Fröling T4e Operating Instructions Manual
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Fröling T4e Operating Instructions Manual

Fröling T4e Operating Instructions Manual

Wood chip boiler
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Operating Instructions
Wood chip boiler T4e
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!
B1560520_en | Edition 11/08/2020
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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Summary of Contents for Fröling T4e

  • Page 1 Operating Instructions Wood chip boiler T4e 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! B1560520_en | Edition 11/08/2020 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 2: Table Of Contents

    Table of contents Table of contents General Product overview T4e Safety Hazard levels of warnings Pictograms used General safety information Permitted uses 2.4.1 The Clean Air Act 1993 and Smoke Control Areas 2.4.2 Permitted fuels Wood chips Wood pellets Changing the fuel 2.4.3...
  • Page 3 Required tools Maintenance work by the operator 5.3.1 Weekly inspection Checking the system pressure Check the thermal discharge valve (from T4e 130) Checking the safety valve Checking the quick vent valve Checking the geared motors 5.3.2 Recurrent check and cleaning...
  • Page 4 Table of contents T4e 200-350 Emissions measurement by chimney sweep or regulatory body 5.5.1 Switch on the system 5.5.2 Start emissions measurement Replacement parts Disposal information 5.7.1 Disposal of the ash 5.7.2 Disposal of system components Troubleshooting General fault with power supply 6.1.1...

  • Page 5: General

    Our sale and delivery conditions will be applicable. 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 enclosed guarantee certificate. Operating Instructions T4e | B1560520_en...

  • Page 6: Product Overview T4E

    General Product overview T4e 1.1 Product overview T4e Wood chip boiler – Fröling T4e Main switch: switches the power supply on and off for the entire system High-limit thermostat STL Mains connection Lambdatronic H 3200 boiler controller, ⇨ See "Overview of the touch display" [page Status display (operating status), ⇨...
  • Page 7 Ceramic igniter with function monitoring Silicon carbide combustion chamber with automatic tipping grate Tipping grate with drive (rotation angle 110°) Ash box for combined automatic ash removal from combustion chamber and heat exchanger Combustion chamber door with inspection glass Operating Instructions T4e | B1560520_en...

  • Page 8: 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 9: Pictograms Used

    Warning of injury to fingers or Warning of injury to fingers or hands, automatic fan hands, automatic screw Warning of injury to fingers or Warning of injury to fingers or hands, gear/chain drive hands, cutting edge Operating Instructions T4e | B1560520_en...

  • Page 10: General Safety Information

    Safety General safety information 2.3 General safety information DANGER If the device is used incorrectly: Incorrect use of the system can cause severe injury and damage. When operating the system: ❒ Observe the instructions and information in the manuals ❒ Observe the details on procedures for operation, maintenance and cleaning, as well as troubleshooting in the respective manuals.

  • Page 11: Permitted Uses

    Safety Permitted uses 2.4 Permitted uses The Froling Wood chip boiler T4e is designed solely for heating domestic water. Only the fuels specified in the "Permitted fuels" section may be used. ⇨ See "Permitted fuels" [page 13] 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 12 Safety Permitted uses The Froling T4e 120kW has been recommended for use in smoke control areas when burning wood pellets only. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 13: Permitted Fuels

    Incorrect parameter settings have a significant adverse effect on the functioning of the boiler, and as a result this will invalidate the guarantee. Therefore: ❒ If the fuel is changed (e.g. from wood chips to pellets), the system must be reset by Froling customer services. Operating Instructions T4e | B1560520_en...

  • Page 14: Non-Permitted Fuels

    Safety Permitted uses 2.4.3 Non-permitted fuels The use of fuels not defined in the "Permitted fuels" section, and particularly the burning of refuse, is not permitted. CAUTION In case of use of non-permitted fuels: Burning non-permitted fuels increases the cleaning requirements and leads to a build-up of aggressive sedimentation and condensation, which can damage the boiler and also invalidates the guarantee.

  • Page 15: Safety Devices

    For T4e 130-350: (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 Operating Instructions T4e | B1560520_en...

  • Page 16: Residual Risks

    Safety Residual risks 2.8 Residual risks WARNING When touching hot surfaces: Severe burns are possible on hot surfaces and the flue gas pipe! When work is carried out on the boiler: ❒ Shut down the boiler according to procedure (“Boiler off” operating status) and allow it to cool down ❒...
  • Page 17 Interference of the pacemaker by electromagnetic fields of the particle separator is possible! Therefore: ❒ Maintain a safety distance of at least one metre from the electrostatic particle separator ❒ Perform work only when the electrostatic particle separator is switched off Operating Instructions T4e | B1560520_en...

  • Page 18: Emergency Procedure

    Safety Emergency procedure 2.9 Emergency procedure 2.9.1 Overheating of the system If the system overheats and the safety devices fail to operate, proceed as follows: NOTICE! Do not under any circumstances switch off the main switch or disconnect the power supply! ❒...

  • Page 19: Notes For Operating A Heating System

    Do not use any solvents or cleaning agents containing chlorine and hydrogen halides in the room where the boiler is installed (e.g. chlorination units for swimming pools). ▪ Keep the air suction opening of the boiler free of dust. Operating Instructions T4e | B1560520_en...

  • Page 20: Requirements For Central Heating Water

    Notes for operating a heating system General information for installation room (boiler room) ▪ The system must be protected against the chewing or nesting of animals (e.g. rodents etc.). 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, etc.) from obstructing the air flow.
  • Page 21 ▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the central heating water comes into contact with aluminium, the pH value must be between 8.0 and ▪ Yearly. Values must be recorded by the owner Operating Instructions T4e | B1560520_en...

  • Page 22: Notes For Using Pressure Maintenance Systems

    Notes for operating a heating system Notes for using pressure maintenance systems 3.4 Notes for using pressure maintenance systems Pressure maintenance systems in hot-water heating systems keep the required pressure within predefined limits and balance out volume variations caused by changes in the hot-water temperature.

  • Page 23: Use With Storage Tank

    NOTICE! Please see the technical data contained in the assembly instructions for further information about standards and regulations as well as the flue gas temperatures when clean and the other flue gas values! Operating Instructions T4e | B1560520_en...

  • Page 24: Operating The System Assembly And Initial Startup

    Operating the System Assembly and initial startup 4 Operating the System 4.1 Assembly and initial startup Assembly, installation and initial startup of the boiler must only be carried out by qualified staff, and these procedures are described in the accompanying assembly instructions.

  • Page 25: 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 Operating Instructions T4e | B1560520_en...

  • Page 26: Blowing In Pellets For A Store With Pellet Screw

    Operating the System Filling/refilling the store with fuel 4.2.3 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 27: Drainage Of Fuel Store

    When the fuel store is emptied, a certain amount of fuel remains and is not removed by the rotary agitator. This is not a malfunction but occurs due to the nature of the system. This effect is amplified when the wood chips are compressed. Operating Instructions T4e | B1560520_en...
  • Page 28 Operating the System Filling/refilling the store with fuel Tips for better emptying: ▪ Use suitable wood chips in terms of moisture content, size etc. ▪ Reduce the dumping height onto the rotary agitator ▪ Avoid compressing the wood chips, e.g. by carefully adding to the fuel store ▪...

  • Page 29: Switching On The Power Supply

    ⇨ See "Emissions measurement by chimney sweep or regulatory body" [page 70] Display of current operating status, boiler ON/OFF ⇨ See "Switch boiler ON/OFF" [page 37] View available functions in the quick menu ⇨ See "Quick menu" [page 34] Operating Instructions T4e | B1560520_en...

  • Page 30: Status Display

    Operating the System Operate the boiler using the touch display Access all system information. No parameters may be changed in the info menu. System menu for opening the system settings. All parameters can be displayed and/or edited depending on the user level. ⇨...

  • Page 31: Display Icons For Froeling-Connect/Remote Control

    ❒ Tap the info menu in the basic display and navigate to the “froeling-connect” menu ➥ The connection status is displayed in the lower range (connected, deactivated, …) NOTICE! Consult the “froeling-connect” operating instructions for a detailed description of the connection status as well as troubleshooting Operating Instructions T4e | B1560520_en...

  • Page 32: Navigation Within The System Menu

    Operating the System Operate the boiler using the touch display Navigation within the system menu The system menu shows the menus available depending on the user level and the system configuration. Use the right and left arrows to navigate to the individual menus. Tap the corresponding icon to open the menu.

  • Page 33: Changing Parameters

    ❒ Use the up and down arrows to set the start and end time and save by tapping on the “Confirm” icon The time window set is saved for all selected days of the week. Operating Instructions T4e | B1560520_en...

  • Page 34: Quick Menu

    Operating the System Operate the boiler using the touch display To delete a saved time window, tap on the “Recycle bin” icon next to it. Quick menu The quick menu provides different functions depending on the system configuration and system status. Icon Description Language selection...

  • Page 35: Select Information Displays

    4 temperature Display of storage tank temperature top, store sensor 2, store sensor 3 and bottom. sensors Circulation Temperatures Display of the status at the flow sensor (if pump present) and the current circulation return temperature. Operating Instructions T4e | B1560520_en...
  • Page 36 Operating the System Operate the boiler using the touch display Menu Selection Icon Description Differencial Temperatures Display of the current temperature from controller source and recess of the differential regulator System CPU/RAM capacity Display of the CPU and RAM capacity in percent 1.

  • Page 37: Switch Boiler On/Off

    The boiler switches to “Boiler OFF” status. All boiler units are deactivated, heating circuits and domestic hot water tanks are controlled according to the programs and times set, the chamber discharge system remains active. Operating Instructions T4e | B1560520_en...

  • Page 38: Change Boiler Mode

    Operating the System Operate the boiler using the touch display 4.4.4 Change boiler mode Depending on the type of boiler, there are several modes available which can be changed directly in the basic display of the touch display. Mode Icon Description Automatic Supply heating circuits and domestic hot water tanks...

  • Page 39: Change Date And Time

    ❒ Tap the information display for the desired DHW tank ❒ Adjust the temperature setpoint by tapping on “+” or “-” NOTICE! If this selection is not configured in the information display in the basic display, open the components in the system menu. Operating Instructions T4e | B1560520_en...

  • Page 40: One-Time Extra Loading Of An Individual Dhw Tank

    Operating the System Operate the boiler using the touch display 4.4.7 One-time extra loading of an individual DHW tank ❒ Tap the information display for the desired DHW tank ❒ Tap the mode icon for the DHW tank ❒ Tap the “extra loading” icon ➥...

  • Page 41: Set The Heating Curve Of A Heating Circuit

    If the outside air temperature in setback mode circuit pump switches off in setback mode (default: 22:00 – 06:00) falls below the set (default: 7°C) value, the heating circuit is activated (pump on, mixing valve regulated as per heating curve) Operating Instructions T4e | B1560520_en...

  • Page 42: Change Room Temperature (Heating Circuit Without Room Temperature Sensor)

    Operating the System Operate the boiler using the touch display 4.4.10 Change room temperature (heating circuit without room temperature sensor) Situation Effect Room temperature generally too low Move heating curve up in parallel. Increase both points on the heating curve by the same temperature level.

  • Page 43: Switch Heating Circuit Mode

    Extra heating The heating circuit is regulated to the set room temperature with no time limitation. To cancel this function prematurely, activate another mode/function. Continuous The heating circuit is regulated to the set setback setback temperature until activation of mode another mode/function. Operating Instructions T4e | B1560520_en...

  • Page 44: Lock Display/Switch User Level

    Operating the System Operate the boiler using the touch display 4.4.13 Lock display/switch user level For safety reasons individual parameters are only visible at specific operating levels. To change to another level it is necessary to enter the relevant user code. ❒...

  • Page 45: Configure The Holiday Program

    If the start date is set in the future, the “suitcase” icon will be highlighted in green. Once the set start time of the holiday program has been reached, the boiler switches to “holiday” mode Operating Instructions T4e | B1560520_en...

  • Page 46: Switch The Boiler On/Off On The Room Console

    Operating the System Switch the boiler ON/OFF on the room console Tap the “suitcase” icon to prematurely end the holiday program. The boiler then switches to the previously activated mode (“water tap” symbol = domestic hot water, “water tap/radiator” symbol = automatic). 4.5 Switch the boiler ON/OFF on the room console Prerequisite: ▪...

  • Page 47: Switching Off The Power Supply

    ➥ Boiler controller is switched off ➥ 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! Operating Instructions T4e | B1560520_en...

  • Page 48: Checking The Fill Level Of The Ash Container And Emptying If Required

    Operating the System Checking the fill level of the ash container and emptying if required 4.7 Checking the fill level of the ash container and emptying if required 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 49 ❒ Replace the ash container in the boiler and clamp with the locking lever ➥ The crescent of the carrying bar should be pointing towards the boiler! ❒ Push the key plate into the safety switch ❒ Close the insulating door Operating Instructions T4e | B1560520_en...
  • Page 50 Operating the System Checking the fill level of the ash container and emptying if required Starting at boiler type 200: In “Boiler off” status: ❒ Open the insulated door (A) ❒ Remove the key plate (B) from the safety limit switch ❒...

  • Page 51: Servicing The System

    ❒ Before starting work, switch off the boiler and allow it to cool down for at least 1 hour NOTICE We recommend that you keep a maintenance book in accordance with ÖNORM M7510 of the Technical Directive for Fire Prevention (TRVB) Operating Instructions T4e | B1560520_en...

  • Page 52: Required Tools

    Servicing the system Required tools 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: ❒...

  • Page 53: Maintenance Work By The Operator

    If large pressure fluctuations are observed: ❒ Ask an expert to inspect the expansion tank Check the thermal discharge valve (from T4e 130) ❒ Check the seal of the discharge valve ➥ The discharge pipe must not drip NOTICE! Exception: Boiler temperature >...

  • Page 54: Checking The Quick Vent Valve

    Servicing the system Maintenance work by the operator Checking the quick vent valve ❒ Regularly check all the quick vent valves on the entire heating system for leaks ➥ If any liquid is leaking, replace the quick vent valves NOTICE! The vent cap (A) must be loose (screw on approx. two revolutions) to ensure correct functioning.

  • Page 55: Recurrent Check And Cleaning

    ❒ Activate “service mode” in the quick menu ➥ The boiler starts the cleaning module and removes any remaining ash in the combustion chamber ➥ Once self-cleaning is finished the boiler switches to "Boiler off" status. Operating Instructions T4e | B1560520_en...

  • Page 56: Lubricate The Stoker Bearings [~1000 B/Every Six Months]

    Servicing the system Maintenance work by the operator Lubricate the stoker bearings [~1000 B/every six months] ❒ Lubricate stoker bearings with three grease gun strokes per grease nipple Check chain and sprockets [~1,000 operating hours / every six month] Kettenspanner nicht einstellbar!! (prl, 10.07.2020) ❒...
  • Page 57 ❒ Check the firebricks and combustion grate for dirt and deposits and clean if necessary ❒ Close the combustion chamber door by turning the Allen wrench (90°) ➥ A – Notch in screw cap vertical: Door open ➥ B – Notch in screw cap horizontal: Door closed Operating Instructions T4e | B1560520_en...

  • Page 58: Clean Heat Exchanger And Flue Gas Collection Chamber [~2500 Bh/Yearly]

    Servicing the system Maintenance work by the operator Clean heat exchanger and flue gas collection chamber [~2500 Bh/yearly] T4e 20-60: T4e 80-350: ❒ Remove the insulating cover and thermal insulation T4e 20-60: ❒ Loosen the lock nuts on both star-shaped screw knobs ➥...

  • Page 59: Clean The Flue Gas Temperature Sensor [~2500 Bh/Yearly]

    ❒ Plug in the connection cable of the induced draught fan Check the draught regulation damper [~2500 Bh/yearly] ❒ Check that the draught controller flap moves freely Operating Instructions T4e | B1560520_en...

  • Page 60: Maintenance Work By Technicians

    Servicing the system Maintenance work by technicians 5.4 Maintenance work by technicians CAUTION If maintenance work is carried out by untrained personnel: Risk of personal injury and damage to property! The following applies for maintenance: ❒ Observe the instructions and information in the manuals ❒...

  • Page 61: Checking And Cleaning The Combustion Grate

    ⇨ See "Checking the fill level of the ash container and emptying if required" [page 48] ❒ Remove the left and right screws on the front cover plate ❒ Slide the cover plate up and remove Operating Instructions T4e | B1560520_en...

  • Page 62: Cleaning The Lambda Probe

    Servicing the system Maintenance work by technicians ❒ Loosen the twin wire clamp with pliers and remove the measurement line from the under-pressure sensor cartridge ❒ Clean the measurement line with gentle compressed air ➥ WARNING! Do not direct compressed air into under-pressure sensor cartridge! This could damage it! ❒...
  • Page 63 ▪ Do not clean the Lambda probe with compressed air ▪ Do not use chemical cleaning agents (brake cleaner, etc.) ▪ Careful handling of the Lambda probe, no “tapping” or cleaning with a wire brush Operating Instructions T4e | B1560520_en...

  • Page 64: Clean The Particle Filter (Optional) And Heat Exchanger Pipes

    Servicing the system Maintenance work by technicians 5.4.4 Clean the particle filter (optional) and heat exchanger pipes NOTICE! Remove the particle filter before cleaning the heat exchanger. Remove and clean the particle filter (optional) For all electrodes and housings of the particulate filter compliance with the following steps is mandatory: ❒...

  • Page 65: Cleaning The Heat Exchanger Pipes

    ❒ Undo the screw connections on the WOS shaft and pull out all shafts ❒ Take off the rear cover from the flue gas nozzle and remove the thermal insulation ❒ Loosen the locking screws using the enclosed spanner Operating Instructions T4e | B1560520_en...
  • Page 66 Servicing the system Maintenance work by technicians ❒ Remove the cleaning cover ❒ For existing e-filter: Remove the earthing bracket from the WOS springs ❒ Pull out the WOS springs ❒ Clean the heat exchanger pipes and WOS springs ❒ Assemble all of the components in reverse order Caution when installing WOS springs:...

  • Page 67: Adjust The Power Of The Wos System

    ❒ Push the lever up and attach it at the applicable hole of the console (C) using the non-threaded stud and spring cotter pin EFFECT: The more tension is applied to the spring, the less force is required to clean the WOS pipes, and the more the impact is damped. Operating Instructions T4e | B1560520_en...

  • Page 68: T4E 80-180

    Servicing the system Maintenance work by technicians T4e 80-180 ❒ Remove the geared motor from the back of the boiler ❒ Remove the three back panels ❒ Push the clamping lever (A) to the right, against the spring’s force, and remove the spring cotter pin and the non-threaded stud ❒...

  • Page 69: T4E 200-350

    ❒ Use the spring cotter pin and non-threaded stud to attach the clamping lever to the applicable hole of console (C) EFFECT: The more tension is applied to the springs, the more force is applied to clean the WOS pipes, and the impact is increased. Operating Instructions T4e | B1560520_en...

  • Page 70: Emissions Measurement By Chimney Sweep Or Regulatory Body

    Servicing the system Emissions measurement by chimney sweep or regulatory body 5.5 Emissions measurement by chimney sweep or regulatory body Various legal regulations stipulate that heating systems must be inspected periodically. In Germany this is regulated by the First Federal Emissions Protection Ordinance (BimSchV) in the last amended version, and in Austria by various state laws.

  • Page 71: Start Emissions Measurement

    (e.g. AWG in Austria) ❒ You can separate and clean recyclable materials and send them to a recycling centre. ❒ The combustion chamber must be disposed of as builders' waste. Operating Instructions T4e | B1560520_en...

  • Page 72: Troubleshooting

    Troubleshooting General fault with power supply 6 Troubleshooting 6.1 General fault with 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 73: Faults With Fault Message

    The error display lists all current faults ❒ Open by tapping the listed fault ❒ The “Message” tab displays the current fault. ❒ Press the “Error resolution” tab to view possible causes and troubleshooting procedures Operating Instructions T4e | B1560520_en...
  • Page 74 Troubleshooting Faults with fault message ❒ Tap the Cancel icon to close the current fault and display the fault list ❒ Tap the Cancel icon again and confirm that you have read all of the errors to return to the basic display ➥...

  • Page 75: Notes

    Notes 7 Notes Operating Instructions T4e | B1560520_en...

  • Page 76: 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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