Froling P4 Operation Manual

Froling P4 Operation Manual

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

Reprinted August 2014

Catalog # P4O2014

Introduction

I

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. They contain safety information and all the operation and maintenance specifications needed to operate the boiler safely, properly and economically.

The constant further development of our products means that there may be minor differences from the pictures and content. If you discover any errors, please let us know.

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.

With proper installation, operation and maintenance your P4 pellet boiler will provide years of safe, dependable, economic and earth friendly heating.

This manual contains paragraphs that require your special attention.

These paragraphs are marked with the safety information according to

ANSI Z535 described in chapter 2.

Units of Measurement

Most hardware and fittings on the boiler are metric (some plumbing fittings are British Straight Thread). In this manual the convention used for dimensions is that values are presented in English units, followed by metric units in parenthesis, for example: 6” (152 mm).

In this manual temperatures are presented as degrees Centigrade.

Note: A conversion table between Centigrade and Fahrenheit is provided

in Section 7.2.

Installation and Warranty Requirements

This product is provided with a limited warranty which is described in

Section 7.1

within this manual. The warranty is contingent upon the

successful and legal installation of the boiler. At a minimum, the installation, adjustment, start up, service, and maintenance of this product must be performed by a licensed professional heating system installer. Where applicable, the installation must be inspected and accepted by the legally responsible entity. Conditions described in the text of the warranty for keeping it in force must be followed by the owner/ system operator.

If the boiler has been purchased through a dealer, the warranty claim must be made to the dealer. Otherwise, claims may be made directly to

Tarm Biomass.

Please read the literature enclosed by the manufacturer regarding the various accessory devices. These devices are warranted by the manufacturer, NOT BY Tarm Biomass. These accessory devices must be

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 [email protected] www.froeling.com

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Introduction

installed and used according to the recommendations of the manufacturer.

Failure to follow these instructions could result in property damage, bodily injury, or death. All boilers must be installed in accordance with national, state, and local plumbing, heating, and electrical codes and the regulations of the serving electric, water, and gas utilities. Contact local building or fire officials before installation about restrictions and installation inspection requirements in your area. 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. If the instructions are in conflict with local code requirements, the local code requirements will prevail.

When in doubt, contact your dealer or Tarm Biomass. The manual and supporting documentation must be retained by the owner/ system operator for reference and future use.

The installer is responsible for familiarizing the owner/ system operator with all aspects of boiler operations, safety procedures, monitoring and cleaning requirements, shut down procedures, and annual maintenance requirements.

N O T E

SAVE THESE INSTRUCTIONS

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Contents

1 Product Overview

1.1

Boiler Fabrication and Testing

1.2

Models and Applications

C

2 Safety 10

2.1

Safety Information 10

2.1.1

Installation Hazards ......................................................................................... 11

2.2

Permitted Uses 13

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 15

2.3.1

Approvals and reporting obligations ................................................................... 15

2.3.2

Requirements for initial filing and re-filling of heating system ................................ 15

2.3.3

Outside Combustion Air .................................................................................... 16

2.3.4

Installing the heating system ............................................................................ 16

2.3.5

Combination with storage tank .......................................................................... 17

2.3.6

Chimney connection / chimney system ............................................................... 17

Barometric Damper ......................................................................................... 18

Basic Boiler Data for Layout of Chimney system .................................................. 18

2.4

Safety Devices 19

2.4.1

Devices for Preventing the Boiler from overheating .............................................. 19

Pressure Relief Valve ....................................................................................... 20

Overheat Thermostat (Safety Temperature Limit Switch-STL) ............................... 20

Overheat loop: with electricity .......................................................................... 20

2.5

Emergency procedure 21

2.5.1

In the event of loss of electrical power ............................................................... 21

2.5.2

Overheating of the system ................................................................................ 22

2.5.3

In the event of chimney fire .............................................................................. 22

2.5.4

Strong Smell of flue gas ................................................................................... 22

3 Operating the system 23

3.1

Initial start-up

3.2

Filling/ refilling the store with fuel

23

23

3.3

Heating up the boiler 24

3.3.1

Switching on the boiler ..................................................................................... 24

3.3.2

Controlling the boiler ........................................................................................ 24

3.3.3

Switching off the boiler ..................................................................................... 24

8

9

9

4 Boiler Control System Lambdatronic S 3200 25

4.1

Overview of the Basic Functions 25

4.1.1

Control Keys and Display .................................................................................. 25

4.1.2

Navigation Keys ............................................................................................... 25

4.1.3

Status LED ...................................................................................................... 26

4.1.4

Function keys .................................................................................................. 26

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 [email protected] www.froeling.com

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Contents

4.1.5

Info Key .......................................................................................................... 27

4.1.6

Graphical Display .............................................................................................. 28

4.1.7

Operating Modes .............................................................................................. 29

4.2

Initial start-up 30

4.2.1

Changing the User Level .................................................................................... 30

4.3

Setting parameters

4.4

Menu Overview

31

32

4.5

Menu-Storage tank 33

4.5.1

Status display of the Thermal Storage Tank ......................................................... 33

4.5.2

Temperature settings for Thermal Storage System ............................................... 33

4.6

Menu-Water 33

4.6.1

Status Displays for the DHW Tank ...................................................................... 33

4.6.2

Temperature Settings of the DHW Tank ............................................................... 34

4.6.3

Heating Times of the DHW Tank ......................................................................... 34

4.7

Menu-Solar 34

4.7.1

Status Displays for the Solar System .................................................................. 34

4.7.2

Temperature Settings for the Solar System .......................................................... 35

4.8

Menu-Pellets 35

4.8.1

Fuel Filling Times .............................................................................................. 35

4.9

Menu-Boiler 36

4.9.1

Status Displays for the Boiler ............................................................................. 36

4.9.2

Temperature Settings for the Boiler .................................................................... 36

4.10

Menu-Manual 37

4.10.1

Manual operation ....................................................................................... 37

4.11

Menu-System 37

4.11.1

Current values .......................................................................................... 37

4.11.2

Error ........................................................................................................ 38

4.11.3

Basic Display parameters ............................................................................ 38

4.11.4

Time settings ............................................................................................ 38

4.11.5

Current User Level ..................................................................................... 38

5 Boiler Servicing 39

5.1

General 39

5.2

Inspection, cleaning and maintenance 40

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 ............................... 43

Clean WOS ...................................................................................................... 44

Cleaning the induced draught ventilator .............................................................. 44

Clean the smoke flue pipe ................................................................................. 44

Checking the draught controller flap and explosion flap ........................................ 45

Clean the flue gas sensors ................................................................................ 45

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Contents

5.3

Spare parts

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45

6 Troubleshooting 46

6.1

General faults in the power supply 46

6.1.1

Behaviour of system after a power failure ........................................................... 46

6.2

Excessive temperature 46

6.3

Error messages at Boiler Control System 47

6.3.1

Procedure for fault messages ............................................................................ 47

6.3.2

Acknowledging a fault message ......................................................................... 47

7 Appendix

7.1

Warranty

7.2

Temperature conversion table

7.3

Manufacturer

7.4

Importer

7.5

Local Dealer

48

48

50

51

51

51

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 [email protected] www.froeling.com

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1 Product Overview

2.3

2.4

2.2

2.1

Ash drawer module (P4 Pellet 8/15/20/25):

3

4

5

Ash drawer module (P4 Pellet 32/38):

Below the insulating cover:

6

7

12 11

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1

8

10

9

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1

Pos Component

1

2

P4 Pellet with integrated Pellets cyclone container

Lambdatronic P 3100 control system

2.1

Navigation keys to move around in the menus and to change the parameter values

2.2

Status LED (operating status): - slow green flashing light: boiler activated

- fast green flashing light: boiler deactivated

- flashing red light: malfunction

2.3

Large graphical display to show operating statuses and parameters

2.4

Function keys for calling up individual boiler functions or modes directly

3

4

5

6

7

Ash drawer - heat exchanger

Ash drawer - Combustion chamber

Ash drawer

Ash container - heat exchanger

Ash container - combustion chamber

8

9

Ash screw and stirrer of the automatic heat exchanger cleaning

Ash screw and guide plates of the combustion chamber cleaning

10

Lever of the ash box lock

11

Service interface of the control

12

Safety temperature limiter - STL

1.1 Boiler Fabrication and Testing

Your boiler was manufactured by Fröling, a world leader in hot water

(hydronic) heating for over 40 years. The P4 Pellet boiler conforms to traditional high standards for quality and reliability. It offers modern pellet boiler technology with high operating efficiencies at over 90%. If treated properly and operated according to the guidelines in this manual it will provide years of safe, dependable, and economical heating.

P4 Pellet boilers are designed and built in accordance with European

Standard EN 303-5. Safety and performance testing and listing for North

American markets have been performed by OMNI Test Laboratories,

Inc., Portland, Oregon. The boiler is tested and listed to applicable UL,

CAN and other standards. The boiler is not ASME stamped. The installer should follow local or state installation requirements.

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. P4 Pellet boilers should be installed with a thermal storage system to prevent short-cycling of the boiler during periods when the building is not calling for heat.

1.2 Models and Applications

Five P4 Pellet boiler models are available (8/15, 20/25, 30/38, 48/60), and 80/100 covering an output range between 35,800Btu/hr and

330,000Btu/hr. Models 8/15, and 20/25 is available with a pneumatic hopper or 280 lb (240 liter) day bin. Specification data for each P4 Pellet boiler is provided in the Installation Manual. The boilers can be utilized as a single heat source, or in parallel with another boiler.

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 [email protected] www.froeling.com

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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.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury.

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!

Installation is to be performed by a qualified installer.

Details on procedure for operation, maintenance and cleaning, as well as troubleshooting for the boilers are included in the individual instructions. Any further work should be carried out by authorised heating engineers or by Fröling customer services.

W A R N I N G

External influences!

Negative external influences, such as insufficient combustion air or non-standard fuel can cause serious faults in combustion (e.g. spontaneous combustion of carbonisation gases or flash fires) which can in turn cause serious accidents!

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2

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. Problems with the flue system, such as poor cleaning of the flue pipe or insufficient chimney draught can cause serious faults in combustion (such as spontaneous combustion of carbonisation gases or flash fires)!

You can only be guaranteed of optimum performance from the boiler if the flue gas system is running smoothly!

2.1.1 Installation Hazards

Install, modify and use only in accordance with manufacturer’s manuals.

Refer to authorities having jurisdiction for proper installation. Contact local building and fire officials about restrictions and installation inspection in your area. If there are no applicable local codes, follow

ANSI/NFPA 211 and CAN/CSA B365. Special precautions are required for passing the Chimney through a combustible wall or ceiling.

Inspect and clean exhaust system, Fuel Loading Chamber, Combustion

Chamber, Ash-Pits, and Heat Exchanger frequently in accordance with owner’s manual.

DANGER!

Working on electrical components may cause severe injuries from electric shocks!

WARNING!

The electrical system of the boiler shall be supplied from a double 115 V 60

Hz (nominal 230 V AC) 15 amp branch circuit including neutral and ground connection. For wiring instructions please refer to Installation Manual!

Chimney must be minimum 5’’ (127 mm) diameter listed UL-103 HT or

ULC-S629 residential all-fuel type or tile-lined masonry for models 8/15 and

20/25 and minimum 6” (150 mm) for models 32/38 and 48/58. Flue connector pipe must be 5” (127mm) or 6’’ (150 mm) diameter (dependent upon boiler model) made of a minimum 24 MSG black steel.

Inadequate design, installation and maintenance of the flue gas system will lead to insufficient chimney draft and could result in Danger of Life or

Severe Injury caused by serious faults in combustion, e.g. explosively combustion of wood gases and flash fires!

This boiler requires fresh air for safe operation and must be installed so there are provision for adequate combustion and ventilation air!

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 [email protected] www.froeling.com

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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. Installation of non-licensed replacement parts will void the warranty!

DANGER!

Risk of Fire or Explosion!

Do not burn coal, fuel coke, garbage and other residual material, painted or treated wood, garbage, gasoline, diesel, fuel oil, naphtha, engine oil, drain oil or other flammable liquids or any other organic materials or other inappropriate materials!

Do not use chemicals, gasoline, oil or any other combustible fluids to start the fire!

Use of inappropriate fuels can result in Danger of Life or Severe

Injury caused by explosive combustion and flash fires!

Burn fuels other than those designated in the manual will void warranty

DANGER!

Explosive Gases!

Never open Ash-Drawer Doors or Heat Exchanger Cover during operation or refueling!

Faulty operation of boiler system will cause Danger of Life or Severe Injury and Property damage!

Flue gases can cause fatal poisoning! In case of strong smell of flue gas:

1. For safety keep all Boiler Doors and Ash-Drawer Doors tightly closed!

2. Ventilate the room where boiler is installed!

3. Close the door of the boiler room and doors to living areas!

WARNING!

Risk of Fire!

tightly closed during operation! Door seals must be maintained in good condition.

Do not operate with flue draft exceeding 0.10 inches in water column (25

Pa), if no Draft Regulator is installed! Excessive draft could cause a solid fuel fire to burn out of control.

Do not store fuel, clothing, furniture or other combustible material within marked installation clearances within boiler is installed!

Faulty operating conditions not complying with Owner’s Manual, such as insufficient combustion air, incorrect or insufficient cleaning and maintenance or non-permitted fuel could result in Danger of Life or Severe

Injury caused by serious faults in combustion (e.g. spontaneous combustion of wood gases or flash fires)!

Inspect and clean Boiler, Flue Gas Pipe and Chimney regularly!

I

2

The Heat Exchanger, Induced Draft Fan, Flue Gas Pipe, and Chimney must be cleaned regularly to remove accumulated creosote and ash. Ensure that the Heat Exchanger, Flue Gas Pipe, and Chimney are cleaned at the end of heating season to minimize corrosion during the summer months.

First firing during start-up of boiler system shall be carried out in accordance to Instruction Label at Fuel Loading Chamber Door and in attendance of an authorized installer or manufacturer’s representative only!

Disregarding of warning may cause damage or explosion of Combustion

Chamber and severe injuries unfavorably!

Gas created during solid-fuel combustion may cause a small flash when the boiler is refueled if not properly vented!

Do not connect to any air distribution duct or system.

DO NOT INSTALL IN A MOBILE HOME

It is necessary to adhere to installation clearances and restrictions.

CAUTION!

Hot Surfaces!

Hot parts and the Flue Gas Pipe can cause serious burns!

Unauthorized access to the boiler room could result in personal injury and damage to property!

Keep children, clothing, and furniture away!

Always use protective gloves while loading boiler or carry out other work on boiler!

Always use Control Handles when opening Boiler Doors!

Do not touch Flue Gas Pipe during operation!

Do not carry out maintenance when the boiler is hot!

Do not touch hot surfaces behind Insulation Door!

Maximum draft marked on nameplate.

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. 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.

2.2.1 Permitted fuel

Wood pellets made from natural wood with a diameter of 6mm and they meet the grade specifications of PFI Certified Premium or Super

Premium.

Applies generally:

Before refilling the store, check for pellet dust and clean if necessary.

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 [email protected] www.froeling.com

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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.

Do not burn coal, fuel coke, garbage, gasoline, diesel, drain oil, naphtha, other flammable liquids, or other organic materials and any other inappropriate materials.

Do not store fuel or other combustible material within marked installation clearances. Keep away from heater while it is in use.

Do not use chemicals, gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to start or freshen up a fire in this heater.

2.2.3 Who may operate the boiler

Non-permitted use of the boiler by unauthorized persons can cause faults in combustion. The operator is responsible to explain all cautions before allowing any person’s access to boiler room.

Unauthorized persons, especially children, are to be kept away from the boiler.

Only trained operators are permitted to operate the boiler.

• The owner/system operator is responsible for correct operation of the boiler per guidelines in this manual.

• Incorrect operation can reduce the boiler life.

Throughout this manual, safety considerations are noted and discussed.

A few general safety considerations to be considered are:

• Safety faults or deficiencies with the boiler or installation must be rectified as quickly as possible; either by the owner/system operator or the installer. Using makeshift compromises during the installation can create an unsafe situation.

• Outlet pipes, ventilation channels, fresh air openings, etc. must not be closed or blocked.

• A chimney connector shall not pass through an attic or roof space, closet or similar concealed space, or a floor, or ceiling.

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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.

2.3.1 Approvals and reporting obligations

 IMPORTANT: Install, modify and use only in accordance with manufacturer’s installation & operation manuals. Refer to authorities having jurisdiction for proper installation. Contact local building and fire officials about restrictions and installation inspection in your area. If there are no applicable local codes, follow ANSI/NFPA 211 and CAN/CSA B365. Special precautions are required for passing the

Chimney through a combustible wall or ceiling.

Inspect and clean exhaust system frequently in accordance with

Owner’s Manual.

2.3.2 Requirements for initial filing and re-filling of heating system

Water quality conditions for initial filling the heating system:

For first filling of heating system water must be clean, pure or purified, odorless and without suspended matter.

For re-filling of small amounts water shall be clean at least.

For swimming pools or spas do not use heating water directly. Proper sized heat exchangers are required! Boiler water is not potable!

Use of a suitable antifreeze mix is allowed, but will cause a loss in heat transfer efficiency.

Note for filling with make-up water:

Bleed the filling hose before connecting to prevent air from getting into the system.

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 [email protected] www.froeling.com

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2.3.3 Outside Combustion Air

Provision for outside combustion air may be necessary to ensure that fuel-burning appliances do not discharge products of combustion into the house. Guidelines to determine the need for additional combustion air may not be adequate for every situation. If in doubt, it is advisable to provide additional air.

Outside air may be required if:

1. The solid fuel fired appliance does not draw steadily; experiences smoke roll out from boiler, burns poorly, or back drafts whether or not there is combustion present.

2. Existing solid fuel fired equipment in the house, such as fireplaces or other heating appliances smell, do not operate properly, suffer smoke roll out when opened, or back-draft whether or not there is any combustion present.

3. Any of the above symptons are alleviated by opening a window slightly on a calm (windless day).

4. The house is built very tightly with a well sealed vapor barrier or foam type insulation and tight fitting windows and/ or has any powered devices which exhaust in the house.

5. There is excessive condensation on windows in the winter.

6. A non-balancing ventilation system is installed in the house.

7. Where fans are used in the fuel storage area, they should be installed so as not to create negative pressures in the room where the boiler is located.

If these, or other indications, suggest that infiltration air is inadequate, additional combustion air should be provided from the outdoors.

If a mechanical ventilation system (air exchange or heat recovery) is already present in the home it may be able to provide sufficient combustion make-up air for the solid fuel fired appliance. 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. Inch per) 2.5cm) 1,000Btu/hr (.30kW/hr).

2.3.4 Installing the heating system

The entire heating system has to be designed according relevant national and local codes. The nominal power of the Central Heating

Boiler shall be corresponding to the calculated heat demand for all heating appliances connected to the heating system both in summer and winter time.

The heating system must be able to carry all heat produced by the

Central Heating Boiler and additional heat source, if applicable. The whole heating system as well as all heating zones has to be hydraulically balanced.

Special arrangements have to be provided for initial filling or re-filling and bleeding of all heating zones. Flow-check valves and zone-valves have to be installed for proper adjustment of water flow rates. All piping must be water and air tight and insulated safely.

If there is a risk of freezing for parts of the heating system all water within these heating zones has to be frost-proof!

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2.3.5 Combination with storage tank

N O T E

We recommend that you use the pellet boiler with a storage tank, as this allows you to achieve a reduction in start-up and shut downs within the ideal performance range of the boiler.

Please contact your installer or a Fröling technician directly for the right measurements of the storage tank.

If your P4 Pellet boiler has been installed with a Thermal Storage

System, this system may require periodic maintenance. Please review the periodic maintenance requirements of your thermal storage system with your installer.

2.3.6 Chimney connection / chimney system

1

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. The entire flue gas system must be designed to prevent, wherever possible, damage caused by seepage, insufficient feed pressure and condensation. Follow manufacturer’s installation instructions for installing and supporting any specific chimney product.

N O T E

The boiler must be connected to a tile-lined masonry chimney or to a factorybuilt Type UL 103 HT (ULC S629 in Canada) approved chimney. The chimney must be in good condition. If the boiler is connected to a dirty or inadequate chimney, it can present a serious fire hazard. All chimneys and connections must conform to NFPA standard #211. No other appliance should be connected to this flue unless allowed by the local code authority. Consult your local inspector for chimney requirements and install the boiler in accordance with all applicable codes.

Flue gas exhaust temperatures can be low enough to cause condensation in chimneys. Condensation will, over time, damage a masonry chimney. Accordingly, installation of a stainless chimney liner

(made with 304, 316, or 321) inside the chimney flue is strongly recommended.

The flue gas temperatures (when cleaned) and the additional flue gas values can be found in the technical specification sheets (See chart below “see chart below “Boiler data for constructing the flue gas system”.

The smoke pipe connecting the boiler to the chimney flue must be black or stainless, have a minimum thickness of 24 gauge, and rise a

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 [email protected] www.froeling.com

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minimum of ¼” per foot of run toward the chimney. Smoke pipe sections must be attached to one another with a minimum of three sheet metal screws and sealed with hi-temperature silicone. The smoke pipe should not contain more than two 90° elbows (45° elbows are preferred over 90° elbows).

The chimney draft must be stable (see chart below “Basic Boiler Data for

Layout of Chimney system”.

The top of the chimney must be 3 feet (0.9 m) above the roof and 2 feet

(0.6 m) above any structure within 10 feet (3.0 m) measured horizontally.

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

Description Unit

Flue gas temperature ºF

Flue gas mass flow RL lb/hr lb/hr

Required Draft RL

PL inch

WC

Flue pipe diameter inches

NL = Nominal Load, PL = Partial Load

8 15

284 300

55

24

0.03

0.02

5

79

33

0.03

0.02

5

20

300

115

44

0.03

0.02

5

25

300

143

55

0.03

0.02

5

P4 Pellet

32

320

172

70

0.03

0.02

6

38

320

203

90

0.03

0.02

6

48

320

309

132

0.03

0.02

6

60

338

342

154

0.03

0.02

6

80

320

474

165

.032

.024

8

100

338

606

209

.032

.024

8

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2.4 Safety Devices

1

2

2

1

Key for automatic mode In case of overheating of the boiler:

2

Safety temperature limiter

(STL)

Press and hold the key for 5 seconds

Automatic mode is switched off

Control follows the boiler shutdown procedure

The pumps continue to run!

Switches off the blower fan at the maximum boiler temperature of

220 °F (105 °C). The pumps continue to run!

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)

 Boiler water temperature exceeding 220ºF (105º C)

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2

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). The circulators continue to run!

In case Overheat Thermostat automatically has been activated:

Wait for boiler temperature to drop below 203 °F (95 °C)

Remove cap of Overheat Thermostat (STL) by screwing-off counterclockwise. STL located at right hand side of Boiler Control System viewed from front side of the boiler.

Release STL by pushing button behind cap using a small screw driver or ball point pen. Release is successful, when fault is gone on display.

Screw-on cap of STL again (clockwise).

On the Boiler Control System there is an Overheat Thermostat. If the boiler exceeds 220 °F (105 °C) it will shut off the Induced Draft Fan.

Overheat loop: with electricity

The Honeywell L4008B aquastat provided with the boiler is wired in parallel with the thermostat on the zone with the most heating capacity in the main living area. Upon reaching the aquastat set point 200 ºF (93

ºC) the heating zone will be activated, pulling heat away from the boiler.

The home owner is alerted to a potential problem with the boiler by an overly warm living space.

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2

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.

Insulate the flue pipes or simply avoid touching them during operation.

Before carrying out maintenance work on/in the boiler:

Press and hold the key for 5 seconds

Boiler follows shutdown procedure and changes to the operating status “Burner off”

W A R N I N G

Do not open the ash doors during operation!

This may cause injury, damage and smoke!

It is forbidden to open the doors behind the insulating door during operation!

W A R N I N G

Do not use unauthorised fuel!

Non-standard fuels can cause serious faults in combustion (e.g. spontaneous combustion of carbonisation gases / flash fires) which can lead to serious accidents!

Only use fuels specified in the chapter on “Permitted Uses” in these instructions.

2.5.1 In the event of loss of electrical power

Do not open any Boiler Doors.

Do not load fuel into the boiler.

 Boiler Control System automatically restarts after power fail restart.

 One hour after power has returned, check system for normal operation and compare the pressure gauge reading to initial settings.

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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.

Turn off the boiler by pressing the key for 5 seconds

Open all mixer taps, switch on all pumps.

Fröling heating circuit control takes over this function in automatic operation.

Leave the boiler room and close the door.

Open any available radiator thermostat valves

2.5.3 In the event of chimney fire

Call the fire department.

Keep all the doors on the boiler closed.

Evacuate your house.

If possible, wet your entire roof with a garden hose.

2.5.4 Strong Smell of flue gas

Flue gases can cause fatal poisoning!

When there is strong smell of flue gas:

Keep all the doors on the boiler closed.

Turn off the boiler by pressing the key for 5 seconds.

Air the room where the boiler is installed.

Close the fire protection door and doors to living areas.

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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

Fröling customer services.

The individual steps for initial start-up are explained in the operating instructions for the controller.

See Section 4 for instructions on the Lambdatronic P 3200

N O T E

If condensation escapes during the initial heat-up phase, this does not indicate a fault.

If this occurs, clean up using a cleaning rag.

3.2 Filling/ refilling the store with fuel

C A U T I O N

Damage and injuries can occur if the store is filled when the boiler is on!

Turn off the boiler by pressing the key for 5 seconds

Allow the boiler to cool down for at least half an hour.

When the boiler has cooled down:

Close all opening to the store to seal out dust

Fill the store with pellets

Only use permitted pellets

Page 13, 2.2.1 Permitted fuel

3

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3.3 Heating up the boiler

Operating the system

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

 Turn on service switch, if installed.

Press the key



Automatic mode



The heating system is controlled via the control system according to the selected mode.

3.3.2 Controlling the boiler

Necessary control steps. Displaying or modifying parameters:

See Chapter 4

3.3.3 Switching off the boiler

Press and hold the key for 5 seconds



The boiler follows the shut-down program and switches to

“Burner OFF” status.



The combustion unit is switched off, the chamber delivery unit and the active hydraulic system are active

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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

Function Keys (4.1.4) Graphical Display (4.1.5) Navigation Keys (4.1.2)

4

4.1.2 Navigation Keys

Key

Status LED (4.2.3)

The Navigation keys are for scrolling in the menu and changing parameter values.

Function for .

UP arrow

DOWN arrow

Navigation: Move up in the menu

Parameter change: Short keystroke: Increase value

Long keystroke: Increase value in steps of 10

Long keystroke (> 10 sec): Increase value in steps of 100

Navigation: Move down in the menu

Parameter change: Short keystroke: Decrease value

Long keystroke: Decrease value in steps of 10

Long keystroke (> 10 sec): Decrease value in steps of 100

Navigation: Go to selected menu

Parameter change: Short keystroke: Unlock parameter for editing or save parameter value

Enter key

Navigation: Go back to higher menu

Parameter change: Short keystroke: Do not save parameter value

Long keystroke: Back to Basic Display without saving

Back key

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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

Long keystroke

........ < 1 sec

........ > 4 sec

Keystroke

Short Chimney sweep

Service

Program

Long Service mode

Short Automatic mode

(On)

Function / Symbol in status line

System is operated for 30 minutes with rated load

To exit this function: Use “Automatic Program” below

Control follows the boiler shutdown procedure and after the cleaning cycle the grate stays in open position. The ID fan runs at controlled speed and the door contact switch is activated.

Recommended for ash discharge

Function not used (exit other functions only)

Automatic

Program

Long Off

Short Party mode

Long Extra heating

The control follows the boiler shutdown procedure and starts with the cleaning cycle. After the cleaning cycle the boiler goes to “Burner OO” status.

The Lambdatronic controls the connected heating components. All parts of the boiler are deactivated.

Function not used

Function not used

Party

Program

Info

Short Display info text

Long No function

Query / Clear text information on menu points or errors.

See section 4.1.5 Info Key

Short Extra loading Function not used

DHW tank-

Program

Long Summer operation Function not used

Short Setback mode Function not used

Long Continuous setback Function not used

Setback

Program

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4

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 key can be pressed to display information or an explanation for every menu point or parameter

The info text is also identified by the frame and the info symbol in the symbol tab.

Info key for pending warning or fault:

If a fault was acknowledged after arising, but not resolved, this is displayed by a warning symbol at the bottom right on the symbol tab.

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Pressing the info key calls up the information on the currently pending fault message again.

How to proceed when troubleshooting an error message:

See 6.3 Error messages

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4.1.6 Graphical Display

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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

This is displayed when the cleaning program has been started.

Key for starting the function.

See page 25, Function Keys

...

Indicates that an info text is displayed. Info texts are also identified by a frame.

...

Shows activation of boiler

See page 25, Function Keys

... shows that the DHW tank pump is active

... shows that the Thermal Storage System circulator is active

... not used

Only shown in the Basic

Display!

... not used

I

4

4.1.7 Operating Modes

Preparation

Heating up

Pre-heating

Ignition

Heating

Constant burn

Cleaning

Shutdown wait

Shutdown wait 1

Shutdown wait 2

Fault

Burner Off

The boiler is ventilated, the sealing slider is opened and the Lambda probe is heated.

The combustion chamber is filled with pellets.

The fan-assisted ignition switches on and the pellets are preheated until a bed of embers is formed. For this period loading is deactivated.

The pellets are ignited with the fan-assisted ignition. The flame is distributed around the whole combustion chamber. The control of the loading unit is defined as “Ignition” in the parameter menu.

The Lambdatronic controls combustion according to the boiler set-points.

The boiler has no power consumption. The ID fan and the loading unit are deactivated.

The Lambdatronic carries out the cleaning program (duration approx. 3 min).

When the boiler is interrupted during the heating up procedures (heating up, pre-heating, ignition), it waits for a specified period of time until the next start attempt.

The ID fan runs to burn the remaining pellets.

The loading unit is deactivated.

The system is still ventilated by chimney draught. The loading unit is deactivated.

CAUTION-Fault persists!

Procedure see Chapter 6-Troubleshooting

The Lambdatronic controls the connected heating components. All parts of the boiler are deactivated.

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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; the display can be configured individually.

4.2.1 Changing the User Level

For safety reasons certain parameters are only visible at specific

User Levels. To change to another level it is necessary to enter the relevant user code: repeatedly repeatedly

...

Child lock

(User Code 0)

Owner

(User Code 1)

Installer / Service

At “Child lock” level, only the Basic Display is shown.

It is not possible to change any parameter at this level.

Standard level for normal operation of controls. All parameters for Owner’s use are displayed and released for adjustment.

Detailed level for Installation and Service purposes. All parameters and system controls available are displayed and released for adjustment. All parameters shown in these operating instructions are available.

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4.3 Setting parameters

Navigate to the desired parameter

Changing values is very simple and is identical for all parameters:

Save value and go back

Unlock parameter for processing Larger

Smaller

4

Back without saving

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 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.

The following parameters, however, can/should be set as desired by the

Owner:

- Desired target boiler temperature

 All temperature values at Boiler Control System are displayed in

Centigrade or °C only!

 Temperature values in Fahrenheit or °F can be estimated using the following conversion table, based on:

°F = 1.8 x °C + 32 °C = (°F - 32) / 1.8

15

20

25

30

35

°C

0

5

10

°F

32

41

°C °F

65 149

70 158

50

59

68

77

75 167

80

176

85

185

90

194

86

95

203

95 100 212

40 104 105 221

45 113 110 230

50 122 115 239

55 131 120 248

60

140

125

257

°F

32

°C

0

°F °C

160 71

40 4 170 77

50

60

70

80

10 175 79

16

180

82

21

185

85

27

190

88

90

32

200

93

100 38 210 99

110 43 220 104

120 49 230 110

130 54 240 116

140 60 250 121

150

66

255

124

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4.4 Menu Overview

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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

I

4.5 Menu-Storage tank

4.5.1 Status display of the Thermal Storage Tank

Storage tank

01 ... 08

Display

Storage tank top temperature

Storage tank bottom temperature

Storage tank pump control

Description

55°C

Current temperature at Thermal Storage System top sensor.

Current temperature at Thermal Storage System bottom sensor.

50°C

0%

Function not used! Pump control either 0% or 100% speed!

Specifies the speed of the Thermal Storage System circulator as a percentage of maximum speed.

4.5.2 Temperature settings for Thermal Storage System

4

Storage Tank

01 ... 08

Setting value

Heating circuit release from following storage tank temperature 35°C

Description

Function not used!

Minimum value for heating circuit release for combination with a

Thermal Storage System.

4.6 Menu-Water

4.6.1 Status Displays for the DHW Tank

Display

DHW tank top temperature

DHW tank pump control

DHW tank 01 ... 08

Description

60°C

Current temperature in the top part of the DHW tank. The DHW tank is heated during the loading times until the specified parameter, “Desired DHW temperature”, is reached.

0%

Specifies the speed of the DHW tank pump as a percentage of maximum speed.

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4.6.2 Temperature Settings of the DHW Tank

DHW tank 01 ... 08

Setting value

Desired

DHW tank temperature

Reload if DHW tank temperature is below

60°C

45°C

Description

When the specified temperature is reached in the DHW tank, the DHW tank loading pump switches off.

Reloading of the DHW tank is authorised when the DHW tank temperature is below this level.

4.6.3 Heating Times of the DHW Tank

DHW tank 01 ... 08

 Times must be set in the service mode.

4.7 Menu-Solar

4.7.1 Status Displays for the Solar System

Display

Collector Temperature 80°C

Solar temperature storage tank bottom 38°C

DHW tank bottom temperature39°C

Collector pump runtime

Collector pump control

1 h

78%

Description

Current temperature at collector.

Current temperature at solar sensor in bottom storage tank.

Current temperature in the lower part of the DHW tank.

Specifies the runtime of the collector pump.

Specifies the speed of the collector pump as a percentage of maximum speed.

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4

4.7.2 Temperature Settings for the Solar System

Setting value

DHW tank temperature setpoint during solar charging 75°C

Temp differential to start collector pump 10°C

Temp difference to stop collector pump

Maximum storage tank bottom temperature during solar charging

5°C

85°C

Description

Up to this temperature the DHW tank is heated by the solar system.

The collector loading pump activates when the collector temperature exceeds the storage or DHW tank temperature by this value.

The collector loading pump activates when the collector temperature exceeds the storage or DHW tank temperature by this value.

Maximum bottom storage tank temperature at which the collector pump is switched off (only with storage tank).

4.8 Menu-Pellets

4.8.1 Fuel Filling Times

Start of 1 st

Setting value

pellet filling

Description

9:00

1 st

Start time for filling. This is only carried out if the fill level in the container is under 85%.

Start of 2 nd

pellet filling 15:00 2 nd

Start time for filling. This is also only carried out if the fill level in the container is under 85%.

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4.9 Menu-Boiler

4.9.1 Status Displays for the Boiler

Display

Boiler temperature

Flue gas temperature

70°C

176°C

Flue gas set-point 178°C

Boiler control variable 95%

ID fan control 75%

ID fan speed 2350U

Air Speed at suction 0.00 m opening

Ignition pipe temperature 0°C

Calculated boiler set-point 70°C

Sensor 1 85°C

4.9.2 Temperature Settings for the Boiler

Description

Actual state values of boiler control system

:

:

Setting value Description

Boiler temperature set-point 80°C The boiler temperature is regulated to this value. (Range: 40-

70ºC) Recommendation: System without storage tank 50ºC,

System with storage tank 70ºC.

Shutdown if current boiler temperature is higher than boiler

If the boiler temperature exceeds the set-point by this parameter value, the boiler switches to constant burn status. The boiler starts up again below the temperature set-point.

Always switch off above highest possible boiler temperature setpoint + 3ºC

Minimum boiler temperature to release all pumps 35ºC

If the boiler temperature exceeds the maximum set-point by this parameter, the boiler switches to constant burn status. The heating circuit and store loading pumps will also begin to run to cool the boiler. The boiler starts up again below the temperature set-point.

The pumps are released at this boiler temperature. (Hysteresis

2ºC).

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4.10 Menu-Manual

4.10.1 Manual operation

Digital Outputs Description

WOS-drive OFF

Burn back flap-drive OFF

Manual filling of pellet container OFF

After activating the parameter, the container is filled with fuel, regardless of fill level, until the function is turned off or the switch point of the level sensors is reached.

If a vacuum screw delivery system is installed, the screw is activated at defined intervals (15s on 15s off).

The jam sensor is not analyzed.

When the level sensor reaches its limit value, the fill level is set to 100%.

Grate-Drive OFF

Open and close grate manually.

4.11 Menu-System

4.11.1 Current values

Parameter

Boiler temperature

Flue gas temperature

ID fan control

70°C

90°C

75%

Residual oxygen content 12.3%

External temperature 23°C

Service Hours 26h

Software version Version: 50.04

Build: 04.12

Description

Display of the current state values for boiler control system

:

:

4

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4.11.2 Error

4.11.3 Basic Display parameters

See 6.3 Error messages at

Boiler Control System

Basic Display

Position 1

Position 2

4.11.4 Time settings

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:

Boiler, flue gas, external, room, DHW tank, storage tank top, storage tank bottom, storage tank graphic, residual O2, ID fan.

In American configuration Date and Time are used for display purposes only!

Format of Calendar Date:

Weekday (2 letters) – Day (2 digits) . Month (2 digits) . Year (2 digits) e.g.: MO 07.07.08 = Monday 07 th

of July, 2008

Format of Time:

Hour (2 digits, 24-hour-clock) : Minute (2 digits) : Second (2 digits) e.g.: 15:24:07 = 3:24 pm and 7 seconds

4.11.5 Current User Level

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5 Boiler Servicing

5.1 General

5

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.

Protective gloves should generally be worn when working on the boiler.

Only operate the boiler using the handles provided for this purpose.

Before starting any maintenance work:

Press and hold the key for 5 seconds

Boiler follows shutdown procedure and changes to the operating status “Burner off”

Allow the boiler to calm down for at least 1 hour

After maintenance has been carried out switch the boiler on in the desired mode.

 In service mode the boiler does not start automatically.

W A R N I N G

Incorrect or insufficient cleaning and maintenance of the boiler can cause serious faults in combustion (e.g. spontaneous combustion of carbonisation gases / flash fires). The instructions and information provided in this manual shall be observed.

Follow instructions for cleaning and maintenance within this chapter. Any further work shall be carried out by authorized heating engineers.

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5.2 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.

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.

W A R N I N G

Disposal of Ashes-

Ashes should be placed in a metal container with tight-fitting lid. The closed container of ashes should be placed on a noncombustible floor or on the ground, well away from all combustible materials, pending final disposal. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed container until all cinders have throughly cooled.

W A R N I N G

Solid-fuel burning appliances need to be cleaned frequently because soot, creosote, and ash may accumulate. If there is a soot or creosote fire, please do the following:

Establish a routine for the storage of fuel, care of the appliance, and firing techniques.

Check daily for creosote build-up until experience shows how often cleaning is necessary.

Be aware that the hotter the fire, the less creosote is deposited, and that weekly cleanings may be necessary in mild weather, even though monthly cleanings may be enough in the coldest months.

Have a clearly understood plan to handle a chimney fire.

The chimney should be inspected periodically to determine if creosote build-up has occurred. If a significant layer of creosote has accumulated (3mm or more) it should be removed to reduce the risk of a chimney fire.

A small and intense fire is preferable to a large smoldering one to reduce the amount of creosote deposition.

Emptying the ash drawers (for P4 Pellet 8/15/20/25)

Open insulation door

Open ash doors

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Take the ash drawers out a bit

This pushes the ash lying in front of the drawer into the ash bowl

Thread in the transport cover as illustrated and pull out the ash drawer, until the cover settles into position

Take the ash drawer to the emptying point and empty it

To remove the transport cover the locking lever must be pushed up

Emptying the ash container (for P4 Pellet 32/38, 48/60, 80/100)

Open insulation door

Push the locking lever upwards

5

Pull out the ash container

Put the cover cap supplied on the flange of the ash container

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 [email protected] www.froeling.com

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5

Take the ash container to the emptying point and empty it

To remove the cover the clamp must be unlocked and opened

Check the grate and combustion chamber

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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”

The ID fan turns at a controlled speed and the combustion grate stays in open position. for 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

If there is a lot of dirt, clean the combustion chamber

Page 43, Clean the flue gas collection chamber and the heat exchanger

I

5

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. When ignited, this creosote makes an extremely hot fire. The chimney and chimney connector should be inspected at least twice monthly during the heating season to determine if a creosote build-up has occurred. If creosote has accumulated it should be removed to reduce the risk of a chimney fire.

5.2.2 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

Remove the internal heat exchanger cover

Clean the flues and the combustion chambers beneath them with a cleaning brush

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 [email protected] www.froeling.com

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Clean WOS

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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

Cleaning the induced draught ventilator

Detach the induced draught ventilator on the back of the boiler

Check for dirt and damage

Clean the blower wheel with a soft brush or paint brush

Do not move the balancing weights on the blower wheel!

Clean the smoke flue pipe

Clean the connecting pipe between the boiler and the chimney regularly with a chimney sweeping brush

Depending on the layout of the flue pipes and the chimney draught cleaning yearly may not be enough!

W A R N I N G

Soot and Flyash: Formation and Need for Removal-The products of combustion will contain small particles of flyash. The flyash will collect in the exhaust venting system and restrict the flow of the flue gases. Incomplete combustion, such as occurs during start-up, shutdown, or incorrect operation of the heater will lead to some soot formation which will collect in the exhaust venting system. The exhaust venting system should be inspected at least once every year to determine if cleaning is necessary.

I

Checking the draught controller flap and explosion flap

Check the draught controller flap and explosion flap for ease of operation

Maximum permissible setting: 25 Pa

Ideal setting: 20 Pa

Clean the flue gas sensors

Remove the insulating cover

Loosen the wing screw and remove the flue gas sensor

5

Carefully wipe off the flue gas sensor with a clean cloth

Slide in the flue gas sensor and secure it hand-tight

5.3 Spare parts

N O T E

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

Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com

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6 Troubleshooting

6.1 General faults in the power supply

Error

Nothing is shown on the display

No power to the controls

Cause of error

General power failure

FI circuit breaker or line protection is switched off

Error correction

Switch on the FI circuit breaker or line protection

6.1.1 Behaviour of system after a power failure

When the power supply has been restored the boiler returns to the previously specified mode and is controlled according to the specified program.

EXCEPTION:

If the boiler was at operating status “Heating up”, “Pre-heating” or

“Ignition” it follows shutdown procedure and cleaning is started. Only then does the boiler switch to “Preparation” operating status and the system starts again.

6.2 Excessive temperature

1

The Overheat Thermostat stops combustion at a boiler temperature of

222°F (105°C). The circulators continue to run!

In case Overheat Thermostat automatically has been activated:

Wait for boiler temperature to drop below 203°F (95°C)

Remove cap of Overheat Thermostat (STL) by screwing-off counterclockwise. STL located at right hand side of Boiler Control System viewed from front side of the boiler.

Release STL by pushing button behind cap using a small screw driver or ball point pen. Release was successfully, when fault is gone on display.

Screw-on cap of STL again (clockwise).

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6.3 Error messages at Boiler Control System

6

2

1

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

Boiler shuts down immediately, heating circuit controls and pumps remain active

6.3.1 Procedure for fault messages

The procedure for a fault message as well as causes for faults and procedure for troubleshooting are described in the operating instructions of the boiler controls:

 See the operating instructions for the Lambdatronic P 3200

6.3.2 Acknowledging a fault message

Trace and remove the fault and then:

Press the key

Status LED flashes green

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 [email protected] www.froeling.com

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7

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.

WARRANTY IS VOID if the boiler is operated with fuel other than premium wood pellets certified by the Pellet

Fuels Institute.

BOILER BODY -- LIMITED 20 YEAR WARRANTY: Subject to the below limitations, Tarm Biomass warrants the steel boiler body (not including doors, burn chamber, or other components) against defects in materials or workmanship causing breaks or leaks that significantly impair the boiler’s performance. During the first five years of the warranty period Tarm Biomass will pay for all required labor at the usual and customary rate paid by Tarm Biomass for similar labor performed in Lyme, NH, and provide or pay the cost of all materials for the repair of the warranted unit. In years six through twenty Tarm Biomass will pay the below stated percentage multiplied by the retail price of the warranted unit on the date of purchase to the original purchaser toward the cost of repair of the warranted item or, if Tarm Biomass and the original purchaser agree, use the resultant sum as a partial allowance toward Tarm Biomass’s replacement of the warranted item. The original purchaser shall be responsible for all shipping and installation charges in connection with any replacement or repair.

A year for the purposes of this warranty is defined as either 365 calendar days or 3000 service hours, whichever is less.

Warranty Year (beginning from date of purchase) Percentage Tarm Biomass will pay

1-5 100%

6

7

60%

50%

8

9

40%

30%

10-20 20%

Example 1: Repair costing $250.00 in year 7, Tarm Biomass will pay $125.00 (50% of this repair).

Example 2: Boiler (original retail $10,000.00) needs major repair in year 9. Tarm Biomass will pay $3,000

(30% of $10,000) toward replacement with similar warranted unit or up to 30% of the repair cost ($3,000 maximum).

OTHER COMPONENTS -- LIMITED THREE YEAR WARRANTY

Subject to the application of the following percentages to parts and/or labor, Tarm Biomass provides the following limited warranty of each of its steel doors, high temperature insulation boards, burn chamber, day hopper, auger mechanism, ash bins, and turbulators against defects in material and workmanship causing breaks or leaks that significantly impair the boiler’s performance.

Warranty Year (beginning from date of purchase)

1

Percentage Tarm Biomass will pay

100% of parts and labor

2 100% of parts ONLY

3 50% of parts ONLY

OTHER COMPONENTS – ONE YEAR WARRANTY

Motors, electronics, controls, and other electronic components have a one year warranty.

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7

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’ LIMITED WARRANTY IS IN

LIEU OF AND TO THE EXCEPTION OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING,

BUT NOT LIMITED TO, WARRANTIES OF MERCHANTABILITY OR WARRANTIES OF FITNESS FOR A

PARTICULAR PURPOSE. EXCEPT AS OTHERWISE PROVIDED BY THIS LIMITED WARRANTY, TARM

BIOMASS TAKES NO RESPONSIBILITY FOR THE QUALITY OF TARM BIOMASS PRODUCTS OR THAT

THE GOODS WILL BE FIT FOR ANY PARTICULAR PURPOSE FOR WHICH YOU MAY BE BUYING THESE

GOODS. UNDER NO CIRCUMSTANCES SHALL TARM BIOMASS BE SUBJECT TO INCIDENTAL,

CONSEQUENTIAL, INDIRECT, SPECIAL, PUNITIVE, ENHANCED COMPENSATORY, OR CONTINGENT

DAMAGES, WHETHER A CLAIM IS BASED ON CONTRACT, TORT, STRICT LIABILITY, OR ANY OTHER

THEORY OF LAW, ALL SUCH DAMAGES AND CLAIMS BEING SPECIFICALLY DISCLAIMED.

Tarm Biomass’ limited warranty is void if a Tarm Biomass product is installed by someone other than a qualified contractor whose principal occupation is the sale or installation of plumbing and heating equipment, or if the original purchaser fails to have the boiler serviced or inspected at least once every year by an experienced and qualified service person. Repairs or replacements under this limited warranty must be performed by your dealer or someone authorized by him. You may be required to present this limited warranty to the dealer before any work is performed. You must pay for any work performed that is not covered by this limited warranty or that is not authorized by the dealer. Tarm Biomass’ limited warranty shall be construed under the laws of New Hampshire. Any dispute arising out of this warranty shall be tried only in a court in the State of

New Hampshire, including the United States District Court for the State of New Hampshire. If any legal action is brought in connection with this limited warranty, the prevailing party shall be entitled to recover all reasonable expenses it incurs in the action, including its reasonable attorneys’ fees, from the nonprevailing party.

TARM BIOMASS’ LIMITED WARRANTY EXPRESSLY EXCLUDES COVERAGE FOR THE FOLLOWING:

1.

2.

3.

Ordinary wear and tear and repairs or replacements necessitated by normal use.

Repairs or replacements arising from corrosion including, but not limited to, the effects of a corrosive water supply or corrosive by-products of combustion formed when a boiler is run during warm weather temperatures or under other conditions that do not permit the boiler to reach necessary operating temperatures on a frequent basis as described in the Owner’s Manual provided by Tarm Biomass.

Repairs or replacements of fittings, motors, fuel units, oil and gas burners, any and all controls, relief or regulating valves, transformers, and accessories.

4.

5.

Repairs or replacements to repair damage caused by (i) operation with inadequate draft, (ii) having installed a boiler model that is incorrectly sized for the application (too few or too many BTU’s under normal operating conditions) or that is otherwise inappropriate for the application, (iii) burning other than premium wood pellets certified by the Pellet Fuels Institute, or excessive boiler internal temperature from burning improper materials as fuel or operating the boiler without appropriate draft control (for example, burning the boiler too hot when the boiler is coming up to temperature from a cold start), or (iv) any similar use that violates or is not recommended in the Owner’s Manual provided by Tarm Biomass.

The repair or replacement of any component furnished by any other manufacturer or damage caused by the functioning or malfunctioning of any such component.

This warranty gives you specific legal rights. You may also have other rights that vary from state to state. This warranty shall not be construed as inconsistent with any federal, state, or municipal law, regulation, or code that was applicable to the original installation site on the date the Tarm Biomass product was installed.

Questions regarding this warranty may be referred to:

Tarm Biomass, 4 Britton Lane, PO Box 285, Lyme, NH 03768 U.S.A. (603) 795-9100

KEEP THIS INFORMATION FOR YOUR RECORDS:

Model: __________ ______ Place of Purchase: ___________________ __

Serial No.: _________________________ Installation Date:_______________

Installer:_______________________________________________________________________

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 [email protected] www.froeling.com

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7.2 Temperature conversion table

°C °F

40 104

°C °F

80 176

°C °F °C °F

135 275 220 428

45 113 82 179.6

140 284 225 437

50 122 84 183.2

145 293 230 446

52 125.6

86 186.8

150 302 235 455

54 129.2

88 190.4

155 311 240 464

56 132.8

90 194 160 320 245 473

58 136.4

92 197.6

165 329 250 482

60 140 94 201.2

170 338 255 491

62 143.6

96 204.8

175 347 260 500

64 147.2

98 208.4

180 356 265 509

66 150.8

100 212 185 365 270 518

68 154.4

105 221

70 158 110 230

72 161.6

115 239

74 165.2

120 248

190

195

200

205

274

383

392

401

275

280

285

290

527

537

545

554

76 168.8

125 257

78 172.4

130 266

210 410 295 563

215 419 300 572

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7.3 Manufacturer

FRÖLING GmbH

Industriestraße 12

A-4710 Grieskirchen

AUSTRIA

TEL +0043 (0)7248 606 0

E-MAIL [email protected]

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 [email protected]

INTERNET www.tarmbiomass.com

7.5 Local Dealer

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 [email protected] www.froeling.com

7

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