Fröling PT4e 200 Bedienungsanleitung

Installation Instructions

Pellet boiler PT4e 200-250

Translation of the original German installation instructions for technicians

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

M2280120_en | Edition 06/03/2020

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

Table of Contents

1 General 4

2 Safety 5

2.1 Hazard levels of warnings 5

2.2 Qualification of assembly staff 6

2.3 Personal protective equipment for assembly staff 6

3 Design Information 7

3.1 Notes on standards 7

3.1.1 General standards for heating systems 7

3.1.2 Standards for structural and safety devices 7

3.1.3 Standards for heating water 7

3.1.4 Regulations and standards for permitted fuels 8

3.2 Installation and approval of the heating system 9

3.3 General information for installation room (boiler room) 9

3.4 Requirements for central heating water 10

3.5 Notes for using pressure maintenance systems 11

3.6 Return temperature control 12

3.7 Use with storage tank 12

3.8 Chimney connection/chimney system 13

3.8.1 Draught limiter 13

3.8.2 Measuring port 13

3.9 Boiler ventilation 14

4 Technology 15

4.1 Dimensions 15

4.2 Components and connections 17

4.3 External suction module 18

4.4 Technical data 19

4.4.1 PT4e 200 - 250 19

4.4.2 Boiler data for planning the flue gas system 20

5 Assembly 21

5.1 Materials supplied 21

5.2 Transport 21

5.3 Positioning 22

5.4 Temporary storage 23

5.5 Setting up in the boiler room 23

5.5.1 Remove cardboard and transport frame 23

5.5.2 Moving the boiler in the boiler room 23

5.5.3 Operating and maintenance areas of the equipment 24

5.6 Dismantling for location where positioning is difficult 25

5.7 Assembly work 28

Table of Contents

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

5.7.1 Levelling the boiler 28

5.7.2 Installing the pellet suction system 28

5.7.3 Control the return temperature control 31

5.7.4 Adjusting the height of the ash container 31

5.7.5 Install the line regulating valve 32

5.7.6 Installing the external suction module 33

5.7.7 Assembly information for hose lines 35

Potential equalisation

5.8 Hydraulic connection 37

5.9 Electrical connection 38

5.9.1 Lay the cable to the boiler controller 38

5.9.2 Connect the suction unit components 39

Electrical connection

230 V power supply

Connect the suction turbine

Connect the fill level sensors

Supply with 24V DC

Connect sensor of the stoker monitoring

Check the digital module

5.9.3 Mains connection 42

5.9.4 Information on circulating pumps 42

5.9.5 Connecting the discharge system 43

Bag silo / cube / individual probe

pellet mole

1-2-3 suction module

Pellet suction screw DM 80

RS 4 / RS 8 pellet suction system

Configuring the discharge system in the software

5.10 Final installation steps 49

6 Start-up 51

6.1 Before commissioning / configuring the boiler 51

6.2 Initial startup 52

6.2.1 Permitted fuels 52

Wood pellets

6.2.2 Non-permitted fuels 52

7 Decommissioning 53

7.1 Mothballing 53

7.2 Disassembly 53

7.3 Disposal 53

8 Notes 54

9 Appendix 56

9.1 Addresses 56

9.1.1 Address of manufacturer 56

Customer service

9.1.2 Address of the installer 56

Table of Contents

Installation Instructions PT4e 200-250 | M2280120_en 3

1 General

Thank you for choosing a quality product from Froling. The product features a state-of-

the-art design and conforms to all currently applicable standards and testing

guidelines.

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

documentation makes a significant contribution to safe, appropriate, environmentally

friendly and economical operation of the system.

The constant further development of our products means that there may be minor

differences from the pictures and content. If you discover any errors, please let us

know: [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.

Issuing a delivery

certificate

1General

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

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.

NOTICE

The dangerous situation may occur and if measures are not observed it will lead

to damage to property or pollution.

Safety 2

Hazard levels of warnings

Installation Instructions PT4e 200-250 | M2280120_en 5

2.2 Qualification of assembly staff

CAUTION

Assembly and installation by unqualified persons:

Risk of personal injury and damage to property

During assembly and installation:

❒ Observe the instructions and information in the manuals

❒ Only allow appropriately qualified personnel to work on the system

Assembly, installation, initial startup and servicing must always be carried out by

qualified personnel:

- Heating technician / building technician

- Electrical installation technician

- Froling customer services

The assembly staff must have read and understood the instructions in the

documentation.

2.3 Personal protective equipment for assembly staff

You must ensure that staff have the protective equipment specified by accident

prevention regulations.

▪ For transportation, setup and assembly:

- suitable work wear

- protective gloves

- sturdy shoes (min. protection class S1P)

2Safety

Qualification of assembly staff

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

3 Design Information

3.1 Notes on standards

The system must be installed and commissioned in accordance with the local fire and

building regulations. Unless contrary to other national regulations, the latest versions

of the following standards and guidelines apply:

3.1.1 General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fed

combustion systems, nominal heat output up to 500 kW

EN 12828 Heating systems in buildings - design of water-based heating

systems

EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods

Part 1: Chimneys serving one appliance

ÖNORM H 5151 Planning of central hot water heating systems with or without hot

water preparation

ÖNORM M 7510-1 Guidelines for checking central heating systems

Part 1: General requirements and one-off inspections

ÖNORM M 7510-4 Guidelines for checking central heating systems

Part 4: Simple check for heating plants for solid fuels

3.1.2 Standards for structural and safety devices

ÖNORM H 5170 Heating installation - Requirements for construction and safety

engineering, as well as fire prevention and environmental

protection

ÖNORM M 7137 Compressed untreated wood – Requirements for storing pellets

at the end customer’s site

TRVB H 118 Technical directives for fire protection/prevention (Austria)

3.1.3 Standards for heating water

ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in

closed warm water heating systems at operating temperatures

up to 100°C (Austria).

VDI 2035 Prevention of damage hot water heating systems (Germany)

Design Information 3

Notes on standards

Installation Instructions PT4e 200-250 | M2280120_en 7

SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioning

systems (Switzerland)

UNI 8065 Technical standard regulating hot water preparation.

DM 26.06.2015 (Ministerial Decree specifying the minimum

requirements)

Follow the instructions of this standard and any related updates.

(Italy)

3.1.4 Regulations and standards for permitted fuels

1. BImSchV First Order of the German Federal Government for the

implementation of the Federal Law on Emission Protection

(Ordinance on Small and Medium Combustion Plants) in the

version published on 26 January 2010,

BGBl. JG 2010 Part I No. 4.

EN ISO 17225-2 Solid bio-fuel - Fuel specifications and classes

Part 2: Wood pellets for use in industrial and domestic systems

3Design Information

Notes on standards

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

3.2 Installation and approval of the heating system

The boiler should be operated in a closed heating system. The following standards

govern the installation:

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: report to the construction authorities of the community or magistrate

Germany: report new installations to an approved chimney sweep / the building

authorities.

3.3 General information for installation room (boiler room)

Boiler room characteristics

▪ The floor must be even, clean and dry and have an adequate load-bearing

capacity.

▪ 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 ensure sufficient

lighting in the boiler room in accordance with national workplace design

regulations.

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

manufacturer.

▪ Danger of fire due to flammable materials.

The floor of the boiler room must not be flammable. 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 and hydrogen

halides in the room where the boiler is installed (e.g. chlorination units for

swimming pools).

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

▪ The system must be protected against the chewing or nesting of animals (e.g.

rodents etc.).

Note on standards

Design Information 3

Installation and approval of the heating system

Installation Instructions PT4e 200-250 | M2280120_en 9

Ventilation of the boiler room

Ventilation air for the boiler room should be taken from and expelled directly outside,

and the openings and air ducts should be designed to prevent weather conditions

(foliage, snowdrifts, 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:

ÖNORM H 5170 - Construction and fire protection requirements

TRVB H118 - Technical directives on fire protection/prevention

3.4 Requirements for central heating water

Unless contrary to other national regulations, the latest versions of the following

standards and guidelines apply:

Austria:

Germany:

ÖNORM H 5195

VDI 2035

Switzerland

Italy:

SWKI BT 102-01

UNI 8065

Observe the standards and also follow the recommendations below:

❒ Aim for a pH value of between 8.2 and 10.0. If the central heating water comes

into contact with aluminium, the pH value must be between 8.0 and 8.5

❒ Use prepared water which complies with the standards cited above for filling and

make-up water

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

operation

❒ When filling with make-up water, always bleed the filling hose before connecting,

in order to prevent air from entering the system

Advantages of prepared water:

▪ Complies with the applicable standards

▪ Less of a drop in output due to reduced limescale build-up

▪ Less corrosion due to fewer aggressive substances

▪ Long-term cost savings thanks to improved energy efficiency

Note on standards

3Design Information

General information for installation room (boiler room)

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

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