Froling Turbomat TM 400 User manual

Installation Instructions
Turbomat TM 400-500
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M0690213_en | Edition 31/03/2014
Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at

Table of contents
1 General 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 Protective equipment for assembly staff 6
2.4 Design Information 6
2.4.1 Notes on standards 6
General standards for heating systems 6
Standards for structural and safety devices 7
Standards for heating water 7
Standards for permitted fuels 7
2.4.2 Installation and approval of the heating system 7
2.4.3 General information for installation room (boiler room) 8
2.4.4 Requirements for central heating water 8
2.4.5 Notes for using pressure maintenance systems 9
2.4.6 Return lift 10
2.4.7 Use with storage tank 10
2.4.8 Chimney connection/chimney system 11
Draught limiter 11
Boiler data for planning the flue gas system 11
3 Technology 12
3.1 Dimensions 12
3.2 Components and connections 13
3.3 Technical specifications 14
4 Assembly 16
4.1 Transport 16
4.2 Positioning 16
4.3 Temporary storage 16
4.4 Setting up in the boiler room 16
4.4.1 Moving the boiler in the boiler room 16
4.4.2 Minimum distances in the boiler room 17
4.5 Installing the boiler 18
4.5.1 General information 18
4.5.2 Bolting together the combustion chamber and heat exchanger 18
4.5.3 Assembling the stoker unit 20
4.5.4 Repositioning the EOS rods (if required) 21
4.5.5 Assemble the case cooling duct (optional) 21
4.5.6 Assembling the insulation floor base frame 23
4.5.7 Fitting thermal insulation to the boiler 26
4.5.8 Assembling the upper insulation base frame 28
4.5.9 Installing the insulating side panels 31
4.5.10 Installing the heat exchanger ash removal unit 35
4.5.11 Installing the induced draught fan 39
4.5.12 Assembling the FGR (optional) 41
4.5.13 Mounting the cover on the slide-on duct 43
Table of contents
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4.5.14 Assembling the automatic ignition 44
4.5.15 Installing the combustion chamber overpressure and temperature sensors 45
4.5.16 Installing the combustion chamber ash removal unit 46
4.5.17 Installing the grate drive 48
4.5.18 Installing the air flap actuators 49
4.5.19 Installing the combustion air fan 52
4.5.20 Installing the STL and boiler and undergrate sensor 53
4.5.21 Assembling the EOS drive with function monitoring 55
4.5.22 Assembling the insulated doors and covers 55
4.5.23 Assembling the burner pivoting mechanism (optional) 58
4.5.24 Installing the boiler controller when operating the burner (optional) 59
4.6 Power connection and wiring 60
4.7 Thermal discharge safety device connection 61
4.8 Connecting the slide-on duct cooling 62
5 Commissioning 63
5.1 Before commissioning / configuring the boiler 63
5.2 Initial startup 64
5.2.1 Permitted fuels 64
Wood chips 64
Wood pellets 64
Wood shavings 64
Miscanthus 65
Changing the fuel 65
5.2.2 Non-permitted fuels 66
5.3 Heating up for the first time 66
6 Decommissioning 68
6.1 Out of service for long periods 68
6.2 Disassembly 68
6.3 Disposal 68
7 Appendix 69
7.1 Addresses 69
7.1.1 Address of manufacturer 69
7.1.2 Address of the installer 69
Table of contents
Installation Instructions Turbomat TM 400-500 | M0690213_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. Observing the requirements and safety information in the docu‐
mentation makes a significant contribution to safe, appropriate, environmentally friend‐
ly and economical operation of the system.
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
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2 Safety
2.1 Hazard levels of warnings
This documentation uses warnings with the following hazard levels to indicate direct
hazards and important safety instructions:
DANGER
The dangerous situation is imminent and if measures are not observed it will lead
to serious injury or death. You must follow the instructions!
WARNING
The dangerous situation may occur and if measures are not observed it will lead
to serious injury or death. Work with extreme care.
CAUTION
The dangerous situation may occur and if measures are not observed it will lead
to minor injuries or damage to property.
Safety 2
Hazard levels of warnings
Installation Instructions Turbomat TM 400-500 | M0690213_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
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 heat output up to 500 kW
EN 12828 Heating systems in buildings - design of water-based heating
systems
EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods
Part 1: Chimneys serving one appliance
2Safety
Qualification of assembly staff
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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)
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
Note on standards
Safety 2
Design Information
Installation Instructions Turbomat TM 400-500 | M0690213_en 7

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.
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.
Note on standards
Note on standards
2Safety
Design Information
8 Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at

Observe the standards and also follow the recommendations below:
❒Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to
5.6 dH)
❒ Use softened water as the make-up water
❒ Avoid leaks and use a closed heating system to maintain water quality during op‐
eration
2.4.5 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required pres‐
sure within predefined limits and balance out volume variations caused by changes in
the hot-water temperature. Two main systems are used:
Compressor-controlled pressure maintenance
In compressor-controlled pressure maintenance units, a variable air cushion in the ex‐
pansion tank is responsible for volume compensation and pressure maintenance. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐
to the heating water.
Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐
tenance pump, relief valve and an unpressurised receiving tank. The valve releases
hot water into the receiving tank if the pressure is too high. If the pressure drops below
a preset value, the pump draws water from the receiving tank and feeds it back into
the heating system. Pump-controlled pressure maintenance systems with open expan‐
sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the
water, exposing the connected system components to the risk of corrosion. These
systems offer no oxygen removal for the purposes of corrosion control as required by
VDI 2035 and in the interests of corrosion protection should not be used.
Safety 2
Design Information
Installation Instructions Turbomat TM 400-500 | M0690213_en 9

2.4.6 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).
2.4.7 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 69]
2Safety
Design Information
10 Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at

2.4.8 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 cal‐
culated 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.
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.
Boiler data for planning the flue gas system
Description TM
400 500
Flue gas temperature at nominal load °C 140
Flue gas temperature at partial load 110
Flue gas mass flow with wood chip W30,
14% O2
kg/h 2,060 2,576
Flue gas mass flow with wood chip W30,
9% O2
1,111 1,389
Flue gas mass flow with wood pellets 14%
O2
1,729 2,161
Flue gas mass flow with wood pellets 9%
O2
939 1,174
Required feed pressure at nominal load mbar 0.05
Required feed pressure at partial load 0.02
Flue pipe diameter mm 350
Safety 2
Design Information
Installation Instructions Turbomat TM 400-500 | M0690213_en 11

3 Technology
3.1 Dimensions
Item Description Unit TM 400 TM 500
H1 Height, boiler incl. insulation mm 2,660 2,660
H2 Height of return connection mm 710 710
H3 Height of flow connection mm 2,000 2,000
H4 Height, flue gas pipe connection excl. flue gas
return
mm 985 985
H5 Height, flue gas pipe connection incl. flue gas
return
mm 2,075 2,075
BTotal width incl. fittings mm 2,990 2,990
B1 Width, boiler incl. insulation mm 2,495 2,495
LTotal length incl. fittings mm 3,595 3,595
L1 Length, stoker unit mm 1,050 1,050
3Technology
Dimensions
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3.2 Components and connections
Item Description Unit TM 400 TM 500
ABoiler flow connection inches DN100 / PN16
BBoiler return connection inches DN100 / PN 16
CThermal discharge safety device connection inches ¾” ET ¾” ET
DFlue gas pipe connection without FGR (flue gas recir‐
culation)
mm 350 350
EFlue gas pipe connection with FGR (flue gas recircu‐
lation)
mm 350 350
Technology 3
Components and connections
Installation Instructions Turbomat TM 400-500 | M0690213_en 13

3.3 Technical specifications
Description TM
400 500
Nominal heat output kW 399 499
Heat output range kW 119-399 149-499
Electrical connection 400 V / 50 Hz / 35 A or as per circuit diagram
Power consumption (pellets, wood chip) kW 1.38 / 1.75 1.57 / 2.08
Total weight incl. fittings kg 8,400 8,400
Weight - combustion chamber 2,200 2,200
Weight - heat exchanger 2,150 2,150
Heat exchanger water capacity l 750 750
Water pressure drop
(ΔT = 10 / 20 K)
mbar 14.3 / 5.6 19 / 8.5
Minimum boiler return temperature °C 65
Maximum permitted operating tempera‐
ture
°C 90
Permitted operating pressure bar 6
Boiler class as per EN 303-5:2012 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
1.Detailed information on the fuel is included in the operating instructions in the section on “Permitted fuels”
400 500
Testing institute TÜV Austria1)
Test report no. 11-UW/Wels-EX-177/5 11-UW/Wels-EX-177/1
Date of issue 20/03/2012 18/09/2011
1.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels
Test data for wood chips - emissions in [mg/MJ] (nominal load/partial load)
Carbon monoxide (CO) mg/MJ 9 / 4 <2 / 4
Nitrogen oxide (NOx) mg/MJ 44 / 51 46 / 51
Organic hydrocarbons (OGC) mg/MJ <1 / <2 <1 / <2
Dust mg/MJ 15 / 11 18 / 11
Boiler efficiency % 93.9 / 90.3 93.6 / 90.3
Test data for wood chips - emissions in [mg/m³]1) (nominal load/partial load)
Carbon monoxide (CO) mg/m³ 14 / 5 <2 / 5
Nitrogen oxide (NOx) mg/m³ 65 / 76 67 / 76
Organic hydrocarbons (OGC) mg/m³ <1 / <3 <1 / <3
Dust mg/m³ 22 / 16 26 / 16
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%
3Technology
Technical specifications
14 Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at

Test data for pellets - emissions in [mg/MJ] (nominal load/partial load)
Carbon monoxide (CO) mg/MJ <2 / <3 <2 / <3
Nitrogen oxide (NOx) mg/MJ 63 / 71 66 / 71
Organic hydrocarbons (OGC) mg/MJ <1 / <2 <1 / <2
Dust mg/MJ 12 / 10 13 / 10
Boiler efficiency % 93.9 / 92.0 94.4 / 92.0
Test data for pellets - emissions in [mg/m³]1) (nominal load/partial load)
Carbon monoxide (CO) mg/m³ <3 / <4 <2 / <4
Nitrogen oxide (NOx) mg/m³ 93 / 105 97 / 105
Organic hydrocarbons (OGC) mg/m³ <1 / <2 <1 / <2
Dust mg/m³ 17 / 15 19 / 15
1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%
Technology 3
Technical specifications
Installation Instructions Turbomat TM 400-500 | M0690213_en 15

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 eyelet(s) 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 conditions and frost can damage components, particularly electric ones!
4.4 Setting 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.
4Assembly
Transport
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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)
A
B
D
C
Item Description Unit TM 400/500
ASpace required for inspection area of infeed mm 500
BSpace required for inspection area of heat exchanger
- lateral
500
CSpace required for inspection area - front 1,000
DSpace required for inspection area of combustion
chamber - lateral
950
Minimum room height 3,300
Assembly 4
Setting up in the boiler room
Installation Instructions Turbomat TM 400-500 | M0690213_en 17

4.5 Installing the boiler
NOTICE
Reduction in performance due to air leakage
The use of flanges without sealing cords can result in a reduction in performance
due to air leakage
Therefore:
❒ sealing cords or the surface sealant provided must be used on all the flanged
connections on the following components: loading; ash removal; pressure
ducting; air ducts for primary, secondary and tertiary air; ducting for combus‐
tion air fan; flue gas and flue gas return piping.
4.5.1 General information
Front and back of boiler
The front of the boiler is its operating side. All of the elements necessary for operating
the unit, e.g. combustion chamber, burning chamber and ash can can be found on the
front.
The back of the boiler is opposite the front and is where the stoker unit, EOS drive and
complete flue gas system can be found.
Heat exchanger on the left or right
A general distinction is made between whether the heat exchanger is located to the
left or right of the combustion chamber (as seen from the front = operating side). It is
important to determine whether the heat exchanger will be installed to the left or right if
there is no existing layout plan.
The following images show the instructions for installing a heat exchanger to the right
of the combustion chamber. If it is to be installed to the left, the steps should be car‐
ried out in the same way but on the other side.
4.5.2 Bolting together the combustion chamber and heat exchanger
❒ Position the combustion chamber as per the layout plan ensuring it is level.
❒Weld the nuts (M12) on the grate shaft of the heat exchanger
4Assembly
Installing the boiler
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❒ Fit the seal cord
❒Position the heat exchanger on the combustion chamber
➥Ensure that the locating pins are inserted correctly
❒ Check the caps on the end of the grate shafts
➥If necessary, tighten to the stop
❒Fix the heat exchanger to the flange with 6 M12 nuts and washers (socket span‐
ner size SW 19 mm)
➥Tighten the nuts so that the flange ring is seated inside the cord seal channel
Assembly 4
Installing the boiler
Installation Instructions Turbomat TM 400-500 | M0690213_en 19

❒ Ensure the complete assembly is level by adjusting the feet (spanner size SW
30 mm)
➥Check that none of the adjustable feet are loose
❒Slide the insulation sheet steel panels (1) on both sides under the heat exchanger
and feed through the pins (2)
4.5.3 Assembling the stoker unit
❒ Secure the stoker duct to the slide-on duct using 4 M10x40 bolts and M10 nuts
❒Secure the flange plate with 4 M10x20 bolts and M10 nuts
❒ Fix the rotary valve or the burn back flap (depending on the version) in place using
four M12 screws and nuts.
➥Fit the burn back flap so that the pivot point of the flap is on the side opposite
the boiler.
❒ Push in the stoker screw
❒Fit the flange plate onto the stoker screw and align it parallel to the stoker duct
flange
➥Check that the stoker screw can turn freely
4Assembly
Installing the boiler
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