Installation and Servicing
0051
Instructions
Alpha InTec
30C and 34C
Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing Combination 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
Alpha InTec 30C (NG) G.C. No. 47 532 48
Alpha InTec 34C (NG) G.C. No. 47 532 49
Alpha InTec 30C (LPG) G.C. No. 47 532 55
Alpha InTec 34C (LPG) G.C. No. 47 532 56
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. 1.038431 ST.001939/000
0515/D350
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 InTec 30C and 34C - Benchmark Scheme
2
CONTENTS
1 Introduction ........................................3
2 Technical data ...................................4
3 General boiler information .................10
4 Installation ......................................... 17
5 Commissioning ..................................25
6 Routine servicing ...............................29
8 Wiring diagrams ................................39
9 Error codes and fault finding..............41
10 Short parts list ...................................43
11 Energy classification ..........................44
Benchmark Checklist .........................50
Service record ................................... 51
7 Component replacement ...................32
1 INTRODUCTION
The Alpha InTec range of high efficiency condensing boilers are wall mounted, fan assisted room-sealed combination boilers.
The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve.
These are combination boilers providing both central heating and domestic hot water at mains pressure.
The boilers are supplied with a pump, pressure relief valve, expansion vessel and pressure gauge fully assembled and
tested. They are 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, i.e. 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 L1.
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 Flues
BS 5546: Installation of hot water supplies for domestic purposes
BS 6700: Design, installation, testing and maintenance of services supplying water
BS 6798: Installation of gas fired hot water boilers
BS 6891: Gas installation
BS 7593: Code of Practice for treatment of water in heating systems
BS 7671: Requirements for electrical installations, IEE Wiring Regulations
BS EN 12828 Heating systems in Buildings. Design for water based heating systems
BS EN 12831 Heating systems in Buildings. Method of calculation for design heat load
BS EN 14336 Heating systems in Buildings. Installation and commissioning of water based heating systems
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 IPX4D, i.e. 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 boiler installations are registered by the installer through the Gas Safe Gas Work Notification Scheme.
3. The boiler must only be used with Alpha CD condensing flue components.
NOTE: All models may be supplied ready for use with Propane (LPG) - Refer to Section 2.2 for data specific to Propane versions.
The boilers are designed for use with a fully pumped, sealed and pressurised heating system using only Propane gas.
In addition to the regulations and requirements stated in these installation and servicing instructions, the boiler must be
installed in accordance with BS 5482:1 - The Installation of Propane Burning Appliances in Permanent Dwellings.
Installation pipes, cylinders and pressure regulators should be fitted in accordance with BS5482:1. Bulk tank installations must
comply with the requirements of the Home Office code of practice for the storage of liquefied petroleum gas at fixed installations.
Propane boilers must not be installed in a room or internal space below ground level, e.g. in a basement or cellar, except
where at least one side is open to ground level.
Propane supply pipes must be capable of delivering the required quantity of gas in addition to the demand from any other
appliances in the house. The complete installation must be tested for gas soundness against leaks.
Propane boilers have been tested and factory set for use with Propane, it should only be necessary to ensure the correct
gas supply pressure of 37 mbar is available.
Alpha InTec 30C and 34C - Contents/Introduction
3
2 TECHNICAL DATA
2.1 TECHNICAL PERFORMANCE DATA - NATURAL GAS (Cat I2H 2H - G20 20 mbar)
InTec 30C InTec 34C
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
Heat output max. - DHW kW
Gas rate at max. output m³/h
Gas supply pressure mbar
Max. CH temperature °C
Gas burner injector diameter mm
Differential burner pressure - min. mbar
Differential burner pressure - CH mbar
Differential burner pressure - DHW mbar
DHW flow rate at 35°C rise l/min
DHW flow rate at 30°C rise l/min
Dry NOx weight mg/kWh
Dry NOx ppm
NOx Class
Factory set CO
at maximum CH output %
CO
2
at maximum DHW output %
CO
2
at minimum output %
CO
2
(± 0.25%)
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 %
32.7
27.1
29.5
24.4
26.3
23.6
4.8
29.0
31.7
3.12
20
82
6.8
0.15
2.34
3.65
12.0
14.0
30
17
5
9.45
9.45
8.6
19
200
0.003
90.0
88.2
88 (XL)
37.9
31.5
33.7
28.0
30.7
27.6
7.2
33.7
36.7
3.62
20
82
N/A
0.15
1.33
2.06
14.5
16.9
36
20
5
9.5
9.5
8.7
27
200
0.003
90.5
88.8
87 (XL)
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
Alpha InTec 30C and 34C - Technical Data
4
2.5
0.5
1.0
3.0
8.0
1.0
120
6
2.5
0.5
1.0
3.0
8.0
1.0
125
6
2.2 TECHNICAL PERFORMANCE DATA - PROPANE GAS (Cat I3P 3P - G31 - 37 mbar)
InTec 30C InTec 34C
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
Heat output max. - DHW kW
Gas rate at max. output l/h
Gas supply pressure mbar
Max. CH temperature °C
Gas burner injector diameter mm
Differential burner pressure - min. mbar
Differential burner pressure - CH mbar
Differential burner pressure - DHW mbar
DHW flow rate at 35°C rise l/min
DHW flow rate at 30°C rise l/min
Factory set max. CO
CO
maximum - CH output %
2
CO
maximum - DHW output %
2
CO
minimum output %
2
Maximum CO/CO
(± 0.5%)
2
Ratio
2
32.7
27.1
29.5
24.4
26.3
23.6
4.8
29.0
31.7
4.5
37
82
4.8
0.18
2.7
4.16
12.0
14.0
10.6
10.6
9.7
0.003
37.9
31.5
33.7
28.0
30.7
27.6
7.2
33.7
36.7
5.2
37
82
5.8
0.25
2.24
3.44
14.5
16.9
10.5
10.5
9.4
0.003
2.3 PHYSICAL DATA
Boiler flow and return connections mm
Relief valve connection 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
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
Factory fitted Filling loop
Factory fitted Seasonality valve
GasSaver compatible - Solar compatible
InTec 30C InTec 34C
22
15
15
22
720
440
300
150
250
235
150
5
450
110
39
42
12
14
60/100
Yes
Yes
Yes
22
15
15
22
720
440
300
150
250
235
150
5
450
110
41
44
12
14
60/100
Yes
Yes
Yes
Alpha InTec 30C and 34C - Technical Data
5
2.4 FLUE LENGTHS
CD Easy-Flue 500 mm with terminal and 90° bend. A CD Easy-Flue 1000 mm with terminal and 90° bend is also available.
CD 750 mm and 1000 mm flue extensions are available.
Length of Flue Required:-
Rear Flue = wall thickness + 160 mm (includes terminal). This is without back frame, add 45 mm if the wall jig is used.
Side Flue = wall thickness + distance between wall and side of boiler + 245 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.
2.5 PUMP OPERATION
The boiler is equipped with a variable speed low power consumption pump.
Pump display - See Fig. 2.1
Pump
1
2
1 Function selection button
2 Green (G) / Red (R) LED
3 Four yellow (Y) LEDs
3
Fig. 2.1
During normal operation the green LED (2) is on and the four yellow LEDs (3) indicate the power level according to the
following table:
Pump LEDs
G
On
Y
On
Y
Off
Y
Off
Y
Off
G
On
Y
On
Y
On
Y
Off
Y
Off
G
On
Y
On
Y
On
Y
On
Y
Off
G
On
Y
On
Y
On
Y
On
Y
On
Power consumption
Alpha InTec 30C and 34C - Technical Data
6
0 - 25 %
25 - 50 %
50 - 75 %
75 - 100 %
Pump function modes - To see the current operation mode press button (1) once.
The circulator has various built-in operation modes, however the operation mode should be selected according to the boiler model.
InTec 30-34C the default setting is constant curve speed 3.
The table below shows the possible mode settings.
G
Pump LEDs
G
On
Y
On
Y
On
Y
Off
Y
Off
G
On
Y
On
Y
On
Y
On
Y
Off
G
On
Y
On
Y
On
Y
On
Y
On
On
Y
On
Y
On
Y
Off
Y
On
Mode setting
Do not use
Constant curve
speed 2
Constant curve
speed 3 ( )default
Constant curve
speed 4
To change operation mode press and hold the button until the display flashes, the button can then be pressed sequentially to
scroll through the functions modes. When the required function is selected this mode will be stored and the display will revert
to show the current power level.
Pump function lock - The button has a feature that locks the setting to prevent accidental modification, to lock the pump
setting press button (1) for over 10 seconds (the current configuration flashes), the lock is confirmed by all LEDs on the
control panel flashing. To unlock the button press again over 10 seconds.
Pump By-pass - The boiler is supplied with by-pass fully opened. If necessary, the by-pass can be regulated to system
requirements from maximum (by-pass open) to minimum (by-pass closed). Adjust using a flat head screwdriver, turn
clockwise to open the by-pass; turn anti-clockwise to close it.
Pump fault display - In the event of malfunction the LEDs provide information on the pump operation status as shown in the
following table:
Pump LEDs
(first one red)
R
On
Y
Off
Y
Off
Y
Off
Y
On
Decription
Pump blocked
Diagnostics
The pump cannot restart
automatically due to an anomaly
Wait for pump to make automatic release
attempts or manually release motor shaft
using screw in centre of the head
If anomaly persists replace the pump
Remedy
R
On
Y
Off
Y
Off
Y
On
Y
Off
R
On
Y
Off
Y
On
Y
Off
Y
Off
Abnormal situation
(the pump continues to run)
Low power supply voltage
Electrical fault
(pump blocked)
Voltage out of range
The pump is locked due to
power supply too low or
serious malfunction
Check power supply
Check power supply, if anomaly persists
replace the pump
Alpha InTec 30C and 34C - Technical Data
7
230 V ~ 50 Hz CONNECTIONS LOW VOLTAGE CONNECTIONS ONLY
(optional Climatic or RF Climatic control)
External
probe
(optional)
Alpha
Climatic control
(optional)
DHW inlet
NTC sensor
(optional)
RF Climatic
control receiver
(optional)
RF Climatic
control (optional)
Low voltage terminal block
8 9 10
11 12
13
+
_
Room
thermostat
(optional)
Supply
230 V ~ 50 Hz
L N
1 2
Blue
G/Y
Brown
Link
Red
Mains terminal block
230 V ~ Control connections
WARNING
Ensure Control wires are
connected correctly - refer to the
control and boiler instructions for
connection details.
1 2 3
4
5
Blue
Brown
Red
Red
Not Used
Optional Alpha controls
Remove the link between 1 and 2 if the
optional Alpha Climatic control or 230 V
room thermostat is used.
2.6 ELECTRICAL CONNECTIONS
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.
Fig. 2.2
8
Alpha InTec 30C and 34C - Technical Data
2.7 BOILER SCHEMATIC
14
21
30
31
22
9
12
34
23
11
1
-
+
7
20
8
33
32
13
-
+
10
5
15
4
16
17
6
19
3
35
29
36
37
2
24
25
Gas
Condensate
discharge
1 - Heat exchanger thermal fuse
2 - DHW flow switch, filter and flow regulator
3 - Diverter valve
4 - Gas valve
5 - Primary temperature sensor
6 - DHW heat exchanger
7 - Main burner
8 - Primary/condensing heat exchanger
9 - Manual air vent
10 - Fan
11 - Pressure differential test points
12 - Flue hood
13 - Overheat thermostat
Domestic
hot water
outlet
Cold mains
water inlet
14 - Expansion vessel
15 - Automatic air vent
16 - Pump
17 - Drain point
18 - Pressure relief valve
19 - Primary pressure switch
20 - Ignition electrodes
21 - Flame sensing electrode
22 - DHW temperature sensor
23 - Flue sampling point
24 - Gas service cock
25 - Mains inlet on/off valve
26 - On/off valve (2 off)
Primary
Heating
return
27
18
28
26
Primary
Heating flow
27 - Automatic by-pass
28 - Cyclone separator (if applicable)
29 - Condensate trap
30 - Injector
31 - Venturi
32 - Venturi positive point
33 - Venturi negative point
34 - Flue temperature sensor
35 - Diverter valve motor
36 - Filling loop (if applicable)
37 - Flow regulator (if fitted)
Fig. 2.3
Alpha InTec 30C and 34C - Technical Data
9
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.
For horizontal flues ensure that the Easy-Flue outer duct is installed horizontally (please note that the Easy-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.
It is recommended that 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 Easy-Flue 500 mm (includes 90° bend and terminal) - Part No. 6.2000510.
CD Easy-Flue 1000 mm (includes 90° bend and terminal) - Part No. 6.2001010.
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 assembly. Refer to the separate installation instructions supplied with the assembly.
The following methods determine the correct length of flue required.
For rear exit flue (including terminal) L = B + 160 mm (205 mm if wall jig is used)
For side exit flue (including terminal) L = B + C + 245 mm (min. side clearance required is 5 mm)
For vertical flue L = H minus 1000 mm for vertical terminal assembly
Where L = Required flue length
B = Finished wall thickness
C = Distance from the inside wall to the side of the boiler
H = Distance from top of boiler side panel to roof position
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. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally
and only 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.
4. Further Plume management flue accessories are available - Refer to the Easy-Flue installation instructions.
10
Alpha InTec 30C and 34C - General Boiler Information
HORIZONTAL FLUE OPTIONS - Lmax = 12 metres
Not less than
300 mm
H
Not less than
300 mm
(245 mm length includes terminal)
L = B + C + 245 mm
C
B
B
F
E
L = B + E + F + 245 mm + (90° bend = 1.3 metre)
(add 45 mm to 'F' if a jig is used)
L = B + C + E + 245 mm
C
B
E
C
B
VERTICAL FLUE OPTIONS
L = B + C + 245 mm + (2 x 45° bends = 1.8 metre)
Not less than
300 mm
Not less than
300 mm
H
Hmax = 15 m Hmax = 13.2 m
Fig. 3.1
Alpha InTec 30C and 34C - General Boiler Information
11
3.5 FLUE TERMINAL LOCATION - Figs. 3.2 and 3.3
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. 3.2
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 InTec 30C and 34C - General Boiler Information
12
Proximity of flue duct outlets to boundaries
The flue duct shall be sited so that it is at least 600 mm (see Fig. 3.3) 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. 3.3
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 InTec 30C and 34C - General Boiler Information
13
3.7 CENTRAL HEATING SYSTEM - Fig. 3.4
The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS EN 12828 and BS 6798.
The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump
head, expansion vessel size, mean radiator temperature, etc. 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. 3.4. 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 relief valve - complying with BS 6759 and set to operate at 3 bar. The discharge pipe must be routed clear of the
boiler and terminated in such a manner that it can be seen, but cannot cause injury to persons or property.
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.
Cyclone - This is a device fitted in the heating return within the optional Premier Pack wall jig to remove any foreign or solid
matter etc. from the system.
Static head of system
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
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
Fig. 3.4
3.8 FILLING THE CENTRAL HEATING SYSTEM - Fig. 3.5
The system design pressure (cold) should be set to 1.0 bar. This pressure is equivalent to a static head (see Fig. 3.4) of 10.2
metres of water.
Provision must be made for filling the system. This is done by the use of a filling loop. See Fig. 3.5.
A filling loop is factory fitted to the InTec C models but must be supplied by the installer for X models.
Filling of the system must be carried out in a manner approved by the local Water Undertaking. Where allowed, the system
may be filled via a temporary connection as shown in Fig. 3.5. After filling, always disconnect the flexible hose of the filling
loop.
All fittings used in the system must be able to withstand pressures up to 3 bar.
Drain taps (to BS 2879) must be used to allow the system to be completely drained.
Heating circuit
return
Alpha InTec 30C and 34C - General Boiler Information
14
Stop
valve
temporarily connected
Fig. 3.5
Hose
unions
Filling loop
Double check
valve assembly
Test cock
Stop
valve
Mains
water
supply
3.9 FLUSHING THE HEATING SYSTEM
It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha InTec boiler. Failure to
do so will invalidate the warranty.
The primary condensing heat exchanger is constructed in stainless steel and therefore is compatible with most materials
used in a heating system.
If a cleaning agent and inhibitor are used, they must be applied in accordance with their manufacturers instructions. Only
products from Fernox and Sentinel are acceptable for use with the Alpha InTec boilers. Further information can be obtained
from Fernox (Tel: 0870 870 0362) or Sentinel (Tel: 0151 420 9563).
If the Cyclone is fitted in the heating return on the jig, the heating system should still be thoroughly flushed as detailed below.
The Cyclone collection point should be emptied via the drain point (see Fig. 4.5) after flushing has been completed.
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, primary heat exchanger and radiators.
b. Check for leaks.
c. Drain the system.
d. If required, 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. As required, add the recommended inhibitor to the system as instructed by the inhibitor manufacturer.
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 recommended cleaner manufacturer.
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 recommended cleaner manufacturer.
vi) Ensure the system is flushed to remove any remains of the cleaner and check for leaks.
c. As required, add the recommended inhibitor to the system as instructed by the inhibitor manufacturer.
3.10 DISPOSAL OF CONDENSATE
Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha InTec 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 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.
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. 3.6 and 3.7.
Note: All pipework must have a continuous fall (see Figs. 3.6 and 3.7) from the boiler and must be of an acid resistant
material such as plastic waste pipe. (copper or steel is not suitable).
It should be noted that the connection of a condensate pipe to a drain may be subject to local building control requirements.
Optional Condensate Trace Heating Kit
An optional Alpha InTec 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 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 and the boiler is on, the relay PCB is operated and voltage is supplied to the
trace heating wire causing it to heat up and prevent the condensate from freezing. When the outside temperature rises to
4°C or the boiler pump stops, the trace heater is switched off. The connection of the outside weather probe supplied with this
kit also enables the weather compensation feature on the boiler.
Alpha InTec 30C and 34C - General Boiler Information
15
Use waterproof
supported
pipework insulation
Plastic pipe
Minimum gradient 2½°
in very exposed
positions
Open end of pipe
diverted into gully
below grid but above
water level
Fig. 3.6 - External gully
22mm termination from boiler, increase to 32 mm if external
Cement mortar sealing
500 mm min.
O
2½ fall
100mm plastic tube
Ensure pipe is
adequately
Ground level (either/or)
25mm
300mm
Bottom of tube sealed
Soakaway depth 400mm
filled with limestone chippings
Two rows of 3 x 12mm
holes at 25mm centres,
50mm from the bottom
of the tube. Holes to face
away from house.
Fig. 3.7 - External soakaway
3.11 DOMESTIC HOT WATER SYSTEM
The minimum flow rate needed for the flow switch and burner to operate is 2.5 litres/min.
The incoming mains water pressure should be between 0.2 and 8 bar to ensure efficient operation. If the pressure is above 7
bar a pressure reducing valve 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.
Seasonality valve - This valve maintains the hot water temperature (factory set) for both summer and winter conditions by
automatically changing the flow rate through the boiler. However, if adjustment of the setting is required, refer to Section
5.6.2.
Alpha InTec 30C and 34C - General Boiler Information
16
4 INSTALLATION
Template
Outline of
boiler
Wall
mounting
bracket
fixing holes
Wall jig
fixing holes
140 mm
(185 mm if wall jig used)
Ensure line is level
Rear exit hole
110 mm dia.
Position of
110 mm hole
to be cut for
side exit flue
145 mm
=
=
440 mm5 mm
5 mm
Boiler
Minimum clearances
150 mm
(250 mm with Premier pack)
235 mm - Can be reduced to
150 mm when using a
vertical flue
300 mm (345 mm if wall jig used)
4.1 UNPACKING
1. The boxes required when the boiler is installed with a horizontal flue are as follows:-
Box 1.............................. Cased boiler fitted with water and gas valves, union bends and washers
Mounting bracket plus screws and wall plugs
Condensate discharge pipe
Literature pack and Wall template
Box 2 .................................CD Easy-Flue 500 mm or CD Easy-Flue 1000 mm. Both include 90° bend and horizontal flue terminal
Note: NOT required for vertical flue
Notes: a. All flues must be suitable for InTec condensing boilers.
b. CD 750 mm and 1000 mm flue extensions are available, if required.
Box 3 (if applicable) ....... Premier Pack includes: wall mounting jig with template, cyclone, bottom tray, earth bonding plate,
spacers, pressure relief pipe terminal, split flow and return union bends, screw pack and fitting
instructions.
2. Unpack boiler and remove the loose items, packs and mounting bracket.
Note: The boiler can be stood in an upright position, (to allow this, the union bends have been turned upwards so that
they do not protrude beneath the bottom - check this before standing the boiler upright). It is recommended that two
persons lift the boiler
4.2 CLEARANCES REQUIRED - Fig. 4.1
4.3 PREPARE THE WALL - Fig. 4.2
If the optional wall jig is used refer to the
instructions supplied with the kit.
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 or, if applicable the wall jig fixings.
If rear exit flue is used, mark the position of
the hole for the flue.
The wall jig is supplied with a pressure
relief valve discharge pipe for use when
the boiler is mounted on an external wall
where the outside is inaccessible, if you
wish to use this pipe - mark it's position.
3. Side exit flue - Continue the horizontal centre
line of the flue across the wall to the side
wall, then along the side wall 140 mm, 185
mm if the wall jig is used (ensure the lines
are horizontal). This will give the position of
the centre of the hole for the flue.
720 mm
Minimum
clearance
of 450 mm
from front
of boiler
Fig. 4.1
Fig. 4.2
Alpha InTec 30C and 34C - Installation
17
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 collar supplied, cut a 130 mm dia. flue hole using a 127 mm
core drill.
5. Drill the fixing holes (10 mm dia.) to accept the No.10 plugs supplied. Using the screws supplied, fit the mounting bracket
or wall jig if used. If applicable drill a 22 mm dia. hole for the pressure relief valve discharge pipe terminal supplied with
the jig.
IMPORTANT: If the wall jig is used, follow the instructions supplied with the Premier Pack to fit the jig,
mount the boiler and connect the pipework.
Pour water into flue duct
4.4 FIT THE BOILER - Refer to Figs. 4.2 and 4.3
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.
Location for
wall mounting
bracket on
rear of boiler
Always grip the boiler firmly, and before lifting feel where the weight is concentrated
to establish the centre of gravity, repositioning yourself as necessary.
4.5 CONNECT THE PIPEWORK - Fig. 4.4 or 4.5
1. Thoroughly flush out all the water pipework. Refer to Section 3.9.
2. The valves/fittings have been factory fitted, however, check that all the
connections underneath the boiler have been tightened, especially the
union bends.
Note: If applicable the heating union bends supplied with the wall jig have
been designed to enable the heating pipes to be routed from above and/or below using the same fitting.
Note: When soldering to the boiler union bends, ensure the bends are not connected to the valves, otherwise the
internal seals may be damaged.
3. Connect the system pipework to the boiler. One metre of copper pipe must be fitted to the boiler before connecting to
any plastic pipework.
Note: Do not forget that the pressure relief valve discharge pipe must be routed clear of the boiler to a drain in such a
manner that it may be seen, but cannot cause injury to persons or property.
4. Connect the 22 mm condensate trap drain pipe to the condensate discharge pipe using the clip supplied.
Ensure that the condensate discharge pipe is as required in Section 3.10.
Pour at least 0.5 litre of water into the flue duct, as shown in Fig. 4.3, and check the condensate discharge pipe for
soundness.
5. Ensure that all the valves are closed (spindle flats at right angles to valve) and do not turn on the water or gas supplies at
this stage.
Fig. 4.3 - rear of boiler
Seasonality valve
Filling
loop
Condensate
trap
Condensate
discharge
pipe
20
65 70 45705895
C B FD
C models
A - Heating flow (22 mm)
B - Hot water outlet (15 mm)
Alpha InTec 30C and 34C - Installation
18
Filling loop taps
37
E
C - Gas inlet (22 mm)
D - Cold water mains inlet (15 mm)
Cold water
inlet filter
Heating return
valve
Heating flow
valve
Heating drain
point
23
A
Condensate discharge pipe
20
65 70 45705895
Fig. 4.4 - Without wall jig
Condensate trap
C B FD
X models
E - Heating return (22 mm)
F - Pressure relief valve (15 mm)
Cold water
inlet filter
Heating return
valve
Heating flow
valve
Heating drain
point
23
37
A
E
Seasonality valve
Filling
loop
Condensate
trap
Condensate
discharge
pipe
20
65 70 45705895
C B FD
A - Heating flow (22 mm)
B - Hot water outlet (15 mm)
Filling loop taps
C models
Cold water
inlet filter
Heating return
valves
Heating flow
valve
Heating drain
point
Cyclone drain
point
Wall jig
23
37
A
E
C - Gas inlet (22 mm)
D - Cold water mains inlet (15 mm)
Condensate discharge pipe
Condensate trap
20
65 70 45705895
C B FD
X models
E - Heating return (22 mm)
F - Pressure relief valve (15 mm)
37
A
E
Fig. 4.5 - With wall jig
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.
Cold water
inlet filter
Heating return
valves
Heating flow
valve
Heating drain
point
Cyclone drain
point
Wall jig
23
(B + C)
B (mm)
Max
525
970
Min
300
760
CD Easy-Flue
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
500 mm
1000 mm
Fig. 4.7
B + C (mm)
Max
Min
440
215
885
675
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 InTec 30C and 34C - Installation
19
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.
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
140 (185 if wall jig used)
Fig. 4.9 - Rear flue
4.7 REDUCING THE FLUE - Fig. 4.10
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.
Alpha InTec 30C and 34C - Installation
20
Allow 20 mm 30 mm
Do not cut past this point
Fig. 4.10
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:-
11.885 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:
120
20
Terminal
Flue sealing
collar
CD Easy-Flue
Ensure outer flue duct of Easy-Flue is horizontal
Inner seal joint
Flue length (L)
Fig. 4.12 - Side flue
Extension clamp
Inner seal joint
CD Flue extension
Alpha InTec 30C and 34C - Installation
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
21
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. 4.12.
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. 4.13) securing the terminal and remove the terminal by pulling it from the flue
assembly. Remove the screw (2 in Fig. 4.13) 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. 4.14.
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. 4.14.
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. 4.13
Alpha InTec 30C and 34C - Installation
22
Terminal end section
from CD Easy-Flue
Min.
400 mm
C
Terminal end section
from CD Easy-Flue
Note:
1. Ensure each joint is
secured with the screw
supplied.
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.
C
Terminal end section
from CD Easy-Flue
PM length = C + (2 x 93° bend = 2.6 m) + (2 x 45° bends = 1.8 m)
Flue sealing collar
CD Easy-Flue
PM length = C + (1 x 93° bend = 1.3 m) + (2 x 45° bends = 1.8 m)
Ensure there is a slope of approximately
3° back towards the Easy-Flue
PM length = C + (4 x 93° bend = 5.2 m)
Fig. 4.14
Note: The equivalent horizontal flue assembly length + the equivalent plume management length (PM length) must not
exceed the maximum flue length stated for each boiler, i.e.
Alpha InTec boiler maximum equivalent flue length must not exceed 12 metres.
C
Alpha InTec 30C and 34C - Installation
23
4.10 CONNECT THE MAINS SUPPLY - Fig. 4.15
1. Gain access to the boiler terminal block by releasing the
Terminal block cover
two fixing screws (one each side) securing the control
panel and lowering the panel. Refer to Technical Data,
Section 2.6 for connection details.
2. Note: This boiler has been fitted with a mains supply cable.
However, if it is necessary to fit an alternative supply cable,
ensure the cable clamp that has been fitted is removed
and connect as follows:-
Mains terminal strip
Remove link 1 to 2
when connecting
external controls
Remove the three screws securing the terminal block
cover from the back of the control box (see Fig. 4.15).
Pass the mains supply cable through the cable clamp
and connect as follows:- Brown to L, Blue to N and
Green/Yellow to
. Ensure correct polarity.
Note: Ensure that the length of the earth wire is such
Relay board
(optional)
that if the supply cable is pulled out of its clamp the live
and neutral wires become taut before the earth wire.
Rear of control panel
The main terminal block can be removed by pulling it off
the pins to give easy access to the terminals.
Do not switch on the electrical supply at this stage.
Fig. 4.15
3. If an external control, i.e. room thermostat or external clock is to be fitted, remove the terminal block cover and remove
the link between terminals 1 and 2. Pass the cable through the cable clamp and connect it to terminals 1 and 2. Replace
the terminal block cover. (Refer to Section 2.6).
4. Replace the terminal block, ensuring it is located correctly on the plastic pins and replace the cover.
5. Ensure that there is sufficient free cable to allow the control panel to be raised and lowered then tighten the cable clamp
screws.
6. Leave the control panel open until commissioning procedures have been completed.
7. Carry out electrical system checks - Short circuit, Polarity, Earth continuity and Resistance to earth with a suitable multimeter.
Grommets
Cable clamps
4.11 FIT ALPHA CONTROLS (standard 240 V clock option) - Fig. 4.16
Ensure the electrical supply to the boiler is isolated.
Important: Only use the Alpha single channel controls. Do not fit any two channel controls.
1. Remove the three screws securing the terminal block cover at the rear of the control panel.
2. Remove and discard the blanking panel.
3. Insert the control into the opening and secure in place with the three screws supplied.
4. Remove the terminal block cover.
5. Disconnect the control wiring from the terminal block and connect it to the control as follows:-
Blue wire to terminal 1, Brown wire to terminal 2 and Red wires to terminals 3 and 4, (or as per the instructions supplied
with the control). Ensure wiring is correct.
6. Replace the terminal block cover. Do not overtighten the fixing screws.
7. Leave the control panel open until commissioning procedures have been completed.
Terminal block cover
Remove link 1 to 2
when connecting
external controls
Control fixing screws
Grommets
Cable clamps
Alpha InTec 30C and 34C - Installation
24
Relay board
(optional)
Rear of control panel
Fig. 4.16
5 COMMISSIONING
When commissioning the boiler, ensure the Benchmark Checklist at the back of these instructions is completed.
5.1 FILL THE SYSTEM
1. The boiler is fitted with an automatic air vent positioned on the pump (see Fig. 7.5), ensure that the vent is always open.
2. Open the central heating flow and return valves (vertical slot in-line with valve) (see Fig. 4.4 or 4.5).
3. Open the fill point valves on the filling loop until water is heard to flow.
4. To remove the air - Vent each radiator in turn, starting with the lowest in the system.
5. Vent air from the primary heat exchanger via the manual vent at the top left hand side (see Fig. 5.4).
6. Check the operation of the pressure relief valve (see Fig. 7.5) by turning the head anti-clockwise until it clicks. The click
is the valve lifting off its seat allowing water to escape from the system - check that this is actually happening.
7. Continue to fill the system until the pressure gauge indicates 1.0 bar. Close the fill point valve and check the system for
water soundness, rectifying where necessary. Disconnect the filling loop from the mains supply.
Water may be released from the system by manually opening the drain point (see Fig. 7.5) until the system design
pressure is obtained. The system design pressure (cold) should be between 0.75 and 1.25 bar.
Refer to Sections 3.8 and 3.9. Filling and Flushing the system.
8. Open the cold water mains inlet valve (see Fig. 4.4 or 4.5). Turn on all hot water taps and allow water to flow until no air
is present. Turn off taps.
9. Ensure that the condensate trap has been filled with water. Refer to Section 4.5, paragraph 4.
5.2 BOILER CONTROLS - Fig. 5.1
5 6
4
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
3
RESET
RESET
°C
bar
x100rpm
BOOST
INFO
12
1.5
1
0.5
0
CORRECT PRESSURE
WHEN COLD
721
2
2.5
3
bar
3.5
4
8 9 10
RESET
BOOST
11 12
°C
bar
x100rpm
13
14
151617181920
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
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)
error codes
15 Boiler in Stand-by mode
Fig. 5.1
5.3 TEST FOR GAS TIGHTNESS AND PURGE THE SUPPLY
1. With the boiler connected, pressure test the gas supply and inlet pipework connected to the boiler for tightness in
accordance with BS 6891.
2. Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 5.2) and purge in accordance with BS 6891.
3. Retighten the test point screw and test for gas tightness. Close the boiler gas service cock.
Alpha InTec 30C and 34C - Commissioning
25
5.4 INITIAL LIGHTING - Refer to Fig. 5.1
1. Before turning on the gas and electrical supplies check the heating system is filled to the correct pressure. Refer to
Section 5.1 Fill the System. The pressure gauge on the right of the control panel indicates the heating system pressure.
When the boiler is cold the needle should be within the green band.
2. With the gas and electrical supplies to the boiler off, ensure that the mains water inlet valve and the central heating flow
and return valves are open.
3. Turn on the gas and electrical supplies to the boiler.
When the electricity supply is turned on, the boiler will automatically go through a system purging cycle for 8 minutes
counting down from 96 on the display. This can be interrupted by pressing the RESET button (item 3 in Fig. 5.1). It is
recommended that this cycle is allowed to complete when first lighting the boiler to help remove air from the system.
After this the boiler will be in either Standby or On mode, the On-Off/Standby button (item 1 in Fig. 5.1) is used to scroll
between these modes or press and hold it in to turn the boiler off.
Note: This does not isolate the electricity supply to the boiler.
4. Ensure all external controls are calling for heat.
If the optional controls are fitted, refer to the instructions supplied, and ensure they are in an 'on' mode.
5. Press the Summer/Winter button (item 2 in Fig. 5.1) to select either summer (
Summer (
and the heating will not function even if requested by any controls. The desired hot water temperature can be set using
the hot water selector switch (item 5 in Fig. 5.1) on the control panel, when the tap is open the display will indicate the
actual primary flow temperature (item 14 in Fig. 5.1).
Winter (
fitted. The boiler will always prioritise hot water when any hot outlet tap is opened. The heating will activate depending
on the request from any external controls fitted. The domestic hot water (item 5 in Fig. 5.1) and central heating (item
6 in Fig. 5.1) selector switches on the control panel can then be turned to the required set temperatures shown on the
display. The display will then display the actual primary flow temperature (item 14 in Fig. 5.1) when operating in heating
or hot water.
Note: If a weather compensation probe is fitted a gradient 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. Refer to
external probe instructions for further information on this feature.
6. From this moment the boiler functions automatically. With no demand for heat (central heating or domestic hot water
production) the boiler goes to “standby” function.
Each time the burner ignites, the flame present symbol (item 10 in Fig. 5.1) is displayed together with the relative
strength of the flame.
For any controls fitted please refer to the instructions supplied with the controls for connection and operation details.
): In this mode the boiler will only fire when hot water is requested through opening a hot water outlet tap
): In this mode the boiler will function in heating and hot water depending on the request from any controls
) or winter ( ) mode.
5.5 BOILER OPERATION
Domestic hot water supply always takes priority over central heating. If a demand for hot water is required during a central
heating period, the boiler will automatically switch to the hot water mode until the demand is satisfied. This interruption in the
central heating is only when the demand for hot water is present and should not be noticed by the User.
Central heating mode
If there is a call for heat, the pump will start to circulate the central heating water. The fan will run and the pre-mix burner will
light. The burner output then automatically adjusts to suit the system demand; as the temperature of the water in the boiler
approaches that set by the adjustable temperature thermostat, the burner output is reduced. When the set temperature is
reached, the burner is turned off. The fan continues to run for 30 seconds and the pump continues to run for three minutes,
after which the burner can relight if required. If the primary sensor has not registered the pre-set temperature but the room
thermostat is satisfied the burner is turned off. The fan continues to run for 30 seconds and the pump continues to run for 10
seconds. In this instance there is no delay before the burner will relight.
If there is a demand for DHW during the burner delay, the boiler will operate to provide DHW until the tap is closed; the boiler
will then immediately revert to provide CH if there is a demand.
Note: If the system pressure is very low, the primary pressure switch will prevent the boiler from operating.
Domestic hot water mode
When a demand for hot water (by opening a hot tap, etc.) is sensed by the flow switch, the pump starts and the burner
lights, increasing immediately to its maximum output. Water in the boiler is then diverted from the central heating system
to the domestic hot water heat exchanger, heating the incoming mains water. The burner output is varied to maintain the
temperature of the hot water as that set by the adjustable temperature selector. When the flow switch senses that hot water
is no longer required the burner is turned off and the boiler immediately returns to the central heating mode.
If the selector is set for hot water only - The burner is turned off, the fan will continue to run for 50 seconds and the pump will
stop immediately.
In both modes the fan modulates according to the output required.
Alpha InTec 30C and 34C - Commissioning
26
Max. CO
adjustment
2
Outlet
pressure
test point
Inlet
pressure
test point
Min. CO
adjustment
(under cap)
2
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.
Any other pipework outside of the boiler must be protected from the risk of freezing and insulated. Additional protection from
an external frost thermostat and pipe thermostats should be considered.
Pump Cycle
If the electrical supply is on and the boiler has not operated for 24 hours in heating or hot water, the pump will operate
automatically for thirty seconds every 24 hours.
5.6 CHECK THE BURNER PRESSURES AND COMBUSTION - Figs. 5.2 and 5.3
Press and hold in the reset button for eight seconds and the boiler will fire at a fixed output depending on the position of the
boiler central heating thermostat knob.
Turn the boiler central heating thermostat to maximum to check the maximum central heating burner pressure.
With the boiler central heating thermostat set to maximum fully open a hot tap to check the maximum domestic hot water
burner pressure. In this mode the inlet gas supply pressure and CO/CO
Refer to Technical Data, Section 2.1 and 2.2 for the required differential burner pressure values.
Note: The burner pressure settings have been factory set and should not require adjusting.
Combustion testing must be carried out by a competent person using a calibrated analyser conforming to BS EN 50379 part 3.
ratio can be checked.
2
-
+
Fig. 5.2
5.7 FINAL COMMISSIONING
1. Allow the heating system to heat up, then balance the system to achieve the necessary temperature difference across
the heating flow and return pipes at the boiler and check the system volume and pressure. (Refer to Technical Data,
Sections 2.1, 2.2 and 2.3).
2. Seasonality valve - The valve can be adjusted to the User's requirements, i.e. to the required temperature of hot water
from the tap. This is achieved by fully opening a hot water tap and turning the adjusting screw (refer to Fig. 4.4) with a
screwdriver. Anticlockwise to increase the temperature and clockwise to decrease.
3. Turn off the boiler.
4. Thoroughly flush out the water pipework (refer to Section 3.9) and with no pressure in the boiler heating circuit, empty the
cyclone (if applicable) at it's drain point (see Fig. 4.4 or 4.5) of any debris. Clean the mains water inlet filter (see Fig. 4.4
or 4.5).
5. Re-pressurise the system as described in Section 5.1.
P1P2
-
+
Fig. 5.3
Alpha InTec 30C and 34C - Commissioning
27
5.8 FINAL ASSEMBLY
1. Raise the control panel and secure in position with the screws provided.
Note: If the wall jig is used, fit the bottom tray over the base of the boiler.
2. If the boiler is to be left in service with the User, set the controls, clock (if fitted, see User's Operating manual) and room
thermostat (if fitted) to the User's requirements.
3. If the boiler is not to be handed over immediately, close the boiler gas service cock and switch off the electrical supply.
4. If there is any possibility of the boiler being left during frost conditions, then the boiler and system should be drained
(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.
5. Complete the details of the installation in the Benchmark Checklist at the back of these instructions.
5.9 USER INFORMATION
The User must be advised (and demonstrated if necessary) of the following important points:-
1. How to light and turn off the boiler and how to operate the system controls.
2. The importance of annual servicing of the boiler to ensure safe and efficient operation.
3. That any servicing or replacement of parts must only be carried out by a Gas Safe registered engineer.
4. Ensure that the boiler controls and room thermostat (if fitted) are set to the User's requirements.
5. Tell the User about the sealed system pressure.
6. Tell the User that if the electrical supply is on and the boiler has not operated for 24 hours for heating or hot water, the
pump will automatically operate for 30 seconds.
7. Explain to the User that an internal frost thermostat is fitted in the boiler, and that the electrical supply to the boiler must
be left on for the thermostat to operate, i.e. the boiler must be set to standby.
8. Explain to the User that in certain weather conditions the terminal will emit a plume of steam, i.e. water vapour. This is
safe and quite normal.
9. 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.
Note: It is a requirement that the installation is registered by the installer through the Gas Safe Gas Work Notification
Scheme.
12. Leave these Installation and Servicing instructions with the User for use on future calls.
5.10 INFORMATION MENU
By pressing the info button (item 4 in Fig. 5.1) the information menu is accessed, this will then show the information
according to the table below.
Info Menu
(d - prefix)
d0
d1
d2
d3
d4
d5
d6
d7
d8
d9
Information
Not used
Flame signal
Central heating water temperature leaving the boiler
Domestic hot water temperature leaving the boiler
Central heating set point temperature
Domestic hot water set point temperature
External weather compensation probe temperature (value flashes if negative)
Mains inlet temperature or FlowSmart cylinder temperature (if sensor fitted)
Not used
Fault history - by rotating the CH knob (item 6 in Fig. 5.1) in this menu the last five faults will be displayed
mA x 10 (approx)
Error code
Units
Shown
°C
°C
°C
°C
°C
°C
Alpha InTec 30C and 34C - Commissioning
28
6 ROUTINE SERVICING
To ensure efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals.
The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year
should be adequate.
It is the law that any service work must be carried out by a competent person, i.e. Gas Safe registered personnel.
Warning: Before servicing the boiler, isolate the electrical supply and close the boiler gas service cock. Allow the boiler to cool.
The data label is positioned on the inside of the left hand side panel.
Always test for gas tightness after servicing any gas carrying components.
Always carry out electrical system checks i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable
meter before and after servicing.
General
Please Note: During routine servicing, and after any maintenance or change of part of the combustion circuit, the following
must be checked:
1. The integrity of the flue system and the flue seals, as described in Section 4.6 and 4.7.
2. The integrity of the boiler combustion circuit and relevant seals.
3. The operational (working) gas inlet pressure at maximum rate, as described in Section 5.6.
4. The combustion performance, as described below.
Competence to carry out the check of combustion performance
Please Note: BS 6798:2009 Specification for installation and maintenance of gas-fired boilers of rated input not exceeding
70 kW net advises that:
1. The person carrying out a combustion measurement should have been assessed as competent in the use of a
flue analyser and the interpretation of the results.
2. The flue gas analyser used should be one meeting the requirements of BS 7927 or BS-EN 50379-3 and be
calibrated in accordance with the analyser manufacturers' requirements.
3. Competence can be demonstrated by satisfactory completion of the CPA1ACS assessment, which covers the use
of electronic portable combustion gas analysers in accordance with BS 7967, Parts 1 to 4.
Combustion check
Connect the flue gas analyser to the flue gas sampling point as shown in Fig. 6.1.
Notes: 1. Prior to servicing, it is recommended that a flue gas analyser is used to measure the performance of the boiler
(refer to Fig. 6.1 for the position of the flue sampling point). If the CO/CO
or when other checks and comments from the customer have indicated that there may be problems, cleaning of
the heat exchanger will be necessary. All Sections 6.1, 6.2, 6.3 and 6.4 must be carried out. Repeat the flue gas
analyser test after reassembling the boiler and check that the CO/CO2 ratio is less than 0.003.
If the CO/CO
ratio reading of below 0.003.
ratio reading is still above, then you must repeat Sections 6.1, 6.2, 6.3 and 6.4 until you obtain a
2
If the combustion reading is greater than the acceptable value AND the integrity of the complete flue
system and combustion circuit seals have been verified and the inlet gas pressure (and gas rate) have
been verified. Please call our Technical Helpline.
2. If the CO/CO
there are no problems then only Section 6.1 and Section 6.2 paragraphs 1, 2 and 3 need to be carried out to
ratio measured is less than 0.003 and other checks and comments from the customer suggest
2
allow a visual check of the components within the room sealed chamber.
3. If a flue gas analyser is not available, then all Sections 6.1, 6.2, 6.3 and 6.4 must be carried out.
ratio measured is greater than 0.003
2
6.1 IMPORTANT NOTES PRIOR TO SERVICING
1. Check the entire flue length and joints including the flue terminal outside. Ensure that all of the flue assembly has been
installed correctly and there are no blockages.
2. Run the boiler and check the operation of its controls.
3. Refer to Fig. 6.1 for location of flue sampling point.
4. Ensure that all system connections and fittings are sound. Remake any joints and check the tightness of any fittings that
may be leaking.
5. Refill, vent and re-pressurise the system as necessary. (Refer to Commissioning, Section 5.1).
If the system pressure exceeds 2.5 bar when operating at maximum temperature, the heating expansion vessel should
be checked and re-pressurised, if necessary.
Note: 1. Check the expansion vessel charge only when the system pressure is zero.
2. The expansion vessel pressure test point is accessible from inside the boiler at the front.
6. Check that the condensate trap drain pipe is connected and all joints are sound.
7. Record details of the service in the Service Record at the back of these instructions.
Alpha InTec 30C and 34C - Routine Servicing
29
Front case locating pins
Front case fixing screws
Four nuts and washers and
four screws securing combustion
chamber front assembly
Combustion chamber
front assembly
Flame sensing
electrode
Expansion vessel
test/fill point
Gas pipe union
Fan assembly
Fan assembly
fixing screws
Manual air vent
Flue gas
sampling point
Viewing window
Air supply pipe
Air supply pipe
fixing screw
Ignition generator
Pressure tube
connections
Air supply pipe
fixing screw
Fig. 6.1
6.2 PREPARE FOR SERVICING - Fig. 6.1
1. Ensure the electrical supply is isolated and the gas supply is off.
2. Release the two screws securing the control panel and lower the panel.
3. Remove the four screws securing the front case. Lift the case up and forwards to remove.
4. Disconnect the gas supply pipe union from the manifold.
5. Remove the two screws securing the air supply pipe and remove the pipe.
6. Remove the two screws securing the fan assembly to the combustion chamber front.
7. Remove the two pressure tubes, noting their positions.
8. Disconnect the electrode lead from the ignition generator and the in-line connector to the flame sensing electrode.
9. Remove the four nuts and washers and four screws securing the combustion chamber front assembly and remove the
assembly.
6.3 CLEANING THE BOILER
1. Remove any deposits from heat exchanger using a suitable soft brush. Do not use a brush with metallic bristles.
2. Check the condition of the combustion chamber insulation panels. Any damaged panels must be replaced. (Refer to
Component Replacement, Section 7.19).
3. Check the condition of the burner injector on the combustion chamber front assembly, carefully clean them with a soft
brush if necessary - Do not use a brush with metallic bristles as this might damage the injector.
4. Remove any deposits from the heat exchanger coils. This can be done by suction or water sprayed onto the coils.
Ensure all electrical components are protected from water. Any water used to clean the heat exchanger will drain to the
condensate trap.
5. Unscrew and replace the injector should it appear damaged.
6. Remove the four screws securing the burner (see Fig. 6.2) and remove the burner. Clean the burner with a soft brush
and check that the flame ports are clear. Blockages may be removed with a stiffer brush. Tap the burner, open end
down, to remove any deposits from inside.
7. Check the condition of the electrodes.
8. Check the spark gap, positioning and height of the electrodes, see Fig. 6.2.
9. Unscrew the condensate trap drain cap to remove any deposits.
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 30C and 34C - Routine Servicing
30
Front panel insulation
Combustion chamber
front assembly
Electrode gap
3 - 4 mm
Ignition electrodes
Burner
Burner to electrode
gap 6 mm
Flame sensing
electrode
Fig. 6.2
6.4 RE-ASSEMBLE THE BOILER
1. 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. This is to ensure the condensate trap is full of water before operating the boiler.
2. Replace the combustion chamber front assembly, ensuring it is correctly located.
3. Re-connect gas pipe union, reconnect the electrode leads and refit the air supply pipe.
4. Test the connections for gas tightness and re-commission, Sections 5.3 and 5.7.
5. Place the front case panel in position and secure in position with the four screws previously removed, see Fig. 6.2.
6. Raise the control panel and secure in position with the two screws provided.
7. Check the operation of the boiler. (Refer to Sections 5.4 and 5.5).
8. Return all controls to their original settings.
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.
Alpha InTec 30C and 34C - Routine Servicing
31
7 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.
Always test for gas tightness after replacing any gas carrying components or disturbing any gas connections.
Always carry out electrical system checks i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable
meter after servicing.
Check the operation of the boiler. (Refer to Sections 5.4 and 5.5).
Ensure that all the controls are returned to their original settings.
The replacement of components in Sections 7.3 to 7.18 does not require draining of the boiler.
7.1 GENERAL ACCESS - Fig. 6.1
Ensure the electrical supply is isolated and the gas supply is off.
1. If access is required behind the control panel - Lower the control cover flap (not X models) and release the two control
panel fixing screws (one each side) and lower the panel.
2. To gain access behind the casing - When the control panel is lowered, it exposes four fixing screws that secure the front
cover. Remove these screws and lift the front cover off its locating pins at the top of the boiler.
3. To gain access to the control panel components/PCB - Remove the five screws securing the rear cover and
carefully raise the cover. When replacing the cover, ensure no wires are trapped and all wiring is secured. Secure with
five screws - do not overtighten.
7.2 DRAINING THE BOILER - Figs. 2.3, 4.4 or 4.5
Isolate the electricity supply and close the boiler gas service cock, see Fig. 13. Allow the boiler to cool.
1. Heating circuit
Close the central heating flow and return valves, see Fig. 4.4 or 4.5.
Connect a suitable pipe to the drain point, see Figs. 4.4 or 4.5 and 7.5 and route it to a suitable container. Open the
drain point.
2. Hot water circuit
Close the mains water inlet valve, see Fig. 4.4 or 4.5.
Open any hot tap below the level of the boiler to allow as much draining as possible.
Note: Some water will remain in the components and care must be taken when removing them.
7.3 ELECTRODES - Fig. 7.1
Gain access behind the room sealed chamber panel as in Section 7.1.
1. Ignition electrode and lead
Remove the two screws securing the air inlet pipe and remove the pipe.
Disconnect the lead from the ignition generator, noting its position.
Remove the two screws securing the electrode to the front of the combustion chamber and carefully withdraw the electrode.
2. Flame sensing electrode and lead
Disconnect the flame sensing electrode in-line connector.
Remove the two screws securing the electrode to the front of the combustion chamber and carefully withdraw the electrode.
Re-assemble in reverse order
7.4 MAIN BURNER - Fig. 6.2
1. Remove the burner assembly as described in Routine Servicing, Section 6.2.
2. Remove the four screws securing the burner to the combustion chamber front assembly.
3. Re-assemble with a new burner as described in Routine Servicing, Section 6.4.
7.5 BURNER INJECTOR - Fig. 6.1
1. Gain access to the room sealed chamber as described in Section 7.1.
2. Undo the gas pipe union to the combustion chamber front to gain access.
3. Unscrew the damaged injector and screw in a replacement.
4. Re-assemble in reverse order.
Alpha InTec 30C and 34C - Component Replacement
32
7.6 FAN - Fig. 6.1
1. Gain access behind the room sealed chamber as described in Section 7.1.
2. Remove the two screws securing the air supply pipe (see Fig. 6.1) and remove the pipe.
3. Unplug the fan plug and remove the two screws securing the fan to the combustion chamber front (see Fig. 6.1).
4. Withdraw the fan to the right of the boiler - this can be made easier if the right hand side panel is removed.
5. Remove the air inlet elbow from the old fan and fit it to the new one.
6. Re-assemble in reverse order ensuring that the pressure tubes are connected correctly.
7. Test the boiler as described in Routine Servicing, Section 6.4 paragraphs 5 to 9.
Expansion vessel
Flue temperature
sensor
Heat exchanger
thermal fuse
Ignition electrodes
Flame sensing
electrode
Overheat thermostat
Ignition generator
Fan assembly
Primary temperature
sensor
Gas valve
Fig. 7.1
7.7 IGNITION GENERATOR - Fig. 7.1
1. Gain access behind the front panel as described in Section 7.1.
2. Remove the screw securing the air supply pipe (see Fig. 6.1) and remove the pipe.
3. Disconnect all the wires from the ignition generator.
4. Loosen the two screws securing the generator - slide it downwards to remove.
4. Slide the new generator in position, tighten the screws and re-connect the wires.
5. Re-assemble in reverse order.
7.8 OVERHEAT THERMOSTAT - Fig. 7.1
1. Gain access behind the front panel as described in Section 7.1.
2. Disconnect the wiring from the overheat thermostat.
3. Remove the two screws securing the overheat thermostat and remove it from the flow pipe.
4. Fit the new overheat thermostat and re-assemble in reverse order.
7.9 FLUE TEMPERATURE SENSOR - Fig. 7.1
1. Gain access behind the front panel as described in Section 7.1.
2. Disconnect the wiring.
3. Using a 13 mm spanner, turn the sensor 90° anti-clockwise and withdraw it from the heat exchanger.
4. Fit the new sensor and re-assemble in reverse order.
Alpha InTec 30C and 34C - Component Replacement
33
7.10 GAS VALVE - Fig. 7.1
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.
1. Gain access behind the front casing as in Section 7.1.
2. Disconnect the positive pressure tube from the gas valve.
3. Disconnect the electrical plug.
4. Disconnect the burner manifold pipe union and the gas inlet pipe union.
5. Remove the two screws from beneath the boiler and lift out the valve assembly.
6. Fit the new assembly and re-assemble in reverse order and test for gas tightness.
7. Light the boiler. (Refer to Commissioning, Section 5.4) and adjust the gas valve as described in the instructions supplied
with the replacement valve.
8. Complete re-assembly as described in Routine Servicing, Section 6.4 paragraphs 5 to 9.
7.11 FUSE - Fig. 7.2
The fuse is located on the PCB.
1. Gain access as described in Installation, Section 4.8.
2. Lift out and remove the fuse. Fit a 3.15 AF fuse as a replacement.
Note: A spare fuse is supplied, as shown in Fig. 31.
3. Re-assemble in reverse order.
PCB fuse
7.12 PCB - Fig. 7.2
PCB
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.
Spare fuse
1. Gain access behind the control panel as described in Section 7.1.
2. Disconnect all the wiring connectors from the PCB.
Fig. 7.2
3. Remove the five fixing screws and carefully withdraw the board from
the switch spindles.
4. Re-assemble in reverse order. Refer to the wiring diagram in Section 8.1 for connections.
5. Light the boiler and adjust the PCB as described in the instructions supplied with the replacement PCB.
7.13 DIVERTER VALVE MOTOR - Fig. 7.3
1. Gain access behind the front casing as described in Section 8.1.
2. Remove the diverter valve motor head by unplugging its electrical connection and withdrawing the retaining clip
upwards from the back of the motor.
3. Withdraw the motor forwards from the valve body.
4. Re-assemble in reverse order with a new motor.
DHW temperature sensor
Retaining
clip
Condensate trap
Alpha InTec 30C and 34C - Component Replacement
34
Diverter valve
motor and
assembly
DHW Flow
switch
Flow switch
bottom fixing
screw
Fig. 7.3
7.14 ALPHA CONTROLS (if fitted) - Fig. 4.16
Back panel
Note: For replacement only use an Alpha single channel control. Do not fit a two channel control.
1. Gain access behind the control panel as described in Section 7.1.
2. Remove the three screws securing the terminal block cover at the rear of the panel.
3. Disconnect the wiring from the control.
4. Remove the three control retaining screws and withdraw the control from the panel.
5. Fit the new control, and connect the wires as follows:-
Blue to terminal 1, Brown to terminal 2 and Red wires to terminals 3 and 4, (or as per the instructions supplied with the
control).
6. Re-assemble in reverse order. Refer to the User's instructions and the boiler's control cover to set the control.
7.15 DHW TEMPERATURE SENSOR - Fig. 7.3
1. The DHW sensor is positioned in the hot water outlet pipe to the left of the flow switch, see Fig. 7.5. Unplug the two
connections and unclip the sensor from the pipe.
2. Re-assemble in reverse order with a new sensor.
7.16 COMBUSTION CHAMBER INSULATION
Gain access to the combustion chamber as described in Section 7.1.
Front panel insulation - Fig. 6.2
1. Remove the electrodes from the combustion chamber front as described in Section 7.3.
2. Remove the four screws securing the burner.
3. Carefully remove the insulation.
Back panel insulation - Fig. 7.4
1. Remove the combustion chamber front/burner assembly.
2. Carefully remove the insulation, suction applied to the centre of the insulation will aid this.
Fit a new panel and re-assemble in reverse order.
7.17 CONDENSATE TRAP - Figs. 4.4 or 4.5 and 7.3
1. Gain access behind the front casing as described in Section 7.1.
2. Disconnect the top and drain connection of the condensate trap.
3. Place a container under the boiler and unscrew the bowl at the bottom of the trap, see Fig. 4.4 or 4.5. Some water will spill
from the trap.
4. Remove the screw securing the trap to the bottom of the boiler casing and lift out the trap.
5. Fit the new trap in reverse order.
Note: Fill the new trap with water once installed.
7.18 CYCLONE (if wall jig is fitted) - Fig. 4.5
1. Remove the bottom tray and close the heating return isolating valves either side of the cyclone.
2. Disconnect the unions from the cyclone. Remove the two screws securing
the support bracket and remove the cyclone. Re-assemble with a new
cyclone.
3. Pressurise the system. (Refer to Commissioning, Section 5.1).
Manual air vent
Thermal fuse
7.19 HEAT EXCHANGER THERMAL FUSE - Fig. 7.4
Note: If the thermal fuse has failed or operated, the heat exchanger must be
replaced. Do not attempt to remove the thermal fuse. Disturbing the sealant
securing the thermal fuse will invalidate the warranty.
1. Gain access behind the front casing as described in Section 7.1.
2. Disconnect the wire from the thermal fuse and remove the heat exchanger
as described in Section 7.21.
3. Fit a new heat exchanger and re-assemble in reverse order.
insulation
Fig. 7.4
Alpha InTec 30C and 34C - Component Replacement
35
7.20 DHW FLOW SWITCH - Fig. 7.3
1. Gain access behind the front casing as described in Section 7.1.
2. Isolate the mains water supply and open all hot taps to drain any water from the boiler.
3. Disconnect the wires from the switch.
4. Undo the union nut and remove the fixing screw from the bottom of the switch.
5. Remove the two 4 mm socket head capscrews securing the top switch and lift out the switch.
6. Fit the new switch and re-assemble in reverse order.
7.21 PRIMARY HEAT EXCHANGER - Figs. 7.1 and 7.4
1. Gain access behind the room sealed chamber panel as described in Section 7.1 and drain the boiler heating circuit as
described in Section 7.2.
2. Remove the burner as described in Section 6.2 (Routine Servicing).
3. Unplug the connections from the flue temperature sensor and thermal fuse, see Fig. 7.1.
4. Disconnect the condensate drain pipe by pulling its rubber connector from the heat exchanger.
5. Remove the screws securing the ignition generator bracket, disconnect the earth lead and remove the ignition
generator.
6. Unplug the fan and remove it from the boiler.
7. Remove the heating flow and return pipe-retaining clips from the primary heat exchanger and pull the pipes downwards
from the heat exchanger connections.
8. Slide the heat exchanger downwards and forwards to disconnect from the flue connection and withdraw it from the
boiler.
9. Re-assemble in reverse order, ensuring that new seals are used.
Lubricating the seals with soap and water will aid assembly.
10. Refill, pressurise the system and vent the air from the heat exchanger using the manual air vent. (Refer to
Commissioning, Section 5.1).
7.22 PRESSURE GAUGE - Fig. 7.5
1. Gain access behind the casing and drain the boiler heating circuit as described in Sections 7.1 and 7.2.
2. Withdraw the retaining clip securing the pressure gauge sensor (just to the left of the automatic air vent) and withdraw
the sensor.
3. Remove the main cable grommet in the bottom panel and remove the sensor tube.
4. Depress the two lugs on the pressure gauge and push it out of the control panel.
5. Fit the new gauge using a new 'O' ring on the connection if necessary.
6. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
Primary pressure switch
Pressure gauge sensor position
Automatic air vent
Pump
Pressure relief valve
Drain point
Pressure gauge
Alpha InTec 30C and 34C - Component Replacement
36
Fig. 7.5
7.23 PRIMARY TEMPERATURE SENSOR - Fig. 7.1
1. Gain access as described in Section 7.1 and drain the heating circuit described in Section 7.2.
2. Disconnect the wiring and unscrew the sensor. Re-assemble in reverse order with a new sensor and sealing washer.
3. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
7.24 AUTOMATIC AIR VENT - Fig. 7.5
1. Gain access behind the front casing and drain the boiler heating circuit as described in Sections 7.1 and 7.2.
2. Turn the automatic air vent anticlockwise and lift it out
3. Insert the new air vent using a new washer and turn it clockwise to lock it in position.
4. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
7.25 PUMP - Fig. 7.5
Gain access behind the front casing and drain the boiler heating circuit as described in Sections 7.1 and 7.2.
Pump head
1. Using a 4 mm Allen key remove the four socket head screws securing the pump head to the body. Withdraw the head
and disconnect the plug.
2. Connect the plug to the new head. Ensure the pump is set to maximum (3) and re-assemble in reverse order.
3. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
4. Set the pump function correctly. (Refer to Section 2.5).
7.26 PRIMARY PRESSURE SWITCH - Fig. 7.5
1. Gain access behind the front casing and drain the boiler heating circuit as described in Sections 7.1 and 7.2.
2. Disconnect the wiring from the pressure switch.
3. Withdraw the retaining clip on the left side of the switch and lift the switch upwards to remove.
4. Insert a new switch and re-assemble in reverse order.
When connecting the wiring to the new switch the polarity of the wires is not important.
7.27 PRESSURE RELIEF VALVE - Fig. 7.5
1. Gain access behind the front casing and drain the boiler heating circuit as described in Sections 7.1 and 7.2.
2. Disconnect the pressure relief valve outlet fitting.
3. Remove the two screws securing the expansion relief valve and the left hand DHW manifold securing screw.
4. Withdraw the retaining clip from the valve and pull the valve from the pump housing.
5. Re-assemble in reverse order.
6. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
7.28 DHW HEAT EXCHANGER
1. Gain access behind the front casing and drain the boiler heating and hot water circuits as described in Sections 7.1 and
7.2.
2. Release the nut securing the condensate pipe and remove the flexible condensate pipe from the condensate trap.
Rotate the pipe to clear.
3. To create more space to withdraw the heat exchanger - Remove the screw securing the fan air inlet pipe and remove
the pipe, remove the screws securing the fan and move it to the right hand side of the chamber.
4. Remove the diverter valve motor as described in Section 7.13.
5. Using a 4 mm Allen key unscrew the two socket head capscrews securing the DHW heat exchanger. Withdraw the heat
exchanger from the boiler by moving it to the left and rotating it to remove.
Note: Be careful not to allow water to drip onto any electrical components.
6. Re-assemble in reverse order making sure that the printing on the heat exchanger is at the top when fitted and that the
seals are in position in the manifold.
7. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
Alpha InTec 30C and 34C - Component Replacement
37
7.29 MAINS WATER INLET FILTER - Fig. 4.4 or 4.5
1. The mains water inlet filter is located in the body of the DHW flow switch. Refer to Section 7.17 to remove the flow
switch.
2. The filter can be removed using a small screwdriver.
3. Clean the filter and re-assemble in reverse order.
7.30 DIVERTER VALVE CARTRIDGE - Fig. 7.3
1. Gain access behind the front casing and drain the boiler heating circuit as described in Sections 7.1 and 7.2.
2. Remove the diverter valve motor as described in Section 7.13.
3. Using a 28 mm spanner turn the diverter valve cartridge anticlockwise until its retaining lugs hit the stops.
4. Withdraw the cartridge taking care not to spill any water onto any electrical components.
5. Insert the new cartridge with the locating lug at the top and push firmly into place. Using a 28 mm spanner turn the cartridge
clockwise until the retaining lugs are locked into position.
6. Re-assemble in reverse order.
7. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
7.31 EXPANSION VESSEL - Fig. 7.1
Note: Check that the pressure of the new vessel is 1 bar before it is installer.
1. Gain access behind the front casing and drain the boiler heating circuit as described in Sections 7.1 and 7.2.
2. Disconnect the pipe from the expansion vessel.
3. Remove the screw securing the top support bracket.
4. Remove the three screws securing the side panel and remove the panel.
5. Lift the expansion vessel out of the boiler.
6. 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.
7. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
7.32 SEASONALITY VALVE - Fig. 4.4 or 4.5
1. Gain access behind the front casing and drain the hot water circuit as described in Sections 7.1 and 7.2.
2. Remove the valve by disconnecting the unions from the bottom of the boiler, the mains inlet valve and filling loop.
3. Re-assemble in reverse order using a new valve.
Alpha InTec 30C and 34C - Component Replacement
38
8 WIRING DIAGRAMS
R
5
4
3
2
1
R
Alpha controls (optional)
Remove link
to connect
Alpha controls
Flue
Sensor
Flow
Sensor
DHW
Sensor
Heat
Exchanger
Thermal
Fuse
Overheat
Thermostat
Low voltage electrical connections
230 V electrical connections
DHW
Flow
Switch
System
Pressure
Switch
Br
Bl
Bl
Br
W
G Or
Bk
Br
Bl
W
G Or
Bl
Bl
Gy
Bk
Gy
W
W
G
Gy
Br
R
Bk
Br
R
R
Gy
R
Bk
Or
G
Gy
Bl
R
Br
R
Br
Bk
R BrBl
Br
R
Bl
Bl
G/Y
Bl
Gy
21
Colour Code
Br Brown
Bk Black
Bl Blue
R Red
Or Orange
G Green
G/Y Green/Yellow
W White
Gy Grey
Remove the link between terminal
block connections 1 and 2 if the
optional Alpha Climatic control or
230 V room thermostat is used.
X21
X26
50 5152 53 54 55 56 57 58
Relay Board
(optional)
X20
X16 X4
244
2
5
1
153
3
X12
4
2
3
6
5
17
X18
4
2
3
6
5
178
X14
4
2
3
6
5
1
7
8
9
10
11
X7
4
2
3
6
5
1
X17
3
5
4
1
2
6
X19
2 1
X3
L
N 3
4
X10
X9
X11
X15
1
1
223
3
Fuse
3.15 AF
Transformer
DHW SET
+
CH SET
+
B A
X5
1234
56
X8
1
X6
R2
Alpha
Climatic Control
(optional)
+
-
Fan
8 9 10
11 12
13
1 2
L N
Room
thermostat
(optional)
Link
Supply
230 V
~ 50 Hz
Br
Bl
Boiler
Pump
Diverter
Valve
Br
DHW
CH
Bl
Bk
-UB
PWM
GND
HS
+UB
External
Sensor
(optional)
DHW
Inlet sensor
(optional)
8.1 ILLUSTRATED WIRING DIAGRAM
R
G/Y
Br Bl
Spark
Generator
Ignition
Electrodes
Flame
Sensing
Electrode
Gas
W
Gy
R
GRG
RWBlOrBk
Or
Gy
W
Or
Valve
Gy
Bk
Br
Gy
Bl
RBkWW
GG
Alpha InTec 30C and 34C - Wiring Diagrams
39
8.2 FUNCTIONAL FLOW WIRING DIAGRAM
N
L
N
DHW Sensor
External Sensor
(optional)
Flue
Sensor
Fan
Diverter
Valve Motor
Overheat
Thermostat
Heat Exchanger
Thermal Fuse
X16 X4
244
2
5
1
153
3
X12
4
2
3
6
5
17
X18
4
2
3
6
5
178
X14
4
2
3
6
5
1
7
8
9
10
11
X7
4
2
3
6
5
1
X17
3
5
4
1
2
6
X19
2 1
X3
L
N 3
4
X10
X9
X11
X15
1
1
223
3
Fuse
3.15 AF
Transformer
DHW SET
+
CH SET
+
B A
X5
1234
56
X8
1
X6
R2
N
Spark
Generator
N
N
DHW Flow Switch
Climatic Control (low voltage)
(optional)
X3
L
X3
4
X16
1
X3
N
X16
3
X9
2
2
1
PCB
Note: Main Terminal Block
PCB Connection
To connect external controls remove link
from terminals 1 and 2 and connect 240 V
switched live to terminal 1.
(24 V DC)
(15 - 20 V DC)
+
-
X3
3
Flame Sensing
Electrode
BUS
Fuse 3.15 AF
(on PCB)
230/240V ~ 50Hz
Fuse 3A
Remove link to connect
external control
1
2
3
4
Alpha Control
(Optional)
Pump
System Pressure Switch
Alpha InTec 30C and 34C - Wiring Diagrams
40
Flow
DHW Inlet
Sensor (optional)
Gas Valve
Sensor
9 ERROR CODES AND FAULT FINDING
9.1 CARRY OUT INITIAL FAULT FINDING CHECKS
1. 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 flow rate is more than 2.5 litre/min
2. Carry out electrical system checks, i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter.
Note: These checks must be repeated after any servicing or fault finding.
3. Ensure all external controls are calling for heat and check all external and internal fuses.
4. Check that the gas and water pipework has been connected to the correct connections on the boiler and all valves are open.
However, before any servicing or replacement of parts ensure the gas and electrical supplies are isolated.
9.2 ERROR CODES AND FAULT FINDING
Error
code
01
02
03
04
05
Fault Fault description Possible causes
Ignition failure
Overheat boiler lock
out
High flue thermostat
temperature
Gas valve electrical
connection fault
Heating flow sensor
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
Incorrect flow sensor resistance value
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
Flow sensor wire connections
Flow sensor faulty
DHW sensor fault
06
(InTec C, X, GS only)
Maximum number of
08
resets
Primary system
10
pressure low
Cylinder sensor fault
12
(InTec S and
FlowSmart only)
Internal wiring error
15
Fan fault
16
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
Fan wiring fault or fan faulty
Alpha InTec 30C and 34C - Error Codes and Fault Finding
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
Check fan wiring connections
Fan fault
PCB fault
41
Error
code
Fault Fault description Possible causes
20
24
25
27
29
31
37
38
Flame sensing fault
Control panel button
fault
Overheat lock out
Insufficient primary
flow
Flue sensor fault
Loss of
communication with
external control
(Alpha Climatic)
Low supply voltage
Loss of flame
rectification
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
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
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
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
43
44
46
47
51
Loss of flame
rectification
Safety lock out
External sensor
intervention
Reduced burner
output
Climatic RF
communication fault
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
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
Error between the communication of the
Climatic transmitter and boiler receiver
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
Air in heat exchanger
Restricted primary flow
Heat exchanger air flow blocked
Flue restriction
Flue sensor fault
Pump fault
Batteries require replacing
Distance between boiler and climatic control
too great
Interference
Object blocking signal (metallic)
Alpha InTec 30C and 34C - Error Codes and Fault Finding
42
10 SHORT PARTS LIST
Reference
Description
Spark generator
Diverter valve cartridge assembly
Seasonality valve
Pressure gauge
Condensate trap assembly
Flue sensor
DHW sensor
Overheat thermostat
Flame sensing electrode
Flue turret
DHW flow switch
Ignition electrode
Pump head
Filling loop
Flue turret foam seal
Primary heat exchanger (30C)
Primary heat exchanger (34C)
Burner (30C)
Burner (34C)
Diverter valve motor
Pressure switch
DHW heat exchanger plus seals - 18 plate
PCB
Condensate trap bowl
Primary NTC sensor
Injector 6.8 mm (30C - NG)
Injector 4.8 mm (30C - LPG)
Injector 5.8 mm (34C - LPG)
Pressure relief valve 3 bar
Gas valve
Automatic air vent with 'O' ring
Drip tray/flue connection
Expansion vessel 8L
Fan (30C)
Fan (34C)
Flue turret assembly
Complete boiler seal kit
Hydraulic circuit seal kit
Primary H/E seal kit
Air/flue system seal kit
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Alpha Pt. No.
1.018162
3.020380
3.017106
1.023551
3.017281
1.024296
1.025380
1.025797
1.032007
1.030738
1.028570
3.017477
1.038161
3.020960
1.030666
1.031448
1.031449
1.019622
1.031824
1.028572
1.027277
3.022784
1.030267
1.019228
1.021762
1.031471
1.022052
1.022049
1.028643
1.031823
1.027110
1.030667
1.030996
1.027178
1.029719
3.022546
3.022652
3.022653
3.022654
3.022655
British Gas GC No.
Alpha InTec 30C and 34C - Short Parts List
43
11 ENERGY CLASSIFICATION
11.1 TECHNICAL PARAMETERS FOR MIXED BOILERS (IN COMPLIANCE WITH REGULATION 813/2013)
The values in the following tables refer to the maximum heating output.
Model(s): InTec 30C
Condensing boiler: YES
Low-temperature boiler: NO
B1 boiler: NO
Cogeneration space heater: NO Equipped with a supplementary heater: NO
Combination heater: YES
Item Symbol Value Unit Item Symbol Value Unit
Rated heat output P
n
20 kW
For boiler space heaters and boiler combination heaters: useful
heat output
At rated heat output and high
temperature regime (*)
At 30% of rated heat output and low
temperature regime (**)
P
P
4
1
20.0 kW
7.2 kW
Seasonal space heating energy
efficiency
For boiler space heaters and boiler combination heaters: Useful
efficiency
At rated heat output and high
temperature regime (*)
At 30% of rated heat output and low
temperature regime (**)
Auxiliary electricity consumption Other items
At full load el
At part load el
In standby mode P
0.034 kW Standby heat loss P
max
0.019 kW Ignition burner power consumption P
min
0.006 kW Emissions of nitrogen oxides NO
SB
For combination heaters:
η
s
η
4
η
1
stby
ign
X
91 %
88.7 %
95.5 %
0.090 kW
0.000 kW
27
mg /
kWh
Declared load profile XL Water heating energy efficiency η
Daily electricity consumption Q
0.215 kWh Daily fuel consumption Q
elec
WH
fuel
88 %
21.831 kWh
Contact details Alpha Therm Ltd., Nepicar House, Wrotham Heath, Kent. TN15 7RS
(*) High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet.
(**) Low temperature means for condensing boilers 30°C, for low-temperature boilers 37°C and for other heaters 50°C return temperature.
Model(s): InTec 34C
Condensing boiler: YES
Low-temperature boiler: NO
B1 boiler: NO
Cogeneration space heater: NO Equipped with a supplementary heater: NO
Combination heater: YES
Item Symbol Value Unit Item Symbol Value Unit
Rated heat output P
n
28 kW
For boiler space heaters and boiler combination heaters: useful
heat output
At rated heat output and high
temperature regime (*)
At 30% of rated heat output and low
temperature regime (**)
P
P
4
1
28.0 kW
84.2 kW
Seasonal space heating energy
efficiency
η
s
92 %
For boiler space heaters and boiler combination heaters: Useful
efficiency
At rated heat output and high
temperature regime (*)
At 30% of rated heat output and low
temperature regime (**)
η
4
η
1
88.8 %
96.8 %
Auxiliary electricity consumption Other items
At full load el
At part load el
In standby mode P
0.035 kW Standby heat loss P
max
0.017 kW Ignition burner power consumption P
min
0.006 kW Emissions of nitrogen oxides NO
SB
stby
ign
X
0.042 kW
0.000 kW
32
mg /
kWh
For combination heaters:
Declared load profile XL Water heating energy efficiency η
Daily electricity consumption Q
0.196 kWh Daily fuel consumption Q
elec
WH
fuel
87 %
22.163 kWh
Contact details Alpha Therm Ltd., Nepicar House, Wrotham Heath, Kent. TN15 7RS
(*) High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet.
(**) Low temperature means for condensing boilers 30°C, for low-temperature boilers 37°C and for other heaters 50°C return temperature.
Alpha InTec 30C and 34C - Energy Classification
44
11.2 PRODUCT DATA SHEET (IN COMPLIANCE WITH REGULATION 811/2013)
InTec 30C
InTec 30 C
++
A
+
A
A
B
C
D
E
F
G
48 dB
A
24
kW
D
E
F
G
InTec 34C
InTec 34 C
XL
++
A
A
B
C
A
+
A
A
B
C
D
E
F
G
A
D
E
F
G
XL
A
A
B
C
28
47 dB
kW
Parameter value
Yearly energy consumption for the heating function (QHE)
Yearly electricity consumption for the
domestic hot water function (AEC)
Yearly fuel consumption for the domestic
hot water function (AFC)
Seasonal room heating yield (ηs) 91 %
Domestic hot water production yield (ηwh) 88 %
76.3 GJ
47 kWh
17 GJ
Parameter value
Yearly energy consumption for the heating function (QHE)
Yearly electricity consumption for the
domestic hot water function (AEC)
Yearly fuel consumption for the domestic
hot water function (AFC)
Seasonal room heating yield (ηs) 92 %
Domestic hot water production yield (ηwh) 87 %
87.7 GJ
43 kWh
17 GJ
Alpha InTec 30C and 34C - Energy Classification
45
11.3 FACSIMILE FOR FILLING IN ROOM HEATING SYSTEM ASSEMBLY CHART
1
Seasonal space heating energy efciency of boiler
‘I’
%
Temperature control
From che of temperature
control
Supplementary boiler
From che of boiler
Solar contribution
From che of solar device
Collector size
(in m2)
( ‘III’ x + ‘IV’ x ) x (0.9 x ( / 100) x =
Supplementary heat pump
From che of heat pump
Solar contribution AND Supplementary heat pump
Select smaller value
Seasonal space heating energy efciency of package
Class I = 1 %, Class II = 2 %,
Class III = 1.5 %, Class IV = 2 %,
Class V = 3 %, Class VI = 4 %,
Class VII = 3.5 %, Class VIII = 5 %
Seasonal space heating energy afciency
( - ‘I’ ) x 0,1 =
Tank volume
(in m3)
0.5 x O 0.5 x =
Collector efciency
Seasonal space heating energy afciency
( - ‘I’ ) x ‘II’ =
4 5
(in %)
(in %)
(in %)
Tank rating
A* = 0.95, A = 0.91
B = 0.86, C = 0.83
D-G = 0.81
+
±
+
+
-
2
%
3
%
4
%
5
%
6
%
7
%
Seasonal space heating energy efciency class of package
+++
++
G F E D C B A A
< 30 % ≥ 30 % ≥ 34 % ≥ 36 % ≥ 75 % ≥ 82 % ≥ 90 % ≥ 98 % ≥ 125 %≥ 150 %
Boiler and supplementary heat pump installed with low temperature heat emitters at 35°C?
From che of heat pump
The energy efciency of the package of products provided for in this che may not correspond to its
actual energy efciency once installed in a building, as the efciency is inuenced by further factors
such as heat loss in the distribution system and the dimensioning of the products in relation to building
size and characteristics.
7
+ ( 50 x ‘II’ ) =
+
A
A
%
Alpha InTec 30C and 34C - Energy Classification
46
11.4 ROOM HEATING SYSTEM ASSEMBLY CHART
Seasonal space heating energy efciency of boiler
1
____
%
Temperature control
From che of temperature
control
Supplementary boiler
From che of boiler
Solar contribution
From che of solar device
Collector size
2
)
(in m
( ____ x + ____ x ) x (0,9 x ( / 100) x =
Supplementary heat pump
From che of heat pump
Solar contribution AND Supplementary heat pump
Select smaller value
Seasonal space heating energy efciency of package
Class I = 1 %, Class II = 2 %,
Class III = 1.5 %, Class IV = 2 %,
Class V = 3 %, Class VI = 4 %,
Class VII = 3.5 %, Class VIII = 5 %
Seasonal space heating energy afciency
( - ______ ) x 0,1 =
Tank volume
(in m3)
0.5 x O 0.5 x =
Collector efciency
Seasonal space heating energy afciency
( - _____ ) x _______ =
4 5
(in %)
(in %)
(in %)
Tank rating
A* = 0.95, A = 0.91
B = 0.86, C = 0.83
D-G = 0.81
+
±
+
+
-
2
%
3
%
4
%
5
%
6
%
7
%
Seasonal space heating energy efciency class of package
+++
++
G F E D C B A A
< 30 % ≥ 30 % ≥ 34 % ≥ 36 % ≥ 75 % ≥ 82 % ≥ 90 % ≥ 98 % ≥ 125 %≥ 150 %
Boiler and supplementary heat pump installed with low temperature heat emitters at 35°C?
From che of heat pump
The energy efciency of the package of products provided for in this che may not correspond to its
actual energy efciency once installed in a building, as the efciency is inuenced by further factors
such as heat loss in the distribution system and the dimensioning of the products in relation to building
size and characteristics.
7
+ ( 50 x ______ ) =
+
A
A
%
11.5 PARAMETERS FOR FILLING IN ASSEMBLY CHART
Parameter InTec 30C InTec 34C
‘I’ 91 92
‘II’ * *
‘III’ 1.11 0.95
‘IV’ 0.44 0.37
* To be established by means of table 5 of Regulation 811/2013 in case of “assembly” including a heat pump to integrate the
boiler. In this case the boiler must be considered as the main appliance of the assembly.
Alpha InTec 30C and 34C - Energy Classification
47
11.6 DOMESTIC HOT WATER PRODUCTION SYSTEM ASSEMBLY CHART
Water heating energy efciency of combination heater
Declared load prole:
Solar contribution
From che of solar device
( 1.1 x _____ - 10 % ) x _____ - ____ - ______ =
Water heating energy efciency of package under average climate
Water heating energy efciency class of package under average climate
G F E D C B A A
M
L
XL
XXL
< 27 %
< 27 %
< 27 %
< 28 %
≥ 27 %
≥ 27 %
≥ 27 %
≥ 28 %
≥ 30 %
≥ 30 %
≥ 30 %
≥ 32 %
Auxiliary electricity
≥ 33 %
≥ 36 %
≥ 34 %
≥ 37 %
≥ 35 %
≥ 38 %
≥ 36 %
≥ 40 %
≥ 39 %
≥ 50 %
≥ 55 %
≥ 60 %
≥ 65 %
≥ 75 %
≥ 80 %
≥ 85 %
+
A
≥ 100 %
≥ 115 %
≥ 123 %
≥ 131 %
+
++
A
≥ 130 %
≥ 150 %
≥ 160 %
≥ 170 %
1
_____
2
3
+++
≥ 163 %
≥ 188 %
≥ 200 %
≥ 213 %
%
%
%
Water heating energy efciency under colder and warmer climate conditions
3 2
Colder: - 0.2 x =
3 2
Warmer : + 0.4 x =
The energy efciency of the package of products provided for in this che may not correspond to its
actual energy efciency once installed in a building, as the efciency is inuenced by further factors
such as heat loss in the distribution system and the dimensioning of the products in relation to building
size and characteristics.
%
%
11.7 PARAMETERS FOR FILLING IN DHW PACKAGE ASSEMBLY CHART
Parameter InTec 30C InTec 34C
‘I’ 88 87
‘II’ * *
‘III’ * *
* To be determined according to Regulation 811/2014 and transient calculation methods as per Notice of the European
Community no. 207/2014.
Alpha InTec 30C and 34C - Energy Classification
48
11.8 FACSIMILE FOR FILLING IN DOMESTIC HOT WATER PRODUCTION SYSTEM ASSEMBLY CHART
Water heating energy efciency of combination heater
Declared load prole:
Solar contribution
From che of solar device
( 1.1 x ‘I’ - 10 % ) x ‘II’ - ‘III’ - ‘I’ =
Water heating energy efciency of package under average climate
Water heating energy efciency class of package under average climate
G F E D C B A A
M
L
XL
XXL
< 27 %
< 27 %
< 27 %
< 28 %
≥ 27 %
≥ 27 %
≥ 27 %
≥ 28 %
≥ 30 %
≥ 30 %
≥ 30 %
≥ 32 %
Auxiliary electricity
≥ 33 %
≥ 36 %
≥ 34 %
≥ 37 %
≥ 35 %
≥ 38 %
≥ 36 %
≥ 40 %
≥ 39 %
≥ 50 %
≥ 55 %
≥ 60 %
≥ 65 %
≥ 75 %
≥ 80 %
≥ 85 %
+
A
≥ 100 %
≥ 115 %
≥ 123 %
≥ 131 %
+
++
A
≥ 130 %
≥ 150 %
≥ 160 %
≥ 170 %
1
‘I’
2
3
+++
≥ 163 %
≥ 188 %
≥ 200 %
≥ 213 %
%
%
%
Water heating energy efciency under colder and warmer climate conditions
3 2
Colder : - 0.2 x =
3 2
Warmer : + 0.4 x =
The energy efciency of the package of products provided for in this che may not correspond to its
actual energy efciency once installed in a building, as the efciency is inuenced by further factors
such as heat loss in the distribution system and the dimensioning of the products in relation to building
size and characteristics.
%
%
Alpha InTec 30C and 34C - Energy Classification
49
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. This does not affect the customer’s statutory rights.
Customer name: Telephone number:
Address:
Boiler make and model:
Boiler serial number:
Commissioned by (PRINT NAME): Gas Safe register number:
Company name: Telephone number:
Company address:
Commissioning date:
To be completed by the customer on receipt of a Building Regulations Compliance Certifcate*
Building Regulations Notifcation Number (if applicable):
CONTROLS (tick the appropriate boxes)
Time and temperature control to heating
Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination Boiler
Heating zone valves Fitted Not required
Hot water zone valves Fitted Not required
Thermostatic radiator valves Fitted Not required
Automatic bypass to system Fitted Not required
Boiler interlock Provided
ALL SYSTEMS
The system has been fushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions Yes
What system cleaner was used?
What inhibitor was used? Quantity litres
Has a primary water system flter been installed? Yes No
CENTRAL HEATING MODE measure and record:
Gas rate m³/hr OR ft³/hr
Burner operating pressure (if applicable) mbar OR Gas inlet pressure mbar
Central heating fow temperature °C
Central heating return temperature °C
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)? Yes No
If yes, and if required by the manufacturer, has a water scale reducer been ftted? Yes No
What type of scale reducer has been ftted?
DOMESTIC HOT WATER MODE Measure and Record:
Gas rate m³/hr OR ft³/hr
Burner operating pressure (at maximum rate) mbar OR Gas inlet pressure at maximum rate mbar
Cold water inlet temperature °C
Hot water has been checked at all outlets Yes Temperature °C
Water fow rate I/min
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes
ALL INSTALLATIONS
Record the following:
The heating and hot water system complies with the appropriate Building Regulations Yes
The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes
Commissioning Engineer’s Signature
Customer’s Signature
(To confrm satisfactory demonstration and receipt of manufacturer’s literature)
All installations in England and wales must be notified to Local Authority Building Control (LABC) either directly or through a
*
Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer.
At max. rate: CO ppm AND CO/CO
At min. rate: (where possible) CO ppm AND CO/CO
Room thermostat and programmer/timer Programmable room thermostat
Load/weather compensation Optimum start control
²
²
Ratio
Ratio
© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
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.
SERVICE 01
Engineer name:
Company name:
Telephone No:
Gas safe register No:
Record:
Comments:
Signature
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible)
SERVICE 03
Engineer name:
Company name:
Telephone No:
Gas safe register No:
Record:
Comments:
Signature
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible) CO ppm AND CO
SERVICE 05
Engineer name:
Company name:
Telephone No:
Gas safe register No:
Record:
Comments:
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible) CO ppm AND CO
Date:
CO ppm AND CO²%
Date:
²
Date:
²
SERVICE 02
Engineer name:
Company name:
Telephone No:
Gas safe register No:
Record:
Comments:
Signature
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible)
CO ppm AND CO²%
SERVICE 04
Engineer name:
Company name:
Telephone No:
Gas safe register No:
%
Record:
Comments:
Signature
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible) CO ppm AND CO
SERVICE 06
Engineer name:
Company name:
Telephone No:
Gas safe register No:
%
Record:
Comments:
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible) CO ppm AND CO
Date:
Date:
Date:
%
²
%
²
Signature
SERVICE 07
Engineer name:
Company name:
Telephone No:
Gas safe register No:
Record:
Comments:
Signature
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible) CO ppm AND CO
SERVICE 09
Engineer name:
Company name:
Telephone No:
Gas safe register No:
Record:
Comments:
Signature
All installations in England and wales must be notified to Local Authority Building Control (LABC) either directly or through a
*
Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer.
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible) CO ppm AND CO
Date:
Date:
%
²
%
²
Signature
SERVICE 08
Engineer name:
Company name:
Telephone No:
Gas safe register No:
Record:
Comments:
Signature
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible) CO ppm AND CO
SERVICE 10
Engineer name:
Company name:
Telephone No:
Gas safe register No:
Record:
Comments:
Signature
At max. rate: CO ppm AND CO²%
At min. rate:
(Where Possible) CO ppm AND CO
Date:
Date:
%
²
%
²
© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
5
Alpha InTec 30C and 34C
calling Gas Safe on 0800 408 5500.
have a registration number. Both should be recorded in the Checklist. You can check your installer is Gas Safe registered by
shown in back of the Installation and Servicing instructions. All Gas Safe registered installers carry a Gas Safe ID card and
The Benchmark Checklist must be fully completed by the installer on installation of the boiler. The Benchmark Checklist is
compliance with the law. The manufacturer's instructions must not be taken in any way as over-riding statutory obligations.
Failure to install or service appliances correctly could lead to prosecution. It is in your interest and that of safety to ensure
It is the law that all gas appliances are installed and serviced by a competent person, i.e. Gas Safe registered personnel.
Current Gas Safety (Installation and Use) Regulations:-
10 GAS SAFETY REGULATIONS
THE APPLIANCE MUST BE EARTHED.
The brown wire must be connected to the terminal which is marked with the letter L or coloured red.
The blue wire must be connected to the terminal which is marked with either the letter N or coloured black.
, or coloured green or green and yellow.
earth symbol
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
terminals in your plug. In this case proceed as follows:The colour of the wires in the mains lead of the boiler may not correspond with the coloured markings identifying the
To connect a plug:-
plug is used.
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
8. ELECTRICAL SUPPLY
all naked flames. Contact your local Gas Region immediately on 0800 111 999.
If a fault or gas leak is suspected, turn off the gas supply. Do not touch any electrical switches, do not smoke and extinguish
7. GAS LEAK
For advice on servicing contact:- The Alpha Helpline: 0844 871 8764.
To maintain efficient and safe operation of your boiler, routine annual servicing is essential.
6. SERVICING
Use only a damp cloth and mild detergent to clean the boiler outer casing. Do not use abrasive cleaners.
5. CLEANING
your plumbing merchant or installer for advice when considering purchasing such items.
Any equipment such as mixing valves, showers, bidets etc. must be designed to operate at mains water pressure. Contact
4. ADDITIONAL BATHROOM FITTINGS
If the mains water supply fails, there will be no hot water from the taps. The boiler will continue to provide central heating.
normal operation. Remember to reset any controls, if fitted, when the supply is restored.
In the event of an electrical supply failure the boiler will not operate. When the supply is restored, the boiler will return to
3. MAINS FAILURE
terminal. This is safe and quite normal.
Note: The Alpha InTec boilers are high efficiency condensing boilers and when operating vapour will be emitted from the
contact your Service Engineer.
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
2. FLUE TERMINAL
near the boiler or flue pipe.
Do not store any other articles in a cupboard containing the boiler and never place any clothing or combustible material on or
Each side: 5 mm, Front: 450 mm
Top: (horizontal flue) 235 mm, Top: (vertical flue) 150 mm, Bottom: 150 mm, Bottom: (with Jig) 250 mm,
Always ensure the following clearances are available around the casing of the boiler:-
1. BOILER LOCATION
9 IMPORTANT NOTES
4
Wall
Alpha InTec 30C and 34C
Optional boiler controlled condensate trace heating kit ..............................................................................Part No. 6.5500000
External weather compensation probe ....................................................................................................... Part No. 3.022383
Alpha Climatic wireless programmable boiler energy manager (boiler mounted receiver) .........................Part No. 3.022143
Alpha Climatic wired programmable boiler energy manager (boiler mounted) ...........................................Part No. 3.022144
Alpha Easy Stat wireless programmable room thermostat (boiler mounted receiver) ................................Part No. 7.2000050
7 day digital heating clock (boiler mounted) ............................................................................................... Part No. 6.1000210
24hr mechanical heating clock (boiler mounted) ........................................................................................ Part No. 6.1000201
Available Alpha controls:
Please refer to the instructions provided with the controls for further information on their setting and use.
boiler we recommend the Alpha Climatic controls with enhanced remote boiler functions and efficiency control.
boilers are compatible with most controls available on the market. However to get the most comfort and efficiency from your
There is a range of controls available from Alpha to operate your boiler. In addition to the items listed below the Alpha InTec
8 OPTIONAL BOILER CONTROLS (if fitted)
for external condensate drainage pipework, incorporating an external frost thermostat, should be considered.
In situations where there are likely to be extremes of temperature or wind-chill the use of a proprietary trace-heating system
the risk from freezing.
If the condensate drain pipe runs outside it should be fitted with increased diameter pipe and be suitably lagged to reduce
which is collected within the boiler (as condensate) and run to a suitable drainage point via the condensate drainage pipe.
High efficiency (condensing) boilers remove more useful heat from the combustion gases, resulting in additional water vapour
7 CONDENSATE DRAINAGE
heating when the temperature falls below 5°C.
If Alpha external controls are fitted, a frost protection setting is incorporated into the room thermostat activating the central
Further protection for the mains water supply and heating circuit must be provided separately.
'Standby' or 'On' mode.
For this function to be active the gas and electricity supplies to the boiler must be turned on and the boiler be in either
4°C the boiler will fire in heating mode and raise the temperature of the heating water (in the boiler only) to 30°C.
The boiler has a built in frost protection function to protect the boiler (only) from freezing. If water within the boiler falls below
5 FROST PROTECTION
Fig. 3 - Underneath of boiler
Filling loop taps
Filling loop
3
9 8
7
6
5
4
3
2
1
0
Alpha InTec 30C and 34C
the pressure on the gauge goes down into the green area.
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
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.
and 1.5 bar pressure.
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
should be opened a quarter of a turn and the water will start to refill the system (water should be heard filling the system).
To fill or pressurise the system open one tap fully by turning it 90° anticlockwise in line with the tap housing. The second tap
These taps should normally be in the closed position 90° to the tap housing.
shown in Fig. 3 (C model shown with factory fitted filling loop).
The filling loop on the underside or underneath the boiler will have two tap connections at either end of the filling loop as
Do not attempt to fill or pressurise the system while the system is hot - wait for it to cool.
InTec C models are supplied with a factory fitted filling loop located underneath the boiler, (a flexible silver coloured braided hose).
4 FILL AND PRESSURISE THE SYSTEM
Fig. 2 - External weather compensation probe fitted
External temperature (°C)
-510 0 -10 -1520
5
27 15
system such as under floor heating
is used with a low temperature
ie. 25 to 50°C range when boiler
Flow temperature in brackets
the central heating selector switch
Setting 1 to 9 as selected using
symbol (item 18 in Fig. 1) in the display, it will
Flow temperature (°C)
25 (25)
60 (40)
85 (50)
temperature will still be maintained according to the setting of the room thermostat.
Note: This is the temperature of the water supplied to the radiators and not the desired room temperature. The time and
i.e. line 6 will give a flow temperature of 60°C when the external temperature is 10°C.
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
When an external weather probe is fitted, the central heating selector switch (item 6 in Fig. 1) will no longer adjust the flow
room thermostat.
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
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
If an external weather compensation probe is fitted, indicated by the
When the heating is on the temperature of the water leaving the boiler to the radiators will be displayed.
The temperature of the central heating water can be adjusted by turning the central heating selector switch (item 6 in Fig. 1).
water temperature to the tap.
When a tap is opened the display will indicate the temperature of water in the boiler heating the tap water and not the actual
required value shown on the display in °C.
The temperature of the hot water to the taps can be adjusted by turning the hot water selector switch (item 5 in Fig. 1) to the
3 HEATING AND HOT WATER TEMPERATURE
temperature from any heating controls fitted. Hot water will always take priority over heating when a hot outlet tap is opened.
Winter setting - The boiler will operate in both heating and hot water. The heating will activate depending on the time and
if requested by external controls (frost protection and pump cycle are still active).
Summer setting - The boiler will only provide hot water when a tap is turned on and the central heating will not activate even
(item 2 in Fig. 1).
On - In this mode the boiler can be switched between 'Summer' or 'Winter' settings by pressing the Summer/Winter button
Off - In this mode there is electrical power to the boiler but the boiler will not function in any condition.
2
Alpha InTec 30C and 34C
features are still active.
Standby - In this mode the boiler will not provide hot water or central heating, but frost protection and pump circulation
button for eight seconds to turn the boiler off.
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
After this purging operation the boiler will be in 'Standby' or 'On' mode.
from the system.
Note: It is important to allow this purging operation to function when the boiler has been initially installed to remove all the air
installer then this operation can be terminated by pressing the reset button (item 3 in Fig. 1).
and off to help remove any air that may be trapped in the heating system. If the boiler has already been commissioned by the
for 8 minutes; this is indicated by a count down on the display starting from 96. During this operation the pump will turn on
Switch the boiler on at the mains supply socket switch. The boiler will automatically go through a system purging operation
incorrect refer to Section 5.
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
The boiler controls are located on the control panel, located behind a drop down flap.
Fig. 1
151617181920
14
x100rpm
bar
BOOST
°C
RESET
13
11 12
8 9 10
21 Optional boiler controls (if fitted)
20 FlowSmart option
(optional)
19 Boiler connected to remote control
probe active (optional)
18 Functioning with external temperature
17 Solar function active
16 Presence of external connected devices
WHEN COLD
CORRECT PRESSURE
0
4
0.5
3.5
bar
3
1
2.5
1.5
2
721
error codes
power scale
“RESET” button
x100rpm
bar
°C
12
15 Boiler in Stand-by mode
14 Temperature indicator, boiler info and
13 Central heating mode active
12 Operating in winter mode
11 Operating in summer mode
10 Flame present symbol and relative
9 Boiler locked does not require reset via
INFO
BOOST
RESET
RESET
3
8 DHW mode active
7 Heating system pressure gauge
selector switch
6 Central heating water temperature
selector switch
5 Domestic hot water temperature
4 Information button
3 Reset button
2 Summer/Winter button
1 On-Off/Standby button
4
5 6
will always take priority over the central heating whenever a hot tap is opened.
2 OPERATING THE BOILER
The boilers will provide central heating when required during the on times as set according to the controls fitted. Hot water
compensation feature.
In addition all InTec models feature optional connections for an outside sensor to enable the boilers built in weather
the system temperature depending on the room temperature and heat losses.
standard controls or the enhanced Alpha Climatic boiler energy manager further improving the system efficiency by varying
The InTec range are designed to work with most central heating controls however we recommend the Alpha Easy Stat
The boiler output will automatically adjust according to the requirements of the system.
burner efficiency and reduced electrical consumption together with high quality and reliability.
The Alpha InTec range of high efficiency condensing boilers incorporate the latest technology in boiler design. With improved
1 INTRODUCTION
Please read these instructions carefully before operating your boiler.
0051
0515/D350
© Alpha Therm Limited 2015.
Part No. 1.038431 ST.001939/000
Leave these instructions with the User
Set for use with Natural Gas
Alpha InTec 34C (LPG) G.C. No. 47 532 56
Alpha InTec 30C (LPG) G.C. No. 47 532 55
Alpha InTec 34C (NG) G.C. No. 47 532 49
Alpha InTec 30C (NG) G.C. No. 47 532 48
Kent TN15 7RS
Wrotham Heath, Sevenoaks,
Nepicar House, London Road,
to alter the specification at any time in the interest of product improvement.
These instructions have been carefully prepared but we reserve the right
website: www.alpha-innovation.co.uk
ALPHA HELPLINE Tel: 0844 871 8764
For Technical help or for Service call ...
Gas Fired, High Efficiency Condensing Combination Boilers
Wall Mounted, Fan Assisted, Room Sealed,
30C and 34C
Alpha InTec
Instructions
User
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