Froling P4 Owner's Manual
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Froling P4 Owner's Manual

Wood pellet boiler
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Owner's Manual
P4 Wood Pellet Boiler
Report # 456-S-02-2
Certified to U.S. Standard: UL 2523-2009
Read and follow the operating instructions and safety information! Subject to technical change!
Fröling GmbH, Industriestrasse 12, A-4710 Grieskirchen Austria
www.froling.com

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  • Page 1 Owner’s Manual P4 Wood Pellet Boiler Report # 456-S-02-2 Certified to U.S. Standard: UL 2523-2009 Read and follow the operating instructions and safety information! Subject to technical change! Fröling GmbH, Industriestrasse 12, A-4710 Grieskirchen Austria www.froling.com...
  • Page 2 Reprinted August 2014 Catalog # P4O2014...
  • Page 3 Subject to technical change. The P4 Pellet boiler is produced using the highest quality materials and modern production system. The use of high technology laser cutting and robotic welding system, accompanied by time honoured European design, craftsmanship and attention to detail, results in a long lasting boiler with unmatched fit and finish.
  • Page 4 This boiler is safety tested and listed. The P4 pellet boiler does not carry an ASME stamp. The instructions in this manual and in supporting documentation (additional instructions, diagrams, and component information provided by Tarm Biomass) must be followed.

  • Page 5: Table Of Contents

    Contents 1 Product Overview 1.1 Boiler Fabrication and Testing 1.2 Models and Applications 2 Safety 2.1 Safety Information 2.1.1 Installation Hazards ..................11 2.2 Permitted Uses 2.2.1 Permitted fuel ....................13 2.2.2 Non-permitted fuels ..................14 2.2.3 Who may operate the boiler ................14 2.3 Design Information 2.3.1 Approvals and reporting obligations ..............

  • Page 6: Boiler Servicing

    5.2 Inspection, cleaning and maintenance 5.2.1 Cleaning ......................40 Emptying the ash drawers (for P4 Pellet 8/15/20/25) ........... 40 Emptying the ash container (for P4 Pellet 32/38 and 48/60) ........41 Check the grate and combustion chamber ............42 5.2.2 Yearly check ....................43 Clean the flue gas collection chamber and the heat exchanger .......

  • Page 7: Troubleshooting

    Contents 5.3 Spare parts 6 Troubleshooting 6.1 General faults in the power supply 6.1.1 Behaviour of system after a power failure ............46 6.2 Excessive temperature 6.3 Error messages at Boiler Control System 6.3.1 Procedure for fault messages ................47 6.3.2 Acknowledging a fault message .................

  • Page 8: Product Overview

    1 Product Overview Ash drawer module (P4 Pellet 8/15/20/25): Ash drawer module (P4 Pellet 32/38): Below the insulating cover: Page 8 B0430207...

  • Page 9: Boiler Fabrication And Testing

    The P4 Pellet boiler is a pellet boiler designed and constructed for highly efficient combustion of wood pellets. Do not burn other fuels in the P4 Pellet boiler. The P4 Pellet boiler is not a self contained weather-tight boiler. It should be installed within the heated building.

  • Page 10: Safety

    2 Safety This manual contains paragraphs that require your special attention. These paragraphs are marked with the symbols described below: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

  • Page 11: Installation Hazards

    Instructions and information for versions and minimum values, as well as norms and guidelines for heating components in the instructions must be observed! W A R N I N G Severe injuries and damage can be caused by an inadequate flue gas system! Inspect and clean flues and chimney regularly.
  • Page 12 CAUTION!  Do not connect this unit to a Chimney flue serving another appliance! Flooring must be a minimum 3/8’’ (10 mm) non-combustible material covering the installation clearance area! The floor must be level and reinforced if required. For construction of the floor beneath the boiler please pay attention to weight of boiler, water content and wood fuel according to the Installation Manual! Use original spare parts only.

  • Page 13: Permitted Uses

    Ensure that any faults, which might impair safety, are rectified immediately. The Fröling P4 Pellet is intended exclusively for heating up heating water. Use only the fuels specified under 2.2.1. The manufacturer or supplier is not liable for any damages resulting from non-permitted uses.

  • Page 14: Non-Permitted Fuels

    2.2.2 Non-permitted fuels C A U T I O N Non-permitted fuels! Burning non-permitted fuels increases the cleaning requirements and leads to a build-up of aggressive sedimentation and condensation, which can lead to damage to the boiler and also voids the warranty! Using non-standard fuels can lead to severe faults with combustion.

  • Page 15: Design Information

    2.3 Design Information It is unlawful 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 16: Outside Combustion Air

    The ventilation system may need to be re-balanced after installation of the Froling P4. N O T E Canadian installations must conform to ANSI/NFPA outside air requirements of 1 sq.

  • Page 17: Combination With Storage Tank

    2.3.6 Chimney connection / chimney system The chimney is one of the most critical factors in the successful operation of any solid fuel heater, including the Fröling P4 boiler. A good chimney will provide a continuous and dependable draft to pull the exhaust gasses out of the building.

  • Page 18: Barometric Damper

     We recommend that you install a barometric damper. 1  Install the barometric damper directly under the mouth of the flue line, as there is always low pressure there. 1 Basic Boiler Data for Layout of Chimney system P4 Pellet Description Unit Flue gas temperature ºF...

  • Page 19: Safety Devices

     Once the temperature falls to below approx. 203 °F (95 °C), the STL can be reset mechanically. 2.4.1 Devices for Preventing the Boiler from overheating The P4 Pellet boiler comes with safety systems to prevent the following:  Pressure in the boiler exceeding 30 psi (2 bar) (over pressure) ...

  • Page 20: Pressure Relief Valve

    Pressure Relief Valve Protection against over-heating/ excessive pressure: When the system pressure reaches a maximum of 30 psi (2 bar), the Pressure Relief Valve opens and the heating water is released in the form of steam. Overheat Thermostat (Safety Temperature Limit Switch-STL) The Overheat Thermostat stops combustion at a boiler temperature of 220 °F (105 °C).

  • Page 21: Emergency Procedure

    2.5 Emergency procedure 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 22: Overheating Of The System

    If system pressure is low, replenish water to the heating system according plumber’s instructions. 2.5.2 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. ...

  • Page 23: Operating The System

    3 Operating the system 3.1 Initial start-up 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 start-up should be carried out with an authorised installer or with ...

  • Page 24: 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 ...

  • Page 25: Boiler Control System Lambdatronic S 3200

    4 Boiler Control System Lambdatronic S 3200 This chapter contains information about use, control parameters, troubleshooting and the electrical connections of the Boiler Control System Lambdatronic S 3200. All parameters, which are visible at the service technician operator level, are shown. The parameters at Owner’s level are shown with a grey background! 4.1 Overview of the Basic Functions 4.1.1 Control Keys and Display...

  • Page 26: Status Led

    4.1.3 Status LED The status LED shows the operating status of the system: Green flashing light: BOILER ACTIVE Flashing red light: WARNING or FAULT 4.1.4 Function keys The function keys of the Lambdatronic P 3200 have dual functions. Different functions can be called with long or short keystrokes, using the following definitions of keystroke duration: Short keystroke ..

  • Page 27: Info Key

    4.1.5 Info Key The info key can be pressed at any time and always shows a text window, with information about the current menu point or the currently pending error. Error messages always have the highest priority. Info key in normal operation: In Normal mode (without faults) the info The info text is also identified by the frame key can be pressed to display information...

  • Page 28: Graphical Display

    4.1.6 Graphical Display Shows operating mode or menu name Shows the current time Shows the main values in the Basic Display (adjustable), menu content, parameters and info texts Status line Shown when a error message is pending. Pressing the info key displays texts for troubleshooting. Shows the Thermal Storage System loading status …...

  • Page 29: Operating Modes

    4.1.7 Operating Modes Preparation The boiler is ventilated, the sealing slider is opened and the Lambda probe is heated. Heating up The combustion chamber is filled with pellets. Pre-heating The fan-assisted ignition switches on and the pellets are preheated until a bed of embers is formed.

  • Page 30: Initial Start-Up

    4.2 Initial start-up After power up the start logo is displayed. The Boiler Control System performs a system check. After the system check the Basic Display is shown. The Basic Display is shown as default during normal operation, giving information about the two most important parameters;...

  • Page 31: Setting Parameters

    4.3 Setting parameters Changing values is very simple and is identical for all parameters: Save value and go back Unlock parameter for processing Larger Navigate to the desired parameter Smaller Back without saving  All parameter values are pre-set to allow optimal operation in a wide range of application without any need of further changes to the parameter.

  • Page 32: Menu Overview

    4.4 Menu Overview  See 4.5 Menu-Storage tank  See 4.6 Menu-Water  See 4.7 Menu-Solar  See 4.8 Menu-Pellets  See 4.9 Menu-Boiler  See 4.10 Menu-Manual  See 4.11 Menu-System Page 32 B0430207...

  • Page 33: Menu-Storage Tank

    4.5 Menu-Storage tank 4.5.1 Status display of the Thermal Storage Tank Storage tank 01 ... 08 Display Description Storage tank top Current temperature at Thermal Storage System top sensor. temperature 55°C Storage tank bottom Current temperature at Thermal Storage System bottom sensor. temperature 50°C Storage tank pump control...

  • Page 34: Temperature Settings Of The Dhw Tank

    4.6.2 Temperature Settings of the DHW Tank DHW tank 01 ... 08 Setting value Description Desired When the specified temperature is reached in the DHW tank, the DHW tank loading pump switches off. DHW tank temperature 60°C Reload if DHW tank Reloading of the DHW tank is authorised when the DHW tank temperature is below this level.

  • Page 35: Temperature Settings For The Solar System

    4.7.2 Temperature Settings for the Solar System Setting value Description DHW tank temperature setpoint Up to this temperature the DHW tank is heated by the solar system. during solar charging 75°C Temp differential to start The collector loading pump activates when the collector temperature exceeds the storage or DHW tank temperature by this collector pump 10°C...

  • Page 36: Menu-Boiler

    4.9 Menu-Boiler 4.9.1 Status Displays for the Boiler Display Description Boiler temperature 70°C Actual state values of boiler control system Flue gas temperature 176°C Flue gas set-point 178°C Boiler control variable ID fan control ID fan speed 2350U Air Speed at suction 0.00 m opening Ignition pipe temperature...

  • Page 37: Menu-Manual

    4.10 Menu-Manual 4.10.1 Manual operation Digital Outputs Description Ash Screw-Drive Switching Relevant Unit On and Off WOS-drive Burn back flap-drive Manual filling of pellet After activating the parameter, the container is filled with fuel, regardless of fill level, until the function is turned off or the container switch point of the level sensors is reached.

  • Page 38: Error

    4.11.2 Error  See 6.3 Error messages at Boiler Control System 4.11.3 Basic Display parameters Basic Display Description The display of the two positions in the basic display can be adjusted individually, and for each position you can choose from the following parameters: Position 1 Boiler, flue gas, external, room, DHW tank, storage tank top,...

  • Page 39: Boiler Servicing

    5 Boiler Servicing 5.1 General R I S K Work on electrical components is very dangerous. Avoid severe personal injuries and death. Only licensed electricians to perform electrical work!  W A R N I N G The boiler is hot. Flue gas pipe and hot parts can cause serious burns! Wait for the boiler to cool down before starting any maintenance work.

  • Page 40: Inspection, Cleaning And Maintenance

     Recommended: When cleaning, use an ash vacuum. 5.2.1 Cleaning The ash drawers (P4 Pellet 8-25) or ash container (P4 Pellet 32-100) 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 41: Emptying The Ash Container (For P4 Pellet 32/38 And 48/60)

    To remove the  transport cover the locking lever must be pushed Emptying the ash container (for P4 Pellet 32/38, 48/60, 80/100) Open insulation door  Push the locking lever upwards  Pull out the ash container ...

  • Page 42: Check The Grate And Combustion Chamber

    P4 Pellet 8/15/20/25: Open the insulating door, open the right ash door and pull out  the ash drawer For P4 Pellet 32/38, 48/60, and 80/100: Open the insulating door, take out the right ash container and  open the ash door Check the combustion grate and combustion chamber for dirt ...

  • Page 43: Yearly Check

    W A R N I N G Creosote-Formation and Need for Removal-When wood is burned slowly, it produces tar and other organic vapors, which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow-burning fire. As a result, creosote residue accumulates on the flue lining.

  • Page 44: Clean Wos

    Clean WOS Remove the insulating cover and cleaning cover  Page 43, 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 ...

  • Page 45: Checking The Draught Controller Flap And Explosion Flap

    Installing non-original parts voids the guarantee! Only replace components or parts with original replacement parts  Please refer to Froling Spare Parts List Pellet P4 - USA Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Page 45 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 info@froeling.com www.froeling.com...

  • Page 46: Troubleshooting

    6 Troubleshooting 6.1 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 6.1.1 Behaviour of system after a power failure...

  • Page 47: Error Messages At Boiler Control System

    6.3 Error messages at Boiler Control System 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 48: Appendix

    7 Appendix 7.1 Warranty – Fröling P4 Wood Pellet Boiler LIMITED WARRANTY - FOR USE ONLY IN THE UNITED STATES Tarm Biomass (“Importer”) warrants the steel boiler identified below and its steel doors, high temperature insulation boards, burn chamber, day hopper, auger mechanism, ash bins, and turbulators against defects in material and workmanship under normal use and service TO THE ORIGINAL PURCHASER AT THE ORIGINAL INSTALLATION SITE in the United States under the following terms.
  • Page 49 TARM BIOMASS’ LIMITED EXPRESS WARRANTY IS ONLY EXTENDED TO AND COVERS THE TARM BIOMASS PRODUCT’S END USER WHO OWNS THE BUILDING IN WHICH THE TARM BIOMASS PRODUCT IS INSTALLED, AND COVERS ONLY REPAIRS OR REPLACEMENTS RESULTING FROM DEFECTS IN MATERIALS AND WORKMANSHIP.THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION IN THIS LIMITED WARRANTY, AND TARM BIOMASS’...

  • Page 50: Temperature Conversion Table

    7.2 Temperature conversion table °C °F °C °F °C °F °C °F 179.6 183.2 125.6 186.8 129.2 190.4 132.8 136.4 197.6 201.2 143.6 204.8 147.2 208.4 150.8 154.4 161.6 165.2 168.8 172.4 Page 50 B0430207...

  • Page 51: Manufacturer

    7.3 Manufacturer FRÖLING GmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL +0043 (0)7248 606 0 E-MAIL info@froling.com INTERNET www.froling.com 7.4 Importer Tarm Biomass 4 Britton Lane P.O. Box 285 Lyme, NH 03768 PHONE 800.782.9927 E-MAIL info@tarmbiomass.com INTERNET www.tarmbiomass.com 7.5 Local Dealer Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen...

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