Froling TX 250 User manual

Fröling Heizkessel- und Behälterbau Ges.m.b.H  Industriestraße 12 A-4710 Grieskirchen
Tel [phone] Fax [phone] [e-mail]  www.froeling.com
Operating Instructions
TX 150 - 250
English version of operating instructions for operators.
Read and follow the instructions and safety instructions!
Subject to technical change.

Introduction
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Dear customer,
Congratulations on choosing a quality product from FRÖLING.
The FRÖLING TX wood chip boiler features a state-of-the-art design that
conforms to all currently applicable standards and testing guidelines.
Please read and observe the operating instructions and always keep
them close to the boiler for reference. They contain safety information
and all the operation and maintenance specifications needed to operate
the boiler safely, properly and economically.
The constant further development of our products means that the
pictures and content may differ slightly. If you discover any errors,
please let us know. Subject to technical change.
Document reference number B067 - Version 03 - Published 05/2012
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.

Contents
Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 3
Tel [phone] Fax [phone] [email protected] www.froeling.com B 067 03 11_en
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1General 5
1.1 Product Overview 5
2Safety 8
2.1 Hazard levels of warnings 8
2.2 Pictograms used 9
2.3 Safety Information 10
2.4 Permitted uses 11
2.4.1 The Clean Air Act 1993 and Smoke Control Areas ..............................................11
2.4.2 Permitted fuels .............................................................................................12
Wood chips..................................................................................................12
Pellets ........................................................................................................12
Changing the fuel.........................................................................................13
2.4.3 Non-permitted fuels.......................................................................................13
2.4.4 Qualification of operating staff ........................................................................13
2.4.5 Protective equipment for operating staff ...........................................................13
2.5 Design Information 14
2.5.1 Heating System Installation/ Standards.....................................................14
2.5.2 General information for installation room (boiler room) .............................14
Boiler room characteristics........................................................................14
Ventilation of the boiler room....................................................................15
2.5.3 Requirements for heating water.................................................................15
2.5.4 Combination with storage tank........................................................................15
Return lift....................................................................................................16
2.6 Safety devices 17
2.6.1 Devices for preventing the boiler from overheating ............................................18
Thermal discharge safety device.....................................................................18
Safety Temperature Limiter STL .....................................................................18
Safety valve (provided by the customer)..........................................................18
2.7 Residual risks 19
2.8 Emergency procedure 20
2.8.1 System overheating.......................................................................................20
2.8.2 Smell of flue gas ...........................................................................................20
3Operating the system 21
3.1 Assembly and initial startup 21
3.2 Filling/ refilling the store with fuel 21
3.2.1 Loading wood chips in a partially emptied store .................................................22
3.2.2 Loading wood chips in an empty store..............................................................22
3.2.3 Blowing in pellets for a store with pellet screw...................................................23
3.2.4 Blowing in pellets for a partially emptied store with stirrer...................................23
3.2.5 Blowing in pellets for an empty store with stirrer ...............................................24
3.3 Heating the boiler 25
3.3.1 Switching on the system ................................................................................25
3.3.2 Switching on the boiler ..................................................................................25
3.3.3 Controlling the boiler .....................................................................................25
3.3.4 Switching off the boiler ..................................................................................25

Contents
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3.3.5 Switching off the System ............................................................................... 25
4Boiler maintenance 26
4.1 General information on maintenance 26
4.2 Inspection and cleaning 27
4.2.1 Inspection.................................................................................................... 27
Checking the thermal discharge safety device .................................................. 27
Check safety valve ....................................................................................... 27
Check the system pressure............................................................................ 27
Check the geared motors .............................................................................. 27
4.2.2 Cleaning...................................................................................................... 28
Empty the ash container retort....................................................................... 28
Empty the heat exchanger ash container ......................................................... 29
4.2.3 Monthly inspection ........................................................................................ 30
Activate service mode................................................................................... 30
Clean the combustion chamber and combustion space....................................... 30
4.2.4 Annual inspection.......................................................................................... 32
Clean the heat-exchanger ............................................................................. 32
Clean the area below the step grate................................................................ 32
Clean the flue gas recirculation (FGR) (optional)............................................... 33
Clean the induced draught fan ....................................................................... 34
Clean the combustion air blower fan ............................................................... 34
Check the under-pressure controller ............................................................... 34
Check the combustion chamber overpressure sensor......................................... 35
Check door seals.......................................................................................... 35
Check the draught controller flap and explosion flap.......................................... 35
4.3 Instructions for measuring emissions 36
4.3.1 Measurement at rated load............................................................................. 36
Activate chimney-sweep mode....................................................................... 36
4.3.2 Measurement at partial load (if necessary) ....................................................... 36
4.4 Maintenance agreement / Customer service 37
4.5 Replacement parts 37
4.6 Disposal information 37
4.6.1 Ash disposal............................................................................................... 37
4.6.2 Disposal of system components ................................................................. 37
5Troubleshooting 38
5.1 General faults in power supply 38
5.1.1 System procedure following power failure......................................................... 38
5.2 Excessive temperature 38
5.3 Faults with fault message 39
5.3.1 Procedure for fault messages.......................................................................... 39
5.3.2 Acknowledging a fault message....................................................................... 39
6Appendix 40
6.1 Addresses 40
6.1.1 Manufacturer’s Address.................................................................................. 40
6.1.2 Installer’s address......................................................................................... 40

General
Product Overview
Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 5
Tel [phone] Fax [phone] [email protected] www.froeling.com B 067 03 11_en
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1General
1.1 Product Overview
Pos. Description
1 Wood chip boiler - Fröling TX
2 Switch cabinet with integrated Lambdatronic H 3200 controller
2.1 Selector switch for induced draft fan
3 Main switch: switch the power supply on and off for the entire system
4 Control panel of the Lambdatronic H 3200 controller
4.1 Status LED (operating status)
- green lighting: boiler activated
- green flashing (5 seconds off, 1 second on): boiler deactivated
- orange flashing: warning
- red flashing: Fault
4.2 Large graphical display to show operating statuses and parameters
4.3 Navigation keys to move around in the menus and to change the parameter values
4.4 Function keys for calling up individual boiler functions or modes directly
5 Insulated door
6 Automatic ash removal ashcan
7 Ash removal unit or second ash box with automatic heat exchanger ash removal
3
2
1
6
5
7
TX 250 only:
2.1
4.2
4.1
4.3
4.4
4

General
Product Overview
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Pos. Description
8 Fuel transport unit with top gravity shaft, burn back flap or rotary valve as a burn back protection
system and stoker screw for fuel transport
9 Automatic tipping grate
10 Combustion chamber door
11 Heat exchanger door
12 Efficiency Optimisation System (WOS) with turbulators
13 Boiler outfeed connection
14 Boiler return connection
15 Thermal discharge safety device connection
5
9
11
8
11
10
13
14
9
15
12

General
Product Overview
Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 7
Tel [phone] Fax [phone] [email protected] www.froeling.com B 067 03 11_en
1
Pos. Description
16 Automatic drive for heat exchanger cleaning
17 Induced draught fan
18 Flue gas recirculation (optional)
19 Secondary air control with actuator drive
20 Primary air control with actuator drive
21 Automatic ignition
22 Air slide for flue gas recirculation
18
20
17
21
16
19
22

Safety
Product Overview
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2Safety
2.1 Hazard levels of warnings
In these operating instructions warnings are used 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 observe the
measure!
WARNING
The dangerous situation may occur and if measures are not observed
it will lead to serious injury or death. Work with extreme caution!
CAUTION
The dangerous situation may occur and if measures are not observed
it will lead to light injuries or damage to property!

Safety
Pictograms used
Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 9
Tel [phone] Fax [phone] [email protected] www.froeling.com B 067 03 11_en
2
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 machine guidelines, signs fitted directly in the hazard
area indicate immediate hazards or safety procedures. These stickers
must not be removed or covered.
Observe the operating
instructions Wear safety shoes
Wear protective gloves Turn off the main switch
Keep the doors closed
Unauthorised access
prohibited
Hot surface warning
Hazardous electrical
voltage warning
Hazardous or irritant
materials warning
Automatic system start-
up warning
Warning of injury to
fingers or hands,
automatic fan
Warning of injury to
fingers or hands,
automatic screw

Safety
Safety Information
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2.3 Safety Information
DANGER
Non-permitted use!
Incorrect use of the boiler can cause severe injuries and damage!
The instructions and information provided in the instructions
should be observed!
Details on procedure for operation, maintenance and cleaning, as
well as troubleshooting for the boiler are included in the
individual instructions. Any further work should be carried out by
authorised heating engineers or by Fröling customer services.
WARNING
External influences!
Negative external influences, such as insufficient combustion air or a
fuel that is not permitted can cause serious faults in combustion (e.g.
spontaneous combustion of carbonisation gases or flash fires) which
can in turn cause serious accidents!
Instructions and information for 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 system, such as poor cleaning of the flue pipe
or insufficient chimney draught can cause serious faults in
combustion (such as spontaneous combustion of carbonisation gases
or flash fires)!
You can only be guaranteed of optimum performance from the boiler if the
flue gas system is running smoothly!