Froling P4 Pellet 8-60 Assembly Instructions Manual
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Assembly instructions
P4 Pellet 8 - 60
Read and follow the assembly instructions and safety information
Subject to technical change.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen
Tel. +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 info@froeling.com www.froeling.com
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Summary of Contents for Froling P4 Pellet 8-60
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Page 1: Assembly Instructions
Assembly instructions P4 Pellet 8 - 60 Read and follow the assembly instructions and safety information Subject to technical change. Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Tel. +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 info@froeling.com www.froeling.com... -
Page 3: Guarantee Conditions
Introduction Dear installer, The FRÖLING P4 Pellet is a state-of-the-art design that conforms to all currently applicable standards and testing guidelines. Please read and follow the assembly instructions. They contain safety instructions as well as comprehensive information about transporting, setting up and assembling the boiler. The constant further development of our products means that there may be minor differences from the pictures and content. -
Page 4: Table Of Contents
Contents 1 General information 1.1 Notes on standards 1.2 Design Information 1.2.1 Approvals and reporting obligations ..............7 1.2.2 Requirements for hot water supplies ..............7 1.2.3 Ventilation of boiler room .................. 8 1.2.4 Installing the heating system / Standards ............8 1.2.5 Combination with storage tank ................ -
Page 5: Initial Startup
Contents 4 Initial startup 4.1 Configuring the boiler 4.2 Setting “Max Level” sensor 5 Appendix 5.1 Delivery Certificate 5.2 Notes Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Page 5 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 info@froeling.com www.froeling.com M0930408_en... -
Page 6: General Information
General Standards, Design, Assembly 1 General information C A U T I O N Assembly and installation by untrained personnel. Danger: Personal injury and damage to property. The instructions and information provided in the instructions should be observed! Only allow trained staff (heating installers or licensed electricians) to perform set-up and installation! 1.1 Notes on standards The boiler must be installed and started up in compliance with local fire... -
Page 7: Design Information
General Standards, Design, Assembly 1.2 Design Information It is forbidden to carry out modifications to the boiler or to change or deactivate safety equipment. In addition to the operating instructions and the applicable regulations for the country in which the boiler will be operated for installation and operation of the boiler system, all fire, police, and electrical regulations must be observed. -
Page 8: Ventilation Of Boiler Room
General Standards, Design, Assembly 1.2.3 Ventilation of boiler room The openings for the supply air and the exhaust air should be arranged as nearly opposite each other as possible to achieve a good thermal draught effect. The supply air must be drawn in directly from outside. The exhaust air must be discharged directly outside. -
Page 9: Chimney Connection / Chimney System
General Standards, Design, Assembly 1.2.6 Chimney connection / chimney system EN 303-5 specifies that the entire flue gas system must be designed to prevent, wherever possible, damage caused by seepage, insufficient feed pressure and condensation. It should be noted here that flue gas temperatures of less than 160 K above room temperature can occur within the permitted operating range of the boiler. -
Page 10: Installation Information
General Standards, Design, Assembly 1.3 Installation Information Water lines should not be located in close proximity to the storage area or the feeder units due to the dangers posed by condensation and bursting water pipes! Check the delivered items for foreign objects in the individual components. -
Page 11: Potential Equalisation
General Standards, Design, Assembly Potential equalisation When connecting the hose lines to the individual connection pipes, ensure there is potential equalization throughout the line! Expose approximately 3 cm of the earth conductor at the end of the hose line TIP: Slit the insulation open along the wire with a knife Bend the earth wire inwards in a loop This prevents the earth wire from being damaged by the feed of pellets. -
Page 12: Technology
Technology Components, Connections, and Dimensions 2 Technology 2.1 Components and connections P4 Pellet Pos. Component Unit 8 / 15 20 / 25 32 / 38 48/60 Boiler outfeed connection Boiler return feed connection Inch Drain Air vent Pellet suction line DA 60 DA 60 DA 60... -
Page 13: Dimensions
Technology Components, Connections, and Dimensions 2.2 Dimensions P4 Pellet Dimensions Component Unit 8 / 15 20 / 25 32 / 38 48 / 60 Length, boiler Total length inc. induced draught fan 1110 Width, boiler Width, boiler, inc. support for 1100 positioning unit Total width, inc. -
Page 14: Technical Specifications
Technology Technical specifications 2.3 Technical specifications 2.3.1 P4 Pellet 8/15/20/25 P4 Pellet Component Unit Rated heat output 10,5 14,9 20,0 25,0 Heating efficiency range 3,1-10,5 3,1-14,9 6,0-20,0 7,5-25,0 Mains connection 230V / 50Hz fused 16A Output Weight of boiler Boiler capacity (water) Upstream resistance (ΔT=20°C) mbar Minimum return feed temperature... -
Page 15: P4 Pellet 32/38/48/60
Technology Components, Connections, and Dimensions 2.3.2 P4 Pellet 32/38/48/60 P4 Pellet Component Unit Rated heat output 32,0 38,0 48,0 58,5 Heating efficiency range 8,9-32,0 8,9-38,0 14,4-48 17,3-58,5 Mains connection 230V / 50Hz fused 16A Output Weight of boiler Boiler capacity (water) Upstream resistance (ΔT=20°C) mbar Minimum return feed temperature... -
Page 16: Assembly
Installation Transport and Assembly 3 Assembly 3.1 Transport The boiler is delivered packed in cardboard and on a pallet. Move the boiler without jarring or jolting Observe the transport information on the packaging. Consider centre of mass! The boiler is marked with a sticker on the opposite of the side to lift 3.1.1 Positioning Position a fork-lift or similar lifting device at the pallet and position... -
Page 17: Setting Up In The Boiler Room
Installation Transport and Assembly 3.2 Setting up in the boiler room 3.2.1 Remove boiler from pallet At the front of the boiler: Open insulation door Pull out floor insulation Remove protective transport materials on the left and right in the recess TIP: For transport in the boiler room remove the insulating door. -
Page 18: Minimum Distances In The Boiler Room
Installation Transport and Assembly 3.2.3 Minimum distances in the boiler room P4 Pellet Dimensions Component Unit 8/15 20/25 32/38 48/60 Minimum distance between suction cyclone and wall Maintenance range for ID fan Space for insulated door Minimum distance from side of boiler to wall Page 18 M0930408_en... -
Page 19: Assembling The Pellet Boiler
Installation Assembling the Pellet Boiler 3.3 Assembling the Pellet Boiler 3.3.1 Removing the suction cyclone Remove sound insulation cover Open the clamps on the suction unit container and lift the cover The induced draught unit set is in the suction unit container 3.3.2 Fitting the induced draught fan Remove pre-installed cover plate Unscrew pre-installed nuts and... -
Page 20: Install Delivery System
Installation Install delivery system 3.4 Install delivery system 3.4.1 Universal suction system Variant 2 - Eco pellet box Variant 1 - Komfort pellet box 25 m Suction hose Manual re-arranging unit (Variant 2) Hose clamps 50-65 mm 2 Blind plates (Variant 2) 2 Fire protection choke collar 6 Star-shaped handle (Variant 2) (only in Austria) -
Page 21: Variant 1 - Comfort Pellet Box
Installation Install delivery system Variant 1 - Comfort pellet box Position Comfort pellet box (D) at hole in the wall For maintenance purposes, the distance to the wall 10 cm on the board side of the pellet box should be at least 10 cm. -
Page 22: Variant 2 - Eco Pellet Box
Installation Install delivery system Variant 2 - Eco pellet box Place the wall installation module (F) by the hole in the wall Secure the insertion module to the wall using four M8x50 frame screws and 10 mm dowels Pack the space in the hole in the wall with a non- flammable material The partition must be insulated to conform with ÖNORM B 3836 or DIN 4102-11! -
Page 23: Installing The Suction Probes And Lines
Installation Install delivery system Installing the suction probes and lines Position the suction probes (K) at equal distances in the pellet supply bin Secure the suction probes to the bottom using frame screws Fix hose lines (A)to the suction probe using hose clips (B) Lay the hose lines to the pellet box and secure them using hose clips... -
Page 24: Suction Screw System
Installation Install delivery system 3.4.2 Suction screw system Flange bearing Gearbox flange Ejector flange Drive flange seal Trough mount with rubber pad Geared motor Bearing flange 2 Cover plates for wall penetration Open trough Main worm Suction intake with integrated support Shaft end for main worm Proximity switch Worm extension (if needed) - Page 25 Installation Install delivery system Thread the main screw (H1) into the hole The keyway must point towards the boiler! Thread the closed trough (J) on to the main worm on the storage area side The rectangular flange points away from the storage area! Thread the open trough (I) on to the main worm...
- Page 26 Installation Install delivery system Secure the bearing flange (D) and the trough mount (C) to the trough using four M10 x 40 mm bolts and nuts - 17 mm hexagonal nut Place the flange bearing unit (A) and the ejecting flange (B) on the shaft and secure them to the bearing flange using two M14 x 35 mm hexagonal screws and spacer washers...
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Page 27: Bag Silo System
Installation Install delivery system Lay the hose lines to the boiler, through identified openings at the back plate and install with hose clamps to the identified connections Suction line: hose line to left connection (1) on the back of the boiler Return-air line: hose line to right connection (2) on the back of the boiler WARNING! When connecting the hose lines,... - Page 28 Installation Install delivery system Mount bag silo as it is described in the delivered assembly instructions Thread flange ring (1) onto bag silo Fit bag silo and flange ring onto the bolts on the suction probe and screw it together. Thread one fire protection choke collar each (B) on to the suction and return-air lines Fire protection choke collars only in...
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Page 29: Pellet Storage Area
Installation Install delivery system 3.4.4 Pellet storage area For the universal suction system, the pellet store must be built with an inclined floor! The following picture shows the most important components: 2 Filler pipes Earth wire Planking on the storage area door Sloping floor Impact cushion Under-floor structure for sloping floor... -
Page 30: Sloping Floor
Installation Install delivery system Sloping floor Fig.1: Store for a delivery unit with a suction probe Fig.2: Store for a delivery unit with a screw The under-floor structure should be dimensioned so that the sloping floor is not deformed when subjected to static load. You should ensure that the pellets can slide down smoothly. -
Page 31: Electrical Connection
Installation Connect pellet boiler 3.5 Electrical Connection R I S K Working on electrical components. Danger: Serious injuries from electric shocks. Work on electrical components should only be carried out by authorised technicians Flexible sheath conductors should be used for the wiring which should be measured in compliance with the applicable regional standards and guidelines The supply line (mains connection) must be fitted with a max. -
Page 32: Connecting The Comfort Pellet Box
Installation Connect pellet boiler 3.5.1 Connecting the Comfort pellet box The connection of the Comfort pellet box to the pellet module board is established using a flexible cable (5x0.75mm², e.g. YMM as per ÖVE- K41-5 or H05VV-F as per DIN VDE 0281-5). This is a 24V control line. -
Page 33: Initial Startup
Initial startup 4 Initial startup 4.1 Configuring the boiler The boiler must be configured to the heating system on initial start-up. N O T E Optimum efficiency and consequently efficient operation with low emissions can only be guaranteed if the system is adjusted by qualified technicians and the specified factory settings are observed. -
Page 34: Appendix
Appendix Delivery Certificate 5 Appendix 5.1 Delivery Certificate Customer no.: Customer address: Installer: Telephone number: P4 Pellet: P4 Pellet 8 P4 Pellet 32 P4 Pellet 15 P4 Pellet 38 P4 Pellet 20 P4 Pellet 48 P4 Pellet 25 P4 Pellet 60 Serial number Delivery system: Bag silo system... -
Page 35: Notes
Appendix Notes 5.2 Notes Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Page 35 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 info@froeling.com www.froeling.com M0930408_en...
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