alpha InTec 30C (LPG) User guide

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: [phone]

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: [phone]) or Sentinel (Tel: [phone]).

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