Froling TX 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
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.
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.
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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1Product Overview 5
1.1 5
2Safety 8
2.1 Safety Information 8
2.2 Permitted uses 9
2.2.1 Permitted fuels ...............................................................................................9
Wood chips....................................................................................................9
Pellets ..........................................................................................................9
Changing the fuel.........................................................................................10
2.2.2 Non-permitted fuels.......................................................................................10
2.3 Qualification of operating staff 10
2.4 Protective equipment for operating staff 11
2.5 Design Information 11
2.5.1 Official approval and obligation to report ..........................................................11
2.5.2 Requirements for heating water ......................................................................11
2.5.3 Ventilation of boiler room ...............................................................................12
2.5.4 Heating System Installation/ Standards............................................................12
Storage tank................................................................................................12
Return lift....................................................................................................12
2.6 Safety devices 13
2.6.1 Devices for preventing the boiler from overheating ............................................14
Thermal discharge safety device.....................................................................14
Safety Temperature Limiter STL .....................................................................14
Safety valve (provided by the customer)..........................................................14
2.7 Safety information for installation room 14
2.8 Residual risks 15
2.9 Emergency procedure 16
2.9.1 System overheating.......................................................................................16
2.9.2 Smell of flue gas ...........................................................................................16
3Operating the system 17
3.1 Assembly and initial startup 17
3.2 Filling/ refilling the store with fuel 17
3.2.1 Loading wood chips in a partially emptied store .................................................17
3.2.2 Loading wood chips in an empty store..............................................................18
3.2.3 Blowing in pellets for a store with pellet screw...................................................18
3.2.4 Blowing in pellets for a partially emptied store with stirrer...................................19
3.2.5 Blowing in pellets for an empty store with stirrer ...............................................19
3.3 Heating the boiler 21
3.3.1 Switching on the system ................................................................................21
3.3.2 Switching on the boiler ..................................................................................21
3.3.3 Controlling the boiler .....................................................................................21
3.3.4 Switching off the boiler ..................................................................................21
3.3.5 Switching off the System................................................................................21
4Boiler maintenance 22

Contents
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4.1 General information on maintenance 22
4.2 Inspection and cleaning 23
4.2.1 Inspection.................................................................................................... 23
Checking the thermal discharge safety device .................................................. 23
Check safety valve ....................................................................................... 23
Check the system pressure............................................................................ 23
Check the geared motors .............................................................................. 23
4.2.2 Cleaning...................................................................................................... 24
Empty the ash container retort....................................................................... 24
Empty the heat exchanger ash container ......................................................... 25
4.2.3 Monthly inspection ........................................................................................ 26
Activate service mode................................................................................... 26
Clean the combustion chamber and combustion space....................................... 26
4.2.4 Annual inspection.......................................................................................... 28
Clean the heat-exchanger ............................................................................. 28
Clean the area below the step grate................................................................ 28
Clean the flue gas recirculation (FGR) (optional)............................................... 29
Clean the induced draught fan ....................................................................... 30
Clean the combustion air blower fan ............................................................... 30
Check the under-pressure controller ............................................................... 30
Check the combustion chamber overpressure sensor......................................... 31
Check door seals.......................................................................................... 31
Check the draught controller flap and explosion flap.......................................... 31
4.3 Instructions for measuring emissions 32
4.3.1 Measurement at rated load............................................................................. 32
Activate chimney-sweep mode....................................................................... 32
4.3.2 Measurement at partial load (if necessary) ....................................................... 32
4.4 Maintenance agreement / Customer service 33
4.5 Replacement parts 33
5Troubleshooting 34
5.1 General faults in power supply 34
5.1.1 System procedure following power failure......................................................... 34
5.2 Excessive temperature 34
5.3 Faults with fault message 35
5.3.1 Procedure for fault messages.......................................................................... 35
5.3.2 Acknowledging a fault message....................................................................... 35

General
Product Overview
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1General
1.1 Product Overview
Pos. Description Symb.
1 Wood chip boiler - Fröling TX
2 Switch cabinet with integrated Lambdatronic H 3200 controller
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): - slow green flashing light: boiler activated
- fast green flashing light: boiler deactivated
- red flashing light: 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
4.2
4.4
4
4.3
4.1
3
2
1
6
5
7

General
Product Overview
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Pos. Description Symb.
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 Symb.
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 Flue gas recirculation for step grate
23 Flue gas recirculation for tipping grate
18
20
17
21
16
22
23
19

Safety
Safety Information
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2Safety
2.1 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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2.2 Permitted uses
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. Ensure that any faults, which might impair safety, are rectified
immediately.
The TX series wood chip boiler is intended exclusively for
heating central heating water. Use only the fuels specified
under 2.2.1.
The manufacturer or supplier is not liable for any damages
resulting from non-permitted uses.
2.2.1 Permitted fuels
Wood chips
Designation as per
ÖNORM
M 7133 ÖNORM/DIN CEN/TS 14961
Description as per
ÖNORM M 7133
W20 M20 Air driedWater
content W30 M30 Suitable for storage
G30 P16 Fine wood chipsSize
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
Qualification of operating staff
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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.
2.2.2 Non-permitted fuels
CAUTION
Use of non-permitted fuels:
Burning non-permitted fuels leads to a build-up of aggressive
sedimentation and condensation, which can lead to damage to the
boiler and also voids the warranty!
All fuels not defined under 2.1.1 are considered non-permitted. Due to
various air-quality protection regulations, non-permitted fuels include:
•Chipboard waste, treated wood-wastes, pure grinding dust,
•Refuse, large quantities of paper, cardboard packaging, ...
•Coal (brown coal, anthracite coal, briquettes...)
2.3 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.

Safety
Protective equipment for operating staff
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2.4 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by
accident prevention regulations.
yDuring operation, inspection and cleaning of the boiler:
- Sturdy shoes
- protective gloves
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 Official approval and obligation to report
NOTICE
Each heating system must be officially authorised.
The appropriate supervisory authority (inspection agency) must always be
informed when a heating system is installed or modified, 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
and to the building authorities.
Other countries: Observe local regulations for authorisation
2.5.2 Requirements for heating water
The requirements for heating water are based on the following
standards:
Applicable standards:
Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1
If the system is topped up or refilled:
Prepare (soften) the water to prevent boiler scaling.
§

Safety
Design Information
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2.5.3 Ventilation of boiler room
The openings for the supply air and the exhaust air should be arranged
as close to opposite each other as possible to achieve a good thermal
draught effect.
Draw in the supply air directly from outside. Expel the exhaust air
directly outside.
Provided they are not contradicted by the relevant building regulations
room where the boiler is to be installed, the following standards apply:
Applicable standards:
- TRVB H 118
- ÖNORM H 5170
Provide a supply air cross-section of 2 cm2per kW of boiler rated output,
as per ÖNORM H 5170, but a total cross-section of at least 200 cm2
2.5.4 Heating System Installation/ Standards
The following standards govern the installation of heating systems:
Applicable standards:
ÖNORM / DIN EN 12828 Heating Systems in Buildings
Storage tank
NOTICE
A storage tank with the proper dimensions will guarantee the best boiler
operating values during the entire heating period.
Please contact your installer or Fröling directly for the right measurements for
the storage tank.
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.
§
§

Safety
Safety devices
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2.6 Safety devices
1 Automatic operation button
If the boiler overheats:
Press and hold this button for 5 seconds
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 14, 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 information for installation room
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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.
2.7 Safety information for installation room
•Danger of fire due to flammable materials. No flammable materials
should be stored near the boiler.
•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.
•The room where the boiler is installed must be frost-proof.
2

Safety
Residual risks
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2.8 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 this button 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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2.9 Emergency procedure
2.9.1 System overheating
If the system overheats in spite of the safety devices, proceed as
follows:
Keep all the doors on the boiler closed.
Turn off the boiler by pressing the button for 5 seconds
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:
2.9.2 Smell of flue gas
DANGER
Smell of flue gas!
Flue gases can cause fatal poisoning!
Keep all the doors on the boiler closed.
Turn off the boiler by pressing the button for 5 seconds
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

Operating the system
Assembly and initial startup
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3Operating the system
3.1 Assembly and initial startup
Assembly, installation and initial startup of the boiler must only be
carried out by qualified staff, and these procedures are described in the
accompanying assembly instructions.
See TX assembly instructions
NOTICE
Optimum efficiency and efficient, low-emission operation can
only be guaranteed if the system is set up by trained
professionals and observing the standard factory settings.
Take the following precautions:
Initial start-up should be carried out with an authorised installer or with
Fröling customer services.
3.2 Filling/ refilling the store with fuel
When you fill the store you should always ensure that you are using the
right fuel:
Page 9, 2.2.1 Permitted fuels
Caution:
Depending on the fuel and the fill level, different procedures must be
followed for filling the fuel store.
3.2.1 Loading wood chips in a partially emptied store
If there is still sufficient fuel in the store (the head of the stirrer is
completely covered with fuel), the store can be filled:
Load the fuel at the filling opening

Operating the system
Filling/ refilling the store with fuel
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3.2.2 Loading wood chips in an empty store
CAUTION! If the head of the stirrer is already free of material
and the arms / spring blades are extended, then the feeder
unit must be active during the filling process.
Press and hold this button for 5 seconds
“Extra heating” mode is activated
Load a small quantity of wood chips and wait at least half an hour
(preferably an hour) until the arms / spring blades are touching the
head of the stirrer
Only then should you load the remaining material
3.2.3 Blowing in pellets for a store with pellet screw
For systems with a pellet screw, the boiler must be in “OFF” status when
the store is filled. The under-pressure from the blowing could bring
smoke back into the store.
Switch off the boiler by pressing the button for 5 seconds and
allow it to cool down for at least two hours.
Close all openings to the store to seal out dust
Blow the fuel into the store

Operating the system
Filling/ refilling the store with fuel
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3.2.4 Blowing in pellets for a partially emptied store with stirrer
If there is still sufficient fuel in the store (the head of the stirrer is
completely covered with fuel), the store can be filled:
Switch off the boiler by pressing the button for 5 seconds and
allow it to cool down for at least two hours.
Close all openings to the store to seal out dust
Blow the fuel into the store
3.2.5 Blowing in pellets for an empty store with stirrer
CAUTION! If the head of the stirrer is already free of material
and the arms / spring blades are extended, then the feeder
unit must be active during the filling process, however the
boiler must be in “OFF” status.
Turn off the boiler by pressing the button for 5 seconds and
allow it to cool down for at least two hours
Close all openings to the store to seal out dust

Operating the system
Filling/ refilling the store with fuel
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Call up the “Manual operation” menu
Activate the following units in the order shown:
- Ash screw ON
- Grate tip drive ON
- Stoker FORWARD
- BBF manual ON (or Rotary valve ON)
- Oufeeder - manual FORWARD
Blow the fuel into the store
After about 5 minutes deactivate the parameter, “Outfeeder -
manual”, and the parameter “BBF manual” or “Rotary valve”
Wait until the stoker is completely emptied, and only then deactivate
the parameter, “Stoker”
If there is a fuel residue in the stoker, there is a danger of a flash
fire the next time the boiler is started, due to a excessive infeed
quantity.
Wait until all the pellets in the retort have been transported to the
ash bucket, and only then deactivate the parameter “Ash screw” and
the parameter “grate tip drive”
Remove all the pellets remaining on the grate from the combustion
chamber
If there is fuel residue in the boiler, the chamber can be damaged
the next time the boiler is started.
Empty the ash bucket after the end of the procedure
If there is fuel residue in the ash bucket, there is a danger of fire.
repeatedly