Fröling PE1c Pellet 16-22 User manual

Operating Instructions
Pellet boiler PE1c Pellet
Translation of the original German operating instructions for the operator
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B1590420_en | Edition 17/02/2021
Fröling Ges.m.b.H. | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of contents
1 General 5
1.1 Product overview PE1c Pellet 6
2 Safety 7
2.1 Hazard levels of warnings 7
2.2 Pictograms used 8
2.3 General safety information 9
2.4 Permitted uses 10
2.4.1 The Clean Air Act 1993 and Smoke Control Areas 10
2.4.2 Permitted fuels 11
Wood pellets 11
2.4.3 Non-permitted fuels 12
2.5 Qualification of operating staff 12
2.6 Protective equipment for operating staff 12
2.7 Safety Devices 13
2.8 Residual risks 14
2.9 Emergency procedure 16
2.9.1 Overheating of the system 16
2.9.2 Smell of flue gas 16
2.9.3 Fire in the system 16
3 Notes for operating a heating system 17
3.1 Installation and approval of the heating system 17
3.2 General information for installation room (boiler room) 17
3.3 Room air-independent operation 18
3.4 Requirements for central heating water 19
3.5 Notes for using pressure maintenance systems 21
3.6 Use with storage tank 21
3.7 Chimney connection/chimney system 22
3.8 Condensate drainage 22
4 Operating the system 23
4.1 Assembly and initial startup 23
4.2 Switching on the power supply 24
4.3 Operate the boiler using the touch display 24
4.3.1 Overview of the touch display 24
Status display 25
Control icons 25
Display icons for froeling-connect/remote control 26
Navigation within the system menu 27
Changing parameters 28
Change time window 28
Quick menu 29
4.3.2 Select information displays 30
Table of contents
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4.3.3 Switch boiler ON/OFF 32
4.3.4 Change boiler mode 33
4.3.5 Change date and time 33
4.3.6 Change desired DHW tank temperature 34
4.3.7 One-time extra loading of an individual DHW tank 34
4.3.8 One-time extra loading of all existing DHW tanks. 34
4.3.9 Set the heating curve of a heating circuit 35
4.3.10 Change room temperature (heating circuit without room temperature sensor) 36
4.3.11 Change room temperature (heating circuit with room temperature sensor) 37
4.3.12 Switch heating circuit mode 37
4.3.13 Lock display/switch user level 38
4.3.14 Change the name of the components 38
4.3.15 Configure the holiday program 39
4.4 Switch the boiler ON/OFF on the room console 40
4.5 Filling the pellet store 41
4.5.1 Notes on filling the fuel stores 41
4.5.2 Correct the remaining pellet amount in store room 42
4.5.3 Adjust the pellet consumption counter to the fuel 42
4.5.4 Setting the automatic notification for minimum level 44
4.5.5 Resetting the pellet consumption counter 45
4.6 Check the fill level of the ash container and empty if required 45
4.6.1 Check the fill level of the ash container 45
4.6.2 Empty ash container 46
4.7 Switching off the power supply 47
5 Servicing the system 48
5.1 General information on servicing 48
5.2 Required tools 49
5.3 Maintenance work by the operator 50
5.3.1 Inspection 50
Checking the system pressure 50
Checking the safety valve 50
Checking the quick vent valve 50
5.3.2 Cleaning 51
Clean the burn-out ring and burners 51
Check the condensation drain 52
5.3.3 Periodic inspection and cleaning 54
Flush the condensation drain 54
Check rinse water cleaning 54
Clean the heat exchanger and WOS springs 56
Clean the induced draft fan 58
Clean the flue gas temperature sensor 58
Cleaning the flue gas pipe 58
Checking the draught controller flap 59
Clean the screen on the flushing device 59
5.4 Maintenance work by technicians 60
5.4.1 Checking and cleaning the combustion grate 61
5.4.2 Cleaning the measurement line of the underpressure controller 61
5.4.3 Cleaning the Lambda probe 62
5.5 Emissions measurement by chimney sweep or regulatory body 63
5.5.1 Switch on the system 63
5.5.2 Start emissions measurement 64
5.6 Replacement parts 64
Table of contents
Operating Instructions PE1c Pellet | B1590420_en 3

5.7 Disposal information 64
5.7.1 Disposal of the ash 64
5.7.2 Disposal of system components 64
6 Troubleshooting 65
6.1 General fault with power supply 65
6.1.1 Behaviour of system after a power failure 65
6.2 Excessive temperature 65
6.3 Faults with fault message 66
6.3.1 Procedure for fault messages 66
7 Appendix 68
7.1 Addresses 68
7.1.1 Address of manufacturer 68
Customer service 68
7.1.2 Address of the installer 68
Table of contents
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1 General
Thank 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
guidelines.
Please read and observe the documentation provided and always keep it close to the
system for reference. Observing the requirements and safety information in the
documentation makes a significant contribution to safe, appropriate, environmentally
friendly and economical operation of the system.
The constant further development of our products means that there may be minor
differences from the pictures and content. If you discover any errors, please let us
know: [email protected].
Subject to technical change.
Warranty and Guarantee Conditions
Our sale and delivery conditions will be applicable. These conditions have been made
available to customers, and customers have been made aware of them at the time of
order completion.
You can also find the guarantee conditions on the enclosed guarantee certificate.
General 1
Operating Instructions PE1c Pellet | B1590420_en 5

1.1 Product overview PE1c Pellet
2.1
2.2
2.3
2.4
2.3
1Pellet boiler PE1c Pellet
2Boiler controller Lambdatronic P 3200, ⇨ See "Overview of the touch display" [page
24]
2.1 Large touch screen for displaying / modifying operating statuses and parameters
2.2 Status display (operating status), ⇨ See "Status display" [page 25]
2.3 Brightness sensor for automatically adjusting the brightness of the display
2.4 USB port for connecting a USB stick for software updates
3Main switch
4High-limit thermostat (STL)
5Door switch
6Maintenance opening for combustion chamber (behind cover)
7Ash container for automatic ash removal
8Quick start guide
1General
Product overview PE1c Pellet
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2 Safety
2.1 Hazard levels of warnings
This documentation uses warnings with the following hazard levels to indicate direct
hazards and important safety instructions:
DANGER
The dangerous situation is imminent and if measures are not observed it will lead
to serious injury or death. You must follow the instructions!
WARNING
The dangerous situation may occur and if measures are not observed it will lead
to serious injury or death. Work with extreme care.
CAUTION
The dangerous situation may occur and if measures are not observed it will lead
to minor injuries.
NOTICE
The dangerous situation may occur and if measures are not observed it will lead
to damage to property or pollution.
Safety 2
Hazard levels of warnings
Operating Instructions PE1c Pellet | B1590420_en 7

2.2 Pictograms used
The following symbols are used in the documentation and/or on the boiler to show
what is required and forbidden and to give warnings.
In accordance with the Machinery Directive, signs fitted directly within the danger area
of the boiler indicate immediate hazards or safety procedures. These stickers must not
be removed or covered.
Refer to the operating
instructions
Wear safety shoes
Wear protective gloves Turn off the main switch
Keep the doors closed Wear a dust mask
Work under the supervision of a
second person
Lock
Unauthorised access prohibited No fire, open flames or smoking
Warning - hot surface Warning - hazardous electrical
voltage
Warning - hazardous or irritant
materials
Warning - automatic boiler
startup
Warning of injury to fingers or
hands, automatic fan
Warning of injury to fingers or
hands, automatic screw
Warning of injury to fingers or
hands, gear/chain drive
Warning of injury to fingers or
hands, cutting edge
Hand injury warning Warning of injury from being
pulled into rotating shafts
Increased CO concentration
warning
Slipping hazard warning
2Safety
Pictograms used
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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 respective manuals.
❒ Any work above and beyond this (e.g. servicing) must be carried out by a
heating engineer approved by Fröling Heizkessel- und Behälterbau GesmbH
or by Froling customer services
WARNING
External influences:
Negative external influences, such as insufficient combustion air or non-standard
fuel, can cause serious faults in combustion (e.g. spontaneous combustion of
carbonisation 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 must
be 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
insufficient chimney draught, can cause serious faults in combustion (such as
spontaneous 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 2
General safety information
Operating Instructions PE1c Pellet | B1590420_en 9

2.4 Permitted uses
The Froling Pellet boiler PE1c Pellet is designed solely for heating domestic water.
Only the fuels specified in the "Permitted fuels" section may be used.
⇨ See "Permitted fuels" [page 11]
The unit should only be operated when it is in full working order. It must be operated in
accordance with the instructions, observing safety precautions, and you should ensure
you are aware of the potential hazards. The inspection and cleaning intervals in the
operating instructions must be observed. Ensure that any faults which might impair
safety are rectified immediately.
The manufacturer or supplier is not liable for any damage resulting from non-permitted
uses.
Only original spare parts or specific alternative spare parts authorised by the
manufacturer may be used. Any kind of change or modification made to the product
will invalidate the manufacturer’s conformity with the applicable guideline(s). In such
cases, the product will need to undergo new hazard evaluation procedures by the
operator. The operator will then be fully responsible for the declaration of conformity
according to the valid guideline(s) for the product and will need to issue a
corresponding declaration for the device. This person will then assume all of the rights
and responsibilities of a manufacturer.
2.4.1 The Clean Air Act 1993 and Smoke Control Areas
Under the Clean Air Act local authorities may declare the whole or part of the district of
the authority to be a smoke control area. It is an offence to emit smoke from a
chimney of a building, from a furnance or from any fixed boiler if located in a
designated smoke control area. It is also an offence to acquire an „unauthorised
fuel“ for use within a smoke control area unless it is used in an „exempt“ appliance
(„exempted“ from the controls which generally apply in the smoke control area). The
Secretary of State for Environment, Food and Rural Affairs has powers under the Act
to authorise smokeless fuels or exempt appliances for use in smoke control areas in
England. In Scotland and Wales this power rests with Ministers in the devolved
administrations for those countries. Separate legislation, the Clean Air (Northern
Ireland) Order 1981, applies in Northern Ireland. Therefore it is a requirement that
fuels burnt or obtained for use in smoke control areas have been „authorised“ in
Regulations and that appliances used to burn solid fuel in those areas (other than
„authorised“ fuels) have been exempted by an Order made and signed by the
Secretary of State or Minister in the devolved administrations.
Further information on the requirements of the Clean Air Act can be found here: http://
smokecontrol.defra.gov.uk
Your local authority is responsible for implementing the Clean Air Act 1993 including
designation and supervision of smoke control areas and you can contact them for
details of Clean Air Act requirements.
The Froling PE1c Pellet 16 and PE1c Pellet 22 have been recommended as suitable
for use in smoke control areas when burning fuels as listed under "Permitted fuels".
2Safety
Permitted uses
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2.4.2 Permitted fuels
Wood pellets
Wood pellets made from natural wood with a diameter of 6 mm
EU: Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06
and/or: EN
plus / DIN plus certification scheme
General note:
Before refilling the store, check for pellet dust and clean if necessary.
TIP: Fit the Froling PST pellet deduster for separating the dust particles contained in
the return air
Note on standards
Safety 2
Permitted uses
Operating Instructions PE1c Pellet | B1590420_en 11

2.4.3 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section, and particularly the
burning 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 a
build-up of aggressive sedimentation and condensation, which can damage the
boiler and also invalidates the guarantee. Using non-standard fuels can also lead
to serious problems with combustion.
For this reason, when operating the boiler:
❒ Only use permitted fuels
2.5 Qualification of operating staff
CAUTION
If unauthorised persons enter the Installation room:
Risk of personal injury and damage to property
❒ The operator is responsible for keeping unauthorised persons, in particular
children, away from the system.
Only trained operators are permitted to operate the unit. The operator must also have
read and understood the instructions in the documentation.
2.6 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations!
▪ For operation, inspection and cleaning:
–Suitable work wear
– Protective gloves
– Sturdy shoes
– Dust mask
When working with dust from the electrostatic
particle separator, use dust masks in filter class
FFP2 or higher
2Safety
Permitted uses
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2.7 Safety Devices
2.1
SV
2.1 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:
❒ Tap “Boiler OFF"
➥Automatic mode is switched off
➥Control system follows the boiler shutdown procedure
❒ Switch off the main switch and let the boiler cool down
4 SAFETY TEMPERATURE LIMITER (STL)
(protection against overheating)
The STL (high-limit thermostat) switches off the combustion system when the boiler
reaches 100°C. The pumps continue to run. Once the temperature falls below approx.
75°C, the STL can be reset mechanically.
5 DOOR SWITCH
(protection against access to moving components)
If the insulated door opens while the boiler is operating, all of the units stop to prevent
injuries at moving components. If the insulated door remains open for more than a
specified time, the boiler automatically follows the shutdown procedure.
SV SAFETY VALVE
(protection against overheating/excess pressure)
When the boiler pressure reaches a maximum of 3 bar, the safety valve opens and the
heated water is blown off in the form of steam.
Safety 2
Safety Devices
Operating Instructions PE1c Pellet | B1590420_en 13

2.8 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 according to procedure (“Boiler off” operating status) and
allow it to cool down
❒ Protective gloves must usually be worn for work on the boiler, and it should
only be operated using the handles provided
❒ Insulate the flue gas pipes and do not touch them during operation
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 the boiler to cool for at least 1 hour
❒ Switch off the main switch and take precautions to prevent accidental
switching on
WARNING
If non-permitted fuel types are used:
Non-standard fuels can cause serious faults in combustion (e.g. spontaneous
combustion of carbonisation gases / flash fires) which can lead to serious
accidents!
Take the following precautions:
❒ Only use fuels specified in the "Permitted fuels" section of these operating
instructions.
2Safety
Residual risks
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DANGER
If maintenance work is performed when the system is in operation:
Risk to life from high voltage electrodes!
Before carrying out work on/in the electrostatic precipitator:
❒ Switch off the power supply and take precautions to prevent accidental
switching on
❒ Earth and short circuit HV electrodes
❒ Always have work carried out by a qualified electrician
❒ Observe the applicable standards and regulations
➥Work must not be carried out on electrical components by unauthorised
persons
DANGER
Persons using pacemakers whilst in the immediate vicinity of the electrostatic
particle separator:
Interference of the pacemaker by electromagnetic fields of the particle separator
is possible!
Therefore:
❒ Maintain a safety distance of at least one metre from the electrostatic particle
separator
❒ Perform work only when the electrostatic particle separator is switched off
Safety 2
Residual risks
Operating Instructions PE1c Pellet | B1590420_en 15

2.9 Emergency procedure
2.9.1 Overheating of the system
If the system overheats and the safety devices fail to operate, proceed as follows:
NOTICE! Do not under any circumstances switch off the main switch or disconnect the
power supply.
❒Keep all the doors on the boiler closed
❒ Open all mixing valve taps, switch on all pumps.
➥The Froling heating circuit control takes on this function in automatic operation.
❒ Leave the boiler room and close the door
❒ Open any thermostatic valves on the radiator and ensure sufficient heat
dissipation from the rooms
If the temperature does not drop:
❒ Contact the installer or Froling customer services
2.9.2 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
Recommendation: Do not install smoke alarms and carbon monoxide detectors near
the system.
2.9.3 Fire in the system
DANGER
In case of fire in the system:
Risk of death by fire and poisonous gases
Emergency procedure in case of fire:
❒ Leave the boiler room
❒ Close the doors
❒ Inform the fire department
2Safety
Emergency procedure
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3 Notes for operating a heating system
Carrying out modifications to the system and changing or disabling safety equipment
is prohibited.
Always comply with all fire, building and electrical regulations when installing or
operating the system, in addition to following the operating instructions and mandatory
regulations that apply in the country in which the tank is operated.
3.1 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
EN 12828 - Heating Systems in Buildings
NOTICE! Each heating system must be officially approved.
The appropriate supervisory authority (inspection agency) must always be informed
when installing or modifying a heating system, and authorisation must be obtained
from the building authorities:
Austria: report to the construction authorities of the community or magistrate
Germany: report new installations to an approved chimney sweep / the building
authorities.
3.2 General information for installation room (boiler room)
Boiler room characteristics
▪ The floor must be even, clean and dry and have an adequate load-bearing
capacity.
▪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 ensure sufficient
lighting in the boiler room in accordance with national workplace design
regulations.
▪ When using the boiler above 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
The floor of the boiler room must not be flammable. 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 and hydrogen
halides in the room where the boiler is installed (e.g. chlorination units for
swimming pools).
▪ Keep the air suction opening of the boiler free of dust.
▪ The system must be protected against the chewing or nesting of animals (e.g.
rodents etc.).
Note on standards
Notes for operating a heating system 3
Installation and approval of the heating system
Operating Instructions PE1c Pellet | B1590420_en 17

Ventilation of the boiler room
Ventilation 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
(foliage, 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 requirements
TRVB H118 - Technical directives on fire protection/prevention
3.3 Room air-independent operation
The PE1c Pellet has a central air connection on the back of the boiler. If appropriate
supply air and flue gas connections are installed, the boiler can be classified according
to EN 15035 as a type C42 / type C82 or according to DIBt as a type FC42x / type FC52x.
The conditions for room air-independent operation of the boiler at the installation site
must be clarified with the local authority responsible (authority, chimney sweep, ...).
Definitions as per EN 15035
Boiler that is connected via its combustion air supply and flue gas outlet, with a
connecting piece that may be supplied, to a shared chimney with a shaft for
combustion air supply and a shaft for flue gas outlet. The mouths of the air and flue
gas chimney are either concentric or so close to each other that similar wind
conditions apply.
NOTICE! Air is supplied by an air and flue gas system!
A boiler that is connected via its combustion air supply and flue gas outlet, with a
connecting 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
system!
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 of
pressure and/or seal from dirt!
The second index "2" (C42 / C82) indicates type C boilers with a blower fan downstream
of the combustion chamber or the heat exchanger.
Definitions as per DIBt
One appliance with flue gas fan for connection to an air/flue system. The combustion
air line from the air shaft and the connecting piece to the chimney are part of the
appliance.
Note on standards
Type C4
Type C8
Type FC42x
3Notes for operating a heating system
General information for installation room (boiler room)
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One appliance with flue gas fan for connection to a chimney. The combustion air line
from the air shaft and the connecting piece to the chimney are part of the appliance.
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 1
r:d ≥ 1
For example:
- Diameter of supply air connection = 60 mm
- Minimum radius of pipe bends = 60 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.
In addition, the following applies: The maximum resistance of the supply air line is 20
Pa!
You can find the necessary dimensions of the supply air connections in the boiler in
the technical data sheets.
3.4 Requirements for central heating water
Unless contrary to other national regulations, the latest versions of the following
standards and guidelines apply:
Austria:
Germany:
ÖNORM H 5195
VDI 2035
Switzerland
:
Italy:
SWKI BT 102-01
UNI 8065
Observe the standards and also follow the recommendations below:
❒Aim for a pH value of between 8.2 and 10.0. If the central heating water comes
into contact with aluminium, the pH value must be between 8.0 and 8.5
❒ Use prepared water which complies with the standards cited above for filling and
make-up water
❒ Avoid leaks and use a closed heating system to maintain water quality during
operation
❒ When filling with make-up water, always bleed the filling hose before connecting,
in order to prevent air from entering the system
Advantages of prepared water:
▪ Complies with the applicable standards
▪ Less of a drop in output due to reduced limescale build-up
▪ Less corrosion due to fewer aggressive substances
▪ Long-term cost savings thanks to improved energy efficiency
Type FC52x
Notes for operating a heating system 3
Requirements for central heating water
Operating Instructions PE1c Pellet | B1590420_en 19

Permitted water hardness for the fill and make-up water in accordance with VDI 2035:
Overall heat
output
Total hardness at
<20 l/kW minimum
individual heat output 1)
Total hardness at
>20 ≤50 l/kW minimum
individual heat output 1)
Total hardness at
>50 l/kW minimum
individual heat output 1)
kW °dH mol/m³ °dH mol/m³ °dH mol/m³
≤50 no demand or 11.2 2 0.11 0.02
<16.8 2) <3 2)
>50 ≤200 11.2 2 8.4 1.5
>200 ≤600 8.4 1.5 0.11 0.02
>600 0.11 0.02
1.From specific system volume (litres nominal capacity/heat output; for multi-boiler systems use the smallest individual heat output)
2.In the case of systems with central heating boilers and for systems with electric heating elements
Additional requirements for Switzerland
The filling and make-up water must be demineralised (fully purified)
▪The water must not contain any ingredients that could settle and accumulate in the
system
▪ This makes the water non-electroconductive, which prevents corrosion
▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can
weaken corrosive materials in certain conditions
If some of the system water is lost, e.g. during repairs, the make-up water must also be
demineralised. It is not enough to soften the water. The heating system must be
professionally cleaned and rinsed before filling the units.
Inspection:
▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the central
heating water comes into contact with aluminium, the pH value must be between 8.0 and
8.5
▪ Yearly. Values must be recorded by the owner
3Notes for operating a heating system
Requirements for central heating water
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