Alpha InTec 30C Installation And Servicing Instruction
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Alpha InTec 30C Installation And Servicing Instruction

Wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing combination boilers
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Installation and Servicing
Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing Combination Boilers
0051
These instructions have been carefully prepared but we reserve the right
to alter the specification at any time in the interest of product improvement.
© Alpha Therm Limited 2015.
Instructions
Alpha InTec
30C and 34C
For Technical help or for Service call ...
ALPHA HELPLINE Tel: 0844 871 8764
website: www.alpha-innovation.co.uk
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Alpha InTec 30C (NG)
Alpha InTec 34C (NG)
Alpha InTec 30C (LPG)
Alpha InTec 34C (LPG)
Set for use with Natural Gas
Leave these instructions with the User
G.C. No. 47 532 48
G.C. No. 47 532 49
G.C. No. 47 532 55
G.C. No. 47 532 56
Part No. 1.038431 ST.001939/000
0515/D350

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Summary of Contents for Alpha InTec 30C

  • Page 1 30C and 34C Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing Combination Boilers For Technical help or for Service call ... ALPHA HELPLINE Tel: 0844 871 8764 website: www.alpha-innovation.co.uk Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN15 7RS Alpha InTec 30C (NG) G.C.
  • Page 2 Benchmark Service Interval Record and left with the householder. www.centralheating.co.uk Useful contact details: Gas Safe Register - 0800 408 5577 - www.gassaferegister.co.uk Alpha Heating Innovation: General Sales Enquiries - 0844 871 8760 Technical Helpline - 0844 871 8764 Alpha InTec 30C and 34C - Benchmark Scheme...

  • Page 3: Table Of Contents

    Component replacement ....32 INTRODUCTION The Alpha InTec range of high efficiency condensing boilers are wall mounted, fan assisted room-sealed combination boilers. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve. These are combination boilers providing both central heating and domestic hot water at mains pressure.

  • Page 4: Technical Data

    Min. primary system pressure Recommended system pressure - Cold System pressure relief valve setting Expansion vessel size litres Expansion vessel charge pressure Electrical power consumption - Max. Watts Electrical power consumption - Standby Watts Alpha InTec 30C and 34C - Technical Data...
  • Page 5 Boiler operating weight (full of water) approx. Max. total flue length Horizontal Max. total flue length Vertical 60/100 60/100 Flue system diameter Factory fitted Filling loop Factory fitted Seasonality valve GasSaver compatible - Solar compatible Alpha InTec 30C and 34C - Technical Data...
  • Page 6 During normal operation the green LED (2) is on and the four yellow LEDs (3) indicate the power level according to the following table: Pump LEDs Power consumption 0 - 25 % 25 - 50 % 50 - 75 % 75 - 100 % Alpha InTec 30C and 34C - Technical Data...
  • Page 7 (the pump continues to run) Low power supply voltage Electrical fault The pump is locked due to Check power supply, if anomaly persists (pump blocked) power supply too low or replace the pump serious malfunction Alpha InTec 30C and 34C - Technical Data...
  • Page 8 WARNING Ensure Control wires are RF Climatic connected correctly - refer to the control receiver control and boiler instructions for (optional) connection details. RF Climatic Optional Alpha controls control (optional) Fig. 2.2 Alpha InTec 30C and 34C - Technical Data...
  • Page 9 24 - Gas service cock 37 - Flow regulator (if fitted) 12 - Flue hood 25 - Mains inlet on/off valve 13 - Overheat thermostat 26 - On/off valve (2 off) Fig. 2.3 Alpha InTec 30C and 34C - Technical Data...

  • Page 10: General Boiler Information

    2. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally and only 14 metres vertically. 3. Failure to use Alpha CD flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe.
  • Page 11 VERTICAL FLUE OPTIONS Not less than 300 mm Not less than 300 mm Not less than 300 mm Not less than 300 mm Hmax = 15 m Hmax = 13.2 m Fig. 3.1 Alpha InTec 30C and 34C - General Boiler Information...
  • Page 12 However, If the terminal is fitted less than 2 m above a surface where there is no public access, the terminal must be protected by a terminal guard. A suitable guard is available from Alpha Therm Ltd. Alpha InTec 30C and 34C - General Boiler Information...
  • Page 13 The boiler may be installed in a cupboard or compartment, provided it is correctly designed for that purpose, i.e. complies with the Building Regulations and the requirements of BS 6798. Alpha InTec 30C and 34C - General Boiler Information...
  • Page 14 Drain taps (to BS 2879) must be used to allow the system to be completely drained. Hose unions Double check valve assembly Heating circuit Mains return water Stop Stop supply valve valve Test cock Filling loop temporarily connected Fig. 3.5 Alpha InTec 30C and 34C - General Boiler Information...
  • Page 15 FLUSHING THE HEATING SYSTEM It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha InTec boiler. Failure to do so will invalidate the warranty. The primary condensing heat exchanger is constructed in stainless steel and therefore is compatible with most materials used in a heating system.
  • Page 16 Seasonality valve - This valve maintains the hot water temperature (factory set) for both summer and winter conditions by automatically changing the flow rate through the boiler. However, if adjustment of the setting is required, refer to Section 5.6.2. Alpha InTec 30C and 34C - General Boiler Information...

  • Page 17: Installation

    140 mm, 185 boiler mm if the wall jig is used (ensure the lines Template are horizontal). This will give the position of Fig. 4.2 the centre of the hole for the flue. Alpha InTec 30C and 34C - Installation...
  • Page 18 E - Heating return (22 mm) B - Hot water outlet (15 mm) D - Cold water mains inlet (15 mm) F - Pressure relief valve (15 mm) Fig. 4.4 - Without wall jig Alpha InTec 30C and 34C - Installation...
  • Page 19 FIT THE FLUE - Figs. 4.5 and 4.6 The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only. The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below.
  • Page 20 Note: Ensure that all cuts are square and free from burrs. Once assembled with the components pushed home, the flue is fully sealed. Allow 20 mm 30 mm Do not cut past this point Fig. 4.10 Alpha InTec 30C and 34C - Installation...
  • Page 21 Use the template (supplied with the boiler) to mark the required flue position, ensure the slope towards the boiler is correct. Determine the overall flue length as described in Section 4.6, paragraph 2 to determine the number of Alpha CD 750 or 1000 mm flue extensions required.
  • Page 22 Plume Management 45° bend 60 mm dia. (each 45° bend equivalent to 0.9 m flue length) Plume Management 1000 mm extension 60 mm dia. (equivalent to 1 m flue length) 60 mm dia. wall bracket Fig. 4.13 Alpha InTec 30C and 34C - Installation...
  • Page 23 Note: The equivalent horizontal flue assembly length + the equivalent plume management length (PM length) must not exceed the maximum flue length stated for each boiler, i.e. Alpha InTec boiler maximum equivalent flue length must not exceed 12 metres. Alpha InTec 30C and 34C - Installation...
  • Page 24 Ensure the electrical supply to the boiler is isolated. Important: Only use the Alpha single channel controls. Do not fit any two channel controls. Remove the three screws securing the terminal block cover at the rear of the control panel.

  • Page 25: Commissioning

    Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 5.2) and purge in accordance with BS 6891. Retighten the test point screw and test for gas tightness. Close the boiler gas service cock. Alpha InTec 30C and 34C - Commissioning...
  • Page 26 If the selector is set for hot water only - The burner is turned off, the fan will continue to run for 50 seconds and the pump will stop immediately. In both modes the fan modulates according to the output required. Alpha InTec 30C and 34C - Commissioning...
  • Page 27 (if applicable) at it's drain point (see Fig. 4.4 or 4.5) of any debris. Clean the mains water inlet filter (see Fig. 4.4 or 4.5). Re-pressurise the system as described in Section 5.1. Alpha InTec 30C and 34C - Commissioning...
  • Page 28 Mains inlet temperature or FlowSmart cylinder temperature (if sensor fitted) °C Not used Fault history - by rotating the CH knob (item 6 in Fig. 5.1) in this menu the last five faults will be displayed Error code Alpha InTec 30C and 34C - Commissioning...

  • Page 29: Routine Servicing

    2. The expansion vessel pressure test point is accessible from inside the boiler at the front. Check that the condensate trap drain pipe is connected and all joints are sound. Record details of the service in the Service Record at the back of these instructions. Alpha InTec 30C and 34C - Routine Servicing...
  • Page 30 Note: Before removing the cap, ensure that the water released from the trap can be contained to avoid spillage. The trap will contain no more than 200 cc of condensate water. Replace the drain cap. Alpha InTec 30C and 34C - Routine Servicing...
  • Page 31 To ensure correct and safe operation of the appliance, it is essential that any worn or failed components are replaced with only genuine Alpha spare parts. Use of non-genuine Alpha spares could invalidate your warranty and may pose a potential safety hazard.

  • Page 32: Component Replacement

    Gain access to the room sealed chamber as described in Section 7.1. Undo the gas pipe union to the combustion chamber front to gain access. Unscrew the damaged injector and screw in a replacement. Re-assemble in reverse order. Alpha InTec 30C and 34C - Component Replacement...
  • Page 33 Gain access behind the front panel as described in Section 7.1. Disconnect the wiring. Using a 13 mm spanner, turn the sensor 90° anti-clockwise and withdraw it from the heat exchanger. Fit the new sensor and re-assemble in reverse order. Alpha InTec 30C and 34C - Component Replacement...
  • Page 34 Withdraw the motor forwards from the valve body. Re-assemble in reverse order with a new motor. Retaining DHW temperature sensor clip Diverter valve motor and assembly Condensate trap DHW Flow switch Flow switch bottom fixing screw Fig. 7.3 Alpha InTec 30C and 34C - Component Replacement...
  • Page 35 7.14 ALPHA CONTROLS (if fitted) - Fig. 4.16 Note: For replacement only use an Alpha single channel control. Do not fit a two channel control. Gain access behind the control panel as described in Section 7.1. Remove the three screws securing the terminal block cover at the rear of the panel.
  • Page 36 Fit the new gauge using a new 'O' ring on the connection if necessary. Refill and pressurise the system. (Refer to Commissioning, Section 5.1). Primary pressure switch Pressure gauge sensor position Automatic air vent Pump Pressure relief valve Drain point Pressure gauge Fig. 7.5 Alpha InTec 30C and 34C - Component Replacement...
  • Page 37 Re-assemble in reverse order making sure that the printing on the heat exchanger is at the top when fitted and that the seals are in position in the manifold. Refill and pressurise the system. (Refer to Commissioning, Section 5.1). Alpha InTec 30C and 34C - Component Replacement...
  • Page 38 Gain access behind the front casing and drain the hot water circuit as described in Sections 7.1 and 7.2. Remove the valve by disconnecting the unions from the bottom of the boiler, the mains inlet valve and filling loop. Re-assemble in reverse order using a new valve. Alpha InTec 30C and 34C - Component Replacement...

  • Page 39: Wiring Diagrams

    DHW SET Remove the link between terminal block connections 1 and 2 if the 12 34 5 6 optional Alpha Climatic control or Alpha controls (optional) 230 V room thermostat is used. Transformer Alpha InTec 30C and 34C - Wiring Diagrams...
  • Page 40 (15 - 20 V DC) Sensor (optional) Transformer Note: Main Terminal Block Gas Valve PCB Connection To connect external controls remove link from terminals 1 and 2 and connect 240 V switched live to terminal 1. Alpha InTec 30C and 34C - Wiring Diagrams...

  • Page 41: Error Codes And Fault Finding

    Combination boiler DHW sensor X4 System boiler link X14 Refer to wiring diagram Fan fault Fan wiring fault or fan faulty Check fan wiring connections Fan fault PCB fault Alpha InTec 30C and 34C - Error Codes and Fault Finding...
  • Page 42 Error between the communication of the Batteries require replacing communication fault Climatic transmitter and boiler receiver Distance between boiler and climatic control too great Interference Object blocking signal (metallic) Alpha InTec 30C and 34C - Error Codes and Fault Finding...

  • Page 43: Short Parts List

    1.030996 Fan (30C) 1.027178 Fan (34C) 1.029719 Flue turret assembly 3.022546 Complete boiler seal kit 3.022652 Hydraulic circuit seal kit 3.022653 Primary H/E seal kit 3.022654 Air/flue system seal kit 3.022655 Alpha InTec 30C and 34C - Short Parts List...

  • Page 44: Energy Classification

    Contact details Alpha Therm Ltd., Nepicar House, Wrotham Heath, Kent. TN15 7RS (*) High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet. (**) Low temperature means for condensing boilers 30°C, for low-temperature boilers 37°C and for other heaters 50°C return temperature.
  • Page 45 (AFC) Seasonal room heating yield (ηs) 91 % Seasonal room heating yield (ηs) 92 % Domestic hot water production yield (ηwh) 88 % Domestic hot water production yield (ηwh) 87 % Alpha InTec 30C and 34C - Energy Classification...
  • Page 46 Alpha InTec 30C and 34C - Energy Classification...
  • Page 47 * To be established by means of table 5 of Regulation 811/2013 in case of “assembly” including a heat pump to integrate the boiler. In this case the boiler must be considered as the main appliance of the assembly. Alpha InTec 30C and 34C - Energy Classification...
  • Page 48 11.7 PARAMETERS FOR FILLING IN DHW PACKAGE ASSEMBLY CHART Parameter InTec 30C InTec 34C ‘I’ ‘II’ ‘III’ * To be determined according to Regulation 811/2014 and transient calculation methods as per Notice of the European Community no. 207/2014. Alpha InTec 30C and 34C - Energy Classification...
  • Page 49 Alpha InTec 30C and 34C - Energy Classification...

  • Page 50: Benchmark Checklist

    GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty.

  • Page 51: Service Record

    SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s specifed spare part when replacing controls.

This manual is also suitable for:

Intec 34c47 532 4847 532 4947 532 5547 532 56

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