Froling P4 Pellet 80, P4 Pellet 100, P4 Pellet 105 Assembly Instructions Manual

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen

Tel [phone] Fax [phone] [e-mail] www.froeling.com

Assembly Instructions

P4 Pellet 8 - 105

English version of the assembly instructions for technicians.
Read and follow the instructions and safety instructions!
Subject to technical change.

Introduction

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Dear customer,

The FROLING P4 Pellet is a state-of-the-art design that conforms to all
currently applicable standards and testing guidelines.

Please read and follow the assembly instructions. They contain safety
instructions and comprehensive information relating to transporting,
setting up and assembling the boiler.

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

Subject to technical change.

Delivery certificate

Keeping a record that the delivery was received correctly and collecting
customer-specific data relating to the system allows us to respond
quickly should problems arise.

We would therefore ask you to confirm that you have received the
product in good condition.

Please send Froling a copy of the delivery certificate, filled in and signed
by the customer.

Guarantee conditions

Our sale and delivery conditions generally apply. These conditions have
been made available to customers, and customers have been made
aware of them at the time of order completion.

You can also find the guarantee conditions on the enclosed guarantee
certificate.

Address of manufacturer

FRÖLING
Heizkessel- und Behälterbau GesmbH

Industriestraße 12
A-4710 Grieskirchen
AUSTRIA

TEL [phone]
FAX [phone]
E-MAIL [e-mail]
WEBSITE www.froeling.com

Contents

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 3
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1 General Information 5

1.1 Standards 5

1.2 Qualification of assembly staff 5

1.3 Protective equipment for assembly staff 6

1.4 Design information 6

1.4.1 Installation and approval of the heating system ....................................................6

1.4.2 Information on the installation room (boiler room) ................................................6

Boiler room characteristics ................................................................................6

Ventilation of the boiler room.............................................................................7

1.4.3 Heating water requirements ...............................................................................7

1.4.4 Combination with storage tank ...........................................................................7

1.4.5 Chimney connection/chimney system ..................................................................8

Draught limiter................................................................................................8

Boiler data relating to design of the flue gas system P4 Pellet 8/15/20/25/32/38 ......8

Boiler data relating to design of the flue gas system P4 Pellet 48/60/80/100/105......9

1.4.6 Room air-independent operation .........................................................................9

Minimum specification of connection lines.......................................................... 10

1.4.7 Notes on boiler ventilation ...............................................................................10

2 Technology 11

2.1 Components and Connections 11

2.2 Dimensions 12

2.2.1 Supply air connections for room air-independent operation ................................... 13

2.2.2 Flue gas pipe position...................................................................................... 13

2.3 Technical specifications 14

2.3.1 P4 Pellet 8/15/20/25....................................................................................... 14

2.3.2 P4 Pellet 32/38/48/60 ..................................................................................... 15

2.3.3 P4 Pellet 80/100/105 ......................................................................................16

2.3.4 Airborne sound level ....................................................................................... 17

3 Assembly 18

3.1 Transportation 18

3.1.1 Positioning..................................................................................................... 18

3.1.2 Temporary storage .........................................................................................18

3.2 Set-up in the boiler room 19

3.2.1 Removing the boiler from the pallet................................................................... 19

3.2.2 Moving the boiler in the boiler room .................................................................. 20

3.2.3 Minimum distances in the boiler room................................................................ 20

3.3 Dismantling for location where positioning is difficult 21

3.3.1 Dismantling the stoker assembly and insulation ..................................................21

3.3.2 Remove the door and ash drawer (P4 Pellet 8/15/20/25)...................................... 23

3.3.3 Dismantling the suction cyclone cover................................................................ 24

3.3.4 Dismantling the stoker unit .............................................................................. 25

3.3.5 Positioning dimensions after dismantling ............................................................ 28

3.3.6 Notes on reassembly....................................................................................... 29

Contents

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3.4 Assembling the Pellet Boiler 30

3.4.1 Installing the induced draught fan..................................................................... 30

3.4.2 Fit the ash container and doors (P4 Pellet 32/38/48/60/80/100/105) ..................... 31

3.5 Installing the discharge system 32

3.5.1 General installation information ........................................................................ 32

3.5.2 Hose Lines..................................................................................................... 32

Potential Equalisation..................................................................................... 33

3.5.3 Universal suction system ................................................................................. 34

Variant 1 – Komfort pellet box......................................................................... 35

Variant 2 – Eco pellet box ............................................................................... 36

Installing the suction probes and lines .............................................................. 37

3.5.4 Suction screw system...................................................................................... 38

3.5.5 Bag silo discharge system................................................................................ 41

3.5.6 Pellet storage area.......................................................................................... 43

Size of store ................................................................................................. 43

Sloping floor ................................................................................................. 44

Impact cushion.............................................................................................. 44

3.6 Electrical Connection 45

3.6.1 Connecting the Komfort pellet box .................................................................... 46

4 Initial Start-up 47

4.1 Configuring the Boiler 47

4.2 Setting the “Max level and min level” sensor 47

General

Standards, personnel, design

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 5
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1 General Information

1.1 Standards

The installation and commissioning of the boiler must be carried out in
accordance with local fire and building regulations.

The following standards and regulations should be observed in any case:

ÖNORM/DIN EN 303-5 Boilers for solid fuels, manually and automatically fed combustion systems;

rated heat output up to 300 kW;

ÖNORM M 7510-1 Guidelines for checking heating systems

Part 1: General requirements and one-off inspection

ÖNORM M 7510-4 Guidelines for checking heating systems

Part 4: Simple check for heating plants for solid fuels

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

EN 13384-1 Chimneys serving one appliance

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

ÖNORM H 5170 Construction and fire protection requirements

ÖNORM M 7135 Compressed untreated wood or bark – pellets and briquettes – Requirements

and test

DIN 51731 Testing solid fuels – compressed untreated wood – Requirements and testing

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

heating systems at operating temperatures up to 100 °C (Austria only).

VDI 2035 Prevention of damage in water heating installations - Scale formation in

domestic hot water supply installations and water heating installations
(Germany only)

SWKI 97-1 Lime scale and corrosion protection in heating systems (Switzerland only)

1.BImSchV First Ordinance on Implementation of the Federal Emissions Control Act

1.2 Qualification of assembly staff

CAUTION

Assembly and installation by untrained personnel:

Risk of injury and damage to equipment!

The instructions and information provided in the instructions
should be observed!

Only allow trained staff to carry out assembly and installation!

Assembly, installation, initial startup and servicing must only be carried
out by qualified people:

- Heating technicians / building technicians

- Electrical installation technicians

- Froling customer services
The assembly staff must have read and understood the instructions in

the documentation.

General

Standards, personnel, design

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1.3 Protective equipment for assembly staff

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

y During transportation, set-up and assembly of the boiler:

- Work clothing

- Safety shoes

- Protective gloves

1.4 Design information

It is forbidden to carry out modifications to the boiler or to change or
deactivate safety equipment.

Always comply with all fire, building, and electrical regulations when
installing or operating the boiler system, and follow the operating
instructions and mandatory regulations that apply in the country in
which the boiler is operated.

1.4.1 Installation and approval of the heating system

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

Applicable standard:

ÖNORM / DIN EN 12828 Heating systems in buildings

 Each heating system must be officially approved.

The appropriate supervisory authority (inspection agency) must always
be informed when installing or modifying a heating system, and
authorisation must be obtained from the building authorities:

- Austria: Report to the construction authorities of the community or
magistrate

- Germany: Report new installations to an approved chimney sweeper /
the building authorities.

1.4.2 Information on the installation room (boiler room)

Boiler room characteristics

 There must not be a potentially explosive atmosphere in the boiler

room as the boiler is not suitable for use in potentially explosive
environments.

 The boiler room must be frost-free.
 The boiler does not provide any light, so the customer must provide

sufficient lighting in the boiler room in accordance with national
workplace design regulations.

 When using the boiler above 2000 metres above sea level you should

consult the manufacturer.

§

General

Standards, personnel, design

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Ventilation of the boiler room

Ventilation air for the boiler room should be taken from and expelled
directly outside, and the openings and air ducts should be designed to
prevent weather conditions (foliage, snowdrifts, ...) from having any
effect on the air flow.

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

Applicable standards:

- TRVB H 118

- ÖNORM H 5170

- UNI 10683

1.4.3 Heating water requirements

There are no special requirements for the filling water of the heating
system. The following standards and guidelines apply:

Applicable standards and guidelines:

Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1
Italy: D.P.R. no. 412

 Notice on filling with make-up water:

Always bleed the filling hose before connecting, in order to prevent
air from entering the system.

1.4.4 Combination with storage tank

NOTICE

It is not generally necessary to use a storage tank for the system to run
smoothly. However we recommend that you use it with a storage tank, as this
allows you to achieve continuous reduction within the ideal performance range
of the boiler.

For the correct dimensions of the storage tank and the line insulation (in
accordance with ÖNORM M 7510 or guideline UZ37) please consult your
installer or Froling.

§

§

General

Standards, personnel, design

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1.4.5 Chimney connection/chimney system

EN 303-5 specifies that the entire flue gas system must be designed to
prevent, wherever possible, damage caused by seepage, insufficient
feed pressure and condensation. It should be noted here that flue gas
temperatures of less than 160 K above room temperature can occur
within the permitted operating range of the boiler.

The flue gas temperatures (for clean systems) and additional flue gas
values can be found in the technical specification sheets.

À See “Boiler data relating to design of the flue gas system”

Connect to the chimney via the shortest path, preferably with a vertical
gradient of less than 30–45°. Insulate the connecting piece. The entire
flue gas system (chimney and connection) must be calculated as per
ÖNORM/DIN EN 13384-1 or prior standards ÖNORM M 7515/DIN 4705-1.

Local regulations and other statutory regulations also apply.
 The chimney must be approved by a smoke trap sweeper or chimney

sweep!

 As per TRVB H 118 (only in Austria) an explosion flap must be

installed in the flue pipe or in the chimney.

Draught limiter

 Recommended: Installing a draught limiter 1
 Install the draught limiter directly under the mouth of the flue line,

as the pressure is lower at this location.

Boiler data relating to design of the flue gas system P4 Pellet
8/15/20/25/32/38

P4 Pellet

Description Units 8 15 20 25 32 38

Flue gas temperature RL °C 140 150 150 150 160 160

Flue gas mass flow RL
PL

kg/h

25
11

36
15

52
20

65
25

78
32

92
41

Flue gas mass flow RL
PL

kg/s

0.007

0.003

0.010

0.004

0.014

0.006

0.018

0.007

0.022

0.009

0.025

0.011

Necessary RL
Feed pressure PL

Pa

8
6

8
6

8
6

8
6

8
6

8
6

Necessary RL
Feed pressure PL

mbar

0.08

0.06

0.08

0.06

0.08

0.06

0.08

0.06

0.08

0.06

0.08

0.06

Flue pipe diameter mm 130 130 130 130 150 150

RL = Rated Load, PL = Partial Load

1

General

Standards, personnel, design

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Boiler data relating to design of the flue gas system P4 Pellet
48/60/80/100/105

P4 Pellet

Description Units 48 60 80 100 105

Flue gas temperature RL °C 160 170 160 170 170

Flue gas mass flow RL
PL

kg/h

140

60

155

70

215

75

275

95

285
100

Flue gas mass flow RL
PL

kg/s

0,039
0,017

0,043
0,019

0,060
0,021

0,0760,02

6

0,079
0,028

Necessary RL
Feed pressure PL

Pa

8
6

8
6

8
6

8
6

8
6

Necessary RL
Feed pressure PL

mbar

0,08
0,06

0,08
0,06

0,08
0,06

0.08

0.06

0,08
0,06

Flue pipe diameter mm 150 150 200 200 200

RL = Rated Load, PL = Partial Load

1.4.6 Room air-independent operation

The P4 Pellet boiler has a central air connection on the back of the
boiler. If appropriate supply air and flue gas connections are installed,
the boiler can be operated independently of room air as a type C

42

or

type C

82

in the sense of EN 15035.

Definition of type C

4

as per EN 15035:

Boiler that is connected via its combustion air supply and flue gas outlet,
with a connecting piece that may be supplied, to a shared chimney with
a shaft for combustion air supply and a shaft for flue gas outlet. The
mouths of the air and flue gas chimney are either concentric or so close
to each other that similar wind conditions apply.

 Air is supplied by an air and flue gas system.

Definition of type C

8

as per EN 15035:

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

 Air supply via an air supply line that is independent from the

chimney system.

 This design requires a wind protection device. If a protective grating

is fitted, you must ensure that the mesh size is sufficiently large to
prevent a significant loss of pressure and/or seal from dirt.

The second index “2” (C

42

/ C82) indicates type C boilers with a blower

fan behind the combustion chamber or the heat exchanger.

General

Standards, personnel, design

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

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

r:d ≥ 1

For example P4 Pellet 8/15:

- Diameter of supply air connection = 80 mm

- Minimum radius of pipe bends = 80 mm

 Install the supply air line in as straight a line as possible and over the

shortest path. The number of pipe bends should be kept to a
minimum (ideally a maximum of 4 bends).

 Also: The resistance of the supply air line can be a maximum of 20 Pa.

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

À See 2.2.1 Supply air connections for room air-independent operation

Minimum specification of connection lines

Connecting piece for the combustion air supply as per EN 1856-2:

EN 1856-2 - T080 - N2 - D

Connecting piece for the flue gas outlet as per EN 1856-2:

EN 1856-2 - T200 - P1 - W

TXXX ... Temperature class (specified in °C)
N2 ... Pressure class with test pressure = 20 Pa
P1 ... Pressure class with test pressure = 200 Pa
D ... Condensation resistance not required (dry)
W ... Condensation resistance required (damp)

1.4.7 Notes on boiler ventilation

The boiler system should be set up rising slightly towards the back left,
so the ventilation connection is the highest point of the boiler.

Fitting a functioning, automatic ventilating valve ensures constant
removal of air in the boiler.

This prevents malfunctions due to air in the boiler system.

 Fit an automatic ventilating valve!
 Tip: Fit a vertical pipe before the automatic ventilating valve as a

calming section, to ensure it is positioned above the level of the
boiler water.

A microbubble separator can also optionally be fitted in the lines to the
boiler.

Technology

Components, connections, and dimensions

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2 Technology

2.1 Components and Connections

Pos. Description Units 8 / 15 20 / 25 32 / 38 48/60 80/100/105

A Boiler flow connection 1 6/4 6/4 6/4 2
B Boiler return connection 1 6/4 6/4 6/4 2
C Drain 1/2 1/2 1/2 1/2 1

D Air vent

Inch

1/2 1/2 1/2 1 1

E Pellet suction line
F Return-air line

DA 60 DA 60 DA 60 DA 60 DA 60

G Flue gas pipe connection

mm

130 130 150 150 200

1 Lambdatronic P 3200 control
2 Switch box
3 Induced draught fan
4 Safety temperature limiter - STL
5 Main switch
6 Service interface

3

C A G 1 2 4 B D E F 5 6

Technology

Components, connections, and dimensions

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2.2 Dimensions

Dimension Description Units 8 / 15 20 / 25 32 / 38 48 / 60 80/100/105

L Length, boiler 740 740
L* Length, boiler 820 900 1000
L1 Total length inc. induced

draught fan

940 940

L1* Total length inc. induced

draught fan

mm

1020 1100 1070

B Width of boiler 600 770 860 1030 1235

B* Width, boiler, inc. support

for positioning unit

1)

705 875 965 1275 1480

W1 Total width, inc. suction

cyclone

mm

1185 1355 1445 1790 2085

H Height, boiler

2)

1280 1280 1430 1585 1710

H1 Total height, inc. suction

cyclone

1660 1660 1900 1900 1900

H2 Height, flue pipe connection 1350 1350 1530 1685 1785
H3 Height, flow connection 460 460 460 515 520
H4 Height, return connection 940 955 1085 1240 1360
H5 Height, drainage connection 460 460 460 515 520
H6 Height, ventilation

connection

1030 1030 1155 1310 1430

H8 Height, induced draught fan

connection

1090 1090 1215 1375 1495

H15 Height, suction system

connection

mm

1480 1480 1720 1720 1720

Flue pipe diameter mm 130 130 150 150 200

1) Corresponds to the minimum positioning width after removing the stoker assembly, suction cyclone and positioning unit.

2) Corresponds to the minimum positioning height after removing the stoker assembly, suction cyclone and positioning
unit.

Technology

Technical specifications

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2.2.1 Supply air connections for room air-independent operation

P4 Pellet 8 / 15

P4 Pellet 20 / 25 P4 Pellet 32 / 38

P4 Pellet 48 / 60

100 115 115 170

235

230

215

305

P4 Pellet 80 / 100

315

190

P4 Pellet

Description Units 8/15 20/25 32/38 48/60 80/100/105

Supply air connection pipe (external diameter) mm 80 100 125 160 200

2.2.2 Flue gas pipe position

P4 Pellet

Description Units 8/15 20/25 32/38 48/60 80/100/105

A – Lateral distance mm 420 585 650 815 1000

B – Depth distance mm 90 90 85 90 80

Technology

Technical specifications

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2.3 Technical specifications

2.3.1 P4 Pellet 8/15/20/25

P4 Pellet

Description Units 8 15 20 25

Rated heat output 10,5 14,9 20,0 25,0

Heating efficiency range

kW

3.1-10.5 3.1-14.9 6.0-20.0 7.5-25.0

Mains connection 230V / 50Hz fused 16A

Output W 96 123 110 110

Boiler weight kg 350 350 430 430

Boiler capacity (water) L 70 70 80 80

Upstream resistance (ΔT=20°C) mbar 4.3 6.1 4.5 2.9

Min. boiler return temperature Not applicable due to internal return temperature control

Maximum boiler temperature setting 80 80 80 80

Minimum boiler temperature setting

°C

40 40 40 40

Permitted operating pressure bar 3 3 3 3

Boiler class 3 3 3 3

Permitted fuel Wood pellets Ø 6mm as per ÖNORM M 7135 / DIN 51731

Test report data

Testing institute TÜV Austria1)

2) 3)

2) 4)

Test report no. 06-UWC

Wels-EX-

295/2

06-UWC

Wels-EX-

295/1

Test data at rated load

Carbon monoxide (CO) [mg/MJ] 24 39 35 30

Nitrogen oxide (NOx) [mg/MJ] 74 74 76 78

Organic Hydrocarbons (OGC) [mg/MJ] < 1.0 0.6 0.7 0.9

Dust [mg/MJ] 14 12 11 11

Boiler efficiency rating [%] 91.6 90.9 91.9 92.9

Test data at partial load

Carbon monoxide (CO) [mg/MJ] 77 77 72 66

Nitrogen oxide (NOx) [mg/MJ] 69 69 71 73

Organic Hydrocarbons (OGC) [mg/MJ] 1.4 1.4 1.3 1.1

Dust [mg/MJ] 11 11 11 10

Boiler efficiency rating [%] 92.0 92.0 93.3 94.5

1) TÜV Austria, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels

2) In accordance with ÖNORM / DIN EN 303-5, chapter 5.1.3 type test: for a boiler from a range with a consistent
structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤ 2 : 1, to carry out the
tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that
have not been tested in a range, whose values have been determined depending on rated heat output by interpolation,
fulfil the requirements of the norm.

3) Values of the type P4 Pellet 20 are interpolated between the test protocol 06-UWC/Wels-EX-295/1 and K44302/2.

4) Values of the type P4 Pellet 25 are interpolated between the test protocol 06-UWC/Wels-EX-295/1 and K44302/2.

Technology

Technical specifications

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2.3.2 P4 Pellet 32/38/48/60

P4 Pellet

Description Units 32 38 48 60

Rated heat output 32,0 38,0 48,0 58,5

Heating efficiency range

kW

8.9-32.0 8.9-38.0 14.4-48 17.3-58.5

Mains connection 230V / 50Hz fused 16A

Output W 110 110 120 120

Boiler weight kg 530 530 760 760

Boiler capacity (water) L 125 125 170 170

Upstream resistance (ΔT=20°C) mbar 1.5 2.1 3.6 5.3

Min. boiler return temperature Not applicable due to internal return temperature control

Maximum boiler temperature setting 80 80 80 80

Minimum boiler temperature setting

°C

40 40 40 40

Permitted operating pressure bar 3 3 3 3

Boiler class 3 3 3 3

Permitted fuel Wood pellets Ø 6mm as per ÖNORM M 7135 / DIN 51731

Test report data

Testing institute TÜV SÜD SZA1)

3) 4)

TÜV2)

Test report no. K44302/6 K44302/4 - 08-UWC/

Wels-EX-337

Test data at rated load

Carbon monoxide (CO) [mg/MJ] 31 45 25 5

Nitrogen oxide (NOx) [mg/MJ] 79 77 77 77

Organic Hydrocarbons (OGC) [mg/MJ] 1.0 1.0 1.5 < 2

Dust [mg/MJ] 10 9 10 11

Boiler efficiency rating [%] 93.5 92.6 92.4 92.1

Test data at partial load

Carbon monoxide (CO) [mg/MJ] 61 61 36 10

Nitrogen oxide (NOx) [mg/MJ] 75 75 71 66

Organic Hydrocarbons (OGC) [mg/MJ] 1.0 1.0 1.5 < 2

Dust [mg/MJ] 10 10 10 10

Boiler efficiency rating [%] 95.7 95.7 94.0 92.3

1) TÜV SÜD SZA Austria, Technische Prüf-GmbH, accredited initial and boiler inspection body in accordance with BGBl. no.
211/92 Arsenal, Object 207, A-1030 Wien

2) TÜV Austria, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels

3) In accordance with ÖNORM / DIN EN 303-5, chapter 5.1.3 type test: for a boiler from a range with a consistent
structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤ 2 : 1, to carry out the
tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that
have not been tested in a range, whose values have been determined depending on rated heat output by interpolation,
fulfil the requirements of the norm.

4) Values of the model, P4 Pellet 48, are interpolated between the test protocol K44302/4 and 08-UWC/Wels-EX-337.

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Technical specifications

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2.3.3 P4 Pellet 80/100/105

P4 Pellet

Description Units 80 100 105

Rated heat output 80,0 100,0 105,0

Heating efficiency range

kW

24,0-80,0 30-100,0 24,0-105,0

Mains connection 230V / 50Hz fused 16A

Output W 115 112 112

Boiler weight kg 1090 1100 1100

Boiler capacity (water) L 280 280 280

Upstream resistance (ΔT=20°C) mbar 4,3 4,3 4,3

Min. boiler return temperature Not applicable due to internal return temperature control

Maximum boiler temperature setting 80 80 80

Minimum boiler temperature setting

°C

40 40 40

Permitted operating pressure bar 3 3 3

Boiler class 3 3 3

Permitted fuel Wood pellets Ø 6mm as per ÖNORM M 7135 / DIN 51731

Test report data

Testing institute TÜV1)

Test report no. TÜV

2)3)

10-UW/Wels-

EX-242/1

Test data at rated load

Carbon monoxide (CO) [mg/MJ] 6 6 6

Nitrogen oxide (NOx) [mg/MJ] 80 83 83

Organic Hydrocarbons (OGC) [mg/MJ] <1,5 <1 <1

Dust [mg/MJ] 12 13 13

Boiler efficiency rating [%] 93,2 94,3 94,3

Test data at partial load

Carbon monoxide (CO) [mg/MJ] 29 29 29

Nitrogen oxide (NOx) [mg/MJ] 62 62 62

Organic Hydrocarbons (OGC) [mg/MJ] <1 <1 <1

Dust [mg/MJ] 10 10 10

Boiler efficiency rating [%] 93,7 93,7 93,7

1) TÜV Austria, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels

2) In accordance with ÖNORM / DIN EN 303-5, chapter 5.1.3 type test: for a boiler from a range with a consistent
structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤ 2 : 1, to carry out the
tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that
have not been tested in a range, whose values have been determined depending on rated heat output by interpolation,
fulfil the requirements of the norm.

3) Values of the model, P4 Pellet 80, are interpolated between the test protocol 08-UW/Wels-EX-337 and 10-UW/Wels-EX­242/1. Partial load data from test protocol 10-UW/Wels-EX242/1

Technology

Technical specifications

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2.3.4 Airborne sound level

The sound level specified in the following table is based on sound
measurements on a P4 Pellet 15. (measuring device: Omega HHSL 1)

The sound level of the individual units was plotted at a distance of 1 m
from the sound source.

Ambient level for measurement: 32 dBA

Unit Measurement

Units in continuous operation:

Induced draught fan (activation: 50%) 41 dBA

Induced draught fan (activation: 65%) 44 dBA

Induced draught fan (activation: 90%) 50 dBA

Units in non-continuous operation:

Suction turbine 68 dBA

Grate motor 42 dBA

Stoker motor / Stoker screw 33 dBA

Ignition fan 53 dBA

WOS motor / WOS system 60 dBA

Burn back slide valve actuator (open) 34 dBA

Burn back slide valve actuator (close) 50 dBA

Please note that all the measurements were taken in-house and do not
come from a certified test station. This data should therefore be viewed
as individual measurements to be used as guidelines.

Please also note the sound levels required in the standards listed below,
which must be fulfilled by planning and construction measures:

ÖNORM B 8115-2 Sound insulation and room acoustics in building

construction - Requirements for sound insulation

ÖNORM H 5190 Heating systems - Acoustic insulation

Installation

Transport and Setup

Page 18

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3 Assembly

3.1 Transportation

The boiler is delivered packed in cardboard and
on a pallet.

 Move without jarring or jolting
 Protect the packaging against damp
 Consult the delivery information on the

packaging.

 Observe the centre of gravity of the pallet!

The boiler is marked opposite the lifting side
with a sticker.

3.1.1 Positioning

U Position a lifting truck or similar lifting device at the pallet and

position the boiler

If it is not possible to position the boiler on the pallet:

U Remove the cardboard and remove the boiler from the pallet

À See 3.2.1 Removing the boiler from the pallet

If the boiler must be dismantled for positioning:

U Dismantle the components of the boiler until it can be brought into

position

À See 3.3 Dismantling for location where positioning is difficult

For positioning using a crane:

U Remove the insulating cover, the

WOS cover and the heat exchanger
cover

 The hoisting point for the crane eye

is below the cover.

3.1.2 Temporary storage

If the system is to be installed at a later date:

U Store the boiler, insulation and control unit in a safe, dust-free, and

dry location
 Moisture and frost reduce the effectiveness of insulation and can

destroy electronic components.

Do NOT use forklifts for this task!

Installation

Transport and Setup

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3.2 Set-up in the boiler room

3.2.1 Removing the boiler from the pallet

U Remove packing bands with an appropriate tool
U Pull off the cardboard from above

U Remove the transport covers (1) of the ash drawers (P4 Pellet 8-25)

or insulated door(s) and ash bucket (P4 Pellet 32-105) and cleaning
devices (2)

U Remove the protective casing

On the front of the boiler, P4 Pellet 8/15/20/25:

U Open the insulating door
U Remove securing devices used during transportation on the left and

right side of the base.

U Pull out the lock bolt of the door hinge (1) and remove it from the

guide

U Remove the insulated door and pull out the floor insulation

On the front of the boiler, P4 Pellet 32/38/48/60/80/100/105:

U Remove securing devices used during transportation on the left and

right side of the base.

U Remove 2 screws each on the left and right of the ash collecting

plate and remove the collecting plate

U Pull out the floor insulation behind

At the back of the boiler:

U Remove securing devices used during transportation on the left and

right side of the base.

1

1

2

Installation

Transport and Setup

Page 20

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3.2.2 Moving the boiler in the boiler room

U Position a lifting truck or similar lifting device with an appropriate

load-bearing capacity at the base frame of the boiler and move to
the specified place

U Set up boiler at intended location

 Put red boiler underlays under the frame.
 Observe the minimum distances in the boiler room.

3.2.3 Minimum distances in the boiler room

P4 Pellet

Description Units 8/15 20/25 32/38 48/60 80/100/105

A Minimum distance to suction

cyclone assembly

300 300 300 300 300

B Induced draught fan

maintenance area

300 300 300 300 300

Space for insulated door 550 720 830 490 590 C

Space requirement with
plug-in insulated door

400 400 300 - -

D Minimum distance to side of

boiler

mm

200 200 200 200 200

Installation

Transport and Setup

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3.3 Dismantling for location where positioning is difficult

If the boiler cannot be brought into position because the space is
confined, it is possible to dismantle individual components.

The following steps show the maximum possible dismantling steps. You
should only carry out the steps that are necessary for positioning.

3.3.1 Dismantling the stoker assembly and insulation

U Remove the locking screws on the sound insulation hood of the

stoker assembly and remove the sound insulation hood.

U Lift the front part of the stoker assembly upwards and remove.

U Lift the back part of the stoker assembly upwards and remove
U Remove insulating cover

Installation

Transport and Setup

Page 22

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U Unscrew the screws under the insulated cover with the contact

washers at the flaps of the controller cover.

U Open insulated door (only for P4 Pellet 8/15/20/25)

U Unscrew the screw together with the contact washer on the bottom

side of the controller cover

U Remove the controller cover

Installation

Transport and Setup

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3.3.2 Remove the door and ash drawer (P4 Pellet 8/15/20/25)

U Fold out the hinge pins at the top of the insulated door and pull down
U Lift the insulated door from the lower hinge and remove

U Open both ash doors and remove the ash drawer together with

accessories

U You can optionally remove the upper cover of the settling chamber

and the inner cover

Installation

Transport and Setup

Page 24

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3.3.3 Dismantling the suction cyclone cover

U Remove the covering of the

middle cable duct

At the pellet module:

U Unplug the relevant plugs:

- “Suction unit M3”

- “Max level S1”

- “Gate valve M8”

U Separate the cable tie at the cable leadthrough
U Unthread the cables that have been unplugged

Installation

Transport and Setup

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U Wind up the unplugged cables at the units
U Open the clamps and take off the cover

3.3.4 Dismantling the stoker unit

U Remove the covering of the cable duct

At the pellet module:

U Unplug the relevant plugs:

- “Grate drive M6”

- “Burn back flap M7”

- “Stoker motor M1”

- “Ignition E1”

U Unthread the cables of the unplugged units

Installation

Transport and Setup

Page 26

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U Loosen the locking screw on the ignition fan
U Take out the ignition fan

U Remove the back and front locking split pin of the grate drive and

pull out the bolt
 CAUTION! Secure the grate motor so it cannot fall down when the

bolt is removed.

U Push the bushing back at the grate rod
U Remove the grate motor

Installation

Transport and Setup

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U Depending on the design, cut open the aluminium band from the

heat insulation mat below the stoker duct and remove

U Remove two screw connections on the right and left at the stoker

unit flange
 The screws can be removed completely as the stoker unit is hung

on the boiler on two hooks.

The following assembly step requires two people:

 Weight of stoker unit P4 Pellet 8/15/20/25: approx. 32 kg

Weight of stoker unit P4 Pellet 32/38: approx. 36 kg
Weight of stoker unit P4 Pellet 48/60: approx. 46 kg
Weight of stoker unit P4 Pellet 80/100/105: approx. 68 kg

U Pull the stoker unit up slightly until the hooks come out of the stoker

flange

U Tip the unit back slightly and lift away

 The P4 Pellet is fully dismantled and can now be brought into

position.

Installation

Transport and Setup

Page 28

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3.3.5 Positioning dimensions after dismantling

P4 Pellet

Dimension Description Units 8/15 20/25 32/38 48/60 80/100/105

L Length, boiler 740 740 740 8201) 9102)

B Width of boiler 705 875 965 1275 1480

H Height of boiler

mm

1280 1280 1430 1585 1710

1) If the control unit is dismantled, the dimension can be reduced to 780 mm (e.g. for bringing into position through doors
with a clearance of 800 mm)

2) If the control unit is dismantled, the dimension can be reduced to 880 mm (e.g. for bringing into position through doors
with a clearance of 900 mm)

Dismantling the control unit:

U Remove the lateral plexiglass covers and secure the nuts of the

screw connection so they cannot turn

U Remove the screws on the left and right on the underside
U Remove the cable marked “Display” and pull up and out
U Remove the control unit

Installation

Transport and Setup

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3.3.6 Notes on reassembly

U After positioning the boiler, assemble in reverse order

It is particularly important to observe the following points during
assembly:

U Depending on the design of the insulation, after fitting the stoker

unit and the insulating material it may be necessary to stick a new
aluminium band on top of the aluminium band that was previously
cut.

When fitting the grate motor, check that it is in the correct position on
the back support:

- Top position = P4 Pellet 8/15/20/25

- Bottom position = P4 Pellet 32/38

- A position = P4 Pellet 48/60/80/100/105

Observe the installation position of the actuating sleeve between the
grate motor and the slide rod

U Carefully screw in the locking screw finger-tight

 You must not carry on tightening to the extent that the ignition

fan pipe is deformed

 Fix the cable with the cable ties supplied.
 There must not be any loose cables in the area of the igniter.
 Only connect the power supply after completing assembly.
 The individual units should be checked by the qualified technician

and adjusted if necessary during initial start-up.

Installation

Assembling the Pellet Boiler

Page 30

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3.4 Assembling the Pellet Boiler

3.4.1 Installing the induced draught fan

U Remove the locking screws on the sound insulation hood of the

stoker assembly and remove the sound insulation hood.

U Open the clamps on the suction cyclone container and lift the cover

´ The induced draught set is in the suction cyclone container

U Remove the induced draught fan from the suction cyclone container

U Remove pre-installed cover plate
U Unscrew pre-installed nuts and spacer washers
U Attach and fix the ID fan as illustrated

 The straight edge of the tube flange must be at the top.

U Join both cables of the ID fan with the pre-installed cables

 Ensure that the locking device (1) clicks into place.

U Push the cable behind the cladding and put back the cover plate.

1

Installation

Assembling the Pellet Boiler

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3.4.2 Fit the ash container and doors (P4 Pellet 32/38/48/60/80/100/105)

U Remove the insulating cover and unscrew the two top retaining

screws with the contact washers of the controller cover

 Caution: Do not lose the contact washers!

U Unscrew the lower retaining screw with contact washer and remove

the controller cover

U Put the insulated door in the boiler base and secure at the top with

bolts

U Take the two cover caps for the ash containers from the ash

containers and position them in the open flaps

U Put in the ash containers and secure with the locking lever

Installation

Install discharge system

Page 32

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3.5 Installing the discharge system

3.5.1 General installation information

NOTICE

 Water lines should not be located in close proximity to the pellet store and the feeder units

due to the dangers posed by condensation and bursting water pipes!

 Check the delivered items for foreign objects in the individual components
 In the pellet store room an impact cushion must be installed on the opposite side to the filler

pipes. This reduces wear on the pellets when they are blown in and stops the finish being
worn off. Broken pieces of masonry or finish and other foreign bodies (small stones, pieces
of wood, screws, etc.) can block the discharge system or the pellet feed into the boiler and
cause the system to fail. In case of faults due to such foreign bodies, the guarantee is void.

 In time pellets leave dust on the ground; this can impair the process of moving them from

the pellet storage area. For this reason you should check and clean if necessary before
refilling.

3.5.2 Hose Lines

For the hose lines used with the suction device, the universal suction system, and the bag silo
discharge unit, observe the following:

 Do not kink the hose lines! Minimum bending radius = 30cm
 Lay the hose lines as straight as possible! If the lines are sagging, it can lead to so-called

“pockets.” Problem-free pellet feeding can not be guaranteed.

 Lay the hose lines in short segments away from walking areas!
 Hose lines are not UV-proof!

Therefore: do not lay the hose lines outdoors!

 Hose lines are suitable for temperatures up to 60°C!

Therefore: Hose lines must not come into contact with flue gas pipes or uninsulated heating
pipes!

 Hose lines must be grounded on both ends, to ensure that no static charge builds up as a

result of transporting the pellets!

 The suction line must be a single piece!
 The return-air line can be made up of several pieces, but potential equalization must be

established throughout the line!

Installation

Install discharge system

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Potential Equalisation

When connecting the hose lines to the individual connection pipes,
ensure there is potential equalization throughout the line!

U Expose approximately 3 cm of the grounding strap on the end of the

hose line

 TIP: Slit the insulation open along the wire with a knife

U Bend the earth wire inwards in a loop

´ This prevents the earth wire from being damaged by the feed of

pellets.

U Install a hose clamp on the hose line
U Put the hose line on the connection

 Ensure that contact is established between the grounding strap and

the connection!

U Tighten the hose clamp

Installation

Install discharge system

Page 34

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3.5.3 Universal suction system

A 25 m Suction hose G Manual re-arranging unit (Variant 2)

B Hose clamps 50-65 mm H 2 x Blind plates (Variant 2)

C 2 x Fire protection choke collars

(only in Austria)

I 6 x Star-shaped screw knobs (Variant 2)

D Komfort pellet box (Variant 1) J Cover plate for wall

E Support for fire protection choke collar (Variant 1) K Suction probe

F Installation module for wall

280

250

50

Before installation:

U Prepare a wall penetration for the pellet box

(width: 28cm, height: 25cm)
 Maintain a distance of at least 5 cm from the

finished floor.

F

G

I

A

C

A

B

E

D

J

B

A

B

K

Variant 2 -
Eco pellet box

Variant 1 -
Komfort pellet box

G

H

280

Dimensions in mm

50

250

Installation

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Variant 1 – Komfort pellet box

U Position Komfort pellet box (D) at the wall

penetration

 The distance from the wall on the board side

of the pellet box should be at least 10 cm for
maintenance purposes.

U Fix Pellet box to the wall with 4 M8x50 frame

screws and 10 mm dowels

U Fill the space in the wall penetration with a non-

flammable material
 The partition must be insulated as per ÖNORM

B 3836 or DIN 4102-11!

U Put the cover plate for the wall (J) onto the pipes

of the pellet box

U Secure the cover plate to the wall using 4 M8x50

frame screws and 10 mm dowels

U Mount the bracket (E) for fire protection choke

collars on the pellet box
 Fire protection choke collars only in Austria.

D

J

E

10 cm

Installation

Install discharge system

Page 36

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Variant 2 – Eco pellet box

U Place the wall insertion module (F) at the wall

penetration

U Secure the insertion module to the wall using 4

M8x50 frame screws and 10 mm dowels

U Fill the space in the wall penetration with a non-

flammable material
 The partition should be insulated in

accordance with
ÖNORM B 3836 or DIN 4102-11.

U Place the wall cover plate (J) on the insertion

module pipes

U Secure the cover plate to the wall using 4 M8x50

frame screws and 10 mm dowels

U Install 2 blind plates (H) on the insertion module

using 2 star-shaped screw knobs (I)

U Install interchange unit (G) using 2 star-shaped

screw knobs

 No position is specified for the interchange

unit!

F

J

G

I

H

Installation

Install discharge system

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Installing the suction probes and lines

U Position the suction probes (K) at equal distances

in the pellet supply bin

U Secure the suction probes to the bottom using

frame screws

U Fix hose lines (A) to the suction probe using hose

clips (B)

U Lay the hose lines to the pellet box and secure

them using hose clips

 CAUTION! Read the label on the suction probe

or pellet box about the suction line and
return-air line! Ensure correct connection!

 CAUTION! When connecting the hose lines,

beware of potential equalisation!

À Page 33, Potential Equalisation
À For information on store layout see 3.5.6

Pellet storage area

U Thread the fire protection choke collar (C) on to

the hose line (A)

 Fire protection choke collars only in Austria.

U Attach the hose lines to the pellet box pipes

using hose clips (B)

U Lay the hose lines to the boiler, through

identified openings at the back plate and install
with hose clamps to the identified connections

 CAUTION! Read the label on the suction probe

or pellet box about the suction line and
return-air line! Ensure correct connection!

 Suction line: hose line to left connection (1)

on the back of the boiler

 Return-air line: hose line to right connection

(2) on the back of the boiler

 CAUTION! When connecting the hose lines,

beware of potential equalisation!

À Page 33, Potential Equalisation

1

2

K

B

A

A

B

B

C

A

B

C

A

Installation

Install discharge system

Page 38

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3.5.4 Suction screw system

A Flange bearing H Gearbox flange

B Ejector flange I Drive flange seal

C Trough mount with rubber pad J Geared motor

D Bearing flange K 2 x Cover plates for wall penetration

E Open trough L Main worm

F Suction intake with integrated support M Shaft end for main worm

G Proximity switch N Worm extension (if needed)

Before installation:

U Prepare wall penetration for suction piece

(width: 34cm, height: 20cm)
 Ensure that the channel in the wall

penetration is positioned off centre.

A

B

C

D

E

F

M

L

K

H

I

J

N

G

Installation

Install discharge system

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U Thread the basic screw (H1) into the

penetration

 The key-way must be toward the boiler!

U Thread the closed trough (J) onto the basic

screw on the store side
 The quadratic flange points out of the

store!

U Thread the open trough (I) onto the basic

screw

U Secure together using 4 M10x30 hexagonal

bolts and nuts

Depending on the length of the discharge unit, a
screw extension may be necessary:

U Place the screw extension (N) on the basic

screw (L) and secure it using spring dowels

 The screw blade must always be rising.

If no additional screw is used:

U Put the the end of the basic screw shaft (M)

on the basic screw shaft (L) and secure it
using spring dowels

U Secure the gearing flange (I) and the gearing

flange seal (H) to the suction piece using 4
hexagonal M10 x 40 mm bolts and nuts

- 17 mm hexagonal nut

U Lubricate the screw stub shaft
U Put on the geared motor (J)

 Take care when inserting the key-way into

the groove of the shaft!

U Attach the geared motor on the gearing flange

(l) using 4 M8 x 16 mm hexagonal bolts with
spacer washers

- Hexagonal nut dimension 13 mm

U Install the proximity switch (G) on the

inspection cover of the suction piece
 The proximity switch should project

approx. 1cm into the suction piece

 Adjusting the sensitivity during the initial

start-up

À Page 47, 4.2 Setting the “Max level and

min level” sensor

H1

I

J

N

M

H

I

J

G

G

L

L

Installation

Install discharge system

Page 40

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U Secure the bearing flange (D) and the trough

mount (C) to the trough using 4 hexagonal M10 x
40 mm bolts and nuts

- Hexagonal nut SW 17 mm

U Place the flange bearing unit (A) and the ejecting

flange (B) on the shaft and secure them to the
bearing flange using 2 M14 x 35 mm hexagonal
bolts and spacer washers

- 21 mm socket spanner
 Do not lubricate! The flange bearing is

permanently lubricated and is maintenance
free!

U Arrange the trough parallel to the store wall
U Secure the trough mount and suction piece to the

floor using 2 10 mm dowels and 8 x 70 mm
frame screws

U Fill the space in the wall penetration with a non-

flammable material
 The partition must be insulated as per ÖNORM

B 3836 or DIN 4102-11!

U Secure the wall penetration cover plates (K) to

the external store wall using 3 10 mm dowels
and 8 x 50 mm frame screws

U Finally, the inclined bottom is installed

 The plates of the inclined bottom must not be

placed on the trough!

À Page 44, Sloping floor

U Lay both hose lines in the boiler room to the

suction intake

On the left and right of the suction intake:

U Secure the suction hose (B) to the suction

connecting piece using a hose clamp (D)
 No connection side specified for suction or

return-air line!

U Put the supplied fire protection choke collar (1)

on the hose and secure it to the suction piece
using 2 self-tapping screws

 Fire protection choke collars only in Austria.

D

C

B

A

K

B

1

D

Installation

Install discharge system

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U Lay the hose lines to the boiler, through

identified openings at the back plate and install
with hose clamps to the identified connections

 Suction line: hose line to left connection (1)

on the back of the boiler

 Return-air line: hose line to right connection

(2) on the back of the boiler

 CAUTION! When connecting the hose lines,

beware of potential equalisation!

À Page 33, Potential Equalisation

3.5.5 Bag silo discharge system

U Fit frame with bag silo

À See assembly instructions “Pellet bag silo Type I - V”

 Observe the height of the boiler room during

planning.

Type I, II Type III - V

H Bag silo frame height [cm] 185 190

H1 Height including filler coupling [cm] 205 210

H2 Required minimum room height

1)

[cm]

Ideal store room height

2)

[cm]

215
230

220
230

1) Minimum room height for connection to filler pipe in installation room.

2) When full, the bag silo has a heap shape. Optimum height is for use of the whole capacity.

1

2

Installation

Install discharge system

Page 42

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U Fit the bag silo in accordance with the assembly

instructions supplied

U Put the flange ring (1) onto the bag silo
U Put the bag silo and flange ring onto the probe at

the threaded bolts and screw them together

U Thread one fire protection choke collar each (B)

onto the suction and return-air lines

 Fire protection choke collars only in Austria.

U Run hose lines through the openings in the wall

into the pellet store

U Secure the hose lines to the silo suction probe

using hose clamps (D)

 Read the label on the silo suction probe!
 Suction line: The hose line to the cover of the

suction unit

 Return-air line: The hose line to the suction

motor

U Lay the hose lines to the boiler, through

identified openings at the back plate and install
with hose clamps to the identified connections

 CAUTION! Observe the label for the suction

line and the return-air line on the silo suction
probe and boiler. Ensure correct connection!

 Suction line: hose line to left connection (1)

on the back of the boiler

 Return-air line: hose line to right connection

(2) on the back of the boiler

 CAUTION! When connecting the hose lines,

beware of potential equalisation!

À Page 33, Potential Equalisation

1

B

D

1

2

Installation

Install discharge system

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3.5.6 Pellet storage area

For the universal suction system, the pellet store must be built with an
inclined floor!

The following picture shows the most important components:

A 2 x Filler pipes

B Earth wire

C Planking on the store door

D Sloping floor

E Impact cushion

F Under-floor structure for sloping floor

Size of store

The storage area should be able to hold approximately 1.5 times the
annual requirement. The exact amount of required space depends on
the system’s heating load.

 Rule of thumb formula: 1m³ store / kW heating burden

A

B C D

E

F

Installation

Install discharge system

Page 44

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Sloping floor

Fig.1: Store for a discharge unit with a suction probe Fig.2: Store for a discharge unit with a screw

The under-floor structure should be dimensioned so that the sloping
floor is not deformed when subjected to static load. You should ensure
that the pellets can slide down smoothly. This means the sloped floor
should be at an angle of at least 45° and have a smooth surface (we
recommend laminate).

When planning the under-floor structure, note:

 1 m³ of pellets roughly corresponds to a weight of 650 kg!
 Ideally the suction probes should already be fitted before the sloped

floor is constructed.

 A distance of 20 cm should be maintained between the cross-pieces

and the suction probe should be centrally positioned. (see Fig. 1)

 The weight of the pellets must not be borne by the trough! (see Fig. 2)

Impact cushion

The baffle plate is made of rubber and is positioned opposite the filling
nozzles at a distance of approximately 20 cm from the wall. It prevents
pellets from striking the wall and knocking off pieces of the finish when
filling.

 Pieces of the finish, screws, and other foreign objects can clog the

suction probe!

 CAUTION! Damage caused by foreign objects is not covered by the

guarantee!

NOTICE

In time pellets leave dust on the ground; this can impair the process of
moving them from the storage area.

 Check the storage area before re-filling and clean if necessary
 Regular complete emptying and cleaning of the storage area ensures

consistent readiness for operation!

Installation

Connecting the pellet boiler

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3.6 Electrical Connection

DANGER

When working on electric components:

Risk of serious injuries from electric shocks

U Work on electrical components should only be carried out by authorised

technicians

 Wiring should be installed using flexible sheathed cable and

dimensioned in compliance with the locally applicable standards and
guidelines

 The power supply line (mains connection) must be fitted with a C16

A fuse by the customer.

U Remove insulating cover
U 2 pieces Unscrew the retaining screws with contact washers behind

the control unit

U Open the insulated door and remove the centrally positioned

retaining screw and contact from below

U Remove the front insulating cover and wire the connections in

accordance with the circuit diagram

À Schematic diagrams: See operating instructions “Lambdatronic P

3200”

CAUTION

When using energy-efficient pumps on the speed-regulated pump
outputs:

Malfunctions of the boiler and the hydraulic system are possible!

Take the following precautions:
You must not connect any EC motor pumps at the speed-

regulated pump outputs of the boards.

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

Installation

Connecting the pellet boiler

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3.6.1 Connecting the Komfort pellet box

The connection of the Comfort pellet box to the pellet module board is
established using a flexible cable (5x0.75mm², e.g. YMM as per ÖVE­K41-5 or H05VV-F as per DIN VDE 0281-5).

This is a 24V control line.

The previous figure shows the plugged-in 5-pin connecting plug of the
Komfort pellet box and the accompanying connection layout of the
Lambdatronic P3200 control system.

To check the plug arrangement:

U Detach the protective plate (1) from

the board

U Perform check using the board’s

labels

 The actuators (2) of the pellet

box must be switched to the “R”
position!

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

1

2

Commissioning

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4 Initial Start-up

4.1 Configuring the Boiler

The boiler must be adjusted to the requirements of the heating system
during commissioning

NOTICE

 Optimum performance and efficient operation with low emissions can

only be guaranteed if the system is set up by a qualified technician
and the specified factory settings are observed.

Take the following precautions:

U We recommend that the system is commissioned by Froling customer

services or an authorised installer.

Before heating up the boiler for the first time:

U Set the controller to match your heating system.

The keypad layout and necessary control steps for modifying the
parameters can be found in the accompanying operating instructions for
the “Lambdatronic P 3200”.

4.2 Setting the “Max level and min level” sensor

In delivery configuration, the factory settings of the sensor are secured
with a seal. Changes to the settings should only be carried out by
qualified technicians.

Depending on the design, a min level sensor may also be installed.

 The monitoring LED (1) should only illuminate when identifying

materials!

U If the monitoring LED stays on permanently, the sensitivity is set too

high!

´ Reduce the sensitivity by turning the adjusting screw (2) to the

left

U If the monitoring LED does not react when pellets are being fed in,

the sensitivity is set too low!

´ Increase the sensitivity of the adjusting screw by turning to the

right

1

2