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
Operating Instructions
P4 Pellet 8 - 60
Read and follow the operating instructions and safety information.
Subject to technical change.
July 2009

Introduction
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Page 3
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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. Observing the requirements and
safety information in the instruction manual makes a significant
contribution to safe, appropriate, environmentally friendly and
economical operation of the system.
The continuous development of our products means that there may be
minor differences between the illustrations and other content of the
document. If you discover any errors, please let us know.
Subject to technical change.

Contents
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1Product Overview 6
2Safety 8
2.1 Safety Information 8
2.2 Permitted Uses 9
2.2.1 Permitted fuel..................................................................................................9
2.2.2 Non-permitted fuels..........................................................................................9
2.2.3 Who may operate the boiler? .............................................................................9
2.3 Design Information 10
2.3.1 Approvals and reporting obligations .................................................................. 10
2.3.2 Requirements for hot water supplies ................................................................. 10
2.3.3 Ventilation of boiler room ................................................................................ 11
2.3.4 Installing the heating system / Standards .......................................................... 11
2.3.5 Combination with storage tank......................................................................... 11
2.3.6 Chimney connection / chimney system .............................................................. 12
Draught limiter.............................................................................................. 12
Boiler data for constructing the flue gas system:................................................ 12
2.4 Safety Devices 13
2.5 Safety instructions for the installation room 14
2.6 Residual risks 15
2.7 Emergency procedure 16
2.7.1 Overheating of the system............................................................................... 16
2.7.2 Smell of flue gas ............................................................................................ 16
2.7.3 Fire .............................................................................................................. 16
3Operating the system 17
3.1 Initial startup 17
3.2 Filling/ refilling the store with fuel 17
3.3 Heating up the boiler 18
3.3.1 Switching on the boiler.................................................................................... 18
3.3.2 Controlling the boiler ...................................................................................... 18
3.3.3 Switching off the boiler.................................................................................... 18
4Boiler servicing 19
4.1 General information on servicing 19
4.2 Inspection, cleaning and maintenance 20
4.2.1 Inspection ..................................................................................................... 20
Check safety valve......................................................................................... 20
Checking the system pressure ......................................................................... 20
4.2.2 Cleaning........................................................................................................ 21
Emptying the ash drawers (for P4 Pellet 8/15/20/25).......................................... 21
Emptying the ash container (for P4 Pellet 32/38/48/60) ...................................... 22
Check the grate and combustion chamber......................................................... 23
4.2.3 Yearly check .................................................................................................. 24
Clean the flue gas collection chamber and the heat exchanger ............................. 24

Contents
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Clean WOS....................................................................................................25
Cleaning the induced draught ventilator ............................................................25
Clean the smoke flue pipe ...............................................................................25
Checking the draught controller flap and explosion flap .......................................25
Clean the flue gas sensors...............................................................................26
4.3 Testing Emissions 26
4.3.1 Measurement at rated load ..............................................................................26
4.4 Maintenance agreement / Customer service 27
4.5 Replacement parts 27
5Troubleshooting 28
5.1 General faults in the power supply 28
5.1.1 Behaviour of system after a power failure...........................................................28
5.2 Excessive temperature 28
5.3 Faults with fault codes 29
5.3.1 Procedure for fault messages............................................................................29
5.3.2 Acknowledging a fault message ........................................................................29
6Appendix 30
6.1 Guarantee conditions 30
6.2 Address of manufacturer 30
6.3 Declaration of Conformity 31

Product Overview
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1Product Overview
Ash drawer module (P4 Pellet 32/38/48/60):
Below the insulating cover:
2
1
4
11
12
6
3
8 9
A
sh drawer module (P4 Pellet 8/15/20/25):
5
7
10
2.1
2.2
2.4
2.3

Product Overview
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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 P4 Pellet 32/38: Ash screw and guide plates of the combustion chamber cleaning
P4 Pellet 48/60: Ash screw and stirrer of the combustion chamber cleaning
10 Lever of the ash box lock
11 Service interface of the control
12 Safety temperature limiter - STL

Safety
Safety Information
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2Safety
2.1 Safety Information
RISK
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!
Details on procedure for operation, maintenance and cleaning, as
well as troubleshooting for the boiler are included in the
individual instructions. Any further work should be carried out by
authorised heating engineers or by Fröling 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!
Instructions and information for versions and minimum values, as
well as norms 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 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!

Safety
Permitted Uses
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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
Applicable standards:
Austria: ÖNORM M 7135 - HP 1
and/or DINplus certification program
Germany: DIN 51731 - HP 5, DINplus certification program
and/or ÖNORM M 7135 - HP 1
Applies generally:
Before refilling the store, check for pellet dust and clean if necessary.
2.2.2 Non-permitted fuels
The use of fuels not defined under 2.2.1, and particularly the burning of
refuse, is not permitted.
CAUTION
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.
2.2.3 Who may operate the boiler?
Only trained operators are permitted to operate the boiler.
CAUTION
No unauthorised access to the boiler room!
Danger: Personal injury and damage to property.
It is the responsibility of the operator to ensure that unauthorised persons,
especially children, are kept away from the boiler.

Safety
Design Information
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2.3 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.
2.3.1 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.
2.3.2 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.
§

Safety
Design Information
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2.3.3 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
2.3.4 Installing the heating system / Standards
The boiler shall only be operated within a pressurized (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
2.3.5 Combination with storage tank
NOTE
It is not 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.
ÀPage 30, 6.2 Address of manufacturer
§
§

Safety
Design Information
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2.3.6 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 there.
Boiler data for constructing the flue gas system:
P4 Pellet
Component Unit 8 15 20 25 32 38 48 60
Flue gas temperature NL °C 140 150 150 150 160 160 160 170
Flue gas mass flow NL
PL
kg/h 25
11 36 15 52 20 65 25 78 32 92 41 140 60 155 70
Flue gas mass flow NL
PL
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 NL
required PL
Pa 8
6 8 6 8 6 8 6 8 6 8 6 8 6 8 6
Feed pressure NL
required PL
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

Safety
Safety Devices
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2.4 Safety Devices
1 Key for automatic mode In case of overheating of the boiler:
UPress 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 105 °C. The pumps continue to run!
Once the temperature falls to below approx. 95 °C, the STL
can be reset mechanically.
3 Safety valve Protection against over-heating
When the boiler pressure reaches a maximum of 3 bar, the safety
valve opens and the heating water is released in the form of steam.
2
1
3

Safety
Safety Devices
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2.5 Safety instructions for the installation room
1) Danger of fire due to flammable materials.
No flammable materials should be stored near the boiler.
2) Damage due to impurities in combustion air.
Do not use any hydrogen halides or any cleaning agents containing
chlorine in the room where the boiler is installed.
3) Keep the air suction opening of the boiler free of dust.
4) The room where the boiler is installed must be frost-proof.

Safety
Residual risks
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2.6 Residual risks
WARNING
Do not touch the hot surface!
Hot parts and the flue pipe can cause serious burns!
UProtective gloves should generally be worn when working on
the boiler.
UOnly operate the boiler using the handles provided for this
purpose.
UInsulate the flue pipes or simply avoid touching them during
operation.
Before carrying out maintenance work on/in the boiler:
UPress and hold the key for 5 seconds
´Boiler follows shutdown procedure and changes to the
operating status “Burner off”
WARNING
Do not open the ash doors during operation!
This may cause injury, damage and smoke!
It is forbidden to open the doors behind the insulating door
during operation!
WARNING
Do not use unauthorised fuel!
Non-standard fuels can cause serious faults in combustion (e.g.
spontaneous combustion of carbonisation gases / flash fires) which
can lead to serious accidents!
Only use fuels specified in the chapter on “Permitted Uses” in
these instructions.

Safety
Emergency procedure
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2.7 Emergency procedure
2.7.1 Overheating of the system
If the system overheats in spite of the safety devices, proceed as
follows:
UKeep all the doors on the boiler closed.
UTurn off the boiler by pressing the key for 5 seconds
UOpen all mixer taps, switch on all pumps.
´Fröling heating circuit control takes over this function in
automatic operation.
ULeave the boiler room and close the door.
UOpen any available radiator thermostat valves
If the temperature does not drop, inform the installer or Fröling
customer services:
ÀPage 30, 6.2 Address of manufacturer
2.7.2 Smell of flue gas
RISK
Smell of flue gas!
Flue gases can cause fatal poisoning!
UKeep all the doors on the boiler closed.
UTurn off the boiler by pressing the key for 5 seconds
UAir the room where the boiler is installed
UClose the fire protection door and doors to living areas.
2.7.3 Fire
RISK
Fire!
In case of fire, there is risk of burns and explosions!
UTurn off the boiler
UUse a tested fire extinguisher for fire class AB to fight the fire
AB powder

Operating the system
Commissioning
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3Operating the system
3.1 Initial startup
NOTE
Optimum efficiency and efficient, low-emission operation can
only be guaranteed if the system is set up by trained
professionals and observing the standard factory settings.
Take the following precautions:
UInitial startup should be carried out with an authorised installer or with
Fröling customer services.
The individual steps for initial startup are explained in the operating
instructions for the controller.
ÀSee the operating instructions for the Lambdatronic P 3200
NOTE
If condensation escapes during the initial heatup phase, this does not
indicate a fault.
If this occurs, clean up using a cleaning rag.
3.2 Filling/ refilling the store with fuel
CAUTION
Damage and injuries can occur if the store is filled when the boiler is
on!
UTurn off the boiler by pressing the key for 5 seconds
UAllow the boiler to cool down for at least half an hour.
When the boiler has cooled down:
UClose all opening to the store to seal out dust
UFill the store with pellets
Only use permitted pellets
ÀPage 9, 2.2.1 Permitted fuel

Operating the system
Heating up the boiler
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3.3 Heating up the boiler
NOTE
Changing the factory settings for primary and secondary air can
have a negative effect on efficiency and emissions of the
system.
3.3.1 Switching on the boiler
UPress the key
´Automatic mode
´The heating system is controlled via the control system according
to the selected mode.
3.3.2 Controlling the boiler
Necessary control steps. Displaying or modifying parameters:
ÀSee operating instructions Lambdatronic P 3200
3.3.3 Switching off the boiler
UPress and hold the key for 5 seconds
´The boiler follows the shut-down program and switches to
“Burner OFF” status.
´The combustion unit is switched off, the chamber delivery unit
and the active hydraulic system are active

Boiler servicing
Inspection, cleaning and maintenance
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4Boiler servicing
4.1 General information on servicing
RISK
Working on electrical components.
Danger: Serious injuries from electric shocks.
UWork on electrical components should only be carried out by authorised
technicians
WARNING
Do not carry out maintenance when the boiler is hot!
Hot parts and the flue pipe can cause serious burns!
UProtective gloves should generally be worn when working on
the boiler.
UOnly operate the boiler using the handles provided for this
purpose.
Before starting any maintenance work:
UPress and hold the key for 5 seconds
´Boiler follows shutdown procedure and changes to the
operating status “Burner off”
UAllow the boiler to calm down for at least 1 hour
UAfter maintenance has been carried out switch the boiler on
in the desired mode.
In service mode the boiler does not start automatically.
WARNING
Non-permitted cleaning and maintenance!
Incorrect or insufficient cleaning and maintenance of the boiler can
cause serious faults in combustion (e.g. spontaneous combustion of
carbonisation gases / flash fires) and this can lead to serious
accidents!
Clean the boiler following the instructions. Follow the boiler
operating instructions.
Note
We recommend that you keep a maintenance book in accordance with
ÖNORM M7510 of the Technical Directive for Fire Prevention (TRVB)

Boiler servicing
Inspection, cleaning and maintenance
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4.2 Inspection, cleaning and maintenance
Regular cleaning of the boiler extends its life and is a basic
requirement for smooth running.
So clean the boiler regularly!
Recommended: When cleaning, use an ash vacuum.
4.2.1 Inspection
Check safety valve
Check the boiler regularly for dirt:
UCheck the safety valve regularly
following the manufacturer's
specifications.
Checking the system pressure
UCheck the system pressure on the
pressure gauge
´The value must be 20% over the
pre-stressed pressure of the
expansion tank
ÀExpansion tank operating
instructions
If the system pressure decreases:
UTop up with water
If this occurs frequently, the seal
of the heating system is faulty!
Inform your installer!
If large pressure fluctuations are
observed:
UHave the expansion tank checked.