Froling S4 Turbo 15 Manual de usuario
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
7
Standards for structural and safety devices
8
Standards for heating water
8
Regulations and 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) 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
14
Measuring port
14
Boiler data for planning the flue gas system
15
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
33
Door handles
33
4.4.4 Setting and checking the seal on the doors 34
Checking the settings of the door stop
34
Checking the settings of the door handle
34
Table of Contents
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Checking the door stop seal
35
Checking the door handle seal
35
4.5 Assembling the S4 Turbo 15-40 36
4.5.1 Assembly overview 36
Air duct system
36
S4 Turbo 15-28 EOS system
37
S4 Turbo 32-40 EOS system
38
Insulation
39
Boiler with pellet flange
40
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
42
servo-motors on the left
43
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
57
EOS system
58
Insulation
59
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
62
servo-motors on the left
63
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
81
5.2.2 Fuels permitted under certain conditions 82
Wood briquettes
82
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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