Alpha Intec12s User manual

Alpha System Boiler InTec S Range

These sophisticated system boilers represent the ultimate in boiler design, perfectly il-

lustrating the ethos behind our new InTec range.

Alpha InTec12s, Alpha InTec18s, Alpha InTec28s System Boilers

Features

• Daily pump kick

• Frost thermostat

• Stainless steel heat exchanger

• Valves and tails factory fitted

• LCD display on control panel

• Detailed fault codes

• Grundfos pump and hydroblock assembly

• Easy-access NTCs on front of pipes

• Available for NG and LPG

•

As well as boasting the same level of advancement and innovation as our InTec combi-

nation boilers, they also have identical casing. This makes them one of the smallest

system boilers available, something which aids positioning and installation.

With three outouts to choose from, InTec S models are ideal for any small to large home

where a system boiler is the preferred option.

Optional accessory

The optional three-way diverter valve kit operates as a hot water priority valve, meaning

if the heating is on and there is a hot water demand, the valve will divert the primary

heat to the cylinder until the cylinder sensor is satisfied. Requires a quick recovery cyl-

inder.

Model

Lift

wei

ght

(kg)

DHW

output

(kW)

output

(kW)

Flow

rate l/

min

NOx rat-

ing (mg/

kWh)

Dimen-

sions

(mm)

GasSaver

compati-

ble

SolarS-

mart

compati-

ble

Stan-

dard

guaran-

tee

Guaran-

tee with

InTec12S

13.2

720x440

x300

5 yr

7 yr

InTec18S

20.0

720x440

x300

5 yr

7 yr

InTec28S

30.7

720x440

x300

5 yr

7 yr

User's

Instructions

Alpha InTec 12S, 18S, 28S

Range of Wall Mounted, Fan Assisted, Room Sealed,

Gas Fired, High Efﬁciency Condensing System Boilers

Nepicar House, London Road,

Wrotham Heath, Sevenoaks,

Kent TN15 7RS

For Technical help or for Service call ...

ALPHA HELPLINE Tel: 0844 871 8764

website: www.alpha-innovation.co.uk

British Gas

Service Listed

0051

For use with Natural Gas or Propane Gas (AS SUPPLIED)

Leave these instructions with the User

2Alpha InTec S

The Alpha InTec range of high efﬁciency condensing boilers incorporate the latest technology in boiler design. With improved

burner efﬁciency and reduced electrical consumption together with high quality and reliability.

The boiler output will automatically adjust according to the requirements of the system.

The InTec range are designed to work with most central heating controls however we recommend the Alpha two channel

versions of built in clock or Comfort RF external thermostat programmer.

Alternatively with the use of the Alpha system diverter kit the enhanced Alpha Climatic boiler energy manager can be used

to increase comfort and efﬁciency. When using the Climatic control unit the efﬁciency can be further enhanced with the use

of the outside sensor to enable the boiler's built in weather compensation feature.

The boilers will provide both central heating and hot water when required according to the times and temperatures set by the

controls ﬁtted. Hot water cylinder heating will take priority over heating. Simultaneous heating and hot water can be achieved

when using a mid position Y-plan valve or S-plan system.

Fig. 1

2 OPERATING THE BOILER

1 INTRODUCTION

Make sure the heating system is ﬁlled and the needle on the pressure gauge (item 7 in Fig. 1) is in the green band. If

incorrect refer to Section 4.

Switch the boiler on at the mains supply socket switch. The boiler will automatically go through a system purging operation

for 8 minutes; this is indicated by a count down on the display starting from 96. During this operation the pump will turn on

and off to help remove any air that may be trapped in the heating system. If the boiler has already been commissioned by the

installer then this operation can be terminated by pressing the reset button (item 3 in Fig. 1).

Note: It is important to allow this purging operation to function when the boiler has been initially installed to remove all the air

from the system.

After this purging operation the boiler will be in 'Standby' or 'On' mode.

By pressing the On-Off button (item 1 in Fig. 1) the Standby or On mode can be selected, or press 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 still active.

Off - In this mode there is electrical power to the boiler but the boiler will not function in any condition.

1 On-Off/Standby button

2 Summer/Winter button

3 Reset button

4 Information button

5*Domestic hot water temperature

selector switch

6 Central heating water temperature

selector switch

7 Heating system pressure gauge

8*DHW mode active

9 Boiler locked does not require reset via

“RESET” button

10 Flame present symbol and relative

power scale

11*Operating in summer mode

12 Operating in winter mode

13 Central heating mode active

14 Temperature indicator, boiler info and

error codes

15 Boiler in Stand-by mode

16 Presence of external connected devices

17 Solar function active

18 Functioning with external temperature

probe active (optional)

19 Boiler connected to remote control

(optional)

20 Not used on this model

21 Optional boiler controls (if ﬁtted)

bar

22.5

3.5

1.5

0.5

CORRECT PRESSURE

WHEN COLD

RESET

INFO

RESET

BOOST

bar

°C

x100rpm

5 6 721

RESET

BOOST

bar

°C

x100rpm

8 9 10 11 12 13

151617181920

The boiler controls are located on the control panel located behind a drop down ﬂap.

Please read these instructions carefully before operating your boiler.

*The summer hot water mode and hot water temperature selector switch will only function when using the Alpha System Diverter kit in conjunction

with a hot water cylinder. When using a standard Y or S plan system the boiler must be left in winter mode and only the Heating thermostat used.

Alpha InTec S

Summer setting - This function can only be used if the boiler is ﬁtted with an Alpha System kit allowing control of the

hot water cylinder using the boiler controls. This has the added advantage of allowing you to independently control the

temperature of the heating hot water and the cylinder hot water. In this mode the boiler will only supply hot water to the

cylinder when the temperature of the cylinder water is below that set by the hot water selector switch (item 5 in Fig. 1). When

heating the hot water cylinder the central heating will not function even if requested by any controls. The desired hot water

cylinder temperature can be set using the hot water selector switch.

Winter setting - In this mode the boiler will operate to requests for both heating and hot water. For a system ﬁtted with a

standard Y or S plan the boiler should always be left in the winter mode. The boiler will always prioritise hot water when

requested by external controls. The heating will activate depending on the request from any external controls ﬁtted. The LCD

display will then display the actual temperature of the water leaving the boiler when operating to provide heating or hot water.

Note: When using a standard Y or S plan system the central heating selector switch (item 6 in Fig. 1) must be set

above the cylinder thermostat value.

External weather compensation probe (only for use with the Alpha system diverter kit) - The temperature of the

central heating water can be adjusted by turning the central heating selector switch (item 6 in Fig. 1). When the heating is on

the temperature of the water leaving the boiler to the radiators will be displayed.

If an external weather compensation probe is ﬁtted, indicated by the symbol (item 18 in Fig. 1) in the display, it will

automatically vary the temperature of the water in the radiators and on mild day the radiators will not feel as hot as on a cold

day, this is normal and not a fault with the boiler or heating circuit. The room temperature will still be maintained as set by the

room thermostat.

When an external weather probe is ﬁtted, the central heating selector switch (item 6 in Fig. 1) will no longer adjust the ﬂow

temperature in °C, instead the display will show a scale of 1 to 9. Each number corresponds to a line on the graph in Fig 2

i.e. line 6 will give a ﬂow temperature of 60°C when the external temperature is 10°C.

Note: This is the temperature of the water supplied to the radiators and not the desired room temperature. The time and

temperature will still be maintained according to the setting of the room thermostat.

3 HEATING AND HOT WATER TEMPERATURE

On - In this mode the boiler can be switched between 'Summer' or 'Winter' settings by pressing the Summer/Winter button

(item 2 in Fig. 1).

Press the Summer/Winter button (item 2 in Fig. 1) to select either heating and hot water or hot water only.

If an InTec S boiler is used with a conventional Y-plan, the boiler must be set to winter mode to provide heat to the hot water

cylinder.

Fig. 2 - External weather compensation probe ﬁtted

Flow temperature (°C)

External temperature (°C)

27 15 5-510 0 -10 -1520

25 (25)

60 (40)

85 (50)

Flow temperature in brackets

ie. 25 to 50°C range when boiler

is used with a low temperature

system such as under floor heating

Setting 1 to 9 as selected using

the central heating selector switch

9 8 765

4 FILL AND PRESSURISE THE SYSTEM

InTec S models should have a ﬁlling loop ﬁtted by the installer located in the pipework close to the boiler.

Do not attempt to ﬁll or pressurise the system while the system is hot - wait for it to cool.

The ﬁlling loop will have two tap connections at either end of the ﬁlling loop. These taps should normally be in the closed

position 90° to the tap housing.

4Alpha InTec S

To ﬁll or pressurise the system open one tap fully by turning it 90° anticlockwise in line with the tap housing. The second tap

should be opened a quarter of a turn and the water will start to reﬁll the system (water should be heard ﬁlling the system).

You should see the pressure gauge (item 7 in Fig. 1) rise back up into the green area on the pressure gauge between 1 bar

and 1.5 bar pressure.

Once the pressure gauge is in the green area turn the taps back to the off position and the water will stop ﬁlling the system.

If you happen to ﬁll the system too much and the pressure gauge is over the green area, just bleed water from a radiator until

the pressure on the gauge goes down into the green area.

6 FROST PROTECTION

7 CONDENSATE DRAINAGE

High efﬁciency (condensing) boilers remove more useful heat from the combustion gases, resulting in additional water vapour

which is collected within the boiler (as condensate) and run to a suitable drainage point via the condensate drainage pipe.

If the condensate drain pipe runs outside 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 proprietary trace-heating system

for external condensate drainage pipework, incorporating an external frost thermostat, should be considered.

5 INFORMATION MENU

Info Menu

(d - preﬁx)

Information

Flame signal

Central heating water temperature leaving the boiler

Domestic hot water cylinder temperature (only if Alpha System diverter valve kit ﬁtted)

Central heating set point temperature

Domestic hot water set point temperature (only if Alpha System diverter valve kit ﬁtted)

External weather compensation probe temperature (value ﬂashes if negative)

Not used

Fault history - by rotating the CH knob (item 6 in Fig. 1) in this menu the last ﬁve faults will be displayed

Units

Shown

mA x 10 (approx)

°C

Error code

The boiler has a built in frost protection function to protect the boiler (only) from freezing. If water within the boiler falls below

4°C the boiler will ﬁre in heating mode and raise the temperature of the heating water (in the boiler only) to 30°C.

For this function to be active the gas and electricity supplies to the boiler must be turned on and the boiler be in either

'Standby' or 'On' mode.

Further protection for the mains water supply and heating circuit must be provided separately.

If Alpha external controls are ﬁtted, a frost protection setting is incorporated into the room thermostat activating the central

heating when the temperature falls below 5°C.

By pressing the info button (item 4 in Fig. 1) the information menu is accessed this will then show the information according

to the table below.

Alpha InTec S

The InTec range of boilers are ﬁtted with a fault code display feature.

If a fault occurs a fault code will be displayed in the LCD display screen (item 14 in Fig. 1), indicated with an alternating

ﬂashing E followed by the fault code. A list of fault codes are given in the table below.

In the event of a fault occurring ﬁrstly check that the gas and electricity supplies are on and that any external controls ﬁtted

are set and working correctly.

Press the reset button (item 3 in Fig. 1) on the control panel to restart the boiler if the fault occurs again, make a note of the

fault code and contact your installer or Alpha technical Helpline for further advice.

8 OPERATIONAL FAULTS

Error

code

Fault Fault description Possible causes

Gas supply

Check pressure tubes

Ignition electrode gap

Flame sensor electrode gap

Ignition generator or lead

Flame sensor electrode lead

Gas valve setting

Gas valve

PCB

Pump or ﬂow problem

Blocked heat exchanger

Air in heat exchanger

Overheat thermostat

Thermal fuse (if open circuit then 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 sensor wire connections

Flow sensor faulty

DHW sensor wiring connection

DHW sensor faulty

Refer to fault history codes (INFO menu d9)

Check expansion vessel pressure (1 bar)

Leak in system

Expansion relief valve operated

Primary pressure switch

Cylinder sensor wiring connections

Cylinder sensor faulty

Check internal wiring connections to PCB

Combination boiler DHW sensor X4

System boiler link X14

Refer to wiring diagram

Flame not detected during ignition sequence

Overheat thermostat or thermal fuse has operated

Flue thermostat intervention (ﬂue temperature

over 113°C)

Gas valve wiring circuit fault detected

Incorrect ﬂow sensor resistance value

DHW sensor resistance value is incorrect

Maximum number of resets reached (5)

Primary pressure switch has operated

Incorrect cylinder sensor resistance

Incorrect wiring conﬁguration detected

Ignition failure

Overheat boiler lock

out

High ﬂue thermostat

temperature

Gas valve electrical

connection fault

Heating ﬂow sensor

fault

DHW sensor fault

(InTec C, X, GS only)

Maximum number of

resets

Primary system

pressure low

Cylinder sensor fault

(InTec S and

FlowSmart only)

Internal wiring error

6Alpha InTec S

Error

code

Fault Fault description Possible causes

Check fan wiring connections

Fan fault

PCB fault

Check ﬂame sensing electrode and lead

PCB fault

Check for jammed control panel buttons

Check for jammed PCB buttons

Air in heat exchanger

Blocked or restricted primary ﬂow

Heat exchanger air ﬂow blocked

Flue restriction

Flue sensor fault

Pump fault

Boiler or heating circuit valve closed

Blocked or restricted primary ﬂow

Air in heat exchanger

Boiler or heating circuit valve closed

Pump fault

Primary ﬂow sensor fault

Check sensor wiring connection

Flue sensor faulty

Remote control or receiver connection wiring

Remote control or receiver

Check mains power supply

Check ﬂame sensing electrode and lead

Check for ﬂue gas recirculation

Check/adjust the gas valve settings

Check/adjust the fan speed settings

Check gas supply/working pressure

Check ﬂame sensing electrode and lead

Check for ﬂue gas recirculation

Check/adjust the gas valve settings

Check/adjust the fan speed settings

Check external control (room thermostat)

requests

Rapid on/off hot tap requests

Check external sensor and cable are not

damaged or wet

Check continuity of external sensor and circuit

Check connection at X19 on PCB and sensor

connecting block

Air in heat exchanger

Restricted primary ﬂow

Heat exchanger air ﬂow blocked

Flue restriction

Flue sensor fault

Pump fault

Fan wiring fault or fan faulty

False ﬂame detection

Flame detected but gas valve is not open

Control panel button stuck in the on position

Rapid temperature rise of ﬂue sensor

Rapid temperature rise of primary sensor

Flue sensor resistance out of range

Loss of connection between the boiler and

Alpha Climatic control unit

Insufﬁcient supply voltage to operate boiler

Flame detected but signal is lost. Ignition

reattempts after fan purge

Repeated loss of ﬂame signal during operation

(shown as E38 in the fault code history in the

INFO menu)

The boiler has attempted to ﬁre repeatedly for

the maximum time limit

No continuity of external sensor circuit

Flue thermostat has sensed high ﬂue gas

temperature (110°C) and reduced the burner

output to prevent damage. If the temperature

continues to rise the boiler will lock out and E03

will be displayed

Fan fault

Flame sensing fault

Control panel button

fault

Overheat lock out

Insufﬁcient primary

ﬂow

Flue sensor fault

Loss of

communication with

external control

(Alpha Climatic)

Low supply voltage

Loss of ﬂame

rectiﬁcation

Loss of ﬂame

rectiﬁcation

Safety lock out

External sensor

intervention

Reduced burner

output

Alpha InTec S

10 GAS SAFETY REGULATIONS

1. BOILER LOCATION

Always ensure the following clearances are available around the casing of the boiler:-

Top: (horizontal ﬂue) 235 mm, Top: (vertical ﬂue) 150 mm, Bottom: 150 mm, Bottom: (with Jig) 250 mm,

Each side: 5 mm, Front: 450 mm

Do not store any other articles in a cupboard containing the boiler and never place any clothing or combustible material on or

near the boiler or ﬂue pipe.

2. FLUE TERMINAL

The terminal on the outside wall must not be allowed to be obstructed. If it is damaged, in any way, turn the boiler off and

contact your Service Engineer.

Note: The Alpha InTec boilers are high efﬁciency condensing boilers and when operating vapour will be emitted from the

terminal. This is safe and quite normal.

3. MAINS FAILURE

In the event of an electrical supply failure the boiler will not operate. When the supply is restored, the boiler will return to

normal operation. Remember to reset any controls, if ﬁtted, when the supply is restored.

If the mains water supply fails, there will be no hot water from the taps. The boiler will continue to provide central heating.

4. ADDITIONAL BATHROOM FITTINGS

Any equipment such as mixing valves, showers, bidets etc. must be designed to operate at mains water pressure. Contact

your plumbing merchant or installer for advice when considering purchasing such items.

5. CLEANING

Use only a damp cloth and mild detergent to clean the boiler outer casing. Do not use abrasive cleaners.

6. SERVICING

To maintain efﬁcient and safe operation of your boiler, routine annual servicing is essential.

For advice on servicing contact:- The Alpha Helpline: 0844 871 8764.

7. GAS LEAK

If a fault or gas leak is suspected, turn off the gas supply. Do not touch any electrical switches, do not smoke and extinguish

all naked ﬂames. Contact your local Gas Region immediately on 0800 111 999.

8. ELECTRICAL SUPPLY

The boiler requires a 230/240 V ~ 50 Hz supply, fused at 3 A if a 13 A 3-pin plug is used or a 5 A fuse if any other type of

plug is used.

To connect a plug:-

The colour of the wires in the mains lead of the boiler may not correspond with the coloured markings identifying the

terminals in your plug. In this case proceed as follows:-

The wire coloured green and yellow must be connected to the terminal in the plug that is marked with the letter E, or by the

earth symbol , or coloured green or green and yellow.

The blue wire must be connected to the terminal which is marked with either the letter Nor coloured black.

The brown wire must be connected to the terminal which is marked with the letter Lor coloured red.

THE APPLIANCE MUST BE EARTHED.

9 IMPORTANT NOTES

Current Gas Safety (Installation and Use) Regulations:-

It is the law that all gas appliances are installed and serviced by a competent person, i.e. Gas Safe registered personnel.

Failure to install or service appliances correctly could lead to prosecution. It is in your interest and that of safety to ensure

compliance with the law. The manufacturer's instructions must not be taken in any way as over-riding statutory obligations.

The Benchmark Checklist must be fully completed by the installer on installation of the boiler. The Benchmark Checklist is

shown in back of the Installation and Servicing instructions. All Gas Safe registered installers carry a Gas Safe ID card and

have a registration number. Both should be recorded in the Checklist. You can check your installer is Gas Safe registered by

calling Gas Safe on 0800 408 5500.

Instructions compiled and designed by Publications 2000 - Tel: 01670 356211 05/11/D272

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.

NepicarHouse, LondonRoad,WrothamHeath,

Sevenoaks, Kent TN15 7RS

Tel: 0844 871 8764

email: info@alpha-innovation.co.uk

website: www.alpha-innovation.co.uk Part No. 1.030786 Rev 15.035285/000

11 OPTIONAL BOILER CONTROLS (if ﬁtted)

There is a range of controls available from Alpha to operate your boiler. In addition to the items listed below the Alpha InTec

boilers are compatible with most controls available on the market. However to get the most comfort and efﬁciency from your

boiler we recommend the Alpha Climatic controls with enhanced remote boiler functions and efﬁciency control.

Please refer to the instructions provided with the controls for further information on their setting and use.

Available Alpha controls:

7 day digital heating clock- two channel (boiler mounted)..........................................................................Part No.6.1000220

Alpha Comfort 7 day wireless programmable room thermostat - two channel (boiler mounted receiver) ..Part No.3.022142

*Alpha Climatic wired programmable boiler energy manager (boiler mounted) .........................................Part No. 3.022144

*Alpha Climatic wireless programmable boiler energy manager (boiler mounted receiver) .......................Part No. 3.022143

*External weather compensation probe......................................................................................................Part No. 3.022383

Alpha System diverter valve kit ..................................................................................................................Part No. 3.022382

Optional boiler controlled condensate trace heating kit..............................................................................Part No. 6.5500000