Page 1
Operating Instructions
Pellet boiler PE1 Pellet (Touch)
Translation of the original German operating instructions for the operator
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B1000315_en | Edition 30/06/2015
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Page 2
Contents
1 General 4
1.1 PE1 Pellet product overview 5
2 Safety 6
2.1 Hazard levels of warnings 6
2.2 Pictograms used 7
2.3 General safety information 8
2.4 Permitted uses 8
2.4.1 The Clean Air Act 1993 and Smoke Control Areas 9
2.4.2 Permitted fuels 10
Wood pellets
10
2.4.3 Non-permitted fuels 10
2.5 Qualification of operating staff 11
2.6 Protective equipment for operating staff 11
2.7 Design information 11
2.7.1 Installation and approval of the heating system 11
2.7.2 General information for installation room (boiler room) 12
2.7.3 Requirements for central heating water 12
2.7.4 Notes for using pressure maintenance systems 13
2.7.5 Use with storage tank 13
2.7.6 Chimney connection/chimney system 13
2.8 Safety Devices 15
2.9 Residual risks 16
2.10 Emergency procedure 17
2.10.1 Overheating of the system 17
2.10.2 Smell of flue gas 17
2.10.3 Fire in the system 17
3 Operating the system 18
3.1 Assembly and initial startup 18
3.2 Filling the pellet store 19
3.2.1 General advice for working in the store 19
3.3 Heating up the boiler 20
3.3.1 Switching on the power supply 20
3.3.2 Switching on the boiler 20
3.3.3 Regulating the boiler 20
3.3.4 Switching off the boiler 20
3.3.5 Switching off the power supply 20
4 Boiler Servicing 21
4.1 General information on servicing 21
4.2 Inspection and cleaning 22
4.2.1 Required tools and equipment 22
4.2.2 Inspection 22
Checking the system pressure
22
Checking the safety valve
22
Contents
2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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4.2.3 Cleaning 23
Emptying the ashcan (PE1 Pellet 7-10)
23
Emptying the ash container (PE1 Pellet 15-35)
23
Cleaning the grate and combustion chamber
24
4.2.4 Periodic inspection and cleaning 25
Cleaning the heat exchanger
25
Cleaning the flue gas pipe
26
Checking the draught controller flap
26
4.2.5 Inspection and cleaning the DHW tank unit (optional) 26
Safety devices
26
Pressure reducing valve
26
Magnesium corrosion protection anode
27
Interior cleaning / removing limescale deposits
27
4.3 Emissions measurement by chimney sweep or regulatory body 28
4.4 Maintenance agreement / Customer service 28
4.5 Replacement parts 28
4.6 Disposal information 29
4.6.1 Disposal of the ash 29
4.6.2 Disposal of system components 29
5 Troubleshooting 30
5.1 General fault with power supply 30
5.1.1 Behaviour of system after a power failure 30
5.2 Excessive temperature 30
5.3 Faults with fault message 31
5.3.1 Procedure for fault messages 31
5.3.2 Acknowledging a fault message 31
6 Appendix 32
6.1 Addresses 32
6.1.1 Address of manufacturer 32
6.1.2 Address of the installer 32
Contents
Operating Instructions PE1 Pellet (Touch) | B1000315_en 3
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1 General
Thank you for choosing a quality product from Froling. The product features a state-ofthe-art design and conforms to all currently applicable standards and testing
guidelines.
Please read and observe the documentation provided and always keep it close to the
system for reference. Observing the requirements and safety information in the
documentation makes a significant contribution to safe, appropriate, environmentally
friendly and economical operation of the system.
The constant further development of our products means that there may be minor
differences from the pictures and content. If you discover any errors, please let us
know: [email protected].
Subject to technical change.
Warranty and Guarantee Conditions
Our sale and delivery conditions will be applicable. 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.
1
General
4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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1.1 PE1 Pellet product overview
4
7.1
7.2
8
6
5
1
2
3
2.2
6.1
2.4
2.3
2.1
1 PE1 Pellet pellet boiler
2 Boiler controller, Lambdatronic P 3200 PE1
2.1 4.3" touch screen for displaying / modifying operating statuses and parameters
2.2 Status LED to display the operating status:
- GREEN constant: BOILER SWITCHED ON
- GREEN flashing (interval: 5 sec. OFF, 1 sec ON): BOILER SWITCHED OFF
- ORANGE flashing: WARNING
- RED flashing: FAULT or ALARM
2.3 Brightness sensor for automatically adjusting the brightness of the display
2.4 USB port for connecting a USB stick for software updates
3 Main switch
4 High-limit thermostat (STL)
5 Door switch
6 Maintenance opening for combustion chamber (underneath the cover)
6.1 Inspection glass for checking combustion
7.1 Ash container for automatic ash removal (PE1 Pellet 15-35)
7.2 Ashcan (PE1 Pellet 7/10)
8 Quick start guide
General
1
PE1 Pellet product overview
Operating Instructions PE1 Pellet (Touch) | B1000315_en 5
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2 Safety
2.1 Hazard levels of warnings
This documentation uses warnings with the following hazard levels to indicate direct
hazards and important safety instructions:
DANGER
The dangerous situation is imminent and if measures are not observed it will lead
to serious injury or death. You must follow the instructions!
WARNING
The dangerous situation may occur and if measures are not observed it will lead
to serious injury or death. Work with extreme care.
CAUTION
The dangerous situation may occur and if measures are not observed it will lead
to minor injuries or damage to property.
2
Safety
Hazard levels of warnings
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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2.2 Pictograms used
The following symbols are used in the documentation and/or on the boiler to show
what is required and forbidden and to give warnings.
In accordance with the Machinery Directive, signs fitted directly within the danger area
of the boiler indicate immediate hazards or safety procedures. These stickers must not
be removed or covered.
Refer to the operating
instructions
Wear safety shoes
Wear protective gloves Turn off the main switch
Keep the doors closed Wear a dust mask
Work under the supervision of a
second person
Lock
Unauthorised access prohibited
No fire, open flames or smoking
Warning - hot surface Warning - hazardous electrical
voltage
Warning - hazardous or irritant
materials
Warning - automatic boiler
startup
Warning of injury to fingers or
hands, automatic fan
Warning of injury to fingers or
hands, automatic screw
Warning of injury to fingers or
hands, gear/chain drive
Warning of injury to fingers or
hands, cutting edge
Hand injury warning Warning of injury from being
pulled into rotating shafts
Increased CO concentration
warning
Slipping hazard warning
Safety
2
Pictograms used
Operating Instructions PE1 Pellet (Touch) | B1000315_en 7
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2.3 General safety information
DANGER
If the device is used incorrectly:
Incorrect use of the system can cause severe injury and damage.
When operating the system:
❒ Observe the instructions and information in the manuals.
❒ Observe the details on procedures for operation, maintenance and cleaning,
as well as troubleshooting in the individual manuals.
❒ Any work above and beyond this should be carried out by authorised heating
engineers or by Froling customer services.
WARNING
External influences:
Negative external influences, such as insufficient combustion air or non-standard
fuel, can cause serious faults in combustion (e.g. spontaneous combustion of
carbonisation gases or flash fires) which can in turn cause serious accidents!
When operating the boiler, please note the following:
❒ Instructions and information regarding versions and minimum values, as well
as standards and guidelines for heating components in the instructions must
be observed.
WARNING
Severe injuries and damage can be caused by an inadequate flue gas system.
Problems with the flue gas system, such as poor cleaning of the flue pipe or
insufficient chimney draught, can cause serious faults in combustion (such as
spontaneous combustion of carbonisation gases or flash fires).
Take the following precautions:
❒ Optimum boiler performance can only be guaranteed if the flue gas system is
functioning correctly.
2.4 Permitted uses
The Froling Pellet boiler PE1 Pellet is designed solely for heating domestic water.
Only use fuels specified in the "Permitted fuels" section.
⇨ See "Permitted fuels" [page 10]
2
Safety
General safety information
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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The unit should only be operated when it is in full working order. It must be operated in
accordance with the instructions, observing safety precautions, and you should ensure
you are aware of the potential hazards. The inspection and cleaning intervals in the
operating instructions must be observed. Ensure that any faults which might impair
safety are rectified immediately.
The manufacturer or supplier is not liable for any damage resulting from non-permitted
uses.
Only original spare parts or specific alternative spare parts authorised by the
manufacturer may be used. Any kind of change or modification made to the product
will invalidate its manufacturer’s CE conformity. In such cases, the product will need to
undergo new hazard evaluation procedures by the operator. The operator will then be
fully responsible for the declaration of conformity according to the valid guideline(s) for
the product and will need to attach the new CE label to the device. This person will
then assume all of the rights and responsibilities of a manufacturer.
2.4.1 The Clean Air Act 1993 and Smoke Control Areas
Under the Clean Air Act local authorities may declare the whole or part of the district of
the authority to be a smoke control area. It is an offence to emit smoke from a
chimney of a building, from a furnance or from any fixed boiler if located in a
designated smoke control area. It is also an offence to acquire an „unauthorised
fuel“ for use within a smoke control area unless it is used in an „exempt“ appliance
(„exempted“ from the controls which generally apply in the smoke control area). The
Secretary of State for Environment, Food and Rural Affairs has powers under the Act
to authorise smokeless fuels or exempt appliances for use in smoke control areas in
England. In Scotland and Wales this power rests with Ministers in the devolved
administrations for those countries. Separate legislation, the Clean Air (Northern
Ireland) Order 1981, applies in Northern Ireland. Therefore it is a requirement that
fuels burnt or obtained for use in smoke control areas have been „authorised“ in
Regulations and that appliances used to burn solid fuel in those areas (other than
„authorised“ fuels) have been exempted by an Order made and signed by the
Secretary of State or Minister in the devolved administrations.
Further information on the requirements of the Clean Air Act can be found here:
http://
smokecontrol.defra.gov.uk
Your local authority is responsible for implementing the Clean Air Act 1993 including
designation and supervision of smoke control areas and you can contact them for
details of Clean Air Act requirements.
The Froling PE1 Pellet 7, PE1 Pellet 10, PE1 Pellet 15, PE1 Pellet 20, PE1 Pellet 25,
PE1 Pellet 30 and PE1 Pellet 35 have been recommended as suitable for use in
smoke control areas when burning fuels as listed under "Permitted fuels".
Safety
2
Permitted uses
Operating Instructions PE1 Pellet (Touch) | B1000315_en 9
Page 10
2.4.2 Permitted fuels
Wood pellets
Wood pellets made from natural wood with a diameter of 6 mm
EU: Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06
and/or: EN
plus
/ DIN
plus
certification scheme
General note:
Before refilling the store, check for pellet dust and clean if necessary.
2.4.3 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section, and particularly the
burning of refuse, is not permitted.
CAUTION
In case of use of non-permitted fuels:
Burning non-permitted fuels increases the cleaning requirements and leads to a
build-up of aggressive sedimentation and condensation, which can damage the
boiler and also invalidates the guarantee. Using non-standard fuels can also lead
to serious problems with combustion.
For this reason, when operating the boiler:
❒ Only use permitted fuels
Note on standards
2
Safety
Permitted uses
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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2.5 Qualification of operating staff
CAUTION
If unauthorised persons enter the installation room / boiler room:
Risk of personal injury and damage to property
❒ The operator is responsible for keeping unauthorised persons, in particular
children, away from the system.
Only trained operators are permitted to operate the unit. The operator must also have
read and understood the instructions in the documentation.
2.6 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For operation, inspection and cleaning:
- suitable work wear
- protective gloves
- sturdy shoes
2.7 Design information
It is forbidden to carry out modifications to the boiler or to change or deactivate safety
equipment.
Always comply with all fire, building, and electrical regulations when installing or
operating the boiler system, and follow the operating instructions and mandatory
regulations that apply in the country in which the boiler is operated.
2.7.1 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
ÖNORM / DIN EN 12828 Heating Systems in Buildings
NOTICE! Each heating system must be officially approved.
The appropriate supervisory authority (inspection agency) must always be informed
when installing or modifying a heating system, and authorisation must be obtained
from the building authorities:
Austria: report to the construction authorities of the community or magistrate
Germany: report new installations to an approved chimney sweep / the building
authorities.
Note on standards
Safety
2
Qualification of operating staff
Operating Instructions PE1 Pellet (Touch) | B1000315_en 11
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2.7.2 General information for installation room (boiler room)
Boiler room characteristics
▪ There must not be a potentially explosive atmosphere in the boiler room as the
boiler is not suitable for use in potentially explosive environments.
▪ The boiler room must be frost-free.
▪ The boiler does not provide any light, so the customer must provide sufficient light‐
ing in the boiler room in accordance with national workplace design regulations.
▪ When using the boiler over 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
No flammable materials should be stored near the boiler. Flammable objects (e.g.
clothing) must not be put on the boiler to dry.
▪ Damage due to impurities in combustion air.
Do not use any solvents or cleaning agents containing chlorine in the room where
the boiler is installed.
▪ Keep the air suction opening of the boiler free from dust.
Ventilation of the boiler room
Ventilation air for the boiler room should be taken from and expelled directly outside,
and the openings and air ducts should be designed to prevent weather conditions
(foliage, snowdrifts, etc.) from obstructing the air flow.
Unless otherwise specified in the applicable building regulations for the boiler room,
the following standards apply to the design and dimensions of the air ducts:
ÖNORM H 5170 - Construction and fire protection requirements
TRVB H118 - Technical directives on fire protection/prevention
2.7.3 Requirements for central heating water
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195
VDI 2035
SWKI 97-1
D.P.R. no. 412
NOTICE! Note on filling with make-up water: Always bleed the filling hose before
connecting, in order to prevent air from entering the system.
Observe the standards and also follow the recommendations below:
❒
Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (equivalent to
5.6 dH)
❒ Use prepared water which complies with the standards cited above for filling and
makeup water
❒ Avoid leaks and use a closed heating system to maintain water quality during
operation
Note on standards
Note on standards
2
Safety
Design information
12 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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2.7.4 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required
pressure within predefined limits and balance out volume variations caused by
changes in the hot-water temperature. Two main systems are used:
Compressor-controlled pressure maintenance
In compressor-controlled pressure maintenance units, a variable air cushion in the
expansion tank is responsible for volume compensation and pressure maintenance. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen
into the heating water.
Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressuremaintenance pump, relief valve and an unpressurised receiving tank. The valve
releases hot water into the receiving tank if the pressure is too high. If the pressure
drops below a preset value, the pump draws water from the receiving tank and feeds it
back into the heating system. Pump-controlled pressure maintenance systems with
open expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via the
surface of the water, exposing the connected system components to the risk of
corrosion. These systems offer no oxygen removal for the purposes of corrosion
control as required by VDI 2035 and in the interests of corrosion protection should not
be used.
2.7.5 Use with storage tank
NOTICE
In principle it is not necessary to use a storage tank for the system to run
smoothly. However, we recommend that you use the system with a storage tank,
as this ensures a continuous supply of fuel in the ideal output range of the boiler.
For the correct dimensions of the storage tank and the line insulation (in accordance
with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling.
⇨ See "Addresses" [page 32]
2.7.6 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. Please note in this respect that flue gas temperatures lower than 160K
above room temperature can occur in the permitted operating range of the boiler.
Safety
2
Design information
Operating Instructions PE1 Pellet (Touch) | B1000315_en 13
Page 14
NOTICE! Please see the technical data contained in the assembly instructions for
further information about standards and regulations as well as the flue gas
temperatures when clean and the other flue gas values!
2
Safety
Design information
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2.8 Safety Devices
SV
4
5
3
2.1
2.1 BOILER OFF
(switches off the boiler to prevent overheating)
❒ Tap “Boiler OFF"
➥ Automatic mode is switched off
➥ Control system follows the boiler shutdown procedure
➥ The pumps continue to run
3 MAIN SWITCH
(switches off the power supply)
Before carrying out work on/in the boiler:
❒ Tap “Boiler OFF"
➥ Automatic mode is switched off
➥ Control system follows the boiler shutdown procedure
❒ Switch off the main switch and let the boiler cool down
4 HIGH-LIMIT THERMOSTAT (STL)
(protection against overheating)
The STL (high-limit thermostat) switches off the combustion system when the boiler
reaches 100°C. The pumps continue to run. Once the temperature falls below approx.
75°C, the STL can be reset mechanically.
5 DOOR CONTACT SWITCH
(protection against access to moving components)
If the insulated door opens while the boiler is operating, all of the units stop to prevent
injuries at moving components. If the insulated door remains open for more than 30
seconds, the boiler is switched off automatically.
SV SAFETY VALVE
(protection against overheating/excessive pressure)
When the boiler pressure reaches a maximum of 3 bar, the safety valve opens and the
heated water is blown off in the form of steam.
Safety
2
Safety Devices
Operating Instructions PE1 Pellet (Touch) | B1000315_en 15
Page 16
2.9 Residual risks
WARNING
When touching hot surfaces:
Severe burns are possible on hot surfaces and the flue gas pipe!
When work is carried out on the boiler:
❒ Shut down the boiler in a controlled way (operating status "Boiler off") and
allow it to cool down
❒ Protective gloves must generally be worn for work on the boiler, and it should
only be operated using the handles provided
❒ Insulate the flue pipes or simply avoid touching them during operation.
WARNING
When inspecting and cleaning the boiler with the main switch on:
Serious injuries possible due to automatic boiler startup!
Before inspection and cleaning work in/on the boiler:
❒ Switch the boiler off by tapping “Boiler off”
The boiler follows the shutdown procedure and switches to "Boiler off“ mode
❒ Allow boiler to cool for at least 1 hour
❒ Switch off the main switch and take precautions to prevent accidental
switching on.
WARNING
If non-permitted fuel types are used:
Non-standard fuels can cause serious faults in combustion (e.g. spontaneous
combustion of carbonisation gases / flash fires) which can lead to serious
accidents!
Take the following precautions:
❒ Only use fuels specified in the "Permitted fuels" section of these operating
instructions.
2
Safety
Residual risks
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Page 17
2.10 Emergency procedure
2.10.1 Overheating of the system
If the system overheats and the safety devices fail, proceed as follows:
NOTICE! Do not under any circumstances switch off the main switch or disconnect the
power supply.
❒
Keep all the doors on the boiler closed
❒ Open all mixing valve taps, switch on all pumps.
➥ The Froling heating circuit control performs this function in automatic operation.
❒ Leave the boiler room and close the door
❒ Open any available radiator thermostat valves
If the temperature does not drop:
❒ Contact the installer or Froling customer services
⇨ See "Addresses" [page 32]
2.10.2 Smell of flue gas
DANGER
If you smell flue gas in the boiler room:
Inhaling toxic flue gas can be fatal!
If you smell flue gas in the room where the boiler is installed:
❒ Keep all the doors on the boiler closed
❒ Shut down the boiler according to procedure
❒ Ventilate the room where the boiler is installed
❒ Close the fire door and doors to living areas
2.10.3 Fire in the system
DANGER
In case of fire in the system:
Risk of death by fire and poisonous gases
Emergency procedure in case of fire:
❒ Leave the boiler room
❒ Close the doors
❒ Inform the fire department
Safety
2
Emergency procedure
Operating Instructions PE1 Pellet (Touch) | B1000315_en 17
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3 Operating the system
3.1 Assembly and initial startup
Assembly, installation and initial startup of the boiler must only be carried out by
qualified staff, and these procedures are described in the accompanying assembly
instructions.
NOTICE! See assembly instructions for the PE1 Pellet
NOTICE
Optimum efficiency and efficient, low-emission operation can only be guaranteed
if the system is set up by trained professionals and the standard factory settings
are observed.
Take the following precautions:
❒
Initial startup should be carried out with an authorised installer or with Froling
customer services
The individual steps for initial start-up are explained in the operating instructions for
the controller
NOTICE! See operating instructions for the Lambdatronic P 3200 PE1
The customer is responsible for ensuring the following prior to initial start-up of the
system by Froling customer services:
▪
Electrical installation
▪ Installation of water pipes
▪ Flue gas connection including all insulation work
▪ Work must comply with local fire protection regulations
▪ It is essential that the electrician who has carried out the installation work is
available when starting up the system for the first time to make any changes to the
wiring which may become necessary.
▪ During initial start-up, operating staff are shown how to use the boiler. It is
imperative for proper handover of the product that those involved are present as
this is a one-off opportunity.
3
Operating the system
Assembly and initial startup
18 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Page 19
3.2 Filling the pellet store
CAUTION
Filling the store when the boiler is switched on
could result in damage and consequential injury!
When filling the fuel store:
❒ Switch off the boiler by tapping “Boiler OFF”
➥ The boiler follows the shutdown procedure and switches to "Boiler off"
status
❒ Allow the boiler to cool for at least half an hour
When the boiler has cooled down:
❒
Before filling check the store for fines and clean if necessary
➥ Observe the general advice for working in the store.
⇨ See "General advice for working in the store" [page 19]
❒ Close all openings to the store to seal out dust
❒ Fill the store with pellets
➥ Only use permitted pellets
⇨ See "Permitted fuels" [page 10]
3.2.1 General advice for working in the store
Risk of injury due to moveable parts!
Shut off the feeder unit before entering the store!
When cleaning the store an increased amount of dust may be
generated. Wear a dust mask when working in the store.
Adequately ventilate the store before entering. Keep the door open
and always have a second person present. Observe the CO
concentration limit (< 30ppm).
Slick surfaces in the fuel store present a slipping hazard!
Unauthorised access prohibited! Keep children away!
Keep the fuel store locked and store the key in a safe place!
No fire, open flames or smoking in the store!
Operating the system
3
Filling the pellet store
Operating Instructions PE1 Pellet (Touch) | B1000315_en 19
Page 20
3.3 Heating up the boiler
NOTICE
Do not modify the factory settings!
Changing the system's factory settings can be detrimental to efficiency and
emissions of the system.
3.3.1 Switching on the power supply
❒ Turn on the main switch
➥ There is voltage at all of the boiler's components
➥ When the control has completed the system start, the boiler is ready for
operation
3.3.2 Switching on the boiler
❒ Switch the boiler on by tapping “Boiler ON”
➥ Automatic mode is active
➥ The heating system is controlled via the controller according to the selected
mode in automatic mode
❒
For other modes press the relevant function key
➥ Information on function keys in the relevant operating instructions for the
"Lambdatronic P 3200" boiler controller
3.3.3 Regulating the boiler
For the necessary steps, and how to display and alter parameters:
NOTICE! See operating instructions for boiler controller!
3.3.4 Switching off the boiler
❒ Switch boiler off by tapping “Boiler OFF”
➥ The boiler follows the shutdown program and switches to "
Boiler off" status
➥ The combustion unit is switched off, the chamber discharge unit and the entire
hydraulic system remain active
3.3.5 Switching off the power supply
❒ Turn off the main switch
➥ Boiler controller is switched off
➥ There is no power supply to any of the boiler components
NOTICE! Frost protection function is no longer active!
3
Operating the system
Heating up the boiler
20 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Page 21
4 Boiler Servicing
4.1 General information on servicing
DANGER
When working on electrical components:
Risk of electrocution!
When work is carried out on electrical components:
❒ Only have work carried out by a qualified electrician
❒ Observe the applicable standards and regulations
➥ Work must not be carried out on electrical components by unauthorised
persons
WARNING
When inspecting and cleaning the boiler with the main switch on:
Serious injuries possible due to automatic boiler startup!
Before inspection and cleaning work in/on the boiler:
❒ Switch the boiler off by tapping “Boiler off”
The boiler follows the shutdown procedure and switches to "Boiler off“ mode
❒ Allow boiler to cool for at least 1 hour
❒ Switch off the main switch and take precautions to prevent accidental
switching on.
WARNING
Incorrect inspection and cleaning:
Incorrect or insufficient inspection and cleaning of the boiler can cause serious
faults in combustion (e.g. spontaneous combustion of carbonisation gases / flash
fires) and this can lead to serious accidents and damage!
Take the following precautions:
❒ Clean the boiler following the instructions in the instruction manual. Follow the
boiler operating instructions.
NOTICE
We recommend that you keep a maintenance book in accordance with ÖNORM
M7510 of the Technical Directive for Fire Prevention (TRVB)
Boiler Servicing
4
General information on servicing
Operating Instructions PE1 Pellet (Touch) | B1000315_en 21
Page 22
4.2 Inspection and cleaning
4.2.1 Required tools and equipment
For carrying out cleaning and maintenance work the following tools and equipment are
required:
▪
Furnace tool, cleaning brush for heat exchanger pipes (included in delivery)
▪ Only for PE1 Pellet 7-10: Transport hook for ashcan (included in delivery)
▪ Only for PE1 Pellet 25-35: Mounting bracket for burner insert (included in delivery)
▪ Spanner or box wrench set
▪ Phillips screwdriver
▪ Small brush or cleaning brush
▪ Ash vacuum
4.2.2 Inspection
Checking the system pressure
❒ Check the system pressure on the pressure gauge
➥ The value must be 20% above the pre-stressed pressure of the expansion tank
NOTICE! Check that the position of the pressure gauge and rated pressure of
the expansion tank match your installer's specifications!
If the system pressure decreases:
❒ Top up with water
NOTICE! If this happens frequently, the seal of the heating system is faulty! Inform
your installer
If large pressure fluctuations are observed:
❒ Ask an expert to inspect the expansion tank
Checking the safety valve
❒ Check the seal of the safety valve regularly and ensure that the valve is not dirty
NOTICE! Inspection work must be carried out in accordance with the
manufacturer’s instructions.
4
Boiler Servicing
Inspection and cleaning
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4.2.3 Cleaning
The ash drawer must be emptied at the correct interval according to energy
requirements and fuel quality. The grate, burn-out tray and combustion chamber
should also be checked at these intervals.
Emptying the ashcan (PE1 Pellet 7-10)
❒
Open the insulated door
❒ Push the locking lever down and pull out the ashcan
❒ Hang the transport hook opposite the locking lever, take the ashcan to the
emptying point and empty it
Emptying the ash container (PE1 Pellet 15-35)
1.
2.
3.
1. Open the insulated door of the boiler
2.
Open the clamps on the left and right of the ash container
3. Remove the ash container from the ash screw duct
Boiler Servicing
4
Inspection and cleaning
Operating Instructions PE1 Pellet (Touch) | B1000315_en 23
Page 24
❒ Close the sliding valve on the back and take the ash container to the emptying
point
❒
Open both fasteners on the ash container cover
➥ PE1 Pellet 15-20: Clamps from the sides
➥ PE1 Pellet 25-35: Turn-lock fasteners from the top
❒ Remove cover and empty ash container
Cleaning the grate and combustion chamber
1.
2.
3.
PE1 Pellet 25-35
1. Pull the maintenance cover up and remove it. Unscrew the screw connections on
the maintenance cover and remove the maintenance cover
2. Pull the burn-out tray and burner insert upwards from the combustion chamber
Clean both components thoroughly. Check that the air openings in the burner
insert are not blocked.
Dismantling the burner insert for PE1 Pellet 25-35:
Hang the supplied mounting bracket in the openings that are positioned diagonally
opposite each other (as illustrated), pull the burner insert upwards and turn 90°
before removing it from the combustion chamber.
3. Clean the entire combustion area thoroughly, as well as the combustion chamber
below with the furnace tool, brush and ash vacuum.
4
Boiler Servicing
Inspection and cleaning
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Page 25
4.2.4 Periodic inspection and cleaning
The boiler must be cleaned and inspected at appropriate intervals depending on the
service hours and fuel quality.
Annual cleaning and inspection (1500 to 2000 service hours) is usually sufficient. For
fuels with a higher ash content (indicated by short emptying intervals for the ash
container), the work should be carried out more frequently.
Cleaning the heat exchanger
1.
4.
2.
3.
1. Undo the locking screw at the back of the boiler and remove the insulating cover.
2.
Disconnect the connection cable to the induced draught fan
3. Remove the thermal insulation beneath
4. Loosen the screws on the heat exchanger cover and remove cover including
induced draught fan
1.
2.
3.
4.
1. Remove the pipe locking pin from the WOS mount and take out the bracket
including WOS springs from the heat exchanger.
2.
Place the WOS springs on a suitable surface and clean with a brush.
3. Clean the heat exchanger pipes with the brush provided. Ensure that the brush
has been pushed through completely and is only then pulled back up. Repeat the
procedure several times.
Boiler Servicing
4
Inspection and cleaning
Operating Instructions PE1 Pellet (Touch) | B1000315_en 25
Page 26
4. Clean the flue gas collection chamber and the flue gas pipe opening using an ash
vacuum. Take care not to damage the flue gas temperature sensor and the
lambda probe.
Cleaning the flue gas pipe
❒ Remove the inspection cover on the connecting pipe
❒ Clean the connecting pipe between the boiler and chimney with a chimney
sweep's brush
➥ Depending on the layout of the flue gas pipes and the chimney draught
cleaning, yearly may not be enough!
Checking the draught controller flap
❒ Check that the draught controller flap moves freely
4.2.5 Inspection and cleaning the DHW tank unit (optional)
The following tasks must only be carried out by a qualified technician. We recommend
a yearly inspection / cleaning by Fröling customer services or by an authorised partner
(third party maintenance) of Fröling Heizkessel- und Behälterbau GesmbH.
NOTICE
Unless otherwise stipulated by local regulations, perform all maintenance work for
drinking water systems in accordance with EN 1717 and EN 806.
Safety devices
❒ Ensure the air outlet pipes on the safety valves are unobstructed
❒ Check that the safety devices on the heating system work correctly and in
accordance with the manufacturer’s instructions
❒ Check that the hot water and drinking water (if fitted) safety valves work correctly
and in accordance with the manufacturer’s instructions
Pressure reducing valve
❒ Check any existing pressure reducing valve for wear and correct function in
accordance with the manufacturer's instructions
4
Boiler Servicing
Inspection and cleaning
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Page 27
Magnesium corrosion protection anode
The magnesium corrosion protection anode protects the domestic water tank from
corrosion and is therefore depleted over time, depending on the aggressiveness of the
water. It must therefore be replaced at regular intervals, so that the corrosion
protection is retained.
NOTICE! If the magnesium corrosion protection anode is not replaced in good time, it
can lead to corrosion in the DHW tank.
❒ Check the magnesium corrosion protection anode initially after 2 years and then
annually in accordance with DIN 4753
❒ Check the magnesium corrosion protection anode during the internal cleaning
⇨ See "Interior cleaning / removing limescale deposits" [page 27]
❒ Check the magnesium corrosion protection anode for wear after removal of the
maintenance flange
➥ In the case of wear (loss of material thickness to 1/3 of the original diameter)
the anode must be replaced
Interior cleaning / removing limescale deposits
Check the domestic hot water tank of the optional DHW tank unit annually for
limescale deposits, and clean if necessary:
❒ Close cold water supply line, release pressure in system and open drainage on
domestic hot water tank
➥ Ensure it is vented by opening one of the valves in the drinking water supply
system
❒ Remove the front cover of the DHW tank unit and maintenance flange of the
domestic water tank
❒ Clean the domestic water tank inside with a jet of water
➥ If necessary, remove harder residues with a wooden spatula, cleaning brush or
limescale remover.
➥ Warning! Do not use sharp, metal tools. Do not use descaling agents.
❒ Remove residual water or sludge residues with a wet vacuum
❒ Wipe interior surfaces with a sponge or rag
❒ Check magnesium protection anode and replace, if necessary
⇨ See "Magnesium corrosion protection anode" [page 27]
❒ When replacing, fit a new seal on maintenance flange
NOTICE! Rinse DHW tank before starting up again in accordance with EN 14336
❒ Clean the outer parts with a wet cloth whenever necessary
➥ Avoid cleaning agents which are abrasive or contain solvents
Boiler Servicing
4
Inspection and cleaning
Operating Instructions PE1 Pellet (Touch) | B1000315_en 27
Page 28
4.3 Emissions measurement by chimney sweep or regulatory body
Various legal regulations stipulate that heating systems must be inspected
periodically. In Germany this is regulated by the First Federal Emissions Protection
Ordinance (BimSchV) in the last amended version, and in Austria by various state
laws. It is important to ensure that the boiler is clean and that there is adequate heat
consumption on the day of the measurement. (e.g. the storage tank must be able to
take heat for the duration of the measurement).
For further information and the procedure for measuring emissions, see the attached
cleaning instructions “Preparation for measuring emissions”.
4.4 Maintenance agreement / Customer service
NOTICE! We recommend a yearly inspection by Froling customer services or an
authorised partner (third party maintenance).
Regular maintenance and servicing by a heating specialist will ensure a long, troublefree service life for your heating system. It will ensure that your system stays
environmentally-friendly and operates efficiently and cost-effectively.
In the course of this maintenance the entire system is inspected and optimised,
particularly regulation and control of the boiler. The emission measurement carried out
can also be used to draw conclusions about the combustion performance of the boiler.
For this reason, FROLING offers a service agreement, which optimises operating
safety. Please see the details in the accompanying guarantee certificate.
Your Froling customer service office will also be happy to advise you.
NOTICE
All national and regional regulations relating to regular testing of the system must
be observed. Please be advised that, in Austria, commercial systems with a rated
heat output of 50 kW or more must be regularly tested at yearly intervals in
accordance with the Heating Plant Regulations (Feuerungsanlagen-Verordnung).
4.5 Replacement parts
With Froling original replacement parts in your boiler, you are using parts that match
perfectly. As the parts fit together so well, installation times are shortened and a long
service life is maintained.
NOTICE
Installing non-original parts will invalidate the guarantee.
❒ Only replace components or parts with original replacement parts
4
Boiler Servicing
Emissions measurement by chimney sweep or regulatory body
28 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Page 29
4.6 Disposal information
4.6.1 Disposal of the ash
❒ dispose of ash in accordance with the Waste Management Act (AWG)
❒ dispose of ash in accordance with local regulations
4.6.2 Disposal of system components
❒ Ensure that they are disposed of in an environmentally friendly way in accordance
with waste management regulations in the country (e.g. AWG in Austria)
❒
You can separate and clean recyclable materials and send them to a recycling
centre.
Austria:
Other countries:
Boiler Servicing
4
Disposal information
Operating Instructions PE1 Pellet (Touch) | B1000315_en 29
Page 30
5 Troubleshooting
5.1 General fault with power supply
Error characteristics Cause of error Elimination of error
Nothing is shown on the
display
No power to the controller
General power failure
Main switch is turned off
FI circuit breaker or line
protection is switched off
Faulty fuse in the controller
Turn on the main switch
Switch on the FI circuit
breaker or line protection
Replace the fuse – note the
amperage (6.3AT)
5.1.1 Behaviour of system after a power failure
When the power supply has been restored, the boiler returns to the previous mode
and is controlled according to the specified program.
❒ After a power failure, check whether the STL (high-limit thermostat) has tripped.
❒ Keep the doors of the boiler closed during and after the power failure, at least until
the induced draught fan automatically starts up again.
EXCEPTION:
If the boiler operating status was "Heating up", "Pre-heating" or "Ignition" before the
power failure, the boiler follows the shutdown procedure and cleaning commences.
Only then does the boiler switch to "Preparation" operating status and the system
starts up again.
5.2 Excessive temperature
The high-limit thermostat (STL) shuts down the boiler when it reaches a temperature
of max. 100°C. The pumps continue to run.
Once the temperature falls below approx. 75°C, the STL (high-limit thermostat) can be
reset mechanically:
❒
Unscrew the cap on the STL (high-limit thermostat)
❒ Unlock the STL (high-limit thermostat) by pressing with a screwdriver
5
Troubleshooting
General fault with power supply
30 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Page 31
5.3 Faults with fault message
If a fault has occurred and has not yet been cleared:
❒
Status LED indicates the nature of the fault
- Orange flashing: Warning
- Red flashing: Error or alarm
❒ A fault message is shown on the display
The term "fault" is a collective term for warnings, errors and alarms. The boiler reacts
differently to the three types of message:
WARNING In case of warnings the boiler initially continues controlled
operation, giving the option of resolving the error quickly to
prevent a shutdown.
ERROR The boiler follows the shutdown procedure and remains in
"Boiler off" status until the problem is resolved.
ALARM An alarm triggers a system emergency stop. The boiler shuts
down immediately, the heating circuit controller and pumps
remain active.
5.3.1 Procedure for fault messages
The procedure in the case of a fault message, the causes of faults and procedure for
troubleshooting are described in the operating instructions for the boiler controller:
IMPORTANT! See operating instructions for the
Lambdatronic P 3200 P1
5.3.2 Acknowledging a fault message
Trace and remove the fault and then:
❒
Tap the “Cancel” symbol
➥ Status LED constant or flashing green light (depending on operating status)
- Green constant: Boiler switched on
- Green flashing: Boiler switched off
Troubleshooting
5
Faults with fault message
Operating Instructions PE1 Pellet (Touch) | B1000315_en 31
Page 32
6 Appendix
6.1 Addresses
6.1.1 Address of manufacturer
FRÖLING
Heizkessel- und Behälterbau GesmbH
Industriestraße 12
A-4710 Grieskirchen
AUSTRIA
TEL 0043 (0)7248 606 0
FAX 0043 (0)7248 606 600
INTERNET www.froeling.com
6.1.2 Address of the installer
Stamp
6
Appendix
Addresses
32 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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