Installation Instructions TX English version of the assembly instructions for technicians. Read and follow the instructions and safety instructions! Subject to technical change. Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen
Introduction I Dear customer, The FRÖLING TX 150 wood chip boiler features a state-of-the-art design that conforms to all currently applicable standards and testing guidelines. Please read and follow the installation instructions. They contain safety instructions and comprehensive information relating to transporting, setting up and assembling the boiler. The constant further development of our products means that the pictures and content may differ slightly. If you discover any errors, please let us know. Subject to technical change. Delivery certificate Keeping a record that the delivery was received correctly and collecting customer-specific data relating to the system allows us to respond quickly should problems arise. We would therefore ask you to confirm that you have received the product in good condition. Please send Fröling a copy of the delivery certificate, filled in and signed by the customer. Guarantee conditions Our sale and delivery conditions generally apply. These conditions have been made available to customers, and customers have been made aware of them at the time of order completion. You can also find the guarantee conditions on the enclosed guarantee certificate. Address of manufacturer FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL +43 (0)7248 606 0 FAX +43 (0)7248 606 600 E-MAIL info@froeling.com WEBSITE www.froeling.com Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 3
C Contents 1 General Information 6 1.1 Standards 6 1.2 Qualification of assembly staff 7 1.3 Protective equipment for assembly staff 7 1.4 Design information 7 1.4.1 Installation and approval of the heating system... 7 1.4.2 Information on the installation room (boiler room)... 8 Boiler room characteristics... 8 Ventilation of the boiler room... 8 1.4.3 Heating water requirements... 8 Combination with storage tank... 8 Return lift... 9 1.4.4 Chimney connection / Chimney system... 9 2 Technology 10 2.1 Dimensions and connections TX 10 2.2 Technical Specifications 11 3 Assembly 12 3.1 Transport 12 3.1.1 Positioning... 12 3.1.2 Temporary storage... 12 3.2 Set-up in the boiler room 12 3.2.1 Moving the boiler in the boiler room... 12 3.2.2 Minimum distances in the boiler room... 13 3.2.3 General information on the boiler room... 13 3.3 14 3.3.1 Positioning the retort in the heat exchanger... 14 3.3.2 Remove the blind plug and cover... 16 3.3.3 Installing the tipping grate motor and tipping sensor... 16 3.3.4 Installing the retort ash removal unit... 17 3.3.5 Installing the insulation mounting brackets... 18 3.3.6 Installing the heat exchanger ash removal unit with ashcan... 20 3.3.7 Installing the insulating side panels... 21 3.3.8 Installing the WOS drive... 26 3.3.9 Installing the overpressure monitor... 28 3.3.10 Installing the underpressure controller... 28 3.3.11 Installing the ignition fan... 29 3.3.12 Installing the actuators for the air flaps... 29 3.3.13 Installing the induced draught fan... 30 3.3.14 Installing the infeed unit... 32 3.3.15 Installing the lambda probe and flue gas sensor... 32 3.3.16 Installing the combustion air blower fan... 33 3.3.17 Installing the combustion chamber temperature sensor... 33 Page 4 s
Contents C 3.3.18 Installing the insulated door... 34 3.3.19 Installing the switch cabinet... 34 3.3.20 Installing the heat exchanger ash removal unit with ash screw (optional)... 35 3.3.21 Installing flue gas recirculation FGR (optional)... 38 3.3.22 Putting on the cover... 39 3.4 Electrical connection 40 3.4.1 Laying the cable... 40 3.4.2 Installing cable covers... 40 3.5 Connecting the thermal discharge safety device 41 4 Commissioning / Decommissioning 42 4.1 Configuring the Boiler 42 4.2 Out of service for long periods 42 4.3 Disassembly 42 4.4 Disposal 42 5 Appendix 43 5.1 Delivery certificate - TX 43 Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 5
1 General information Notes on standards 1 General Information 1.1 Standards The installation and commissioning of the boiler must be carried out in accordance with local fire and building regulations. The following standards and regulations should be observed in any case: ÖNORM/DIN EN 303-5 EN 12828 ÖNORM M 7510-1 ÖNORM M 7510-4 EN 13384-1 ÖNORM H 5170 prtrvb H 118 ÖNORM M 7132 ÖNORM M 7133 ÖNORM M 7135 DIN 51731 EN 60335-1 ÖNORM H 5195-1 VDI 2035 - Sheet 1 SWKI 97-1 FAV 1.BImSchV Boilers for solid fuels, manually and automatically fed combustion systems; rated heat output up to 300 kw; Heating systems in buildings - design of water-based heating systems Guidelines for checking heating systems Part 1: General requirements and one-off inspection Guidelines for checking heating systems Part 4: Simple check for heating plants for solid fuels Chimneys - Thermal and fluid dynamic calculation methods Part 1: Chimneys serving one appliance Heating installations - requirements for construction and safety engineering, and fire prevention and environmental protection Technical directives on fire protection/prevention Automatic wood burning system (only in Austria) Energy-efficient use of wood and bark as fuel Definition and features Wood chips for energy production - Requirements and test specifications. Compressed untreated wood or bark pellets and briquettes Requirements and test specifications Testing solid fuels compressed untreated wood Requirements and testing Safety of household and similar electrical appliances - Part 1: General Prevention of damage by corrosion and scale formation in hot water heating systems at operating temperatures up to 100 C (Austria only). Prevention of damage in water heating systems - Scale formation in domestic water heating systems and hot water heating systems (Germany only) Water quality for heating, steam, cooling and air conditioning systems (Switzerland only) Heating plant regulations of the Austrian federal government, BGBl. II no. 131/1997, in the applicable version. First regulations of the German federal government for implementation of the federal emission protection law, BGBl. I S.491, in the applicable version Page 6 s
General information Design Information 1 1.2 Qualification of assembly staff CAUTION Assembly and installation by untrained personnel: Risk of injury and damage to equipment! The instructions and information provided in the instructions should be observed! Only allow trained staff to carry out assembly and installation! Assembly, installation, initial startup and servicing must only be carried out by qualified people: - Heating technicians / building technicians - Electrical installation technicians - Fröling customer services The assembly staff must have read and understood the instructions in the documentation. 1.3 Protective equipment for assembly staff You must ensure that staff have the protective equipment specified by accident prevention regulations. During transportation, set-up and assembly of the boiler: - Work clothing - Safety shoes - Protective gloves 1.4 Design information It is forbidden to carry out modifications to the boiler or to change or deactivate safety equipment. Always comply with all fire, building, and electrical regulations when installing or operating the boiler system, and follow the operating instructions and mandatory regulations that apply in the country in which the boiler is operated. 1.4.1 Installation and approval of the heating system The installation of a heating system is subject to the following standards: Applicable standard: ÖNORM / DIN EN 12828 Heating systems in buildings 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: Report to the construction authorities of the community or magistrate - Germany: Report new installations to an approved chimney sweeper / the building authorities. Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 7
1 General information Notes on standards 1.4.2 Information on the 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 lighting in the boiler room in accordance with national workplace design regulations. When using the boiler above 2000 metres above sea level you should consult the manufacturer. 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 (foliage, snowdrifts,...) from having any effect on the air flow. Unless otherwise specified in the applicable building regulations for the boiler room, the following standards apply for the design and dimensions of the air ducts: Applicable standards: - TRVB H 118 - ÖNORM H 5170 1.4.3 Heating water requirements There are no special requirements for the filling water of the heating system. The following standards and guidelines apply: Applicable standards and guidelines: Austria: ÖNORM H 5195-1 Germany: VDI 2035 Switzerland: SWKI 97-1 Note on filling with make-up water: bleed the filling hose before connecting to prevent air from getting into the system. Combination with storage tank NOTICE A storage tank with the proper dimensions will guarantee the best boiler operating values during the entire heating period. 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 Fröling. Page 8 s
General information Design Information 1 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 return lift. Condensation water forms an aggressive condensate when combined with combustion residue, leading to damage to the boiler. Regulations stipulate the use of a return lift. The minimum return temperature is 65 C. We recommend fitting some kind of control device (e.g. thermometer). 1.4.4 Chimney connection / Chimney system The boiler is operated in the permitted operating range with a flue gas temperature of less than 160K above room temperature. Therefore the flue gas system should be designed to prevent seepage, insufficient feed pressure and condensation, in accordance with EN 303-5. The entire flue gas system (chimney and connection) should be calculated in accordance with EN 13384-1. The flue gas temperatures and flue gas values required for calculation should be taken from the technical data. 2.2 Technical Specifications Local regulations and other statutory regulations also apply: The chimney must be approved by a smoke trap sweeper or chimney sweep! As per TRVB H 118 (only in Austria) an explosion flap must be installed in the flue pipe or in the chimney. Recommendation: Fit the draught limiter directly under the mouth of the flue line, as the pressure is lower at this location. Design information: The connection to the chimney should be as short as possible and should slant upwards with an angle of 30 to 45. All flue gas pipes and components that come in contact with the flue gas (FGR, ID fan housing) should be insulated by the customer. When fitting the flue gas pipes, ensure that the cleaning openings are accessible. Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 9
2 Technology Dimensions 2 Technology 2.1 Dimensions and connections TX Pos. Description Unit TX 150 H Height of boiler 1880 H1 Height of outfeed connection / return connection 1935 mm H2 Height of flue gas pipe connection without flue gas return 770 H3 Height of flue gas pipe connection with flue gas return 1270 B Width of boiler mm 1900 L Total length of boiler and fittings 2410 L1 Length, boiler 960 mm L2 Length of stoker unit 890 L3 Length of ash container 560 D B C Pos. Description Unit TX 150 A Flue gas pipe diameter mm 200 B Boiler outfeed connection mm DN65 C Connecting the thermal discharge safety device Inch 1/2 D Boiler return connection mm DN65 E Connection for filling / emptying cock Inch 3/4 A E E Page 10 s
Technology Technical specifications 2 2.2 Technical Specifications Description Unit TX 150 Rated heat output (spruce wood chip W30) kw 150 Fuel supply required (spruce wood chip ÖNORM M 7133, W30) 53 kg/h Fuel supply required (wood pellets ÖNORM M 7135, W10) 40 Permitted fuels 1) Wood chips / ÖNORM M 7133 or Pellets 6mm / ÖNORM M 7135 Heat exchanger surface area m² 15 Total weight of the boiler 1950 Weight retort kg 900 Weight heat exchanger 1050 Boiler water capacity L 440 Permitted operating pressure bar 3 Max. permitted temperature 110 Permitted operating temperature (outfeed temperature) C 95 Minimum return feed temperature 65 Water side resistance (ΔT = 20K) mbar 10 Flow (ΔT = 20K) (ΔT = 15K) m³/h 6,44 8,60 Chimney design data: Flue gas pipe diameter mm 200 Flue gas temperature at rated load C 150 Flue gas mass flow with wood chips as per ÖNORM M 7133, W30 (10% O 2, flue gas temp. 150 C) Flue gas mass flow with wood chips as per ÖNORM M 7133, W10 (14% O 2, flue gas temp. 150 C) m³/h kg/h m³/h kg/h Draught requirement at induced draught fan outlet Pa 2 1) Detailed information on the fuel is included in the operating instructions, in the section on Permitted fuels 561 461 792 658 Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 11 M1
3 Assembly 3 Assembly 3.1 Transport Move the boiler without jarring or jolting Consult the delivery information on the packaging. 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,...) 3.1.1 Positioning Attach a cable winch or similar lifting device to the eyelets on the boiler 3.1.2 Temporary storage If the system is to be installed at a later date: Store the boiler, insulation, and controller indoors in a protected dust-free, dry place. Moisture reduces the effectiveness of the insulation and destroys electronic components. 3.2 Set-up in the boiler room 3.2.1 Moving the boiler in the boiler room Position a lifting truck or similar lifting device with an appropriate load-bearing capacity at the base frame of the boiler and lift Set up boiler at intended location Observe the minimum distances in the boiler room (see 3.2.2). Page 12 s
Assembly 3 3.2.2 Minimum distances in the boiler room The boiler should always be set up so that it is fully accessible to allow fast and easy maintenance. Observe the applicable standards and regulations when setting up the boiler. Observe additional standards for noise protection (ÖNORM H 5190 - Noise protection measures) Dimension Description Units TX 150 A Space requirement for inspection area of infeed 400 B Distance from heat exchanger side to wall 300 mm C Space requirement for removal of ash box 400 D Space requirement for inspection area of retort 400 3.2.3 General information on the boiler room Danger of fire due to flammable materials. No flammable materials should be stored near the boiler. 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 of dust. The room where the boiler is installed must be frost-proof. Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 13
3 Assembly 3.3 3.3.1 Positioning the retort in the heat exchanger The following illustrations show the steps for assembling the heat exchanger on the left. If the heat exchanger is fitted on the right, the steps should be carried out in the same way. Lift the retort with a lifting truck and position laterally in the heat exchanger If there is not enough space to bring in the retort from the side, it is possible to bring it in from the front: Insert the lift truck at the retort opposite the supporting post on the ash flange Place a piece of pipe, square timber or similar with a height of approx. 75mm below the retort Lift the retort with the lifting truck and remove the supporting post on the ash flange Position the retort in the heat exchanger from the front After installation, refit the supporting post at the ash flange Page 14 s
Assembly 3 After positioning the retort in the heat exchanger: Tighten the retort against the heat exchanger with carrying bolts through the lateral cutouts in the main frame Check that the retort is aligned with the heat exchanger and seal cord is lying evenly Fit the discharge flange on the combustion chamber door side as illustrated Open the heat exchanger door and place the ceramic fibre mats on the retort as shown Place fireclay blocks on the ceramic fibre mats as shown Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 15
3 Assembly 3.3.2 Remove the blind plug and cover Remove the middle blind plug for combustion chamber temperature sensors opposite the heat exchanger door Remove two blind plugs for the overpressure monitor and underpressure sensor cartridge on the infeed side For systems with flue gas recirculation (FGR): Remove the blanking plate on the retort on the left by the infeed unit 3.3.3 Installing the tipping grate motor and tipping sensor Remove the cover plate below the combustion chamber door Fit the tipping grate motor with sheet mount on the left shaft Fit the tipping grate sensor with sheet mount as shown and fix the sensor with 1-2mm separation Fit the cover plate Page 16 s
Assembly 3 3.3.4 Installing the retort ash removal unit Remove the locking screw with the spacer washer Grease the shaft stub Put the flange plate and the rubber seal onto the ash screw Put on the gear motor and screw it to the flange plate Secure the ash screw with the spacer washer and the locking screw that was previously removed Put the ceramic fibre seal over the ash screw and push the entire unit in at the flange Screw the entire unit to the ash removal flange Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 17
3 Assembly 3.3.5 Installing the insulation mounting brackets Fix the console on the combustion chamber door side on the main frame Heat exchanger insulation mounting Retort insulation mounting Fit a heat exchanger insulation mounting at the front and the back of the heat exchanger between the ash removal flanges Fit the two retort insulation mountings on the infeed side as shown Page 18 s
Assembly 3 Fit the external insulation mounting (angled and long bracket) for insulation of the retort on the combustion chamber door side as shown The illustration on the left shows the insulation mounting for systems with the heat exchanger on the left. If the heat exchanger is fitted on the right, a narrower insulation mounting must be used (right illustration). Fit the internal insulation mounting (long bracket) for front insulation of the retort on the combustion chamber door side Put one insulation mounting each on the left and the right at the back The lug with the threaded bore hole must point downwards Put two large washers on each welded bolt Insert the top insulation mounting between the large washers and fix lightly Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 19
3 Assembly Put on the cable duct as shown and fix on the heat exchanger 3.3.6 Installing the heat exchanger ash removal unit with ashcan Place the rubber seal on the flange plates Fit the blanking plate with 4 hexagonal bolts Fit the flange plates on the infeed side Insert the ashcan on the combustion chamber door side Secure the ashcans using 4 star-shaped screws Page 20 s
Assembly 3 3.3.7 Installing the insulating side panels NOTICE The separate parts of the boiler insulation are fitted with a protective film. This must always be removed before installation. The WOS system is fitted on the infeed side Separate the pre-punched cutout for the WOS with an angle grinder Cut out the thermal insulation behind with a knife Put the insulating side panels onto the lower insulation mounting and push them onto the heat exchanger Screw each insulating side panel to the heat exchanger with 3 Allen screws and shaped washers Screw on the insulating panel at the top with a cable duct Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 21
3 Assembly Remove both rectangular cutouts for the switch cabinet holder Remove the cutout for the boiler drain on the bottom at the right Fit the insulating side panel to the heat exchanger on the combustion chamber door side as described above Insert a heat insulation mat between the two side panels Remove the blind plugs at the lateral boiler drain of the heat exchanger and remove the relevant cutout in the side plate Put on the side plate and fix to the insulating side panels on the left and right with self-tapping screws Page 22 s
Assembly 3 Put the lower retort insulation on the mounting brackets on the basic frame on the infeed side and fix with 2 Allen screws and shaped washers on both middle mounting brackets For systems with flue gas recirculation (picture bottom right): Remove the inner cutout for the flue gas recirculation connection and bend the edges in at a right angle Cut out the thermal insulation behind with a knife Put the top insulation over the bracket on the infeed side and put it onto the middle insulation mounting brackets Put the lower insulation on the mounting brackets on the combustion chamber door side and fix to the two middle mounting brackets with 2 Allen screws and shaped washers each Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 23
3 Assembly Pull out the thermal insulation on the inside of the upper insulation until the bore hole is accessible for fitting the STL Push the STL through the bore hole from the inside and fix on the outside with the relevant nut Then screw on the black cover cap Insert the boiler sensor and STL sensor into the left immersion sleeve with a pressure spring (omega spring) Put the top insulation over the bracket on the combustion chamber door side and put it onto the middle insulation mounting brackets Screw the insulation onto the upper brackets using thread forming screws Use a battery drill with Torx-30 bit insert for fixing Page 24 s
Assembly 3 Adjust the insulation with a sprit level by moving the upper mounting bracket and fix the position Remove the inner cutout for the inspection cover and bend the edges in at a right angle Put on the side plate and fix to the insulating side panels on the left and right with self-tapping screws Cut through the thermal insulation in the area of the inspection cover with a knife Fit the cover plate with self-tapping screws Fit the cover plate below the combustion chamber door Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 25
3 Assembly Fit the lower cover plate for the tipping grate drive Place heat insulation mats in the spaces between the cable ducts as shown 3.3.8 Installing the WOS drive Put tension springs between the WOS lever and the tension hook on the heat exchanger Fit tappet bushing with set screw in the middle position of the WOS disc Page 26 s
Assembly 3 Put the WOS disc onto the WOS mount as shown Fit the entire unit on the heat exchanger Degrease the shaft stub of the WOS disc Put on the WOS drive and screw on the WOS mount Insert the key and screw in the shaft circlip Position the bottom part of the WOS cover on the insulation as shown and fix with drilling screws Position the top part of the WOS cover flush with the bottom part and fix to the insulation with drilling screws Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 27
3 Assembly 3.3.9 Installing the overpressure monitor Screw in the extension pipe of the overpressure monitor on the infeed side at the bottom next to the secondary air slide valve Screw the brass bushing into the extension pipe Slide in the overpressure monitor and secure it with a locking screw 3.3.10 Installing the underpressure controller Screw in the double nipple and reducing socket above the overpressure monitor Screw the tubing nozzle into the reducing socket Fit the underpressure sensor cartridge on the console with slotted screws Fit the console on the insulation with drilling screws Page 28 s
Assembly 3 Connect transparent tubing to the hose nozzle and Minus on the underpressure sensor cartridge with a hose clamp 3.3.11 Installing the ignition fan Screw in the ignition tube on the right next to the infeed unit and insert the ignition fan in the ignition tube as shown Carefully screw in the locking screw finger-tight The locking screw must not be tightened to the extent that it deforms the ignition fan pipe 3.3.12 Installing the actuators for the air flaps Remove the pre-installed torque supports on the flange plates of the sliding air valve Insert the torque supports at the actuator as shown Put the actuator for primary air and the torque support on the primary air bar (on the right next to the infeed duct), so the connection cables point upwards and fix with the screws that were previously removed Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 29
3 Assembly Put the actuator for secondary air and the torque support on the secondary air bar (above the infeed duct), so the connection cables point downwards and fix with the screws that were previously removed Fit at the two actuators with self-tapping screws 3.3.13 Installing the induced draught fan Fit the flue gas connection pipe for the induced draught fan at the heat exchanger on the infeed side Stick the seal cord on the flange as shown Stick the seal cord on the interior of the induced draught console as shown Insert threaded rods with joint in the base plates Page 30 s
Assembly 3 Fit the assembled supports on the bottom of the induced draught console Screw the induced draught console to the flue gas connection pipe Stick seal cord to a flange of the induced draught compensator Screw the induced draught compensator to the induced draught console Fit 4 rubber buffers on the induced draught fan Screw the induced draught fan with rubber buffers onto the induced draught console and to the induced draught compensator Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 31
3 Assembly Stick seal cord at the flue gas pipe connection Fit blanking plate and cover plate opposite the induced draught unit 3.3.14 Installing the infeed unit Position the pre-installed infeed unit with ceramic fibre seal on the flange of the infeed duct Screw the infeed unit to the infeed duct Fit the carrying bolt on the lower flange of the infeed unit and tighten slightly 3.3.15 Installing the lambda probe and flue gas sensor Screw in the lambda probe and plastic bushing in the flue gas connection pipe Screw in the brass bushing opposite the lambda probe Insert the flue gas sensor and secure it using the wing screw Page 32 s
Assembly 3 3.3.16 Installing the combustion air blower fan Fit the combustion air blower fan above the combustion chamber door as shown 3.3.17 Installing the combustion chamber temperature sensor Push the cover hood onto the shaped screws of the insulating side panels at the top with spring shackles Screw the lug at the bottom of the cover hood to the insulating side panel Screw in the spacer tube with flange Screw in the combustion chamber temperature sensor and fix to the flange Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 33
3 Assembly 3.3.18 Installing the insulated door Fit flange bushings at the left and right door mounts Hang the right and left insulated doors 3.3.19 Installing the switch cabinet Screw the switch cabinet console on the combustion chamber door side to the heat exchanger Put the switch cabinet on the console Open the switch cabinet door and screw the switch cabinet to the console or the insulating side panel Page 34 s
Assembly 3 3.3.20 Installing the heat exchanger ash removal unit with ash screw (optional) Version: Heat exchanger left Version: Heat exchanger right The following steps are for the version with the heat exchanger on the left. If the heat exchanger is on the right, the steps should be adjusted appropriately. Put the rubber seal on the flange plate and fit the gear motor Heat exchanger left: the motor must point upwards Heat exchanger right: the motor must point downwards Remove the pre-installed locking screw with spacer washer from the ash screw and degrease the shaft stub Put on the gear motor at the ash screw Insert the key and chain wheel Fit the locking screw with spacer washer that was previously removed Insert the entire unit on the infeed side in the left heat exchanger ash removal unit Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 35
3 Assembly Fit both flange bearings at the pedestal as shown Do not tighten the screws! Push the ash screw through at the flange plate and pedestal Insert spacer sleeve as a shaft extension Put on the chain wheel and fix with locking screw and spacer washer Page 36 s
Assembly 3 Screw the pedestal to the flange plate and insert at the right heat exchanger ash removal unit Align the ash screw and fix the position by tightening the screws on both flange bearings Fit the assembly bracket for the chain tensioner to the pedestal Fit the chain tensioner to the assembly bracket Fit the securing flap for the protective cover as shown Put the roller chain over both chain wheels and secure to the connecting link Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 37
3 Assembly Tighten the chain with the chain tensioner Heat exchanger left: chain tensioner points upwards Heat exchanger right: chain tensioner points downwards Put on the protective cover and fix to the pedestal at the lug and laterally Put on the ash container of the heat exchanger ash removal unit and fix to the flange with wing nuts 3.3.21 Installing flue gas recirculation FGR (optional) Fit the FGR primary air box on the left next to the infeed unit as shown Page 38 s
Assembly 3 Put the flue gas collecting box on the induced draught fan and screw to the flange Connect the FGR primary air box and flue gas collecting box with the flue gas pipes provided Cut the flue gas pipes to length according to the layout of the units (heat exchanger left/right) Deburr the cut edges of the flue gas pipes after cutting to length Apply high temperature silicon before fitting the pipe clamps. The flue gas recirculation piping should be insulated after installation 3.3.22 Putting on the cover Put on the divided steel cover in the area of the outfeed and return connections Put on the insulating cover on top of the WOS cover Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 39
3 Assembly Connecting the boiler 3.4 Electrical connection Working on electrical components DANGER Risk of serious injuries from electric shocks Work on electrical components should only be carried out by authorised technicians Wiring should be installed using flexible sheathed cable and dimensioned in compliance with the locally applicable standards and guidelines 3.4.1 Laying the cable Lay the cables from the components through the cable ducts to the switch cabinet Secure the cables in the switch cabinet to the terminal strips provided using cable ties (= strain relief) NOTICE The cables of the individual units may have excess length. These cables should be coiled in the cable duct. Spread the coils of excess cable over the entire cable ducts to prevent the cable ducts from being over full. Bind the freely hanging cable to the drive motors using cable ties. The cables must not come into contact with the stoker duct. Wire the connections according to the schematic diagram See boiler control unit operating instructions for circuit diagrams 3.4.2 Installing cable covers After the end of electrical wiring: Put on the cable duct covers Fit the duct cover below the switch cabinet Fit edge protectors at cable leadthroughs Fit the cable duct cover plate at the top of the insulating side panels Page 40 s
Assembly Connecting the boiler 3 3.5 Connecting the thermal discharge safety device Remove the blind plug on the right next to the immersion sleeve for the safety temperature limiter and boiler sensor Seal and fit the immersion sleeve for thermal discharge safety device sensor and Insert the thermal discharge safety device sensor in the immersion sleeve and fix the protective hose with a locking screw NOTICE The thermal discharge safety device must be connected in accordance with 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. 5 4 2 1 3 1 Thermal discharge safety device sensor 2 Thermal discharge safety device (opens at 95 C) 3 Cleaning valve (T-piece) 4 Dirt trap 5 Pressure reducing valve *) *) Required when the cold water pressure is 6 bar. It must be impossible to shut off the connection manually. Minimum cold water pressure = 2 bar Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 41
4 Commissioning / Decommissioning 4 Commissioning / Decommissioning 4.1 Configuring the Boiler The boiler must be adjusted to the requirements of the heating system during commissioning NOTICE Optimum performance and efficient operation with low emissions can only be guaranteed if the system is set up by a qualified technician and the specified factory settings are observed. Take the following precautions: We recommend that the system is commissioned by Fröling customer services or an authorised installer. Before heating up the boiler for the first time: Set the controller to match your heating system. The keypad assignment and the steps necessary to modify the control parameters are detailed in the accompanying operating instructions for the boiler control unit. 4.2 Out of service for long periods If the boiler is out of service for several weeks (e.g. during the summer), we recommend that you perform the following maintenance tasks: Thoroughly clean the boiler. Completely close all doors and flaps If the boiler is to remain out of service during the winter: Have a trained specialist completely empty the system Protection from freezing! 4.3 Disassembly To disassemble the boiler, perform the assembly steps in reverse order. Assembly steps see 3.3 4.4 Disposal Dispose of all waste in an environment-friendly manner and in accordance with waste disposal regulations. Separate and clean recyclable materials and send them to a recycling centre. Page 42 s
Appendix Delivery certificate 5 5 Appendix 5.1 Delivery certificate - TX Customer no. Customer address: Installer: Telephone number: Fröling TX 150 kw Serial number Following items checked: System operation training provided System maintenance training provided Operating principle and self-checking of safety devices training provided All technical documents delivered in accordance with the table of contents of the document folder Test heating performed Commissioning report given to customer Telephone number for manufacturer's service department indicated Rating plate attached 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 Finally, we ask that you have the customer sign a copy of this confirmation and send it to FRÖLING Ges.m.b.H.. Fax: +43 (0)7248 606 600 Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen, Austria Page 43