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Summary of Contents for Fröling Turbomat TM 150
- Page 1 Installation instructions Turbomat TM 150 - 250 Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M0651322_en | Edition 05/01/2023...
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Page 2: Table Of Contents
5.5.13 Fitting the safety temperature limiter, boiler sensor and return sensor........43 5.5.14 Fitting the door contact switch ....................44 5.5.15 Fitting the WOS Drive ........................ 45 5.5.16 Installing the grate drive......................46 M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 3 6.3 Heating up for the first time ........................74 6.3.1 Screed drying..........................75 7 Decommissioning ............................77 7.1 Out of service for long periods ......................77 7.2 Disassembly............................77 7.3 Disposal ..............................77 M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 4: General
Froling. On commissioning by FROLING Customer Service the validity of the delivery certificate will be noted on the customer service record. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 5: Safety
The dangerous situation may occur and if measures are not observed it will lead to minor injuries. NOTICE The dangerous situation may occur and if measures are not observed it will lead to damage to property or pollution. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 6: Qualification Of Assembly Staff
You must ensure that staff have the protective equipment specified by accident prevention regulations! ▪ During transport, erection and installation: - wear suitable work wear - wear protective gloves - wear safety shoes (min. protection class S1P) M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 7: Design Information
Water quality for heating, steam, cooling and air conditioning systems (Switzerland) UNI 8065 Technical standard regulating hot water preparation. DM 26.06.2015 (Ministerial Decree specifying the minimum requirements) Follow the instructions of this standard and any related updates. (Italy) M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 8: Regulations And Standards For Permitted Fuels
▪ Installation at altitude higher than 2000 metres above sea level only after consultation with the manufacturer ▪ The system must be protected against gnawing and nesting by animals (such as rodents) ▪ No flammable materials in proximity to the system M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 9: Chimney Connection/Chimney System
Please note within the permissible operating range of the boiler flue gas temperatures lower than 160K above room temperature may occur. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 10: Connection Line To The Chimney
▪ 1.5 x nominal diameter of connection line for radiation shield with rear ventilation, but at least 200 mm (NM) NOTICE! The minimum distances must be observed in accordance with the standards and guidelines applicable in the region M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 11: Measuring Port
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the pressure is constantly low at this point. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 12: Domestic Hot Water
1. For calculating the specific system volume, the smallest individual heating capacity is to be used for systems with several heat generators. 2. In systems with several heat generators with different specific water contents, the smallest specific water content is decisive in each case. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 13: 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. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 14: Storage Tank
Take the following precautions: r Regulations stipulate the use of a return temperature control. Ä The minimum return temperature is 60 °C. We recommend fitting some kind of control device (e.g. thermometer). M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 15: Technology
Length, combustion chamber excl. insulation 1720 1880 1880 Length, ash container Length, heat exchanger excluding insulation Length, stoker unit Minimum room height 2370 2370 2370 Minimum size of entrance (WxH) 1000x1950 M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 16: Components And Connections
DN65 / PN 6 Boiler flow connection DN65 / PN 6 Safety heat exchanger connection 1/2“ IT Flue gas pipe connection 200 mm 250 mm Broadband probe connection Flue gas temperature sensor connection M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 17: Technical Data
Fuel efficiency at rated heat output (η 82.3 83.3 84.4 Fuel efficiency at 30% of rated heat output (η 81.4 81.8 82.3 Auxiliary current consumption at rated heat output 0.657 0.539 0.416 M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 18: Boiler Data For Planning The Flue Gas System
Required feed pressure at outlet of induced draught housing at nominal load mbar 0.02 Required feed pressure at outlet of induced draught housing at partial load mbar 0.05 Maximum permissible feed pressure mbar Flue gas pipe diameter M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 19: Installation
If the system is to be assembled at a later stage: r Store components at a protected location, which is dry and free from dust Ä Damp conditions and frost can damage components, particularly electric ones! M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 20: Setting Up In The Boiler Room
▪ Observe the applicable standards and regulations when setting up the system! ▪ Comply with additional standards for noise protection! (ÖNORM H 5190 - Noise protection measures) 800 mm 300 mm 400 mm 400 mm 2,370 mm M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 21: Installing The Boiler
If the heat exchanger is to be installed to the left, the steps should be carried out in the same way but on the other side. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 22: Bolting Together The Combustion Chamber And Heat Exchanger
Align the combustion chamber before you fix it to the heat exchanger. Align it with the two referencing stops. Referencing stop on the heat exchanger Referencing stop on the base frame M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 23 On the back of the combustion chamber, remove the blanking plugs for combustion chamber overpressure sensor, the combustion chamber temperature sensor, the automatic ignition and the underpressure controller. r On the back of the combustion chamber, remove the support. M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 24: Fitting The Thermal Discharge Safety Sensor
Push the thermal discharge safety sensor (3) into the immersion sleeve (2). r Push the protective tube over the thermal discharge safety sensor and then slightly tighten the fixing screw (4). M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 25: Installing The Combustion Chamber Firebricks
Pass the ceramic fibre mats through the opening in the heat exchanger and lay them in the combustion chamber as shown in the figure. Ä Ensure that you lay two mats alongside each other on the heat exchanger side. M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 26 Pass the firebricks through the opening in the heat exchanger and lay them on the ceramic fibre mats as shown in the figure. Ä Tip: Positioning the firebricks is easier with two people standing on the opposite sides of the chamber. M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 27: Changing Over The Wos Rods (Where Necessary)
Lock the clamping pad (3) on the EOS lever (4) and pull it out of the EOS shaft (5). r Remove the clamping bracket (6) and fit it on the opposite side. M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 28 Refit the bearing bush (9) and blanking plug (10) that you removed previously on the opposite side. r Attach the EOS shaft (5) and clamping pad (8) to the side of the bearing bush (9) M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 29: Fitting The Insulation Base Frame
Position the heat insulation mat (1). r Position the cable duct (2) on top and fix it to the heat exchanger. r Fit the cross-piece (3) of the upper base frame to the cable duct (2). M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 30 Fit the frame component (3) for the insulation door at the top to the front lengthways strut (1) and at the bottom to the brackets. r Align the frame component (3) with the adjustable feet. M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 31: Fitting The Insulating Side Panels
Hang the insulation side panel at the top at the bracket (2) of the base frame. r Fix the insulation side panel at the top to the base frame with two screws. NOTICE! Fit all the other side panels in the same way. M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 32 Fit the insulation side panel to the front of the heat exchanger. r Fit the insulation side panel to the right-hand side of the combustion chamber. Ä Fix it to base frame at the frame with four screws. M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 33: Fitting The Ash Cans To The Heat Exchanger Ash Removal Unit
Fit the blanking plate (1) complete with the seal gasket (2) to the flange plate (3). r Fit both flange plates to the back of the heat exchanger. r Fitting the cover M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 34: Fitting The Heat Exchanger Ash Removal Unit With Ash Screw (Optional)
Ä The key groove in the ash screw must be aligned with the key groove in the gear motor. r Slide the motor key (5) into the groove. r Fit the sprocket (6). r Slide the sprocket key (7) into the groove and fit the shaft retainer (8). M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 35 Set the sprocket on the chain tensioner so that all the three sprockets are aligned with each other. r Wind the roller chain onto the motor and bearing bracket sprockets. Tension the chain and fix in place with the spacer sleeve. M0651322_en | Installation instructions Turbomat TM 150 - 250...
- Page 36 Assemble the ash removal unit flange as shown in the figure below: M8x25 hexagonal head screw Ash removal flange Spring washer Locking lever Bush M8 toothed washer M8 nut Plastic grip M0651322_en | Installation instructions Turbomat TM 150 - 250...
- Page 37 Bend the clamp (3) over the insulation side panel. Lay the safety switch cable to the control cabinet. r Fit the cable duct under the safety switch. Ä Insert the clamps into the insulation. Fold the cable duct upwards and fasten with screws. M0651322_en | Installation instructions Turbomat TM 150 - 250...
- Page 38 Push the side lever on the ash removal flange downwards to fix the ash can in place. r Push the key plate into the safety switch. r Set the safety switch so that the key plate engages correctly. r Tighten the safety switch screws. M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 39: Fitting The Combustion Chamber Ash Removal Unit
First fit the shaft retainer washer (6) followed by the angle bracket (7) and then the screw for the shaft retainer (6) r Fit the cover (8) to the insulation side panel 4 - 5mm M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 40 Fit the ash removal unit flange and seal on the right hand side of the combustion chamber r Slide the sensors into the clamping plate r Fit the cover on to the ash removal flange M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 41: Fitting The Control Cabinet
Open the control cabinet door. Fix the bottom corners of the control cabinet to the insulation side panel. r Fit the cable duct (4) on top of the control cabinet. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 42: Fitting The Combustion Air Fan
Run the temperature sensor cable to the control cabinet r Fit the combustion air fan complete with the ceramic fibre seal. TM 200-250 r Fit the combustion air fan complete with the ceramic fibre seal. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 43: Fitting The Safety Temperature Limiter, Boiler Sensor And Return Sensor
(2) of the boiler flow r Push the return flow sensor into the immersion sleeve of the boiler return. r Lay all the sensor cables in the cable duct to the control cabinet. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 44: Fitting The Door Contact Switch
Ä Lay the connecting cable through the opening in the frame element and then onwards to the control cabinet. r Fit the side cable duct (4). r Fit the cover (5). M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 45: Fitting The Wos Drive
Ä The motor must face downwards. r Position the bracket (8) for the function monitor behind the motor mounting bracket (1) and then fix in place together with gear motor (5) with the two bottom screws. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 46: Installing The Grate Drive
Slide the key (5) into the groove and fit the shaft retainer (6). r Fit the seal (2) and the blanking flange (7) on the opposite side to the gear motor (4). M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 47: Installing The Stoker Unit
Fit the stocker unit complete with the ceramic fibre seal to the slide-on duct. r Adjust the stoker unit with the adjustable foot and then tighten the screw on the adjustable foot. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 48: Installing The Induced Draught Fan
Fit the discharge system (feed screw, etc.) according to the installation instructions enclosed. 5.5.18 Installing the induced draught fan r 4x Fit the rubber buffers to the induced draught fan. r 2x Fit the adjustable feet to the induced draught fan M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 49 Adjust the induced draught bracket with the adjustable feet. NOTICE! The ID fan must be insulated by the customer! Make sure the drive assembly of the induced draught fan can be removed. M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 50: Fitting The Primary And Secondary Air Servo Motors
Set the direction of rotation of the servo-motor (1) to left (L). r Press the unlock key (2) and turn the drive for the shaft to the air duct (3) to the left as far as the stop M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 51 Mount primary air servo motor (2) on the pneumatic rods. Ä The connecting cable must face upwards. r Close off the openings with heat insulation mats (3). r Fit the cover plates (4). M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 52: Fitting The Cover On The Slide-On Duct
Fit the upper cover plate (4) and screw to the insulation side panel and the side cover plates. On versions with NO FGR: r Close off the opening for the FGR duct with heat insulation mats (5). r Fit the cover plate (6). M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 53: Installing The Underpressure Controller
Insert the double wire hose clip (2) on the igniter tube (1). r Insert the ignition blower (3) into the igniter tube (1) and fix in place using the double wire hose clip (2). M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 54: Installing The Combustion Chamber Overpressure And Temperature Sensors
Unscrew the connector box cover. Connect up the compensating line as follows: - green wire to the terminal with the green dot - white wire to the unmarked terminal - shield not connected up. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 55: Fitting The Temperature Sensor Under The Moving Grate
Fit the cover (7). 5.5.25 Fitting the broad band probe and flue gas sensor r Screw the bushing (1) into the sleeve and gently tighten M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 56: Install The Flue Gas Recirculation (Fgr) (Optional)
Fit the connecting bracket (5) with the fibreglass seal (2) to the lower FGR duct (6). r Position the fibreglass seal (2) and fit the upper FGR duct (3) and lower FGR duct (6). M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 57 Ä The servo-motor must be on the left stop and mounted so that the direction of rotation left (“L”) is visible r Install the air vane on the flue gas bracket M0651322_en | Installation instructions Turbomat TM 150 - 250...
- Page 58 Wrap the heat insulation mat (2) around the upper FGR duct and fix in place using spring clips at the bottom. r Wrap the heat insulation mat (3) around the lower FGR duct and fix in place using spring clips at the top. M0651322_en | Installation instructions Turbomat TM 150 - 250...
- Page 59 Insert the heat insulation removed previously (1) on the end of the FGR duct and fit the side cover plate (2). r Fit the cover plates on the flange (3) and the lower FGR duct (4). r Fit the servo motor to the connecting bracket. M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 60: Fitting The Covers To The Back Of The Heat Exchanger
Fit the cover (5) and the cover plate (4) on the WOS drive. 5.5.28 Fitting the insulated doors and the ash container to the combustion chamber r Hang the insulated doors on the hinge pins on the frame M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 61: Connect The Electrostatic Precipitator (Optional)
▪ B – Upper flue gas connection: Clean gas outlet (pipe to the induced draught) r Refer to the enclosed instructions for the electrostatic precipitator for all steps pertaining to installation and operation M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 62: Hydraulic Connection
≤ 300 kW), DN40 (> 300 to ≤ 600 kW), DN50 (> 600 to ≤ 900 kW) ▪ Maximum pressure setting in terms of the permissible operating pressure of the boiler, see the section “Technical Data” M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 63 ▪ Its size must comply with the design information in EN 12828 - Appendix D ▪ Ideally it should be installed in the return line. Follow the manufacturer’s installation instructions We recommend installing some sort of monitoring device (such as a thermometer) M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 64: Connecting The Slide-On Duct Cooling (From 200 Kw)
2.5 m 9 Safety valve DN15 General requirement: All pipe connections must be capable of being shut off and disassembled for maintenance work. Do not employ any press-fit connections. M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 65 2.5 m 9 Safety valve DN15 General requirement: All pipe connections must be capable of being shut off and disassembled for maintenance work. Do not employ any press-fit connections. M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 66: Power Connection And Wiring
Establish potential equalisation to all boiler components Ä Fuel outfeeder, ash removal, induced draught fan, FGR blower fan, flue gas pipe, pipes, control cabinet etc. IMPORTANT: The potential equalisation must comply with current directives, regulations and standards. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 67: Fitting The Insulation Cover And The Cover Plate
Fit the cable duct cover (5). r Fit the cover (6) on top of the combustion chamber. r Lay the insulation mat (7) on the right on top of the heat exchanger. Fit the cover (8). M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 68: Final Installation Steps
Ä The door can be closed with a normal amount of effort: Setting OK Ä The cannot be closed or can only be closed with great effort. Push the locking plate toward the front. Ü "Setting the combustion chamber door" [} 70] M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 69 The door is sealed. Ä If the paper can be removed: The door is not sealed properly - Push the locking plate toward the back. See also 2 Adjusting the combustion chamber doors [} 70] M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 70: Adjusting The Combustion Chamber Doors
Ä Caution: The locking plate must be aligned in the same way at the top and bottom. r Fix the locking plate in position at the top and bottom with the lock nuts (1). M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 71: 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. M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 72: Initial Startup
General note: Before refilling the store, check for pellet dust and clean if necessary. TIP: Fit the Froling PST pellet deduster for separating the dust particles contained in the return air M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 73 Therefore: r If the fuel is changed (e.g. from wood chips to pellets), the system must be reset by Froling customer services. M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 74: Non-Permitted Fuels
Provide the following quantities of dry firewood: Ä Systems up to 250 kW: ¼ m³ Ä Systems up to 500 kW: ½ m³ Ä Systems up to 1500 kW: 1 m³ M0651322_en | Installation instructions Turbomat TM 150 - 250... -
Page 75: Screed Drying
Set the boiler to user level “Service technician” and activate “Baking mode” in the quick selection menu. r Fill combustion chamber with approx. 1/3 of the firewood provided. r Ignite firewood and allow to burn away with the combustion chamber door half open. M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 76 Close the combustion chamber door. r 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). M0651322_en | Installation instructions Turbomat TM 150 - 250...
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Page 77: Decommissioning
(e.g. AWG in Austria) r You can separate and clean recyclable materials and send them to a recycling centre. r The combustion chamber must be disposed of as builders' waste. M0651322_en | Installation instructions Turbomat TM 150 - 250... - Page 78 M0651322_en | Installation instructions Turbomat TM 150 - 250...
- Page 79 M0651322_en | Installation instructions Turbomat TM 150 - 250...
- Page 80 Manufacturer’s address Froling srl Froling SARL Fröling Heizkessel- und Zweigniederlassung Behälterbau GesmbH Aschheim Industriestraße 12 Max-Planck-Straße 6 Via J. Ressel 2H 1, rue Kellermann A-4710 Grieskirchen 85609 Aschheim I-39100 Bolzano (BZ) F-67450 Mundolsheim +43 (0) 7248 606 0 +49 (0) 89 927 926 0 +39 (0) 471 060460 +33 (0) 388 193 269 info@froeling.com...
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