Page 1 Service manual Control System SPS 4000 V. 2.0.220 Translation of the original German operating instructions for technicians and operators Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! B0960622_en | Edition 17/10/2022 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 2: Table Of Contents
Table of contents 5.1 Environment 1 General 5.1.1 Distributor 1... 4 Settings 1.1 Safety information Storage tank distributor 1... 4 Network circuit 1... 2 2 Overview of the basic functions Heating circuit 1... 10 DHW tank 1... 5 2.1 Touch display 5.1.2 Settings for direct heat distribution 5.1.3 Storage tank 2.2 Control icons...
Page 3 Discharge / configurations 5.8.6 Ash removal 9 Appendix 5.8.7 Flue gas treatment 9.1 Addresses 5.8.8 Inputs & outputs 9.1.1 Address of manufacturer 5.8.9 Operation hours 9.1.2 Address of the installer 5.8.10 Backup & restore Service manual SPS 4000 | B0960622_en...
Page 4: General
Subject to technical change. About these instructions The range of functions of the SPS 4000 depends on the user level currently set. These instructions show all the parameters that are available with full functionality in the "Service" user level (maximum configuration with all possible system components).
Page 5: Safety Information
❒ Insulate the flue gas pipes and do not touch them during operation The information on safety, standards and guidelines in the assembly and operating instructions for the boiler should also be observed! Service manual SPS 4000 | B0960622_en...
Page 6: Overview Of The Basic Functions
Overview of the basic functions Touch display 2 Overview of the basic functions 2.1 Touch display Standby icon for switching the system on/off with display of the current system status Navigation area for quick switching between the start page and the individual menus Display area for the selected menu Area for status displays (Ethernet, USB etc.) Quick selection area...
Page 7: Control Icons
The information is ordered in a circular buffer. The up and down arrows are used to switch between the individual pages. Quick select icon Opens the quick menu. Various functions are available depending on the user level, system configuration and current status. Service manual SPS 4000 | B0960622_en...
Page 8: Operating Statuses
Overview of the basic functions Operating statuses 2.3 Operating statuses Availability of the listed operating statuses depend on the set boiler type! Fault* The boiler is shut down. Error messages or alarms that have not been acknowledged are displayed. Off* The boiler is shut down and ready to start.
Page 9 (e.g. logs). *static state: These states last until they are changed by interactions or other external influences. All of the other states are only temporary and have a maximum duration. Service manual SPS 4000 | B0960622_en...
Page 10: Operation
Operation Switching the boiler on/off 3 Operation 3.1 Switching the boiler on/off BOILER ON The boiler is switched on. The boiler system is controlled according to the programs and times set. BOILER OFF The PLC shuts down the boiler in a controlled way. After the shut down procedure, the boiler switches to the “OFF”...
Page 11: Trend Display
Start/stop automatic scrolling of the trend display; left arrow / right arrow to move the trend display along the time axis. Scaling of the time axis as a value input or incrementally by tapping the respective magnifying glass icon. Service manual SPS 4000 | B0960622_en...
Page 12 Operation Trend display Tapping on a current value opens the configuration: Maximum value of the current value for the value axis. Minimum value of the current value for the value axis. Dropdown field to select the current value. Specifies whether the current value is to be displayed as a trend line. Visibility can be changed during the recording by tapping the eye icon.
Page 13: Manual Operation
❒ Press the menu item in the right column ➥ The lower menu level is displayed and the current menu level moves one column to the left ➥ When the lowest menu level is reached, the corresponding parameters are displayed Service manual SPS 4000 | B0960622_en...
Page 14: Displaying/Changing Parameters
Operation System menu Displaying higher-level menu items ❒ In the address line tap on the back icon ➥ The current menu level moves one column to the right 3.4.1 Displaying/changing parameters It is only possible to view or edit parameter details if there is a pen icon beside the parameter value: ❒...
Page 15 ❒ Tap the numeric keypad icon or value field ➥ The Enter values window for parameters will appear ❒ Type in the relevant value on the numeric keypad ❒ Confirm your entry by tapping the confirm icon Service manual SPS 4000 | B0960622_en...
Page 16: Fault Information
Operation Fault information 3.5 Fault information If a fault occurs in the system, the warning symbol flashes in the quick selection area. ❒ Tap the warning symbol in the quick selection area ➥ The list of the faults that are currently present is displayed ❒...
Page 17: Quick Functions
The code for this user level is provided by Fröling during the user training. Service Accessible via the USB stick using the licence file or one-off password. For the configuration and commissioning of the system and access to the control parameters. Service manual SPS 4000 | B0960622_en...
Page 18: User Levels With Static Code
A USB stick with a licence file is required to switch to the “Service” user level. The required file is available in the Fröling partner area for authorised users. If the SPS 4000 detects a valid licence file on the connected USB stick, it automatically switches to the “Service” user level. Tapping the service icon displays the licence file data.
Page 19: Service" User Level With One-Off
❒ Tap the date and time area on the start screen ➥ The menu for setting the date and time will appear ❒ Tap the desired display value to change it ➥ Numeric keypad for changing the value is displayed Service manual SPS 4000 | B0960622_en...
Page 20: Obtain Data Via Time Server
Setting the date and time 3.9.1 Obtain data via time server If the SPS 4000 is connected to a network via an Internet connection or local time server, the automatic retrieval of the date and time is recommended. ❒ In the system menu, navigate to the submenu “PLC” ➾ “Date & Time”...
Page 21: Initial Startup
➥ After the system start of the controller, the boiler type is set to the default “Turbomat TM 150” and the SPS hardware is not configured ❒ Before setting the boiler type, perform a software update and start the hardware detection Service manual SPS 4000 | B0960622_en...
Page 22: Changing The Language
Initial startup Changing the language 4.3 Changing the language ❒ Tap the quick select icon on the start screen ❒ Open the language selection by tapping the language icon ❒ Open the drop down menu by tapping the arrow icon ❒...
Page 23 ➥ This method works both with the compressor integrated in Windows and all others, for example: WinZip, 7zip, WinRAR, etc. ❒ Connect the USB stick with the update information to the USB interface of the SPS Service manual SPS 4000 | B0960622_en...
Page 24: Perform Hardware Detection Manually
4.5 Perform hardware detection manually Automatic hardware detection is performed after a software update or a cold start of the SPS 4000. In case of an error or to perform a check, this procedure can also be done manually. The detection is carried out in four steps;...
Page 25 ➥ Configuration file is generated from the components found. The process can take a moment depending on the hardware installed. ❒ Tap to finish ➥ Configuration file is written to the system directory and the SPS restarts Service manual SPS 4000 | B0960622_en...
Page 26: Configuring The System
Initial startup Configuring the system ❒ After the SPS has restarted, open the "Hardware" menu from the start screen and check that the list of components found is correct. 4.6 Configuring the system NOTICE! The complete configuration of the system is only possible in the “Service” user level. As inputs can have an impact on subsequent menu items, the order of this menu structure, starting with the “System &...
Page 27: Finishing Configuration
DN 50. ❒ Turn on the main switch ❒ Set the boiler controller to the system type. ❒ Load the boiler default values. ❒ Check the system pressure of the heating system Service manual SPS 4000 | B0960622_en...
Page 28 Initial startup Before commissioning / configuring the boiler ❒ Check that the heating system is fully ventilated ❒ Check all quick vent valves of the entire heating system for leaks NOTICE! The factory-fitted quick vent valve of the pellet unit is located behind the front insulated door ❒...
Page 29: Menus And Parameters
The speed control of the distributor pump is limited to this value (e.g. in case of a systemic adjustment of the maximum pump speed). Storage tank distributor 1... 4 System menu Environment Distributors Storage tank ⇨ See "Storage tank" [page 31] Service manual SPS 4000 | B0960622_en...
Page 30: Network Circuit 1
Menus and parameters Environment Network circuit 1... 2 System menu Environment Distributors Network circuit ⇨ See "Network circuit 1... 2" [page 32] Heating circuit 1... 10 System menu Environment Distributors Heating circuit ⇨ See "Heating circuit 1... 10" [page 34] DHW tank 1...
Page 31: Settings For Direct Heat Distribution
It must be taken loading setpoint at +10°C” parameter would produce a into account that 0% corresponds to the minimum storage lower value. tank charge. If, for example, the “Storage tank loading Service manual SPS 4000 | B0960622_en...
Page 32: Network Circuit 1
Menus and parameters Environment Storage tank temperature average value at 0% loading Storage tank distributor 1...4 mode maintain the required storage tank charge beforehand This average temperature in the storage tank means 0% instead. This gives a range within which the boiler can storage tank charge.
Page 33 Defines the flow temperature setpoint if the fixed specified setpoint and actual value for warning message setpoint is set. If the current flow temperature is lower than the calculated flow temperature setpoint, a warning is issued. Service manual SPS 4000 | B0960622_en...
Page 34: Heating Circuit 1
Menus and parameters Environment Network circuit 1…2 flow temperature control Network circuit 1…2 flow temperature control ▪ Weather-compensated: Setpoint is modified based on Defines whether there is a specified setpoint for the flow the outside temperature and the parameters specified temperature and which value is used.
Page 35: Dhw Tank 1
If the heat source (boiler or storage tank) has enough completed. energy, DHW tank loading will remain active until the set loading increase is reached (“DHW tank loading temperature minimum difference for loading” parameter). Service manual SPS 4000 | B0960622_en...
Page 36: System Connection
Menus and parameters System connection 5.2 System connection 5.2.1 Cascade System menu System connection Cascade 0% output demand stage 1 at output requirement 100% output demand stage 2 at output requirement Specifies the output at 0% output demand during stage 1. Specifies the output at 100% output demand during stage 1.
Page 37: Boiler
0-10 V signal to an analogue input ▪ ModBus: The boiler temperature setpoint is specified by an external control system to the modbus interface ▪ Manual: The manual value is used to specify the output Service manual SPS 4000 | B0960622_en...
Page 38: Chimney Sweep
Menus and parameters Boiler Chimney sweep System menu Boiler Modes Chimney sweep Chimney sweep mode heating time Relative reduction of grate control during chimney sweep mode The time set here specifies the length of time for which the chimney sweeper function is carried out. As soon as the The grate control is reduced by this value during chimney chimney sweeper function is started the remaining time is sweep mode.
Page 39: Shut Down For Cleaning
(similar to winter mode). Please note that the parameter should be disabled again after the measurement has been carried out (= set to "0"). Service manual SPS 4000 | B0960622_en...
Page 40: Boiler Settings
Menus and parameters Boiler 5.3.2 Boiler settings System menu Boiler Boiler settings Boiler stops automatically in continuous load when no heat Pump run-on required Time the boiler loading pump continues to run for after the Do you want the boiler to switch off automatically in boiler has shut down (boiler status off, standby, shutdown continuous load mode, when there is no heat consumption etc.).
Page 41 3-point return mixer has had enough pump are activated. time to adjust to the new setpoint and the new return temperature has also had an effect on the boiler Service manual SPS 4000 | B0960622_en...
Page 42: Air Damper/Blower Fan
Menus and parameters Boiler 5.3.4 Air damper/blower fan Blower fan and air duct system System menu Boiler Air damper/ Blower fan and blower fan air duct system Primary air when boiler off Secondary air opening at 100% control Specifies the primary air value when the boiler is "Off". Specifies the secondary air flap position at 100% secondary air (setting range 0 –...
Page 43 100%. elapsed approximately five times. The parameter has an attenuating function on the output signal of the tertiary air, thereby preventing the tertiary air flap from opening too quickly. Service manual SPS 4000 | B0960622_en...
Page 44: Fgr
Menus and parameters Boiler Air flap secondary1 stop 0% opening Air flap tertiary1 stop 0% opening If the value is below this, the flap is detected as being If the value is below this, the flap is detected as being closed.
Page 45 Due to tolerances in the return signal, an open flap may return an opening of just under 100%. Specifies which curve will be used to control the FGR primary air from the stop point until the maximum combustion chamber temperature is reached. Service manual SPS 4000 | B0960622_en...
Page 46: Frequency Converter
Menus and parameters Boiler Frequency converter Induced draught FC System menu Boiler Air damper/blower fan Frequency converter Induced draught FC ID fan elapse time (P110) ID fan minimal frequency (P104) Specifies the maximum speed of changes to the control. Minimum frequency to which the motor can be controlled. Peaks are attenuated thus protecting the fans.
Page 47: Lambda Probe
Once the set time in hours in the “Off” operating status has elapsed, calibration of the Lambda probe starts No infeed below residual oxygen content automatically. Specifies the residual oxygen content in percent under which the material infeed is stopped. Service manual SPS 4000 | B0960622_en...
Page 48: Calibration
Menus and parameters Boiler Calibration System menu Boiler Lambda probe Calibration Delete calibration values The calibration data of the Lambda probe will be deleted and set to the default value (21% oxygen = 10 V at analogue input). 5.3.6 Ignite System menu Boiler Ignite...
Page 49: Flue Gas
If the difference between the flue gas temperature and the boiler temperature in “heating" status falls below this Specifies the attenuation of the flue gas control. specified value, the “safety time expired" error will appear after a safety time (“safety time” parameter). Service manual SPS 4000 | B0960622_en...
Page 50: Filter
Menus and parameters Boiler 5.3.8 Filter System menu Boiler Filter Use filter? Filter rotary valve cycle Specifies whether a filter is used. Cycle time of the rotary valve at the filter. Once this time has elapsed, the rotary valve is switched on for a defined amount of time.
Page 51: Heat Exchanger
Manual heat exchanger The menu is used to test and calibrate the WOS. The calibration is only possible if the corresponding inputs and outputs are configured. ⇨ See "Perform hardware detection manually" [page 24] Service manual SPS 4000 | B0960622_en...
Page 52 Menus and parameters Boiler WOS not calibrated The default values are used for the WOS controller. Start WOS calibration Five cycles are completed and the average time is calculated. The limit values are calculated from this average. Once the calibration is completed, the WOS is in the “calibrated” state and the determined values are used for the controller.
Page 53: Grate
Grate control during heating up and shutting down If this temperature is exceeded under the grate, the power Control of the grate in the operating statuses heating up is reduced to min and the temperature is observed. and shutting down Service manual SPS 4000 | B0960622_en...
Page 54: Ash Removal
Menus and parameters Boiler Duration of infeed reduction when max. temp. under grate Duration till shutdown when max. temp. under grate exceeded exceeded Time the boiler delivers minimum output to cool the grate Time to observe undergrate temperature after it was too high 5.3.12 Ash removal System menu...
Page 55: Joint Ash Removal
When the temperature in the slide-on duct rises by the set value, a warning message appears on the display. When the criteria for switching off is reached, the slide-on duct cooling continues to remain active for the set time. Service manual SPS 4000 | B0960622_en...
Page 56: Control Parameters
Menus and parameters Boiler 5.3.15 Control parameters System menu Boiler Control parameters Power calculation attenuation Induced draught Tn Specifies the delay time in seconds, when the DDC signal Reset time of the PI controller for the induced draught. is changed from 0 to 100%. Boiler-Kp Min.
Page 57: Fuel Feed
"slumber" or "Off") the stoker screw is controlled in cycles burn back flap is closed during ignition. until the time arrives to empty the stoker and prevent a burn back. Service manual SPS 4000 | B0960622_en...
Page 58: Conveyor
Menus and parameters Fuel feed Delay error overfilling rotary valve Maximum empty stoker time The time by which an error message is delayed when the If it is not clear during this time that the stoker is empty, an overflow sensor of the rotary valve activates. error is issued.
Page 59: Hopper 1
40 seconds and the pause time is 32 seconds. is triggered. The switching of the two parameters is defined by the current consumption of the hopper. Low current consumption = bunker empty, high current consumption = bunker full. Service manual SPS 4000 | B0960622_en...
Page 60: Chamber Discharge System Sliding Floor
Menus and parameters Fuel feed 5.4.5 Chamber discharge system Sliding floor System menu Fuel feed Chamber discharge system Sliding floor Sliding floor startup delay Sliding floor automatic run runtime If the light barrier of the filling level monitor to the transfer Specifies the duration of the automatic run.
Page 61: Rotary Agitator
Fuel Drying feed Maximum duration drying system fault The fault message of an external drying system can be evaluated. After this time has elapsed, an error is issued and the system is switched off. Service manual SPS 4000 | B0960622_en...
Page 62: Plc
Menus and parameters 5.5 PLC 5.5.1 Date & time System menu Date & Time Setting times Time zone Local settings: The date and time must be set manually Selection of local UTC zones. NTP time server: Date and time are obtained from a time Automatic switching between summer and winter time server In a network environment with Internet access, the SPS...
Page 63: Network
Defines how long the set operator level remains active within this time, the screen saver is activated. during a period of inactivity. If the display is not operated within this time, the SPS will automatically switch back to the customer level. Service manual SPS 4000 | B0960622_en...
Page 64: Hardware
Since the number and type of unit vary depending on the system setup, automatic hardware detection must be carried out on the SPS 4000 during commissioning. The detection is carried out in four steps. The following order must be observed.
Page 65: Plc Restart
The controller is restarted. After the restart the boiler is in “Boiler OFF” operating status. Cold start The control is restarted and reinitialised. After the restart the boiler is in “Boiler OFF” operating status. Service manual SPS 4000 | B0960622_en...
Page 66: Diagnosis
Menus and parameters Diagnosis 5.6 Diagnosis 5.6.1 Error System menu Diagnosis Error Delete fault log The fault log displays the faults that have already been rectified (corrected and acknowledged) in list form. This list can be deleted by tapping on “Delete fault log”. 5.6.2 Inputs and outputs System menu Diagnosis...
Page 67 ❒ After tapping “On with value”, the input/output is set to the previously set value ➥ When the dialogue box is opened, the field “On with value” is automatically filled with the value at the time of opening. The value can be "frozen" by tapping on it. Service manual SPS 4000 | B0960622_en...
Page 68: System Diagnostics Manager
Menus and parameters Diagnosis 5.6.3 System Diagnostics Manager System menu Diagnosis System Diagnostics Manager Used to display the parameters of the SPS system (CPU utilisation, CPU temperature, network settings, etc.) and is intended for service technicians. To exit, tap the Back icon at the bottom left of the display. Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 69: Log
ERROR reporting chain delay For signal chains with external systems, the forwarding of For signal chains with external systems, the forwarding of alarm messages is delayed by this value. error messages is delayed by this value. Service manual SPS 4000 | B0960622_en...
Page 70: User-Defined Messages
Menus and parameters Diagnosis WARNING reporting chain delay Issuing of errors to the linked/cascade participants For signal chains with external systems, the forwarding of Defines whether faults on the linked/cascade participants warning messages is delayed by this value. should be displayed on the boiler. FC warnings delay Shutdown delay at a fault In order to ignore short FC error messages, the fault must...
Page 71: Usb Recording
Indicates whether recording of the trend remains active when the system is switched off. By deactivating the function, the trend will stop after the shutdown and the data will remain in place (in case of an error). Service manual SPS 4000 | B0960622_en...
Page 72: Quick Select
Menus and parameters Quick select 5.7 Quick select Select language To change the current language of the display. Start cleaning the display The display is locked for 10 seconds for cleaning purposes. Extra heating The “Extra heating” mode is activated for the set duration. Chimney sweep mode, full load The “Chimney sweep mode, full load”...
Page 73: System Configuration
Details on the name and residence of the operator. Operator name Freely selectable name for the operator. Customer number Unique identification number of the operator. The customer number must be specified when contacting Fröling customer services. Service manual SPS 4000 | B0960622_en...
Page 74: System Connection
Menus and parameters System configuration System connection System menu System configuration System & operator System connection Role in the linked system Own slave ID Defines the role in the cascade. A cascade consists of a Prerequisite: Parameter “Cascade user” = Slave master and up to three slave systems.
Page 75 Network circuit 1...2 belongs to Freely selectable name for the network circuit. ▪ Direct heat distribution The network circuit is supplied directly by the boiler. ▪ Distributor 1...4 The network circuit is supplied by a distributor. Service manual SPS 4000 | B0960622_en...
Page 76: External Connection
Menus and parameters System configuration Network circuit 1...2 number of pumps Network circuit 1...2 M-bus address of heat meter Specifies the number of pumps in the network circuit. Specifies the M-bus address of the heat meter. Network circuit 1...2 differential pressure sensors Specifies the position of the differential pressure sensors.
Page 77: System Connection
– System & operator – System connection” Specifies whether there is a checksum fault. and the master must be provided with this information. Cascade boiler 1...5 Specifies if the boiler is integrated in a cascade. Service manual SPS 4000 | B0960622_en...
Page 78: Boiler
Menus and parameters System configuration 5.8.4 Boiler System menu System configuration Boiler Maximum possible boiler temperature setpoint Ash removal combustion chamber active with ash removal heat exchanger? Parameter for setting the maximum boiler temperature setpoint. The control band always starts at the temperature value which is set for the “Minimum boiler temperature Specifies if the ash removal setpoint”...
Page 79 Can “Shut down for cleaning” be activated? Specifies if a compressed If the “Shut down for cleaning” function is supported for air cleaner is installed on the this boiler, the option to activate is allowed. boiler. Service manual SPS 4000 | B0960622_en...
Page 80: Fuel Feed
Menus and parameters System configuration 5.8.5 Fuel feed Hydraulic units System menu System configuration Fuel feed Hydraulic units Hydraulic unit 1...2 number of 4/3 directional valve Hydraulic unit 1...2 double pump Specifies the number of 4/3 directional valves. Specifies whether a double pump is used. Hydraulic unit 1...2 pressure-free star/delta start-up? Specifies whether a pressure-free star/delta start-up is used.
Page 81: Discharge / Configurations
Example 1 - rotary agitator with separate drive and two feed screws Feed screw 2 Feed screw 1 Rotary agitator separately driven Service manual SPS 4000 | B0960622_en...
Page 82 Menus and parameters System configuration Parameterization procedure for this example: ❒ In the "Feeder unit" menu set the “Feed screw" parameter to “2” ❒ In the "Chamber discharge system" menu set the “Rotary agitator separately driven" parameter to “1” ❒ In the “Order / Configuration” menu tap on the first entry “Stoker” ❒...
Page 83 ❒ For the “Stoker is loaded by” parameter select the entry “Feed screw 1” ❒ In the “Cascade user” submenu for parameter “Boiler 2 loaded by” select the entry “Rotary agitator separately driven 1” Service manual SPS 4000 | B0960622_en...
Page 84: Ash Removal
Menus and parameters System configuration ❒ In the “Feed screw 1” submenu for parameter “Feed screw 1 loaded by” select the entry “Feed screw 2” ❒ In the “Feed screw 2” submenu for parameter “Feed screw 2 loaded by” select the entry “Feed screw 3”...
Page 85: Flue Gas Treatment
Multicyclone installed? Filter type Specifies if a multicyclone is integrated into the flue gas Specifies which type of filter is used. line. Multicyclone rotary valve installed Specifies whether a multicyclone rotary valve is installed. Service manual SPS 4000 | B0960622_en...
Page 86: Inputs & Outputs
Menus and parameters System configuration 5.8.8 Inputs & outputs System menu System configuration Inputs & outputs In this menu, inputs and outputs are assigned to the ports of the I/O cards in the SPS rack. ❒ Open the relevant submenu (analogue, digital, etc.) ❒...
Page 87 When the node number is set, the socket number and the module clamping position are automatically filled in. Conversely, the node number is also calculated automatically. 2. All settings in the change dialogue box are only applied by tapping on the apply or confirm icon. Service manual SPS 4000 | B0960622_en...
Page 88: Operation Hours
▪ Set all parameters to factory default out for possible recovery files and displayed in the drop- Tap the icon to reset the SPS 4000 to the factory default down field. settings. All the settings for the boiler and the boiler ❒...
Page 89: Troubleshooting
If the fault has been successfully acknowledged and is no longer present, the entry in the current fault is removed: ❒ In the fault information, tap on the "Fault log" tab ➥ The list of the last fault messages with additional information on occurrence, acknowledgement and associated times is displayed Service manual SPS 4000 | B0960622_en...
Page 90: Electric Components And Wiring
Electric components and wiring 7 Electric components and wiring 7.1 PLC The controller consists of a main electrical cabinet and two expansion switch cabinets. The CPU and display unit are installed in the main electrical cabinet. Additional connections to system components or a customer's own control system are wired to the main control cabinet.
Page 91: Connections
Ethernet port (RJ45 shielded, transfer rate 10/100 MBit/s) USB interface: Type A, USB 1.1, USB 2.0, current limit max. 0.49A USB interface: Type A, USB 1.1, USB 2.0, current limit max. 0.10A Power supply Service manual SPS 4000 | B0960622_en...
Page 92: X20 - Module Layout
Electric components and wiring 7.1.2 X20 – module layout The X20 input/output rack is a modular system, consisting of several modules, which in turn are made up of three components. Bus module Electronic module Terminal block Assembling the module Top view Front view ❒...
Page 93 ❒ Position the electronic modules beside the bus module as shown and push in until they engage ❒ Hook the terminal block onto the electronic module ❒ Push the terminal block into the electronic module until it engages Service manual SPS 4000 | B0960622_en...
Page 94 Electric components and wiring Fitting the modules to the top hat rail Top hat rail lever unlocked Top hat rail lever locked (module fixed to top hat rail) (module can be removed) ❒ Tilt up the top rail lever of all modules in the rack ❒...
Page 95: X20 Module Types
▪ Input voltage for X2X link supply too low Red illuminated (e) Incorrect firmware Green flashing (r) Orange No communication at X2X link Communication at X2X link OK X2X link supply OK Power supply unit overloaded (additional supply modules required) Service manual SPS 4000 | B0960622_en...
Page 96 Electric components and wiring NOTICE! Connection 1-5 does not have to be wired as there is an internal jumper between terminal 1-4 and terminal 1-5. Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 97 Electric components and wiring The connection diagram below shows how the module is wired: Wire jumper for supplying the X2X link Service manual SPS 4000 | B0960622_en...
Page 98: Ps2100
Electric components and wiring PS2100 Additional module for the feed at the bus and for input/output modules. Colour Status Description Green Not in operation (no power supply) Quick flashes Reset mode Flashing Preoperative mode Module in operation No error / no supply to module Double flashing LED indicates one of the following operating statuses: ▪...
Page 99 Module for additional supply Distinctive features: Distinctive features: ▪ Name BM01 ▪ Name BM11 ▪ No gold contacts at bottom ▪ Gold contacts at bottom ▪ Module colour: light grey ▪ Module colour: dark grey Service manual SPS 4000 | B0960622_en...
Page 100 Electric components and wiring The image below shows one possible setup: Start of the rack with the BR9300 module. The inputs/outputs are supplied up to point 2. A PS2100 module needs to be inserted here to supply the subsequent inputs/outputs with 24V up to point 3. This setup could, for example, be a locking unit.
Page 101: Bt9100
▪ I/O supply too low ▪ Input voltage for X2X link supply too low Red illuminated (e) / Green flashing (r) Incorrect firmware Orange No communication at X2X link Communication at X2X link OK Service manual SPS 4000 | B0960622_en...
Page 102 Electric components and wiring The connection diagram below shows how the module is wired without a feed for the internal I/O power supply: The connection diagram below shows how the module is wired with a feed for the internal I/O power supply: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 103: Cs1012
Red illuminated (e) Incorrect firmware Green flashing (r) Yellow None of the slaves send data At least one slave transmits data via the M-Bus M-Bus supply OK Short circuit / overload on the M-Bus Service manual SPS 4000 | B0960622_en...
Page 104 Electric components and wiring CS1012 The connection diagram below shows how the module is wired: NOTICE! The maximum permissible line resistance (longest loop) is 250Ω. The maximum permissible line capacitance for the entire bus is 500 nF. Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 105: Cs1030
The module is sending data via the RS485/RS422 interface Yellow The module is receiving data via the RS485/RS422 interface Yellow The terminating resistor integrated in the module is switched on DATA + (A) DATA - (B) CS1030 Service manual SPS 4000 | B0960622_en...
Page 106: Di2377
Electric components and wiring DI2377 Module with two digital counting inputs for measuring the speed. Colour Status Description Green Not in operation (no power supply) Quick flashes Reset mode Flashing Preoperative mode Module in operation No error / no supply to module Red illuminated (e) Incorrect firmware Green flashing (r)
Page 107: Di9371
Not in operation (no power supply) Quick flashes Reset mode Flashing Preoperative mode Module in operation No error / no supply to module Red illuminated (e) Incorrect firmware Green flashing (r) 1-12 Green Input status of the corresponding input Service manual SPS 4000 | B0960622_en...
Page 108 Electric components and wiring The connection diagram below shows how the module is wired: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 109: Do9322
No error / no supply to module Quick flashes Warning/error at an output. Level monitoring at digital outputs has activated. Red illuminated (e) Incorrect firmware Green flashing (r) 1-12 Green Output status of the corresponding output Service manual SPS 4000 | B0960622_en...
Page 110 Electric components and wiring The connection diagram below shows how the module is wired: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 111: Do8332
Single Flash Warning/error of an I/O channel. Level monitoring at digital outputs has activated. Double flash I/O supply too low Red on / green single flash Incorrect firmware Orange Output status of corresponding digital output Service manual SPS 4000 | B0960622_en...
Page 112 Electric components and wiring The connection diagram below shows how the module is wired: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 113: Do6639
No error / no supply to module Error or reset status Red on / green single flash Incorrect firmware Orange Output status of corresponding digital output The connection diagram below shows how the module is wired: Service manual SPS 4000 | B0960622_en...
Page 114 Electric components and wiring Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 115: Do2633
No error / no supply to module Error or reset status Quick flashes Zero-crossing signal has failed (no input/output voltage or input/output voltage too low) Red illuminated (e) Incorrect firmware Green flashing (r) Orange Control status of corresponding digital output Service manual SPS 4000 | B0960622_en...
Page 116 Electric components and wiring The connection diagram below shows how the module is wired in two-wire technique: The connection diagram below shows how the module is wired in three-wire technique: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 117: Ai4622
Reset mode Flashing Preoperative mode Module in operation No error / no supply to module Error or reset status Red illuminated (e) Incorrect firmware Green flashing (r) Green Value = 0 Value ≠ 0 Service manual SPS 4000 | B0960622_en...
Page 118 Electric components and wiring The connection diagram below shows how the module is wired: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 119: Ai4222
No error / no supply to module Error or reset status Red illuminated (e) Incorrect firmware Green flashing (r) Green Broken cable or sensor unplugged Flashing Overflow or underflow of input signal Analogue-digital converter works; value is OK Service manual SPS 4000 | B0960622_en...
Page 120 Electric components and wiring The connection diagram below shows how the module is wired: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 121: Ao4622
Reset mode Flashing Preoperative mode Module in operation No error / no supply to module Error or reset status Red illuminated (e) Incorrect firmware Green flashing (r) Orange Value = 0 Value ≠ 0 Service manual SPS 4000 | B0960622_en...
Page 122 Electric components and wiring The connection diagram below shows how the module is wired: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 123: Ao2622
Modbus BOOT (during firmware update) Flashing Preoperative mode Module in operation No error / no supply to module Error or reset status Red illuminated (e) / Green flashing (r) Incorrect firmware Orange Value = 0 Value ≠ 0 Service manual SPS 4000 | B0960622_en...
Page 124 Electric components and wiring The connection diagram below shows how the module is wired: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 125: At2402
Warning/error of an I/O channel. Overflow or underflow of analogue inputs Red illuminated (e) / Green flashing (r) Incorrect firmware Green The input is switched off Flashing Overflow/underflow or broken cable of input signal Value is OK Service manual SPS 4000 | B0960622_en...
Page 126 Electric components and wiring + Thermo contact 1 + Thermo contact 2 - Thermo contact 1 - Thermo contact 2 AT2402 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 127: At6402
Warning/error of an I/O channel. Overflow or underflow of analogue inputs Red illuminated (e) / Green flashing (r) Incorrect firmware Green The input is switched off Flashing Overflow/underflow or broken cable of input signal Value is OK Service manual SPS 4000 | B0960622_en...
Page 128 Electric components and wiring For type K thermocouples, the following applies: Plus (+) = green, minus (-) = white Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 129: At4222
Warning/error of an I/O channel. Overflow or underflow of analogue inputs Red illuminated (e) / Green flashing (r) Incorrect firmware Green The input is switched off Flashing Overflow/underflow or broken cable of input signal Value is OK Service manual SPS 4000 | B0960622_en...
Page 130 Electric components and wiring The connection diagram below shows how the module is wired: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 131 The left-hand side shows the connection of a 3-wire sensor. On the right-hand side, the connection of a 2-wire sensor is shown according to the 3-wire principle. In this case, the second and third terminals (both minus poles) are connected (bridged) directly on the field terminal. Service manual SPS 4000 | B0960622_en...
Page 132: Sensor Characteristic Line Pt100
Electric components and wiring Sensor characteristic line PT100 7.2 Sensor characteristic line PT100 The table below shows the resistance [Ω] of the temperature sensor at a certain temperature. The temperature in a table cell is determined by the start temperature of the line plus the value of the column: Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 133: Sensor Characteristic Line Type K
The table below shows the thermoelectric voltage [mV] of the temperature sensor at the specified temperature difference. The temperature in a table cell is determined by the start temperature of the line plus the value of the column: Service manual SPS 4000 | B0960622_en...
Page 134 Electric components and wiring Sensor characteristic line type K Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 135: Frequency Converter
Up arrow Scroll down through groups and parameters. Increase/reduce the value of a flashing digit Down arrow Enter Go forward one step in the program menu. Save a change to a parameter value Service manual SPS 4000 | B0960622_en...
Page 136: Changing Parameters
Electric components and wiring Frequency converter 7.4.2 Changing parameters Step Description Connecting the power supply 3x escape until “0.0” appears in the display The group menu letter flashes when you press the Enter button Press the arrow buttons to select the relevant group menu (d,P,t,C,A) Enter the previously selected group menu.
Page 137 You can restore the factory settings by setting parameter P 112 to 1. The parameter then automatically returns to the value 0 and the frequency converter displays the message "F048". Service manual SPS 4000 | B0960622_en...
Page 138: Cascade / Modbus
Electric components and wiring Cascade / Modbus 7.5 Cascade / Modbus The CS1030 communication module must be used for cabling in a cascade or for integration into a ModBus system. ⇨ See "CS1030" [page 105] In addition, the following wiring diagrams and connection instructions must be observed. Wiring the cascade When wiring the cascade, make sure that the terminating resistor is activated for the communication module on the master boiler and the last slave boiler.
Page 139 In addition, a terminating resistor must be ensured by the higher-level system. Superordinate Modbus system (Terminating resistor 120 Ohm) Data - Data + Terminating Terminating Terminating Terminating resistor ON resistor OFF resistor OFF resistor ON Service manual SPS 4000 | B0960622_en...
Page 140: Terminating Resistor At Communication Module
Electric components and wiring Cascade / Modbus 7.5.1 Terminating resistor at communication module The terminating resistors on the first and last participants must be activated for integration into a cascade or a higher modbus system. The terminating resistor must be deactivated on all other communication modules. The position of the switch is located on the bottom of the CS 1030 communication module.
Page 141: M-Bus
The CS1012 communication module must be used for cabling the M-bus (meter bus). CS1012 A maximum of three heat meters can be evaluated on the SPS 4000. There are no specific limitations for cabling the M-bus. User can be connected in either a star or line structure.
Page 142: Notes
Notes 8 Notes Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 143 Notes Service manual SPS 4000 | B0960622_en...
Page 144: Appendix
Appendix Addresses 9 Appendix 9.1 Addresses 9.1.1 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 9.1.2 Address of the installer Stamp Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

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