Euroheat thermodual tda 30 Installation & Servicing Instructions Manual

Installation Servicing Instructions

Thermodual TDA

30/40

www.euroheat.co.uk

Part Number:

Serial Number:

TDA Thermodual Installation Manual

2 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions

EASY AND SAFE OPERATION This operating manual contains important instructions on the

• SHT TDA Thermodual 30

• SHT TDA Thermodual 40

READING THE INSTALLATION MANUAL This installation manual must be read and applied by everyone

who operates or works on the heating system SHT TDA

Thermodual

TECHNICAL CHANGES We continuously develop and improve our boilers. The

information in this edition was correct at the time of going to

press. All details in these instructions on standards, regulations

and worksheets should be checked before use and should be

compared with the regulations applying locally at the site

where the boiler is installed. We reserve the right to make

changes which may then deviate from the technical details

and illustrations in this operating manual.

1.1 Structure of

the Installation

Manual

NOTES ON THIS MANUAL This explains how to use this operating manual.

SAFETY NOTES This explains everything on the subject of safety that you

should consider when using the heating system.

PLANNING AND INSTALLATION This explains how to properly plan for and install the heating

system.

COMMISSIONING THE SYSTEM This explains how the heating system is to be put into initial

service.

CLEANING AND MAINTAINING THE

HEATING SYSTEM

This explains how to clean the heating system and who is

responsible for its maintenance.

TROUBLESHOOTING This explains how to rectify faults in the heating system.

WARRANTY This explains the terms and conditions of the warranty.

APPENDIX This explains the EC Declaration of Conformity.

1. Introduction

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TDA Thermodual Installation Manual

2. Safety instructions

2.1 Intended

use

BASIC PRINCIPLES FOR THE CONSTRUCTION OF THE SYSTEM

BASIC PRINCIPLES

The heating system was built using state of the art technology

and conforms to recognised safety regulations. Nevertheless, its

use still poses the risks of injury or death of the user or a third

party, and of adverse effects upon the heating system itself or

upon other material goods.

Have your specialist heating company provide you with a detailed

explanation of the operation of the heating system.

USING THE HEATING SYSTEM

Only use the heating system if in perfect condition. Use it properly,

as intended, and be aware of safety concerns and the dangers

involved under observance of the operating manual. Have any

faults which could impair safety ﬁxed immediately.

BASIC PRINCIPLES REGARDING THE CONTENT OF THE OPERATING

MANUAL

SCOPE

The content of this operating manual is intended exclusively for

the planning, installation and operation of the heating system

TDA Thermodual. Any further implementation of applicable

standards, for example with regard to the installation of the

heating system (pipework, etc.) is not part of this operating

manual. SHT Austria does not assume any liability for this.

APPLICATION OF THE

HEATING SYSTEM

The heating system TDA Thermodual is designed for the use

of wood pellets conforming to EN Plus standard and split logs

(w<30 %); materials not suitable for combustion are: wood dust,

wood chips, solid- liquid- or gaseous fossil fuels, etc. In addition

no PVC-containing waste products, cardboard containers, paper,

coated wood, etc. must be burnt; the wood must be free from

foreign bodies (nails, screws,etc.). See Section 3.4 for more

details on fuels. Fuels prepared from painted, varnished or coated

wood should not be used. Any other application is considered

improper use. The manufacturer will accept no liability for any

damage resulting from improper use. The operating company/

owner bears sole responsibility in such cases. Proper use includes

adherence to the installation, operation and maintenance

requirements speciﬁed by the manufacturer.

Modiﬁcation of the speciﬁed operating values will affect the

heating system’s control program and could lead to malfunctions.

Only trained maintenance and operating personnel may

undertake modiﬁcations to the operating values.

UK SMOKE CONTROL AREAS

The TDA Thermodual models have been recommended for

exemption under Section 21 of the Clean Air Act 1993 for use in

smoke control areas when burning wood logs or wood pellets

which are selected in accordance with the recommendations on

fuel in this manual.

TDA Thermodual Installation Manual

4 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions

 Contact with the hot surfaces of the boiler can lead to burns. Wait until the boiler has cooled

down before touching uninsulated components.

 Danger of asphyxiation and explosion from carbon monoxide. When the boiler is in operation,

carbon monoxide escaping from opened cleaning or inspection hatches can pose a danger of

asphyxiation or explosions. Do not leave these open any longer than necessary.

 Opening doors and lids to hot combustion residues can pose the danger of ﬁres. Keep the

openings closed during operation, and when performing cleaning work, allow the combustion

residue to cool down before you place them in a ﬁreproof container.

 The boiler weighs over 750kg. If the boiler is dropped during transport, persons can be

seriously injured and the boiler can be damaged. Make sure that you use appropriate lifting gear

when transporting, moving and installing the boiler.

 When working on the pellet grate, cleaning turbulators, and pellet delivery systems, hands

or arms could be injured. Turn off the main power switch when working on these components.

2.2 Residual

Risk

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TDA Thermodual Installation Manual

3. Scope of Delivery

3.1 Scope of

Delivery

Article Number Description Quantity Pre-Installed

8B2420

Boiler Body TDA 1 N

8C2410

Induced draught fan with ﬂange 1 Y

9M3242

Data plate 1 N

2I2416

Secondary air ﬂap insulated gasket 1 Y

2H2209

Seal for draught fan 10mm 1 Y

9W0001

SHT Logo 1 Y

8C2412

Primary air ﬂap, complete 1 Y

8C2414

Primary air ﬂap, complete 1 Y

1K2422

Casing complete, including TC3 wiring loom 1 Y

8A4230

Thermocontrol panel TC3 1 Y

8A4240

Thermocontrol IO circuit board TC3 1 Y

B21025

EW1 extension module 1 Y

4A2216

Immersion sensor 3 N

4A4210

External sensor AF200 1 N

4A4212

Flow sensor VF202 2 N

2X4305

Insulated glove 2 N

2X2516

Round brush 48 x 100 x 1200mm 1 N

A21002

Cleaning set VN 22-55 1 N

Please check your appliance carefully after unpacking for signs of damage and to ensure all parts

have been delivered. Record any visible defects on the delivery note and inform the supplier

immediately. Please take pictures of any damage for future reference.

3.2 Unpacking

and Inspection

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6 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions

TDA rear view (with casing) TDA right side view (with casing)

TDA front view (with casing) TDA left side view (with casing)

4. Technical Data

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TDA Thermodual Installation Manual

TDA 30 TDA 40

Nominal rating*

kW

28 38

Power range 8.4 - 28 11.4 - 38

Boiler water content Litres Ltr approx. 150 approx. 150

Fuel capacity Ltr approx. 175 approx. 175

Width

Boiler dimensions

without casing

mm

761 761

Height 1500 1500

Depth 1207 1207

T

Boiler dimensions

with casing

mm

1184 1184

T1 1220 1220

B/B1 865/852 865/852

H 1594 1594

A 1322 1322

C 830 830

D 563 563

E

Filling door opening

400 400

F 337 337

Boiler weight kg approx. 780 approx. 780

Ø Flue pipe mm 150 150

Draught

requirement**

Pa 15 15

Heating surface m2 2.1 2.1

G Supply and return

Inch

5/4 5/4

G

Safety

supply and return

3/4 3/4

*The type-tested capacity range is to be inferred from the original test certiﬁcates and may

differ slightly from the values speciﬁed.

**Pressure conversion from Pa to bar

105 Pa [N/m²] = 1 bar

Conversion example:

105 Pa = 1 bar

100,000 Pa = 1 bar

20 Pa = 0.0002 bar = 0.2 mbar

TDA Thermodual Installation Manual

8 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions

Control unit

Door contact switch

Log Loading door

Log loading space

Secondary air ﬂap

Secondary-combustion

chamber

Ash door

Ash pans

Primary air ﬂap

Pellet insertion

channel

Ignition element

Control panel

Control unit/circuit

board:

All data is saved on the circuit board. All operational sequences are coordinated

via the control unit/circuit board.

Control panel: The entire system is operated via the control panel.

Door contact switch: The door contact switch indicates whether the ﬁlling door and ash door are

closed.

Log loading door The ﬁlling door must be opened to insert ﬁrewood.

Log loading space Firewood is inserted into the ﬁlling space.

Secondary-combustion

chamber:

Unburnt gases are burnt in the secondary combustion chamber.

Ignition element: The ignition element ensures automatic ignition of the pellets/ﬁrewood.

Primary air ﬂap: The primary air required for combustion ﬂows through the primary air ﬂap.

Secondary air ﬂap: The secondary air required for combustion ﬂows through the secondary air ﬂap.

Ash door: The ash door must be opened to access the ash chamber.

Ash pan: All unburnt material is collected in the ash pans.

Pellet insertion

channel:

Transports pellets into the pellet combustion chamber.

5. Overview

5.1 Main Components

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TDA Thermodual Installation Manual

5.2 External

Casings

11

2

14

4

10

3

13

9

1

12

8

7

6

5

Description

1 Rear panel

2 Base plate and insulation pad

3 Left hand side panel

4 Right hand side panel

5 Control panel bracket

6 Control panel

7 Side cover

8 Filling plate

9 Control unit cover

10 Design element and protective cover

11 Front lid and insulation pad

12 Rear lid and insulation pad

13 Rear cover/ﬂame sensor cover

14 Ash tray

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10 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions

A

C

B

Legend TDA 30/40

A 2875

B 2260

C 2500

Legend TDA 30/40

A 3270

B 2750

C 2357

6.1 Minimum

Boiler Room

Sizing with

Single

2500 Litre

Accumulator

6. Boiler Room Sizing

6.2 Minimum

Boiler Room

Sizing with

Twin 1250 Litre

Accumulators

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TDA Thermodual Installation Manual

Measurement Description TDA 30/40

A Wall to front 650

B Wall to right 300

C Wall to rear 500

D Wall to left 100

E

Width with manual ﬁll

pellet hopper

1420

E

Width with intermediate

pellet hopper

1325

Minimum room width

with manual ﬁll pellet

hopper

1820

Minimum room width

with intermediate pellet

hopper

1725

Minimum room depth 2357

Minimum room height 2100

Please note the above

dimensions do not include the

accumulator or expansion vessel.

If siting the accumulator in the

boiler room then the necessary

dimensions will need to be

increased respectively

(including room height).

6.3 Minimum

Clearances -

Manual Fill &

Intermediate

Pellet Hopper

C

B

E

A

D

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Measurement Description TDA 30/40

A Wall to front 650

B Wall to right 650

C Wall to rear 500

D Wall to left 100

E

Width with Vario auger

system

1127

Minimum room width

with Vario auger system

2077

Minimum room depth 2357

Minimum room height 2100

Please note the above

dimensions do not include

the accumulator or

expansion vessel. If siting

the accumulator in the boiler

room then the necessary

dimensions will need to be

increased respectively

(including room height).

6.4 Minimum

Clearances -

Vario Flexible

Auger

C

B

E

A

D

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TDA Thermodual Installation Manual

7. Boiler Assembly

Approved Document B, of the Building Regulations states that boiler houses are classed as “places

of special ﬁre hazard”.

Requirements

 The requirements for a designated compartment is that the responsible person must carry

out a risk assessment for the location and take into account the requirements of the Building

Regulations Approved Document B1 and B2 (For larger dwellings over 200 m2 per storey).

 As a “Places of Special ﬁre Hazard” there must be a separate ﬁre compartment constructed.

This means that if an existing room is altered, such as a utility room or garage, it must be

ﬁreproofed to make it a special compartment as well as in the case of a new construction.

 This compartment should not form a part of one of the exits from the property that will

have to be used as a ﬁre exit. There can be a door between the boiler house and the rest of the

property and there can be a door that from the boiler house to the outside but this cannot be

classed as one of the property exits.

 As a “Places of Special Fire Hazard” it has to be treated as a separate compartment and the

materials used for the lining of the walls and ceilings for ﬁre protection must meet the National

Class1 or European class C-s3,d2.

 Any wall or ﬂoor between a garage and a house must have 30 minutes ﬁre resistance with a

self closing door and must be classed as smoke sealed along its jambs and head.

 Any services that pass through the wall between the boiler house and the dwelling should have

adequate ﬁre stopping as ADB1 section 7, paragraphs 7.6-7.9 i.e. if the pipe is none combustible

and has an internal diameter less than 160 mm. • If the boiler house, plant room or fuel store is in

the basement of a property then this must have its own separate natural smoke and heat outlet.

7.1 Boiler

Room

Requirements

The boiler should only be installed in a dry room. The boiler has a minimum ventilation requirement

of 15,000mm

2

.in order to provide sufﬁcient air for combustion. The ventilation should be located

at low level (within 1 metre of the ﬂoor height) if possible.

In installations where the ambient boiler room temperature is likely to exceed 30 degrees C (high

summertime use and or/highly insulated boiler room) additional high level ventilation should

be installed to dissipate excess heat.

7.2 Boiler Room

Ventilation

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14 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions

7.3 Unhinge

Doors

Before lifting the boiler off the pallet, we recommend unhinging both the ﬁlling and the ash

door. Please put them down carefully to avoid any damage.

Do not unscrew the hinges on the boiler side panels as the doors may become misaligned and

therefore the door tightness and correct functioning of the door contact switches cannot be

guaranteed.

There are two possible ways to lift the boiler off the pallet. At least two persons should always

lift the boiler off the pallet.

 Remove the top lid (front and rear) and top insulation slabs from the boiler. Attach a suitable

lifting hook to the two crane eyelets located on either side of the boiler. The boiler can then be

lifted using suitable lifting equipment (forklift, lifting frame).

 Remove the base plate and insulation slab from underneath the boiler. A forklift can then be

used underneath the boiler to lift it from the pallet.

CAUTION. The boiler weighs over 750kg. If the boiler is dropped during transport, people can be

seriously injured and the boiler can be damaged.

Make sure that you use appropriate lifting gear when installing the boiler.

7.4 Lifting the

Boiler

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TDA Thermodual Installation Manual

The boiler should be installed on a non-combustible surface of a suitable construction. Adjust the

four legs on the base of the boiler so that it stands evenly or slightly raised to the rear.

7.5 Siting the

Boiler

Adjustable Legs

 Place the ash tray in front of the assembled boiler.

7.6 Fitting the

Ash Tray

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16 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions

NB. Not applicable if using the Vario Flexible Auger

 Apply the supplied gasket to the pellet insertion ﬂange located on the lower right hand side

of the boiler.

 Install the hopper and insertion channel directly on the right-hand side of the boiler and align

with the height of the boiler by using the adjustable screws on the feet of the hopper.

 Insert the auger fully into the combustion chamber and secure ﬁrmly to the pellet insertion

ﬂange with the four bolts provided.

 Connect the cable for the insertion motor (2) to the corresponding plug on the side panel of

the boiler.

 Connect the cable for the temperature sensor (13) to the corresponding plug on the side

panel of the boiler. Place the temperature sensor into the designated tube located underneath

the pellet insertion ﬂange and tighten

7.7 Connecting

the Manual/

Intermediate

Pellet Hopper

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TDA Thermodual Installation Manual

 Connect the ﬂue starter onto the ﬂue spigot located on the rear of the boiler and ensure an

airtight seal using a suitable high temperature sealant.

 Drill through the ﬂue starter stand and bolt to the two support brackets of the ﬂue starter.

 Mount the ﬂue draught stabiliser onto the branch at the base ﬂue starter.

 Connect the drain plug on the base of the ﬂue starter kit to a copper pipe and drain to waste.

7.8 Connecting

the Flue Starter

Kit

TDA Thermodual Installation Manual

18 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions

 Please see separate or instructions on connecting the Vario Flexible Auger or Visionconvey

Screw Suction system.

7.9 Connecting

the Vario

Flexible Auger

or Visionconvey

Suction system

IN1233 Edition 2 Installation Servicing Instructions 19

TDA Thermodual Installation Manual

** speciﬁed values have been determined in the SHT laboratory.

8. Chimney System

The ﬂue must conﬁrm to relevant local regulations. All ﬂue pipes must be hermetically

sealed.

We always recommend installing a draught stabiliser in the chimney.

Important considerations when designing your system are:

In order to ensure maximum combustion the ﬂue pipe should have as few curves as

possible, and all curves should point upwards to the chimney.

Cross-sectional reductions (bottle-necks) and/or several elbows are to be avoided.

Flue gas temperatures should not exceed 210° C on a continuous basis (with a clean

boiler).

Always make sure that the ﬂue gas can escape in a free and unhindered manner (do

not cover or block the chimney)

Flue gas must be able to escape through the chimney in such a way that the

condensation of ﬂue gas vapours in the chimney will not result in any damage.

It should be noted that ﬂue gas temperatures below 160°C develop in the lower power

range. Therefore the heating system must be connected to a highly insulated chimney

which is insensitive to moisture (or to another ﬂue gas system which is insensitive to

moisture and approved by the building authority in accordance with DIN 4705 Part 2).

Fuel

Boiler

model

Flue gas mass

ﬂow

in g/sec

Net ﬂue gas

temperature in °C

Required Flue

Draught (PA)

NL TL NL TL

Pellets

TDA 30 18.7** 10.4** 135.3** 84.8** 15

TDA 40 21.4** 10.4** 159** 84.8** 15

Firewood

TDA 30 15.2** 14.6** 157.1** 152.9** 15

TDA 40 17.9** 10** 176** 112.3** 15

TDA Thermodual Installation Manual

20 IN1233 Oct 2014 Edition 5 Installation Servicing Instructions

9.1 Basic

Hydraulic

Connections

9. Hydraulic Connections

Heating

circuit ﬂow

Heating

circuit return

Boiler safety set

Auto air

vent

Thermal

safety device

Nickel

cap valve

Auto air

vent

Layering

valve

Pressure

switch

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