Froling Turbomatic TMC 28-55 Service manual

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen
Tel [phone] Fax [phone] [email protected] www.froeling.com
Installation Instructions
Turbomatic TMC 28-55
Be sure to read and comply with the operating instructions and safety
instructions.
Subject to technical change.

Introduction
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Dear customer,
The FRÖLING Turbomatic wood chip boiler features a state-of-the-art
design that conforms to all currently applicable standards and testing
guidelines.
Please read and follow the installation instructions. They contain safety
instructions and comprehensive information relating to transporting,
setting up and assembling the boiler.
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.
Delivery Certificate
Keeping a record that the delivery was received correctly and collecting
customer-specific data relating to the system allows us to respond
quickly should problems arise.
We would therefore ask you to confirm that you have received the
product in good condition.
Please send Fröling a copy of the delivery certificate, filled in and signed
by the customer.

Introduction
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Guarantee Conditions
Our sale and delivery conditions generally apply. 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 in the enclosed guarantee
certificate.
Address of manufacturer
FRÖLING
Heizkessel- und Behälterbau GesmbH
Industriestraße 12
A-4710 Grieskirchen
AUSTRIA
TEL [phone]
FAX [phone]
E-MAIL [e-mail]
WEBSITE www.froeling.com

Contents
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1General Information 6
1.1 Notes on Standards 6
1.2 Design Information 7
1.2.1 Approval and obligation to report...................................................................... 7
1.2.2 Requirements for central heating water ............................................................. 7
1.2.3 Ventilation of boiler room ................................................................................ 7
1.2.4 Installing the heating system / Standards .......................................................... 8
Combination with storage tank .........................................................................8
Return feed lift...............................................................................................8
1.2.5 Chimney connection/chimney system ................................................................ 9
Draught limiter...............................................................................................9
Boiler data for constructing the flue gas system:.................................................9
2Technology 10
2.1 Turbomatic TMC 28-55 dimensions 10
2.2 Components and Connections 11
2.3 Technical specifications 12
Test data for operation with wood chips........................................................... 12
Test data for operation with pellets ................................................................. 13
3Installation 14
3.1 Transport 14
3.1.1 Positioning................................................................................................... 14
3.1.2 Temporary storage ....................................................................................... 14
3.2 Setting up in the boiler room 14
3.2.1 Removing the boiler from the pallet ................................................................ 14
3.2.2 Moving the boiler in the boiler room ................................................................ 14
3.2.3 Minimum distances in the boiler room.............................................................. 15
3.2.4 General information for boiler room................................................................. 15
3.3 Assembly work 16
3.3.1 Installing the chamber in the boiler ................................................................. 16
3.3.2 Installing the stoker...................................................................................... 19
Installing the burn back flap drive (only with burn back flap) .............................. 20
3.3.3 Installing the induced draught fan................................................................... 21
3.3.4 Installing the WOS Drive ............................................................................... 22
3.3.5 Fitting the automatic heat exchanger ash removal (optional) .............................. 23
Conversion for ashcan on right ....................................................................... 23
Assembly work on boiler................................................................................ 24
3.3.6 Installing the combustion chamber overpressure sensor..................................... 26
3.3.7 Fitting switch cabinet and cable ducts.............................................................. 26
3.4 Electrical connection 28
3.4.1 Laying the cable ........................................................................................... 28
3.5 Connecting the thermal discharge safety device 29
3.5.1 Thermal discharge safety device sensor ........................................................... 29

Contents
Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Page 5
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4Initial startup / Decommissioning 30
4.1 Configuring the boiler 30
4.2 Mothballing 30
4.3 Disassembly 30
4.4 Disposal 30
5Appendix 31
5.1 Delivery certificate -TMC 28-55 31

General Information
Notes on standards
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1General Information
WARNING
Assembly and installation by untrained personnel!
Risk of injury and damage to equipment!
Only allow trained technicians (heating installers or licensed electricians) to
perform set-up and installation!
1.1 Notes on Standards
ÖNORM/DIN EN 303-5 Heating boilers for solid fuels, hand and automatically stocked, nominal heat
output of up to 300 kW - Terminology, requirements, testing and marking
ÖNORM M 7510 Guidelines for checking central heating systems
ÖNORM / DIN EN 12828 Heating systems in buildings - design of water-based heating systems
ÖNORM B 8130 Safety devices, open water-heating systems
ÖNORM B 8131 Closed water-heating systems, safety requirements
DIN 4751 Parts 1-4 Heating system safety equipment
ÖNORM / DIN EN 13384-1 Chimneys serving one appliance
ÖNORM M 7515 /
DIN 4705-1
Calculating chimney dimensions for combustion systems
TRVB H118 Technical directives for fire protection/prevention
ÖNORM H5170 Construction and fire protection requirements
ÖNORM H5190 Heating equipment - noise protection measures
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 only).
VDI 2035 Prevention of damage in water heating installations - Scale formation in
domestic hot water supply installations and water heating installations
(Germany only)
SWKI 97-1 Limescale and corrosion protection in heating systems (Switzerland only)

General information
Design information
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1.2 Design Information
It is forbidden to carry out modifications to the boiler or to change or
deactivate safety equipment.
In addition to the documentation provided and the regulations for
installation and operation of the boiler system applicable in the country
in which the boiler will be operated, all fire, police, and electrical
regulations must be observed.
1.2.1 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.
1.2.2 Requirements for central heating water
The requirements pertaining to the water used to fill the boiler are
based on the following standards and guidelines:
Applicable standards and guidelines:
Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1
There are no other special requirements for central heating water.
Note on filling with make-up water: bleed the filling hose before
connecting to prevent air from getting into the system.
1.2.3 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 should be fed in directly from outside.
Unless otherwise stipulated by the building regulations applicable to the
room where the boiler is to be installed, the following standards shall
apply:
Applicable Standards:
- TRVB H 118
- ÖNORM H 5170
§
§

General information
Notes on standards
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1.2.4 Installing the heating system / Standards
The following standards govern the installation of heating systems:
Applicable Standards:
ÖNORM / DIN EN 12828 Heating Systems in Buildings
The following prior standards still apply:
Austria: - Closed systems as per ÖNORM B 8131
- Open systems as per ÖNORM B 8130
Germany: - Closed systems as per DIN 4751 Part 2
- Open systems as per DIN 4751 Part 1
Combination with storage tank
NOTICE
It is not generally necessary to use a storage tank for the system to run
smoothly. However we recommend that you use it with a storage tank, as this
allows you to achieve continuous reduction within the ideal performance 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 Fröling.
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.
The minimum return feed temperature is 55 °C. We recommend fitting
some kind of control device (e.g. thermometer).
§

General information
Design information
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1.2.5 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.
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 technical specification sheets.
ÀBoiler 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.
Draught limiter
We recommend that a draught limiter is
fitted (1)
Install the draught limiter directly under
the mouth of the flue line, as the
pressure is lower at this location.
Boiler data for constructing the flue gas system
Description Units 28 35 48 55
Flue gas temperature RL
PL
°C 165
120
180
120
170
120
185
120
Flue gas mass flow RL
PL
kg/s 0.025
0.009
0.031
0.011
0.040
0.015
0.050
0.017
Required feed pressure RL
PL
mbar 0.12
0.06
0.15
0.08
0.18
0.12
0.20
0.14
Flue pipe diameter mm 150 150 150 150
RL = Rated load, PL = Partial load;
1

Technology
Dimensions
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2Technology
2.1 Turbomatic TMC 28-55 dimensions
Pos. Description Unit TMC 28 / 35 TMC 48 / 55
H Height of boiler 1425 1520
H1 Overall height 1825 1835
H2 Height, flue pipe connection 1525 1630
H3 Height, outfeed connection 1275 1375
H4 Height, return connection 140 140
H5 Height, drain 120 120
H8 Height, induced draught fan connection 1210 1310
H15 Height, gravity shaft connection with BBF1/ RV2630 / 595 610 / 595
H18 Height, safety battery connection
mm
885 980
B Width of boiler 570 670
B1 Overall width with BBF1/ RV21730 / 1815 1810 / 1905
B12 Width, ash container 325 325
B14 Width, stoker unit BBF1/ RV2835 / 920 830 / 910
B15 Width, gravity shaft connection BBF1/ RV2615 / 610 605 / 600
B23 Width, switch cabinet small / large
mm
400 / 600 400 / 600
L Length, boiler 1225 1315
L8 Length, induced draught fan 180 180
L15 Length to gravity shaft connection
mm
710 805
1) BBF = burn back flap; 2) RV = rotary valve

Technology
Components and connections
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2.2 Components and Connections
7
8
A
B
1
2
C
3
6
4D
5
E
Turbomatic
Pos. Description Unit 28 / 35 48 / 55
A Flue gas pipe diameter mm 150 150
B Boiler outfeed connection 6/4 6/4
C Connecting the Thermal Discharge Safety Device 1/2 1/2
D Boiler return feed connection 6/4 6/4
E Connection for filling / emptying cock
Inch
1/2 1/2
1 Combustion air blower fan
2 Ash container
3 Automatic ignition
4 Automatic ash removal drive
(optional: automatic heat exchanger ash removal)
5 Stoker drive
6 Switch cabinet with integrated “Lambdatronic H3000” control
7 Induced draught fan
8 Servo-motors for primary and secondary air
9 Tipping grate drive
9

Technology
Technical Specifications
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2.3 Technical specifications
Description Unit 28 35 48 55
Rated heat output 28 35 48 55
Heating efficiency range kW 8.4 - 28 10.5 - 35 14.4 - 48 16.5 - 55
Mains connection 400V / 50Hz fused 20A
Boiler class 3 3 3 3
Boiler weight kg 420 425 500 505
Boiler water volume L 114 114 185 185
Permitted outfeed temperature 95 95 95 95
Minimum return feed temperature °C 55 55 55 55
Permitted operating pressure bar 3 3 3 3
Upstream resistance (ΔT=20°C) mbar 6.5 7.5 17 19
Permitted fuel 1) Wood chip / ÖNORM M 7133 or
wood pellets 6mm / ÖNORM M 7135
Heat output from fuel at rated heat
output kW 30.4 38.2 52.8 60.7
1) Detailed information on the fuel is included in the operating instructions, in the section on “Permitted fuels”
Test data for operation with wood chips
Description Unit 28 35 48 55
Testing institute BLT Wieselburg
Test report no. 014/00 009/00
Date of issue 22.05.2000
1) 1) 25.04.2000
Carbon monoxide (CO) Rated load
Partial load mg/MJ
66.00
195.00
62.37
184.89
55.63
166.11
52.00
156.00
Nitrogen oxide (NOx) Rated load
Partial load
mg/MJ 91.00
not measured
96.19
not measured
105.81
not measured
111.00
not measured
Organic hydrocarbons Rated load
Partial load
mg/MJ <1
5.00
<1
5.26
<1
5.74
<1
6.00
Dust Rated load
Partial load
mg/MJ 17.00
not measured
20.11
not measured
25.89
not measured
29.00
not measured
Boiler efficiency rating Rated load
Partial load
% 91.30
90.80
91.09
90.75
90.71
90.65
90.50
90.60
1) Values for boiler sizes 35 kW and 48 kW are interpolated (calculated as per EN 303-5)

Technology
Technical Specifications
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Test data for operation with pellets
Description Unit 28 35 48 55
Testing institute BLT Wieselburg
Test report no. 014/00 009/00
Date of issue 22.05.2000
1) 1) 25.04.2000
Carbon monoxide (CO) Rated load
Partial load mg/MJ
31.00
56.00
31.52
65.07
32.48
81.93
33.00
91.00
Nitrogen oxide (NOx) Rated load
Partial load
mg/MJ 59.00
not measured
64.96
not measured
76.04
not measured
82.00
not measured
Organic hydrocarbons Rated load
Partial load
mg/MJ <1
1.00
<1
1.00
<1
1.00
<1
<1
Dust Rated load
Partial load
mg/MJ 6.00
not measured
7.81
not measured
11.19
not measured
13.00
not measured
Boiler efficiency rating Rated load
Partial load
% 92.00
91.90
91.64
91.87
90.96
91.83
90.60
91.80
1) Values for boiler sizes 35 kW and 48 kW are interpolated (calculated as per EN 303-5)

Installation
Transport and setup
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3Installation
3.1 Transport
The boiler comes in cardboard packaging on 3 pallets together with the
chamber discharge unit.
Move the boiler without jarring or jolting
Follow the transport instructions on the packaging when moving the
boiler.
3.1.1 Positioning
UPlace a fork-lift or similar lifting device with a minimum fork length of
1100 mm and an appropriate load-bearing capacity at the pallet and
position the boiler
If it is not possible to position the boiler on the pallet:
URemove cardboard packaging
URemove boiler from pallet
ÀSee 3.2.1 Removing the boiler from the pallet
3.1.2 Temporary storage
If the system is to be installed at a later date:
UStore the boiler, insulation and control unit in a safe, dust-free, and
dry location
Moisture reduces the effectiveness of the insulation and destroys
electronic components.
3.2 Setting up in the boiler room
3.2.1 Removing the boiler from the pallet
URemove 4 screws from the boiler
bottom
ULift the boiler off the pallet
3.2.2 Moving the boiler in the boiler room
UPosition a fork-lift or similar lifting device with an appropriate load-
bearing capacity at the base frame of the boiler and lift
USet up boiler at intended location
Observe the minimum distances in the boiler room (see 3.2.3).

Installation
Transport and setup
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3.2.3 Minimum distances in the boiler room
The boiler should always be set up so that it is fully accessible to
allow fast and easy maintenance.
Observe the applicable standards and regulations when setting up
the boiler.
Also observe the standards pertaining to noise protection
(ÖNORM H 5190 - Noise protection measures)
Dimension Description Units 28 - 55
A Minimum distance from back of boiler to
wall 500
B Minimum distance from front of boiler to
wall (space required for opening insulating
door)
800
C Minimum distance between stoker and
wall 300
D Minimum distance from edge of boiler to
wall (space required to empty ashcan)
mm
700
3.2.4 General information for boiler 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.

Installation
Assembly work
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3.3 Assembly work
3.3.1 Installing the chamber in the boiler
The chamber can be installed with the
stoker connection on the right or the
left.
UTurn the chamber according to the
discharge side and position on the
base of the boiler
Ensure that the seal is centred and
in the correct position.
UScrew the chamber to the boiler
Ensure an even contact pressure.
UScrew reducing socket onto igniter
tube
UAttach insulation on stoker side
UScrew in ignition sleeve on reducing
socket
Only carry out the following assembly
step on the G50 stoker shown. If you are
using a G30 stoker you must first fit the
stoker
UFit the stoker duct cover plates

Installation
Assembly work
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UInsert the ignition fan with safety guard in ignition sleeve and hand
tighten the retaining screw
Take care not to damage the igniter.
UFit the flush-back hose to the ignition fan using a hose clamp
ULay the hose to connect to the chamber and secure using hose clamp
UAttach insulation on grate shaft side
as illustrated
Ensure that the fitted screws
engage securely in the spring
shackles.
UAttach the front chamber insulation
Ensure that the fitted screws
engage securely in the spring
shackles.

Installation
Assembly work
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UAttach the cover on the grate shaft
side
Bundle the motor cables and
thread them through the opening
in the cover
TIP: Tie the cables of the
individual units to a cable harness
using cable ties
UFit combustion air blower fan with
seal to flange

Installation
Assembly work
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3.3.2 Installing the stoker
A
Assembled stoker unit with rotary
valve
B
Assembled stoker unit with burn back
flap
C
3 pieces Seals for gravity shaft
D
Stoker duct seal
E
Gravity shaft nozzle 15°
F
Screw set
The following steps will guide you
through the assembly process when
installing a G30 stoker.
If you are using a G50 stoker, the
connection flange comes out of the
insulation (see image on left).
The assembly steps apply by analogy in
the same order.
Assembly G50 stoker
UAttach seal for stoker duct and fit
stoker unit
UScrew in carrying bolt on stoker
flange and tighten
Assembly G30 stoker
A
B
E
C D F

Installation
Assembly work
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UFit left and right cover plates to
insulation on stoker duct
Installing the burn back flap drive (only with burn back flap)
Back-fire flap drive must be pre-
tensioned by 5°.
(delivery configuration)
ÀSee included manufacturer’s
documentation for how to pre-
tension the drive
UInsert clamping piece as illustrated
(90° position) and secure at back
with fixing clamp
UAttach drive to shaft of burn back
flap
UTighten clamping piece so that the
clamp and triangular shafts fit
positively
UTurn the whole unit 90° anti-
clockwise
´The burn back flap is closed