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Installation Instructions
Lambdamat LM 1000
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1650115_en | Edition 21/10/2015
Froling GesmbH | Industriestraße 12 | www.froeling.com
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Summary of Contents for Froling Lambdamat LM 1000
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Page 1: Installation Instructions
Installation Instructions Lambdamat LM 1000 Translation of the original German installation instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M1650115_en | Edition 21/10/2015 Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 2: Table Of Contents
Laying the arch Installing the boiler 4.6.1 General information 4.6.2 Bolting together the combustion chamber and heat exchanger 4.6.3 Removing the various blanking plugs and fitting the igniter tube for the automatic ignition (optional). Froling GesmbH | Industriestraße 12 | www.froeling.com... - Page 3 Table of contents 4.6.4 Fitting the immersion sleeves for the thermal discharge valve and undergrate sensor. 4.6.5 Installing the stoker unit 4.6.6 Installing the hydraulic stoker unit 4.6.7 Installing the air controllers 4.6.8 Fitting thermal insulation to the boiler 4.6.9 Fitting the insulation base frame 4.6.10 Fitting the insulating side panels and STL...
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Page 4: 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 5: 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 6: Qualification Of Assembly Staff
500 kW EN 12828 Heating systems in buildings - design of water-based heating systems EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods Part 1: Chimneys serving one appliance Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 7: Standards For Structural And Safety Devices
Safety Design Information ÖNORM H 5151 Planning of central hot water heating systems with or without hot water preparation ÖNORM M 7510-1 Guidelines for checking central heating systems Part 1: General requirements and one-off inspections ÖNORM M 7510-4 Guidelines for checking central heating systems Part 4: Simple check for heating plants for solid fuels Standards for structural and safety devices ÖNORM H 5170... -
Page 8: General Information For Installation Room (Boiler Room)
Germany: VDI 2035 Switzerland: SWKI 97-1 Italy: D.P.R. no. 412 NOTICE! Note on filling with make-up water: Always bleed the filling hose before connecting, in order to prevent air from entering the system. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 9: Notes For Using Pressure Maintenance Systems
Safety Design Information Observe the standards and also follow the recommendations below: ❒ Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (equivalent to 5.6 dH) ❒ Use prepared water which complies with the standards cited above for filling and makeup water ❒... -
Page 10: 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 70] 2.4.8 Chimney connection/chimney system... -
Page 11: Draught Limiter
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the pressure is constantly low at this point. Boiler data for planning the flue gas system Description Lambdamat LM 1000 Flue gas temperature at nominal load °C Flue gas temperature at partial load... -
Page 12: Technical Information
1. If ash is to be removed from the boiler via an ash screw, a base must be provided by the customer beneath the boiler. 2. If the base is higher than 260 mm (minimum height), the difference between the actual base height and the minimum height must be added to this value Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 13: Components And Connections
Technical information Components and connections 3.2 Components and connections Item Description Unit LM 1000 Boiler flow connection Inches DN125 / PN 6 Boiler return connection Inches DN125 / PN 6 Safety battery connection Inches 1” ET Flue gas pipe connection FGR (flue gas recirculation) connection Broadband probe connection Flue gas temperature sensor connection... -
Page 14: Technical Specifications
< 70 1. Electric fuses and power consumption vary depending on design and features 2. Detailed information on the fuel is included in the operating instructions, in the section on “Permitted fuels” Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 15: Installation
Installation Transport 4 Installation 4.1 Transport NOTICE Possibility of damage to components if handled incorrectly ❒ Follow the transport instructions on the packaging ❒ Transport components with care to avoid damage ❒ Protect components against damp ❒ Unloading, positioning and installation should only be performed by trained professionals! Staff must be trained in techniques for moving heavy loads (correct tools and lifting equipment, hooking and slinging points, etc.) 4.2 Temporary storage... -
Page 16: Fitting The Ash Duct For Removing Ash From The Combustion Chamber (Optional)
▪ Observe the applicable standards and regulations when setting up the system. ▪ Observe additional standards for noise protection (ÖNORM H 5190 - Noise protection measures) Froling GesmbH | Industriestraße 12 | www.froeling.com... - Page 17 Installation Setting up in the boiler room Lambdamat 1000 without ash box/ash screw Item Description Unit LM 1000 Distance between stoker and wall Distance between side of boiler and wall Distance between reversing chamber door and wall 3380 Distance between side of boiler (Multicyclone) and wall 1500 Minimum room height 4000...
- Page 18 1. The side of the boiler on which the ash screw is pulled out for maintenance (B or D) should be positioned at least 2100mm from the wall so that the ash screw can be pulled the whole way out. Froling GesmbH | Industriestraße 12 | www.froeling.com...
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Page 19: Laying Firebricks In The Combustion Chamber
Installation Laying firebricks in the combustion chamber 4.5 Laying firebricks in the combustion chamber 4.5.1 Fireclay lining overview 16-30 Item units Description Item units Description Combustion chamber base frame Ceramic fibre mat B Firebrick lining Expansion joint brick A (AK60–64x124x187mm) Insulating panel A (30x634x1200mm) Expansion joint brick B (AK60–64x124x250mm) Insulating panel B (30x950x1200mm) -
Page 20: General
❒ Plates (23) serve to level off the height for the supports. NOTICE! Normal bricks and expansion joint bricks of AK60 quality appear slightly darker in the images of the following assembly steps. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 21: Laying Rows Of Bricks 1 To
Installation Laying firebricks in the combustion chamber 4.5.3 Laying rows of bricks 1 to 5 ❒ Position insulating panel K (13) at the front and 2x insulating panel H (10) on the left and right. ❒ Lay 2x crossbar C (26) and 1x crossbar A (24) at the front. ❒... - Page 22 (holes are already provided in insulating panel) ❒ Lay the fifth row of bricks. ➥ Normal bricks A/B (21/22), expansion joint bricks D (20) ❒ Screw 2x air nozzles (14) each into insulating panels on left and right. Froling GesmbH | Industriestraße 12 | www.froeling.com...
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Page 23: Laying Rows Of Bricks 6 To
Installation Laying firebricks in the combustion chamber 4.5.4 Laying rows of bricks 6 to 9 ❒ Lay the sixth row of bricks. ➥ Normal bricks A/B (21/22), expansion joint bricks C (19) ❒ Screw 2x air nozzles (14) each into insulating panels on left and right. ❒... -
Page 24: Laying Rows Of Bricks 16 To
➥ Normal bricks B (22), expansion joint bricks D (20), plate (23) ❒ Lay the 12th row of bricks. ➥ Normal bricks B (22), expansion joint bricks C (19), plate (23) ❒ Lay 4x support B (28) each on the left and right. Froling GesmbH | Industriestraße 12 | www.froeling.com... - Page 25 Installation Laying firebricks in the combustion chamber ❒ Lay the 13th row of bricks. ➥ Normal bricks A/B (21/22), expansion joint bricks D (20), plate (23) ❒ Lay 6x supports B (28) each on the left and right. ❒ Lay the 14th row of bricks. ➥...
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Page 26: Laying Rows Of Bricks 16 To 24
❒ Lay the 19th row of bricks. ➥ Normal bricks A/B (21/22), expansion joint bricks D (20) ❒ Lay the 20th row of bricks. ➥ Normal bricks B (22), expansion joint bricks C (19) Froling GesmbH | Industriestraße 12 | www.froeling.com... - Page 27 Installation Laying firebricks in the combustion chamber ❒ Lay the 21st row of bricks. ➥ Normal bricks B (22), expansion joint bricks D (20) ❒ Lay crossbar C (26) at front. ❒ Lay the 22nd row of bricks. ➥ Normal bricks B (22), expansion joint bricks C (19) ❒...
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Page 28: Laying The Arch
➥ Position one arch brick (29) each on left and right at supports and join with an anchor brick (30) NOTICE! If the heat exchanger is placed on the combustion chamber before the firebricks are laid, you must lay the top row of arch bricks first. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 29: Installing The Boiler
Installation Installing the boiler 4.6 Installing the boiler 4.6.1 General information NOTICE Reduction in performance due to air leakage The use of flanges without sealing cords can result in a reduction in performance due to air leakage Therefore: ❒ Sealing cords or the surface sealant provided must be used on all the flanged connections on the following components: loading;... -
Page 30: Removing The Various Blanking Plugs And Fitting The Igniter Tube For The Automatic Ignition
For automatic ignition (optional): ❒ Remove the blanking plates for the automatic ignition from both sides of the combustion chamber. ❒ Screw in the igniter tubes for the automatic ignition. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 31: Fitting The Immersion Sleeves For The Thermal Discharge Valve And Undergrate Sensor
Installation Installing the boiler 4.6.4 Fitting the immersion sleeves for the thermal discharge valve and undergrate sensor. ❒ Seal the immersion sleeves for the thermal discharge valve in top of heat exchanger. ❒ Seal the immersion sleeve for undergrate sensor on left OR right-hand side of boiler. -
Page 32: Installing The Hydraulic Stoker Unit
❒ Fit the discharge system (feed screw, etc.) according to the installation instructions enclosed. 4.6.7 Installing the air controllers ❒ Fit the air controllers for secondary air to both sides of the combustion chamber. Froling GesmbH | Industriestraße 12 | www.froeling.com... - Page 33 Installation Installing the boiler ❒ Fit the air controllers for primary air (1) and tertiary air (2) to the left OR right-hand side of the boiler. ➥ The picture shows them fitted to the right-hand side of the boiler. If one or both of the air controllers is/are being fitted to the left side, remove the blanking plates on the left before fitting the air controller and fit on the right instead of the air controller.
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Page 34: Fitting Thermal Insulation To The Boiler
❒ Fit the thermal insulation at the front in the case of a heat exchanger. ❒ Fit the heat insulation mats to the left and right of the boiler and secure with tension springs. ❒ Make cutouts in the heat insulation mats at all the required places. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 35: Fitting The Insulation Base Frame
Installation Installing the boiler 4.6.9 Fitting the insulation base frame Side support elements Centre lengthways strut Supports (optional with ash removal Bottom support elements by screw) Back "Portal" frame element Top support elements Bottom rear cross-piece Centre rear cross-pieces Front "Portal" frame element Centre front cross-piece Bottom front cross-pieces Support plate... - Page 36 ➥ Adjust the height of the supports to the height of the base. ❒ Fit the "Portal" frame element (4) and bottom cross-piece (5) to the front. ➥ First hook onto the support elements with the clamps, then secure with the screws. Froling GesmbH | Industriestraße 12 | www.froeling.com...
- Page 37 Installation Installing the boiler ❒ Fit the lengthways struts (6+7) on the left. ➥ First hook onto the support elements with the clamps, then secure with the screws. ❒ Fit the lengthways struts (6+7) on the right. ➥ First hook onto the support elements with the clamps, then secure with the screws.
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Page 38: Fitting The Insulating Side Panels And Stl
❒ Fit the insulating side panels to the front of the boiler. ❒ Fit the door frame for the burning and combustion chamber door and for the cleaning port doors. ❒ Fit the insulating side panels to the left-hand side of the boiler. Froling GesmbH | Industriestraße 12 | www.froeling.com... - Page 39 Installation Installing the boiler ❒ Fit the insulating side panels to the right-hand side of the boiler. ➥ Caution: With side panel with piece no. (1), fit the high-limit thermostat (STL) at the same time – see next assembly steps. ❒...
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Page 40: Fitting Various Covers
❒ Refit the lock nut (2) to the front of the STL. Refit the cap (1). ❒ Fit the cover with STL to the insulating side panel. ❒ Fit the insulation covers to the top and top slant. 4.6.11 Fitting various covers ❒ Fit the top covers. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 41: Fitting The Door Contact Switch
Installation Installing the boiler ❒ Fit the side covers. ▪ If an automatic ignition is being fitted, do not fit the round cover plates (1). ▪ Fit the two-part cover plate (2) to the side of the combustion air fan, the single-part cover plate (3) to the opposite side. - Page 42 ➥ Fix the key plate in position (2). Open and close the door several times and check that the door contact switch (3) has properly engaged. ❒ Lay the connecting cable through the opening in the frame element and then onwards to the control cabinet. Froling GesmbH | Industriestraße 12 | www.froeling.com...
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Page 43: Fitting The Combustion Chamber Ash Removal Unit (Optional)
Installation Installing the boiler 4.6.13 Fitting the combustion chamber ash removal unit (optional) The ash container for removing ash from the combustion chamber by ash screw can be fitted to the right or left-hand side of the boiler. The following steps show how to fit it to the right-hand side of the boiler. - Page 44 ❒ Push the key plate into the safety switch. ❒ Set the safety switch so that the key plate engages correctly. ❒ Tighten the screws on the safety switch. Froling GesmbH | Industriestraße 12 | www.froeling.com...
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Page 45: Installing The Underpressure Controller
Installation Installing the boiler 4.6.14 Installing the underpressure controller Caution: Install the underpressure controller opposite the undergrate sensor. ❒ Assemble the double thread nipple (1), reduction union (2) and hose nipple (3). ❒ Screw the assembled unit onto the side of the combustion chamber from which the blanking plug was previously removed. -
Page 46: Installing The Combustion Chamber Overpressure And Temperature Sensors
❒ Unscrew the connector box cover. Connect up the compensating line as follows: - green wire to the terminal with the green dot - white wire to the unmarked terminal - shield not connected up. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 47: Fitting The Broadband Probe And Various Sensors
Installation Installing the boiler 4.6.16 Fitting the broadband probe and various sensors. ❒ Screw in bushing (1) on flue gas chamber and gently tighten. ❒ Screw the broadband probe (2) into the bushing (1) and tighten slightly using an Allen key (22 mm). ❒... -
Page 48: Installing The Servo-Motors
❒ Plug the servo-motor for primary air (2) and tertiary air (3) into the pneumatic rods on the side where the respective air controllers were previously fitted. ➥ Picture shows servo-motors on right-hand side of boiler. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 49: Fitting The Combustion Air Fan
Installation Installing the boiler 4.6.18 Fitting the combustion air fan ❒ Fit combustion air fan with seal. 4.6.19 Fitting the automatic ignition (optional) The automatic ignition can be fitted to the left or right-hand side of the boiler. The following steps show how to fit it to the right-hand side of the boiler. Proceed in the same way to fit it to the left-hand side. -
Page 50: Fitting An Additional Ignition For Hydraulic Stoker Unit (Optional)
This type of door is fitted the same way as the reversing chamber door without air distribution frame. ❒ Hang the reversing chamber door on the hinges on the right-hand side of the boiler with ring bolts. Froling GesmbH | Industriestraße 12 | www.froeling.com... - Page 51 Installation Installing the boiler ❒ Close the reversing chamber door and tilt the ring bolts forwards with the knob. ❒ Tighten the triangle star knob so that the door is securely closed. The stop on the reversing chamber door can be swapped if necessary as follows: Remove the ring bolts (1) and triangle star knobs (2) as well as 2x ring bolts with spacer sleeve (3) and fit to the other side.
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Page 52: Fitting The Compressed Air Cleaner (Optional)
❒ Fit the double nipple (3), taper (4), elbow (1) and hose connection (2) to the right- hand side of the reversing chamber door on the air distribution frame. ❒ Fit the hose between the compressed air tank and air distribution frame to the hose connection using hose clamps. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 53: Fitting The Ash Sliding System (Optional)
Installation Installing the boiler 4.6.23 Fitting the ash sliding system (optional) An ash sliding system is required if the boiler is operated with underfloor ash removal and the room in which the ash is removed is not airtight. ❒ Fit the gravity shaft (1) with seal to the underside of the combustion chamber. ❒... -
Page 54: Fitting The Flue Gas Recirculation (Fgr) (Optional)
❒ Fit the secondary air box with ceramic fibre seal to primary air box. ❒ Remove the cover plate (if installed) from between the ignition and servo-motor. ❒ Cut out the heat insulation mat and remove. Froling GesmbH | Industriestraße 12 | www.froeling.com... - Page 55 Installation Installing the boiler ❒ Remove the blanking plate and seal. ❒ Fit the pipe between the secondary air box and the boiler. ❒ Remove the cover plate (if installed) from the right-hand side of the boiler between the ignition and servo-motor. ❒...
- Page 56 ➥ The assembly material provided is a suggestion. Ensure you use material best suited to the surface. ❒ Fit the cover plates to the right-hand side of the boiler. ❒ Fit the cover plates to the left-hand side of the boiler. Froling GesmbH | Industriestraße 12 | www.froeling.com...
- Page 57 Installation Installing the boiler Installing the servo-motors ❒ Check that the air flaps are at the left stop. ➥ All air flaps are closed. ➥ Where necessary, turn the air flaps to the left stop using pliers. ❒ Set the direction of rotation of the servo-motor (1) to left (L). ❒...
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Page 58: Flue Gas Piping
❒ Fit the induced draught fan with the rubber buffers to the bracket. ❒ Fit the flue pipe compensator and induced draught fan to the Multicyclone. ❒ Fit the bracket. NOTICE! The customer is responsible for insulating all piping! Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 59: Power Connection And Wiring
Installation Power connection and wiring 4.8 Power connection and wiring 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 60: Connecting The Hydraulic Safety Devices
▪ Its size must comply with the design information in EN 12828 - Appendix D ▪ Ideally it should be installed in the return line. Follow the manufacturer’s installation instructions Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 61: Connecting Up The Slide-On Duct Cooling
Installation Connecting up the slide-on duct cooling 4.10 Connecting up the slide-on duct cooling The following is a schematic diagram Boiler flow Slide-on duct loading pump: ▪ No gravitational brake. Boiler return ▪ Up to 500 kW output: – e.g. Wilo Yonos Para 25/1-4, Slide-on duct flow Yonos Pico 25/1-4, Grundfos alpha2 25-40 or the like... -
Page 62: Final Installation Steps
➥ If the paper cannot be removed: door is tightly sealed. ➥ If the paper can be removed: door is not sealed properly - tighten the locking hook! ⇨ See "Adjusting the doors" [page 63] Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 63: Adjusting The Doors
Installation Final installation steps 4.11.2 Adjusting the doors The example below shows how to position the combustion chamber door. The procedure is the same for checking the seal on the burning chamber door. ❒ Loosen the nut on the locking hook. ❒... -
Page 64: Commissioning
Take the following precautions: ❒ Initial startup should be carried out with an authorised installer or with Froling customer services NOTICE Foreign bodies in the heating system impair its operational safety and can result in damage to property. -
Page 65: Initial Startup
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 66: Miscanthus
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 | Industriestraße 12 | www.froeling.com... -
Page 67: Heating Up For The First Time
Take the following precautions: ❒ Initial startup should be carried out with an authorised installer or with Froling customer services The customer is responsible for ensuring the following prior to initial start-up of the system by Froling customer services: ▪... -
Page 68: Screed Drying
NOTICE! Fissures in the fireclay are normal and do not indicate a fault. NOTICE If condensation escapes during the initial heat-up phase, this does not indicate a fault. ❒ Tip: If this occurs, clean up using a cleaning rag. Froling GesmbH | Industriestraße 12 | www.froeling.com... -
Page 69: Decommissioning
Decommissioning Out of service for long periods 6 Decommissioning 6.1 Out of service for long periods The following measures should be taken if the boiler is to remain out of service for several weeks (e.g. during the summer): ❒ Clean the boiler thoroughly and close the doors fully. ❒... -
Page 70: Appendix
7.1 Addresses 7.1.1 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 7.1.2 Address of the installer Stamp Froling GesmbH | Industriestraße 12 | www.froeling.com...
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