Fröling TI 350 Installation Instructions Manual
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Fröling TI 350 Installation Instructions Manual

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Installation Instructions
TI 350
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1830521_en | Edition 18/02/2021
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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  • Page 1 Installation Instructions TI 350 Translation of the original German installation instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M1830521_en | Edition 18/02/2021 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 2: Table Of Contents

    Table of Contents Table of Contents General Safety Hazard levels of warnings Qualification of assembly staff Personal protective equipment for assembly staff Design Information Notes on standards 3.1.1 General standards for heating systems 3.1.2 Standards for structural and safety devices 3.1.3 Standards for heating water 3.1.4...
  • Page 3 Permitted fuels Wood chips Wood pellets Wood shavings Miscanthus Changing the fuel 6.2.2 Non-permitted fuels Heating up for the first time 6.3.1 Screed drying Decommissioning Out of service for long periods Disassembly Disposal Notes Appendix Installation Instructions TI 350 | M1830521_en...
  • Page 4 Table of Contents Addresses 9.1.1 Address of manufacturer Customer service 9.1.2 Address of the installer Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 5: General

    Froling. On commissioning by FROLING Customer Service the validity of the delivery certificate will be noted on the customer service record. Installation Instructions TI 350 | M1830521_en...

  • Page 6: Safety

    Safety Hazard levels of warnings 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.

  • Page 7: Qualification Of Assembly Staff

    You must ensure that staff have the protective equipment specified by accident prevention regulations. ▪ For transportation, setup and assembly: - suitable work wear - protective gloves - sturdy shoes (min. protection class S1P) Installation Instructions TI 350 | M1830521_en...

  • Page 8: Design Information

    Design Information Notes on standards 3 Design Information 3.1 Notes on standards The system must be installed and commissioned in accordance with the local fire and building regulations. Unless contrary to other national regulations, the latest versions of the following standards and guidelines apply: 3.1.1 General standards for heating systems EN 303-5 Boilers for solid fuels, manually and automatically fed...

  • Page 9: Regulations And Standards For Permitted Fuels

    ▪ Danger of fire due to flammable materials. The floor of the boiler room must not be flammable. No flammable materials should be stored near the boiler. Never place flammable objects (e.g. clothing, etc.) on the boiler to dry. Installation Instructions TI 350 | M1830521_en...

  • Page 10: Requirements For Central Heating Water

    Design Information General information for installation room (boiler room) ▪ Damage due to impurities in combustion air. Do not use any solvents or cleaning agents containing chlorine and hydrogen halides in the room where the boiler is installed (e.g. chlorination units for swimming pools).
  • Page 11 ▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the central heating water comes into contact with aluminium, the pH value must be between 8.0 and ▪ Yearly. Values must be recorded by the owner Installation Instructions TI 350 | M1830521_en...

  • Page 12: Notes For Using Pressure Maintenance Systems

    Design Information Notes for using pressure maintenance systems 3.5 Notes for using pressure maintenance systems Pressure maintenance systems in hot-water heating systems keep the required pressure 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 expansion tank is responsible for volume compensation and pressure maintenance.

  • Page 13: Use With Storage Tank

    NOTICE! Install the draught limiter directly under the mouth of the flue line, as the pressure is constantly low at this point. Installation Instructions TI 350 | M1830521_en...

  • Page 14: Technology

    Technology Dimensions 4 Technology 4.1 Dimensions Item Description Unit Value Total length including fittings 3460 Total length without fittings 2455 Length, combustion chamber ash container Length, heat exchanger ash container Boiler height including insulation 2475 Height, heat exchanger ash container Height of return connection Height of stoker including burn back protection system Height, flue gas pipe connection with FGR...

  • Page 15: Components And Connections

    Thermal discharge valve connection (burn through elbow) inches ” AG without optional pipe assembly Thermal discharge valve connection (burn through elbow) inches ” AG with optional pipe assembly Flue gas pipe connection with FGR (flue gas recirculation) Installation Instructions TI 350 | M1830521_en...

  • Page 16: Technical Data

    Technology Technical data 4.3 Technical data Description Value Nominal output Output range 105-350 Required fuel consumption at nominal load kg/h Electrical connection 400V / 50 Hz / C35A or as per circuit diagram Power consumption wood chips (NL / PL) <0.8 / 0.4 % of nominal output Power consumption pellets (NL / PL) <0.6 / 0.3 % of nominal output...
  • Page 17 1. Emissions of particulate matter, organic gaseous compounds, carbon monoxide and nitrogen oxides shall be expressed standardised to a dry flue gas basis at 10 % oxygen and standard conditions at 0°C and 1013 millibar Installation Instructions TI 350 | M1830521_en...

  • Page 18: Boiler Data For Planning The Flue Gas System

    Technology Technical data 4.3.1 Boiler data for planning the flue gas system Description TI 350 Flue gas temperature at nominal load °C Flue gas temperature at partial load Flue gas volume/mass flow with wood chip W30, 1574 12% O (1327)

  • Page 19: Assembly

    ➥ Damp conditions and frost can damage components, particularly electric ones! 5.3 Positioning ❒ Secure cable winch or similar lifting device to the attachment points and position the components ➥ CAUTION: It is forbidden to stand under suspended loads! Installation Instructions TI 350 | M1830521_en...

  • Page 20: Setting Up In The Boiler Room

    Assembly Setting up in the boiler room CAUTION: Do not tilt the heat exchanger during installation or assembly! – see sticker (A). After positioning the heat exchanger, check the correct position of the firebricks (B). 5.4 Setting up in the boiler room 5.4.1 Moving the boiler in the boiler room ❒...

  • Page 21: Operating And Maintenance Areas Of The Equipment

    ▪ Observe additional standards for noise protection! (ÖNORM H 5190 - Noise protection measures) 1500 mm 400 mm 400 mm 675 mm 2900 mm (3500 mm) 1. Required room height to pull out the turbulators Installation Instructions TI 350 | M1830521_en...

  • Page 22: Installing The Boiler

    Assembly Installing the boiler 5.5 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 23: Installing The Grate Drive

    ❒ Install the gears as shown ➥ With the help of a suitable tool, position the crank shaft so that the groove is aligned with the groove of the gears ❒ Slide key into groove and fit shaft retainer Installation Instructions TI 350 | M1830521_en...

  • Page 24: Installing The Stoker Unit

    Assembly Installing the boiler 5.5.3 Installing the stoker unit ❒ Transport the stoker unit to the slide-on duct using a suitable pipe (A – e.g. 1” pipe) through bracket (B) ❒ Remove the pre-assembled adjustable foot (C) and bracket (B) ❒...
  • Page 25 WOS lever (if required)" [page 26] IMPORTANT: Check the tightness of the blanking plates (A), the two safety batteries (B) as well as all blanking plugs (C) and immersion sleeves (D) are and tighten them if necessary! Installation Instructions TI 350 | M1830521_en...

  • Page 26: Repositioning The Wos Lever (If Required)

    Assembly Installing the boiler 5.5.5 Repositioning the WOS lever (if required) The WOS drive is always fitted to the back of the boiler. If the WOS lever is located on the front, the WOS rods must be repositioned as follows. ❒...

  • Page 27: Fitting The Wos Drive

    ❒ Fix the motor mount to the gearbox flange using the four screws as shown ❒ Fit WOS drive to heat exchanger ❒ Attach tension spring to linking plate and WOS lever Installation Instructions TI 350 | M1830521_en...

  • Page 28: Installing The Air Controllers

    Assembly Installing the boiler 5.5.7 Installing the air controllers ❒ Remove the stop and sleeve (A) next to the return flow connection ❒ Fit the dual air controller (B) above the stoker ❒ Fit air controller (C) next to stoker ❒...
  • Page 29 ❒ Lubricate shaft stub with copper paste ❒ Fit the geared motor onto the shaft stub ➥ Ensure groove in shaft stub is aligned with groove in geared motor ❒ Slide key into groove and fit shaft retainer Installation Instructions TI 350 | M1830521_en...

  • Page 30: Installing The Heat Exchanger Ash Removal Unit

    Assembly Installing the boiler 5.5.9 Installing the heat exchanger ash removal unit Heat exchanger right Heat exchanger left The following instructions are for fitting the automatic heat exchanger ash removal screw unit to a boiler with the heat exchanger mounted on the right. The instructions also apply to boilers with the heat exchanger mounted on the left.
  • Page 31 ❒ Insert the flange plate with the ash screw into the heat exchanger on the back of the boiler and fix in place with screws ❒ Fit the container connection to the front of the boiler ➥ The levers on the locking mechanism must face outwards Installation Instructions TI 350 | M1830521_en...

  • Page 32: Installing The Air Ducts

    Assembly Installing the boiler 5.5.10 Installing the air ducts ❒ Fit the secondary air duct (A – short) and primary air duct (B – long) with seals to the rear of the boiler as shown ➥ The air ducts must run in the direction of the heat exchanger 5.5.11 Installing the adapter flange und pump assembly (optional) ❒...

  • Page 33: Installing The Igniter Tube And Undergrate Temperature Sensor

    5.5.13 Installing the spacer plate on the combustion chamber ❒ Fit the spacer plate (M) as shown on both sides of the base plate of the combustion chamber, ⇨ See "Installing the frames" [page 36] Installation Instructions TI 350 | M1830521_en...

  • Page 34: Positioning Two-Layer Thermal Insulation On The Combustion Chamber

    Assembly Installing the boiler 5.5.14 Positioning two-layer thermal insulation on the combustion chamber 1st layer positioning ❒ Lay the thermal insulation (A) over the combustion chamber from the front ❒ Fix the thermal insulation at the front (B, C) in place using tension springs ➥...

  • Page 35: Positioning Thermal Insulation On The Heat Exchanger

    ❒ Position thermal insulation (B, C) on the flow connection at the front and back ❒ Position round thermal insulation (D) at the front of the flow, return and blanking plate of the safety battery Installation Instructions TI 350 | M1830521_en...

  • Page 36: Installing The Frames

    Assembly Installing the boiler 5.5.16 Installing the frames Frames overview ❒ Fix the support element (C) to the spacer plate with two screws ❒ Position the support element (C) at the rear of the combustion chamber so that the recess of the bottom spacer plate touches the base plate of the combustion chamber ❒...
  • Page 37 ❒ Fit lengthways strut (G) to the fixing brackets (O) ❒ Hang cross-piece (F) below container connections and fix in place ❒ Insert cross-piece (P) under the stoker, hang it on to the frame and fix it in place Installation Instructions TI 350 | M1830521_en...
  • Page 38 Assembly Installing the boiler ❒ Hang cross-piece (Q) onto the support elements and fix it in place ❒ Position the front support elements (A) on the combustion chamber so that the recesses of the bottom spacer plates make contact with the bottom plate of the combustion chamber ❒...
  • Page 39 ➥ TIP: Screw one screw into each of the upper holes of the support elements and hang the cable duct (L) Screw one screw into each of the lower holes and tighten all screws Installation Instructions TI 350 | M1830521_en...
  • Page 40 Assembly Installing the boiler ❒ Fit cable ducts (K, L) to the support elements ❒ Screw one screw into each of the upper holes of the support elements and hang the cable duct (J) ❒ Screw two screws into each of the lower holes and tighten all screws ❒...

  • Page 41: Preparing The Cooling Piping (Optional)

    Establish connections with stainless steel corrugated hoses including flat seal (D) as follows: ❒ A: Pump assembly and side connection to the slide-on duct ❒ B: Upper connection to the slide-on duct with lateral connection to the burn through elbow Installation Instructions TI 350 | M1830521_en...

  • Page 42: Installing The Piping Of The Safety Battery

    Assembly Installing the boiler ❒ C: Rear connection to burn through elbow with connection to the heat exchanger 5.5.19 Installing the piping of the safety battery The following step describes the procedure when the heat exchanger is located on the right-hand side For heat exchangers located on the left-hand side, pipe connections A are not required, the pipe connections B are inserted at the rear support element.

  • Page 43: Fit Sensor And Wire Components

    The high-limit thermostat is fitted later, ⇨ See "Installing the cladding" [page 45] ❒ Remove the blanking plug from the side of the combustion chamber and screw in immersion sleeve tightly ❒ Insert and secure the undergrate temperature sensor Installation Instructions TI 350 | M1830521_en...
  • Page 44 Assembly Installing the boiler ❒ Lay the following cables to the cable duct: - Boiler sensor from boiler return (A) - Boiler sensor and STL capillary from boiler flow (B) - WOS-drive (C) - Pump assembly optional (D) - Drive for rotary valve and stoker (E) - Drive for moving grate (F) - Servo-motor next to stoker (G) - Undergrate temperature sensor (H)

  • Page 45: Installing The Cladding

    ❒ Fix the cover plate to the cover plate (A) and fit the cover plate onto the frame ❒ Feed the STL cable through the cut-out from the back into the cable duct ❒ Fix cover plates (D, E) next to stoker Installation Instructions TI 350 | M1830521_en...
  • Page 46 Assembly Installing the boiler ❒ Cut out pre-punched blanking for WOS drive at the corresponding cover plate (A) with angle grinder (B) ❒ Fit the STL to the cover plate (C) in the same way as before and fix it to the cover plate (A) ❒...
  • Page 47 ❒ Attach cover plates (A) onto the levers and fix them to the frame ❒ Fix cover plates (B) onto the outside of the frame Installation Instructions TI 350 | M1830521_en...

  • Page 48: Fitting The Control Cabinet

    Assembly Installing the boiler Fix the cover plates to the frame as shown: 5.5.22 Fitting the control cabinet ❒ Fix flat-headed screw with nut and washer at the rear of the control cabinet ❒ Hang the control cabinet from the recesses on the cross frame and fix it with screws at the bottom Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 49: Installing The Combustion Chamber Door Components

    ❒ Close the door and as you are doing so, slide the key plate so that it engages smoothly with the door contact switch ❒ Fix the key plate in position. Open and close the door several times and check that the door contact switch has properly engaged. Installation Instructions TI 350 | M1830521_en...

  • Page 50: Installing The Ash Container Limit Switch

    Assembly Installing the boiler ❒ Fit the rotary disc (A) to the combustion chamber door ❒ Open the door slightly and insert the cover (B) ❒ Fix the cover to the door ❒ Attach the spherical handle (C) to the rotary disc 5.5.24 Installing the ash container limit switch ❒...

  • Page 51: Installing The Combustion Chamber Temperature Sensor And Ignition

    ❒ Insert the ignition fan (A) into the igniter tube and fix in place using the double screw clip (B) ❒ Fit the cover (C) ❒ Connect cable (D) to the ignition fan and lay it to the control cabinet ❒ Fit the cover (E) Installation Instructions TI 350 | M1830521_en...

  • Page 52: Installing The Underpressure Controller

    Assembly Installing the boiler 5.5.26 Installing the underpressure controller ❒ Install differential pressure transmitter (A) next to safety battery ❒ Insert the reducing plug (B) at connection "-" on the transmitter ❒ Attach air hose with "-" hose nipple to the transmitter and lay it to the hose nipple on the combustion chamber temperature sensor ➥...

  • Page 53: Installing Remaining Covers

    ❒ Hang cover (B) over the stoker unit and fix it in place ❒ Hang cover (C) over the combustion chamber temperature sensor and fix it in place ❒ Fit the cover (D) next to the drive of the moving grate Installation Instructions TI 350 | M1830521_en...

  • Page 54: Installing The Broadband Probe And Flue Gas Temperature Sensor

    Assembly Installing the boiler 5.5.28 Installing the broadband probe and flue gas temperature sensor ❒ Screw the brass bushing (A) for the flue gas temperature sensor into the induced draught fan flange ❒ Push the flue gas temperature sensor (B) in so that it protrudes approx. 20 mm from the housing and secure the position with the wing screw ❒...

  • Page 55: Installing The Flue Gas Recirculation (Fgr)

    ➥ Fit the servo-motor with the “L” motor side at the front (orange side) ➥ Flue gas flap must be open in a currentless state ❒ Wire the servo-motor via the cable duct to the control cabinet Installation Instructions TI 350 | M1830521_en...
  • Page 56 Assembly Installing the boiler ❒ Fit the secondary air box (B) to the upper connection with seal ➥ Flue pipe connection top and bottom ❒ Fit the primary air box (C) to the lower connection with seal ➥ Flue pipe connection top only ❒...
  • Page 57 ❒ Version with heat exchanger on the left: Connect pipe section (C) and primary air box to the flue pipe elbow (D) and two flue pipes (G) ➥ Adjust the lengths of the flue pipes ❒ Secure screw connection between induced draught fan and flue gas collecting box Installation Instructions TI 350 | M1830521_en...
  • Page 58 Assembly Installing the boiler ❒ Install differential pressure transmitter (F) right next to secondary air box ❒ Remove blanking plug on the side of the secondary air box and fit hose nipple (E) ❒ Fit air hose to hose nipple (E) using hose clamp ❒...

  • Page 59: Positioning The Ash Container

    ❒ Push the key plate into the safety switch ❒ Set the safety switch so that the key plate engages correctly ❒ Tighten the screws on the safety switch Installation Instructions TI 350 | M1830521_en...

  • Page 60: Flue Gas Piping

    Assembly Installing the boiler 5.5.32 Flue gas piping ❒ Connect the on-site flue gas system to the flue gas collecting box IMPORTANT: Insulate all piping, collecting boxes, induced draught fan and FGR blower fan on site! Make sure the drive assemblies of the blower fans can still be removed.

  • Page 61: Potential Equalisation

    ❒ Place cover (A) onto the combustion chamber ❒ Fit covers (B) on both sides of the control cabinet ❒ Fit side covers (C, F) and covers (D, E) at the back over cable ducts Installation Instructions TI 350 | M1830521_en...

  • Page 62: Connecting The Hydraulic Safety Devices

    Assembly Connecting the hydraulic safety devices 5.7 Connecting the hydraulic safety devices Thermal discharge valve ▪ The thermal discharge safety device must be connected in accordance with ÖNORM/DIN EN 303-5 and as shown in the diagram above ▪ The discharge safety sensor must be connected to a pressurised cold water mains supply (temperature ≤...
  • Page 63 ▪ Installation in boiler return to prevent dirt deposits in the heat exchanger ▪ Position the screw-in part downward so that the sieve can be cleaned easily ▪ TIP: Provide an option for shut-off immediately upstream and downstream of the dirt trap Installation Instructions TI 350 | M1830521_en...

  • Page 64: Cooling Connection

    Assembly Cooling connection 5.8 Cooling connection The following is a schematic diagram Boiler flow Slide-on duct loading pump: ▪ no gravitational brake. Boiler return ▪ Up to 350 kW output: – e.g. Wilo Stratos 30/1-8, Slide-on duct return Grundfos Magna 3 32-80 similar Slide-on duct flow –...

  • Page 65: Final Installation Steps

    ➥ If the paper cannot be removed: door is tightly sealed. ➥ If the paper can be removed: door is not sealed properly - tighten the locking hook! ⇨ See "Adjusting the door" [page 66] Installation Instructions TI 350 | M1830521_en...

  • Page 66: Adjusting The Door

    Assembly Final installation steps 5.9.2 Adjusting the door ❒ Open the combustion chamber door ❒ Loosen the lock nut on the locking hook ❒ Tighten or loosen the locking hook as required ❒ Fix in place using lock-nuts Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 67: Commissioning

    ❒ Check that the drives and servo motors are working and turning in the right direction NOTICE! Check the digital and analogue inputs and outputs - See the instruction manual for the boiler controller. Installation Instructions TI 350 | M1830521_en...

  • Page 68: Initial Startup

    Commissioning Initial startup 6.2 Initial startup 6.2.1 Permitted fuels Wood chips Criterion Designation as per Description acc. to ÖNORM M 7133 ÖNORM M 7133 EN ISO 17225 Water content air-dried suitable for storage Size P16S Fine wood chip P31S Medium-sized wood chip Note on standards Fuel acc.

  • Page 69: Miscanthus

    Using non-standard fuels can also lead to serious problems with combustion. For this reason, when operating the boiler: ❒ Only use permitted fuels Installation Instructions TI 350 | M1830521_en...

  • Page 70: Heating Up For The First Time

    Commissioning Heating up for the first time 6.3 Heating up for the first time NOTICE Optimum efficiency and efficient, low-emission operation can only be guaranteed if the system is set up by trained professionals and the standard factory settings are observed. Take the following precautions: ❒...

  • Page 71: Screed Drying

    500°C. REMEDY: Only keep the combustion chamber door open a fraction! After adding the last batch of firewood: ❒ Allow the fire on the grate to burn out. ❒ Close the combustion chamber door. Installation Instructions TI 350 | M1830521_en...
  • Page 72 Commissioning Heating up for the first time ❒ Leave the boiler in this state for a few hours (ideally overnight). The boiler can then be used in accordance with the operating instructions ("Operating the system" section). Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 73: Decommissioning

    ❒ Ensure that the system is disposed of in an environmentally friendly way in accordance with waste management regulations. ❒ You can separate and clean recyclable materials and send them to a recycling centre. ❒ The combustion chamber must be disposed of as builders' waste. Installation Instructions TI 350 | M1830521_en...

  • Page 74: Notes

    Notes 8 Notes Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 75 Notes Installation Instructions TI 350 | M1830521_en...

  • Page 76: Appendix

    Appendix Addresses 9 Appendix 9.1 Addresses 9.1.1 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 EMAIL info@froeling.com INTERNET www.froeling.com Customer service Austria 0043 (0)7248 606 7000 Germany 0049 (0)89 927 926 400 Worldwide...

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