Installation and Servicing Instructions

Transcription

1 Installation and Servicing Instructions Alpha Pro Tec Plus 50, 70, 90 and 5 Wall Mounted, Fan Assisted, Gas Fired, High Efficiency Condensing System Boilers For Technical help or for Service call... ALPHA HELPLINE Tel: Nepicar House, London Road, Wrotham Heath, Sevenoaks, Kent TN5 7RS 005 Set for use with Natural Gas Leave these instructions with the User

2 BENCHMARK SCHEME To comply with Building Regulations Part L (Part 6 in Scotland) the boiler should be installed in accordance with the manufacturer s instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Checklist at the back of these instructions Code of Practice For the installation, commissioning and servicing of domestic heating and hot water products. Benchmark places responsibilities on both manufacturers and installers*. The purpose is to ensure that customers** are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. Installers are required to carry out work in accordance with the following: Standards of Work Be competent and qualified to undertake the work required. Install, commission, service and use products in accordance with the manufacturer's instructions provided. Ensure that where there is responsibility for design work, the installation is correctly sized and fit for purpose. Meet the requirements of the appropriate Building Regulations. Where this involves notifiable work be a member of a Competent Persons Scheme or confirm that the customer has notified Local Authority Control (LABC), prior to work commencing. Complete all relevant sections of the Benchmark Checklist/Service Record when carrying out commissioning or servicing of a product or system. Ensure that the product or system is left in a safe condition and, where possible, in good working order. Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing work. Refer to the manufacturer's helpline where assistance is needed. Report 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. Hand over the manufacturer's instructions, including the Benchmark Checklist, to the customer on completion of an installation. Obtain the customer's signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of manufacturer's instructions. Advise the customer that regular product servicing is needed, in line with manufacturers' recommendations, to ensure that safety and efficiency is maintained. Respond promptly to calls from a customer following completion of their work, providing advice and assistance by phone and, if necessary, visiting the customer. Rectify any installation problems at no cost to the customer during the installer's guarantee period. * The use of the word "installer" is not limited to installation itself and covers those carrying out installation, commissioning and/or servicing of heating and hot water products, or the use of supporting products (such as water treatment or test equipment). ** Customer includes householders, landlords and tenants. Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation. To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed. The service details should be recorded on the Benchmark Service Interval Record and left with the householder. Useful contact details: Gas Safe Register Alpha Heating Innovation: General Sales Enquiries Technical Helpline Alpha Pro Tec Plus 50, 70, 90, 5 - Benchmark Scheme

3 CONTENTS Introduction General data General boiler information... 4 Installation Commissioning and using the boiler Routine servicing Wiring diagram Fault finding Programming the boiler PCB Performance data...38 Cascade system installation Short parts llist Energy classification...44 Benchmark Checklist...52 Service record...53 INTRODUCTION The Alpha Pro Tec Plus range are wall mounted high efficiency condensing, fan assisted system boilers. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve. These are system boilers providing heating only for sealed central heating systems. However, they may be used with an open central heating system if required - refer to Section 3.8. The boilers are supplied with type B23 flue configuration (open chamber and forced draught) but can be changed to type C (room sealed) by using a kit. The boilers are fitted with a pump, 4 bar safety valve and pressure gauge fully assembled and tested. They are designed for use with a fully pumped, sealed and pressurised central heating system. If used with an open system refer to Section 3.8. The boilers can be supplied for use with Natural gas or Propane Gas (LPG). Note: There are a number of additional controls and accessories available for use with the boilers to enable cascade and zone installations to be used - See Section. Further information is available from Alpha Therm Ltd. IMPORTANT It is the law that all gas appliances are installed by a competent person, ie Gas Safe registered personnel, in accordance with the following recommendations:- Current Gas Safety (Installation and Use) Regulations All current Building Regulations issued by the Department of the Environment, i.e. Approved Document L26. Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department UK Water Regulations/Byelaws (Scotland) Health & Safety Document No. 635 (The Electricity At Work Regulations 989) The installation should also be in accordance with the following British Standard Codes of Practice:- BS 5440-: Flueing and Ventilation Requirements BS : Installation and Maintenance of Flues and Ventilation BS 5546: Specification for Water Heating Appliances BS 6644: 20...Specification for Installation gas fired boilers 70 kw.8 MW BS 6798: Specification for Installation gas fired boilers up to 70 kw BS 689: A2: Installation of low pressure Gas Pipework IGEM/UP/2...Installation of pipework IGEM/UP/4...Commissioning of gas fired plant IGE/UP/0...Installation of Flued gas appliances IGEM/UP/6...Design for natural gas installations IGE/UP/ and A...Strength Testing and tightness testing Natural Gas Installations Reference should also be made to any other standards and requirements relating to the installation depending on the location and use. Reference should be made to DEFRA document 'Guide to condensing boiler installation assessment procedures for dwellings'. If installation is in a timber framed building, refer to the Institute of Gas Engineers document IGE/UP/7. This appliance meets the requirements of IPX5D, ie degree of protection against moisture. This appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health). Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety to ensure that the law is complied with. Manufacturer's instructions must NOT be taken in anyway as over-riding statutory obligations. Notes:. Ensure that the Benchmark Checklist has been completed after the boiler has been installed and commissioned. 2. It is the law that all domestic boiler installations are registered by the installer through the Gas Safe Notification Scheme. Propane Gas (LPG) - In addition to the regulations and requirements stated, the boiler must be installed in accordance with BS 5482: - The Installation of Propane Burning Appliances in Permanent Dwellings. Alpha Pro Tec Plus 50, 70, 90, 5 - Contents/Introduction 3

4 2 GENERAL DATA 2. TECHNICAL DATA Model Pro Tec Plus Heat output condensing (50/30 C) kw Heat output non condensing (80/60 C) kw Heat output minimum kw NOx Class Maximum CO/CO 2 Ratio Maximum CO ppm 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 System safety valve setting bar Electrical power supply V ~ 50 Hz Electrical power consumption - Maximum Watts Electrical power consumption - Standby Watts PHYSICAL DATA Model Pro Tec Plus Boiler flow and return connections BSP Pressure relief valve connection BSP Gas connection BSP Boiler dimensions Height mm Width mm Depth mm Clearances for servicing Bottom mm Top (horizontal flue) mm Top (vertical flue) mm Sides mm Front mm Boiler dry lift weight kg Boiler operating weight (full of water) approx. kg Water content litre ½" ¾" 28 mm ½" ½" ¾" ¾" 28 mm 28 mm ½" ¾" 28 mm Alpha Pro Tec Plus 50, 70, 90, 5 - Data

5 2.3 COMBUSTION DATA Natural Gas G20 (Cat I2H 2H) Model Pro Tec Plus Heat input (gross) kw Heat input (net) kw Gas burner injector diameter mm Gas supply pressure mbar Gas rate at maximum output m 3 /h Flue mass flow rate at maximum output kg/h Flue mass flow rate at minimum output kg/h Flue temperature (nominal) C CO 2 at maximum output (factory set) CO 2 at minimum output (factory set) CO (nominal) at 0 O 2 ppm CO weight (nominal) mg/kwh Dry NOX weighted mg/kwh Propane G3 (Cat I3P 3P) Model Pro Tec Plus 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 CO 2 at maximum output (factory set) CO 2 at minimum output (factory set) CO (nominal) at 0 O 2 ppm CO weight (nominal) mg/kwh Dry NOX weighted mg/kwh Alpha Pro Tec Plus 50, 70, 90, 5 - Data 5

6 2.4 FLUE DATA Model Pro Tec Plus * Max. flue length 80/25 concentric (room sealed) m * Max. flue length 80 single pipe (B23 open flue) m Flue system (optional) Concentric flue mm Hole in wall required mm Flue system (as supplied) Open flue mm Hole in wall required mm / / / / * Maximum Flue Lengths (includes first bend onto boiler flue connection for horizontal installations) Open flue - Maximum horizontal or vertical flue with single 80 mm dia. according to Table above 90 bend is equivalent to 2. m of flue length 45 bend is equivalent to.3 m of flue length Vertical terminal is equivalent to 2 m of flue length Concentric flue - Maximum horizontal flue or vertical flue according to Table above 90 bend is equivalent to.9 m of flue length 45 bend is equivalent to.4 m of flue length Vertical terminal is equivalent to 2 m of flue length Notes:. Ensure all flues slope downwards towards the boiler by a minimum of 25 to 30 mm per metre of flue. 2. It is recommended that horizontal and vertical flue assemblies should be supported approximately every.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. 2.5 PUMP The boiler is equipped with a variable speed low power consumption pump. During the DHW mode, the pump always runs at the maximum speed. During the CH mode, two different functioning modes of the pump are available, AUTO and FIXED. AUTO - The pump speed is controlled automatically in order to give a proportional pump head, the pump speed varies based on the heat output supplied by the burner - the greater the heat output the higher the pump speed. It is possible to adjust the pump speed range in the boiler parameter menu. Parameter A3 adjusts the maximum speed between values 5 to 9 and parameter A4 the minimum between 5 and the maximum setting (A3). FIXED - If the parameters 'A3' and 'A4' are set to the same value, the pump runs at the constant speed level set. Note: For correct operation of the boiler, do not set values lower than the minimum value indicated above (i.e. lower than 5). Pump release - After a prolonged period of inactivity, the pump might stick, and it may be necessary to turn the motor shaft using a screwdriver. Take great care during this operation to avoid damage to the motor. By-pass Regulation (part. 24 Fig. -30) - The boiler leaves the factory with the by-pass open. If necessary, the by-pass can be adjusted to the system requirements from minimum (by-pass closed) to maximum (by-pass open). Adjust using a flat head screwdriver, turn clockwise to open the by-pass, and anticlockwise to close. For larger systems an additional external pump can be fitted and controlled by the boiler using a relay switch. See Fig Alpha Pro Tec Plus 50, 70, 90, 5 - Data

7 Pro Tec Plus Head (m water) A B Pump power consumption (W) Flow rate (l/h) A = Available pump head B = Pump power com=nsumption (dotted area) Fig. 2. Pro Tec Plus 70, Head (m water) A B Pump power consumption (W) Flow rate (l/h) A = Available pump head B = Pump power com=nsumption (dotted area) Fig. 2.2 Alpha Pro Tec Plus 50, 70, 90, 5 - Data 7

8 Pro Tec Plus Head (m water) A B Pump power consumption (W) Flow rate (l/h) A = Available pump head B = Pump power com=nsumption (dotted area) Fig ELECTRICAL CONNECTIONS Note: This Appliance Must Be Earthed External relay (optional) Coil 220 V ~ 50 Hz Max. 0. A External pump Cascade pump DHW sensor (optional) External sensor (optional) 3-way valve (optional) 220/240 A B Remote switching (optional) i.e. room thermostat remove link F to E AB Mains Supply 220 V ~ 50 Hz Fuse 3.5 AF L L N N L DO NOT connect 220/240 V N L IT IS IK Q P C D R H G J F E L R R2 A A2 S S OTOT2 Y Z M O N N L External reset 220/240 V Alarm free contact Max. A 220/240 V Cascade flow sensor Cascade boiler connections ( to 6) _ + Open Therm _ + Analog input 0-0 V 37 A 38 B Zone manager (optional) Fig Alpha Pro Tec Plus 50, 70, 90, 5 - Data

9 2.7 BOILER SCHEMATIC Pro Tec Plus (P3) Flow Gas Condensate discharge Return Tundish 2 Safety valve (4 bar) 3 Drain point 4 Flow manifold 5 Condensate trap 6 Gas valve 7 Injector 8 Fan 9 Manifold cover 0 Ignition electrode Combustion chamber cover 2 Heat exchanger 3 Heat exchanger automatic air vent 4 Flue sensor 5 Thermofuse 6 Air sampling point 7 Flue sampling point 8 Flue hood 9 Venturi positive point (P2) 20 Overheat thermostat (manual reset) 2 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 Fig. 2.5 Alpha Pro Tec Plus 50, 70, 90, 5 - Data 9

10 Pro Tec Plus 70, 90, (P3) Flow Gas Condensate discharge Return Tundish 2 Safety valve (4 bar) 3 Drain point 4 Primary pressure switch 5 Flow manifold 6 Gas valve 7 Fan 8 Injector 9 Air inlet pipe 0 Flame sensing electrode Combustion chamber cover 2 Heat exchanger 3 Flue hood 4 Air sampling point 5 Flue sampling point 6 Heat exchanger automatic air vent 7 Primary flow temperature sensor 8 Overheat thermostat 9 Primary return temperature sensor 20 Overheat thermostat (manual reset) 2 Flue sensor 22 Burner 23 Thermofuse 24 Ignition electrode 25 Manifold cover 26 Venturi 27 Pump 28 Condensate trap Fig Alpha Pro Tec Plus 50, 70, 90, 5 - Data

11 3 GENERAL BOILER INFORMATION 3. GAS SUPPLY Natural Gas: The meter and supply pipes must be capable of delivering the required quantity of gas in addition to the demand from any other appliances. The boiler requires at least a 28 mm gas supply pipe and ensure the inlet supply pressure is at least 20 mbar (Natural Gas) The complete installation, including the meter, must be tested for gas tightness and purged as described in BS 689 and IGE/UP/, IGE/UP/A or IGE/UPB. Propane Gas (LPG): The local Propane Gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas, 37 mbar for Propane Gas (LPG). 3.2 ELECTRICAL SUPPLY The boiler requires a 220/240 V ~ 50 Hz permanent mains supply, fused at 3 A Note: The boiler must be earthed. There must only be one common isolator, providing complete electrical isolation, for the boiler and any external controls. This boiler has been fitted with a supply cable, however, if it is necessary to fit a cable use PVC insulated cable not less than 0.75 mm² (24 x 0.2 mm). The boiler should be connected to a fused three pin plug and unswitched shuttered socket outlet, or a fused double pole switch with a contact separation of at least 3 mm in both poles. Wiring external to the boiler must be in accordance with the current IEE Wiring Regulations (BS 767). 3.3 AIR SUPPLY Open flued (Type B23 flue) Alpha Pro Tec Plus boilers leave the factory with 'B23' type configuration (open chamber and forced draught - single flue pipe) and receive the air for combustion from openings in the rear of the boiler, therefore air supply for combustion and ventilation must be provided in accordance with BS 5440:2 (for domestic installations with a net input less than 70 kw) or BS 6644 (for commercial installations with a net input over 70 Kw). Room sealed (Type C flue) If the boilers are converted to a 'C' type configuration (sealed chamber and forced draught - concentric flue pipe) as described in Section 3.4 only air for ventilation is required.. 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 low level air vents must communicate with the same room or must be on the same wall to outside air. Both the high and low level vent must each have a free area as per BS 5440:2 or BS The minimum clearances for servicing must always be maintained. 3.4 FLUE SYSTEM The flue system must be installed in accordance with BS 5440: or BS For horizontal flues ensure the flue assembly slopes downwards towards the boiler by a minimum of mm per metre of flue. It is recommended that horizontal and vertical flue assemblies should be supported at least every.5 m with access provided to the joints. Alpha Pro Tec Plus boilers leave the factory with 'B23' type flue configuration (open chamber and forced draught - single flue pipe). To change the configuration to 'C' type (sealed chamber and forced draught - concentric flue pipe), remove the 80 mm dia. adapter, the bracket and gasket from the top of the boiler and fit the concentric flue adaptor, see Sections 4.5 and 4.6. Note:. Under no circumstances must the flue length (including allowances for extra bends) exceed the maximum flue lengths stated for each type of flue. 2. Failure to use the correct Alpha flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe. Seals for flue elements - If lubrication of components (already performed by the manufacturer) is not sufficient, remove the residual lubricant using a dry cloth, then to ease fitting apply a small amount of common or industrial talc to the seal. Ensure that the seals are correctly located in the elbows and extensions when assembling the flue. Note: Do not use silicone or other oil based lubricants on the flue seals. Alpha Pro Tec Plus 50, 70, 90, 5 - General Boiler Information

12 Flue components are available as follows:- Open flue - 80 mm dia. single pipe Horizontal terminal kit 80 mm dia. (includes metre straight terminal section, one 90 bend and two collars) Vertical terminal kit 80 mm dia Extension pipe metre x 80 mm dia bend 80 mm dia bend 80 mm dia mm flue support bracket Pitched roof flashing (universal) Flat roof flashing (universal) Concentric flue - 80/25 mm dia Horizontal terminal kit 80/25 mm dia. (includes metre straight terminal section, one 90 bend, two collars and adaptor with square gasket) Vertical terminal kit 80/25 mm dia. (includes adaptor with square gasket) Extension kit metre x 80/25 mm dia bend 80/25 mm dia bend 80/25 mm dia Pitched roof flashing (universal) Flat roof flashing (universal) Cascade flue options are also available for multiple boilers Horizontal Concentric Flue Options L Max. L Max. Open flue: 80 mm dia. single pipe 90 bend is equivalent to 2. m of flue length 45 bend is equivalent to.3 m of flue length Concentric flue: 80/25 mm dia. 90 bend is equivalent to.9 m of flue length 45 bend is equivalent to.4 m of flue length Pro Tec Plus model 80/25 mm Concentric flue 80 mm Open flue m 30 m L Max m 8 m 28 m 4 m 5 5 m 8.5 m Fig Alpha Pro Tec Plus 50, 70, 90, 5 - General Boiler Information

13 3.4.2 Vertical Concentric Flue Options Not less than 000 mm Not less than 000 mm L Max. L Max. L Max. Pro Tec Plus model 80/25 mm Concentric flue 80 mm Open flue m 30 m 70 m 28 m 90 8 m 4 m 5 5 m 8.5 m Fig FLUE TERMINATION The Alpha Pro Tec Plus range of boilers can be individually flued using either 80 mm open flue configuration or 80/25 mm concentric flue. Multiple boilers can be individually flued or cascade flue kits are also available in 00 mm or 200 mm. When installing these boilers careful planning and consideration for the flue system must be undertaken. All flue systems must conform to the relevant standards depending on the boiler size and configuration. Refer to BS 6644, BS 5440 or IGE/UP/0 for the correct flue location requirements. 3.6 BOILER LOCATION The boiler is not suitable for external installation unless it is installed within a purpose designed weatherproof building. The boiler must be installed on a flat vertical wall which is capable of supporting the weight of the boiler. The boiler can be fitted to or adjacent to a wall comprising of a combustible material without the need for a special thermal insulation barrier. 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/UP/7. The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current IEE Wiring (BS 767) Regulations, and in Scotland, 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 roomsealed 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 electricity. 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 and BS Propane Gas (LPG): Installation pipes, cylinders and pressure regulators should be fitted in accordance with BS 5482:. Bulk tank installation must comply with the requirements of the Home Office code of practice for the storage of liquefied petroleum gas at fixed installations. The boiler must not be installed in a room or internal space below ground level, e.g. in a basement or cellar, except where at least one side is open to ground level. 3.7 FROST PROTECTION The boiler is fitted with a frost thermostat that activates the pump and burner when the system water temperature in the boiler falls below 3 C. The electrical supply to the boiler must be left on for the thermostat to operate and the selector switch must be set to ON. Alpha Pro Tec Plus 50, 70, 90, 5 - General Boiler Information 3

14 3.8 CENTRAL HEATING SYSTEM - Fig. 3.3 The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS The system should be designed to operate with flow temperatures of up to 85 C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. Refer to the pump performance graph Section 2.5 for guidelines. However, if the boiler is to be used with an open central heating system refer to Fig. 3.3 and use a barrier heat exchanger (i.e. separates the boiler primary circuit from the open heating circuit). This will also ensure the boiler heat exchanger is protected from an old/dirty system. Sealed system volume - An expansion vessel is not incorporated into the boiler. An expansion vessel must be fitted in the position shown in Fig To check correct operation of the expansion vessel the system pressure should not be more than 3.5 bar when the system is at maximum operating temperature (for further guidance refer to BS 7074:), For example an 8 litre expansion vessel is suitable for a sealed system of 80 litres. Expansion vessels should be set to bar before the system is filled. The boiler is supplied with the following components built in:- Pressure relief valve - complying with BS 6759 and set to operate at 4 bar. The discharge pipe must be routed clear of the boiler and terminated in such a manner that it can be seen, but cannot cause injury to persons or property. Pressure gauge - To indicate the system 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 temperature of parameter No. 02 as described in Section 9. In this mode it is advisable to include a safety limit thermostat set at 55 C in series with the boiler controls. The thermostat must be positioned in the system flow pipe at more than 2 metres from the boiler. Make up vessel (sealed system only) Static head of system Boiler Automatic air vent Expansion vessel (sealed system only) Double check valve assy. (sealed system only) Filling point (sealed system only) Heating flow Return Barrier heat exchanger used on open or old/dirty systems Note: A drain tap should be installed at the lowest point of the heating circuit and beneath the appliance. Heating return System drain tap Return Flow Flow Heating flow Heating return Fit pump if Barrier heat exchanger used Expansion vessel (sealed system only) Drain tap Fig FILLING THE SEALED CENTRAL HEATING SYSTEM - Figs. 3.4, 3.6 The system design pressure (cold) should be set to.0 bar. This pressure is equivalent to a static head (see Fig. 3.3) of 0.2 metres of water. Provision should be made to replace water lost from the system. This can be by manual or automatic means, as shown in Figs. 3.4 and 3.5. The position for connecting an automatic make-up vessel is indicated in Fig A double check valve assembly must be used, as shown in Fig Alpha Pro Tec Plus 50, 70, 90, 5 - General Boiler Information

15 Filling of the system must be carried out in a manner approved by the local Water Undertaking. Where allowed, the system may be filled via a temporary connection as shown in Fig After filling, always disconnect the flexible hose of the filling loop. All fittings used in the system must be able to withstand pressures up to 4 bar. Drain taps (to BS 2879) must be used to allow the system to be completely drained. A pressurisation unit may also be used to maintain the system level. Refer to the instructions supplied with the unit for correct installation. Heating circuit return Stop valve Hose unions Double check valve assembly Test cock Filling loop temporarily connected Stop valve Mains water supply Heating circuit return Double check valve assembly Test cock Overflow Stop valve Mains water supply Feed cistern to be located above highest point in the system Fig. 3.4 Fig FLUSHING THE HEATING SYSTEM It is essential that the central heating system is thoroughly cleaned and flushed when fitting an Alpha Pro Tec Plus boiler. Failure to do so will invalidate the warranty. If this is difficult because the system is old/dirty refer to Section 3.8, Fig. 3.3 gives consideration to using a barrier heat exchanger. The primary condensing heat exchanger is constructed in stainless steel and therefore is compatible with most materials used in a heating system. A cleaning agent and inhibitor should be used, they must be applied in accordance with their manufacturers instructions. Only products from Fernox and Sentinel are acceptable for use with the Alpha Pro Tec Plus boilers. Further information can be obtained from Fernox (Tel: ) or Sentinel (Tel: ). The system should be flushed in accordance with BS 7593 and BS The following procedures are recommended:. 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 the system as instructed by the recommended cleaner manufacturer. Note: Ensure that the system is flushed to remove any remains of the cleaner. e. If chemical cleaner is not used to clean the system:- i) Refill the system. ii) Switch on the boiler and allow the system to heat up to the normal operating temperature. iii) Rapidly drain the system while the water is still hot. iv) Refill the system. f. As required, add the recommended inhibitor to the system as instructed by the inhibitor manufacturer. g. Recheck for leaks. 2. Installing onto an existing system, clean the system before fitting the new boiler:- a. If the old boiler is still working:- i) Switch on the boiler and allow the system to heat up to the normal operating temperature. ii) Rapidly drain the system while the water is still hot. iii) Refill and chemically clean the system as instructed by the recommended cleaner manufacturer. iv) Ensure the system is flushed to remove any remains of the cleaner. v) Fit the new boiler. b. If the old boiler is not working:- i) Rapidly drain the system. ii) Remove the old boiler. iii) Flush the system through. iv) Fit the new boiler. v) Refill and chemically clean the system as instructed by the recommended cleaner manufacturer. vi) Ensure the system is flushed to remove any remains of the cleaner. c. As required, add the recommended inhibitor to the system as instructed by the inhibitor manufacturer. d. Check for leaks. Alpha Pro Tec Plus 50, 70, 90, 5 - General Boiler Information 5

16 3. DISPOSAL OF CONDENSATE Provision must be made for the safe disposal of condensate produced by Alpha Pro Tec Plus boilers and reference should be made to BS 6798: 2000 for the requirements on the disposal of condensate. The boilers incorporate a condensate trap which has a seal greater than 75 mm, therefore no additional trap is required. The condensate should ideally be discharged internally into an internal waste pipe or soil pipe to avoid the possible risk of freezing. The pipework must be in at least 22 mm pipe. External pipe runs should be avoided, but if it is necessary, the pipework should be at least 32 mm and protected from the risk of freezing with waterproof insulation and the length should be kept to a maximum 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 requirements. Plastic pipe Use waterproof pipework insulation in very exposed positions Ensure pipe is adequately supported Open end of pipe diverted into gully below grid but above water level Minimum gradient 2½ Fig External gully 22mm termination from boiler Cement mortar sealing 500 mm min. O 2½ fall Ground level (either/or) 00mm plastic tube 25mm 300mm Bottom of tube sealed Soakaway depth 400mm filled with limestone chippings Two rows of 3 x 2mm holes at 25mm centres, 50mm from the bottom of the tube. Holes to face away from house. Fig External soakaway 6 Alpha Pro Tec Plus 50, 70, 90, 5 - General Boiler Information

17 4 INSTALLATION 4. UNPACKING. The basic boiler is supplied in a single box, containing the following:- Cased boiler supplied with water connections and washers Mounting hooks and wall plugs with coach screws Tundish for pressure relief valve outlet Condensate discharge pipe Gas service cock 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 4.2. Pro Tec Plus Dia E G 92 SV CD 30 HF HR E - Electrical connection G - Gas supply HR - Heating return HF - Heating flow CD - Condensate drain SV - Safety valve outlet (tundish) Fig. 4. Alpha Pro Tec Plus 50, 70, 90, 5 - Installation 7

18 MINIMUM TOP CLEARANCE 350 mm TOP OF CASING WITH COVER BOILER MOUNTING HOOK FIXING HOLE MINIMUM SIDE CLEARANCE 0 mm BOTTOM OF CASING HEATING FLOW (/2" BSP) Dia. 50 E G 92 SV CD 30 HF HR SAFETY VALVE (3/4" BSP) MINIMUM BOTTOM CLEARANCE 250 mm GAS (28 mm) BOILER MOUNTING HOOK FIXING HOLE MINIMUM SIDE CLEARANCE 0 mm HEATING RETURN (/2" BSP) Pro Tec Plus 70, 90, Dia. A A B C Pro Tec Plus 70 Pro Tec Plus 90, mm 632 mm 265 mm 40 mm 497 mm 627 mm E G CD 3 HF SV HR B C E - Electrical connection G - Gas supply HR - Heating return HF - Heating flow CD - Condensate drain SV - Safety valve outlet (tundish) Fig PREPARE THE WALL - Fig Decide upon the position of the boiler taking into account the clearances required for servicing (refer to Section 2.2) and the flue terminal position. 2. Tape the template to the wall (ensure it is level and the right way up) and mark the position of the two holes for the boiler mounting hooks. 3. Drill the fixing holes (2 mm dia.) to accept the No. 2 plugs supplied. Screw the boiler mounting hooks fully into the plugs. 4. Cut suitable holes in the wall/roof 00 mm dia for open flue 80 mm dia. pipe or 27 mm dia. for concentric flue. Use the centre line positions given on the flue template. For side flue follow the horizontal line (ensuring at least a 25 mm/m fall towards the boiler) to the corner then 40 mm along the side wall to the centre of the hole for the flue. 5. Lift the boiler and locate it on the mounting hooks. Note: When handling or lifting always use safe techniques - keep your back straight, bend your knees, don't twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible. Where possible transport the boiler using a sack truck or other suitable trolley. Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. Centre line for horizontal concentric flue 70 mm Centre line for horizontal open flue Centre line for vertical flues Alpha Fig mm Top of casing with cover 8 Alpha Pro Tec Plus 50, 70, 90, 5 - Installation

19 4.4 CONNECT THE PIPEWORK. Thoroughly flush out all the system pipework. Refer to Section Connect the system flow and return pipework to the boiler using suitable isolating valves. Note: Do not forget that the pressure relief valve discharge pipe must be routed clear of the boiler to a drain in such a manner that it may be seen, but cannot cause injury to persons or property. 3. Connect the 22 mm condensate trap drain pipe to the condensate discharge pipe using the clip supplied. Ensure that the condensate discharge pipe is as required in Section 3.. Pour at least litre of water into the flue duct, as shown in Fig. 4.4, and check the condensate discharge pipe for soundness 4. Ensure that all the valves are closed and do not turn on the water or gas supplies at this stage. Fig 'B23' TYPE SINGLE PIPE 80 mm FLUE KITS Vertical kit - see Fig. 4.5 and 4.6, and refer to Section 3.4. Fig. 4.5 shows the vertical flue kit parts. To assemble the kit to the boiler - Slide the flue pipe down through the roof seal and place the seal over the flue duct. Push the flue duct into the flue socket on top of the boiler up to the stop. Ensure the seal is pushed in position against the ceiling. To install extensions or other flue components, proceed as follows: fit the male end of the pipe or elbow up to the stop on the female 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.5 m with access provided to the joints. Vertical terminal 430 mm Minimum Flue pipe L Max. Seal Seal L Max. Pro Tec Plus 50 Pro Tec Plus 70 Pro Tec Plus 90 Pro Tec Plus 5 30 m 28 m 4 m 8.5 m Fig. 4.5 Fig. 4.6 Horizontal through the wall kit - see Fig. 4.7 and 4.8, and refer to Section 3.4. Figs. 4.8 and 4.9 show the horizontal through the wall kit parts. To assemble the kit to the boiler - Fit the male end of the flue elbow into central flue outlet on the top of the boiler to the stop. Place the outer seal over the flue duct and slide it through the wall from the outside. Place the inner seal over the flue duct then insert the duct 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 as follows: fit the male end (smooth) of the pipe or elbow up to the stop on the female socket (with lip seals) of the previously installed component, this will ensure a secure fit and seal of the joints. Note: To prevent condensate lying in the flue pipe, slope the pipe towards the boilers with a minimum slope of (25-30 mm per metre). When installing the extensions, a wall/ceiling mounted clamp must be installed at least every.5 metres. Alpha Pro Tec Plus 50, 70, 90, 5 - Installation 9

20 Flue elbow Flue pipe Inner seal Outer seal Fig mm L Max. 70 mm 00 mm Pro Tec Plus 50 Pro Tec Plus 70 Pro Tec Plus 90 Pro Tec Plus 5 L Max. 30 m 28 m 4 m 8.5 m Note: Ensure the flue slopes downwards towards the boiler by a minimum of 25 to 30 mm per metre (2.5 to 3 ) Fig 'C' TYPE CONCENTRIC FLUE KITS Convert the boiler from the factory supplied 'B23' type configuration to 'C' type, i.e. room sealed concentric flue by removing the 80 mm dia. adaptor and four screws securing the fixing plate and gasket from the top of the boiler. Horizontal through the wall concentric flue kit - see Fig. 4.9 and 4.0. Fig. 4.9 shows the flue kit parts that need to be fitted to the boiler to ensure the room sealed concentric flue can be used. To assemble the kit to the boiler - Fit the adapter into the central flue outlet on the top of the boiler up to the stop. Slide the square gasket over the adapter up to the groove, then fix it to the cover by means of the previously removed fixing plate and four screws. 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 as follows: fit the male end (smooth) of the concentric pipe or concentric elbow up to the stop on the female socket (with lip seals) of the previously installed component, this will ensure a secure fit and seal of the joints. Note: To prevent condensate lying in the flue pipe, slope the pipe towards the boilers with a minimum slope of 3 (25-30 mm per metre). When installing the extensions, a wall/ceiling mounted clamp must be installed every.5 metres. Flue elbow Fixing plate Inner seal Outer seal Square gasket Adapter Concentric flue pipe Fig Alpha Pro Tec Plus 50, 70, 90, 5 - Installation

21 L Max. 36 mm 80 mm Inner seal L Max. 200 mm Note: Ensure the flue slopes downwards towards the boiler by a minimum of 25 to 30 mm per metre (2.5-3 ) Outer seal Pro Tec Plus 50 Pro Tec Plus 70 Pro Tec Plus 90 Pro Tec Plus m m 8 m 5 m Fig CONNECT THE MAINS SUPPLY AND EXTERNAL CONTROLS - Fig. 4. Gain access as described below while referring to Fig Remove the case front panel as follows: a. Remove the two screws () from the bottom of the front panel (2). b. Grip the handle in the bottom of the panel and pull it forwards to detach it from the central catches (3) then slide it down from the top fixings (4) and remove. 2. Remove the two screws and washers (5) securing the sides of the control panel. Press the two side hooks (6) and tilt the control panel (7) forwards. Remove the three screws (8) securing the control box cover (9) to gain access to the terminal block. Refer to Technical Data, Section 2.3 for connection details. Note: This boiler has been fitted with a mains supply cable. However, if it is necessary to fit an alternative supply cable, ensure the cable clamp that has been fitted is removed and connect as follows:- Pass the 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. is to be fitted, refer to Fig. 4.. Do not connect 220/240 volts to any of the other terminals. It is recommended that only the mains supply is connected to the boiler when first commissioning. External controls can then be connected after the boiler has been commissioned. This prevents any external controls interrupting the commissioning process. 4. Ensure that there is sufficient free cable to allow the control panel to be raised and lowered then tighten the cable clamp screws. 5. Leave the control panel open until commissioning procedures have been completed. 6. Carry out electrical system checks - Short circuit, Polarity, Earth continuity and Resistance to earth with a suitable multimeter. External relay (optional) Coil 220 V ~ 50 Hz Max. 0. A 3-way valve (optional) 220/240 B A AB External pump Cascade pump DHW sensor (optional) External sensor (optional) Remote switching (optional) i.e. room thermostat remove link F to E Mains Supply 220 V ~ 50 Hz Fuse 3.5 AF L L N N L DO NOT connect 220/240 V N L IT IS IK Q P C D R H G J F E N L R R2 A A2 S S OTOT2 Y Z M O N L External reset 220/240 V Alarm free contact Max. A 220/240 V Cascade flow sensor Fig. 4. Cascade boiler connections ( to 6) _ + _ + Open Therm Analog input 0-0 V 37 A 38 B Zone manager (optional) Alpha Pro Tec Plus 50, 70, 90, 5 - Installation 2

22 Fig Alpha Pro Tec Plus 50, 70, 90, 5 - Installation

23 + 5 COMMISSIONING and USING THE BOILER When commissioning the boiler, ensure the Benchmark Checklist is completed. 5. FILL THE SYSTEM If the front cover has not been removed, refer to Section The Pro Tec Plus 50 has two automatic air vents (see Fig. 6.2), the Pro Tec Plus 70, 90, 5 boilers have one automatic air vent (see Fig. 6.3). Ensure that these are always open. 2. Open the central heating flow and return valves. 3. Open the fill point valve on the filling loop until water is heard to flow. 4. To remove the air - Vent each radiator in turn, starting with the lowest in the system. Note: The Pro Tec Plus 50 model must be vented using the manual air vent on the top left of the heat exchanger (see Fig. 6.2). 5. It is important that the pump (see Fig. 6.2 or 6.3) is properly vented to avoid it running dry and damaging its bearings. Unscrew and remove the cap from the centre of the pump. Using a suitable screwdriver rotate the exposed spindle about half a turn, then replace the cap. 6. Check the operation of the safety valve (see Fig. 6.2 or 6.3) by turning the head anti-clockwise until it clicks. The click is the valve lifting 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.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 manually operating the drain point (see Fig. 2.4 or 2.5) until the system design pressure is obtained. The system design pressure (cold) should be between 0.75 and.25 bar. Refer to Sections 3.9 and 3.0. Filling and Flushing the system. 5.2 TEST FOR GAS TIGHTNESS AND PURGE THE SUPPLY. With the boiler gas service cock closed. Pressure test the gas supply and inlet pipework connection to the boiler gas service cock for tightness in accordance with BS Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 5.). Ensure the gas supply is on and open the boiler service cock to purge in accordance with BS Retighten the test point screw and test for gas tightness. Close the boiler gas service cock. Pro Tec Plus 50, 70 gas valve Pro Tec Plus 90, 5 gas valve P (P3) 3 P Inlet gas pressure point 2 - Outlet gas pressure point 3 - Off/Set adjustment screw (minimum) 4 - Outlet flow regulator (maximum) 2 (P3) Fig. 5. Alpha Pro Tec Plus 50, 70, 90, 5 - Commissioning 23

24 5.3 BOILER CONTROLS - Fig. 5.2 Raise the control panel cover using the handle '3' in Fig ON 2 bar A B C RESET On/Off switch 2 - Main flow temperature - Increase or Decrease 3 - Control panel cover handle 4 - DHW temperature - Increase or Decrease (optional) 5 - System pressure gauge 6 - Summer/Winter mode selector button (A) 7 - Reset and information button (B) 8 - Hot water enable/disable button (C) 9 - LCD display 0 - Heating function - Numeric indicators - Temperature, Info and Fault codes 2 - Open Therm function 3 - Information icon 4 - Wireless feature 5 - Reset required 6 - Engineer mode for system setup 7 - Standby mode 8 - External temperature feature (optional) 9 - Measurement value units 20 - DHW function active (optional) 2 - DHW function disabled 22 - Burner ON 23 - Reset required 24 - Internal pump running 25 - Summer mode active Fig BOILER LCD DISPLAY AND CONTROL BUTTONS The boiler display (see Fig. 5.2), is composed of a 4-character display and 7 buttons. By using these buttons it is possible to adjust the boiler as it would be by using traditional selector switches and knobs. The function of each button is listed in Fig When the boiler is operating, the display indicates the mode icons and the boiler flow temperature. 5.5 INITIAL LIGHTING - Refer to Fig Ensure that the gas and electrical supplies to the boiler are off and that the heating flow and return valves are open. 2. Check that the system has been pressurised to the required pressure (at least bar). 3. Turn on the gas and electrical supplies to the boiler. 4. Ensure any external controls are calling for heat. 5. Set the On/Off switch to ON. The boiler pump will run through a brief air purging cycle. At the beginning of this cycle the display will check the software and connections. When the purge cycle is complete the boiler will then respond to the request of the heating controls and the burner will light if a demand is present. The boiler 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 Alpha Pro Tec Plus 50, 70, 90, 5 - Commissioning