Fröling T4e 20 Installation Instructions Manual
Wood chip boiler
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Summary of Contents for Fröling T4e 20
- Page 1 Installation instructions Wood chip boiler T4e 20-180 Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M1980822_en | Edition 31/10/2022...
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Page 2: Table Of Contents
5.2 Temporary storage..........................38 5.3 Positioning............................. 39 5.4 Positioning at the installation site ......................40 5.4.1 Remove boiler from pallet ......................40 5.4.2 Operating and maintenance areas of the equipment..............42 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 3 6.3.2 Installing the stoker unit ......................44 6.3.3 Control the return temperature control..................46 6.3.4 Install line regulating valve (T4e 20-60 - optional) ..............47 6.3.5 Install line regulating valve (T4e 80-180 - optional) ..............48 6.3.6 Adjusting the height of the ash container................... 49 6.4 Hydraulic connection..........................
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Page 4: General
ESP: 20, 25, 30, 35, 45, 50, 60, 80, 90, 100, 108 , 110, 130, 140, 150, 160, 170, 180; 1) T4e 108 and T4e 108 ESP only available in Italy M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
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. M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
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) M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
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) M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
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 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 9: Chimney Connection/Chimney System
Please note within the permissible operating range of the boiler flue gas temperatures lower than 160K above room temperature may occur. M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
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 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 11: Measuring Port
TRVB H 118 (only Austria) stipulates that an explosion flap must be installed in the connection line to the chimney, directly next to the boiler. It should be situated in such a way that is poses no risk to persons! M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 12: Combustion Air
(maximum flow rate = 1 m/ Note on standards ÖNORM H 5170 - Construction and fire protection requirements TRVB H118 - Technical directives on fire protection/prevention M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 13: Simultaneous Operation With Other Air-Drawing Systems
Alternating operation An approved safety system (such as a flue gas thermostat) ensures (e.g. by switching off the power supply) that the boiler cannot be operated simultaneously with the air-drawing appliance. M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 14: 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. M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 15: 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. M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 16: Storage Tank
Recommendation: r Fit a microbubble separator in the pipes to the boiler Ä Follow the manufacturer's instructions! M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 17: Technical Information
Total width, including stoker unit 1410 1410 1570 1565 Total height incl. flue gas nozzle 1545 1745 1790 1895 Height, boiler 1490 1690 1740 1840 1. Safety heat exchanger connection opposite stoker M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 18 ▪ Rear flue gas pipe connection (optional) on the side facing away from the stoker (T4e 20-110) or on the left side of the boiler, respectively (T4e 130-180) ▪ Safety heat exchanger on the side facing away from the stoker (T4e 130-180)
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Page 19: Components And Connections
Mixing valve for the return temperature control Pump for the return temperature control Line regulating valve (optional) Ash container 40 Litres 55 Litres 75 Litres Drainage 1/2” 1“ 1“ Safety heat exchanger 1/2“ M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 20: Technical Specifications
Useful heat delivered at 30% of rated heat output (P 10.5 Fuel efficiency at rated heat output (η 83.9 83.5 83.8 84.2 Fuel efficiency at 30% of rated heat output (η 82.9 83.2 83.4 83.6 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 21: T4E 20 - 35 Esp
Energy efficiency class of boiler Energy efficiency index (EEI) of boiler Heating space annual rate of use ηs Energy efficiency index (EEI) of boiler and controller combined Energy efficiency class of boiler and controller combined M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 22 1. The emissions of dust, gaseous organic compounds, carbon monoxide and nitrogen oxides are stated in a standardised form based on dry flue gas with a oxygen content of 10 % and under standard conditions at 0°C and 1013 millibar M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 23: T4E 45 - 60
Fuel efficiency at 30% of rated heat output (η 84.1 84.0 83.9 Auxiliary current consumption at rated heat output 0.070 0.077 0.090 Auxiliary current consumption at 30% of rated heat 0.037 0.037 0.037 output (η M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 24: T4E 45 - 60 Esp
Energy efficiency class of boiler Energy efficiency index (EEI) of boiler Heating space annual rate of use ηs Energy efficiency index (EEI) of boiler and controller combined Energy efficiency class of boiler and controller combined M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 25 1. The emissions of dust, gaseous organic compounds, carbon monoxide and nitrogen oxides are stated in a standardised form based on dry flue gas with a oxygen content of 10 % and under standard conditions at 0°C and 1013 millibar M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 26: T4E 80 - 110
0.057 output (η Auxiliary current consumption in standby mode (P 0.010 0.012 0.015 0.014 0.014 Regulation (EU) 2015/1189 – emissions in [mg/m³] Annual space heating emissions of dust (PM) ≤ 30 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 27: T4E 80 - 110 Esp
Useful heat delivered at rated heat output (P Useful heat delivered at 30% of rated heat output (P 24.0 27.0 30.0 32.4 33.0 Fuel efficiency at rated heat output (η 83.8 83.7 83.7 83.7 83.7 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 28 1. The emissions of dust, gaseous organic compounds, carbon monoxide and nitrogen oxides are stated in a standardised form based on dry flue gas with a oxygen content of 10 % and under standard conditions at 0°C and 1013 millibar M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 29: T4E 130 - 150
0.058 0.058 0.059 output (η Auxiliary current consumption in standby mode (P 0.014 0.014 0.014 Regulation (EU) 2015/1189 – emissions in [mg/m³] Annual space heating emissions of dust (PM) ≤ 30 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 30: T4E 130 - 150 Esp
Useful heat delivered at 30% of rated heat output (P 39.0 42.0 45.0 Fuel efficiency at rated heat output (η 83.7 83.7 83.7 Fuel efficiency at 30% of rated heat output (η 84.8 84.6 84.5 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 31 1. The emissions of dust, gaseous organic compounds, carbon monoxide and nitrogen oxides are stated in a standardised form based on dry flue gas with a oxygen content of 10 % and under standard conditions at 0°C and 1013 millibar M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 32: T4E 160 - 180
0.060 0.060 0.061 output (η Auxiliary current consumption in standby mode (P 0.014 0.013 0.013 Regulation (EU) 2015/1189 – emissions in [mg/m³] Annual space heating emissions of dust (PM) ≤ 30 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 33: T4E 160 - 180 Esp
Useful heat delivered at 30% of rated heat output (P Fuel efficiency at rated heat output (η 83.7 83.8 83.8 Fuel efficiency at 30% of rated heat output (η 84.3 84.1 84.0 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 34 1. The emissions of dust, gaseous organic compounds, carbon monoxide and nitrogen oxides are stated in a standardised form based on dry flue gas with a oxygen content of 10 % and under standard conditions at 0°C and 1013 millibar M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 35: Boiler Data For Planning The Flue Gas System
°C Flue gas temperature at partial load - volume concentration at nominal load / partial load 13.3 / 13.3 / 13.8 / 13.8 / 13.8 / 12.3 12.3 12.8 12.8 12.8 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 36 -Volume concentration at nominal load/partial load 7.0 / 8.0 6.5 / 7.5 6.5 / 7.5 Flue gas mass flow at nominal load kg/h kg/s 0.112 0.115 0.122 Flue gas mass flow at partial load kg/h M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 37: Data For Planning A Backup Power Supply
The system can be operated with an emergency generator. The following information must be observed during planning. Description Value Continuous output (three phase) 6375 Nominal voltage 400 ± 6% Frequency 50 ± 2% M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 38: Transport And Storage
If the system is to be assembled at a later stage: r Store components at a protected location, which is dry and free from dust Ä Damp conditions and frost can damage components, particularly electric ones! M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 39: Positioning
Remove the insulating cover and thermal insulation Ä T4e 20-110: one insulated cover Ä T4e 130-180: two insulating covers r Undo the screw connection and open the heat exchanger cover Ä Use the spanner provided M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 40: Positioning At The Installation Site
Open the insulated door and pull the key plate from the safety limit switch r Use the locking lever to unlock the ash container and pull off the ash container from the boiler M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 41 Lift it and transport it to the intended position Ä Observe the operating and maintenance areas of the equipment in the process! NOTICE! The insertion dimensions match the dimensions of the boiler, see chapter "Dimensions". M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 42: Operating And Maintenance Areas Of The Equipment
700 mm 800 mm 800 mm 150 mm 500 mm 300 mm 300 mm 500 mm 1. When using electrostatic particle separator ESP (optional) 2. Maintenance area to expand the WOS springs upwards M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 43: Assembly
Line regulating valve (optional) 6.2 Accessories supplied (T4e 20-60) (T4e 80-180) Furnace tool with bracket Key for door mountings and WOS cover Socket wrench AF 13 Cleaning brush 24 x 50 x 1200 M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 44: Installing The Boiler
Insert the appropriate pipe (e.g. 1” pipe) into the bracket (A) of the stoker unit and transport the stoker unit to the boiler r Remove the shutter masks from the stoker side r Remove the pre-installed screws on the connection flange M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 45 Adjust the height using the adjustable base (C) as required r Secure the stoker unit to the connection flange using the previously removed screws r Remove the bracket. It is no longer needed r Assemble the entire discharge system M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 46: Control The Return Temperature Control
Ä The mixer valve completely closes off the system return r Turn the mixing drive clockwise until it stops Ä The system return is completely open and the bypass line coming from above is completely closed M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 47: Install Line Regulating Valve (T4E 20-60 - Optional)
NOTICE! After filling the boiler with domestic hot water, check the return temperature control for leaks! 6.3.4 Install line regulating valve (T4e 20-60 - optional) r Remove rear cover plate and both rear panels M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 48: Install Line Regulating Valve (T4E 80-180 - Optional)
Ä Remove the burrs with a half-round file r Install rear cover plate on the line regulating valve 6.3.5 Install line regulating valve (T4e 80-180 - optional) r Remove cover plate from back panel and centre back panel M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 49: Adjusting The Height Of The Ash Container
Pull out the spring cotter on the transport wheels and adjust the height Ä If the ash container is mounted, the wheels rest on the ground r Remove the ash container from the boiler and level it using the adjustable foot M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 50: Hydraulic Connection
▪ Its size must comply with the design information in EN 12828 - Appendix D ▪ Ideally it should be installed in the return line. Follow the manufacturer’s installation instructions M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 51 Assembly | 6 We recommend installing some sort of monitoring device (such as a thermometer) M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 52: Electrical Connection
Remove the cable ties from the tag connector r Bind the individual cores together with cable ties (A) M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 53: Board Overview
Assembly | 6 6.5.1 Board overview T4e 20-60 Item Description Item Description Main switch Hydraulic module High-limit thermostat (STL) Core module Service interface Wood chip module Device connection terminal Plug power pack M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 54 6 | Assembly T4e 80-180 Item Description Item Description Main switch Core module High-limit thermostat (STL) Wood chip module Service interface Plug power pack Device connection terminal Digital module (optional) Hydraulic module M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 55: Laying Cables
Plug the following components into the cable that is already in place Ä Stoker drive Ä Glow igniters r Ensure that the cables do not touch the hot boiler components M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 56: Attach The Mains Connection To The Boiler
Ä The power supply line (mains connection) must be fitted with a C16 A fuse by the customer. 6.5.4 Potential equalisation r The potential equalisation on the boiler base must comply with current directives, regulations and standards. M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 57: Final Installation Steps
- 2 lense-head screws M4 x 8 with contact washer r Put on the heat exchanger cover and attach using star-shaped screws r Put down the cover and thermal insulation Ä PT4e 20-110: one cover Ä PT4e 130-180: two covers M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 58 Slide the ash container on to the ash duct of the boiler r Push the key plate (A) into the safety limit switch r Push the locking lever (B) down and close the insulated door (C) M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
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Page 59: Insulate The Connection Line
Glue the half shells to each other 6.6.2 Install the brackets for accessories r Using appropriate fasteners, attach the brackets to the wall on the boiler r Attach the accessories to the brackets M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 60: Stick On An Additional Identification Plate (Applicable To T4E Esp)
6 | Assembly 6.6.3 Stick on an additional identification plate (applicable to T4e ESP) r Stick the additional identification plate (A) visibly on the side panel of the boiler M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 61: Start-Up
Check that the drives and servo motors are working and turning in the right direction r Check safety switch of ash box is working correctly NOTICE! Check the digital and analogue inputs and outputs - See the instruction manual for the boiler controller. M1980822_en | Installation instructions Wood chip boiler T4e 20-180... -
Page 62: 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. M1980822_en | Installation instructions Wood chip boiler T4e 20-180... - Page 63 Notes M1980822_en | Installation instructions Wood chip boiler T4e 20-180...
- Page 64 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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