Froling Turbomatic 28 - 55 kW User manual

Fröling Heizkessel- und Behälterbau Ges.m.b.H  Industriestraße 12 A-4710 Grieskirchen
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Operating Instructions
(Turbomatic 28 - 55 kW)
(Turbomatic 70 - 100 kW)
Turbomatic TMC 28-100
(with Lambdatronic H 3200)
Be sure to read and comply with the operating instructions and safety
information
Subject to technical change.

Introduction
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Dear customer,
Congratulations on choosing a quality product from FRÖLING.
The FRÖLING Turbomatic waste wood boiler features 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 close to the boiler for reference. They contain safety information
and all the operation and maintenance specifications needed to operate
the boiler safely, properly and economically.
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.
Subject to technical change.

Contents
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1Product Overview 6
2Safety 8
2.1 Safety Information 8
2.2 Permitted Uses 9
2.2.1 Permitted fuels...............................................................................................9
Wood chips ...................................................................................................9
Pellets ........................................................................................................ 10
Shavings..................................................................................................... 10
Miscanthus.................................................................................................. 10
Changing the fuel......................................................................................... 11
2.2.2 Non-permitted fuels ...................................................................................... 11
2.2.3 Who may operate the boiler?.......................................................................... 11
2.3 Design Information 12
2.3.1 Approval and obligation to report .................................................................... 12
2.3.2 Requirements for central heating water............................................................ 12
2.3.3 Ventilation of boiler room............................................................................... 13
2.3.4 Installing the heating system / Standards......................................................... 13
Storage tank ............................................................................................... 13
Return feed lift ............................................................................................ 14
2.3.5 Chimney connection/chimney system .............................................................. 14
Draught limiter ............................................................................................ 15
Boiler data for constructing the flue gas system: .............................................. 15
2.4 Safety devices 16
2.4.1 Devices for preventing the boiler from overheating ............................................ 17
Thermal discharge safety device..................................................................... 17
Safety Temperature Limiter STL..................................................................... 17
Safety valve................................................................................................ 17
2.5 Safety instructions for the installation room 17
2.6 Residual risks 18
2.7 Emergency procedure 19
2.7.1 Overheating of the system ............................................................................. 19
2.7.2 Smell of flue gas........................................................................................... 19
3Operating the system 20
3.1 Initial start-up 20
3.2 Filling/ refilling the store with fuel 20
3.2.1 Loading wood chips in a partially emptied store................................................. 21
3.2.2 Loading wood chips in an empty store.............................................................. 21
3.2.3 Blowing in pellets for a store with pellet screw .................................................. 22
3.2.4 Blowing in pellets for a partially emptied store with stirrer .................................. 22
3.2.5 Blowing in pellets for an empty store with stirrer............................................... 23
3.3 Heating up the boiler 24
3.3.1 Switching on the system................................................................................ 24
3.3.2 Switching on the boiler .................................................................................. 24
3.3.3 Controlling the boiler..................................................................................... 24
3.3.4 Switching off the boiler.................................................................................. 24
3.3.5 Switching off the system................................................................................ 24

Contents
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3.4 Emergency firewood operation 25
3.4.1 Modifying the boiler for emergency firewood operation .......................................25
3.4.2 Setting the controller for emergency firewood operation .....................................27
3.4.3 Filling the boiler with firewood.........................................................................28
3.5 Modifying the boiler for normal operation 28
4Boiler servicing 29
4.1 General information on servicing 29
4.1.1 Service mode ...............................................................................................30
4.2 Inspection, cleaning and maintenance 31
4.2.1 Inspection....................................................................................................31
Checking the ash level ..................................................................................31
Checking the thermal discharge safety device...................................................32
Checking the system pressure........................................................................32
Checking the geared motors ..........................................................................32
4.2.2 Monthly cleaning...........................................................................................33
Cleaning the combustion chamber ..................................................................33
Cleaning the heat-exchanger and flue gas collection chamber .............................33
Removing ash from the cleaning system..........................................................34
Cleaning the flue gas sensors.........................................................................34
4.2.3 Annual check................................................................................................35
Cleaning the smoke flue pipe .........................................................................35
Checking the draught controller flap and explosion flap......................................35
Cleaning the induced draught ventilator...........................................................35
Cleaning the combustion air blower fan ...........................................................36
Checking the combustion chamber door...........................................................36
Cleaning the combustion chamber door below the ash baffle...............................36
4.3 Instructions for measuring emissions 37
4.3.1 Measurement at rated load.............................................................................37
Activating chimney-sweep mode.....................................................................37
4.3.2 Measurement at partial load (if necessary)........................................................37
4.4 Maintenance agreement / Customer service 38
4.5 Replacement parts 38
5Troubleshooting 39
5.1 General faults in the power supply 39
5.1.1 Behaviour of system after a power failure.........................................................39
5.2 Excessive temperature 39
5.3 Faults with fault message 40
5.3.1 Procedure for fault messages..........................................................................40
5.3.2 Acknowledging a fault message.......................................................................40
6Appendix 41
6.1 Guarantee conditions 41
6.2 Address of manufacturer 41
6.3 Declaration of conformity 42

Product overview
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1Product overview
4.2
4.4
4
4.3
4.1 3
2
1
5 6
12
13
10
8
8
9
7
11

Product overview
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Pos. Description Symb.
1 Wood chip boiler - Fröling Turbomatic
2 Switch cabinet with integrated Lambdatronic H 3200 controller
3 Main switch: switch the power supply on and off for the entire system
4 Control panel of the Lambdatronic H 3200 controller
4.1 Status LED (operating status): - slow green flashing light: boiler activated
- fast green flashing light: boiler deactivated
- red flashing light: Fault
4.2 Large graphical display to show operating statuses and parameters
4.3 Navigation keys to move around in the menus and to change the parameter values
4.4 Function keys for calling up individual boiler functions or modes directly
5 Fuel transport unit with top gravity shaft, burn back flap or rotary valve as a burn back protection
system and stoker screw for fuel transport
6 Automatic ignition
7 Automatic tipping grate with shaker
8 Ash box of automatic ash removal unit or second ash box for automatic heat exchanger ash removal
unit (optional for TMC 28-55, standard part of delivery for TMC 70-100)
9 Combustion air blower fan: pressure-side fan for supplying primary and secondary air
10 WOS system with turbulators and automatic drive for heat exchanger cleaning
11 Combustion chamber door with inspection glass
12 Secondary air control with actuator drive
13 Primary air control with actuator drive

Safety
Safety information
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2Safety
2.1 Safety information
DANGER
Non-permitted use!
Incorrect use of the boiler can cause severe injuries and damage!
The instructions and information provided in the instructions
should be observed!
Details on procedure for operation, maintenance and cleaning, as
well as troubleshooting for the boiler are included in the
individual instructions. Any further work should be carried out by
authorised heating engineers or by Fröling customer services.
WARNING
External influences!
Negative external influences, such as insufficient combustion air or
non-permitted fuel can cause serious faults in combustion (e.g.
spontaneous combustion of carbonisation gases or flash fires) which
can in turn cause
serious accidents!
Instructions and information for versions and minimum values, as
well as norms 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 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)!
You can only be guaranteed of optimum performance from the boiler if the
flue gas system is running smoothly!

Safety
Permitted uses
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2.2 Permitted uses
The boiler should only be operated when it is in full working order.
It should be operated in accordance with the instructions, observing
safety precautions, and you should ensure you are aware of the
potential hazards.
Ensure that any faults, which might impair safety, are rectified
immediately.
The Turbomatic series wood chip boiler is intended exclusively
for heating central heating water. Use only the fuels specified
under 2.2.1.
The manufacturer or supplier is not liable for any damages
resulting from non-permitted uses.
2.2.1 Permitted fuels
Wood chips
Designation as per
ÖNORM
M 7133 ÖNORM/DINCEN/ TS 14961
Description as per
ÖNORM M 7133
W20 M20 Air driedWater
content W30 M30 Suitable for storage
G30 P16 Fine wood chipsSize
G50 P45 Medium wood chips
(only for TMC 70 - 100)
Applicable Standards:
Austria: ÖNORM M 7133 or ÖNORM CEN/TS 14961
Germany: Wood chips in accordance with §3 (1) point 4 of the 1st
BImSchV i.d.g.F.
Specifications as per DIN CEN/TS 14961 and/or ÖNORM M
7133
§

Safety
Safety information
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Pellets Wood pellets made from natural wood with a diameter of 6 - 10 mm
Exception:
When using a pellet suction system the maximum diameter is of the
wood pellets is limited to 6 mm.
Applicable Standards:
Austria: ÖNORM M 7135 - HP 1 and/or
DINplus certification program
Germany: DIN 51731 - HP 5, DINplus certification program and/or
ÖNORM M 7135 - HP 1
Generally applicable:
Before refilling the store, check for pellet dust and clean if necessary.
Shavings As shavings generally cause problems with combustion, it is only
permitted to use them after authorisation from Fröling. 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.
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:
The regional regulations for burning Miscanthus should be
observed. Operation may only be possible with individual
authorisation
§

Safety
Permitted uses
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Changing the fuel
CAUTION
Incorrectly set fuel parameters:
Incorrect parameter settings have a significant effect on the
functioning of the boiler, and as a result this will void the guarantee.
If the fuel is changed (e.g. from wood chips to pellets), the system must be
reset by Fröling customer services.
2.2.2 Non-permitted fuels
CAUTION
Use of non-permitted fuels:
Burning non-permitted fuels leads to a build-up of aggressive
sedimentation and condensation, which can lead to damage to the
boiler and also voids the warranty!
All fuels not defined under 2.1.1 are considered non-permitted. Due to
various air-quality protection regulations, non-permitted fuels include:
•Chipboard waste, treated wood-wastes, pure grinding dust,
•Refuse, large quantities of paper, cardboard packaging, ...
•Coal (brown coal, anthracite coal, briquettes...)
2.2.3 Who may operate the boiler?
Only trained operators are permitted to operate the boiler.
CAUTION
If unauthorised persons enter the boiler room:
Risk of injury and damage to equipment!
It is the responsibility of the operator to ensure that unauthorised persons,
especially children, are kept away from the boiler.

Safety
Design information
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2.3 Design information
It is forbidden to carry out modifications to the boiler or to change or
deactivate safety equipment.
Always comply with all fire, building, and electrical regulations when
installing or operating the boiler system, in addition to following the
operating instructions and mandatory regulations that apply in the
country in which the boiler is operated.
2.3.1 Approval and obligation to report
NOTICE
Each heating system must be officially authorised.
The appropriate supervisory authority (inspection agency) must always be
informed when installing or modifying a heating system, and authorisation
obtained from the building authorities.
Austria: Inform the civic/municipal building authorities.
Germany: Register with an approved chimney sweep/the building
authorities.
Other countries: Observe local regulations for authorisation
2.3.2 Requirements for central heating water
The requirements for heating water are based on the following
standards:
Applicable standards:
Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1
If the system is topped up or refilled:
Prepare (soften) the water to prevent boiler scaling.
§

Safety
Design information
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2.3.3 Ventilation of boiler room
The openings for the supply air and the exhaust air should be arranged
as close to opposite each other as possible to achieve a good thermal
draught effect.
The supply air must be drawn in directly from outside. Exhaust air
must be discharged directly outside.
Provided they are not contradicted by the relevant building regulations
room where the boiler is to be installed, the following standards apply:
Applicable Standards:
- TRVB H 118
- ÖNORM H 5170
Provide a supply air cross-section of 2 cm2per kW of boiler rated output,
as per ÖNORM H 5170, but a total cross-section of at least 200 cm2
2.3.4 Installing the heating system / Standards
The following standards govern the installation of heating systems:
Applicable standards:
ÖNORM / DIN EN 12828 Heating Systems in Buildings
Storage tank
NOTICE
A storage tank with the proper dimensions will guarantee the best boiler
operating values during the entire heating period.
Please contact your installer or Fröling directly for the right measurements for
the storage tank.
§
§

Safety
Design information
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Return feed lift
If the hot water return feed is below the minimum return feed
temperature, some of the hot water outfeed will be mixed in.
CAUTION
Risk of dropping below dew point/condensation formation if operated
without return feed lift.
Condensation water forms an aggressive condensate when combined
with combustion residue, leading to damage to the boiler.
Regulations stipulate the use of a return feed lift.
2.3.5 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.
It should be noted here that flue gas temperatures of less than 160 K
above room temperature can occur within the permitted operating range
of the boiler.
The flue gas temperatures (for clean systems) and additional flue gas
values can be found in the technical specification sheets.
Page 15, Boiler data for constructing the flue gas system:
The connection between the boiler and the chimney system should be as
short as possible. The incline of the connection should not exceed 30 -
45°. Insulate the connection.
The entire flue gas system (chimney and connection) must be calculated
as per ÖNORM /DIN EN 13384-1 or prior standards
ÖNORM M 7515/DIN 4705-1.
Local regulations and other statutory regulations also apply.
The chimney must be authorised by a smoke trap sweeper or
chimney sweep.
As per TRVB H 118 (only in Austria) an explosion flap must be
installed in the flue pipe or in the chimney. (installing an explosion
flap is recommended, except in Austria)

Safety
Design information
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Draught limiter
We recommend that a draught limiter is
fitted (A)
Install the draught limiter directly under
the mouth of the flue line, as there is
always low pressure there.
Boiler data for constructing the flue gas system:
Description Units 28 35 48 55 70 85 100
Flue gas temperature RL °C 165 180 170 185 170 170 180
Flue gas mass flow RL kg/h 87 111 150 175 220 265 315
Flue gas mass flow RL kg/s 0.024 0.031 0.042 0.049 0.061 0.074 0.088
Feed pressure required RL
PL
Pa 10
5 10 5 10 5 10 5 10 5 10 5 10 5
Feed pressure required RL
PL
mbar 0.10
0.05 0.10 0.05 0.10 0.05 0.10 0.05 0.10 0.05 0.10 0.05 0.10 0.05
Flue pipe diameter mm 150 150 150 150 200 200 200
RL = Rated load, PL = Partial load;
A

Safety
Safety devices
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2.4 Safety devices
1 Automatic operation button If the boiler overheats:
Press and hold the button for 5 seconds
Automatic operation is switched off and the controller
follows the boiler shutdown procedure
The pumps continue to run!
Never use the main switch.
2 Safety temperature limiter (back
of boiler) Page 17,
Devices for preventing the boiler from overheating
3 Main switch
For shutting down the entire system
The power to all components is switched off.
Only switch off the main switch when the boiler has cooled
down and the controller is switched off (“Boiler off” status).
4 Fuses (in switch cabinet) They fuse the controller and electrical components When
changing the fuses, note the following:
Only have the fuses changed by an electrician, and the
power supply should be switched off.
Observe the rated current on the fuses.
Not
shown Water sprinkler system
In case of burn back, the valve of the water sprinkler system
opens and water goes into the gravity shaft as well as the duct
of the feed screw.
This need only be connected when specified by the
authorities.
4
1
3
2

Safety
Safety devices
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2.4.1 Devices for preventing the boiler from overheating
Thermal discharge safety device
At around 100 °C a valve opens and sends cold water to the safety
heat-exchanger to decrease the temperature.
Safety Temperature Limiter STL
Stops combustion at a max. boiler temperature of 105 °C. The pumps
continue to run.
Once the temperature has fallen to under approx. 95 °C, the safety
temperature limiter (1) can be unlocked mechanically.
Safety valve
Protection against over-heating/ excessive pressure:
When the boiler pressure reaches a maximum of 3 bar, the safety valve
opens and the heating water is released in the form of steam.
2.5 Safety instructions for the installation room
•Danger of fire due to flammable materials.
No flammable materials should be stored near the boiler.
•Damage due to impurities in combustion air.
Do not use any solvents or cleaning agents containing chlorine in the
room where the boiler is installed.
•Keep the air suction opening of the boiler free of dust.
•The room where the boiler is installed must be frost-proof.
1

Safety
Emergency procedure
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2.6 Residual risks
WARNING
Touching hot surfaces!
Hot parts and the flue pipe can cause serious burns!
It should be standard practice to wear protective gloves when
working on the boiler.
Only operate the boiler using the handles provided for this
purpose.
Insulate the flue pipes or simply avoid touching them during
operation.
Before carrying out maintenance work on/in the boiler:
Press and hold the button for 5 seconds
The controller follows the shutdown procedure and starts
with the cleaning cycle.
After the cleaning cycle the boiler goes to the operating
status, “Cleaning possible”
WARNING
Opening the combustion chamber door during operation!
This may cause injury, damage and smoke!
It is forbidden to open the doors behind the insulating door
during operation!
WARNING
Use of non-permitted fuel!
Non-standard fuels can cause serious faults in combustion (e.g.
spontaneous combustion of carbonisation gases / flash fires) which
can lead to serious accidents!
Only use fuels specified in the chapter on “Permitted Uses” in
these operating instructions.

Safety
Residual risks
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2.7 Emergency procedure
2.7.1 Overheating of the system
If the system overheats in spite of the safety devices, proceed as
follows:
Keep all the doors on the boiler closed.
Turn off the boiler by pressing the button for 5 seconds
Under no circumstances use the main switch!
Open all mixer taps, switch on all pumps.
Fröling heating circuit control takes over this function in
automatic operation.
When using a third party controller, carry out the relevant
measures to activate the mixer and pumps manually.
Leave the boiler room and close the door.
Open any available radiator thermostat valves
If the temperature does not drop, inform the installer or Fröling
customer services:
Page 41, 6.2 Address of manufacturer
2.7.2 Smell of flue gas
DANGER
Smell of flue gas!
Flue gases can cause fatal poisoning!
Keep all the doors on the boiler closed.
Turn off the boiler by pressing the button for 5 seconds
Under no circumstances use the main switch!
Air the room where the boiler is installed
Close the door of the installation or boiler room and doors to
living areas.

Operating the system
Initial start-up / loading fuel
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3Operating the system
3.1 Initial start-up
NOTICE
Optimum efficiency and efficient, low-emission operation can
only be guaranteed if the system is set up by trained
professionals and observing the standard factory settings.
Take the following precautions:
Initial start-up should be carried out with an authorised installer or with
Fröling customer services.
The individual steps for initial start-up are explained in the operating
instructions for the controller.
See the operating instructions for the Lambdatronic H 3200
NOTICE
If condensation escapes during the initial heat-up phase, this does
not indicate a fault.
If this occurs, clean up using a cleaning rag.
3.2 Filling/ refilling the store with fuel
When you fill the store you should always ensure that you are using the
right fuel:
Page 9, 2.2.1 Permitted fuels
The following also applies when loading fuel:
Pellets are delivered by tanker and blown into the store. The boiler must
be “OFF” when filling the store. The under-pressure from the blowing
could bring smoke back into the store.
CAUTION
Injuries and damage to property from blowing pellets into the store
when the boiler is switched on!
Turn off the boiler by pressing the button for 5 seconds
Let the boiler cool down in “Boiler Off” status for at least an hour