Fröling PT4e 120 Installation Instructions Manual
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Installation Instructions
Pellet boiler PT4e 120-180
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M2270020_en | Edition 02/03/2020
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Table of Contents
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Summary of Contents for Fröling PT4e 120
- Page 1 Installation Instructions Pellet boiler PT4e 120-180 Translation of the original German installation instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M2270020_en | Edition 02/03/2020 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 2: Table Of Contents
3.8.2 Measuring port Boiler ventilation Technology Dimensions Components and connections External suction module Technical data 4.4.1 PT4e 120 - 150 4.4.2 PT4e 160 - 180 4.4.3 Boiler data for planning the flue gas system Assembly Materials supplied Transport Positioning Temporary storage Setting up in the boiler room 5.5.1... - Page 3 Before commissioning / configuring the boiler Initial startup 6.2.1 Permitted fuels Wood pellets 6.2.2 Non-permitted fuels Decommissioning Mothballing Disassembly Disposal Notes Appendix Addresses 9.1.1 Address of manufacturer Customer service 9.1.2 Address of the installer Installation Instructions PT4e 120-180 | M2270020_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 minor injuries. NOTICE The dangerous situation may occur and if measures are not observed it will lead to damage to property or pollution. Installation Instructions PT4e 120-180 | M2270020_en... -
Page 6: Qualification Of Assembly Staff
Safety Qualification of assembly staff 2.2 Qualification of assembly staff CAUTION Assembly and installation by unqualified persons: Risk of personal injury and damage to property During assembly and installation: ❒ Observe the instructions and information in the manuals ❒ Only allow appropriately qualified personnel to work on the system Assembly, installation, initial startup and servicing must always be carried out by qualified personnel: - Heating technician / building technician... -
Page 7: Design Information
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). VDI 2035 Prevention of damage hot water heating systems (Germany) Installation Instructions PT4e 120-180 | M2270020_en... -
Page 8: Regulations And Standards For Permitted Fuels
Design Information Notes on standards SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioning systems (Switzerland) UNI 8065 Technical standard regulating hot water preparation. DM 26.06.2015 (Ministerial Decree specifying the minimum requirements) Follow the instructions of this standard and any related updates. (Italy) 3.1.4 Regulations and standards for permitted fuels 1. -
Page 9: Installation And Approval Of The Heating System
(e.g. chlorination units for swimming pools). ▪ Keep the air suction opening of the boiler free of dust. ▪ The system must be protected against the chewing or nesting of animals (e.g. rodents etc.). Installation Instructions PT4e 120-180 | M2270020_en... -
Page 10: Requirements For Central Heating Water
Design Information General information for installation room (boiler room) 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, etc.) from obstructing the air flow. -
Page 11: Notes For Using Pressure Maintenance Systems
If the pressure is too high, air is released by means of a solenoid valve. The systems are built solely with closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen into the heating water. Installation Instructions PT4e 120-180 | M2270020_en... -
Page 12: Return Temperature Control
Design Information Return temperature control Pump-controlled pressure maintenance A pump-controlled pressure maintenance unit essentially consists of a pressure- maintenance pump, relief valve and an unpressurised receiving tank. The valve releases hot water into the receiving tank if the pressure is too high. If the pressure drops below a preset value, the pump draws water from the receiving tank and feeds it back into the heating system. -
Page 13: Chimney Connection/Chimney System
The diameter of the measuring probe used by Froling customer service is 14 mm. To avoid measuring errors due to the ingress of false air, the diameter of the measuring port must not exceed 21 mm. Installation Instructions PT4e 120-180 | M2270020_en... -
Page 14: Boiler Ventilation
Design Information Boiler ventilation 3.9 Boiler ventilation ❒ Fit the automatic ventilating valve at the highest point on the boiler or at the ventilation connection (if present). ➥ This ensures that air in the boiler is constantly expelled, thus preventing malfunctions caused by air in the boiler ❒... -
Page 15: Technology
Total length incl. ash container 1790 2105 Length, back of boiler to stoker 1160 connection Length of particle separator (optional) 1. Value can be increased by 40 mm (max.) by adjusting the adjustable foot Installation Instructions PT4e 120-180 | M2270020_en... - Page 16 Technology Dimensions PT4e 120-180 Item Description 140-180 Height, flow connection 1545 1660 Height of rear flue gas pipe 1210 1290 connection (optional) Height, return connection with 1135 1210 integrated return feed boost Height, drainage connection Height, safety heat exchanger 1620...
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Page 17: Components And Connections
2“ Mixing valve for the return temperature control Pump for the return temperature WILO Stratos Para WILO Stratos Para control 30/1-8 30/1-12 Line regulating valve (optional) Drainage 1“ Ash container 55 Litres 75 Litres Installation Instructions PT4e 120-180 | M2270020_en... -
Page 18: External Suction Module
Technology External suction module 4.3 External suction module Measur Description Unit Size 1 Size 2 ement 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) Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 19: Technical Data
1. Emissions of particulate matter, organic gaseous compounds, carbon monoxide and nitrogen oxides shall be expressed standardised to a dry flue gas basis at 10 % oxygen and standard conditions at 0°C and 1013 millibar Installation Instructions PT4e 120-180 | M2270020_en... -
Page 20: Pt4E 160 - 180
Technology Technical data 4.4.2 PT4e 160 - 180 Description PT4e 160 - 180 Nominal output Heat output range 48-160 51-170 54-180 Electrical connection 400V / 50Hz / fused C16A Power consumption (NL/PL) for boiler without ESP 123 / 52 123 / 53 122 / 54 Weight of boiler (including stoker, without water) 1641... -
Page 21: Boiler Data For Planning The Flue Gas System
Flue gas mass flow at partial load kg/h kg/s 0.035 0.036 0.038 Required feed pressure at nominal load mbar 0.05 Required feed pressure at partial load mbar 0.02 Maximum permissible feed pressure mbar Flue pipe diameter Installation Instructions PT4e 120-180 | M2270020_en... -
Page 22: Assembly
Assembly Materials supplied 5 Assembly 5.1 Materials supplied Pre-assembled boiler on pallet In the ash container for the boiler: ▪ SW 13 mm socket wrench ▪ Key for Lambda probe (up to PT4e 180) ▪ Adjusting spanner ▪ Boiler documents Contained in cardboard box for External suction module boiler:... -
Page 23: Positioning
Positioning using a crane: PT4e 120-180: ❒ Remove the insulating cover and thermal insulation ➥ PT4e 120: one insulating cover ➥ PT4e 140-180: two insulating covers ❒ Undo the screw connection and open the heat exchanger cover ➥ Use the spanner provided Also for PT4e 120: ❒... -
Page 24: Temporary Storage
Assembly Temporary storage ❒ Hang the crane hook on the two eye bolts in the flue gas collection chamber and bring in the boiler 5.4 Temporary storage If the system is to be assembled at a later stage: ❒ Store components at a protected location, which is dry and free from dust ➥... -
Page 25: Moving The Boiler In The Boiler Room
❒ Position a forklift or similar lifting device with a suitable load-bearing capacity at the base frame ❒ Lift and transport to the intended position in the installation room. ➥ Pay attention to the operating and maintenance areas of the equipment in the process! Installation Instructions PT4e 120-180 | M2270020_en... -
Page 26: Operating And Maintenance Areas Of The Equipment
▪ Observe the applicable standards and regulations when setting up the system. ▪ Observe additional standards for noise protection! (ÖNORM H 5190 - Noise protection measures) PT4e 120 PT4e 140-180 800 mm 300 mm... -
Page 27: Assembly Work
(A) ❒ If necessary, adjust the height on the adjustable feet of the stoker unit ❒ Secure the stoker unit ❒ Mount the rotary valve unit on the stoker unit as shown Installation Instructions PT4e 120-180 | M2270020_en... - Page 28 Assembly Assembly work ❒ Secure the cyclone container to the rotary valve unit ➥ Note the cut-out for the drive ratio (A) of the rotary valves! ❒ Remove the cover from the control cabinet ❒ Undo the four screws on the control cabinet holder ❒...
- Page 29 Assembly Assembly work ❒ Ensure that the cables do not touch the hot boiler components ➥ Follow the safety instructions, ⇨ See "Electrical connection" [page 38] ❒ Install the cover on the cable duct Installation Instructions PT4e 120-180 | M2270020_en...
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Page 30: Control The Return Temperature Control
Assembly Assembly work 5.6.3 Control the return temperature control ❒ Remove both back panels ❒ Tighten all of the connections on the return temperature control using a pipe wrench ➥ Connections may have loosened during transport. ➥ IMPORTANT: Before and after filling the system with heated water, check the seal of the screw connections on the return temperature control Return temperature control left ❒... -
Page 31: Install The Line Regulating Valve
NOTICE! After connecting the hydraulics and filling the boiler with domestic hot water it is essential to check the return temperature control for leaks. 5.6.4 Install the line regulating valve ❒ Remove cover plate from back panel and centre back panel Installation Instructions PT4e 120-180 | M2270020_en... -
Page 32: Adjusting The Height Of The Ash Container
Assembly Assembly work ❒ Remove pipe section ❒ Seal line regulating valve instead ➥ IMPORTANT: Pay attention to direction of flow. Arrow (A) must point downward! ❒ Install centre back panel ❒ Remove the perforation on the cover plate ➥ Remove the burrs with a half-round file ❒... -
Page 33: Installing The External Suction Module
➥ If the suction module is positioned at a maximum distance of 2 m to the boiler, the power supply line can be plugged in as is. When distances are greater the power supply line must be lengthened accordingly on-site Installation Instructions PT4e 120-180 | M2270020_en... - Page 34 Assembly Assembly work ❒ Unwind the cable of the suction turbine and feed it through the opening of the housing underside ❒ Remove the protective cap on the underside of the suction module ❒ Lay the return air line from the suction point to the suction module and fix it to the pressure side (position 1) with a hose clamp ❒...
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Page 35: Assembly Information For Hose Lines
▪ The return-air line can be made up of several sections, but consistent potential equalisation must be established throughout the line. ▪ For systems starting at 48 kW, only suction hoses with PU inlets are recommended due to the increased load. Installation Instructions PT4e 120-180 | M2270020_en... -
Page 36: Potential Equalisation
Assembly Assembly work Potential equalisation When connecting the hose lines to the individual connections, ensure there is consistent potential equalisation throughout the line. ❒ Expose approximately 8 cm of the earth wire at the end of the hose line ➥ TIP: Slit the insulation open along the wire with a knife ❒... -
Page 37: Hydraulic Connection
▪ Its size must comply with the design information in EN 12828 - Appendix D ▪ Ideally it should be installed in the return line. Follow the manufacturer’s installation instructions We recommend installing some sort of control device (e.g. thermometer) Installation Instructions PT4e 120-180 | M2270020_en... -
Page 38: Electrical Connection
Assembly Electrical connection 5.8 Electrical connection DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: ❒ Always have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥... - Page 39 Assembly Electrical connection ❒ Slide the controller cover backwards and lift off ❒ Wire all the components via cable duct (A) in the side panel to the controller box Installation Instructions PT4e 120-180 | M2270020_en...
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Page 40: Connect The Suction Unit Components
Assembly Electrical connection 5.8.2 Connect the suction unit components Electrical connection ❒ Lay cables of components to control cabinet ➥ Lay the cables so that nobody will trip over them! ➥ Do not lay the cable over or around sharp edges! ❒... -
Page 41: Connect The Fill Level Sensors
Connect sensor of the stoker monitoring Fühler 2 FRKEM ❒ Connect sensor of the stoker monitoring to the "Sensor 2” position on the core module in the boiler controller Installation Instructions PT4e 120-180 | M2270020_en... -
Page 42: Check The Digital Module
Assembly Electrical connection Check the digital module ❒ Set the module address of the digital module to “3” 5.8.3 Mains connection At the back of the boiler: ❒ Press the mains plug to release it and remove ❒ Open the plug and connect the mains connection cable ➥... - Page 43 ➥ 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 PT4e 120-180 | M2270020_en...
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Page 44: Connecting The Discharge System
Assembly Electrical connection 5.8.5 Connecting the discharge system Depending on the conditions of the fuel store, the following pellet discharge systems can be connected: ▪ bag silo, cube or individual probe ▪ Pellet suction screw DM 80 ▪ RS 4 / RS 8 pellet suction system ▪... -
Page 45: Pellet Mole
7 9 11 13 15 17 19 2 PE 4 PE PE 8 10 12 14 16 18 PE X1 => X2: 5, 2 ... braun 6, 3 ... blau ❒ Transfer enabling signal from terminal block X1 to X2 Installation Instructions PT4e 120-180 | M2270020_en... - Page 46 Assembly Electrical connection 11 13 15 17 19 21 23 25 27 8 10 PE 12 14 PE 16 18 PE 20 22 24 26 8, 12, 16 ... L 10, 14, 18 ... N ... PE ❒ Lay the cables of the pellet moles to the control cabinet of the suction system and connect them according to the circuit diagram 11 13 15 17...
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Page 47: Pellet Suction Screw Dm 80
❒ Lay connection line for signal/position control from “room temperature sensor RF 2 (20)” or “flow temperature sensor VF 2 (22)” outputs on core module to the control cabinet of the suction system and connect according to circuit diagram Installation Instructions PT4e 120-180 | M2270020_en... - Page 48 Assembly Electrical connection 11 13 15 17 19 21 23 25 27 8 10 PE 12 14 PE 16 18 PE 20 22 24 26 7, 11, 15 ... Rechts-Lauf Rechts-Lauf 8, 12, 16 ... Links-Lauf 9, 13, 17 ... frei 10, 14, 18 ...
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Page 49: Configuring The Discharge System In The Software
When using the RS 4 or RS 8 pellet suction system, individual probes can be locked: In the “Discharge” menu, select the respective cyclone and enable or disable the required suction probes Cyclone 1 System menu Discharge Installation Instructions PT4e 120-180 | M2270020_en... -
Page 50: Final Installation Steps
Assembly Final installation steps 5.9 Final installation steps ❒ Place the controller cover on the controller box and slide forward ❒ Attach the controller cover with retaining screw and contact washers ❒ Put on the heat exchanger cover and attach using star-shaped screws ❒... -
Page 51: Start-Up
❒ Check that the drives and servo motors are working and turning in the right direction. NOTICE! Check the digital and analogue inputs and outputs - See the instruction manual for the boiler controller. Installation Instructions PT4e 120-180 | M2270020_en... -
Page 52: Initial Startup
Start-up Initial startup 6.2 Initial startup 6.2.1 Permitted fuels Wood pellets Wood pellets made from natural wood with a diameter of 6 mm Note on standards Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06 plus / DIN plus certification scheme and/or: General note:... -
Page 53: Decommissioning
(e.g. AWG in Austria) ❒ You can separate and clean recyclable materials and send them to a recycling centre. ❒ The combustion chamber must be disposed of as builders' waste. Installation Instructions PT4e 120-180 | M2270020_en... -
Page 54: Notes
Notes 8 Notes Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 55 Notes Installation Instructions PT4e 120-180 | M2270020_en...
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Page 56: Appendix Addresses
Appendix Addresses 9 Appendix 9.1 Addresses 9.1.1 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 EMAIL info@froeling.com INTERNET www.froeling.com Customer service Austria 0043 (0)7248 606 7000 Germany 0049 (0)89 927 926 400 Worldwide...
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