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Froling FHG 20, Installation Manual

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Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria 

www.froling.com 

A French language manual may be 

obtained from Tarm Biomass by 

calling 800-782-9927 or by email 

request to: [email protected]. 

 
 
 

Installation Manual 

 

Wood-Fired Central Heating Boiler 

FHG  

 

 
 

 
 
 

 
 

Read and follow the operating instructions and safety information! Subject to technical change! 

Summary of Contents for FHG 20

Page 1: ...A French language manual may be obtained from Tarm Biomass by calling 800 782 9927 or by email request to info tarmusa com Installation Manual Wood Fired Central Heating Boiler FHG Read and follow th...

Page 2: ...Update Date May 2014 Reprint date Nov 2014...

Page 3: ...any errors please let us know We reserve the right make technical changes Installation Requirements It is strongly recommended that the installer resist the temptation to simply get started without r...

Page 4: ...port 18 3 1 1 Positioning 18 3 1 2 Remove boiler from pallet 18 3 1 3 Temporary storage 18 3 2 Setting up in the boiler room 19 3 2 1 Moving the boiler in the boiler room 19 3 2 2 Minimum distances in...

Page 5: ...Supply and Pump 1 42 Wiring diagram 43 Wiring diagram for overheat aquastat connections 43 4 First Start up 44 4 1 General information 44 4 1 1 Before heating up for the first time 44 4 1 2 Preparing...

Page 6: ...Parameters Boiler Temperature visible for service purposes only 56 Adjustable Parameters Flue Gas 57 Adjustable Parameters Air settings 57 Adjustable Parameters Lambda values 58 Calibrating the Lambda...

Page 7: ...m a double 115 V 60 Hz nominal 230 V AC 15 amp branch circuit including neutral and ground connection For wiring instructions please refer to Section 3 7 in this Installation Manual Chimney must be 6...

Page 8: ...nderstand the installation tasks and contact Tarm Biomass for help when necessary Tarm Biomass will provide phone assistance at no additional cost to the original boiler owner to assure success in the...

Page 9: ...of heating system Water quality conditions for initial filling the heating system For first filling of heating system water must be clean pure or purified odorless and without suspended matter Water...

Page 10: ...tside air Outside air should be ducted to no closer than 12 30 cm from the boiler A 6 150 mm duct should be large enough for all sizes unless the duct run is over 25 feet 7 6 m In addition to local co...

Page 11: ...iomass when burning the wood boiler in conjunction with a back up boiler The BLTCONTROL is a three position control that allows switching between wood only wood with automatic back up or back up only...

Page 12: ...provide a continuous and dependable draft to pull the exhaust gasses out of the building NOTICE The boiler must be connected to a 6 150 mm diameter Factory Built Type UL 103 HT ULC S629 in Canada app...

Page 13: ...al flue gas values can be found in table Basic boiler data for layout of Chimney system below The Flue Gas Pipe connecting the Boiler to the Chimney flue must be black or stainless have a minimum thic...

Page 14: ...t is always higher than 0 10 2 5 mm water column 25 Pa a second draft regulator may be required Recommended draft regulator location is shown position 1 The installation of a draft regulator as well a...

Page 15: ...return connection 1 50 3 Connection for filling drainage cock 0 50 4 2 x safety heat exchanger connection sleeves for thermal discharge safety device Not used in North America 0 50 5 Flue gas sensor c...

Page 16: ...s Pipe Connection 60 25 64 H3 Height of Supply Feed Connection 50 25 54 H4 Height of Return Feed Connection 5 5 H5 Height of Drain 4 75 4 75 H18 Height of Safety Battery Connection 35 35 B Total Width...

Page 17: ...Loading Chamber Door inches 13 x 14 50 13 x 14 50 13 x 14 50 13 x 14 50 Fuel Loading Chamber Capacity Cu Ft 5 5 7 4 7 4 Wood Length inches 21 21 21 21 Water Contents Gallons 32 32 50 50 Upstream Resis...

Page 18: ...ting device to the eyelet on the boiler and position the boiler 3 1 2 Remove boiler from pallet At the front of the boiler Remove securing devices used during transportation on the left and right side...

Page 19: ...ve the packing materials carefully Risk of scratching the insulation Position the boiler at the designated location The boiler must be positioned so that it is rise slightly towards the supply fitting...

Page 20: ...g brush small L Cleaning brush large The following are also included in the package contents but not pictured Lambdatronic control unit pressure relief valve pressure temperature gauge Honeywell overh...

Page 21: ...ch Rotate the pre heating chamber door and the combustion chamber door and attach them on the left hand side Additional steps for the fuel loading chamber door Remove the gasket then remove the radiat...

Page 22: ...vided Insert flange bushing into door handle Fasten the door handle in place Repeat the above steps for the pre heating chamber door and the combustion chamber door Fitting the door for closure is acc...

Page 23: ...ll the pneumatic rods for the primary and secondary air For both pneumatic rods Remove the split pin opposite the spring and pull off one of the air flaps Right hand actuators The hex head bolt 1 in t...

Page 24: ...uator mounting bracket as shown using the pre installed screws 3 5 3 Installing the heat exchanger system Remove the screw on the upper cleaning cover Remove the cleaning cover Hook the turbulators sp...

Page 25: ...the boiler insulation are fitted with a protective film This must always be removed before installation The following steps apply if the insulating door is attached on the right side If the insulating...

Page 26: ...nsulate Insert the insulating side panel into the tab 2 at the base of the boiler Hang the top of door from the door bracket using the threaded bolt Fit the spacer washers and screw the nuts on lightl...

Page 27: ...bracket 1 instead of the door bracket described above Fit the left hand insulating side panel at the base of the boiler Ensure that the panel is properly engaged in the tab at the base of the boiler M...

Page 28: ...the front face of the boiler body Recommendation Install the cleaning port door on same side as the cleaning lever Install the cleaning port door using 3 Allen screws Start with the large threaded bo...

Page 29: ...and fasten it at the lower edge Thread the cables for the actuators through the pre stamped opening Attach the insulating back panel to the complete assembly Tighten the screws on the blank cover and...

Page 30: ...l the cables for the actuators using the stickers provided Upper actuator primary air Lower actuator secondary air Push on the cable cover and fix in position using self tapping screws 3 5 6 Fitting t...

Page 31: ...ating door The following steps are for a door attached on the right If the insulating door is attached on the left carry out the steps with the sides reversed accordingly Slide the lower door bracket...

Page 32: ...side panel Fasten the lower door bracket so that this set up is maintained Install magnetic latches top and bottom on the inside of the insulating door Lay the additional insulating wool pad 1 in posi...

Page 33: ...slide in fully Installing the cleaning lever for the heat exchanger system On the same side as the brass bushing Remove the pre punched perforation from the insulating side panel File rough edges usi...

Page 34: ...ntrol box on the boiler Remove the cover from the control unit Attach the control unit to the boiler using four self tapping screws Installing the flue gas sensor Screw in the brass bushing for the fl...

Page 35: ...mbda probe Screw the bushing into the flue gas nozzle and tighten gently Screw the lambda probe into the bushing and tighten gently Never place a wrench or pliers on the cylindrical metal body Install...

Page 36: ...rature of 180 F 82 C The minimum pipe size for this loop is 1 recommended and if possible the loop should be located and pitched to maximize natural thermal convection of the water The loop must be po...

Page 37: ...required This electrical connection should be from a dedicated 15 amp circuit breaker A master service switch for the boiler mounted on or in the proximity of the boiler is recommended Locally enforc...

Page 38: ...g actuators Primary and Secondary Air Damper Actuator Induced Draft Fan Feed Draft Fan Wires through Back Panel Feed Wires Through Wire Knockout Plug in Draft Fan Connector Feed Through Air Damper Wir...

Page 39: ...n Austria Page 39 www froling com M1060008_US 3 3 7 3 Connecting sensors Flue Gas Sensor Lambda Probe Feed through Lambda Probe Wires Feed Wires through Wire Knockout Plug in Broadband Probe Connector...

Page 40: ...3 Sensor of Door Switch Sensors for Thermal Storage System Feed through Door Sensor Switch Wires Connect Wires to Connector Plug in the Door Switch Connector Feed through Sensor Wires Connect Wires to...

Page 41: ...fety Temperature Limiter and its bulb Feed bulb and capillary to back of boiler Bring the bulb to the back of the boiler Prepare STL bulb and boiler temperature sensor Install bulbs into well Install...

Page 42: ...ction Page 42 M1060008_US v 3 Connecting Main Supply and Pump 1 Mount Interface Panel Loosen Mounting Nut Mount Wire End into Control Head an and Wires Attach this end to circulator Remove Knockouts o...

Page 43: ...iestrasse 12 A 4710 Grieskirchen Austria Page 43 www froling com M1060008_US 3 Wiring diagram Wiring diagram for overheat aquastat connections Typical Circulator or Zone Valve Controller Honeywell L40...

Page 44: ...r during first start up does not indicate a fault If this occurs clean up using a cleaning rag 4 1 1 Before heating up for the first time Check the system pressure of the heating system Check that the...

Page 45: ...during heating season 4 1 4 Error status of Boiler Control System Check the Status LED at Boiler Control Display unit for activated and error free system green flashing light In case any error message...

Page 46: ...menu Parameter change Short keystroke Increase value Long keystroke Increase value in steps of 10 Long keystroke 10 sec Increase value in steps of 100 DOWN arrow Navigation Move down in the menu Param...

Page 47: ...Service operation Function not used Automatic Program Short Automatic On Function not used exit other functions only Long Off Function not used Party Program Short Party operation Function not used L...

Page 48: ...frame and the info symbol in the status line Info key for pending error messages If an error message was acknowledged after arising but not resolved this is displayed by an error symbol at the bottom...

Page 49: ...es that an info text is displayed Info texts are also identified by a frame Shows activation of boiler See page 47 Function Keys not used Only shown in the Basic Display shows that the Thermal Storage...

Page 50: ...below the set point of boiler temperature the Boiler Control System returns to Heating mode Do not open Boiler Doors Do not refill fuel Door open The Insulation Door is open the Induced Draft Fan runs...

Page 51: ...For safety reasons certain parameters are only visible at specific User Levels To change to another level it is necessary to enter the relevant user code Child lock User Code 0 At Child lock level onl...

Page 52: ...r can should be set as desired by the Owner Desired target boiler temperature All temperature values at Boiler Control System are displayed in Centigrade or C only Temperature values in Fahrenheit or...

Page 53: ...1 Status display of the Thermal Storage System Storage tank 01 08 Display Description Storage tank top temperature 55 C Current temperature at Thermal Storage System top sensor Storage tank bottom tem...

Page 54: ...r temperature is higher than boiler setpoint 8 C If the boiler temperature exceeds the target value by this parameter value the Boiler Control System switches to Slumber mode on off control The combus...

Page 55: ...ircuit pump 0 A 0 Primary air flap OPEN A 0 Primary air flap CLOSE A 0 Secondary air flap OPEN A 0 Secondary air flap CLOSE A 0 Standby relay A 0 5 7 2 Analog Outputs Analog Outputs Description Primar...

Page 56: ...y Parameter Description Boiler temperature setpoint 80 C Major set point for Boiler Control System The boiler temperature is continuously controlled to reach and hold this temperature Shutdown if curr...

Page 57: ...boiler 15 C Starting condition for Heating mode Flue gas temperature below which boiler switches to SHUTDOWN status 80 C If the flue gas temperature is below this value for the duration of the maximu...

Page 58: ...da should be performed before initial start up Boiler doors must be open and Lambda Probe activated See section 5 7 1 for Lambda probe activation Parameter Description Broadband probe heating current...

Page 59: ...en content 8 0 Oxygen control 36 Secondary air 36 Position of secondary air flap 38 Board temperature 38 C Service hours 23h Service hours in slumber 2 1h Software version Version 50 04 Build 04 12 5...

Page 60: ...ime are used for display purposes only Format of Calendar Date Weekday 2 letters Day 2 digits Month 2 digits Year 2 digits e g MO 07 07 08 Monday 07th of July 2008 Format of Time Hour 2 digits 24 hour...

Page 61: ...YES S4 Turbo 34 40 Ignition installed NO S4 Turbo 50 60 Return feed lift pump Installed NO FHG Turbo 3000 20 Selected FHG Turbo 3000 30 Return feed mixer installed NO FHG Turbo 3000 40 FHG Turbo 3000...

Page 62: ...em only H3200 Variant 1 Do not select H3200 Variant 2 und 5 H3200 Variant 3 H3200 Variant 4 Hydraulic system DHW Tank System DHW tank 01 installed J N Not used Do not change DHW tank 08 installed J N...

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