Froling S3 Turbo 18 Installation Instructions Manual
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Froling S3 Turbo 18 Installation Instructions Manual

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Installation Instructions

Firewood boiler S3 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!
M1080813_en | Edition 30/09/2013
Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at

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  • Page 1: Installation Instructions

    Installation Instructions Firewood boiler S3 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! M1080813_en | Edition 30/09/2013 Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...

  • Page 2: Table Of Contents

    Setting and checking the seal on the doors Positioning the doors Installing the boiler 4.5.1 Assembly overview Insulation Air duct system WOS system S3 Turbo 18-28 WOS system S3 Turbo 36-45 Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...
  • Page 3 Table of Contents 4.5.2 Installing the flue gas pipe nozzle 4.5.3 Fit the induced draught fan 4.5.4 Installing the pneumatic rods for the primary and secondary air 4.5.5 Final steps before insulating 4.5.6 Installing the insulation 4.5.7 Installing the door switch 4.5.8 Installing the back panel 4.5.9...

  • 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

    Safety Hazard levels of warnings 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.

  • Page 6: Qualification Of Assembly Staff

    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‐...

  • Page 7: Design Information

    Safety Design Information 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‐...

  • Page 8: Standards For Permitted Fuels

    Safety Design Information 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‐...

  • Page 9: Requirements For Central Heating Water

    Safety Design Information 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: Note on standards ÖNORM H 5170 - Construction and fire protection requirements 2.4.4 Requirements for central heating water The following standards and guidelines apply: Note on standards...

  • Page 10: Notes For Using Pressure Maintenance Systems

    Safety Design Information 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‐...

  • Page 11: Combination With Storage Tank

    Safety Design Information 2.4.7 Combination with storage tank Observe the regional regulations for using a storage tank! Certain subsidy guidelines prescribe compulsory requirements for the installation of storage tanks. Up-to-date information about individual subsidy guidelines can be found at www.froeling.com. General information Channelling the heat generated by the Firewood boiler to a storage tank, can bring major advantages, including:...
  • 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. Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...

  • Page 13: Chimney Connection/Chimney System

    Safety Design Information 2.4.8 Chimney connection/chimney system EN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐ ever possible, damage caused by seepage, insufficient feed pressure and condensa‐ tion. Please note in this respect that flue gas temperatures lower than 160K above room temperature can occur in the permitted operating range of the boiler.

  • Page 14: Technology

    Technology Dimensions 3 Technology 3.1 Dimensions Di‐ Description Unit S3 Turbo S3 Turbo men‐ 18-28 36-45 sion Length, boiler 1160 1250 Total length incl. induced draught fan 1260 1350 Width, boiler Total width inc. side cleaning door Height, boiler 1470 1570 Total height incl.

  • Page 15: Components And Connections

    Technology Components and connections 3.2 Components and connections Item Description Unit S3 Turbo Boiler flow connection inches Boiler return connection inches Drainage connection inches Safety battery connection inches Immersion sleeve for thermal discharge valve (sup‐ inches plied by the customer) Immersion sleeve for boiler sensor and STL inches Flue gas pipe connection...

  • Page 16: Technical Specifications

    Technology Technical specifications 3.3 Technical specifications Description S3 Turbo 18 S3 Turbo 28 Nominal output 22.5 Electrical connection 230V / 50Hz / fused C13A Power consumption at nominal load 50 - 70 Power consumption in slumber mode Weight of boiler incl. insulation and control Total boiler capacity (water) Water pressure drop (ΔT = 10 / 20 K)
  • Page 17 Technology Technical specifications Test report data Description S3 Turbo 18 S3 Turbo 28 S3 Turbo 18 - 28 Testing institute TÜV Austria TÜV Austria Test report no. 11-U-407/SD 11-U-407/SD Date of issue 22/07/2011 22/07/2011 Boiler class as per EN 303-5:2012 Boiler efficiency 91.1...
  • Page 18 Technology Technical specifications Test data - Emissions in [mg/m³] (nominal load) Dust mg/m³ 10 / 14 14 / 15 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% Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...

  • Page 19: Assembly

    Assembly Materials supplied 4 Assembly 4.1 Materials supplied The boiler comes on a pallet together with insulation, controller and accessories. Some of the components come in cardboard packaging. Boiler Flue gas pipe nozzle Insulation Ceramic fibre seal Controller Induced draught fan WOS system (heat exchanger Cardboard box containing small parts optimization system)

  • Page 20: Positioning

    Assembly Positioning 4.2 Positioning NOTICE Damage to components if handled incorrectly ❒ Follow the transport instructions on the packaging ❒ Transport components with care to avoid damage ❒ Protect the packaging against damp conditions ❒ Pay attention to the pallet's centre of gravity when lifting ❒...

  • Page 21: Setting Up In The Boiler Room

    ➥ A total of four screws, left/right, front/rear ❒ Lift boiler from pallet TIP: Use Froling’s KHV 1400 boiler lifting system to help remove the pallet! 4.3.2 Moving the boiler in the boiler room ❒ Position a fork-lift or similar lifting device with a suitable load-bearing capacity at the base frame ❒...

  • Page 22: Minimum Distances In The Boiler Room

    Assembly Setting up in the boiler room 4.3.3 Minimum distances in the boiler room ▪ The system should generally be set up so that it is accessible from all sides allow‐ ing quick and easy maintenance. ▪ Regional regulations regarding necessary maintenance areas for inspecting the chimney should be observed in addition to the specified minimum distances! ▪...
  • Page 23 Assembly Before Installation ❒ Undo the retainer of the hinge pin at the top and bottom door hinge ➥ You can use two screwdrivers to gently bend the retainer plate out to loosen it ❒ Take out the top and bottom hinge pins and remove the combustion chamber door ❒...

  • Page 24: Converting The Fuel Loading Door

    Assembly Before Installation ❒ Use suitable tools (e.g. screwdriver and hammer) to push the hinge far enough to‐ ward the rear so that when the door is closed, there is slight resistance at a gap of approx. 2-3 cm ➥ Caution: the hinge must be aligned in the same way at the top and bottom! ❒...

  • Page 25: Fitting The Door Handles

    Assembly Before Installation ❒ Carefully lift out the insulating plate ❒ Turn the insulating plate by 180° and position it so that it lines up with the holes provided ❒ Re-install the radiation plate ❒ Use contact adhesive to fix the seal in place 4.4.2 Fitting the door handles The example below shows how to mount the fuel loading door handles.

  • Page 26: Setting And Checking The Seal On The Doors

    Assembly Before Installation 4.4.3 Setting and checking the seal on the doors The example below shows how to set and check the seals on the fuel loading doors. The procedure is the same for the combustion chamber door and the pre-heating chamber door! On the side with the door stop Checking the setting:...

  • Page 27: Positioning The Doors

    Assembly Before Installation On the side with the door handle ❒ Close the door Checking the setting: ➥ If the door can be opened with the usual force: Setting okay ➥ If the door cannot be opened with the usual force or must be forced open :push the locking plate toward the front ⇨...

  • Page 28: Installing The Boiler

    Assembly Installing the boiler 4.5 Installing the boiler 4.5.1 Assembly overview Insulation Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...
  • Page 29 Magnetic latches Grip recess Flange bushing (8x6x12x8) Sticker, FROELING S3 TURBO U-plate – S3 Turbo 36/45 fitting grooved pin (6x30) – S3 Turbo 18/28 Lower door bracket Lower spacer plate Complete floor insulation Insulation mounting brackets, left Insulation cover plate, left...

  • Page 30: Air Duct System

    Assembly Installing the boiler Air duct system Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...
  • Page 31 Assembly Installing the boiler Item Quan‐ Description tity [units] Induced draught fan 2800U, complete, with rotation speed transducer Ceramic fibre seal 210x144x12 Flue gas pipe nozzle ø150 Blanking plug 3/4" Air duct, primary air, left and right Rubber seal for profile 12x2x15x23, L=1600 Air flap Manual controller for air control system (S-Tronic/S-Tronic Plus) Handle, black...

  • Page 32: Wos System S3 Turbo

    Assembly Installing the boiler WOS system S3 Turbo 18-28 Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...
  • Page 33 Assembly Installing the boiler Item Quan‐ Description tity [units] WOS lever, complete Handle Brass bushing SW27x20 WOS turbulator ø50x6x3x837 WOS bracket, complete 6x3 Linking plate for turbulator 6x3 Bolt ø8x16 Spacer washer M8 Split pin ø2x16 Stay tube WOS Clamping jaw Spacer tube ø21.3x50 Rosette ø77x15.5 Installation Instructions S3 Turbo | M1080813_en...

  • Page 34: Wos System S3 Turbo 36-45

    Assembly Installing the boiler WOS system S3 Turbo 36-45 Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...
  • Page 35 Assembly Installing the boiler Item Quan‐ Description tity [units] WOS lever, complete Handle Brass bushing SW27x20 WOS turbulator ø50x6x3x932 WOS bracket, complete 6x3 Linking plate for turbulator 6x3 Stay tube Clamping jaw Bolt ø8x16 Split pin ø2x16 Spacer washer M8 Spacer tube ø21.3x91 Rosette ø77x15.5 Installation Instructions S3 Turbo | M1080813_en...

  • Page 36: Wos System S3 Turbo

    Assembly Installing the boiler 4.5.2 Installing the flue gas pipe nozzle ❒ Place the ceramic fibre seal in position ❒ Position the flue gas pipe nozzle and attach it using the pre-installed spacer wash‐ ers and nuts ➥ Caution: ½" connection must point to the right as seen from behind! 4.5.3 Fit the induced draught fan ❒...
  • Page 37 Assembly Installing the boiler Manual controller/ser‐ vo-motor, left ❒ Loosen the two screws at the lower and upper air duct on the right side of the boil‐ ❒ Screw in the screws at the lower and upper air duct on the left side of the boiler far enough to allow the air flap to make contact with the thread Manual controller/ser‐...

  • Page 38: Final Steps Before Insulating

    Assembly Installing the boiler ❒ Insert the air flaps on the pneumatic rods on the left side and secure them with split pins ➥ CAUTION: The air flaps must be situation in the same position as those on the opposite side! ❒...

  • Page 39: Installing The Insulation

    Assembly Installing the boiler 4.5.6 Installing the insulation NOTICE Separate parts of the boiler are fitted with a protective film. This MUST be re‐ moved before assemby! ❒ Push in the bottom insulation ❒ Inset the two L-shaped insulation cover plates at the insulating side panels at left and right and secure them with three thread forming screws each ➥...
  • Page 40 Assembly Installing the boiler ❒ Cut the perforated plates for the cleanout opening on both sides and bend them inward ➥ Caution: bend the plates > 100° inward! ❒ Place one large spacer washer on each of the threaded bolts to the right and the left above on the boiler ❒...

  • Page 41: Installing The Door Switch

    Assembly Installing the boiler 4.5.7 Installing the door switch ❒ Secure the bracket with pre-mounted door switch to the upper spacer plate with two thread forming screws M4x8 4.5.8 Installing the back panel ❒ Position the rear thermal insulation on the rear side of the boiler ❒...

  • Page 42: Aligning The Insulation And Attaching The Controller

    Assembly Installing the boiler 4.5.9 Aligning the insulation and attaching the controller ❒ Hang the lower spacer plate on the rivets (1) between the insulating side panels and attach with one thread forming screw (2) each ❒ Push the insulating side panels toward the rear until the borehole on the flaps cor‐ responds with the borehole on the side panels ❒...
  • Page 43 Assembly Installing the boiler ❒ Insert one countersunk cross-head screw each to the left and right through the bracket and control from below ❒ Use nuts to secure the countersunk cross-head screws from the top. ❒ Put the top heat insulation mat on ➥...

  • Page 44: Installing The Cleaning Port Door And Blank Cover

    Assembly Installing the boiler ❒ Screw in two carrying bolts (hexagonal bolts M6x100) to the left and right at the bottom rear side of the controller far enough to ensure that the controller and insu‐ lation are supported adequately 4.5.10 Installing the cleaning port door and blank cover NOTICE! Recommendation for easier maintenance: mount the cleaning port door on the same side as the WOS lever! ❒...
  • Page 45 Assembly Installing the boiler S3 Turbo 18/28: ❒ Tap in a fitting grooved pin at the lower door bracket ❒ Slide the lower door bracket into the base of the boiler ➥ Insert the fitting grooved pin (1) into the insulation ➥...
  • Page 46 Assembly Installing the boiler ❒ Secure the lower door bracket ❒ At the front end of the lower door bracket, insert a hexagonal screw M6x30 from below, secure it with a nut and place a spacer washer on top ❒ Insert flange bushings at the top and the bottom on the side of the insulated door with the stop ❒...

  • Page 47: Fitting The Sensors

    Assembly Installing the boiler ❒ Position magnetic latches on the inside of the insulated door at the top and bottom ❒ Mount counter plates for the magnetic latches to the left insulation side panel ❒ Check to see if the gap between the insulation side panel and the insulated door is the same size along the entire height of the boiler ➥...

  • Page 48: Install The Broadband Probe (Only With S-Tronic Lambda)

    Assembly Installing the boiler ❒ Push the flue gas temperature sensor in so that it protrudes approx. 20 mm from the housing and secure the position with the wing screw ❒ Push the boiler sensor and STL capillary into the pre-installed immersion sleeve with the pressure spring during boiler outfeed ❒...

  • Page 49: Installing The Wos System

    ➥ File rough edges using a half-round file and remove burrs ❒ Slide the plastic cover onto the WOS lever S3 Turbo 18/28: S3 Turbo 36/45: ❒ Remove the heat exchanger cover ❒ Hang the WOS turbulators on the linking plate of the stay tube ➥...
  • Page 50 Assembly Installing the boiler S3 Turbo 18/28: ❒ Position the WOS turbulators at the heat exchanger pipes S3 Turbo 36/45: ❒ Position the WOS turbulators at the heat exchanger pipes ❒ Position the spacer tube at the stay tube ❒ Push the WOS lever through the distance and stay tubes from the outside and se‐...

  • Page 51: Installing The Manual Controller/Servo-Motors

    Assembly Installing the boiler S3 Turbo 18/28: S3 Turbo 36/45: ❒ Place the heat exchanger cover on top ❒ Turn the handle of the heat exchanger cover to the right ❒ Tighten the nut below the handle 4.5.15 Installing the manual controller/servo-motors ❒...

  • Page 52: Mounting The Servo-Motors (With S-Tronic Lambda Control)

    Assembly Installing the boiler ❒ Check to see if the air flaps can be opened to the right ➥ The exact position of the manual controller is set on initial start-up ⇨ See "Boiler with manual controller" [page 65] ❒ Use thread forming screws to secure the cover plate on the opposite side Mounting the servo-motors (with S-Tronic Lambda control) ❒...
  • Page 53 Assembly Installing the boiler ❒ Use thread forming screws to secure the cover plate on the opposite side ❒ Attach the sticker at the end of the servo-motor cable ➥ Primary air: top servo-motor ➥ Secondary air: bottom servo-motor ❒ Push in the pre-punched opening for the cable duct onto the insulation ❒...

  • Page 54: Power Connection And Wiring

    Assembly Power connection and wiring 4.6 Power connection and wiring DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: ❒ Only have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥...
  • Page 55 Assembly Power connection and wiring Connection instructions Port Cable dimensions / Specifications / Information Bus (1) Port with cable – LIYCY paired 2x2x0.5; Connecting the bus cable ❒ Warning! CAN L and CAN H must not be connected to +U Bus (2) Patch cable CAT 5 RJ45 SFTP 1:1 configuration Bus (3)
  • Page 56 Assembly Power connection and wiring Mains connection ❒ Connect power supply at ST 18 plug (1) ➥ The power supply line (mains connection) must be fitted with a max. C13A fuse by the customer! Connecting the door switch and display ❒...

  • Page 57: Hydraulic System

    Assembly Power connection and wiring Connecting the high-limit thermostat (STL) and boiler sensor ❒ Connect the STL and boiler sensor Hydraulic system Possible, non-binding planning suggestion: Weather-activated heating circuit control externally! Flow temp. sensor 1/2 External sensor Note: Please install a mixing valve to limit the outlet temp.

  • Page 58: S-Tronic Plus / S-Tronic Lambda Control

    Assembly Power connection and wiring 4.6.2 S-Tronic Plus / S-Tronic Lambda control Power connection ❒ Run the cable of the flue gas temperature sensor, boiler sensor, induced draught, S-Tronic Plus: STL, display and door switch to the controller and connect the wiring in accord‐ ance with the operating instructions of the boiler control ➥...

  • Page 59: Information On Circulating Pumps

    Assembly Power connection and wiring 4.6.3 Information on circulating pumps NOTICE According to 2012/622/EU external, wet running circulating pumps must comply with the following limit values of the Energy Efficiency Index (EEI): - Effective from 01/01/2013: Wet running circulating pumps with EEI ≤ 0.27 - Effective from 08/01/2015: Wet running circulating pumps with EEI ≤...
  • Page 60 Assembly Power connection and wiring ❒ Attach the covers to the controller cable ducts ❒ Put on the controller cover ❒ Secure the controller cover with 2 screws and contact washers ❒ Put on the back heat insulation mat ❒ Put on the rear insulating cover Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...

  • Page 61: Connecting The Hydraulic Safety Devices

    Assembly Connecting the hydraulic safety devices 4.7 Connecting the hydraulic safety devices Thermal discharge valve ▪ The thermal discharge safety device must be connected in accordance with ÖNORM/DIN EN 303-5 and as shown in the diagram above. ▪ The discharge safety device must be connected to a pressurised mains water supply in such a way that it cannot be shut off ▪...

  • Page 62: 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 63: 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. 5.2.2 Fuels permitted under certain conditions Wood briquettes Wood briquettes for non-industrial use with a diameter of 5-10 cm and 5-50 cm long.

  • Page 64: Non-Permitted Fuels

    ▪ 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. 5.2.3 Non-permitted fuels The use of fuels not defined in the "Permitted fuels"...

  • Page 65: Boiler With Lambda Control

    Start-up Initial startup Once the material in the boiler has burnt down, the boiler can be used in accordance with the operating instructions ("Operating the system" section). NOTICE If condensation escapes during the initial heat-up phase, this does not indicate a fault.
  • Page 66 The terms used, i.e. “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 67 Start-up Initial startup Setting the primary air The nominal output of the boiler is set via the primary air and adjusted to the fuel used. Combustion air Effect Setting More primary air Higher flue gas temperature, Rotate manual controller clockwise greater output ("plus"...

  • Page 68: Decommissioning

    Decommissioning Mothballing 6 Decommissioning 6.1 Mothballing The following measures should be taken if the boiler is to remain out of service for several weeks (e.g. during the summer): ❒ Clean the boiler thoroughly and close the doors fully If the boiler is to remain out of service during the winter: ❒...

  • Page 69: Appendix

    Appendix Pressure equipment regulation 7 Appendix 7.1 Pressure equipment regulation Installation Instructions S3 Turbo | M1080813_en...

  • Page 70: Technical Specifications - S3 Turbo With Partial Load Values

    Appendix Technical specifications - S3 Turbo with partial load values 7.2 Technical specifications - S3 Turbo with partial load values Test report data - Description S3 Turbo 28 Lambda Control Testing institute TÜV Austria Test report no. 08-UW/Wels-EX-299/5 Date of issue 04/12/2010 Boiler class as per EN 303-5:2012 Nominal output / range...

  • Page 71: Addresses

    Appendix 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 S3 Turbo | M1080813_en...

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