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Alpha InTec 40GS2, Инструкции по установке и обслуживанию

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Alpha InTec 40GS2 - Routine Servicing

7.2  PREPARE FOR SERVICING - Fig. 7.1

1.  Ensure the electrical supply is isolated and the gas supply is off.
2.  Release the two screws securing the control panel and lower the panel.
3.  Remove the four screws securing the front case. Lift the case up and forwards to remove.
4.  Disconnect the gas supply pipe union from the manifold.
5.  Remove the two screws securing the air supply pipe and remove the pipe.
6.  Release the two screws securing the fan assembly to the combustion chamber front.
7.  Remove the two pressure tubes, noting their positions.
8.  Disconnect the electrode lead from the ignition generator and the in-line connector to the flame sensing electrode.
9.  Remove the four nuts and washers and four screws securing the combustion chamber front assembly and remove the 

assembly.

Fig. 7.1

Front case 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 window

Four nuts and washers
and four screws
securing combustion
chamber front assembly

Flue gas
sampling point

Fan assembly
fixing screws

Fan assembly

Manual air vent

Expansion vessel
test/fill point

Ignition generator

Flame sensing
electrode

5.  Refill, vent and re-pressurise the system as necessary. (Refer to Commissioning, Section 6.1).
 

If the system pressure exceeds 2.5 bar when operating at maximum temperature, the heating expansion vessel should 
be checked and re-pressurised, if necessary.

 

Note: 1. 

Check the expansion vessel charge only when the system pressure is zero.

  

2.

  The expansion vessel pressure test point is accessible from inside the boiler at the front.

6.  Check that the condensate trap drain pipe is connected and all joints are sound.
7.  Record details of the service in the Service Record at the back of these instructions.

Содержание InTec 40GS2

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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