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Fröling T4e Operating Instructions Manual
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Fröling T4e Operating Instructions Manual

Fröling T4e Operating Instructions Manual

Wood chip boiler
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Operating instructions
Wood chip boiler T4e
Translation of original German version of operating instructions for operators.
Read and follow all instructions and safety instructions.
All errors and omissions excepted.
B1560624_en | Edition 13/08/2024

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Summary of Contents for Fröling T4e

  • Page 1 Operating instructions Wood chip boiler T4e Translation of original German version of operating instructions for operators. Read and follow all instructions and safety instructions. All errors and omissions excepted. B1560624_en | Edition 13/08/2024...
  • Page 2 Setting the heating curve for a heating circuit................40 4.4.10 Change room temperature (heating circuit without room temperature sensor) ....... 41 4.4.11 Change room temperature (heating circuit with room temperature sensor) ......42 B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 3 Adjust the power of the WOS system ..................73 5.4.6 Changing the blades on the rotary valve ................. 76 5.4.7 Cleaning the FGR duct for the T4e 300-350................79 5.5 Emissions measurement by chimney sweep or regulatory body ............80 5.5.1 Switch on the system ....................... 80 5.5.2...
  • Page 4 Our sale and delivery conditions will be applicable. These conditions have been made available to customers, and customers have been made aware of them at the time of order completion. You can also find the guarantee conditions on the enclosed guarantee certificate. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 5 Brightness sensor to automatically adjust the display brightness USB port for connecting a USB stick for software updates Insulating cover Heat exchanger cover Service – interface (for T4e 300-350 rear insulated door) B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 6 Silicon carbide combustion chamber with automatic tipping grate Tipping grate with drive (rotation angle 110°) Ash box for combined automatic ash removal from combustion chamber and heat exchanger Combustion chamber door with inspection glass B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 7 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. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 8 Warning of injury to fingers or Warning of injury to fingers or hands, automatic fan hands, automatic screw Warning of injury to fingers or Warning of injury to fingers or hands, gear/chain drive hands, cutting edge B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 9 (such as spontaneous combustion of carbonisation gases or flash fires). Take the following precautions: r Optimum boiler performance can only be guaranteed if the flue gas system is functioning correctly. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 10 Clean Air Act requirements. The Froling T4e 20, T4e 25, T4e 30, T4e 35, T4e 45, T4e 50, T4e 60, T4e 80, T4e 90, T4e 100, T4e 110, T4e 130, T4e 140, T4e 150, T4e 160, T4e 170, T4e 180, T4e 200, T4e 250, T4e 300 and T4e 350 have been recommended for use in smoke control areas when burning wood chip and wood pellets only.
  • Page 11 Therefore: r If the fuel is changed (e.g. from wood chips to pellets), the system must be reset by Froling customer services. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 12 ▪ For operation, inspection and cleaning: - suitable work wear - protective gloves - sturdy shoes - dust mask When working with dust from the electrostatic particle separator, use dust masks in filter class FFP2 or higher B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 13 For T4e 130-350: THERMAL DISCHARGE VALVE (protection against overheating) The thermal discharge valve opens at approx. 100°C and feeds cold water to the safety heat exchanger to lower the boiler temperature B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 14 Non-standard fuels can cause serious faults in combustion (e.g. spontaneous combustion of carbonisation gases / flash fires) which can lead to serious accidents! Take the following precautions: r Only use fuels specified in the "Permitted fuels" section of these operating instructions. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 15 The boiler follows the shutdown procedure and switches to "Boiler off“ mode r Allow the boiler to cool for at least 1 hour r Switch off the main switch and take precautions to prevent accidental switching on B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 16 Emergency procedure in case of fire: r Leave the room in which the boiler is installed and close the doors r Press the on-site EMERGENCY STOP button r Inform the fire department B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 17 ▪ 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 B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 18 The combustion air is taken from the installation site. The unpressurised flow of the required air quantity must be ensured accordingly. 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 B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 19 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) B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 20 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. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 21 (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 B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 22 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. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 23 NOTICE! Please see the technical data contained in the assembly instructions for further information about standards and regulations as well as the flue gas temperatures when clean and the other flue gas values! B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 24 NOTICE If condensation escapes during the initial heat-up phase, this does not indicate a fault. r Tip: If this occurs, clean up using a cleaning rag. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 25 If there is still sufficient fuel in the fuel store (the rotary agitator head is completely covered with fuel and the rotary agitator arms / spring blades are not extended), the store can be filled. r Load the fuel at the filling opening B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 26 Switch off the boiler by tapping “Boiler off” at the mode icon and allow to cool for at least two hours r Close all openings to the store to seal out dust r Blow the fuel into the store B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 27 If the rotary agitator head is already free from material and the rotary agitator arms / spring blades are extended, they should be covered with the remaining fuel in the fuel store and retracted. This should be done well before the agreed loading time. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 28 Blow the fuel into the fuel store If the fuel store is completely empty and there is no residual fuel to redistribute: r Contact Froling and seek advice before filling the fuel store B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 29 4.3 Switching on the power supply r Turn on the main switch Ä There is voltage at all of the boiler's components Ä When the control has completed the system start, the boiler is ready for operation B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 30 Ü "Change boiler mode" [} 38] Display icons for using froeling-connect Ü "Display icons for froeling-connect/remote control" [} 32] Brightness sensor for automatically adjusting the brightness of the display LED frame to display the current system status B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 31 Opens quick menu. Selection of functions depending on user level, configuration and current status. Tap to change parameters (dropdown menu or numeric keypad) Opens system menu. Menu display depends on user level and configuration Back to higher menu level. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 32 Tap the info menu in the basic display and navigate to the “froeling-connect” menu Ä The connection status is displayed in the lower range (connected, deactivated, …) NOTICE! Consult the “froeling-connect” operating instructions for a detailed description of the connection status as well as troubleshooting B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 33 Tap the respective tab to carry out settings in the menus. Icon Status Temperatures Times Service General settings Solar heat meter B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 34 Use the up and down arrows to set the start and end time and save by tapping the “Confirm” icon The time window set is saved for all selected days of the week. To delete a saved time window, tap on the “Recycle bin” icon next to it. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 35 Setting wizard Switching on for the first time: Setting the language, manufacturer’s number, date and time Connect: Setting parameters required for the boiler to use the “froeling-connect.com” (IP address, display password, …) B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 36 System CPU/RAM capacity Display of the CPU and RAM capacity in percent 1. This selection merges two tiles together, reducing the maximum number of information displays! B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 37 When using more than two store sensors, it is possible to have an information display with storage tank temperatures in accordance with the number of sensors. An information display that spans two areas is used. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 38 Supply heating circuits and domestic hot water tanks with heat according to the selected heating times. NOTICE! Consult the enclosed operating instructions for the boiler controller for a detailed description of the boiler modes. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 39 Tap the mode icon for the DHW tank r Tap the “extra loading” icon Ä One-time loading of DHW tank starts. Once the selected DHW tank temperature setpoint has been reached, loading stops and the icon switches to “automatic”. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 40 “Lowering the flow temperature in setback mode”. Heating limits The outside air temperature heat limits are set in the “Temperatures” tab and they activate/deactivate the heating circuit depending on the outside air temperature or time period. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 41 5°C, and never more than 3°C for a low temperature circuit. Once the changes have been made, wait a few days and assess comfort levels before carrying out additional changes. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 42 To cancel this function prematurely, activate another mode/function. Continuous The heating circuit is regulated to the set setback mode setback temperature until activation of another mode/function. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 43 20 characters are available for the name. r Navigate to the “System” menu and open the “Renaming” sub-menu r Tap the desired component and use the keyboard to rename it B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 44 If the start date is set in the future, the “suitcase” icon will be highlighted in green. Once the set start time of the holiday program has been reached, the boiler switches to “holiday” mode B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 45 [} 32]), the boiler can be switched on and off on the room console. Boiler remote control deactivated Boiler remote control activated r Switch the boiler ON/OFF by tapping on the current operating status B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 46 Ä The components powered via the control cabinet are powered down Ä CAUTION: the expansion switch cabinet, which has its own power supply, is still live. NOTICE! Frost protection function is no longer active! B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 47 Disconnect the ash container from the locking lever and pull it away from the boiler r Close the hinged lid on the ash container Ä Make sure that the hinged lid snaps into place! B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 48 Insert the carrying bar with handles on the back of the ash container and secure it with a pipe locking pin Ä The crescent (1) of the carrying bar must face away from the ash container Ä The ash container can now be moved to the emptying point B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 49 Ä If either of the two chambers is more than two thirds full, empty the ash container r Put the cover on the ash container and use the side clamps to close it again B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 50 Disconnect the ash container from the locking lever and pull it away from the boiler r Close the two openings at the back of the ash container with the slide plates B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 51 (e.g. spontaneous combustion of carbonisation gases / flash fires) and this can lead to serious accidents and damage! Take the following precautions: r Clean the boiler following the instructions in the instruction manual. Follow the boiler operating instructions. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 52 53x53x110 cleaning brush to clean the WOS springs Not included: Spanner or box wrench AF 13 Screwdriver set (Philips, flat head, Torx T20, T25, T30) Small brush or cleaning brush Ash vacuum B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 53 Inform your installer If large pressure fluctuations are observed: r Ask an expert to inspect the expansion tank Check the thermal discharge valve (from T4e 130) r Check the seal of the discharge valve Ä The discharge pipe must not drip NOTICE! Exception: Boiler temperature >...
  • Page 54 Always wear protective gloves when working on the boiler r Only operate the boiler using the handles provided r Follow the procedure below when starting and finishing inspection and cleaning work B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 55 Ä Once self-cleaning is finished the boiler switches to "Boiler off" status. Lubricate the stoker bearings [~1000 B/every six months] r Lubricate stoker bearings with three grease gun strokes per grease nipple B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 56 Open the insulated door and remove the ash container r Open the combustion chamber door by turning the Allen wrench (90°) Ä Use the Allen wrench included (A – AF 13 mm) B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 57 Ä A – Notch in screw cap vertical: Door open Ä B – Notch in screw cap horizontal: Door closed Clean heat exchanger and flue gas collection chamber [~2500 Bh/yearly] T4e 20-60: T4e 80-350: B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 58 NOTICE! WOS springs do not have to be removed for cleaning! Cleaning the FGR duct of the T4e 20-250 [~2500 Bh / annually] The following steps for cleaning the FGR duct on a T4e 45-60 are illustrated. Proceed similarly for all other output ratings.
  • Page 59 Using a cleaning brush, carefully clean the FGR duct (A) and remove deposits from the air duct (B) NOTICE! During subsequent assembly, make sure that the air damper and servo- motor are set to the anti-clockwise stop. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 60 5 | Servicing the system Cleaning the FGR duct of the T4e 300-350 [~2500 Bh / annually] r Removing the centre back panel r Remove the cover including the air damper and servo-motor r Using a cleaning brush, carefully clean the FGR duct (A) and remove deposits from the air duct (B) NOTICE! During subsequent assembly, make sure that the air damper and servo-...
  • Page 61 Plug in the connection cable of the induced draught fan Check the draught regulation damper [~2500 Bh/yearly] r Check that the draught controller flap moves freely B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 62 Check the entire exhaust duct before and after the electrostatic particle separator for contamination r If there are visible deposits larger than 5 mm, clean the flue gas line in accordance with the manufacturer's instructions for the electrostatic particle separator B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 63 Please be advised that, in Austria, commercial systems with a rated heat output of 50 kW or more must be regularly tested at yearly intervals in accordance with the Heating Plant Regulations (Feuerungsanlagen-Verordnung). B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 64 Check the grate for damage such as cracks NOTICE! Small cracks and minor deformations of the grate will not affect performance. If however large cracks are found, or parts have broken off the grate, the grate must be exchanged. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 65 Servicing the system | 5 Replacing the combustion grate lNOTICE! Optionally a grate set for special fuels can be installed. On T4e 80-180 systems, the grate set is supplied with modification instructions. r Loosen the screws on the grate and lift it out...
  • Page 66 Adjust the position of the locking cam (I) to leave a gap of approx. 3 mm between the fuel feed-in grate (G) and tipping grate (H) r Fix the position using the screw (J) B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 67 Ä WARNING! Do not direct compressed air into under-pressure sensor cartridge! This could damage it! r After cleaning, refit the measurement line Depending on the design, port “-” (A) or “HI” (B) B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 68 Starting at boiler type 80: r Remove the back insulating cover by pulling it up and fold the thermal insulation down r Loosen the spring bolts and open the front cover of the heat exchanger B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 69 ▪ Do not clean the Lambda probe with compressed air ▪ Do not use chemical cleaning agents (brake cleaner, etc.) ▪ Handle the Lambda probe carefully, i.e. do not “tap” it or use a wire brush to clean it B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 70 Ä CAUTION: In so doing, pay special attention to electrode (C). Starting at boiler type 80: r Undo the external screws on the cover and carefully remove the entire unit Ä CAUTION: The electrodes (C) require special attention! B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 71 Carefully clean the isolator (D) and electrode with a soft cloth Cleaning the heat exchanger pipes For boilers without electrostatic precipitators: r Remove the lower cover plate from the reversing chamber on the stoker side r Remove the cover located behind it B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 72 Push the WOS springs with round cutouts down into the heat exchanger pipes Ä In so doing, press the inside panel of the spring into the slot (A) until it stops B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 73 EFFECT: The more tension is applied to the spring, the less force is required to clean the WOS pipes, and the more the impact is damped. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 74 Use the spring cotter pin and non-threaded stud to attach the clamping lever (A) EFFECT: The more tension is applied to the spring, the more force is applied to clean the WOS pipes, and the impact is increased. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 75 Use the spring cotter pin and non-threaded stud to attach the clamping lever to the applicable hole of console (C) EFFECT: The more tension is applied to the springs, the more force is applied to clean the WOS pipes, and the impact is increased. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 76 Pull off the washer, sprocket wheel, spacer ring and fitted key r Pull the geared motor and torque support off the shaft r Loosen the screws on the stoker and thread the tread upwards B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 77 Ä The bearing cover will be forced away from the housing r Pull the bearing cover including the rotor out of the housing r Remove the blades from the rotor and replace them with new ones B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 78 Ä High force required, or the shaft cannot be rotated: Remove a shim from behind the reaction plate r Repeat the procedure until the rotor can be rotated NOTICE! Assemble all components in reverse order B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 79 Servicing the system | 5 5.4.7 Cleaning the FGR duct for the T4e 300-350 Ü "Cleaning the FGR duct of NOTICE! For disassembly of the air damper see chapter the T4e 300-350 [~2500 Bh / annually]" [} 60]. r Take off the maintenance cover under the air duct...
  • Page 80 Ä When the control has completed the system start, the boiler is ready for operation r Switch the boiler on by tapping “Boiler ON” Ä Automatic mode is active. The heating system is controlled via the controller according to the selected mode in automatic mode B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 81 (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. B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 82 100°C. The pumps continue to run. Once the temperature falls below approx. 75°C, the STL can be reset mechanically. r Unscrew the cap on the STB (high-limit thermostat) r Unlock the STL by pressing with a screwdriver B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 83 The error display lists all current faults r Open by tapping the listed fault r The “Message” tab displays the current fault. r Press the “Error resolution” tab to view possible causes and troubleshooting procedures B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 84 Tap the Cancel icon to close the current fault and display the fault list r Tap the Cancel icon again and confirm that you have read all of the errors to return to the basic display Ä The boiler is in the previously set mode B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 85 Notes B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 86 B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 87 B1560624_en | Operating instructions Wood chip boiler T4e...
  • Page 88 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...