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Fröling PT4e 200 Installation Instructions Manual
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Fröling PT4e 200 Installation Instructions Manual

Fröling PT4e 200 Installation Instructions Manual

Pellet boiler
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Installation instructions
Pellet boiler PT4e 200-350 (ESP)
Translation of original German version of installation instructions for technicians.
Read and follow all instructions and safety instructions.
All errors and omissions excepted.
M2280424_en | Edition 13/08/2024

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Summary of Contents for Fröling PT4e 200

  • Page 1 Installation instructions Pellet boiler PT4e 200-350 (ESP) Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M2280424_en | Edition 13/08/2024...
  • Page 2 4.1 Dimensions PT4e 200-250 (electrostatic particle separator) ..............19 4.2 Dimensions PT4e 300-350 (electrostatic particle separator) ..............21 4.3 Components and connections PT4e 200-250 (electrostatic particle separator) ........23 4.4 Components and connections PT4e 300-350 (electrostatic particle separator) ........24 4.5 External suction module........................
  • Page 3 Levelling the boiler ........................41 6.3.2 Installing the pellet suction system ..................41 6.3.3 Checking the return temperature control (PT4e 200-250) ............43 6.3.4 Checking the return temperature control (PT4e 300-350) ............44 6.3.5 Align the ash container ......................44 6.3.6...
  • Page 4 1.1 About this manual These installation instructions contain information for the following boiler sizes of PT4e / PT4e ESP: 200, 230, 250, 300, 350; M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 5 Identification code / Material Disposal information Corrugated cardboard Paper collection Wood Check the regulations for correct disposal applicable in your local area Low Density Plastics collection Polyethylene (LDPE) LDPE Expanded polystyrene Plastics collection M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 6 The dangerous situation may occur and if measures are not observed it will lead to minor injuries. NOTICE The dangerous situation may occur and if measures are not observed it will lead to damage to property or pollution. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 7 You must ensure that staff have the protective equipment specified by accident prevention regulations! ▪ During transport, erection and installation: - wear suitable work wear - wear protective gloves - wear safety shoes (min. protection class S1P) M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 8 Water quality for heating, steam, cooling and air conditioning systems (Switzerland) UNI 8065 Technical standard regulating hot water preparation. DM 26.06.2015 (Ministerial Decree specifying the minimum requirements) Follow the instructions of this standard and any related updates. (Italy) M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 9 ▪ The system must be protected against gnawing and nesting by animals (such as rodents) ▪ No flammable materials in proximity to the system ▪ Observe national and regional regulations regarding the installation of smoke detectors and carbon monoxide detectors M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 10 Please note within the permissible operating range of the boiler flue gas temperatures lower than 160K above room temperature may occur. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 11 ▪ 1.5 x nominal diameter of connection line for radiation shield with rear ventilation, but at least 200 mm (NM) NOTICE! The minimum distances must be observed in accordance with the standards and guidelines applicable in the region M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 12 TRVB H 118 (only Austria) stipulates that an explosion flap must be installed in the connection line to the chimney, directly next to the boiler. It should be situated in such a way that is poses no risk to persons! M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 13 Boiler in room air-dependent operation Air extraction system (such as centralised dust extraction system, room ventilation) Under-pressure monitoring system Combustion air supply from outside M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 14 The installation site must have a minimum volume in accordance with the applicable regional standards. Note on standards Austria: OIB Guideline 3 - Hygiene, health and environmental protection Germany: Model Firing Ordinance (MFeuV) M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 15 1. For calculating the specific system volume, the smallest individual heating capacity is to be used for systems with several heat generators. 2. In systems with several heat generators with different specific water contents, the smallest specific water content is decisive in each case. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 16 (TIP: system separation) ▪ Check the antifreeze dosage regularly according to the manufacturer's instructions ▪ Dispose of frost-protected heat transfer medium at the end of its shelf life and refill the system M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 17 These systems offer no oxygen removal for the purposes of corrosion control as required by VDI 2035 and in the interests of corrosion protection should not be used. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 18 Fit a microbubble separator in the pipes to the boiler Recommendation: Ä Follow the manufacturer's instructions! M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 19 Width of particle separator (optional) Width, boiler 1060 Width of stoker unit Total width, including stoker unit 1800 Total height incl. flue gas nozzle 2025 Boiler height 1950 Height of hose line connection 1,805 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 20 Height, safety heat exchanger connection 1755 Height of rear flue gas pipe connection 1350 Distance between safety heat exchanger connections Height, drainage connection Height of return connection 1320 Height, flow connection 1770 1. optional M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 21 Total height incl. flue gas nozzle 1980 Height of hose line connection 1,805 Height, connection to safety heat exchanger 1740 1. Safety heat exchanger on the side facing away from the stoker M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 22 Distance between flue gas pipe connection and side of boiler Distance between drainage connection and side of boiler 1060 Height of connection for flow 1790 Height of return connection 1390 Height, drainage connection Height, flue pipe connection 1420 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 23 Mixing valve for the return temperature control Pump for the return temperature control Line regulating valve Drainage 1“ Ash container 160 Litres Suction hose connection (PELLETS sticker) 50 mm Return-air line connection 50 mm M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 24 Primary air actuator for flue gas recirculation Line regulating valve Drive for ash removal Drainage 1“ Ash container 160 Litres Suction hose connection (PELLETS sticker) 50 mm Return-air line connection 50 mm M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 25 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) M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 26 Auxiliary current consumption in standby mode (P 0.013 0.013 0.013 Temperature controller used Lambdatronic H 3200 Class of the temperature controller Contribution of the temperature controller to the energy efficiency index of a combined system M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 27 Heating up mode automatic Condensing boiler Solid fuel boiler for combined heat and power Combined heating system Ü "Storage tank" [} 18] Storage tank volume Preferred fuel Compressed wood in the form of pellets M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 28 Test book number PB 225 PB 226 1. equivalent to approx. 110 kg of pellets with a bulk density of 650 kg/m³ 2. Pump output less water resistance in the boiler M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 29 4.6.4 PT4e 300-350 electrostatic particle separator Description PT4e 300–350 electrostatic particle separator Nominal output range 90 – 300 103.2 - 344 Boiler efficiency (NCV) at nominal load/partial load 93.9 / 93.8 94.3 / 93.9 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 30 Annual space heating emissions of dust (PM) mg/m³ Annual space heating emissions of gaseous organic mg/m³ < 3 < 3 compounds (GOC) Annual space heating emissions of carbon monoxide mg/m³ (CO) M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 31 1. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 32 Continuous output (three phase) 6375 Nominal voltage 400 ± 6% Frequency 50 ± 2% At output 300-350 kW: Description Value Continuous output (three phase) 9960 Nominal voltage 400 ± 6% Frequency 50 ± 2% M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 33 If the system is to be assembled at a later stage: r Store components at a protected location, which is dry and free from dust Ä Damp conditions and frost can damage components, particularly electric ones! M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 34 Ä 200-250 kW: two insulating covers Ä 300-350 kW: three insulating covers r Loosen the screw connection on the front heat exchanger cover and open the cover Ä Use the spanner provided M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 35 NOTICE! Only take those steps absolutely necessary to bring in the boiler. r Remove the insulated cover above the heat exchanger Ä 200-250 kW: two insulating covers Ä 300-350 kW: three insulating covers r Undo both screws and remove controller cover M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 36 Ä Cables can remain in the cable duct on the side panel r Remove the ignition unit including glow igniter beside stoker r Undo the screws and remove the side panels M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 37 1980 NOTICE! Assemble all components in reverse order. Connect the glow igniter plug on the wood chip module to the “ELECTRICAL IGNITION” position and the stoker drive to the “STOKER SCREW” position. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 38 5.5.1 Remove cardboard and transport frame r Remove strapping and lift off the cardboard r Remove transport frame from front and back r Remove the sides of the transport frame from the boiler base M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 39 (ÖNORM H 5190 - Noise protection measures) PT4e 200-250 PT4e 300-350 900 mm 300 mm 300 mm 500 mm 150 mm 300 mm 500 mm 300 mm 1. Maintenance area to expand the WOS springs upwards M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 40 Suction module cover hood Stoker duct cover Suction module 6.2 Accessories supplied Furnace tool with bracket Key for door mountings and WOS cover Socket wrench AF 13 Cleaning brush 24 x 50 x 1200 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 41 Position a Sylomer pad under each adjustable foot and align the stoker unit so that it is horizontal r Mount the rotary valve unit onto the stoker unit as illustrated - 4 hexagonal screws M8 x 20 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 42 Position the thermal insulation panels on the flange of the stoker as shown r Position the thermal insulation panels on the stoker as shown r Wrap thermal insulation around the stoker duct M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 43 Ä Screw 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 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 44 Slide the ash container onto the boiler and attach using clamping lever r Loosen the screw connection and adjust castors to the ground r Horizontally align the ash container and attach the screw connection r Remove the ash container and spacer plate M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 45 Pull off the seal on the affected duct r Slide spacer plate and seal back onto the duct r Slide the ash container onto the boiler and check the pressure again M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 46 Ä 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 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 47 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. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 48 ▪ The return-air line can be made up of several sections, but consistent potential equalisation must be established throughout the line. ▪ For systems over 35 kW, only hose lines with PU inlet are recommended due to the increased load M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 49 Remove paint from the affected area if necessary Ä 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 lubrication grease!) M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 50 DN15 (≤ 50 kW), DN20 (> 50 to ≤ 100 kW), DN25 (> 100 to ≤ 200 kW), DN32 (> 200 to ≤ 300 kW), DN40 (> 300 to ≤ 600 kW), DN50 (> 600 to ≤ 900 kW) M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 51 As soon as the system has reached the specified working pressure, the system is unlocked by activating the reset button manually. NOTICE! Omitted if a water shortage safety device (9) is integrated in the installation M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 52 Flexible sheathed cable must be used for the wiring; this must be of the correct size to comply with applicable regional standards and regulations Ä YMM to ÖVE-K41-5 or H05VV-F to DIN VDE 0881-5 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 53 Digital module (address 1) Main switch Plug power pack Mains connection plug Terminal blocks Core module Feed system module (address 0) Return mixer module (not used) Wood chip module Hydraulic module M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 54 Item Description High-limit thermostat (STL) Digital module Main switch Core module Wood chip module Line protective circuit breaker, 3-pole Feed system module Analogue module Plug power pack Terminal blocks Hydraulic module M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 55 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) F5 (21) F6 (22) Item Description Item Description Feed system module (address 1) Power supply plug Main switch M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 56 Ensure that the cables do not touch the hot boiler components Ä Compliance with the warning sign is mandatory, Ü "Electrical connection" [} 52] Ä Do not install cable across sharp edges M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 57 3 ..L 4 ..N PE ... PE r Connect the suction turbine's power supply line inside he distributor box Ä Connecting cable 3 x 1.5 mm² with earth conductor M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 58 Connect the temperature sensor of the stoker monitoring unit KM-17 Kernmodul Core module r Connect the temperature sensor of the stoker monitoring unit at the core module in the boiler controller M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 59 F6 (22) r Connect the supply cable for the geared motor of the double rotary valve to the feed system module Ä Connecting cable 4 x 1.5 mm² with earth conductor M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 60 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” M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 61 Connect the power supply line from the distributor box to the socket of the extension cable and onto the shaker Ä Connecting cable 3 x 1.5 mm² with earth conductor M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 62 Connect the geared motor of the pellet suction screw to the boiler controller. The connection can be found on the feed system module Ä Connecting cable 4 x 1.5 mm² with earth conductor, max. 0.75kW / 400V M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 63 Establish a connection line for the position control from the distributor box to the 3-pin plug of the change-over unit Ä Connecting cable 3 x 0.75 mm² without earth conductor M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 64 Establish a connection line from the distributor box to the circuit board on the suction module Ä Connecting cable 5 x 0.75 mm² without earth conductor r Set the direction of rotation of the servo-motor to right (R) M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 65 5 (X1) => 2 (X2) 6 (X1) => 3 (X2) r Create a connection line for the enabling signal from terminal block X1 to X2. Ä Connecting cable 2 x 1.5 mm² without earth conductor M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 66 5 (X1) => 2 (X2) 6 (X1) => 3 (X2) r Create a connection line for the enabling signal from terminal block X1 to X2. Ä Connecting cable 2 x 1.5 mm² without earth conductor M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 67 Feed system module Address “1” Suction system 03 Sensor 2 Output 2 Sensor 1 Output 1 Suction system 02 Feed system module address “0" Suction system 01 Sensor 1 Output 1 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 68 Connect the sensors of the pellet suction screws 2 and 3, which are located on the feed system module (address 1), inside the wall-mounted cabinet Ä Connecting cable 3 x 0.75 mm² without earth conductor M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 69 Connect the geared motor for the pellet suction screws 2 and 3, which are located on the feed system module (address 1), inside the wall-mounted cabinet Ä Connecting cable 4 x 1.5 mm² with earth conductor, max. 0.75kW / 400V M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 70 Ä Connecting cable 4 x 0.75 mm² with earth conductor, max. 0.15kW / 230V Ä Connecting cable 3 x 0.75 mm² without earth conductor, screened if longer than 25 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 71 Attach the connection line for the positio control from the distributor box to the 3-pin plug of the change-over unit Ä Connecting cable 3 x 0.75 mm² without earth conductor M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 72 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. Ä The power supply line (mains connection) must be fitted with a C25A fuse by the customer. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 73 Fit the covers to the side panel of the boiler and secure them - 4x M4 x 10 raised-head screws r Place the controller cover on the controller box and slide forward r Attach the controller cover with retaining screw and contact washers M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 74 Slide the ash container onto the ash duct and secure with the locking lever (A) r Slide the key plate (B) into the safety limit switch and close both insulated doors M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 75 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 6.6.2 Install the brackets for accessories M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 76 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 M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 77 Check that the drives and servo motors are working and turning in the right direction r Check safety switch of ash box is working correctly NOTICE! Check the digital and analogue inputs and outputs - See the instruction manual for the boiler controller. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 78 Using non-standard fuels can also lead to serious problems with combustion! For this reason, when operating the boiler: r Use only the permitted fuels M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 79 (e.g. AWG in Austria) r You can separate and clean recyclable materials and send them to a recycling centre. r The combustion chamber must be disposed of as builders' waste. M2280424_en | Installation instructions Pellet boiler PT4e 200-350 (ESP)
  • Page 80 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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