Froling S4 Turbo 15 Bedienungsanleitung

Installation Instructions

Firewood boiler S4 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!

M0971117_en | Edition 24/03/2017

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

Table of Contents

1 General 5

2 Safety 6

2.1 Hazard levels of warnings 6

2.2 Qualification of assembly staff 7

2.3 Personal protective equipment for assembly staff 7

2.4 Design Information 7

2.4.1 Notes on standards 7

General standards for heating systems

Standards for structural and safety devices

Standards for heating water

Regulations and standards for permitted fuels

2.4.2 Installation and approval of the heating system 8

2.4.3 General information for installation room (boiler room) 9

2.4.4 Requirements for central heating water 10

2.4.5 Notes for using pressure maintenance systems 11

2.4.6 Return lift 12

2.4.7 Combination with storage tank 13

2.4.8 Chimney connection/chimney system 14

Draught limiter

Measuring port

Boiler data for planning the flue gas system

3 Technology 17

3.1 Dimensions - S4 Turbo 17

3.2 SP Dual measurements 18

3.3 Components and connections 19

3.4 Note on SP Dual return feed connection 20

3.5 Technical specifications 21

4 Assembly 26

4.1 Materials supplied 26

4.1.1 Tools required 26

4.2 Positioning 27

4.2.1 Temporary storage 27

4.3 Setting up in the boiler room 28

4.3.1 Remove boiler from pallet 28

4.3.2 Moving the boiler in the boiler room 28

4.3.3 Minimum distances in the boiler room 28

4.4 Before Installation 30

4.4.1 Changing door stops (as needed) 30

4.4.2 Fitting the door handles 32

4.4.3 Adjusting the doors 32

Door stop side

Door handles

4.4.4 Setting and checking the seal on the doors 34

Checking the settings of the door stop

Checking the settings of the door handle

Table of Contents

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Checking the door stop seal

Checking the door handle seal

4.5 Assembling the S4 Turbo 15-40 36

4.5.1 Assembly overview 36

Air duct system

S4 Turbo 15-28 EOS system

S4 Turbo 32-40 EOS system

Insulation

Boiler with pellet flange

4.5.2 Installing the induced draught fan and flue gas pipe nozzle 41

4.5.3 Assembling the heat-exchanger lever bushing 41

4.5.4 Installing the pneumatic rods for the primary and secondary air 42

servo-motors on the right

servo-motors on the left

4.5.5 Installing the insulation 44

4.5.6 Installing the control 45

4.5.7 Installing the back panel 46

4.5.8 Installing the floor insulation 46

4.5.9 Installing the insulated door 47

4.5.10 Attaching the controller 49

4.5.11 Fitting the broadband probe, boiler sensor, flue gas temperature sensor and STL 51

4.5.12 Installing the servo-motors 52

4.5.13 Installing the WOS system 53

4.6 Assembling the S4 Turbo 50-60 57

4.6.1 Assembly overview 57

Air duct system

EOS system

Insulation

4.6.2 Assembling the heat-exchanger lever bushing 61

4.6.3 Installing the pneumatic rods for the primary and secondary air 61

servo-motors on the right

servo-motors on the left

4.6.4 Installing the insulation 64

4.6.5 Installing the control 65

4.6.6 Installing the back panel 66

4.6.7 Installing the floor insulation 66

4.6.8 Installing the insulated door 67

4.6.9 Attaching the controller 69

4.6.10 Fitting the broadband probe, boiler sensor, flue gas temperature sensor and STL 71

4.6.11 Installing the servo-motors 72

4.6.12 Installing the induced draught fan 73

4.6.13 Installing the WOS system 75

4.7 Electrical connection and wiring 76

4.7.1 Information on circulating pumps 77

4.7.2 Concluding work 78

4.8 Hydraulic connection 78

4.9 Connecting the hydraulic safety devices 79

5 Start-up 80

5.1 Before commissioning / configuring the boiler 80

5.2 Initial startup 81

5.2.1 Permitted fuels 81

Firewood

5.2.2 Fuels permitted under certain conditions 82

Wood briquettes

Table of Contents

Installation Instructions S4 Turbo | M0971117_en 3

5.2.3 Non-permitted fuels 82

5.2.4 Heating up for the first time 82

6 Decommissioning 84

6.1 Mothballing 84

6.2 Disassembly 84

6.3 Disposal 84

7 Appendix 85

7.1 Pressure equipment regulation 85

7.2 Technical specifications - S4 Turbo with partial load values 86

7.2.1 Test report data S4 Turbo 22-28 86

7.2.2 Test report data S4 Turbo 34-40 87

7.2.3 Test report data S4 Turbo 50-60 88

7.3 Addresses 89

7.3.1 Address of manufacturer 89

7.3.2 Address of the installer 89

Table of Contents

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

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

guidelines.

Please read and observe the documentation provided and always keep it close to the

system for reference. Observing the requirements and safety information in the

documentation makes a significant contribution to safe, appropriate, environmentally

friendly and economical operation of the system.

The constant further development of our products means that there may be minor

differences from the pictures and content. If you discover any errors, please let us

know: [email protected].

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

certificate

General 1

Installation Instructions S4 Turbo | M0971117_en 5

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.

2Safety

Hazard levels of warnings

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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 by

qualified personnel:

- Heating technician / building technician

- Electrical installation technician

- Froling customer services

The assembly staff must have read and understood the instructions in the

documentation.

2.3 Personal protective equipment for assembly staff

You must ensure that staff have the protective equipment specified by accident

prevention regulations.

▪ For transportation, setup and assembly:

- suitable work wear

- protective gloves

- sturdy shoes (min. protection class S1P)

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. Unless contrary to other national regulations, the latest versions

of the following standards and guidelines apply:

General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fed

combustion systems, nominal heat output up to 500 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

Safety 2

Qualification of assembly staff

Installation Instructions S4 Turbo | M0971117_en 7

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

water preparation

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

protection

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 Prevention of damage hot water heating systems (Germany)

SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioning

systems (Switzerland)

UNI 8065 Technical standard regulating hot water preparation.

DM 26.06.2015 (Ministerial Decree specifying the minimum

requirements)

Follow the instructions of this standard and any related updates.

Regulations and standards for permitted fuels

1. BImSchV First Order of the German Federal Government for the

implementation of the Federal Law on Emission Protection

(Ordinance on Small and Medium Combustion Plants) in the

version published on 26 January 2010,

BGBl. JG 2010 Part I No. 4.

EN ISO 17225-3 Solid bio-fuel - Fuel specifications and classes

Part 3: Wood briquettes for non-industrial use

EN ISO 17225-5 Solid bio-fuel - Fuel specifications and classes

Part 5: Firewood for non-industrial use

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:

EN 12828 - Heating Systems in Buildings

NOTICE! Each heating system must be officially approved.

Note on standards

2Safety

Design Information

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

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: report to the construction authorities of the community or magistrate

Germany: report new installations to an approved chimney sweep / the building

authorities.

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 design

regulations.

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

manufacturer.

▪ Danger of fire due to flammable materials.

The floor of the boiler room must not be flammable. 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 and hydrogen

halides in the room where the boiler is installed (e.g. chlorination units for

swimming 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 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

(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 requirements

Note on standards

Safety 2

Design Information

Installation Instructions S4 Turbo | M0971117_en 9

2.4.4 Requirements for central heating water

Unless contrary to other national regulations, the latest versions of the following

standards and guidelines apply:

Austria:

Germany:

ÖNORM H 5195

VDI 2035

Switzerland:

Italy:

SWKI BT 102-01

UNI 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

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

2Safety

Design Information

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

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