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Operating Instructions
TX
English version of operating instructions for operators.
Read and follow the instructions and safety instructions!
Subject to technical change.
Fröling Heizkessel- und Behälterbau Ges.m.b.H
Industriestraße 12
A-4710 Grieskirchen
Tel +43 (0) 7248 606-0
Fax +43 (0) 7248 606-600
info@froeling.com
www.froeling.com
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Summary of Contents for Froling TX
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Page 1: Operating Instructions
Operating Instructions English version of operating instructions for operators. Read and follow the instructions and safety instructions! Subject to technical change. Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 info@froeling.com www.froeling.com... -
Page 2: Guarantee Conditions
Dear customer, Congratulations on choosing a quality product from FRÖLING. The FRÖLING TX wood chip boiler features a state-of-the-art design that conforms to all currently applicable standards and testing guidelines. Please read and observe the operating instructions and always keep them close to the boiler for reference. -
Page 3: Table Of Contents
Contents 1 Product Overview 2 Safety 2.1 Safety Information 2.2 Permitted uses 2.2.1 Permitted fuels ....................9 Wood chips....................9 Pellets ......................9 Changing the fuel ..................10 2.2.2 Non-permitted fuels..................10 2.3 Qualification of operating staff 2.4 Protective equipment for operating staff 2.5 Design Information 2.5.1 Official approval and obligation to report ............ - Page 4 Contents 4.1 General information on maintenance 4.2 Inspection and cleaning 4.2.1 Inspection....................23 Checking the thermal discharge safety device ..........23 Check safety valve ..................23 Check the system pressure................23 Check the geared motors ................23 4.2.2 Cleaning ...................... 24 Empty the ash container retort...............
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Page 5: Product Overview
1.1 Product Overview Pos. Description Symb. Wood chip boiler - Fröling TX Switch cabinet with integrated Lambdatronic H 3200 controller Main switch: switch the power supply on and off for the entire system Control panel of the Lambdatronic H 3200 controller... - Page 6 General Product Overview Pos. Description Symb. Fuel transport unit with top gravity shaft, burn back flap or rotary valve as a burn back protection system and stoker screw for fuel transport Automatic tipping grate Combustion chamber door Heat exchanger door Efficiency Optimisation System (WOS) with turbulators Boiler outfeed connection Boiler return connection...
- Page 7 General Product Overview Pos. Description Symb. Automatic drive for heat exchanger cleaning Induced draught fan Flue gas recirculation (optional) Secondary air control with actuator drive Primary air control with actuator drive Automatic ignition Flue gas recirculation for step grate Flue gas recirculation for tipping grate Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen...
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Page 8: Safety
Safety Safety Information 2 Safety 2.1 Safety Information DANGER Non-permitted use! Incorrect use of the boiler can cause severe injuries and damage! The instructions and information provided in the instructions should be observed! Details on procedure for operation, maintenance and cleaning, as well as troubleshooting for the boiler are included in the individual instructions. -
Page 9: Permitted Uses
Ensure that any faults, which might impair safety, are rectified immediately. The TX series wood chip boiler is intended exclusively for heating central heating water. Use only the fuels specified under 2.2.1. -
Page 10: Changing The Fuel
Safety Qualification of operating staff Changing the fuel CAUTION Incorrectly set fuel parameters: Incorrect parameter settings have a significant effect on the functioning of the boiler, and as a result this will void the guarantee. If the fuel is changed (e.g. from wood chips to pellets), the system must be reset by Fröling customer services. -
Page 11: Protective Equipment For Operating Staff
Safety Protective equipment for operating staff 2.4 Protective equipment for operating staff You must ensure that staff have the protective equipment specified by accident prevention regulations. During operation, inspection and cleaning of the boiler: - Sturdy shoes - protective gloves 2.5 Design Information It is forbidden to carry out modifications to the boiler or to change or deactivate safety equipment. -
Page 12: Ventilation Of Boiler Room
Safety Design Information 2.5.3 Ventilation of boiler room The openings for the supply air and the exhaust air should be arranged as close to opposite each other as possible to achieve a good thermal draught effect. Draw in the supply air directly from outside. Expel the exhaust air directly outside. -
Page 13: Safety Devices
Safety Safety devices 2.6 Safety devices Automatic operation button If the boiler overheats: Press and hold this button for 5 seconds Automatic operation is switched off and the controller follows the boiler shutdown procedure The pumps continue to run! Never use the main switch! Safety temperature limiter (back Page 14, Devices for preventing the boiler from overheating of boiler) -
Page 14: Devices For Preventing The Boiler From Overheating
Safety Safety information for installation room 2.6.1 Devices for preventing the boiler from overheating Thermal discharge safety device At around 100 °C a valve opens and sends cold water to the safety heat-exchanger to decrease the temperature. Safety Temperature Limiter STL Stops combustion at a max. -
Page 15: Residual Risks
Safety Residual risks 2.8 Residual risks WARNING Touching hot surfaces! Hot parts and the flue pipe can cause serious burns! Always wear protective gloves when working on the boiler. Only operate the boiler using the handles provided for this purpose Insulate the flue gas pipes and avoid touching them during operation Before carrying out maintenance work on/in the boiler:... -
Page 16: Emergency Procedure
Safety Emergency procedure 2.9 Emergency procedure 2.9.1 System overheating If the system overheats in spite of the safety devices, proceed as follows: Keep all the doors on the boiler closed. Turn off the boiler by pressing the button for 5 seconds Under no circumstances use the main switch! Open all mixer taps and switch on all pumps. -
Page 17: Operating The System
Assembly, installation and initial startup of the boiler must only be carried out by qualified staff, and these procedures are described in the accompanying assembly instructions. See TX assembly instructions NOTICE Optimum efficiency and efficient, low-emission operation can only be guaranteed if the system is set up by trained professionals and observing the standard factory settings. -
Page 18: Loading Wood Chips In An Empty Store
Operating the system Filling/ refilling the store with fuel 3.2.2 Loading wood chips in an empty store CAUTION! If the head of the stirrer is already free of material and the arms / spring blades are extended, then the feeder unit must be active during the filling process. -
Page 19: Blowing In Pellets For A Partially Emptied Store With Stirrer
Operating the system Filling/ refilling the store with fuel 3.2.4 Blowing in pellets for a partially emptied store with stirrer If there is still sufficient fuel in the store (the head of the stirrer is completely covered with fuel), the store can be filled: Switch off the boiler by pressing the button for 5 seconds and allow it to cool down for at least two hours. - Page 20 Operating the system Filling/ refilling the store with fuel Call up the “Manual operation” menu Activate the following units in the order shown: - Ash screw - Grate tip drive - Stoker FORWARD - BBF manual (or Rotary valve ON) - Oufeeder - manual FORWARD Blow the fuel into the store...
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Page 21: Heating The Boiler
Operating the system Heating the boiler 3.3 Heating the boiler 3.3.1 Switching on the system Turn the main switch on the side of the switch cabinet to the “ON” position After the system check by the controller, the system is ready for operation “Boiler Off”... -
Page 22: Boiler Maintenance
Boiler maintenance General information on maintenance 4 Boiler maintenance 4.1 General information on maintenance DANGER Working on electrical components Risk of serious injuries from electric shocks Work on electrical components should only be carried out by authorised technicians WARNING Servicing when the boiler is switched on or hot: Serious injuries from automatic startup of the boiler and serious burns on hot parts and on the flue gas pipe are possible! Only carry out work on the boiler when the main switch is... -
Page 23: Inspection And Cleaning
Boiler maintenance Inspection and cleaning 4.2 Inspection and cleaning Regular cleaning of the boiler extends its life and is a basic requirement for smooth running based on output. So clean the boiler regularly! Recommended: When cleaning, use an ash vacuum. 4.2.1 Inspection Checking the thermal discharge safety device Check the seal of the discharge valve at regular intervals... -
Page 24: Cleaning
Boiler maintenance Inspection and cleaning 4.2.2 Cleaning Notice -> Main switch OFF Only check the ash level when “Boiler OFF” Empty the ash container retort The ash containers must be emptied at the correct intervals according to energy requirements and fuel quality. Remove the ash container cover and check the level If the ash container is full, unscrew the wing nuts on the discharge flange... -
Page 25: Empty The Heat Exchanger Ash Container
Boiler maintenance Inspection and cleaning Empty the heat exchanger ash container For heat exchanger with ashcan: Remove the star-shaped screws of the ashcan Take out the ashcan and remove the ash For heat exchanger with ash screws: Remove the ash container cover and check the level If the ash container is full, unscrew the wing nuts on the flange Separate the ash container and take it to the ash disposal point Fröling Heizkessel- und Behälterbau Ges.m.b.H... -
Page 26: Monthly Inspection
Boiler maintenance Inspection and cleaning 4.2.3 Monthly inspection Activate service mode For cleaning tasks in the boiler activate service mode: Press and hold this button for 5 seconds The controller follows the shutdown procedure and starts with the cleaning cycle After the cleaning cycle the boiler goes to the operating status, “Cleaning possible”... - Page 27 Boiler maintenance Inspection and cleaning Close the heat exchanger door and open the combustion chamber door Remove a lot of ash with a shovel Clean the step grate and sloping plates with the furnace tool Clean the side walls of the combustion chamber with the furnace tool Clean the primary air openings in the step grate and sloping plates with a suitable tool (screwdriver or similar) After cleaning the combustion space and the combustion chamber:...
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Page 28: Annual Inspection
Boiler maintenance Inspection and cleaning 4.2.4 Annual inspection Carry out annually, however at least after 2500 service hours! For the annual inspection: Switch off the main switch when the boiler has cooled down Clean the heat-exchanger Remove the insulated cover and open the cleaning cover Remove all dirt and deposits for the flue gas chamber. -
Page 29: Clean The Flue Gas Recirculation (Fgr) (Optional)
Boiler maintenance Inspection and cleaning Clean the flue gas recirculation (FGR) (optional) Remove the pipe insulation from the inspection cover. Remove the inspection cover and clean the pipes of the flue gas recirculation unit with a brush After cleaning the pipes: Remove the inspection cover of the flue gas recirculation box Clean the interior with an ash vacuum Remove the inspection cover of the... -
Page 30: Clean The Induced Draught Fan
Boiler maintenance Inspection and cleaning Clean the induced draught fan Remove both cables from the induced draft fan Mark the flange position and loosen the screws on the fan flange Take out the induced draught fan and clean the blower wheel with a brush. -
Page 31: Check The Combustion Chamber Overpressure Sensor
Boiler maintenance Inspection and cleaning Check the combustion chamber overpressure sensor Loosen the retaining screw. Pull the combustion chamber overpressure sensor out of the spacer pipe. Clean the sensor with a fine cloth. Check that the spacer pipe is free. Insert the combustion chamber overpressure sensor and fix gently with fixing screws... -
Page 32: Instructions For Measuring Emissions
Boiler maintenance Instructions for measuring emissions 4.3 Instructions for measuring emissions 4.3.1 Measurement at rated load Ensure the highest possible heat consumption: Ensure that heating pumps are switched on Open mixer valves and radiator valves Set the boiler loading time to the current time Set the boiler temperature setpoint to 85°C Chimney sweep mode takes over this function Activate chimney-sweep mode... -
Page 33: Maintenance Agreement / Customer Service
Boiler maintenance Maintenance agreement / Customer service 4.4 Maintenance agreement / Customer service Long service life with a service agreement! Regular maintenance and servicing by a heating specialist will ensure a long, trouble-free service life for your heating system. It will ensure that your system stays environmentally-friendly and operates efficiently and cost-effectively. -
Page 34: Troubleshooting
Troubleshooting General faults in power supply 5 Troubleshooting 5.1 General faults in power supply Error characteristics Cause of error Error correction Nothing is shown on the • General power failure display • FI circuit breaker or line Switch on the FI circuit breaker or No power to the controller protection is switched off line protection... -
Page 35: Faults With Fault Message
Troubleshooting Faults with fault message 5.3 Faults with fault message If a fault has occurred and has not yet been cleared: Status LED (1) flashes red A fault message is shown on the display (2) An internal distinction is made between 2 types of message: Warning Boiler follows shutdown procedure Error...
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