Fröling PT4e 100 Installation Instructions Manual
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Summary of Contents for Fröling PT4e 100
- Page 1 Installation instructions Pellet boiler PT4e 100-180 (ESP) Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M2270322_en | Edition 09/05/2022...
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Page 2: Table Of Contents
3.9 Return temperature control ........................16 3.10 Boiler ventilation............................ 16 4 Technology ..............................17 4.1 Dimensions of the PT4e 100-180 / PT4e 100-180 ESP (Electrostatic Particle Separator)....17 4.2 Components and connections....................... 19 4.3 External suction module........................20 4.4 Technical data............................21 4.4.1 PT4e 100 - 120 .......................... - Page 3 7.1 Before commissioning / configuring the boiler ..................70 7.2 Initial startup............................71 7.2.1 Permitted fuels ........................... 71 7.2.2 Non-permitted fuels........................71 8 Decommissioning ............................72 8.1 Mothballing............................72 8.2 Disassembly............................72 8.3 Disposal ..............................72 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 4: General
1.1 About this manual These installation instructions contain information for the following boiler sizes of PT4e / PT4e ESP: 100, 110, 120, 140, 150, 160, 170, 180; M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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) M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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) M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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! M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 16: Storage Tank
Recommendation: r Fit a microbubble separator in the pipes to the boiler Ä Follow the manufacturer's instructions! M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 17: Technology
Technology | 4 4 Technology 4.1 Dimensions of the PT4e 100-180 / PT4e 100-180 ESP (Electrostatic Particle Separator) Dimensi Description 100-120 130-180 Distance between connection to safety heat exchanger and front of the boiler Distance between safety heat exchanger connections... - Page 18 Distance between drainage connection and side of boiler Height, drainage connection Height, return connection 1135 1210 Height of rear flue gas pipe connection 1210 1290 Height, safety heat exchanger connection 1620 Height, flow connection 1545 1660 1. optional M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 19: Components And Connections
WILO Stratos Para WILO Stratos Para 30/1-8 30/1-12 Line regulating valve Drainage 1“ Ash container 55 Litres 75 Litres Suction hose connection (PELLETS sticker) 50 mm Return-air line connection 50 mm M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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) M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 21: Technical Data
Fuel efficiency at 30% of rated heat output (η 87.9 87.8 87.6 Auxiliary current consumption at rated heat output 0.129 0.128 0.127 Auxiliary current consumption at 30% of rated heat 0.048 0.049 0.049 output (η M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 22: Pt4E 100 - 120 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 100 - 120 ESP Heating up mode automatic Condensing boiler M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 24: Pt4E 140 - 150
87.1 Auxiliary current consumption at rated heat output 0.125 0.124 Auxiliary current consumption at 30% of rated heat 0.051 0.052 output (η Auxiliary current consumption in standby mode (P 0.014 0.014 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 25: Pt4E 140 - 150 Esp
Solid fuel boiler for combined heat and power Combined heating system Ü "Storage tank" [} 16] Storage tank volume Characteristics when operated exclusively with the preferred fuel Useful heat delivered at rated heat output (P 142.6 153.8 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 26 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 27: Pt4E 160 - 180
Auxiliary current consumption at rated heat output 0.124 0.123 0.122 Auxiliary current consumption at 30% of rated heat 0.052 0.053 0.054 output (η Auxiliary current consumption in standby mode (P 0.014 0.013 0.013 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 28: Pt4E 160 - 180 Esp
Solid fuel boiler for combined heat and power Combined heating system Ü "Storage tank" [} 16] Storage tank volume Characteristics when operated exclusively with the preferred fuel Useful heat delivered at rated heat output (P 165.1 176.3 187.6 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 29 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 30: Boiler Data For Planning The Flue Gas System
- volume concentration at nominal load / partial load 12.8 / 11.8 13.3 / 12.3 13.3 / 12.3 Volume concentration at nominal load/partial load 7.5 / 8.5 7.0 / 8.0 7.0 / 8.0 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 31: Data For Planning A Backup Power Supply
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% M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 32: 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! M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 33: Positioning
Remove the cover and thermal insulation Ä PT4e 100-120: one cover Ä PT4e 140-180: two covers r Undo the screw connection and open the heat exchanger cover Ä Use the spanner provided M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 34: Positioning At The Installation Site
Open the insulated door and pull the key plate from the safety limit switch r Use the locking lever to unlock the ash container and pull off the ash container from the boiler M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 35 Lift it and transport it to the intended position Ä Observe the operating and maintenance areas of the equipment in the process! NOTICE! The insertion dimensions match the dimensions of the boiler, see chapter "Dimensions". M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 36: Operating And Maintenance Areas Of The Equipment
▪ Comply with additional standards for noise protection! (ÖNORM H 5190 - Noise protection measures) 800 mm 300 mm 300 mm 500 mm 300 mm 500 mm 300 mm 1. Maintenance area to expand the WOS springs upwards M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 37: 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 38: Installing The Boiler
Use the adjustable feet and align the flange of the stoker unit horizontally. r Mount the rotary valve unit on the stoker unit as illustrated - 4 hexagonal screws M8 x 20 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 39 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 40: Control The Return Temperature Control
Ä The mixer valve completely closes off the system return r Turn the mixing drive clockwise until it stops Ä The system return is completely open and the bypass line coming from above is completely closed M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 41 Turn the knob on the housing of the mixing drive back to automatic mode r Install the back panels NOTICE! After filling the boiler with domestic hot water, check the return temperature control for leaks! M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 42: Install The Line Regulating Valve
Ä IMPORTANT: Pay attention to direction of flow. Arrow (A) must point downward! r Install centre back panel r Remove the perforation on the cover plate Ä Remove the burrs with a half-round file r Install cover plate on the balancing valve M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 43: Adjusting The Height Of The Ash Container
Depending on the boiler type, two different sized suction modules are used. The installation itself is the same for both sizes. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 44 Fix the second part of the return-air line to the under-pressure side (position 2) with a hose clamp and lay the line to the boiler NOTICE! When connecting the lines, pay attention to equipotential bonding, Ü "Assembly information for hose lines" [} 46] M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 45: 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. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 46: 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 47 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!) M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 48: 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) M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 49: Electrical Connection
Remove the cable ties from the tag connector r Bind the individual cores together with cable ties (A) M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 50: Board Overview
Service interface Plug power pack Device connection terminal Digital module Hydraulic module Distributor box PT4e 100-180 Item Description Item Description Digital module Mains filter Relay Terminal blocks Line protective circuit breaker M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 51 Feed system module (for pellet suction screw) F1 (17) F2 (18) F3 (19) F4 (20) F5 (21) F6 (22) Item Description Item Description Feed system module Power supply plug Main switch M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 52: Lay The Cable To The Boiler Controller
Ensure that the cables do not touch the hot boiler components Ä Compliance with the warning signs is mandatory, Ü "Electrical connection" [} 49] Ä Do not install cable across sharp edges M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 53: 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 54 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 55 Check the digital module Digital module r Set the module address of the digital module inside the distributor box to “3” M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 56: 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 57 ▪ Check end jumper ▪ Check module address NOTICE! See feed system module installation instructions for more details Schematic diagram of the electrical connection of the discharge systems: Feed system module address “0” M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 58 Feed system module F4 (20) F5 (21) F6 (22) r Connect the geared motor of the pellet suction screw inside the wall-mounted cabinet. The connection can be found on the feed system module M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 59 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 60: 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. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 61 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) M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 62 NOTICE! See feed system module installation instructions for more details Diagram of electrical connection of feed systems: Feed system module Feed system module Suction system 03 address “0" Address “1” Sensor 1 Output 1 Suction system 02 Suction system 01 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 63 Geared motor 1 Geared motor 2 r Connect the geared motor for the pellet suction screws 1 and 2, which are located on the feed system module (address 0), inside the wall-mounted cabinet M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 64 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 65 20, 23, 26 ... VF 2 RF 2 21, 24, 27 ... RF 2 r Attach the connection line for the positio control from the distributor box to the 3-pin plug of the change-over unit M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Page 66: Attach The Mains Connection To The Boiler
Ä The power supply line (mains connection) must be fitted with a C16 A fuse by the customer. 6.5.7 Potential equalisation r The potential equalisation on the boiler base must comply with current directives, regulations and standards. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 67: Final Installation Steps
- 2 lense-head screws M4 x 8 with contact washer r Put on the heat exchanger cover and attach using star-shaped screws r Put down the cover and thermal insulation Ä PT4e 100-120: one cover Ä PT4e 140-180: two covers M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 68: 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 69: 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 70: 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. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 71: 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 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) -
Page 72: 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. M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP) - Page 73 Notes M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 74 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 75 M2270322_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
- Page 76 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...
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