Wood chip boiler T4 24-150 - fgebiomass.co.uk · Wood chip boiler T4 24-150 ... 4.4 Setting up in the boiler room 19 4.4.1 Remove boiler from pallet (T4 24-110) 19 ... 4.6.2 Laying

Installation Instructions

Wood chip boiler T4 24-150

Translation of the original German operating instructions for techniciansRead and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!M1210713_en | Edition 18/11/2013

Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Contents

1 General 4

2 Safety 52.1 Hazard levels of warnings 52.2 Qualification of assembly staff 62.3 Protective equipment for assembly staff 62.4 Design Information 72.4.1 Notes on standards 7 General standards for heating systems 7 Standards for structural and safety devices 7 Standards for heating water 7 Standards for permitted fuels 82.4.2 Installation and approval of the heating system 82.4.3 General information for installation room (boiler room) 82.4.4 Requirements for central heating water 92.4.5 Notes for using pressure maintenance systems 92.4.6 Return temperature control 102.4.7 Use with storage tank 112.4.8 Chimney connection/chimney system 11 Draught limiter 11 Boiler data for planning the flue gas system 12

3 Technology 133.1 Dimensions 133.2 Technical specifications 14

4 Installation 174.1 Transport 174.2 Positioning 174.3 Temporary storage 184.4 Setting up in the boiler room 194.4.1 Remove boiler from pallet (T4 24-110) 194.4.2 Remove the protective transportation frame (T4 130/150) 194.4.3 Moving the boiler in the boiler room 194.4.4 Minimum distances in the boiler room 204.5 Assembly work 214.5.1 Installing the Ash Container 214.5.2 Assemble the stoker unit 224.5.3 Mount the cover plate on the rear boiler wall (T4 130/150) 234.6 Electrical connection 234.6.1 Removing the controller cover 234.6.2 Laying cables 244.6.3 Mains connection 254.6.4 Information on circulating pumps 26

5 Start-up 275.1 Before commissioning / configuring the boiler 27

Contents

2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

6 Decommissioning 286.1 Mothballing 286.2 Disassembly 286.3 Disposal 28

7 Appendix 297.1 Addresses 297.1.1 Address of manufacturer 297.1.2 Address of the installer 29

Contents

Installation Instructions T4 24-150 | M1210713_en 3

1 GeneralThank 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 guide‐lines.Please read and observe the documentation provided and always keep it close to thesystem for reference. It contains important safety information and all the operation andmaintenance specifications needed to operate the system safely, properly, environ‐mentally friendly and cost-effectively.The constant further development of our products means that there may be minor dif‐ferences from the pictures and content. If you discover any errors, please let us know:[email protected] 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 orheating engineers are requested to return a copy of the delivery certificate togetherwith the guarantee card to Froling. On commissioning by FROLING Customer Servicethe validity of the delivery certificate will be noted on the customer service record.

Issuing a delivery cer‐tificate

1 General


2 Safety

2.1 Hazard levels of warningsThis documentation uses warnings with the following hazard levels to indicate directhazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will leadto serious injury or death. You must follow the instructions!

WARNING

The dangerous situation may occur and if measures are not observed it will leadto serious injury or death. Work with extreme care.

CAUTION

The dangerous situation may occur and if measures are not observed it will leadto minor injuries or damage to property.

Safety 2Hazard levels of warnings


2.2 Qualification of assembly staff

CAUTION

Assembly and installation by untrained personnel:

Risk of personal injury and damage to property.

During assembly and installation:❒ Observe the instructions and information in the manuals❒ Only allow trained staff to carry out assembly and installation

Assembly, installation, initial startup and servicing must always be carried out by quali‐fied personnel:- Heating technician / building technician- Electrical installation technician- Froling customer servicesThe assembly staff must have read and understood the instructions in the documenta‐tion.

2.3 Protective equipment for assembly staffYou must ensure that staff have the protective equipment specified by accident pre‐vention regulations.

▪ For transportation, setup and assembly:- suitable workwear- protective gloves- sturdy shoes

2 SafetyQualification of assembly staff


2.4 Design Information

2.4.1 Notes on standardsThe system must be installed and commissioned in accordance with the local fire andbuilding regulations. The following standards and regulations should always be ob‐served:

General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fed combus‐tion systems, nominal heat output up to 500 kW

EN 12828 Heating systems in buildings - design of water-based heatingsystems

EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methodsPart 1: Chimneys serving one appliance

ÖNORM M 7510-1 Guidelines for checking central heating systemsPart 1: General requirements and one-off inspections

ÖNORM M 7510-4 Guidelines for checking central heating systemsPart 4: Simple check for heating plants for solid fuels

Standards for structural and safety devices

ÖNORM H 5170 Heating installation - Requirements for construction and safetyengineering, as well as fire prevention and environmental pro‐tection

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 inclosed warm water heating systems at operating temperaturesup to 100 °C (Austria).

VDI 2035 Sheet 1 Prevention of damage in water heating systems - Scale forma‐tion in domestic water heating systems and hot water heatingsystems (Germany)

SWKI 97-1 Water quality for heating, steam, cooling and air conditioningsystems (Switzerland)

D.P.R. no. 412 Regulations for the planning, installation, running/operation andmaintenance of heating systems in buildings to reduce energyconsumption with reference to Article 4, Comma 4 of the Legis‐lative Decree of 9 January 1991, No. 10 (Italy)

Safety 2Design Information


Standards for permitted fuels

EN 14961-2 Solid biofuel, fuel specifications and classes.Part 2: Wood pellets for non-industrial use

EN 14961-4 Solid biofuel, fuel specifications and classes.Part 2: Wood chips for non-industrial use

1. BImSchV First Ordinance of the German Federal Government for imple‐mentation of the Federal Emission Protection Law, BGBl. I P.491, in the applicable version.

2.4.2 Installation and approval of the heating systemThe boiler should be operated in a closed heating system. The following standardsgovern 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 informedwhen installing or modifying a heating system, and authorisation must be obtainedfrom the building authorities:Austria: Inform the civic/municipal building authorities.Germany: Notify an approved chimney sweep and 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 wherethe boiler is installed.

▪ Keep the air suction opening of the boiler free from dust.

Ventilation of the boiler roomVentilation 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 (foli‐age, snowdrifts, etc.) from obstructing the air flow.

Note on standards

2 SafetyDesign Information


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 requirementsTRVB H118 - Technical directives on fire protection/prevention

2.4.4 Requirements for central heating waterThe following standards and guidelines apply:

Austria:Germany:Switzerland:Italy:

ÖNORM H 5195-1VDI 2035SWKI 97-1D.P.R. no. 412

NOTICE! Note on filling with make-up water: always bleed the filling hose before con‐necting, 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 op‐

eration

2.4.5 Notes for using pressure maintenance systemsPressure maintenance systems in hot-water heating systems keep the required pres‐sure within predefined limits and balance out volume variations caused by changes inthe hot-water temperature. Two main systems are used:

Compressor-controlled pressure maintenance

In compressor-controlled pressure maintenance units, a variable air cushion in the ex‐pansion tank is responsible for volume compensation and pressure maintenance. Ifthe pressure is too low, the compressor pumps air into the tank. If the pressure is toohigh, air is released by means of a solenoid valve. The systems are built solely withclosed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐to the domestic hot water.

Pump-controlled pressure maintenance

A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐tenance pump, relief valve and an unpressurised receiving tank. The valve releaseshot water into the receiving tank if the pressure is too high. If the pressure drops belowa preset value, the pump draws water from the receiving tank and feeds it back intothe heating system. Pump-controlled pressure maintenance systems with open expan‐sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of thewater, exposing the connected system components to the risk of corrosion. Thesesystems offer no oxygen removal for the purposes of corrosion control as required byVDI 2035 and in the interests of corrosion protection should not be used.

Note on standards

Note on standards



2.4.6 Return temperature controlIf the hot water return is below the minimum return temperature, some of the hot wateroutfeed will be mixed in.

CAUTION

Risk of dropping below dew point/condensation formation if operated without re‐turn temperature control.

Condensation water forms an aggressive condensate when combined with com‐bustion residue, leading to damage to the boiler.

Take the following precautions:❒ We recommend using a return temperature control.

➥ The minimum return temperature is 45 °C. We recommend fitting somesort 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 smooth‐ly. However, we recommend that you use the system with a storage tank, as thisensures 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 accordancewith ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling. ⇨ See "Addresses" [page 29]

2.4.8 Chimney connection/chimney systemEN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐ever possible, damage caused by seepage, insufficient feed pressure and condensa‐tion. Please note in this respect that flue gas temperatures lower than 160K aboveroom temperature can occur in the permitted operating range of the boiler. The flue gas temperatures (for clean systems) and additional flue gas values can befound in the table below. The connection between the boiler and the chimney system should be as short aspossible. The upward angle of the connection should not exceed 30° - 45°. Insulatethe connection. The entire flue gas system - chimney and connection - should be cal‐culated 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 chimneysweep.NOTICE! TRVB H 118 (Austria only) stipulates that an explosion flap must be installedin the connecting piece (flue pipe) directly next to the boiler. It should be situated insuch a way that is poses no risk to persons!

Draught limiterThe installation of a draught limiter is recommended.NOTICE! Install the draught limiter directly under the mouth of the flue line, as thepressure is constantly low at this point.



Boiler data for planning the flue gas system

Description T4

24 30 40 50

Flue gas temperature at nominal load °C 125 135 130 140

Flue gas temperature at partial load 80 85 80 85

Flue gas mass flow at nominal load kg/s 0.019 0.023 0.031 0.038

Flue gas mass flow at partial load 0.008 0.009 0.012 0.015

Required feed pressure at nominal load mbar 0.05 0.05 0.05 0.05

Required feed pressure at partial load 0.02 0.02 0.02 0.02

Maximum permissible feed pressure as per ÖNORM / DIN EN 303-5

Flue spigot diameter mm 150 150 150 150

Description T4

60 75 90 100 110

Flue gas temperature at nominal load °C 130 140 135 140 145

Flue gas temperature at partial load 80 85 80 80 85

Flue gas mass flow at nominal load kg/s 0.046 0.058 0.071 0.077 0.083

Flue gas mass flow at partial load 0.017 0.021 0.025 0.027 0.029

Required feed pressure at nominalload

mbar 0.05 0.05 0.05 0.05 0.05

Required feed pressure at partial load 0.02 0.02 0.02 0.02 0.02


Flue spigot diameter mm 200 200 200 200 200

Description T4

130 150

Flue gas temperature at nominal load °C 135 145

Flue gas temperature at partial load 80 85

Flue gas mass flow at nominal load kg/s 0.101 0.119

Flue gas mass flow at partial load 0.033 0.037

Required feed pressure at nominal load mbar 0.05 0.05

Required feed pressure at partial load 0.02 0.02


Flue spigot diameter mm 200 200



3 Technology

3.1 Dimensions

Item Description Unit 24/30 40/50 60/75 90/100/110 130/150

H Height, boiler mm 1390 1620 1620 1720 1720

H1 Total height incl. flue gas pipeconnection

1440 1670 1670 1770 1770

H2 Height, flow connection 1195 1425 1425 1530 1540

Boiler outfeed connection 6/4“ 6/4“ 6/4“ 6/4“ DN65 / PN6

H3 Height, return connection mm 270 270 270 170 200

Boiler return connection 6/4“ 6/4“ 6/4“ 2“ DN65 / PN6

H4 Height, drainage connection mm 140 140 140 140 140

Boiler drainage connection Inch 1/2 1/2 1/2 1 1

H5 Height, rotary valve connection mm 600 650 650 650 650

B Width, boiler mm 600 770 770 880 880

B1 Total width with stoker unit 1360 1530 1530 1640 1640

B2 Width of stoker unit 760 760 760 760 760

B3 Distance from boiler side to stok‐er connection

470 470 470 470 470

L Length, boiler mm 1200 1200 1570 1570 1905

L1 Total length incl. ash containerand induced draught fan

1430 1430 1840 1840 2300

L2 Length, back of boiler to stokerconnection

755 755 1045 1045 1305

Technology 3Dimensions


3.2 Technical specifications

Description T4

24 30 40 50

Rated heat output kW 24 30 40 50

Output range 7.2-24.0 9.0-30.0 12.0-40.0 15.0-50.0

Electrical connection 400 V / 50 Hz / C16A

Power consumption W 45-115 54-142 51-150 47-158

Boiler weight kg 620 640 840 860

Boiler capacity (water) l 105 105 160 160

Water pressure drop (ΔT = 10 / 20 K) mbar 3.9 / 1.2 4.8 / 1.4 5.2 / 1.8 5.5 / 2.2

Min. boiler return temperature °C 45

Max. permitted operating temperature 90

Permitted operating pressure bar 3

Boiler class as per EN 303-5: 2012 5

Airborne sound level dB(A) < 70

Permitted fuel as per EN 14961 1) Part 2: Wood pellets class A1 / D06Part 4: Wood chips class A2 / P16A-P45A

Description Test report data

24 30 40 50

Testing institute TÜV 2) 3) 4) TÜV 2)

Test report no. 10-UW/Wels-EX-191/2

10-UW/Wels-EX-191/4

- 10-UW/Wels-EX-191/5

1.Detailed information on the fuel is included in the operating instructions, in the section on "Permitted fuels"2.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels3.As per ÖNORM / DIN EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent structure it is sufficient, if the ratio of nominal heat output from the largest to the

smallest boiler is ≤2:1, to carry out the tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not been tested inthe range, whose values have been determined depending on the rated heat output by interpolation, fulfil the requirements of the norm.

4.Values for the types T4 – 40 are interpolated between the test protocol 10-UW/Wels-EX-191/4 and 10-UW/Wels-EX-191/5!

Test data – Wood chips NL / PL NL / PL NL / PL NL / PL

Carbon monoxide (CO) mg/MJ 9 / 28 35 / 28 25 / 34 14 / 40

Nitrous oxide (NOx) mg/MJ 70 / - 92 / - 88 / - 84 / 64

Organic hydrocarbons (OGC) mg/MJ <1 / 1.3 <1 / 1.3 <1 / <2 <1 / <1

Dust mg/MJ 13 / - 13 / - 12 / - 10 / 7

Boiler efficiency % 92.3 / 91.6 91.0 / 91.6 92.1 / 92.4 93.1 / 93.2

Test data – Pellets NL / PL NL / PL NL / PL NL / PL

Carbon monoxide (CO) mg/MJ 8 / 69 7 / 23 <6 / 18 <4 / 12

Nitrous oxide (NOx) mg/MJ 70 / - 72 / - 72 / - 71 / 54

Organic hydrocarbons (OGC) mg/MJ <1 / 1.4 <1 / <1 <1 / <1 <1 / <1

Dust mg/MJ 11 / - 12 / - 11 / - 9 / 6

Boiler efficiency % 92.2 / 91.0 92.0 / 91.4 93.1 / 92.3 94.2 / 93.2

3 TechnologyTechnical specifications


Description T4

60 75 90 100 110

Rated heat output kW 60 75 90 99 110

Output range 18 - 60 22.5 - 75 27 - 90 30 - 99 33 - 110


Power consumption W 51 - 176 56 - 204 61 - 232 65 - 250 65 - 250

Boiler weight kg 1060 1080 1350 1360 1370

Boiler capacity (water) l 220 220 260 260 260

Water pressure drop (ΔT = 10 / 20 K) mbar 7.8 / 2.6 11.4 / 3.2 14.9 / 3.8 17.2 / 4.2 18.7 / 5.2







Description Test report data

60 75 90 100 110

Testing institute 2) 3) TÜV 4) TÜV 4)

Test report no. - 10-UW/Wels-

EX-191/6 &8

10-UW/Wels-

EX-191/7 &9

1.Detailed information on the fuel is included in the operating instructions, in the section on “Permitted fuels”2.As per ÖNORM / DIN EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent structure it is sufficient, if the ratio of nominal heat output from the largest to the

smallest boiler is ≤2:1, to carry out the tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not been tested inthe range, whose values have been determined depending on the rated heat output by interpolation, fulfil the requirements of the norm.

3.Values for the types T4 – 60, 75 and T4-90 are interpolated between the test protocol 10-UW/Wels-EX-191/5 and 10-UW/Wels-EX-191/6!4.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

Test data – Wood chips NL / PL NL / PL NL / PL NL / PL NL / PL

Carbon monoxide (CO) mg/MJ 12.6 / 33.2 10.5 / 23 8.4 / 12.8 7 / 6 7 / 6

Nitrous oxide (NOx) mg/MJ 82 / 65 79 / 68 76 / 70 74 / 71 74 / 71

Organic hydrocarbons (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1 <1 / <1

Dust mg/MJ 10.6 / 7.6 11.5 / 8.5 12.4 / 9.4 13 / 10 13 / 10

Boiler efficiency % 93.1 / 93.3 93.0 / 93.6 92.9 / 93.8 92.9 / 93.9 92.9 / 93.9

Test data – Pellets NL / PL NL / PL NL / PL NL / PL NL / PL

Carbon monoxide (CO) mg/MJ 5 / 11,6 6.5 / 11 8 / 10.4 9 / 10 9 / 10

Nitrous oxide (NOx) mg/MJ 70 / 53 69 / 53 68 / 52 67 / 51 67 / 51

Organic hydrocarbons (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1 <1 / <1

Dust mg/MJ 8.8 / 7 8.5 / 8.5 8.2 / 10 8 / 11 8 / 11

Boiler efficiency % 94.1 / 93.5 93.9 / 93.9 93.6 / 94.3 93.5 / 94.6 93.5 / 94.6

Technology 3Technical specifications


Description T4

130 150

Nominal heat output kW 130 150

Heat output range 39 - 130 45 – 150


Power consumption W 110 - 240 110 – 270

Boiler weight kg 1730 1750

Boiler capacity (water) l 340 340







1.Detailed information on the fuel is included in the operating instructions, in the section on “Permitted fuels”

3 TechnologyTechnical specifications


4 Installation

4.1 TransportThe product is delivered on pallet(s) in cardboard packaging.

NOTICE

Damage to components if handled incorrectly

❒ Follow the transport instructions on the packaging.❒ Transport components with care to avoid damage❒ Protect the packaging against damp❒ Pay attention to the pallet's centre of gravity when lifting

4.2 Positioning❒ Position a fork-lift or similar lifting device at the pallet and bring in the components

If the boiler cannot be brought in on the pallet:❒ Remove the cardboard and remove the boiler from the pallet

⇨ See "Remove boiler from pallet (T4 24-110)" [page 19] or⇨ See "Remove the protective transportation frame (T4 130/150)" [page 19]

Positioning using a crane (T4 24-50)

❒ Removing the insulating cover and the insulating mat❒ Loosen the lock nut on the star-shaped screw knob❒ Unlock the cover by turning the star-shaped screw knob and remove

Installation 4Transport


❒ Pull out the guide plate

➥ The two lifting eye bolts for the boiler are located under the guide plate

Positioning using a crane (T4 60-150)

❒ Removing the insulating cover and the insulating mat

➥ The lifting eye bolt is underneath the insulating material in front of the heat ex‐changer cover

➥ TIP: also remove the controller cover during transportation to avoid damage

4.3 Temporary storageIf 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 InstallationTemporary storage


4.4 Setting up in the boiler room

4.4.1 Remove boiler from pallet (T4 24-110)

❒ Remove securing devices used during transportation on the left and right side of

the boiler❒ Pull out floor insulation❒ Lift boiler off pallet

TIP: We recommend using Froling’s KHV 1400 boiler lifting system to help remove thepallet

4.4.2 Remove the protective transportation frame (T4 130/150)

❒ After removing the cardboard, disassemble the protective transportation frame by

loosening the screws

4.4.3 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.

Installation 4Setting up in the boiler room


4.4.4 Minimum distances in the boiler room▪ The system should generally be set up so that it is accessible from all sides allow‐

ing 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)

Description Unit 24/30 40/50 60/75 90-150

A Minimum distance insulated door to wall

mm 600 800 800 900

B Minimum distance side of boiler to wall

200 200 200 200

C Minimum distance back of boiler to wall

500 500 500 500

D Minimum distance stoker to wall

300 300 300 300

Minimum store height 1700 1900 2050 2150

4 InstallationSetting up in the boiler room


4.5 Assembly work

4.5.1 Installing the Ash Container

❒ Open the side clamps and remove the ash container cover❒ Remove the contents from the ash container

❒ Open the insulated door and push the locking lever up❒ Place the ash container in the boiler and clamp with the locking lever❒ Replace the cover and secure with the clamps

➥ Make sure that the pin (2) is inserted in the limit switch (1) correctly

Installation 4Assembly work


4.5.2 Assemble the stoker unit

❒ Remove the upper and lower shutter mask on the stoker side❒ Remove the pre-installed screws on the connection flange

❒ Position the stoker unit by the boiler as shown❒ Push the stoker unit towards the boiler and insert into the connection flange be‐

side the two lock bolts (1)➥ Adjust the height of the stoker unit if necessary using the adjustable feet

❒ Secure the unit to the boiler using the previously removed screws

❒ Place the hose clamp provided on the igniter tube❒ Push the ignition fan into the igniter tube and secure with the hose clamp

4 InstallationAssembly work


4.5.3 Mount the cover plate on the rear boiler wall (T4 130/150)

❒ Position the lower cover plate on the rear boiler wall and attach to the boiler using

screws

4.6 Electrical connection

DANGER

When working on electrical components:

Risk of electrocution!

When work is carried out on electrical components:❒ Only have work carried out by a qualified electrician❒ Observe the applicable standards and regulations

➥ Work must not be carried out on electrical components by unauthorisedpersons

4.6.1 Removing the controller cover

❒ Removing the insulating cover and the insulating mat

Installation 4Assembly work


❒ Remove the locking screws on the controller cover❒ Push the controller cover back and then lift off

With the T4 60-150:

❒ After undoing the locking screws, slide the two covers back at the same time and

then lift off the controller cover (= front part)

4.6.2 Laying cablesLay the stoker drive and ignition fan cables and the connection cable for the dischargesystem in the cable duct from the stoker unit to the boiler:

❒ Remove the cover of the cable duct on the stoker duct❒ Run the cables up through the insulating side panel

4 InstallationElectrical connection


❒ Pull the cables up through the side openings in the controller box and secure to

the strain relief bar with cable ties❒ Lay all stoker cables in the cable duct and replace the cover on the duct

❒ Replace the cover plate on the stoker duct❒ Wire the connections according to the wiring diagram

NOTICE! See boiler control unit operating instructions for circuit diagrams❒ Once the wiring has been completed, replace the controller cover

4.6.3 Mains connectionAt the back of the boiler:❒ Press the mains plug to release it and remove❒ Open the plug and connect the mains connection cable

➥ Flexible sheathed cable must be used for the wiring; this must be of the correctsize to comply with applicable regional standards and regulations.

➥ The power supply line (mains connection) must be fitted with a C16A fuse bythe customer.

Installation 4Electrical connection


4.6.4 Information on circulating pumps

NOTICE

According to 2012/622/EU external, wet running circulating pumps must complywith the following limit values of the Energy Efficiency Index (EEI):

- Effective from 01/01/2013: Wet running circulating pumps with EEI ≤ 0.27- Effective from 08/01/2015: Wet running circulating pumps with EEI ≤ 0.23

Only high efficiency pumps with a connection option for a control signal (PDM / 0-10V)should be connected to speed-controlled pump outputs (pump 1 on the core moduleand pump outputs on the hydraulic module). In this case, the control line is connectedto the corresponding PDM outputs of the boards. Observe the connection instructionsin the boiler controller documentation!

CAUTION

When using high efficiency pumps without an additional control line at speed-con‐trolled pump outputs:

Malfunctions of the boiler, the pump and the hydraulic system may occur!

Therefore:❒ Do not connect EC motor pumps without a control line to the speed-controlled

pump outputs of the boards.➥ Only use special high efficiency pumps with a connection option for a con‐

trol line (PDM/0-10V)!➥ Observe the additional instructions and information on board outputs in the

operation instructions for the boiler controller.

4 InstallationElectrical connection


5 Start-up

5.1 Before commissioning / configuring the boilerThe boiler must be adjusted to the heating system during commissioning.

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteedif the system is set up by trained professionals and the standard factory settingsare observed.

Take the following precautions:❒ Initial startup should be carried out with an authorised installer or with Froling

customer services

❒ Adjust the boiler controller to the system type❒ Apply boiler standard values

NOTICE! The keypad assignment and the steps necessary to modify the parametersare detailed in the operating instructions for the boiler control unit.❒ Check the system pressure of the heating system❒ Check that the heating system is completely vented❒ Check that the safety devices are present and working correctly❒ Check that there is sufficient ventilation in the boiler room❒ Check the seal of the boiler

➥ All doors and inspection openings must be tightly sealed! ❒ Check that drives and actuators are working and turning in the right direction

NOTICE! For how to check the analogue and digital outputs, see the operating instruc‐tions for the boiler controller ❒ Check that the door contact switch is working correctly

NOTICE! For how to check the digital inputs see the operating instructions for the boil‐er controller.

Start-up 5Before commissioning / configuring the boiler


6 Decommissioning

6.1 MothballingThe following measures should be taken if the boiler is to remain out of service forseveral weeks (e.g. during the summer):❒ Clean the boiler thoroughly and close the doors fully

If the boiler is to remain out of service during the winter:❒ Have the system completely drained by a qualified technician

➥ Protection against frost

6.2 DisassemblyTo disassemble the system, follow the steps for assembly in reverse order.

6.3 Disposal❒ Ensure that the system is disposed of in an environmentally friendly way in ac‐

cordance with waste management regulations.❒ You can separate and clean recyclable materials and send them to a recycling

centre.❒ The combustion chamber must be disposed of as builders' waste.

6 DecommissioningMothballing


7 Appendix

7.1 Addresses

7.1.1 Address of manufacturer

FRÖLINGHeizkessel- und Behälterbau GesmbH Industriestraße 12A-4710 GrieskirchenAUSTRIA TEL 0043 (0)7248 606 0FAX 0043 (0)7248 606 600INTERNET www.froeling.com

7.1.2 Address of the installer

Stamp

Appendix 7Addresses


Documents

Wood chip boiler T4 24-150 - fgebiomass.co.uk · Wood chip boiler T4 24-150 ... 4.4 Setting up in the boiler room 19 4.4.1 Remove boiler from pallet (T4 24-110) 19 ... 4.6.2 Laying