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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. M2270424_en | Edition 13/08/2024...
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Table of Contents 1 General ................................. 1.1 About this manual ..........................1.2 Disposal of packaging materials ......................2 Safety................................2.1 Hazard levels of warnings ........................2.2 Qualification of assembly staff ......................2.3 Personal protective equipment for assembly staff ................3 Design Information............................3.1 Overview of standards ..........................
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Table of Contents 6.1 Assembly overview ..........................40 6.2 Accessories supplied ..........................40 6.3 Installing the boiler ..........................41 6.3.1 Levelling the boiler ........................41 6.3.2 Installing the pellet suction system ..................41 6.3.3 Control the return temperature control..................43 6.3.4 Adjusting the height of the ash container.................
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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.
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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...
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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.
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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: ▪...
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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...
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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.
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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.
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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.
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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.
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Design Information | 3 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.
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3 | Design Information 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...
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Design Information | 3 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...
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3 | Design Information 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 ▪...
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Design Information | 3 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.
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3 | Design Information 3.8 Storage tank In principle it is not necessary to use a storage tank for the system to run smoothly. However we recommend that you use the system with a storage tank, as this ensures a continuous supply of fuel in the ideal output range of the boiler.
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Design Information | 3 3.9 Return temperature control As long as the hot water return is below the minimum return temperature, part of the hot water flow is added. This function is assumed by the function which increases the temperature inside the boiler. 3.10 Boiler ventilation r Fit the automatic ventilating valve at the highest point on the boiler or at the ventilation connection (if present).
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4 | Technology 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 Length of particle separator (optional) Distance between stoker and back of the boiler 1165...
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Technology | 4 Dimensi Description 100-120 130-180 Distance between flow connection and side of boiler Distance between flue gas pipe connection and side of boiler Distance from rear flue gas pipe connection to side of boiler Distance between return connection and side of boiler Distance between drainage connection and side of boiler Height, drainage connection Height of return connection...
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4 | Technology 4.2 Components and connections Item Description 100-120 140-180 Flue gas pipe connection 179 mm 199 mm Safety heat exchanger ½“ Induced draught fan Boiler flow 2“ Rear flue gas pipe connection (optional) 179 mm 199 mm Boiler return 2“...
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Technology | 4 4.3 External suction module Dimensi Description Unit Size 1 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) Connection return air line (line from boiler) M2270424_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Technology | 4 Description PT4e 160 - 180 Annual space heating emissions of gaseous organic mg/m³ < 3 < 3 < 3 compounds (GOC) Annual space heating emissions of carbon monoxide mg/m³ (CO) Annual space heating emissions of nitrogen oxides mg/m³...
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4 | Technology Description PT4e 160 - 180 ESP Fuel efficiency at rated heat output (η 86.8 86.9 86.9 Fuel efficiency at 30% of rated heat output (η 87.0 86.8 86.7 Auxiliary current consumption at rated heat output 0.211 0.213 0.215 Auxiliary current consumption at 30% of rated heat 0.052...
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Technology | 4 4.4.7 Boiler data for planning the flue gas system Description PT4e / PT4e ESP Flue gas temperature at nominal load °C Flue gas temperature at partial load - volume concentration at nominal load / partial load 12,8 / 11,8 13.3 / 12.3 13.8 / 12.8 -Volume concentration at nominal load/partial load...
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4 | Technology Description PT4e / PT4e ESP Flue gas mass flow at nominal load kg/h kg/s 0.092 0.094 0.100 Flue gas mass flow at partial load kg/h kg/s 0.029 0.029 0.031 Required feed pressure at nominal load mbar 0.05 Required feed pressure at partial load mbar 0.02...
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Transport and storage | 5 5 Transport and storage 5.1 Delivery configuration The boiler and associated components are delivered on a pallet. Item Description Unit PT4e / PT4e ESP 100-120 140-180 Length 1870 2180 Width Height 1995 2095 Centre of gravity: Length 1,020 1210...
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5 | Transport and storage 5.3 Positioning NOTICE Damage to components if handled incorrectly r Follow the transport instructions on the packaging r Transport components with care to avoid damage r Protect the packaging against damp conditions r Pay attention to the pallet's centre of gravity when lifting r Position a fork-lift or similar lifting device at the pallet and bring in the components If the boiler cannot be brought in on the pallet: r Remove the cardboard and take the boiler off the pallet...
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Transport and storage | 5 Also for PT4e 100-120: r Disconnect the plug connection (A) from the Lambda probe cable r Protect the cable from damage r Hang the crane hook on the crane eye bolts in the flue gas collection chamber and bring in the boiler 5.4 Positioning at the installation site 5.4.1 Remove boiler from pallet...
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5 | Transport and storage r Remove securing devices used during transportation on the left and right side of the boiler r Pull out floor insulation r Lift boiler from pallet When using the Fröling boiler lifting system KHV 1400: r Remove the lower cover plate on the boiler's back panel r Use the boiler lifting system to raise the boiler and pull out the palette Ä...
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Transport and storage | 5 5.4.2 Operating and maintenance areas of the equipment ▪ The system should generally be set up so that it is accessible from all sides to allow quick and easy maintenance! ▪ Regional regulations regarding necessary maintenance areas for inspecting the chimney should be observed in addition to the specified distances! ▪...
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6 | Assembly 6 Assembly 6.1 Assembly overview Hose clamp Stoker duct thermal insulation Cyclone container Stoker unit seal Rotary valve unit Floor insulation Distributor box Sylomer pads (5 pieces) temperature sensor Ash container Stoker unit Suction module cover hood Stoker unit cover plates Suction module 6.2 Accessories supplied...
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Assembly | 6 6.3 Installing the boiler 6.3.1 Levelling the boiler r Lift the boiler using an appropriate lifting device r Position a Sylomer pad under the boiler base Ä Sylomer pads prevent the transmission of noise to the ground r Carefully release the lifting device and check that the boiler is level r If necessary, level the boiler using load-bearing pads 6.3.2 Installing the pellet suction system...
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6 | Assembly r Secure the cyclone container to the rotary valve unit - 4 M8 x 16 hexagon head screws Ä When doing so, position the cut-out (A) above the housing (B) of the rotary valve r Remove the cover from the distributor box - 4 lens-head screw M6 x 20 incl.
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Assembly | 6 6.3.3 Control the return temperature control r Remove both back panels r Tighten all of the connections on the return temperature control using a pipe wrench Ä Connections may have loosened during transport. Ä IMPORTANT: Before and after filling the system with heated water, check the seal of the screw connections on the return temperature control Return temperature control left r Set the knob on the housing of the mixing drive to manual mode (A)
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6 | Assembly Return temperature control right r Set the knob on the housing of the mixing drive to manual mode (A) r Turn the mixing drive clockwise until it stops Ä The mixer valve completely closes off the system return r Turn the mixing drive counter clockwise until it stops Ä...
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Assembly | 6 6.3.4 Adjusting the height of the ash container r Pull out the spring cotter on the transport wheels and adjust the height Ä If the ash container is mounted, the wheels rest on the ground r Remove the ash container from the boiler and level it using the adjustable foot 6.3.5 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.
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6 | 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...
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Assembly | 6 6.3.6 Fit the suction hoses to the boiler r 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.
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6 | Assembly 6.3.7 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.
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Assembly | 6 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...
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6 | Assembly 6.4 Hydraulic connection PT4e 140-180: Thermal discharge valve ▪ The thermal discharge safety device must be connected in accordance with ÖNORM/ DIN EN 303-5 and as shown in the diagram above ▪ The discharge safety sensor must be connected to a pressurised cold water mains supply (temperature ≤...
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Assembly | 6 6.5 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...
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6 | Assembly 6.5.1 Board overview PT4e 100-180 Item Description Item Description Main switch Core module High-limit thermostat (STL) Wood chip module Service interface Plug power pack Device connection terminal Digital module (address 1) Hydraulic module Feed system module in the back panel (address M2270424_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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Assembly | 6 Distributor box PT4e 100-180 Item Description Item Description Digital module (address 3) Mains filter Relay Terminal blocks Line protective circuit breaker External feed system module in the wall-mounted cabinet (if using pellet suction screw with change-over) F1 (17) F2 (18) F3 (19) F4 (20)
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6 | Assembly 6.5.2 Lay the cable to the boiler controller r Remove the cover and thermal insulation Ä PT4e 100-120: one cover Ä PT4e 140-180: two covers r Undo the retaining screw and contact washer on the back of the controller cover r Slide the controller cover back and lift off If a pellet suction screw is fitted...
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Assembly | 6 6.5.3 Connect the suction unit components Some components are connected using double deck terminal blocks located inside the suction unit's distributor box. These double deck terminal blocks consist of two separate decks in which the centre connections (1) and the outer connections (2) are connected to each other.
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6 | Assembly Connect the fill level sensors 7 9 11 13 15 17 19 2 PE 4 PE 6 PE 8 10 12 14 16 18 PE 7 ... brown 10 ... brown 8 ... white 11 ... white 9 ...
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Assembly | 6 Connecting the geared motor of the stoker screw Wood chip module r Connect the supply cable for the geared motor of the stoker screw to the wood chip module in the boiler controller Ä Connecting cable 4 x 1.5 mm² with earth conductor Connecting the geared motor of the double rotary valve Wood chip module r Connect the supply cable for the geared motor of the double rotary valve to the wood...
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6 | Assembly Establish bus connection Digital module Hydraulic module r Use a vacant port to establish a bus connection from the digital module inside the distributor box to the hydraulic module inside the boiler control Ä Patch cable CAT 5 RJ45 SFTP 1:1 configuration Check the digital module Digital module r Set the module address of the digital module inside the distributor box to “3”...
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Assembly | 6 6.5.4 Connect an individual discharge systems Depending on the conditions of the fuel store, the following pellet discharge systems can be connected: ▪ Bag silo, Cube RS 4 manual or individual probe ▪ Pellet mole ▪ Pellet suction screw ▪...
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6 | Assembly Pellet mole 7 9 11 13 15 17 19 2 PE 4 PE 6 PE 8 10 12 14 16 18 PE 5 ..L 6 ..N PE ... PE r Establish the power supply line from the distributor box to the plug connection or the mole junction box Ä...
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6 | Assembly 6.5.5 Connect multiple discharge systems with change-over units When using the 1-2-3 suction module, up to three discharge systems of the same boiler can be used: ▪ Bag silo, Cube, RS 4 manual or individual probe ▪ Pellet mole ▪...
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Assembly | 6 Additional information for bag silos with shakers 11 13 15 17 19 21 23 25 27 8 10 PE 12 14 PE 16 18 PE 20 22 24 26 8 ..L 12 ..L 16 ..L Shaker 3 10 ..
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6 | Assembly Pellet mole with change-over 7 9 11 13 15 17 2 PE 4 PE 6 PE 8 10 12 14 16 18 PE 13 ... SL Zu 14 ... SL Auf 15 ... PL Zu 16 ... PL Auf 17 ...
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Assembly | 6 Pellet suction screw with change-over feature NOTICE! For the electrical wiring of the components an additional discharge module is required. Perform the following steps on the feed system module: ▪ Establish BUS connection to boiler ▪ Establish 24V connection to boiler ▪...
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6 | Assembly 7 9 11 13 15 17 2 PE 4 PE 6 PE 8 10 12 14 16 18 PE 13 ... SL Zu 14 ... SL Auf 15 ... PL Zu 16 ... PL Auf 17 ... GND r Establish a connection line from the distributor box to the circuit board on the suction module Ä...
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Assembly | 6 F2 (18) F3 (19) F4 (20) Feed system module F5 (21) F6 (22) Geared motor 1 r Connect the geared motor for the pellet suction screw 1 to the feed system module (address 0) inside the back panel of the boiler Ä...
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6 | Assembly RS 4 / RS 8 pellet suction system with change-over 7 9 11 13 15 17 2 PE 4 PE 6 PE 8 10 12 14 16 18 PE 13 ... SL Zu 14 ... SL Auf 15 ...
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6 | Assembly 6.5.6 Attach the mains connection to the boiler r Press the mains plug on the back of he boiler to release and remove it r Open the plug and connect the mains connection cable Ä Flexible sheathed cable must be used for the wiring; this must be of the correct size to comply with applicable regional standards and regulations.
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Assembly | 6 6.6 Final installation steps r Check that the cables are correctly laid Ä Ensure that the cables do not touch the hot boiler components r Install the cover of the cable duct - 2 lens-head screws M6 x 12 r Install the cover plates to the side panel of the boiler - 8 lens-head screw M4 x 8 r Place the controller cover on the controller box and fix it...
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6 | Assembly r Slide the floor insulation under the boiler until it stops r Slide the ash container on to the ash duct of the boiler r Push the key plate (A) into the safety limit switch r Push the locking lever (B) down and close the insulated door (C) 6.6.1 Insulate the connection line When using the optionally available thermal insulation supplied by Fröling GesmbH, perform the following steps:...
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Assembly | 6 6.6.2 Install the brackets for accessories r Using appropriate fasteners, attach the brackets to the wall on the boiler r Attach the accessories to the brackets 6.6.3 Affixing the identification plate r Glue the supplied identification plate (A) and additional identification plate (B - for electrostatic particle separator) visibly to the right-hand side panel of the boiler M2270424_en | Installation instructions Pellet boiler PT4e 100-180 (ESP)
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7 | Start-up 7 Start-up 7.1 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...
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Start-up | 7 7.2 Initial startup 7.2.1 Permitted fuels Wood pellets Wood pellets made from natural wood with a diameter of 6 mm Note on standards Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06 and/or: ENplus / DINplus certification scheme General note:...
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8 | Decommissioning 8 Decommissioning 8.1 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...
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