Froling Turbomat TM 320 Installation Instructions Manual

Text of Froling Turbomat TM 320 User Guide:

• ❒ Fit the upper frame element in the middle of the combustion chamber 4.5.11 Assembling the flange for the heat exchanger ash removal system ❒ 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

• Froling Turbomat TM 320, 4.5.8 Fitting various fittings ❒ Fit the supply air duct for the combustion air fan on the outside of the combustion chamber ➥ Version with heat exchanger on the left: remove the blanking plate from the right and replace it to the left ❒ Attach the spring at the bottom to the clamping bracket on the heat exchanger and at the top to the heat-exchanger lever ❒ Attach the motor mount for the WOS drive to the threaded bolts on the heat exchanger and fix in place using bolts and spacer washe

• ❒ Insert the flow temperature sensor (A) and return feed sensor (B) into the appropriate immersion sleeve ❒ Optional: Cut into the thermal insulation around the jacket cooling air controller (C) but do not remove the insulating material ❒ Hang the insulating side panels at the front of the heat exchanger ❒ Remove the cap and fixing bolt of the high-limit thermos

• Froling Turbomat TM 320, ▪ 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). ▪ Keep the air suction opening of the boiler free of dust. ▪ The system must be protected against the chewing or nesting of animals (e.g. rodents etc.). Ventilation of the boiler room Ventilation air for the boiler room should be taken from and expelled directly outside, and the openings and air ducts should

• Froling Turbomat TM 320, 5 Commissioning 5.1 Before commissioning / configuring the boiler The boiler must be configured to the heating system on initial start-up. 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: ❒ 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 dama

• Froling Turbomat TM 320, ❒ 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 4 Assembly Installing the boiler 38 Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at

• Froling Turbomat TM 320, ❒ 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 ❒ Remove the bolts and spacer washers from the blanking plate and swing out the blanking plate ❒ Swing the oil burner in and fix it in place using the pre-assembled bolts and spacer washers Assembly 4 Installing the boiler Installation Instructions Turbomat TM 320-500 | M0690817_en 73

• Froling Turbomat TM 320, Limit values for filling and make-up water: Austria Germany Switzerland Total hardness ≤ 1.0 mmol/L ≤ 2.0 mmol/L < 0.1 mmol/L Conductivity - <100µS/cm < 100 µS/cm pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5 Chloride < 30 mg/L < 30 mg/L < 30 mg/L Additional requirements for Switzerland The filling and make-up water must be demineralised (fully purified) ▪ The water must not contain any ingredients that could settle and accumulate in the system ▪ This makes the water non-electroconductive, which prevents corrosion ▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can weaken corrosive materials

• Froling Turbomat TM 320, 2.4 Design Information 2.4.1 Notes on standards The system must be installed and commissioned in accordance with the local fire and building regulations. Unless contrary to other national regulations, the latest versions of the following standards and guidelines apply: General standards for heating systems EN 303-5 Boilers for solid fuels, manually and automatically fed combustion systems, nominal heat output up to 500 kW EN 12828 Heating systems in buildings - design of water-based heating systems EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods Part 1: Chimneys serving one appli

• Froling Turbomat TM 320, ▪ The store should be fitted with a pressure release device in accordance with regional regulations. ▪ The same limits apply for the permitted water content of sawdust as for wood chips. NOTICE For fuels with a water content < W30 the boiler's rated heat output can only be guaranteed if it is used with a flue gas recirculation system (FGR). Miscanthus Switchgrass or elephant grass (Latin name: miscanthus) is a C4 plant. Standards and regulations for burning these plants have not been stan

• Froling Turbomat TM 320, ❒ 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. ❒ Position both ash containers on the ash removal unit flanges ❒ Push the side lever on the ash removal unit flange downwards to fix the ash container in place ❒ Push the key plate into the safety switch ❒ Set the safety switch so that the key plate engages correctly ❒ Tighten the safety switch screws 4.5.21 Fitting the combustion chamber ash removal unit (optional) If the heat exchanger is mounted to the left, modify the ash removal un

• Froling Turbomat TM 320, 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 ❒ Position the boiler in line with the discharge system or according to the diagram and connect to the discharge system 4.5.5 Bolting together the combustion chamber and heat exchanger ❒ Position the combustion chamber as per the layout plan, ensuring it is level In the delivery configuration, the blanking plate is mounted on the left-hand flange on the combustion chamber, meaning the heat exchanger can be

• ❒ 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 ➥ Caution: there are 8 holes for the fitted screws which are also for when the heat exchanger is installed to the left. Ensure you always use the holes which are closer to the front of the

• Froling Turbomat TM 320, ❒ 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 lugs on the cross-pieces and lengthways struts on the combustion chamber slot into each other correctly ❒ Fit hexagonal screws to the entire base frame to provide support Assembly 4 Installing the boiler Installation Instructions Turbomat TM 320-500 | M0690817_en 31

• Froling Turbomat TM 320, Installation Instructions Turbomat TM 320-500 Translation of the original German installation instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M0690817_en | Edition 15/03/2017 Fröling GesmbH | 4710 Grieskirchen, Industriestraße 12 | www.froeling.at

• Froling Turbomat TM 320, 5.3 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: ❒ 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: ▪ Electrical installation ▪ Installation of water pipes ▪ Connect flue gas including all insulation work ▪ Work must comply with local fire protection regulation

• Froling Turbomat TM 320, Test data for wood chips - emissions in [mg/m³] 1) (nominal load/partial load) Dust mg/m³ 27 / 11 22 / 16 26 / 16 26 / 16 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% Test data for pellets - emissions in [mg/MJ] (nominal load/partial load) Carbon monoxide (CO) mg/MJ 7 / 8 <2 / <3 <1 / 2 <1 / 2 Nitrogen oxide (NOx) mg/MJ 44 / 46 63 / 71 66 / 71 66 / 71 Organic hydrocarbons (OGC) mg/MJ <2 / <2 <1 / <2 <1 / <2 <1 / <2 Dust mg/MJ 13 / 9 12 / 10 13 / 10 13 / 10 Boiler efficiency % 92.7 / 90.1 93.9 / 92.0 94.4 / 92.0 94.4 /

• Froling Turbomat TM 320, ❒ Lubricate the bolts with copper paste ❒ Fit the intermediate hinges (A) onto the joints on the boiler using long bolts (B) ❒ Fit the end hinges (C) onto the intermediate hinges (A) using long bolts (B) ❒ Mount the blind flange (D) and oil burner flange (E) onto the end hinges (C) using short bolts (F) ❒ 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 4 Assembly Installing the boiler 72 Fröling GesmbH | 4710 Grieskirchen, I

• Froling Turbomat TM 320, 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 ❒ Follow the transport instructions on the packaging ❒ Transport components with care to avoid damage ❒ Protect components against damp ❒ Unloading, positioning and install

• Froling Turbomat TM 320, ❒ 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 ➥ Maintenance area under the moving grate ❒ Position the heat insulation mats on the side of the combustion chamber and fix in place using tension springs ❒ Cut the perforations out of the heat insulation mat on the side of the heat exchanger and remove the insulat

• ❒ 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. ❒ Position the ash container at the ash removal unit flange ❒ Push the lever on the side of the ash removal unit flange downwards to lock the ash container in place ❒ P

• Froling Turbomat TM 320, 4.7 Connecting the hydraulic safety devices 1.1 1.2 1.3 1.5 1.4 1 5 1.6 1 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 ≤ 15°C) in such a way that it cannot be shut off ▪ A pressure reducing valve (1.5) is required for a cold water pressure of ≥ 6 bar Minimum cold water pressure = 2 bar 1.1 Sensor of thermal discharge safety device 1.2 Thermal discharge valve (opens at approx. 95°C) 1.3 Cleaning valve (T-piece) 1.4

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