Froling S4 Turbo Bedienungsanleitung

Operating Instructions

Log wood boiler S4 Turbo

Translation of the original German operating instructions for the operator

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

B0510512_en | Edition 25/06/2013

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

Table of Contents

1 General 4

1.1 S4 Turbo Product Overview 5

2 Safety 7

2.1 Hazard levels of warnings 7

2.2 Pictograms used 8

2.3 General safety information 9

2.4 Permitted uses 10

2.4.1 Permitted fuels 10

Firewood

2.4.2 Fuels permitted under certain conditions 11

Wood briquettes

2.4.3 Non-permitted fuels 11

2.5 Qualification of operating staff 12

2.6 Protective equipment for operating staff 12

2.7 Design information 12

2.7.1 Installation and approval of the heating system 12

2.7.2 General information for installation room (boiler room) 13

2.7.3 Requirements for central heating water 13

2.7.4 Return lift 14

2.7.5 Combination with storage tank 14

2.7.6 Chimney connection/chimney system 14

2.8 Safety devices 15

2.9 Residual risks 15

2.10 Emergency procedure 17

2.10.1 Overheating of the system 17

2.10.2 Smell of flue gas 17

3 Operating the System 18

3.1 Assembly and initial startup 18

3.2 Heating up the boiler 19

3.2.1 Switching on the power supply 19

3.2.2 Switching on the boiler 19

3.2.3 Before heating up the boiler 19

Reloading intervals when operating with storage tank

Determining the right amount of fuel

Fuel table

Fill level in boiler

Reloading intervals when operating without storage tank or if the storage tank is too small

3.2.4 Heating the boiler with firewood 22

3.2.5 Heating up the boiler with automatic ignition 24

3.2.6 Regulating the boiler 24

3.2.7 Reloading firewood 25

3.2.8 Switching off the power supply 26

4 Boiler servicing 27

4.1 General information on servicing 27

Table of Contents

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

4.2 Inspection and cleaning 28

4.2.1 Prior to heating up 28

Always move the WOS lever

Check the ignition pipe (only with automatic ignition)

4.2.2 Inspection 29

Checking the system pressure

Checking the thermal discharge safety device

Checking the safety valve

4.2.3 Cleaning 29

Emptying ash

Cleaning the grating

4.2.4 Annual inspection 31

Cleaning the carbonisation gas duct

Checking the primary air openings

Cleaning the heat exchanger pipes

Checking the seal on the doors

Cleaning the flue gas temperature sensor

Clean the flue gas pipe

Checking the draught controller flap

Cleaning the induced draught fan

4.3 Emissions measurement by chimney sweep or regulatory body 36

4.3.1 Measuring at rated load in firewood mode 36

4.3.2 Measuring at partial load in firewood mode (if required) 36

4.4 Maintenance agreement / Customer service 37

4.5 Replacement parts 37

4.6 Disposal information 37

4.6.1 Disposal of the ash 37

4.6.2 Disposal of system components 37

5 Troubleshooting 38

5.1 General fault with power supply 38

5.1.1 Behaviour of system after a power failure 38

5.2 Excessive temperature 38

5.3 Faults with fault message 39

5.3.1 Procedure for fault messages 39

5.3.2 Acknowledging a fault message 39

6 Appendix 40

6.1 Addresses 40

6.1.1 Address of manufacturer 40

6.1.2 Address of the installer 40

Table of Contents

Operating Instructions S4 Turbo | B0510512_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:

[email protected]

Subject to technical change.

Guarantee conditions

Our sale and delivery conditions generally apply. These conditions have been made

available to customers, and customers have been made aware of them at the time of

order completion.

You can also find the guarantee conditions on the enclosed guarantee certificate.

1General

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

1.1 S4 Turbo Product Overview

1Insulated door

1.1 Maintenance overview

2Fuel loading door

3Pre-heating chamber door

4Combustion chamber door with inspection glass

5Control panel of the Lambdatronic S3200

5.1 Visual display showing operating statuses and parameters

5.2 Status LED (operating status):

- GREEN constant: BOILER ACTIVE (heating up/heating)

- GREEN flashing (interval: 5 sec. OFF, 1 sec ON): OFF

- ORANGE flashing: WARNING

- RED flashing: FAULT

5.3 Navigation keys to move around in the menus and to change the parameter values

5.4 Function keys to call up individual boiler functions directly

NOTICE! For key layout see control unit operating instructions

General 1

S4 Turbo Product Overview

Operating Instructions S4 Turbo | B0510512_en 5

Underneath the back insulating cover (9):

6Lever for heat exchanger cleaning system (WOS)

7Actuators for automatic regulation of primary and secondary air

8Automatic ignition (optional)

9Back insulating cover

10 Heat exchanger cover: Maintenance opening for cleaning the WOS system and heat

exchanger

11 Main switch

12 Service port

13 STL high-limit thermostat

1General

S4 Turbo Product Overview

6 Froling GesmbH | A-4710 Grieskrichen, 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

Operating Instructions S4 Turbo | B0510512_en 7

2.2 Pictograms used

The following symbols are used in the documentation and/or on the boiler to show

what is required and forbidden and to give warnings.

In accordance with the Machinery Directive, signs fitted directly within the danger area

of the boiler indicate immediate hazards or safety procedures. These stickers must not

be removed or covered.

Refer to the operating instruc‐

tions

Wear safety shoes

Wear protective gloves Turn off the main switch

Keep the doors closed

Unauthorised access prohibited

Warning - hot surface Warning - hazardous electrical

voltage

Warning - hazardous or irritant

materials

Warning - automatic boiler start‐

Warning of injury to fingers or

hands, automatic fan

2Safety

Pictograms used

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

2.3 General safety information

DANGER

If the device is used incorrectly:

Incorrect use of the system can cause severe injury and damage.

When operating the system:

❒ Observe the instructions and information in the manuals

❒ Observe the details on procedures for operation, maintenance and cleaning,

as well as troubleshooting in the individual manuals.

❒ Any work above and beyond this should be carried out by authorised heating

engineers or by Froling customer services.

WARNING

External influences:

Negative external influences, such as insufficient combustion air or non-standard

fuel, can cause serious faults in combustion (e.g. spontaneous combustion of car‐

bonisation gases or flash fires) which can in turn cause serious accidents!

When operating the boiler, please note the following:

❒ Instructions and information regarding versions and minimum values, as well

as standards and guidelines for heating components in the instructions must

be observed.

WARNING

Severe injuries and damage can be caused by an inadequate flue gas system.

Problems with the flue gas system, such as poor cleaning of the flue pipe or insuf‐

ficient chimney draught, can cause serious faults in combustion (such as sponta‐

neous combustion of carbonisation gases or flash fires).

Take the following precautions:

❒ Optimum boiler performance can only be guaranteed if the flue gas system is

functioning correctly.

Safety 2

General safety information

Operating Instructions S4 Turbo | B0510512_en 9

2.4 Permitted uses

The Froling Firewood boiler S4 Turbo is designed solely for heating domestic water.

Only use fuels specified in the "Permitted fuels" section.

⇨ See "Permitted fuels" [page 10]

The unit should only be operated when it is in full working order. It should be operated

in accordance with the instructions, observing safety precautions, and you should en‐

sure you are aware of the potential hazards. The inspection and cleaning intervals in

the operating instructions should be observed. Ensure that any faults which might im‐

pair safety are rectified immediately.

The manufacturer or supplier is not liable for any damage resulting from non-permitted

uses.

2.4.1 Permitted fuels

Firewood

Firewood up to max. 55 cm long.

Water content (w) greater than 15% (equivalent to wood moisture u > 17%)

Water content (w) less than 25% (equivalent to wood moisture u < 33%)

EU: Fuel acc. to EN 14961 - Part 5: Firewood class A2 / D15 L50

Germany

also:

Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance

(BimSchV) in the last amended version)

▪ Values in practice:

- Hardwood: 2 years in dry storage

- Soft wood: 1 year in dry storage

▪Store stacks of split wood sheltered from the rain

▪ Create a dry underlay, where possible with air access (line with round timber, pallets,

etc.)

▪ Use wind-exposed areas where possible for storage (e.g. store at edge of forest instead

of in forest)

▪ Walls of buildings facing the sun are ideal

▪ If possible, stock fuel for the day in a warm place (e.g. in boiler room) (pre-heats the

fuel!)

NOTICE! Use fuels that are consistent in size and water content.

NOTICE! Burning extremely dry fuels (w < 15%) may require repairs by qualified staff.

Please contact Froling customer services or your installer.

Water content

Note on standards

Tips for

storing wood

2Safety

Permitted uses

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

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