Operating Instructions Turbomat TM 150/199/220 Translation of the original German operating instructions for the operator Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! B0310611_en Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.
Contents Contents 1 General 4 1.1 Product overview 5 2 Safety 7 2.1 Hazard levels of warnings 7 2.2 Pictograms used 8 2.3 General safety information 9 2.4 Permitted uses 2.4.1 10 Wood pellets Wood shavings Miscanthus Changing the fuel 10 10 10 11 2.4.2 2.4.3 2.4.4 Non-permitted fuels Qualification of operating staff Protective equipment for operating staff 11 11 12 2.5 Design information 12 2.5.
Contents 4.1 General information on servicing 27 4.2 Inspection and cleaning 28 4.3 Maintenance schedule 29 Daily Weekly Monthly Quarterly Six-monthly Yearly Empty the ash container 30 30 31 32 34 36 39 4.3.1 Required jobs and checks 30 4.3.2 4.3.3 Maintenance schedule for safety devices Maintenance instructions for hydraulic system 40 41 4.4 Preparing to test emissions 42 4.5 Maintenance agreement / Customer service 42 4.6 Replacement parts 42 4.
1 General 1 General Thank you for choosing a quality product from Froling. The product features a state-ofthe-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 and cost-ef‐ fectively.
1 General Product overview 1.1 Product overview 1 2 4 3 6 7 5 9 8 1 Wood chip boiler – Froling Turbomat 150 kW or 220 kW 2 Vertical 3-pass heat exchanger with Efficiency Optimisation System (WOS) 3 Cleaning port door 4 Multi-layer heat insulation for extremely low radiant heat losses.
1 General Product overview 12 13 14 14 10 20 18 16 19 12 22 17 21 11 10 Switch cabinet with integrated Lambdatronic H 3000 controller 11 Main switch: Switches the power supply on and off for the entire system 12 Selector switch for induced draught fan: AUTO: The induced draught fan is switched on and off by the Lambdatronic H 3000 OFF: The induced draught fan is switched off MANUAL: The induced draught fan is switched on and is not controlled by the Lamb‐ datronic 6 13 Control panel of the L
2 Safety Hazard levels of warnings 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.
2 Safety Pictograms used 2.2 Pictograms used The following symbols are used in the documentation and/or on the boiler to show what is required and forbidden and to give warnings. In accordance with machine guidelines, signs fitted directly in the hazard area indicate immediate hazards or safety procedures. These stickers must not be removed or cov‐ ered.
2 Safety General safety information 2.3 General safety information DANGER If the device is used incorrectly: Incorrect use of the system can cause severe injury and damage. When operating the system: ❒ Observe the instructions and information in the manuals ❒ Observe the details on procedures for operation, maintenance and cleaning, as well as troubleshooting in the individual manuals. ❒ Any work above and beyond this should be carried out by authorised heating engineers or by Froling customer services.
2 Safety Permitted uses 2.4 Permitted uses The Froling Turbomat TM is designed exclusively for heating domestic water. Only use fuels specified in the "Permitted fuels" section. ⇨ See "Permitted fuels" [page 10] The boiler should only be operated when it is in full working order. It should be operat‐ ed in accordance with the instructions, observing safety precautions, and you should ensure you are aware of the potential hazards.
2 Safety Permitted uses Changing the fuel CAUTION Incorrect parameter settings: Incorrect parameter settings have a significant adverse effect on the functioning of the boiler, and as a result this will invalidate the guarantee. Take the following precautions: ❒ If the fuel is changed (e.g. from wood chips to pellets), the system must be reset by Froling customer services. 2.4.
2 Safety Permitted uses 2.4.4 Protective equipment for operating staff You must ensure that staff have the protective equipment specified by accident pre‐ vention regulations. ▪ For inspection and cleaning: - suitable workwear - protective gloves - sturdy shoes ▪ Additional for operating: - Hearing protection (sound level > 70 dB) - Protective goggles 2.5 Design information Carrying out modifications to the system and changing or deactivating safety equip‐ ment is prohibited.
2 Safety Design information ▪ 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 of dust.
2 Safety Design information 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 lift. 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 lift. ➥ The minimum return temperature is 65 °C.
2 Safety Safety devices 2.
2 Safety Safety devices Item 1 Description Main switch Description Before starting any maintenance work: Switch off the entire system ❒ The power to all components is switched off. 2 Stop button If the system overheats: Switch off the boiler ❒ The pumps continue to run ➥ CAUTION! Always turn off the heating using the STOP button. Never use the main switch.
2 Safety Safety devices 2.6.
2 Safety Residual risks 2.7 Residual risks WARNING When touching hot surfaces: Severe burns are possible on hot surfaces and the flue gas pipe! When work is carried out on the boiler: ❒ Shut down the boiler in a controlled way (operating status "Switched off Off") and allow it to cool down ❒ Protective gloves must generally be worn for work on the boiler, and it should only be operated using the handles provided ❒ Insulate the flue pipes or simply avoid touching them during operation.
2 Safety Emergency procedure 2.8 Emergency procedure 2.8.1 Overheating of the system If the system overheats and the safety devices fail to operate, proceed as follows: NOTICE! Do not under any circumstances switch off the main switch or disconnect the power supply. ❒ Keep all the doors on the boiler closed ❒ Open all mixer taps, switch on all pumps. ➥ The Froling heating circuit control takes on this function in automatic operation.
3 Operating the system Assembly and initial startup 3 Operating the system 3.1 Assembly and initial startup Montage, Installation und Erstinbetriebnahme des Kessels darf nur durch qualifiziertes Personal erfolgen und wird in der beigelegten Montageanleitung beschrieben. Siehe Montageanleitung Turbomat TM 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.
3 Operating the system Filling/refilling the store with fuel 3.2 Filling/refilling the store with fuel Generell ist beim Befüllen des Lagerraumes auf die Verwendung des richtigen Brenn‐ stoffes zu achten: ⇨ See "Permitted fuels" [page 10] Für das Einblasen von Brennmaterial gilt zusätzlich: Anlagen, bei denen das Brennmaterial mittels Tankwagen angeliefert und in den La‐ gerraum eingeblasen wird, müssen mit einer Zellradschleuse ausgestattet sein.
3 Operating the system Filling/refilling the store with fuel 3.2.1 Sliding floor discharge unit ❒ The maximum dumping height (depending on the fuel density) as specified in the operating instructions for the sliding floor must not be exceeded. ❒ Driving over the fuel in the store can cause the material to be compacted. ➥ This may stop the slide rods from running smoothly.
Operating the system Filling/refilling the store with fuel 3 Blowing in fuel with the stirrer arms free and residual fuel present ❒ Before filling the store, shovel any residual fuel over the middle of the stirrer ❒ Switch on the stirrer for 4 minutes using the "Man. fuelling in com. chamb." parameter to draw the arms in. ❒ When the arms are drawn in against the stirrer plate, the store can be filled by blowing in fuel.
3 Operating the system Heating the boiler 3.3 Heating the boiler 3.3.1 Switching on the system ❒ Turn the main switch on the switch cabinet to the "ON" position ➥ After the system check by the controller, the system is ready for operation ➥ "Switched off Off" appears on the display 3.3.2 Switching on the boiler Heating up with automatic ignition (LM 500 Kom only) ❒ Press the Start button ➥ Fuel is fed into the combustion chamber and heated by the ignition blower fan.
3 Operating the system Heating the boiler Once the firewood is alight: ❒ Use the cleaning tool to push fuel to the back of the combustion chamber Start the boiler: ❒ Close the combustion chamber door ❒ Set the "ID fan" selector switch to "AUTO" ❒ Acknowledge the combustion chamber door error message ❒ Press the Start button ➥ The boiler is switched on and begins to heat up 3.3.
3 Operating the system Heating the boiler 3.3.
4 Servicing General information on servicing 4 Servicing 4.1 General information on servicing Regular cleaning of the boiler extends its life and is a basic requirement for smooth operation. You should therefore clean the boiler regularly.
4 Servicing Inspection and cleaning WARNING Inspection and cleaning of the combustion chamber with the combustion chamber temperature sensor in position Risk of damage to the thermocouple! Before inspection and cleaning work in the combustion chamber: ❒ Mark the position of the thermocouple. ❒ Loosen the clamp and pull out the thermocouple. ➥ After maintenance: ❒ Carefully clean any tar or soot deposits from the thermocouple.
Servicing Maintenance schedule 4 4.
4 Servicing Maintenance schedule 4.3.1 Required jobs and checks ❒ The following maintenance schedule is based on max. 3000 service hours per year. ➥ Reduce the intervals if this number is exceeded. Daily 1 Chamber + heat exchanger ❒ General visual inspection ❒ Clean components if necessary ➥ Change defective components immediately. 2 ID fan + flue gas pipe ❒ General visual inspection ❒ Clean components if necessary ➥ Change defective components immediately.
4 Servicing Maintenance schedule Monthly 7 Combustion chamber ❒ Using the flat scraper, pull the ash on the combustion chamber grate out through the cleaning port door ❒ Carefully remove deposits on side walls using the flat scraper and cleaning brush ➥ CAUTION! Be careful not to damage the firebricks with the flat scraper or cleaning brush.
4 Servicing Maintenance schedule ➥ Change any worn or deformed components ❒ Check the grate drive for dirt and deposits 9 Air-cooled grate side plates ❒ Check the grate side plates for dirt and slag and clean the openings with a slotted screwdriver if necessary Quarterly 10 Flue gas sensor ❒ Loosen the retaining screw and pull out the flue gas sensor ❒ Wipe off the flue gas sensor with a clean cloth ❒ Insert the flue gas sensor back into the flue gas pipe and finger-tighten the retain‐ ing screw 32 F
4 Servicing Maintenance schedule 11 Lambda probe ❒ Unscrew and remove the Lambda probe ➥ CAUTION: Lambda probe may be hot! ❒ Refit and finger-tighten the lambda probe ➥ Check the seal after tightening ➥ Do not use sharp objects or compressed air to clean the openings in the lamb‐ da probe 12 Conveyor grate In the chamber opposite the heat exchanger: ❒ Remove the cover from the cleaning hatch ❒ Remove the cleaning cover Operating Instructions TM 150/199/220 | B0310611_en 33
4 Servicing Maintenance schedule ❒ Check the grate area and ash rakes for dirt and deposits. Clean where necessary ➥ Check the seal when replacing the cleaning cover Six-monthly 13 Flue gas pipe (option) ❒ Remove the pipe insulation from the inspection cover ❒ Unfasten the nuts on the inspection cover and remove the cover ❒ Check the pipe for dirt and deposits.
4 Servicing Maintenance schedule 15 Heat exchanger ❒ Open the cover on the heat exchanger ❒ Remove all dirt and deposits from the chamber ❒ Check the turbulator or check the function of the WOS (min. stroke approx. 5 cm) ➥ Use a vacuum cleaner for this job.
4 Servicing Maintenance schedule ❒ Check the seal when replacing the ash removal flange ➥ Because of the high temperatures to which the screw is exposed, never re‐ move all the ash. Always leave a thin layer of ash to protect it.
4 Servicing Maintenance schedule 19 Heat exchanger cover ❒ Check fibre-glass seal for perfect alignment on the door frame ➥ Check the imprint on the fibre-glass seal. If the imprint of the seal is broken: ❒ The seal is no longer guaranteed ❒ Tighten the door latches or change the fibre-glass seal. 20 Cleaning port door + combustion chamber door ❒ Check fibre-glass seal for perfect alignment on the door frame ➥ Check the imprint on the fibre-glass seal.
4 Servicing Maintenance schedule ❒ Mark the position of the flange ❒ Loosen the blower flange screws ❒ Take out the blower and clean the blower wheel with a brush ➥ Refit in the marked position 22 Flue gas pipe ❒ Check the flue gas pipe and chimney for deposits and clean with the flue brush where necessary ➥ Always use stainless steel brushes to clean stainless steel flue pipes, chimney pipes and connections 23 Bearings ❒ Grease all bearings of the screws and the drives 24 Slide-in unit ❒ Check the fu
4 Servicing Maintenance schedule Empty the ash container Entaschung Wärmetauscher Entaschung Retorte Chamber ash removal: ❒ Unscrew the wing nuts on the ash container flange ❒ Separate the ash container from the flange and take the ash container to the ash disposal point Heat exchanger ash removal ❒ Unscrew the wing nuts on the ash box flange ❒ Separate the ash box from the flange and take the ash box to the ash disposal point Boiler with ash drawer (depending on model): ❒ Remove the star-shaped screws
4 Servicing Maintenance schedule 4.3.2 Maintenance schedule for safety devices No. 1 Component / Maintenance Operation System pressure Int. D ❒ Check the system pressure on the pressure gauge ➥ The value must be 20% over the pre-stressed pressure of the ex‐ pansion tank NOTICE! See the expansion tank operating instructions If the system pressure is less: ❒ Top up the water ☞ If this occurs frequently it indicates that the heating system is not sealed correctly. Call the installer.
4 Servicing Maintenance schedule 4.3.3 Maintenance instructions for hydraulic system WARNING Do not use unskilled personnel for hydraulic system maintenance Risk of injury and damage to property! Take the following precautions: ❒ Only allow trained professionals to carry out servicing and maintenance work on the hydraulic system. Follow the manufacturer's operating instructions. NOTICE! Do not allow the oil temperature to exceed +50°C or fall below -30°C.
4 Servicing Preparing to test emissions 4.4 Preparing to test emissions ❒ According to the stipulations of Austrian standard ÖNORM M 5861-1, the flue gas piping must have a built-in DN100 test flange. ❒ The entire system must be thoroughly cleaned 2 to 3 days before emission tests are performed. (The entire system in this case means: ash containers, combustion chamber, vault, heat exchanger, smoke flue pipe connection between boiler and cyclone, container under cyclone, flue gas piping and chimney).
4 Servicing Disposal information NOTICE Installing non-original parts will invalidate the guarantee. ❒ Only replace components or parts with original replacement parts 4.7 Disposal information 4.7.1 Disposal of the ash ❒ The ash should be disposed of in accordance with waste management regula‐ tions. 4.7.2 Disposal of system components ❒ Ensure that they are disposed of in an environmentally friendly way in accordance with waste management regulations.
5 Troubleshooting General faults in the power supply 5 Troubleshooting 5.1 General faults in the power supply Error characteristics Cause of error Elimination of error Nothing is shown on the dis‐ play General power failure No power to the controller Main switch is turned off Turn on the main switch FI circuit breaker or line pro‐ tection is switched off Switch on the FI circuit break‐ er or line protection Faulty fuse in the controller Replace the fuse – note the amperage (10AT) 5.1.
5 Troubleshooting Faults with fault message 5.3 Faults with fault message If a fault has occurred and has not yet been cleared: ❒ Status LED flashes red ❒ A fault message is shown on the display The term "fault" is a collective term for warnings, errors and alarms. The boiler reacts differently to the three types of message: WARNING In case of warnings the boiler initially continues controlled opera‐ tion, giving the option of resolving the error quickly to prevent a shutdown.
6 Appendix Addresses 6 Appendix 6.1 Addresses 6.1.1 Address of manufacturer FRÖLING Heizkessel- und Behälterbau GesmbH Industriestaße 12 A-4710 Grieskirchen AUSTRIA TEL 0043 (0)7248 606 0 FAX 0043 (0) 7248 606 600 INTERNET www.froeling com 6.1.2 Address of the installer Stamp 46 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.
