Fröling Lambdamat LM 750 User manual

Installation Instructions
Lambdamat LM 750/1500
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M2050121_en | Edition 18/02/2021
Fröling Ges.m.b.H | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of contents
1 General 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 Personal protective equipment for assembly staff 6
3 Design Information 7
3.1 Notes on standards 7
3.1.1 General standards for heating systems 7
3.1.2 Standards for structural and safety devices 7
3.1.3 Standards for heating water 7
3.1.4 Regulations and standards for permitted fuels 8
3.2 Installation and approval of the heating system 9
3.3 General information for installation room (boiler room) 9
3.4 Requirements for central heating water 10
3.5 Notes for using pressure maintenance systems 11
3.6 Return lift 12
3.7 Use with storage tank 12
3.8 Chimney connection/chimney system 13
3.8.1 Draught limiter 13
4 Technical information 14
4.1 Dimensions 14
4.2 Components and connections 15
4.3 Technical specifications 16
5 Installation 18
5.1 Transport 18
5.2 Temporary storage 18
5.3 Positioning 18
5.3.1 Fit the ash duct for ash removal of the combustion chamber (only with Lambdamat 750). 19
5.3.2 Bolting together the combustion chamber and heat exchanger 19
5.4 Setting up in the boiler room 20
5.4.1 Moving the boiler in the boiler room 20
5.4.2 Operating and maintenance areas of the equipment 20
5.5 Laying firebricks in the combustion chamber 22
5.5.1 General 22
5.5.2 Laying firebricks 23
5.6 Installing the boiler 24
5.6.1 General information 24
5.6.2 Installing the stoker unit 24
5.6.3 Installing the hydraulic stoker unit 25
5.6.4 Fitting the burn back slide valve 26
5.6.5 Installing the air controllers 27
Table of contents
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5.6.6 Fitting the immersion sleeves for the thermal discharge valve and undergrate sensor 28
5.6.7 Fitting thermal insulation to the boiler 28
5.6.8 Fitting the insulation base frame 29
5.6.9 Fitting the side panels 32
5.6.10 Fitting various covers 35
5.6.11 Fitting the door contact switch 36
5.6.12 Fitting the combustion chamber ash removal unit (optional) 37
5.6.13 Installing the underpressure controller 40
5.6.14 Installing the combustion chamber overpressure and temperature sensors 40
5.6.15 Fitting the Lambda probe and various sensors 41
5.6.16 Installing the servo-motors 42
5.6.17 Fitting the combustion air fan 43
5.6.18 Fitting the automatic ignition (optional) 44
5.6.19 Fitting an additional ignition for hydraulic stoker unit (optional) 44
5.6.20 Fitting the compressed air cleaner (optional) 45
5.6.21 Fitting the ash sliding system (optional) 46
5.6.22 Installing flue gas recirculation FGR (optional) 47
5.7 Flue gas piping 51
5.8 Hydraulic connection 52
5.8.1 Thermal discharge safety device with zone valve 53
5.9 Power connection and wiring 54
5.9.1 Potential equalisation 54
5.10 Connecting up the slide-on duct cooling 55
5.11 Connecting the hydraulic cylinder 56
6 Commissioning 57
6.1 Before commissioning / configuring the boiler 57
6.1.1 Compressed air cleaner (optional) 58
6.2 Initial startup 59
6.2.1 Permitted fuels 59
Wood chips 59
Wood shavings 59
Miscanthus 60
Changing the fuel 60
6.2.2 Non-permitted fuels 60
6.3 Heating up for the first time 60
6.3.1 Screed drying 61
7 Decommissioning 63
7.1 Out of service for long periods 63
7.2 Disassembly 63
7.3 Disposal 63
8 Appendix 64
8.1 Addresses 64
8.1.1 Address of manufacturer 64
Customer service 64
8.1.2 Address of the installer 64
Table of contents
Installation Instructions Lambdamat LM 750/1500 | M2050121_en 3

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.
The EC Declaration of Conformity is only valid in conjunction with a delivery certificate,
which has been filled in correctly and signed as part of the commissioning process.
The original document remains at the installation site. Commissioning installers or
heating engineers are requested to return a copy of the delivery certificate together
with the guarantee card to Froling. On commissioning by FROLING Customer Service
the validity of the delivery certificate will be noted on the customer service record.
Issuing a delivery
certificate
1General
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2 Safety
2.1 Hazard levels of warnings
This documentation uses warnings with the following hazard levels to indicate direct
hazards and important safety instructions:
DANGER
The dangerous situation is imminent and if measures are not observed it will lead
to serious injury or death. You must follow the instructions!
WARNING
The dangerous situation may occur and if measures are not observed it will lead
to serious injury or death. Work with extreme care.
CAUTION
The dangerous situation may occur and if measures are not observed it will lead
to minor injuries.
NOTICE
The dangerous situation may occur and if measures are not observed it will lead
to damage to property or pollution.
Safety 2
Hazard levels of warnings
Installation Instructions Lambdamat LM 750/1500 | M2050121_en 5

2.2 Qualification of assembly staff
CAUTION
Assembly and installation by unqualified persons:
Risk of personal injury and damage to property
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow appropriately qualified personnel to work on the system
Assembly, installation, initial startup and servicing must always be carried out by
qualified personnel:
- Heating technician / building technician
- Electrical installation technician
- Froling customer services
The assembly staff must have read and understood the instructions in the
documentation.
2.3 Personal protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For transportation, setup and assembly:
- suitable work wear
- protective gloves
- sturdy shoes (min. protection class S1P)
2Safety
Qualification of assembly staff
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3 Design Information
3.1 Notes on standards
The system must be installed and commissioned in accordance with the local fire and
building regulations. Unless contrary to other national regulations, the latest versions
of the following standards and guidelines apply:
3.1.1 General standards for heating systems
EN 303-5 Boilers for solid fuels, manually and automatically fed
combustion systems, nominal heat output up to 500 kW
EN 12828 Heating systems in buildings - design of water-based heating
systems
EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods
Part 1: Chimneys serving one appliance
ÖNORM H 5151 Planning of central hot water heating systems with or without hot
water preparation
ÖNORM M 7510-1 Guidelines for checking central heating systems
Part 1: General requirements and one-off inspections
ÖNORM M 7510-4 Guidelines for checking central heating systems
Part 4: Simple check for heating plants for solid fuels
3.1.2 Standards for structural and safety devices
ÖNORM H 5170 Heating installation - Requirements for construction and safety
engineering, as well as fire prevention and environmental
protection
TRVB H 118 Technical directives for fire protection/prevention (Austria)
3.1.3 Standards for heating water
ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in
closed warm water heating systems at operating temperatures
up to 100°C (Austria).
VDI 2035 Prevention of damage hot water heating systems (Germany)
SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
UNI 8065 Technical standard regulating hot water preparation.
DM 26.06.2015 (Ministerial Decree specifying the minimum
requirements)
Follow the instructions of this standard and any related updates.
(Italy)
Design Information 3
Notes on standards
Installation Instructions Lambdamat LM 750/1500 | M2050121_en 7

3.1.4 Regulations and standards for permitted fuels
1. BImSchV First Order of the German Federal Government for the
implementation of the Federal Law on Emission Protection
(Ordinance on Small and Medium Combustion Plants) in the
version published on 26 January 2010,
BGBl. JG 2010 Part I No. 4.
EN ISO 17225-2 Solid bio-fuel - Fuel specifications and classes
Part 2: Wood pellets for use in industrial and domestic systems
EN ISO 17225-4 Solid bio-fuel - Fuel specifications and classes
Part 4: Wood chips for non-industrial use
3Design Information
Notes on standards
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3.2 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
EN 12828 - Heating Systems in Buildings
NOTICE! Each heating system must be officially approved.
The appropriate supervisory authority (inspection agency) must always be informed
when installing or modifying a heating system, and authorisation must be obtained
from the building authorities:
Austria: report to the construction authorities of the community or magistrate
Germany: report new installations to an approved chimney sweep / the building
authorities.
3.3 General information for installation room (boiler room)
Boiler room characteristics
▪ The floor must be even, clean and dry and have an adequate load-bearing
capacity.
▪There must not be a potentially explosive atmosphere in the boiler room as the
boiler is not suitable for use in potentially explosive environments.
▪ The boiler room must be frost-free.
▪ The boiler does not provide any light, so the customer must ensure sufficient
lighting in the boiler room in accordance with national workplace design
regulations.
▪ When using the boiler above 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
The floor of the boiler room must not be flammable. No flammable materials
should be stored near the boiler. Flammable objects (e.g. clothing) must not be put
on the boiler to dry.
▪ Damage due to impurities in combustion air.
Do not use any solvents or cleaning agents containing chlorine and hydrogen
halides in the room where the boiler is installed (e.g. chlorination units for
swimming pools).
▪ Keep the air suction opening of the boiler free of dust.
▪ The system must be protected against the chewing or nesting of animals (e.g.
rodents etc.).
Ventilation of the boiler room
Ventilation air for the boiler room should be taken from and expelled directly outside,
and the openings and air ducts should be designed to prevent weather conditions
(foliage, snowdrifts, etc.) from obstructing the air flow.
Note on standards
Design Information 3
Installation and approval of the heating system
Installation Instructions Lambdamat LM 750/1500 | M2050121_en 9

Unless otherwise specified in the applicable building regulations for the boiler room,
the following standards apply to the design and dimensions of the air ducts:
ÖNORM H 5170 - Construction and fire protection requirements
TRVB H118 - Technical directives on fire protection/prevention
3.4 Requirements for central heating water
Unless contrary to other national regulations, the latest versions of the following
standards and guidelines apply:
Austria:
Germany:
ÖNORM H 5195
VDI 2035
Switzerland
:
Italy:
SWKI BT 102-01
UNI 8065
Observe the standards and also follow the recommendations below:
❒Aim for a pH value of between 8.2 and 10.0. If the central heating water comes
into contact with aluminium, the pH value must be between 8.0 and 8.5
❒ Use prepared water which complies with the standards cited above for filling and
make-up water
❒ Avoid leaks and use a closed heating system to maintain water quality during
operation
❒ When filling with make-up water, always bleed the filling hose before connecting,
in order to prevent air from entering the system
Advantages of prepared water:
▪ Complies with the applicable standards
▪ Less of a drop in output due to reduced limescale build-up
▪ Less corrosion due to fewer aggressive substances
▪ Long-term cost savings thanks to improved energy efficiency
Note on standards
3Design Information
Requirements for central heating water
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Permitted water hardness for the fill and make-up water in accordance with VDI 2035:
Overall heat
output
Total hardness at
<20 l/kW minimum
individual heat output 1)
Total hardness at
>20 ≤50 l/kW minimum
individual heat output 1)
Total hardness at
>50 l/kW minimum
individual heat output 1)
kW °dH mol/m³ °dH mol/m³ °dH mol/m³
≤50 no demand or 11.2 2 0.11 0.02
<16.8 2) <3 2)
>50 ≤200 11.2 2 8.4 1.5
>200 ≤600 8.4 1.5 0.11 0.02
>600 0.11 0.02
1.From specific system volume (litres nominal capacity/heat output; for multi-boiler systems use the smallest individual heat output)
2.In the case of systems with central heating boilers and for systems with electric heating elements
Additional requirements for Switzerland
The filling and make-up water must be demineralised (fully purified)
▪The water must not contain any ingredients that could settle and accumulate in the
system
▪ This makes the water non-electroconductive, which prevents corrosion
▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can
weaken corrosive materials in certain conditions
If some of the system water is lost, e.g. during repairs, the make-up water must also be
demineralised. It is not enough to soften the water. The heating system must be
professionally cleaned and rinsed before filling the units.
Inspection:
▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the central
heating water comes into contact with aluminium, the pH value must be between 8.0 and
8.5
▪ Yearly. Values must be recorded by the owner
3.5 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required
pressure within predefined limits and balance out volume variations caused by
changes in the hot-water temperature. Two main systems are used:
Compressor-controlled pressure maintenance
In compressor-controlled pressure maintenance units, a variable air cushion in the
expansion tank is responsible for volume compensation and pressure maintenance. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen
into the heating water.
Design Information 3
Notes for using pressure maintenance systems
Installation Instructions Lambdamat LM 750/1500 | M2050121_en 11

Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressure-
maintenance pump, relief valve and an unpressurised receiving tank. The valve
releases hot water into the receiving tank if the pressure is too high. If the pressure
drops below a preset value, the pump draws water from the receiving tank and feeds it
back into the heating system. Pump-controlled pressure maintenance systems with
open expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via the
surface of the water, exposing the connected system components to the risk of
corrosion. These systems offer no oxygen removal for the purposes of corrosion
control as required by VDI 2035 and in the interests of corrosion protection should not
be used.
3.6 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 temperature control.
Condensation water forms an aggressive condensate when combined with
combustion residue, leading to damage to the boiler.
Take the following precautions:
❒ Regulations stipulate the use of a return temperature control.
➥The minimum return temperature is 60 °C. We recommend fitting some
sort of control device (e.g. thermometer).
3.7 Use with storage tank
NOTICE
In principle it is not necessary to use a storage tank for the system to run
smoothly. However, we recommend that you use the system with a storage tank,
as this ensures a continuous supply of fuel in the ideal output range of the boiler.
For the correct dimensions of the storage tank and the line insulation (in accordance
with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling.
⇨ See "Addresses" [page 64]
3Design Information
Return lift
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3.8 Chimney connection/chimney system
EN 303-5 specifies that the entire flue gas system must be designed to prevent,
wherever possible, damage caused by seepage, insufficient feed pressure and
condensation. Please note in this respect that flue gas temperatures lower than 160K
above room temperature can occur in the permitted operating range of the boiler.
The flue gas temperatures (for clean systems) and additional flue gas values can be
found in the table below.
The connection between the boiler and the chimney system should be as short as
possible. The upward angle of the connection should not exceed 30 - 45°. Insulate the
connection. The entire flue gas system - chimney and connection - should be
calculated in accordance with EN 13384-1.
Local regulations and other statutory regulations also apply.
NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney
sweep.
3.8.1 Draught limiter
We generally recommend the installation of a draught limiter. A draught limiter must
be installed if the maximum permissible feed pressure as given in the boiler data for
planning the flue gas system is exceeded.
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the
pressure is constantly low at this point.
Design Information 3
Chimney connection/chimney system
Installation Instructions Lambdamat LM 750/1500 | M2050121_en 13

4 Technical information
4.1 Dimensions
B4
L
H
B
B2 L1
L2
H1
H3
B
B1
H2
H2
Item Description Unit Lambdamat
750 1500
HHeight, boiler mm 3600 4585
H1 Height, flow/return connection 3660 4660
H2 Height, stoker including burn back protection system
(wood chips BBF 300)
1220 1500
H3 Height, flue gas pipe connection 3250 4200
H4 Minimum height, base 1) 260 -
WWidth, boiler 1630 1850
W1 Width, stoker incl. gears 1290 1290
W2 Width, ash container (optional) 1295 1295
LLength, boiler incl. reversing chamber door and flue gas pipe
connection
3075 4360
L1 Length, boiler 2710 3935
L2 Length, flue gas collection box 255 600
1.Base required for ash removal to ash container via screw
4Technical information
Dimensions
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4.2 Components and connections
Item Description Unit LM 750 LM 1500
ABoiler flow connection inches DN100 / PN 6 DN150 / PN 6
BBoiler return connection inches DN100 / PN 6 DN150 / PN 6
CSafety battery connection inches 1” ET 1” ET
DFlue gas pipe connection mm 400 500
EFGR (flue gas recirculation) connection mm 300 300
FBroadband probe connection - -
GFlue gas temperature sensor connection - -
HSafety valve connection (provided by the customer) inches DN65 / PN 6 DN80 / PN 6
IDrainage connection inches 2“ IT 2“ IT
Technical information 4
Components and connections
Installation Instructions Lambdamat LM 750/1500 | M2050121_en 15

4.3 Technical specifications
Description LM 750 LM 1500
Nominal output kW 750 1500
Output range kW 225 - 750 450 - 1500
Nominal fuel heating efficiency with wood chips kW 833 1667
Efficiency at nominal load / partial load % 90.0 / 90.3 > 90.0
Quantity of wood chips required at nominal load kg/h 242 490
Electrical connection 400 V / 50 Hz
Electric fuses1) A as per circuit diagram
Electrical power consumption W as per circuit diagram
Dimensions required for combustion chamber
installation (LxWxH)
mm 3600 x 1600 x 1850 4780 x 1830 x 2700
Dimensions required for heat exchanger installation
(LxWxH)
mm 3050 x 1600 x 1650 3980 x 1850 x 1950
Weight – combustion chamber kg 3620 7600
Weight – heat exchanger kg 3500 8200
Weight – fireclay kg 4320 7500
Total weight excl. fittings kg 11440 23300
Heat exchanger water capacity l 1840 4240
Water pressure drop (ΔT = 20 K) mbar 15 63
Flow rate (ΔT = 20 K) m³/h 32.4 66
Minimum ventilation opening as per ÖNORM H 5170 cm² 1666 3338
Minimum boiler return temperature °C 65
Maximum permitted operating temperature °C 95
Maximum permitted working over-pressure bar 6
Permitted fuel as per EN ISO 17225 3) Part 4: Wood chips class A2 / P16S-P45S
Airborne sound level dB(A) < 70
1.Electric fuses and power consumption vary depending on design and features
2.Use the maximum attainable oxygen content for chimney design
3.Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”
4Technical information
Technical specifications
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Boiler data for planning the flue gas system
Description LM 750 LM 1500
Flue gas temperature at nominal load / partial load °C 220 / 160
Draught requirement at ID fan outlet at
nominal load / partial load
Pa 5 / 2
mbar 0.05 / 0.02
CO2- volume concentration at nominal load / partial
load
% 10.3 / 10.3
Flue gas mass flow with wood chip W30, 12% O2 2) m3/h (kg/h) 4419 (3120) 8838 (6240)
Flue gas mass flow with wood chips W30, 9% O2m3/h (kg/h) 3143 (2214) 6285 (4428)
Recommended maximum chimney draught Pa 60
mbar 0.6
Technical information 4
Technical specifications
Installation Instructions Lambdamat LM 750/1500 | M2050121_en 17

5 Installation
WARNING
Risk of falling when working at a height
Therefore:
❒Implement appropriate measures in accordance with the applicable national
industrial safety guidelines to protect against the risk of falling (e.g. ladders,
platforms, etc.)
5.1 Transport
NOTICE
Possibility of damage to components if handled incorrectly
❒Follow the transport instructions on the packaging
❒ Transport components with care to avoid damage
❒ Protect components against damp
❒ Unloading, positioning and installation should only be performed by trained
professionals! Staff must be trained in techniques for moving heavy loads
(correct tools and lifting equipment, hooking and slinging points, etc.)
5.2 Temporary storage
If the system is to be assembled at a later stage:
❒Store components at a protected location, which is dry and free from dust
➥Damp conditions and frost can damage components, particularly electric ones!
5.3 Positioning
❒ Secure cable winch or similar lifting device to the attachment points on the heat
exchanger (A) and the combustion chamber (B) and position the components.
5Installation
Transport
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5.3.1 Fit the ash duct for ash removal of the combustion chamber (only with
Lambdamat 750).
NOTICE! If ash is to be removed from the boiler via an ash screw, a base must be
provided by the customer beneath the boiler.
⇨ See "Dimensions" [page 14]
If an ash screw (optional) is provided for removing ash from the combustion chamber,
the ash duct should be fitted as follows when the combustion chamber is being
positioned.
❒ Fit the ash duct to the underside of the combustion chamber.
5.3.2 Bolting together the combustion chamber and heat exchanger
❒ Position the heat exchanger on the centre of the combustion chamber and secure
to the combustion chamber with 4x screws and nuts.
➥Also screw on the earthing wire (supplied) with the toothed washer as potential
equalisation.
Installation 5
Positioning
Installation Instructions Lambdamat LM 750/1500 | M2050121_en 19

5.4 Setting up in the boiler room
5.4.1 Moving the boiler in the boiler room
❒ Position a lifting device with a suitable load-bearing capacity at the base frame.
❒Lift and transport to the intended position in the installation room.
➥Observe the minimum distances in the boiler room.
5.4.2 Operating and maintenance areas of the equipment
▪ The system should generally be set up so that it is accessible from all sides
allowing quick and easy maintenance.
▪Regional regulations regarding necessary maintenance areas for inspecting the
chimney should be observed in addition to the specified distances!
▪ Observe the applicable standards and regulations when setting up the system.
▪ Observe additional standards for noise protection!
(ÖNORM H 5190 - Noise protection measures)
Lambdamat without ash box/ash screw
D
B
AC E
Item LM 750 LM 1500
A2800 mm 3700 mm
B900 mm
C500 mm
D1500 mm
E3800 mm 4900 mm
5Installation
Setting up in the boiler room
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