Froling S3 Turbo User manual

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen
Tel [phone] Fax [phone] [email protected] www.froeling.com
Operating Instructions
S3 Turbo
Be sure to read and comply with the operating instructions and safety information
Subject to technical change.

Introduction
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Dear customer,
Congratulations on choosing a quality product from FRÖLING.
The FRÖLING S3 Turbo is a state-of-the-art design that conforms to all
currently applicable standards and testing guidelines.
Please read and observe the operating instructions and always keep
them close to the boiler for reference. Observing the requirements
and safety information in the instruction manual 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.
Subject to technical change.

Contents
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1Product Overview 6
2Safety 7
2.1 Safety Information 7
2.2 Permitted uses 8
2.2.1Permitted fuels.................................................................................................8
2.2.2Non-permitted fuels..........................................................................................8
2.2.3Who may operate the boiler? .............................................................................8
2.3 Design Information 9
2.3.1Approval and obligation to report........................................................................9
2.3.2Requirements for central heating water ...............................................................9
2.3.3Ventilation of boiler room ................................................................................ 10
2.3.4Installing the heating system / Standards .......................................................... 10
Return feed lift.............................................................................................. 10
Mandatory buffer storage tank......................................................................... 11
2.3.5Chimney connection / chimney system .............................................................. 11
Draught limiter.............................................................................................. 11
Boiler data for constructing the flue gas system:................................................ 11
2.4 Safety Devices 12
2.4.1Devices for preventing the boiler from overheating.............................................. 12
Thermal discharge safety device ...................................................................... 12
Safety Temperature Limiter STL....................................................................... 12
Safety valve.................................................................................................. 13
2.5 Safety instructions for the installation room 13
2.6 Residual risks 14
2.7 Emergency procedure 15
2.7.1Overheating of the system............................................................................... 15
2.7.2Smell of flue gas ............................................................................................ 15
2.7.3Fire .............................................................................................................. 15
3Operating the system 16
3.1 Initial startup 16
3.2 Heating the boiler 17
3.2.1Switching on the system.................................................................................. 17
3.2.2Heating the boiler........................................................................................... 17
3.2.3Refilling with fuel............................................................................................ 18
Reloading intervals ........................................................................................ 18
3.2.4Switching off the system ................................................................................. 18
3.3 Display 19
3.3.1Status displays............................................................................................... 19
tk - boiler temperature................................................................................... 19
tAG - flue gas temperature.............................................................................. 19
tür – front insulated door open ........................................................................ 19
3.3.2Display for closed insulated door....................................................................... 19
3.3.3Display for open insulated door ........................................................................ 19
3.3.4Error displays................................................................................................. 19

Contents
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4Boiler servicing 20
4.1 General information on servicing 20
4.2 Inspection, cleaning and self maintenance 21
4.2.1Daily maintenance / Each time before heating up ................................................21
Cleaning the heat exchanger pipes (for boiler with WOS system) ..........................21
4.2.2Weekly maintenance.......................................................................................21
Removing ash................................................................................................21
Cleaning the passage to the side of the combustion chamber ...............................21
Checking the thermal discharge safety device ....................................................22
Checking the system pressure .........................................................................22
4.2.3Monthly maintenance ......................................................................................22
Cleaning the grating.......................................................................................22
Cleaning the flue gas sensors...........................................................................23
Cleaning the heat exchanger pipes (for boiler without WOS system)......................23
4.2.4Annual maintenance........................................................................................24
Checking the primary air openings....................................................................24
Cleaning the carbonisation gas duct..................................................................24
Checking the seal on the doors ........................................................................24
Cleaning the flue gas pipe ...............................................................................24
Checking the draught limiter and explosion flap (if present) .................................24
Cleaning the induced draught ventilator ............................................................25
4.3 Testing Emissions 25
4.3.1Measurement at rated load ..............................................................................25
4.4 Maintenance agreement / Customer service 25
4.5 Replacement parts: 26
4.6 Disposal information 26
4.6.1Disposal of the ash .........................................................................................26
4.6.2Disposal of system components ........................................................................26
5Troubleshooting 27
5.1 General faults in the power supply 27
5.1.1Behaviour of system after a power failure...........................................................27
5.2 Excessive temperature 27
5.3 Error messages 28
5.3.1Displays in case of errors.................................................................................28
STL - display.................................................................................................28
127 °C display...............................................................................................28
999 °C display...............................................................................................28
SZG - display ................................................................................................29
6Appendix 30
6.1 Guarantee Conditions 30
6.2 Address of manufacturer 30
6.3 Declaration of Conformity 31

Product Overview
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1Product Overview
Pos. Description
1 Firewood boiler S3 Turbo
2 Insulated door for reduced heat radiation
3 Fuel loading door
4 Pre-heating chamber door
5 Combustion chamber door
6 Side cleaning door
7 Boiler controller
7.1 Induced draught On / Off
7.2 3-character display to show: boiler temperature, flue gas temperature, errors
8 Main switch: switches the system on and off
9 STL – Safety Temperature Limiter
3
4
5
7.1
1
2
6
7
7.2
98

Safety
Permitted Uses
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2Safety
2.1 Safety Information
DANGER
Non-permitted use!
Incorrect use of the boiler can cause severe injuries and damage!
The instructions and information provided in the instructions
should be observed!
Details on procedure for operation, maintenance and cleaning,
as well as troubleshooting for the boiler are included in the
individual instructions. Any further work should be carried out by
authorised heating engineers or by Fröling 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!
Instructions and information for versions and minimum values,
as well as norms and guidelines for heating components in the
instructions must be observed!
WARNING
An inadequate flue gas system can cause severe injuries and damage!
Problems with the flue 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)!
You can only be guaranteed of optimum performance from the boiler if the
flue gas system is running smoothly!

Safety
Safety Information
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2.2 Permitted uses
The boiler should only be operated when it is in full working order. It
should be operated in accordance with the instructions, observing safety
precautions, and you should ensure you are aware of the potential
hazards.
Ensure that any faults, which might impair safety, are rectified
immediately.
The Fröling S3 Turbo is intended exclusively for heating up
central heating water. Use only the fuels specified under 2.2.1.
The manufacturer or supplier is not liable for any damages
resulting from non-permitted uses.
2.2.1 Permitted fuels
For Austria:
Firewood with a max. length of 55cm (w < 25%)
For Germany:
Fuel class 4 (§3 of the 1st BimSchV i. d. g. F.)
Values in practice: Hardwood 2 years in dry storage
Soft wood 1 year in dry storage
Coarse wood chips 1 year in dry storage
Use fuels that are consistent in size and water content.
ÀFurther information on fuel in the in the assembly instructions,
section 2.3
2.2.2 Non-permitted fuels
The use of fuels not defined under 2.2.1, and particularly the burning of
refuse, is not permitted.
CAUTION
Non-permitted fuels!
Burning non-permitted fuels increases the cleaning requirements and leads to
a build-up of aggressive sedimentation and condensation, which can lead to
damage to the boiler and also voids the warranty. Using non-standard fuels
can lead to severe problems with combustion.
2.2.3 Who may operate the boiler?
Only trained operators are permitted to operate the boiler.
CAUTION
No unauthorised access to the boiler room!
Risk of injury and damage to equipment!
It is the responsibility of the operator to ensure that unauthorised persons,
especially children, are kept away from the boiler.

Safety
Design Information
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2.3 Design Information
It is forbidden to carry out modifications to the boiler or to change or
deactivate safety equipment.
Always comply with all fire, building, and electrical regulations when
installing or operating the boiler system, in addition to following the
operating instructions and mandatory regulations that apply in the
country in which the boiler is operated.
2.3.1 Approval and obligation to report
NOTICE
Each heating system must be officially authorised.
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: Register with an approved chimney sweep/the building authorities.
2.3.2 Requirements for central heating water
The requirements pertaining to the water used to fill the boiler are
based on the following standards and guidelines:
Applicable standards and guidelines:
Austria: ÖNORM H 5195-1
Germany: VDI 2035
Switzerland: SWKI 97-1
There are no other special requirements for central heating water.
Note on filling with make-up water: bleed the filling hose before
connecting to prevent air from getting into the system.
§

Safety
Design Information
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2.3.3 Ventilation of boiler room
The openings for the supply air and the exhaust air should be arranged
as close to opposite each other as possible to achieve a good thermal
draught effect.
The supply air must be drawn in directly from outside. Exhaust air
must be discharged directly outside.
Unless otherwise stipulated by the building regulations applicable to the
room where the boiler is to be installed, the following standards shall
apply:
Applicable Standards:
- ÖNORM H 5170
2.3.4 Installing the heating system / Standards
The following standards govern the installation of heating systems:
Applicable Standards:
ÖNORM / DIN EN 12828 Heating Systems in Buildings
The following prior standards still apply:
Austria: - Closed systems as per ÖNORM B 8131
- Open systems as per ÖNORM B 8130
Germany: - Closed systems as per DIN 4751 Part 2
- Open systems as per DIN 4751 Part 1
Return feed lift
If the hot water return feed is below the minimum return feed
temperature, some of the hot water outfeed will be mixed in.
CAUTION
Risk of dropping below dew point/condensation formation if operated
without return feed lift.
Condensation water forms an aggressive condensate when combined
with combustion residue, leading to damage to the boiler.
Regulations stipulate the use of a return feed lift.
The minimum return feed temperature is 55 °C. We recommend fitting
some kind of control device (e.g. thermometer).
§
§

Safety
Design Information
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Mandatory buffer storage tank
You can find more detailed information about storage tank design in the
boiler assembly instructions.
ÀSee assembly instructions “1.2 Design information”
2.3.5 Chimney connection / chimney system
EN 303-5 specifies that the entire flue gas system must be designed to
prevent, wherever possible, damage caused by seepage, insufficient
feed pressure and condensation.
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 technical specification sheets.
ÀSee “Boiler data for constructing the flue gas system:”
Connect to the chimney via the shortest path, preferably with a vertical
gradient of less than 30–45°. Insulate the connecting piece.
The entire flue gas system (chimney and connection) must be calculated
as per ÖNORM/DIN EN 13384-1 or prior standards
ÖNORM M 7515/DIN 4705-1.
Local regulations and other statutory regulations also apply.
The chimney must be authorised by a smoke trap sweeper or
chimney sweep.
Draught limiter
We recommend that a draught limiter is fitted (1)
Install the draught limiter directly under the mouth of the flue line,
as there is always low pressure there.
Boiler data for constructing the flue gas system:
Description Unit S3 Turbo
Description Unit 18 28 36 45
WOS system - No Yes No Yes Yes Yes
Rated heat output kW 18 22.5 25 30 36 45
Flue gas temperature RL °C 150 150 170 170 150 170
Flue gas mass flow RL kg/s 0.013 0.016 0.018 0.022 0.026 0.033
Minimum feed pressure 0.08 0.08 0.08 0.08 0.08 0.08
Maximum permissible feed
pressure mbar As per ÖNORM/DIN EN 303-5, Section 4.2.3
Flue pipe diameter mm 150 150 150 150 150 150
RL = Rated load
1

Safety
Safety Devices
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2.4 Safety Devices
8 Main switch For shutting down the entire system
´The power to all components is
switched off.
Caution! Only switch off the boiler
when it has burnt down and cooled off.
9 Safety temperature
limiter (STL) ÀSee 2.4.1 Devices for preventing the boiler
from overheating
2.4.1 Devices for preventing the boiler from overheating
Thermal discharge safety device
At around 100 °C a valve opens and sends cold water to the safety
heat-exchanger to reduce the temperature.
Safety Temperature Limiter STL
Switches off the blower fan at the maximum boiler temperature of 105
°C. The pumps continue to run.
Once the temperature falls to below approx. 95 °C, the STL can be
mechanically unlocked:
UUnscrew the cap on the STL (9)
UUnlock the STL by pressing with a screwdriver
8 9
9

Safety
Safety Devices
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Safety valve
Protection against over-heating/ excessive pressure:
When the boiler pressure reaches a maximum of 3 bar, the safety valve
opens and the heating water is released in the form of steam.
2.5 Safety instructions for the installation room
1) Danger of fire due to flammable materials.
No flammable materials should be stored near the boiler.
2) Damage due to impurities in combustion air.
Do not use any hydrogen halides or cleaning agents that
contain chlorine in the boiler installation room.
3) Keep the air suction opening of the boiler free of dust.
4) The room where the boiler is installed must be frost-proof.

Safety
Emergency procedure
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2.6 Residual risks
WARNING
Touching hot surfaces!
Hot parts and the flue pipe can cause serious burns!
UIt should be standard practice to wear protective gloves when
working on the boiler.
UOnly operate the boiler using the handles provided for this
purpose.
UInsulate the flue pipes or simply avoid touching them during
operation.
WARNING
Opening the combustion chamber door during operation!
This may cause injury, damage and smoke!
Do not open the doors behind the insulated door while the
system is operating!
WARNING
Use of non-permitted fuel!
Non-standard fuels can cause serious faults in combustion (e.g.
spontaneous combustion of carbonisation gases / flash fires) which
can lead to serious accidents!
Only use fuels specified in the chapter on “Permitted Uses” in
these operating instructions.

Safety
Residual risks
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2.7 Emergency procedure
2.7.1 Overheating of the system
If the system overheats in spite of the safety devices, proceed as
follows:
Do not interrupt the power supply under any circumstances.
UKeep all the doors on the boiler closed.
UOpen all mixer taps, switch on all pumps.
´Fröling heating circuit control takes over this function in
automatic operation.
ULeave the boiler room and close the door.
UOpen any available radiator thermostat valves
If the temperature does not drop, inform the installer or Fröling
customer services:
ÀPage 30, 6.2 Address of manufacturer
2.7.2 Smell of flue gas
DANGER
Smell of flue gas!
Flue gases can cause fatal poisoning!
UKeep all the doors on the boiler closed.
UAir the room where the boiler is installed
UClose the fire protection door and doors to living areas
2.7.3 Fire
DANGER
Fire!
In case of fire, there is a risk of burns and explosions!
UTurn off the boiler
UUse a tested fire extinguisher for fire class AB to fight the fire
AB powder

Operating the system
Initial startup
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Operating the system
3.1 Initial startup
NOTICE
Optimum efficiency and efficient, low-emission operation
can only be guaranteed if the system is set up by trained
professionals and observing the standard factory settings.
Take the following precautions:
UInitial startup should be carried out with an authorised installer or with
Fröling customer services.
NOTICE
If condensation escapes during the initial heatup phase, this does not
indicate a fault.
If this occurs, clean up using a cleaning rag.
CAUTION
Heating up the boiler too rapidly on initial startup!
Possible damage to the equipment!
If the output during the heating-up process is too great, the combustion
chamber may be damaged as a result of drying out too rapidly!
Drying fissures, on the other hand, are normal and do not indicate a
malfunction.
During initial startup of the boiler:
Place 1 piece of wood diagonally (1) across the combustion
chamber
ULoad the boiler with a small amount of firewood (max. 10-20% of the fuel
loading chamber)
UIgnite it and allow it to burn up with the central pre-heating chamber door
open

Operating the system
Heating the boiler
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3.2 Heating the boiler
3.2.1 Switching on the system
USwitch on the main switch (8) on the controls
´After the system check, the control system is ready for operation
3.2.2 Heating the boiler
UOpen the insulated door and the fuel loading door
UIt is recommended that you do not remove the ash in the
combustion chamber during each heating-up process, to protect the
combustion chamber.
UFill the fuel loading chamber in accordance with the output
Use firewood with a length of approximately 50 cm and arrange it
lengthwise
The flame slot must not be obscured!
After the first layer of pieces of wood lay cardboard on flat
UClose the fuel loading door
UOpen the pre-heating chamber door and ignite the cardboard
UIf the underpressure from the induced draught fan is too strong for
the firing material to be ignited:
Switch off the induced draught fan using the induced draught
button (7.1)
Ignite the firing material
Press the induced draught button (7.1) again to switch the
induced draught fan on
ULeave the pre-heating chamber door open for approximately 5
minutes
´A bed of embers forms
UClose the pre-heating chamber door and the insulated door
The flue gas temperature must be > 130°C!
7.1
8

Operating the system
Heating the boiler
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3.2.3 Refilling with fuel
A WARNING
Touching hot surfaces behind the insulated door!
Risk of burns from hot surfaces!
By the nature of its operation, the surfaces and operating
elements in the area behind the insulated door get hot! When
working with firewood, there is also a risk of injury from splinters.
UWhen working on the boiler during operation, particularly
when reloading fuel, it should be standard practice to wear
protective gloves.
UOpen the fuel loading door slowly and check the fuel
Has the fuel in the boiler burnt down:
URefill fuel
If there is enough fuel in the boiler:
UClose the fuel loading door immediately
Reloading intervals
The reloading intervals should depend exclusively on the storage tank.
If the temperature of the storage tank above has dropped to a certain
temperature (floor heating: approx. 30-40 °C, radiator heating: approx.
50 °C), reload fuel.
The amount of fuel should be measured so as to ensure that the storage
tank is continuously warmed to the maximum storage temperature
(max. 80-90 °C).
The amount to reload also depends on the type of fuel.
3.2.4 Switching off the system
CAUTION! Only when the boiler when it has burnt down and
cooled off.
USwitch off the main switch (8) on the control unit
´The control is switched off
´All the system components are powered down
8

Operating the system
Display
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3.3 Display
3.3.1 Status displays
tk - boiler temperature
Current boiler temperature [°C]
tAG - flue gas temperature
Current flue gas temperature [°C]
tür – front insulated door open
Door switch open
3.3.2 Display for closed insulated door
Boiler temperature and flue gas temperature are displayed alternately:
Boiler
temperature e.g.: 80°C Flue gas temperature e.g.: 167°C
3.3.3 Display for open insulated door
Operating status of the induced draught fan (on/off) and flue gas
temperature are shown alternately:
Insulated door
open Induced draught fan on Flue gas temperature e.g.:
167°C
The induced draught fan can be switched on and off using the
induced draught button. If the insulated door is closed.
3.3.4 Error displays
ÀSee “5.3.1 Displays in case of errors”

Boiler servicing
Inspection, cleaning and maintenance
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4Boiler servicing
4.1 General information on servicing
DANGER
Working on electrical components
Risk of serious injuries from electric shocks
UWork on electrical components should only be carried out by authorised
technicians
WARNING
Carrying out maintenance when the boiler is hot!
Hot parts and the flue pipe can cause serious burns!
UIt should be standard practice to wear protective gloves when
working on the boiler.
UOnly operate the boiler using the handles provided for this
purpose.
Before starting any maintenance work:
UAllow the fuel in the boiler to burn off
UAllow the boiler to cool off for at least 1 hour
WARNING
Non-permitted cleaning and maintenance!
Incorrect or insufficient cleaning and maintenance of the boiler can
cause serious faults in combustion (e.g. spontaneous combustion of
carbonisation gases / flash fires) and this can lead to serious
accidents!
Clean the boiler following the instructions. Follow the boiler
operating instructions.
NOTICE
We recommend you keep a maintenance book in accordance with ÖNORM
M7510