Fröling SP Dual compact Installation Instructions Manual
Dual fuel boiler
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- Service handbook (120 pages) ,
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- Installation instructions manual (92 pages)
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Summary of Contents for Fröling SP Dual compact
- Page 1 Installation instructions Dual fuel boiler SP Dual compact Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M1820921_en | Edition 12/07/2021...
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Page 2: Table Of Contents
5.4.3 Operating and maintenance areas of the equipment..............28 6 Installation..............................30 6.1 Required accessories and tools......................30 6.2 Accessories supplied ..........................30 6.3 Assembly overview pellet unit....................... 31 6.4 Assembly overview S1 Turbo (F)......................32 M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 3 7.2.4 Heating up for the first time......................77 8 Decommissioning............................78 8.1 Mothballing ............................78 8.2 Disassembly ............................78 8.3 Disposal ..............................78 9 Appendix ..............................79 9.1 Pressure equipment regulation......................79 M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 4: General
1.1 About this manual These installation instructions contain information for the following sizes of SP Dual compact boilers: SP Dual compact 15, SP Dual compact 20 M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 5: Safety
The dangerous situation may occur and if measures are not observed it will lead to minor injuries. NOTICE The dangerous situation may occur and if measures are not observed it will lead to damage to property or pollution. M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 6: Qualification Of Assembly Staff
You must ensure that staff have the protective equipment specified by accident prevention regulations! ▪ During transport, erection and installation: - wear suitable work wear - wear protective gloves - wear safety shoes (min. protection class S1P) M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
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. (Italy) M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 8: Regulations And Standards For Permitted Fuels
▪ Installation at altitude higher than 2000 metres above sea level only after consultation with the manufacturer ▪ The system must be protected against gnawing and nesting by animals (such as rodents) ▪ No flammable materials in proximity to the system M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 9: Chimney Connection/Chimney System
▪ 100 mm if at least 20 mm thermal insulation is installed ▪ 375 mm if no thermal insulation is present Recommendation: three times the diameter of the connection line M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 10: Measuring Port
TRVB H 118 (only Austria) stipulates that an explosion flap must be installed in the connection line to the chimney, directly next to the boiler. It should be situated in such a way that is poses no risk to persons! M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 11: Electrostatic Particle Separator
Ü "Measuring port" [} 10] ▪ Locate the electrostatic particle separator in accordance with the planning for the flue gas system ▪ Install the electrostatic particle separator in accordance with the manufacturer's instructions supplied M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 12: Combustion Air
(maximum flow rate = 1 m/ Note on standards ÖNORM H 5170 - Construction and fire protection requirements TRVB H118 - Technical directives on fire protection/prevention M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 13: Simultaneous Operation With Other Air-Drawing Systems
Alternating operation An approved safety system (such as a flue gas thermostat) ensures (e.g. by switching off the power supply) that the boiler cannot be operated simultaneously with the air-drawing appliance. M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 14: Domestic Hot Water
1. From specific system volume (litres nominal capacity/heat output; for multi-boiler systems use the smallest individual heat output) 2. In the case of systems with central heating boilers and for systems with electric heating elements M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 15: 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. M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 16: 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 Dual fuel boiler SP Dual compact must always be connected to a storage tank with adequate storage capacity. -
Page 17: Return Lift
Fit a microbubble separator in the pipes to the boiler Recommendation: Ä Follow the manufacturer's instructions! M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 18: Technical Information
Height of hose line connection 1255 Height, safety heat exchanger connection 1040 Height, drainage connection Height, flow connection 1055 1. When using the optional flue pipe nozzle for low chimney connections M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 19: Components And Connections
16 mm Position for Lambda probe 3/4" IT Position for flue gas temperature sensor 1/2“ IT Pipe union - Pellet unit outfeed to firewood boiler return 1“ 1. Included in delivery M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 20: Technical Specifications
Energy efficiency index (EEI) of boiler Heating space annual rate of use ηs Energy efficiency index (EEI) of boiler and controller combined Energy efficiency class of boiler and controller combined M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 21 1. The emissions of dust, gaseous organic compounds, carbon monoxide and nitrogen oxides are stated in a standardised form based on dry flue gas with a oxygen content of 10 % and under standard conditions at 0°C and 1013 millibar M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 22: Boiler Data For Planning The Flue Gas System
Flue gas mass flow at partial load kg/s 0.006 0.007 Minimum feed pressure at nominal load mbar 0.08 Minimum feed pressure at partial load mbar 0.08 Maximum permissible feed pressure mbar Flue pipe diameter M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 23: External Suction Module
Length of suction module Width of suction module Height of suction module Total height incl. hose connection Return-air line connection (line to suction point) Return-air line connection (line to boiler) M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 24: Transport And Storage
If the system is to be assembled at a later stage: r Store components at a protected location, which is dry and free from dust Ä Damp conditions and frost can damage components, particularly electric ones! M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 25: Positioning
Attach the crane hook to the attachment point correctly and position the boiler 5.4 Positioning at the installation site 5.4.1 Removing boiler from pallet r Lift the cardboard boxes for the insulation, controller and control off the pallet M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 26 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 r Transport boiler to the intended position at the installation location Ä Ü "Positioning at the installation site" [} 25] M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 27: Removing The Pellet Unit From The Pallet
Undo the screws on the top of the rear panel and lift off the rear panel r Open the insulated door and remove the cover plate from the top hinge M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 28: Operating And Maintenance Areas Of The Equipment
▪ Observe the applicable standards and regulations when setting up the system. ▪ Observe additional standards for noise protection! (ÖNORM H 5190 - Noise protection measures) M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 29 815 mm 400 mm 500 mm / 200 mm 500 mm 1. Maintenance work to boiler’s heat exchanger only possible from front 2. Maintenance area to expand the WOS springs upwards M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 30: Installation
Cleaning brush 30 x 20 x 90 Ash shovel Cleaning brush Ø 54 x 1350 Hook Furnace tool with bracket Spanner for door mountings Ash drawer with bracket Socket wrench AF 13 M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 31: Assembly Overview Pellet Unit
Sound insulation dowel Ø 12 x 45 Suction module cover WOS drive (optional) Spring WOS shaft Pipe locking pin Bracket with WOS drive Spring cotter Ø 1.6 mm WOS cover plate WOS drive cover M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 32: Assembly Overview S1 Turbo (F)
6 | Installation 6.4 Assembly overview S1 Turbo (F) M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 33 Cover plate for air control Flue gas temperature sensor wing screw Insulated door Lambda probe bushing Door pin Lambda probe adaptor 7” Touch control Lambda probe 1. For firewood boilers with pellet flange M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 34: Before Installation
Take out the top and bottom hinge pins and take off the fuel loading door r Remove the locking plate and hinge Ä To do so, remove the locking cam and lock nuts r Reinstall the locking plate and hinge on the other side M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 35 NOTICE! If the door stops have been changed, you must check the seal of the doors and readjust if necessary. Ü "Checking the seal on the doors" [} 36] Ü "Positioning the doors" [} 37] M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 36: Checking The Seal On The Doors
Check the seal again after positioning the doors r Repeat the procedure at the side of the door stop at the bottom and at the side of the door handle M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 37: Positioning The Doors
If the door will not close, move the locking cams forward slightly Ä Caution: The two locking cams (top and bottom) must be adjusted equally! r Tighten the lock nuts (M8) M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 38: Install Firewood Boiler
Slide the floor insulation underneath the boiler from the front r Wrap the thermal insulation around the ID fan housing Ä Pay attention to the cutouts for the induced draught fan and Lambda probe M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 39 Screw the nuts and bolts as shown on to the supplied door mounting plate r Place the entire door mounting on the bottom of the boiler and attach from below using two screws M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
- Page 40 Fit the right side panel to the side lug (A) on the boiler base r Attach the side panel and bracket to the boiler Ä Tighten the screws only slightly so the side panel can be aligned later M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
- Page 41 Fit the control screw heads into the cutouts on the side panels r Insert the spacer plate beneath the control r Attach the spacer plate and control to the side panel using two screws r Tighten both screws on the cutouts M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 42: Fitting The Air Control
Run the servo-motor cable via the cable duct and out the top of the right side panel r Use four screws to attach the cover plate for the air control M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 43: Installing The Wos Lever
Loosen the screws slightly and unhook the cover plate from the side panel r Remove the stop from the WOS lever behind the control Ä The stop is no longer required. M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 44 Remove the pipe locking pin from the WOS rod and pull the WOS lever out the front r Instead, slide the supplied WOS lever into WOS rod and secure using pipe locking pin M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
- Page 45 Place the cleaning cover on the boiler and attach using a socket wrench r Fit the WOS cover plate to the opening on the side r Put the front cover plate back on the screw heads and tighten the screws M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 46: Installing The Insulated Door
Ä If necessary adjust the side panels at the brackets r When the positioning is correct, tighten the screws in the brackets r Close the round cutouts in the front cover plate using plastic plugs M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 47 For automatic WOS: Fit the cover on the WOS bracket r Place the thermal insulation on the boiler as shown Ä For automatic WOS: Separate the thermal insulation around the WOS cover along the perforation M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 48: Fitting The Controller Box
Push the boiler sensor and the STL capillary with the pressure spring (6) into the shrink-wrapped immersion sleeve of the boiler flow NOTICE! Thermal discharge valve is not included! M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 49: 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 r Plug in both induced draught cables and secure with cable ties M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 50: Fitting The Pellet Unit
Remove the cover plate and thermal insulation from the firewood boiler flange r Completely press in and remove the perforations (A and B) on the side panel r Remove the blanking plate of the flange M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 51 Completely screw in four adjusting screws (galvanized, yellow) on the flange Ä Adjusting screws function afterwards as the stop when setting the gap size IMPORTANT: Despite the aforementioned adjusting screws the flange seal is sufficiently compressed! M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
- Page 52 Screw the pellet unit to the flange of the firewood boiler using four M8 x 40 (B) hexagonal screws r Once you have done this, check that the clearance (C) between the firewood boiler insulation and the pellet unit is consistent M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
- Page 53 Tighten all of the screw connections (A and B) once again r Attach the base frame of the pellet unit both front and back to the firewood boiler using two screws and spacer washers M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 54: Fitting The Air Connection
Attach the cover plate of the combustion chamber cover to the bolts (A) and flip the cover plate up r Fit the insulated door on the bolts r Install cover plate on the top hinge M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 55 Loosen the screwed connection on the adjustment angle and correct the gap Ä Use the top screws (A) to adjust the gap from side to side Ä Use the front screw (B) to adjust the gap at the top M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 56: Connecting The Discharge System
Ä If the suction module is positioned at a maximum distance of 2 m to the boiler, the power supply line can be plugged in as is. When distances are greater the power supply line must be lengthened accordingly on-site M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 57 Fix the second part of the return-air line to the under-pressure side (position 2) with a hose clamp and lay the line to the boiler NOTICE! When connecting the lines, pay attention to equipotential bonding, Ü "Assembly information for hose lines" [} 59] M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 58: Connecting The Hose Lines
Run the return air line (A) to the left connection r Run the suction hose (B) to the right connection NOTICE! Ensure the potential equalisation matches the discharge system assembly instructions when connecting the hose lines! M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 59: Assembly Information For Hose Lines
▪ The return-air line can be made up of several sections, but consistent potential equalisation must be established throughout the line. ▪ For systems over 35 kW, only suction hoses with PU inlet are recommended due to the increased load M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 60 Ä TIP: If stiffness occurs when trying to attach the hoses to the connectors, pour a few drops of water onto the pipe (do not use lubrication grease!) r Secure the hose line with a hose clamp M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 61: Hydraulic Connection
Insert the pipe union as shown and fit to the screw connections Ä Do not forget to fit the seals provided! r Hang the cover plate on the screw heads and secure it with screws M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 62 ▪ Ideally it should be installed in the return line. Follow the manufacturer’s installation instructions We recommend fitting some sort of control device (e.g. thermometer) Internal pipe connection ▪ Pellet unit outfeed to return firewood boiler (included in delivery) M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 63: Electrical Connection
Remove the cable ties from the tag connector r Bind the individual cores together with cable ties (A) M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 64: Board Overview
Device connection terminal Service interface Main switch Core module Mains connection plug Return mixer module (optional) High-limit thermostat STL Hydraulic module Item Designation Item Designation Digital module Pellet module Pellet module expansion M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 65: Connect The Firewood Boiler Components
KM-27 KM-11 (Saugzug) (NOT-HALT) KM-02 Boiler display KM-15 Flue gas temperature sensor KM-07 Servo-motor KM-16 Door switch KM-10 High-limit thermostat KM-25 Boiler sensor KM-13 Lambda probe KM-27 Induced draught fan M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 66: Connect The Components Of The Pellet Unit
Open the insulated door of the pellet unit and remove the cover plate behind the door r Run the cable through the perforated opening (A) to the firewood boiler controller box and plug into the boards: M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 67 KM-29 (Netz) KM-08 (Kombiantrieb) KM-28 5V/P3 (Pumpe 1) KM-09 (Verriegelung) KM-10 (STB) KM-27 KM-11 (Saugzug) (NOT-HALT) KM-08 Primary air KM-17 WOS monitoring (for automatic WOS) KM-09 Lock KM-18 temperature sensor M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
- Page 68 HY-01 HY-02 FRHYU22 (Bus) Mains fuse Module address HY-03 / HY-04 HY-13 HY-14 HY-15 (Pumpe _.1) (Pumpe _.2) (Netz) (Bus) HY-01 Bus connection (alternatively on the return mixer module) HY-02 M1820921_en | Installation instructions Dual fuel boiler SP Dual compact...
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Page 69: Potential Equalisation
NOTICE! Compliance with additional information in the relevant boiler controller documentation is mandatory! 6.10.4 Potential equalisation r The potential equalisation on the boiler base must comply with current directives, regulations and standards. M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 70: Final Installation Steps
Put on the top cover r Insert side panel into lugs (A) and attach at the top r Insert the rear panel on the bottom (B) and attach at the top M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 71: Positioning The Boiler Stickers
6.11.1 Positioning the boiler stickers r Remove the protective film from the sticker r Position the backing film featuring “SP DUAL COMPACT” in the upper left corner of the insulated door, ensuring all of the air bubbles have been removed... -
Page 72: Affixing The Identification Plate
Cut the half shells of thermal insulation to length and lay them on the connection line r Create an opening for access to the measuring port r Apply protective foil at the projecting lugs r Glue the half shells to each other M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 73: Install The Brackets For Accessories
Installation | 6 6.11.4 Install the brackets for accessories r Using appropriate fasteners, attach the brackets to the wall on the boiler r Attach the accessories to the brackets M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 74: Start-Up
Check that the drives and servo motors are working and turning in the right direction r Check that the door contact switch is working efficiently. NOTICE! Check the digital and analogue inputs and outputs - See the instruction manual for the boiler controller. M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 75: Initial Startup
▪ stack split wood and store in such a way that it is protected from the elements ▪ If possible, stock fuel for the day in a warm place (e.g. in boiler room) (pre-heats the fuel!) M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 76: Fuels Permitted Under Certain Conditions
▪ Even when using the settings for dry fuel, burning wood briquettes can cause combustion problems. In such cases, repairs must be carried out by qualified staff. Please contact Froling customer services or your installer. M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 77: Non-Permitted Fuels
For this reason the following applies the first time you heat up the boiler: r Carry out initial start-up of the firewood boiler with less amount of fuel M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 78: Decommissioning
(e.g. AWG in Austria) r You can separate and clean recyclable materials and send them to a recycling centre. r The combustion chamber must be disposed of as builders' waste. M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... -
Page 79: Appendix
Appendix | 9 9 Appendix 9.1 Pressure equipment regulation M1820921_en | Installation instructions Dual fuel boiler SP Dual compact... - Page 80 Manufacturer’s address Froling srl Froling SARL Fröling Heizkessel- und Zweigniederlassung Behälterbau GesmbH Aschheim Industriestraße 12 Max-Planck-Straße 6 Via J. Ressel 2H 1, rue Kellermann A-4710 Grieskirchen 85609 Aschheim I-39100 Bolzano (BZ) F-67450 Mundolsheim +43 (0) 7248 606 0 +49 (0) 89 927 926 0 +39 (0) 471 060460 +33 (0) 388 193 269 info@froeling.com...
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