Froling Turbomatic TMC 70 User 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 70-100
Be sure to read and comply with the operating instructions and safety
instructions.
Subject to technical change.

Introduction
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I
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.
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 70-110 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
Installing fitted screws .................................................................................. 17
3.3.2 Installing the boiler insulation......................................................................... 17
Installing the insulation mounting brackets....................................................... 17
Installing the securing plate and impact plate for the WOS ................................. 18
Installing the insulating side panels................................................................. 18
Installing the front insulating side panels ......................................................... 19
Insulation - installing the chamber.................................................................. 23
3.3.3 Installing the induced draught fan................................................................... 24
3.3.4 Installing the WOS drive................................................................................ 25
3.3.5 Installing the heat exchanger ash removal unit ................................................. 26
3.3.6 Installing the chamber ash removal unit .......................................................... 27
3.3.7 Installing the combustion air blower fan........................................................... 27
3.3.8 Installing the stoker unit................................................................................ 28
3.3.9 Installing the igniter...................................................................................... 28
3.3.10 Installing the combustion chamber overpressure sensor..................................... 29

Contents
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3.3.11 Installing the underpressure controller ............................................................. 30
3.3.12 Completing the combustion chamber door ........................................................ 31
3.3.13 Install the insulating door .............................................................................. 31
3.3.14 Fitting the noise protection hood and ashcans ................................................... 32
3.3.15 Fitting switch cabinet and cable ducts .............................................................. 33
3.3.16 Final tests.................................................................................................... 34
3.4 Electrical connection 35
3.4.1 Laying the cable ........................................................................................... 35
3.4.2 Install the boiler sensor and sensor for the STL ................................................. 35
3.5 Connecting the thermal discharge safety device 36
3.5.1 Installing the thermal discharge safety device sensor......................................... 36
4Initial startup / Decommissioning 37
4.1 Configuring the boiler 37
4.2 Mothballing 37
4.3 Disassembly 37
4.4 Disposal 37
5Appendix 38
5.1 Delivery certificate - TMC 70-110 38

General Information
Notes on standards
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1General Information
CAUTION
Assembly and installation by untrained personnel!
Risk of injury and damage to equipment!
The instructions and information provided in the instructions
should be observed!
Only trained technicians may assemble and install the system
(i.e. heating installers or licensed electricians)!
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 70 85 100
Flue gas temperature RL
PL
°C 170
120
170
120
190
120
Flue gas mass flow RL
PL
kg/s 0.052
0.021
0.063
0.026
0.077
0.031
Required feed pressure RL
PL
mbar 0.10
0.06
0.10
0.06
0.15
0.08
Flue pipe diameter mm 200 200 200
RL = Rated load, PL = Partial load;
1

Technology
Dimensions
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2Technology
2.1 Turbomatic TMC 70-110 dimensions
Pos. Description Unit TMC 70 / 85 / 100
H Height of boiler 1740
H1 Overall height 1980
H2 Height, flue pipe connection 1720
H3 Height, outfeed connection 1595
H4 Height, return connection 450
H5 Height, drain 125
H8 Height, induced draught fan connection 1540
H15 Height, gravity shaft connection 730
H18 Height, safety battery connection
mm
1200
B Width of boiler 820
B1 Overall width 2040
B12 Width, ash container 325
B14 Width, stoker unit 895
B15 Width, gravity shaft 550
B23 Width, switch cabinet
mm
600
L Length, boiler 1580
L8 Length, induced draught fan 470
L15 Length to gravity shaft connection left / right
mm
965 / 1015

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
Pos. Description Unit TMC 70 / 85 / 100
A Flue gas pipe diameter mm 200
B Boiler outfeed connection 2
C Connecting the thermal discharge safety device 1/2
D Boiler return feed connection 2
E Connection for filling / emptying cock
Inch
1/2
1 Combustion air blower fan
2 2 Ash container
3 Automatic ignition
4 2 drives for the front and rear automatic ash removal
5 Stoker drive
6 Switch cabinet with integrated Lambdatronic H 3200 controller
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 70 85 100
Rated heat output 70 85 100
Heating efficiency range kW 21 - 70 25.5 - 85 30 - 100
Mains connection 400V / 50Hz fused 20A
Boiler class 3 3 3
Boiler weight kg 1250 1250 1250
Boiler water volume L 300 300 300
Permitted outfeed temperature 95 95 95
Minimum return feed temperature °C 55 55 55
Permitted operating pressure bar 3 3 3
Upstream resistance (ΔT=20°C) mbar 15 15 15.6
Permitted fuel 1) Wood chip/ ÖNORM M 7133 or
wood pellets 6mm / ÖNORM M 7135
Fuel heating efficiency at
rated heat output kW 77.1 93.3 108
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 70 85 100
Testing institute BLT Wieselburg
Test report no.
Date of issue
1) 1) 1)
Carbon monoxide (CO) Rated load
Partial load mg/MJ
53.09
126.82
54.18
97.64
55.27
68.45
Nitrogen oxide (NOx) Rated load
Partial load
mg/MJ
102.00
not measured
93.00
not measured
84.00
not measured
Organic hydrocarbons Rated load
Partial load
mg/MJ
<1
4.64
<1
3.27
<1
1.91
Dust Rated load
Partial load
mg/MJ
26.00
not measured
23.00
not measured
20.00
not measured
Boiler efficiency rating Rated load
Partial load
%
90.80
91.34
91.10
92.07
91.40
92.81
1) Values for boiler sizes 70 kW, 85 kW and 100 kW are interpolated (calculated as per EN 303-5)

Technology
Technical specifications
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Test data for operation with pellets
Description Unit 70 85 100
Testing institute BLT Wieselburg
Test report no.
Date of issue
1) 1) 1)
Carbon monoxide (CO) Rated load
Partial load mg/MJ
25.09
68.09
17.18
45.18
9.27
22.27
Nitrogen oxide (NOx) Rated load
Partial load
mg/MJ
74.09
not measured
66.18
not measured
58.27
not measured
Organic hydrocarbons Rated load
Partial load
mg/MJ
<1
<1
<1
<1
<1
<1
Dust Rated load
Partial load
mg/MJ
10.27
not measured
7.55
not measured
4.82
not measured
Boiler efficiency rating Rated load
Partial load
%
91.31
91.83
92.02
91.85
92.73
91.88
1) Values for boiler sizes 70 kW, 85 kW and 100 kW are interpolated (calculated as per EN 303-5)

Installation
Assembly work
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3Installation
3.1 Transport
The boiler comes in cardboard packaging on 4 pallets together with the
chamber delivery 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
Assembly work
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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 70-100
A Minimum distance from back of boiler to wall 700
B Minimum distance from front of boiler to wall
(space required for opening insulating door) 950
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
If the boiler has been placed in the right position, 4 rubber supports
must be inserted beneath the bottom of the boiler:
ULift boiler
UPlace 4 rubber supports on the 4 corners of the bottom of the boiler
The chamber is delivered assembled and
tested:
UUnpack the chamber and remove
from the pallet
UM5 threaded holes on the chamber
opposite the operating side should
be closed with M5 hexagonal screws
or heat resistant adhesive tape
URemove the chamber from the pallet
and position in the boiler
The connection flange for the
stoker duct should be on the left
or right depending on the side
where it is required
Follow the installation plan.
UPosition the chamber so that the
holes are aligned with the securing
flaps
UScrew the chamber to the boiler
body by tightening the individual
screws equally
- 4 hexagonal screws M10x45
- 4 hexagonal nuts M10
- 4 spacer washers M10
The seal cord of the chamber must
also fit closely with the boiler.

Installation
Assembly work
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Installing fitted screws
UScrew 12 fitted screws to the threaded holes in the chamber
provided
3.3.2 Installing the boiler insulation
Installing the insulation mounting brackets
UFit 2 insulation mounting brackets on the left and right of the
bottom of the boiler
- 4 hexagonal screws M6x12

Installation
Assembly work
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Installing the securing plate and impact plate for the WOS
UInstall the securing plate and the impact plate on threaded bolts on
the left side of the boiler as shown
- 2 spacer washers M8
- 2 locknuts M8
UInstall the buffer stop on the impact plate
Installing the insulating side panels
NOTICE
The separate parts of the boiler insulation are fitted with a protective film.
This must always be removed before installation.
For both rear insulating side-panels:
UBend in the pre-punched blanking for
the flange of the heat exchanger ash
remover in the right corner
UInsert the side panel at the bottom insulation mounting brackets at
the rear left and push it onto the boiler
USecure the side panel to the WOS impact plate to prevent tipping
(e.g. with a screwdriver)

Installation
Assembly work
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UFit the connection profile on the left side panel with a self-tapping
screw
UPut on the back heat insulation mat
UPut the side panel on at the back on the right by the insulation
mounting brackets at the bottom
UPush the side panel onto the boiler
and screw to the connecting profile
with a self-tapping screw
Installing the front insulating side panels
UInsert the left insulation cover plate to the left side panel at the
front as shown and fix with self-tapping screws
UPosition the top insulation mounting
bracket at the holes on the top side
USecure the bracket using 2 thread
forming screws M6x12

Installation
Assembly work
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UPut the slit on the bottom side of the
front side panel onto the insulating door
mounting bracket above the chamber
UInsert the fitted screws of the side panel
into the spring shackles of the back side
panel and press on
URepeat the steps for the right side panel
UPut a spacer washer Ø 44 mm onto the
threaded bolts on the boiler
UPush the front side panel onto the boiler
and put the insulation mounting bracket
onto the threaded bolts
UPut on another spacer washer Ø 44 mm
and screw on the insulation mounting
bracket lightly
- Spacer washer M8
- Hexagonal nut M8
Ensure that the insulating side panel is
not distorted when you fix the bracket.
UConnect the front and rear insulating
side panels with connection platelets
and 2 self-tapping screws