pellet boiler p4 pellet 8 - 105 - · pdf filethese instructions together with those in the...

Installation Instructions

Pellet Boiler P4 Pellet 8 - 105

Translation of the original German installation instructions for techniciansRead and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!M0931113_en | Edition 25/02/2014

Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Version of 27 Oct 2011

Page 1 of 7

SUPPLEMENTARY INSTALLATION INSTRUCTIONS FOR THE UK MARKET TO BE READ IN CONJUNCTION WITH THOSE IN THE MAIN INSTRUCTION MANUAL

These instructions together with those in the instruction manual cover the basic principles to ensure the satisfactory installation of the boiler, although detail may need slight modification to suit particular local site conditions. In all cases the installation must comply with current Building Regulations, Local Authority Byelaws and other specifications or regulations as they affect the installation of the boiler. It should be noted that the Building Regulations requirements may be met by adopting the relevant recommendations given in British Standards BS 8303, BS EN15287-1:2007 as an alternative means to achieve an equivalent level of performance to that obtained following the guidance given in Approved Document J. Please note that it is a legal requirement under England and Wales Building Regulations that the installation of the boiler is either carried out under Local Authority Building Control approval or is installed by a Competent Person registered with a Government approved Competent Persons Scheme. HETAS Ltd operate such a Scheme and a listing of their Registered Competent Persons can be found on their website at www.hetas.co.uk. CO Alarms:- Building regulations require that when ever a new or replacement fixed solid fuel or wood/biomass appliance is installed in a dwelling a carbon monoxide alarm must be fitted in the same room as the appliance. Further guidance on the installation of the carbon monoxide alarm is available in BS EN 50292:2002 and from the alarm manufacturer’s instructions. Provision of an alarm must not be considered a substitute for either installing the appliance correctly or ensuring regular servicing and maintenance of the appliance and chimney system.

HEALTH AND SAFETY PRECAUTIONS

Special care must be taken when installing the boiler such that the requirements of the Health and Safety at Work Act are met. Handling Adequate facilities must be available for loading, unloading and site handling. Fire Cement Some types of fire cement are caustic and should not be allowed to come into contact with the skin. In case of contact wash immediately with plenty of water. Asbestos This boiler contains no asbestos. If there is a possibility of disturbing any asbestos in the course of installation then please seek specialist guidance and use appropriate protective equipment. Metal Parts When installing or servicing this boiler care should be taken to avoid the possibility of personal injury.

http://www.hetas.co.uk/


Page 2 of 7

BOILER PERFORMANCE The nominal heat outputs for the various boilers are detailed in the main instruction manual:

PREPARATORY WORK AND SAFETY CHECKS

IMPORTANT WARNING This boiler must not be installed into a chimney that serves any other heating appliance. There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to emit fumes into the room.

Chimney In order for the boiler to perform satisfactorily the chimney height must be sufficient to ensure an adequate draught of approximately 15 Pa so as to clear the products of combustion and prevent smoke problems into the room. NOTE: A chimney height of not less than 4.5 metres measured vertically from the outlet of the boiler to the top of the chimney should be satisfactory. Alternatively the calculation procedure given in BS EN 13384-1 may be used as the basis for deciding whether a particular chimney design will provide sufficient draught. The outlet from the chimney should be above the roof of the building in accordance with the provisions of Building Regulations Approved Document J. Because these boilers run at high efficiencies the temperature of the flue gases is lower than conventional solid fuel appliances. Although they are not classed as condensing appliances, the low flue gas temperature results in condensation occurring within the flue. Any chimney flue system must therefore be able to withstand the effects of condensate and operate under wet conditions (designation letter W). In addition it should be soot fire resistant and able to withstand the corrosive effects of flue products generated by solid fuels (designation G and 3 respectively). If installation is into an existing masonry chimney then it will require re-lining with a liner meeting the specification described above. Existing concrete or clay lined chimneys are not suitable for these boilers and must be lined as described above. All installations must be in accordance with Building Regulations Approved Document J. Any existing chimney must be clear of obstruction and have been swept clean immediately before installation of the lining system. If there is no existing chimney then any new system must be to the designation described above and in accordance with Building Regulations Approved Document J. A single wall metal fluepipe is suitable for connecting the boiler to the chimney but is not suitable for use as the complete chimney. The chimney and connecting fluepipe must not be less than the size of the outlet socket of the boiler. The length of this connecting pipe should be kept to a minimum. Refer also to the main instruction manual for further guidance.

Any bend in the chimney or connecting fluepipe should not exceed 45 . 90 bends should not be used, except for connecting to a rear outlet appliance, and the connection should be no more than 150 mm in length and have a debris trap. Combustible material should not be located where the heat dissipating through the walls of fireplaces or flues could ignite it. Therefore when installing the boiler in the presence of combustible materials due account must be taken of the guidance on the separation of combustible material given in Building Regulations Approved Document J and also in these boiler instructions. If it is found that there is excessive draught in the chimney then a draught stabiliser should be fitted in the chimney above the chimney above the flue pipe connection. Fitting of a draught stabiliser will affect the requirement for the permanent air supply into the room in which the boiler is fitted in accordance with


Page 3 of 7

Approved Document J (see also combustion air supply). Adequate provision e.g. easily accessible soot door or doors must be provided for sweeping the chimney and connecting fluepipe.

Connection to the chimney All the boilers have a flue gas connector that allows connection to the main chimney using a suitable connecting pipe. All joints must be sealed in accordance with the recommendations in Approved Document J. See also “Chimney” above.

Hearth The hearth should be able to accommodate the weight of the boiler and its chimney if the chimney is not independently supported. The weight of the boiler is indicated in the instruction manual. The boiler should always be installed on a non-combustible hearth of a size and construction that is in accordance with the provisions of the current Building Regulations Approved Document J. The clearance distances to combustible material beneath, surrounding or upon the hearth and walls adjacent to the hearth should comply with the guidance on the separation of combustible material given in Building Regulations Approved Document J and also in these boiler instructions.

Combustion air supply In order for the boiler to perform efficiently and safely there should be an adequate air supply into the room in which the boiler is installed to provide combustion air. This is particularly necessary if the room is double-glazed or a flue draught stabiliser is operating in the same room as the appliance. The provision of air supply to the boiler must be in accordance with current Building Regulations Approved Document J. An opening window is not appropriate for this purpose.

Connection to the central heating system Ensure the heating system is the correct design for the boiler. It is an essential requirement that the system incorporates a heat storage buffer tank (often referred to as an accumulator). Full guidance is given in the main installation manual. Depending on the intended design of the heating installation and also on the output of the boiler, the central heating system must be in accordance, as appropriate, with either BS 6880:1988 Parts 1 to 3, Code of Practice for low temperature hot water heating systems of output greater than 45kW. Further guidance is available from the following sources: BS EN 14336:2004: Heating Systems in Buildings. Installation and commissioning of water based heating systems. BS EN 12828: 2003; Heating Systems in Buildings. Design of water based heating systems. BS EN 12831: 2003; Heating Systems in Buildings. Method for calculation of the design heat load. Particular attention must be paid to the installation and correct functioning of any Thermal Safety Device where necessary. This is described fully in the installation manual.


Page 4 of 7

Electrical connections The installation of any electrical services during the installation of this boiler and the associated heating system must be carried out by a registered competent electrician and in accordance with the requirements of the latest issue of BS 7671.

Commissioning and handover Before commissioning this boiler be sure to read and follow the operation manuals to ensure that everything is carried out in accordance with the correct procedures. Ensure any loose parts are fitted in accordance with the instructions. Once the boiler is under fire check all seals for soundness and that the boiler and water system are operating correctly. Ensure that the flue is functioning correctly and that all products of combustion are vented safely to atmosphere via the chimney terminal. On completion of the installation and commissioning ensure that the instruction manuals for the boiler are left with the customer. Ensure to advise the customer on the correct use of the appliance with the fuels likely to be used on the boiler and warn them to use only the recommended fuels for the boiler. The user should be given a demonstration of the required routine maintenance and safety checks. Remind the user of the importance of regular chimney sweeping and servicing by qualified persons to ensure continued safe operation of the boiler. Leave the boiler operational and inform the user that this is the case. Advise the user what to do should smoke or fumes be emitted from the boiler. The customer should be warned about the dangers to children, aged and/or infirm persons and that access to the boiler should be protected by a lockable door.


Page 5 of 7

SUPPLEMENTARY OPERATING INSTRUCTIONS FOR THE UK MARKET TO BE READ IN CONJUNCTION WITH THOSE IN THE OPERATION MANUAL

READ THE OPERATION MANUAL AND TT HH EE SS EE II NN SS TT RR UU CC TT II OO NN SS

CC AARR EE FF UU LL LL YY BB EE FF OO RR EE UU SS II NN GG TT HH EE BB OO II LL EE RR

WARNING NOTE

Properly installed, operated and maintained this boiler will not emit fumes into the dwelling. Occasional fumes from de-ashing and re-fuelling may occur. However, persistent fume emission is potentially dangerous and must not be tolerated. If fume emission does persist, then the following immediate action should be taken:- (a) Open doors and windows to ventilate room (b) Shut the boiler down in accordance with the instructions and vacate the room/building. (c) Check for flue or chimney blockage and clean if required (d) Do not attempt to relight the fire until the cause of the fume emission has been identified and corrected. If

necessary seek expert advice. The most common cause of fume emission is flueway or chimney blockage. For your own safety these must be kept clean at all times.

IMPORTANT NOTES

General Before lighting the boiler check with the installer that the installation work and commissioning checks described in the installation instructions have been carried out correctly and that the chimney has been swept clean, is sound and free from any obstructions. As part of the boilers’ commissioning and handover the installer should have shown you how to operate the boiler correctly. In particularly cold weather the boiler should not be lit if there is a possibility that any part of the heating system is frozen. In case of a system fault the boiler is designed to safely shut itself down automatically. If however there is a need to manually shut the boiler down please follow the instructions given in the operation manual. This should only be done in emergency situations. Always ensure the fuel charging door and the ash door are firmly shut after attending to the boiler as overheating of the boiler may occur if these doors are not fully closed.

CO Alarm Your installer should have fitted a CO alarm in the same room as the appliance. If the alarm sounds unexpectedly, follow the instructions given under “Warning Note” above.


Page 6 of 7

Protection of vulnerable persons This type of boiler is unlikely to be installed in a part of the home that would be considered as part of the general living area or easily accessible from such. It is intended to be installed in its own boiler room. This boiler room should be guarded effectively with the use of an appropriate lockable door.

Chimney cleaning The chimney should be swept a minimum of twice a year. It is important that the flue connection and chimney are swept prior to lighting up after a prolonged shutdown period. In situations where it is not possible to sweep through the boiler the installer will have provided alternative means, such as a soot door. After sweeping the chimney the boiler flue outlet and the flue pipe connecting the boiler to the chimney must be cleaned with a flue brush.

Periods of Prolonged Non-Use If the boiler is to be left unused for a prolonged period of time then it should be given a thorough clean to remove ash and unburned fuel residues. To enable a good flow of air through the boiler to reduce condensation and to avoid door seals becoming stuck and subsequently damaged, leave the filling hatch and combustion chamber doors slightly ajar. These actions will reduce the possibility of unnecessary damage and corrosion. It is important to check, and clean if necessary, the connecting pipe and the chimney prior to lighting up the boiler after a prolonged period of non-use.

Extractor fan There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to emit smoke and fumes into the room.

Aerosol sprays Do not use an aerosol spray on or near the boiler when it is alight.

Use of operating tools Always use the operating tools provided when handling parts likely to be hot when the boiler is in use.

Chimney Fires If the chimney is thoroughly and regularly swept, chimney fires should not occur. However, if a chimney fire does occur the control system of the boiler should shut down the system. Please follow the instructions in the operation manual for emergency manually shutting down the boiler if it appears that the boiler has not shut down automatically. This should cause the chimney fire to go out in which case the control should be kept at the minimum setting until the fire in the boiler has gone out. The chimney and flueways should then be cleaned. If the chimney fire does not go out when the above action is taken then the fire brigade should be called immediately. After a chimney fire the chimney should be carefully examined for any damage. Expert advice should be sought if necessary


Page 7 of 7

Permanent air vent The boiler requires a permanent and adequate air supply in order for it to operate safely and efficiently. In accordance with current Building Regulations the installer may have fitted a permanent air supply vent into the room in which the boiler is installed to provide combustion air. This air vent should not under any circumstances be shut off or sealed.

Recommended fuels The boiler is designed to burn specific wood based fuels as detailed in the main instructions.

HETAS Ltd Approval This appliance has obtained HETAS Ltd approval for burning the specified fuels. Approval does not cover the use of other fuels either alone or mixed with the recommended fuels listed, nor does it cover instructions for the use of other fuels.

Installation Instructions

Pellet Boiler P4 Pellet 8 - 105

Translation of the original German installation instructions for techniciansRead and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!M0931113_en | Edition 25/02/2014


Table of Contents

1 General 4

2 Safety 52.1 Hazard levels of warnings 52.2 Qualification of assembly staff 62.3 Protective equipment for assembly staff 62.4 Design Information 72.4.1 Notes on standards 7 General standards for heating systems 7 Standards for structural and safety devices 7 Standards for heating water 7 Standards for permitted fuels 82.4.2 Installation and approval of the heating system 82.4.3 General information for installation room (boiler room) 82.4.4 Requirements for central heating water 92.4.5 Notes for using pressure maintenance systems 92.4.6 Use with storage tank 102.4.7 Chimney connection/chimney system 11 Draught limiter 11 Boiler data for planning the flue gas system 112.4.8 Room air-independent operation 122.4.9 Boiler ventilation 13

3 Technology 143.1 Dimensions 143.1.1 Supply air connections for room air-independent operation 153.1.2 Flue gas pipe position 153.2 Components and connections 163.3 Technical specifications 173.3.1 P4 Pellet 8/15/20/25 173.3.2 P4 Pellet 32/38/45/48/60 183.3.3 P4 Pellet 80/100/105 193.3.4 Airborne sound level 20

4 Assembly 214.1 Materials supplied 214.1.1 Tools required 214.2 Positioning 214.3 Temporary storage 224.4 Setting up in the boiler room 234.4.1 Remove boiler from pallet 234.4.2 Moving the boiler in the boiler room 244.4.3 Minimum distances in the boiler room 254.5 Dismantling for location where positioning is difficult 264.5.1 Removing the stoker assembly and insulation 264.5.2 Removing the door and ash drawer (P4 Pellet 8 - 25) 274.5.3 Dismantling the suction cyclone cover 284.5.4 Dismantling the stoker unit 29

Table of Contents

2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.5.5 Positioning dimensions after dismantling 324.5.6 Notes for reassembly 334.6 Assembling the pellet boiler 344.6.1 Before Installation 34 Checking the seal of the ash doors 34 Adjusting the doors 344.6.2 Fitting the induced draught fan 374.6.3 Fitting the ash container and doors (P4 Pellet 32 - 105) 384.7 Connecting the discharge system 394.8 Power connection 404.8.1 Information on circulating pumps 414.8.2 Comfort pellet box port 42

5 Start-up 435.1 Before commissioning / configuring the boiler 435.1.1 Setting the "Max level and Min level” sensor 445.2 Initial startup 445.2.1 Permitted fuels 44 Wood pellets 445.2.2 Non-permitted fuels 445.2.3 Heating up for the first time 45

6 Decommissioning 466.1 Mothballing 466.2 Disassembly 466.3 Disposal 46

7 Appendix 477.1 Addresses 477.1.1 Address of manufacturer 477.1.2 Address of the installer 47

Table of Contents

Installation Instructions P4 Pellet 8 - 105 | M0931113_en 3

1 GeneralThank you for choosing a quality product from Froling. The product features a state-of-the-art design and conforms to all currently applicable standards and testing guide‐lines.Please read and observe the documentation provided and always keep it close to thesystem for reference. It contains important safety information and all the operation andmaintenance specifications needed to operate the system safely, properly, environ‐mentally friendly and cost-effectively.The constant further development of our products means that there may be minor dif‐ferences from the pictures and content. If you discover any errors, please let us know:[email protected] to technical change. The EC Declaration of Conformity is only valid in conjunction with a delivery certificate,which has been filled in correctly and signed as part of the commissioning process.The original document remains at the installation site. Commissioning installers orheating engineers are requested to return a copy of the delivery certificate togetherwith the guarantee card to Froling. On commissioning by FROLING Customer Servicethe validity of the delivery certificate will be noted on the customer service record.

Issuing a delivery cer‐tificate

1 General


2 Safety

2.1 Hazard levels of warningsThis documentation uses warnings with the following hazard levels to indicate directhazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will leadto serious injury or death. You must follow the instructions!

WARNING

The dangerous situation may occur and if measures are not observed it will leadto serious injury or death. Work with extreme care.

CAUTION

The dangerous situation may occur and if measures are not observed it will leadto minor injuries or damage to property.

Safety 2Hazard levels of warnings


2.2 Qualification of assembly staff

CAUTION

Assembly and installation by untrained personnel:

Risk of personal injury and damage to property.

During assembly and installation:❒ Observe the instructions and information in the manuals❒ Only allow trained staff to carry out assembly and installation

Assembly, installation, initial startup and servicing must always be carried out by quali‐fied personnel:- Heating technician / building technician- Electrical installation technician- Froling customer servicesThe assembly staff must have read and understood the instructions in the documenta‐tion.

2.3 Protective equipment for assembly staffYou must ensure that staff have the protective equipment specified by accident pre‐vention regulations.

▪ For transportation, setup and assembly:- suitable workwear- protective gloves- sturdy shoes

2 SafetyQualification of assembly staff


2.4 Design Information

2.4.1 Notes on standardsThe system must be installed and commissioned in accordance with the local fire andbuilding regulations. The following standards and regulations should always be ob‐served:

General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fed combus‐tion systems, nominal heat output up to 500 kW

EN 12828 Heating systems in buildings - design of water-based heatingsystems

EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methodsPart 1: Chimneys serving one appliance

ÖNORM M 7510-1 Guidelines for checking central heating systemsPart 1: General requirements and one-off inspections

ÖNORM M 7510-4 Guidelines for checking central heating systemsPart 4: Simple check for heating plants for solid fuels

Standards for structural and safety devices

ÖNORM H 5170 Heating installation - Requirements for construction and safetyengineering, as well as fire prevention and environmental pro‐tection

ÖNORM M 7137 Compressed untreated wood – Requirements for storing pelletsat the end customer’s site

TRVB H 118 Technical directives for fire protection/prevention (Austria)

Standards for heating water

ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation inclosed warm water heating systems at operating temperaturesup to 100 °C (Austria).

VDI 2035 Sheet 1 Prevention of damage in water heating systems - Scale forma‐tion in domestic water heating systems and hot water heatingsystems (Germany)

SWKI 97-1 Water quality for heating, steam, cooling and air conditioningsystems (Switzerland)

D.P.R. no. 412 Regulations for the planning, installation, running/operation andmaintenance of heating systems in buildings to reduce energyconsumption with reference to Article 4, Comma 4 of the Legis‐lative Decree of 9 January 1991, No. 10 (Italy)

Safety 2Design Information


Standards for permitted fuels

EN 14961-2 Solid biofuel, fuel specifications and classes.Part 2: Wood pellets for non-industrial use

1. BImSchV First Ordinance of the German Federal Government for imple‐mentation of the Federal Emission Protection Law, BGBl. I P.491, in the applicable version.

2.4.2 Installation and approval of the heating systemThe boiler should be operated in a closed heating system. The following standardsgovern the installation:

ÖNORM / DIN EN 12828 Heating Systems in Buildings

NOTICE! Each heating system must be officially approved.The appropriate supervisory authority (inspection agency) must always be informedwhen installing or modifying a heating system, and authorisation must be obtainedfrom the building authorities:Austria: Inform the civic/municipal building authorities.Germany: Notify an approved chimney sweep and the building authorities.

2.4.3 General information for installation room (boiler room)

Boiler room characteristics▪ There must not be a potentially explosive atmosphere in the boiler room as the

boiler is not suitable for use in potentially explosive environments.▪ The boiler room must be frost-free.▪ The boiler does not provide any light, so the customer must provide sufficient light‐

ing in the boiler room in accordance with national workplace design regulations.▪ When using the boiler over 2000 metres above sea level you should consult the

manufacturer.▪ Danger of fire due to flammable materials.

No flammable materials should be stored near the boiler. Flammable objects (e.g.clothing) must not be put on the boiler to dry.

▪ Damage due to impurities in combustion air.Do not use any solvents or cleaning agents containing chlorine in the room wherethe boiler is installed.

▪ Keep the air suction opening of the boiler free from dust.

Ventilation of the boiler roomVentilation air for the boiler room should be taken from and expelled directly outside,and the openings and air ducts should be designed to prevent weather conditions (foli‐age, snowdrifts, etc.) from obstructing the air flow. Unless otherwise specified in the applicable building regulations for the boiler room,the following standards apply to the design and dimensions of the air ducts:

Note on standards

2 SafetyDesign Information


ÖNORM H 5170 - Construction and fire protection requirementsTRVB H118 - Technical directives on fire protection/prevention

2.4.4 Requirements for central heating waterThe following standards and guidelines apply:

Austria:Germany:Switzerland:Italy:

ÖNORM H 5195-1VDI 2035SWKI 97-1D.P.R. no. 412

NOTICE! Note on filling with make-up water: always bleed the filling hose before con‐necting, in order to prevent air from entering the system. Observe the standards and also follow the recommendations below:❒ Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to

5.6 dH)❒ Use softened water as the make-up water❒ Avoid leaks and use a closed heating system to maintain water quality during op‐

eration

2.4.5 Notes for using pressure maintenance systemsPressure maintenance systems in hot-water heating systems keep the required pres‐sure within predefined limits and balance out volume variations caused by changes inthe hot-water temperature. Two main systems are used:

Compressor-controlled pressure maintenance

In compressor-controlled pressure maintenance units, a variable air cushion in the ex‐pansion tank is responsible for volume compensation and pressure maintenance. Ifthe pressure is too low, the compressor pumps air into the tank. If the pressure is toohigh, air is released by means of a solenoid valve. The systems are built solely withclosed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐to the heating water.

Pump-controlled pressure maintenance

A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐tenance pump, relief valve and an unpressurised receiving tank. The valve releaseshot water into the receiving tank if the pressure is too high. If the pressure drops belowa preset value, the pump draws water from the receiving tank and feeds it back intothe heating system. Pump-controlled pressure maintenance systems with open expan‐sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of thewater, exposing the connected system components to the risk of corrosion. Thesesystems offer no oxygen removal for the purposes of corrosion control as required byVDI 2035 and in the interests of corrosion protection should not be used.

Note on standards

Note on standards



2.4.6 Use with storage tank

NOTICE

In principle it is not necessary to use a storage tank for the system to run smooth‐ly. However, we recommend that you use the system with a storage tank, as thisensures a continuous supply of fuel in the ideal output range of the boiler.

For the correct dimensions of the storage tank and the line insulation (in accordancewith ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling. ⇨ See "Addresses" [page 47]



2.4.7 Chimney connection/chimney systemEN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐ever possible, damage caused by seepage, insufficient feed pressure and condensa‐tion. Please note in this respect that flue gas temperatures lower than 160K aboveroom temperature can occur in the permitted operating range of the boiler. The flue gas temperatures (for clean systems) and additional flue gas values can befound in the table below. The connection between the boiler and the chimney system should be as short aspossible. The upward angle of the connection should not exceed 30° - 45°. Insulatethe connection. The entire flue gas system - chimney and connection - should be cal‐culated in accordance with EN 13384-1. Local regulations and other statutory regulations also apply.NOTICE! The chimney must be authorised by a smoke trap sweeper or chimneysweep.NOTICE! TRVB H 118 (Austria only) stipulates that an explosion flap must be installedin the connecting piece (flue pipe) directly next to the boiler. It should be situated insuch a way that is poses no risk to persons!

Draught limiterThe installation of a draught limiter is recommended.NOTICE! Install the draught limiter directly under the mouth of the flue line, as thepressure is constantly low at this point.

Boiler data for planning the flue gas system

Description P4 Pellet

8 15 20 25 32 38

Flue gas temperature at nominalload

°C 140 150 150 150 160 160

Flue gas mass flow at nominalload

kg/s 0.007 0.010 0.014 0.018 0.022 0.025

Flue gas mass flow at partial load 0.003 0.004 0.006 0.007 0.009 0.011

Required feed pressure at nominalload

mbar 0.08 0.08 0.08 0.08 0.08 0.08

Required feed pressure at partialload

0.06 0.06 0.06 0.06 0.06 0.06

Maximum permissible feed pres‐sure

as per ÖNORM / DIN EN 303-5

Flue spigot diameter mm 130 130 130 130 150 150




45 / 48 60 80 100 105

Flue gas temperature at nominal load °C 160 170 160 170 170

Flue gas mass flow at nominal load kg/s 0.039 0.043 0.060 0.076 0.079

Flue gas mass flow at partial load 0.017 0.019 0.021 0.026 0.028

Required feed pressure at nominalload

mbar 0.08 0.08 0.08 0.08 0.08

Required feed pressure at partial load 0.06 0.06 0.06 0.06 0.06

Maximum permissible feed pressure as per ÖNORM / DIN EN 303-5

Flue spigot diameter mm 150 150 200 200 200

2.4.8 Room air-independent operationThe P4 Pellet has a central air connection on the back of the boiler. If appropriate sup‐ply air and flue gas connections are installed, the boiler can be operated independent‐ly of room air as a type C42 or type C82 in the sense of EN 15035.

Definition of type C8 as per EN 15035

A boiler that is connected via its combustion air supply and flue gas outlet, with a con‐necting piece that may be supplied, to a shared chimney with a shaft for combustionair supply and a shaft for flue gas outlet. The mouths of the air and flue gas chimneyare either concentric or so close to each other that similar wind conditions apply.NOTICE! Air is supplied by an air and flue gas system!

Definition of type C8 as per EN 15035

A boiler that is connected via its combustion air supply and flue gas outlet, with a con‐necting piece, to a wind protection device and a single or shared chimney. NOTICE! Air supply via an air supply line that is independent from the chimney sys‐tem!NOTICE! This design requires a wind protection device. If a protective grating is fitted,you must ensure that the mesh size is sufficiently large to prevent a significant loss ofpressure and/or seal from dirt! The second index "2" (C42 / C82) indicates type C boilers with a blower fan downstreamof the combustion chamber or the heat exchanger.



When dimensioning pipe bends in the supply air line you should note that:

The ratio of the radius of curvature (r) to pipe diameter (d) should be greater than 1r:d ≥ 1

For example:- Diameter of supply air connection = 80 mm- Minimum radius of pipe bends 80 mm

Install the supply air line in as straight a line as possible and over the shortest path.Keep the number of pipe bends to a minimum (ideally a maximum of 4 bends)!In addition, the following applies: The maximum resistance of the supply air line is 20Pa! You can find the necessary dimensions of the supply air connections in the boiler inthe technical data sheets.

Minimum specification of connection lines

Connecting piece for the combustion air supply as per EN 1856-2EN 1856-2 - T080 - N2 - D Connecting piece for the flue gas outlet as per EN 1856-2EN 1856-2 - T200 - P1 - W

TXXX Temperature class (specified in °C)

N2 Pressure class with test pressure = 20 Pa

P1 Pressure class with test pressure = 200 Pa

D Condensation resistance not required (dry)

W Condensation resistance required (damp)

2.4.9 Boiler ventilation❒ Fit the automatic ventilating valve at the highest point on the boiler or at the venti‐

lation connection (if present).➥ This ensures that air in the boiler is constantly expelled, thus preventing mal‐

functions caused by air in the boiler❒ Check that the boiler ventilation is working properly

➥ After installation and periodically according to manufacturer’s instructions ❒ Fit a vertical pipe as a calming section in front of the automatic ventilating valve in

such a way that the ventilating valve is positioned above the water level in the boil‐er

❒ Fit a microbubble separator in the pipes to the boiler

➥ Follow the manufacturer's instructions!

Tip:

Recommendation:



3 Technology

3.1 Dimensions

Item Description Unit 8/15 20/25 32/38 45/48/60 80 - 105

L Length, boiler mm 740 740 - - -

L* Length, boiler mm - - 820 900 1000

L1 Total length incl. induced draughtfan

mm 940 940 - - -

L1* Total length incl. induced draughtfan

mm - - 1020 1100 1070

B Width, boiler mm 600 770 860 1030 1235

B* Width, boiler, incl. support for posi‐tioning unit 1)

mm 705 875 965 1275 1480

B1 Total width including suction cy‐clone

mm 1185 1355 1445 1790 2085

H Height, boiler 2) mm 1280 1280 1430 1585 1710

H1 Total height incl. suction cyclone mm 1660 1660 1900 1900 1900

H2 Height, flue gas pipe connection mm 1350 1350 1530 1685 1785

H3 Height, flow connection mm 460 460 460 515 520

H4 Height, return connection mm 940 955 1085 1240 1360

H5 Height, drainage connection mm 460 460 460 515 520

H6 Height, ventilation connection mm 1030 1030 1155 1310 1430

H8 Height, induced draught fan connec‐tion

mm 1090 1090 1215 1375 1495

H15 Height, suction system connection mm 1480 1480 1720 1720 17201.Corresponds to the minimum positioning width after removing the stoker assembly, suction cyclone and positioning unit2.Corresponds to the minimum positioning height after removing the stoker assembly, suction cyclone and positioning unit

3 TechnologyDimensions


3.1.1 Supply air connections for room air-independent operation

Description Unit 8/15 20/25 32/38 45/48/60 80 - 105

Supply air connection pipe (external diame‐ter)

mm 80 100 125 160 200

3.1.2 Flue gas pipe position

Description Unit 8/15 20/25 32/38 45/48/60 80 - 105

A – Lateral distance mm 420 585 650 815 1000

B - Depth distance mm 90 90 85 90 80

Technology 3Dimensions


3.2 Components and connections

Item Description Unit 8/15 20/25 32/38 45/48/60 80 - 105

1 Boiler flow connection inches 1 6/4 6/4 6/4 2

2 Boiler return connection inches 1 6/4 6/4 6/4 2

3 Drainage connection inches 1/2 1/2 1/2 1/2 1

4 Air vent connection inches 1/2 1/2 1/2 1 1

5 Pellet suction line mm DA 60 DA 60 DA 60 DA 60 DA 60

6 Pellet return air line mm DA 60 DA 60 DA 60 DA 60 DA 60

7 Flue spigot diameter (DM) mm 130 130 150 150 200

8 Induced draught fan

9 Controller box

10 Lambdatronic P 3200 control

11 High-limit thermostat (STL)

12 Main switch

13 Service interface

3 TechnologyComponents and connections


3.3 Technical specifications

3.3.1 P4 Pellet 8/15/20/25


8 15 20 25

Nominal heat output kW 10.5 14.9 20.0 25.0

Heat output range 3.1-10.5 3.1-14.9 6.0-20.0 7.5-25.0

Electrical connection 230V / 50Hz / C16A

Power consumption W 48 55 71 87

Boiler weight kg 350 350 430 430

Boiler capacity (water) l 70 70 80 80

Water pressure drop (ΔT = 20 K) mbar 4.3 6.1 4.5 2.8

Min. boiler return temperature °C Not applicable due to internal return temperature control

Max. permitted operating temperature 80

Min. operating temperature setting 40

Permitted operating pressure bar 3

Boiler class as per EN 303-5:2012 5

Airborne sound level dB(A) < 70

Permitted fuel as per EN 14961 1) Part 2: Wood pellets class A1 / D06

Description Test report data

8 15 20 25

Testing institute TÜV Süd2) 3) 4) 3) 5)

Test report no. 2211099-1 2211099-2 2213065-1 2213065-21.Detailed information on the fuel is included in the operating instructions, in the section on "Permitted fuels"2.TÜV SÜD, Landesgesellschaft Österreich GmbH, Grazer Straße 18, A – 8600 Bruck an der Mur3.As per ÖNORM / DIN EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent structure it is sufficient, if the ratio of nominal heat output from the largest to the

smallest boiler ≤ 2 : 1, to carry out the tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not been tested inthe range, whose values have been determined depending on the nominal heat output by interpolation, fulfil the requirements of the norm.

4.Values of P4 Pellet 20 models are interpolated between the test protocol 2211099-2 and K44302/2.5.Values of P4 Pellet 25 models are interpolated between the test protocol 2211099-2 and K44302/2.

Test data NL / PL NL / PL NL / PL NL / PL

Carbon monoxide (CO) mg/MJ 8 / 15 8 / 15 14 / 31 20 / 46

Nitrous oxide (NOx) mg/MJ 72 / 58 76 / 58 77 / 64 79 / 70

Organic hydrocarbons (OGC) mg/MJ <1 / 1.0 1.0 / 1.0 1.0 / 1.0 1.0 / 1.0

Dust mg/MJ 14 / 1.3 12 / 1.3 11 / 4 10.7 / 7.2

Boiler efficiency % 93.9 / 92.2 93.3 / 92.2 93.5 / 93.4 93.6 / 94.6

Technology 3Technical specifications


3.3.2 P4 Pellet 32/38/45/48/60


32 38 45* 48 60

Nominal heat output kW 32.0 38.0 45.0 48.0 58.5

Heat output range 8.9-32.0 8.9-38.0 13.5-45 13.5-48 17.3-58.5


Power consumption W 110 110 120 120 120

Boiler weight kg 530 530 760 760 760

Boiler capacity (water) l 125 125 170 170 170

Water pressure drop (ΔT = 20 K) mbar 1.5 2.1 3.2 3.6 5.3









32 38 45* 48 60

Testing institute TÜV SÜD SZA2) TÜV3) 4) 5) TÜV3)

Test report no. K44302/6 K44302/4 13-U-584/SD

10-UW/Wels-

EX-242

10-UW/Wels-

EX-242/36)

08-UWC/Wels-

EX-337

1.Detailed information on the fuel is included in the operating instructions, in the section on "Permitted fuels"2.TÜV SÜD SZA Austria, Technische Prüf-GmbH, accredited initial and boiler inspection body in accordance with BGBl no. 211/92 Arsenal, Objekt 207, A-1030 Vienna3.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels4.As per ÖNORM / DIN EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent structure it is sufficient, if the ratio of nominal heat output from the largest to the

smallest boiler ≤ 2 : 1, to carry out the tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not been tested inthe range, whose values have been determined depending on the nominal heat output by interpolation, fulfill the requirements of the norm.

5.Values of P4 Pellet 48 models are interpolated between the test protocol K44302/4 and 08-UWC/Wels-EX-337.6.Partial load values of P4 Pellet 48 models from test protocol 10-UW/Wels-EX-242/3

* Boiler model only available in UK

Test data NL / PL NL / PL NL / PL NL / PL NL / PL

Carbon monoxide (CO) mg/MJ 31 / 61 45 / 61 31 / 44 25 / 11 5 / 10

Nitrous oxide (NOx) mg/MJ 79 / 75 77 / 75 77 / 72 77 / 60 77 / 66

Organic hydrocarbons (OGC) mg/MJ 1.0 / 1.0 1.0 / 1.0 <2 / <2 <2 / <1 <2 / <2

Dust mg/MJ 10 / 10 9 / 10 9,7 / 10 10 / 6 11 / 10

Boiler efficiency % 93.5 / 95.7 92.6 / 95.7 92,4 / 94,5 92.4 / 92.3 92.1 / 92.3

3 TechnologyTechnical specifications


3.3.3 P4 Pellet 80/100/105


80 100* 100 105

Nominal heat output kW 80.0 99.0 100.0 105.0

Heat output range 24.0-80.0 24.0-99.0 24.0-100.0 24.0-105.0


Power consumption W 115 112 112 112

Boiler weight kg 1090 1100

Boiler capacity (water) l 280

Water pressure drop (ΔT = 20 K) mbar 4.8 4.3









80 100* 100 105

Testing institute TÜV 2)

Test report no. 10-UW/Wels-EX-242/4

10-UW/Wels-EX-242/5

10-UW/Wels-EX-242/1

10-UW/Wels-EX-242/2

1.Detailed information on the fuel is included in the operating instructions, in the section on "Permitted fuels"2.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels3.As per ÖNORM / DIN EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent structure it is sufficient, if the ratio of nominal heat output from the largest to the

smallest boiler ≤ 2 : 1, to carry out the tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not been tested inthe range, whose values have been determined depending on the nominal heat output by interpolation, fulfill the requirements of the norm.

4.Values of P4 Pellet 80 models are interpolated between the test protocol 08-UW/Wels-EX-337 and 10-UW/Wels-EX-242/1. Partial load values from test protocol 10-UW/Wels-EX-242/1

* Boiler model only available in UK

Test data NL / PL NL / PL NL / PL NL / PL

Carbon monoxide (CO) mg/MJ 6 / 29 6 / 29 6 / 29 6 / 29

Nitrous oxide (NOx) mg/MJ 80 / 62 83 / 62 83 / 62 83 / 62

Organic hydrocarbons (OGC) mg/MJ <2 / <1 <1 / <1 <1 / <1 <1 / <1

Dust mg/MJ 12 / 10 13 / 10 13 / 10 13 / 10

Boiler efficiency % 93.2 / 93.7 94.3 / 93.7 94.3 / 93.7 94.3 / 93.7

Technology 3Technical specifications


3.3.4 Airborne sound levelThe sound levels specified in the following table are based on a sound measurementon a P4 Pellet 15. (measuring device: Omega HHSL 1) The sound level of the individual units was plotted at a distance of 1 m from the soundsource.Ambient level for measurement: 32 dBA

Unit Measurement

Units in continuous operation:

Induced draught fan (activation: 50%) 41 dBA



Units in non-continuous operation:

Suction turbine 68 dBA

Grate motor 42 dBA

Stoker motor / Stoker screw 33 dBA

Ignition fan 53 dBA

WOS motor / WOS system 60 dBA

Burn back slide valve actuator (open) 34 dBA

Burn back slide valve actuator (close) 50 dBA

Please note that all the measurements were taken in-house and do not come from acertified test centre. This data should, therefore, be viewed as individual guidelinemeasurements. Please also note the sound levels required in the standards listed below, which mustbe fulfilled by planning and construction measures:

ÖNORM B 8115-2 Sound insulation and room acoustics in building construction -Requirements for sound insulation

ÖNORM H 5190 Heating systems - Acoustic insulation

3 TechnologyTechnical specifications


4 Assembly

4.1 Materials suppliedThe boiler comes pre-assembled on a pallet in cardboard packaging.

1 Pre-assembled boiler Not pictured:

2 P4 Pellet 8-25: Transport covers of ashcansP4 Pellet 32-105:Insulated door(s) and ash container

In the suction cyclone container:▪ ID fan▪ Accessories package:

adjusting spanner, heating circuitcontroller, DHW tank sensor boil‐er underlay, 2x hose clamps

3 Cleaning devices Installation and operating instructions,guarantee certificate, identificationplate

4.1.1 Tools requiredThe following tools are required for assembling the P4 Pellet:❒ Socket set

4.2 Positioning

NOTICE

Damage to components if handled incorrectly

❒ Follow the transport instructions on the packaging❒ Transport components with care to avoid damage❒ Protect the packaging against damp conditions❒ Pay attention to the pallet's centre of gravity when lifting

❒ Position a fork-lift or similar lifting device at the pallet and bring in the components

If the boiler cannot be brought in on the pallet:

Assembly 4Materials supplied


❒ Remove the cardboard and remove the boiler from the pallet⇨ See "Remove boiler from pallet" [page 23]

If you need to dismantle the boiler to bring it in:❒ Dismantle the components of the boiler until it can be brought in

⇨ See "Dismantling for location where positioning is difficult" [page 26]

Positioning using a crane:

❒ Remove the insulating cover, heat exchanger cover and combustion chamber cov‐er

❒ Correctly attach the crane hook to the attachment point for lifting eye bolt (under‐neath the cover) and position the boiler

4.3 Temporary storageIf the system is to be assembled at a later stage:❒ Store components at a protected location, which is dry and free from dust

➥ Damp conditions and frost can damage components, particularly electric ones!

4 AssemblyTemporary storage


4.4 Setting up in the boiler room

4.4.1 Remove boiler from pallet

❒ Remove packing bands with suitable tools❒ Lift off the cardboard

❒ Remove the transport covers (1) from the ashcan (P4 Pellet 8 – 25) / insulateddoor(s) and ash container (P4 Pellet 32 – 105) as well as the cleaning devices (2)

❒ Remove the protective casing

On the front of the boiler (P4 Pellet 8 - 25):❒ Open the insulated door❒ Remove securing devices used during transportation on the left and right side of

the base❒ Tilt the lock bolt for the door hinges forwards❒ Lift the insulated door out of the hinges and remove❒ Pull out floor insulation

On the front of the boiler (P4 Pellet 32 - 105):❒ Remove securing devices used during transportation on the left and right side of

the base❒ Remove two screws each on the left and right of the ash collecting plate and re‐

move the collecting plate❒ Pull out the floor insulation behind

Assembly 4Setting up in the boiler room


At the back of the boiler:❒ Remove securing devices used during transportation on the left and right side of

the base ❒ Lift boiler off pallet

TIP: Use Froling’s KHV 1400 boiler lifting system to help remove the pallet!

4.4.2 Moving the boiler in the boiler room❒ Position a fork-lift or similar lifting device with a suitable load-bearing capacity at

the base frame❒ Lift and transport to the intended position in the installation room

➥ Observe the minimum distances in the boiler room.

4 AssemblySetting up in the boiler room


4.4.3 Minimum distances in the boiler room▪ The system should generally be set up so that it is accessible from all sides allow‐

ing quick and easy maintenance.▪ Regional regulations regarding necessary maintenance areas for inspecting the

chimney should be observed in addition to the specified minimum distances!▪ Observe the applicable standards and regulations when setting up the system.▪ Observe additional standards for noise protection

(ÖNORM H 5190 - Noise protection measures)

Without calorific value heat exchanger: With calorific value heat exchanger

P4 Pellet

Description Unit 8/15 20/25 32/38 45-60 80-105

A Minimum distance to stoker assembly mm 300 300 300 300 300

B Induced draught fan maintenance area 300 300 300 300 300

B* Space required incl. maintenance area for in‐duced draught fan with calorific value heat ex‐changer

600 600 - - -

C Space for insulated door 550 720 830 490 590

Space requirement with plug-in insulated door 400 400 300 - -

D Minimum distance to side of boiler 200 200 200 200 200

Assembly 4Setting up in the boiler room


4.5 Dismantling for location where positioning is difficultIf there is not enough room to bring in the pre-assembled boiler, certain componentscan be dismantled.This section shows the maximum possible disassembly. Only dismantle the parts ab‐solutely necessary to bring in the boiler.

4.5.1 Removing the stoker assembly and insulation

❒ Remove the locking screws on the sound insulation hood of the stoker assemblyand remove the sound insulation hood

❒ Lift the front part of the stoker assembly up and remove

❒ Lift the back part of the stoker assembly up and remove❒ Remove the insulating cover

❒ Remove the two screws and contact washers from the flaps of the controller cover➥ Caution: Do not lose the contact washers!

❒ Open the insulated door (P4 Pellet 8/15/20/25)

4 AssemblyDismantling for location where positioning is difficult


❒ Remove the screw and contact washer on the bottom of the controller cover❒ Remove the controller cover

4.5.2 Removing the door and ash drawer (P4 Pellet 8 - 25)

❒ Tilt the lock bolt for the door hinges forwards❒ Lift the insulated door out of the hinges and remove

❒ Open both ash doors and remove the ash drawer

Assembly 4Dismantling for location where positioning is difficult


❒ Remove the heat exchanger cover and combustion chamber cover to further re‐duce the weight

4.5.3 Dismantling the suction cyclone cover

❒ Remove the covering of the middle cableduct

At the pellet module:❒ Unplug the units:▪ "Suction unit M3"▪ "Max level S1"▪ "Gate valve M8"

❒ Undo the cable ties at the cable leadthrough❒ Pull out the cables of the unplugged units

Optional:



❒ Wind up the unplugged cables on the units❒ Open the clamps and take off the cover

4.5.4 Dismantling the stoker unit

❒ Remove the covering of the cable duct At the pellet module:❒ Unplug the units:▪ "Grate drive M6"▪ "Burn back flap M7"▪ "Stoker motor M1"▪ "Ignition E1"

❒ Pull out the cables of the unplugged units



❒ Undo the screw and remove the clamp on the ignition blower fan❒ Remove the ignition fan

❒ Remove the spring cotter at the front and back of the grate drive and remove thebolts➥ CAUTION: Secure the grate motor so that it does not fall!

❒ Push the sleeve on the grate rod back❒ Remove the grate motor



❒ Push the heat insulation mat aside slightly and remove two screws each from theright and left of the flange of the stoker unit➥ You can remove the screws completely as the stoker unit is secured to the boil‐

er with two hooks NOTICE! The following steps require two people:▪ Weight of stoker unit P4 Pellet 8 – 25: approx. 32kg▪ Weight of stoker unit P4 Pellet 32/38: approx. 36 kg▪ Weight of stoker unit P4 Pellet 45/48/60: approx. 46 kg▪ Weight of stoker unit P4 Pellet 80 - 105: approx. 68 kg

❒ Pull the stoker unit up slightly until the hooks come out of the stoker flange❒ Tip the unit back slightly and lift away

The P4 is now fully dismantled and can be brought in.



4.5.5 Positioning dimensions after dismantling

P4 Pellet

Dimen‐sion

Description 8/15 20/25 32/38 45/48/60 80-105

L Length, boiler mm 740 740 740 8201) 9102)

B Width, boiler 705 875 965 1275 1480

H Height, boiler 1280 1280 1430 1585 17101.You can reduce the size to 780 mm by removing the control (e.g. to fit through a door with a clearance of 800 mm)2.You can reduce the size to 880 mm by removing the control (e.g. to fit through a door with a clearance of 900 mm)

Removing the control

❒ Remove the left and right end caps

❒ Secure the bottom nuts to the bracket of the control❒ Remove the screws on the right and left of the control❒ Unplug the cable marked “Display” and pull up out of the controller❒ Remove the control



4.5.6 Notes for reassembly❒ After positioning, reassemble the boiler in the reverse order

It is particularly important to carry out the following steps during assembly:

Assembling the grate motor:

P4 Pellet 8-38:❒ Correct position at back support:▪ P4 Pellet 8 – 15: top position▪ P4 Pellet 20 - 38: bottom position

❒ Check that the housing is in the right position at the grate rod (see figure)

Ignition fan❒ Fit the clamp to the igniter tube using screws

➥ Fix the cable with the cable ties supplied.➥ There must not be any loose cables in the area of the igniter.➥ Only connect the power supply after completing assembly.

NOTICE! The individual units should be checked by a qualified technician and adjus‐ted if necessary during initial start-up.



4.6 Assembling the pellet boiler

4.6.1 Before Installation

Checking the seal of the ash doors❒ Open the door

❒ Insert a sheet of paper at the top between the door and boiler❒ Close the door❒ Try to pull the sheet of paper out

➥ If the paper cannot be removed:The door seal is OK and the settings are correct

➥ If the paper can be removed:The door is not sealed properly and must be adjusted!

❒ Check the seal again after positioning the doors ❒ Repeat the procedure at the bottom of the ash door and on the side of the door

handle above and below the door handle as well as at the same positions on theother ash door

Adjusting the doors

❒ Using an Allen key (13 mm), loosen the lock nuts on the locking cams at the topand bottom

❒ Close the door➥ With a gap of approx. 2 to 3 cm there should be a noticeable resistance

P4 Pellet 8 – 25:

4 AssemblyAssembling the pellet boiler


❒ If the resistance is too low or too high, move the locking cams backwards or for‐wards using an Allen key (32 mm)➥ The movement of the locking cams causes the hinged plate to move, allowing

the contact pressure to be adjusted➥ Caution: The two locking cams (top and bottom) must be aligned

❒ Close the door❒ If the door will not close, move the locking cams forward slightly

➥ Caution: The two locking cams (top and bottom) must be aligned ❒ Secure the lock nuts again

The locking plate can be moved in the same way using the locking cam at the side ofthe door handle, allowing the contact pressure to be adjusted on this side On the side with the door stop:❒ Adjust the doors with the locking cam as explained above

On the side with the door handle:

❒ Loosen the lock nuts at the top and bottom of the locking plate using an Allen key(13 mm)

❒ Close the door➥ With a gap of approx. 2 to 3 cm there should be a noticeable resistance

P4 Pellet 32 – 105:

Assembly 4Assembling the pellet boiler


❒ If the resistance is too low or too high, move the locking plate backwards or for‐wards using appropriate tools (e.g. screwdriver and hammer)➥ Caution: The locking plate must be aligned at the top and bottom.

❒ Close the door❒ If the door will not close, move the locking plate forward slightly

➥ Caution: The locking plate must be aligned at the top and bottom. ❒ Secure the lock nuts again



4.6.2 Fitting the induced draught fan

❒ Remove the locking screws on the sound insulation hood of the stoker assemblyand remove the sound insulation hood

❒ Open the clamps on the suction cyclone container and remove the cover❒ Remove the cardboard containing the induced draught fan and accessories pack‐

age from the suction cyclone container

❒ Remove the pre-assembled induced draught cover plates❒ Remove the pre-assembled nuts and spacer washers for induced draught❒ Attach and fit the ID fan as illustrated

❒ Join the two cables of the ID fan with the pre-installed cables➥ The locking device (1) must click into place.

❒ Push the cable behind the cladding and replace the induced draught cover plates.

Assembly 4Assembling the pellet boiler


4.6.3 Fitting the ash container and doors (P4 Pellet 32 - 105)

❒ Remove the insulating cover❒ Remove the two screws and contact washers from the flaps of the controller cover

➥ Caution: Do not lose the contact washers!


❒ Hang the insulated door to the boiler base and secure with lock bolt



❒ Take the two covers for the ash containers out of the ash containers, position andsecure with clamps

❒ Put the left and right ash containers onto the ash screws and secure with lever ❒ Replace the controller cover after connecting to the power supply

4.7 Connecting the discharge system ❒ Fit the discharge system according to the installation instructions enclosed

❒ Connect the suction hose and return air line at the back of the boiler:➥ Left port (1) = suction hose (Pellets sticker)➥ Right port (2) = return air line

NOTICE! Ensure the potential equalisation matches the discharge system assemblyinstructions when connecting the lines!

Assembly 4Connecting the discharge system


4.8 Power connection

DANGER

When working on electrical components:

Risk of electrocution!

When work is carried out on electrical components:❒ Only have work carried out by a qualified electrician❒ Observe the applicable standards and regulations

➥ Work must not be carried out on electrical components by unauthorisedpersons

❒ Flexible sheathed cable must be used for the wiring; this must be of the correct

size to comply with applicable regional standards and regulations.❒ The power supply line (mains connection) must be fitted with a C16A fuse by the

customer.

❒ Remove the insulating cover❒ Remove the two screws and contact washers from the flaps of the controller cover

➥ Caution: Do not lose the contact washers!❒ Open the insulated door (P4 Pellet 8/15/20/25)


4 AssemblyPower connection


❒ Wire the connections in accordance with the circuit diagram➥ For circuit diagrams see operating instructions for "Lambdatronic P 3200"

❒ To reassemble the controller cover and insulating cover, perform the disassembly

steps in the reverse order

4.8.1 Information on circulating pumps

NOTICE

According to 2012/622/EU external, wet running circulating pumps must complywith the following limit values of the Energy Efficiency Index (EEI):

- Effective from 01/01/2013: Wet running circulating pumps with EEI ≤ 0.27- Effective from 08/01/2015: Wet running circulating pumps with EEI ≤ 0.23

Only high efficiency pumps with a connection option for a control signal (PDM / 0-10V)should be connected to speed-controlled pump outputs (pump 1 on the core moduleand pump outputs on the hydraulic module). In this case, the control line is connectedto the corresponding PDM outputs of the boards. Observe the connection instructionsin the boiler controller documentation!

CAUTION

When using high efficiency pumps without an additional control line at speed-con‐trolled pump outputs:

Malfunctions of the boiler, the pump and the hydraulic system may occur!

Therefore:❒ Do not connect EC motor pumps without a control line to the speed-controlled

pump outputs of the boards.➥ Only use special high efficiency pumps with a connection option for a con‐

trol line (PDM/0-10V)!➥ Observe the additional instructions and information on board outputs in the

operation instructions for the boiler controller.

Assembly 4Power connection


4.8.2 Comfort pellet box portWith the automatic universal suction system, the Comfort pellet box is connected tothe core module using flexible cable (5x0.75mm2, YMM as per ÖVE-K41-5 or H05VV-F as per DIN VDE 0881-5). This is a 24V control line.

Comfort pellet box Core module of Lambdatronic P3200

OpenClosed

OpenClosed

The previous figure shows the plugged-in 5-pin connecting plug of the Comfort pelletbox and the accompanying connection layout at the Lambdatronic P 3200 controller. To check the plug configuration:❒ Perform check using the board's labels

➥ The actuators (1) of the pellet box must be switched to the "R" position. The actuators are ready to plug in and are connected to the board.The pellet box comes with all the necessary plug clips.

1

4 AssemblyPower connection


5 Start-up

5.1 Before commissioning / configuring the boilerThe boiler must be adjusted to the heating system during commissioning.

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteedif the system is set up by trained professionals and the standard factory settingsare observed.

Take the following precautions:❒ Initial startup should be carried out with an authorised installer or with Froling

customer services

❒ Adjust the boiler controller to the system type❒ Apply boiler standard values

NOTICE! The keypad assignment and the steps necessary to modify the parametersare detailed in the operating instructions for the boiler control unit.❒ Check the system pressure of the heating system❒ Check that the heating system is completely vented❒ Check that the safety devices are present and working correctly❒ Check that there is sufficient ventilation in the boiler room❒ Check the seal of the boiler

➥ All doors and inspection openings must be tightly sealed! ❒ Check that drives and actuators are working and turning in the right direction

NOTICE! For how to check the analogue and digital outputs, see the operating instruc‐tions for the boiler controller ❒ Check that the door contact switch is working correctly

NOTICE! For how to check the digital inputs see the operating instructions for the boil‐er controller.

Start-up 5Before commissioning / configuring the boiler


5.1.1 Setting the "Max level and Min level” sensor

In delivery configuration, the factory settings of the sen‐sor are secured with a seal. Changes to the settingsshould only be carried out by qualified technicians.The monitoring LED should only light up when materi‐als are detected.❒ If the monitoring LED stays on permanently, the

sensitivity is set too high➥ Reduce the sensitivity by turning the adjusting

screw to the left❒ If the monitoring LED does not react when pellets

are being fed in, the sensitivity is set too low.➥ Increase the sensitivity of the adjusting screw

by turning to the right

1

2

5.2 Initial startup

5.2.1 Permitted fuels

Wood pelletsWood pellets made from natural wood with a diameter of 6 mm

EU: Fuel acc. to EN 14961 - Part 2: Wood pellets class A1 / D06

and/or: Certification program ENplus or DINplus

General note:Before refilling the store, check for pellet dust and clean if necessary.

5.2.2 Non-permitted fuelsThe use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐ing of refuse, is not permitted.

CAUTION

In case of use of non-permitted fuels:

Burning non-permitted fuels increases the cleaning requirements and leads to abuild-up of aggressive sedimentation and condensation, which can damage theboiler and also invalidates the guarantee. Using non-standard fuels can also leadto serious problems with combustion.

For this reason, when operating the boiler:❒ Only use permitted fuels

Note on standards

5 Start-upBefore commissioning / configuring the boiler


5.2.3 Heating up for the first time

NOTICE

If condensation escapes during the initial heat-up phase, this does not indicate afault.

❒ Tip: If this occurs, clean up using a cleaning rag.

NOTICE! See boiler controller operating instructions for all the steps necessary to startup for the first time Lambdatronic P 3200

Start-up 5Initial startup


6 Decommissioning

6.1 MothballingThe following measures should be taken if the boiler is to remain out of service forseveral weeks (e.g. during the summer):❒ Clean the boiler thoroughly and close the doors fully

If the boiler is to remain out of service during the winter:❒ Have the system completely drained by a qualified technician

➥ Protection against frost

6.2 DisassemblyTo disassemble the system, follow the steps for assembly in reverse order.

6.3 Disposal❒ Ensure that they are disposed of in an environmentally friendly way in accordance

with waste management regulations.❒ You can separate and clean recyclable materials and send them to a recycling

centre.

6 DecommissioningMothballing


7 Appendix

7.1 Addresses

7.1.1 Address of manufacturer

FRÖLINGHeizkessel- und Behälterbau GesmbH Industriestraße 12A-4710 GrieskirchenAUSTRIA TEL 0043 (0)7248 606 0FAX 0043 (0)7248 606 600INTERNET www.froeling.com

7.1.2 Address of the installer

Stamp

Appendix 7Addresses


Operating Instructions

Pellet boiler P4 Pellet (Touch)

Translation of the original German operating instructions for the operatorRead and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!B0870112_en | Edition 25/02/2014


Table of Contents

1 General 41.1 P4 Pellet product overview 5

2 Safety 72.1 Hazard levels of warnings 72.2 Pictograms used 82.3 General safety information 92.4 Permitted uses 102.4.1 Permitted fuels 10 Wood pellets 102.4.2 Non-permitted fuels 102.5 Qualification of operating staff 112.6 Protective equipment for operating staff 112.7 Design information 112.7.1 Installation and approval of the heating system 112.7.2 General information for installation room (boiler room) 122.7.3 Requirements for central heating water 122.7.4 Use with storage tank 132.7.5 Chimney connection/chimney system 132.8 Safety devices 142.9 Residual risks 152.10 Emergency procedure 162.10.1 Overheating of the system 162.10.2 Smell of flue gas 16

3 Operating the System 173.1 Assembly and initial startup 173.2 Filling the pellet store 183.2.1 General advice for working in the store 183.3 Heating up the boiler 183.3.1 Switching on the power supply 193.3.2 Switching on the boiler 193.3.3 Regulating the boiler 193.3.4 Switching off the boiler 193.3.5 Switching off the power supply 19

4 Boiler servicing 204.1 General information on servicing 204.2 Inspection and cleaning 214.2.1 Inspection 21 Checking the system pressure 21 Checking the safety valve 214.2.2 Cleaning 22 Emptying the ash drawers (for P4 Pellet 8-25) 22 Emptying the ash container (for P4 Pellet 32-105) 23 Check the grate and combustion chamber 24 Check the downpipe for dirt (P4 Pellet 45 and up) 24

Table of Contents


4.2.3 Annual check 25 Cleaning the flue gas collection chamber and the heat exchanger 25 Clean WOS 26 Cleaning the induced draught fan 26 Cleaning the flue gas pipe 26 Cleaning the flue gas temperature sensor 27

4.3 Emissions measurement by chimney sweep or regulatory body 274.3.1 Measuring at rated load in pellet mode 274.4 Maintenance agreement / Customer service 284.5 Replacement parts 284.6 Disposal information 284.6.1 Disposal of the ash 284.6.2 Disposal of system components 28

5 Troubleshooting 295.1 General fault with power supply 295.1.1 Behaviour of system after a power failure 295.2 Excessive temperature 295.3 Faults with fault message 305.3.1 Procedure for fault messages 305.3.2 Acknowledging a fault message 30

6 Appendix 316.1 Addresses 316.1.1 Address of manufacturer 316.1.2 Address of the installer 31

Table of Contents

Operating Instructions P4 Pellet (Touch) | B0870112_en 3

1 GeneralThank you for choosing a quality product from Froling. The product features a state-of-the-art design and conforms to all currently applicable standards and testing guide‐lines.Please read and observe the documentation provided and always keep it close to thesystem for reference. It contains important safety information and all the operation andmaintenance specifications needed to operate the system safely, properly, environ‐mentally friendly and cost-effectively.The constant further development of our products means that there may be minor dif‐ferences from the pictures and content. If you discover any errors, please let us know:[email protected] to technical change.

Guarantee conditions

Our sale and delivery conditions generally apply. These conditions have been madeavailable to customers, and customers have been made aware of them at the time oforder completion.You can also find the guarantee conditions on the enclosed guarantee certificate.

1 General


1.1 P4 Pellet product overview

1 P4 Pellet with integrated pellet cyclone container

2 Control panel of the Lambdatronic P 3200 Touch control

2.1 Status LED (operating status):- GREEN constant: BOILER SWITCHED ON- GREEN flashing (interval: 5 sec OFF, 1 sec ON): BOILER SWITCHED OFF- ORANGE flashing: WARNING- RED flashing: FAULT

2.2 Large touch display for showing and changing operating statuses and parameters

2.3 Brightness sensor for automatically adjusting the brightness of the display

2.4 USB port for connecting a USB stick for software updates

3 Main switch

4 High-limit thermostat (STL)

5 Service interface

General 1P4 Pellet product overview


Ash removal unit P4 Pellet 8-25

6 Ash drawer - heat exchanger

7 Ash drawer - combustion chamber

8 Ash drawer

Ash removal unit P4 Pellet 32-105:

9 Ash container - heat exchanger

10 Ash container - combustion chamber

11 Ash screw and rotary agitator of the automatic heat exchanger cleaner

12 Ash screw and rotary agitator of the combustion chamber ash removal unit

13 Lever of the ash box lock

1 GeneralP4 Pellet product overview


2 Safety

2.1 Hazard levels of warningsThis documentation uses warnings with the following hazard levels to indicate directhazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will leadto serious injury or death. You must follow the instructions!

WARNING

The dangerous situation may occur and if measures are not observed it will leadto serious injury or death. Work with extreme care.

CAUTION

The dangerous situation may occur and if measures are not observed it will leadto minor injuries or damage to property.

Safety 2Hazard levels of warnings


2.2 Pictograms usedThe following symbols are used in the documentation and/or on the boiler to showwhat is required and forbidden and to give warnings.In accordance with the Machinery Directive, signs fitted directly within the danger areaof the boiler indicate immediate hazards or safety procedures. These stickers must notbe removed or covered.

Refer to the operating instruc‐tions

Wear safety shoes

Wear protective gloves Turn off the main switch

Keep the doors closed Wear a dust mask

Work under the supervision of asecond person

Lock

Unauthorised access prohibited No fire, open flames or smoking

Warning - hot surface Warning - hazardous electricalvoltage

Warning - hazardous or irritantmaterials

Warning - automatic boiler start‐up

Warning of injury to fingers orhands, automatic fan

Warning of injury to fingers orhands, automatic screw

Warning of injury to fingers orhands, gear/chain drive

Warning of injury to fingers orhands, cutting edge

Hand injury warning Warning of injury from beingpulled into rotating shafts

Increased CO concentrationwarning

Slipping hazard warning

2 SafetyPictograms used


2.3 General safety information

DANGER

If the device is used incorrectly:

Incorrect use of the system can cause severe injury and damage.

When operating the system:❒ Observe the instructions and information in the manuals.❒ Observe the details on procedures for operation, maintenance and cleaning,

as well as troubleshooting in the individual manuals.❒ Any work above and beyond this should be carried out by authorised heating

engineers or by Froling customer services.

WARNING

External influences:

Negative external influences, such as insufficient combustion air or non-standardfuel, can cause serious faults in combustion (e.g. spontaneous combustion of car‐bonisation gases or flash fires) which can in turn cause serious accidents!

When operating the boiler, please note the following:❒ Instructions and information regarding versions and minimum values, as well

as standards and guidelines for heating components in the instructions mustbe observed.

WARNING

Severe injuries and damage can be caused by an inadequate flue gas system.

Problems with the flue gas system, such as poor cleaning of the flue pipe or insuf‐ficient chimney draught, can cause serious faults in combustion (such as sponta‐neous combustion of carbonisation gases or flash fires).

Take the following precautions:❒ Optimum boiler performance can only be guaranteed if the flue gas system is

functioning correctly.

Safety 2General safety information


2.4 Permitted usesThe Froling Pellet boiler P4 Pellet is designed solely for heating domestic water. Onlyuse fuels specified in the "Permitted fuels" section.⇨ See "Permitted fuels" [page 10]The unit should only be operated when it is in full working order. It should be operatedin accordance with the instructions, observing safety precautions, and you should en‐sure you are aware of the potential hazards. The inspection and cleaning intervals inthe operating instructions should be observed. Ensure that any faults which might im‐pair safety are rectified immediately.The manufacturer or supplier is not liable for any damage resulting from non-permitteduses.

2.4.1 Permitted fuels

Wood pelletsWood pellets made from natural wood with a diameter of 6 mm

EU: Fuel acc. to EN 14961 - Part 2: Wood pellets class A1 / D06

Also: ENplus / DINplus certification scheme

General note:Before refilling the store, check for pellet dust and clean if necessary.

2.4.2 Non-permitted fuelsThe use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐ing of refuse, is not permitted.

CAUTION

In case of use of non-permitted fuels:

Burning non-permitted fuels increases the cleaning requirements and leads to abuild-up of aggressive sedimentation and condensation, which can damage theboiler and also invalidates the guarantee. Using non-standard fuels can also leadto serious problems with combustion.

For this reason, when operating the boiler:❒ Only use permitted fuels

Note on standards

2 SafetyPermitted uses


2.5 Qualification of operating staff

CAUTION

If unauthorised persons enter the installation room / boiler room:

Risk of personal injury and damage to property

❒ The operator is responsible for keeping unauthorised persons, in particularchildren, away from the system.

Only trained operators are permitted to operate the unit. The operator must also haveread and understood the instructions in the documentation.

2.6 Protective equipment for operating staffYou must ensure that staff have the protective equipment specified by accident pre‐vention regulations.

▪ For operation, inspection and cleaning:- suitable work wear- protective gloves- sturdy shoes

2.7 Design informationIt is forbidden to carry out modifications to the boiler or to change or deactivate safetyequipment.Always comply with all fire, building, and electrical regulations when installing or oper‐ating the boiler system, and follow the operating instructions and mandatory regula‐tions that apply in the country in which the boiler is operated.

2.7.1 Installation and approval of the heating systemThe boiler should be operated in a closed heating system. The following standardsgovern the installation:

ÖNORM / DIN EN 12828 Heating Systems in Buildings

NOTICE! Each heating system must be officially approved.The appropriate supervisory authority (inspection agency) must always be informedwhen installing or modifying a heating system, and authorisation must be obtainedfrom the building authorities:Austria: Inform the civic/municipal building authorities.Germany: Notify an approved chimney sweep and the building authorities.

Note on standards

Safety 2Qualification of operating staff


2.7.2 General information for installation room (boiler room)

Boiler room characteristics▪ There must not be a potentially explosive atmosphere in the boiler room as the

boiler is not suitable for use in potentially explosive environments.▪ The boiler room must be frost-free.▪ The boiler does not provide any light, so the customer must provide sufficient light‐

ing in the boiler room in accordance with national workplace design regulations.▪ When using the boiler over 2000 metres above sea level you should consult the

manufacturer.▪ Danger of fire due to flammable materials.

No flammable materials should be stored near the boiler. Flammable objects (e.g.clothing) must not be put on the boiler to dry.

▪ Damage due to impurities in combustion air.Do not use any solvents or cleaning agents containing chlorine in the room wherethe boiler is installed.

▪ Keep the air suction opening of the boiler free from dust.

Ventilation of the boiler roomVentilation air for the boiler room should be taken from and expelled directly outside,and the openings and air ducts should be designed to prevent weather conditions (foli‐age, snowdrifts, etc.) from obstructing the air flow. Unless otherwise specified in the applicable building regulations for the boiler room,the following standards apply to the design and dimensions of the air ducts:

ÖNORM H 5170 - Construction and fire protection requirementsTRVB H118 - Technical directives on fire protection/prevention

2.7.3 Requirements for central heating waterThe following standards and guidelines apply:

Austria:Germany:Switzerland:Italy:

ÖNORM H 5195-1VDI 2035SWKI 97-1D.P.R. no. 412

NOTICE! Note on filling with make-up water: always bleed the filling hose before con‐necting, in order to prevent air from entering the system.

Note on standards

Note on standards

2 SafetyDesign information


2.7.4 Use with storage tank

NOTICE

In principle it is not necessary to use a storage tank for the system to run smooth‐ly. However, we recommend that you use the system with a storage tank, as thisensures a continuous supply of fuel in the ideal output range of the boiler.

For the correct dimensions of the storage tank and the line insulation (in accordancewith ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling. ⇨ See "Addresses" [page 31]

2.7.5 Chimney connection/chimney systemEN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐ever possible, damage caused by seepage, insufficient feed pressure and condensa‐tion. Please note in this respect that flue gas temperatures lower than 160K aboveroom temperature can occur in the permitted operating range of the boiler. NOTICE! Please see the technical data contained in the assembly instructions for fur‐ther information about standards and regulations as well as the flue gas temperatureswhen clean and the other flue gas values!

Safety 2Design information


2.8 Safety devices

SV

34

2.2

2.2 BOILER OFF (switches off the boiler to prevent overheating)❒ Tap “Boiler off"

➥ Automatic mode is switched off➥ Control system follows the boiler shutdown procedure➥ Pumps continue to run

3 MAIN SWITCH (switches off the power supply)Before carrying out work on/in the boiler:❒ Press the standby key

➥ Automatic mode is switched off➥ Control system follows the boiler shutdown procedure

❒ Switch off the main switch and let the boiler cool down

4 HIGH-LIMIT THERMOSTAT (STL) (protection against overheating)The STL switches off the combustion system when the boiler reaches 105°C. Thepumps continue to run. Once the temperature falls below approx. 75°C, the STL canbe reset mechanically.

SV SAFETY VALVE (protection against overheating/excess pressure)When the boiler pressure reaches a maximum of 3 bar, the safety valve opens and theheated water is blown off in the form of steam.

2 SafetySafety devices


2.9 Residual risks

WARNING

When touching hot surfaces:

Severe burns are possible on hot surfaces and the flue gas pipe!

When work is carried out on the boiler:❒ Shut down the boiler in a controlled way (operating status "Boiler off") and al‐

low it to cool down❒ Protective gloves must generally be worn for work on the boiler, and it should

only be operated using the handles provided❒ Insulate the flue pipes or simply avoid touching them during operation.

WARNING

If the ash doors are opened during operation:

Opening a door may result in injury or damage or flue gas generation!

Therefore:❒ Do not open the doors while the boiler is operating!

WARNING

When inspecting and cleaning the boiler with the main switch on:

Serious injuries possible due to automatic boiler startup!

Before inspection and cleaning work in/on the boiler:❒ Switch the boiler off by tapping “Boiler off”

The boiler follows the shutdown procedure and switches to "Boiler off“ mode❒ Allow boiler to cool for at least 1 hour❒ Switch off the main switch and take precautions to prevent accidental switch‐

ing on.

WARNING

If non-permitted fuel types are used:

Non-standard fuels can cause serious faults in combustion (e.g. spontaneouscombustion of carbonisation gases / flash fires) which can lead to serious acci‐dents!

Take the following precautions:❒ Only use fuels specified in the "Permitted fuels" section of these operating in‐

structions.

Safety 2Residual risks


2.10 Emergency procedure

2.10.1 Overheating of the systemIf the system overheats and the safety devices fail, proceed as follows: NOTICE! Do not under any circumstances switch off the main switch or disconnect thepower supply. ❒ Keep all the doors on the boiler closed❒ Switch boiler off by tapping “Boiler OFF”❒ Open all mixing valve taps, switch on all pumps.

➥ The Froling heating circuit control performs this function in automatic operation.❒ Leave the boiler room and close the door❒ Open any available radiator thermostat valves

If the temperature does not drop:❒ Contact the installer or Froling customer services

⇨ See "Addresses" [page 31]

2.10.2 Smell of flue gas

DANGER

If you smell flue gas in the boiler room:

Inhaling toxic flue gas can be fatal!

If you smell flue gas in the room where the boiler is installed:❒ Keep all the doors on the boiler closed❒ Shut down the boiler according to procedure❒ Ventilate the room where the boiler is installed❒ Close the fire door and doors to living areas

2 SafetyEmergency procedure


3 Operating the System

3.1 Assembly and initial startupAssembly, installation and initial startup of the boiler must only be carried out by quali‐fied staff, and these procedures are described in the accompanying assembly instruc‐tions.NOTICE! See assembly instructions for the P4 Pellet

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteedif the system is set up by trained professionals and the standard factory settingsare observed.

Take the following precautions:❒ Initial startup should be carried out with an authorised installer or with Froling

customer services

The individual steps for initial start-up are explained in the operating instructions forthe controllerNOTICE! See operating instructions for the Lambdatronic P 3200 The customer is responsible for ensuring the following prior to initial start-up of thesystem by Froling customer services:▪ Electrical installation▪ Installation of water pipes▪ Flue gas connection including all insulation work▪ Work must comply with local fire protection regulations

▪ It is essential that the electrician who has carried out the installation work is availa‐

ble when starting up the system for the first time to make any changes to the wir‐ing which may become necessary.

▪ During initial start-up, operating staff are shown how to use the boiler. It is impera‐tive for proper handover of the product that those involved are present as this is aone-off opportunity.

NOTICE

If condensation escapes during the initial heat-up phase, this does not indicate afault.

❒ Tip: If this occurs, clean up using a cleaning rag.

Operating the System 3Assembly and initial startup


3.2 Filling the pellet store When the boiler has cooled down:❒ Before filling check the store for fines and clean if necessary

➥ Observe the general advice for working in the store.⇨ See "General advice for working in the store" [page 18]

❒ Close all openings to the store to seal out dust❒ Fill the store with pellets

➥ Only use permitted pellets⇨ See "Permitted fuels" [page 10]

3.2.1 General advice for working in the store

Risk of injury due to moveable parts!Shut off the feeder unit before entering the store!

When cleaning the store an increased amount of dust may be gener‐ated. Wear a dust mask when working in the store.

Adequately ventilate the store before entering. Keep the door openand always have a second person present. Observe the CO concen‐tration limit (< 30ppm).

Slick surfaces in the fuel store present a slipping hazard!

Unauthorised access prohibited! Keep children away!Keep the fuel store locked and store the key in a safe place!

No fire, open flames or smoking in the store!

3.3 Heating up the boiler

NOTICE

Do not modify the factory settings!

Changing the system's factory settings can be detrimental to efficiency and emis‐sions of the system.

3 Operating the SystemFilling the pellet store


3.3.1 Switching on the power supply❒ Turn on the main switch

➥ There is voltage at all of the boiler's components➥ When the control has completed the system start, the boiler is ready for opera‐

tion

3.3.2 Switching on the boiler❒ Switch the boiler on by tapping “Boiler ON”

➥ Automatic mode is active➥ The heating system is controlled via the controller according to the selected

mode in automatic mode❒ For other modes press the relevant function key

➥ Information on function keys in the relevant operating instructions for the"Lambdatronic P 3200" boiler controller

3.3.3 Regulating the boilerFor the necessary steps, and how to display and alter parameters:NOTICE! See operating instructions for boiler controller!

3.3.4 Switching off the boiler❒ Switch boiler off by tapping “Boiler OFF”

➥ The boiler follows the shutdown program and switches to "Boiler off" status➥ The combustion unit is switched off, the chamber discharge unit and the entire

hydraulic system remain active

3.3.5 Switching off the power supply

WARNING

When turning off the main switch in automatic mode:

Serious combustion faults leading to serious accidents are possible.

Before turning off the main switch:❒ Switch boiler off by tapping “Boiler OFF”

➥ The boiler follows the shutdown procedure and switches to "Boiler off“ sta‐tus after the cleaning cycle

❒ Turn off the main switch

➥ Boiler controller is switched off➥ There is no power supply to any of the boiler components

NOTICE! Frost protection function is no longer active!

Operating the System 3Heating up the boiler


4 Boiler servicing

4.1 General information on servicing

DANGER

When working on electrical components:

Risk of electrocution!

When work is carried out on electrical components:❒ Only have work carried out by a qualified electrician❒ Observe the applicable standards and regulations

➥ Work must not be carried out on electrical components by unauthorisedpeople

WARNING

When inspecting and cleaning the boiler with the main switch on:

Serious injuries possible due to automatic boiler startup!

Before inspection and cleaning work in/on the boiler:❒ Switch the boiler off by tapping “Boiler off”

The boiler follows the shutdown procedure and switches to "Boiler off“ mode❒ Allow boiler to cool for at least 1 hour❒ Switch off the main switch and take precautions to prevent accidental switch‐

ing on.

WARNING

During inspection and cleaning work to the hot boiler:

Hot parts and the flue gas pipe can cause serious burns!

Take the following precautions:❒ It should be standard practice to wear protective gloves when working on the

boiler.❒ Only operate the boiler using the handles provided❒ Before starting any maintenance work activate “Service mode” in the quick

menu

➥ The boiler follows the shutdown procedure and switches to "Boiler off" sta‐tus

❒ Allow boiler to cool for at least 1 hour❒ After maintenance has been carried out switch the boiler on in the desired

mode.➥ In service mode the boiler does not start automatically.

4 Boiler servicingGeneral information on servicing


WARNING

Incorrect inspection and cleaning:

Incorrect or insufficient inspection and cleaning of the boiler can cause seriousfaults in combustion (e.g. spontaneous combustion of carbonisation gases / flashfires) and this can lead to serious accidents and damage!

Take the following precautions:❒ Clean the boiler following the instructions in the instruction manual. Follow the

boiler operating instructions.

NOTICE

We recommend that you keep a maintenance book in accordance with ÖNORMM7510 of the Technical Directive for Fire Prevention (TRVB)

4.2 Inspection and cleaning❒ Regular cleaning of the boiler extends its life and is a basic requirement for

smooth running.❒ Recommendation: use an ash vacuum for cleaning.

4.2.1 Inspection

Checking the system pressure❒ Check the system pressure on the pressure gauge

➥ The value must be 20% above the pre-stressed pressure of the expansion tankNOTICE! Check that the position of the pressure gauge and rated pressure ofthe expansion tank match your installer's specifications!

If the system pressure decreases:❒ Top up with water

NOTICE! If this happens frequently, the seal of the heating system is faulty! Informyour installer

If large pressure fluctuations are observed:❒ Ask an expert to inspect the expansion tank

Checking the safety valve ❒ Check the seal of the safety valve regularly and ensure that the valve is not dirty

NOTICE! Inspection work must be carried out in accordance with the manufactur‐er’s instructions.

Boiler servicing 4Inspection and cleaning


4.2.2 CleaningThe ash drawers (P4 Pellet 8-25) or ash container (P4 Pellet 32-105) must be emptiedat intervals according to energy requirements and pellet quality. The grate and com‐bustion chamber should also be checked at these intervals for dirt.

Emptying the ash drawers (for P4 Pellet 8-25)

❒ Open the insulated door and position the ash drawer below the ash doors to catch

any ash that might overflow❒ Open ash doors

❒ Pull the ash drawer out slightly

➥ This pushes the ash lying in front of the drawer into the ash bowl❒ Put the transport cover on as illustrated and pull out the ash drawer until the trans‐

port cover engages

❒ Take the ashcan to the emptying point and empty it

➥ Push up the locking lever to remove the transport cover.

4 Boiler servicingInspection and cleaning


Emptying the ash container (for P4 Pellet 32-105)

❒ Open the insulated door and push the locking lever up❒ Pull out the ash container and put the cover plate provided onto the flange of the

ash container

❒ Take the ash container to the emptying point and empty it

➥ To remove the cover the clamp must be unlocked and opened



Check the grate and combustion chamber

NOTICE! Only clean the grate and combustion chamber when the boiler has cooleddown! For P4 Pellet 8/15/20/25:❒ Open the insulating door, open the ash door on the right and pull out the ash

drawer For P4 Pellet 32/38/48/60/80/100/105:❒ Open the insulating door, take out the ash container on the right and open the ash

door ❒ Check the combustion grate and combustion chamber for dirt❒ If there is a lot of dirt, clean the combustion chamber

⇨ See "Cleaning the flue gas collection chamber and the heat exchanger" [page25]

Check the downpipe for dirt (P4 Pellet 45 and up)

❒ Check the downpipe (1) between the burner gate valve and combustion grate for

dirt❒ If there is a lot of dirt or caking, clean the downpipe

➥ For cleaning use a large crosshead screwdriver and a wire brush, for example.



4.2.3 Annual check

Cleaning the flue gas collection chamber and the heat exchanger

❒ Remove the insulating cover and turn the seal screws on the cleaning cover anti‐

clockwise using the tool supplied to loosen❒ Remove the cleaning cover

❒ Clean the flue gas collection chamber and the opening to the induced draught fan

with a brush❒ Remove any soot which has accumulated

➥ Recommendation: use an ash vacuum

❒ Remove the internal heat exchanger cover❒ Clean the flue pipes and the combustion chamber underneath with a cleaning

brush



Clean WOS

❒ Remove the insulating cover and cleaning cover

⇨ See "Cleaning the flue gas collection chamber and the heat exchanger" [page25]

❒ Remove the retainer at the bottom at the lock bolt, push the lock bolt up and re‐

move❒ Remove the WOS mount along with the springs❒ Clean the heat exchanger pipes with cleaning brush provided

Cleaning the induced draught fan

❒ Unplug the connection cable of the induced draught fan❒ Remove the induced draught fan from the back of the boiler❒ Check for dirt and damage❒ Clean the blower wheel from the inside out using a soft brush or paint brush

❒ Remove dirt and deposits from the induced draught housing using a scraper❒ Remove any ash which has gathered using an ash vacuum❒ Fit the ID fan and plug in the connection cable

Cleaning the flue gas pipe❒ Switch off the induced draught fan

➥ This prevents damage to the fan from the cleaning brush❒ Remove the inspection cover on the connecting pipe❒ Clean the connecting pipe between the boiler and chimney with a chimney sweep‐

ing brush➥ Depending on the layout of the flue gas pipes and the chimney draught, clean‐

ing once a year may not be enough!



Cleaning the flue gas temperature sensor

❒ Release the retaining screw and take the flue gas temperature sensor (AF) out of

the flue gas pipe❒ Wipe the flue gas temperature sensor with a clean cloth❒ Push in the flue gas temperature sensor until about 20 mm of the sensor remains

protruding from the bushing and secure with fixing screw

4.3 Emissions measurement by chimney sweep or regulatory bodyVarious legal regulations stipulate that heating systems must be inspected periodical‐ly. In Germany this is regulated by the First Federal Emissions Protection Ordinance(BimSchV) in the last amended version, and in Austria by various state laws. The boil‐er must always be cleaned 2-3 heating days prior to measurement. It is important toensure that there is adequate heat consumption on the day of the measurement. (e.g.storage tank must be able to take heat for the duration of the measurement).

4.3.1 Measuring at rated load in pellet mode❒ Activate “chimney sweep mode” in the quick menu▪ The boiler runs for 45 min at nominal load

- Boiler temperature is set to 70°C - Heating pumps switch on and mixer valves open- DHW tank and store loading pump are controlled as normal

❒ Perform the measurement under the following conditions➥ Flue gas temperature at approx. 110 – 150°C➥ CO2 content of the flue gas between 10 and 13%➥ Boiler temperature above 65°C



4.4 Maintenance agreement / Customer serviceNOTICE! We recommend a yearly inspection by Froling customer services or an au‐thorised partner (third party maintenance).Regular maintenance and servicing by a heating specialist will ensure a long, trouble-free service life for your heating system. It will ensure that your system stays environ‐mentally-friendly and operates efficiently and cost-effectively.In the course of this maintenance the entire system is inspected and optimised, partic‐ularly regulation and control of the boiler. The emission measurement carried out canalso be used to draw conclusions about the combustion performance of the boiler.For this reason, FROLING offers a service agreement, which optimises operatingsafety. Please see the details in the accompanying guarantee certificate.Your Froling customer service office will also be happy to advise you.

NOTICE

All national and regional regulations relating to regular testing of the system mustbe observed. Please be advised that, in Austria, commercial systems with a ratedheat output of 50 kW or more must be regularly tested at yearly intervals in ac‐cordance with the Heating Plant Regulations (Feuerungsanlagen-Verordnung).

4.5 Replacement partsWith Froling original replacement parts in your boiler, you are using parts that matchperfectly. As the parts fit together so well, installation times are shortened and a longservice life is maintained.

NOTICE

Installing non-original parts will invalidate the guarantee.

❒ Only replace components or parts with original replacement parts

4.6 Disposal information

4.6.1 Disposal of the ash❒ The ash should be disposed of in accordance with waste management regula‐

tions.

4.6.2 Disposal of system components❒ Ensure that they are disposed of in an environmentally friendly way in accordance

with waste management regulations.❒ You can separate and clean recyclable materials and send them to a recycling

centre.

4 Boiler servicingMaintenance agreement / Customer service


5 Troubleshooting

5.1 General fault with power supply

Error characteristics Cause of error Elimination of error

Nothing is shown on the dis‐playNo power to the controller

General power failureMain switch is turned offFI circuit breaker or line pro‐tection is switched offFaulty fuse in the controller

Turn on the main switchSwitch on the FI circuit break‐er or line protectionReplace the fuse – note theamperage (10AT)

5.1.1 Behaviour of system after a power failureWhen the power supply has been restored, the boiler returns to the previous modeand is controlled according to the specified program.❒ After a power failure, check whether the STL (high-limit thermostat) has tripped.❒ Keep the doors of the boiler closed during and after the power failure, at least until

the induced draught fan automatically starts up again.EXCEPTION:If the boiler operating status was "Heating up", "Pre-heating" or "Ignition" before thepower failure, the boiler follows the shutdown procedure and cleaning commences.Only then does the boiler switch to "Preparation" operating status and the systemstarts up again.

5.2 Excessive temperatureThe high-limit thermostat (STL) shuts down the boiler when it reaches a temperatureof max. 105°C. The pumps continue to run.Once the temperature falls below approx. 75°C, the STL (high-limit thermostat) can bereset mechanically:❒ Unscrew the cap on the STL (high-limit thermostat)❒ Unlock the STL (high-limit thermostat) by pressing with a screwdriver

Troubleshooting 5General fault with power supply


5.3 Faults with fault message

If a fault has occurred and has not yet been cleared:❒ Status LED indicates the nature of the fault

- Orange flashing: Warning- Red flashing: Error or alarm

❒ A fault message is shown on the display The term "fault" is a collective term for warnings, errors and alarms. The boiler reactsdifferently to the three types of message:

WARNING In case of warnings the boiler initially continues controlled opera‐tion, giving the option of resolving the error quickly to prevent ashutdown.

ERROR The boiler follows the shutdown procedure and remains in "Boil‐er off" status until the problem is resolved.

ALARM An alarm triggers a system emergency stop. The boiler shutsdown immediately, the heating circuit controller and pumps re‐main active.

5.3.1 Procedure for fault messagesThe procedure in the case of a fault message, the causes of faults and procedure fortroubleshooting are described in the operating instructions for the boiler controller:IMPORTANT! See operating instructions for the Lambdatronic P 3200

5.3.2 Acknowledging a fault messageTrace and remove the fault and then:❒ Tap the “Cancel” symbol

➥ Status LED constant or flashing green light (depending on operating status)- Green constant: Boiler switched on- Green flashing: Boiler switched off

5 TroubleshootingFaults with fault message


6 Appendix

6.1 Addresses

6.1.1 Address of manufacturer

FRÖLINGHeizkessel- und Behälterbau GesmbH Industriestaße 12A-4710 GrieskirchenAUSTRIA TEL 0043 (0)7248 606 0FAX 0043 (0) 7248 606 600INTERNET www.froeling com

6.1.2 Address of the installer

Stamp

Appendix 6Addresses


http://www.froeling/

pellet boiler p4 pellet 8 - 105 - · pdf filethese instructions together with those in the...

Documents