminal end section (push-fit) previously removed. Refer
to Fig. 4.13.
v. The Plume Management components available for extending the inner flue duct are as follows:-
Plume Management 93° bend 60 mm dia. (each 93° bend equivalent to 1.3 m flue length)
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
1
1
2
Fig. 4.12
Alpha InTec² 26E, 30CE and 35CE - Installation
21
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