Fröling PE1e Installation Instructions Manual
External ash removal, pellet boilers
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Also See for PE1e:
- Installation instructions manual (76 pages) ,
- Operating instructions manual (68 pages) ,
- Service handbook (112 pages)
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Summary of Contents for Fröling PE1e
- Page 1 Installation instructions External ash removal for PE1e Pellet 45-60 Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M2490021_en | Edition 11/03/2022...
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Page 2: Table Of Contents
Table of contents 1 General ................................. 1.1 Product overview........................... 2 Safety................................2.1 Hazard levels of warnings ........................2.2 Permitted uses ............................2.2.1 Area of Application........................2.2.2 Permitted fuels ........................... 2.3 General safety information ........................2.4 Qualification of staff..........................2.4.1 Qualification of assembly staff ....................2.4.2 Personal protective equipment for assembly staff .............. -
Page 3: General
General | 1 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 4: Product Overview
1 | General 1.1 Product overview Ash transfer box Downpipe with inspection opening Pipe bend 90° Connection box Supporting post Roller limit switch Coreless screw Ø 70 mm Standard waste bin 240 litres Riser Flap-bottomed container 330 Litres Coreless screw geared motor M2490021_en | Installation instructions External ash removal... -
Page 5: Safety
Safety | 2 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 6: Permitted Uses
2 | Safety 2.2 Permitted uses The external ash removal for PE1e Pellet is intended solely for the removal of combustion residue in the form of ash from the Fröling boilers listed in the section entitled “Area of application”. The ash is discharged into the standard waste bin, flap-bottomed container or other suitable container provided. -
Page 7: General Safety Information
Safety | 2 2.3 General safety information r Refer to the safety information, information on residual risks and design information in the installation and operating instructions for the boiler in question. NOTICE In addition to these instructions, please also note all specifications, safety information and standards in the installation and operating instructions for the boiler in question. -
Page 8: Protective Equipment For Operating Staff
2 | Safety 2.4.3 Qualification of operating staff CAUTION If unauthorised persons enter the Installation room: Risk of personal injury and damage to property r The operator is responsible for keeping unauthorised persons, in particular children, away from the system. Only trained operators are permitted to operate the unit. -
Page 9: Design Information
Safety | 2 2.5 Design information Carrying out modifications to the system and changing or disabling safety equipment is prohibited. Always comply with all fire, building and electrical regulations when installing or operating the system, in addition to following the operating instructions and mandatory regulations that apply in the country in which the tank is operated. -
Page 10: Technology
3 | Technology 3 Technology 3.1 Dimensions Item Description Unit Value Width of standard waste bin With of ash discharge system 2050 Width, boiler Width of flap-bottomed container Depth of standard waste bin Depth of flap-bottomed container Height of standard waste bin 1065 Height of ash discharge system 2000... -
Page 11: Technical Data
Technology | 3 3.2 Technical data Description Unit Value Power supply to geared motor 230 V / 50 Hz Power consumption of geared motor 180 (ABM) 250 (STM) Speed of coreless screw 30.6 Weight of standard waste bin (empty) Weight of standard waste bin (filled with ash) approx. -
Page 12: Assembly
4 | Assembly 4 Assembly CAUTION Assembly and installation by unqualified persons: Risk of personal injury and damage to property During assembly and installation: r Observe the instructions and information in the manuals r Only allow appropriately qualified personnel to work on the system 4.1 Materials supplied Geared motor Screw bearing... -
Page 13: Required Tools
Assembly | 4 4.2 Required tools The following tools are required for assembly: ▪ Spirit level ▪ Power drill with Ø 14 mm (surface) drill bit ▪ Phillips screwdriver ▪ Spanner or box wrench set (widths across flats 8–32 mm) ▪... -
Page 14: Installation Position
4 | Assembly 4.5.1 Installation position The pipe bend can be fitted to the right or left-hand side of the boiler. Furthermore, the riser can be installed on the pipe bend in 45° increments. 4.6 Installing external ash removal WARNING Working on a system which is operational/hot: Risk of serious injuries from automatic start-up of the system and severe burns from hot parts and the flue gas pipe! -
Page 15: Boiler Preparation
Assembly | 4 4.6.1 Boiler preparation r Open the front insulating door r Loosen the star-shaped knobs and swivel to one side r Fold the cover plate forward r Pull out both ash containers r Remove upper cover r Remove front side panel - 4x fillister head screw M6 x 12 r Undo two screws and pull the bracket out to the front - 2x hexagon screw M8 x 25... -
Page 16: Mount The Lower Part Of The Ash Transfer Box (Ash Removal Right)
4 | Assembly 4.6.2 Mount the lower part of the ash transfer box (ash removal right) r Remove the blanking plate on the right side of the boiler base - 2x fillister head screw M6 x 12 r Push the screw bearing (A) and screw guide (B) into the ash transfer box and mount it - 4x hexagon screw M8 x 30 per side Ä... -
Page 17: Mount Bottom Part Of The Ash Transfer Box (Ash Removal Left)
Assembly | 4 4.6.3 Mount bottom part of the ash transfer box (ash removal left) r Remove the blanking plate on the left side of the boiler base - 2x fillister head screw M6 x 12 r Push the screw bearing (A) and screw guide (B) into the ash transfer box and mount it - 4x hexagon screw M8 x 30 per side Ä... -
Page 18: Mount Upper Part Of Ash Transfer Box
4 | Assembly 4.6.4 Mount upper part of ash transfer box r Break out the round perforation between the ash removal ducts and remove burrs using a half-round file r Insert flange bush into recess and mount it - 2x fillister head screw M6 x 12 r Push top part onto the ash removal ducts and mount on the bottom part - 2x hexagonal screw M8 x 30 - 2x hexagonal screw M8 x 190... -
Page 19: Installing The Ash Duct
Assembly | 4 4.6.5 Installing the ash duct Ø 14 mm r Mount pipe bend and seal on the intermediate flange - 4x hexagonal screw M8 x 35 r Transfer the holes on the adjustable foot to the ground and dismantle the adjustable foot - 2x round-head screw M10 x 20 r Drill two fastening holes and knock in dowel Ø... - Page 20 4 | Assembly r Remove the key and shaft retainer from the shaft stub of the coreless screw r Lubricate the shaft stub with copper paste r Push coreless screw into pipe bend r Dismantle the cover on the upper part and ensure that the coreless screw is positioned on the screw bearing (A) - 8x fillister head screw M6 x 20 r Place seal (A) on the pipe bend...
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Page 21: Assembly Of The Geared Motor
Assembly | 4 r Use hose clamps to secure the connecting hose and connecting piece (A) to the downpipe of the riser Ä Ensure that handle can be hung on the downpipe hook (B) 4.6.6 Assembly of the geared motor ABM geared motor: r Install the geared motor on the connection flange of the upper part - 4x cylinder head screw M8 x 95... -
Page 22: Installing The Coreless Screw
4 | Assembly 4.6.7 Installing the coreless screw r Remove the inspection cover from the downpipe - 4x hexagonal screw M8 x 20 r Slide the screw end into the geard motor Ä TIP: Guide the coreless screw into the inspection opening (C) by reaching in r Push the key (A) into the groove and secure the screw with the shaft lock (B) - 1x hexagonal screw M10 x 20 with wedge locking disk M2490021_en | Installation instructions External ash removal... -
Page 23: Positioning Standard Waste Bin / Flap-Bottomed Container
Assembly | 4 4.6.8 Positioning standard waste bin / flap-bottomed container The following steps illustrate the positioning of the standard waste bin. Proceed in the same way for the flap-bottomed container. r Loosen the star-shaped knobs on the cover and remove the locking plate Ä... -
Page 24: Laying Cables
4 | Assembly 4.6.10 Laying cables r Open the insulated door and remove the controller cover - 4x fillister head screw M4 x 8 r Remove the cover plate from the boiler base - 2x fillister head screw M6 x 12 r Route the cable of the roller limit switch (A) and the geared motor (B) to the connection box (C) r Route connection line (D) of connection box (C) to the pellet module (E) as shown... -
Page 25: Electrical Connection
Assembly | 4 4.7 Electrical connection DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: r Always have work carried out by a qualified electrician r Observe the applicable standards and regulations Ä... -
Page 26: Final Installation Steps
4 | Assembly 4.8 Final installation steps r Mount controller - 4x fillister head screw M4 x 8 incl. contact disk r Thread in front side panel at the tabs on the boiler base and secure - 4x fillister head screw M6 x 12 r Place the upper cover on the boiler and close the insulated door r Secure the cable with cable tie at the intended positions (A) r Slide rubber grommet into the bottom cut-out of the cover and attach the cover... -
Page 27: Operation
Operation | 5 5 Operation WARNING Inspection and cleaning work on a system which is operational: Risk of serious injuries from automatic startup of the system and severe burns from hot parts and the flue gas pipe! When working on the system: r always wear protective gloves r only operate the boiler using the handles provided r switch off the boiler by tapping “Boiler off”... -
Page 28: Check The Fill Level Of The Container And Empty If Required
5 | Operation 5.1 Check the fill level of the container and empty if required The ash container has no system for measuring the fill level. For this reason, check the fill level at appropriate intervals based on energy requirements, fuel quality and the number of operating hours. -
Page 29: Checking The Geared Motors
Operation | 5 Flap-bottomed container: r Loosen star-shaped knobs r Remove connecting piece and check fill level Emptying flap-bottomed container: r Hang the connecting piece on the downpipe hook r Instead attach the locking plate using the star-shaped knobs r Use star-shaped knob (A) to secure flap-bottomed container to the forks of the forklift and transport to the unloading point Ä... -
Page 30: Troubleshooting
6 | Troubleshooting 6 Troubleshooting NOTICE For more information on dealing with error messages, refer to the operating instructions for the boiler and boiler controller. WARNING Working on a system which is operational/hot: Risk of serious injuries from automatic start-up of the system and severe burns from hot parts and the flue gas pipe! When working on the system: r always wear protective gloves... -
Page 31: Checking The Roller Limit Switch
Troubleshooting | 6 6.1 Checking the roller limit switch Roller (A) on the roller limit switch must be pressed down when the connecting piece is installed (there is an audible click when it is installed correctly) r Adjust the distance of the roller limit switch (A) Checking the function: Manual operation System menu... - Page 32 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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