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Operating instructions Firewood boiler S4 Turbo Translation of original German version of operating instructions for operators. Read and follow all instructions and safety instructions. All errors and omissions excepted. B1510622_en | Edition 02/11/2022...
Table of Contents 1 General ................................. 1.1 Operating principle ..........................1.2 S4 Turbo Product Overview ........................2 Safety................................2.1 Hazard levels of warnings ........................2.2 Pictograms used ........................... 2.3 General safety information ........................2.4 Permitted uses ............................2.4.1 Permitted fuels ........................... 2.4.2 Fuels permitted under certain conditions ...................
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Table of Contents 4.6.6 One-time extra loading of an individual DHW tank ..............42 4.6.7 One-time extra loading of all existing DHW tanks..............42 4.6.8 Set the heating curve of a heating circuit................... 43 4.6.9 Change room temperature (heating circuit without room temperature sensor) ......44 4.6.10 Change room temperature (heating circuit with room temperature sensor) ......
1 | 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.
General | 1 1.2 S4 Turbo Product Overview Insulated door Maintenance overview Fuel loading door Pre-heating chamber door Combustion chamber door with inspection glass Ü "Overview of the touch display" [} 32] Lambdatronic S 3200 control, Lever for heat exchanger cleaning system (WOS) Actuators for automatic regulation of primary and secondary air Automatic ignition (optional) Back insulating cover...
2 | Safety 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.
Safety | 2 2.2 Pictograms used The following symbols are used in the documentation and/or on the boiler to show what is required and forbidden and to give warnings. In accordance with the Machinery Directive, signs fitted directly within the danger area of the boiler indicate immediate hazards or safety procedures.
2 | Safety 2.3 General safety information DANGER If the device is used incorrectly: Incorrect use of the system can cause severe injury and damage. When operating the system: r Observe the instructions and information in the manuals r Observe the details on procedures for operation, maintenance and cleaning, as well as troubleshooting in the respective manuals.
Safety | 2 2.4 Permitted uses The Froling Firewood boiler S4 Turbo is designed solely for heating domestic water. Only the fuels specified in the "Permitted fuels" section may be used. Ü "Permitted fuels" [} 9] The unit should only be operated when it is in full working order. It must be operated in accordance with the instructions, observing safety precautions, and you should ensure you are aware of the potential hazards.
2 | Safety Storage time dependent upon water content Wood type Water content 15 – 25% less than 15 Storage in heated and ventilated room Soft wood (e.g. approx. from 1 year (approx. 20°C) spruce) 6 months Hardwood (e.g. 1 – 1.5 years from 2 years beech) Outdoor storage (protected from elements,...
Safety | 2 2.4.3 Non-permitted fuels The use of fuels other than those defined in the "Permitted fuels" section, and particularly the burning of refuse, is not permitted NOTICE In case of use of non-permitted fuels: Burning non-permitted fuels increases the cleaning requirements and leads to a build-up of aggressive sedimentation and condensation, which can damage the boiler and also invalidates the guarantee! Using non-standard fuels can also lead to serious problems with combustion!
2 | Safety 2.7 Safety devices Underneath the back insulating cover (9): MAIN SWITCH (switches off the power supply) For shutting down the entire system r The power to all components is switched off. Ä WARNING! Only switch off the boiler when it has burnt down and cooled off. HIGH-LIMIT THERMOSTAT (STL) (protection against overheating) The STL switches off the combustion system when the boiler reaches 105°C.
Safety | 2 2.8 Residual risks WARNING When the main switch is switched off in heating mode: The boiler is placed in an uncontrolled state. Any resulting boiler malfunctions can cause serious injury and damage. Therefore: r Allow the fire to burn out completely and let the boiler cool, only then switch off the main switch.
2 | Safety WARNING When inspecting and cleaning the boiler with the main switch on: Serious injuries possible due to boiler/individual components starting up automatically (induced draught)! Before inspection and cleaning work in/on the boiler: r Allow the fuel in the boiler to burn off r Allow boiler to cool off and switch off main switch NOTICE Automatic ignition set incorrectly or not carried out...
Safety | 2 2.9.2 Smell of flue gas DANGER If you smell flue gas in the boiler room: Inhaling toxic flue gas can potentially be fatal! If you smell flue gas in the room where the boiler is installed: r Keep all the doors on the boiler closed r Ventilate the room where the boiler is installed r Close the fire door and doors to living areas r Allow the fire to burn out completely and let the boiler cool...
2 | Safety 2.9.4 Fire in the system DANGER In case of fire in the system: Risk of death by fire and poisonous gases Emergency procedure in case of fire: r Leave the boiler room r Close the doors r Inform the fire department B1510622_en | Operating instructions Firewood boiler S4 Turbo...
Notes for operating a heating system | 3 3 Notes for operating a heating system Carrying out modifications to the system and changing or disabling safety equipment is prohibited. Always comply with all fire, building and electrical regulations when installing or operating the system, in addition to following the operating instructions and mandatory regulations that apply in the country in which the tank is operated.
3 | Notes for operating a heating system 3.3 Combustion air Boiler in room air-dependent operation Air extraction system (such as centralised dust extraction system, room ventilation) Under-pressure monitoring system Combustion air supply from outside 3.3.1 Combustion air supply at the installation room The system is operated in open flue mode, i.e.
Notes for operating a heating system | 3 3.3.2 Simultaneous operation with other air-drawing systems Where the boiler is operated in room air-dependent mode with simultaneous operation of other air-drawing systems (such as room ventilation), safety devices are necessary: ▪ Air pressure monitor ▪...
3 | Notes for operating a heating system 3.4 Domestic hot 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: r Aim for a pH value of between 8.2 and 10.0.
Notes for operating a heating system | 3 Additional requirements for Switzerland The filling and make-up water must be demineralised (fully purified) ▪ The water must not contain any ingredients that could settle and accumulate in the system ▪ This makes the water non-electroconductive, which prevents corrosion ▪...
3 | Notes for operating a heating system 3.6 Return lift If the hot water return temperature is below the minimum return temperature, some of the hot water outfeed will be mixed in. NOTICE Risk of dropping below dew point/condensation formation if operated without return temperature control.
Operating the System | 4 4 Operating the System 4.1 Assembly and initial startup Assembly, installation and initial startup of the boiler must only be carried out by qualified staff, and these procedures are described in the accompanying assembly instructions. NOTICE! See assembly instructions for theS4 Turbo NOTICE Optimum efficiency and efficient, low-emission operation can only be guaranteed if the...
4 | Operating the System 4.2 Switching on the power supply r Turn on the main switch Ä There is voltage at all of the boiler's components Ä When the control has completed the system start, the boiler is ready for operation 4.3 Before heating up the boiler 4.3.1 Clean the heat exchanger pipes Automatic WOS...
Operating the System | 4 4.3.3 Reloading intervals when operating with storage tank Reloading intervals and amounts should be determined exclusively according to the storage tank for efficient and environmentally-friendly heating. r Check the store load status on the display Load status Procedure No bars or one bar in the store load status means that the storage...
4 | Operating the System 4.3.5 Reload quantity calculation The reload quantity calculation is used to display on the control how much firewood is required to refill the boiler based on the current storage tank fill level. It does not take into account boiler efficiency, pipe losses and the energy required to heat the boiler and heating system.
Operating the System | 4 4.3.6 Determining the right amount of fuel The amount of fuel added should allow the storage tank to be constantly heated to the max. storage tank temperature (= boiler target temperature). Please note that the amount to reload also depends on the type of fuel.
20%. Using our example above with beech, the fill level of an S4 Turbo 34 would, therefore, be approx. one third. Fill level Weight at fill level S4 Turbo 15-28 S4 Turbo 32-60 Beech approx. 45 kg approx. 55 kg Spruce approx.
Operating the System | 4 4.4 Heat up firewood manually r Open the insulated door and the fuel loading door r Check the ash level in the combustion chamber and empty if necessary Ä It is recommended that you do not remove the ash in the combustion chamber during each heating-up process, but rather when the middle row of holes of the combustion chamber guards is no longer visible.
4 | Operating the System r Leave the pre-heating chamber door open for approximately 5 minutes Ä A bed of embers forms r Close the pre-heating chamber door and the insulated door Ä NOTE: Wait for the message on the boiler display 4.5 Heat up the firewood with automatic ignition NOTICE Fill fuel loading chamber for later manual / automatic ignition...
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Operating the System | 4 1. First layer of small pieces of split wood 2. Second layer of cardboard 3. Place a piece of cardboard in front of the igniter tube (A) 4. Third layer with more small pieces of split wood 5.
4 | Operating the System 4.6 Operate the boiler using the touch display 4.6.1 Overview of the touch display Display of freely selectable information Ü "Select information displays" [} 37] Display and switch the current user level Ü "Lock display/switch user level" [} 46] Display and change the current date/time Ü...
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Operating the System | 4 USB interface for software update (➾ see operating instructions for the boiler controller) NOTICE! USB interface is for service purposes only and must not be used for charging devices or for PC connections! Status display The status display indicates the system’s operating status: ▪...
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4 | Operating the System Display icons for froeling-connect/remote control The icons for connection status and remote control are displayed at the top left of the touch display. Tap on these icons to open the “Connection Centre”. In the menu, the connection to froeling-connect as well as the remote control (switching on and off by external users) is activated/deactivated Status to froeling-connect...
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Operating the System | 4 Navigation within the system menu The system menu shows the menus available depending on the user level and the system configuration. Use the right and left arrows to navigate to the individual menus. Tap the corresponding icon to open the menu. Within the individual menus, the status display is shown with current values.
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4 | Operating the System Changing parameters If there is a “pencil” symbol next to a parameter text, the parameter can be edited. Depending on the type of parameter, it can be edited using the numeric keypad or by selecting from a list and then tapping on the “Confirm” symbol. Numeric keypad Dropdown list Change time window...
Operating the System | 4 Quick menu The quick menu provides different functions depending on the system configuration and system status. Icon Description Language selection Sets the desired system language: Deutsch – English – Francais – Italiano – Slovenski – Cesky – Polski – Svenska – Espanol –...
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4 | Operating the System Menu Selection Icon Description Temperatures Display of boiler und flue gas temperature Calorific value heat Display of boiler and flue gas temperature exchanger before or after the calorific value heat exchanger. Operation hours Display of the operating hours and the operating hours since last maintenance.
Operating the System | 4 When using more than two store sensors, it is possible to have an information display with storage tank temperatures in accordance with the number of sensors. An information display that spans two areas is used. 4.6.3 Change boiler mode Depending on the type of boiler, there are several modes available which can be changed directly in the basic...
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4 | Operating the System Mode Icon Description Automatic Supply heating circuits and domestic hot water tanks with heat according to the selected heating times. Domestic hot water The domestic hot water tank is supplied with heat within the selected loading times. Heating circuits are switched off, frost protection remains active.
Operating the System | 4 4.6.4 Change date and time Tap on the displayed date and time to change the date and time in the basic display. Use the up and down arrows to adjust the settings and tap on the “Confirm” icon to save. B1510622_en | Operating instructions Firewood boiler S4 Turbo...
4 | Operating the System 4.6.5 Change desired DHW tank temperature r Tap the information display for the desired DHW tank r Adjust the temperature setpoint by tapping on “+” or “-” NOTICE! If this selection is not configured in the information display in the basic display, open the components in the system menu.
Operating the System | 4 4.6.8 Set the heating curve of a heating circuit A flow temperature is calculated using the heating curve of the heating circuit depending Example of floor heating on the outside air temperature and the two adjustable parameters “flow temperature at -10°C outside air temperature”...
4 | Operating the System 4.6.9 Change room temperature (heating circuit without room temperature sensor) Situation Effect Room temperature generally too low Move heating curve up in parallel. Increase both points on the heating curve by the same temperature level. (see figure 1) Room temperature on cold days too low, OK on Change the slope of the heating curve.
Operating the System | 4 4.6.10 Change room temperature (heating circuit with room temperature sensor) r Tap information display of the desired heating circuit r Tap “+” or “-” to adjust the desired room temperature NOTICE! If this selection is not configured in the information display in the basic display, open the components in the system menu.
4 | Operating the System 4.6.12 Lock display/switch user level For safety reasons, individual parameters are only visible at specific operating levels. To change to another level it is necessary to enter the relevant user code. r Tap on the icon for the user level in the upper area of the basic display and enter the code.
Operating the System | 4 4.6.14 Configure the holiday program Setting a start and end date in the holiday program determines a time period in which an active heating circuit is regulated for the set setback temperature and in which an activated boiler is not loaded.
4 | Operating the System Tap the “suitcase” icon to prematurely end the holiday program. The boiler then switches to the previously activated mode (“water tap” symbol = domestic hot water, “water tap/ radiator” symbol = automatic). 4.6.15 Activate automatic ignition r Tap the system menu in the basic display and navigate to the “Ignition”...
Operating the System | 4 4.7 Reloading firewood WARNING Touching hot surfaces behind the insulated door can cause burns! By the nature of its operation, the surfaces and operating elements in the area behind the insulated door get hot! When working with firewood, there is also a risk of injury from splinters.
4 | Operating the System 4.8 Switching off the power supply WARNING When the main switch is switched off in heating mode: The boiler is placed in an uncontrolled state. Any resulting boiler malfunctions can cause serious injury and damage. Therefore: r Allow the fire to burn out completely and let the boiler cool, only then switch off the main switch.
Operating the System | 4 4.9.1 Emptying ash Recommendation: Do not remove the ash in the combustion chamber each time you heat up the boiler, only when the middle row of holes in the cladding plates is no longer visible. This protects the combustion chamber and makes the heating-up process more efficient.
5 | Servicing the system 5 Servicing the system 5.1 General information on servicing DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: r Always have work carried out by a qualified electrician r Observe the applicable standards and regulations Ä...
Servicing the system | 5 5.2 Required tools The following tools are required for carrying out cleaning and maintenance work: Included in delivery: Furnace tool with bracket Spanner for door mountings Ash shovel Ash drawer Cleaning brush (30x20) for cleaning the carbonisation gas duct Cleaning brush (Ø54) for cleaning the heat exchanger Not included: Spanner or box wrench AF 13...
5 | Servicing the system 5.3 Maintenance work by the operator r Regular cleaning of the boiler extends its life and is a basic requirement for smooth running. r Recommendation: Use an ash vacuum for cleaning. Reassemble the boiler components dismantled during maintenance in the reverse order after the work has been completed..
Servicing the system | 5 Checking the quick vent valve r Regularly check all the quick vent valves on the entire heating system for leaks Ä If any liquid is leaking, replace the quick vent valves NOTICE! The vent cap (A) must be loose (screw on approx. two revolutions) to ensure correct functioning.
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5 | Servicing the system r Clean the inner walls using the flat scraper (B) r Unhinge the front air guide plate and clean the slits Ä For cleaning use the door adjusting spanner provided if suitable Cleaning the heat exchanger pipes S4 Turbo 22-40 r Lift off the back insulating cover and remove the heat exchanger cover Ä...
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Ä The bristles cannot be turned in the pipe. r Push the ash forwards out of the lower channel of the combustion chamber into the ash drawer provided using the furnace tool S4 Turbo 15-28 S4 Turbo 34-40 S4 Turbo 50-60...
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5 | Servicing the system S4 Turbo 50-60 r Lift off the back insulating cover and remove the heat exchanger cover Ä Use spanner (A) provided r Remove both pipe locking pins (B) r Pull out WOS lever and remove cover plate (C) r Remove blanking plugs (D) and pull out the WOS shaft behind r Loosen carrier plate (E) and lift out the turbulators together with the mounting bracket B1510622_en | Operating instructions Firewood boiler S4 Turbo...
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Servicing the system | 5 r Remove the ash build-up in the pipes using the cleaning brush Ä The cleaning brush must be pushed all the way through before pulling it up. Ä The bristles cannot be turned in the pipe. r Push the ash forwards out of the lower channel of the combustion chamber into the ash drawer provided using the furnace tool r Before fitting in the heat exchanger pipes, check that the WOS springs are correctly...
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5 | Servicing the system Cleaning the flue gas temperature sensor S4 Turbo 22-40: r Remove the insulating cover and thermal insulation r Release the retaining screw and remove the flue gas temperature sensor from the flue gas pipe r Wipe the flue gas temperature sensor with a clean cloth r Push in the flue gas temperature sensor until about 20 mm of the sensor remains protruding from the bushing and secure with fixing screw S4 Turbo 50-60:...
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Servicing the system | 5 r Undo the tension springs on the top and remove the thermal insulation r Release the retaining screw and remove the flue gas temperature sensor from the flue gas pipe r Wipe the flue gas temperature sensor with a clean cloth r Push in the flue gas temperature sensor until about 20 mm of the sensor remains protruding from the bushing and secure with fixing screw Cleaning the flue gas pipe...
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5 | Servicing the system Cleaning the induced draught fan Check the induced draught fan for dirt and deposits and clean if necessary NOTICE! Deposits on the running wheel can cause an imbalance in the ID fan, which can result in noise or, in the worst case, bearing damage. Cleaning (if required) r Unplug the connection cable of the induced draught fan r Remove the induced draught fan from the back of the boiler...
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Servicing the system | 5 Checking the seal on the doors Checking the tightness is shown below using the example of the fuel loading door and is carried out in the same way for the other boiler doors. On the door stop side and door handle side: r Open the door and insert a sheet of paper at both the top and the bottom of the door stop between the door and the boiler r Close the door and try to pull out the sheets of paper...
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5 | Servicing the system r Loosen the nut at the top and bottom of the locking plate and set the contact pressure on the door handle side r Use suitable tools (e.g. screwdriver and hammer) to move the locking plate towards the back or the front as required Ä...
Servicing the system | 5 5.4 Servicing the condensing boiler heat exchanger (optional) The condensing boiler heat exchanger must be inspected and cleaned at appropriate intervals depending on the operating hours and fuel quality. Inspection and cleaning must be repeated after not more than 250 operating hours or at least once a month.
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5 | Servicing the system Manual operation of the flushing device r Use the included cleaning plate (D) to remove any deposits from the condensing boiler heat exchanger from above Depending on the design, the access panel on the back of the condensing boiler heat exchanger may be removed: r Unplug the induced draught fan cable and pull it out of the back panel r Remove the cover plate for ID fan and back panel...
Servicing the system | 5 5.4.2 Checking the condensation drain NOTICE! If the condensation drain is blocked, the condensing boiler heat exchanger will fill with condensation, thus preventing the flue gas from escaping through the chimney, which could in turn lead to problems with combustion. For this reason it is important to check the condensation drain regularly! At the back of the boiler below the condensing boiler heat exchanger: r Position a suitable container below the siphon to catch the condensation that runs out...
5 | Servicing the system 5.5 Maintenance work by technicians CAUTION If maintenance work is carried out by untrained personnel: Risk of personal injury and damage to property! The following applies for maintenance: r Observe the instructions and information in the manuals r Only allow appropriately qualified personnel to work on the system Only qualified staff are permitted to carry out maintenance work in this chapter: ▪...
Servicing the system | 5 5.5.1 Cleaning the Lambda probe S4 Turbo 22-40: r Remove the back insulating cover and thermal insulation upwards S4 Turbo 50-60: r Remove the cover plates for ID fan (A), rear cover (B) und housing (C) B1510622_en | Operating instructions Firewood boiler S4 Turbo...
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5 | Servicing the system r Carefully remove the Lambda probe (1), adapter (2) and plastic bushing (3) Ä Pay attention to the cables of the Lambda probe! r Carefully remove impurities from the measuring ports with a fine brush and ash vacuum Ä...
Servicing the system | 5 5.6 Emissions measurement by chimney sweep or regulatory body Various legal regulations stipulate that heating systems must be inspected periodically. In Germany this is regulated by the First Federal Emissions Protection Ordinance (BimSchV) in the last amended version, and in Austria by various state laws. The following minimum requirements must be met by the operator of the system for a successful measurement: r Thoroughly clean the boiler 2 heating days (1 heating day = 1 day during which the...
5 | Servicing the system 5.6.2 Create the measurement conditions and perform the measurement r Fill the boiler approx. 1/4 full with small pieces of split wood in accordance with the operating instructions and heat up Ä TIP: The smaller the wood is split, the better and faster the bed of embers forms r Ensure that the operating conditions are fulfilled Ä...
Servicing the system | 5 5.7 Replacement parts With Froling original replacement parts in your system, you are using parts that match perfectly. As the parts fit together so well, installation times are shortened and a long service life is maintained. NOTICE Installing non-original parts will invalidate the guarantee.
6 | Troubleshooting 6 Troubleshooting 6.1 General fault with power supply Error characteristics Cause of error Elimination of error Nothing is shown on the General power failure display No power to the controller Main switch is turned off Turn on the main switch FI-protective circuit breaker, Switch on the protective circuit power line protection or SPS...
Troubleshooting | 6 6.3 Excessive temperature The high-limit thermostat (STL) switches off the blower fan at a maximum boiler temperature of 105 °C. The pumps continue to run. Once the temperature falls below approx. 75°C, the STL can be reset mechanically. r Unscrew the cap on the STB (high-limit thermostat) r Unlock the STL by pressing with a screwdriver 6.4 Faults with fault message...
6 | Troubleshooting 6.4.1 Procedure for fault messages If a fault occurs on the boiler, it will be shown on the display. If the fault is acknowledged, although it has not been rectified, the window with the associated fault can be reopened as follows: Open error display Current fault list System menu...
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