Froling P4 Pellet 8-60 User manual

Fröling GmbH, Industriestrasse 12, A-4710 Grieskirchen Austria
www.froling.com
Owner’s Manual
P4 Wood Pellet Boiler
Certified to U.S. Standard: UL 2523-2009
Read and follow the operating instructions and safety information! Subject to technical change!
Report # 456-S-02-2

Catalog # P4O2014

Introduction
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Dear customer,
Congratulations on choosing a quality product from FRÖLING.
The FRÖLING P4 Pellet features a state-of-the-art design that conforms
to all currently applicable standards and testing guidelines.
Please read and observe the operating instructions and always keep
them close to the boiler for reference. They contain safety information
and all the operation and maintenance specifications needed to operate
the boiler safely, properly and economically.
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.
Subject to technical change.
The P4 Pellet boiler is produced using the highest quality materials and
modern production system. The use of high technology laser cutting and
robotic welding system, accompanied by time honoured European
design, craftsmanship and attention to detail, results in a long lasting
boiler with unmatched fit and finish.
With proper installation, operation and maintenance your P4 pellet boiler
will provide years of safe, dependable, economic and earth friendly
heating.
This manual contains paragraphs that require your special attention.
These paragraphs are marked with the safety information according to
ANSI Z535 described in chapter 2.
Units of Measurement
Most hardware and fittings on the boiler are metric (some plumbing
fittings are British Straight Thread). In this manual the convention used
for dimensions is that values are presented in English units, followed by
metric units in parenthesis, for example: 6” (152 mm).
In this manual temperatures are presented as degrees Centigrade.
Note: A conversion table between Centigrade and Fahrenheit is provided
in Section 7.2.
Installation and Warranty Requirements
This product is provided with a limited warranty which is described in
Section 7.1 within this manual. The warranty is contingent upon the
successful and legal installation of the boiler. At a minimum, the
installation, adjustment, start up, service, and maintenance of this
product must be performed by a licensed professional heating system
installer. Where applicable, the installation must be inspected and
accepted by the legally responsible entity. Conditions described in the
text of the warranty for keeping it in force must be followed by the
owner/ system operator.
If the boiler has been purchased through a dealer, the warranty claim
must be made to the dealer. Otherwise, claims may be made directly to
Tarm Biomass.
Please read the literature enclosed by the manufacturer regarding the
various accessory devices. These devices are warranted by the
manufacturer, NOT BY Tarm Biomass. These accessory devices must be

Introduction
Page 4
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installed and used according to the recommendations of the
manufacturer.
Failure to follow these instructions could result in property damage,
bodily injury, or death. All boilers must be installed in accordance with
national, state, and local plumbing, heating, and electrical codes and the
regulations of the serving electric, water, and gas utilities. Contact local
building or fire officials before installation about restrictions and
installation inspection requirements in your area. This boiler is safety
tested and listed. The P4 pellet boiler does not carry an ASME stamp.
The instructions in this manual and in supporting documentation
(additional instructions, diagrams, and component information provided
by Tarm Biomass) must be followed. If the instructions are in conflict
with local code requirements, the local code requirements will prevail.
When in doubt, contact your dealer or Tarm Biomass. The manual and
supporting documentation must be retained by the owner/ system
operator for reference and future use.
The installer is responsible for familiarizing the owner/ system operator
with all aspects of boiler operations, safety procedures, monitoring and
cleaning requirements, shut down procedures, and annual maintenance
requirements.
NOTE
SAVE THESE INSTRUCTIONS

Contents
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1Product Overview 8
1.1 Boiler Fabrication and Testing 9
1.2 Models and Applications 9
2Safety 10
2.1 Safety Information 10
2.1.1 Installation Hazards ......................................................................................... 11
2.2 Permitted Uses 13
2.2.1 Permitted fuel ................................................................................................. 13
2.2.2 Non-permitted fuels ......................................................................................... 14
2.2.3 Who may operate the boiler .............................................................................. 14
2.3 Design Information 15
2.3.1 Approvals and reporting obligations ................................................................... 15
2.3.2 Requirements for initial filing and re-filling of heating system ................................ 15
2.3.3 Outside Combustion Air .................................................................................... 16
2.3.4 Installing the heating system ............................................................................ 16
2.3.5 Combination with storage tank .......................................................................... 17
2.3.6 Chimney connection / chimney system ............................................................... 17
Barometric Damper ......................................................................................... 18
Basic Boiler Data for Layout of Chimney system.................................................. 18
2.4 Safety Devices 19
2.4.1 Devices for Preventing the Boiler from overheating .............................................. 19
Pressure Relief Valve ....................................................................................... 20
Overheat Thermostat (Safety Temperature Limit Switch-STL)............................... 20
Overheat loop: with electricity .......................................................................... 20
2.5 Emergency procedure 21
2.5.1 In the event of loss of electrical power ............................................................... 21
2.5.2 Overheating of the system ................................................................................ 22
2.5.3 In the event of chimney fire .............................................................................. 22
2.5.4 Strong Smell of flue gas ................................................................................... 22
3Operating the system 23
3.1 Initial start-up 23
3.2 Filling/ refilling the store with fuel 23
3.3 Heating up the boiler 24
3.3.1 Switching on the boiler ..................................................................................... 24
3.3.2 Controlling the boiler........................................................................................ 24
3.3.3 Switching off the boiler..................................................................................... 24
4Boiler Control System Lambdatronic S 3200 25
4.1 Overview of the Basic Functions 25
4.1.1 Control Keys and Display .................................................................................. 25
4.1.2 Navigation Keys............................................................................................... 25
4.1.3 Status LED...................................................................................................... 26
4.1.4 Function keys.................................................................................................. 26

Contents
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4.1.5 Info Key ..........................................................................................................27
4.1.6 Graphical Display..............................................................................................28
4.1.7 Operating Modes ..............................................................................................29
4.2 Initial start-up 30
4.2.1 Changing the User Level....................................................................................30
4.3 Setting parameters 31
4.4 Menu Overview 32
4.5 Menu-Storage tank 33
4.5.1 Status display of the Thermal Storage Tank .........................................................33
4.5.2 Temperature settings for Thermal Storage System ...............................................33
4.6 Menu-Water 33
4.6.1 Status Displays for the DHW Tank ......................................................................33
4.6.2 Temperature Settings of the DHW Tank...............................................................34
4.6.3 Heating Times of the DHW Tank .........................................................................34
4.7 Menu-Solar 34
4.7.1 Status Displays for the Solar System ..................................................................34
4.7.2 Temperature Settings for the Solar System..........................................................35
4.8 Menu-Pellets 35
4.8.1 Fuel Filling Times..............................................................................................35
4.9 Menu-Boiler 36
4.9.1 Status Displays for the Boiler .............................................................................36
4.9.2 Temperature Settings for the Boiler ....................................................................36
4.10 Menu-Manual 37
4.10.1 Manual operation.......................................................................................37
4.11 Menu-System 37
4.11.1 Current values ..........................................................................................37
4.11.2 Error ........................................................................................................38
4.11.3 Basic Display parameters............................................................................38
4.11.4 Time settings ............................................................................................38
4.11.5 Current User Level .....................................................................................38
5Boiler Servicing 39
5.1 General 39
5.2 Inspection, cleaning and maintenance 40
5.2.1 Cleaning ..........................................................................................................40
Emptying the ash drawers (for P4 Pellet 8/15/20/25) ...........................................40
Emptying the ash container (for P4 Pellet 32/38 and 48/60)..................................41
Check the grate and combustion chamber...........................................................42
5.2.2 Yearly check ....................................................................................................43
Clean the flue gas collection chamber and the heat exchanger...............................43
Clean WOS......................................................................................................44
Cleaning the induced draught ventilator..............................................................44
Clean the smoke flue pipe .................................................................................44
Checking the draught controller flap and explosion flap ........................................45
Clean the flue gas sensors ................................................................................45

Contents
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5.3 Spare parts 45
6Troubleshooting 46
6.1 General faults in the power supply 46
6.1.1 Behaviour of system after a power failure ........................................................... 46
6.2 Excessive temperature 46
6.3 Error messages at Boiler Control System 47
6.3.1 Procedure for fault messages ............................................................................ 47
6.3.2 Acknowledging a fault message ......................................................................... 47
7Appendix 48
7.1 Warranty 48
7.2 Temperature conversion table 50
7.3 Manufacturer 51
7.4 Importer 51
7.5 Local Dealer 51

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1Product Overview
Ash drawer module (P4 Pellet 32/38):
Below the insulating cover:
2
1
4
11
12
6
3
8
9
Ash drawer module (P4 Pellet 8/15/20/25):
5
7
10
2.1
2.2
2.4
2.3

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Pos
Component
1
P4 Pellet with integrated Pellets cyclone container
2
Lambdatronic P 3100 control system
2.1
Navigation keys to move around in the menus and to change the parameter values
2.2
Status LED (operating status): - slow green flashing light: boiler activated
- fast green flashing light: boiler deactivated
- flashing red light: malfunction
2.3
Large graphical display to show operating statuses and parameters
2.4
Function keys for calling up individual boiler functions or modes directly
3
Ash drawer - heat exchanger
4
Ash drawer - Combustion chamber
5
Ash drawer
6
Ash container - heat exchanger
7
Ash container - combustion chamber
8
Ash screw and stirrer of the automatic heat exchanger cleaning
9
Ash screw and guide plates of the combustion chamber cleaning
10
Lever of the ash box lock
11
Service interface of the control
12
Safety temperature limiter - STL
1.1 Boiler Fabrication and Testing
Your boiler was manufactured by Fröling, a world leader in hot water
(hydronic) heating for over 40 years. The P4 Pellet boiler conforms to
traditional high standards for quality and reliability. It offers modern
pellet boiler technology with high operating efficiencies at over 90%. If
treated properly and operated according to the guidelines in this manual
it will provide years of safe, dependable, and economical heating.
P4 Pellet boilers are designed and built in accordance with European
Standard EN 303-5. Safety and performance testing and listing for North
American markets have been performed by OMNI Test Laboratories,
Inc., Portland, Oregon. The boiler is tested and listed to applicable UL,
CAN and other standards. The boiler is not ASME stamped. The installer
should follow local or state installation requirements.
The P4 Pellet boiler is a pellet boiler designed and constructed for highly
efficient combustion of wood pellets.
Do not burn other fuels in the P4 Pellet boiler. The P4 Pellet boiler is not
a self contained weather-tight boiler. It should be installed within the
heated building. P4 Pellet boilers should be installed with a thermal
storage system to prevent short-cycling of the boiler during periods
when the building is not calling for heat.
1.2 Models and Applications
Five P4 Pellet boiler models are available (8/15, 20/25, 30/38, 48/60),
and 80/100 covering an output range between 35,800Btu/hr and
330,000Btu/hr. Models 8/15, and 20/25 is available with a pneumatic
hopper or 280 lb (240 liter) day bin. Specification data for each P4 Pellet
boiler is provided in the Installation Manual. The boilers can be utilized
as a single heat source, or in parallel with another boiler.

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2Safety
This manual contains paragraphs that require your special attention.
These paragraphs are marked with the symbols described below:
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
2.1 Safety Information
R I S K
Non-permitted use!
Incorrect use of the boiler can cause severe injuries and damage!
The instructions and information provided in the instructions
should be observed!
Installation is to be performed by a qualified installer.
Details on procedure for operation, maintenance and cleaning, as
well as troubleshooting for the boilers are included in the
individual instructions. Any further work should be carried out by
authorised heating engineers or by Fröling customer services.
W A R NIN G
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!

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Instructions and information for versions and minimum values, as
well as norms and guidelines for heating components in the
instructions must be observed!
W AR N IN G
Severe injuries and damage can be caused by an inadequate flue gas
system!
Inspect and clean flues and chimney regularly. Problems with the flue
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)!
You can only be guaranteed of optimum performance from the boiler if the
flue gas system is running smoothly!
2.1.1 Installation Hazards
Install, modify and use only in accordance with manufacturer’s manuals.
Refer to authorities having jurisdiction for proper installation. Contact
local building and fire officials about restrictions and installation
inspection in your area. If there are no applicable local codes, follow
ANSI/NFPA 211 and CAN/CSA B365. Special precautions are required
for passing the Chimney through a combustible wall or ceiling.
Inspect and clean exhaust system, Fuel Loading Chamber, Combustion
Chamber, Ash-Pits, and Heat Exchanger frequently in accordance with
owner’s manual.
DANGER!
Working on electrical components may cause severe injuries from electric
shocks!
WARNING!
The electrical system of the boiler shall be supplied from a double 115 V 60
Hz (nominal 230 V AC) 15 amp branch circuit including neutral and ground
connection. For wiring instructions please refer to Installation Manual!
Chimney must be minimum 5’’ (127 mm) diameter listed UL-103 HT or
ULC-S629 residential all-fuel type or tile-lined masonry for models 8/15 and
20/25 and minimum 6” (150 mm) for models 32/38 and 48/58. Flue
connector pipe must be 5” (127mm) or 6’’ (150 mm) diameter (dependent
upon boiler model) made of a minimum 24 MSG black steel.
Inadequate design, installation and maintenance of the flue gas system will
lead to insufficient chimney draft and could result in Danger of Life or
Severe Injury caused by serious faults in combustion, e.g. explosively
combustion of wood gases and flash fires!
This boiler requires fresh air for safe operation and must be installed so
there are provision for adequate combustion and ventilation air!

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CAUTION!
Do not connect this unit to a Chimney flue serving another appliance!
Flooring must be a minimum 3/8’’ (10 mm) non-combustible material
covering the installation clearance area! The floor must be level and
reinforced if required. For construction of the floor beneath the boiler please
pay attention to weight of boiler, water content and wood fuel according to
the Installation Manual!
Use original spare parts only. Installation of non-licensed replacement parts
will void the warranty!
DANGER!
Risk of Fire or Explosion!
Do not burn coal, fuel coke, garbage and other residual material,
painted or treated wood, garbage, gasoline, diesel, fuel oil, naphtha,
engine oil, drain oil or other flammable liquids or any other organic
materials or other inappropriate materials!
Do not use chemicals, gasoline, oil or any other combustible fluids to
start the fire!
Use of inappropriate fuels can result in Danger of Life or Severe
Injury caused by explosive combustion and flash fires!
Burn fuels other than those designated in the manual will void
warranty
DANGER!
Explosive Gases!
Never open Ash-Drawer Doors or Heat Exchanger Cover during operation
or refueling!
Faulty operation of boiler system will cause Danger of Life or Severe Injury
and Property damage!
Flue gases can cause fatal poisoning! In case of strong smell of flue gas:
1. For safety keep all Boiler Doors and Ash-Drawer Doors tightly closed!
2. Ventilate the room where boiler is installed!
3. Close the door of the boiler room and doors to living areas!
WARNING!
Risk of Fire!
For safety keep all Boiler Doors and Ash-Drawer Doors and all Covers
tightly closed during operation! Door seals must be maintained in good
condition.
Do not operate with flue draft exceeding 0.10 inches in water column (25
Pa), if no Draft Regulator is installed! Excessive draft could cause a solid
fuel fire to burn out of control.
Do not store fuel, clothing, furniture or other combustible material within
marked installation clearances within boiler is installed!
Faulty operating conditions not complying with Owner’s Manual, such as
insufficient combustion air, incorrect or insufficient cleaning and
maintenance or non-permitted fuel could result in Danger of Life or Severe
Injury caused by serious faults in combustion (e.g. spontaneous
combustion of wood gases or flash fires)!
Inspect and clean Boiler, Flue Gas Pipe and Chimney regularly!

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The Heat Exchanger, Induced Draft Fan, Flue Gas Pipe, and Chimney must
be cleaned regularly to remove accumulated creosote and ash. Ensure that
the Heat Exchanger, Flue Gas Pipe, and Chimney are cleaned at the end of
heating season to minimize corrosion during the summer months.
First firing during start-up of boiler system shall be carried out in
accordance to Instruction Label at Fuel Loading Chamber Door and in
attendance of an authorized installer or manufacturer’s representative only!
Disregarding of warning may cause damage or explosion of Combustion
Chamber and severe injuries unfavorably!
Gas created during solid-fuel combustion may cause a small flash when the
boiler is refueled if not properly vented!
Do not connect to any air distribution duct or system.
DO NOT INSTALL IN A MOBILE HOME
It is necessary to adhere to installation clearances and restrictions.
CAUTION!
Hot Surfaces!
Hot parts and the Flue Gas Pipe can cause serious burns!
Unauthorized access to the boiler room could result in personal injury and
damage to property!
Keep children, clothing, and furniture away!
Always use protective gloves while loading boiler or carry out other work on
boiler!
Always use Control Handles when opening Boiler Doors!
Do not touch Flue Gas Pipe during operation!
Do not carry out maintenance when the boiler is hot!
Do not touch hot surfaces behind Insulation Door!
Maximum draft marked on nameplate.
2.2 Permitted Uses
The boiler should only be operated when it is in full working order. It
should be operated in accordance with the instructions, observing safety
precautions, and you should ensure you are aware of the potential
hazards. Ensure that any faults, which might impair safety, are rectified
immediately.
The Fröling P4 Pellet is intended exclusively for heating up
heating water. Use only the fuels specified under 2.2.1.
The manufacturer or supplier is not liable for any damages
resulting from non-permitted uses.
2.2.1 Permitted fuel
Wood pellets made from natural wood with a diameter of 6mm and they
meet the grade specifications of PFI Certified Premium or Super
Premium.
Applies generally:
Before refilling the store, check for pellet dust and clean if necessary.

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2.2.2 Non-permitted fuels
C A U T I ON
Non-permitted fuels!
Burning non-permitted fuels increases the cleaning requirements and
leads to a build-up of aggressive sedimentation and condensation,
which can lead to damage to the boiler and also voids the warranty!
Using non-standard fuels can lead to severe faults with combustion.
Do not burn coal, fuel coke, garbage, gasoline, diesel, drain oil,
naphtha, other flammable liquids, or other organic materials
and any other inappropriate materials.
Do not store fuel or other combustible material within marked
installation clearances. Keep away from heater while it is in
use.
Do not use chemicals, gasoline, gasoline-type lantern fuel,
kerosene, charcoal lighter fluid, or similar liquids to start or
freshen up a fire in this heater.
2.2.3 Who may operate the boiler
Non-permitted use of the boiler by unauthorized persons can cause
faults in combustion. The operator is responsible to explain all cautions
before allowing any person’s access to boiler room.
Unauthorized persons, especially children, are to be kept away from the
boiler.
Only trained operators are permitted to operate the boiler.
• The owner/system operator is responsible for correct operation of the
boiler per guidelines in this manual.
• Incorrect operation can reduce the boiler life.
Throughout this manual, safety considerations are noted and discussed.
A few general safety considerations to be considered are:
• Safety faults or deficiencies with the boiler or installation must be
rectified as quickly as possible; either by the owner/system operator or
the installer. Using makeshift compromises during the installation can
create an unsafe situation.
• Outlet pipes, ventilation channels, fresh air openings, etc. must not be
closed or blocked.
• A chimney connector shall not pass through an attic or roof space,
closet or similar concealed space, or a floor, or ceiling.

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2.3 Design Information
It is unlawful to carry out modifications to the boiler or to change or
deactivate safety equipment.
In addition to the operating instructions and the applicable regulations
for the country in which the boiler will be operated for installation and
operation of the boiler system, all fire, police, and electrical regulations
must be observed.
2.3.1 Approvals and reporting obligations
IMPORTANT: Install, modify and use only in accordance with
manufacturer’s installation & operation manuals. Refer to authorities
having jurisdiction for proper installation. Contact local building and
fire officials about restrictions and installation inspection in your
area. If there are no applicable local codes, follow ANSI/NFPA 211
and CAN/CSA B365. Special precautions are required for passing the
Chimney through a combustible wall or ceiling.
Inspect and clean exhaust system frequently in accordance with
Owner’s Manual.
2.3.2 Requirements for initial filing and re-filling of heating system
Water quality conditions for initial filling the heating system:
For first filling of heating system water must be clean, pure or purified,
odorless and without suspended matter.
For re-filling of small amounts water shall be clean at least.
For swimming pools or spas do not use heating water directly. Proper
sized heat exchangers are required! Boiler water is not potable!
Use of a suitable antifreeze mix is allowed, but will cause a loss in heat
transfer efficiency.
Note for filling with make-up water:
Bleed the filling hose before connecting to prevent air from getting
into the system.

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2.3.3 Outside Combustion Air
Provision for outside combustion air may be necessary to ensure that
fuel-burning appliances do not discharge products of combustion into
the house. Guidelines to determine the need for additional combustion
air may not be adequate for every situation. If in doubt, it is advisable
to provide additional air.
Outside air may be required if:
1. The solid fuel fired appliance does not draw steadily; experiences
smoke roll out from boiler, burns poorly, or back drafts whether
or not there is combustion present.
2. Existing solid fuel fired equipment in the house, such as fireplaces
or other heating appliances smell, do not operate properly, suffer
smoke roll out when opened, or back-draft whether or not there
is any combustion present.
3. Any of the above symptons are alleviated by opening a window
slightly on a calm (windless day).
4. The house is built very tightly with a well sealed vapor barrier or
foam type insulation and tight fitting windows and/ or has any
powered devices which exhaust in the house.
5. There is excessive condensation on windows in the winter.
6. A non-balancing ventilation system is installed in the house.
7. Where fans are used in the fuel storage area, they should be
installed so as not to create negative pressures in the room
where the boiler is located.
If these, or other indications, suggest that infiltration air is inadequate,
additional combustion air should be provided from the outdoors.
If a mechanical ventilation system (air exchange or heat recovery) is
already present in the home it may be able to provide sufficient
combustion make-up air for the solid fuel fired appliance. The ventilation
system may need to be re-balanced after installation of the Froling P4.
NOT E
Canadian installations must conform to ANSI/NFPA outside air
requirements of 1 sq. Inch per) 2.5cm) 1,000Btu/hr (.30kW/hr).
2.3.4 Installing the heating system
The entire heating system has to be designed according relevant
national and local codes. The nominal power of the Central Heating
Boiler shall be corresponding to the calculated heat demand for all
heating appliances connected to the heating system both in summer and
winter time.
The heating system must be able to carry all heat produced by the
Central Heating Boiler and additional heat source, if applicable. The
whole heating system as well as all heating zones has to be hydraulically
balanced.
Special arrangements have to be provided for initial filling or re-filling
and bleeding of all heating zones. Flow-check valves and zone-valves
have to be installed for proper adjustment of water flow rates. All piping
must be water and air tight and insulated safely.
If there is a risk of freezing for parts of the heating system all water
within these heating zones has to be frost-proof!

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2.3.5 Combination with storage tank
NOT E
We recommend that you use the pellet boiler with a storage tank, as this
allows you to achieve a reduction in start-up and shut downs within the ideal
performance range of the boiler.
Please contact your installer or a Fröling technician directly for the right
measurements of the storage tank.
If your P4 Pellet boiler has been installed with a Thermal Storage
System, this system may require periodic maintenance. Please review
the periodic maintenance requirements of your thermal storage system
with your installer.
2.3.6 Chimney connection / chimney system
The chimney is one of the most critical factors in the successful
operation of any solid fuel heater, including the Fröling P4 boiler. A good
chimney will provide a continuous and dependable draft to pull the
exhaust gasses out of the building. The entire flue gas system must be
designed to prevent, wherever possible, damage caused by seepage,
insufficient feed pressure and condensation. Follow manufacturer’s
installation instructions for installing and supporting any specific
chimney product.
NOT E
The boiler must be connected to a tile-lined masonry chimney or to a factory-
built Type UL 103 HT (ULC S629 in Canada) approved chimney. The chimney
must be in good condition. If the boiler is connected to a dirty or inadequate
chimney, it can present a serious fire hazard. All chimneys and connections
must conform to NFPA standard #211. No other appliance should be
connected to this flue unless allowed by the local code authority. Consult your
local inspector for chimney requirements and install the boiler in accordance
with all applicable codes.
Flue gas exhaust temperatures can be low enough to cause
condensation in chimneys. Condensation will, over time, damage a
masonry chimney. Accordingly, installation of a stainless chimney liner
(made with 304, 316, or 321) inside the chimney flue is strongly
recommended.
The flue gas temperatures (when cleaned) and the additional flue gas
values can be found in the technical specification sheets (See chart
below “see chart below “Boiler data for constructing the flue gas
system”.
The smoke pipe connecting the boiler to the chimney flue must be black
or stainless, have a minimum thickness of 24 gauge, and rise a
1

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2
minimum of ¼” per foot of run toward the chimney. Smoke pipe
sections must be attached to one another with a minimum of three
sheet metal screws and sealed with hi-temperature silicone. The smoke
pipe should not contain more than two 90° elbows (45° elbows are
preferred over 90° elbows).
The chimney draft must be stable (see chart below “Basic Boiler Data for
Layout of Chimney system”.
The top of the chimney must be 3 feet (0.9 m) above the roof and 2 feet
(0.6 m) above any structure within 10 feet (3.0 m) measured
horizontally.
Barometric Damper
We recommend that you install a barometric damper. 1
Install the barometric damper directly under the mouth of the flue
line, as there is always low pressure there. 1
Basic Boiler Data for Layout of Chimney system
P4 Pellet
Description
Unit
8
15
20
25
32
38
48
60
80
100
Flue gas temperature
ºF
284
300
300
300
320
320
320
338
320
338
Flue gas mass flow RL
PL
lb/hr
lb/hr
55
24
79
33
115
44
143
55
172
70
203
90
309
132
342
154
474
165
606
209
Required Draft RL
PL
inch
WC
0.03
0.02
0.03
0.02
0.03
0.02
0.03
0.02
0.03
0.02
0.03
0.02
0.03
0.02
0.03
0.02
.032
.024
.032
.024
Flue pipe diameter
inches
5
5
5
5
6
6
6
6
8
8
NL = Nominal Load, PL = Partial Load

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Page 19
Tel [phone] Fax [phone] [email protected] www.froeling.com B0430207
2
2.4 Safety Devices
1
Key for automatic mode
In case of overheating of the boiler:
Press and hold the key for 5 seconds
Automatic mode is switched off
Control follows the boiler shutdown procedure
The pumps continue to run!
2
Safety temperature limiter
(STL)
Switches off the blower fan at the maximum boiler temperature of
220 °F (105 °C). The pumps continue to run!
Once the temperature falls to below approx. 203 °F (95 °C),
the STL can be reset mechanically.
2.4.1 Devices for Preventing the Boiler from overheating
The P4 Pellet boiler comes with safety systems to prevent the following:
Pressure in the boiler exceeding 30 psi (2 bar) (over pressure)
Boiler water temperature exceeding 220ºF (105º C)
2
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Page 20
B0430207 I
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Pressure Relief Valve
Protection against over-heating/ excessive pressure:
When the system pressure reaches a maximum of 30 psi (2 bar), the
Pressure Relief Valve opens and the heating water is released in the form
of steam.
Overheat Thermostat (Safety Temperature Limit Switch-STL)
The Overheat Thermostat stops combustion at a boiler temperature of
220 °F (105 °C). The circulators continue to run!
In case Overheat Thermostat automatically has been activated:
Wait for boiler temperature to drop below 203 °F (95 °C)
Remove cap of Overheat Thermostat (STL) by screwing-off counter-
clockwise. STL located at right hand side of Boiler Control System
viewed from front side of the boiler.
Release STL by pushing button behind cap using a small screw
driver or ball point pen. Release is successful, when fault is gone on
display.
Screw-on cap of STL again (clockwise).
On the Boiler Control System there is an Overheat Thermostat. If the
boiler exceeds 220 °F (105 °C) it will shut off the Induced Draft Fan.
Overheat loop: with electricity
The Honeywell L4008B aquastat provided with the boiler is wired in
parallel with the thermostat on the zone with the most heating capacity
in the main living area. Upon reaching the aquastat set point 200 ºF (93
ºC) the heating zone will be activated, pulling heat away from the boiler.
The home owner is alerted to a potential problem with the boiler by an
overly warm living space.