Technical data

34
Alpha InTec S - Component Replacement
7.15 CONDENSATE TRAP - Fig. 13
1. Gain access behind the front casing as described in Section 7.1.
2. Disconnect the top and drain connection of the condensate trap.
3. Place a container under the boiler and unscrew the bowl at the bottom of the trap, see Fig. 13. Some water will spill from
the trap.
4. Remove the screw securing the trap to the bottom of the boiler casing and lift out the trap.
5. Fit the new trap in reverse order.
Note: Fill the new trap with water once installed.
7.16 CYCLONE (if wall jig is fitted) - Fig. 13b
1. Remove the bottom tray and close the isolating valves either side of the cyclone.
2. Disconnect the unions from the cyclone. Remove the two screws securing the support bracket and remove the cyclone.
Re-assemble with a new cyclone.
3. Pressurise the system. (Refer to Commissioning, Section 5.1).
7.17 HEAT EXCHANGER THERMAL FUSE - Fig. 33
Note: If the thermal fuse has failed or operated, the heat exchanger must be
replaced. Do not attempt to remove the thermal fuse. Disturbing the sealant
securing the thermal fuse will invalidate the warranty.
1. Gain access behind the front casing as described in Section 7.1.
2. Disconnect the wire from the thermal fuse and remove the heat exchanger
as described in Section 7.18.
3. Fit a new heat exchanger and re-assemble in reverse order.
7.18 PRIMARY HEAT EXCHANGER - Figs. 31 and 33
1. Gain access behind the room sealed chamber panel as described in Section
7.1 and drain the boiler heating circuit as described in Section 7.2.
2. Remove the burner as described in Section 6.2 (Routine Servicing).
3. Unplug the connections from the flue temperature sensor and thermal fuse. See Fig. 31.
4. Disconnect the condensate drain pipe by pulling its rubber connector from the heat exchanger.
5. Remove the screws securing the ignition generator bracket, disconnect the earth lead and remove the ignition
generator.
6. Unplug the fan and remove it from the boiler.
7. Remove the heating flow and return pipe-retaining clips from the primary heat exchanger and pull the pipes downwards
from the heat exchanger connections.
8. Slide the heat exchanger downwards and 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 assembly.
10. Refill, pressurise the system and vent the air from the heat exchanger using the manual air vent. (Refer to
Commissioning, Section 5.1).
7.19 PRESSURE GAUGE - Fig. 34
1. Gain access behind the casing and drain the boiler heating circuit as described in Sections 7.1 and 7.2.
2. Withdraw the retaining clip securing the pressure gauge sensor (just to the left of the automatic air vent) and withdraw
the sensor.
3. Remove the main cable grommet in the bottom panel and remove the sensor tube.
4. Depress the two lugs on the pressure gauge and push it out of the control panel.
5. Fit the new gauge using a new 'O' ring on the connection if necessary.
6. Refill and pressurise the system. (Refer to Commissioning, Section 5.1).
7.20 PRIMARY TEMPERATURE SENSOR - Fig. 31
1. Gain access as described in Section 8.1 and drain the heating circuit as described in Section 7.2.
2. The primary temperature sensor is positioned on the bottom left hand side of the heat exchanger flow pipe, see Fig. 31.
Disconnect the wiring and unscrew the sensor. Re-assemble in reverse order with a new sensor and sealing washer.
Fig. 33
Thermal fuse
Back panel
insulation
Manual air vent