D'Alessandro Termomeccanica CSA30 GM, CSA45 GM, CSA60 GM, CSA80 GM, CSA100 GM Use And Maintenance Manual

1

C.da Cerreto, 55 - 66010 MIGLIANICO (CH) – Italy Tel. [phone] Fax [phone]

http://www.caldaiedalessandro.it e-mail: [e-mail]

Heat generator with mobile grid burner for woody

biomasses

Serie CSA 30-100 GM

USE and MAINTENANCE MANUAL

Ver. 1.0 - QCGM30100UK0313

2

ATTENTION!

Refer to section 6 in this manual to install the boiler. Make sure to
have fulfilled the following obligations before switching on the ma­chine:

Electric Connections

The following connections are compulsory upon installation:

1. Mains power supply

2. Ambient thermostat

3. Circulation pump

4. Tank float for fire-prevention.

The CSA GM series boilers must be fitted with a water storage con­nected to the fire-prevention valve located on the side of the hopper
(ref. Fig. A). The storage filling state must be handled by an electro­nic float connected to the machine's control system (ref. Control unit
manual). Failure to connect the float to the control unit, prevents
switch-on of the boiler itself.

5. It is possible to install an external clock to time the generator's
switch-ons, as an option. (consult the control board's use manual

- Annex A).

230Vac

N

F

N.B. The pump's connection clamps do not provide power
supply. It is a free contact.
The pump must be connected as follows:

3

Flue

The flue represents one of the fundamental elements of the heat gen­erator.

The correct designing, in the form and dimensions of the fumes evacuation
system guarantees the correct and always efficient generator functioning
and prevents potentially dangerous situations for the user.
For correct installation, refer to section 6.5 at page 23 of this manual and,
however, use experienced staff.

Figure A

Fire-resistant

It is essential for first ignition to be gradual, without bringing the gen­erator to maximum temperature, to avoid the fire-resistant material inside

the combustion chamber from being damaged. Re-start the generator and
bring it to maximum temperature and, therefore, at normal functioning, only
after cooling.

4

1 MAIN INFORMATION 6

1.1 Identification and purpose of the document 6

1.2 Technical data plate 6

1.3 CE Marking 6

1.4 Standard of reference 7

1.5 Typographical conventions 7

1.6 Warranty and responsibility 7

2 SAFETY AND RESIDUE RISKS 8

2.1 Risks linked to using the generator 8

2.2 Residue risks 8

2.3 Intended use of generator 9

2.4 Improper use of generator 9

3 TECHNICAL FEATURES AND DIMENSIONS 10

3.1 Illustration of generator functioning 10

3.2 Description of generator functioning 11

3.3 List of components and spare parts 12

3.4 Technical features 15

3.5 Main dimensions 16

3.6 Hydraulic connections - connections 17

4 FUEL 18

4.1 Usable fuels 18

4.2 Other fuels 18

5 TRANSPORT AND HANDLING 19

5.1 Generality 19

5.2 Transport and handling 19

6 INSTALLATION AND TESTING 21

6.1 Main installation prescriptions 21

6.2 Installer fulfilments (Italy) 21

6.3 Installer fulfilments (Foreign Countries) 21

6.4 Installation premises 21

6.5 Flue and draught 22

6.6 Electric system and connections 23

6.7 Final test 23

7 START-UP, IGNITION AND CHECK 24

7.1 Commissioning checks 24

7.2 First ignition 24

7.3 Regime functioning 24

INDEX

5

ATTACHMENTS

Attachment “A”: Control board electric ignition use manual.

Attachment “B”: Control board electric ignition and lambda use manual.

7.4 Frequent heat request condition 24

7.5 Occasional heat request condition 25

7.6 Regulation 25

7.7 Primary and secondary comburent air regulation 25

7.8 Conical screw fuel regulation 26

7.9 Grid speed regulation 27

7.10 Switch-off 27

8 CLEANING 28

8.1 Generality 28

8.2 Table of the periodical maintenance operations 28

9 MAINTENANCE 30

9.1 Generality 30

9.2 Table of the periodical cleaning operations 30

10 ANOMALIES, FAULTS AND MALFUNCTIONING, FAQ and Answers 31

10.1 Anomalies and Faults Table 31

10.2 Malfunctioning table 32

11 NOISE 32

11.1 Generality 32

11.2 Sound emission values 32

12 TERMINATION OF SERVICE AND SCRAPPING 32

12.1 Generality 32

12.2 Scrapping 32

A FAC-SIMILE of the DECLARATIONS OF CONFORMITY 34

B FAC-SIMILE of the PARTIAL SWITCHING OFF DECLARATION 35

6

1. MAIN INFORMATION

1.1 Identification and purpose of the document

This instructions manual, drawn up by D'ALESSANDRO TERMOMECCANICA, is integrating part of the
heat generator, which reproduction, even partial, is forbidden.

The purpose of this document is to supply the users of the generator all information necessary for
its correct use, in the safest conditions for persons, animals and things.

The identification of D'Alessandro Termomeccanica as Manufacturer is demonstrated, pursuant
to that specified in Directive 2006/42/CE by means of the following deeds:

 Declaration of conformity
 CE Marking
 Use and maintenance manual

The precise manufacturer company name is:
:

D'Alessandro Termomeccanica - C.da Cerreto 55
66016 Miglianico (CH) - Italy

obtainable from the data plate on the left panel of the generator, having the CE mark.

1.2 Plate

As well as the manufacturer company name, the plate on the generator also has the following ge­nerator data:

 Year of manufacture

 Series

 model

 Serial no.

 Nominal power

 Maximum working pressure

 Maximum working temperature

 Water content

 Empty weight

 Absorbed electric power

 Mains voltage

1.3 CE Marking

The technical data plate on the generator having the exact manufacturer company name, the
identification data and the CE mark, as well as the attached declaration of conformity, certify the
correspondence of the generator to the European Directives applicable to it.

7

1.4 Standard of reference

The Manual has been drawn up in relation to that established by the following Directives, Stan­dards and Regulations:

1. Directive 85/374/CEE on the responsibility of damages due to faulty product

2. Directive 92/59/ CEE on the general safety of the products

3. Directive 2006/42/CE on Machinery Safety

4. Directive 2006/95/CE on the Safety of the electric material

5. Directive 2004/108/CE on the electromagnetic compatibility of the machinery

6. Directive 89/106/CEE on construction products

7. Technical regulation UNI EN 12100-1/2 on machinery safety (Foundations)

8. Technical regulation UNI EN 1050 on machinery safety (Principles for the risk evaluation)

9. Technical regulation CEI EN 60204-1 on machinery safety (Electric equip.)

1.5 Typographical conventions

In reading this manual, particular ATTENTIONmust be given to the parts marked with the symbols
shown below:

1.6 Warranty and responsibility

Both the mechanical and electrical parts of the generator are covered by warranty, as regulated
by the Directive of the European Community 1999/44/CE protecting the user in the presence of
any manufacturing defects, for a period of two years.

The warranty becomes void for damages to the generator deriving from:

 Transport and/or handling (if under Client responsibility)
 Assembly errors by the installer;
 No maintenance and cleaning of the generator envisioned in this manual;
 Faults and/or breaks not attributable to the malfunctioning of the generator;
 Causes not dependant from the manufacturer.

The warranty is only valid towards the original client and only when he has fully become the ow­ner of the generator.
Controversies between D'Alessandro Termomeccanica and the purchaser will be solved by
means of arbitration; in case of no agreement on the arbitration panel, the competence will be of
the Court of Chieti.
The above points are taken from the main sales conditions constituting integrating and substantial
part of the purchase contract, and to which reference must be made for further considerations not
reported herein.

The warranty or the responsibility of the manufacturer cannot be invoked in case of damage to
persons and/or things if the damage is the consequence of one of the following causes:

 Incorrect installation of the generator
 Improper use of generator
 Amendments to the generator

DANGER

OBLIGATION

PROHIBITION

IMPORTANT NOTE

ATTENTION

WARNING

8

2. SAFETY AND RESIDUE RISKS

2.1 Risks linked to using the generator

The generator is manufactured in compliance with the essential safety requisites requested by the
European Directives applicable to it.
The European and National Regulations relating to the safety concerning said type of machine
have been considered during designing, bearing in mind the state-of-the-art.
Nevertheless, dangerous conditions may arise if:

The generator is used in an improper manner.
The generator is installed by inexperienced persons.
The safety use instructions contained in this manual are not complied with.

2.2 Residue risks

The generator has been conceived, designed and manufactured bearing in mind all Safety Stan­dard currently in force and applicable thereto. Despite having evaluated every possible cause of
risk, comparing it with that envisioned by the Standard in force, it is reasonably possible that, as
well as those deriving from an improper use, the following residue risks may arise:

DANGER BURNS

During ignition of firebox, access to inspection and cleaning doors with firebox on or
not completely out..

DANGER ELECTROCUTION

The generator is connected and controlled by appropriate electric board equipped
with all the devices necessary for the protection against overloads and short circuits.
For protection against indirect contacts, we recommend powering the board with line
protected by differential switch with maximum intervention threshold 30 mA.

DANGER INJURIES TO HAND

During cleaning and/or maintenance of the fuel conical screw..

DANGER INJURIES TO FINGERS

During check and maintenance of the chain transmission parts in correspondence of
the geared motor.

PROTECTION GLOVES OBLIGATION

During all maintenance and cleaning we recommend the use of protection gloves.

DANGER SUSPENDED LOADS

During transport and handling of the generators.

DANGER ASPHYXIA

In case of insufficient fumes evacuation (draught). We recommend an accurate and
periodical cleaning of the flue, of the tubes nest and of the generator firebox.

9

The generator produces low pressure hot water, it is suitable for non-powdered solid
fuel combustion with mechanical feeding.

Any other use constitutes improper use.

2.3 Intended use of generator

The use of wood or similar large fuels constitutes an improper use.

Installation of the generator in open places exposed to atmospheric agents constitu-
tes an improper use.

2.4 Improper use of generator

PROTECTION HELMET OBLIGATION

During all handling and transport of generators.

PROTECTION MASK OBLIGATION

During all maintenance and cleaning of the flues.

10

3.1 Illustration of generator functioning

Il The generator body is of "Marina" type while the burner consists of a thick metal base
with insulating cast which lower part houses the mobile grid. The fuel fumes released on
the grid make four smoke turns transferring heat to the generator body's metal walls and
constitute a system for the production of hot water for civil and industrial heating. The
functioning principle of the "CSA GM" generator is illustrated in fig.3.1.A

3. TECHNICAL FEATURES AND DIMENSIONS

Fig.3.1.A

11

3.2 Description of generator functioning

The fuel in CSA GM type generators is extracted from the circular hopper through specific
motorised blades that convey it towards the drop hole in the upper screw.
The rotary valve has the function of interrupting the fuel's continuity between the two
screws, preventing return of eventual flames that might rise back up to the fuel hopper.
The rotation speed of the screw determines the correct feeding of the grid firebox, there­fore being a significant factor for the correct functioning of the generator.
The fuel present in the grid firebox is burnt with the introduction of primary and secondary
air.
The heat developed inside the combustion chamber is transferred to water filled gaps
through the generator's steel walls.
The hot fumes make an initial turn inside the grid firebox, go through the combustion
chamber of the generator's body, cross the central tube and, by means of the upper door
cavity, pass through the tubes nest up to the ejection in the rear fumes fitting, making four
smoke passes which are the particularity of this type of heat generator.

The optimal combustion control is obtained with suitable regulations of the primary and
secondary air and the fuel ratio, based on the boiler's power. The combustion quality can
be visually checked or using suitable fumes analysers.

The use instructions of the boiler's control board are provided in a file, supplied together
with this use and maintenance manual (Attachment A or Attachment B)

WARNING

12

3.3 List of components and spare parts

The following figures illustrate the CSA GM generator's main components. The list of the
parts will be subsequently quoted for the identification of the spare parts and as reference
for the descriptions in the subsequent chapters.

Fig.3.3.1.A

13

Fig.3.3.1.B

14

POS. DESCRIPTION CODE

1

Boiler body

2

Burner base

3

Lower door safety end run

4

Secondary air electric fan

5

Ashes extraction screw motor

6

Combustion check lower inspection hole

7

Ash collection draw

8

Lower door

9

Mobile grid cast iron firebars

10

Fire-resistant panels

11

Inspection hole

12

Upper door

13

Command and control electric board

14

Hatch on fuel hopper

15

Stub pipe for autom. loading connection

16

Fuel hopper

17

Sleeves for min/max level sensors connection

18

Fire-prevention valve

19

Geared motor for hopper mixer

20

Upper screw tube

21

Transmission protection carter

22

Conical screw adjustable speed gear motor

23

Rotary valve transmission shaft

24

Conical screw pipe

25

Limit switch run grid mobile

26

Primary air electric fan

27

Gear motor grid mobile

28

Pipe cooling air ignition

29

Pipe pression air back stop smoke

30

Ispection door compartment subgrid

31

Ispection door conducted air

32

Spark plug ignition

33

Flame check valve rotary valve

34

Rotary valve and screw inspection compartment

35

Rear fumes carrier

36

Blade mixer

CSA GM MODEL COMPONENTS KEY

Tab.3.3

15

3.4 Technical features
Tab.3.4.1 details all technical features of the ”CSA GM” mod. generators. Tab.3.5 shows

the overall dimensions of all models.
For any other information, please contact the technical department of D’ALESSANDRO
TERMOMECCANICA s.r.l.

BOILERS MODELS

CSA30

GM

CSA45

GM

CSA60

GM

CSA80

GM

CSA100

GM

nominal power (kW) 30 45 60 80 100

power to firebox (kW) 34.9 52 71 94 115

max working pressure (bar) 3

hydraulic test pressure (bar) 4.5

max working temperature (°C) 90

mains voltage (V) 230

electric utilities absorption (excluding optionals) (kWh) 1.13

regime fuel consumption (¹)

(Kg/h) 7.1 10.6 14.4 19.2 23.4

hopper volume (dcm³) 480

water side load loss (10K) (mbar) 32 58 72 87 109

water side load loss (20K) (mbar) 13 16 31 49 61.3

pump activation minimum temperature (°C) 40

boiler water content (l.) 130 155 205 255 305

fumes average temperature (clean boiler) (°C)

170 (20%)

chimney draught depression (Pa)

-20 (30%)

fumes chimney diameter (mm) 200

combustion chamber volume (dcm³) 95 115 135 175 215

L x H combustion chamber opening dimensions (mm) 490x395

boiler empty mass (tolerance ± 5%)

(Kg) 400 500 650 750 850

thermal drain valve capacity (Δt=80°C at 1.5 bar) (l./h) 1882

(¹) the l.h.v. (lower heat value) of reference of the fuel is equal to 17.6 MJ/Kg (4.9 kWh/kg), as from prospectus 8 of Standard
EN303-5 for test type "C" fuel

tab. 3.4.1

16

3.5 Main dimensions

tab. 3.5

Dimension K* refers to the rear stub dimensions in case of disassembly for
screws maintenance/replacement. This dimension is to be considered during
the generator's design and/or insertion in the thermal power stations.

17

3.6 Connections / connessioni

The dimensions of all connections present on the generators, based on the model, are summa­rised in tab.3.6 with reference to fig.3.5.

POS. Q.tà DESCRIZIONE TIPO UNITA' DIMENSIONI

Pos. Q.ty description type unit dimension

N1

1

mandata manicotto

ISO7/1 - DN 40

outlet water socket

N2

1

ritorno manicotto

ISO7/1 - DN 40

inlet water socket

Tab.3.6.2

POS. Q.tà DESCRIZIONE TIPO UNITA' DIMENSIONI

Pos. Q.ty description type unit dimension

T1

1

Sensore livello minimo combustibile foro

ISO7/1 - DN Ø50

Level sensor combustible hole

T2

1

Boccaporto ispezione Foro quadro

ISO7/1 - DN 300x400

Ispection hatch Hole square

T3

1

Tronchetto per valvola antincendio tronchetto

ISO7/1 - DN 20

Nozzle for fire fighting system nozzle

T4

1

Predisposizione attacco sensore livello max manicotto

ISO7/1 - DN 65

Connection maximum level sensor input socket

T5

1

Predisposizione attacco sensore livello min. manicotto

ISO7/1 - DN 65

Connection minimum level sensor input socket

Connessioni Idrauliche

Hydraulic connections

T6

1

Boccaporto di carico manuale Foro quadro

ISO7/1 - DN 430x430

Hatch for manual load combustible Hole square

T7

1

Predisposizione attacco caricam. Autom. Tubo+flangia

ISO7/1 - DN

Ø159 - 190x190

Nozzle for connect automatic combustible feeding Hole+flange

tab. 3.6.1

18

4.1 Fuels usable by CSA GM model
Wood original solid fuel is admitted for use, which:
Vegetable material produced by forestry, forest maintenance and by pruning interventions, from
the machining of raw wood: cortex, sawdust, chippings and firewood chippings, flakes and wood
chippings from the wood industry machining or from woodworking without glues or other chemical
substances.

The following ground solid fuels are also admitted for use in addition to the above biomasses:

 wood pellets
 exhausted olive residues
 ground olive stone
 crushed peach, apricots husks and similar

All biomass above must be characteristic of the marketing and use, also for the wood chips will be
referred to the characteristics of shape and size and according ÖNORM 7133, max size G50.
The efficiency of the heat generator is guaranteed with a humidity of fuel not exceeding 30%, for
higher humidity reference must be made to the diagram of derating below.

4.2 Other fuels
To use fuels not included in point 4.1, please contact our technical department.

4. FUEL

19

5. TRANSPORT AND HANDLING

5.1 Generality

The heat generator is supplied fully assembled and ready for installation. It is protected
with packaging material and fixed on wooden platforms for handling with forklift .

5.2 Transport and handling

The generator transport and handling operations must be carried out by qualified staff us­ing suitable hoisting means.
For hoisting the generator, refer to the empty mass indicated, for each type, on to the da­ta plate.

ATTENTION!!

THE TRANSPORT AND HANDLING OF GENERATORS MUST BE
CARRIED OUT BY SPECIALISED STAFF USING SUITABLE HOIST­ING MEANS AND INDIVIDUAL PROTECTIONS.

5.2.1 Lifting and handling on platform

20

21

6.1 Main installation prescriptions

The electric and thermo-hydraulic installation of the heat generator and any other assistance and
extraordinary maintenance intervention, must be carried out by persons registered in the installing
companies register instituted with C.C.I.A. (Chamber of Commerce, Industry, Craftsman and Agri­culture). as established by MD. 37/08. The thermo-hydraulic and electric installers must issue
Certification of Conformity pursuant to MD. 37/08 and relative Implementation regulation.

6.2 Adempimenti Installer fulfilments. (ITALY)

The thermal plant, at the service of heat generators with power to firebox above 34.9 KW (30.000
Kcal/h), must be realised according to a project drawn up by qualified staff registered with a pro­fessional register.
The installer must, before installation, present to the territorially competent ISPESL, a plant report
with project.
The Thermal power stations with total nominal power of the firebox higher than (115 KW) 100.000
Kcal/h are subject to F.P.C. (Fire Prevention Certificate)
Before starting work it is necessary to present request of Project Review pursuant to Italian Presi­dential Decree 37/98 with methods envisioned in M.D Int. 4/05/98.

The thermal-hydraulic plant at the service of the generator can be realised with open expansion
vessel and with closed expansion vessel, in any case, the installer must respect the Standards
of Collection R of I.S.P.E.S.L.

ATTENTON !!

THE GENERATOR MUST BE INSTALLED BY SPECIALISED STAFF AND ENA-

BLED TO INSTALL THERMAL AND ELECTRIC PLANTS

6.3 Installer fulfilments. (FOREIGN COUNTRIES)

The realisation of heating and/or hot water production plants using generators of which in this
manual, is not governed by even regulations among the various countries, therefore the installer
in each country will refer to that set out by the local regulations.

6.4 Installation premises - thermal power station
The heat generators with power to the firebox above 34.9 kW (30.000 kcal/h) must be installed in
suitable premises, separate from other premises by means of structures REI 120.

Each Thermal power station must have a surface of not less than 6 sq m, with flat and smooth
floor and with permanent openings not below to 1/30 of the total surface of the premises.
The heat generator must be stable and levelled (flat).
The heat generators with power to the firebox below 34.9 kW (30.000 kcal/h) must, according to
good sense, be installed in suitable premises, even if not subjected to specific standard. These
premises must be sufficiently ventilated and lit and must be leave enough space for maintenance
and cleaning operations.

6. INSTALLATION AND TESTING

22

In light of that described, the flue must be dimensioned depending on the section and power of
the generator firebox, therefore the dimensioning must be carried out, case by case, by a quali­fied sector technician (see Standard UN 13384). For parallel connected generators, each must
have its own flue calculated for each individual generator.
Given the difference of the generator installation places, the section and height of the flue must
guarantee, with the generator running, a minimum draught of at least –20 Pa (±30%)measured by
applying a connecting nozzle fitting of 1/4” to the sleeve located at the side of the porthole of the
lower door and by introducing a rubber tube connected to a common draught gauge (see fig.

6.6.1). Tab.3.4.1 and tab.3.4.2 indicate the maximum draught values.
In case the necessary draught for functioning is not obtained, we recommend installing an electric
fan at the end of the flue, for forced draught.

6.5 Flue and draught

The flue represents one of the most important elements for the correct functioning of the genera­tor.
Usually, to obtain a good draught, the flue must be thermally insulated, possibly designed with
double insulated wall to avoid the cooling of the fumes and, therefore, maintain that pressure dif­ferent enabling the fumes to rise along the chimney pipe up to the external output.
The danger of acid condense, due to the features of the used fuel, recommends the use of stain­less steel for parts in contact with the fumes. The surrounding structures can influence the correct
functioning of the flue: for example, the distance and height of the adjacent buildings, for which
the regulations in force impose that the end of the flue must exceed by at least 1 m the hipped
roof or of any other construction at a distance of at least 10 m.

 An excessive draught decreases the generator efficiency: part of the fuel gases together

with fuel parts are sucked in flue before being completely burnt, increasing the consumption
of necessary fuel.

 A scarce draught decreases the generator efficiency, in that it slows down combustion,

producing fumes return.

The section of the flue must have the same diameter of the fumes fitting, section shrinking is not admitted.
Furthermore, its weight must not burden on the same fumes fitting to avoid subsidence of the generator
structure .

Fig.6.6.3 represents the correct assembly.

fig. 6.6.1

23

6.6 Electric system and connections.

The generator is equipped with non automatic main switch.
We recommend protecting the plant's power supply line by means of a differential mag-
neto-thermal switch with intervention threshold not higher than 30 mA.
All foreign masses and piping will be connected by means of equipotential pipe to a
ground node.

Refer to the control unit's manual with regard to the electronic control connection.

6.7 Plant final testing

Only when the generator is completely installed, meaning positioned and levelled, con­nected to the hydraulic circuit, connected to the electric board and fed with suitable fuel,
can ignition be carried out by qualified staff, recommended by the area dealer.

All above connections are the responsibility of the final client.

fig. 6.6.3

24

7. START-UP, IGNITION AND CHECK

7.1 Commissioning checks

Before generator commissioning it is essential to check that:

 The installer has issued regular Certification of Conformity
 The water plant is regularly filled with the correct level of liquid inside the OPEN or

CLOSED expansion vessel.

 The hopper is filled with suitable fuel (see chepter 4).

7.2 Start-up

After having carried out the checks of which in point 7.1, it is possible to start the heat
generator.
The operations to be carried out are:

1. Activate the main switch on the board.

2. Introduce fuel on the grid as described in attachment A, checking through the open
door, that the fuel has deposited on the first two rows.

3. Close the firebox door.

4. Ignite fuel as described in attachment A relative section.

5. Regulate the primary and secondary air respectively through the regulation knobs

(fig.7.7)

7.3 Regime functioning

After start-up and regulations, the heat generator functioning proceeds automatically.

7.4 Frequent heat request condition

During regime functioning, with request of hot water, the fuel conveying screw and the
comburent air are regulated by a regulation thermostat:

 the screw and electric fans stop once the pre-fixed maximum temperature is reached
 when the water temperature has dropped by a few degrees, the screw and the fans

automatically re-start until the subsequent reaching of the pre-fixed maximum tempera­ture.

The heat request can also be controlled by means of an ambient thermostat (timed ther­mostat), that must be connected to the appropriate clamps with which the control board is
equipped (see electronic control unit manual- Attachment “A” or “B”).

This is also a description of the ignition process and fuelling. In this case, the actions to
be taken depend on the control unit, therefore refer to its manual for further details.

See attachment “A” or attachment “B”

ATTENTON !!

FIRST IGNITION MUST BE CARRIED OUT GRADUALLY WITHOUT BRINGING
THE GENERATOR TO MAXIMUM TEMPERATURE, TO AVOID THE FIRE­RESISTANT MATERIAL IN THE COMBUSTION CHAMBER FROM BEING DAMA­GED. RE-START THE GENERATOR AND BRING IT TO MAXIMUM TEMPERATURE
AND, THEREFORE, AT NORMAL FUNCTIONING, ONLY AFTER COOLING.

25

7.6 Regulation

Usually, the correct combustion is obtained upon reaching of the correct ratio between
fuel amount and comburent air amount. In ideal combustion conditions, a clear and lumi­nous flame is generated, easily visible from the porthole. (fig. 3.3.1.A)

7.7 Primary and secondary comburent air regulation

The correct amount of primary and secondary comburent air depends on the type and
consistency of the used fuel. Excellent combustion will be obtained after repeated adjust­ment interventions, conditioned by the used fuel.
The comburent air is regulated manually by acting on the knobs indicated in fig.7.7.1 and

7.7.3. Once the fuel capacity has been fixed (see paragraph 7.8) depending on the power
of the boiler and the relative consumption (see tab.3.4.1), the primary air can be opti­mised with recommended regulation during the interval between 5 and 6. The secondary
air can be regulated during interval 4 and 5. (fig. 7.7.2 and fig.7.7.4).

fig. 7.7

7.5 Occasional heat request condition

The control unit allows connecting an external timer to avoid the fuel inside the firebox
going out and the consequent re-ignition operations, in the event of no hot water request
for long periods. This device allows the control unit to activate the screw at regular inter­vals, providing sufficient fuel to maintain the firebox ignited.

fig. 7.7.1

fig. 7.7.2

fig. 7.7.4

fig. 7.7.3

knob regulation secondary

comburent air

knob regulation primary

comburent air

26

In case of using solid fuels different to the fuel of reference (wood pellet) without certifica­tion, we recommend checking its l.h.v. in order to guarantee optimal performances. In
case the fuel has a l.h.v. different to that of reference (wood pellet), tab. 7.8 will be mere­ly indicative. Various attempts must be made to obtain an optimal regulation by carrying
out the above-described operations.

fig. 7.8

WARNING

The variator knob of the fuel conical screw must be turned with motor running, never
turn the variator knob with motor off (fig.8.4)

fig. 7.8.1

tab. 7.8

7.8 Regulation of the conical screw fuel

The fuel conveying capacity, measurable in mc/h or kg/h, depends on the apparent mass
density of the fuel and the number of turns of the screw; reference is made to the wood
pellet having a lower heating value (l.h.v.) by 17.6 MJ/kg (4.9 kWh/kg) as from prospectus
8 of Standard EN303-5 for the fuel of test “C”, approximate dimensions Ø6 x 25mm and
an apparent mass density between 600 and 660 kg/mc.
Each boiler model has a turns regulation based on the power to firebox, obtained by act­ing on the variator variation knob, indicated in fig.7.8 and by counting the turns from the
upper screw pinion mark (fig. 7.8.1) with reference to arrow (A) on the carter.
These nominal regulation values are shown in tab. 7.8.

MODELS

REGOLAZIONE NOMINALE

(no. turns/min.)

CSA30 GM 0.24

CSA45 GM 0.36

CSA60 GM 0.49

CSA80 GM 0.64

CSA100 GM 0.79

27

ATTENTION!!

It is forbidden to exceed the maximum regulation values in case of using fuel
with higher l.h.v. by 4.9 kWh/kg.

7.10 Switch-off

Interrupt feeding the screw and powering the fan by acting on the switch on the electronic
control unit's control panel to switch-off the generator (see attachment "A" or “B”).
Generator can also be switched off through no fuel in the hopper.

7.9 Mobile grate speed regulation

The mobile grate is moved by gear motor that turn a threaded bar giving an alternate hor­izontal move to the structure of the grid mobile placed in the lower part of the basement.
The speed of the alternate movement of the grate is controlled by limit switch and the
electronic control board according to the different functioning phases of the generator.
This speed is regulated at its minimum to have the fuel as much time as possible on the
grate surfaces.

limit switch minimum

stroke

limit switch max stroke

contact bar

28

8.1 Generality

The grid's firebox and the fumes pipes of the generator must be periodically cleared from
solid fuel residues (ash).
The maintenance of fumes pipes cleared by ash guarantees draught efficiency and,
therefore, greater yield of the heat generator. Tab. 8.2 lists the cleaning operations in
chronological order.

ATTENTION!!

BEFORE CLEANING, DISCONNECT THE ELECTRIC ENERGY
FROM THE GENERATOR BY INTERVENING ON THE MAIN SWITCH
AND ENSURE THAT THE RESIDUE FUEL INSIDE THE FIREBOX IS
OFF AND HAS COOLED DOWN

CLEANING THE GRID

OPERATION: removal of ashes or deposits from the grid's firebars surfaces.
PERIODICITY: 7 / 15 days
NOTES: Remove the individual firebars from the clamping bars where they are housed, making

sure to start from the upper row downwards, if required.

REFERENCE: fig.8.2

CLEANING THE UNDER-GRILL COMPARTMENT

OPERATION(1): checking and cleaning of the ashes below the grid's housing compartment, ac-

cessible from the lower lids "A". We recommend also removing the ashes on the slide guide of
the wheels on which the mobile grid's carriage slides.
OPERATION(2): checking and cleaning of the ashes from the air passage pipes accessible from
lids "B".

PERIODICITY(1): Once every 2/3 months.
PERIODICITY(2): Once every 6 months
NOTES: we recommend using an adequate vacuum.
REFERENCE(1)(2): fig. 8.2C

SMOKE FITTING

OPERATION: checking and cleaning of ashes deposited on lower part in correspondence of ex-

traction doors with the use of provided pipe brush.

PERIODICITY: 20 / 30 days
NOTE: also periodically check the flue and seals along the path.
REFERENCE: fig. 8.2B

CLEANING OF THE TUBES NEST

OPERATION: check and cleaning of the ashes inside the tubes nest; opening the upper door and

using the provided pipe brush. In case the turbolators are inserted (optional), careful to remove
them from each pipe before cleaning.

PERIODICITY: 5 / 10 days
REFERENCE: fig. 8.2D

8. CLEANING

tab. 8.2

8.2 Table of the periodical cleaning operations

29

FUEL HOPPER

OPERATION: check and cleaning with hopper empty from dust and deposits due to humidity and

type of fuel used.

PERIODICITY: 30 / 60 days
NOTES: check the fuel does not contain foreign bodies that might damage the screws.
REFERENCE: fig. 3.3.1B pos.16

To avoid dangerous concentrations in air that might trigger detonation or fire, in addi­tion to previous boiler cleaning operations, it is important to remove dust stored on the
thermal power station floor and on the boiler's external parts.

During all cleaning and maintenance operations, we recommend restoring the state of
the gaskets of the lids in the original dismantling conditions, to avoid emission of dust
and/or fumes inside the thermal power station. Replace any worn gaskets.

fig. 8.2A

fig. 8.2B

fig. 8.2D

fig. 8.2E

ASH COLLECTION DRAW

OPERATION: removal of ashes from the side collection draw.
PERIODICITY: visual check by lifting the seal lid, however no later than 2/3 days of continuous

functioning.

NOTES: open the two side hooks "A" and remove the draw from the handles, to disassemble.
REFERENCE: fig. 8.2A

fig. 8.2C

A

B

30

OPERATION

OBJECT OF THE

CHECK

PERIODICITY ACTIONS TO TAKE REFERENCE

CHECK

PRIMARY AND
SECONDARY AIR
FANS

BEGINNING SEA­SON

check that the fans turn and do not
cause vibrations, in case remove the
excess dust and dirt.

Fig.3.3.1A-B

GRID HANDLING
SYSTEM

BEGINNING SEA­SON OR AFTER A
LONG INACTIVITY
PERIOD

Check for foreign bodies on the slide rod
and that the end runs correctly function

Fig.xx

ELECTRIC SYS­TEM

BEGINNING SEA­SON OR AFTER A
LONG INACTIVITY
PERIOD

Test the differential switch functioning.
Check connections with the earthing
system.

REDUCERS

BEGINNING SEA­SON

check the oil level of the reducers from
appropriate warning light. If the level is
low, top-up with corresponding oil.

Fig.3.3.1A-B

LUBRICATION

GRID HANDLING
SYSTEM

ONCE A MONTH Clean and grease the slide bar Fig.10.2

AIR VENTILATION
PIPES BLADES

BEGINNING SEA­SON OR AFTER A
LONG INACTIVITY
PERIOD

lubricate the rotary transversal pin of the
internal blade of the primary and sec­ondary air pipe using spray oil

Fig.7.7

SCREW PINION
BEARING

BEGINNING SEA­SON

Using a greasing nipple, grease the
bearing.

Fig.3.3.1A-B

tab.9.2

9. MAINTENANCE

9.1 Generality

The heat generator must be submitted to regular maintenance to guarantee the efficiency of all
components determining the correct operating of the generator and its main yield. Tab. 9.1 sum­marises the main operations.

ATTENTION!!

BEFORE MAINTENANCE, DISCONNECT THE ELECTRIC ENERGY
FROM THE GENERATOR BY INTERVENING ON THE MAIN
SWITCH AND ENSURE THAT THE RESIDUE FUEL INSIDE THE
FIREBOX IS OFF AND HAS COOLED DOWN

ATTENTION!!

MAINTENANCE MUST ONLY BE CARRIED OUT BY QUALIFIED
STAFF

9.2 Table of the periodical maintenance operations

31

10. ANOMALIES, FAULTS AND MALFUNCTIONING - FAQ AND ANSWERS

10.1 Anomalies and faults table. FAQ and answers.

SIGN PROBABLE CAUSES SOLUTIONS

insufficient conveying of fuel

a) check there is sufficient fuel inside the hopper. a) fill the hopper with fuel.

b) check there are no objects inside the hopper
preventing the descending of the fuel or that the
same fuel has formed bridges.

b) re-mix the fuel inside the hopper.

a) check geared motor functioning fig.3.3.1.B
pos.22 by specifically observing whether the motor
turns, as well as the transmission chain's pinion.

a) ensure that the motor is pow­ered or call the technical after­sales assistance.

The fuel conveying screw
does not turn

d) removing the carter, check that the safety bolt
(fig. 10.1) fixing the pinion to the counter shaft is not
broken.

b) in case of empty rotation, mean­ing breaking of the bolt, call the
technical after-sales assistance.

e) removing the carter, check that the transmission
chain does not jump out from the pinion teeth due to
no tension.

c) call the technical after-sales as­sistance.

The fuel conical screw speed
cannot be regulated using the
manual variator

a) broken mechanical variator. a) call the technical after-sales

assistance.

The grid's movement rod
does not turn.

a) broken mechanical variator. a) call the technical after-sales

assistance.

Insufficient air for combustion

a) check operating of the fans fig.3.3.1A-B is not
prevented from foreign bodies inside the grid or that
the motor is correctly powered.

a) remove any foreign bodies and
check that the electric connector is
connected. Should the problem
persist, call the technical after-

sales assistance.
b) check that regulation knob fig.7.7 regulating the
opening of the blades loosens and tightens and that
the blades are not blocked by deposits, dust or oth­er.

b) clean the knob threading by re-

moving the deposits and lubricate.

On the contrary, call the technical

after-sales assistance.

c) check that the grid firebars' holes are not ob­structed by unburnt fuel residues.

c) clean as described in chap. 8

d) check any dust deposits on the fans blades. d) remove the dust using com-

pressed air.

tab. 10.1

ATTENTION!!

BEFORE PERFORMING THE OPERATIONS DESCRIBED IN CHAP. 9, DISCON­NECT THE ELECTRIC ENERGY FROM THE GENERATOR BY INTERVENING
ON THE MAIN SWITCH AND ENSURE THAT THE RESIDUE FUEL INSIDE THE
FIREBOX IS OFF AND HAS COOLED DOWN

32

10.2 Malfunctioning table. FAQ and answers.

SIGN PROBABLE CAUSES SOLUTIONS

Smoke flows back inside the
fuel hopper.

a) check the flue's draught depression is that
requested in paragraph 6.5

a) In which case, take technical precau­tions from sector qualified staff.

Incorrect combustion

a) check balancing between fuel capacity and
air capacity, with reference to that described
in chap. 7

a) If phenomenon persists, call the tech­nical after-sales assistance.

fig. 10.1

11. NOISE

11.1 Generality

The acoustic pressure levels of the generator are not significant.

11.2 Sound emission values sonora

Measurements taken in ambient type (thermal power station with surface over 6 sq m have high­lighted Leq,d continuous sound pressure levels and peak below 76 dB(A)

12. TERMINATION OF SERVICE AND SCRAPPING

12.1 Generality

The generator, fully manufactured with ferrous materials, does not contain damaging materials for
the environment.

12.2 Scrapping

At the end of the generator life-span, it constitutes "waste" as defined by Legislative Decree 3
April 2006, no. 152, and must be transferred to companies having Regional Authorisation for the
collection of Waste.

fig. 10.2

clean and grase

the slide bar

33

NOTES

34

D'Alessandro Termomeccanica

C.da Cerreto, 55 - 66010 MIGLIANICO (CH)

in the person of RAFFAELE D'ALESSANDRO

DECLARES

under his exclusive responsibility that the

BOILERS for SOLID FUELS,

WITH MANUAL and AUTOMATIC FEEDING, with THERMAL

POWER UP TO 300 KW

of the CSA GM Series

Models 30-45-60-80-100

to which this declaration refers are

COMPLIANT

With Directive 89/106/CEE (Construction Products), with Directive 73/23/CEE (Low Voltage), with
Directive 2004/108/CEE (Electromagnetic Compatibility) integrated with CE mark according to Di­rective 93/68 CEE.

The Harmonised Standards or technical specification (allocations) that have been applied in compli­ance with the "state-of-the-art", with regard to the safety of the products, in force in the EU, are:

EN 60335.1
EN 6100-3-2
EN 55014.1
EN 50165
EN 6100-3-3
EN 55014.2

Miglianico lì------------------------

D'Alessandro Termomeccanica S.r.l.

DECLARATION OF CONFORMITY

A. COPY OF DECLARATION OF CONFORMITY

35

D’ALESSANDRO TERMOMECCANICA S.r.l.

declares that:

the heat generators fed with non-powdered solid fuels with mechanical feeding manufac-

tured by D’ALESSANDRO TERMOMECCANICA S.r.l. :

correspond to the definition of which in point 2.3, of Collection R Ed. 2005 – File R.3. -

CHAP. R.3.D. (Partial switching off and fuelling system)

are equipped, if with nominal power above 100 kW, with integrated safety exchanger.

Miglianico (CH) 08/05/2007

In witness whereof

D’ALESSANDRO TERMOMECCANICA S.r.l.

C.da Cerreto, 55 - 66010 MIGLIANICO (CH) – Italy

Tel. [phone] Fax [phone]

http://www.caldaiedalessandro.it e-mail: [e-mail]

B. PARTIAL SWITCHING OFF DECLARATION