Froling P4 Pellet 100 Assembly Instructions Manual

Assembly Instructions
P4 Pellet 8 - 105
English version of the assembly instructions for technicians.
Read and follow the instructions and safety instructions!
Subject to technical change.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
I
Introduction
Dear customer,
The FROLING P4 Pellet is a state-of-the-art design that conforms to all
currently applicable standards and testing guidelines.
Please read and follow the assembly instructions. They contain safety
instructions and comprehensive information relating to transporting,
setting up and assembling the boiler.
The constant further development of our products means that there may
be minor differences from the pictures and content. If you discover any
errors, please let us know.
Subject to technical change.
Delivery certificate
Keeping a record that the delivery was received correctly and collecting
customer-specific data relating to the system allows us to respond
quickly should problems arise.
We would therefore ask you to confirm that you have received the
product in good condition.
Please send Froling a copy of the delivery certificate, filled in and signed
by the customer.
Guarantee conditions
Our sale and delivery conditions generally apply. These conditions have
been made available to customers, and customers have been made
aware of them at the time of order completion.
You can also find the guarantee conditions on the enclosed guarantee
certificate.
Address of manufacturer
FRÖLING
Heizkessel- und Behälterbau GesmbH
Industriestraße 12
A-4710 Grieskirchen
AUSTRIA
TEL +43 (0)7248 606 0
FAX +43 (0)7248 606 600
E-MAIL [email protected]
WEBSITE www.froeling.com
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Contents
1 General Information
C
5
1.1 Standards
5
1.2 Qualification of assembly staff
5
1.3 Protective equipment for assembly staff
6
1.4 Design information
6
1.4.1 Installation and approval of the heating system ....................................................6
1.4.2 Information on the installation room (boiler room) ................................................6
Boiler room characteristics ................................................................................6
Ventilation of the boiler room.............................................................................7
1.4.3 Heating water requirements ...............................................................................7
1.4.4 Combination with storage tank ...........................................................................7
1.4.5 Chimney connection/chimney system ..................................................................8
Draught limiter ................................................................................................8
Boiler data relating to design of the flue gas system P4 Pellet 8/15/20/25/32/38 ......8
Boiler data relating to design of the flue gas system P4 Pellet 48/60/80/100/105 ......9
1.4.6 Room air-independent operation .........................................................................9
Minimum specification of connection lines .......................................................... 10
1.4.7 Notes on boiler ventilation ............................................................................... 10
2 Technology
2.1 Components and Connections
11
11
2.2 Dimensions
12
2.2.1 Supply air connections for room air-independent operation ................................... 13
2.2.2 Flue gas pipe position ...................................................................................... 13
2.3 Technical specifications
14
2.3.1 P4 Pellet 8/15/20/25 ....................................................................................... 14
2.3.2 P4 Pellet 32/38/48/60 ..................................................................................... 15
2.3.3 P4 Pellet 80/100/105 ...................................................................................... 16
2.3.4 Airborne sound level ....................................................................................... 17
3 Assembly
18
3.1 Transportation
18
3.1.1 Positioning..................................................................................................... 18
3.1.2 Temporary storage ......................................................................................... 18
3.2 Set-up in the boiler room
19
3.2.1 Removing the boiler from the pallet................................................................... 19
3.2.2 Moving the boiler in the boiler room .................................................................. 20
3.2.3 Minimum distances in the boiler room................................................................ 20
3.3 Dismantling for location where positioning is difficult
21
3.3.1 Dismantling the stoker assembly and insulation .................................................. 21
3.3.2 Remove the door and ash drawer (P4 Pellet 8/15/20/25)...................................... 23
3.3.3 Dismantling the suction cyclone cover................................................................ 24
3.3.4 Dismantling the stoker unit .............................................................................. 25
3.3.5 Positioning dimensions after dismantling ............................................................ 28
3.3.6 Notes on reassembly ....................................................................................... 29
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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3.4 Assembling the Pellet Boiler
30
3.4.1 Installing the induced draught fan..................................................................... 30
3.4.2 Fit the ash container and doors (P4 Pellet 32/38/48/60/80/100/105) ..................... 31
3.5 Installing the discharge system
32
3.5.1 General installation information ........................................................................ 32
3.5.2 Hose Lines..................................................................................................... 32
Potential Equalisation ..................................................................................... 33
3.5.3 Universal suction system ................................................................................. 34
Variant 1 – Komfort pellet box ......................................................................... 35
Variant 2 – Eco pellet box ............................................................................... 36
Installing the suction probes and lines .............................................................. 37
3.5.4 Suction screw system...................................................................................... 38
3.5.5 Bag silo discharge system................................................................................ 41
3.5.6 Pellet storage area.......................................................................................... 43
Size of store ................................................................................................. 43
Sloping floor ................................................................................................. 44
Impact cushion.............................................................................................. 44
3.6 Electrical Connection
45
3.6.1 Connecting the Komfort pellet box .................................................................... 46
4 Initial Start-up
47
4.1 Configuring the Boiler
47
4.2 Setting the “Max level and min level” sensor
47
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General
Standards, personnel, design
1 General Information
1.1 Standards
The installation and commissioning of the boiler must be carried out in
accordance with local fire and building regulations.
The following standards and regulations should be observed in any case:
ÖNORM/DIN EN 303-5
Boilers for solid fuels, manually and automatically fed combustion systems;
rated heat output up to 300 kW;
ÖNORM M 7510-1
Guidelines for checking heating systems
Part 1: General requirements and one-off inspection
ÖNORM M 7510-4
Guidelines for checking heating systems
Part 4: Simple check for heating plants for solid fuels
EN 12828
Heating systems in buildings - design of water-based heating systems
EN 13384-1
Chimneys serving one appliance
TRVB H 118
Technical directives for fire protection/prevention (Austria only)
ÖNORM H 5170
Construction and fire protection requirements
ÖNORM M 7135
Compressed untreated wood or bark – pellets and briquettes – Requirements
and test
DIN 51731
Testing solid fuels – compressed untreated wood – Requirements and testing
ÖNORM H 5195-1
Prevention of damage by corrosion and scale formation in closed warm-waterheating systems at operating temperatures up to 100 °C (Austria only).
VDI 2035
Prevention of damage in water heating installations - Scale formation in
domestic hot water supply installations and water heating installations
(Germany only)
SWKI 97-1
Lime scale and corrosion protection in heating systems (Switzerland only)
1.BImSchV
First Ordinance on Implementation of the Federal Emissions Control Act
1.2 Qualification of assembly staff
CAUTION
Assembly and installation by untrained personnel:
Risk of injury and damage to equipment!
The instructions and information provided in the instructions
should be observed!
Only allow trained staff to carry out assembly and installation!
Assembly, installation, initial startup and servicing must only be carried
out by qualified people:
- Heating technicians / building technicians
- Electrical installation technicians
- Froling customer services
The assembly staff must have read and understood the instructions in
the documentation.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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1.3 Protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by
accident prevention regulations.
y During transportation, set-up and assembly of the boiler:
- Work clothing
- Safety shoes
- Protective gloves
1.4 Design information
It is forbidden to carry out modifications to the boiler or to change or
deactivate safety equipment.
Always comply with all fire, building, and electrical regulations when
installing or operating the boiler system, and follow the operating
instructions and mandatory regulations that apply in the country in
which the boiler is operated.
1.4.1 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following
standards govern the installation:
Applicable standard:
ÖNORM / DIN EN 12828 Heating systems in buildings
§
Each heating system must be officially approved.
The appropriate supervisory authority (inspection agency) must always
be informed when installing or modifying a heating system, and
authorisation must be obtained from the building authorities:
- Austria:
Report to the construction authorities of the community or
magistrate
- Germany: Report new installations to an approved chimney sweeper /
the building authorities.
1.4.2 Information on the installation room (boiler room)
Boiler room characteristics
There must not be a potentially explosive atmosphere in the boiler
room as the boiler is not suitable for use in potentially explosive
environments.
The boiler room must be frost-free.
The boiler does not provide any light, so the customer must provide
sufficient lighting in the boiler room in accordance with national
workplace design regulations.
When using the boiler above 2000 metres above sea level you should
consult the manufacturer.
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Standards, personnel, design
Ventilation of the boiler room
Ventilation air for the boiler room should be taken from and expelled
directly outside, and the openings and air ducts should be designed to
prevent weather conditions (foliage, snowdrifts, ...) from having any
effect on the air flow.
Unless otherwise specified in the applicable building regulations for the
boiler room, the following standards apply for the design and dimensions
of the air ducts:
§
Applicable standards:
- TRVB H 118
- ÖNORM H 5170
- UNI 10683
1.4.3 Heating water requirements
There are no special requirements for the filling water of the heating
system. The following standards and guidelines apply:
Applicable standards and guidelines:
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195-1
VDI 2035
SWKI 97-1
D.P.R. no. 412
§
Notice on filling with make-up water:
Always bleed the filling hose before connecting, in order to prevent
air from entering the system.
1.4.4 Combination with storage tank
NOTICE
It is not generally necessary to use a storage tank for the system to run
smoothly. However we recommend that you use it with a storage tank, as this
allows you to achieve continuous reduction within the ideal performance range
of the boiler.
For the correct dimensions of the storage tank and the line insulation (in
accordance with ÖNORM M 7510 or guideline UZ37) please consult your
installer or Froling.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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Standards, personnel, design
1.4.5 Chimney connection/chimney system
EN 303-5 specifies that the entire flue gas system must be designed to
prevent, wherever possible, damage caused by seepage, insufficient
feed pressure and condensation. It should be noted here that flue gas
temperatures of less than 160 K above room temperature can occur
within the permitted operating range of the boiler.
The flue gas temperatures (for clean systems) and additional flue gas
values can be found in the technical specification sheets.
À See “Boiler data relating to design of the flue gas system”
Connect to the chimney via the shortest path, preferably with a vertical
gradient of less than 30–45°. Insulate the connecting piece. The entire
flue gas system (chimney and connection) must be calculated as per
ÖNORM/DIN EN 13384-1 or prior standards ÖNORM M 7515/DIN 4705-1.
1
Local regulations and other statutory regulations also apply.
The chimney must be approved by a smoke trap sweeper or chimney
sweep!
As per TRVB H 118 (only in Austria) an explosion flap must be
installed in the flue pipe or in the chimney.
Draught limiter
Recommended: Installing a draught limiter 1
Install the draught limiter directly under the mouth of the flue line,
as the pressure is lower at this location.
Boiler data relating to design of the flue gas system P4 Pellet
8/15/20/25/32/38
P4 Pellet
Description
Units
8
15
20
25
32
38
Flue gas temperature
RL
°C
140
150
150
150
160
160
Flue gas mass flow
RL
PL
kg/h
25
11
36
15
52
20
65
25
78
32
92
41
Flue gas mass flow
RL
PL
kg/s
0.007
0.003
0.010
0.004
0.014
0.006
0.018
0.007
0.022
0.009
0.025
0.011
Necessary
Feed pressure
RL
PL
Pa
8
6
8
6
8
6
8
6
8
6
8
6
Necessary
Feed pressure
RL
PL
mbar
0.08
0.06
0.08
0.06
0.08
0.06
0.08
0.06
0.08
0.06
0.08
0.06
mm
130
130
130
130
150
150
Flue pipe diameter
RL = Rated Load, PL = Partial Load
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Standards, personnel, design
Boiler data relating to design of the flue gas system P4 Pellet
48/60/80/100/105
P4 Pellet
Description
Units
48
60
80
100
105
Flue gas temperature
RL
°C
160
170
160
170
170
Flue gas mass flow
RL
PL
kg/h
140
60
155
70
215
75
275
95
285
100
Flue gas mass flow
RL
PL
kg/s
0,039
0,017
0,043
0,019
0,060
0,021
0,0760,02
6
0,079
0,028
Necessary
Feed pressure
RL
PL
Pa
8
6
8
6
8
6
8
6
8
6
Necessary
Feed pressure
RL
PL
mbar
0,08
0,06
0,08
0,06
0,08
0,06
0.08
0.06
0,08
0,06
mm
150
150
200
200
200
Flue pipe diameter
RL = Rated Load, PL = Partial Load
1.4.6 Room air-independent operation
The P4 Pellet boiler has a central air connection on the back of the
boiler. If appropriate supply air and flue gas connections are installed,
the boiler can be operated independently of room air as a type C42 or
type C82 in the sense of EN 15035.
Definition of type C4 as per EN 15035:
Boiler that is connected via its combustion air supply and flue gas outlet,
with a connecting piece that may be supplied, to a shared chimney with
a shaft for combustion air supply and a shaft for flue gas outlet. The
mouths of the air and flue gas chimney are either concentric or so close
to each other that similar wind conditions apply.
Air is supplied by an air and flue gas system.
Definition of type C8 as per EN 15035:
A boiler that is connected via its combustion air supply and flue gas
outlet, with a connecting piece, to a wind protection device and a single
or shared chimney.
Air supply via an air supply line that is independent from the
chimney system.
This design requires a wind protection device. If a protective grating
is fitted, you must ensure that the mesh size is sufficiently large to
prevent a significant loss of pressure and/or seal from dirt.
The second index “2” (C42 / C82) indicates type C boilers with a blower
fan behind the combustion chamber or the heat exchanger.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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When dimensioning pipe bends in the supply air line you should note that:
The ratio of the radius of curvature (r) to
pipe diameter (d) should be greater than 1:
r:d ≥ 1
For example P4 Pellet 8/15:
- Diameter of supply air connection = 80 mm
- Minimum radius of pipe bends = 80 mm
Install the supply air line in as straight a line as possible and over the
shortest path. The number of pipe bends should be kept to a
minimum (ideally a maximum of 4 bends).
Also: The resistance of the supply air line can be a maximum of 20 Pa.
You can find the necessary dimensions of the supply air connections in
the boiler in the technical data sheets.
À See 2.2.1 Supply air connections for room air-independent operation
Minimum specification of connection lines
Connecting piece for the combustion air supply as per EN 1856-2:
EN 1856-2 - T080 - N2 - D
Connecting piece for the flue gas outlet as per EN 1856-2:
EN 1856-2 - T200 - P1 - W
TXXX
N2
P1
D
W
...
...
...
...
...
Temperature class (specified in °C)
Pressure class with test pressure = 20 Pa
Pressure class with test pressure = 200 Pa
Condensation resistance not required (dry)
Condensation resistance required (damp)
1.4.7 Notes on boiler ventilation
The boiler system should be set up rising slightly towards the back left,
so the ventilation connection is the highest point of the boiler.
Fitting a functioning, automatic ventilating valve ensures constant
removal of air in the boiler.
This prevents malfunctions due to air in the boiler system.
Fit an automatic ventilating valve!
Tip: Fit a vertical pipe before the automatic ventilating valve as a
calming section, to ensure it is positioned above the level of the
boiler water.
A microbubble separator can also optionally be fitted in the lines to the
boiler.
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Technology
Components, connections, and dimensions
2 Technology
2.1 Components and Connections
4
5
6
1
G
E
F
3
D
B
2
C
A
Pos.
Description
Units
A
Boiler flow connection
B
Boiler return connection
C
Drain
D
Air vent
E
Pellet suction line
F
Return-air line
G
Flue gas pipe connection
1
Lambdatronic P 3200 control
2
Switch box
3
Induced draught fan
4
Safety temperature limiter - STL
5
Main switch
6
Service interface
Inch
mm
8 / 15
20 / 25
32 / 38
48/60
80/100/105
1
6/4
6/4
6/4
2
1
6/4
6/4
6/4
2
1/2
1/2
1/2
1/2
1
1/2
1/2
1/2
1
1
DA 60
DA 60
DA 60
DA 60
DA 60
130
130
150
150
200
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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Components, connections, and dimensions
2.2 Dimensions
Dimension
Description
L
Length, boiler
L*
Length, boiler
L1
Total length inc. induced
draught fan
L1*
Total length inc. induced
draught fan
B
*
B
W1
H
Units
mm
Width of boiler
Width, boiler, inc. support
for positioning unit 1)
mm
Total width, inc. suction
cyclone
Height, boiler
2)
8 / 15
20 / 25
740
740
940
32 / 38
48 / 60
80/100/105
820
900
1000
1020
1100
1070
940
600
770
860
1030
1235
705
875
965
1275
1480
1185
1355
1445
1790
2085
1280
1280
1430
1585
1710
H1
Total height, inc. suction
cyclone
1660
1660
1900
1900
1900
H2
Height, flue pipe connection
1350
1350
1530
1685
1785
H3
Height, flow connection
460
460
460
515
520
H4
Height, return connection
940
955
1085
1240
1360
H5
Height, drainage connection
460
460
460
515
520
H6
Height, ventilation
connection
1030
1030
1155
1310
1430
H8
Height, induced draught fan
connection
1090
1090
1215
1375
1495
Height, suction system
connection
1480
1480
1720
1720
1720
130
130
150
150
200
H15
Flue pipe diameter
mm
mm
1)
Corresponds to the minimum positioning width after removing the stoker assembly, suction cyclone and positioning unit.
2)
Corresponds to the minimum positioning height after removing the stoker assembly, suction cyclone and positioning
unit.
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Technology
Technical specifications
2.2.1 Supply air connections for room air-independent operation
315
215
230
100
P4 Pellet 80 / 100
P4 Pellet 48 / 60
P4 Pellet 32 / 38
305
P4 Pellet 20 / 25
235
P4 Pellet 8 / 15
115
115
170
190
P4 Pellet
Description
Units
8/15
20/25
32/38
48/60
80/100/105
Supply air connection pipe (external diameter)
mm
80
100
125
160
200
2.2.2 Flue gas pipe position
P4 Pellet
Description
Units
8/15
20/25
32/38
48/60
80/100/105
A – Lateral distance
mm
420
585
650
815
1000
B – Depth distance
mm
90
90
85
90
80
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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Technical specifications
2.3 Technical specifications
2.3.1 P4 Pellet 8/15/20/25
P4 Pellet
Description
Rated heat output
Heating efficiency range
Units
kW
8
15
20
25
10,5
14,9
20,0
25,0
3.1-10.5
3.1-14.9
6.0-20.0
7.5-25.0
Mains connection
230V / 50Hz fused 16A
Output
W
96
123
110
110
Boiler weight
kg
350
350
430
430
L
70
70
80
80
mbar
4.3
6.1
4.5
2.9
Boiler capacity (water)
Upstream resistance (ΔT=20°C)
Min. boiler return temperature
Maximum boiler temperature setting
Minimum boiler temperature setting
Permitted operating pressure
Not applicable due to internal return temperature control
°C
bar
Boiler class
Permitted fuel
80
80
80
80
40
40
40
40
3
3
3
3
3
3
3
3
Wood pellets Ø 6mm as per ÖNORM M 7135 / DIN 51731
Test report data
TÜV Austria1)
Testing institute
Test report no.
06-UWC
Wels-EX295/2
2) 3)
2) 4)
06-UWC
Wels-EX295/1
Test data at rated load
Carbon monoxide (CO)
[mg/MJ]
24
39
35
30
Nitrogen oxide (NOx)
[mg/MJ]
74
74
76
78
Organic Hydrocarbons (OGC)
[mg/MJ]
< 1.0
0.6
0.7
0.9
Dust
[mg/MJ]
14
12
11
11
91.6
90.9
91.9
92.9
Boiler efficiency rating
[%]
Test data at partial load
Carbon monoxide (CO)
[mg/MJ]
77
77
72
66
Nitrogen oxide (NOx)
[mg/MJ]
69
69
71
73
Organic Hydrocarbons (OGC)
[mg/MJ]
1.4
1.4
1.3
1.1
Dust
[mg/MJ]
11
11
11
10
92.0
92.0
93.3
94.5
Boiler efficiency rating
[%]
1)
TÜV Austria, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels
2)
In accordance with ÖNORM / DIN EN 303-5, chapter 5.1.3 type test: for a boiler from a range with a consistent
structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤ 2 : 1, to carry out the
tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that
have not been tested in a range, whose values have been determined depending on rated heat output by interpolation,
fulfil the requirements of the norm.
3)
Values of the type P4 Pellet 20 are interpolated between the test protocol 06-UWC/Wels-EX-295/1 and K44302/2.
4)
Values of the type P4 Pellet 25 are interpolated between the test protocol 06-UWC/Wels-EX-295/1 and K44302/2.
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Technical specifications
2.3.2 P4 Pellet 32/38/48/60
P4 Pellet
Description
Rated heat output
Heating efficiency range
Units
kW
32
38
48
60
32,0
38,0
48,0
58,5
8.9-32.0
8.9-38.0
14.4-48
17.3-58.5
Mains connection
230V / 50Hz fused 16A
Output
W
110
110
120
120
Boiler weight
kg
530
530
760
760
L
125
125
170
170
mbar
1.5
2.1
3.6
5.3
Boiler capacity (water)
Upstream resistance (ΔT=20°C)
Min. boiler return temperature
Maximum boiler temperature setting
Minimum boiler temperature setting
Permitted operating pressure
Not applicable due to internal return temperature control
°C
bar
Boiler class
Permitted fuel
80
80
80
80
40
40
40
40
3
3
3
3
3
3
3
3
Wood pellets Ø 6mm as per ÖNORM M 7135 / DIN 51731
Test report data
TÜV SÜD SZA1)
Testing institute
Test report no.
K44302/6
3) 4)
K44302/4
-
TÜV2)
08-UWC/
Wels-EX-337
Test data at rated load
Carbon monoxide (CO)
[mg/MJ]
31
45
25
5
Nitrogen oxide (NOx)
[mg/MJ]
79
77
77
77
Organic Hydrocarbons (OGC)
[mg/MJ]
1.0
1.0
1.5
<2
Dust
[mg/MJ]
10
9
10
11
93.5
92.6
92.4
92.1
Boiler efficiency rating
[%]
Test data at partial load
Carbon monoxide (CO)
[mg/MJ]
61
61
36
10
Nitrogen oxide (NOx)
[mg/MJ]
75
75
71
66
Organic Hydrocarbons (OGC)
[mg/MJ]
1.0
1.0
1.5
<2
Dust
[mg/MJ]
10
10
10
10
95.7
95.7
94.0
92.3
Boiler efficiency rating
[%]
1)
TÜV SÜD SZA Austria, Technische Prüf-GmbH, accredited initial and boiler inspection body in accordance with BGBl. no.
211/92 Arsenal, Object 207, A-1030 Wien
2)
TÜV Austria, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels
3)
In accordance with ÖNORM / DIN EN 303-5, chapter 5.1.3 type test: for a boiler from a range with a consistent
structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤ 2 : 1, to carry out the
tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that
have not been tested in a range, whose values have been determined depending on rated heat output by interpolation,
fulfil the requirements of the norm.
4)
Values of the model, P4 Pellet 48, are interpolated between the test protocol K44302/4 and 08-UWC/Wels-EX-337.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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Technology
Technical specifications
2.3.3 P4 Pellet 80/100/105
P4 Pellet
Description
Rated heat output
Heating efficiency range
Units
kW
80
100
105
80,0
100,0
105,0
24,0-80,0
30-100,0
24,0-105,0
Mains connection
230V / 50Hz fused 16A
Output
W
115
112
112
Boiler weight
kg
1090
1100
1100
L
280
280
280
mbar
4,3
4,3
4,3
Boiler capacity (water)
Upstream resistance (ΔT=20°C)
Min. boiler return temperature
Maximum boiler temperature setting
Minimum boiler temperature setting
Permitted operating pressure
Not applicable due to internal return temperature control
°C
bar
Boiler class
Permitted fuel
80
80
80
40
40
40
3
3
3
3
3
3
Wood pellets Ø 6mm as per ÖNORM M 7135 / DIN 51731
Test report data
TÜV1)
Testing institute
TÜV2)3)
Test report no.
10-UW/WelsEX-242/1
Test data at rated load
Carbon monoxide (CO)
[mg/MJ]
6
6
6
Nitrogen oxide (NOx)
[mg/MJ]
80
83
83
Organic Hydrocarbons (OGC)
[mg/MJ]
<1,5
<1
<1
Dust
[mg/MJ]
12
13
13
93,2
94,3
94,3
Boiler efficiency rating
[%]
Test data at partial load
Carbon monoxide (CO)
[mg/MJ]
29
29
29
Nitrogen oxide (NOx)
[mg/MJ]
62
62
62
Organic Hydrocarbons (OGC)
[mg/MJ]
<1
<1
<1
Dust
[mg/MJ]
10
10
10
93,7
93,7
93,7
Boiler efficiency rating
[%]
1)
TÜV Austria, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels
2)
In accordance with ÖNORM / DIN EN 303-5, chapter 5.1.3 type test: for a boiler from a range with a consistent
structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤ 2 : 1, to carry out the
tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that
have not been tested in a range, whose values have been determined depending on rated heat output by interpolation,
fulfil the requirements of the norm.
3)
Values of the model, P4 Pellet 80, are interpolated between the test protocol 08-UW/Wels-EX-337 and 10-UW/Wels-EX242/1. Partial load data from test protocol 10-UW/Wels-EX242/1
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Technical specifications
2.3.4 Airborne sound level
The sound level specified in the following table is based on sound
measurements on a P4 Pellet 15. (measuring device: Omega HHSL 1)
The sound level of the individual units was plotted at a distance of 1 m
from the sound source.
Ambient level for measurement: 32 dBA
Unit
Measurement
Units in continuous operation:
Induced draught fan (activation: 50%)
41 dBA
Induced draught fan (activation: 65%)
44 dBA
Induced draught fan (activation: 90%)
50 dBA
Units in non-continuous operation:
Suction turbine
68 dBA
Grate motor
42 dBA
Stoker motor / Stoker screw
33 dBA
Ignition fan
53 dBA
WOS motor / WOS system
60 dBA
Burn back slide valve actuator (open)
34 dBA
Burn back slide valve actuator (close)
50 dBA
Please note that all the measurements were taken in-house and do not
come from a certified test station. This data should therefore be viewed
as individual measurements to be used as guidelines.
Please also note the sound levels required in the standards listed below,
which must be fulfilled by planning and construction measures:
ÖNORM B 8115-2
Sound insulation and room acoustics in building
construction - Requirements for sound insulation
ÖNORM H 5190
Heating systems - Acoustic insulation
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 17
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Installation
Transport and Setup
3 Assembly
3.1 Transportation
Do NOT use forklifts for this task!
The boiler is delivered packed in cardboard and
on a pallet.
Move without jarring or jolting
Protect the packaging against damp
Consult the delivery information on the
packaging.
Observe the centre of gravity of the pallet!
The boiler is marked opposite the lifting side
with a sticker.
3.1.1 Positioning
U
Position a lifting truck or similar lifting device at the pallet and
position the boiler
If it is not possible to position the boiler on the pallet:
U Remove the cardboard and remove the boiler from the pallet
À See 3.2.1 Removing the boiler from the pallet
If the boiler must be dismantled for positioning:
U Dismantle the components of the boiler until it can be brought into
position
À See 3.3 Dismantling for location where positioning is difficult
For positioning using a crane:
Remove the insulating cover, the
WOS cover and the heat exchanger
cover
The hoisting point for the crane eye
is below the cover.
U
3.1.2 Temporary storage
If the system is to be installed at a later date:
Store the boiler, insulation and control unit in a safe, dust-free, and
dry location
Moisture and frost reduce the effectiveness of insulation and can
destroy electronic components.
U
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Transport and Setup
3.2 Set-up in the boiler room
3.2.1 Removing the boiler from the pallet
U
U
Remove packing bands with an appropriate tool
Pull off the cardboard from above
1
2
U
U
1
Remove the transport covers (1) of the ash drawers (P4 Pellet 8-25)
or insulated door(s) and ash bucket (P4 Pellet 32-105) and cleaning
devices (2)
Remove the protective casing
On the front of the boiler, P4 Pellet 8/15/20/25:
U Open the insulating door
U Remove securing devices used during transportation on the left and
right side of the base.
U Pull out the lock bolt of the door hinge (1) and remove it from the
guide
U Remove the insulated door and pull out the floor insulation
On the front of the boiler, P4 Pellet 32/38/48/60/80/100/105:
Remove securing devices used during transportation on the left and
right side of the base.
U Remove 2 screws each on the left and right of the ash collecting
plate and remove the collecting plate
U Pull out the floor insulation behind
U
At the back of the boiler:
Remove securing devices used during transportation on the left and
right side of the base.
U
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 19
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Installation
Transport and Setup
3.2.2 Moving the boiler in the boiler room
U
U
Position a lifting truck or similar lifting device with an appropriate
load-bearing capacity at the base frame of the boiler and move to
the specified place
Set up boiler at intended location
Put red boiler underlays under the frame.
Observe the minimum distances in the boiler room.
3.2.3 Minimum distances in the boiler room
P4 Pellet
Description
Units
8/15
20/25
32/38
48/60
80/100/105
A
Minimum distance to suction
cyclone assembly
300
300
300
300
300
B
Induced draught fan
maintenance area
300
300
300
300
300
C
Space for insulated door
550
720
830
490
590
Space requirement with
plug-in insulated door
400
400
300
-
-
Minimum distance to side of
boiler
200
200
200
200
200
D
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mm
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Installation
Transport and Setup
3.3 Dismantling for location where positioning is difficult
If the boiler cannot be brought into position because the space is
confined, it is possible to dismantle individual components.
The following steps show the maximum possible dismantling steps. You
should only carry out the steps that are necessary for positioning.
3.3.1 Dismantling the stoker assembly and insulation
U
U
U
U
Remove the locking screws on the sound insulation hood of the
stoker assembly and remove the sound insulation hood.
Lift the front part of the stoker assembly upwards and remove.
Lift the back part of the stoker assembly upwards and remove
Remove insulating cover
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 21
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Transport and Setup
U
U
U
U
Page 22
M0930811
Unscrew the screws under the insulated cover with the contact
washers at the flaps of the controller cover.
Open insulated door (only for P4 Pellet 8/15/20/25)
Unscrew the screw together with the contact washer on the bottom
side of the controller cover
Remove the controller cover
v
3
Installation
Transport and Setup
3.3.2 Remove the door and ash drawer (P4 Pellet 8/15/20/25)
U
U
Fold out the hinge pins at the top of the insulated door and pull down
Lift the insulated door from the lower hinge and remove
U
Open both ash doors and remove the ash drawer together with
accessories
U
You can optionally remove the upper cover of the settling chamber
and the inner cover
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 23
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Installation
Transport and Setup
3.3.3 Dismantling the suction cyclone cover
U
Remove the covering of the
middle cable duct
At the pellet module:
U Unplug the relevant plugs:
- “Suction unit M3”
- “Max level S1”
- “Gate valve M8”
U
U
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M0930811
Separate the cable tie at the cable leadthrough
Unthread the cables that have been unplugged
v
3
Installation
Transport and Setup
U
U
Wind up the unplugged cables at the units
Open the clamps and take off the cover
3.3.4 Dismantling the stoker unit
U
Remove the covering of the cable duct
At the pellet module:
U Unplug the relevant plugs:
- “Grate drive M6”
- “Burn back flap M7”
- “Stoker motor M1”
- “Ignition E1”
U
Unthread the cables of the unplugged units
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 25
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Installation
Transport and Setup
U
U
U
Remove the back and front locking split pin of the grate drive and
pull out the bolt
CAUTION! Secure the grate motor so it cannot fall down when the
bolt is removed.
U
Push the bushing back at the grate rod
Remove the grate motor
U
Page 26
M0930811
Loosen the locking screw on the ignition fan
Take out the ignition fan
v
3
Installation
Transport and Setup
U
Depending on the design, cut open the aluminium band from the
heat insulation mat below the stoker duct and remove
U
Remove two screw connections on the right and left at the stoker
unit flange
The screws can be removed completely as the stoker unit is hung
on the boiler on two hooks.
The following assembly step requires two people:
Weight of stoker unit P4 Pellet 8/15/20/25: approx. 32 kg
Weight of stoker unit P4 Pellet 32/38: approx. 36 kg
Weight of stoker unit P4 Pellet 48/60: approx. 46 kg
Weight of stoker unit P4 Pellet 80/100/105: approx. 68 kg
U Pull the stoker unit up slightly until the hooks come out of the stoker
flange
U Tip the unit back slightly and lift away
The P4 Pellet is fully dismantled and can now be brought into
position.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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Installation
Transport and Setup
3.3.5 Positioning dimensions after dismantling
P4 Pellet
Dimension
Description
L
Length, boiler
B
Width of boiler
H
Height of boiler
Units
mm
8/15
20/25
32/38
48/60
1)
80/100/105
740
740
740
820
9102)
705
875
965
1275
1480
1280
1280
1430
1585
1710
1)
If the control unit is dismantled, the dimension can be reduced to 780 mm (e.g. for bringing into position through doors
with a clearance of 800 mm)
2)
If the control unit is dismantled, the dimension can be reduced to 880 mm (e.g. for bringing into position through doors
with a clearance of 900 mm)
Dismantling the control unit:
U
U
U
U
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M0930811
Remove the lateral plexiglass covers and secure the nuts of the
screw connection so they cannot turn
Remove the screws on the left and right on the underside
Remove the cable marked “Display” and pull up and out
Remove the control unit
v
3
Installation
Transport and Setup
3.3.6 Notes on reassembly
U
After positioning the boiler, assemble in reverse order
It is particularly important to observe the following points during
assembly:
U
Depending on the design of the insulation, after fitting the stoker
unit and the insulating material it may be necessary to stick a new
aluminium band on top of the aluminium band that was previously
cut.
When fitting the grate motor, check that it is in the correct position on
the back support:
-
Top position = P4 Pellet 8/15/20/25
Bottom position = P4 Pellet 32/38
A position = P4 Pellet 48/60/80/100/105
Observe the installation position of the actuating sleeve between the
grate motor and the slide rod
U
Carefully screw in the locking screw finger-tight
You must not carry on tightening to the extent that the ignition
fan pipe is deformed
Fix the cable with the cable ties supplied.
There must not be any loose cables in the area of the igniter.
Only connect the power supply after completing assembly.
The individual units should be checked by the qualified technician
and adjusted if necessary during initial start-up.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 29
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Installation
Assembling the Pellet Boiler
3.4 Assembling the Pellet Boiler
3.4.1 Installing the induced draught fan
U
U
Remove the locking screws on the sound insulation hood of the
stoker assembly and remove the sound insulation hood.
Open the clamps on the suction cyclone container and lift the cover
´ The induced draught set is in the suction cyclone container
U
Remove the induced draught fan from the suction cyclone container
U
Remove pre-installed cover plate
Unscrew pre-installed nuts and spacer washers
Attach and fix the ID fan as illustrated
The straight edge of the tube flange must be at the top.
U
U
1
U
U
Page 30
M0930811
Join both cables of the ID fan with the pre-installed cables
Ensure that the locking device (1) clicks into place.
Push the cable behind the cladding and put back the cover plate.
v
3
Installation
Assembling the Pellet Boiler
3.4.2 Fit the ash container and doors (P4 Pellet 32/38/48/60/80/100/105)
U
Remove the insulating cover and unscrew the two top retaining
screws with the contact washers of the controller cover
Caution: Do not lose the contact washers!
U
Unscrew the lower retaining screw with contact washer and remove
the controller cover
U
Put the insulated door in the boiler base and secure at the top with
bolts
Take the two cover caps for the ash containers from the ash
containers and position them in the open flaps
U
U
Put in the ash containers and secure with the locking lever
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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Install discharge system
3.5 Installing the discharge system
3.5.1 General installation information
NOTICE
Water lines should not be located in close proximity to the pellet store and the feeder units
due to the dangers posed by condensation and bursting water pipes!
Check the delivered items for foreign objects in the individual components
In the pellet store room an impact cushion must be installed on the opposite side to the filler
pipes. This reduces wear on the pellets when they are blown in and stops the finish being
worn off. Broken pieces of masonry or finish and other foreign bodies (small stones, pieces
of wood, screws, etc.) can block the discharge system or the pellet feed into the boiler and
cause the system to fail. In case of faults due to such foreign bodies, the guarantee is void.
In time pellets leave dust on the ground; this can impair the process of moving them from
the pellet storage area. For this reason you should check and clean if necessary before
refilling.
3.5.2 Hose Lines
For the hose lines used with the suction device, the universal suction system, and the bag silo
discharge unit, observe the following:
Do not kink the hose lines! Minimum bending radius = 30cm
Lay the hose lines as straight as possible! If the lines are sagging, it can lead to so-called
“pockets.” Problem-free pellet feeding can not be guaranteed.
Lay the hose lines in short segments away from walking areas!
Hose lines are not UV-proof!
Therefore: do not lay the hose lines outdoors!
Hose lines are suitable for temperatures up to 60°C!
Therefore: Hose lines must not come into contact with flue gas pipes or uninsulated heating
pipes!
Hose lines must be grounded on both ends, to ensure that no static charge builds up as a
result of transporting the pellets!
The suction line must be a single piece!
The return-air line can be made up of several pieces, but potential equalization must be
established throughout the line!
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Installation
Install discharge system
Potential Equalisation
When connecting the hose lines to the individual connection pipes,
ensure there is potential equalization throughout the line!
U
Expose approximately 3 cm of the grounding strap on the end of the
hose line
TIP: Slit the insulation open along the wire with a knife
U
Bend the earth wire inwards in a loop
´ This prevents the earth wire from being damaged by the feed of
pellets.
U
Install a hose clamp on the hose line
Put the hose line on the connection
U
Ensure that contact is established between the grounding strap and
the connection!
U
Tighten the hose clamp
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 33
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Installation
Install discharge system
3.5.3 Universal suction system
F
J
A
G
B
H
D
G
A
B
I
K
E
Variant 2 Eco pellet box
B
C
Variant 1 Komfort pellet box
A
25 m Suction hose
G
Manual re-arranging unit (Variant 2)
B
Hose clamps 50-65 mm
H
2 x Blind plates (Variant 2)
C
2 x Fire protection choke collars
(only in Austria)
I
6 x Star-shaped screw knobs (Variant 2)
D
Komfort pellet box (Variant 1)
J
Cover plate for wall
E
Support for fire protection choke collar (Variant 1)
K
Suction probe
F
Installation module for wall
50
50
250
250
A
Page 34
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280
280
Before installation:
U Prepare a wall penetration for the pellet box
(width: 28cm, height: 25cm)
Maintain a distance of at least 5 cm from the
finished floor.
Dimensions in mm
v
3
Installation
Install discharge system
Variant 1 – Komfort pellet box
U
Position Komfort pellet box (D) at the wall
penetration
The distance from the wall on the board side
of the pellet box should be at least 10 cm for
maintenance purposes.
10 cm
U
Fix Pellet box to the wall with 4 M8x50 frame
screws and 10 mm dowels
U
Fill the space in the wall penetration with a nonflammable material
The partition must be insulated as per ÖNORM
B 3836 or DIN 4102-11!
D
J
Put the cover plate for the wall (J) onto the pipes
of the pellet box
U Secure the cover plate to the wall using 4 M8x50
frame screws and 10 mm dowels
U
U
Mount the bracket (E) for fire protection choke
collars on the pellet box
Fire protection choke collars only in Austria.
E
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 35
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Installation
Install discharge system
Variant 2 – Eco pellet box
U
F
U
U
Fill the space in the wall penetration with a nonflammable material
The partition should be insulated in
accordance with
ÖNORM B 3836 or DIN 4102-11.
U
Place the wall cover plate (J) on the insertion
module pipes
Secure the cover plate to the wall using 4 M8x50
frame screws and 10 mm dowels
J
U
H
I
G
Page 36
M0930811
Place the wall insertion module (F) at the wall
penetration
Secure the insertion module to the wall using 4
M8x50 frame screws and 10 mm dowels
U
Install 2 blind plates (H) on the insertion module
using 2 star-shaped screw knobs (I)
U
Install interchange unit (G) using 2 star-shaped
screw knobs
No position is specified for the interchange
unit!
v
3
Installation
Install discharge system
Installing the suction probes and lines
A
B
K
Position the suction probes (K) at equal distances
in the pellet supply bin
U Secure the suction probes to the bottom using
frame screws
U Fix hose lines (A) to the suction probe using hose
clips (B)
U Lay the hose lines to the pellet box and secure
them using hose clips
U
B
A
B
CAUTION! Read the label on the suction probe
or pellet box about the suction line and
return-air line! Ensure correct connection!
CAUTION! When connecting the hose lines,
beware of potential equalisation!
À Page 33, Potential Equalisation
À For information on store layout see 3.5.6
Pellet storage area
C
A
Thread the fire protection choke collar (C) on to
the hose line (A)
Fire protection choke collars only in Austria.
U Attach the hose lines to the pellet box pipes
using hose clips (B)
U
U
B
CAUTION! Read the label on the suction probe
or pellet box about the suction line and
return-air line! Ensure correct connection!
C
A
1
2
Lay the hose lines to the boiler, through
identified openings at the back plate and install
with hose clamps to the identified connections
Suction line: hose line to left connection (1)
on the back of the boiler
Return-air line: hose line to right connection
(2) on the back of the boiler
CAUTION! When connecting the hose lines,
beware of potential equalisation!
À Page 33, Potential Equalisation
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 37
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Installation
Install discharge system
3.5.4 Suction screw system
G
J
H
I
N
M
K
F
D
E
L
C
B
A
A
Flange bearing
H
Gearbox flange
B
Ejector flange
I
Drive flange seal
C
Trough mount with rubber pad
J
Geared motor
D
Bearing flange
K
2 x Cover plates for wall penetration
E
Open trough
L
Main worm
F
Suction intake with integrated support
M
Shaft end for main worm
G
Proximity switch
N
Worm extension (if needed)
Before installation:
Prepare wall penetration for suction piece
(width: 34cm, height: 20cm)
Ensure that the channel in the wall
penetration is positioned off centre.
U
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Installation
Install discharge system
U
H1
U
J
U
I
U
L
Thread the basic screw (H1) into the
penetration
The key-way must be toward the boiler!
Thread the closed trough (J) onto the basic
screw on the store side
The quadratic flange points out of the
store!
Thread the open trough (I) onto the basic
screw
Secure together using 4 M10x30 hexagonal
bolts and nuts
Depending on the length of the discharge unit, a
screw extension may be necessary:
U Place the screw extension (N) on the basic
screw (L) and secure it using spring dowels
N
The screw blade must always be rising.
L
If no additional screw is used:
U Put the the end of the basic screw shaft (M)
on the basic screw shaft (L) and secure it
using spring dowels
M
J
U
U
U
G
I
U
H
U
G
Secure the gearing flange (I) and the gearing
flange seal (H) to the suction piece using 4
hexagonal M10 x 40 mm bolts and nuts
- 17 mm hexagonal nut
Lubricate the screw stub shaft
Put on the geared motor (J)
Take care when inserting the key-way into
the groove of the shaft!
Attach the geared motor on the gearing flange
(l) using 4 M8 x 16 mm hexagonal bolts with
spacer washers
- Hexagonal nut dimension 13 mm
Install the proximity switch (G) on the
inspection cover of the suction piece
The proximity switch should project
approx. 1cm into the suction piece
Adjusting the sensitivity during the initial
start-up
À Page 47, 4.2 Setting the “Max level and
min level” sensor
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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Installation
Install discharge system
U
U
D
B
C
A
U
U
U
U
K
U
U
D
1
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M0930811
B
Secure the bearing flange (D) and the trough
mount (C) to the trough using 4 hexagonal M10 x
40 mm bolts and nuts
- Hexagonal nut SW 17 mm
Place the flange bearing unit (A) and the ejecting
flange (B) on the shaft and secure them to the
bearing flange using 2 M14 x 35 mm hexagonal
bolts and spacer washers
- 21 mm socket spanner
Do not lubricate! The flange bearing is
permanently lubricated and is maintenance
free!
Arrange the trough parallel to the store wall
Secure the trough mount and suction piece to the
floor using 2 10 mm dowels and 8 x 70 mm
frame screws
Fill the space in the wall penetration with a nonflammable material
The partition must be insulated as per ÖNORM
B 3836 or DIN 4102-11!
Secure the wall penetration cover plates (K) to
the external store wall using 3 10 mm dowels
and 8 x 50 mm frame screws
Finally, the inclined bottom is installed
The plates of the inclined bottom must not be
placed on the trough!
À Page 44, Sloping floor
Lay both hose lines in the boiler room to the
suction intake
On the left and right of the suction intake:
U Secure the suction hose (B) to the suction
connecting piece using a hose clamp (D)
No connection side specified for suction or
return-air line!
U Put the supplied fire protection choke collar (1)
on the hose and secure it to the suction piece
using 2 self-tapping screws
Fire protection choke collars only in Austria.
v
3
Installation
Install discharge system
U
1
2
Lay the hose lines to the boiler, through
identified openings at the back plate and install
with hose clamps to the identified connections
Suction line: hose line to left connection (1)
on the back of the boiler
Return-air line: hose line to right connection
(2) on the back of the boiler
CAUTION! When connecting the hose lines,
beware of potential equalisation!
À Page 33, Potential Equalisation
3.5.5 Bag silo discharge system
U
Fit frame with bag silo
À See assembly instructions “Pellet bag silo Type I - V”
Observe the height of the boiler room during
planning.
H
H1
H2
Bag silo frame height
Height including filler coupling
1)
Required minimum room height
Ideal store room height 2)
Type I, II
Type III - V
[cm]
185
190
[cm]
205
210
[cm]
[cm]
215
230
220
230
1)
Minimum room height for connection to filler pipe in installation room.
2)
When full, the bag silo has a heap shape. Optimum height is for use of the whole capacity.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 41
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Installation
Install discharge system
U
Fit the bag silo in accordance with the assembly
instructions supplied
U
Put the flange ring (1) onto the bag silo
Put the bag silo and flange ring onto the probe at
the threaded bolts and screw them together
1
U
U
D
U
U
Thread one fire protection choke collar each (B)
onto the suction and return-air lines
Fire protection choke collars only in Austria.
Run hose lines through the openings in the wall
into the pellet store
Secure the hose lines to the silo suction probe
using hose clamps (D)
Read the label on the silo suction probe!
Suction line: The hose line to the cover of the
suction unit
Return-air line: The hose line to the suction
motor
B
U
1
2
Lay the hose lines to the boiler, through
identified openings at the back plate and install
with hose clamps to the identified connections
CAUTION! Observe the label for the suction
line and the return-air line on the silo suction
probe and boiler. Ensure correct connection!
Suction line: hose line to left connection (1)
on the back of the boiler
Return-air line: hose line to right connection
(2) on the back of the boiler
CAUTION! When connecting the hose lines,
beware of potential equalisation!
À Page 33, Potential Equalisation
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M0930811
v
3
Installation
Install discharge system
3.5.6 Pellet storage area
For the universal suction system, the pellet store must be built with an
inclined floor!
The following picture shows the most important components:
B
A
C
D
E
F
A
2 x Filler pipes
B
Earth wire
C
Planking on the store door
D
Sloping floor
E
Impact cushion
F
Under-floor structure for sloping floor
Size of store
The storage area should be able to hold approximately 1.5 times the
annual requirement. The exact amount of required space depends on
the system’s heating load.
Rule of thumb formula: 1m³ store / kW heating burden
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 43
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3
Installation
Install discharge system
Sloping floor
Fig.1: Store for a discharge unit with a suction probe
Fig.2: Store for a discharge unit with a screw
The under-floor structure should be dimensioned so that the sloping
floor is not deformed when subjected to static load. You should ensure
that the pellets can slide down smoothly. This means the sloped floor
should be at an angle of at least 45° and have a smooth surface (we
recommend laminate).
When planning the under-floor structure, note:
1 m³ of pellets roughly corresponds to a weight of 650 kg!
Ideally the suction probes should already be fitted before the sloped
floor is constructed.
A distance of 20 cm should be maintained between the cross-pieces
and the suction probe should be centrally positioned. (see Fig. 1)
The weight of the pellets must not be borne by the trough! (see Fig. 2)
Impact cushion
The baffle plate is made of rubber and is positioned opposite the filling
nozzles at a distance of approximately 20 cm from the wall. It prevents
pellets from striking the wall and knocking off pieces of the finish when
filling.
Pieces of the finish, screws, and other foreign objects can clog the
suction probe!
CAUTION! Damage caused by foreign objects is not covered by the
guarantee!
NOTICE
In time pellets leave dust on the ground; this can impair the process of
moving them from the storage area.
Check the storage area before re-filling and clean if necessary
Regular complete emptying and cleaning of the storage area ensures
consistent readiness for operation!
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v
3
Installation
Connecting the pellet boiler
3.6 Electrical Connection
DANGER
When working on electric components:
Risk of serious injuries from electric shocks
U
Work on electrical components should only be carried out by authorised
technicians
Wiring should be installed using flexible sheathed cable and
dimensioned in compliance with the locally applicable standards and
guidelines
The power supply line (mains connection) must be fitted with a C16
A fuse by the customer.
U
U
U
U
Remove insulating cover
2 pieces Unscrew the retaining screws with contact washers behind
the control unit
Open the insulated door and remove the centrally positioned
retaining screw and contact from below
Remove the front insulating cover and wire the connections in
accordance with the circuit diagram
À Schematic diagrams: See operating instructions “Lambdatronic P
3200”
CAUTION
When using energy-efficient pumps on the speed-regulated pump
outputs:
Malfunctions of the boiler and the hydraulic system are possible!
Take the following precautions:
You must not connect any EC motor pumps at the speedregulated pump outputs of the boards.
Observe the additional instructions and information on board
outputs in the operation instructions of the boiler controller.
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
Page 45
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Installation
Connecting the pellet boiler
3.6.1 Connecting the Komfort pellet box
The connection of the Comfort pellet box to the pellet module board is
established using a flexible cable (5x0.75mm², e.g. YMM as per ÖVEK41-5 or H05VV-F as per DIN VDE 0281-5).
This is a 24V control line.
The previous figure shows the plugged-in 5-pin connecting plug of the
Komfort pellet box and the accompanying connection layout of the
Lambdatronic P3200 control system.
To check the plug arrangement:
U Detach the protective plate (1) from
the board
U Perform check using the board’s
labels
The actuators (2) of the pellet
box must be switched to the “R”
position!
2
1
The actuators are ready to plug in and are connected to the board. All
necessary plug clips are included with the pellet box in delivery
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4
Commissioning
4 Initial Start-up
4.1 Configuring the Boiler
The boiler must be adjusted to the requirements of the heating system
during commissioning
NOTICE
Optimum performance and efficient operation with low emissions can
only be guaranteed if the system is set up by a qualified technician
and the specified factory settings are observed.
Take the following precautions:
U We recommend that the system is commissioned by Froling customer
services or an authorised installer.
Before heating up the boiler for the first time:
U Set the controller to match your heating system.
The keypad layout and necessary control steps for modifying the
parameters can be found in the accompanying operating instructions for
the “Lambdatronic P 3200”.
4.2 Setting the “Max level and min level” sensor
In delivery configuration, the factory settings of the sensor are secured
with a seal. Changes to the settings should only be carried out by
qualified technicians.
Depending on the design, a min level sensor may also be installed.
2
1
The monitoring LED (1) should only illuminate when identifying
materials!
U
If the monitoring LED stays on permanently, the sensitivity is set too
high!
´ Reduce the sensitivity by turning the adjusting screw (2) to the
left
U
If the monitoring LED does not react when pellets are being fed in,
the sensitivity is set too low!
´ Increase the sensitivity of the adjusting screw by turning to the
right
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria
Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com
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