Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected]www.froeling.com Installation Instructions Turbomatic TMC 28-55 Be sure to read and comply with the operating instructions and safety instructions. Subject to technical change.
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Be sure to read and comply with the operating instructions and safety instructions. Subject to technical change.
Introduction
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Dear customer, The FRÖLING Turbomatic wood chip boiler features a state-of-the-art design that conforms to all currently applicable standards and testing guidelines. Please read and follow the installation instructions. They contain safety instructions and comprehensive information relating to transporting, setting up and assembling the boiler. 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. Subject to technical change.
Delivery Certificate Keeping a record that the delivery was received correctly and collecting customer-specific data relating to the system allows us to respond quickly should problems arise. We would therefore ask you to confirm that you have received the product in good condition. Please send Fröling a copy of the delivery certificate, filled in and signed by the customer.
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. You can also find the guarantee conditions in the enclosed guarantee certificate.
Address of manufacturer
FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL +43 (0)7248 606 0 FAX +43 (0)7248 606 600 E-MAIL [email protected] WEBSITE www.froeling.com
Contents
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1 General Information 6
1.1 Notes on Standards 6 1.2 Design Information 7
1.2.1 Approval and obligation to report ...................................................................... 7 1.2.2 Requirements for central heating water ............................................................. 7 1.2.3 Ventilation of boiler room ................................................................................ 7 1.2.4 Installing the heating system / Standards .......................................................... 8
Combination with storage tank ......................................................................... 8 Return feed lift ............................................................................................... 8
1.2.5 Chimney connection/chimney system ................................................................ 9 Draught limiter............................................................................................... 9 Boiler data for constructing the flue gas system:................................................. 9
Test data for operation with wood chips ........................................................... 12 Test data for operation with pellets ................................................................. 13
3.2 Setting up in the boiler room 14 3.2.1 Removing the boiler from the pallet ................................................................ 14 3.2.2 Moving the boiler in the boiler room ................................................................ 14 3.2.3 Minimum distances in the boiler room.............................................................. 15 3.2.4 General information for boiler room................................................................. 15
3.3 Assembly work 16 3.3.1 Installing the chamber in the boiler ................................................................. 16 3.3.2 Installing the stoker...................................................................................... 19
Installing the burn back flap drive (only with burn back flap) .............................. 20 3.3.3 Installing the induced draught fan................................................................... 21 3.3.4 Installing the WOS Drive ............................................................................... 22 3.3.5 Fitting the automatic heat exchanger ash removal (optional) .............................. 23
Conversion for ashcan on right ....................................................................... 23 Assembly work on boiler................................................................................ 24
3.3.6 Installing the combustion chamber overpressure sensor..................................... 26 3.3.7 Fitting switch cabinet and cable ducts.............................................................. 26
3.4 Electrical connection 28 3.4.1 Laying the cable ........................................................................................... 28
Assembly and installation by untrained personnel! Risk of injury and damage to equipment!
Only allow trained technicians (heating installers or licensed electricians) to perform set-up and installation!
1.1 Notes on Standards
ÖNORM/DIN EN 303-5 Heating boilers for solid fuels, hand and automatically stocked, nominal heat output of up to 300 kW - Terminology, requirements, testing and marking
ÖNORM M 7510 Guidelines for checking central heating systems
ÖNORM / DIN EN 12828 Heating systems in buildings - design of water-based heating systems
ÖNORM B 8130 Safety devices, open water-heating systems
ÖNORM B 8131 Closed water-heating systems, safety requirements
DIN 4751 Parts 1-4 Heating system safety equipment
ÖNORM / DIN EN 13384-1 Chimneys serving one appliance
ÖNORM M 7515 / DIN 4705-1
Calculating chimney dimensions for combustion systems
TRVB H118 Technical directives for fire protection/prevention
ÖNORM H5170 Construction and fire protection requirements
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 only).
VDI 2035 Prevention of damage in water heating installations - Scale formation in domestic hot water supply installations and water heating installations (Germany only)
SWKI 97-1 Limescale and corrosion protection in heating systems (Switzerland only)
It is forbidden to carry out modifications to the boiler or to change or deactivate safety equipment. In addition to the documentation provided and the regulations for installation and operation of the boiler system applicable in the country in which the boiler will be operated, all fire, police, and electrical regulations must be observed.
1.2.1 Approval and obligation to report
NOTICE
Each heating system must be officially authorised. The appropriate supervisory authority (inspection agency) must always be informed when installing or modifying a heating system, and authorisation obtained from the building authorities. Austria: Inform the civic/municipal building authorities. Germany: Register with an approved chimney sweep/the building authorities.
1.2.2 Requirements for central heating water
The requirements pertaining to the water used to fill the boiler are based on the following standards and guidelines:
Applicable standards and guidelines: Austria: ÖNORM H 5195-1 Germany: VDI 2035 Switzerland: SWKI 97-1
There are no other special requirements for central heating water.
Note on filling with make-up water: bleed the filling hose before connecting to prevent air from getting into the system.
1.2.3 Ventilation of boiler room
The openings for the supply air and the exhaust air should be arranged as close to opposite each other as possible to achieve a good thermal draught effect.
The supply air should be fed in directly from outside. Unless otherwise stipulated by the building regulations applicable to the room where the boiler is to be installed, the following standards shall apply:
Applicable Standards: - TRVB H 118 - ÖNORM H 5170
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General information Notes on standards
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1 1.2.4 Installing the heating system / Standards
The following standards govern the installation of heating systems:
Applicable Standards: ÖNORM / DIN EN 12828 Heating Systems in Buildings The following prior standards still apply: Austria: - Closed systems as per ÖNORM B 8131 - Open systems as per ÖNORM B 8130 Germany: - Closed systems as per DIN 4751 Part 2 - Open systems as per DIN 4751 Part 1
Combination with storage tank
NOTICE
It is not generally necessary to use a storage tank for the system to run smoothly. However we recommend that you use it with a storage tank, as this allows you to achieve continuous reduction within the ideal performance 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 Fröling.
Return feed lift If the hot water return feed is below the minimum return feed temperature, some of the hot water outfeed will be mixed in.
CAUTION
Risk of dropping below dew point/condensation formation if operated without return feed lift. Condensation water forms an aggressive condensate when combined with combustion residue, leading to damage to the boiler.
Regulations stipulate the use of a return feed lift.
The minimum return feed temperature is 55 °C. We recommend fitting some kind of control device (e.g. thermometer).
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 technical specification sheets.
Boiler data for constructing the flue gas system The connection between the boiler and the chimney system should be as short as possible. The incline of the connection should not exceed 30 - 45°. Insulate the connection. The entire flue gas system (chimney and connection) must be calculated as per ÖNORM/DIN EN 13384-1 or prior standards ÖNORM M 7515/DIN 4705-1. Local regulations and other statutory regulations also apply.
The chimney must be authorised by a smoke trap sweeper or chimney sweep.
As per TRVB H 118 (only in Austria) an explosion flap must be installed in the flue pipe or in the chimney.
Draught limiter
We recommend that a draught limiter is fitted (1)
Install the draught limiter directly under the mouth of the flue line, as the pressure is lower at this location.
Boiler data for constructing the flue gas system
Description Units 28 35 48 55
Flue gas temperature RL PL
°C 165 120
180 120
170 120
185 120
Flue gas mass flow RL PL
kg/s 0.025 0.009
0.031 0.011
0.040 0.015
0.050 0.017
Required feed pressure RL PL
mbar 0.12 0.06
0.15 0.08
0.18 0.12
0.20 0.14
Flue pipe diameter mm 150 150 150 150
RL = Rated load, PL = Partial load;
1
Technology Dimensions
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2 Technology
2.1 Turbomatic TMC 28-55 dimensions
Pos. Description Unit TMC 28 / 35 TMC 48 / 55
H Height of boiler 1425 1520
H1 Overall height 1825 1835
H2 Height, flue pipe connection 1525 1630
H3 Height, outfeed connection 1275 1375
H4 Height, return connection 140 140
H5 Height, drain 120 120
H8 Height, induced draught fan connection 1210 1310
1) Values for boiler sizes 35 kW and 48 kW are interpolated (calculated as per EN 303-5)
Installation Transport and setup
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3 Installation
3.1 Transport
The boiler comes in cardboard packaging on 3 pallets together with the chamber discharge unit.
Move the boiler without jarring or jolting Follow the transport instructions on the packaging when moving the boiler.
3.1.1 Positioning
Place a fork-lift or similar lifting device with a minimum fork length of 1100 mm and an appropriate load-bearing capacity at the pallet and position the boiler
If it is not possible to position the boiler on the pallet:
Remove cardboard packaging Remove boiler from pallet
See 3.2.1 Removing the boiler from the pallet
3.1.2 Temporary storage
If the system is to be installed at a later date: Store the boiler, insulation and control unit in a safe, dust-free, and
dry location Moisture reduces the effectiveness of the insulation and destroys electronic components.
3.2 Setting up in the boiler room
3.2.1 Removing the boiler from the pallet
Remove 4 screws from the boiler
bottom Lift the boiler off the pallet
3.2.2 Moving the boiler in the boiler room
Position a fork-lift or similar lifting device with an appropriate load-bearing capacity at the base frame of the boiler and lift
Set up boiler at intended location
Observe the minimum distances in the boiler room (see 3.2.3).
The following steps will guide you through the assembly process when installing a G30 stoker. If you are using a G50 stoker, the connection flange comes out of the insulation (see image on left). The assembly steps apply by analogy in the same order.
Assembly G50 stoker
Attach seal for stoker duct and fit stoker unit
Screw in carrying bolt on stoker flange and tighten
Assembly G30 stoker
A
B
E C
D F
Installation Assembly work
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Fit left and right cover plates to insulation on stoker duct
Installing the burn back flap drive (only with burn back flap)
Back-fire flap drive must be pre-tensioned by 5°. (delivery configuration)
See included manufacturer’s documentation for how to pre-tension the drive
Insert clamping piece as illustrated (90° position) and secure at back with fixing clamp
Attach drive to shaft of burn back flap
Tighten clamping piece so that the clamp and triangular shafts fit positively
3.3.5 Fitting the automatic heat exchanger ash removal (optional)
A Ash baffle (2x with Turbomatic 48-55)
B Flange with ash plate
C Ash screw
D Ash removal flange for ashcan
E Ashcan
F Geared motor
not shown Rubber seal and screw set
NOTICE
The components for assembling the ashcan come delivered on the left hand side of the boiler. If you want the ashcan on the right hand side the flanges must be changed round.
Conversion for ashcan on right
Unscrew 2 hexagonal screws on the ash removal flange Turn the flange plate 180° Reassemble the ash removal flange
A D
C E
F
B
Installation Assembly work
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Dismantle the flange by undoing the screws Turn the flange plate and the insulating plate 180° Reassemble the flange
Assembly work on boiler
Fit the geared motor and seal to the flange as illustrated using the hexagonal screws provided
Do not tighten the screws yet
Remove the sticky tape and key-way safety device from the shaft stub on the ash screw
Thread the ash screw through the gears
Ensure that the ash screw is threaded into the gear key-way.
3.5 Connecting the thermal discharge safety device
NOTICE
The thermal discharge safety device must be connected in accordance with ÖNORM/DIN EN 303-5 as shown in the following diagram.
The discharge safety device must be connected to a pressurised mains water supply in such a way that it cannot be shut off.
1 Thermal discharge safety device sensor
2 Thermal discharge safety device (opens at 95 °C)
3 Safety valve
4 Cleaning valve (T-piece)
5 Check valve
6 Dirt trap
7 Pressure reducing valve*)
*) Required when the cold water pressure is greater than 6 bar. It must be not be possible to shut off the connection manually. Minimum cold water pressure = 2 bar
3.5.1 Thermal discharge safety device sensor
Remove front blind plug and seal
immersion sleeve Insert sensor for thermal discharge
safety device in immersion sleeve
1
2
7
6
5
4
3
Initial startup / decommissioning
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4 Initial startup / Decommissioning
4.1 Configuring the boiler
The boiler must be adjusted to the requirements of the heating system during commissioning
NOTICE
Optimum performance and efficient operation with low emissions can only be guaranteed if the system is set up by a qualified technician and the specified factory settings are observed.
Take the following precautions:
We recommend that the system is commissioned by Fröling customer services or an authorised installer.
Before heating up the boiler for the first time:
Adjust the control unit to the system type The keypad assignment and the steps necessary to modify the control parameters are detailed in the accompanying operating instructions for the boiler control unit.
4.2 Mothballing
If the boiler is out of service for several weeks (e.g. during the summer), we recommend that you perform the following maintenance tasks:
Carefully clean the boiler Completely close all doors and flaps
If the boiler is to remain out of service during the winter:
Have the system completely drained by a qualified technician Protect against frost!
4.3 Disassembly
To disassemble the boiler, perform the assembly steps in reverse order. Installation steps see 3.3 Assembly work
4.4 Disposal
Dispose of all waste in an environmentally-friendly manner and in accordance with waste disposal regulations.
Separate and clean recyclable materials and send them to a recycling centre.
Operating principle and self-checking of safety devices discussed
All technical documentation handed over (documentation, certificate of conformity, ...)
Test heating performed
Commissioning report given to customer
Telephone number for manufacturer’s service department indicated
Rating plate attached
Following items checked:
No defects found
Notice: All national and regional regulations relating to initial testing and subsequent testing of the system must be observed. Please be advised that, in Austria, commercial systems with a rated heat output ≥ 50 kW must be regularly tested at yearly intervals in accordance with the Heating Plant Regulations (FeuerungsanlagenVO).
Date Customer Installer
Finally, we ask that you have the customer sign a copy of this confirmation and send it to FRÖLING Ges.m.b.H. Fax: +43 (0)7248 606 600