Fröling PE1 Pellet 20 Assembly Instructions Manual
Pellet boiler
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Summary of Contents for Fröling PE1 Pellet 20
- Page 1 Assembly Instructions Pellet boiler PE1 Pellet 20/35 Read and follow the instructions and safety informations! Technical changes, typographical errors and omissions reserved! M2030120_en-us | Edition 11/11/2020 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 2: Table Of Contents
What to do in the case of danger Staff requirements Personal protective equipment 2.10 Replacement parts 2.11 Environmental protection 2.12 The operator's responsibilities Technical information PE1 Pellet 20/35 dimensions Components and connections Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 3 4.5.6 Install the protective plate for the flue pipe 4.5.7 Electrical connection Potential equalisation Information on circulating pumps Final installation steps Start-up Before commissioning / configuring the boiler Decommissioning Mothballing Disassembly Disposal Notes Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us...
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Page 4: Supplementary Instructions
Supplementary instructions 1 Supplementary instructions These instructions ensure safe and efficient use of the (hereinafter referred to as the “system"). These instructions are a component part of the system and must be kept next to the system and within the immediate reach of staff at all times. Staff must carefully read and understand these instructions before commencing all work. -
Page 5: Safety
Special safety information The following symbols are used to draw your attention to particular hazards Tips and recommendations Italics indicate useful tips and recommendations as well as information for efficient and smooth running. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 6: Permitted Uses
Safety Permitted uses Other markers The following markers are used in these instructions to highlight operating guidelines, results, lists, references, and other elements: Marker Explanation Step-by-step operating instructions ❒ ➥ Results of actions Links to sections of these instructions and oth- ➾... -
Page 7: Space Required
(100 mg/L), i.e. soft water is required. ▪ The chlorine concentration in the water must not exceed 58 grain/fl.oz. (30 mg/L). ▪ The pH value in the heating system must be between 8.0 and 8.6. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 8: Ventilation Requirements For Boiler Room
Safety Requirements at the place of installation ▪ If the water quality is too poor, use additives to prepare the water. If you are top- ping up with small amounts, always use clean water. The hot water must not be used directly in swimming pools or thermae. Use a NOTICE heat consumer of the right size to consume the heat. -
Page 9: Requirements For The Heating System
Fuel delivery hose must be supplied by your local Froling boiler representative and must be manufactured according to ISO 3994 (specifies requirements for helical ther- moplastic reinforced hoses) and certified to UL 94 HB (flammability of plastic materi- als). Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 10: Combination With A Storage Tank
Safety Requirements at the place of installation 2.3.9 Combination with a storage tank A storage tank does not need to be used for the heating system to run smoothly. How- ever, we recommend that you use the system with a storage tank to ensure a continu- ous supply of fuel in the boiler’s ideal output range. -
Page 11: Basic Data For Designing The Chimney Connection
CAUTION UMN (25 Pa) COULD CAUSE FIRE TO BURN OUT OF CONTROL AND CAUSE AN UNSAFE CONDITION! ❒ Maximum permitted setting: 0.10 inches WC (25 Pa) Ideal setting: 0.04 inches WC (10 Pa) Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 12: Safety Devices
Safety Safety devices 2.4 Safety devices 2.4.1 Position of safety devices BOILER OFF (switches off the boiler to prevent overheating) ❒ Tap “Boiler OFF” ➥ Automatic mode is switched off ➥ Control system follows the boiler shutdown procedure ➥ Pumps continue to run MAIN SWITCH (switches off the power supply) Before carrying out work on/in the boiler: ❒... -
Page 13: Safety Markers
Switch off the main switch for the fuel infeed and take precautions to prevent acciden- tal switching on before entering the fuel storage room. Securing the main switch Switch off the main switch and secure with a padlock when carrying out maintenance work to the boiler. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 14: Prohibitions
Safety Safety markers 2.5.2 Prohibitions Unauthorized access prohibited Only persons authorized by the operator may enter the danger zone and fuel storage room. Keep children away! Keep the fuel storage room locked and keep the access key in a safe place. Protect the fuel from moisture. No fire, open flames or smoking Areas marked with this are at risk of fire or explosion. -
Page 15: Additional Safety Signage
2.5.4 Additional safety signage Warning sign for covers DO NOT ALTER THIS EQUIPMENT IN ANY WAY! KEEP COVER CLOSED DURING OPERATION! Do not modify the system peripherals. The covers must be kept shut during operation. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 16: Signage On The Boiler
For wiring instructions please refer to Installation Manual! Chimney must be 5” (129mm – PE1 Pellet 20) or 6’’ (149 mm – PE1 Pellet 35) diameter listed UL-103 HT or ULC-S629 residential all-fuel type or tile-lined masonry. Flue connector pipe must be 5” (129mm – PE1 Pellet 20) or 6’’ (149 mm – PE1 Pellet 35) diameter made of a minimum 24 MSG black steel. -
Page 17: Notice Of Risks During Operation
Insulate flue pipe and do not touch during operation. Do not carry out maintenance when the boiler is hot. Do not touch hot surfaces behind Boiler doors and Covers. A 2151 00 17 Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 18: Notice Regarding Procedures In An Emergency
Safety Safety markers Notice regarding procedures in an emergency PE1 Pellet – WOOD PELLET FIRED BOILER EMERGENCY PROCEDURES DANGER! In case of strong smell of flue gas! Flue gases can cause fatal poisoning! - Do not open any boiler doors or covers, or fuel transportation system door or covers! - Turn off the boiler by pressing “Boiler OFF”... -
Page 19: Sign On Fuel Store
❒ Always wear hearing protection when working around the discharge system ➥ Depending on the discharge system and fuel, the noise level inside the dis- charge system can reach over 80 dB(A) during transportation of the fuel. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... - Page 20 Safety Residual risks Risk of falling Risk of falling when working close to the boiler! WARNING ❒ When working on ladders, always ensure that the ladder is securely positioned on a firm and even surface. ❒ Always observe the relevant safety regulations when working with a hoist. ❒...
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Page 21: Risks From Electricity
❒ Switch off the main switch and take precautions to prevent accidental switching ➥ There is a risk of serious injury from the system starting up automatically if it is switched on during inspection and cleaning. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 22: Danger From Fire And Explosion
Safety Residual risks Screw movement Risk of injury from getting crushed, trapped and caught in moving screws! WARNING ❒ Never step onto the screws (if present) in the fuel store. ❒ Never reach into the transport screw of the fuel infeed or the ash discharge screws (if present) when they are running. -
Page 23: Danger From High Temperatures
❒ Keep children and unauthorized persons away from the boiler and fuel store. ❒ Allow the boiler to cool before carrying out any maintenance work. ➥ Touching hot surfaces on the boiler, on the flue gas pipe and on heating pipes can cause serious burns. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 24: Risks From Flue Gases, Incorrect Fuel And Other Equipment
Safety Residual risks Hot media Risk of scalding from hot media! WARNING ❒ Temperature modifications in the control system must only be undertaken in con- sultation with the manufacturer. ❒ Do not touch heating pipes and consumer loads in the heating circuit (radiator etc.) during operation. - Page 25 ❒ Never use chemicals, kerosene, charcoal, spirits or other flammable liquids to start or reignite the combustion process in the boiler. ➥ Using the incorrect fuel can cause dangerous malfunctions or damage to the system or the discharge system. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us...
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Page 26: What To Do In The Case Of Danger
Safety What to do in the case of danger 2.7 What to do in the case of danger What to do if the system overheats (at temperatures above 220°F (105°C)) Risk of injury from switching the system off prematurely at the main switch! WARNING ❒... -
Page 27: Staff Requirements
The heating system installer must have undertaken training and have professional experience of at least one year in his field of application. The skills of the heating system installer include: ❒ Understanding technical contexts Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... - Page 28 Safety Staff requirements ❒ Reading and understanding technical drawings and diagrams ❒ Installing system components ❒ Installing and connecting of heating lines ❒ Performing maintenance work ❒ Dismantling and repairing or replacing system components, if a problem occurs Licensed electrician Thanks to his training, knowledge, experiences and knowledge of relevant standards and provisions the licensed electrician is capable of performing the following tasks on electrical systems professionally and according to safety requirements:...
- Page 29 ❒ Date of training ❒ Name of the trainees ❒ Contents of the training ❒ Name of the instructor ❒ Signatures of the trainees and the instructor Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us...
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Page 30: Personal Protective Equipment
Safety Personal protective equipment 2.9 Personal protective equipment Personal protective equipment is used to protect persons from compromised health and safety at work. During the various types of work to and with the system the staff must wear personal protective equipment which is set out separately in the individual sections of this man- ual. -
Page 31: Environmental Protection
Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... - Page 32 Safety The operator's responsibilities Operator duties The system is used in the commercial sector. The system operator is therefore subject to the legal obligations for safety at work. In addition to the safety instructions in this manual, the applicable regulations on safe- ty, safety at work and environmental protection must be observed.
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Page 33: Technical Information
Height, flow connection (930) (1160) Height, return connection 29.5 (750) (920) Height, drainage connection (95) (175) Height of supply air connection (for room air-independent operation) (390) (460) Height of suction system connection (1110) (1380) Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 34: Components And Connections
Technical information Components and connections 3.2 Components and connections Description Unit PE1 Pellet Boiler flow connection inches 1 IT Boiler return connection 1 IT Drainage connection ½ IT Supply air connection (external diame- inches ter) (mm) Flue gas pipe connection 5 (129) 6 (149) Pellet suction line connection... -
Page 35: Technical Data
104 (40) 122 (50) 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 Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 36: Emission Data
Technical information Technical data 3.3.1 Emission data Description Unit PE1 Pellet 8-HOUR OUTPUT RATING [Q Btu/hr out-8hr 8-HOUR AVERAGE EFFICIENCY [03B7 avg-8hr 8-HOUR AVERAGE EFFIENCY [η avg-8hr (Using lower heating value) MAXIMUM OUTPUT REATING [Q Btu/hr 68.200 119.500 ANNUAL EFFICIENCY RATING [η 78.4 80.1 (Using higher heating value) -
Page 37: External Suction Module
10.4 (265) Height of suction module 9 235 Total height incl. hose connection 11.2 (285) Return-air line connection inches 2 (50) (line to suction point) (mm) Return-air line connection 2 (50) (line to boiler) Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 38: Assembly
Assembly Tools required 4 Assembly Several parts of the boiler are covered with a protective film. This film MUST be NOTICE removed before assembly! 4.1 Tools required The following tools are required for assembling the boiler and suction module: ▪ Spanner or box wrench set ▪... -
Page 39: 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 climate conditions and frost can damage components, particularly elec- tric ones! Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 40: Install Pe1 Pellet
Assembly Install PE1 Pellet 4.5 Install PE1 Pellet 4.5.1 Remove boiler from pallet ❒ Cut through the strapping and lift off the cardboard ❒ Remove components behind boiler (suction module, furnace tool, etc.) from pallet ❒ Loosen the transport lock on the back of the boiler ❒... -
Page 41: Pe1 Pellet 35 - Prepare The Boiler For Transport And Setup
TIP: Uniquely identify the cables (top bushing: BUS, bottom bushing: ETHERNET) ❒ 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 Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... - 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 Fröling 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.
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Page 43: Align The Boiler With The Floor
Install PE1 Pellet 4.5.3 Align the boiler with the floor For PE1 Pellet 20 the leveling feet are adjusted from the outside. The the leveling feet ⇨ See of PE1 Pellet 35 are only accessible by removing the front protective plate, "PE1 Pellet 35 –... -
Page 44: Installing The Discharge System
Assembly Install PE1 Pellet ca. 30 mm ❒ Pull the console of the supply air connection to the rear until approx. 30 mm (1.18 inches) of the pipe protrudes ❒ Fasten both screws ❒ Remove the grille from the cover plate ❒... - Page 45 ⇨ NOTICE! When connecting the lines, pay attention to equipotential bonding, See "Assembly information for hose lines" [page 47] ❒ Secure the cover hood with the previously removed screws Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us...
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Page 46: Fit The Suction Hoses To The Boiler
Assembly Install PE1 Pellet Fit the suction hoses to the boiler ❒ Remove the cover plate at the connections ❒ Fix the suction hoses to the connections using hose clamps ➥ Left-hand connection: Return-air line ➥ Right-hand connection: Suction hose (PELLETS sticker) ⇨... -
Page 47: 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 48 kW, only suction hoses with PU inlet are recommended due to the increased load. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... - Page 48 Assembly Install PE1 Pellet Potential equalisation When connecting the hose lines to the individual connections, ensure there is consis- tent potential equalisation throughout the line. ❒ Expose approximately 8 cm (3.15 inches) of the earth wire at the end of the hose line ➥...
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Page 49: Install The Protective Plate For The Flue Pipe
❒ Hang the protective plate onto the back of the boiler and fix the plate using the screws ➥ The protective plate is designed to shield boiler components from the hot flue pipe to the smoke stack. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 50: Electrical Connection
Assembly Install PE1 Pellet 4.5.7 Electrical connection When working on electrical components: DANGER Risk of electrocution! When work is carried out on electrical components: ❒ Only have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥... -
Page 51: Potential Equalisation
NOTICE! Compliance with additional information in the relevant boiler controller documentation is mandatory! Potential equalisation PE1 Pellet 20 PE1 Pellet 35 ❒ The potential equalisation on the boiler base must comply with current directives, regulations and standards. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 52: Information On Circulating Pumps
Assembly Install PE1 Pellet Information on circulating pumps According to 2012/622/EU external, wet running circulating pumps must comply NOTICE with the following limit values of the Energy Efficiency Index (EEI): - Effective from 01/01/2013: Wet running circulating pumps with EEI ≤ 0.27 - Effective from 08/01/2015: Wet running circulating pumps with EEI ≤... -
Page 53: Final Installation Steps
Final installation steps 4.6 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 Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 54: Start-Up
Start-up Before commissioning / configuring the boiler 5 Start-up 5.1 Before commissioning / configuring the boiler The boiler must be adjusted to the heating system during commissioning. Optimum efficiency and efficient, low-emission operation can only be guaran- NOTICE teed if the system is set up by trained professionals and the standard factory settings are observed. -
Page 55: Decommissioning
❒ Ensure that they are disposed of in an environmentally friendly way in accordance with waste management regulations in the country (e.g. AWG in Austria) ❒ You can separate and clean recyclable materials and send them to a recycling centre. Assembly Instructions PE1 Pellet 20/35 | M2030120_en-us... -
Page 56: Notes
Notes 7 Notes Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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