Froling TX 250 Bedienungsanleitung

Installation Instructions

Wood chip boiler TX 150-250

Translation of the original German operating instructions for technicians!

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

M1320112_en | Edition 08/04/2013

Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

Contents

1 General 4

2 Safety 5

2.1 Hazard levels of warnings 5

2.2 Qualification of assembly staff 6

2.3 Protective equipment for assembly staff 6

2.4 Design Information 7

2.4.1 Notes on standards 7

General standards for heating systems

Standards for structural and safety devices

Standards for heating water

Standards for permitted fuels

2.4.2 Installation and approval of the heating system 8

2.4.3 General information for installation room (boiler room) 8

2.4.4 Requirements for central heating water 9

2.4.5 Return lift 9

2.4.6 Use with storage tank 10

2.4.7 Chimney connection/chimney system 10

Draught limiter

Boiler data for planning the flue gas system

3 Technology 12

3.1 Dimensions 12

3.2 Technical specifications 13

4 Assembly 15

4.1 Transport 15

4.2 Positioning 15

4.3 Temporary storage 15

4.4 Set-up in the boiler room 15

4.4.1 Moving the boiler in the boiler room 15

4.4.2 Minimum distances in the boiler room 16

4.5 Mounting steps 17

4.5.1 General information 17

4.5.2 Screwing the fire box with the heat exchanger 18

4.5.3 Installing sensor of thermal discharge system 19

4.5.4 Assembly of fireclay blocks 20

4.5.5 Preparation of flue gas recirculation connection (Option) 21

4.5.6 Retrofitting the WOS bar (if necessary) 22

4.5.7 Installing lower main frame of insulation 23

4.5.8 Installing upper main frame of insulation 24

4.5.9 Installing the frame for the insulating door 25

4.5.10 Installing the insulating side panels 26

4.5.11 Complete the heat exchanger cover and the combustion chamber door 29

4.5.12 Check grate settings and install the tipping grate motor 31

4.5.13 Installing the fire box ash removal unit 33

4.5.14 Installing the switch cabinet and cable ducts 37

4.5.15 Installing the stoker unit 39

4.5.16 Installing the automatic igniter 40

Contents

2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

4.5.17 Installing the actuators of the air flaps 41

4.5.18 Installing overpressure monitor and temperature sensor 42

4.5.19 Installing the underpressure measurement 43

4.5.20 Installing the WOS drive 44

4.5.21 Heat exchanger ash removal unit with ash box 46

4.5.22 Heat exchanger ash removal unit with ash screw (optional) 47

4.5.23 Installing the combustion air blower fan 54

4.5.24 Installing the STL and the boiler sensor 55

4.5.25 Installing the ID fan 56

4.5.26 Installing the FGR air box (optional) 57

4.5.27 Installing the flue gas recirculation FGR (optional) 58

4.5.28 Installing insulating door and cover plates 60

4.6 Electrical connection 61

4.6.1 Installing insulating covers and cover plates 61

4.7 Connecting the thermal discharge system 64

5 Start-up 65

5.1 Before commissioning / configuring the boiler 65

5.2 Initial startup 66

5.2.1 Permitted fuels 66

Wood pellets

Wood chips

5.2.2 Heating up for the first time 66

6 Decommissioning 67

6.1 Mothballing 67

6.2 Disassembly 67

6.3 Disposal 67

7 Appendix 68

7.1 Addresses 68

7.1.1 Address of manufacturer 68

7.1.2 Address of the installer 68

Contents

Installation Instructions TX 150-250 | M1320112_en 3

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 guide‐

lines.

Please read and observe the documentation provided and always keep it close to the

system for reference. It contains important safety information and all the operation and

maintenance specifications needed to operate the system safely, properly, environ‐

mentally friendly and cost-effectively.

The constant further development of our products means that there may be minor dif‐

ferences from the pictures and content. If you discover any errors, please let us know:

[email protected]

Subject to technical change.

The EC Declaration of Conformity is only valid in conjunction with a delivery certificate,

which has been filled in correctly and signed as part of the commissioning process.

The original document remains at the installation site. Commissioning installers or

heating engineers are requested to return a copy of the delivery certificate together

with the guarantee card to Froling. On commissioning by FROLING Customer Service

the validity of the delivery certificate will be noted on the customer service record.

Issuing a delivery cer‐

tificate

1General

4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

2 Safety

2.1 Hazard levels of warnings

This documentation uses warnings with the following hazard levels to indicate direct

hazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will lead

to serious injury or death. You must follow the instructions!

WARNING

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.

Safety 2

Hazard levels of warnings

Installation Instructions TX 150-250 | M1320112_en 5

2.2 Qualification of assembly staff

CAUTION

Assembly and installation by untrained personnel:

Risk of personal injury and damage to property.

During assembly and installation:

❒ Observe the instructions and information in the manuals

❒ Only allow trained staff to carry out assembly and installation

Assembly, installation, initial startup and servicing must always be carried out by quali‐

fied personnel:

- Heating technician / building technician

- Electrical installation technician

- Froling customer services

The assembly staff must have read and understood the instructions in the documenta‐

tion.

2.3 Protective equipment for assembly staff

You must ensure that staff have the protective equipment specified by accident pre‐

vention regulations.

▪ For transportation, setup and assembly:

- suitable workwear

- protective gloves

- sturdy shoes

2Safety

Qualification of assembly staff

6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

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. The following standards and regulations should always be ob‐

served:

General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fed combus‐

tion systems, nominal output up to 300 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 appliance

ÖNORM M 7510-1 Guidelines for checking central heating systems

Part 1: General requirements and one-off inspections

ÖNORM M 7510-4 Guidelines for checking central heating systems

Part 4: Simple check for heating plants for solid fuels

Standards for structural and safety devices

ÖNORM H 5170 Heating installation - Requirements for construction and safety

engineering, as well as fire prevention and environmental pro‐

tection

TRVB H 118 Technical directives for fire protection/prevention (Austria)

Standards for heating water

ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in

closed warm water heating systems at operating temperatures

up to 100 °C (Austria).

VDI 2035 Sheet 1 Prevention of damage in water heating systems - Scale forma‐

tion in domestic water heating systems and hot water heating

systems (Germany)

SWKI 97-1 Water quality for heating, steam, cooling and air conditioning

systems (Switzerland)

D.P.R. no. 412 Regulations for the planning, installation, running/operation and

maintenance of heating systems in buildings to reduce energy

consumption with reference to Article 4, Comma 4 of the Legis‐

lative Decree of 9 January 1991, No. 10 (Italy)

Safety 2

Design Information

Installation Instructions TX 150-250 | M1320112_en 7

Standards for permitted fuels

EN 14961-2 Solid biofuel, fuel specifications and classes.

Part 2: Wood pellets for non-industrial use

EN 14961-4 Solid biofuel, fuel specifications and classes.

Part 2: Wood chips for non-industrial use

1. BImSchV First Ordinance of the German Federal Government for imple‐

mentation of the Federal Emission Protection Law, BGBl. I P.

491, in the applicable version.

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:

ÖNORM / DIN 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:

Austria: Inform the civic/municipal building authorities.

Germany: Notify an approved chimney sweep and the building authorities.

2.4.3 General information for installation room (boiler room)

Boiler room characteristics

▪ There must not be a potentially explosive atmosphere in the boiler room as the

boiler is not suitable for use in potentially explosive environments.

▪ The boiler room must be frost-free.

▪ The boiler does not provide any light, so the customer must provide sufficient light‐

ing in the boiler room in accordance with national workplace design regulations.

▪ When using the boiler over 2000 metres above sea level you should consult the

manufacturer.

▪ Danger of fire due to flammable materials.

No flammable materials should be stored near the boiler. Flammable objects (e.g.

clothing) must not be put on the boiler to dry.

▪ Damage due to impurities in combustion air.

Do not use any solvents or cleaning agents containing chlorine in the room where

the boiler is installed.

▪ Keep the air suction opening of the boiler free from dust.

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 be designed to prevent weather conditions (foli‐

age, snowdrifts, etc.) from obstructing the air flow.

Note on standards

2Safety

Design Information

8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

Unless otherwise specified in the applicable building regulations for the boiler room,

the following standards apply to the design and dimensions of the air ducts:

ÖNORM H 5170 - Construction and fire protection requirements

TRVB H118 - Technical directives on fire protection/prevention

2.4.4 Requirements for central heating water

The following standards and guidelines apply:

Austria:

Germany:

Switzerland:

Italy:

ÖNORM H 5195-1

VDI 2035

SWKI 97-1

D.P.R. no. 412

NOTICE! Note on filling with make-up water: Always bleed the filling hose before con‐

necting, in order to prevent air from entering the system.

2.4.5 Return lift

If the hot water return is below the minimum return temperature, some of the hot water

outfeed will be mixed in.

CAUTION

Risk of dropping below dew point/condensation formation if operated without re‐

turn temperature control.

Condensation water forms an aggressive condensate when combined with com‐

bustion residue, leading to damage to the boiler.

Take the following precautions:

❒ Regulations stipulate the use of a return temperature control.

➥The minimum return temperature is 65 °C. We recommend fitting some

sort of control device (e.g. thermometer).

Note on standards

Safety 2

Design Information

Installation Instructions TX 150-250 | M1320112_en 9

2.4.6 Use with storage tank

NOTICE

In principle it is not necessary to use a storage tank for the system to run smooth‐

ly. However we recommend that you use the system with a storage tank, as this

ensures a continuous supply of fuel in the ideal output range of the boiler.

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 68]

2.4.7 Chimney connection/chimney system

EN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐

ever possible, damage caused by seepage, insufficient feed pressure and condensa‐

tion. Please note in this respect that flue gas temperatures lower than 160K above

room temperature can occur in the permitted operating range of the boiler.

The flue gas temperatures (for clean systems) and additional flue gas values can be

found in the table below.

The connection between the boiler and the chimney system should be as short as

possible. The upward angle of the connection should not exceed 30 - 45°. Insulate the

connection. The entire flue gas system - chimney and connection - should be calcula‐

ted in accordance with EN 13384-1.

Local regulations and other statutory regulations also apply.

NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney

sweep.

NOTICE! TRVB H 118 (Austria only) stipulates that an explosion flap must be installed

in the connecting piece (flue pipe) directly next to the boiler. It should be situated in

such a way that is poses no risk to persons!

Draught limiter

The installation of a draught limiter is recommended.

NOTICE! Install the draught limiter directly under the mouth of the flue line, as the

pressure is constantly low at this point.

2Safety

Design Information

10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froling.com

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