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Installation Instructions Turbomat TM 300-500 Translation of the original German installation instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M0690616_en | Edition 10/03/2016 Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at...
Table of contents Table of contents General Safety Hazard levels of warnings Qualification of assembly staff Personal 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 Regulations and standards for permitted fuels 2.4.2 Installation and approval of the heating system...
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Changing the fuel 5.2.2 Non-permitted fuels Heating up for the first time 5.3.1 Screed drying 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 300-500 | M0690616_en...
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 guidelines. Please read and observe the documentation provided and always keep it close to the system for reference.
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 300-500 | M0690616_en...
Assembly, installation, initial startup and servicing must always be carried out by qualified personnel: - Heating technician / building technician - Electrical installation technician - Froling customer services The assembly staff must have read and understood the instructions in the documentation. 2.3 Personal protective equipment for assembly staff You must ensure that staff have the protective equipment specified by accident prevention regulations.
Solid bio-fuel - Fuel specifications and classes Part 2: Wood pellets for use in industrial and domestic systems EN ISO 17225-4 Solid bio-fuel - Fuel specifications and classes Part 4: Wood chips for non-industrial use Installation Instructions Turbomat TM 300-500 | M0690616_en...
Safety Design Information 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 EN 12828 - Heating Systems in Buildings NOTICE! Each heating system must be officially approved. The appropriate supervisory authority (inspection agency) must always be informed when installing or modifying a heating system, and authorisation must be obtained from the building authorities:...
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 into the heating water. Installation Instructions Turbomat TM 300-500 | M0690616_en...
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 85]...
Technology Dimensions 3 Technology 3.1 Dimensions Item Designation Unit TM 300/320 TM 400/500 Boiler height including insulation 2560 2660 Height of return connection Height of flow connection 1850 2000 Height of stoker including burn back protection system Height, flue gas pipe connection without FGR Height, flue gas pipe connection with FGR 2005 2075...
Technology Technical specifications 3.3 Technical specifications Description Nominal output Heat output range 90-300 96-320 119-399 149-499 Electrical connection 400V / 50Hz / C35A or as per circuit diagram Power consumption (pellets / wood chips) 1.27 / 1.6 1.27 / 1.6 1.38 / 1.75 1.57 / 2.08 Total weight incl.
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20 / 13 17 / 15 19 / 15 1. Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13% Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Transport 4 Assembly DANGER Risk of falling when working at a height Therefore: ❒ Implement appropriate measures in accordance with the applicable national industrial safety guidelines to protect against the risk of falling (e.g. ladders, platforms, etc.) 4.1 Transport NOTICE Possibility of damage to components if handled incorrectly ❒...
❒ 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. Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Setting up in the boiler room 4.4.2 Minimum distances in the boiler room ▪ The system should generally be set up so that it is accessible from all sides allowing quick and easy maintenance. ▪ Regional regulations regarding necessary maintenance areas for inspecting the chimney should be observed in addition to the specified minimum distances! ▪...
The only differences are when installing the insulating side panels in the TM 300/320 and TM 400/500 which are described separately in the section entitled “Assembling the insulating side panels”. ⇨ See "Installing the insulating side panels" [page 38] Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler 4.5.2 Installing the grate drive ❒ Assemble the crank shaft ➥ Push/pull the moving grate forwards with the help of a suitable tool ➥ The crank shaft should face outwards! ❒ Assemble the blind flange opposite the crank shaft ❒...
❒ Fit the discharge system (feed screw, etc.) according to the installation instructions enclosed ❒ Position the boiler in line with the discharge system or according to the diagram and connect to the discharge system Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler 4.5.4 Installing the hydraulic stoker unit (optional) ❒ Fit the hydraulic stoker unit to the slide-on duct ❒ Align the entire stoker unit with the adjustable feet ❒ Fit the discharge system (feed screw, etc.) according to the installation instructions enclosed ❒...
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❒ Check the distance between the heat exchanger and the combustion chamber ➥ A: TM 300/320: 51 mm / TM 400/500: 63.5 mm ➥ B: TM 300-500: 88 mm ➥ Max. permissible deviation: +/- 8 mm Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ Ensure the entire system is level by adjusting the feet (C) ➥ Check that none of the adjustable feet are loose ❒ Slide the insulation sheet steel panel under the heat exchanger ❒ Place 3 insulating panels on the insulation sheet ➥...
4.5.7 Repositioning the EOS rods (if required) The WOS drive is always fitted to the back of the boiler. If the heat exchanger is installed on the left, you will need to change over the WOS rods as follows. Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ Open the heat exchanger covers ❒ Loosen the clamping jaw and remove the heat-exchanger lever from the shaft ❒ Remove the cover plate with the clamping bracket and fit it on the opposite side ❒ Remove the spacer sleeve (A) from the shaft ❒...
❒ Attach the motor mount for the WOS drive to the threaded bolts on the heat exchanger and fix in place using bolts and spacer washers Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler Version with heat exchanger on the left: ❒ Remove the primary air controller and replace on the opposite side of the stoker ➥ The air controller must be on the outside of the combustion chamber! For the oil burner pivoting mechanism (optional): ❒...
❒ Fit the angled elements to the outside of the heat exchanger ❒ Attach the lengthways strut to the angled elements ❒ Fit the lengthways struts to both sides of the combustion chamber Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ Fit the cross-pieces on the back of the lengthways struts ➥ Ensure that the lugs on the cross-pieces and lengthways struts on the combustion chamber slot into each other correctly ❒ Fit the cross-pieces on the front of the lengthways struts ➥...
❒ Ensure that the heat exchanger ash removal baffle plates are positioned correctly ❒ Assemble the flange for ash removal from the heat exchanger ➥ The flange for the induced draught box should face outwards from the back! Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler 4.5.12 Fitting thermal insulation to the boiler ❒ Cut the perforations out from the heat insulation mat and remove the insulating material ❒ Attach the heat insulation mats to the front and back of the heat exchanger ash removal system ❒...
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❒ Cut the perforations out of the heat insulation mat at the front and remove the insulating material ➥ Combustion air fan supply air ❒ Lay the heat insulation mats on top of the combustion chamber and fix in place using tension springs Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ Cut through and remove the rear part of the heat insulation (A) from the heat insulation mat to be attached to the side of the heat exchanger ❒ Cut out the insulating material from the rear part of the heat insulation mat on the combustion chamber from the perforations (B) but do not remove it ➥...
❒ Remove the blanking plate and align the FGR duct 4.5.14 Assembling the upper insulation base frame ❒ Assemble the lengthways strut on the outside of the combustion chamber to the upper frame element ➥ Partially tighten the screws Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ Insert the combustion chamber support elements on both sides into the base frame at the front and back ❒ Attach the outside support elements to the upper lengthways strut at the front and back ➥ The lugs must be aligned properly! ➥...
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❒ Fit the cross-pieces on the front and back of the combustion chamber to the lengthways struts ➥ Partially tighten the screws ❒ Insert the heat exchanger support elements into the base frame Installation Instructions Turbomat TM 300-500 | M0690616_en...
The procedures for assembling the insulating side panels on the Turbomat TM 300/320 and TM 400/500 are different. ⇨ See "Turbomat TM 300/320" [page 39] ⇨ See "Turbomat TM 400/500" [page 45] The assembly steps are then the same for all boiler sizes from the following chapters.
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❒ Cut the pre-punched blanking around the connection to the slide-on duct cooling (E) and drainage (F) from the insulation ❒ Hang the insulating side panel on the back of the heat exchanger Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler For the oil burner pivoting mechanism (optional): ❒ Cut out the pre-punched blanking around the cover (A) and joints (B) on the pivoting mechanism and remove the thermal insulation beneath ❒ Install the 4 fitted screws (C) with washers ➥...
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❒ Optional: Cut into the thermal insulation around the jacket cooling air controller (C) but do not remove the insulating material ❒ Hang the insulating side panel at the front of the heat exchanger Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ Remove the cap and fixing bolt of the high-limit thermostat (STL) (A) ❒ Push the STL (A) from the back and through the cover plate ❒ Refit the lock nut to the front of the STL. Refit the cap ❒...
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❒ Cut out the pre-punched blanking around the FGR flange insulation ➥ Turn the FGR duct insulation 180° when installing the heat exchanger on the left ❒ Fit the insulation for the FGR duct Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ Cut off the insulating side panel along the perforations on the FGR duct ❒ Cut out the pre-punched blanking around the slide-on duct flow (A) insulation ❒ Optional: Cut out the pre-punched blanking around the slide-on duct automatic ignition (B) insulation ❒...
Turbomat TM 400/500 Assembling side panels on the TM 300/320 ⇨ See "Turbomat TM 300/320" [page 39] ❒ Cut out and remove half of the thermal insulation for the heat-exchanger drive (A) and the thermal insulation for the WOS bracket (B) ❒...
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Assembly Installing the boiler ❒ Optional: Cut out the pre-punched blanking around the combustion chamber ash removal (A) insulation and cut out and remove the thermal insulation beneath ❒ Cut out and remove the thermal insulation around the supply air duct (B) and combustion air fan (C) ❒...
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❒ Fit the cover plate with STL to the insulating side panel ❒ Run all the cables from the sensors out through the insulation ❒ Hang the insulating side panels on the heat exchanger Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ When you have finished fitting all the side panels, check that they fit correctly and bolt them to the base frame ➥ Check that the insulating side panels are flush and check that there are no gaps between them ❒...
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❒ Cut out the pre-punched blanking around the slide-on duct flow (A) insulation ❒ Optional: Cut out the pre-punched blanking around the slide-on duct automatic ignition (B) insulation ❒ Fit the insulating side panel above the slide-on duct Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler ❒ Wrap the heat insulation mat around the slide-on duct ❒ Assemble the upper cover plates; hang the upper cover plate to the back of the boiler using the hooks and then fix using screws ➥ Heat exchanger right: fit the cover plates so that the front cover plate is slightly to the left (A) ➥...
❒ 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. Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler 4.5.18 Installing the air flap actuators ❒ Check that the air flaps are at the left stop ➥ All air flaps should be are closed ➥ Where necessary, turn the air flaps to the left stop using pliers ❒...
➥ Caution: fit the servo-motor with the “L” motor side at the front 4.5.19 Assembling different cover plates ❒ Install the cover plates as shown ➥ Cover plate (A) optional for jacket cooling Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler ❒ Install the cover plates as shown ➥ If an (optional) jacket cooling is installed, the pre-punched blanking for the jacket cooling servo-motor must be cut out at the two-part cover plate (A) 4.5.20 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...
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❒ Slide the sprocket key (F) into the groove and fit the shaft retainer (G) ❒ Insert the flange plate with the ash screw into the heat exchanger on the back of the boiler and fix in place with screws Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ Set the sprocket on the chain tensioner so that all the three sprockets are aligned with each other ❒ Wind the roller chain onto the motor and bearing block sprockets. Tension the chain and fix in place with a chain lock ❒...
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❒ Fit the cover plate under the ash removal unit flanges ❒ Assemble the safety switch on the brackets ❒ Align and fit both safety switches complete with brackets to the insulating side panel ➥ Do not fully tighten the screws yet Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler ❒ Press the clamp forwards and remove the ash container coupling caps ➥ Store the coupling cap in a suitable location where you can find it later. It will be needed when disposing of the ash. ❒...
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❒ Fit the geared motor onto the shaft stub ➥ Ensure the groove the shaft stub is aligned with the groove in the geared motor ❒ Slide the key into the groove and fit the shaft retainer Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler ❒ Press the clamp forwards and remove the ash container coupling caps ➥ Store the coupling cap in a suitable location where you can find it later. It will be needed when disposing of the ash. ❒...
4.5.23 Fitting the FGR blower fan ❒ Remove the thermal insulation and cover plate from the FGR bracket on the back of the heat exchanger ❒ Fit the FGR bracket and replace the thermal insulation Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler 180° ❒ Remove the drive assembly from the FGR blower fan, rotate 180° and re-fit ➥ Makes the connection easier ❒ Fit the FGR blower fan with the rubber buffers on the bracket and level ➥ TIP: Use the spacers (A) provided to align the FGR blower fan. ❒...
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➥ Cut out the upper cover plate pre-punched blanking on the side of the heat- exchanger drive NOTICE! The FGR blower fan must be insulated by the customer! Make sure the drive assembly of the FGR blower fan can be removed. Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler 4.5.24 Installing the induced draught fan ❒ Mount the induced draught fan bracket onto the flange ➥ Align correctly using the adjustable feet and fix in place using the spacer washer and hexagon bolt ❒ Fit the flue pipe compensator and screws complete with spring washers and spacer washers to the induced draught fan bracket ➥...
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❒ Push the flue gas temperature sensor (D) in so that it protrudes approx. 20 mm from the housing (E) and secure it in position with the wing screw ❒ Wrap the heat insulation mat around the induced draught fan flange and fix in place using tension springs Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler ➥ Run the cable from the broadband probe and flue gas temperature sensor out from the thermal insulation ❒ Cut out the upper cover plate from the perforation ❒ Cut out the pre-punched blanking for the ash removal and motor on the cover plate on the side of the combustion chamber ❒...
❒ Place the double screw clip (B) onto the igniter tube (A) ❒ Insert the ignition fan (C) into the igniter tube (A) and fix in place using the double screw clip (B) ❒ Fit the cover (D) Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler Fitting the automatic ignition to the slide-on duct (optional): ❒ Remove the blanking plug ❒ Insert the igniter tube (A) ❒ Attach the double nipple (B), sleeve (C) and elbow (D) to the igniter tube (A) ❒...
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❒ Fit the burning and combustion chamber door covers and adjust ❒ Attach the spherical handle to the combustion chamber inspection glass ❒ Place the insulating covers on top of the combustion chamber ❒ Close the heat exchanger cover Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Installing the boiler ❒ Lift the four screws on the outside of the heat exchanger cover and tighten using bolts ❒ Insert a washer into the two central threaded bolts and fix in place using nuts ❒ Fit both heat exchanger insulating covers 4.5.29 Fitting the pivoting mechanism for the oil burner (optional) ❒...
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❒ Fit the safety switch with the securing plate to the joint next to the oil burner flange ❒ Fit the oil burner onto the oil burner flange ❒ Place thermal insulation around the oil burner flange ❒ Fit the cover plate to the oil burner flange Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Installing the boiler ❒ Fit the safety switch onto the bracket and then the bracket onto the insulation under the opening for the oil burner pivoting mechanism ❒ Place covers on the fitted screws in the insulation Inserting the oil burner ❒...
❒ Tie any loose hanging cables to the drive motors using cable ties. The cables must not come into contact with the stoker duct! CAUTION! Lay the cables from components without risk of stumbling! NOTICE! To save from damage use cable ducts or conduits for laying! Installation Instructions Turbomat TM 300-500 | M0690616_en...
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Assembly Power connection and wiring ATTENTION: At following areas no electric installations are allowed: ▪ Entire top of boiler (heat exchanger and combustion chamber) ▪ Entire front of boiler ▪ Minimum distance of 150 mm to insulation of the FGR duct ▪...
▪ 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 Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Connecting up the slide-on duct cooling 4.8 Connecting up the slide-on duct cooling The following is a schematic diagram Boiler flow Slide-on duct loading pump: ▪ No gravitational brake. Boiler return ▪ Flow rate approx. 2m ▪ Output up to 500 kW: e.g. Wilo Slide-on duct flow Yonos Para 25/1-4, Yonos Pico 25/1-4, Grundfos alpha2 25-40 or...
➥ If the paper cannot be removed: the door is sealed. ➥ If the paper can be removed: the door is not sealed properly - tighten the locking hook! ⇨ See "Adjusting the doors" [page 78] Installation Instructions Turbomat TM 300-500 | M0690616_en...
Assembly Final installation steps 4.9.2 Adjusting the doors The example below shows how to position the combustion chamber door. The procedure is the same for checking the seal on the combustion chamber door. ❒ Loosen the nut on the locking hook ❒...
Take the following precautions: ❒ Initial startup should be carried out with an authorised installer or with Froling customer services NOTICE Foreign bodies in the heating system impair its operational safety and can result in damage to property.
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 permitted only with authorisation from Froling. The following additional points also apply: ▪ Sawdust and carpentry waste should only be used with systems with a rotary valve.
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 Turbomat TM 300-500 | M0690616_en...
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: ▪...
NOTICE! Fissures in the fireclay are normal and do not indicate a fault. NOTICE If condensation escapes during the initial heat-up phase, this does not indicate a fault. ❒ Tip: If this occurs, clean up using a cleaning rag. Installation Instructions Turbomat TM 300-500 | M0690616_en...
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. ❒...
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