Alfa Plam GRANDE 37 User manual

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A.D.METALNA INDUSTRIJA VRANJE
Radnička br: 1
PELLET BOILER
GRANDE 37
INSTRUCTIONS FOR USE, MAINTENANCE AND INSTALLATION
ENG.V.1.0_JUN 2018

DEAR CUSTOMERS !
Thank you for purchasing the GRANDE 37 Boiler.
Please read this user guide completely and carefully before you install and start using your GRANDE37 Pellet Boiler.
The heating units (hereinafter referred to as "pellet boilers" or "boilers") of Alfa Plam A.D. company have been designed,
manufactured and tested in accordance with the requirements of the applicable European Directives on safety standards.
These instructions are intended for end users, installers and technicians certified for operations on GRANDE 37 Pellet
Boilers. If you have any questions regarding the instructions or need an explanation, please directly contact the
manufacturer or an Alfa Plam authorized dealer.
Printing, translation or reproduction of the user guide, even partially, is only possible with the written permission of the Alfa
Plam company.
The boiler uses pellets as fuel. It operates automatically and uses a screw conveyor for dosing the pellets from the pellet
tank, which is part of the device placed above the boiler part of the plant. Fuel pellets are filled from above through the lid
to be used for that purpose. Make sure that the boiler is properly dimensioned with respect to the heating system and
energy requirements of the facility. Connection and commissioning of the unit should be done by a person authorized by
the Alfa Plam company.
The flame that develops in the boiler during normal combustion of wood biomass releases just the right amount of carbon
dioxide (CO2) that would be released by natural decomposition of the wood. The amount of CO2formed during combustion
or decomposition of the wood corresponds to the amount absorbed by the tree during its life cycle and turned into oxygen
and carbon. By the use of non-renewable energy sources (coal, fuel oil, gas), unlike those energy sources that are based
on wood, much larger amounts of CO2are released in the air. Carbon dioxide builds up during the years and contributes to
enhancing the greenhouse effect. The principle of clean combustion meets all the requirements of preserving the
environment, and the Alfa Plam company has directed all its development and its activities in the direction of fulfilling this
goal.

TABLE OF CONTENTS
1. THE PURPOSE OF THE USER GUIDE......................................................................................................1
2. RESPONSIBILITY OF THE MANUFACTURER ..........................................................................................1
2.1. REQUIRED GENERAL STANDARDS ....................................................................................................1
2.2. The following harmonized standards and/or technical specifications have been applied:...................1
2.3. TRANSPORT AND MOVEMENT OF PELLET BOILERS.......................................................................... 1
2.4. RESPONSIBILITY OF THE INSTALLER ............................................................................................... 2
3. INSTALLATION ..................................................................................................................................... 2
3.1. SETTING UP .....................................................................................................................................2
3.2. THE FLUE GAS EXHAUST SYSTEM.................................................................................................... 4
3.3. AIR SUPPLY ..................................................................................................................................... 6
3.4. CONNECTION TO THE POWER SUPPLY ............................................................................................. 6
4. NON-RETURN VALVE............................................................................................................................7
4.1. MIXING VALVE..................................................................................................................................7
5. BOILER FIRST STARTING ......................................................................................................................7
6. SAFETY WARNINGS..............................................................................................................................8
6.1. SAFETY WARNINGS FOR SERVICE PERSONNEL................................................................................8
6.2. SAFETY WARNINGS FOR USERS.......................................................................................................8
7. INSTRUCTIONS FOR BOILER SAFE STARTING AND SAFE CLEANING .....................................................9
7.1. ROUTINE MAINTENANCE AND CLEANING......................................................................................... 9
7.2. INSPECTION AND PARTS THAT NEED TO BE MAINTAINED............................................................... 10
7.3. ADDITIONAL MAINTENANCE .......................................................................................................... 10
8. IMPORTANT SAFETY INFORMATION................................................................................................... 10
9. PELLET QUALITY IS VERY IMPORTANT............................................................................................... 10
9.1. PELLET STORAGE........................................................................................................................... 11
10. BOILER CONTROL SYSTEM................................................................................................................. 11
10.1. Electrical connection diagram......................................................................................................... 12
10.2. Control panel (display) –keys and functions .................................................................................. 12
10.3. Menu ............................................................................................................................................. 14
10.3.1 Combustion Management Menu.......................................................................................................... 15
10.3.2 Heating Management Menu ................................................................................................................ 16
10.3.3 Chrono Menu ...................................................................................................................................... 17
10.3.4 Load Menu.......................................................................................................................................... 18
10.3.5 Time and Date Menu ........................................................................................................................... 18
10.3.6 Remote Control Menu ......................................................................................................................... 18
10.3.7 Language Selection Menu ................................................................................................................... 19
10.3.8 Keyboard Menu................................................................................................................................... 19
10.3.9 System Menu...................................................................................................................................... 19
10.4. Ignition of the boiler and working phases........................................................................................ 19
10.5. Possible problems and solutions .................................................................................................... 20
11. INFORMATION ON THE DISPOSAL AND STORAGE OF THE BOILER ...................................................... 22
12. TECHNICAL CHARACTERISTICS OF THE GRANDE 37 - PELLET BOILER................................................ 23
13. DIMENSIONS OF BOILER –GRANDE 37 .............................................................................................. 24
14. Scheme of hydraulic installation of pellet boiler –GRANDE 37 ............................................................ 25

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1. THE PURPOSE OF THE USER GUIDE
The purpose of this User Guide is to invite the user to take all necessary safety precautions and provide all the necessary
actions that will guarantee proper and safe use of the heating appliance.
AMENDMENTS
This User Guide takes into account all the advanced technology that existed at the time of launching the pellet boilers on
the market.
It shall not apply to the products already on the market, accompanied by appropriate technical documentation, and
cannot be considered incomplete or inadequate after each change, adaptation or application of new technologies on
newer products.
The contents of this booklet should be carefully read and studied. Any information presented in this booklet should be
considered necessary for the proper installation, use and maintenance of your boiler.
Instructions should be carefully stored in a safe place. Instructions for use, maintenance and installation shall be
considered an integral part of the pellet boilers.
If the boiler is sold to a third owner, care should be taken to deliver this User Guide together with the boiler.
If the instructions happen to get lost, you can request a new copy from the manufacturer or an authorized dealer.
2. RESPONSIBILITY OF THE MANUFACTURER
By the delivery of this User Guide the Alfa Plam company a.d. disclaims any criminal or penal liability for direct or indirect
causing of:
-accidents and /or damage that occurred due to non-compliance with standards or notes contained in this User
Guide;
-accidents and /or damage that occurred due to improper or incorrect use by the user;
-accidents and /or damage due to modification or maintenance without authorization from the manufacturer Alfa
Plam a.d.;
-accidents and /or damage caused by the use of non-original or inappropriate spare parts.
Installing is the sole responsibility of the installer.
REQUIRED GENERAL STANDARDS
The GRANDE 37 product is manufactured in accordance with the following directives:
2006/42/EC Machinery Directive (MD)
2014/30/EU ElectroMagnetic Compatibility Directive (EMCD)
2014/35/EU Low Voltage Directive (LWD)
2011/65/EU Restriction of the use of certain hazardous substances Directive (RoHS Directive)
2009/125/EC Directive, Ecodesign
The following harmonized standards and/or technical specifications
have been applied:
-EN 303-5;
-EN 50581;
-EN 61000-6-2;
-EN 61000-6-3;
-EN 60335-1;
- EN 60335-2-102;
- EN 62233;
- Commission Regulation (EU) 2015/1189;
TRANSPORT AND MOVEMENT OF PELLET BOILERS
Take care of your own safety when moving the boiler.
Prior to transport and movement of the pellet boiler, which should be done with maximum safety precautions, make sure
that the load capacity of the cart is large enough to lift the boiler. Avoid sudden movements and/or improvised ways of
moving the boiler. Handling of the boiler in terms of lifting, shifting and moving from one place to another can be done by
the means of rod-shaped carriers threaded on one end. These rod-shaped carriers (4 pieces) are screwed on points
provided for that on either side of the boiler (Fig. 1). Four men are required for this operation. Boiler brackets are delivered
with the boiler!

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Figure 1. Handling the boiler using the bracket
GATHER ALL PACKAGING MATERIAL AND KEEP IT AWAY FROM THE REACH OF CHILDREN. PARTS OF PACKAGING
MATERIAL (BAGS, FOILS, STYRENE) POSE A CHOKING HAZARD.
RESPONSIBILITY OF THE INSTALLER
The responsibility of the installer is to verify the correctness of installation, air supply and all the conditions that are
required for the installation of pellet boilers.
The responsibility of the installer is to verify compliance with legal regulations in the place where the boiler is installed.
The pellet boiler must be used in accordance with the instructions for use, maintenance and installation, and with respect
to the safety standards prescribed by the regulations in force at the place where the boiler is installed. Obligations of the
installer are defined by the UNI Standard 10683. Installers should check:
-the type of device to be installed,
-the convenience of the installation of the device, i.e. the minimum size of the space in which the pellet boiler is
intended to be installed,
-compliance with regulations concerning draining the flue gases, as identified in the instructions provided by the
manufacturer of the heating plants,
-the inner diameter of the chimney, the material from which it is made, whether it is straight and correct, and
whether it is free from clogging,
-height and possible vertical extension of the chimney,
-the existence and proper resistance of the chimney caps,
-the possibility of supply of the outside air,
-the possibility of concomitant use with other heat sources connected to the existing devices.
If the existence of the above indicated is established, the installation can begin. Follow with due attention the
manufacturer's instructions, the current safety norms and standards for fire protection.
After the first start of the boiler, it is necessary to carry out trial operation of the unit for at least 30 minutes, in order to
check whether all the required conditions are met.
Upon completion of the installation, the installer must submit the following documents to the buyer:
-operating, maintenance and installation instructions, supplied by the manufacturer (if not included as part of
the boiler),
-documents required by the applicable regulations,
-should teach the client how to use the device, how to carry out routine maintenance and cleaning.
3. INSTALLATION
Responsibility for the installation works at the place where the boiler is installed rests solely with the purchaser. Before
beginning the installation works, the installer should check whether all safety requirements are met, in particular:
-Check whether the regulations for the installation of pellet boilers meet local, national and European standards.
-Comply with all requirements stated in this document.
-Check that the pipes and lines for air supply correspond to the type of installation.
-Do not run a temporary electrical connection using inappropriate cables.
-Check grounding of electrical installations.
-Always use personal protective equipment and comply with all prescribed safety precautions.
-Always leave enough space for maintenance.
-Measure emission of flue gases after completion of the installation.
SETTING UP
It is advisable to remove packaging material of the pellet boiler exactly at the place where the boiler is to be installed.
Threaded
rods

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If the adjacent walls and flooring are made of materials that are not heat-resistant, it is necessary to ensure adequate
protection and use of non-combustible insulation material.
To protect the flooring from combustible materials, it is mandatory to insert a metal plate that is 3 to 4 mm thick with the
front side at least 30 cm greater than the depth of the boiler, under the boiler. The pellet boiler must be installed in
accordance with the sketch, which defines the distance from the walls (Figure 2)
Figure 2. The minimum distance of the boiler from the walls
If the pellet boiler is installed in the boiler room where there are other devices that suck the air (other boilers, various
types of suction fans, etc.), make sure that the volume of air entering the premise is sufficient to guarantee safe
operation of the boiler.
If the chimney passes through the ceiling it must be sufficiently insulated with coating of non-flammable insulation
material.
After the pellet boiler is set in place, level it (bring it to a horizontal position) with adjustable legs.
The flue gas exhaust system MUST NOT BE CONNECTED TO:
-the uptake used by other heating devices (boilers, furnaces, fireplaces, etc.),
-the system for air extraction (from the hood, suction fan, etc.).
It is prohibited to install barriers for the regulation of the flow of flue gases!
The connector of the Ø80 mm flue pipe from the pellet boiler to the chimney should have the following characteristics:
-total length of up to 5 m (in the case of the connector of greater length connecting pipes diameter should be
increased to Ø130 mm),
-each elbow of 90˚ reduces the total length of the flue pipe by 1 m,
-cover intended for cleaning should be located on each elbow,
-pipe joints need to be sealed.
In case the resistance in the exhaust system is too high (numerous elbows, inappropriate terminations, bottlenecks
etc.), the flue gas exhaust is not guaranteed and it is necessary to increase the connecting pipes and elbows to greater
dimensions, i.e. to Ø130 mm. Also, when the chimney does not provide proper flue gas exhaust, it may cause
malfunction and consequently alarm activation in the GRANDE boiler. It is recommended that the chimney is inspected
by a professional person before installation of the GRANDE Boiler.
The system for discharging flue gases from the boiler functions at the underpressure generated in the combustion
chamber and the faint pressure in the Ø80 mm flue pipe. Therefore, care should be taken to provide complete tightness of
the flue pipe.
It is necessary to carefully analyze the position and condition of the area through which the chimney passes. If the flue
pipe passes through the wall and/or roof it should be suitably insulated in accordance with the safety regulations for fire
protection.

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Make sure that the room in which the pellet boiler is installed has a sufficient amount of clean air, which guarantees
proper combustion. The air intake pipe should be of a minimum outer diameter of 110 mm and of a maximum length of
10 m. For every 90˚ elbow the maximum length is reduced by 1 m. If the length is too large, it is necessary to increase the
diameter of the air supply pipes.
If the grating is placed on the façade, the area of the air inlet port must be at least 100 cm2or larger.
The device works on 220-230 V, 50 Hz voltage. Make sure that the cables for electrical connection do not pass under the
boiler, that they are installed away from heated surfaces and that they do not come into contact with sharp objects that
may damage them. If the pellet boiler is under increased electrical voltage, the durability of electrical components will be
greatly reduced.
Do note remove the plug from the socket in order to switch off the boiler until the flame in the boiler is extinguished.
THE FLUE GAS EXHAUST SYSTEM
The flue gas exhaust system shall be in accordance with the applicable regulations. Do not connect the flue pipe of the
boiler to the chimney to which other furnaces are connected (Figure 3). The flue gas exhaust system must not end in a
closed and/or in semi-enclosed areas, such as garages, narrow passageways, hallways, sub-corridors and the like. After
connecting the boiler to the chimney, an authorized chimney sweep should check if there are any damages in the
connection and whether the connection is properly sealed. If the chimney is not suitable it must be executed in
accordance with the foregoing requirements (Section 3.1).
Figure 3
An uptake should be grounded in accordance with the applicable regulations. (Grounding is legally defined and
regulated.)
Grounding should be independent of the heating unit.
As far as dimensions and material are concerned, the flue pipe must meet the UNI 9615-9731, UNI 10683 –EN1856-1
standards.
Poorly preserved flue pipes or flue pipes made of inappropriate material (asbestos, galvanized sheet metal, porous
materials) do not comply with applicable regulations and adversely affect the operation of the boiler.
Flue gases can be discharged via the conventional chimney (see figure below) if the following requirements have been
met:
-Check if the chimney is maintained. For proper maintenance and/or restoration contact the chimney sweep.
-Flue gases can be discharged directly into the stack only if it is equipped with an inspection hole and if the
chimney is not larger than 20 X 20 cm, i.e. if the diameter is not larger than 20 cm.
-If the chimney is larger, appropriately insulated stainless steel tube (of a corresponding diameter) should be
inserted in it.
-Make sure that the chimney connection is properly sealed.
-Avoid contact with combustible material (ember) and in any case, install flame retardant insulation.
When fittings are used for connecting the pellet boiler to the chimney, elbows equipped with a cleaning hole shall always
be installed (Figure 4). Using the elbow with a cleaning hole enables routine cleaning without the need for dismantling the
pipe. Exhaust gases in the chimney connector are under slight pressure, thus it is necessary to make sure to check that
the cover for ash cleaning is completely hermetically sealed and that it is closed tightly after each cleaning. Make sure
that everything is properly put back in its place and check the condition of the seals.

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Figure 4. Cleansing element
Pipes should be connected in such a way that their narrow connection element is always turned upward (Figure 4).
We recommend you do not make long horizontal sections of connection to the chimney. If there is no other possibility,
pipes should not have a slope downward, but upward to at least 5%. The horizontal part should not be longer than 2
meters.
Direct connection of the boiler to the chimney with a straight pipe greater than 1 meter in length is not recommended.
Figure 5. Figure 6
Maximum allowed length of 80 mm diameter flue gas pipe to its point of entering the chimney is 6 m. After that the diameter
of a flue gas pipe must be increased to 110 –120 mm. In that case, each elbow accounts for 1 m length. For example, if
there are three bends of 80 mm diameter, the length of the flue gas pipes of 80 mm diameter is thus changed by 3 m. Just
another 3 m of a straight pipe may be placed to the entrance of the chimney, in order to get 6 m length of the flue gas pipes
of 80 mm diameter. After that, the bend must be enlarged, led back to flue gas pipes or should enter the chimney of a
greater diameter, 110 –120 mm.
Care should be taken not to use bends of a sharp angle of 90º. They must be of a certain radius or made in segments.
Sharp angle bend increases resistance of the smoke flow through the bend.
- Each bend must be equipped with the cleaning door.
- Joints between the connection pipes must be tightened.
- For greater spacing, use 100 mm diameter connector. In that case, length of up to 8 m is allowed.
INSULATION AND DIAMETER OF ROOF OPENING
After you have determined the final position of the boiler, make an opening for the passage of the flue pipe. It depends on
the method of installation, pipe diameter and type of walls or roof through which the flue pipe is run. Insulation should be
done using mineral insulation material (glass wool) of nominal density greater than 80 kg/m3.
Ideal underpressure depends primarily on the lack of barrier contractions and/or angular connections. It is recommended
the elbows be at 30˚, 45˚ and 90˚. The 90˚elbows should be three-part elbows (Figure 7). In any case, it is necessary to
ensure that the length of the initial vertical part of the flue pipe is at least 1.5 meters. Proper exhaust of flue gases is
guaranteed in this way only.
Figure 7.

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AIR SUPPLY
For proper combustion it is necessary to renew the air in the room with fresh air coming through an air opening in the
wall through the grate at door of the boiler room or through the open window. These solutions ensure proper combustion
and proper operation of the boiler.
The opening for air supply should be protected with the mesh against rain, wind and insects.
The opening should be located on the outer wall of the room where the pellet boiler is installed.
The UNI Standard 10683 prohibits bringing air from the warehouse for storing flammable materials or from the premises
where there is a risk of fire.
If there are other combustion devices in the room, it is necessary to ensure a sufficient amount of air for proper
combustion within all existing devices, as well as to take into account all the technical characteristics of all ventilation
systems built-in in the boiler room.
Figure 8.
CONNECTION TO THE POWER SUPPLY
The device must be connected to the electricity grid. Our boilers are equipped with an electrical cable for medium
temperature. If the power cord is damaged it must be replaced, so contact our authorized service. Before starting work on
the electrical connection, care should be taken about the following:
Make sure that the characteristics of electrical installations comply with data on the boiler.
The flue gas exhaust system should be grounded in accordance with local regulations. (Grounding is required by
law.)
The power cord must not in any case be exposed to the ambient temperature of over 80˚C. If you want to
connect the boiler directly to the power grid, it is necessary to install a two-pole switch, suitable for the mains
voltage in accordance with the applicable regulations, with contact spacing of at least 3 mm. The green-yellow
earth conductor must be disconnected in the switch. The double pole switch must remain accessible after
finishing the installation of the boiler.
Connecting to the power supply
The pellet boiler should be connected to the electricity grid. The electrical connection cable is 3 m long, white in colour
and marked "220 V". Another connection cable is black, intended for connection of the circulation pump and marked
"Pump".
Figure 9.
White –boiler supply (220 V)
Black –circulation pump

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If the power cord is damaged, replace it. Replacement must be done only by an authorized person.
The power connector should remain available after the final installation of pellet boilers.
After installing the boiler the measurement of emission of flue gases is required.
4. NON-RETURN VALVE
Installation of a non-return valve in the hydraulic heating system is mandatory.
The function of the non - return valve is to prevent cooling of the water in the boiler and condensation in the boiler
and flue pipes. Condensation can occur as long as you do not spend 2 –3 fuel tanks.
Occurrence of condensation in the boiler is normal for the first ignition.
The non –return valve is installed at the outlet of the pump, behind the pump, instead in front of the pump. Care
must be taken about the direction of installation of the valve. Also, when purchasing, care must be taken of
whether the valves are placed on horizontal, on vertical line, or as inclined, because there are valves that are
installed only horizontally or only vertically, or that are universal.
Ensure that the non –return valve can be opened easily (try by finger), so that it can be opened by the pump power.
The non –return valve is placed behind each pump. If there are more pumps in the installation, then more non –
return valves are needed.
Connections to the boiler are 1". Non –return valves should also be 1", or larger.
If the non –return valve is not installed, the guarantee will not apply!
Diagram for installation of non –return valve:
1. Boiler Grande,
2. Circular pump,
3. Non - return valve
MIXING VALVE
- It is recommended that the hydraulic installation is fitted with a four –way mixing valve.
- For small installation a mixing valve is not required.
- For large installation a mixing valve is recommended.
- For underfloor heating installations a mixing valve is required. We recommend special thermostatic valves for underfloor
heating, which regulate the temperature of the water entering the floor of up to 50ºC. If there is no such a thermostatic
mixing valve, temperature of water entering the flooring system must be regulated in some other way. It is the job of the
designer and the installer.
- The mixing valve should be 1".
5. BOILER FIRST STARTING
The first starting of the boiler must be done only by an authorized person, otherwise the warranty becomes invalid.
INSTRUCTIONS FOR THE SAFETY OF PERSONS, ANIMALS OR PROPERTY
We want to draw attention of installers to some procedures to be followed so that proper installing of pellet boilers could
be guaranteed. It is necessary to comply with the required standards, but they themselves are not sufficient. For more
detailed information, it is necessary to read the rest of the instructions for use, maintenance and installation.
Connect the pellet boiler to the power grid.
Do not allow children or animals to approach the boiler.