alpha InTec 50CS User guide

Installation, User and
Servicing Instructions
InTec 50CS
Floor standing, high output,
condensing boiler
Leave these instructions with the User
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-certication 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*. e 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 qualied 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 t for purpose.
• Meet the requirements of the appropriate Building Regulations. Where this involves notiable work be a member of a
Competent Persons Scheme or conrm that the customer has notied Local Authority Control (LABC), prior to work commencing.
• Complete all relevant sections of the Benchmark Check list/Service Record when carrying out commissioning or servicing of a product or system.
• Ensure that the product or system is le in a safe condition and, where possible, in good working order.
• Highlight to the customer any remedial or improvement work identied 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 conrm 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 eciency 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.
* e 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.
e Benchmark Scheme is managed and promoted by:
Heating and Hotwater Industry Council (HHIC)
Camden House, Warwick Rd Kenilworth CV8 1TH
Telephone: 01926 513747 E-mail: info@hhic.org.uk Website: www.hhic.org.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
2Alpha Intec 50CS
CONTENTS
USER pageINSTALLATOR page MAINTENANCE page
1 Boiler installation. ................................................3
1.1 Introduction. ........................................................3
1.2 Dimensions. ..........................................................4
1.3 Connections. ........................................................................4
1.4 Remote controls and programmable room
thermostats (optional).........................................5
1.5 External temperature sensor (optional). ...........5
1.6 Fit the ue. ............................................................6
1.7 Reduce the ue. ....................................................7
1.8 Extend the ue .....................................................8
1.9 Plume management components (optional). ...9
1.10 Vertical ue options. ..........................................11
1.11 Disposal of condensate. .....................................11
1.12 Flush the system. ...............................................12
1.13 Fill the system. ....................................................12
1.14 Circulation pump. ..............................................13
1.15 Boiler components. ............................................15
2 User and maintenance instructions. ................16
2.1 Servicing. ............................................................16
2.2 General warnings. ..............................................16
2.3 Control panel. .....................................................16
2.4 Operating modes. ..............................................17
2.5 Using the boiler. .................................................17
2.6 Fault signals. .......................................................18
2.7 Boiler shutdown. ................................................19
2.8 Restore the system pressure. .............................19
2.9 Drain the system. ...............................................19
2.10 Drain the hot water system. ..............................19
2.11 Anti-freeze protection. ......................................19
2.12 Case cleaning. .....................................................19
2.13 Decommissioning. .............................................19
2.14 Parameters and information menu. ................20
3 Boiler start-up (initial check). ..........................21
3.1 Hydraulic diagram. ............................................21
3.2 Wiring diagram. .................................................22
3.3 Troubleshooting. ................................................22
3.4 “Chimney sweep function”. ...............................22
3.5 Pump anti-seize function. .................................23
3.6 ree-way anti-seize function. .........................23
3.7 Radiator anti-freeze function. ..........................23
3.8 P.C.B. periodic self-check. ................................23
3.9 Automatic vent function. ..................................23
3.10 Yearly appliance check and maintenance. ......23
3.11 Casing removal. ..................................................24
3.12 Combustion settings. .........................................25
3.13 Technical data. ....................................................26
3.14 Short parts list ....................................................27
Benchmark checklist .........................................28
Service record .....................................................29
1 BOILER INSTALLATION
1.1 INTRODUCTION.
e Alpha InTec 50CS is a oor standing, high eciency, condensing, room-sealed combination boiler. e burner is lit electronically and the heat output is controlled by a modulating fan and gas valve.
is is a combination boiler (for domestic use only) providing both central heating and domestic hot water at mains pressure. e boiler is supplied with a pump, pressure relief valve, expansion vessel and pressure gauge fully assembled and tested. It is designed for use with a
fully pumped, sealed and pressurised central heating system. e boiler must be installed indoors in a frost free environment.
IMPORTANT
is boiler meets the requirements for Building Regulations for unvented hot water storage systems and the Local Authority must be notied of the intention to install. erefore the installation must be carried out by a person competent to install unvented hot water systems.
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 (e Electricity At Work Regulations 1989) e 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 red 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. is appliance meets the requirements of IPX4D, i.e. degree of protection against moisture. is 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 aer 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 Notication Scheme.
3. e boiler must only be used with Alpha CD condensing ue components.
NOTE: e boiler can be supplied ready for use with Propane (LPG). e LPG boiler is also designed for use with a fully pumped, sealed and pressurised heating system. In addition to the regulations and requirements stated in these installation and servicing instructions, LPG boilers must be installed in accordance
with BS 5482:1 - e Installation of Propane Burning Appliances in Permanent Dwellings. Installation pipes, cylinders and pressure regulators for LPG boilers should be tted in accordance with BS5482:1. Bulk tank installations must comply
with the requirements of the Home Oce code of practice for the storage of liqueed petroleum gas at xed installations. LPG 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. LPG supply pipes must be capable of delivering the required quantity of gas in addition to the demand from any other appliances in the house. e
complete installation must be tested for gas soundness against leaks. LPG boilers have been tested and factory set for use with Propane (LPG), it should only be necessary to ensure the correct gas supply pressure of 37 mbar is
available.
INSTALLATIONUSERMAINTENANCE
3 Alpha Intec 50CS
1.2 DIMENSIONS
INSTALLATIONUSERMAINTENANCE
Flue elbow centreline
133
20
23
44
307
320
A
F
60 60
E
G
80
40 40
C
45 45 40
I
B
6
850
650
Height (mm) Width (mm) Depth (mm)
850 650 600
Connections
Gas Domestic hot water Central heating
A B C E F
3/4" 1/2" 1/2" 3/4" 3/4"
1.3 CONNECTIONS
Gas connection:
e boiler is designed to operate with Natural gas (Cat I2H 2H - G20 - supplied at 20 mbar) or Propane gas (Cat I3P 3P - G31 - supplied at 37 mbar). Supply pipes must be the same as or larger than the 3/4" boiler tting. Before connecting the gas line, carefully clean inside all the supply pipes to remove any residue that could impair boiler performance. Also make sure the gas corresponds to that for which the boiler is prepared (see boiler data-plate).
e gas supply pipe must be suitably dimensioned according to current regulations in order to guarantee correct gas ow to the burner even in conditions of maximum boiler output and to guarantee appliance efficiency (technical specications).
Storage tanks (LPG):
- New LPG storage tanks may contain residual
inert gases (nitrogen) that degrade the mixture delivered to the appliance causing functioning anomalies.
- Due to the composition of the LPG mixture,
layering of the mixture components may occur during the period of storage in the tanks. is can cause a variation in the heating power of the mixture delivered to the appliance, with subsequent change in its performance.
973
600
Hydraulic connection:
Important: in order not to void the warranty
before making the boiler connections, carefully ush the heating system (pipes, radiators, etc.) with de-scaling products to remove any deposits that could compromise correct boiler operation.
For further detail see Section 1.12.
Mains cold water
DHW
Power supply cable
57
H
211
65
70
D
A - Gas B - Domestic hot water outlet C - Cold water inlet D - Condensate outlet E - Central heating return F - Central heating ow G - DHW temp/press relief valve H - CH pressure relief valve I - Secondary circuit (optional)
Safety valve
CH return
CH flow
Gas
814
Fig. 1-1
Fig. 1-2
4Alpha Intec 50CS
Condensate drain:
To drai n the condensate produced by the appliance, it is necessary to connect to the drainage system by means of acidic condensate resistant pipes having a diameter of at least 22 mm. e system connecting the appliance to the drainage system must be carried out in such a way as to prevent freezing of the liquid contained in it. Before appliance commissioning, ensure that the condensate can be correctly removed. Also, comply with national and local regulations on discharging waste waters.
For further detail see Section 1.11.
Electrical connection:
e boiler has an IPX5D protection rating for the entire appliance. Electrical safety of the appliance is reached only when it is correctly connected to an ecient earthing system as specied by current safety standards.
e power supply cable must be connected to a 230V ±10% / 50Hz mains supply respecting L-N polarity and earth connection must also have a multi-pole circuit breaker.
, this network
1.4 REMOTE CONTROLS AND PROGRAMMABLE ROOM THERMOSTATS OPTIONAL
e boiler is suitable for use with programmable room timer thermostats or remote controls, which are available as optional kits. Alpha programmable room thermostats are connected with 2 wires only. Carefully read the user and assembly instructions supplied with the kit.
Installation on low temperature system:
e boiler can directly supply a low temperature system by acting on parameter 'P66' (Service Engineers Document - Programming the PCB) and setting the ow temperature adjustment range 'P66/A' and 'P66/B'. In this situation it is good practice to insert a safety device in series with the power supply and boiler. is device is made up from a thermostat with a temperature limit of 60°C. e thermostat must be positioned on the system ow pipe at a distance of at least 2 metres from the boiler.
1.5 EXTERNAL TEMPERATURE SENSOR OPTIONAL
e boiler is suitable for use with the external sensor (Fig. 1-3), which is available as an optional kit. The sensor can be connected directly to the boiler electrical system and allows the maximum ow temperature to be automatically decrea sed whe n the exter nal temperature increases, in order to adjust the heat supplied to the system according to the change in external temperature. e external sensor always operates when connected, regardless of the presence or type of room thermostat used and can work in combination with Alpha programmable thermostats. e correlation between system ow temperature and external temperature is determined by the parameters set in menu 'M5' under 'P66' according to the curves represented in the diagram (Fig. 1-4). e external sensor must be connected to terminals 38 and 39 on the boiler PCB, (Fig. 3-2).
INSTALLATIONUSERMAINTENANCE
45
58
31
Fig. 1-3 Fig. 1-4
e following controls for the InTec50CS are also available from Alpha:
Part No. 3.021395, CAR V2 ....................InTec50CS wired modulating thermostat
Part No. 3.021622, Crono 7 .....................InTec50CS wired digital thermostat
Part No. 3.021624, Crono 7RF ................InTec 50CS wireless digital termostat
Flow temperature depending on the external temperature and user
adjustments of the central heating temperature.
T
T Max
T Min
EXTERNAL SENSOR:
T = Central heating temperature TE = External temperature. TMAX - TMIN = Selected ow temp. range.
OFFSET
TE
TE MaxTE Min
5 Alpha Intec 50CS
openings of the
1.6 FIT THE FLUE  FIGS. 5 AND 16
e following procedure applies to tting an Alpha CD Easy-Flue to both rear or side exit ue - horizontally only.
- e CD Easy-Flues are suitable for use in the ue length ranges shown in the tables in Figs 1-5 and 1-6.
Note: Where the length is less than the
minimum or more than the maximum, refer to Section 1.7.
INSTALLATIONUSERMAINTENANCE
Boiler
Rear Flue
(B + C)
Using a single
CD Easy-Flue
500 mm
1000 mm
B + C (mm)
Max
Min
355
130
800
590
Fig. 1-5 Rear ue
(B + C)
Using a singleCD
Easy-Flue
500 mm
1000 mm
Side Flue
Boiler
- Determine the overall length (L) of ue required, (see Fig. 1-7) as follows:-
Rear exit L = wall thickness (B) + distance between boiler and wall (C) + 230 mm
le exit L = wall thickness (B) + distance between boiler and wall (C) + 442 mm
Right exit L = wall thickness (B) + distance between boiler and wall (C) + 58 mm
B + C (mm)
Min
Max
-
143
378
742
Boiler
L
(B + C)
Side Flue
Right hand exit ueLe hand exit ue
Using a single
CD Easy-Flue
500 mm
1000 mm
B + C (mm)
Min
Max
302
527
762
972
Fig. 1-6 Side ue
Seal joint with tape
- Adjust the telescopic section of the ue 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.
- Pass the ue assembly through the wall (from inside or outside).
Fig. 1-7
Note: Internal tting - If there is no access to
make good the outside wall, locate the outside (black) ue sealing collar onto the outer duct of the ue immediately before the terminal grille onto the location provided. Push the ue assembly through the 130 mm ue hole, so that the collar completely passes through the wall. en pull the ue 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 ue terminal. See Fig. 1-8.
130 mm
Fig. 1-8 - Fitting the ue from inside
Check collar is sealing the wall and it is not restricting any
flue terminal
6Alpha Intec 50CS
- 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.
- Fit the inside (white) ue sealing collar over the Easy-Flue. If it was not previously tted, t the outside (black) ue sealing collar onto the ue immediately before the terminal grille onto the location provided.
Ensure the inner duct within the terminal is at the top.
The inner duct must
Note:
be positioned to slope towards the boiler
Terminal
Flue sealing collar
- 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 ue assembly to the bend with the clamp (three screws) located centrally over the joint.
Inner duct seal
120
20
65
CD Easy-Flue
210
Note: Check the ue terminal protrudes 120
mm out of the wall and the inner duct of the terminal is positioned correctly (see Fig. 1-9).
- Make good the inside wall by pushing the inside ue sealing collar upto the wall.
INSTALLATIONUSERMAINTENANCE
This dimension will be greater if the boiler is not against the wall
End of outer duct
Inner duct
Easy-Flue 45 mm clamp
Elbow seal joint
90° bend
Easy-Flue 40 mm clamp and seal
Side of boiler
Note: Ensure the outer flue duct is horizontal
1.7 REDUCING THE FLUE  FIG. 110
When the ue length required is less than the minimum stated in Section 1.6, paragraph 1, refer to Fig. 1-10.
Discard the rst 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 ue is fully sealed.
Allow 20 mm
30 mm
307
This dimension will be greater
if the boiler is not against the wall
Fig. 1-9 - Rear ue
Do not cut past this point
Fig. 1-10
7 Alpha Intec 50CS
1.8 EXTENDING THE FLUE  FIG. 111
40 mm clamp
Note: e ue 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 ue length of 12 m.
- When the ue length required is more than the maximum stated in Section 1.6, paragraph 1, refer to the table below and Fig. 1-6.
INSTALLATIONUSERMAINTENANCE
Rear Flue length (B + C)
Up to maximum:-
11.885 m
Additional support brackets are required when extending the ue. ese are available from Alpha, Part No. 6.1000355.
Side Flue length (B + C)
Up to maximum:-
11.805 m
Comments
Alpha CD 750 mm ue extension (Part No. 6.2000750) or 1000 mm extension (Part No.
6.2001050) is required to extend the range of telescopic ue. Refer to Section 1.8 for instructions on how to extend the ue. Note: A 130 mm ue hole (127 mm core drill) may be required in the wall. is is when
the extended ue is passed through the wall.
- Use the template (supplied with the boiler) to mark the required ue position, ensure the slope towards the boiler is correct.
- Determine the overall ue length as described in Section 1.6, paragraph 2 to determine the number of Alpha CD 750 or 1000 mm ue extensions required.
- 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 ue is fully sealed.
Ensure the inner duct within the terminal is at the top.
The inner duct must be positioned
Note:
to slope towards the boiler
120
20
- 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.
- Mark the end of the ue assembly 'TOP' where it is connected to the boiler, so that the 'TOP' of the ue terminal is aligned with the 'TOP' at the boiler end of the ue assembly.
- Pass the complete ue assembly through the wall.
- 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 tted before assembling the ue.
Ensure outer flue duct of Easy-Flue is horizontal
CD Easy-Flue
Extension clamp
Inner seal joint
- Slide the larger Easy-Flue 45 mm clamp (two screws) over the outer duct and pull the ue assembly towards the bend, locating the inner duct into the seal joint on the bend.
- Secure the ue 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 ue 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. 1-11 or 1.12.
- Make good the outside wall by fitting the outside sealing collar (black) onto the location provided immediately behind the ue terminal grille. Make good the inside wall using the inside sealing collar (white) if required.
Ensure the flue extension slopes downwards towards the boiler by a minimum of 25 - 30 mm per metre
Easy-Flue 45 mm clamp
Terminal
Flue sealing collar
Inner seal joint
Flue length (L)
CD Flue extension
End of extension
8Alpha Intec 50CS
422
517
90° bend
Easy-Flue
and seal
Seal joint
Front of boiler
Fig. 1-11 - Le side ue
Ensure the flue extension slopes
lue sealing
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
Seal joint
Ensure outer flue duct of Easy-Flue is horizontal
Extension clamp
Inner seal joint
CD Flue extension
End of extension
38
Ensure the inner duct within the terminal is at the top.
Note:
to slope towards the boiler
CD Easy-Flue
Inner seal joint
The inner duct must be positioned
120
20
INSTALLATIONUSERMAINTENANCE
Terminal
F collar
133
Front of boiler
1.9. FIT PLUME MANAGEMENT COMPONENTS  OPTIONAL
e following procedures detail the options for management of the exhaust ue gas/plume emitted from the terminal.
- e terminal supplied with the Easy-Flue can
be altered to divert exhaust ue gas/plume at an angle.
is can be achieved by simply turning the end
section of the terminal to the desired angle.
- e CD Easy-Flue can be converted to allow the
inner ue duct to be extended so as to position the terminal in an area where the exhaust ue gas/plume will not cause a nuisance. is can be done before or aer installation of the ue, providing there is access to the terminal from outside.
a. Remove the screws (1 in Fig. 1-13) securing
the terminal and remove the terminal by pulling it from the ue assembly. Remove the screw (2 in Fig. 1-13) securing the terminal end section and remove the end section from the terminal.
Flue length (L)
b. Locate a 93° Plume Management bend
into the ue assembly and rotate it to the direction required.
c. Connect to the 93° bend the required Plume
Management components as detailed and refer to Fig. 1-14.
Notes:
- e wall support brackets must be used to secure the Plume Management pipework to the wall and prevent disconnection of the 93° bend from the ue assembly or any other component.
- Each joint must be secured with one of the screws provided to prevent accidental disconnection.
- Ensure there is always a slight slope towards the ue assembly tted 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.
Fig. 1-12 - Right side ue
d. Terminate the Plume Management pipework
by tting the terminal end section (push-t) previously removed. Refer to Fig. 1-13.
e. The Plume Management components
available for extending the inner ue 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 ue length)
60 mm dia. wall bracket
1
1
2
Fig. 1-13
9 Alpha Intec 50CS
INSTALLATIONUSERMAINTENANCE
Terminal end section
from CD Easy-Flue
Min. 400 mm
C
Terminal end
section from
CD Easy-Flue
Notes:
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)
Ensure there is a slope of approximately
Flue sealing collar
CD Easy-Flue
PM length = C + (1 x 93° bend = 1.3 m) + (2 x 45° bends = 1.8 m)
Note: e equivalent horizontal ue assembly length + the equivalent plume management length (PM length) must not exceed the maximum ue length stated for the boiler, i.e. e boiler maximum equivalent ue length must not exceed 12 metres.
3° back towards the Easy-Flue
PM length = C + (4 x 93° bend = 5.2 m)
C
Fig. 1-14
10Alpha Intec 50CS
Not less than
300 mm
H
Not less than
300 mm
1.10. VERTICAL FLUE OPTIONS
Hmax = 15 m Hmax = 13.2 m
Not less than
300 mm
Not less than
300 mm
INSTALLATIONUSERMAINTENANCE
H
Fig. 1-15
1.11 DISPOSAL OF CONDENSATE.
Provision must be made for the safe disposal of condensate produced by the ue gases of the Alpha InTec boilers and reference should be made to BS 6798 for the requirements on the disposal of condensate.
e 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. e 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. 1.16 and 1.17.
Plastic pipe
Note: All pipework must have a continuous fall (see Figs. 1.16 and 1.17) 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. e outside weather probe measures the external temperature, activating the trace heating cable only when the boiler is in operation and producing condensate. is feature together with the latest technology variable resistance heating cable ensures only a small amount of electrical energy is used.
Use waterproof pipework insulation in very exposed positions
Ensure pipe is adequately supported
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 o. e connection of the outside weather probe supplied with this kit also enables the weather compensation feature on the boiler.
Open end of pipe
Minimum gradient 2½°
diverted into gully below grid but above water level
Fig. 1-16
11 Alpha Intec 50CS
INSTALLATIONUSERMAINTENANCE
22mm termination from boiler, increase to 32 mm if external
Cement mortar sealing
500 mm min.
O
2½ fall
25mm
100mm plastic tube
Ground level (either/or)
300mm
Bottom of tube sealed
Soakaway depth 400mm filled with limestone chippings
1.12 FLUSH THE SYSTEM.
It is essential that the central heating system is thoroughly cleaned and ushed when tting an Alpha InTec boiler. Failure to do so will invalidate the warranty.
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).
e system should be ushed in accordance with BS 7593 and BS EN 14336. e following procedures are recommended:
- Installing onto a new system:­ Fill the system, vent at automatic air vents
and radiators. Check for leaks. Drain the system. If required, chemically clean the system as
instructed by the recommended cleaner
manufacturer. Note: Ensure that the system is ushed to
remove any remains of the cleaner. If chemical cleaner is not used to clean the
system:-
a Rell the system. b Switch on the boiler and allow the
system to heat up to the normal operating temperature.
c Switch o the boiler and drain the
system while the water is still hot.
d Rell the system and check for leaks.
As required, add the recommended inhibitor
to the system as instructed by the
inhibitor manufacturer.
Two rows of 3 x 12mm holes at 25mm centres, 50mm from the bottom of the tube. Holes to face away from house.
- Installing onto an existing system, clean the system before tting the new boiler:-
If the old boiler is still working:-
a Switch on the boiler and allow the
system to heat up to the normal operating temperature.
b Switch o the boiler and drain the
system while the water is still hot.
c Rell and chemically clean the system
as instructed by the recommended cleaner manufacturer.
d Ensure the system is ushed to remove
any remains of the cleaner.
e Fit the new boiler.
If the old boiler is not working:-
a Drain the system. b Remove the old boiler. c Flush the system through. d Fit the new boiler. e Rell and chemically clean the system
as instructed by the recommended cleaner manufacturer.
f Ensure the system is ushed to remove
any remains of the cleaner and check for leaks.
As required, add the recommended inhibitor
to the system as instructed by the inhibitor manufacturer.
Fig. 1-17
1.13 FILL THE SYSTEM.
e boiler is tted with two automatic air vents (see Fig. 1.18), ensure that the vents are always open. Open the central heating ow and return valves.
Open the ll point valves on the lling loop until water is heard to ow.
To remove the air - Vent each radiator in turn, starting with the lowest in the system.
It is important that the pumps are properly vented to avoid them running dry and damaging the bearings. Unscrew and remove the cap from the centre of the pump. Using a suitable screwdriver rotate the exposed spindle about half a turn, then replace the cap.
Check the operation of the pressure relief valve (see Fig. 1.18) by turning the head anti-clockwise until it clicks. e click is the valve liing o its seat allowing water to escape from the system ­check that this is actually happening.
Continue to ll the system until the pressure gauge indicates 1.0 bar. Close the ll point valve and check the system for water soundness, rectifying where necessary. Disconnect the lling loop from the mains supply.
Water may be released from the system by manually opening the drain point (see Fig. 1.18) until the system design pressure is obtained. e system design pressure (cold) should be between
0.75 and 1.25 bar.
Open the cold water mains inlet valve (see Fig.
1.18). Turn on all hot water taps and allow water to ow until no air is present. Turn o taps.
Ensure that the condensate trap has been lled with water. Refer to Section 1.11.
12Alpha Intec 50CS
1.14 CIRCULATION PUMP FIG. 118.
e Alpha Intec boilers are supplied with 2 types of pump, both with variable speed adjuster. ese settings are suitable for most systems.
•Boiler pump. e motor has a 3- speed control.
e boiler does not operate correctly with the control set at the slowest speed. For optimal functionality, use the pump at maximum speed (max. head).
Pump release. If the pump becomes stuck aer
a long period of inactivity, it must be released. Loosen the front cap, making sure that the water that escapes cannot cause injury/damage to persons/objects and turn the motor sha very carefully using a screwdriver so as not to damage the sha. Once the pump has been released, close the vent cap.
•Zone 1 pump. The pump is ideal for the
requirements of each heating system in a domestic and residential environment. In fact, the pump is equipped with electronic control that allows the advanced functions to be set.
Programme P (P-V) - Proportional curve (Green LED). This allows the head to be
proportionally reduced as the system heat demand decreases (ow rate reduction). Due to this function, the electrical consumption of the pump will be reduced: the power used by the pump decreases together with the pressure level and ow rate. With this setting, the pump guarantees optimal performance in most heating systems, there by being particularly suitable in single-pipe and two­pipe installations. Any noise of the water ow in the pipes, valves and radiators is eliminated by reducing the head.
Programmes C3 and C4 (P-C) - Constant curve (White or Orange LED). e pump
maintains a constant head as the system heat demand decreases (ow rate reduction). With these settings, the pump is suitable for all oor systems where all the circuits must be balanced for the same drop in head.
MIN-MAX Program (Blue LED). e pump is distinguished by adjustable operating curves by positioning the selector in any point between the Min and Max positions, thereby satisfying any installation requirement (from a simple single-pipe to more modern and sophisticated systems) and always guarantee optimum performance. e precise working point can be selected in the entire eld of use by gradually adjusting the speed.
Adjustments. Turn the selector and set it on the desired curve to adjust the pump.
Diagnostics in real time: a bright LED
(in various colours) provides information regarding the pump operating status.
Programme LED colour
P (ΔP-V) green
C3 (ΔP-C) - H=3 m white
C4 (ΔP-C) - H=4 m orange
Min - Max blue
ATTENTION! e pump is blocked but still live.
red
Possible pump release. A stuck pump is
indicated by a xed red LED. Turn the selector up to the MAX position, disconnect and reconnect the power to restart the automatic release process. e pump will then activate the procedure that will last a maximum of 15 minutes and the LED will ash upon each restart. It then turns blue for a few seconds and goes back to red if the attempt to restart is not successful. Once the process is complete, set the selector back to the desired curve and if the problem has not been resolved, perform the manual release procedure as follows.
- Disconnect the power to the boiler (the LED goes o).
- Close the system ow and return and let the pump cool down.
- Empty the system circuit via the relative valve.
- Remove the motor and clean the impeller.
- Once the release is complete, remount the motor.
- Fill the primary circuit; restore the power of the boiler and set the desired curve.
Important: Take care if the system has been in
operation as the water may be HOT.
INSTALLATIONUSERMAINTENANCE
13 Alpha Intec 50CS
6
C
5
60
50
INSTALLATIONUSERMAINTENANCE
4
3
Head (m)
2
1
0
0
6
5
4
3
Head (m)
2
1
0
0
A
B
D
200 400 600 800 1000 1200 1400 1600 1800 2000
Flow (l/h)
A = Head available to the system with pump at maximum speed B = Head available to the system with pump at minimum speed C = Pump power at maximum speed D = Pump power at minimum speed
E
G
F
J
H
200 400 600 800 1000 1200 1400 1600 1800 2000
Flow (l/h)
I
40
30
20
10
0
60
50
40
30
20
10
0
Power (W)
Power (W)
E = Head available to the system with pump selector in position C4 (standard setting) F = Head available to the system with pump selector in position P G = Head available to the system with pump selector in position C3 H = Pump power with selector in position P I = Pump power with selector in position C4 (standard setting) J = Pump power with selector in position C3
Fig. 1-18
14Alpha Intec 50CS
1.15 BOILER COMPONENTS
11
12
13
14
15
16
10
18
17
1
2
3
4
5
6
7
8
9
19
20
21
22
23
24
25
26
27
33 34
INSTALLATIONUSERMAINTENANCE
28
29
30
31
32
35
36
1 - Gas valve
2 - Flue thermostat 3 - DHW expansion vessel (3 litre) 4 - Flame sensing electrode 5 - System pump 6 - Automatic air vent 7 - Hydraulic manifold 8 - Fan 9 - Check valve 10 - Domestic hot water temperature sensor 11 - System pressure switch 12 - Manifold drain tap 13 - Automatic air vent 14 - Boiler pump 15 - Hot water store drain tap 16 - System drain tap 17 - Flue gas sampling point 18 - Pressure test points 19 - Manual air vent 20 - Ignition generator 21 - Air supply pipe 22 - Condensing heat exchanger 23 - Burner 24 - Ignition electrode 25 - Venturi 26 - Flow sensor 27 - Burner injector 28 - Overheat thermostats 29 - System safety valve (3 bar) 30 - Condensate trap 31 - Diverter valve 32 - System expansion vessel (11.7 litre) 33 - Hot water cyliner assembly (53 litre) 34 - Control panel 35 - Inlet lter, ow regulator, check valve tting 36 - domestic hot water safety valve (8 bar)
Fig. 1-19
15 Alpha Intec 50CS
USER INSTRUCTIONS.
2
2.1 SERVICING.
Imp ortant: the boil er requires perio dical
maintenance and regular checks of energy eciency in compliance with national, regional or local provisions in force. is ensures that the optimal safety, performance and operation characteristics of the boiler remain unchanged over time.
INSTALLATIONUSERMAINTENANCE
We re c ommend a ye arly c leaning a nd maintenance contract with your Service engineer.
2.2 GENERAL WARNINGS.
Use of the boiler by unskilled persons or children is strictly prohibited. For safety purposes, check that the ue terminal is not blocked.
2.3 CONTROL PANEL.
If temporary shutdown of the boiler is required, proceed as follows: a) drain the water system if anti-freeze is not
used.
b) shut-o all electrical, water and gas supplies.
In the case of work or maintenance to structures located in the vicinity of ducting or devices for flue extraction and relative accessories, switch o the appliance and on completion of operations ensure that a qualied technician checks eciency of the ducting or other devices. Never clean the appliance or connected parts with highly ammable substances. Never leave containers and ammable substances in the same environment as the appliance.
•Attention: the use of components that employ
electrical power requires some fundamental rules to be observed:
- do not touch the appliance with wet or moist parts of the body; do not touch when barefoot;
- never pull electrical cables or leave the appliance exposed to atmospheric agents (rain, sunlight, etc..);
- the appliance power cable must not be replaced by the user;
- in the event of damage to the cable, switch o the appliance and only contact qualied sta for replacement;
- if the appliance is not to be used for a certain period, disconnect the main power switch.
N.B.: the temperatures indicated by the display has a tolerance of +/- 3°C due to environmental conditions that cannot be blamed on the boiler.
Key
- Stand-by / On Button
A - Summer ( B - DHW priority button ( ) C - (RESET) /menu exit (ESC) reset button D - Menu entry button (MENU)/ data conrmation (OK) 1 - Domestic hot water temperature selector switch 2 - Domestic hot water temperature set 3 - Central heating temperature selector switch 4 - Central heating temperature set
) and winter ( ) functioning mode selection button
1
10 11 12
13
14
5 - Presence of anomalies 6 - Display of boiler operating mode 8 - Flame presence symbol and
relative output scale
9 and 7 - Primary heat exchanger output
water temperature 10 - Boiler in stand-by 11 - Boiler connected to remote
control (Optional) 12 - Functioning in summer mode 13 - Anti-freeze function in progress 14 - Functioning in winter mode 15 - Domestic hot water priority
functioning active
23
24
8
15
16 - Presence of external connected
devices 17 - Display of menu items 18 - Functioning with external
temperature probe active 19 - Display of data conrmation or
menu access 20 and 7 - External temperature display
with external probe connected
(optional) 21 - Display of reset or exit menu
3
request 22 - Chimney sweep function
in progress 23 - Boiler pressure gauge 24 - Multi-function display
22
16
2
5
17
18
4
21
7
19
9
Fig. 2-1
6
20
16Alpha Intec 50CS
2.4 OPERATING MODES.
Below is a list of boiler operating modes
that appear on the status display (item 6 in Fig. 2-1) together with a brief description.
Display (item 6) Description of operating mode
SUMMER
WINTER
DHW ON
CH ON
F3
Summer operating mode without request in progress. Boiler in stand-by for domestic hot water request.
Winter operating mode without request in progress. Boiler in stand-by for domestic hot water or central heating request.
Domestic hot water mode in progress. Boiler operating, domestic hot water heating in progress.
Central heating mode in progress. Boiler operating, central heating in progress.
Anti-freeze mode in progress. Boiler operating to restore the minimum safety temperature against boiler freezing.
With domestic hot water priority disabled (item 15 sysmbol o), the boiler only operates
DHW OFF
in central heating mode for 1 hour, however keeping the domestic hot water store at minimum temperature (20°C), aer which the boiler goes back to the normal operation, previously set.
Post ventilation in progress.
F4
Fan in function aer a request for domestic hot water or central heating in order to evacuate residual fumes.
Post circulation in progress.
F5
Pump operating aer a request for domestic hot water or central heating in order to cool the primary circuit.
e optional environment thermostat (TA) not working, the boiler functions all the time
P33
in central heating mode. (Can be activated through the 'Customisation' menu. It allows activation of the central heating even if the TA is out of order).
Reset attempts nished.
STOP
Wait for 1 hour to re-acquire 1 attempt. (See Ignition failure on following page).
ERR xx
SET
SET
Fault present with relative error code. e boiler does not work. (see Section 2.6, fault signals).
During rotation of the domestic hot water temperature selector switch (item 1 Fig. 2-1) the adjustment status of the domestic hot water temperature is displayed.
During rotation of the central heating selector switch (item 3 Fig. 2-1) the adjustment status of the boiler ow temperature for central heating is displayed.
In presence of the external probe (optional) replace the 'SET' item.
SET
e value that appears is the correction of the ow temperature with respect to the functioning curve set by the external probe. See OFFSET on external probe graphics (Fig. 1-4).
System deaeration in progress.
F8
During this phase, which lasts 18 hours, the boiler pump is started at pre-established intervals, thus allowing deaeration of the central heating system.
2.5 USING THE BOILER.
Refer to Fig. 2-1. Before lighting make sure the central heating
system is lled with water and that the pressure gauge (item 23) indicates a pressure of 1 - 1.2 bar;
Open the gas cock upstream from the boiler.
With the boiler o, only the stand-by symbol (item 10) appears on the display. By pressing the (
) button the boiler switches on. Once the boiler is on, by pressing button 'A' repeatedly, the operating mode changes and
passes alternatively from summer ( winter (
) operating modes.
) and
•Summ er (
): in this mod e the boi ler
operates only to provide domestic hot water. The temperature is set using the selector switch (item 1) and the relative temperature (item 2) is indicated on the display and the 'SET' indication appears (Fig. 2-2). By turning the selector switch (item 1) in a clockwise direction the temperature increases and in an anti-clockwise direction it decreases.
Set domestic hot water temperature
SET DHW
6
Fig. 2-2
1
2
°C
ESC
During the heating of the domestic hot water
'DHW ON' appears on the status display (item 6) and at the same time as the burner lights the ame presence display switches on (item 8) together with the output scale next to it. e displays (items 7 and 9) indicate the instantaneous outlet temperature from the primary heat exchanger. As shown in Fig. 2-3.
Summer operating mode with domestic hot
water only
12
°C
DHW ON
7
8
°C
MENU
6
9
1
2
Fig. 2-3
•Winter( ): in this mode the boiler operates
to provide both domestic hot water and central heating. e temperature of the domestic hot water is always adjusted using the selector switch (item 1), the central heating temperature is adjusted using the selector switch (item 3) and the relative temperature is indicated on the display (item 4) and the 'SET' appears on the status display (item 6). As shown in Fig. 2-4.
By turning the selector switch (item 3) in a
clockwise direction the temperature increases and in an anti-clockwise direction it decreases.
Set the central heating ow temperature
3
°C
ESC
SET
6
4
Fig. 2-4
During the request for central heating 'CH ON'
appears on the status display (item 6) and at the same time as burner lights the ame presence display switches on (item 8) together with the output scale next to it. e displays (items 7 and 9) indicate the instantaneous outlet temperature from the primary heat exchanger. As shown in Fig. 2-5.
Winter operating mode with domestic hot
water and central heating
14
8
1
2
°C
CH ON
697
3
°C°C
MENU
4
Fig. 2-5
In the central heating mode, if the temperature
of the water contained in the system is sucient to heat the radiators, the burner will shut o and only the pump will operate.
INSTALLATIONUSERMAINTENANCE
17 Alpha Intec 50CS
•Domestic hot water priority function By
pressing button 'B' the DHW priority function is deactivated, which is marked by the switch­o of the symbol (item 15 in Fig. 2-1) on the display. e disabled function keeps the water contained in the storage tank at a temperature of 20°C for 1 hour, giving the priority to central heating.
•Functioning with external sensor (Fig. 2-6)
optional. In the case of a system with optional
external sensor, the boiler ow temperature for central heating is managed by the external
INSTALLATIONUSERMAINTENANCE
sensor depending on the external temperature measured (Par. 1.5). It is possible to modify the ow temperature from -15°C to +15°C with respect to the adjustment curve (Fig. 1-4 Oset value). is correction, which can be activated using the selector switch (item
3) is kept active for any external temperature measured. The modification of the offset temperature is indicated on the display (item 7). e temperature indicated on the display (item
4) is the current ow temperature and aer a few seconds from the modication it is updated with the new correction. 'SET' appears on the status display (Fig. 2-6). By turning the selector switch (item 3) in a clockwise direction the temperature increases and in an anti-clockwise direction it decreases.
Set central heating ow temperature with
external sensor (optional)
°C
°C
ESC
SET
647
During a request for central heating 'CH ON' appears on the status indicator (item 6) and at the same time as burner lights the ame presence display switches on (item 8) together with the output scale next to it. e displays (items 7 and
9) indicate the instantaneous outlet temperature from the primary heat exchanger. In the central heating mode, if the temperature of the water contained in the system is sucient to heat the radiators, the boiler will only function with the activation of the boiler pump.
Winter operating mode with external
sensor (optional)
14
8
CH ON
697
°C°C
°C
MENU
1
2
Fr om t h is m oment the b oil er operat es automatically. With no demand for heat (central heating or domestic hot water) the boiler goes into 'stand-by' mode, equivalent to the boiler being powered without the boiler alight.
3
18
3
4
18
Fig. 2-6
Fig. 2-7
Note: e boiler may start-up automatically if the anti-freeze mode is activated, (item 13 Fig. 2-1). Also, the boiler can operate for a brief period of time aer a demand for domestic hot water in order to return the domestic hot water store back to temperature.
Important: With the boiler in stand-by mode (
) hot water cannot be produced and the safety systems cannot be guaranteed, such as pump anti-block, anti-freeze and three way anti-block.
2.6 FAULT SIGNALS.
e Alpha InTec boiler signals any faults by the ashing symbol (item 5 in Fig. 2-1) along with 'ERRxx' on the staus display (item 6). Where 'xx' corresponds to the error code described in the following table.
Fault signalled
Error
code
Ignition failure 01
Safety thermostat fault (overheating), ame control fault
02
Flue safety thermostat fault 03
Short circuit or bad connection 04
Flow sensor fault 05
Maximum number of resets reached 08
Insucient system pressure 10
Storage tank sensor fault 12
Conguration error 15
Fan fault 16
Flame sensing fault 20
Return sensor fault 23
Push button control panel fault 24
Insucient circulation 27
Loss of remote control communication
31
Low temperature zone 2 sensor fault 32
Low temperature zone 3 sensor fault 33
Low temperature zone 2 safety thermostat operation Low temperature zone 3 safety thermostat operation
34
35
IMG Bus communication loss 36
Low power supply voltage 37
Loss of ame signal 38
Ignition failure. e boiler lights automatically with each demand for ce nt ral heating or domestic hot water. If it does not light within 10 seconds, the boiler remains in stand-by for 30 seconds, tries again and if the second attempt fails it will go into 'ignition block' (ERR01). To eliminate 'ignition block' the Reset button 'C' must be pressed. e fault can be reset 5 times
consecutively, aer which the function disabled for at least one hour. One attempt is allowed every hour for a maximum of 5 attempts. By switching the boiler on and o the 5 attempts are re-acquired. On commissioning or after extended inactivity it may be necessary to eliminate the 'ignition fault'. If this phenomenon occurs frequently, contact a qualied engineer for assistance.
Safety thermostat fault (overheating). During operation, if a fault causes excessive overheating of the boiler, or a fault occurs in the ame control section, an overheating fault is triggered in the boiler (ERR02). To eliminate 'overheating fault' the Reset button 'C' must be pressed. If this phenomenon occurs frequently, call a qualied engineer for assistance.
Flue safety thermostat fault. is occurs in the case of partial internal obstruction (due to the presence of lime scale) or external blockage (combustion resi dues) to the combusti on chamber. To eliminate the 'ue thermostat fault' the Reset button 'C' must be pressed. Call a qualied engineer to remove the obstructions.
Short circuit or bad connection. is occurs in the case of faults to the safety thermostat (overheating) or fault in the flame sensing control. e boiler does not start and a qualied engineer must be called.
Flow sensor fault. If the board detects a fault with the system NTC ow sensor, the boiler will not start. Call a qualied egineer for assistance.
Maximum number of resets reached. The maximum number of 5 resets has been reached. Refer to previos paragraph - Ignition failure.
Insucient system pressure. Low water pressure inside the central heating system is detected and prevents the boiler operating. Check the boiler pressure gauge (item 1, Fig. 2-1) is between 1 and 1.2 bar. Restore to the correct pressure if necessary and check for leaks.
Storage tank sensor fault. If the board detects a fault with the storage tank sensor, the boiler will not produce domestic hot water. A qualied engineer must be called.
Conguration error. If the board detects a fault in the electric wiring, the boiler will not start. If normal conditions are restored the boiler restarts without having to be reset. If the fault persists, contact a qualied engineer for assistance.
Fan fault. is occurs if the fan has a mechanical or electrical fault. To eliminate the 'fan fault' the Reset button 'C' must be pressed. If the fault persists, contact a qualied engineer for assistance.
Flame sensing fault.is occurs in case of a leak on the detection circuit or fault in the ame control unit. e boiler can be reset in order to allow a new ignition attempt. If the boiler does not start, contact a qualied engineer for assistance.
Return sensor fault. In this condition the boiler does not correctly control the pump if set at 'Auto'. e boiler continues functioning but to eliminate the fault, contact a qualied engineer for assistance.
18Alpha Intec 50CS
Push button control panel fault. is occurs when the circuit board detects a fault on the push button control panel. If normal conditions are restored the boiler restarts without having to be reset. If this fault persists, contact a qualied engineer for assistance.
Insucient circulation. is occurs if there is overheating in the boiler due to insucient water circulating in the primary circuit, the causes can be:
- low system circulation - check that no shut-o devices are closed on the heating circuit and that the system is free of air (deaerated).
- circulating pump blocked - free the circulating pump.
If this phenomenon occurs frequently, contact a qualied engineer for assistance.
Loss of remote control communication. is occurs in the case of connection to a remote control that is not compatible. Try the connection procedure again by turning the boiler o and then back on again. If the Remote Control is still not detected on re-starting the boiler will switch to local operating mode, i.e. using the controls on the boiler itself. In this case the boiler cannot activate the 'Central heating' function. To make the boiler function in 'Heating' mode, activate the 'Emergency' function present inside the 'Customisations' menu (Section 2.14, P33). If this phenomenon occurs frequently, contact a qualied engineer for assistance.
Low temperature zone 2 sensor fault. If the board detects a fault with the low temperature zone 2 sensor, the boiler will not function in that zone. A qualied engineer must be called.
Low temperature zone 3 sensor fault. If the board detects a fault with the low temperature zone 3 sensor, the boiler will not function in that zone. A qualied engineer must be called.
Low temperature zone 2 safety thermostat operation. During operation, if a fault causes
excessive overheating of the low temperature zone 2, the boiler will not satisfy the requests of that zone. If normal conditions are restored the boiler restarts without having to be reset. A qualied engineer must be called.
Low temperature zone 3 safety thermostat operation. During operation, if a fault causes
excessive overheating of the low temperature zone 3, the boiler will not satisfy the requests of that zone. If normal conditions are restored the boiler restarts without having to be reset. A qualied engineer must be called.
IMG Bus communication loss. If due to a fault on the boiler control unit, communication is lost between the control unit and the zone control unit or on the IMG Bus, the boiler will not satisfy central heating requests. A qualied engineer must be called.
Low power supply voltage. is occurs when the supply voltage is lower than the allowed limits for the correct operation of the boiler. If normal conditions are restored, the boiler re-starts without having to be reset. If this occurs frequently, contact a qualied engineer for assistance.
Loss of ame signal. is occurs when the boiler has lit correctly but the burner ame switches o unexpectedly, a new attempt at ignition is performed and if normal conditions are restored, the boiler does not have to be reset (this fault can be checked in the list of errors P19 present in the 'M1' menu in Section 2.14.). If this phenomenon occurs frequently, contact a qualied engineer for assistance.
2.7 BOILER SHUTDOWN.
Switch the boiler off by pressing the “ button, disconnect the isolation switch outside of the boiler and close the gas cock upstream from the appliance. Never leave the boiler switched on if le unused for prolonged periods.
2.8 RESTORE THE SYSTEM PRESSURE.
Periodically check the system water pressure. e boiler pressure gauge should read a pressure between 1 and 1.2 bar.
If the pressure falls below 1 bar (with the system cold) restore normal pressure via the system lling valve located in the right side of the boiler and accessible behind the bottom cover (Fig. 2-8).
Note: Ensure the valve is closed aer lling. If pressure reaches 3 bar the safety valve may be activated. In this case contact a qualified engineer for assistance. In the event of frequent pressure drops, contact a qualied engineer to check for possible system leakage.
2.9 DRAIN THE SYSTEM.
To drain the boiler, use the central heating drain tap (Fig. 2-8). Before draining, ensure that the lling valve is closed.
Hot water store drain tap
2.10 DRAIN THE HOT WATER SYSTEM.
To drain the domestic hot water system, use the hot water store drain tap (Fig. 2-8).
Note: Before performing this operation close the boiler cold water inlet valve and open a hot water tap in order to allow the store to drain.
2.11 ANTIFREEZE PROTECTION.
e boiler controls include an anti-freeze mode that activates the pump and burner when the system water temperature in the boiler falls
”,
below 4°C.
e anti-freeze function is only guaranteed if:
- the boiler has a constant supply of gas and electricity.
- the boiler is not in stand-by(
- the boiler ignition has not locked out.
- the boiler essential components are not faulty.
In the case of prolonged inactivity (second home), we recommend that:
- the electricity supply is disconnected.
- the central heating and boiler domestic hot water circuits are drained. In systems that are drained frequently, lling must be carried out with suitably treated water to eliminate hardness that can cause lime-scale.
2.12 CASE CLEANING.
Use damp cloths and neutral detergent to clean the boiler casing. Never use abrasive or powder detergents.
2.13 DECOMMISSIONING.
In the event of permanent shutdown of the boiler, contact a qualied engineer for the procedures and ensure that the electrical, water and gas supplies are shut o and disconnected.
).
INSTALLATIONUSERMAINTENANCE
Central heating drain tap
Fig. 2-8
19 Alpha Intec 50CS
2.14 PARAMETERS AND INFORMATION MENU REFER ALSO TO FIG. 21.
By pressing the button 'D' it is possible to access a menu divided into three main parts:
- 'M1' - Information.
- 'M3' - Customisations.
- 'M5' - Congurations, menu reserved for the
engineer and for which a password is required.
Information Menu. is menu contains various information relative to the boiler operation:
INSTALLATIONUSERMAINTENANCE
Level 1 Button Level 2 Button Level 3 Button Description
P11
P12 View the total operating hours of the boiler P13 View the number of burner ignitions
P14
(with optional
external sensor
M1
D
C
present)
- - -
(without optional
external sensor)
P15 P17 View the fan speed P18 e value displayed does not aect this model
P19
Turn the central heating temperature selector
switch (item 3) to scroll through the menu items.
Press button 'D' to access the various levels of
the menu.
Press button 'C' to go back one level.
View the management soware version of the boiler P.C.B.
D
C
D
C
D
C
P14/A View the current external temperature (optional external sensor used)
P14/B
P14/C
RESET
select
xx = soware display version yy = ignition control soware version (burner control) zz = P.C.B. soware version
View the minimum external temperature recorded (optional external sensor used)
View the maximum external temperature recorded (optional external sensor used)
D
x
By pressing button 'D' the MIN and MAX temperatures measured are zeroed
C
No display on this boiler model
View the last 5 events that caused a boiler shutdown. e sequential number from 1 to 5 is indicated in the display (position 6) with the relative error code in postion 7. By pressing button 'D' repeatedly it is possible to view the operating time and the number of ignitions at which the anomaly occurred
Customisation menu. is menu contains all options that can be customised. (e rst item of the various options that appears inside the parameter is that selected by default).
Level 1 Button Level 2 Button Level 3 Button Level 4 Button Description
P31
D
M3
C
P33
RESET
D
C
D
C
D
x
select
C
Important: if the international language is to be restored (A1), proceed as follows:
- press button 'D' to enter the configuration menu.
- turn selector switch '3' to 'PERSONAL'.
- press button 'D' to conrm.
- turn selector switch '3' to 'DATI'.
AUTO
(Default)
ON e display is always lit up
OFF
P32/B
OFF
ON
D
x
select
C
D
C
D
x
select
C
ITALIANO
A1
(Default)
- press button 'D' to conrm.
- turn selector switch '3' to 'LINGUA'.
- press button 'D' to conrm.
- turn selector switch '3' to 'A1'.
- press button 'D' to conrm. At this point the international items indicated in the menu tables appear on the display.
e display lights up when the burner is ignited and when the controls are accessed, it remains on for 5 seconds aer the last operation performed
e display only lights up when the controls are accessed and remains on for 5 seconds aer the last operation performed
D
All descriptions are given in Italian
x
select
All descriptions are given in alphanumerical format
C
In winter mode, by activating this function it is possible to activate the central heating function even if the optional environmental thermostat (TA) is out of service
By pressing button 'D' the customisations made are zeroed, restoring the factory ser values
20Alpha Intec 50CS
BOILER STARTUP
3
INITIAL CHECK.
To commission the boiler:
- ensure that the Benchmark information and Checklist is completed.
- make sure that the type of gas used corresponds to boiler settings.
- check connection to a 230V-50Hz power supply, correct L-N polarity and the earthing connection.
- make sure the central heating system is lled with water, all radiators have been vented and that the pressure gauge indicates a pressure of 1 to 1.2 bar.
3.1 HYDRAULIC DIAGRAM.
- check that the automatic air vent cap is open and that the system is well deaerated.
- switch the boiler on and check correct ignition.
- check the burner pressure in domestic hot water and central heating modes.
- check the CO minimum ow rate.
- check activation of the safety device in the event of no gas, as well as the relative activation time.
- check activation of the main switch located upstream from the boiler and in the boiler.
- check that the ue is operating correctly.
in the ue at maximum and
2
- check that all control devices are working.
- check the production of domestic hot water.
- check the water circuits for leaks rectifying where necessary.
- check ventilation and/or aeration of the installation room where provided.
If any checks/inspection give negative results, do not start the boiler.
After commi ssioning the boiler, ensure the Benchmark Checkli st at the back od these instructions is completed.
INSTALLATIONUSERMAINTENANCE
Domestic hot water
outlet
47
46
45
44
43
42
41
40
39
From
item
38
42
Primary heating
Cold mains water inlet
24
23
22
21
return
20
Primary heating flow
19
37
36
35
34
18
17
P
(P1) (P2)
Gas
16
152914
(P3)
Gas
13
12
11
10
9
8
7
6
5
4
3
1 - Condensate trap 2 - Air intake pipe 3 - Fan 4 - Burner injector 5 - Flame sensing electrode 6 - Burner 7 - Flue safety thermostat 8 - Heat exchanger 9 - Manual air vent 10 - Flue hood 11 - Gas valve outlet pressure point (P3) 12 - Gas valve 13 - Gas service cock 14 - Air sample point 15 - Flue sample point 16 - Venturi pressure points
33 27
32 26
31 25
30
17 - Overheat thermostats 18 - System pump 19 - CH isolation valves 20 - Automatic air vent 21 - Hydraulic manifold 22 - Manifold drain tap 23 - Filling loop 24 - Check valve 25 - Venturi
26 - Positive pressure point (P1) 27 - CH expansion vessel 28 - CH pressure relief valve 29 - Diverter valve 30 - Pressure switch 31 - Boiler pump 32 - Automatic air vent
28
21 Alpha Intec 50CS
2
Condensate
1
discharge
33 - CH drain tap 34 - Venturi negative pressure point (P2) 35 - Gas manifold 36 - Ignition electrode 37 - Flow temperature sensor 38 - Tundish 39 - Hot water store drain tap 40 - DHW temperature sensor 41 - DHW expansion vessel 42 - DHW expansion relief valve 43 - Check valve 44 - Flow regulator 45 - Filter 46 - Pressure reducing valve 47 - DHW isolation valve
Fig. 3-1
3.2 WIRING DIAGRAM.
Flue safety
thermostat
Flame sensing
electrode
Fan
Gas valve
Boiler pump Spark generator
Mains supply
230/240 V ~ 50 Hz
AUX
230/240 V ~ 50 Hz
Max. 2 A
Ignition electrodes
Filter
Pump relay board
Diverter valve
Display
System pump
DO NOT CONNECT 230/240V~50Hz
External
sensor
(optional)
Volt free room
thermostat
(optional)
Overheat
thermostats
System
pressure switch
DHW
sensor
PCB
Flow
sensor
CH ON
Fuse 3.15 AF
X11
X10
X1
X4
X9
X19
X18
LINK
X7
X2
X14 X12
X8
X17
X3
X1
X1
X2
Transformer
X5 X6
X16X15
IMG BUS
C.A.R.
BUS
1 234
5 6
7
1 234
5
1234
56
7
NL
B
A
12
3
112
2
3
383940
41 42
43
2144
1 234
5 678 9
10
11
1 2
3 4 5 6
7
R
R
R
Gy
Gy G/y
G/y
Gy
R
R
R
R R
Bk
Bk
Bk
Bk
Bk
Bk
Bk
Bk
Bk
Bl
Bk
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Br
Br
Br
Br
Br
Br
Bl
Gy
Gy
W
CH
DHW
W
W
W
W
W
W
Or
Or Or
P
P
G/Y
+UB
-UB
HS
GND
PWM
INSTALLATIONUSERMAINTENANCE
Colour Code
Br - Brown Bk - Black Bl - Blue
Room thermostat: To fit an external room thermostat connect it to terminals 40 and 41, removing the link rst.
R - Red Or - Orange G/Y - Green/Yellow
e connector X5 is used for the connection to the relay board.
3.3 TROUBLESHOOTING.
Note: Maintenance must be carried out by a
qualied Engineer.
- Smell of gas. Caused by leakage from gas pipes. Check pipework for soundness, rectifying where necessary.
- Repeated ignition failure. No gas, check the presence of pressure in the supply and that the gas supply cock is open. Incorrect adjustment of the gas valve, check the correct calibration of the gas valve.
- Irregular combustion or noisiness. is may be caused by: a dirty burner, incorrect combustion parameters, flu e terminal not correct ly installed. Clean the above components and ensure correct installation of the terminal, check correct setting of the gas valve (O-Set setting) and correct percentage of CO2 in the ue gas.
W - White Gy - Grey P - Pink
- Frequent operation of the overheat safety thermostat. It can depend on the lack of water in the boiler, poor water circulation in the system or blocked pump. Check on the pressure gauge that the system pressure is within established limits. Check that the radiator valves are not closed and also the operation of the pump.
- Blocked condensate trap. is may be caused by dirt or combustion products deposited inside. Check, by means of the condensate drain cap, that there are no residues of material blocking the ow of condensate.
- Heat exchanger blocked. is may be caused by the trap being blocked. Check, by means of the condensate drain cap, that there are no residues of material blocking the ow of condensate.
- Noise due to air in the system. Make sure the cap on the automatic air vent has been opened (item 6 Fig. 1-19). Make sure the system pressure and expansion vessel factory set pressure values are within the set limits; e factory set pressure values of the expansion vessel must be 1.0 bar, the value of system pressure must be between 1 and 1.2 bar. Check that system has been lled and vented correctly.
- Noise due to air inside the heat exchanger. Make sure the heat exchanger has been vented correctly (use the manual air vent, item 19 Fig. 1-19). Ensure the air vent is closed aer use..
- Domestic hot water store temperature sensor failure. e boiler or store do not have to be drained in order to replace the DHW sensor, as the sensor is not in direct contact with the DHW present in the boiler.
3.4 CHIMNEY SWEEP FUNCTION.
When this function is activated the boiler operates only by adjusting the central heating selector switch (item 3, Fig. 2-1). In this state all adjustments are excluded and only the safety thermostat and the limit thermostat remain active. To activate the chimney sweep press the Reset button 'C' for a time between 8 and 15 seconds in absence of domestic hot water and central heating requests. Its activation is indicated by the relative symbol (item 22, Fig. 2-1). is function allows the engineer to check the combustion parameters. Aer the checks, deactivate the function by switching the boiler o and on again using the Stand-by button
Fig. 3-2
.
22Alpha Intec 50CS
3.5 PUMP ANTISEIZE FUNCTION.
e boiler has a function that starts the pump at least once every 24 hours for the duration of 30 seconds in order to reduce the risk of the pump becoming blocked due to prolonged inactivity.
3.6 THREEWAY VALVE ANTISEIZE FUNCTION.
Both in 'domestic hot water' and 'central heating' modes the boiler has a function that starts the three-way valve 24 hours after it was last in operation, running it for a full cycle so as to reduce the risk of the valve becoming blocked due to prolonged inactivity.
3.7 RADIATOR ANTIFREEZE FUNCTION.
If the system return water is below 4°C, the boiler starts up until reaching 42°C.
3.8 P.C.B. PERIODIC SELFCHECK.
During operation in central heating mode or with the boil er in stand-by mode, this function activates every 18 hours aer the last boiler check/power supply. When operating in domestic hot water mode the self-check starts within 10 minutes aer the end of the last hot water draw-o, for approximately 10 seconds.
Note: During self-check, the boiler remains o.
3.9 AUTOMATIC VENT FUNCTION.
In the case of new central heating systems it is very important that the system is vented correctly. To activate the 'F8' function (Section
2.4), press buttons 'B and C' at the same time
(Fig. 2-1) for 5 seconds with boiler in stand-by. e operation consists of cyclic operation of the pump (100 sec ON, 20 sec OFF) and the 3-way valve (120 sec domestic hot water, 120 sec central heating). e operation ends aer 18 hours or by switching the boiler on using the ignition button
.
3.10 YEARLY APPLIANCE CHECK AND MAINTENANCE.
e following checks and maintenance must be performed at least once a year.
- The Benchmark Service Record must be
completed in order to preserve the boiler warranty.
- Clean the ue side of the heat exchanger.
- Clean the main burner.
- Check correct ignition and operation.
- Check correct calibration of the burner in
domestic hot water and central heating modes.
- Check correct operation of the controls, in
particular:
- the operation of main electrical switch on the
boiler.
- system control thermostat operation.
- dome st ic hot water control thermostat
operation.
- Check the gas circuit for soundness.
- Check the operation of the flame sensing
control:
- check that the relative intervention time is
less than 10 seconds.
- Visually check for water leaks or oxidation
from/on connections and traces of condensate residues inside the sealed chamber.
- Check, by means of the condensate drain cap,
that there are no residues of material blocking the ow of condensate.
- Check contents of the condensate drain trap.
- Visually check that the water safety drain valve
is not blocked.
- Check that, aer discharging system pressure
and bringing it to zero (read on boiler pressure gauge), the expans ion vessel factor y-set pressure is 1.0 bar (primary CH vessel).
- Check that the domestic hot water expansion
vessel load is at a pressure between 3 and 3.5 bar.
- Check that the system static pressure (aer
refilling the system and when it is cold) is between 1 and 1.2 bar.
- Visually check that the safety and control
devices have not been tampered with and/or shorted, in particular:
- temperature safety thermostat.
- system pressure switch.
- Check the condition and integrity of the
electrical system and in particular:
- electrical power cables must be inside the
sleeving.
- there must be no traces of blackening or
burning.
Note: When carrying out maintenance on the boiler, also check the central heating system to ensure it is functioning correctly and free of leaks.
INSTALLATIONUSERMAINTENANCE
23 Alpha Intec 50CS
INSTALLATIONUSERMAINTENANCE
B
B
A
4
3
4
3
3.11 CASING REMOVAL.
For ease of boiler maintenance the casing can be completely removed as follows.
•Openthecontrolpanel(item1,Fig.3-3).
- Press the centre of the control panel cover (2) to open it and lower the panel. ­Carefully remove the rubber bump stops (3) and loosen the two screws (4).
- Step A. Li the control panel up, gripping it at the sides, to disengage it from the locking pin (5).
- Step B. Pull the control panel forwards slightly.
- Step C. Hinge open the panel as shown in Fig. 3-3.
•Removethelowerpanel(item6,Fig.3-4).
- Step D. Press down on the two catches (7)
- Step E. Hinge the cover forwards on the two screws (8) and li it o the screws.
•Removetheremaingcasepanels(Fig.3-5).
- Top cover (item 9, Fig. 3-5). Remove the two screws (10), pull the cover forwards slightly to disengage the xings (see view A) and li it o.
- Rear top cover (item 11, Fig. 3-5). Remove the two screws (12) and li o the cover.
- Front panel (item 13, Fig. 3-5). Remove the two screws (14), li up the cover slightly to disengage the xings (see view B) then pull it forwards o the side panels.
- Side panels (item 16, Fig. 3-5). Remove the upper and lower screws (15) then slide the panel forwards to disengage it from the rear xings (see view C).
2
1
A
C
1
5
Fig. 3-3
E
D
8
7
8
6
7
Fig. 3-4
24Alpha Intec 50CS
10
12
9
11
View A
INSTALLATIONUSERMAINTENANCE
14
16
13
14
15
View B
15
15
View C
16
Fig. 3-5
3.12 COMBUSTION SETTINGS.
Natural Gas Propane
Supply pressure mbar 20 37 Burner nozzle mm N/A 6.00 Flue ow rate at max heat output kg/h 52 53 Flue ow rate at min heat output kg/h 12 12 CO
at Q. Nom./Min. % 9.40 / 8.90 10.50 / 10.30
2
CO at 0% di O NOX at 0% of O2 at Nom.Q./Min. ppm 83 / 43 99 / 54 Flue temperature at nominal output °C 73 74 Flue temperature at minimum output °C 64 66 Gas rate at maximum heat output m³/h 3.49 N/A Gas rate at maximum heat output kg/h N/A 2.57
at Q. Nom./Min. ppm 206 / 9 190 / 8
2
25 Alpha Intec 50CS
3.13 TECHNICAL DATA.
Maximum heat input kW 33.0
Minimum heat input kW 7.3
Maximum heat output (useful) kW 32.0
Minimum heat output (useful) kW 6.9
Eciency 80/60 Nom./Min. % 96.9 / 94.5
Eciency 50/30 Nom./Min. % 104.7 / 105.8
Eciency 40/30 Nom./Min. % 107.3 / 107.3
Heat loss at casing with burner O/On (80-60°C) % 0.80 / 0.20
INSTALLATIONUSERMAINTENANCE
Heat loss at ue with burner O/On (80-60°C) % 0.02 / 2.90
Central heating circuit max. operating pressure bar 3
Central heating circuit max. operating temperature °C 90
Max. adjustable central heating temperature °C 25 - 85
Min. adjustable central heating temperature °C 25 - 50
System expansion vessel total volume l 11.7
System expansion vessel factory-set pressure bar 1.0
Domestic hot water expansion vessel total volume l 3.0
Domestic hot water expansion vessel factory-/set pressure bar 2.5
Water content in generator l 4.0
Total head available with 1000 l/h m H
O 3.61
2
Hot water production useful heat output kW 32.0
Domestic hot water adjustable temperature °C 20 - 60
Domestic hot water circuit ow limiter at 2 bar l/min 12.6
Min. pressure domestic hot water circuit bar 0.3
Max. pressure domestic hot water circuit bar 8.0
*Flow rate 'D' according to EN 625 l/min 19.5
Continuous draw capacity (∆T 30°C) l/min 15.8
Domestic hot water performance classication according to EN 13203-1

Weight of full boiler kg 147.7
Weight of empty boiler kg 90.1
Power supply connection V/Hz 230/50
Power input A 0.85
Installed electric power W 165
Pump consumption W 34
Fan consumption W 26.4
Equipment electrical system protection - IPX5D
Flue gas max. temperature °C 75
class - 5
NO
X
Weighted NO
X
mg/kWh 52
Weighted CO mg/kWh 17
Type of appliance
C13 / C33 / C43 / C53 / C83 /
C93 / B33 / B53p
Category II2H3B/P
- Flue temperature values refer to an air inlet
temperature of 15°C and ow temperature of 50°C.
- The dat a relevant to domestic hot water
performance refer to a dynamic inlet pressure of 2 bar and an inlet temperature of 15°C, the values are measured directly at the boiler outlet to obtain the data declared mixing with cold water may be necessary.
- * Specific capacity 'D': domestic hot water ow rate corresponding to an average increase of 30K, which the boiler can supply in two successive withdrawals.
To achieve these higher ow rates the ow
restrictor must be removed from the cold inlet connection. See Section 1.15 item 35.
26Alpha Intec 50CS
3.14 SHORT PARTS LIST.
Description Alpha Part No.
Hydraulic assembly ........................................................................................3.020477
DHW cylinder (complete assembly) ...........................................................3.023189
Circulating pump 15 - 60 - 130 .....................................................................1.032756
Bottom front case panel .................................................................................2.013823
Control panel door assembly ........................................................................ 3.017249
Display board ..................................................................................................1.032461
Burner manifold ............................................................................................. 1.025506
Pump assembly (head and housing) ............................................................ 3.020069
CH expansion vessel (12 litre) ......................................................................1.027232
Flue thermostat (110 °C) ................................................................................1.025798
3-way valve complete cartridge ..................................................................... 3.013730
Drain tting with hose union ........................................................................ 1.4275
Pressure sampling point cap ..........................................................................1.025690
Heating manifold drain tap ........................................................................... 1.0113
Front case panel ............................................................................................... 2.013824
DHW expansion vessel (3 litre) .....................................................................1.033497
Safety valve - DHW (6 bar) ........................................................................... 1.018091
D.15 pipe - safety valve outlet .......................................................................1.033560
Automatic air vent valve + 'O' ring ..............................................................1.017113
D.15 pipe - heating system safety valve .......................................................1.033634
Burner .............................................................................................................. 1.019622
NTC fast immersion probe ...........................................................................1.021762
Flue hood assembly ........................................................................................ 3.020662
Condensation module ...................................................................................1.024965
Bottom frame assembly .................................................................................3.019766
Cylinder top plug ............................................................................................1.1122
Cylinder tank gasket ......................................................................................1.7199
Relay PCB ........................................................................................................1.027418
Control panel knob ....................................................................................... 1.022370
Pressure gauge .................................................................................................1.032278
Hot water outlet cylinder tting ...................................................................1.5370
PCB ...................................................................................................................1.028532
Pressure switch ...............................................................................................1.025006
Gas valve ..........................................................................................................1.031823
Lehand case panel ........................................................................................2.013822
Plug for ange with sample points ...............................................................1.025278
Drain tting .....................................................................................................3.023191
Safety valve - CH (3 bar) ...............................................................................1.033574
Automatic air vent .......................................................................................... 1.2295
Flow regulator (pink - 14 litres) ....................................................................1.032198
Righthand case panel ..................................................................................... 2.013821
Top case panel (front) ....................................................................................2.015009
Top case panel (rear) ...................................................................................... 2.014920
Fan ....................................................................................................................1.029719
Diverter valve motor ...................................................................................... 1.018064
Sealed chamber cover with window ............................................................3.019767
Venturi .............................................................................................................1.024392
Spark generator ...............................................................................................1.025360
Ignition electrode assembly ...........................................................................3.017477
Flame sensing electrode .................................................................................1.028890
Overheat thermostat (100°C) .......................................................................1.025797
Condensate drain pipe ................................................................................... 1.027265
Condensate trap ..............................................................................................3.020486
Complete connection kit ...............................................................................3.023368
INSTALLATIONUSERMAINTENANCE
27 Alpha Intec 50CS
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 this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
Customer Name
Address
Boiler Make and Model
Boiler Serial Number
Commissioned by (print name)
Company Name Telephone Number
Company Address
INSTALLATIONUSERMAINTENANCE
To be completed by the customer on receipt of a Building Regulations Compliance Certificate
Building Regulations Notification Number (if applicable)
CONTROLS Tick the appropriate boxes
Time and Temperature Control to Heating Room Thermostat and Programmable Load/Weather Optimum Start
remiT/remmargorP Room Thermostat Compensation Control
Telephone Number
Gas Safe Register licence No.
Commissioning Date
:
*
remiT/remmargorPdnatatsomrehTrednilyCretaWtoHotlortnoCerutarepmeTdnaemiT Combination
dettiFsevlaVenoZgnitaeH Not Required
dettiFsevlaVenoZretaWtoH Not Required
dettiFsevlaVrotaidaRcitatsomrehT
dettiFmetsySotssapyBcitamotuA Not Required
Boiler
Not Required
dedivorPkcolretnIrelioB
ALL SYSTEMS
The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions
What system cleaner was used?
What inhibitor was used? Quantity litres
CENTRAL HEATING MODE
Gas Rate
Central Heating Flow Temperature °C
Central Heating Return Temperature °C
Measure and Record:
)elbacilppafi(erusserPgnitarepOrenruB
3
m
/hr OR
mbar OR Gas Inlet Pressure mbar
seY
3
ft
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)?
If yes, has a water scale reducer been fitted? Yes No
What type of scale reducer has been fitted?
DOMESTIC HOT WATER MODE Measure and Record:
etaRsaG
erutarepmeTtelnIretaWdloC °C
Hot water has been checked at all outlets Yes Temperature °C
etaRwolFretaW l/min
3
ROrh/
m
Yes No
)etarmumixamta(erusserPtelnIsaGROrabm)etarmumixamta(erusserPgnitarepOrenruB
3
ft
mbar
CONDENSING BOILERS ONLY
8976SB/6455SBro/dnasnoitcurtsnis’rerutcafunamehthtiwecnadroccanidellatsnineebsahniardetasnednocehT
seY
/hr
/hr
INSTALLATIONS
If required by the manufacturer, record the following
The manufactur
Commissioning Engineer’s Signature
Customer’s Signature
(To confirm 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.
©Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
er’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes
CO
2
% OR CO ppm OR CO/CO
Ratio
2
seYsnoitalugeRgnidliuBetairporppaehthtiwseilpmocmetsysretawtohdnagnitaehehT
seYsnoitcurtsnis’rerutcafunamehthtiwecnadroccanidenoissimmocdnadellatsnineebevahstcudorpdetaicossadnareliobehT
seYremotsucehtybdootsrednudnaotdetartsnomedneebevahslortnocmetsysdnareliobehtfonoitarepoehT
28Alpha Intec 50CS
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service 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 specified spare part when replacing controls.
SERVICE 1
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Gas Safe Register licence No. Gas Safe Register licence No.
Comments
Signature
SERVICE 3
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Gas Safe Register licence No. Gas Safe Register licence No.
Comments
Signature
SERVICE 5 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Gas Safe Register licence No. Gas Safe Register licence No.
Comments
Date
Date
Yes No
Yes No
Yes No
SERVICE 2
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Comments
Signature
SERVICE 4
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Comments
Signature
SERVICE 6 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Comments
Date
Date
Yes No
Yes No
Yes No
Signature
SERVICE 7 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Gas Safe Register licence No. Gas Safe Register licence No.
Comments
Signature
Yes No
SERVICE 9 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Gas Safe Register licence No. Gas Safe Register licence No.
Comments
Signature
Yes No
Signature
SERVICE 8 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Comments
Signature
SERVICE 10 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Comments
Signature
29 Alpha Intec 50CS
Yes No
Yes No
30Alpha Intec 50CS
31 Alpha Intec 50CS
During the useful life of the unit, the performance is aected by external factors, such as the hardness of tap water, weathering, deposits in the ue and so on. e data given refers only to new units correctly installed and used in accordance with the instructions.
Note: It is recommended that the boiler is serviced annually.
www.alpha-innovation.co.uk
For Technical help or for Service call the Alpha Helpline or use the following e-mail:
info@alpha-innovation.co.uk Alpha Helpline 0844 871 8764
Alpha erm Limited Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS
ese instructions have been carefully prepared but we reserve the right to alter the specication at any time in the interest of product improvement. © Alpha erm Limited 2013.
Part No. 1.034294 rev. 15.039381/000
03/2013 D323
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