Fröling TI 350 User manual

Installation Instructions
TI 350
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1830521_en | Edition 18/02/2021
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of Contents
1 General 5
2 Safety 6
2.1 Hazard levels of warnings 6
2.2 Qualification of assembly staff 7
2.3 Personal protective equipment for assembly staff 7
3 Design Information 8
3.1 Notes on standards 8
3.1.1 General standards for heating systems 8
3.1.2 Standards for structural and safety devices 8
3.1.3 Standards for heating water 8
3.1.4 Regulations and standards for permitted fuels 9
3.2 Installation and approval of the heating system 9
3.3 General information for installation room (boiler room) 9
3.4 Requirements for central heating water 10
3.5 Notes for using pressure maintenance systems 12
3.6 Return lift 12
3.7 Use with storage tank 13
3.8 Chimney connection/chimney system 13
3.8.1 Draught limiter 13
4 Technology 14
4.1 Dimensions 14
4.2 Components and connections 15
4.3 Technical data 16
4.3.1 Boiler data for planning the flue gas system 18
5 Assembly 19
5.1 Transport 19
5.2 Temporary storage 19
5.3 Positioning 19
5.4 Setting up in the boiler room 20
5.4.1 Moving the boiler in the boiler room 20
5.4.2 Operating and maintenance areas of the equipment 21
5.5 Installing the boiler 22
5.5.1 General information 22
5.5.2 Installing the grate drive 23
5.5.3 Installing the stoker unit 24
5.5.4 Bolting together the combustion chamber and heat exchanger 24
5.5.5 Repositioning the WOS lever (if required) 26
5.5.6 Fitting the WOS drive 27
5.5.7 Installing the air controllers 28
5.5.8 Installing the ash removal chamber 28
5.5.9 Installing the heat exchanger ash removal unit 30
Table of Contents
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5.5.10 Installing the air ducts 32
5.5.11 Installing the adapter flange und pump assembly (optional) 32
5.5.12 Installing the igniter tube and undergrate temperature sensor 33
5.5.13 Installing the spacer plate on the combustion chamber 33
5.5.14 Positioning two-layer thermal insulation on the combustion chamber 34
5.5.15 Positioning thermal insulation on the heat exchanger 35
5.5.16 Installing the frames 36
5.5.17 Preparing the cooling piping (optional) 41
5.5.18 Installing the cooling piping (optional) 41
5.5.19 Installing the piping of the safety battery 42
5.5.20 Fit sensor and wire components 43
5.5.21 Installing the cladding 45
5.5.22 Fitting the control cabinet 48
5.5.23 Installing the combustion chamber door components 49
5.5.24 Installing the ash container limit switch 50
5.5.25 Installing the combustion chamber temperature sensor and ignition 51
5.5.26 Installing the underpressure controller 52
5.5.27 Installing remaining covers 53
5.5.28 Installing the broadband probe and flue gas temperature sensor 54
5.5.29 Installing the induced draught fan 54
5.5.30 Installing the flue gas recirculation (FGR) 55
5.5.31 Positioning the ash container 59
5.5.32 Flue gas piping 60
5.6 Power connection and wiring 60
5.6.1 Potential equalisation 61
5.6.2 Installing the cable duct covers 61
5.7 Connecting the hydraulic safety devices 62
5.8 Cooling connection 64
5.9 Final installation steps 65
5.9.1 Setting and checking the seal on the door 65
5.9.2 Adjusting the door 66
6 Commissioning 67
6.1 Before commissioning / configuring the boiler 67
6.2 Initial startup 68
6.2.1 Permitted fuels 68
Wood chips 68
Wood pellets 68
Wood shavings 68
Miscanthus 69
Changing the fuel 69
6.2.2 Non-permitted fuels 69
6.3 Heating up for the first time 70
6.3.1 Screed drying 71
7 Decommissioning 73
7.1 Out of service for long periods 73
7.2 Disassembly 73
7.3 Disposal 73
8 Notes 74
9 Appendix 76
Table of Contents
Installation Instructions TI 350 | M1830521_en 3

9.1 Addresses 76
9.1.1 Address of manufacturer 76
Customer service 76
9.1.2 Address of the installer 76
Table of Contents
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1 General
Thank you for choosing a quality product from Froling. The product features a state-of-
the-art design and conforms to all currently applicable standards and testing
guidelines.
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
documentation makes a significant contribution to safe, appropriate, environmentally
friendly and economical operation of the system.
The constant further development of our products means that there may be minor
differences from the pictures and content. If you discover any errors, please let us
know: [email protected].
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
certificate
General 1
Installation Instructions TI 350 | M1830521_en 5

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.
NOTICE
The dangerous situation may occur and if measures are not observed it will lead
to damage to property or pollution.
2Safety
Hazard levels of warnings
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2.2 Qualification of assembly staff
CAUTION
Assembly and installation by unqualified persons:
Risk of personal injury and damage to property
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow appropriately qualified personnel to work on the system
Assembly, installation, initial startup and servicing must always be carried out by
qualified personnel:
- Heating technician / building technician
- Electrical installation technician
- Froling customer services
The assembly staff must have read and understood the instructions in the
documentation.
2.3 Personal protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For transportation, setup and assembly:
- suitable work wear
- protective gloves
- sturdy shoes (min. protection class S1P)
Safety 2
Qualification of assembly staff
Installation Instructions TI 350 | M1830521_en 7

3 Design Information
3.1 Notes on standards
The system must be installed and commissioned in accordance with the local fire and
building regulations. Unless contrary to other national regulations, the latest versions
of the following standards and guidelines apply:
3.1.1 General standards for heating systems
EN 303-5 Boilers for solid fuels, manually and automatically fed
combustion 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
ÖNORM H 5151 Planning of central hot water heating systems with or without hot
water preparation
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
3.1.2 Standards for structural and safety devices
ÖNORM H 5170 Heating installation - Requirements for construction and safety
engineering, as well as fire prevention and environmental
protection
TRVB H 118 Technical directives for fire protection/prevention (Austria)
3.1.3 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 hot water heating systems (Germany)
SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
UNI 8065 Technical standard regulating hot water preparation.
DM 26.06.2015 (Ministerial Decree specifying the minimum
requirements)
Follow the instructions of this standard and any related updates.
(Italy)
3Design Information
Notes on standards
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3.1.4 Regulations and standards for permitted fuels
1. BImSchV First Order of the German Federal Government for the
implementation of the Federal Law on Emission Protection
(Ordinance on Small and Medium Combustion Plants) in the
version published on 26 January 2010,
BGBl. JG 2010 Part I No. 4.
EN ISO 17225-2 Solid bio-fuel - Fuel specifications and classes
Part 2: Wood pellets for use in industrial and domestic systems
EN ISO 17225-4 Solid bio-fuel - Fuel specifications and classes
Part 4: Wood chips for non-industrial use
3.2 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
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:
Austria: report to the construction authorities of the community or magistrate
Germany: report new installations to an approved chimney sweep / the building
authorities.
3.3 General information for installation room (boiler room)
Boiler room characteristics
▪ The floor must be even, clean and dry and have an adequate load-bearing
capacity.
▪There must not be a potentially explosive atmosphere in the boiler room as the
boiler is not suitable for use in such an environment.
▪ The boiler room must be frost-free.
▪ The boiler does not provide any light, so adequate lighting must be ensured in the
boiler room in accordance with national workplace design regulations.
▪ When using the boiler above 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
The floor of the boiler room must not be flammable. No flammable materials
should be stored near the boiler. Never place flammable objects (e.g. clothing,
etc.) on the boiler to dry.
Note on standards
Design Information 3
Notes on standards
Installation Instructions TI 350 | M1830521_en 9

▪ Damage due to impurities in combustion air.
Do not use any solvents or cleaning agents containing chlorine and hydrogen
halides in the room where the boiler is installed (e.g. chlorination units for
swimming pools).
▪Keep the air suction opening of the boiler free of dust.
▪ The system must be protected against the chewing or nesting of animals (e.g.
rodents etc.).
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
(foliage, 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
3.4 Requirements for central heating water
Unless contrary to other national regulations, the latest versions of the following
standards and guidelines apply:
Austria:
Germany:
ÖNORM H 5195
VDI 2035
Switzerland:
Italy:
SWKI BT 102-01
UNI 8065
Observe the standards and also follow the recommendations below:
❒Aim for a pH value of between 8.2 and 10.0. If the central heating water comes
into contact with aluminium, the pH value must be between 8.0 and 8.5
❒ Use prepared water which complies with the standards cited above for filling and
make-up water
❒ Avoid leaks and use a closed heating system to maintain water quality during
operation
❒ When filling with make-up water, always bleed the filling hose before connecting,
in order to prevent air from entering the system
Note on standards
3Design Information
General information for installation room (boiler room)
10 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Advantages of prepared water:
▪Complies with the applicable standards
▪ Less of a drop in output due to reduced limescale build-up
▪ Less corrosion due to fewer aggressive substances
▪ Long-term cost savings thanks to improved energy efficiency
Permitted water hardness for the fill and make-up water in accordance with VDI 2035:
Overall heat
output
Total hardness at
<20 l/kW minimum
individual heat output 1)
Total hardness at
>20 ≤50 l/kW minimum
individual heat output 1)
Total hardness at
>50 l/kW minimum
individual heat output 1)
kW °dH mol/m³ °dH mol/m³ °dH mol/m³
≤50 no demand or 11.2 2 0.11 0.02
<16.8 2) <3 2)
>50 ≤200 11.2 2 8.4 1.5
>200 ≤600 8.4 1.5 0.11 0.02
>600 0.11 0.02
1.From specific system volume (litres nominal capacity/heat output; for multi-boiler systems use the smallest individual heat output)
2.In the case of systems with central heating boilers and for systems with electric heating elements
Additional requirements for Switzerland
The filling and make-up water must be demineralised (fully purified)
▪The water must not contain any ingredients that could settle and accumulate in the
system
▪ This makes the water non-electroconductive, which prevents corrosion
▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can
weaken corrosive materials in certain conditions
If some of the system water is lost, e.g. during repairs, the make-up water must also be
demineralised. It is not enough to soften the water. The heating system must be
professionally cleaned and rinsed before filling the units.
Inspection:
▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the central
heating water comes into contact with aluminium, the pH value must be between 8.0 and
8.5
▪ Yearly. Values must be recorded by the owner
Design Information 3
Requirements for central heating water
Installation Instructions TI 350 | M1830521_en 11

3.5 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required
pressure 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
expansion 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
into the heating water.
Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressure-
maintenance 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 expansion 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.
3.6 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
return temperature control.
Condensation water forms an aggressive condensate when combined with
combustion 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 60 °C. We recommend fitting some
sort of control device (e.g. thermometer).
3Design Information
Notes for using pressure maintenance systems
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3.7 Use with storage tank
NOTICE
In principle it is not necessary to use a storage tank for the system to run
smoothly. 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.
3.8 Chimney connection/chimney system
EN 303-5 specifies that the entire flue gas system must be designed to prevent,
wherever possible, damage caused by seepage, insufficient feed pressure and
condensation. Please note in this respect that flue gas temperatures lower than 160K
above room temperature can occur in the permitted operating range of the boiler.
The flue gas temperatures (for clean systems) and additional flue gas values can be
found in the 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
calculated in accordance with EN 13384-1.
Local regulations and other statutory regulations also apply.
NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney
sweep.
3.8.1 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.
Design Information 3
Use with storage tank
Installation Instructions TI 350 | M1830521_en 13

4 Technology
4.1 Dimensions
L1
L2 L3
H
H1
H2
H3
H4
H5
H6
H7
B1
B2 B3
B4
BL
Item Description Unit Value
LTotal length including fittings mm 3460
L1 Total length without fittings 2455
L2 Length, combustion chamber ash container 605
L3 Length, heat exchanger ash container 320
HBoiler height including insulation 2475
H1 Height, heat exchanger ash container 635
H2 Height of return connection 705
H3 Height of stoker including burn back protection system 825
H4 Height, flue gas pipe connection with FGR 1630
H5 Height of flow connection 1890
H6 Height, combustion chamber door opening 530
H7 Height, combustion chamber ash container 540
BTotal width including fittings 2670
B1 Total width without fittings 2415
W2 Width, combustion chamber door opening 510
B3 Width, combustion chamber ash container 780
B4 Width, heat exchanger ash container 280
4Technology
Dimensions
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4.2 Components and connections
Item Description Unit Value
1Boiler flow connection inches DN100 / PN16
2Boiler return connection inches DN100 / PN16
3Drainage connection inches 1“
4Thermal discharge valve connection (heat exchanger) inches 3/4 ” AG
5Thermal discharge valve connection (burn through elbow)
without optional pipe assembly
inches 1/2 ” AG
Thermal discharge valve connection (burn through elbow)
with optional pipe assembly
inches 3/4 ” AG
6Flue gas pipe connection with FGR (flue gas recirculation) mm 300
Technology 4
Components and connections
Installation Instructions TI 350 | M1830521_en 15

4.3 Technical data
Description Value
Nominal output kW 350
Output range 105-350
Required fuel consumption at nominal load kg/h 110
Electrical connection 400V / 50 Hz / C35A or as per
circuit diagram
Power consumption wood chips (NL / PL) W <0.8 / 0.4 % of nominal output
Power consumption pellets (NL / PL) W <0.6 / 0.3 % of nominal output
Minimum room height mm 2900
Dimensions required for combustion chamber installation
(LxWxH)
2550 x 1100 x 1500
Dimensions required for heat exchanger installation
(LxWxH)
1250 x 1400 x 2400
Total weight incl. fittings kg 5630
Weight - combustion chamber 1270
Weight - heat exchanger 1600
Weight - fireclay 1060
Heat exchanger water capacity l 590
Water pressure drop
(ΔT = 20 / 10 K)
mbar 3 / 15
Flow rate (ΔT = 20 / 10 K) m³/h 15 / 30
Minimum boiler return temperature °C 65
Maximum permitted operating temperature °C 90
Permitted operating pressure bar 6
Boiler class as per EN 303-5:2012 5
Flue gas temperature (NL / PL) °C 140 / 110
Flue gas volume/mass flow with wood chips W30, 12% O2
2)
m3/h (kg/h) 1574
(1327)
Flue gas volume/mass flow with wood chip W30, 9% O21152
(969)
Flue gas volume/mass flow with wood pellets 12% O21307
(1114)
Flue gas volume/mass flow with wood pellets 9% O2955
(815)
Required feed pressure at outlet of induced draught
housing at nominal load
Pa 5
mbar 0.05
Required feed pressure at outlet of induced draught
housing at partial load
Pa 2
mbar 0.02
Maximum permissible feed pressure Pa 30
mbar 0.3
4Technology
Technical data
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Description Value
Permitted fuel as per EN ISO 17225 1) Part 2: Wood pellets class A1 / D06
Part 4: Wood chips class A1 /
P16S-P31S
Airborne sound level dB(A) <70
Minimum ventilation opening as per ÖNORM H 5170 cm² 755
Test book number PB 099 00 17
1.Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”
2.Use higher oxygen content for chimney design
Regulation (EU) 2015/1189 - ηs in [%]
Heating space annual rate of use ηs with wood chips as fuel 78
Heating space annual rate of use ηs with pellets as fuel 82
Regulation (EU) 2015/1189 - Emissions in [mg/m³]1)
seasonal space heating emissions of particulate (PM) ≤ 40
seasonal space heating emissions of organic gaseous compounds
(OGC)
≤ 20
seasonal space heating emissions of carbon monoxide (CO) ≤ 500
seasonal space heating emissions of nitrogen oxides (NOx) ≤ 200
1.Emissions of particulate matter, organic gaseous compounds, carbon monoxide and nitrogen oxides shall be expressed standardised to a dry flue gas basis at 10 % oxygen and
standard conditions at 0°C and 1013 millibar
Technology 4
Technical data
Installation Instructions TI 350 | M1830521_en 17

4.3.1 Boiler data for planning the flue gas system
Description TI 350
Flue gas temperature at nominal load °C 140
Flue gas temperature at partial load 110
Flue gas volume/mass flow with wood chip W30,
12% O2
m3/h
(kg/h)
1574
(1327)
Flue gas volume/mass flow with wood chip W30,
9% O2
1152
(969)
Flue gas volume/mass flow with wood pellets
12% O2
1307
(1114)
Flue gas volume/mass flow with wood pellets 9%
O2
955
(815)
Required feed pressure at outlet of induced
draught housing at nominal load
Pa 5
mbar 0.05
Required feed pressure at outlet of induced
draught housing at partial load
Pa 2
mbar 0.02
Maximum permissible feed pressure Pa 30
mbar 0.3
Flue pipe diameter mm 300
4Technology
Technical data
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5 Assembly
WARNING
Risk of falling when working at a height
Therefore:
❒Implement appropriate measures in accordance with the applicable national
industrial safety guidelines to protect against the risk of falling (e.g. ladders,
platforms, etc.)
5.1 Transport
NOTICE
Possibility of damage to components if handled incorrectly
❒Follow the transport instructions on the packaging
❒ Transport components with care to avoid damage
❒ Protect components 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.)
5.2 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!
5.3 Positioning
❒ Secure cable winch or similar lifting device to the attachment points and position
the components
➥CAUTION: It is forbidden to stand under suspended loads!
Assembly 5
Transport
Installation Instructions TI 350 | M1830521_en 19

CAUTION: Do not tilt the heat exchanger during installation or assembly! – see sticker
(A).
After positioning the heat exchanger, check the correct position of the firebricks (B).
5.4 Setting up in the boiler room
5.4.1 Moving the boiler in the boiler room
❒ Position a forklift 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.
➥Pay attention to the operating and maintenance areas of the equipment in the
process!
5Assembly
Setting up in the boiler room
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