Fröling Lambdatronic H 3200 User manual

Service manual
Lambdatronic H 3200 for wood chip boiler
Core module version 50.04 - Build 05.17 | Touch control version 60.01 - Build 01.35
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B1480519_en | Edition 19/04/2019
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

1 General 4
1.1 About these instructions 4
1.2 Safety information 4
2 Power connection and wiring 5
2.1 Core module and connection options 5
2.1.1 Board view - core module 5
Connection instructions 5
2.1.2 Mains connection 7
2.1.3 Connecting the flue gas temperature
sensor
7
2.1.4 Connecting the remote control 8
2.1.5 Boiler enable contact 8
2.1.6 Connecting a high efficiency pump to the
core module
9
2.1.7 Heating circuit pump 0 / burner relay 10
2.1.8 Operating signal 10
2.2 Expansion modules 11
2.2.1 Heating circuit module 11
2.2.2 Hydraulic module 12
Connecting an isolating valve 13
Connecting a high efficiency pump to the hydraulic
module
14
2.2.3 Wood chip module 15
2.2.4 Power supply 18
2.2.5 Analogue module 19
External power demand 0-10V 19
2.2.6 Digital module 20
Connection of the second tipping grate T4 130/150
pellets
21
2.2.7 Connecting the bus cable 22
2.2.8 Connect the patch cable to the bus plug 22
2.2.9 Setting end jumpers 22
2.2.10 Setting the module address 23
2.3 Connection diagrams according to
pump types
24
2.4 Frequency converter 25
2.4.1 Operating elements 25
2.4.2 Changing parameters 26
3 Initial start-up with settings wizards 28
3.1 Before switching on for the first time 28
3.1.1 Controller check 28
3.1.2 Check on the connected units 28
3.1.3 System check 28
3.2 General information about the settings
wizard
29
3.3 Switching on for the first time 31
3.4 Starting the setting wizard 32
4 Parameters overview 33
4.1 Heating 33
4.1.1 Heating - Status 33
4.1.2 Heating – Temperatures 34
4.1.3 Heating - Times 35
4.1.4 Heating - Service 35
4.1.5 Heating - Heating up program 36
Heating up programs 37
Configure program 8 37
Heating circuits used 38
4.1.6 Heating - General settings 38
4.2 Water 39
4.2.1 Water - Status 39
4.2.2 Water - Temperatures 39
4.2.3 Water - Times 40
4.2.4 Water - Service 40
4.3 Solar 42
4.3.1 Solar - Status 42
4.3.2 Solar - Temperatures 43
4.3.3 Solar - Times 44
4.3.4 Solar - Service 44
4.3.5 Solar - Heat meter 46
4.4 Buffer tank 48
4.4.1 Buffer tank - Status 48
4.4.2 Buffer tank - Temperatures 49
4.4.3 Buffer tank - Times 50
4.4.4 Buffer tank - Service 50
4.5 Boiler 52
4.5.1 Boiler - Status 52
4.5.2 Boiler - Temperatures 53
4.5.3 Boiler - Times 54
4.5.4 Boiler - Service 54
4.5.5 Boiler - General settings 55
Boiler - General settings - MODBUS settings 56
Boiler - General settings - Operator data 56
4.6 Boiler 2 57
4.6.1 Boiler 2 - Status 57
4.6.2 Boiler 2 - Temperatures 58
4.6.3 Boiler 2 - Service 59
4.7 Fuel 60
4.7.1 Fuel - Service 60
4.8 Feed system 61
4.8.1 Feed system - Screw 1 on LB 61
Table of contents
2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.8.2 Feed system - Screw 2 on LB 62
4.8.3 Feed system - Rotary agitator 63
4.8.4 Discharge - Cyclone 1 (feed system-
configuration 8)
64
4.8.5 Feed system - Cyclone 1 / 2 (suction
screw)
65
4.8.6 Feed system - Cyclone 1 / 2 (4/8 probe
switch)
66
4.9 Network pump 68
4.9.1 Network pump - Status 68
4.9.2 Network pump - Temperatures 69
4.9.3 Network pump - Service 70
4.10 Cascade 72
4.10.1 Cascade - Status 72
4.10.2 Cascade - Backup boiler 72
4.10.3 Cascade - Temperatures 73
4.10.4 Cascade - Service 74
4.11 Difference regulator 75
4.11.1 Difference regulator - Status 75
4.11.2 Difference regulator - Temperatures 75
4.11.3 Difference regulator - Times 76
4.11.4 Difference regulator - Service 76
4.12 Circulation pump 77
4.12.1 Circulation pump - Status 77
4.12.2 Circulation pump - Temperatures 77
4.12.3 Circulation pump - Times 78
4.12.4 Circulation pump - Service 78
4.13 Manual 79
4.13.1 Manual - Manual operation 79
4.13.2 Manual - Digital outputs 80
4.13.3 Manual - Analogue outputs 80
4.13.4 Manual - Digital inputs 81
4.14 System 82
4.14.1 System - Settings 82
Setting - Boiler temperature 82
Setting - Slide-on duct 83
Setting - Flue gas 84
Setting - Ignition 92
Setting - Air settings 93
Setting - Fuel slide-in 95
Setting - Vibration / WOS / Cleaning 98
Setting - WOS / Cleaning 99
Set - Cleaning 100
Setting - Combustion chamber 101
Setting - Lambda values 103
Set - Lambda probe 104
Setting - General settings 106
4.14.2 System - Current values 108
Operation hours 108
4.14.3 System - Sensors and pumps 109
4.14.4 System - System selection 109
4.15 Diagnostics 110
4.15.1 Diagnosis – Current fault list 110
4.15.2 Diagnosis – Clear pending error 110
4.15.3 Diagnostics - Error history 110
4.15.4 Diagnostics - Clear error history 110
4.16 Touchscreen 111
4.16.1 Touchscreen - Display settings 111
Display settings - General 111
Display settings - Basic display 112
Display settings - Date / Time 112
Display settings - Software update / Service 112
4.16.2 Touchscreen - Display operating rights 113
Froling Connect 114
4.16.3 Touchscreen - Display allocation 114
5 FAQ 115
5.1 Calibrate the broadband probe 115
5.2 PDM / 0 - 10V settings 116
5.3 Boiler operating statuses 117
5.4 Boiler modes 118
5.4.1 "Automatic” mode without storage tank 118
5.4.2 “Automatic” mode with storage tank 119
5.4.3 “Continuous load” mode without storage
tank
120
5.4.4 “Continuous load” mode with storage
tank
120
5.4.5 “Domestic hot water” mode without
storage tank
120
5.4.6 “Domestic hot water” mode with storage
tank
122
5.5 Setting times 123
5.6 Calibrating the touchscreen 125
5.7 Software update Lambdatronic 3200 127
5.7.1 Carrying out a software update on the
boiler controller
128
5.7.2 Carrying out a software update on the
touch control
130
5.7.3 Finishing a software update 131
6 Notes 132
7 Appendix 134
7.1 Addresses 134
7.1.1 Address of manufacturer 134
Customer service 134
7.1.2 Address of the installer 134
Table of contents
Service manual Lambdatronic H 3200 for wood chip boiler | B1480519_en 3

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!
1General
About these instructions
4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2 Power connection and wiring
2.1 Core module and connection options
2.1.1 Board view - core module
Mains fuse
Connection instructions
Connection / Name Note
KM-01 BUS Connection with cable – LIYCY paired 2x2x0.5;
⇨ See "Connecting the bus cable" [page 22]
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
Power connection and wiring 2
Core module and connection options
Service manual Lambdatronic H 3200 for wood chip boiler | B1480519_en 5

Connection / Name Note
KM-04 COM 2 Null modem cable 9-pin SUB-D;
Connection is used e.g. as MODBUS interface
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 or NTK 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 (LSM11) or NTK
switching-type sensor (OZA685)
KM-14 Boiler enable Connection cable1) 2 x 0.75 mm2
Caution! The connection must be a floating connection.
⇨ See "Boiler enable contact" [page 8]
KM-15 Flue gas temperature sensor Connection cable1) 3 x 0.75 mm2
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 sensor Connection cable1) 2 x 0.75 mm2
KM-25 Boiler sensor
KM-26 PWM / 0-10V pump 1
KM-27 ID 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
2Power connection and wiring
Core module and connection options
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Connection / Name Note
KM-29 Mains connection Connection cable1) 3 x 1.5 mm2, fuse provided by customer: C16A
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 / 500W
KM-33 Heating circuit pump 1
KM-34 Heating circuit pump 0 / burner relay Connection cable1) 3 x 1.5 mm2, max. 3A / 600VA
KM-35 Operating signal Connection cable1) 2 x 0.75 mm2
⇨ See "Operating signal" [page 10]
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 flue gas temperature sensor
green-yellow
red +
blue -
Core module
Power connection and wiring 2
Core module and connection options
Service manual Lambdatronic H 3200 for wood chip boiler | B1480519_en 7

2.1.4 Connecting the remote control
A room temperature sensor is included in the remote control, which sends the current room temperature to the
control.
affecting room:
AUS
UHR
NACHT
TAG
FV
RFFV
COM
Raumfühler FRA
RF 1/2
Kernmodul S/P/H 3200
not affecting room:
AUS
UHR
NACHT
TAG
FV
RFFV
COM
Raumfühler FRA
RF 1/2
Kernmodul S/P/H 3200
Switch settings:
Boiler off Heating circuit deactivated, only frost protection!
Automatic Heating phases according to setback program
Setback mode Ignores the heating phases
Party switch Ignores the setback
Handwheel… Allows you to adjust the temperature by +/- 3°C
IMPORTANT! See assembly instructions/functional description for room temperature sensor FRA
2.1.5 Boiler enable contact
When commissioning the boiler system using the settings wizards, the parameter “How is the boiler enable
contact on the core module being used?” is called up to enable potential 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
not in use No effect on boiler operation (contact must not be clamped/bridged)
Enable/disable boiler As long as the boiler enable contact is closed, the boiler controller
operates according to the specified parameters (mode, time
window, etc.). If the boiler enable contact is opened, the boiler
loses the enable and follows the shutdown procedure. As long as
the boiler enable 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 enable contact is open, the boiler controller
operates according to the specified parameters. If the boiler enable
contact is closed, the boiler starts in continuous load operation (e.g.
heat requirements of a heating fan).
2Power connection and wiring
Core module and connection options
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.1.6 Connecting a high efficiency pump to the core module
Wire the high efficiency pump as shown in the connection diagram below:
KERNMODUL
FRKEM25
PDM / 0-10V (+)
PDM / 0-10V ( )
Pump 1 (L)
Pump 1 ( )
Pump 1 (N)
❒ Connect the power supply for the high efficiency pump to output "Pump 1" of the core module
❒ Connect the PDM cable of the high efficiency pump to the corresponding port “PDM / 0-10V”
➥Make sure that the cables are configured correctly (polarity) in accordance with the connection diagram
of the pump!
Important! When using a Froling pump assembly:
⇨ See "Connection diagrams according to pump types" [page 24]
Power connection and wiring 2
Core module and connection options
Service manual Lambdatronic H 3200 for wood chip boiler | B1480519_en 9

2.1.7 Heating circuit pump 0 / burner relay
The connection “Heating circuit pump 0”, can be used for heating circuit pump 0 or as burner relays depending
on the system setting.
Connecting a HCP 0 up to max. 2 Ampere:
Core module
L1
N
HCP
0
Connecting a HCP 0 up to max. 5 Ampere:
Connection as burner relays:
Core module
L1
N
To oil boiler control:
floating contact for burner
release
2.1.8 Operating signal
On the core module, connection position 35, it is possible to issue an operating signal potential-free. In the
menu “Manual” -> “Digital outputs” the status can be viewed under parameter “ Standby relay ”.
⇨ See "Manual - Digital outputs" [page 80]
Operating status Relay status
Boiler off, standby, fault 0
All other operating statuses (e.g. preparation, heating up, pre-heating, ignition, heating, slumber,
cleaning, shutdown wait 1, shutdown wait 2, etc.)
1
2Power connection and wiring
Core module and connection options
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com