Fröling T4e User manual

Operating Instructions
Wood chip boiler T4e
Translation of the original German operating instructions for the operator
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B1560520_en | Edition 11/08/2020
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of contents
1 General 5
1.1 Product overview T4e 6
2 Safety 8
2.1 Hazard levels of warnings 8
2.2 Pictograms used 9
2.3 General 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 13
Wood chips 13
Wood pellets 13
Changing the fuel 13
2.4.3 Non-permitted fuels 14
2.5 Qualification of operating staff 14
2.6 Protective equipment for operating staff 14
2.7 Safety devices 15
2.8 Residual risks 16
2.9 Emergency procedure 18
2.9.1 Overheating of the system 18
2.9.2 Smell of flue gas 18
2.9.3 Fire in the system 18
3 Notes for operating a heating system 19
3.1 Installation and approval of the heating system 19
3.2 General information for installation room (boiler room) 19
3.3 Requirements for central heating water 20
3.4 Notes for using pressure maintenance systems 22
3.5 Return temperature control 22
3.6 Use with storage tank 23
3.7 Chimney connection/chimney system 23
4 Operating the System 24
4.1 Assembly and initial startup 24
4.2 Filling/refilling the store with fuel 25
4.2.1 Loading of fuel for a partially emptied store with rotary agitator 25
4.2.2 Loading wood chips in an empty store (not under pressure) 25
4.2.3 Blowing in pellets for a store with pellet screw 26
4.2.4 Blowing in fuel for a partially emptied store with rotary agitator 26
4.2.5 Blowing in fuel for an empty store with rotary agitator 26
4.2.6 Drainage of fuel store 27
4.3 Switching on the power supply 29
4.4 Operate the boiler using the touch display 29
4.4.1 Overview of the touch display 29
Table of contents
2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Status display 30
Control icons 30
Display icons for froeling-connect/remote control 31
Navigation within the system menu 32
Changing parameters 33
Change time window 33
Quick menu 34
4.4.2 Select information displays 35
4.4.3 Switch boiler ON/OFF 37
4.4.4 Change boiler mode 38
4.4.5 Change date and time 39
4.4.6 Change desired DHW tank temperature 39
4.4.7 One-time extra loading of an individual DHW tank 40
4.4.8 One-time extra loading of all existing DHW tanks. 40
4.4.9 Set the heating curve of a heating circuit 41
4.4.10 Change room temperature (heating circuit without room temperature sensor) 42
4.4.11 Change room temperature (heating circuit mit room temperature sensor) 42
4.4.12 Switch heating circuit mode 43
4.4.13 Lock display/switch user level 44
4.4.14 Change the name of the components 44
4.4.15 Configure the holiday program 45
4.5 Switch the boiler ON/OFF on the room console 46
4.6 Switching off the power supply 47
4.7 Checking the fill level of the ash container and emptying if required 48
5 Servicing the system 51
5.1 General information on servicing 51
5.2 Required tools 52
5.3 Maintenance work by the operator 53
5.3.1 Weekly inspection 53
Checking the system pressure 53
Check the thermal discharge valve (from T4e 130) 53
Checking the safety valve 53
Checking the quick vent valve 54
Checking the geared motors 54
5.3.2 Recurrent check and cleaning 55
Before starting inspection and cleaning work 55
After inspection and cleaning work 55
Lubricate the stoker bearings [~1000 B/every six months] 56
Check chain and sprockets [~1,000 operating hours / every six month] 56
Clean the combustion chamber [~2500 Bh /yearly] 56
Clean heat exchanger and flue gas collection chamber [~2500 Bh/yearly] 58
Clean the flue gas temperature sensor [~2500 Bh/yearly] 59
Clean the flue gas pipe [~2500 Bh /yearly] 59
Check the draught regulation damper [~2500 Bh/yearly] 59
5.4 Maintenance work by technicians 60
5.4.1 Checking and cleaning the combustion grate 61
5.4.2 Cleaning the measurement line of the underpressure controller 61
5.4.3 Cleaning the Lambda probe 62
5.4.4 Clean the particle filter (optional) and heat exchanger pipes 64
Remove and clean the particle filter (optional) 64
Cleaning the heat exchanger pipes 65
5.4.5 Adjust the power of the WOS system 67
T4e 20-60 67
T4e 80-180 68
Table of contents
Operating Instructions T4e | B1560520_en 3

T4e 200-350 69
5.5 Emissions measurement by chimney sweep or regulatory body 70
5.5.1 Switch on the system 70
5.5.2 Start emissions measurement 71
5.6 Replacement parts 71
5.7 Disposal information 71
5.7.1 Disposal of the ash 71
5.7.2 Disposal of system components 71
6 Troubleshooting 72
6.1 General fault with power supply 72
6.1.1 Behaviour of system after a power failure 72
6.2 Excessive temperature 72
6.3 Faults with fault message 73
6.3.1 Procedure for fault messages 73
7 Notes 75
8 Appendix 76
8.1 Addresses 76
8.1.1 Address of manufacturer 76
Customer service 76
8.1.2 Address of the installer 76
Table of contents
4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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.
Warranty and Guarantee Conditions
Our sale and delivery conditions will be applicable. 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.
General 1
Operating Instructions T4e | B1560520_en 5

1.1 Product overview T4e
5.1
5.2
5.3
5.4
1Wood chip boiler – Fröling T4e
2Main switch: switches the power supply on and off for the entire system
3High-limit thermostat STL
4Mains connection
5Lambdatronic H 3200 boiler controller, ⇨ See "Overview of the touch display" [page
29]
5.1 Status display (operating status), ⇨ See "Status display" [page 30]
5.2 Large touch screen for displaying and changing operating statuses and parameters
5.3 Brightness sensor to automatically adjust the display brightness
5.4 USB port for connecting a USB stick for software updates
6Insulating cover
7Heat exchanger cover
8Service port
1General
Product overview T4e
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

9Lambda probe for fuel adjustment
10 Integrated return temperature control with pump, mixing valve and ball valve
11 Speed regulated EC induced draught fan
12 WOS system with turbulators and automatic drive for heat exchanger cleaning of the
second and third draught
13 Twin-chamber rotary valve (Ø 200 mm) as burn back protection system (RSE)
14 Integrated electrostatic particle separator (optional)
15 Stoker screw (Ø 100 mm)
16 Ceramic igniter with function monitoring
17 Silicon carbide combustion chamber with automatic tipping grate
18 Tipping grate with drive (rotation angle 110°)
19 Ash box for combined automatic ash removal from combustion chamber and heat
exchanger
20 Combustion chamber door with inspection glass
General 1
Product overview T4e
Operating Instructions T4e | B1560520_en 7

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.
2Safety
Hazard levels of warnings
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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 the Machinery Directive, signs fitted directly within the danger area
of the boiler indicate immediate hazards or safety procedures. These stickers must not
be removed or covered.
Refer to the operating
instructions
Wear safety shoes
Wear protective gloves Turn off the main switch
Keep the doors closed
Unauthorised access prohibited
Warning - hot surface Warning - hazardous electrical
voltage
Warning - hazardous or irritant
materials
Warning - automatic boiler
startup
Warning of injury to fingers or
hands, automatic fan
Warning of injury to fingers or
hands, automatic screw
Warning of injury to fingers or
hands, gear/chain drive
Warning of injury to fingers or
hands, cutting edge
Safety 2
Pictograms used
Operating Instructions T4e | B1560520_en 9

2.3 General safety information
DANGER
If the device is used incorrectly:
Incorrect use of the system can cause severe injury and damage.
When operating the system:
❒ Observe the instructions and information in the manuals
❒ Observe the details on procedures for operation, maintenance and cleaning,
as well as troubleshooting in the respective manuals.
❒ Any work above and beyond this (e.g. servicing) must be carried out by a
heating engineer approved by Fröling Heizkessel- und Behälterbau GesmbH
or by Froling customer services
WARNING
External influences:
Negative external influences, such as insufficient combustion air or non-standard
fuel, can cause serious faults in combustion (e.g. spontaneous combustion of
carbonisation gases or flash fires) which can in turn cause serious accidents!
When operating the boiler, please note the following:
❒ Instructions and information regarding 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 gas 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).
Take the following precautions:
❒ Optimum boiler performance can only be guaranteed if the flue gas system is
functioning correctly.
2Safety
General safety information
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.4 Permitted uses
The Froling Wood chip boiler T4e is designed solely for heating domestic water. Only
the fuels specified in the "Permitted fuels" section may be used.
⇨ See "Permitted fuels" [page 13]
The unit should only be operated when it is in full working order. It must 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 the
operating instructions must be observed. Ensure that any faults which might impair
safety are rectified immediately.
The manufacturer or supplier is not liable for any damage resulting from non-permitted
uses.
Only original spare parts or specific alternative spare parts authorised by the
manufacturer may be used. Any kind of change or modification made to the product
will invalidate the manufacturer’s conformity with the applicable guideline(s). In such
cases, the product will need to undergo new hazard evaluation procedures by the
operator. The operator will then be fully responsible for the declaration of conformity
according to the valid guideline(s) for the product and will need to issue a
corresponding declaration for the device. This person will then assume all of the rights
and responsibilities of a manufacturer.
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 furnance 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 T4e 20kW, 25kW, 30kW, 35kW, 45kW, 50kW, 60kW have been
recommended for use in smoke control areas when burning wood chip only.
The Froling T4e 80kW, 90kW, 100kW, 110kW, 200kW and 250kW have been
recommended for use in smoke control areas when burning wood chip and wood
pellets only.
Safety 2
Permitted uses
Operating Instructions T4e | B1560520_en 11

The Froling T4e 120kW has been recommended for use in smoke control areas when
burning wood pellets only.
2Safety
Permitted uses
12 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.4.2 Permitted fuels
Wood chips
Criterion Designation as per Description as per
ÖNORM M 7133
ÖNORM M 7133 EN ISO 17225
Water content W20 M20 air-dried
W30 M30 suitable for storage
W35 M35 limited suitability for
storage
Size G30 P16S Fine wood chip
G50 P31S Medium-sized wood
chip
EU: Fuel as per EN 17225 – Part 4: Wood chips class A2 / P16S-P31S M35
Additional for
Germany:
Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance
(BimSchV) in the last amended version)
Wood pellets
Wood pellets made from natural wood with a diameter of 6 mm
EU: Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06
and/or: EN
plus / DIN plus certification scheme
General note:
Before refilling the store, check for pellet dust and clean if necessary.
Changing the fuel
CAUTION
Incorrect fuel parameter settings:
Incorrect parameter settings have a significant adverse effect on the functioning
of the boiler, and as a result this will invalidate the guarantee.
Therefore:
❒ If the fuel is changed (e.g. from wood chips to pellets), the system must be
reset by Froling customer services.
Note on standards
Note on standards
Safety 2
Permitted uses
Operating Instructions T4e | B1560520_en 13

2.4.3 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section, 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 damage the
boiler and also invalidates the guarantee. Using non-standard fuels can also lead
to serious problems with combustion.
For this reason, when operating the boiler:
❒ Only use permitted fuels
2.5 Qualification of operating staff
CAUTION
If unauthorised persons enter the Installation room / boiler room:
Risk of personal injury and damage to property
❒ The operator is responsible for keeping unauthorised persons, in particular
children, away from the system.
Only trained operators are permitted to operate the unit. The operator must also have
read and understood the instructions in the documentation.
2.6 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations!
▪ For operation, inspection and cleaning:
- suitable work wear
- protective gloves
- sturdy shoes
- dust mask
2Safety
Permitted uses
14 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.7 Safety devices
TA
1 BOILER OFF
(switches off the boiler to prevent overheating)
❒ Tap “Boiler off”
➥Automatic mode is switched off
➥Control system follows the boiler shutdown procedure
➥Pumps continue to run
2 MAIN SWITCH
(switches off the power supply)
Before carrying out work on/in the boiler:
❒ Tap “Boiler off”
➥Automatic mode is switched off
➥Control system follows the boiler shutdown procedure
❒ Switch off the main switch and let the boiler cool down
3 SAFETY TEMPERATURE LIMITER (STL)
(protection against overheating)
The STL (high-limit thermostat) switches off the combustion system when the boiler
reaches 100°C. The pumps continue to run. Once the temperature falls below approx.
75°C, the STL can be reset mechanically.
On site:
SV SAFETY VALVE
(protection against overheating/excess pressure)
When the boiler pressure reaches a maximum of 3 bar, the safety valve opens and the
heated water is blown off in the form of steam.
For T4e 130-350:
TV THERMAL DISCHARGE VALVE
(protection against overheating)
The thermal discharge valve opens at approx. 100°C and feeds cold water to the
safety heat exchanger to lower the boiler temperature
Safety 2
Safety devices
Operating Instructions T4e | B1560520_en 15

2.8 Residual risks
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
WARNING
When inspecting and cleaning the boiler with the main switch on:
Serious injuries possible due to automatic boiler startup!
Before inspection and cleaning work in/on the boiler:
❒ Switch the boiler off by tapping “Boiler off”
The boiler follows the shutdown procedure and switches to "Boiler off“ mode
❒ Allow the boiler to cool for at least 1 hour
❒ Switch off the main switch and take precautions to prevent accidental
switching on
WARNING
If non-permitted fuel types are used:
Non-standard fuels can cause serious faults in combustion (e.g. spontaneous
combustion of carbonisation gases / flash fires) which can lead to serious
accidents!
Take the following precautions:
❒ Only use fuels specified in the "Permitted fuels" section of these operating
instructions.
2Safety
Residual risks
16 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

DANGER
If maintenance work is performed when the system is in operation:
Risk to life from high voltage electrodes!
Before carrying out work on/in the electrostatic precipitator:
❒ Switch off the power supply and take precautions to prevent accidental
switching on
❒ Earth and short circuit HV electrodes
❒ 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
DANGER
Persons using pacemakers whilst in the immediate vicinity of the electrostatic
particle separator:
Interference of the pacemaker by electromagnetic fields of the particle separator
is possible!
Therefore:
❒ Maintain a safety distance of at least one metre from the electrostatic particle
separator
❒ Perform work only when the electrostatic particle separator is switched off
Safety 2
Residual risks
Operating Instructions T4e | B1560520_en 17

2.9 Emergency procedure
2.9.1 Overheating of the system
If the system overheats and the safety devices fail to operate, proceed as follows:
NOTICE! Do not under any circumstances switch off the main switch or disconnect the
power supply!
❒Keep all the doors on the boiler closed
❒ Switch boiler off by tapping “Boiler OFF”
❒ Open all mixing valve taps, switch on all pumps.
➥The Froling heating circuit control takes on this function in automatic operation.
❒ Leave the boiler room and close the door
❒ Open any thermostatic valves on the radiator and ensure sufficient heat
dissipation from the rooms
If the temperature does not drop:
❒ Contact the installer or Froling customer services
⇨ See "Addresses" [page 76]
2.9.2 Smell of flue gas
DANGER
If you smell flue gas in the boiler room:
Inhaling toxic flue gas can be fatal!
If you smell flue gas in the room where the boiler is installed:
❒ Keep all the doors on the boiler closed
❒ Shut down the boiler according to procedure
❒ Ventilate the room where the boiler is installed
❒ Close the fire door and doors to living areas
Recommendation: Do not install smoke alarms and carbon monoxide detectors near
the system.
2.9.3 Fire in the system
DANGER
In case of fire in the system:
Risk of death by fire and poisonous gases
Emergency procedure in case of fire:
❒ Leave the boiler room
❒ Close the doors
❒ Inform the fire department
2Safety
Emergency procedure
18 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

3 Notes for operating a heating system
Carrying out modifications to the system and changing or disabling safety equipment
is prohibited.
Always comply with all fire, building and electrical regulations when installing or
operating the system, in addition to following the operating instructions and mandatory
regulations that apply in the country in which the tank is operated.
3.1 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.
3.2 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.
Note on standards
Notes for operating a heating system 3
Installation and approval of the heating system
Operating Instructions T4e | B1560520_en 19

▪ 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.
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
3.3 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
3Notes for operating a heating system
General information for installation room (boiler room)
20 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com