Froling P1 Pellet Installation Instructions Manual

Installation Instructions

Pellet boiler P1 Pellet

Translation of the original German installation instructions for technicians

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

M1440213_en | Edition 23/09/2013

Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Version of 27 Oct 2011

SUPPLEMENTARY INSTALLATION INSTRUCTIONS FOR THE UK MARKET

TO BE READ IN CONJUNCTION WITH THOSE IN THE MAIN INSTRUCTION MANUAL

These instructions together with those in the instruction manual cover the basic principles to ensure the satisfactory installation of the boiler, although detail may need slight modification to suit particular local site conditions.

In all cases the installation must comply with current Building Regulations, Local Authority

Byelaws and other specifications or regulations as they affect the installation of the boiler.

It should be noted that the Building Regulations requirements may be met by adopting the relevant recommendations given in British Standards BS 8303, BS EN15287-1:2007 as an alternative means to achieve an equivalent level of performance to that obtained following the guidance given in Approved Document J.

Please note that it is a legal requirement under England and Wales Building Regulations that the installation of the boiler is either carried out under Local Authority Building Control approval or is installed by a Competent Person registered with a Government approved

Competent Persons Scheme. HETAS Ltd operate such a Scheme and a listing of their

Registered Competent Persons can be found on their website at

www.hetas.co.uk

.

CO Alarms:-

Building regulations require that when ever a new or replacement fixed solid fuel or wood/biomass appliance is installed in a dwelling a carbon monoxide alarm must be fitted in the same room as the appliance. Further guidance on the installation of the carbon

monoxide alarm is available in BS EN 50292:2002 and from the alarm manufacturer’s

instructions. Provision of an alarm must not be considered a substitute for either installing the appliance correctly or ensuring regular servicing and maintenance of the appliance and chimney system.

HEALTH AND SAFETY PRECAUTIONS

Special care must be taken when installing the boiler such that the requirements of the Health and Safety at

Work Act are met.

Handling

Adequate facilities must be available for loading, unloading and site handling.

Fire Cement

Some types of fire cement are caustic and should not be allowed to come into contact with the skin. In case of contact wash immediately with plenty of water.

Asbestos

This boiler contains no asbestos. If there is a possibility of disturbing any asbestos in the course of installation then please seek specialist guidance and use appropriate protective equipment.

Metal Parts

When installing or servicing this boiler care should be taken to avoid the possibility of personal injury.

Page 1 of 7


BOILER PERFORMANCE

The nominal heat outputs for the various boilers are detailed in the main instruction manual:

PREPARATORY WORK AND SAFETY CHECKS

IMPORTANT WARNING

This boiler must not be installed into a chimney that serves any other heating appliance.

There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to emit fumes into the room.

Chimney

In order for the boiler to perform satisfactorily the chimney height must be sufficient to ensure an adequate draught of approximately 15 Pa so as to clear the products of combustion and prevent smoke problems into the room.

NOTE: A chimney height of not less than 4.5 metres measured vertically from the outlet of the boiler to the top of the chimney should be satisfactory. Alternatively the calculation procedure given in BS EN 13384-1 may be used as the basis for deciding whether a particular chimney design will provide sufficient draught.

The outlet from the chimney should be above the roof of the building in accordance with the provisions of

Building Regulations Approved Document J.

Because these boilers run at high efficiencies the temperature of the flue gases is lower than conventional solid fuel appliances. Although they are not classed as condensing appliances, the low flue gas temperature results in condensation occurring within the flue. Any chimney flue system must therefore be able to withstand the effects of condensate and operate under wet conditions (designation letter W). In addition it should be soot fire resistant and able to withstand the corrosive effects of flue products generated by solid fuels

(designation G and 3 respectively). If installation is into an existing masonry chimney then it will require relining with a liner meeting the specification described above. Existing concrete or clay lined chimneys are not suitable for these boilers and must be lined as described above. All installations must be in accordance with

Building Regulations Approved Document J.

Any existing chimney must be clear of obstruction and have been swept clean immediately before installation of the lining system.

If there is no existing chimney then any new system must be to the designation described above and in accordance with Building Regulations Approved Document J.

A single wall metal fluepipe is suitable for connecting the boiler to the chimney but is not suitable for use as the complete chimney. The chimney and connecting fluepipe must not be less than the size of the outlet socket of the boiler. The length of this connecting pipe should be kept to a minimum. Refer also to the main instruction manual for further guidance.

Any bend in the chimney or connecting fluepipe should not exceed 45 . 90 bends should not be used, except for connecting to a rear outlet appliance, and the connection should be no more than 150 mm in length and have a debris trap.

Combustible material should not be located where the heat dissipating through the walls of fireplaces or flues could ignite it. Therefore when installing the boiler in the presence of combustible materials due account must be taken of the guidance on the separation of combustible material given in Building Regulations Approved

Document J and also in these boiler instructions.

If it is found that there is excessive draught in the chimney then a draught stabiliser should be fitted in the chimney above the chimney above the flue pipe connection. Fitting of a draught stabiliser will affect the requirement for the permanent air supply into the room in which the boiler is fitted in accordance with

Page 2 of 7


Approved Document J (see also combustion air supply).

Adequate provision e.g. easily accessible soot door or doors must be provided for sweeping the chimney and connecting fluepipe.

Connection to the chimney

All the boilers have a flue gas connector that allows connection to the main chimney using a suitable connecting pipe. All joints must be sealed in accordance with the recommendations in Approved Document J.

See also “Chimney” above.

Hearth

The hearth should be able to accommodate the weight of the boiler and its chimney if the chimney is not independently supported. The weight of the boiler is indicated in the instruction manual.

The boiler should always be installed on a non-combustible hearth of a size and construction that is in accordance with the provisions of the current Building Regulations Approved Document J.

The clearance distances to combustible material beneath, surrounding or upon the hearth and walls adjacent to the hearth should comply with the guidance on the separation of combustible material given in Building

Regulations Approved Document J and also in these boiler instructions.

Combustion air supply

In order for the boiler to perform efficiently and safely there should be an adequate air supply into the room in which the boiler is installed to provide combustion air. This is particularly necessary if the room is doubleglazed or a flue draught stabiliser is operating in the same room as the appliance. The provision of air supply to the boiler must be in accordance with current Building Regulations Approved Document J. An opening window is not appropriate for this purpose.

Connection to the central heating system

Ensure the heating system is the correct design for the boiler. It is an essential requirement that the system incorporates a heat storage buffer tank (often referred to as an accumulator). Full guidance is given in the main installation manual. Depending on the intended design of the heating installation and also on the output of the boiler, the central heating system must be in accordance, as appropriate, with either BS 6880:1988

Parts 1 to 3, Code of Practice for low temperature hot water heating systems of output greater than 45kW.

Further guidance is available from the following sources: BS EN 14336:2004: Heating Systems in Buildings.

Installation and commissioning of water based heating systems. BS EN 12828: 2003; Heating Systems in

Buildings. Design of water based heating systems. BS EN 12831: 2003; Heating Systems in Buildings.

Method for calculation of the design heat load.

Particular attention must be paid to the installation and correct functioning of any Thermal Safety Device where necessary. This is described fully in the installation manual.

Page 3 of 7


Electrical connections

The installation of any electrical services during the installation of this boiler and the associated heating system must be carried out by a registered competent electrician and in accordance with the requirements of the latest issue of BS 7671.

Commissioning and handover

Before commissioning this boiler be sure to read and follow the operation manuals to ensure that everything is carried out in accordance with the correct procedures.

Ensure any loose parts are fitted in accordance with the instructions.

Once the boiler is under fire check all seals for soundness and that the boiler and water system are operating correctly. Ensure that the flue is functioning correctly and that all products of combustion are vented safely to atmosphere via the chimney terminal.

On completion of the installation and commissioning ensure that the instruction manuals for the boiler are left with the customer. Ensure to advise the customer on the correct use of the appliance with the fuels likely to be used on the boiler and warn them to use only the recommended fuels for the boiler. The user should be given a demonstration of the required routine maintenance and safety checks. Remind the user of the importance of regular chimney sweeping and servicing by qualified persons to ensure continued safe operation of the boiler.

Leave the boiler operational and inform the user that this is the case.

Advise the user what to do should smoke or fumes be emitted from the boiler. The customer should be warned about the dangers to children, aged and/or infirm persons and that access to the boiler should be protected by a lockable door.

Page 4 of 7

Contents

Contents

1

2

2.1

2.2

2.3

2.4

2.4.1

2.4.2

2.4.3

2.4.4

2.4.5

2.4.6

2.4.7

2.4.8

3

3.1

3.2

3.3

3.4

3.5

4

4.1

4.2

4.3

4.4

4.4.1

4.4.2

4.4.3

4.5

4.5.1

4.5.2

4.5.3

4.6

4.6.1

4.6.2

4.7

4.7.1

2

General

Safety

Hazard levels of warnings

Qualification of assembly staff

Protective equipment for assembly staff

Design Information

Notes on standards

General standards for heating systems

Standards for structural and safety devices

Standards for heating water

Standards for permitted fuels

Installation and approval of the heating system

General information for installation room (boiler room)

Requirements for central heating water

Notes for using pressure maintenance systems

Use with storage tank

Chimney connection/chimney system

Draught limiter

Boiler data for planning the flue gas system

Room air-independent operation

Technology

Dimensions - P1 Pellet

Dimensions - P1 Pellet with hydraulic and boiler block

Components and connections

Dimensions and connections - external suction module

Technical specifications

Assembly

Transport

Positioning

Temporary storage

Setting up in the boiler room

Remove pellet boiler from pallet

Moving the boiler in the boiler room

Minimum distances in the boiler room

Installing the boiler

Aligning the boiler on the floor

Adding a boiler block

Adding a hydraulic block

Installing the discharge system

Installing the external suction module

Connecting suction hoses to the boiler

Electrical Connection

Information on circulating pumps


4

5

6

7

9

9

8

8

7

7

8

7

7

10

10

10

11

11

5

6

13

13

14

15

16

17

19

19

19

19

22

22

23

26

20

20

20

20

29

29

29

30

30

Contents

6

6.1

6.2

6.3

4.7.2

5

5.1

5.2

5.2.1

5.2.2

7

7.1

7.1.1

7.1.2

Universal suction system

Start-up

Before commissioning / configuring the boiler

Initial startup

Permitted fuels

Wood pellets

Non-permitted fuels

Decommissioning

Mothballing

Disassembly

Disposal

Appendix

Addresses

Address of manufacturer

Address of the installer

31

32

32

33

33

33

33

34

34

34

34

35

35

35

35

Installation Instructions P1 Pellet | M1440213_en 3

1

General

1 General

Issuing a delivery cer‐ tificate

Thank you for choosing a quality product from Froling. The product features a state-ofthe-art design and conforms to all currently applicable standards and testing guide‐ lines.

Please read and observe the documentation provided and always keep it close to the system for reference. It contains important safety information and all the operation and maintenance specifications needed to operate the system safely, properly, environ‐ mentally friendly and cost-effectively.

The constant further development of our products means that there may be minor dif‐ ferences from the pictures and content. If you discover any errors, please let us know: [email protected]

Subject to technical change.

The EC Declaration of Conformity is only valid in conjunction with a delivery certificate, which has been filled in correctly and signed as part of the commissioning process.

The original document remains at the installation site. Commissioning installers or heating engineers are requested to return a copy of the delivery certificate together with the guarantee card to Froling. On commissioning by FROLING Customer Service the validity of the delivery certificate will be noted on the customer service record.

4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Safety


2

2 Safety

2.1 Hazard levels of warnings

This documentation uses warnings with the following hazard levels to indicate direct hazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will lead to serious injury or death. You must follow the instructions!

WARNING

The dangerous situation may occur and if measures are not observed it will lead to serious injury or death. Work with extreme care.

CAUTION

The dangerous situation may occur and if measures are not observed it will lead to minor injuries or damage to property.


2

Safety

Qualification of assembly staff

2.2 Qualification of assembly staff

CAUTION

Assembly and installation by untrained personnel:

Risk of personal injury and damage to property.

During assembly and installation:

❒ Observe the instructions and information in the manuals

❒ Only allow trained staff to carry out assembly and installation

Assembly, installation, initial startup and servicing must always be carried out by quali‐ fied personnel:

- Heating technician / building technician

- Electrical installation technician

- Froling customer services

The assembly staff must have read and understood the instructions in the documenta‐ tion.

2.3 Protective equipment for assembly staff

You must ensure that staff have the protective equipment specified by accident pre‐ vention regulations.

▪ For transportation, setup and assembly:

- suitable workwear

- protective gloves

- sturdy shoes


Safety

Design Information

2

2.4 Design Information

2.4.1 Notes on standards

The system must be installed and commissioned in accordance with the local fire and building regulations. The following standards and regulations should always be ob‐ served:

General standards for heating systems

EN 303-5

EN 12828

EN 13384-1

ÖNORM M 7510-1

ÖNORM M 7510-4

Boilers for solid fuels, manually and automatically fed combus‐ tion systems, nominal output up to 300 kW

Heating systems in buildings - Design of water-based heating systems

Chimneys - Thermal and fluid dynamic calculation methods

Part 1: Chimneys serving one appliance

Guidelines for checking central heating systems

Part 1: General requirements and one-off inspections

Guidelines for checking central heating systems

Part 4: Simple check for heating plants for solid fuels

Standards for structural and safety devices

ÖNORM H 5170

ÖNORM M 7137

TRVB H 118

Standards for heating water

Heating installation - Requirements for construction and safety engineering, as well as fire prevention and environmental pro‐ tection

Compressed untreated wood – Requirements for storing pellets at the end customer’s site

Technical directives for fire protection/prevention (Austria)

ÖNORM H 5195-1

VDI 2035 Sheet 1

SWKI 97-1

D.P.R. no. 412

Prevention of damage by corrosion and scale formation in closed warm water heating systems at operating temperatures up to 100 °C (Austria).

Prevention of damage in water heating systems - Scale forma‐ tion in domestic water heating systems and hot water heating systems (Germany)

Water quality for heating, steam, cooling and air conditioning systems (Switzerland)

Regulations for the planning, installation, running/operation and maintenance of heating systems in buildings to reduce energy consumption with reference to Article 4, Comma 4 of the Legis‐ lative Decree of 9 January 1991, No. 10 (Italy)


2

Safety

Design Information

Standards for permitted fuels

EN 14961-2

1. BImSchV

Solid biofuel, fuel specifications and classes.

Part 2: Wood pellets for non-industrial use

First Ordinance of the German Federal Government for imple‐ mentation of the Federal Emission Protection Law, BGBl. I P.

491, in the applicable version.

8

2.4.2 Installation and approval of the heating system

The boiler should be operated in a closed heating system. The following standards govern the installation:

Note on standards

ÖNORM / DIN EN 12828 Heating Systems in Buildings

NOTICE! 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: Inform the civic/municipal building authorities.

Germany: Notify an approved chimney sweep and the building authorities.

2.4.3 General information for 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 light‐ ing in the boiler room in accordance with national workplace design regulations.

▪ When using the boiler over 2000 metres above sea level you should consult the manufacturer.

▪ Danger of fire due to flammable materials.

No flammable materials should be stored near the boiler. Flammable objects (e.g.

clothing) must not be put on the boiler to dry.

▪ Damage due to impurities in combustion air.

Do not use any solvents or cleaning agents containing chlorine in the room where the boiler is installed.

▪ Keep the air suction opening of the boiler free from dust.

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 (foli‐ age, snowdrifts, etc.) from obstructing the air flow.

Unless otherwise specified in the applicable building regulations for the boiler room, the following standards apply to the design and dimensions of the air ducts:


Safety

Design Information

2

Note on standards

ÖNORM H 5170 - Construction and fire protection requirements

TRVB H118 - Technical directives on fire protection/prevention

2.4.4 Requirements for central heating water

The following standards and guidelines apply:

Note on standards

Austria:

Germany:

Switzerland:

Italy:

ÖNORM H 5195-1

VDI 2035

SWKI 97-1

D.P.R. no. 412

NOTICE! Note on filling with make-up water: Always bleed the filling hose before con‐ necting, in order to prevent air from entering the system.

Observe the standards and also follow the recommendations below:

❒ Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to

5.6 dH)

❒ Use softened water as the make-up water

❒ Avoid leaks and use a closed heating system to maintain water quality during op‐ eration

2.4.5 Notes for using pressure maintenance systems

Pressure maintenance systems in hot-water heating systems keep the required pres‐ sure within predefined limits and balance out volume variations caused by changes in the hot-water temperature. Two main systems are used:

Compressor-controlled pressure maintenance

In compressor-controlled pressure maintenance units, a variable air cushion in the ex‐ pansion tank is responsible for volume compensation and pressure maintenance. If the pressure is too low, the compressor pumps air into the tank. If the pressure is too high, air is released by means of a solenoid valve. The systems are built solely with closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐ to the domestic hot water.

Pump-controlled pressure maintenance

A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐ tenance pump, relief valve and an unpressurised receiving tank. The valve releases hot water into the receiving tank if the pressure is too high. If the pressure drops below a preset value, the pump draws water from the receiving tank and feeds it back into the heating system. Pump-controlled pressure maintenance systems with open expan‐ sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the water, exposing the connected system components to the risk of corrosion. These systems offer no oxygen removal for the purposes of corrosion control as required by

VDI 2035 and in the interests of corrosion protection should not be used.


10

2

Safety

Design Information

2.4.6 Use with storage tank

NOTICE

In principle it is not necessary to use a storage tank for the system to run smooth‐ ly. However, we recommend that you use the system with a storage tank, as this ensures a continuous supply of fuel in the ideal output 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.

⇨ See "Addresses" [page 35]

2.4.7 Chimney connection/chimney system

EN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐ ever possible, damage caused by seepage, insufficient feed pressure and condensa‐ tion. Please note in this respect that flue gas temperatures lower than 160K above room temperature can occur in the permitted operating range of the boiler.

The flue gas temperatures (for clean systems) and additional flue gas values can be found in the table below.

The connection between the boiler and the chimney system should be as short as possible. The upward angle of the connection should not exceed 30 - 45°. Insulate the connection. The entire flue gas system - chimney and connection - should be calcula‐ ted in accordance with EN 13384-1.

Local regulations and other statutory regulations also apply.

NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney sweep.

NOTICE! TRVB H 118 (Austria only) stipulates that an explosion flap must be installed in the connecting piece (flue pipe) directly next to the boiler. It should be situated in such a way that is poses no risk to persons!

Draught limiter

The installation of a draught limiter is recommended.

NOTICE! Install the draught limiter directly under the mouth of the flue line, as the pressure is constantly low at this point.


Safety

Design Information

2

Boiler data for planning the flue gas system

Description

Flue gas temperature at nominal load

Flue gas mass flow at nominal load

Flue gas mass flow at partial load

Flue gas mass flow at nominal load

°C kg/h kg/s

Flue gas mass flow at partial load

Required feed pressure at nominal load Pa

Required feed pressure at partial load

Required feed pressure at nominal load mbar

Required feed pressure at partial load

Maximum permissible feed pressure

Flue spigot diameter mm

7

140

17

7

0.005

0.002

10

P1 Pellet

15

150

25

150

36

7

0.007

0.002

16

0.010

0.004

5

2

0.05

0.02

In accordance with ÖNORM/DIN EN 303-5

100 130

20

150

52

20

0.014

0.005

2.4.8 Room air-independent operation

The P1 Pellet has a central air connection on the back of the boiler. If appropriate sup‐ ply air and flue gas connections are installed, the boiler can be operated independent‐ ly of room air as a type C

42

or type C

82

in the sense of EN 15035.

Definition of type C

8

as per EN 15035

Boiler that is connected via its combustion air supply and flue gas outlet, with a con‐ necting 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.

NOTICE! Air is supplied by an air and flue gas system!

Definition of type C

8

as per EN 15035

A boiler that is connected via its combustion air supply and flue gas outlet, with a con‐ necting piece, to a wind protection device and a single or shared chimney.

NOTICE! Air supply via an air supply line that is independent from the chimney sys‐ tem!

NOTICE! 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" (C

42

/ C

82

) indicates type C boilers with a blower fan downstream of the combustion chamber or the heat exchanger.

When dimensioning pipe bends in the supply air line you should note that:


2

Safety

Design Information

The ratio of the radius of curvature (r) to pipe diameter (d) should be greater than 1 r:d ≥ 1

For example:

- Diameter of supply air connection = 60 mm

- Minimum radius of pipe bends 60 mm

Install the supply air line in as straight a line as possible and over the shortest path.

Keep the number of pipe bends to a minimum (ideally a maximum of 4 bends)!

In addition, the following applies: The maximum resistance of the supply air line is 20

Pa!

You can find the necessary dimensions of the supply air connections in the boiler in the technical data sheets.

D

W

TXXX

N2

P1

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

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)


Technology

Dimensions - P1 Pellet

3 Technology

3.1 Dimensions - P1 Pellet

3

Dimen‐ sion

L

L1

B

H

H1

H2

H3

H4

H5

H6

H7

Description

Length, boiler

Total length incl. flue gas pipe connection

Width, boiler

Height, boiler

Height, flue gas pipe connection

Height, ventilation connection

Height, return connection

Height, flow connection

Height, drainage connection

Height, supply air connection

(for room air-independent operation)

Height, suction system connection

Unit mm

940

870

250

240

370

P1 Pellet

7 - 10

650

15 - 20

650

680

600

1200

960

685

750

1200

940

935

870

290

100

360

1110 1110


3

Technology

Dimensions - P1 Pellet with hydraulic and boiler block

3.2 Dimensions - P1 Pellet with hydraulic and boiler block

14

Dimen‐ sion

Description

L1

L2

B

Length, boiler block

Length, hydraulic block

Width of boiler with hydraulic block

H

H1

H2

H3

Overall height of boiler with DHW block

Height, boiler block

Height, boiler block and hydraulic block

Height of flow/return connection of the heating circuits

Height of flow/return connection of the boiler H4

H5

H6

H7

H8

H9

Height of the drainage connection of the boiler

Height of the hot water/circulation connection of the boiler block

Height of the cold water supply of the boiler block

Height, electronic heating cartridge connection

Height, drainage connection of boiler block

H10 Height, flue gas pipe connection

H11 Height, supply air connection (for room air-in‐ dependent operation)

H12 Height, suction system connection

Unit mm

160

185

165

1570

980

1720

P1 Pellet

7 - 10 15 - 20

1150

500

660

1150

500

660

1810

630

1330

1260

1810

630

1330

1260

710

690

350

710

690

350

160

185

165

1550

970

1720


Technology

Components and connections

3.3 Components and connections

3

No.

1

2

3

Boiler flow connection

Boiler return connection

Description

Drainage connection

(with optional hydraulic unit designed as a boiler filling and drainage system)

Air vent connection

7

8

9

4

5

6

Supply air connection (external diameter)

Pellet suction line connection

Return-air line connection

Flue gas pipe connection

Flow and return connection for heating circuit 1

(heating circuit group with high efficiency pump and mixing valve)

10 Flow and return connection for additional heating circuit group

11 Line regulating valve

12 Safety group with

- pressure gauge for system pressure

- quick vent valve

- safety valve

13 Expansion tank (18 litres) integrated into hydraulic block

14 Connection, cold water supply of the tank unit

15 Connection, hot water for the tank unit

16 Connection, circulation line

17 Connection, tank unit drainage

18 Connection for E-cartridge

Unit

Inches mm inches

Inches

P1 Pellet

3/4 IT

3/4 IT

1/2 IT

IG 1

3/4 ET

3/4 ET

3/4 ET

1/2 IT

6/4 IT

1/2 IT

60

50

50

100

1 ET


3

Technology

Dimensions and connections - external suction module

No.

Description Unit

19 Maintenance flange with insulated magnesium protective anode

Not pic‐ tured

DHW loading pump (Wilo Yonos Para) integrated into hydraulic block

3.4 Dimensions and connections - external suction module

P1 Pellet

Dimen‐ sion

D

L

H1

H2

1

2

Name

Suction turbine diameter

Total length incl. wall bracket

Suction turbine height

Total height incl. wall bracket

Return-air line connection (line to suction point)

Return-air line connection (line to boiler)

Unit mm

Suction module

240

265

245

325 mm 50

50


Technology


3

3.5 Technical specifications

Technical specifica‐ tions

P1 Pellet 7-10

Description

Nominal heat output

Output range

Electrical connection

Power consumption

Boiler weight

Total boiler capacity (water)

Pellet container capacity

Ashcan capacity

Domestic hot water content with optional boil‐ er block

Water pressure drop (ΔT = 20 K)

Minimum boiler return temperature

Test report data

P1 Pellet 7-10 kW

W kg l

P1 Pellet 7

7

P1 Pellet 10

10

2 - 7 2 - 10

230V / 50Hz / fused C16A

43 approx. 200 approx. 35

32

13

50 approx. 200 approx. 35

32

13

130

Maximum boiler temperature setting

Minimum boiler temperature setting

Airborne sound level

Boiler class as per EN 303-5:2012

Permitted fuel mbar 0.8

2.1

Not applicable due to internal return temperature control

°C dB(A)

90

40

< 70

5

Wood pellets D06 in accordance with EN

14961-2 class A1

Testing institute

Description P1 Pellet 7

TÜV SÜD

1)

Test report no.

Date of issue

2212100-2

20/06/2013

1.TÜV SÜD, Landesgesellschaft Österreich GmbH, Grazer Straße 18, A - 8600 Bruck an der Mur, Austria

P1 Pellet 10

TÜV SÜD

1)

2212100-1

21/06/2013

Test data - Emissions in [mg/MJ]

1)

(nominal load/partial load)

Carbon monoxide (CO)

Nitrogen oxide (NOx) mg/MJ mg/MJ

2 / 10

80 / 69

Organic hydrocarbons (OGC)

Dust mg/MJ mg/MJ

< 1.0 / 1.0

10.3 / 4.0

11 / 11

83 / 69

1.0 / 1.0

11.2 / 4.0

Boiler efficiency % 94.3 / 90.9

94.5 / 90.9

1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m³]

1)

(nominal load/partial load)

Carbon monoxide (CO) mg/m³ 4 / 15

Nitrogen oxide (NOx) mg/m³ 125 / 107

17 / 15

130 / 107

Organic hydrocarbons (OGC)

Dust mg/m³ mg/m³

< 1.0 / 2.0

16.2 / 6.2

1.0 / 2.0

17.4 / 6.2

Boiler efficiency % 94.3 / 90.9

94.5 / 90.9

1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%


3

Technology


Technical specifica‐ tions

P1 Pellet 15-20

Description

Nominal heat output

Heat output range

Electrical connection

Boiler weight

Pellet container capacity

Ash box capacity

Domestic hot water content with optional boil‐ er block

Minimum boiler return temperature

Maximum boiler temperature setting

Minimum boiler temperature setting

Airborne sound level

Boiler class as per EN 303-5:2012

Permitted fuel kW kg l

P1 Pellet 15

15

P1 Pellet 20

20

4,5 - 15 6 - 20

230V / 50Hz / fused C16A approx. 250

41

18 approx. 250

41

18

130

°C

Not applicable due to internal return temperature control

90

40 dB(A) < 70

5

Wood pellets D06 in accordance with EN

14961-2 class A1


Assembly

Transport

4

4 Assembly

4.1 Transport

The product is delivered on pallet(s) in cardboard packaging.

NOTICE

Damage to components if handled incorrectly

❒ Follow the transport instructions on the packaging.

❒ Transport components with care to avoid damage

❒ Protect the packaging against damp

❒ Pay attention to the pallet's centre of gravity when lifting

4.2 Positioning

❒ Position a fork-lift or similar lifting device at the pallet and bring in the components

If the boiler cannot be brought in on the pallet:

❒ Remove the cardboard and remove the boiler from the pallet

⇨ See "Remove pellet boiler from pallet" [page 20]

For positioning using a crane:

❒ Remove the insulating cover

❒ Secure the crane hook to the crane eye below and lift the boiler

4.3 Temporary storage

If the system is to be assembled at a later stage:

❒ Store components at a protected location, which is dry and free from dust

➥ Damp and frost can damage components, particularly electric ones!


20

4

Assembly


4.4 Setting up in the boiler room

4.4.1 Remove pellet boiler from pallet

The boiler comes screwed to the pallet:

❒ Remove the transport locks

❒ Lift unit off pallet

4.4.2 Moving the boiler in the boiler room

❒ Position a fork-lift or similar lifting device with a suitable load-bearing capacity at the base frame

❒ Lift and transport to the intended position in the installation room

➥ Observe the minimum distances in the boiler room.

4.4.3 Minimum distances in the boiler room

▪ The system should generally be set up so that it is accessible from all sides allow‐ ing quick and easy maintenance.

▪ Regional regulations regarding necessary maintenance areas for inspecting the chimney should be observed in addition to the specified minimum distances!

▪ Observe the applicable standards and regulations when setting up the system.

▪ Observe additional standards for noise protection

(ÖNORM H 5190 - Noise protection measures)

Minimum distances - P1 Pellet

B

A

C

D

Pos.

Name

A Distance - insulated door to wall

B Distance – boiler side to wall

(controller side)

C Distance – back to wall

D Distance – boiler side to wall

(door stop side)

Minimum space (length x width)

P1 Pellet

600 mm

300 mm

300 mm

100 mm

1540 x 1000 mm


Assembly


Minimum distances - P1 Pellet with hydraulic and boiler block

B

A

D

Pos.

Name

A Distance - insulated door to wall

B Distance – boiler side to wall

(controller side)

C Distance – back to wall

D Distance – boiler side to wall

(door stop side)

Minimum space (length x width)

4

P1 Pellet with hydraulic and boiler block

600 mm

300 mm

-

100 mm

1740 x 1000 mm


4

4.5 Installing the boiler

4.5.1 Aligning the boiler on the floor

P1 Pellet

Assembly


After positioning, the boiler must be aligned on the floor:

❒ Use a hexagonal spanner to set the adjustable feet on the underside of the boiler

P1 Pellet with boiler block or as a complete unit

If a boiler block is being added to the boiler or it has come fully preassembled as a unit with a hydraulic and boiler block, adjustable feet are not required.

22

❒ Lift boiler and position the boiler underlays provided under the base frame


Assembly


4

4.5.2 Adding a boiler block

An optional boiler block can be added to the P1 Pellet. All the components and corre‐ sponding flat seals required for fitting to the boiler and operating the DHW tank are provided. Materials and tools for sealing the threaded joints are not included.

❒ Before assembly, position the boiler block on the boiler underlays provided at the place of installation

❒ Remove the front cladding plates from the boiler block

❒ Remove the adjustable feet from the boiler and place the boiler on the boiler block

➥ Note the information about lifting the boiler

⇨ See "Positioning" [page 19]

❒ Screw the boiler to the boiler block and replace the cladding plates


4

Assembly


❒ Fit the threaded socket (G 1" to R 3/4") to the return connection on the boiler

❒ Fit the reducing nipple (G 1" to Rp 3/4") to the return connection on the DHW tank

❒ Screw the pipe bend, line regulating valve, T-piece and pump ball valve together as shown and fit to the return connection of the boiler

➥ Fit the SIL seals provided to all flat-sealing joints

❒ Put the insulation jacket onto the line regulating valve

❒ Fit the blanking plug (G 1") to T-piece

➥ If other components are being added to the heating system in the course of in‐ stallation, the blanking plug is not required. In this case, this connection serves as the return connection of the boiler

24

❒ Screw the pump ball valve and return pipe joint together as shown and fit to the return connection on the DHW tank


❒ Fit the DHW loading pump between the two pump ball valves with SIL seals

❒ Put the insulation jacket onto the pump


Assembly


4

❒ Fit threaded socket (G 1" to R 3/4") to the flow connection on the boiler

❒ Fit the reducing nipple (G 1" to Rp 3/4") to the flow connection on the DHW tank

❒ Screw together the pipe bend, two-way zone valve and flow pipe union as shown and fit to the flow connections on the boiler and DHW tank


❒ Fit the blanking plug (G 1") to T-piece

➥ If other components are being added to the heating system in the course of in‐ stallation, the blanking plug is not required. In this case, this connection serves as the flow connection of the boiler

❒ When you have finished, tighten all the joints again

❒ Place the cover plate onto the boiler block and secure with self-tapping screws


4

Assembly


4.5.3 Adding a hydraulic block

An optional hydraulic block can be added to the P1 Pellet. Depending on the scope of delivery, up to two heating circuits can be supplied. All the components and corre‐ sponding flat seals required for fitting to the boiler and operating the heating circuit(s) are provided. Materials and tools for sealing the threaded joints are not included.

Once you have positioned the boiler at the place of installation:

❒ Take off the cover plates and remove all cladding plates from the hydraulic block

❒ Fit threaded socket (G 1" to R 1/2") to the ventilation connection on the boiler

❒ Fit one threaded socket each (G 1" on R 3/4") to the flow and return connection on the boiler

❒ Fit threaded socket (G 3/4" on R 1/2") to the drainage connection on the boiler

26

❒ Position the hydraulic block at the back of the boiler as shown and adjust to the height of the boiler using the adjustable feet

❒ After aligning, screw the hydraulic block to the boiler

❒ Fit the pipe union for drain to boiler with SIL seal (18x12x2)


Assembly


4

❒ Screw cap valve, elbow pipe (3/4") and threaded socket (G 1" on R 3/4") as well as a double nipple (1") at the top connection to the return pipe union as shown and fit to the diaphragm expansion tank


❒ Fit the blanking plug (G 1") to the bottom and side connection with SIL seal

➥ If other components are being added to the heating system in the course of in‐ stallation, the blanking plug at the side connection is not required. In this case, this connection serves as the return connection of the boiler

❒ Screw together the pipe bend, line regulating valve and pipe union as shown and fit to the return connection on the boiler and to the previously assembled return pipe union


➥ If other components are being added to the heating system in the course of in‐ stallation, the circulating pump is installed instead of the blanking plug.

❒ Fit the flow pipe to the flow connection on the boiler

❒ Fit blanking plug (G 1") to the side connection

➥ If other components are being added to the heating system in the course of in‐ stallation, the blanking plug is not required. In this case, this connection serves as the flow connection of the boiler

❒ Screw the flow and return connection on the heating circuit manifold to the respec‐ tive pipe unions on the boiler each with a pipe bend and a ball valve (1")



4

Assembly


❒ Screw the pipe bend and boiler safety block together and fit to the ventilation con‐ nection on the boiler


❒ Fit the protective plate for the flue pipe and cover plate to the back of the boiler

❒ When you have finished, tighten all the joints again

➥ Also check pre-installed joints, for example the blanking plugs on the heating circuit manifold and the heating circuit assemblies and tighten if necessary

28

❒ Replace the cladding plates removed at the start of assembly on the frame and screw to the hydraulic block and back of the boiler at the dedicated holes

❒ Finally, fit the cover plates


Assembly

Installing the discharge system

4

4.6 Installing the discharge system

Once the discharge system has been assembled in accordance with the assembly in‐ structions enclosed, the suction and return air line needs to be connected to the boiler and the external suction module connected as well.

4.6.1 Installing the external suction module

For the P1 Pellet, the pellets are loaded using an external suction module. The suction module is installed in the return-air line between the boiler and the suction point. Its position can be chosen freely.

❒ Install the wall console with the included anchors and screws at any desired posi‐ tion in the return-air line.

➥ If the suction module is positioned at a maximum distance of 2 m to the boiler, the power supply line can be plugged in as is. At greater distances, the power supply line must be lengthened accordingly on-site!

❒ Lay the return-air line from the suction point to the suction module and connect it to the pressure side (position 1).

❒ Connect the second part of the return-air line to the under-pressure side (position

2) and lay the line to the boiler

4.6.2 Connecting suction hoses to the boiler

At the back of the boiler:

❒ Connect the suction hose of the discharge system to the right connection (“PEL‐

LETS” label)

❒ Connect the return-air line of the discharge system from the external suction mod‐ ule to the left connection

NOTICE! Ensure the potential equalisation matches the discharge system assembly instructions when connecting the hose lines!


30

4

Assembly


4.7 Electrical Connection

DANGER

When working on electrical components:

Risk of electrocution!

When work is carried out on electrical components:

❒ Only have work carried out by a qualified electrician

❒ Observe the applicable standards and regulations

➥ Work must not be carried out on electrical components by unauthorised people

❒ Remove the insulating cover and the side control cover

❒ Connect the power supply cable at the mains connection plug provided

➥ Flexible sheathed cable must be used for the wiring; this must be of the correct size to comply with applicable regional standards and regulations.

➥ The power supply line (mains connection) must be fitted with a C16 A fuse by the customer.

4.7.1 Information on circulating pumps

NOTICE

According to 2012/622/EU external, wet running circulating pumps must comply with the following limit values of the Energy Efficiency Index (EEI):

- Effective from 01/01/2013: Wet running circulating pumps with EEI ≤ 0.27

- Effective from 08/01/2015: Wet running circulating pumps with EEI ≤ 0.23

Only high efficiency pumps with a connection option for a control signal (PDM / 0-10V) should be connected to speed-controlled pump outputs (pump 1 on the core module and pump outputs on the hydraulic module). In this case, the control line is connected to the corresponding PDM outputs of the boards. Observe the connection instructions in the boiler controller documentation!


Assembly


4

CAUTION

When using high efficiency pumps without an additional control line at speed-con‐ trolled pump outputs:

Malfunctions of the boiler, the pump and the hydraulic system may occur!

Therefore:

❒ Do not connect EC motor pumps without a control line to the speed-controlled pump outputs of the boards.

➥ Only use special high efficiency pumps with a connection option for a con‐ trol line (PDM/0-10V)!

➥ Observe the additional instructions and information on board outputs in the operation instructions for the boiler controller.

4.7.2 Universal suction system

With the automatic universal suction system, the Pellet-Box Comfort is linked to the

Core module using flexible cable (5x0.75mm

2

, YMM as per ÖVE-K41-5 or H05VV-F as per DIN VDE 0881-5). This is a 24V control line.

The previous figure shows the plugged-in 5-pin connecting plug of the Comfort pellet box and the accompanying connection layout of the control Lambdatronic P 3200 P1.

To check the plug arrangement:

❒ Perform check using the board's labels

The actuators (1) of the pellet-box must be switched to the "R" position!

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


5

Start-up

Before commissioning / configuring the boiler

5 Start-up

5.1 Before commissioning / configuring the boiler

The boiler must be adjusted to the heating system during commissioning.

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteed if the system is set up by trained professionals and the standard factory settings are observed.

Take the following precautions:

❒ Initial startup should be carried out with an authorised installer or with Froling customer services

❒ Adjust the boiler controller to the system type

❒ Apply boiler standard values

NOTICE! The keypad assignment and the steps necessary to modify the parameters are detailed in the operating instructions for the boiler control unit.

❒ Check the system pressure of the heating system

❒ Check that the heating system is completely vented

❒ Check that the safety devices are present and working correctly

❒ Check that there is sufficient ventilation in the boiler room

❒ Check the seal of the boiler

➥ All doors and inspection openings must be tightly sealed!

❒ Check that drives and actuators are working and turning in the right direction

NOTICE! For how to check the analogue and digital outputs, see the operating instruc‐ tions for the boiler controller

❒ Check that the door contact switch is working correctly

NOTICE! For how to check the digital inputs see the operating instructions for the boil‐ er controller.


Start-up

Initial startup

5

5.2 Initial startup

5.2.1 Permitted fuels

Wood pellets

Wood pellets made from natural wood with a diameter of 6 mm

Note on standards

EU: Fuel acc. to EN 14961 - Part 2: Wood pellets class A1 / D06 and/or: Certification program EN plus

or DIN plus

General note:

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

5.2.2 Non-permitted fuels

The use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐ ing of refuse, is not permitted.

CAUTION

In case of use of non-permitted fuels:

Burning non-permitted fuels increases the cleaning requirements and leads to a build-up of aggressive sedimentation and condensation, which can damage the boiler and also invalidates the guarantee. Using non-standard fuels can also lead to serious problems with combustion.

For this reason, when operating the boiler:

❒ Only use permitted fuels


6

Decommissioning

Mothballing

6 Decommissioning

6.1 Mothballing

The following measures should be taken if the boiler is to remain out of service for several weeks (e.g. during the summer):

❒ Clean the boiler thoroughly and close the doors fully

If the boiler is to remain out of service during the winter:

❒ Have the system completely drained by a qualified technician

➥ Protection against frost

6.2 Disassembly

To disassemble the system, follow the steps for assembly in reverse order.

6.3 Disposal

❒ Ensure that they are disposed of in an environmentally friendly way in accordance with waste management regulations.

❒ You can separate and clean recyclable materials and send them to a recycling centre.


Appendix

Addresses

7 Appendix

7.1 Addresses

7.1.1 Address of manufacturer

FRÖLING

Heizkessel- und Behälterbau GesmbH

Industriestraße 12

A-4710 Grieskirchen

AUSTRIA

TEL 0043 (0)7248 606 0

FAX 0043 (0)7248 606 600

INTERNET www.froeling.com

7.1.2 Address of the installer

Stamp

7


Operating Instructions

Translation of the original German operating instructions for the operator

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

B1000013_en | Edition 02/09/2013



SUPPLEMENTARY OPERATING INSTRUCTIONS FOR THE UK MARKET

TO BE READ IN CONJUNCTION WITH THOSE IN THE OPERATION MANUAL

READ THE OPERATION MANUAL AND

T H E S E

I

I N S T R U C T

I

I

O

N

S

C A R E F U L L Y B E F O R E U S

I

I N G

T

H E

B

O

I

I L

E

R

WARNING NOTE

Properly installed, operated and maintained this boiler will not emit fumes into the dwelling. Occasional fumes from de-ashing and re-fuelling may occur. However, persistent fume emission is potentially dangerous and must not be tolerated. If fume emission does persist, then the following immediate action should be taken:-

(a) Open doors and windows to ventilate room

(b) Shut the boiler down in accordance with the instructions and vacate the room/building.

(c) Check for flue or chimney blockage and clean if required

(d) Do not attempt to relight the fire until the cause of the fume emission has been identified and corrected. If necessary seek expert advice.

The most common cause of fume emission is flueway or chimney blockage. For your own safety these must be kept clean at all times.

IMPORTANT NOTES

General

Before lighting the boiler check with the installer that the installation work and commissioning checks described in the installation instructions have been carried out correctly and that the chimney has been swept c lean, is sound and free from any obstructions. As part of the boilers’ commissioning and handover the installer should have shown you how to operate the boiler correctly.

In particularly cold weather the boiler should not be lit if there is a possibility that any part of the heating system is frozen.

In case of a system fault the boiler is designed to safely shut itself down automatically. If however there is a need to manually shut the boiler down please follow the instructions given in the operation manual. This should only be done in emergency situations.

Always ensure the fuel charging door and the ash door are firmly shut after attending to the boiler as overheating of the boiler may occur if these doors are not fully closed.

CO Alarm

Your installer should have fitted a CO alarm in the same room as the appliance. If the alarm sounds unexpectedly, follow the instructions given under “Warning Note” above.

Page 5 of 7


Protection of vulnerable persons

This type of boiler is unlikely to be installed in a part of the home that would be considered as part of the general living area or easily accessible from such. It is intended to be installed in its own boiler room. This boiler room should be guarded effectively with the use of an appropriate lockable door.

Chimney cleaning

The chimney should be swept a minimum of twice a year. It is important that the flue connection and chimney are swept prior to lighting up after a prolonged shutdown period.

In situations where it is not possible to sweep through the boiler the installer will have provided alternative means, such as a soot door. After sweeping the chimney the boiler flue outlet and the flue pipe connecting the boiler to the chimney must be cleaned with a flue brush.

Periods of Prolonged Non-Use

If the boiler is to be left unused for a prolonged period of time then it should be given a thorough clean to remove ash and unburned fuel residues. To enable a good flow of air through the boiler to reduce condensation and to avoid door seals becoming stuck and subsequently damaged, leave the filling hatch and combustion chamber doors slightly ajar. These actions will reduce the possibility of unnecessary damage and corrosion.

It is important to check, and clean if necessary, the connecting pipe and the chimney prior to lighting up the boiler after a prolonged period of non-use.

Extractor fan

There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to emit smoke and fumes into the room.

Aerosol sprays

Do not use an aerosol spray on or near the boiler when it is alight.

Use of operating tools

Always use the operating tools provided when handling parts likely to be hot when the boiler is in use.

Chimney Fires

If the chimney is thoroughly and regularly swept, chimney fires should not occur. However, if a chimney fire does occur the control system of the boiler should shut down the system. Please follow the instructions in the operation manual for emergency manually shutting down the boiler if it appears that the boiler has not shut down automatically. This should cause the chimney fire to go out in which case the control should be kept at the minimum setting until the fire in the boiler has gone out. The chimney and flueways should then be cleaned. If the chimney fire does not go out when the above action is taken then the fire brigade should be called immediately.

After a chimney fire the chimney should be carefully examined for any damage. Expert advice should be sought if necessary

Page 6 of 7


Permanent air vent

The boiler requires a permanent and adequate air supply in order for it to operate safely and efficiently.

In accordance with current Building Regulations the installer may have fitted a permanent air supply vent into the room in which the boiler is installed to provide combustion air. This air vent should not under any circumstances be shut off or sealed.

Recommended fuels

The boiler is designed to burn specific wood based fuels as detailed in the main instructions.

HETAS Ltd Approval

This appliance has obtained HETAS Ltd approval for burning the specified fuels. Approval does not cover the use of other fuels either alone or mixed with the recommended fuels listed, nor does it cover instructions for the use of other fuels.

Page 7 of 7

Contents

2

3

3.1

3.2

3.2.1

3.3

3.3.1

3.3.2

3.3.3

3.3.4

3.3.5

4

4.1

4.2

4.2.1

4.2.2

1

1.1

General

Product overview, P1 Pellet

2 Safety

2.1

2.2

2.3

2.4

2.4.1

2.4.2

2.5


Pictograms used

General safety information

Permitted uses

Permitted fuels

Wood pellets

Non-permitted fuels

Qualification of operating staff

Protective equipment for operating staff 2.6

2.7

2.7.1

2.7.2

2.7.3

2.7.4

2.7.5

2.7.6

2.8

Design information

Installation and approval of the heating system

General information for installation room (boiler room)

Requirements for central heating water

Notes for using pressure maintenance systems

Use with storage tank

Chimney connection/chimney system

Safety Devices

2.9

Residual risks

2.10

Emergency procedure

2.10.1

Overheating of the system

2.10.2

Smell of flue gas

2.10.3

Fire in the system

Operating the system

Assembly and initial startup

Filling the pellet store

General advice for working in the store

Heating up the boiler

Switching on the power supply

Switching on the boiler

Regulating the boiler

Switching off the boiler

Switching off the power supply

Boiler Servicing

General information on servicing

Inspection and cleaning

Inspection

Checking the system pressure

Checking the safety valve

Cleaning

Empty the ash drawer


6

8

9

9

9

9

10

10

6

7

15

17

17

17

17

10

10

11

11

12

12

13

14

4

5

18

18

19

19

20

20

20

20

20

20

21

21

22

22

22

22

22

22

Contents

5

5.1

5.1.1

5.2

5.3

5.3.1

5.3.2

6

6.1

6.1.1

6.1.2

44.3

4.3.1

4.4

4.5

4.6

4.6.1

4.6.2

4.2.3

Emptying the ash container (P1 Pellet 15-20)

Check the grate and combustion chamber

Periodic inspection and cleaning

Cleaning the heat exchanger and flue gas temperature sensor

Cleaning the induced draught fan

Cleaning the flue gas pipe

Checking the draught controller flap

Emissions measurement by chimney sweep or regulatory body

Measurement at nominal load

Maintenance agreement / Customer service

Replacement parts

Disposal information

Disposal of the ash

Disposal of system components

Troubleshooting

General fault with power supply

Behaviour of system after a power failure

Excessive temperature

Faults with fault message

Procedure for fault messages

Acknowledging a fault message

Appendix

Addresses

Address of manufacturer

Address of the installer

32

32

32

32

30

30

30

30

31

31

31

28

29

29

29

28

28

28

23

24

25

25

27

27

27

Operating Instructions P1 Pellet (Touch) | B1000013_en 3

1

11 General

General

Thank you for choosing a quality product from Fröling. The product features a state-ofthe-art design and conforms to all currently applicable standards and testing guide‐ lines.

Please read and observe the documentation provided and always keep it close to the system for reference. Observing the requirements and safety information in the docu‐ mentation makes a significant contribution to safe, appropriate, environmentally friend‐ ly and economical operation of the system.

The constant further development of our products means that there may be minor dif‐ ferences from the pictures and content. If you discover any errors, please let us know: [email protected].

Subject to technical change.

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.


General

Product overview, P1 Pellet

11.1 Product overview, P1 Pellet

1

1 Pellet boiler, P1 Pellet

2 Boiler controller, Lambdatronic P 3200 P1

2.1

4.3" touch screen for displaying / modifying operating statuses and parameters

2.2

Status LED to display the operating status:

- GREEN constant: BOILER SWITCHED ON

- GREEN flashing (interval: 5 sec. OFF, 1 sec ON): BOILER SWITCHED OFF

- ORANGE flashing: WARNING

- RED flashing: FAULT or ALARM

2.3

Brightness sensor to automatically adjust the display brightness

4

5

2.4

USB port for connecting a USB stick for software updates

3 Main switch

High-limit thermostat (STL)

Door contact switch

6 Maintenance opening for combustion chamber (underneath the cover)

6.1

Inspection glass for checking combustion

7

8

Ashcan (P1 Pellet 7/10) or ash container for automatic ash removal (P1 Pellet 15/20)

Quick start guide


2

Safety


22 Safety

2.1 Hazard levels of warnings

This documentation uses warnings with the following hazard levels to indicate direct hazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will lead to serious injury or death. You must follow the instructions!

WARNING

The dangerous situation may occur and if measures are not observed it will lead to serious injury or death. Work with extreme care.

CAUTION

The dangerous situation may occur and if measures are not observed it will lead to minor injuries or damage to property.


Safety

Pictograms used

2

22.2 Pictograms used

The following symbols are used in the documentation and/or on the boiler to show what is required and forbidden and to give warnings.

In accordance with the Machinery Directive, signs fitted directly within the danger area of the boiler indicate immediate hazards or safety procedures. These stickers must not be removed or covered.

Refer to the operating instruc‐ tions

Wear safety shoes

Wear protective gloves Turn off the main switch

Wear a dust mask

Lock

Keep the doors closed

Work under the supervision of a second person

Unauthorised access prohibited

Warning - hot surface

Warning - hazardous or irritant materials

Warning of injury to fingers or hands, automatic fan

Warning of injury to fingers or hands, gear/chain drive

Hand injury warning

Increased CO concentration warning

Operating Instructions P1 Pellet (Touch) | B1000013_en

No fire, open flames or smoking

Warning - hazardous electrical voltage

Warning - automatic boiler start‐ up

Warning of injury to fingers or hands, automatic screw

Warning of injury to fingers or hands, cutting edge

Warning of injury from being pulled into rotating shafts

Slipping hazard warning

7

8

2

Safety

General safety information

22.3 General safety information

DANGER

If the device is used incorrectly:

Incorrect use of the system can cause severe injury and damage.

When operating the system:

❒ Observe the instructions and information in the manuals

❒ Observe the details on procedures for operation, maintenance and cleaning, as well as troubleshooting in the individual manuals.

❒ Any work above and beyond this should be carried out by authorised heating engineers or by Froling customer services.

WARNING

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 car‐ bonisation gases or flash fires) which can in turn cause serious accidents!

When operating the boiler, please note the following:

❒ Instructions and information regarding versions and minimum values, as well as standards and guidelines for heating components in the instructions must be observed.

WARNING

Severe injuries and damage can be caused by an inadequate flue gas system.

Problems with the flue gas system, such as poor cleaning of the flue pipe or insuf‐ ficient chimney draught, can cause serious faults in combustion (such as sponta‐ neous combustion of carbonisation gases or flash fires).


❒ Optimum boiler performance can only be guaranteed if the flue gas system is functioning correctly.


Safety

Permitted uses

2

22.4 Permitted uses

The Froling Pellet boiler P1 Pellet is designed solely for heating domestic water. Only use fuels specified in the "Permitted fuels" section.

⇨ See "Permitted fuels" [page 9]

The unit 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 en‐ sure you are aware of the potential hazards. The inspection and cleaning intervals in the operating instructions should be observed. Ensure that any faults which might im‐ pair safety are rectified immediately.

The manufacturer or supplier is not liable for any damage resulting from non-permitted uses.

2.4.1 Permitted fuels

Wood pellets

Wood pellets made from natural wood with a diameter of 6 mm

Note on standards

EU: Fuel acc. to EN 14961 - Part 2: Wood pellets class A1 / D06 and/or: Certification program EN plus

or DIN plus

General note:

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

2.4.2 Non-permitted fuels

The use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐ ing of refuse, is not permitted.

CAUTION

In case of use of non-permitted fuels:

Burning non-permitted fuels increases the cleaning requirements and leads to a build-up of aggressive sedimentation and condensation, which can damage the boiler and also invalidates the guarantee. Using non-standard fuels can also lead to serious problems with combustion.

For this reason, when operating the boiler:

❒ Only use permitted fuels


10

2

Safety

Qualification of operating staff

22.5 Qualification of operating staff

CAUTION

If unauthorised persons enter the installation room / boiler room:

Risk of personal injury and damage to property

❒ The operator is responsible for keeping unauthorised persons, in particular children, away from the system.

Only trained operators are permitted to operate the unit. The operator must also have read and understood the instructions in the documentation.

2.6 Protective equipment for operating staff

You must ensure that staff have the protective equipment specified by accident pre‐ vention regulations.

▪ For operation, inspection and cleaning:

- suitable work wear

- protective gloves

- sturdy shoes

2.7 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 oper‐ ating the boiler system, and follow the operating instructions and mandatory regula‐ tions that apply in the country in which the boiler is operated.

2.7.1 Installation and approval of the heating system

The boiler should be operated in a closed heating system. The following standards govern the installation:

Note on standards

ÖNORM / DIN EN 12828 Heating Systems in Buildings

NOTICE! 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: Inform the civic/municipal building authorities.

Germany: Notify an approved chimney sweep and the building authorities.


Safety

Design information

2

22.7.2 General information for 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 light‐ ing in the boiler room in accordance with national workplace design regulations.

▪ When using the boiler over 2000 metres above sea level you should consult the manufacturer.

▪ Danger of fire due to flammable materials.

No flammable materials should be stored near the boiler. Flammable objects (e.g.

clothing) must not be put on the boiler to dry.

▪ Damage due to impurities in combustion air.

Do not use any solvents or cleaning agents containing chlorine in the room where the boiler is installed.

▪ Keep the air suction opening of the boiler free from dust.

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 (foli‐ age, snowdrifts, etc.) from obstructing the air flow.

Unless otherwise specified in the applicable building regulations for the boiler room, the following standards apply to the design and dimensions of the air ducts:

Note on standards

ÖNORM H 5170 - Construction and fire protection requirements

TRVB H118 - Technical directives on fire protection/prevention

2.7.3 Requirements for central heating water

The following standards and guidelines apply:

Note on standards

Austria:

Germany:

Switzerland:

Italy:

ÖNORM H 5195-1

VDI 2035

SWKI 97-1

D.P.R. no. 412

NOTICE! Note on filling with make-up water: Always bleed the filling hose before con‐ necting, in order to prevent air from entering the system.

Observe the standards and also follow the recommendations below:

❒ Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to

5.6 dH)

❒ Use softened water as the make-up water


12

2

Safety

Design information

❒ Avoid leaks and use a closed heating system to maintain water quality during op‐ eration

22.7.4 Notes for using pressure maintenance systems

Pressure maintenance systems in hot-water heating systems keep the required pres‐ sure within predefined limits and balance out volume variations caused by changes in the hot-water temperature. Two main systems are used:

Compressor-controlled pressure maintenance

In compressor-controlled pressure maintenance units, a variable air cushion in the ex‐ pansion tank is responsible for volume compensation and pressure maintenance. If the pressure is too low, the compressor pumps air into the tank. If the pressure is too high, air is released by means of a solenoid valve. The systems are built solely with closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐ to the domestic hot water.

Pump-controlled pressure maintenance

A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐ tenance pump, relief valve and an unpressurised receiving tank. The valve releases hot water into the receiving tank if the pressure is too high. If the pressure drops below a preset value, the pump draws water from the receiving tank and feeds it back into the heating system. Pump-controlled pressure maintenance systems with oopen expan‐ sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the water, exposing the connected system components to the risk of corrosion. These systems offer no oxygen removal for the purposes of corrosion control as required by

VDI 2035 and iin the interests of corrosion protection should not be used.

2.7.5 Use with storage tank

NOTICE

In principle it is not necessary to use a storage tank for the system to run smooth‐ ly. However, we recommend that you use the system with a storage tank, as this ensures a continuous supply of fuel in the ideal output 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.



Safety

Design information

2

22.7.6 Chimney connection/chimney system

EN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐ ever possible, damage caused by seepage, insufficient feed pressure and condensa‐ tion. Please note in this respect that flue gas temperatures lower than 160K above room temperature can occur in the permitted operating range of the boiler.

NOTICE! Please see the technical data contained in the assembly instructions for fur‐ ther information about standards and regulations as well as the flue gas temperatures when clean and the other flue gas values!


2

22.8 Safety Devices

Safety

Safety Devices

14

2.1

BOILER OFF

(switches off the boiler to prevent overheating)

❒ Tap “Boiler OFF"

➥ Automatic mode is switched off

➥ Control system follows the boiler shutdown procedure

➥ The pumps continue to run

3

4

MAIN SWITCH

(switches off the power supply)

Before carrying out work on/in the boiler:

❒ Tap “Boiler OFF"

➥ Automatic mode is switched off

➥ Control system follows the boiler shutdown procedure

❒ Switch off the main switch and let the boiler cool down

HIGH-LIMIT THERMOSTAT (STL)

(protection against overheating)

The STL (high-limit thermostat) switches off the combustion system when the boiler reaches 100°C. The pumps continue to run. Once the temperature falls below approx.

75°C, the STL can be reset mechanically.

5 DOOR CONTACT SWITCH (protection against access to moving components)

If the insulated door opens while the boiler is operating, all of the units stop to prevent injuries at moving components. If the insulated door remains open for more than 30 seconds, the boiler is switched off automatically.

SV SAFETY VALVE

(protection against overheating/excessive pressure)

When the boiler pressure reaches a maximum of 3 bar, the safety valve opens and the heated water is blown off in the form of steam.


Safety

Residual risks

2

22.9 Residual risks

WARNING

When touching hot surfaces:

Severe burns are possible on hot surfaces and the flue gas pipe!

When work is carried out on the boiler:

❒ Shut down the boiler in a controlled way (operating status "Boiler off") and al‐ low it to cool down

❒ Protective gloves must generally be worn for work on the boiler, and it should only be operated using the handles provided

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

WARNING

When inspecting and cleaning the boiler with the main switch on:

Serious injuries possible due to automatic boiler startup!

Before inspection and cleaning work in/on the boiler:

❒ Switch the boiler off by tapping “Boiler off”

The boiler follows the shutdown procedure and switches to "Boiler off“ mode

❒ Allow boiler to cool for at least 1 hour

❒ Switch off the main switch and take precautions to prevent accidental switch‐ ing on.

WARNING

If non-permitted fuel types are used:

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


❒ Only use fuels specified in the "Permitted fuels" section of these operating in‐ structions.


22

Safety

Residual risks


Safety

Emergency procedure

2

22.10 Emergency procedure

2.10.1 Overheating of the system

If the system overheats and the safety devices fail, proceed as follows:

NOTICE! Do not under any circumstances switch off the main switch or disconnect the power supply.

❒ Keep all the doors on the boiler closed

❒ Open all mixing valve taps, switch on all pumps.

➥ The Froling heating circuit control performs this function in automatic operation.

❒ Leave the boiler room and close the door

❒ Open any available radiator thermostat valves

If the temperature does not drop:

❒ Contact the installer or Froling customer services


2.10.2 Smell of flue gas

DANGER

If you smell flue gas in the boiler room:

Inhaling toxic flue gas can be fatal!

If you smell flue gas in the room where the boiler is installed:

❒ Keep all the doors on the boiler closed

❒ Shut down the boiler according to procedure

❒ Ventilate the room where the boiler is installed

❒ Close the fire door and doors to living areas

2.10.3 Fire in the system

DANGER

In case of fire in the system:

Risk of death by fire and poisonous gases

Emergency procedure in case of fire:

❒ Leave the boiler room

❒ Close the doors

❒ Inform the fire department


3


Assembly and initial startup

33 Operating the system

3.1 Assembly and initial startup

Assembly, installation and initial startup of the boiler must only be carried out by quali‐ fied staff, and these procedures are described in the accompanying assembly instruc‐ tions.

NOTICE! See assembly instructions for the P1 Pellet

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteed if the system is set up by trained professionals and the standard factory settings are observed.


❒ Initial startup should be carried out with an authorised installer or with Froling customer services

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

NOTICE! See operating instructions for the Lambdatronic P 3200 P1

The customer is responsible for ensuring the following prior to initial start-up of the system by Froling customer services:

▪ Electrical installation

▪ Installation of water pipes

▪ Flue gas connection including all insulation work

▪ Work must comply with local fire protection regulations

▪ It is essential that the electrician who has carried out the installation work is availa‐ ble when starting up the system for the first time to make any changes to the wir‐ ing which may become necessary.

▪ During initial start-up, operating staff are shown how to use the boiler. It is impera‐ tive for proper handover of the product that those involved are present as this is a one-off opportunity.

NOTICE

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

❒ Tip: If this occurs, clean up using a cleaning rag.



Filling the pellet store

3

33.2 Filling the pellet store

CAUTION

Filling the store when the boiler is switched on could result in damage and consequential injury!

When filling the fuel store:

❒ Switch off the boiler by tapping “Boiler OFF”

➥ The boiler follows the shutdown procedure and switches to "Boiler off" sta‐ tus

❒ Allow the boiler to cool for at least half an hour

When the boiler has cooled down:

❒ Before filling check the store for fines and clean if necessary

➥ Observe the general advice for working in the store.

⇨ See "General advice for working in the store" [page 19]

❒ Close all openings to the store to seal out dust

❒ Fill the store with pellets

➥ Only use permitted pellets

⇨ See "Permitted fuels" [page 9]

3.2.1 General advice for working in the store

Risk of injury due to moveable parts!

Shut off the feeder unit before entering the store!

When cleaning the store an increased amount of dust may be gener‐ ated. Wear a dust mask when working in the store.

Adequately ventilate the store before entering. Keep the door open and always have a second person present. Observe the CO concen‐ tration limit (< 30ppm).

Slick surfaces in the fuel store present a slipping hazard!

Unauthorised access prohibited! Keep children away!

Keep the fuel store locked and store the key in a safe place!

No fire, open flames or smoking in the store!


20

3


Heating up the boiler

33.3 Heating up the boiler

NOTICE

Do not modify the factory settings!

Changing the system's factory settings can be detrimental to efficiency and emis‐ sions of the system.

3.3.1 Switching on the power supply

❒ Turn on the main switch

➥ There is voltage at all of the boiler's components

➥ When the control has completed the system start, the boiler is ready for opera‐ tion

3.3.2 Switching on the boiler

❒ Switch the boiler on by tapping “Boiler ON”

➥ Automatic mode is active

➥ The heating system is controlled via the controller according to the selected mode in automatic mode

❒ For other modes press the relevant function key

➥ Information on function keys in the relevant operating instructions for the

"Lambdatronic P 3200" boiler controller

3.3.3 Regulating the boiler

For the necessary steps, and how to display and alter parameters:

NOTICE! See operating instructions for boiler controller!

3.3.4 Switching off the boiler

❒ Switch boiler off by tapping “Boiler OFF”

➥ The boiler follows the shutdown program and switches to "Boiler off" status

➥ The combustion unit is switched off, the chamber discharge unit and the entire hydraulic system remain active

3.3.5 Switching off the power supply

❒ Turn off the main switch

➥ Boiler controller is switched off

➥ There is no power supply to any of the boiler components

NOTICE! Frost protection function is no longer active!


Boiler Servicing

General information on servicing

4

44 Boiler Servicing

4.1 General information on servicing

DANGER

When working on electrical components:

Risk of electrocution!

When work is carried out on electrical components:

❒ Only have work carried out by a qualified electrician

❒ Observe the applicable standards and regulations

➥ Work must not be carried out on electrical components by unauthorised persons

WARNING

When inspecting and cleaning the boiler with the main switch on:

Serious injuries possible due to automatic boiler startup!

Before inspection and cleaning work in/on the boiler:

❒ Switch the boiler off by tapping “Boiler off”

The boiler follows the shutdown procedure and switches to "Boiler off“ mode

❒ Allow boiler to cool for at least 1 hour

❒ Switch off the main switch and take precautions to prevent accidental switch‐ ing on.

WARNING

Incorrect inspection and cleaning:

Incorrect or insufficient inspection and cleaning of the boiler can cause serious faults in combustion (e.g. spontaneous combustion of carbonisation gases / flash fires) and this can lead to serious accidents and damage!


❒ Clean the boiler following the instructions in the instruction manual. Follow the boiler operating instructions.

NOTICE

We recommend that you keep a maintenance book in accordance with ÖNORM

M7510 of the Technical Directive for Fire Prevention (TRVB)


4

Boiler Servicing


44.2 Inspection and cleaning

4.2.1 Inspection

Checking the system pressure

❒ Check the system pressure on the pressure gauge

➥ The value must be 20% above the pre-stressed pressure of the expansion tank

NOTICE! Check that the position of the pressure gauge and rated pressure of the expansion tank match your installer's specifications!

If the system pressure decreases:

❒ Top up with water

NOTICE! If this happens frequently, the seal of the heating system is faulty! Inform your installer

If large pressure fluctuations are observed:

❒ Ask an expert to inspect the expansion tank

Checking the safety valve

❒ Check the seal of the safety valve regularly and ensure that the valve is not dirty

NOTICE! Inspection work must be carried out in accordance with the manufactur‐ er’s instructions.

4.2.2 Cleaning

The ash drawer must be emptied at the correct interval according to energy require‐ ments and fuel quality. The grate, burn-out tray and combustion chamber should also be checked at these intervals.

Empty the ash drawer

22

❒ Open insulated door

❒ Press the latch down and pull out the ash drawer

❒ Take the ash drawer to the emptying point and empty it


Boiler Servicing


EEmptying the ash container (P1 Pellet 15-20)

4

❒ Open the insulated door

❒ Open the clamps on the left and right of the ash container

❒ Remove the ash container from the ash screw duct

❒ Close the sliding valve on the back of the ash container

❒ Take the ash container to the emptying point and empty it


4

Boiler Servicing


NOTICE! Only clean the grate, burn-out tray and combustion chamber when the boiler has cooled down!

❒ Open insulated door

❒ Pull up and remove the maintenance cover

❒ Unscrew the screw connections on the maintenance cover

❒ Remove the maintenance cover

❒ Check the combustion chamber and burn-out tray for dirt and deposits. Clean where necessary.

❒ Remove the burn-out tray and check the combustion chamber below for dirt and deposits. Clean where necessary.


Boiler Servicing


4

44.2.3 Periodic inspection and cleaning

The boiler must be cleaned and inspected at appropriate intervals depending on the service hours and fuel quality.

Annual cleaning and inspection (1500 to 2000 service hours) is usually sufficient. For fuels with a higher ash content (indicated by short emptying intervals for the ash con‐ tainer), the work should be carried out more frequently.

Cleaning the heat exchanger and flue gas temperature sensor

❒ Undo the locking screw at the back of the boiler and remove the insulating cover

❒ Disconnect the connection cable to the induced draught

❒ Remove the thermal insulation and undo the screws on the heat exchanger cover

❒ Remove the heat exchanger cover together with the induced draught fan

❒ Remove the pipe locking pin from the WOS mount


44

Boiler Servicing


❒ Take the WOS mount off the shaft and remove it together with the WOS springs

❒ Clean the heat exchanger pipes with the brush provided

❒ Clean the flue gas collection chamber and the flue gas pipe opening

❒ Loosen the locking screw on the brass bushing of the flue gas temperature sensor

(AF)

❒ Remove the flue gas temperature sensor and clean it with a clean cloth

❒ Slide the flue gas temperature sensor into the middle of the flue gas pipe and se‐ cure it carefully with a locking screw

❒ To reassemble the components, perform the disassembly steps in reverse order


Boiler Servicing


4

❒ Remove the insulating cover

❒ Remove the screw connections on the induced draught fan

❒ Remove the induced draught fan from the heat exchanger

❒ Check the blower wheel for dirt and damage and clean it with a soft brush or paint brush

NOTICE! When mounting the induced draught fan, check the seal for damage and correct fitting! Replace the seal as necessary!

Cleaning the flue gas pipe

❒ Remove the inspection cover on the connecting pipe

❒ Clean the connecting pipe between the boiler and chimney with a chimney sweep's brush

➥ Depending on the layout of the flue gas pipes and the chimney draught clean‐ ing, yearly may not be enough!

Checking the draught controller flap

❒ Check that the draught controller flap moves freely


28

4

Boiler Servicing

Emissions measurement by chimney sweep or regulatory body

44.3 Emissions measurement by chimney sweep or regulatory body

Various legal regulations stipulate that heating systems must be inspected periodical‐ ly. In Germany this is regulated by the First Federal Emissions Protection Ordinance

(BimSchV) in the last amended version, and in Austria by various state laws. The boil‐ er must always be cleaned 2-3 heating days prior to measurement. It is important to ensure that there is adequate heat consumption on the day of the measurement. (e.g.

storage tank must be able to take heat for the duration of the measurement).

4.3.1 Measurement at nominal load

❒ Activate “Chimney-sweep mode” in the quick menu

➥ The boiler runs for 45 minutes at nominal load

- Boiler temperature is set to 70 °C

- Heating pumps switch on and the mixer valves open

- DHW tank and storage tank loading pump are controlled as normal

❒ Perform the measurement under the following conditions

➥ Flue gas temperature at approx. 110 – 150 °C

➥ CO

2

content of the flue gas between 8 and 11%

➥ Boiler temperature above 65°C

4.4 Maintenance agreement / Customer service

NOTICE! We recommend a yearly inspection by Froling customer services or an au‐ thorised partner (third party maintenance).

Regular maintenance and servicing by a heating specialist will ensure a long, troublefree service life for your heating system. It will ensure that your system stays environ‐ mentally-friendly and operates efficiently and cost-effectively.

In the course of this maintenance the entire system is inspected and optimised, partic‐ ularly regulation and control of the boiler. The emission measurement carried out can also be used to draw conclusions about the combustion performance of the boiler.

For this reason, FROLING offers a service agreement, which optimises operating safety. Please see the details in the accompanying guarantee certificate.

Your Froling customer service office will also be happy to advise you.

NOTICE

All national and regional regulations relating to regular testing of the system must be observed. Please be advised that, in Austria, commercial systems with a rated heat output of 50 kW or more must be regularly tested at yearly intervals in ac‐ cordance with the Heating Plant Regulations (Feuerungsanlagen-Verordnung).

4.5 Replacement parts

With Froling original replacement parts in your boiler, you are using parts that match perfectly. As the parts fit together so well, installation times are shortened and a long service life is maintained.


Boiler Servicing

Disposal information

4

Installing non-original parts will invalidate the guarantee.

❒ Only replace components or parts with original replacement parts

4.6 Disposal information

4.6.1 Disposal of the ash

❒ The ash should be disposed of in accordance with waste management regula‐ tions.

4.6.2 Disposal of system components

❒ Ensure that they are disposed of in an environmentally friendly way in accordance with waste management regulations.

❒ You can separate and clean recyclable materials and send them to a recycling centre.


5

Troubleshooting

General fault with power supply

55 Troubleshooting

5.1 General fault with power supply

Error characteristics

Nothing is shown on the dis‐ play

No power to the controller

Cause of error

General power failure

Main switch is turned off

FI circuit breaker or line pro‐ tection is switched off

Faulty fuse in the controller

Elimination of error

Turn on the main switch

Switch on the FI circuit break‐ er or line protection

Replace the fuse – note the amperage (6.3AT)

5.1.1 Behaviour of system after a power failure

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

Keep the doors of the boiler closed during and after the power failure, at least until the induced draught fan automatically starts up again.

EXCEPTION:

If the boiler operating status was "Heating up", "Pre-heating" or "Ignition" before the power failure, the boiler follows the shutdown procedure and cleaning commences.

Only then does the boiler switch to "Preparation" operating status and the system starts up again.

5.2 Excessive temperature

The high-limit thermostat (STL) shuts down the boiler when it reaches a temperature of max. 100°C. The pumps continue to run.

Once the temperature falls below approx. 75°C, the STL (high-limit thermostat) can be reset mechanically:

❒ Unscrew the cap on the STL (high-limit thermostat)

❒ Unlock the STL (high-limit thermostat) by pressing with a screwdriver


Troubleshooting

Faults with fault message

55.3 Faults with fault message

5

If a fault has occurred and has not yet been cleared:

❒ Status LED indicates the nature of the fault

- Orange flashing: Warning

- Red flashing: Error or alarm

❒ A fault message is shown on the display

The term "fault" is a collective term for warnings, errors and alarms. The boiler reacts differently to the three types of message:

WARNING

ERROR

ALARM

In case of warnings the boiler initially continues controlled opera‐ tion, giving the option of resolving the error quickly to prevent a shutdown.

The boiler follows the shutdown procedure and remains in "Boil‐ er off" status until the problem is resolved.

An alarm triggers a system emergency stop. The boiler shuts down immediately, the heating circuit controller and pumps re‐ main active.

5.3.1 Procedure for fault messages

The procedure in the case of a fault message, the causes of faults and procedure for troubleshooting are described in the operating instructions for the boiler controller:

IMPORTANT! See operating instructions for the Lambdatronic P 3200 P1

5.3.2 Acknowledging a fault message

Trace and remove the fault and then:

❒ Tap the “Cancel” symbol

➥ Status LED constant or flashing green light (depending on operating status)

- Green constant: Boiler switched on

- Green flashing: Boiler switched off


6

66 Appendix

6.1 Addresses

6.1.1 Address of manufacturer

FRÖLING

Heizkessel- und Behälterbau GesmbH

Industriestraße 12

A-4710 Grieskirchen

AUSTRIA

TEL 0043 (0)7248 606 0

FAX 0043 (0)7248 606 600

INTERNET www.froeling.com

6.1.2 Address of the installer

Stamp

Appendix

Addresses


No results