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8.11 CONDENSATE TRAP - Figs. 7.7 and 8.2
Gain access as described in Section 8.1.
Note: Before removing the trap, ensure that the water from the trap can be contained to avoid spillage.
1.
Pull the flue drain hose off the top of the condensate trap and pull the rubber condensate hose adapter out of the
bottom of the boiler. The cable tie is used for production and can be discarded.
2.
Remove the trap fixing screw from the bottom of the boiler and turn the trap to the left to disconnect it from the
expansion valve outlet pipe.
3.
Lift out the trap being careful not to spill any condense water, remove the trap from the boiler.
4.
It is important to clean the trap every time the trap is removed to flush out any deposits from the collection bowl.
Note: Partially fill the trap before replacing.
8.12 DHW FLOW SWITCH - Fig. 8.2
1.
Gain access behind the front casing as described in Section 8.1.
2.
Isolate the mains water supply and open all hot taps to drain any water from the boiler.
3.
Disconnect the wires from the switch.
4.
Below the boiler undo the mains cold water inlet connection union nut and remove the fixing screw from the bottom of
the switch.
5.
Remove the two 4 mm cap head screws securing the top of the switch and lift upwards to remove.
6.
Fit the new switch and re-assemble in reverse order.
7.
Visually inspect for leakage after reconnecting the mains cold water supply.
Condensate trap
DHW temperature sensor
Gas valve
8.13 PRIMARY HEAT EXCHANGER - Fig. 7.6
Gain access and drain the boiler heating circuit as described in Sections 8.1 and 8.2.
1.
Remove the condensate trap assembly as described in Section 8.11.
2.
Remove the burner as described in Section 7.3.
3.
Unplug the connection from the flue temperature sensor and remove the sensor as described in Section 8.6.
4.
Disconnect the condensate drain pipe by pulling its rubber connector from the heat exchanger.
5.
Unscrew the flue sampling point cap and remove the complete fitting from the top of the case.
6.
Disconnect the flue sensor wires and remove the lower retaining screw on the bottom of the heat exchanger..
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.
Lift the heat exchanger upwards and forwards to disconnect it from the bottom bracket and withdraw it from the boiler.
9.
Refit the flue temperature sensor.
10. Reassemble in reverse order using the lubricant supplied with the heat exchanger kit.
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.
Fig. 8.2
Alpha E-Tec Plus 28, 33 and 38 - Component Replacement
DHW flow switch
Diverter valve motor
45
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