Fröling S3 Turbo User manual

Froling Heizkessel- und Behälterbau Ges.m.b.H, Industriestraße 12, A-4710 Grieskirchen
Tel [phone] Fax [phone] [email protected] www.froeling.com
4
Assembly Instructions
S3 Turbo
Read and follow the operating instructions and safety information!
Subject to technical change!

Table of Contents
1 Safety 5
1.1 Explanation of symbols 5
1.2 Permitted Uses 7
1.3 Requirements at the place of installation 8
1.3.1 Approval for the heating system 8
1.3.2 Space required 8
1.3.3 Requirements for central heating water 9
1.3.4 Ventilation requirement for boiler room 10
1.3.5 Requirements for the heating system 10
1.3.6 Requirements for the boiler room 10
1.3.7 Combination with thermal storage 11
1.3.8 Return temperature control 11
1.3.9 Requirements for the chimney connection 12
Basic data for designing the chimney connection 12
1.4 Safety markers 13
1.4.1 Mandatory signs 13
1.4.2 Prohibitions 15
1.4.3 Warning signs 15
1.4.4 Signage on the boiler 16
Notice of risks during installation 16
Notice of risks during operation 17
Notice regarding procedures in an emergency 18
1.5 Residual risks 19
1.5.1 Basic risks 19
1.5.2 Risks from electricity 19
1.5.3 Danger from fire and explosion 20
1.5.4 Danger from high temperatures 22
1.5.5 Risks from flue gases, lubricants and other equipment 23
1.6 What to do in the case of danger 24
1.7 Staff requirements 25
1.8 Personal protective equipment 27
1.9 Replacement parts 28
1.10 Environmental protection 29
1.11 The operator's responsibilities 30
2 Technology 31
2.1 Dimensions 31
2.2 Components and connections 32
2.3 Technical data 33
3 Assembly 34
3.1 Materials supplied 34
3.1.1 Tools required 34
3.2 Positioning 35
3.2.1 Temporary storage 35
3.3 Setting up in the boiler room 36
Table of Contents
2 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com

3.3.1 Remove boiler from pallet 36
3.3.2 Moving the boiler in the boiler room 36
3.3.3 Space required 37
3.4 Before Installation 37
3.4.1 Changing door stops (as needed) 37
Converting the fuel loading door 39
3.4.2 Fitting the door handles 40
3.4.3 Set and check the seal on the doors 40
Adjusting the doors 42
3.5 Installing the boiler 43
3.5.1 Assembly overview 43
Insulation 43
Air duct system 45
WOS system S3 Turbo 30 46
EOS system S3 Turbo 50 47
3.5.2 Fit flue gas pipe nozzle and the induced draught fan 48
3.5.3 Installing the pneumatic rods for the primary and secondary air 48
3.5.4 Final steps before insulating 50
3.5.5 Installing the insulation 50
3.5.6 Fitting the door contact switch 53
3.5.7 Installing the back panel 53
3.5.8 Aligning the insulation and attaching the controller 54
3.5.9 Installing the cleaning door and blank cover 56
3.5.10 Installing the insulated door 56
3.5.11 Fitting the sensors 59
3.5.12 Fit the broadband probe 60
3.5.13 Installing the WOS system 61
3.5.14 Installing the servo-motors 62
3.6 Power connection and wiring 63
3.6.1 Wiring the ID fan 64
3.6.2 Wiring 64
3.6.3 Information on circulating pumps 65
Connecting a squirrel cage standard pump 65
Connecting a high efficiency pump 66
3.6.4 Final installation steps 67
4 Start-up 68
4.1 Before commissioning / configuring the boiler 68
4.2 Initial startup 69
4.2.1 Permitted fuels 69
4.2.2 Non-permitted fuels 70
5 Decommissioning 71
5.1 Mothballing 71
5.2 Disassembly 71
5.3 Disposal 71
6 Appendix 72
6.1 Hydraulic diagram 72
6.2 Addresses 73
6.2.1 Address of manufacturer 73
6.2.2 Address of importer 73
6.2.3 Address of Local Dealer 73
Table of Contents
Montageanleitung S3 Turbo | M1870119_en-us 3

Supplementary instructions
These instructions ensure safe and efficient use of the S3 Turbo (hereinafter referred
to as the “system"). These instructions are a component part of the system and must
be kept next to the system and within the immediate reach of staff at all times.
Staff must carefully read and understand these instructions before commencing all
work. All the safety instructions and operating guidelines specified in this manual must
be observed to ensure safety at work. In addition, the local accident prevention
regulations and general safety regulations apply to the area of application of the
system.
Images in these instructions are intended solely to aid understanding and may differ
from the actual design.
NOTICE
SAVE THESE INSTRUCTIONS!
Copyright
This instruction manual is protected by copyright.
This instruction manual must not be transferred to third parties, reproduced in any
form – even excerpts thereof – or the contents used and/or disclosed without the
written consent of Froling Ges.m.b.H. (hereinafter “manufacturer”), unless for internal
purposes. Failures to comply with this shall incur damages. The manufacturer
reserves the right to assert further claims.
The manufacturer holds the copyright.
© Froling Ges.m.b.H.
Supplementary instructions
4 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com

1 Safety
1.1 Explanation of symbols
Safety information
Safety information in these instructions is indicated by symbols. The safety information
is preceded by signal words which reflect the extent of the risk.
DANGER
This symbol and signal word combination indicates a hazardous situation which
will lead to death or serious injury if it is not avoided.
WARNING
This symbol and signal word combination indicates a hazardous situation which
could lead to death or serious injury if it is not avoided.
CAUTION
This symbol and signal word combination indicates a hazardous situation which
could lead to slight or minor injuries if it is not avoided.
NOTICE
This signal word indicates important, but not safety-related information e.g.
damage to property or pollution
Safety information in operating instructions
Safety information can refer to certain, individual operating instructions. To avoid
disrupting the flow of the text when you are performing the action, this safety
information is not incorporated in the operating instruction. The signal words set out
above are used.
Example:
❒ Undo screw
❒CAUTION! Pinching hazard at cover
Take care when closing the cover.
❒ Tighten the screw
Safety 1
Explanation of symbols
Montageanleitung S3 Turbo | M1870119_en-us 5

Special safety information
The following symbols are used to draw your attention to particular hazards
Tips and recommendations
Italics indicate useful tips and recommendations as well as information for efficient and
smooth running.
Other markers
The following markers are used in these instructions to highlight operating guidelines,
results, lists, references, and other elements:
Marker Explanation
❒ Step-by-step operating instructions
➥ Results of actions
▪Lists without a specified order
[Button] Operating elements (e.g. button, switch),
display elements (e.g. signal lights)
“Display“ Screen elements (e.g. buttons, assignment of
function keys)
Units used
All units of measure are specified in these operating instructions in both SAE units and
SI units. The SAE unit appears first, followed by the SI unit in brackets.
Example using information about heat output: 17 (5) BTU/h (kW) equals
17 BTU/h (SAE system) or 5 kW (SI system).
1Safety
Explanation of symbols
6 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com

1.2 Permitted Uses
The S3 Turbo boiler is designed exclusively for heating domestic water. Only use
those fuels specified in the “Permitted fuels” section.
Permitted use includes compliance with all the specifications in this instruction
manual.
Any use other than or above and beyond the permitted use is considered misuse.
WARNING
Danger of misuse
❒Do not install the system in a mobile home.
❒ Do not operate the system in an explosive atmosphere.
❒ Keep the air inlet to the boiler room clear at all times.
❒ Only use fuels permitted by the manufacturer.
❒ Never store flammable materials close to the boiler.
❒ Never set flammable objects on the boiler to dry (e.g. clothing).
❒ Do not use any hydrogen halides or cleaning agents containing chlorine in the
boiler installation room.
❒ Keep covers and doors closed during operation.
❒ The chimney is only to be used as an outlet for one heating system.
❒ Do not use the hot water directly in swimming pools or thermal baths and do
not use as drinking water.
❒ Do not alter the boiler controller.
❒ DO NOT BURN GARBAGE, GASOLINE, NAPHTA, ENGINE OIL OR OTHER
INAPPROPRIATE MATERIALS.
❒ DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE.
❒ DO NOT OPERATE WITH FLUE DRAFT EXCEEDING 0.12 INCHES WATER
COLUMN (30 Pa).
❒ UNSAFE TO ADJUST FLUE DRAFT HIGHER THAN 0.12 INCHES WATER
COLUMN (30 Pa).
❒ THE HEAT EXCHANGER, DRAFT INDUCES, FLUE PIPE, AND CHIMNEY
MUST BE CLEANED REGULARLY TO REMOVE ACCUMULATED
CREOSOTE AND ASH. ENSURE THAT THE HEAT EXCHANGER, FLUE
PIPE, AND CHIMNEY ARE CLEANED AT THE END OF HEATING SEASON
TO MINIMIZE CORROSION DURING THE SUMMER MONTHS. THE
APPLIANCE, FLUE PIPE, AND CHIMNEY MUST BE IN GOOD CONDITION.
THESE INSTRUCTIONS ALSO APPLY TO A DRAFT INDUCER IF USED.
➥Misuse of the boiler can create hazardous situations.
Safety 1
Permitted Uses
Montageanleitung S3 Turbo | M1870119_en-us 7

1.3 Requirements at the place of installation
1.3.1 Approval for the heating system
The appropriate supervisory authority (inspection agency) must always be informed
when installing or modifying a heating system, and authorization must be obtained
from the building authorities. Also observe ANSI/NFPA 211 and CAN/CSA B365 for
the installation.
1.3.2 Space required
FOR SAFE INSTALLATION AND OPERATION CLEARANCES TO COMBUSTIBLES
MUST BE MAINTAINED.
The diagram below shows how much space is required for the system in the boiler
room.
The boiler may only be installed on non-combustible floors with these clearances.
Dimens
ion
Name S3 Turbo
ADistance - front of boiler to wall 36“ (900 mm)
BDistance – side of boiler to wall 32“ (800 mm)
CDistance – back to wall 14“ (350 mm)
DDistance – side of boiler to wall 9“ (250 mm)
Distance between ceiling and boiler 18“ (460 mm)
1Safety
Requirements at the place of installation
8 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com

1.3.3 Requirements for central heating water
Water quality
Water of the following quality is required for the first fill:
▪ The water must be clean, pure or purified as well as odorless and must not contain
suspended matter.
▪ The water hardness must not exceed 190 grain/fl.oz. or 100 ppm CaCO3
(100 mg/L), i.e. soft water is required.
▪ The chlorine concentration in the water must not exceed 58 grain/fl.oz. (30 mg/L).
▪ The pH value in the heating system must be between 8.0 and 8.6.
▪ If the water quality is too poor, use additives to prepare the water. If you are
topping up with small amounts, always use clean water.
NOTICE
The hot water must not be used directly in swimming pools or thermae. Use a
heat consumer of the right size to consume the heat. Do not use the heating
water as drinking water.
To ensure good water quality during operation, avoid leaks and use a closed heating
system. If necessary, use a return temperature control.
First fill
To prevent air from getting into the heating system during the first fill, fill the filling
hose with water.
Frost protection
You can add anti-freeze to the heating water, however, this can reduce the heating
efficiency. Always follow the manufacturer’s dosing instructions when using anti-
freeze, as using the incorrect amount can cause corrosion. Check the concentration of
the anti-freeze at regular intervals.
Safety 1
Requirements at the place of installation
Montageanleitung S3 Turbo | M1870119_en-us 9

1.3.4 Ventilation requirement for boiler room
Introduction
The external combustion air must meet certain requirements to ensure that adequate
combustion air is supplied to the boiler and no by-products from the combustion get
into the boiler room.
Ventilation air for the boiler room must be taken from and expelled directly outside,
and the openings and air ducts must be designed to prevent weather conditions (e.g.
from foliage or snowdrifts), plants or animals from obstructing the air flow. Permanent
ventilation is required to ensure that the boiler runs smoothly.
In North America there are several regulations which govern the minimum
requirements of combustion air for chimneys.
The boiler must be installed in such a way that it receives adequate ventilation and
combustion air and that the fuel in the boiler burns. The exhaust air must be expelled
safely outside via the chimney and maintained within a safe temperature range.
Boiler rooms are usually so small that normal ventilation does not provide enough air
and air must be brought in from outside. External air openings and air channels must
be of an appropriate size to supply adequate combustion air. The design must comply
with NFPA 211.
Consult your local chimney inspector for the installation and install the boiler in
accordance with the applicable local regulations.
Recommended size of air openings according to NFPA 54 and NFPA 211:
The boiler requires a fresh air supply of between 1 sq.in. per 2,500 BTU/h and
1 sq.in. per 4,000 BTU/h (550 mm²/kW and 880 mm²/kW), depending on local
conditions and the climate zone. Local conditions may necessitate an additional air
supply.
1.3.5 Requirements for the heating system
▪ The whole heating system must be designed in accordance with relevant national
and local regulations.
▪The boiler’s nominal load must be adjusted to the calculated heating requirements
of all the consumer loads connected in the heating circuit in summer and winter.
▪ The heating system must be big enough to transport the heat generated by the
boiler and an additional heat source (if present). The pressure throughout the
whole system including all heating zones must be even.
▪ Special equipment must be available for filling and ventilating the heating circuit.
Flow valves and zone valves must be fitted to set the correct water flow volume.
▪ All fitted pipes must be water-tight and air-tight and safely insulated.
▪ If there is a risk of parts of the heating system freezing, add anti-freeze to the
water in these heat zones.
1.3.6 Requirements for the boiler room
▪ 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.
1Safety
Requirements at the place of installation
10 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com

▪ There is no lighting on the boiler. Therefore, the customer must provide sufficient
lighting in the boiler room in accordance with national workplace design
regulations.
▪Always consult the manufacturer when using the boiler at more than 2000 meters
above sea level.
▪ Always keep the air suction opening of the boiler free from dust.
▪ The boiler room must be at least (mm) high.
1.3.7 Combination with thermal storage
Your S3 Turbo boiler must be installed with a Thermal Storage System. The purpose
of the thermal storage system is to absorb heat produced by the boiler if the building
load cannot use all of the heat being produced. This means that the boiler will be
batch fired. Batch firing requires that the boiler only be loaded with fuel and ignited
when the thermal storage temperature is depleted adequately so that it can absorb the
energy produced from the next fire. There may be some instances when the heating
load will use all of the heat being produced by the boiler. In such cases, the boiler may
be loaded continuously.
Your boiler is equipped with a timer that provides feedback about how many hours of
run time (active burning) or slumber time (boiler is stopped because no heat is being
taken from it) are accumulating. Slumber hours should be minimized as much as
possible. If you find slumber hours increasing, it is likely that you are over-filling the
boiler with wood and it is cycling on and off rather than having continuous run times.
Over filling the boiler may result in corrosion of the firebox wall, damage to the
combustion chamber, damage to the firebox aprons, soot accumulation in the heat
exchange and dirty emissions.
Your thermal storage system may require periodic maintenance. Please review the
periodic maintenance requirements of your thermal storage system with your installer.
1.3.8 Return temperature control
It is recommended you fit a return temperature control when installing the heating
system. If the hot water return is below the minimum return temperature, some of the
hot water outflow will be mixed in via the return temperature control.
NOTICE
Risk of dropping below dew point/condensation formation if operated without
return temperature control.
The manufacturer stipulates using a return temperature control. The minimum
return temperature is 140°F (60°C). It is recommended you fit some kind of
control device (e.g. thermometer). The controller of the return temperature control
can be integrated in the boiler controller.
❒ Condensation water forms an aggressive condensate when combined with
combustion residue, leading to damage to the boiler. If the outside
temperature is low, condensation water can freeze at the chimney outlet,
which can result in inadequate chimney escape, limited boiler output and a
system breakdown.
Safety 1
Requirements at the place of installation
Montageanleitung S3 Turbo | M1870119_en-us 11

1.3.9 Requirements for the chimney connection
The chimney connection must be big enough to channel flue gases from the building.
The whole flue gas system must be designed to prevent possible seepage, insufficient
feed pressure and condensation.
The manufacturer recommends fitting a draft regulator to limit the pressure to 0.12
inch WC (30 Pa). The draft regulator should be fitted directly on the chimney
connection where the pressure is very low.
The boiler must be connected to a brick chimney or a shop-made chimney in
accordance with UL 103 HT (ULC S629 in Canada). The chimney must be clean and
in good condition at the time of installation.
The pipe unions within the chimney must be made of stainless special steel (with 304,
316 or 321 alloys). The flue gas connection pipe must be made of untreated steel or
stainless steel with a thickness of 24 Gauge. The minimum rise of the pipe must be ¼"
per foot for the progression towards the chimney. The chimney and the flue gas
connection pipe must have a diameter of at least 6" (150 mm). The individual pipe
sections must be joined together with at least three self-tapping screws and the joins
sealed using high-temperature silicone. The flue gas pipe must not contain more than
two 90° bends.
All connections must conform to NFPA 211. Consult your local chimney sweep for the
installation and install the boiler in accordance with the applicable local regulations.
The chimney connection, ventilation ducts and fresh air openings must not be closed
over or blocked.
The flue gas pipe must not be displaced by an attic, loft, fuel store or similar areas.
Basic data for designing the chimney connection
Description S3 Turbo
30 50
Flue gas temperature at nominal load °C 220 220
°F 430 430
Flue gas temperature at partial load °C 150 150
°F 300 300
Flue gas mass flow at nominal load kg/h 76 122
lb/h 167 270
Flue gas mass flow at partial load kg/h 43 65
lb/h 95 143
Required feed pressure at nominal load Pa 8 8
in WC 0.03 0.03
Maximum permissible feed pressure Pa 30 30
in WC 0.12 0.12
Flue pipe diameter mm 150 150
inches 6 6
1Safety
Requirements at the place of installation
12 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com

CAUTION
ADJUSTMENT OF THE FLUE DRAFT HIGHER THAN 0.12 INCHES WATER
COLUMN (30 Pa) COULD CAUSE A FIRE TO BURN OUT OF CONTROL AND
AN UNSAFE CONDITION!
❒Maximum permitted setting: 0.12 inches WC (30 Pa)
Ideal setting: 0.04 inches WC (10 Pa)
1.4 Safety markers
WARNING
Danger if signage is illegible!
❒Ensure that all safety, warning and operating instructions are always in a
clearly legible condition.
❒ Replace damaged stickers and signs immediately.
➥Over time stickers and signs can get dirty or otherwise unrecognizable
which means that dangers cannot be identified and the necessary
operating information cannot be observed. This poses a risk of injury.
The following stickers are located in the work area. They refer to the area immediately
surrounding where they are affixed.
1.4.1 Mandatory signs
Refer to the operating instructions
Only use the indicated system once you have read the operating instructions.
Wear hearing protection
This sign indicates that hearing protection must be worn in the area concerned.
Wear protective gloves
This sign indicates that protective gloves must be worn in the area concerned.
Wear safety shoes
This sign indicates that safety shoes must be worn in the area concerned.
Wear a dust mask
This sign indicates that a dust mask must be worn in the area concerned.
Keep the doors closed
Keep the doors closed during operation.
Turning off the main switch
Switch off the main switch and take precautions to prevent accidental switching on
before carrying out work to the system
Safety 1
Safety markers
Montageanleitung S3 Turbo | M1870119_en-us 13

Switch off the main switch for the fuel infeed and take precautions to prevent
accidental switching on before entering the fuel storage room.
Securing the main switch
Switch off the main switch and secure with a padlock when carrying out maintenance
work to the boiler.
1Safety
Safety markers
14 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com

1.4.2 Prohibitions
Unauthorized access prohibited
Only persons authorized by the operator may enter the danger zone and fuel storage
room. Keep children away! Keep the fuel storage room locked and keep the access
key in a safe place. Protect the fuel from moisture.
No fire, open flames or smoking
Areas marked with this are at risk of fire or explosion. Keep ignition sources away from
these areas.
1.4.3 Warning signs
Automatic start-up
This sign indicates that there is a risk of the system starting up automatically. Work
may only be carried out in areas with this marking if the system has been secured.
Electric current
Only licensed electricians may work in workspace with this marking.
Unauthorized persons are not permitted to enter work areas with this marking or open
the cabinet with this marking.
Harmful or irritant materials
These materials can be irreparably harmful to health, trigger allergic reactions or
irritate the mucous membranes.
Observe the information on the packaging and containers.
Danger from carbon monoxide
There is a risk of poisoning from a possible concentration of carbon monoxide in the
fuel storage room and boiler room. Ventilate the fuel storage room for at least
15 minutes before entering. Two people must always be present when working in the
fuel storage room. The access door must be kept open at all times. Also wear a dust
mask because of the high dust levels.
Hand injuries
Keep hands away from areas bearing this warning.
There is a risk that your hands could get trapped, pulled in or otherwise injured.
Hot surfaces
Hot surfaces, such as hot system parts, may not always be obvious. Do not touch
these parts without protective gloves.
Risk of falling
There is a risk of falling in the fuel store because of slippery surfaces or fuel lying
about. Take extreme care and wear personal protective equipment.
Risk of injury at fans
Keep hands away from areas bearing this warning.
There is a risk that your hands could get trapped, pulled into or otherwise injured in
automatic fans.
Safety 1
Safety markers
Montageanleitung S3 Turbo | M1870119_en-us 15

1.4.4 Signage on the boiler
Notice of risks during installation
S3 Turbo - WOOD FIRED GASIFICATION HYDRONIC FURNACE
A 851 02 19 - T249260
INSTALLATION HAZARDS
Install, modify and use only in accordance with manufacturer’s manuals. Refer to authorities having jurisdiction for
proper installation. Contact local building and fire officials about restrictions and installation inspection in your area. If
there are no applicable local codes, follow ANSI/NFPA 211 and CAN/CSA B365. Special precautions are required
for passing the chimney through a combustible wall or ceiling.
Inspect and clean exhaust system, loading chamber, burning chamber, ash-pits, and heat exchanger frequently in
accordance with owner’s manual.
Basic boiler data for layout of chimney system S3 Turbo
Quantity Unit 30 50
051/022051/022C°erutarepmetsageulF
003/034003/034F°daollaitrap/detaR
56/22134/67h/gkwolfssamsageulF
341/07259/761h/bldaollaitrap/detaR
)nmulocretawsehcni30.0(aP8noitcennocsageulfsreliobtatfardmuminiM
)nmulocretawsehcni21.0(aP03noitcennocsageulfsreliobtatfardmumixaM
)sehcni6(mm051retemaiDrotcennocsageulF
)F°091(C°88erutarepmetretawmumixaM
)isp03(rab2erusserpgnikrowelbawollamumixaM
)isp72.76(rab5.4erusserPtseT
Mimimum Pressure Relief Valve )h/utB000,535(Wk551yticapaC
For detailed design information please refer to Installation Manual!
For unit specifications, see the plaque located directly on the boiler!
DANGER!
Working on electrical components may cause severe injuries from electric shocks!
WARNING!
The electrical system of the boiler shall be supplied from a double 115 V 60 Hz (nominal 230 V AC) 15 amp
branch circuit including neutral and earth connection. For wiring instructions please refer to installation Manual!
Chimney must be 6’’ (150 mm) diameter listed UL-103 HT or ULC-S629 residential all-fuel type or tile-lined
masonry. Flue connector pipe must be 6’’ (150 mm) diameter made of a minimum 24 MSG black steel.
Inadequate design, installation and maintenance of the flue gas system will lead to insufficient chimney draft and
could result in Danger of Life or Severe Injury caused by serious faults in combustion, e.g. explosivel
y
combustion of carbonization gases and flash fires!
This boiler requires fresh air for safe operation and must be installed so there are provision for adequate
combustion and ventilation air!
CAUTION!
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE!
LOAD FUEL CAREFULLY OR DAMAGE WILL RESULT.
REFER TO OWNER´S MANUAL. DO NOT ALTER THIS EQUIPMENT IN ANY WAY.
UNSAFE TO ADJUST FLUE DRAFT HIGHER THAN 0.12 INCHES WATER COLUMN (30 Pa).
MAY BE CONNECTED TO AN EXISTING BOILER SYSTEM.
Flooring must be a minimum 3/8’’ (10 mm) non-combustible material covering the installation clearance area! The
base shall be horizontally, planar and reinforced if required. For construction of base please mind the weight o
f
boiler, water content and wood fuel according Installation Manual!
This boiler is not for use with an automatic stoker
Connection to an existing boiler system in combination with heat storage only!
Use original spare parts only. Installation of non-licensed replacement parts will void the warranty!
1Safety
Safety markers
16 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com

Notice of risks during operation
S3 Turbo - WOOD FIRED GASIFICATION HYDRONIC FURNACE
A 852 01 16
OPERATION HAZARDS
NOTICE! Burn Wood only, max. length 21'' (51cm)!
Load fuel carefully or damage will result!
Build the wood fire directly on the boiler Fuel Loading Chamber refractory floor!
Do not use small pieces or wood waste that could fall through the center slot in the refractory.
DANGER! Risk of Fire or Explosion!
Do not burn garbage, gasoline, drain oil or other flammable liquids.
DO NOT BURN GARBAGE, GASOLINE, NAPHTA, ENGINE OIL, OR OTHER INAPPROPRIATE MATERIALS!
Do not use chemicals to start up unit firing.
DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE.
Use of inappropriate fuels can result in Danger of Life or Severe Injury caused by explosive combustion and flash
fires!
Burning fuels other than designated will void the warranty!
DANGER! Explosive Gases!
Never open Combustion Chamber Door, Ash-Pit Door, Ash-Pit Cask Cover or Heat Exchanger Cask Cove
r
during operation or refueling!
Faulty operation of boiler system will cause Danger of Life or Severe Injury and Material Damage!
Flue gases can cause fatal poisoning! In case of strong smell of flue gas:
1. For safety keep all boiler doors and ash-pit doors tightly closed!
2. Air the room where boiler is installed!
3. Close the door of the boiler room and doors to living areas!
WARNING! Risk of Fire!
KEEP ALL BOILER DOORS, FUEL STORAGE DOOR AND ALL COVERS TIGHTLY CLOSED DURING
OPERATION!
AFTER OPENING BOILER DOORS OR COVERS CLOSE ALL DOORS, COVERS AND CASING TIGHTLY!
DO NOT OPERATE WITH FLUE DRAFT EXCEEDING 0.12 INCHES WATER COLUMN (30 Pa)!
UNSAFE TO ADJUST FLUE DRAFT HIGHER THAN 0.12 INCHES WATER COLUMN (30 Pa)!
THE HEAT EXCHANGER, DRAFT INDUCER, FLUE PIPE, AND CHIMNEY MUST BE CLEANED REGULARLY
TO REMOVE ACCUMULATED CREOSOTE AND ASH. ENSURE THAT THE HEAT EXCHANGER, FLUE PIPE,
AND CHIMNEY ARE CLEANED AT THE END OF HEATING SEASON TO MINIMIZE CORROSION DURING
THE SUMMER MONTHS. THE APPLIANCE, FLUE PIPE, AND CHIMNEY MUST BE IN GOOD CONDITION.
THESE INSTRUCTIONS ALSO APPLY TO A DRAFT INDUCER IF USED.
Do not store fuel, clothing, furniture or other combustible material within marked installation clearances!
Faulty operating conditions not complying with Owner’s Manual, such as insufficient combustion air, incorrect or
insufficient cleaning and maintenance or non-permitted fuel could result in Danger of Life or Severe Injury caused
by serious faults in combustion (e.g. spontaneous combustion of carbonization gases or flash fires)!
Inspect and clean appliance, flues and chimney regularly!
First firing during start-up of boiler system shall be carried out in accordance to Instruction Label at Fuel Loading
Chamber Door and in attendance of an authorized installer or manufacturer’s representative only! Disregarding o
f
warning may cause damage or explosion of combustion chamber and severe injuries unfavorably!
Gas performed during solid-fuel combustion may cause a small explosion when the boiler is refueled!
CAUTION! Hot surfaces!
Hot parts and the flue pipe can cause serious burns!
Do not touch during operation!
Maximum draft marked on nameplate!
Unauthorized access to the boiler room could result in personal injury and damage to property!
FOR SAFETY KEEP FIRING AND ASHPIT DOORS TIGHTLY CLOSED.
Keep children away!
Always use protective gloves while loading boiler or carry out other work on boiler! Also mind the risk of injuries
by splinters of fire wood!
Always use control handles when open boiler doors!
Insulate flue pipe or do not touch during operation!
Do not carry out maintenance when the boiler is hot!
Do not touch hot surfaces behind Insulation Door!
Safety 1
Safety markers
Montageanleitung S3 Turbo | M1870119_en-us 17

Notice regarding procedures in an emergency
S3 Turbo - WOOD FIRED GASIFICATION HYDRONIC FURNACE
A 853 01 16
HAZARDS DURING REFUELING AND EMERGENCY PROCEDURES
DANGER! In case of strong smell of flue gas!
Flue gases can cause fatal poisoning!
1. For safety keep all boiler doors and ash-pit doors tightly closed!
2. Air the room where boiler is installed!
3. Close the door oft he boiler room and doors to living areas!
DANGER! In the event of loss of electrical power!
- Do not open any Boiler or Ash-pit Door!!
- Do not load fuel into the boiler!
- Boiler Control automatically restarts after power fail restart
- One hour after power has returned, check system for normal operation and compare manometer reading to
initial settings. If system pressure is below, replenish water to the hydronic system according plumber’s
instructions.
DANGER! In the event of runaway fire!
- Turn off Emergency Switch, if installed.
- Do not open any Boiler or Ash-pit Door!
- DO NOT SWITCH OFF MAIN ISOLATOR AT CONTROL SYSTEM!
- In case no Emergency Switch is installed:
1. Open Insulation Door slightly and keep it opened
2. Push Arrow-Down Key at Boiler Control to switch off ID-Fan
3. Keep Insulation Door opened
4. Do not open Ash-pit Door or any Boiler Door behind Insulation Door
- When there is no more risk of runaway fire, turn on Emergency Switch and close Insulation Door and resume
to normal operation of the system.
To cool overheated boiler (over 220°F / 105°C)!
- Do not open any Boiler or Ash-pit Door!
- Turn all thermostats in your house to their highest temperature settings and open all windows.
- Open all hot water faucets.
- When boiler temperature has dropped below 180°F (82°C), reverse the above steps.
- In case Safety Temperature Limit Switch automatically has been activated please refer to Owner’s Manual.
1Safety
Safety markers
18 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com

1.5 Residual risks
1.5.1 Basic risks
Incorrect operation
WARNING
Risk of injury from operating the system incorrectly!
❒Modifications to the boiler controller must only be undertaken in consultation
with the manufacturer.
➥Modifying parameters on the boiler controller can cause malfunctions.
1.5.2 Risks from electricity
Electric current
DANGER
Risk of death from electrocution!
❒Only allow licensed electricians to carry out electrical work to the electrical
system.
❒ If the isolation gets damaged, switch off the power supply immediately and
have it repaired.
❒ Prior to commencing work to active parts, shut off electrical systems and
equipment so that they are no longer live and secure so that they remain off
for the duration of the work. Follow the five safety rules:
- Disconnect.
- Secure against switching back on.
- Check the system is no longer live.
- Earth and short circuit.
- Cover or shield any adjacent live parts.
❒ Never bypass or disable fuses. When replacing fuses, use the correct
amperage.
❒ Always lay lines and cables far away from hot surfaces.
❒ Use shielded cables when using frequency converters.
❒ Ensure that the system is properly earthed with a protective earth system.
Have all component assemblies checked at regular intervals to ensure the
correct earthing.
❒ Keep moisture away from live parts. This can cause short circuits.
➥Touching live parts can cause immediate death by electrocution. Damage
to the isolation or individual components can be perilous.
Safety 1
Residual risks
Montageanleitung S3 Turbo | M1870119_en-us 19

1.5.3 Danger from fire and explosion
Risk of fire and explosion
WARNING
Risk of fire and explosion around the boiler!
❒ DO NOT BURN GARBAGE, GASOLINE, NAPHTHA, ENGINE OIL OR
OTHER INAPPROPRIATE MATERIALS.
❒ DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE.
❒ DO NOT OPERATE WITH FLUE DRAFT EXCEEDING 0.12 INCHES WATER
COLUMN (30 Pa).
❒ UNSAFE TO ADJUST FLUE DRAFT HIGHER THAN 0.12 INCHES WATER
COLUMN (30 Pa).
❒ THE HEAT EXCHANGER, DRAFT INDUCER, FLUE PIPE, AND CHIMNEY
MUST BE CLEANED REGULARLY TO REMOVE ACCUMULATED
CREOSOTE AND ASH.
❒ DO NOT INSTALL IN A MOBILE HOME.
❒ Keep covers on the boiler and the access door to the storeroom closed during
operation.
❒ Smoking, fire and naked flames are not permitted in the store and boiler room.
❒ Do not store flammable materials in the boiler room.
❒ Do not set flammable objects on the boiler to dry (e.g. clothing).
❒ Always ensure that the boiler room is adequately ventilated.
❒ Maintain and inspect the heating system at the prescribed intervals. Ensure
that the chimney vent is cleaned regularly.
❒ Do not use any hydrogen halides or cleaning agents containing chlorine in the
boiler room.
❒ Observe the safety signs around the system.
➥Using the boiler incorrectly can cause fire or explosions.
1Safety
Residual risks
20 Froling GesmbH | A-4710 Grieskirchen | www.froeling.com