Froling P1 Pellet Installation Operating Instructions

8/20/2019 Froling P1 Pellet Installation Operating Instructions

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Installation Instructions

Pellet boiler P1 Pellet

Translation of the original German installation instructions for techniciansRead and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!M1440213_en | Edition 23/09/2013

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


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Version of 27 Oct 2011

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SUPPLEMENTARY INSTALLATION INSTRUCTIONS FOR THE UK MARKETTO BE READ IN CONJUNCTION WITH THOSE IN THE MAIN INSTRUCTION MANUAL

These instructions together with those in the instruction manual cover the basic principlesto ensure the satisfactory installation of the boiler, although detail may need slightmodification to suit particular local site conditions.In all cases the installation must comply with current Building Regulations, Local AuthorityByelaws and other specifications or regulations as they affect the installation of the boiler.It should be noted that the Building Regulations requirements may be met by adopting therelevant recommendations given in British Standards BS 8303, BS EN15287-1:2007 as analternative means to achieve an equivalent level of performance to that obtained followingthe guidance given in Approved Document J.

Please note that it is a legal requirement under England and Wales Building Regulationsthat the installation of the boiler is either carried out under Local Authority Building Controlapproval or is installed by a Competent Person registered with a Government approvedCompetent Persons Scheme. HETAS Ltd operate such a Scheme and a listing of theirRegistered Competent Persons can be found on their website at www.hetas.co.uk .

CO Alarms:-

Building regulations require that when ever a new or replacement fixed solid fuel orwood/biomass appliance is installed in a dwelling a carbon monoxide alarm must be fittedin the same room as the appliance. Further guidance on the installation of the carbonmonoxide alarm is available in BS EN 50292:2002 and from the alarm manufacturer’s

instructions. Provision of an alarm must not be considered a substitute for either installingthe appliance correctly or ensuring regular servicing and maintenance of the appliance andchimney system.

HEALTH AND SAFETY PRECAUTIONS

Special care must be taken when installing the boiler such that the requirements of the Health and Safety atWork Act are met.

Handling

Adequate facilities must be available for loading, unloading and site handling.

Fire Cement

Some types of fire cement are caustic and should not be allowed to come into contact with the skin. In caseof contact wash immediately with plenty of water.

Asbestos

This boiler contains no asbestos. If there is a possibility of disturbing any asbestos in the course of installationthen please seek specialist guidance and use appropriate protective equipment.

Metal Parts

When installing or servicing this boiler care should be taken to avoid the possibility of personal injury.


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BOILER PERFORMANCE

The nominal heat outputs for the various boilers are detailed in the main instruction manual:

PREPARATORY WORK AND SAFETY CHECKS

IMPORTANT WARNING

This boiler must not be installed into a chimney that serves any other heating appliance.

There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to emitfumes into the room.

Chimney

In order for the boiler to perform satisfactorily the chimney height must be sufficient to ensure an adequatedraught of approximately 15 Pa so as to clear the products of combustion and prevent smoke problems intothe room.

NOTE: A chimney height of not less than 4.5 metres measured vertically from the outlet of the boiler to the topof the chimney should be satisfactory. Alternatively the calculation procedure given in BS EN 13384-1 may beused as the basis for deciding whether a particular chimney design will provide sufficient draught.

The outlet from the chimney should be above the roof of the building in accordance with the provisions ofBuilding Regulations Approved Document J.

Because these boilers run at high efficiencies the temperature of the flue gases is lower than conventionalsolid fuel appliances. Although they are not classed as condensing appliances, the low flue gas temperatureresults in condensation occurring within the flue. Any chimney flue system must therefore be able to withstandthe effects of condensate and operate under wet conditions (designation letter W). In addition it should besoot fire resistant and able to withstand the corrosive effects of flue products generated by solid fuels(designation G and 3 respectively). If installation is into an existing masonry chimney then it will require re-lining with a liner meeting the specification described above. Existing concrete or clay lined chimneys are notsuitable for these boilers and must be lined as described above. All installations must be in accordance withBuilding Regulations Approved Document J.

Any existing chimney must be clear of obstruction and have been swept clean immediately before installationof the lining system.

If there is no existing chimney then any new system must be to the designation described above and inaccordance with Building Regulations Approved Document J.

A single wall metal fluepipe is suitable for connecting the boiler to the chimney but is not suitable for use as

the complete chimney. The chimney and connecting fluepipe must not be less than the size of the outletsocket of the boiler. The length of this connecting pipe should be kept to a minimum. Refer also to the maininstruction manual for further guidance.

Any bend in the chimney or connecting fluepipe should not exceed 45 . 90 bends should not be used,except for connecting to a rear outlet appliance, and the connection should be no more than 150 mm in lengthand have a debris trap.

Combustible material should not be located where the heat dissipating through the walls of fireplaces or fluescould ignite it. Therefore when installing the boiler in the presence of combustible materials due account mustbe taken of the guidance on the separation of combustible material given in Building Regulations ApprovedDocument J and also in these boiler instructions.

If it is found that there is excessive draught in the chimney then a draught stabiliser should be fitted in thechimney above the chimney above the flue pipe connection. Fitting of a draught stabiliser will affect therequirement for the permanent air supply into the room in which the boiler is fitted in accordance with


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Approved Document J (see also combustion air supply).

Adequate provision e.g. easily accessible soot door or doors must be provided for sweeping the chimney andconnecting fluepipe.

Connection to the chimney

All the boilers have a flue gas connector that allows connection to the main chimney using a suitableconnecting pipe. All joints must be sealed in accordance with the recommendations in Approved Document J.See also “Chimney” above.

Hearth

The hearth should be able to accommodate the weight of the boiler and its chimney if the chimney is notindependently supported. The weight of the boiler is indicated in the instruction manual.

The boiler should always be installed on a non-combustible hearth of a size and construction that is inaccordance with the provisions of the current Building Regulations Approved Document J.

The clearance distances to combustible material beneath, surrounding or upon the hearth and walls adjacentto the hearth should comply with the guidance on the separation of combustible material given in BuildingRegulations Approved Document J and also in these boiler instructions.

Combustion air supply

In order for the boiler to perform efficiently and safely there should be an adequate air supply into the room inwhich the boiler is installed to provide combustion air. This is particularly necessary if the room is double-glazed or a flue draught stabiliser is operating in the same room as the appliance. The provision of air supplyto the boiler must be in accordance with current Building Regulations Approved Document J. An openingwindow is not appropriate for this purpose.

Connection to the central heating system

Ensure the heating system is the correct design for the boiler. It is an essential requirement that the systemincorporates a heat storage buffer tank (often referred to as an accumulator). Full guidance is given in themain installation manual. Depending on the intended design of the heating installation and also on the outputof the boiler, the central heating system must be in accordance, as appropriate, with either BS 6880:1988Parts 1 to 3, Code of Practice for low temperature hot water heating systems of output greater than 45kW.Further guidance is available from the following sources: BS EN 14336:2004: Heating Systems in Buildings.Installation and commissioning of water based heating systems. BS EN 12828: 2003; Heating Systems inBuildings. Design of water based heating systems. BS EN 12831: 2003; Heating Systems in Buildings.Method for calculation of the design heat load.

Particular attention must be paid to the installation and correct functioning of any Thermal Safety Device

where necessary. This is described fully in the installation manual.


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Electrical connections

The installation of any electrical services during the installation of this boiler and the associated heatingsystem must be carried out by a registered competent electrician and in accordance with the requirements ofthe latest issue of BS 7671.

Commissioning and handover

Before commissioning this boiler be sure to read and follow the operation manuals to ensure that everything iscarried out in accordance with the correct procedures.

Ensure any loose parts are fitted in accordance with the instructions.

Once the boiler is under fire check all seals for soundness and that the boiler and water system are operatingcorrectly. Ensure that the flue is functioning correctly and that all products of combustion are vented safely toatmosphere via the chimney terminal.

On completion of the installation and commissioning ensure that the instruction manuals for the boiler are leftwith the customer. Ensure to advise the customer on the correct use of the appliance with the fuels likely to beused on the boiler and warn them to use only the recommended fuels for the boiler. The user should be givena demonstration of the required routine maintenance and safety checks. Remind the user of the importance ofregular chimney sweeping and servicing by qualified persons to ensure continued safe operation of the boiler.Leave the boiler operational and inform the user that this is the case.

Advise the user what to do should smoke or fumes be emitted from the boiler. The customer should bewarned about the dangers to children, aged and/or infirm persons and that access to the boiler should beprotected by a lockable door.


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Contents

1 General 4

2 Safety 52.1 Hazard levels of warnings 52.2 Qualification of assembly staff 62.3 Protective equipment for assembly staff 62.4 Design Information 72.4.1 Notes on standards 7 General standards for heating systems 7 Standards for structural and safety devices 7 Standards for heating water 7

Standards for permitted fuels 82.4.2 Installation and approval of the heating system 82.4.3 General information for installation room (boiler room) 82.4.4 Requirements for central heating water 92.4.5 Notes for using pressure maintenance systems 92.4.6 Use with storage tank 102.4.7 Chimney connection/chimney system 10 Draught limiter 10 Boiler data for planning the flue gas system 112.4.8 Room air-independent operation 11

3 Technology 13

3.1 Dimensions - P1 Pellet 133.2 Dimensions - P1 Pellet with hydraulic and boiler block 143.3 Components and connections 153.4 Dimensions and connections - external suction module 163.5 Technical specifications 17

4 Assembly 194.1 Transport 194.2 Positioning 19

4.3 Temporary storage 194.4 Setting up in the boiler room 204.4.1 Remove pellet boiler from pallet 204.4.2 Moving the boiler in the boiler room 204.4.3 Minimum distances in the boiler room 204.5 Installing the boiler 224.5.1 Aligning the boiler on the floor 224.5.2 Adding a boiler block 234.5.3 Adding a hydraulic block 264.6 Installing the discharge system 29

4.6.1 Installing the external suction module 294.6.2 Connecting suction hoses to the boiler 294.7 Electrical Connection 304.7.1 Information on circulating pumps 30

Contents

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


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4.7.2 Universal suction system 31

5 Start-up 325.1 Before commissioning / configuring the boiler 32

5.2 Initial startup 335.2.1 Permitted fuels 33 Wood pellets 335.2.2 Non-permitted fuels 33

6 Decommissioning 346.1 Mothballing 346.2 Disassembly 346.3 Disposal 34

7 Appendix 357.1 Addresses 357.1.1 Address of manufacturer 357.1.2 Address of the installer 35

Contents

Installation Instructions P1 Pellet | M1440213_en 3


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1 GeneralThank you for choosing a quality product from Froling. The product features a state-of-the-art design and conforms to all currently applicable standards and testing guide‐lines.Please read and observe the documentation provided and always keep it close to thesystem for reference. It contains important safety information and all the operation andmaintenance specifications needed to operate the system safely, properly, environ‐mentally friendly and cost-effectively.The constant further development of our products means that there may be minor dif‐ferences from the pictures and content. If you discover any errors, please let us know:[email protected] to technical change. The EC Declaration of Conformity is only valid in conjunction with a delivery certificate,which has been filled in correctly and signed as part of the commissioning process.The original document remains at the installation site. Commissioning installers or heating engineers are requested to return a copy of the delivery certificate together with the guarantee card to Froling. On commissioning by FROLING Customer Servicethe validity of the delivery certificate will be noted on the customer service record.

Issuing a delivery cer‐

tificate

1 General



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2 Safety

2.1 Hazard levels of warningsThis documentation uses warnings with the following hazard levels to indicate directhazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not o bserved it will leadto serious injury or death. You must follow the instructions

WARNING

The dangerous situation may occur and if mea sures are not observed it will leadto serious injury or death. Work w ith extreme care.

CAUTION

The dangerous situation may occur and if mea sures are not observed it will leadto minor injuries or damage to property.

Safety 2Hazard levels of warnings



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2.2 Qualification of assembly staff

CAUTION

Assembly and installation by untrained personnel:

Risk of personal injury and dam age to property.

During assembly and installation:❒ Observe the instructions and information in the manuals❒ Only allow trained staff to carry out assembly and installation

Assembly, installation, initial startup and servicing must always be carried out by quali‐fied personnel:- Heating technician / building technician- Electrical installation technician- Froling customer servicesThe assembly staff must have read and understood the instructions in the documenta‐tion.

2.3 Protective equipment for assembly staffYou must ensure that staff have the protective equipment specified by accident pre‐

vention regulations.

▪ For transportation, setup and assembly:- suitable workwear - protective gloves- sturdy shoes

2 SafetyQualification of assembly staff



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2.4 Design Information

2.4.1 Notes on standards

The system must be installed and commissioned in accordance with the local fire andbuilding regulations. The following standards and regulations should always be ob‐served:

General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fed combus‐tion systems, nominal output up to 300 kW

EN 12828 Heating systems in buildings - Design of water-based heatingsystems

EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methodsPart 1: Chimneys serving one appliance

ÖNORM M 7510-1 Guidelines for checking central heating systemsPart 1: General requirements and one-off inspections

ÖNORM M 7510-4 Guidelines for checking central heating systemsPart 4: Simple check for heating plants for solid fuels

Standards for structural and safety devices

ÖNORM H 5170 Heating installation - Requirements for construction and safety

engineering, as well as fire prevention and environmental pro‐tection

ÖNORM M 7137 Compressed untreated wood – Requirements for storing pelletsat the end customer’s site

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

Standards for heating water

ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation inclosed warm water heating systems at operating temperatures

up to 100 °C (Austria).VDI 2035 Sheet 1 Prevention of damage in water heating systems - Scale forma‐

tion in domestic water heating systems and hot water heatingsystems (Germany)

SWKI 97-1 Water quality for heating, steam, cooling and air conditioningsystems (Switzerland)

D.P.R. no. 412 Regulations for the planning, installation, running/operation andmaintenance of heating systems in buildings to reduce energyconsumption with reference to Article 4, Comma 4 of the Legis‐lative Decree of 9 January 1991, No. 10 (Italy)

Safety 2Design Information



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Standards for p ermitted fuels

EN 14961-2 Solid biofuel, fuel specifications and classes.Part 2: Wood pellets for non-industrial use

1. BImSchV First Ordinance of the German Federal Government for imple‐mentation of the Federal Emission Protection Law, BGBl. I P.491, in the applicable version.

2.4.2 Installation and approval of the heating systemThe boiler should be operated in a closed heating system. The following standardsgovern 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 informedwhen installing or modifying a heating system, and authorisation must be obtainedfrom the building authorities:Austria: Inform the civic/municipal building authorities.Germany: Notify an approved chimney sweep and the building authorities.

2.4.3 General information for installation room (boiler room)

Boiler room characteristics

▪ There must not be a potentially explosive atmosphere in the boiler room as theboiler 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 wherethe 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 (foli‐age, 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:

Note on standards

2 SafetyDesign Information



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ÖNORM H 5170 - Construction and fire protection requirementsTRVB H118 - Technical directives on fire protection/prevention

2.4.4 Requirements for central heating waterThe following standards and guidelines apply:

Austria:Germany:Switzerland:Italy:

ÖNORM H 5195-1VDI 2035SWKI 97-1D.P.R. no. 412

NOTICE Note on filling with make-up water: Always bleed the filling hose before con‐necting, 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 (corresponds to

5.6 dH)❒ Use softened water as the make-up water ❒ Avoid leaks and use a closed heating system to maintain water quality during op‐

eration

2.4.5 Notes for using pressure maintenance systemsPressure maintenance systems in hot-water heating systems keep the required pres‐sure within predefined limits and balance out volume variations caused by changes inthe hot-water temperature. Two main systems are used:

Compressor-controlled pressure maintenance

In compressor-controlled pressure maintenance units, a variable air cushion in the ex‐pansion 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 withclosed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐to the domestic hot water.

Pump-controlled pressure maintenance

A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐tenance pump, relief valve and an unpressurised receiving tank. The valve releaseshot water into the receiving tank if the pressure is too high. If the pressure drops belowa preset value, the pump draws water from the receiving tank and feeds it back intothe heating system. Pump-controlled pressure maintenance systems with open expan‐sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of thewater, exposing the connected system components to the risk of corrosion. Thesesystems offer no oxygen removal for the purposes of corrosion control as required byVDI 2035 andin the interests of corrosion protection should not be used .

Note on standards

Note on standards




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2.4.6 Use with storage tank

NOTICEIn principle it is not necessary to use a storage tank for the system to run smooth‐ly. However, we recommend that you use the system with a storage tank, as thisensures 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 accordancewith ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling.

⇨ See "Addresses" [page 35]

2.4.7 Chimney connection/chimney systemEN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐ever possible, damage caused by seepage, insufficient feed pressure and condensa‐tion. Please note in this respect that flue gas temperatures lower than 160K aboveroom temperature can occur in the permitted operating range of the boiler. The flue gas temperatures (for clean systems) and additional flue gas values can befound in the table below.

The connection between the boiler and the chimney system should be as short aspossible. The upward angle of the connection should not exceed 30 - 45°. Insulate theconnection. The entire flue gas system - chimney and connection - should be calcula‐ted in accordance with EN 13384-1. Local regulations and other statutory regulations also apply.NOTICE The chimney must be authorised by a smoke trap sweeper or chimneysweep.NOTICE TRVB H 118 (Austria only) stipulates that an explosion flap must be installedin the connecting piece (flue pipe) directly next to the boiler. It should be situated insuch a way that is poses no risk to persons

Draught limiter

The installation of a draught limiter is recommended.NOTICE Install the draught limiter directly under the mouth of the flue line, as thepressure is constantly low at this point.




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Boiler data for planning the flue gas system

Description P1 Pellet

7 10 15 20

Flue gas temperature at nominal load °C 140 150 150 150

Flue gas mass flow at nominal load kg/h 17 25 36 52

Flue gas mass flow at partial load 7 7 16 20

Flue gas mass flow at nominal load kg/s 0.005 0.007 0.010 0.014

Flue gas mass flow at partial load 0.002 0.002 0.004 0.005

Required feed pressure at nominal load Pa 5

Required feed pressure at partial load 2

Required feed pressure at nominal load mbar 0.05

Required feed pressure at partial load 0.02Maximum permissible feed pressure In accordance with ÖNORM/DIN EN 303-5

Flue spigot diameter mm 100 130

2.4.8 Room air-independent operationThe P1 Pellet has a central air connection on the back of the boiler. If appropriate sup‐ply air and flue gas connections are installed, the boiler can be operated independent‐ly of room air as a type C42 or type C82 in the sense of EN 15035.

Definition of type C 8 as per EN 15035

Boiler that is connected via its combustion air supply and flue gas outlet, with a con‐necting piece that may be supplied, to a shared chimney with a shaft for combustionair supply and a shaft for flue gas outlet. The mouths of the air and flue gas chimneyare either concentric or so close to each other that similar wind conditions apply.NOTICE 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 con‐necting piece, to a wind protection device and a single or shared chimney.

NOTICE Air supply via an air supply line that is independent from the chimney sys‐temNOTICE 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 ofpressure and/or seal from dirt

The second index "2" (C42 / C82) indicates type C boilers with a blower fan downstreamof the combustion chamber or the heat exchanger.When dimensioning pipe bends in the supply air line you should note that:




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

For example:- Diameter of supply air connection = 60 mm- Minimum radius of pipe bends 60 mm

Install the supply air line in as straight a line as possible and over the shortest path.Keep the number of pipe bends to a minimum (ideally a maximum of 4 bends)!In addition, the following applies: The maximum resistance of the supply air line is 20Pa! You can find the necessary dimensions of the supply air connections in the boiler inthe technical data sheets.

Minimum specification of connection lines

Connecting piece for the combustion air supply as per EN 1856-2EN 1856-2 - T080 - N2 - D Connecting piece for the flue gas outlet as per EN 1856-2EN 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)




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3 Technology

3.1 Dimensions - P1 Pellet

Dimen‐sion

Description Unit P1 Pellet

7 - 10 15 - 20

L Length, boiler mm 650 650

L1 Total length incl. flue gas pipe connection 680 685

B Width, boiler 600 750

H Height, boiler 1200 1200

H1 Height, flue gas pipe connection 960 940

H2 Height, ventilation connection 940 935

H3 Height, return connection 870 870

H4 Height, flow connection 250 290

H5 Height, drainage connection 240 100

H6 Height, supply air connection(for room air-independent operation)

370 360

H7 Height, suction system connection 1110 1110

Technology 3Dimensions - P1 Pellet



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3.2 Dimensions - P1 Pellet with hydraulic and boiler block

Dimen‐

sionDescription Unit P1 Pellet

7 - 10 15 - 20

L1 Length, boiler block mm 1150 1150

L2 Length, hydraulic block 500 500

B Width of boiler with hydraulic block 660 660

H Overall height of boiler with DHW block 1810 1810

H1 Height, boiler block 630 630

H2 Height, boiler block and hydraulic block 1330 1330

H3 Height of flow/return connection of the heatingcircuits

1260 1260

H4 Height of flow/return connection of the boiler 710 710

H5 Height of the drainage connection of the boiler 690 690

H6 Height of the hot water/circulation connectionof the boiler block

350 350

H7 Height of the cold water supply of the boiler block

160 160

H8 Height, electronic heating cartridge connection 185 185

H9 Height, drainage connection of boiler block 165 165H10 Height, flue gas pipe connection 1570 1550

H11 Height, supply air connection (for room air-in‐dependent operation)

980 970

H12 Height, suction system connection 1720 1720

3 TechnologyDimensions - P1 Pellet with hydraulic and boiler block



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3.3 Components and connections

No. Description Unit P1 Pellet

1 Boiler flow connection Inches 3/4 IT

2 Boiler return connection 3/4 IT

3 Drainage connection(with optional hydraulic unit designed as a boiler filling and

drainage system)

1/2 IT

4 Air vent connection 1/2 IT

5 Supply air connection (external diameter) mm 60

6 Pellet suction line connection 50

7 Return-air line connection 50

8 Flue gas pipe connection 100

9 Flow and return connection for heating circuit 1(heating circuit group with high efficiency pump and mixingvalve)

inches 1 ET

10 Flow and return connection for additional heating circuitgroup

IG 1

11 Line regulating valve

12 Safety group with- pressure gauge for system pressure- quick vent valve- safety valve

13 Expansion tank (18 litres) integrated into hydraulic block

14 Connection, cold water supply of the tank unit Inches 3/4 ET

15 Connection, hot water for the tank unit 3/4 ET

16 Connection, circulation line 3/4 ET

17 Connection, tank unit drainage 1/2 IT

18 Connection for E-cartridge 6/4 IT

Technology 3Components and connections



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No. Description Unit P1 Pellet

19 Maintenance flange with insulated magnesium protective anode

Notpic‐

tured

DHW loading pump (Wilo Yonos Para) integrated into hydraulic block

3.4 Dimensions and connections - external suction module

Dimen‐sion

Name Unit Suction module

D Suction turbine diameter mm 240

L Total length incl. wall bracket 265H1 Suction turbine height 245

H2 Total height incl. wall bracket 325

1 Return-air line connection (line to suction point) mm 50

2 Return-air line connection (line to boiler) 50

3 TechnologyDimensions and connections - external suction module



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3.5 Technical specificationsDescription P1 Pellet 7 P1 Pellet 10

Nominal heat output kW 7 10

Output range 2 - 7 2 - 10

Electrical connection 230V / 50Hz / fused C16A

Power consumption W 43 50

Boiler weight kg approx. 200 approx. 200

Total boiler capacity (water) l approx. 35 approx. 35

Pellet container capacity 32 32

Ashcan capacity 13 13

Domestic hot water content with optional boil‐er block

130

Water pressure drop (ΔT = 20 K) mbar 0.8 2.1

Minimum boiler return temperature Not applicable due tointernal return temperature control

Maximum boiler temperature setting °C 90

Minimum boiler temperature setting 40

Airborne sound level dB(A) < 70

Boiler class as per EN 303-5:2012 5

Permitted fuel Wood pellets D06 in accordance with EN14961-2 class A1

Description P1 Pellet 7 P1 Pellet 10

Testing institute TÜV SÜD1) TÜV SÜD1)

Test report no. 2212100-2 2212100-1

Date of issue 20/06/2013 21/06/20131.TÜV SÜD, Landesgesellschaft Österreich GmbH, Grazer Straße 18, A - 8600 Bruck an der Mur, Austria

Test data - Emissions in [mg/MJ]1) (nominal load/partial load)

Carbon monoxide (CO) mg/MJ 2 / 10 11 / 11

Nitrogen oxide (NOx) mg/MJ 80 / 69 83 / 69Organic hydrocarbons (OGC) mg/MJ < 1.0 / 1.0 1.0 / 1.0

Dust mg/MJ 10.3 / 4.0 11.2 / 4.0

Boiler efficiency % 94.3 / 90.9 94.5 / 90.91.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m³]1) (nominal load/partial load)

Carbon monoxide (CO) mg/m³ 4 / 15 17 / 15

Nitrogen oxide (NOx) mg/m³ 125 / 107 130 / 107

Organic hydrocarbons (OGC) mg/m³ < 1.0 / 2.0 1.0 / 2.0

Dust mg/m³ 16.2 / 6.2 17.4 / 6.2Boiler efficiency % 94.3 / 90.9 94.5 / 90.91.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%

Technical specifica‐

tions

P1 Pellet 7-10

Test report data

P1 Pellet 7-10

Technology 3Technical specifications



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Description P1 Pellet 15 P1 Pellet 20

Nominal heat output kW 15 20

Heat output range 4,5 - 15 6 - 20Electrical connection 230V / 50Hz / fused C16A

Boiler weight kg approx. 250 approx. 250

Pellet container capacity l 41 41

Ash box capacity 18 18

Domestic hot water content with optional boil‐er block

130

Minimum boiler return temperature Not applicable due tointernal return temperature control

Maximum boiler temperature setting °C 90

Minimum boiler temperature setting 40

Airborne sound level dB(A) < 70

Boiler class as per EN 303-5:2012 5

Permitted fuel Wood pellets D06 in accordance with EN14961-2 class A1

Technical specifica‐

tions

P1 Pellet 15-20

3 TechnologyTechnical specifications



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4 Assembly

4.1 TransportThe product is delivered on pallet(s) in cardboard packaging.

NOTICE

Damage to components if handled incorrectly

❒ Follow the transport instructions on the packaging.❒ Transport components with care to avoid damage❒ Protect the packaging against damp❒ Pay attention to the pallet's centre of gravity when lifting

4.2 Positioning❒ Position a fork-lift or similar lifting device at the pallet and bring in the components

If the boiler cannot be brought in on the pallet:❒ Remove the cardboard and remove the boiler from the pallet⇨ See "Remove pellet boiler from pallet" [page 20]

For positioning using a crane:

❒ Remove the insulating cover ❒ Secure the crane hook to the crane eye below and lift the boiler

4.3 Temporary storageIf the system is to be assembled at a later stage:❒ Store components at a protected location, which is dry and free from dust➥ Damp and frost can damage components, particularly electric ones!

Assembly 4Transport



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4.4 Setting up in the boiler room

4.4.1 Remove pellet boiler from pallet

The boiler comes screwed to the pallet:❒ Remove the transport locks❒ Lift unit off pallet

4.4.2 Moving the boiler in the boiler room❒ Position a fork-lift or similar lifting device with a suitable load-bearing capacity at

the base frame❒ Lift and transport to the intended position in the installation room➥ Observe the minimum distances in the boiler room.

4.4.3 Minimum distances in the boiler room

▪ The system should generally be set up so that it is accessible from all sides allow‐ing quick and easy maintenance.

▪ Regional regulations regarding necessary maintenance areas for inspecting thechimney should be observed in addition to the specified minimum distances!

▪ Observe the applicable standards and regulations when setting up the system.▪ Observe additional standards for noise protection

(ÖNORM H 5190 - Noise protection measures)

Minimum distances - P1 P ellet

A

B

DC

Pos. Name P1 Pellet

A Distance - insulated door to wall 600 mm

B Distance – boiler side to wall(controller side)

300 mm

C Distance – back to wall 300 mm

D Distance – boiler side to wall(door stop side)

100 mm

Minimum space (length x width) 1540 x 1000 mm

4 AssemblySetting up in the boiler room



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Minimum distances - P1 Pellet with hydraulic and boiler block

C

A

B

D

Pos. Name P1 Pellet with hydraulic and boiler block

A Distance - insulated door to wall 600 mm

B Distance – boiler side to wall(controller side)

300 mm

C Distance – back to wall -

D Distance – boiler side to wall(door stop side)

100 mm

Minimum space (length x width) 1740 x 1000 mm

Assembly 4Setting up in the boiler room



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4.5 Installing the boiler

4.5.1 Aligning the boiler on the floor

P1 Pellet

After positioning, the boiler must be aligned on the floor:❒ Use a hexagonal spanner to set the adjustable feet on the underside of the boiler

P1 Pellet with boiler block or as a complete unit

If a boiler block is being added to the boiler or it has come fully preassembled as a unitwith a hydraulic and boiler block, adjustable feet are not required.

❒ Lift boiler and position the boiler underlays provided under the base frame

4 AssemblyInstalling the boiler



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4.5.2 Adding a boiler blockAn optional boiler block can be added to the P1 Pellet. All the components and corre‐sponding flat seals required for fitting to the boiler and operating the DHW tank are

provided. Materials and tools for sealing the threaded joints are not included.

❒ Before assembly, position the boiler block on the boiler underlays provided at the

place of installation❒ Remove the front cladding plates from the boiler block❒ Remove the adjustable feet from the boiler and place the boiler on the boiler block➥ Note the information about lifting the boiler ⇨ See "Positioning" [page 19]

❒ Screw the boiler to the boiler block and replace the cladding plates

Assembly 4Installing the boiler



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❒ Fit the threaded socket (G 1" to R 3/4") to the return connection on the boiler ❒ Fit the reducing nipple (G 1" to Rp 3/4") to the return connection on the DHW tank❒ Screw the pipe bend, line regulating valve, T-piece and pump ball valve together

as shown and fit to the return connection of the boiler ➥ Fit the SIL seals provided to all flat-sealing joints

❒ Put the insulation jacket onto the line regulating valve❒ Fit the blanking plug (G 1") to T-piece➥ If other components are being added to the heating system in the course of in‐

stallation, the blanking plug is not required. In this case, this connection servesas the return connection of the boiler

❒ Screw the pump ball valve and return pipe joint together as shown and fit to the

return connection on the DHW tank➥ Fit the SIL seals provided to all flat-sealing joints

❒ Fit the DHW loading pump between the two pump ball valves with SIL seals❒ Put the insulation jacket onto the pump




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❒ Fit threaded socket (G 1" to R 3/4") to the flow connection on the boiler ❒ Fit the reducing nipple (G 1" to Rp 3/4") to the flow connection on the DHW tank❒ Screw together the pipe bend, two-way zone valve and flow pipe union as shown

and fit to the flow connections on the boiler and DHW tank➥ Fit the SIL seals provided to all flat-sealing joints

❒ Fit the blanking plug (G 1") to T-piece➥ If other components are being added to the heating system in the course of in‐

stallation, the blanking plug is not required. In this case, this connection servesas the flow connection of the boiler

❒ When you have finished, tighten all the joints again❒ Place the cover plate onto the boiler block and secure with self-tapping screws




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4.5.3 Adding a hydraulic blockAn optional hydraulic block can be added to the P1 Pellet. Depending on the scope of delivery, up to two heating circuits can be supplied. All the components and corre‐

sponding flat seals required for fitting to the boiler and operating the heating circuit(s)are provided. Materials and tools for sealing the threaded joints are not included. Once you have positioned the boiler at the place of installation:

❒ Take off the cover plates and remove all cladding plates from the hydraulic block❒ Fit threaded socket (G 1" to R 1/2") to the ventilation connection on the boiler ❒ Fit one threaded socket each (G 1" on R 3/4") to the flow and return connection on

the boiler ❒ Fit threaded socket (G 3/4" on R 1/2") to the drainage connection on the boiler

❒ Position the hydraulic block at the back of the boiler as shown and adjust to theheight of the boiler using the adjustable feet

❒ After aligning, screw the hydraulic block to the boiler ❒ Fit the pipe union for drain to boiler with SIL seal (18x12x2)




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❒ Screw cap valve, elbow pipe (3/4") and threaded socket (G 1" on R 3/4") as well

as a double nipple (1") at the top connection to the return pipe union as shown andfit to the diaphragm expansion tank➥ Fit the SIL seals provided to all flat-sealing joints

❒ Fit the blanking plug (G 1") to the bottom and side connection with SIL seal➥ If other components are being added to the heating system in the course of in‐

stallation, the blanking plug at the side connection is not required. In this case,this connection serves as the return connection of the boiler

❒ Screw together the pipe bend, line regulating valve and pipe union as shown andfit to the return connection on the boiler and to the previously assembled returnpipe union➥ Fit the SIL seals provided to all flat-sealing joints➥ If other components are being added to the heating system in the course of in‐

stallation, the circulating pump is installed instead of the blanking plug.

❒ Fit the flow pipe to the flow connection on the boiler ❒ Fit blanking plug (G 1") to the side connection➥ If other components are being added to the heating system in the course of in‐

stallation, the blanking plug is not required. In this case, this connection servesas the flow connection of the boiler

❒ Screw the flow and return connection on the heating circuit manifold to the respec‐tive pipe unions on the boiler each with a pipe bend and a ball valve (1")➥ Fit the SIL seals provided to all flat-sealing joints




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❒ Screw the pipe bend and boiler safety block together and fit to the ventilation con‐

nection on the boiler ➥ Fit the SIL seals provided to all flat-sealing joints

❒ Fit the protective plate for the flue pipe and cover plate to the back of the boiler ❒ When you have finished, tighten all the joints again➥ Also check pre-installed joints, for example the blanking plugs on the heating

circuit manifold and the heating circuit assemblies and tighten if necessary

❒ Replace the cladding plates removed at the start of assembly on the frame and

screw to the hydraulic block and back of the boiler at the dedicated holes❒ Finally, fit the cover plates




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4.6 Installing the discharge systemOnce the discharge system has been assembled in accordance with the assembly in‐structions enclosed, the suction and return air line needs to be connected to the boiler

and the external suction module connected as well.

4.6.1 Installing the external suction moduleFor the P1 Pellet, the pellets are loaded using an external suction module. The suctionmodule is installed in the return-air line between the boiler and the suction point. Itsposition can be chosen freely.

❒ Install the wall console with the included anchors and screws at any desired posi‐tion in the return-air line.➥ If the suction module is positioned at a maximum distance of 2 m to the boiler,

the power supply line can be plugged in as is. At greater distances, the power supply line must be lengthened accordingly on-site!

❒ Lay the return-air line from the suction point to the suction module and connect itto the pressure side (position 1).

❒ Connect the second part of the return-air line to the under-pressure side (position2) and lay the line to the boiler

4.6.2 Connecting suction hoses to the boilerAt the back of the boiler:❒ Connect the suction hose of the discharge system to the right connection (“PEL‐

LETS” label)❒ Connect the return-air line of the discharge system from the external suction mod‐

ule to the left connection NOTICE Ensure the potential equalisation matches the discharge system assemblyinstructions when connecting the hose lines

Assembly 4Installing the discharge system



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4.7 Electrical Connection

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 unauthorisedpeople

❒ Remove the insulating cover and the side control cover ❒ Connect the power supply cable at the mains connection plug provided➥ Flexible sheathed cable must be used for the wiring; this must be of the correct

size to comply with applicable regional standards and regulations.➥ The power supply line (mains connection) must be fitted with a C16 A fuse by

the customer.

4.7.1 Information on circulating pumps

NOTICE

According to 2012/622/EU external, wet running circulating pumps must com plywith the following limit values of the Energy Efficiency Index (EEI):

- Effective from 01/01/2013: W et running circulating pumps with EEI ≤ 0.27- Effective from 08/01/2015: W et running circulating pumps with EEI ≤ 0.23

Only high efficiency pumps with a connection option for a control signal (PDM / 0-10V)should be connected to speed-controlled pump outputs (pump 1 on the core moduleand pump outputs on the hydraulic module). In this case, the control line is connectedto the corresponding PDM outputs of the boards. Observe the connection instructionsin the boiler controller documentation!

4 AssemblyElectrical Connection



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CAUTION

When using high efficiency pumps without an additional control line at speed-con‐trolled pump outputs:

Malfunctions of the boiler, the pump and the hydraulic system m ay occur

Therefore:❒ Do not connect EC motor pumps without a control line to the speed-controlled

pump outputs of the boards.➥ Only use special high efficiency pumps with a connection option for a con‐

trol line (PDM/0-10V)!➥ Observe the additional instructions and information on board outputs in the

operation instructions for the boiler controller.

4.7.2 Universal suction systemWith the automatic universal suction system, the Pellet-Box Comfort is linked to theCore module using flexible cable (5x0.75mm2, YMM as per ÖVE-K41-5 or H05VV-Fas per DIN VDE 0881-5). This is a 24V control line. The previous figure shows the plugged-in 5-pin connecting plug of the Comfort pelletbox and the accompanying connection layout of the control Lambdatronic P 3200 P1. To check the plug arrangement:

❒ Perform check using the board's labelsThe actuators (1) of the pellet-box must beswitched to the "R" position! 1

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

Assembly 4Electrical Connection



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5 Start-up

5.1 Before commissioning / configuring the boilerThe boiler must be adjusted to the heating system during commissioning.

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteedif the system is set up by trained professionals and the standard factory settingsare observed.

Take the following precautions:

❒ Initial startup should be carried out with an authorised installer or with Frolingcustomer services

❒ Adjust the boiler controller to the system type❒ Apply boiler standard values

NOTICE The keypad assignment and the steps necessary to modify the parametersare detailed in the operating instructions for the boiler control unit.❒ Check the system pressure of the heating system❒ Check that the heating system is completely vented❒ Check that the safety devices are present and working correctly❒ Check that there is sufficient ventilation in the boiler room❒ Check the seal of the boiler ➥ All doors and inspection openings must be tightly sealed!

❒ Check that drives and actuators are working and turning in the right direction

NOTICE For how to check the analogue and digital outputs, see the operating instruc‐tions for the boiler controller ❒ Check that the door contact switch is working correctly

NOTICE For how to check the digital inputs see the operating instructions for the boil‐er controller.

5 Start-upBefore commissioning / configuring the boiler



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5.2 Initial startup

5.2.1 Permitted fuels

Wood pellets

Wood pellets made from natural wood with a diameter of 6 mm

EU: Fuel acc. to EN 14961 - Part 2: Wood pellets class A1 / D06

and/or: Certification program ENplus or DINplus

General note:Before refilling the store, check for pellet dust and clean if necessary.

5.2.2 Non-permitted fuelsThe use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐ing 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 abuild-up of aggressive sedimentation and condensation, which can dam age theboiler and also invalidates the guarantee. Using non-standard fuels can also leadto serious problems with comb ustion.

For this reason, when operating the boiler:❒ Only use permitted fuels

Note on standards

Start-up 5Initial startup



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6 Decommissioning

6.1 MothballingThe following measures should be taken if the boiler is to remain out of service for several weeks (e.g. during the summer):❒ Clean the boiler thoroughly and close the doors fully

If the boiler is to remain out of service during the winter:❒ Have the system completely drained by a qualified technician➥ Protection against frost

6.2 Disassembly

To disassemble the system, follow the steps for assembly in reverse order.

6.3 Disposal❒ Ensure that they are disposed of in an environmentally friendly way in accordance

with waste management regulations.❒ You can separate and clean recyclable materials and send them to a recycling

centre.

6 DecommissioningMothballing



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7 Appendix

7.1 Addresses

7.1.1 Address of manufacturer

FRÖLINGHeizkessel- und Behälterbau GesmbH Industriestraße 12A-4710 GrieskirchenAUSTRIA TEL 0043 (0)7248 606 0FAX 0043 (0)7248 606 600

INTERNET www.froeling.com

7.1.2 Address of the installer

Stamp

Appendix 7Addresses



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Operating Instructions

Pellet boiler P1 Pellet (Touch)

Translation of the original German operating instructions for the operatorRead and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!B1000013_en | Edition 02/09/2013

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


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Page 6 of 7

Protection of vulnerable persons

This type of boiler is unlikely to be installed in a part of the home that would be considered as part of thegeneral living area or easily accessible from such. It is intended to be installed in its own boiler room. Thisboiler room should be guarded effectively with the use of an appropriate lockable door.

Chimney cleaning

The chimney should be swept a minimum of twice a year. It is important that the flue connection and chimneyare swept prior to lighting up after a prolonged shutdown period.

In situations where it is not possible to sweep through the boiler the installer will have provided alternativemeans, such as a soot door. After sweeping the chimney the boiler flue outlet and the flue pipe connectingthe boiler to the chimney must be cleaned with a flue brush.

Periods of Prolonged Non-Use

If the boiler is to be left unused for a prolonged period of time then it should be given a thorough clean toremove ash and unburned fuel residues. To enable a good flow of air through the boiler to reducecondensation and to avoid door seals becoming stuck and subsequently damaged, leave the filling hatch andcombustion chamber doors slightly ajar. These actions will reduce the possibility of unnecessary damage andcorrosion.

It is important to check, and clean if necessary, the connecting pipe and the chimney prior to lighting up theboiler after a prolonged period of non-use.

Extractor fan

There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to emitsmoke and fumes into the room.

Aerosol sprays

Do not use an aerosol spray on or near the boiler when it is alight.

Use of operating tools

Always use the operating tools provided when handling parts likely to be hot when the boiler is in use.

Chimney Fires

If the chimney is thoroughly and regularly swept, chimney fires should not occur. However, if a chimney firedoes occur the control system of the boiler should shut down the system. Please follow the instructions in the

operation manual for emergency manually shutting down the boiler if it appears that the boiler has not shutdown automatically. This should cause the chimney fire to go out in which case the control should be kept atthe minimum setting until the fire in the boiler has gone out. The chimney and flueways should then becleaned. If the chimney fire does not go out when the above action is taken then the fire brigade should becalled immediately.

After a chimney fire the chimney should be carefully examined for any damage. Expert advice should besought if necessary


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Page 7 of 7

Permanent air vent

The boiler requires a permanent and adequate air supply in order for it to operate safely and efficiently.In accordance with current Building Regulations the installer may have fitted a permanent air supply vent intothe room in which the boiler is installed to provide combustion air. This air vent should not under anycircumstances be shut off or sealed.

Recommended fuels

The boiler is designed to burn specific wood based fuels as detailed in the main instructions.

HETAS Ltd Approval

This appliance has obtained HETAS Ltd approval for burning the specified fuels. Approval does not cover theuse of other fuels either alone or mixed with the recommended fuels listed, nor does it cover instructions forthe use of other fuels.


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Contents

1 General 41.1 Product overview, P1 Pellet 5

2 Safety 62.1 Hazard levels of warnings 62.2 Pictograms used 72.3 General safety information 82.4 Permitted uses 92.4.1 Permitted fuels 9 Wood pellets 92.4.2 Non-permitted fuels 92.5 Qualification of operating staff 102.6 Protective equipment for operating staff 102.7 Design information 102.7.1 Installation and approval of the heating system 102.7.2 General information for installation room (boiler room) 112.7.3 Requirements for central heating water 112.7.4 Notes for using pressure maintenance systems 122.7.5 Use with storage tank 122.7.6 Chimney connection/chimney system 132.8 Safety Devices 142.9 Residual risks 152.10 Emergency procedure 172.10.1 Overheating of the system 172.10.2 Smell of flue gas 172.10.3 Fire in the system 17

3 Operating the system 183.1 Assembly and initial startup 183.2 Filling the pellet store 193.2.1 General advice for working in the store 19

3.3 Heating up the boiler 203.3.1 Switching on the power supply 203.3.2 Switching on the boiler 203.3.3 Regulating the boiler 203.3.4 Switching off the boiler 203.3.5 Switching off the power supply 20

4 Boiler Servicing 214.1 General information on servicing 214.2 Inspection and cleaning 224.2.1 Inspection 22 Checking the system pressure 22 Checking the safety valve 224.2.2 Cleaning 22 Empty the ash drawer 22

Contents



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Emptying the ash container (P1 Pellet 15-20) 23 Check the grate and combustion chamber 244.2.3 Periodic inspection and cleaning 25 Cleaning the heat exchanger and flue gas temperature sensor 25 Cleaning the induced draught fan 27 Cleaning the flue gas pipe 27 Checking the draught controller flap 27

4.3 Emissions measurement by chimney sweep or regulatory body 284.3.1 Measurement at nominal load 284.4 Maintenance agreement / Customer service 284.5 Replacement parts 284.6 Disposal information 294.6.1 Disposal of the ash 294.6.2 Disposal of system components 29

5 Troubleshooting 305.1 General fault with power supply 305.1.1 Behaviour of system after a power failure 305.2 Excessive temperature 305.3 Faults with fault message 315.3.1 Procedure for fault messages 315.3.2 Acknowledging a fault message 31

6 Appendix 326.1 Addresses 32

6.1.1 Address of manufacturer 326.1.2 Address of the installer 32

Contents

Operating Instructions P1 Pellet (Touch) | B1000013_en 3


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1 GeneralThank you for choosing a quality product from Fröling. The product features a state-of-the-art design and conforms to all currently applicable standards and testing guide‐lines.Please read and observe the documentation provided and always keep it close to thesystem for reference. Observing the requirements and safety information in the docu‐mentation makes a significant contribution to safe, appropriate, environmentally friend‐ly and economical operation of the system.The constant further development of our products means that there may be minor dif‐ferences from the pictures and content. If you discover any errors, please let us know:[email protected] to technical change.

Guarantee conditions

Our sale and delivery conditions generally apply. These conditions have been madeavailable 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



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1.1 Product overview, P1 Pellet

1 Pellet boiler, P1 Pellet

2 Boiler controller, Lambdatronic P 3200 P1

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 to automatically adjust the display brightness

2.4 USB port for connecting a USB stick for software updates

3 Main switch

4 High-limit thermostat (STL)

5 Door contact switch

6 Maintenance opening for combustion chamber (underneath the cover)

6.1 Inspection glass for checking combustion

7 Ashcan (P1 Pellet 7/10) or

ash container for automatic ash removal (P1 Pellet 15/20)8 Quick start guide

General 1Product overview, P1 Pellet



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2 Safety

2.1 Hazard levels of warningsThis documentation uses warnings with the following hazard levels to indicate directhazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will leadto serious injury or death. You must follow the instructions

WARNING

The dangerous situation may occur and if measures are not observed it will leadto serious injury or death. W ork with extreme care.

CAUTION

The dangerous situation may occur and if measures are not observed it will leadto minor injuries or damage to property.

2 SafetyHazard levels of warnings



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2.2 Pictograms usedThe following symbols are used in the documentation and/or on the boiler to showwhat is required and forbidden and to give warnings.

In accordance with the Machinery Directive, signs fitted directly within the danger areaof the boiler indicate immediate hazards or safety procedures. These stickers must notbe removed or covered.

Refer to the operating instruc‐tions

Wear safety shoes

Wear protective gloves Turn off the main switch

Keep the doors closed Wear a dust mask

Work under the supervision of asecond person

Lock

Unauthorised access prohibited No fire, open flames or smoking

Warning - hot surface Warning - hazardous electricalvoltage

Warning - hazardous or irritantmaterials

Warning - automatic boiler start‐up

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 beingpulled into rotating shafts

Increased CO concentrationwarning

Slipping hazard warning

Safety 2Pictograms used



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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-standardfuel, can cause serious faults in combustion (e.g. spontaneous combustion of car‐bonisation 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 mustbe 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 insuf‐ficient chimney draught, can cause serious faults in combustion (such as spo nta‐

neous com bustion 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 SafetyGeneral safety information



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2.4 Permitted usesThe Froling Pellet boiler P1 Pellet is designed solely for heating domestic water. Onlyuse fuels specified in the "Permitted fuels" section.

⇨ See "Permitted fuels" [page 9]The unit should only be operated when it is in full working order. It should be operatedin accordance with the instructions, observing safety precautions, and you should en‐sure you are aware of the potential hazards. The inspection and cleaning intervals inthe operating instructions should be observed. Ensure that any faults which might im‐pair safety are rectified immediately.The manufacturer or supplier is not liable for any damage resulting from non-permitteduses.

2.4.1 Permitted fuelsWood pellets

Wood pellets made from natural wood with a diameter of 6 mm

EU: Fuel acc. to EN 14961 - Part 2: Wood pellets class A1 / D06

and/or: Certification program ENplus or DINplus

General note:Before refilling the store, check for pellet dust and clean if necessary.

2.4.2 Non-permitted fuelsThe use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐ing 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 abuild-up of aggressive sedimentation and condensation, which can damage theboiler and also invalidates the guarantee. Using non-standard fuels can also leadto serious problems with combustion.

For this reason, when operating the boiler:❒ Only use permitted fuels

Note on standards

Safety 2Permitted uses



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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 damag e 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 haveread and understood the instructions in the documentation.

2.6 Protective equipment for operating staffYou must ensure that staff have the protective equipment specified by accident pre‐vention regulations.

▪ For operation, inspection and cleaning:- suitable work wear - protective gloves- sturdy shoes

2.7 Design informationIt is forbidden to carry out modifications to the boiler or to change or deactivate safetyequipment.Always comply with all fire, building, and electrical regulations when installing or oper‐ating the boiler system, and follow the operating instructions and mandatory regula‐tions that apply in the country in which the boiler is operated.

2.7.1 Installation and approval of the heating systemThe boiler should be operated in a closed heating system. The following standardsgovern 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 informedwhen installing or modifying a heating system, and authorisation must be obtainedfrom the building authorities:Austria: Inform the civic/municipal building authorities.Germany: Notify an approved chimney sweep and the building authorities.

Note on standards

2 SafetyQualification of operating staff



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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 theboiler 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 wherethe 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 (foli‐age, 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 requirementsTRVB H118 - Technical directives on fire protection/prevention

2.7.3 Requirements for central heating waterThe following standards and guidelines apply:

Austria:Germany:Switzerland:Italy:

ÖNORM H 5195-1VDI 2035SWKI 97-1D.P.R. no. 412

NOTICE Note on filling with make-up water: Always bleed the filling hose before con‐necting, 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 (corresponds to5.6 dH)❒ Use softened water as the make-up water

Note on standards

Note on standards

Safety 2Design information



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

2.7.4 Notes for using pressure maintenance systemsPressure maintenance systems in hot-water heating systems keep the required pres‐sure within predefined limits and balance out volume variations caused by changes inthe hot-water temperature. Two main systems are used:

Compressor-controlled pressure maintenance

In compressor-controlled pressure maintenance units, a variable air cushion in the ex‐pansion 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 toohigh, 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 in‐to the domestic hot water.

Pump-controlled pressure maintenance

A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐tenance pump, relief valve and an unpressurised receiving tank. The valve releaseshot water into the receiving tank if the pressure is too high. If the pressure drops belowa preset value, the pump draws water from the receiving tank and feeds it back intothe heating system. Pump-controlled pressure maintenance systems with o pen expan‐sion 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. Thesesystems offer no oxygen removal for the purposes of corrosion control as required byVDI 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 smooth‐ly. However, we recommend that you use the system with a storage tank, as thisensures 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 accordancewith ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling. ⇨ See "Addresses" [page 32]

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2.7.6 Chimney connection/chimney systemEN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐ever possible, damage caused by seepage, insufficient feed pressure and condensa‐

tion. Please note in this respect that flue gas temperatures lower than 160K aboveroom temperature can occur in the permitted operating range of the boiler. NOTICE Please see the technical data contained in the assembly instructions for fur‐ther information about standards and regulations as well as the flue gas temperatureswhen clean and the other flue gas values

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2.8 Safety Devices

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 preventinjuries at moving components. If the insulated door remains open for more than 30seconds, 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 theheated water is blown off in the form of steam.

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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 al‐

low 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 switch‐

ing on.

WARNING

If non-permitted fuel types are used:

Non-standard fuels can cause serious faults in combustion (e.g. spontaneouscombustion of carbonisation gases / flash fires) which can lead to serious acci‐dents

Take the following precautions:

❒ Only use fuels specified in the "Permitted fuels" section of these operating in‐structions.

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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 thepower 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

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3 Operating the system

3.1 Assembly and initial startupAssembly, installation and initial startup of the boiler must only be carried out by quali‐fied staff, and these procedures are described in the accompanying assembly instruc‐tions.NOTICE See assembly instructions for the P1 Pellet

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteedif the system is set up by trained professionals and the standard factory settingsare 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 P1

The customer is responsible for ensuring the following prior to initial start-up of thesystem 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 availa‐

ble when starting up the system for the first time to make any changes to the wir‐ing which may become necessary.

▪ During initial start-up, operating staff are shown how to use the boiler. It is impera‐tive for proper handover of the product that those involved are present as this is aone-off opportunity.

NOTICE

If condensation escapes during the initial heat-up phase, this does not indicate afault.

❒ Tip: If this occurs, clean up using a cleaning rag.

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3.2 Filling the pellet store

CAUTION

Filling the store when the boiler is switched on

could result in damage and consequential injury

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Froling P1 Pellet Installation Operating Instructions

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