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Installation Instructions
Lambdamat LM 750/1500
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M2050121_en | Edition 18/02/2021
Fröling Ges.m.b.H | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Related Manuals for Fröling Lambdamat LM 750
Summary of Contents for Fröling Lambdamat LM 750
- Page 1 Installation Instructions Lambdamat LM 750/1500 Translation of the original German installation instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M2050121_en | Edition 18/02/2021 Fröling Ges.m.b.H | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 2: Table Of Contents
Table of contents Table of contents General Safety Hazard levels of warnings Qualification of assembly staff Personal protective equipment for assembly staff Design Information Notes on standards 3.1.1 General standards for heating systems 3.1.2 Standards for structural and safety devices 3.1.3 Standards for heating water 3.1.4... - Page 3 Non-permitted fuels Heating up for the first time 6.3.1 Screed drying Decommissioning Out of service for long periods Disassembly Disposal Appendix Addresses 8.1.1 Address of manufacturer Customer service 8.1.2 Address of the installer Installation Instructions Lambdamat LM 750/1500 | M2050121_en...
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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
The dangerous situation may occur and if measures are not observed it will lead to minor injuries. NOTICE The dangerous situation may occur and if measures are not observed it will lead to damage to property or pollution. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 6: Qualification Of Assembly Staff
Safety Qualification of assembly staff 2.2 Qualification of assembly staff CAUTION Assembly and installation by unqualified persons: Risk of personal injury and damage to property During assembly and installation: ❒ Observe the instructions and information in the manuals ❒ Only allow appropriately qualified personnel to work on the system Assembly, installation, initial startup and servicing must always be carried out by qualified personnel: - Heating technician / building technician... -
Page 7: Design Information
Water quality for heating, steam, cooling and air conditioning systems (Switzerland) UNI 8065 Technical standard regulating hot water preparation. DM 26.06.2015 (Ministerial Decree specifying the minimum requirements) Follow the instructions of this standard and any related updates. (Italy) Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 8: Regulations And Standards For Permitted Fuels
Design Information Notes on standards 3.1.4 Regulations and standards for permitted fuels 1. BImSchV First Order of the German Federal Government for the implementation of the Federal Law on Emission Protection (Ordinance on Small and Medium Combustion Plants) in the version published on 26 January 2010, BGBl. -
Page 9: Installation And Approval Of The Heating System
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, etc.) from obstructing the air flow. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 10: Requirements For Central Heating Water
Design Information Requirements for central heating water Unless otherwise specified in the applicable building regulations for the boiler room, the following standards apply to the design and dimensions of the air ducts: Note on standards ÖNORM H 5170 - Construction and fire protection requirements TRVB H118 - Technical directives on fire protection/prevention 3.4 Requirements for central heating water Unless contrary to other national regulations, the latest versions of the following... -
Page 11: Notes For Using Pressure Maintenance Systems
If the pressure is too high, air is released by means of a solenoid valve. The systems are built solely with closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen into the heating water. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 12: Return Lift
Design Information Return lift Pump-controlled pressure maintenance A pump-controlled pressure maintenance unit essentially consists of a pressure- maintenance pump, relief valve and an unpressurised receiving tank. The valve releases hot water into the receiving tank if the pressure is too high. If the pressure drops below a preset value, the pump draws water from the receiving tank and feeds it back into the heating system. -
Page 13: Chimney Connection/Chimney System
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the pressure is constantly low at this point. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 14: Technical Information
Technical information Dimensions 4 Technical information 4.1 Dimensions Item Description Unit Lambdamat 1500 Height, boiler 3600 4585 Height, flow/return connection 3660 4660 Height, stoker including burn back protection system 1220 1500 (wood chips BBF 300) Height, flue gas pipe connection 3250 4200 Minimum height, base... -
Page 15: Components And Connections
FGR (flue gas recirculation) connection Broadband probe connection Flue gas temperature sensor connection Safety valve connection (provided by the customer) inches DN65 / PN 6 DN80 / PN 6 Drainage connection inches 2“ IT 2“ IT Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 16: Technical Specifications
Technical information Technical specifications 4.3 Technical specifications Description LM 750 LM 1500 Nominal output 1500 Output range 225 - 750 450 - 1500 Nominal fuel heating efficiency with wood chips 1667 Efficiency at nominal load / partial load 90.0 / 90.3 >... - Page 17 Flue gas mass flow with wood chip W30, 12% O /h (kg/h) Flue gas mass flow with wood chips W30, 9% O 3143 (2214) 6285 (4428) /h (kg/h) Recommended maximum chimney draught mbar Installation Instructions Lambdamat LM 750/1500 | M2050121_en...
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Page 18: Installation
Installation Transport 5 Installation WARNING Risk of falling when working at a height Therefore: ❒ Implement appropriate measures in accordance with the applicable national industrial safety guidelines to protect against the risk of falling (e.g. ladders, platforms, etc.) 5.1 Transport NOTICE Possibility of damage to components if handled incorrectly ❒... -
Page 19: Fit The Ash Duct For Ash Removal Of The Combustion Chamber (Only With Lambdamat 750)
❒ Position the heat exchanger on the centre of the combustion chamber and secure to the combustion chamber with 4x screws and nuts. ➥ Also screw on the earthing wire (supplied) with the toothed washer as potential equalisation. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 20: Setting Up In The Boiler Room
Installation Setting up in the boiler room 5.4 Setting up in the boiler room 5.4.1 Moving the boiler in the boiler room ❒ Position a lifting device with a suitable load-bearing capacity at the base frame. ❒ Lift and transport to the intended position in the installation room. ➥... - Page 21 1. The side of the boiler on which the ash screw is pulled out for maintenance (B or D) should be positioned at least 2100 mm from the wall so that the ash screw can be pulled the whole way out. Installation Instructions Lambdamat LM 750/1500 | M2050121_en...
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Page 22: Laying Firebricks In The Combustion Chamber
Installation Laying firebricks in the combustion chamber 5.5 Laying firebricks in the combustion chamber 5.5.1 General Use Carathin K65-2 mortar where normal bricks and expansion joint bricks of AK60 quality are being laid. ≥12mm NOTICE! Caution: Expansion joints must be at least 12mm wide. NOTICE! Ceramic fibre mats (16) must always be placed between expansion joint bricks and crossbars / between two expansion joint bricks. -
Page 23: Laying Firebricks
Ersatz für: Projekt Kunde ACHTUNG: P100764 Vermiculite im Bereich der Schweißnaht Ers. durch: Zeichnungsnummer Rev. Blatt HEIZKESSEL- UND BEHÄLTERBAU Ges.m.b.H. Z097198-IDW (Stoß Innenmantel / Retorte) ausnehmen. A-4710 Grieskirchen, Industriestraße 12 Datum Bearbeiter Letzte Änderung Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 24: Installing The Boiler
Installation Installing the boiler 5.6 Installing the boiler 5.6.1 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 25: Installing The Hydraulic Stoker Unit
❒ Fit the discharge system (feed screw, etc.) according to the installation instructions enclosed. 5.6.3 Installing the hydraulic stoker unit ❒ Fit hydraulic stoker unit to slide-on duct. ❒ Align the entire stoker unit with the adjustable feet. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 26: Fitting The Burn Back Slide Valve
Installation Installing the boiler 5.6.4 Fitting the burn back slide valve The burn back slide valve can be positioned as shown below depending on the space available in the installation room – follow the installation diagram! ❒ Fit the burn back slide valve with seal to the hydraulic stoker. ❒... -
Page 27: Installing The Air Controllers
❒ Re-fit the blanking plate to the air boxes. ❒ Fit the torque supports to the air damper shafts. ❒ Remove the blanking plate and replace it with the pipe with seal (A). Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 28: Fitting The Immersion Sleeves For The Thermal Discharge Valve And Undergrate Sensor
Installation Installing the boiler 5.6.6 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 the undergrate sensor on the same side of the boiler as the combustion air fan. -
Page 29: Fitting The Insulation Base Frame
17 Short lengthways strut L = 817 mm Bottom lengthways strut L = 3733 mm All frame elements feature the position number from the overview so that all parts can be clearly identified. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... - Page 30 Installation Installing the boiler ❒ Position the four corner rods (1-4) on the boiler. ➥ Distinctive feature: the front ones have a cut-out for ring bolts (B), the back ones have extra lugs (A) – see overview. ❒ Join the corner rods (1-4) to the bottom cross-piece (11) at the front and back of the boiler.
- Page 31 ❒ Place eight top cover plates (A) on the boiler as shown in the diagram and secure to the lengthways strut (8). Note the layout: ▪ Flow (B) and return (C) opening ▪ Dotted lines (D) indicate 45° angled parts Installation Instructions Lambdamat LM 750/1500 | M2050121_en...
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Page 32: Fitting The Side Panels
Installation Installing the boiler 5.6.9 Fitting the side panels Use the supplied countersunk head screws with slit and cup washers to fit the side panels. NOTICE! Only hand-tighten screws to avoid damage and deformation to the side panels! ❒ Cut out all the pre-cut perforations required for the boiler on the side panels. ❒... - Page 33 ❒ Fit the flue gas chamber insulation to the side of the corner rods and beneath the cross-piece. ❒ Weld the insulation to the top cover plates (A). ❒ Fit the back panel below the flue gas chamber. ❒ Fit the door frame to the cleaning door. Installation Instructions Lambdamat LM 750/1500 | M2050121_en...
- Page 34 Installation Installing the boiler ❒ For stoker unit with screw: Cut out the perforation (A) on the back panels and tilt the parts angled by hand (B) back 90°. ❒ Insert and fit the two back panels on the stoker. ❒...
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Page 35: Fitting Various Covers
❒ Fit the covers to the two safety batteries. Fit all the covers: ❒ Supply air box (A) ❒ Entire FGR piping (B) ❒ Door frame (C) ❒ Primary air and two secondary air dampers Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 36: Fitting The Door Contact Switch
Installation Installing the boiler 5.6.11 Fitting the door contact switch Before fitting the insulation panels, check that the tunnel door and the combustion chamber door are tight as explained below. ❒ Open the door. ❒ Insert a sheet of paper at both the top and the bottom between the door and the boiler. -
Page 37: Fitting The Combustion Chamber Ash Removal Unit (Optional)
The following steps show how to fit it to the right-hand side of the boiler. If the ash container is to be fitted to the left, the steps are the same but on the opposite side. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... - Page 38 Installation Installing the boiler ❒ Push the ash screw (1) into the right of the combustion chamber. ❒ Fit the ash removal unit flange (2) with seal to the right of the combustion chamber. ❒ Fit the safety switch (3) to the bracket (4). ❒...
- Page 39 ❒ 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. Installation Instructions Lambdamat LM 750/1500 | M2050121_en...
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Page 40: Installing The Underpressure Controller
Installation Installing the boiler 5.6.13 Installing the underpressure controller The underpressure controller should be fitted to the same side of the boiler as the FGR blower fan. ❒ Assemble the double thread nipple (1), reduction union (2) and hose nipple (3). ❒... -
Page 41: Fitting The Lambda Probe And Various Sensors
(5). Secure it in this position with the wing screw. ❒ Fit the sensor box of the Lambda probe to a suitable place on the boiler and wire according to enclosed instructions. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 42: Installing The Servo-Motors
Installation Installing the boiler Insert the following sensors into the respective immersion sleeves: ❒ A: Return sensor ❒ B: Capillary of high-limit thermostat (STL) ❒ C: Sensor of thermal discharge safety device ❒ D: Sensor of thermal discharge safety device ❒... -
Page 43: Fitting The Combustion Air Fan
❒ Fit the support provided to the combustion air fan and anchor to ground. TIP: Fit the combustion air fan to the opposite side of the compressed air tank to make space for the switching units of the compressed air supply. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 44: Fitting The Automatic Ignition (Optional)
Installation Installing the boiler 5.6.18 Fitting the automatic ignition (optional) The automatic ignition is fitted to the left or right-hand side of the boiler, therefore, perform the following steps on both sides. ❒ Remove the blanking plate (1). ❒ Screw in the igniter tube (2) and seal. ❒... -
Page 45: Fitting The Compressed Air Cleaner (Optional)
❒ Fit the hose (6) between the compressed air tank and air distribution frame to the hose connection using hose clamps (5). ❒ Fit the control boxes (7) at a suitable place on the boiler. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 46: Fitting The Ash Sliding System (Optional)
Installation Installing the boiler 5.6.21 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 47: Installing Flue Gas Recirculation Fgr (Optional)
❒ Secure the mounting plate to the secondary air box. ❒ Remove the transport guard from the flue pipe clip (A) and take out the guard (B). ❒ Secure the flue pipe clip (A) with the seal to the secondary air box. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... - Page 48 Installation Installing the boiler ❒ Seal the guard (B) as shown with high temperature silicon (C) and insert in the flue pipe clip (A). ❒ Remove the U-sheets (A) from the FGR blower fan. ➥ These are no longer required. ❒...
- Page 49 ❒ Fit the pipe bend with flange on the opposite side of the boiler. ❒ Fit the piping in such a way that the flue pipes are at the same height on each side. Installation Instructions Lambdamat LM 750/1500 | M2050121_en...
- Page 50 Installation Installing the boiler ❒ Connect the secondary air box piping behind the boiler. ❒ Fit the support (A) to the pipe bend with the flange, adjust the height and anchor to ground. ❒ Finish the piping. NOTE: All of the piping and FGR blower fan must be insulated by the customer. Make sure the drive assembly of the blower fan can be removed.
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Page 51: Flue Gas Piping
❒ Fit the bracket. NOTICE! The customer is responsible for insulating all piping as well as the induced draught fan and the FGR fan! Make sure the drive assemblies of the blower fans can be removed. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 52: Hydraulic Connection
Installation Hydraulic connection 5.8 Hydraulic connection Thermal discharge valve ▪ The thermal discharge safety device must be connected in accordance with ÖNORM/DIN EN 303-5 and as shown in the diagram above ▪ The discharge safety sensor must be connected to a pressurised cold water mains supply (temperature ≤... -
Page 53: Thermal Discharge Safety Device With Zone Valve
❒ Place the rotary drive on the zone valve in such a way that the flat area of the pin fits into the drive housing ❒ Turn the rotary drive clockwise by approx. 90° until both torque supports (E) of the drive match the bores (F) on the zone valve Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 54: Power Connection And Wiring
Installation Power connection and wiring 105°C click ❒ Secure rotary drive to zone valve ➥ The rotary drive must audibly engage! ❒ Connect the cable of the rotary drive to the “Valve thermal discharge safety device” contact in the control cabinet, observing the circuit diagram of the boiler! ❒... -
Page 55: Connecting Up The Slide-On Duct Cooling
FLOW LINE of the slide-on duct must be OPEN (may only be closed during repair of the slide-on duct). Remove the lever in the open position and keep in a safe place! Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 56: Connecting The Hydraulic Cylinder
Installation Connecting the hydraulic cylinder Connection cable Safety valve – only required for boilers with (If a gate valve or ball valve is used in the hydraulic feed flow line of the slide-on duct, a safety valve with a DN 15 must be installed!) General specification for pipe connections: ▪... -
Page 57: Commissioning
❒ Check that the drives and servo motors are working and turning in the right direction NOTICE! Check the digital and analogue inputs and outputs - See the instruction manual for the boiler controller. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 58: Compressed Air Cleaner (Optional)
Commissioning Before commissioning / configuring the boiler 6.1.1 Compressed air cleaner (optional) If there is a compressed air cleaner installed for the heat exchanger, check the following settings: ❒ Maximum pressure: 4 bar ➥ Set mechanically on pressure reducer ❒ Compressed air monitor setting: 2 bar Set the following parameters on the mecair controller of the compressed air cleaner: ❒... -
Page 59: Initial Startup
▪ The same limits apply for the permitted water content of sawdust as for wood chips. NOTICE For fuels with a water content < W30 the boiler's rated heat output can only be guaranteed if it is used with a flue gas recirculation system (FGR). Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 60: Miscanthus
Commissioning Initial startup Miscanthus Switchgrass or elephant grass (Latin name: miscanthus) is a C4 plant. Standards and regulations for burning these plants have not been standardised, so the following applies: NOTICE! The regional regulations for burning miscanthus should be observed. Operation may only be possible by special permit. -
Page 61: Screed Drying
❒ Tip: If this occurs, clean up using a cleaning rag. 6.3.1 Screed drying The combustion chamber must be slowly screed dried as described below when heating up for the first time to dry out the fireclay. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... - Page 62 Commissioning Heating up for the first time CAUTION If the boiler heats up too quickly on initial start-up: If the output during the heating-up process is too great, the combustion chamber may be damaged as a result of drying out too rapidly! For this reason the following applies the first time you heat up the boiler: ❒...
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Page 63: Decommissioning
❒ Ensure that the system is disposed of in an environmentally friendly way in accordance with waste management regulations. ❒ You can separate and clean recyclable materials and send them to a recycling centre. ❒ The combustion chamber must be disposed of as builders' waste. Installation Instructions Lambdamat LM 750/1500 | M2050121_en... -
Page 64: Appendix Addresses
Appendix Addresses 8 Appendix 8.1 Addresses 8.1.1 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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