Benchmark Alpha E-Tec Plus 28 Installation And Servicing Instruction

Wall mounted, fan assisted, room sealed, gas fired, high efficiency condensing combination boiler

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Installation and Servicing

E-Tec Plus 28, 33 and 38

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.

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

Alpha E-Tec Plus 38

Set for use with Natural Gas

Leave these instructions with the User

G.C. No. 47 532 77

G.C. No. 47 532 78

G.C. No. 47 532 79

Part No. 1.043044 rev. ST.004614/001

0220/D409

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Summary of Contents for Benchmark Alpha E-Tec Plus 28

Page 1 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 G.C. No. 47 532 77 Alpha E-Tec Plus 33 G.C. No. 47 532 78 Alpha E-Tec Plus 38 G.C.
Page 2 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.
Page 3: Table Of Contents
Failure to comply with the installation instructions implies personal responsibility and may invalidate the warranty. Notes: 1. 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.
Page 4: Safety Symbols And Information
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, 33 and 38 - Safety Symbols and Information...
Page 5 Boiler operating weight (full of water) approx. E-Tec Plus 28 35.8 E-Tec Plus 33 37.9 E-Tec Plus 38 40.5 Max. total flue length Horizontal Max. total flue length Vertical Flue system diameter 60/100 Alpha E-Tec Plus 28, 33 and 38 - Safety Symbols and Information...
Page 6: Technical Data
10.6 (+0.3/-0.1) 10.0 (+0.4/-0.2) 9.9 (+0.4/-0.2%) Gas rate at maximum output kg/h (g/s) 2.24 (0.62) 2.53 (0.70) 3.03 (0.84) Note: OtherTechnical data is the same as NG data. Alpha E-Tec Plus 28, 33 and 38 - Technical Data...
Page 7 (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, 33 and 38 - Technical Data...
Page 8 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. 3.2 Alpha E-Tec Plus 28, 33 and 38 - Technical Data...
Page 9 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. 3.3 Alpha E-Tec Plus 28, 33 and 38 - Technical Data...
Page 10 .....DHW minimum heat input nw min. Class ....NO Class .......CH minimum heat input n min. CONDENSING ..Condensing boiler ....DHW maximum heat input nw max.......CH maximum heat input n max. Alpha E-Tec Plus 28, 33 and 38 - Technical Data...
Page 11 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. 3.5 Alpha E-Tec Plus 28, 33 and 38 - Technical Data...
Page 12: General Boiler Information
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. Alpha E-Tec Plus 28, 33 and 38 - General Boiler Information...
Page 13 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, 33 and 38 - General Boiler Information...
Page 14 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, 33 and 38 - General Boiler Information...
Page 15 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, 33 and 38 - General Boiler Information...
Page 16 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, 33 and 38 - General Boiler Information...
Page 17 (minimum 32 mm) Ensure pipe is adequately supported Open end of pipe diverted into gully below grid but above water level Minimum gradient 2½° Fig. 4.7 - External gully Alpha E-Tec Plus 28, 33 and 38 - General Boiler Information...
Page 18 25mm centres, 50mm from the bottom Soakaway depth 400mm of the tube. Holes to face filled with limestone chippings away from house. Fig. 4.8 - External soakaway Alpha E-Tec Plus 28, 33 and 38 - General Boiler Information...
Page 19: Installation
130 mm dia. flue hole using a 127 mm core drill. Drill the fixing holes (10 mm dia.) to accept the No.10 plugs Outline of supplied. Using the screws supplied, fit the mounting bracket. boiler Template Fig. 5.2 Alpha E-Tec Plus 28, 33 and 38 - Installation...
Page 20 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, 33 and 38 - Installation...
Page 21 Alternatively plume management components can be used with supports where necessary. All joints between flue sections should be connected using the clamps provided. It is not required to add additional screws through the clamps and into the flue sections. Alpha E-Tec Plus 28, 33 and 38 - Installation...
Page 22 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, 33 and 38 - Installation...
Page 23 90° bend Easy-Flue 40 mm clamp Terminal Inner seal joint and seal CD Flue extension Seal joint Flue sealing collar Flue length (L) Front of boiler Fig. 5.11 - Side flue Alpha E-Tec Plus 28, 33 and 38 - Installation...
Page 24 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, 33 and 38 - Installation...
Page 25 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, 33 and 38 - Installation...
Page 26 Remove the links between terminal blocks 1 and 2. Replace the control panel cover in reverse order. Note: Ensure all wires and connections are secured safely before replacing covers. Fig. 5.16 Alpha E-Tec Plus 28, 33 and 38 - Installation...
Page 27 Note: The temperature of the radiators will vary depending on the outside temperature; the required room temperature will still be maintained by the room thermostat. 8 7 6 Max. System temperature (°C) Min. External temperature (°C) Fig. 5.18 Alpha E-Tec Plus 28, 33 and 38 - Installation...
Page 28: Commissioning
COMMISSIONING When commissioning the boiler, ensure the Benchmark Checklist at the back of these instructions is completed. FILL THE SYSTEM The boiler is fitted with an automatic air vent positioned on the pump (see Fig. 7.6), ensure that the vent is always open.
Page 29 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, 33 and 38 - Commissioning...
Page 30 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, 33 and 38 - Commissioning...
Page 31 CHECKING THE COMBUSTION - CHIMNEY SWEEP MODE As part of the Benchmark Checklist procedure the combustion levels of the boiler when the installation is completed must be measured and recorded. The air gas ratio of the boiler has been factory-set and should not require adjusting during commissioning. If adjustment is recommended or required the engineer must be competent to carry out this work.
Page 32 Show the User the position of the condensate discharge pipes. 10. Leave the instructions with the User. 11. Ensure the Benchmark Checklist at the back of these instructions has been completed after the boiler has been installed and commissioned. Note: It is a requirement that the installation is registered by the installer through the Gas Safe Gas Work Notification Scheme.
Page 33 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, 33 and 38 - Commissioning...
Page 34 ← 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, 33 and 38 - Commissioning...
Page 35 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, 33 and 38 - Commissioning...
Page 36 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, 33 and 38 - Commissioning...
Page 37: Routine Servicing
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, 33 and 38 - Routine Servicing...
Page 38 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, 33 and 38 - Routine Servicing...
Page 39 (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, 33 and 38 - Routine Servicing...
Page 40 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, 33 and 38 - Routine Servicing...
Page 41 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, 33 and 38 - Routine Servicing...
Page 42 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. Alpha E-Tec Plus 28, 33 and 38 - Routine Servicing...
Page 43: Component Replacement
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, 33 and 38 - Component Replacement...
Page 44 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, 33 and 38 - Component Replacement...
Page 45 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, 33 and 38 - Component Replacement...
Page 46 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, 33 and 38 - Component Replacement...
Page 47 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, 33 and 38 - Component Replacement...
Page 48: Wiring Diagram
P ..Purple R ..Red M20..Fan V ..Violet M30..3-way valve motor W ..White S4 ....DHW flow switch Y ..Yellow S5 ....System pressure switch T1 ....Transformer T2 ....Ignition transformer Y1 ....Gas valve Alpha E-Tec Plus 28, 33 and 38 - Wiring Diagram...
Page 49: Error Codes And Fault Finding
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, 33 and 38 - Error Codes and Fault Finding...
Page 50 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, 33 and 38 - Error Codes and Fault Finding...
Page 51 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, 33 and 38 - Error Codes and Fault Finding...
Page 52: Short Parts List
1.039776 Burner front insulation panel (71.5 dia.) - 38 and 33 1.039141 Burner front insulation panel (75 dia.) - 38 1.040668 Flue sensor 1.024296 Rear combustion insulation panel 1.040351 Alpha E-Tec Plus 28, 33 and 38 - Short Parts List...
Page 53: Energy Classification
(*) 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. Alpha E-Tec Plus 28, 33 and 38 - Energy Classification...
Page 54 Yearly fuel consumption for the domestic hot water function (AFC) 17 GJ 17 GJ 18 GJ Seasonal room heating yield (ηs) 93 % 93 % 93 % Domestic hot water production yield (ηwh) 87 % 87 % 85 % Alpha E-Tec Plus 28, 33 and 38 - Energy Classification...
Page 55 Alpha E-Tec Plus 28, 33 and 38 - Energy Classification...
Page 56 Alpha E-Tec Plus 28, 33 and 38 - Energy Classification...
Page 57 * 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, 33 and 38 - Energy Classification...
Page 58 E-Tec Plus 33 E-Tec Plus 38 ‘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, 33 and 38 - Energy Classification...
Page 59 Alpha E-Tec Plus 28, 33 and 38 - Page intentionally Blank...
Page 60: Benchmark Checklist
Where possible, has a ﬂue integrity check been undertaken in accordance with manufacturers’ instructions, and readings are correct? The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturers’ literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Commissioning Engineer’s signature Customer’s signature...
Page 61: Service Record
SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’...
Page 62 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’...
Page 63 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers speciﬁed spare parts.

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Alpha e-tec plus 33 Alpha e-tec plus 38 47 532 77 47 532 78 47 532 79

Benchmark Alpha E-Tec Plus 28 Installation And Servicing Instruction

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