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Installation instructions Firewood boiler S3 Turbo Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M1081724_en | Edition 12/06/2024...
4.1 Dimensions, S3 Turbo........................... 21 4.2 Components and connections....................... 22 4.3 Technical specifications ........................23 4.3.1 S3 Turbo 18-20 .......................... 23 4.3.2 S3 Turbo 30 ..........................24 4.3.3 S3 Turbo 40-45 .......................... 25 4.3.4 Boiler data for planning the flue gas system ................28 4.3.5 Data for planning a backup power supply..................
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Table of Contents 6.3 Before Installation ..........................34 6.3.1 Changing door stops (as needed)....................34 6.3.2 Checking the seal on the doors ....................36 6.3.3 Adjusting the doors ........................37 6.4 Installing the boiler ..........................38 6.4.1 Assembly overview ........................38 6.4.2 Installing flue gas pipe nozzle and the induced draught fan ............
, 20, 30, 30 (31 kW) , 40, 45; 1) S3 Turbo 18 only available in Italy; 2) S3 Turbo 30 with 31 kW nominal heat output only available in Austria and Italy; 1.2 Operating principle The Fröling S3 Turbo is a wood boiler for the non-condensing combustion of firewood.
General | 1 1.3 Disposal of packaging materials All packaging materials should be disposed of in accordance with the relevant regulations. In addition, check the regulations for correct disposal applicable in your local area. Data under the identification system of Directive 97/129/EC: Identification code / Material Disposal information Corrugated cardboard...
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 Qualification of assembly staff CAUTION Assembly and installation by unqualified persons: Risk of personal injury and damage to property During assembly and installation: r Observe the instructions and information in the manuals r Only allow appropriately qualified personnel to work on the system Assembly, installation, initial startup and servicing must only be carried out by qualified personnel: ▪...
3 | Design Information 3 Design Information 3.1 Overview of standards Perform installation and commissioning of the system in accordance with the local fire and building regulations. Unless contrary to other national regulations, the latest versions of the following standards and guidelines apply: 3.1.1 General standards for heating systems EN 303-5 Boilers for solid fuels, manually and automatically fed combustion...
Design Information | 3 3.1.4 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.
3 | Design Information 3.4 Chimney connection/chimney system Connection line to the chimney Measuring port Draught limiter Explosion flap (for automatic boilers) Thermal insulation NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney sweep. The entire flue gas system (chimney and connection) must be laid out as per ÖNORM / DIN EN 13384-1 or ÖNORM M 7515 / DIN 4705-1.
Design Information | 3 3.4.1 Connection line to the chimney Requirements for the connection line: ▪ this should be as short as possible and follow an upward incline to the chimney (30 - 45° recommended) ▪ thermally insulated MFeuV (Germany) EN 15287-1 and EN 15287-2 3 x D (min.
3 | Design Information 3.4.2 Measuring port For emissions measurement on the system, a suitable measuring port must be installed in the connection line between the boiler and chimney system. Upstream of the measuring port (M) there should be a straight run-in section with a length about twice the diameter (D) of the connection line.
Design Information | 3 3.4.4 Electrostatic particle separator For reduction in the emissions an electrostatic particle separator may optionally be installed in the flue gas line. For planning and installation, comply with the following points: ▪ Position the measuring port (M) downstream of the electrostatic particle separator (E) as specified in the instructions Ü...
3 | Design Information 3.5 Combustion air 3.5.1 General requirement For safe operation, the boiler requires around 1.5 - 3.0 m³ of combustion air per kW nominal heat output and operating hour. The air supply can be provided by free ventilation (e.g.
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Design Information | 3 The minimum cross-sectional area of the supply air opening from outside depends on the nominal heat output of the boiler. Austria 400 cm² net minimum cross-sectional area plus 4 cm² for every kW of nominal heat output above 100 kW Germany 150 cm²...
3 | Design Information 3.6 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 Use prepared water which complies with the standards cited above for filling and make-up water r Avoid leaks and use a closed heating system to maintain water quality during...
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Design Information | 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 | Design Information 3.7 Pressure maintenance systems Pressure maintenance systems in hot-water heating systems keep the required pressure within predefined limits and balance out volume variations caused by changes in the hot- water temperature. Two main systems are used: Compressor-controlled pressure maintenance In compressor-controlled pressure maintenance units, a variable air cushion in the expansion tank is responsible for volume compensation and pressure maintenance.
1700 2500 1. Also applies to S3 Turbo 18 (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) Certain countries have recommended storage capacities; these are listed below. The...
3 | Design Information Germany The first BImSchV (Ordinance on small and medium-sized heating plants of 26 January 2010, BGBl. I P. 38) stipulates a minimum water heat storage tank volume of 55 litres per kilowatt of rated heat output; a water heat storage tank with a volume of 12 litres per litre of fuel loading chamber is recommended.
PB 090 Boiler class as per EN 303-5: 2012 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%)
4 | Technology Model identifier S3 Turbo Class of the temperature controller Contribution of the temperature controller to the energy efficiency index of a combined system Energy efficiency index (EEI) of the combined boiler and controller Energy efficiency class of the combined boiler and controller Annual space heating emissions of dust (PM) mg/m³...
Bmax air duct Combustion air volume at rated heat output m³/h 1. Also applies to S3 Turbo 18 - 22 kW nominal output 4.3.5 Data for planning a backup power supply Description Value Continuous output (single phase)
Transport and storage | 5 5 Transport and storage 5.1 Delivery configuration The boiler comes packed in protective casing on a pallet. Item Description Unit S3 Turbo 18-30 40-45 Length 1270 Width Height 1680 Weight Centre of gravity Length Width Height Components Boiler S3 Turbo...
5 | Transport and storage 5.3 Positioning NOTICE Damage to components if handled incorrectly r Follow the transport instructions on the packaging r Transport components with care to avoid damage r Protect the packaging against damp conditions r Pay attention to the pallet's centre of gravity when lifting r Position a fork-lift or similar lifting device at the pallet and bring in the components If the boiler cannot be brought in on the pallet: r remove the cardboard and take the boiler off the pallet...
Transport and storage | 5 5.4 Positioning at the installation site 5.4.1 Remove boiler from pallet r Remove the cardboard box with the insulation and controller from the boiler and put it in a safe place r Remove the transport locks r Lift boiler from pallet TIP: use Froling’s KHV 1400 boiler lifting system to help remove the pallet! r Position a fork-lift or similar lifting device with a suitable load-bearing capacity at the...
5 | Transport and storage 5.4.2 Operating and maintenance areas of the equipment ▪ The system should generally be set up so that it is accessible from all sides to allow quick and easy maintenance! ▪ Regional regulations regarding necessary maintenance areas for inspecting the chimney should be observed in addition to the specified distances! ▪...
Assembly | 6 6 Assembly 6.1 Required tools and equipment The following tools and resources are required for assembly: r Spanner or box wrench set (widths across flats 8 - 32 mm) r Set of Allen keys r Flat head and cross-head screwdrivers r Hammer r Diagonal cutting pliers r Half-round file...
6 | Assembly 6.3 Before Installation 6.3.1 Changing door stops (as needed) The following steps are illustrated based on changing the fuel loading door from right- hand mounting to left-hand mounting. Perform these steps in the same way for the door of the pre-heating and combustion chamber.
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Assembly | 6 For the fuel loading door 180° r Cautiously remove the seal, protective plate and insulating panel r Turn the components through 180° and reinstall them on the door plate Ä When doing so, use contact adhesive to fix the seal in place r Position the fuel loading door on the hinge and secure it with the top and bottom hinge pins r Slide the shaft retainers on to the hinge pins...
6 | Assembly 6.3.2 Checking the seal on the doors The following steps are illustrated based on the fuel loading door. Perform these steps in the same way for the door of the pre-heating and combustion chamber. r Close the door Ä...
Assembly | 6 6.3.3 Adjusting the doors The following steps are illustrated based on the fuel loading door. Perform these steps in the same way for the door of the pre-heating and combustion chamber. r Loosen the nuts on the locking plate and hinge r Using a suitable tool, move the locking plate and hinge forwards or backwards r Tighten the nuts IMPORTANT: Align the locking plate and hinge identically at the top and bottom...
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6 | Assembly Item Quant Description Item Quant Description Bracket, left Cover plate Thermal insulation, rear Air flap manual controller (only for S-Tronic Plus) Back panel, complete Air flap handle (only for S-Tronic Plus) Cover plate for ID fan Sticker, "Primary air actuator" (only with S-Tronic Lambda) Heat insulation mat, top Sticker, "Secondary air actuator"...
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Assembly | 6 WOS system S3 Turbo 20-30 Item Quanti Description EOS cleaning cover, complete Grey cast iron bushing Plastic cover WOS lever EOS bracket, complete 6 x 3 Pipe locking pin EOS turbulator Ø 50 x 6 x 3 x 837 M1081724_en | Installation instructions Firewood boiler S3 Turbo...
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6 | Assembly WOS system S3 Turbo 40-45 Item Quanti Description EOS cleaning cover, complete Grey cast iron bushing Plastic cover WOS lever EOS turbulator Ø 50 x 6 x 3 x 932 EOS bracket, complete 6 x 3 Pipe locking pin M1081724_en | Installation instructions Firewood boiler S3 Turbo...
Assembly | 6 6.4.2 Installing flue gas pipe nozzle and the induced draught fan r Place the ceramic fibre seal in position r Position the flue gas pipe nozzle and attach it using the free issue spacer washers and nuts Ä...
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6 | Assembly 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.
Assembly | 6 6.4.4 Final steps before insulating r Remove the side blanking plate and cleaning door r Remove plugs, then seal and screw in the immersion sleeve (A) for thermal discharge safety device sensor Only for S-Tronic Plus: r Seal the broadband probe connection with a 3/4" blanking plug (B) Ä...
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6 | Assembly r 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 Ä Insert the cover plates such that the rivet (C) is at the bottom! r Insert the insulation mounting brackets at both insulating side panels and secure them with the two top thread forming screws (B) Ä...
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Assembly | 6 r Place one large spacer washer on each of the threaded bolts to the right and the left above on the boiler r Insert the insulating side panels at the base of the boiler at the flap and push them onto the boiler r Position the side panels with the door bracket onto the threaded bolts and secure them lightly with a large and a small spacer washer and nut...
6 | Assembly 6.4.6 Installing the door switch r Secure the bracket with pre-mounted door switch to the upper spacer plate with two thread forming screws M4 x 8 Ä The reel of the door contact switch must protrude at the front from the opening of the spacer plate.
Assembly | 6 6.4.8 Aligning the insulation and attaching the controller r Hang the lower spacer plate on the rivets (A) between the insulating side panels and attach with one thread forming screw each r Push the insulating side panels toward the rear until the borehole on the flaps corresponds with the borehole on the side panels r Secure the insulating side panels to the right and left at the flap on the boiler base with thread forming screws...
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6 | Assembly r Position the control on top r Insert one countersunk cross-head screw (A) each to the left and right through the bracket and control from below r Use nuts (B) to secure the countersunk cross-head screws from the top r Put the top heat insulation mat on Ä...
Assembly | 6 6.4.9 Installing the cleaning port door and blank cover NOTICE! Recommendation for easier maintenance: mount the cleaning door on the same side as the WOS lever! r Use three Allen screws to mount the cleaning door on the desired side Ä...
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6 | Assembly S3 Turbo 40/45: r Mount the lower door bracket with two hexagonal screws M6 x 12 on the U-profile r Insert the door bracket with the U-profile and lightly tighten the two hexagonal screws M6 x 12 r Measure the distance from the insulating side panel to the centre of the borehole for the insulated door on the upper bracket r Measure the distance from the insulating side panel to the centre of the borehole on...
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Assembly | 6 r Mount the insulated door onto the lower door bracket using the hexagonal screw r Attach the insulated door to the upper door bracket with hinge pin (A) Ä Insert the hinge pin through the control and the upper door bracket r Position magnetic latches (B) on the inside of the insulated door at the top and bottom r Mount counter plates for the magnetic latches (A) to the left insulation side panel r Check to see if the gap between the insulation side panel and the insulated door is the...
6 | Assembly 6.4.11 Fitting the sensors r Screw in the brass bushing (A) for the flue gas temperature sensor Ä Make sure that the borehole with the thread is situated at the upper area of the brass bushing r Push the flue gas temperature sensor in so that it protrudes approx. 20 mm from the housing and secure the position with the wing screw r Push the boiler sensor and STL capillary into the pre-installed immersion sleeve with the pressure spring (B) during boiler outfeed...
Assembly | 6 6.4.13 Installing the WOS system r Remove the pre-cut perforation (A) from the insulation side panel on the same side as the brass bushing Ä File rough edges using a half-round file and remove burrs r Slide the plastic cover (B) onto the WOS lever r Remove the heat exchanger cover (C) using the key supplied Ä...
6 | Assembly 6.4.14 Installing the manual controller/servo-motors r 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 Ä Check that the air flaps are at the left stop Mount the manual controller (with S-Tronic Plus control) r Place the air flap manual controllers on the pneumatic rod so that the manual controller is at the left stop and secure them with one thread forming screw each...
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Assembly | 6 Mounting the servo-motors (with S-Tronic Lambda control) r Check that the air flaps are at the left stop Ä All air flaps should be are closed r Set the actuators: Ä Set the direction of rotation of the actuator (1) to left (L) Ä...
6 | Assembly Fit the cover plate. r Use thread forming screws to secure the cover plate on the opposite side 6.5 Power connection and wiring 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...
6 | Assembly 6.5.2 Connecting components r Run the cables of the following components to the boiler controller and connect them to the boards in the controller box Ä Tuck any extra cable into the cable duct Core module: KM-36 (Optionsmodul) KM-02 KM-01...
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Assembly | 6 KM-10 High-limit thermostat KM-27 Induced draught fan Once the individual components have been wired: Mains connection: r Providing network connection Ä The power supply line (network connection) must be fitted with a max. C16A fuse by the customer! Ä...
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6 | Assembly Hydraulic system for S-Tronic Plus / S-Tronic Lambda No hydraulic module is included in the standard delivery of facilities with S-Tronic Plus or S-Tronic Lambda (the same as S-Tronic Plus but with Lambda controller for the boiler). The system selection “Hydraulic system for S-Tronic”...
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Assembly | 6 S-Tronic Plus / S-Tronic Lambda with hygienic layered tanks and return temperature control with mixing valve Note: Please install a mixing valve to limit the outlet temp. of the Hygienic solar layerd tank H2: Connections are represented schematically Flow temperature sensor 2 Heating circuit pump 2 Domestic...
6 | Assembly 6.5.3 Potential equalisation r The potential equalisation on the boiler base must comply with current directives, regulations and standards. 6.6 Concluding work r Put the front heat insulation mat on r Attach the covers (A) to the controller cable ducts r Put on the controller cover r Use the two thread forming screws incl.
Assembly | 6 6.6.1 Insulate the connection line When using the optionally available thermal insulation supplied by Fröling GesmbH, perform the following steps: r 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...
6 | Assembly 6.7 Hydraulic connection S3 Turbo Thermal discharge valve ▪ The thermal discharge safety device must be connected in accordance with ÖNORM/ DIN EN 303-5 and as shown in the diagram above ▪ The discharge safety sensor must be connected to a pressurised cold water mains supply (temperature ≤...
Start-up | 7 7 Start-up 7.1 Before commissioning / configuring the boiler The boiler must be configured to the heating system during 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. Take the following precautions: r Initial startup should be carried out with an authorised installer or with Froling customer services...
7 | Start-up 7.2 Initial startup 7.2.1 Permitted fuels Firewood Firewood up to max. 55 cm long. Water content Water content (w) greater than 15% (equivalent to wood moisture u > 17%) Water content (w) less than 25% (equivalent to wood moisture u < 33%) Note on standards Fuel as per EN ISO 17225 –...
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Start-up | 7 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,...
7 | Start-up 7.2.2 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: Fuel class 5a (§3 of the First Federal Emissions Protection Ordinance...
Start-up | 7 7.2.4 Heating up for the first time CAUTION If the boiler heats up too quickly on initial start-up: If the output during the heating-up process is too great, the combustion chamber may be damaged as a result of drying out too rapidly! For this reason the following applies the first time you heat up the boiler: r Start the firewood boiler for the first time in accordance with the heating instructions Heating instructions when starting up a firewood boiler for the first time...
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7 | Start-up Initial start-up using manual controller 100% r 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. Soft wood Hardwood Long split wood...
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Start-up | 7 NOTICE! The smaller the wood is cut, the faster a bed of embers forms Once the bed of embers has fully formed, the combustion air can be readjusted if necessary after measuring the O content: M1081724_en | Installation instructions Firewood boiler S3 Turbo...
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7 | Start-up Setting the primary air (boiler with one or two manual controllers) The nominal output of the boiler is set via the primary air and adjusted to the fuel used. Combustion air Effect Setting More primary air Higher flue gas temperature, Rotate manual controller clockwise greater output ("plus"...
Decommissioning | 8 8 Decommissioning 8.1 Mothballing The following measures should be taken if the boiler is to remain out of service for several weeks (e.g. during the summer): r Clean the boiler thoroughly and close the doors fully If the boiler is to remain out of service during the winter: r Have the system completely drained by a qualified technician Ä...
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