Fröling Turbomat 320 User manual

Operating Instructions
Turbomat TM 320 - 550
Translation of the original German operating instructions for operators
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B0340720_en | Edition 16/03/2020
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Contents
1 General 5
1.1 Product overview 6
2 Safety 8
2.1 Hazard levels of warnings 8
2.2 Pictograms used 9
2.3 General safety information 10
2.4 Permitted uses 11
2.4.1 The Clean Air Act 1993 and Smoke Control Areas 11
2.4.2 Permitted fuels 11
Wood chips 11
Wood pellets 13
Wood shavings 13
Miscanthus 13
Changing the fuel 14
2.4.3 Non-permitted fuels 14
2.4.4 Qualification of operating staff 14
2.4.5 Protective equipment for operating staff 14
2.5 Safety devices 16
2.5.1 External safety devices 17
Hydraulic chamber safety switch 17
Guardrail 17
2.6 Residual risks 18
2.7 Emergency procedure 20
2.7.1 Overheating of the system 20
2.7.2 Smell of flue gas 20
2.7.3 Fire in the system 20
3 Notes for operating a heating system 21
3.1 Installation and approval of the heating system 21
3.2 General information for installation room (boiler room) 21
3.3 Requirements for central heating water 22
3.4 Notes for using pressure maintenance systems 24
3.5 Return lift 24
3.6 Use with storage tank 25
3.7 Chimney connection/chimney system 25
4 Operating the system 26
4.1 Assembly and initial startup 26
4.2 Filling the store space with fuel 27
4.2.1 Loading of fuel for a partially emptied store with rotary agitator 28
4.2.2 Loading fuel in an empty store space with a rotary agitator 28
Rotary agitator with combined drive system 29
Rotary agitator with separate drive system (optional) 30
4.2.3 Blowing in fuel for a partially emptied store with rotary agitator 30
4.2.4 Blowing in fuel for an empty store with rotary agitator 31
Contents
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Rotary agitator with combined drive system 32
Rotary agitator with separate drive system (optional) 32
4.2.5 Blowing in pellets for a store with pellet screw 32
4.2.6 Loading fuel in a store space with a sliding floor discharge unit 33
4.2.7 Loading fuel in a store space with a horizontal screw discharge unit 34
4.2.8 Loading fuel in a store space with an inclined screw discharge unit 34
4.2.9 Drainage of fuel store 34
4.3 Heating up the boiler 35
4.3.1 Switching on the power supply 35
4.3.2 Switching on the boiler 35
4.3.3 Regulating the boiler 35
4.3.4 Switching off the boiler 35
4.3.5 Switching off the power supply 36
5 Servicing the System 37
5.1 General information on servicing 37
5.2 Required tools 39
5.3 Maintenance work by the operator 40
5.3.1 Inspection 40
Checking the system pressure 40
Checking the thermal discharge safety device 40
Checking the safety valve 40
Checking the geared motors 40
Checking the quick vent valve 41
Checking the draught controller flap 41
General weekly inspection 41
5.3.2 Cleaning 42
Emptying the combustion chamber ash container 42
Emptying the ash container in the heat exchanger 43
Cleaning the combustion and burning chamber 45
5.3.3 Periodic inspection and cleaning 48
5.3.4 Periodic inspection and cleaning (approx. 1,000 hrs) 49
Cleaning the ash from the heat exchanger 50
Cleaning the flue gas temperature sensor 51
Cleaning the heat exchanger 51
Cleaning the flue gas recirculation (FGR) duct 52
Lubricate the stoker bearings 54
Cleaning the area under the moving grate 54
5.3.5 Periodic inspection and cleaning (approx. 3,000 hrs) 55
Cleaning the fireclay elements 56
Setting and checking the seal on the doors 57
Adjusting the doors 58
Cleaning the FGR blower fan 58
Cleaning the induced draught fan 58
Checking the heat exchanger ash removal drive 59
Check the igniter tube 59
Cleaning the secondary air duct 60
Checking the underpressure controller 60
Cleaning the combustion air blower fan 61
Checking the combustion chamber overpressure sensor 61
Lubricating the bearings 62
Checking the flue gas pipe 62
5.4 Maintenance work by technicians 62
5.4.1 Cleaning the Lambda probe 63
5.5 Maintenance instructions for hydraulic system 64
Contents
Operating Instructions TM 320 - 550 | B0340720_en 3

5.6 Emissions measurement by chimney sweep or regulatory body 65
5.6.1 Switch on the system 65
5.6.2 Start emissions measurement 65
5.7 Replacement parts 66
5.8 Disposal information 66
5.8.1 Disposal of the ash 66
5.8.2 Disposal of system components 66
6 Troubleshooting 67
6.1 General faults in the power supply 67
6.1.1 Behaviour of system after a power failure 67
6.2 Excessive temperature 67
6.3 Faults with fault message 68
6.3.1 Procedure for fault messages 68
7 Notes 69
8 Appendix 72
8.1 Addresses 72
8.1.1 Address of manufacturer 72
Customer service 72
8.1.2 Address of the installer 72
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.
Warranty and Guarantee Conditions
Our sale and delivery conditions will be applicable. These conditions have been made
available to customers, and customers have been made aware of them at the time of
order completion.
You can also find the guarantee conditions on the enclosed guarantee certificate.
General 1
Operating Instructions TM 320 - 550 | B0340720_en 5

1.1 Product overview
1 Wood chip boiler - Froling Turbomat
2 Control cabinet with integrated controller
3 Main switch: switches the power supply on and off for the entire system
4 SPS 4000 control panel
5 Combustion chamber door
6 Burning chamber door
7 Combustion chamber ash container
8 Ash container heat exchanger (2)
9 Safety temperature limiter (STL)
10 Boiler return connection
11 Boiler flow connection
12 Heat exchanger insulating covers
Underneath: Efficiency Optimisation System (EOS) with turbulators
13 Servo-motor case cooling
14 Servo-motor I tertiary air
1General
Product overview
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15 Flue gas recirculation (FGR)
16 Induced draught fan
17 Flue gas recirculation (FGR) duct
18 Drive for automatic heat exchanger cleaning
19 Secondary air servo-motor
20 Secondary air servo-motor flue gas recirculation (FGR)
21 Primary air servo-motor flue gas recirculation (FGR)
22 Burn back protection system (shown here: burn back flap; optional: rotary valve)
23 Stoker duct
24 Primary air servo-motor
25 Automatic ignition
26 Drive for combustion chamber ash removal
27 Servo-motor II tertiary air
28 Combustion air fan
General 1
Product overview
Operating Instructions TM 320 - 550 | B0340720_en 7

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 Pictograms used
The following symbols are used in the documentation and/or on the boiler to show
what is required and forbidden and to give warnings.
In accordance with the Machinery Directive, signs fitted directly within the danger area
of the boiler indicate immediate hazards or safety procedures. These stickers must not
be removed or covered.
Refer to the operating
instructions
Wear safety shoes
Always wear protective gloves Wear hearing protection
Keep the doors closed Turn off the main switch
Unauthorised access prohibited No not walk on the surface
Warning - hot surface Warning - hazardous electrical
voltage
Warning - hazardous or irritant
materials
Warning - automatic boiler
startup
Hand injury warning Warning of injury to fingers or
hands, automatic fan
Cutting injury warning Warning of injury to fingers or
hands, automatic screw
Safety 2
Pictograms used
Operating Instructions TM 320 - 550 | B0340720_en 9

2.3 General safety information
DANGER
If the device is used incorrectly:
Incorrect use of the system can cause severe injury and damage.
When operating the system:
❒ Observe the instructions and information in the manuals.
❒ Observe the details on procedures for operation, maintenance and cleaning,
as well as troubleshooting in the individual manuals.
❒ Any work above and beyond this should be carried out by authorised heating
engineers or by Froling customer services.
WARNING
External influences:
Negative external influences, such as insufficient combustion air or non-standard
fuel, can cause serious faults in combustion (e.g. spontaneous combustion of
carbonisation gases or flash fires) which can in turn cause serious accidents!
When operating the boiler, please note the following:
❒ Instructions and information regarding versions and minimum values, as well
as standards and guidelines for heating components in the instructions must
be observed.
WARNING
Severe injuries and damage can be caused by an inadequate flue gas system.
Problems with the flue gas system, such as poor cleaning of the flue pipe or
insufficient chimney draught, can cause serious faults in combustion (such as
spontaneous combustion of carbonisation gases or flash fires).
Take the following precautions:
❒ Optimum boiler performance can only be guaranteed if the flue gas system is
functioning correctly.
2Safety
General safety information
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2.4 Permitted uses
The Froling Turbomat TM is designed exclusively for heating domestic water. Only
use fuels specified in the "Permitted fuels" section.
⇨ See "Permitted fuels" [page 11]
The unit should only be operated when it is in full working order. It must be operated in
accordance with the instructions, observing safety precautions, and you should ensure
you are aware of the potential hazards. The inspection and cleaning intervals in the
operating instructions must be observed. Ensure that any faults which might impair
safety are rectified immediately.
The manufacturer or supplier is not liable for any damage resulting from non-permitted
uses.
Only original spare parts or specific alternative spare parts authorised by the
manufacturer may be used. Any kind of change or modification made to the product
will invalidate the manufacturer’s conformity with the applicable guideline(s). In such
cases, the product will need to undergo new hazard evaluation procedures by the
operator. The operator will then be fully responsible for the declaration of conformity
according to the valid guideline(s) for the product and will need to issue a
corresponding declaration for the device. This person will then assume all of the rights
and responsibilities of a manufacturer.
2.4.1 The Clean Air Act 1993 and Smoke Control Areas
In England appliances are exempted by publication on a list by the Secretary of State
in accordance with changes made to sections 20 and 21 of the Clean Air Act 1993 by
section 15 of the Deregulation Act 2015. In Scotland appliances are exempted by
publication on a list by Scottish Ministers under section 50 of the Regulatory Reform
(Scotland) Act 2014. Similarly, In Northern Ireland appliances are exempted by
publication on a list by the Department of Agriculture, Environment and Rural Affairs
under Section 16 of the Environmental Better regulation Act (Northern Ireland) 2016.
In Wales appliances are exempted by regulations made by Welsh Ministers.
Your local authority is responsible for implementing the Clean Air Act 1993 including
designation and supervision of smoke control areas and you can contact them for
details of Clean Air Act requirements.
2.4.2 Permitted fuels
Wood chips
Criterion ÖNORM M 7133 EN ISO 17225 Description acc. to
ÖNORM M 7133
Water content W20 M20 air-dried
W30 M30 suitable for storage
W35 - limited suitability for
storage
W40 1) M40 1) high-moisture wood
chips
W50 1) -freshly-harvested
wood chips
Size G30 P16S Fine wood chip
Safety 2
Permitted uses
Operating Instructions TM 320 - 550 | B0340720_en 11

Criterion ÖNORM M 7133 EN ISO 17225 Description acc. to
ÖNORM M 7133
G50 P31S
from 400 kW: P45S
Medium-sized wood
chip
G100 2) P63 2) Coarse wood chips
1.partial load conditions only to a limited extent
2.for hydraulic feeders only
NOTICE! In case of operating under partial load conditions and fuels with a water
content of >W35, power consumption of less than 65% of the nominal output is not
permitted!
EU: Fuel acc. to EN ISO 17225 - Part 4: Wood chips class A1 / P16S-P45S
Additional for
Germany:
Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance
(BimSchV) in the last amended version)
Note on standards
2Safety
Permitted uses
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Wood pellets
Wood pellets made from natural wood with a diameter of 6 mm
EU: Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06
and/or: EN
plus / DIN plus certification scheme
General note:
Before refilling the store, check for pellet dust and clean if necessary.
TIP: Fit the PST pellet deduster for separating the dust particles contained in the
return air
Wood shavings
Wood shavings generally cause problems with combustion. Therefore their use is
permitted 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
regional regulations.
▪ The same limits apply for the permitted water content of sawdust as for wood
chips.
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
applies:
NOTICE! The regional regulations for burning miscanthus should be observed.
Operation may only be possible by special permit.
Note on standards
Safety 2
Permitted uses
Operating Instructions TM 320 - 550 | B0340720_en 13

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.
2.4.3 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section, and particularly the
burning 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
2.4.4 Qualification of operating staff
CAUTION
If unauthorised persons enter the boiler room:
Risk of personal injury and damage to property
❒ The operator is responsible for keeping unauthorised persons, in particular
children, away from the system.
Only trained operators are permitted to operate the unit. The operator must also have
read and understood the instructions in the documentation.
2.4.5 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
2Safety
Permitted uses
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▪ For inspection and cleaning:
- suitable workwear
- protective gloves
- sturdy shoes
▪ Additional for operating:
- Hearing protection (sound level > 70 dB)
- Protective goggles
Safety 2
Permitted uses
Operating Instructions TM 320 - 550 | B0340720_en 15

2.5 Safety devices
TA
1 BOILER OFF
(switches off the boiler to prevent overheating)
❒ Tap “Boiler off”
➥Automatic mode is switched off
➥Control system follows the boiler shutdown procedure
➥The pumps continue to run
NOTICE! Never use the main switch!
2 MAIN SWITCH (switches off the power supply)
Before carrying out work on the boiler:
❒ Tap “Boiler off”
➥Automatic mode is switched off
➥Control system follows the boiler shutdown procedure
❒ Switch off the main switch and let the boiler cool down
3 SAFETY OVERLOAD SWITCHES, MOTOR PROTECTION SWITCHES, RESIDUAL
CURRENT PROTECTIVE DEVICES (RCD)
Switch off the related component in the event of fault currents or overloads.
4 SAFETY TEMPERATURE LIMITER (STL) (protection against overheating)
The STL switches off the combustion system when the boiler reaches 95 - 100°C. The
pumps continue to run. Once the temperature falls to below approx. 85°C, the STL
can be reset mechanically.
5 DOOR CONTACT SWITCH
When the door is opened, the induced draught is kept at a constant speed and the
combustion air and FGR blower fan stops.
2Safety
Safety devices
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TV THERMAL DISCHARGE VALVE
(protection against overheating)
The thermal discharge valve opens at approx. 100°C and feeds cold water to the
safety heat exchanger to lower the boiler temperature
SAFETY VALVE
(not shown, supplied by the customer)
When the boiler pressure reaches a maximum of 6 bar, the safety valve opens and the
heated water is blown off in the form of steam.
2.5.1 External safety devices
Hydraulic chamber safety switch
Before starting any maintenance work in the hydraulic chamber of the sliding floor:
❒ Turn the safety switch to the "0" position
➥The boiler follows the shutdown procedure and the discharge is deactivated
❒ Turning the selector switch past the "0" position engages the locking lever
➥The switch can be locked with a padlock to prevent it from being switched on
again
On completion of the maintenance work:
❒ Remove the padlock
❒ Turn the selector switch past the "0" position to automatically release the locking
switch. The selector switch can now be turned back to the "1" position.
❒ Acknowledge the fault and press the Start button to activate the boiler
Guardrail
When working at a height, appropriate measures must be taken in accordance with
the applicable national industrial safety guidelines to protect against the risk of falling
(e.g. ladders, platforms, etc.). It is the responsibility of the operator to select and
provide these means.
Alternatively, a railing can be fitted to the top of the boiler as per EN ISO 14122.
Safety 2
Safety devices
Operating Instructions TM 320 - 550 | B0340720_en 17

2.6 Residual risks
WARNING
When touching hot surfaces:
Severe burns are possible on hot surfaces and the flue gas pipe!
When work is carried out on the boiler:
❒ Shut down the boiler according to procedure (“Switched off OFF” operating
status) and allow it to cool down
❒ Protective gloves must usually be worn for work on the boiler, and it should
only be operated using the handles provided
❒ Insulate the flue gas pipes and do not touch them during operation
WARNING
Opening the door to the combustion or burning chamber, or the cleaning door or
lids during operation
may result in injury or damage or flue gas generation!
Therefore:
❒ Do not open any doors or lids while the boiler is in operation!
WARNING
If non-permitted fuel types are used:
Non-standard fuels can cause serious faults in combustion (e.g. spontaneous
combustion of carbonisation gases / flash fires) which can lead to serious
accidents!
Take the following precautions:
❒ Only use fuels specified in the "Permitted fuels" section of these operating
instructions.
2Safety
Residual risks
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WARNING
Inspection and cleaning work on a system which is operational:
Risk of serious injuries from automatic startup of the system and severe burns
from hot parts and the flue gas pipe!
When working on the system:
❒ always wear protective gloves
❒ only operate the boiler using the handles provided
❒ switch off the boiler by tapping “Boiler off” at the mode icon
➥The boiler follows the shutdown procedure and switches to “Switched off
Off“ status
❒ switch off the main switch and take precautions to prevent accidental
switching on
❒ allow the boiler to cool off for at least 1 hour
❒ once all of the tasks have been completed, turn the main switch back on and
switch the boiler on in the desired mode
Safety 2
Residual risks
Operating Instructions TM 320 - 550 | B0340720_en 19

2.7 Emergency procedure
2.7.1 Overheating of the system
If the system overheats and the safety devices fail to operate, proceed as follows:
NOTICE! Do not under any circumstances switch off the main switch or disconnect the
power supply!
❒Keep all the doors on the boiler closed
❒ Open all mixing valve taps, switch on all pumps.
➥The Froling heating circuit control takes on this function in automatic operation.
❒ If a third-party controller is used, carry out the appropriate measures to activate
the mixer taps and pumps manually.
❒ Leave the boiler room and close the door
❒ Increase heat consumption by turning on all radiators and other appliances
❒ Open any thermostatic valves on the radiator and ensure sufficient heat
dissipation from the rooms
If the temperature does not drop:
❒ Contact the installer or Froling customer services
⇨ See "Addresses" [page 72]
2.7.2 Smell of flue gas
DANGER
If you smell flue gas in the boiler room:
Inhaling toxic flue gas can be fatal!
If you smell flue gas in the room where the boiler is installed:
❒ Keep all the doors on the boiler closed
❒ Shut down the boiler according to procedure
❒ Ventilate the room where the boiler is installed
❒ Close the fire door and doors to living areas
Recommendation: Do not install smoke alarms and carbon monoxide detectors near
the system.
2.7.3 Fire in the system
DANGER
In case of fire in the system:
Risk of death by fire and poisonous gases
Emergency procedure in case of fire:
❒ Leave the boiler room
❒ Close the doors
❒ Inform the fire department
2Safety
Emergency procedure
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