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Operating Instructions
Wood chip boiler T4 24-150
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!
B0830317_en | Edition 03/10/2017
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Summary of Contents for Froling T4 Series
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Page 1: Operating Instructions
Wood chip boiler T4 24-150 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! B0830317_en | Edition 03/10/2017 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 2: 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 Regulating the boiler 3.3.4 Switching off the boiler 3.3.5 Switching off the power supply Boiler Servicing Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 3 Table of Contents General information on servicing Inspection and cleaning 4.2.1 Inspection Checking the system pressure Checking the safety valve Checking the geared motors 4.2.2 Cleaning Emptying the ash container 4.2.3 Recurrent check and cleaning Before starting inspection and cleaning work After inspection and cleaning work Clean the combustion chamber Cleaning the heat-exchanger and flue gas collection chamber...
- Page 4 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.
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Page 5: General T4 Product Overview
General T4 product overview 1.1 T4 product overview Wood chip boiler – Froling T4 Main switch: switches the power supply on and off for the entire system High-limit thermostat STL Mains supply Control panel of the Lambdatronic H 3200 T4 Touch controller... - Page 6 Ash box for combined automatic ash removal from combustion chamber and heat exchanger Combustion chamber door with screw lock and inspection glass WOS system with turbulators and automatic drive for heat exchanger cleaning Broadband probe Flue gas temperature sensor Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 7: 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 8: 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. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 9 Safety General safety information WARNING External influences: Negative external influences, such as insufficient combustion air or non-standard fuel, can cause serious faults in combustion (e.g. spontaneous combustion of carbonisation gases or flash fires) which can in turn cause serious accidents! When operating the boiler, please note the following: ❒...
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Page 10: Permitted Uses
Clean Air Act requirements. The Froling S1 Turbo 15 and S1 Turbo 20 have been recommended as suitable for use in smoke control areas when burning fuels as listed under "Permitted fuels". -
Page 11: Permitted Fuels
Therefore: ❒ If the fuel is changed (e.g. from wood chips to pellets), the system must be reset by Froling customer services. Operating Instructions T4 24-150 | B0830317_en... -
Page 12: Non-Permitted Fuels
2.6 Protective equipment for operating staff You must ensure that staff have the protective equipment specified by accident prevention regulations. ▪ For operation, inspection and cleaning: - suitable work wear - protective gloves - sturdy shoes Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 13: Design Information
Safety Design information 2.7 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. -
Page 14: Requirements For Central Heating Water
≤ 2.0 mmol/L < 0.1 mmol/L Conductivity < 100µS/cm < 100 µS/cm pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5 Chloride < 30 mg/L < 30 mg/L < 30 mg/L Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 15: Notes For Using Pressure Maintenance Systems
Safety Design information Additional requirements for Switzerland: The filling and make-up water must be demineralised (fully purified) ▪ The water must not contain any ingredients that could settle and accumulate in the system ▪ This makes the water non-electroconductive, which prevents corrosion ▪... -
Page 16: Return Temperature Control
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 43] 2.7.7 Chimney connection/chimney system... -
Page 17: Safety Devices
Safety Safety devices 2.8 Safety devices (switches off the boiler to prevent overheating) BOILER OFF ❒ Tap “Boiler off” ➥ Automatic mode is switched off ➥ Control system follows the boiler shut-down procedure ➥ Pumps continue to run (switches off the power supply) MAIN SWITCH Before carrying out work on/in the boiler: ❒... -
Page 18: 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 19: Emergency Procedure
❒ Switch boiler off by tapping “Boiler OFF” ❒ 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 20: Fire In The System
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 21: 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 22: Filling/Refilling The Store With Fuel
❒ Load a small quantity of wood chips and wait until the arms / spring blades are touching the head of the rotary agitator (approx. 2 revolutions) ❒ Only then should you load the remaining material Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 23: Blowing In Pellets For A Store With Pellet Screw
Operating the System Filling/refilling the store with fuel 3.2.3 Blowing in pellets for a store with pellet screw ❒ Switch off the boiler by tapping “Boiler off” at the mode icon and allow to cool for at least two hours ❒... -
Page 24: Heating Up The Boiler
❒ Blow the fuel into the store If the fuel store is completely empty and there is no residual fuel to redistribute: ❒ Contact Froling and seek advice before filling the fuel store ⇨ See "Address of manufacturer" [page 43] 3.3 Heating up the boiler... -
Page 25: Switching On The Power Supply
Operating the System Heating up the boiler 3.3.1 Switching on the power supply ❒ Turn on the main switch ➥ There is voltage at all of the boiler's components ➥ When the control has completed the system start, the boiler is ready for operation 3.3.2 Switching on the boiler ❒... -
Page 26: Boiler Servicing
❒ Allow boiler to cool for at least 1 hour ❒ After maintenance has been carried out switch the boiler on in the desired mode. ➥ In service mode the boiler does not start automatically. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 27 Boiler Servicing General information on servicing WARNING Incorrect inspection and cleaning: Incorrect or insufficient inspection and cleaning of the boiler can cause serious faults in combustion (e.g. spontaneous combustion of carbonisation gases / flash fires) and this can lead to serious accidents and damage! Take the following precautions: ❒...
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Page 28: Inspection And Cleaning
➥ 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. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 29: Cleaning
Boiler Servicing Inspection and cleaning 4.2.2 Cleaning Emptying the ash container The ash container must be emptied at appropriate intervals depending on energy requirements and fuel quality. If the ash container is full before you check the ash level, the warning “ash box full, please empty”... - Page 30 ❒ Replace the ash container in the boiler and clamp with the locking lever ❒ Replace the cover and secure with the clamps ➥ Make sure that the pin is inserted in the limit switch correctly. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 31: Recurrent Check And Cleaning
Boiler Servicing Inspection and cleaning 4.2.3 Recurrent check and cleaning The boiler must be cleaned and inspected at appropriate intervals depending on the service hours and fuel quality. For fuels with a low ash content (standard wood chips), annual cleaning and inspection (2000 to 2500 service hours) is usually sufficient. -
Page 32: Clean The Combustion Chamber
➥ Do not throw the ash onto the grate ❒ Remove the ash deposits from the walls of the entire combustion chamber (top, side, back) using an ash scraper or broom (working with an ash vacuum is best) Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 33: Cleaning The Heat-Exchanger And Flue Gas Collection Chamber
Boiler Servicing Inspection and cleaning ❒ Remove the burn-out opening ❒ Check the firebricks and combustion grate for dirt and deposits and clean if necessary (ash vacuum recommended) ❒ Install the burn-out opening ➥ The opening must be facing the fuel infeed side! Cleaning the heat-exchanger and flue gas collection chamber ❒... - Page 34 ❒ Clean the entire area with an ash vacuum ❒ Remove spring cotter from the eyebolt ❒ Remove eyebolt from the mounting sheet and WOS shaft ❒ Remove mounting sheet including turbulators from the boiler Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 35: Clean The Heat Exchanger Pipes
Boiler Servicing Inspection and cleaning Clean the heat exchanger pipes ❒ Clean the rectangular heat exchanger pipes using the cleaning brush provided ❒ Brush several times with the round cleaning brush to properly clean the heat exchanger pipes ❒ Use the ash vacuum to remove any residual ash from the flue gas collection chamber ❒... -
Page 36: Cleaning The Flue Gas Temperature Sensor
➥ Depending on the layout of the flue gas pipes and the chimney draught, cleaning once a year may not be enough! ❒ Plug in the connection cable of the induced draught fan Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 37: Check The Seal On The Doors
Boiler Servicing Inspection and cleaning Check the seal on the doors Check the door stop side ❒ Open the door ❒ Insert a sheet of paper at both the top and the bottom of the door stop between the door and the boiler ❒... -
Page 38: Checking The Draught Controller Flap
➥ WARNING! Do not direct compressed air into under-pressure sensor cartridge! This could damage it! ❒ After cleaning, refit the measurement line Depending on the design, port “-” (A) or “HI” (B) See also 2 Emptying the ash container [➙ 29] Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 39: Emissions Measurement By Chimney Sweep Or Regulatory Body
➥ The display will indicate that the boiler is ready for measurement 4.4 Maintenance agreement / Customer service NOTICE! We recommend a yearly inspection by Froling customer services or an authorised partner (third party maintenance). Regular maintenance and servicing by a heating specialist will ensure a long, trouble- free service life for your heating system. -
Page 40: Replacement Parts
Heating Plant Regulations (Feuerungsanlagen-Verordnung). 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 a long service life is maintained. -
Page 41: Troubleshooting
Troubleshooting General fault with power supply 5 Troubleshooting 5.1 General fault with power supply Error characteristics Cause of error Elimination of error Nothing is shown on the General power failure display Main switch is turned off Turn on the main switch No power to the controller FI circuit breaker or line Switch on the FI circuit... -
Page 42: Faults With Fault Message
Trace and remove the fault and then: ❒ Tap the “Cancel” symbol ➥ Status LED constant or flashing green light (depending on operating status) - Green constant: Boiler switched on - Green flashing: Boiler switched off Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... -
Page 43: Appendix
Appendix Addresses 6 Appendix 6.1 Addresses 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 EMAIL info@froeling.com INTERNET www.froeling.com Customer service Austria 0043 (0)7248 606 7000 Germany 0049 (0)89 927 926 400 Worldwide...
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