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Related Manuals for Fröling Lambdamat LM 800
Summary of Contents for Fröling Lambdamat LM 800
- Page 1 Installation instructions Lambdamat LM 800-1000 KOM Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M1650422_en | Edition 18/08/2022...
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Page 2: Table Of Contents
5.6.8 Fitting thermal insulation to the boiler ..................32 5.6.9 Fitting the insulation base frame ....................33 5.6.10 Mount the side panels and safety temperature limiter (STL) ............. 36 5.6.11 Assembling the covers....................... 39 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 3 6.3 Heating up for the first time ........................68 6.3.1 Screed drying..........................69 7 Decommissioning ............................70 7.1 Out of service for long periods ......................70 7.2 Disassembly............................70 7.3 Disposal ..............................70 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 4: General
Froling. On commissioning by FROLING Customer Service the validity of the delivery certificate will be noted on the customer service record. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
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. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 6: Qualification Of Assembly Staff
You must ensure that staff have the protective equipment specified by accident prevention regulations! ▪ During transport, erection and installation: - wear suitable work wear - wear protective gloves - wear safety shoes (min. protection class S1P) M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
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) M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 8: Regulations And Standards For Permitted Fuels
▪ Installation at altitude higher than 2000 metres above sea level only after consultation with the manufacturer ▪ The system must be protected against gnawing and nesting by animals (such as rodents) ▪ No flammable materials in proximity to the system M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 9: Chimney Connection/Chimney System
EN 303-5 specifies that the entire flue gas system must be designed to prevent, wherever possible, damage caused by seepage, insufficient feed pressure and condensation. Please note within the permissible operating range of the boiler flue gas temperatures lower than 160K above room temperature may occur. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 10: Connection Line To The Chimney
▪ 1.5 x nominal diameter of connection line for radiation shield with rear ventilation, but at least 200 mm (NM) NOTICE! The minimum distances must be observed in accordance with the standards and guidelines applicable in the region M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 11: Measuring Port
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the pressure is constantly low at this point. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 12: Domestic Hot Water
1. For calculating the specific system volume, the smallest individual heating capacity is to be used for systems with several heat generators. 2. In systems with several heat generators with different specific water contents, the smallest specific water content is decisive in each case. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 13: Pressure Maintenance Systems
These systems offer no oxygen removal for the purposes of corrosion control as required by VDI 2035 and in the interests of corrosion protection should not be used. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 14: Storage Tank
Take the following precautions: r Regulations stipulate the use of a return temperature control. Ä The minimum return temperature is 60 °C. We recommend fitting some kind of control device (e.g. thermometer). M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 15: Technical Information
2,690 Length of boiler 3,540 Length of compressed air cleaner (optional) Length, flue gas collection box 1. Base required when ash is removed from the combustion chamber into the lateral ash container M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 16: Components And Connections
450 mm FGR (flue gas recirculation) connection 300 mm Broadband probe connection Flue gas temperature sensor connection Safety valve connection (provided by the customer) DN65 / PN 6 Drainage connection 2“ IT M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 17: Technical Specifications
1. Electric fuses and power consumption vary depending on design and features 2. > 95 °C upon request 3. Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels” M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 18 2. Electric fuses and power consumption vary depending on design and features 3. > 95 °C upon request 4. Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels” M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
- Page 19 Draught requirement at ID fan outlet at partial load mbar 0.02 Recommended maximum chimney draught mbar Flue gas pipe diameter 1. only available in Great Britain 2. use the maximum attainable oxygen content for chimney design M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 20: Installation
Store components at a protected location, which is dry and free from dust Ä Damp conditions and frost can damage components, particularly electric ones! 5.3 Positioning r Secure the slings or chains to the hooking point securely and position the boiler M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 21: Fitting The Ash Duct For Removing Ash From The Combustion Chamber (Optional)
TIP: Mount the ash channel also when the combustion chamber is used in as follows r Fit the ash duct to the underside of the combustion chamber - 8 hexagonal screws M10 x 30 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 22: Positioning At The Installation Site
(ÖNORM H 5190 - Noise protection measures) 3,380 mm 700 mm 1,740 mm (2,100 mm for dismantling the ash screw for maintenance tasks) Stoker: 2,240 mm hydraulic slide-on duct: 3,000 mm 1,400 mm 3,740 mm 4,000 mm M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 23: Laying Firebricks In The Combustion Chamber
Insulating panel I (30x88x1200mm) Crossbar C (124x196x1182mm) Insulating panel J (30x950x1200mm) Support A (130x198x504mm) Insulating panel K (30x950x1200mm) Support B (124x130x198mm) Air nozzles Arch brick Ceramic fibre mat A Arch anchor brick M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 24: General
▪ The fireclay lining is fully assembled in the combustion chamber and is secured by a wooden structure for transport; the arch bricks are included in the delivery. Ü "Laying arch bricks" [} 26] M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 25: Laying Firebricks
The included fireclay diagram shows the exact layout of all firebricks, ceramic fibre mats and insulating panels. For the sake of simplicity, all normal bricks and expansion joint bricks of AK60 quality appear slightly darker in the fireclay diagram. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 26: Laying Arch Bricks
Lay 18 rows of arch brick from back to front on top row of supports Ä Position a ceramic fibre mat in front of the first row and after the tenth row M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 27: Installing The Boiler
▪ Page 1: Air regulator for primary air (A), bottom grate temperature sensor (B) and combustion air fan (C) ▪ Page 2: Vacuum transmitter (D), burning chamber excess pressure monitor (E), combustion chamber temperature sensor (F) und FGR blower fan (G) M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 28: Bolting Together The Combustion Chamber And Heat Exchanger
Remove the 1/2” blanking plugs for the under-pressure controller and undergrate sensor (3) from both sides Ä The underpressure controller is later fitted to one side and the undergrate sensor to the other M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 29: Fitting The Immersion Sleeves For The Thermal Discharge Valve And Undergrate Sensor
5.6.4 Fitting the immersion sleeves for the thermal discharge valve and undergrate sensor. r Seal the immersion sleeves for the thermal discharge valve in top of heat exchanger r Seal the immersion sleeve for undergrate sensor on left or right-hand side of boiler M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 30: Installing The Stoker Unit
Mount the hydraulic stoker unit onto the slide-on duct and align it with the adjustable feet. - 12 hexagonal screws M16 x 60 r Fit the discharge system (feed screw, etc.) according to the installation instructions enclosed M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 31: Installing The Air Controllers
When using a combustion air fan on the left-hand side of the boiler, the air duct must be converted, following these steps: r Dismantle air duct (5) and blanking plate (6) and mount on opposite side - 10 self-tapping hexagonal head screws M8 x 25 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 32: Fitting Thermal Insulation To The Boiler
Fit the heat insulation mats to the left and right of the boiler and secure with tension springs r Make cutouts in the heat insulation mats at all the required places M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 33: Fitting The Insulation Base Frame
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 Bottom lengthways struts Crossbar Top lengthways struts "Portal“ lengthways struts M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 34 Hang the “Portal” (4) frame element and bottom cross-piece (5) to the support elements and attach them in place - top: 4 lens-head screws M6 x 12 - bottom: 2 lens-head screws M6 x 12 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
- Page 35 Attach the front center (12) of the cross piece to the lateral support elements - 4 lens-head screws M6 x 12 r Attach the bottom-left (9) and top (10) to the lateral support elements - 4 lens-head screws M6 x 12 for each support element M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 36: Mount The Side Panels And Safety Temperature Limiter (Stl)
Mount the side panels to the flue gas chamber - 20 lens-head screws M6 x 12 r Install side panel at the bottom of the flue gas chamber - 12 lens-head screws M4 x 8 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 37 - lens-head screws M4 x 8 (quantity depending on position) Ä Caution: At the same time, attach the safety temperature limiter to the front side panel (1) - see next assembly steps M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
- Page 38 Install the cover on the side panel r Mount four covers on both sloping sides - 10 lens-head screw M6 x 12 for each cover r Place the top cover onto the boiler M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 39: Assembling The Covers
▪ Fit the cover plate with the cut-out (6) to the side of the air controller for primary air, fit the cover plate without the cut-out (7) to the opposite side ▪ If using boilers with flue gas recirculation (FGR) do not instsll the cover plates (7, 8) M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 40: Fitting The Door Contact Switch
Install the cover plate onto the burning chamber door - 4 self-tapping hexagonal screws M8 x 16 r Install the handle onto the burning chamber door - 2 hexagonal screws M8 x 25 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 41 (3) r Attach the screws (1) on the key plate (2) r Lay the connecting cable through the opening in the frame element and then onwards to the control cabinet M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 42: Install The Ash Removal Unit Of The Combustion Chamber Onto The Lateral Ash Container (Optional)
Install the flange plate (2) and seal (3) onto the ash duct - 4 hexagonal screws M10 x 25 r Install the bearing flange (4) on the flange plate (2) - 4 hexagonal screws M12 x 25 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 43 Push the ash container onto the ash removal flange and use handle to lock it into place r Push the key plate into the safety switch r Set the safety switch so that the key plate engages correctly r Tighten the screws on the safety switch M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 44: Installing The Underpressure Controller
Unscrew the connector box cover and connect the compensating line as follows: - green wire to the terminal with the green dot - white wire to the unmarked terminal - do not connect the shield M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 45: Fitting The Broadband Probe And Sensors
Fit the sensor box to the base frame of the insulation or to the insulation at eye level r Push the return feed sensor (6) and boiler sensor (7) into the immersion sleeve r Push the undergrate sensor (8) into the immersion sleeve opposite the underpressure controller M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 46: Installing The Servo-Motors
Push the servo-motors for the primary air (2) and tertiary air (3) onto the pneumatic rods at the specified side; then fasten it using the torque support Ä Picture shows servo-motors on right-hand side of boiler M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 47: Fitting The Combustion Air Fan
NOTICE! Ensure to install automatic ignition equally on both sides of the boiler. r Insert the ignition fan (3) into the igniter tube (1) and secure using the double wire hose clip (2) r Install the cover - 4 lens-head screws M4 x 8 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 48: Fitting An Additional Ignition For Hydraulic Stoker Unit (Optional)
Remove the blanking plugs above der hydraulic stoker unit r Insert the igniter tube r Insert the ignition blower into the igniter tube and fix in place using the double screw clip M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 49: Fitting The Reversing Chamber Door
Hang the reversing chamber door on the hinges on the right-hand side of the boiler with ring bolts r Close the reversing chamber door and tilt the ring bolts forwards with the knob r Tighten the triangle star knob so that the door is securely closed M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 50: 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 air distribution frame r Push the hose onto the hose screw connection on the compressed air tank and air distribution frame M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 51: Fitting The Ash Sliding System (Optional)
Install the lower ash slide valve (E) and seal to the to the upper ash slide valve and onto the brackets (D) - 12 hexagonal screws M10 x 45 - 4 hexagonal screws M12 x 45 M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 52: Installing Flue Gas Recirculation Fgr (Optional)
Cut out the heat insulation mat and remove it r Remove the blanking plate and seal r Install the pipe between the secondary air box and the boiler - 8 hexagonal screws M10 x 30 for each flange M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 53 Ä Use suitable mounting material for each substrate r Install the cover plates onto the right and left-hand side of the boiler - lens-head screws M4 x 8 (quantity depending on position) M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
- Page 54 Fit the angle bracket to the FGR blower fan - 2 hexagonal screws M8 x 20 r Establish potential equalisation from secondary air box to FGR blower fan M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
- Page 55 - 8 hexagonal screws M10 x 30 Ä Establish the potential equalisation r Install flue gas damper (A) in flue gas piping r Feed flue gas to the on-site flue gas system, e.g. with T-piece (B – optional) M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 56: Assembling The Fgr Underpressure Controller (Optional)
The induced draught fan and FGR fan can be fitted to different types of brackets. The following steps explain how to fit the induced draught fan to a wall bracket. Proceed in the same way accordingly to fit to other brackets and to fit the FGR fan. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 57 Fit the bracket IMPORTANT: Insulate all piping, collection boxes, induced draught fan and FGR blower fan on site! Make sure the drive assemblies of the blower fans can still be removed. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 58: Hydraulic Connection
▪ Unhindered and safe escape of the steam or water that is released must be ensured Return temperature control Diaphragm expansion tank M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 59: 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 r Turn the rotary drive clockwise by approx. 90° until both torque supports (E) of the drive match the bores (F) on the zone valve M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 60 Set the high-limit thermostat (STL) to 105 °C and install it according to the installation manual for the boiler M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 61: Connecting Up The Slide-On Duct Cooling
▪ 500 - 1500 kW rated heat output: place flow rate approx. 2.5 m 9 Safety valve DN15 10 Connection cable (only required for hydraulic feed systems) M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 62: Power Connection And Wiring
Ä Item 1: Earth connection r Establish potential equalisation to all boiler components Ä Fuel outfeeder, ash removal, induced draught fan, FGR blower fan, flue gas pipe, pipes, control cabinet etc. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 63: Final Installation Steps
Ä If the paper cannot be removed: door is tightly sealed. Ä If the paper can be removed: door is not sealed properly – tighten the locking hook! Ü "Positioning the burning chamber and combustion chamber door" [} 64] M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 64: Positioning The Burning Chamber And Combustion Chamber Door
Loosen the nut on the locking hook r Tighten or loosen the locking hook as required r Fix in place using lock-nuts M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 65: 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. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 66: Compressed Air Cleaner (Optional)
Fuel as per EN 17225 – Part 4: Wood chips class A1 / P16S-P45S Additional for Fuel class 4 (§3 of the 1st Federal Emissions Protection Ordinance (BimSchV) Germany: in the last amended version) M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 67 Therefore: r If the fuel is changed (e.g. from wood chips to pellets), the system must be reset by Froling customer services. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
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Page 68: Non-Permitted Fuels
Provide the following quantities of dry firewood: Ä Systems up to 250 kW: ¼ m³ Ä Systems up to 500 kW: ½ m³ Ä Systems up to 1500 kW: 1 m³ M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 69: Screed Drying
Close the combustion chamber door. r Leave the boiler in this state for a few hours (ideally overnight). The boiler can then be used in accordance with the operating instructions ("Operating the system" section). M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... -
Page 70: Decommissioning
(e.g. AWG in Austria) r You can separate and clean recyclable materials and send them to a recycling centre. r The combustion chamber must be disposed of as builders' waste. M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM... - Page 71 Notes M1650422_en | Installation instructions Lambdamat LM 800-1000 KOM...
- Page 72 Manufacturer’s address Froling srl Froling SARL Fröling Heizkessel- und Zweigniederlassung Behälterbau GesmbH Aschheim Industriestraße 12 Max-Planck-Straße 6 Via J. Ressel 2H 1, rue Kellermann A-4710 Grieskirchen 85609 Aschheim I-39100 Bolzano (BZ) F-67450 Mundolsheim +43 (0) 7248 606 0 +49 (0) 89 927 926 0 +39 (0) 471 060460 +33 (0) 388 193 269 info@froeling.com...
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