Froling P4 Pellet 8 Assembly Instructions Manual
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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.
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
info@froeling.com www.froeling.com
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Summary of Contents for Froling P4 Pellet 8
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Page 1: Assembly Instructions
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. 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... -
Page 2: Guarantee Conditions
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. -
Page 3: Table Of Contents
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 ............ - Page 4 Contents 3.4 Assembling the Pellet Boiler 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 3.5.1 General installation information ................ 32 3.5.2 Hose Lines..................... 32 Potential Equalisation ..................
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Page 5: General Information
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. Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 5 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 info@froeling.com www.froeling.com... -
Page 6: Protective Equipment For Assembly Staff
General Standards, personnel, design 1.3 Protective equipment for assembly staff You must ensure that staff have the protective equipment specified by accident prevention regulations. During 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. -
Page 7: Ventilation Of The Boiler Room
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. Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 7 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 info@froeling.com www.froeling.com... -
Page 8: Chimney Connection/Chimney System
General Standards, personnel, design 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. -
Page 9: Boiler Data Relating To Design Of The Flue Gas System P4 Pellet 48/60/80/100/105
General Standards, personnel, design Boiler data relating to design of the flue gas system P4 Pellet 48/60/80/100/105 P4 Pellet Description Units Flue gas temperature °C Flue gas mass flow kg/h Flue gas mass flow 0,039 0,043 0,060 0,0760,02 0,079 kg/s 0,017 0,019 0,021... -
Page 10: Minimum Specification Of Connection Lines
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. -
Page 11: Technology
Technology Components, connections, and dimensions 2 Technology 2.1 Components and Connections Pos. Description Units 8 / 15 20 / 25 32 / 38 48/60 80/100/105 Boiler flow connection Boiler return connection Inch Drain Air vent Pellet suction line DA 60 DA 60 DA 60 DA 60... -
Page 12: Dimensions
Technology Components, connections, and dimensions 2.2 Dimensions Dimension Description Units 8 / 15 20 / 25 32 / 38 48 / 60 80/100/105 Length, boiler Length, boiler 1000 Total length inc. induced draught fan Total length inc. induced 1020 1100 1070 draught fan Width of boiler... -
Page 13: Supply Air Connections For Room Air-Independent Operation
Technology Technical specifications 2.2.1 Supply air connections for room air-independent operation P4 Pellet 80 / 100 P4 Pellet 8 / 15 P4 Pellet 20 / 25 P4 Pellet 32 / 38 P4 Pellet 48 / 60 P4 Pellet Description Units... -
Page 14: Technical Specifications
Technology Technical specifications 2.3 Technical specifications 2.3.1 P4 Pellet 8/15/20/25 P4 Pellet Description Units Rated heat output 10,5 14,9 20,0 25,0 Heating efficiency range 3.1-10.5 3.1-14.9 6.0-20.0 7.5-25.0 Mains connection 230V / 50Hz fused 16A Output Boiler weight Boiler capacity (water) Upstream resistance (ΔT=20°C) -
Page 15: P4 Pellet 32/38/48/60
Technology Technical specifications 2.3.2 P4 Pellet 32/38/48/60 P4 Pellet Description Units Rated heat output 32,0 38,0 48,0 58,5 Heating efficiency range 8.9-32.0 8.9-38.0 14.4-48 17.3-58.5 Mains connection 230V / 50Hz fused 16A Output Boiler weight Boiler capacity (water) Upstream resistance (ΔT=20°C) mbar Min. -
Page 16: P4 Pellet 80/100/105
Technology Technical specifications 2.3.3 P4 Pellet 80/100/105 P4 Pellet Description Units Rated heat output 80,0 100,0 105,0 Heating efficiency range 24,0-80,0 30-100,0 24,0-105,0 Mains connection 230V / 50Hz fused 16A Output Boiler weight 1090 1100 1100 Boiler capacity (water) Upstream resistance (ΔT=20°C) mbar Min. -
Page 17: Airborne Sound Level
Technology Technical specifications 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. -
Page 18: Assembly
Installation Transport and Setup 3 Assembly 3.1 Transportation The boiler is delivered packed in cardboard and on a pallet. Move without jarring or jolting Protect the packaging against damp Do NOT use forklifts for this task! Consult the delivery information on the packaging. -
Page 19: Set-Up In The Boiler Room
3.2.1 Removing the boiler from the pallet Remove packing bands with an appropriate tool Pull off the cardboard from above Remove 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) -
Page 20: Moving The Boiler In The Boiler Room
Installation Transport and Setup 3.2.2 Moving the boiler in the boiler room Position 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 Set up boiler at intended location Put red boiler underlays under the frame. -
Page 21: Dismantling For Location Where Positioning Is Difficult
Installation Transport and Setup 3.3 Dismantling for location where positioning is difficult If the boiler cannot be brought into position because the space is confined, it is possible to dismantle individual components. The following steps show the maximum possible dismantling steps. You should only carry out the steps that are necessary for positioning. - Page 22 Unscrew the screws under the insulated cover with the contact washers at the flaps of the controller cover. Open insulated door (only for P4 Pellet 8/15/20/25) Unscrew the screw together with the contact washer on the bottom side of the controller cover...
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Page 23: Remove The Door And Ash Drawer (P4 Pellet 8/15/20/25)
Installation Transport and Setup 3.3.2 Remove the door and ash drawer (P4 Pellet 8/15/20/25) Fold out the hinge pins at the top of the insulated door and pull down Lift the insulated door from the lower hinge and remove Open both ash doors and remove the ash drawer together with... -
Page 24: Dismantling The Suction Cyclone Cover
Installation Transport and Setup 3.3.3 Dismantling the suction cyclone cover Remove the covering of the middle cable duct At the pellet module: Unplug the relevant plugs: - “Suction unit M3” - “Max level S1” - “Gate valve M8” Separate the cable tie at the cable leadthrough Unthread the cables that have been unplugged Page 24 M0930811... -
Page 25: Dismantling The Stoker Unit
Installation Transport and Setup Wind up the unplugged cables at the units Open the clamps and take off the cover 3.3.4 Dismantling the stoker unit Remove the covering of the cable duct At the pellet module: Unplug the relevant plugs: - “Grate drive M6”... - Page 26 Installation Transport and Setup Loosen the locking screw on the ignition fan Take out the ignition fan Remove the back and front locking split pin of the grate drive and pull out the bolt CAUTION! Secure the grate motor so it cannot fall down when the bolt is removed.
- Page 27 The following assembly step requires two people: Weight of stoker unit P4 Pellet 8/15/20/25: approx. 32 kg Weight of stoker unit P4 Pellet 32/38: approx. 36 kg Weight of stoker unit P4 Pellet 48/60: approx. 46 kg Weight of stoker unit P4 Pellet 80/100/105: approx.
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Page 28: Positioning Dimensions After Dismantling
Installation Transport and Setup 3.3.5 Positioning dimensions after dismantling P4 Pellet Dimension Description Units 8/15 20/25 32/38 48/60 80/100/105 Length, boiler Width of boiler 1275 1480 Height of boiler 1280 1280 1430 1585 1710 1) If the control unit is dismantled, the dimension can be reduced to 780 mm (e.g. for bringing into position through doors with a clearance of 800 mm) 2) If the control unit is dismantled, the dimension can be reduced to 880 mm (e.g. -
Page 29: Notes On Reassembly
When fitting the grate motor, check that it is in the correct position on the back support: Top position = P4 Pellet 8/15/20/25 Bottom position = P4 Pellet 32/38 A position = P4 Pellet 48/60/80/100/105 Observe the installation position of the actuating sleeve between the... -
Page 30: Assembling The Pellet Boiler
Installation Assembling the Pellet Boiler 3.4 Assembling the Pellet Boiler 3.4.1 Installing the induced draught fan Remove the locking screws on the sound insulation hood of the stoker assembly and remove the sound insulation hood. Open the clamps on the suction cyclone container and lift the cover The induced draught set is in the suction cyclone container Remove the induced draught fan from the suction cyclone container Remove pre-installed cover plate... -
Page 31: Fit The Ash Container And Doors (P4 Pellet 32/38/48/60/80/100/105)
Installation Assembling the Pellet Boiler 3.4.2 Fit the ash container and doors (P4 Pellet 32/38/48/60/80/100/105) Remove the insulating cover and unscrew the two top retaining screws with the contact washers of the controller cover Caution: Do not lose the contact washers! Unscrew the lower retaining screw with contact washer and remove the controller cover Put the insulated door in the boiler base and secure at the top with... -
Page 32: Installing The Discharge System
Installation Install discharge system 3.5 Installing the discharge system 3.5.1 General installation information N O T I C E Water lines should not be located in close proximity to the pellet store and the feeder units due to the dangers posed by condensation and bursting water pipes! Check the delivered items for foreign objects in the individual components In the pellet store room an impact cushion must be installed on the opposite side to the filler pipes. -
Page 33: Potential Equalisation
Installation Install discharge system Potential Equalisation When connecting the hose lines to the individual connection pipes, ensure there is potential equalization throughout the line! Expose approximately 3 cm of the grounding strap on the end of the hose line TIP: Slit the insulation open along the wire with a knife Bend the earth wire inwards in a loop This prevents the earth wire from being damaged by the feed of pellets. -
Page 34: Universal Suction System
Installation Install discharge system 3.5.3 Universal suction system Variant 2 - Eco pellet box Variant 1 - Komfort pellet box 25 m Suction hose Manual re-arranging unit (Variant 2) Hose clamps 50-65 mm 2 x Blind plates (Variant 2) 2 x Fire protection choke collars 6 x Star-shaped screw knobs (Variant 2) (only in Austria) Komfort pellet box (Variant 1) -
Page 35: Variant 1 - Komfort Pellet Box
Installation Install discharge system Variant 1 – Komfort pellet box Position Komfort pellet box (D) at the wall penetration The distance from the wall on the board side of the pellet box should be at least 10 cm for 10 cm maintenance purposes. -
Page 36: Variant 2 - Eco Pellet Box
Installation Install discharge system Variant 2 – Eco pellet box Place the wall insertion module (F) at the wall penetration Secure the insertion module to the wall using 4 M8x50 frame screws and 10 mm dowels Fill the space in the wall penetration with a non- flammable material The partition should be insulated in accordance with... -
Page 37: Installing The Suction Probes And Lines
Installation Install discharge system Installing the suction probes and lines Position the suction probes (K) at equal distances in the pellet supply bin Secure the suction probes to the bottom using frame screws Fix hose lines (A) to the suction probe using hose clips (B) Lay the hose lines to the pellet box and secure them using hose clips... -
Page 38: Suction Screw System
Installation Install discharge system 3.5.4 Suction screw system Flange bearing Gearbox flange Ejector flange Drive flange seal Trough mount with rubber pad Geared motor Bearing flange 2 x Cover plates for wall penetration Open trough Main worm Suction intake with integrated support Shaft end for main worm Proximity switch Worm extension (if needed) - Page 39 Installation Install discharge system Thread the basic screw (H1) into the penetration The key-way must be toward the boiler! Thread the closed trough (J) onto the basic screw on the store side The quadratic flange points out of the store! Thread the open trough (I) onto the basic screw Secure together using 4 M10x30 hexagonal...
- Page 40 Installation Install discharge system Secure the bearing flange (D) and the trough mount (C) to the trough using 4 hexagonal M10 x 40 mm bolts and nuts - Hexagonal nut SW 17 mm Place the flange bearing unit (A) and the ejecting flange (B) on the shaft and secure them to the bearing flange using 2 M14 x 35 mm hexagonal bolts and spacer washers...
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Page 41: Bag Silo Discharge System
Installation Install discharge system Lay the hose lines to the boiler, through identified openings at the back plate and install with hose clamps to the identified connections Suction line: hose line to left connection (1) on the back of the boiler Return-air line: hose line to right connection (2) on the back of the boiler CAUTION! When connecting the hose lines,... - Page 42 Installation Install discharge system Fit the bag silo in accordance with the assembly instructions supplied Put the flange ring (1) onto the bag silo Put the bag silo and flange ring onto the probe at the threaded bolts and screw them together Thread one fire protection choke collar each (B) onto the suction and return-air lines Fire protection choke collars only in Austria.
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Page 43: Pellet Storage Area
Installation Install discharge system 3.5.6 Pellet storage area For the universal suction system, the pellet store must be built with an inclined floor! The following picture shows the most important components: 2 x Filler pipes Earth wire Planking on the store door Sloping floor Impact cushion Under-floor structure for sloping floor... -
Page 44: Sloping Floor
Installation Install discharge system Sloping floor Fig.1: Store for a discharge unit with a suction probe Fig.2: Store for a discharge unit with a screw The under-floor structure should be dimensioned so that the sloping floor is not deformed when subjected to static load. You should ensure that the pellets can slide down smoothly. -
Page 45: Electrical Connection
Installation Connecting the pellet boiler 3.6 Electrical Connection D A N G E R When working on electric components: Risk of serious injuries from electric shocks Work on electrical components should only be carried out by authorised technicians Wiring should be installed using flexible sheathed cable and dimensioned in compliance with the locally applicable standards and guidelines The power supply line (mains connection) must be fitted with a C16... -
Page 46: Connecting The Komfort Pellet Box
Installation Connecting the pellet boiler 3.6.1 Connecting the Komfort pellet box The connection of the Comfort pellet box to the pellet module board is established using a flexible cable (5x0.75mm², e.g. YMM as per ÖVE- K41-5 or H05VV-F as per DIN VDE 0281-5). This is a 24V control line. -
Page 47: Initial Start-Up
Take the following precautions: We recommend that the system is commissioned by Froling customer services or an authorised installer. Before heating up the boiler for the first time: Set the controller to match your heating system.
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