Alpha InTec 40GS2 Installation And Servicing Instructions Download Page 1

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Alpha InTec 40GS2 (NG) G.C. No. 47 532 51

Installation and Servicing

Instructions

Alpha InTec 40GS2

Wall Mounted, Fan Assisted, Room Sealed,

Gas Fired, High Efficiency Condensing Combination Boiler

with a Passive Flue Gas Heat Recovery Device

Nepicar House, London Road,

Wrotham Heath, Sevenoaks,

Kent TN15 7RS

For Technical help or for Service call ...

ALPHA HELPLINE Tel: 0344 871 8764

website: www.alpha-innovation.co.uk

Set for use with Natural Gas

Leave these instructions with the User

These instructions have been carefully prepared but we reserve the right
to alter the specification at any time in the interest of product improvement.
© Alpha Therm Limited 2020.

Part No. 1.044210 ST.004691/000

02/20/D406

Summary of Contents for InTec 40GS2

Page 1: ...se London Road Wrotham Heath Sevenoaks Kent TN15 7RS For Technical help or for Service call ALPHA HELPLINE Tel 0344 871 8764 website www alpha innovation co uk Set for use with Natural Gas Leave these...

Page 2: ...ort 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 r...

Page 3: ...the Scottish Development Department UK Water Regulations Byelaws Scotland Health Safety Document No 635 The Electricity At Work Regulations 1989 The installation should also be in accordance with the...

Page 4: ...tion point READ AND UNDERSTAND THE INSTRUCTIONS Read and understand the appliance s instructions before performing any operation carefully following the indications provided RECOVERABLE OR RECYCLABLE...

Page 5: ...wing Part L Building Regulations where the mains water hardness exceeds 200 parts per million provision should be made to treat the feed water to the hot water circuit of combination boilers to reduce...

Page 6: ...at maximum DHW output CO2 at minimum output CO weight nominal mg kWh CO max ppm Maximum CO CO2 Ratio SAP SEDBUK seasonality efficiency 2005 SAP SEDBUK seasonality efficiency 2009 EN13203 2 DHW effici...

Page 7: ...l flue length 8 m Maximum vertical flue length including terminal is 10 m Each additional CD 90 Bend is equivalent to 1 3 m of flue length Each CD 45 Bend is equivalent to 0 9 m of flue length The CD...

Page 8: ...e current configuration flashes the lock is confirmed by all LEDs on the control panel flashing To unlock the button press again over 10 seconds Pump By pass The boiler is supplied with by pass fully...

Page 9: ...m water 8 7 6 5 4 3 2 1 0 0 200 400 600 800 1000 1200 1400 1600 0 10 20 30 40 50 60 70 80 Alpha InTec 40GS2 Technical Data Note This Appliance Must Be Earthed Optional integral single channel control...

Page 10: ...ling points 20 Pressure sampling points 21 Flue temperature sensor 22 Primary temperature sensor 23 Overheat thermostats 24 Ignition electrodes 25 Burner 26 Gas manifold 27 Expansion vessel 28 Automat...

Page 11: ...ue Horizontal and vertical flue assemblies should be supported every metre with access provided to the joints All joints between flue sections should be connected using the clamps provided It is not r...

Page 12: ...r Information L B C 245 mm C B E C B E B F B C L B E F 245 mm 90 bend 1 3 metre L B C 245 mm 2 x 45 bends 1 8 metre Fig 4 1 VERTICAL FLUE OPTIONS 245 mm length includes terminal Hmax 10 m Hmax 8 2 m N...

Page 13: ...t be exposed to the external air and the position must allow the free passage of air across it at all times 8 A terminal must not be sited below 2 m where people have access to such as public footpath...

Page 14: ...rrier If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineers Guide for Gas Installations in Timber Frame Housing reference IGE...

Page 15: ...ure of 0 8 bar By pass The boiler incorporates an automatic by pass however if external zone valves are fitted an additional external by pass must be fitted 4 7 FILLING THE CENTRAL HEATING SYSTEM Fig...

Page 16: ...flue gases of the Alpha InTec boilers and reference should be made to BS 6798 for the requirements on the disposal of condensate The boilers incorporate a condensate trap which has a seal of 75 mm the...

Page 17: ...ed positions Ensure pipe is adequately supported Plastic pipe Minimum gradient 2 Ground level either or 22mm termination from boiler increase to 32 mm if external 2 fall O 25mm 300mm Two rows of 3 x 1...

Page 18: ...required when the boiler is installed with a horizontal flue are as follows Box 1 Cased boiler fitted with water and gas valves union bends and washers Mounting bracket plus screws and wall plugs Con...

Page 19: ...ler One metre of copper pipe must be fitted to the boiler before connecting to any plastic pipework Note Do not forget that the pressure relief valve discharge pipe must be routed clear of the boiler...

Page 20: ...tance 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...

Page 21: ...uct of the terminal is positioned correctly see Fig 5 9 8 Make good the inside wall by pushing the inside flue sealing collar upto the wall Fig 5 8 Fitting the flue from inside 7 7 REDUCING THE FLUE F...

Page 22: ...orporates 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...

Page 23: ...the terminal from outside i Remove the screws 1 in Fig 5 12 securing the terminal and remove the terminal by pulling it from the flue assembly Remove the screw 2 in Fig 5 12 securing the terminal end...

Page 24: ...lue Ensure there is a slope of approximately 3 back towards the Easy Flue Fig 5 13 Note The equivalent horizontal flue assembly length the equivalent plume management length PM length must not exceed...

Page 25: ...inal block cover Refer to Section 3 5 4 Replace the terminal block ensuring it is located correctly on the plastic pins and replace the cover 5 Ensure that there is sufficient free cable to allow the...

Page 26: ...g 5 3 Turn on all hot water taps and allow water to flow until no air is present Turn off taps 9 Ensure that the flue gas heat recovery unit and condensate trap have been filled with water Refer to Se...

Page 27: ...utside temperature Refer to external probe instructions for further information on this feature 6 From this moment the boiler functions automatically With no demand for heat central heating or domesti...

Page 28: ...s in standby mode The boiler will operate until the water temperature in the boiler reaches 42 C Any other pipework outside of the boiler must be protected from the risk of freezing and insulated Addi...

Page 29: ...ically operate for 30 seconds 7 Explain to the User that an internal frost thermostat is fitted in the boiler and that the electrical supply to the boiler must be left on for the thermostat to operate...

Page 30: ...CPA1ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Combustion check Connect the flue gas analyser to the flue gas sampling...

Page 31: ...locating pins Front case fixing screws Combustion chamber front assembly Gas pipe union Air supply pipe fixing screw Air supply pipe fixing screw Air supply pipe Pressure tube connections Viewing wind...

Page 32: ...rom the trap can be contained to avoid spillage The trap will contain no more than 200 cc of condensate water Replace the drain cap Fig 7 2 Electrode gap 3 4 mm Burner Burner to electrode gap 6 mm Fla...

Page 33: ...e cover When replacing the cover ensure no wires are trapped and all wiring is secured Secure with five screws do not overtighten 8 2 DRAINING THE BOILER Figs 3 4 5 3 Isolate the electricity supply an...

Page 34: ...nerator in position tighten the screws and re connect the wires 5 Re assemble in reverse order 8 7 OVERHEAT THERMOSTATS Fig 8 1 Note There are two overheat thermostats wired in series please be sure t...

Page 35: ...spare fuse is supplied as shown in Fig 8 2 Check the spare fuse has the correct value before installing it 3 Re assemble in reverse order 8 11 PCB Fig 8 2 Note The replacement of the gas valve or PCB...

Page 36: ...ve the insulation suction applied to the centre of the insulation will aid this Fit a new panel and re assemble in reverse order 8 16 CONDENSATE TRAP Figs 5 3 and 8 3 1 Gain access behind the front ca...

Page 37: ...forwards to disconnect from the flue connection and withdraw it from the boiler 9 Re assemble in reverse order ensuring that new seals are used Lubricating the seals with soap and water will aid asse...

Page 38: ...nd re assemble in reverse order When connecting the wiring to the new switch the polarity of the wires is not important 8 25 PRESSURE RELIEF VALVE Fig 8 5 1 Gain access behind the front casing and dra...

Page 39: ...ection 8 1 2 Isolate the mains water supply and open all hot taps to drain any water from the boiler 3 Undo the three union nuts from the valve 4 Remove the two screws at the front securing the bracke...

Page 40: ...Bk Br R R Gy R Bk Or G Gy Bl R Br R R Br Bk R Br Bl Br R Bl Bl G Y Bl Gy 2 1 Colour Code Br Brown Bk Black Bl Blue R Red Or Orange G Green G Y Green Yellow W White Gy Grey Remove the link between ter...

Page 41: ...2 3 6 5 1 7 X18 4 2 3 6 5 1 7 8 X14 4 2 3 6 5 1 7 8 9 10 11 X7 4 2 3 6 5 1 X17 3 5 4 1 2 6 X19 2 1 X3 L N 3 4 X10 X9 X11 X15 1 1 2 2 3 3 Fuse 3 15 AF 250 V Transformer DHW SET CH SET B A X5 123456 X8...

Page 42: ...replace primary heat exchanger Blocked or restricted primary flow Heat exchanger air flow blocked Flue restriction Flue sensor fault Gas valve lead connection fault Faulty gas valve Faulty PCB Flow s...

Page 43: ...t exchanger air flow blocked Flue restriction Flue sensor fault Pump fault Batteries require replacing Distance between boiler and climatic control too great Interference Object blocking signal metall...

Page 44: ...ssembly Flue sensor DHW sensor Overheat thermostat Flame sensing electrode DHW flow switch Ignition electrode Pump head Filling loop Flue turret foam seal Primary heat exchanger Burner Diverter valve...

Page 45: ...rated heat output and high temperature regime 4 89 4 At 30 of rated heat output and low temperature regime P1 9 1 kW At 30 of rated heat output and low temperature regime 1 97 5 Auxiliary electricity...

Page 46: ...nced by further factors such as heat loss in the distribution system and the dimensioning of the products in relation to building size and characteristics Seasonal space heating energy efficiency of p...

Page 47: ...ectricity 3 G F E D C B A A A A 27 27 27 28 27 27 27 28 30 30 30 32 33 34 35 36 36 37 38 40 39 50 55 60 65 75 80 85 100 115 123 131 130 150 160 170 163 188 200 213 M L XL XXL 3 2 3 2 The energy effici...

Page 48: ...GJ Yearly electricity consumption for the domestic hot water function AEC 55 kWh Yearly fuel consumption for the domestic hot water function AFC 16 GJ Seasonal room heating yield s 92 Domestic hot wa...

Page 49: ...uilding as the efficiency is influenced by further factors such as heat loss in the distribution system and the dimensioning of the products in relation to building size and characteristics Seasonal s...

Page 50: ...contribution From fiche of solar device 1 _____ 2 1 1 x _____ 10 x _____ ____ ______ Auxiliary electricity 3 G F E D C B A A A A 27 27 27 28 27 27 27 28 30 30 30 32 33 34 35 36 36 37 38 40 39 50 55 60...

Page 51: ...51 Alpha InTec 40GS2 Page intentionally Blank...

Page 52: ...rs complete DHW mode gas rate m3 hr or ft3 hr Central heating output left at factory settings Yes No If no what is the maximum central heating output selected kW Dynamic gas inlet pressure mbar Centra...

Page 53: ...service in accordance with the manufacturers instructions and BS 7593 It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to att...

Page 54: ...service in accordance with the manufacturers instructions and BS 7593 It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to att...

Page 55: ...service in accordance with the manufacturers instructions and BS 7593 It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to att...

Page 56: ...o not smoke extinguish all naked flames and open all doors and windows Contact the National Gas Emergency Service immediately on 0800 111 999 8 ELECTRICAL SUPPLY The boiler requires a 230 V 50 Hz supp...

Page 57: ...it should be fitted with increased diameter pipe and be suitably lagged to reduce the risk from freezing In situations where there are likely to be extremes of temperature or wind chill the use of a p...

Page 58: ...ll only provide hot water when a tap is turned on and the central heating will not activate even if requested by external controls frost protection and pump cycle are still active Winter setting The b...

Page 59: ...and hold the On Off button for eight seconds to turn the boiler off Standby In this mode the boiler will not provide hot water or central heating but frost protection and pump circulation features are...

Page 60: ...Efficiency Condensing Combination Boiler with a Passive Flue Gas Heat Recovery Device Nepicar House London Road Wrotham Heath Sevenoaks Kent TN15 7RS For Technical help or for Service call ALPHA HELP...

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