Operating Instructions Turbomatic TMC 28-100
Contents
1. an Severe injuries and damage can be caused by an inadequate flue gas system Problems with the flue 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 You can only be guaranteed of optimum performance from the boiler if the flue gas system is running smoothly Page 8 froling Safety 2 Permitted uses 2 2 Permitted uses The boiler should only be operated when it is in full working order It should be operated in accordance with the instructions observing safety precautions and you should ensure you are aware of the potential hazards Ensure that any faults which might impair safety are rectified immediately The Turbomatic series wood chip boiler is intended exclusively for heating central heating water Use only the fuels specified under 2 2 1 The manufacturer or supplier is not liable for any damages resulting from non permitted uses 2 2 1 Permitted fuels Wood chips Designation as per ONORM ONORM DI NCEN ONORM M 7133 M7133 TS 14961 wo mo Acres C wo M30 surabi for storage Go pe rmemondenps Description as per Water content Applicable Standards Medium wood chips only for TMC 70 100 Austria ONORM M 7133 or ONORM CEN TS 14961 Germany Wood chips in accordance with 83 1 point 4 of the 1st BI2. froling amp Operating Instructions o il au pae Ei Turbomatic 28 55 kW Turbomatic 70 100 kW Turbomatic TMC 28 100 with Lambdatronic H 3200 Be sure to read and comply with the operating instructions and safety information Subject to technical change Fr ling Heizkessel und Behalterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com Introduction Dear customer Congratulations on choosing a quality product from FR LING The FR LING Turbomatic waste wood boiler features a state of the art design that conforms to all currently applicable standards and testing guidelines Please read and observe the operating instructions and always keep them close to the boiler for reference They contain safety information and all the operation and maintenance specifications needed to operate the boiler safely properly and economically The constant further development of our products means that there may be minor differences from the pictures and content If you discover any errors please let us know Subject to technical change Fr ling Heizkessel und Behalterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 3 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B 059 00 08 C Contents 1 Product Overview 6 2 Safety 8 2 1 Safety I nform
3. Turbomatic 55 Turbomatic 70 Turbomatic 85 Turbomatic 100 Turbomatic 110 with feeder systems Bottom stirrer BRK spring blade stirrer FBR articulated arm delivery unit GLA pellet screw pellets suction system EC Directives 98 37 EC Machine directive 2006 95 EC Low voltage directive 2004 108 EC EMC directive Applicable standards and guidelines EN 60335 1 A14 Household and similar electrical appliances Safety EN 61000 6 2 Electromagnetic compatibility immunity to interference EN 61000 6 3 Electromagnetic compatibility interference emission EN 303 05 Boilers for solid fuels up to 300 kW Requirements testing and designation TRVB H118 Technical directives on fire protection prevention Automatic wood burning systems We hereby certify that the series produced versions of the above products comply with the directives guidelines and standards specified Grieskirchen 17 10 2007 p TA Lia Quality assurance Technical services Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com C0120207 Page 42 froling B 059 00 08 Your Notes 9 Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 43 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08
4. 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 2 Safety Design information 2 3 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 in addition to following the operating instructions and mandatory regulations that apply in the country in which the boiler is operated 2 3 1 Approval and obligation to report NOTICE Each heating system must be officially authorised The appropriate supervisory authority inspection agency must always be informed when installing or modifying a heating system and authorisation obtained from the building authorities Austria Inform the civic municipal building authorities Germany Register with an approved chimney sweep the building authorities Other countries Observe local regulations for authorisation 2 3 2 Requirements for central heating water The requirements for heating water are based on the following standards Applicable standards Austria ONORM H 5195 1 Germany VDI 2035 Switzerland SWKI 97 1 If the system is topped up or refilled Prepare soften the water to prevent boiler scaling Page 12 B 059 00 08 Design information Safety 2 2 3 3 Ventilation of boiler room The openings for the supply air and the exhaust air sh
5. 3 It should be standard practice to wear protective gloves when working on the boiler 3 Only operate the boiler using the handles provided for this purpose 3 Insulate the flue pipes or simply avoid touching them during operation Before carrying out work in the boiler 3 Turn off the boiler by pressing the button for 5 seconds and let it cool off Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 25 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 3 Operating the system Heating up the boiler When the boiler has cooled off a Remove the burn out opening from the combustion chamber 3 Push the guide plates in the U profiles up and remove 3 Check the guide plates for dirt Clean where necessary 3 Insert the burn out plate with the cutouts 1 behind the U profiles 3 Insert the guide plates at the U profiles in the combustion chamber and push downwards o Ensure that the burn out slit 2 is at the bottom 3 Put the grate insert into the combustion chamber as shown oc Frolingo Operating the system 3 Heating up the boiler 3 4 2 Setting the controller for emergency firewood operation For emergency firewood operation the mode must be set to Firewood operation on the controller 3 Call up the Mode menu Heizen 08 00 16 01 Anlage I Kessel 60 C Abgas 130 C iT Einst
6. EASE E EEEE EENEN 24 3 3 4 SWILCHINGCOM TMG DON CL d disse ast ed a E ne ne rn 24 3 35 SWIENING OFF IHRE SVEN ren nr Eee 24 Page 4 B 059 00 08 Contents C 3 4 Emergency firewood operation 25 3 4 1 Modifying the boiler for emergency firewood operation sssssesresesrrsrererrrrerrr reser rara 25 3 4 2 Setting the controller for emergency firewood operation sssssieserrsrererrrrerrrrrrer rensa 27 3 4 3 Filling the boiler with fireWOOd cc cece cece ee eeeee seen cess rare Arn RAK RR KRKA KRKA RK RR KR KRK K RKA 28 3 5 Modifying the boiler for normal operation 28 4 Boiler servicing 29 4 1 General information on servicing 29 4 1 1 Service NOMS a a a en dawns SE ea 30 4 2 Inspection cleaning and maintenance 3l 4 2 1 gs 81 ell 0 ee ee ee Eee ee ee ee ee 31 CHECKING NE SSA VR ee ee ea ee SRK 31 Checking the thermal discharge Safety CEViCO ssssresesesrererrerrrererrr reser ers er er reser nenn 32 Checking the system PreEeSSUlG ssesesrereserrrsrererrererrrr ere rskr rer Kr KRK Kr KR KKR KRK RR KRK KRK KRKA AA 32 Checking the Geared MOTOTS esse ss sis ssd ss a area RER SEN rk RA KRA ER ARA 32 2 222 MONLY Cle GTI rn set ee area ran 33 Cleaning the combustion chamber siosrosssesrsresrsrrrerrrrererrrrr rer reser kr KKR KR KRK KR KR KR KKR KRA a 33 Cleaning the heat exchanger and flue gas collection chamber s ssssssssrsrsrsrrsrrrrererrr ra 33 Removing ash from the cleaning system sssosessssesrsrerererrerer
7. installer or Froling customer services Page 32 B 059 00 08 Boiler servicing 4 Inspection cleaning and maintenance 4 2 2 Monthly cleaning Cleaning the combustion chamber 3 Open the insulating door and combustion chamber door 3 Remove the burn out opening 3 Remove the dirt on the burn out opening with a brush o Take out the ash baffle on the back of the combustion chamber and clean 3 Remove soot that has built up on the side walls with the ash scraper 3 Carry out a visual inspection of the firebrick for damage a Loosen the screw on the upper cleaning cover 3 Remove the cleaning cover 3 Clean the flue gas collection chamber and the opening to the induced draught fan with a brush 3 Remove any ash which has fallen down We recommend that you use an ash vacuum Fr ling Heizkessel und Behalterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 33 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B 059 00 08 4 Boiler servicing Inspection cleaning and maintenance Removing ash from the cleaning system For Turbomatic 28 55 3 Open the side cleaning door and remove the ash We recommend that you use an ash vacuum For optional automatic heat exchanger ash removal unit 3 Empty rear ash box 1 Cleaning the flue gas sensors On flue gas pipe 3 Loosen the threaded pin and remove the flue gas sensor a Wipe off the flue
8. of the stirrer is completely covered with fuel the store can be filled 3 Load the fuel at the filling opening 3 2 2 Loading wood chips in an empty store CAUTION If the head of the stirrer is already free of material and the arms spring blades are extended then the feeder unit must be active during the filling process 3 Press and hold the Q button for 5 seconds gt Extra heating mode is activated 3 Load a small quantity of wood chips and wait until the arms spring blades are touching the head of the stirrer approx 2 revolutions 3 Only then should you load the remaining material Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 21 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 3 Operating the system Initial start up loading fuel 3 2 3 Blowing in pellets for a store with pellet screw For systems with a pellet screw the boiler must be in OFF status when the store is filled The under pressure from the blowing could bring smoke back into the store 3 Switch off the boiler by pressing the button for 5 seconds and allow it to cool down for at least two hours 3 Close all openings to the store to seal out dust 3 Blow the fuel into the store 3 2 4 Blowing in pellets for a partially emptied store with stirrer If there is still sufficient fuel in the store the head of the stirrer is c
9. operated without return feed lift Condensation water forms an aggressive condensate when combined with combustion residue leading to damage to the boiler Regulations stipulate the use of a return feed lift 2 3 5 Chimney connection chimney system EN 303 5 specifies that the entire flue gas system must be designed to prevent wherever possible damage caused by seepage insufficient feed pressure and condensation It should be noted here that flue gas temperatures of less than 160 K above room temperature can occur within the permitted operating range of the boiler The flue gas temperatures for clean systems and additional flue gas values can be found in the technical specification sheets Page 15 Boiler data for constructing the flue gas system The connection between the boiler and the chimney system should be as Short as possible The incline of the connection should not exceed 30 45 Insulate the connection The entire flue gas system chimney and connection must be calculated as per ONORM DIN EN 13384 1 or prior standards ONORM M 7515 DIN 4705 1 Local regulations and other statutory regulations also apply The chimney must be authorised by a smoke trap sweeper or chimney sweep As per TRVB H 118 only in Austria an explosion flap must be installed in the flue pipe or in the chimney installing an explosion flap is recommended except in Austria Page 14 B 059 00 08 Safety 2 Design infor
10. power supply should be switched off Observe the rated current on the fuses Water sprinkler system In case of burn back the valve of the water sprinkler system opens and water goes into the gravity shaft as well as the duct of the feed screw This need only be connected when specified by the authorities Page 16 B 059 00 08 Safety 2 Safety devices 2 4 1 Devices for preventing the boiler from overheating Thermal discharge safety device At around 100 C a valve opens and sends cold water to the safety heat exchanger to decrease the temperature Safety Temperature Limiter STL a NM Stops combustion at a max boiler temperature of 105 C The pumps continue to run Once the temperature has fallen to under approx 95 C the safety 1 temperature limiter 1 can be unlocked mechanically x Safety valve Protection against over heating excessive pressure When the boiler pressure reaches a maximum of 3 bar the safety valve opens and the heating water is released in the form of steam 2 5 Safety instructions for the installation room e Danger of fire due to flammable materials No flammable materials should be stored near the boiler e 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 e Keep the air suction opening of the boiler free of dust e The room where the boiler is install
11. 00 9 Combustion air blower fan pressure side fan for supplying primary and secondary air BET n Ec EEN WOS system with turbulators and automatic drive for heat exchanger cleaning Combustion chamber door with inspection glass Secondary air control with actuator drive Primary air control with actuator drive Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 7 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B 059 00 08 2 Safety Safety information 2 Safety 2 1 Safety information A DANGER Non permitted use Incorrect use of the boiler can cause severe injuries and damage The instructions and information provided in the instructions should be observed Details on procedure for operation maintenance and cleaning as well as troubleshooting for the boiler are included in the individual instructions Any further work should be carried out by authorised heating engineers or by Froling customer services External influences Negative external influences such as insufficient combustion air or non permitted fuel can cause serious faults in combustion e g Spontaneous combustion of carbonisation gases or flash fires which can in turn cause serious accidents Instructions and information for versions and minimum values as well as norms and guidelines for heating components in the instructions must be observed
12. 3 3 5 Switching off the system a CAUTION Only when the boiler is cold in Boiler Off status o Switch off the main switch on the controller gt The controller is switched off gt The components powered via the switch cabinet are powered down amp The expansion switch cabinet which has its own power supply is still live Page 24 B 059 00 08 Operating the system 3 Heating up the boiler 3 4 Emergency firewood operation Incorrect emergency firewood operation Damage to the boiler is possible The following points must be observed for emergency firewood operation 3 Operate only in exceptional cases gt We accept no responsibility for damage caused by continuous emergency operation 3 Connect a thermal discharge safety device to the safety battery 3 Feed based on output 3 Use a storage tank of the right size eS Only convert to emergency operation and activate or convert back to standard operation and activate in Boiler Off operating status The Turbomatic TMC series boiler offers the option of manual emergency firewood operation This requires the optional expansion set for emergency firewood operation consisting of e 1 x grate insert set 1 e 1 x combustion plate 2 e 1 x cover plate 3 3 4 1 Modifying the boiler for emergency firewood operation Do not carry out modifications when the boiler is hot Hot parts and the flue pipe can cause serious burns
13. ain active 5 3 1 Procedure for fault messages The procedure for a fault message as well as causes for faults and procedure for troubleshooting are described in the operating instructions for the boiler controller See the operating instructions for the Lambdatronic H 3200 5 3 2 Acknowledging a fault message Trace and remove the fault and then 3 Press the button gt Status LED flashes green Page 40 B 059 00 08 Appendix 6 Manufacturer s guarantee conditions 6 Appendix 6 1 Guarantee Conditions Our sale and delivery conditions generally apply These conditions have been made available to customers and customers have been made aware of them at the time of order completion You can also find the guarantee conditions on the enclosed guarantee certificate 6 2 Address of manufacturer FROLING Heizkessel und Beh lterbau GesmbH Industriestra e 12 A 4710 Grieskirchen AUSTRIA TEL 43 0 7248 606 0 FAX 43 0 7248 606 600 E MAIL info froeling com WEBSITE www froeling com Fr ling Heizkessel und Beh lterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 41 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B 059 00 08 6 Appendix Declaration of Conformity 6 3 Declaration of Conformity froling amp EU DECLARATION OF CONFORMITY Product Wood chip and pellet burner with automatic loading Types Turbomatic 28 Turbomatic 35 Turbomatic 48
14. ation 8 2 2 Permitted Uses 9 2 2 od 68 21 T ee eee ee ee eee en ern 9 WOOO CMDS aaa een nn re ER ree ee ee rere 9 EL WINE ERDE 10 SAVINGS er eds en Teer nennen ee 10 KSE ALALE E an ren ee ea ern en 10 Changing the fuel ss ss sme b s se sed sade re ba dir Ro AAA UR RR r Kor BRA EAA KRA Kr 11 22 2 NOP PEMICCeG THES een Tan RK ar re shears ANNARS ee 11 2 2 3 Who may operate the boiler smisssssosesreresesrsrererrererrrrer er ee rer rr rar Kr RK KKR KRK R KKR KR KKR KR Aa 11 2 3 Design I nformation 12 2 3 1 Approval and obligation to report srsssssssesrsssseserrerrrrrrererrrrr rer rer rr rr rr Kr KRK RR KR KRK KRKA Aa 12 2 3 2 Requirements for central heating WatCri ssssssosesrsresererrererrrrerer reser rr rr r er rr rer rr r rer ess 12 2 3 3 Ventilation Of boiler room ssessssssesesreserrrsrererrrrerrrr rr er rr rr rr Kr KKR KR KR KKR KR KRK RR KR KKR KRK RR RR KRA 13 2 3 4 Installing the heating system StanNCarCOS ssrrsrsrsrersersrererrrrrrer rr reser rr rer rr nnnn nennen 13 SLOG OG L K ee re Tee E A A AEE E E T EE E ET 13 RElUrN 1660 ING eera a E E N a teens 14 2 3 5 Chimney connection chimney system sesesserereerererrrrerrrrerrrrrrrrerrererrrrrrererrne 14 DUONE AO Era E a ER een 15 Boiler data for constructing the flue gas system ossssesssesrsrerrsrrrerer reser rss rr rer saras 15 2 4 Safety devices 16 2 4 1 Devices for preventing the boiler from overheating ssssssssesrsrerersrrrerrrrr
15. e Tor fault Messages dxicdadevaavvariees aan a na 40 5 3 2 Acknowledging a fault MESSAGE cccee cece cece cece rN EA 40 6 Appendix 41 6 1 Guarantee conditions 41 6 2 Address of manufacturer 41 6 3 Declaration of conformity 42 Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 5 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B 059 00 08 1 Product overview 1 Product overview FROLING TOF v Page 6 B 059 00 08 Product overview 1 Description Wood chip boiler Froling Turbomatic Switch cabinet with integrated Lambdatronic H 3200 controller Main switch switch the power supply on and off for the entire system Control panel of the Lambdatronic H 3200 controller Status LED operating status slow green flashing light boiler activated fast green flashing light boiler deactivated red flashing light Fault Large graphical display to show operating statuses and parameters Navigation keys to move around in the menus and to change the parameter values Function keys for calling up individual boiler functions or modes directly Fuel transport unit with top gravity shaft burn back flap or rotary valve as a burn back protection system and stoker screw for fuel transport 6 Automatic ignition Automatic tipping grate with shaker RR TE fn unit optional for TMC 28 55 standard part of delivery for TMC 70 1
16. ed must be frost proof Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 17 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 2 Safety Emergency procedure 2 6 Residual risks Touching hot surfaces Hot parts and the flue pipe can cause serious burns 3 It should be standard practice to wear protective gloves when working on the boiler 3 Only operate the boiler using the handles provided for this purpose 3 Insulate the flue pipes or simply avoid touching them during operation Before carrying out maintenance work on in the boiler 3 Press and hold the button for 5 seconds gt The controller follows the shutdown procedure and starts with the cleaning cycle gt After the cleaning cycle the boiler goes to the operating Status Cleaning possible Opening the combustion chamber door during operation This may cause injury damage and smoke It is forbidden to open the doors behind the insulating door during operation Use of non permitted fuel Non standard fuels can cause serious faults in combustion e g spontaneous combustion of carbonisation gases flash fires which can lead to serious accidents Only use fuels specified in the chapter on Permitted Uses in these operating instructions ji Page 18 B 059 00 08 Safety 2 Residual risks 2 7 Emerg
17. ellen gt O ap ep Q p pa Betriebsart Winterbetrieb 2 In the mode menu Anlage 16 o Press the button Betriebsart gt A is shown next to the mode ur Winterbetrieb gt Parameter is released for editing um i m Anlage 9 Press the button until Firewood operation Banlabsarf ee appears in the display Scheitholzbetrieb 9 Press the button gt Firewood operation is set Anlage Betriebsart Scheitholzbetrieb o Press the button 2x gt A starting screen with the operating status Emerg Oper Shutdown is displayed NB FeuerAus 08 14 gt Emergency firewood operation has not yet Kessel 25 C been started I Abgas 26 C Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 27 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B 059 00 08 3 Operating the system Heating up the boiler 3 4 3 Filling the boiler with firewood o Open the insulating door and combustion NB T r offen 08 14 chamber door I Kessel 25 C gt Combustion air blower fan and induced I Abgas 26 C draught fan switch on amp 3 Put a layer of firewood onto the emergency grate 3 Put crumpled paper and firewood on top of it 3 Arrange the required quantity of firewood lengthwise o Light the paper 3 Press the button and close all the doors NB Anheizen 108 14 gt Eme
18. ency procedure 2 7 1 Overheating of the system If the system overheats in spite of the safety devices proceed as follows 3 Keep all the doors on the boiler closed o Turn off the boiler by pressing the button for 5 seconds Under no circumstances use the main switch 3 Open all mixer taps switch on all pumps Fr ling heating circuit control takes over this function in automatic operation When using a third party controller carry out the relevant measures to activate the mixer and pumps manually 3 Leave the boiler room and close the door 3 Open any available radiator thermostat valves If the temperature does not drop inform the installer or Froling customer services Page 41 6 2 Address of manufacturer 2 7 2 Smell of flue gas Smell of flue gas Flue gases can cause fatal poisoning 3 Keep all the doors on the boiler closed 3 Turn off the boiler by pressing the button for 5 seconds Under no circumstances use the main switch g Air the room where the boiler is installed 3 Close the door of the installation or boiler room and doors to living areas Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 19 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 3 Operating the system Initial start up loading fuel 3 Operating the system 3 1 Initial start up NOTICE Optimum eff
19. es or with the covers open This can damage the boiler and the chamber Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 31 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 4 Boiler servicing Inspection cleaning and maintenance Checking the thermal discharge safety device o Check the seal of the discharge valve gt The discharge pipe must not drip Exception boiler temperature gt 95 C If water is dripping from the discharge pipe 3 Clean the discharge safety device or have the installer replace it if necessary Check the safety valve as per the manufacturer s specifications Checking the system pressure o Check the system pressure on the pressure gauge gt The value must be 20 over the pre stressed pressure of the expansion tank Expansion tank operating instructions If the system pressure decreases 3 Reload with water amp If this occurs frequently the seal of the heating system is faulty Inform your installer In case of large pressure fluctuations 3 Have the expansion tank checked Checking the geared motors 3 Carry out a visual inspection of the seal on the geared motors of the stoker screw and ash screw gt There should not be a large quantity of lubricant coming out amp If afew drops of lubricant are coming out this can be normal If a lot of lubricant is being lost inform your
20. ew drive ON OFF e WOS drive ON OFF e Tilt motor ON OFF e Vibrator ON OFF o After maintenance has been carried out switch the boiler on in the desired mode In service mode the boiler does not start automatically Page 30 B 059 00 08 Boiler servicing 4 Inspection cleaning and maintenance 4 2 Inspection cleaning and maintenance Regular cleaning of the boiler extends its life and is a basic requirement for smooth running based on output So clean the boiler regularly 4 2 1 Inspection Checking the ash level The ash box must be emptied at the correct interval according to energy requirements and fuel quality 3 Open the insulating door and combustion chamber door 3 Carry out a visual inspection of the combustion chamber for dirt In the Manual operation menu 3 Switch on the ash screw 3 Open the tipping grate 3 Tip up the burn out opening and move the ash in the combustion chamber downwards gt The ash screw brings the ash that falls into the ash box o Clean the combustion chamber and chamber In the Manual operation menu 3 Stop the ash screw 3 Close the tipping grate o Remove the cover of the ash box and check the ash level o If necessary remove the ash box from the screw duct and empty CAUTION Always ensure that the ash boxes are pushed fully onto the screw duct and the covers are closed tightly CAUTION Never operate the boiler for a long period without ash box
21. gas sensor with a clean cloth 3 Slide in the flue gas sensing element and secure it hand tight using the threaded pin Page 34 B 059 00 08 Boiler servicing 4 Inspection cleaning and maintenance 4 2 3 Annual check Carry out annually or at least after 1500 hours of operation The following applies for the annual check o Turn off the main switch on the switch cabinet when the boiler has cooled off Cleaning the smoke flue pipe 3 Clean the connecting pipe between the boiler and the chimney regularly with a chimney sweeping brush o After cleaning clean fallen ash from the induced draught unit housing to prevent the fan from becoming blocked amp TIP remove the flue gas sensors before cleaning to avoid damage Depending on the layout of the flue pipes and the chimney draught cleaning annually may not be enough The cleaning interval should be adjusted accordingly Checking the draught controller flap and explosion flap o Check the draught controller flap and explosion flap for ease of movement If they cannot move smoothly have them replaced immediately Settings see page 15 Boiler data for constructing the flue gas system Cleaning the induced draught ventilator 3 Detach the induced draught ventilator on the back of the boiler a Check for dirt and damage o Clean the blower wheel with a soft brush or paint brush Do not move the balancing weights on the blower wheel Fr l
22. iciency and efficient low emission operation can only be guaranteed if the system is set up by trained professionals and observing the standard factory settings Take the following precautions 3 Initial start up 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 See the operating instructions for the Lambdatronic H 3200 NOTICE If condensation escapes during the initial heat up phase this does not indicate a fault If this occurs clean up using a cleaning rag 3 2 Filling refilling the store with fuel When you fill the store you should always ensure that you are using the right fuel Page 9 2 2 1 Permitted fuels The following also applies when loading fuel Pellets are delivered by tanker and blown into the store The boiler must be OFF when filling the store The under pressure from the blowing could bring smoke back into the store Injuries and damage to property from blowing pellets into the store when the boiler is switched on 3 Turn off the boiler by pressing the button for 5 seconds g Let the boiler cool down in Boiler Off status for at least an hour a Frolingo Operating the system 3 Initial start up loading fuel 3 2 1 Loading wood chips in a partially emptied store If there is still sufficient fuel in the store the head
23. ing Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 35 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 Boiler servicing Inspection cleaning and maintenance Page 36 B 059 00 08 Cleaning the combustion air blower fan Unscrew 4 screws on the blower fan and take off the protective grating Clean the running wheel and protective grating cloth compressed air Put the protective grating back on and fix with screws Switch the main switch on the switch cabinet back on Checking the combustion chamber door g g Close the combustion chamber door and check its seal Check glass fibre seal 1 for perfect alignment on the door frame gt Imprint in the fibre glass seal If the seal is coloured black at several points or the imprint is interrupted Cleaning the combu gt The seal is no longer efficient Tighten the door latches or replace the glass fibre seal p stion chamber door below the ash baffle Remove the front insulation of the chamber and take off the inspection cover 1 Remove the ash under the ash baffle Take off the ash baffle and clean The illustrations above show the place of installation for the stoker unit left For the stoker unit right the ash baffle is behind the ash screw froling Boiler servicing 4 Inspection cleaning and maintenance 4 3 Instr
24. mSchV i d g F Specifications as per DIN CEN TS 14961 and or NORM M 7133 Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 9 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 2 Safety Safety information Pellets Wood pellets made from natural wood with a diameter of 6 10 mm Exception When using a pellet suction system the maximum diameter is of the wood pellets is limited to 6 mm Applicable Standards S Austria NORM M 7135 HP 1 and or DI Nplus certification program Germany DIN 51731 HP 5 DINplus certification program and or NORM M 7135 HP 1 Generally applicable Before refilling the store check for pellet dust and clean if necessary Shavings As shavings generally cause problems with combustion it is only permitted to use them after authorisation from Fr ling The following additional points also apply Sawdust and carpentry waste should only be used with systems with a rotary valve The store should be fitted with a pressure release device in accordance with regional regulations The same limits apply for the permitted water content of sawdust as for wood chips Miscanthus Switchgrass or elephant grass Latin name Miscanthus is a C4 plant Standards and regulations for burning these plants have not been Standardised so the following applies The regional regula
25. mation Draught limiter We recommend that a draught limiter is fitted A Install the draught limiter directly under the mouth of the flue line as there is always low pressure there Boiler data for constructing the flue gas system Description I Units Tue es epost AL ee as m ovo aes aro ro aan Prue gas mass flow mul kom er am 150 1s 220 265 ms Feed pressure required oe 0 10 0 10 0 10 0 10 0 10 0 10 0 10 Er e co m ES ED 0 05 Flue pipe diameter Flue pipe diameter diameter RL Rated load PL Partial ie Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 15 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 2 Safety Safety devices 2 4 Safety devices If the boiler overheats Press and hold the button for 5 seconds gt Automatic operation is switched off and the controller follows the boiler shutdown procedure The pumps continue to run Never use the main switch For shutting down the entire system 3 The power to all components is switched off Only switch off the main switch when the boiler has cooled down and the controller is switched off Boiler off status Fuses in switch cabinet They fuse the controller and electrical components When changing the fuses note the following Only have the fuses changed by an electrician and the
26. oiler 3 Only operate the boiler using the handles provided for this purpose 3 Insulate the flue pipes or simply avoid touching them during operation Before starting any maintenance work 3 Press and hold the button for 5 seconds gt The controller follows the shutdown procedure and starts with the cleaning cycle gt After the cleaning cycle the boiler goes to the operating Status Cleaning possible a After maintenance has been carried out switch the boiler on in the desired mode In service mode the boiler does not start automatically Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 29 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 4 Boiler servicing Inspection cleaning and maintenance 4 1 1 Service mode Service mode should be activated for maintenance work on the boiler Reinigen m glich 16 14 3 Press and hold the button for 5 seconds I Kessel 58 C gt The controller follows the shutdown procedure and starts with the cleaning cycle Abgas 90 C gt After the cleaning cycle the boiler goes to the operating status 5 Cleaning possible 3 Call up the Manual operation menu Heizen 08 00 i Hand 15 02 I Kessel 60 C Abgas 130 C Handbetrieb D repeatedly The following manual operation functions are possible in service mode e Ash scr
27. ompletely covered with fuel the store can be filled 3 Switch off the boiler by pressing the button for 5 seconds and allow it to cool down for at least two hours 3 Close all openings to the store to seal out dust 3 Blow the fuel into the store Page 22 B 059 00 08 Operating the system 3 Initial start up loading fuel 3 2 5 Blowing in pellets for an empty store with stirrer CAUTION If the head of the stirrer is already free of material and the arms spring blades are extended then the feeder unit must be active during the filling process however the boiler must be in OFF status 3 Turn off the boiler by pressing the button for 5 seconds and allow it to cool down for at least two hours 3 Close all openings to the store to seal out dust 3 Call up the Manual operation menu Heizen 08 00 Hand 15 02 Kessel 60 C j Abgas 130 C Handbetrieb repeatedly 3 Activate the following units in the order shown Ash screw ON Tilt motor ON Stoker FORWARD Burn back flap drive ON or rotary valve ON Pellet feeder system from bunker FORWARD o Blow the fuel into the store 3 After approx 5 min deactivate the feed screw and burn back flap a Wait until the stoker is completely emptied and only then deactivate the stoker screw If there is a fuel residue in the stoke there is a danger of a flash fire the next time the boiler is started due to a large feed quan
28. ould be arranged as close to opposite each other as possible to achieve a good thermal draught effect amp The supply air must be drawn in directly from outside Exhaust air must be discharged directly outside Provided they are not contradicted by the relevant building regulations room where the boiler is to be installed the following standards apply Applicable Standards TRVB H 118 ONORM H 5170 Provide a supply air cross section of 2 cm per kW of boiler rated output as per NORM H 5170 but a total cross section of at least 200 cm 2 3 4 Installing the heating system Standards The following standards govern the installation of heating systems Applicable standards ONORM DIN EN 12828 Heating Systems in Buildings Storage tank NOTI CE A storage tank with the proper dimensions will guarantee the best boiler operating values during the entire heating period Please contact your installer or Fr ling directly for the right measurements for the storage tank Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 13 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B 059 00 08 2 Safety Design information Return feed lift If the hot water return feed is below the minimum return feed temperature some of the hot water outfeed will be mixed in Risk of dropping below dew point condensation formation if
29. rerrr rer ere rss 17 Thermal discharge safety CQVIiCO ssssssssesesrererrrsrererrrrererrrr ere rskr rer Kr Kar KRK R KR KKR KRK R RKA ta 17 Safety Temperature Limiter STE arroan cece eeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeneenas 17 SALE aks a er eet sus eS er ne ne a ee ee ee er ene 17 2 5 Safety instructions for the installation room 17 2 6 Residual risks 18 2 7 Emergency procedure 19 2 7 1 Overheating of the system cc cccccccces sees cece eee eeeeeeeeeeeeeeeteseeaneeeeeettategagenrenngs 19 27 2 SINC OF TUS Os een E EAE E Ea E 19 3 Operating the system 20 3 1 Initial start up 20 3 2 Filling refilling the store with fuel 20 3 2 1 Loading wood chips in a partially emptied StOrG ssr s srsreserrsrererrrrerrrrrr er rr reser rr rea 21 3 2 2 Loading wood chips in an empty StOrG ssssssesesreserrrsrererrrrererrrrer rr rer rr rr rr Kr KRK KR Ana 21 3 2 3 Blowing in pellets for a store with pellet screw sssssessesesrererrrsrererrrrerrr rr rer rr rer rr reses 22 3 2 4 Blowing in pellets for a partially emptied store with stirrer ssssssossssssesrsrsrerrrrerer reses 22 3 2 5 Blowing in pellets for an empty store with stirrer smosssosesrsresesrererrrrererrrr er rr rer er essens 23 3 3 Heating up the boiler 24 3 3 1 Switching on the system cc cece cee cece eee e ee eee estes eeee rr ker Kr Kr KRKA KR KKR KR KRK RR KR KRK KRK RAA 24 353 2 SWIECHING Of EHE DOLL ER ee ee ansehe 24 3 3 3 COMEFONING The DONE rerin idni einar AREEN
30. rgency firewood operation has started Kessel 25 C gt Operating status Emerg Oper Heating Abgas 26 C up is displayed 3 5 Modifying the boiler for normal operation The procedure to modify the boiler for normal operation is of course carried out in the opposite order to the modifications for emergency operation NOTICE Before starting up the automatic burner check and clean the boiler The main points to check are the chamber the induced draught fan and the heat exchanger equipment Page 28 B 059 00 08 Boiler servicing 4 Inspection cleaning and maintenance 4 Boiler servicing 4 1 General information on servicing Working on electrical components Risk of serious injuries from electric shocks 3 Work on electrical components should only be carried out by authorised technicians Non permitted cleaning and maintenance Incorrect or insufficient cleaning and maintenance 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 Only clean the boiler when it is in Boiler Off operating status and in accordance with the instructions Follow the boiler operating instructions Carrying out maintenance when the boiler ts hot an Hot parts and the flue pipe can cause serious burns 3 It should be standard practice to wear protective gloves when working on the b
31. rrrerer rr rer kr rr rr KKR KKR rn sa 34 Cleaning the flue GAS SenNSOTS smseocerielis cece ee bene sne idre ira bodde bes Res R keines 34 42 3 PANU CN GCK 2er RS DR KAR RS ESR AGN 35 Cleaning the smoke flue pipe sssssresesreresesrrsrererrererrrrerer reser rr rar Kr Kr KKR KR KRK KR KR KRK KRK RAA 35 Checking the draught controller flap and explosion flaP sssssesresesrsrrrrsrrrerer re reser rna 35 Cleaning the induced draught VentilatOrl sesesrererrrsrerrrrrrerrrrrrrr rr rer rr reser rr rea 35 Cleaning the combustion air blower fan ssisnSlsesssssseresrsrererrrrerrrr rr rr rr rer rr KRK Kr KR KKR KKR Aes 36 Checking the combustion chamber COOL ssssrsseserrererrrrererrr rer rr rr rer rr rer rr Kr KRK KKR Ana 36 Cleaning the combustion chamber door below the ash baffl amp sssssssssssrsserererererrr ra 36 4 3 I nstructions for measuring emissions 37 4 3 1 Measurement at ated 1039 un einer 37 Activating chimney sweep Mode 2zsssssensnennnnnennennennnesnnnnnnnnnnen nennen SNRA 37 4 3 2 Measurement at partial load if NECESSALY ssssssesrsreserrrsrererrrrerrr reser rr rer rr rr rer rr resta 37 4 4 Maintenance agreement Customer service 38 4 5 Replacement parts 38 5 Troubleshooting 39 5 1 General faults in the power supply 39 5 1 1 Behaviour of system after a power failure s ssssssssesrsrerererrrrerer reser rr rr rer rr rer KKR KKR kr sa 39 5 2 Excessive temperature 39 5 3 Faults with fault message 40 5 3 1 Procedur
32. t breaker or line Switch on the FI circuit breaker or No power to the controller protection is switched off line protection Main switch is turned off Turn on the main switch Faulty fuse in the controller Turn off the main switch Replace fuse note current e g 10A Turn on the main switch 5 1 1 Behaviour of system after a power failure When the power supply has been restored the boiler returns to the previously specified mode and is controlled according to the specified program 5 2 Excessive temperature The safety temperature limiter STL shuts down the boiler when it reaches a temperature of approx 100 C After the boiler has cooled down the safety temperature limiter must be manually unlocked 3 Unscrew the cap on the safety temperature limiter 1 o Reset the safety temperature limiter by pressing with a screw driver 3 Replace the cap Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 39 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 5 Troubleshooting 5 3 Faults with fault message FROLING If a fault has occurred and has not yet been cleared gt Status LED 1 flashes red A fault message is shown on the display 2 An internal distinction is made between 2 types of message Warning Boiler follows shutdown procedure Boiler shuts down immediately heating circuit controller and pumps rem
33. times must be reset to their original value Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 37 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com e www froeling com B 059 00 08 4 Boiler servicing Inspection cleaning and maintenance 4 4 Maintenance agreement Customer service Long service life with a service agreement Regular maintenance and servicing by a heating specialist will ensure a long trouble free service life for your heating system It will ensure that your system stays environmentally friendly and operates efficiently and cost effectively 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 is also glad to advise you 4 5 Replacement parts Page 38 B 059 00 08 With Froling original replacement parts in your boiler you are using parts which match perfectly As the parts fit together so well installation times are shortened and lifespan is maintained NOTI CE I nstalling non original parts voids the guarantee 3 Only replace components or parts with original replacement parts Troubleshooting 5 5 Troubleshooting 5 1 General faults in the power supply Error characteristics Cause of error Error correction Nothing is shown on the General power failure display FI circui
34. tions for burning Miscanthus should be observed Operation may only be possible with individual authorisation Page 10 froling Safety 2 Permitted uses Changing the fuel I ncorrectly set fuel parameters I ncorrect parameter settings have a significant effect on the functioning of the boiler and as a result this will void the guarantee If the fuel is changed e g from wood chips to pellets the system must be reset by Fr ling customer services 2 2 2 Non permitted fuels Use of non permitted fuels Burning non permitted fuels leads to a build up of aggressive sedimentation and condensation which can lead to damage to the boiler and also voids the warranty All fuels not defined under 2 1 1 are considered non permitted Due to various air quality protection regulations non permitted fuels include e Chipboard waste treated wood wastes pure grinding dust e Refuse large quantities of paper cardboard packaging e Coal brown coal anthracite coal briquettes 2 2 3 Who may operate the boiler Only trained operators are permitted to operate the boiler If unauthorised persons enter the boiler room m Risk of injury and damage to equipment It is the responsibility of the operator to ensure that unauthorised persons especially children are kept away from the boiler Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 11 Tel 43
35. tity a Wait until all the pellets in the chamber have been transported to the ash bucket and only then deactivate the ash screw amp If there is fuel residue in the boiler the chamber can be damaged the next time the boiler is started 3 Empty the ash bucket after the end of the procedure If there is fuel residue in the ash bucket there is a danger of fire Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 A 4710 Grieskirchen Page 23 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B 059 00 08 3 Operating the system Heating up the boiler 3 3 Heating up the boiler 3 3 1 Switching on the system o Turn the main switch on the side of the switch cabinet to the ON position gt After the system check by the controller the system is ready for operation gt Boiler Off is shown on the display 3 3 2 Switching on the boiler a Press the button gt Automatic operation is activated gt The heating system is controlled via the controller according to the selected mode 3 3 3 Controlling the boiler See the operating instructions for the Lambdatronic H 3200 3 3 4 Switching off the boiler o Press and hold the button for 5 seconds gt The boiler follows the shutdown program and switches to Boiler OFF status gt The combustion unit is switched off the chamber delivery unit and the active hydraulic system are active
36. uctions for measuring emissions 4 3 1 Measurement at rated load o For the highest possible heat consumption Ensure that heating pumps are switched on Open mixer valves and radiator valves Set the DHW tank loading time to the current time Set the boiler temperature setpoint to 85 C Chimney sweep mode takes over this function Activating chimney sweep mode o Press the button gt The chimney sweeper program for boiler measurement is started The system is operated for 45 minutes at rated load For this aim the maximum boiler temperature the maximum heating circuit flow temperature and the DHW tank loading are released When is it possible to measure e Flue gas temperature at approx 170 C e QO content of the flue gas between 8 and 12 corresponds to a CO content between 13 and 19 e Boiler temperature above 65 C 4 3 2 Measurement at partial load if necessary oO For heat consumption ensure Ensure that heating pumps are switched on Open mixer valves and radiator valves Set the DHW tank loading time to the current time o Force partial load After measuring at rated load lower the boiler temperature setpoint by 5 C When is it possible to measure e Flue gas temperature at approx 140 C e QO content of the flue gas between 10 and 14 corresponds to a CO content between 11 and 7 e Boiler temperature above 65 C After measurement all adjusted parameters e g DHW tank loading
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