Froling TX 150, TX 250 Operating Instructions Manual

Fröling Heizkessel- und Behälterbau Ges.m.b.H  Industriestraße 12  A-4710 Grieskirchen

Tel [phone]

 Fax [phone]  [email protected]  www.froeling.com

Operating Instructions

TX 150 - 250

English version of operating instructions for operators.
Read and follow the instructions and safety instructions!
Subject to technical change.

Introduction

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Dear customer,

Congratulations on choosing a quality product from FRÖLING.

The FRÖLING TX wood chip boiler features a state-of-the-art design that
conforms to all currently applicable standards and testing guidelines.

Please read and observe the operating instructions and always keep
them close to the boiler for reference. They contain safety information
and all the operation and maintenance specifications needed to operate
the boiler safely, properly and economically.

The constant further development of our products means that the
pictures and content may differ slightly. If you discover any errors,
please let us know. Subject to technical change.

Document reference number B067 - Version 03 - Published 05/2012

Guarantee conditions

Our sale and delivery conditions generally apply. 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.

Contents

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1 General 5

1.1 Product Overview 5

2 Safety 8

2.1 Hazard levels of warnings 8

2.2 Pictograms used 9

2.3 Safety Information 10

2.4 Permitted uses 11

2.4.1 The Clean Air Act 1993 and Smoke Control Areas .............................................. 11

2.4.2 Permitted fuels ............................................................................................. 12

Wood chips .................................................................................................. 12

Pellets ........................................................................................................ 12

Changing the fuel ......................................................................................... 13

2.4.3 Non-permitted fuels ....................................................................................... 13

2.4.4 Qualification of operating staff ........................................................................ 13

2.4.5 Protective equipment for operating staff ........................................................... 13

2.5 Design Information 14

2.5.1 Heating System Installation/ Standards ..................................................... 14

2.5.2 General information for installation room (boiler room) ............................. 14

Boiler room characteristics ........................................................................ 14

Ventilation of the boiler room .................................................................... 15

2.5.3 Requirements for heating water ................................................................. 15

2.5.4 Combination with storage tank ........................................................................ 15

Return lift .................................................................................................... 16

2.6 Safety devices 17

2.6.1 Devices for preventing the boiler from overheating ............................................ 18

Thermal discharge safety device ..................................................................... 18

Safety Temperature Limiter STL ..................................................................... 18

Safety valve (provided by the customer) .......................................................... 18

2.7 Residual risks 19

2.8 Emergency procedure 20

2.8.1 System overheating ....................................................................................... 20

2.8.2 Smell of flue gas ........................................................................................... 20

3 Operating the system 21

3.1 Assembly and initial startup 21

3.2 Filling/ refilling the store with fuel 21

3.2.1 Loading wood chips in a partially emptied store ................................................. 22

3.2.2 Loading wood chips in an empty store .............................................................. 22

3.2.3 Blowing in pellets for a store with pellet screw ................................................... 23

3.2.4 Blowing in pellets for a partially emptied store with stirrer ................................... 23

3.2.5 Blowing in pellets for an empty store with stirrer ............................................... 24

3.3 Heating the boiler 25

3.3.1 Switching on the system ................................................................................ 25

3.3.2 Switching on the boiler .................................................................................. 25

3.3.3 Controlling the boiler ..................................................................................... 25

3.3.4 Switching off the boiler .................................................................................. 25

Contents

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3.3.5 Switching off the System ............................................................................... 25

4 Boiler maintenance 26

4.1 General information on maintenance 26

4.2 Inspection and cleaning 27

4.2.1 Inspection .................................................................................................... 27

Checking the thermal discharge safety device .................................................. 27

Check safety valve ....................................................................................... 27

Check the system pressure ............................................................................ 27

Check the geared motors .............................................................................. 27

4.2.2 Cleaning ...................................................................................................... 28

Empty the ash container retort ....................................................................... 28

Empty the heat exchanger ash container ......................................................... 29

4.2.3 Monthly inspection ........................................................................................ 30

Activate service mode ................................................................................... 30

Clean the combustion chamber and combustion space ....................................... 30

4.2.4 Annual inspection .......................................................................................... 32

Clean the heat-exchanger ............................................................................. 32

Clean the area below the step grate ................................................................ 32

Clean the flue gas recirculation (FGR) (optional) ............................................... 33

Clean the induced draught fan ....................................................................... 34

Clean the combustion air blower fan ............................................................... 34

Check the under-pressure controller ............................................................... 34

Check the combustion chamber overpressure sensor ......................................... 35

Check door seals .......................................................................................... 35

Check the draught controller flap and explosion flap .......................................... 35

4.3 Instructions for measuring emissions 36

4.3.1 Measurement at rated load ............................................................................. 36

Activate chimney-sweep mode ....................................................................... 36

4.3.2 Measurement at partial load (if necessary) ....................................................... 36

4.4 Maintenance agreement / Customer service 37

4.5 Replacement parts 37

4.6 Disposal information 37

4.6.1 Ash disposal ............................................................................................... 37

4.6.2 Disposal of system components ................................................................. 37

5 Troubleshooting 38

5.1 General faults in power supply 38

5.1.1 System procedure following power failure ......................................................... 38

5.2 Excessive temperature 38

5.3 Faults with fault message 39

5.3.1 Procedure for fault messages .......................................................................... 39

5.3.2 Acknowledging a fault message ....................................................................... 39

6 Appendix 40

6.1 Addresses 40

6.1.1 Manufacturer’s Address .................................................................................. 40

6.1.2 Installer’s address ......................................................................................... 40

General

Product Overview

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1 General

1.1 Product Overview

Pos. Description

1 Wood chip boiler - Fröling TX
2 Switch cabinet with integrated Lambdatronic H 3200 controller

2.1 Selector switch for induced draft fan
3 Main switch: switch the power supply on and off for the entire system
4 Control panel of the Lambdatronic H 3200 controller

4.1 Status LED (operating status)

- green lighting: boiler activated

- green flashing (5 seconds off, 1 second on): boiler deactivated

- orange flashing: warning

- red flashing: Fault

4.2 Large graphical display to show operating statuses and parameters

4.3 Navigation keys to move around in the menus and to change the parameter values

4.4 Function keys for calling up individual boiler functions or modes directly
5 Insulated door
6 Automatic ash removal ashcan
7 Ash removal unit or second ash box with automatic heat exchanger ash removal

3

2

1

6

5

7

TX 250 only:

2.1

4.2

4.1

4.3

4.4

4

General

Product Overview

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Pos. Description

8 Fuel transport unit with top gravity shaft, burn back flap or rotary valve as a burn back protection

system and stoker screw for fuel transport

9 Automatic tipping grate
10 Combustion chamber door
11 Heat exchanger door
12 Efficiency Optimisation System (WOS) with turbulators
13 Boiler outfeed connection
14 Boiler return connection
15 Thermal discharge safety device connection

5

9

11

8

11

10

13

14

9

15

12

General

Product Overview

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Pos. Description

16 Automatic drive for heat exchanger cleaning
17 Induced draught fan
18 Flue gas recirculation (optional)
19 Secondary air control with actuator drive
20 Primary air control with actuator drive
21 Automatic ignition
22 Air slide for flue gas recirculation

18

20

17

21

16

19

22

Safety

Product Overview

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2 Safety

2.1 Hazard levels of warnings

In these operating instructions warnings are used 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 observe the
measure!

WARNING

The dangerous situation may occur and if measures are not observed
it will lead to serious injury or death. Work with extreme caution!

CAUTION

The dangerous situation may occur and if measures are not observed
it will lead to light injuries or damage to property!

Safety

Pictograms used

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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 machine guidelines, signs fitted directly in the hazard
area indicate immediate hazards or safety procedures. These stickers
must not be removed or covered.

Observe the operating
instructions

Wear safety shoes

Wear protective gloves

Turn off the main switch

Keep the doors closed

Unauthorised access
prohibited

Hot surface warning

Hazardous electrical
voltage warning

Hazardous or irritant
materials warning

Automatic system start­up warning

Warning of injury to
fingers or hands,
automatic fan

Warning of injury to
fingers or hands,
automatic screw

Safety

Safety Information

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2.3 Safety Information

DANGER

Non-permitted use!
Incorrect use of the boiler can cause severe injuries and damage!

The instructions and information provided in the instructions
should be observed!

Details on procedure for operation, maintenance and cleaning, as
well as troubleshooting for the boiler are included in the
individual instructions. Any further work should be carried out by
authorised heating engineers or by Fröling customer services.

WARNING

External influences!

Negative external influences, such as insufficient combustion air or a
fuel that is not permitted can cause serious faults in combustion (e.g.
spontaneous combustion of carbonisation gases or flash fires) which
can in turn cause serious accidents!

Instructions and information for 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 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)!

You can only be guaranteed of optimum performance from the boiler if the
flue gas system is running smoothly!

Safety

Permitted uses

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2.4 Permitted uses

The TX series wood chip boiler is intended exclusively for heating central
heating water. Use only the fuels specified under 2.4.2.

The boiler should only be operated when it is in full working order. It
should 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 these operating instructions
should be observed. Ensure that any faults, which might impair safety,
are rectified immediately.

The manufacturer or supplier is not liable for any damages resulting
from non-permitted uses.

2.4.1 The Clean Air Act 1993 and Smoke Control Areas

Under the Clean Air Act local authorities may declare the whole or part
of the district of the authority to be a smoke control area. It is an
offence to emit smoke from a chimney of a building, from a furnace or
from any fixed boiler if located in a designated smoke control area. It is
also an offence to acquire an "unauthorised fuel" for use within a smoke
control area unless it is used in an "exempt" appliance ("exempted"
from the controls which generally apply in the smoke control area).

The Secretary of State for Environment, Food and Rural Affairs has
powers under the Act to authorise smokeless fuels or exempt appliances
for use in smoke control areas in England. In Scotland and Wales this
power rests with Ministers in the devolved administrations for those
countries. Separate legislation, the Clean Air (Northern Ireland) Order
1981, applies in Northern Ireland. Therefore it is a requirement that
fuels burnt or obtained for use in smoke control areas have been
"authorised" in Regulations and that appliances used to burn solid fuel in
those areas (other than "authorised" fuels) have been exempted by an
Order made and signed by the Secretary of State or Minister in the
devolved administrations.

Further information on the requirements of the Clean Air Act can be
found here: http://smokecontrol.defra.gov.uk/

Your local authority is responsible for implementing the Clean Air Act
1993 including designation and supervision of smoke control areas and
you can contact them for details of Clean Air Act requirements”

The Froling TX 150, TX 200, TX 250 have been recommended as
suitable for use in smoke control areas when burning fuels as listed
under 2.4.2

Safety

Permitted uses

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2.4.2 Permitted fuels

Wood chips

Designation as per

Description as per

ÖNORM M 7133

ÖNORM

M 7133

ÖNORM/DIN

CEN/TS 14961

Water
content

W20 M20 Air dried
W30 M30 Suitable for storage

Size G30 P16 Fine wood chips

G50 P45 Medium wood chips

Applicable standards:

Austria: ÖNORM M 7133 or ÖNORM CEN/TS 14961
Germany: Wood chips in accordance with §3 (1) point 4 of the 1st

BImSchV in the applicable version.

Specifications as per DIN CEN/TS 14961 and/or

ÖNORM M 7133

Pellets

Wood pellets made from natural wood with a diameter of 6 - 10 mm

Applicable standards:

Austria: ÖNORM M 7135 - HP 1 and/or DINplus certification
program

Germany: DIN 51731 - HP 5, DINplus certification program and/or
ÖNORM M 7135 - HP 1

Generally applicable:

Before refilling the store, check for pellet dust and clean if necessary.

§

§

Safety

Permitted uses

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Changing the fuel

CAUTION

Incorrectly set fuel parameters:

Incorrect parameter settings have a significant effect on the
functioning of the boiler, and as a result this will void the guarantee.

If the fuel is changed (e.g. from wood chips to pellets), the system must be
reset by Fröling customer services.

2.4.3 Non-permitted fuels

The use of fuels not defined under 2.4.2, 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 lead to
damage to the boiler and also voids the warranty! Using non-standard fuels
can lead to severe problems with combustion.

2.4.4 Qualification of operating staff

Only trained operators are permitted to operate the boiler. The operator
must also have read and understood the instructions in the
documentation.

CAUTION

If unauthorised persons enter the boiler room:

Risk of injury and damage to equipment!

It is the responsibility of the operator to ensure that unauthorised persons,
especially children, are kept away from the boiler.

2.4.5 Protective equipment for operating staff

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

 During operation, inspection and cleaning of the boiler:

- Sturdy shoes

- protective gloves

Safety

Design Information

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2.5 Design Information

It is forbidden to carry out modifications to the boiler or to change or
deactivate safety equipment.

Always comply with all fire, building, and electrical regulations when
installing or operating the boiler system, and follow the operating
instructions and mandatory regulations that apply in t he country in
which the boiler is operated.

2.5.1 Heating System Installation/ Standards

The boiler should be operated in a closed heating system. The following
standards govern the installation:

Applicable standards:

ÖNORM / DIN EN 12828 Heating systems in buildings

 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 sweeper
/ the building authorities.

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 above 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 hydrogen halides or any cleaning agents containing
chlorine in the room where the boiler is installed.

 Keep the air suction opening of the boiler free of dust.

§

Safety

Design Information

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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, ...) from having any
effect on the air flow.

Unless otherwise specified in the applicable building regulations for th e
boiler room, the following standards apply for the design and dimensions
of the air ducts:

Applicable standards:

- TRVB H 118

- ÖNORM H 5170

2.5.3 Requirements for heating water

There are no special requirements for the filling water of the heating
system. The following standards and guidelines apply:

Applicable standards and guidelines:

Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1
Italy: D.P.R. no. 412

 Notice on f illing with make-up water:
Always bleed the filling hose before connecting, in order to prevent
air from entering the system.

2.5.4 Combination with storage tank

NOTICE

Using a storage tank allows you to achieve continuous reduction within the
ideal performance 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.

§

§

Safety

Design Information

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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 lift.

Condensation water forms an aggressive condensate when combined
with combustion residue, leading to damage to the boiler.

Regulations stipulate the use of a return lift.

 The minimum return temperature is 65 °C. We recommend fitting some

kind of control device (e.g. thermometer).

Safety

Safety devices

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2.6 Safety devices

1 Standby button

If the boiler overheats:

 Press the standby key ( )

 Automatic operation is switched off and the controller

follows the boiler shutdown procedure

 The pumps continue to run!
 Never use the main switch!

2 Safety temperature limiter (back

of boiler)

 Page 18, Devices for preventing the boiler from overheating

3 Main switch

For shutting down the entire system:
 Only switch off the main switch when the boiler has cooled

down and the controller is switched off (“Boiler off” status).

 Turn the main switch to the “O” position

 The power to all components is switched off.

Not

shown

Water sprinkler system

In case of burn back, the valve of the water sprinkler system
opens and water goes into the gravity shaft as well as the duct
of the feed screw.

 This need only be connected when specified by the

authorities.

1

3

2

Safety

Safety devices

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2.6.1 Devices for preventing the boiler from overheating

Thermal discharge safety device

At around 100 °C a valve opens and sends cold water to the safety
heat-exchanger to decrease the temperature.

Safety Temperature Limiter STL

Stops combustion at a max. boiler temperature of 105 °C. The pumps
continue to run.

 Once the temperature has fallen below the unlocking point (approx.

95 °C), the safety temperature limiter (2) can be unlocked
mechanically.

Safety valve (provided by the customer)

Protection against over-heating/ excessive pressure:
When the boiler pressure reaches a maximum of 3 bar, the safety valve

opens and the heating water is released in the form of steam.

2

Safety

Residual risks

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2.7 Residual risks

WARNING

Touching hot surfaces!

Hot parts and the flue pipe can cause serious burns!

 Always wear protective gloves when working on the boiler.
 Only operate the boiler using the handles provided for this

purpose

 Insulate the flue gas pipes and avoid touching them during

operation

Before carrying out maintenance work on/in the boiler:

 Press and hold the service program key ( ) for 5 seconds

 The controller follows the shutdown procedure and starts

with the cleaning cycle

 After the cleaning cycle the boiler goes to the operating

status, “Cleaning possible”

WARNING

Opening the combustion chamber door during operation!

This may cause injury, damage and smoke!

It is forbidden to open the doors behind the insulating door
during operation!

WARNING

Use of non-permitted fuel!

Non-standard fuels can cause serious faults in combustion (e.g.
spontaneous combustion of carbonisation gases / flash fires) which
can lead to serious accidents!

Only use fuels specified in the chapter on “Permitted Uses” in
these operating instructions.

Safety

Emergency procedure

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2.8 Emergency procedure

2.8.1 System overheating

If the system overheats in spite of the safety devices, proceed as
follows:

 Keep all the doors on the boiler closed.
 Switch off the boiler using the standby key ( )

 Under no circumstances use the main switch!

 Open all mixer taps and switch on all pumps.

 Fröling heating circuit control takes over this function in

automatic operation.

 When using a third party controller, carry out the relevant

measures to activate the mixer and pumps manually.

 Exit the boiler room and close the door
 Open any available radiator thermostat valves

If the temperature does not drop, inform the installer or Fröling
customer services:

2.8.2 Smell of flue gas

DANGER

Smell of flue gas!
Flue gases can cause fatal poisoning!

 Keep all the doors on the boiler closed.
 Switch off the boiler using the standby key ( )

 Under no circumstances use the main switch!

 Ventilate the installation room
 Close the door of the installation room or boiler room and

doors to living areas

Operating the system

Assembly and initial startup

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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.

 See TX assembly instructions

NOTICE

 Optimum efficiency and efficient, low-emission operation can

only be guaranteed if the system is set up by trained
professionals and observing the standard factory settings.

Take the following precautions:

 Initial start-up should be carried out with an authorised installer or with

Fröling customer services.

3.2 Filling/ refilling the store with fuel

When you fill the store you should always ensure that you are using the
right fuel:

 Page 12, 2.4.2

Operating the system

Filling/ refilling the store with fuel

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Permitted fuels

Caution:

Depending on the fuel and the fill level, differen t procedures must be
followed for filling the fuel store.

3.2.1 Loading wood chips in a partially emptied store

If there is still sufficient fuel in the store (the head of the stirrer is
completely covered with fuel), the store can be filled:

 Load the fuel at the filling openin g

3.2.2 Loading wood chips in an empty store

 CAUTION! If the head of the stirrer is already free of material

and the arms / spring blades are extended, then the feeder
unit must be active during the filling process.

 Press and hold the service program key ( ) for 5 seconds

 “Extra heating” mode is activated

 Load a small quantity of wood chips and wait at least half an hour

(preferably an hour) until the arms / spring blades are touching the
head of the stirrer

 Only then should you load the remaining material

Operating the system

Filling/ refilling the store with fuel

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3.2.3 Blowing in pellets for a store with pellet screw

For systems with a pellet screw, the boiler must be in “OFF” status when
the store is filled. The under-pressure from the blowing could bring
smoke back into the store.

 Switch off the boiler using the standby key ( ) and allow it to cool

down 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 pellets for a partially emptied store with stirrer

If there is still sufficient fuel in the store (the head of the stirrer is
completely covered with fuel), the store can be filled:

 Switch off the boiler using the standby key ( ) and allow it to cool

down for at least two hours.

 Close all openings to the store to seal out dust
 Blow the fuel into the store

Operating the system

Filling/ refilling the store with fuel

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3.2.5 Blowing in pellets for an empty store with stirrer

 CAUTION! If the head of the stirrer is already free of material

and the arms / spring blades are extended, then the feeder
unit must be active during the filling process, however the
boiler must be in “OFF” status.

 Switch off the boiler using the standby key ( ) and switch off main

switch

 Switch off main switch of expension switch cabinet (if available)

 Put residual fuel (corners, walls) in the storage room onto the top of

the outfeeder-system

 Take care to the instructions for working in the fuel storage room

 See notes in the access area of the storage room

After working in the storage room:

 Switch on main switch of the boiler and the expension switch cabinet

(if available)

 Press and hold the party key ( )for 5 seconds

 “Extra heating” mode is activated

 Wait until the arms / spring blades are touching the head of the

stirrer (about 2 turns)

 Switch off the boiler using the standby key ( ) and allow it to cool

down for at least two hours.

 Close all openings to the store to seal out dust
 Blow the fuel into the store

If the storage room is completely empty and there is no residual fuel:

 Contact Froling before filling the store

Operating the system

Heating the boiler

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3.3 Heating the boiler

3.3.1 Switching on the system

 Turn the main switch on the side of the switch cabinet to the “ON”

position

 After the system check by the controller, the system is ready for

operation

 “Boiler Off” is shown on the display

3.3.2 Switching on the boiler

 Press the standby key ( )

 Automatic mode is activated
 The heating system is controlled via the controller according to

the selected mode.

3.3.3 Controlling the boiler

 See the operating instructions for the Lambdatronic H 3200

3.3.4 Switching off the boiler

 Press the standby key ( )

 The boiler follows the shut-down program and switches to “Boiler

OFF” status.

 The combustion unit is switched off, the chamber discharge unit

and the active hydraulic system are active

3.3.5 Switching off the System

WARNING

When switching off the main switch in automatic mode:

Serious combustion faults leading to serious accidents are possible!

Before switching off the main switch:

 Switch off the boiler by pressing the standby key ( )

 Boiler follows shutdown procedure and changes to the

operating status “Boiler off”

 CAUTION! Only when the boiler is cold, in “Boiler Off” status!

 Switch off the main switch on the controller

 The controller is switched off
 The components powered via the switch cabinet are powered

down

 The expansion switch cabinet, which has its own power supply, is

still live!

Boiler maintenance

General information on maintenance

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4

4 Boiler maintenance

4.1 General information on maintenance

DANGER

Working on electrical components
Risk of serious injuries from electric shocks

 Work on electrical components should only be carried out by

authorised technicians

WARNING

Servicing when the boiler is switched on or hot:

Serious injuries from automatic startup of the boiler and serious
burns on hot parts and on the flue gas pipe are possible!

 Only carry out work on the boiler when the main switch is

turned off

 Always wear protective gloves when working on the boiler.
 Only operate the boiler using the handles provided for this

purpose

Before maintenance work:

 Switch off the boiler using the standby key ( ) and allow it

to cool down

 When the boiler has cooled down, switch it off with the main

switch and secure so that it cannot be switched on again

WARNING

Non-permitted cleaning and maintenance!

Incorrect or insufficient cleaning and maintenance 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!

Only clean the boiler when it is in “Boiler Off” operating status
and in accordance with the instructions. 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)

Boiler maintenance

Inspection and cleaning

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4.2 Inspection and cleaning

 Regular cleaning of the boiler extends its life and is a basic

requirement for smooth running based on output. So clean the
boiler regularly!

 Recommended: When cleaning, use an ash vacuum.

4.2.1 Inspection

Checking the thermal discharge safety device

 Check the seal of the discharge valve at regular intervals

 The discharge pipe must not drip

 Exception: boiler temperature > 95 °C

If water is dripping from the discharge pipe:

 Clean the discharge safety device or have the installer replace it if

necessary

Check safety valve

 Check the safety valve as per the manufacturer’s instructions.

 See the operating instructions of the safety valve

Check the system pressure

 Read off the system pressure on the pressure gauge

 The value must be above the pre-stressed pressure of the

expansion tank by 20%

 Expansion tank operating instructions

If the system pressure decreases:

 Top up the water

 If this occurs frequently, the seal of the heating system is faulty!

Inform your installer!

In case of large pressure fluctuations:

 Have the expansion tank checked

Check the geared motors

 Carry out a visual inspection of the seal on the geared motors of the

stoker screw and ash screw

 There must not be a large quantity of lubricant coming out.

 If a few drops of lubricant are coming out, this can be normal. If a lot

of lubricant is being lost, inform your installer or Fröling customer
services.

Boiler maintenance

Inspection and cleaning

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4

4.2.2 Cleaning

Notice -> Main switch OFF
Only check the ash level when “Boiler OFF”

Empty the ash container retort

The ash containers must be emptied at the correct intervals according to
energy requirements and fuel quality.

 Remove the ash container cover and check the level
 If the ash container is full, unscrew the wing nuts on the discharge

flange

 When removing the ash container, insert the transport handle and

secure with a split pin

 Separate the ash container and take it to the ash disposal point

Boiler maintenance

Inspection and cleaning

Fröling Heizkessel- und Behälterbau Ges.m.b.H

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Empty the heat exchanger ash container

For heat exchanger with ashcan:

 Remove the star-shaped screws of the ashcan
 Take out the ashcan and remove the ash

For heat exchanger with ash screws:

 Remove the ash container cover and check the level
 If the ash container is full, unscrew the wing nuts on the flange
 Separate the ash container and take it to the ash disposal point

Boiler maintenance

Inspection and cleaning

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4

4.2.3 Monthly inspection

Activate service mode

For cleaning tasks in the boiler activate service mode:

 Press and hold the service program key ( ) for 5 seconds

 The controller follows the shutdown procedure and starts with the

cleaning cycle

 After the cleaning cycle the boiler goes to the operating status,

“Cleaning possible”

 The tipping grate remains in open position

 Switch off the main switch

Clean the combustion chamber and combustion space

 Open the insulated doors and heat exchanger door
 Remove a lot of ash from the combustion space with a shovel
 Clean the combustion chamber sensor with a soft brush

 Clean the side walls of the combustion space with the furnace tool
 Bring the remaining ash down into the combustion chamber below

with the furnace tool

Boiler maintenance

Inspection and cleaning

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 Close the heat exchanger door and open the combustion chamber

door

 Remove a lot of ash with a shovel
 Clean the step grate and sloping plates with the furnace tool

 Clean the side walls of the combustion chamber with the furnace tool
 Clean the primary air openings in the step grate and sloping plates

with a suitable tool (screwdriver or similar)

After cleaning the combustion space and the combustion chamber:

 Close the boiler doors and insulated doors
 Switch on the main switch

 The tipping grate closes and the controller switches to “Boiler

Off” mode.

 Switch off the main switch again and open the doors
 Check the cleanliness of the tipping grate once more in closed

position and clean the air openings with a suitable tool
(screwdriver or similar)

Boiler maintenance

Inspection and cleaning

Page 32

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4

4.2.4 Annual inspection

 Carry out annually, however at least after 2500 service hours!

For the annual inspection:

 Switch off the main switch when the boiler has cooled down

Clean the heat-exchanger

 Remove the insulated cover and open the cleaning cover
 Remove all dirt and deposits for the flue gas chamber.

Clean the area below the step grate

 Remove the blanking plate and the thermal insulation
 Remove the inspection cover

 Clean away the ash below the step grate with the furnace tool or an

ash vacuum

 Clean the side passage to the flue gas recirculation (optional)

Boiler maintenance

Inspection and cleaning

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Clean the flue gas recirculation (FGR) (optional)

 Remove the pipe insulation from the

inspection cover.

 Remove the inspection cover and

clean the pipes of the flue gas
recirculation unit with a brush

After cleaning the pipes:

 Remove the inspection cover of the flue gas recirculation box
 Clean the interior with an ash vacuum

 Remove the inspection cover of the

flue gas recirculation air box

 Clean the interior with an ash vacuum

Boiler maintenance

Inspection and cleaning

Page 34

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4

Clean the induced draught fan

 Remove both cables from the induced draft fan

 Mark the flange position and loosen the screws on the fan flange
 Take out the induced draught fan and clean the blower wheel with a

brush.

 Clean the interior of the induced draught fan housing with an ash

vacuum

Clean the combustion air blower fan

 Clean any dust and deposits from

the protective grating

 Dismantle the protective grating and

clean the fan with a soft brush where
necessary.

Check the under-pressure controller

 Remove the silicon tube from the

differential pressure transducer.

 Using compressed air, blow out the

hose in the direction of the
combustion chamber to remove any
deposits.

 Connect the silicon hose at “Minus”.

Boiler maintenance

Inspection and cleaning

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Check the combustion chamber overpressure sensor

 Loosen the retaining screw.
 Pull the combustion chamber

overpressure sensor out of the
spacer pipe.

 Clean the sensor with a fine cloth.
 Check that the spacer pipe is free.
 Insert the combustion chamber

overpressure sensor and fix gently
with fixing screws

Check door seals

 Check that the ceramic fibre seal of the combustion chamber door,

the heat exchanger door and the heat exchanger cover is positioned
correctly on the frame

 Check the imprint on the ceramic fibre seal.

If the imprint of the seal is broken:

 The seal is no longer efficient.

 Adjust the door fastenings or replace the glass fibre seal

 After adjusting the combustion chamber door and the heat

exchanger door, you must check that the door contact switch is
working and if necessary it must be reset.

Check the draught controller flap and explosion flap

 Check the draught controller flap and explosion flap for ease of

operation

 If they cannot move smoothly, have them replaced immediately.

Boiler maintenance

Instructions for measuring emissions

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4.3 Instructions for measuring emissions

4.3.1 Measurement at rated load

 Ensure the highest possible heat consumption:

- Ensure that heating pumps are switched on

- Open mixer valves and radiator valves

- Set the boiler loading time to the current time

- Set the boiler temperature setpoint to 85°C

 Chimney sweep mode takes over this function

Activate chimney-sweep mode

 Press the service program key ( ) briefly

 The chimney sweeper program for boiler measurement is started.

The system is operated for 45 minutes at rated load. For this
purpose the maximum boiler temperature, the maximum heating
circuit flow temperature and the DHW tank loading are released.

When is it possible to measure:

• Flue gas temperature at approx. 140°C

• O

2

content of the flue gas between 8 and 12% (corresponds to a

CO

2

content between 13 and 19%)

• Boiler temperature above 65°C

4.3.2 Measurement at partial load (if necessary)

 Ensure heat consumption:

- Ensure that heating pumps are switched on

- Open mixer valves and radiator valves

- Set the boiler loading time to the current time

 Force partial load:

- After measuring at rated load, lower the boiler temperature
setpoint by 5°C

When is it possible to measure:

• Flue gas temperature at approx. 120°C

• O

2

content of the flue gas between 10 and 14% (corresponds to a

CO

2

content between 11 and 7%)

• Boiler temperature above 65°C

 After measurement all adjusted parameters (e.g. DHW tank loading

times, ...) must be reset to their original value!

Boiler maintenance

Maintenance agreement / Customer service

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4.4 Maintenance agreement / Customer service

 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, trouble-free service life for your heating system.

It will ensure that your system stays environmentally-friendly an d
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 is also glad to advise you.

4.5 Replacement parts

With Fröling 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 lifespan is maintained.

NOTICE

Installing non-original parts voids the guarantee!

 Only replace components or parts with original replacement parts

4.6 Disposal information

4.6.1 Ash disposal

 The ash should be disposed of in accordance with waste
management law (AWG).

4.6.2 Disposal of system components

 Ensure that they are disposed of in an environmentally friendly way

in accordance with waste management law.

 You can separate and clean recyclable materials and send them to a

recycling centre.

Troubleshooting

General faults in power supply

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5 Troubleshooting

5.1 General faults in power supply

Error characteristics Cause of error Error correction

Nothing is shown on the
display

No power to the controller

• General power failure

• FI circuit breaker or line

protection is switched off

• Main switch is turned off

• Faulty glass tube fuse in the

controls

 Switch on the FI circuit breaker or

line protection

 Switch on the main switch
 Switch off the main switch
 Replace fuse – note current

(e.g. 10A)

 Switch on the main switch

5.1.1 System procedure following power failure

When the power supply has been restored the boiler returns to the
previously specified mode and is controlled according to the specified
program.

5.2 Excessive temperature

The safety temperature limiter (STL) shuts down the boiler when it
reaches a temperature of max. 105°C. After the boiler has cooled down,
the safety temperature limiter must be manually unlocked:

 Unscrew the cap on the safety temperature limiter (2)
 Reset the safety temperature limiter by pressing with a screw-driver.
 Replace the cap

2

Troubleshooting

Faults with fault message

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5.3 Faults with fault message

If a fault message is pending:

 Status LED (4.1) indicates the type of fault:

- Orange flashing: warning

- Red flashing: error or alarm

 The relevant fault message is shown on the display (4.2)

The term “fault” is a collective term for warnings, errors and alarms.
The boiler reacts differently to the three types of message:

WARNING In case of warnings the boiler initially continues controlled

operation, giving the option of resolving the error quickly to
prevent a shutdown.

ERROR The boiler follows shutdown procedure and remains in “Boiler

off” status until the problem is resolved.

ALARM 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

The procedure in case of fault message, the causes for faults and
procedure for troubleshooting are described in the operating instructions
for the boiler controller:

 See the operating instructions for the Lambdatronic H 3200

5.3.2 Acknowledging a fault message

Trace and remove the fault and then:

 Press the enter key ( )

 Status LED constant or flashing green light (depending on

operating status)

- Green constant: boiler switched on

- Green flashing: boiler switched off

4.1

4.2

Appendix

Addresses

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6 Appendix

6.1 Addresses

6.1.1 Manufacturer’s Address

FRÖLING
Heizkessel- und Behälterbau GesmbH

Industriestraße 12
A-4710 Grieskirchen
AUSTRIA

TEL [phone]
FAX [phone]
E-MAIL [email protected]
WEBSITE www.froeling.com

6.1.2 Installer’s address

STAMP