Fröling T4e 20 Installation Instructions Manual

Wood chip boiler

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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.

M1981024_en | Edition 13/08/2024

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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. M1981024_en | Edition 13/08/2024...
Page 2 5 Transport and storage ..........................45 5.1 Delivery configuration..........................45 5.2 Temporary storage..........................45 5.3 Positioning............................. 46 5.4 Positioning at the installation site ......................47 5.4.1 Remove boiler from pallet ......................47 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 3 Affixing the identification plate ....................64 7 Start-up................................. 65 7.1 Before commissioning / configuring the boiler ..................65 8 Decommissioning ............................66 8.1 Mothballing............................66 8.2 Disassembly............................66 8.3 Disposal ..............................66 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 4 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 5 Identification code / Material Disposal information Corrugated cardboard Paper collection Wood Check the regulations for correct disposal applicable in your local area Low Density Plastics collection Polyethylene (LDPE) LDPE Expanded polystyrene Plastics collection M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 6 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. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 7 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) M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 8 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) M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 9 ▪ The system must be protected against gnawing and nesting by animals (such as rodents) ▪ No flammable materials in proximity to the system ▪ Observe national and regional regulations regarding the installation of smoke detectors and carbon monoxide detectors M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 10 Please note within the permissible operating range of the boiler flue gas temperatures lower than 160K above room temperature may occur. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 11 ▪ 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 12 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! M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 13 Boiler in room air-dependent operation Air extraction system (such as centralised dust extraction system, room ventilation) Under-pressure monitoring system Combustion air supply from outside M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 14 The installation site must have a minimum volume in accordance with the applicable regional standards. Note on standards Austria: OIB Guideline 3 - Hygiene, health and environmental protection Germany: Model Firing Ordinance (MFeuV) M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 15 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. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 16 (TIP: system separation) ▪ Check the antifreeze dosage regularly according to the manufacturer's instructions ▪ Dispose of frost-protected heat transfer medium at the end of its shelf life and refill the system M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 17 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. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 18 Fit a microbubble separator in the pipes to the boiler Recommendation: Ä Follow the manufacturer's instructions! M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 19 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 20 ▪ 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)
Page 21 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“ M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 22 Auxiliary current consumption at 30% of rated heat 0.039 0.039 0.039 0.038 output (η Auxiliary current consumption in standby mode (P 0.005 0.005 0.005 0.005 Energy efficiency class of the boiler Energy efficiency index (EEI) of boiler M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 23 2. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 24 Auxiliary current consumption in standby mode (P 0.007 0.007 0.006 0.006 Energy efficiency class of the boiler Energy efficiency index (EEI) of boiler Temperature controller used Lambdatronic H 3200 Class of the temperature controller M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 25 2. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 26 Auxiliary current consumption in standby mode (P 0.004 0.004 0.004 Energy efficiency class of the boiler Energy efficiency index (EEI) of boiler Temperature controller used Lambdatronic H 3200 Class of the temperature controller M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 27 2. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 28 Auxiliary current consumption in standby mode (P 0.005 0.004 0.006 Energy efficiency class of the boiler Energy efficiency index (EEI) of boiler Temperature controller used Lambdatronic H 3200 Class of the temperature controller M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 29 2. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 30 Auxiliary current consumption at 30% of rated heat 0.047 0.051 0.056 0.056 0.057 output (η Auxiliary current consumption in standby mode (P 0.009 0.012 0.015 0.014 0.014 Temperature controller used Lambdatronic H 3200 Class of the temperature controller M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 31 2. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 32 Auxiliary current consumption at 30% of rated heat 0.086 0.094 0.101 0.100 0.100 output (η Auxiliary current consumption in standby mode (P 0.010 0.012 0.015 0.016 0.016 Temperature controller used Lambdatronic H 3200 Class of the temperature controller M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 33 2. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 34 Auxiliary current consumption in standby mode (P 0.014 0.014 0.014 Temperature controller used Lambdatronic H 3200 Class of the temperature controller Contribution of the temperature controller to the energy efficiency index of a combined system M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 35 1. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 36 Auxiliary current consumption in standby mode (P 0.019 0.020 0.022 Temperature controller used Lambdatronic H 3200 Class of the temperature controller Contribution of the temperature controller to the energy efficiency index of a combined system M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 37 1. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 38 Auxiliary current consumption in standby mode (P 0.014 0.013 0.013 Temperature controller used Lambdatronic H 3200 Class of the temperature controller Contribution of the temperature controller to the energy efficiency index of a combined system M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 39 1. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 40 Auxiliary current consumption in standby mode (P 0.023 0.025 0.026 Temperature controller used Lambdatronic H 3200 Class of the temperature controller Contribution of the temperature controller to the energy efficiency index of a combined system M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 41 1. Specified emission values refer to dry flue gas with an oxygen content of 10 % and under standard conditions at 0°C and 1013 millibars. The evaluation values reported are rounded to the nearest whole number. Values labelled with "<" represent the relative detection limit of the measuring methods or measuring device configurations used. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 42 Flue gas mass flow at partial load kg/h kg/s 0.011 0.012 0.013 Required feed pressure at nominal load mbar 0.05 Required feed pressure at partial load mbar 0.02 Maximum permissible feed pressure mbar Flue pipe diameter M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 43 Flue gas temperature at nominal load °C Flue gas temperature at partial load - volume concentration at nominal load / partial load 13.3 / 12.3 13.8 / 12.8 13.8 / 12.8 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 44 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% M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 45 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! M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 46 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 front heat exchanger cover Ä Use the spanner provided M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 47 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 48 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". M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 49 700 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 50 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 51 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 52 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 53 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 54 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 55 ▪ 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 We recommend installing some sort of monitoring device (such as a thermometer) M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 56 Remove the cable ties from the tag connector r Bind the individual cores together with cable ties (A) r Attach cable and cable ties to the strain reliefs on the boiler M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 57 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 58 Core module High-limit thermostat (STL) Wood chip module Service interface Plug power pack Device connection terminal Digital module (optional - address 1) Hydraulic module Feed system module in the back panel (address M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 59 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 60 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. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 61 Fit the tread to the screw heads, move it sideways until it clicks and then attach Ä The tread makes it easier to perform maintenance on the heat exchanger and controller box M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 62 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) M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 63 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 M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 64 6.6.3 Affixing the identification plate r Glue the supplied identification plate (A) and additional identification plate (B - for electrostatic particle separator) visibly to the right-hand side panel of the boiler M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 65 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. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 66 (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. M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 67 Notes M1981024_en | Installation instructions Wood chip boiler T4e 20-180...
Page 68 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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