Pellergy A-60 User manual

SAVE THESE INSTRUCTIONS pellergy.com
Installation Manual
Alpha Series
Wood pellet-firedcentralheatingboiler
FOR USE IN CANADA/USA
UL 391-2010
CAN / CSA-B366.1-11
V1.0 27AUG2014

Table of contents
2
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 ...................................................................................................................................... 10
1.2.1 Adjust barometric damper.............................................................................................................................11
1.2.2 Essential parts for field assembly........................................................................................................................11
1.3 Boiler/heater room/installation room ............................................................................................12
1.4 Fuel storage ................................................................................................................................12
2. For the Installer................................................................................................................13
2.1 Delivery, packaging....................................................................................................................... 13
2.1.1 Alpha Series.................................................................................................................................................13
2.1.2 Optional accessories.....................................................................................................................................13
2.2 System ........................................................................................................................................ 14
2.2.1 Area of use ...................................................................................................................................................14
2.2.2 Standards ............................................................................................................................................................14
2.2.3 Circulation pump...........................................................................................................................................14
2.2.4 Return temperature.............................................................................................................................................14
2.2.5 Accumulator tank..........................................................................................................................................14
2.2.6 Heating water................................................................................................................................................14
2.2.7 Water-side resistance (pressure loss) of the Alpha Series pellet central heating boiler..................................15
2.2.8 Operating with external control ...........................................................................................................................15
2.3 Combustion air ....................................................................................................................... 16
2.3.1 Operating with room air.................................................................................................................................16
2.4 Bringing the unit inside ........................................................................................................... 17
2.4.1 Removing hopper..........................................................................................................................................18
2.4.2 Removing control panel.................................................................................................................................19
2.4.3 Removing floor plate............................................................................................................................................21
2.5 Minimum clearances ............................................................................................................... 21
2.6 Dimensional sketches ..................................................................................................................22
2.7 Installation sequence .................................................................................................................... 22
2.8 Installing, preparing for installation .......................................................................................... 23
2.9 Assembling of hopper lid for Alpha Series without vacuum feed unit ............................................ 24
2.10 Fitting feed unit on hopper ............................................................................................................ 26
2.12 Fitting cleaning tools .............................................................................................................. 28
2.11 Installing the exhaust pipe ............................................................................................................ 28
2.13 Hydraulic schematic................................................................................................................ 29
2.13.1 Hydraulic installation –overview ...................................................................................................................32
2.13.2 Dimensioning the storage room..........................................................................................................................33

Table of contents
3
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 ......................................................................................................................................... 39
3.3 Safety device and function checks .................................................................................................. 42
4. For the Service Technician................................................................................................. 42
4.1 Start-up and operating instructions .......................................................................................... 42
4.2 Service and repair work........................................................................................................... 42
4.3 Safety device and function checks .................................................................................................. 42
4.4 Technical data for calculating the flue gas system .........................................................................43
4.5 Technical data –General ............................................................................................................... 43
4.6 Service level ................................................................................................................................44
4.6.1 Parameters...................................................................................................................................................46
4.6.2 Start-up.........................................................................................................................................................50
4.6.3 Actuator test..................................................................................................................................................50
4.6.4 Settings ........................................................................................................................................................50
4.7 DisplayPlusplus basic settings ........................................................................................................ 52
4.8 Installation instructions for 3-way changeover unit, fire protection collars, suction probes...............54
4.8.1 Delivered parts, packaging............................................................................................................................54
4.8.2 Notes on installing the suction probes................................................................................................................55
4.8.3 Notes on installing the supply and return air hoses .......................................................................................56
4.8.4 Notes on installing the changeover unit.........................................................................................................58
4.8.5 Installation ....................................................................................................................................................59
4.8.6 Affixing stickers....................................................................................................................................................64
4.8.7 Electrical connections ...................................................................................................................................64
4.9 Basic Alpha Series 100–260 circuitry .............................................................................................. 65
4.10 Alpha Series connection diagram ................................................................................................... 66
5. Commissioning checklist................................................................................................67
6. Maintenance checklist.....................................................................................................71

4
1.
ImportantinformationfortheTechnician
DANGER
DANGER
CAUTION
WARNING
DANGER
DANGER
1. Important information for the Technician
1.1 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. Installation should be performed only by appropriately qualified
technicians.
1.1.1 Importantinformationbeforeyoubegin
This manual contains data with US units. The units in the original manual are European units. If there is a data
conflict between these units, the data with European units is always valid.
The original manual is written in German –this is an English translation. In case of conflicts, the German version
takes precedence.
Please follow the safety instructions (symbols) on the machine!
Please refer to the instructions in chapter 1.6!
The specified safety requirements are to be followed in accordance with nationally
applicable regulations, standards and guidelines.
1.1.1 Cautionsymbols
This means that you must follow the safety instructions. There is a slight risk of
injury.
This means that you must follow the safety instructions. There is a slight risk of
injury.
This means that it is essential that you follow the safety instructions. There is a
veryseriousriskofinjuryor death.
This indicates that there is a very serious risk of injury or death by high voltage.
La beli d e nt G m b H Art.-N o. : W 08 -05
INFORMATION
Ignoringthewarningsidentifiedcanleadtomalfunctionof,ordamageto,theboi-
ler/heaterorheatingsystem.

1.
ImportantinformationfortheTechnician
5
CAUTION
CAUTION
CAUTION
CAUTION
WARNING
CAUTION
CAUTION
CAUTION
CAUTION
1.1.2 Liability exclusion
All work should be performed exclusively by trained personnel. Local safety regulations must be complied with in
all cases; in the event of a conflict and/or contradiction between these regulations and the working instructions
in this document (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. No liability is accepted for errors in translation.
1.1.3 Safety instructions
Riskoffireorexplosion.
Do not use chemicals or fluids to start the fire.
Healthandenvironmentalhazard.
Do not burn garbage, gasoline, naphtha, engine oil, or other inappropriate materials.
Opening door can crush and cut.
Neverput hands between door and frame of theheating chamber onthe hingeside
when opening door.
Closing door can crush and cut.
Never put hands between door and frame of the heating chamber.
Watch for other people, especially children.
Entanglement hazard.
Do not open cover of charging auger when heating.
Handle with care when servicing charging screw.
Ashtraycancrushandcut.
Never put hands between ash tray and frame.
Never put hands into closing bracket.
Never put hands between ash tray and closing bracket.
Coverplateforpelletchambercancrushandcut.
Takecare when opening the cover plate.
Only authorized personnel is allowed to open cover plate.
Closing door can crush and cut.
Never put hands between door and frame of the pellet chamber when closing door.
Never put hands between door and closing bracket of the pellet chamber when
closing door. Never put hands into the hinge area when opening door.
Opening door can crush and cut.
Never put hands between door and frame of the pellet chamber on the hinge side
when opening door. Never put hands between door and closing bracket.

1.
ImportantinformationfortheTechnician
6
CAUTION
CAUTION
CAUTION
CAUTION
DANGER
CAUTION
WARNING
DANGER
WARNING
Ashtraycancrushandcut–removingashtray.
Never put hands between frame of boiler/heater and ash tray when removing ash
tray.
Ashtraycancrushandcut–mountingashtray.
Never put hands between frame of boiler/heater and ash tray when mounting ash
tray.
Ashtraycancrushandcut–displacingashtray.
Never put hands between floor of the heating boiler and ash tray when moving ash
tray.
Pinch point hazard.
Never put hands between cover plate of heating chamber and housing when ope-
ning or closing.
Smoke gas danger.
Make sure there is adequate ventilation in the boiler room.
Hotwater–hotsteam.Injuryhazard.
Safety devices (such as relief valve) will open automatically and release hot water
or hot steam. Keep away from safety devices. Do not operate safety devices manu-
ally when system water is hot or when device is in operation.
Fire hazard.
Lack of water can lead to fire in Pellet Hopper.
Do not operate this device when water level in water container is below minimum!
Do not use fluids other than pure water.
Monitor the water level monthly and refill up to minimum level when necessary.
Always keep water container closed with original lid. –Spare no. 007073.
See Alpha SeriesOperatingManualchapter3.7forcontrolandrefillprocedure.
Riskoffireorexplosion.
Exposure may result in severe injury or death.
Do not fill with garbage, drain oil, gasoline, other flammable liquids or any other
fuelthanthose listedonthe ratingplate.
Do not use chemicals to ignite fuel.
Do not use chemicals, sprays or flammable substances to clean combustion room
or any burner component.
Donot use boiler/heater cleaners.Do notfillorlight burner manually.
Do not smoke! Do not handle with open fire. Keep away any source of ignition.
Do not open combustion chamber door during operation, power failure or any
alarms.
Fall hazard.
Do not sit, stand or walk on machine.
Keep children away.

1.
ImportantinformationfortheTechnician
7
WARNING
DANGER
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
CAUTION
Fire hazard.
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.
La beli d e nt G m b H
Art.-N o. : W 0 8 -0 5
Hazardous voltage.
Do not remove cover.
Keep away from electric components.
Disconnect power before servicing or cleaning.
Burnhazard–hotsurface.
Do not touch frame, cover or inside of the heating chamber when heating.
Cool down before cleaning and servicing.
Keepchildrenaway.Keeppets away.
Do not touch backside, chimney or any other pipework during operation.
Injuryhazard.
All components and surfaces keep hot for a long period after switching off unit!
Do switch off and cool down unit two hours before cleaning or touching combustion
room or any components.
Use heat-proof hand cloves.
Use provided tools.
Healthhazard.
Combustion particulates may contain harmful substances.
Use a fine-dust face mask during cleaning.
Turningscrewcancrushanddismember.
Keep hands out of feedopening.
Do not remove cover during normal operation.
Hand crush hazard.
Automatic start-up if safety switch is activated.
Do not push safety switch.
Moving parts behind the combustion chamber door may start automatically –this
can lead to loss of fingers or other serious bodily injury.
Disconnect from power before opening combustion chamber door.
Riskofhealthhazard.
Do not connect to an existing boiler/heater system.
Crush hazard.
Opencoveroftheelectronicunituntilitisclamping.
Ifnotclampingthecover mayfalldown.
Machine starts automatically.
WARNING Moving parts can crush and cut.
Do not remove guarding.
Do not touch rotating parts.
Keep children away.
Keeppetsaway.

1.
ImportantinformationfortheTechnician
8
WARNING
CAUTION
WARNING
DANGER
WARNING
CAUTION
WARNING
WARNING
Riskofhandinjury.
Takecare when opening the cleaning flap. Cleaning flap can open suddenly.
When opening the cleaning flap, use the tool provided and wear protective gloves.
Pinch point hazard.
Take care when closing the cover of the smoke funnel chamber.
Crush hazard.
Payattentionwhenmovingthemachinewithcraneorforklift.
Smoke gas danger.
Mount a warning plate on door of heating room.
Healthhazard.
In case of a runaway fire or if flue pipe becomes red hot, disconnect power if the
plug, main switch, or circuit breaker is safe to reach. Call the fire department (911)
and evacuate the building. Do not enter smoke-filled rooms to disconnect power.
Injuryhazardbyhot waterorsteam.
Safety devices (such as relief valve, drain valve) will open automatically and res-
lease hot water or hot steam. Keep away from safety devices. Do not operate safety
devices manually when the system is hot.
Health hazard from chemical substances.
Some states list chemical substances known to cause cancer, birth defects, death,
serious illness or other reproductive harm. This product may contain such sub-
stances, either from the fuel, fuel combustion, or in components of the product
itself.
Pelletfeedsystem:Service,MaintenanceandRules
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
inanyway.
For use in combination with Pellergy Alpha Series pellet-fired central heating
boiler/ furnace only.
Do not use to transport any material other than wood pellet fuel listed on the boiler
nameplate or in the boiler manuals.
Do not use for vacuum cleaning.
The pellet feed system starts automatically and will make noise. People who are
easily startled or with cardiac problems should keep away.
WARNING
Necessary tasks.
The heat exchanger, flue pipe and chimney must be cleaned regularly to remo-
ve accumulated creosote and ash. Ensure that the heat exchanger, flue pipe and
chimney are cleaned at the end of the heating season to minimize corrosion during
the summer months. The appliance, flue pipe and chimney must be in good condi-
tion. These instructions also apply to a draft inducer if used.
La beli d e nt G m b H
Ar t.-N o.: W 08 - 0 5

1.
ImportantinformationfortheTechnician
9
DANGER
WARNING
DANGER
WARNING
La beli d e nt G m b H
Art.-N o. : W 0 8 -0 5
CAUTION
Pelletfeedunit:Fireandexplosionhazard
Can lead to serious injury or death! Ground suction hoses must be installed as
described in the installation manual at every connection to avoid static sparking
and dust ignition. The pellet feed unit is for use with the day hopper only. The pellet
feed unit must be braced, anchored, or strapped to avoid falling or shifting during
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.
Do not use pellet feed automatic changeover unit inside pellet storage or whe-
re there is a lot of dust present. Connect delivery hoses to pellet feed automatic
changeoverunitasdescribedintheinstallationmanualtoavoidstaticsparkingor
dustignition.
Clearances and installation instructions
Minimum clearances from combustible or noncombustible construction:
2 inches left, 12 inches back, 24 inches top (right),
6 inches right side, 22 inches front –see chapter 2.5
Access to the back side is required to allow the service of parts such as the drain
valve, relief valve and inspection fittings.
Thisunitisfordryindoorinstallationonly.Notforinstallationoncombustiblefloo-
ring.Notforinstallationinmanufacturedhomesormobilehomes.
Riskofseriousbodilyinjuryordeath.
Thisboiler/heaterisequipped for onetypeofwoodpelletsonly.Checkthename-
plate behind top lid for the correct pellets. Do not use this boiler/heater with any
fuel other than the one listed on the name plate. Failure to use the correct fuel
can cause problems which can result in death, serious bodily injury or property
damage.
Fire hazard.
Do not operate with incorrect draft. Check nameplate behind top lid for correct
draft.
Do not operate while refilling the bulk hopper.
Do not operate with the door or ash removal covering open or when the ash box is
removed.
Do not store fuel or other combustible material within the boiler room.
Inspect and clean flues and chimney regularly.
Have a trained professional inspect safety devices, such as the relief valve and
drain valve, regularly.
Caution
For supply connections use 12 AWG or larger wires acceptable for at least 176 °F
(80°C) onaGFCIcircuitonly! The boiler requires a dedicated 20A circuit.
WARNING
Pelletfeedautomaticchangeoverunit:Injuryhazardbymovingpartsandelec-
tricity
Can lead to serious injury or death.
Device starts automatically. Device restarts automatically after power failure.
Do not remove cover.
This part should be serviced by trained personnel only..
La beli d e nt G m b H
Art.-N o. : W 0 8 -0 5

1.
ImportantinformationfortheTechnician
10
DANGER
1.2 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
UL2523/UL103. All relevant datatosizeaflue properlyislisted under Technical data for calculating the flue.
Becauseofthelowminimumfluegastemperatureofthedevice,amoistureandwaterresistantfluegassystem
isrequired.
The use of a double wall stainless steel system is required.
A brick chimney may be used if it is damp and water resistant (e.g., refractory brick), properly insulated, and
fulfills the requirements of technical calculations.
In the case of an existing non- damp and water resistant chimney, a properly designed, insulated single wall
stainless steel pipe may be used.
In either case, ask your local building inspector or flue expert for correct design and flue sizing.
For directions on installing and supporting your chimney, follow the instructions provided by your flue system‘s
manufacturer.
Apressurereliefvalveneedstobeinstalledinthefluegassystem.
Whenever possible, a barometric damper should be installed according to local building codes.
DO NOT install a barometric damper in sleeping and living areas!
Injuryhazard.
In case of a system malfunction, flue gas may leak out. This can lead to asphyxi-
ation.
The minimum required draft at the flue gas collar is -0.02 in H2O (-0.05 mbar).
The maximum allowed draft at the flue gas collar is -0.08 in H2O (-0.2 mbar).
The minimum required flue pipe diameter is 5 inches / 130 mm. The use of a flue pipe diameter greater than 6
inches / 150 mm requires a proper calculation from your local building inspector or flue expert first.
The picture below shows one possible way to install a barometric damper in combination with a pressure relief
port.
Combined barometric damper and pressure
relief port
Fig.2 Alpha Series with barometric damper and
pressure relief port
INFORMATION This unit is not to be connected to a chimney flue serving another appliance.

1.
ImportantinformationfortheTechnician
11
CAUTION
CAUTION
1.2.1 Adjust barometric damper
Adjust barometric damper according to the manufacturer‘s instructions. Toaccess the measurement opening,
removethebacklid andtheplugattheflue gas collar.Measurethedraftwithan appropriateanalyzer.Adjustfor
thefluedraftlistedontheboiler/heaternameplate.Replacetheplugandclosethelidaftermeasuringthedraft.
This should not be altered for increased firing for any reason!
1.2.2 Essentialpartsforfieldassembly
The following UL listed components must be completely unobstructed on the boiler/heater:
– Pressure Relief Valve with 30 psi opening pressure Article no.: 003493
– LowWaterCut-Off withManual Resetfor 110–120 V 15 AArticleno.: 003495
– PressureGaugeArticleno.: 003494
– Expansion Tank with atleast15% totalsystem water volume capacityArticle no.:003496,003497, 003498
– Automatic Air Vent Article no.: 003499
A flue pipe adapter of 5.12” (130 mm) to 5.00” (127 mm) is included (Article no.: 003501) to connect the flue
pipe.
READandFOLLOWinstallationinstructionsforproperfluesizingandfluedesign!
All flue systems must meet UL103. All flue systems must be water resistant (stainless steel) and insulated
(double wall system).
DO NOT INSTALL BAROMETRIC DAMPER OR PRESSURE RELIEF VALVE IN
LIVING OR SLEEPING AREA!!

1.
ImportantinformationfortheTechnician
12
CAUTION
Storage room
Alpha Series
100–260
Furthest probe
Boiler/Heater
room
Vacuum Unit
Auto ChangeoverUnit
1.3 Boiler/heaterroom/installationroom
INFORMATION
The configuration of the entire system must comply with the requirements of
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.
– Sufficient ventilation of the installation area must be assured. See chapter 2.3 Combustion air.
– The boiler/heater must be installed in a dry location!
– Theboiler/heater maynotbeinstalledinroomsthatareverydustyorhumid.
Permissible limit values: Air humidity: 85 % at room temperature of 77 °F / 25 °C (non-condensing)
Room temperature: +2 to +104 °F / +40 °C
1.4 Fuelstorage
The pellets must be stored in a dry place in order to achieve trouble-free operation with optimum combustion
and at maximum efficiency. The pellets can be stored in bulk in a storage room, sheet steel tank, fabric tank or
a buried tank. The requirements for pellet storage are defined in ÖNORM M7137 for Austria or the Firing Ordi-
nanceFeuVforGermany. PELLETS MUST NOT BE EXPOSED TO DIRECT MOISTURE OR WATER!
Seetheseparateplanningdocumentsforplanninginformationaboutpelletstorage.
Maximumtransportlengthorheightforapelletfeedsystem:
These max.values require a stable power supply(min. 110 V AC under load!).
Max.distanceof80ft/25m betweenfurthestprobe and pellet boiler/heater with max.totalheight difference of
6ft/ 1.8 m
Max.distanceof50ft / 15m betweenfurthestprobe and pellet boiler/heater with max.total height difference of
9ft/ 2.8 m
Max.distanceof30ft/10m betweenfurthestprobe and pellet boiler/heater with max.totalheight difference of
14 ft /4.5 m
Total height difference: Sum of lengths of all rising pipes
The pellets must be transported carefully into and out of the storage room so as to
maintain good pellet quality.
Alpha Series60/100 (3probe optional setup):
Returnair
Filling
connection
Fig.3 Storage room, Boiler/Heater room –view from above

13
2.
For the Installer
3
2
1*
3*
2
2
2. For the Installer
2.1 Delivery, packaging
2.1.1 Alpha Series
The boiler/heater arrives fully fitted, insulated, and enclosed in a stable crate with the control panel. Cleaning
tools are packed in the combustion chamber. The hopper cover is packed in a cardboard box or the feed unit (for
fully automated pellet feed) is packed in a cardboard box.
1.1.1 Optional accessories
Accessoriesforfullyautomatedpelletfeed
– Automatic changeover unit (1) with cover plate (2) and 3 suction probes (3)
– Transport hose (4) with flexible earth leads DN 50/25 m (supply and return air hose)
4
1
Fig.4 Optional Accessories for automatic pellet feed
Optional Accessories for storage room
– Filling coupling set (1) NW 3.94 in / 100 mm (2 Storz
A couplings with 19.7 in / 0.5 m pipe, incl. fastening
material) –with blockable blind covers
– Z-brackets (2) (4 of 39.4 in / 4 of 1 m each) incl. bolts
and dowels for storage room door
– Baffle plate (3) made from plastic (59 x 59 x 0.08 in /
1500 mm x 1500 mm x 2 mm) incl. fastening material
for storage room
– Fire protection collars (2 pieces) incl. masonry attach-
ment
– Pipe clamp for grounding the filling and return air
lines Ø 19.7 in / Ø 100 mm and attaching them to the
wall
– Pipes and bends (natural aluminium) for extending
the filling and return air pipes Ø 19.7 in / Ø 100 mm
*)Pleasenote: 1+3 arenot included inPellergy delivery.
Mustbe providedelsewhere.
Fig.5 Accessories for storage room

14
2.
For the Installer
2.2 System
2.2.1 Areaofuse
Theboilers/heatersaredesignedandapprovedasheatgeneratorsforhotwaterheatingsystems
withpermissibleflowtemperaturesofupto194 °F/90°C.
The maximum flow temperature is factory-set at 176 °F / 80°C. They maybe installed onlyin sealed systems.
2.2.2 Standards
In the absence of local building codes, the following European standard should be followed: EN 12828.
2.2.3 Circulation pump
Werecommend using pumps efficiency class A.
2.2.4 Returntemperature
The standard return flow temperature increase allows the Alpha Series to operate with a return temperature
down tomin. 68°F / 20 °C. No external return flow temperature increase isrequired.
Exception: Systems with an accumulator tank in which the accumulator tank is loaded directly from Alpha Series.
2.2.5 Accumulator tank
Inprincipleapelletboiler/heater system doesnotneedanaccumulatortank.Aguaranteedminimumheatcon-
sumption isrequired, e.g., fit a consumer circuit that cannot beblocked off ordo not fit thermostat valves on all
radiators.
TheAlpha Series60/100needsabufferONLYif:
– Thetotalheatingrequirementsofthe buildingarelessthan50% ofthe boiler‘s/heater´snominaloutput.
INFORMATION
If using a buffer, the Alpha Series return flow temperature must be increased –
see hydraulic diagram in the planning documents. Contact Pellergy!!
2.2.6 Heatingwater
a) The chemical composition of the heating water must meet the specifications of ÖNORM H 5195 Part 1 or VDI
2035P1. According toÖNORM M 5195 Part 1(2010edition), the condition of theheating watermustbe checked
every 2 years by a heating technician in order to avoid corrosion and sediment accumulation in the heating
system.
b) The pipe lines and heating appliances should be thoroughly rinsed before the boiler is connected.
c) To protect the boiler from contamination from the heating system, installation of a dirt trap is required in old
or existing systems (mesh size 0.019 in / 0.5 mm) with stopcocks installed in the return line.
d) If oxygen diffusion or sludge build-up cannot be prevented, the system must be segregated by means of a heat
exchanger.
e) If antifreeze is used, a minimum volume of 20 % antifreeze is required, otherwise corrosion prevention is not
guaranteed and any warranty is void.

15
2.
For the Installer
2.2.7 Water-sideresistance(pressureloss)oftheAlpha Seriespellet
central heating boiler
5283
2642
2376
2113
1849
1585
1321
1057
793
528
264
238
211
185
159
132
106
79
53
Alpha Series Models 60/100
Diagram 1
40
2.1 4.2 6.3 8.4 12.6 16.8 21 42 63 84 105 147 210
14.7 16.8 126 168
Pressure loss (psi)
2.2.8 Operatingwithexternalcontrol
Thefollowingrequirementsmustbesatisfied forcontrolinterface with the Alpha Series boiler:
– Boiler Condense Protection:
All external circulator pumps mayonlybeswitchedonwithaboiler temperatureofmorethan122°F
(50°C)iftheburner is onandmustbeswitchedoff ataboiler temperatureof lessthan113°F (45°C).
This is accomplished through the incorporation of a control circuit within the Alpha Series boiler
using the Boiler Condense Protection output relay. This relay (Normally Open, Dry Contact) closes
once the boiler reaches 122°F (50°C) and there is a call for heat, and opens if the boiler falls below
113°F (45°C). No external mixing valve is necessary (subject to min. load and max. water volume
requirements) as the Alpha Series boiler provides mixing internally. All external circulation through
the boiler MUST be enabled and disabled through the use of this relay.
– Boiler Overheat Protection:
During the boiler’s burnout phase (shutdown as a result of no call for heat), an amount of wood pellet fuel
remains in the combustion chamber. To avoid overheating the boiler and the production of damaging
steam, the Alpha Series boiler incorporates an overheat feature. The Overheat Protection Relay
(Normally Open, Dry Contact) closes once the demand for heat has been removed. This relay stays
closed for a minimum of 10 minutes .The single largest zone must be enabled by this relay in order to
circulate water through the boiler during the burnout phase. Failure to do so will cause damage to the
boiler and void the warranty!
– 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.
Flow
rate
(gal/h)

16
2.
For the Installer
2.3 Combustionair
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.
INFORMATION
Malfunctions or other issues caused byinadequate combustion air are not covered
by the warrantee.
2.3.1 Operatingwithroomair
Combustionair supplydirectlyfromtheboiler/heaterroom
Ifcombustionairisdrawndirectlybythesystemfrom theboiler/heaterroom,theroom must beadequatelyven-
tilated.Thecombustionairshouldbedirectedneartheboiler.
The minimum area of free cross-section must be 1.25 in2per 10,000 btu/hr (2.5 cm2 per kW) of the
boiler‘s nominal total output1. The ventilation opening to the outdoors for combustion air should be
designed as follows2:
– theflowofairmustnotberestrictedinanywaybytheweather(e.g.,snow,leaves),
– the free cross-section area remains the same when taking the the cover grille, discs, etc. into consideration.
1
The boiler‘s nominal total outputis the sum of the nominal outputs ofall heat generators installed inthe same boiler / installation room.
2
The values stated herein are the absolute minimum per the boiler manufacturer. Local Codes and regulation may require greater values.

17
2.
For the Installer
Illustration may vary
2.4 Bringing the unit inside
INFORMATION
The appliance must bebrought into the building and installed without subjecting
it to significant impacts or jostling. All warranty claims will be invalidated if the
appliance is damaged due to having been taken into the building and installed
incorrectlyoriftheappliancemalfunctionsasaconsequence ofthis.
There are several possible forms of delivery for the Alpha Series. It is best to move the boiler into the
installation site in its crate (33 in / 790 mm wide). In order to bring the boiler in more easily and more safely in
tightareas,several add-onscanberemovedtomaketheAlpha Seriessmallerandlighter.
INFORMATION
The dimensioned parts are the rough key measurements. Small components (e.g.,
exhaust pipe, door mounting, etc.) are outside the dimensioned area.
Thefour most useful installationdimensionsorinstallationweights are:
a) Move Alpha Series to installation site with crate –Fig. 6.
b) Alpha Series without crate, hopper, left-hand side wall, rear wall, cladding door on left, combustion chamber
door, ash container or ash pan, fan box, fan unit –Fig. 7.
c) In addition to scenario (b), system without control panel and right side panel –Fig. 8.
d) Inadditiontoscenario( c),systemwithoutfloorplate(noillustration).
Fig.6
Alpha Series60/100 incrate
Fig.7
Alpha Series60/100 withoutcrate,
Fig.8
Alpha Series60/100
without
claddingand hopper
control panel
Pleasepayattentiontothebelowchartie.boilerweight–toavoidissueswhilebringingtheunitinside!
Boilerweightsafterremovingadd-ons:
Alpha
Series
Alpha
Series
Assembly and disassembly
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
left, left-hand side wall, rear wall, ash container or
ash pan, combustion chamber door, fan unit, fan
box
lb/kg
515/234
539/245
approx. 1.5 hours
c) Alpha Series as above, also without control panel
and right-hand side wall
lb/kg
461/210
485/220
approx. 2.5 hours
d) Alpha Series as in point c), also without floor plate
lb/kg
434/197
459/208
approx. 2.6 hours
63.78
in
1620 mm
55.79
in
1417 mm
44.76
in
1137 mm

18
2.
For the Installer
2.4.1 Removinghopper
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 screwin the inside of the deviceunder the hopper next to the rear
panel cladding (Fig. 10) and remove rear panel upwards –Fig. 11.
Fig.9 Unhinging claddingdoor Fig.10 Removing1 screw Fig. 11 Unhinging rear panel
– Removehopper side wall; remove2 screws in inside of the device under the hopper next tothe side panel (Fig.
12) and remove the side panel.
– Remove sensor from safety thermostat auger tube; loosen sensor guard (Fig. 13) and take out sensor.
– Unscrew both nuts from the side of the auger tube flange –Fig. 14.
Fig. 12 Removing screws from inside next
to side panel Fig.13 Loosening sensor guard Fig. 14 Unscrewingnuts(2x)
– Disconnect plug from auger motor –Fig. 15.
– Remove hopper support feet: unscrew 4 nuts –Fig. 16.
– Loosen proximityswitchin hopper,loosen screws one turn, turn flange with proximityswitchcounter-clock-
wiseandpressoutwards–Fig.16.
Fig. 15 Disconnecting auger motor plug Fig. 16 Removingsupport feet Fig. 17 Loosening proximity switch

2.
For the Installer
19
– 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.
Fig.18 Unscrewingnuts (3x) andbolt (1x) Fig.19 Taking off hopper Fig. 20 Removing combustion chamber
doorand ashpan
– Removefan wheel and fan box (see Alpha Series Operating Manual, cleaning fan wheel,fan box)
2.4.2 Removing control panel
– Lift cladding cover. Loosen the 2 screws on the side of the control panel cover (Fig. 21) and remove cover.
– Loosen ground cable and plug connection and remove strain relief (cable ties) –Fig.22.
– Remove cladding cover control panel; remove 2 bolts with nuts (Fig. 23) and take off cover.
Fig. 21 Loosening 2 bolts,removingcontrol
panelcover Fig. 22 Loosengroundcable and plug connection Fig. 23 Unscrewingcladding cover
– Remove boiler/heater sensor, safety thermostat sensor and exhaust gas sensor, unscrewcoveronrear wall
(Fig.24).Pullboiler/heaterandsafetythermostatsensoroutofimmersionsleeve,pullexhaustgassensorout
ofprotectivetubeinflueoutlet(Fig.25).Guideall3sensorsoutofthecableduct.
Fig.24 Removingcover Fig. 25 Pulling out sensor
Groundcabel
Plug connection
Nuts
Bolt

2.
For the Installer
29
– 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. 27 Disconnecting door safetyswitch Fig. 28 Removing thermocontrol sensor
– Remove 4 rear screws from control panel with retaining bracket –Fig. 29.
– Disconnect all cables from cable harness and unscrew complete cable harness with strain relief (pinch off
cableties) –Fig. 30.
– Takeoff control panel –Fig. 31.
Fig. 29 Removingretaining bracket Fig. 30 Unscrewing strain relief Fig. 31 Control panel removed
– Remove cladding bracket (2 screws) at the bottom front –Fig. 32.
– Unhook and remove right side panel at bottom –Fig. 33.
Please note: Do not remove insulation from side wall. The heating surface cleaning rod uses this insulation.
Fig. 32 Unscrewing connectionbracket Fig. 33 Unhinging right side wall
Assembly:
Aftertransportingintotheboiler/heaterroom,reassembletheAlpha Seriesinreverse order.