wood chip boiler t4 24-150 - loco2 heat installation... · 2018. 7. 17. · en 13384-1 chimneys -...

Installation Instructions

Wood chip boiler T4 24-150

Translation of the original German operating instructions for techniciansRead and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!M1211017_en | Edition 27/03/2017

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

Contents

1 General 41.1 About this manual 4

2 Safety 52.1 Hazard levels of warnings 52.2 Qualification of assembly staff 62.3 Personal protective equipment for assembly staff 62.4 Design Information 72.4.1 Notes on standards 7 General standards for heating systems 7 Standards for structural and safety devices 7 Standards for heating water 7 Regulations and standards for permitted fuels 82.4.2 Installation and approval of the heating system 82.4.3 General information for installation room (boiler room) 82.4.4 Requirements for central heating water 92.4.5 Notes for using pressure maintenance systems 102.4.6 Return temperature control 112.4.7 Use with storage tank 112.4.8 Chimney connection/chimney system 12 Draught limiter 12 Measuring port 12 Boiler data for planning the flue gas system 13

3 Technology 153.1 Dimensions 153.2 Technical specifications 16

4 Installation 224.1 Transport 224.2 Positioning 224.3 Temporary storage 234.4 Setting up in the boiler room 244.4.1 Remove boiler from pallet (T4 24-110) 244.4.2 Remove the protective transportation frame (T4 130/150) 244.4.3 Moving the boiler in the boiler room 244.4.4 Minimum distances in the boiler room 254.5 Assembly work 264.5.1 Installing the Ash Container 264.5.2 Assemble the stoker unit 274.5.3 Mount the cover plate on the rear boiler wall (T4 130/150) 284.6 Electrical connection 284.6.1 Removing the controller cover 284.6.2 Laying cables 294.6.3 Mains connection 304.6.4 Information on circulating pumps 31

5 Start-up 32

Contents

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

5.1 Before commissioning / configuring the boiler 32

6 Decommissioning 336.1 Mothballing 336.2 Disassembly 336.3 Disposal 33

7 Appendix 347.1 Addresses 347.1.1 Address of manufacturer 347.1.2 Address of the installer 34

Contents

Installation Instructions T4 24-150 | M1211017_en 3

1 GeneralThank 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 testingguidelines.Please read and observe the documentation provided and always keep it close to thesystem for reference. Observing the requirements and safety information in thedocumentation makes a significant contribution to safe, appropriate, environmentallyfriendly and economical operation of the system.The constant further development of our products means that there may be minordifferences from the pictures and content. If you discover any errors, please let usknow: [email protected] 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 orheating engineers are requested to return a copy of the delivery certificate togetherwith the guarantee card to Froling. On commissioning by FROLING Customer Servicethe validity of the delivery certificate will be noted on the customer service record.

1.1 About this manualThese installation instructions contain information for the following T4 boilers:T4-24, T4-30, T4-40, T4-50, T4-60, T4-701), T4-75, T4-90, T4-100 (99 kW)2), T4-100, T4-110, T4-130, T4-150

1) T4-70 only available in France; 2) T4-100 with 99kW nominal output only available in UK;

Issuing a deliverycertificate

1 GeneralAbout this manual


2 Safety

2.1 Hazard levels of warningsThis documentation uses warnings with the following hazard levels to indicate directhazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will leadto serious injury or death. You must follow the instructions!

WARNING

The dangerous situation may occur and if measures are not observed it will leadto serious injury or death. Work with extreme care.

CAUTION

The dangerous situation may occur and if measures are not observed it will leadto minor injuries or damage to property.

Safety 2Hazard levels of warnings


2.2 Qualification of assembly staff

CAUTION

Assembly and installation by unqualified persons:

Risk of personal injury and damage to property

During assembly and installation:❒ Observe the instructions and information in the manuals❒ Only allow appropriately qualified personnel to work on the system

Assembly, installation, initial startup and servicing must always be carried out byqualified personnel:- Heating technician / building technician- Electrical installation technician- Froling customer servicesThe assembly staff must have read and understood the instructions in thedocumentation.

2.3 Personal protective equipment for assembly staffYou must ensure that staff have the protective equipment specified by accidentprevention regulations.

▪ For transportation, setup and assembly:- suitable work wear- protective gloves- sturdy shoes (min. protection class S1P)

2 SafetyQualification of assembly staff


2.4 Design Information

2.4.1 Notes on standardsThe system must be installed and commissioned in accordance with the local fire andbuilding regulations. Unless contrary to other national regulations, the latest versionsof the following standards and guidelines apply:

General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fedcombustion systems, nominal heat output up to 500 kW

EN 12828 Heating systems in buildings - design of water-based heatingsystems

EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methodsPart 1: Chimneys serving one appliance

ÖNORM H 5151 Planning of central hot water heating systems with or without hotwater preparation

ÖNORM M 7510-1 Guidelines for checking central heating systemsPart 1: General requirements and one-off inspections

ÖNORM M 7510-4 Guidelines for checking central heating systemsPart 4: Simple check for heating plants for solid fuels

Standards for structural and safety devices

ÖNORM H 5170 Heating installation - Requirements for construction and safetyengineering, as well as fire prevention and environmentalprotection

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 inclosed warm water heating systems at operating temperaturesup to 100°C (Austria).

VDI 2035 Prevention of damage hot water heating systems (Germany)

SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioningsystems (Switzerland)

UNI 8065 Technical standard regulating hot water preparation.DM 26.06.2015 (Ministerial Decree specifying the minimumrequirements)Follow the instructions of this standard and any related updates.

Safety 2Design Information


Regulations and standards for permitted fuels

1. BImSchV First Order of the German Federal Government for theimplementation of the Federal Law on Emission Protection(Ordinance on Small and Medium Combustion Plants) in theversion published on 26 January 2010, BGBl. JG 2010 Part I No. 4.

EN ISO 17225-2 Solid bio-fuel - Fuel specifications and classesPart 2: Wood pellets for use in industrial and domestic systems

EN ISO 17225-4 Solid bio-fuel - Fuel specifications and classesPart 4: Wood chips for non-industrial use

2.4.2 Installation and approval of the heating systemThe boiler should be operated in a closed heating system. The following standardsgovern the installation:

EN 12828 - Heating Systems in Buildings

NOTICE! Each heating system must be officially approved.The appropriate supervisory authority (inspection agency) must always be informedwhen installing or modifying a heating system, and authorisation must be obtainedfrom the building authorities:Austria: report to the construction authorities of the community or magistrateGermany: report new installations to an approved chimney sweep / the buildingauthorities.

2.4.3 General information for installation room (boiler room)

Boiler room characteristics▪ The floor must be even, clean and dry and have an adequate load-bearing

capacity.▪ 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 ensure sufficient

lighting in the boiler room in accordance with national workplace designregulations.

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

▪ Danger of fire due to flammable materials. The floor of the boiler room must not be flammable. No flammable materialsshould be stored near the boiler. Flammable objects (e.g. clothing) must not be puton the boiler to dry.

Note on standards

2 SafetyDesign Information


▪ Damage due to impurities in combustion air.Do not use any solvents or cleaning agents containing chlorine and hydrogenhalides in the room where the boiler is installed (e.g. chlorination units forswimming pools).

▪ Keep the air suction opening of the boiler free of dust.▪ The system must be protected against the chewing or nesting of animals (e.g.

rodents etc.).

Ventilation of the boiler roomVentilation 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, etc.) from obstructing the air flow. 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 requirementsTRVB H118 - Technical directives on fire protection/prevention

2.4.4 Requirements for central heating waterUnless contrary to other national regulations, the latest versions of the followingstandards and guidelines apply:

Austria:Germany:

ÖNORM H 5195VDI 2035

Switzerland:Italy:

SWKI BT 102-01UNI 8065

Observe the standards and also follow the recommendations below:❒ Aim for a pH value of between 8.2 and 10.0. If the central heating water comes

into contact with aluminium, the pH value must be between 8.0 and 8.5❒ Use prepared water which complies with the standards cited above for filling and

makeup water❒ Avoid leaks and use a closed heating system to maintain water quality during

operation❒ When filling with make-up water, always bleed the filling hose before connecting,

in order to prevent air from entering the system Advantages of prepared water:▪ Complies with the applicable standards▪ Less of a drop in output due to reduced limescale build-up▪ Less corrosion due to fewer aggressive substances▪ Long-term cost savings thanks to improved energy efficiency

Note on standards



Limit values for filling and make-up water:

Austria Germany Switzerland

Total hardness ≤ 1.0 mmol/L ≤ 2.0 mmol/L < 0.1 mmol/L

Conductivity - < 100µS/cm < 100 µS/cm

pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5

Chloride < 30 mg/L < 30 mg/L < 30 mg/L

Additional requirements for Switzerland:

The filling and make-up water must be demineralised (fully purified)▪ The water must not contain any ingredients that could settle and accumulate in the

system▪ This makes the water non-electroconductive, which prevents corrosion▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can

weaken corrosive materials in certain conditions If some of the system water is lost, e.g. during repairs, the make-up water must also bedemineralised. It is not enough to soften the water. The heating system must beprofessionally cleaned and rinsed before filling the units. Inspection:

▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the centralheating water comes into contact with aluminium, the pH value must be between 8.0 and8.5

▪ Yearly. Values must be recorded by the owner

2.4.5 Notes for using pressure maintenance systemsPressure maintenance systems in hot-water heating systems keep the requiredpressure within predefined limits and balance out volume variations caused bychanges in the hot-water temperature. Two main systems are used:

Compressor-controlled pressure maintenance

In compressor-controlled pressure maintenance units, a variable air cushion in theexpansion tank is responsible for volume compensation and pressure maintenance. Ifthe pressure is too low, the compressor pumps air into the tank. If the pressure is toohigh, air is released by means of a solenoid valve. The systems are built solely withclosed-diaphragm expansion tanks to prevent the damaging introduction of oxygeninto the heating water.

Pump-controlled pressure maintenance

A pump-controlled pressure maintenance unit essentially consists of a pressure-maintenance pump, relief valve and an unpressurised receiving tank. The valvereleases hot water into the receiving tank if the pressure is too high. If the pressuredrops below a preset value, the pump draws water from the receiving tank and feeds itback into the heating system. Pump-controlled pressure maintenance systems with



open expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via thesurface of the water, exposing the connected system components to the risk ofcorrosion. These systems offer no oxygen removal for the purposes of corrosioncontrol as required by VDI 2035 and in the interests of corrosion protection should notbe used.

2.4.6 Return temperature controlIf the hot water return is below the minimum return temperature, some of the hot wateroutfeed will be mixed in.

CAUTION

Risk of dropping below dew point/condensation formation if operated withoutreturn temperature control.

Condensation water forms an aggressive condensate when combined withcombustion residue, leading to damage to the boiler.

Take the following precautions:❒ We recommend using a return temperature control.

➥ The minimum return temperature is 45 °C. We recommend fitting somesort of control device (e.g. thermometer).

2.4.7 Use with storage tank

NOTICE

In principle it is not necessary to use a storage tank for the system to runsmoothly. 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 accordancewith ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling.⇨ See "Addresses" [page 34]



2.4.8 Chimney connection/chimney systemEN 303-5 specifies that the entire flue gas system must be designed to prevent,wherever possible, damage caused by seepage, insufficient feed pressure andcondensation. Please note in this respect that flue gas temperatures lower than 160Kabove 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 befound in the table below.The connection between the boiler and the chimney system should be as short aspossible. The upward angle of the connection should not exceed 30 - 45°. Insulate theconnection. The entire flue gas system - chimney and connection - should becalculated 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 chimneysweep.NOTICE! TRVB H 118 (Austria only) stipulates that an explosion flap must be installedin the connecting piece (flue pipe) directly next to the boiler. It should be situated insuch a way that is poses no risk to persons!

Draught limiterWe generally recommend the installation of a draught limiter. A draught limiter mustbe installed if the maximum permissible feed pressure as given in the boiler data forplanning the flue gas system is exceeded.NOTICE! Install the draught limiter directly under the mouth of the flue line, as thepressure is constantly low at this point.

Measuring portFor measuring the emissions of the system, a suitable measuring port must beinstalled in the connecting piece between the boiler and chimney system.

D

D

M

2 x D

In front of the measuring port (M) a straight inlet section should be located at adistance corresponding to about twice the diameter (D) of the connecting piece. Astraight outlet section at a distance corresponding to about the single diameter of theconnecting piece should be provided after the measuring port. The measuring portmust remain closed whenever the system is in operation.Ensure that the outside diameter of the sampling probes in the measuring port canaccommodate up to 13 mm. To avoid the ingress of false air, the diameter of themeasuring port must not exceed 21 mm.



Boiler data for planning the flue gas system

Designation T4

24 30 40 50

Flue gas temperature at nominal load °C 125 135 130 140

Flue gas temperature at partial load 80 85 80 85

Flue gas mass flow at nominal load kg/h 68 83 112 137

kg/s 0.019 0.023 0.031 0.038

Flue gas mass flow at partial load kg/h 29 32 43 54

kg/s 0.008 0.009 0.012 0.015

Required feed pressure at nominal load Pa 5 5 5 5

mbar 0.05 0.05 0.05 0.05

Required feed pressure at partial load Pa 2 2 2 2

mbar 0.02 0.02 0.02 0.02

Maximum permissible feed pressure Pa 30

mbar 0.3

Flue pipe diameter mm 149 149 149 149

Description T4

60 701) 75 90




kg/s 0.046 0.054 0.058 0.071


kg/s 0.017 0.020 0.021 0.025


mbar 0.05 0.05 0.05 0.05


mbar 0.02 0.02 0.02 0.02


mbar 0.3

Flue pipe diameter mm 179 179 179 1991.T4-70 only available in France



Designation T4

100 110 130 150




kg/s 0.077 0.083 0.101 0.119


kg/s 0.027 0.029 0.033 0.037


mbar 0.05 0.05 0.05 0.05


mbar 0.02 0.02 0.02 0.02


mbar 0.3

Flue pipe diameter mm 199 199 199 199



3 Technology

3.1 Dimensions

Item Description Unit 24/30 40/50 60/75 90/100/110 130/150

H Height, boiler mm 1390 1620 1620 1720 1720

H1 Total height including flue gaspipe connection

1440 1670 1670 1770 1770

H2 Height, flow connection 1195 1425 1425 1530 1540

Boiler outfeed connection 6/4“ 6/4“ 6/4“ 2“ DN65 / PN6

H3 Height, return connection mm 270 270 270 170 200

Boiler return connection 6/4“ 6/4“ 6/4“ 2“ DN65 / PN6

H4 Height, drainage connection mm 140 140 140 140 140

Boiler drainage connection Inch 1/2 1/2 1/2 1 1

H5 Height, rotary valve connection mm 600 650 650 650 650

B Width, boiler mm 600 770 770 880 880

B1 Total width with stoker unit 1360 1530 1530 1640 1640

B2 Width of stoker unit 760 760 760 760 760

B3 Distance from boiler side tostoker connection

470 470 470 470 470

L Length, boiler mm 1200 1200 1570 1570 1905

L1 Total length including ashcontainer and ID fan

1430 1430 1840 1840 2300

L2 Length, back of boiler to stokerconnection

755 755 1045 1045 1305

Technology 3Dimensions


3.2 Technical specifications

Designation T4

24 30 40 50

Rated heat output kW 24 30 40 50

Output range 7.2-24.0 9.0-30.0 12.0-40.0 15.0-50.0

Electrical connection 400 V / 50 Hz / C16A

Power consumption W 45-115 54-142 51-150 47-158

Boiler weight kg 620 640 840 860

Boiler capacity (water) l 105 105 160 160

Water pressure drop (ΔT = 10/20 K) mbar 3.9 / 1.2 4.8 / 1.4 5.2 / 1.8 5.5 / 2.2

Min. boiler return temperature °C 45

Max. permitted operating temperature 90

Permitted operating pressure bar 3

Boiler class as per EN 303-5: 2012 5

Airborne sound level dB(A) < 70

Permitted fuel as per EN ISO 17225 1) Part 2: Wood pellets class A1 / D06part 4: Wood chips class A1 / P16S-P31S

1.Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”

Designation Test report data

24 30 40 50

Testing institute TÜV 1)

Test report number (wood chips/pellets fuel) 10-UW/Wels-EX-191/1

10-UW/Wels-EX-191/3

11-U-368 10-UW/Wels-EX-191/5

1.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

Test data with wood chip fuelEmissions in [mg/MJ] 1) (nominal load/partial load)

24 30 40 50

Carbon monoxide (CO) mg/MJ 9 / 28 35 / 28 25 / 34 14 / 40

Nitrous oxide (NOx) mg/MJ 70 / 57 92 / 57 88 / 61 84 / 64

Organic carbon (OGC) mg/MJ <1 / 1.3 <1 / 1.3 <1 / 1.1 <1 / <1

Dust mg/MJ 13 / 15 13 / 15 12 / 11 10 / 7

Boiler efficiency % 92.3 / 91.6 91.0 / 91.6 92.1 / 92.4 93.1 / 93.21.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data with wood chip fuelEmissions in [mg/m³] 1) (nominal load/partial load)

24 30 40 50

Carbon monoxide (CO) mg/m³ 13 / 40 52 / 40 36 / 50 20 / 59

Nitrous oxide (NOx) mg/m³ 103 / 83 135 / 83 130 / 89 124 / 95

Organic carbon (OGC) mg/m³ <1 / 1.9 <1 / 1.9 <1 / <2 <1 / <2

Dust mg/m³ 19 / 22 19 / 22 17 / 17 15 / 11

Boiler efficiency % 92.3 / 91.6 91.0 / 91.6 92.1 / 92.4 93.1 / 93.21.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%

3 TechnologyTechnical specifications


Regulation (EU) 2015/1187

Energy efficiency A+ A+ A+ A+


Energy efficiency index of the boiler model 111 110 113 116

Seasonal space heating energy efficiency % 75 75 77 79

Energy efficiency index of the boiler in package withtemperature control

113 112 115 118

Energy efficiency class of the boiler in package withtemperature control

A+ A+ A+ A+

Test data with wood pellet fuelEmissions in [mg/MJ] 1) (nominal load/partial load)

24 30 40 50

Carbon monoxide (CO) mg/MJ 8 / 69 7 / 23 6 / 18 <4 / 12


Organic carbon (OGC) mg/MJ <1 / 1.4 <1 / <1 <1 / <1 <1 / <1

Dust mg/MJ 11 / 19 12 / 12 11 / 9 9 / 6


Test data with wood pellet fuelEmissions in [mg/m³] 1) (nominal load/partial load)

24 30 40 50

Carbon monoxide (CO) mg/m³ 12 / 101 10 / 34 8 / 26 <5 / 17


Organic carbon (OGC) mg/m³ <1 / 2 <1 / <2 <1 / <2 <1 / <2

Dust mg/m³ 16 / 29 17 / 18 15 / 14 13 / 9



Energy efficiency A+ A+ A+ A+


Energy efficiency index of the boiler model 114 114 118 121

Seasonal space heating energy efficiency % 77 77 80 82


116 116 120 125


A+ A+ A+ A++

Designation T4

60 70 1) 75 90

Nominal output kW 60 69 75 90

Output range 18 - 60 20.7 - 69 22.5 - 75 27 - 90


Power consumption W 51 - 176 54 - 193 56 - 204 61 - 232

Technology 3Technical specifications


Designation T4

60 70 1) 75 90

Boiler weight kg 1060 1070 1080 1350

Boiler capacity (water) l 220 220 220 260

Water pressure drop (ΔT = 10/20 K) mbar 7.8 / 2.6 9.9 / 3.0 11.4 / 3.2 14.9 / 3.8







1.T4-70 only available in France2.Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”


60 70 1) 75 90


Test report no. 14-U-342 14-U-343 14-U-344 14-U-3451.T4-70 only available in France2.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels


60 70 75 90



Organic carbon (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1

Dust mg/MJ 11 / 8 11 / 8 12 / 9 12 / 9



60 70 75 90



Organic carbon (OGC) mg/m³ <1 / <2 <1 / <2 <1 / <2 <1 / <2

Dust mg/m³ 16 / 12 17 / 12 17 / 13 18 / 13



Energy efficiency A+ A+ -

Rated heat output kW 60 69 -

Energy efficiency index of the boiler model 116 116 -

Seasonal space heating energy efficiency % 79 79 -





118 118 -


A+ A+ -


60 70 75 90



Organic carbon (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1

Dust mg/MJ 9 / 7 9 / 8 9 / 9 8 / 10



60 70 75 90



Organic carbon (OGC) mg/m³ <2 / <2 <2 / <2 <2 / <2 <2 / <2

Dust mg/m³ 13 / 10 13 / 12 13 / 13 12 / 15



Energy efficiency A+ A+ -

Rated heat output kW 60 69 -

Energy efficiency index of the boiler model 122 122 -

Seasonal space heating energy efficiency % 83 83 -


126 126 -


A++ A++ -

Designation T4

100 100 1) 110 130 150

Nominal output kW 100 99 110 130 150

Heat output range 30 - 100 29.7 - 99 33 - 110 39 - 130 45 – 150


Power consumption W 65 - 250 65 - 250 65 - 250 90 - 240 115 - 264

Boiler weight kg 1360 1360 1370 1730 1750

Boiler capacity (water) l 260 260 260 340 340

Water pressure drop (ΔT = 10/20 K) mbar 17.2 / 4.2 17.2 / 4.2 18.7 / 5.2 23.3 / 6.9 30.6 / 8.3




Designation T4

100 100 1) 110 130 150






1.T4-100 with 99 kW nominal output only available in UK2.Detailed information on the fuel can be found in the operating instructions in the section entitled “Permitted fuels”


100 100 1) 110 130 150


Test report no. 10-UW/Wels-

EX-191/6 &8

10-UW/Wels-

EX-191/10

10-UW/Wels-

EX-191/7 &9

13-UW/Wels-

EX-257/2

13-UW/Wels-

EX-257/1

1.T4-100 with 99 kW nominal output only available in UK2.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels


100 100(99 kW)

110 130 150

Carbon monoxide (CO) mg/MJ 7 / 6 7 / 6 7 / 6 7 / 17 4 / 17

Nitrous oxide (NOx) mg/MJ 74 / 71 74 / 71 74 / 71 65 / 78 64 / 78

Organic hydrocarbons (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1 <1 / <1

Dust mg/MJ 13 / 10 13 / 10 13 / 10 10 / 9 12 / 9

Boiler efficiency % 92.9 / 93.9 92.9 / 93.9 92.9 / 93.9 93.3 / 94.6 93.8 / 94.61.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ


100 100(99 kW)

110 130 150

Carbon monoxide (CO) mg/m³ 10 / 8 10 / 8 10 / 8 11 / 25 6 / 25

Nitrous oxide (NOx) mg/m³ 108 / 105 108 / 105 108 / 105 95 / 114 94 / 114

Organic hydrocarbons (OGC) mg/m³ <1 / <2 <1 / <2 <1 / <2 <1 / <2 <1 / <2

Dust mg/m³ 19 / 14 19 / 14 19 / 14 15 / 13 18 / 13

Boiler efficiency % 92.9 / 93.9 92.9 / 93.9 92.9 / 93.9 93.3 / 94.6 93.8 / 94.61.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%


100 100(99 kW)

110 130 150

Carbon monoxide (CO) mg/MJ 9 / 10 9 / 10 9 / 10 8 / 9 7 / 7

Nitrous oxide (NOx) mg/MJ 67 / 51 67 / 51 67 / 51 69 / 56 71 / 61

Organic hydrocarbons (OGC) mg/MJ <1 / <1 <1 / <1 <1 / <1 <1 / <1 <1 / <1

Dust mg/MJ 8 / 11 14 / 11 8 / 11 8 / 9 8 / 6

Boiler efficiency % 93.5 / 94.6 93.7 / 94.6 93.5 / 94.6 93.7 / 94.5 93.8 / 94.51.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ




100 100(99 kW)

110 130 150

Carbon monoxide (CO) mg/m³ 14 / 15 13 / 15 14 / 15 12 / 13 10 / 10

Nitrous oxide (NOx) mg/m³ 99 / 76 98 / 76 99 / 76 102 / 83 105 / 89

Organic hydrocarbons (OGC) mg/m³ <2 / <2 <1 / <2 <2 / <2 <2 / <2 <2 / <2

Dust mg/m³ 12 / 16 20 / 16 12 / 16 12 / 13 11 / 9

Boiler efficiency % 93.5 / 94.6 93.7 / 94.6 93.5 / 94.6 93.7 / 94.5 93.8 / 94.51.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%



4 Installation

4.1 TransportThe product is delivered on pallet(s) in cardboard packaging.

NOTICE

Possibility of damage to components if handled incorrectly

❒ Follow the transport instructions on the packaging❒ Transport components with care to avoid damage❒ Protect components against damp❒ Pay attention to the pallet's centre of gravity when lifting

4.2 Positioning❒ Position a fork-lift or similar lifting device at the pallet and bring in the components

If the boiler cannot be brought in on the pallet:❒ Remove the cardboard and remove the boiler from the pallet

⇨ See "Remove boiler from pallet (T4 24-110)" [page 24] or⇨ See "Remove the protective transportation frame (T4 130/150)" [page 24]

Positioning using a crane (T4 24-50)

❒ Removing the insulating cover and the insulating mat❒ Loosen the lock nut on the star-shaped screw knob❒ Unlock the cover by turning the star-shaped screw knob and remove

4 InstallationTransport


❒ Pull out the guide plate

➥ The two lifting eye bolts for the boiler are located under the guide plate

Positioning using a crane (T4 60-150)

❒ Removing the insulating cover and the insulating mat

➥ The lifting eye bolt is underneath the insulating material in front of the heatexchanger cover

➥ TIP: also remove the controller cover during transportation to avoid damage

4.3 Temporary storageIf the system is to be assembled at a later stage:❒ Store components at a protected location, which is dry and free from dust

➥ Damp conditions and frost can damage components, particularly electric ones!

Installation 4Temporary storage


4.4 Setting up in the boiler room

4.4.1 Remove boiler from pallet (T4 24-110)

❒ Remove securing devices used during transportation on the left and right side of

the boiler❒ Pull out floor insulation❒ Lift boiler off pallet

TIP: We recommend using Froling’s KHV 1400 boiler lifting system to help remove thepallet

4.4.2 Remove the protective transportation frame (T4 130/150)

❒ After removing the cardboard, disassemble the protective transportation frame by

loosening the screws

4.4.3 Moving the boiler in the boiler room❒ Position a fork-lift or similar lifting device with a suitable load-bearing capacity at

the base frame❒ Lift and transport to the intended position in the installation room

➥ Observe the minimum distances in the boiler room.

4 InstallationSetting up in the boiler room


4.4.4 Minimum distances in the boiler room▪ The system should generally be set up so that it is accessible from all sides

allowing quick and easy maintenance.▪ Regional regulations regarding necessary maintenance areas for inspecting the

chimney should be observed in addition to the specified minimum distances!▪ Observe the applicable standards and regulations when setting up the system.▪ Observe additional standards for noise protection

(ÖNORM H 5190 - Noise protection measures)

Description Unit 24/30 40/50 60-75 90-150

A Minimum distance insulated door to wall

mm 600 800 800 900

B Minimum distance side of boiler to wall

200 200 200 200

C Minimum distance back of boiler to wall

500 500 500 500

D Minimum distance stoker to wall

300 300 300 300

Minimum store height 1700 1900 2050 2150

Installation 4Setting up in the boiler room


4.5 Assembly work

4.5.1 Installing the Ash Container

❒ Open the side clamps and remove the ash container cover❒ Remove the contents from the ash container

❒ Open the insulated door and push the locking lever up❒ Place the ash container in the boiler and clamp with the locking lever❒ Replace the cover and secure with the clamps

➥ Make sure that the pin (2) is inserted in the limit switch (1) correctly

4 InstallationAssembly work


4.5.2 Assemble the stoker unit

❒ Remove the upper and lower shutter mask on the stoker side❒ Remove the pre-installed screws on the connection flange

❒ Position the stoker unit by the boiler as shown❒ Push the stoker unit towards the boiler and insert into the connection flange

beside the two lock bolts (1)➥ Adjust the height of the stoker unit if necessary using the adjustable feet

❒ Secure the unit to the boiler using the previously removed screws

❒ Place the hose clamp provided on the igniter tube❒ Push the ignition fan into the igniter tube and secure with the hose clamp

Installation 4Assembly work


4.5.3 Mount the cover plate on the rear boiler wall (T4 130/150)

❒ Position the lower cover plate on the rear boiler wall and attach to the boiler using

screws

4.6 Electrical connection

DANGER

When working on electrical components:

Risk of electrocution!

When work is carried out on electrical components:❒ Only have work carried out by a qualified electrician❒ Observe the applicable standards and regulations

➥ Work must not be carried out on electrical components by unauthorisedpersons

4.6.1 Removing the controller cover

❒ Removing the insulating cover and the insulating mat

4 InstallationAssembly work


❒ Remove the locking screws on the controller cover❒ Push the controller cover back and then lift off

With the T4 60-150:

❒ After undoing the locking screws, slide the two covers back at the same time and

then lift off the controller cover (= front part)

4.6.2 Laying cablesLay the stoker drive and ignition fan cables and the connection cable for the dischargesystem in the cable duct from the stoker unit to the boiler:

❒ Remove the cover of the cable duct on the stoker duct❒ Run the cables up through the insulating side panel

Installation 4Electrical connection


❒ Pull the cables up through the side openings in the controller box and secure to

the strain relief bar with cable ties❒ Lay all stoker cables in the cable duct and replace the cover on the duct

❒ Replace the cover plate on the stoker duct❒ Wire the connections according to the wiring diagram

NOTICE! See boiler control unit operating instructions for circuit diagrams❒ Once the wiring has been completed, replace the controller cover

4.6.3 Mains connectionAt the back of the boiler:❒ Press the mains plug to release it and remove❒ Open the plug and connect the mains connection cable

➥ Flexible sheathed cable must be used for the wiring; this must be of the correctsize to comply with applicable regional standards and regulations.

➥ The power supply line (mains connection) must be fitted with a C16A fuse bythe customer.

4 InstallationElectrical connection


4.6.4 Information on circulating pumps

NOTICE

According to 2012/622/EU external, wet running circulating pumps must complywith the following limit values of the Energy Efficiency Index (EEI):

- Effective from 01/01/2013: Wet running circulating pumps with EEI ≤ 0.27- Effective from 08/01/2015: Wet running circulating pumps with EEI ≤ 0.23

Only high efficiency pumps with a connection option for a control signal (PDM / 0-10V)should be connected to speed-controlled pump outputs (pump 1 on the core moduleand pump outputs on the hydraulic module). In this case, the control line is connectedto the corresponding PDM outputs of the boards. Observe the connection instructionsin the boiler controller documentation!

CAUTION

When using high efficiency pumps without an additional control line at speed-controlled pump outputs:

Malfunctions of the boiler, the pump and the hydraulic system may occur!

Therefore:❒ Do not connect EC motor pumps without a control line to the speed-controlled

pump outputs of the boards.➥ Only use special high efficiency pumps with a connection option for a

control line (PDM/0-10V)!➥ Observe the additional instructions and information on board outputs in the

operation instructions for the boiler controller.

Installation 4Electrical connection


5 Start-up

5.1 Before commissioning / configuring the boilerThe boiler must be configured to the heating system on initial start-up.

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteedif the system is set up by trained professionals and the standard factory settingsare observed.

Take the following precautions:❒ Initial startup should be carried out with an authorised installer or with Froling

customer services

NOTICE

Foreign bodies in the heating system impair its operational safety and can resultin damage to property.

As a result:❒ The whole system should be rinsed out before initial start-up in accordance

with EN 14336.❒ Recommendation: Make sure the hose diameter of the flush nozzles in the

flow and return complies with ÖNORM H 5195 and is the same as the hosediameter in the heating system, however not more than DN 50.

❒ Turn on the main switch❒ Set the boiler controller to the system type.❒ Load the boiler default values.

NOTICE! For the keypad layout and instructions for modifying the parameters, see theinstruction manual for the boiler controller.❒ Check the system pressure of the heating system.❒ Check that the heating system is fully vented.❒ Check that all water connections are tightly sealed

➥ Pay particular attention to those connections from which plugs were removedduring assembly.

❒ Check that the safety devices are present and working efficiently.❒ Check that there is sufficient ventilation in the boiler room.❒ Check the seal of the boiler.

➥ All doors and inspection openings must be tightly sealed.❒ Check that the drives and servo motors are working and turning in the right

direction.❒ Check safety switch of ash box is working correctly

NOTICE! Check the digital and analog inputs and outputs - See the instruction manualfor the boiler controller.

5 Start-upBefore commissioning / configuring the boiler


6 Decommissioning

6.1 MothballingThe following measures should be taken if the boiler is to remain out of service forseveral weeks (e.g. during the summer):❒ Clean the boiler thoroughly and close the doors fully

If the boiler is to remain out of service during the winter:❒ Have the system completely drained by a qualified technician

➥ Protection against frost

6.2 DisassemblyTo disassemble the system, follow the steps for assembly in reverse order.

6.3 Disposal❒ Ensure that they are disposed of in an environmentally friendly way in accordance

with waste management regulations in the country (e.g. AWG in Austria)❒ You can separate and clean recyclable materials and send them to a recycling

centre.❒ The combustion chamber must be disposed of as builders' waste.

Decommissioning 6Mothballing


7 Appendix

7.1 Addresses

7.1.1 Address of manufacturer

FRÖLINGHeizkessel- und Behälterbau GesmbH Industriestraße 12A-4710 GrieskirchenAUSTRIA TEL 0043 (0)7248 606 0FAX 0043 (0)7248 606 600INTERNET www.froeling.com

7.1.2 Address of the installer

Stamp

7 AppendixAddresses


wood chip boiler t4 24-150 - loco2 heat installation... · 2018. 7. 17. · en 13384-1 chimneys -...

Documents