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Operating Instructions
Lambdamat LM 1000 SPS
Translation of the original German operating instructions for the operator
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B1300015_en | Edition 11/08/2015
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Table of Contents
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Summary of Contents for Froling Lambdamat LM 1000 SPS
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Page 1: Operating Instructions
Lambdamat LM 1000 SPS Translation of the original German operating instructions for the operator Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! B1300015_en | Edition 11/08/2015 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 2: Table Of Contents
Loading fuel in a store space with a sliding floor discharge unit 3.2.7 Loading fuel in a store space with a horizontal screw discharge unit 3.2.8 Loading fuel in a store space with an inclined screw discharge unit Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 3 Table of contents Heating up the boiler 3.3.1 Switching on the power supply 3.3.2 Switching on the boiler 3.3.3 Controlling the boiler 3.3.4 Switching off the boiler 3.3.5 Switching off the power supply Servicing General information on servicing Inspection 4.2.1 Checking the system pressure 4.2.2 Checking the thermal discharge safety device...
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Page 4: Froling Gesmbh | A-4710 Grieskirchen, Industriestraße 12 | Www.froeling.com
Behaviour of system after a power failure Excessive temperature Faults with fault message 5.3.1 Procedure for fault messages 5.3.2 Acknowledging a fault message Appendix Addresses 6.1.1 Address of manufacturer 6.1.2 Address of the installer Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 5: General
General 1 General Thank you for choosing a quality product from Froling. The product features a state-of- the-art design and conforms to all currently applicable standards and testing guidelines. Please read and observe the documentation provided and always keep it close to the system for reference. -
Page 6: Lambdamat Lm 1000 Product Overview
Ash container 300l (optional) Flue gas recirculation (FGR) (optional) Drive for ash removal (optional) Primary air servo-motor flue gas recirculation (FGR) Burning chamber overpressure Secondary air servo-motor flue gas monitor recirculation (FGR) Under-pressure controller Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 7 General Lambdamat LM 1000 Product Overview Compressed air tank of compressed Secondary air servo-motor II air cleaner (optional) Air distribution frame of compressed Tertiary air servo-motor air cleaner (optional) Primary air actuator High-limit thermostat (STL) Operating Instructions | B1300015_en...
- Page 8 General Lambdamat LM 1000 Product Overview Stoker duct High-temperature firebrick-lined combustion chamber Burn back protection system (shown Multiple-pass heat exchanger here: burn back flap; optional: rotary valve) Moving grate Cleaning door Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 9: Safety
Safety Hazard levels of warnings 2 Safety 2.1 Hazard levels of warnings This documentation uses warnings with the following hazard levels to indicate direct hazards and important safety instructions: DANGER The dangerous situation is imminent and if measures are not observed it will lead to serious injury or death. -
Page 10: Pictograms Used
Warning - hazardous or irritant Warning - automatic boiler materials startup Hand injury warning Warning of injury to fingers or hands, automatic fan Cutting injury warning Warning of injury to fingers or hands, automatic screw Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 11: General Safety Information
❒ Observe the details on procedures for operation, maintenance and cleaning, as well as troubleshooting in the individual manuals. ❒ Any work above and beyond this should be carried out by authorised heating engineers or by Froling customer services. WARNING External influences: Negative external influences, such as insufficient combustion air or non-standard fuel, can cause serious faults in combustion (e.g. -
Page 12: Permitted Uses
Safety Permitted uses 2.4 Permitted uses The Froling Lambdamat is designed exclusively for heating domestic water. Only use fuels specified in the "Permitted fuels" section. ⇨ See "Permitted fuels" [page 12] The unit should only be operated when it is in full working order. It must be operated in accordance with the instructions, observing safety precautions, and you should ensure you are aware of the potential hazards. -
Page 13: Wood Pellets
Before refilling the store, check for pellet dust and clean if necessary. Wood shavings Wood shavings generally cause problems with combustion. Therefore their use is permitted only with authorisation from Froling. The following additional points also apply: ▪ Sawdust and carpentry waste should only be used with systems with a rotary valve. -
Page 14: Changing The Fuel
Using non-standard fuels can also lead to serious problems with combustion. For this reason, when operating the boiler: ❒ Only use permitted fuels Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 15: Qualification Of Operating Staff
Safety Permitted uses 2.4.3 Qualification of operating staff CAUTION If unauthorised persons enter the boiler room: Risk of personal injury and damage to property ❒ The operator is responsible for keeping unauthorised persons, in particular children, away from the system. Only trained operators are permitted to operate the unit. -
Page 16: General Information For Installation Room (Boiler Room)
❒ Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to 5.6 dH) ❒ Use softened water as the make-up water ❒ Avoid leaks and use a closed heating system to maintain water quality during operation Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 17: Return Lift
For the correct dimensions of the storage tank and the line insulation (in accordance with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling. ⇨ See "Addresses" [page 60] 2.5.6 Chimney connection/chimney system... -
Page 18: Safety Devices
Once the temperature falls to below approx. 85°C, the STL can be reset mechanically. DOOR CONTACT SWITCH When the door is opened, the induced draught is kept at a constant speed and the combustion air and FGR blower fan stops. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 19: External Safety Devices
Safety Safety devices (protection against overheating) THERMAL DISCHARGE VALVE The thermal discharge valve opens at approx. 100°C and feeds cold water to the safety heat exchanger to lower the boiler temperature (not shown, supplied by the customer) SAFETY VALVE When the boiler pressure reaches a maximum of 6 bar, the safety valve opens and the heated water is blown off in the form of steam. -
Page 20: Residual Risks
/ flash fires) which can lead to serious accidents! Take the following precautions: ❒ Only use fuels specified in the "Permitted fuels" section of these operating instructions. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 21: Emergency Procedure
❒ Keep all the doors on the boiler closed ❒ Open all mixing valve taps, switch on all pumps. ➥ The Froling heating circuit control performs this function in automatic operation. ❒ If a third-party controller is used, carry out the appropriate measures to activate the mixer taps and pumps manually. -
Page 22: Smell Of Flue Gas
In case of fire in the system: Risk of death by fire and poisonous gases Emergency procedure in case of fire: ❒ Leave the boiler room ❒ Close the doors ❒ Inform the fire department Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 23: Operating The System
Take the following precautions: ❒ Initial startup should be carried out with an authorised installer or with Froling customer services The individual steps for initial start-up are explained in the operating instructions for... -
Page 24: Filling The Store Space With Fuel
❒ Switch off the boiler by tapping “Boiler off” at the mode icon ➥ The boiler follows the shutdown procedure and switches to “Switched off OFF” status ❒ Leave to cool for at least two hours in “Switched off Off” mode. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 25: Loading Of Fuel For A Partially Emptied Store With Rotary Agitator
Operating the system Filling the store space with fuel 3.2.1 Loading of fuel for a partially emptied store with rotary agitator If there is still sufficient fuel in the store (the head of the rotary agitator is completely covered with fuel and the rotary agitator arms are not extended), the store can be filled: ❒... -
Page 26: Rotary Agitator With Combined Drive System
➥ The rotary agitator runs for approx. 3 minutes ❒ Wait until the rotary agitator arms / spring blades are touching the head of the rotary agitator (approx. 2 revolutions) ❒ Add the rest of the fuel Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 27: Blowing In Fuel For A Partially Emptied Store With Rotary Agitator
Operating the system Filling the store space with fuel 3.2.3 Blowing in fuel for a partially emptied store with rotary agitator If there is still sufficient fuel in the store (the head of the rotary agitator is completely covered with fuel and the rotary agitator arms are not extended), the store can be filled as follows: ❒... -
Page 28: Rotary Agitator With Combined Drive System
❒ Switch off the boiler by tapping “Boiler off” at the mode icon and allow to cool for at least two hours ❒ Close all openings to the store to seal out dust ❒ Add the rest of the fuel Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 29: Rotary Agitator With Separate Drive System (Optional)
Operating the system Filling the store space with fuel Rotary agitator with separate drive system (optional) In the case of rotary agitators with a separate drive system, the head of the rotary agitator can be operated separately from the discharge screw. After working in the store: ❒... -
Page 30: Loading Fuel In A Store Space With A Horizontal Screw Discharge Unit
❒ If the feed system is not running when the store is filled, the screw can be held upright using string. ➥ TIP: the string should be thin enough for it to break as the store is filled. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 31: Heating Up The Boiler
Operating the system Heating up the boiler 3.3 Heating up the boiler NOTICE Do not modify the factory settings! Changing the system's factory settings can be detrimental to efficiency and emissions of the system. NOTICE It is not permitted to manually feed fuel into the boiler!! 3.3.1 Switching on the power supply ❒... -
Page 32: Switching Off The Power Supply
➥ The components powered via the control cabinet are powered down ➥ CAUTION: the expansion switch cabinet, which has its own power supply, is still live. NOTICE! Frost protection function is no longer active! Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 33: Servicing
Servicing General information on servicing 4 Servicing 4.1 General information on servicing DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: ❒ Only have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥... - Page 34 ▪ Flat scraper ▪ Brush (Ø 53 mm) ❒ Regular cleaning of the boiler extends its life and is a basic requirement for smooth running. ❒ Recommendation: use an ash vacuum for cleaning. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 35: Inspection
❒ Carry out a visual inspection of the seal on the geared motors in the system ➥ There should be no significant leakage of lubricant NOTICE! The presence of a few drops of lubricant may be normal. If there is significant loss of lubricant, inform your installer or Froling customer services Operating Instructions | B1300015_en... -
Page 36: General Visual Inspection
– The combustion air and FGR blower fan must stop when the door is opened ▪ Igniter tube – must not be obstructed! ▪ High-limit thermostat (STL) ▪ Loading system water sprinkler system – Note the manufacturer’s specifications ▪ Emergency stop switch Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 37: Cleaning
Servicing Cleaning 4.3 Cleaning The frequency at which the following cleaning work is carried out depends on energy requirements, fuel quality and the number of operating hours. WARNING When removing the ash container cover during operation: False air infiltration via the ash screw duct can lead to uncontrolled combustion and the risk of accidents. - Page 38 2. Position the ash container at the ash removal unit flange 3. Push the lever on the side of the ash removal unit flange downwards to lock the ash container in place 4. Push the key plate into the safety switch Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 39: Cleaning The Combustion And Burning Chamber
Servicing Cleaning 4.3.2 Cleaning the combustion and burning chamber WARNING Inspection and cleaning work on a system which is operational: Risk of serious injuries from automatic startup of the system and severe burns from hot parts and the flue gas pipe! When working on the system: ❒... -
Page 40: Cleaning The Burning Chamber
❒ Remove any dirt (nails, stones, slag, etc.) from the moving grate ❒ Clean the primary air slot with a suitable tool (e.g. screwdriver) ➥ The primary air slots must be free from obstructions! Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 41: Emptying The Multicyclone Ash Container
Servicing Cleaning ❒ Turn on the main switch ❒ Activating the moving grate and ash removal screws in manual mode ➥ Ash that gathers is moved into the ash container ❒ Empty the ash container whenever necessary 4.3.3 Emptying the multicyclone ash container ❒... -
Page 42: Periodic Inspection And Cleaning
⇨ See "Checking the position and seal of the burning ⇨ See "Cleaning the induced draft fan" [page 53] and combustion chamber door" [page 48] ⇨ See "Cleaning the fireclay elements" [page 50] Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 43: Periodic Inspection And Cleaning (Approx. 1,000 Hrs)
Servicing Periodic inspection and cleaning (approx. 1,000 hrs) 4.5 Periodic inspection and cleaning (approx. 1,000 hrs) For fuels with a low ash content, cleaning and inspection after approx. 1,000 service hours is usually sufficient (under normal use conditions, approximately every quarter). For less efficient fuels and fuels with a high ash content (indicated by short emptying intervals for the ash container), the work should be carried out more frequently accordingly. -
Page 44: Cleaning The Broadband Probe
❒ Wipe the flue gas temperature sensor with a clean cloth ❒ Insert the flue gas sensor back into the flue gas temperature gas pipe and finger- tighten the retaining screw Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 45: Cleaning The Flue Gas Recirculation (Fgr) Duct
Servicing Periodic inspection and cleaning (approx. 1,000 hrs) 4.5.4 Cleaning the flue gas recirculation (FGR) duct (Pos. D ⇨ See "Periodic inspection and cleaning" [page 42]) 1. Remove the pipe insulation (supplied by the customer) from the FGR duct 1. Remove the maintenance openings from the FGR duct 2. -
Page 46: Cleaning The Area Under The Moving Grate
❒ Check the grate, grate shafts and grate bearings for wear and deformation ➥ Exchange components wherever necessary ❒ Check the grate drive for dirt and deposits and ensure it operates smoothly ❒ Check the seal on the cleaning cover Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 47: Periodic Inspection And Cleaning (Approx. 3,000 Hrs)
Servicing Periodic inspection and cleaning (approx. 3,000 hrs) 4.6 Periodic inspection and cleaning (approx. 3,000 hrs) 4.6.1 Cleaning the combustion air fan (Pos. G ⇨ See "Periodic inspection and cleaning" [page 42]) ❒ Clean any dust and deposits from the protective grating ❒... -
Page 48: Checking The Seal Of The Reversing Chamber Door
➥ The door cannot be closed or can only be closed with great effort: loosen the locking hook. ⇨ See "Positioning the burning chamber and combustion chamber door" [page Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 49: Positioning The Burning Chamber And Combustion Chamber Door
Servicing Periodic inspection and cleaning (approx. 3,000 hrs) Checking the seal ❒ Open the door ❒ Insert a sheet of paper at both the top and the bottom between the door and the boiler ❒ Close the door ❒ Try to pull out the sheet of paper. ➥... -
Page 50: Cleaning The Fireclay Elements
3. Carefully clean the bottom of the heat exchanger and the top of the upper vault with the cleaning brush 4. Carefully clean the side walls with the flat scraper 5. Check the fireclay elements for wear Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 51: Checking The Underpressure Controller
Servicing Periodic inspection and cleaning (approx. 3,000 hrs) 1. Open the combustion chamber door 2. Carefully clean the bottom of the upper vault and the top of the lower vault with the cleaning brush 3. Carefully clean the side walls with the flat scraper 4. -
Page 52: Checking The Combustion Chamber Overpressure Sensor
4.6.9 Cleaning the FGR blower fan (Pos. N ⇨ See "Periodic inspection and cleaning" [page 42]) ❒ Mark the position of the flange ❒ Loosen the screws on the flange Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 53: Cleaning The Induced Draft Fan
Servicing Periodic inspection and cleaning (approx. 3,000 hrs) ❒ Take out the blower fan and clean the blower wheel with a brush ❒ Check the seal and replace if necessary ❒ Replace the blower fan ➥ Check the marking on the flange! 4.6.10 Cleaning the induced draft fan (Pos. -
Page 54: Maintenance Instructions For Hydraulic System
➥ The remaining old oil will be pushed out of the hose and into the container ❒ Refit the hydraulic hoses and check the seal ❒ Bleed the hydraulic system and check the oil level NOTICE! Dispose of hydraulic oil in accordance with local regulations! Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 55: Emissions Measurement By Chimney Sweep Or Regulatory Body
Heating Plant Regulations (Feuerungsanlagen-Verordnung). 4.10 Replacement parts With Froling original replacement parts in your boiler, you are using parts that match perfectly. As the parts fit together so well, installation times are shortened and a long service life is maintained. -
Page 56: Disposal Information
❒ You can separate and clean recyclable materials and send them to a recycling centre. ❒ The combustion chamber must be disposed of as builders' waste. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 57: Troubleshooting
Troubleshooting General faults in the power supply 5 Troubleshooting 5.1 General faults in the power supply Error characteristics Cause of error Elimination of error Nothing is shown on the General power failure display No power to the controller Main switch is turned off Turn on the main switch FI-protective circuit breaker, Switch on the protective circuit... - Page 58 5.3.1 Procedure for fault messages Troubleshooting and fault messages See operating instructions SPS 4000 5.3.2 Acknowledging a fault message Trace and remove the fault and then: Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
- Page 59 Troubleshooting Faults with fault message ❒ Call up the current fault list (Quick menu / Error display) ❒ Use the up/down arrow (1) to navigate to the current fault ➥ The selected fault is indicated by an arrow symbol (2) ❒...
- Page 60 6.1.1 Address of manufacturer FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL 0043 (0)7248 606 0 FAX 0043 (0)7248 606 600 INTERNET www.froeling.com 6.1.2 Address of the installer Stamp Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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