D'Alessandro Termomeccanica CSA30 GM User 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 ma-
chine:
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 con-
nected to the fire-prevention valve located on the side of the hopper
(ref. Fig. A). The storage filling state must be handled by an electro-
nic 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 gen-
erator.
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 gen-
erator 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 ge-
nerator 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, Stan-
dards 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 ow-
ner 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 Stan-
dard 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, there-
fore 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 summa-
rised 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 us-
ing suitable hoisting means.
For hoisting the generator, refer to the empty mass indicated, for each type, on to the da-
ta plate.
ATTENTION!!
THE TRANSPORT AND HANDLING OF GENERATORS MUST BE
CARRIED OUT BY SPECIALISED STAFF USING SUITABLE HOIST-
ING MEANS AND INDIVIDUAL PROTECTIONS.
5.2.1 Lifting and handling on platform

20