Firewood boiler S1 Turbo - PTH Hout CV · Installation Instructions Firewood boiler S1 Turbo Translation of the original German installation instructions for technicians Read and

Installation Instructions

Firewood boiler S1 Turbo

Translation of the original German installation instructions for techniciansRead and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!M1470517_en | Edition 28/03/2017

Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of Contents

1 General 4

2 Safety 52.1 Hazard levels of warnings 52.2 Qualification of assembly staff 62.3 Personal protective equipment for assembly staff 62.4 Design Information 72.4.1 Notes on standards 7 General standards for heating systems 7 Standards for structural and safety devices 7 Standards for heating water 7 Regulations and standards for permitted fuels 82.4.2 Installation and approval of the heating system 82.4.3 General information for installation room (boiler room) 92.4.4 Requirements for central heating water 102.4.5 Notes for using pressure maintenance systems 112.4.6 Return lift 122.4.7 Combination with storage tank 132.4.8 Chimney connection/chimney system 14 Draught limiter 14 Measuring port 15 Boiler data for planning the flue gas system 15

3 Technology 163.1 Dimensions S1 Turbo 163.2 Dimensions SP Dual compact 173.3 Components and connections 183.4 Technical specifications 19

4 Assembly 214.1 Materials supplied 214.1.1 Tools required 214.2 Positioning 224.3 Temporary storage 224.4 Setting up in the boiler room 234.4.1 Removing boiler from pallet 234.4.2 Recommended clearances in the boiler room 244.5 Before Installation 264.5.1 Changing door stops (as needed) 264.5.2 Fitting the door handles 284.5.3 Checking the seal on the doors 294.5.4 Positioning the doors 304.6 Installing the boiler 324.6.1 Assembly overview 324.6.2 Fit the induced draught fan 344.6.3 Installing the insulation 344.6.4 Fitting the air control 38

Table of Contents

2 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.6.5 Installing the insulated door 394.6.6 Installing the WOS lever 404.6.7 Fitting the controller box 414.6.8 Fitting the broadband probe and sensors 424.6.9 Attaching the induced draught cable 444.7 Electrical connection and wiring 454.7.1 Potential equalisation 474.7.2 Information on circulating pumps 484.7.3 Concluding work 494.8 Connecting the hydraulic safety devices 50

5 Start-up 525.1 Before commissioning / configuring the boiler 525.2 Initial startup 535.2.1 Permitted fuels 53 Firewood 535.2.2 Fuels permitted under certain conditions 54 Wood briquettes 545.2.3 Non-permitted fuels 545.2.4 Heating up for the first time 55 Boiler with Lambda control 55 Boiler with manual controller 55

6 Decommissioning 586.1 Mothballing 586.2 Disassembly 586.3 Disposal 58

7 Appendix 597.1 Pressure equipment regulation 597.2 Technical specifications - Lambda control with partial load values 607.3 Addresses 627.3.1 Address of manufacturer 627.3.2 Address of the installer 62

Table of Contents

Installation Instructions S1 Turbo | M1470517_en 3

1 GeneralThank 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 testingguidelines.Please read and observe the documentation provided and always keep it close to thesystem for reference. Observing the requirements and safety information in thedocumentation makes a significant contribution to safe, appropriate, environmentallyfriendly and economical operation of the system.The constant further development of our products means that there may be minordifferences from the pictures and content. If you discover any errors, please let usknow: [email protected] to technical change. The EC Declaration of Conformity is only valid in conjunction with a delivery certificate,which has been filled in correctly and signed as part of the commissioning process.The original document remains at the installation site. Commissioning installers orheating engineers are requested to return a copy of the delivery certificate togetherwith the guarantee card to Froling. On commissioning by FROLING Customer Servicethe validity of the delivery certificate will be noted on the customer service record.

Issuing a deliverycertificate

1 General


2 Safety

2.1 Hazard levels of warningsThis documentation uses warnings with the following hazard levels to indicate directhazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will leadto serious injury or death. You must follow the instructions!

WARNING

The dangerous situation may occur and if measures are not observed it will leadto serious injury or death. Work with extreme care.

CAUTION

The dangerous situation may occur and if measures are not observed it will leadto minor injuries or damage to property.

Safety 2Hazard levels of warnings


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:❒ Observe the instructions and information in the manuals❒ Only allow appropriately qualified personnel to work on the system

Assembly, installation, initial startup and servicing must always be carried out byqualified personnel:- Heating technician / building technician- Electrical installation technician- Froling customer servicesThe assembly staff must have read and understood the instructions in thedocumentation.

2.3 Personal protective equipment for assembly staffYou must ensure that staff have the protective equipment specified by accidentprevention regulations.

▪ For transportation, setup and assembly:- suitable work wear- protective gloves- sturdy shoes (min. protection class S1P)

2 SafetyQualification of assembly staff


2.4 Design Information

2.4.1 Notes on standardsThe system must be installed and commissioned in accordance with the local fire andbuilding regulations. Unless contrary to other national regulations, the latest versionsof the following standards and guidelines apply:

General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fedcombustion systems, nominal heat output up to 500 kW

EN 12828 Heating systems in buildings - design of water-based heatingsystems

EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methodsPart 1: Chimneys serving one appliance

ÖNORM H 5151 Planning of central hot water heating systems with or without hotwater preparation

ÖNORM M 7510-1 Guidelines for checking central heating systemsPart 1: General requirements and one-off inspections

ÖNORM M 7510-4 Guidelines for checking central heating systemsPart 4: Simple check for heating plants for solid fuels

Standards for structural and safety devices

ÖNORM H 5170 Heating installation - Requirements for construction and safetyengineering, as well as fire prevention and environmentalprotection

Standards for heating water

ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation inclosed warm water heating systems at operating temperaturesup to 100°C (Austria).

VDI 2035 Prevention of damage hot water heating systems (Germany)

SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioningsystems (Switzerland)

UNI 8065 Technical standard regulating hot water preparation.DM 26.06.2015 (Ministerial Decree specifying the minimumrequirements)Follow the instructions of this standard and any related updates.

Safety 2Design Information


Regulations and standards for permitted fuels

1. BImSchV First Order of the German Federal Government for theimplementation of the Federal Law on Emission Protection(Ordinance on Small and Medium Combustion Plants) in theversion published on 26 January 2010, BGBl. JG 2010 Part I No. 4.

EN ISO 17225-3 Solid bio-fuel - Fuel specifications and classesPart 3: Wood briquettes for non-industrial use

EN ISO 17225-5 Solid bio-fuel - Fuel specifications and classesPart 5: Firewood for non-industrial use

2.4.2 Installation and approval of the heating systemThe boiler should be operated in a closed heating system. The following standardsgovern the installation:

EN 12828 - Heating Systems in Buildings

NOTICE! Each heating system must be officially approved.The appropriate supervisory authority (inspection agency) must always be informedwhen installing or modifying a heating system, and authorisation must be obtainedfrom the building authorities:Austria: report to the construction authorities of the community or magistrateGermany: report new installations to an approved chimney sweep / the buildingauthorities.

Note on standards

2 SafetyDesign Information


2.4.3 General information for installation room (boiler room)

Boiler room characteristics▪ The floor must be even, clean and dry and have an adequate load-bearing

capacity.▪ There must not be a potentially explosive atmosphere in the boiler room as the

boiler is not suitable for use in potentially explosive environments.▪ The boiler room must be frost-free.▪ The boiler does not provide any light, so the customer must ensure sufficient

lighting in the boiler room in accordance with national workplace designregulations.

▪ When using the boiler above 2000 metres above sea level you should consult themanufacturer.

▪ Danger of fire due to flammable materials. The floor of the boiler room must not be flammable. No flammable materialsshould be stored near the boiler. Flammable objects (e.g. clothing) must not be puton the boiler to dry.

▪ Damage due to impurities in combustion air.Do not use any solvents or cleaning agents containing chlorine and hydrogenhalides in the room where the boiler is installed (e.g. chlorination units forswimming pools).

▪ Keep the air suction opening of the boiler free of dust.▪ The system must be protected against the chewing or nesting of animals (e.g.

rodents etc.).

Ventilation of the boiler roomVentilation air for the boiler room should be taken from and expelled directly outside,and the openings and air ducts should be designed to prevent weather conditions(foliage, snowdrifts, etc.) from obstructing the air flow. Unless otherwise specified in the applicable building regulations for the boiler room,the following standards apply to the design and dimensions of the air ducts:

ÖNORM H 5170 - Construction and fire protection requirements

Note on standards



2.4.4 Requirements for central heating waterUnless contrary to other national regulations, the latest versions of the followingstandards and guidelines apply:

Austria:Germany:

ÖNORM H 5195VDI 2035

Switzerland:Italy:

SWKI BT 102-01UNI 8065

Observe the standards and also follow the recommendations below:❒ Aim for a pH value of between 8.2 and 10.0. If the central heating water comes

into contact with aluminium, the pH value must be between 8.0 and 8.5❒ Use prepared water which complies with the standards cited above for filling and

makeup water❒ Avoid leaks and use a closed heating system to maintain water quality during

operation❒ When filling with make-up water, always bleed the filling hose before connecting,

in order to prevent air from entering the system Advantages of prepared water:▪ Complies with the applicable standards▪ Less of a drop in output due to reduced limescale build-up▪ Less corrosion due to fewer aggressive substances▪ Long-term cost savings thanks to improved energy efficiency

Limit values for filling and make-up water:

Austria Germany Switzerland

Total hardness ≤ 1.0 mmol/L ≤ 2.0 mmol/L < 0.1 mmol/L

Conductivity - < 100µS/cm < 100 µS/cm

pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5

Chloride < 30 mg/L < 30 mg/L < 30 mg/L



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▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can

weaken corrosive materials in certain conditions If some of the system water is lost, e.g. during repairs, the make-up water must also bedemineralised. It is not enough to soften the water. The heating system must beprofessionally cleaned and rinsed before filling the units. Inspection:

▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the centralheating water comes into contact with aluminium, the pH value must be between 8.0 and8.5

▪ Yearly. Values must be recorded by the owner

2.4.5 Notes for using pressure maintenance systemsPressure maintenance systems in hot-water heating systems keep the requiredpressure within predefined limits and balance out volume variations caused bychanges 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 theexpansion tank is responsible for volume compensation and pressure maintenance. Ifthe pressure is too low, the compressor pumps air into the tank. If the pressure is toohigh, air is released by means of a solenoid valve. The systems are built solely withclosed-diaphragm expansion tanks to prevent the damaging introduction of oxygeninto the heating water.

Pump-controlled pressure maintenance

A pump-controlled pressure maintenance unit essentially consists of a pressure-maintenance pump, relief valve and an unpressurised receiving tank. The valvereleases hot water into the receiving tank if the pressure is too high. If the pressuredrops below a preset value, the pump draws water from the receiving tank and feeds itback into the heating system. Pump-controlled pressure maintenance systems withopen expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via thesurface of the water, exposing the connected system components to the risk ofcorrosion. These systems offer no oxygen removal for the purposes of corrosioncontrol as required by VDI 2035 and in the interests of corrosion protection should notbe used.



2.4.6 Return liftIf the hot water return is below the minimum return temperature, some of the hot wateroutfeed will be mixed in.

CAUTION

Risk of dropping below dew point/condensation formation if operated withoutreturn temperature control.

Condensation water forms an aggressive condensate when combined withcombustion residue, leading to damage to the boiler.

Take the following precautions:❒ Regulations stipulate the use of a return temperature control.

➥ The minimum return temperature is 60 °C. We recommend fitting somesort of control device (e.g. thermometer).



2.4.7 Combination with storage tankObserve the regional regulations for using a storage tank!Certain subsidy guidelines prescribe compulsory requirements for the installation ofstorage tanks. Up-to-date information about individual subsidy guidelines can be foundat www.froeling.com. Channelling the heat generated by the Firewood boiler to a storage tank can bringmajor advantages, including:❒ better utilisation of fuel❒ more user-friendly operation in terms of reloading intervals❒ maximum independence from instantaneous heating requirements❒ minimal dirt in boiler and flue gas system

As the boiler’s minimum continuous heat output is 30% above the nominal heatoutput, we as boiler manufacturer are obliged under EN 303-5:2012, Section 4.4.6 toadvise that the Firewood boiler S1 Turbo must always be connected to a storage tankwith adequate storage capacity.Certain countries have recommended storage capacities; these are listed below. Thespecified values apply when the nominal heat output of the boiler corresponds to theheating requirements of the building and a maximum of 50% of the nominal heatoutput can be dissipated to the building being heated under partial load conditions.The storage tank capacity can be calculated according to EN 303-5:2012 using thefollowing formula:

VSp= 15TBx QN(1 - 0.3 x QH/Qmin)

VSp

QN

TB

QH

Qmin

Storage tank capacity in [l]Nominal heat output of boiler in [kW]Burn-off period of boiler in [h]1)

Heating load of building in [kW]Minimum heat output of boiler in [kW] 2)

1.Sample combustion times for various fuels are provided in the technical data2.The boiler’s minimum output is the lowest value of the output range in the technical data. If there is no minimum heat output specified, use

the nominal heat output (Qmin = QN)

According to the relevant Austrian laws governing energy technology, which are basedon Art. 15a B-VG "Agreement on protective measures for small furnaces" (2012):No storage tank is required on manually fed biomass boilers that have been positivelytested at both nominal load and partial load (below 50% of nominal load) to ensurethey adhere to the emissions limits specified in that agreement.Recommended storage tank capacity:

Unit S1 Turbo 15 S1 Turbo 20

Recommended storage tank capacity1) [l] 1000 10001.Values for calculating the capacity can be found in the technical data or the technical data with partial load inspection (if available)

General information

Austria



http://www.froeling.com

The first BImSchV (Ordinance on small and medium-sized heating plants of 26January 2010, BGBl. I P. 38) stipulates a minimum water heat storage tank volume of55 litres per kilowatt of rated heat output; a water heat storage tank with a volume of12 litres per litre of fuel loading chamber is recommended.Recommended storage tank capacity:

Unit S1 Turbo 15 S1 Turbo 20

Recommended storage tank capacity1) [l] 1000 15001.Values for calculating the capacity can be found in the technical data or the technical data with partial load inspection (if available)

For the correct dimensions of the storage tank and the line insulation (e.g. in accordance with ÖNORM M 7510 or guideline UZ37) please consult your installer orFroling.

2.4.8 Chimney connection/chimney systemEN 303-5 specifies that the entire flue gas system must be designed to prevent,wherever possible, damage caused by seepage, insufficient feed pressure andcondensation. Please note in this respect that flue gas temperatures lower than 160Kabove room temperature can occur in the permitted operating range of the boiler.The flue gas temperatures (for clean systems) and additional flue gas values can befound in the table below.The connection between the boiler and the chimney system should be as short aspossible. The upward angle of the connection should not exceed 30 - 45°. Insulate theconnection. The entire flue gas system - chimney and connection - should becalculated in accordance with EN 13384-1.Local regulations and other statutory regulations also apply.NOTICE! The chimney must be authorised by a smoke trap sweeper or chimneysweep.

Draught limiterWe generally recommend the installation of a draught limiter. A draught limiter mustbe installed if the maximum permissible feed pressure as given in the boiler data forplanning the flue gas system is exceeded.NOTICE! Install the draught limiter directly under the mouth of the flue line, as thepressure is constantly low at this point.

Germany



Measuring portFor measuring the emissions of the system, a suitable measuring port must beinstalled in the connecting piece between the boiler and chimney system.

D

D

M

2 x D

In front of the measuring port (M) a straight inlet section should be located at adistance corresponding to about twice the diameter (D) of the connecting piece. Astraight outlet section at a distance corresponding to about the single diameter of theconnecting piece should be provided after the measuring port. The measuring portmust remain closed whenever the system is in operation.Ensure that the outside diameter of the sampling probes in the measuring port canaccommodate up to 13 mm. To avoid the ingress of false air, the diameter of themeasuring port must not exceed 21 mm.

Boiler data for planning the flue gas system

Description S1 Turbo 15 S1 Turbo 20

Flue gas temperature at nominal load °C 150 170

Flue gas temperature at partial load °C - 130

Flue gas mass flow at nominal load kg/s 0.010 0.013

Flue gas mass flow at partial load kg/s - 0.007

Required feed pressure at nominal load Pa 8 8

mbar 0.08 0.08

Required feed pressure at partial load Pa - 8

mbar - 0.08

Maximum permissible feed pressure Pa 30 30

mbar 0.3 0.3

Flue pipe diameter mm 129 129



3 Technology

3.1 Dimensions S1 Turbo

H

H1

H3

H2

H6

H4

H5

B

B1

L

L1

Measurement

Description Unit Value

L Length of boiler mm 1000

L1 Total length incl. induced draught fan 1080

B Width, boiler 685

B1 Width of boiler incl. WOS lever 790

H Height, boiler 1235

H1 Total height incl. flue gas nozzle 1300

H2 Height, flue pipe connection 1450

H3 Height, flow connection 1055

H4 Height, return connection 150

H5 Height, safety battery connection 1040

H6 Height, drainage connection 125

3 TechnologyDimensions S1 Turbo


3.2 Dimensions SP Dual compact

H1 H

H3

H2

H5

H4

H6H7

B1

B

B2 L1

L

L2

Measurement


L Total length, SP Dual compact incl. ID fan mm 1080

L1 Length, firewood boiler 1000

L2 Length, pellet boiler 895

B Total width, SP Dual compact incl. WOS lever 1105

B1 Width, firewood boiler 685

B2 Width, pellet unit 315

H Height, pellet unit 1335

H1 Height, firewood boiler 1235

H2 Height, flue pipe connection 1450

H3 Height, flow - firewood boiler connection 1055

H4 Height, return - firewood boiler connection 150

H5 Height, return - pellet unit connection 130

H6 Height, safety battery - firewood boiler connection 1040

H7 Height, suction system - pellet unit connection 1253

Technology 3Dimensions SP Dual compact


3.3 Components and connections

Item Description Unit Value

1 Boiler flow connection inches 1

2a Boiler return connection on S1 Turbo (F) inches 1

2b Boiler return connection – connection to pellet unitoutfeed on SP Dual compact

inches 1

3 Drainage connection inches ½

4 Safety battery connection inches ½

5 Immersion sleeve for thermal discharge valve(supplied by the customer)

inches ½

6 Flue gas pipe connection mm 129

7 Immersion sleeve for boiler sensor and STL inches ½

8 Broadband probe connection inches ¾

9 Flue gas temperature sensor connection inches ½

3 TechnologyComponents and connections


3.4 Technical specifications

Description S1 Turbo / S1 Turbo F1)

15 20

Nominal heat output kW 15 20

Electrical connection 230V / 50Hz / fused C16A

Power consumption at nominal load W 37 42

Power consumption in slumber mode 3 3

Weight of boiler incl. insulation and control kg 455 465

Total boiler capacity (water) l 90 90

Water pressure drop (ΔT = 10 / 20 K) mbar 3.5 / 0.5 8.3 / 1.5

Minimum boiler return temperature °C 60

Maximum permitted operating temperature 90

Permitted operating pressure bar 3

Airborne sound level dB(A) < 70

Permitted fuel as per EN 14961 Part 5: Firewood class A2 / D15 L50

Fuel loading door dimensions (width / height) mm 350 / 360 350 / 360

Fuel loading chamber capacity l 80 80

Combustion time2) - Beech h 4.9 - 7.0 3.5 - 5.0

Combustion time2) - Spruce 3.0 - 4.2 2.1 - 3.01.With regards to the approval of drawings for “S1 Turbo xx F” type boilers, the test results on the heating technology requirements of the “S1

Turbo xx” wood chip boiler according to EN 303-5 can be used.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%)

Regulation (EU) 2015/1187

Energy efficiency A+ A+

Rated heat output kW 15 20

Energy efficiency index of the boiler model 118 117

Seasonal space heating energy efficiency % 80 80

Energy efficiency index of the boiler in package withtemperature control

120 119

Energy efficiency class of the boiler in package withtemperature control

A+ A+


15 20

Testing institute TÜV Austria2) TÜV Austria2)

Test report no. 13-UW/Wels-EX-044/1

13-UW/Wels-EX-044/2

Date of issue 20/03/2013 21/03/2013

Boiler class as per EN 303-5:2012 5 5

Boiler efficiency % 92.5 92.01.With regards to the approval of drawings for “S1 Turbo xx F” type boilers, the test results on the heating technology requirements of the “S1

Turbo xx” wood chip boiler according to EN 303-5 can be used.2.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

Test report data - Lambda Control

Technology 3Technical specifications


Test data - Emissions in [mg/MJ]1) (nominal load)

Carbon monoxide (CO) mg/MJ 69 51

Nitrogen oxide (NOx) mg/MJ 80 88

Organic hydrocarbons (OGC) mg/MJ 3 3

Dust mg/MJ 8 101.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m³]1) (nominal load)

Carbon monoxide (CO) mg/m³ 102 75

Nitrogen oxide (NOx) mg/m³ 118 129

Organic hydrocarbons (OGC) mg/m³ 5 5

Dust mg/m³ 11 151.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%


15 20

Testing institute TÜV Austria2) TÜV Austria2)


13-UW/Wels-EX-044/4

Date of issue 18/06/2013 19/06/2013

Boiler class as per EN 303-5:2012 5 5

Boiler efficiency % 92.6 92.61.With regards to the approval of drawings for “S1 Turbo xx F” type boilers, the test results on the heating technology requirements of the “S1

Turbo xx” wood chip boiler according to EN 303-5 can be used.2.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

Test data - Emissions in [mg/MJ]1) (nominal load)

Carbon monoxide (CO) mg/MJ 165 100

Nitrogen oxide (NOx) mg/MJ 90 86

Organic hydrocarbons (OGC) mg/MJ 4 2

Dust mg/MJ 8 101.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m³]1) (nominal load)

Carbon monoxide (CO) mg/m³ 243 147

Nitrogen oxide (NOx) mg/m³ 132 126

Organic hydrocarbons (OGC) mg/m³ 6 4

Dust mg/m³ 11 141.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%

Test report data - Manual controller

3 TechnologyTechnical specifications


4 Assembly

4.1 Materials suppliedThe boiler comes on a pallet together with insulation, controller and accessories.Some of the components come in cardboard packaging.

1 Boiler Accessories (not pictured):

2 Insulation ▪ Induced draught and seals

3 Controller ▪ Cleaning devices

4.1.1 Tools requiredThe following tools are required for assembly:❒ Spanner or box wrench set (widths across flats 8 - 32 mm)❒ Set of Allen keys❒ Flat head and cross-head screwdrivers❒ Hammer❒ Diagonal cutting pliers❒ Half-round file❒ Power drill or cordless screwdriver with Torx bit insert

Assembly 4Materials supplied


4.2 Positioning

NOTICE

Damage to components if handled incorrectly

❒ Follow the transport instructions on the packaging❒ Transport components with care to avoid damage❒ Protect the packaging against damp conditions❒ Pay attention to the pallet's centre of gravity when lifting

❒ 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:❒ Remove the cardboard and remove the boiler from the pallet

⇨ See "Removing boiler from pallet" [page 23]

Positioning using a crane

❒ Attach the crane hook to the attachment point correctly and position the boiler

4.3 Temporary storageIf the system is to be assembled at a later stage:❒ Store components at a protected location, which is dry and free from dust

➥ Damp conditions and frost can damage components, particularly electric ones!

4 AssemblyPositioning


4.4 Setting up in the boiler room

4.4.1 Removing boiler from pallet❒ Lift the cardboard box with the insulation from the pallet❒ Remove the cardboard with the controller from the boiler and put in a safe place

❒ Undo the nuts (M10) with washers at the top frame of the pallet❒ Remove the top frame of the pallet❒ Undo the wood screws (T30) and remove the angle clamp brackets

❒ Lift the boiler using a fork-lift or similar lifting device with the appropriate load-bearing capacity and remove the bottom supports of the pallet

❒ Transport boiler to the intended position in the installation room➥ Observe the recommended clearances in the boiler room!

Assembly 4Setting up in the boiler room


4.4.2 Recommended clearances in the boiler room▪ The system should generally be set up so that it is accessible from all sides

allowing quick and easy maintenance.▪ Regional regulations regarding necessary maintenance areas for inspecting the

chimney should be observed in addition to the specified minimum distances!▪ Observe the applicable standards and regulations when setting up the system.▪ Observe additional standards for noise protection

(ÖNORM H 5190 - Noise protection measures)

Measurement


A Distance – front of boiler to wall mm 800

B Distance – side of boiler to wall 200

C Distance – back to wall 400

D Distance – side of boiler to wall 500

Minimum room height 2000

Recommendedclearances

S1 Turbo

4 AssemblySetting up in the boiler room


A

B

D

C

B1

Measurement


A Distance – front of boiler to wall mm 800

B Distance – boiler side with pellet unit to wall 500

B1 Distance – boiler side without pellet unit to wall 815

C Distance – back to wall 400

D Distance – side of boiler to wall 500 (2001)

Minimum room height 20001.Maintenance work to boiler’s heat exchanger only possible from front

Recommendedclearances S1 Turbo F

(SP Dual compact)

Assembly 4Setting up in the boiler room


4.5 Before Installation

4.5.1 Changing door stops (as needed)The boiler comes with the door stop on the right. If you want to change the side thedoor stops are on, proceed as follows.

Changing the fuel loading door stop

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! ❒ Open the fuel loading door

❒ 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❒ Take off the fuel loading door

4 AssemblyBefore Installation


❒ Remove the locking plate and hinge➥ Do this by undoing the locking cam and lock nut (M8)

❒ Fit the hinge back onto the other side

❒ Attach the locking cam at the top and bottom as shown and secure with spacerwasher and lock nut (M8)

❒ Attach the locking plate to the other side❒ Using the locking cam, spacer washer and lock nut (M8) secure at the top and

bottom as shown

Assembly 4Before Installation


❒ Hang the door again with the stop on the other side❒ Secure at the top and bottom with the hinge pins❒ Refit the retainers to the top and bottom hinge pins

➥ to do so, we recommend using two screwdrivers NOTICE! If the door stops have been changed, you must check the seal of the doorsand readjust if necessary.⇨ See "Checking the seal on the doors" [page 29]⇨ See "Positioning the doors" [page 30]

4.5.2 Fitting the door handlesThe example below shows how to mount the fuel loading door handles. The procedureis the same for mounting the door handles of the combustion chamber door!

❒ Insert the flange bushing (1) into the door handle (2) and position it alongside thehole (3) provided

❒ Secure door handle (2) with hexagonal screw M8 x 30 (4)



4.5.3 Checking the seal on the doorsThe example below shows how to check the seal on the fuel loading door. Theprocedure is the same for checking the seal on the combustion chamber door.

❒ Insert a sheet of paper at the side of the door stop at the top between the door andthe boiler

❒ Close the door❒ Try to pull out the sheets of paper.

➥ If the paper cannot be removed: The door seal is OK and the settings are correct

➥ If the paper can be removed: The door is not sealed properly and must be adjusted Increase the contact pressure at the locking cam:⇨ See "Positioning the doors" [page 30]

❒ Check the seal again after positioning the doors

❒ Repeat the procedure at the side of the door stop at the bottom and at the side ofthe door handle



4.5.4 Positioning the doorsThe example below shows how to position the fuel loading door. The procedure is thesame for positioning the combustion chamber door!

❒ Using an Allen key (SW 13 mm), loosen the lock nuts (M8) on the locking cams atthe top and bottom

❒ Close the door➥ With a gap of approx. 2 to 3 cm there should be a noticeable resistance

❒ If the resistance is too low or too high, move the locking cams backwards orforwards using the key provided (SW 32 mm)➥ The movement of the locking cams causes the hinged plate to move, allowing

the contact pressure to be adjusted➥ Caution: The two locking cams (top and bottom) must be adjusted equally!

❒ Close the door❒ If the door will not close, move the locking cams forward slightly

➥ Caution: The two locking cams (top and bottom) must be adjusted equally! ❒ Tighten the lock nuts (M8)

The locking plate can be moved in the same way using the locking cam at the side ofthe door handle, allowing the contact pressure to be adjusted on this side.





4.6 Installing the boiler

4.6.1 Assembly overview

1

2

3 4

5

6

6

7

8

33

15

32

23

2425

28

29

30

21

10

11

9

14

1312

16

17

18

22

22

26

27

34

35

36

37

39

38

30

20

19

31

31

M6x20 M6x12M6

M8 M8M6x16 M6

M8x25

M4x8 M5M5x12

M6x12

M4x8M3x10

Ø15x1,6Ø6x20

M6x100

M4

101 102 103 104 105 106 107 108 109 110

111 112 113 114 115 116 117 118 119

4 AssemblyInstalling the boiler


Item units Description Item units Description

1 1 Fibre-glass seal for induced draught fan 2 1 Induced draught fan SPG ø180

3 1 Thermal insulation for induced draught unithousing

4 1 Thermal insulation for back panel

5 1 Back panel 6 2 Cover plate for ID fan

7 1 Cover plate, boiler return 8 1 Thermal insulation for top of boiler

9 1 Controller box, complete 10 1 Controller cover

11 1 Thermal insulation for cleaning cover 12 1 Controller cover

13 1 Thermal insulation for reversing chambercover

14 1 Cable duct

15 1 WOS lever 16 1 Bracket for controller box

17 1 Side panel, left 18 1 Cover plate with brush

19 1 Cover plate WOS 20 1 Stop for WOS lever

21 1 Cover plate with door contact switch 22 2 Plugs, plastic

23 1 Insulating door mounting 24 1 Servo-motor

25 1 Torque support for actuators 26 1 Mounting plate manual controller

27 1 Manual controller 28 1 Cover plate for air control

29 1 Insulated door 30 1 Touch control panel

31 2 End caps, control 32 1 Floor insulation

33 1 Side panel, right 34 1 Cover plate for pellet flange

35 1 Flue gas temperature sensor 36 1 Flue gas temperature sensor bushing

37 1 Flue gas temperature sensor wing screw 38 1 Broadband probe bushing

39 1 Broadband probe

Item Description Item Description

101 Countersunk head screw M3 x 10 T10 102 Lens-head screw M4 x 8 black, galvanised T20

103 Lens-head screw M4 x 8 blue, galvanised T20 104 Contact washer M4

105 Countersunk head screw M5 x 12 T25 106 Hexagonal nut M5

107 Set screw M6 x 20 108 Spacer washer M6

109 Hexagonal screw M6 x 12 SW10 110 Hexagonal screw M6 x 100 SW10

111 Hinge pins Ø 6 x 20 112 Round-head screw M6 x 16

113 Hexagonal nut M6 SW10 114 Lens-head screw M6 x 12 T30

115 Locking washer, polyethylene Ø 15 x 1.6 116 Hexagonal screw M8 x 25 SW13

117 Bolts M8 118 Hexagonal nut M8, flat SW13

119 Tension spring

NOTICE! Number varies depending on the model

Assembly 4Installing the boiler


4.6.2 Fit the induced draught fan

❒ Secure the set screw M6 x 20 (1) at the upper borehole❒ Mount the fibre-glass seal for the induced draught fan on the set screw❒ Secure the induced draught fan with the four hexagon screws (M6 x 12) and

spacer washers

4.6.3 Installing the insulation

NOTICE

The individual parts of the boiler insulation covered with a protective film. Youmust remove the protective film before proceeding with installation.

❒ Slide the floor insulation under the boiler from the front



❒ Insert the thermal insulation on the induced draught fan housing and secure withthe tension springs➥ Position the small perforation (top) with the connections for broadband probe

and flue gas temperature sensor

❒ Position the rear thermal insulation at the back panel and secure to the boiler withthe tension springs



❒ Screw in bolts (M8) and nuts on the door bearing panel provided as shown❒ Place the complete door bearing on the bottom of the boiler and secure from

above with two round-head screws M6 x 16 including nuts and washers

❒ Secure the bracket (A) on the left side panel with two hexagonal screws (M8 x 25)and spacer washers

❒ Attach the right and left side panels of the boiler➥ First insert the bottom to the side flaps (B) on boiler base

❒ Hang the left side panel onto the front fastening bolt (C)❒ Secure the side panels to the boiler with the brackets

➥ Only screw in the two hexagonal screws M8 x 25 loosely

Right door stop

Left door stop



❒ Hang the back panel and secure with four lens-head screws M4 x 8❒ Secure the cover plates for ID fan with six lens-head screws M4 x 8

❒ Secure the control to the bracket on the left and right using countersunk headscrews M5 x 12

❒ Secure the cover plate including door contact switch with lens-head screws M4 x 8❒ Secure plugs to the cut-out sections of the cover plate



4.6.4 Fitting the air control

L

❒ Turn the sliding valve for the air duct in an anti-clockwise direction as far as thestop

❒ Set the direction of rotation of the actuator (1) to left (L)❒ Press the unlock key (2) and turn the drive for the shaft to the air duct (3) in an

anti-clockwise direction as far as the stop❒ Place the servo-motor on the shaft and secure torque support with two lens-head

screws M6 x 12❒ Run the cable of the servo-motor up through the cable duct

AL

Verbrennungsluft / combustion air /

air de combustion / aria comburente /

aire de combustión

A19000015

PL SL

❒ Place the mounting plate for the manual controller on the shaft and secure withtwo lens-head screws M6 x 12

❒ Place the manual controller on the shaft➥ The arrow should be at the top right (see picture)

❒ Turn the manual controller to the right (see picture) and secure with lens-headscrew M6 X 12➥ The exact position of the manual controller is set on initial start-up

⇨ See "Boiler with manual controller" [page 55]

Variant 1 - Fitting theservo-motor

Variant 2 - Fitting themanual controller



❒ Secure the cover plate for the air control with four lens-head screws M4 x 8

4.6.5 Installing the insulated door

1. Secure the counter plate provided for magnetic latch to the side panel opposite thedoor stop with countersunk head screw M3 x 10

2. Secure bolts M8 including locking washer from below with hexagonal nut on theinsulating door

3. Hang the bottom of the insulated door onto the bolt of the door bearing4. Position the top of the insulated door and secure with the hinge pin5. Attach the caps on the ends of the control on each side

Right door stop

Left door stop



❒ Measure the distance between the insulating door and the control (left and right)when the insulating door is closed➥ The two distances must be equal!➥ Align the side panels as required

❒ Tighten hexagonal screws M8 x 25 on both brackets

❒ Place thermal insulation on boiler

4.6.6 Installing the WOS lever

❒ Push the WOS lever into the side hole and tighten❒ Push the WOS lever down and tighten at the flat part with spanner (SW 13 mm)



❒ Pull the WOS lever 5 – 10 times every time you heat up the boiler➥ This keeps the heating surfaces clean and saves fuel.

4.6.7 Fitting the controller box

❒ Thread the cables of the servo-motor (A) through the hole on the bottom of thecontroller box

❒ Thread the cables of the door contact switch and control (B) through the hole atthe front of the controller box

❒ Place the controller box on the boiler➥ Insert the cut-out (C), front left on the controller box, in the slit of the bracket

(D)❒ Secure the controller box with two lens-head screws M4 x 8 including contact

washers (E)❒ Align the controller box horizontally using the hexagonal screw M6 x 100 (F) at the

back left



❒ Position the cable duct on the right side panel➥ Insert the cable duct attachment hooks into the holes provided on the side

panel❒ Secure the cable duct at the back of the controller box with two lens-head screw

M4 x 8 including contact washer❒ Secure the back panel on the cable duct with lens-head screw M4 x 8

4.6.8 Fitting the broadband probe and sensors

❒ Unscrew the pre-installed bushing from the broadband probe❒ Screw the bushing into the induced draught box and gently tighten❒ Screw the broadband probe into the bushing and gently tighten using an Allen key

(SW 22 mm)❒ Screw in the brass bushing for the flue gas temperature sensor❒ 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❒ Run the cable from the broadband probe and flue gas temperature sensor to the

controller box via the cable duct➥ Tuck any extra cable into the cable duct



❒ Lay the capillary tube from the controller box back through the cable duct❒ Push the boiler sensor and the STL capillary with the pressure spring (1) into the

pre-installed immersion sleeve (2) of the boiler flow. NOTICE! Thermal discharge valve is not included!

❒ Remove pre-installed blanking plug of the boiler flow and then seal the immersionsleeve of the thermal discharge safety device

❒ Slide the sensor and metal tube insulation into the immersion sleeve and securewith slotted screw



4.6.9 Attaching the induced draught cable

❒ Run the induced draught cable through the round cut-out section in the back panelto the induced draught unit via the cable duct➥ Tuck any extra cable into the cable duct

❒ Attach the two induced draught cables and secure with cable ties



4.7 Electrical connection and wiring

DANGER

When working on electrical components:

Risk of electrocution!

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 unauthorisedpersons

Run cable to boiler controller box and connect to the boards:

Broadband probe on core module

FRKEM

Breitband-

Sonde

Breitband-

Sonde

Flue gas temperature sensor on coremodule

FRKEM

Abgas-Fühler

Boiler sensor on core module

FRKEM

Kessel-Fühler KF

Assembly 4Electrical connection and wiring


ID fan on core module

FRKEM

Saugzug

STL on core module

FRKEM

STB

Door contact switch on core module

FRKEM

Türkontakt-

schalter TKS

Servo-motor on core moduleSekundär-

FRKEM

Luft

Control on core module

FRKEM

BU

S (3

)

❒ Wire the components according to the electrical connection diagram➥ Flexible sheathed cable must be used for the wiring; this must be of the correct

size to comply with applicable regional standards and regulations.

4 AssemblyElectrical connection and wiring


Once the individual components have been wired:

Netz

Netz

❒ Wire the mains connection in the controller box➥ The power supply line (mains connection) must be fitted with a max. C13A fuse

by the customer.➥ Observe the circuit diagrams in the boiler controller operating instructions.

4.7.1 Potential equalisation

❒ The potential equalisation on the boiler base must comply with current directives,regulations and standards.



4.7.2 Information on circulating pumps

NOTICE

According to 2012/622/EU external, wet running circulating pumps must complywith the following limit values of the Energy Efficiency Index (EEI):

- Effective from 01/01/2013: Wet running circulating pumps with EEI ≤ 0.27- Effective from 08/01/2015: Wet running circulating pumps with EEI ≤ 0.23

Only high efficiency pumps with a connection option for a control signal (PDM / 0-10V)should be connected to speed-controlled pump outputs (pump 1 on the core moduleand pump outputs on the hydraulic module). In this case, the control line is connectedto the corresponding PDM outputs of the boards. Observe the connection instructionsin the boiler controller documentation!

CAUTION

When using high efficiency pumps without an additional control line at speed-controlled pump outputs:

Malfunctions of the boiler, the pump and the hydraulic system may occur!

Therefore:❒ Do not connect EC motor pumps without a control line to the speed-controlled

pump outputs of the boards.➥ Only use special high efficiency pumps with a connection option for a

control line (PDM/0-10V)!➥ Observe the additional instructions and information on board outputs in the

operation instructions for the boiler controller.

4 AssemblyElectrical connection and wiring


4.7.3 Concluding work

❒ Attach the covers to the controller box cable ducts❒ Put on the controller cover

➥ Insert the cover attachment hooks into the holes provided on the controller box❒ Secure the controller cover with lens-head screw M4 x 8 including contact washer

❒ Put on the thermal insulation for the reversing chamber cover and cleaning cover❒ Put on the controller lid



4.8 Connecting the hydraulic safety devices

1.1

2

34

1.2

1.3

1.5

1.6

1.4

1.1

2

34

1.2

1.3

1.5

1.6

1.4

M

S1 Turbo (F)

SP Dual compact

4 AssemblyConnecting the hydraulic safety devices


1 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 ≤ 15°C) in such a way that it cannot be shut off▪ A pressure reducing valve (1.5) is required for a cold water pressure of ≥ 6 bar

Minimum cold water pressure = 2 bar 1.1 Sensor of thermal discharge safety device 1.2 Thermal discharge valve (opens at approx. 95°C)1.3 Cleaning valve (T-piece)1.4 Dirt trap1.5 Pressure reducing valve1.6 Free outlet without counter pressure

2 Safety valve▪ Safety valve as per ÖNORM EN ISO 4126-1, diameter as per EN 12828 or

national regulations▪ The safety valve must be installed in an accessible place on the heat generator or

in direct proximity in the flow pipe in such a way that it cannot be shut off

3 Return temperature control

4 Diaphragm expansion tank▪ The diaphragm pressurised expansion tank must conform to EN 13831 and hold

at least the maximum expansion volume of the system’s heated water including awater seal

▪ Its size must comply with the design information in EN 12828 - Appendix D▪ Ideally it should be installed in the return line. Follow the manufacturer’s

installation instructions

5 Internal pipe connection▪ Pellet unit outfeed to return firewood boiler (included in delivery)

Assembly 4Connecting the hydraulic safety devices


5 Start-up

5.1 Before commissioning / configuring the boilerThe boiler must be configured to the heating system on initial start-up.

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteedif the system is set up by trained professionals and the standard factory settingsare observed.

Take the following precautions:❒ Initial startup should be carried out with an authorised installer or with Froling

customer services

NOTICE

Foreign bodies in the heating system impair its operational safety and can resultin damage to property.

As a result:❒ The whole system should be rinsed out before initial start-up in accordance

with EN 14336.❒ Recommendation: Make sure the hose diameter of the flush nozzles in the

flow and return complies with ÖNORM H 5195 and is the same as the hosediameter in the heating system, however not more than DN 50.

❒ Turn on the main switch❒ Set the boiler controller to the system type.❒ Load the boiler default values.

NOTICE! For the keypad layout and instructions for modifying the parameters, see theinstruction manual for the boiler controller.❒ Check the system pressure of the heating system.❒ Check that the heating system is fully vented.❒ Check that all water connections are tightly sealed

➥ Pay particular attention to those connections from which plugs were removedduring assembly.

❒ Check that the safety devices are present and working efficiently.❒ Check that there is sufficient ventilation in the boiler room.❒ Check the seal of the boiler.

➥ All doors and inspection openings must be tightly sealed.❒ Check that the drives and servo motors are working and turning in the right

direction.❒ Check that the door contact switch is working efficiently.

NOTICE! Check the digital and analog inputs and outputs - See the instruction manualfor the boiler controller.

5 Start-upBefore commissioning / configuring the boiler


5.2 Initial startup

5.2.1 Permitted fuels

FirewoodFirewood up to max. 55 cm long.

Water content (w) greater than 15% (equivalent to wood moisture u > 17%)Water content (w) less than 25% (equivalent to wood moisture u < 33%)

EU: Fuel as per EN ISO 17225 – Part 5: Firewood class A2 / D15 L50

Additional forGermany: Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance

(BimSchV) in the last amended version)

▪ Use wind-exposed areas where possible for storage (e.g. store at edge of forest insteadof in forest)

▪ Walls of buildings facing the sun are ideal▪ Create a dry underlay, where possible with air access (line with round timber, pallets,

etc.)▪ stack split wood and store in such a way that it is protected from the elements▪ If possible, stock fuel for the day in a warm place (e.g. in boiler room) (pre-heats the

fuel!)

Storage time dependent upon water content

Wood type Water content

15 – 25% less than 15%

Storage in heated and ventilated room(approx. 20°C)

Soft wood (e.g.spruce)

approx.6 months

from 1 year

Hardwood (e.g.beech)

1 – 1.5 years from 2 years

Outdoor storage (protected fromelements, exposed to wind)

Soft wood (e.g.spruce)

2 summers from 2 years

Hardwood (e.g.beech)

3 summers from 3 years

Freshly cut wood has an approximate water content of 50 to 60%. As the above tableshows, the water content of the firewood decreases the longer the wood is storeddepending on how dry and warm the storage location is. The ideal water content offirewood is between 15 and 25%. If the water content falls below 15%, we recommendyou adjust the combustion control to the fuel.

Water content

Note on standards

Tips for storing wood

Start-up 5Initial startup


5.2.2 Fuels permitted under certain conditions

Wood briquettesWood briquettes for non-industrial use with a diameter of 5-10 cm and 5-50 cm long.

EU: Fuel acc. to EN ISO 17225 - Part 3:wood briquettes class B / D100 L500 Form 1 - 3

Additional forGermany: Fuel class 5a (§3 of the First Federal Emissions Protection Ordinance

(BimSchV) in the last amended version)

▪ Wood briquettes must be heated up with firewood as per EN 17225-5 (at least two layers of firewood under the wood briquettes)

▪ The fuel loading chamber must not be filled more than 3/4 full, as the wood briquettesexpand during combustion

▪ Burning wood briquettes can cause problems in combustion. In such cases, repairs mustbe carried out by qualified staff. Please contact Froling customer services or yourinstaller.

5.2.3 Non-permitted fuelsThe use of fuels not defined in the "Permitted fuels" section, and particularly theburning of refuse, is not permitted.

CAUTION

In case of use of non-permitted fuels:

Burning non-permitted fuels increases the cleaning requirements and leads to abuild-up of aggressive sedimentation and condensation, which can damage theboiler and also invalidates the guarantee. Using non-standard fuels can also leadto serious problems with combustion.

For this reason, when operating the boiler:❒ Only use permitted fuels

Note on standards

Notes on use

5 Start-upInitial startup


5.2.4 Heating up for the first time

NOTICE

If condensation escapes during the initial heat-up phase, this does not indicate afault.

❒ Tip: If this occurs, clean up using a cleaning rag.

CAUTION

If the boiler heats up too quickly on initial start-up:

If the output during the heating-up process is too great, cracks in the combustionchamber may appear as a result of drying out too rapidly!

For this reason the following applies the first time you heat up the boiler:❒ Carry out initial start-up of the firewood boiler with less amount of fuel

Boiler with Lambda control ❒ Open the insulated door and the fuel loading door❒ Fill the fuel loading chamber for initial start-up and heat up

NOTICE! See boiler operating instructions

Boiler with manual controller

AL

Verbrennungsluft / combustion air /

air de combustion / aria comburente /

aire de combustión

A19000015

PL SL

❒ 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 Short split wood Long split wood Short split wood

w > 20% w < 20% w > 20% w < 20% w > 20% w < 20% w > 20% w < 20%

20 – 30% 30 – 40% 50 – 60% 60 – 70% 20 – 30% 30 – 40% 50 – 60% 60 – 70%

If you use wood briquettes for initial start-up (only permitted under certain conditions!),you can use roughly the same settings as for short split hardwood.The table shows the setting values for the manual controller of the air flap, whichensures a smooth start-up. The setting values for the manual controller may need tobe changed during emissions measurements. For this reason, these values should notbe used as standard values for operating the boiler! The terms used, i.e. “long split wood” (edge length EL > 10 cm) and “short split wood”(edge length EL < 10 cm), have been defined in these instructions by Froling; there isno fuel standard or similar guidelines. ❒ Open the insulated door and the fuel loading door❒ Fill the fuel loading chamber for initial start-up and heat up

NOTICE! See boiler operating instructions Tip: Line the first 20 cm of the fuel loading chamber with short split wood (edge lengthEL < 10 cm). This reduces the time taken for a bed of embers to form.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 ifnecessary after measuring the O2 content:

5 Start-upInitial startup


Setting the combustion air

The nominal output of the boiler is set via the primary air and adjusted to the fuelused.The secondary air sets the O2 content of the flue gas and thus the quality ofcombustion. Therefore:

Combustion air Effect Setting

More primary air

Less secondary air

Higher flue gas temperature, greater outputLess O2 content

Turn manual controller direction 0%(anti-clockwise)

Less primary air

More secondary air

Lower flue gas temperature, lower outputMore O2 content

Turn manual controller direction100% (clockwise)

NOTICE! The manual controller should be set so that the O2 content is between 7 and9%. ❒ Once the manual controller has been correctly set, secure it in that position

After starting up for the first time and once the combustion air has been set, the boileris optimally set to the fuel used.For further use of the boiler, please note the following:❒ Use fuels that are consistent in size, type and water content❒ If a very different type of fuel is used, get a qualified technician to check the air

flap setting and adjust if necessary



6 Decommissioning

6.1 MothballingThe following measures should be taken if the boiler is to remain out of service forseveral weeks (e.g. during the summer):❒ Clean the boiler thoroughly and close the doors fully

If the boiler is to remain out of service during the winter:❒ Have the system completely drained by a qualified technician

➥ Protection against frost

6.2 DisassemblyTo disassemble the system, follow the steps for assembly in reverse order.

6.3 Disposal❒ Ensure that they are disposed of in an environmentally friendly way in accordance

with waste management regulations in the country (e.g. AWG in Austria)❒ You can separate and clean recyclable materials and send them to a recycling

centre.❒ The combustion chamber must be disposed of as builders' waste.

6 DecommissioningMothballing


7 Appendix

7.1 Pressure equipment regulation

Appendix 7Pressure equipment regulation


7.2 Technical specifications - Lambda control with partial load values

Description S1 Turbo 20 / S1 Turbo F

Nominal heat output / range kW 20 / 10 - 20

Electrical connection 230V / 50Hz / fused C16A

Power consumption at nominal load W 42

Power consumption in slumber mode 3

Weight of boiler incl. insulation and control kg 465

Total boiler capacity (water) l 90

Water pressure drop (ΔT = 10 / 20 K) mbar 8.3 / 1.5

Minimum boiler return temperature °C 60

Maximum permitted operating temperature 90

Permitted operating pressure bar 3

Airborne sound level dB(A) < 70

Permitted fuel as per EN 14961 Part 5: Firewood class A2 / D15 L50

Fuel loading door dimensions (width / height) mm 350 / 360

Fuel loading chamber capacity l 80

Combustion time 1) - Beech h 3.5 - 5.0

Combustion time1) - Spruce 2.1 - 3.01.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%)

Regulation (EU) 2015/1187

Energy efficiency A+

Rated heat output kW 20

Energy efficiency index of the boiler model 116

Seasonal space heating energy efficiency % 78

Energy efficiency index of the boiler in package withtemperature control

118

Energy efficiency class of the boiler in package withtemperature control

A+

7 AppendixTechnical specifications - Lambda control with partial load values


Description S1 Turbo 20 / S1 Turbo F

Testing institute TÜV Austria1)


Date of issue 21/06/2013

Boiler class as per EN 303-5:2012 4

Boiler efficiency % 92.01.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

Test data - Emissions in [mg/MJ]1) (nominal load/partial load)

Carbon monoxide (CO) mg/MJ 51 / 391

Nitrogen oxide (NOx) mg/MJ 88 / 84

Organic hydrocarbons (OGC) mg/MJ 3 / 19

Dust mg/MJ 10 / 81.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m³]1) (nominal load/partial load)

Carbon monoxide (CO) mg/m³ 75 / 574

Nitrogen oxide (NOx) mg/m³ 129 / 123

Organic hydrocarbons (OGC) mg/m³ 5 / 28

Dust mg/m³ 15 / 111.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%

Test report data -Lambda Control

Appendix 7Technical specifications - Lambda control with partial load values


7.3 Addresses

7.3.1 Address of manufacturer

FRÖLINGHeizkessel- und Behälterbau GesmbH Industriestraße 12A-4710 GrieskirchenAUSTRIA TEL 0043 (0)7248 606 0FAX 0043 (0)7248 606 600INTERNET www.froeling.com

7.3.2 Address of the installer

Stamp

7 AppendixAddresses


Documents

Firewood boiler S1 Turbo - PTH Hout CV · Installation Instructions Firewood boiler S1 Turbo Translation of the original German installation instructions for technicians Read and