Installation and Servicing
0051
Instructions
Eco
Wall Mounted, Fan Assisted, Room Sealed,
Gas Fired, High Efficiency Condensing Combination Boiler
For Technical help or for Service call ...
ALPHA HELPLINE Tel: 0844 871 8764
website: www.alpha-innovation.co.uk
Nepicar House, London Road,
Wrotham Heath, Sevenoaks,
Kent TN15 7RS
Alpha Eco G.C. No. 47 532 59
For use with Natural Gas only
Leave these instructions with the User
BENCHMARK SCHEME
To comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be installed in accordance with the
manufacturer’s instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Checklist at the back of these instructions
Code of Practice
For the installation, commissioning and servicing of domestic heating and hot water products.
Benchmark places responsibilities on both manufacturers and installers*. The purpose is to ensure that customers** are
provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with
the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building
Regulations. Installers are required to carry out work in accordance with the following:
Standards of Work
• Be competent and qualified to undertake the work required.
• Install, commission, service and use products in accordance with the manufacturer's instructions provided.
• Ensure that where there is responsibility for design work, the installation is correctly sized and fit for purpose.
• Meet the requirements of the appropriate Building Regulations. Where this involves notifiable work be a member of a
Competent Persons Scheme or confirm that the customer has notified Local Authority Control (LABC), prior to work
commencing.
• Complete all relevant sections of the Benchmark Checklist/Service Record when carrying out commissioning or
servicing of a product or system.
• Ensure that the product or system is left in a safe condition and, where possible, in good working order.
• Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing work.
• Refer to the manufacturer's helpline where assistance is needed.
• Report product faults and concerns to the manufacturer in a timely manner.
Customer Service
• Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request.
• Give a full and clear explanation/demonstration of the product or system and its operation to the customer.
• Hand over the manufacturer's instructions, including the Benchmark Checklist, to the customer on completion of an installation.
• Obtain the customer's signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of
manufacturer's instructions.
• Advise the customer that regular product servicing is needed, in line with manufacturers' recommendations, to ensure
that safety and efficiency is maintained.
• Respond promptly to calls from a customer following completion of their work, providing advice and assistance by
phone and, if necessary, visiting the customer.
• Rectify any installation problems at no cost to the customer during the installer's guarantee period.
* The use of the word "installer" is not limited to installation itself and covers those carrying out installation, commissioning and/or servicing of heating and hot water
products, or the use of supporting products (such as water treatment or test equipment).
** Customer includes householders, landlords and tenants.
Benchmark Commissioning and Servicing Section
It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and
the data fields on the commissioning checklist completed in full.
To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one
month of the installation.
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.
www.centralheating.co.uk
Useful contact details: Gas Safe Register - 0800 408 5577 - www.gassaferegister.co.uk
Alpha Heating Innovation: General Sales Enquiries - 0844 871 8760
Technical Helpline - 0844 871 8764
Eco - Benchmark Scheme
2
CONTENTS
1 Introduction ........................................3
2 Technical data ...................................4
3 General boiler information ................. 8
4 Installation .........................................20
5 Commissioning ..................................24
6 Routine servicing ...............................27
7 Component replacement ................... 27
8 Wiring diagrams ................................33
9 Error codes and fault finding..............35
10 Short parts list ...................................37
Benchmark Checklist .........................38
Service Record .................................. 39
1 INTRODUCTION
The Eco high efficiency condensing boiler is a wall mounted, fan assisted room-sealed combination boiler. The burner is lit
electronically and the heat output is controlled by a modulating fan and gas valve.
The Eco is a combination boiler providing both central heating and domestic hot water at mains pressure.
The boiler is supplied with a pump, pressure relief valve, expansion vessel and pressure gauge fully assembled and tested. It
is designed for use with a fully pumped, sealed and pressurised central heating system.
IMPORTANT
Failure to install and commission this appliance in compliance with the manufacturer's instructions may invalidate the warranty.
It is the law that all gas appliances are installed by a competent person, i.e. Gas Safe registered personnel, in accordance
with the following recommendations:Current Gas Safety (Installation and Use) Regulations
All current Building Regulations issued by the Department of the Environment, i.e. Approved Document L1.
Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department
UK Water Regulations/Byelaws (Scotland)
Health & Safety Document No. 635 (The Electricity At Work Regulations 1989)
The installation should also be in accordance with the following British Standard Codes of Practice:-
BS 5440:1 Flues
BS 5546: Installation of hot water supplies for domestic purposes
BS 6700: Design, installation, testing and maintenance of services supplying water
BS 6798: Installation of gas fired hot water boilers
BS 6891: Gas installation
BS 7593: Code of Practice for treatment of water in heating systems
BS 7671: Requirements for electrical installations, IEE Wiring Regulations
BS EN 12828 Heating systems in Buildings. Design for water based heating systems
BS EN 12831 Heating systems in Buildings. Method of calculation for design heat load
BS EN 14336 Heating systems in Buildings. Installation and commissioning of water based heating systems
Reference should be made to DEFRA document 'Guide to condensing boiler installation assessment procedures for dwellings'.
If installation is in a timber framed building, refer to the Institute of Gas Engineers document IGE/UP/7.
This appliance meets the requirements of IPX4D, i.e. degree of protection against moisture.
This appliance contains no asbestos and no substances have been used in the construction process that contravene the
COSHH Regulations (Control of Substances Hazardous to Health).
Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety to ensure that
the law is complied with.
Manufacturer's instructions must NOT be taken in anyway as over-riding statutory obligations.
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 boiler installations are registered by the installer through the Gas Safe Gas Work Notification Scheme.
3. The boiler must only be used with Alpha CD condensing flue components.
Eco - Contents/Introduction
3
2 TECHNICAL DATA
2.1 TECHNICAL PERFORMANCE DATA - NATURAL GAS (Cat I2H 2H - G20 20 mbar)
Eco
Heat input gross - DHW kW
Heat input gross - CH kW
Heat input net - DHW kW
Heat input net - CH kW
Heat output condensing (50/30°C) - CH kW
Heat output non condensing (80/60°C) CH kW
Heat output min. - CH kW
Heat output nominal - DHW kW
Heat output max. - DHW kW
Gas rate at max. output m³/h
Gas supply pressure mbar
Max. CH temperature °C
Gas burner injector diameter mm
Differential burner pressure - min. mbar
Differential burner pressure - CH mbar
Differential burner pressure - DHW mbar
DHW flow rate at 35°C rise l/min
DHW flow rate at 30°C rise - EN625 l/min
DHW flow regulator l/min
Dry NOx weight mg/kWh
Dry NOx ppm
NOx Class
Factory set CO
at maximum CH output %
CO
2
at maximum DHW output %
CO
2
at minimum output %
CO
2
(± 0.25%)
2
CO weight (nominal) mg/kWh
CO (max) ppm
Maximum CO/CO
Ratio
2
SAP/SEDBUK seasonality efficiency 2005 %
SAP/SEDBUK seasonality efficiency 2009 %
EN13203/2 DHW efficiency %
31.4
26.8
28.3
24.2
25.7
23.7
5.5
27.7
28.1
3.0
20
82
7.0
0.19
2.31
3.00
11.6
13.6
12
39
22
5
9.45
9.55
8.9
14
200
0.003
90.3
88.8
77.2
Max. primary system pressure bar
Min. primary system pressure bar
Recommended system pressure - Cold bar
System pressure relief valve setting bar
Expansion vessel size litres
Expansion vessel charge pressure bar
Electrical power consumption - Max. Watts
Electrical power consumption - Standby Watts
Eco - Technical Data
4
2.5
0.5
1.0
3.0
8.0
1.0
115
6
2.2 PHYSICAL DATA
Boiler flow and return connections mm
Relief valve connection mm
DHW inlet (cold) DHW outlet (hot) connections mm
Gas connection diameter mm
Boiler dimensions Height mm
Width mm
Depth mm
Clearances for servicing Bottom mm
Bottom (with jig) mm
Top (horizontal flue) mm
Top (vertical flue) mm
Sides mm
Front mm
Recommended hole size for flue pipe mm
Boiler dry lift weight kg
Boiler operating weight (full of water) approx. kg
Max. total flue length Horizontal m
Max. total flue length Vertical m
Flue system diameter mm
Eco
22
15
15
22
720
440
300
150
250
235
150
5
450
110
38
40
12
14
60/100
2.3 FLUE LENGTHS
A standard 750 mm horizontal flue terminal kit is supplied with the boiler.
CD 750 mm and 1000 mm flue extensions are available.
Length of Flue Required:-
Rear Flue = wall thickness + 180 mm (includes terminal).
Side Flue = wall thickness + distance between wall and side of boiler + 265 mm (includes terminal)
Vertical Flue = distance from top of boiler side panel to required roof position minus 1000 mm for vertical terminal assembly
Maximum horizontal flue length = 12 m.
Maximum vertical flue length including terminal is 14 m.
Each additional CD 90° Bend is equivalent to 1.3 m of flue length.
Each CD 45° Bend is equivalent to 0.9 m of flue length.
The CD Vertical Flue terminal assembly is equivalent to 1 m of flue length.
Eco - Technical Data
5
230 V ~ 50 Hz CONNECTIONS LOW VOLTAGE CONNECTIONS ONLY
(optional Climatic or RF Climatic control)
External
probe
(optional)
Alpha
Climatic control
(optional)
DHW inlet
NTC sensor
(optional)
RF Climatic
control receiver
(optional)
RF Climatic
control (optional)
Low voltage terminal block
8 9 10
11 12
13
+
_
Room
thermostat
(optional)
Supply
230 V ~ 50 Hz
L N
1 2
Blue
G/Y
Brown
Link
Red
Mains terminal block
230 V ~ Control connections
WARNING
Ensure Control wires are
connected correctly - refer to the
control and boiler instructions for
connection details.
1 2 3
4
5
Blue
Brown
Red
Red
Not Used
Optional Alpha controls
Remove the link between 1 and 2 if the
optional Alpha Climatic control or 230 V
room thermostat is used.
2.4 AVAILABLE PUMP HEAD FOR CENTRAL HEATING
5.0
4.5
4.0
3.5
3.0
2.5
2.0
Head (metres)
1.5
1.0
0.5
0
200 600 1000 1400800 1200 16004000
Flow (litres/hr)
2.5 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.
6
Eco - Technical Data
Fig. 1
2.6 BOILER SCHEMATIC
14
21
30
31
22
9
12
34
23
11
1
-
+
7
20
8
33
32
13
-
+
10
5
15
4
16
17
6
19
3
35
29
36
37
2
24
25
Gas
Condensate
discharge
1 - Heat exchanger thermal fuse
2 - DHW flow switch, filter and flow regulator
3 - Diverter valve
4 - Gas valve
5 - Primary temperature sensor
6 - DHW heat exchanger
7 - Main burner
8 - Primary/condensing heat exchanger
9 - Manual air vent
10 - Fan
11 - Pressure differential test points
12 - Flue hood
13 - Overheat thermostat
Domestic
hot water
outlet
Cold mains
water inlet
14 - Expansion vessel
15 - Automatic air vent
16 - Pump
17 - Drain point
18 - Pressure relief valve
19 - Primary pressure switch
20 - Ignition electrodes
21 - Flame sensing electrode
22 - DHW temperature sensor
23 - Flue sampling point
24 - Gas service cock
25 - Mains inlet on/off valve
26 - On/off valve (2 off)
Primary
Heating
return
27
18
26
Primary
Heating flow
27 - Automatic by-pass
28 - N/A
29 - Condensate trap
30 - Injector
31 - Venturi
32 - Venturi positive point
33 - Venturi negative point
34 - Flue temperature sensor
35 - Diverter valve motor
36 - Filling loop (if applicable)
37 - Flow regulator (if fitted)
Fig. 2
Eco - Technical Data
7
3 GENERAL BOILER INFORMATION
3.1 GAS SUPPLY
The meter and supply pipes must be capable of delivering the required quantity of gas in addition to the demand from any
other appliances in the house.
Refer to Technical performance data in Section 2.1 and 2.2.
The complete installation, including the meter, must be tested for gas tightness and purged as described in BS 6891.
3.2 ELECTRICAL SUPPLY
The boiler requires a 230/240 V ~ 50 Hz mains supply, fused at 3 A
The boiler must be earthed.
There must only be one common isolator, providing complete electrical isolation, for the boiler and any external controls.
This boiler has been fitted with a supply cable, however, if it is necessary to fit a cable use PVC insulated cable not less than
0.75 mm² (24 x 0.2 mm) to BS 6500 Table 16. The boiler should be connected to a fused three pin plug and unswitched shuttered
socket outlet (both complying with BS 1363), or a fused double pole switch with a contact separation of at least 3 mm in both poles.
Wiring external to the boiler must be in accordance with the current IEE Wiring Regulations (BS 7671).
Note: If a room thermostat is fitted, it must be suitable for 230/240 V switching.
3.3 AIR SUPPLY
The boiler does not require any air vents for cooling in the room in which it is installed or when installed in a cupboard or
compartment. The minimum clearances for servicing must always be maintained.
Note: A cupboard or compartment used to enclose the boiler must be designed and constructed specifically for the purpose,
i.e. comply with the Building Regulations.
3.4 FLUE SYSTEM - Fig. 3
The flue system must be installed in accordance with BS 5440:1.
When using the horizontal flue kit supplied ensure that the flue outer duct is installed horizontally (please note that the flue
inner duct already has a pre-determined slope towards the boiler for condensate to run back towards the boiler).
When additional flue extensions are used, ensure the flue slopes downwards towards the boiler by a minimum of 25 - 30 mm
per metre of flue.
It is recommended that horizontal and vertical flue assemblies should be supported approximately every 1.5 m with access
provided to the joints.
Flue components are available as follows:-
CD 750 mm flue extension - Part No. 6.2000750.
CD 1000 mm flue extension - Part No. 6.2001050.
CD 100 mm flue support brackets (pack of 5) - Part No. 6.1000355.
CD 90° bend - Part No. 6.2000590.
CD 45° bend - Part No. 6.2000545.
CD Vertical flue terminal assembly. Refer to the separate installation instructions supplied with the assembly.
The following methods determine the correct length of flue required.
For rear exit flue (including terminal) L = B + 180 mm
For side exit flue (including terminal) L = B + C + 265 mm (min. side clearance required is 5 mm)
For vertical flue L = H minus 1000 mm for vertical terminal assembly
Where L = Required flue length
B = Finished wall thickness
C = Distance from the inside wall to the side of the boiler
H = Distance from top of boiler side panel to roof position
Note: 1. If an extra 90° bend is used, this reduces the maximum flue length by 1.3 m. Each 45° bend used reduces the
maximum flue length by 0.9 m.
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.
Eco - General Boiler Information
8
HORIZONTAL FLUE OPTIONS - Lmax = 12 metres
Not less than
300 mm
H
Not less than
300 mm
(265 mm length includes terminal)
L = B + C + 265 mm
C
B
B
F
E
L = B + E + F + 265 mm + (90° bend = 1.3 metre)
L = B + C + E + 265 mm
C
B
E
C
B
VERTICAL FLUE OPTIONS
L = B + C + 265 mm + (2 x 45° bends = 1.8 metre)
Not less than
300 mm
Not less than
300 mm
H
Hmax = 15 m Hmax = 13.2 m
Fig. 3
Eco - General Boiler Information
9
3.5 FLUE TERMINAL LOCATION - Figs. 4 and 5
J
D
G
H I
Q
Boundary
O
P
N
A Directly below an opening, air brick, windows, etc.
B Below gutters, soil pipes or drain pipes
C Below eaves
D Below balconies
E From a vertical drain pipe or soil pipe
F From an internal or external corner
G Above ground, roof or balcony level
H From a surface or boundary facing the terminal
I From a terminal facing the terminal
J Above an opening, air brick, window etc.
K Vertically from a terminal on the same wall
L Horizontally from a terminal on the same wall
M Horizontally from an opening, air brick, window etc.
N Minimum protrusion through a roof
O From a vertical obstruction
P From an openable window
Q From an adjacent vertical terminal
Min. distance (mm)Terminal position
(See Note 1)
300
75 (See Note 3)
200 (See Note 3)
200 (See Note 3)
150 (See Note 3)
300 (See Note 2)
300
600
(See Note 4)
1200 mm
300
(See Note 1)
1500 mm
300 mm
300 mm
(See Note 1)
300 mm
300 mm
600 mm
600 mm
Fig. 4
Notes:
1. In addition, the terminal should not be nearer than 150 mm to the framework of an opening into the building, i.e. a
window surround or door surround.
2. This clearance may be reduced to 25 mm without effecting the performance of the boiler. However, to ensure the
condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferable.
3. These clearances may be reduced to 25 mm without effecting the performance of the boiler. However, to ensure the
condensate plume does not affect adjacent surfaces the terminal can be extended beyond gutters, pipes, eaves,
balconies etc. by upto 500 mm. If the flue is extended more than 500 mm outside, it should be boxed and insulated.
4. To reduce the possibility of nuisance to neighbouring buildings etc. it is recommended the terminal should not be less
than 2500 mm from car parking spaces, building boundary walls, fences etc.
5. A terminal must not be sited under a car port roof.
6. In certain weather conditions the terminal will emit a plume of steam. If possible avoid positioning the terminal where
this may cause a nuisance, i.e. positions A, D, G, H, J or M.
7. The flue terminal must be exposed to the external air and the position must allow the free passage of air across it at all times.
8. A terminal must not be sited below 2 m where people have access to, such as public footpaths, access routes, patios
etc. However, If the terminal is fitted less than 2 m above a surface where there is no public access, the terminal must
be protected by a terminal guard. A suitable guard is available from Alpha Therm Ltd.
Eco - General Boiler Information
10
Proximity of flue duct outlets to boundaries
The flue duct shall be sited so that it is at least 600 mm (see Fig. 5) from the boundary line when facing it and at least 300 mm
from the boundary line when running parallel to it.
Boundary
Building
Terminal facing the boundary
Boundary
Building
Terminal at an angle to the boundary
Terminal
300 mm
600 mm
600 mm
Terminal
Fig. 5
Boundary
Building
Terminal parallel to the boundary
Adjacent building
Boundary
Building
Terminal facing an opening
in adjacent building
Terminal
300 mm
Terminal
Window
2000 mm
3.6 BOILER LOCATION
The boiler is not suitable for external installation unless it is installed within a purpose designed weatherproof building.
The boiler must be installed on a flat vertical wall which is capable of supporting the weight of the boiler. The boiler can be fitted
to or adjacent to a wall comprising of a combustible material without the need for a special thermal insulation barrier.
If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with the Institute of Gas Engineers
'Guide for Gas Installations in Timber Frame Housing', reference IGE/UP/7.
The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the
current IEE Wiring (BS 7671) Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in
Scotland, with respect to the installation of the boiler in a room or internal space containing a bath or shower. Where a roomsealed boiler is installed in a room containing a bath or shower, it must not be possible for a person using the bath or shower
to touch any electrical switch or boiler control utilising mains electricity.
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.
Eco - General Boiler Information
11
3.7 CENTRAL HEATING SYSTEM - Fig. 6
The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS EN 12828 and BS 6798.
The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump
head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. Refer to the pump performance
table for guidelines.
System volume - The expansion vessel incorporated into the boiler is suitable for a sealed heating system with a maximum
water content of 80 litres (18 gal). Above 80 litres, consideration should be given to fitting an additional expansion vessel
fitted in the position shown in Fig. 6. To check correct operation of the expansion vessel(s) the system pressure should not be
more than 2.5 bar when the system is at maximum operating temperature (for further guidance refer to BS 7074:1).
The boiler is supplied with the following components built in:-
Pressure relief valve - complying with BS 6759 and set to operate at 3 bar. The discharge pipe must be routed clear of the
boiler and terminated in such a manner that it can be seen, but cannot cause injury to persons or property.
Pressure gauge - To indicate the system pressure to be maintained.
Expansion vessel - Conforming to BS 4814 with a capacity of 8 litres and pre-charged to a pressure of 1.0 bar.
By-pass - The boiler incorporates an automatic by-pass, therefore an automatic by-pass is not required for the system.
Static head of system
Boiler
casing
Automatic
air vent
Additional expansion
vessel (if required)
Filling point
Heating flow
DHW outlet
Mains water inlet
Note: If the mains is fitted with water
meter, check valves or loose jumper stop
cock, then a DHW expansion device must
be fitted.
Note: A drain tap should be installed at the lowest point
Heating return
System
drain tap
of the heating circuit and beneath the appliance.
Fig. 6
3.8 FILLING THE CENTRAL HEATING SYSTEM - Fig. 7
The system design pressure (cold) should be set to 1.0 bar. This pressure is equivalent to a static head (see Fig. 6) of 10.2
metres of water.
Provision must be made for filling the system. This is done by the use of a filling loop. See Fig. 7. A filling loop is not supplied
with this boiler.
Filling of the system must be carried out in a manner approved by the local Water Undertaking. Where allowed, the system
may be filled via a temporary connection as shown in Fig. 7. After filling, always disconnect the flexible hose of the filling loop.
All fittings used in the system must be able to withstand pressures up to 3 bar.
Drain taps (to BS 2879) must be used to allow the system to be completely drained.
Eco - General Boiler Information
12
Heating circuit
return
Stop
valve
temporarily connected
Hose
unions
Filling loop
Fig. 7
Double check
valve assembly
Test cock
Stop
valve
Mains
water
supply
Loading...