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Operating Instructions
Wood chip boiler T4 24-150
Translation of the original German operating instructions for the operator
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B0830519_en | Edition 09/05/2019
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Table of Contents
Related Manuals for Fröling T4 24-150
Summary of Contents for Fröling T4 24-150
- Page 1 Operating Instructions Wood chip boiler T4 24-150 Translation of the original German operating instructions for the operator Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! B0830519_en | Edition 09/05/2019 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 2: Table Of Contents
Table of Contents Table of Contents General T4 product overview Safety Hazard levels of warnings Pictograms used General safety information Permitted uses 2.4.1 The Clean Air Act 1993 and Smoke Control Areas 2.4.2 Permitted fuels Wood chips Wood pellets Changing the fuel 2.4.3 Non-permitted fuels Protective equipment for operating staff... - Page 3 Checking and cleaning the combustion grate 5.5.2 Cleaning the measurement line of the underpressure controller 5.5.3 Cleaning the Lambda probe Emissions measurement by chimney sweep or regulatory body 5.6.1 Switch on the system 5.6.2 Start emissions measurement Replacement parts Operating Instructions T4 24-150 | B0830519_en...
- Page 4 Table of Contents Disposal information 5.8.1 Disposal of the ash 5.8.2 Disposal of system components Troubleshooting General fault with power supply 6.1.1 Behaviour of system after a power failure Excessive temperature Faults with fault message 6.3.1 Procedure for fault messages Acknowledging a fault message Stiffness / Tipping grate blockage Notes...
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Page 5: General
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. Operating Instructions T4 24-150 | B0830519_en... -
Page 6: T4 Product Overview
General T4 product overview 1.1 T4 product overview Wood chip boiler – Froling T4 Main switch: switches the power supply on and off for the entire system High-limit thermostat STL Mains supply Control panel of the Lambdatronic H 3200 T4 Touch controller Status LED (operating status): - GREEN constant: BOILER SWITCHED ON - GREEN flashing (interval: 5 sec OFF, 1 sec ON): BOILER SWITCHED OFF... - Page 7 Ash box for combined automatic ash removal from combustion chamber and heat exchanger Combustion chamber door with screw lock and inspection glass WOS system with turbulators and automatic drive for heat exchanger cleaning Broadband probe Flue gas temperature sensor Operating Instructions T4 24-150 | B0830519_en...
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Page 8: Safety
Safety Hazard levels of warnings 2 Safety 2.1 Hazard levels of warnings This documentation uses warnings with the following hazard levels to indicate direct hazards and important safety instructions: DANGER The dangerous situation is imminent and if measures are not observed it will lead to serious injury or death. -
Page 9: Pictograms Used
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 Operating Instructions T4 24-150 | B0830519_en... -
Page 10: General Safety Information
Safety General safety information 2.3 General safety information DANGER If the device is used incorrectly: Incorrect use of the system can cause severe injury and damage. When operating the system: ❒ Observe the instructions and information in the manuals. ❒ Observe the details on procedures for operation, maintenance and cleaning, as well as troubleshooting in the individual manuals. -
Page 11: Permitted Uses
"Permitted fuels". The Froling T4-24, T4-30, T4-40, T4-50, T4-60, T4-75, T4-90, T4-100, T4-110, T4-130 and T4-150 have been recommended as suitable for use in smoke control areas when burning fuels as listed under "Permitted fuels". Operating Instructions T4 24-150 | B0830519_en... -
Page 12: Permitted Fuels
Safety Permitted uses 2.4.2 Permitted fuels Wood chips Criterion Designation as per Description acc. to ÖNORM M 7133 ÖNORM M 7133 EN ISO 17225 Water content air-dried suitable for storage Size P16S Fine wood chip P31S Medium-sized wood chip Note on standards Fuel acc. -
Page 13: Wood Pellets
Therefore: ❒ If the fuel is changed (e.g. from wood chips to pellets), the system must be reset by Froling customer services. Operating Instructions T4 24-150 | B0830519_en... -
Page 14: Non-Permitted Fuels
Safety Permitted uses 2.4.3 Non-permitted fuels The use of fuels not defined in the "Permitted fuels" section, and particularly the burning of refuse, is not permitted. CAUTION In case of use of non-permitted fuels: Burning non-permitted fuels increases the cleaning requirements and leads to a build-up of aggressive sedimentation and condensation, which can damage the boiler and also invalidates the guarantee. -
Page 15: Safety Devices
(protection against overheating/excess pressure) SAFETY VALVE When the boiler pressure reaches a maximum of 3 bar, the safety valve opens and the heated water is blown off in the form of steam. Operating Instructions T4 24-150 | B0830519_en... -
Page 16: Residual Risks
Safety Residual risks 2.7 Residual risks WARNING When touching hot surfaces: Severe burns are possible on hot surfaces and the flue gas pipe! When work is carried out on the boiler: ❒ Shut down the boiler according to procedure (“Boiler off” operating status) and allow it to cool down ❒... -
Page 17: Emergency Procedure
In case of fire in the system: Risk of death by fire and poisonous gases Emergency procedure in case of fire: ❒ Leave the boiler room ❒ Close the doors ❒ Inform the fire department Operating Instructions T4 24-150 | B0830519_en... -
Page 18: Notes For Operating A Heating System
Notes for operating a heating system Installation and approval of the heating system 3 Notes for operating a heating system Carrying out modifications to the system and changing or disabling safety equipment is prohibited. Always comply with all fire, building and electrical regulations when installing or operating the system, in addition to following the operating instructions and mandatory regulations that apply in the country in which the tank is operated. -
Page 19: Ventilation Of The Boiler Room
▪ Complies with the applicable standards ▪ Less of a drop in output due to reduced limescale build-up ▪ Less corrosion due to fewer aggressive substances ▪ Long-term cost savings thanks to improved energy efficiency Operating Instructions T4 24-150 | B0830519_en... -
Page 20: Notes For Using Pressure Maintenance Systems
Notes for operating a heating system Notes for using pressure maintenance systems Permitted water hardness for the fill and make-up water in accordance with VDI 2035: Overall heat Total hardness at Total hardness at Total hardness at output <20 l/kW minimum >20 <50 l/kW minimum >50 l/kW minimum individual heat output... -
Page 21: Return Temperature Control
Please note in this respect that flue gas temperatures lower than 160K above room temperature can occur in the permitted operating range of the boiler. Operating Instructions T4 24-150 | B0830519_en... - Page 22 Notes for operating a heating system Chimney connection/chimney system 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! Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 23: Operating The System Assembly And Initial Startup
NOTICE If condensation escapes during the initial heat-up phase, this does not indicate a fault. ❒ Tip: If this occurs, clean up using a cleaning rag. Operating Instructions T4 24-150 | B0830519_en... -
Page 24: Filling/Refilling The Store With Fuel
Operating the System Filling/refilling the store with fuel 4.2 Filling/refilling the store with fuel When filling the store you should always ensure that you are using the right fuel: ⇨ See "Permitted fuels" [page 12] 4.2.1 Loading of fuel for a partially emptied store with rotary agitator If there is still sufficient fuel in the store (the head of the rotary agitator is completely covered with fuel and the rotary agitator arms are not extended), the store can be filled:... -
Page 25: Blowing In Pellets For A Store With Pellet Screw
❒ Switch off the boiler by tapping “Boiler off” at the mode icon and allow to cool for at least two hours ❒ Close all openings to the store to seal out dust ❒ Blow the fuel into the store 4.2.5 Blowing in fuel for an empty store with rotary agitator Operating Instructions T4 24-150 | B0830519_en... -
Page 26: Drainage Of Fuel Store
Operating the System Filling/refilling the store with fuel NOTICE! If the head of the rotary agitator is already free of material and the arms / spring blades are extended, the store must not be filled until the following actions have been taken: ❒... - Page 27 ▪ Reduce the dumping height onto the rotary agitator ▪ Avoid compressing the wood chips, e.g. by carefully adding to the fuel store ▪ Design the walls in the bunker so they are as smooth as possible Operating Instructions T4 24-150 | B0830519_en...
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Page 28: Switching On The Power Supply
Operating the System Switching on the power supply 4.3 Switching on the power supply ❒ Turn on the main switch ➥ There is voltage at all of the boiler's components ➥ When the control has completed the system start, the boiler is ready for operation 4.4 Operate the boiler using the touch display 4.4.1 Overview of the touch display... -
Page 29: Status Display
Discards any values entered without saving; and closes messages Back to basic display Accesses all system information Opens quick menu. Selection of functions depending on user level, configuration and current status. Tap to change parameters (dropdown menu or numeric keypad) Operating Instructions T4 24-150 | B0830519_en... -
Page 30: Display Icons For Froeling-Connect/Remote Control
Operating the System Operate the boiler using the touch display Opens system menu. Menu display depends on user level and configuration Back to higher menu level. Display icons for froeling-connect/remote control The icons for connection status and remote control are displayed at the top left of the touch display. -
Page 31: Navigation Within The System Menu
Tap the respective tab to carry out settings in the menus. Icon Status Temperatures Times Service General settings Solar heat meter Operating Instructions T4 24-150 | B0830519_en... -
Page 32: Changing Parameters
Operating the System Operate the boiler using the touch display Changing parameters If there is a “pencil” symbol next to a parameter text, the parameter can be edited. Depending on the type of parameter, it can be edited using the numeric keypad or by selecting from a list and then tapping on the “Confirm”... -
Page 33: Quick Menu
List of all pending boiler faults and how to eliminate them. Setting wizard Switching on for the first time: Setting the language, production number, date and time Connect: Setting parameters required for the boiler to use the “froeling-connect.com” (IP address, display password, …) Operating Instructions T4 24-150 | B0830519_en... -
Page 34: Select Information Displays
Operating the System Operate the boiler using the touch display 4.4.2 Select information displays Tapping on the freely selectable information displays in the basic display opens the respective menu. The following options are available depending on the system configuration: Menu Selection Icon Description... - Page 35 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! Operating Instructions T4 24-150 | B0830519_en...
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Page 36: Switch Boiler On/Off
Operating the System Operate the boiler using the touch display 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. 4.4.3 Switch boiler ON/OFF The hydraulic system is controlled in accordance with the mode that is set, regardless of boiler status,... -
Page 37: Change Boiler Mode
Heating circuits und domestic hot water tanks are supplied with heat in accordance with the selected heating times. NOTICE! Consult the enclosed operating instructions for the boiler controller for a detailed description of the boiler modes. Operating Instructions T4 24-150 | B0830519_en... -
Page 38: Change Date And Time
Operating the System Operate the boiler using the touch display 4.4.5 Change date and time Tap on the displayed date and time to change the date and time in the basic display. Use the up and down arrows to adjust the settings and tap on the “Confirm” icon to save. -
Page 39: One-Time Extra Loading Of An Individual Dhw Tank
In the case of several DHW tanks, the “extra loading” function in the quick menu is used to start a one-time extra loading of all existing DHW tanks. ⇨ See "Quick menu" [page 33] Operating Instructions T4 24-150 | B0830519_en... -
Page 40: Set The Heating Curve Of A Heating Circuit
Operating the System Operate the boiler using the touch display 4.4.9 Set the heating curve of a heating circuit A flow temperature is calculated using the heating curve of the heating circuit Example of depending on the outside air temperature and the two adjustable parameters “flow floor heating temperature at -10°C outside air temperature”... -
Page 41: Change Room Temperature (Heating Circuit Without Room Temperature Sensor)
4.4.11 Change room temperature (heating circuit mit room temperature sensor) ❒ Tap information display of the desired heating circuit ❒ Tap “+” or “-” to adjust the desired room temperature Operating Instructions T4 24-150 | B0830519_en... -
Page 42: Switch Heating Circuit Mode
Operating the System Operate the boiler using the touch display NOTICE! If this selection is not configured in the information display in the basic display, open the components in the system menu. Otherwise, the room temperature can be adjusted directly on the remote control/room console. -
Page 43: Lock Display/Switch User Level
The names of the DHW tank, storage tank and heating circuits can be freely selected. A maximum of 20 characters are available for the name. ❒ Navigate to the “System” menu and open the “Renaming” sub-menu ❒ Tap the desired component and use the keyboard to rename it Operating Instructions T4 24-150 | B0830519_en... -
Page 44: Configure The Holiday Program
Operating the System Operate the boiler using the touch display 4.4.15 Configure the holiday program Setting a start and end date in the holiday program determines a time period in which an active heating circuit is regulated for the set setback temperature and in which an activated boiler is not loaded. -
Page 45: Switch The Boiler On/Off On The Room Console
[page 30]), the boiler can be switched on and off on the room console. Boiler remote control deactivated Boiler remote control activated ❒ Switch the boiler ON/OFF by tapping on the current operating status Operating Instructions T4 24-150 | B0830519_en... -
Page 46: Switching Off The Power Supply
Operating the System Switching off the power supply 4.6 Switching off the power supply WARNING When turning off the main switch in automatic mode: Serious combustion faults leading to serious accidents are possible. Before turning off the main switch: ❒ Switch boiler off by tapping “Boiler OFF” ➥... -
Page 47: Checking The Fill Level Of The Ash Container And Emptying If Required
Before checking the ash level / emptying the ash container: ❒ Switch off the boiler by tapping “Boiler off” ➥ The boiler follows the shutdown procedure and switches to "Boiler off" status. Operating Instructions T4 24-150 | B0830519_en... - Page 48 Operating the System Checking the fill level of the ash container and emptying if required In “Boiler off” status: ❒ Open the insulated door (A) ❒ Open the side clamps (B) and remove the ash container cover (C) ➥ Note the sticker on the cover of the ash container! ❒...
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Page 49: Servicing The System
❒ Before starting work, switch off the boiler and allow it to cool down for at least 1 hour NOTICE We recommend that you keep a maintenance book in accordance with ÖNORM M7510 of the Technical Directive for Fire Prevention (TRVB) Operating Instructions T4 24-150 | B0830519_en... -
Page 50: Required Tools
Servicing the system Required tools WARNING Incorrect inspection and cleaning: Incorrect or insufficient inspection and cleaning of the boiler can cause serious faults in combustion (e.g. spontaneous combustion of carbonisation gases / flash fires) and this can lead to serious accidents and damage! Take the following precautions: ❒... -
Page 51: Maintenance Work By The Operator
➥ There should be no significant leakage of lubricant. NOTICE! The presence of a few drops of lubricant may be normal. If there is significant loss of lubricant, inform your installer or Froling customer services. Operating Instructions T4 24-150 | B0830519_en... -
Page 52: Recurrent Check And Cleaning
Servicing the system Maintenance work by the operator 5.3.2 Recurrent check and cleaning WARNING Inspection and cleaning work with the boiler switched on Serious injuries from automatic startup of the boiler and severe burns from hot parts and the flue gas pipe are possible. Therefore: ❒... -
Page 53: Clean The Combustion Chamber
➥ Do not throw the ash onto the grate ❒ Remove the ash deposits from the walls of the entire combustion chamber (top, side, back) using an ash scraper or broom (working with an ash vacuum is best) Operating Instructions T4 24-150 | B0830519_en... -
Page 54: Lubricate The Stoker Bearings [~1000 B/Every Six Months]
Servicing the system Maintenance work by the operator ❒ Remove the burn-out opening ❒ Check the firebricks and combustion grate for dirt and deposits and clean if necessary (ash vacuum recommended) ❒ Install the burn-out opening ➥ The opening must be facing the fuel infeed side! Lubricate the stoker bearings [~1000 B/every six months] ❒... -
Page 55: Cleaning The Heat-Exchanger And Flue Gas Collection Chamber
❒ Unlock the cover by turning the star-shaped screw knob and open T4 60-150: ➥ In the case of low down boiler rooms, you can remove the heat exchanger cover: ❒ Undo the screw connections on the hinge of the cover and remove the cover Operating Instructions T4 24-150 | B0830519_en... -
Page 56: Clean The Heat Exchanger Pipes [~2500 Bh/Yearly]
Servicing the system Maintenance work by the operator 3. 3. 3. 4. ❒ Pull out the guide plate(s) ❒ Clean the entire area with an ash vacuum ❒ Remove spring cotter from the eyebolt ❒ Remove eyebolt from the mounting sheet and WOS shaft ❒... - Page 57 ❒ After cleaning, reassemble the dismantled components in the reverse order ➥ Take care to insert the guide plate properly (do not leave a large gap between the boiler and the sheet metal). ➥ Ensure that all of the maintenance openings are properly closed. Operating Instructions T4 24-150 | B0830519_en...
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Page 58: Clean The Flue Gas Temperature Sensor [~2500 Bh/Yearly]
Servicing the system Maintenance work by the operator Clean the flue gas temperature sensor [~2500 Bh/yearly] 1. Remove the insulating cover and thermal insulation 2. Release the retaining screw and remove the flue gas temperature sensor from the flue gas pipe 3. -
Page 59: Servicing The Condensing Boiler Heat Exchanger (Optional)
For this reason it is important to check the condensation drain regularly! Operating Instructions T4 24-150 | B0830519_en... - Page 60 Servicing the system Servicing the condensing boiler heat exchanger (optional) At the back of the boiler below the condensing boiler heat exchanger: ❒ Position a suitable container below the siphon to catch the condensation that runs ❒ Remove and check the siphon for dirt and deposits ❒...
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Page 61: Maintenance Work By Technicians
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). Operating Instructions T4 24-150 | B0830519_en... -
Page 62: Checking And Cleaning The Combustion Grate
Servicing the system Maintenance work by technicians 5.5.1 Checking and cleaning the combustion grate ❒ Open the insulating door and combustion chamber door ❒ T4 24-110: Remove the burn-out opening (A) ❒ T4 130-150: Remove the two-part fireclay burn-out opening (B) ➥... -
Page 63: Cleaning The Lambda Probe
▪ Do not clean the Lambda probe with compressed air ▪ Do not use chemical cleaning agents (brake cleaner, etc.) ▪ Careful handling of the Lambda probe, no “tapping” or cleaning with a wire brush Operating Instructions T4 24-150 | B0830519_en... -
Page 64: Emissions Measurement By Chimney Sweep Or Regulatory Body
Servicing the system Emissions measurement by chimney sweep or regulatory body 5.6 Emissions measurement by chimney sweep or regulatory body Various legal regulations stipulate that heating systems must be inspected periodically. In Germany this is regulated by the First Federal Emissions Protection Ordinance (BimSchV) in the last amended version, and in Austria by various state laws. -
Page 65: Start Emissions Measurement
(e.g. AWG in Austria) ❒ You can separate and clean recyclable materials and send them to a recycling centre. ❒ The combustion chamber must be disposed of as builders' waste. Operating Instructions T4 24-150 | B0830519_en... -
Page 66: Troubleshooting
Troubleshooting General fault with power supply 6 Troubleshooting 6.1 General fault with power supply Error characteristics Cause of error Elimination of error Nothing is shown on the General power failure display Main switch is turned off Turn on the main switch No power to the controller FI circuit breaker or line Switch on the FI circuit... -
Page 67: Faults With Fault Message
Open error display Current fault list System menu Diagnostics The error display lists all current faults ❒ Open by tapping the listed fault ❒ The “Message” tab displays the current fault. Operating Instructions T4 24-150 | B0830519_en... -
Page 68: Acknowledging A Fault Message
Troubleshooting Acknowledging a fault message ❒ Press the “Error resolution” tab to view possible causes and troubleshooting procedures ❒ Once the fault has been resolved, tap the Cancel icon to return to the basic display. 6.4 Acknowledging a fault message Trace and remove the fault and then: ❒... -
Page 69: Stiffness / Tipping Grate Blockage
❒ Press the unlocking mechanism (A) on the servo-motor ❒ Manually tilt the tipping grate until the grate opens/closes easily NOTE: Clean the tipping grate after the stiffness has been alleviated, ⇨ See "Checking and cleaning the combustion grate" [page 62] Operating Instructions T4 24-150 | B0830519_en... -
Page 70: Notes
Notes 7 Notes Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 71 Notes Operating Instructions T4 24-150 | B0830519_en...
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Page 72: Appendix Addresses
Appendix Addresses 8 Appendix 8.1 Addresses 8.1.1 Address of manufacturer FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL 0043 (0)7248 606 0 FAX 0043 (0)7248 606 600 EMAIL info@froeling.com INTERNET www.froeling.com Customer service Austria 0043 (0)7248 606 7000 Germany 0049 (0)89 927 926 400 Worldwide...
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