Froling S1 Turbo User manual

Installation Instructions
Fire wood boiler S1 Turbo
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1470113_en | Edition 17/09/2013
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of Contents
1 General 4
2 Safety 5
2.1 Hazard levels of warnings 5
2.2 Qualification of assembly staff 6
2.3 Protective equipment for assembly staff 6
2.4 Design Information 7
2.4.1 Notes on standards 7
General standards for heating systems 7
Standards for structural and safety devices 7
Standards for heating water 7
Standards for permitted fuels 8
2.4.2 Installation and approval of the heating system 8
2.4.3 General information for installation room (boiler room) 8
2.4.4 Requirements for central heating water 9
2.4.5 Notes for using pressure maintenance systems 9
2.4.6 Return lift 10
2.4.7 Combination with storage tank 11
2.4.8 Chimney connection/chimney system 13
Draught limiter 13
Boiler data for planning the flue gas system 13
3 Technology 14
3.1 Dimensions 14
3.2 Components and connections 15
3.3 Technical specifications 16
4 Assembly 18
4.1 Materials supplied 18
4.1.1 Tools required 18
4.2 Positioning 18
4.3 Temporary storage 19
4.4 Setting up in the boiler room 19
4.4.1 Removing boiler from pallet 19
4.4.2 Minimum distances in the boiler room 20
4.5 Before Installation 21
4.5.1 Changing the stop of the fuel loading door and the combustion chamber door 21
4.5.2 Checking the seal on the doors 24
4.5.3 Positioning the doors 25
4.6 Installing the boiler 26
4.6.1 Assembly overview 26
4.6.2 Installing the induced draught fan 28
4.6.3 Installing the insulation 28
4.6.4 Fitting the air control 32
Variant 1 - Fitting the servo-motor 32
Variant 2 - Fitting the manual controller 33
4.6.5 Fitting the controller box 34
4.6.6 Fitting the broadband probe, flue gas temperature sensor and STL 36
Table of Contents
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4.6.7 Attaching the induced draught cable 37
4.6.8 Installing the insulated door 37
4.7 Electrical connection and wiring 40
4.7.1 Information on circulating pumps 40
4.7.2 Concluding work 41
4.8 Connecting the hydraulic safety devices 43
4.9 Installing the WOS system (optional) 44
5 Start-up 49
5.1 Before commissioning / configuring the boiler 49
5.2 Initial startup 50
5.2.1 Permitted fuels 50
Firewood 50
5.2.2 Fuels permitted under certain conditions 51
Wood briquettes 51
5.2.3 Non-permitted fuels 52
5.2.4 Heating up for the first time 53
Boiler with Lambda control 53
Boiler with manual controller 53
6 Decommissioning 56
6.1 Mothballing 56
6.2 Disassembly 56
6.3 Disposal 56
7 Appendix 57
7.1 Pressure equipment regulation 57
7.2 Technical specifications - Lambda control with partial load values 58
7.3 Addresses 59
7.3.1 Address of manufacturer 59
7.3.2 Address of the installer 59
Table of Contents
Installation Instructions S1 Turbo | M1470113_en 3

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 guide‐
lines.
Please read and observe the documentation provided and always keep it close to the
system for reference. It contains important safety information and all the operation and
maintenance specifications needed to operate the system safely, properly, environ‐
mentally friendly and cost-effectively.
The constant further development of our products means that there may be minor dif‐
ferences from the pictures and content. If you discover any errors, please let us know:
[email protected]
Subject 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 or
heating engineers are requested to return a copy of the delivery certificate together
with the guarantee card to Froling. On commissioning by FROLING Customer Service
the validity of the delivery certificate will be noted on the customer service record.
Issuing a delivery cer‐
tificate
1General
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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 or damage to property.
Safety 2
Hazard levels of warnings
Installation Instructions S1 Turbo | M1470113_en 5

2.2 Qualification of assembly staff
CAUTION
Assembly and installation by untrained personnel:
Risk of personal injury and damage to property.
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow trained staff to carry out assembly and installation
Assembly, installation, initial startup and servicing must always be carried out by quali‐
fied personnel:
- Heating technician / building technician
- Electrical installation technician
- Froling customer services
The assembly staff must have read and understood the instructions in the documenta‐
tion.
2.3 Protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by accident pre‐
vention regulations.
▪ For transportation, setup and assembly:
- suitable workwear
- protective gloves
- sturdy shoes
2Safety
Qualification of assembly staff
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.4 Design Information
2.4.1 Notes on standards
The system must be installed and commissioned in accordance with the local fire and
building regulations. The following standards and regulations should always be ob‐
served:
General standards for heating systems
EN 303-5 Boilers for solid fuels, manually and automatically fed combus‐
tion systems, nominal output up to 300 kW
EN 12828 Heating systems in buildings - Design of water-based heating
systems
EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods
Part 1: Chimneys serving one appliance
ÖNORM M 7510-1 Guidelines for checking central heating systems
Part 1: General requirements and one-off inspections
ÖNORM M 7510-4 Guidelines for checking central heating systems
Part 4: Simple check for heating plants for solid fuels
Standards for structural and safety devices
ÖNORM H 5170 Heating installation - Requirements for construction and safety
engineering, as well as fire prevention and environmental pro‐
tection
Standards for heating water
ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in
closed warm water heating systems at operating temperatures
up to 100 °C (Austria).
VDI 2035 Sheet 1 Prevention of damage in water heating systems - Scale forma‐
tion in domestic water heating systems and hot water heating
systems (Germany)
SWKI 97-1 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
D.P.R. no. 412 Regulations for the planning, installation, running/operation and
maintenance of heating systems in buildings to reduce energy
consumption with reference to Article 4, Comma 4 of the Legis‐
lative Decree of 9 January 1991, No. 10 (Italy)
Safety 2
Design Information
Installation Instructions S1 Turbo | M1470113_en 7

Standards for permitted fuels
EN 14961-3 Solid bio-fuel - Fuel specifications and classes
Part 2: Wood briquettes for non-industrial use
EN 14961-5 Solid bio-fuel - Fuel specifications and classes
Part 5: Firewood for non-industrial use
1. BImSchV First Ordinance of the German Federal Government for imple‐
mentation of the Federal Emission Protection Law, BGBl. I P.
491, in the applicable version.
2.4.2 Installation and approval of the heating system
The boiler should be operated in a closed heating system. The following standards
govern the installation:
ÖNORM / DIN 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: Inform the civic/municipal building authorities.
Germany: Notify an approved chimney sweep and the building authorities.
2.4.3 General information for installation room (boiler room)
Boiler room characteristics
▪ 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 provide sufficient light‐
ing in the boiler room in accordance with national workplace design regulations.
▪ When using the boiler over 2000 metres above sea level you should consult the
manufacturer.
▪ Danger of fire due to flammable materials.
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 in the room where
the boiler is installed.
▪ Keep the air suction opening of the boiler free from dust.
Ventilation of the boiler room
Ventilation 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 (foli‐
age, snowdrifts, etc.) from obstructing the air flow.
Note on standards
2Safety
Design Information
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

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
2.4.4 Requirements for central heating water
The following standards and guidelines apply:
Austria:
Germany:
Switzerland:
Italy:
ÖNORM H 5195-1
VDI 2035
SWKI 97-1
D.P.R. no. 412
NOTICE! Note on filling with make-up water: Always bleed the filling hose before con‐
necting, in order to prevent air from entering the system.
Observe the standards and also follow the recommendations below:
❒Max. cumulative value for alkaline earth: 1.0 mmol/l or 100 mg/l (corresponds to
5.6 dH)
❒ Use softened water as the make-up water
❒ Avoid leaks and use a closed heating system to maintain water quality during op‐
eration
2.4.5 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required pres‐
sure within predefined limits and balance out volume variations caused by changes in
the hot-water temperature. Two main systems are used:
Compressor-controlled pressure maintenance
In compressor-controlled pressure maintenance units, a variable air cushion in the ex‐
pansion tank is responsible for volume compensation and pressure maintenance. If
the pressure is too low, the compressor pumps air into the tank. If the pressure is too
high, air is released by means of a solenoid valve. The systems are built solely with
closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen in‐
to the domestic hot water.
Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressure-main‐
tenance pump, relief valve and an unpressurised receiving tank. The valve releases
hot water into the receiving tank if the pressure is too high. If the pressure drops below
a preset value, the pump draws water from the receiving tank and feeds it back into
the heating system. Pump-controlled pressure maintenance systems with open expan‐
sion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the
Note on standards
Note on standards
Safety 2
Design Information
Installation Instructions S1 Turbo | M1470113_en 9

water, exposing the connected system components to the risk of corrosion. These
systems offer no oxygen removal for the purposes of corrosion control as required by
VDI 2035 and in the interests of corrosion protection should not be used.
2.4.6 Return lift
If the hot water return is below the minimum return temperature, some of the hot water
outfeed will be mixed in.
CAUTION
Risk of dropping below dew point/condensation formation if operated without re‐
turn temperature control.
Condensation water forms an aggressive condensate when combined with com‐
bustion 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 some
sort of control device (e.g. thermometer).
2Safety
Design Information
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2.4.7 Combination with storage tank
Observe the regional regulations for using a storage tank!
Certain subsidy guidelines prescribe compulsory requirements for the installation of
storage tanks. Up-to-date information about individual subsidy guidelines can be found
at www.froeling.com.
Channelling the heat generated by the Firewood boiler to a storage tank, can bring
major 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 heat out‐
put, we as boiler manufacturer are obliged under EN 303-5:2012, Section 4.4.6 to ad‐
vise that the Firewood boiler S1 Turbo must always be connected to a storage tank
with adequate storage capacity.
Certain countries have recommended storage capacities; these are listed below. The
specified values apply when the nominal heat output of the boiler corresponds to the
heating requirements of the building and a maximum of 50% of the nominal heat out‐
put 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 the fol‐
lowing formula:
VSp = 15TB x 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 data
2.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)
NOTICE! EN 303-5:2012 stipulates that the storage tank capacity is at least 300l!
According to the relevant Austrian laws governing energy technology, which are based
on 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 positively
tested at both nominal load and partial load (below 50% of nominal load) to ensure
they adhere to the emissions limits specified in that agreement.
General information
Austria
Safety 2
Design Information
Installation Instructions S1 Turbo | M1470113_en 11

Recommended storage tank capacity:
Unit S1 Turbo 15 S1 Turbo 15S S1 Turbo 20
Recommended storage tank capacity1) [l] 1000 1000 1000
1.Values for calculating the capacity can be found in the technical data or the technical data with partial load inspection (if available)
The first BImSchV (Ordinance on small and medium-sized heating plants of 26 Janu‐
ary 2010, BGBl. I p. 38) stipulates a minimum water heat storage tank capacity of 55
litres per kilowatt of nominal heat output; a water heat storage tank with a capacity of
12 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 1500
1.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 or
Froling.
Germany
2Safety
Design Information
12 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.4.8 Chimney connection/chimney system
EN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐
ever possible, damage caused by seepage, insufficient feed pressure and condensa‐
tion. Please note in this respect that flue gas temperatures lower than 160K above
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 be
found in the table below.
The connection between the boiler and the chimney system should be as short as
possible. The upward angle of the connection should not exceed 30 - 45°. Insulate the
connection. The entire flue gas system - chimney and connection - should be calcula‐
ted 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 chimney
sweep.
Draught limiter
The installation of a draught limiter is recommended.
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the
pressure is constantly low at this point.
Boiler data for planning the flue gas system
Name S1 Turbo
15
S1 Turbo
15S
S1 Turbo
20
Flue gas temperature at nominal load °C 150 160 170
Flue gas temperature at partial load °C - 120 130
Flue gas mass flow at nominal load kg/s 0.010 0.012 0.013
Flue gas mass flow at partial load kg/s - 0.006 0.007
Required feed pressure at nominal and
partial load
mbar 0.08 0.08 0.08
Maximum permissible feed pressure In accordance with ÖNORM/DIN EN 303-5
Flue spigot diameter mm 130 130 130
Safety 2
Design Information
Installation Instructions S1 Turbo | M1470113_en 13

3 Technology
3.1 Dimensions
Dimen‐
sion
Name Unit S1 Turbo
LLength, boiler mm 1000
L1 Total length incl. induced draught fan 1080
WWidth, boiler 685
HHeight, boiler 1235
H1 Total height incl. Flue gas nozzle 1290
H2 Height, flue spigot 1450
H3 Height, flow connection 1055
H4 Height, return connection 200
H5 Height, safety battery connection 1040
H6 Height, drainage connection 120
3Technology
Dimensions
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3.2 Components and connections
Item Name Unit S1 Turbo
1 Boiler flow connection Inches 1
2 Boiler return connection Inches 1
3 Drainage connection Inches ½
4 Safety battery connection Inches ½
5 Immersion sleeve for thermal discharge valve (sup‐
plied by the customer)
Inches ½
6 Flue spigot mm 130
7 Immersion sleeve for boiler sensor and STL Inches ½
8 Broadband probe connection Inches ¾
9 Flue gas temperature sensor connection Inches ½
Technology 3
Components and connections
Installation Instructions S1 Turbo | M1470113_en 15

3.3 Technical specifications
Name S1 Turbo 15 S1 Turbo 20
Nominal heat output kW 15 20
Electrical connection 230V / 50Hz / fused C13A
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 time 1) - Beech h 4.9 - 7.0 3.5 - 5.0
Combustion time1) - Spruce 3.0 - 4.2 2.1 - 3.0
1.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%)
Name S1 Turbo 15 S1 Turbo 20
Testing institute TÜV Austria1) TÜV Austria1)
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 92.0
1.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 69 51
Nitrogen oxide (NOx) mg/MJ 80 88
Organic hydrocarbons (OGC) mg/MJ 3 3
Dust mg/MJ 8 10
1.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 15
1.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
3Technology
Technical specifications
16 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Name S1 Turbo 15 S1 Turbo 20
Testing institute TÜV Austria1) TÜV Austria1)
Test report no. 13-UW/Wels-
EX-044/3
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 92,6
1.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 10
1.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 14
1.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
Technology 3
Technical specifications
Installation Instructions S1 Turbo | M1470113_en 17

4 Assembly
4.1 Materials supplied
The 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 required
The following tools are required for assembling the S1 Turbo:
❒Spanner or box wrench set (widths across flats 8 – 32 mm)
❒ Allen key set
❒ Flat head and cross-head screw drivers
❒ Hammer
❒ Diagonal cutting pliers
❒ Half-round file
❒ Power drill or cordless screwdriver with Torx bit insert
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
❒ 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
4Assembly
Materials supplied
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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 19]
Positioning using a crane
❒ Attach the crane hook to the attachment point correctly and position the boiler
4.3 Temporary storage
If the system is to be assembled at a later stage:
❒Store components at a protected location, which is dry and free from dust
➥Damp and frost can damage components, particularly electric ones!
4.4 Setting up in the boiler room
4.4.1 Removing boiler from pallet
❒ Lift the cardboard box with the insulation off the pallet
❒Remove the cardboard with the controller from the boiler and put in a safe place
❒ Undo the screws on the top frame of the pallet
➥Two screws each on the right and left, front and back
❒Remove the top frame of the pallet
Assembly 4
Temporary storage
Installation Instructions S1 Turbo | M1470113_en 19

❒ Undo the four screws which connect the side of the boiler to the bottom supports
of the pallet
❒Lift the boiler using a fork-lift or similar lifting device with the appropriate load-bear‐
ing capacity and remove the bottom supports of the pallet
❒ Transport boiler to the intended position in the installation room
➥Observe the minimum distances from other objects in the boiler room!
4.4.2 Minimum distances in the boiler room
▪ The system should generally be set up so that it is accessible from all sides allow‐
ing 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)
Dimen‐
sion
Name Unit S1 Turbo
ADistance - front of boiler to wall mm 800
WDistance – side of boiler to wall 200 (500)1)
CDistance – back to wall 400
DDistance – side of boiler to wall 200 (500)1)
1.One side of the boiler (B or D) should be at least 500 mm from the wall to allow easy access for connecting the appliance and for mainte‐
nance work (e.g. induced draught).
4Assembly
Setting up in the boiler room
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