Page 1
Installation instructions Pellet boiler PE1 Pellet PE1 Pellet 7-35 PE1 Pellet Unit 7-20 Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M1441624_en | Edition 12/06/2024...
4.1 Dimensions - PE1 Pellet 7-35 ....................... 22 4.2 Dimensions - PE1 Pellet Unit 7-20......................23 4.3 Components and connections - PE1 Pellet 7-35 .................. 25 4.4 Components and connections - PE1 Pellet Unit 7-20 ................26 4.5 Technical specifications ........................27 4.5.1 PE1 Pellet 7-10 / PE1 Pellet Unit 7-10..................
Page 3
Contents 5.6.1 Moving the boiler in the boiler room................... 40 5.6.2 Operating and maintenance areas of the equipment..............40 5.7 Install PE1 Pellet ........................... 41 5.7.1 Remove boiler from pallet ......................41 5.7.2 PE1 Pellet 25-35 – Prepare the boiler for transport and setup ..........43 5.7.3 Aligning the boiler on the floor ....................
1 | General 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.
General | 1 1.2 Disposal of packaging materials All packaging materials should be disposed of in accordance with the relevant regulations. In addition, check the regulations for correct disposal applicable in your local area. Data under the identification system of Directive 97/129/EC: Identification code / Material Disposal information Corrugated cardboard...
2 | Safety 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.
Safety | 2 2.2 Qualification of assembly staff 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 Assembly, installation, initial startup and servicing must only be carried out by qualified personnel: ▪...
3 | Design Information 3 Design Information 3.1 Overview of standards Perform installation and commissioning of the system 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 combustion...
Design Information | 3 3.1.4 Regulations and standards for permitted fuels 1. BImSchV First Order of the German Federal Government for the implementation of the Federal Law on Emission Protection (Ordinance on Small and Medium Combustion Plants) in the version published on 26 January 2010, BGBl.
3 | Design Information 3.4 Chimney connection/chimney system Connection line to the chimney Measuring port Draught limiter Explosion flap (for automatic boilers) Thermal insulation NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney sweep. The entire flue gas system (chimney and connection) must be laid out as per ÖNORM / DIN EN 13384-1 or ÖNORM M 7515 / DIN 4705-1.
Design Information | 3 3.4.1 Connection line to the chimney Requirements for the connection line: ▪ this should be as short as possible and follow an upward incline to the chimney (30 - 45° recommended) ▪ thermally insulated MFeuV (Germany) EN 15287-1 and EN 15287-2 3 x D (min.
3 | Design Information 3.4.2 Measuring port For emissions measurement on the system, a suitable measuring port must be installed in the connection line between the boiler and chimney system. Upstream of the measuring port (M) there should be a straight run-in section with a length about twice the diameter (D) of the connection line.
Design Information | 3 3.4.5 Electrostatic particle separator For reduction in the emissions an electrostatic particle separator may optionally be installed in the flue gas line. For planning and installation, comply with the following points: ▪ Position the measuring port (M) downstream of the electrostatic particle separator (E) as specified in the instructions Ü...
3 | Design Information 3.5 Combustion air 3.5.1 General requirement For safe operation, the boiler requires around 1.5 - 3.0 m³ of combustion air per kW nominal heat output and operating hour. The air supply can be provided by free ventilation (e.g.
Page 15
Design Information | 3 The minimum cross-sectional area of the supply air opening from outside depends on the nominal heat output of the boiler. Austria 400 cm² net minimum cross-sectional area plus 4 cm² for every kW of nominal heat output above 100 kW Germany 150 cm²...
3 | Design Information 3.5.3 Room air-independent operation (RIO) General requirement The combustion air is supplied to the boiler via a separate duct from the outside of the building. The supply must be dimensioned so that the total pressure drop at nominal load does not exceed 20 Pa.
Page 17
Design Information | 3 ▪ For dimensions of the combustion air connection (2) on the boiler, see chapter "Technical data" IMPORTANT: Do not reduce the dimensions of the connection ▪ In the duct, use bends (7) with the largest possible ratio (≥1) of radius of curvature (r) to duct diameter (d) ▪...
3 | Design Information 3.6 Domestic hot water Unless contrary to other national regulations, the latest versions of the following standards and guidelines apply: Austria: ÖNORM H 5195 Switzerland: SWKI BT 102-01 Germany: VDI 2035 Italy: UNI 8065 Observe the standards and also follow the recommendations below: r Use prepared water which complies with the standards cited above for filling and make-up water r Avoid leaks and use a closed heating system to maintain water quality during...
Page 19
Design Information | 3 Additional requirements for Switzerland The filling and make-up water must be demineralised (fully purified) ▪ The water must not contain any ingredients that could settle and accumulate in the system ▪ This makes the water non-electroconductive, which prevents corrosion ▪...
3 | Design Information 3.7 Pressure maintenance systems Pressure maintenance systems in hot-water heating systems keep the required pressure within predefined limits and balance out volume variations caused by changes in the hot- water temperature. Two main systems are used: Compressor-controlled pressure maintenance In compressor-controlled pressure maintenance units, a variable air cushion in the expansion tank is responsible for volume compensation and pressure maintenance.
Design Information | 3 3.9 Boiler ventilation r Fit the automatic ventilating valve at the highest point on the boiler or at the ventilation connection (if present). Ä This ensures that air in the boiler is constantly expelled, thus preventing malfunctions caused by air in the boiler r Check that the boiler ventilation is working properly Ä...
4 | Technology 4 Technology 4.1 Dimensions - PE1 Pellet 7-35 Dimensi Description Unit 7 - 10 15 - 20 25 - 35 Total length including flue gas pipe connection Length of boiler Overall width of boiler Distance from drainage to side of boiler...
Technology | 4 4.2 Dimensions - PE1 Pellet Unit 7-20 Dimensi Description Unit 7 - 10 15 - 20 Length, hydraulic unit Distance of flow/circulation pipe connection from the rear wall Distance return/hot water connection from the rear wall Length, PE1 Pellet Unit 1150 1190 Distance between flue gas pipe connection and side of boiler...
Page 24
4 | Technology Dimensi Description Unit 7 - 10 15 - 20 Height, PE1 Pellet Unit 1850 1850 Height, electronic heating cartridge connection Height, drainage connection of DHW tank M1441624_en | Installation instructions Pellet boiler PE1 Pellet...
4 | Technology 4.4 Components and connections - PE1 Pellet Unit 7-20 9 10 Item Description PE1 Pellet 7-10 15-20 System expansion flow connection 1” IT System expansion return connection 1” IT Drainage connection (with optional hydraulic unit designed as a boiler 1/2“...
Page 28
4 | Technology Product data in accordance with the regulations (EU) 2015/1187 and 2015/1189 Description PE1 Pellet / PE1 Pellet Unit Heating up mode automatic Condensing boiler Solid fuel boiler for combined heat and power Combined heating system Storage tank volume Ü...
Page 30
4 | Technology Product data in accordance with the regulations (EU) 2015/1187 and 2015/1189 Description PE1 Pellet / PE1 Pellet Unit Heating up mode automatic Condensing boiler Solid fuel boiler for combined heat and power Combined heating system Storage tank volume Ü...
4 | Technology Description PE1 Pellet Temperature controller used Lambdatronic P 3200 Class of the temperature controller Contribution of the temperature controller to the energy efficiency index of a combined system Energy efficiency index (EEI) of the combined boiler and controller Energy efficiency class of the combined boiler and controller Heating space annual rate of use ηs...
Page 33
Technology | 4 Product data in accordance with the regulations (EU) 2015/1187 and 2015/1189 Description PE1 Pellet Heating up mode automatic Condensing boiler Solid fuel boiler for combined heat and power Combined heating system Storage tank volume Ü "Storage tank" [} 20] Preferred fuel Compressed wood in the form of pellets Useful heat delivered at rated heat output (P...
4 | Technology 4.5.5 Boiler data for planning the flue gas system The flue gas performance values listed below should be used for calculation of the fluid dynamics for flue gas systems as specified in the EN 13384 series of standards. The flue gas performance values for the respective outputs are applicable under typical operating conditions when using fuels consistent with the fuel class specified in EN ISO 17225.
Technology | 4 In Germany, the following are applicable: When using a buffer storage tank with a minimum volume according to 1st BimSchV (Federal Emissions Regulation), continuous supply can be achieved in the ideal output range of the boiler. In this case, no verification calculation for the flue gas system in partial load operation is performed! 4.5.6 Data for planning a backup power supply Description...
5 | Assembly 5 Assembly IMPORTANT: The individual parts of the boiler insulation covered with a protective film. The protective film must be removed before proceeding with the installation! 5.1 Tools required The following tools are required for assembling the boiler and suction module: ▪...
Assembly | 5 5.2 Included in delivery The boiler comes on a pallet together with the suction module and accessories. Some of the components come in cardboard packaging. Boiler PE1 Pellet Unit Protective plate for flue pipe Ü "Installing the protective plate for the Ü...
5 | Assembly Boiler filling and drainage system Ü "Install boiler filling and drainage system" [} 48] 5.3 Transport The product is delivered on pallet(s) in cardboard packaging. NOTICE Possibility of damage to components if handled incorrectly r Follow the transport instructions on the packaging r Transport components with care to avoid damage r Protect components against damp r Pay attention to the pallet's centre of gravity when lifting...
Assembly | 5 Positioning using a crane: r Open the insulated door r Unlock the cover by undoing the retaining screws r Lift the cover on the front edge slightly and remove it towards the front r Transport the boiler using a crane hook NOTICE! The PE1 Pellet Unit can also be transported on the crane hook.
Assembly | 5 Operating and maintenance areas of the PE1 Pellet Unit 1 ... PE1 Pellet Unit pellet boiler | 2 ... Condensing boiler heat exchanger 600 mm 300 mm 30 mm 100 mm 500 mm 1. Maintenance area to expand the WOS springs upwards 5.7 Install PE1 Pellet 5.7.1 Remove boiler from pallet r Cut through the reinforcing tape and lift off the cardboard box...
Page 42
5 | Assembly r 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 M1441624_en | Installation instructions Pellet boiler PE1 Pellet...
Assembly | 5 5.7.2 PE1 Pellet 25-35 – Prepare the boiler for transport and setup The following preparations are necessary in order to remove the PE1 Pellet 25-35 from the pallet using the Fröling KHV 1400 boiler lifting system or similar hoisting equipment and transporting it.
Page 44
5 | Assembly r Undo the screws on the front cover plate r Unlock cover plate to the right and lift off to the front r Remove the protective plate from the bottom of the boiler r 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.
Assembly | 5 5.7.3 Aligning the boiler on the floor For the PE1 Pellet 7-20 the adjustable feet are adjusted from the outside. The adjustable feet of the PE1 Pellet 25-35 are accessible only by removing the front protective plate, Ü...
5 | Assembly 5.7.4 Prepare for room air-independent operation r Remove the covering grid plate on the rear of the boiler r Loosen both screws (A) on the supply air connection ca. 30 mm r Pull back the bracket for the supply air connection until approx. 30 mm of pipe is protruding r Secure both screws r Remove the grill from the cover plate...
Assembly | 5 5.8 Install the PE1 Pellet Unit 5.8.1 Remove boiler from pallet r Cut through the strapping and lift off the cardboard r Loosen the nuts and washers on the top of the pallet and remove the crosspieces r Remove the rear crosspiece r Loosen the screws and remove the clamping angles r Lift the boiler using a forklift or similar lifting device with the appropriate load-bearing...
5 | Assembly 5.8.2 Align the boiler with the floor r Lift the boiler using a forklift or similar lifting device with the appropriate load-bearing capacity and position the boiler underlays 5.8.3 Install boiler filling and drainage system r Remove the right blanking plug from the DHW tank and seal the boiler filling and drainage system in the sleeve instead M1441624_en | Installation instructions Pellet boiler PE1 Pellet...
Assembly | 5 5.8.4 Expansion with electronic heating cartridge (optional) 60-80Nm r Remove the left blanking plug from the DHW tank and seal the electric heating cartridge in the sleeve instead r Tighten the electric heating cartridge with the included spanner (60-80 Nm) r Run the cable up to the boiler controller 5.8.5 Install the connection set for room air-independent operation (optional) Depending on how the system is set up, the air connection for room air-independent...
Page 50
5 | Assembly r Remove the cover plate and grill from the back panel of the boiler r Loosen both screws on the air connection r Pull the bracket out until it stops and secure using screws r Slide the air hose onto both pipes and secure with pipe clamps Variant 2: Top air connection r Lift off both rear covers r Push out the perforation on the cover and remove the burrs using a half-round file...
Assembly | 5 r Remove the cover plate and grill from the back panel of the boiler r Loosen both screws on the air connection r Pull the bracket out until it stops and secure using screws r Slide the air hose onto both pipes and secure with pipe clamps 5.8.6 Expansion with pipe assembly for storage loading (optional) r Remove the pipe connecting piece from the boiler return r Instead, fit the included pipe assembly for storage loading including seals...
5 | Assembly 5.8.7 Expansion with pump assembly for second heating circuit (optional) r Remove thermal insulation from pump assembly r Push the cover plate next to the pump assembly slightly forward and unhinge r Loosen both screws on the inside of the frame and unhook the right side panel r Undo both screws on the top and unhook the back panel r Shut off the ball valves (A) on the piping to the pump assembly r Shut off the flow to the pump assembly by turning the thermometer (B)
Page 53
Assembly | 5 r Fit the elbows, including seals, to the ball valves r Fit the distributor, including seals, to the bottom of the pump assembly and to the elbows Ä CAUTION: Pay attention to the directions of flow (A)! r Attach the thermal insulation to the distributor r Slide the support (B), thread facing down, into the distributor bar r Attach the retaining plates to the frame and to the supports...
5 | Assembly r Fit the rear panel to the frame and use two screws to secure it on the top r Fit the side panel and use two screws to secure it to the frame 5.8.8 Fit the front cover r Undo the screws on the right side panel and remove the side panel r Remove the screws from the frame behind r Insert the bolts on the included cover on the left frame and use the previously...
Assembly | 5 5.8.9 Disassembling to make transporting the PE1 Pellet Unit easier r Lift box off pallet r Lift off both rear covers r Undo the piping for the boiler’s flow and return r Undo the piping for boiler drainage r Open the insulated door and slightly loosen the retaining screws behind it r Lift the top cover slightly at the front and unhook r Undo both screws at the top of the right side panel and unhook the side panel...
Page 56
5 | Assembly r Unplug the connectors for the following components in the controller box and pull the cable from opening (A) on the controller box: Ä B – mixing valve for the first heating circuit on the core module Ä...
Assembly | 5 5.9 Installing the discharge system Once the discharge system has been assembled in accordance with the assembly instructions enclosed, the suction and return air line needs to be connected to the boiler and the external suction module connected as well. 5.9.1 Installing the external suction module The pellets are loaded using an external suction module built into the return air line between the boiler and the suction point.
Page 58
5 | Assembly Ø 12 mm Ø 12 mm r Undo the screws on the suction module and remove the cover hood r Install the bottom panel including the supplied dowels and screws at any desired position in the return air line Ä...
Assembly | 5 5.9.2 Connect the suction hoses to the boiler r Dismantle the cover plate on the connections r Use hose clamps to secure suction hoses to the connections Ä Left-hand connection: Return-air line Ä Right-hand connection: Suction hose (sticker PELLETS) Ü...
5 | Assembly 5.9.3 Assembly information for hose lines < 0,5m < 0,5m R > 30cm Please note the following: ▪ Do not kink the hose lines! Minimum bending radius = 30cm ▪ Lay the hose lines as straight as possible! Sagging lines can lead to so-called “pockets”, which may cause problems with the pellet feed.
Assembly | 5 Potential equalisation NOTICE! Ensure consistent potential equalisation when connecting the hose lines! r Expose the earth wire of the hose line to approx. 8 cm Ä TIP: Slit the insulation open along the wire with a knife r Bend the earth wire inwards in a loop Ä...
5 | Assembly 5.11 Power connection and wiring 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 64
5 | Assembly 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 NOTICE! Compliance with additional information in the relevant boiler controller documentation is mandatory!
Assembly | 5 5.11.3 Potential equalisation PE1 Pellet 7-20 PE1 Pellet 25-35 PE1 Pellet Unit 7-20 r The potential equalisation on the boiler base must comply with current directives, regulations and standards. M1441624_en | Installation instructions Pellet boiler PE1 Pellet...
5 | Assembly 5.12 Final installation steps r Insert side panel into lugs (A) and attach at the top r Insert the cover at the rear and attach it with a retaining screw r Place both covers on the back r Place thermal insulation on the pump assembly M1441624_en | Installation instructions Pellet boiler PE1 Pellet...
Assembly | 5 5.12.1 Insulate the connection line When using the optionally available thermal insulation supplied by Fröling GesmbH, perform the following steps: r 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...
6 | Start-up 6 Start-up 6.1 Filling the system with drinking water When using optional boiler blocks (PE1 Pellet Unit), the system must be filled with drinking water before the first start. NOTICE Damage to the electric heating element as a result of incorrect start-up The electric heating element can be destroyed if installed (electrically isolated) in a system which is not completely filled before start-up Therefore:...
Start-up | 6 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. Take the following precautions: r Initial startup should be carried out with an authorised installer or with Froling customer services...
6 | Start-up Note on standards Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06 and/or: ENplus / DINplus certification scheme General note: Before refilling the store, check for pellet dust and clean if necessary. TIP: Fit the Froling PST pellet deduster for separating the dust particles contained in the return air 6.3.2 Non-permitted fuels...
Decommissioning | 7 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): r Clean the boiler thoroughly and close the doors fully If the boiler is to remain out of service during the winter: r Have the system completely drained by a qualified technician Ä...
Need help?
Do you have a question about the PE1 Pellet 7 and is the answer not in the manual?
Questions and answers