Froling P4 Pellet 8-60, P4 Pellet 8, P4 Pellet 15, P4 Pellet 20, P4 Pellet 25 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 - 60

Read and follow the assembly instructions and safety information
Subject to technical change.

Introduction

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M0930408_en

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Dear installer,

The FRÖLING 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 as well as comprehensive information about 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 of correct delivery and customer-specific data for 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 Fröling a copy of the shipping document, completely filled
out 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 in 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]
INTERNET www.froeling.com

Contents

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1 General information 6

1.1 Notes on standards 6

1.2 Design Information 7

1.2.1 Approvals and reporting obligations ....................................................................7

1.2.2 Requirements for hot water supplies ................................................................... 7

1.2.3 Ventilation of boiler room ..................................................................................8

1.2.4 Installing the heating system / Standards ............................................................ 8

1.2.5 Combination with storage tank ........................................................................... 8

1.2.6 Chimney connection / chimney system ................................................................ 9

Draught limiter................................................................................................9

Boiler data for constructing the flue gas system:..................................................9

1.3 Installation Information 10

1.3.1 Hose lines ..................................................................................................... 10

Potential equalisation ..................................................................................... 11

2 Technology 12

2.1 Components and connections 12

2.2 Dimensions 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

3 Assembly 16

3.1 Transport 16

3.1.1 Positioning..................................................................................................... 16

3.1.2 Temporary storage ......................................................................................... 16

3.2 Setting up in the boiler room 17

3.2.1 Remove boiler from pallet................................................................................ 17

3.2.2 Transporting in the boiler room ........................................................................ 17

3.2.3 Minimum distances in the boiler room................................................................ 18

3.3 Assembling the Pellet Boiler 19

3.3.1 Removing the suction cyclone .......................................................................... 19

3.3.2 Fitting the induced draught fan......................................................................... 19

3.4 Install delivery system 20

3.4.1 Universal suction system ................................................................................. 20

Variant 1 - Comfort pellet box ......................................................................... 21

Variant 2 - Eco pellet box................................................................................ 22

Installing the suction probes and lines .............................................................. 23

3.4.2 Suction screw system...................................................................................... 24

3.4.3 Bag silo system.............................................................................................. 27

3.4.4 Pellet storage area.......................................................................................... 29

Size of storage area....................................................................................... 29

Sloping floor ................................................................................................. 30

Impact cushion.............................................................................................. 30

3.5 Electrical Connection 31

3.5.1 Connecting the Comfort pellet box .................................................................... 32

Contents

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4 Initial startup 33

4.1 Configuring the boiler 33

4.2 Setting “Max Level” sensor 33

5 Appendix 34

5.1 Delivery Certificate 34

5.2 Notes 35

General

Standards, Design, Assembly

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1 General information

CAUTION

Assembly and installation by untrained personnel.

Danger: Personal injury and damage to property.

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

Only allow trained staff (heating installers or licensed electricians)
to perform set-up and installation!

1.1 Notes on standards

The boiler must be installed and started up in compliance with local fire
and building regulations and the following standards:

ÖNORM / DIN EN 303-5 Heating boilers for solid fuels, manually and automatically loaded combustion

systems, nominal heat output of up to 300 kW - Terminology, requirements,
testing and marking

ÖNORM M 7510 Guidelines for checking central heating systems

ÖNORM / DIN EN 12828 Heating systems in buildings - design of hot water heating systems

ÖNORM B 8130 Safety devices, open water heating systems

ÖNORM B 8131 Closed water heating systems, safety requirements

DIN 4751 Parts 1-4 Heating system safety equipment

ÖNORM / DIN EN 13384-1 Chimneys serving one appliance

ÖNORM M 7515 /DIN 4705-1 Calculating chimney dimensions for combustion systems

TRVB H118 Technical directives for fire protection/prevention (Austria only)

ÖNORM H5170 Construction and fire protection requirements

VDI 2035 Prevention of damage caused by scaling in hot water and water heating

systems (Germany only)

ÖNORM H 5195-1 Protection against corrosion and scaling damage in hot water systems with

operating temperatures to 100°C (Austria only).

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

General

Standards, Design, Assembly

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1.2 Design Information

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

In addition to the operating instructions and the applicable regulations
for the country in which the boiler will be operated for installation and
operation of the boiler system, all fire, police, and electrical regulations
must be observed.

1.2.1 Approvals and reporting obligations

NOTE

Each heating system must be officially approved.

When installing or modifying a heating system, you must inform the
inspectors from the supervisory authority and get authorisation 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.

1.2.2 Requirements for hot water supplies

The requirements pertaining to the water used to fill the boiler are
based on the following standards and guidelines:

Applicable standards and directives:

Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1

There are no other special requirements for domestic hot water apart
from this.

 Note for filling with make-up water:

Bleed the filling hose before connecting to prevent air from getting
into the system.

§

General

Standards, Design, Assembly

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1.2.3 Ventilation of boiler room

The openings for the supply air and the exhaust air should be arranged
as nearly opposite each other as possible to achieve a good thermal
draught effect.

 The supply air must be drawn in directly from outside. The exhaust

air must be discharged directly outside.

Unless otherwise provided by the relevant building regulations for the
room where the boiler is to be installed, the following standards apply:

Applicable standards:

- TRVB H 118

- ÖNORM H 5170

Rule of thumb:
Provide a supply air cross-section of 2 cm

2

per kW of boiler rated output,

as per ÖNORM H 5170, but a total cross-section of at least 200 cm

2

1.2.4 Installing the heating system / Standards

The boiler has to be installed in a closed hydraulic system. The following
standards govern the installation of heating systems:

Applicable standards:

ÖNORM / DIN EN 12828 Heating Systems in Buildings

The following prior standards still apply:
Austria: - Closed systems as per ÖNORM B 8131

Germany: - Closed systems as per DIN 4751 Part 2

1.2.5 Combination with storage tank

NOTE

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.

Please contact your installer or a Fröling technician directly for the right
measurements of the storage tank (as per ÖNORM M 7510 resp.
Directive UZ37).

§

§

General

Standards, Design, Assembly

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1.2.6 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 (when cleaned) and the additional flue gas
values can be found in the technical specification sheets.

À See “Boiler data for constructing the flue gas system”

Establish the connection to the chimney via the shortest path, ascending
as much under 30 – 45° as possible 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 and other legal regulations also apply.
 The chimney must be approved by a smoke trap sweeper or chimney

sweeper.

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

installed in the flue pipe or in the chimney.

Draught limiter

 We recommend that you install a draught limiter 1
 Install the draught limiter directly under the mouth of the flue line,

as there is always low pressure here!

Boiler data for constructing the flue gas system:

P4 Pellet

Component MEH 8 15 20 25 32 38 48 60

Flue gas N

L

temperature

°C 140 150 150 150 160 160 160 170

Flue gas mass flow N

L

P

L

kg/h

25
11

36
15

52
20

65
25

78
32

92
41

140

60

155

70

Flue gas mass flow N

L

P

L

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

0,039
0,017

0,043
0,019

Feed pressure N

L

required P

L

Pa

8
6

8
6

8
6

8
6

8
6

8
6

8
6

8
6

Feed pressure N

L

required P

L

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

0,08
0,06

0,08
0,06

Flue pipe diameter mm 130 130 130 130 150 150 150 150

NL = Nominal Load, PL = Partial Load

1

General

Standards, Design, Assembly

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1.3 Installation Information

 Water lines should not be located in close proximity to the storage

area or 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 delivery 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.

1.3.1 Hose lines

For the hose lines used with the suction device, the universal suction
system, and the silo delivery 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 sections 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 un-insulated heating pipes!

 Hose lines must be earthed on both sides to ensure that no static

charge builds up as a result of transporting the pellets!

 The suction line must be in a single section!
 The return-air line can be made up of several sections, but potential

equalisation must be established throughout the line!

General

Standards, Design, Assembly

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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 earth conductor at 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 Fit a hose clip to the hose line
U Attach the hose line to the connector

 Ensure that contact is established between the earth conductor and

the connector!

U Tighten the hose clip

Technology

Components, Connections, and Dimensions

Page 12

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2 Technology

2.1 Components and connections

P4 Pellet

Pos. Component Unit 8 / 15 20 / 25 32 / 38 48/60

A Boiler outfeed connection 1 6/4 6/4 6/4
B Boiler return feed connection 1 6/4 6/4 6/4
C Drain 1/2 1/2 1/2 1/2
D Air vent

Inch

1/2 1/2 1/2 1

E Pellet suction line
F Return-air line

DA 60 DA 60 DA 60 DA 60

G Flue gas pipe connection

mm

130 130 150 150

1 Lambdatronic P 3200 control system
2 Switch box
3 Safety temperature limiter - STL
4 Induced draught fan

4

C A G

1

2

3 B D E F

Technology

Components, Connections, and Dimensions

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2.2 Dimensions

P4 Pellet

Dimensions Component Unit 8 / 15 20 / 25 32 / 38 48 / 60

L Length, boiler 1) 740 740 820

L1 Total length inc. induced draught fan

mm

930 930 1110 900

B Width, boiler 600 770 860

B* Width, boiler, inc. support for

positioning unit

2)

700 870 960

1100

B1 Total width, inc. suction cyclone

mm

1185 1355 1445 1030

H Height, boiler

3)

1280 1280 1430 1275

H1 Total height, inc. suction cyclone 1660 1660 1900 1790
H2 Height, flue pipe connection 1350 1350 1530 1585
H3 Height, outfeed connection 460 460 460 1900
H4 Height, return connection 940 955 1085 1685
H5 Height, drainage connection 460 460 460 515
H6 Height, ventilation connection 1030 1030 1155 1240
H8 Height, induced draught fan

connection

1090 1090 1215 515

H15 Height, suction system connection

mm

1485 1485 1720 1310

Flue pipe diameter mm 130 130 150 1375

1) Corresponds to the minimum positioning length

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

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

Technology

Technical specifications

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2.3 Technical specifications

2.3.1 P4 Pellet 8/15/20/25

P4 Pellet

Component Unit 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

Weight of boiler 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

Minimum return feed temperature Not applicable because of internal return feed lift

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 [mg/MJ] < 1,0 0,6 0,7 0,9

Dust [mg/MJ] 14 12 11 11

Kesselwirkungsgrad [%] 91,6 90,9 91,9 92,9

Prüfdaten bei Teillast

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

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

Organic hydrocarbons [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.

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

Technology

Components, Connections, and Dimensions

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2.3.2 P4 Pellet 32/38/48/60

P4 Pellet

Component Unit 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

Weight of boiler 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

Minimum return feed temperature Not applicable because of internal return feed lift

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 [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

Prüfdaten bei Teillast

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

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

Organic hydrocarbons [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 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.

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

Installation

Transport and Assembly

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3 Assembly

3.1 Transport

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

 Move the boiler without jarring or jolting
 Observe the transport information on the

packaging.

 Consider centre of mass!

The boiler is marked with a sticker on the
opposite of the side to lift

3.1.1 Positioning

U Position a fork-lift 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 cardboard packaging
U Take the unit from the pallet, and if necessary also dismantle the

suction unit assembly

À See 3.2.1 Remove boiler from pallet

3.1.2 Temporary storage

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

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.

Installation

Transport and Assembly

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3.2 Setting up in the boiler room

3.2.1 Remove boiler from pallet

At the front of the boiler:

U Open insulation door
U Pull out floor insulation
U Remove protective transport materials on the left and right in the

recess

 TIP: For transport in the boiler room remove the insulating door.

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

guide

U Remove the insulating door

At the back of the boiler:

U Remove protective transport materials on the left and right in the

recess

3.2.2 Transporting in the boiler room

U Position a fork-lift or similar lifting device at the base frame of the

boiler and transport it to the designated position

If no lifting device of this type is available:

U After removing the suction unit thread a carrying belt through the

lateral openings (1) of the base frame and lift the boiler

U Position transport rollers or similar with appropriate load-bearing

capacity under the base frame and move to the designated position

U Set up boiler at intended location

 Observe the minimum distances in the boiler room.

1

1

Installation

Transport and Assembly

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3.2.3 Minimum distances in the boiler room

P4 Pellet

Dimensions Component Unit 8/15 20/25 32/38 48/60

A Minimum distance

between suction
cyclone and wall

300 300 300 300

B Maintenance

range for ID fan

300 300 300 300

C Space for

insulated door

550 720 830 490

D Minimum distance

from side of boiler
to wall

mm

200 200 200 200

Installation

Assembling the Pellet Boiler

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3.3 Assembling the Pellet Boiler

3.3.1 Removing the suction cyclone

U Remove sound insulation cover
U Open the clamps on the suction unit container and lift the cover

´ The induced draught unit set is in the suction unit container

3.3.2 Fitting the induced draught fan

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 must be up.

U Join both cables of the ID fan with the pre-installed cables
U Push the cable behind the cladding and put back the cover plate.

Installation

Install delivery system

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3.4 Install delivery system

3.4.1 Universal suction system

A 25 m Suction hose G Manual re-arranging unit (Variant 2)
B Hose clamps 50-65 mm H 2 Blind plates (Variant 2)
C 2 Fire protection choke collar

(only in Austria)

I 6 Star-shaped handle (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 hole in wall for 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

Install delivery system

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Variant 1 - Comfort pellet box

U Position Comfort pellet box (D) at hole in the

wall

 For maintenance purposes, the distance to the

wall
on the board side of the pellet box should be
at least 10 cm.

U Fix Pellet box to the wall with 4 frame screws

M8x50 and 10 mm dowels

U Pack the space in the hole in the wall with a non-

flammable material
 The partition must be insulated to conform

with ÖNORM B 3836 or DIN 4102-11!

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

of the pellet box

U Secure the cover plate to the wall using four

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 delivery system

Page 22

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3

Variant 2 - Eco pellet box

U Place the wall installation module (F) by the hole

in the wall

U Secure the insertion module to the wall using

four M8x50 frame screws and 10 mm dowels

U Pack the space in the hole in the wall with a non-

flammable material
 The partition must be insulated to conform

with ÖNORM B 3836 or DIN 4102-11!

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

module pipes

U Secure the cover plate to the wall using four

M8x50 frame screws and 10 mm dowels

U Fit 2 cover plates (H) to the installation module

using two star-shaped screws (I)

U Fit change unit (G) with 2 star-shaped screws

 The position of the change unit is not

specified!

F

J

G

I

H

Installation

Install delivery system

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M0930408_en

3

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

 WARNING! Read the label on the suction

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

 WARNING! When connecting the hose lines,

beware of potential equalisation!

À Page 11, Potential equalisation

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

 WARNING! 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

 WARNING! When connecting the hose lines,

beware of potential equalisation!

À Page 11, Potential equalisation

1

2

K

B

A

A

B

B

C

A

B

C

A

Installation

Install delivery system

Page 24

M0930408_en I

3

3.4.2 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 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 hole in wall for suction intake (width:

40cm, height: 22cm)
 Ensure that the channel in the hole in the wall

is positioned off centre.

A

B

C

D

E

F

M

L

K

H

I

J

N

G

Installation

Install delivery system

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3

U Thread the main screw (H1) into the hole

 The keyway must point towards the boiler!

U Thread the closed trough (J) on to the main

worm on the storage area side
 The rectangular flange points away from

the storage area!

U Thread the open trough (I) on to the main

worm

U Screw them together using four M10x30

hexagon bolts and nuts

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

U Place the screw extension (N) on the main

screw (L) and secure it using clamping pins

 The screw blade must always be rising.

If no additional screw is used:

U Put the main screw's shaft end (M) on the

main screw's shaft (L) and secure it using
clamping pins

U Secure the gearing flange (I) and the gearing

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

- 17 mm socket spanner

U Lubricate the screw's shaft end
U Fit the drive motor (J)

 Take care when inserting the keyway into

the shaft's groove!

U Attach the geared motor on the gearing flange

(l) using four M8 x 16 mm hexagonal screws
and spacer washers - 13 mm hexagonal nut

U Fit the proximity switch (G) to the inspection

cover of the suction intake
 The proximity switch should project

approx. 1cm into the suction intake!

 Adjusting the sensitivity during the initial

start-up

À Page 33, 4.2 Setting “Max Level” sensor

H1

I

J

G

N

M

H

I

J

G

G

L

L

Installation

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M0930408_en I

3

U Secure the bearing flange (D) and the trough

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

U - 17 mm hexagonal nut
U Place the flange bearing unit (A) and the ejecting

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

U - 21 mm socket spanner

 Do not lubricate! The flange bearing is

permanently lubricated and is maintenance
free!

U Arrange the trough parallel to the storage area

wall

U Secure the trough mount and suction piece to the

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

U Pack the space in the hole in the wall with a non-

flammable material
 The partition must be insulated to conform

with ÖNORM B 3836 or DIN 4102-11!

U Secure the wall penetration cover plates (K) to

the store room external wall using three

U 10 mm dowels and 8 x 50 mm frame screws
U Finally, the sloping floor is installed

 The plates of the sloping floor must not be

placed on the trough!

À Page 30, 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 side specified for connecting the 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 two self-tapping screws

 Fire protection choke collars only in Austria.

D

C

B

A

K

B

1

D

Installation

Install delivery system

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3

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

 WARNING! When connecting the hose lines,

beware of potential equalisation!

À Page 11, Potential equalisation

3.4.3 Bag silo system

U Fit frame with sack silo

À See assembly instructions “Pellet

sack 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 height1) [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 delivery system

Page 28

M0930408_en I

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U Mount bag silo as it is described in the delivered

assembly instructions

U Thread flange ring (1) onto bag silo
U Fit bag silo and flange ring onto the bolts on the

suction probe and screw it together.

U Thread one fire protection choke collar each (B)

on to 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: hose line to the cover of the

suction cyclone

 Return-air line: 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

 WARNING! 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

 WARNING! When connecting the hose lines,

beware of potential equalisation!

À Page 11, Potential equalisation

B

D

1 2

1

Installation

Install delivery system

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3

3.4.4 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 Filler pipes
B Earth wire
C Planking on the storage area door

D Sloping floor

E Impact cushion
F Under-floor structure for sloping floor

Size of storage area

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

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M0930408_en I

3

Sloping floor

Fig.1: Store for a delivery unit with a suction probe Fig.2: Store for a delivery 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 weighs approximately 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 impact cushion is made of rubber and should be positioned opposite
the filler pipes at least 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!

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

guarantee!

NOTE

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

Connect pellet boiler

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3.5 Electrical Connection

RISK

Working on electrical components.

Danger: Serious injuries from electric shocks.

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

technicians

 Flexible sheath conductors should be used for the wiring which

should be measured in compliance with the applicable regional
standards and guidelines

 The supply line (mains connection) must be fitted with a max. 16 A

fuse by the customer.

U Remove the insulating cover

U 2 Unscrew the self-tapping

screws behind the control

U Open the insulating door and

remove the centrally positioned
fixing screw from below.

U Remove the front insulation

cover

U Wire the connections according

to the schematic diagram:

À For circuit diagram see operating

instructions “Lambdatronic P
3200”

Installation

Connect pellet boiler

Page 32

M0930408_en I

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3.5.1 Connecting the Comfort 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
Comfort 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 Carry out a check using the board

description

 The servomotors (2) of the pellet

box must be switched to the “R”
position!

The servomotors 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

Core module of the Lambdatronic P3200

Primary ai

r

Secondary ai

r

Initial startup

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4

4 Initial startup

4.1 Configuring the boiler

The boiler must be configured to the heating system on initial start-up.

NOTE

 Optimum efficiency and consequently efficient operation with low

emissions can only be guaranteed if the system is adjusted by
qualified technicians and the specified factory settings are observed.

Take the following precautions:

U It is recommended that the system is put into operation by the Fröling

customer service or an authorised installer.

Before you start heating with the boiler for the first time:

U Adjust the control to the system type

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 “Max 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.

 The monitoring LED (1) should only light up 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

Appendix

Delivery Certificate

Page 34

M0930408_en I

5

5 Appendix

5.1 Delivery Certificate

Customer no.:

Customer address: Installer:

Telephone number:

U

P4 Pellet 8 U P4 Pellet 32

U

P4 Pellet 15 U P4 Pellet 38

U

P4 Pellet 20 U P4 Pellet 48

P4 Pellet:

U

P4 Pellet 25 U P4 Pellet 60

Serial number

U

Bag silo system

U

Universal suction system Uno pellet box

U

Universal suction system Eco pellet box

U

Universal suction system Comfort pellet box

U

Underground feeder tank system

Delivery system:

U

U System operation discussed U

System maintenance discussed

U Operating principle and self-checking of

safety devices discussed.

U

All technical documentation handed over
(documentation, certificate of conformity, ...)

U Test heating performed U

Commissioning report given to customer

U Rating plate attached U

Telephone number for manufacturer’s service
department indicated

U No defects found
U

Notice:
All national and regional regulations relating to initial testing and subsequent testing of the system

must be observed. Please be advised that, in Austria, commercial systems with a rated heat output
≥ 50 kW must be regularly tested at yearly intervals in accordance with the Heating Plant Regulations
(FeuerungsanlagenVO).

Date Customer Installer

Finally, we ask that you have the customer sign a copy of this confirmation and send it to FRÖLING
Ges.m.b.H. . Fax: [phone]

Appendix

Notes

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5.2 Notes