Fröling Lambdatronic H 3200 User manual

Service manual
Lambdatronic H 3200 for wood chip boiler
Core module version 50.04 - Build 05.19 | Touch control version 60.01 - Build 01.37
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B1480721_en | Edition 12/08/2021
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

1 General 5
1.1 About these instructions 5
1.2 Safety information 5
2 Power connection and wiring 6
2.1 Core module and connection options 6
2.1.1 Board view - core module 6
2.1.2 Mains connection 8
2.1.3 Connecting the outside temperature
sensor
8
2.1.4 FRA room temperature sensor 9
2.1.5 Boiler enable contact 10
2.1.6 Connecting a circulating pump to the core
module
10
2.1.7 Connecting an isolating valve to the core
module
12
2.1.8 Heating circuit pump 0 / burner relay 13
2.1.9 Operating signal 13
2.2 Expansion modules 14
2.2.1 Heating circuit module 14
2.2.2 Hydraulic module 15
Connecting a circulating pump to the hydraulic
module
16
Connecting an isolating valve to the hydraulic
module
20
2.2.3 Wood chip module 21
2.2.4 Plug power pack FRSNT17 23
2.2.5 Plug power pack Meanwell LRS-100-24 24
2.2.6 Analogue module 25
External power demand
26
2.2.7 Digital module 27
2.2.8 Feed system module 31
2.3 BUS connection 33
2.3.1 Connecting the bus cable 34
2.3.2 Setting end jumpers 34
2.3.3 Setting the module address 35
2.3.4 Potential equalisation / potential
separation
36
2.4 Connection information according to
pump types
37
2.5 Frequency converter 38
2.5.1 Operating elements 38
2.5.2 Changing parameters 39
3 Initial start-up with settings wizards 41
3.1 Before switching on for the first time 41
3.1.1 Controller check 41
3.1.2 Check on the connected units 41
3.1.3 System check 41
3.2 General information about the settings
wizard
42
3.3 Switching on for the first time 43
3.4 Starting the setting wizard 44
4 Parameters overview 46
4.1 Heating 46
4.1.1 Heating - Status 46
4.1.2 Heating – Temperatures 47
4.1.3 Heating - Times 48
4.1.4 Heating - Service 48
4.1.5 Heating - Heating up program 49
Heating up programs
50
Configure program 8
50
Heating circuits used
50
4.1.6 Heating - General settings 51
4.2 Water 52
4.2.1 Water - Status 52
4.2.2 Water - Temperatures 52
4.2.3 Water - Times 53
4.2.4 Water - Service 53
4.3 Solar 55
4.3.1 Solar - Status 55
4.3.2 Solar - Temperatures 56
4.3.3 Solar - Times 57
4.3.4 Solar - Service 57
4.3.5 Solar - Heat meter 59
4.4 Buffer tank 60
4.4.1 Buffer tank - Status 60
4.4.2 Buffer tank - Temperatures 61
4.4.3 Buffer tank - Times 62
4.4.4 Buffer tank - Service 62
4.5 Boiler 64
4.5.1 Boiler - Status 64
4.5.2 Boiler - Temperatures 65
4.5.3 Boiler - Times 66
4.5.4 Boiler - Service 66
4.5.5 Boiler - General settings 67
Boiler - General settings - MODBUS settings
68
Boiler - General settings - Operator data
68
4.6 Boiler 2 69
4.6.1 Boiler 2 - Status 69
4.6.2 Boiler 2 - Temperatures 69
4.6.3 Boiler 2 - Service 70
Table of contents
2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.7 Fuel 71
4.7.1 Fuel - Service 71
4.8 Feed system 71
4.8.1 Feed system - Screw 1 on LB 71
4.8.2 Feed system - Screw 2 on LB 72
4.8.3 Feed system - Rotary agitator 73
4.8.4 Discharge - Cyclone 1 (feed system-
configuration 8)
74
4.8.5 Feed system - Cyclone 1 (suction screw) 76
4.8.6 Feed system - Cyclone 1 (4/8x toggle) 77
4.8.7 Feed system - Cyclone 1 (1-2-3 suction
module)
78
4.9 Network pump 80
4.9.1 Network pump - Status 80
4.9.2 Network pump - Temperatures 80
4.9.3 Network pump - Service 81
4.10 Cascade 82
4.10.1 Cascade - Status 82
4.10.2 Cascade - Backup boiler 82
4.10.3 Cascade - Temperatures 83
4.10.4 Cascade - Service 84
4.11 Difference regulator 85
4.11.1 Difference regulator - Status 85
4.11.2 Difference regulator - Temperatures 85
4.11.3 Difference regulator - Times 86
4.11.4 Difference regulator - Service 86
4.12 Circulation pump 87
4.12.1 Circulation pump - Status 87
4.12.2 Circulation pump - Temperatures 87
4.12.3 Circulation pump - Times 88
4.12.4 Circulation pump - Service 88
4.13 Manual 89
4.13.1 Manual - Manual operation 89
4.13.2 Manual - Digital outputs 90
4.13.3 Manual - Analogue outputs 90
4.13.4 Manual - Digital inputs 91
4.14 System 92
4.14.1 System - Settings 92
Setting - Boiler temperature
92
Setting - Slide-on duct
92
Setting - Flue gas
93
Setting - Ignition
101
Setting - Air settings
102
Setting - Fuel slide-in
104
Setting - Vibration / WOS / Cleaning
107
Setting - WOS / Cleaning
108
Set - Cleaning
109
Setting - Combustion chamber
110
Setting - Lambda values
112
Set - Lambda probe
113
Set - Quantity of heat calculation
115
Setting - General settings
115
4.14.2 System - Current values 116
Operation hours
116
4.14.3 System - Sensors and pumps 117
4.14.4 System - System selection 117
4.15 Diagnostics 118
4.15.1 Diagnosis – Current fault list 118
4.15.2 Diagnosis – Clear pending error 118
4.15.3 Diagnostics - Error history 118
4.15.4 Diagnostics - Clear error history 119
4.16 Touchscreen 120
4.16.1 Touchscreen - Display settings 120
Display settings - General
120
Display settings - Basic display
121
Display settings - Date / Time
121
Display settings - Software update / Service
121
4.16.2 Touchscreen - Display operating rights 122
Froling Connect
122
4.16.3 Touchscreen - Display allocation 123
5 FAQ 124
5.1 Activation options of pump outlets 124
5.2 Boiler operating statuses 125
5.3 Determination of the quantity of heat 126
5.3.1 Assembly Information 126
5.3.2 Functioning and configuration 126
Calculating the feed output of the circulating pump
126
Setting the type of heat quantity calculation
127
Configuring the heat quantity calculation
127
5.4 Boiler modes 128
5.4.1 "Automatic” mode without storage tank 128
5.4.2 “Automatic” mode with storage tank 129
5.4.3 “Continuous load” mode without storage
tank
130
5.4.4 “Continuous load” mode with storage
tank
131
5.4.5 “Domestic hot water” mode without
storage tank
131
5.4.6 “Domestic hot water” mode with storage
tank
132
5.5 Setting times 133
5.6 Calibrating the touchscreen 135
5.7 Software update Lambdatronic 3200 137
5.7.1 Carrying out a software update on the
boiler controller
138
5.7.2 Carrying out a software update on the
touch control
140
5.7.3 Finishing a software update 141
Table of contents
Service manual Lambdatronic H 3200 for wood chip boiler | B1480721_en 3

5.8 USB data recording 142
6 Notes 143
7 Appendix 144
7.1 Addresses 144
7.1.1 Address of manufacturer 144
Customer service
144
7.1.2 Address of the installer 144
Table of contents
4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

1 General
1.1 About these instructions
Please read and follow the operating instructions, in particular the safety information contained therein. Keep
them available next to the boiler.
These operating instructions include important information about operation, electrical connection and
troubleshooting. The parameters shown depend on the set boiler type and the system configuration!
The constant further development of our products means that there may be minor differences from the pictures
and content. If you discover any errors, please let us know: [email protected].
1.2 Safety information
DANGER
When working on electrical components:
Risk of electrocution!
When work is carried out on electrical components:
❒ Always 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
WARNING
When touching hot surfaces:
Severe burns are possible on hot surfaces and the flue gas pipe!
When work is carried out on the boiler:
❒ Shut down the boiler according to procedure (“Boiler off” operating status) and allow it to
cool down
❒ Protective gloves must usually be worn for work on the boiler, and it should only be
operated using the handles provided
❒ Insulate the flue gas pipes and do not touch them during operation
The information on safety, standards and guidelines in the assembly and operating instructions for the boiler
should also be observed!
General 1
About these instructions
Service manual Lambdatronic H 3200 for wood chip boiler | B1480721_en 5

2 Power connection and wiring
2.1 Core module and connection options
2.1.1 Board view - core module
6,3 AT
sw +
gr -
IN
+24V
grün-gelb
rot +
blau -
ws 13VDC
NZ
COM
PZ
S
HE-
HE+
ZU
AUF
P2
5V/P3
ZU
AUF
P2
5V/P3
ws 13VDC
KM-35
(Betriebssignal)
KM-02
(Bus)
KM-01
(Bus)
KM-04
(COM 2)
KM-06
(Breitbandsonde)
KM-09
(Verriegelung)
KM-10
(STB)
KM-11
(NOT-HALT)
KM-07
(siehe Tabelle ...)
KM-08
(siehe Tabelle ...)
KM-05
(COM 1)
KM-03
(Bus)
KM-36
(Optionsmodul) L N
PEPEPE
KM-34
(Heizkreispumpe 0
oder Brennerrelais)
KM-33
(Heizkreispumpe 1)
KM-32
(Heizkreispumpe 2)
KM-31
(Mischer 1)
KM-30
(Mischer 2)
KM-29
(Netz)
KM-28
(Pumpe 1)
KM-27
(Saugzug)
FRKEM29
L1
N
N
L
N
L
N
L
N
LV
LV
L
Sig
+5V
N
L
N
AUF
ZU
N
AUF
ZU
KM-26 (PWM / 0-10V Pumpe 1) KM-25 (Kesselfühler) KM-24 (Rücklauffühler) KM-23 (Vorlauffühler 1) KM-22 (Vorlauffühler 2) KM-21 (Raumfühler 1) KM-20 (Raumfühler 2) KM-19 (Außenfühler) KM-18 (Fühler 1) KM-17 (Fühler 2) KM-16 (Türkontaktschalter)
KM-15
(Abgasfühler)
KM-14
(Kesselfreigabe)
KM-13
(Lambdasonde)
KM-12 (Durchflussmesser)
End jumper
Mains fuse
Core module
Connection / Name Note
KM-01 BUS Connection with cable – LIYCY paired 2x2x0.5;
⇨ See "Connecting the bus cable" [page 34]
Caution! CAN L and CAN H must not be connected to +UBUS!
KM-02 BUS Patch cable CAT 5 RJ45 SFTP 1:1 configuration; pellet module
connection
KM-03
KM-04 COM 2 Null modem cable 9-pin SUB-D;
Connection is used e.g. as MODBUS interface
2Power connection and wiring
Core module and connection options
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Connection / Name Note
KM-05 COM 1 Null modem cable 9-pin SUB-D;
Service interface for software update and connection to visualisation
software
KM-06 Broadband probe Connection cable1) 5 x 0.75 mm2
Connection of a Bosch (item number 69001A) or NTK (item number
69003) broadband Lambda probe
KM-07 Primary air T4 90-150
TX
TI
Connection cable1) 5 x 0.75 mm2
KM-08 Air flap T4 24-75
T4e 20-250
Connection cable1) 5 x 0.75mm2;
Combined air damper for primary and secondary air
Secondary air T4 90-150
TX
TI
Connection cable1) 5 x 0.75 mm2;
KM-09 Lock Connection cable1) 2 x 0.75 mm2
KM-10 High-limit thermostat
KM-11 EMERGENCY STOP Caution! Do not connect the emergency stop/shutdown switch to the
boiler power supply line. The switch must be a N/C switch and it
must be linked to the 24V safety chain of the STL at this terminal.
KM-12 Flowmeter Connection cable1) 2 x 0.75 mm2
KM-13 Lambda probe Connection cable1) 4 x 0.75 mm²
Connection of a Bosch switching-type sensor (type LSM11) or NTK
switching-type sensor (type OZA685, item number: 69400)
KM-14 Boiler release Connection cable1) 2 x 0.75 mm2
Caution! The connection must be a floating connection.
⇨ See "Boiler enable contact" [page 10]
KM-15 Flue gas temperature sensor Only use connection cable of the component
KM-16 Door switch for ash box Connection cable1) 2 x 0.75 mm2
KM-17 Sensor 2 Connection cable1) 2 x 0.75 mm2
KM-18 Sensor 1 Connection cable1) 2 x 0.75 mm2, sensor 1 in the STL housing
KM-19 Outside temperature sensor Connection cable1) 2 x 0.75 mm2, shielded from 25 m cable length
KM-20 Room temperature sensor heating circuit
2
KM-21 Room temperature sensor heating circuit
1
KM-22 Flow temperature sensor heating circuit
2
KM-23 Flow temperature sensor heating circuit
1
KM-24 Return feed sensor Connection cable1) 2 x 0.75 mm2
KM-25 Boiler sensor
KM-26 PDM / 0-10V pump 1
KM-27 Induced draught fan Connection cable1) 3 x 1.5 mm2 for power supply, Connection
cable1) 3 x 0.75 mm2 for analysis of current speed
KM-28 Pump 1 Connection cable1) 3 x 1.5 mm2, max. 1.5A / 280W / 230V
KM-29 Mains connection Connection cable1) 3 x 1.5 mm2, fuse provided by customer: C16A
Power connection and wiring 2
Core module and connection options
Service manual Lambdatronic H 3200 for wood chip boiler | B1480721_en 7

Connection / Name Note
KM-30 Mixing valve heating circuit 2 Connection cable1) 4 x 0.75 mm2, max. 0.15A / 230V
KM-31 Mixing valve heating circuit 1
KM-32 Heating circuit pump 2 Connection cable1) 3 x 1.5 mm2, max. 2.5A
KM-33 Heating circuit pump 1
KM-34 Heating circuit pump 0
or burner relay
Connection cable1) 3 x 1.5 mm2, max. 2A
KM-35 Operating signal Connection cable1) 2 x 0.75 mm2
⇨ See "Operating signal" [page 13]
KM-36 Optional module
1.YMM as per ÖVE-K41-5 or H05VV-F as per DIN VDE 0881-5
2.1.2 Mains connection
Connect the power supply at the “mains connection" plug
❒ Flexible sheathed cable must be used for the wiring; this must be of the correct size to comply with
applicable regional standards and regulations.
2.1.3 Connecting the outside temperature sensor
The outside temperature sensor is included with the materials supplied for the boiler and is usually mounted on
an outer wall that is not directly exposed to the sun. It continuously measures the ambient temperature and
forms part of the weather-compensated heating circuit control.
KM-19 / Außenfühler
In the delivered state, the outside temperature sensor is read in by the core module ("KM-19 / outside
temperature sensor" connection). Alternatively, the outside temperature sensor can be connected to an
additional heating circuit module.
⇨ See "Heating circuit module" [page 14]
2Power connection and wiring
Core module and connection options
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.1.4 FRA room temperature sensor
In addition to recording the current room temperature, the Froling FRA room temperature sensor also has a
handwheel to adjust the required room temperature and a slide switch to set the mode for the heating circuit.
AUS
UHR
NACHT
TAG
FV
RFFV
COM
Raumfühler FRA
RF 1/2
Kernmodul S/P/H 3200
AUS
UHR
NACHT
TAG
FV
RFFV
COM
Raumfühler FRA
RF 1/2
Kernmodul S/P/H 3200
affecting room: not affecting room:
Possible positions of the mode switch:
Boiler off Heating circuit deactivated, only frost protection!
Automatic mode Heating and setback phases according to the set times
Setback mode Ignores the heating phases and continuously controls the
room temperature to the temperature set in setback mode
Party switch Ignores the setback phases and continuously controls the
room temperature to the temperature set in heating mode
Handwheel… Allows you to adjust the temperature by +/- 3°C
IMPORTANT! Refer to the supplied assembly instructions for more detailed explanations on connecting and
operating the FRA room temperature sensor.
Power connection and wiring 2
Core module and connection options
Service manual Lambdatronic H 3200 for wood chip boiler | B1480721_en 9

2.1.5 Boiler enable contact
When commissioning the boiler using the settings wizard, the boiler release contact function (“How is the
boiler release contact on the core module being used?”) is called up to enable the optional
analysis of an external floating release or start contact. The following functions are possible depending on the
setting and electrical connection:
Connection position Setting Description
6,3 AT
sw +
gr -
IN
+24V
grün-gelb
rot +
blau -
ws 13VDC
NZ
COM
PZ
S
HE-
HE+
ZU
AUF
P2
5V/P3
ZU
AUF
P2
5V/P3
ws 13VDC
KM-35
(Betriebssignal)
KM-02
(Bus)
KM-01
(Bus)
KM-04
(COM 2)
KM-06
(Breitbandsonde)
KM-09
(Verriegelung)
KM-10
(STB)
KM-11
(NOT-HALT)
KM-07
(siehe Tabelle ...)
KM-08
(siehe Tabelle ...)
KM-05
(COM 1)
KM-03
(Bus)
KM-36
(Optionsmodul) L N
PEPEPE
KM-34
(Heizkreispumpe 0
oder Brennerrelais)
KM-33
(Heizkreispumpe 1)
KM-32
(Heizkreispumpe 2)
KM-31
(Mischer 1)
KM-30
(Mischer 2)
KM-29
(Netz)
KM-28
(Pumpe 1)
KM-27
(Saugzug)
FRKEM29
L1
N
N
L
N
L
N
L
N
LV
LV
L
Sig
+5V
N
L
N
AUF
ZU
N
AUF
ZU
KM-26 (PWM / 0-10V Pumpe 1) KM-25 (Kesselfühler) KM-24 (Rücklauffühler) KM-23 (Vorlauffühler 1) KM-22 (Vorlauffühler 2) KM-21 (Raumfühler 1) KM-20 (Raumfühler 2) KM-19 (Außenfühler) KM-18 (Fühler 1) KM-17 (Fühler 2) KM-16 (Türkontaktschalter)
KM-15
(Abgasfühler)
KM-14
(Kesselfreigabe)
KM-13
(Lambdasonde)
KM-12 (Durchflussmesser)
not in use No effect on boiler operation (contact must not be clamped/
bridged).
Release/disable boiler As long as the boiler release contact is closed, the boiler controller
operates according to the specified parameters (mode, time
window, etc.). If the boiler release contact is opened, the boiler is
no longer released and follows the shutdown procedure. As long as
the boiler release contact is open, heating requirements are
ignored. (e.g. flue gas thermostat of a supply boiler, house
distribution box).
Extra heating As long as the boiler release contact is open, the boiler controller
operates according to the specified parameters. If the boiler release
contact is closed, the boiler starts in continuous load operation (e.g.
heat requirements of a heating fan).
2.1.6 Connecting a circulating pump to the core module
Different types of wiring must be implemented depending on the type of pump:
High efficiency pump with control line (PWM / 0-10V)
On high efficiency pumps with an additional wired control line, the speed control is implemented via the
additional connection for the PWM or 0-10V signal.
FRKEM29
Pumpe 1
N
PE
L
LV
N
Netz
PE
L
AO-P1
PWM
0-10V
❒ Connect the power supply for the high efficiency pump to output “Pump 1” of the core module
❒ Connect the PWM cable of the high efficiency pump to the corresponding “PWM / 0-10V” port
➥Make sure that the cables are configured correctly (polarity) in accordance with the connection diagram
of the pump!
❒ Set control of the pump in the relevant menu to “Field pump / PWM” or “Field pump / 0-10V”
2Power connection and wiring
Core module and connection options
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com