Fröling PT4e 200 Original Installation Instructions
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Fröling PT4e 200 Original Installation Instructions

Pellet boiler
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Installation instructions
Pellet boiler PT4e 200-250 (ESP)
Translation of original German version of installation instructions for technicians.
Read and follow all instructions and safety instructions.
All errors and omissions excepted.
M2280322_en | Edition 09/05/2022

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  • Page 1 Installation instructions Pellet boiler PT4e 200-250 (ESP) Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M2280322_en | Edition 09/05/2022...

  • Page 2: Table Of Contents

    3.8 Storage tank............................16 3.9 Return temperature control ........................16 3.10 Boiler ventilation............................ 16 4 Technology ..............................17 4.1 Dimensions of the PT4e 200-250 / PT4e 200-250 ESP................ 17 4.2 Components and connections....................... 19 4.3 External suction module........................20 4.4 Technical data............................21 4.4.1 PT4e 200 - 250 ..........................
  • Page 3 7.1 Before commissioning / configuring the boiler ..................65 7.2 Initial startup............................66 7.2.1 Permitted fuels ........................... 66 7.2.2 Non-permitted fuels........................66 8 Decommissioning ............................67 8.1 Mothballing............................67 8.2 Disassembly............................67 8.3 Disposal ..............................67 M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 4: General

    1.1 About this manual These installation instructions contain information for the following boiler sizes of PT4e / PT4e ESP: 200, 230, 250; M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • 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. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 6: Qualification Of Assembly Staff

    You must ensure that staff have the protective equipment specified by accident prevention regulations! ▪ During transport, erection and installation: - wear suitable work wear - wear protective gloves - wear safety shoes (min. protection class S1P) M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 7: Design Information

    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) M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 8: Regulations And Standards For Permitted Fuels

    ▪ Installation at altitude higher than 2000 metres above sea level only after consultation with the manufacturer ▪ The system must be protected against gnawing and nesting by animals (such as rodents) ▪ No flammable materials in proximity to the system M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 9: Chimney Connection/Chimney System

    Please note within the permissible operating range of the boiler flue gas temperatures lower than 160K above room temperature may occur. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 10: Connection Line To The Chimney

    ▪ 1.5 x nominal diameter of connection line for radiation shield with rear ventilation, but at least 200 mm (NM) NOTICE! The minimum distances must be observed in accordance with the standards and guidelines applicable in the region M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 11: Measuring Port

    TRVB H 118 (only Austria) stipulates that an explosion flap must be installed in the connection line to the chimney, directly next to the boiler. It should be situated in such a way that is poses no risk to persons! M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 12: Combustion Air

    (maximum flow rate = 1 m/ Note on standards ÖNORM H 5170 - Construction and fire protection requirements TRVB H118 - Technical directives on fire protection/prevention M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 13: Simultaneous Operation With Other Air-Drawing Systems

    Alternating operation An approved safety system (such as a flue gas thermostat) ensures (e.g. by switching off the power supply) that the boiler cannot be operated simultaneously with the air-drawing appliance. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 14: Domestic Hot Water

    1. For calculating the specific system volume, the smallest individual heating capacity is to be used for systems with several heat generators. 2. In systems with several heat generators with different specific water contents, the smallest specific water content is decisive in each case. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 15: Pressure Maintenance Systems

    These systems offer no oxygen removal for the purposes of corrosion control as required by VDI 2035 and in the interests of corrosion protection should not be used. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 16: Storage Tank

    Recommendation: r Fit a microbubble separator in the pipes to the boiler Ä Follow the manufacturer's instructions! M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 17: Technology

    Technology | 4 4 Technology 4.1 Dimensions of the PT4e 200-250 / PT4e 200-250 ESP Dimensi Description 200-250 Length of particle separator (optional) Distance between stoker and back of the boiler 1310 Length of boiler 2005 Total length 2680 Width of particle separator (optional)
  • Page 18 Height, safety heat exchanger connection 1755 Height of rear flue gas pipe connection 1350 Distance between safety heat exchanger connections Height, drainage connection Height, return connection 1240 Height, flow connection 1770 1. optional M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 19: Components And Connections

    Pump for the return temperature control WILO Stratos Para 30/1-8 Line regulating valve Drainage 1“ Ash container 160 Litres Suction hose connection (PELLETS sticker) 50 mm Return-air line connection 50 mm M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 20: External Suction Module

    Size 2 Length of suction module Width 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) M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 21: Technical Data

    Fuel efficiency at 30% of rated heat output (η 86.4 86.4 86.4 Auxiliary current consumption at rated heat output 0.120 0.146 0.162 Auxiliary current consumption at 30% of rated heat 0.055 0.055 0.055 output (η M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 22: Pt4E 200 - 250 Esp

    3. Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels” Regulation (EU) 2015/1187 Heating space annual rate of use ηs ≥ 78 Additional data for regulation (EU) 2015/1189 Description PT4e ESP Heating up mode automatic Condensing boiler M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 23 1. The emissions of dust, gaseous organic compounds, carbon monoxide and nitrogen oxides are stated in a standardised form based on dry flue gas with a oxygen content of 10 % and under standard conditions at 0°C and 1013 millibar M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 24: Boiler Data For Planning The Flue Gas System

    The system can be operated with an emergency generator. The following information must be observed during planning. Description Value Continuous output (three phase) 6375 Nominal voltage 400 ± 6% Frequency 50 ± 2% M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 25: Transport And Storage

    If the system is to be assembled at a later stage: r Store components at a protected location, which is dry and free from dust Ä Damp conditions and frost can damage components, particularly electric ones! M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 26: Positioning

    Position a forklift or similar lifting device at the boiler base and bring in the components Ä PT4e 200-250: Min. fork length 1,500 mm, min. load capacity 2,500 kg If you need to dismantle the boiler to bring it in: r Remove cardboard and transport frame Ü...

  • Page 27: Dismantling For Location Where Positioning Is Difficult

    NOTICE! Only take those steps absolutely necessary to bring in the boiler. r Remove the insulated cover above the heat exchanger Ä PT4e 200-250: two insulating covers r Undo both screws and remove controller cover M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 28 Ä Cables can remain in the cable duct on the side panel r Remove the ignition unit including glow igniter beside stoker r Undo the screws and remove the side panels M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 29 2030 NOTICE! Assemble all components in reverse order. Connect the glow igniter plug on the wood chip module to the “ELECTRICAL IGNITION” position and the stoker drive to the “STOKER SCREW” position. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 30: Positioning At The Installation Site

    5.5.1 Remove cardboard and transport frame r Remove strapping and lift off the cardboard r Remove transport frame from front and back r Remove the sides of the transport frame from the boiler base M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 31: Operating And Maintenance Areas Of The Equipment

    ▪ Comply with additional standards for noise protection! (ÖNORM H 5190 - Noise protection measures) 900 mm 300 mm 300 mm 500 mm 300 mm 500 mm 300 mm 1. Maintenance area to expand the WOS springs upwards M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 32: Assembly

    Suction module Stoker duct thermal insulation 6.2 Accessories supplied Furnace tool with bracket Key for door mountings and WOS cover Socket wrench AF 13 Cleaning brush 24 x 50 x 1200 M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 33: Installing The Boiler

    Use the adjustable feet and align the flange of the stoker unit horizontally. r Mount the rotary valve unit onto the stoker unit as illustrated - 4 hexagonal screws M8 x 20 M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 34 Hang the distributor box on the screw heads and tighten the screws r Position the thermal insulation on the stoke flange r Position the thermal insulation panels on the stoker as shown r Wrap thermal insulation around the stoker duct M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 35 Remove the cover on the cable duct r Loosen the screws of the clamping plate on the stoker duct r Push temperature sensor under clamping plate and fix with screws M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 36: Control The Return Temperature Control

    Slide the ash container onto the boiler and attach using clamping lever r Loosen the screw connection and adjust castors to the ground r Horizontally align the ash container and attach the screw connection r Remove the ash container and spacer plate M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 37 Pull off the seal on the affected duct r Slide spacer plate and seal back onto the duct r Slide the ash container onto the boiler and check the pressure again M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 38: Install The Line Regulating Valve

    Remove the perforations (A) on the lower cover plate Ä Remove the burrs with a half-round file r Install the lower cover plate on the line regulating valves r Install rear cover plate on the return M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 39: Installing The External Suction Module

    Ä 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 M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 40 NOTICE! When connecting the lines, pay attention to equipotential bonding, Ü "Assembly information for hose lines" [} 42] r Secure the cover hood with the previously removed screws M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 41: Fit The Suction Hoses To The Boiler

    Fix the suction hoses to the connections using hose clamps Ä When doing so, attach the "PELLETS" sticker at the connection point of the pellet suction hose NOTICE! When connecting the suction hoses, pay attention to the equipotential bonding. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 42: 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 over 35 kW, only hose lines with PU inlet are recommended due to the increased load M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 43 Remove paint from the affected area if necessary Ä TIP: If stiffness occurs when trying to attach the hoses to the connectors, pour a few drops of water onto the pipe (do not use lubrication grease!) M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 44: 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 monitoring device (such as a thermometer) M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 45: Electrical Connection

    Remove the cable ties from the tag connector r Bind the individual cores together with cable ties (A) M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 46: Board Overview

    Feed system module Return mixer module (not used) Wood chip module Hydraulic module Distributor box PT4e 200-250 Item Description Item Description Digital module Mains filter Relay Terminal blocks Line protective circuit breaker M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 47 Feed system module (if using pellet suction screw with change-over) F1 (17) F2 (18) F3 (19) F4 (20) F5 (21) F6 (22) Item Description Item Description Feed system module Power supply plug Main switch M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 48: Lay The Cable To The Boiler Controller

    Ensure that the cables do not touch the hot boiler components Ä Compliance with the warning sign is mandatory, Ü "Electrical connection" [} 45] Ä Do not install cables across sharp edges M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 49: Connect The Suction Unit Components

    4 PE 6 PE 8 10 12 14 16 18 PE 3 ..L 4 ..N GND ... PE r Connect the suction turbine's power supply line inside he distributor box M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 50 Connect the temperature sensor of the stoker monitoring unit KM-17 Kernmodul Core module r Connect the temperature sensor of the stoker monitoring unit at the core module in the boiler controller M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 51 Check the digital module Digital module r Set the module address of the digital module inside the distributor box to “3” M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 52: Connect An Individual Discharge Systems

    8 10 12 14 16 18 PE 5 ..L 6 ..N GND ... PE r Connect the power supply line from the distributor box to the socket of the extension cable and onto the shaker M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 53 F3 (19) F4 (20) F5 (21) F6 (22) r Connect the geared motor of the pellet suction screw to the boiler controller. The connection can be found on the feed system module M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 54 20 ... VF 2 RF 2 21 ... RF 2 r Establish a connection line for the position control from the distributor box to the 3-pin plug of the change-over unit M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 55: Connect Multiple Discharge Systems With Change-Over Units

    PE 8 10 12 14 16 18 PE X1 (5) => X2 (2) X1 (6) => X2 (3) r Create a connection line for the enabling signal from terminal block X1 to X2. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 56 Pellet mole 1 10, 14, 18 ... N GND ... PE r Establish power supply lines from the distributor box to the plug-in connections (Pellets Mole Classic) or connection boxes (Pellets Mole E3) M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 57 F4 (20) F5 (21) F6 (22) Sensor 1 r Connect the sensor of the pellet suction screws 1, which is located on the feed system module (address 0), inside the wall-mounted cabinet M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 58 Geared motor 2 Geared motor 3 r Connect the geared motor for the pellet suction screws 2 and 3, which are located on the feed system module (address 1), inside the wall-mounted cabinet M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 59 9, 13, 17 ... frei 10, 14, 18 ... N ... GND Links-Lauf r Attach the connection line for the motor control from the distributor box to the 4-pin plug of the change-over unit M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 60: Attach The Mains Connection To The Boiler

    Ä Flexible sheathed cable must be used for the wiring; this must be of the correct size to comply with applicable regional standards and regulations. Ä The power supply line (mains connection) must be fitted with a C16 A fuse by the customer. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 61: Potential Equalisation

    Install the covers to the side panel of the boiler and tighten it r Place the controller cover on the controller box and slide forward r Attach the controller cover with retaining screw and contact washers M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 62 Slide the ash container onto the ash duct and secure with the locking lever (A) r Slide the key plate (B) into the safety limit switch and close both insulated doors M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 63: Insulate The Connection Line

    Cut the half shells of thermal insulation to length and lay them on the connection line r Create an opening for access to the measuring port r Apply protective foil at the projecting lugs r Glue the half shells to each other M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 64: Install The Brackets For Accessories

    Attach the accessories to the brackets 6.6.3 Stick on an additional identification plate (applicable to T4e ESP) r Stick the additional identification plate (A) visibly on the side panel of the boiler M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 65: Start-Up

    Check that the drives and servo motors are working and turning in the right direction r Check safety switch of ash box is working correctly NOTICE! Check the digital and analogue inputs and outputs - See the instruction manual for the boiler controller. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 66: Initial Startup

    Using non-standard fuels can also lead to serious problems with combustion! For this reason, when operating the boiler: r Use only the permitted fuels M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)

  • Page 67: Decommissioning

    (e.g. AWG in Austria) r You can separate and clean recyclable materials and send them to a recycling centre. r The combustion chamber must be disposed of as builders' waste. M2280322_en | Installation instructions Pellet boiler PT4e 200-250 (ESP)
  • Page 68 Manufacturer’s address Froling srl Froling SARL Fröling Heizkessel- und Zweigniederlassung Behälterbau GesmbH Aschheim Industriestraße 12 Max-Planck-Straße 6 Via J. Ressel 2H 1, rue Kellermann A-4710 Grieskirchen 85609 Aschheim I-39100 Bolzano (BZ) F-67450 Mundolsheim +43 (0) 7248 606 0 +49 (0) 89 927 926 0 +39 (0) 471 060460 +33 (0) 388 193 269 info@froeling.com...

This manual is also suitable for:

Pt4e 230Pt4e 250

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