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Summary of Contents for Fröling S1 Turbo 15
- Page 1 Installation instructions Firewood boiler S1 Turbo (F) Translation of original German version of installation instructions for technicians. Read and follow all instructions and safety instructions. All errors and omissions excepted. M1471124_en | Edition 12/06/2024...
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Page 2: Table Of Contents
Table of Contents 1 General ................................. 1.1 About this manual ..........................1.2 Operating principle ..........................1.3 Disposal of packaging materials ......................2 Safety................................2.1 Hazard levels of warnings ........................2.2 Qualification of assembly staff ......................2.3 Personal protective equipment for assembly staff ................3 Design Information............................ - Page 3 Table of Contents 6.4.2 Checking the seal on the doors ....................37 6.4.3 Adjusting the doors ........................38 6.4.4 Positioning the boiler on the boiler base frame (optional)............39 6.5 Installing the boiler ..........................40 6.5.1 Fit the induced draught fan ......................40 6.5.2 Installing the insulation.......................
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Page 4: General
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. -
Page 5: Disposal Of Packaging Materials
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... -
Page 6: Safety
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. -
Page 7: Qualification Of Assembly Staff
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: ▪... -
Page 8: Design Information
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... -
Page 9: Regulations And Standards For Permitted Fuels
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. -
Page 10: Chimney Connection/Chimney System
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. -
Page 11: Connection Line To The Chimney
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. -
Page 12: Measuring Port
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. -
Page 13: Electrostatic Particle Separator
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... -
Page 14: Combustion Air
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. - Page 15 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...
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Page 16: Domestic Hot Water
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... - Page 17 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 ▪...
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Page 18: Pressure Maintenance Systems
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. -
Page 19: Storage Tank
For the correct dimensions of the storage tank and the line insulation (for instance to ÖNORM M 7510 or guideline UZ37) please consult your installer or Fröling. Recommended storage tank capacity: Unit S1 Turbo 15 (F) S1 Turbo 20 (F) Recommended storage tank capacity 1000 1250 1. - Page 20 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.
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Page 21: Return Lift
Design Information | 3 3.9 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. -
Page 22: Technology
4 | Technology 4 Technology 4.1 Dimensions of S1 Turbo (F) Dimensi Description 15-20 Length of boiler 1000 Total length incl. induced draught fan 1080 Overall width of boiler incl. WOS lever Width, boiler Distance between flue gas pipe connection and side of boiler Distance between safety heat exchanger connection and side of boiler Distance between safety heat exchanger connections Distance between flow connection and side of boiler... -
Page 23: Components And Connections
Technology | 4 4.2 Components and connections Item Description S1 Turbo 15-20 (F) Boiler flow connection 1” IT Boiler return connection on S1 Turbo (F) 1” IT Boiler return connection – connection to pellet unit outfeed on SP Dual compact 1”... -
Page 24: Technical Specifications
4 | Technology 4.3 Technical specifications Description S1 Turbo (F) Nominal output Boiler efficiency (NCV) 92,6 92.2 Electrical connection 230V / 50Hz / fused C16A Weight of boiler incl. insulation and control Total boiler capacity (water) Water pressure drop (ΔT = 10 / 20 K) mbar 3.5 / 0.5 8.3 / 1.5... -
Page 25: Boiler Data For Planning The Flue Gas System
Technology | 4 Model identifier S1 Turbo (F) 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... - Page 26 4 | Technology Description Value Frequency 50 ± 2% M1471124_en | Installation instructions Firewood boiler S1 Turbo (F)
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Page 27: Transport And Storage
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 S1 Turbo 15-20 (F) Length 1250 Width Height 1690 Weight Centre of gravity Length Width... -
Page 28: Positioning
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 firewood boiler cannot be brought in on the pallet: r remove the cardboard and take the boiler off the pallet... -
Page 29: Positioning At The Installation Site
Transport and storage | 5 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 r Remove the nuts and washers on the top frame of the pallet r Remove the top frame of the pallet r Remove the wood screws and clamping angles r Lift the boiler using a fork-lift or similar lifting device with the appropriate load-bearing... -
Page 30: Operating And Maintenance Areas Of The Equipment
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! ▪... - Page 31 Transport and storage | 5 Operating and maintenance areas of the SP Dual compact B B1 1 ... Firewood boiler S1 Turbo F | 2 ... Pellet unit 800 mm 500 mm 815 mm 400 mm 500 mm / 200 1.
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Page 32: Assembly
6 | Assembly 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... -
Page 33: Assembly Overview S1 Turbo (F)
Assembly | 6 6.3 Assembly overview S1 Turbo (F) Item Quant Description Item Quant Description Fibre-glass seal for induced draught fan Plugs, plastic Induced draught fan Ø 180 Cover plate with door contact switch Thermal insulation for induced draught unit Stop for WOS lever housing Thermal insulation for back panel... - Page 34 6 | Assembly Item Quant Description Item Quant Description Cover plate pellet flange Thermal insulation for reversing chamber cover Floor insulation Controller cover Insulating door mounting Cover Torque support for actuators Flue gas temperature sensor bushing Servo-motor Flue gas temperature sensor Cover plate for air control Flue gas temperature sensor wing screw Insulated door...
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Page 35: Before Installation
Assembly | 6 6.4 Before Installation 6.4.1 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 combustion chamber. - Page 36 6 | Assembly r Undo the hexagon screw on the fuel loading door and remove the door handle and flange sleeve r Slide the door handle in on the other side and insert the flange sleeve r Attach the door handle using a hexagon screw 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...
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Page 37: Checking The Seal On The Doors
Assembly | 6 6.4.2 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 combustion chamber. r Close the door Ä Slight resistance noticeable at a door gap (A) of 2-3 cm: It is acceptable to make an adjustment at the hinge side Ä... -
Page 38: Adjusting The Doors
6 | Assembly r Open the door r Place a sheet of paper on both sides of the door and close the door r Try to pull out the sheet of paper Ä If the paper cannot be pulled out: the door is tightly sealed Ä... -
Page 39: Positioning The Boiler On The Boiler Base Frame (Optional)
Assembly | 6 6.4.4 Positioning the boiler on the boiler base frame (optional) r Lift the boiler and position it on the boiler base frame Ä When doing so, thread the lugs on the boiler base frame (A) into the recesses in the boiler base (B) Ä... -
Page 40: Installing The Boiler
6 | Assembly 6.5 Installing the boiler 6.5.1 Fit the induced draught fan r Fasten a shaft screw to the top hole on the ID fan housing r Mount the seal for the induced draught fan on the shaft screw r Fasten the induced draught fan using four hexagon screws including washers r Remove the blanking plug from the induced draught unit housing and above the boiler flow... - Page 41 Assembly | 6 r Position the rear thermal insulation on the back wall and attach to the boiler using 6 tension springs Right door stop Left door stop r Screw the nuts and bolts as shown on to the supplied door mounting plate r Place the entire door bearing on the bottom of the boiler and attach from below using two screws TIP: If the boiler has a pellet flange, it is recommended to fit the door stop on the...
- Page 42 6 | Assembly r Use two screws to attach the bracket to the left side panel r Fit the left side panel to the side lug (A) and the front safety bolt (B) on the bottom of the boiler r Attach the side panel and bracket to the boiler Ä...
- Page 43 Assembly | 6 r Attach the rear panel to the side panels r Attach the ID fan cover plate to the back panel r 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 M1471124_en | Installation instructions Firewood boiler S1 Turbo (F)
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Page 44: Fitting The Air Control
6 | Assembly 6.5.3 Fitting the air control r Turn the slide valve for air flow to the left until it stops (anti-clockwise) r Set the direction of rotation of the servo-motor (1) to left (L) r Press the release button (2) and turn the shaft receptacle (3) to the left until it stops r Put the servomotor on the shaft and use two screws to attach torque supports r 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... -
Page 45: Installing The Wos Lever
Assembly | 6 6.5.4 Installing the WOS lever SW 13 mm r Loosen the screws slightly and unhook the cover plate from the left side panel r Screw the WOS lever into shaft and place the wrench on the flattened area to tighten 6.5.5 Installing the insulated door Installation of the insulated door is explained below using the example of the door stop on the left. - Page 46 6 | Assembly r When insulated door is closed: Measure the distance to the left and right between the insulated door and the control Ä The two distances must be equal! 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 r Place the thermal insulation on the boiler as shown...
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Page 47: Fitting The Controller Box
Assembly | 6 6.5.6 Fitting the controller box r Place the controller box on the boiler Ä In so doing, fit the cutout next to the service interface into the slit on the bracket r Fasten the controller box with two screws and align it horizontally using the adjusting screw (A) 6.5.7 Installing the Lambda probe, sensor and thermal discharge valve r Screw bushing (1) into flue pipe nozzle and tighten slightly... -
Page 48: Attaching The Induced Draught Cable
6 | Assembly r Slide the sensor and metal tube insulation into the immersion sleeve and secure with slotted screw 6.5.8 Attaching the induced draught cable r 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 M1471124_en | Installation instructions Firewood boiler S1 Turbo (F) -
Page 49: Hydraulic Connection
Assembly | 6 6.6 Hydraulic connection S1 Turbo SP Dual compact M1471124_en | Installation instructions Firewood boiler S1 Turbo (F) - Page 50 6 | Assembly 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 ≤...
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Page 51: Electrical Connection And Wiring
Assembly | 6 6.7 Electrical 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... -
Page 52: Board Overview
6 | Assembly 6.7.1 Board overview Item Description Item Description Device connection terminal Service interface Main switch Core module Mains connection plug Return mixer module (optional) High-limit thermostat STL Hydraulic module M1471124_en | Installation instructions Firewood boiler S1 Turbo (F) -
Page 53: Connecting Components
Assembly | 6 6.7.2 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... -
Page 54: Potential Equalisation
6 | Assembly 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 Observe the circuit diagrams in the boiler controller operating instructions. Ä... -
Page 55: Concluding Work
Assembly | 6 6.8 Concluding work r Fit the tabs (A) on the controller cover into the slots on the side panel r Secure the controller cover in place using two screws and contact washers r Install the cover for the cable duct Ä... -
Page 56: Positioning The Boiler Stickers
6 | Assembly 6.8.1 Positioning the boiler stickers r Remove the protective film from the sticker r Position the backing film featuring “S1 TURBO” in the upper left corner of the insulating door, ensuring all of the air bubbles have been removed r Make several passes over the sticker so the writing adheres to the insulated door r Carefully pull off the transparent backing film 6.8.2 Insulate the connection line... -
Page 57: Install The Brackets For Accessories
Assembly | 6 6.8.3 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 6.8.4 Affixing the identification plate r Affix the supplied rating plate (A) where it can easily be seen on the right side panel of the boiler M1471124_en | Installation instructions Firewood boiler S1 Turbo (F) -
Page 58: Start-Up
7 | Start-up 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... -
Page 59: Initial Startup
Start-up | 7 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 –... - Page 60 7 | Start-up 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,...
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Page 61: Fuels Permitted Under Certain Conditions
Start-up | 7 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 acc. to 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... -
Page 62: Decommissioning
8 | Decommissioning 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... -
Page 63: Appendix
Appendix | 9 9 Appendix 9.1 Pressure equipment regulation M1471124_en | Installation instructions Firewood boiler S1 Turbo (F) - Page 64 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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