Fröling S3 Turbo Installation Instructions Manual
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Fröling S3 Turbo Installation Instructions Manual

Firewood boiler
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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!
M1081217_en | Edition 23/03/2017
Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at

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  • Page 1 All manuals and user guides at all-guides.com 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! M1081217_en | Edition 23/03/2017...

  • Page 2: Table Of Contents

    All manuals and user guides at all-guides.com Table of Contents Table of Contents General About this manual Safety Hazard levels of warnings Qualification of assembly staff Personal protective equipment for assembly staff Design Information 2.4.1 Notes on standards General standards for heating systems Standards for structural and safety devices Standards for heating water Regulations and standards for permitted fuels...
  • Page 3 Non-permitted fuels 5.2.4 Heating up for the first time Boiler with Lambda control Boiler with manual controller Decommissioning Mothballing Disassembly Disposal Appendix Pressure equipment regulation Addresses 7.2.1 Address of manufacturer 7.2.2 Address of the installer Installation Instructions S3 Turbo | M1081217_en...

  • Page 4: General

    , S3 Turbo 20, S3 Turbo 30 (31 kW) S3 Turbo 40, S3 Turbo 45 1) S3 Turbo 18 only available in Italy; 2) S3 Turbo 30 with 31 kW nominal output only available in Austria and Italy; Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...

  • 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 S3 Turbo | M1081217_en...

  • Page 6: Qualification Of Assembly Staff

    All manuals and user guides at all-guides.com Safety Qualification of assembly staff 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 ❒...

  • 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 S3 Turbo | M1081217_en...

  • Page 8: Regulations And Standards For Permitted Fuels

    All manuals and user guides at all-guides.com 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: Requirements For Central Heating Water

    ▪ 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 Installation Instructions S3 Turbo | M1081217_en...
  • Page 10 All manuals and user guides at all-guides.com Safety Design Information Austria Germany Switzerland pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5 Chloride < 30 mg/L < 30 mg/L < 30 mg/L Additional requirements for Switzerland: The filling and make-up water must be demineralised (fully purified) ▪...

  • Page 11: Notes For Using Pressure Maintenance Systems

    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). Installation Instructions S3 Turbo | M1081217_en...

  • Page 12: 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 S3 Turbo must always be connected to a storage tank with adequate storage capacity.
  • Page 13 3000 Recommended storage tank capacity 1. Applies for S3 Turbo 18 as well (only available in Italy) 2. 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.

  • Page 14: Chimney Connection/Chimney System

    All manuals and user guides at all-guides.com 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, wherever possible, damage caused by seepage, insufficient feed pressure and condensation. 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 15: Boiler Data For Planning The Flue Gas System

    Required feed pressure at nominal load mbar 0.08 Required feed pressure at partial load mbar 0.08 Maximum permissible feed pressure mbar Flue pipe diameter 1. Applies for S3 Turbo 18 as well (only available in Italy) Installation Instructions S3 Turbo | M1081217_en...

  • Page 16: Technology

    Height of flow connection 1280 1380 Height of return connection Height of safety battery connection Height of drainage connection 1. Applies for S3 Turbo 18 as well (only available in Italy) Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...

  • Page 17: Components And Connections

    Immersion sleeve for thermal discharge valve inches (supplied by the customer) Immersion sleeve for boiler sensor and STL inches Flue gas pipe connection Flue gas temperature sensor connection inches Broadband probe connection inches Installation Instructions S3 Turbo | M1081217_en...

  • Page 18: Technical Specifications

    - spruce 3.0 - 4.4 3.3 - 4.8 1. S3 Turbo 18 only available in Italy 2. Values specified for combustion time are guideline values at nominal load and will vary depending on water content (15-25%) and fill level (80-100%)
  • Page 19 2.8 - 3.9 1. S3 Turbo 30 with 31 kW nominal output only available in Austria and Italy 2. Values specified for combustion time are guideline values at nominal load and will vary depending on water content (15-25%) and fill level...
  • Page 20 All manuals and user guides at all-guides.com Technology Technical specifications S3 Turbo 40 - 45 Name S3 Turbo 40 S3 Turbo 45 Nominal output Electrical connection 230V / 50Hz / fused C13A Power consumption at nominal load 53 – 73 Power consumption in slumber mode Weight of boiler incl.
  • Page 21 Boiler class as per EN 303-5: 2012 4 with partial load inspection 1. S3 Turbo 30 with 31 kW nominal output only available in Austria and Italy Test data - Emissions in [mg/MJ] (nominal load / partial load) Carbon monoxide (CO) mg/MJ 62 / –...
  • Page 22 All manuals and user guides at all-guides.com Technology Technical specifications Test report data Name S3 Turbo 40 S3 Turbo 45 S3 Turbo 40 - 45 Test book number PB0920016 PB0340011 Nominal output Boiler class as per EN 303-5: 2012 Test data - Emissions in [mg/MJ]...

  • Page 23: 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 S3 Turbo | M1081217_en...

  • Page 24: Positioning

    All manuals and user guides at all-guides.com 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 ❒...

  • Page 25: Setting Up In The Boiler Room

    ❒ Position a fork-lift or similar lifting device with a suitable load-bearing capacity at the base frame ❒ Lift and transport to the intended position in the installation room ➥ Observe the minimum distances in the boiler room. Installation Instructions S3 Turbo | M1081217_en...

  • Page 26: Minimum Distances In The Boiler Room

    ▪ Observe additional standards for noise protection (ÖNORM H 5190 - Noise protection measures) Dimens Description Unit S3 Turbo Distance - front of boiler to wall Distance – side of boiler to wall 800 (200) Distance – back to wall Distance –...
  • Page 27 ❒ Rotate the door and rehang it 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 Installation Instructions S3 Turbo | M1081217_en...

  • Page 28: Converting The Fuel Loading Door

    All manuals and user guides at all-guides.com Assembly Before Installation ❒ Use suitable tools (e.g. screwdriver and hammer) to push the hinge far enough toward the rear so that when the door is closed, there is slight resistance at a gap of approx.

  • Page 29: Fitting The Door Handles

    ⇨ See "Positioning the doors" [page 31] ➥ Resistance noticeable at a gap of >3 cm: Setting must be corrected - push the hinge toward the front ⇨ See "Positioning the doors" [page 31] Installation Instructions S3 Turbo | M1081217_en...
  • Page 30 All manuals and user guides at all-guides.com Assembly Before Installation Checking the seal: ❒ Open the door ❒ Insert a sheet of paper at both the top and the bottom of the door stop between the door and the boiler ❒...

  • Page 31: Positioning The Doors

    ➥ Caution: the locking plate and/or hinge must be aligned in the same way at the top and bottom! ❒ Tighten the nuts at the top and bottom Installation Instructions S3 Turbo | M1081217_en...

  • Page 32: Installing The Boiler

    All manuals and user guides at all-guides.com Assembly Installing the boiler 4.5 Installing the boiler 4.5.1 Assembly overview Insulation S-Tronic Lambda S-Tronic Plus S3 Turbo 40-45 S3 Turbo 20-30 Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...
  • Page 33 Heat insulation mat, top Sticker, "Secondary air actuator" (only with S-Tronic Lambda) Upper spacer plate Torque support (only with S-Tronic Lambda) Door contact switch incl. cable Servo-motor LM 24AP5-F/300.1 (only with S-Tronic Lambda) Heat insulation mat, top/rear Installation Instructions S3 Turbo | M1081217_en...

  • Page 34: Air Duct System

    All manuals and user guides at all-guides.com Assembly Installing the boiler Air duct system Item Quantity Description [units] Induced draught fan 2800U, complete, with rotation speed transducer Flue gas pipe nozzle Ø 150 Ceramic fibre seal 210 x 144 x 12 Pneumatic rods, complete Sliding valve Ø...

  • Page 35: Wos System S3 Turbo

    Quantity Name [units] WOS cleaning cover, complete Grey cast iron bushing Plastic cover WOS lever WOS bracket, complete 6 x 3 Pipe locking pin WOS turbulator Ø 50 x 6 x 3 x 837 Installation Instructions S3 Turbo | M1081217_en...

  • Page 36: Wos System S3 Turbo

    All manuals and user guides at all-guides.com Assembly Installing the boiler WOS system S3 Turbo 40-45 Item Quantity Name [units] WOS cleaning cover, complete Grey cast iron bushing Plastic cover WOS lever WOS turbulator Ø 50 x 6 x 3 x 932...

  • Page 37: Fit Flue Gas Pipe Nozzle And The Induced Draught Fan

    The following procedures are used to mount the pneumatic rod if the manual controller/servo-motors are mounted on the right side of the boiler. If the manual controller/servo-motors are mounted on the left side of the boiler, complete the following procedures with the sides reversed accordingly. Installation Instructions S3 Turbo | M1081217_en...
  • Page 38 All manuals and user guides at all-guides.com Assembly Installing the boiler ❒ Loosen the two screws (A) at the lower and upper air duct on the left side of the boiler ❒ Unscrew the screws (A) at the lower and upper air duct on the right side of the boiler far enough to allow the air flap to make contact with the thread ❒...

  • Page 39: Final Steps Before Insulating

    Only for S-Tronic Plus: ❒ Seal the broadband probe connection with a 3/4" blanking plug (B) ➥ On the S3 Turbo with S-Tronic Lambda, the broadband probe will be mounted here later 4.5.5 Installing the insulation NOTICE The individual parts of the boiler insulation covered with a protective film.
  • Page 40 All manuals and user guides at all-guides.com Assembly Installing the boiler ❒ 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 (A) each ➥ Insert the cover plates such that the rivet (C) is at the bottom! ❒...
  • Page 41 ❒ Hang the upper spacer plate on the rivets between the insulating side panels and attach with thread forming screws ➥ At the same time, this procedure also secures the bracket to the insulating side panels at the front Installation Instructions S3 Turbo | M1081217_en...

  • Page 42: Installing The Door Switch

    All manuals and user guides at all-guides.com Assembly Installing the boiler 4.5.6 Installing the door switch ❒ Secure the bracket with pre-mounted door switch to the upper spacer plate with two thread forming screws M4 x 8 ➥ The reel of the door contact switch must protrude at the front from the opening of the spacer plate.

  • Page 43: Aligning The Insulation And Attaching The Controller

    ➥ Adjust the position of the side panels if necessary ❒ Tighten the nuts (A) on the two brackets of the insulating side panels at the top of the boiler Installation Instructions S3 Turbo | M1081217_en...
  • Page 44 All manuals and user guides at all-guides.com Assembly Installing the boiler ❒ Position the control on top ❒ Insert one countersunk cross-head screw (A) each to the left and right through the bracket and control from below ❒ Use nuts (B) to secure the countersunk cross-head screws from the top ❒...

  • Page 45: Installing The Cleaning Port Door And Blank Cover

    ❒ Tap in a fitting grooved pin (A) at the lower door bracket ❒ Slide the lower door bracket into the base of the boiler ➥ Insert the fitting grooved pin (A) into the insulation ➥ Lightly tighten the two hexagonal screws M6 x 12 (B) Installation Instructions S3 Turbo | M1081217_en...
  • Page 46 All manuals and user guides at all-guides.com Assembly Installing the boiler S3 Turbo 40/45: ❒ Mount the lower door bracket with two hexagonal screws M6 x 12 on the U-profile ❒ Insert the door bracket with the U-profile and lightly tighten the two hexagonal screws M6 x 12 ❒...
  • Page 47 ❒ 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 ➥ If necessary, correct the position of the lower door bracket Installation Instructions S3 Turbo | M1081217_en...

  • Page 48: Fitting The Sensors

    All manuals and user guides at all-guides.com Assembly Installing the boiler 4.5.11 Fitting the sensors ❒ Screw in the brass bushing (A) for the flue gas temperature sensor ➥ Make sure that the borehole with the thread is situated at the upper area of the brass bushing ❒...

  • Page 49: Installing The Wos System

    ➥ Loosen the nut first, then turn the start knob counter clockwise ❒ Hang the WOS turbulators on the linking plate of the stay tube as shown (D - S3 Turbo 20/30, E - S3 Turbo 40/45) ➥ Make sure that you fit the turbulators in the right direction: ➥...

  • Page 50: Installing The Manual Controller/Servo-Motors

    All manuals and user guides at all-guides.com Assembly Installing the boiler 4.5.14 Installing the manual controller/servo-motors ❒ Secure the cover plate on the manual controller/servo-motor side using thread forming screws, ensuring that the three holes (A) are in the direction of the back of the boiler ➥...

  • Page 51: Fit The Cover Plate

    ❒ Run the cable from the two servo-motors through the cable duct upward to the controller Fit the cover plate. ❒ Use thread forming screws to secure the cover plate on the opposite side Installation Instructions S3 Turbo | M1081217_en...

  • Page 52: Power Connection And Wiring

    All manuals and user guides at all-guides.com 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 ❒...

  • Page 53: Hydraulic System

    Layered tank Pump assembly DHW tank S3 Turbo Unicell NT -S Note: Controller S-Tronic Plus NOTICE! It is not possible to combine the control of a return mixer with the control of a boiler! Installation Instructions S3 Turbo | M1081217_en...

  • Page 54: Information On Circulating Pumps

    All manuals and user guides at all-guides.com Assembly Power connection and wiring 4.6.2 Information on circulating pumps Connecting a high efficiency pump 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 ≤...

  • Page 55: Connecting A Squirrel Cage Standard Pump

    ❒ EC motor pumps must not be connected to speed-controlled pump outputs (pump 1) ➥ When using the S3 Turbo firewood boiler in conjunction with the S-Tronic Plus or S-Tronic Lambda controller, the connection diagram above must be followed for using a high efficiency pump with control line! Connecting a squirrel cage standard pump If a squirrel cage standard pump (e.g.

  • Page 56: Concluding Work

    All manuals and user guides at all-guides.com Assembly Power connection and wiring 4.6.3 Concluding work ❒ Put the front heat insulation mat on ❒ Attach the covers (A) to the controller cable ducts ❒ Put on the controller cover ❒ Use the two thread forming screws incl. contact washers to secure the controller cover ❒...

  • Page 57: 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 installation instructions Installation Instructions S3 Turbo | M1081217_en...

  • Page 58: Start-Up

    All manuals and user guides at all-guides.com Start-up Before commissioning / configuring the boiler 5 Start-up 5.1 Before commissioning / configuring the boiler The boiler must be configured to the heating system on initial start-up. NOTICE Optimum efficiency and efficient, low-emission operation can only be guaranteed if the system is set up by trained professionals and the standard factory settings are observed.

  • Page 59: 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 S3 Turbo | M1081217_en...

  • Page 60: Fuels Permitted Under Certain Conditions

    All manuals and user guides at all-guides.com Start-up Initial startup 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. Note on standards Fuel as per EN ISO 17225 - Part 3: wood briquettes class B / D100 L500 Form 1 - 3 Additional for Germany:...

  • Page 61: Heating Up For The First Time

    ❒ Tip: If this occurs, clean up using a cleaning rag. Boiler with Lambda control ❒ Open the insulated door and the fuel loading door ❒ Fill the fuel loading chamber for initial start-up and heat up NOTICE! See boiler operating instructions Installation Instructions S3 Turbo | M1081217_en...

  • Page 62: Boiler With Manual Controller

    All manuals and user guides at all-guides.com Start-up Initial startup Boiler with manual controller 100% ❒ 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.
  • Page 63 After starting up for the first time and once the combustion air has been set, the boiler is optimally set to the fuel used. For further use of the boiler, please note the following: ❒ Use fuels that are consistent in size, type and water content Installation Instructions S3 Turbo | M1081217_en...
  • Page 64 All manuals and user guides at all-guides.com Start-up Initial startup ❒ If a very different type of fuel is used, get a qualified technician to check the air flap setting and adjust if necessary Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...

  • Page 65: Decommissioning

    (e.g. AWG in Austria) ❒ You can separate and clean recyclable materials and send them to a recycling centre. ❒ The combustion chamber must be disposed of as builders' waste. Installation Instructions S3 Turbo | M1081217_en...

  • Page 66: Appendix

    All manuals and user guides at all-guides.com Appendix Pressure equipment regulation 7 Appendix 7.1 Pressure equipment regulation Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at...

  • Page 67: Addresses

    7.2 Addresses 7.2.1 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 7.2.2 Address of the installer Stamp Installation Instructions S3 Turbo | M1081217_en...

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