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
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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
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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
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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
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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!

Safety
Permitted uses
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2.4 Permitted uses
The TX series wood chip boiler is intended exclusively for heating central
heating water. Use only the fuels specified under 2.4.2.
The boiler 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 ensure you are aware of the potential
hazards.
The inspection and cleaning intervals in these operating instructions
should be observed. Ensure that any faults, which might impair safety,
are rectified immediately.
The manufacturer or supplier is not liable for any damages 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 chimney of a building, from a furnace 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 within 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, applies in Northern Ireland. Therefore it is a requirement that
fuels burnt or obtained for use in smoke control areas have been
"authorised" in Regulations and that appliances used to burn solid fuel in
those areas (other than "authorised" fuels) have been exempted by an
Order made and signed by the Secretary of State or Minister in the
devolved 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 details of Clean Air Act requirements”
The Froling TX 150, TX 200, TX 250 have been recommended as
suitable for use in smoke control areas when burning fuels as listed
under 2.4.2

Safety
Permitted uses
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2.4.2 Permitted fuels
Wood chips
Designation as per Description as per
ÖNORM M 7133
ÖNORM
M 7133 ÖNORM/DIN CEN/TS 14961
Water
content W20 M20 Air dried
W30 M30 Suitable for storage
Size G30 P16 Fine wood chips
G50 P45 Medium wood chips
Applicable standards:
Austria: ÖNORM M 7133 or ÖNORM CEN/TS 14961
Germany: Wood chips in accordance with §3 (1) point 4 of the 1st
BImSchV in the applicable version.
Specifications as per DIN CEN/TS 14961 and/or
ÖNORM M 7133
Pellets Wood pellets made from natural wood with a diameter of 6 - 10 mm
Applicable standards:
Austria: ÖNORM M 7135 - HP 1 and/or DINplus certification
program
Germany: DIN 51731 - HP 5, DINplus certification program and/or
ÖNORM M 7135 - HP 1
Generally applicable:
Before refilling the store, check for pellet dust and clean if necessary.
§
§

Safety
Permitted uses
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Changing the fuel
CAUTION
Incorrectly set fuel parameters:
Incorrect parameter settings have a significant effect on the
functioning of the boiler, and as a result this will void the guarantee.
If the fuel is changed (e.g. from wood chips to pellets), the system must be
reset by Fröling customer services.
2.4.3 Non-permitted fuels
The use of fuels not defined under 2.4.2, and particularly the burning 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 lead to
damage to the boiler and also voids the warranty! Using non-standard fuels
can lead to severe problems with combustion.
2.4.4 Qualification of operating staff
Only trained operators are permitted to operate the boiler. The operator
must also have read and understood the instructions in the
documentation.
CAUTION
If unauthorised persons enter the boiler room:
Risk of injury and damage to equipment!
It is the responsibility of the operator to ensure that unauthorised persons,
especially children, are kept away from the boiler.
2.4.5 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by
accident prevention regulations.
During operation, inspection and cleaning of the boiler:
- Sturdy shoes
- protective gloves

Safety
Design Information
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2.5 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.
2.5.1 Heating System Installation/ Standards
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.
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 sweeper
/ the building authorities.
2.5.2 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 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 hydrogen halides or any cleaning agents containing
chlorine in the room where the boiler is installed.
Keep the air suction opening of the boiler free of dust.
§

Safety
Design Information
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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 5170
2.5.3 Requirements for heating water
There are no special requirements for the filling water of the heating
system. 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
Notice on filling with make-up water:
Always bleed the filling hose before connecting, in order to prevent
air from entering the system.
2.5.4 Combination with storage tank
NOTICE
Using a storage tank 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.
§
§

Safety
Design Information
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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.
Regulations stipulate the use of a return lift.
The minimum return temperature is 65 °C. We recommend fitting some
kind of control device (e.g. thermometer).

Safety
Safety devices
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2.6 Safety devices
1 Standby button If the boiler overheats:
Press the standby key ( )
Automatic operation is switched off and the controller
follows the boiler shutdown procedure
The pumps continue to run!
Never use the main switch!
2 Safety temperature limiter (back
of boiler) Page 18, Devices for preventing the boiler from overheating
3 Main switch
For shutting down the entire system:
Only switch off the main switch when the boiler has cooled
down and the controller is switched off (“Boiler off” status).
Turn the main switch to the “O” position
The power to all components is switched off.
Not
shown Water sprinkler system
In case of burn back, the valve of the water sprinkler system
opens and water goes into the gravity shaft as well as the duct
of the feed screw.
This need only be connected when specified by the
authorities.
1
3
2

Safety
Safety devices
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2.6.1 Devices for preventing the boiler from overheating
Thermal discharge safety device
At around 100 °C a valve opens and sends cold water to the safety
heat-exchanger to decrease the temperature.
Safety Temperature Limiter STL
Stops combustion at a max. boiler temperature of 105 °C. The pumps
continue to run.
Once the temperature has fallen below the unlocking point (approx.
95 °C), the safety temperature limiter (2) can be unlocked
mechanically.
Safety valve (provided by the customer)
Protection against over-heating/ excessive pressure:
When the boiler pressure reaches a maximum of 3 bar, the safety valve
opens and the heating water is released in the form of steam.
2

Safety
Residual risks
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2.7 Residual risks
WARNING
Touching hot surfaces!
Hot parts and the flue pipe can cause serious burns!
Always wear protective gloves when working on the boiler.
Only operate the boiler using the handles provided for this
purpose
Insulate the flue gas pipes and avoid touching them during
operation
Before carrying out maintenance work on/in the boiler:
Press and hold the service program key ( ) for 5 seconds
The controller follows the shutdown procedure and starts
with the cleaning cycle
After the cleaning cycle the boiler goes to the operating
status, “Cleaning possible”
WARNING
Opening the combustion chamber door during operation!
This may cause injury, damage and smoke!
It is forbidden to open the doors behind the insulating door
during operation!
WARNING
Use of non-permitted fuel!
Non-standard fuels can cause serious faults in combustion (e.g.
spontaneous combustion of carbonisation gases / flash fires) which
can lead to serious accidents!
Only use fuels specified in the chapter on “Permitted Uses” in
these operating instructions.

Safety
Emergency procedure
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2.8 Emergency procedure
2.8.1 System overheating
If the system overheats in spite of the safety devices, proceed as
follows:
Keep all the doors on the boiler closed.
Switch off the boiler using the standby key ( )
Under no circumstances use the main switch!
Open all mixer taps and switch on all pumps.
Fröling heating circuit control takes over this function in
automatic operation.
When using a third party controller, carry out the relevant
measures to activate the mixer and pumps manually.
Exit the boiler room and close the door
Open any available radiator thermostat valves
If the temperature does not drop, inform the installer or Fröling
customer services:
2.8.2 Smell of flue gas
DANGER
Smell of flue gas!
Flue gases can cause fatal poisoning!
Keep all the doors on the boiler closed.
Switch off the boiler using the standby key ( )
Under no circumstances use the main switch!
Ventilate the installation room
Close the door of the installation room or boiler room and
doors to living areas