Alpha Pro Tec 115 Installation And Servicing Instructions Download

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Installation and Servicing

Instructions

Alpha Pro Tec 50, 70, 90 and 115

Wall Mounted, Fan Assisted, Gas Fired, High Efficiency

Condensing System Boilers

For use with Natural Gas or Propane Gas (LPG)

Leave these instructions with the User

Nepicar House, London Road,

Wrotham Heath, Sevenoaks,

Kent TN15 7RS

For Technical help or for Service call ...

ALPHA HELPLINE

Tel: 0870 3001964

0051

Summary of Contents for Pro Tec 115

Page 1: ...an Assisted Gas Fired High Efficiency Condensing System Boilers For use with Natural Gas or Propane Gas LPG Leave these instructions with the User Nepicar House London Road Wrotham Heath Sevenoaks Kent TN15 7RS For Technical help or for Service call ALPHA HELPLINE Tel 0870 3001964 0051 ...

Page 2: ...rt 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 Handoverthemanufacturer sinstructions includingtheBenchmarkChecklist tothecustomeroncom...

Page 3: ... No 635 The Electricity At Work Regulations 1989 The installation should also be in accordance with the following British Standard Codes of Practice BS 5440 1 2008 Flueing and Ventilation Requirements BS 5440 2 2009 Installation and Maintenance of Flues and Ventilation BS 5546 2010 Specification for Water Heating Appliances BS 6644 2011 Specification for Installation gas fired boilers 70 kW 1 8 MW...

Page 4: ...m SAP SEDBUK seasonality efficiency 2005 SAP SEDBUK seasonality efficiency 2009 Effieciency at maximum output 60ºC 80ºC Effieciency at maximum output 30ºC 50ºC Effieciency at part load 30ºC 50ºC Effieciency at part load 30ºC 40ºC Maximum system temperature C Adjustable system temperature C Maximum primary system pressure bar Minimum primary system pressure bar Recommended system pressure Cold bar ...

Page 5: ... 12 07 178 19 56 9 6 9 0 16 18 33 56 9 51 3 7 9 20 5 43 81 9 53 9 5 9 1 14 15 39 Pro Tec 115 Pro Tec 50 Pro Tec 70 Pro Tec 90 Heat input gross kW Heat input net kW Gas burner injector diameter mm Gas supply pressure mbar Gas rate at maximum output l h Flue mass flow rate at maximum output kg h Flue mass flow rate at minimum output kg h Flue temperature nominal C CO2 at maximum output factory set C...

Page 6: ...etre of flue 2 It is recommended that horizontal and vertical flue assemblies should be supported approximately every 1 5 m with access provided to the joints 3 These dimensions only apply for flue parts supplied by Alpha Cascade flue options are also available please contact Alpha for further details 2 4 FLUE DATA 2 5 AVAILABLE PUMP HEAD Fig 2 1 The Pro Tec boilers are fitted with a 3 speed pump ...

Page 7: ...6 0 0 Flow rate l h Head m water 7 0 8 0 9 0 0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 A B 1 0 2 0 3 0 4 0 5 0 6 0 0 Flow rate l h Head m water 7 0 8 0 9 0 10 0 11 0 0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 Fig 2 2 Fig 2 3 ...

Page 8: ...Fuse 3 15 AF Open Therm Alarm free contact Max 1 A 220 240 V External reset 220 240 V N N L L N L Zone manager optional Analog input 0 10 V 37 A 38 B _ _ R1 R2 A1 A2 S1 S2 1 2 3 4 5 6 Y Z M O OT1OT2 3 way valve optional 220 240 DHW sensor optional External sensor optional Remote switching optional i e room thermostat remove link F to E DO NOT connect 220 240 V N N L L L A B AB External relay optio...

Page 9: ...16 Air sampling point 17 Flue sampling point 18 Flue hood 19 Venturi positive point P2 20 Overheat thermostat manual reset 21 Overheat thermostat 22 Primary flow temperature sensor 23 Primary return temperature sensor 24 Flame sensing electrode 25 Primary flow sensor 26 Air inlet pipe 27 Burner 28 Venturi 29 Automatic air vent 30 Pump 2 7 BOILER SCHEMATIC Pro Tec 50 15 14 13 12 11 10 9 8 7 6 5 4 3...

Page 10: ... valve 7 Fan 8 Injector 9 Air inlet pipe 10 Flame sensing electrode 11 Combustion chamber cover 12 Heat exchanger 13 Flue hood 14 Air sampling point 15 Flue sampling point 16 Heat exchanger automatic air vent 17 Primary flow temperature sensor 18 Overheat thermostat 19 Primary return temperature sensor 20 Overheat thermostat manual reset 21 Flue sensor 22 Burner 23 Thermofuse 24 Ignition electrode...

Page 11: ... Section 3 4 only air for ventilation is required 1 If the boiler is installed in a room No air vents are required in the room in which the boiler is installed 2 If the boiler is installed in a cupboard or compartment Permanent air vents for ventilation are required in the cupboard or compartment one at high level and one at low level either direct to the outside air or to a room Both the high and...

Page 12: ... square gasket 6 2003225 Vertical terminal kit 80 125 mm dia includes adaptor with square gasket 6 2003210 Extension kit 1 metre x 80 125 mm dia 6 2003290 90 bend 80 125 mm dia 6 2003245 45 bend 80 125 mm dia 6 1000380 Pitched roof flashing universal 6 1000390 Flat roof flashing universal Cascade flue options are also available for multiple boilers Open flue 80 mm dia single pipe 90 bend is equiva...

Page 13: ...land the electrical provisions of the Building Regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower Where a room sealed boiler is installed in a room containing a bath or shower it must not be possible for a person using the bath or shower to touch any electrical switch or boiler control utilising mains electricit...

Page 14: ...pressure to be maintained By pass The boiler has no built in by pass therefore a by pass is required for the system Installation on a low temperature heating system The boiler can directly feed a low temperature system varying the maximum delivery temperature of the boiler and setting a value of between 20 and 85 C To vary the boiler maximum delivery temperature modify the boiler maximum delivery ...

Page 15: ...ith the Alpha Pro Tec boilers Further information can be obtained from Fernox Tel 0179 9521133 or Sentinel Tel 0151 4209563 The system should be flushed in accordance with BS 7593 and BS 5449 The following procedures are recommended 1 Installing onto a new system a Fill the system vent at high points at pump and radiators b Check for leaks c Rapidly drain the system d If required chemically clean ...

Page 16: ...aximum of 3 m Termination should be into an external gulley or soakaway as shown in Figs 3 6 and 3 7 Note All pipework must have a continuous fall see Figs 3 6 and 3 7 from the boiler and must be of an acid resistant material such as plastic waste pipe copper or steel is not suitable It should be noted that the connection of a condensate pipe to a drain may be subject to local building control req...

Page 17: ... and 28 mm connection tail Literature pack and Wall template Other parts of the flue system are supplied in separate packs as ordered 2 Unpack boiler and remove the loose items 4 2 DIMENSIONS and CONNECTIONS Fig 14 Alpha Pro Tec Installation Fig 4 1 4 2 1 Pro Tec 50 450 225 225 80 Dia 765 843 946 994 457 140 200 220 281 453 442 221 221 71 71 300 30 92 50 G CD SV HF HR E E Electrical connection G G...

Page 18: ... the load as close to your body as possible Wherepossibletransporttheboilerusingasacktruckorothersuitabletrolley Always grip the boiler firmly and before lifting feel where the weight is concentrated to establish the centre of gravity repositioning yourself as necessary Fig 4 2 4 2 2 Pro Tec 70 90 115 A B C Pro Tec 70 502 mm 265 mm 497 mm Pro Tec 90 115 632 mm 410 mm 627 mm SV HF HR 80 Dia 60 G CD...

Page 19: ... socket with lip seals of the previously installed component this will ensure a secure fit and seal of the joints Ensure all joints have the seal located correctly and the tape supplied is applied around each joint to ensure the flue ducts cannot be pulled apart It is recommended that the flue should be supported at least every 1 5 m with access provided to the joints Fig 4 5 Fig 4 6 Horizontal th...

Page 20: ... Fit the male end of the flue elbow up to the stop on the adapter Place the outer seal over the concentric flue pipe and slide it through the wall from the outside Place the inner seal over the concentric flue pipe then insert the pipe into the elbow up to the stop Slide the seals along the duct to seal it to the inside and outside of the wall To install extensions or other flue components proceed...

Page 21: ...mains supply cable through the cable clamp and connect as follows Brown to L Blue to N and Green Yellow to Ensure correct polarity Note Ensure that the length of the earth wire is such that if the supply cable is pulled out of its clamp the live and neutral wires become taut before the earth wire Do not switch on the electrical supply at this stage 3 If any external control i e room thermostat etc...

Page 22: ...22 Alpha Pro Tec Installation Fig 4 11 2 1 1 4 3 5 6 6 7 9 8 8 8 ...

Page 23: ...fting off its seat allowing water to escape from the system check that this is actually happening 7 Continue to fill the system until the pressure gauge indicates 1 0 bar Close the fill point valve and check the system for water soundness rectifying where necessary Disconnect the filling loop from the mains supply If the system has been over pressurised water may be released from the system by man...

Page 24: ...er will only fire at low level initially and will ramp up gradually according to the heat demand Allow the boiler to run and heat the circuit checking for leaks and correct circulation testing any secondary circuits and zone controls for correct operation During operation gas working pressure and gas rate checks can be conducted using the engineering function Refer to Section 5 9 1 On Off switch 2...

Page 25: ...ed You will need to press button B to save the new value The temperature reading will flash during adjustment If a certain amount of time lapses without saving the value the boiler will exit the setting mode and maintain the previous setting Winter In this mode the boiler provides both DHW and room heating By pressing the or buttons as shown in Fig 5 6 once you can view the temperature setting By ...

Page 26: ...nside the menu you will momentarily see the parameter number followed by the value To scroll through the various parameters press the and buttons as shown in Fig 5 11 To exit the menu press and hold B in again While the parameter value is being displayed it is possible to momentarily see the relative code again by pressing button A The viewable parameters are listed in the following table Fig 5 11...

Page 27: ...panel replace the front cover and secure in position with the screws previously removed 2 If the boiler is to be left in service with the User set any external controls to the User s requirements 3 If the boiler is not to be handed over immediately close the boiler gas service cock and switch off the electrical supply 4 If there is any possibility of the boiler being left during frost conditions t...

Page 28: ...nt which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Combustion check Connect the flue gas analyser to the flue gas sampling point as shown in Fig 6 4 or 6 5 Notes 1 Prior to servicing it is recommended that a flue gas analyser is used to measure the performance of the boiler If the CO CO2 ratio measured is greater than 0 003 or when other...

Page 29: ...ntrol panel Press the two side hooks 6 and tilt the control panel 7 forwards 3 Remove the bottom panel 9 by removing the four screws 10 4 If necessary you can remove the top cover 11 and side panels 13 Loosen the seven screws 12 securing the top cover 11 Remove the two screws 14 securing the side panel 13 Lift the side panel and pull it forwards unhooking it from the rear panel view A in Fig 6 1 L...

Page 30: ...h a soft brush if necessary Do not use a brush with metallic bristles as this might damage the burner 4 Remove any deposits from the heat exchanger coils This can be done by suction or water sprayed onto the coils Ensure all electrical components are protected from water Any water used to clean the heat exchanger will drain through the condensate trap 5 Check the condition of the electrodes 6 Chec...

Page 31: ...sor 14 Automatic air vent 15 Test points air A flue F 16 Flue hood manifold 17 Manual air vent 18 Condensing heat exchanger 19 Heat exchanger thermal fuse 20 Overheat thermostat manual reset 21 Burner 22 Air intake pipe 23 System return NTC 24 Primary flow sensor 25 Automatic air vent 26 Pump 27 Condensate trap 28 Flow manifold 29 Safety valve 4 bar 30 Gas cock 31 Tundish Front Left side 1 2 3 4 5...

Page 32: ... Air intake pipe 14 Ignition unit 15 Overheat thermostat manual reset 16 Ignition electrode 17 Heat exchanger thermal fuse 18 Flame detection electrode 19 Combustion chamber front cover 20 Manifold cover 21 Venturi housing 22 Condensate trap 23 Fan 24 Gas valve 25 System pressure switch 26 Flow manifold 27 Safety valve 4 bar 28 PCB 29 Test points air A flue F 12 11 10 9 8 7 6 5 4 3 2 1 29 F A 13 1...

Page 33: ... Br Br Br Br Br Br Br Br R R R R R R R Bk Bk Bk Bk Bk Bk Bk Bk CH DHW L L L L L N N N N L N N L R Gy Gy Gy Gy W E4 E5 E13 B10 Y1 G2 M1 L L N VB PWM GND HS VB N M20 S1 BUS E2 A2 X40 S20 B4 B2 M30 E1 B5 External Pump 220Vac 50Hz Mains Supply 220Vac 50Hz X02 X00 X04 X01 X13 X12 X11 X03 X06 X15 X00 X01 X05 X02 X11 X14 X14 F00 F01 Low Voltage Low Voltage 220 Vac 50 Hz A4 A F G E D B C X05 X03 X01 X04 X...

Page 34: ... is too high The boiler output is insufficient for the system Check system circulation System volume or flow is too high The boiler output is insufficient for the system Check system circulation Check operation of zone valves Check resistances and function of flow and return sensors Check flow sensor connections and wires Check for water ingress in connections Check flow sensor connections and dam...

Page 35: ...sor short circuit DHW sensor out of range DHW sensor measures a temperature outside normal working range Low powers supply voltage Insufficient system flow Pro Tec 50 model only Insufficient system pressure Pro Tec 70 90 115 models Flue sensor short circuit Flue sensor out of range Flue sensor measures a temperature outside normal working range Flow and return sensor anomily detected The sensor sh...

Page 36: ...0 0 Set CH flow temp Set max flow temp Heating hysteresis cycling Anti cycling time Stabalisation period CH ramp up time Post circulation Max heat power output Min heat power output Min pump flow rate Anti humidity setting Not used Boiler power value External sensor setting External sensor offset DHW set temp Not used DHW reheat temp DHW overrun cycle Max DHW output power Min DHW ouput power P01 P...

Page 37: ...ow temp during DHW function when using external thermostat Min flow temp during DHW function this value is above DHW set temp P16 Time to continue firing to avoid boiler cycling during DHW function when set value is achieved Set the max fan speed boiler max output power Set the min fan speed boiler min output power Not used on these boiler models Not used on these boiler models Used to select the ...

Page 38: ...30 0 28 0 26 0 24 0 22 0 20 0 18 0 16 0 14 0 12 0 10 0 8 0 6 0 5 0 Burner Gas Flow Rate m h 5 44 5 21 4 98 4 75 4 53 4 31 4 10 3 88 3 67 3 46 3 25 3 04 2 83 2 62 2 41 2 20 1 99 1 78 1 57 1 35 1 14 0 92 0 69 0 58 Fan Revs rpm 6550 6320 6090 5870 5640 5410 5190 4960 4730 4500 4270 4030 3800 3560 3320 3080 2830 2580 2320 2060 1790 1520 1240 1100 Burner Gas Flow Rate m h 3 99 3 82 3 65 3 49 3 33 3 17 ...

Page 39: ...44 1 22 1 00 0 80 Fan Revs rpm 6500 6340 6180 6020 5860 5700 5550 5390 5230 5070 4910 4750 4600 4440 4280 4120 3960 3800 3640 3480 3320 3160 3000 2840 2680 2510 2350 2190 2020 1860 1690 1520 1350 1200 Burner Gas Flow Rate m h 5 85 5 68 5 52 5 35 5 19 5 03 4 87 4 71 4 55 4 39 4 23 4 07 3 91 3 75 3 60 3 44 3 28 3 12 2 96 2 81 2 65 2 49 2 33 2 17 2 02 1 86 1 70 1 54 1 38 1 22 1 06 0 90 0 74 0 59 Fan ...

Page 40: ... 94 2 62 2 30 1 97 1 64 1 32 0 99 Fan Revs rpm 6850 6610 6370 6140 5910 5680 5460 5230 5010 4790 4580 4360 4150 3940 3740 3530 3330 3120 2930 2730 2530 2340 2140 1950 1760 1570 1390 1200 Burner Gas Flow Rate m h 7 17 6 93 6 68 6 44 6 20 5 96 5 72 5 48 5 24 5 00 4 77 4 53 4 29 4 05 3 82 3 58 3 34 3 11 2 87 2 63 2 40 2 16 1 92 1 68 1 45 1 21 0 97 0 73 Fan Revs rpm 6400 6180 5950 5740 5520 5310 5100 ...

Page 41: ...30 1 97 1 64 1 32 1 21 Fan Revs rpm 7000 6800 6600 6400 6210 6010 5820 5630 5440 5260 5070 4890 4710 4530 4350 4180 4000 3830 3660 3490 3320 3150 2990 2820 2660 2500 2340 2180 2020 1860 1710 1560 1400 1250 1200 Burner Gas Flow Rate m h 8 86 8 62 8 37 8 13 7 89 7 65 7 40 7 16 6 92 6 68 6 44 6 20 5 97 6 73 5 49 5 25 5 01 4 78 4 54 4 30 4 06 3 83 3 59 3 35 3 12 2 88 2 64 2 40 2 16 1 92 1 69 1 45 1 21...

Page 42: ...er to suit Additional controls are availble to enable mixed and or direct heating zones and a hot water cylinder Alternatively a barrier heat exchanger can be used to separate the system from the boiler enabling connection to gravity or older heating circuits maintaining a clean pressurised circuit on the boilers 11 CASCADE SYSTEM INSTALLATION F R G CD SV F R G CD SV F R G CD SV F R G CD SV F R G ...

Page 43: ... thermostat manual reset Flue sensor Pro Tec 50 Flue sensor Pro Tec 70 90 115 Condensate trap Cascade address unit Spark generator Wall mounting hook Test point cover unit Wall fixing kit hooks screws plugs Hydraulic circuit seal kit Air intake and flue circuit seal kit Gas circuit seal kit Heat exchanger seal kit Complete boiler seal kit Ignition electrode lead Flame sensing electrode lead Descri...

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Page 45: ...45 Alpha Pro Tec Blank Page ...

Page 46: ...ure and record Gas rate m hr OR ft hr Burner operating pressure if applicable mbar OR Gas inlet pressure mbar Central heating fow temperature C Central heating return temperature C COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes and if required by the manufacturer has a water scale reducer been ftted Yes No What type of scale reducer has been ftted DOME...

Page 47: ...egister No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 04 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 05 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Wher...

Page 48: ...uctions 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 2014 Alpha Therm Limited NepicarHouse LondonRoad WrothamHeath Sevenoaks Kent TN15 7RS Tel 0870 3001964 email info alphatherm co uk website www alpha innovation co uk ...

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