Page 1 Operating Instructions Boiler controller SPS 4000 (PP 65) Version 01.09 Translation of the original German operating instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! B0960623_en | Edition 05/04/2023 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 2: Table Of Contents
Table of Contents 4.10 I/O configuration 1 General 4.10.1 I/O configuration according to circuit diagram 1.1 Safety information 4.11 Setting the parameters of the 2 Overview of the basic functions frequency converter 4.12 Finishing configuration 2.1 Touch display 4.13 Performing the first start / Checking 2.2 Control icons the settings 3 Operation...
Page 3 5.4.6 SPS restart BR9300 PS2100 5.5 Diagnosis BT9100 5.5.1 Error CS1012 Current faults CS1030 Fault log DI2377 Clear error DI9371 DO9322 5.5.2 Inputs and outputs DO8332 5.5.3 System DO6639 5.5.4 Message forwarding DO2633 AI4622 Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 4 8.1.3 Back up/restore memory card 7.4 Frequency converter 8.1.4 Connecting to the SPS with PC Connection via a local network (LAN) 7.4.1 Operating elements Direct connection to SPS 4000 7.4.2 Changing parameters SPS 4000 network settings PC network settings 7.5 Cascade / Modbus 8.1.5 System Diagnostic Manager (SDM)
Page 5: 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 6: Safety Information
General Safety information 1.1 Safety information DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: ❒ Always have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥...
Page 7: Overview Of The Basic Functions
Image of the set boiler type System menu icon for opening the system settings. All parameters can be displayed/edited depending on the user level Quick menu icon for viewing the available quick functions Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 8: Control Icons
Overview of the basic functions Control icons Info menu icon for viewing all system information Mode icon for switching the boiler on/off Mode display Operating status display 2.2 Control icons Cancel icon Discards any values entered without saving and closes messages. Confirm icon Confirms any values entered and activates parameters.
Page 9 Back icon Takes you back up one menu level of the system menu. Can be used to return to the basic display. Operating Instructions SPS 4000 (PP 65) | B0960623_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: Navigating Within Submenus
You can open any other menu items available in the same way. The individual menus are divided into tabs for quicker navigation. ❒ Tap on the desired tab ➥ The list of parameters for the selected area will appear Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 12: Displaying/Changing Parameters
Operation Displaying/changing parameters The parameter list shows three parameters. The up and down arrows can be used to scroll through longer lists of parameters. If you have reached the start or end of the parameter list, the relevant arrow symbol will become inactive.
Page 13: Displaying Parameter Info
Specified values for quick selection of standard, minimum and maximum (equals the setting range for the parameter) 3.3.1 Displaying parameter info ❒ Tap the Info icon in the parameter view ➥ The info view opens Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 14: Changing The Parameter Value
Operation Displaying/changing parameters The info view shows a description of the parameter in continuous text. You can use the up and down arrows to scroll through long descriptions. 3.3.2 Changing the parameter value There are different ways of entering values depending on the type of parameter (increase/reduce value, keypad entry, list box).
Page 15 ❒ Tap the numeric keypad icon ➥ 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 Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 16: Quick Menu
Operation Quick menu 3.4 Quick menu The quick menu shows the quick functions available depending on the user level and the system configuration. Tapping the icon starts the function or automatically takes you to the relevant position in the system menu. The quick menu is structured in a circular buffer, which can be navigated using the right and left arrows.
Page 17: Setting The Date And Time
➥ The menu for setting the date and time will be displayed ❒ Tap the relevant value to change it ❒ Enter the new value using the numeric keypad ❒ Save the change by tapping the confirm icon Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 18: Setting Times
Operation Setting times Set the time zone using the following settings menu: System menu Date & time 3.7 Setting times The desired time window for the component can be set in the "Times" tab in the individual menus of the heating components (e.g.
Page 19: Applying The Time Setting For Several Days
❒ Use the left or right arrow to navigate to the day of the week with the desired heating times ❒ Tap the icon beside the heating times ➥ The "Transfer program" menu will appear Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 20: Switching User Level
Operation Switching user level ❒ Select the relevant days of the week that you want the heating times to apply to ❒ Tap the confirm icon to transfer the times to the selected days and close the menu 3.8 Switching user level ❒...
Page 21 Operation Switching user level ❒ Enter the user code using the numeric keypad and confirm by tapping the confirm icon ➥ The functions listed in the selected user level are available Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 22: Initial Startup
Initial startup Before switching on for the first time 4 Initial startup 4.1 Before switching on for the first time NOTICE You should have the initial startup carried out by the authorised heating engineer from Froling customer services. ❒ Check that there are no foreign bodies in the control cabinet (pieces of wire, washers, screws etc.) ❒...
Page 23: Changing The Language
❒ Open the language selection by tapping the language icon ❒ Open the drop down menu by tapping the arrow icon ❒ Select the relevant language and confirm by tapping the confirm icon Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 24: Performing A Software Update
Initial startup Performing a software update 4.4 Performing a software update IMPORTANT! Before performing the software update, save the current configuration: System menu System Backup Back up configuration ❒ Connect the USB stick to the USB interface of the PLC ❒...
Page 25 ❒ Tap the update icon to start the procedure ➥ The controller will now reboot several times ❒ Following the update, check the software version on the “System” tab in the info menu Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 26: Perform Hardware Detection Manually
Initial startup 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 PLC 4000. In the event of an error or to perform a check, this procedure can also be done manually. The detection is carried out in four steps.
Page 27 ➥ The configuration file is written to the system directory and the PLC reboots itself ❒ After the PLC has rebooted, open the "Hardware list" menu from the start screen and check that the list of components found is correct. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 28: Configuring The Boiler
Initial startup Configuring the boiler 4.6 Configuring the boiler Once you have successfully updated the software and completed the hardware configuration, you need to set the boiler type and boiler-specific parameters. 4.6.1 Setting the boiler type To set the boiler type, go to the corresponding “Boiler type" menu: System menu System Boiler type...
Page 29: Configure Fuel Feed
Standard rotary agitator, pellet screw Separately powered rotary agitator Sliding floor / Sliding floor, controlled externally Oblique screw / Oblique screw, Horizontal screw / Horizontal screw, Suction system controlled externally controlled externally Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 30: Fuel Feed: General Information
Initial startup Configure fuel feed Sliding floor with interchangeable Chamber discharge system, controlled externally with/without container level container As for the sliding floor, the control is in Use with chamber discharge systems without setting the exact type. Request is a fuel store. However, to activate the made via a switch contact on the SPS.
Page 31 Specifies if a hopper is used in the feed system to the boiler. Hopper Burn back protection system Back burn slide valve / cross feeder Burn back flap Coupled rotary valve Separate rotary valve Rotary valve, coupled + separate 2x separate rotary valve Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 32: Configure Hydraulic System
Initial startup Configure hydraulic system Determine maximum fuel feed-in above grate differential pressure Prerequisite: The required differential pressure transmitter must be installed on the boiler! Activates the calculation of the fuel infeed quantity by evaluating the differential pressure above the combustion grate.
Page 33: Sample Configuration
Initial startup Configure hydraulic system 4.8.1 Sample configuration Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 34 Initial startup Configure hydraulic system Procedure for configuring the sample hydraulic system In the “System menu” => “System configuration” => “Hydraulic system”: ❒ Number of additional distributors: 4 ❒ Number of storage tanks: 4 ❒ Number of heating circuits: 8 ❒...
Page 35: Configure Additional System Options
Heating circuits Cascade configuration & system ⇨ See "Cascade" [page 105] 4.9.3 Flue gas treatment System menu System Heating circuits Flue gas configuration & system treatment ⇨ See "Exhaust gas treatment" [page 106] Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 36: I/O Configuration
Initial startup I/O configuration 4.10 I/O configuration During the I/O configuration the parameters for inputs and outputs are assigned to the ports of the I/O cards in the PLC rack. Please refer to the section entitled “Electrical connection and wiring" for instructions on how to connect and a description of the different card types.
Page 37 The speed of the units controlled by the phase angle modules is monitored by the counter inputs of the same name. 3. Duplicate assignment Duplicate assignment of outputs is not permitted! Duplicate assignment of inputs can be performed as required on a case-by-case basis! Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 38: I/O Configuration According To Circuit
Initial startup I/O configuration 4.10.1 I/O configuration according to circuit diagram The system-specific circuit diagram is placed in the boiler control cabinet. This shows the system components and their cabling. The circuit diagram shows all the information necessary for configuration of the individual inputs and outputs of the PLC 4000.
Page 39: Setting The Parameters Of The Frequency Converter
The following parameters need to be changed on initial startup to ensure that the frequency converters on the bus start up properly: Parameter Name Factory setting ID Fan C 303 Node address P 106 Start source 1. CAF = combustion air fan 2. Parameter value "5" = ModBus RS485 Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 40: Finishing Configuration
Initial startup Finishing configuration 4.12 Finishing configuration Setting customer-specific parameters ❒ Set the parameters for heating times, storage tank loading times and DHW tank loading times ❒ Set the operating mode, times and temperatures for any standby boilers that may be connected Performing the functional inspection ❒...
Page 41 => Decrease the value (in percent) at the parameter “Maximum infeed” ➥ Path to the parameter: System menu => Fuel feed => Feed screws / feeder Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 42: Menus And Parameters
Menus and parameters Heating circuits & system 5 Menus and parameters 5.1 Heating circuits & system 5.1.1 System pressure System pressure configuration System menu Heating circuits & System pressure system System pressure maintenance measuring range Level sensor output Defines the measuring range of the pressure sensor Defines the type of output from the sensor signal.
Page 43 (e.g. as a system-based adjustment to the maximum pump speed). Network pump control default If the network pump is controlled by static values, the analogue output is incremented by the set value. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 44: Backup Boiler / Swivel Burner
Menus and parameters Heating circuits & system 5.1.3 Backup boiler / Swivel burner Backup boiler – Configuration System menu Heating circuits & Backup boiler system Backup boiler designation Enable the backup boiler depending on the storage tank temperature Freely definable designation of the backup boiler. Maximum 32 characters.
Page 45: Swivel Burner - Configuration
If the startup criteria is fulfilled for this duration, Swivel burner: 0% demand during storage tank loading the second stage of the oil burner is activated. Storage tank charge at which the oil burner is requested with 0%. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 46: Cascade
Menus and parameters Heating circuits & system 5.1.4 Cascade Cascade - Temperatures System menu Heating circuits & Cascade system 0% output demand stage 1 at output requirement Quick start if store discharge is greater than [%/10min] 0% output demand stage 2 at output requirement Quick start if the storage tank empties by more than this value within 10 minutes.
Page 47: Cascade - Configuration
If the filter cutoff flap could not be moved within this time, a Specifies the cleaning intervals of the electrostatic fault is reported precipitator, in minutes. The quick cleaning is performed whilst the system is in operation. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 48 Menus and parameters Heating circuits & system Duration of quick cleaning Minimum for activation of the HV module Specifies the duration of cleaning the electrostatic Defines the lower limit of control. In operation, activation precipitator, in seconds. The quick cleaning is performed must not be performed below a certain minimum value, whilst the system is in operation.
Page 49: Flue Gas Heat Exchanger (Fghe)
If the differential pressure of the flue gas in the FGHE exceeds this value, the FGHE will be deactivated. The FGHE may be so dirty that the flue gas cannot escape properly. Manual cleaning is required. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 50: Hydraulics: General Information
Menus and parameters Heating circuits & system 5.1.6 Hydraulics: general information System menu Heating circuits & Pumps system - general Pump operation when boiler off Start time of pumps when the boiler is off On this day, pumps currently not in use are periodically The boiler should be shut down, but nevertheless all the started to prevent the pumps from sticking.
Page 51 Specifies if the speed of the feeder pump should be dependent on a temperature sensor. If this parameter is active, the associated setting parameters (return temperature setpoint, minimum and maximum speed) are displayed. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 52: Boiler Distributor
Menus and parameters Heating circuits & system 5.1.8 Boiler distributor This menu shows all of the components that were assigned to the boiler in the system configuration. Configuration System menu Heating circuits Boiler distributor Configuration & system DHW priority DHW tank enabled by top boiler storage tank If this parameter is active, the heating circuits are Prerequisite: A storage tank and one or more DHW tanks deactivated during active boiler loading in order to ensure...
Page 53: Distributor
▪ Heating circuits menu ⇨ See "Heating circuits" [page ▪ DHW tank menu ⇨ See "DHW tank" [page 56] ▪ Storage tank menu ⇨ See "Storage tank" [page 57] Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 54: Heating Circuits
Menus and parameters Heating circuits & system 5.1.10 Heating circuits Heating circuits - Temperatures System menu Heating circuits Heating circuits & system Flow temperature at +10°C outside temperature Minimum flow temperature Defines the desired flow temperature in °C at an outside Minimum temperature in °C for the lower limit of the flow temperature of +10°C.
Page 55: Heating Circuits - Times
Defines the delay of the stepped controller for the heating (24 hrs), the setback mode and the set heating times circuit mixer. are ignored. ▪ Off: The heating circuit is deactivated, the frost protection function remains active Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 56: Dhw Tank
Menus and parameters Heating circuits & system 5.1.11 DHW tank DHW tank - Temperatures System menu Heating circuits DHW tank & system Set DHW temperature Minimum difference between storage tank and DHW tank for DHW tank loading. If the DHW tank temperature falls below the value set here within the set time window, DHW tank loading is released.
Page 57: Dhw Tank - Configuration
If the demand of the storage tank falls to 0%, the boiler is operated with minimum output (minimum feed) until overloading of the storage tank is reached. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 58: Buffer Tank - Temperatures
Menus and parameters Heating circuits & system Buffer tank - Temperatures System menu Heating circuits Storage tank & system Top storage tank minimum temperature Average storage tank temperature at 0% load Minimum temperature in storage tank (top store sensor), This average temperature in the storage tank means 0% from which the boiler is started for storage tank loading.
Page 59: Buffer Tank - Times
Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 60: Storage Tank - Configuration
Menus and parameters Heating circuits & system Storage tank - Configuration System menu Heating circuits Storage tank & system Use multi-sensor management? Storage tank control storage tank load is reached, but attempts to maintain Specifies whether storage tank management with more the required storage tank load beforehand instead.
Page 61: Boiler
(top storage tank, bottom storage tank). The boiler starts as soon as the minimum temperature in the storage tank falls below and produces heat in nominal load until the through- loading criteria is reached. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 62: Boiler Times
Menus and parameters Boiler 5.2.2 Boiler times System menu Boiler Boiler times Start boiler enable time 1 Start boiler enable time 2 In “continuous load” mode you can define time windows In “continuous load” mode you can define time windows within which the boiler is active / inactive.
Page 63: Water Temperatures
Minimum boiler temperature setpoint Otherwise the boiler would shut down, even if there is power consumption. Minimum setting value of the boiler temperature setpoint. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 64 Menus and parameters Boiler Return feed temperature setpoint delay Pump changeover after runtime The return setpoint is raised cyclically after this time to Prerequisite: Two controlled boiler loading pumps are reach the desired boiler temperature. This time should be configured set such that the return is only increased again when the Defines the runtime until the system automatically effect of the previous increase can be seen.
Page 65: Lambda Probe Configuration
For measurement, the probe must first be warmed up using the built-in heating. Lambda probe error after If the measured value remains less than 2.5% for longer than the set duration, an error is reported. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 66: Manual
Menus and parameters Boiler Manual System menu Boiler Lambda probe Configuration Delete calibration value of lambda probe Start auto-calibration The calibration data of the lambda probe will be deleted Automatic calibration of the lambda probe is triggered. and set to the default value (21% oxygen = 10 V at ⇨...
Page 67: Air Flaps/Blower Fan
The parameter has an controlled. attenuating function on the output signal of the primary air, thereby preventing the primary air flap from opening too quickly. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 68 Menus and parameters Boiler Primary air opening at 100% control Min. duration combustion air fan run-on residual oxygen content. This means that when there are Specifies the primary air flap position at 100% primary air low residual oxygen content values during shutdown the (setting range 0 –...
Page 69 FGR operation. This means that the actual start point of the tertiary air may be different from the secondary air value displayed on the controller, as the internal value is higher. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 70: Frequency Converter
Menus and parameters Boiler Air flap tertiary2 stop 0% opening Air flap tertiary2 stop 100% opening If the value is below this, the flap is detected as being If the value is above this, the flap is detected as being closed.
Page 71: Test
“safety time expired" error will appear temperature” parameter -> "100% power at flue gas after a safety time (“safety time” parameter). temperature” parameter). This prevents the cold fire clay from heating up too quickly. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 72: Combustion Chamber
Menus and parameters Boiler Ignition power at flue gas temperature Flue gas control delay Specifies the flue gas temperature that must be reached, Internal control parameter: specifies the attenuation of the so that power can be increased. Below this temperature flue gas control.
Page 73: Heat Exchanger Cleaning
Number of monitoring errors before a warning is triggered speed monitor. Defines the number of successive occurrences of exceeding the WOS runtime before a warning is triggered. A WOS run within the limit values resets the counter. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 74: Manual Heat Exchanger
Menus and parameters Boiler Max. runtime of the WOS linear drive Maximal permissible time within which the linear drive must reach the relevant end position. If the time is exceeded the drive will be reversed and then attempt to reach the end position. Manual heat exchanger The menu is used to test and calibrate the WOS.
Page 75: Fgr
If the combustion chamber temperature falls so automatically based on the boiler status FGR run-on. low that the CCT signal falls below this value again, the flue gas recirculation will be deactivated again. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 76 Menus and parameters Boiler FGR cleaning duration FGR primary air delay Duration of automatic cleaning of FGR air duct. FGR activation delay to prevent vibration. Min. FGR control for FGR start FGR power influence The FGR is only activated when demand equals or Specifies as a percentage the influence that the current exceeds this value.
Page 77 Output voltage at 100% control Upper limit of the analogue control of the FGR fan. Minimum control FGR fan Specifies the control voltage (0-10V) output when the ID fan control is 0%. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 78: Frequency Converter
Menus and parameters Boiler Frequency converter System menu Boiler FGR nominal motor voltage (P101) FGR start source (P106) Nominal voltage of motor according to identification plate. Specifies the value of the frequency converter. FGR motor nominal frequency (P102) FGR run-up time (P109) Nominal frequency of the motor that is to be controlled.
Page 79: Grate
Heat exchanger ash screw interval If the ash container is full, the boiler is switched off once Cycle time after which the ash screw on the heat the set delay time has elapsed. exchanger is activated. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 80 Menus and parameters Boiler Ash screw 2 run-on Ash rake acc. to grate end positions Run-on of the second ash screw compared to the first ash The ash rake is activated according to the grate end screw. positions. Combustion chamber ash screw speed [rpm] Number of ash rake passes Speed of the ash screw used to detect speed.
Page 81: 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. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 82: Special Mode
Menus and parameters Boiler 5.2.16 Special mode System menu Boiler Spec. operation Extra heating duration Relative reduction of grate activation during chimney sweep mode The time set here specifies how long extra heating lasts. Specifies the relative reduction of grate activation during chimney sweep mode.
Page 83: External Boiler Control
Specifies the fuel feed-in interval of the stoker screw in “slumber” operating mode in minutes. Minimum combustion chamber temperature in slumber Specifies the minimum temperature of the combustion chamber in “slumber” operating mode, in °C. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 84: Control Parameters
Menus and parameters Boiler 5.2.19 Control parameters System menu Boiler Control parameters Power calculation attenuation Boiler-Tn Specifies the delay time in seconds, when the DDC signal Reset time of the PI controller for the boiler controller is changed from 0 to 100%. ID fan Kp Min.
Page 85: Feed Screw/Feeder
Specifies the return time of the feed screw in seconds. and the feed screw detects no material during this time, the “gravity shaft empty (level sensor!)” error message appears. If this parameter is set to "0" there is no error message. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 86 Menus and parameters Fuel feed Feed screw 1 runtime until override Feed screw 2 … 6 runtime until override Defines the time for override activation of the discharge or Defines the time for override activation of the discharge or oblique screw. The discharge screw or oblique screw is oblique screw.
Page 87: Automatic Infeed Calculation
The boiler starts with this value for the maximum fuel feed- in. Caution: Via the parameter “Monitoring time for start value tracking” and “Delta +/- for start value tracking” the start value for the slide-in control during operation is adjusted. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 88: Hopper
Menus and parameters Fuel feed 5.3.4 Hopper System menu Fuel Hopper feed Hopper rotary agitator runtime Refill hopper timeout Hopper rotary agitator runtime at interval If the hopper is not filled within this period of time, an error is triggered. Hopper rotary agitator runtime in % The hopper rotary agitator runtime equals this percentage interval value.
Page 89: Sliding Floor
If the level sensor (distance sensor, light scanner) detects material over this time period, the sliding floor is switched If the external demand drops out the sliding floor is then off. stopped only after expiry of the set duration. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 90 Menus and parameters Fuel feed Discharge runtime until sliding floor override Maximum time until sliding floor end position Defines the time for override activation of the sliding floor. As a maximum, the sliding floor is allowed the set time in The sliding floor is activated for a set time (“sliding floor total in order to reach the end position.
Page 91: Suction System
Maximum runtime of suction turbine. If the fill level is not is not in use. recognized as full, a warning is issued. ▪ YES: Cyclone on the induced draught discharge system is in use. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 92: Rotary Valves
Menus and parameters Fuel feed Induced draught turbine flow Change-over unit positioning offset sensor Specifies the pre-run time of the induced draught turbine. Specifies the correction value in seconds in order to balance out irregularities in the slide position at the Suction turbine run-on change-over unit.
Page 93: Plc
Specifies whether the system switches automatically between summer time and winter time. 5.4.2 Software System menu Software Displays the current software version and execution of software updates ⇨ See "Performing a software update" [page 24] Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 94: Connections
Menus and parameters 5.4.3 Connections Network Shows the current status of the network. Configuration System menu Connections Network Configuration Obtain IP address automatically Timeout connections Activate automatic obtaining of IP address (DHCP)? Time in idle after which the connection to the PC visualisation software is reset IpAddress Hostname...
Page 95: Field Bus
Setting the Baud rate to match the requirements of the communication RS485 network or the higher-level/external Modbus master. All devices in the network must use the same Modbus cascade slave ID settings! Unique slave identification in cascade network Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 96: Display
Menus and parameters M-bus System menu Connections Field bus M-bus NOTICE! Menu is displayed only if the associated interface Heat meter 1 name card CS1012 was detected. Heat meter 2 name Communications protocol of the M-bus Heat meter 3 name ▪...
Page 97: Calibrate Touchscreen
The controller is rebooted. After the reboot the boiler is in the boiler is in boiler OFF status. “Boiler OFF” operating status. Do not use this function when the boiler is in operation! Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 98: Diagnosis
Menus and parameters Diagnosis 5.5 Diagnosis 5.5.1 Error Current faults System menu Diagnosis Error Current faults Displays a list of current faults: To acknowledge current faults: ▪ Navigate to the fault message using the UP and DOWN arrows ▪ After the fault has been rectified, acknowledge the fault message by pressing the confirm icon –...
Page 99: Clear Error
Temperature inputs type K Used to test the temperature inputs for type K sensors and is intended only for service technicians. The parameters displayed vary depending on the configuration. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 100: System
Menus and parameters Diagnosis 5.5.3 System 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. 5.5.4 Message forwarding System menu Diagnosis Message forwarding ALARM reporting chain delay...
Page 101: Diagnostic Data
An active recording is also displayed by a status icon on the start screen. Pressing this icon stops the recording. NOTICE! Remove the USB device only after stopping the recording! Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 102: Usb Recording Configuration
Menus and parameters Diagnosis Configuration System menu Diagnosis USB recording Configuration Recording interval Current values Digital inputs The data of the SPS is written to the USB device at the specified interval. Digital outputs Manual switch Max. size of files (MB) Heat meter Defines the maximum size of a recording file.
Page 103: Operating Times
Specifies whether a network pump is installed. Number of DHW tanks Number of network pumps Specifies the number of DHW tanks that can be controlled via this system. Specifies the number of network pumps installed. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 104: Heating Circuits & System
Menus and parameters System configuration Control source for the network pump Control source for the network pump ▪ according to the return temperature Specifies the control source for the network pump. ▪ according to the pressure differential ▪ No control source / external control source ▪...
Page 105: Buffer Tank
A freely selected designation can be assigned to the respective backup boiler. Cascade System menu System Heating circuits Cascade configuration & system Cascade function Specifies which function this boiler assumes within a cascade of multiple boilers. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 106: Exhaust Gas Treatment
Menus and parameters System configuration Exhaust gas treatment System menu System Heating circuits Flue gas configuration & system treatment Multi-cyclone installed? Flue gas heat exchanger installed? Specifies if a multi-cyclone is connected to the flue gas Specifies whether a flue gas heat exchanger is installed. pipe.
Page 107: Boiler
Joint ash removal installed? Specifies if there is a joint ash line section for multiple boilers. If the parameter is set to “Yes”, joint ash removal with ash removal for the boiler is activated. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 108 Menus and parameters System configuration Type of Lambda probe Blower fan impeller cleaner installed? Selection of lambda probes used: Specifies whether a blower fan impeller cleaner is installed. ▪ Broadband probe ▪ NTK switching-type sensor Casing cooling installed? All the parameters can be viewed in the “Lambda probe” Specifies whether casing cooling is installed.
Page 109: Fuel Feed
Specifies whether a hopper is installed. ▪ Hydraulic conveyor ▪ Raking chain / band Number of feed screws Specifies the number of feed screws. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 110: Inputs And Outputs
Menus and parameters System configuration Burn back protection system Number of chamber discharge system rotary valves ▪ Hydraulic conveyor: burn back protection integrated in Specifies how many rotary valves are used in the chamber feeder unit discharge system. ▪ Burn back slide: for conveyor belt and raking chain Maximum fuel feed-in determined by the grate pressure conveyor differential...
Page 111: Operator Data
USB storage device. When saving, a CFG file is automatically created. The file name is a combination of customer number, manufacturer number, date and time. The file can be opened using the Fröling visualisation software. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 112: Load Configuration
Menus and parameters System configuration Load configuration System menu System Backup Load configuration configuration This function is used to restore a saved configuration. When this menu is selected, the connected USB searches for any configuration files present (*.cfg) and displays them in the selection field.
Page 113: Fuel Specifications
❒ Select fuel from the options - Wood chips over 35% - Wood chips up to 35% - Wood chips up to 20% - Pellets ❒ Tapping the icon accepts the specifications for the selected fuel Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 114: Own Templates
Menus and parameters System configuration Own templates System menu System Specified configuration values templates In this menu, specified fuel values can be saved and loaded. Load template ❒ Select template ❒ Tapping the icon accepts the specifications for the selected fuel Save / Manage templates The service code must be entered to manage or save current settings! ❒...
Page 115: Exporting Fuel Feed Models
\spsdata\UserConfigs\ on the USB stick is performed ❒ Select saved fuel feed models ❒ If the option “Import fuel feed models from the USB stick” is chosen, the selected fuel feed model is imported. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 116: Factory Setting
Set all parameters and configurations to factory default (Urinit) Tap the icon to reset the SPS 4000 to the factory default settings. All the settings for the boiler and the boiler All configurations and parameters are reset to the default system, as well as the customer-specific parameters will values.
Page 117: Troubleshooting
Troubleshooting Fault handling 6 Troubleshooting 6.1 Fault handling Fault Preparation Pre-heat phase Fire present Heating Empty stoker run-on Restart cleaning run-on Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 118: Fault Message List
Troubleshooting Fault message list 6.2 Fault message list Error text Initialisation of PLC4000 successful An internal error has occurred. Please check the log. The controller has been rebooted because a performance discrepancy was detected at the user interface. A system error has occurred. Please check the log. The controller was restarted by a reset Power failure {DTPowerfail} Parameter initialisation error.
Page 119 Back-burn flap not closing An air flap is not responding A fault is present at an air flap Feed screw 2 overcurrent Feed screw 2 level switch timeout Under-grate sensor loss of signal Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 120 Troubleshooting Fault message list Error text Light barrier burn back gate valve overflow protection The combustion chamber ash screw 2 motor protection has tripped. The combustion chamber ash screw thermal contact has tripped The heat exchanger ash screw thermal contact has tripped The grate motor thermal contact has tripped Lambda probe defective Excess pressure in the combustion chamber...
Page 121 FGR fan power supply FGR fan open circuit FGR fan not rotating Check the FGR configuration FGR fan speed too low Combustion air power supply Combustion air open circuit Combustion air fan not rotating Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 122 Troubleshooting Fault message list Error text Error in the configuration of the combustion air fan Raking chain/conveyor belt overfilled Primary air flap timeout Primary air flap Secondary air damper 1 timeout Secondary air damper 1 error Secondary air damper 2 timeout Secondary air damper 2 error Tertiary air flap 1 timeout Tertiary air flap 1 error...
Page 123 Flue gas heat exchanger cut-off flap failing to close None Flow rate in the flue gas heat exchanger Excessive temperature flue gas heat exchanger Flue gas heat exchanger must be cleaned Excessive pressure differential in the flue gas heat exchanger Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 124 Troubleshooting Fault message list Error text Filter bypass failing to open Filter bypass failing to close Filter cut-off flap failing to open Filter cut-off flap failing to close Filter cleaning timeout Filter fault Filter limestone deficiency: Please check the fill level of the limestone container Filter rotary valve fault Ash container not connected Filter cleaning compressed air fault...
Page 125 The feed screw 3 motor protection switch has tripped Feed screw 3 overcurrent Feed screw 3 level switch timeout The feed screw 4 motor protection switch has tripped Feed screw 4 overcurrent Feed screw 4 level switch timeout Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 126 Troubleshooting Fault message list Error text Chamber discharge system error The chamber discharge system / agitator motor protection switch has tripped The of the chamber discharge system thermal contact has tripped Discharge gravity chute open Sliding floor too frequent overpressure. Both sliding floor limit switches activated.
Page 127 Distributor pump 2 fault Distributor pump 3 fault Distributor pump 4 fault Distributor pump 5 fault Distributor pump 6 fault Distributor pump 1 motor protection fault Distributor pump 2 motor protection fault Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 128 Troubleshooting Fault message list Error text Distributor pump 3 motor protection fault Distributor pump 4 motor protection fault Distributor pump 5 motor protection fault Distributor pump 6 motor protection fault DHW tank pump 1 fault DHW tank pump 2 fault DHW tank pump 3 fault DHW tank pump 4 fault Test Message: Everything OK...
Page 129 The temperature sensor ‘Network return temperature' is not connected, connected incorrectly or defective. The temperature sensor ‘Heating circuit 1’ is not connected, connected incorrectly or defective. The temperature sensor ‘Heating circuit 2’ is not connected, connected incorrectly or defective. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 130 Troubleshooting Fault message list Error text The temperature sensor ‘Heating circuit 3’ is not connected, connected incorrectly or defective. The temperature sensor ‘Heating circuit 4’ is not connected, connected incorrectly or defective. The temperature sensor ‘Heating circuit 5’ is not connected, connected incorrectly or defective. The temperature sensor ‘Heating circuit 6’...
Page 131 The temperature sensor ‘Storage tank 6 sensor 4’ is not connected, connected incorrectly or defective. The temperature sensor ‘Storage tank 6 sensor 5’ is not connected, connected incorrectly or defective. The temperature sensor ‘Storage tank 6 sensor 6’ is not connected, connected incorrectly or defective. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 132 Troubleshooting Fault message list Error text The temperature sensor ‘Storage tank 6 sensor 7’ is not connected, connected incorrectly or defective. The temperature sensor ‘Storage tank 6 sensor 8’ is not connected, connected incorrectly or defective. The temperature sensor ‘Storage tank 6 sensor 9’ is not connected, connected incorrectly or defective. The temperature sensor ‘Storage tank 6 sensor 10’...
Page 133: Electric Components And Wiring
7 Electric components and wiring 7.1 SPS The controller consists of two main components. The CPU/display unit and the input/output rack. In addition, the frequency converters are connected to the controller by modbus. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 134: Display
Electric components and wiring 7.1.1 Display Power Panel PP65, 5.7" QVGA colour TFT display with touch screen (resistive), 128 MByte DRAM, 232 kByte SRAM, CompactFlash slot, Ethernet 10/100, 1x X2X link, 2x USB, protection class IP65 (front) Ports and displays Power supply Ethernet port (RJ45 shielded, transfer rate 10/100 MBit/s) Two USB ports (type A, USB 1.1, USB 2.0)
Page 135 33 dec (33 / 16 -> 2 + 1 remainder) = 21 hex (x16 = 2, x1 = 1) e.g. 180 dec (180/16 -> 11 + 4 remainder) = B4 hex (x16 = B, x1 = 4) Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 136: Changing The Compact Flash
Electric components and wiring Status displays The following status LEDs are below the node number switches: Colour Status Description Status Error/reset Orange Boot / ready mode User Green On/off LED being operated by the application Orange The module is sending data via the X2X interface Orange Access to the Compact Flash medium Changing the Compact Flash...
Page 137: Replacing The Battery
➥ Only handle the battery by the faces ➥ When inserting the battery, ensure that the ribbon for removing it again is correctly positioned ❒ Replace the battery cover and switch on the power supply Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 138: 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 139 ❒ 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 Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 140 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 141: 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) Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 142 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. The connection diagram below shows how the module is wired: Wire jumper for supplying the X2X link Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 143: Ps2100
Double flashing LED indicates one of the following operating statuses: ▪ I/O supply too low ▪ Input voltage for X2X link supply too low Red illuminated (e) Incorrect firmware Green flashing (r) Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 144 Electric components and wiring For this module, you will need to decide whether it is to be used as an additional supply or as a separate feed from the rest (e.g. to create interlocking voltages). It is mainly used with the SPS4000 to create interlocking voltages.
Page 145 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. A PS2100 module is inserted again here to supply the remaining inputs/outputs with 24V. This setup could, for example, be another locking unit. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 146: Bt9100
Electric components and wiring BT9100 The BT9100 is a bus transmitter module and is used to seamlessly expand the X20 system. The stations can be up to 100 metres apart. NOTICE! The bus transmitter module must only be operated with the BM11 bus module! If the feed for the internal I/O supply is used, this potential group must not be powered by any other module.
Page 147 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: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 148: Cs1012
Electric components and wiring CS1012 Module for use as an M-Bus master. Heat meters approved by Froling can be read out on the M-Bus. Colour Status Description Green Not in operation (no power supply) Single Flash Unlink mode Double flash Boot mode (during firmware update) Flashing Preoperative mode...
Page 149 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. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 150: Cs1030
Electric components and wiring CS1030 Module for communicating with the frequency converters and for communicating in cascades and Modbus systems. A X2X link cable is required for custom assembly. ⇨ See "Cascade / Modbus" [page 182] Colour Status Description Green Not in operation (no power supply) Quick flashes Reset mode...
Page 151: Di2377
Reset mode Flashing Preoperative mode Module in operation No error / no supply to module Red illuminated (e) Incorrect firmware Green flashing (r) 1 - 2 Green Input status of the corresponding input Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 152: Di9371
Electric components and wiring DI9371 Module with twelve digital inputs (24 VDC). The inputs feature sink wiring and 1 line terminal. Colour Status Description Green Not in operation (no power supply) Flashing rapidly Reset mode Flashing Pre-operative mode Module in operation No error / no supply to module Lit up red (e) Incorrect firmware...
Page 153 Electric components and wiring The connection diagram below shows how the module is wired: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 154: Do9322
Electric components and wiring DO9322 Module with twelve digital outputs (24 VDC / 0.5 A). The outputs feature source wiring and 1 line terminal. Colour Status Description Green Not in operation (no power supply) Flashing rapidly Reset mode Flashing Pre-operative mode Module in operation No error / no supply to module Flashing rapidly...
Page 155 Electric components and wiring The connection diagram below shows how the module is wired: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 156: Do8332
Electric components and wiring DO8332 Module with eight outputs. The outputs feature source wiring and 1 wire technology. Maximum rated output current 2A Colour Status Description Green Not in operation (no power supply) Single Flash Reset mode Flashing Preoperative mode Module in operation No error / no supply to module Single Flash...
Page 157 Electric components and wiring The connection diagram below shows how the module is wired: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 158: Do6639
Electric components and wiring DO6639 Module with six relay outputs (230 VAC / 2 A). The outputs are normally open and isolated as single channels. Colour Status Description Green Not in operation (no power supply) Single Flash Reset mode Flashing Preoperative mode Module in operation No error / no supply to module...
Page 159 Electric components and wiring Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 160: Do2633
Electric components and wiring DO2633 The module has 2 Triac outputs (2x phase control), 2/3 line terminal. The power supply (L and N) are fed directly to the module. NOTICE! This module must only be used with a BM32 bus module. Colour Status Description...
Page 161 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: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 162: Ai4622
Electric components and wiring AI4622 Module with four analogue voltage inputs and current inputs. Colour Status Description Green Not in operation (no power supply) Flashing rapidly Reset mode Flashing Pre-operative mode Module in operation No error / no supply to module Error status or reset status Lit up red (e) Incorrect firmware...
Page 163 Electric components and wiring The connection diagram below shows how the module is wired: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 164: Ai4222
Electric components and wiring AI4222 Module with four analogue voltage inputs. Colour Status Description Green Not in operation (no power supply) Flashing rapidly Reset mode Flashing Pre-operative mode Module in operation No error / no supply to module Error status or reset status Lit up red (e) Incorrect firmware Flashing green (r)
Page 165 Electric components and wiring The connection diagram below shows how the module is wired: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 166: Ao4622
Electric components and wiring AO4622 Module with four analogue voltage and current outputs. Colour Status Description Green Not in operation (no power supply) Flashing rapidly Reset mode Flashing Pre-operative mode Module in operation No error / no supply to module Error status or reset status Lit up red (e) Incorrect firmware...
Page 167 Electric components and wiring The connection diagram below shows how the module is wired: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 168: Ao2622
Electric components and wiring AO2622 Module with two analogue voltage outputs and current outputs. Colour Status Description Green Not in operation (no power supply) Flashing rapidly Reset mode Double flash Modbus BOOT (during firmware update) Flashing Pre-operative mode Module in operation No error / no supply to module Error status or reset status Lit up red (e) / flashing green (r)
Page 169 Electric components and wiring The connection diagram below shows how the module is wired: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 170: At2402
Electric components and wiring AT2402 Module with two temperature inputs for thermocouples (e.g. flue gas temperature sensor, combustion chamber sensor). 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 Error or reset status Single Flash...
Page 171 Electric components and wiring + Thermo contact 1 + Thermo contact 2 - Thermo contact 1 - Thermo contact 2 AT2402 Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 172: At6402
Electric components and wiring AT6402 Module with six temperature inputs for thermocouples (e.g. flue gas temperature sensor, combustion chamber sensor). 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 Error or reset status Single Flash...
Page 173 Electric components and wiring For type K thermocouples, the following applies: Plus (+) = green, minus (-) = white Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 174: At4222
Electric components and wiring AT4222 Module with four temperature inputs for the measurement of PT100 and PT1000 sensors (e.g. boiler temperature sensor, store sensor,...). 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 Error or reset status...
Page 175 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. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 176: 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 177: 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: Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 178 Electric components and wiring Sensor characteristic line type K Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 179: 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 Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 180: 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 181 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". Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 182: 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 150] 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 183 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 Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 184: Terminating Resistor At Communication Module
The CS1012 communication module must be used for cabling the M-bus (meter bus). ⇨ See "CS1012" [page 148] 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 185: Appendix
None of the PT100 store sensors are connected any more using a Rinck element; instead they are connected directly to the SPS 4000. There is no longer an analysis via averager, as all temperatures can be read off directly on the SPS 4000.
Page 186: Lambda Probe 0-10V
Appendix Lambda probe 0-10V The residual oxygen is measured on the SPS 4000 using the broadband probe and the 0-10V signal of the sensor box. 8.1.2 Boiler program (Start-shut down) The diagram below illustrates a possible boiler program sequence without the occurrence of a fault:...
Page 187: Back Up/Restore Memory Card
The installation package is available as a compressed file “PVI_4.2.4.102_CD.zip”. ❒ Extract the installation package to any folder ❒ Go to that folder and run "Install.exe" ❒ Select the relevant language on the start screen Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 188 Appendix ❒ In the menu tree on the left, select "PVI Development" ❒ Click “Start installation" to run ➥ Follow the instructions of the installation wizard ➥ Once the software has been successfully installed, "B&R Automation" will appear in the start menu Step 2 - Runtime Utility Center ❒...
Page 189 ❒ To back up and restore memory cards, click the third menu item “Create / restore a drive image" ❒ Insert the CompactFlash card into the relevant slot in the computer or use an appropriate card reader Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 190 Appendix ❒ Click the “Update” button to browse the available drives ❒ Select the drive with the memory card from the dropdown menu and confirm Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 191 ➥ For better traceability, the filename should contain the name of the system/customer and the current date ➥ When creating the name, do not use any spaces, full stops or special characters (underscores "_" are allowed) ➥ The special data format "zp2" must not be changed Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 192 Appendix ❒ Confirm current file settings with “Save" The process can take some time depending on the amount of data. The progress bar shows the current status while the image file is being created. Once the backup has been created, a message appears stating that the process has been successfully completed Step 4 - Restore memory card Once again, the memory card must be recognised and correctly assigned.
Page 193 ❒ If you do not want to delete the data on the memory card, you can cancel the process here ❒ To start, confirm the warning message with “Yes" ➥ All the data on partitions on the memory card will be deleted and overwritten with the backup data Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 194: Connecting To The Sps With Pc
8.1.4 Connecting to the SPS with PC A PC connection to the SPS 4000 is required for the data exchange via the Froling visualisation software or for analysis via the System Diagnostic Manager. For a connection to the SPS 4000, the Ethernet interface integrated on the back of the display is used.
Page 195: Direct Connection To Sps 4000
If the system is not integrated into a local area network, the PC is connected directly to the Ethernet interface of the SPS 4000 with a cross-over cable. A cross-over cable is used for direct connections between two network- compatible devices. The difference compared to a conventional network cable is that the signals for sending and receiving data are crossed.
Page 196: Sps 4000 Network Settings
Appendix SPS 4000 network settings The network settings can be changed in the following menu: System menu Connections Network ❒ In the “Network” menu, tap the tab for configuration ➥ The parameters necessary for network configuration are displayed DHCP settings DHCP permits the assignment of the network configuration to network participants via a server.
Page 197 (e.g. 192.000.002.042 -> 192.0.2.42). It is important that every device in the network is assigned a different IP address. For manual input of an IP address into the PLC 4000, DHCP must be deactivated. ⇨ See "DHCP settings" [page 196] Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 198 Appendix ❒ Tap on the parameter "IpAdresse" ➥ A detail view of the parameter will be displayed ❒ Tap the numeric keypad icon ➥ Value inputs for editing the address are displayed ❒ Type in the relevant address using the numeric keypad ➥...
Page 199: Pc Network Settings
❒ Confirm your entry by tapping the confirm icon PC network settings Network settings in Windows XP To change the network settings under Windows XP, proceed as follows: ❒ Under "Start -> Settings" select the menu item "Network connections" Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 200 Appendix ❒ In the "Network connections" window, double click on "LAN connections" ➥ The status window for the LAN connections will open ❒ Click on the "Properties" button in the status window ➥ The properties window for the LAN connections will be opened Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 201 If the PC is connected to an existing network by a server/router: ❒ Select "Obtain IP address automatically" and press “OK” to confirm ➥ The network settings are called up automatically by the server/router and the PC is linked into the local network Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 202 Appendix If the PC is connected to an existing network by manually inputting the network settings (e.g. other than by a server/router), or the PC is directly connected to the PLC: ❒ Select "Use the following IP address" ❒ Input the IP address ➥...
Page 203 ➥ The Network and Sharing Center will be opened ❒ In the "Network and Sharing Center" window, click on "LAN connections" in the active networks ➥ The status window for the LAN connections will open Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 204 Appendix ❒ Click on the "Properties" button in the status window ➥ The properties window for the LAN connections will be opened ❒ Select the "Internet protocol version 4(TCP/IPv4)" element in the properties window and click on "Properties" ➥ The properties for the Internet protocol (TCP/IP) will be displayed Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 205 ➥ If the PC is connected to an existing network the IP address must not match any of the addresses of existing devices in the network. If the PC is directly connected to the PLC 4000, use codes such as "192.168.0.99" for the PLC and "192.168.0.100" for the PC Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 206 Appendix ❒ Inputting the subnet mask ➥ If the boiler is connected to an existing local network, the subnet mask must be set up to be the same as for the existing devices in the network. If the PC is directly connected to the PLC 4000, "255.255.255.0"...
Page 207: System Diagnostic Manager (Sdm)
➥ The System Diagnostic Manager of B&R is started The navigation area to select the desired category is located on the left side. The saving a log file is important for a functional analysis of the PLC 4000. Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 208: Saving Log File To Data Medium
Appendix Saving log file to data medium ❒ In the navigation area, select the category "Logger" ❒ Select the desired logger module and click on "Upload from target" ➥ The window for saving the logger file will be displayed. ❒ Select the desired directory and click on "OK” to start the saving process Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
Page 209: Create System Dump
❒ Select menu item “Parameters + Data Files” and continue with “OK” ➥ Confirm the security prompt ❒ To save the data, select the function “Upload form target”, select the desired directory and start the save process Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 210: Calibration Of The Lambda Probe
Appendix 8.1.6 Calibration of the lambda probe Start the manual calibration of the lambda probe in the following menu: System menu Boiler Lambda probe Important for manual calibration: ▪ Combustion chamber temperature less than 200 °C (can however be cancelled by acknowledgement) ▪...
Page 211: Notes
Appendix Notes 8.2 Notes Operating Instructions SPS 4000 (PP 65) | B0960623_en...
Page 212: Addresses
Appendix Addresses 8.3 Addresses 8.3.1 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 0043 (0)7248 606 0...

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