Fröling T4e Bedienungsanleitung

Operating Instructions

Wood chip boiler T4e

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!

B1560520_en | Edition 11/08/2020

Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of contents

1 General 5

1.1 Product overview T4e 6

2 Safety 8

2.1 Hazard levels of warnings 8

2.2 Pictograms used 9

2.3 General safety information 10

2.4 Permitted uses 11

2.4.1 The Clean Air Act 1993 and Smoke Control Areas 11

2.4.2 Permitted fuels 13

Wood chips

Wood pellets

Changing the fuel

2.4.3 Non-permitted fuels 14

2.5 Qualification of operating staff 14

2.6 Protective equipment for operating staff 14

2.7 Safety devices 15

2.8 Residual risks 16

2.9 Emergency procedure 18

2.9.1 Overheating of the system 18

2.9.2 Smell of flue gas 18

2.9.3 Fire in the system 18

3 Notes for operating a heating system 19

3.1 Installation and approval of the heating system 19

3.2 General information for installation room (boiler room) 19

3.3 Requirements for central heating water 20

3.4 Notes for using pressure maintenance systems 22

3.5 Return temperature control 22

3.6 Use with storage tank 23

3.7 Chimney connection/chimney system 23

4 Operating the System 24

4.1 Assembly and initial startup 24

4.2 Filling/refilling the store with fuel 25

4.2.1 Loading of fuel for a partially emptied store with rotary agitator 25

4.2.2 Loading wood chips in an empty store (not under pressure) 25

4.2.3 Blowing in pellets for a store with pellet screw 26

4.2.4 Blowing in fuel for a partially emptied store with rotary agitator 26

4.2.5 Blowing in fuel for an empty store with rotary agitator 26

4.2.6 Drainage of fuel store 27

4.3 Switching on the power supply 29

4.4 Operate the boiler using the touch display 29

4.4.1 Overview of the touch display 29

Table of contents

2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Status display

Control icons

Display icons for froeling-connect/remote control

Navigation within the system menu

Changing parameters

Change time window

Quick menu

4.4.2 Select information displays 35

4.4.3 Switch boiler ON/OFF 37

4.4.4 Change boiler mode 38

4.4.5 Change date and time 39

4.4.6 Change desired DHW tank temperature 39

4.4.7 One-time extra loading of an individual DHW tank 40

4.4.8 One-time extra loading of all existing DHW tanks. 40

4.4.9 Set the heating curve of a heating circuit 41

4.4.10 Change room temperature (heating circuit without room temperature sensor) 42

4.4.11 Change room temperature (heating circuit mit room temperature sensor) 42

4.4.12 Switch heating circuit mode 43

4.4.13 Lock display/switch user level 44

4.4.14 Change the name of the components 44

4.4.15 Configure the holiday program 45

4.5 Switch the boiler ON/OFF on the room console 46

4.6 Switching off the power supply 47

4.7 Checking the fill level of the ash container and emptying if required 48

5 Servicing the system 51

5.1 General information on servicing 51

5.2 Required tools 52

5.3 Maintenance work by the operator 53

5.3.1 Weekly inspection 53

Checking the system pressure

Check the thermal discharge valve (from T4e 130)

Checking the safety valve

Checking the quick vent valve

Checking the geared motors

5.3.2 Recurrent check and cleaning 55

Before starting inspection and cleaning work

After inspection and cleaning work

Lubricate the stoker bearings [~1000 B/every six months]

Check chain and sprockets [~1,000 operating hours / every six month]

Clean the combustion chamber [~2500 Bh /yearly]

Clean heat exchanger and flue gas collection chamber [~2500 Bh/yearly]

Clean the flue gas temperature sensor [~2500 Bh/yearly]

Clean the flue gas pipe [~2500 Bh /yearly]

Check the draught regulation damper [~2500 Bh/yearly]

5.4 Maintenance work by technicians 60

5.4.1 Checking and cleaning the combustion grate 61

5.4.2 Cleaning the measurement line of the underpressure controller 61

5.4.3 Cleaning the Lambda probe 62

5.4.4 Clean the particle filter (optional) and heat exchanger pipes 64

Remove and clean the particle filter (optional)

Cleaning the heat exchanger pipes

5.4.5 Adjust the power of the WOS system 67

T4e 20-60

T4e 80-180

Table of contents

Operating Instructions T4e | B1560520_en 3

T4e 200-350

5.5 Emissions measurement by chimney sweep or regulatory body 70

5.5.1 Switch on the system 70

5.5.2 Start emissions measurement 71

5.6 Replacement parts 71

5.7 Disposal information 71

5.7.1 Disposal of the ash 71

5.7.2 Disposal of system components 71

6 Troubleshooting 72

6.1 General fault with power supply 72

6.1.1 Behaviour of system after a power failure 72

6.2 Excessive temperature 72

6.3 Faults with fault message 73

6.3.1 Procedure for fault messages 73

7 Notes 75

8 Appendix 76

8.1 Addresses 76

8.1.1 Address of manufacturer 76

Customer service

8.1.2 Address of the installer 76

Table of contents

4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

1 General

Thank you for choosing a quality product from Froling. The product features a state-of-

the-art design and conforms to all currently applicable standards and testing

guidelines.

Please read and observe the documentation provided and always keep it close to the

system for reference. Observing the requirements and safety information in the

documentation makes a significant contribution to safe, appropriate, environmentally

friendly and economical operation of the system.

The constant further development of our products means that there may be minor

differences from the pictures and content. If you discover any errors, please let us

know: [email protected].

Subject to technical change.

Warranty and Guarantee Conditions

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.

General 1

Operating Instructions T4e | B1560520_en 5

1.1 Product overview T4e

5.1

5.2

5.3

5.4

1Wood chip boiler – Fröling T4e

2Main switch: switches the power supply on and off for the entire system

3High-limit thermostat STL

4Mains connection

5Lambdatronic H 3200 boiler controller, ⇨ See "Overview of the touch display" [page

29]

5.1 Status display (operating status), ⇨ See "Status display" [page 30]

5.2 Large touch screen for displaying and changing operating statuses and parameters

5.3 Brightness sensor to automatically adjust the display brightness

5.4 USB port for connecting a USB stick for software updates

6Insulating cover

7Heat exchanger cover

8Service port

1General

Product overview T4e

6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

9Lambda probe for fuel adjustment

10 Integrated return temperature control with pump, mixing valve and ball valve

11 Speed regulated EC induced draught fan

12 WOS system with turbulators and automatic drive for heat exchanger cleaning of the

second and third draught

13 Twin-chamber rotary valve (Ø 200 mm) as burn back protection system (RSE)

14 Integrated electrostatic particle separator (optional)

15 Stoker screw (Ø 100 mm)

16 Ceramic igniter with function monitoring

17 Silicon carbide combustion chamber with automatic tipping grate

18 Tipping grate with drive (rotation angle 110°)

19 Ash box for combined automatic ash removal from combustion chamber and heat

exchanger

20 Combustion chamber door with inspection glass

General 1

Product overview T4e

Operating Instructions T4e | B1560520_en 7

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. You must follow the instructions!

WARNING

The dangerous situation may occur and if measures are not observed it will lead

to serious injury or death. Work with extreme care.

CAUTION

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.

2Safety

Hazard levels of warnings

8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.2 Pictograms used

The following symbols are used in the documentation and/or on the boiler to show

what is required and forbidden and to give warnings.

In accordance with the Machinery Directive, signs fitted directly within the danger area

of the boiler indicate immediate hazards or safety procedures. These stickers must not

be removed or covered.

Refer to the operating

instructions

Wear safety shoes

Wear protective gloves Turn off the main switch

Keep the doors closed

Unauthorised access prohibited

Warning - hot surface Warning - hazardous electrical

voltage

Warning - hazardous or irritant

materials

Warning - automatic boiler

startup

Warning of injury to fingers or

hands, automatic fan

Warning of injury to fingers or

hands, automatic screw

Warning of injury to fingers or

hands, gear/chain drive

Warning of injury to fingers or

hands, cutting edge

Safety 2

Pictograms used

Operating Instructions T4e | B1560520_en 9

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 respective manuals.

❒ Any work above and beyond this (e.g. servicing) must be carried out by a

heating engineer approved by Fröling Heizkessel- und Behälterbau GesmbH

or by Froling customer services

WARNING

External influences:

Negative external influences, such as insufficient combustion air or non-standard

fuel, can cause serious faults in combustion (e.g. spontaneous combustion of

carbonisation gases or flash fires) which can in turn cause serious accidents!

When operating the boiler, please note the following:

❒ Instructions and information regarding versions and minimum values, as well

as standards and guidelines for heating components in the instructions must

be observed.

WARNING

Severe injuries and damage can be caused by an inadequate flue gas system.

Problems with the flue gas system, such as poor cleaning of the flue pipe or

insufficient chimney draught, can cause serious faults in combustion (such as

spontaneous combustion of carbonisation gases or flash fires).

Take the following precautions:

❒ Optimum boiler performance can only be guaranteed if the flue gas system is

functioning correctly.

2Safety

General safety information

10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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