Fröling SPS 4000 User manual

Operating Instructions
Boiler controller SPS 4000 (PP 65)
Version 01.09
Translation of the original German operating instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B0960623_en | Edition 05/04/2023
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

1 General 5
1.1 Safety information 6
2 Overview of the basic functions 7
2.1 Touch display 7
2.2 Control icons 8
3 Operation 10
3.1 Switching the boiler on/off 10
3.2 Navigation within the system menu 10
3.2.1 Navigating within submenus 11
3.3 Displaying/changing parameters 12
3.3.1 Displaying parameter info 13
3.3.2 Changing the parameter value 14
3.4 Quick menu 16
3.5 Activating manual operation 16
3.6 Setting the date and time 17
3.7 Setting times 18
3.7.1 Applying the time setting for several days 19
3.8 Switching user level 20
4 Initial startup 22
4.1 Before switching on for the first time 22
4.2 Switching on for the first time 22
4.3 Changing the language 23
4.4 Performing a software update 24
4.5 Perform hardware detection manually 26
4.6 Configuring the boiler 28
4.6.1 Setting the boiler type 28
4.6.2 Setting the boiler-specific parameters 28
4.7 Configure fuel feed 29
4.7.1 Chamber discharge system 29
4.7.2 Fuel feed: general information 30
4.8 Configure hydraulic system 32
4.8.1 Sample configuration 33
4.9 Configure additional system options 35
4.9.1 Backup boiler 35
4.9.2 Cascade 35
4.9.3 Flue gas treatment 35
4.10 I/O configuration 36
4.10.1 I/O configuration according to circuit
diagram
38
4.11 Setting the parameters of the
frequency converter
39
4.12 Finishing configuration 40
4.13 Performing the first start / Checking
the settings
40
5 Menus and parameters 42
5.1 Heating circuits & system 42
5.1.1 System pressure 42
System pressure configuration
42
5.1.2 Network pump 42
Network pump configuration
42
5.1.3 Backup boiler / Swivel burner 44
Backup boiler – Configuration
44
Swivel burner – Configuration
45
5.1.4 Cascade 46
Cascade - Temperatures
46
Power demand in cascade mode
46
Cascade - Configuration
47
5.1.5 Flue gas treatment 47
Flue gas filter
47
Flue gas heat exchanger (FGHE)
49
5.1.6 Hydraulics: general information 50
5.1.7 Feeder pumps 50
Configuration
50
5.1.8 Boiler distributor 52
Configuration
52
Assigned components
52
5.1.9 Distributor 1 - 6 53
Configuration
53
Assigned components
53
5.1.10 Heating circuits 54
Heating circuits - Temperatures
54
Heating circuits - Times
55
Heating circuits - Configuration
55
5.1.11 DHW tank 56
DHW tank - Temperatures
56
DHW tank - Times
56
DHW tank - Configuration
57
5.1.12 Storage tank 57
Boiler behaviour
57
Buffer tank - Temperatures
58
Buffer tank - Times
59
Storage tank - Configuration
60
5.2 Boiler 61
5.2.1 Mode 61
5.2.2 Boiler times 62
5.2.3 Boiler settings 62
5.2.4 Water temperatures 63
5.2.5 Lambda probe 65
Configuration 65
Table of Contents
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Manual
66
5.2.6 Ignite 66
5.2.7 Air flaps/blower fan 67
Configuration
67
Frequency converter
70
Test
71
5.2.8 Flue gas 71
5.2.9 Combustion chamber 72
5.2.10 Heat exchanger cleaning 73
Heat exchanger configuration
73
Manual heat exchanger
74
5.2.11 FGR 75
Configuration
75
Frequency converter 78
FGR test
78
5.2.12 Grate 79
5.2.13 Ash Removal 79
5.2.14 Joint ash removal 81
5.2.15 Slide-on duct 81
5.2.16 Special mode 82
5.2.17 External boiler control 83
5.2.18 Slumber 83
5.2.19 Control parameters 84
5.3 Fuel feed 84
5.3.1 Stoker 84
5.3.2 Feed screw/feeder 85
5.3.3 Automatic infeed calculation 87
5.3.4 Hopper 88
5.3.5 Chamber discharge system 88
5.3.6 Sliding floor 89
5.3.7 Suction system 91
Cyclone 1
91
Cyclone 2
91
5.3.8 Rotary valves 92
5.4 PLC 93
5.4.1 Date & time 93
5.4.2 Software 93
5.4.3 Connections 94
Network
94
Field bus
95
5.4.4 Display 96
Display settings
96
Calibrate touchscreen
97
5.4.5 Hardware 97
5.4.6 SPS restart 97
5.5 Diagnosis 98
5.5.1 Error 98
Current faults
98
Fault log
98
Clear error
99
5.5.2 Inputs and outputs 99
5.5.3 System 100
5.5.4 Message forwarding 100
5.5.5 Diagnostic data 101
5.5.6 USB recording 101
Configuration
102
5.5.7 Current values 102
5.5.8 Operating times 103
5.6 System configuration 103
5.6.1 Hydraulic system 103
5.6.2 Heating circuits & system 104
Heating circuits
104
DHW tank 104
Buffer tank
105
Backup boiler 105
Cascade
105
Exhaust gas treatment 106
Pumps
106
5.6.3 Boiler type 106
5.6.4 Boiler 107
5.6.5 Fuel feed 109
Chamber discharge system
109
Fuel feed
109
5.6.6 Inputs and outputs 110
5.6.7 Operating times 110
5.6.8 Operator data 111
5.6.9 Backup 111
Save configuration
111
Load configuration 112
5.6.10 Specification values 112
Boiler specifications
112
Fuel specifications
113
Own templates
114
Exporting fuel feed models
115
Factory setting
116
6 Troubleshooting 117
6.1 Fault handling 117
6.2 Fault message list 118
7 Electric components and wiring 133
7.1 SPS 133
7.1.1 Display 134
Ports and displays 134
Changing the Compact Flash
136
Replacing the battery 137
7.1.2 X20 – module layout 138
7.1.3 X20 module types 141
BR9300
141
PS2100
143
BT9100
146
CS1012
148
CS1030
150
DI2377
151
DI9371
152
DO9322
154
DO8332
156
DO6639
158
DO2633
160
AI4622
162
Table of Contents
Operating Instructions SPS 4000 (PP 65) | B0960623_en 3

AI4222
164
AO4622
166
AO2622
168
AT2402
170
AT6402
172
AT4222
174
7.2 Sensor characteristic line PT100 176
7.3 Sensor characteristic line type K 177
7.4 Frequency converter 179
7.4.1 Operating elements 179
7.4.2 Changing parameters 180
7.5 Cascade / Modbus 182
7.5.1 Terminating resistor at communication
module
184
7.6 M-bus 184
8 Appendix 185
8.1 FAQ 185
8.1.1 Changes - control cabinet H 3000 to SPS
4000
185
Regulating flaps
185
Sensors
185
Multi-sensor storage tank management
185
Flue gas temperature sensor
185
Casing cooling
185
Separation of fault contacts
185
Grate hydraulics LM 750/1000 control
185
Lambda probe 0-10V
186
8.1.2 Boiler program (Start-shut down) 186
8.1.3 Back up/restore memory card 187
8.1.4 Connecting to the SPS with PC 194
Connection via a local network (LAN)
194
Direct connection to SPS 4000
195
SPS 4000 network settings
196
PC network settings
199
8.1.5 System Diagnostic Manager (SDM) 207
Saving log file to data medium
208
Create system dump
209
8.1.6 Calibration of the lambda probe 210
8.2 Notes 211
8.3 Addresses 212
8.3.1 Address of manufacturer 212
Customer service
212
8.3.2 Address of the installer 212
Table of Contents
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1 General
Thank you for choosing a quality product from Froling. The product features a state-of-the-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: [email protected].
Subject to technical change.
About these instructions
The range of functions of the SPS 4000 depends on the user level currently set. These instructions show all the
parameters that are available with full functionality in the "Service" user level (maximum configuration with all
possible system components). The range available varies according to the user level set.
NOTICE
The values given in the parameter lists are examples, and should not be used as standard
values!
General 1
Operating Instructions SPS 4000 (PP 65) | B0960623_en 5

1.1 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
Safety information
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2 Overview of the basic functions
2.1 Touch display
A
B
CD
E
F GH
I
J
K
ADisplays the date and time. Tapping the date or time opens the dialogue for modification.
BThe USB icon displays the status of the USB connection.
▪Icon grey: No USB storage media plugged in
▪ Icon white: USB storage media plugged in; active recording is displayed below the icon
Tapping the icon opens the menu for USB recording.
⇨ See "USB recording" [page 101]
CThe network icon displays the status of the network connection.
▪Icon grey: The network is not available or the network cable is not plugged in
▪ Icon white: The network cable is plugged in
Tapping the icon opens the network settings.
⇨ See "Network" [page 94]
DDisplay of current user level. Tapping the text opens the dialogue for switching the user level.
⇨ See "Switching user level" [page 20]
EImage of the set boiler type
FSystem menu icon for opening the system settings. All parameters can be displayed/edited depending on the
user level
GQuick menu icon for viewing the available quick functions
Overview of the basic functions 2
Touch display
Operating Instructions SPS 4000 (PP 65) | B0960623_en 7

HInfo menu icon for viewing all system information
IMode icon for switching the boiler on/off
JMode display
KOperating status display
2.2 Control icons
Cancel icon
Discards any values entered without saving and closes messages.
Confirm icon
Confirms any values entered and activates parameters.
Home icon
Tapping the Home icon takes you back to the basic display from any menu.
Info menu icon
To access all system information. The information is ordered in a circular buffer. The right and left arrows are
used to switch between the individual pages.
Quick menu icon
Opens the quick menu. Various functions are available depending on the user level, system configuration
and current status.
Pen icon
If a parameter has the pen symbol beside it, it means that the parameter can be adjusted. If you open the
parameter, either the numeric keypad or a list box for changing the value of the parameter will appear.
2Overview of the basic functions
Control icons
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System menu icon
Opens the system settings. Depending on the operating level and system configuration, the various menu
items available are organised in a circular buffer which can be navigated using the right and left arrow.
Back icon
Takes you back up one menu level of the system menu. Can be used to return to the basic display.
Overview of the basic functions 2
Control icons
Operating Instructions SPS 4000 (PP 65) | B0960623_en 9

3 Operation
3.1 Switching the boiler on/off
BOILER ON
The boiler is switched on. The boiler system is controlled according to the programs and times set.
BOILER OFF
The PLC shuts down the boiler in a controlled way. After the shut down procedure, the boiler switches to the
“OFF” status (switched off - off). The PLC controls the connected heating system. All the boiler units are
deactivated. The chamber discharge system remains active!
3.2 Navigation within the system menu
The system menu shows the menu items available depending on the user level and the system configuration.
Tap the icon to open the corresponding menu item. The system menu is structured in a circular buffer, which
can be navigated using the right and left arrows.
3Operation
Switching the boiler on/off
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3.2.1 Navigating within submenus
After you open a menu item, the corresponding status display with current values will appear. If, for example,
several heating circuits are installed, you can use the right and left arrows to navigate to the desired heating
circuit. You can open any other menu items available in the same way.
The individual menus are divided into tabs for quicker navigation.
❒ Tap on the desired tab
➥The list of parameters for the selected area will appear
Operation 3
Navigation within the system menu
Operating Instructions SPS 4000 (PP 65) | B0960623_en 11

The parameter list shows three parameters. The up and down arrows can be used to scroll through longer lists
of parameters. If you have reached the start or end of the parameter list, the relevant arrow symbol will become
inactive.
3.3 Displaying/changing parameters
It is only possible to view or edit parameter details if there is a pen icon beside the parameter value:
❒ Tap the relevant parameter
➥The detailed view of the parameter will open
3Operation
Displaying/changing parameters
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AParameter name
BDisplays the changed value
CCurrent parameter value setting. Parameter is reset to this value if you cancel the entry
DSpecified values for quick selection of standard, minimum and maximum (equals the setting range for the
parameter)
3.3.1 Displaying parameter info
❒ Tap the Info icon in the parameter view
➥The info view opens
Operation 3
Displaying/changing parameters
Operating Instructions SPS 4000 (PP 65) | B0960623_en 13

The info view shows a description of the parameter in continuous text. You can use the up and down arrows to
scroll through long descriptions.
3.3.2 Changing the parameter value
There are different ways of entering values depending on the type of parameter (increase/reduce value, keypad
entry, list box). In each case, you need to tap the confirm icon to save the entry.
Increasing/reducing the value
❒ Change the parameter value using the up and down arrows
➥The changed value appears in the display field
❒ You can also tap “Minimum", “Default" or “Maximum" to set to the respective value displayed below
❒ Tap the confirm icon to save the set value
➥The parameter value is saved and the setting dialogue closes
3Operation
Displaying/changing parameters
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Entering a value
If a numeric keypad icon appears beside the parameter value in the display field, you can enter the value
directly:
❒ Tap the numeric keypad icon
➥The Enter values window for parameters will appear
❒ Type in the relevant value on the numeric keypad
❒ Confirm your entry by tapping the confirm icon
Operation 3
Displaying/changing parameters
Operating Instructions SPS 4000 (PP 65) | B0960623_en 15

3.4 Quick menu
The quick menu shows the quick functions available depending on the user level and the system configuration.
Tapping the icon starts the function or automatically takes you to the relevant position in the system menu. The
quick menu is structured in a circular buffer, which can be navigated using the right and left arrows.
3.5 Activating manual operation
No matter where you are in the menu, you can open the “Manual switch” menu from the bottom menu bar. The
number of available manual functions depends on the configuration of the system, the current user level and the
current boiler status.
❒ Open the "Manual switch" menu
❒ Navigate to the relevant function using the up and down arrows
❒ Activate the unit by tapping "Manual"
➥The unit will be regulated to the value specification set in the respective menu
➥The function will remain active until the process is ended by tapping "Auto" or the Manual switch menu is
closed
3Operation
Quick menu
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3.6 Setting the date and time
❒ Tap the date and time area on the start screen
➥The menu for setting the date and time will be displayed
❒ Tap the relevant value to change it
❒ Enter the new value using the numeric keypad
❒ Save the change by tapping the confirm icon
Operation 3
Setting the date and time
Operating Instructions SPS 4000 (PP 65) | B0960623_en 17

Set the time zone using the following settings menu:
System menu PLC Date & time
3.7 Setting times
The desired time window for the component can be set in the "Times" tab in the individual menus of the heating
components (e.g. heating circuit). The structure of the time menu and the procedure for changing the times are
always the same.
❒ Use the left or right arrow to navigate to the desired day of the week
❒ Tap the relevant time window from a maximum of four
➥The edit window will appear
3Operation
Setting times
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❒ Set the start and end time for the time window using the up and down arrows
➥The hours and minutes are set separately for each time
❒ Apply the set time window by tapping the confirm icon
3.7.1 Applying the time setting for several days
The heating times set for a certain day can be applied to other days:
❒ Use the left or right arrow to navigate to the day of the week with the desired heating times
❒ Tap the icon beside the heating times
➥The "Transfer program" menu will appear
Operation 3
Setting times
Operating Instructions SPS 4000 (PP 65) | B0960623_en 19

❒ Select the relevant days of the week that you want the heating times to apply to
❒ Tap the confirm icon to transfer the times to the selected days and close the menu
3.8 Switching user level
❒ Tap the quick select icon on the start screen
❒ Use the left and right arrows to navigate to the user level icon
❒ Open the input field for the user code by tapping the user level icon
3Operation
Switching user level
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