Froling TX 250 User manual

Installation Instructions
Wood chip boiler TX 150-250
Translation of the original German operating instructions for technicians!
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1320112_en | Edition 08/04/2013
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

Contents
1 General 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 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
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 Return lift 9
2.4.6 Use with storage tank 10
2.4.7 Chimney connection/chimney system 10
Draught limiter 10
Boiler data for planning the flue gas system 11
3 Technology 12
3.1 Dimensions 12
3.2 Technical specifications 13
4 Assembly 15
4.1 Transport 15
4.2 Positioning 15
4.3 Temporary storage 15
4.4 Set-up in the boiler room 15
4.4.1 Moving the boiler in the boiler room 15
4.4.2 Minimum distances in the boiler room 16
4.5 Mounting steps 17
4.5.1 General information 17
4.5.2 Screwing the fire box with the heat exchanger 18
4.5.3 Installing sensor of thermal discharge system 19
4.5.4 Assembly of fireclay blocks 20
4.5.5 Preparation of flue gas recirculation connection (Option) 21
4.5.6 Retrofitting the WOS bar (if necessary) 22
4.5.7 Installing lower main frame of insulation 23
4.5.8 Installing upper main frame of insulation 24
4.5.9 Installing the frame for the insulating door 25
4.5.10 Installing the insulating side panels 26
4.5.11 Complete the heat exchanger cover and the combustion chamber door 29
4.5.12 Check grate settings and install the tipping grate motor 31
4.5.13 Installing the fire box ash removal unit 33
4.5.14 Installing the switch cabinet and cable ducts 37
4.5.15 Installing the stoker unit 39
4.5.16 Installing the automatic igniter 40
Contents
2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

4.5.17 Installing the actuators of the air flaps 41
4.5.18 Installing overpressure monitor and temperature sensor 42
4.5.19 Installing the underpressure measurement 43
4.5.20 Installing the WOS drive 44
4.5.21 Heat exchanger ash removal unit with ash box 46
4.5.22 Heat exchanger ash removal unit with ash screw (optional) 47
4.5.23 Installing the combustion air blower fan 54
4.5.24 Installing the STL and the boiler sensor 55
4.5.25 Installing the ID fan 56
4.5.26 Installing the FGR air box (optional) 57
4.5.27 Installing the flue gas recirculation FGR (optional) 58
4.5.28 Installing insulating door and cover plates 60
4.6 Electrical connection 61
4.6.1 Installing insulating covers and cover plates 61
4.7 Connecting the thermal discharge system 64
5 Start-up 65
5.1 Before commissioning / configuring the boiler 65
5.2 Initial startup 66
5.2.1 Permitted fuels 66
Wood pellets 66
Wood chips 66
5.2.2 Heating up for the first time 66
6 Decommissioning 67
6.1 Mothballing 67
6.2 Disassembly 67
6.3 Disposal 67
7 Appendix 68
7.1 Addresses 68
7.1.1 Address of manufacturer 68
7.1.2 Address of the installer 68
Contents
Installation Instructions TX 150-250 | M1320112_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 guide‐
lines.
Please read and observe the documentation provided and always keep it close to the
system for reference. It contains important safety information and all the operation and
maintenance specifications needed to operate the system safely, properly, environ‐
mentally friendly and cost-effectively.
The constant further development of our products means that there may be minor dif‐
ferences 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 cer‐
tificate
1General
4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

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 TX 150-250 | M1320112_en 5

2.2 Qualification of assembly staff
CAUTION
Assembly and installation by untrained personnel:
Risk of personal injury and damage to property.
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow trained staff to carry out assembly and installation
Assembly, installation, initial startup and servicing must always be carried out by quali‐
fied personnel:
- Heating technician / building technician
- Electrical installation technician
- Froling customer services
The assembly staff must have read and understood the instructions in the documenta‐
tion.
2.3 Protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by accident pre‐
vention regulations.
▪ For transportation, setup and assembly:
- suitable workwear
- protective gloves
- sturdy shoes
2Safety
Qualification of assembly staff
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

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. The following standards and regulations should always be ob‐
served:
General standards for heating systems
EN 303-5 Boilers for solid fuels, manually and automatically fed combus‐
tion systems, nominal output up to 300 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 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 pro‐
tection
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 Sheet 1 Prevention of damage in water heating systems - Scale forma‐
tion in domestic water heating systems and hot water heating
systems (Germany)
SWKI 97-1 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
D.P.R. no. 412 Regulations for the planning, installation, running/operation and
maintenance of heating systems in buildings to reduce energy
consumption with reference to Article 4, Comma 4 of the Legis‐
lative Decree of 9 January 1991, No. 10 (Italy)
Safety 2
Design Information
Installation Instructions TX 150-250 | M1320112_en 7

Standards for permitted fuels
EN 14961-2 Solid biofuel, fuel specifications and classes.
Part 2: Wood pellets for non-industrial use
EN 14961-4 Solid biofuel, fuel specifications and classes.
Part 2: Wood chips for non-industrial use
1. BImSchV First Ordinance of the German Federal Government for imple‐
mentation of the Federal Emission Protection Law, BGBl. I P.
491, in the applicable version.
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:
ÖNORM / DIN 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: Inform the civic/municipal building authorities.
Germany: Notify an approved chimney sweep and the building authorities.
2.4.3 General information for installation room (boiler room)
Boiler room characteristics
▪ 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 provide sufficient light‐
ing in the boiler room in accordance with national workplace design regulations.
▪ When using the boiler over 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
No flammable materials should be stored near the boiler. Flammable objects (e.g.
clothing) must not be put on the boiler to dry.
▪ 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 from dust.
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 (foli‐
age, snowdrifts, etc.) from obstructing the air flow.
Note on standards
2Safety
Design Information
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

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
The following standards and guidelines apply:
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195-1
VDI 2035
SWKI 97-1
D.P.R. no. 412
NOTICE! Note on filling with make-up water: Always bleed the filling hose before con‐
necting, in order to prevent air from entering the system.
2.4.5 Return lift
If the hot water return is below the minimum return temperature, some of the hot water
outfeed will be mixed in.
CAUTION
Risk of dropping below dew point/condensation formation if operated without re‐
turn temperature control.
Condensation water forms an aggressive condensate when combined with com‐
bustion residue, leading to damage to the boiler.
Take the following precautions:
❒ Regulations stipulate the use of a return temperature control.
➥The minimum return temperature is 65 °C. We recommend fitting some
sort of control device (e.g. thermometer).
Note on standards
Note on standards
Safety 2
Design Information
Installation Instructions TX 150-250 | M1320112_en 9

2.4.6 Use with storage tank
NOTICE
In principle it is not necessary to use a storage tank for the system to run smooth‐
ly. However we recommend that you use the system with a storage tank, as this
ensures a continuous supply of fuel in the ideal output 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 Froling.
⇨ See "Addresses" [page 68]
2.4.7 Chimney connection/chimney system
EN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐
ever possible, damage caused by seepage, insufficient feed pressure and condensa‐
tion. 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 table below.
The connection between the boiler and the chimney system should be as short as
possible. The upward angle of the connection should not exceed 30 - 45°. Insulate the
connection. The entire flue gas system - chimney and connection - should be calcula‐
ted in accordance with EN 13384-1.
Local regulations and other statutory regulations also apply.
NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney
sweep.
NOTICE! TRVB H 118 (Austria only) stipulates that an explosion flap must be installed
in the connecting piece (flue pipe) directly next to the boiler. It should be situated in
such a way that is poses no risk to persons!
Draught limiter
The installation of a draught limiter is recommended.
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the
pressure is constantly low at this point.
2Safety
Design Information
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

Boiler data for planning the flue gas system
Description TX
150 200 250
Flue gas temperature at nominal load °C 150 150 150
Flue gas temperature at partial load 110 110 110
Flue gas mass flow - wood chips W30, 13% O2kg/h 665 882 1108
Flue gas mass flow - wood chips W30, 9% O2420 557 700
Flue gas mass flow - pellets 13% O2559 741 931
Flue gas mass flow - pellets 9% O2355 471 591
Required feed pressure at nominal load mbar 0,05 0,05 0,05
Required feed pressure at partial load 0,02 0,02 0,02
Maximum permissible feed pressure gem. ÖNORM / DIN EN 303-5
Flue pipe diameter mm 200 250 250
Safety 2
Design Information
Installation Instructions TX 150-250 | M1320112_en 11

3 Technology
3.1 Dimensions
Item Description Unit TX 150 TX 200 TX 250
H1 Height, boiler mm 1880 1880 1880
H2 Height, flow and return connection 1935 1935 1935
H4 Height, flue pipe connection without FGR 770 960 960
H5 Height, flue pipe connection without FGR 1410 1445 1445
H6 Height, stoker unit with rotary valve 790 865 865
B1 Overall width mm 1970 2070 2070
LLength, boiler mm 2620 2980 2980
L1 Length, retort 1090 1400 1400
L2 Length, stoker unit 940 970 970
L3 Length, ash box 590 610 610
Item Description TX 150 TX 200 TX 250
ABoiler outfeed connection Inch 2½ 2½ 2½
BBoiler return connection Inch 2½ 2½ 2½
CConnection of thermal discharge safety device (near boiler
flow connection)
Inch ½ ½ ½
DBoiler drainage connection Inch ¾ ¾ ¾
EFlue pipe connection mm 200 250 250
3Technology
Dimensions
12 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

3.2 Technical specifications
Description TX
150 200 250
Rated heat output kW 150 199 250
Output range kW 45 – 150 59 - 199 75 – 250
Electrical connection 400V / 50Hz /
C20A
400V / 50Hz / C35A
Total weight of boiler kg 2730 3390 3390
Weight – retort 855 1120 1120
Weight - heat exchanger 1000 1280 1280
Boiler capacity (water) l 440 570 570
Water pressure drop
(ΔT = 10 / 20 K)
mbar 36 / 12 55 / 18 74 / 25
Min. boiler return temperature °C 65
Max. permitted operating temperature °C 90
Permitted operating pressure bar 3
Boiler class as per EN 303-5:1999
(pr EN 303-5:2012)
3 (5)
Permitted fuel as per EN 14961 1) Part 2: Wood pellets class A1 / D06
Part 4: Wood chips class A2 / P16A-P45A
Airborne sound level dB(A) < 70
150 200 250
Testing institute TÜV 2) TÜV 3) 4) TÜV 2)
Test report no. 10-UW/Wels-
EX-119
13-U-032/SD 11-UW/Wels-
EX-249
1.Detailed information on the fuel is included in the operating instructions, in the section on "Permitted fuels"
2.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels
3.As per EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤2 : 1,
to carry out the tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not been tested in the range, whose
values have been determined depending on the rated heat output by interpolation, fulfil the requirements of the norm
4.Values for the types TX 200 are interpolated between the types TX 150 and TX 250, test protocol 10-UW/Wels-EX-119 and 11-UW/Wels-EX-249!
Test data wood chips - Emissions in [mg/MJ] (RL / PL)
Carbon monoxide (CO) mg/MJ <4 / 35 5 / 33 7 / 30
Nitrous oxide (NOx) mg/MJ 78 / 63 74 / 61 69 / 58
Organic hydrocarbons (OGC) mg/MJ <1 / <1 <1 / <2 <1 / <2
Dust mg/MJ 23 / 15 20 / 17 17 / 19
Boiler efficiency % 92,1 / 92,3 92,9 / 92,5 93,7 / 92,8
Test data wood chips - Emissions in [mg/m³]1) (RL / PL)
Carbon monoxide (CO) mg/m³ <6 / 52 8 / 48 11 / 44
Nitrous oxide (NOx) mg/m³ 115 / 93 108 / 89 101 / 85
Organic hydrocarbons (OGC) mg/m³ <1 / <2 <1 / <2 <1 / <2
Dust mg/m³ 34 / 22 29 / 25 25 / 28
Boiler efficiency % 92,1 / 92,3 92,9 / 92,5 93,7 / 92,8
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%
Technology 3
Technical specifications
Installation Instructions TX 150-250 | M1320112_en 13

Test data pellets - Emissions in [mg/MJ] (RL / PL)
Carbon monoxide (CO) mg/MJ 5 / 16 5 / 11 4 / 6
Nitrogen oxide (NOx) mg/MJ 64 / 57 67 / 57 70 / 58
Organic hydrocarbons (OGC) mg/MJ <1 / <1 <2 / <2 <2 / <2
Dust mg/MJ 24 / 14 18 / 12 11 / 9
Boiler efficiency % 90,8 / 93,4 92,1 / 92,7 93,5 / 92,0
Test data pellets - Emissions in [mg/m³]1) (RL / PL)
Carbon monoxide (CO) mg/m³ 8 / 23 7 / 16 6 / 8
Nitrogen oxide (NOx) mg/m³ 94 / 84 98 / 85 103 / 86
Organic hydrocarbons (OGC) mg/m³ <1 / <1 <2 / <2 <2 / <2
Dust mg/m³ 35 / 21 25 / 17 15 / 13
Boiler efficiency % 90,8 / 93,4 92,1 / 92,7 93,5 / 92,0
1.Emissions values are based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%
3Technology
Technical specifications
14 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

4 Assembly
4.1 Transport
NOTICE
Damage to components if handled incorrectly
❒ Follow the transport instructions on the packaging
❒ Transport components with care to avoid damage
❒ Protect the packaging against damp
❒ Operate unloading, positioning and mounting only by trained professionals!
Staff has to be familiar with the handling and moving of heavy loads! (tools
and lifting tools , lashing points, etc.)
4.2 Positioning
❒ Attach a cable winch or similar lifting device to the eyelets on the boiler
4.3 Temporary storage
If the system is to be assembled at a later stage:
❒Store components at a protected location, which is dry and free from dust
➥Damp and frost can damage components, particularly electric ones!
4.4 Set-up in the boiler room
4.4.1 Moving the boiler in the boiler room
❒ Position a fork-lift or similar lifting device with a suitable load-bearing capacity at
the base frame
❒Lift and transport to the intended position in the installation room
➥Observe the minimum distances in the boiler room.
Assembly 4
Transport
Installation Instructions TX 150-250 | M1320112_en 15

4.4.2 Minimum distances in the boiler room
▪ The system should generally be set up so that it is accessible from all sides allow‐
ing quick and easy maintenance.
▪Regional regulations regarding necessary maintenance areas for inspecting the
chimney should be observed in addition to the specified minimum distances!
▪ Observe the applicable standards and regulations when setting up the system.
▪ Observe additional standards for noise protection
(ÖNORM H 5190 - Noise protection measures)
TX 150: TX 200/250:
Pos. Description Unit TX 150/200/250
ASpace requirement for inspection area of infeed mm
(inch)
400 (16)
BDistance from heat exchanger side to wall 300 (12)
CSpace requirement for removal of ash box 400 (16)
DSpace requirement for inspection area of retort 400 (16)
4Assembly
Set-up in the boiler room
16 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

4.5 Mounting steps
4.5.1 General information
Boiler front side and boiler back side
The front side is considered as operator side of the boiler. All for operation necessary
elements like combustion chamber door, ash box and control box are arranged on the
front side. The back side is the opposite side. On the back side the stoker unit, the
WOS-drive as well as the whole exhaust gas routing system are arranged.
Heat exchanger left or right
In general it is different, if the heat exchanger of the TX (front view = operator side) is
positioned on the left or the right side of the fire box. Before mounting it has to be de‐
fined, whether the heat exchanger is mounted on the left or the right, as far as it is not
defined by an existing floor plan.
Heat exchanger left Heat exchanger right
1 Fire box 2 Heat exchanger
The following illustrations of mounting steps show the heat exchanger on the right
side. If the heat exchanger is arranged on the left side, the mounting steps have to be
applied laterally reversed by analogy.
Assembly 4
Mounting steps
Installation Instructions TX 150-250 | M1320112_en 17

4.5.2 Screwing the fire box with the heat exchanger
Positioning of the fire box from the side
❒ Insert the lift truck at the fire box opposite and lift it up as far as the fire box can be
positioned without colliding with the heat exchanger
❒Bring in the fire box completely at the side of the heat exchanger and lower it slow‐
ly
❒ Remove the supporting post on the ash flange of the fire box
Positioning the fire box from the front
If there is not enough space to bring in the fire box from the side, it is possible to bring
it in from the front:
❒ Insert the lift truck at the fire box opposite the supporting post
❒Place a piece of pipe, square timber or similar with a height of approx. 75 mm be‐
low the fire box as a distance piece
❒ Lift the fire box with the lifting truck and remove the supporting post on the ash
flange
❒ Position the loading arm of the lift truck by the openings of the main frame und in‐
sert the fire box as far as the distance piece can be positioned within the apron
❒ Lower the fire box, position the distance piece within the apron, lift the fire box
once again and bring it completely in.
4Assembly
Mounting steps
18 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

Adjust and fix the fire box
Before fixing, the fire box has to be adjusted in the heat exchanger. Two arrestors
have to be attended.
Arrestor - Heat exchanger Arrestor - Main frame
After positioning of the fire box in the heat exchanger:
❒ Tighten the fire box against the heat exchanger with carrying bolts through the lat‐
eral cutouts in the main frame
➥Check that the fire box is aligned with the heat exchanger and pay attention on
seal cord, it shall have a constant closing!
4.5.3 Installing sensor of thermal discharge system
❒ Remove blind plug at the heat exchanger
❒Use both thread tape and pipe dope and screw in thermowell
Assembly 4
Mounting steps
Installation Instructions TX 150-250 | M1320112_en 19

❒ Insert sensor of the thermal discharge system at thermowell
❒Insert protective tube of the sensor and tighten the fixing screw gently
4.5.4 Assembly of fireclay blocks
❒ Remove bolting on the heat exchanger cover
❒Remove the heat exchanger cover
❒ Place ceramic fibre mats on the fire box as shown
➥Make sure that two mats are placed on the side to the heat exchanger
❒Place fireclay blocks on the ceramic fibre mats as shown
➥Place the lateral capstone on the side to the heat exchanger with the grade
downwards
4Assembly
Mounting steps
20 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com