Alpha E-Tec Plus 28 Installation And Servicing Instructions
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Alpha E-Tec Plus 28 Installation And Servicing Instructions

Wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing combination boiler
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Installation and Servicing
E-Tec Plus 28 and 33
Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing Combination Boiler
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 2018.
Instructions
For Technical help or for Service call ...
ALPHA HELPLINE Tel: 0344 871 8764
website: www.alpha-innovation.co.uk
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Alpha E-Tec Plus 28
Alpha E-Tec Plus 33
Set for use with Natural Gas
Leave these instructions with the User
G.C. No. 47 532 77
G.C. No. 47 532 78
Part No. 1.042373 rev. ST.003780/000
0918/D387

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  • Page 1 Installation and Servicing Instructions E-Tec Plus 28 and 33 Wall Mounted, Fan Assisted, Room Sealed, Gas Fired, High Efficiency Condensing Combination Boiler For Technical help or for Service call ... ALPHA HELPLINE Tel: 0344 871 8764 website: www.alpha-innovation.co.uk Nepicar House, London Road,...
  • Page 2 Service Interval Record and left with the householder. www.centralheating.co.uk Useful contact details: Gas Safe Register - 0800 408 5577 - www.gassaferegister.co.uk Alpha Heating Innovation: General Sales Enquiries - 0344 871 8760 Technical Helpline - 0344 871 8764 Alpha E-Tec Plus 28 and 33 - Benchmark Scheme...
  • Page 3 Service Record ........59 INTRODUCTION The E-Tec Plus 28 and 33 are wall mounted, room sealed, fan assisted, high efficiency, condensing boilers. The burner is lit electronically and the heat output is controlled by a modulating fan and gas valve. The E-Tec Plus 28 and 33 are combination boilers providing both central heating and domestic hot water at mains pressure.
  • Page 4 The user must not dispose of the appliance at the end of its service life as municipal waste, but send it to appropriate collection centres. PERSONAL PROTECTIVE EQUIPMENT SAFETY GLOVES SAFETY GOGGLES SAFETY FOOTWEAR Alpha E-Tec Plus 28 and 33 - Safety Symbols...
  • Page 5 11.4 (+0.1/-0.3) 11.2 (+0.2/-0.4) at minimum output 10.6 (+0.3/-0.1) 10.0 (+0.4/-0.2) Gas rate at maximum output kg/h (g/s) 2.24 (0.62) 2.53 (0.70) Note: OtherTechnical data is the same as NG data. Alpha E-Tec Plus 28 and 33 - Technical Data...
  • Page 6 (by-pass closed). Adjust using a flat head screwdriver, turn anticlockwise to close the by-pass, and clockwise to open. With the by-pass in the closed position the system must have a continuous open circuit. If zone valves are used in the system an external by-pass must be fitted. Alpha E-Tec Plus 28 and 33 - Technical Data...
  • Page 7 3.5.1 E-Tec Plus 28 Available Pump Head and Power Consumption 1000 1200 1400 1600 Flow rate (l/h) A+B = Head available with by-pass closed B = Head available with by-pass open C+D = Power consumed by the pump with by-pass open (dotted area) D = Power consumed by the pump with by-pass closed (dotted area) Fig.
  • Page 8 ELECTRICAL CONNECTIONS Note: This Appliance Must Be Earthed Optional integral single channel controls are available if required. Note: Only use the Alpha single channel controls. Do not fit any two channel controls. Programmer clock (optional) J2 on PCB Colour Code...
  • Page 9 Safety valve indicator Condensate trap Burner Filling loop 3 bar safety valve Primary return sensor Heating return isolation valve Expansion vessel with integrated filling valve Heating flow isolation valve Fig. 3.4 Alpha E-Tec Plus 28 and 33 - Technical Data...
  • Page 10 2. Under no circumstances must the flue length (including allowances for extra bends) exceed 12 metres horizontally and only 14 metres vertically. 3. Failure to use Alpha flue components with the boiler will invalidate the boilers CE approval, guarantee and may be unsafe.
  • Page 11 Fig. 4.1 VERTICAL FLUE OPTIONS Not less than 300 mm Not less than 300 mm Hmax = 14 m Hmax = 12.2 m (14 m - 1.8 m) Fig. 4.2 Alpha E-Tec Plus 28 and 33 - General Boiler Information...
  • Page 12 Where a terminal is sited below 2 m from the ground or floor level, the terminal must be protected by a terminal guard. In these situations, consideration should also be given to prevent nuisance plume and fumes in areas such as access routes, passageways, patios, balconies etc. Alpha E-Tec Plus 28 and 33 - General Boiler Information...
  • Page 13 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. Alpha E-Tec Plus 28 and 33 - General Boiler Information...
  • Page 14 Drain valves (to BS 2879) must be fitted in the heating system to allow the system to be fully drained. Filling control valves Sliding temporary connection Fig. 4.6 Alpha E-Tec Plus 28 and 33 - General Boiler Information...
  • Page 15 4.10 DISPOSAL OF CONDENSATE Provision must be made for the safe disposal of condensate produced by the flue gases of the Alpha boilers and reference should be made to BS 6798 for the requirements on the disposal of condensate.
  • Page 16 Before the mains water supply pipe is connected to the boiler, it should be thoroughly flushed out to avoid the danger of dirt or foreign matter entering the boiler. Alpha E-Tec Plus 28 and 33 - General Boiler Information...
  • Page 17 Condensate discharge pipe Literature pack and Wall template A suitable Alpha flue system must be selected to use with the boiler. Notes: a. All flues must be suitable for Alpha condensing boilers. b. CD 750 mm and 1000 mm flue extensions are available, if required.
  • Page 18 B - DHW outlet elbow - (15 mm) C - Cold water mains inlet - (15 mm) D - Heating return - (22 mm) E - Heating flow - (22 mm) Fig. 5.4 Alpha E-Tec Plus 28 and 33 - Installation...
  • Page 19 FIT THE FLUE - Figs. 5.5 and 5.6 The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only. The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below.
  • Page 20 Note: Ensure that all cuts are square and free from burrs. Once assembled with the components pushed home, the flue is fully sealed. Allow 20 mm 30 mm Do not cut past this point Fig. 5.10 Alpha E-Tec Plus 28 and 33 - Installation...
  • Page 21 Use the template (supplied with the boiler) to mark the required flue position, ensure the slope towards the boiler is correct. Determine the overall flue length as described in Section 4.6, paragraph 2 to determine the number of Alpha CD 750 or 1000 mm flue extensions required.
  • Page 22 Plume Management 1000 mm extension 60 mm dia. (equivalent to 1 m flue length) - Part No. 6.2001310. 60 mm dia. wall bracket - Part No. 6.2001260. Plume kit (2 x 93° bends 1 x 1000 mm extension and wall bracket) - Part No. 6.2001300. Fig. 5.12 Alpha E-Tec Plus 28 and 33 - Installation...
  • Page 23 Note: The equivalent horizontal flue assembly length + the equivalent plume management length (PM length) must not exceed the maximum flue length stated for each boiler, i.e. E-Tec boilers - the maximum equivalent flue length must not exceed 12 metres. Alpha E-Tec Plus 28 and 33 - Installation...
  • Page 24 5.11 FITTING BOILER CONTROLS It is recommended that Alpha controls are used with the boiler to maintain efficient and correct operation of the boiler. Please note that using controls that are not supplied or recommended by Alpha may invalidate the boiler warranty and may not control the boiler correctly.
  • Page 25 Note: Before purchasing / installing Open Therm type controls from an alternative manufacturer, it is the installers responsibility to ensure they are compatible with the Alpha boiler. Remove the control panel as described in Section 5.10, if it has not already been removed.
  • Page 26 Loosen the gas inlet pressure test point screw on the gas valve (see Fig. 6.2) and purge in accordance with BS 6891. Retighten the test point screw and test for gas tightness. Close the boiler gas service cock. Alpha E-Tec Plus 28 and 33 - Commissioning...
  • Page 27 The lighting mode can be varied via parameter 't8' in the PCB programming menu. For any controls fitted please refer to the instructions supplied with the controls for connection and operation details and Section 5.11. Alpha E-Tec Plus 28 and 33 - Commissioning...
  • Page 28 Pump Cycle If the electrical supply is on and the boiler has not operated for 24 hours in heating or hot water, the pump will operate automatically for thirty seconds every 24 hours. Alpha E-Tec Plus 28 and 33 - Commissioning...
  • Page 29 Tell the User that if the electrical supply is on and the boiler has not operated for 24 hours for heating or hot water, the pump will automatically operate for 30 seconds. Alpha E-Tec Plus 28 and 33 - Commissioning...
  • Page 30 Reset to return to the Info number. Info Menu Information Units (d - prefix) Shown FlowSmart cylinder temperature adjustment (optional) with Alpha Diverter kit only °C Flame signal µA Central heating water temperature leaving the boiler °C Domestic hot water temperature leaving the boiler °C...
  • Page 31 F (+) A (-) Outlet pressure test point Gas outlet flow Inlet pressure adjustment screw test point (Max. CO ) Off/Set adjustment screw (Min. CO ) Wiring plug Fig. 6.2 Fig. 6.3 Alpha E-Tec Plus 28 and 33 - Commissioning...
  • Page 32 P0 - P5 ← RESET ← RESET ← RESET RESET + INFO Parameter (Without t0 - t9 → → value memorising) > 5 secs A0 - A6 S0 - S2 > 1 sec (Memorise) Alpha E-Tec Plus 28 and 33 - Commissioning...
  • Page 33 Section of the remote control communication protocol 0 - 1 0 - Alpha Climatic communication 1 - OpenTherm type remote control - Boiler terminal block link 1 protocol setting to 2 must be present Alpha E-Tec Plus 28 and 33 - Commissioning...
  • Page 34 0 Fixed - The switch-off temperature is fixed at the maximum value regardless of the value set on the control panel 1 Corrolated - The boiler switches off according to the temperature Alpha E-Tec Plus 28 and 33 - Commissioning...
  • Page 35 Section 7.1 and Section 7.3 paragraphs 1, 2 and 3 need to be carried out to allow a visual check of the components within the room sealed chamber. Note: For any maintenance operation not shown, contact Alpha Innovation Helpline. Alpha E-Tec Plus 28 and 33 - Routine Servicing...
  • Page 36 Take care not to damage the insulation on the back of the panel as this forms part of the casing room seal. Fig. 7.2 Alpha E-Tec Plus 28 and 33 - Routine Servicing...
  • Page 37 (view 'A' in Fig. 7.4) Lower the panel out and away from the top cover. Note: The side panels require no sealing strip as the front case insulation forms the room seal. View A Fig. 7.4 Alpha E-Tec Plus 28 and 33 - Routine Servicing...
  • Page 38 Check the condition of the burner injector in the gas valve outlet, carefully clean with a soft brush if necessary - Do not use a brush with metallic bristles as this might damage the injector. Unscrew and replace the injector should it appear damaged. Alpha E-Tec Plus 28 and 33 - Routine Servicing...
  • Page 39 Automatic air vent Gas injector Boiler pump Gas valve 3 bar safety valve DHW heat exchanger By-pass Boiler drain point Diverter valve DHW temperature sensor Safety valve operation indicator Fig. 7.6 Alpha E-Tec Plus 28 and 33 - Routine Servicing...
  • Page 40 To ensure correct and safe operation of the appliance, it is essential that any worn or failed components are replaced with only genuine Alpha spare parts. Use of non-genuine Alpha spares could invalidate your warranty and may pose a potential safety hazard.
  • Page 41 Remove the gas valve pressure tube from the fan inlet Withdraw the fan assembly forwards. Re-assemble in reverse order. Test the boiler, check the ignition and test the combustion as described in Section 7. Alpha E-Tec Plus 28 and 33 - Component Replacement...
  • Page 42 Unplug the wiring and unclip the sensor from the DHW outlet pipe as required. Re-assemble in reverse order with a new sensor ensuring a good contact between the pipe and sensor. Alpha E-Tec Plus 28 and 33 - Component Replacement...
  • Page 43 Note: Lubricating the seals with soap and water will aid assembly. 11. Refill boiler, pressurise the system and visually inspect for leaks. 12. Test the boiler, check the ignition and test the combustion as described in Section 7. Alpha E-Tec Plus 28 and 33 - Component Replacement...
  • Page 44 Disconnect the clear plastic tube from the pressure relief valve. Remove the retaining clip securing the expansion relief valve and pull the valve forwards to remove. Re-assemble in reverse order. Refill and pressurise the system. (Refer to Commissioning, Section 6.1). Alpha E-Tec Plus 28 and 33 - Component Replacement...
  • Page 45 Test the boiler, check the ignition and test the combustion as described in Section 7. 8.25 ALPHA CONTROLS (if fitted) Refer to section 5.11 on the connection options for boiler controls. Alpha E-Tec Plus 28 and 33 - Component Replacement...
  • Page 46 -Vcc (optional) connect 220 V Climatic Control room thermostat (optional) When an Alpha Climatic control is connected to terminals 41 and 44 +Vcc remove the links between terminal blocks 1 and 2 Colour Code Component identification B1 ....Flow sensor Bk ..Black Bl ..Blue...
  • Page 47 Control panel button stuck in the on position Check for jammed control panel buttons fault Check for jammed PCB buttons * When external zone valves are fitted an external by-pass must also be installed. Alpha E-Tec Plus 28 and 33 - Error Codes and Fault Finding...
  • Page 48 Possible failure of one or both sensors Check sensor wiring and connections fault Check sensor resistance Return/flow sensor Possible failure of one or both sensors Check sensor wiring and connections fault Check sensor resistance Alpha E-Tec Plus 28 and 33 - Error Codes and Fault Finding...
  • Page 49 Fuse on main PCB blown Incorrect power supply. Seized or sticking pump - Check pump for free rotation Boiler component drawing excessive current. Check individual components in turn Alpha E-Tec Plus 28 and 33 - Error Codes and Fault Finding...
  • Page 50 1.020393 Boiler wall bracket 2.015350 Boiler connection kit 3.024893 Boiler accessory box complete 3.026880 Wall template 1.039776 Burner front insulation panel 1.039141 Flue sensor 1.024296 Rear combustion insulation panel 1.040351 Alpha E-Tec Plus 28 and 33 - Short Parts List...
  • Page 51 Contact details Alpha Therm Ltd., Nepicar House, Wrotham Heath, Kent. TN15 7RS (*) High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet. (**) Low temperature means for condensing boilers 30°C, for low-temperature boilers 37°C and for other heaters 50°C return temperature.
  • Page 52 (AFC) Seasonal room heating yield (ηs) 93 % Seasonal room heating yield (ηs) 93 % Domestic hot water production yield (ηwh) 87 % Domestic hot water production yield (ηwh) 87 % Alpha E-Tec Plus 28 and 33 - Energy Classification...
  • Page 53 Alpha E-Tec Plus 28 and 33 - Energy Classification...
  • Page 54 Alpha E-Tec Plus 28 and 33 - Energy Classification...
  • Page 55 * To be established by means of table 5 of Regulation 811/2013 in case of “assembly” including a heat pump to integrate the boiler. In this case the boiler must be considered as the main appliance of the assembly. Alpha E-Tec Plus 28 and 33 - Energy Classification...
  • Page 56 Parameter E-Tec Plus 28 E-Tec Plus 33 ‘I’ ‘II’ ‘III’ * To be determined according to Regulation 811/2014 and transient calculation methods as per Notice of the European Community no. 207/2013. Alpha E-Tec Plus 28 and 33 - Energy Classification...
  • Page 57 Alpha E-Tec Plus 28 and 33 - Page intentionally Blank...
  • Page 58 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty.
  • Page 59 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s specifed spare part when replacing controls.

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