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Installation Instructions
Pellet boiler PE1 Pellet 7-35
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1441017_en | Edition 24/03/2017
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Summary of Contents for Froling PE1 Pellet 7-35
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Page 1: Installation Instructions
Pellet boiler PE1 Pellet 7-35 Translation of the original German installation instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M1441017_en | Edition 24/03/2017 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 2: Table Of Contents
PE1 Pellet 7-10 / PE1 Pellet 7-10 Unit 3.5.2 PE1 Pellet 15-20 / PE1 Pellet 15-20 Unit 3.5.3 PE1 Pellet 25-30 3.5.4 PE1 Pellet 32-35 External suction module Assembly Tools required Transport Positioning Temporary storage Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 3 4.11.1 Information on circulating pumps Start-up Filling the system with drinking water Before commissioning / configuring the boiler Decommissioning Mothballing Disassembly Disposal Appendix Addresses 7.1.1 Address of manufacturer 7.1.2 Address of the installer Installation Instructions PE1 Pellet 7-35 | M1441017_en...
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Page 4: General
General 1 General Thank you for choosing a quality product from Froling. The product features a state-of- the-art design and conforms to all currently applicable standards and testing guidelines. Please read and observe the documentation provided and always keep it close to the system for reference. -
Page 5: Safety
The dangerous situation may occur and if measures are not observed it will lead to serious injury or death. Work with extreme care. CAUTION The dangerous situation may occur and if measures are not observed it will lead to minor injuries or damage to property. Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 6: Qualification Of Assembly Staff
500 kW EN 12828 Heating systems in buildings - design of water-based heating systems EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods Part 1: Chimneys serving one appliance Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 7: Standards For Structural And Safety Devices
26 January 2010, BGBl. JG 2010 Part I No. 4. EN ISO 17225-2 Solid bio-fuel - Fuel specifications and classes Part 2: Wood pellets for use in industrial and domestic systems Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 8: Installation And Approval Of The Heating System
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, etc.) from obstructing the air flow. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 9: Requirements For Central Heating Water
≤ 2.0 mmol/L < 0.1 mmol/L Conductivity < 100µS/cm < 100 µS/cm pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5 Chloride < 30 mg/L < 30 mg/L < 30 mg/L Installation Instructions PE1 Pellet 7-35 | M1441017_en... - Page 10 ▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the central heating water comes into contact with aluminium, the pH value must be between 8.0 and ▪ Yearly. Values must be recorded by the owner Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 11: Notes For Using Pressure Maintenance Systems
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. ⇨ See "Addresses" [page 69]... -
Page 12: Chimney Connection/Chimney System
Ensure that the outside diameter of the sampling probes in the measuring port can accommodate up to 13 mm. To avoid the ingress of false air, the diameter of the measuring port must not exceed 21 mm. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 13: Boiler Data For Planning The Flue Gas System
0.05 Required feed pressure at partial load mbar 0.02 Maximum permissible feed pressure mbar Flue pipe diameter Supply air connection for room air- independent operation Combustion air volume at nominal load m³/h Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 14: Room Air-Independent Operation
One appliance with flue gas fan for connection to a chimney. The combustion air line from the air shaft and the connecting piece to the chimney are part of the appliance. When dimensioning pipe bends in the supply air line you should note that: Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 15: Air Supply In The Installation Room
NOTICE! Install the combustion air supply (piping) in accordance with the applicable standards ⇨ See "Notes on standards" [page 6] ❒ Connect supply air duct to the connection provided (external combustion air) on the pellet boiler and make sure that it is properly sealed. Installation Instructions PE1 Pellet 7-35 | M1441017_en... - Page 16 ➥ Depends on the average room temperature and the temperature of the outside air, as well as the local conditions ➥ The surface temperature must be higher than the room temperature's dew point even in unfavourable weather conditions (cold winters) Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 17: Simultaneous Operation With Other Air-Drawing Systems
❒ Only use approved safety equipment (e.g. under-pressure monitoring system and/ or window-tilting switch with DIBt certification [DE]) ❒ Make sure that the combustion air supply line and the connecting piece are properly sealed at the chimney Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 18: Room Air-Independent Appliance
Any further processing of the signals must also comply with this safety philosophy. Shutting down the power supply is permitted and sufficient. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 19: Requirements For Operating The Room Air-Dependent Appliance Simultaneously With An Air-Drawing
Recommendation for room ventilation systems: ❒ Use fail-safe room ventilation systems with F classification NOTICE! Cooker hoods with recirculation mode do not need to meet any special requirements Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 20: Technology
1170 Height of flow connection 1160 Height of return connection Height of drainage connection Height of supply air connection (for room air-independent operation) Height of suction system connection 1110 1110 1380 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 21: Dimensions - Pe1 Pellet 7-20 Unit
Height, electronic heating cartridge connection Height, drainage connection of boiler block Height, flue gas pipe connection 1570 1550 Height, supply air connection (for room air- independent operation) Height, suction system connection 1720 1720 Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 22: Connections - Pe1 Pellet
1/2 IT Supply air connection (external diameter) Flue gas pipe connection Pellet suction line connection Return-air line connection 1. optional flue gas diameter of 129 mm without additional connecting adapter possible Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 23: Components And Connections - Pe1 Pellet 7-20 Unit
Connection, cold water supply of the tank unit 3/4 ET Drainage connection for the tank unit (boiler 1/2 IT filling and drainage system are not included in delivery) Connection for E-cartridge 6/4 IT Maintenance flange with insulated magnesium protective anode Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 24: Technical Specifications
Fuel acc. to EN ISO 17225 - part 2: wood pellets Class A1 / D06 1. The technical specifications of the optional components can be found in the enclosed supplier documentation Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 25 17.4 / 6.2 Boiler efficiency 94.3 / 90.9 94.5 / 90.9 1. Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13% Installation Instructions PE1 Pellet 7-35 | M1441017_en...
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Page 26: Pe1 Pellet 15-20 / Pe1 Pellet 15-20 Unit
Energy efficiency index of the boiler model Seasonal space heating energy efficiency Energy efficiency index of the boiler in package with temperature control Energy efficiency class of the boiler in package with temperature control Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 27 14.0 / 5.8 Boiler efficiency 94.7 / 91.1 95.0 / 91.1 1. Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13% Installation Instructions PE1 Pellet 7-35 | M1441017_en...
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Page 28: Pe1 Pellet
Energy efficiency index of the boiler model Seasonal space heating energy efficiency Energy efficiency index of the boiler in package with temperature control Energy efficiency class of the boiler in package with temperature control Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 29 10.5 / 6.2 Boiler efficiency 94.0 / 94.7 94.2 / 94.7 1. Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13% Installation Instructions PE1 Pellet 7-35 | M1441017_en...
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Page 30: Pe1 Pellet 32-35
Energy efficiency index of the boiler model Seasonal space heating energy efficiency Energy efficiency index of the boiler in package with temperature control Energy efficiency class of the boiler in package with temperature control Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 31 12.4 / 6.2 Boiler efficiency 94.2 / 94.7 94.3 / 94.7 1. Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13% Installation Instructions PE1 Pellet 7-35 | M1441017_en...
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Page 32: Pe1 Pellet
Width of suction module Length of suction module Height of suction module Total height incl. hose connection Return-air line connection (line to suction point) Return-air line connection (line to boiler) Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 33: Assembly
Possibility of damage to components if handled incorrectly ❒ Follow the transport instructions on the packaging ❒ Transport components with care to avoid damage ❒ Protect components against damp ❒ Pay attention to the pallet's centre of gravity when lifting Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 34: Positioning
If the system is to be assembled at a later stage: ❒ Store components at a protected location, which is dry and free from dust ➥ Damp conditions and frost can damage components, particularly electric ones! Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 35: Setting Up In The Boiler Room
▪ Observe the applicable standards and regulations when setting up the system. ▪ Observe additional standards for noise protection (ÖNORM H 5190 - Noise protection measures) Recommended minimum clearances - PE1 Pellet 7-35 Description 7 - 10 15 - 20... - Page 36 Distance – side of boiler to wall 100 mm (door stop side) Minimum space (length x width) [mm] 1750 x 1000 1750 x 1150 Minimum room height incl. 250 cm maintenance area (1) Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 37: Install Pe1 Pellet
[page ⇨ See "Installing the ⇨ See "Install the protective ⇨ See "Hydraulic connection" ⇨ See "Electrical Connection" discharge system" [page plate for the flue pipe" [page [page 63] [page 64] Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 38: Remove Boiler From Pallet
Assembly Install PE1 Pellet 4.6.1 Remove boiler from pallet The boiler comes bolted to a pallet and must be removed as follows: PE1 Pellet 7-20 PE1 Pellet 25-35 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 39: Pe1 Pellet 25-35 - Prepare The Boiler For Transport And Setup
4.6.2 PE1 Pellet 25-35 – Prepare the boiler for transport and setup From boiler size PE1 Pellet 25, the following steps are necessary for the transport and for the subsequent alignment of the adjustable feet: 2x M5x10 3x M5x10 1x M4x8 2x M4x8 Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 40: Aligning The Boiler On The Floor
After positioning, the boiler must be aligned on the floor. Different approaches are required depending on the boiler size: PE1 Pellet 7-20 For the PE1 Pellet 7-20, the adjustable feet are easily accessible with tools from outside: Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 41 ⇨ See "PE1 Pellet 25-35 – Prepare the boiler for transport and setup" [page 39] ➥ The adjustable feet are accessible after removing the floor insulation ❒ Use a hexagonal spanner to set the adjustable feet in the base frame of the boiler Installation Instructions PE1 Pellet 7-35 | M1441017_en...
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Page 42: Prepare For Room Air-Independent Operation
Assembly Install PE1 Pellet 4.6.4 Prepare for room air-independent operation With the following modifications, the PE1 Pellet can be operated independently of the room air: 4x M4x8 4x M4x8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 43: Install The Pe1 Pellet Unit
[page plate for the flue pipe" [page circuit" [page 53] installation site" [page 57] ⇨ See "Hydraulic connection" ⇨ See "Electrical Connection" [page 63] [page 64] Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 44: Remove Boiler From Pallet
Assembly Install the PE1 Pellet Unit 4.7.1 Remove boiler from pallet The Unit comes bolted to a pallet and must be removed as follows: 4x M10 4x Ø5x60 8x Ø5x40 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 45: Fit The
Install the PE1 Pellet Unit 4.7.2 Fit the front cover Once the Unit has been positioned and aligned, the front cover must be fitted as follows: 2x M5x10 2x M5x10 2x M5x10 2x M5x10 Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 46: Align The Boiler With The Floor
4.7.3 Align the boiler with the floor After positioning, the boiler must be aligned on the floor. The PE1 Pellet 7-20 Unit comes without adjusting feet and must be positioned using the boiler underlays provided. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 47: Install The Connection Set For Room Air-Independent Operation
4.7.4 Install the connection set for room air-independent operation The PE1 Pellet 7-20 can be operated independently of the room air. This requires an optional connection set, which is installed as follows: Variant 1: Rear connection 2x M4x8 4x M4x8 Installation Instructions PE1 Pellet 7-35 | M1441017_en... - Page 48 Assembly Install the PE1 Pellet Unit Variant 2: Top connection 2x M4x8 4x M4x8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 49: Expansion With Electronic Heating Cartridge
4.7.5 Expansion with electronic heating cartridge The boiler block of the PE1 Pellet 7-20 Unit can be fitted with an electronic heating cartridge. This requires the following modifications: 2x M5x10 2x M5x10 60-80Nm Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 50: Install Boiler Filling And Drainage System
To drain the boiler of the PE1 Pellet 7-20 Unit in a controlled manner, we recommend the installation of a boiler filling and drainage system. It is mounted as follows to the lowest part of the boiler: Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 51: Expansion With Pipe Assembly For Storage Loading
4.7.7 Expansion with pipe assembly for storage loading If a storage tank is connected to the PE1 Pellet Unit, an optional pipe assembly for storage loading is required. This requires the following modifications: 2x Ø30x2 2x M4x8 Installation Instructions PE1 Pellet 7-35 | M1441017_en... - Page 52 Assembly Install the PE1 Pellet Unit AO-P1 FRHYU 2x M4x8 Pumpe 1 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 53: Expansion With Pump Assembly For Second Heating Circuit
4.7.8 Expansion with pump assembly for second heating circuit The hydraulic block can be expanded with an optional pump assembly for a second heating circuit. This requires the following modifications: 2x M5x10 2x M5x10 2x M5x10 Installation Instructions PE1 Pellet 7-35 | M1441017_en... - Page 54 Assembly Install the PE1 Pellet Unit 2x M8x20 4x M8x20 2x M8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
- Page 55 Assembly Install the PE1 Pellet Unit 2x M4x8 Installation Instructions PE1 Pellet 7-35 | M1441017_en...
- Page 56 Assembly Install the PE1 Pellet Unit 4x M5x10 2x M4x8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 57: Disassemble For Easier Transport To The Installation Site
4.7.9 Disassemble for easier transport to the installation site If the height of the PE1 Pellet Unit prevents it from being transported as a single unit, it can be disassembled as follows into its individual components. 2x M4x8 4x M4x8 Installation Instructions PE1 Pellet 7-35 | M1441017_en... - Page 58 Assembly Install the PE1 Pellet Unit FRKEM AO-P2 HKP 1 Heizkreis- FRHYU pumpe Mischer 1 Netz Pumpe 2 Vorlauf- fühler 1x M5x10 2x M5x10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
- Page 59 Assembly Install the PE1 Pellet Unit 4x M10x30 4x M5x10 Once they have been transported to the installation room, they can be re-assembled in reverse order. Installation Instructions PE1 Pellet 7-35 | M1441017_en...
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Page 60: Installing The Discharge System
Depending on the boiler type, two different sized suction modules are used. The installation itself is the same for both sizes. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 61 Assembly Installing the discharge system 8x M6x20 3x Ø6x45 3x Ø12x45 Ø 12 mm Ø 12 mm Installation Instructions PE1 Pellet 7-35 | M1441017_en...
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Page 62: Install The Protective Plate For The Flue Pipe
4.9 Install the protective plate for the flue pipe To prevent contact with the components of the hot flue pipe, a protective plate must be fitted as follows to the rear boiler wall: Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 63: Hydraulic Connection
❒ The hydraulic connection must be fitted by the customer in such a way that the cover (B) can be easily unscrewed (A) and removed. ➥ Keep the maintenance area toward the back clear Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 64: Electrical Connection
❒ Only have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥ Work must not be carried out on electrical components by unauthorised persons C16A 2x M4x8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 65: Information On Circulating Pumps
➥ Only use special high efficiency pumps with a connection option for a control line (PDM/0-10V)! ➥ Observe the additional instructions and information on board outputs in the operation instructions for the boiler controller. Installation Instructions PE1 Pellet 7-35 | M1441017_en... -
Page 66: Start-Up
❒ Bleed all the drinking water supply valves connected to the heating system in order until water starts to come out ➥ This ensures there is no air in the drinking water pipe system Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 67: Before Commissioning / Configuring The Boiler
Take the following precautions: ❒ Initial startup should be carried out with an authorised installer or with Froling customer services NOTICE Foreign bodies in the heating system impair its operational safety and can result in damage to property. -
Page 68: Decommissioning
❒ Ensure that they are disposed of in an environmentally friendly way in accordance with waste management regulations in the country (e.g. AWG in Austria) ❒ You can separate and clean recyclable materials and send them to a recycling centre. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 69: Appendix
7.1 Addresses 7.1.1 Address of manufacturer FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL 0043 (0)7248 606 0 FAX 0043 (0)7248 606 600 INTERNET www.froeling.com 7.1.2 Address of the installer Stamp Installation Instructions PE1 Pellet 7-35 | M1441017_en...
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