Installation Instructions
Wood chip boiler T4 24-150
Translation of the original German operating instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1211017_en | Edition 27/03/2017
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Contents
1 General 4
1.1 About this manual 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 Personal protective equipment for assembly staff 6
2.4 Design Information 7
2.4.1 Notes on standards 7
General standards for heating systems
7
Standards for structural and safety devices
7
Standards for heating water
7
Regulations and standards for permitted fuels
8
2.4.2 Installation and approval of the heating system 8
2.4.3 General information for installation room (boiler room) 8
2.4.4 Requirements for central heating water 9
2.4.5 Notes for using pressure maintenance systems 10
2.4.6 Return temperature control 11
2.4.7 Use with storage tank 11
2.4.8 Chimney connection/chimney system 12
Draught limiter
12
Measuring port
12
Boiler data for planning the flue gas system
13
3 Technology 15
3.1 Dimensions 15
3.2 Technical specifications 16
4 Installation 22
4.1 Transport 22
4.2 Positioning 22
4.3 Temporary storage 23
4.4 Setting up in the boiler room 24
4.4.1 Remove boiler from pallet (T4 24-110) 24
4.4.2 Remove the protective transportation frame (T4 130/150) 24
4.4.3 Moving the boiler in the boiler room 24
4.4.4 Minimum distances in the boiler room 25
4.5 Assembly work 26
4.5.1 Installing the Ash Container 26
4.5.2 Assemble the stoker unit 27
4.5.3 Mount the cover plate on the rear boiler wall (T4 130/150) 28
4.6 Electrical connection 28
4.6.1 Removing the controller cover 28
4.6.2 Laying cables 29
4.6.3 Mains connection 30
4.6.4 Information on circulating pumps 31
5 Start-up 32
Contents
2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
5.1 Before commissioning / configuring the boiler 32
6 Decommissioning 33
6.1 Mothballing 33
6.2 Disassembly 33
6.3 Disposal 33
7 Appendix 34
7.1 Addresses 34
7.1.1 Address of manufacturer 34
7.1.2 Address of the installer 34
Contents
Installation Instructions T4 24-150 | M1211017_en 3
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.
The EC Declaration of Conformity is only valid in conjunction with a delivery certificate,
which has been filled in correctly and signed as part of the commissioning process.
The original document remains at the installation site. Commissioning installers or
heating engineers are requested to return a copy of the delivery certificate together
with the guarantee card to Froling. On commissioning by FROLING Customer Service
the validity of the delivery certificate will be noted on the customer service record.
1.1 About this manual
These installation instructions contain information for the following T4 boilers:
T4-24, T4-30, T4-40, T4-50, T4-60, T4-701), T4-75, T4-90,
T4-100 (99 kW)2), T4-100, T4-110, T4-130, T4-150
1) T4-70 only available in France; 2) T4-100 with 99kW nominal output only available in UK;
Issuing a delivery
certificate
1
General
About this manual
4 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
Installation Instructions T4 24-150 | M1211017_en 5
2.2 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.
2.3 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
Safety
Qualification of assembly staff
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
2.4 Design Information
2.4.1 Notes on standards
The system must be installed and commissioned in accordance with the local fire and
building regulations. Unless contrary to other national regulations, the latest versions
of the following standards and guidelines apply:
General standards for heating systems
EN 303-5 Boilers for solid fuels, manually and automatically fed
combustion systems, nominal heat output up to 500 kW
EN 12828 Heating systems in buildings - design of water-based heating
systems
EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods
Part 1: Chimneys serving one appliance
ÖNORM H 5151 Planning of central hot water heating systems with or without hot
water preparation
ÖNORM M 7510-1 Guidelines for checking central heating systems
Part 1: General requirements and one-off inspections
ÖNORM M 7510-4 Guidelines for checking central heating systems
Part 4: Simple check for heating plants for solid fuels
Standards for structural and safety devices
ÖNORM H 5170 Heating installation - Requirements for construction and safety
engineering, as well as fire prevention and environmental
protection
TRVB H 118 Technical directives for fire protection/prevention (Austria)
Standards for heating water
ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in
closed warm water heating systems at operating temperatures
up to 100°C (Austria).
VDI 2035 Prevention of damage hot water heating systems (Germany)
SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
UNI 8065 Technical standard regulating hot water preparation.
DM 26.06.2015 (Ministerial Decree specifying the minimum
requirements)
Follow the instructions of this standard and any related updates.
Safety
2
Design Information
Installation Instructions T4 24-150 | M1211017_en 7
Regulations and standards for permitted fuels
1. BImSchV First Order of the German Federal Government for the
implementation of the Federal Law on Emission Protection
(Ordinance on Small and Medium Combustion Plants) in the
version published on 26 January 2010,
BGBl. JG 2010 Part I No. 4.
EN ISO 17225-2 Solid bio-fuel - Fuel specifications and classes
Part 2: Wood pellets for use in industrial and domestic systems
EN ISO 17225-4 Solid bio-fuel - Fuel specifications and classes
Part 4: Wood chips for non-industrial use
2.4.2 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
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: report to the construction authorities of the community or magistrate
Germany: report new installations to an approved chimney sweep / the building
authorities.
2.4.3 General information for installation room (boiler room)
Boiler room characteristics
▪ The floor must be even, clean and dry and have an adequate load-bearing
capacity.
▪ 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 ensure sufficient
lighting in the boiler room in accordance with national workplace design
regulations.
▪ When using the boiler above 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
The floor of the boiler room must not be flammable. No flammable materials
should be stored near the boiler. Flammable objects (e.g. clothing) must not be put
on the boiler to dry.
Note on standards
2
Safety
Design Information
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
▪ Damage due to impurities in combustion air.
Do not use any solvents or cleaning agents containing chlorine and hydrogen
halides in the room where the boiler is installed (e.g. chlorination units for
swimming pools).
▪
Keep the air suction opening of the boiler free of dust.
▪ The system must be protected against the chewing or nesting of animals (e.g.
rodents etc.).
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
2.4.4 Requirements for central heating water
Unless contrary to other national regulations, the latest versions of the following
standards and guidelines apply:
Austria:
Germany:
ÖNORM H 5195
VDI 2035
Switzerland:
Italy:
SWKI BT 102-01
UNI 8065
Observe the standards and also follow the recommendations below:
❒
Aim for a pH value of between 8.2 and 10.0. If the central heating water comes
into contact with aluminium, the pH value must be between 8.0 and 8.5
❒ Use prepared water which complies with the standards cited above for filling and
makeup water
❒ Avoid leaks and use a closed heating system to maintain water quality during
operation
❒ When filling with make-up water, always bleed the filling hose before connecting,
in order to prevent air from entering the system
Advantages of prepared water:
▪ Complies with the applicable standards
▪ Less of a drop in output due to reduced limescale build-up
▪ Less corrosion due to fewer aggressive substances
▪ Long-term cost savings thanks to improved energy efficiency
Note on standards
Safety
2
Design Information
Installation Instructions T4 24-150 | M1211017_en 9
Limit values for filling and make-up water:
Austria Germany Switzerland
Total hardness ≤ 1.0 mmol/L ≤ 2.0 mmol/L < 0.1 mmol/L
Conductivity - < 100µS/cm < 100 µS/cm
pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5
Chloride < 30 mg/L < 30 mg/L < 30 mg/L
Additional requirements for Switzerland:
The filling and make-up water must be demineralised (fully purified)
▪ The water must not contain any ingredients that could settle and accumulate in the
system
▪ This makes the water non-electroconductive, which prevents corrosion
▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can
weaken corrosive materials in certain conditions
If some of the system water is lost, e.g. during repairs, the make-up water must also be
demineralised. It is not enough to soften the water. The heating system must be
professionally cleaned and rinsed before filling the units.
Inspection:
▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the central
heating water comes into contact with aluminium, the pH value must be between 8.0 and
8.5
▪ Yearly. Values must be recorded by the owner
2.4.5 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required
pressure within predefined limits and balance out volume variations caused by
changes in the hot-water temperature. Two main systems are used:
Compressor-controlled pressure maintenance
In compressor-controlled pressure maintenance units, a variable air cushion in the
expansion tank is responsible for volume compensation and pressure maintenance. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen
into the heating water.
Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressuremaintenance pump, relief valve and an unpressurised receiving tank. The valve
releases hot water into the receiving tank if the pressure is too high. If the pressure
drops below a preset value, the pump draws water from the receiving tank and feeds it
back into the heating system. Pump-controlled pressure maintenance systems with
2
Safety
Design Information
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
open expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via the
surface of the water, exposing the connected system components to the risk of
corrosion. These systems offer no oxygen removal for the purposes of corrosion
control as required by VDI 2035 and in the interests of corrosion protection should not
be used.
2.4.6 Return temperature control
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:
❒ We recommend using a return temperature control.
➥ The minimum return temperature is 45 °C. We recommend fitting some
sort of control device (e.g. thermometer).
2.4.7 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 34]
Safety
2
Design Information
Installation Instructions T4 24-150 | M1211017_en 11
2.4.8 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.
The flue gas temperatures (for clean systems) and additional flue gas values can be
found in the table below.
The connection between the boiler and the chimney system should be as short as
possible. The upward angle of the connection should not exceed 30 - 45°. Insulate the
connection. The entire flue gas system - chimney and connection - should be
calculated in accordance with EN 13384-1.
Local regulations and other statutory regulations also apply.
NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney
sweep.
NOTICE! TRVB H 118 (Austria only) stipulates that an explosion flap must be installed
in the connecting piece (flue pipe) directly next to the boiler. It should be situated in
such a way that is poses no risk to persons!
Draught limiter
We generally recommend the installation of a draught limiter. A draught limiter must
be installed if the maximum permissible feed pressure as given in the boiler data for
planning the flue gas system is exceeded.
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the
pressure is constantly low at this point.
Measuring port
For measuring the emissions of the system, a suitable measuring port must be
installed in the connecting piece between the boiler and chimney system.
D
D
M
2 x D
In front of the measuring port (M) a straight inlet section should be located at a
distance corresponding to about twice the diameter (D) of the connecting piece. A
straight outlet section at a distance corresponding to about the single diameter of the
connecting piece should be provided after the measuring port. The measuring port
must remain closed whenever the system is in operation.
Ensure that the outside diameter of the sampling probes in the measuring port can
accommodate up to 13 mm. To avoid the ingress of false air, the diameter of the
measuring port must not exceed 21 mm.
2
Safety
Design Information
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Boiler data for planning the flue gas system
Designation T4
24 30 40 50
Flue gas temperature at nominal load °C 125 135 130 140
Flue gas temperature at partial load 80 85 80 85
Flue gas mass flow at nominal load kg/h 68 83 112 137
kg/s 0.019 0.023 0.031 0.038
Flue gas mass flow at partial load kg/h 29 32 43 54
kg/s 0.008 0.009 0.012 0.015
Required feed pressure at nominal load Pa 5 5 5 5
mbar 0.05 0.05 0.05 0.05
Required feed pressure at partial load Pa 2 2 2 2
mbar 0.02 0.02 0.02 0.02
Maximum permissible feed pressure Pa 30
mbar 0.3
Flue pipe diameter mm 149 149 149 149
Description T4
60
70
1)
75 90
Flue gas temperature at nominal load °C 130 135 140 135
Flue gas temperature at partial load 80 80 85 80
Flue gas mass flow at nominal load kg/h 166 194 209 256
kg/s 0.046 0.054 0.058 0.071
Flue gas mass flow at partial load kg/h 61 72 76 90
kg/s 0.017 0.020 0.021 0.025
Required feed pressure at nominal load Pa 5 5 5 5
mbar 0.05 0.05 0.05 0.05
Required feed pressure at partial load Pa 2 2 2 2
mbar 0.02 0.02 0.02 0.02
Maximum permissible feed pressure Pa 30
mbar 0.3
Flue pipe diameter mm 179 179 179 199
1.T4-70 only available in France
Safety
2
Design Information
Installation Instructions T4 24-150 | M1211017_en 13
Designation T4
100 110 130 150
Flue gas temperature at nominal load °C 140 145 135 145
Flue gas temperature at partial load 80 85 80 85
Flue gas mass flow at nominal load kg/h 277 299 364 428
kg/s 0.077 0.083 0.101 0.119
Flue gas mass flow at partial load kg/h 97 104 119 133
kg/s 0.027 0.029 0.033 0.037
Required feed pressure at nominal load Pa 5 5 5 5
mbar 0.05 0.05 0.05 0.05
Required feed pressure at partial load Pa 2 2 2 2
mbar 0.02 0.02 0.02 0.02
Maximum permissible feed pressure Pa 30
mbar 0.3
Flue pipe diameter mm 199 199 199 199
2
Safety
Design Information
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3 Technology
3.1 Dimensions
Item Description Unit 24/30 40/50 60/75 90/100/110 130/150
H Height, boiler mm 1390 1620 1620 1720 1720
H1 Total height including flue gas
pipe connection
1440 1670 1670 1770 1770
H2 Height, flow connection 1195 1425 1425 1530 1540
Boiler outfeed connection 6/4“ 6/4“ 6/4“ 2“ DN65 / PN6
H3 Height, return connection mm 270 270 270 170 200
Boiler return connection 6/4“ 6/4“ 6/4“ 2“ DN65 / PN6
H4 Height, drainage connection mm 140 140 140 140 140
Boiler drainage connection Inch 1/2 1/2 1/2 1 1
H5 Height, rotary valve connection mm 600 650 650 650 650
B Width, boiler mm 600 770 770 880 880
B1 Total width with stoker unit 1360 1530 1530 1640 1640
B2 Width of stoker unit 760 760 760 760 760
B3 Distance from boiler side to
stoker connection
470 470 470 470 470
L Length, boiler mm 1200 1200 1570 1570 1905
L1 Total length including ash
container and ID fan
1430 1430 1840 1840 2300
L2 Length, back of boiler to stoker
connection
755 755 1045 1045 1305
Technology
3
Dimensions
Installation Instructions T4 24-150 | M1211017_en 15
3.2 Technical specifications
Designation T4
24 30 40 50
Rated heat output kW 24 30 40 50
Output range 7.2-24.0 9.0-30.0 12.0-40.0 15.0-50.0
Electrical connection 400 V / 50 Hz / C16A
Power consumption W 45-115 54-142 51-150 47-158
Boiler weight kg 620 640 840 860
Boiler capacity (water) l 105 105 160 160
Water pressure drop (ΔT = 10/20 K) mbar 3.9 / 1.2 4.8 / 1.4 5.2 / 1.8 5.5 / 2.2
Min. boiler return temperature °C 45
Max. permitted operating temperature 90
Permitted operating pressure bar 3
Boiler class as per EN 303-5: 2012 5
Airborne sound level dB(A) < 70
Permitted fuel as per EN ISO 17225
1)
Part 2: Wood pellets class A1 / D06
part 4: Wood chips class A1 / P16S-P31S
1.Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”
Designation Test report data
24 30 40 50
Testing institute
TÜV
1)
Test report number (wood chips/pellets fuel) 10-UW/Wels-
EX-191/1
10-UW/Wels-
EX-191/3
11-U-368 10-UW/Wels-
EX-191/5
1.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels
Test data with wood chip fuel
Emissions in [mg/MJ] 1) (nominal load/partial load)
24 30 40 50
Carbon monoxide (CO) mg/MJ 9 / 28 35 / 28 25 / 34 14 / 40
Nitrous oxide (NOx) mg/MJ 70 / 57 92 / 57 88 / 61 84 / 64
Organic carbon (OGC) mg/MJ <1 / 1.3 <1 / 1.3 <1 / 1.1 <1 / <1
Dust mg/MJ 13 / 15 13 / 15 12 / 11 10 / 7
Boiler efficiency % 92.3 / 91.6 91.0 / 91.6 92.1 / 92.4 93.1 / 93.2
1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ
Test data with wood chip fuel
Emissions in [mg/m³]
1)
(nominal load/partial load)
24 30 40 50
Carbon monoxide (CO) mg/m³ 13 / 40 52 / 40 36 / 50 20 / 59
Nitrous oxide (NOx) mg/m³ 103 / 83 135 / 83 130 / 89 124 / 95
Organic carbon (OGC) mg/m³ <1 / 1.9 <1 / 1.9 <1 / <2 <1 / <2
Dust mg/m³ 19 / 22 19 / 22 17 / 17 15 / 11
Boiler efficiency % 92.3 / 91.6 91.0 / 91.6 92.1 / 92.4 93.1 / 93.2
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%
3
Technology
Technical specifications
16 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Regulation (EU) 2015/1187
Energy efficiency A+ A+ A+ A+
Rated heat output kW 24 30 40 50
Energy efficiency index of the boiler model 111 110 113 116
Seasonal space heating energy efficiency % 75 75 77 79
Energy efficiency index of the boiler in package with
temperature control
113 112 115 118
Energy efficiency class of the boiler in package with
temperature control
A+ A+ A+ A+
Test data with wood pellet fuel
Emissions in [mg/MJ] 1) (nominal load/partial load)
24 30 40 50
Carbon monoxide (CO) mg/MJ 8 / 69 7 / 23 6 / 18 <4 / 12
Nitrous oxide (NOx) mg/MJ 70 / 52 72 / 54 72 / 54 71 / 54
Organic carbon (OGC) mg/MJ <1 / 1.4 <1 / <1 <1 / <1 <1 / <1
Dust mg/MJ 11 / 19 12 / 12 11 / 9 9 / 6
Boiler efficiency % 92.2 / 91.0 92.0 / 91.4 93.1 / 92.3 94.2 / 93.2
1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ
Test data with wood pellet fuel
Emissions in [mg/m³] 1) (nominal load/partial load)
24 30 40 50
Carbon monoxide (CO) mg/m³ 12 / 101 10 / 34 8 / 26 <5 / 17
Nitrous oxide (NOx) mg/m³ 103 / 77 106 / 80 105 / 80 104 / 80
Organic carbon (OGC) mg/m³ <1 / 2 <1 / <2 <1 / <2 <1 / <2
Dust mg/m³ 16 / 29 17 / 18 15 / 14 13 / 9
Boiler efficiency % 92.2 / 91.0 92.0 / 91.4 93.1 / 92.3 94.2 / 93.2
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%
Regulation (EU) 2015/1187
Energy efficiency A+ A+ A+ A+
Rated heat output kW 24 30 40 50
Energy efficiency index of the boiler model 114 114 118 121
Seasonal space heating energy efficiency % 77 77 80 82
Energy efficiency index of the boiler in package with
temperature control
116 116 120 125
Energy efficiency class of the boiler in package with
temperature control
A+ A+ A+ A++
Designation T4
60
70
1)
75 90
Nominal output kW 60 69 75 90
Output range 18 - 60 20.7 - 69 22.5 - 75 27 - 90
Electrical connection 400 V / 50 Hz / C16A
Power consumption W 51 - 176 54 - 193 56 - 204 61 - 232
Technology
3
Technical specifications
Installation Instructions T4 24-150 | M1211017_en 17
Designation T4
60
70
1)
75 90
Boiler weight kg 1060 1070 1080 1350
Boiler capacity (water) l 220 220 220 260
Water pressure drop (ΔT = 10/20 K) mbar 7.8 / 2.6 9.9 / 3.0 11.4 / 3.2 14.9 / 3.8
Min. boiler return temperature °C 45
Max. permitted operating temperature 90
Permitted operating pressure bar 3
Boiler class as per EN 303-5: 2012 5
Airborne sound level dB(A) < 70
Permitted fuel as per EN ISO 17225
1)
Part 2: Wood pellets class A1 / D06
part 4: Wood chips class A1 / P16S-P31S
1.T4-70 only available in France
2.
Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”
Designation Test report data
60
70
1)
75 90
Testing institute
TÜV
1)
Test report no. 14-U-342 14-U-343 14-U-344 14-U-345
1.T4-70 only available in France
2.
TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels
Test data with wood chip fuel
Emissions in [mg/MJ] 1) (nominal load/partial load)
60 70 75 90
Carbon monoxide (CO) mg/MJ 13 / 33 11 / 27 11 / 23 8 / 13
Nitrous oxide (NOx) mg/MJ 82 / 65 80 / 67 79 / 68 76 / 70
Organic carbon (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1
Dust mg/MJ 11 / 8 11 / 8 12 / 9 12 / 9
Boiler efficiency % 93.1 / 93.3 93.0 / 93.5 93.0 / 93.6 92.9 / 93.8
1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ
Test data with wood chip fuel
Emissions in [mg/m³]
1)
(nominal load/partial load)
60 70 75 90
Carbon monoxide (CO) mg/m³ 18 / 49 16 / 40 15 / 34 12 / 18
Nitrous oxide (NOx) mg/m³ 121 / 97 118 / 99 116 / 100 111 / 103
Organic carbon (OGC) mg/m³ <1 / <2 <1 / <2 <1 / <2 <1 / <2
Dust mg/m³ 16 / 12 17 / 12 17 / 13 18 / 13
Boiler efficiency % 93.1 / 93.3 93.0 / 93.5 93.0 / 93.6 92.9 / 93.8
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%
Regulation (EU) 2015/1187
Energy efficiency A+ A+ -
Rated heat output kW 60 69 -
Energy efficiency index of the boiler model 116 116 -
Seasonal space heating energy efficiency % 79 79 -
3
Technology
Technical specifications
18 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Regulation (EU) 2015/1187
Energy efficiency index of the boiler in package with
temperature control
118 118 -
Energy efficiency class of the boiler in package with
temperature control
A+ A+ -
Test data with wood pellet fuel
Emissions in [mg/MJ] 1) (nominal load/partial load)
60 70 75 90
Carbon monoxide (CO) mg/MJ 5 / 12 6 / 11 7 / 11 8 / 10
Nitrous oxide (NOx) mg/MJ 70 / 53 69 / 53 69 / 53 68 / 52
Organic carbon (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1
Dust mg/MJ 9 / 7 9 / 8 9 / 9 8 / 10
Boiler efficiency % 94.1 / 93.5 93.9 / 93.7 93.9 / 93.9 93.6 / 94.3
1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ
Test data with wood pellet fuel
Emissions in [mg/m³] 1) (nominal load/partial load)
60 70 75 90
Carbon monoxide (CO) mg/m³ 7 / 17 8 / 16 10 / 16 12 / 15
Nitrous oxide (NOx) mg/m³ 103 / 79 102 / 78 102 / 78 100 / 77
Organic carbon (OGC) mg/m³ <2 / <2 <2 / <2 <2 / <2 <2 / <2
Dust mg/m³ 13 / 10 13 / 12 13 / 13 12 / 15
Boiler efficiency % 94.1 / 93.5 93.9 / 93.7 93.9 / 93.9 93.6 / 94.3
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%
Regulation (EU) 2015/1187
Energy efficiency A+ A+ -
Rated heat output kW 60 69 -
Energy efficiency index of the boiler model 122 122 -
Seasonal space heating energy efficiency % 83 83 -
Energy efficiency index of the boiler in package with
temperature control
126 126 -
Energy efficiency class of the boiler in package with
temperature control
A++ A++ -
Designation T4
100
100
1)
110 130 150
Nominal output kW 100 99 110 130 150
Heat output range 30 - 100 29.7 - 99 33 - 110 39 - 130 45 – 150
Electrical connection 400 V / 50 Hz / C16A
Power consumption W 65 - 250 65 - 250 65 - 250 90 - 240 115 - 264
Boiler weight kg 1360 1360 1370 1730 1750
Boiler capacity (water) l 260 260 260 340 340
Water pressure drop (ΔT = 10/20 K) mbar 17.2 / 4.2 17.2 / 4.2 18.7 / 5.2 23.3 / 6.9 30.6 / 8.3
Min. boiler return temperature °C 45
Technology
3
Technical specifications
Installation Instructions T4 24-150 | M1211017_en 19
Designation T4
100
100
1)
110 130 150
Max. permitted operating temperature 90
Permitted operating pressure bar 3
Boiler class as per EN 303-5: 2012 5
Airborne sound level dB(A) < 70
Permitted fuel as per EN ISO 17225
2)
Part 2: Wood pellets class A1 / D06
part 4: Wood chips class A1 / P16S-P31S
1.T4-100 with 99 kW nominal output only available in UK
2.Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”
Designation Test report data
100
100
1)
110 130 150
Testing institute
TÜV
2)
Test report no. 10-UW/
Wels-
EX-191/6 &
8
10-UW/
Wels-
EX-191/10
10-UW/
Wels-
EX-191/7 &
9
13-UW/
Wels-
EX-257/2
13-UW/
Wels-
EX-257/1
1.T4-100 with 99 kW nominal output only available in UK
2.
TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels
Test data with wood chip fuel
Emissions in [mg/MJ] 1) (nominal load/partial load)
100 100
(99 kW)
110 130 150
Carbon monoxide (CO) mg/MJ 7 / 6 7 / 6 7 / 6 7 / 17 4 / 17
Nitrous oxide (NOx) mg/MJ 74 / 71 74 / 71 74 / 71 65 / 78 64 / 78
Organic hydrocarbons (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1 <1 / <1
Dust mg/MJ 13 / 10 13 / 10 13 / 10 10 / 9 12 / 9
Boiler efficiency % 92.9 / 93.9 92.9 / 93.9 92.9 / 93.9 93.3 / 94.6 93.8 / 94.6
1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ
Test data with wood chip fuel
Emissions in [mg/m³]
1)
(nominal load/partial load)
100 100
(99 kW)
110 130 150
Carbon monoxide (CO) mg/m³ 10 / 8 10 / 8 10 / 8 11 / 25 6 / 25
Nitrous oxide (NOx) mg/m³ 108 / 105 108 / 105 108 / 105 95 / 114 94 / 114
Organic hydrocarbons (OGC) mg/m³ <1 / <2 <1 / <2 <1 / <2 <1 / <2 <1 / <2
Dust mg/m³ 19 / 14 19 / 14 19 / 14 15 / 13 18 / 13
Boiler efficiency % 92.9 / 93.9 92.9 / 93.9 92.9 / 93.9 93.3 / 94.6 93.8 / 94.6
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%
Test data with wood pellet fuel
Emissions in [mg/MJ] 1) (nominal load/partial load)
100 100
(99 kW)
110 130 150
Carbon monoxide (CO) mg/MJ 9 / 10 9 / 10 9 / 10 8 / 9 7 / 7
Nitrous oxide (NOx) mg/MJ 67 / 51 67 / 51 67 / 51 69 / 56 71 / 61
Organic hydrocarbons (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1 <1 / <1
Dust mg/MJ 8 / 11 14 / 11 8 / 11 8 / 9 8 / 6
Boiler efficiency % 93.5 / 94.6 93.7 / 94.6 93.5 / 94.6 93.7 / 94.5 93.8 / 94.5
1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ
3
Technology
Technical specifications
20 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Test data with wood pellet fuel
Emissions in [mg/m³] 1) (nominal load/partial load)
100 100
(99 kW)
110 130 150
Carbon monoxide (CO) mg/m³ 14 / 15 13 / 15 14 / 15 12 / 13 10 / 10
Nitrous oxide (NOx) mg/m³ 99 / 76 98 / 76 99 / 76 102 / 83 105 / 89
Organic hydrocarbons (OGC) mg/m³ <2 / <2 <1 / <2 <2 / <2 <2 / <2 <2 / <2
Dust mg/m³ 12 / 16 20 / 16 12 / 16 12 / 13 11 / 9
Boiler efficiency % 93.5 / 94.6 93.7 / 94.6 93.5 / 94.6 93.7 / 94.5 93.8 / 94.5
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%
Technology
3
Technical specifications
Installation Instructions T4 24-150 | M1211017_en 21
4 Installation
4.1 Transport
The product is delivered on pallet(s) in cardboard packaging.
NOTICE
Possibility of damage to components if handled incorrectly
❒
Follow the transport instructions on the packaging
❒ Transport components with care to avoid damage
❒ Protect components against damp
❒ Pay attention to the pallet's centre of gravity when lifting
4.2 Positioning
❒ Position a fork-lift or similar lifting device at the pallet and bring in the components
If the boiler cannot be brought in on the pallet:
❒
Remove the cardboard and remove the boiler from the pallet
⇨ See "Remove boiler from pallet (T4 24-110)" [page 24] or
⇨ See "Remove the protective transportation frame (T4 130/150)" [page 24]
Positioning using a crane (T4 24-50)
❒
Removing the insulating cover and the insulating mat
❒ Loosen the lock nut on the star-shaped screw knob
❒ Unlock the cover by turning the star-shaped screw knob and remove
4
Installation
Transport
22 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒
Pull out the guide plate
➥ The two lifting eye bolts for the boiler are located under the guide plate
Positioning using a crane (T4 60-150)
❒
Removing the insulating cover and the insulating mat
➥ The lifting eye bolt is underneath the insulating material in front of the heat
exchanger cover
➥ TIP: also remove the controller cover during transportation to avoid damage
4.3 Temporary storage
If the system is to be assembled at a later stage:
❒
Store components at a protected location, which is dry and free from dust
➥ Damp conditions and frost can damage components, particularly electric ones!
Installation
4
Temporary storage
Installation Instructions T4 24-150 | M1211017_en 23
4.4 Setting up in the boiler room
4.4.1 Remove boiler from pallet (T4 24-110)
❒ Remove securing devices used during transportation on the left and right side of
the boiler
❒ Pull out floor insulation
❒ Lift boiler off pallet
TIP: We recommend using Froling’s KHV 1400 boiler lifting system to help remove the
pallet
4.4.2 Remove the protective transportation frame (T4 130/150)
❒
After removing the cardboard, disassemble the protective transportation frame by
loosening the screws
4.4.3 Moving the boiler in the boiler room
❒ Position a fork-lift or similar lifting device with a suitable load-bearing capacity at
the base frame
❒
Lift and transport to the intended position in the installation room
➥ Observe the minimum distances in the boiler room.
4
Installation
Setting up in the boiler room
24 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.4.4 Minimum distances in the boiler room
▪ The system should generally be set up so that it is accessible from all sides
allowing quick and easy maintenance.
▪
Regional regulations regarding necessary maintenance areas for inspecting the
chimney should be observed in addition to the specified minimum distances!
▪ Observe the applicable standards and regulations when setting up the system.
▪ Observe additional standards for noise protection
(ÖNORM H 5190 - Noise protection measures)
Description Unit 24/30 40/50 60-75 90-150
A Minimum distance
insulated door to wall
mm 600 800 800 900
B Minimum distance
side of boiler to wall
200 200 200 200
C Minimum distance
back of boiler to wall
500 500 500 500
D Minimum distance
stoker to wall
300 300 300 300
Minimum store height 1700 1900 2050 2150
Installation
4
Setting up in the boiler room
Installation Instructions T4 24-150 | M1211017_en 25
4.5 Assembly work
4.5.1 Installing the Ash Container
❒ Open the side clamps and remove the ash container cover
❒ Remove the contents from the ash container
❒
Open the insulated door and push the locking lever up
❒ Place the ash container in the boiler and clamp with the locking lever
❒ Replace the cover and secure with the clamps
➥ Make sure that the pin (2) is inserted in the limit switch (1) correctly
4
Installation
Assembly work
26 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.5.2 Assemble the stoker unit
❒
Remove the upper and lower shutter mask on the stoker side
❒ Remove the pre-installed screws on the connection flange
❒
Position the stoker unit by the boiler as shown
❒ Push the stoker unit towards the boiler and insert into the connection flange
beside the two lock bolts (1)
➥ Adjust the height of the stoker unit if necessary using the adjustable feet
❒ Secure the unit to the boiler using the previously removed screws
❒
Place the hose clamp provided on the igniter tube
❒ Push the ignition fan into the igniter tube and secure with the hose clamp
Installation
4
Assembly work
Installation Instructions T4 24-150 | M1211017_en 27
4.5.3 Mount the cover plate on the rear boiler wall (T4 130/150)
❒
Position the lower cover plate on the rear boiler wall and attach to the boiler using
screws
4.6 Electrical connection
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
4.6.1 Removing the controller cover
❒
Removing the insulating cover and the insulating mat
4
Installation
Assembly work
28 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒
Remove the locking screws on the controller cover
❒ Push the controller cover back and then lift off
With the T4 60-150:
❒ After undoing the locking screws, slide the two covers back at the same time and
then lift off the controller cover (= front part)
4.6.2 Laying cables
Lay the stoker drive and ignition fan cables and the connection cable for the discharge
system in the cable duct from the stoker unit to the boiler:
❒
Remove the cover of the cable duct on the stoker duct
❒ Run the cables up through the insulating side panel
Installation
4
Electrical connection
Installation Instructions T4 24-150 | M1211017_en 29
❒
Pull the cables up through the side openings in the controller box and secure to
the strain relief bar with cable ties
❒ Lay all stoker cables in the cable duct and replace the cover on the duct
❒
Replace the cover plate on the stoker duct
❒ Wire the connections according to the wiring diagram
NOTICE! See boiler control unit operating instructions for circuit diagrams
❒ Once the wiring has been completed, replace the controller cover
4.6.3 Mains connection
At the back of the boiler:
❒
Press the mains plug to release it and remove
❒ Open the plug and connect the mains connection cable
➥ Flexible sheathed cable must be used for the wiring; this must be of the correct
size to comply with applicable regional standards and regulations.
➥ The power supply line (mains connection) must be fitted with a C16A fuse by
the customer.
4
Installation
Electrical connection
30 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.6.4 Information on circulating pumps
NOTICE
According to 2012/622/EU external, wet running circulating pumps must comply
with the following limit values of the Energy Efficiency Index (EEI):
- Effective from 01/01/2013: Wet running circulating pumps with EEI ≤ 0.27
- Effective from 08/01/2015: Wet running circulating pumps with EEI ≤ 0.23
Only high efficiency pumps with a connection option for a control signal (PDM / 0-10V)
should be connected to speed-controlled pump outputs (pump 1 on the core module
and pump outputs on the hydraulic module). In this case, the control line is connected
to the corresponding PDM outputs of the boards. Observe the connection instructions
in the boiler controller documentation!
CAUTION
When using high efficiency pumps without an additional control line at speedcontrolled pump outputs:
Malfunctions of the boiler, the pump and the hydraulic system may occur!
Therefore:
❒ Do not connect EC motor pumps without a control line to the speed-controlled
pump outputs of the boards.
➥ Only use special high efficiency pumps with a connection option for a
control line (PDM/0-10V)!
➥ Observe the additional instructions and information on board outputs in the
operation instructions for the boiler controller.
Installation
4
Electrical connection
Installation Instructions T4 24-150 | M1211017_en 31
5 Start-up
5.1 Before commissioning / configuring the boiler
The boiler must be configured to the heating system on initial start-up.
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
NOTICE
Foreign bodies in the heating system impair its operational safety and can result
in damage to property.
As a result:
❒ The whole system should be rinsed out before initial start-up in accordance
with EN 14336.
❒ Recommendation: Make sure the hose diameter of the flush nozzles in the
flow and return complies with ÖNORM H 5195 and is the same as the hose
diameter in the heating system, however not more than DN 50.
❒
Turn on the main switch
❒ Set the boiler controller to the system type.
❒ Load the boiler default values.
NOTICE! For the keypad layout and instructions for modifying the parameters, see the
instruction manual for the boiler controller.
❒ Check the system pressure of the heating system.
❒ Check that the heating system is fully vented.
❒ Check that all water connections are tightly sealed
➥ Pay particular attention to those connections from which plugs were removed
during assembly.
❒ Check that the safety devices are present and working efficiently.
❒ Check that there is sufficient ventilation in the boiler room.
❒ Check the seal of the boiler.
➥ All doors and inspection openings must be tightly sealed.
❒ Check that the drives and servo motors are working and turning in the right
direction.
❒ Check safety switch of ash box is working correctly
NOTICE! Check the digital and analog inputs and outputs - See the instruction manual
for the boiler controller.
5
Start-up
Before commissioning / configuring the boiler
32 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
6 Decommissioning
6.1 Mothballing
The following measures should be taken if the boiler is to remain out of service for
several weeks (e.g. during the summer):
❒
Clean the boiler thoroughly and close the doors fully
If the boiler is to remain out of service during the winter:
❒ Have the system completely drained by a qualified technician
➥ Protection against frost
6.2 Disassembly
To disassemble the system, follow the steps for assembly in reverse order.
6.3 Disposal
❒ Ensure that they are disposed of in an environmentally friendly way in accordance
with waste management regulations in the country (e.g. AWG in Austria)
❒
You can separate and clean recyclable materials and send them to a recycling
centre.
❒ The combustion chamber must be disposed of as builders' waste.
Decommissioning
6
Mothballing
Installation Instructions T4 24-150 | M1211017_en 33
7 Appendix
7.1 Addresses
7.1.1 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
7.1.2 Address of the installer
Stamp
7
Appendix
Addresses
34 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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