Froling T4 Series Bedienungsanleitung

Installation and Operating Instructions

Ash discharge into a standard dustbin

for T4 / TX / P4 Pellet

Translation of the original German operating and installation instructions for technicians and operators

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

M1590214_en | Edition 05/02/2015

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

Table of Contents

1 General 4

1.1 Product overview 5

2 Safety 6

2.1 Hazard levels of warnings 6

2.2 Permitted uses 7

2.2.1 Area of Application 7

2.2.2 Permitted fuels 7

2.3 General safety information 7

2.4 Qualification of staff 8

2.4.1 Qualification of assembly staff 8

2.4.2 Personal protective equipment for assembly staff 8

2.4.3 Qualification of operating staff 8

2.4.4 Protective equipment for operating staff 9

2.5 Design information 9

2.5.1 Standards 9

2.5.2 General information for installation room 9

3 Technology 10

3.1 Dimensions of ash transfer box for T4 / TX 10

3.2 Dimensions of ash transfer box for P4 Pellet 11

3.3 Technical specifications 12

4 Assembly 13

4.1 Materials supplied 14

4.2 Transport 14

4.3 Temporary storage 15

4.4 Installation site 15

4.5 Assembly overview 16

4.5.1 Ash transfer box for T4 / TX 16

4.5.2 Ash transfer box for P4 Pellet 17

4.5.3 Hose with screw, supporting post and gravity shaft 18

4.5.4 Standard dustbin 19

4.6 Assembling the ash discharge system 20

4.6.1 Modifying the ash transfer box for P4 Pellet (where required) 20

4.6.2 Modifying the ash transfer box for T4 / TX (where required) 21

4.6.3 Removing the boiler ash container 21

4.6.4 Assembling the ash transfer box on the T4 / TX 21

4.6.5 Assembling the ash transfer box on the P4 Pellet 22

4.6.6 Assembling the discharge pipe and supporting post 23

4.6.7 Assembling the coreless screw and drive unit with gravity shaft 24

4.6.8 Aligning the ash discharge system 26

4.6.9 Assembling the standard dustbin 27

4.7 Connecting the system 28

4.7.1 Connecting the ash discharge system to the TX 28

4.7.2 Connecting the safety switch on the standard dustbin to the TX 28

Table of Contents

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

4.7.3 Connecting the ash discharge system to the T4 29

4.7.4 Connecting the safety switch on the standard dustbin to the T4 29

4.7.5 Connecting the ash discharge system to the P4 Pellet 30

4.7.6 Connecting the safety switch on the standard dustbin to the P4 Pellet 30

5 Servicing 31

5.1 Inspection and cleaning 31

5.1.1 Checking the ash level in the dustbin 32

5.1.2 Emptying the dustbin 33

5.1.3 Checking the geared motors 34

5.1.4 Maintenance agreement / Customer service 34

5.1.5 Replacement parts 34

5.1.6 Disposal information 35

Disposal of the ash

Disposal of system components

6 Troubleshooting 36

6.1 Blockage in ash discharge on the T4/TX 36

6.2 Blockage in ash discharge on the P4 Pellet 38

7 Appendix 40

7.1 Addresses 40

7.1.1 Address of manufacturer 40

7.1.2 Address of the installer 40

Table of Contents

Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 3

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.

This is an incomplete machine as defined by the Machinery Directive. The incomplete

machine must only be started up when it has been confirmed that the machine, in

which the incomplete machine has been installed, conforms to the provisions of

Directive 2006/42/EC.

Compliance with the open provisions and verification of the correct installation must be

confirmed in the delivery certificate of the declaration of installation (included in

documentation).

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.

Issuing a delivery

certificate

1General

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

1.1 Product overview

AAsh transfer box for T4 / TX

BAsh transfer box for P4 Pellet

CCladding for P4 Pellet

(mounted onto the boiler instead of the insulated doors)

DDischarge pipe with coreless screw for transporting ash to the gravity shaft

ESupporting post for holding up and levelling the discharge pipe

FDrive unit with geared motor

GGravity shaft with flexible high-temperature hose and safety switch

H240 l standard dustbin with attachments

General 1

Product overview

Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 5

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 or damage to property.

2Safety

Hazard levels of warnings

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

2.2 Permitted uses

Froling’s ash discharge system is only applicable to the removal of combustion

residue in the form of ash from the Froling boilers detailed in the section entitled “Area

of Application”. The ash will be discharged into the provided standard dustbin or any

other suitable recipient.

The unit should only be operated when it is in full working order. It must be operated in

accordance with the instructions, observing safety precautions, and you should ensure

you are aware of the potential hazards. The inspection and cleaning intervals in the

operating instructions must be observed. Ensure that any faults which might impair

safety are rectified immediately.

The manufacturer or supplier is not liable for any damage resulting from non-permitted

uses.

Only original spare parts or specific alternative spare parts authorised by the

manufacturer may be used. Any kind of change or modification made to the product

will invalidate its manufacturer’s CE conformity. In such cases, the product will need to

undergo new hazard evaluation procedures by the operator. The operator will then be

fully responsible for the declaration of conformity according to the valid guideline(s) for

the product and will need to attach the new CE label to the device. This person will

then assume all of the rights and responsibilities of a manufacturer.

2.2.1 Area of Application

The Froling ash discharge system can be used in conjunction with the following

Froling boilers:

▪T4 24 – 150 wood chip boiler

▪ TX 150 – 250 wood chip boiler

▪ P4 Pellet 45 – 105 pellet boiler

2.2.2 Permitted fuels

Only use the fuels permitted in the boiler. Please refer to the section entitled

“Permitted fuels” in the boiler’s assembly and operating instructions.

2.3 General safety information

❒ Refer to the safety information, information on residual risks and design

information in the installation and operating instructions for the boiler in question.

NOTICE

In addition to these instructions, please also note all specifications, safety

information and standards in the installation and operating instructions for the

boiler in question.

Safety 2

Permitted uses

Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 7

2.4 Qualification of staff

2.4.1 Qualification of assembly staff

CAUTION

Assembly and installation by unqualified persons:

Risk of personal injury and damage to property

During assembly and installation:

❒ Observe the instructions and information in the manuals

❒ Only allow appropriately qualified personnel to work on the system

Assembly, installation, initial startup and servicing must always be carried out by

qualified personnel:

- Heating technician / building technician

- Electrical installation technician

- Froling customer services

The assembly staff must have read and understood the instructions in the

documentation.

2.4.2 Personal protective equipment for assembly staff

You must ensure that staff have the protective equipment specified by accident

prevention regulations.

▪ For transportation, setup and assembly:

- suitable work wear

- protective gloves

- sturdy shoes (min. protection class S1P)

2.4.3 Qualification of operating staff

CAUTION

If unauthorised persons enter the installation room / boiler room:

Risk of personal injury and damage to property

❒ The operator is responsible for keeping unauthorised persons, in particular

children, away from the system.

Only trained operators are permitted to operate the unit. The operator must also have

read and understood the instructions in the documentation.

2Safety

Qualification of staff

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

2.4.4 Protective equipment for operating staff

You must ensure that staff have the protective equipment specified by accident

prevention regulations.

▪ For operation, inspection and cleaning:

- suitable work wear

- protective gloves

- sturdy shoes

2.5 Design information

Carrying out modifications to the system and changing or deactivating 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.

2.5.1 Standards

The system must be installed and commissioned in accordance with the local fire and

building regulations. The following standards and regulations should be observed in

any case:

ÖNORM / DIN EN 60204 Safety of machines; Electrical equipment of machines, Part 1:

General requirements

TRVB H 118 Technical directives for fire protection/prevention (Austria)

ÖNORM H 5170 Construction and fire protection requirements (Austria)

ÖNORM H 5190 Heating systems - Acoustic insulation

EN ISO 13857 Safety of machines; Safety distances for maintaining a safe

distance from hazardous areas

2.5.2 General information for installation room

▪ Danger of fire due to flammable materials.

–No flammable materials should be stored near the ash discharge system.

– Flammable objects (e.g. clothing) must not be put on the system to dry.

– The floor under the system must be fire-resistant.

▪ There is a possibility of dust near the system.

Safety 2

Qualification of staff

Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 9

3 Technology

3.1 Dimensions of ash transfer box for T4 / TX

Dimensi

Description Unit Ash discharge system for

T4 TX

H1 Total height of ash discharge system mm 1,725

H2 Height of standard dustbin mm 1,040

H3 Height of drive unit and gravity shaft

(excluding high-temperature hose)

mm 470

H4 Height of ash transfer box mm 305 325

W1 Total width of ash discharge system mm 2,700

W2 Width of ash transfer box

incl. connection flange

mm 430

W3 Width of ash transfer box

without connection flange

mm 330

W4 Width of standard dustbin mm 600

L1 Length of ash transfer box mm 430 340

L2 Length of standard dustbin mm 725

DHose diameter mm 90

3Technology

Dimensions of ash transfer box for T4 / TX

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

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