Froling T4 60 User manual

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen
Tel [phone] Fax [phone] [email protected] www.froeling.com
Installation Instructions
T4 – 24-110
English version of the assembly instructions for technicians.
Read and follow the instructions and safety instructions!
Subject to technical change.

Introduction
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Dear customer,
The FROLING T4 wood chip boiler features a state-of-the-art design that
conforms to all currently applicable standards and testing guidelines.
Please read and follow the installation instructions. They contain safety
instructions and comprehensive information relating to transporting,
setting up and assembling the boiler.
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.
Subject to technical change.
Document reference number M121 – Version 05 – Published 06/2012
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.
Delivery certificate
The EC Declaration of Conformity is only valid in conjunction with
a delivery certificate filled in correctly and signed as part of the
commissioning process. The original document remains at the
installation site. Commissioning installers or heating engineers are
requested to return a copy of the delivery certificate together with the
guarantee card to Froling. On commissioning by FROLING Customer
Service the validity of the delivery certificate will be noted on the
customer service record.
Address of manufacturer
FRÖLING
Heizkessel- und Behälterbau GesmbH
Industriestraße 12
A-4710 Grieskirchen
AUSTRIA
TEL [phone]
FAX [phone]
E-MAIL [e-mail]
WEBSITE www.froeling.com

Contents
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1General Information 6
1.1 Standards 6
1.2 Qualification of assembly staff 7
1.3 Protective equipment for assembly staff 7
1.4 Design information 7
1.4.1 Installation and approval of the heating system .................................................... 7
1.4.2 Information on the installation room (boiler room) ................................................ 8
Boiler room characteristics................................................................................8
Ventilation of the boiler room ............................................................................8
1.4.3 Heating water requirements............................................................................... 8
Combination with storage tank ..........................................................................9
Return lift.......................................................................................................9
1.4.4 Chimney connection/chimney system ................................................................ 10
Draught limiter.............................................................................................. 10
Boiler data for constructing the flue gas system (T4 24-50) ................................. 10
Boiler data for constructing the flue gas system (T4 60-110)................................ 11
2Technology 12
2.1 Dimensions - T4 12
2.2 Technical specifications 13
3Assembly 15
3.1 Transport 15
3.1.1 Positioning..................................................................................................... 15
Positioning using a crane (T4 24-50) ................................................................ 15
Positioning using a crane (T4 60-110)............................................................... 16
3.1.2 Temporary storage ......................................................................................... 16
3.2 Set-up in the boiler room 16
3.2.1 Removing the boiler from the pallet .................................................................. 16
3.2.2 Moving the boiler in the boiler room .................................................................. 16
3.2.3 Minimum distances in the boiler room................................................................ 17
3.3 Assembly work 18
3.3.1 Installing the ash container.............................................................................. 18
3.3.2 Installing the stoker unit.................................................................................. 19
3.4 Electrical connection 20
3.4.1 Removing the controller cover .......................................................................... 20
3.4.2 Laying cables................................................................................................. 21
3.4.3 Mains connection............................................................................................ 22
3.4.4 Note on pumps .............................................................................................. 22
4Commissioning / Decommissioning 23
4.1 Configuring the boiler 23
4.2 Out of service for long periods 23

Contents
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4.3 Disassembly 23
4.4 Disposal 23

General
Standards, personnel, design
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1General Information
1.1 Standards
The installation and commissioning of the boiler must be carried out in
accordance with local fire and building regulations.
The following standards and regulations should be observed in any case:
ÖNORM/DIN EN 303-5 Boilers for solid fuels, manually and automatically fed combustion systems;
rated heat output up to 300 kW;
EN 12828 Heating systems in buildings - design of water-based heating systems
ÖNORM M 7510-1 Guidelines for checking heating systems
Part 1: General requirements and one-off inspection
ÖNORM M 7510-4 Guidelines for checking heating systems
Part 4: Simple check for heating plants for solid fuels
EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods
Part 1: Chimneys serving one appliance
TRVB H 118 Technical directives for fire protection/prevention “Automatic wood burning
systems” (Austria only)
ÖNORM H 5170 Construction and fire protection requirements
ÖNORM M 7133 Wood chips for energy production - Requirements and test specifications.
ÖNORM M 7135 Compressed untreated wood or bark – pellets and briquettes – Requirements
and testing
DIN 51731 Testing solid fuels – compressed untreated wood – Requirements and testing
ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in closed warm-water-
heating systems at operating temperatures up to 100 °C (Austria only).
VDI 2035 Prevention of damage in water heating installations - Scale formation in
domestic hot water supply installations and water heating installations
(Germany only)
SWKI 97-1 Lime scale and corrosion protection in heating systems (Switzerland only)
1.BImSchV First Ordinance on Implementation of the Federal Emissions Control Act

General
Standards, personnel, design
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1.2 Qualification of assembly staff
CAUTION
Assembly and installation by untrained personnel:
Risk of injury and damage to equipment!
The instructions and information provided in the instructions
should be observed!
Only allow trained staff to carry out assembly and installation!
Assembly, installation, initial startup and servicing must only be carried
out by qualified people:
- Heating technicians / building technicians
- Electrical installation technicians
- Froling customer services
The assembly staff must have read and understood the instructions in
the documentation.
1.3 Protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by
accident prevention regulations.
During transportation, set-up and assembly of the boiler:
- Work clothing
- Safety shoes
- Protective gloves
1.4 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 operating the boiler system, and follow the operating
instructions and mandatory regulations that apply in the country in
which the boiler is operated.
1.4.1 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following
standards govern the installation:
Applicable standards:
ÖNORM / DIN EN 12828 Heating systems in buildings
Each heating system must be officially approved.
§

General
Standards, personnel, design
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The appropriate supervisory authority (inspection agency) must always
be informed when installing or modifying a heating system, and
authorisation must be obtained from the building authorities:
- Austria: Report to the construction authorities of the community or
magistrate
- Germany: Report new installations to an approved chimney sweep /
the building authorities.
1.4.2 Information on the 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 lighting in the boiler room in accordance with national
workplace design regulations.
When using the boiler above 2000 metres above sea level you should
consult the manufacturer.
Danger of fire due to flammable materials!
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 of 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 (foliage, snowdrifts, ...) from having any
effect on the air flow.
Unless otherwise specified in the applicable building regulations for the
boiler room, the following standards apply for the design and dimensions
of the air ducts:
Applicable standards:
- TRVB H 118
- ÖNORM H 517
- UNO 10683
1.4.3 Heating water requirements
The following standards and guidelines apply:
Applicable standards and guidelines:
Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1
Italy: D.P.R. no. 412
§
§

General
Standards, personnel, design
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 9
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Notice on filling with make-up water:
Always bleed the filling hose before connecting, in order to prevent
air from entering the system.
Combination with storage tank
NOTICE
It is not generally necessary to use a storage tank for the system to run
smoothly. However we recommend that you use it with a storage tank, as this
allows you to achieve continuous reduction within the ideal performance 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.
Return lift
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 return lift.
Condensation water forms an aggressive condensate when combined
with combustion residue, leading to damage to the boiler.
We recommend using a return lift.
The minimum return temperature is 45 °C. We recommend fitting some
kind of control device (e.g. thermometer).

General
Standards, personnel, design
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1.4.4 Chimney connection/chimney system
EN 303-5 specifies that the entire flue gas system must be designed to
prevent, wherever possible, damage caused by seepage, insufficient
feed pressure and condensation.
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.
The flue gas temperatures (for clean systems) and additional flue gas
values can be found in the technical specification sheets.
Boiler data for constructing the flue gas system
The connection between the boiler and the chimney system should be as
short as possible. The incline of the connection should not exceed 30 - 45°.
Insulate the connection.
The entire flue gas system - the chimney and its connection - must be
designed as per ÖNORM / DIN EN 13384-1.
Local regulations and other statutory
regulations also apply.
The chimney must be approved by a
smoke trap sweeper or chimney sweep!
As per TRVB H 118 (Austria only) an
explosion flap must be installed in the
flue pipe or in the chimney.
Draught limiter
Recommended: Installing a draught
limiter (DL)
Install the draught limiter directly under
the mouth of the flue line, as the
pressure is lower at this location.
Boiler data for constructing the flue gas system (T4 24-50)
Description Unit 24 30 40 50
Flue gas temperature RL
PL
°C 125
80
135
85
130
80
140
85
Flue gas mass flow RL
PL
kg/h 68.9
29.2
83.0
32.3
110.7
42.9
138.4
53.6
Flue gas mass flow RL
PL
kg/s 0.019
0.008
0.023
0.009
0.031
0.012
0.038
0.015
Feed pressure required RL
PL
Pa 5
2
5
2
5
2
5
2
Feed pressure required RL
PL
mbar 0.05
0.02
0.05
0.02
0.05
0.02
0.05
0.02
Flue pipe diameter mm 150 150 150 150
RL = Rated load, PL = Partial load;
DL

General
Standards, personnel, design
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Boiler data for constructing the flue gas system (T4 60-110)
Description Unit 60 75 90 100 110
Flue gas temperature RL
PL
°C 130
80
140
85
135
80
140
80
145
85
Flue gas mass flow RL
PL
kg/h 166,2
62,3
207,8
75,4
255,6
90
277,2
97,2
298,8
104,4
Flue gas mass flow RL
PL
kg/s 0,046
0,017
0,058
0,021
0,071
0,025
0,077
0,027
0,083
0,029
Feed pressure required RL
PL
Pa 5
2
5
2
5
2
5
2
5
2
Feed pressure required RL
PL
mbar 0,05
0,02
0,05
0,02
0,05
0,02
0,05
0,02
0,05
0,02
Flue pipe diameter mm 200 200 200 200 200
RL = Rated load, PL = Partial load;

Technology
Dimensions - T4
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2Technology
2.1 Dimensions - T4
Item Description Unit 24/30 40/50 60/75 90/100/110
H Height of boiler 1390 1620 1620 1720
H1 Total height including flue gas
pipe connection
mm 1440 1670 1670 1770
Height, outfeed connection mm 1195 1425 1425 1530H2
Boiler outfeed connection Zoll 6/4 6/4 6/4 2
Height, return connection mm 270 270 270 170H3
Boiler return connection Zoll 6/4 6/4 6/4 2
Height, drainage connection mm 140 140 140 140H4
Boiler drainage connection Zoll 1/2 1/2 1/2 1
H5 Height, rotary valve connection mm 580 650 650 650
B Width of boiler 600 770 770 880
B1 Total width with stoker unit 1360 1530 1530 1640
B2 Width, stoker unit 760 760 760 760
B3 Distance from boiler side to
stoker connection
mm
470 470 470 470
L Length, boiler 1200 1200 1570 1570
L1 Total length including ash
container and ID fan
1430 1430 1920 1920
L2 Length from back side of boiler
to stoker connection
mm
755 755 1045 1045

Technology
Technical specifications
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2.2 Technical specifications
T4
Description Unit 24 30 40 50
Rated heat output 24 30 40 50
Heating efficency range kW 7,2-24,0 9,0-30,0 12,0-40,0 15,0-50,0
Electrical connection 400V / 50Hz / C20A
Electrical consumption W 45 - 115 54 - 142 51 - 150 47 - 158
Boiler weight kg 620 640 840 860
Boiler water capacity l 105 105 160 160
Upstream resistence (ΔT= 10 / 20°C) mbar 3,9 / 1,2 4,8 / 1,4 5,2 / 1,8 5,5 / 2,2
Minimum return temperature 45
Maximum permitted boiler operating
temperature
°C 90
Permitted operating pressure bar 3
Airborne sound level dB(A) < 70
Boiler class according to EN 303-5: 1999
(pr EN 303-5: 2012)
3 (5)
Permitted fuel according to EN 149611) Part 2: wood pellets class A1 / D06
Part 4: wood chips class A2 / P16A-P45A
Test report data
Testing institute TÜV 2) 3) 4) TÜV
2)
Test report no. 10-UW/
Wels-EX-
191/2
10-UW/
Wels-EX-
191/4
- 10-UW/
Wels-EX-
191/5
Test data – Fuel wood chip RL PL RL PL RL PL RL PL
Carbon monoxide (CO) [mg/MJ] 9 / 28 35 / 28 24,5 / 34 14 / 40
Nitrogen oxide (NOx) [mg/MJ] 70 / - 92 / - 88 / - 84 / 64
Organic Hydrocarbons (OGC) [mg/MJ] <1 / 1,3 <1 / 1,3 <1 / <2 <1 / <1
Dust [mg/MJ] 13 / - 13 / - 11,5 / - 10 / 7
Boiler efficiency rating [%] 92,3 / 91,6 91,0 / 91,6 92,1 / 92,4 93,1 / 93,2
Test data – Fuel pellets RL PL RL PL RL PL RL PL
Carbon monoxide (CO) [mg/MJ] 8 / 69 7 / 23 <6 / 18 <4 / 12
Nitrogen oxide (NOx) [mg/MJ] 70 / - 72 / - 72 / - 71 / 54
Organic Hydrocarbons (OGC) [mg/MJ] <1 / 1,4 <1 / <1 <1 / <1 <1 / <1
Dust [mg/MJ] 11 / - 12 / - 10,5 / - 9 / 6
Boiler efficiency rating [%] 92,2 / 91,0 92,0 / 91,4 93,1 / 92,3 94,2 / 93,2
1) Detailed information on the fuel is included in the operating instructions, in the section on “Permitted fuels”
2) TÜV Austria Services GmbH, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels
3) In accordance with ÖNORM / DIN EN 303-5, Kap. 5.1.3 type test: for a boiler from a range with a consistent structure it
is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤2 : 1, to carry out the tests with
the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not
been tested in a range, whose values have been determined depending on rated heat output by interpolation, fulfil the
requirements of the norm.
4) Values of the model T4 - 40 are interpolated between the test protocol 10-UW/Wels-EX-191/4 and 10-UW/Wels-EX-
191/5!

Technology
Technical specifications
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T4
Description Unit 60 75 90 100 110
Rated heat output 60 75 90 100 110
Heating efficiency range kW 18 – 60 22,5 – 75 27 – 90 30 – 100 33 - 110
Electrical connection 400V / 50Hz / C20A
Electrical consumption W 51 - 176 56 - 204 61 - 232 65 - 250 65 - 250
Boiler weight kg 1060 1060 1350 1360 1370
Boiler water capacity l 220 220 260 260 260
Upstream resistence
(ΔT= 10 / 20°C) mbar 7,8 / 2,6 11,4 / 3,2 14,9 / 3,8 17,2 / 4,2 18,7 / 5,2
Minimum return temperature 45
Maximum permitted boiler
operating temperature
°C 90
Permitted operating pressure bar 3
Airborne sound level dB(A) < 70
Boiler class according to
EN 303-5:1999 (pr EN 303-5: 2012)
3 (5)
Permitted fuel according to EN 149611) Part 2: wood pellets class A1 / D06
Part 4: wood chips class A2 / P16A-P45A
Test report data
Testing institute 2) 3) TÜV
4) TÜV 4)
Test report no. - 10-UW/
Wels-EX-
191/6
10-UW/
Wels-
EX-
191/7
Test data- Fuel wood chip RL PL RL PL RL PL RL PL RL PL
Carbon monoxide (CO) [mg/MJ] 12,6 / 33,2
10,5 / 23 8,4 / 12,8
7 / 6 7 / 6
Nitrogen oxide (NOx) [mg/MJ] 82 / 65 79 / 68 76 / 70 74 / 71 74 / 71
Organic Hydrocarbons
(OGC) [mg/MJ]
<1 / <1 <1 / <1 <1 / <1 <1 / <1 <1 / <1
Dust [mg/MJ] 10,6 / 7,6 11,5 / 8,5 12,4 / 9,4 13 / 10 13 / 10
Boiler efficiency rating [%] 93,1 / 93,3 93,0 / 93,6 92,9 / 93,8 92,9 / 93,9 92,9 / 93,9
Test data – Fuel pellets RL PL RL PL RL PL RL PL RL PL
Carbon monoxide (CO) [mg/MJ] 5 / 11,6
6,5 / 11 8 / 10,4
9 / 10 9 / 10
Nitrogen oxide (NOx) [mg/MJ] 70 / 53 69 / 53 68 / 52 67 / 51 67 / 51
Organic Hydrocarbons
(OGC) [mg/MJ]
<1 / <1 <1 / <1 <1 / <1 <1 / <1 <1 / <1
Dust [mg/MJ] 10 / 7 11,5 / 8,5 13 / 10 14 / 11 14 / 11
Boiler efficiency rating [%] 94,1 / 93,5 93,9 / 93,9 93,8 / 94,3 93,7 / 94,6 93,7 / 94,6
1) Detailed information on the fuel is included in the operating instructions, in the section on “Permitted fuels”
2) In accordance with ÖNORM / DIN EN 303-5, Kap. 5.1.3 type test: for a boiler from a range with a consistent structure it
is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤2 : 1, to carry out the tests with the
smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not been
tested in a range, whose values have been determined depending on rated heat output by interpolation, fulfil the
requirements of the norm.
3) Values of the models T4-60, T4-75 and T4-90 are interpolated between the test protocol 10-UW/Wels-EX-191/5 and
10-UW/Wels-EX-191/6!
4) TÜV Austria Services GmbH, Environment and Chemistry Division, Am Thalbach 15, A-4600 Thalheim/Wels

Assembly
Transport
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3Assembly
3.1 Transport
The boiler comes in cardboard packaging on 2 pallets together with the
fuel outfeeder.
Move the boiler without jarring or jolting
Consult the delivery information on the packaging.
3.1.1 Positioning
Position a lifting truck or similar lifting device with an appropriate
load-bearing capacity at the pallet and position the boiler
If it is not possible to position the boiler on the pallet:
Remove the cardboard and remove the boiler from the pallet
See 3.2.1 Removing the boiler from the pallet
Positioning using a crane (T4 24-50)
Remove the insulating cover and the insulating mat
Loosen the lock nut on the star-shaped screw knob
Unlock the cover by turning the star-shaped screw knob and remove
the cover
Pull out the guide plate
The two lifting eye bolts (E) for the boiler are located under the
guide plate
E
E

Assembly
Set-up in the boiler room
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Positioning using a crane (T4 60-110)
Remove the insulating cover and the insulating mat
The lifting eye bolts (E) for the boiler is in front of heat-exchanger
cover plate below the mat
Tip: To avoid damage, for transport remove also the cover plate of
the controller
3.1.2 Temporary storage
If the system is to be installed at a later date:
Store the boiler in a protected location, which is dry and free of dust
Moisture can reduce the effectiveness of the thermal insulation
and destroy electronic components!
3.2 Set-up in the boiler room
3.2.1 Removing the boiler from the pallet
Remove securing devices used during transportation on the left and
right side of the boiler
Pull out the floor insulation
Lift the boiler off the pallet
3.2.2 Moving the boiler in the boiler room
Position a lifting truck or similar lifting device with an appropriate
load-bearing capacity at the base frame of the boiler and lift
Set up boiler at intended location
Observe the minimum distances in the boiler room (see 3.2.3).
E

Assembly
Set-up in the boiler room
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3.2.3 Minimum distances in the boiler room
The boiler should always be set up so that it is fully accessible to
allow fast and easy maintenance.
Observe the applicable standards and regulations when setting up
the boiler.
Observe additional standards for noise protection
(ÖNORM H 5190 - Noise protection measures)
Description Unit 24/30 40/50 60/75 90-110
A Distance to wall
opposite stoker 600 800 800 900
B Maintenance area for
ID fan 200 200 200 200
C Distance from stoker
unit to wall 500 500 500 500
D Maintenance area on
operating side 300 300 300 300
Minimum room height
mm
1700 1900 1900 2150

Assembly
Assembly work
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3.3 Assembly work
3.3.1 Installing the ash container
Open the clamps on the ash
container cover and remove the
cover
Remove the items included with
delivery from the ash container
Open the insulating door and pull the locking lever up
Place the ash container in the boiler and clamp with the locking lever
Replace the cover and secure with
the clamps
Make sure that the pin (P) is
inserted in the limit switch (L)
correctly
P
L

Assembly
Assembly work
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3.3.2 Installing the stoker unit
Remove the upper and lower shutter mask on the stoker side
Remove the pre-installed screws on the connection flange
Position the stoker unit by the boiler as shown
Push the stoker unit up to the boiler and insert the two lock bolts
(LB) into the connection flange
Adjust the height of the stoker if necessary using the adjustable
feet
Secure the unit to the boiler by means of the previously removed
screws
Place the hose clamp included with delivery on the ignition tube
Push the ignition fan into the ignition tube and secure with the hose
clamp
LB

Assembly
Electrical connection
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3.4 Electrical connection
DANGER
Working on electrical components
Risk of serious injuries from electric shocks
Work on electrical components should only be carried out by authorised
technicians
3.4.1 Removing the controller cover
Remove the insulating cover and the insulating mat
Remove the locking screws on the controller cover
Push the controller cover back and then lift away
At T4 60-110:
After removing the locking srews move both covers backward an
then lift up the controller cover (= front part)