Operating Instructions
Lambdamat LM 1000 SPS
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!
B1300015_en | Edition 11/08/2015
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Table of contents
1 General 5
1.1 Lambdamat LM 1000 Product Overview 6
2 Safety 9
2.1 Hazard levels of warnings 9
2.2 Pictograms used 10
2.3 General safety information 11
2.4 Permitted uses 12
2.4.1 Permitted fuels 12
Wood chips
12
Wood pellets
13
Wood shavings
13
Miscanthus
13
Changing the fuel
14
2.4.2 Non-permitted fuels 14
2.4.3 Qualification of operating staff 15
2.4.4 Protective equipment for operating staff 15
2.5 Design information 15
2.5.1 Installation and approval of the heating system 15
2.5.2 General information for installation room (boiler room) 16
2.5.3 Requirements for central heating water 16
2.5.4 Return lift 17
2.5.5 Use with storage tank 17
2.5.6 Chimney connection/chimney system 17
2.6 Safety devices 18
2.6.1 External safety devices 19
Hydraulic chamber safety switch
19
Guardrail
19
2.7 Residual risks 20
2.8 Emergency procedure 21
2.8.1 Overheating of the system 21
2.8.2 Smell of flue gas 22
2.8.3 Fire in the system 22
3 Operating the system 23
3.1 Assembly and initial startup 23
3.2 Filling the store space with fuel 24
3.2.1 Loading of fuel for a partially emptied store with rotary agitator 25
3.2.2 Loading fuel in an empty store space with a rotary agitator 25
Rotary agitator with combined drive system
26
Rotary agitator with separate drive system (optional)
26
3.2.3 Blowing in fuel for a partially emptied store with rotary agitator 27
3.2.4 Blowing in fuel for an empty store with rotary agitator 27
Rotary agitator with combined drive system
28
Rotary agitator with separate drive system (optional)
29
3.2.5 Blowing in pellets for a store with pellet screw 29
3.2.6 Loading fuel in a store space with a sliding floor discharge unit 29
3.2.7 Loading fuel in a store space with a horizontal screw discharge unit 30
3.2.8 Loading fuel in a store space with an inclined screw discharge unit 30
Table of contents
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3.3 Heating up the boiler 31
3.3.1 Switching on the power supply 31
3.3.2 Switching on the boiler 31
3.3.3 Controlling the boiler 31
3.3.4 Switching off the boiler 31
3.3.5 Switching off the power supply 32
4 Servicing 33
4.1 General information on servicing 33
4.2 Inspection 35
4.2.1 Checking the system pressure 35
4.2.2 Checking the thermal discharge safety device 35
4.2.3 Checking the safety valve 35
4.2.4 Checking the geared motors 35
4.2.5 General visual inspection 36
4.3 Cleaning 37
4.3.1 Emptying the combustion chamber ash container (optional) 37
4.3.2 Cleaning the combustion and burning chamber 39
Cleaning the burning chamber
40
Cleaning the combustion chamber
40
4.3.3 Emptying the multicyclone ash container 41
4.4 Periodic inspection and cleaning 42
4.5 Periodic inspection and cleaning (approx. 1,000 hrs) 43
4.5.1 Cleaning the ash transfer chamber 43
4.5.2 Cleaning the broadband probe 44
4.5.3 Cleaning the flue gas temperature sensor 44
4.5.4 Cleaning the flue gas recirculation (FGR) duct 45
4.5.5 Checking the heat exchanger 45
4.5.6 Cleaning the area under the moving grate 46
4.6 Periodic inspection and cleaning (approx. 3,000 hrs) 47
4.6.1 Cleaning the combustion air fan 47
4.6.2 Checking the seal of the cleaning port doors 47
4.6.3 Checking the seal of the reversing chamber door 48
4.6.4 Checking the position and seal of the burning and combustion chamber door 48
4.6.5 Positioning the burning chamber and combustion chamber door 49
4.6.6 Cleaning the fireclay elements 50
4.6.7 Checking the underpressure controller 51
4.6.8 Checking the combustion chamber overpressure sensor 52
4.6.9 Cleaning the FGR blower fan 52
4.6.10 Cleaning the induced draft fan 53
4.6.11 Lubricating the bearings 53
4.6.12 Checking the flue gas pipe 53
4.7 Maintenance instructions for hydraulic system 54
4.8 Emissions measurement by chimney sweep or regulatory body 55
4.9 Maintenance agreement / Customer service 55
4.10 Replacement parts 55
4.11 Disposal information 56
4.11.1 Disposal of the ash 56
4.11.2 Disposal of system components 56
5 Troubleshooting 57
5.1 General faults in the power supply 57
Table of contents
Operating Instructions | B1300015_en 3
5.1.1 Behaviour of system after a power failure 57
5.2 Excessive temperature 57
5.3 Faults with fault message 57
5.3.1 Procedure for fault messages 58
5.3.2 Acknowledging a fault message 58
6 Appendix 60
6.1 Addresses 60
6.1.1 Address of manufacturer 60
6.1.2 Address of the installer 60
Table of contents
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1 General
Thank you for choosing a quality product from Froling. The product features a state-ofthe-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: doku@froeling.com.
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 | B1300015_en 5
1.1 Lambdamat LM 1000 Product Overview
1 Control cabinet with integrated
controller
12 Secondary air servo-motor I
2 Main switch: switches the power
supply on and off for the entire system
13 Automatic ignition
3 SPS 4000 control panel 14 Burning chamber temperature sensor
4 Reversing chamber door 15 Thermal discharge valve connection
5 Combustion chamber door 16 Boiler return connection
6 Burning chamber door 17 Safety valve connection
7 Combustion air blower fan 18 Boiler flow connection
8 Ash container 300l (optional) 19 Flue gas recirculation (FGR)
(optional)
9 Drive for ash removal (optional) 20 Primary air servo-motor flue gas
recirculation (FGR)
10 Burning chamber overpressure
monitor
21 Secondary air servo-motor flue gas
recirculation (FGR)
11 Under-pressure controller
1
General
Lambdamat LM 1000 Product Overview
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
22 Compressed air tank of compressed
air cleaner (optional)
25 Secondary air servo-motor II
23 Air distribution frame of compressed
air cleaner (optional)
26 Tertiary air servo-motor
24 Primary air actuator 27 High-limit thermostat (STL)
General
1
Lambdamat LM 1000 Product Overview
Operating Instructions | B1300015_en 7
28 Stoker duct 31 High-temperature firebrick-lined
combustion chamber
29 Burn back protection system (shown
here: burn back flap; optional: rotary
valve)
32 Multiple-pass heat exchanger
30 Moving grate 33 Cleaning door
1
General
Lambdamat LM 1000 Product Overview
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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.
Safety
2
Hazard levels of warnings
Operating Instructions | B1300015_en 9
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
Always wear protective gloves Wear hearing protection
Keep the doors closed Turn off the main switch
Unauthorised access prohibited No not walk on the surface
Warning - hot surface Warning - hazardous electrical
voltage
Warning - hazardous or irritant
materials
Warning - automatic boiler
startup
Hand injury warning Warning of injury to fingers or
hands, automatic fan
Cutting injury warning Warning of injury to fingers or
hands, automatic screw
2
Safety
Pictograms used
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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.
❒ Any work above and beyond this should be carried out by authorised heating
engineers 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.
Safety
2
General safety information
Operating Instructions | B1300015_en 11
2.4 Permitted uses
The Froling Lambdamat is designed exclusively for heating domestic water. Only use
fuels specified in the "Permitted fuels" section.
⇨ See "Permitted fuels" [page 12]
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.
2.4.1 Permitted fuels
Wood chips
Criterion ÖNORM M 7133 EN ISO 17225 Description as per
ÖNORM M 7133
Water content W20 M20 air-dried
W30 M30 suitable for storage
W35 - limited suitability for
storage
W40
1)
M40
1)
high-moisture wood
chips
W50
1)
- freshly-harvested
wood chips
Size G30 P16S Fine wood chip
G50 P31S Medium-sized wood
chip
G100
2)
P45S
2)
Coarse wood chips
1.partial load conditions only to a limited extent
2.
for hydraulic feeders only
NOTICE! In case of operating under partial load conditions and fuels with a water
content of >W35, power consumption of less than 65% of the nominal output is not
permitted!
EU: Fuel as per EN 17225 – Part 4: Wood chips class A1 / P16S-P45S
Additional for
Germany:
Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance
(BimSchV) - applicable version)
Note on standards
2
Safety
Permitted uses
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Wood pellets
Wood pellets made from natural wood with a diameter of 6 mm
EU: Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06
and/or: EN
plus
/ DIN
plus
certification scheme
General note:
Before refilling the store, check for pellet dust and clean if necessary.
Wood shavings
Wood shavings generally cause problems with combustion. Therefore their use is
permitted only with authorisation from Froling. The following additional points also
apply:
▪ Sawdust and carpentry waste should only be used with systems with a rotary
valve.
▪ The store should be fitted with a pressure release device in accordance with
regional regulations.
▪ The same limits apply for the permitted water content of sawdust as for wood
chips.
NOTICE
For fuels with a water content < W30 the boiler's rated heat output can only be
guaranteed if it is used with a flue gas recirculation system (FGR).
Miscanthus
Switchgrass or elephant grass (Latin name: miscanthus) is a C4 plant. Standards and
regulations for burning these plants have not been standardised, so the following
applies:
NOTICE! The regional regulations for burning miscanthus should be observed.
Operation may only be possible by special permit.
Note on standards
Safety
2
Permitted uses
Operating Instructions | B1300015_en 13
Changing the fuel
CAUTION
Incorrect fuel parameter settings:
Incorrect parameter settings have a significant adverse effect on the functioning
of the boiler, and as a result this will invalidate the guarantee.
Therefore:
❒ If the fuel is changed (e.g. from wood chips to pellets), the system must be
reset by Froling customer services.
2.4.2 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. Using non-standard fuels can also lead
to serious problems with combustion.
For this reason, when operating the boiler:
❒ Only use permitted fuels
2
Safety
Permitted uses
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2.4.3 Qualification of operating staff
CAUTION
If unauthorised persons enter the 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.
2.4.4 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For inspection and cleaning:
- suitable workwear
- protective gloves
- sturdy shoes
▪ Additional for operating:
- Hearing protection (sound level > 70 dB)
- Protective goggles
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 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
ÖNORM / DIN EN 12828 Heating Systems in Buildings
NOTICE! Each heating system must be officially approved.
The appropriate supervisory authority (inspection agency) must always be informed
when installing or modifying a heating system, and authorisation must be obtained
from the building authorities:
Austria: Inform the civic/municipal building authorities.
Germany: Notify an approved chimney sweep and the building authorities.
Note on standards
Safety
2
Permitted uses
Operating Instructions | B1300015_en 15
2.5.2 General information for installation room (boiler room)
Boiler room characteristics
▪ There must not be a potentially explosive atmosphere in the boiler room as the
boiler is not suitable for use in potentially explosive environments.
▪ The boiler room must be frost-free.
▪ The boiler does not provide any light, so the customer must provide sufficient
lighting in the boiler room in accordance with national workplace design
regulations.
▪ When using the boiler over 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
No flammable materials should be stored near the boiler. Flammable objects (e.g.
clothing) must not be put on the boiler to dry.
▪ Damage due to impurities in combustion air.
Do not use any solvents or cleaning agents containing chlorine in the room where
the boiler is installed.
▪ Keep the air suction opening of the boiler free from dust.
Ventilation of the boiler room
Ventilation air for the boiler room should be taken from and expelled directly outside,
and the openings and air ducts should be designed to prevent weather conditions
(foliage, snowdrifts, etc.) from obstructing the air flow.
Unless otherwise specified in the applicable building regulations for the boiler room,
the following standards apply to the design and dimensions of the air ducts:
ÖNORM H 5170 - Construction and fire protection requirements
TRVB H118 - Technical directives on fire protection/prevention
2.5.3 Requirements for central heating water
The following standards and guidelines apply:
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195-1
VDI 2035
SWKI 97-1
D.P.R. no. 412
NOTICE! Note on filling with make-up water: always bleed the filling hose before
connecting, in order to prevent air from entering the system.
Observe the standards and also follow the recommendations below:
❒
Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to
5.6 dH)
❒ Use softened water as the make-up water
❒ Avoid leaks and use a closed heating system to maintain water quality during
operation
Note on standards
Note on standards
2
Safety
Design information
16 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
2.5.4 Return lift
If the hot water return is below the minimum return temperature, some of the hot water
outfeed will be mixed in.
CAUTION
Risk of dropping below dew point/condensation formation if operated without
return temperature control.
Condensation water forms an aggressive condensate when combined with
combustion residue, leading to damage to the boiler.
Take the following precautions:
❒ Regulations stipulate the use of a return temperature control.
➥ The minimum return temperature is 65 °C. We recommend fitting some
sort of control device (e.g. thermometer).
2.5.5 Use with storage tank
NOTICE
In principle it is not necessary to use a storage tank for the system to run
smoothly. However, we recommend that you use the system with a storage tank,
as this ensures a continuous supply of fuel in the ideal output range of the boiler.
For the correct dimensions of the storage tank and the line insulation (in accordance
with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling.
⇨ See "Addresses" [page 60]
2.5.6 Chimney connection/chimney system
EN 303-5 specifies that the entire flue gas system must be designed to prevent,
wherever possible, damage caused by seepage, insufficient feed pressure and
condensation. 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.
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!
Safety
2
Design information
Operating Instructions | B1300015_en 17
2.6 Safety devices
1 BOILER OFF
(switches off the boiler to prevent overheating)
❒ Tap “Boiler off”
➥ Automatic mode is switched off
➥ Control system follows the boiler shutdown procedure
➥ The pumps continue to run
NOTICE! Never use the main switch!
2 MAIN SWITCH
(switches off the power supply)
Before carrying out work on the boiler:
❒ Tap “Boiler off”
➥ Automatic mode is switched off
➥ Control system follows the boiler shutdown procedure
❒ Switch off the main switch and let the boiler cool down
3 SAFETY OVERLOAD SWITCHES, MOTOR PROTECTION SWITCHES, RESIDUAL
CURRENT PROTECTIVE DEVICES (RCD)
Switch off the related component in the event of fault currents or overloads.
4 SAFETY TEMPERATURE LIMITER (STL)
(protection against overheating)
The STL switches off the combustion system when the boiler reaches 95 - 100°C. The
pumps continue to run. Once the temperature falls to below approx. 85°C, the STL
can be reset mechanically.
5 DOOR CONTACT SWITCH
When the door is opened, the induced draught is kept at a constant speed and the
combustion air and FGR blower fan stops.
2
Safety
Safety devices
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TV 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
SAFETY VALVE
(not shown, supplied by the customer)
When the boiler pressure reaches a maximum of 6 bar, the safety valve opens and the
heated water is blown off in the form of steam.
2.6.1 External safety devices
Hydraulic chamber safety switch
Before starting any maintenance work in the hydraulic chamber of the sliding floor:
❒ Turn the safety switch to the "0" position
➥ The boiler follows the shutdown procedure and the discharge is deactivated
❒ Turning the selector switch past the "0" position engages the locking lever
➥ The switch can be locked with a padlock to prevent it from being switched on
again
On completion of the maintenance work:
❒ Remove the padlock
❒ Turn the selector switch past the "0" position to automatically release the locking
switch. The selector switch can now be turned back to the "1" position.
❒ Acknowledge the fault and press the Start button to activate the boiler
Guardrail
When working at a height, appropriate measures must be taken in accordance with
the applicable national industrial safety guidelines to protect against the risk of falling
(e.g. ladders, platforms, etc.). It is the responsibility of the operator to select and
provide these means.
Alternatively, a railing can be fitted to the top of the boiler as per EN ISO 14122.
Safety
2
Safety devices
Operating Instructions | B1300015_en 19
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 in a controlled way (operating status "Switched off OFF")
and allow it to cool down
❒ Protective gloves must generally be worn for work on the boiler, and it should
only be operated using the handles provided
❒ Insulate the flue pipes or simply avoid touching them during operation.
WARNING
Opening the door to the combustion or burning chamber, or the cleaning door or
lids during operation
may result in injury or damage or flue gas generation!
Therefore:
❒ Do not open any doors or lids while the boiler is in operation!
WARNING
If non-permitted fuel types are used:
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:
❒ Only use fuels specified in the "Permitted fuels" section of these operating
instructions.
2
Safety
Residual risks
20 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
WARNING
Inspection and cleaning work on a system which is operational:
Risk of serious injuries from automatic startup of the system and severe burns
from hot parts and the flue gas pipe!
When working on the system:
❒ always wear protective gloves
❒ only operate the boiler using the handles provided
❒ switch off the boiler by tapping “Boiler off” at the mode icon
➥ The boiler follows the shutdown procedure and switches to “Switched off
OFF“ status
❒ switch off the main switch and take precautions to prevent accidental
switching on
❒ allow the boiler to cool off for at least 1 hour
❒ once all of the tasks have been completed, turn the main switch back on and
switch the boiler on in the desired mode
2.8 Emergency procedure
2.8.1 Overheating of the system
If the system overheats and the safety devices fail, proceed as follows:
NOTICE! Do not under any circumstances switch off the main switch or disconnect the
power supply.
❒
Keep all the doors on the boiler closed
❒ Open all mixing valve taps, switch on all pumps.
➥ The Froling heating circuit control performs this function in automatic operation.
❒ If a third-party controller is used, carry out the appropriate measures to activate
the mixer taps and pumps manually.
❒ Leave the boiler room and close the door
❒ Increase heat consumption by turning on all radiators and other appliances
❒ Open any available radiator thermostat valves
If the temperature does not drop:
❒ Contact the installer or Froling customer services
⇨ See "Addresses" [page 60]
Safety
2
Emergency procedure
Operating Instructions | B1300015_en 21
2.8.2 Smell of flue gas
DANGER
If you smell flue gas in the boiler room:
Inhaling toxic flue gas can be fatal!
If you smell flue gas in the room where the boiler is installed:
❒ Keep all the doors on the boiler closed
❒ Shut down the boiler according to procedure
❒ Ventilate the room where the boiler is installed
❒ Close the fire door and doors to living areas
2.8.3 Fire in the system
DANGER
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
2
Safety
Emergency procedure
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3 Operating the system
3.1 Assembly and initial startup
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.
NOTICE! See assembly instructions for the Lambdamat
NOTICE
Optimum efficiency and efficient, low-emission operation can only be guaranteed
if the system is set up by trained professionals and the standard factory settings
are observed.
Take the following precautions:
❒
Initial startup should be carried out with an authorised installer or with Froling
customer services
The individual steps for initial start-up are explained in the operating instructions for
the controller
NOTICE! See operating instructions for the SPS 4000
The customer is responsible for ensuring the following prior to initial start-up of the
system by Froling customer services:
▪
Electrical installation
▪ Installation of water pipes
▪ Flue gas connection including all insulation work
▪ Work must comply with local fire protection regulations
▪ The operator must ensure that at least 50% of the boiler's rated heat output can be
extracted from the network on commissioning.
▪ The necessary "dry run" of the system means that the discharge system must be
empty at the start of initial startup. Fuel must be available, however, so that the
discharge system can be filled once the system is released.
▪ When heating up the boiler for the first time to dry out the fireclay concrete, the
customer must provide approx. 1 m³ of dry firewood.
▪ It is essential that the electrician who has carried out the installation work is
available when starting up the system for the first time to make any changes to the
wiring which may become necessary.
▪ During initial start-up, operating staff are shown how to use the boiler. It is
imperative for proper handover of the product that those involved are present as
this is a one-off opportunity.
Operating the system
3
Assembly and initial startup
Operating Instructions | B1300015_en 23
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.
3.2 Filling the store space with fuel
Note the following when loading the machine with fuel:
❒ only use permitted fuels!
⇨ See "Permitted fuels" [page 12]
❒ remove foreign bodies in the store space before filling
NOTICE! Systems in which the fuel is delivered by tanker and is blown into the store
space must be fitted with a rotary valve.
CAUTION
Entering the store space when the system is switched on
Risk of injury due to automatic startup of system, particularly the discharge
system!
Therefore, before entering the fuel store space:
❒ switch off the boiler by tapping “Boiler off” at the mode icon
➥ The boiler follows the shutdown procedure and switches to “Switched off
OFF” status
❒ turn off the boiler’s main switch
❒ turn off the main switch on the expansion switch cabinet (if installed)
For blowing in fuel the following precautions also apply:
CAUTION
Blowing in fuel when the boiler is switched on:
The negative pressure resulting from blowing in fuel can lead to smoke being
sucked back into the store if the boiler is operational. Possible excess pressure
could cause smoke to escape into the installation room, possibly resulting in injury
and damage!
Therefore, before blowing in the fuel:
❒ Switch off the boiler by tapping “Boiler off” at the mode icon
➥ The boiler follows the shutdown procedure and switches to “Switched off
OFF” status
❒ Leave to cool for at least two hours in “Switched off Off” mode.
3
Operating the system
Filling the store space with fuel
24 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
3.2.1 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:
❒
Load the fuel at the filling opening
3.2.2 Loading fuel in an empty store space with a rotary agitator
NOTICE
Filling an empty store space with a rotary agitator:
With the store space completely empty or almost empty, the rotary agitator arms /
spring blades are fully extended. If the rotary agitator arms / spring blades are
covered in this position with a large amount of fuel, the weight of the fuel will stop
them from working properly.
Therefore, when filling an empty store space or when the rotary agitator arms are
extended:
❒ First of all place a small amount of fuel (approx. 2 – 3 m³) on and around the
head of the rotary agitator
❒ Only add the rest of the fuel once the rotary agitator arms are back on the
head of the rotary agitator
❒ It is important you follow the procedure given below!
Operating the system
3
Filling the store space with fuel
Operating Instructions | B1300015_en 25
❒ Switch off the boiler by tapping “Boiler off” at the mode icon and allow to cool for at
least two hours
❒
Disconnect the boiler’s main switch
❒ Turn off the main switch on the expansion switch cabinet (if installed)
❒ Pile up the residual fuel (in the corners and on the walls) in the fuel store on and
around the head of the rotary agitator and on the discharge screw by hand.
➥ The head of the rotary agitator should be completely covered.
❒ Follow the instructions on working in the fuel store!
NOTICE! Refer to the notice (supplied with the boiler) at the entrance to the store
If the head of the rotary agitator is not adequately covered by the remaining fuel:
❒
Load a small amount of fuel (approx. 2-3 m³)
➥ Pile it up on and around the head of the rotary agitator
➥ The head of the rotary agitator should be completely covered
Rotary agitator with combined drive system
After working in the store:
❒ Turn on the boiler’s main switch
❒ Turn on the main switch on the expansion switch cabinet (if installed)
❒ Switch on the boiler by tapping “Boiler on” at the mode icon
❒ For the highest possible heat consumption
➥ the storage tank must be able to store enough heat
❒ Wait until the rotary agitator arms / spring blades are touching the head of the
rotary agitator (approx. 2 revolutions)
❒ Add the rest of the fuel
Rotary agitator with separate drive system (optional)
In the case of rotary agitators with a separate drive system, the head of the rotary
agitator can be operated separately from the discharge screw.
After working in the store:
❒ Turn on the boiler’s main switch
❒ Turn on the main switch on the expansion switch cabinet (if installed)
❒ Tap “Manual” in “Bunker filling rotary agitator” during manual operation
➥ The rotary agitator runs for approx. 3 minutes
❒
Wait until the rotary agitator arms / spring blades are touching the head of the
rotary agitator (approx. 2 revolutions)
❒ Add the rest of the fuel
3
Operating the system
Filling the store space with fuel
26 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
3.2.3 Blowing in 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
as follows:
❒
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
3.2.4 Blowing in fuel for an empty store with rotary agitator
Operating the system
3
Filling the store space with fuel
Operating Instructions | B1300015_en 27
NOTICE
Filling an empty store space with a rotary agitator:
With the store space completely empty or almost empty, the rotary agitator arms /
spring blades are fully extended. If the rotary agitator arms / spring blades are
covered in this position with a large amount of fuel, the weight of the fuel will stop
them from working properly.
Therefore, when filling an empty store space or when the rotary agitator arms are
extended:
❒ First of all place a small amount of fuel (approx. 2 – 3 m³) on and around the
head of the rotary agitator
❒ Only add the rest of the fuel once the rotary agitator arms are back on the
head of the rotary agitator
❒ It is important you follow the procedure given below!
❒
Switch off the boiler by tapping “Boiler off” at the mode icon and allow to cool for at
least two hours
❒ Disconnect the boiler’s main switch
❒ Turn off the main switch on the expansion switch cabinet (if installed)
❒ Pile up the residual fuel (in the corners and on the walls) in the fuel store on and
around the head of the rotary agitator and on the discharge screw by hand.
➥ The head of the rotary agitator should be completely covered.
❒ Follow the instructions on working in the fuel store!
NOTICE! Refer to the notice (supplied with the boiler) at the entrance to the store
If the head of the rotary agitator is not adequately covered by the remaining fuel:
❒
Close all openings to the store to seal out dust
❒ Load a small amount of fuel (approx. 2-3 m³)
➥ Pile it up on and around the head of the rotary agitator
➥ The head of the rotary agitator should be completely covered
Rotary agitator with combined drive system
After working in the store:
❒ Turn on the boiler’s main switch
❒ Turn on the main switch on the expansion switch cabinet (if installed)
❒ Switch on the boiler by tapping “Boiler on” at the mode icon
❒ For the highest possible heat consumption
➥ the storage tank must be able to store enough heat
❒ Wait until the rotary agitator arms / spring blades are touching the head of the
rotary agitator (approx. 2 revolutions)
❒ 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
❒ Add the rest of the fuel
3
Operating the system
Filling the store space with fuel
28 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Rotary agitator with separate drive system (optional)
In the case of rotary agitators with a separate drive system, the head of the rotary
agitator can be operated separately from the discharge screw.
After working in the store:
❒ Turn on the boiler’s main switch
❒ Turn on the main switch on the expansion switch cabinet (if installed)
❒ Tap “Manual” in “Bunker filling rotary agitator” during manual operation
➥ The rotary agitator runs for approx. 3 minutes
❒
Wait until the rotary agitator arms / spring blades are touching the head of the
rotary agitator (approx. 2 revolutions)
❒ Close all openings to the store to seal out dust
❒ Add the rest of the fuel
3.2.5 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
3.2.6 Loading fuel in a store space with a sliding floor discharge unit
❒ The maximum dumping height (depending on the fuel density) as specified in the
operating instructions for the sliding floor must not be exceeded.
❒
Driving over the fuel in the store can cause the material to be compacted.
➥ This may stop the slide rods from running smoothly.
Filling the store by driving over the slide rods
Slide rods can be driven over, provided the following precautions are taken:
❒ The slide rods must be covered by a residual fuel layer approx. 30 cm deep so
that the truck does not drive directly over the sliding floor keyways.
❒ On no account may the truck drive over the longitudinal support for the slide rods.
(Provide guidance systems for driving the truck into the store, or position gates
appropriately)
❒ While the truck is on the sliding floor, the hydraulic unit must be switched off
❒ While it is on the sliding floor the truck should be manoeuvred as little as possible
Filling the store by tipping fuel onto or next to the slide rods
❒ If the fuel can be tipped out without driving over the slide rods, the store can be
filled while the boiler is running
Operating the system
3
Filling the store space with fuel
Operating Instructions | B1300015_en 29
3.2.7 Loading fuel in a store space with a horizontal screw discharge unit
❒ When the boiler system is running, fuel can be tipped into the store at any time.
➥ CAUTION: fuel may only be blown in if the pressure conditions in the store are
suitable and the water content of the fuel does not exceed a maximum of W30.
3.2.8 Loading fuel in a store space with an inclined screw discharge unit
The inclined screw must always be moved into an upright position in order to fill the
store.
This can be done as follows:
❒
If the store is filled while the boiler system is running, the screw moves
automatically into an upright position.
➥ If the store is empty, the screw must be moved by hand into an upright position
and wedged with fuel.
❒ If the feed system is not running when the store is filled, the screw can be held
upright using string.
➥ TIP: the string should be thin enough for it to break as the store is filled.
3
Operating the system
Filling the store space with fuel
30 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
3.3 Heating up the boiler
NOTICE
Do not modify the factory settings!
Changing the system's factory settings can be detrimental to efficiency and
emissions of the system.
NOTICE
It is not permitted to manually feed fuel into the boiler!!
3.3.1 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
3.3.2 Switching on the boiler
❒ Switch the boiler on by tapping “Boiler ON”
➥ Automatic mode is active
➥ The heating system is controlled via the controller according to the selected
mode in automatic mode
❒
For other modes press the relevant function key
➥ Information on function keys in the relevant operating instructions for the "SPS
4000" boiler controller
3.3.3 Controlling the boiler
Please see the relevant operating instructions for the "SPS 4000" boiler controller for
the necessary control steps, as well as displaying and modifying parameters
3.3.4 Switching off the boiler
❒ Switch boiler off by tapping “Boiler OFF”
➥ The boiler follows the shutdown program and switches to "
Switched off OFF"
status
➥ The combustion unit is switched off, the chamber discharge unit and the entire
hydraulic system remain active
Operating the system
3
Heating up the boiler
Operating Instructions | B1300015_en 31
3.3.5 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”
➥ The boiler follows the shutdown procedure and switches to "Switched off
OFF“ status after the cleaning cycle
❒ Turn off the main switch
➥ Boiler controller is switched off
➥ The components powered via the control cabinet are powered down
➥ CAUTION: the expansion switch cabinet, which has its own power supply, is
still live.
NOTICE! Frost protection function is no longer active!
3
Operating the system
Heating up the boiler
32 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4 Servicing
4.1 General information on servicing
DANGER
When working on electrical components:
Risk of electrocution!
When work is carried out on electrical components:
❒ Only have work carried out by a qualified electrician
❒ Observe the applicable standards and regulations
➥ Work must not be carried out on electrical components by unauthorised
persons
DANGER
Risk of falling when working at a height
Therefore:
❒
Implement appropriate measures in accordance with the applicable national
industrial safety guidelines to protect against the risk of falling (e.g. ladders,
platforms, etc.)
WARNING
Inspection and cleaning work on a system which is operational:
Risk of serious injuries from automatic startup of the system and severe burns
from hot parts and the flue gas pipe!
When working on the system:
❒ always wear protective gloves
❒ only operate the boiler using the handles provided
❒ switch off the boiler by tapping “Boiler off” at the mode icon
➥ The boiler follows the shutdown procedure and switches to “Switched off
OFF“ status
❒ switch off the main switch and take precautions to prevent accidental
switching on
❒ allow the boiler to cool off for at least 1 hour
❒ once all of the tasks have been completed, turn the main switch back on and
switch the boiler on in the desired mode
Servicing
4
General information on servicing
Operating Instructions | B1300015_en 33
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:
❒ Clean the boiler following the instructions in the instruction manual. Follow the
boiler operating instructions.
NOTICE
We recommend that you keep a maintenance book in accordance with ÖNORM
M7510 of the Technical Directive for Fire Prevention (TRVB)
NOTICE
As well as the cleaning and maintenance tasks explained in these instructions,
also refer to the specifications according to TRVB H 118 given in the enclosed
inspection book.
NOTICE! The boiler must be cleaned and inspected at appropriate intervals
depending on the service hours and fuel quality.
Cleaning kit provided:
▪ Chamber plate (triangular plate)
▪ Flat scraper
▪ Brush (Ø 53 mm)
❒ Regular cleaning of the boiler extends its life and is a basic requirement for
smooth running.
❒ Recommendation: use an ash vacuum for cleaning.
4
Servicing
General information on servicing
34 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.2 Inspection
4.2.1 Checking the system pressure
❒ Check the system pressure on the pressure gauge
➥ The value must be 20% above the pre-stressed pressure of the expansion tank
NOTICE! Check that the position of the pressure gauge and rated pressure of
the expansion tank match your installer's specifications!
If the system pressure decreases:
❒
Top up with water
NOTICE! If this happens frequently, the seal of the heating system is faulty! Inform
your installer
If large pressure fluctuations are observed:
❒ Ask an expert to inspect the expansion tank
4.2.2 Checking the thermal discharge safety device
❒ Check the seal of the discharge valve
➥ The discharge pipe must not drip
NOTICE! Exception: Boiler temperature > 100 °C
If water is dripping from the discharge pipe:
❒
Clean the discharge safety device in accordance with the manufacturer's
instructions or have it checked/replaced by the installer if necessary
4.2.3 Checking the safety valve
❒
Check the seal of the safety valve regularly and ensure that the valve is not dirty
NOTICE! Inspection work must be carried out in accordance with the
manufacturer’s instructions.
4.2.4 Checking the geared motors
❒ Carry out a visual inspection of the seal on the geared motors in the system
➥ 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
Servicing
4
Inspection
Operating Instructions | B1300015_en 35
4.2.5 General visual inspection
Regular general visual and functional inspections should be carried out on all the
components making up the boiler.
❒
Clean components wherever necessary
❒ Immediately change or have someone exchange defective components
Pay particular attention to the following components when carrying out the
inspections:
▪ Burning chamber
▪ Combustion chamber
▪ Heat exchanger
▪ ID fan
▪ Flue gas recirculation (FGR)
▪ Combustion air blower fan
▪ Burn back protection system
– Check function and seal
▪ Screw drives
– Loading and ash removal
▪ Door contact switch
– When the door is opened, the induced draught unit must operate at full speed
– The combustion air and FGR blower fan must stop when the door is opened
▪ Igniter tube
– must not be obstructed!
▪ High-limit thermostat (STL)
▪ Loading system water sprinkler system
– Note the manufacturer’s specifications
▪ Emergency stop switch
4
Servicing
Inspection
36 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.3 Cleaning
The frequency at which the following cleaning work is carried out depends on energy
requirements, fuel quality and the number of operating hours.
WARNING
When removing the ash container cover during operation:
False air infiltration via the ash screw duct can lead to uncontrolled combustion
and the risk of accidents.
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 "Switched off
OFF" status.
4.3.1 Emptying the combustion chamber ash container (optional)
NOTICE! The current fill level of the ash container can also be checked while the
boiler is in operation. Important:
▪
The ash container cover must be closed again within 15 seconds
▪ Caution: if the cover remains open for more than 15 seconds, the boiler is
switched off automatically.
1. Remove the key plate from the safety switch
2.
Slide back the cover of the ash container
3. Remove the cover and check the fill level
4. Put the cover back on and slide it forwards until it clicks in place
– If the container does not need emptying, slide the key plate back into the
safety switch
Servicing
4
Cleaning
Operating Instructions | B1300015_en 37
If the container needs emptying, proceed as follows:
1.
switch off the boiler by tapping “Boiler off” at the mode icon
1. Push the side lever up to release the ash container
2.
Pull out the ash container
3. Push the coupling cap onto the ash container
4. Take the ash container to the emptying point and empty it
NOTICE
Caution: The ash compacted by the ash screws weighs approx. 1kg/L! At least
two people are therefore required to transport the ash container depending on its
fill level!
To replace the ash container:
1. Remove the coupling cap
–
Slide the upper flap forwards
2. Position the ash container at the ash removal unit flange
3. Push the lever on the side of the ash removal unit flange downwards to lock the
ash container in place
4. Push the key plate into the safety switch
4
Servicing
Cleaning
38 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.3.2 Cleaning the combustion and burning chamber
WARNING
Inspection and cleaning work on a system which is operational:
Risk of serious injuries from automatic startup of the system and severe burns
from hot parts and the flue gas pipe!
When working on the system:
❒ always wear protective gloves
❒ only operate the boiler using the handles provided
❒ switch off the boiler by tapping “Boiler off” at the mode icon
➥ The boiler follows the shutdown procedure and switches to “Switched off
OFF“ status
❒ switch off the main switch and take precautions to prevent accidental
switching on
❒ allow the boiler to cool off for at least 1 hour
❒ once all of the tasks have been completed, turn the main switch back on and
switch the boiler on in the desired mode
NOTICE! In order to avoid damage to the combustion chamber temperature sensor, it
should be removed before starting work in the combustion chamber
❒ Note the position of the combustion chamber temperature sensor (1)
➥ e.g. with the help of sticky tape
❒
Loosen the screws on the bracket (2)
❒ Carefully remove the combustion chamber temperature sensor
➥ if necessary, clean carefully
❒ When all tasks have been completed, replace the combustion chamber
temperature sensor
Servicing
4
Cleaning
Operating Instructions | B1300015_en 39
Cleaning the burning chamber
❒ Open the combustion chamber door
❒
Pull the ash deposits on the upper side of middle vault towards you using a flat
scraper
❒ Using a flat scraper, carefully push the ash on the upper side of the lower vault
towards the rear
➥ The ash will fall down into the combustion chamber
Cleaning the combustion chamber
❒ Open the combustion chamber door
❒
Remove unburned material and foreign bodies from the combustion chamber
❒ Using a flat scraper, move the ash on the combustion chamber grate towards the
ash shaft
❒ Remove any dirt (nails, stones, slag, etc.) from the moving grate
❒
Clean the primary air slot with a suitable tool (e.g. screwdriver)
➥ The primary air slots must be free from obstructions!
4
Servicing
Cleaning
40 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒
Turn on the main switch
❒ Activating the moving grate and ash removal screws in manual mode
➥ Ash that gathers is moved into the ash container
❒ Empty the ash container whenever necessary
4.3.3 Emptying the multicyclone ash container
❒ Check the ash level and empty the container if necessary
Servicing
4
Cleaning
Operating Instructions | B1300015_en 41
4.4 Periodic inspection and cleaning
E
approx. 1000h:
⇨ See "Cleaning the ash transfer chamber" [page 43] ⇨ See "Cleaning the flue gas recirculation (FGR) duct"
[page 45]
⇨ See "Cleaning the broadband probe" [page 44]
E
⇨ See "Checking the heat exchanger" [page 45]
⇨ See "Cleaning the flue gas temperature sensor"
[page 44]
⇨ See "Cleaning the area under the moving grate"
[page 46]
approx. 3000h:
⇨ See "Cleaning the combustion air fan" [page 47] ⇨ See "Checking the underpressure controller" [page
51]
⇨ See "Checking the seal of the cleaning port doors"
[page 47]
⇨ See "Checking the combustion chamber
overpressure sensor" [page
52]
⇨ See "Checking the seal of the reversing chamber
door" [page 48]
⇨ See "Cleaning the FGR blower fan" [page 52]
⇨ See "Checking the position and seal of the burning
and combustion chamber door" [page
48]
⇨ See "Cleaning the induced draft fan" [page 53]
⇨ See "Cleaning the fireclay elements" [page 50]
4
Servicing
Periodic inspection and cleaning
42 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.5 Periodic inspection and cleaning (approx. 1,000 hrs)
For fuels with a low ash content, cleaning and inspection after approx. 1,000 service
hours is usually sufficient (under normal use conditions, approximately every quarter).
For less efficient fuels and fuels with a high ash content (indicated by short emptying
intervals for the ash container), the work should be carried out more frequently
accordingly.
WARNING
Inspection and cleaning work on a system which is operational:
Risk of serious injuries from automatic startup of the system and severe burns
from hot parts and the flue gas pipe!
When working on the system:
❒ always wear protective gloves
❒ only operate the boiler using the handles provided
❒ switch off the boiler by tapping “Boiler off” at the mode icon
➥ The boiler follows the shutdown procedure and switches to “Switched off
OFF“ status
❒ switch off the main switch and take precautions to prevent accidental
switching on
❒ allow the boiler to cool off for at least 1 hour
❒ once all of the tasks have been completed, turn the main switch back on and
switch the boiler on in the desired mode
4.5.1 Cleaning the ash transfer chamber
(Pos. A ⇨ See "Periodic inspection and cleaning" [page
42])
1. Remove the cleaning door at the back of the boiler
2.
Check the ash level and clean the ash transfer chamber if necessary
– Tip: use an ash vacuum!
Servicing
4
Periodic inspection and cleaning (approx. 1,000 hrs)
Operating Instructions | B1300015_en 43
4.5.2 Cleaning the broadband probe
(Pos. B ⇨ See "Periodic inspection and cleaning" [page
42])
❒ Unscrew the broadband probe
➥ CAUTION: broadband probe may be hot!
❒ Remove dirt with a soft brush
➥ Tip: to remove all the dirt, use an ash vacuum afterwards
➥ CAUTION: Do not use sharp objects or compressed air to clean the broadband
probe
❒
Screw in the broadband probe once more by hand
4.5.3 Cleaning the flue gas temperature sensor
(Pos. C ⇨ See "Periodic inspection and cleaning" [page
42])
❒ Loosen the retaining screw and pull out the flue gas temperature sensor
❒
Wipe the flue gas temperature sensor with a clean cloth
❒ Insert the flue gas sensor back into the flue gas temperature gas pipe and finger-
tighten the retaining screw
4
Servicing
Periodic inspection and cleaning (approx. 1,000 hrs)
44 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.5.4 Cleaning the flue gas recirculation (FGR) duct
(Pos. D ⇨ See "Periodic inspection and cleaning" [page
42])
1. Remove the pipe insulation (supplied by the customer) from the FGR duct
1. Remove the maintenance openings from the FGR duct
2.
Remove the maintenance openings from the FGR boxes
3. Check the entire FGR duct and clean if necessary
– Tip: use an ash vacuum!
4.5.5 Checking the heat exchanger
(Pos. E ⇨ See "Periodic inspection and cleaning" [page
42])
1. Open the reversing chamber door
2.
Check the heat exchanger pipes and if necessary clean thoroughly with a brush or
another suitable cleaning device
NOTICE! If the boiler features an automatic compressed air cleaner (optional), the
cleaning interval increases accordingly, however the cleaning procedure set out above
must be carried out at least once a year.
Servicing
4
Periodic inspection and cleaning (approx. 1,000 hrs)
Operating Instructions | B1300015_en 45
4.5.6 Cleaning the area under the moving grate
(Pos. F ⇨ See "Periodic inspection and cleaning" [page
42])
❒ Remove the cover plate
❒
Remove the thermal insulation
❒ Loosen the screws on the sensor and take out the sensor
❒
Loosen the nuts on the cleaning cover
❒ Remove the cleaning cover
❒
Check the moving grate area and ash rakes for dirt and deposits. Clean where
necessary
❒ Check the grate, grate shafts and grate bearings for wear and deformation
➥ Exchange components wherever necessary
❒ Check the grate drive for dirt and deposits and ensure it operates smoothly
❒ Check the seal on the cleaning cover
4
Servicing
Periodic inspection and cleaning (approx. 1,000 hrs)
46 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.6 Periodic inspection and cleaning (approx. 3,000 hrs)
4.6.1 Cleaning the combustion air fan
(Pos. G ⇨ See "Periodic inspection and cleaning" [page
42])
❒ Clean any dust and deposits from the protective grating
❒
Remove the protective grating and clean the fan with a soft brush where
necessary
4.6.2 Checking the seal of the cleaning port doors
(Pos. H ⇨ See "Periodic inspection and cleaning" [page
42])
1. Open the reversing chamber door
2.
Check that the fibre-glass seal of the cleaning port doors is perfectly aligned on
the door frame
– Imprint on the fibre-glass seal or ceramic packing
If the imprint of the seal is broken:
❒ The seal is no longer guaranteed
❒ Replace the fibre-glass seal or ceramic packing
Servicing
4
Periodic inspection and cleaning (approx. 3,000 hrs)
Operating Instructions | B1300015_en 47
4.6.3 Checking the seal of the reversing chamber door
(Pos. I ⇨ See "Periodic inspection and cleaning" [page
42])
❒ Check fibre-glass seal for perfect alignment on the door frame
➥ Imprint on the fibre-glass seal or ceramic packing
If the imprint of the seal is broken:
❒
The seal is no longer guaranteed
❒ Tighten the door latches or replace the fibre-glass seal or ceramic packing
4.6.4 Checking the position and seal of the burning and combustion chamber door
(Pos. J ⇨ See "Periodic inspection and cleaning" [page
42])
The example below of the burning chamber door shows how to check the position and
seal. The procedure is the same for checking the seal on the combustion chamber
door.
NOTICE! The seals must be replaced if they have turned black!
Checking the settings
❒ Close the door
➥ The door can be closed with a normal amount of effort:
does not require adjustment.
➥ The door cannot be closed or can only be closed with great effort:
loosen the locking hook.
⇨ See "Positioning the burning chamber and combustion chamber door" [page
49]
4
Servicing
Periodic inspection and cleaning (approx. 3,000 hrs)
48 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Checking the seal
❒ Open the door
❒
Insert a sheet of paper at both the top and the bottom between the door and the
boiler
❒ Close the door
❒ Try to pull out the sheet of paper.
➥ If the paper cannot be removed:
door is tightly sealed.
➥ If the paper can be removed:
door is not sealed properly - tighten the locking hook!
⇨ See "Positioning the burning chamber and combustion chamber door" [page
49]
4.6.5 Positioning the burning chamber and combustion chamber door
The example below shows how to position the burning chamber door. The procedure
is the same for checking the seal on the combustion chamber door.
❒ Loosen the nut on the locking hook
❒
Tighten or loosen the locking hook as required
❒ Fix in place using lock-nuts
Servicing
4
Periodic inspection and cleaning (approx. 3,000 hrs)
Operating Instructions | B1300015_en 49
4.6.6 Cleaning the fireclay elements
(Pos. K ⇨ See "Periodic inspection and cleaning" [page
42])
NOTICE! In order to avoid damage to the combustion chamber temperature sensor, it
should be removed before starting work in the combustion chamber
❒ Note the position of the combustion chamber temperature sensor (1)
➥ e.g. with the help of sticky tape
❒
Loosen the screws on the bracket (2)
❒ Carefully remove the combustion chamber temperature sensor
➥ if necessary, clean carefully
❒ When all tasks have been completed, replace the combustion chamber
temperature sensor
1. Open the reversing chamber door
2.
Open the two cleaning port doors
3. Carefully clean the bottom of the heat exchanger and the top of the upper vault
with the cleaning brush
4. Carefully clean the side walls with the flat scraper
5. Check the fireclay elements for wear
4
Servicing
Periodic inspection and cleaning (approx. 3,000 hrs)
50 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
1. Open the combustion chamber door
2.
Carefully clean the bottom of the upper vault and the top of the lower vault with the
cleaning brush
3. Carefully clean the side walls with the flat scraper
4. Open the burning chamber door
5. Carefully clean the bottom of the lower vault with the cleaning brush
6. Carefully clean the side walls with the flat scraper
7. Check the fireclay elements for wear
8. Remove any ash which has gathered.
9. Close all doors again
4.6.7 Checking the underpressure controller
(Pos. L ⇨ See "Periodic inspection and cleaning" [page
42])
❒ Disconnec the silicone hose from the differential pressure transducer
❒ Using compressed air, blow out the hose in the direction of the combustion space
to remove any deposits
❒ Connect the silicone hose to “Minus”
Servicing
4
Periodic inspection and cleaning (approx. 3,000 hrs)
Operating Instructions | B1300015_en 51
4.6.8 Checking the combustion chamber overpressure sensor
(Pos. M ⇨ See "Periodic inspection and cleaning" [page
42])
❒ Loosen the retaining screw
❒
Pull the combustion chamber excess pressure sensor out of the spacer tube
❒ Clean the sensor with a fine cloth
❒ Check that the spacer tube is clear
❒ Insert the combustion chamber excess pressure sensor and fix loosely with fixing
screws
4.6.9 Cleaning the FGR blower fan
(Pos. N ⇨ See "Periodic inspection and cleaning" [page
42])
❒ Mark the position of the flange
❒
Loosen the screws on the flange
4
Servicing
Periodic inspection and cleaning (approx. 3,000 hrs)
52 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒ Take out the blower fan and clean the blower wheel with a brush
❒
Check the seal and replace if necessary
❒ Replace the blower fan
➥ Check the marking on the flange!
4.6.10 Cleaning the induced draft fan
(Pos. O ⇨ See "Periodic inspection and cleaning" [page
42])
1. Remove the inspection cover
2.
Carefully clean the running wheel and coil of the induced draught fan with a brush
4.6.11 Lubricating the bearings
❒ Grease the bearings of the screws and the drives at the correct points.
4.6.12 Checking the flue gas pipe
❒ Check the flue gas pipe and chimney
❒
Where necessary, remove any deposits using a cleaning brush
➥ Always use stainless steel brushes to clean stainless steel flue pipes, chimney
pipes and connections!
Servicing
4
Periodic inspection and cleaning (approx. 3,000 hrs)
Operating Instructions | B1300015_en 53
4.7 Maintenance instructions for hydraulic system
WARNING
Do not use unskilled personnel for hydraulic system maintenance
Risk of injury and damage to property!
Take the following precautions:
❒ Only allow trained professionals to carry out servicing and maintenance work
on the hydraulic system. Follow the manufacturer's operating instructions.
NOTICE! Do not allow the oil temperature to exceed +50°C or fall below -30°C.
The interval at which oil should be changed depends on a variety of factors including
the age of the oil and the amount of dirt contained in it. As a general rule, the oil
should be changed at the following intervals:
Interval [service hours] Component / Maintenance Operation
50 – 100 ONE-TIME maintenance after first commissioning:
❒
Change the oil and the filter
50 ❒ Check the oil level
➥ The oil must show no visible signs of foaming
❒
Check the tightness of screw connectors
200 ❒ Check the return filter for dirt (pressure gauge on filter)
❒
Change the filter cartridge if necessary
5,000 (or yearly) ❒ Change the oil
❒
Change the return filter and the vent filter sets
Recommended procedure for oil change:
❒
Move all hydraulic cylinders to the end stop
➥ This will expel all the oil
❒ Drain off or pump off the oil from the hydraulic unit
❒ Remove the unit cover or open the inspection cover
❒ Thoroughly clean the oil tank (make sure you remove all oil sludge)
❒ Change the return filter and the vent filter sets
❒ Refit the unit cover or close the inspection cover
❒ Fill the tank with hydraulic oil to the level mark shown on the inspection glass
☞ Use the hydraulic oil grade specified by the manufacturer
❒ At the other end of the cylinder plunger (relative to its current position), remove the
hydraulic cylinder hose fitted to the fixed piping side.
❒ Using the hydraulic unit move the cylinders to the other end position
➥ The remaining old oil will be pushed out of the hose and into the container
❒ Refit the hydraulic hoses and check the seal
❒ Bleed the hydraulic system and check the oil level
NOTICE! Dispose of hydraulic oil in accordance with local regulations!
4
Servicing
Maintenance instructions for hydraulic system
54 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.8 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. It is important to ensure that the boiler is clean and that there is adequate heat
consumption on the day of the measurement. (e.g. the storage tank must be able to
take heat for the duration of the measurement).
For further information and the procedure for measuring emissions, see the attached
cleaning instructions “Preparation for measuring emissions”.
4.9 Maintenance agreement / Customer service
NOTICE! We recommend a yearly inspection by Froling customer services or an
authorised partner (third party maintenance).
Regular maintenance and servicing by a heating specialist will ensure a long, troublefree service life for your heating system. It will ensure that your system stays
environmentally-friendly and operates efficiently and cost-effectively.
In the course of this maintenance the entire system is inspected and optimised,
particularly regulation and control of the boiler. The emission measurement carried out
can also be used to draw conclusions about the combustion performance of the boiler.
For this reason, FROLING offers a service agreement, which optimises operating
safety. Please see the details in the accompanying guarantee certificate.
Your Froling customer service office will also be happy to advise you.
NOTICE
All national and regional regulations relating to regular testing of the system must
be observed. 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).
4.10 Replacement parts
With Froling original replacement parts in your boiler, you are using parts that match
perfectly. As the parts fit together so well, installation times are shortened and a long
service life is maintained.
NOTICE
Installing non-original parts will invalidate the guarantee.
❒ Only replace components or parts with original replacement parts
Servicing
4
Emissions measurement by chimney sweep or regulatory body
Operating Instructions | B1300015_en 55
4.11 Disposal information
4.11.1 Disposal of the ash
❒ The ash should be disposed of in accordance with waste management
regulations.
4.11.2 Disposal of system components
❒ Ensure that the system is disposed of in an environmentally friendly way in
accordance with waste management regulations.
❒
You can separate and clean recyclable materials and send them to a recycling
centre.
❒ The combustion chamber must be disposed of as builders' waste.
4
Servicing
Disposal information
56 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
5 Troubleshooting
5.1 General faults in the power supply
Error characteristics Cause of error Elimination of error
Nothing is shown on the
display
General power failure
No power to the controller Main switch is turned off
FI-protective circuit breaker,
power line protection or SPS
power line protection tripped
Turn on the main switch
Switch on the protective circuit
breaker
5.1.1 Behaviour of system after a power failure
When the power supply has been restored, the boiler returns to the previous mode
and is controlled according to the specified program.
❒ After a power failure, check whether the STL (high-limit thermostat) has tripped.
❒ Keep the doors of the boiler closed during and after the power failure, at least until
the induced draught fan automatically starts up again.
5.2 Excessive temperature
The high-limit thermostat (STL) shuts down the boiler when it reaches a temperature
of 95 - 100°C. The pumps continue to run.
Once the temperature falls to below approx. 85°C, the STL can be reset mechanically.
❒
Unscrew the cap on the STL
❒ Unlock the STL by pressing with a screwdriver
5.3 Faults with fault message
If a fault has occurred and has not yet been cleared:
Troubleshooting
5
General faults in the power supply
Operating Instructions | B1300015_en 57
▪ A warning symbol (1) flashes in the Quick menu
▪
In case of a fault/alarm, the operating status “Fault Off” (2) is displayed
❒ Navigate to the error display using the Quick menu
➥ The current fault list is displayed:
The term “fault” is a collective term for warnings, errors and alarms. The boiler reacts
differently to the three types of message:
Type of fault Character Boiler behaviour
WARNING
▪ YELLOW warning sign
▪
Message with YELLOW
background
In case of warnings the boiler initially
continues controlled operation, giving the
option of resolving the error quickly to
prevent a shutdown.
ERROR
▪ ORANGE warning sign
▪
Message with ORANGE
background
The boiler follows the shutdown procedure
and remains in "Switched off OFF" status
until the problem is resolved.
ALARM
▪ RED warning sign
▪
Message with RED
background
An alarm triggers a system emergency
stop. The boiler shuts down immediately,
the heating circuit controller and pumps
remain active.
5.3.1 Procedure for fault messages
Troubleshooting and fault messages
See operating instructions
SPS 4000
5.3.2 Acknowledging a fault message
Trace and remove the fault and then:
5
Troubleshooting
Faults with fault message
58 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒ Call up the current fault list (Quick menu / Error display)
❒ Use the up/down arrow (1) to navigate to the current fault
➥ The selected fault is indicated by an arrow symbol (2)
❒
Acknowledge the current fault by tapping the check mark (3)
❒ A symbol (4) appears once the fault has been acknowledged
➥ Once all faults have been fixed and acknowledged, all warning symbols
disappear from the starting page
Troubleshooting
5
Faults with fault message
Operating Instructions | B1300015_en 59
6 Appendix
6.1 Addresses
6.1.1 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
INTERNET www.froeling.com
6.1.2 Address of the installer
Stamp
6
Appendix
Addresses
60 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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