Froling P4 Pellet 8-60 User manual

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen
Tel. [phone] Fax [phone] [email protected] www.froeling.com
Assembly instructions
P4 Pellet 8 - 60
Read and follow the assembly instructions and safety information
Subject to technical change.

Introduction
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Page 3
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I
Dear installer,
The FRÖLING P4 Pellet is a state-of-the-art design that conforms to all
currently applicable standards and testing guidelines.
Please read and follow the assembly instructions. They contain safety
instructions as well as comprehensive information about transporting,
setting up and assembling the boiler.
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.
Delivery Certificate
Keeping a record of correct delivery and customer-specific data for the
system allows us to respond quickly should problems arise.
We would therefore ask you to confirm that you have received the
product in good condition.
Please send Fröling a copy of the shipping document, completely filled
out and signed by the customer.
Guarantee Conditions
Our sale and delivery conditions generally apply. 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 in the enclosed guarantee
certificate.
Address of manufacturer
FRÖLING
Heizkessel- und Behälterbau GesmbH
Industriestraße 12
A-4710 Grieskirchen
AUSTRIA
TEL [phone]
FAX [phone]
E-MAIL [e-mail]
INTERNET www.froeling.com

Contents
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1General information 6
1.1 Notes on standards 6
1.2 Design Information 7
1.2.1 Approvals and reporting obligations .................................................................... 7
1.2.2 Requirements for hot water supplies ................................................................... 7
1.2.3 Ventilation of boiler room .................................................................................. 8
1.2.4 Installing the heating system / Standards ............................................................ 8
1.2.5 Combination with storage tank ........................................................................... 8
1.2.6 Chimney connection / chimney system ................................................................ 9
Draught limiter................................................................................................9
Boiler data for constructing the flue gas system:..................................................9
1.3 Installation Information 10
1.3.1 Hose lines ..................................................................................................... 10
Potential equalisation ..................................................................................... 11
2Technology 12
2.1 Components and connections 12
2.2 Dimensions 13
2.3 Technical specifications 14
2.3.1 P4 Pellet 8/15/20/25....................................................................................... 14
2.3.2 P4 Pellet 32/38/48/60 ..................................................................................... 15
3Assembly 16
3.1 Transport 16
3.1.1 Positioning..................................................................................................... 16
3.1.2 Temporary storage ......................................................................................... 16
3.2 Setting up in the boiler room 17
3.2.1 Remove boiler from pallet................................................................................ 17
3.2.2 Transporting in the boiler room ........................................................................ 17
3.2.3 Minimum distances in the boiler room................................................................ 18
3.3 Assembling the Pellet Boiler 19
3.3.1 Removing the suction cyclone .......................................................................... 19
3.3.2 Fitting the induced draught fan......................................................................... 19
3.4 Install delivery system 20
3.4.1 Universal suction system ................................................................................. 20
Variant 1 - Comfort pellet box ......................................................................... 21
Variant 2 - Eco pellet box................................................................................ 22
Installing the suction probes and lines .............................................................. 23
3.4.2 Suction screw system...................................................................................... 24
3.4.3 Bag silo system.............................................................................................. 27
3.4.4 Pellet storage area.......................................................................................... 29
Size of storage area....................................................................................... 29
Sloping floor ................................................................................................. 30
Impact cushion.............................................................................................. 30
3.5 Electrical Connection 31
3.5.1 Connecting the Comfort pellet box .................................................................... 32

Contents
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4Initial startup 33
4.1 Configuring the boiler 33
4.2 Setting “Max Level” sensor 33
5Appendix 34
5.1 Delivery Certificate 34
5.2 Notes 35

General
Standards, Design, Assembly
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1General information
CAUTION
Assembly and installation by untrained personnel.
Danger: Personal injury and damage to property.
The instructions and information provided in the instructions
should be observed!
Only allow trained staff (heating installers or licensed electricians)
to perform set-up and installation!
1.1 Notes on standards
The boiler must be installed and started up in compliance with local fire
and building regulations and the following standards:
ÖNORM / DIN EN 303-5 Heating boilers for solid fuels, manually and automatically loaded combustion
systems, nominal heat output of up to 300 kW - Terminology, requirements,
testing and marking
ÖNORM M 7510 Guidelines for checking central heating systems
ÖNORM / DIN EN 12828 Heating systems in buildings - design of hot water heating systems
ÖNORM B 8130 Safety devices, open water heating systems
ÖNORM B 8131 Closed water heating systems, safety requirements
DIN 4751 Parts 1-4 Heating system safety equipment
ÖNORM / DIN EN 13384-1 Chimneys serving one appliance
ÖNORM M 7515 /DIN 4705-
1
Calculating chimney dimensions for combustion systems
TRVB H118 Technical directives for fire protection/prevention (Austria only)
ÖNORM H5170 Construction and fire protection requirements
VDI 2035 Prevention of damage caused by scaling in hot water and water heating
systems (Germany only)
ÖNORM H 5195-1 Protection against corrosion and scaling damage in hot water systems with
operating temperatures to 100°C (Austria only).
SWKI 97-1 Limescale and corrosion protection in heating systems (Switzerland only)

General
Standards, Design, Assembly
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1.2 Design Information
It is forbidden 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.
1.2.1 Approvals and reporting obligations
NOTE
Each heating system must be officially approved.
When installing or modifying a heating system, you must inform the
inspectors from the supervisory authority and get authorisation from the
building authorities.
Austria: Report to the construction authorities of the community or
magistrate
Germany: Report new installations to an approved chimney sweeper /
the building authorities.
1.2.2 Requirements for hot water supplies
The requirements pertaining to the water used to fill the boiler are
based on the following standards and guidelines:
Applicable standards and directives:
Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1
There are no other special requirements for domestic hot water apart
from this.
Note for filling with make-up water:
Bleed the filling hose before connecting to prevent air from getting
into the system.
§

General
Standards, Design, Assembly
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1.2.3 Ventilation of boiler room
The openings for the supply air and the exhaust air should be arranged
as nearly opposite each other as possible to achieve a good thermal
draught effect.
The supply air must be drawn in directly from outside. The exhaust
air must be discharged directly outside.
Unless otherwise provided by the relevant building regulations for the
room where the boiler is to be installed, the following standards apply:
Applicable standards:
- TRVB H 118
- ÖNORM H 5170
Rule of thumb:
Provide a supply air cross-section of 2 cm2per kW of boiler rated output,
as per ÖNORM H 5170, but a total cross-section of at least 200 cm2
1.2.4 Installing the heating system / Standards
The boiler has to be installed in a closed hydraulic system. The following
standards govern the installation of heating systems:
Applicable standards:
ÖNORM / DIN EN 12828 Heating Systems in Buildings
The following prior standards still apply:
Austria: - Closed systems as per ÖNORM B 8131
Germany: - Closed systems as per DIN 4751 Part 2
1.2.5 Combination with storage tank
NOTE
It is not generally necessary to use a storage tank for the system to run
smoothly. However we recommend that you use it with a storage tank, as this
allows you to achieve continuous reduction 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 (as per ÖNORM M 7510 resp.
Directive UZ37).
§
§

General
Standards, Design, Assembly
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Page 9
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1.2.6 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.
It should be noted here that flue gas temperatures of less than 160 K
above room temperature can occur within the permitted operating range
of the boiler.
The flue gas temperatures (when cleaned) and the additional flue gas
values can be found in the technical specification sheets.
ÀSee “Boiler data for constructing the flue gas system”
Establish the connection to the chimney via the shortest path, ascending
as much under 30 – 45° as possible Insulate the connecting piece.
The entire flue gas system (chimney and connection) must be calculated
as per ÖNORM / DIN EN 13384-1 or prior standards ÖNORM M 7515 /
DIN 4705-1.
Local and other legal regulations also apply.
The chimney must be approved by a smoke trap sweeper or chimney
sweeper.
As per TRVB H 118 (only in Austria) an explosion flap must be
installed in the flue pipe or in the chimney.
Draught limiter
We recommend that you install a draught limiter 1
Install the draught limiter directly under the mouth of the flue line,
as there is always low pressure here!
Boiler data for constructing the flue gas system:
P4 Pellet
Component MEH 8 15 20 25 32 38 48 60
Flue gas N
L
temperature
°C 140 150 150 150 160 160 160 170
Flue gas mass flow N
L
P
L
kg/h 25
11
36
15
52
20
65
25
78
32
92
41
140
60
155
70
Flue gas mass flow N
L
P
L
kg/s 0,007
0,003
0,010
0,004
0,014
0,006
0,018
0,007
0,022
0,009
0,025
0,011
0,039
0,017
0,043
0,019
Feed pressure N
L
required P
L
Pa 8
6
8
6
8
6
8
6
8
6
8
6
8
6
8
6
Feed pressure N
L
required P
L
mbar 0,08
0,06
0,08
0,06
0,08
0,06
0,08
0,06
0,08
0,06
0,08
0,06
0,08
0,06
0,08
0,06
Flue pipe diameter mm 130 130 130 130 150 150 150 150
NL = Nominal Load, PL = Partial Load
1

General
Standards, Design, Assembly
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1.3 Installation Information
Water lines should not be located in close proximity to the storage
area or the feeder units due to the dangers posed by condensation
and bursting water pipes!
Check the delivered items for foreign objects in the individual
components.
In the pellet store room an impact cushion must be installed on the
opposite side to the filler pipes. This reduces wear on the pellets
when they are blown in and stops the finish being worn off. Broken
pieces of masonry or finish and other foreign bodies (small stones,
pieces of wood, screws, etc.) can block the delivery system or the
pellet feed into the boiler and cause the system to fail. In case of
faults due to such foreign bodies, the guarantee is void.
In time pellets leave dust on the ground; this can impair the process
of moving them from the pellet storage area.
For this reason you should check and clean if necessary before
refilling.
1.3.1 Hose lines
For the hose lines used with the suction device, the universal suction
system, and the silo delivery unit, observe the following:
Do not kink the hose lines! Minimum bending radius = 30cm.
Lay the hose lines as straight as possible! If the lines are sagging, it
can lead to so-called “pockets.” Problem-free pellet feeding can not
be guaranteed.
Lay the hose lines in short sections away from walking areas!
Hose lines are not UV-proof!
Therefore: do not lay the hose lines outdoors!
Hose lines are suitable for temperatures up to 60°C!
Therefore: Hose lines must not come into contact with flue gas pipes
or un-insulated heating pipes!
Hose lines must be earthed on both sides to ensure that no static
charge builds up as a result of transporting the pellets!
The suction line must be in a single section!
The return-air line can be made up of several sections, but potential
equalisation must be established throughout the line!

General
Standards, Design, Assembly
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Potential equalisation
When connecting the hose lines to the individual connection pipes,
ensure there is potential equalization throughout the line!
UExpose approximately 3 cm of the earth conductor at the end of the
hose line
TIP: Slit the insulation open along the wire with a knife
UBend the earth wire inwards in a loop
´This prevents the earth wire from being damaged by the feed of
pellets.
UFit a hose clip to the hose line
UAttach the hose line to the connector
Ensure that contact is established between the earth conductor and
the connector!
UTighten the hose clip

Technology
Components, Connections, and Dimensions
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2Technology
2.1 Components and connections
P4 Pellet
Pos. Component Unit 8 / 15 20 / 25 32 / 38 48/60
A Boiler outfeed connection 1 6/4 6/4 6/4
B Boiler return feed connection 1 6/4 6/4 6/4
C Drain 1/2 1/2 1/2 1/2
D Air vent
Inch
1/2 1/2 1/2 1
E Pellet suction line
F Return-air line DA 60 DA 60 DA 60 DA 60
G Flue gas pipe connection
mm
130 130 150 150
1 Lambdatronic P 3200 control system
2 Switch box
3 Safety temperature limiter - STL
4 Induced draught fan
4
C
A
G
1
2
3
B
D
E
F

Technology
Components, Connections, and Dimensions
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2.2 Dimensions
P4 Pellet
Dimensions Component Unit 8 / 15 20 / 25 32 / 38 48 / 60
L Length, boiler 1) 740 740 820
L1 Total length inc. induced draught fan mm 930 930 1110 900
B Width, boiler 600 770 860
B*Width, boiler, inc. support for
positioning unit 2) 700 870 960 1100
B1 Total width, inc. suction cyclone
mm
1185 1355 1445 1030
H Height, boiler 3) 1280 1280 1430 1275
H1 Total height, inc. suction cyclone 1660 1660 1900 1790
H2 Height, flue pipe connection 1350 1350 1530 1585
H3 Height, outfeed connection 460 460 460 1900
H4 Height, return connection 940 955 1085 1685
H5 Height, drainage connection 460 460 460 515
H6 Height, ventilation connection 1030 1030 1155 1240
H8 Height, induced draught fan
connection
1090 1090 1215 515
H15 Height, suction system connection
mm
1485 1485 1720 1310
Flue pipe diameter mm 130 130 150 1375
1) Corresponds to the minimum positioning length
2) Corresponds to the minimum positioning width after removing the stoker assembly, suction cyclone and positioning unit
3) Corresponds to the minimum positioning height after removing the stoker assembly, suction cyclone and positioning
unit

Technology
Technical specifications
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2.3 Technical specifications
2.3.1 P4 Pellet 8/15/20/25
P4 Pellet
Component Unit 8 15 20 25
Rated heat output 10,5 14,9 20,0 25,0
Heating efficiency range kW 3,1-10,5 3,1-14,9 6,0-20,0 7,5-25,0
Mains connection 230V / 50Hz fused 16A
Output W 96 123 110 110
Weight of boiler kg 350 350 430 430
Boiler capacity (water) L 70 70 80 80
Upstream resistance (ΔT=20°C) mbar 4,3 6,1 4,5 2,9
Minimum return feed temperature Not applicable because of internal return feed lift
Maximum boiler temperature setting 80 80 80 80
Minimum boiler temperature setting °C 40 40 40 40
Permitted operating pressure bar 3 3 3 3
Boiler class 3 3 3 3
Permitted fuel Wood pellets Ø 6mm as per ÖNORM M 7135 / DIN
51731
Test report data
Testing institute TÜV-Austria1) 2) 3) 2) 4)
Test report no. 06-UWC
Wels-EX-
295/2
06-UWC
Wels-EX-
295/1
Test data at rated load
Carbon monoxide (CO) [mg/MJ] 24 39 35 30
Nitrogen oxide (NOx) [mg/MJ] 74 74 76 78
Organic hydrocarbons [mg/MJ] < 1,0 0,6 0,7 0,9
Dust [mg/MJ] 14 12 11 11
Kesselwirkungsgrad [%] 91,6 90,9 91,9 92,9
Prüfdaten bei Teillast
Carbon monoxide (CO) [mg/MJ] 77 77 72 66
Nitrogen oxide (NOx) [mg/MJ] 69 69 71 73
Organic hydrocarbons [mg/MJ] 1,4 1,4 1,3 1,1
Dust [mg/MJ] 11 11 11 10
Boiler efficiency rating [%] 92,0 92,0 93,3 94,5
1) TÜV Austria, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels
2) In accordance with ÖNORM / DIN EN 303-5, chapter 5.1.3 type test: for a boiler from a range with a consistent
structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤2 : 1, to carry out the
tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that
have not been tested in a range, whose values have been determined depending on rated heat output by interpolation,
fulfil the requirements of the norm.
3) Values of the type P4 Pellet 20 are interpolated between the test protocol 06-UWC/Wels-EX-295/1 and K44302/2.
5) Values of the type P4 Pellet 25 are interpolated between the test protocol 06-UWC/Wels-EX-295/1 and K44302/2.

Technology
Components, Connections, and Dimensions
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2.3.2 P4 Pellet 32/38/48/60
P4 Pellet
Component Unit 32 38 48 60
Rated heat output 32,0 38,0 48,0 58,5
Heating efficiency range kW 8,9-32,0 8,9-38,0 14,4-48 17,3-58,5
Mains connection 230V / 50Hz fused 16A
Output W 110 110 120 120
Weight of boiler kg 530 530 760 760
Boiler capacity (water) l 125 125 170 170
Upstream resistance (ΔT=20°C) mbar 1,5 2,1 3,6 5,3
Minimum return feed temperature Not applicable because of internal return feed lift
Maximum boiler temperature setting 80 80 80 80
Minimum boiler temperature setting °C 40 40 40 40
Permitted operating pressure bar 3 3 3 3
Boiler class 3 3 3 3
Permitted fuel Wood pellets Ø 6mm as per ÖNORM M 7135 / DIN
51731
Test report data
Testing institute TÜV SÜD SZA1) 3) 4) TÜV2)
Test report no. K44302/6 K44302/4 - 08-UWC/
Wels-EX-
337
Test data at rated load
Carbon monoxide (CO) [mg/MJ] 31 45 25 5
Nitrogen oxide (NOx) [mg/MJ] 79 77 77 77
Organic hydrocarbons [mg/MJ] 1,0 1,0 1,5 < 2
Dust [mg/MJ] 10 9 10 11
Boiler efficiency rating [%] 93,5 92,6 92,4 92,1
Prüfdaten bei Teillast
Carbon monoxide (CO) [mg/MJ] 61 61 36 10
Nitrogen oxide (NOx) [mg/MJ] 75 75 71 66
Organic hydrocarbons [mg/MJ] 1,0 1,0 1,5 < 2
Dust [mg/MJ] 10 10 10 10
Boiler efficiency rating [%] 95,7 95,7 94,0 92,3
1) TÜV Austria, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels
2) In accordance with ÖNORM / DIN EN 303-5, chapter 5.1.3 type test: for a boiler from a range with a consistent
structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤2 : 1, to carry out the
tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that
have not been tested in a range, whose values have been determined depending on rated heat output by interpolation,
fulfil the requirements of the norm.
3) Values of the type P4 Pellet 20 are interpolated between the test protocol 06-UWC/Wels-EX-295/1 and K44302/2.
5) Values of the type P4 Pellet 25 are interpolated between the test protocol 06-UWC/Wels-EX-295/1 and K44302/2.

Installation
Transport and Assembly
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3Assembly
3.1 Transport
The boiler is delivered packed in cardboard
and on a pallet.
Move the boiler without jarring or jolting
Observe the transport information on the
packaging.
Consider centre of mass!
The boiler is marked with a sticker on the
opposite of the side to lift
3.1.1 Positioning
UPosition a fork-lift or similar lifting device at the pallet and position
the boiler
If it is not possible to position the boiler on the pallet:
URemove cardboard packaging
UTake the unit from the pallet, and if necessary also dismantle the
suction unit assembly
ÀSee 3.2.1 Remove boiler from pallet
3.1.2 Temporary storage
If the system is to be installed at a later time:
UStore the boiler, insulation and control unit in a safe, dust-free, and
dry location
Moisture and frost reduce the effectiveness of insulation and can
destroy electronic components.

Installation
Transport and Assembly
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3.2 Setting up in the boiler room
3.2.1 Remove boiler from pallet
At the front of the boiler:
UOpen insulation door
UPull out floor insulation
URemove protective transport materials on the left and right in the
recess
TIP: For transport in the boiler room remove the insulating door.
UPull out the lock bolt of the door hinge (1) and remove it from the
guide
URemove the insulating door
At the back of the boiler:
URemove protective transport materials on the left and right in the
recess
3.2.2 Transporting in the boiler room
UPosition a fork-lift or similar lifting device at the base frame of the
boiler and transport it to the designated position
If no lifting device of this type is available:
UAfter removing the suction unit thread a carrying belt through the
lateral openings (1) of the base frame and lift the boiler
UPosition transport rollers or similar with appropriate load-bearing
capacity under the base frame and move to the designated position
USet up boiler at intended location
Observe the minimum distances in the boiler room.
1
1

Installation
Transport and Assembly
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3.2.3 Minimum distances in the boiler room
P4 Pellet
Dimensions Component Unit 8/15 20/25 32/38
48/60
A Minimum distance
between suction
cyclone and wall
300 300 300 300
B Maintenance
range for ID fan 300 300 300 300
C Space for
insulated door 550 720 830 490
D Minimum distance
from side of boiler
to wall
mm
200 200 200 200

Installation
Assembling the Pellet Boiler
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3.3 Assembling the Pellet Boiler
3.3.1 Removing the suction cyclone
URemove sound insulation cover
UOpen the clamps on the suction unit container and lift the cover
´The induced draught unit set is in the suction unit container
3.3.2 Fitting the induced draught fan
URemove pre-installed cover plate
UUnscrew pre-installed nuts and
spacer washers
UAttach and fix the ID fan as
illustrated
The straight edge must be up.
UJoin both cables of the ID fan with the pre-installed cables
UPush the cable behind the cladding and put back the cover plate.

Installation
Install delivery system
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3.4 Install delivery system
3.4.1 Universal suction system
A 25 m Suction hose G Manual re-arranging unit (Variant 2)
B Hose clamps 50-65 mm H 2 Blind plates (Variant 2)
C 2 Fire protection choke collar
(only in Austria) I 6 Star-shaped handle (Variant 2)
D Komfort pellet box (Variant 1) J Cover plate for wall
E Support for fire protection choke collar (Variant 1) K Suction probe
F Installation module for wall
280
250
50
Before installation:
UPrepare hole in wall for pellet box (width: 28cm,
height: 25cm)
Maintain a distance of at least 5 cm from the
finished floor.
F
G
I
A
C
A
B
E
D
J
B
A
B
K
Variant 2 - Eco
pellet box
Variant 1 - Komfort
pellet box
G
H
280 Dimensions in mm
50
250