Installation Instructions
Turbomat TM 150 - 250
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M0650314_en | Edition 11/08/2014
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Table of Contents
1 General 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 Personal protective equipment for assembly staff 6
2.4 Design Information 6
2.4.1 Notes on standards 6
General standards for heating systems
6
Standards for structural and safety devices
7
Standards for heating water
7
Regulations and standards for permitted fuels
7
2.4.2 Installation and approval of the heating system 7
2.4.3 General information for installation room (boiler room) 8
2.4.4 Requirements for central heating water 8
2.4.5 Notes for using pressure maintenance systems 9
2.4.6 Return lift 10
2.4.7 Use with storage tank 10
2.4.8 Chimney connection/chimney system 10
Draught limiter
11
Boiler data for planning the flue gas system
11
3 Technology 12
3.1 Dimensions 12
3.2 Components and connections 13
3.3 Technical data 14
4 Installation 16
4.1 Transport 16
4.2 Positioning 16
4.3 Temporary storage 16
4.4 Setting up in the boiler room 16
4.4.1 Moving the boiler in the boiler room 16
4.4.2 Minimum space requirements in the boiler room 17
4.5 Installing the boiler 18
4.5.1 General information 18
4.5.2 Bolting together the combustion chamber and heat exchanger 19
4.5.3 Fitting the thermal discharge safety sensor 20
4.5.4 Installing the combustion chamber firebricks 21
4.5.5 Changing over the WOS rods (where necessary) 23
4.5.6 Fitting the insulation base frame 25
4.5.7 Fitting the insulating side panels 27
4.5.8 Fitting the ash cans to the heat exchanger ash removal unit 29
4.5.9 Fitting the heat exchanger ash removal unit with ash screw (optional) 30
4.5.10 Fitting the combustion chamber ash removal unit 34
4.5.11 Fitting the control cabinet 36
4.5.12 Fitting the combustion air fan 37
4.5.13 Fitting the safety temperature limiter, boiler sensor and return sensor. 38
Table of Contents
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4.5.14 Fitting the door contact switch 39
4.5.15 Fitting the WOS Drive 40
4.5.16 Installing the grate drive 41
4.5.17 Installing the stoker unit 42
4.5.18 Installing the induced draught fan 43
4.5.19 Fitting the primary and secondary air servo motors 45
4.5.20 Fitting the cover on the slide-on duct 46
4.5.21 Installing the underpressure controller 47
4.5.22 Installing the automatic ignition 47
4.5.23 Installing the combustion chamber overpressure and temperature sensors 48
4.5.24 Fitting the temperature sensor under the moving grate 49
4.5.25 Fitting the broad band probe and flue gas sensor 49
4.5.26 Assembling the FGR (optional) 50
4.5.27 Fitting the covers to the back of the heat exchanger 53
4.5.28 Fitting the insulated doors and the ash container to the combustion chamber 54
4.6 Power connection and wiring 55
4.6.1 Potential equalisation 55
4.6.2 Fitting the insulation cover and the cover plate 56
4.7 Connecting up thermal discharge safety sensor connection 57
4.8 Connecting up the slide-on duct cooling 58
4.9 Final installation steps 59
4.9.1 Setting and testing the seal on the combustion chamber doors 59
Checking the settings of the door stop
59
Checking the settings of the door handle
59
Checking the door stop seal
60
Checking the door handle seal
60
4.9.2 Adjusting the combustion chamber doors 61
Door stop side
61
Door handles
61
5 Commissioning 62
5.1 Before commissioning / configuring the boiler 62
5.2 Initial startup 63
5.2.1 Permitted fuels 63
Wood chips
63
Wood pellets
63
Wood shavings
63
Miscanthus
64
Changing the fuel
64
5.2.2 Non-permitted fuels 64
5.3 Heating up for the first time 65
6 Decommissioning 66
6.1 Out of service for long periods 66
6.2 Disassembly 66
6.3 Disposal 66
7 Appendix 67
7.1 Addresses 67
7.1.1 Address of manufacturer 67
7.1.2 Address of the installer 67
Table of Contents
Installation Instructions | M0650314_en 3
1 General
Thank you for choosing a quality product from Froling. The product features a state-ofthe-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 the
system for reference. Observing the requirements and safety information in the docu‐
mentation makes a significant contribution to safe, appropriate, environmentally friend‐
ly and economical operation of the system.
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:
doku@froeling.com.
Subject 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 or
heating engineers are requested to return a copy of the delivery certificate together
with the guarantee card to Froling. On commissioning by FROLING Customer Service
the validity of the delivery certificate will be noted on the customer service record.
Issuing a delivery cer‐
tificate
1
General
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2 Safety
2.1 Hazard levels of warnings
This documentation uses warnings with the following hazard levels to indicate direct
hazards and important safety instructions:
DANGER
The dangerous situation is imminent and if measures are not observed it will lead
to serious injury or death. You must follow the instructions!
WARNING
The dangerous situation may occur and if measures are not observed it will lead
to serious injury or death. Work with extreme care.
CAUTION
The dangerous situation may occur and if measures are not observed it will lead
to minor injuries or damage to property.
Safety
2
Hazard levels of warnings
Installation Instructions | M0650314_en 5
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 services
The assembly staff must have read and understood the instructions in the documenta‐
tion.
2.3 Personal protective equipment for assembly staff
You 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
2.4 Design Information
2.4.1 Notes on standards
The system must be installed and commissioned in accordance with the local fire and
building 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 heating
systems
EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods
Part 1: Chimneys serving one appliance
2
Safety
Qualification of assembly staff
6 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
ÖNORM M 7510-1 Guidelines for checking central heating systems
Part 1: General requirements and one-off inspections
ÖNORM M 7510-4 Guidelines for checking central heating systems
Part 4: Simple check for heating plants for solid fuels
Standards for structural and safety devices
ÖNORM H 5170 Heating installation - Requirements for construction and safety
engineering, 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 in
closed warm water heating systems at operating temperatures
up to 100 °C (Austria)
VDI 2035 Prevention of damage in water heating systems (Germany)
SWKI 97-1 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
D.P.R. n° 412 Regulations for the planning, installation, running/operation and
maintenance of heating systems in buildings to reduce energy
consumption with reference to Article 4, Comma 4 of the Legis‐
lative Decree of 9 January 1991, No. 10 (Italy)
Regulations and standards for permitted fuels
1. BImSchV First Order for the implementation of the Federal Law on emis‐
sion protection (Ordinance on Small and Medium Combustion
Plants) in the version published on 26 January 2010,
BGBl. JG 2010 Part I No. 4.
EN 14961-2 Solid bio-fuel - Fuel specifications and classes
Part 2: Wood pellets for non-industrial use
EN 14961-4 Solid bio-fuel - Fuel specifications and classes
Part 2: Wood chips for non-industrial use
2.4.2 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern 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 informed
when installing or modifying a heating system, and authorisation must be obtained
from the building authorities:
Note on standards
Safety
2
Design Information
Installation Instructions | M0650314_en 7
Austria: report to the construction authorities of the community or magistrate
Germany: report new installations to an approved chimney sweep / the building au‐
thorities.
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 where
the boiler is installed.
▪ Keep the air suction opening of the boiler free from dust.
Ventilation of the boiler room
Ventilation 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.
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 requirements
TRVB H118 - Technical directives on fire protection/prevention
2.4.4 Requirements for central heating water
The following standards and guidelines apply:
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195-1
VDI 2035
SWKI 97-1
D.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.
Note on standards
Note on standards
2
Safety
Design Information
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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 systems
Pressure maintenance systems in hot-water heating systems keep the required pres‐
sure within predefined limits and balance out volume variations caused by changes in
the 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. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐
to the heating 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 releases
hot water into the receiving tank if the pressure is too high. If the pressure drops below
a preset value, the pump draws water from the receiving tank and feeds it back into
the heating system. Pump-controlled pressure maintenance systems with open expan‐
sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the
water, exposing the connected system components to the risk of corrosion. These
systems offer no oxygen removal for the purposes of corrosion control as required by
VDI 2035 and in the interests of corrosion protection should not be used.
Safety
2
Design Information
Installation Instructions | M0650314_en 9
2.4.6 Return lift
If the hot water return is below the minimum return temperature, some of the hot water
outfeed 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:
❒ Regulations stipulate the use of a return temperature control.
➥ The minimum return temperature is 65 °C. We recommend fitting some
sort 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 this
ensures 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 accordance
with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling.
⇨ See "Addresses" [page 67]
2.4.8 Chimney connection/chimney system
EN 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 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 table below.
The connection between the boiler and the chimney system should be as short as
possible. The upward angle of the connection should not exceed 30° - 45°. Insulate
the 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.
2
Safety
Design Information
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NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney
sweep.
Draught limiter
We generally recommend the installation of a draught limiter. A draught limiter must
be installed if the maximum permissible feed pressure as given in the boiler data for
planning the flue gas system is exceeded.
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the
pressure is constantly low at this point.
Boiler data for planning the flue gas system
Description TM 150 TM 200 TM 250
Flue gas temperature at nominal load °C 150 150 150
Flue gas temperature at partial load 110 110 110
Flue gas mass flow with wood chip W30,
13% O
2
m3/h
(kg/h)
807 (665) 1071 (882) 1346 (1108)
Flue gas mass flow with wood chip W30,
9% O
2
511 (420) 648 (557) 852 (700)
Flue gas mass flow with wood pellets 13%
O
2
673 (559) 893 (741) 1121 (931)
Flue gas mass flow with wood pellets 9%
O
2
426 (355) 566 (471) 711 (591)
Required feed pressure at outlet of induced
draught housing at nominal load
Pa 2 2 2
mbar 0.02 0.02 0.02
Required feed pressure at outlet of induced
draught housing at partial load
Pa 5 5 5
mbar 0.05 0.05 0.05
Maximum permissible feed pressure Pa 50 50 50
mbar 0.5 0.5 0.5
Flue gas pipe diameter mm 200 250 250
Safety
2
Design Information
Installation Instructions | M0650314_en 11
3 Technology
3.1 Dimensions
Posi‐
tion
Description Unit TM 150 TM 200 TM 250
H1 Boiler height including insulation mm 1880 1880 1880
H2 Height, flow/return connection mm 1935 1935 1935
H3 Height of stoker including burn back protection system mm 790 850 850
H4 Height, flue gas pipe connection without FGR mm 770 1080 1080
H5 Height, flue gas pipe connection with FGR mm 1105 1080 1080
B Total width including fittings mm 2170 2180 2180
B1 Width, boiler including insulation mm 1870 1930 1930
B2 Width, ash trolley mm 870 870 870
L Total length including fittings mm 2630 2860 2860
L1 Length, combustion chamber without insulation mm 1720 1880 1880
L2 Length, stoker unit mm 940 970 970
L3 Length, ash container mm 600 600 600
L4 Length, heat exchanger without insulation mm 790 950 950
3
Technology
Dimensions
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3.2 Components and connections
E
Posi‐
tion
Description Unit TM 150 TM 200 TM 250
A Boiler return connection Inches 2½ 2½ 2½
B Boiler flow connection Inches 2½ 2½ 2½
C Thermal discharge safety sensor connection Inches ½ ½ ½
D Flue gas pipe connection without FGR (flue gas recircula‐
tion)
mm 200 250 250
E Flue gas pipe connection with FGR (flue gas recirculation) mm 150 150 150
F Broadband probe connection Inches 3/4 3/4 3/4
F Flue gas temperature sensor connection Inches 1/2 1/2 1/2
Technology
3
Components and connections
Installation Instructions | M0650314_en 13
3.3 Technical data
Description TM
150 200 250
Nominal heat output kW 150 199 250
Heat output range kW 45 – 150 59 - 199 75 – 250
Electrical connection 400V / 50Hz / fuse protection C35A
Power consumption (pellets, wood chip) W 545 / 657 578 / 659 612 / 660
Total weight including fittings kg 3300 3820 3820
Weight - combustion chamber 1150 1290 1290
Weight - heat exchanger 1000 1280 1280
Heat exchanger water capacity l 440 570 570
Water pressure drop (ΔT = 10 / 20 K) mbar 36 / 12 55 / 18 74 / 25
Minimum boiler return temperature °C 65
Maximum permitted operating temperature °C 90
Permitted operating pressure bar 3
Permitted fuel as per EN 14961
1)
Part 2: Wood pellets class A1 / D06
Part 4: Wood chips class A2 / P16A-P45A
Airborne sound level dB(A) < 70
1.Detailed information on the fuel is included in the operating instructions, in the section on “Permitted fuels”
150 200 250
Accredited Technical Inspection Association
TÜV
1)
TÜV
2) 3)
TÜV
1)
Test report no. 13-UW/Wels-
EX-033
14-U-187/SD 13-UW/Wels-
EX-308
Boiler class as per EN 303-5:2012 5 5 5
1.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels
2.
As per EN 303-5, Section 5.1.3 Type test: For a boiler from a range with the same constructional characteristics it is sufficient, if the ratio of nominal heat output from the largest to the
smallest boiler is ≤ 2:1, to perform the tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not been tested in
the range, whose values have been determined depending on the rated heat output by interpolation, fulfil the requirements of the standard.
3.Values for the Type TM 200 are between those for the TM 150 and the TM 250 as certified in test reports 13-UW/Wels-EX-033 and 13-UW/Wels-EX-308.
Test data for wood chips - emissions in [mg/MJ] (nominal load/partial load)
Carbon monoxide (CO) mg/MJ 2 / 50 5 / 54 8 / 58
Nitrogen oxide (NOx) mg/MJ 82 / 79 87 / 78 92 / 76
Organic hydrocarbons (OGC) mg/MJ <1 / <2 <1 / <2 <1 / <2
Dust mg/MJ 9 / 17 9 / 18 9 / 19
Boiler efficiency % 91.6 / 90.6 92.4 / 91.1 93.3 / 91.6
Test data for wood chips - emissions in [mg/m³]1) (nominal load/partial load)
Carbon monoxide (CO) mg/m³ 2 / 73 6 / 79 11 / 85
Nitrogen oxide (NOx) mg/m³ 120 / 116 127 / 114 135 / 111
Organic hydrocarbons (OGC) mg/m³ <1 / <2 <1 / <2 <1 / <2
Dust mg/m³ 13 / 24 13 / 25 14 / 27
Boiler efficiency % 91.6 / 90.6 92.4 / 91.1 93.3 / 91.6
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%
3
Technology
Technical data
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Test data for pellets - emissions in [mg/MJ] (nominal load/partial load)
Carbon monoxide (CO) mg/MJ 12 / 73 9 / 79 6 / 86
Nitrogen oxide (NOx) mg/MJ 67 / 53 63 / 53 59 / 53
Organic hydrocarbons (OGC) mg/MJ <1 / <2 <1 / <2 <1 / 1.0
Dust mg/MJ 9 / 10 8 / 11 6 / 13
Boiler efficiency % 93.4 / 91.2 93.7 / 91.4 94.1 / 91.7
Test data for pellets - Emissions in [mg/m³]1) (nominal load/partial load)
Carbon monoxide (CO) mg/m³ 13 / 107 11 / 117 9 / 127
Nitrogen oxide (NOx) mg/m³ 99 / 77 93 / 77 86 / 78
Organic hydrocarbons (OGC) mg/m³ <2 / <2 <2 / <2 <2 / 1.5
Dust mg/m³ 13 / 14 11 / 16 8 / 19
Boiler efficiency % 93.4 / 91.2 93.7 / 91.4 94.1 / 91.7
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%
Technology
3
Technical data
Installation Instructions | M0650314_en 15
4 Installation
4.1 Transport
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
❒ Unloading, positioning and installation should only be performed by trained
professionals! Staff must be trained in techniques for moving heavy loads
(correct tools and lifting equipment, hooking and slinging points, etc.)
4.2 Positioning
❒ Secure the slings or chains to the hooking point securely and position the boiler
4.3 Temporary storage
If 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!
4.4 Setting up in the boiler room
4.4.1 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.
4
Installation
Transport
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4.4.2 Minimum space requirements 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)
A
B
D
C
Posi‐
tion
Description Unit TM 150-250
A Distance between stoker and wall mm 400
B Distance between side of boiler (heat exchanger) and wall 300
C Distance between insulated door and wall 800
D Distance between side of boiler (combustion chamber) and wall 400
Installation
4
Setting up in the boiler room
Installation Instructions | M0650314_en 17
4.5 Installing the boiler
NOTICE
Reduction in performance due to air leakage
The use of flanges without sealing cords can result in a reduction in performance
due to air leakage
Therefore:
❒ Sealing cords or the surface sealant provided must be used on all the flanged
connections on the following components: loading; ash removal; pressure
ducting; air ducts; combustion air fan; flue gas and flue gas return piping.
4.5.1 General information
Front and back of boiler
The front of the boiler is its operating side. All of the operating controls for the combus‐
tion chamber door, ash can, control cabinet and other components are on the front of
the unit.
The back of the boiler is opposite the front The stoker unit, EOS drive and complete
flue gas system are on the back of the boiler.
Heat exchanger on the left or right
The heat exchanger of the Turbomat can be on the left or the right (when seen from
the front, operator side) of the combustion chamber. Before you start installation,
check if the heat exchanger is to be installed on the left or the right. In some cases this
is already indicated on the layout drawing.
Version: Heat exchanger left Version: Heat exchanger right
1 Combustion chamber 2 Heat exchanger
4
Installation
Installing the boiler
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NOTICE! The figures below show the instructions for installing a heat exchanger to the
right of the combustion chamber. If the heat exchanger is to be installed to the left, the
steps should be carried out in the same way but on the other side.
4.5.2 Bolting together the combustion chamber and heat exchanger
Positioning the combustion chamber
❒ Position the fork-lift under the combustion chamber from the side. Raise the com‐
bustion chamber just enough so that it can be positioned in the the heat exchang‐
er without colliding.
❒ Push the combustion chamber fully home into the side of the heat exchanger and
then slowly lower it into position.
Aligning and fixing the combustion chamber
Align the combustion chamber before you fix it to the heat exchanger. Align it with the
two referencing stops.
Referencing stop on the heat exchanger Referencing stop on the base frame
Installation
4
Installing the boiler
Installation Instructions | M0650314_en 19
After positioning the combustion chamber in the heat exchanger:
❒ Working through the openings in the base frame, insert and tighten the clamping
screws until the combustion chamber is tight against the heat exchanger.
➥ Check that the combustion chamber is aligned flush with the heat exchanger
and that the seal cord is lying evenly.
❒ On the back of the combustion chamber, remove the blanking plugs for combus‐
tion chamber overpressure sensor, the combustion chamber temperature sensor,
the automatic ignition and the underpressure controller.
❒
On the back of the combustion chamber, remove the support.
4.5.3 Fitting the thermal discharge safety sensor
❒ On the back of the heat exchanger, remove the blanking plug (1).
❒
Seal the immersion sleeve (2) and screw it into the heat exchanger.
❒ Push the thermal discharge safety sensor (3) into the immersion sleeve (2).
❒ Push the protective tube over the thermal discharge safety sensor and then slight‐
ly tighten the fixing screw (4).
4
Installation
Installing the boiler
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4.5.4 Installing the combustion chamber firebricks
❒ Remove the front cover (1) and the back cover (2) from the heat exchanger.
❒ Pass the ceramic fibre mats through the opening in the heat exchanger and lay
them in the combustion chamber as shown in the figure.
➥ Ensure that you lay two mats alongside each other on the heat exchanger side.
Installation
4
Installing the boiler
Installation Instructions | M0650314_en 21
❒ Pass the firebricks through the opening in the heat exchanger and lay them on the
ceramic fibre mats as shown in the figure.
➥ Tip: Positioning the firebricks is easier with two people standing on the opposite
sides of the chamber.
4
Installation
Installing the boiler
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❒ Refit the front cover (1) and the back cover (2) to the heat exchanger.
❒ Fit the blanking cover to the air duct channel on the front of the heat exchanger.
4.5.5 Changing over the WOS rods (where necessary)
The WOS drive is always fitted to the back of the boiler opposite the control cabinet. If
the heat exchanger is installed on the left it will be necessary to change over the WOS
rods as follows.
❒ Lock the lock nuts (1) on the knobs (2). Turn the knobs (2) clockwise until they
stop and then open the heat exchanger cover.
❒ Lock the clamping pad (3) on the WOS lever (4) and pull it out of the WOS shaft
(5).
❒ Remove the clamping bracket (6) and fit it on the opposite side.
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Installation Instructions | M0650314_en 23
❒ Remove the securing pin (7) and pull out the WOS shaft (5).
❒
Remove the washer (8).
❒ Unscrew the bearing bush (9) on the shaft.
❒ Remove the blanking plug (10) from the opposite side.
❒ Insert the WOS shaft (5) with the washer (8) on the opposite side and push it
through.
❒ Refit the bearing bush (9) and blanking plug (10) that you removed previously on
the opposite side.
❒ Secure the shaft (5) with the securing pin (7).
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24 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.5.6 Fitting the insulation base frame
NOTICE
The individual parts of the boiler insulation covered with a protective film. You
must remove the protective film before proceeding with installation.
❒ Fit the cross-piece (1) of the lower base frame to the boiler.
❒ Slide a piece of floor insulation (2) under the combustion chamber and another
piece under the heat exchanger.
❒ Fit the lengthways strut (3) to the cross-pieces (1).
➥ Ensure that the lugs on the cross-pieces and lengthways struts slot into each
other correctly (4).
❒ Position the heat insulation mat (1).
❒
Position the cable duct (2) on top and fix it to the heat exchanger.
❒ Fit the cross-piece (3) of the upper base frame to the cable duct (2).
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Installation Instructions | M0650314_en 25
❒ Fit the upper right hand part of the lengthways strut to the cross-pieces.
➥ Ensure that the punched marking “OUTSIDE” is legible when seen from the
right.
❒
Push the bracket under the heat exchanger on the left and fix in place with the
cross-piece.
❒ Push the bracket under the heat exchanger on the right and fix in place with the
cross-piece.
❒
Push the floor insulation into the front area under the heat exchanger.
❒ Fit the front lengthways strut (1) to the cable duct on the heat exchanger.
❒
Fit the cable duct (2) to the front lengthways struts (1).
❒ Fit the frame component (3) for the insulation door at the top to the front length‐
ways strut (1) and at the bottom to the brackets.
❒ Align the frame component (3) with the adjustable feet.
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26 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒ Attach the heat insulation mat with the cut-out (1) to the heat exchanger door.
❒
Position two sections of heat insulation mat (2) on top of the combustion chamber.
❒ Position the heat insulation mat (3) on the front of the heat exchanger door and fix
in place with spring clips.
4.5.7 Fitting the insulating side panels
Fit the insulation side panels to the combustion chamber as follows:
❒ Hang the insulation side panel at the bottom at the bracket (1) of the base frame.
❒
Hang the insulation side panel at the top at the bracket (2) of the base frame.
❒ Fix the insulation side panel at the top to the base frame with two screws.
NOTICE! Fit all the other side panels in the same way.
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Installation Instructions | M0650314_en 27
❒ Fit the crank shaft of the moving grate on the heat exchanger side used.
❒ Fit the insulation side panel to the right-hand side of the heat exchanger.
❒
Fit the insulation side panel to the back of the heat exchanger.
➥ Remove the pre-punched cut-out for the WOS from the insulation side panel.
❒ Fit the insulation side panel to the front of the heat exchanger.
❒
Fit the insulation side panel to the right-hand side of the combustion chamber.
➥ Fix it to base frame at the frame with four screws.
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28 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒ Fit the insulation side panel to the front, left hand side of the combustion chamber.
➥ Fix it to base frame at the frame with four screws.
❒
Fit the insulation side panel to the back, left hand side of the combustion chamber.
❒ When you have finished fitting all the side panels, check that they fit correctly.
➥ Check that the insulation side panels are flush and check that there are no
gaps between the insulation side panels.
➥ If necessary, slightly loosen the fixing the panels to the base frame, adjust and
align the insulation side panels and then re-tighten the screws.
4.5.8 Fitting the ash cans to the heat exchanger ash removal unit
❒ Fit the blanking plate (1) complete with the seal gasket (2) to the flange plate (3).
❒
Fit both flange plates to the back of the heat exchanger.
❒ Fitting the cover
❒
Push the ash cans (1) into the front of the heat exchanger and fix in place with the
star-grip screws (2).
❒ Fit the cover (3) above the ashcan.
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Installation Instructions | M0650314_en 29
4.5.9 Fitting the heat exchanger ash removal unit with ash screw (optional)
Heat exchanger right Heat exchanger left
The following instructions are for fitting the automatic heat exchanger ash removal
screw unit to a boiler with the heat exchanger mounted on the right. The instructions
also apply to boilers with the heat exchanger mounted on the left. It is important to
note that the gear motor (1) must always be mounted on the combustion chamber
side. This is to ensure that in the event of a roller chain fault ash removal will take
place at the first pull. With the heat exchanger on the right, the chain tensioner (2) is at
the bottom. With the heat exchanger on the left, the chain tensioner is at the top.
❒
Grease the shaft stub on both ash screws.
❒ Fit the gear motor (1) complete with the seal gasket (2) to the flange plate (3).
❒
Insert the ash screw (4) through the flange plate and into the gear motor.
➥ The key groove in the ash screw must be aligned with the key groove in the
gear motor.
❒ Slide the motor key (5) into the groove.
❒ Fit the sprocket (6).
❒ Slide the sprocket key (7) into the groove and fit the shaft retainer (8).
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30 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒ Fit the bearing bracket (1) to the flange plate (2).
❒
Insert the ash screw (3) through the flange plate.
❒ Fit the sprocket (4).
❒ Slide the key (5) into the groove and fit the shaft retainer (6).
❒ Push the flange plates with the ash screw into the back of the boiler as shown in
the figure. Fix to the insulation side panel with screws.
❒
Fit the chain tensioner (1) to the bearing block.
➥ Engage the chain tensioner (1) with the bolts on the bearing block so that the
chain is tensioned correctly.
❒ Set the sprocket on the chain tensioner so that all the three sprockets are aligned
with each other.
❒
Wind the roller chain onto the motor and bearing bracket sprockets. Tension the
chain and fix in place with the spacer sleeve.
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Installation Instructions | M0650314_en 31
❒ Fitting the cover over the heat exchanger ash removal unit
❒
Assemble the ash removal unit flange as shown in the figure below:
2 4
5 7
1 M8x25 hexagonal head screw 2 Ash removal flange
3 Spring washer 4 Locking lever
5 Bush 6 M8 toothed washer
7 M8 nut 8 Plastic grip
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32 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒ Fitting the ash removal unit flange to the front of the boiler
➥ Position the flanges so that the levers on the locking mechanism face out‐
wards.
❒
Fit the cover above the outer ash removal unit flange.
❒ Fit the safety switch (1) to the brackets (2).
❒
Align and fit both safety switches (1) complete with brackets (2) to the insulation
side panel.
➥ Do not fully tighten the screws yet
❒ Bend the clamp (3) over the insulation side panel. Lay the safety switch cable to
the control cabinet.
❒ Fit the cable duct under the safety switch.
➥ Insert the clamps into the insulation. Fold the cable duct upwards and fasten
with screws.
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Installation Instructions | M0650314_en 33
❒ Press the clamp (1) forwards and remove the cover plate of the ash cans.
➥ Store the cover plate in a suitable location where you can find it later. It will be
needed when disposing of the ash.
❒
Position both ash cans on the ash removal unit flanges.
❒ Push the side lever on the ash removal flange downwards to fix the ash can in
place.
❒
Push the key plate into the safety switch.
❒ Set the safety switch so that the key plate engages correctly.
❒ Tighten the safety switch screws.
4.5.10 Fitting the combustion chamber ash removal unit
❒ Fit the flange plate (1) with the seal (2) and the flange bearing (3) on the left of the
combustion chamber.
❒
Push the ash screw (4) with the seal washer (5) on the right of the combustion
chamber.
❒ Fit the spacer (7) and the circlip (8) to the shaft stub.
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34 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒ Fit the torque support (1) and the sensor bracket (2) to the gear motor as shown in
the figure.
❒
Fix the proximity sensor (3) to the sensor bracket (2).
❒ Fit the gear motor (4) onto the shaft stub.
➥ Ensure that the key groove the shaft stub is aligned with the key groove in the
gear motor.
❒ Slide the key (5) into the groove.
❒ First fit the shaft retainer washer (6) followed by the angle bracket (7) and then the
screw for the shaft retainer (6).
❒ Fit the cover (8) to the insulation side panel.
4 - 5mm
❒ Set the proximity sensor (3):
➥ Distance between sensor (3) and the angle bracket (7): 4 – 5mm
❒
Fitting the sensor cover on the sensor bracket.
If the heat exchanger is mounted to the left, modify the ash removal unit flange before
you start assembly as follows:
❒ Dismantle the lever on the ash removal flange, turn it through 180° and then refit
it.
Heat exchanger on the
left:
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Installation Instructions | M0650314_en 35
❒ Fit the ash removal unit flange with seal on the right of the combustion chamber.
❒
Fit the cover (1) for the ash removal unit flange.
❒ Fit the safety switch (2) to the bracket (3).
❒ Fit the bracket (3) to the insulation side panel.
❒ Bend the clamp (4) over the insulation side panel. Lay the safety switch cable to
the control cabinet.
4.5.11 Fitting the control cabinet
❒ Hang the control cabinet (1), with the fixing bolts (2) provided (flat-head bolts in
the control cabinet packaging), in the locating slots (3) in the insulation side panel.
❒ Open the control cabinet door. Fix the bottom corners of the control cabinet to the
insulation side panel.
❒ Fit the cable duct (4) on top of the control cabinet.
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36 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.5.12 Fitting the combustion air fan
❒ Fit the combustion air fan complete with the ceramic fibre seal.
❒ Fit the combustion air fan complete with the ceramic fibre seal.
TM 150
TM 200-250
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Installation Instructions | M0650314_en 37
4.5.13 Fitting the safety temperature limiter, boiler sensor and return sensor.
❒ Remove the cap (1) and the lock nut (2) from the safety temperature limiter (STL)
(3).
❒
Plug the STL (3) from the back through the frame element.
❒ Refit the lock nut (2) to the front of the STL. Refit the cap (1).
❒ Pass the STL capillary through the opening in the frame element and lay it to the
immersion sleeve of the boiler flow.
❒ Push the boiler sensor and the STL capillary with the pressure spring (1) into the
pre-installed immersion sleeve (2) of the boiler flow.
❒ Push the return flow sensor into the immersion sleeve of the boiler return.
❒
Lay all the sensor cables in the cable duct to the control cabinet.
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38 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.5.14 Fitting the door contact switch
❒ Attach the cover plate (1) to the combustion chamber door and fix it in place on
the left and right with self-tapping screws.
❒
Fit the door contact switch (2) to the frame element.
❒ Set the door contact switch as follows:
➥ Loosen the screws (1) on the key plate (2).
➥ Close the combustion chamber door and as you are doing this slide the key
plate (2) so that it engages smoothly with the door contact switch (3).
➥ Fix the key plate in position (2). Open and close the combustion chamber door
several times and check that the door contact switch (3) is tripped correctly.
➥ Lay the connecting cable through the opening in the frame element and then
onwards to the control cabinet.
❒
Fit the side cable duct (4).
❒ Fit the cover (5).
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Installation Instructions | M0650314_en 39
4.5.15 Fitting the WOS Drive
❒ Fix the motor mounting bracket (1) with threaded bolts (2) to the heat exchanger.
❒
Fit the flat head screw, bore bush and nut (3) to the WOS disc (4).
❒ Insert the WOS disc (4) into the gear motor (5).
➥ The key groove in the ash screw WOS disc must be aligned with the key
groove in the gear motor.
❒ Slide the key (6) into the groove and fit the shaft retainer (7).
4-5mm
❒ Fit the gear motor (5) complete with the WOS disc (4) to the motor mounting
bracket (1) with the two top screws.
➥ The motor must face downwards.
❒
Position the bracket (8) for the function monitor behind the motor mounting bracket
(1) and then fix in place together with gear motor (5) with the two bottom screws.
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40 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒ Fix the sensor (9) for the function monitor to the bracket (8).
❒
Attach the spring (10) at the bottom to the clamping bracket (11) and at the top to
the WOS lever (12).
❒ Set the sensor (9) for the function monitor as follows:
➥ Distance (13) between the sensor (9) and the WOS lever (12): 4-5mm
4.5.16 Installing the grate drive
Prepare the gear motor:
❒
Remove the shipping clamp from the gear motor.
❒ Fit the vent screw (supplied) to the highest point.
❒ Grease the shaft stub (1).
❒
Insert the seal (2) and the cover plate (3) onto the shaft.
❒ Fit the gear motor (4)
❒ Slide the key (5) into the groove and fit the shaft retainer (6).
❒ Fit the seal (2) and the blanking flange (7) on the opposite side to the gear motor
(4).
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Installation Instructions | M0650314_en 41
4.5.17 Installing the stoker unit
❒ Remove the pre-assembled adjustable foot.
❒
Change the adjustable foot to the other side and then refit it.
➥ Do not fully tighten the screws yet.
❒ Fit the stocker unit complete with the ceramic fibre seal to the slide-on duct.
❒
Adjust the stoker unit with the adjustable foot and then tighten the screw on the
adjustable foot.
TM 150:
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42 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
❒ Fit the adapter flange (1) with the seal (2) to the slide-on duct.
❒
Fit the stoker unit (3) with the seal (4) to the adapter flange (1).
❒ Adjust the stoker unit with the adjustable foot and then tighten the screw on the
adjustable foot.
❒ Fit the discharge system (feed screw, etc.) according to the installation instructions
enclosed.
4.5.18 Installing the induced draught fan
❒ Fit the four rubber buffers on the induced draught fan.
❒
Fit the two adjustable feet on the induced draught fan.
TM 200-250:
Installation
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Installation Instructions | M0650314_en 43
❒ Fit the flue pipe compensator (1) with its fibreglass seal (2) and screws complete
with spring washers and spacer washers to the induced draught fan.
➥ Also screw on the earthing wire (3) (supplied) with the toothed washer as po‐
tential equalisation.
❒
Fit the induced draught fan with its fibreglass seal (2) on the flue pipe compensa‐
tor (1) with the nuts and the spring washers and spacer washers to the induced
draught bracket.
➥ Also screw on the earthing wire (3) (supplied) with the toothed washer as po‐
tential equalisation.
➥ Position the rubber buffers (4) of the induced draught fan in the slots in the in‐
duced draught bracket.
❒ Fit flange of the induced draught bracket complete with the ceramic fibre seal to
the back of the heat exchanger.
❒
Adjust the induced draught bracket with the adjustable feet.
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44 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.5.19 Fitting the primary and secondary air servo motors
❒ Check that the air flaps are at the left stop.
➥ All air flaps are closed.
➥ Where necessary, turn the air flaps to the left stops using a pliers.
L
❒ Set the direction of rotation of the servo-motor (1) to left (L).
❒
Press the unlock key (2) and turn the drive for the shaft to the air duct (3) to the
left as far as the stop
❒ Mount secondary air servo motor (1) on the pneumatic rods.
➥ The connecting cable must face downwards.
❒
Mount primary air servo motor (2) on the pneumatic rods.
➥ The connecting cable must face upwards.
❒ Close off the openings with heat insulation mats (3).
❒ Fit the cover plates (4).
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Installation Instructions | M0650314_en 45
4.5.20 Fitting the cover on the slide-on duct
❒ Wrap the heat insulation mat (1) around the slide-on duct.
❒
Attach the cover plates (2) to the insulation side panels using the hooks (3).
❒ Fit the upper cover plate (4) and screw to the insulation side panel and the side
cover plates.
On versions with NO FGR:
❒ Close off the opening for the FGR duct with heat insulation mats (5).
❒ Fit the cover plate (6).
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46 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.5.21 Installing the underpressure controller
❒ Assemble the double thread nipple (1), reduction union (2) and hose nipple (3).
❒
Screw this assembly into the right of the stoker.
❒ Fix the underpressure sensor (4) with two self-tapping screws to the insulation
side panel.
❒ Insert the hose clamp (5) on the silicon hose and on the hose nipple (3) and then
tighten.
❒ Fit the spring washer (6).
❒ Fix the other end of the silicon hose to the "-" nipple of the underpressure sensor
(4) with the hose clamp (5) and tighten.
➥ Do not remove the red reduction plug.
4.5.22 Installing the automatic ignition
❒ Screw in the igniter tube (1).
❒
Insert the double wire hose clip (2) on the igniter tube (1).
❒ Insert the ignition blower (3) into the igniter tube (1) and fix in place using the dou‐
ble wire hose clip (2).
❒ Fit the cover.
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Installation Instructions | M0650314_en 47
4.5.23 Installing the combustion chamber overpressure and temperature sensors
40-50mm
❒ Screw in the spacer tube (1).
❒
Screw the brass bush (2) into the spacer tube (1).
❒ Push in the combustion chamber overpressure sensor (3) and slightly tighten the
retaining screw.
❒ Screw in the flanged pipe (4).
❒ Fit the counter flange (5).
❒ Insert the combustion chamber temperature sensor (6) so that it projects by ap‐
prox. 40 - 50 mm into the combustion chamber (7).
❒ Fix in position on the counterflange with the clamping screws. Only finger tighten
the screw.
Combustion chamber temperature sensor (6):
❒ Unscrew the connector box cover. Connect up the compensating line as follows:
- green wire to the terminal with the green dot
- white wire to the unmarked terminal
- shield not connected up.
❒ Fit the cover plate.
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48 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.5.24 Fitting the temperature sensor under the moving grate
❒ Removing the blanking plug (1).
❒
Insert the immersion sleeve (2).
❒ Push the sensor (3) into the immersion sleeve.
❒ Position the heat insulation mat (4).
❒ Bend the clamp (5) over the insulation side panel.
❒ Lay the compensating wire (6) of the sensor in a loop and then lead it along the
cable duct to the control cabinet.
❒ Fit the cover (7).
4.5.25 Fitting the broad band probe and flue gas sensor
❒ Screw the bush (1) into the induced draught fan flange and finger tighten.
❒
Screw the broadband probe (2) into the bush (1) and tighten slightly using an Allen
key (22 mm).
❒ Screw in the brass bush (3) for the flue gas sensor (4).
❒ Push the flue gas sensor (4) in so that approx. 20 mm is still projecting from the
housing. Secure it in this position with the wing screw (5).
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Installation Instructions | M0650314_en 49
4.5.26 Assembling the FGR (optional)
❒ Remove the FGR duct cover (alongside the stoker unit).
Assemble the FGR duct:
Version with heat exchanger on the right: Version with heat exchanger on the left:
❒ Fit the intermediate flange (1) with the fibreglass seal (2) to the upper FGR duct
(3).
❒
Fit the cover (4) with the fibreglass seal (2) to the upper FGR duct (3).
❒ Fit the connecting bracket (5) with the fibreglass seal (2) to the lower FGR duct
(6).
❒ Position the fibreglass seal (2) and fit the upper FGR duct (3) and lower FGR duct
(6).
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❒ Fit the FGR duct with the connecting bracket (1) to the boiler.
❒
Wrap the heat insulation mat (2) around the connecting bracket and fix in place
using spring clips.
❒ Insert the heat insulation mat (3) on the front of the connecting bracket.
❒ Remove the pre-punched cut-out for the flange from the heat insulation (1).
➥ Keep the heat insulation, you will need it later.
❒
Wrap the heat insulation mat (2) around the upper FGR duct and fix in place using
spring clips at the bottom.
❒ Wrap the heat insulation mat (3) around the lower FGR duct and fix in place using
spring clips at the top.
Version with heat exchanger on the right: Version with heat exchanger on the left:
❒ Assemble the cover for the connecting bracket.
❒
Press in the bottom clamp.
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Installation Instructions | M0650314_en 51
❒ Fit the cover for the connecting bracket.
❒
Fit the cover for the FGR duct.
❒ Insert the heat insulation removed previously (1) on the end of the FGR duct and
fit the side cover plate (2).
❒
Fit the cover plates on the flange (3) and the lower FGR duct (4).
❒ Fit the fan box (5) with its seals to the flange of the induced draught fan.
❒ Fit the bracket (6) for the FGR blower fan on the induced draught duct.
❒ Fit the FGR blower fan (1):
➥ Under the bracket (2).
➥ With the seal to the top of the connecting flange of the FGR duct (3).
➥ With the seal to the side of the fan box (4).
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❒ Fit the servo motor to the connecting bracket.
4.5.27 Fitting the covers to the back of the heat exchanger
❒ Fit the cover plate (1) to the induced draught duct.
❒
Fit the cable duct (2) to the insulation.
❒ Cut out the pre-punched cut-out (3) from the cover plate (4).
❒ Fit the cover (5) and the cover plate (4) on the WOS drive.
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Installation Instructions | M0650314_en 53
4.5.28 Fitting the insulated doors and the ash container to the combustion chamber
❒ Hang the insulated doors on the hinge bolts on the frame.
❒ Position the ash container at the ash removal unit flange.
❒
Push the lever on the side of the ash removal unit flange downwards to lock the
ash container in place.
❒ Push the key plate into the safety switch.
❒ Set the safety switch so that the key plate engages correctly.
❒ Tighten the screws on the safety switch.
4
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54 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.6 Power connection and wiring
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 unauthorised
persons
❒
Lay the cables from the components through the cable ducts to the control cabi‐
net.
❒ Wire the connections according to the wiring diagram.
❒ Secure the cables in the control cabinet to the terminal strips provided using cable
ties (= strain relief).
Notes about laying the cables
▪ Tie any loose hanging cables to the drive motors using cable ties. The cables
must not come into contact with the stoker duct.
4.6.1 Potential equalisation
❒ The potential equalisation must comply with current directives, regulations and
standards.
➥ Pos. 1: Earth connection
Installation
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Power connection and wiring
Installation Instructions | M0650314_en 55
4.6.2 Fitting the insulation cover and the cover plate
❒ Fit the cover plate (1) to the cable duct.
❒
Fit the cover (2) to the heat exchanger.
➥ Attach the clamps (3) at the side in and fix in place with screws at the bottom.
❒ Fit the cable duct (4) underneath.
❒ Fit the cable duct (1) underneath the WOS drive.
➥ Insert the clamps (2) into the insulation. Fold the cable duct upwards and fas‐
ten with screws.
❒
Fit the cover (3) and its cover plate to the left on top of the heat exchanger.
❒ Fit the cover (4) in the middle on top of the heat exchanger and fit its cover plate.
❒ Fit the cable duct cover (5).
❒ Fit the cover (6) on top of the combustion chamber.
❒ Lay the insulation mat (7) on the right on top of the heat exchanger. Fit the cover
(8).
4
Installation
Power connection and wiring
56 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.7 Connecting up thermal discharge safety sensor connection
▪ Connect up the thermal discharge safety sensor as per EN 303-5 and the circuit
diagram below.
▪
The discharge safety sensor must be connected to a pressurised mains water
supply in such a way that it cannot be shut off.
1
2
3
4
5
1 Thermal discharge safety sensor probe
2 Thermal discharge safety sensor (opens at approx. 95°C)
3 Cleaning valve (T-piece)
4 Dirt trap
5
Pressure reducer valve
1)
1.Required when the cold water pressure is greater than 6 bar. It must be impossible to shut off the connection manually. Minimum cold
water pressure = 2 bar at 10°C
Installation
4
Connecting up thermal discharge safety sensor connection
Installation Instructions | M0650314_en 57
4.8 Connecting up the slide-on duct cooling
The following is a schematic diagram
1 Boiler flow 7 Slide-on duct loading pump:
▪
No gravitational brake.
▪ Flow rate: 2m3/h (approx.)
▪ Output up to 500 kW: alpha2
25-40 or similar
2 Boiler return
3 Slide-on duct flow
4 Heat exchanger drainage
5 Slide-on duct return 8 Thermometer (recommended)
6 Gate valve or ball valve
General specification for pipe connections:
▪
Must be shut-off type.
▪ No press-fit connection.
▪ Must be possible to disassemble without removing the piping.
4
Installation
Connecting up the slide-on duct cooling
58 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.9 Final installation steps
4.9.1 Setting and testing the seal on the combustion chamber doors
Checking the settings of the door stop
❒ Close the door.
➥ A slight resistance must be felt when there is a gap of 2 - 3 cm:
Setting OK
➥ No resistance or only very slight resistance felt:
Setting must be corrected - Push the hinge toward the back.
⇨ See "Setting the combustion chamber door" [page
61]
➥ Resistance noticeable at a gap of >3 cm:
Setting must be corrected - Push the hinge toward the front.
⇨ See "Setting the combustion chamber door" [page 61]
Checking the settings of the door handle
❒ Close the door.
➥ The door can be closed with a normal amount of effort:
Setting OK
➥ The cannot be closed or can only be closed with great effort.
Push the locking plate toward the front.
⇨ See "Setting the combustion chamber door" [page 61]
Installation
4
Final installation steps
Installation Instructions | M0650314_en 59
Checking the door stop seal
❒ Open the door.
❒
Insert a sheet of paper at both the top and the bottom of the door stop between
the door and the boiler.
❒ Close the door.
❒ Try to pull out the sheets of paper.
➥ If the paper cannot be removed:
The door is sealed.
➥ If the paper can be removed:
The door is not sealed properly - Push the hinge toward the back.
⇨ See "Setting the combustion chamber door" [page 61]
Checking the door handle seal
❒ Open the door.
❒
Insert a sheet of paper at both the top and the bottom area at the side of the door
handle between the door and the boiler.
❒ Close the door.
❒ Try to pull out the sheets of paper.
➥ If the paper cannot be removed:
The door is sealed.
➥ If the paper can be removed:
The door is not sealed properly - Push the locking plate toward the back.
See also
2 Adjusting the combustion chamber doors [➙ 61]
4
Installation
Final installation steps
60 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.9.2 Adjusting the combustion chamber doors
Door stop side
❒ Loosen the lock nuts (1) at the top and bottom of the hinge using an Allen key.
❒
Use suitable tools (e.g. screwdriver and hammer) to move the hinge towards the
back or the front as required.
➥ Caution: The hinges must be aligned in the same way at the top and bottom.
❒ Fix the hinge in position with the lock nuts (1) at the top and the bottom.
Door handles
❒ Loosen the lock nuts (1) at the top and bottom of the locking plate.
❒ Use suitable tools (e.g. screwdriver and hammer) to move the locking plate to‐
wards the back or the front as required.
➥ Position the locking plate so that the door closes easily.
➥ Caution: The locking plate must be aligned in the same way at the top and bot‐
tom.
❒ Fix the locking plate in position at the top and bottom with the lock nuts (1).
Installation
4
Final installation steps
Installation Instructions | M0650314_en 61
5 Commissioning
5.1 Before commissioning / configuring the boiler
The boiler must be adjusted to the heating system during commissioning.
NOTICE
Optimum efficiency and efficient, low-emission operation can only be guaranteed
if the system is set up by trained professionals and the standard factory settings
are observed.
Take the following precautions:
❒
Initial startup should be carried out with an authorised installer or with Froling
customer services
❒
Turn on the main switch
❒ Set the boiler controller to the system type.
❒ Load the boiler default values.
NOTICE! For the keypad layout and instructions for modifying the parameters, see the
instruction manual for the boiler controller.
❒ Check the system pressure of the heating system.
❒ Check that the heating system is fully vented.
❒ Check that the safety devices are present and working efficiently.
❒ 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 the drives and servo motors are working and turning in the right direc‐
tion.
❒ Check that the door contact switch is working efficiently.
NOTICE! Check the digital and analog inputs and outputs - See the instruction manual
for the boiler controller.
5
Commissioning
Before commissioning / configuring the boiler
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5.2 Initial startup
5.2.1 Permitted fuels
Wood chips
Criterion ÖNORM M 7133 CEN/TS 14961 Description acc. to
ÖNORM M 7133
Water content W20 M20 air-dried
W30 M30 suitable for storage
W35 - limited suitability for stor‐
age
W40
1)
M40 high-moisture wood chips
Size G30 P16A / P16B fine wood chip
G50 P45A medium-sized wood chip
1.partial load conditions only to a limited extent
NOTICE! In case of operating under partial load conditions and fuels with a water con‐
tent of >W35, power consumption of less than 65% of the nominal output is not per‐
mitted!
EU: Fuel acc. to EN 14961 - Part 4: Wood chips class A2 / P16A-P45A
Additional for
Germany: Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance
(BimSchV) - applicable version)
Wood pellets
Wood pellets made from natural wood with a diameter of 6 mm
EU: Fuel acc. to EN 14961 - Part 2: Wood pellets class A1 / D06
and/or: Certification program EN
plus
or DIN
plus
General note:
Before refilling the store, check for pellet dust and clean if necessary.
Wood shavings
Wood shavings generally cause problems with combustion. Therefore their use is per‐
mitted only with authorisation from Froling. The following additional points also apply:
▪ Sawdust and carpentry waste should only be used with systems with a rotary
valve.
▪ The store should be fitted with a pressure release device in accordance with re‐
gional regulations.
▪ The same limits apply for the permitted water content of sawdust as for wood
chips.
Note on standards
Note on standards
Commissioning
5
Initial startup
Installation Instructions | M0650314_en 63
NOTICE
For fuels with a water content < W30 the boiler's rated heat output can only be
guaranteed if it is used with a flue gas recirculation system (FGR).
Miscanthus
Switchgrass or elephant grass (Latin name: miscanthus) is a C4 plant. Standards and
regulations for burning these plants have not been standardised, so the following ap‐
plies:
NOTICE! The regional regulations for burning miscanthus should be observed. Opera‐
tion may only be possible by special permit.
Changing the fuel
CAUTION
Incorrect fuel parameter settings:
Incorrect parameter settings have a significant adverse effect on the functioning
of the boiler, and as a result this will invalidate the guarantee.
Therefore:
❒ If the fuel is changed (e.g. from wood chips to pellets), the system must be
reset by Froling customer services.
5.2.2 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐
ing of refuse, is not permitted.
CAUTION
In case of use of non-permitted fuels:
Burning non-permitted fuels increases the cleaning requirements and leads to a
build-up of aggressive sedimentation and condensation, which can damage the
boiler and also invalidates the guarantee. Using non-standard fuels can also lead
to serious problems with combustion.
For this reason, when operating the boiler:
❒ Only use permitted fuels
5
Commissioning
Initial startup
64 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
5.3 Heating up for the first time
NOTICE
Optimum efficiency and efficient, low-emission operation can only be guaranteed
if the system is set up by trained professionals and the standard factory settings
are observed.
Take the following precautions:
❒
Initial startup should be carried out with an authorised installer or with Froling
customer services
The customer is responsible for ensuring the following prior to initial start-up of the
system by Froling customer services:
▪
Electrical installation
▪ Installation of water pipes
▪ Flue gas connection including all insulation work
▪ Work must comply with local fire protection regulations
▪ The operator must ensure that at least 50% of the boiler's rated heat output can be
extracted from the network on commissioning.
▪ The necessary "dry run" of the system means that the discharge system must be
empty at the start of initial startup. Fuel must be available, however, so that the
discharge system can be filled once the system is released.
▪ When heating up the boiler for the first time to dry out the fireclay concrete, the
customer must provide approx. 1 m³ of dry firewood.
▪ It is essential that the electrician who has carried out the installation work is availa‐
ble when starting up the system for the first time to make any changes to the wir‐
ing which may become necessary.
▪ During initial start-up, operating staff are shown how to use the boiler. It is impera‐
tive for proper handover of the product that those involved are present as this is a
one-off opportunity.
The individual steps for initial start-up are explained in the operating instructions for
the controller
NOTICE! See operating instructions for the SPS 4000
Commissioning
5
Heating up for the first time
Installation Instructions | M0650314_en 65
6 Decommissioning
6.1 Out of service for long periods
The following measures should be taken if the boiler is to remain out of service for
several weeks (e.g. during the summer):
❒
Clean the boiler thoroughly and close the doors fully
❒ Place approx. 5 kg of loose lime in the combustion chamber
➥ This absorbs moisture and thereby prevents corrosion when the boiler is out of
service
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 Disassembly
To 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
Decommissioning
Out of service for long periods
66 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
7 Appendix
7.1 Addresses
7.1.1 Address of manufacturer
FRÖLING
Heizkessel- und Behälterbau GesmbH
Industriestraße 12
A-4710 Grieskirchen
AUSTRIA
TEL 0043 (0)7248 606 0
FAX 0043 (0)7248 606 600
INTERNET www.froeling.com
7.1.2 Address of the installer
Stamp
Appendix
7
Addresses
Installation Instructions | M0650314_en 67
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