Froling P4 Pellet 15 Assembly Instructions Manual Download Page 1

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Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen

Tel. +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com

Assembly instructions

P4 Pellet 8 - 60

Read and follow the assembly instructions and safety information
Subject to technical change.

Summary of Contents for P4 Pellet 15

Page 1: ...Industriestrasse 12 A 4710 Grieskirchen Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com Assembly instructions P4 Pellet 8 60 Read and follow the assembly instructions and safety information Subject to technical change ...

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Page 3: ...t 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 Condition...

Page 4: ...s 14 2 3 1 P4 Pellet 8 15 20 25 14 2 3 2 P4 Pellet 32 38 48 60 15 3 Assembly 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 indu...

Page 5: ...trasse 12 A 4710 Grieskirchen Page 5 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com M0930408_en C 4 Initial startup 33 4 1 Configuring the boiler 33 4 2 Setting Max Level sensor 33 5 Appendix 34 5 1 Delivery Certificate 34 5 2 Notes 35 ...

Page 6: ...arking 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 Calc...

Page 7: ...ch 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 ...

Page 8: ...ut 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 pe...

Page 9: ... 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 Instal...

Page 10: ...ss 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...

Page 11: ...ction pipes ensure there is potential equalization throughout the line U Expose 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 U Bend the earth wire inwards in a loop This prevents the earth wire from being damaged by the feed of pellets U Fit a hose clip to the hose line U Attach the hose line to the connector Ensure ...

Page 12: ...iler 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 ...

Page 13: ... 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 ...

Page 14: ...g 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...

Page 15: ...a 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...

Page 16: ...U Position 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 U Remove cardboard packaging U Take the unit from the pallet and if necessary also dismantle the suction unit assembly À See 3 2 1 Remove boiler from pallet 3 1 2 Temporary storage If the system is to be installed at a later time U Store the boiler insul...

Page 17: ...e door hinge 1 and remove it from the guide U Remove the insulating door At the back of the boiler U Remove protective transport materials on the left and right in the recess 3 2 2 Transporting in the boiler room U Position 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 U After removin...

Page 18: ...oiler 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 ...

Page 19: ...yclone U Remove sound insulation cover U Open 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 U Remove pre installed cover plate U Unscrew pre installed nuts and spacer washers U Attach and fix the ID fan as illustrated The straight edge must be up U Join both cables of the ID fan with t...

Page 20: ... 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 U Prepare 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...

Page 21: ...e board side of the pellet box should be at least 10 cm U Fix Pellet box to the wall with 4 frame screws M8x50 and 10 mm dowels U Pack the space in the hole in the wall with a non flammable material The partition must be insulated to conform with ÖNORM B 3836 or DIN 4102 11 U Put the cover plate for the wall J onto the pipe of the pellet box U Secure the cover plate to the wall using four M8x50 fr...

Page 22: ...the hole in the wall with a non flammable material The partition must be insulated to conform with ÖNORM B 3836 or DIN 4102 11 U Place the wall cover plate J on the installation module pipes U Secure the cover plate to the wall using four M8x50 frame screws and 10 mm dowels U Fit 2 cover plates H to the installation module using two star shaped screws I U Fit change unit G with 2 star shaped screw...

Page 23: ...rect connection WARNING When connecting the hose lines beware of potential equalisation À Page 11 Potential equalisation U Thread the fire protection choke collar C on to the hose line A Fire protection choke collars only in Austria U Attach the hose lines to the pellet box pipes using hose clips B U Lay the hose lines to the boiler through identified openings at the back plate and install with ho...

Page 24: ... Geared motor D Bearing flange K 2 Cover plates for wall penetration E Open trough L Main worm F Suction intake with integrated support M Shaft end for main worm G Proximity switch N Worm extension if needed Before installation U Prepare hole in wall for suction intake width 40cm height 22cm Ensure that the channel in the hole in the wall is positioned off centre A B C D E F M L K H I J N G ...

Page 25: ...ain screw L and secure it using clamping pins The screw blade must always be rising If no additional screw is used U Put the main screw s shaft end M on the main screw s shaft L and secure it using clamping pins U Secure the gearing flange I and the gearing flange seal H to the suction piece using four M10 x 40 mm bolts and nuts 17 mm socket spanner U Lubricate the screw s shaft end U Fit the driv...

Page 26: ...e space in the hole in the wall with a non flammable material The partition must be insulated to conform with ÖNORM B 3836 or DIN 4102 11 U Secure the wall penetration cover plates K to the store room external wall using three U 10 mm dowels and 8 x 50 mm frame screws U Finally the sloping floor is installed The plates of the sloping floor must not be placed on the trough À Page 30 Sloping floor U...

Page 27: ...o right connection 2 on the back of the boiler WARNING When connecting the hose lines beware of potential equalisation À Page 11 Potential equalisation 3 4 3 Bag silo system U Fit frame with sack silo À See assembly instructions Pellet sack silo Type I V Observe the height of the boiler room during planning Type I II Type III V H Bag silo frame height cm 185 190 H1 Height including filler coupling...

Page 28: ...ion probe using hose clamps D Read the label on the silo suction probe Suction line hose line to the cover of the suction cyclone Return air line hose line to the suction motor U Lay the hose lines to the boiler through identified openings at the back plate and install with hose clamps to the identified connections WARNING Observe the label for the suction line and the return air line on the silo ...

Page 29: ...llet store must be built with an inclined floor The following picture shows the most important components A 2 Filler pipes B Earth wire C Planking on the storage area door D Sloping floor E Impact cushion F Under floor structure for sloping floor Size of storage area The storage area should be able to hold approximately 1 5 times the annual requirement The exact amount of required space depends on...

Page 30: ...stance of 20 cm should be maintained between the cross pieces and the suction probe should be centrally positioned see Fig 1 The weight of the pellets must not be borne by the trough see Fig 2 Impact cushion The impact cushion is made of rubber and should be positioned opposite the filler pipes at least 20 cm from the wall It prevents pellets from striking the wall and knocking off pieces of the f...

Page 31: ...authorised technicians Flexible sheath conductors should be used for the wiring which should be measured in compliance with the applicable regional standards and guidelines The supply line mains connection must be fitted with a max 16 A fuse by the customer U Remove the insulating cover U 2 Unscrew the self tapping screws behind the control U Open the insulating door and remove the centrally posit...

Page 32: ...in connecting plug of the Comfort pellet box and the accompanying connection layout of the Lambdatronic P3200 control system To check the plug arrangement U Detach the protective plate 1 from the board U Carry out a check using the board description The servomotors 2 of the pellet box must be switched to the R position The servomotors are ready to plug in and are connected to the board All necessa...

Page 33: ...ised installer Before you start heating with the boiler for the first time U Adjust the control to the system type The keypad layout and necessary control steps for modifying the parameters can be found in the accompanying operating instructions for the Lambdatronic P 3200 4 2 Setting Max Level sensor In delivery configuration the factory settings of the sensor are secured with a seal Changes to t...

Page 34: ...lf checking of safety devices discussed U All technical documentation handed over documentation certificate of conformity U Test heating performed U Commissioning report given to customer U Rating plate attached U Telephone number for manufacturer s service department indicated U No defects found U Notice All national and regional regulations relating to initial testing and subsequent testing of t...

Page 35: ...endix Notes Fröling Heizkessel und Behälterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 35 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com M0930408_en 5 5 2 Notes ...

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