Fröling Turbomat 320 User manual

Operating Instructions
Turbomat 320/500
Read and follow the operating instructions and safety information.
Edition: 11/2004
Fröling Boiler and Container Making GmbH, Industriestraße 12, A-4710 Grieskirchen
Tel. [phone] Fax [phone] [e-mail] www.froeling.com

Table of Contents
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Table of Contents
1Product overview 4
2General information 6
2.1 Permitted uses 6
2.1.1 Permitted fuel ............................................................................................................... 6
2.1.2 Who May Operate the Boiler......................................................................................... 6
2.2 Design information 7
2.2.1 Official approval and reporting obligations .................................................................... 7
2.2.2 Domestic hot water requirements.................................................................................. 7
2.3 Safety devices 8
2.4 Residual risks 10
2.5 Emergency actions 11
3Operating the system 12
3.1 Starting up for the first time 12
3.1.1 Checking the heating system...................................................................................... 12
3.2 Heating up the boiler 12
3.2.1 Switching on the system ............................................................................................. 12
3.2.2 Switching on the boiler................................................................................................ 12
Heating with the automatic igniter .......................................................................... 12
Heating without the automatic igniter...................................................................... 13
3.2.3 Controlling the boiler................................................................................................... 13
3.2.4 Switching off the boiler................................................................................................ 13
3.2.5 Switching off the system ............................................................................................. 13
4Boiler maintenance 14
4.1 Inspection, cleaning, and maintenance 15
4.1.1 Maintenance schedule for Turbomat 320.................................................................... 16
Emptying theash can.............................................................................................. 23
4.1.2 Maintenance schedule for safety devices.................................................................... 24
4.2 Summer service 25
5Troubleshooting 26
5.1 External faults 26
5.2 Internal boiler faults 26
5.2.1 Resetting the safety temperature limiter (STB)............................................................ 26
5.2.2 Acknowledging a fault message.................................................................................. 26

Table of Contents
Fröling Boiler and Container Making GmbH, Industriestraße 12, A-4710 Grieskirchen page 3
Tel. [phone] Fax [phone] [e-mail] www.froeling.com Edition: 02.06.2005
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6Appendix 27
6.1 Preparing to test emissions 27
6.2 Maintenance instructions for hydraulic equipment 28
6.3 Addresses 29
6.3.1 Manufacturer's address .............................................................................................. 29
6.3.2 Your Installer's Address .............................................................................................. 29
6.4 Declaration of Conformity 30
6.5 Your notes 31

Product Overview
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Dear Customer,
Congratulations on choosing a quality product from FRÖLING.
The FRÖLING Turbomat is a state-of-the-art design that conforms to all currently applicable
standards and testing guidelines.
Please read and observe the operating instructions and always keep them available in close
proximity to the boiler. They contain safety information and all the operation and maintenance
specifications needed to operate the boiler safely, properly, and economically.
1 Product overview
Pos. Description
1 Waste wood boiler –Fröling Turbomat 320 kW or 500 kW
2 Tunnel door
3 Combustion chamber door
4 Mobile ashcan; Automatic ash removal - combustion chamber
5 Two-piece ashcan; Automatic ash removal - heat exchanger
6 Switch gear cabinet with integrated controller
7 Selector switch for induced draught fan:
AUTO: The induced draught fan is switched on and off by the controller.
0: The induced draught fan is switched off.
MANUAL: The induced draught fan is switched on and off by the operator and not by the
controller.
8 Main switch: switches the system on and off
9 Lambdatronic H 3000 controller
10 LED indicating operating status:
Long green blinking: boiler activated
Short green blinking: boiler deactivated
Red blinking: Fault
11 Two-row display showing: operating mode, operating status, parameters, ...
12 START key: switches on boiler
13 STOP key: switches off boiler
14 Temperature selector: selects temperature setpoint
15 BACK key: returns you to a previous menu, undoes a data entry
16 PLUS key: moves the arrow up, increases or activates a parameter
17 MINUS key: moves the arrow down, decreases or deactivates a parameter
18 ENTER key: takes you to a submenu, calls up or confirms entries

Product Overview
Fröling Boiler and Container Making GmbH, Industriestraße 12, A-4710 Grieskirchen page 5
Tel. [phone] Fax [phone] [e-mail] www.froeling.com Edition: 02.06.2005
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General Information
Permitted Uses
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2 General information
2.1 Permitted uses
The boiler should only be operated when it is fully efficient. The boiler should be operated in
accordance with the instructions given in this manual. Implement all the necessary safety
precautions. Before you start using the boiler, make sure that you are aware of the potential
hazards involved. Ensure that any malfunctions, which might impact safety are traced any
removed immediately.
The Turbomat is designed exclusively for heating domestic water. Only use the fuels
specified below 2.1.1.
The manufacturer or supplier are not liable for any damages resulting from non-
permitted uses.
2.1.1 Permitted fuel
For Germany: waste-wood conforming to 1. BImSchV of 15 July 1988
For Austria: waste-wood conforming to ÖNORM M 7133
Designation Description
W20 air dried
W30 requires storage
W35 requires limited storage
W40 damp
Water content
W50 wet
G30 Fine waste-wood (for screw feeders)
G50 Medium waste-wood (for screw feeders)
Size
G100 Large waste-wood (for hydraulic feeders only)
IMPORTANT
Corrosive deposits. Do not burn non-approved fuels. Do not operate at low temperatures which
cause condensation. Burning non-approved fuels will cause a build up of corrosive deposits.
Condensation also corrodes.
Operating under these conditions will void your guarantee. May cause
damage or corrosion in the combustion chamber.
2.1.2 Who May Operate the Boiler
Only trained operators are permitted to operate the boiler.
IMPORTANT
No unauthorized access to the boiler room.
Hazard: Personal injury and damage to property.
It is the responsibility of the operator to ensure that unauthorized persons, especially
children, are kept away from the boiler.

General Information
Design Information
Fröling Boiler and Container Making GmbH, Industriestraße 12, A-4710 Grieskirchen page 7
Tel. [phone] Fax [phone] [e-mail] www.froeling.com Edition: 02.06.2005
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2.2 Design information
As a rule, the operator is not authorized to modify or disable the safety equipment.
In addition to the operating instructions and the applicable regulations for the country in which
the boiler will be operated, all fire, police, and electrical regulations must be observed.
2.2.1 Official approval and reporting obligations
NOTE
Each heating system must be officially approved.
In Austria:
- New installations must be reported to the local building or police authorities.
In Germany:
- Report new installations to an approved chimney sweep and to the building authorities.
2.2.2 Domestic hot water requirements
There are no special requirements for domestic hot water supplies.
Applicable standards:
Austria: ÖNORM H 5195, ÖNORM H 5195-2
Germany: VDI 2035
If the system is topped up or refilled:
Prepare (soften) the water to prevent boiler scaling.

General Information
Safety devices
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2.3 Safety devices
B
C
3
4
1
A
2
5
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General Information
Safety Devices
Fröling Boiler and Container Making GmbH, Industriestraße 12, A-4710 Grieskirchen page 9
Tel. [phone] Fax [phone] [e-mail] www.froeling.com Edition: 02.06.2005
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Pos. Component Description
1 Main switch Before maintenance: Switch off the entire system
All components are switched off and powered
down
2 STOP key In the event of over-heating, shuts down boiler
The pumps continue to run.
IMPORTANT: To stop heating operations,
always use the STOP key only.
Do not use the main switch.
3 Door contact switch, tunnel door
4 Door contact switch, combustion
chamber door
If you open the door while the boiler is operating, switch
the induced draught fan to full speed.
5 Safety overload switches, motor
overload switch
Switch off the related component in the event of fault
currents or overloads.
6 Power supply fuses
7 Motherboard fuses
Properly fuse the control system and any electronic
components
When changing fuses, fit fuses with the rated
current specified.
Devices for preventing the boiler from over-heating:
A Boiler controller Switches the boiler off if the boiler temperature is set 5°C
(standard) above the setpoint value.
B Safety temperature limiter (STB) Switches off the blower fan at the maximum boiler
temperature of 100 °C. The pumps continue to run.
Once the temperature falls to below 95 °C, the STB can
be reset mechanically
Unscrew the cap on the safety temperature limiter
Using a screwdriver, press the reset button
C Safety battery valve Opens at a temperature of 105 °C and feeds cold water to
the safety heat exchanger (safety battery).
D Safety valve (not illustrated,
provided by the customer)
When the boiler pressure is too high, the safety valve
opens and vents off the hot water as steam.
Before you start up the system again, top up the
system to replace any water which has been lost
through venting.

General Information
Residual risks
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2.4 Residual risks
IMPORTANT
Do not touch hot surfaces and flue gas pipes.
Burns hazard
Only operate the boiler using the handles provided for this purpose.
Insulate the flue gas pipes or simply avoid touching them during operation.
IMPORTANT
Do not open the combustion chamber door during operation.
Equipment damage hazard.
Opening the door during operation will cause a loss of draught in the combustion chamber.
Flash fire hazard
Increase the speed of the induced draught fan to the maximum to compensate for any
loss of draught. Dust can be sucked up by the chimney and expelled into the open air.
Take the following precautions:
Only open the door when a fault is present
Before starting any maintenance work:
Turn the induced draught selector switch to the "0" (OFF) position.
Switch off the boiler and allow it to cool down.
IMPORTANT
Do not use unauthorized fuel types.
Equipment damage hazard.
Only use permitted fuels.
See 2.1.1 Permitted fuel
IMPORTANT
Failure to observe specified cleaning and maintenance intervals.
Equipment damage hazard.
This will void your guarantee.
Failure to observe the specified cleaning and maintenance intervals can cause hazardous
operating conditions (e.g. blow-back, flash fires).
Your guarantee will not cover damage caused in these circumstances.