Fröling S3 Turbo Assembly Instructions Manual
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Summary of Contents for Fröling S3 Turbo
- Page 1 Assembly Instructions S3 Turbo Read and follow the operating instructions and safety information! Subject to technical change! Froling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 info@froeling.com www.froeling.com...
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Page 2: Table Of Contents
Table of Contents Table of Contents Safety Explanation of symbols Permitted Uses Requirements at the place of installation 1.3.1 Approval for the heating system 1.3.2 Space required 1.3.3 Requirements for central heating water 1.3.4 Ventilation requirement for boiler room 1.3.5 Requirements for the heating system 1.3.6 Requirements for the boiler room... - Page 3 Installing the boiler 3.5.1 Assembly overview Insulation Air duct system WOS system S3 Turbo 30 EOS system S3 Turbo 50 3.5.2 Fit flue gas pipe nozzle and the induced draught fan 3.5.3 Installing the pneumatic rods for the primary and secondary air 3.5.4...
- Page 4 Supplementary instructions Supplementary instructions These instructions ensure safe and efficient use of the S3 Turbo (hereinafter referred to as the “system"). These instructions are a component part of the system and must be kept next to the system and within the immediate reach of staff at all times.
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Page 5: Safety
The signal words set out above are used. Example: ❒ Undo screw ❒ CAUTION! Pinching hazard at cover Take care when closing the cover. ❒ Tighten the screw Montageanleitung S3 Turbo | M1870119_en-us... - Page 6 Safety Explanation of symbols Special safety information The following symbols are used to draw your attention to particular hazards Tips and recommendations Italics indicate useful tips and recommendations as well as information for efficient and smooth running. Other markers The following markers are used in these instructions to highlight operating guidelines, results, lists, references, and other elements: Marker Explanation...
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Page 7: Permitted Uses
Safety Permitted Uses 1.2 Permitted Uses The S3 Turbo boiler is designed exclusively for heating domestic water. Only use those fuels specified in the “Permitted fuels” section. Permitted use includes compliance with all the specifications in this instruction manual. Any use other than or above and beyond the permitted use is considered misuse. -
Page 8: Requirements At The Place Of Installation
The diagram below shows how much space is required for the system in the boiler room. The boiler may only be installed on non-combustible floors with these clearances. Dimens Name S3 Turbo Distance - front of boiler to wall 36“ (900 mm) Distance – side of boiler to wall 32“ (800 mm) Distance –... -
Page 9: Requirements For Central Heating Water
You can add anti-freeze to the heating water, however, this can reduce the heating efficiency. Always follow the manufacturer’s dosing instructions when using anti- freeze, as using the incorrect amount can cause corrosion. Check the concentration of the anti-freeze at regular intervals. Montageanleitung S3 Turbo | M1870119_en-us... -
Page 10: Ventilation Requirement For Boiler Room
Safety Requirements at the place of installation 1.3.4 Ventilation requirement for boiler room Introduction The external combustion air must meet certain requirements to ensure that adequate combustion air is supplied to the boiler and no by-products from the combustion get into the boiler room. -
Page 11: Combination With Thermal Storage
▪ The boiler room must be at least (mm) high. 1.3.7 Combination with thermal storage Your S3 Turbo boiler must be installed with a Thermal Storage System. The purpose of the thermal storage system is to absorb heat produced by the boiler if the building load cannot use all of the heat being produced. -
Page 12: Requirements For The Chimney Connection
The flue gas pipe must not be displaced by an attic, loft, fuel store or similar areas. Basic data for designing the chimney connection Description S3 Turbo Flue gas temperature at nominal load °C °F Flue gas temperature at partial load °C... -
Page 13: Safety Markers
Keep the doors closed Keep the doors closed during operation. Turning off the main switch Switch off the main switch and take precautions to prevent accidental switching on before carrying out work to the system Montageanleitung S3 Turbo | M1870119_en-us... - Page 14 Safety Safety markers Switch off the main switch for the fuel infeed and take precautions to prevent accidental switching on before entering the fuel storage room. Securing the main switch Switch off the main switch and secure with a padlock when carrying out maintenance work to the boiler.
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Page 15: Prohibitions
Take extreme care and wear personal protective equipment. Risk of injury at fans Keep hands away from areas bearing this warning. There is a risk that your hands could get trapped, pulled into or otherwise injured in automatic fans. Montageanleitung S3 Turbo | M1870119_en-us... -
Page 16: Signage On The Boiler
Safety markers 1.4.4 Signage on the boiler Notice of risks during installation S3 Turbo - WOOD FIRED GASIFICATION HYDRONIC FURNACE INSTALLATION HAZARDS Install, modify and use only in accordance with manufacturer’s manuals. Refer to authorities having jurisdiction for proper installation. Contact local building and fire officials about restrictions and installation inspection in your area. If there are no applicable local codes, follow ANSI/NFPA 211 and CAN/CSA B365. -
Page 17: Notice Of Risks During Operation
Safety Safety markers Notice of risks during operation S3 Turbo - WOOD FIRED GASIFICATION HYDRONIC FURNACE OPERATION HAZARDS NOTICE! Burn Wood only, max. length 21'' (51cm)! Load fuel carefully or damage will result! Build the wood fire directly on the boiler Fuel Loading Chamber refractory floor! Do not use small pieces or wood waste that could fall through the center slot in the refractory. -
Page 18: Notice Regarding Procedures In An Emergency
Safety Safety markers Notice regarding procedures in an emergency S3 Turbo - WOOD FIRED GASIFICATION HYDRONIC FURNACE HAZARDS DURING REFUELING AND EMERGENCY PROCEDURES DANGER! In case of strong smell of flue gas! Flue gases can cause fatal poisoning! 1. For safety keep all boiler doors and ash-pit doors tightly closed! 2. -
Page 19: Residual Risks
Have all component assemblies checked at regular intervals to ensure the correct earthing. ❒ Keep moisture away from live parts. This can cause short circuits. ➥ Touching live parts can cause immediate death by electrocution. Damage to the isolation or individual components can be perilous. Montageanleitung S3 Turbo | M1870119_en-us... -
Page 20: Danger From Fire And Explosion
Safety Residual risks 1.5.3 Danger from fire and explosion Risk of fire and explosion WARNING Risk of fire and explosion around the boiler! ❒ DO NOT BURN GARBAGE, GASOLINE, NAPHTHA, ENGINE OIL OR OTHER INAPPROPRIATE MATERIALS. ❒ DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE. ❒... - Page 21 ➥ Problems with the flue system, such as poor cleaning of the flue pipe or insufficient chimney escape can cause serious faults in combustion (such as spontaneous combustion of carbonization gases/explosion). Montageanleitung S3 Turbo | M1870119_en-us...
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Page 22: Danger From High Temperatures
Safety Residual risks 1.5.4 Danger from high temperatures Hot surfaces WARNING Risk of injury from hot surfaces! ❒ FOR SAFETY REASONS, KEEP ALL DOORS TIGHTLY CLOSED. ❒ Before all work on the boiler, burn out the fuel-loading chamber and let the boiler cool. -
Page 23: Risks From Flue Gases, Lubricants And Other Equipment
❒ If you smell flue gas keep all the doors on the boiler closed. ❒ Ventilate the boiler room. ❒ Close the fire door and doors to living areas. ➥ Contact with flue gases can cause perilous situations. Montageanleitung S3 Turbo | M1870119_en-us... -
Page 24: What To Do In The Case Of Danger
Safety What to do in the case of danger Explosive dusts WARNING Risk of death from fire and explosion due to dispersed dust deposits! ❒ Do not smoke within or close to the danger zone or boiler. Do not work with any kind of naked flame, fire or ignition sources. -
Page 25: Staff Requirements
The operator is the person who operates the heating system for commercial or economic purposes by himself or cedes use/application to a third party and bears the legal responsibility concerning the product for the protection of the user or third parties during the operation. Montageanleitung S3 Turbo | M1870119_en-us... - Page 26 Safety Staff requirements He has been trained by the manufacturers and the suppliers in dealing with the system and its components and can independently detect potential hazards and avoid the associated risks. Froling customer service or an authorized partner The Froling customer service or its authorized partner is able to perform the tasks assigned to it and recognize and avoid possible dangers thanks to its professional, product-related training, knowledge and experience as well as its knowledge of the relevant local regulations.
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Page 27: Personal Protective Equipment
Protective workwear: Protective workwear is tight-fitting work clothing with low tear resistance, narrow sleeves and without any protruding parts. Protective goggles Protective goggles are used to protect the eyes from flying parts when cleaning the system. Montageanleitung S3 Turbo | M1870119_en-us... -
Page 28: Replacement Parts
Safety Replacement parts Protective gloves Protective gloves are used to protect the hands against friction, abrasion, puncture, or deeper injuries and contact with hot surfaces. Safety shoes Safety shoes protect feet from crushing and falling parts as well as from sliding on slippery surfaces. -
Page 29: Environmental Protection
Other waste should not be placed in this container. Firebricks The combustion chamber must be disposed of as construction waste. Montageanleitung S3 Turbo | M1870119_en-us... -
Page 30: The Operator's Responsibilities
Safety The operator's responsibilities 1.11 The operator's responsibilities Operator The operator is the person who operates the system for commercial or economic purposes by himself or cedes use to a third party and bears the legal responsibility concerning the product for the protection of the user, staff or third parties during the operation. -
Page 31: Technology
1750 1850 Height of flow connection 1280 1380 50 ½ 54 ⅓ Height of return connection 5 ½ 5 ½ Height of safety battery connection 38 ¼ Height of drainage connection 4 ¾ 4 ¾ Montageanleitung S3 Turbo | M1870119_en-us... -
Page 32: Components And Connections
Technology Components and connections 2.2 Components and connections Item Description Unit S3 Turbo Boiler flow connection inches Boiler return connection inches Drainage connection inches Safety battery connection inches Immersion sleeve for thermal discharge valve inches (supplied by the customer) Immersion sleeve for boiler sensor and STL... -
Page 33: Technical Data
Combustion time – soft wood 2.8 - 3.9 2.7 - 4.0 1. 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%) Montageanleitung S3 Turbo | M1870119_en-us... -
Page 34: Assembly
Assembly Materials supplied 3 Assembly 3.1 Materials supplied Boiler Cardboard box containing small parts Insulation Pneumatic rods, complete Controller Ash shovel EOS system (heat exchanger Cleaning kit optimisation system) Flue gas pipe nozzle Cleaning brush, small Ceramic fiber seal Cleaning brush, large Induced draft fan Not pictured: installation and operating instructions, guarantee certificate, identification plate... -
Page 35: Positioning
If the system is to be assembled at a later stage: ❒ Store components at a protected location, which is dry and free from dust ➥ Damp climate conditions and frost can damage components, particularly electric ones! Montageanleitung S3 Turbo | M1870119_en-us... -
Page 36: Setting Up In The Boiler Room
Setting up in the boiler room 3.3 Setting up in the boiler room 3.3.1 Remove boiler from pallet S3 Turbo 30/50 ❒ Cut through and remove tension bars with diagonal cutting pliers ❒ Remove the wooden slats which are fixed with nails ➥... -
Page 37: Space Required
The following example using the fuel loading door shows how to change the door stop. The procedure is the same for changing the stop on the combustion chamber door and pre-heating chamber door! ❒ Open the fuel loading door Montageanleitung S3 Turbo | M1870119_en-us... - Page 38 Assembly Before Installation ❒ Undo the retainer of the hinge pin at the top and bottom door hinge ➥ For example, use two screwdrivers to gently bend the retainer plate out to loosen it ❒ Take out the top and bottom hinge pins and take off the fuel loading door ❒...
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Page 39: Converting The Fuel Loading Door
❒ Turn the insulating plate (C), radiation plate (B) and seal (A) by 180° and position them so that they line up with the holes provided ❒ Refit the radiation plate (B) and insulating plate (C) ❒ Use contact adhesive to fix the seal (A) in place Montageanleitung S3 Turbo | M1870119_en-us... -
Page 40: Fitting The Door Handles
Assembly Before Installation 3.4.2 Fitting the door handles The procedure is the same for all doors. ❒ Insert the flange bushing (1) into the door handle (2) and position it alongside the hole (3) provided ❒ Fix the door handle (2) in place using screws (4) 3.4.3 Set and check the seal on the doors The example below shows how to set and check the seals on the fuel loading doors. - Page 41 ❒ Insert a sheet of paper at both the top and the bottom area at the side of the door handle between the door and the boiler ❒ Close the door ❒ Try to pull out the sheets of paper Montageanleitung S3 Turbo | M1870119_en-us...
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Page 42: Adjusting The Doors
Assembly Before Installation ➥ If the paper cannot be removed: the door is sealed. ➥ If the paper can be removed: The door is not sealed properly - push the locking plate toward the back. ⇨ See "Adjusting the doors" [page 42] Adjusting the doors ❒... -
Page 43: Installing The Boiler
Assembly Installing the boiler 3.5 Installing the boiler 3.5.1 Assembly overview Insulation S3 Turbo 50 S3 Turbo 30 Montageanleitung S3 Turbo | M1870119_en-us... - Page 44 Insulated door, complete Hexagonal screw M6 x 100 Magnetic latches Insulating cover, back Control, complete Controller cover U-plate – S3 Turbo 36/45 Heat insulation mat, top/front Lower door bracket Bracket, right Cover plate, insulated door, bottom Hinge pin, insulated door...
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Page 45: Air Duct System
Flue gas pipe nozzle Ø 150 Ceramic fiber seal 210 x 144 x 12 Pneumatic rods, complete Sliding valve Ø 100 Split pin Ø 3.2 x 20 Door handle, black Bushing Ø 10 x 20 Hexagonal screw M8 x 30 Montageanleitung S3 Turbo | M1870119_en-us... -
Page 46: Wos System S3 Turbo 30
Assembly Installing the boiler WOS system S3 Turbo 30 Item Quanti Description [units] EOS cleaning cover, complete Brass bushing Plastic cover WOS lever EOS bracket, complete 6 x 3 Pipe locking pin EOS turbulator Ø 50 x 6 x 3 x 837... - Page 47 Assembly Installing the boiler EOS system S3 Turbo 50 Item Quanti Description [units] EOS cleaning cover, complete Brass bushing Plastic cover WOS lever EOS turbulator Ø 50 x 6 x 3 x 932 EOS bracket, complete 6 x 3 Pipe locking pin...
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Page 48: Fit Flue Gas Pipe Nozzle And The Induced Draught Fan
Assembly Installing the boiler 3.5.2 Fit flue gas pipe nozzle and the induced draught fan ❒ Place the ceramic fiber seal in position ❒ Position the flue gas pipe nozzle and attach it using the pre-installed spacer washers and nuts ➥... - Page 49 (A) ➥ CAUTION: the air flaps must be situation in the same position as those on the opposite side! ❒ Turn both pneumatic rods in an anti-clockwise direction as far as the stop Montageanleitung S3 Turbo | M1870119_en-us...
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Page 50: Eos System S3 Turbo
Assembly Installing the boiler 3.5.4 Final steps before insulating ❒ Remove the side blanking plate and cleaning door ❒ Remove plugs, then seal and screw in the immersion sleeve (A) for thermal discharge safety device sensor ❒ Remove the screw cap from the side on which the heat-exchanger lever will be mounted later and replace it with a brass bushing (B) ➥... - Page 51 ➥ At the front, the bracket will be secured later when the upper spacer plate is inserted! ❒ Cut the perforated flaps for the cleanout opening on both sides and bend them inward ➥ Caution: Bend the flaps > 100° inward! Montageanleitung S3 Turbo | M1870119_en-us...
- Page 52 Assembly Installing the boiler ❒ Place one large spacer washer on each of the threaded bolts to the right and the left above on the boiler ❒ Insert the insulating side panels at the base of the boiler at the flap and push them onto the boiler ❒...
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Page 53: Fitting The Door Contact Switch
❒ Secure the left and right back panel to the side panel with seven thread forming screws (A) each ➥ Leave the top three holes free ❒ Installing the induced draught cover plates ❒ Secure both terminal blocks to the back pane with the three thread forming screws Montageanleitung S3 Turbo | M1870119_en-us... -
Page 54: Aligning The Insulation And Attaching The Controller
Assembly Installing the boiler 3.5.8 Aligning the insulation and attaching the controller ❒ Hang the lower spacer plate on the rivets (A) between the insulating side panels and attach with one thread forming screw each ❒ Push the insulating side panels toward the rear until the borehole on the flaps corresponds with the borehole on the side panels ❒... - Page 55 ❒ Screw in two carrying bolts (B - hexagonal bolts M6 x 100) to the left and right at the bottom rear side of the controller box far enough to ensure that the controller box and insulation are supported adequately Montageanleitung S3 Turbo | M1870119_en-us...
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Page 56: Installing The Cleaning Door And Blank Cover
S3 Turbo 30: ❒ Tap in a fitting grooved pin (A) at the lower door bracket ❒ Slide the lower door bracket into the base of the boiler ➥... - Page 57 ❒ Secure the two hexagonal screws of lower door bracket ❒ At the front end of the lower door bracket, insert a hexagonal screw M6 x 30 from below, secure it with a nut and place a spacer washer on top Montageanleitung S3 Turbo | M1870119_en-us...
- Page 58 Assembly Installing the boiler ❒ Mount the insulated door onto the lower door bracket using the hexagonal screw ❒ Attach the insulated door to the upper door bracket with hinge pin (A) ➥ Insert the hinge pin through the control and the upper door bracket ❒...
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Page 59: Fitting The Sensors
❒ Fit the cables for the flue gas sensor, the STL capillary and the boiler sensor in the cable duct with a strain relief. ❒ Push the strain relief into cut-out on the cover plate. Montageanleitung S3 Turbo | M1870119_en-us... -
Page 60: Fit The Broadband Probe
Assembly Installing the boiler ❒ Close the opening of the cable duct with cover plate and secure the cover plate with two thread forming screws 3.5.12 Fit the broadband probe ❒ Unscrew the pre-installed bushing (A) from the broadband probe ❒... -
Page 61: 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 30, E - S3 Turbo 50) ➥ Make sure that you fit the turbulators in the right direction: ➥... -
Page 62: Installing The Servo-Motors
Assembly Installing the boiler 3.5.14 Installing the servo-motors ❒ Secure the cover plate on the servo-motor side using thread forming screws, ensuring that the three holes (A) are in the direction of the back of the boiler ➥ Check that the air flaps are at the left stop ➥... -
Page 63: Power Connection And Wiring
When work is carried out on electrical components: ❒ Only have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥ Work must not be carried out on electrical components by unauthorised persons Montageanleitung S3 Turbo | M1870119_en-us... -
Page 64: Wiring The Id Fan
Assembly Power connection and wiring 3.6.1 Wiring the ID fan ❒ Secure the cable leadthrough with a nut in one of the free cut-outs on the terminal block ❒ Remove lugs on the cover on the occupied positions with a suitable tool ❒... -
Page 65: Information On Circulating Pumps
3.6.3 Information on circulating pumps Connecting a squirrel cage standard pump If a squirrel cage standard pump (e.g. existing installation) is used as a store loading pump, this must be connected according to the following connection diagram: Montageanleitung S3 Turbo | M1870119_en-us... -
Page 66: Connecting A High Efficiency Pump
❒ EC motor pumps must not be connected to speed-controlled pump outputs without additional control signal ➥ When using the S3 Turbo firewood boiler in conjunction with the “S-Tronic Lambda” controller, the wiring diagram above must be followed for using a high efficiency pump with control line. -
Page 67: Final Installation Steps
❒ Put on the controller cover ❒ Use the two thread forming screws incl. contact washers to secure the controller cover ❒ Put on the back heat insulation mat ❒ Put on the rear insulating cover Montageanleitung S3 Turbo | M1870119_en-us... -
Page 68: Start-Up
Start-up Before commissioning / configuring the boiler 4 Start-up 4.1 Before commissioning / configuring the boiler The boiler must be adjusted to the heating system during commissioning. 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 69: Initial Startup
The wood will dry out most quickly if it is cut into the appropriate length and split into pieces 4 – 5“ (10 – 12 cm) thick. The best length is 21“ (52 cm) for the S3 Turbo boiler. The wood is best stored in the open air under cover. Wood will dry most quickly if it is carefully stacked alternatively lengthwise and crosswise so that air can penetrate into the stack. -
Page 70: Non-Permitted Fuels
Start-up Initial startup 4.2.2 Non-permitted fuels DANGER Non-permitted fuels Burning non-permitted fuels increases cleaning requirements and leads to a build- up of aggressive sedimentation and condensation, which can result in damage to the boiler and void the warranty! Using non-standard fuels can result in severe combustion malfunctions. -
Page 71: Decommissioning
❒ Ensure that the system is disposed of in an environmentally sensitive way in accordance with waste management regulations. ❒ You can separate and clean recyclable materials and send them to a recycling center. ❒ The combustion chamber must be disposed of as construction waste. Montageanleitung S3 Turbo | M1870119_en-us... -
Page 72: Appendix
Appendix Hydraulic diagram 6 Appendix 6.1 Hydraulic diagram Froling GesmbH | A-4710 Grieskirchen | www.froeling.com... -
Page 73: Addresses
FROLING 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 6.2.2 Address of importer STAMP 6.2.3 Address of Local Dealer STAMP Montageanleitung S3 Turbo | M1870119_en-us...
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