Froling P4 Pellet 8 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 - 105
English version of the assembly instructions for technicians.
Read and follow the instructions and safety instructions!
Subject to technical change.

Introduction
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Dear customer,
The FROLING 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 and comprehensive information relating to 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 that the delivery was received correctly and collecting
customer-specific data relating to 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 Froling a copy of the delivery certificate, filled in 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 on 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]
WEBSITE www.froeling.com

Contents
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 3
Tel [phone] Fax [phone] [email protected] www.froeling.com M0930811
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1General Information 5
1.1 Standards 5
1.2 Qualification of assembly staff 5
1.3 Protective equipment for assembly staff 6
1.4 Design information 6
1.4.1 Installation and approval of the heating system ....................................................6
1.4.2 Information on the installation room (boiler room) ................................................6
Boiler room characteristics ................................................................................6
Ventilation of the boiler room.............................................................................7
1.4.3 Heating water requirements ...............................................................................7
1.4.4 Combination with storage tank ...........................................................................7
1.4.5 Chimney connection/chimney system ..................................................................8
Draught limiter................................................................................................8
Boiler data relating to design of the flue gas system P4 Pellet 8/15/20/25/32/38 ......8
Boiler data relating to design of the flue gas system P4 Pellet 48/60/80/100/105......9
1.4.6 Room air-independent operation .........................................................................9
Minimum specification of connection lines..........................................................10
1.4.7 Notes on boiler ventilation ............................................................................... 10
2Technology 11
2.1 Components and Connections 11
2.2 Dimensions 12
2.2.1 Supply air connections for room air-independent operation ................................... 13
2.2.2 Flue gas pipe position...................................................................................... 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
2.3.3 P4 Pellet 80/100/105 ...................................................................................... 16
2.3.4 Airborne sound level ....................................................................................... 17
3Assembly 18
3.1 Transportation 18
3.1.1 Positioning..................................................................................................... 18
3.1.2 Temporary storage ......................................................................................... 18
3.2 Set-up in the boiler room 19
3.2.1 Removing the boiler from the pallet................................................................... 19
3.2.2 Moving the boiler in the boiler room .................................................................. 20
3.2.3 Minimum distances in the boiler room................................................................ 20
3.3 Dismantling for location where positioning is difficult 21
3.3.1 Dismantling the stoker assembly and insulation .................................................. 21
3.3.2 Remove the door and ash drawer (P4 Pellet 8/15/20/25)...................................... 23
3.3.3 Dismantling the suction cyclone cover................................................................ 24
3.3.4 Dismantling the stoker unit .............................................................................. 25
3.3.5 Positioning dimensions after dismantling ............................................................ 28
3.3.6 Notes on reassembly....................................................................................... 29

Contents
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3.4 Assembling the Pellet Boiler 30
3.4.1 Installing the induced draught fan..................................................................... 30
3.4.2 Fit the ash container and doors (P4 Pellet 32/38/48/60/80/100/105) ..................... 31
3.5 Installing the discharge system 32
3.5.1 General installation information ........................................................................ 32
3.5.2 Hose Lines..................................................................................................... 32
Potential Equalisation ..................................................................................... 33
3.5.3 Universal suction system ................................................................................. 34
Variant 1 – Komfort pellet box......................................................................... 35
Variant 2 – Eco pellet box ............................................................................... 36
Installing the suction probes and lines .............................................................. 37
3.5.4 Suction screw system...................................................................................... 38
3.5.5 Bag silo discharge system................................................................................ 41
3.5.6 Pellet storage area.......................................................................................... 43
Size of store ................................................................................................. 43
Sloping floor ................................................................................................. 44
Impact cushion.............................................................................................. 44
3.6 Electrical Connection 45
3.6.1 Connecting the Komfort pellet box .................................................................... 46
4Initial Start-up 47
4.1 Configuring the Boiler 47
4.2 Setting the “Max level and min level” sensor 47

General
Standards, personnel, design
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 5
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1
1General Information
1.1 Standards
The installation and commissioning of the boiler must be carried out in
accordance with local fire and building regulations.
The following standards and regulations should be observed in any case:
ÖNORM/DIN EN 303-5 Boilers for solid fuels, manually and automatically fed combustion systems;
rated heat output up to 300 kW;
ÖNORM M 7510-1 Guidelines for checking heating systems
Part 1: General requirements and one-off inspection
ÖNORM M 7510-4 Guidelines for checking heating systems
Part 4: Simple check for heating plants for solid fuels
EN 12828 Heating systems in buildings - design of water-based heating systems
EN 13384-1 Chimneys serving one appliance
TRVB H 118 Technical directives for fire protection/prevention (Austria only)
ÖNORM H 5170 Construction and fire protection requirements
ÖNORM M 7135 Compressed untreated wood or bark – pellets and briquettes – Requirements
and test
DIN 51731 Testing solid fuels – compressed untreated wood – Requirements and testing
ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in closed warm-water-
heating systems at operating temperatures up to 100 °C (Austria only).
VDI 2035 Prevention of damage in water heating installations - Scale formation in
domestic hot water supply installations and water heating installations
(Germany only)
SWKI 97-1 Lime scale and corrosion protection in heating systems (Switzerland only)
1.BImSchV First Ordinance on Implementation of the Federal Emissions Control Act
1.2 Qualification of assembly staff
CAUTION
Assembly and installation by untrained personnel:
Risk of injury and damage to equipment!
The instructions and information provided in the instructions
should be observed!
Only allow trained staff to carry out assembly and installation!
Assembly, installation, initial startup and servicing must only be carried
out by qualified people:
- Heating technicians / building technicians
- Electrical installation technicians
- Froling customer services
The assembly staff must have read and understood the instructions in
the documentation.

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Standards, personnel, design
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1.3 Protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by
accident prevention regulations.
yDuring transportation, set-up and assembly of the boiler:
- Work clothing
- Safety shoes
- Protective gloves
1.4 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.
1.4.1 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following
standards govern the installation:
Applicable standard:
ÖNORM / DIN EN 12828 Heating systems in buildings
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 sweeper /
the building authorities.
1.4.2 Information on the installation room (boiler room)
Boiler room characteristics
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 provide
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.
§

General
Standards, personnel, design
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 7
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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, ...) from having any
effect on the air flow.
Unless otherwise specified in the applicable building regulations for the
boiler room, the following standards apply for the design and dimensions
of the air ducts:
Applicable standards:
- TRVB H 118
- ÖNORM H 5170
- UNI 10683
1.4.3 Heating water requirements
There are no special requirements for the filling water of the heating
system. The following standards and guidelines apply:
Applicable standards and guidelines:
Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1
Italy: D.P.R. no. 412
Notice on filling with make-up water:
Always bleed the filling hose before connecting, in order to prevent
air from entering the system.
1.4.4 Combination with storage tank
NOTICE
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.
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.
§
§

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Standards, personnel, design
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1.4.5 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 (for clean systems) and additional flue gas
values can be found in the technical specification sheets.
ÀSee “Boiler data relating to design of the flue gas system”
Connect to the chimney via the shortest path, preferably with a vertical
gradient of less than 30–45°. 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 regulations and other statutory regulations also apply.
The chimney must be approved by a smoke trap sweeper or chimney
sweep!
As per TRVB H 118 (only in Austria) an explosion flap must be
installed in the flue pipe or in the chimney.
Draught limiter
Recommended: Installing a draught limiter 1
Install the draught limiter directly under the mouth of the flue line,
as the pressure is lower at this location.
Boiler data relating to design of the flue gas system P4 Pellet
8/15/20/25/32/38
P4 Pellet
Description Units 8 15 20 25 32 38
Flue gas temperature RL °C 140 150 150 150 160 160
Flue gas mass flow RL
PL
kg/h 25
11
36
15
52
20
65
25
78
32
92
41
Flue gas mass flow RL
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
Necessary RL
Feed pressure PL Pa 8 6
8
6
8
6
8
6
8
6
8
6
Necessary RL
Feed pressure 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
Flue pipe diameter mm 130 130 130 130 150 150
RL = Rated Load, PL = Partial Load
1

General
Standards, personnel, design
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Boiler data relating to design of the flue gas system P4 Pellet
48/60/80/100/105
P4 Pellet
Description Units 48 60 80 100 105
Flue gas temperature RL °C 160 170 160 170 170
Flue gas mass flow RL
PL
kg/h 140
60
155
70
215
75
275
95
285
100
Flue gas mass flow RL
PL
kg/s 0,039
0,017
0,043
0,019
0,060
0,021
0,0760,02
6
0,079
0,028
Necessary RL
Feed pressure PL Pa 8 6
8
6
8
6
8
6
8
6
Necessary RL
Feed pressure PL mbar 0,08 0,06
0,08
0,06
0,08
0,06
0.08
0.06
0,08
0,06
Flue pipe diameter mm 150 150 200 200 200
RL = Rated Load, PL = Partial Load
1.4.6 Room air-independent operation
The P4 Pellet boiler has a central air connection on the back of the
boiler. If appropriate supply air and flue gas connections are installed,
the boiler can be operated independently of room air as a type C42 or
type C82 in the sense of EN 15035.
Definition of type C4as per EN 15035:
Boiler that is connected via its combustion air supply and flue gas outlet,
with a connecting piece that may be supplied, to a shared chimney with
a shaft for combustion air supply and a shaft for flue gas outlet. The
mouths of the air and flue gas chimney are either concentric or so close
to each other that similar wind conditions apply.
Air is supplied by an air and flue gas system.
Definition of type C8as per EN 15035:
A boiler that is connected via its combustion air supply and flue gas
outlet, with a connecting piece, to a wind protection device and a single
or shared chimney.
Air supply via an air supply line that is independent from the
chimney system.
This design requires a wind protection device. If a protective grating
is fitted, you must ensure that the mesh size is sufficiently large to
prevent a significant loss of pressure and/or seal from dirt.
The second index “2” (C42 / C82) indicates type C boilers with a blower
fan behind the combustion chamber or the heat exchanger.

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Standards, personnel, design
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When dimensioning pipe bends in the supply air line you should note that:
The ratio of the radius of curvature (r) to
pipe diameter (d) should be greater than 1:
r:d ≥1
For example P4 Pellet 8/15:
- Diameter of supply air connection = 80 mm
- Minimum radius of pipe bends = 80 mm
Install the supply air line in as straight a line as possible and over the
shortest path. The number of pipe bends should be kept to a
minimum (ideally a maximum of 4 bends).
Also: The resistance of the supply air line can be a maximum of 20 Pa.
You can find the necessary dimensions of the supply air connections in
the boiler in the technical data sheets.
ÀSee 2.2.1 Supply air connections for room air-independent operation
Minimum specification of connection lines
Connecting piece for the combustion air supply as per EN 1856-2:
EN 1856-2 - T080 - N2 - D
Connecting piece for the flue gas outlet as per EN 1856-2:
EN 1856-2 - T200 - P1 - W
TXXX ... Temperature class (specified in °C)
N2 ... Pressure class with test pressure = 20 Pa
P1 ... Pressure class with test pressure = 200 Pa
D ... Condensation resistance not required (dry)
W ... Condensation resistance required (damp)
1.4.7 Notes on boiler ventilation
The boiler system should be set up rising slightly towards the back left,
so the ventilation connection is the highest point of the boiler.
Fitting a functioning, automatic ventilating valve ensures constant
removal of air in the boiler.
This prevents malfunctions due to air in the boiler system.
Fit an automatic ventilating valve!
Tip: Fit a vertical pipe before the automatic ventilating valve as a
calming section, to ensure it is positioned above the level of the
boiler water.
A microbubble separator can also optionally be fitted in the lines to the
boiler.

Technology
Components, connections, and dimensions
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2
2Technology
2.1 Components and Connections
Pos. Description Units
8 / 15 20 / 25 32 / 38 48/60 80/100/105
A Boiler flow connection 1 6/4 6/4 6/4 2
B Boiler return connection 1 6/4 6/4 6/4 2
C Drain 1/2 1/2 1/2 1/2 1
D Air vent
Inch
1/2 1/2 1/2 1 1
E Pellet suction line
F Return-air line DA 60 DA 60 DA 60 DA 60 DA 60
G Flue gas pipe connection
mm
130 130 150 150 200
1 Lambdatronic P 3200 control
2 Switch box
3 Induced draught fan
4 Safety temperature limiter - STL
5 Main switch
6 Service interface
3
C
A
G
1
2
4
B
D
E
F
5
6

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Components, connections, and dimensions
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2.2 Dimensions
Dimension Description Units
8 / 15 20 / 25
32 / 38
48 / 60 80/100/105
L Length, boiler 740 740
L* Length, boiler 820 900 1000
L1 Total length inc. induced
draught fan
940 940
L1* Total length inc. induced
draught fan
mm
1020 1100 1070
B Width of boiler 600 770 860 1030 1235
B*Width, boiler, inc. support
for positioning unit 1) 705 875 965 1275 1480
W1 Total width, inc. suction
cyclone
mm
1185 1355 1445 1790 2085
H Height, boiler 2) 1280 1280 1430 1585 1710
H1 Total height, inc. suction
cyclone
1660 1660 1900 1900 1900
H2 Height, flue pipe connection 1350 1350 1530 1685 1785
H3 Height, flow connection 460 460 460 515 520
H4 Height, return connection 940 955 1085 1240 1360
H5 Height, drainage connection 460 460 460 515 520
H6 Height, ventilation
connection
1030 1030 1155 1310 1430
H8 Height, induced draught fan
connection
1090 1090 1215 1375 1495
H15 Height, suction system
connection
mm
1480 1480 1720 1720 1720
Flue pipe diameter mm 130 130 150 150 200
1) Corresponds to the minimum positioning width after removing the stoker assembly, suction cyclone and positioning unit.
2) Corresponds to the minimum positioning height after removing the stoker assembly, suction cyclone and positioning
unit.

Technology
Technical specifications
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2.2.1 Supply air connections for room air-independent operation
P4 Pellet 8 / 15 P4 Pellet 20 / 25 P4 Pellet 32 / 38 P4 Pellet 48 / 60
100 115 115 170
235
230
215
305
P4 Pellet 80 / 100
315
190
P4 Pellet
Description Units
8/15 20/25 32/38 48/60 80/100/105
Supply air connection pipe (external diameter)
mm 80 100 125 160 200
2.2.2 Flue gas pipe position
P4 Pellet
Description Units 8/15 20/25 32/38 48/60 80/100/105
A – Lateral distance mm 420 585 650 815 1000
B – Depth distance mm 90 90 85 90 80

Technology
Technical specifications
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2.3 Technical specifications
2.3.1 P4 Pellet 8/15/20/25
P4 Pellet
Description Units 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
Boiler weight 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
Min. boiler return temperature Not applicable due to internal return temperature control
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 (OGC) [mg/MJ] < 1.0 0.6 0.7 0.9
Dust [mg/MJ] 14 12 11 11
Boiler efficiency rating [%] 91.6 90.9 91.9 92.9
Test data at partial load
Carbon monoxide (CO) [mg/MJ] 77 77 72 66
Nitrogen oxide (NOx) [mg/MJ] 69 69 71 73
Organic Hydrocarbons (OGC) [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.
4) Values of the type P4 Pellet 25 are interpolated between the test protocol 06-UWC/Wels-EX-295/1 and K44302/2.

Technology
Technical specifications
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2.3.2 P4 Pellet 32/38/48/60
P4 Pellet
Description Units 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
Boiler weight 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
Min. boiler return temperature Not applicable due to internal return temperature control
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 (OGC) [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
Test data at partial load
Carbon monoxide (CO) [mg/MJ] 61 61 36 10
Nitrogen oxide (NOx) [mg/MJ] 75 75 71 66
Organic Hydrocarbons (OGC) [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 SÜD SZA Austria, Technische Prüf-GmbH, accredited initial and boiler inspection body in accordance with BGBl. no.
211/92 Arsenal, Object 207, A-1030 Wien
2) TÜV Austria, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels
3) 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.
4) Values of the model, P4 Pellet 48, are interpolated between the test protocol K44302/4 and 08-UWC/Wels-EX-337.

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Technical specifications
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2.3.3 P4 Pellet 80/100/105
P4 Pellet
Description Units 80 100 105
Rated heat output 80,0 100,0 105,0
Heating efficiency range kW 24,0-80,0 30-100,0 24,0-105,0
Mains connection 230V / 50Hz fused 16A
Output W 115 112 112
Boiler weight kg 1090 1100 1100
Boiler capacity (water) L 280 280 280
Upstream resistance (ΔT=20°C) mbar 4,3 4,3 4,3
Min. boiler return temperature Not applicable due to internal return temperature control
Maximum boiler temperature setting 80 80 80
Minimum boiler temperature setting °C 40 40 40
Permitted operating pressure bar 3 3 3
Boiler class 3 3 3
Permitted fuel Wood pellets Ø 6mm as per ÖNORM M 7135 / DIN 51731
Test report data
Testing institute TÜV1)
Test report no. TÜV2)3) 10-UW/Wels-
EX-242/1
Test data at rated load
Carbon monoxide (CO) [mg/MJ] 6 6 6
Nitrogen oxide (NOx) [mg/MJ] 80 83 83
Organic Hydrocarbons (OGC) [mg/MJ] <1,5 <1 <1
Dust [mg/MJ] 12 13 13
Boiler efficiency rating [%] 93,2 94,3 94,3
Test data at partial load
Carbon monoxide (CO) [mg/MJ] 29 29 29
Nitrogen oxide (NOx) [mg/MJ] 62 62 62
Organic Hydrocarbons (OGC) [mg/MJ] <1 <1 <1
Dust [mg/MJ] 10 10 10
Boiler efficiency rating [%] 93,7 93,7 93,7
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 model, P4 Pellet 80, are interpolated between the test protocol 08-UW/Wels-EX-337 and 10-UW/Wels-EX-
242/1. Partial load data from test protocol 10-UW/Wels-EX242/1

Technology
Technical specifications
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2.3.4 Airborne sound level
The sound level specified in the following table is based on sound
measurements on a P4 Pellet 15. (measuring device: Omega HHSL 1)
The sound level of the individual units was plotted at a distance of 1 m
from the sound source.
Ambient level for measurement: 32 dBA
Unit Measurement
Units in continuous operation:
Induced draught fan (activation: 50%) 41 dBA
Induced draught fan (activation: 65%) 44 dBA
Induced draught fan (activation: 90%) 50 dBA
Units in non-continuous operation:
Suction turbine 68 dBA
Grate motor 42 dBA
Stoker motor / Stoker screw 33 dBA
Ignition fan 53 dBA
WOS motor / WOS system 60 dBA
Burn back slide valve actuator (open) 34 dBA
Burn back slide valve actuator (close) 50 dBA
Please note that all the measurements were taken in-house and do not
come from a certified test station. This data should therefore be viewed
as individual measurements to be used as guidelines.
Please also note the sound levels required in the standards listed below,
which must be fulfilled by planning and construction measures:
ÖNORM B 8115-2 Sound insulation and room acoustics in building
construction - Requirements for sound insulation
ÖNORM H 5190 Heating systems - Acoustic insulation

Installation
Transport and Setup
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3Assembly
3.1 Transportation
The boiler is delivered packed in cardboard and
on a pallet.
Move without jarring or jolting
Protect the packaging against damp
Consult the delivery information on the
packaging.
Observe the centre of gravity of the pallet!
The boiler is marked opposite the lifting side
with a sticker.
3.1.1 Positioning
UPosition a lifting truck or similar lifting device at the pallet and
position the boiler
If it is not possible to position the boiler on the pallet:
URemove the cardboard and remove the boiler from the pallet
ÀSee 3.2.1 Removing the boiler from the pallet
If the boiler must be dismantled for positioning:
UDismantle the components of the boiler until it can be brought into
position
ÀSee 3.3 Dismantling for location where positioning is difficult
For positioning using a crane:
URemove the insulating cover, the
WOS cover and the heat exchanger
cover
The hoisting point for the crane eye
is below the cover.
3.1.2 Temporary storage
If the system is to be installed at a later date:
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.
Do NOT use forklifts for this task!

Installation
Transport and Setup
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3.2 Set-up in the boiler room
3.2.1 Removing the boiler from the pallet
URemove packing bands with an appropriate tool
UPull off the cardboard from above
URemove the transport covers (1) of the ash drawers (P4 Pellet 8-25)
or insulated door(s) and ash bucket (P4 Pellet 32-105) and cleaning
devices (2)
URemove the protective casing
On the front of the boiler, P4 Pellet 8/15/20/25:
UOpen the insulating door
URemove securing devices used during transportation on the left and
right side of the base.
UPull out the lock bolt of the door hinge (1) and remove it from the
guide
URemove the insulated door and pull out the floor insulation
On the front of the boiler, P4 Pellet 32/38/48/60/80/100/105:
URemove securing devices used during transportation on the left and
right side of the base.
URemove 2 screws each on the left and right of the ash collecting
plate and remove the collecting plate
UPull out the floor insulation behind
At the back of the boiler:
URemove securing devices used during transportation on the left and
right side of the base.
1
1
2

Installation
Transport and Setup
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M0930811 v
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3.2.2 Moving the boiler in the boiler room
UPosition a lifting truck or similar lifting device with an appropriate
load-bearing capacity at the base frame of the boiler and move to
the specified place
USet up boiler at intended location
Put red boiler underlays under the frame.
Observe the minimum distances in the boiler room.
3.2.3 Minimum distances in the boiler room
P4 Pellet
Description Units 8/15 20/25 32/38 48/60 80/100/105
A Minimum distance to suction
cyclone assembly 300 300 300 300 300
B Induced draught fan
maintenance area 300 300 300 300 300
Space for insulated door 550 720 830 490 590C
Space requirement with
plug-in insulated door 400 400 300 - -
D Minimum distance to side of
boiler
mm
200 200 200 200 200