Froling S4 Turbo 15 User manual

Installation Instructions
Firewood boiler S4 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!
M0971117_en | Edition 24/03/2017
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of Contents
1 General 5
2 Safety 6
2.1 Hazard levels of warnings 6
2.2 Qualification of assembly staff 7
2.3 Personal protective equipment for assembly staff 7
2.4 Design Information 7
2.4.1 Notes on standards 7
General standards for heating systems 7
Standards for structural and safety devices 8
Standards for heating water 8
Regulations and 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) 9
2.4.4 Requirements for central heating water 10
2.4.5 Notes for using pressure maintenance systems 11
2.4.6 Return lift 12
2.4.7 Combination with storage tank 13
2.4.8 Chimney connection/chimney system 14
Draught limiter 14
Measuring port 14
Boiler data for planning the flue gas system 15
3 Technology 17
3.1 Dimensions - S4 Turbo 17
3.2 SP Dual measurements 18
3.3 Components and connections 19
3.4 Note on SP Dual return feed connection 20
3.5 Technical specifications 21
4 Assembly 26
4.1 Materials supplied 26
4.1.1 Tools required 26
4.2 Positioning 27
4.2.1 Temporary storage 27
4.3 Setting up in the boiler room 28
4.3.1 Remove boiler from pallet 28
4.3.2 Moving the boiler in the boiler room 28
4.3.3 Minimum distances in the boiler room 28
4.4 Before Installation 30
4.4.1 Changing door stops (as needed) 30
4.4.2 Fitting the door handles 32
4.4.3 Adjusting the doors 32
Door stop side 33
Door handles 33
4.4.4 Setting and checking the seal on the doors 34
Checking the settings of the door stop 34
Checking the settings of the door handle 34
Table of Contents
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Checking the door stop seal 35
Checking the door handle seal 35
4.5 Assembling the S4 Turbo 15-40 36
4.5.1 Assembly overview 36
Air duct system 36
S4 Turbo 15-28 EOS system 37
S4 Turbo 32-40 EOS system 38
Insulation 39
Boiler with pellet flange 40
4.5.2 Installing the induced draught fan and flue gas pipe nozzle 41
4.5.3 Assembling the heat-exchanger lever bushing 41
4.5.4 Installing the pneumatic rods for the primary and secondary air 42
servo-motors on the right 42
servo-motors on the left 43
4.5.5 Installing the insulation 44
4.5.6 Installing the control 45
4.5.7 Installing the back panel 46
4.5.8 Installing the floor insulation 46
4.5.9 Installing the insulated door 47
4.5.10 Attaching the controller 49
4.5.11 Fitting the broadband probe, boiler sensor, flue gas temperature sensor and STL 51
4.5.12 Installing the servo-motors 52
4.5.13 Installing the WOS system 53
4.6 Assembling the S4 Turbo 50-60 57
4.6.1 Assembly overview 57
Air duct system 57
EOS system 58
Insulation 59
4.6.2 Assembling the heat-exchanger lever bushing 61
4.6.3 Installing the pneumatic rods for the primary and secondary air 61
servo-motors on the right 62
servo-motors on the left 63
4.6.4 Installing the insulation 64
4.6.5 Installing the control 65
4.6.6 Installing the back panel 66
4.6.7 Installing the floor insulation 66
4.6.8 Installing the insulated door 67
4.6.9 Attaching the controller 69
4.6.10 Fitting the broadband probe, boiler sensor, flue gas temperature sensor and STL 71
4.6.11 Installing the servo-motors 72
4.6.12 Installing the induced draught fan 73
4.6.13 Installing the WOS system 75
4.7 Electrical connection and wiring 76
4.7.1 Information on circulating pumps 77
4.7.2 Concluding work 78
4.8 Hydraulic connection 78
4.9 Connecting the hydraulic safety devices 79
5 Start-up 80
5.1 Before commissioning / configuring the boiler 80
5.2 Initial startup 81
5.2.1 Permitted fuels 81
Firewood 81
5.2.2 Fuels permitted under certain conditions 82
Wood briquettes 82
Table of Contents
Installation Instructions S4 Turbo | M0971117_en 3

5.2.3 Non-permitted fuels 82
5.2.4 Heating up for the first time 82
6 Decommissioning 84
6.1 Mothballing 84
6.2 Disassembly 84
6.3 Disposal 84
7 Appendix 85
7.1 Pressure equipment regulation 85
7.2 Technical specifications - S4 Turbo with partial load values 86
7.2.1 Test report data S4 Turbo 22-28 86
7.2.2 Test report data S4 Turbo 34-40 87
7.2.3 Test report data S4 Turbo 50-60 88
7.3 Addresses 89
7.3.1 Address of manufacturer 89
7.3.2 Address of the installer 89
Table of 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.
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
certificate
General 1
Installation Instructions S4 Turbo | M0971117_en 5

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.
2Safety
Hazard levels of warnings
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2.2 Qualification of assembly staff
CAUTION
Assembly and installation by unqualified persons:
Risk of personal injury and damage to property
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow appropriately qualified personnel to work on the system
Assembly, installation, initial startup and servicing must always be carried out by
qualified personnel:
- Heating technician / building technician
- Electrical installation technician
- Froling customer services
The assembly staff must have read and understood the instructions in the
documentation.
2.3 Personal protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For transportation, setup and assembly:
- suitable work wear
- protective gloves
- sturdy shoes (min. protection class S1P)
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. Unless contrary to other national regulations, the latest versions
of the following standards and guidelines apply:
General standards for heating systems
EN 303-5 Boilers for solid fuels, manually and automatically fed
combustion systems, nominal heat output up to 500 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
Safety 2
Qualification of assembly staff
Installation Instructions S4 Turbo | M0971117_en 7

ÖNORM H 5151 Planning of central hot water heating systems with or without hot
water preparation
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
protection
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 Prevention of damage hot water heating systems (Germany)
SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioning
systems (Switzerland)
UNI 8065 Technical standard regulating hot water preparation.
DM 26.06.2015 (Ministerial Decree specifying the minimum
requirements)
Follow the instructions of this standard and any related updates.
Regulations and standards for permitted fuels
1. BImSchV First Order of the German Federal Government for the
implementation of the Federal Law on Emission Protection
(Ordinance on Small and Medium Combustion Plants) in the
version published on 26 January 2010,
BGBl. JG 2010 Part I No. 4.
EN ISO 17225-3 Solid bio-fuel - Fuel specifications and classes
Part 3: Wood briquettes for non-industrial use
EN ISO 17225-5 Solid bio-fuel - Fuel specifications and classes
Part 5: Firewood for non-industrial use
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:
EN 12828 - Heating Systems in Buildings
NOTICE! Each heating system must be officially approved.
Note on standards
2Safety
Design Information
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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.
2.4.3 General information for installation room (boiler room)
Boiler room characteristics
▪ The floor must be even, clean and dry and have an adequate load-bearing
capacity.
▪ There must not be a potentially explosive atmosphere in the boiler room as the
boiler is not suitable for use in potentially explosive environments.
▪ The boiler room must be frost-free.
▪ The boiler does not provide any light, so the customer must ensure sufficient
lighting in the boiler room in accordance with national workplace 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.
▪ The system must be protected against the chewing or nesting of animals (e.g.
rodents etc.).
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
(foliage, snowdrifts, etc.) from obstructing the air flow.
Unless otherwise specified in the applicable building regulations for the boiler room,
the following standards apply to the design and dimensions of the air ducts:
ÖNORM H 5170 - Construction and fire protection requirements
Note on standards
Safety 2
Design Information
Installation Instructions S4 Turbo | M0971117_en 9

2.4.4 Requirements for central heating water
Unless contrary to other national regulations, the latest versions of the following
standards and guidelines apply:
Austria:
Germany:
ÖNORM H 5195
VDI 2035
Switzerland:
Italy:
SWKI BT 102-01
UNI 8065
Observe the standards and also follow the recommendations below:
❒ Aim for a pH value of between 8.2 and 10.0. If the central heating water comes
into contact with aluminium, the pH value must be between 8.0 and 8.5
❒ Use prepared water which complies with the standards cited above for filling and
makeup water
❒ Avoid leaks and use a closed heating system to maintain water quality during
operation
❒ When filling with make-up water, always bleed the filling hose before connecting,
in order to prevent air from entering the system
Advantages of prepared water:
▪ Complies with the applicable standards
▪ Less of a drop in output due to reduced limescale build-up
▪ Less corrosion due to fewer aggressive substances
▪ Long-term cost savings thanks to improved energy efficiency
Limit values for filling and make-up water:
Austria Germany Switzerland
Total hardness ≤ 1.0 mmol/L ≤ 2.0 mmol/L < 0.1 mmol/L
Conductivity - < 100µS/cm < 100 µS/cm
pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5
Chloride < 30 mg/L < 30 mg/L < 30 mg/L
2Safety
Design Information
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Additional requirements for Switzerland:
The filling and make-up water must be demineralised (fully purified)
▪ The water must not contain any ingredients that could settle and accumulate in the
system
▪ This makes the water non-electroconductive, which prevents corrosion
▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can
weaken corrosive materials in certain conditions
If some of the system water is lost, e.g. during repairs, the make-up water must also be
demineralised. It is not enough to soften the water. The heating system must be
professionally cleaned and rinsed before filling the units.
Inspection:
▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the central
heating water comes into contact with aluminium, the pH value must be between 8.0 and
8.5
▪ Yearly. Values must be recorded by the owner
2.4.5 Notes for using pressure maintenance systems
Pressure maintenance systems in hot-water heating systems keep the required
pressure 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
expansion 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
into the heating water.
Pump-controlled pressure maintenance
A pump-controlled pressure maintenance unit essentially consists of a pressure-
maintenance pump, relief valve and an unpressurised receiving tank. The 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 expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via the
surface of the 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.
Safety 2
Design Information
Installation Instructions S4 Turbo | M0971117_en 11

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
return temperature control.
Condensation water forms an aggressive condensate when combined with
combustion 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
output, we as boiler manufacturer are obliged under EN 303-5:2012, Section 4.4.6 to
advise that the Firewood boiler S4 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
output 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
following formula:
VSp= 15TBx QN(1 - 0.3 x QH/Qmin)
VSp
QN
TB
QH
Qmin
Storage tank capacity in [l]
Nominal heat output of boiler in [kW]
Burn-off period of boiler in [h]1)
Heating load of building in [kW]
Minimum heat output of boiler in [kW] 2)
1.Sample combustion times for various fuels are provided in the technical 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)
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.
Recommended storage tank capacity:
Unit S4 Turbo
15 - 22
S4 Turbo
28 - 60
Recommended storage tank capacity1) [l] 2000 1500
1.Values for calculating the capacity can be found in the technical data or the technical data with partial load inspection (if available)
General information
Austria
Safety 2
Design Information
Installation Instructions S4 Turbo | M0971117_en 13

The first BImSchV (Ordinance on small and medium-sized heating plants of 26
January 2010, BGBl. I P. 38) stipulates a minimum water heat storage tank volume of
55 litres per kilowatt of rated heat output; a water heat storage tank with a volume of
12 litres per litre of fuel loading chamber is recommended.
Recommended storage tank capacity:
Unit S4 Turbo
15 - 34
S4 Turbo
40 - 50
S4 Turbo
60
Recommended storage tank capacity1) [l] 2000 2800 3300
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.
2.4.8 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 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
calculated 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
We generally recommend the installation of a draught limiter. A draught limiter must
be installed if the maximum permissible feed pressure as given in the boiler data for
planning the flue gas system is exceeded.
NOTICE! Install the draught limiter directly under the mouth of the flue line, as the
pressure is constantly low at this point.
Measuring port
For measuring the emissions of the system, a suitable measuring port must be
installed in the connecting piece between the boiler and chimney system.
Germany
2Safety
Design Information
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D
D
M
2 x D
In front of the measuring port (M) a straight inlet section should be located at a
distance corresponding to about twice the diameter (D) of the connecting piece. A
straight outlet section at a distance corresponding to about the single diameter of the
connecting piece should be provided after the measuring port. The measuring port
must remain closed whenever the system is in operation.
Ensure that the outside diameter of the sampling probes in the measuring port can
accommodate up to 13 mm. To avoid the ingress of false air, the diameter of the
measuring port must not exceed 21 mm.
Boiler data for planning the flue gas system
Description S4 Turbo
15 22 28 321)
Flue gas temperature at nominal load °C 140 160 180 140
Flue gas temperature at partial load - 110 130 110
Flue gas mass flow at nominal load kg/s 0.011 0.016 0.021 0.025
Flue gas mass flow at partial load - 0.007 0.010 0.012
Required feed pressure at nominal load Pa 8 8 8 8
mbar 0.08 0.08 0.08 0.08
Required feed pressure at partial load Pa - 8 8 8
mbar - 0.08 0.08 0.08
Maximum permissible feed pressure Pa 30 30 30 30
mbar 0.3 0.3 0.3 0.3
Flue pipe diameter mm 149 149 149 149
1.S4 Turbo 32 only available in Italy
Description S4 Turbo
34 40 50 60
Flue gas temperature at nominal load °C 140 170 150 170
Flue gas temperature at partial load 110 130 100 110
Flue gas mass flow at nominal load kg/s 0.025 0.030 0.033 0.041
Flue gas mass flow at partial load 0.012 0.015 0.016 0.020
Required feed pressure at nominal load Pa 8 8 8 8
mbar 0.08 0.08 0.08 0.08
Required feed pressure at partial load Pa 8 8 8 8
mbar 0.08 0.08 0.08 0.08
Safety 2
Design Information
Installation Instructions S4 Turbo | M0971117_en 15

Description S4 Turbo
34 40 50 60
Maximum permissible feed pressure Pa 30 30 30 30
mbar 0.3 0.3 0.3 0.3
Flue pipe diameter mm 149 149 149 149
2Safety
Design Information
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3 Technology
3.1 Dimensions - S4 Turbo
L
L1
H1
H
B1
B
H4
H3
H5
H2
L1*
H1*
H2*
H6
Dim
ensi
on
Description Unit S4 Turbo
15-28
S4 Turbo
32-40
S4 Turbo
50-60
LLength, boiler mm 1,125 1,215 1,215
L1 Total length including induced draught
fan
1,300 1,390 -
L1* Total length including induced draught
fan
- - 1,680
WWidth, boiler 570 670 670
W1 Total width incl. actuators 635 735 735
HHeight, boiler 1,565 1,565 1,565
H1 Total height incl. flue gas nozzle 1,610 1,610 -
H1* Height of induced draught unit housing - - 1,480
H2 Height, flue pipe connection 1,830 1,830 -
H2* Height, flue pipe connection - - 1,700
H3 Height, flow connection 1,360 1,360 1,360
H4 Height, return connection 140 140 140
H5 Height, safety battery connection 970 970 960
H6 Height, drainage connection 120 120 120
Technology 3
Dimensions - S4 Turbo
Installation Instructions S4 Turbo | M0971117_en 17

3.2 SP Dual measurements
The following measurements must be observed for retrofitting the pellet unit at a later
date.
Dimen
sion
Description Unit SP Dual 15-28 SP Dual 32-40
LLength, firewood boiler mm 1125 1215
L1 Length, pellet unit mm 1285 1370
BSP Dual width mm 1000 1100
B1 Total width, SP Dual incl. heat-
exchanger lever
mm 1050 1150
B2 Width, firewood boiler mm 570 670
B3 Width, pellet unit mm 430 430
HHeight, boiler mm 1565 1565
H1 Total height incl. flue gas nozzle mm 1610 1610
H2 Height, flue gas pipe connection mm 1830 1830
H3 Height, flow – firewood boiler
connection
mm 1360 1360
H4 Height, return – firewood boiler
connection
mm 140 140
H5 Height, safety heat exchanger
connection
mm 970 970
H6 Height of drainage connection mm 120 120
H7 Height, flow and return - pellet unit
connection
mm 140 160
H8 Height, suction system connection mm 1370 1360
H9 Height, pellet unit mm 1465 1465
H10 Total height, pellet unit, incl. suction
turbine
mm 1545 1545
H11 Total space with cover open mm 1865 1865
Flue pipe diameter mm 150 150
Weight – pellet unit kg 310 310
3Technology
SP Dual measurements
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3.3 Components and connections
S4 Turbo 15 - 40 S4 Turbo 50 - 60
Item Description Unit S4 Turbo
1 Boiler flow connection TU inches 6/4
2 Boiler return connection TU inches 6/4
3 Drainage connection TU inches 1/2
4 Safety battery connection TU inches 1/2
5 Flue gas temperature sensor connection mm 6
6 Broadband probe connection TU inches 3/4
7 2x immersion sleeves for:
▪ thermal discharge valve (installed by
the customer)
▪ Boiler sensor and STL
TU inches 1/2
8 Flue gas pipe connection mm 149
Technology 3
Components and connections
Installation Instructions S4 Turbo | M0971117_en 19

3.4 Note on SP Dual return feed connection
ca. 300mm
ca. 175mm
When retrofitting the pellet unit of the SP Dual,
the return feed is connected to the pellet unit
due to the different water flow.
Ensure to allow for the offset of the return feed
connection (see illustration) in the piping of
the S4 Turbo with pellet flange, so that the
pellet unit can be retrofitted easily.
3Technology
Note on SP Dual return feed connection
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