Froling P4 Pellet 8-60 User manual

Operating Instructions
Pellet boiler P4 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!
B0870417_en | Edition 12/09/2017
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of Contents
1 General 4
1.1 P4 Pellet product overview 5
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 Design information 13
2.7.1 Installation and approval of the heating system 13
2.7.2 General information for installation room (boiler room) 13
2.7.3 Requirements for central heating water 14
2.7.4 Notes for using pressure maintenance systems 15
2.7.5 Use with storage tank 16
2.7.6 Chimney connection/chimney system 16
2.8 Safety devices 17
2.9 Residual risks 18
2.10 Emergency procedure 19
2.10.1 Overheating of the system 19
2.10.2 Smell of flue gas 19
2.10.3 Fire in the system 20
3 Operating the System 21
3.1 Assembly and initial startup 21
3.2 Filling the pellet store 22
3.2.1 General advice for working in the store 22
3.3 Heating up the boiler 23
3.3.1 Switching on the power supply 23
3.3.2 Switching on the boiler 23
3.3.3 Regulating the boiler 23
3.3.4 Switching off the boiler 23
3.3.5 Switching off the power supply 24
4 Boiler Servicing 25
4.1 General information on servicing 25
4.2 Inspection and cleaning 26
4.2.1 Inspection 26
Checking the system pressure 26
Checking the safety valve 26
4.2.2 Cleaning 27
Table of Contents
2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Emptying the ash drawers (for P4 Pellet 15/20/25) 27
Emptying the ash container (for P4 Pellet 32-105) 28
Check the grate and combustion chamber 28
Check the downpipe for dirt (P4 Pellet 45 and up) 29
4.2.3 Annual check 30
Cleaning the flue gas collection chamber and the heat exchanger 30
Clean WOS 31
Cleaning the induced draught fan 31
Cleaning the flue gas pipe 32
Cleaning the flue gas temperature sensor 32
Cleaning the flow sensor 33
4.3 Emissions measurement by chimney sweep or regulatory body 34
4.3.1 Switch on the system 34
4.3.2 Emissions measurement by chimney sweep or regulatory body 34
4.4 Maintenance agreement / Customer service 35
4.5 Replacement parts 35
4.6 Disposal information 36
4.6.1 Disposal of the ash 36
4.6.2 Disposal of system components 36
5 Troubleshooting 37
5.1 General fault with power supply 37
5.1.1 Behaviour of system after a power failure 37
5.2 Excessive temperature 37
5.3 Faults with fault message 38
5.3.1 Procedure for fault messages 38
5.3.2 Acknowledging a fault message 38
6 Appendix 39
6.1 Addresses 39
6.1.1 Address of manufacturer 39
Customer service 39
6.1.2 Address of the installer 39
Table of Contents
Operating Instructions P4 Pellet | B0870417_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.
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.
1General
4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

1.1 P4 Pellet product overview
2.1
2.4
2.3
2.2
1P4 Pellet with integrated pellet cyclone container
2Control 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
3Main switch
4High-limit thermostat (STL)
5Service interface
General 1
P4 Pellet product overview
Operating Instructions P4 Pellet | B0870417_en 5

Ash removal unit P4 Pellet 8-25
6Ash drawer - heat exchanger
7Ash drawer - combustion chamber
8Ash drawer
Ash removal unit P4 Pellet 32-105:
9Ash 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
1General
P4 Pellet product overview
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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 P4 Pellet | B0870417_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
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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-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 P4 Pellet | B0870417_en 9

2.4 Permitted uses
The Froling Pellet boiler P4 Pellet is designed solely for heating domestic water. Only
the fuels specified in the "Permitted fuels" section must 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 S1 Turbo 15 and S1 Turbo 20 have been recommended as suitable for
use in smoke control areas when burning fuels as listed under "Permitted fuels".
2Safety
Permitted uses
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

The Froling P4 Pellet 8, P4 Pellet 15, P4 Pellet 20, P4 Pellet 25, P4 Pellet 32, P4
Pellet 38, P4 Pellet 45, P4 Pellet 48, P4 Pellet 60, P4 Pellet 70, P4 Pellet 80 and P4
Pellet 100 have been recommended as suitable for use in smoke control areas when
burning fuels as listed under "Permitted fuels".
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 PST pellet deduster for separating the dust particles contained in the
return air
Note on standards
Safety 2
Permitted uses
Operating Instructions P4 Pellet | B0870417_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 / boiler 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
2Safety
Permitted uses
12 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.7 Design information
It is forbidden to carry out modifications to the boiler or to change or deactivate safety
equipment.
Always comply with all fire, building, and electrical regulations when installing or
operating the boiler system, and follow the operating instructions and mandatory
regulations that apply in the country in which the boiler is operated.
2.7.1 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.
2.7.2 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.
Note on standards
Safety 2
Design information
Operating Instructions P4 Pellet | B0870417_en 13

▪ The system must be protected against the chewing or nesting of animals (e.g.
rodents etc.).
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
2.7.3 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
makeup 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
2Safety
Design information
14 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Limit values for filling and make-up water:
Austria Germany Switzerland
Total hardness ≤ 1.0 mmol/L ≤ 2.0 mmol/L < 0.1 mmol/L
Conductivity - < 100µS/cm < 100 µS/cm
pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5
Chloride < 30 mg/L < 30 mg/L < 30 mg/L
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
2.7.4 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.
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
Safety 2
Design information
Operating Instructions P4 Pellet | B0870417_en 15

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.
2.7.5 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 39]
2.7.6 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.
NOTICE! Please see the technical data contained in the assembly instructions for
further information about standards and regulations as well as the flue gas
temperatures when clean and the other flue gas values!
2Safety
Design information
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2.8 Safety devices
2.2
SW
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:
❒ 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 HIGH-LIMIT THERMOSTAT (STL)
(protection against overheating)
The STL switches off the combustion system when the boiler reaches 105°C. The
pumps continue to run. Once the temperature falls below approx. 75°C, the STL can
be 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 the
heated water is blown off in the form of steam.
Safety 2
Safety devices
Operating Instructions P4 Pellet | B0870417_en 17

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

2.10 Emergency procedure
2.10.1 Overheating of the system
If the system overheats and the safety devices fail, 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
❒ 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 39]
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
Recommendation: Do not install smoke alarms and carbon monoxide detectors near
the system.
Safety 2
Emergency procedure
Operating Instructions P4 Pellet | B0870417_en 19

2.10.3 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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