Summary of Contents for Pellergy A-60
- Page 1 SAVE THESE INSTRUCTIONS Installation Manual Alpha Series Wood pellet-fired central heating boiler FOR USE IN CANADA / USA UL 391-2010 CAN / CSA-B366.1-11 V1.0 27AUG2014...
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Page 2: Table Of Contents
Table of contents Table of contents 1. Important information for the installer ................4 1.1 Safety precautions .......................... 4 1.1.1 Important information before you begin ......................4 1.1.2 Caution symbols ............................. 4 1.1.3 Liability exclusion ............................5 1.1.4 Safety instructions ............................5 1.2 Flue ............................ - Page 3 Table of contents 2.14 Initial start-up and operating instructions .................. 34 3. For the Electrician ....................... 35 3.1 Electrical connections......................35 3.1.1 Electrical connection for power supply 110-120 V AC, control and changeover unit ..........36 3.1.2 Feed unit connections ........................... 38 3.2 Wiring ............................
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Page 4: Safety Precautions
Important information for the Technician Important information for the Technician Safety precautions The boiler/heater and related accessories are state of the art and meet all applicable safety regulations. Your boiler/heater and all accessories operate using 110–120 V AC electric current. Improper installation or repair can pose a threat of life-threatening electric shock. -
Page 5: Liability Exclusion
(e.g., impairment) then the local regulations should be adhered to in any event and the working instruction should not be carried out; PELLERGY LLC does not accept any liability for any injury to persons or da- mage to property caused by incorrectly following the instructions and/or violating the local safety regulations! Subject to modifications. - Page 6 Important information for the Technician Ash tray can crush and cut – removing ash tray. CAUTION Never put hands between frame of boiler/heater and ash tray when removing ash tray. Ash tray can crush and cut – mounting ash tray. CAUTION Never put hands between frame of boiler/heater and ash tray when mounting ash tray.
- Page 7 Important information for the Technician Fire hazard. WARNING Hot ash can cause fire in vacuum cleaner. Wait until unit has shut down completely and has cooled for at least 2 hours prior to vacuuming ash or dirt. Machine starts automatically. WARNING Moving parts can crush and cut.
- Page 8 The pellet feed system operates automatically. All service and maintenance must be done by trained specialists only. Do not alter this equipment or its accessories in any way. For use in combination with Pellergy Alpha Series pellet-fired central heating WARNING boiler/ furnace only.
- Page 9 DANGER an earthquake. Instructions can be obtained from your local Pellergy dealer or wholesaler. Pellet feed automatic changeover unit: Fire and explosion hazard Fire and explosion hazard can lead to serious injury or death.
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Page 10: Flue
Important information for the Technician Flue A properly dimensioned flue is required for the optimal and safe function of the device. The design of the whole flue system needs to meet local building codes. All components used neet to meet UL 2523 / UL 103. -
Page 11: Adjust Barometric Damper
Important information for the Technician 1.2.1 Adjust barometric damper Adjust barometric damper according to the manufacturer‘s instructions. To access the measurement opening, remove the back lid and the plug at the flue gas collar. Measure the draft with an appropriate analyzer. Adjust for the flue draft listed on the boiler/heater name plate. -
Page 12: Boiler/Heater Room/Installation Room
Important information for the Technician 1.3 Boiler/heater room/installation room The configuration of the entire system must comply with the requirements of INFORMATION regional legislation, applicable regulations, standards and guidelines. – The minimum clearances for connections, cleaning and maintenance must be complied with – see chapter 2.6 Minimum service clearances. -
Page 13: For The Installer
– Pipes and bends (natural aluminium) for extending the filling and return air pipes Ø 19.7 in / Ø 100 mm *) Please note: 1 + 3 are not included in Pellergy delivery. Must be provided elsewhere. Fig. 5... -
Page 14: System
If using a buffer, the Alpha Series return flow temperature must be increased – INFORMATION see hydraulic diagram in the planning documents. Contact Pellergy!! 2.2.6 Heating water a) The chemical composition of the heating water must meet the specifications of ÖNORM H 5195 Part 1 or VDI 2035 P1. -
Page 15: Water-Side Resistance (Pressure Loss) Of The Alpha Series Pellet Central Heating Boiler
For the Installer 2.2.7 Water-side resistance (pressure loss) of the Alpha Series pellet central heating boiler 5283 2642 2376 2113 1849 1585 1321 Alpha Series Models 60/100 1057 12.6 16.8 21 84 105 147 14.7 16.8 126 168 Diagram 1 Pressure loss (psi) 2.2.8 Operating with external control The following requirements must be satisfied for control interface with the Alpha Series boiler:... -
Page 16: Combustion Air
For the Installer 2.3 Combustion air An adequate supply of combustion air is absolutely essential. The combustion air must be free from pollutants (gases, vapors and dusts), otherwise malfunctions and increased wear (e.g., corrosion) may occur. Malfunctions or other issues caused by inadequate combustion air are not covered INFORMATION by the warrantee. -
Page 17: Bringing The Unit Inside
Boiler weights after removing add-ons: Alpha Alpha Assembly and disassembly Series Series times for experienced fitters Model A-60 Model A-100 – a) Alpha Series incl. crate lb/kg 809 / 367 833 / 378 b) Alpha Series without: crate, hopper, cladding door on... -
Page 18: Removing Hopper
For the Installer Removing hopper 2.4.1 Order for disassembly: – Remove wood partitions with the exception of the base pallet (see chapter 2.8) . – Unhook cladding door on left (Fig. 9) and remove ash container. – Remove hopper rear wall cladding; remove 1 screw in the inside of the device under the hopper next to the rear panel cladding (Fig. -
Page 19: Removing Control Panel
For the Installer – Unscrew 3 nuts and 1 bolt on the outside side of the hopper (Fig. 18), remove the hopper (slide along the auger) – Fig. 19. – Unhook combustion chamber door and remove ash pan– Fig. 20. Nuts Bolt Fig. - Page 20 For the Installer – Unscrew cover at top; remove screws (Fig. 26). Carefully lift cover off, pull cable off door safety switch – Fig. 27. – Take off insulation at front and remove thermocontrol sensor – Fig. 28. Fig. 26 Unscrewing cover at front Fig.
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Page 21: Removing Floor Plate
For the Installer 2.4.3 Removing floor plate – Remove 2 rear nuts, 1 front right nut (Fig. 34) and boiler/heater from floor plate. Bolted on at 2 points at the rear Bolted on at 1 point at the front right Fig. -
Page 22: Dimensional Sketches
For the Installer 2.6 Dimensional sketches All dimensions in inch / mm: 4.65 in 9.49 in 118 mm 241 mm 2.56 in 13.5 in 343 mm 1.02 in 26 mm 4.76 28.82 in 121 mm 732 mm 18.6 in 473 mm 40.47 in 1028 mm Fig. -
Page 23: Installing, Preparing For Installation
For the Installer 2.8 Installing, preparing for installation – The boiler is best transported to the installation site in the crate and removed once there – Figs. 39 to 50. If the boiler cannot be taken to the installation site in the crate, remove the crate and various attachments – see chapter 2.4. -
Page 24: Assembling Of Hopper Lid For Alpha Series Without Vacuum Feed Unit
For the Installer Remove the desiccant bags Remove the desiccant bags from the pellet hopper, the switch board, the ash container and the burner – Fig. 51 – 53. Fig. 51 Remove from the pellet hopper Fig. 52 Remove from the switch board Fig. - Page 25 For the Installer – Insert guard (Fig. 56), then fasten it to hopper using the 2 nuts removed earlier – Fig. 57. Fig. 56 Inserting guard Fig. 57 Screwing on guard rail with 2 nuts. – Use the center screws from the inspection cover to mount the guard at the front. – Figs. 58, 59. Fig.
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Page 26: Fitting Feed Unit On Hopper
For the Installer 2.10 Fitting feed unit on hopper Leave feed unit in cardboard box until it is fitted on the Alpha Series hopper. Only un- screw transport protection after assembly on the hopper – Fig. 63. The INFORMATION bottom flap in the feed unit must not be damaged. Two people are needed for assembly. - Page 27 For the Installer – Remove transport protection. To do this, loosen the 2 screws at the front and remove the transport protection – Fig. 67. – Remove adhesive protection strip from flap. Flap must be able to move freely. – Fig. 68. –...
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Page 28: Fitting Cleaning Tools
For the Installer 2.11 Installing the exhaust pipe Comply with minimum clearances in section 2.4! Installing: Mount flue pipe adapter (Fig. 73) on flue gas collar with 1 screw – Fig. 74. Fig. 73 Mounted flue pipe adapter Fig. 74 Fasten screw with nut driver Flue Gas Adapter must be sealed properly! CAUTION To seal properly, use heat resistant silicon and/or an appropriate tape. - Page 29 Alpha Series 60/100 pellet-fired central heating Sample Schematic! boiler/furnace This is an example only! All work must be done by Pellergy trained personnel. Zone regulation system All installation must comply with local codes and ordinances regarding wiring, piping safety equipment etc.
- Page 30 Alpha Series 60/100 pellet-fired central heating Sample Schematic! boiler/furnace This is an example only! All work must be done by Pellergy trained personnel. Zone regulation system All installation must comply with local codes and ordinances regarding wiring, piping safety equipment etc.
- Page 31 Alpha Series 60/100 pellet-fired central heating Sample Schematic! boiler/furnace This is an example only! All work must be done by Pellergy trained personnel. Zone regulation system All installation must comply with local codes and ordinances regarding wiring, piping safety equipment etc.
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Page 32: Hydraulic Installation - Overview
Alpha Series components are exposed to moisture. All installation work must be performed by Pellergy trained personnel only! All installation work must be done according to local building codes! The illustration below shows a basic system setup, without any safety devices. - Page 33 For the Installer 2.13.1 The correct dimensioning of the storage room The storage room should be large enough to store the quantity of fuel required for one year. The size of the storage room depends on the building heating load. In principle the following rule of thumb applies: Building heating load in kW x factor 3 ft / kW or 0.9 m³/kW = storage room volume in ft (incl.
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Page 34: Initial Start-Up And Operating Instructions
2.14 Initial start-up and operating instructions Pellergy Customer Service or the customer service partner will start up the boiler/heater for the first time, and will familiarize the customer with the system operation and cleaning of the boiler/heater, with reference to the Operating Manual. -
Page 35: For The Electrician
For the Electrician For the Electrician Electrical connections The boiler/heater and related accessories are designed to be installed only in dry areas (protection type IP 10). Installation of electrical components may only be performed by a qualified technician. The regulations and speci- fications of ÖVE, VDI, SEV and local ordinances must be followed. -
Page 36: Electrical Connection For Power Supply 110-120 V Ac, Control And Changeover Unit
For the Electrician To access the various levels of the control panel: – Raise cladding cover at rear, unhook and pull backwards – Fig. 79. – Fold up cladding cover at front, as noted in Fig. 80 Fig. 79 Taking off cladding cover at rear Fig. - Page 37 For the Electrician Install control input – External Heat Demand: An external (2-point controller) Normally Open (N.O.) contact with ZERO POTENTIAL VOLTAGE (dry contact) provides the input signal to the Alpha Series boiler to fire the burner. This connection is made via the External Heat Demand input to the boiler. The following requirements must be also be satisfied for proper interface: –...
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Page 38: Feed Unit Connections
For the Electrician 3.1.2 Feed unit connections The feed unit has 2 cables running to the Alpha Series: (1) proximity switch and (1) 110-120 V AC power supply. Proximity switch: The proximity switch is connected in the control panel top part. To access the control panel top part, unscrew the 2 screws on the side of the control panel cover (Fig. -
Page 39: Wiring
For the Electrician 3.2 Wiring Circulation control and anti-corrosion Diagram shows how to connect the primary pump to the Alpha Series´s circulator control when using a bypass or hea- der or zone valves, to prevent Alpha Series from corroding. No heating pump can consume energy from Alpha Series without an anti-corrosion function. Failure to take anti-cor- rosion measures can result in serious equipment damage. - Page 40 Circulation control and anti-corrosion Diagram shows how to connect the Heater´s circuit cntroller (internally wired) to the Heating zone Controller to prevent Alpha Series from corroding. All zone pump or zone valves must be connected accordingly! Failure to take anti-corrosion measures can result in serious equipment damage! All components shown under ”EXTERNAL“...
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Page 41: Safety Device And Function Checks
To prevent injuries and burns by contact with hot water test all safety devices when WARNING unit is turned off and cooled down only! If you have an annually maintenance contract with a certified Pellergy Partner all this test are done by him during maintenance work. -
Page 42: Technical Data For Calculating The Flue Gas System
For the Service Technician 4.4 Technical data for calculating the flue gas system Formula A-60 (Low) A-60 (High) A-100 (Low) A-100 (High) Alpha Series pellet boiler Unit min. max. min. max. min. max. min. max. symbols Nominal thermal output Btu/hr... -
Page 43: Service Level
For the Service Technician 4.6 Service level System parameters, start-up or actuator test can be displayed, modified and/or performed on the Service level. Only trained service personnel may perform system modifications on the Service WARNING level. Structure on the Service level: Language selection Boiler/Heater DisplayPlusplus... - Page 44 For the Service Technician Service level Boiler temperature Pressing the Menu button (Fig.90) shows the “Operator le- °F vel”, “Service level”, “Information level”, and “MES Module” in the display – Fig. 91. (Operating phases) Info Menu Fig. 90 Use the arrow buttons to select the “Service level” sub- Operator level menu –...
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Page 45: Parameters
For the Service Technician Select the required item, “Parameters”, “Start-up”, “Actua- Parameters tor test” or “Settings“ and confirm by pressing the Choose Start-up button – Fig. 94. Actuator test For further settings, see chapters 4.6.1 – 4.6.4. Settings Choose Back Fig. - Page 46 Delivery time ignition phase Actual value 120 s Fuel quantity in the ignition phase. min. 96 s max. 144 s Alpha Series A-60 (LOW) A-60 (HIGH) A-100 (LOW) A-100 (HIGH) Factory setting: 120 s 90 s 110 s 85 s –...
- Page 47 For the Service Technician Type of pellet feed system Type of pellet feed system Without feed system Setting for whether operation is without feed system, with 2 to 8 probes or with Suction turbine with 2 probes a mixer (buried tank). Suction turbine with 3 probes Suction turbine with 4 probes Suction turbine with 6 probes...
- Page 48 – Save Back Fig. 108 Limits for blower/fan speed Limits for blower speed Minimum 1050 rpm Maximum 1950 rpm A-60 (LOW) A-60 (HIGH) Minimum Maximum Minimum Maximum Factory setting: 1000 2000 1100 2600 Choose...
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Page 49: Start-Up
For the Service Technician 4.6.2 Start-up The auger conveyor and the feed can be selected on the Start-up level with the arrow buttons, then confirmed or selected using the Choose button. A self-test is started at the end of the start-up. Auger conveyor Start-up Auger conveyor... - Page 50 For the Service Technician Install display module Start installation procedure The install display module is not needed for an individual Alpha Series boiler; it Please press LON button on auto- only needs to be used for a cascade system – see “Planning and assembly” matic firing device briefly instruc- tions for pellet cascade.
- Page 51 For the Service Technician 4.7 DisplayPlus basic settings The basic settings are used to: – set whether the DisplayPlus controls a wood or pellet boiler/heater or whether it is solely used for master operation; – switch the master operation functions on and off; –...
- Page 52 For the Service Technician Language selection Language selection Deutsch The DisplayPlusplus can show the display texts in various languages. The English language required can be selected in this sub-menu. Française Italiano Choose Back Fig. 124 Boiler Boiler Pellets Setting to determine what kind of boiler/heater the DisplayPlus controls, e.g., Wood wood or pellet boiler/heater or whether it is solely used for master operation.
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Page 53: Installation Instructions For 3-Way Changeover Unit, Fire Protection Collars, Suction Probes
For the Service Technician 4.8 Installation Instructions for 3-way changeover unit, fire protection collars, suction probes (OPTIONAL) 4.8.1 Scope of delivery, packaging Automatic changeover unit with cover plate, 3x Suction probes – BIO 020 Part Quantity Designation M8 x 30 hexagon screw M8x30 brass dowel 05/2010 U-washers 8... -
Page 54: Notes On Installing The Suction Probes
For the Service Technician 4.8.2 Notes on installing the suction probes For information on installing the suction probes in a sheet steel tank or fabric tank, see the installation instructions for sheet steel and fabric tanks. For information INFORMATION about configuring pellet stores, see the planning document ”Pellet stores for pel- let boilers“... -
Page 55: Notes On Installing The Supply And Return Air Hoses
For the Service Technician 4.8.2 Notes on installing the supply and return air hoses 4.8.2.1 Maximum transport length and height for pellet feed system INFORMATION These maximum values require a stable electricity supply (min. 110 V AC under load). Alpha Series pellet boiler: Max. - Page 56 For the Service Technician 4.8.2.3 Installing the supply and return air hoses – Expose approx. 2.6 in / 5 cm of the flexible grounding leads on all hose ends and bend inwards into the hose – Fig. 131. – Slide hose clips over the hose and plug into connectors. The grounding wire must have good contact with the connectors.
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Page 57: Notes On Installing The Changeover Unit
For the Service Technician 4.8.3 Notes on installing the changeover unit Some states/cities may require a fire stop between the bulk wood pellet hopper (main wood pellet storage) and the room where the appliance is installed (mechanical room). If this applies to your state/city, follow your local building codes to install a proper fire stop. -
Page 58: Installation
For the Service Technician 4.8.4 Installation Path of pellets The pellets move from probes A1, A2, and A3 through the corresponding cover plate holes A1, A2, and A3 to the rear of the changeover unit (A). They then pass through the front of the changeover unit (A) to the pellet boiler (A). Path of return air The return air follows a path from the pellet boiler (B) or suction turbine to the front of the changeover unit (B). - Page 59 For the Service Technician 2. Fit cover plate inside storage room – Drill 4 mounting holes 0.31 inch / 8 mm in diameter. – Insert 4 x F8 dowels. (plastic anchors) – Temporarily screw down cover plate with four 6 x 50 hexagon head wood screws and U-washers 6 [large dia- meter] –...
- Page 60 For the Service Technician 4. Mounting the changeover unit To make it easier to fit the hoses, the changeover unit should be at the same INFORMATION height as the hoses (wooden boards or similar can be laid underneath). – Drill holes for metal dowels 0.39 inch / 10 mm in diameter and insert brass dowels. Please note! DANGER The changeover unit should be attached with the brass dowels provided.
- Page 61 For the Service Technician 5. Fill masonry feed-through with mineral wool – Unscrew cover plate in storage room, fill masonry feed-through with mineral wool – Fig. 142. – Screw down cover plate inside storage room – Fig. 143. Fig. 142 Filling masonry feed-through with Fig.
- Page 62 For the Service Technician 7. Trim the delivery hose to the appropriate length to reach from the changeover unit to the boiler or suction turbine and lay inside plastic tubes It is best to lay the hoses in plastic tubes secured with clips – Fig. 145. INFORMATION –...
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Page 63: Affixing Stickers
For the Service Technician 4.8.5 Affixing stickers Affix the enclosed yellow ”Wood pellet storage room“ sticker and white ”Storage room filled“ sticker on the pellet storage room door. Every time the storage room is filled, the date and volume should be recorded on the ”Storage room filled“... -
Page 64: Basic Alpha Series 100-260 Circuitry
For the Service Technician 4.9 Basic Alpha Series 100–260 circuitry... - Page 65 **Burner safety switch **wire bridge **wire bridge **wire bridge **low water cut-off 110-120V voltage low water cut-off supply voltage 110-120V/60Hz X102.4 Protective Boiler Alpha Series/E1.7A X102.1 Protective Boiler Alpha Series/E1.7A ZSP 4630-SO not used 1X103.2 Protective Boiler Alpha Series/E1.3B potential free contact 1X103.1 Protective Boiler Alpha Series/E1.3B 0-10V heat demand...
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Page 66: Commissioning Checklist
(e.g., impairment) then the local regulations should be adhered to in any event and the working instruction should not be carried out; PELLERGY LLC does not accept any liability for any injury to persons or damage to property caused by incorrectly following the instructions and/or violating the local safety regulations! Subject to modifications. - Page 67 (e.g., impairment) then the local regulations should be adhered to in any event and the working instruction should not be carried out; PELLERGY LLC does not accept any liability for any injury to persons or damage to property caused by incorrectly following the instructions and/or violating the local safety regulations! Subject to modifications.
- Page 68 (e.g., impairment) then the local regulations should be adhered to in any event and the working instruction should not be carried out; PELLERGY LLC does not accept any liability for any injury to persons or damage to property caused by incorrectly following the instructions and/or violating the local safety regulations! Subject to modifications.
- Page 69 (e.g., impairment) then the local regulations should be adhered to in any event and the working instruction should not be carried out; PELLERGY LLC does not accept any liability for any injury to persons or damage to property caused by incorrectly following the instructions and/or violating the local safety regulations! Subject to modifications.
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Page 70: Maintenance Checklist
(e.g. impairment) then the local regulations should be adhered to in any event and the working instruction should not be carried out; PELLERGY LLC does not accept any liability for any injury to persons or damage to property caused by incorrectly following the instructions and/or violating the local safety regulations! Subject to modifications. - Page 71 (e.g. impairment) then the local regulations should be adhered to in any event and the working instruction should not be carried out; PELLERGY LLC does not accept any liability for any injury to persons or damage to property caused by incorrectly following the instructions and/or violating the local safety regulations! Subject to modifications.
- Page 72 (e.g. impairment) then the local regulations should be adhered to in any event and the working instruction should not be carried out; PELLERGY LLC does not accept any liability for any injury to persons or damage to property caused by incorrectly following the instructions and/or violating the local safety regulations! Subject to modifications.
- Page 73 UL 391-2010 CAN / CSA-B366.1-11 Pellergy LLC 157 Pioneer Center, Suite 1 Montpelier, VT 05602 USA Tel. +802.371.0098 Fax +802.419.4769 E-mail: info@pellergy.com www.pellergy.com Subject to technical modifications.