Froling S1 Turbo Bedienungsanleitung
Installation Instructions
Fire wood boiler S1 Turbo
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1470113_en | Edition 17/09/2013
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
Table of Contents
1 General 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 Protective equipment for assembly staff 6
2.4 Design Information 7
2.4.1 Notes on standards 7
General standards for heating systems
7
Standards for structural and safety devices
7
Standards for heating water
7
Standards for permitted fuels
8
2.4.2 Installation and approval of the heating system 8
2.4.3 General information for installation room (boiler room) 8
2.4.4 Requirements for central heating water 9
2.4.5 Notes for using pressure maintenance systems 9
2.4.6 Return lift 10
2.4.7 Combination with storage tank 11
2.4.8 Chimney connection/chimney system 13
Draught limiter
13
Boiler data for planning the flue gas system
13
3 Technology 14
3.1 Dimensions 14
3.2 Components and connections 15
3.3 Technical specifications 16
4 Assembly 18
4.1 Materials supplied 18
4.1.1 Tools required 18
4.2 Positioning 18
4.3 Temporary storage 19
4.4 Setting up in the boiler room 19
4.4.1 Removing boiler from pallet 19
4.4.2 Minimum distances in the boiler room 20
4.5 Before Installation 21
4.5.1 Changing the stop of the fuel loading door and the combustion chamber door 21
4.5.2 Checking the seal on the doors 24
4.5.3 Positioning the doors 25
4.6 Installing the boiler 26
4.6.1 Assembly overview 26
4.6.2 Installing the induced draught fan 28
4.6.3 Installing the insulation 28
4.6.4 Fitting the air control 32
Variant 1 - Fitting the servo-motor
32
Variant 2 - Fitting the manual controller
33
4.6.5 Fitting the controller box 34
4.6.6 Fitting the broadband probe, flue gas temperature sensor and STL 36
Table of Contents
2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
4.6.7 Attaching the induced draught cable 37
4.6.8 Installing the insulated door 37
4.7 Electrical connection and wiring 40
4.7.1 Information on circulating pumps 40
4.7.2 Concluding work 41
4.8 Connecting the hydraulic safety devices 43
4.9 Installing the WOS system (optional) 44
5 Start-up 49
5.1 Before commissioning / configuring the boiler 49
5.2 Initial startup 50
5.2.1 Permitted fuels 50
Firewood
50
5.2.2 Fuels permitted under certain conditions 51
Wood briquettes
51
5.2.3 Non-permitted fuels 52
5.2.4 Heating up for the first time 53
Boiler with Lambda control
53
Boiler with manual controller
53
6 Decommissioning 56
6.1 Mothballing 56
6.2 Disassembly 56
6.3 Disposal 56
7 Appendix 57
7.1 Pressure equipment regulation 57
7.2 Technical specifications - Lambda control with partial load values 58
7.3 Addresses 59
7.3.1 Address of manufacturer 59
7.3.2 Address of the installer 59
Table of Contents
Installation Instructions S1 Turbo | M1470113_en 3
1 General
Thank 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 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, environ‐
mentally friendly and cost-effectively.
The constant further development of our products means that there may be minor dif‐
ferences from the pictures and content. If you discover any errors, please let us know:
Subject 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 or
heating engineers are requested to return a copy of the delivery certificate together
with the guarantee card to Froling. On commissioning by FROLING Customer Service
the validity of the delivery certificate will be noted on the customer service record.
Issuing a delivery cer‐
tificate
1General
4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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.
CAUTION
The dangerous situation may occur and if measures are not observed it will lead
to minor injuries or damage to property.
Safety 2
Hazard levels of warnings
Installation Instructions S1 Turbo | M1470113_en 5
2.2 Qualification of assembly staff
CAUTION
Assembly and installation by untrained personnel:
Risk of personal injury and damage to property.
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow trained staff to carry out assembly and installation
Assembly, installation, initial startup and servicing must always be carried 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 the documenta‐
tion.
2.3 Protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by accident pre‐
vention regulations.
▪ For transportation, setup and assembly:
- suitable workwear
- protective gloves
- sturdy shoes
2Safety
Qualification of assembly staff
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
2.4 Design Information
2.4.1 Notes on standards
The system must be installed and commissioned in accordance with the local fire and
building regulations. The following standards and regulations should always be ob‐
served:
General standards for heating systems
EN 303-5 Boilers for solid fuels, manually and automatically fed combus‐
tion systems, nominal output up to 300 kW
EN 12828 Heating systems in buildings - Design of water-based heating
systems
EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods
Part 1: Chimneys serving one appliance
ÖNORM M 7510-1 Guidelines for checking central heating systems
Part 1: General requirements and one-off inspections
ÖNORM M 7510-4 Guidelines for checking central heating systems
Part 4: Simple check for heating plants for solid fuels
Standards for structural and safety devices
ÖNORM H 5170 Heating installation - Requirements for construction and safety
engineering, as well as fire prevention and environmental pro‐
tection
Standards for heating water
ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in
closed warm water heating systems at operating temperatures
up to 100 °C (Austria).
VDI 2035 Sheet 1 Prevention of damage in water heating systems - Scale forma‐
tion in domestic water heating systems and hot water heating
systems (Germany)
SWKI 97-1 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
D.P.R. no. 412 Regulations for the planning, installation, running/operation and
maintenance of heating systems in buildings to reduce energy
consumption with reference to Article 4, Comma 4 of the Legis‐
lative Decree of 9 January 1991, No. 10 (Italy)
Safety 2
Design Information
Installation Instructions S1 Turbo | M1470113_en 7
Standards for permitted fuels
EN 14961-3 Solid bio-fuel - Fuel specifications and classes
Part 2: Wood briquettes for non-industrial use
EN 14961-5 Solid bio-fuel - Fuel specifications and classes
Part 5: Firewood for non-industrial use
1. BImSchV First Ordinance of the German Federal Government for imple‐
mentation of the Federal Emission Protection Law, BGBl. I P.
491, in the applicable version.
2.4.2 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
ÖNORM / DIN EN 12828 Heating Systems in Buildings
NOTICE! 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: Inform the civic/municipal building authorities.
Germany: Notify an approved chimney sweep and the building authorities.
2.4.3 General information for 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 light‐
ing in the boiler room in accordance with national workplace design regulations.
▪ When using the boiler over 2000 metres above sea level you should consult the
manufacturer.
▪ 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 from dust.
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 (foli‐
age, snowdrifts, etc.) from obstructing the air flow.
Note on standards
2Safety
Design Information
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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 requirements
2.4.4 Requirements for central heating water
The following standards and guidelines apply:
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195-1
VDI 2035
SWKI 97-1
D.P.R. no. 412
NOTICE! Note on filling with make-up water: Always bleed the filling hose before con‐
necting, in order to prevent air from entering the system.
Observe the standards and also follow the recommendations below:
❒Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to
5.6 dH)
❒ Use softened water as the make-up water
❒ Avoid leaks and use a closed heating system to maintain water quality during op‐
eration
2.4.5 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required pres‐
sure within predefined limits and balance out volume variations caused by changes 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 the ex‐
pansion tank is responsible for volume compensation and pressure maintenance. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐
to the domestic hot water.
Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐
tenance pump, relief valve and an unpressurised receiving tank. The valve releases
hot water into the receiving tank if the pressure is too high. If the pressure drops below
a preset value, the pump draws water from the receiving tank and feeds it back into
the heating system. Pump-controlled pressure maintenance systems with open expan‐
sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the
Note on standards
Note on standards
Safety 2
Design Information
Installation Instructions S1 Turbo | M1470113_en 9
water, exposing the connected system components to the risk of corrosion. These
systems offer no oxygen removal for the purposes of corrosion control as required by
VDI 2035 and in the interests of corrosion protection should not be used.
2.4.6 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 temperature control.
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 temperature control.
➥The minimum return temperature is 60 °C. We recommend fitting some
sort of control device (e.g. thermometer).
2Safety
Design Information
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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