Euroheat thermodual tda 30 Release note

Installation Servicing Instructions
Thermodual TDA
30/40
www.euroheat.co.uk
Part Number:
Serial Number:

TDA Thermodual Installation Manual
2 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions
EASY AND SAFE OPERATION This operating manual contains important instructions on the
• SHT TDA Thermodual 30
• SHT TDA Thermodual 40
READING THE INSTALLATION MANUAL This installation manual must be read and applied by everyone
who operates or works on the heating system SHT TDA
Thermodual
TECHNICAL CHANGES We continuously develop and improve our boilers. The
information in this edition was correct at the time of going to
press. All details in these instructions on standards, regulations
and worksheets should be checked before use and should be
compared with the regulations applying locally at the site
where the boiler is installed. We reserve the right to make
changes which may then deviate from the technical details
and illustrations in this operating manual.
1.1 Structure of
the Installation
Manual
NOTES ON THIS MANUAL This explains how to use this operating manual.
SAFETY NOTES This explains everything on the subject of safety that you
should consider when using the heating system.
PLANNING AND INSTALLATION This explains how to properly plan for and install the heating
system.
COMMISSIONING THE SYSTEM This explains how the heating system is to be put into initial
service.
CLEANING AND MAINTAINING THE
HEATING SYSTEM
This explains how to clean the heating system and who is
responsible for its maintenance.
TROUBLESHOOTING This explains how to rectify faults in the heating system.
WARRANTY This explains the terms and conditions of the warranty.
APPENDIX This explains the EC Declaration of Conformity.
1. Introduction

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TDA Thermodual Installation Manual
2. Safety instructions
2.1 Intended
use
BASIC PRINCIPLES FOR THE CONSTRUCTION OF THE SYSTEM
BASIC PRINCIPLES The heating system was built using state of the art technology
and conforms to recognised safety regulations. Nevertheless, its
use still poses the risks of injury or death of the user or a third
party, and of adverse effects upon the heating system itself or
upon other material goods.
Have your specialist heating company provide you with a detailed
explanation of the operation of the heating system.
USING THE HEATING SYSTEM Only use the heating system if in perfect condition. Use it properly,
as intended, and be aware of safety concerns and the dangers
involved under observance of the operating manual. Have any
faults which could impair safety fixed immediately.
BASIC PRINCIPLES REGARDING THE CONTENT OF THE OPERATING
MANUAL
SCOPE The content of this operating manual is intended exclusively for
the planning, installation and operation of the heating system
TDA Thermodual. Any further implementation of applicable
standards, for example with regard to the installation of the
heating system (pipework, etc.) is not part of this operating
manual. SHT Austria does not assume any liability for this.
APPLICATION OF THE
HEATING SYSTEM
The heating system TDA Thermodual is designed for the use
of wood pellets conforming to EN Plus standard and split logs
(w<30 %); materials not suitable for combustion are: wood dust,
wood chips, solid- liquid- or gaseous fossil fuels, etc. In addition
no PVC-containing waste products, cardboard containers, paper,
coated wood, etc. must be burnt; the wood must be free from
foreign bodies (nails, screws,etc.). See Section 3.4 for more
details on fuels. Fuels prepared from painted, varnished or coated
wood should not be used. Any other application is considered
improper use. The manufacturer will accept no liability for any
damage resulting from improper use. The operating company/
owner bears sole responsibility in such cases. Proper use includes
adherence to the installation, operation and maintenance
requirements specified by the manufacturer.
Modification of the specified operating values will affect the
heating system’s control program and could lead to malfunctions.
Only trained maintenance and operating personnel may
undertake modifications to the operating values.
UK SMOKE CONTROL AREAS The TDA Thermodual models have been recommended for
exemption under Section 21 of the Clean Air Act 1993 for use in
smoke control areas when burning wood logs or wood pellets
which are selected in accordance with the recommendations on
fuel in this manual.

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Contact with the hot surfaces of the boiler can lead to burns. Wait until the boiler has cooled
down before touching uninsulated components.
Danger of asphyxiation and explosion from carbon monoxide. When the boiler is in operation,
carbon monoxide escaping from opened cleaning or inspection hatches can pose a danger of
asphyxiation or explosions. Do not leave these open any longer than necessary.
Opening doors and lids to hot combustion residues can pose the danger of fires. Keep the
openings closed during operation, and when performing cleaning work, allow the combustion
residue to cool down before you place them in a fireproof container.
 The boiler weighs over 750kg. If the boiler is dropped during transport, persons can be
seriously injured and the boiler can be damaged. Make sure that you use appropriate lifting gear
when transporting, moving and installing the boiler.
 When working on the pellet grate, cleaning turbulators, and pellet delivery systems, hands
or arms could be injured. Turn off the main power switch when working on these components.
2.2 Residual
Risk

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3. Scope of Delivery
3.1 Scope of
Delivery
Article Number Description Quantity Pre-Installed
8B2420 Boiler Body TDA 1 N
8C2410 Induced draught fan with flange 1 Y
9M3242 Data plate 1 N
2I2416 Secondary air flap insulated gasket 1 Y
2H2209 Seal for draught fan 10mm 1 Y
9W0001 SHT Logo 1 Y
8C2412 Primary air flap, complete 1 Y
8C2414 Primary air flap, complete 1 Y
1K2422 Casing complete, including TC3 wiring loom 1 Y
8A4230 Thermocontrol panel TC3 1 Y
8A4240 Thermocontrol IO circuit board TC3 1 Y
B21025 EW1 extension module 1 Y
4A2216 Immersion sensor 3 N
4A4210 External sensor AF200 1 N
4A4212 Flow sensor VF202 2 N
2X4305 Insulated glove 2 N
2X2516 Round brush 48 x 100 x 1200mm 1 N
A21002 Cleaning set VN 22-55 1 N
Please check your appliance carefully after unpacking for signs of damage and to ensure all parts
have been delivered. Record any visible defects on the delivery note and inform the supplier
immediately. Please take pictures of any damage for future reference.
3.2 Unpacking
and Inspection

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TDA rear view (with casing) TDA right side view (with casing)
TDA front view (with casing) TDA left side view (with casing)
4. Technical Data

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TDA Thermodual Installation Manual
TDA 30 TDA 40
Nominal rating* kW 28 38
Power range 8.4 - 28 11.4 - 38
Boiler water content Litres Ltr approx. 150 approx. 150
Fuel capacity Ltr approx. 175 approx. 175
Width
Boiler dimensions
without casing
mm
761 761
Height 1500 1500
Depth 1207 1207
T
Boiler dimensions
with casing
mm
1184 1184
T1 1220 1220
B/B1 865/852 865/852
H 1594 1594
A 1322 1322
C 830 830
D 563 563
EFilling door opening 400 400
F 337 337
Boiler weight kg approx. 780 approx. 780
Ø Flue pipe mm 150 150
Draught
requirement** Pa 15 15
Heating surface m2 2.1 2.1
G Supply and return
Inch
5/4 5/4
GSafety
supply and return 3/4 3/4
*The type-tested capacity range is to be inferred from the original test certificates and may
differ slightly from the values specified.
**Pressure conversion from Pa to bar
105 Pa [N/m²] = 1 bar
Conversion example:
105 Pa = 1 bar
100,000 Pa = 1 bar
20 Pa = 0.0002 bar = 0.2 mbar

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Control unit
Door contact switch
Log Loading door
Log loading space
Secondary air flap
Secondary-combustion
chamber
Ash door
Ash pans
Primary air flap
Pellet insertion
channel
Ignition element
Control panel
Control unit/circuit
board:
All data is saved on the circuit board. All operational sequences are coordinated
via the control unit/circuit board.
Control panel: The entire system is operated via the control panel.
Door contact switch: The door contact switch indicates whether the filling door and ash door are
closed.
Log loading door The filling door must be opened to insert firewood.
Log loading space Firewood is inserted into the filling space.
Secondary-combustion
chamber:
Unburnt gases are burnt in the secondary combustion chamber.
Ignition element: The ignition element ensures automatic ignition of the pellets/firewood.
Primary air flap: The primary air required for combustion flows through the primary air flap.
Secondary air flap: The secondary air required for combustion flows through the secondary air flap.
Ash door: The ash door must be opened to access the ash chamber.
Ash pan: All unburnt material is collected in the ash pans.
Pellet insertion
channel:
Transports pellets into the pellet combustion chamber.
5. Overview
5.1 Main Components

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TDA Thermodual Installation Manual
5.2 External
Casings 11
2
14
4
10
3
13
9
1
12
8
7
6
5
Description
1Rear panel
2Base plate and insulation pad
3Left hand side panel
4Right hand side panel
5Control panel bracket
6Control panel
7Side cover
8Filling plate
9Control unit cover
10 Design element and protective cover
11 Front lid and insulation pad
12 Rear lid and insulation pad
13 Rear cover/flame sensor cover
14 Ash tray

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A
C
C
B
B
Legend TDA 30/40
A2875
B2260
C2500
Legend TDA 30/40
A3270
B2750
C2357
6.1 Minimum
Boiler Room
Sizing with
Single
2500 Litre
Accumulator
6. Boiler Room Sizing
6.2 Minimum
Boiler Room
Sizing with
Twin 1250 Litre
Accumulators

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Measurement Description TDA 30/40
AWall to front 650
BWall to right 300
CWall to rear 500
DWall to left 100
EWidth with manual fill
pellet hopper 1420
EWidth with intermediate
pellet hopper 1325
Minimum room width
with manual fill pellet
hopper
1820
Minimum room width
with intermediate pellet
hopper
1725
Minimum room depth 2357
Minimum room height 2100
Please note the above
dimensions do not include the
accumulator or expansion vessel.
If siting the accumulator in the
boiler room then the necessary
dimensions will need to be
increased respectively
(including room height).
6.3 Minimum
Clearances -
Manual Fill &
Intermediate
Pellet Hopper C
B
E
A
D

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Measurement Description TDA 30/40
AWall to front 650
BWall to right 650
CWall to rear 500
DWall to left 100
EWidth with Vario auger
system 1127
Minimum room width
with Vario auger system 2077
Minimum room depth 2357
Minimum room height 2100
Please note the above
dimensions do not include
the accumulator or
expansion vessel. If siting
the accumulator in the boiler
room then the necessary
dimensions will need to be
increased respectively
(including room height).
6.4 Minimum
Clearances -
Vario Flexible
Auger
C
B
E
A
D

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7. Boiler Assembly
Approved Document B, of the Building Regulations states that boiler houses are classed as “places
of special fire hazard”.
Requirements
The requirements for a designated compartment is that the responsible person must carry
out a risk assessment for the location and take into account the requirements of the Building
Regulations Approved Document B1 and B2 (For larger dwellings over 200 m2 per storey).
As a “Places of Special fire Hazard” there must be a separate fire compartment constructed.
This means that if an existing room is altered, such as a utility room or garage, it must be
fireproofed to make it a special compartment as well as in the case of a new construction.
This compartment should not form a part of one of the exits from the property that will
have to be used as a fire exit. There can be a door between the boiler house and the rest of the
property and there can be a door that from the boiler house to the outside but this cannot be
classed as one of the property exits.
As a “Places of Special Fire Hazard” it has to be treated as a separate compartment and the
materials used for the lining of the walls and ceilings for fire protection must meet the National
Class1 or European class C-s3,d2.
Any wall or floor between a garage and a house must have 30 minutes fire resistance with a
self closing door and must be classed as smoke sealed along its jambs and head.
Any services that pass through the wall between the boiler house and the dwelling should have
adequate fire stopping as ADB1 section 7, paragraphs 7.6-7.9 i.e. if the pipe is none combustible
and has an internal diameter less than 160 mm. • If the boiler house, plant room or fuel store is in
the basement of a property then this must have its own separate natural smoke and heat outlet.
7.1 Boiler
Room
Requirements
The boiler should only be installed in a dry room. The boiler has a minimum ventilation requirement
of 15,000mm2.in order to provide sufficient air for combustion. The ventilation should be located
at low level (within 1 metre of the floor height) if possible.
In installations where the ambient boiler room temperature is likely to exceed 30 degrees C (high
summertime use and or/highly insulated boiler room) additional high level ventilation should
be installed to dissipate excess heat.
7.2 Boiler Room
Ventilation

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7.3 Unhinge
Doors
Before lifting the boiler off the pallet, we recommend unhinging both the filling and the ash
door. Please put them down carefully to avoid any damage.
Do not unscrew the hinges on the boiler side panels as the doors may become misaligned and
therefore the door tightness and correct functioning of the door contact switches cannot be
guaranteed.
There are two possible ways to lift the boiler off the pallet. At least two persons should always
lift the boiler off the pallet.
Remove the top lid (front and rear) and top insulation slabs from the boiler. Attach a suitable
lifting hook to the two crane eyelets located on either side of the boiler. The boiler can then be
lifted using suitable lifting equipment (forklift, lifting frame).
Remove the base plate and insulation slab from underneath the boiler. A forklift can then be
used underneath the boiler to lift it from the pallet.
CAUTION. The boiler weighs over 750kg. If the boiler is dropped during transport, people can be
seriously injured and the boiler can be damaged.
Make sure that you use appropriate lifting gear when installing the boiler.
7.4 Lifting the
Boiler

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TDA Thermodual Installation Manual
The boiler should be installed on a non-combustible surface of a suitable construction. Adjust the
four legs on the base of the boiler so that it stands evenly or slightly raised to the rear.
7.5 Siting the
Boiler
Adjustable Legs
Place the ash tray in front of the assembled boiler.
7.6 Fitting the
Ash Tray

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NB. Not applicable if using the Vario Flexible Auger
Apply the supplied gasket to the pellet insertion flange located on the lower right hand side
of the boiler.
Install the hopper and insertion channel directly on the right-hand side of the boiler and align
with the height of the boiler by using the adjustable screws on the feet of the hopper.
Insert the auger fully into the combustion chamber and secure firmly to the pellet insertion
flange with the four bolts provided.
Connect the cable for the insertion motor (2) to the corresponding plug on the side panel of
the boiler.
Connect the cable for the temperature sensor (13) to the corresponding plug on the side
panel of the boiler. Place the temperature sensor into the designated tube located underneath
the pellet insertion flange and tighten
7.7 Connecting
the Manual/
Intermediate
Pellet Hopper

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Connect the flue starter onto the flue spigot located on the rear of the boiler and ensure an
airtight seal using a suitable high temperature sealant.
Drill through the flue starter stand and bolt to the two support brackets of the flue starter.
Mount the flue draught stabiliser onto the branch at the base flue starter.
Connect the drain plug on the base of the flue starter kit to a copper pipe and drain to waste.
7.8 Connecting
the Flue Starter
Kit

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Please see separate or instructions on connecting the Vario Flexible Auger or Visionconvey
Screw Suction system.
7.9 Connecting
the Vario
Flexible Auger
or Visionconvey
Suction system

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TDA Thermodual Installation Manual
** specified values have been determined in the SHT laboratory.
8. Chimney System
The flue must confirm to relevant local regulations. All flue pipes must be hermetically
sealed.
We always recommend installing a draught stabiliser in the chimney.
Important considerations when designing your system are:
In order to ensure maximum combustion the flue pipe should have as few curves as
possible, and all curves should point upwards to the chimney.
Cross-sectional reductions (bottle-necks) and/or several elbows are to be avoided.
Flue gas temperatures should not exceed 210° C on a continuous basis (with a clean
boiler).
Always make sure that the flue gas can escape in a free and unhindered manner (do
not cover or block the chimney)
Flue gas must be able to escape through the chimney in such a way that the
condensation of flue gas vapours in the chimney will not result in any damage.
It should be noted that flue gas temperatures below 160°C develop in the lower power
range. Therefore the heating system must be connected to a highly insulated chimney
which is insensitive to moisture (or to another flue gas system which is insensitive to
moisture and approved by the building authority in accordance with DIN 4705 Part 2).
Fuel Boiler
model
Flue gas mass
flow
in g/sec
Net flue gas
temperature in °C Required Flue
Draught (PA)
NL TL NL TL
Pellets TDA 30 18.7** 10.4** 135.3** 84.8** 15
TDA 40 21.4** 10.4** 159** 84.8** 15
Firewood TDA 30 15.2** 14.6** 157.1** 152.9** 15
TDA 40 17.9** 10** 176** 112.3** 15

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9.1 Basic
Hydraulic
Connections
9. Hydraulic Connections
Heating circuit flow
Heating circuit return
Boiler safety set
Auto air
vent
Thermal
safety device
Nickel
cap valve
Auto air
vent
Layering
valve
Pressure
switch