Froling T4 Series User manual

Installation and Operating Instructions
Ash discharge into a standard dustbin
for T4 / TX / P4 Pellet
Translation of the original German operating and installation instructions for technicians and operators
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1590214_en | Edition 05/02/2015
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of Contents
1 General 4
1.1 Product overview 5
2 Safety 6
2.1 Hazard levels of warnings 6
2.2 Permitted uses 7
2.2.1 Area of Application 7
2.2.2 Permitted fuels 7
2.3 General safety information 7
2.4 Qualification of staff 8
2.4.1 Qualification of assembly staff 8
2.4.2 Personal protective equipment for assembly staff 8
2.4.3 Qualification of operating staff 8
2.4.4 Protective equipment for operating staff 9
2.5 Design information 9
2.5.1 Standards 9
2.5.2 General information for installation room 9
3 Technology 10
3.1 Dimensions of ash transfer box for T4 / TX 10
3.2 Dimensions of ash transfer box for P4 Pellet 11
3.3 Technical specifications 12
4 Assembly 13
4.1 Materials supplied 14
4.2 Transport 14
4.3 Temporary storage 15
4.4 Installation site 15
4.5 Assembly overview 16
4.5.1 Ash transfer box for T4 / TX 16
4.5.2 Ash transfer box for P4 Pellet 17
4.5.3 Hose with screw, supporting post and gravity shaft 18
4.5.4 Standard dustbin 19
4.6 Assembling the ash discharge system 20
4.6.1 Modifying the ash transfer box for P4 Pellet (where required) 20
4.6.2 Modifying the ash transfer box for T4 / TX (where required) 21
4.6.3 Removing the boiler ash container 21
4.6.4 Assembling the ash transfer box on the T4 / TX 21
4.6.5 Assembling the ash transfer box on the P4 Pellet 22
4.6.6 Assembling the discharge pipe and supporting post 23
4.6.7 Assembling the coreless screw and drive unit with gravity shaft 24
4.6.8 Aligning the ash discharge system 26
4.6.9 Assembling the standard dustbin 27
4.7 Connecting the system 28
4.7.1 Connecting the ash discharge system to the TX 28
4.7.2 Connecting the safety switch on the standard dustbin to the TX 28
Table of Contents
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4.7.3 Connecting the ash discharge system to the T4 29
4.7.4 Connecting the safety switch on the standard dustbin to the T4 29
4.7.5 Connecting the ash discharge system to the P4 Pellet 30
4.7.6 Connecting the safety switch on the standard dustbin to the P4 Pellet 30
5 Servicing 31
5.1 Inspection and cleaning 31
5.1.1 Checking the ash level in the dustbin 32
5.1.2 Emptying the dustbin 33
5.1.3 Checking the geared motors 34
5.1.4 Maintenance agreement / Customer service 34
5.1.5 Replacement parts 34
5.1.6 Disposal information 35
Disposal of the ash 35
Disposal of system components 35
6 Troubleshooting 36
6.1 Blockage in ash discharge on the T4/TX 36
6.2 Blockage in ash discharge on the P4 Pellet 38
7 Appendix 40
7.1 Addresses 40
7.1.1 Address of manufacturer 40
7.1.2 Address of the installer 40
Table of Contents
Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_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.
This is an incomplete machine as defined by the Machinery Directive. The incomplete
machine must only be started up when it has been confirmed that the machine, in
which the incomplete machine has been installed, conforms to the provisions of
Directive 2006/42/EC.
Compliance with the open provisions and verification of the correct installation must be
confirmed in the delivery certificate of the declaration of installation (included in
documentation).
Warranty and Guarantee Conditions
Our sale and delivery conditions will be applicable. These conditions have been made
available to customers, and customers have been made aware of them at the time of
order completion.
You can also find the guarantee conditions on the enclosed guarantee certificate.
Issuing a delivery
certificate
1General
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1.1 Product overview
E
AAsh transfer box for T4 / TX
BAsh transfer box for P4 Pellet
CCladding for P4 Pellet
(mounted onto the boiler instead of the insulated doors)
DDischarge pipe with coreless screw for transporting ash to the gravity shaft
ESupporting post for holding up and levelling the discharge pipe
FDrive unit with geared motor
GGravity shaft with flexible high-temperature hose and safety switch
H240 l standard dustbin with attachments
General 1
Product overview
Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 5

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.
2Safety
Hazard levels of warnings
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2.2 Permitted uses
Froling’s ash discharge system is only applicable to the removal of combustion
residue in the form of ash from the Froling boilers detailed in the section entitled “Area
of Application”. The ash will be discharged into the provided standard dustbin or any
other suitable recipient.
The unit should only be operated when it is in full working order. It must be operated in
accordance with the instructions, observing safety precautions, and you should ensure
you are aware of the potential hazards. The inspection and cleaning intervals in the
operating instructions must be observed. Ensure that any faults which might impair
safety are rectified immediately.
The manufacturer or supplier is not liable for any damage resulting from non-permitted
uses.
Only original spare parts or specific alternative spare parts authorised by the
manufacturer may be used. Any kind of change or modification made to the product
will invalidate its manufacturer’s CE conformity. In such cases, the product will need to
undergo new hazard evaluation procedures by the operator. The operator will then be
fully responsible for the declaration of conformity according to the valid guideline(s) for
the product and will need to attach the new CE label to the device. This person will
then assume all of the rights and responsibilities of a manufacturer.
2.2.1 Area of Application
The Froling ash discharge system can be used in conjunction with the following
Froling boilers:
▪T4 24 – 150 wood chip boiler
▪ TX 150 – 250 wood chip boiler
▪ P4 Pellet 45 – 105 pellet boiler
2.2.2 Permitted fuels
Only use the fuels permitted in the boiler. Please refer to the section entitled
“Permitted fuels” in the boiler’s assembly and operating instructions.
2.3 General safety information
❒ Refer to the safety information, information on residual risks and design
information in the installation and operating instructions for the boiler in question.
NOTICE
In addition to these instructions, please also note all specifications, safety
information and standards in the installation and operating instructions for the
boiler in question.
Safety 2
Permitted uses
Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 7

2.4 Qualification of staff
2.4.1 Qualification of assembly staff
CAUTION
Assembly and installation by unqualified persons:
Risk of personal injury and damage to property
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow appropriately qualified personnel to work on the system
Assembly, installation, initial startup and servicing must always be carried out by
qualified personnel:
- Heating technician / building technician
- Electrical installation technician
- Froling customer services
The assembly staff must have read and understood the instructions in the
documentation.
2.4.2 Personal protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For transportation, setup and assembly:
- suitable work wear
- protective gloves
- sturdy shoes (min. protection class S1P)
2.4.3 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.
2Safety
Qualification of staff
8 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.4.4 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For operation, inspection and cleaning:
- suitable work wear
- protective gloves
- sturdy shoes
2.5 Design information
Carrying out modifications to the system and changing or deactivating safety
equipment is prohibited.
Always comply with all fire, building, and electrical regulations when installing or
operating the system, in addition to following the operating instructions and mandatory
regulations that apply in the country in which the tank is operated.
2.5.1 Standards
The system must be installed and commissioned in accordance with the local fire and
building regulations. The following standards and regulations should be observed in
any case:
ÖNORM / DIN EN 60204 Safety of machines; Electrical equipment of machines, Part 1:
General requirements
TRVB H 118 Technical directives for fire protection/prevention (Austria)
ÖNORM H 5170 Construction and fire protection requirements (Austria)
ÖNORM H 5190 Heating systems - Acoustic insulation
EN ISO 13857 Safety of machines; Safety distances for maintaining a safe
distance from hazardous areas
2.5.2 General information for installation room
▪ Danger of fire due to flammable materials.
–No flammable materials should be stored near the ash discharge system.
– Flammable objects (e.g. clothing) must not be put on the system to dry.
– The floor under the system must be fire-resistant.
▪ There is a possibility of dust near the system.
Safety 2
Qualification of staff
Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 9

3 Technology
3.1 Dimensions of ash transfer box for T4 / TX
Dimensi
on
Description Unit Ash discharge system for
T4 TX
H1 Total height of ash discharge system mm 1,725
H2 Height of standard dustbin mm 1,040
H3 Height of drive unit and gravity shaft
(excluding high-temperature hose)
mm 470
H4 Height of ash transfer box mm 305 325
W1 Total width of ash discharge system mm 2,700
W2 Width of ash transfer box
incl. connection flange
mm 430
W3 Width of ash transfer box
without connection flange
mm 330
W4 Width of standard dustbin mm 600
L1 Length of ash transfer box mm 430 340
L2 Length of standard dustbin mm 725
DHose diameter mm 90
3Technology
Dimensions of ash transfer box for T4 / TX
10 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

3.2 Dimensions of ash transfer box for P4 Pellet
Dimensi
on
Description Unit Ash transfer box for P4 Pellet
45-60 70-105
H1 Total height of ash discharge system mm 1,725
H2 Height of standard dustbin mm 1,040
H3 Height of drive unit and gravity shaft
(excluding high-temperature hose)
mm 470
H4 Height of cladding mm 615
H5 Height of ash transfer box mm 165
W1 Total width of ash discharge system mm 3,295 3,465
W2 Width of ash transfer box mm 1,020 1,110
W4 Width of standard dustbin mm 600
L1 Length of ash transfer box mm 370
L2 Length of standard dustbin mm 725
DHose diameter mm 90
Technology 3
Dimensions of ash transfer box for P4 Pellet
Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 11

3.3 Technical specifications
Ash discharge system
Description Unit Ash discharge system
T4 TX P4 Pellet
Power supply to geared motor 230 V/50 Hz
Power consumption of geared motor W 180
Speed of coreless screw rpm 29
Weight of ash transfer box kg 17 14 13
Weight of gravity shaft with motor kg 14
Weight of hoses with screw kg 24
Standard dustbin
Description Unit Value
Net weight kg 37
Net weight including components kg 40
Capacity l 240
Max. load according to EN 840 kg 96
Material - Hot-dip galvanised sheet metal
Thickness of back and cover mm 1.25
3Technology
Technical specifications
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4 Assembly
CAUTION
Assembly and installation by unqualified persons:
Risk of personal injury and damage to property
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow appropriately qualified personnel to work on the system
WARNING
Working on a system which is operational/hot:
Risk of serious injuries from automatic start-up of the system and severe burns
from hot parts and the flue gas pipe!
When working on the system:
❒ always wear protective gloves
❒ only operate the boiler using the handles provided
❒ switch off the boiler by tapping “Boiler off” at the mode icon
➥The boiler follows the shutdown procedure and switches to “Boiler off”
status
❒ switch off the main switch and take precautions to prevent accidental
switching on
❒ allow the boiler to cool off for at least 1 hour
❒ once all of the tasks have been completed, turn the main switch back on and
switch the boiler on in the desired mode
Assembly 4
Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 13

4.1 Materials supplied
T4 TX
P4 Pellet
E
AAsh transfer box incl. flange for T4 FCoreless screw
BAsh transfer box incl. flange for TX GTension rings
CCladding for P4 Pellet H1 pipe bend, 1 straight pipe
DAsh transfer box incl. flange
for P4 Pellet
IGravity shaft with geared motor and
flexible high-temperature hose
ESupporting post J240 l standard dustbin with attachments
4.2 Transport
The product is delivered on pallet(s) in cardboard packaging.
NOTICE
Possibility of damage to components if handled incorrectly
❒Follow the transport instructions on the packaging
❒ Transport components with care to avoid damage
❒ Protect components against damp
❒ Pay attention to the pallet's centre of gravity when lifting
4Assembly
Materials supplied
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4.3 Temporary storage
If the system is to be assembled at a later stage:
❒Store components at a protected location, which is dry and free from dust
➥Damp conditions and frost can damage components, particularly electric ones!
4.4 Installation site
▪ In order to make it easier to empty the dustbin, the emptying point and the ash
discharge system should be located level to each other
▪The door opening at the installation site should be large enough to let the dustbin
pass easily
⇨ See "Dimensions of ash transfer box for T4 / TX" [page 10]
⇨ See "Dimensions of ash transfer box for P4 Pellet" [page 11]
▪ If the dustbin needs to be transported to the emptying point with a forklift, enough
room must be left at the installation site to let the forklift manoeuvre
Assembly 4
Temporary storage
Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 15

4.5 Assembly overview
4.5.1 Ash transfer box for T4 / TX
15 15
T4 TX
1
2
3
3
3
3
3
4
4
4
5
66
6
7
9
10
11
12
13
14
8
1
8
9
10
11
12
13
14
2
3
3
3
3
3
4
4
4
5
66
6
7
Item Qty
[units]
Description Item Qty
[units]
Description
1 1 Complete ash transfer box 9 1 Cover, complete
2 1 Welded-assembly ash transfer
box
10 1 Silicone foam seal (left)
3 5 Silicone foam seal 11 1 Silicone foam seal (centre)
4 3 Cover plate 12 1 Silicone foam seal (right)
5 1 Connection flange with guide 13 1 Sticker, “Warning! Hot
surface!”
6 3 Adjustable foot 14 1 Chain
7 1 Cover plate with edge 15 1 Key plate
8 2 Ash flap (only T4)
4Assembly
Assembly overview
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4.5.2 Ash transfer box for P4 Pellet
1
2
3
3
4
4
4
4
5
5
5
5
6
7
89
9
10
11
11
12
12 12 12
12
12
12
12
12
12
12
12
10
10
10
13
14
14
15
15
15
15
16
16 17
Item Qty
[units]
Description Item Qty
[units]
Description
1 1 Complete ash transfer box 10 4 Silicone foam seal
2 1 Welded-assembly ash transfer
box
11 2 Sticker, “Warning! Hot surface!”
3 2 Locking plate 12 12 Countersunk bolt
4 4 Pressure spring 13 1 Cladding (underneath, complete)
5 4 Flat-headed screw 14 2 Grip recess
6 1 Tension ring 15 4 Double ball catch
7 1 Ring seal 16 2 Key plate
8 1 Cover plate 17 1 Sticker, quick reference guide
9 2 Cover, complete
Assembly 4
Assembly overview
Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 17

4.5.3 Hose with screw, supporting post and gravity shaft
15
16
17
18
17
18
19
20
19
21
22
23 24
25
26
1
23
4
2
3
3
2
5
6
7
8
9
10
11
12 12
13
13
14
Item Qty
[units]
Description Item Qty
[units]
Description
1 1 Hose with screw and supporting
post
14 1 Coreless screw
2 3 Ring seal 15 1 Gravity shaft unit, complete
3 3 Tension ring 16 1 Gravity shaft bracket
4 1 Pipe bend 17 2 Silicone foam seal
5 1 Straight pipe with flange 18 2 Inspection cover
6 1 Pipe clamp 19 2 Hose clamp
7 1 Attachment bracket 20 1 High-temperature hose
8 1 Swivelling supporting post 21 1 Gravity shaft connection flange
9 1 Upper bracket 22 1 Safety switch
10 1 Support plate with rotary disc 23 1 Silicone foam seal
11 1 Ground section for supporting
post
24 1 Adapter flange
12 2 Dowel 25 1 Offset geared motor
13 2 Frame screw 26 1 Counter plate
4Assembly
Assembly overview
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4.5.4 Standard dustbin
1
2
4
3
5
67
88
9
10
11
11
12 13
13
13
13
14
15
16
Item Qty
[units]
Description Item Qty
[units]
Description
1 1 Standard dustbin with
attachments
9 1 Silicone foam seal
2 1 240 l standard dustbin 10 1 Locking plate
3 1 Rubber seal for profile 11 2 Star knob
4 1 Silicone foam seal 12 1 Bracket
5 1 Flange bracket 13 4 M6x9 flat-headed screw
6 1 Spacer plate 14 1 Clamping plate
7 1 Key plate 15 1 Bearing pin
8 2 Bush 16 1 Hooked bracket
Assembly 4
Assembly overview
Installation and Operating Instructions Ash discharge into a standard dustbin | M1590214_en 19

4.6 Assembling the ash discharge system
WARNING
Working on a system which is operational/hot:
Risk of serious injuries from automatic start-up of the system and severe burns
from hot parts and the flue gas pipe!
When working on the system:
❒ always wear protective gloves
❒ only operate the boiler using the handles provided
❒ switch off the boiler by tapping “Boiler off” at the mode icon
➥The boiler follows the shutdown procedure and switches to “Boiler off”
status
❒ switch off the main switch and take precautions to prevent accidental
switching on
❒ allow the boiler to cool off for at least 1 hour
❒ once all of the tasks have been completed, turn the main switch back on and
switch the boiler on in the desired mode
NOTICE! These instructions show how to install the ash discharge system to the right
of the boiler (when looking at it from the front). To install the system in a different
position, modify the ash transfer box and follow the same steps but to the other side of
the boiler.
4.6.1 Modifying the ash transfer box for P4 Pellet (where required)
When delivered, the cover plate is mounted to the left-hand side of the ash transfer
box (so that the ash discharge system can be mounted to the right of the boiler).
Where necessary, the ash discharge system can also be installed to the left of the P4
Pellet boiler.
Carry out the following steps to modify the ash transfer box:
❒ Remove the tension ring and the cover plate with the seal and then reassemble on
the other side
NOTICE! Make sure to complete the following steps on the opposite side!
4Assembly
Assembling the ash discharge system
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