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Operating Instructions
P4 Pellet 8 - 60
Read and follow the operating instructions and safety information.
Subject to technical change.
July 2009
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: Operating Instructions
Operating Instructions P4 Pellet 8 - 60 Read and follow the operating instructions and safety information. Subject to technical change. July 2009 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 Introduction Dear customer, Congratulations on choosing a quality product from FRÖLING. The FRÖLING P4 Pellet features a state-of-the-art design that conforms to all currently applicable standards and testing guidelines. Please read and observe the operating instructions and always keep them close to the boiler for reference. Observing the requirements and safety information in the instruction manual makes a significant contribution to safe, appropriate, environmentally friendly and economical operation of the system.
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Page 4: Table Of Contents
Contents 1 Product Overview 2 Safety 2.1 Safety Information 2.2 Permitted Uses 2.2.1 Permitted fuel ....................9 2.2.2 Non-permitted fuels ..................9 2.2.3 Who may operate the boiler? ................9 2.3 Design Information 2.3.1 Approvals and reporting obligations ..............10 2.3.2 Requirements for hot water supplies .............. - Page 5 Contents Clean WOS....................25 Cleaning the induced draught ventilator ............25 Clean the smoke flue pipe ................25 Checking the draught controller flap and explosion flap ........25 Clean the flue gas sensors................26 4.3 Testing Emissions 4.3.1 Measurement at rated load ................26 4.4 Maintenance agreement / Customer service 4.5 Replacement parts 5 Troubleshooting...
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Page 6: Product Overview
Product Overview 1 Product Overview Ash drawer module (P4 Pellet 8/15/20/25): Ash drawer module (P4 Pellet 32/38/48/60): Below the insulating cover: Page 6 B0430408_en... - Page 7 Product Overview Component P4 Pellet with integrated Pellets cyclone container Lambdatronic P 3100 control system Navigation keys to move around in the menus and to change the parameter values Status LED (operating status): - slow green flashing light: boiler activated - fast green flashing light: boiler deactivated - flashing red light: malfunction Large graphical display to show operating statuses and parameters...
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Page 8: Safety
Safety Safety Information 2 Safety 2.1 Safety Information R I S K Non-permitted use! Incorrect use of the boiler can cause severe injuries and damage! The instructions and information provided in the instructions should be observed! Details on procedure for operation, maintenance and cleaning, as well as troubleshooting for the boiler are included in the individual instructions. -
Page 9: Permitted Uses
Safety Permitted Uses 2.2 Permitted Uses The boiler should only be operated when it is in full working order. It should be operated in accordance with the instructions, observing safety precautions, and you should ensure you are aware of the potential hazards. -
Page 10: Design Information
Safety Design Information 2.3 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 11: Ventilation Of Boiler Room
Safety Design Information 2.3.3 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 12: Chimney Connection / Chimney System
Safety Design Information 2.3.6 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 13: Safety Devices
Safety Safety Devices 2.4 Safety Devices Key for automatic mode In case of overheating of the boiler: Press and hold the key for 5 seconds Automatic mode is switched off Control follows the boiler shutdown procedure The pumps continue to run! Safety temperature limiter Switches off the blower fan at the maximum boiler temperature of (STL) -
Page 14: Safety Instructions For The Installation Room
Safety Safety Devices 2.5 Safety instructions for the installation room 1) Danger of fire due to flammable materials. No flammable materials should be stored near the boiler. 2) Damage due to impurities in combustion air. Do not use any hydrogen halides or any cleaning agents containing chlorine in the room where the boiler is installed. -
Page 15: Residual Risks
Safety Residual risks 2.6 Residual risks W A R N I N G Do not touch the hot surface! Hot parts and the flue pipe can cause serious burns! Protective gloves should generally be worn when working on the boiler. Only operate the boiler using the handles provided for this purpose. -
Page 16: Emergency Procedure
Safety Emergency procedure 2.7 Emergency procedure 2.7.1 Overheating of the system If the system overheats in spite of the safety devices, proceed as follows: Keep all the doors on the boiler closed. Turn off the boiler by pressing the key for 5 seconds Open all mixer taps, switch on all pumps. -
Page 17: Operating The System
Operating the system Commissioning 3 Operating the system 3.1 Initial startup N O T E Optimum efficiency and efficient, low-emission operation can only be guaranteed if the system is set up by trained professionals and observing the standard factory settings. Take the following precautions: Initial startup should be carried out with an authorised installer or with Fröling customer services. -
Page 18: Heating Up The Boiler
Operating the system Heating up the boiler 3.3 Heating up the boiler N O T E Changing the factory settings for primary and secondary air can have a negative effect on efficiency and emissions of the system. 3.3.1 Switching on the boiler Press the Automatic mode The heating system is controlled via the control system according... -
Page 19: Boiler Servicing
Boiler servicing Inspection, cleaning and maintenance 4 Boiler servicing 4.1 General information on servicing 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 W A R N I N G Do not carry out maintenance when the boiler is hot! Hot parts and the flue pipe can cause serious burns! -
Page 20: Inspection, Cleaning And Maintenance
Boiler servicing Inspection, cleaning and maintenance 4.2 Inspection, cleaning and maintenance Regular cleaning of the boiler extends its life and is a basic requirement for smooth running. So clean the boiler regularly! Recommended: When cleaning, use an ash vacuum. 4.2.1 Inspection Check safety valve Check the boiler regularly for dirt: Check the safety valve regularly... -
Page 21: Cleaning
Boiler servicing Inspection, cleaning and maintenance 4.2.2 Cleaning The ash drawers (P4 Pellet 8-25) or ash container (P4 Pellet 32-38) must be emptied at intervals according to energy requirements and pellet quality. The grate and combustion chamber should also be checked at these intervals for dirt. -
Page 22: Emptying The Ash Container (For P4 Pellet 32/38/48/60)
Boiler servicing Inspection, cleaning and maintenance Emptying the ash container (for P4 Pellet 32/38/48/60) Open insulation door Push the locking lever upwards Pull out the ash container Put the cover cap supplied on the flange of the ash container Take the ash container to the emptying point and empty it To remove the cover the clamp must be unlocked and opened... -
Page 23: Check The Grate And Combustion Chamber
Boiler servicing Inspection, cleaning and maintenance Check the grate and combustion chamber Only clean the grate and combustion chamber when the boiler has cooled down Press and hold the key for 5 seconds Boiler follows shutdown procedure and changes to the status “Burner off”... -
Page 24: Yearly Check
Boiler servicing Inspection, cleaning and maintenance 4.2.3 Yearly check Clean the flue gas collection chamber and the heat exchanger Remove the insulating cover Turn the screw-handles on the cleaning cover anti-clockwise to loosen them Remove the cleaning cover Clean the flue gas collection chamber and the opening to the induced draught fan with a brush Remove any soot which has fallen in We recommend that you use an ash vacuum... -
Page 25: Clean Wos
Boiler servicing Inspection, cleaning and maintenance Clean WOS Remove the insulating cover and cleaning cover Page 24, Clean the flue gas collection chamber and the heat exchanger Push the lock bolt upwards and remove Remove the WOS mount along with the springs Clean the heat exchanger pipes with cleaning brush Cleaning the induced draught ventilator Detach the induced draught... -
Page 26: Clean The Flue Gas Sensors
Boiler servicing Inspection, cleaning and maintenance Clean the flue gas sensors Remove the insulating cover Loosen the wing screw and remove the flue gas sensor Carefully wipe off the flue gas sensor with a clean cloth Slide in the flue gas sensor and secure it hand-tight 4.3 Testing Emissions 4.3.1... -
Page 27: Maintenance Agreement / Customer Service
Boiler servicing Inspection, cleaning and maintenance 4.4 Maintenance agreement / Customer service We recommend a yearly inspection by Fröling customer services or an authorised partner (third party maintenance)! Regular maintenance and servicing by a heating specialist will ensure a long, trouble-free service life for your heating system. Regular servicing will ensure that your system stays environmentally- friendly and operates efficiently and cost-effectively. -
Page 28: Troubleshooting
Troubleshooting 5 Troubleshooting 5.1 General faults in the power supply Error Cause of error Error correction Nothing is shown on the General power failure display FI circuit breaker or line Switch on the FI circuit breaker or line No power to the controls protection is switched off protection 5.1.1 Behaviour of system after a power failure... -
Page 29: Faults With Fault Codes
Troubleshooting 5.3 Faults with fault codes If a fault has occurred and has not yet been cleared: Status LED (1) flashes red A fault message is shown on the display (2) An internal distinction is made between 2 types of message: Warning Boiler follows shutdown procedure Error... -
Page 30: Appendix
Appendix Manufacturer information 6 Appendix 6.1 Guarantee conditions Our sale and delivery conditions generally apply. These conditions have been made available to customers, and customers have been made aware of them at the time of order completion. You can also find the guarantee conditions in the enclosed guarantee certificate. -
Page 31: Declaration Of Conformity
Appendix Declaration of Conformity 6.3 Declaration of Conformity EC – DECLARATION OF CONFORMITY Product: Pellet boiler Types: P4 Pellet 8 / P4 Pellet 15 / P4 Pellet 20 / P4 Pellet 25 / P4 Pellet 32 / P4 Pellet 38 / P4 Pellet 48 / P4 Pellet 60 with delivery systems Screw suction system, universal suction system, sack silo delivery...
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Backfire slide valve does not close