Froling Lambdamat LM 1000 User manual

Installation Instructions
Lambdamat LM 1000
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1650115_en | Edition 21/10/2015
Froling GesmbH | Industriestraße 12 | www.froeling.com

Table of contents
1 General 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 Personal protective equipment for assembly staff 6
2.4 Design Information 6
2.4.1 Notes on standards 6
General standards for heating systems 6
Standards for structural and safety devices 7
Standards for heating water 7
Regulations and standards for permitted fuels 7
2.4.2 Installation and approval of the heating system 7
2.4.3 General information for installation room (boiler room) 8
2.4.4 Requirements for central heating water 8
2.4.5 Notes for using pressure maintenance systems 9
2.4.6 Return lift 10
2.4.7 Use with storage tank 10
2.4.8 Chimney connection/chimney system 10
Draught limiter 11
Boiler data for planning the flue gas system 11
3 Technical information 12
3.1 Dimensions 12
3.2 Components and connections 13
3.3 Technical specifications 14
4 Installation 15
4.1 Transport 15
4.2 Temporary storage 15
4.3 Positioning 15
4.3.1 Fitting the ash duct for removing ash from the combustion chamber (optional) 16
4.4 Setting up in the boiler room 16
4.4.1 Moving the boiler in the boiler room 16
4.4.2 Minimum distances in the boiler room 16
4.5 Laying firebricks in the combustion chamber 19
4.5.1 Fireclay lining overview 19
4.5.2 General 20
4.5.3 Laying rows of bricks 1 to 5 21
4.5.4 Laying rows of bricks 6 to 9 23
4.5.5 Laying rows of bricks 10 to 15 24
4.5.6 Laying rows of bricks 16 to 24 26
4.5.7 Laying the arch 28
4.6 Installing the boiler 29
4.6.1 General information 29
4.6.2 Bolting together the combustion chamber and heat exchanger 29
4.6.3 Removing the various blanking plugs and fitting the igniter tube for the automatic ignition
(optional).
30
Table of contents
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4.6.4 Fitting the immersion sleeves for the thermal discharge valve and undergrate sensor. 31
4.6.5 Installing the stoker unit 31
4.6.6 Installing the hydraulic stoker unit 32
4.6.7 Installing the air controllers 32
4.6.8 Fitting thermal insulation to the boiler 34
4.6.9 Fitting the insulation base frame 35
4.6.10 Fitting the insulating side panels and STL 38
4.6.11 Fitting various covers 40
4.6.12 Fitting the door contact switch 41
4.6.13 Fitting the combustion chamber ash removal unit (optional) 43
4.6.14 Installing the underpressure controller 45
4.6.15 Installing the combustion chamber overpressure and temperature sensors 46
4.6.16 Fitting the broadband probe and various sensors. 47
4.6.17 Installing the servo-motors 48
4.6.18 Fitting the combustion air fan 49
4.6.19 Fitting the automatic ignition (optional) 49
4.6.20 Fitting an additional ignition for hydraulic stoker unit (optional) 50
4.6.21 Fitting the reversing chamber door 50
4.6.22 Fitting the compressed air cleaner (optional) 52
4.6.23 Fitting the ash sliding system (optional) 53
4.6.24 Fitting the flue gas recirculation (FGR) (optional) 54
4.7 Flue gas piping 58
4.8 Power connection and wiring 59
4.8.1 Potential equalisation 59
4.9 Connecting the hydraulic safety devices 60
4.10 Connecting up the slide-on duct cooling 61
4.11 Final installation steps 62
4.11.1 Setting and checking the seal on the doors 62
4.11.2 Adjusting the doors 63
5 Commissioning 64
5.1 Before commissioning / configuring the boiler 64
5.2 Initial startup 65
5.2.1 Permitted fuels 65
Wood chips 65
Wood pellets 65
Wood shavings 65
Miscanthus 66
Changing the fuel 66
5.2.2 Non-permitted fuels 66
5.3 Heating up for the first time 67
5.3.1 Screed drying 68
6 Decommissioning 69
6.1 Out of service for long periods 69
6.2 Disassembly 69
6.3 Disposal 69
7 Appendix 70
7.1 Addresses 70
7.1.1 Address of manufacturer 70
7.1.2 Address of the installer 70
Table of contents
Installation Instructions | M1650115_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.
The EC Declaration of Conformity is only valid in conjunction with a delivery certificate,
which has been filled in correctly and signed as part of the commissioning process.
The original document remains at the installation site. Commissioning installers or
heating engineers are requested to return a copy of the delivery certificate together
with the guarantee card to Froling. On commissioning by FROLING Customer Service
the validity of the delivery certificate will be noted on the customer service record.
Issuing a delivery
certificate
1General
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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
Installation Instructions | M1650115_en 5

2.2 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.
2.3 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 Design Information
2.4.1 Notes on standards
The system must be installed and commissioned in accordance with the local fire and
building regulations. Unless contrary to other national regulations, the latest versions
of the following standards and guidelines apply:
General standards for heating systems
EN 303-5 Boilers for solid fuels, manually and automatically fed
combustion systems, nominal heat output up to 500 kW
EN 12828 Heating systems in buildings - design of water-based heating
systems
EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods
Part 1: Chimneys serving one appliance
2Safety
Qualification of assembly staff
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ÖNORM H 5151 Planning of central hot water heating systems with or without hot
water preparation
ÖNORM M 7510-1 Guidelines for checking central heating systems
Part 1: General requirements and one-off inspections
ÖNORM M 7510-4 Guidelines for checking central heating systems
Part 4: Simple check for heating plants for solid fuels
Standards for structural and safety devices
ÖNORM H 5170 Heating installation - Requirements for construction and safety
engineering, as well as fire prevention and environmental
protection
TRVB H 118 Technical directives for fire protection/prevention (Austria)
Standards for heating water
ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in
closed warm water heating systems at operating temperatures
up to 100 °C (Austria)
VDI 2035 Prevention of damage in water heating systems (Germany)
SWKI 97-1 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
D.P.R. n° 412 Regulations for the planning, installation, running/operation and
maintenance of heating systems in buildings to reduce energy
consumption with reference to Article 4, Comma 4 of the
Legislative Decree of 9 January 1991, No. 10 (Italy)
Regulations and standards for permitted fuels
1. BImSchV First Order of the German Federal Government for the
implementation of the Federal Law on Emission Protection
(Ordinance on Small and Medium Combustion Plants) in the
version published on 26 January 2010,
BGBl. JG 2010 Part I No. 4.
EN ISO 17225-2 Solid bio-fuel - Fuel specifications and classes
Part 2: Wood pellets for use in industrial and domestic systems
EN ISO 17225-4 Solid bio-fuel - Fuel specifications and classes
Part 4: Wood chips for non-industrial use
2.4.2 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.
Note on standards
Safety 2
Design Information
Installation Instructions | M1650115_en 7

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 sweep / the building
authorities.
2.4.3 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 light‐
ing 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
2.4.4 Requirements for central heating water
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195
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.
Note on standards
Note on standards
2Safety
Design Information
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Observe the standards and also follow the recommendations below:
❒Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (equivalent to
5.6 dH)
❒ Use prepared water which complies with the standards cited above for filling and
makeup water
❒ Avoid leaks and use a closed heating system to maintain water quality during
operation
2.4.5 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required
pressure within predefined limits and balance out volume variations caused by
changes in the hot-water temperature. Two main systems are used:
Compressor-controlled pressure maintenance
In compressor-controlled pressure maintenance units, a variable air cushion in the
expansion tank is responsible for volume compensation and pressure maintenance. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen
into the heating water.
Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressure-
maintenance pump, relief valve and an unpressurised receiving tank. The valve
releases hot water into the receiving tank if the pressure is too high. If the pressure
drops below a preset value, the pump draws water from the receiving tank and feeds it
back into the heating system. Pump-controlled pressure maintenance systems with
open expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via the
surface of the water, exposing the connected system components to the risk of
corrosion. These systems offer no oxygen removal for the purposes of corrosion
control as required by VDI 2035 and in the interests of corrosion protection should not
be used.
Safety 2
Design Information
Installation Instructions | M1650115_en 9

2.4.6 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).
2.4.7 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 70]
2.4.8 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.
The flue gas temperatures (for clean systems) and additional flue gas values can be
found in the table below.
The connection between the boiler and the chimney system should be as short as
possible. The upward angle of the connection should not exceed 30 - 45°. Insulate the
connection. The entire flue gas system - chimney and connection - should be
calculated in accordance with EN 13384-1.
Local regulations and other statutory regulations also apply.
NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney
sweep.
2Safety
Design Information
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Draught limiter
We generally recommend the installation of a draught limiter. A draught limiter must
be installed if the maximum permissible feed pressure as given in the boiler data for
planning the flue gas system is exceeded.
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the
pressure is constantly low at this point.
Boiler data for planning the flue gas system
Description Lambdamat LM 1000
Flue gas temperature at nominal load °C 220
Flue gas temperature at partial load 160
Flue gas mass flow with wood chip W30, 13% O2m3/h
(kg/h)
6769 (4783)
Flue gas mass flow with wood chip W30, 9% O24123 (2906)
Flue gas mass flow with wood pellets 13% O25590 (3984)
Flue gas mass flow with wood pellets 9% O23422 (2444)
Required feed pressure at outlet of induced
draught housing at nominal load
Pa 5
mbar 0.05
Required feed pressure at outlet of induced
draught housing at partial load
Pa 2
mbar 0.02
Maximum permissible feed pressure Pa 50
mbar 0.5
Flue gas pipe diameter mm 450
Safety 2
Design Information
Installation Instructions | M1650115_en 11

3 Technical information
3.1 Dimensions
B4 B5L3
Item Description Unit LM 1000
Excluding base1) Including base1)
HHeight, boiler mm 3625 38852)
H1 Height, flow/return connection mm 3482 37422)
H2 Height, flue gas pipe connection mm 3298 35582)
H3 Height, stoker including burn back protection system
(wood chips BBF 300)
mm 1053 13132)
BWidth, boiler mm 1650
B1 Width, combustion air fan mm 461
B2 Width, automatic ignition (optional) /
combustion chamber temperature sensor
mm 260
270
B3 Width, compressed air cleaner (optional) mm 845
B4 Width, FGR mm 1063
B5 Width, ash container (optional) mm 1262
LLength, boiler incl. reversing chamber door mm 3538
L1 Length, compressed air cleaner (optional) mm 295
L2 Length, flue gas collection box mm 293
L3 Length, stoker unit (wood chips BBF 300) mm 1282
SBase1) - minimum height mm 260
1.If ash is to be removed from the boiler via an ash screw, a base must be provided by the customer beneath the boiler.
2.If the base is higher than 260 mm (minimum height), the difference between the actual base height and the minimum height must be added to this value
3Technical information
Dimensions
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3.2 Components and connections
E
Item Description Unit LM 1000
ABoiler flow connection Inches DN125 / PN 6
BBoiler return connection Inches DN125 / PN 6
CSafety battery connection Inches 1” ET
DFlue gas pipe connection mm 450
EFGR (flue gas recirculation) connection mm 300
FBroadband probe connection -
GFlue gas temperature sensor connection -
HSafety valve connection (provided by the customer) DN65 / PN 6
IDrainage connection Inches 2“ IT
Technical information 3
Components and connections
Installation Instructions | M1650115_en 13

3.3 Technical specifications
Description LM 1000
Nominal output kW 980
Heat output range kW 295-980
Nominal fuel heating efficiency with wood chips kW 1089
Efficiency at nominal load / partial load % 90,0 / 90,3
Quantity of fuel required at nominal load kg/h 317
Electrical connection 400V / 50Hz
Electric fuses1) A as per circuit diagram
Electrical power consumption W as per circuit diagram
Total weight excl. fittings kg 13000
Weight – retort kg 3700
Weight - heat exchanger kg 4600
Weight - fireclay kg 4700
Heat exchanger water capacity l 2390
Water pressure drop (ΔT = 20 / 10 K) mbar 27 / 81
Flow rate (ΔT = 20 / 10 K) m³/h 43 / 86
Minimum boiler return temperature °C 65
Maximum permitted operating temperature °C 90
Maximum permitted operating pressure bar 6
Min. supply air opening as per Austrian Standard
ÖNORM H5170
cm22178
Permitted fuel as per EN ISO 17225 2) Part 2: Wood pellets class A1 / D06
Part 4: Wood chips class A2 / P16S-P45S
Airborne sound level dB(A) < 70
1.Electric fuses and power consumption vary depending on design and features
2.Detailed information on the fuel is included in the operating instructions, in the section on “Permitted fuels”
3Technical information
Technical specifications
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4 Installation
4.1 Transport
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
❒ Unloading, positioning and installation should only be performed by trained
professionals! Staff must be trained in techniques for moving heavy loads
(correct tools and lifting equipment, hooking and slinging points, etc.)
4.2 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!
4.3 Positioning
❒ Secure the slings or chains to the hooking point securely and position the boiler
Installation 4
Transport
Installation Instructions | M1650115_en 15

4.3.1 Fitting the ash duct for removing ash from the combustion chamber (optional)
NOTICE! If ash is to be removed from the boiler via an ash screw, a base must be
provided by the customer beneath the boiler.
⇨ See "Dimensions" [page 12]
If an ash screw (optional) is provided for removing ash from the combustion chamber,
the ash duct should be fitted as follows when the ash combustion chamber is being
positioned.
❒ Fit the ash duct on the underside of the combustion chamber
4.4 Setting up in the boiler room
4.4.1 Moving the boiler in the boiler room
❒ Position a fork-lift or similar lifting device with a suitable load-bearing capacity at
the base frame
❒Lift and transport to the intended position in the installation room
➥Observe the minimum distances in the boiler room.
4.4.2 Minimum distances in the boiler room
▪ The system should generally be set up so that it is accessible from all sides
allowing quick and easy maintenance.
▪Regional regulations regarding necessary maintenance areas for inspecting the
chimney should be observed in addition to the specified minimum distances!
▪ Observe the applicable standards and regulations when setting up the system.
▪ Observe additional standards for noise protection
(ÖNORM H 5190 - Noise protection measures)
4Installation
Positioning
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Lambdamat 1000 without ash box/ash screw
A
B
D
C
Item Description Unit LM 1000
ADistance between stoker and wall mm 500
BDistance between side of boiler and wall 900
CDistance between reversing chamber door and wall 3380
DDistance between side of boiler (Multicyclone) and wall 1500
Minimum room height 4000
Installation 4
Setting up in the boiler room
Installation Instructions | M1650115_en 17

Lambdamat 1000 with ash box/ash screw
A
B
D
C
Item Description Unit LM 1000
ADistance between stoker and wall mm 500
BDistance between side of boiler and wall 1500 (2100)1)
CDistance between reversing chamber door and wall 3380
DDistance between side of boiler (Multicyclone) and wall 2100 (1500)1)
Minimum room height 4000
1.The side of the boiler on which the ash screw is pulled out for maintenance (B or D) should be positioned at least 2100mm from the wall so
that the ash screw can be pulled the whole way out.
4Installation
Setting up in the boiler room
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4.5 Laying firebricks in the combustion chamber
4.5.1 Fireclay lining overview
1
2
3
4
55
6
3
7
8
9
10
13
10
7
8
9
3
6
5
5
11
27
28
29
25
26
23
24
16
17
18
22
21
20
19
16-30
12
30
15
15 14
14
14
14
Item units Description Item units Description
1 1 Combustion chamber base frame 16 80 Ceramic fibre mat B
2 1 Firebrick lining 17 2 Expansion joint brick A (AK60–64x124x187mm)
3 3 Insulating panel A (30x634x1200mm) 18 4 Expansion joint brick B (AK60–64x124x250mm)
4 1 Insulating panel B (30x950x1200mm) 19 62 Expansion joint brick C (A40t–64x124x187mm)
5 4 Insulating panel C (30x308x634mm) 20 52 Expansion joint brick D (A40t–64x124x250mm)
6 2 Insulating panel D (30x634x1200mm) 21 100 Normal brick A (AK60)
7 2 Insulating panel E (30x616x950mm) 22 403 Normal brick (A40t)
8 2 Insulating panel F (30x950x1200mm) 23 20 Plate (A40t)
9 2 Insulating panel G (30x950x1200mm) 24 4 Crossbar A (124x130x1182mm)
10 2 Insulating panel H (30x290x404mm) 25 1 Crossbar B (124x196x1182mm – fuel feed-in)
11 1 Insulating panel I (30x88x1200mm) 26 4 Crossbar C (124x196x1182mm)
12 1 Insulating panel J (30x950x1200mm) 27 8 Support A (130x198x504mm)
13 1 Insulating panel K (30x950x1200mm) 28 36 Support B (124x130x198mm)
14 30 Air nozzles 29 68 Arch brick
15 2 Ceramic fibre mat A 30 34 Arch anchor brick
Installation 4
Laying firebricks in the combustion chamber
Installation Instructions | M1650115_en 19

4.5.2 General
Use Carathin K65-2 mortar where normal bricks and expansion joint bricks of AK60
quality (pieces 17, 18, 21) are being laid.
≥12mm
NOTICE! Caution: Expansion joints must be at least 12mm wide.
NOTICE! Ceramic fibre mats B (16) must always be placed between expansion joint
bricks and crossbars / between two expansion joint bricks.
❒ Shorten the length of normal bricks as required.
❒Recess and, if necessary, shorten the length and/or height of normal bricks in
places where air nozzles, the combustion chamber temperature sensor,
combustion chamber low pressure warning device and the automatic ignition are
positioned.
❒ Plates (23) serve to level off the height for the supports.
NOTICE! Normal bricks and expansion joint bricks of AK60 quality appear slightly
darker in the images of the following assembly steps.
4Installation
Laying firebricks in the combustion chamber
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