Fröling SP Dual compact 15 User manual

Operating Instructions
Dual fuel boiler SP Dual compact
Translation of the original German operating instructions for the operator
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
B1500319_en | Edition 19/05/2021
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Contents
1 General 5
1.1 SP Dual compact Product Overview 6
2 Safety 8
2.1 Hazard levels of warnings 8
2.2 Pictograms used 9
2.3 General safety information 10
2.4 Permitted uses 11
2.4.1 The Clean Air Act 1993 and Smoke Control Areas 11
2.4.2 Permitted fuels 12
Firewood 12
Wood pellets 13
2.4.3 Fuels permitted under certain conditions 13
Wood briquettes 13
2.4.4 Non-permitted fuels 14
2.5 Qualification of operating staff 14
2.6 Protective equipment for operating staff 14
2.7 Safety Devices 15
2.8 Residual risks 16
2.9 Emergency procedure 18
2.9.1 Overheating of the system 18
2.9.2 Smell of flue gas 18
2.9.3 Power failure / induced draught fan failure 19
2.9.4 Fire in the system 19
3 Notes for operating a heating system 20
3.1 Installation and approval of the heating system 20
3.2 General information for installation room (boiler room) 20
3.3 Requirements for central heating water 21
3.4 Notes for using pressure maintenance systems 23
3.5 Return lift 23
3.6 Combination with storage tank 24
3.7 Chimney connection/chimney system 24
4 Operating the system 25
4.1 Assembly and initial startup 25
4.2 Filling the pellet store 26
4.2.1 General advice for working in the store 26
4.3 Switching on the power supply 27
4.4 Before heating up the boiler 27
4.4.1 Operating the WOS lever 27
4.4.2 Reloading intervals when operating with storage tank 27
4.4.3 Determining the right amount of fuel 28
4.4.4 Fuel table 29
Contents
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4.4.5 Fill level in boiler 29
4.4.6 Reloading intervals when operating without storage tank or if the storage tank is too small 29
4.5 Heat up firewood manually 30
4.6 Ignite firewood with pellet unit once 31
4.7 Operate the boiler using the touch display 33
4.7.1 Overview of the touch display 33
Status display 34
Control icons 34
Display icons for froeling-connect/remote control 35
Navigation within the system menu 35
Changing parameters 37
Change time window 37
Quick menu 38
4.7.2 Select information displays 39
4.7.3 Switch pellet unit ON/OFF 41
4.7.4 Change boiler mode 42
4.7.5 Change date and time 42
4.7.6 Change desired DHW tank temperature 43
4.7.7 One-time extra loading of an individual DHW tank 43
4.7.8 One-time extra loading of all existing DHW tanks. 43
4.7.9 Set the heating curve of a heating circuit 44
4.7.10 Change room temperature (heating circuit without room temperature sensor) 45
4.7.11 Change room temperature (heating circuit with room temperature sensor) 45
4.7.12 Switch heating circuit mode 46
4.7.13 Lock display/switch user level 46
4.7.14 Change the name of the components 47
4.7.15 Configure the holiday program 48
4.8 Switch the boiler ON/OFF on the room console 49
4.9 Reloading firewood 50
4.10 Switching off the power supply 50
4.11 Boiler in combi mode 51
4.11.1 Switching on the boiler 51
4.11.2 How combi mode works 52
4.11.3 Switching off the boiler 52
4.12 Checking the ash level in the boiler 53
4.12.1 Removing ash 53
4.12.2 Cleaning the combustion grate 54
4.12.3 Empty the ash drawer of the pellet unit 54
5 Servicing the system 55
5.1 General information on servicing 55
5.2 Required tools 56
5.3 Maintenance work by the operator 57
5.3.1 Inspection 57
Checking the system pressure 57
Checking the thermal discharge safety device 57
Checking the safety valve 57
Checking the quick vent valve 57
5.3.2 Periodic inspection and cleaning 58
Cleaning the carbonisation gas duct 58
Checking the primary air openings 58
Cleaning the flue gas temperature sensor 59
Cleaning the flue gas pipe 60
Contents
Operating Instructions SP Dual compact | B1500319_en 3

Checking the draught controller flap 60
Cleaning the induced draught fan 60
Clean the heat exchanger pipes 61
Cleaning the grate and combustion chamber 63
Checking the seal on the doors 63
5.4 Maintenance work by technicians 65
5.4.1 Checking and cleaning the combustion grate 66
5.4.2 Cleaning the measurement line of the underpressure controller 68
5.4.3 Cleaning the Lambda probe 68
5.5 Servicing the condensing boiler heat exchanger (optional) 69
5.5.1 Inspecting the heat exchanger 69
5.5.2 Checking the condensation drain 71
5.6 Emissions measurement by chimney sweep or regulatory body 72
5.6.1 Starting the emissions measurement in pellet mode 72
5.6.2 Performing the emissions measurement in firewood mode 73
General information on measurement 73
Create the measurement conditions and perform the measurement 73
5.7 Replacement parts 74
5.8 Disposal information 74
5.8.1 Disposal of the ash 74
5.8.2 Disposal of system components 74
6 Troubleshooting 75
6.1 Carbonisation gas duct flap is stiff 75
6.2 General fault with power supply 76
6.2.1 Behaviour of system after a power failure 76
6.3 Extra cleaning of flue gas paths 76
6.4 Excessive temperature 78
6.5 Faults with fault message 78
6.5.1 Procedure for fault messages 79
7 Appendix 80
7.1 Addresses 80
7.1.1 Address of manufacturer 80
Customer service 80
7.1.2 Address of the installer 80
Contents
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1 General
Thank you for choosing a quality product from Froling. The product features a state-of-
the-art design and conforms to all currently applicable standards and testing
guidelines.
Please read and observe the documentation provided and always keep it close to the
system for reference. Observing the requirements and safety information in the
documentation makes a significant contribution to safe, appropriate, environmentally
friendly and economical operation of the system.
The constant further development of our products means that there may be minor
differences from the pictures and content. If you discover any errors, please let us
know: [email protected].
Subject to technical change.
Warranty and Guarantee Conditions
Our sale and delivery conditions will be applicable. These conditions have been made
available to customers, and customers have been made aware of them at the time of
order completion.
You can also find the guarantee conditions on the enclosed guarantee certificate.
General 1
Operating Instructions SP Dual compact | B1500319_en 5

1.1 SP Dual compact Product Overview
1Firewood boiler insulated door
1.1 Maintenance overview for firewood boiler
2Firewood boiler fuel loading door
3Firewood boiler combustion chamber door with inspection glass
4Pellet unit insulated door
5Pellet unit ashcan
6Lambdatronic SP 3200 boiler controller
7Control opening for inspecting the automatic quick vent valve
8Pellet unit insulating cover
9Lever of the heat exchanger cleaner (WOS system)
10 Heat exchanger cover: maintenance opening for cleaning the WOS system and heat
exchanger
11 Main switch
12 Service port
13 STL high-limit thermostat
14 Back insulating cover of firewood boiler
1General
SP Dual compact Product Overview
6 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

5.1
5.2
5.3
5.4
6.1 Large touchscreen showing operating statuses and parameters
6.2 Status LED to display the operating status ⇨ See "Status display" [page 34]
6.3 Brightness sensor for automatically adjusting the brightness of the display
6.4 USB port for connecting a USB stick for software updates
General 1
SP Dual compact Product Overview
Operating Instructions SP Dual compact | B1500319_en 7

2 Safety
2.1 Hazard levels of warnings
This documentation uses warnings with the following hazard levels to indicate direct
hazards and important safety instructions:
DANGER
The dangerous situation is imminent and if measures are not observed it will lead
to serious injury or death. You must follow the instructions!
WARNING
The dangerous situation may occur and if measures are not observed it will lead
to serious injury or death. Work with extreme care.
CAUTION
The dangerous situation may occur and if measures are not observed it will lead
to minor injuries.
NOTICE
The dangerous situation may occur and if measures are not observed it will lead
to damage to property or pollution.
2Safety
Hazard levels of warnings
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2.2 Pictograms used
The following symbols are used in the documentation and/or on the boiler to show
what is required and forbidden and to give warnings.
In accordance with the Machinery Directive, signs fitted directly within the danger area
of the boiler indicate immediate hazards or safety procedures. These stickers must not
be removed or covered.
Refer to the operating
instructions
Wear safety shoes
Wear protective gloves Turn off the main switch
Keep the doors closed Wear a dust mask
Work under the supervision of a
second person
Lock
Unauthorised access prohibited No fire, open flames or smoking
Warning - hot surface Warning - hazardous electrical
voltage
Warning - hazardous or irritant
materials
Warning - automatic boiler
startup
Warning of injury to fingers or
hands, automatic fan
Warning of injury to fingers or
hands, automatic screw
Warning of injury to fingers or
hands, gear/chain drive
Warning of injury to fingers or
hands, cutting edge
Hand injury warning Warning of injury from being
pulled into rotating shafts
Increased CO concentration
warning
Slipping hazard warning
Safety 2
Pictograms used
Operating Instructions SP Dual compact | B1500319_en 9

2.3 General safety information
DANGER
If the device is used incorrectly:
Incorrect use of the system can cause severe injury and damage.
When operating the system:
❒ Observe the instructions and information in the manuals
❒ Observe the details on procedures for operation, maintenance and cleaning,
as well as troubleshooting in the respective manuals.
❒ Any work above and beyond this (e.g. servicing) must be carried out by a
heating engineer approved by Fröling Heizkessel- und Behälterbau GesmbH
or by Froling customer services
WARNING
External influences:
Negative external influences, such as insufficient combustion air or non-standard
fuel, can cause serious faults in combustion (e.g. spontaneous combustion of
carbonisation gases or flash fires) which can in turn cause serious accidents!
When operating the boiler, please note the following:
❒ Instructions and information regarding versions and minimum values, as well
as standards and guidelines for heating components in the instructions must
be observed.
WARNING
Severe injuries and damage can be caused by an inadequate flue gas system.
Problems with the flue gas system, such as poor cleaning of the flue pipe or
insufficient chimney draught, can cause serious faults in combustion (such as
spontaneous combustion of carbonisation gases or flash fires).
Take the following precautions:
❒ Optimum boiler performance can only be guaranteed if the flue gas system is
functioning correctly.
2Safety
General safety information
10 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.4 Permitted uses
The Froling Dual fuel boiler SP Dual compact is designed solely for heating domestic
water. Only the fuels specified in the "Permitted fuels" section may be used.
⇨ See "Permitted fuels" [page 12]
The unit should only be operated when it is in full working order. It must be operated in
accordance with the instructions, observing safety precautions, and you should ensure
you are aware of the potential hazards. The inspection and cleaning intervals in the
operating instructions must be observed. Ensure that any faults which might impair
safety are rectified immediately.
The manufacturer or supplier is not liable for any damage resulting from non-permitted
uses.
Only original spare parts or specific alternative spare parts authorised by the
manufacturer may be used. Any kind of change or modification made to the product
will invalidate the manufacturer’s conformity with the applicable guideline(s). In such
cases, the product will need to undergo new hazard evaluation procedures by the
operator. The operator will then be fully responsible for the declaration of conformity
according to the valid guideline(s) for the product and will need to issue a
corresponding declaration for the device. This person will then assume all of the rights
and responsibilities of a manufacturer.
2.4.1 The Clean Air Act 1993 and Smoke Control Areas
Under the Clean Air Act local authorities may declare the whole or part of the district of
the authority to be a smoke control area. It is an offence to emit smoke from a
chimney of a building, from a furnance or from any fixed boiler if located in a
designated smoke control area. It is also an offence to acquire an „unauthorised
fuel“ for use within a smoke control area unless it is used in an „exempt“ appliance
(„exempted“ from the controls which generally apply in the smoke control area). The
Secretary of State for Environment, Food and Rural Affairs has powers under the Act
to authorise smokeless fuels or exempt appliances for use in smoke control areas in
England. In Scotland and Wales this power rests with Ministers in the devolved
administrations for those countries. Separate legislation, the Clean Air (Northern
Ireland) Order 1981, applies in Northern Ireland. Therefore it is a requirement that
fuels burnt or obtained for use in smoke control areas have been „authorised“ in
Regulations and that appliances used to burn solid fuel in those areas (other than
„authorised“ fuels) have been exempted by an Order made and signed by the
Secretary of State or Minister in the devolved administrations.
Further information on the requirements of the Clean Air Act can be found here: http://
smokecontrol.defra.gov.uk
Your local authority is responsible for implementing the Clean Air Act 1993 including
designation and supervision of smoke control areas and you can contact them for
details of Clean Air Act requirements.
The Froling SP Dual compact 15 and SP Dual compact 20 have been recommended
as suitable for use in smoke control areas when burning fuels as listed under
"Permitted fuels".
Safety 2
Permitted uses
Operating Instructions SP Dual compact | B1500319_en 11

2.4.2 Permitted fuels
Firewood
Firewood 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 for
Germany: 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 instead
of 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 from
elements, 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 table
shows, the water content of the firewood decreases the longer the wood is stored
depending on how dry and warm the storage location is. The ideal water content of
firewood is between 15 and 25%. If the water content falls below 15%, we recommend
you adjust the combustion control to the fuel.
Water content
Note on standards
Tips for
storing wood
2Safety
Permitted uses
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Wood pellets
Wood pellets made from natural wood with a diameter of 6 mm
EU: Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06
and/or: EN
plus / DIN plus certification scheme
General note:
Before refilling the store, check for pellet dust and clean if necessary.
TIP: Fit the Froling PST pellet deduster for separating the dust particles contained in
the return air
2.4.3 Fuels permitted under certain conditions
Wood briquettes
Wood briquettes for non-industrial use with a diameter of 5-10 cm and 5-50 cm long.
EU: Fuel as per EN ISO 17225 - Part 3:
wood briquettes class B / D100 L500 Form 1 - 3
Additional for
Germany: Fuel class 5a (§3 of the First Federal Emissions Protection Ordinance
(BImSchV) - applicable version)
▪ When burning wood briquettes use the settings for extremely dry fuel
▪Wood briquettes must be heated up with firewood as per EN ISO 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 briquettes
expand during combustion
▪ Even when using the settings for dry fuel, burning wood briquettes can cause
combustion problems. In such cases, repairs must be carried out by qualified staff.
Please contact Froling customer services or your installer.
Note on standards
Note on standards
Notes on
use
Safety 2
Permitted uses
Operating Instructions SP Dual compact | B1500319_en 13

2.4.4 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section, and particularly the
burning 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 a
build-up of aggressive sedimentation and condensation, which can damage the
boiler and also invalidates the guarantee. Using non-standard fuels can also lead
to serious problems with combustion.
For this reason, when operating the boiler:
❒ Only use permitted fuels
2.5 Qualification of operating staff
CAUTION
If unauthorised persons enter the Installation room:
Risk of personal injury and damage to property
❒ The operator is responsible for keeping unauthorised persons, in particular
children, away from the system.
Only trained operators are permitted to operate the unit. The operator must also have
read and understood the instructions in the documentation.
2.6 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations!
▪ For operation, inspection and cleaning:
–Suitable work wear
– Protective gloves
– Sturdy shoes
– Dust mask
2Safety
Permitted uses
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2.7 Safety Devices
6.5 BOILER OFF
(switches off the boiler to prevent overheating)
❒ Tap “Boiler off"
➥Automatic mode is switched off
➥Control follows the boiler shutdown procedure
➥Pumps continue to run
11 MAIN SWITCH
(switches off the power supply)
Before carrying out work on/in the boiler:
❒ Press the standby key
➥Automatic mode is switched off
➥Control system follows the boiler shutdown procedure
❒ Switch off the main switch and let the boiler cool down
13 SAFETY TEMPERATURE LIMITER (STL)
(protection against overheating)
The STL switches off the combustion system at a maximum boiler temperature of 105
°C. The pumps continue to run. Once the temperature falls below approx. 75°C, the
STL can be reset mechanically.
TA THERMAL DISCHARGE VALVE
(protection against overheating)
The thermal discharge valve opens at approx. 100°C and feeds cold water to the
safety heat exchanger to lower the boiler temperature
SV SAFETY VALVE
(protection against overheating/excess pressure)
When the boiler pressure reaches a maximum of 3 bar, the safety valve opens and the
heated water is blown off in the form of steam.
Safety 2
Safety Devices
Operating Instructions SP Dual compact | B1500319_en 15

2.8 Residual risks
WARNING
When the main switch is switched off in heating mode:
The boiler is not controlled. Any resulting boiler malfunctions can cause serious
injury and damage.
Take the following precautions:
❒ Allow the fire to burn out completely and let the boiler cool
➥ID fan switches off when "Off" status has been reached
(flue gas temperature < 80°C, boiler temperature < 65°C)
❒ Only then is it safe to switch off the main switch
WARNING
When touching hot surfaces:
Severe burns are possible on hot surfaces and the flue gas pipe!
When work is carried out on the boiler:
❒ Shut down the boiler according to procedure (“Off” operating status) and allow
it to cool down
❒ Protective gloves must usually be worn for work on the boiler, and it should
only be operated using the handles provided
❒ Insulate the flue gas pipes and do not touch them during operation
WARNING
When inspecting and cleaning the boiler with the main switch on:
Serious injuries possible due to automatic boiler startup!
Before inspection and cleaning work in/on the boiler:
❒ Switch the boiler off by tapping “Boiler off”
The boiler follows the shutdown procedure and switches to "Off“ mode
❒ Allow the boiler to cool for at least 1 hour
❒ Switch off the main switch and take precautions to prevent accidental
switching on
2Safety
Residual risks
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WARNING
If non-permitted fuel types are used:
Non-standard fuels can cause serious faults in combustion (e.g. spontaneous
combustion of carbonisation gases / flash fires) which can lead to serious
accidents!
Take the following precautions:
❒ Only use fuels specified in the "Permitted fuels" section of these operating
instructions.
WARNING
If you open the combustion chamber door/fuel loading door during operation:
This could result in injury, damage or flue gas generation!
Therefore:
❒ Never open the combustion chamber door during operation
❒ The fuel loading door must be kept closed during operation and may only be
opened briefly during reloading intervals
Safety 2
Residual risks
Operating Instructions SP Dual compact | B1500319_en 17

2.9 Emergency procedure
2.9.1 Overheating of the system
If the system overheats and the safety devices fail to operate, proceed as follows:
NOTICE! Do not under any circumstances switch off the main switch or disconnect the
power supply.
❒Keep all the doors on the boiler closed
❒ Open all mixing valve taps, switch on all pumps.
➥The Froling heating circuit control takes on this function in automatic operation.
❒ Leave the boiler room and close the door
❒ Open any thermostatic valves on the radiator and ensure sufficient heat
dissipation from the rooms
If the temperature does not drop:
❒ Contact the installer or Froling customer services
2.9.2 Smell of flue gas
DANGER
If you smell flue gas in the boiler room:
Inhaling toxic flue gas can potentially be fatal!
If you smell flue gas in the room where the boiler is installed:
❒ Keep all the doors on the boiler closed
❒ Ventilate the room where the boiler is installed
❒ Close the fire door and doors to living areas
❒ Allow the fire to burn out completely and let the boiler cool
Recommendation: Do not install smoke alarms and carbon monoxide detectors near
the system.
2Safety
Emergency procedure
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2.9.3 Power failure / induced draught fan failure
A power failure, among others, can be identified based on the following points:
▪Display remains dark despite touching it
▪ LED status does not flash / light up
▪ No noise from the units (e.g. induced draught fan) can be heard
If the induced draught fan fails when there is power supply, the display shows the
error message “ID fan does not rotate, in spite of full
activation”.
DANGER
In the event of a power failure or induced draught fan failure during heating mode:
The boiler is placed in an uncontrolled state. Life-threatening injury is possible
when opening the doors.
What to do in the event of a power failure / induced draught fan failure:
❒ Keep all the doors on the boiler closed
❒ Ventilate the room where the boiler is installed
❒ Close the fire door and doors to living areas
❒ Allow the fire to burn out completely and let the boiler cool
Recommendation: Equip the boiler with an uninterruptible power supply (USV,
photovoltaic system, etc.). This ensures correct combustion of the firewood and
prevents possible uncontrolled conditions (tarring of the heat exchanger, etc.).
Recommendation: Do not install smoke alarms and carbon monoxide detectors near
the system.
2.9.4 Fire in the system
DANGER
In case of fire in the system:
Risk of death by fire and poisonous gases
Emergency procedure in case of fire:
❒ Leave the boiler room
❒ Close the doors
❒ Inform the fire department
Safety 2
Emergency procedure
Operating Instructions SP Dual compact | B1500319_en 19

3 Notes for operating a heating system
Carrying out modifications to the system and changing or disabling safety equipment
is prohibited.
Always comply with all fire, building and electrical regulations when installing or
operating the system, in addition to following the operating instructions and mandatory
regulations that apply in the country in which the tank is operated.
3.1 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern 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 informed
when installing or modifying a heating system, and authorisation must be obtained
from the building authorities:
Austria: report to the construction authorities of the community or magistrate
Germany: report new installations to an approved chimney sweep / the building
authorities.
3.2 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 design
regulations.
▪ When using the boiler above 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
The floor of the boiler room must not be flammable. No flammable materials
should be stored near the boiler. Flammable objects (e.g. clothing) must not be put
on the boiler to dry.
▪ Damage due to impurities in combustion air.
Do not use any solvents or cleaning agents containing chlorine and hydrogen
halides in the room where the boiler is installed (e.g. chlorination units for
swimming pools).
▪ Keep the air suction opening of the boiler free of dust.
Note on standards
3Notes for operating a heating system
Installation and approval of the heating system
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