Fröling TI 350 User manual

Operating Instructions
Wood chip boiler TI 350
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!
B1380220_en | Edition 16/03/2020
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of contents
1 General 5
1.1 Product overview 6
2 Safety 10
2.1 Hazard levels of warnings 10
2.2 Pictograms used 11
2.3 General safety information 12
2.4 Permitted uses 13
2.4.1 The Clean Air Act 1993 and Smoke Control Areas 13
2.4.2 Permitted fuels 14
Wood chips 14
Wood pellets 14
Wood shavings 14
Miscanthus 15
Changing the fuel 15
2.4.3 Non-permitted fuels 15
2.4.4 Qualification of operating staff 16
2.4.5 Protective equipment for operating staff 16
2.5 Safety devices 17
2.5.1 External safety devices 18
Hydraulic chamber safety switch 18
Guardrail 18
2.6 Residual risks 19
2.7 Emergency procedure 21
2.7.1 Overheating of the system 21
2.7.2 Smell of flue gas 21
2.7.3 Fire in the system 21
3 Notes for operating a heating system 22
3.1 Installation and approval of the heating system 22
3.2 General information for installation room (boiler room) 22
3.3 Requirements for central heating water 23
3.4 Notes for using pressure maintenance systems 25
3.5 Return lift 25
3.6 Use with storage tank 26
3.7 Chimney connection/chimney system 26
4 Operating the system 27
4.1 Assembly and initial startup 27
4.2 Filling/refilling the store with fuel 28
4.2.1 Loading of fuel for a partially emptied store with rotary agitator 28
4.2.2 Loading wood chips in an empty store (not under pressure) 28
4.2.3 Blowing in pellets for a store with pellet screw 29
4.2.4 Blowing in fuel for a partially emptied store with rotary agitator 29
4.2.5 Blowing in fuel for an empty store with rotary agitator 30
4.2.6 Drainage of fuel store 31
Table of contents
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4.3 Switching on the power supply 32
4.4 Operate the boiler using the touch display 32
4.4.1 Overview of the touch display 32
Status display 33
Control icons 33
Display icons for froeling-connect/remote control 34
Navigation within the system menu 35
Changing parameters 36
Change time window 36
Quick menu 37
4.4.2 Select information displays 38
4.4.3 Change boiler mode 41
4.4.4 Change date and time 42
4.4.5 Change desired DHW tank temperature 42
4.4.6 One-time extra loading of an individual DHW tank 43
4.4.7 One-time extra loading of all existing DHW tanks. 43
4.4.8 Set the heating curve of a heating circuit 44
4.4.9 Change room temperature (heating circuit without room temperature sensor) 45
4.4.10 Change room temperature (heating circuit mit room temperature sensor) 45
4.4.11 Switch heating circuit mode 46
4.4.12 Lock display/switch user level 47
4.4.13 Change the name of the components 47
4.4.14 Configure the holiday program 48
4.5 Switch the boiler ON/OFF on the room console 49
4.6 Switching off the power supply 50
4.7 Checking the fill level of the ash container and emptying if required 51
4.7.1 Emptying the combustion chamber ash container 51
4.7.2 Emptying the heat exchanger ash container 52
5 Servicing the system 54
5.1 General information on servicing 54
5.2 Required tools 56
5.3 Maintenance work by the operator 57
5.3.1 Inspection 57
Checking the system pressure 57
Checking the thermal discharge safety device 57
Checking the safety valve 57
Checking the geared motors 57
Checking the quick vent valve 58
Checking the draught controller flap 58
General weekly inspection 58
5.3.2 Periodic inspection and cleaning 59
5.3.3 Periodic inspection and cleaning (approx. 1,000 hrs) 60
Cleaning the ash from the heat exchanger 61
Cleaning the heat exchanger 61
Clean the flue gas temperature sensor 62
Cleaning the flue gas recirculation (AGR) 63
Cleaning the area under the moving grate 64
Lubricate the stoker bearings 65
5.3.4 Periodic inspection and cleaning (approx. 3,000 hrs) 66
Cleaning the fireclay elements 66
Setting and checking the seal on the door 67
Adjusting the door 68
Cleaning the induced draught fan 69
Checking the heat exchanger ash removal drive 70
Table of contents
Operating Instructions TI 350 | B1380220_en 3

Checking the underpressure controller 70
Lubricating the bearings 70
Checking the flue gas pipe 70
Check the igniter tube 71
5.4 Maintenance work by technicians 72
5.4.1 Cleaning the Lambda probe 73
5.5 Maintenance instructions for hydraulic system 74
5.6 Emissions measurement by chimney sweep or regulatory body 75
5.6.1 Switch on the system 75
5.6.2 Start emissions measurement 75
5.7 Replacement parts 76
5.8 Disposal information 76
5.8.1 Disposal of the ash 76
5.8.2 Disposal of system components 76
6 Troubleshooting 77
6.1 General faults in the power supply 77
6.1.1 Behaviour of system after a power failure 77
6.2 Excessive temperature 77
6.3 Faults with fault message 78
6.3.1 Procedure for fault messages 78
7 Appendix 80
7.1 Addresses 80
7.1.1 Address of manufacturer 80
Customer service 80
7.1.2 Address of the installer 80
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.
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 TI 350 | B1380220_en 5

1.1 Product overview
1Wood chip boiler - Froling TI
2Control cabinet with integrated Lambdatronic H 3200 controller
3Main switch: switches the power supply on and off for the entire system
4Control panel of the Lambdatronic H 3200 - Touch controller
4.1 Status LED (operating status)
- GREEN constant: BOILER SWITCHED ON
- GREEN flashing (interval: 5 sec OFF, 1 sec ON): BOILER SWITCHED OFF
- ORANGE flashing: WARNING
- RED flashing: FAULT
4.2 Large touch screen for displaying and changing operating statuses and parameters
4.3 Brightness sensor for automatically adjusting the display brightness
4.4 USB port for connecting a USB stick for software updates
5Ash container for automatic combustion chamber ash removal
6Ash container for automatic heat exchanger ash removal
7Combustion chamber door
1General
Product overview
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8Heat exchanger covers
Below: Efficiency Optimisation System (EOS) with turbulators
9Fuel transport unit with rotary valve as burn back protection (BBF) and stoker screw
for fuel transport
10 Moving grate with automatic drive
11 Efficiency Optimisation System (EOS) with turbulators
12 Combustion chamber door
13 Combustion chamber, complete
14 Heat exchanger, complete
15 Burn through elbow with safety battery
General 1
Product overview
Operating Instructions TI 350 | B1380220_en 7

16 Automatic drive for Efficiency Optimisation System (WOS)
17 Boiler flow connection
18 Boiler return connection
19 Induced draught fan
20 Flue gas recirculation (FGR)
21 Secondary air control with servo-motor drive
22 Combustion chamber temperature sensor (behind cover)
23 Under-pressure controller
24 High-limit thermostat STL (heat exchanger)
25 High-limit thermostat STL (behind cover)
26 Thermal discharge valve connection (heat exchanger)
27 Thermal discharge valve connection (burn through elbow)
28 Automatic drive for heat exchanger ash removal
29 Automatic drive for combustion chamber ash removal
30 Automatic drive for moving grate
31 Secondary air servo-motor flue gas recirculation (FGR)
32 Primary air servo-motor flue gas recirculation (FGR)
33 Automatic ignition
1General
Product overview
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

34 Primary air control with servo-motor drive (behind cover)
35 Undergrate thermostat
General 1
Product overview
Operating Instructions TI 350 | B1380220_en 9

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
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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
Always wear protective gloves Wear hearing protection
Keep the doors closed Turn off the main switch
Unauthorised access prohibited No not walk on the surface
Warning - hot surface Warning - hazardous electrical
voltage
Warning - hazardous or irritant
materials
Warning - automatic boiler
startup
Hand injury warning Warning of injury to fingers or
hands, automatic fan
Cutting injury warning Warning of injury to fingers or
hands, automatic screw
Safety 2
Pictograms used
Operating Instructions TI 350 | B1380220_en 11

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 individual manuals.
❒ Any work above and beyond this should be carried out by authorised heating
engineers 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
12 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.4 Permitted uses
The Froling TI is designed exclusively for heating domestic water. Only use fuels
specified in the "Permitted fuels" section.
⇨ See "Permitted fuels" [page 14]
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
In England appliances are exempted by publication on a list by the Secretary of State
in accordance with changes made to sections 20 and 21 of the Clean Air Act 1993 by
section 15 of the Deregulation Act 2015. In Scotland appliances are exempted by
publication on a list by Scottish Ministers under section 50 of the Regulatory Reform
(Scotland) Act 2014. Similarly, In Northern Ireland appliances are exempted by
publication on a list by the Department of Agriculture, Environment and Rural Affairs
under Section 16 of the Environmental Better regulation Act (Northern Ireland) 2016.
In Wales appliances are exempted by regulations made by Welsh Ministers.
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 TI 350 Wood Chip and Wood Pellet 350 kW boilerhas been recommended
as suitable for use in smoke control areas when burning Wood Chips and Wood
Pellets.
Safety 2
Permitted uses
Operating Instructions TI 350 | B1380220_en 13

2.4.2 Permitted fuels
Wood chips
Criterion Designation as per Description acc. to
ÖNORM M 7133
ÖNORM M 7133 EN ISO 17225
Water content W20 M20 air-dried
W30 M30 suitable for storage
Size G30 P16S Fine wood chip
G50 P31S Medium-sized wood
chip
EU: Fuel acc. to EN ISO 17225 - Part 4: Wood chips class A1 / P16S-P31S
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.
TIP: Fit the Froling PST pellet deduster for separating the dust particles contained in
the return air
Wood shavings
Wood shavings generally cause problems with combustion. Therefore their use is
permitted only with authorisation from Froling. The following additional points also
apply:
▪ Sawdust and carpentry waste should only be used with systems with a rotary
valve.
▪ The store should be fitted with a pressure release device in accordance with
regional regulations.
▪ The same limits apply for the permitted water content of sawdust as for wood
chips.
Note on standards
Note on standards
2Safety
Permitted uses
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Miscanthus
Switchgrass or elephant grass (Latin name: miscanthus) is a C4 plant. Standards and
regulations for burning these plants have not been standardised, so the following
applies:
NOTICE! The regional regulations for burning miscanthus should be observed.
Operation may only be possible by special permit.
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.
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
Safety 2
Permitted uses
Operating Instructions TI 350 | B1380220_en 15

2.4.4 Qualification of operating staff
CAUTION
If unauthorised persons enter the 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.
2.4.5 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For inspection and cleaning:
- suitable workwear
- protective gloves
- sturdy shoes
▪ Additional for operating:
- Hearing protection (sound level > 70 dB)
- Protective goggles
2Safety
Permitted uses
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2.5 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
➥The pumps continue to run
NOTICE! Never use the main switch!
2 MAIN SWITCH (switches off the power supply)
Before carrying out work on 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 OVERLOAD SWITCHES, MOTOR PROTECTION SWITCHES, RESIDUAL
CURRENT PROTECTIVE DEVICES (RCD)
Switch off the related component in the event of fault currents or overloads.
4 SAFETY TEMPERATURE LIMITER (STL) (protection against overheating)
The STL switches off the combustion system when the boiler reaches 95 - 100°C. The
pumps continue to run. Once the temperature falls below approx. 75°C, the STL can
be reset mechanically.
5 DOOR CONTACT SWITCH
When the door is opened, the induced draught is kept at a constant speed.
Safety 2
Safety devices
Operating Instructions TI 350 | B1380220_en 17

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 VALVE (not shown, supplied by the customer)
When the boiler pressure reaches a maximum of 6 bar, the safety valve opens and the
heating water is released in the form of steam.
2.5.1 External safety devices
Hydraulic chamber safety switch
Before starting any maintenance work in the hydraulic chamber of the sliding floor:
❒ Turn the safety switch to the "0" position
➥The boiler follows the shutdown procedure and the discharge is deactivated
❒ Turning the selector switch past the "0" position engages the locking lever
➥The switch can be locked with a padlock to prevent it from being switched on
again
On completion of the maintenance work:
❒ Remove the padlock
❒ Turn the selector switch past the "0" position to automatically release the locking
switch. The selector switch can now be turned back to the "1" position.
❒ Acknowledge the fault and press the Start button to activate the boiler
Guardrail
When working at a height, appropriate measures must be taken in accordance with
the applicable national industrial safety guidelines to protect against the risk of falling
(e.g. ladders, platforms, etc.). It is the responsibility of the operator to select and
provide these means.
Alternatively, a railing can be fitted to the top of the boiler as per EN ISO 14122.
2Safety
Safety devices
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2.6 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
Opening the door to the combustion or burning chamber, or the cleaning door or
lids during operation
may result in injury or damage or flue gas generation!
Therefore:
❒ Do not open any doors or lids while the boiler is in operation!
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.
Safety 2
Residual risks
Operating Instructions TI 350 | B1380220_en 19

WARNING
Inspection and cleaning work on a system which is operational:
Risk of serious injuries from automatic startup of the system and severe burns
from hot parts and the flue gas pipe!
When working on the system:
❒ always wear protective gloves
❒ only operate the boiler using the handles provided
❒ switch off the boiler by tapping “Boiler off” at the mode icon
➥The boiler follows the shutdown procedure and switches to “Boiler
off“ status
❒ switch off the main switch and take precautions to prevent accidental
switching on
❒ allow the boiler to cool off for at least 1 hour
❒ once all of the tasks have been completed, turn the main switch back on and
switch the boiler on in the desired mode
2Safety
Residual risks
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