Froling Lambdamat LM 1000 SPS User manual

Operating Instructions
Lambdamat LM 1000 SPS
Translation of the original German operating instructions for the operator
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B1300015_en | Edition 11/08/2015
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of contents
1 General 5
1.1 Lambdamat LM 1000 Product Overview 6
2 Safety 9
2.1 Hazard levels of warnings 9
2.2 Pictograms used 10
2.3 General safety information 11
2.4 Permitted uses 12
2.4.1 Permitted fuels 12
Wood chips 12
Wood pellets 13
Wood shavings 13
Miscanthus 13
Changing the fuel 14
2.4.2 Non-permitted fuels 14
2.4.3 Qualification of operating staff 15
2.4.4 Protective equipment for operating staff 15
2.5 Design information 15
2.5.1 Installation and approval of the heating system 15
2.5.2 General information for installation room (boiler room) 16
2.5.3 Requirements for central heating water 16
2.5.4 Return lift 17
2.5.5 Use with storage tank 17
2.5.6 Chimney connection/chimney system 17
2.6 Safety devices 18
2.6.1 External safety devices 19
Hydraulic chamber safety switch 19
Guardrail 19
2.7 Residual risks 20
2.8 Emergency procedure 21
2.8.1 Overheating of the system 21
2.8.2 Smell of flue gas 22
2.8.3 Fire in the system 22
3 Operating the system 23
3.1 Assembly and initial startup 23
3.2 Filling the store space with fuel 24
3.2.1 Loading of fuel for a partially emptied store with rotary agitator 25
3.2.2 Loading fuel in an empty store space with a rotary agitator 25
Rotary agitator with combined drive system 26
Rotary agitator with separate drive system (optional) 26
3.2.3 Blowing in fuel for a partially emptied store with rotary agitator 27
3.2.4 Blowing in fuel for an empty store with rotary agitator 27
Rotary agitator with combined drive system 28
Rotary agitator with separate drive system (optional) 29
3.2.5 Blowing in pellets for a store with pellet screw 29
3.2.6 Loading fuel in a store space with a sliding floor discharge unit 29
3.2.7 Loading fuel in a store space with a horizontal screw discharge unit 30
3.2.8 Loading fuel in a store space with an inclined screw discharge unit 30
Table of contents
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3.3 Heating up the boiler 31
3.3.1 Switching on the power supply 31
3.3.2 Switching on the boiler 31
3.3.3 Controlling the boiler 31
3.3.4 Switching off the boiler 31
3.3.5 Switching off the power supply 32
4 Servicing 33
4.1 General information on servicing 33
4.2 Inspection 35
4.2.1 Checking the system pressure 35
4.2.2 Checking the thermal discharge safety device 35
4.2.3 Checking the safety valve 35
4.2.4 Checking the geared motors 35
4.2.5 General visual inspection 36
4.3 Cleaning 37
4.3.1 Emptying the combustion chamber ash container (optional) 37
4.3.2 Cleaning the combustion and burning chamber 39
Cleaning the burning chamber 40
Cleaning the combustion chamber 40
4.3.3 Emptying the multicyclone ash container 41
4.4 Periodic inspection and cleaning 42
4.5 Periodic inspection and cleaning (approx. 1,000 hrs) 43
4.5.1 Cleaning the ash transfer chamber 43
4.5.2 Cleaning the broadband probe 44
4.5.3 Cleaning the flue gas temperature sensor 44
4.5.4 Cleaning the flue gas recirculation (FGR) duct 45
4.5.5 Checking the heat exchanger 45
4.5.6 Cleaning the area under the moving grate 46
4.6 Periodic inspection and cleaning (approx. 3,000 hrs) 47
4.6.1 Cleaning the combustion air fan 47
4.6.2 Checking the seal of the cleaning port doors 47
4.6.3 Checking the seal of the reversing chamber door 48
4.6.4 Checking the position and seal of the burning and combustion chamber door 48
4.6.5 Positioning the burning chamber and combustion chamber door 49
4.6.6 Cleaning the fireclay elements 50
4.6.7 Checking the underpressure controller 51
4.6.8 Checking the combustion chamber overpressure sensor 52
4.6.9 Cleaning the FGR blower fan 52
4.6.10 Cleaning the induced draft fan 53
4.6.11 Lubricating the bearings 53
4.6.12 Checking the flue gas pipe 53
4.7 Maintenance instructions for hydraulic system 54
4.8 Emissions measurement by chimney sweep or regulatory body 55
4.9 Maintenance agreement / Customer service 55
4.10 Replacement parts 55
4.11 Disposal information 56
4.11.1 Disposal of the ash 56
4.11.2 Disposal of system components 56
5 Troubleshooting 57
5.1 General faults in the power supply 57
Table of contents
Operating Instructions | B1300015_en 3

5.1.1 Behaviour of system after a power failure 57
5.2 Excessive temperature 57
5.3 Faults with fault message 57
5.3.1 Procedure for fault messages 58
5.3.2 Acknowledging a fault message 58
6 Appendix 60
6.1 Addresses 60
6.1.1 Address of manufacturer 60
6.1.2 Address of the installer 60
Table of contents
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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.
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.
General 1
Operating Instructions | B1300015_en 5

1.1 Lambdamat LM 1000 Product Overview
1 Control cabinet with integrated
controller
12 Secondary air servo-motor I
2 Main switch: switches the power
supply on and off for the entire system
13 Automatic ignition
3 SPS 4000 control panel 14 Burning chamber temperature sensor
4 Reversing chamber door 15 Thermal discharge valve connection
5 Combustion chamber door 16 Boiler return connection
6 Burning chamber door 17 Safety valve connection
7 Combustion air blower fan 18 Boiler flow connection
8 Ash container 300l (optional) 19 Flue gas recirculation (FGR)
(optional)
9 Drive for ash removal (optional) 20 Primary air servo-motor flue gas
recirculation (FGR)
10 Burning chamber overpressure
monitor
21 Secondary air servo-motor flue gas
recirculation (FGR)
11 Under-pressure controller
1General
Lambdamat LM 1000 Product Overview
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

22 Compressed air tank of compressed
air cleaner (optional)
25 Secondary air servo-motor II
23 Air distribution frame of compressed
air cleaner (optional)
26 Tertiary air servo-motor
24 Primary air actuator 27 High-limit thermostat (STL)
General 1
Lambdamat LM 1000 Product Overview
Operating Instructions | B1300015_en 7

28 Stoker duct 31 High-temperature firebrick-lined
combustion chamber
29 Burn back protection system (shown
here: burn back flap; optional: rotary
valve)
32 Multiple-pass heat exchanger
30 Moving grate 33 Cleaning door
1General
Lambdamat LM 1000 Product Overview
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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.
Safety 2
Hazard levels of warnings
Operating Instructions | B1300015_en 9

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 the Machinery Directive, signs fitted directly within the danger area
of the boiler indicate immediate hazards or safety procedures. These stickers must not
be removed or covered.
Refer to the operating
instructions
Wear safety shoes
Always wear protective gloves Wear hearing protection
Keep the doors closed Turn off the main switch
Unauthorised access prohibited No not walk on the surface
Warning - hot surface Warning - hazardous electrical
voltage
Warning - hazardous or irritant
materials
Warning - automatic boiler
startup
Hand injury warning Warning of injury to fingers or
hands, automatic fan
Cutting injury warning Warning of injury to fingers or
hands, automatic screw
2Safety
Pictograms used
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2.3 General safety information
DANGER
If the device is used incorrectly:
Incorrect use of the system can cause severe injury and damage.
When operating the system:
❒ Observe the instructions and information in the manuals.
❒ Observe the details on procedures for operation, maintenance and cleaning,
as well as troubleshooting in the individual manuals.
❒ Any work above and beyond this should be carried out by authorised heating
engineers or by Froling customer services.
WARNING
External influences:
Negative external influences, such as insufficient combustion air or non-standard
fuel, can cause serious faults in combustion (e.g. spontaneous combustion of
carbonisation gases or flash fires) which can in turn cause serious accidents!
When operating the boiler, please note the following:
❒ Instructions and information regarding 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 gas 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).
Take the following precautions:
❒ Optimum boiler performance can only be guaranteed if the flue gas system is
functioning correctly.
Safety 2
General safety information
Operating Instructions | B1300015_en 11

2.4 Permitted uses
The Froling Lambdamat is designed exclusively for heating domestic water. Only use
fuels specified in the "Permitted fuels" section.
⇨ See "Permitted fuels" [page 12]
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.
2.4.1 Permitted fuels
Wood chips
Criterion ÖNORM M 7133 EN ISO 17225 Description as per
ÖNORM M 7133
Water content W20 M20 air-dried
W30 M30 suitable for storage
W35 - limited suitability for
storage
W40 1) M40 1) high-moisture wood
chips
W50 1) -freshly-harvested
wood chips
Size G30 P16S Fine wood chip
G50 P31S Medium-sized wood
chip
G100 2) P45S 2) Coarse wood chips
1.partial load conditions only to a limited extent
2.for hydraulic feeders only
NOTICE! In case of operating under partial load conditions and fuels with a water
content of >W35, power consumption of less than 65% of the nominal output is not
permitted!
EU: Fuel as per EN 17225 – Part 4: Wood chips class A1 / P16S-P45S
Additional for
Germany:
Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance
(BimSchV) - applicable version)
Note on standards
2Safety
Permitted uses
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Wood pellets
Wood pellets made from natural wood with a diameter of 6 mm
EU: Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06
and/or: EN
plus / DIN plus certification scheme
General note:
Before refilling the store, check for pellet dust and clean if necessary.
Wood shavings
Wood shavings generally cause problems with combustion. Therefore their use is
permitted only with authorisation from Froling. The following additional points also
apply:
▪ Sawdust and carpentry waste should only be used with systems with a rotary
valve.
▪ The store should be fitted with a pressure release device in accordance with
regional regulations.
▪ The same limits apply for the permitted water content of sawdust as for wood
chips.
NOTICE
For fuels with a water content < W30 the boiler's rated heat output can only be
guaranteed if it is used with a flue gas recirculation system (FGR).
Miscanthus
Switchgrass or elephant grass (Latin name: miscanthus) is a C4 plant. Standards and
regulations for burning these plants have not been standardised, so the following
applies:
NOTICE! The regional regulations for burning miscanthus should be observed.
Operation may only be possible by special permit.
Note on standards
Safety 2
Permitted uses
Operating Instructions | B1300015_en 13

Changing the fuel
CAUTION
Incorrect fuel parameter settings:
Incorrect parameter settings have a significant adverse effect on the functioning
of the boiler, and as a result this will invalidate the guarantee.
Therefore:
❒ If the fuel is changed (e.g. from wood chips to pellets), the system must be
reset by Froling customer services.
2.4.2 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section, 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 damage the
boiler and also invalidates the guarantee. Using non-standard fuels can also lead
to serious problems with combustion.
For this reason, when operating the boiler:
❒ Only use permitted fuels
2Safety
Permitted uses
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2.4.3 Qualification of operating staff
CAUTION
If unauthorised persons enter the 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.
2.4.4 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For inspection and cleaning:
- suitable workwear
- protective gloves
- sturdy shoes
▪ Additional for operating:
- Hearing protection (sound level > 70 dB)
- Protective goggles
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 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
ÖNORM / DIN EN 12828 Heating Systems in Buildings
NOTICE! 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: Inform the civic/municipal building authorities.
Germany: Notify an approved chimney sweep and the building authorities.
Note on standards
Safety 2
Permitted uses
Operating Instructions | B1300015_en 15

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 over 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 from 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, etc.) from obstructing the air flow.
Unless otherwise specified in the applicable building regulations for the boiler room,
the following standards apply to the design and dimensions of the air ducts:
ÖNORM H 5170 - Construction and fire protection requirements
TRVB H118 - Technical directives on fire protection/prevention
2.5.3 Requirements for central heating water
The following standards and guidelines apply:
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195-1
VDI 2035
SWKI 97-1
D.P.R. no. 412
NOTICE! Note on filling with make-up water: always bleed the filling hose before
connecting, in order to prevent air from entering the system.
Observe the standards and also follow the recommendations below:
❒Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to
5.6 dH)
❒ Use softened water as the make-up water
❒ Avoid leaks and use a closed heating system to maintain water quality during
operation
Note on standards
Note on standards
2Safety
Design information
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2.5.4 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 temperature control.
Condensation water forms an aggressive condensate when combined with
combustion residue, leading to damage to the boiler.
Take the following precautions:
❒ Regulations stipulate the use of a return temperature control.
➥The minimum return temperature is 65 °C. We recommend fitting some
sort of control device (e.g. thermometer).
2.5.5 Use with storage tank
NOTICE
In principle it is not necessary to use a storage tank for the system to run
smoothly. However, we recommend that you use the system with a storage tank,
as this ensures a continuous supply of fuel in the ideal output 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.
⇨ See "Addresses" [page 60]
2.5.6 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.
NOTICE! Please see the technical data contained in the assembly instructions for
further information about standards and regulations as well as the flue gas
temperatures when clean and the other flue gas values!
Safety 2
Design information
Operating Instructions | B1300015_en 17

2.6 Safety devices
1 BOILER OFF
(switches off the boiler to prevent overheating)
❒ Tap “Boiler off”
➥Automatic mode is switched off
➥Control system follows the boiler shutdown procedure
➥The pumps continue to run
NOTICE! Never use the main switch!
2 MAIN SWITCH
(switches off the power supply)
Before carrying out work on the boiler:
❒ Tap “Boiler off”
➥Automatic mode is switched off
➥Control system follows the boiler shutdown procedure
❒ Switch off the main switch and let the boiler cool down
3 SAFETY OVERLOAD SWITCHES, MOTOR PROTECTION SWITCHES, RESIDUAL
CURRENT PROTECTIVE DEVICES (RCD)
Switch off the related component in the event of fault currents or overloads.
4 SAFETY TEMPERATURE LIMITER (STL)
(protection against overheating)
The STL switches off the combustion system when the boiler reaches 95 - 100°C. The
pumps continue to run. Once the temperature falls to below approx. 85°C, the STL
can be reset mechanically.
5 DOOR CONTACT SWITCH
When the door is opened, the induced draught is kept at a constant speed and the
combustion air and FGR blower fan stops.
2Safety
Safety devices
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TV THERMAL DISCHARGE VALVE
(protection against overheating)
The thermal discharge valve opens at approx. 100°C and feeds cold water to the
safety heat exchanger to lower the boiler temperature
SAFETY VALVE
(not shown, supplied by the customer)
When the boiler pressure reaches a maximum of 6 bar, the safety valve opens and the
heated water is blown off in the form of steam.
2.6.1 External safety devices
Hydraulic chamber safety switch
Before starting any maintenance work in the hydraulic chamber of the sliding floor:
❒ Turn the safety switch to the "0" position
➥The boiler follows the shutdown procedure and the discharge is deactivated
❒ Turning the selector switch past the "0" position engages the locking lever
➥The switch can be locked with a padlock to prevent it from being switched on
again
On completion of the maintenance work:
❒ Remove the padlock
❒ Turn the selector switch past the "0" position to automatically release the locking
switch. The selector switch can now be turned back to the "1" position.
❒ Acknowledge the fault and press the Start button to activate the boiler
Guardrail
When working at a height, appropriate measures must be taken in accordance with
the applicable national industrial safety guidelines to protect against the risk of falling
(e.g. ladders, platforms, etc.). It is the responsibility of the operator to select and
provide these means.
Alternatively, a railing can be fitted to the top of the boiler as per EN ISO 14122.
Safety 2
Safety devices
Operating Instructions | B1300015_en 19

2.7 Residual risks
WARNING
When touching hot surfaces:
Severe burns are possible on hot surfaces and the flue gas pipe!
When work is carried out on the boiler:
❒ Shut down the boiler in a controlled way (operating status "Switched off OFF")
and allow it to cool down
❒ Protective gloves must generally be worn for work on the boiler, and it should
only be operated using the handles provided
❒ Insulate the flue pipes or simply avoid touching them during operation.
WARNING
Opening the door to the combustion or burning chamber, or the cleaning door or
lids during operation
may result in injury or damage or flue gas generation!
Therefore:
❒ Do not open any doors or lids while the boiler is in operation!
WARNING
If non-permitted fuel types are used:
Non-standard fuels can cause serious faults in combustion (e.g. spontaneous
combustion of carbonisation gases / flash fires) which can lead to serious
accidents!
Take the following precautions:
❒ Only use fuels specified in the "Permitted fuels" section of these operating
instructions.
2Safety
Residual risks
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