Boilers have become an integral technique in almost every home. The breakdown of this technique can make difficulties to its owner. Below there are 8 tables that will be the must-have manual for the owner of Alpha Boilers. They include different error codes that can give the boiler and the ways in which the owner easily repairs the boiler yourself.
| Error code | Meaning | Solution |
|---|---|---|
| Code 71 | Collector sensor fault | Temperature of the collector is below -40*C or above 250°C. |
| Check the collector sensor does it operate | ||
| Sensor cable damaged or short circuited. | ||
| Sensor is faulty. | ||
| Code 72 | Upper cylinder sensor fault | Temperature of the cylinder is below 0°C or above 100*C. |
| Check the upper cylinder sensor: does it operate | ||
| Sensor cable damaged or short circuited. | ||
| Sensor is faulty. | ||
| Code 74 | No circulation in the collector | Check water level in drain back unit. |
| Check the difference in height between the drain back unit pump and the upper most side of the collector. This can be a maximum of 3 metres. | ||
| Check the collector sensor and the lower cylinder sensor, do they operate | ||
| Check the collector tubes, are they blocked with dirt? Is the decline of the pipes within the 40 mm per metre requirement. | ||
| Check the electrical connection and operation of the drain back unit pump and the cylinder pump. | ||
| Code 75 | Collector temperature too high | After 5 minutes the collector temperature is still too high (above 130°C) with the drain back unit pump operating. |
| Check the level of water in the drain back unit. | ||
| Check the difference in height between the drain back unit pump and the upper most side of the collector. This can be a maximum of 3 metres. | ||
| Check the collector sensor and the lower cylinder sensor, do they operate | ||
| Check the collector tubes, are they blocked with dirt? Is the decline of the pipes within the 40 mm per metre requirement. | ||
| Check the electrical connection and operation of the drain back unit pump and the cylinder pump. | ||
| Code 77 | The system is not turned on | The control has not been operating for 30 days. |
| Check the collector sensor and the lower cylinder sensor, do they operate | ||
| Code 80 | Lower cylinder sensor fault | Temperature of the cylinder is below 0°C or above 100*C. |
| Check the lower cylinder sensor: does it operate | ||
| Sensor cable damaged or short circuited. | ||
| Sensor is faulty. |
| Problem | Cause | Solution |
|---|---|---|
| Chimney fire | If your stove has been installed correctly and you have also operated it correctly and regularly carried out the recommended routine checks then it is unlikely that you will ever experience a chimney fire, which can be highly dangerous. | Chimney fires can be detected by an unusual roaring sound and / or unusual vibrations coming from the chimney breast or the stove itself. The sound is not to be confused with the gentle ‘rushing’ sound you may normally hear when a stove has a well performing up-draught. During a chimney fire you may also see sparks or flames exiting from the chimney terminal outside |
| Prevention If you suspect a chimney fire then immediately close the Primary and Secondary Air controls, as well as the Thermostat Control, evacuate the building and call the Fire Service. Never open the stove door as this will make the chimney fire worse by providing additional combustion air. Do not re-enter the building until you have been advised by the Fire Service that it is safe. Do not re-light the stove until the flue system has been thoroughly inspected by an approved installer or chimney sweep and any necessary repairs have been carried out | ||
| Inadequate cleaning | Chimney fires occur when soot and creosote have built up to such a level that they ignite. It is important therefore that your flue system has as many cleaning access points as practicable to enable comprehensive removal of soot, creosote and other debris. This will also minimise the amount of time it takes for a qualified sweep to clean the system making the system safer and its cleaning more cost-effective in the long run | |
| Continuous low burning | To discourage the potential for such soot and creosote build-ups, long periods of consistent ‘slumber’ or overnight burning should be avoided or that these should at least be compensated for by regular burning on full output for short periods (eg 30 minutes per day) to help burn off any likely deposits before they become problematic | |
| Poor fuel choice | As previously mentioned unseasoned or damp wood or fuel should always be avoided as these produce excessive soot and creosote. This is particularly problematic for boiler stoves where the fire chamber temperatures are much lower than in a non-boiler stove and therefore the potential to promote the conditions for dangerous deposits from damp fuel is much greater | |
| Stove, flue or other components glowing red | The Primary and Secondary Air controls, as well as the Thermostat Control, should be immediately closed to let the fire die down to an acceptable level and to reduce the heat output which will in turn eliminate the glow from the over-heated components. At the same time ensure that water within the system is not ‘boiling’. Your central heating system should have the requisite safety valves to prevent this, but if in doubt run off excess hot water and ensure the central heating pump is working to dissipate the excess heat and hot water. Over-firing is dangerous and could permanently damage or warp your boiler stove and its components. The effects of over-firing are fairly obvious to anyone in the stove industry and will invalidate your Alpha Warranty. Check the stove, the flue system and the central heating for any signs of damage or system failure before you re-use the stove | |
| Over-Firing | This is caused by using the stove at a higher output than recommended for prolonged periods of time and / or over-filling the firebox with fuel. The excessive heat in the flue system produced by over-firing could potentially also lead to a chimney fire | |
| Smoke and fumes escaping into the room | When properly installed and operated your stove should not normally emit fumes or smoke into the room. When first using the stove it is normal to experience paint fumes or see light smoke rising from some of the stove’s painted surfaces, but these should eventually pass as the paint cures. Occasional minor smoke escape may also occur during the refuelling process. However, persistent smoke or fumes could be dangerous and in this situation you should take immediate avoiding action. | |
| Prevention: Open doors and windows to ventilate the room and let the fire go out to allow the stove to cool. Never pour water onto the fire as this could cause the cast iron components to break. | ||
| Most importantly, never re-light the stove until the problem has been identified and solved. If in doubt, in the first instance always seek the expert advice of your approved installer, or authorised Alpha dealer. | ||
| There are a number of factors, either alone or combined, which could cause such problems | ||
| A blockage | When safe to do so, examine the flue-way above the baffle plate as well as the chimney system via any inspection hatches and clear any soot blockages. Excessive deposits could also indicate that the chimney or flue itself also needs cleaning | |
| Inadequate supply of combustion air | Check that any permanent air vent fitted to supply the extra combustion air required for the stove has not been accidentally blocked. Remember there should never be an extractor fan in the same room as a stove. A simple way of checking whether or not the stove is receiving enough combustion air is to open a window in the same room as the stove whilst the stove is operating. If this improves the problem then this would certainly indicate that the stove is being starved of combustion air and the advice of the original installer should be sought | |
| Extreme weather conditions | High winds or extremes of temperature can also temporarily affect the performance of the chimney draught and consequently its effectiveness in removing smoke and fumes from the stove’s fire chamber. In the case of freezing temperatures it is important to build a larger pre-fire than normal to quickly provide the additional heat needed to warm the flue system and to counteract the much lower temperatures at the exit point of the chimney. This is particularly important for boiler stoves which have the disadvantage of the fire chamber being surrounded by very cold water. Unusually hot sunny days in the Autumn can sometimes produce negative pressure which will affect the up-draught and in these instances you should open a window or door to the outside to help re-balance the interior and exterior pressures which create the up-draught mechanism. Once you are con- fident that the up-draught has re-started you can then close any doors or windows | |
| High winds | If the problem is associated with high winds and it becomes a regular occurrence, then you will need to fit a specialist chimney cowl. These are designed to provide a stable draught and prevent specific types of problems. Specifying the right cowl should always be left to an approved installer | |
| Flue Exit | Check, especially at the beginning of the heating season, that summer tree growth has not interfered with the free passage of smoke and flue gases from the chimney top | |
| Overheating and excessive fuel consumption | Excessive Chimney Draught | This limits the effectiveness of the air controls so that the fire burns with very strong bright yellow flames and with very little difference when the air controls are operated. In such circumstances, and where possible, an adjustable draught stabiliser in the flue system may need to be fitted to ensure that the stove will always operate under a stable draught to allow the stove’s controls to function correctly. In the interests of safety, because draught stabilisers limit the exit of flue gases from the stove, they should only ever be specified, fitted and subsequently tested by an approved installer |
| Fuel | The fuel itself may be of poor quality. For example pine and other softwoods used in the building trade will burn much quicker than a good hard wood log, such as Oak | |
| Faulty Door Seals | The rope seals around the fire chamber door could have become worn and may not create the air-tight seal needed for the Primary and Secondary Air controls to function correctly. When the stove is cold, you can easily check this seal by placing strips of paper at various points between the door and chamber and checking that when the door is closed it grips this paper. Any paper which can be removed easily would indicate a weakness of the door seal in that particular spot, in which case a complete new rope seal should be fitted | |
| Stove not providing enough heat | This problem is also usually indicated by dull orange lifeless flames and wood that remains black when burning instead of light grey | |
| Poor fuel | Poor heat output is more than likely caused by poor fuel, such as ‘green’ or unseasoned wood or even wet wood. We cannot over-estimate how critical it is to use fully seasoned dry wood in a boiler stove. The easiest way to check whether your wood is fully seasoned is to invest in a moisture meter specifically designed for testing wood fuel. These are relatively inexpensive and can be purchased from your stove dealer. When you bear in mind that seasoned wood with a moisture content of less than 20% will give you approximately 50% more heat than unseasoned wood, a moisture meter is a modest investment which will more than pay for itself | |
| Blockages | When safe to do so, examine the flue-way above the baffle plate as well as the flue liner or chimney system, either through the stove or via any inspection hatches. Clear any soot blockages. Excessive deposits could also indicate a poor choice of fuel or that the chimney or flue itself also needs cleaning more often than previously thought | |
| Circulation Pump | This may need re-adjusting to slow down the system’s flow because it does not provide the water with a slow enough passage through the stove’s boiler to heat up the water sufficiently. This in turn prevents the fire chamber from ever reaching a good operating temperature. It could also be that the central heating system may need to re-balanced at the same time. | |
| Glass staining or blackening | Glass can be cleaned easily if it is undertaken regularly and the deposits are not allowed to build up. A proprietary stove glass spray or gel is strongly recommended | |
| Air Controls | Ensure that you fully understand how the Airwash system works and that you have determined, through some trial and error that you have the correct balance between the Primary, Secondary and Thermostat Controls that your stove needs. Generally, try to use more Secondary Air when burning wood as this air flows down and over the glass to help burn and wash away any particulates that have accumulated there | |
| Poor fuel | Burning damp or unseasoned wood will cause the glass to stain as the moisture from the fuel considerably reduces the fire chamber temperature reducing the effectiveness of the Airwash system. ‘Green’ wood will also encourage sticky deposits on the glass which will prove difficult for the impaired Airwash system to remove | |
| Condensation in the fire chamber | You may see moisture droplets on parts of the boiler or experience damp ash when the stove is cold or after the stove has been used | |
| Atmospheric conditions It is not unusual for condensation to form on a cooling boiler or pipework under certain atmospheric conditions | Such condensation should not be confused with a boiler leak. In the unlikely event of a boiler leak a profuse amount of water, which is usually hard to stem, will occur. This is significantly different from condensation which can be easily dried out with a sponge or tissue or by re-lighting the stove. After the fire has gone out, open all the air controls and leave the stove door slightly open, as this can sometimes help. | |
| Central heating system not providing enough heat or hot water | If you have ensured that the stove is functioning properly ie that it has vibrant yellow flames and is providing heat to the room, but still not delivering sufficient heat through the central heating radiators or hot water then it is more than likely to be a problem with the system. The simplest way to determine this is, if possible, to check that the top water pipe from the stove is hot and that the lower pipe is cooler. If this is the case then this indicates that there is a problem with the system and not the stove | |
| Circulation pump or thermostatic valve failure | A fault in one of the system’s key components could restrict the system flow thus limiting heat to the radiators and / or hot water cylinder. For example, a thermostatic valve may have been activated due to a potential temperature anomaly or have stuck in the wrong position. Identifying the precise problem is a job best left to the original installer or heating engineer |
| Code | Description | Solution |
|---|---|---|
| 0 | Flame sensor fault detected | Check flame sensing electrode and wiring Check PCB |
| 2 | Ignition failure | Check gas supply |
| Check electrode position | ||
| Check flame sensing signal is greater than 6^A | ||
| 3 | Gas valve supply error | Check gas supply |
| 05 06 11 13 14 15 16 17 44 60 | Internal fault (electronics) | Check electrical connections Check PCB |
| 4 | Burner lock-out (electrical fault) | Check electrical connections |
| 7 | Gas valve relay fault | |
| 12 | Overheat safety thermostat operated | Check PCB fuses |
| Check primary flow thermostat | ||
| Check flue thermostat | ||
| 18 | Primary flow temperature too high | Check water circulation Check for air in the system |
| 19 | Primary return temperature too high | |
| 24 | Return temp, higher than flow temp, by more than 10*C after 180 sec | |
| 25 | Rapid primary flow temperature increase | |
| 26 | Insufficient water pressure | Check for system leaks Repressurise the system 0.75 – 1.25 bar |
| 28 | Fan fault (no Hall signal) | Check fan Check fuse F3 |
| 29 | Fan fault | Check fan Check fuse F3 Check electrical connections Check PCB |
| 30 | Temperature difference between system flow and return too high | Check water circulation Check for air in the system |
| Display | Item being diagnosed |
|---|---|
| SO | Software version |
| DO | Frost protection |
| D1 | Mode |
| D2 | Collector temperature |
| D3 | Upper cylinder temperature |
| D4 | Not allocated |
| D5 | Lower cylinder temperature |
| D6 | Not allocated |
| D7 | Drain back unit pump speed |
| D8 | Cylinder pump speed |
| D9 | Not allocated |
| E0- E9 |
| Error code | Fault | Fault description | Possible causes |
|---|---|---|---|
| E01 | Ignition failure | Flame not detected during ignition sequence | 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 |
| E02 | Overheat boiler lock out | Overheat thermostat or thermal fuse has operated | Pump or flow problem |
| Blocked heat exchanger | |||
| Air in heat exchanger | |||
| Overheat thermostat | |||
| Thermal fuse (if open circuit then replace primary heat exchanger) | |||
| E03 | High flue thermostat temperature | Rue thermostat intervention (flue temperature over 113°C) | Blocked or restricted primary flow Heat exchanger air flow blocked Flue restriction Flue sensor fault |
| E04 | Gas valve electrical connection fault | Gas wiring circuit fault detected | Gas valve lead connection fault Faulty gas valve Faulty PCB |
| E05 | Heating flow sensor fault | Incorrect flow sensor resistance value | Flow sensor wire connections Flow sensor faulty |
| E06 | DHW sensor fault (InTec C, X. GS only) | DHW sensor resistance value is incorrect | DHW sensor wiring connection DHW sensor faulty |
| E08 | Maximum number of resets | Maximum number of resets reached | |
| E10 | Primary system pressure low | Primary pressure switch has operated | Check expansion vessel pressure (1 bar) Leak in system |
| Expansion relief valve operated Primary pressure switch | |||
| E12 | Cylinder sensor fault (InTec S and FlowSmart only) | Incorrect cylinder sensor resistance | Cylinder sensor wiring connections Cylinder sensor faulty |
| E15 | Internal wiring error | Incorrect wiring configuration detected | Check internal wiring connections to PCB Combination boiler DHW sensor X4 System boiler link X14 |
| E16 | Fan fault | Fan wiring fault or fan faulty | Check fan wiring connections Fan fault PCB fault |
| E20 | Flame sensing fault | False flame detection Flame detected but gas valve is not open | Check flame sensing electrode and lead PCB fault |
| E24 | Control panel button fault | Control panel button stuck in the on position | Check for jammed control panel buttons Check for jammed PCB buttons |
| E25 | Overheat lock out | Rapid temperature rise of flue sensor | Air in heat exchanger |
| Blocked or restricted primary flow | |||
| Heat exchanger air flow blocked | |||
| Rue restriction | |||
| Rue sensor fault | |||
| Pump fault | |||
| Boiler or heating circuit valve closed | |||
| E27 | Insufficient primary flow | Rapid temperature rise of primary sensor | Blocked or restricted primary flow Air in heat exchanger Boiler or heating circuit valve closed Pump fault |
| Primary flow sensor fault | |||
| E29 | Flue sensor fault | Flue sensor resistance out of range | Check sensor wiring connection Rue sensor faulty |
| E31 | Loss of communication with external control (Alpha Climatic) | Loss of connection between the boiler and Alpha Climatic control unit | Remote control or receiver connection wiring Remote control or receiver |
| E37 | Low supply voltage | Insufficient supply voltage to operate boiler | Check mains power suppty |
| E38 | Loss of flame rectification | Flame detected but signal is lost. Ignition reattempts after fan purge | Check flame sensing electrode and lead Check for flue gas recirculation Check/adjust the gas valve settings Check/adjust the fan speed settings |
| E43 | Loss of flame rectification | Repeated loss of flame signal during operation (shown as E38 in the fault code history in the INFO menu) | Check gas supply/working pressure Check flame sensing electrode and lead Check for flue gas recirculation Check/adjust the gas settings Check/adjust the fan speed settings |
| E44 | Safety lock out | The boiler has attempted to fire repeatedly for the maximum time limit | Check external control (room thermostat) requests |
| Rapid on/off hot tap requests | |||
| E46 | External sensor intervention | No continuity of external sensor circuit | Check external sensor and cable are not damaged or wet |
| Check continuity of external sensor and circuit Check connection at XI9 on PCB and sensor connecting block | |||
| E47 | Reduced burner output | 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 | Air in heat exchanger Restricted primary flow Heat exchanger air flow blocked Rue restriction Rue sensor fault Pump fault |
| Fault code | Fault description | Possible solutions |
|---|---|---|
| FE90 | PCB compatability fault | Check PCB is connected correctly. Check for water ingress in connections. |
| FE94 | Display PCB fault. | Check electrical connections to display board. Check for water ingress in connections. |
| Check for damage to buttons or LCD screen. | ||
| FE95 | Flow sensor out of range or short circuit. | Check flow sensor connections and damaged wires. Check flow sensor resistance values |
| Flow sensor measures a temperature outside normal working range | ||
| FE96 | External sensor fault. | Check external sensor connections and wires. Check for water ingress in connections. |
| Check boiler parameter settings are correct. | ||
| FE97 | Boiler PCB configuration error. | Check all electrical connections |
| Check for correct parameter settings on PCB | ||
| FE99 | PCB communication error. | Check all electrical connections |
| Fault detected in the link between the main PCB and the display | Check for correct parameter settings on PCB |
| Fault code OE | Fault description | Possible solutions |
|---|---|---|
| 01 | Flame sensing fault. | Check flame sensing electrode connections. Check for a short circuit to the electrode or wire. |
| 02 | Flame circuit fault. | Check for correct gas supply (purged and valves open). Check ignition electrode position and spark. |
| Check flame sensing electrode gap and connections. | ||
| 03 | Main PCB fault. | Check all electrical connections. |
| Check for water ingress in connections. | ||
| 04 | Main PCB fault. | Check all electrical connections. |
| Check for water ingress in connections. | ||
| 05 | DHW sensor short circuit. | Check DHW sensor connections and wires. Check for water ingress in connections. |
| 06 | DHW sensor out of range. DHW sensor measures a temperature outside normal working range. | Check DHW sensor connections and damaged cables. Check DHW sensor resistance values. |
| 07 | Low powers supply voltage. | Check electrical socket connections. Check external power supply. |
| 08 | Insufficient system flow – (Pro Tec 50 model only). Insufficient system pressure – (Pro Tec 70, 90, 115 models). | Check the system for circulation and restrictions. Check system pressure and gauge. |
| Check boiler flow meter and connections (Pro Tec 50). | ||
| 09 | Flue sensor short circuit. | Check flue sensor connections and wires. Check for water ingress in connections. |
| 10 | Flue sensor out of range. | Check flue sensor connections and wires. Check flue sensor resistance values. |
| Flue sensor measures a temperature outside normal working range. | ||
| 12 | Flow and return sensor anomily detected. | Check for poor or incorrect circulation. |
| The sensor shows an incorrect temperature value. | Check for external circuit influences. | |
| Check resistances of flow and return sensors. |
| Fault code OA | Fault description | Possible solutions |
|---|---|---|
| OA1 | Ignition failure. | Check for correct gas supply (purged and valves open). Check ignition electrode position and spark. |
| Check flame sensing electrode connections. | ||
| Check gas valve operation. | ||
| OA2 | Overheat thermostat or thermal fuse has operated. | Check flame sensing electrode connections. |
| Check for a short circuit to the electrode or wires. | ||
| Reset overheat thermostat if required. | ||
| OA3 | Overheat thermostat lock-out. | Check for water circulation. |
| Check for air in the heat exchanger. | ||
| Check for system restrictions and blockages. | ||
| Check overheat thermostat and connections. | ||
| Reset overheat thermostat if required | ||
| OA5 | Fan speed fault. | Check flue and ventilation. |
| Check air inlet manifold and pipe. | ||
| Check for fan damage/fault. | ||
| Check fan wire connections. | ||
| OA7 | High flue temperature fault. | Check for air in the primary heat exchanger. |
| Check for system restrictions causing overheating. | ||
| Check the flue run for restrictions or blockages. | ||
| OA9 | Gas valve electrical error. | Check gas valve connections. Check main PCB. |
| Check gas valve operation. Check for gas contamination. | ||
| OA13 | Maximum number of resets reached. More than five reset attempts have been reached within 15 minutes. | Investigate initial fault code displayed. |
| Switch the power supply Off/On to clear this code. | ||
| OA15 | Flow and return sensor anomily detected. The sensor shows an incorrect temperature value. | Check for poor or incorrect circulation. |
| Check for external circuit influences. | ||
| Check resistances of flow and return sensors. | ||
| OA16 | Flow sensor temperature rise incorrect. The time taken for the flow temperature to rise is too great. | Check system circulation. |
| System volume or flow is too high. | ||
| The boiler output is insufficient for the system. | ||
| OA17 | Return sensor temperature rise incorrect. The time taken for the return temperature to rise is too great. | Check system circulation. |
| System volume or flow is too high. | ||
| The boiler output is insufficient for the system. | ||
| OA18 | Flow and return sensor anomily detected. Sudden temperature change detected on the flow or return sensor. | Check system circulation. |
| Check operation of zone valves. | ||
| Check resistances and function of flow and return sensors. | ||
| OA30 | Flow sensor short circuit. | Check flow sensor connections and wires. |
| Check for water ingress in connections. | ||
| OA31 | Flow sensor out of range. Sensor measures a temperature outside normal working range. | Check flow sensor connections and damaged wires. |
| Check sensor resistance values. | ||
| OA37 | Insufficient system flow | Check the system for circulation and restrictions. |
| Check the boiler flow meter connections. | ||
| OA43 | Return sensor short circuit. | Check return sensor connections and wires. |
| Check for water ingress in connections. | ||
| OA44 | Return sensor out of range. Sensor measures a temperature outside normal working range. | Check return sensor connections and damaged wires. |
| Check return sensor resistance values. | ||
| OA80 | Flow and return sensor connection fault. Fault may occur after several minutes of boiler operation. | Check the wires are connected to the correct sensors. |