Fröling SPS 4000 User manual

Service manual
Control System SPS 4000
V. 2.0.220
Translation of the original German operating instructions for technicians and operators
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B0960622_en | Edition 17/10/2022
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

1 General 4
1.1 Safety information 5
2 Overview of the basic functions 6
2.1 Touch display 6
2.2 Control icons 7
2.3 Operating statuses 8
3 Operation 10
3.1 Switching the boiler on/off 10
3.2 Trend display 11
3.3 Manual operation 13
3.4 System menu 13
3.4.1 Displaying/changing parameters 14
Changing the parameter value
14
3.5 Fault information 16
3.6 Quick info 16
3.7 Quick functions 17
3.8 Switching user level 17
3.8.1 User levels with static code 18
3.8.2 “Service” user level with USB stick 18
3.8.3 “Service” user level with one-off
password
19
3.9 Setting the date and time 19
3.9.1 Obtain data via time server 20
4 Initial startup 21
4.1 Before switching on for the first time 21
4.2 Switching on for the first time 21
4.3 Changing the language 22
4.4 Performing a software update 22
4.5 Perform hardware detection manually 24
4.6 Configuring the system 26
4.7 Finishing configuration 27
4.8 Before commissioning / configuring the
boiler
27
5 Menus and parameters 29
5.1 Environment 29
5.1.1 Distributor 1... 4 29
Settings
29
Storage tank distributor 1... 4
29
Network circuit 1... 2
30
Heating circuit 1... 10
30
DHW tank 1... 5
30
5.1.2 Settings for direct heat distribution 31
5.1.3 Storage tank 31
5.1.4 Network circuit 1... 2 32
5.1.5 Heating circuit 1... 10 34
5.1.6 DHW tank 1... 5 35
5.2 System connection 36
5.2.1 Cascade 36
5.2.2 Boiler 1...5 36
5.3 Boiler 37
5.3.1 Modes 37
Boiler mode
37
External boiler controller
37
Chimney sweep
38
Extra heating
38
Shut down for cleaning
39
Special operating modes
39
5.3.2 Boiler settings 40
5.3.3 Water temperatures 40
5.3.4 Air damper/blower fan 42
Blower fan and air duct system
42
FGR
44
Frequency converter
46
5.3.5 Lambda probe 47
Settings
47
Calibration
48
5.3.6 Ignite 48
5.3.7 Flue gas 49
5.3.8 Filter 50
5.3.9 Burning chamber 50
5.3.10 Heat exchanger 51
Heat exchanger configuration
51
Manual heat exchanger 51
5.3.11 Grate 53
5.3.12 Ash removal 54
5.3.13 Joint ash removal 55
5.3.14 Slide-on duct 55
5.3.15 Control parameters 56
5.4 Fuel feed 57
5.4.1 Fuel selection 57
5.4.2 Output settings 57
5.4.3 Stoker 57
5.4.4 Conveyor 58
Feed screw 1... 6
58
Cross conveyor screw 1...3
58
Hopper 1... 3
59
5.4.5 Chamber discharge system 60
Sliding floor
60
Table of contents
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Sliding floor container
60
Rotary agitator
61
Drying
61
5.5 PLC 62
5.5.1 Date & time 62
5.5.2 Software 62
5.5.3 Network 63
5.5.4 Log file 63
5.5.5 Touchscreen & operation 63
Settings
63
5.5.6 Hardware 64
5.5.7 PLC restart 65
5.6 Diagnosis 66
5.6.1 Error 66
5.6.2 Inputs and outputs 66
5.6.3 System Diagnostics Manager 68
5.6.4 Log 69
5.6.5 Message forwarding 69
Error output
69
User-defined messages
70
5.6.6 USB recording 71
5.6.7 Trend display 71
5.7 Quick select 72
5.8 System configuration 73
5.8.1 System & operator 73
System data
73
Operator data
73
System connection
74
System settings
74
5.8.2 Environment 74
Heating circuits & heat distribution
74
External connection
76
5.8.3 System connection 77
Settings
77
Boiler 1... 5
77
5.8.4 Boiler 78
5.8.5 Fuel feed 80
Hydraulic units
80
Conveyor
80
Chamber discharge system
80
Discharge / configurations
81
5.8.6 Ash removal 84
5.8.7 Flue gas treatment 85
5.8.8 Inputs & outputs 86
5.8.9 Operation hours 88
5.8.10 Backup & restore 88
6 Troubleshooting 89
6.1 Procedure in case of malfunctions 89
7 Electric components and wiring 90
7.1 PLC 90
7.1.1 Touchscreen 90
Connections
91
7.1.2 X20 – module layout 92
7.1.3 X20 module types 95
BR9300
95
PS2100
98
BT9100
101
CS1012
103
CS1030
105
DI2377
106
DI9371
107
DO9322
109
DO8332
111
DO6639
113
DO2633
115
AI4622
117
AI4222
119
AO4622
121
AO2622
123
AT2402
125
AT6402
127
AT4222
129
7.2 Sensor characteristic line PT100 132
7.3 Sensor characteristic line type K 133
7.4 Frequency converter 135
7.4.1 Operating elements 135
7.4.2 Changing parameters 136
7.5 Cascade / Modbus 138
7.5.1 Terminating resistor at communication
module
140
7.6 M-bus 141
8 Notes 142
9 Appendix 144
9.1 Addresses 144
9.1.1 Address of manufacturer 144
9.1.2 Address of the installer 144
Table of contents
Service manual SPS 4000 | B0960622_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.
About these instructions
The range of functions of the SPS 4000 depends on the user level currently set. These instructions show all the
parameters that are available with full functionality in the "Service" user level (maximum configuration with all
possible system components). The range available varies according to the user level set.
NOTICE
The values given in the parameter lists are examples, and should not be used as standard
values!
1General
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1.1 Safety information
DANGER
When working on electrical components:
Risk of electrocution!
When work is carried out on electrical components:
❒ Always have work carried out by a qualified electrician
❒ Observe the applicable standards and regulations
➥Work must not be carried out on electrical components by unauthorised persons
WARNING
When touching hot surfaces:
Severe burns are possible on hot surfaces and the flue gas pipe!
When work is carried out on the boiler:
❒ Shut down the boiler according to procedure (“Boiler off” operating status) and allow it to
cool down
❒ Protective gloves must usually be worn for work on the boiler, and it should only be
operated using the handles provided
❒ Insulate the flue gas pipes and do not touch them during operation
The information on safety, standards and guidelines in the assembly and operating instructions for the boiler
should also be observed!
General 1
Safety information
Service manual SPS 4000 | B0960622_en 5

2 Overview of the basic functions
2.1 Touch display
1
2
3
456
1Standby icon for switching the system on/off with display of the current system status
2Navigation area for quick switching between the start page and the individual menus
3Display area for the selected menu
4Area for status displays (Ethernet, USB etc.)
5Quick selection area
6Display of time and date
2Overview of the basic functions
Touch display
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2.2 Control icons
Home icon
To show the basic display. Different values from the boiler and system are displayed as standard on the
basic display.
Trend icon
Opens the trend logging view. Shows the graphic display of up to twelve current values simultaneously.
Manual menu symbol
To show the manual operation functions. The functions are grouped into the main system components and
are dependent on the configuration and user level.
System menu icon
Opens the system settings. The view is arranged in two columns and always shows two menu levels.
Depending on the user level and system configuration, various menu items are available.
Back icon
Takes you back up one menu level of the system menu. Takes you back to the first menu level. The current
menu path is displayed next to the icon.
Pen icon
If a parameter has the pen symbol beside it, it means that the parameter can be adjusted. If you open the
parameter, either the numeric keypad or a list box for changing the value of the parameter will appear.
Cancel icon
Discards any values entered without saving and closes messages.
Accept icon
To accept values entered, without closing the change dialogue.
Confirm icon
Confirms any values entered and activates parameters. The change dialogue is automatically closed after
saving.
Info menu icon
To open the most important system information. The info menu is divided into three main sections, which can
be opened by tapping on the corresponding tab. The information is ordered in a circular buffer. The up and
down arrows are used to switch between the individual pages.
Quick select icon
Opens the quick menu. Various functions are available depending on the user level, system configuration
and current status.
Overview of the basic functions 2
Control icons
Service manual SPS 4000 | B0960622_en 7

2.3 Operating statuses
Availability of the listed operating statuses depend on the set boiler type!
Fault* The boiler is shut down. Error messages or alarms that have not been acknowledged are
displayed.
Off* The boiler is shut down and ready to start.
Standby* The boiler is switched on but has not received a demand yet or no heating requirement has
been determined yet. The boiler waits until there is a requirement.
Preparation The boiler starts with the first step of the start process. The induced draught and combustion
air fans are started up and the Lambda probe is prepared to complete a measurement.
Automatic calibration At the beginning of the start process, the Lambda probe is automatically calibrated at 21%
residual oxygen. The automatic calibration is not completed if it is not possible due to the
combustion chamber temperature or previous switch-off time.
Fill stoker If the stoker is empty before the boiler is started, it is filled during this step so that it can
subsequently be inserted in cycles. This step is not required for hydraulic stokers.
Heating up Material is inserted into the combustion chamber at a defined feed rate and is then checked to
see is the boiler will ignite due to the residual embers.
Pre-heat phase Without supplying anymore fuel, the boiler waits to see if a fire will ignite in the combustion
chamber.
Ignition Addition material is inserted into the combustion chamber at a defined feed rate.
Pre-heat phase The fan-assisted ignition switches on and the fuel is pre-warmed until a flame forms. For this
period, infeed is deactivated.
Ignition The fan-assisted ignition ignites the fuel. The flame is distributed throughout the entire
combustion chamber. The electric ignition is active at the same time. The boiler waits to see if
fire is detected.
Reignition The electric ignition is still active but no further material is inserted. The boiler waits to see if fire
is detected.
Heating* The boiler is heating.
Slumber* The boiler is shutting down. Fuel is inserted periodically to maintain residual embers and to
make it easier to reignite.
Shutdown – Empty stoker The boiler is shutting down. Combustion is continued in a controlled manner until the fuel in the
stoker is used up and the stoker is empty. This step is not required for hydraulic stokers.
FGR run-on The boiler is shutting down. The FGR remains active until the minimum criteria to activate the
AGR are met.
FGR cleaning If the FGR was active, this state is initiated during shutdown. The blower fan is active for a
minimum amount of time to clean the duct.
Blower fan run-on The boiler is shutting down. The blower fans are still active until the residual oxygen in the
boiler has reached an uncritical value.
Ventilate boiler The boiler is shutting down or has already been shutdown. The blower fans are activated until
the temperature in the combustion chamber falls below the setpoint. This ensures that the
combustion chamber can be cooled down quickly for service work.
Prepare case cooling The boiler is shut down or ready for operation. The case temperature has reached the cooling
criterion. In this state, the blower fan is started up and the flaps are set.
Case cooling The boiler is shut down or ready for operation. The induced draught is active and sucks air
from the flaps through the case to cool it down if a defined temperature is exceeded.
Terminate case cooling Case cooling was successful and the case temperature is low enough again or the boiler has
been activated. Case cooling is terminated. The induced draught is deactivated and the flaps
are set.
Prepare baking out mode Only for commissioning: the induced draught and Lambda probe are activated.
2Overview of the basic functions
Operating statuses
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Baking out mode For commissioning only: The induced draught is active at the manually set value. As part of the
commissioning process, the combustion chamber can be heated by manually inserting fuel
(e.g. logs).
*static state: These states last until they are changed by interactions or other external influences. All of the other states are
only temporary and have a maximum duration.
Overview of the basic functions 2
Operating statuses
Service manual SPS 4000 | B0960622_en 9

3 Operation
3.1 Switching the boiler on/off
BOILER ON
The boiler is switched on. The boiler system is controlled according to the programs and times set.
BOILER OFF
The PLC shuts down the boiler in a controlled way. After the shut down procedure, the boiler switches to the
“OFF” status (switched off - off). The SPS controls the connected heating system. All parts of the boiler are
deactivated. The chamber discharge system remains active!
3Operation
Switching the boiler on/off
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3.2 Trend display
Tapping the trend icon in the navigation area opens the trend display. The trend display is used to graphically
display up to twelve selected values.
1
23
4
5
67
1Graphic progression as a line of the selected values in the displayed time range.
2If the “Y-axis” option is selected for the displayed current value, the corresponding value axis is displayed here.
3List of the assigned current values with name and current status.
4Colour of the trend line assigned to the current value.
5For quick switching of line visibility. Defines whether the trend line associated with the current value is
displayed.
6Start/stop automatic scrolling of the trend display; left arrow / right arrow to move the trend display along the
time axis.
7Scaling of the time axis as a value input or incrementally by tapping the respective magnifying glass icon.
Operation 3
Trend display
Service manual SPS 4000 | B0960622_en 11

Tapping on a current value opens the configuration:
1
2
3
4
5
6
1Maximum value of the current value for the value axis.
2Minimum value of the current value for the value axis.
3Dropdown field to select the current value.
4Specifies whether the current value is to be displayed as a trend line. Visibility can be changed during the
recording by tapping the eye icon.
5Defines whether the value axis is displayed in the trend.
6Defines the colour of the trend line.
3Operation
Trend display
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3.3 Manual operation
Depending on the version of the system and user authorization, various manual operation functions are
available, which are divided into several groups. All functions are in automatic mode when opened.
❒ Select the desired group and search for a function in the list. For longer lists you can navigate in the list
using the “arrow up” and “arrow down” buttons
❒ Start the function by tapping the manual operation icon
➥The selected button is displayed in green and the function is carried out
➥The manual operation signal highlighted in orange indicates that a component is being controlled in
manual mode.
❒ The manual operation function is terminated by tapping on the green “Automatic icon”
3.4 System menu
The system menu shows the menu items available depending on the user level and the system configuration.
The view is arranged in two columns and always shows two menu levels. By tapping on a menu item in the left
column, the respective submenu is displayed in the right column. The current menu path is displayed in the
address line above.
Opening the submenu
❒ Press the menu item in the right column
➥The lower menu level is displayed and the current menu level moves one column to the left
➥When the lowest menu level is reached, the corresponding parameters are displayed
Operation 3
Manual operation
Service manual SPS 4000 | B0960622_en 13

Displaying higher-level menu items
❒ In the address line tap on the back icon
➥The current menu level moves one column to the right
3.4.1 Displaying/changing parameters
It is only possible to view or edit parameter details if there is a pen icon beside the parameter value:
1
2
3
4
❒ Tap the relevant parameter
➥The detailed view of the parameter will open
1Name of the parameter, including the currently set value. Parameter is reset to this value if you cancel the entry.
2Displays the changed value.
3Setting range of the parameter. The values can also be selected directly.
4Confirm icon to save and exit the dialogue.
Cancel icon to exit the dialogue without saving the entries
Changing the parameter value
There are different ways of entering values depending on the type of parameter (increase/reduce value, keypad
entry, list box). In each case, you need to tap the confirm icon to save the entry.
3Operation
System menu
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Increasing/reducing the value
❒ Change parameter value with "+" or "-"
➥The changed value appears in the display field
❒ You can also tap “Minimum", “Default" or “Maximum" to set to the respective value displayed below
❒ Tap the confirm icon to save the set value
➥The parameter value is saved and the setting dialogue closes
Entering a value
If a numeric keypad icon appears beside the parameter value in the display field, you can enter the value
directly:
❒ Tap the numeric keypad icon or value field
➥The Enter values window for parameters will appear
❒ Type in the relevant value on the numeric keypad
❒ Confirm your entry by tapping the confirm icon
Operation 3
System menu
Service manual SPS 4000 | B0960622_en 15

3.5 Fault information
If a fault occurs in the system, the warning symbol flashes in the quick selection area.
❒ Tap the warning symbol in the quick selection area
➥The list of the faults that are currently present is displayed
❒ To select a specific fault message for acknowledgement or for longer lists, navigate using the “arrow down”
and “arrow up” buttons
⇨ See "Procedure in case of malfunctions" [page 89]
❒ To close, tap on the warning symbol or in the empty area next to the display field
3.6 Quick info
Quick info is used to display the current operating values of the system and can be displayed at any time.
❒ Tap the info symbol in the quick selection area
➥The quick info is displayed and shows the last page displayed
❒ Select the desired system area by tapping on the tabs in the lower part of the menu
❒ Use “arrow down” and “arrow up” to navigate to the desired page
❒ To close, tap the info icon or tap in the empty area next to the quick info
3Operation
Fault information
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3.7 Quick functions
❒ Tap on the favourites icon in the quick selection area
➥The available quick functions are displayed
❒ Open the desired function by tapping on the corresponding icon
Language selection
To change the current language of the display.
Clean display
The display is locked for 10 seconds for cleaning purposes.
All of the other quick functions are in the quick menu:
⇨ See "Quick select" [page 72]
3.8 Switching user level
Four different user levels are available:
Operating lock If an invalid code is entered, e.g. 0
The display is locked for editing, it is only possible to switch off the system and to switch the user
level.
Operator Static code: 1
Standard user level with all of the regularly required functions and parameters.
Expert Static code. Additional parameters and manual operation are available. Advanced diagnostic
options are available. The code for this user level is provided by Fröling during the user training.
Service Accessible via the USB stick using the licence file or one-off password.
For the configuration and commissioning of the system and access to the control parameters.
Operation 3
Quick functions
Service manual SPS 4000 | B0960622_en 17

3.8.1 User levels with static code
❒ Tap the operator icon in the quick selection area
❒ Enter the user code using the numeric keypad and confirm by tapping the confirm icon
➥The functions in the selected user level are available
3.8.2 “Service” user level with USB stick
A USB stick with a licence file is required to switch to the “Service” user level. The required file is available in the
Fröling partner area for authorised users.
If the SPS 4000 detects a valid licence file on the connected USB stick, it automatically switches to the “Service”
user level. Tapping the service icon displays the licence file data.
3Operation
Switching user level
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3.8.3 “Service” user level with one-off password
If no USB stick with a licence file is available, the one-off password can be entered to switch to the “Service”
user level, if required.
❒ Contact Fröling customer services
❒ Enter the four-digit PIN when prompted by the customer services technician
➥The customer services technician will use the PIN to generate a five-digit one-off password
❒ Enter the one-off password and confirm
➥“Service” user level is active until the user logs out or a set time has expired.
3.9 Setting the date and time
❒ Tap the date and time area on the start screen
➥The menu for setting the date and time will appear
❒ Tap the desired display value to change it
➥Numeric keypad for changing the value is displayed
Operation 3
Switching user level
Service manual SPS 4000 | B0960622_en 19

3.9.1 Obtain data via time server
If the SPS 4000 is connected to a network via an Internet connection or local time server, the automatic retrieval
of the date and time is recommended.
❒ In the system menu, navigate to the submenu “PLC” ➾ “Date & Time”
❒ Open “Time settings” parameter
❒ Set parameter value to “NTP time server” and save the setting
❒ Set the IP address of the desired time server and the respective time zone at the installation site
Date & Time
❒ By tapping on the date or time on the start screen, the status of the synchronization is now displayed
3Operation
Setting the date and time
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