Froling Turbomat TM 400 Installation Instructions Manual
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Froling Turbomat TM 400 Installation Instructions Manual

Froling Turbomat TM 400 Installation Instructions Manual

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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

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  • Page 1 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...

  • Page 2: Table Of Contents

    Table of contents Table of contents General Safety Hazard levels of warnings Qualification of assembly staff Protective equipment for assembly staff Design Information 2.4.1 Notes on standards General standards for heating systems Standards for structural and safety devices Standards for heating water Standards for permitted fuels 2.4.2 Installation and approval of the heating system...
  • Page 3 Miscanthus Changing the fuel 5.2.2 Non-permitted fuels Heating up for the first time Decommissioning Out of service for long periods Disassembly Disposal Appendix Addresses 7.1.1 Address of manufacturer 7.1.2 Address of the installer Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 4: General

    General 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.

  • Page 5: Safety

    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. Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 6: Qualification Of Assembly Staff

    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‐...

  • Page 7: Standards For Structural And Safety Devices

    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: Note on standards ÖNORM / DIN EN 12828 Heating Systems in Buildings Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 8: General Information For Installation Room (Boiler Room)

    Safety Design Information 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.

  • Page 9: Notes For Using Pressure Maintenance Systems

    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. Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 10: Return Lift

    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]...

  • Page 11: Chimney Connection/Chimney System

    Flue gas mass flow with wood pellets 14% 1,729 2,161 Flue gas mass flow with wood pellets 9% 1,174 Required feed pressure at nominal load mbar 0.05 Required feed pressure at partial load 0.02 Flue pipe diameter Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 12: Technology

    Technology Dimensions 3 Technology 3.1 Dimensions Item Description Unit TM 400 TM 500 Height, boiler incl. insulation 2,660 2,660 Height of return connection Height of flow connection 2,000 2,000 Height, flue gas pipe connection excl. flue gas return Height, flue gas pipe connection incl. flue gas 2,075 2,075 return...

  • Page 13: Components And Connections

    DN100 / PN 16 Thermal discharge safety device connection inches ¾” ET ¾” ET Flue gas pipe connection without FGR (flue gas recir‐ culation) Flue gas pipe connection with FGR (flue gas recircu‐ lation) Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 14: Technical Specifications

    Technology Technical specifications 3.3 Technical specifications Description Nominal heat output Heat output range 119-399 149-499 Electrical connection 400 V / 50 Hz / 35 A or as per circuit diagram Power consumption (pellets, wood chip) 1.38 / 1.75 1.57 / 2.08 Total weight incl.
  • Page 15 <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% Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 16: Assembly

    Assembly Transport 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...

  • Page 17: Minimum Distances In The Boiler Room

    Space required for inspection area of infeed Space required for inspection area of heat exchanger - lateral Space required for inspection area - front 1,000 Space required for inspection area of combustion chamber - lateral Minimum room height 3,300 Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 18: Installing The Boiler

    Assembly Installing the boiler 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;...
  • Page 19 ❒ 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 Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 20: Assembling The Stoker Unit

    Assembly Installing the boiler ❒ 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 ❒...

  • Page 21: Repositioning The Eos Rods (If Required)

    ❒ Also remove the tension hook and fix it on the opposite side 4.5.5 Assemble the case cooling duct (optional) ❒ Remove the blanking plate from the front of the heat exchanger Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 22 Assembly Installing the boiler ❒ Position the case cooling duct between the heat exchanger and the combustion chamber ❒ Fix the duct onto the heat exchanger and combustion chamber using M8 screws ❒ Attach the cover plate to the duct ❒...

  • Page 23: Assembling The Insulation Floor Base Frame

    Back heat exchanger cross-piece nal element Back combustion chamber cross- Angled elements piece Front combustion chamber cross- Right heat exchanger longitudinal ele‐ piece ment ❒ Position the left combustion chamber longitudinal element (A) Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 24 Assembly Installing the boiler ❒ Position the left longitudinal element (B) between the combustion chamber and the heat exchanger ❒ Attach these elements to the combustion chamber at the specified points ❒ Position the back (C) and front (D) combustion chamber cross-piece ➥...
  • Page 25 ❒ Fix the front and back cross-pieces to the heat exchanger longitudinal element on the right and to the combustion chamber longitudinal element on the left with thread forming screws ❒ Align the floor base frame on all sides using M8x40 hexagon bolts Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 26: Fitting Thermal Insulation To The Boiler

    Assembly Installing the boiler 4.5.7 Fitting thermal insulation to the boiler ❒ Insert the heat insulation mat into the bottom right between the combustion cham‐ ber and heat exchanger ❒ Lay 4 insulated panels on top of the combustion chamber ➥...
  • Page 27 ❒ Lay the heat insulation mat over the combustion chamber from the side View of the combustion chamber from the right ❒ Fix the heat insulation mats in place using tension springs View of the combustion chamber from the back: Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 28: Assembling The Upper Insulation Base Frame

    Assembly Installing the boiler 4.5.8 Assembling the upper insulation base frame Combustion chamber support mem‐ Central combustion chamber frame bers element Left combustion chamber longitudi‐ Heat exchanger support element nal element Combustion chamber cross-pieces Heat exchanger cross-pieces Right combustion chamber longitu‐ Heat exchanger longitudinal element dinal element Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at...
  • Page 29 ❒ Position the left combustion chamber longitudinal element (B) on the support ele‐ ments ❒ Position the combustion chamber cross-pieces at the front and back between the support elements ❒ Position the right combustion chamber longitudinal element (D) on the support ele‐ ments Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 30 Assembly Installing the boiler ❒ Place the central combustion chamber frame element (E) between the front and back insulation panels ❒ Check that all of the lugs are placed correctly ❒ Line up the frame and screw the frame elements in place ❒...

  • Page 31: Installing The Insulating Side Panels

    ❒ Cut out all of the perforated areas from the insulating side panels depending on the boiler in question ➥ Cut away and remove any thermal insulation below the panels using a knife Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 32 Assembly Installing the boiler ❒ Slide the insulating side panel (1) into place at the bottom and onto the lug in the floor frame (2) ❒ Slide the insulating side panel (1) into place at the top and onto the lugs in the frame (3) ❒...
  • Page 33 ❒ Slide insulating side panels J and K into place ❒ Attach all insulating side panels to the frame with screws ❒ Position the heat exchanger ash removal insulation (L) and attach at the top using three screws Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 34 Assembly Installing the boiler ❒ Slide insulating side panel L into place ❒ Slide insulating side panels M and N into place ❒ Slide insulating side panel O into place ❒ Mount the cover plate (two parts) onto the case cooling (optional) ➥...

  • Page 35: Installing The Heat Exchanger Ash Removal Unit

    ❒ Assemble both flanges (1) for the heat exchanger ash removal ❒ Grease the shaft stub on both ash screws ❒ Place the motor on the right-hand shaft and fix in place with screws Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 36 Assembly Installing the boiler ❒ Place the pedestal on the left-hand shaft and fix in place with screws and spacer washers ❒ Mount a simple chain wheel onto the geared motor ❒ Mount the chain wheel and chain tensioner on the pedestal ❒...
  • Page 37 ❒ Fit the foam rubber seal on the ash removal flanges over the shaft ❒ Fit the plastic handles on the locking levers ➥ If necessary, use a rubber mallet to knock it into place Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 38 Assembly Installing the boiler Front of boiler ❒ Assemble both ash removal flanges with 4 M8x20 hexagon bolts and M8 spacer washers ➥ Position the flanges so that the levers on the locking mechanism face outwards ❒ Install the insulation ❒...

  • Page 39: Installing The Induced Draught Fan

    ❒ Fit seal cord around the induced draught fan flange on the back of the boiler ❒ Mount the induce draught fan bracket onto the flange ➥ Align correctly using the adjustable feet and fix in place using the spacer wash‐ er and hexagon bolt Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 40 Assembly Installing the boiler ❒ Fit seal cord around the flue pipe compensator and mount the flue pipe compen‐ sator onto the induced draught fan bracket ❒ Mount the induced draught fan onto the flue pipe compensator ➥ Also add an earthing connection ➥...

  • Page 41: Assembling The Fgr (Optional)

    (1) 4.5.12 Assembling the FGR (optional) ❒ Mount the FGR duct to the flue pipe elbow on the back of the boiler ❒ Mount the FGR bracket onto the flue pipe elbow Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 42 Assembly Installing the boiler ❒ Mount the rubber buffer on the underside of the FGR blower fan ❒ Position the FGR blower fan on the bracket ❒ Mount the FGR blower fan using rubber buffers ❒ Wrap the complete FGR duct incl. the flue pipe elbow in thermal insulation ➥...

  • Page 43: Mounting The Cover On The Slide-On Duct

    ❒ Mount the cover on the flue pipe elbow ❒ Mount all the inspection opening covers onto the FGR duct cover 4.5.13 Mounting the cover on the slide-on duct ❒ Mount the lateral slide-on duct covers to the insulation Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 44: Assembling The Automatic Ignition

    Assembly Installing the boiler ❒ Mount the top slide-on duct covers to the side covers 4.5.14 Assembling the automatic ignition ❒ Insert the igniter tube ❒ Place the double screw clip onto the igniter tube ❒ Insert the ignition blower into the igniter tube and fix in place using the double screw clip ❒...

  • Page 45: Installing The Combustion Chamber Overpressure And Temperature Sensors

    ❒ Slide the overpressure sensor pipe right in and tighten the retaining screw slightly ❒ Insert the combustion chamber temperature sensor bracket ❒ Insert the combustion chamber temperature sensor to a distance of approx. 40 - 50 mm inside the combustion chamber Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 46: Installing The Combustion Chamber Ash Removal Unit

    Assembly Installing the boiler ❒ Tighten it in place using clamping screws ❒ Remove the cover and connect the compensating line - green wire to terminal with green dot - white wire to unmarked terminal - shield not connected 4.5.16 Installing the combustion chamber ash removal unit ❒...
  • Page 47 ❒ Mount the locking lever on the ash removal flange ❒ Fit the foam rubber seal on the ash removal flange over the shaft ❒ Fit the ash removal flange to the opposite side of the gear assembly Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 48: Installing The Grate Drive

    Assembly Installing the boiler ❒ Assemble the safety switch on the bracket ❒ Mount the safety switch and bracket onto the boiler insulation ❒ Position the ash container ➥ Push the lever on the side of the boiler downwards to lock the ash container in place ❒...

  • Page 49: Installing The Air Flap Actuators

    Actuator I - tertiary air Primary air actuator flue gas recirculation Actuator II - tertiary air Primary air actuator Secondary air actuator ❒ Mount the case cooling actuator (optional) (1) onto the torque support Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 50 Assembly Installing the boiler ❒ Fix actuator I for tertiary air (2) in place ❒ Fit the cover plates ❒ Mount actuator II for tertiary air (3) ❒ Fit the cover plates ❒ Mount the actuator for secondary air (4) ❒...
  • Page 51 ❒ Fit the cover plates ▪ Upper actuator (5) = secondary air flue gas recirculation ▪ Lower actuator (6) = primary air flue gas recirculation ❒ Mount the primary air actuator (7) ❒ Fit the cover plates Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 52: Installing The Combustion Air Fan

    Assembly Installing the boiler 4.5.19 Installing the combustion air fan ❒ Mount the top and bottom cover on the supply air box onto the insulation ❒ Remove the grill from the combustion air fan ❒ Mount the connector supports onto the combustion air fan ❒...

  • Page 53: Installing The Stl And Boiler And Undergrate Sensor

    4.5.20 Installing the STL and boiler and undergrate sensor ❒ Push the STL sensor through the frame and into the immersion sleeve ❒ Push the STL through the back of the cover and fix in place using the nuts sup‐ plied Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 54 Assembly Installing the boiler ❒ Mount the cover with STL onto the insulation using six captive screws ➥ Run the sensor cable through the opening ❒ Attach the black STL button protective cap ❒ Slide the sensor (length: 200 mm) under the moving grate and fix it in place with the screw Case cooling option...

  • Page 55: Assembling The Eos Drive With Function Monitoring

    ❒ Fix the function monitoring (4) to the bracket ❒ Fit the cover plates 4.5.22 Assembling the insulated doors and covers ❒ Place both the front insulating covers on top of the combustion chamber Installation Instructions Turbomat TM 400-500 | M0690213_en...
  • Page 56 Assembly Installing the boiler ❒ Place both the back insulating covers on top of the combustion chamber ❒ Mount the combustion chamber door frame ❒ Mount the burning chamber door frame ❒ Mount the burning and combustion chamber door covers ❒...
  • Page 57 ❒ Tighten the four screws on the outside of the heat exchanger cover ❒ Insert a washer into the two central threaded bolts and fix in place using nuts ❒ Fit both heat exchanger insulating covers Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 58: Assembling The Burner Pivoting Mechanism (Optional)

    Assembly Installing the boiler 4.5.23 Assembling the burner pivoting mechanism (optional) ❒ Mount the hinged joint to fix the mechanism in place (A) ➥ This hinged joint needs to be mounted before the insulating side panels! ❒ Mount the intermediate hinge (B) onto the hinge joint (A) using a long bolt (D) ❒...

  • Page 59: Installing The Boiler Controller When Operating The Burner (Optional)

    ❒ Loosen the 2 slotted screws on the front of the boiler controller and remove the housing ❒ Mount onto the insulation cover using the slotted screws ❒ Mount the cover with the boiler controller onto the heat exchanger Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 60: Power Connection And Wiring

    Assembly Power connection and wiring 4.6 Power connection and wiring DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: ❒ Only have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥...

  • Page 61: Thermal Discharge Safety Device Connection

    1. required when the cold water pressure is greater than 6 bar. It must be impossible to shut off the connection manually. Minimum cold water pressure = 2 bar, 10°C ❒ Insert the thermal discharge safety device sensor (AVTA) into the immersion sleeve ➥ no refitting required! Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 62: Connecting The Slide-On Duct Cooling

    Assembly Connecting the slide-on duct cooling 4.8 Connecting the slide-on duct cooling The following is a schematic diagram Boiler flow Slide-on duct loading pump: ▪ no gravitational brake! Boiler return ▪ output up to 500 kW: alpha2 25-40 or similar Slide-on duct flow Heat exchanger drainage Gate valve or ball valve...

  • Page 63: Commissioning

    Take the following precautions: ❒ Initial startup should be carried out with an authorised installer or with Froling customer services ❒ Adjust the boiler controller to the system type ❒...

  • Page 64: Initial Startup

    Before refilling the store, check for pellet dust and clean if necessary. Wood shavings Wood shavings generally cause problems with combustion. Therefore their use is per‐ mitted only with authorisation from Froling. The following additional points also apply: Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at...

  • Page 65: Miscanthus

    Therefore: ❒ If the fuel is changed (e.g. from wood chips to pellets), the system must be reset by Froling customer services. Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 66: Non-Permitted Fuels

    Take the following precautions: ❒ Initial startup should be carried out with an authorised installer or with Froling customer services The customer is responsible for ensuring the following prior to initial start-up of the system by Froling customer services: ▪...
  • Page 67 The individual steps for initial start-up are explained in the operating instructions for the controller NOTICE! See operating instructions for the SPS 4000 Installation Instructions Turbomat TM 400-500 | M0690213_en...

  • Page 68: Decommissioning

    Decommissioning Out of service for long periods 6 Decommissioning 6.1 Out of service for long periods The following measures should be taken if the boiler is to remain out of service for several weeks (e.g. during the summer): ❒ Clean the boiler thoroughly and close the doors fully ❒...

  • Page 69: Appendix

    7.1 Addresses 7.1.1 Address of manufacturer FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL 0043 (0)7248 606 0 FAX 0043 (0)7248 606 600 INTERNET www.froeling.com 7.1.2 Address of the installer Stamp Installation Instructions Turbomat TM 400-500 | M0690213_en...

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