Fröling PT4e 120 User manual

Installation Instructions
Pellet boiler PT4e 120-180
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M2270020_en | Edition 02/03/2020
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of Contents
1 General 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 Personal protective equipment for assembly staff 6
3 Design Information 7
3.1 Notes on standards 7
3.1.1 General standards for heating systems 7
3.1.2 Standards for structural and safety devices 7
3.1.3 Standards for heating water 7
3.1.4 Regulations and standards for permitted fuels 8
3.2 Installation and approval of the heating system 9
3.3 General information for installation room (boiler room) 9
3.4 Requirements for central heating water 10
3.5 Notes for using pressure maintenance systems 11
3.6 Return temperature control 12
3.7 Use with storage tank 12
3.8 Chimney connection/chimney system 13
3.8.1 Draught limiter 13
3.8.2 Measuring port 13
3.9 Boiler ventilation 14
4 Technology 15
4.1 Dimensions 15
4.2 Components and connections 17
4.3 External suction module 18
4.4 Technical data 19
4.4.1 PT4e 120 - 150 19
4.4.2 PT4e 160 - 180 20
4.4.3 Boiler data for planning the flue gas system 21
5 Assembly 22
5.1 Materials supplied 22
5.2 Transport 22
5.3 Positioning 23
5.4 Temporary storage 24
5.5 Setting up in the boiler room 24
5.5.1 Remove boiler from pallet 24
5.5.2 Moving the boiler in the boiler room 25
5.5.3 Operating and maintenance areas of the equipment 26
5.6 Assembly work 27
5.6.1 Levelling the boiler 27
Table of Contents
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5.6.2 Installing the pellet suction system 27
5.6.3 Control the return temperature control 30
5.6.4 Install the line regulating valve 31
5.6.5 Adjusting the height of the ash container 32
5.6.6 Installing the external suction module 33
5.6.7 Assembly information for hose lines 35
Potential equalisation 36
5.7 Hydraulic connection 37
5.8 Electrical connection 38
5.8.1 Lay the cable to the boiler controller 38
5.8.2 Connect the suction unit components 40
Electrical connection 40
230 V power supply 40
Connect the suction turbine 40
Connect the fill level sensors 41
Supply with 24V DC 41
Connect sensor of the stoker monitoring 41
Check the digital module 42
5.8.3 Mains connection 42
5.8.4 Information on circulating pumps 42
5.8.5 Connecting the discharge system 44
Bag silo / cube / individual probe 44
pellet mole 45
1-2-3 suction module 45
Pellet suction screw DM 80 47
RS 4 / RS 8 pellet suction system 47
Configuring the discharge system in the software 49
5.9 Final installation steps 50
6 Start-up 51
6.1 Before commissioning / configuring the boiler 51
6.2 Initial startup 52
6.2.1 Permitted fuels 52
Wood pellets 52
6.2.2 Non-permitted fuels 52
7 Decommissioning 53
7.1 Mothballing 53
7.2 Disassembly 53
7.3 Disposal 53
8 Notes 54
9 Appendix 56
9.1 Addresses 56
9.1.1 Address of manufacturer 56
Customer service 56
9.1.2 Address of the installer 56
Table of Contents
Installation Instructions PT4e 120-180 | M2270020_en 3

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.
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 or
heating engineers are requested to return a copy of the delivery certificate together
with the guarantee card to Froling. On commissioning by FROLING Customer Service
the validity of the delivery certificate will be noted on the customer service record.
Issuing a delivery
certificate
1General
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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
Installation Instructions PT4e 120-180 | M2270020_en 5

2.2 Qualification of assembly staff
CAUTION
Assembly and installation by unqualified persons:
Risk of personal injury and damage to property
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow appropriately qualified personnel to work on the system
Assembly, installation, initial startup and servicing must always be carried out by
qualified personnel:
- Heating technician / building technician
- Electrical installation technician
- Froling customer services
The assembly staff must have read and understood the instructions in the
documentation.
2.3 Personal protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For transportation, setup and assembly:
- suitable work wear
- protective gloves
- sturdy shoes (min. protection class S1P)
2Safety
Qualification of assembly staff
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3 Design Information
3.1 Notes on standards
The system must be installed and commissioned in accordance with the local fire and
building regulations. Unless contrary to other national regulations, the latest versions
of the following standards and guidelines apply:
3.1.1 General standards for heating systems
EN 303-5 Boilers for solid fuels, manually and automatically fed
combustion systems, nominal heat output up to 500 kW
EN 12828 Heating systems in buildings - design of water-based heating
systems
EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods
Part 1: Chimneys serving one appliance
ÖNORM H 5151 Planning of central hot water heating systems with or without hot
water preparation
ÖNORM M 7510-1 Guidelines for checking central heating systems
Part 1: General requirements and one-off inspections
ÖNORM M 7510-4 Guidelines for checking central heating systems
Part 4: Simple check for heating plants for solid fuels
3.1.2 Standards for structural and safety devices
ÖNORM H 5170 Heating installation - Requirements for construction and safety
engineering, as well as fire prevention and environmental
protection
ÖNORM M 7137 Compressed untreated wood – Requirements for storing pellets
at the end customer’s site
TRVB H 118 Technical directives for fire protection/prevention (Austria)
3.1.3 Standards for heating water
ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in
closed warm water heating systems at operating temperatures
up to 100°C (Austria).
VDI 2035 Prevention of damage hot water heating systems (Germany)
Design Information 3
Notes on standards
Installation Instructions PT4e 120-180 | M2270020_en 7

SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
UNI 8065 Technical standard regulating hot water preparation.
DM 26.06.2015 (Ministerial Decree specifying the minimum
requirements)
Follow the instructions of this standard and any related updates.
(Italy)
3.1.4 Regulations and standards for permitted fuels
1. BImSchV First Order of the German Federal Government for the
implementation of the Federal Law on Emission Protection
(Ordinance on Small and Medium Combustion Plants) in the
version published on 26 January 2010,
BGBl. JG 2010 Part I No. 4.
EN ISO 17225-2 Solid bio-fuel - Fuel specifications and classes
Part 2: Wood pellets for use in industrial and domestic systems
3Design Information
Notes on standards
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3.2 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.
3.3 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
Design Information 3
Installation and approval of the heating system
Installation Instructions PT4e 120-180 | M2270020_en 9

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
3.4 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
Note on standards
3Design Information
General information for installation room (boiler room)
10 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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
3.5 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required
pressure within predefined limits and balance out volume variations caused by
changes in the hot-water temperature. Two main systems are used:
Compressor-controlled pressure maintenance
In compressor-controlled pressure maintenance units, a variable air cushion in the
expansion tank is responsible for volume compensation and pressure maintenance. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen
into the heating water.
Design Information 3
Notes for using pressure maintenance systems
Installation Instructions PT4e 120-180 | M2270020_en 11

Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressure-
maintenance pump, relief valve and an unpressurised receiving tank. The valve
releases hot water into the receiving tank if the pressure is too high. If the pressure
drops below a preset value, the pump draws water from the receiving tank and feeds it
back into the heating system. Pump-controlled pressure maintenance systems with
open expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via the
surface of the water, exposing the connected system components to the risk of
corrosion. These systems offer no oxygen removal for the purposes of corrosion
control as required by VDI 2035 and in the interests of corrosion protection should not
be used.
3.6 Return temperature control
If the hot water return is below the minimum return temperature, some of the hot water
outfeed will be mixed in. This is done by the return temperature control, which is
integrated in the hydraulics on the side panel of the boiler.
3.7 Use with storage tank
NOTICE
In principle it is not necessary to use a storage tank for the system to run
smoothly. However, we recommend that you use the system with a storage tank,
as this ensures 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 accordance
with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling.
⇨ See "Addresses" [page 56]
3Design Information
Return temperature control
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3.8 Chimney connection/chimney system
EN 303-5 specifies that the entire flue gas system must be designed to prevent,
wherever possible, damage caused by seepage, insufficient feed pressure and
condensation. Please note in this respect that flue gas temperatures lower than 160K
above room temperature can occur in the permitted operating range of the boiler.
The flue gas temperatures (for clean systems) and additional flue gas values can be
found in the table below.
The connection between the boiler and the chimney system should be as short as
possible. The upward angle of the connection should not exceed 30 - 45°. Insulate the
connection. The entire flue gas system - chimney and connection - should be
calculated 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 chimney
sweep.
3.8.1 Draught limiter
We generally recommend the installation of a draught limiter. A draught limiter must
be installed if the maximum permissible feed pressure as given in the boiler data for
planning the flue gas system is exceeded.
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the
pressure is constantly low at this point.
3.8.2 Measuring port
For measuring the emissions of the system, a suitable measuring port must be
installed in the connecting piece between the boiler and chimney system.
D
D
M
2 x D
In front of the measuring port (M) a straight inlet section should be located at a
distance corresponding to about twice the diameter (D) of the connecting piece. A
straight outlet section at a distance corresponding to about the single diameter of the
connecting piece should be provided after the measuring port. The measuring port
must remain closed whenever the system is in operation.
The diameter of the measuring probe used by Froling customer service is 14 mm. To
avoid measuring errors due to the ingress of false air, the diameter of the measuring
port must not exceed 21 mm.
Design Information 3
Chimney connection/chimney system
Installation Instructions PT4e 120-180 | M2270020_en 13

3.9 Boiler ventilation
❒ Fit the automatic ventilating valve at the highest point on the boiler or at the
ventilation connection (if present).
➥This ensures that air in the boiler is constantly expelled, thus preventing
malfunctions 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
boiler
❒ Fit a microbubble separator in the pipes to the boiler
➥Follow the manufacturer's instructions!
Tip:
Recommendation:
3Design Information
Boiler ventilation
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4 Technology
4.1 Dimensions
B3
H2
Item Description 120 140-180
HBoiler height mm 1740 1840
H1 Total height including flue gas pipe
connection
1790 1895
H2 Height of suction unit1) 1705
BBoiler width 790
B1 Overall width with suction system 1760
B2 Width of suction system 960
B3 Width of particle separator
(optional)
165
LBoiler length 1420 1770
L1 Total length incl. ash container 1790 2105
L2 Length, back of boiler to stoker
connection
890 1160
L3 Length of particle separator
(optional)
550 715
1.Value can be increased by 40 mm (max.) by adjusting the adjustable foot
Technology 4
Dimensions
Installation Instructions PT4e 120-180 | M2270020_en 15

B5
B6
PT4e 120-180
H3
H7
H5
H6
H4
Item Description 120 140-180
H3 Height, flow connection mm 1545 1660
H4 Height of rear flue gas pipe
connection (optional)
1210 1290
H5 Height, return connection with
integrated return feed boost
1135 1210
H6 Height, drainage connection 200 200
H7 Height, safety heat exchanger
connection
-16201)
B5 Clearance flue gas pipe connection
to side of boiler
495 515
B6 Clearance rear flue gas pipe
connection to side of boiler
(optional)
190 470
1.Connection on right boiler side
4Technology
Dimensions
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4.2 Components and connections
Item Description 120 140-180
AFlue gas pipe connection 179 mm 199 mm
BSafety heat exchanger - ½“
CInduced draught fan -
DBoiler flow 2“
ERear flue gas pipe connection
(optional)
179 mm 199 mm
FBoiler return 2“
GMixing valve for the return
temperature control
-
HPump for the return temperature
control
WILO Stratos Para
30/1-8
WILO Stratos Para
30/1-12
ILine regulating valve (optional) -
JDrainage 1“
KAsh container 55 Litres 75 Litres
Technology 4
Components and connections
Installation Instructions PT4e 120-180 | M2270020_en 17

4.3 External suction module
Measur
ement
Description Unit Size 1 Size 2
BWidth of suction module mm 235 290
LLength of suction module 220 265
H1 Height of suction module 225 235
H2 Total height incl. hose connection 275 285
1Return-air line connection
(line to suction point)
mm 50
2Return-air line connection
(line to boiler)
50
4Technology
External suction module
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4.4 Technical data
4.4.1 PT4e 120 - 150
Description PT4e 120 - 150
120 140 150
Rated heat output kW 120 140 150
Heat output range 36-120 42-140 45-150
Electrical connection 400V / 50Hz / fused C16A
Power consumption (NL/PL) for boiler without ESP 3) W 127 / 49 125 / 51 124 / 52
Weight of boiler (including stoker, without water) kg 1308 1641
Boiler capacity (water) l 228 320
Available feed height of pump 1) (with ΔT = 20K) mbar 460 860 790
Max. permitted operating temperature °C 90
Permitted operating pressure bar 4
Boiler class as per EN 303-5: 2012 5
Airborne sound level dB(A) <70
Permitted fuel as per EN ISO 17225 2) Part 2: Wood pellets class A1 / D06
Test book number (boiler without ESP 3))PB 144 00 20 PB 165 00 20 PB 166 00 20
Test book number (boiler with ESP 3))PB 170 00 20 PB 171 00 20 PB 172 00 20
1.Pump output less water resistance in the boiler
2.Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”
3.ESP: electrostatic particle separator (optional)
Regulation (EU) 2015/1187
Heating space annual rate of use ηs % ≥ 77
Regulation (EU) 2015/1189 - Emissions in [mg/m³]1)
seasonal space heating emissions of particulate (PM) ≤ 40
seasonal space heating emissions of organic gaseous compounds
(OGC)
≤ 20
seasonal space heating emissions of carbon monoxide (CO) ≤ 500
seasonal space heating emissions of nitrogen oxides (NOx) ≤ 200
1.Emissions of particulate matter, organic gaseous compounds, carbon monoxide and nitrogen oxides shall be expressed standardised to a dry flue gas basis at 10 % oxygen and
standard conditions at 0°C and 1013 millibar
Technology 4
Technical data
Installation Instructions PT4e 120-180 | M2270020_en 19

4.4.2 PT4e 160 - 180
Description PT4e 160 - 180
160 170 180
Nominal output kW 160 170 180
Heat output range 48-160 51-170 54-180
Electrical connection 400V / 50Hz / fused C16A
Power consumption (NL/PL) for boiler without ESP 3) W 123 / 52 123 / 53 122 / 54
Weight of boiler (including stoker, without water) kg 1641
Boiler capacity (water) l 320
Available feed height of pump 1) (with ΔT = 20K) mbar 740 620 530
Max. permitted operating temperature °C 90
Permitted operating pressure bar 4
Boiler class as per EN 303-5: 2012 5
Airborne sound level dB(A) <70
Permitted fuel as per EN ISO 17225 2) Part 2: Wood pellets class A1 / D06
Test book number (boiler without ESP 3))PB 167 00 20 PB 168 00 20 PB 169 00 20
Test book number (boiler with ESP 3))PB 173 00 20 PB 174 00 20 PB 175 00 20
1.Pump output less water resistance in the boiler
2.Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”
3.ESP: electrostatic particle separator (optional)
Regulation (EU) 2015/1187
Heating space annual rate of use ηs % ≥ 77
Regulation (EU) 2015/1189 - Emissions in [mg/m³]1)
seasonal space heating emissions of particulate (PM) ≤ 40
seasonal space heating emissions of organic gaseous compounds
(OGC)
≤ 20
seasonal space heating emissions of carbon monoxide (CO) ≤ 500
seasonal space heating emissions of nitrogen oxides (NOx) ≤ 200
1.Emissions of particulate matter, organic gaseous compounds, carbon monoxide and nitrogen oxides shall be expressed standardised to a dry flue gas basis at 10 % oxygen and
standard conditions at 0°C and 1013 millibar
4Technology
Technical data
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