Strebel Turbotec 20-30, 40S-70, 40, 50L – 100L Installation Manual

Installation manual

for the authorised specialist

Turbotec lambda control 20-100 kW

20-30, 40S-70 40, 50L – 100L

12/2014

READ THE INSTRUCTION BOOKLET AND THESE SUPPLEMENTARY

INSTRUCTIONS CAREFULLY BEFORE INSTALLATION

These supplementary instructions together with those further in the instruction booklet
cover the basic principles to ensure the satisfactory installation of the boiler, although
detail may need slight modification to suit particular local site conditions.
In all cases the installation must comply with current Building Regulations, Local Authority

Byelaws and other specifications or regulations as they affect the installation of the boiler.
It should be noted that the Building Regulations requirements may be met by adopting the

relevant recommendations given in British Standards BS 8303, BS EN 15287-1:2007 as an
alternative means to achieve an equivalent level of performance to that obtained following
the guidance given in Approved Document J.

British Standards BS 6700, BS EN 14336:2004: Heating Systems in Buildings. Installation
and commissioning of water based heating systems. BS EN 12828: 2003; Heating Systems
in Buildings. Design of water based heating systems. BS EN 12831: 2003; Heating Systems
in Buildings. Method for calculation of the design heat load. All as applicable to the
appliance.

Please note that it is a legal requirement under England and Wales Building Regulations
that the installation of the boiler is either carried out under Local Authority Building Control
approval or is installed by a Competent Person registered with a Government approved
Competent Persons Scheme. HETAS Ltd operate such a Scheme and a listing of their
Registered Competent Persons can be found on their website at www.hetas.co.uk.

CO Alarms:-

Building regulations require that when ever a new or replacement fixed solid fuel or
wood/biomass appliance is installed in a dwelling a carbon monoxide alarm must be fitted
in the same room as the appliance. Further guidance on the installation of the carbon

monoxide alarm is available in BS EN 50292:2002 and from the alarm manufacturer’s

instructions.
Provision of an alarm must not be considered a substitute for either installing the appliance

correctly or ensuring regular servicing and maintenance of the appliance and chimney
system.

HEALTH AND SAFETY PRECAUTIONS

Special care must be taken when installing the boiler such that the requirements of the Health and
Safety at Work Act are met.

Handling

Adequate facilities must be available for loading, unloading and site handling.

Fire Cement

Some types of fire cement are caustic and should not be allowed to come into contact with the skin. In
case of contact wash immediately with plenty of water.

Asbestos

This boiler contains no asbestos. If there is a possibility of disturbing any asbestos in the course of
installation then please seek specialist guidance and use appropriate protective equipment.

Metal Parts

When installing or servicing this boiler care should be taken to avoid the possibility of personal injury.

BOILER PERFORMANCE

Refer to the main instruction further in this manual for details of the boiler’s performance.

PREPARATORY WORK AND SAFETY CHECKS

IMPORTANT WARNING

This boiler must not be installed into a chimney that serves any other heating appliance.

There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to
emit fumes into the room.

Chimney

In order for the boiler to perform satisfactorily the chimney height must be sufficient to ensure an
adequate draught of approximately 10 - 15 Pa so as to clear the products of combustion and prevent
smoke problems into the room.

NOTE: A chimney height of not less than 4.5 metres measured vertically from the outlet of the boiler to
the top of the chimney should be satisfactory. Alternatively the calculation procedure given in EN 13384­1 may be used as the basis for deciding whether a particular chimney design will provide sufficient
draught. Ensuring the minimum chimney draught is responsibility of the Chimney specialist appointed.

The outlet from the chimney should be above the roof of the building in accordance with the

provisions of Building Regulations Approved Document J.

Because the boiler runs at high efficiencies, the temperature of the flue gases is at times lower than
conventional solid fuel appliances. Although it is not classed as a condensing appliance, the low flue gas
temperature results in condensation occurring within the flue. Any chimney flue system must therefore
be able to withstand the effects of condensate and operate under wet conditions (designation letter W).
In addition it should be soot fire resistant and able to withstand the corrosive effects of flue products
generated by solid fuels (designation G and 3 respectively). If installation is into an existing masonry
chimney then it will require re-lining with a liner meeting the specification described above. Existing
concrete or clay lined chimneys are not suitable for this boiler and must be lined as described above. All
installations must be in accordance with Building Regulations Approved Document J.

Any existing chimney must be clear of obstruction and have been swept clean immediately before
installation of the lining system. Where the chimney is believed to have previously served an open fire
installation it is possible that the higher flue gas temperature from a closed appliance may loosen
deposits that were previously firmly adhered, with the consequent risk of flue blockage. It is therefore
recommended that the chimney be swept a second time within a month of regular use after installation.

If there is no existing chimney then any new system must be to the designation described above

and in accordance with Building Regulations Approved Document J.

A single wall metal fluepipe is suitable for connecting the boiler to the chimney but is not

suitable for use as the complete chimney. The chimney and connecting fluepipe must have a

minimum diameter of 150 mm and its dimension should be not less than the size of the outlet

socket of the boiler.

Any bend in the chimney or connecting fluepipe should not exceed 45. 90 bends should not be used.

Combustible material should not be located where the heat dissipating through the walls of fireplaces or
flues could ignite it. Therefore when installing the boiler in the presence of combustible materials due
account must be taken of the guidance on the separation of combustible material given in Building
Regulations Approved Document J and also in these boiler instructions.

2

Dear Installer,

The Turbotec central heating
boiler has been subjected to
type and performance testing by
the officially authorised testing
bodies Wieselburg, TGM Vienna
and TÜV Bavaria. All boilers
below 45kW are MCS Approved.

According to the test report, the
Turbotec complies with the
applicable requirements of
EN303-5 for wood fuel.

The Turbotec lambda control is a
highly developed product, which
is not to be judged by
conventional standards and for

the installation of which certain
special features need to be
taken into account. Therefore,
we request that you follow the
instructions below precisely.
Compliance with the installation
instructions is a prerequisite for
trouble-free operation and
guarantee. Please consider that
errors during the installation
sooner or later can lead to
difficulties with approval
authorities, to malfunctions or
even to damage; i.e. in all cases

to customer’s complaints.

Moreover, subsequent
rectification is always more

expensive than a proper, careful
implementation right from the
start. A commissioning protocol
is included with the delivery.

It must be our common goal to
hand over to the customer a
correctly operating, highly
efficient system, every unit and
part of which functions as
expected.

In order to attain this goal, you
have to make a very significant
contribution – we wish you every
success in doing so.

Best regards

Strebel Ltd

Unit 1F Albany Park Industrial Estate, Frimley, Camberley
Tel: [phone]
Fax: [phone]
Email: [e-mail]

Thermostrom

Energietechnik Gesellschaft mbH
A-4407 Steyr-Dietachdorf, Ennser Strasse 91

Tel. [phone] / 382 71
Fax [phone]
Email: [e-mail]

3

Overview
General instructions

Area of use/scope of delivery

Overview General instructions................................................. 3

Illustration of boiler types 20-70............................... 4

Illustration of boiler type 60 L................................... 5

Boiler technical data................................................ 6

Boiler dimensions.................................................... 7

Control technical data.............................................. 8

Boiler room/air supply/installation site …..……….... 9

Checks following transport....................................... 9

Assembly Assembly of the cladding with insulation………….. 10

Flue......................................................................... 11

Mounting the air regulation units............................. 11

Mounting the induced draft fan….............................11

Filling and draining.................................................. 11

Heating connections.................................................11

Raising the return temperature............................... 12

Thermal discharge safety device..............................12

Mounting the O2 probe and exhaust fume

sensor.......................................................................12

Mounting the storage tank sensor .......................... 13

Mounting the hydraulic unit .................................... 13

Mounting the control …........................................... 13

Hydraulic diagrams - overview ............................... 14

Hydraulic diagram – system 3 ................................ 15

Electrical connection diagram ................................ 15

System 3................................................................. 16

Functional description ............................................ 16

Important instruction .............................................. 16

Hydraulic diagram – system 3.1 ............................. 17

Electrical connection diagram ................................ 17

System 3.1.............................................................. 18

Function description …........................................... 18

Important instruction .............................................. 18

Settings for system 3 ..............................................19

Table for noting system settings ............................ 20

Aggregate test ...................................................... ..20

Commissioning Instruction/commissioning/handover ...................... 21

Commissioning the control ..................................... 21

Setting the boiler water temperature ...................... 21

Commissioning the boiler........................................ 22

Heating up/adding fuel ........................................... 22

Circuit diagram ....................................................... 23

Short operating instructions: lambda control OFF .. 24

Short operating instructions: lambda control ON..... 25

Maintenance Boiler maintenance ................................................ 26

Malfunctions Troubleshooting ..................................................... 26

General instructions

Installation, assembly, electrical
connections and first commissioning
are tasks for a qualified expert. He is
responsible for ensuring proper
implementation.

Explanation of our warranty
conditions.

We have to exclude our warranty for
damages occurring due to the
following reasons:

- inappropriate or improper use

- incorrect assembly resp.
commissioning by the purchaser or
a third party, including the fitting of
third party parts

- operation of the system with
excessive pressure.

The prerequisites for the provision of
a warranty are:

- correct operation of the boiler

- operation of the system within the
performance limits specified by the
manufacturer

- use of suitable fuels.

- the return of the completed
commissioning protocol to
thermostrom Energietechnik
Gesellschaft mbH.

Instruction for the user

The system will retain its safety and
functions if it is serviced regularly
every year.

Fields of use

Boilers from the Turbotec series are
suitable and approved for use as heat
generators in hot water heating
systems with a permissible flow
temperature of up to 100 °C. They
can be installed in open and closed
systems according to DIN 4751,
sheets 1 and 2, or ÖNORM B 8130
and B 8131.

Scope and method of delivery

Boiler body loose. Cladding with
insulation in a carton. Lambda control,
storage tank sensor, exhaust fume
sensor, O2 probe, induced draft fan,
air regulator units, ash tray,
commissioning protocol, installation
and operating manual stored inside
the filling chamber.

4

Overview
Boiler illustration

20 - 30, 40S, 50 - 70

1 Computer-controlled lambda

control
2 Cladding, front lid
4 Filling door (type 40S-70has two

filling doors)
5 Inner door
6 Filling chamber (fuel storage

chamber)
7 Burner grating
8 Burner brick
9 Primary air regulator unit with seal
10 Secondary air regulator unit with

seal
11 Cladding, actuator cover
12 Flame duct
13 Ashes door with sight glass

14 Ashes chamber
15 Cleaning lid
16 2 sleeves 1/2”
17 Heat exchanger connection R1/2”

for thermal discharge safety device
18 Heating feed connection
19 Opening rod for the gas vent flap
20 Heating return connection
21 Sleeve for O2 probe
22 Exhaust fume nozzle
23 Induced draft fan
24 Filling and emptying sleeve 1/2"
25 Gas vent flap
26 Opening handle for the gas vent

flap
27 Cladding, rear lid

28 Cladding, left side, with plug-in

wiring
29 Transport eye bolt
30 Cladding, right side
31 Insulating panel, top
32 Immersion sleeve for STL and

boiler temperature sensor
33 Exhaust fume baffle plate
34 Cladding, rear side

35 Thread for exhaust fume
sensor

36 Ancillary heating surface
37 Cladding, base
38 Secondary air apertures
39 Primary air apertures
40 Drip tray

5

Overview
Boiler illustration

50L - 100L (Top loading door optional)

1 Computer-controlled lambda

control
2 Cladding, front lid
3 Filling lid
4 Filling door
5 Inner door
6 Filling chamber (fuel storage

chamber)
7 Burner grating
8 Burner brick
9 Primary air regulator unit with

seal
10 Secondary air regulator unit with

seal
11 Cladding, actuator cover
12 Flame duct
13 Ashes door with sight glass

14 Ashes chamber
15 Cleaning lid
16 2 sleeves 1/2”
17 Heat exchanger connection R1/2”

for thermal discharge safety

device
18 Heating feed connection
19 Opening rod for the gas vent flap
20 Heating return connection
21 Sleeve for O2 probe
22 Exhaust fume nozzle
23 Induced draft fan
24 Filling and emptying sleeve 1/2"
25 Gas vent flap
26 Opening handle for the gas vent

flap
27 Cladding, rear lid

28 Cladding, left side, with plug-in

wiring
29 Transport eye bolt
30 Cladding, right side
31 Insulating panel, top
32 Immersion sleeve for STL and

boiler temperature sensor
33 Exhaust fume baffle plate
34 Cladding, rear side
35 Thread for exhaust fume sensor
36 Ancillary heating surface
37 Cladding, base
38 Secondary air apertures
39 Primary air apertures
40 Drip tray
41 Optional Top loading door for
50L, 60L & 75L

6

Overview
Boiler technical data

Boiler

20

25

30

40

40S

50

60

70

50L

60L

75L

100L

Filling doors H/W
(2x for 40S-70)

cm

60/34

60/34

60/34

36/54

36/54

36/54

36/54

36/54

36/54

36/54

36/54

36/54
Flow /return

F/R

1¼’’

1¼’’

1¼’’

1¼’’

1¼’’

1¼’’

1¼’’

1¼’’

1¼’’

1¼’’

1½‘’

1½’’

Drain D 1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

3/4

3/4

Safety heat
exchanger

HE

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

Opt. Filling lid
height/width

cm – –

– – – – – – 36/54

36/54

36/54

–

Weight

kg

515

515

515

710

925

925

925

925

940

940

1080

1200

Transport width

cm

50

50

50

69

69

69

69

69

69

69

69

89

General
operatin
g data

Rated heating power

kW

20

25

30

40

40

50

60

70

50

60

75

93

Max. operating
overpressure

bar 3 3 3 3 3 3 3 3 3 3 3 3

Permissible feed
temperature

°C

100

100

100

100

100

100

100

100

100

100

100

100

Min. return temperature

°C

55

55

55

55

55

55

55

55

55

55

55

55

Qmin. (SWT)

ltr/h

600

600

600

1000 1200

1200

1200

1200

1200

1200

1200

1400

Δp (20K)

mbar

0.57

0.89

1.3

2.3

2.3

3.6

5.2

7.1

3.6

5.2

5.2

6.6

Power
and
emission
data
at tested
rated
power

Exhaust fume
temperature

°C

158

160

163

169

169

173

178

182

173

172

171

169

CO2 content

%

15

15

15

15

15

15

15

16

16

16

15

15

CO (at 13% O2)

mg/Nm3

80

91

102

123

123

144

166

187

126

135

149

172

Solids emission (dust)

mg/Nm3

15

15

14

14

14

14

15

15

14

14

14

14

Boiler efficiency

%

91

90.8

90.6

90.1

90.1

90.3

90.4

90.6

90

90.4

91

91.9

Contents

Boiler water capacity

litres

115

115

115

210

255

255

255

255

370

370

410

470

Filling chamber volume

litres

150

150

150

190

290

290

290

290

340

340

400

460

Filling chamber depth

cm

60

60

60

60

60

60

60

60

110

110

130

110

Combustion duration

approx.

hrs.

7 6 5 5 8 7 6 5 8 6 6

6

Storage
tank
volume

Minimum Volume
Recommended by Strebel

litres

1200

1500

1800

2400

2400

3000

3600

4200

3000

3600

5000

8000

Flue

Required outlet pressure

mbar

0,10

0,10

0,10

0,10

0,10

0,10

0,10

0,10

0,10

0,10

0,10

0,10

Exhaust fume mass flow
rate

g/s

15

19

23

30

30

39

46

54

39

45

45

80

Diameter of exhaust
nozzle

cm

15

15

15

18

18

18

18

18

18

18

20

20

The manufacturer’s tables are authoritative for the dimensioning of the flue etc. Austria/Germany: in the case of existing systems, the flue must
be inspected by a master chimney sweep! UK & Eire: the chimney must be swept as per local regulations.
Strebelwerk GMBH reserve the right to change any data without prior notice.

7

Overview
Boiler dimensions

Turbotec 40 lambda control

Turbotec 20 – 30 lambda control

Turbotec 40S – 70 lambda control

Turbotec 50L – 100L lambda control (Showing optional filling lid centre line)

8

Overview
Control technical data

Mains power supply

230V +10/-15% / 50Hz

Power consumption, electronics

max. 30VA at 230V

Maximum current consumption, entire system

Imax = 6.3 A

Fuse use

5 x 20 mm / 6.3 A quick-blow

Switch-off temperature of the safety temperature limiter

T = 100 C +0 / -5%

Heating circuit pump

Switching output: 230 V / max. 1.5 A

Charge pump for tap water storage tank

Switching output: 230 V / max. 1.5 A

Actuator drive for charge valve

Switching output: 230 V / max. 0.1 A

Induced draft fan

Switching output: 230 V / max. 1.5 A

Primary pump

Switching output: 230 V / max. 1.5 A

Actuator drive for return valve

Switching output: 230 V / max. 0.1 A

Floating switchover contact

Contact load: 230 V / max. 5 A

Control outputs for air regulator units

0 to 10 V / max. 3 mA

Power supply output for air regulator units

AC voltage output: 24 V / 6 VA

Electromagnetic door opener

AC voltage output: 12 V / 16 VA

Power supply output for O2 probe

AC voltage output: 12 V / 16 VA

Measurement input for Pt100 (R=108/20C)

- Storage tank sensor

- boiler sensor

- exhaust fume sensor

Maximum sensor temperature:
Tmax = 150C
Tmax = 150C
Tmax = 600C

Immersion sleeve for boiler sensor and safety temperature
limiter

2x LW7 with cable ties
Ms63, PN16, immersion depth 100

Protection class

IP 40 (appliance detached: IP 00)

Ambient operating temperature

0 C to +50 C

Ambient storage temperature

–20 C to +70 C

There are several controllers available in the Strebel Turbotec boiler range, each with their own special features. These controllers DO NOT
alter the performance of the appliance, only supplementing system/control outputs. Covered in this manual is LC1.