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Installation Instructions

Wood chip boiler TX 150-250

Translation of the original German operating instructions for technicians!

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

M1320112_en | Edition 08/04/2013

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

Содержание TX 150

Страница 1: ...original German operating instructions for technicians Read and follow the instructions and safety information Technical changes typographical errors and omissions reserved M1320112_en Edition 08 04 2...

Страница 2: ...boiler room 15 4 4 1 Moving the boiler in the boiler room 15 4 4 2 Minimum distances in the boiler room 16 4 5 Mounting steps 17 4 5 1 General information 17 4 5 2 Screwing the fire box with the heat...

Страница 3: ...R air box optional 57 4 5 27 Installing the flue gas recirculation FGR optional 58 4 5 28 Installing insulating door and cover plates 60 4 6 Electrical connection 61 4 6 1 Installing insulating covers...

Страница 4: ...if ferences from the pictures and content If you discover any errors please let us know doku froeling com Subject to technical change The EC Declaration of Conformity is only valid in conjunction with...

Страница 5: ...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 Wor...

Страница 6: ...ed out by quali fied personnel Heating technician building technician Electrical installation technician Froling customer services The assembly staff must have read and understood the instructions in...

Страница 7: ...for structural and safety devices NORM H 5170 Heating installation Requirements for construction and safety engineering as well as fire prevention and environmental pro tection TRVB H 118 Technical di...

Страница 8: ...er 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...

Страница 9: ...n necting in order to prevent air from entering the system 2 4 5 Return lift If the hot water return is below the minimum return temperature some of the hot water outfeed will be mixed in CAUTION Risk...

Страница 10: ...gas temperatures for clean systems and additional flue gas values can be found in the table below The connection between the boiler and the chimney system should be as short as possible The upward an...

Страница 11: ...108 Flue gas mass flow wood chips W30 9 O2 420 557 700 Flue gas mass flow pellets 13 O2 559 741 931 Flue gas mass flow pellets 9 O2 355 471 591 Required feed pressure at nominal load mbar 0 05 0 05 0...

Страница 12: ...Overall width mm 1970 2070 2070 L Length boiler mm 2620 2980 2980 L1 Length retort 1090 1400 1400 L2 Length stoker unit 940 970 970 L3 Length ash box 590 610 610 Item Description TX 150 TX 200 TX 250...

Страница 13: ...consistent structure it is sufficient if the ratio of rated heat output from the largest to the smallest boiler 2 1 to carry out the tests with the smallest and the largest boilers The boiler manufact...

Страница 14: ...sions in mg m 1 RL PL Carbon monoxide CO mg m 8 23 7 16 6 8 Nitrogen oxide NOx mg m 94 84 98 85 103 86 Organic hydrocarbons OGC mg m 1 1 2 2 2 2 Dust mg m 35 21 25 17 15 13 Boiler efficiency 90 8 93 4...

Страница 15: ...or similar lifting device to the eyelets on the boiler 4 3 Temporary storage If the system is to be assembled at a later stage Store components at a protected location which is dry and free from dust...

Страница 16: ...le standards and regulations when setting up the system Observe additional standards for noise protection NORM H 5190 Noise protection measures TX 150 TX 200 250 Pos Description Unit TX 150 200 250 A...

Страница 17: ...al it is different if the heat exchanger of the TX front view operator side is positioned on the left or the right side of the fire box Before mounting it has to be de fined whether the heat exchanger...

Страница 18: ...s possible to bring it in from the front Insert the lift truck at the fire box opposite the supporting post Place a piece of pipe square timber or similar with a height of approx 75 mm be low the fire...

Страница 19: ...ox against the heat exchanger with carrying bolts through the lat eral cutouts in the main frame Check that the fire box is aligned with the heat exchanger and pay attention on seal cord it shall have...

Страница 20: ...er cover Remove the heat exchanger cover Place ceramic fibre mats on the fire box as shown Make sure that two mats are placed on the side to the heat exchanger Place fireclay blocks on the ceramic fib...

Страница 21: ...move the blanking plate on the fire box on the left by the infeed unit Fix the inter flange for flue gas recirculation connection along with seal on the boil er Take the previously dismounted screws T...

Страница 22: ...f the shaft Remove the blind plug on the opposite of the WOS shaft Loosen the screwing on the heat exchanger cover set star grip to left hand stop and open the cover Remove safety pin of the WOS shaft...

Страница 23: ...before assemby Insert each bottom insulation below fire box and heat exchanger Place longitudinal and cross elements of the bottom main frame of the insulation on the floor Fix longitudinal elements...

Страница 24: ...as shown on the boiler and position the cable routing above Screw the cable routing to the boiler laterally Place longitudinal elements on the front and the back of the boiler When putting on make su...

Страница 25: ...the corners 4 5 9 Installing the frame for the insulating door Place frame element for insulating door on the front Screw the frame element together with the upper and lower longitudinal element Inser...

Страница 26: ...ing side panel at the upper and lower frame elements Ensure correct threading into the lugs of the lower longitudinal element Separate the pre cut recess for the WOS drive at the back insulating side...

Страница 27: ...ulating side panel Coat spaces with heat insulation mats lateral of the heat exchanger cover TX 250 Mount an additional insulation mat at the frame above the fire box Place the heat insulation mat at...

Страница 28: ...ame using 4 thread forming screws Screw all insulating side panels with elements of the main frame together Cover the inspection opening of the retort with insulation Mount inspection cover at the ins...

Страница 29: ...ustion chamber door Position the cover plate at the heat exchanger cover Fix the cover plate using 4 thread forming screws Mount the heat exchanger cover at the heat exchanger Assembly 4 Mounting step...

Страница 30: ...the key plate so that an unproble matic locking at the safety limit switch is possible Fix the positioning of the key plate and check the correct locking at the limit switch when opening and closing t...

Страница 31: ...unt the safety plate at the grate shaft Position the grate by screwing the shaft bearing Fix the position of the shaft bearing by mounting the safety plate Bring grate to closed position Press the rel...

Страница 32: ...screws M8x20 lining disks M8 and lock nuts M8 at the fire box Thread the proximity sensor at the mounting and fix it easily with pre installed nuts Fix the sensor with approx 1 2 mm 0 04 0 08 inch se...

Страница 33: ...te washer 4 Locking lever 5 Bearing bush 6 Chopper disk M8 7 Lock nut M8 Mount the locking lever at the ash removal flange as seen in the illustration above Put the rubber seal over the channel of the...

Страница 34: ...bolts M8x25 and lining disks M8 Mount the angle plate with 2 thread forming screws at the lug of the ash removal flange Mount the safety limit switch with each 2 fillisters M4x30 lining disks M4 and...

Страница 35: ...heat insulation mats on the ash flange Fix the cover plates on the left and the right of the ash removal flange with thread forming screws Insert the protection plate above the leverage of the tippin...

Страница 36: ...the ash screw onto the back side of the boiler Dismount the shaft circlip big hexagonal bolt and lining disk and the key at the end of the shaft Put the ceramic fibre seal and the gear motor onto the...

Страница 37: ...able 600x600 mm 600x1200 mm 24x24 inch 24x48 inch The following illustrations show the bigger switch cabinet TX200 250 standard delivery contents TX 150 optional Mount the switch cabinet at the heat e...

Страница 38: ...size Fix the switch cabinet duct with hexagonal bolts M8 lining disks M8 and nuts M8 at the switch cabinet Screw the cable duct on the back with the insulating side panel Mount cable so that the cable...

Страница 39: ...rew it with each 4 hexagonal bolts M10x35 washers M10 and hexagonal nuts M10 to the plug in flange Tighten the entire stoker unit incl adjustable foot and fasten the screwing at the adjustable foot Wr...

Страница 40: ...itor pipe Put the double wire spring clamp over the ignitor pipe Put the ignitor into the ignitor pipe and fix it with a double wire spring clamp Tighten the clamp gently to avoid damages Hook the bas...

Страница 41: ...e release knob at the actuator and set the shaft support to the left hand stop while pressing the release knob Put on the actuator for primary air to the right of the stoker unit as illustrated Connec...

Страница 42: ...t the overpressure monitor and tighten the locating screw gently Screw in the flange pipe of the combustion chamber temperature sensor above the overpressure sensor Loosen the clamp screw at the matin...

Страница 43: ...at the unmarked clamp 4 5 19 Installing the underpressure measurement Assemble the double nipple the reducing socket and the hose nipple as illustrated Screw in the entire unit right beside the stoker...

Страница 44: ...4 5 20 Installing the WOS drive Put on the bracket to the stud at the heat exchanger and fix it with 4 washers M8 and lock nuts M8 Mount shouldered bolts M8x20 bushing and lock nuts M8 at WOS disk as...

Страница 45: ...nd lock nuts M8 at the bracket Insert the key and lock it Hook on the tension spring at the WOS lever tighten it and hook it on at the lug Thread the WOS cover from above behind the WOS drive and hook...

Страница 46: ...ger ash removal unit with ash box Put the rubber seal on the flange plate Set on the sealing plate and fix it with 4 hexagonal bolts M8x16 and washers M8 Mount the flange plate at the back of the heat...

Страница 47: ...at exchanger ash removal unit for boilers with the heat exchanger on the right If the heat exchanger is on the left the steps should be adjusted appropriately Please note that the chain tensioner poin...

Страница 48: ...xagonal bolts M8x20 and washers M8 at the heat ex changer Put the rubber seal at the second flange plate Put the gear motor onto and fix it with 4 hexagonal bolts M8x16 Thread in the ash screw at the...

Страница 49: ...de in the entire unit at the heat exchanger and fix it with each 4 hexagonal bolts M8x20 and washers M8 Put on the second chain wheel at the shaft of the ash screw at the pedestal and insert the key S...

Страница 50: ...pedestal so that sufficient tension is generated at the chain Kettenrad am Kettenspanner durch Verdrehen der Sechskantmuttern so einstell en dass alle drei Kettenr der fluchtend ausgerichtet sind Put...

Страница 51: ...t the pedes tal Mount counterpart with captive screws Installing the ash boxes 1 Hexagonal bolt M8x25 2 Ash removal flange 3 Plate washer 4 Locking lever 5 Bushing 6 Lock washer M8 7 Lock nut M8 Assem...

Страница 52: ...washers M8 Place the flanges that way that the locking levers are positioned outside Mount the cover plate above the exterior ash removal flange Mount the retainer for the safety limit switch above t...

Страница 53: ...pping screws M4x30 at the retainer Turn cable gland of the limit switch by 90 if necessary Bend both lugs at the insulating side panel and lay the cable of the safety limit switch upwards to the switc...

Страница 54: ...o the middle of the fire box Combustion air blower fan for TX 200 250 Mount the combustion air blower fan with ceramic fibre seal above the combustion chamber door with 4 hexagonal bolts M6x16 and was...

Страница 55: ...the frame element with a locating screw Put the capillary sensor through the opening at the cable tray and lay it to the ther mowell at the heat exchanger Put the capillary sensor and the boiler sens...

Страница 56: ...intended slotted holes at the ID fan Place the ID console incl seal at the flange and fix it with each 4 hexagonal bolts M8x20 and washers M8 Level the ID console via supports Put the ID fan on the ID...

Страница 57: ...rated on the left and the right of the flange Screw the rubber buffers to the ID console 4 5 26 Installing the FGR air box optional Insert pan cap screw from the back side of the base plate Put the ba...

Страница 58: ...r knob at the lever Mount the FGR air box to the left of the stoker unit at the retort with each 4 hexag onal bolts M8x20 and washers M8 4 5 27 Installing the flue gas recirculation FGR optional Mount...

Страница 59: ...sure the distance between flue gas pipe elbow and FGR air box Cut the tube to the appropriate length Apply refractory silicon to the flue gas pipe clamps Assemble the entire FGR piping and fix the flu...

Страница 60: ...ver plates Mount the insulating doors to the door hinges at the frame element Put on the cable duct cover and fix it with self tapping screws 4 Assembly Mounting steps 60 Froling GesmbH A 4710 Grieski...

Страница 61: ...ith cable ties Notes on laying cables 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 d...

Страница 62: ...TX 150 the cable duct is mounted below the switch cabinet Put on insulating covers on the boiler as seen at the pictures above Lay thermal discharge unit through the opening in the insulating cover an...

Страница 63: ...Apply heat insulation mat on the heat exchanger cover an put on the insulating cover Assembly 4 Electrical connection Installation Instructions TX 150 250 M1320112_en 63...

Страница 64: ...that it cannot be shut off 1 Sensor of thermal discharge safety device 2 Thermal discharge safety device opens at 95 C 3 Cleaning valve T piece 4 Dirt trap 5 Pressure reducing valve1 1 Required when...

Страница 65: ...operating instructions for the boiler control unit Check the system pressure of the heating system Check that the heating system is completely vented Check that the safety devices are present and work...

Страница 66: ...t W20 M20 Air dried W30 M30 Suitable for storage W35 M35 Limited suitability for storage Size G30 P16A P16B Fine wood chip G50 P45A Medium sized wood chips EU Fuel acc to EN 14961 Part 4 Wood chips cl...

Страница 67: ...by a qualified technician Protection against frost 6 2 Disassembly To disassemble the system follow the steps for assembly in reverse order 6 3 Disposal Ensure that the system is disposed of in an en...

Страница 68: ...und Beh lterbau GesmbH Industriesta e 12 A 4710 Grieskirchen AUSTRIA TEL 0043 0 7248 606 0 FAX 0043 0 7248 606 600 INTERNET www froeling com 7 1 2 Address of the installer Stamp 7 Appendix Addresses...

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