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Boiler maintenance

Inspection and cleaning

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen

Page 27

Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com

B 067 00 09

4

Close the heat exchanger door and open the combustion chamber

door

Remove a lot of ash with a shovel

Clean the step grate and sloping plates with the furnace tool

Clean the side walls of the combustion chamber with the furnace tool

Clean the primary air openings in the step grate and sloping plates

with a suitable tool (screwdriver or similar)

After cleaning the combustion space and the combustion chamber:

Close the boiler doors and insulated doors

Switch on the main switch

The tipping grate closes and the controller switches to “Boiler

Off” mode.

Switch off the main switch again and open the doors

Check the cleanliness of the tipping grate once more in closed

position and clean the air openings with a suitable tool

(screwdriver or similar)

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Summary of Contents for TX

Page 1: ... A 4710 Grieskirchen Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com Operating Instructions TX English version of operating instructions for operators Read and follow the instructions and safety instructions Subject to technical change ...

Page 2: ...rly and economically The constant further development of our products means that the pictures and content may differ slightly If you discover any errors please let us know Subject to technical change Guarantee conditions Our sale and delivery conditions generally apply These conditions have been made available to customers and customers have been made aware of them at the time of order completion ...

Page 3: ...ces for preventing the boiler from overheating 14 Thermal discharge safety device 14 Safety Temperature Limiter STL 14 Safety valve provided by the customer 14 2 7 Safety information for installation room 14 2 8 Residual risks 15 2 9 Emergency procedure 16 2 9 1 System overheating 16 2 9 2 Smell of flue gas 16 3 Operating the system 17 3 1 Assembly and initial startup 17 3 2 Filling refilling the ...

Page 4: ...flue gas recirculation FGR optional 29 Clean the induced draught fan 30 Clean the combustion air blower fan 30 Check the under pressure controller 30 Check the combustion chamber overpressure sensor 31 Check door seals 31 Check the draught controller flap and explosion flap 31 4 3 Instructions for measuring emissions 32 4 3 1 Measurement at rated load 32 Activate chimney sweep mode 32 4 3 2 Measur...

Page 5: ... the entire system 4 Control panel of the Lambdatronic H 3200 controller 4 1 Status LED operating status slow green flashing light boiler activated fast green flashing light boiler deactivated red flashing light Fault 4 2 Large graphical display to show operating statuses and parameters 4 3 Navigation keys to move around in the menus and to change the parameter values 4 4 Function keys for calling...

Page 6: ...y valve as a burn back protection system and stoker screw for fuel transport 9 Automatic tipping grate 10 Combustion chamber door 11 Heat exchanger door 12 Efficiency Optimisation System WOS with turbulators 13 Boiler outfeed connection 14 Boiler return connection 15 Thermal discharge safety device connection 5 9 11 8 11 10 13 14 9 15 12 ...

Page 7: ... www froeling com B 067 00 09 1 Pos Description Symb 16 Automatic drive for heat exchanger cleaning 17 Induced draught fan 18 Flue gas recirculation optional 19 Secondary air control with actuator drive 20 Primary air control with actuator drive 21 Automatic ignition 22 Flue gas recirculation for step grate 23 Flue gas recirculation for tipping grate 18 20 17 21 16 22 23 19 ...

Page 8: ...as insufficient combustion air or a fuel that is not permitted can cause serious faults in combustion e g spontaneous combustion of carbonisation gases or flash fires which can in turn cause serious accidents Instructions and information for versions and minimum values as well as standards and guidelines for heating components in the instructions must be observed WARNING Severe injuries and damage...

Page 9: ...rer or supplier is not liable for any damages resulting from non permitted uses 2 2 1 Permitted fuels Wood chips Designation as per ÖNORM M 7133 ÖNORM DIN CEN TS 14961 Description as per ÖNORM M 7133 W20 M20 Air dried Water content W30 M30 Suitable for storage G30 P16 Fine wood chips Size G50 P45 Medium wood chips Applicable standards Austria ÖNORM M 7133 or ÖNORM CEN TS 14961 Germany Wood chips i...

Page 10: ...age to the boiler and also voids the warranty All fuels not defined under 2 1 1 are considered non permitted Due to various air quality protection regulations non permitted fuels include Chipboard waste treated wood wastes pure grinding dust Refuse large quantities of paper cardboard packaging Coal brown coal anthracite coal briquettes 2 3 Qualification of operating staff Only trained operators ar...

Page 11: ...perating instructions and mandatory regulations that apply in the country in which the boiler is operated 2 5 1 Official approval and obligation to report NOTICE Each heating system must be officially authorised The appropriate supervisory authority inspection agency must always be informed when a heating system is installed or modified and authorisation must be obtained from the building authorit...

Page 12: ...on of at least 200 cm2 2 5 4 Heating System Installation Standards The following standards govern the installation of heating systems Applicable standards ÖNORM DIN EN 12828 Heating Systems in Buildings Storage tank NOTICE A storage tank with the proper dimensions will guarantee the best boiler operating values during the entire heating period Please contact your installer or Fröling directly for ...

Page 13: ... to run Never use the main switch 2 Safety temperature limiter back of boiler Page 14 Devices for preventing the boiler from overheating 3 Main switch For shutting down the entire system Only switch off the main switch when the boiler has cooled down and the controller is switched off Boiler off status Turn the main switch to the O position The power to all components is switched off Not shown Wat...

Page 14: ...ture limiter 2 can be unlocked mechanically Safety valve provided by the customer Protection against over heating excessive pressure When the boiler pressure reaches a maximum of 3 bar the safety valve opens and the heating water is released in the form of steam 2 7 Safety information for installation room Danger of fire due to flammable materials No flammable materials should be stored near the b...

Page 15: ...carrying out maintenance work on in the boiler Press and hold this button for 5 seconds The controller follows the shutdown procedure and starts with the cleaning cycle After the cleaning cycle the boiler goes to the operating status Cleaning possible WARNING Opening the combustion chamber door during operation This may cause injury damage and smoke It is forbidden to open the doors behind the ins...

Page 16: ...c operation When using a third party controller carry out the relevant measures to activate the mixer and pumps manually Exit the boiler room and close the door Open any available radiator thermostat valves If the temperature does not drop inform the installer or Fröling customer services 2 9 2 Smell of flue gas DANGER Smell of flue gas Flue gases can cause fatal poisoning Keep all the doors on th...

Page 17: ...on operation can only be guaranteed if the system is set up by trained professionals and observing the standard factory settings Take the following precautions Initial start up should be carried out with an authorised installer or with Fröling customer services 3 2 Filling refilling the store with fuel When you fill the store you should always ensure that you are using the right fuel Page 9 2 2 1 ...

Page 18: ...ty of wood chips and wait at least half an hour preferably an hour until the arms spring blades are touching the head of the stirrer Only then should you load the remaining material 3 2 3 Blowing in pellets for a store with pellet screw For systems with a pellet screw the boiler must be in OFF status when the store is filled The under pressure from the blowing could bring smoke back into the store...

Page 19: ...re can be filled Switch off the boiler by pressing the button for 5 seconds and allow it to cool down for at least two hours Close all openings to the store to seal out dust Blow the fuel into the store 3 2 5 Blowing in pellets for an empty store with stirrer CAUTION If the head of the stirrer is already free of material and the arms spring blades are extended then the feeder unit must be active d...

Page 20: ...nly then deactivate the parameter Stoker If there is a fuel residue in the stoker there is a danger of a flash fire the next time the boiler is started due to a excessive infeed quantity Wait until all the pellets in the retort have been transported to the ash bucket and only then deactivate the parameter Ash screw and the parameter grate tip drive Remove all the pellets remaining on the grate fro...

Page 21: ...vated The heating system is controlled via the controller according to the selected mode 3 3 3 Controlling the boiler See the operating instructions for the Lambdatronic H 3200 3 3 4 Switching off the boiler Press and hold this button for 5 seconds The boiler follows the shut down program and switches to Boiler OFF status The combustion unit is switched off the chamber discharge unit and the activ...

Page 22: ... turned off Always wear protective gloves when working on the boiler Only operate the boiler using the handles provided for this purpose Before maintenance work Turn off the boiler with the key and allow it to cool down When the boiler has cooled down switch it off with the main switch and secure so that it cannot be switched on again WARNING Non permitted cleaning and maintenance Incorrect or ins...

Page 23: ...r have the installer replace it if necessary Check safety valve Check the safety valve as per the manufacturer s instructions See the operating instructions of the safety valve Check the system pressure Read off the system pressure on the pressure gauge The value must be above the pre stressed pressure of the expansion tank by 20 Expansion tank operating instructions If the system pressure decreas...

Page 24: ...sh containers must be emptied at the correct intervals according to energy requirements and fuel quality Remove the ash container cover and check the level If the ash container is full unscrew the wing nuts on the discharge flange When removing the ash container insert the transport handle and secure with a split pin Separate the ash container and take it to the ash disposal point ...

Page 25: ...ww froeling com B 067 00 09 4 Empty the heat exchanger ash container For heat exchanger with ashcan Remove the star shaped screws of the ashcan Take out the ashcan and remove the ash For heat exchanger with ash screws Remove the ash container cover and check the level If the ash container is full unscrew the wing nuts on the flange Separate the ash container and take it to the ash disposal point ...

Page 26: ...eaning cycle the boiler goes to the operating status Cleaning possible The tipping grate remains in open position Switch off the main switch Clean the combustion chamber and combustion space Open the insulated doors and heat exchanger door Remove a lot of ash from the combustion space with a shovel Clean the combustion chamber sensor with a soft brush Clean the side walls of the combustion space w...

Page 27: ... tool Clean the side walls of the combustion chamber with the furnace tool Clean the primary air openings in the step grate and sloping plates with a suitable tool screwdriver or similar After cleaning the combustion space and the combustion chamber Close the boiler doors and insulated doors Switch on the main switch The tipping grate closes and the controller switches to Boiler Off mode Switch of...

Page 28: ... boiler has cooled down Clean the heat exchanger Remove the insulated cover and open the cleaning cover Remove all dirt and deposits for the flue gas chamber Clean the area below the step grate Remove the blanking plate and the thermal insulation Remove the inspection cover Clean away the ash below the step grate with the furnace tool or an ash vacuum Clean the side passage to the flue gas recircu...

Page 29: ...4 Clean the flue gas recirculation FGR optional Remove the pipe insulation from the inspection cover Remove the inspection cover and clean the pipes of the flue gas recirculation unit with a brush After cleaning the pipes Remove the inspection cover of the flue gas recirculation box Clean the interior with an ash vacuum Remove the inspection cover of the flue gas recirculation air box Clean the in...

Page 30: ...n the interior of the induced draught fan housing with an ash vacuum Clean the combustion air blower fan Clean any dust and deposits from the protective grating Dismantle the protective grating and clean the fan with a soft brush where necessary Check the under pressure controller Remove the silicon tube from the differential pressure transducer Using compressed air blow out the hose in the direct...

Page 31: ...ith fixing screws Check door seals Check that the ceramic fibre seal of the combustion chamber door the heat exchanger door and the heat exchanger cover is positioned correctly on the frame Check the imprint on the ceramic fibre seal If the imprint of the seal is broken The seal is no longer efficient Adjust the door fastenings or replace the glass fibre seal After adjusting the combustion chamber...

Page 32: ...g circuit flow temperature and the DHW tank loading are released When is it possible to measure Flue gas temperature at approx 140 C O2 content of the flue gas between 8 and 12 corresponds to a CO2 content between 13 and 19 Boiler temperature above 65 C 4 3 2 Measurement at partial load if necessary Ensure heat consumption Ensure that heating pumps are switched on Open mixer valves and radiator va...

Page 33: ...It will ensure that your system stays environmentally friendly and operates efficiently and cost effectively For this reason FRÖLING offers a service agreement which optimises operating safety Please see the details in the accompanying guarantee certificate Your Fröling customer service office is also glad to advise you 4 5 Replacement parts With Fröling original replacement parts in your boiler y...

Page 34: ...main switch Switch off the main switch Replace fuse note current e g 10A Switch on the main switch 5 1 1 System procedure following power failure When the power supply has been restored the boiler returns to the previously specified mode and is controlled according to the specified program 5 2 Excessive temperature The safety temperature limiter STL shuts down the boiler when it reaches a temperat...

Page 35: ...lay 2 An internal distinction is made between 2 types of message Warning Boiler follows shutdown procedure Error Boiler shuts down immediately heating circuit controller and pumps remain active 5 3 1 Procedure for fault messages The procedure in case of fault message the causes for faults and procedure for troubleshooting are described in the operating instructions for the boiler controller See th...

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