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Installation Manual
Wood-Fired Central Heating Boiler
FHG
A French language manual may be
obtained from Tarm Biomass by
calling 800-782-9927 or by email
request to: info@tarmusa.com.
Read and follow the operating instructions and safety information! Subject to technical change!
Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria
www.froling.com
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Table of Contents
Related Manuals for Froling FHG 20
Summary of Contents for Froling 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. Read and follow the operating instructions and safety information! Subject to technical change! Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria www.froling.com...
- Page 2 Update Date: May 2014 Reprint date: Nov 2014...
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Page 3: Installation Requirements
A means for protecting the boiler against cold return temperatures must also be provided. Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 3 www.froling.com... -
Page 4: Table Of Contents
Contents 1 General information 1.1 Installation Hazards 1.2 Boiler Installation 1.2.1 Planning ......................8 Sizing the Boiler ....................8 Choosing an Installer ..................8 Locating the Boiler and Boiler Clearances ............8 1.2.2 Approvals and reporting obligations ..............9 1.2.3 Requirements for initial filling and re-filling of heating system ......... 9 1.2.4 Ventilation of boiler room .................. - Page 5 5.4 Menu Overview 5.5 Menu - Storage tank 5.5.1 Status display of the Thermal Storage System ............ 53 5.6 Menu – Boiler 5.6.1 Status Displays for the Boiler ................54 Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 5 www.froling.com M1060008_US...
- Page 6 Contents 5.6.2 Temperature settings for the Boiler ..............54 5.7 Menu – Manual 5.7.1 Digital Outputs ....................55 5.7.2 Analog Outputs ....................55 5.7.3 Digital Inputs ....................56 5.8 Menu - System 5.8.1 Adjustable Parameters ..................56 Adjustable Parameters - Boiler Temperature (visible for service purposes only)..56 Adjustable Parameters - Flue Gas ..............
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Page 7: General Information
This boiler is not for use with an automatic stoker Connect to an existing boiler system in combination with heat storage only! Use original spare parts only. Installation of non-licensed replacement parts will void the warranty! Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 7 www.froling.com M1060008_US... -
Page 8: Boiler Installation
General information 1.2 Boiler Installation This section describes the steps to installing and starting-up the boiler. This section is directed at the installer. 1.2.1 Planning Sizing the Boiler It is critical to size the boiler properly. A proper up to date heat load calculation is advised. -
Page 9: Approvals And Reporting Obligations
Use of a suitable antifreeze mix is allowed, but will cause a loss in heat transfer efficiency. Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 9 www.froling.com M1060008_US... -
Page 10: Ventilation Of Boiler Room
If in doubt, it is advisable to provide additional air. The Froling FHG, due to its powerful Induced Draft Fan, needs adequate air to make up for the air being pushed up the Chimney, especially during start up before the Chimney is warm. -
Page 11: Minimum Return Water Temperature
A tankless hot water coil is not available for the Froling FHG boiler. Tarm Biomass recommends the use of the BLTCONTROL (available through Tarm Biomass) when burning the wood boiler in conjunction with a back up boiler. -
Page 12: Combination With Thermal Storage System
General information Combination with Thermal Storage System The Froling FHG boiler is required to be installed with a Thermal Storage System, this system may require periodic maintenance. Please review the periodic maintenance requirements of the thermal storage system with the owner / system operator. - Page 13 10 feet (3.0 m) measured horizontally. For the Froling FHG 20, 30, 40 and 50 best draft will be provided by a Chimney which has an 6” ID round flue, is 20-30 feet (6 – 9 m) in height and which is located inside the heated structure.
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Page 14: Basic Boiler Data For Layout Of Chimney System
General information system, should rarely be off while a fire is present. If however, an irregular or excessively high draft presents problems, the solution is the use of a barometric draft regulator. Installation requirements for a barometric damper (draft regulator). - The diameter of the draft regulator must be equal or greater than that of the Chimney connector. -
Page 15: Technical Data
Lambda probe connector 0.75 Immersion sleeve for boiler sensor and sensor for safety 0.50 temperature limiter Connection sleeve for thermal discharge safety device sensor 0.50 Flue gas connector 6.00 Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 15 www.froling.com M1060008_US... -
Page 16: Dimensions
Technical data 2.2 Dimensions Item Description Unit 20/30 40/50 Total Height of Boiler Total Height of Boiler including the Controller 61.75 65.75 Height of Flue Gas Pipe Connection 60.25 Height of Supply Feed Connection inches 50.25 Height of Return Feed Connection Height of Drain 4.75 4.75... -
Page 17: Specification Data
Waste-Wood Boiler Test Pressure Flue Gas Temperature °F Rated Load Partial Load Minimum Draft Required Inch WC Rated Load -0.060 -0.060 -0.072 -0.072 Partial Load -0.028 -0.040 -0.040 -0.040 Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 17 www.froling.com M1060008_US... -
Page 18: Boiler Installation
Boiler Installation Boiler assembly 3 Boiler Installation 3.1 Transport The boiler comes packed on a pallet. Move the boiler without jarring or jolting Follow the instructions on the packaging when moving the boiler 3.1.1 Positioning Use a fork-lift or similar lifting device to move the pallet and position ... -
Page 19: Setting Up In The Boiler Room
The following minimum distances must be observed in all cases: Front of Appliance to Combustibles inches Side Wall to Appliance inches Back Wall to Appliance inches Ceiling to Appliance inches Combustibles to Flue Pipe inches Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 19 www.froling.com M1060008_US... -
Page 20: Package Contents
Boiler Installation Boiler assembly 3.3 Package contents Boiler Insulation Heat-exchanger system (optional) Flue gas pipe nozzle Ceramic fiber seal Induced draught fan Cardboard box containing small parts Rods for primary and secondary air Ash shovel Cleaning kit Cleaning brush, small Cleaning brush, large The following are also included in the package contents but not pictured: Lambdatronic control unit, pressure relief valve, pressure/temperature... -
Page 21: Fitting Doors On The Left
Re-install the radiation plate Fix the gasket in place using gasket cement To re-mount the door, perform removal procedure in reverse Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 21 www.froling.com M1060008_US... -
Page 22: Fitting The Door Handles
Boiler Installation Boiler assembly 3.4.2 Fitting the door handles For the fuel loading chamber door: Position the door handle in the hole provided Insert flange bushing into door handle Fasten the door handle in place Repeat the above steps for the pre- ... -
Page 23: Installing The Fhg
The flap with the spring (2) must be at the left-hand air duct. Position the flaps on the opposite side Caution: Install the flaps in the same position. Secure the flaps with the split pins Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 23 www.froling.com M1060008_US... -
Page 24: Left-Hand Actuators
Boiler Installation Boiler assembly Left-hand actuators Unscrew and remove the stop screws on the right-hand side of the boiler and fit to the left-hand side Insert the pneumatic rod at the right-hand side of the boiler Carry out the remaining steps as for ... -
Page 25: Final Steps Before Insulating
Push in the pre-cut perforated corners at the cleaning ports to form an angle of approximately 100° Do not remove the corners Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 25 www.froling.com M1060008_US... - Page 26 Boiler Installation Boiler assembly Insert the L-plate into the insulating side panel as shown Fix the L-plate in position using 3 self-tapping screws Caution! Air channels (1) must not be obstructed (do not insulate) Insert the insulating side panel into ...
- Page 27 Mount the lower spacer plate at the lower end between the insulating side panels and secure it using 2 self-tapping screws Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 27 www.froling.com M1060008_US...
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Page 28: Installing The Cleaning Port Door And Blank Cover
Boiler Installation Boiler assembly Installing the cleaning port door and blank cover Slide the complete side insulation assembly towards the rear until the black, perforated L plates meet the front face of the boiler body. Recommendation: Install the cleaning port door on same side as the cleaning lever. -
Page 29: Installing The Insulating Back Panel
(1) and turn the actuator anti- clockwise to the “0” position Turn the selector switch (2) to position “L” using a screw-driver Fit the torque support to the actuator Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 29 www.froling.com M1060008_US... -
Page 30: Fitting The Induced Draught Fan
Boiler Installation Boiler assembly Attach the left- and right-hand cover plates using self-tapping screws Push the actuator onto the pneumatic rod and fasten in position Label 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 ... -
Page 31: Installing The Insulating Door And Insulation Cover
2 M6 x 12 hexagon head screws Slide the door bracket, together with the U-profile, into position and attach using 2 hexagon head screws hexagonal screws Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 31 www.froling.com M1060008_US... - Page 32 Boiler Installation Boiler assembly Mount the insulating door onto the lower door bracket using the hexagon head screw Attach the insulating door at the upper door bracket using a hinge Adjust so there is an air gap of ...
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Page 33: Installing The Floor Insulation
Position the cleaning lever Fit the spacer tube (1) and the heat-exchanger bracket (2) Slide the cleaning lever fully into position and secure using clamping jaws Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 33 www.froling.com M1060008_US... -
Page 34: Installing The Control Unit
Boiler Installation Boiler assembly Place the upper cleaning port cover in position and lock the linkage into place by turning it clockwise to tighten Installing the control unit Position the control box on the boiler Remove the cover from the control unit ... -
Page 35: Installing The Lambda Probe
See chapter 3.7 Electrical connection Position the pieces of insulating wool pad on the left and right of the flue pipe nozzle Position the insulation covers Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 35 www.froling.com M1060008_US... -
Page 36: System Plumbing
140 ºF (60 ºC), is required to temper return water to prevent cold return water from reaching the boiler. This valve helps prevent boiler corrosion. Plumbing diagrams --> Conceptual plumbing diagrams for the Froling FHG are provided in Appendix 10.1 and are also available from Tarm Biomass. -
Page 37: Electrical Connection
Work on electrical components is very dangerous. Avoid severe personal injuries and death. Only licensed electricians to perform electrical work! 3.7.1 Core Module - Overview Both jumpers must be set! Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 37 www.froling.com M1060008_US... -
Page 38: Connecting Actuators
Boiler Installation Electrical connection 3.7.2 Connecting actuators Primary and Secondary Air Damper Actuator Feed Through Air Feed Air Damper Plug in Air Damper Damper Wires Wires Through Wire Wire Connectors Knockout Induced Draft Fan Feed Draft Fan Wires Feed Wires Through Plug in Draft Fan through Back Panel Wire Knockout... -
Page 39: Connecting Sensors
Feed through Flue Gas Plug in Flue Sensor Connect Wires to Sensor Wires Connector Connector Lambda Probe Feed through Lambda Feed Wires through Plug in Broadband Probe Wires Wire Knockout Probe Connector Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 39 www.froling.com M1060008_US... -
Page 40: Sensor Of Door Switch
Boiler Installation Electrical connection Sensor of Door Switch Feed through Door Connect Wires to Plug in the Door Sensor Switch Wires Connector Switch Connector Sensors for Thermal Storage System Feed through Sensor Connect Wires to Plug in Sensor 1 Wires Connector Connector Plug in Sensor 2... -
Page 41: Boiler Sensor And Sensor Of Safety Temperature Limiter
Install bulbs into well Prepare STL bulb and Make sure the sensors boiler temperature are pushed completely sensor into well Install overheat aquastat bulb and well Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 41 www.froling.com M1060008_US... -
Page 42: Connecting Main Supply And Pump 1
Boiler Installation Electrical connection Connecting Main Supply and Pump 1 Mount Interface Panel Loosen Mounting Nut Mount Wire End into Control Head Attach this end to Remove Knockouts on circulator Strain Relief Plate Install Plate Page 42 M1060008_US... -
Page 43: Wiring Diagram
Boiler Installation Electrical connection Wiring diagram Wiring diagram for overheat aquastat connections Honeywell L4008B (Overheat Control) Set to 200ºF Largest Heat Typical Circulator or Zone Zone Valve Controller Thermostat Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 43 www.froling.com M1060008_US... -
Page 44: First Start-Up
First Start-up 4 First Start-up 4.1 General information IMPORTANT: First start up of boiler system shall be carried out only in attendance of an authorized installer or manufacturer’s representative During normal operation of boiler all surfaces and control handles behind insulation door get hot. -
Page 45: Error Status Of Boiler Control System
4.1.5 Starting the boiler for the first time Please refer to the Operation and Service Manual Section 3.1.5 “Starting the boiler for the first time” for first start-up instruction. Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 45 www.froling.com... -
Page 46: Boiler Control System Lambdatronic S 3200
Boiler Control System Lambdatronic S 3200 5 Boiler Control System Lambdatronic S 3200 This chapter contains information about use, control parameters, of the Boiler Control System Lambdatronic S 3200. All parameters, which are visible at the service technician operator level, are shown. The parameters at Owner’s level are shown with a grey background! 5.1 Overview of the Basic Functions 5.1.1 Control keys and Display... -
Page 47: Function Keys
The info key can be pressed at any time and always shows a text window, with information about the current menu point or the currently pending error. Error messages always have the highest priority. Info key in normal operation: Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 47 www.froling.com M1060008_US... - Page 48 Boiler Control System Lambdatronic S 3200 In normal operation (without error The info text is also identified by the frame messages) the info key can be pressed to and the info symbol in the status line. display information or an explanation for every menu point or parameter.
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Page 49: Graphical Display
Three or four dashes in loading status symbol: Do not heat up or recharge the boiler! The Thermal Storage System is still too hot to store additional amount of energy. Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 49 www.froling.com M1060008_US... -
Page 50: Operating Modes
Boiler Control System Lambdatronic S 3200 5.1.5 Operating modes Heating up Mode of Boiler Control System during the heating process up to a certain minimum flue gas temperature. Induced Draft Fan and primary air at 100%. In case of requested fueling wait for operating mode “Heating” or “Off” Heating The Boiler Control System controls combustion according to the boiler set points. -
Page 51: Initial Start-Up (Programming The Controller)
Detailed level for Installation and Service purposes. All parameters and system controls available are displayed and released for adjustment. All parameters shown in these operating instructions are available. *Installer: Please call Tarm Biomass for Installer Code. Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 51 www.froling.com M1060008_US... -
Page 52: Setting Parameters
Boiler Control System Lambdatronic S 3200 5.3 Setting parameters Changing values is very simple and is the identically for all parameters: Save value and go back Unlock parameter for processing Larger Navigate to the desired parameter Smaller Back without saving ... -
Page 53: Menu Overview
Storage tank pump control Function not used! Pump control either 0% or 100% speed! Specifies the speed of the Thermal Storage System circulator as a percentage of maximum speed. *Verify sensor readings. Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 53 www.froling.com M1060008_US... -
Page 54: Menu - Boiler
Boiler Control System Lambdatronic S 3200 5.6 Menu – Boiler 5.6.1 Status Displays for the Boiler Display Description Boiler temperature 80°C Actual state values of boiler control system Flue gas temperature 167°C Flue gas setpoint 165°C Boiler control variable ID fan - control ID fan speed 3240U Primary air... -
Page 55: Menu - Manual
All other pump outputs (circulators): not used address 0 A 0% Pump 1 at hydraulic module address 7 A 0% Pump 2 at hydraulic module address 7 A 0% Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 55 www.froling.com M1060008_US... -
Page 56: Digital Inputs
Boiler Control System Lambdatronic S 3200 5.7.3 Digital Inputs Digital Inputs Description Door switch This menu is used to test the digital inputs by service technicians only! The parameters displayed vary depending on the configuration. Hi-limit stat input In Automatic mode the state of the output signal can be supervised: E-stop input A ... -
Page 57: Adjustable Parameters - Flue Gas
100°C this time starts to run. If it is certain that within this time the two values do not change, the error note “Boiler has air leak” will be displayed. *Change from 90m. Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 57 www.froling.com M1060008_US... -
Page 58: Adjustable Parameters - Lambda Values
Boiler Control System Lambdatronic S 3200 Adjustable Parameters - Lambda values Parameter Description Residual oxygen content The air dampers are regulated according to this target value. setpoint 8.0% Residual oxygen content, If the residual oxygen content in flue gas exceeds this value during above which it switches “Heating”... -
Page 59: Current System Values
Position 1 Boiler temperature, flue gas temperature, Thermal Storage Position 2 System top temperature, Thermal Storage System bottom temperature, Thermal Storage System graphic, residual Oxygen, Induced Draft Fan Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 59 www.froling.com M1060008_US... -
Page 60: Language Settings
Boiler Control System Lambdatronic S 3200 5.8.3 Language settings Current menu language can be changed, e.g. to French (User Code “Installer” necessary) 5.8.4 Time settings In American configuration Date and Time are used for display purposes only! Format of Calendar Date: Weekday (2 letters) –... -
Page 61: System Parameters
Pellet boilers P4 or Pellet boiler P4 - 38 Turbomatic Turbomatic Turbomatic 28...55 Turbomatic 70...110 Wood boiler F2 22 / 30 * All marked components not used! Adjust parameter to NO! Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen, Austria Page 61 www.froling.com M1060008_US... -
Page 62: System Selection
Boiler Control System Lambdatronic S 3200 System selection Syst. selection - Hydraulic system 0 Hydraulic system 1 Do not select! Hydraulic system 2 Hydraulic system 3 Hydraulic system for S3 boiler Select this System only! (Next prompt is NO) H3200 Variant 1 H3200 Variant 2 und 5 Do not select!
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