Froling S1 Turbo Installation Instructions Manual
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Froling S1 Turbo Installation Instructions Manual

Froling S1 Turbo Installation Instructions Manual

Fire wood boiler
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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

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  • Page 1: 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...

  • Page 2: Table Of Contents

    Fitting the air control Variant 1 - Fitting the servo-motor Variant 2 - Fitting the manual controller 4.6.5 Fitting the controller box 4.6.6 Fitting the broadband probe, flue gas temperature sensor and STL Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 3 Boiler with Lambda control Boiler with manual controller Decommissioning Mothballing Disassembly Disposal Appendix Pressure equipment regulation Technical specifications - Lambda control with partial load values Addresses 7.3.1 Address of manufacturer 7.3.2 Address of the installer Installation Instructions S1 Turbo | M1470113_en...

  • Page 4: General

    General 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.

  • Page 5: Safety

    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. Installation Instructions S1 Turbo | M1470113_en...

  • Page 6: Qualification Of Assembly Staff

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

  • Page 7: Design Information

    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) Installation Instructions S1 Turbo | M1470113_en...

  • Page 8: Standards For Permitted Fuels

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

  • Page 9: Requirements For Central Heating Water

    Pump-controlled pressure maintenance systems with open expan‐ sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the Installation Instructions S1 Turbo | M1470113_en...

  • Page 10: Return Lift

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

  • Page 11: Combination With Storage Tank

    As the boiler’s minimum continuous heat output is 30% above the nominal heat out‐ put, we as boiler manufacturer are obliged under EN 303-5:2012, Section 4.4.6 to ad‐ vise that the Firewood boiler S1 Turbo must always be connected to a storage tank with adequate storage capacity.
  • Page 12 1. Values for calculating the capacity can be found in the technical data or the technical data with partial load inspection (if available) For the correct dimensions of the storage tank and the line insulation (e.g. in accordance with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 13: Chimney Connection/Chimney System

    Flue gas mass flow at partial load kg/s 0.006 0.007 Required feed pressure at nominal and mbar 0.08 0.08 0.08 partial load Maximum permissible feed pressure In accordance with ÖNORM/DIN EN 303-5 Flue spigot diameter Installation Instructions S1 Turbo | M1470113_en...

  • Page 14: Technology

    Width, boiler Height, boiler 1235 Total height incl. Flue gas nozzle 1290 Height, flue spigot 1450 Height, flow connection 1055 Height, return connection Height, safety battery connection 1040 Height, drainage connection Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 15: Components And Connections

    Immersion sleeve for thermal discharge valve (sup‐ Inches ½ plied by the customer) Flue spigot Immersion sleeve for boiler sensor and STL Inches ½ Broadband probe connection Inches ¾ Flue gas temperature sensor connection Inches ½ Installation Instructions S1 Turbo | M1470113_en...

  • Page 16: Technical Specifications

    Organic hydrocarbons (OGC) mg/m³ Dust mg/m³ 1. Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13% Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 17 Nitrogen oxide (NOx) mg/m³ Organic hydrocarbons (OGC) mg/m³ Dust mg/m³ 1. Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13% Installation Instructions S1 Turbo | M1470113_en...

  • Page 18: Assembly

    Controller ▪ Cleaning devices 4.1.1 Tools required The following tools are required for assembling the S1 Turbo: ❒ Spanner or box wrench set (widths across flats 8 – 32 mm) ❒ Allen key set ❒ Flat head and cross-head screw drivers ❒...

  • Page 19: Temporary Storage

    ❒ Remove the cardboard with the controller from the boiler and put in a safe place ❒ Undo the screws on the top frame of the pallet ➥ Two screws each on the right and left, front and back ❒ Remove the top frame of the pallet Installation Instructions S1 Turbo | M1470113_en...

  • Page 20: Minimum Distances In The Boiler Room

    1. One side of the boiler (B or D) should be at least 500 mm from the wall to allow easy access for connecting the appliance and for mainte‐ nance work (e.g. induced draught). Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 21: Before Installation

    ❒ Undo the retainer of the hinge pin at the top and bottom door hinge ➥ For example, use two screwdrivers to gently bend the retainer plate out to loos‐ en it ❒ Take out the top and bottom hinge pins ❒ Take off the fuel loading door Installation Instructions S1 Turbo | M1470113_en...
  • Page 22 ❒ Attach the locking plate to the other side ❒ Using the locking cam, spacer washer and lock nut secure at the top and bottom as shown Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 23 NOTICE! If the door stops have been changed, you must check the seal of the doors and readjust if necessary. ⇨ See "Checking the seal on the doors" [page 24] ⇨ See "Positioning the doors" [page 25] Installation Instructions S1 Turbo | M1470113_en...

  • Page 24: Checking The Seal On The Doors

    ❒ Check the seal again after positioning the doors ❒ Repeat the procedure at the side of the door stop at the bottom and at the side of the door handle Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 25: Positioning The Doors

    ❒ Secure the lock nuts again The locking plate can be moved in the same way using the locking cam at the side of the door handle, allowing the contact pressure to be adjusted on this side Installation Instructions S1 Turbo | M1470113_en...

  • Page 26: Installing The Boiler

    Assembly Installing the boiler 4.6 Installing the boiler 4.6.1 Assembly overview Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 27 Cable duct Door bearing, left Door bearing, right Insulated door, front Insulated back panel, complete Induced draught cover plate Heat insulation mat, top, side Heat insulation mat, top, back Controller lid, complete Controller cover, complete Installation Instructions S1 Turbo | M1470113_en...

  • Page 28: Installing The Induced Draught Fan

    ❒ Position the induced draught fan and secure with the four screws and spacer washers 4.6.3 Installing the insulation NOTICE Separate parts of the boiler are fitted with a protective film. This MUST be re‐ moved before assemby! Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 29 ❒ Remove the square plug at the front left of the boiler and replace with brass bush‐ ❒ Tighten the brass bushing with Allen wrench (27 mm) ❒ Insert the thermal insulation for induced draught and secure with the tension springs Installation Instructions S1 Turbo | M1470113_en...
  • Page 30 ➥ Run the bracket diagonally from bottom to top ❒ Secure the bracket with three screws ❒ Attach the right and left insulating side panels of the boiler ➥ First fit the bottom to the side bolts Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 31 ❒ Attach the hinge pins for the insulated door to the side of the door stop ❒ Measure the diagonals and align the insulating side panels so that the two diago‐ nals are the same ➥ Adjust the position of the side panels if necessary Installation Instructions S1 Turbo | M1470113_en...

  • Page 32: Fitting The Air Control

    ❒ Turn the sliding valve for the air duct in an anti-clockwise direction as far as the stop ❒ One of the pins of the air damper has to make contact with the left of the stop screw (pos. 1) Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 33: Variant 2 - Fitting The Manual Controller

    ❒ Turn the sliding valve for the air duct in an anti-clockwise direction as far as the stop ❒ One of the pins of the air damper has to make contact with the left of the stop screw (pos. 1) Installation Instructions S1 Turbo | M1470113_en...

  • Page 34: Fitting The Controller Box

    ➥ The exact position of the manual controller is set on initial start-up ⇨ See "Boiler with manual controller" [page 53] ➥ Fit the cover plate for the air control 4.6.5 Fitting the controller box ❒ Fit the cover plate beneath the control Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 35 ❒ Position the cable duct at the right edge of the insulating side ➥ Insert the cable duct attachment hook into the holes provided on the insulating side panel ❒ Secure the cable duct at the back of the controller with screw incl. contact washer Installation Instructions S1 Turbo | M1470113_en...

  • Page 36: Fitting The Broadband Probe, Flue Gas Temperature Sensor And Stl

    ➥ Tuck any extra cable into the cable duct ❒ Push the boiler sensor and STL capillary into the pre-installed immersion sleeve with the pressure spring during boiler outfeed Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 37: Attaching The Induced Draught Cable

    ❒ Attach the two induced draught cables and secure with cable ties 4.6.8 Installing the insulated door Right door stop ❒ Insert the door bearing provided for the right stop into the hole provided on the right insulation side panel and secure with two screws Installation Instructions S1 Turbo | M1470113_en...
  • Page 38 ❒ Measure the distance from the hinge pin on the control to the left insulated side panel ❒ Punch out the perforated flap for the door bearing on the left insulated side panel using an appropriate tool (e.g. screwdriver) Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 39 ❒ Hang the bottom of the insulated door onto the bolt of the door bearing ❒ Position the top of the insulated door and secure with the hinge pin ❒ Attach the caps on the ends of the control on each side Installation Instructions S1 Turbo | M1470113_en...

  • Page 40: Electrical Connection And Wiring

    In this case, the control line is connected to the corresponding PDM outputs of the boards. Observe the connection instructions in the boiler controller documentation! Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 41: Concluding Work

    ➥ Insert the lid attachment hooks into the holes provided on the controller ❒ Secure the controller lid with the screw ❒ Switch on the main switch on the side of the controller box Installation Instructions S1 Turbo | M1470113_en...
  • Page 42 Assembly Electrical connection and wiring ❒ Place the insulating mats on the back and side of the boiler ❒ Put on the controller cover Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 43: Connecting The Hydraulic Safety Devices

    ▪ Its size must comply with the design information in EN 12828 - Appendix D ▪ Ideally it should be installed in the return line. Follow the manufacturer’s installa‐ tion instructions Installation Instructions S1 Turbo | M1470113_en...

  • Page 44: Installing The Wos System (Optional)

    ❒ Fit the three WOS turbulators to the brackets on the stay tube provided using eye‐ bolt, spacer washer and spring cotter ➥ Ensure that you fit the turbulators in the right direction – see image Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 45 ❒ Unscrew the plug using hexagon spanner head (22 mm) and carefully take out us‐ ing pliers ➥ Ensure that the plug does not fall into the gap between the insulation and cloth‐ ing plate Installation Instructions S1 Turbo | M1470113_en...
  • Page 46 ❒ The hole in the shaft must match the hole in the stay tube ❒ The two holes roughly match when the flat end of the shaft is positioned as shown above ❒ Secure the shaft to the stay tube with pipe locking pin Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
  • Page 47 ❒ Push the WOS lever down and tighten at the flat part with spanner ❒ Refit the cover to the front of the insulation ❒ Attach the cleaning lid and secure with the screws ❒ Put on the insulating mat and controller cover Installation Instructions S1 Turbo | M1470113_en...
  • Page 48 Installing the WOS system (optional) ❒ Pull the WOS lever 5 – 10 times every time you heat up the boiler ➥ This keeps the heating surfaces clean and saves fuel. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 49: Start-Up

    Take the following precautions: ❒ Initial startup should be carried out with an authorised installer or with Froling customer services ❒ Adjust the boiler controller to the system type ❒...

  • Page 50: Initial Startup

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

  • Page 51: Fuels Permitted Under Certain Conditions

    ▪ Even when using the settings for dry fuel, burning wood briquettes can cause combus‐ tion problems. In such cases, repairs must be carried out by qualified staff. Please con‐ tact Froling customer services or your installer. Installation Instructions S1 Turbo | M1470113_en...

  • Page 52: Non-Permitted Fuels

    Using non-standard fuels can also lead to serious problems with combustion. For this reason, when operating the boiler: ❒ Only use permitted fuels Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 53: Heating Up For The First Time

    30 – 40% 50 – 60% 60 – 70% If you use wood briquettes for initial start-up (only permitted under certain conditions!), you can use roughly the same settings as for short split hardwood. Installation Instructions S1 Turbo | M1470113_en...
  • Page 54 The terms used “long split wood” (edge length EL > 10 cm) and “short split wood” (edge length EL < 10 cm) have been defined in these instructions by Froling; there is no fuel standard or similar guidelines.
  • Page 55 ❒ Use fuels that are consistent in size, type and water content ❒ If a very different type of fuel is used, get a qualified technician to check the air flap setting and adjust if necessary Installation Instructions S1 Turbo | M1470113_en...

  • Page 56: Decommissioning

    ❒ You can separate and clean recyclable materials and send them to a recycling centre. ❒ The combustion chamber must be disposed of as builders' waste. Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 57: Appendix

    Appendix Pressure equipment regulation 7 Appendix 7.1 Pressure equipment regulation Installation Instructions S1 Turbo | M1470113_en...

  • Page 58: Technical Specifications - Lambda Control With Partial Load Values

    14 / 12 15 / 11 1. Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13% Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...

  • Page 59: Addresses

    7.3 Addresses 7.3.1 Address of manufacturer FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL 0043 (0)7248 606 0 FAX 0043 (0)7248 606 600 INTERNET www.froeling.com 7.3.2 Address of the installer Stamp Installation Instructions S1 Turbo | M1470113_en...

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