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Froling P4 Pellet 15, Operating Instructions Manual

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Froling P4 Pellet 15 Operating Instructions Manual Download Page 19

Boiler servicing 

Inspection, cleaning and maintenance 

 

 

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

Page 19 

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

 B0430408_en 

 

4 

4

 

Boiler servicing 

4.1

 

General information on servicing 

 

  R I S K  

 

 

 

Working on electrical components. 

 
Danger: Serious injuries from electric shocks. 

 

 

U

 

Work on electrical components should only be carried out by authorised 

technicians 

 

 

 

  W A R N I N G  

 

 

 

Do not carry out maintenance when the boiler is hot! 
 
Hot parts and the flue pipe can cause serious burns! 

 

 

U

 

Protective gloves should generally be worn when working on 

the boiler. 

U

 

Only operate the boiler using the handles provided for this 

purpose. 

 
Before starting any maintenance work: 

U

 

Press and hold the 

 key for 5 seconds 

´

 

Boiler follows shutdown procedure and changes to the 

operating status “Burner off” 

U

 

Allow the boiler to calm down for at least 1 hour 

 

U

 

After maintenance has been carried out switch the boiler on 

in the desired mode.  

 

In service mode the boiler does not start automatically.  

 

 

 

 

 

  W A R N I N G  

 

 

 

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.  

 

 

 

 

 

N o t e  

 

 

 

 

We recommend that you keep a maintenance book in accordance with 

ÖNORM M7510 of the Technical Directive for Fire Prevention (TRVB) 

 

Summary of Contents for P4 Pellet 15

Page 1: ...riestrasse 12 A 4710 Grieskirchen Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com Operating Instructions P4 Pellet 8 60 Read and follow the operating instructions and safety information Subject to technical change July 2009 ...

Page 2: ......

Page 3: ...pplicable 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 ther...

Page 4: ...e 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 3 Operating 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 4 Boiler servicing 19 4 1 Gene...

Page 5: ...n 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 5 Troubleshooting 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 Acknowledgi...

Page 6: ...duct Overview Page 6 B0430408_en I 1 1 Product Overview Ash drawer module P4 Pellet 32 38 48 60 Below the insulating cover 2 1 4 11 12 6 3 8 9 Ash drawer module P4 Pellet 8 15 20 25 5 7 10 2 1 2 2 2 4 2 3 ...

Page 7: ...en 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 hea...

Page 8: ... 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 c...

Page 9: ...f 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 permitt...

Page 10: ...g 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...

Page 11: ...section of 2 cm2 per 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 standa...

Page 12: ...ORM 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 l...

Page 13: ... 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 pressur...

Page 14: ...ls 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 ...

Page 15: ...flue pipes or simply avoid touching them during operation Before carrying out maintenance work on in the boiler U Press 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 ...

Page 16: ...he door U Open any available radiator thermostat valves If the temperature does not drop inform the installer or Fröling customer services À Page 30 6 2 Address of manufacturer 2 7 2 Smell of flue gas RISK Smell of flue gas Flue gases can cause fatal poisoning U Keep all the doors on the boiler closed U Turn off the boiler by pressing the key for 5 seconds U Air the room where the boiler is instal...

Page 17: ...r with Fröling customer services The individual steps for initial startup are explained in the operating instructions for the controller À See 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 inju...

Page 18: ...ic 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 À See operating instructions Lambdatronic P 3200 3 3 3 Switching off the boiler U Press and hold the key for 5 seconds The boiler follows the shut down program and switches to Burner OFF status The combustion unit is ...

Page 19: ...oiler using the handles provided for this purpose Before starting any maintenance work U Press and hold the key for 5 seconds Boiler follows shutdown procedure and changes to the operating status Burner off U Allow the boiler to calm down for at least 1 hour U After maintenance has been carried out switch the boiler on in the desired mode In service mode the boiler does not start automatically WAR...

Page 20: ...eck the boiler regularly for dirt U Check the safety valve regularly following the manufacturer s specifications Checking the system pressure U Check the system pressure on the pressure gauge The value must be 20 over the pre stressed pressure of the expansion tank À Expansion tank operating instructions If the system pressure decreases U Top up with water If this occurs frequently the seal of the...

Page 21: ...ng to energy requirements and pellet quality The grate and combustion chamber should also be checked at these intervals for dirt Emptying the ash drawers for P4 Pellet 8 15 20 25 U Open insulation door U Open ash doors U Take the ash drawers out a bit This pushes the ash lying in front of the drawer into the ash bowl U Thread in the transport cover as illustrated and pull out the ash drawer until ...

Page 22: ...tainer for P4 Pellet 32 38 48 60 U Open insulation door U Push the locking lever upwards U Pull out the ash container U Put the cover cap supplied on the flange of the ash container U Take the ash container to the emptying point and empty it To remove the cover the clamp must be unlocked and opened ...

Page 23: ...ey for 5 seconds Boiler follows shutdown procedure and changes to the status Burner off The ID fan turns at a controlled speed and the combustion grate stays in open position for P4 Pellet 8 15 20 25 U Open the insulating door open the right ash door and pull out the ash drawer For P4 Pellet 32 38 48 60 U Open the insulating door take out the right ash container and open the ash door U Check the c...

Page 24: ...the screw handles on the cleaning cover anti clockwise to loosen them U Remove the cleaning cover U Clean the flue gas collection chamber and the opening to the induced draught fan with a brush U Remove any soot which has fallen in We recommend that you use an ash vacuum U Remove the internal heat exchanger cover U Clean the flues and the combustion chambers beneath them with a cleaning brush ...

Page 25: ...es with cleaning brush Cleaning the induced draught ventilator U Detach the induced draught ventilator on the back of the boiler U Check for dirt and damage U Clean the blower wheel with a soft brush or paint brush Do not move the balancing weights on the blower wheel Clean the smoke flue pipe U Clean the connecting pipe between the boiler and the chimney regularly with a chimney sweeping brush De...

Page 26: ...secure it hand tight 4 3 Testing Emissions 4 3 1 Measurement at rated load U Press this key The boiler is operated for 45 min at rated load Boiler temperature setpoint is set to 70 C Heating pumps switch on and the mixer valves open to max flow temperature setpoint DHW tank and puffer loading pump are controlled as per regular settings When is it possible to measure Flue gas temperature at approx ...

Page 27: ...ctively In the course of this maintenance the entire system is inspected and optimised particularly regulation and control of the boiler The emission measurement carried out can also be used to draw conclusions about the combustion performance of the boiler For this reason Fröling offers a service agreement which maximises operating safety Please see the details in the accompanying guarantee certi...

Page 28: ...the previously specified mode and is controlled according to the specified program EXCEPTION If the boiler was at operating status Heating up Pre heating or Ignition it follows shutdown procedure and cleaning is started Only then does the boiler switch to Preparation operating status and the system starts again 5 2 Excessive temperature The STL shuts down the boiler when it reaches a maximum tempe...

Page 29: ...ernal distinction is made between 2 types of message Warning Boiler follows shutdown procedure Error Boiler shuts down immediately heating circuit controls and pumps remain active 5 3 1 Procedure for fault messages The procedure for a fault message as well as causes for faults and procedure for troubleshooting are described in the operating instructions of the boiler controls À See the operating i...

Page 30: ...ble 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 6 2 Address of manufacturer FRÖLING Heizkessel und Behälterbau GesmbH Industriestraße 12 A 4710 Grieskirchen AUSTRIA TEL 43 0 7248 606 0 FAX 43 0 7248 606 600 E MAIL info froeling com INTERNET www froeling com ...

Page 31: ...rsal suction system sack silo delivery Machine guidelines Low Voltage Directive EMC guideline Household and similar electrical appliances Safety Electromagnetic compatibility immunity to interference Electromagnetic compatibility interference emission Heating boilers for solid fuels up to 300 kW Requirements Testing and Marking Technical directives for fire protection prevention Automatic wood bur...

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