Froling PE1 Pellet Bedienungsanleitung

Installation Instructions

Pellet boiler PE1 Pellet 7-35

Translation of the original German installation instructions for technicians

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

M1441017_en | Edition 24/03/2017

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

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

2.4 Design Information 6

2.4.1 Notes on standards 6

General standards for heating systems

Standards for structural and safety devices

Standards for heating water

Regulations and standards for permitted fuels

2.4.2 Installation and approval of the heating system 8

2.4.3 General information for installation room (boiler room) 8

2.4.4 Requirements for central heating water 9

2.4.5 Notes for using pressure maintenance systems 11

2.4.6 Use with storage tank 11

2.4.7 Chimney connection/chimney system 12

Draught limiter

Measuring port

Boiler data for planning the flue gas system

2.4.8 Room air-independent operation 14

2.4.9 Air supply in the installation room 15

2.4.10 Note on installing an external combustion air supply 15

2.4.11 Simultaneous operation with other air-drawing systems (room ventilation, cooker hood,

centralised dust extraction system, etc.)

Room air-independent appliance

Room air-dependent appliance

Requirements for operating the room air-dependent appliance simultaneously with an air-drawing

system (e.g. with a room ventilation system, centralised dust extraction system, etc.)

3 Technology 20

3.1 Dimensions - PE1 Pellet 7-35 20

3.2 Dimensions - PE1 Pellet 7-20 Unit 21

3.3 Connections - PE1 Pellet 7-35 22

3.4 Components and connections - PE1 Pellet 7-20 Unit 23

3.5 Technical specifications 24

3.5.1 PE1 Pellet 7-10 / PE1 Pellet 7-10 Unit 24

3.5.2 PE1 Pellet 15-20 / PE1 Pellet 15-20 Unit 26

3.5.3 PE1 Pellet 25-30 28

3.5.4 PE1 Pellet 32-35 30

3.6 External suction module 32

4 Assembly 33

4.1 Tools required 33

4.2 Transport 33

4.3 Positioning 34

4.4 Temporary storage 34

Contents

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

4.5 Setting up in the boiler room 35

4.5.1 Moving the boiler in the boiler room 35

4.5.2 Recommended clearances in the boiler room 35

4.6 Install PE1 Pellet 37

4.6.1 Remove boiler from pallet 38

4.6.2 PE1 Pellet 25-35 – Prepare the boiler for transport and setup 39

4.6.3 Aligning the boiler on the floor 40

4.6.4 Prepare for room air-independent operation 42

4.7 Install the PE1 Pellet Unit 43

4.7.1 Remove boiler from pallet 44

4.7.2 Fit the front cover 45

4.7.3 Align the boiler with the floor 46

4.7.4 Install the connection set for room air-independent operation 47

4.7.5 Expansion with electronic heating cartridge 49

4.7.6 Install boiler filling and drainage system 50

4.7.7 Expansion with pipe assembly for storage loading 51

4.7.8 Expansion with pump assembly for second heating circuit 53

4.7.9 Disassemble for easier transport to the installation site 57

4.8 Installing the discharge system 60

4.8.1 Installing the external suction module 60

4.9 Install the protective plate for the flue pipe 62

4.10 Hydraulic connection 63

4.11 Electrical Connection 64

4.11.1 Information on circulating pumps 65

5 Start-up 66

5.1 Filling the system with drinking water 66

5.2 Before commissioning / configuring the boiler 67

6 Decommissioning 68

6.1 Mothballing 68

6.2 Disassembly 68

6.3 Disposal 68

7 Appendix 69

7.1 Addresses 69

7.1.1 Address of manufacturer 69

7.1.2 Address of the installer 69

Contents

Installation Instructions PE1 Pellet 7-35 | M1441017_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 Froling 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 or damage to property.

Safety 2

Hazard levels of warnings

Installation Instructions PE1 Pellet 7-35 | M1441017_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)

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. Unless contrary to other national regulations, the latest versions

of the following standards and guidelines apply:

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

2Safety

Qualification of assembly staff

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

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

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)

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)

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.

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

Safety 2

Design Information

Installation Instructions PE1 Pellet 7-35 | M1441017_en 7

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:

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.

2.4.3 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.).

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.

Note on standards

2Safety

Design Information

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

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

2.4.4 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

makeup 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

Limit values for filling and make-up water:

Austria Germany Switzerland

Total hardness ≤ 1.0 mmol/L ≤ 2.0 mmol/L < 0.1 mmol/L

Conductivity - < 100µS/cm < 100 µS/cm

pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5

Chloride < 30 mg/L < 30 mg/L < 30 mg/L

Note on standards

Safety 2

Design Information

Installation Instructions PE1 Pellet 7-35 | M1441017_en 9

Additional requirements for Switzerland:

The filling and make-up water must be demineralised (fully purified)

▪The water must not contain any ingredients that could settle and accumulate in the

system

▪ This makes the water non-electroconductive, which prevents corrosion

▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can

weaken corrosive materials in certain conditions

If some of the system water is lost, e.g. during repairs, the make-up water must also be

demineralised. It is not enough to soften the water. The heating system must be

professionally cleaned and rinsed before filling the units.

Inspection:

▪ After eight weeks, the pH value of the water must be 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

▪ Yearly. Values must be recorded by the owner

2Safety

Design Information

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

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