installation instructions - wpstatic.idium.no · 4.2 mothballing 40 4.3 disassembly 40 4.4 disposal...

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Fröling Heizkessel- und Behälterbau Ges.m.b.H O Industriestraße 12 O A-4710 Grieskirchen Tel +43 (0) 7248 606-0 O Fax +43 (0) 7248 606-600 O [email protected] O www.froeling.com Installation Instructions Turbomat 150 / 220 Read and follow the installation instructions and safety instructions. All errors and omissions excepted.

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Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen

Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com

Installation Instructions

Turbomat 150 / 220

Read and follow the installation instructions and safety instructions.

All errors and omissions excepted.

Contents

Page 2 M 065 01 08 sa

C

1 Notes on Assembly 4 1.1 Notes on Standards 4

2 Technology 5 2.1 Dimensions 5 2.2 Components and Connections 6 2.3 Technical Specifications 7

2.3.1 Chimney ..........................................................................................7 Using a Brick Chimney.....................................................................8

3 Installation 9 3.1 Transport 9

3.1.1 Temporary storage ............................................................................9 3.2 Setting up in the boiler room 9 3.3 Preparatory Work 10

Detaching the blank cover.............................................................. 10 Removing the Blind Plug ................................................................ 11

3.4 Installing the boiler 12 Installing the insulation mounting brackets....................................... 12 Installing the Grate Drive............................................................... 13 Installing the Ash Removal Chamber ............................................... 14 Installing the Heat Exchanger Ash Removal Unit................................ 16 Installing the Insulating Side Panels ................................................ 17 Installing the Cleaning Door Frame.................................................. 22 Installing the Combustion Chamber Door Frame................................ 24 Installing the WOS Drive................................................................ 26 Installing the Actuators.................................................................. 27 Installing the Underpressure Controller ............................................ 28 Installing the Over-pressure Monitor................................................ 28 Installing the Combustion Chamber Temperature Sensor.................... 29 Installing the Safety Temperature Limiter (STL) and Boiler Sensor....... 29 Installing the Insulating Cover ........................................................ 30 Installing the Lambda probe ........................................................... 30 Installing the Flue Gas Sensor ........................................................ 30 Installing the Induced Draught Unit Housing ..................................... 31 Installing the Delivery Unit ............................................................. 33 Installing the Combustion Air Blower Fan (Turbomat TM 150).............. 34 Installing the Combustion Air Blower Fan (Turbomat TM 220).............. 34 Installing the Grate Thermostat ...................................................... 35 Installing the Shutter Masks ........................................................... 35 Installing the Electric Ignition ......................................................... 36 Installing the Ash Container ........................................................... 36 Installing the Flue Gas Return......................................................... 37

3.5 Electrical Connection 39 Potential Equalisation .................................................................... 39

3.6 Connecting the Thermal Discharge Safety Device 39

Contents

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 3 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

C4 Startup / Shutdown 40

4.1 Commissioning / Configuring the Boiler 40 4.2 Mothballing 40 4.3 Disassembly 40 4.4 Disposal 40

5 Delivery Certificate - TM 150/220 41

Notes on Assembly

Page 4 M 065 01 08 sa

1

1 Notes on Assembly

CAUTION

Assembly and installation by untrained personnel!

Risk of injury and damage to equipment!

Only trained technicians should assemble and install the system (i.e. heating installers or licensed electricians)!

1.1 Notes on Standards

The boiler must be installed and commissioned in compliance with local fire and building regulations and the following standards:

Safety Devices ÖNORM 7425

DIN 4751

TRVB H118

Chimney Connection ÖNORM / DIN EN 13384

DIN 4705-1, 18160-1

Feed Water ÖNORM / DIN EN 12828

ÖNORM H 5195-1

VDI 2035

Structural Devices, Supply Air Cross-Section ÖNORM 5170, 7137

TRVB 118

Electronics Installation, Potential Equalization ÖVE EN 1

VDE 0100

Fuel ÖNORM 7132, 7133, 7135

DIN 51731

PVA Standard

PVD Standard

1.BImSchV

For Industrial Systems FAV

Dear installer,

Please confirm that you have received the product in good condition.

Please send Fröling a copy of the enclosed delivery certificate, completed and signed by the customer.

Thank you!

Technology Dimensions and Connections

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 5 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

2

2 Technology

2.1 Dimensions

Dimensions Description Unit TM 150 TM 220

H1 Height of boiler 1875

H2 Total height with flue gas return (heat exchanger, left)*

2280

H3 Height of flue gas pipe connection with flue gas return

1270 1380

H4 Height of flue gas pipe connection 750 1060

H5 Height of boiler return feed 495

H6 Height of the boiler outfeed

mm

1930

B1 Width of boiler 1200 1485

B2 Length of stoker (inc. gears) mm

845 895

L1 Total length of the system 3595 3685

L2 Total length of boiler 1865 1910

L3 Length of the ash removal chamber ash trolley

mm

930

*) Total height refers to the height of the flue gas pipe connection at the heat exchanger, left.

NOTICE

The following minimum directions apply for installation in the boiler room:

Minimum clearance height = 1950 mm Minimum clearance width = 1000 mm

Technology Dimensions and Connections

Page 6 M 065 01 08 sa

2 2.2 Components and Connections

Pos. Description Unit TM 150 TM 220

A Boiler outfeed connection

B Boiler return feed connection DN 65

C Thermal discharge safety device connection 1/2

Not shown

Drain Inch

3/4

D Flue gas pipe connection mm 200 250

1 Cleaning door

2 Combustion chamber door

3 Electric ignition

4 Geared motor for ash removal unit – chamber

5 Geared motor for ash removal unit – heat exchanger

6 Ash trolley for ash removal – chamber (not shown: ash box for ash removal - heat exchanger)

7 Geared motor for material delivery (stoker )

8 Induced draught unit housing with blower

9 Flue gas return with blower motor (optional flue gas return)

A

1

C

B

D

7

9

6 3

2

4 5 8

Technology Technical Specifications

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 7 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

2

2.3 Technical Specifications

Description Unit TM 150 TM 220

Rated heat output (at W20) 150 220

Fuel heat output (at W20) kW

164.6 241.8

Required fuel consumption (G50 W20) kg/h 42 62

Heat exchanger surface area m² 16.07 17.39

Total weight of the boiler 1925 2655

Weight – chamber 940 1355

Weight – heat exchanger

kg

1050 1300

Boiler water volume l 440 570

Permitted operating pressure bar 3

Max. permitted temperature 110

Permitted operating temperature (outfeed temperature) 95

Minimum return feed temperature

°C

65

Water side resistance (ΔT = 20K) mbar 15.6 15.0

Flow (ΔT = 20K) (ΔT = 15K)

m³/h 6.44 8.60

9.45 12.61

Chimney design data:

Flue gas pipe diameter mm 200 250

Flue gas temperature at rated load °C 190

Flue gas mass flow under rated load (G50 W20, 10% O2, flue gas temp. 190 °C

m³/h kg/h

664 502

885 670

Draught requirement at induced draught fan outlet Pa 2 2

2.3.1 Chimney

Correctly sizing the chimney is important to ensure trouble-free operation of the system. The dimensions must be calculated according to the standard

See “1.1 Notes on Standards”

The flue gas values for the calculation should be taken from the technical specifications. It is important to keep in mind that flue gas temperatures under 150 °C are produced in the lower output range (below 50% of the rated heat output). It is necessary, therefore, to connect the boiler to a structurally compatible, moisture-resistant flue gas system.

Technology Technical Specifications

Page 8 M 065 01 08 sa

2

Using a Brick Chimney

To check for and prevent seepage damage to a chimney that is not moisture-proof, the following measures must be taken:

Measure the outlet temperature at the upper end of the chimney while it is operating

If this is above 80 °C, there is no risk of seepage damage to the chimney

Check the chimney at the cleanout opening after the first week of operation

If the inner wall is dry, you don't need to worry about seepage damage to the chimney.

If the outlet temperature at the upper end of the chimney is too low or the chimney is damp on the inner wall:

Set the minimum flue gas temperature at the controller to at least 150 °C or higher!

Insulate the connecting piece between the boiler and the chimney

Insulate the chimney in cold areas (in the attic, for example)

If no improvement is noted after a second check, check the chimney through the smoke trap sweeper!

NOTICE

Installing a draught limiter or an explosion flap is recommended!

Using a storage tank with the proper dimensions prevents boiler outputs of < 50%!

Installation Transport and Setup

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 9 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

3

3 Installation

3.1 Transport

Follow the transport instructions on the packaging when moving the boiler. Tipping hazard!

Unloading, positioning and installation should only be carried out by trained professionals! Staff must be trained in techniques for moving heavy loads. (correct tools and lifting equipment, anchor points, ...)

To move the unit into the boiler room:

Attach a cable winch or similar lifting device to the eyelets on the boiler

To move the unit around inside the boiler room:

Position a fork-lift or rollers under the stationary main frame

To prevent damage:

Move the boiler without jarring or jolting

Move the packing materials carefully

3.1.1 Temporary storage

If the system is to be installed at a later date:

store the boiler, insulation, and control unit in a safe, dust-free, and dry location

Moisture reduces the effectiveness of the insulation and can destroy electronic components!

3.2 Setting up in the boiler room

Set up the boiler according to the applicable standards and regulations.

The floor under the boiler should have sufficient load capacity and should not be flammable.

Dimensions Description Unit Turbomatic 150

A Minimum distance between delivery unit and wall 300

B Minimum distance between induced draught fan and wall 500

C Minimum distance from front of boiler to wall 800

D Minimum distance between the ash trolley and the wall

mm

1000

Installation Installing the Boiler

Page 10 M 065 01 08 sa

3

3.3 Preparatory Work

Once the unit is brought into the boiler room:

Position the boiler at the intended location

Using a winch or similar if necessary, set up the boiler according to the installation plan

NOTICE

Paint from the body of the boiler may have left dried paint residue in the threaded holes!

Tip: Check all threads before assembly and re-cut them if necessary!

Detaching the blank cover

On the delivery side:

Only for the flue gas return option!

Detach the bottom blank cover for the flue gas return

On the cleaning door side:

Detach the blank cover for the electric ignition

Insert the ignition tube as shown and secure it with the screws from the blank cover

The straight edge must be up.

Installation Installing the Boiler

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 11 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

3Removing the Blind Plug

Remove the blind plug for the combustion chamber temperature sensor and the over-pressure monitor

At the flue gas pipe (back of boiler), remove the blind plug for the flue gas sensor and the Lambda probe

Remove the blind plug for the under-pressure controller sensor

Remove the blind plug for the overpressure

monitor

Remove blind plug and screw in immersion sleeve for grate thermostat

Installation Installing the boiler

Page 12 M 065 01 08 sa

3

3.4 Installing the boiler

Installing the insulation mounting brackets

Install the lower insulation brackets on the sides of the base of the boiler or on the chamber - 4 insulation mounting brackets, small (A) - 2 Insulation mounting brackets, large (B)

On the cleaning door side:

Screw in 2 M6 screws from below into the left and right insulation mounting brackets (chamber)

Place the upper insulation mounting bracket on the threaded bolts and secure it using 2 M8 nuts and spacer washers

Only tighten the nuts after the insulation has been fitted

Place the insulating door mounting bracket for

the cleaning door on the threaded bolts

Align the mounting bracket to the edge of the boiler and secure it using 2 M6 nuts and spacer washers

A

A

B

B

A

A

Installation Installing the boiler

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 13 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

3Installing the Grate Drive

Remove the 4 nuts and spacer washers from the blind flange

Remove the locking screw and fitting key at the shaft stub

Grease the shaft stub

Unscrew the shipping brace at the geared motor

Screw in the vent screw

The vent screw is included with the geared motor!

Place the geared motor into position and secure it using the previously removed nuts and spacer washers

Installation Installing the boiler

Page 14 M 065 01 08 sa

3

Installing the Ash Removal Chamber

Insert the ash screw into the duct - Screw: Ø 110 mm, L = 1525 mm

The shaft stub must be on the heat exchanger side!

Install the discharge unit flange using 4 M10 x 25 bolts and nuts

Do not forget to fit the seal!

Install the flange bearing using 4 M10 screws on the intermediate bearing flange

Screw in the lubricating nipple 1

The lubricating nipple must point upwards when the flange is installed!

Remove the fitting key and locking screw at the shaft stub

Grease the shaft stub

Put the intermediate bearing flange on the shaft stub

Do not forget to fit the seal!

Fix using 4 M10 bolts and nuts

1

Installation Installing the boiler

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3

Unscrew and remove the shipping brace at the geared motor

Screw in the vent screw

The vent screw is included with the geared motor!

Install the torque support with 4 M10 x 20 screws on the gearing unit

Pull out the stub shaft of the screw to the width of the gearing unit (14 cm)

Secure the screw in position at the flange bearing using a worm screw

Place the geared motor on the shaft stub and the bearing flange plate bolt

Insert the fitting key into the groove on the shaft and secure it with a locking screw

Installation Installing the boiler

Page 16 M 065 01 08 sa

3 Installing the Heat Exchanger Ash Removal Unit

Install the end flange on the delivery side of the boiler using 4 M8 hexagonal screws

Place the geared motor on the flange plate as

shown and secure it using 4 M8 screws

Do not forget to fit the rubber seal!

Insert the ash screw and turn it until the key-ways of the screw and the gearing unit are opposite each other - Screw, TM 150: Ø 80 mm, L = 1,002 mm - Screw, TM 220: Ø 80 mm, L = 1242 mm

Insert the key and secure it with a locking screw

Insert the ash removal unit

Secure the flange plate with 4 M8 screws on the boiler

Installation Installing the boiler

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 17 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

3Installing the Insulating Side Panels

Install 6 fitted screws on the insulating back panel

Place the insulating back panel on the back

Separate the perforated flaps on the left and right insulating side panels and bend them back 90°

Cut out the insulation

Hang the insulating side panel on the upper mounting bracket

Insert the insulating side panel into the lower insulation mounting bracket

Installation Installing the boiler

Page 18 M 065 01 08 sa

3

Take care to fit the fitted screws into the spring shackles!

Separate and remove the pre-stamped cutout

on the lower end of the side chamber insulation

Do not confuse the left and right sides! The spring shackle 1 must not point forward!

Place the side chamber insulation over the

flange of the ash removal unit and insert it into the upper insulation bracket

Secure the insulation to the mounting bracket

using a self-tapping screw

1

Installation Installing the boiler

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3

Insert the right insulating side panel into the upper and lower mounting brackets

Take care to insert the fitted screws of the insulating back panel!

Place the ceramic fibre mat on the combustion chamber

Put on 4 insulating wool mats

Run the cable for the door contact switch through the opening in the flap behind the insulating wool to the opening as shown

Install 6 fitted screws

Open the combustion chamber door

Put on the front chamber insulation and insert it into the lower insulation mounting bracket

Installation Installing the boiler

Page 20 M 065 01 08 sa

3

Tip: For the next step remove the primary air slide valve!

Loosen the screws and remove the sliding air valve

Cut out the insulating wool on the rear chamber insulation in the area of the delivery duct

For the flue gas return option:

Take out the lower right pre-stamped cutout and bend the flap back 90°

Place the insulation on the delivery duct and insert it into the upper and lower insulation mounting brackets

Secure the insulating side panels at the upper

insulation mounting brackets

Align the entire insulation and secure it by tightening the upper insulation mounting bracket

Re-install the primary air flap slide valve

Installation Installing the boiler

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 21 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

3

Bend back the pre-cut flaps on the insulating front panel 90°

Run the cable for the door contact switch through the opening in the flap behind the insulating wool to the opening

Place the insulating front panel at the screws of the two lower insulation mounting brackets and put it over the insulating door bracket

Secure it to the insulating door mounting bracket using 2 M6 screws

Place the insulating wool mats on the boiler

Take out the insulating wool at the connections for the boiler outfeed and the safety battery

At the cross-over between the chamber and boiler body, pull down the insulating wool at the sides

Remove the pre-stamped cutout of the side chamber insulation

Only remove the lower part! (see photo)

Installation Installing the boiler

Page 22 M 065 01 08 sa

3

Put on the side chamber insulation

Take care to insert the fitted screws precisely!

Installing the Cleaning Door Frame

Put on the door frame for the cleaning door

Insert the door contact switch through the cutout!

Pre-drill holes on the corners of the door

frame with a 3 mm drill bit

Secure the door frame to the insulation with 4 self-tapping screws

Installation Installing the boiler

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3

Install the securing plate on the door contact switch using the pre-installed nut

Install the securing plate using 2 self-tapping screws

Insert the door contact switch through the cutout in the door frame in such a way that the contact roller projects out of the insulation hole

Secure to the door frame using 2 self-tapping screws

Install an M6 bolt 2 two nuts on the lower insulating door mounting bracket

Insert the insulating door at the bolt of the lower insulating door mounting bracket

Secure the insulating door at the upper insulating door mounting bracket using a hinge pin

Installation Installing the boiler

Page 24 M 065 01 08 sa

3 Installing the Combustion Chamber Door Frame

Put on the door frame with the combustion chamber door open

Secure the door frame to the insulation

Installing the Cleaning Door Frame

Unscrew and remove the combustion chamber locking hook

Install the door contact switch

Installing the Cleaning Door Frame

After installing the door contact switch, re-install the locking hook

Install the door handle on the combustion chamber door using 2 M8 hexagonal screws

Install the glass and frame on the plate using

2 screws

Installation Installing the boiler

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 25 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

3

Screw the screw for the knob through from behind and secure with a nut

Install the plate at the viewing tube flap using an M8 screw

Lock the bolt on the back with a nut

Put the cover plate on the combustion chamber door

Secure it on the left and right using 2 M8 screws with spacer washers

Adjust the door contact switch by shifting the cover plate

Screw on the knob at the inspection glass holder

Installation Installing the boiler

Page 26 M 065 01 08 sa

3 Installing the WOS Drive

Insert the WOS disc at the WOS mounting bracket as shown and install it on the threaded bolts on the boiler

The catches on the WOS must be installed as in the following diagram:

Unscrew the locking screw at the WOS disc shaft

Put on the WOS motor and install it on the WOS mounting bracket as shown

Replace the locking screws at the shaft

WOS disc

2 catches

Installation Installing the boiler

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3

Installing the Actuators

Install torque supports for actuators on the flange plate of the rotary slide valve

Primary air: horizontal mounting bracket Secondary air: vertical mounting bracket

Install the cover plate with 4 self-tapping screws

Turn the pneumatic rods to the left stop

Put the actuators on the torque support and secure them at the clamp

The delivery configuration of the actuators is generally at the left stop! If it is in an incorrect position, correct this using the operating instructions included.

Installation Installing the boiler

Page 28 M 065 01 08 sa

3 Installing the Underpressure Controller

Screw in extension pipe

Screw the tubing nozzle into the extension pipe

Install the pressure measuring transducer on the mounting bracket

Install the mounting bracket on the boiler with 4 self-tapping screws

Connect the transparent tubing at the measuring transducer to the “minus” nipple using a hose clamp

Run the transparent tubing to the hose nozzle of the extension pipe and secure it with a hose clamp

Installing the Over-pressure Monitor

Screw in the extension pipe and the brass bushing

Slide in the over-pressure monitor and secure it at the brass bushing

Installation Installing the boiler

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 29 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

3Installing the Combustion Chamber Temperature Sensor

Hand-tighten the extension pipe with flange

Slide in the combustion chamber temperature sensor and secure it at the flange

Installing the Safety Temperature Limiter (STL) and Boiler Sensor

Remove the housing cover of the safety temperature limiter

Drill a hole in the centre of the bottom of the housing using an 8 mm drill bit and drill 4 holes for securing with a 5 mm drill bit.

Insert the safety temperature limiter sensor through the bottom of the housing

Insert the safety temperature limiter sensor into the hole in the insulation and run it upwards between the plate and the insulation

Secure the safety temperature limiter to the insulation with 4 self-tapping screws

Re-install the housing cover of the safety temperature limiter

On the upper side of the boiler:

Insert the safety temperature limiter sensor and boiler sensor with a clasp into the immersion sleeve

Secure them using the immersion sleeve worm screw

Installation Installing the boiler

Page 30 M 065 01 08 sa

3

Installing the Insulating Cover

Remove the pre-stamped cutouts in the front insulating cover for the boiler outfeed and the safety battery connections

Remove the burrs from the cutouts using a file

Put on the front insulating cover

Insert the cable for the boiler sensor through the opening!

Put on the rear insulating cover

Installing the Lambda probe

Hand-tighten the bushing of the Lambda probe at the flue pipe

Lightly screw the Lambda probe into the bushing

Installing the Flue Gas Sensor

Screw in the brass bushing

Slide in the flue gas sensor as shown and lightly tighten it using the worm screw of the brass bushing

Installation Installing the boiler

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 31 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

3Installing the Induced Draught Unit Housing

Glue the seal cord on the flue pipe

Position the induced draught unit bracket at the flange of the flue gas pipe, align horizontally and secure

Install smoke flue adapter with seal ring

Put 4 rubber buffers on the bracket at the long holes

Do not secure the rubber buffers yet!

Installation Installing the boiler

Page 32 M 065 01 08 sa

3

Put the induced draught unit onto the rubber buffers and align with the rubber buffers

Tighten the rubber buffers between the bracket and the induced draught unit

Screw the smoke flue adapter onto the induced draught unit tightly with a seal ring

To stabilise the far end of the bracket install 2 supports as shown

For Turbomat TM 220 also:

With the Turbomat TM 220 install a flue gas

pipe cone on the induced draught fan

Installation Installing the boiler

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3

Installing the Delivery Unit

Install the delivery duct using 4 M10 bolts and nuts

Do not forget to fit the seal!

Slide in the screw - Screw: Ø 110 mm, L = 980 mm

Install the geared motor on the flange plate using 4 M10 x 20 screws

The longer bezels must point downward!

Install the geared motor with flange plate and seal at the delivery duct using 4 M10 bolts and nuts

Install an M 16 carrying bolt at the flange plate lug

Slightly pre-tighten the delivery duct with the carrying bolt

Unscrew and remove the shipping brace at the geared motor

Screw in the vent screw

The vent screw is included with the geared motor!

Installation Installing the boiler

Page 34 M 065 01 08 sa

3 Installing the Combustion Air Blower Fan (Turbomat TM 150)

Install the combustion air blower on the flange using 4 M6 screws

Installing the Combustion Air Blower Fan (Turbomat TM 220)

Install the suction pipe on the combustion air blower fan

Install the pipe elbow on the boiler above the combustion chamber door

Install the combustion air blower fan on the pipe elbow as shown below

Installation Installing the boiler

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 35 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

3Installing the Grate Thermostat

Cover plate TM 150 Cover plate TM 220

Remove the pre-stamped cutout in the cover plate

Install the cover plate

Install the securing plate and thermostat on the insulation

Insert the sensor into the immersion sleeve

Installing the Shutter Masks

Secure 2 shutter masks on the front side using self-tapping screws

Install shutter masks for the boiler return on the back of the boiler

Put on the cover hood at the WOS drive and

secure it to the insulation

Installation Installing the boiler

Page 36 M 065 01 08 sa

3 Installing the Electric Ignition

Put blower fan 1 for the electric ignition on the ignition tube and secure it with nut

Screw in the seal cord with it!

Installing the Ash Container

Position the ash container at the ash removal unit flange

Adjust for any difference in height by adjusting the castors

Put the ash container on at the ash removal flange

Insert the pin at the ash container flange.

Secure it on the left and right using wingnuts

Put the ash box on the flange of the heat exchanger ash removal unit

1

Installation Installing the boiler

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3

Installing the Flue Gas Return

Flue gas return at heat exchanger, left Flue gas return at heat exchanger, right

Put the fan box on the induced draught unit housing or flue gas pipe cone (only TM 220) and screw it on firmly

If the heat exchanger is on the left, the pipe section between the induced draught unit and the T-piece must also be installed.

Remove the protective grating from the flue gas return blower

Use the high temperature silicon included as a sealing material

Put the flue gas return blower on the bracket of the fan box and screw it on with the flange on the T-piece

Installation Installing the boiler

Page 38 M 065 01 08 sa

3

Install connector supports for the smoke flue on the flue gas return blower

Install the primary air box on the boiler with

sliding air valve

Connect the primary air box and flue gas return blower to the flue pipes as shown in the diagram

File the smoke flues after cutting to length.

Apply high temperature silicon before installing the pipe clamps.

Flue gas return at heat exchanger, left Flue gas return at heat exchanger, right

Installation Electrical Connection

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 39 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

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3.5 Electrical Connection

CAUTION

Work on electrical components.

Risk of injury from electric shock!

Work on electrical components should be carried out by authorised professionals.

Wire the connections according to the schematic diagram:

Schematic diagrams: See operating instructions for “Lambdatronic H 3000”

Potential Equalisation The potential equalisation of the connection is absolutely required and must be carried out in accordance with applicable standards and regulations!

See “1.1 Notes on Standards”

3.6 Connecting the Thermal Discharge Safety Device

NOTICE

The thermal discharge safety device must be connected in accordance with ÖNORM/DIN EN 303-5 as shown in the following diagram.

The discharge safety device must be connected to a pressurised mains water supply in such a way that it cannot be shut off.

1 Thermal discharge safety device sensor

2 Thermal discharge safety device (opens at approx. 95 °C)

3 Cleaning valve (T-piece)

4 Dirt trap

5 Pressure reducing valve

(Required when the cold water pressure is greater than 6 bar.)

Technical specifications:

Safety battery connection 1/2" IT

Minimum pressure 2 bar

Max. permitted operating pressure 16 bar

Required flow volume 1 m³/h

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2

3

4

5

Startup / Shutdown

Page 40 M 065 01 08 sa

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4 Startup / Shutdown

4.1 Commissioning / Configuring the Boiler

The boiler must be adjusted to the requirements of the heating system during commissioning

NOTICE

The initial startup must be carried out by an authorised installer or Fröling's customer service department.

Before heating the boiler for the first time:

Adapt the controller to the system type

The arrangement of the keys and the necessary control steps for branching/modifying the parameters, should be taken from the accompanying “Lambdatronic H 3000” operating instructions

4.2 Mothballing

The following tasks should be carried out if boiler is to remain out of service for several weeks (e.g. during the summer):

Carefully clean the boiler

Completely close all doors and flaps

If the boiler is to remain out of service during the winter:

Have the system completely drained by a qualified technician

Protect against frost!

4.3 Disassembly

To disassemble the boiler, perform the assembly process in reverse order.

See page 12, “Installing the boiler”

4.4 Disposal

Dispose of all waste in an environmentally-friendly manner and in accordance with waste disposal regulations.

Separate and clean recyclable materials and send them to a recycling centre.

Delivery Certificate

Fröling Heizkessel- und Behälterbau Ges.m.b.H Industriestraße 12 A-4710 Grieskirchen Page 41 Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M 065 01 08

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5 Delivery Certificate - TM 150/220

Customer no.

Customer address: Installer:

Telephone number:

150 kW Turbomat

220 kW

Serial number

System operation discussed

System maintenance discussed

Operating principle and self-checking of safety devices discussed

All technical documents given to customer (documentation, certificates of conformity, ...)

Test heating performed

Commissioning report given to customer

Telephone number for manufacturer's service department indicated

Rating plate attached

Following items checked:

No defects found

Notice:

All national and regional regulations relating to initial testing and subsequent testing of the system must be observed. Please be advised that, in Austria, commercial systems with a rated heat output ≥ 50 kW must be regularly tested at yearly intervals in accordance with the Heating Plant Regulations (FeuerungsanlagenVO).

Date Customer Installer

Please complete this form, ask the customer to sign it and return it as confirmation to FRÖLING Ges.m.b.H. Fax: +43 (0)7248 606 600