Operating Instructions T4 – 24-110
Contents
1. tem Deseipion O O OOO O 1 Wood chipboler FroingT SSS 2 Main switch switch the power supply on and off for the entire system SOS 3 Safety Temperature Limiters SSS a Control panel of the LambdatronicH 3200 T4 controler SSSOSC S S Status LED indicating operating status GREEN constant BOILER SWITCHED ON GREEN flashing Interval 5 sec OFF 1 sec ON BOILER SWITCHED OFF ORANGE constant BUS error ORANGE flashing WARNING RED flashing FAULT 4 2 Large graphical display to show operating statuses and parameters SCSC S 7 3 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 Ss insuatingcover SOS e Heatexcnangercover OOOO Page 6 B0710511_en General 1 Product overview ne a ee i Fe Wen em Dee O O OOO Eu Fuel transport unit with rotary valve as a burn back protection system and stoker screw for fuel transport BET 20 combustion retort with firebrick combustion chamber and automatic tipping orate 22 Tach box for the combined automatic sh removal un for the retort and heat exchanger 22 Combustion chamber door with inspection window screwed on 13 wos system win turbultors and automatic arive for heat exchanger cleaning Tas emae O Cas mueossnso 00000 TFT Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Pag2. ccc cece cece cece eeeeeee eee eeeeeeteeeeeeeeeeettsneeaaentengs 14 2 5 4 Combination with storage tank cccccccc cece cece eee cece seen sees eeeeeeeeeeeeeeeetenengaeneenegs 15 Return temperature control ccc ccccccce esse cece cece ee eeeeeeeeeeeeeeeeeeenaeeeeeetteneaannneegs 15 2 5 5 Chimeny connection CHIMNEY system sessesererrerererrererrrrsrerrrrerrrrrrerrrrrrerre 16 2 6 Safety devices 17 2 6 1 Safety temperature limiter STL ccc cece cece ee ee ee eee e eens eeeeeeeeeeeeeeeeeeneenaeneengs 18 250 2 Sav LY Vale rennen een E E een ecins 18 2 7 Residual risks 19 2 8 Emergency actions 20 253 System OVE Neal rennen 20 2 8 2 Smell of flue gaS 24 sseseeeennennnnnneneennnneennnnenennnnnnneennenenenssnnennnnnnennnsnnnnennnn 20 3 Operating the system 21 3 1 Notes on installation 21 3 2 Initial start up 21 3 3 Filling refilling the store with fuel 22 3 3 1 Loading wood chips in a partially emptied store not under pressure eeee 22 3 3 2 Loading wood chips in an empty store not under pressure c cece cece sence eee nenn 22 3 3 3 Blowing in pellets for a store with pellet screw ssssnnssnnnneneeeennnnnnnnnen een nnnn nenn 23 3 3 4 Blowing in fuel for a partially emptied store with stirrer cc cece cece ee eeeeeeeeee nenn 23 3 3 5 Blowing in fuel for an empty store with SUIrrer cece cess scene eee eeeeeeeeeeeneenees 24 3 4 Heating up the boiler 25 34 1 SWITCHI
3. froling Operating Instructions T4 24 110 English version of operating instructions for operators Read and follow the instructions and safety instructions Subject to technical change Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 e info froeling com e www froeling com Introduction i Dear customer Congratulations on choosing a quality product from FROLI NG The FROLING T4 wood chip 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 Observing the requirements and safety information in the instruction manual makes a significant contribution to safe appropriate environmentally friendly and economical operation of the system The constant further development of our products means that there may be minor differences from the pictures and content If you discover any errors please let us know Subject to technical change Document reference number B071 Version 05 Published 05 2012 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 enclose
4. Appendix 6 1 Addresses 6 1 1 Manufacturer s Address FR LING 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 6 1 2 Installer s address STAMP Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 43 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en
5. Clean up using a cleaning rag as necessary Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 21 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 e info froeling com e www froeling com B0710511_en 3 Operating the system Filling refilling the store with fuel 3 3 Filling refilling the store with fuel When you fill the store you should always ensure that you are using the right fuel gt Page 12 2 4 2 Page 22 BO710511 en Operating the system 3 Filling refilling the store with fuel Permitted fuels 3 3 1 Loading wood chips in a partially emptied store not under pressure If there is still sufficient fuel in the store the head of the stirrer is completely covered with fuel the store can be filled I Load the fuel at the filling opening 3 3 2 Loading wood chips in an empty store not under pressure gt 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 Press and hold the party program key for 5 seconds w Extra heating mode is activated g Load a small quantity of wood chips and wait until the arms spring blades are touching the head of the stirrer approx 2 revolutions O Only then should you load the remaining material 3 3 3 Blowing in pellets for a store with pellet screw For systems with a pellet screw the boiler
6. by pressing the standby button and allow it to cool down for at least two hours 7 Close all openings to the store to seal out dust 7 Call up the Manual operation menu Off 07 28 v Heating 03 07 Manual Boiler 26 N Mana Manual Flue gas 28 operation Pr 8 O p p Q p C J Activate the following units in the order shown Tilt motor ON Ash screw ON Discharge system from bunker ON Stoker FORWARD Sg Blow the fuel into the store 7 After approx 5 min deactivate the feed screw 5g Wait until the stoker is completely emptied and only then deactivate the stoker screw gt If there is a fuel residue in the stoker there is a danger of a flash fire the next time the boiler is started due to a excessive infeed quantity g Wait until all the fuel in the retort has been transported to the ash container and only then deactivate the ash screw gt If there is fuel residue in the boiler the chamber can be damaged the next time the boiler is started g Empty the ash container after the end of the procedure c If there is fuel residue in the ash bucket there is a danger of fire 3 4 Heating up the boiler NOTI CE Do not modify the factory settings Changing the system s factory settings can be detrimental to efficiency and emissions of the system 3 4 1 Switching on the system J Turn the main switch on the back of the boiler to the ON position w After th
7. g Put on the cover and fix with the clamps gt Ensure that the pins P are inserted into the limit switch L Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 31 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en 4 Boiler maintenance Inspection and cleaning 4 2 4 Recurring checks and cleaning The boiler should be cleaned and checked at appropriate intervals depending on the service hours and the fuel quality For fuels with a low ash content standard wood chips annual cleaning and checks or 2000 2500 service hours is generally sufficient For problematic fuels and fuels with high ash content these can be recognised by the short emptying interval for the ash box the frequency of these tasks should be increased appropriately Inspection and cleaning work when the boiler is switched on Serious injuries from automatic startup of the boiler and serious burns on hot parts and on the flue gas pipe are possible g Only carry out work on the boiler when the main switch is turned off 1 Always wear protective gloves when working on the boiler Only operate the boiler using the handles provided for this purpose Observe the following procedure for starting and finishing inspection and cleaning work Before inspection and cleaning work g Press the standby key Boiler shuts down and changes to the
8. operating status Boiler off 7 Let the boiler cool down for at least 1 hour On the controller navigate to the Manual operation menu Of 1 028 Heating 08 07 hanual F Boi o i Boiler 26 i A a Manual operation i Flue gas 28 P 8 8 r Press the v key to navigate to the parameter Grate tip drive Press the key to release the parameter for changes and press the key to set to ON The combustion grate is tipped J Switch off the main switch After inspection and cleaning work J Switch on the main switch The combustion grate which has previously been manually opened closes automatically and the boiler changes to Boiler off operating status 7 Press and hold the service program key for 5 seconds w The boiler starts cleaning mode and disposes of all ash residues in the upper combustion chamber When self cleaning has been carried out the boiler changes to Boiler off operating status oe froling Boiler maintenance 4 Inspection and cleaning Cleaning the combustion chamber O Open the insulating door g Loosen the screw connections on the combustion chamber door O Open the combustion chamber door g Remove fallen ash from the upper combustion chamber using a small shovel or similar ash vacuum recommended c Do not throw the ash onto the grate O Remove the burn out opening O Remove the dirt on the burn out opening with a brush O Remove ash that has built up on the side
9. out the guide plate Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 35 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en 4 Boiler maintenance Inspection and cleaning Remove ash below the guide plate with the ash vacuum O Clean the heat exchanger pipes with the cleaning brush supplied w Push the cleaning brush all the way through and only then pull it out g After cleaning refit the parts that have been removed in reverse order Clean the flue gas sensor Loosen the wing screw and remove the flue gas sensor Wipe off the flue gas sensor with a clean cloth Slide in the flue gas sensor and secure it hand tight using the wing screw an gt When replacing the flue gas sensor push it in until about 20 mm of the sensor remains protruding from the bushing Cleaning the smoke flue pipe O Clean the connecting pipe between the boiler and the chimney regularly with a chimney sweeping brush c During cleaning ensure that no ash gets into the induced draught unit housing t TIP remove the flue gas sensors before cleaning to avoid damage gt 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 ie Froling Boiler maintenance 4 Inspection and cleaning Checking the draught controller flap and explosion fla
10. walls with the ash scraper Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 33 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en 4 Boiler maintenance Inspection and cleaning I Clean the combustion chamber bricks and combustion chamber grate with an ash scraper g Remove fallen ash and ash on the guide plates and under the grate using an ash vacuum O Carry out a visual inspection of the combustion chamber brick for damage O Check the combustion chamber grate for cracks and deformation w Small cracks and deformations are not considered defects The boiler must only be taken out of operation when entire pieces of the grate threaten to break off In this case Froling customer services should be informed I Insert the burn out opening t The opening must be opposite the infeed side O Remove the insulating cover and the insulating mat Page 34 B0710511_en Boiler maintenance 4 Inspection and cleaning O Loosen the lock nut at the star shaped screw knob I Unlock the cover by turning the star shaped screw knob and remove At T4 60 110 I Unlock the cover by turning the star shaped screw knob and open Is the room not high enough the heat exchanger cover can be removed completely g Dismount the screws of the hinge and remove the cover I Clean the flue gas collection chamber with an ash vacuum O Take
11. 06 600 info froeling com e www froeling com BO710511_en 5 Eliminating Faults Faults with fault message 5 3 Faults with fault message DO froling DE When a fault message is pending w The status LED 4 1 shows the type of fault Orange constant BUS error Orange flashing Warning Red flashing Error or alarm w The associated fault message is shown on the display 4 2 The term fault is a collective term for warnings errors and alarms The boiler reacts differently to the three types of message In case of warnings e g Ash box full please empty the boiler continues to run offering the opportunity to prevent the shutdown procedure by swiftly resolving the fault The boiler follows shutdown procedure and remains in Boiler off status until the problem is resolved An alarm triggers a system emergency stop The boiler shuts down immediately the heating circuit controller and pumps remain active 5 3 1 Procedure for fault messages The procedure in case of fault message the causes for faults and procedure for troubleshooting are described in the operating instructions for the boiler controller D See the operating instructions for the Lambdatronic H 3200 T4 5 3 2 Acknowledging a fault message Trace and remove the fault and then g Press the ENTER key w The status LED lights up or flashes green depending on the operating status ee Froling Appendix 6 Addresses 6
12. 1 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 e info froeling com e www froeling com B0710511_en 2 Safety Permitted uses 2 4 2 Permitted fuels Wood chips Designation as per Description as per ONORM M ONORM DIN ONORM M 7133 7133 CEN TS 14961 water wzo mo Ara content Limited suitability for storage Size 630 P16A P16B Fine wood chips Applicable standards S EU EN 14961 4 A2 Austria NORM M 7133 or NORM CEN TS 14961 Germany Wood chips in accordance with 3 1 point 4 of the 1st BImSchV i d g F Pellets Wood pellets made from natural wood with a diameter of 6 10 mm S Applicable standards EU EN 14961 2 A1 Austria NORM M 7135 HP 1 and or DINplus certification program Germany DIN 51731 HP 5 DINplus certification program and or ONORM M 7135 HP 1 Generally applicable Before refilling the store check for pellet dust and clean if necessary Changing the fuel If fuel parameters are incorrectly set 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 D See the operating instructions for the H 3200 T4 Page 12 B0710511_en Safety 2 Design I nformation 2 4 3 Non permitted fuels The use of fuels not defined under 2 4 2 and particularly the burning
13. 11_en Eliminating Faults 5 General faults in power supply 5 Eliminating Faults 5 1 General faults in power supply Error characteristics Cause of error Error correction Nothing is shown on the General power failure display Main switch is turned off Turn on the main switch No power to the controller gt See 3 4 1 Switching on the system FI circuit breaker or line Switch on the FI circuit breaker or line protection is switched off protection Faulty fuse in the controls Replace fuse note the current 10AT c Work on electrical components must only be carried out by a qualified electrician 5 1 1 System procedure following 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 gt Keep the doors of the boiler closed during and after the power failure gt After the power failure check if the STL has fallen 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 Unscrew the cap on the STL 1 7 Reset the safety temperature limiter by pressing with a screw driver 5g Replace the cap Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 41 Tel 43 0 7248 606 0 e Fax 43 0 7248 6
14. NG ON ENG SYSCEIN ars een en EEEE ENSA 25 3 4 2 Switching on the boiler ccc ececeeseeseceeeeneeeeenseeeeeceeteeesettseseuueerteentttsugeerenns 25 3 4 3 GONLPONING THE DOWD acter ra ea De ne ee 25 34 4 SWILCHING Off the DONE anne ann dese Ana a dau tania 25 Page 4 BO710511 en Contents 3 4 5 Switching off the power SUPDIY c cece cece cece eee eeeeeeeeeeeeeeeseeneneenees 4 Boiler maintenance 4 1 General information on maintenance 4 2 Inspection and cleaning 4 2 1 Checking the system PIreSSUre ccc cece cece eee eeeeseeeeeeeeeeeteneeaeneenees 4 2 2 Check the geared Motors 2222eessenssnnenn nenne nn non nenn nun ne nenn nneen nennen 4 2 3 Emptying the ash container ccc cece cece cece ee eeeeseeeeeeeeeteenessaennenegs 4 2 4 Recurring checks and cleaning cece cece ce eeeee ee nn nennen nennen nennen nn Before Inspection and cleaning WOFK ccc cece ceeeeeeeeeeeeeeeeeeeetanenaes After inspection and cleaning WOFrK cccce cece cece eeeeeeeeeeeeeeeeaneneaes Cleaning the combustion chamber cccccceeee esse eee eeeeeeeeeeneeenees Cleaning the heat exchanger and flue gas collection chamber Clean the flue gas SENSOLS cc ccccccceseeeeeeeeeeeeeeeeeeeeeeeeeetenesegentenngs Cleaning the smoke flue pipe cece cece ee eeee esse ee eeeeeeeeenneeeeeentegs Checking the draught controller flap and explosion flap Checking the c
15. 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 on Froling Safety 2 Permitted uses 2 4 Permitted uses The Froling T4 wood chip boiler is intended exclusively for heating up central heating water Use only the fuels specified under 2 4 2 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 The inspection and cleaning intervals in these operating instructions should be observed Ensure that any faults which might impair safety are rectified immediately The manufacturer supplier is not liable for any damage resulting from other use 2 4 1 The Clean Air Act 1993 and Smoke Control Areas Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a smoke control area It is an offence to emit smoke from a chimney of a building from a furnace or from any fixed boiler if located in a designated smoke control area It is also an offence to acquire an unauthorised fuel for use within a
16. d guarantee certificate Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 3 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en C Contents 1 General 1 1 Product overview 6 2 Safety 8 2 1 Danger level of warning notices 8 2 2 Symbols used 9 2 3 Safety information 10 2 4 Permitted uses 11 2 4 1 The Clean Air Act 1993 and Smoke Control Areas ccccccccee eee e ee ees 11 2 4 2 Permitted fuels 2222ssssssssnnennnnnnnensnnnenennnn nen nnnnnneennnnnneesennnnnnnnenennnsnnneennnn 12 WY OOO GOS ee ee a ae ee Een ROO EEA aari 12 Pe an ee En ran eee ee eee 12 Chonain TAS THE anne innen eher 12 224 3 NOM Pelle DIE ee N E AA NEE E 13 2 4 4 Qualification of operating Staff sssesererrererrrrererrrrerrrrrrerrrrerrrrrrererrrrrrererrne 13 2 4 5 Protective equipment for operating Staff cc cece cece cece cece eeeeeeeeeeeeeeeeeeeeenenrenes 13 2 5 Design Information 13 2 5 1 Installation and approval of the heating systemM sesssrererrrrererrererrrrrrerrrrererre 13 2 5 2 Information on the installation room boiler FOOM cccceceee esse ee eeeeeeeeeeeneneenes 14 Boiler room characteristics ccc ccccceceee cess cece eee eeeeeeeeeeeeeeeeeeeeeeneeeeeeteaeeggaeneengs 14 Ventilation of the boiler rOOM ccc cccceccee cess iaa KaT EEA RE A 14 2 5 3 Requirements for heating water
17. d near the boiler Flammable objects e g clothing etc must not be put on the boiler to dry ts 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 lt Keep the air suction opening of the boiler free of dust IT iT Ventilation of the boiler room Ventilation air for the boiler room should be taken from and expelled directly outside and the openings and air ducts should be designed to prevent weather conditions foliage snowdrifts from having any effect on the air flow Unless otherwise specified in the applicable building regulations for the boiler room the following standards apply for the design and dimensions of the air ducts Applicable standards S TRVB H 118 NORM H 5170 2 5 3 Requirements for heating water The following standards and guidelines apply Page 14 B0710511_en Safety 2 Design I nformation Applicable standards and guidelines Austria NORM H 5195 1 Germany VDI 2035 Switzerland SWKI 97 1 Italy D R P n 412 gt Notice on filling with make up water Always bleed the filling hose before connecting in order to prevent air from entering the system 2 5 4 Combination with storage tank NOTI CE It is not generally necessary to use a storage tank for the system to run smoothly However we recommend that you use it with a storage tank as this allows you
18. e 7 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 e info froeling com e www froeling com B0710511_en 2 Safety Danger level of warning notices 2 Safety 2 1 Danger level of warning notices These operating instructions use warning notices at the following danger levels to indicate direct hazards and important safety regulations The dangerous situation is imminent and if the measures are not observed it can lead to serious injuries or death You must follow the measure The dangerous situation may occur and if the measures are not observed it can lead to serious injuries or death Work with extreme caution The dangerous situation may occur and if the measures are not observed it can lead to light or superficial injuries or damage to property Page 8 B0710511_en Safety Symbols used 2 2 Symbols used The following signs are used in the documentation to give orders prohibit actions and give warnings In accordance with machine directives signs fitted at the exact point of areas of risk indicate imminent dangers or safety precautions These stickers must not be removed or covered gt eea Observe the operating instructions Wear protective gloves Keep the doors closed Hot surface warning Dangerous or irritant material warning Warning of injuries to fingers or hands automatic fan Warning of injuries to fingers or hands gear chain drive Fr ling Heizkessel und Be
19. e gas temperatures for clean systems and additional flue gasvalues can be found in the technical specification sheets of the assembly instructions The entire flue gas system chimney and connection must be calculated as per ONORM DIN EN 13384 1 Safety 2 Safety devices 2 6 Safety devices Ov froling i a Standby key If the boiler overheats 7 Press the standby key Automatic operation is switched off and the controller follows the boiler shutdown procedure The pumps continue to run w Never use the main switch Safety Temperature Limiter Page 18 D Safety temperature limiter STL Main switch For shutting down the entire system 1 The power to all components is switched off t Only switch off the main switch when the boiler has cooled down and the controller is switched off Boiler off status Glass fuses below the insulating They fuse the controller and electrical components When cover changing the fuses note the following c Only have the fuses changed by an electrician and the power supply should be switched off t Observe the rated current on the fuses Water sprinkler system In case of burn back the valve of the water sprinkler system ct It is only necessary to connect this when required by the opens and water goes into the gravity shaft as well as the duct of the feed screw authorities however it is generally recommended Fr ling Heizkessel und Be
20. e system check by the controller the system is ready for operation Boiler Off is shown on the display 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 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en 3 Operating the system Heating up the boiler 3 4 2 Switching on the boiler g Press the standby key Automatic mode is activated The heating system is controlled via the controller according to the selected mode 3 4 3 Controlling the boiler D See the operating instructions for the Lambdatronic H 3200 T4 3 4 4 Switching off the boiler g Press the standby key The boiler follows the shut down program and switches to Boiler OFF status The combustion unit is switched off the chamber discharge unit and the active hydraulic system are active Page 26 BO710511 en Operating the system 3 Heating up the boiler 3 4 5 Switching off the power supply When switching off the main switch in automatic mode Severe combustion faults are possible and these may cause very serious accidents Before switching off the main switch 1 Press the standby key w gt Boiler follows shutdown procedure and changes to the status Boiler off lt gt CAUTION Only when the boiler is cold in Boiler Off status Switch off the main switch on the back of the boiler w The controller i
21. g Page 30 B0710511_en 4 2 3 Emptying the ash container The ash container must be emptied at the correct interval according to energy requirements and fuel quality If the ash container fills up before the ash level check the warning Ash box full please empty is shown on the display When removing the ash container cover during operation Incorrect air supplied via the ash screw channel can lead to uncontrolled combustion and as a result to accidents Before checking the ash level emptying the ash box 1 Press the standby key w Boiler follows shutdown procedure and changes to the operating status Boiler off In the operating status Boiler off g Open the insulating door Observe the sticker on the cover of the ash container Open the side clamps and take off the cover of the ash container 1 Check the ash level in both chambers w f one of the two chambers is more than two thirds full the ash container should be emptied Open the ash container clamp with the fixing lever 2 Remove the ash container from the boiler 3 Boiler maintenance 4 Inspection and cleaning g Put the transport covers over the openings of the ash container O Put on the cover of the ash container pull out the transport handle and transport the ash container to the emptying point When the ash container has been emptied 7 Put the ash container back on at the boiler and clamp with the fixing lever
22. h lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 17 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en Safety Safety devices Page 18 BO710511 en 2 6 1 Safety temperature limiter STL Stops combustion at a max boiler temperature of 100 C The pumps continue to run ts Once the temperature has fallen to under approx 95 C the safety temperature limiter can be unlocked mechanically D See 5 2 Excessive temperature 2 6 2 Safety valve It protects against overheating and overpressure in the system and the customer must have it installed by the heating engineer When the boiler pressure reaches 3 bar the safety valve opens and the heating water is released in the form of steam Safety 2 Residual risks 2 7 Residual risks On touching hot surfaces Hot parts and the flue pipe can cause serious burns g Always wear protective gloves when working on the boiler 1 Only operate the boiler using the operating elements provided for this purpose 7 Insulate the flue gas pipes and avoid touching them during operation On 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 If inspection or cleaning work is carried out with the main switch on Serious injuries possible due to automatic acti
23. halterbau Ges m b H e 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 BPBPBDP es Wear safety shoes Turn off the main switch Unauthorised access prohibited Dangerous electrical voltage warning Warning that the system starts automatically Warning of injuries to fingers or hands automatic screw Warning of injuries to fingers or hands cutting edge Page 9 BO710511_en 2 Safety Safety information 2 3 Safety information DANGER Non permitted use I ncorrect 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 very serious accidents Instructions and information for versions and minimum values as well as standards and guidelines for heating components in the instructions must be observed i Severe injuries and damage
24. leaned e O content of the flue gas between 10 and 14 corresponds to a CO content between 11 and 7 e Boiler temperature above 65 C lt gt After measurement all adjusted parameters e g DHW tank loading times must be reset to their original value Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 39 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en 4 Boiler maintenance Maintenance agreement Customer service 4 4 Maintenance agreement Customer service t 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 With Froling original replacement parts in your boiler you are using parts that match perfectly As the parts fit together so well installation times are shortened and lifespan is maintained NOTI CE I nstalling non original parts voids the guarantee 1 Only replace components or parts with original replacement parts Page 40 B07105
25. must be in OFF status when the store is filled The under pressure from the blowing could bring Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 23 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en 3 Operating the system Filling refilling the store with fuel smoke back into the store Any overpressure that occurs can cause smoke to escape into the installation room O Switch off the boiler by pressing the standby button and allow it to cool down for at least two hours I Close all openings to the store to seal out dust I Blow the fuel into the store 3 3 4 Blowing in fuel for a partially emptied store with stirrer If there is still sufficient fuel in the store the head of the stirrer is completely covered with fuel the store can be filled as follows O Switch off the boiler by pressing the standby button and allow it to cool down for at least two hours I Close all openings to the store to seal out dust I Blow the fuel into the store 3 3 5 Blowing in fuel for an empty store with stirrer Page 24 BO710511_ en Operating the system 3 Heating up the boiler gt 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 Switch off the boiler
26. of refuse is not permitted If non permitted fuels are used Burning non permitted fuels increases the cleaning requirements and leads to a build up of aggressive sedimentation and condensation which can lead to damage to the boiler and also voids the warranty Using non standard fuels can lead to severe faults with combustion 2 4 4 Qualification of operating staff Only trained operators are permitted to operate the boiler The operator must also have read and understood the instructions in the documentation 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 2 4 5 Protective equipment for operating staff You must ensure that staff have the protective equipment specified by accident prevention regulations e During operation inspection and cleaning of the boiler Sturdy shoes Protective gloves 2 5 Design Information It is forbidden to carry out modifications to the boiler or to change or deactivate safety equipment Always comply with all fire building and electrical regulations when installing or operating the boiler system and follow the operating instructions and mandatory regulations that apply in the country in which the boiler is operated 2 5 1 Installation and approval of the heating system The boiler should be ope
27. oiler maintenance 4 Instructions for measuring emissions 4 3 Instructions for measuring emissions 4 3 1 Measurement at rated load 7 Ensure the highest possible heat consumption Ensure that heating pumps are switched on Open mixer valves and radiator valves Set the boiler loading time to the current time Set the boiler temperature setpoint to 85 C ct Chimney sweep mode takes over this function Activating chimney sweep mode 7 Press the service program key The chimney sweeper program for boiler measurement is started The system is operated for 45 minutes at rated load For this purpose 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 140 C 20 C depending on whether the boiler has been cleaned e O 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 g Ensure heat consumption Ensure that heating pumps are switched on Open mixer valves and radiator valves Set the boiler loading time to the current time 7 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 100 C 20 C depending on whether the boiler has been c
28. ombustion chamber COOP cceeeeeeeeeeeeeeeeeeeneeeeees Clean the measurement line of the underpressure controller 4 3 Instructions for measuring emissions 4 3 1 Measurement at rated l0ad cece cece naaa TAa Activating chimney sweep MOE ccc cc cece cece cece ee eeeeeeeeeeeeeeetaneaaes 4 3 2 Measurement at partial load if NECESSALY ccc cece cece cece eteeeeeeeeees 4 4 Maintenance agreement Customer service 4 5 Replacement parts 5 Eliminating Faults 5 1 General faults in power supply 5 1 1 System procedure following power failUre cce cece cece eee eeeeeeeeeees 5 2 Excessive temperature 5 3 Faults with fault message 5 3 1 Procedure for fault MESSAGES essssererrrrererrererrrrererrrrrrerrerrrrrrne 5 3 2 Acknowledging a fault MESSAGE ccee cece cece ee eeeeeeseeeeeeeseseeeaenteenes 6 Appendix 6 1 Addresses 6 1 1 Manufacturer s ACCreSs c ccc ccc cece ccc cccecncecaeaeeeaecususueauaeaesesntnnnnatans 6 1 2 Installer Ss addreSS iccsoresccaetcrenavovendentesteatexvubededstbewouesousebenanoeusnsseubes Fr ling Heizkessel und Behalterbau Ges m b H e 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 Page 5 BO710511_en 7 General Product overview 1 General At the back of the boiler 1 1 Product overview 2 0 amp froling
29. orm the installer or Froling customer services D Page 42 6 1 Addresses 2 8 2 Smell of flue gas If you can smell flue gas Flue gases can cause fatal poisoning J Keep all the doors on the boiler closed Switch off the boiler by pressing the standby key w Under no circumstances use the main switch g Ventilate the boiler room if there is a connection to the open AY air 1 Close the doors to living areas to prevent an overflow of flue gas Page 20 BO710511_en Operating the system 3 Notes on installation 3 Operating the system 3 1 Notes on installation Assembly installation and initial start up of the boiler must only be carried out by qualified staff and these procedures are described in the accompanying assembly instructions gt See T4 assembly instructions 3 2 Initial start up NOTI CE gt Optimum efficiency 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 O 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 D See the operating instructions for the Lambdatronic H 3200 T4 NOTI CE If condensation escapes during the initial heat up phase this does not indicate a fault w
30. p Check the draught controller flap and explosion flap for ease of operation If they cannot move smoothly have them replaced immediately Checking the combustion chamber door g Close the combustion chamber door and check its seal 7 Check fibre glass seal 1 for perfect alignment on the door frame Imprint in the fibre glass seal If the seal is coloured black at several points or the imprint is interrupted The seal is no longer efficient t Tighten the door latches or replace the fibre glass seal Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 37 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en Boiler maintenance Inspection and cleaning Page 38 B0710511_en Clean the measurement line of the underpressure controller O Open the insulated door and remove the ash box gt See 29 4 2 3 Emptying the ash container g Remove the screws on the left and right on the front cover plate O Push up the cover plate and remove T4 24 75 T4 90 110 O Loosen the double wire clamp with pliers and remove the measurement line g Clean the measurement line with slightly compressed air t CAUTION Do not blow compressed air into the underpressure sensor cartridge The sensor cartridge might be damaged I After cleaning fit the measurement line again in the same position connection froling B
31. rated in a closed heating system The following Standards govern installation Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 13 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en 2 Safety Design Information Applicable standards S NORM DIN EN 12828 Heating systems in buildings gt Each heating system must be officially approved The appropriate supervisory authority inspection agency must always be informed when installing or modifying a heating system and authorisation must be obtained from the building authorities Austria Report to the construction authorities of the community or magistrate Germany Report new installations to an approved chimney sweeper the building authorities 2 5 2 Information on the installation room boiler room Boiler room characteristics gt There must not be a potentially explosive atmosphere in the boiler room as the boiler is not suitable for use in potentially explosive environments The boiler room must be frost free The boiler does not provide any light so the customer must provide sufficient lighting in the boiler room in accordance with national workplace design regulations gt When using the boiler above 2000 metres above sea level you should consult the manufacturer t Danger of fire due to flammable materials Flammable materials must not be store
32. s switched off The components powered via the switch cabinet are powered down ts The expansion switch cabinet which has its own power supply is still live Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 27 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en 4 Boiler maintenance General information on maintenance 4 Boiler maintenance 4 1 General information on maintenance DANGER When working on electric components Risk of serious injuries from electric shocks 1 Work on electrical components should only be carried out by authorised technicians On touching hot surfaces Hot parts and the flue pipe can cause serious burns g Always wear protective gloves when working on the boiler 1 Only operate the boiler using the operating elements provided for this purpose 1 Insulate the flue gas pipes and avoid touching them during operation In case of non permitted inspection and cleaning 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 Clean the boiler following the instructions Follow the boiler operating instructions pA te We recommend that you keep a maintenance book in accordance with ONORM M7510 or the Technical Direc
33. smoke control area unless it is used in an exempt appliance exempted from the controls which generally apply in the smoke control area The Secretary of State for Environment Food and Rural Affairs has powers under the Act to authorise smokeless fuels or exempt appliances for use in smoke control areas in England In Scotland and Wales this power rests with Ministers in the devolved administrations for those countries Separate legislation the Clean Air Northern Ireland Order 1981 applies in Northern Ireland Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas have been authorised in Regulations and that appliances used to burn solid fuel in those areas other than authorised fuels have been exempted by an Order made and signed by the Secretary of State or Minister in the devolved administrations Further information on the requirements of the Clean Air Act can be found here http smokecontrol defra gov uk Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision of smoke control areas and you can contact them for details of Clean Air Act requirements The Froling T4 24 T4 30 T4 40 T4 50 T4 60 T4 75 T4 90 T4 100 and T4 110 have been recommended as suitable for use in smoke control areas when burning fuels as listed under 2 4 2 Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 1
34. tive for Fire Prevention TRVB on Froling Boiler maintenance 4 Inspection and cleaning 4 2 Inspection and cleaning gt Regular cleaning of the boiler extends its life and is a basic requirement for smooth running So clean the boiler regularly lt Recommended When cleaning use an ash vacuum 4 2 1 Checking the system pressure 7 Read off the system pressure on the pressure gauge The value must be above the pre stressed pressure of the expansion tank by 20 gt Expansion tank operating instructions If the system pressure decreases Top up the water gt If this occurs frequently the seal of the heating system is faulty Inform your installer If large pressure fluctuations are observed Have the expansion tank checked by the qualified technician t Position of the manometer and rated pressure according to installer 4 2 2 Check the geared motors J Carry out a visual inspection of all geared motors of the system to check the seal There must not be a large quantity of lubricant coming out gt If a few drops of lubricant are coming out this can be normal If a lot of lubricant is being lost inform your installer or Froling customer services Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 29 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_en Boiler maintenance Inspection and cleanin
35. to achieve continuous reduction within the ideal performance range of the boiler For the correct dimensions of the storage tank and the line insulation in accordance with ONORM M 7510 or guideline UZ37 please consult your installer or Froling D Page 42 6 1 Addresses Return temperature control If the hot water return is below the minimum return temperature some of the hot water flow will be mixed in Risk of dropping below dew point condensation formation if operated without return temperature control Condensation water forms an aggressive condensate when combined with combustion residue leading to damage to the boiler w We recommend that you use a return temperature control e The minimum return temperature is 45 C We recommend fitting some kind of control device e g thermometer Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 15 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 e info froeling com e www froeling com B0710511_en 2 Safety Design Information 2 5 5 Chimeny connection chimney system Page 16 BO710511_en 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 flu
36. vation of the boiler Before inspection or maintenance work on in the boiler 1 Press the standby key gt Boiler follows shutdown procedure and changes to the operating status Boiler off J Let the boiler cool down for at least 1 hour J Switch off the main switch If non permitted fuels are used Non standard fuels can cause serious faults in combustion e g spontaneous combustion of carbonisation gases flash fires which can lead to serious accidents Only use fuels specified in the chapter on Permitted Uses in these operating instructions ji Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra e 12 e A 4710 Grieskirchen Page 19 Tel 43 0 7248 606 0 e Fax 43 0 7248 606 600 info froeling com e www froeling com BO710511_ en 2 Safety Emergency actions 2 8 Emergency actions 2 8 1 System overheating If the system overheats in spite of the safety devices proceed as follows g Keep all the doors on the boiler closed Switch off the boiler by pressing the standby key n gt Under no circumstances use the main switch g Open all mixer taps and switch on all pumps t Froling s heating circuit control takes over this function ts When using a third party controller carry out the relevant measures to activate the mixer and pumps manually J Exit the boiler room and close the door g Open any available radiator thermostat valves If the temperature does not drop inf
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