Froling Turbomat TM 320 User manual

Installation Instructions
Turbomat TM 320-500
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M0690817_en | Edition 15/03/2017
Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at

Table of contents
1 General 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 Personal protective equipment for assembly staff 6
2.4 Design Information 7
2.4.1 Notes on standards 7
General standards for heating systems 7
Standards for structural and safety devices 7
Standards for heating water 7
Regulations and standards for permitted fuels 8
2.4.2 Installation and approval of the heating system 8
2.4.3 General information for installation room (boiler room) 8
2.4.4 Requirements for central heating water 9
2.4.5 Notes for using pressure maintenance systems 10
2.4.6 Return lift 11
2.4.7 Use with storage tank 11
2.4.8 Chimney connection/chimney system 12
Draught limiter 12
Boiler data for planning the flue gas system 12
3 Technology 13
3.1 Dimensions 13
3.2 Components and connections 14
3.3 Technical specifications 15
4 Assembly 17
4.1 Transport 17
4.2 Temporary storage 17
4.3 Positioning 17
4.3.1 Fitting the underfloor ash removal system (optional) 18
4.4 Setting up in the boiler room 18
4.4.1 Moving the boiler in the boiler room 18
4.4.2 Recommended clearances in the boiler room 19
4.5 Installing the boiler 20
4.5.1 General information 20
4.5.2 Installing the grate drive 21
4.5.3 Assembling the stoker unit 22
4.5.4 Installing the hydraulic stoker unit (optional) 23
4.5.5 Bolting together the combustion chamber and heat exchanger 23
4.5.6 Assembling the case cooling duct (optional) 26
4.5.7 Repositioning the EOS rods (if required) 26
4.5.8 Fitting various fittings 28
4.5.9 Removing the different blanking plugs 29
4.5.10 Assembling the insulation floor base frame 30
4.5.11 Assembling the flange for the heat exchanger ash removal system 32
4.5.12 Fitting thermal insulation to the boiler 33
Table of contents
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4.5.13 Assembling the FGR duct 36
4.5.14 Assembling the upper insulation base frame 36
4.5.15 Installing the insulating side panels 39
Turbomat TM 320 40
Turbomat TM 400/500 46
4.5.16 Installing the underpressure controller 51
4.5.17 Installing the combustion chamber overpressure monitor and temperature sensor 52
4.5.18 Installing the air flap actuators 53
4.5.19 Assembling different cover plates 54
4.5.20 Installing the heat exchanger ash removal unit 55
4.5.21 Fitting the combustion chamber ash removal unit (optional) 59
4.5.22 Fitting the heat-exchanger drive 61
4.5.23 Fitting the FGR blower fan 62
4.5.24 Installing the induced draught fan 65
4.5.25 Installing the combustion air fan 67
4.5.26 Fitting the temperature sensor under the moving grate 68
4.5.27 Assembling the automatic ignition 68
4.5.28 Assembling the insulated doors and covers 69
4.5.29 Fitting the pivoting mechanism for the oil burner (optional) 71
4.6 Power connection and wiring 74
4.6.1 Potential equalisation 74
4.6.2 Laying of cables 74
4.7 Connecting the hydraulic safety devices 76
4.8 Connecting up the slide-on duct cooling 78
4.9 Final installation steps 79
4.9.1 Setting and checking the seal on the doors 79
Checking the setting 79
Checking the seal 79
4.9.2 Adjusting the doors 80
5 Commissioning 81
5.1 Before commissioning / configuring the boiler 81
5.2 Initial startup 82
5.2.1 Permitted fuels 82
Wood chips 82
Wood pellets 82
Wood shavings 82
Miscanthus 83
Changing the fuel 83
5.2.2 Non-permitted fuels 83
5.3 Heating up for the first time 84
5.3.1 Screed drying 85
6 Decommissioning 86
6.1 Out of service for long periods 86
6.2 Disassembly 86
6.3 Disposal 86
7 Appendix 87
7.1 Addresses 87
7.1.1 Address of manufacturer 87
7.1.2 Address of the installer 87
Table of contents
Installation Instructions Turbomat TM 320-500 | M0690817_en 3

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
1General
4 Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at

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 or damage to property.
Safety 2
Hazard levels of warnings
Installation Instructions Turbomat TM 320-500 | M0690817_en 5

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)
2Safety
Qualification of assembly staff
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2.4 Design Information
2.4.1 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:
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
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)
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.
Safety 2
Design Information
Installation Instructions Turbomat TM 320-500 | M0690817_en 7

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
2.4.2 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.
2.4.3 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 potentially explosive environments.
▪ The boiler room must be frost-free.
▪ The boiler does not provide any light, so the customer must ensure sufficient
lighting 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. Flammable objects (e.g. clothing) must not be put
on the boiler to dry.
Note on standards
2Safety
Design Information
8 Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at

▪ 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
2.4.4 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
makeup 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
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
Note on standards
Safety 2
Design Information
Installation Instructions Turbomat TM 320-500 | M0690817_en 9

Limit values for filling and make-up water:
Austria Germany Switzerland
Total hardness ≤ 1.0 mmol/L ≤ 2.0 mmol/L < 0.1 mmol/L
Conductivity - <100µS/cm < 100 µS/cm
pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5
Chloride < 30 mg/L < 30 mg/L < 30 mg/L
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
2.4.5 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.
2Safety
Design Information
10 Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at