Fröling PE1 Pellet 7-35 Installation Instructions Manual
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Fröling PE1 Pellet 7-35 Installation Instructions Manual

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Installation Instructions
Pellet boiler PE1 Pellet 7-35 / PE1 Pellet Unit 7-20
PE1 Pellet 7-35
PE1 Pellet Unit 7-20
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1441420_en | Edition 10/01/2020
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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Summary of Contents for Fröling PE1 Pellet 7-35

  • Page 1 Installation Instructions Pellet boiler PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 PE1 Pellet 7-35 PE1 Pellet Unit 7-20 Translation of the original German installation instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M1441420_en | Edition 10/01/2020 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 2: Table Of Contents

    (e.g. with a room ventilation system, centralised dust extraction system, etc.) 3.12 Boiler ventilation Technology Dimensions - PE1 Pellet 7-35 Dimensions - PE1 Pellet Unit 7-20 Connections - PE1 Pellet 7-35 Components and connections - PE1 Pellet Unit 7-20 Technical specifications 4.5.1...
  • Page 3 Before commissioning / configuring the boiler Initial startup 6.3.1 Permitted fuels Wood pellets 6.3.2 Non-permitted fuels 6.3.3 Heating up for the first time Decommissioning Mothballing Disassembly Disposal Notes Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 4 Contents Appendix Addresses 9.1.1 Address of manufacturer Customer service 9.1.2 Address of the installer Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 5: General

    Froling. On commissioning by FROLING Customer Service the validity of the delivery certificate will be noted on the customer service record. Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 6: Safety

    Safety Hazard levels of warnings 2 Safety 2.1 Hazard levels of warnings This documentation uses warnings with the following hazard levels to indicate direct hazards and important safety instructions: DANGER The dangerous situation is imminent and if measures are not observed it will lead to serious injury or death.

  • Page 7: Qualification Of Assembly Staff

    You must ensure that staff have the protective equipment specified by accident prevention regulations. ▪ For transportation, setup and assembly: - suitable work wear - protective gloves - sturdy shoes (min. protection class S1P) Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 8: Design Information

    Design Information Notes on standards 3 Design Information 3.1 Notes on standards The system must be installed and commissioned in accordance with the local fire and building regulations. Unless contrary to other national regulations, the latest versions of the following standards and guidelines apply: 3.1.1 General standards for heating systems EN 303-5 Boilers for solid fuels, manually and automatically fed...

  • Page 9: Regulations And Standards For Permitted Fuels

    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 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 10: Installation And Approval Of The Heating System

    Design Information Installation and approval of the heating system 3.2 Installation and approval of the heating system The boiler should be operated in a closed heating system. The following standards govern the installation: Note on standards EN 12828 - Heating Systems in Buildings NOTICE! Each heating system must be officially approved.

  • Page 11: Requirements For Central Heating Water

    ❒ Avoid leaks and use a closed heating system to maintain water quality during operation ❒ When filling with make-up water, always bleed the filling hose before connecting, in order to prevent air from entering the system Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 12 Design Information Requirements for central heating water Advantages of prepared water: ▪ Complies with the applicable standards ▪ Less of a drop in output due to reduced limescale build-up ▪ Less corrosion due to fewer aggressive substances ▪ Long-term cost savings thanks to improved energy efficiency Permitted water hardness for the fill and make-up water in accordance with VDI 2035: Overall heat Total hardness at...

  • Page 13: 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 72] Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 14: Chimney Connection/Chimney System

    Design Information Chimney connection/chimney system 3.7 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. Please note in this respect that flue gas temperatures lower than 160K above room temperature can occur in the permitted operating range of the boiler.

  • Page 15: Draught Limiter

    The mouths of the air and flue gas chimney are either concentric or so close to each other that similar wind conditions apply. NOTICE! Air is supplied by an air and flue gas system! Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 16: Air Supply In The Installation Room

    Design Information Air supply in the installation room Type C A boiler that is connected via its combustion air supply and flue gas outlet, with a connecting piece, to a wind protection device and a single or shared chimney. NOTICE! Air supply via an air supply line that is independent from the chimney system! NOTICE! This design requires a wind protection device.
  • Page 17 (maximum flow rate = 1 m/s) NOTICE! Observe the standards cited in these instructions as well as other national and local regulations! ⇨ See "Note on standards" [page 8] Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 18: Note On Installing An External Combustion Air Supply

    Design Information Note on installing an external combustion air supply 3.10 Note on installing an external combustion air supply NOTICE! Install the combustion air supply (piping) in accordance with the applicable standards ⇨ See "Notes on standards" [page 8] ❒ Connect supply air duct to the connection provided (external combustion air) on the pellet boiler and make sure that it is properly sealed.

  • Page 19: Simultaneous Operation With Other Air-Drawing Systems

    ❒ Make sure that the combustion air supply line and the connecting piece are properly sealed at the chimney. Any flexible aluminium pipes used for the supply air line must be protected against mechanical loads. Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 20: Room Air-Independent Appliance

    Design Information Simultaneous operation with other air-drawing systems (room ventilation, cooker hood, centralised dust extraction system, etc.) 3.11.1 Room air-independent appliance The pellet boiler is suitable for room air-independent operation up to a maximum permissible room-side under-pressure of 8 Pa. Provided the permissible room-side under-pressure limit is not exceeded, there are no restrictions regarding simultaneous operation of air-drawing systems (e.g.

  • Page 21: Requirements For Operating The Room Air-Dependent Appliance Simultaneously With An Air

    Recommendation: ❒ Fit a microbubble separator in the pipes to the boiler ➥ Follow the manufacturer's instructions! Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 22: Technology

    Technology Dimensions - PE1 Pellet 7-35 4 Technology 4.1 Dimensions - PE1 Pellet 7-35 PE1 Pellet 25-35 PE1 Pellet 7-10 PE1 Pellet 15-20 Dimension Description Unit PE1 Pellet 7 - 10 15 - 20 25 - 35 Length of boiler Total length incl.

  • Page 23: Dimensions - Pe1 Pellet Unit

    Height of flow/return connection of the heating circuits 1260 1260 Height, PE1 Pellet Unit 1810 1810 Height, electronic heating cartridge connection Height, drainage connection of DHW tank Height of the drainage connection of the boiler Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 24: Connections - Pe1 Pellet

    Technology Connections - PE1 Pellet 7-35 4.3 Connections - PE1 Pellet 7-35 Description Unit PE1 Pellet 7-10 15-20 25-35 Boiler flow connection Inches 3/4 IT 1 IT Boiler return connection 3/4 IT 1 IT Drainage connection 1/2 IT Supply air connection (external...

  • Page 25: Components And Connections - Pe1 Pellet Unit

    Drainage connection for the DHW tank (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 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 26: Technical Specifications

    Technology Technical specifications 4.5 Technical specifications 4.5.1 PE1 Pellet 7-10 / PE1 Pellet Unit 7-10 Description PE1 Pellet 7 PE1 Pellet 10 Nominal output Output range 2 - 7 2 - 10 Electrical connection 230V / 50Hz / fused C16A Power consumption Boiler weight approx.

  • Page 27: Pe1 Pellet 15-20 / Pe1 Pellet Unit

    Fuel as per EN ISO 17225 – Part 2: wood pellets Class A1 / D06 Test book number PB0730015 PB0740015 1. The technical specifications of the optional components can be found in the enclosed supplier documentation Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 28: Pe1 Pellet

    Technology Technical specifications Regulation (EU) 2015/1187 Energy efficiency class of boiler Energy efficiency index (EEI) of boiler Heating space annual rate of use η Energy efficiency index (EEI) of boiler and controller combined Energy efficiency class (EEI) of boiler and controller combined Regulation (EU) 2015/1189 - Emissions in [mg/m³] seasonal space heating emissions of particulate (PM)
  • Page 29 60 Pellet container capacity Ash box capacity Water pressure drop (ΔT = 20K) mbar 12.0 14.0 Minimum boiler return temperature Not applicable due to internal return temperature control Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 30 Technology Technical specifications Description PE1 Pellet 32 PE1 Pellet 35 Maximum boiler temperature setting °C Minimum boiler temperature setting Airborne sound level dB(A) < 70 Boiler class as per EN 303-5:2012 Permitted fuel Fuel as per EN ISO 17225 – Part 2: wood pellets Class A1 / D06 Test book number PB0770015...

  • Page 31: Boiler Data For Planning The Flue Gas System

    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 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 32: Pe1 Pellet

    Technology External suction module NOTICE In Germany, the following applies: ❒ Continuous supply of fuel in the boiler’s ideal output range can be achieved by using a storage tank with a minimum volume in accordance with 1. BlmSchV. In this case, no chimney calculations are required in partial load. 4.6 External suction module Measur Description...

  • Page 33: Assembly

    (for module" [page 57] PE1 Pellet 25-35), controller accessories included in ash container (sensor, immersion sleeve etc.)) Not pictured: installation and operating instructions, guarantee certificate, identification plate Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 34: Tools Required

    Assembly Tools required Optionally available for PE1 Pellet Unit: Connection set for operation Pipe assembly for storage tank independent of room air loading ⇨ See "Install the connection set for ⇨ See "Expansion with pipe assembly room air-independent operation for storage loading (optional)" [page (optional)"...

  • Page 35: Transport

    ❒ 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 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 36: Positioning

    Assembly Positioning 5.4 Positioning If the height of the PE1 Pellet Unit prevents it from being transported as a single unit: ❒ ⇨ See "Disassembling to make transporting the PE1 Pellet Unit easier" [page NOTICE! Only remove the PE1 Pellet Unit as a last resort if it connot be transported as a single unit! Transport with fork-lift or similar lifting device ❒...

  • Page 37: 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 ➥ Damp conditions and frost can damage components, particularly electric ones! Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 38: Setting Up In The Boiler Room

    Assembly Setting up in the boiler room 5.6 Setting up in the boiler room 5.6.1 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. ➥...

  • Page 39: Install Pe1 Pellet

    ❒ Cut through the reinforcing tape and lift off the cardboard box ❒ Take the componenets behind the boiler (suction module, furnace tool,…) off the pallet ❒ Remove the transport lock at the back of the boiler Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 40 Assembly Install PE1 Pellet ❒ Lift the boiler and pull the pallet out the front TIP: We recommend using Froling’s KHV 1400 boiler lifting system to make pallet removal easier Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 41: Pe1 Pellet 25-35 - Prepare The Boiler For Transport And Setup

    ❒ Remove insulated door ❒ Unlock the cover by undoing the retaining screws ❒ Lift the cover on the front edge slightly and remove it towards the front Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 42 Assembly Install PE1 Pellet ❒ Undo the screws on the front cover plate ❒ Unlock cover plate to the right and lift off to the front ❒ Remove the protective plate from the bottom of the boiler ❒ Pull out floor insulation The Froling KHV 1400 boiler lifting system can now be used to lift the boiler off the pallet and the boiler can be transported using a forklift or similar lifting device.

  • Page 43: Aligning The Boiler On The Floor

    ❒ Lift the boiler up off the floor and use the adjustable feet to level it ➥ To avoid structure-borned sound transmission, the bottom of the boiler may not rest on the floor Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 44: Prepare For Room Air-Independent Operation

    Assembly Install PE1 Pellet 5.7.4 Prepare for room air-independent operation ❒ Remove the covering grid plate on the rear of the boiler ❒ Loosen both screws (A) on the supply air connection ca. 30 mm ❒ Pull back the bracket for the supply air connection until approx. 30 mm of pipe is protruding ❒...

  • Page 45: Install The Pe1 Pellet Unit

    ❒ Transport boiler to the intended position in the installation room ➥ Observe the operating and maintenance areas of the equipment in the process! Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 46: Align The Boiler With The Floor

    Assembly Install the PE1 Pellet Unit 5.8.2 Align the boiler with the floor ❒ Lift the boiler using a forklift or similar lifting device with the appropriate load- bearing capacity and position the boiler underlays Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 47: Install Boiler Filling And Drainage System

    5.8.3 Install boiler filling and drainage system ❒ Remove the right blanking plug from the DHW tank and seal the boiler filling and drainage system in the sleeve instead Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 48: Expansion With Electronic Heating Cartridge (Optional)

    Assembly Install the PE1 Pellet Unit 5.8.4 Expansion with electronic heating cartridge (optional) 60-80Nm ❒ Remove the left blanking plug from the DHW tank and seal the electric heating cartridge in the sleeve instead ❒ Tighten the electric heating cartridge with the included spanner (60-80 Nm) ❒...
  • Page 49 ❒ Push out the perforation on the cover and remove the burrs using a half-round file ❒ Secure the air connection bracket to the upper side of the frame ➥ The long pipe section points up Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 50: Expansion With Pipe Assembly For Storage Loading (Optional)

    Assembly Install the PE1 Pellet Unit ❒ Remove the cover plate and grill from the back panel of the boiler ❒ Loosen both screws on the air connection ❒ Pull the bracket out until it stops and secure using screws ❒...

  • Page 51: Expansion With Pump Assembly For Second Heating Circuit (Optional)

    ❒ Remove the piping between the pump assembly and the ball valves ❒ Remove the anterior thermal insulation from the second pump assembly and secure the pump assembly to the frame Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 52 Assembly Install the PE1 Pellet Unit ❒ Fit the elbows, including seals, to the ball valves ❒ Fit the distributor, including seals, to the bottom of the pump assembly and to the elbows ➥ CAUTION: Pay attention to the directions of flow (A)! ❒...
  • Page 53 ❒ Fit the rear panel to the frame and use two screws to secure it on the top ❒ Fit the side panel and use two screws to secure it to the frame Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 54: Fit The

    Assembly Install the PE1 Pellet Unit 5.8.8 Fit the front cover ❒ Undo the screws on the right side panel and remove the side panel ❒ Remove the screws from the frame behind ❒ Insert the bolts on the included cover on the left frame and use the previously removed screws to attach to the right frame ❒...

  • Page 55: Disassembling To Make Transporting The Pe1 Pellet Unit Easier

    ❒ Lift the top cover slightly at the front and unhook ❒ Undo both screws at the top of the right side panel and unhook the side panel Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 56 Assembly Install the PE1 Pellet Unit ❒ Unplug the connectors for the following components in the controller box and pull the cable from opening (A) on the controller box: ➥ B – mixing valve for the first heating circuit on the core module ➥...

  • Page 57: Installing The Discharge System

    ➥ 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 PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 58 Assembly Installing the discharge system ❒ 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 ❒...

  • Page 59: Connect The Suction Hoses To The Boiler

    NOTICE! When connecting the lines, pay attention to equipotential bonding, ⇨ See "Assembly information for hose lines" [page 60] ❒ Install the cover plate under the suction hoses Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 60: Assembly Information For Hose Lines

    Assembly Installing the discharge system 5.9.3 Assembly information for hose lines < 0,5m < 0,5m R > 30cm Please note the following with regard to the hose lines used in Froling vacuum discharge systems: ▪ Do not kink the hose lines! Minimum bending radius = 30cm ▪...

  • Page 61: Potential Equalisation

    ➥ 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 grease). ❒ Secure the hose line with a hose clamp Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 62: Install The Protective Plate For The Flue Pipe

    Assembly Install the protective plate for the flue pipe 5.10 Install the protective plate for the flue pipe 90° ❒ Bend the cover plate on the punched edge to 90° ❒ Replace the protective plate on the rear of the boiler and attach it with screws ➥...

  • Page 63: Electrical Connection

    ❒ Undo the screws on the top and remove the side panel ❒ Run the cables of all components through cut-out (A) in the back panel to the controller and plug in to the following boards Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 64 Assembly Electrical Connection Suction module on the pellet module FRPEM Power supply at connector in controller For pipe assembly for storage tank loading Storage tank loading pump on the hydraulic module AO-P1 FRHYU Pumpe 1 For pump assembly for second heating circuit Pump (A), mixing valve (B) and contact sensor (C) on the core module 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 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 66: Final Installation Steps

    Assembly Final installation steps 5.12 Final installation steps ❒ Insert side panel into lugs (A) and attach at the top ❒ Insert the cover at the rear and attach it with a retaining screw ❒ Place both covers on the back ❒...

  • Page 67: 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 Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 68: Before Commissioning / Configuring The Boiler

    Start-up Before commissioning / configuring the boiler 6.2 Before commissioning / configuring the boiler The boiler must be configured to the heating system during initial start-up! NOTICE Optimum efficiency and efficient, low-emission operation can only be guaranteed if the system is set up by trained professionals and the standard factory settings are observed.

  • Page 69: Initial Startup

    ❒ Tip: If this occurs, clean up using a cleaning rag. NOTICE! See boiler controller instruction manual for all the steps necessary to start up for the first time. Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...

  • Page 70: Decommissioning

    Decommissioning Mothballing 7 Decommissioning 7.1 Mothballing The following measures should be taken if the boiler is to remain out of service for several weeks (e.g. during the summer): ❒ Clean the boiler thoroughly and close the doors fully If the boiler is to remain out of service during the winter: ❒...

  • Page 71: Notes

    Notes 8 Notes Installation Instructions PE1 Pellet 7-35 / PE1 Pellet Unit 7-20 | M1441420_en...
  • Page 72 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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Pe1 pellet unit 7-20

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