Froling T4 24-150 User manual

Operating Instructions
Wood chip boiler T4 24-150 (Touch)
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!
B0830113_en | Edition 06/11/2013
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of Contents
1 General 4
1.1 T4 product overview 5
2 Safety 7
2.1 Hazard levels of warnings 7
2.2 Pictograms used 8
2.3 General safety information 9
2.4 Permitted uses 10
2.4.1 The Clean Air Act 1993 and Smoke Control Areas 10
2.4.2 Permitted fuels 11
Wood chips 11
Wood pellets 11
Changing the fuel 11
2.4.3 Non-permitted fuels 12
2.5 Qualification of operating staff 12
2.6 Protective equipment for operating staff 12
2.7 Design information 12
2.7.1 Installation and approval of the heating system 13
2.7.2 General information for installation room (boiler room) 13
2.7.3 Requirements for central heating water 14
2.7.4 Notes for using pressure maintenance systems 14
2.7.5 Return temperature control 15
2.7.6 Use with storage tank 15
2.7.7 Chimney connection/chimney system 15
2.8 Safety devices 16
2.9 Residual risks 17
2.10 Emergency procedure 18
2.10.1 Overheating of the system 18
2.10.2 Smell of flue gas 18
2.10.3 Fire in the system 19
3 Operating the System 20
3.1 Assembly and initial startup 20
3.2 Filling/refilling the store with fuel 21
3.2.1 Loading of fuel for a partially emptied store with rotary agitator 21
3.2.2 Loading wood chips in an empty store (not under pressure) 21
3.2.3 Blowing in pellets for a store with pellet screw 22
3.2.4 Blowing in fuel for a partially emptied store with rotary agitator 22
3.2.5 Blowing in fuel for an empty store with rotary agitator 22
3.3 Heating up the boiler 23
3.3.1 Switching on the power supply 23
3.3.2 Switching on the boiler 24
3.3.3 Controlling the boiler 24
3.3.4 Switching off the boiler 24
3.3.5 Switching off the power supply 24
4 Boiler Servicing 25
Table of Contents
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4.1 General information on servicing 25
4.2 Inspection and cleaning 27
4.2.1 Inspection 27
Checking the system pressure 27
Checking the safety valve 27
Checking the geared motors 27
4.2.2 Cleaning 28
Emptying the ash container 28
4.2.3 Recurrent check and cleaning 30
Before starting inspection and cleaning work 30
After inspection and cleaning work 30
Cleaning the combustion chamber 31
Cleaning the heat-exchanger and flue gas collection chamber 33
Cleaning the flue gas temperature sensor 35
Cleaning the flue gas pipe 35
Checking the seal on the doors 35
Checking the draught controller flap 36
Cleaning the measurement line of the underpressure controller 36
4.3 Emissions measurement by chimney sweep or regulatory body 38
4.3.1 Measurement at nominal load 38
4.3.2 Measurement at partial load (if necessary) 38
4.4 Maintenance agreement / Customer service 39
4.5 Replacement parts 39
4.6 Disposal information 39
4.6.1 Disposal of the ash 39
4.6.2 Disposal of system components 39
5 Troubleshooting 40
5.1 General fault with power supply 40
5.1.1 Behaviour of system after a power failure 40
5.2 Excessive temperature 40
5.3 Faults with fault message 41
5.3.1 Procedure for fault messages 41
5.3.2 Acknowledging a fault message 41
6 Appendix 42
6.1 Addresses 42
6.1.1 Address of manufacturer 42
6.1.2 Address of the installer 42
Table of Contents
Operating Instructions T4 24-150 (Touch) | B0830113_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 guide‐
lines.
Please read and observe the documentation provided and always keep it close to the
system for reference. It contains important safety information and all the operation and
maintenance specifications needed to operate the system safely, properly, environ‐
mentally friendly and cost-effectively.
The constant further development of our products means that there may be minor dif‐
ferences from the pictures and content. If you discover any errors, please let us know:
[email protected]
Subject to technical change.
Guarantee conditions
Our sale and delivery conditions generally apply. 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.
1General
4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

1.1 T4 product overview
1Froling T4 wood chip boiler
2Main switch: switches the power supply on and off for the entire system
3High-limit thermostat STL
4Mains supply
5Control panel of the Lambdatronic H 3200 T4 Touch controller
5.1 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
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
General 1
T4 product overview
Operating Instructions T4 24-150 (Touch) | B0830113_en 5

9Fuel transport unit with rotary valve as a burn back protection system (BBF) and stok‐
er screw for fuel transport
10 Automatic ignition
11 Combustion chamber with fireclay combustion chamber and automatic tipping grate
12 Ash box for combined automatic ash removal from combustion chamber and heat ex‐
changer
13 Combustion chamber door with screw lock and inspection glass
14 WOS system with turbulators and automatic drive for heat exchanger cleaning
15 Broadband probe
16 Flue gas temperature sensor
1General
T4 product overview
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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 or damage to property.
Safety 2
Hazard levels of warnings
Operating Instructions T4 24-150 (Touch) | B0830113_en 7

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 instruc‐
tions
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 start‐
up
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
2Safety
Pictograms used
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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 car‐
bonisation 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 insuf‐
ficient chimney draught, can cause serious faults in combustion (such as sponta‐
neous 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.
Safety 2
General safety information
Operating Instructions T4 24-150 (Touch) | B0830113_en 9

2.4 Permitted uses
The Froling Wood chip boiler T4 is designed solely for heating domestic water. Only
use fuels specified in the "Permitted fuels" section.
⇨ See "Permitted fuels" [page 11]
The unit should only be operated when it is in full working order. It should be operated
in accordance with the instructions, observing safety precautions, and you should en‐
sure you are aware of the potential hazards. The inspection and cleaning intervals in
the operating instructions should be observed. Ensure that any faults which might im‐
pair safety are rectified immediately.
The manufacturer or supplier is not liable for any damage resulting from non-permitted
uses.
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 chim‐
ney 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 with‐
in 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, ap‐
plies in Northern Ireland. Therefore it is a requirement that fuels burnt or obtained for
use in smoke control areas have been „authorised“ in Regluations and that appliances
used to burn solid fuel in those areas (other than „authorised“ fuels) have been ex‐
empted by an Order made and signed by the Secretary of State or Minister in the de‐
volved 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 de‐
tails of Clean Air Act requirements.
The Froling T4-24, T4-30, T4-40, T4-50, T4-60, T4-75, T4-90, T4-100, T4-110, T4-130
and T4-150 have been recommended as suitable for use in smoke control areas when
burning fuels as listed under "Permitted fuels".
2Safety
Permitted uses
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.4.2 Permitted fuels
Wood chips
Criterion Designation as per Description acc. to
ÖNORM M 7133
ÖNORM M 7133 EN 14961
Water content W20 M20 Air-dried
W30 M30 Suitable for storage
W35 M35 Limited suitability for
storage
Size G30 P16A / P16B Fine wood chip
G50 P45A Medium-sized wood
chips
EU: Fuel acc. to EN 14961 - Part 4: Wood chips class A2 / P16A-P45A
Germany
also: Fuel class 4 (§3 of the 1st 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 14961 - Part 2: Wood pellets class A1 / D06
and/or: Certification program EN
plus or DIN plus
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 T4 24-150 (Touch) | B0830113_en 11

2.4.3 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐
ing 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 pre‐
vention regulations.
▪ For operation, inspection and cleaning:
- suitable work wear
- protective gloves
- sturdy shoes
2.7 Design information
It is forbidden to carry out modifications to the boiler or to change or deactivate safety
equipment.
Always comply with all fire, building, and electrical regulations when installing or oper‐
ating the boiler system, and follow the operating instructions and mandatory regula‐
tions that apply in the country in which the boiler is operated.
2Safety
Permitted uses
12 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.7.1 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
ÖNORM / DIN 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: Inform the civic/municipal building authorities.
Germany: Notify an approved chimney sweep and the building authorities.
2.7.2 General information for installation room (boiler room)
Boiler room characteristics
▪ 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 provide sufficient light‐
ing in the boiler room in accordance with national workplace design regulations.
▪ When using the boiler over 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
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 in the room where
the boiler is installed.
▪ Keep the air suction opening of the boiler free from dust.
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 (foli‐
age, 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
Note on standards
Note on standards
Safety 2
Design information
Operating Instructions T4 24-150 (Touch) | B0830113_en 13

2.7.3 Requirements for central heating water
The following standards and guidelines apply:
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195-1
VDI 2035
SWKI 97-1
D.P.R. no. 412
NOTICE! Note on filling with make-up water: Always bleed the filling hose before con‐
necting, in order to prevent air from entering the system.
Observe the standards and also follow the recommendations below:
❒Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to
5.6 dH)
❒ Use softened water as the make-up water
❒ Avoid leaks and use a closed heating system to maintain water quality during op‐
eration
2.7.4 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required pres‐
sure within predefined limits and balance out volume variations caused by changes in
the hot-water temperature. Two main systems are used:
Compressor-controlled pressure maintenance
In compressor-controlled pressure maintenance units, a variable air cushion in the ex‐
pansion tank is responsible for volume compensation and pressure maintenance. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐
to the domestic hot water.
Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐
tenance pump, relief valve and an unpressurised receiving tank. The valve releases
hot water into the receiving tank if the pressure is too high. If the pressure drops below
a preset value, the pump draws water from the receiving tank and feeds it back into
the heating system. Pump-controlled pressure maintenance systems with open expan‐
sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the
water, exposing the connected system components to the risk of corrosion. These
systems offer no oxygen removal for the purposes of corrosion control as required by
VDI 2035 and in the interests of corrosion protection should not be used.
Note on standards
2Safety
Design information
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2.7.5 Return temperature control
If the hot water return is below the minimum return temperature, some of the hot water
outfeed will be mixed in.
CAUTION
Risk of dropping below dew point/condensation formation if operated without re‐
turn temperature control.
Condensation water forms an aggressive condensate when combined with com‐
bustion residue, leading to damage to the boiler.
Take the following precautions:
❒ We recommend using a return temperature control.
➥The minimum return temperature is 45 °C. We recommend fitting some
sort of control device (e.g. thermometer).
2.7.6 Use with storage tank
NOTICE
In principle it is not necessary to use a storage tank for the system to run smooth‐
ly. However, we recommend that you use the system with a storage tank, as this
ensures a continuous supply of fuel in the ideal output range of the boiler.
For the correct dimensions of the storage tank and the line insulation (in accordance
with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling.
⇨ See "Addresses" [page 42]
2.7.7 Chimney connection/chimney system
EN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐
ever possible, damage caused by seepage, insufficient feed pressure and condensa‐
tion. Please note in this respect that flue gas temperatures lower than 160K above
room temperature can occur in the permitted operating range of the boiler.
NOTICE! Please see the technical data contained in the assembly instructions for fur‐
ther information about standards and regulations as well as the flue gas temperatures
when clean and the other flue gas values!
Safety 2
Design information
Operating Instructions T4 24-150 (Touch) | B0830113_en 15

2.8 Safety devices
1
SV
32
1 BOILER OFF
(switches off the boiler to prevent overheating)
❒ Tap “Boiler off”
➥Automatic mode is switched off
➥Control system follows the boiler shut-down 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 shut-down procedure
❒ Switch off the main switch and let the boiler cool down
3 SAFETY TEMPERATURE LIMITER (STL) (protection against overheating)
The STL switches off the combustion system when the boiler reaches 105°C. The
pumps continue to run. Once the temperature falls below approx. 75°C, the STL can
be reset mechanically.
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.
2Safety
Safety devices
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2.9 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 in a controlled way (operating status "Boiler off") and al‐
low 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.
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 boiler to cool for at least 1 hour
❒ Switch off the main switch and take precautions to prevent accidental switch‐
ing 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 acci‐
dents!
Take the following precautions:
❒ Only use fuels specified in the "Permitted fuels" section of these operating in‐
structions.
Safety 2
Residual risks
Operating Instructions T4 24-150 (Touch) | B0830113_en 17

2.10 Emergency procedure
2.10.1 Overheating of the system
If the system overheats and the safety devices fail, 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 performs this function in automatic operation.
❒ If a third-party controller is used, carry out the appropriate measures to activate
the mixer taps and pumps manually.
❒ Leave the boiler room and close the door
❒ Open any available radiator thermostat valves
If the temperature does not drop:
❒ Contact the installer or Froling customer services
⇨ See "Addresses" [page 42]
2.10.2 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
2Safety
Emergency procedure
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2.10.3 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
Safety 2
Emergency procedure
Operating Instructions T4 24-150 (Touch) | B0830113_en 19

3 Operating the System
3.1 Assembly and initial startup
Assembly, installation and initial startup of the boiler must only be carried out by quali‐
fied staff, and these procedures are described in the accompanying assembly instruc‐
tions.
NOTICE! See assembly instructions for the T4
NOTICE
Optimum efficiency and efficient, low-emission operation can only be guaranteed
if the system is set up by trained professionals and the standard factory settings
are observed.
Take the following precautions:
❒Initial startup should be carried out with an authorised installer or with Froling
customer services
The individual steps for initial start-up are explained in the operating instructions for
the controller
NOTICE! See operating instructions for the Lambdatronic H 3200 T4
The customer is responsible for ensuring the following prior to initial start-up of the
system by Froling customer services:
▪Electrical installation
▪ Installation of water pipes
▪ Flue gas connection including all insulation work
▪ Work must comply with local fire protection regulations
▪ The necessary "dry run" of the system means that the discharge system must be
empty at the start of initial startup. Fuel must be available, however, so that the
discharge system can be filled once the system is released.
▪ It is essential that the electrician who has carried out the installation work is availa‐
ble when starting up the system for the first time to make any changes to the wir‐
ing which may become necessary.
▪ During initial start-up, operating staff are shown how to use the boiler. It is impera‐
tive for proper handover of the product that those involved are present as this is a
one-off opportunity.
NOTICE
If condensation escapes during the initial heat-up phase, this does not indicate a
fault.
❒Tip: If this occurs, clean up using a cleaning rag.
3Operating the System
Assembly and initial startup
20 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com