Froling S1 Turbo Installation Instructions Manual
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Installation Instructions
Firewood 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!
M1470517_en | Edition 28/03/2017
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Summary of Contents for Froling S1 Turbo
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Page 1: Installation Instructions
Installation Instructions Firewood 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! M1470517_en | Edition 28/03/2017 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 2 2.4.7 Combination with storage tank 2.4.8 Chimney connection/chimney system Draught limiter Measuring port Boiler data for planning the flue gas system Technology Dimensions S1 Turbo Dimensions SP Dual compact Components and connections Technical specifications Assembly Materials supplied 4.1.1 Tools required...
- 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 | M1470517_en...
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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 guidelines. 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 | M1470517_en... -
Page 6: Qualification Of Assembly Staff
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. -
Page 7: Design Information
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. Installation Instructions S1 Turbo | M1470517_en... -
Page 8: Regulations And Standards For Permitted Fuels
Safety Design Information 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. -
Page 9: General Information For Installation Room (Boiler Room)
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 Installation Instructions S1 Turbo | M1470517_en... -
Page 10: Requirements For Central Heating Water
Safety Design Information 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: ÖNORM H 5195 Switzerland: SWKI BT 102-01 Germany: VDI 2035 Italy: UNI 8065 Observe the standards and also follow the recommendations below: ❒... -
Page 11: Notes For Using Pressure Maintenance Systems
These systems offer no oxygen removal for the purposes of corrosion control as required by VDI 2035 and in the interests of corrosion protection should not be used. Installation Instructions S1 Turbo | M1470517_en... -
Page 12: Return Lift
Safety Design Information 2.4.6 Return lift If the hot water return is below the minimum return temperature, some of the hot water outfeed will be mixed in. CAUTION Risk of dropping below dew point/condensation formation if operated without return temperature control. Condensation water forms an aggressive condensate when combined with combustion residue, leading to damage to the boiler. -
Page 13: Combination With Storage Tank
As the boiler’s minimum continuous heat output is 30% above the nominal heat output, we as boiler manufacturer are obliged under EN 303-5:2012, Section 4.4.6 to advise that the Firewood boiler S1 Turbo must always be connected to a storage tank with adequate storage capacity. -
Page 14: Chimney Connection/Chimney System
55 litres per kilowatt of rated heat output; a water heat storage tank with a volume of 12 litres per litre of fuel loading chamber is recommended. Recommended storage tank capacity: Unit S1 Turbo 15 S1 Turbo 20 1000 1500 Recommended storage tank capacity 1. -
Page 15: Measuring Port
Flue gas mass flow at partial load kg/s 0.007 Required feed pressure at nominal load mbar 0.08 0.08 Required feed pressure at partial load mbar 0.08 Maximum permissible feed pressure mbar Flue pipe diameter Installation Instructions S1 Turbo | M1470517_en... -
Page 16: Technology
Technology Dimensions S1 Turbo 3 Technology 3.1 Dimensions S1 Turbo Measur Description Unit Value ement Length of boiler 1000 Total length incl. induced draught fan 1080 Width, boiler Width of boiler incl. WOS lever Height, boiler 1235 Total height incl. flue gas nozzle... -
Page 17: Dimensions Sp Dual Compact
Height, flow - firewood boiler connection 1055 Height, return - firewood boiler connection Height, return - pellet unit connection Height, safety battery - firewood boiler connection 1040 Height, suction system - pellet unit connection 1253 Installation Instructions S1 Turbo | M1470517_en... -
Page 18: Components And Connections
Components and connections 3.3 Components and connections Item Description Unit Value Boiler flow connection inches Boiler return connection on S1 Turbo (F) inches Boiler return connection – connection to pellet unit inches outfeed on SP Dual compact Drainage connection inches ½... -
Page 19: Technical Specifications
2.1 - 3.0 1. With regards to the approval of drawings for “S1 Turbo xx F” type boilers, the test results on the heating technology requirements of the “S1 Turbo xx” wood chip boiler according to EN 303-5 can be used. - Page 20 92.6 92.6 1. With regards to the approval of drawings for “S1 Turbo xx F” type boilers, the test results on the heating technology requirements of the “S1 Turbo xx” wood chip boiler according to EN 303-5 can be used.
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Page 21: Assembly
❒ Spanner or box wrench set (widths across flats 8 - 32 mm) ❒ Set of Allen keys ❒ Flat head and cross-head screwdrivers ❒ Hammer ❒ Diagonal cutting pliers ❒ Half-round file ❒ Power drill or cordless screwdriver with Torx bit insert Installation Instructions S1 Turbo | M1470517_en... -
Page 22: 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 23: Setting Up In The Boiler Room
❒ Lift the boiler using a fork-lift or similar lifting device with the appropriate load- bearing capacity and remove the bottom supports of the pallet ❒ Transport boiler to the intended position in the installation room ➥ Observe the recommended clearances in the boiler room! Installation Instructions S1 Turbo | M1470517_en... -
Page 24: Recommended Clearances In The Boiler Room
▪ Observe the applicable standards and regulations when setting up the system. ▪ Observe additional standards for noise protection (ÖNORM H 5190 - Noise protection measures) Recommended clearances S1 Turbo Measur Description Unit Value ement Distance –... - Page 25 Distance – boiler side without pellet unit to wall Distance – back to wall Distance – side of boiler to wall 500 (200 Minimum room height 2000 1. Maintenance work to boiler’s heat exchanger only possible from front Installation Instructions S1 Turbo | M1470517_en...
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Page 26: Before Installation
Assembly Before Installation 4.5 Before Installation 4.5.1 Changing door stops (as needed) The boiler comes with the door stop on the right. If you want to change the side the door stops are on, proceed as follows. Changing the fuel loading door stop The following example using the fuel loading door shows how to change the door stop. - Page 27 ❒ Attach the locking cam at the top and bottom as shown and secure with spacer washer and lock nut (M8) ❒ Attach the locking plate to the other side ❒ Using the locking cam, spacer washer and lock nut (M8) secure at the top and bottom as shown Installation Instructions S1 Turbo | M1470517_en...
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Page 28: Fitting The Door Handles
Assembly Before Installation ❒ Hang the door again with the stop on the other side ❒ Secure at the top and bottom with the hinge pins ❒ Refit the retainers to the top and bottom hinge pins ➥ to do so, we recommend using two screwdrivers NOTICE! If the door stops have been changed, you must check the seal of the doors and readjust if necessary. -
Page 29: Checking The Seal On The Doors
⇨ See "Positioning the doors" [page 30] ❒ 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 Installation Instructions S1 Turbo | M1470517_en... -
Page 30: Positioning The Doors
Assembly Before Installation 4.5.4 Positioning the doors The example below shows how to position the fuel loading door. The procedure is the same for positioning the combustion chamber door! ❒ Using an Allen key (SW 13 mm), loosen the lock nuts (M8) on the locking cams at the top and bottom ❒... - Page 31 Assembly Before Installation Installation Instructions S1 Turbo | M1470517_en...
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Page 32: Installing The Boiler
Assembly Installing the boiler 4.6 Installing the boiler 4.6.1 Assembly overview M4x8 M4x8 M3x10 M5x12 M6x20 M6x12 M6x100 M6x16 M6x12 Ø6x20 Ø15x1,6 M8x25 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 33 Lens-head screw M6 x 12 Locking washer, polyethylene Ø 15 x 1.6 Hexagonal screw M8 x 25 SW13 Bolts M8 Hexagonal nut M8, flat SW13 Tension spring NOTICE! Number varies depending on the model Installation Instructions S1 Turbo | M1470517_en...
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Page 34: Fit The Induced Draught Fan
Assembly Installing the boiler 4.6.2 Fit the induced draught fan ❒ Secure the set screw M6 x 20 (1) at the upper borehole ❒ Mount the fibre-glass seal for the induced draught fan on the set screw ❒ Secure the induced draught fan with the four hexagon screws (M6 x 12) and spacer washers 4.6.3 Installing the insulation NOTICE... - Page 35 ➥ Position the small perforation (top) with the connections for broadband probe and flue gas temperature sensor ❒ Position the rear thermal insulation at the back panel and secure to the boiler with the tension springs Installation Instructions S1 Turbo | M1470517_en...
- Page 36 Assembly Installing the boiler Right door stop Left door stop ❒ Screw in bolts (M8) and nuts on the door bearing panel provided as shown ❒ Place the complete door bearing on the bottom of the boiler and secure from above with two round-head screws M6 x 16 including nuts and washers ❒...
- Page 37 ❒ Secure the control to the bracket on the left and right using countersunk head screws M5 x 12 ❒ Secure the cover plate including door contact switch with lens-head screws M4 x 8 ❒ Secure plugs to the cut-out sections of the cover plate Installation Instructions S1 Turbo | M1470517_en...
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Page 38: Fitting The Air Control
Assembly Installing the boiler 4.6.4 Fitting the air control Variant 1 - Fitting the servo-motor ❒ Turn the sliding valve for the air duct in an anti-clockwise direction as far as the stop ❒ Set the direction of rotation of the actuator (1) to left (L) ❒... -
Page 39: Installing The Insulated Door
3. Hang the bottom of the insulated door onto the bolt of the door bearing 4. Position the top of the insulated door and secure with the hinge pin 5. Attach the caps on the ends of the control on each side Installation Instructions S1 Turbo | M1470517_en... -
Page 40: Installing The Wos Lever
Assembly Installing the boiler ❒ Measure the distance between the insulating door and the control (left and right) when the insulating door is closed ➥ The two distances must be equal! ➥ Align the side panels as required ❒ Tighten hexagonal screws M8 x 25 on both brackets ❒... -
Page 41: Fitting The Controller Box
❒ Secure the controller box with two lens-head screws M4 x 8 including contact washers (E) ❒ Align the controller box horizontally using the hexagonal screw M6 x 100 (F) at the back left Installation Instructions S1 Turbo | M1470517_en... -
Page 42: Fitting The Broadband Probe And Sensors
Assembly Installing the boiler ❒ Position the cable duct on the right side panel ➥ Insert the cable duct attachment hooks into the holes provided on the side panel ❒ Secure the cable duct at the back of the controller box with two lens-head screw M4 x 8 including contact washer ❒... - Page 43 ❒ Remove pre-installed blanking plug of the boiler flow and then seal the immersion sleeve of the thermal discharge safety device ❒ Slide the sensor and metal tube insulation into the immersion sleeve and secure with slotted screw Installation Instructions S1 Turbo | M1470517_en...
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Page 44: Attaching The Induced Draught Cable
Assembly Installing the boiler 4.6.9 Attaching the induced draught cable ❒ Run the induced draught cable through the round cut-out section in the back panel to the induced draught unit via the cable duct ➥ Tuck any extra cable into the cable duct ❒... -
Page 45: Electrical Connection And Wiring
Run cable to boiler controller box and connect to the boards: Broadband probe on core module FRKEM Flue gas temperature sensor on core module Abgas- Fühler FRKEM Boiler sensor on core module FRKEM Kessel- Fühler KF Installation Instructions S1 Turbo | M1470517_en... - Page 46 Assembly Electrical connection and wiring ID fan on core module FRKEM STL on core module FRKEM Door contact switch on core module Türkontakt- schalter TKS FRKEM Servo-motor on core module FRKEM Control on core module FRKEM ❒ Wire the components according to the electrical connection diagram ➥...
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Page 47: Potential Equalisation
➥ The power supply line (mains connection) must be fitted with a max. C13A fuse by the customer. ➥ Observe the circuit diagrams in the boiler controller operating instructions. 4.7.1 Potential equalisation ❒ The potential equalisation on the boiler base must comply with current directives, regulations and standards. Installation Instructions S1 Turbo | M1470517_en... -
Page 48: Information On Circulating Pumps
Assembly Electrical connection and wiring 4.7.2 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 49: Concluding Work
❒ Secure the controller cover with lens-head screw M4 x 8 including contact washer ❒ Put on the thermal insulation for the reversing chamber cover and cleaning cover ❒ Put on the controller lid Installation Instructions S1 Turbo | M1470517_en... -
Page 50: Connecting The Hydraulic Safety Devices
Assembly Connecting the hydraulic safety devices 4.8 Connecting the hydraulic safety devices S1 Turbo (F) SP Dual compact Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 51 ▪ 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 installation instructions Internal pipe connection ▪ Pellet unit outfeed to return firewood boiler (included in delivery) Installation Instructions S1 Turbo | M1470517_en...
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Page 52: Start-Up
Take the following precautions: ❒ Initial startup should be carried out with an authorised installer or with Froling customer services NOTICE Foreign bodies in the heating system impair its operational safety and can result in damage to property. -
Page 53: Initial Startup
The ideal water content of firewood is between 15 and 25%. If the water content falls below 15%, we recommend you adjust the combustion control to the fuel. Installation Instructions S1 Turbo | M1470517_en... -
Page 54: Fuels Permitted Under Certain Conditions
▪ The fuel loading chamber must not be filled more than 3/4 full, as the wood briquettes expand during combustion ▪ Burning wood briquettes can cause problems in combustion. In such cases, repairs must be carried out by qualified staff. Please contact Froling customer services or your installer. 5.2.3 Non-permitted fuels The use of fuels not defined in the "Permitted fuels"... -
Page 55: Heating Up For The First Time
A19000015 ❒ Set the manual controller for the air flap as shown in the table below NOTICE! The information below only applies to split wood and not for round timber, square timber etc. Installation Instructions S1 Turbo | M1470517_en... - Page 56 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 57 ❒ 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 | M1470517_en...
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Page 58: 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 59: Appendix
Appendix Pressure equipment regulation 7 Appendix 7.1 Pressure equipment regulation Installation Instructions S1 Turbo | M1470517_en... -
Page 60: Technical Specifications - Lambda Control With Partial Load Values
Appendix Technical specifications - Lambda control with partial load values 7.2 Technical specifications - Lambda control with partial load values Description S1 Turbo 20 / S1 Turbo F Nominal heat output / range 20 / 10 - 20 Electrical connection... - Page 61 Appendix Technical specifications - Lambda control with partial load values Test report data - Description S1 Turbo 20 / S1 Turbo F Lambda Control Testing institute TÜV Austria Test report no. 13-UW/Wels-EX-044/6 Date of issue 21/06/2013 Boiler class as per EN 303-5:2012 Boiler efficiency 92.0...
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Page 62: 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 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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