Fröling Lambdatronic SP 3200 User manual

Service manual
Lambdatronic SP 3200 for dual fuel boiler
Core module version 50.04 - Build 05.14
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B1450217_en | Edition 22/05/2017
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 Electrical connection and wiring 5
2.1 Core modules and connection options 5
2.1.1 Board view - core module 5
Connection instructions 6
2.1.2 Mains connection 8
2.1.3 Connecting the flue gas sensor 8
2.1.4 Heating circuit pump 0 / burner relay 9
2.1.5 Connecting the remote control 10
2.1.6 Connecting a high efficiency pump to the
core module
11
2.1.7 Universal suction system port - RS4 /
RS8
12
2.2 Expansion modules 13
2.2.1 Heating circuit module 13
2.2.2 Hydraulic module 14
Connecting an isolating valve 15
Connecting a high efficiency pump to the hydraulic
module
16
2.2.3 Return mixer module 17
2.2.4 Pellet module 18
Error message switch (on the pellet module) 19
2.2.5 Pellet module expansion 20
Connection instructions for pellet mole 21
2.2.6 Connecting the bus cable 22
2.2.7 Connect the patch cable to the bus plug 22
2.2.8 Setting end jumpers 22
2.2.9 Setting the module address 23
2.3 Connection diagrams according to
pump types
24
3 Overview of the basic functions 25
3.1 Control keys and display 25
3.1.1 Navigation keys 25
3.1.2 Status LED 25
3.1.3 Graphic display 26
3.2 Function keys 27
3.2.1 Standby key 27
3.2.2 Service program key 27
3.2.3 Info key 28
3.2.4 DHW tank program key 28
3.2.5 Party program key 29
3.2.6 Setback program key 29
4 Operation 30
4.1 Before switching on for the first time 30
4.1.1 Controller check 30
4.1.2 Check on the connected units 30
4.1.3 System Check 30
4.2 Initial startup 31
4.2.1 Changing the operating level 31
4.2.2 Setting the system type 32
4.2.3 Before heating up for the first time 39
4.2.4 Starting the system on initial startup 39
4.3 Boiler modes 40
4.3.1 "Automatic” mode without storage tank 40
4.3.2 “Automatic” mode with storage tank 41
4.3.3 “Continuous load” mode without storage
tank
42
4.3.4 “Continuous load” mode with storage
tank
42
4.3.5 “Domestic hot water” mode without
storage tank
42
4.3.6 “Domestic hot water” mode with storage
tank
44
4.4 Operating statuses 45
4.5 Setting parameters 46
4.6 Setting times 47
4.6.1 Deleting a time window 47
5 Parameters overview 48
5.1 Heating 48
5.1.1 Heating - Status 48
5.1.2 Heating - Temperatures 49
5.1.3 Heating - Times 50
5.1.4 Heating - Service 50
5.1.5 Heating - Heating up program 51
Heating up programs 52
Configure program 8 52
Heating circuits used 53
5.1.6 Heating - General settings 53
5.2 Water 54
5.2.1 Water - Status 54
5.2.2 Water - Temperatures 54
5.2.3 Water - Times 55
5.2.4 Water - Service 55
5.3 Solar 57
5.3.1 Solar - Status 57
5.3.2 Solar - Temperatures 58
5.3.3 Solar - Service 59
Table of Contents
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5.3.4 Solar - Heat meter 61
5.4 Buffer tank 62
5.4.1 Buffer tank - Status 62
5.4.2 Buffer tank - Temperatures 62
5.4.3 Buffer tank - Times 64
5.4.4 Buffer tank - Service 64
5.5 Boiler 66
5.5.1 Boiler - Status 66
5.5.2 Boiler - Temperatures 67
5.5.3 Boiler - Times 68
5.5.4 Boiler - Service 68
5.5.5 Boiler - General settings 69
General settings - MODBUS settings 70
5.6 Boiler 2 71
5.6.1 Boiler 2 - Status 71
5.6.2 Boiler 2 - Temperatures 72
5.6.3 Boiler 2 - Service 73
5.7 Fuel 74
5.8 Feed system 75
5.8.1 Feed system - Suction system 1 75
5.8.2 Feed system - Suction system 2 76
5.8.3 Feed system - Suction system 3 77
5.8.4 Feed system - Times 78
5.8.5 Feed system - Service 78
5.8.6 Feed system - Consumption 79
5.8.7 Feed system - General settings 79
5.9 Network pump 80
5.9.1 Network pump - Status 80
5.9.2 Network pump - Temperatures 81
5.9.3 Network pump - Service 82
5.10 Cascade 84
5.10.1 Cascade - Status 84
5.10.2 Cascade - Backup boiler 84
5.10.3 Cascade - Temperatures 85
5.10.4 Cascade - Service 86
5.11 Difference regulator 87
5.11.1 Difference regulator - Status 87
5.11.2 Difference regulator - Temperatures 87
5.11.3 Difference regulator - Times 88
5.11.4 Difference regulator - Service 88
5.12 Circulation pump 89
5.12.1 Circulation pump - Status 89
5.12.2 Circulation pump - Temperatures 89
5.12.3 Circulation pump - Times 90
5.12.4 Circulation pump - Service 90
5.13 Manual 91
5.13.1 Manual - Manual operation 91
5.13.2 Manual - Digital outputs 91
5.13.3 Manual - Analogue outputs 92
5.13.4 Manual - Digital inputs 92
5.14 System 93
5.14.1 System - Settings 93
Setting - Boiler temperature 93
Setting - Flue gas 94
Setting - Ignition 95
Setting - Air settings 96
Setting - Pellet feed 97
Setting the WOS 98
Setting - Fuel outfeeder 98
Setting - Lambda values 100
Setting - Lambda values - LSM11 Lambda probe 101
Setting - Lambda values - Broadband probe 102
Setting - General settings 103
5.14.2 System - Current values 104
Service hours 105
5.14.3 System - Error 106
Error - Error display 106
Error - Clear pending error 106
Error - Error history 106
Error - Clear error history 107
5.14.4 System - Sensors and pumps 107
5.14.5 System - Display operating rights 108
5.14.6 System - Display allocations 109
5.14.7 System - Basic display parameters 110
5.14.8 System - Boiler mode 111
5.14.9 System - Language 112
5.14.10 System - Current Date 112
5.14.11 System - Current Time 112
5.14.12 System - Current User Level 113
5.14.13 System - System selection 113
6 Troubleshooting 114
6.1 Procedure for fault messages 114
7 FAQ 115
7.1 Calibrate the broadband probe 115
7.2 PWM / 0 - 10V settings 116
8 Menu structure - Lambdatronic SP
3200
117
Table of Contents
Service manual Lambdatronic SP 3200 for dual fuel boiler | B1450217_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:
❒ Only 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 people
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 in a controlled way (operating status "Off") and allow it to cool down
❒ Protective gloves must generally be worn for work on the boiler, and it should only be
operated using the handles provided
❒ Insulate the flue pipes or simply avoid touching them during operation.
The information on safety, standards and guidelines in assembly and operating instructions for the boiler should
also be observed.
1General
About these instructions
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2 Electrical connection and wiring
2.1 Core modules and connection options
2.1.1 Board view - core module
Electrical connection and wiring 2
Core modules and connection options
Service manual Lambdatronic SP 3200 for dual fuel boiler | B1450217_en 5

Connection instructions
Port Cable dimensions / Specifications / Information
Bus (1) Port 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!
Bus (2) Patch cable CAT 5 RJ45 SFTP 1:1 configuration
Bus (3) Patch cable CAT 5 RJ45 SFTP 1:1 configuration, boiler display port
COM 2 (4) Null modem cable 9-pin SUB-D;
❒ Port can be used as a MODBUS interface
⇨ See "Boiler - General settings" [page 0 ]
COM 1 (5) Null modem cable 9-pin SUB-D;
❒ Service interface for installing new boiler software or port for the visualisation
software
Broadband probe (6) Connection cable1) 5 x 0.75 mm2
❒ Connection of a BOSCH or NTK broadband Lambda probe
Secondary air (7) Connection cable1) 5 x 0.75 mm²
❒ When using the SP Dual compact dual fuel boiler, the air flap must be connected
a the “Secondary air” connection port
Primary air (8) Connection cable1) 5 x 0.75 mm²
❒ When using the SP Dual compact dual fuel boiler, the combi drive must be
connected at the “Primary air” connection port
Latch (9) Connection cable1) 2 x 0.75 mm2
High-limit thermostat - STL (10)
EMERGENCY STOP (11) Connection cable1) 2 x 0.75mm2
❒ Warning! Do not connect the emergency off/emergency stop switch to the power
supply cable of the boiler. The switch must be a N/C switch and it must be linked
to the 24V safety chain of the STL at this terminal.
Flowmeter FLM (12) Connection cable1) 2 x 0.75mm2
Lambda probe (13) Connection cable1) 4 x 0.75 mm²
❒ LSM11 Lambda probe connection
Boiler release (14) Connection cable1) 2 x 0.75mm2
❒ Warning! The connection must be a floating connection.
Flue gas temperature sensor (15) Connection cable1) 3 x 0.75mm2
Door switch DCS (16) Connection cable1) 2 x 0.75mm2
Sensor 2 (17) Connection cable1) 2 x 0.75mm2
❒ Connect temperature sensor of pellet unit
Sensor 1 (18) Connection cable1) 2 x 0.75mm2
❒ Connect function feedback of automatic WOS (if installed)
Outside temperature sensor (19) Connection cable1) 2 x 0.75mm2, shielded from 25m cable length
Room temperature sensor 2/1
(20/21)
Flow temperature sensor 2/1
(22/23)
Return sensor RTS (24) Connection cable1) 2 x 0.75mm2
Boiler sensor BS (25)
2Electrical connection and wiring
Core modules and connection options
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Port Cable dimensions / Specifications / Information
PWM / 0-10V Pump 1 (26)
Induced draught (27) Connection cable1) 3 x 1.5mm2, power supply
Connection cable1) 3 x 0.75mm2, analysis of current speed
Pump 1 on core module (28) Connection cable 1) 3 x 1.5 mm2, max. 1.5A / 280W / 230V
Mains (29) Connection cable1) 3 x 1.5mm2
Mixing valve 2/1 (30/31) Connection cable1) 4 x 0.75mm2, max. 0.15A / 230V
Heating circuit pump 2/1 (32/33) Connection cable 1) 3 x 1.5 mm2, max. 2.5A / 500W
Heating circuit pump HCP 0 /
burner relay (34)
Connection cable 1) 3 x 1.5 mm2, max. 3A / 600VA
(35) Connection cable1) 2 x 0.75mm2
1.YMM as per ÖVE-K41-5 or H05VV-F as per DIN VDE 0881-5
Electrical connection and wiring 2
Core modules and connection options
Service manual Lambdatronic SP 3200 for dual fuel boiler | B1450217_en 7

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.
Boiler type Electric fuses Fuse type
S1 Turbo 16A C16A
S1 Turbo F 16A C16A
S3 Turbo 13A C13A
S4 Turbo 16A C16A
S4 Turbo F 16A C16A
2.1.3 Connecting the flue gas sensor
green-yellow
red +
blue -
Core module
2Electrical connection and wiring
Core modules and connection options
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2.1.4 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
Electrical connection and wiring 2
Core modules and connection options
Service manual Lambdatronic SP 3200 for dual fuel boiler | B1450217_en 9

2.1.5 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:
Switched-off Heating circuit deactivated, only frost protection!
Automatic mode Heating phases according to setback program
Setback mode Ignores the heating phases
Override circuit Ignores the setback
Handwheel… Allows you to adjust the temperature by +/- 3°C
IMPORTANT! See assembly instructions/functional description for room temperature sensor FRA
2Electrical connection and wiring
Core modules and connection options
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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 PWM cable of the high efficiency pump to the corresponding port “PWM / 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]
Electrical connection and wiring 2
Core modules and connection options
Service manual Lambdatronic SP 3200 for dual fuel boiler | B1450217_en 11

2.1.7 Universal suction system port - RS4 / RS8
Rechts-Lauf
Links-Lauf
N
PE
Nullpunkt
L
Position
Mischer 2
Vorlauffühler VF 2 Raumfühler RF 2
Anschluss Umschalteinheit (4-fach / 8-fach)
AUF
ZU
PE
N
KERNMODUL
FRKEM25
L2
N
L1
L2
N
L1
Rechts-Lauf
Links-Lauf
N
PE
N
L1
NL1
Nullpunkt
Position
❒ Lay connection cable (min. 4 x 1 mm²) for motor control from “mixer 2” output on core module to the 4-pin
plug and connect as shown above
❒ Lay connection cable (min. 3 x 1 mm²) for signal/position control from “flow temperature sensor VF2” and
“room temperature sensor RF2” outputs on core module to the 3-pin plug and connect as shown above
2Electrical connection and wiring
Core modules and connection options
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2.2 Expansion modules
2.2.1 Heating circuit module
Two heating circuits can be controlled as standard with the core module.
To extend the heating circuit control, the heating circuit module boards must be expanded. Eight heating circuit
modules (addresses 0 to 7) can be added, and the module address must be set correctly.
⇨ See "Setting the module address" [page 23]
Heizkreismodul
(FRHEM 16)
Bus (1)
Vorlauffühler 1 (2)
Netz (5)
Mischer 2 (7)
Vorlauffühler 2 (2)
Fühler 1 (4)
Raumfühler 1 (3)
Mischer 1 (7)
Heizkreispumpe 1
(6)
Raumfühler 2 (3)
Heizkreispumpe 2
(6)
Bus
(1)
Modul-Adresse
CAN L
CAN H
+UBus
N
L
N
L
N
L
N
AUF ZU
N
AUF ZU
Connection instructions
Port Cable dimensions / Specifications / Information
Bus (1) Port with cable – LIYCY paired 2x2x0.5;
⇨ See "Connecting the bus cable" [page 22]
❒ Warning! CAN L and CAN H must not be connected to +UBUS!
Flow temperature sensor 1/2 (2) Connection cable1) 2 x 0.75mm2
Room temperature sensor 1/2
(3)
Connection cable1) 2 x 0.75mm2, shielded from 25m cable length
Sensor 1 (4) Connection cable1) 2 x 0.75mm2
❒ Connection of the outside temperature sensor if this should not be connected to the
core mode. The address of the heating circuit to which the outside temperature
sensor is connected must be set in the software.
⇨ See "Boiler - General settings" [page 0 ]
Mains (5) Connection cable1) 3 x 1.5mm2, fuse 10A
Heating circuit pump 1/2 (6) Connection cable 1) 3 x 1.5 mm2, max. 2.5A / 230V / 500W
Mixing valve 1/2 (7) Connection cable1) 4 x 0.75mm2, max. 0.15A / 230V
1.YMM as per ÖVE-K41-5 or H05VV-F as per DIN VDE 0881-5
Electrical connection and wiring 2
Expansion modules
Service manual Lambdatronic SP 3200 for dual fuel boiler | B1450217_en 13

2.2.2 Hydraulic module
The hydraulic module makes the connections of sensors and pumps available for the hydraulic components of
the system (storage tank, DHW tank etc.).
A hydraulic module is included in the delivery as standard (address 0). A further seven modules (addresses 1 to
7) can be retrofitted.
You must ensure that the module address is given correctly.
⇨ See "Setting the module address" [page 23]
AO-
P1
AO-
P2
6,3AT
Hydraulikmodul
(FRHYU 21)
Bus (2)
Fühler 1 (3)
Fühler 5 (7)
Netz (9)
Pumpe 2 (11)
Fühler 2 (4)
Fühler 4 (6) Fühler 3 (5)
Pumpe 1 (10)
Fühler 6 (8)
Bus
(2)
2x Bus
(1)
Modul-Adresse
End-Jumper
Netzsicherung
CAN L
CAN H
+UBus
N
L
N
L
N
L
+ +
Connection instructions
Port Cable dimensions / Specifications / Information
2 x Bus (1) Patch cable CAT 5 RJ45 SFTP 1:1 configuration
Bus (2) Connection with cable - LIYCY paired 2x2x0.5;
⇨ See "Connecting the bus cable" [page 22]
❒ Important! CAN L and CAN H must not be connected to +UBUS !
Sensors 1 – 6 (3-8) Connection cable1) 2 x 0.75mm2, shielded from 25m cable length
Mains (9) Connection cable1) 3 x 1.5mm2, fuse 10A
Pump 1/2 (10/11) Connection cable1) 3 x 1.5mm2, max. 1.5A / 230V / 280W
1.YMM as per ÖVE-K41-5 or H05VV-F as per DIN VDE 0881-5
2Electrical connection and wiring
Expansion modules
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Connecting an isolating valve
If an isolating valve is connected to a speed-controlled pump outlet, an RC element must be used.
Furthermore, the minimum speed for the pump outlet in use must be set to 100% in the boiler control system.
Connection example:
The outer cable L(bn) should be connected to the outer cable of the respective mains supply of the module or to
the core module, HCP0/burner relay output at pin “LV”.
Electrical connection and wiring 2
Expansion modules
Service manual Lambdatronic SP 3200 for dual fuel boiler | B1450217_en 15

Connecting a high efficiency pump to the hydraulic module
Wire the high efficiency pump as shown in the connection diagram below:
❒ Connect the power supply for the high efficiency pump to output "Pump 1" or "Pump 2" of the hydraulic
module
❒ Connect the PWM cables of the high efficiency pump to the corresponding port "AO-P1" or "AO-P2"
➥Make sure that the cables are configured correctly (polarity) in accordance with the connection diagram
of the pump!
2Electrical connection and wiring
Expansion modules
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2.2.3 Return mixer module
The return mixer module provides the connection for a return mixer. The relevant sensor is the return sensor on
the core module. If this module is used, the “Return flow mixer through external module”
parameter must be set to “YES”.
⇨ See "Setting the system type" [page 32]
Connection instructions
Port Cable dimensions / Specifications / Information
Bus (1) Connection with enclosed patch cable 0.5m
2 x mains (2) Connection cable1) 3 x 1.5mm2,
Return mixer (3) Connection cable1) 4 x 0.75mm2, max. 0.15A / 230V
1.YMM as per ÖVE-K41-5 or H05VV-F as per DIN VDE 0881-5
Connection example
Electrical connection and wiring 2
Expansion modules
Service manual Lambdatronic SP 3200 for dual fuel boiler | B1450217_en 17

2.2.4 Pellet module
The pellet module is included in standard delivery and provides the connections of the hardware components for
the pellet feed and pellet combustion:
Port Cable dimensions / Specifications / Information
Ignition - E1 (1) Connection cable of the respective unit
WOS drive M4 (2)
Ash screw M9 (3/4)
Mains (5) Connection cable1) 3 x 1.5mm2
Suction unit M3 (6) Connection cable of the respective unit
Stoker motor M1 (7)
Blower fan M10 (8) Connection of the vibration motor in conjunction with a bag silo as the pellet discharge
system.
Latch (9) Connection cable1) 2 x 0.75mm2
Burn back flap M7 (10) Connection cable of the respective unit
Grate drive M6 (11)
Level MIN S4 (12)
Level MAX S1 (13)
Gate valve M8 (14) Connection of the gate valve on the cover of the pellet container and connection of the
underpressure sensor cartridge (depending on boiler type and output)
Flow sensor S3 (15) Connection cable of the respective unit
2 x bus (16) Patch cable CAT 5 RJ45 SFTP 1:1 configuration
Door contact switch (17) Connection cable of the respective unit
2Electrical connection and wiring
Expansion modules
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Port Cable dimensions / Specifications / Information
Fault message (18) Connection cable1) 3 x 1.5mm2, max. 1A
Pellet module expansion (19) Connection cable of the respective unit
1.YMM as per ÖVE-K41-5 or H05VV-F as per DIN VDE 0881-5
Fuses
F1 3.15 AT 24V
F2 10 AT Stoker motor, blower fan
F3 10 AT Suction unit
Connection configuration for max level S1 and min level S4
Max level S1
+24V
IN
GND
brown
white
blue
- NC +
❒ The black wire of the sensor is not used.
Error message switch (on the pellet module)
Two floating switch contacts are available ("normal open" and "normal closed")for
control of external warning devices (signal lights, signal horn, SMS box, ...).
If a fault occurs both contacts are activated, and the "normally open" closes and
the "normally closed" opens.
❒ Maximum load of the contact: 1A
Electrical connection and wiring 2
Expansion modules
Service manual Lambdatronic SP 3200 for dual fuel boiler | B1450217_en 19

2.2.5 Pellet module expansion
The pellet module controls a suction delivery unit by default. The pellet module expansion is necessary if the
suction screw systems or other discharge systems or system components from third-party manufacturers are
used.
The power supply line and the communication line must be connected to the pellet module.
Connection instructions
Port Cable dimensions / Specifications / Information
Flue gas temperature sensor 2
F1 (1)
Connection cable1) 2 x 0.75mm2
Connection of a second flue gas temperature sensor in conjunction with the condensing
boiler heat exchanger.
Digi IN S8 (2) Connection cable1) 2 x 0.75mm2, 24VDC
24V digital input that determines the open position of the room air flap:
▪ Digital input = 1 when the flap is open
▪ Digital input = 0 when the flap is closed
Jam sensor S2 (3) For connection, see below.
Jam sensor in conjunction with a suction screw as the discharge system.
Reserve (4/5) Not in use!
Room air flap (6) Connection cable1) 3 x 1.5 mm2, max. 1A / 230V
Discharge screw (8) Connection cable1) 3 x 1.5mm2, max. 4A / 230V / 900W
1) YMM as per ÖVE-K41-5 or H05VV-F DIN VDE 0881-5
Jam sensor S2 connection configuration
Jam sensor S2
GND
IN
+24V
blue
black
brown
+ NO -
❒ The white wire of the sensor is not used.
2Electrical connection and wiring
Expansion modules
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