Froling S4 Turbo User manual

Operating Instructions
Log wood boiler S4 Turbo
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!
B0510512_en | Edition 25/06/2013
Froling GesmbH | A-4710 Grieskrichen, Industriestraße 12 | www.froeling.com

Table of Contents
1 General 4
1.1 S4 Turbo Product Overview 5
2 Safety 7
2.1 Hazard levels of warnings 7
2.2 Pictograms used 8
2.3 General safety information 9
2.4 Permitted uses 10
2.4.1 Permitted fuels 10
Firewood 10
2.4.2 Fuels permitted under certain conditions 11
Wood briquettes 11
2.4.3 Non-permitted fuels 11
2.5 Qualification of operating staff 12
2.6 Protective equipment for operating staff 12
2.7 Design information 12
2.7.1 Installation and approval of the heating system 12
2.7.2 General information for installation room (boiler room) 13
2.7.3 Requirements for central heating water 13
2.7.4 Return lift 14
2.7.5 Combination with storage tank 14
2.7.6 Chimney connection/chimney system 14
2.8 Safety devices 15
2.9 Residual risks 15
2.10 Emergency procedure 17
2.10.1 Overheating of the system 17
2.10.2 Smell of flue gas 17
3 Operating the System 18
3.1 Assembly and initial startup 18
3.2 Heating up the boiler 19
3.2.1 Switching on the power supply 19
3.2.2 Switching on the boiler 19
3.2.3 Before heating up the boiler 19
Reloading intervals when operating with storage tank 19
Determining the right amount of fuel 20
Fuel table 21
Fill level in boiler 21
Reloading intervals when operating without storage tank or if the storage tank is too small 21
3.2.4 Heating the boiler with firewood 22
3.2.5 Heating up the boiler with automatic ignition 24
3.2.6 Regulating the boiler 24
3.2.7 Reloading firewood 25
3.2.8 Switching off the power supply 26
4 Boiler servicing 27
4.1 General information on servicing 27
Table of Contents
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4.2 Inspection and cleaning 28
4.2.1 Prior to heating up 28
Always move the WOS lever 28
Check the ignition pipe (only with automatic ignition) 28
4.2.2 Inspection 29
Checking the system pressure 29
Checking the thermal discharge safety device 29
Checking the safety valve 29
4.2.3 Cleaning 29
Emptying ash 30
Cleaning the grating 30
4.2.4 Annual inspection 31
Cleaning the carbonisation gas duct 31
Checking the primary air openings 31
Cleaning the heat exchanger pipes 32
Checking the seal on the doors 33
Cleaning the flue gas temperature sensor 34
Clean the flue gas pipe 35
Checking the draught controller flap 35
Cleaning the induced draught fan 35
4.3 Emissions measurement by chimney sweep or regulatory body 36
4.3.1 Measuring at rated load in firewood mode 36
4.3.2 Measuring at partial load in firewood mode (if required) 36
4.4 Maintenance agreement / Customer service 37
4.5 Replacement parts 37
4.6 Disposal information 37
4.6.1 Disposal of the ash 37
4.6.2 Disposal of system components 37
5 Troubleshooting 38
5.1 General fault with power supply 38
5.1.1 Behaviour of system after a power failure 38
5.2 Excessive temperature 38
5.3 Faults with fault message 39
5.3.1 Procedure for fault messages 39
5.3.2 Acknowledging a fault message 39
6 Appendix 40
6.1 Addresses 40
6.1.1 Address of manufacturer 40
6.1.2 Address of the installer 40
Table of Contents
Operating Instructions S4 Turbo | B0510512_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.
Guarantee conditions
Our sale and delivery conditions generally apply. 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.
1General
4 Froling GesmbH | A-4710 Grieskrichen, Industriestraße 12 | www.froeling.com

1.1 S4 Turbo Product Overview
1Insulated door
1.1 Maintenance overview
2Fuel loading door
3Pre-heating chamber door
4Combustion chamber door with inspection glass
5Control panel of the Lambdatronic S3200
5.1 Visual display showing operating statuses and parameters
5.2 Status LED (operating status):
- GREEN constant: BOILER ACTIVE (heating up/heating)
- GREEN flashing (interval: 5 sec. OFF, 1 sec ON): OFF
- ORANGE flashing: WARNING
- RED flashing: FAULT
5.3 Navigation keys to move around in the menus and to change the parameter values
5.4 Function keys to call up individual boiler functions directly
NOTICE! For key layout see control unit operating instructions
General 1
S4 Turbo Product Overview
Operating Instructions S4 Turbo | B0510512_en 5

Underneath the back insulating cover (9):
6Lever for heat exchanger cleaning system (WOS)
7Actuators for automatic regulation of primary and secondary air
8Automatic ignition (optional)
9Back insulating cover
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
1General
S4 Turbo Product Overview
6 Froling GesmbH | A-4710 Grieskrichen, Industriestraße 12 | www.froeling.com

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
Operating Instructions S4 Turbo | B0510512_en 7

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 instruc‐
tions
Wear safety shoes
Wear protective gloves Turn off the main switch
Keep the doors closed
Unauthorised access prohibited
Warning - hot surface Warning - hazardous electrical
voltage
Warning - hazardous or irritant
materials
Warning - automatic boiler start‐
up
Warning of injury to fingers or
hands, automatic fan
2Safety
Pictograms used
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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 individual manuals.
❒ Any work above and beyond this should be carried out by authorised heating
engineers 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 car‐
bonisation 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 insuf‐
ficient chimney draught, can cause serious faults in combustion (such as sponta‐
neous 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.
Safety 2
General safety information
Operating Instructions S4 Turbo | B0510512_en 9

2.4 Permitted uses
The Froling Firewood boiler S4 Turbo is designed solely for heating domestic water.
Only use fuels specified in the "Permitted fuels" section.
⇨ See "Permitted fuels" [page 10]
The unit 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 en‐
sure you are aware of the potential hazards. The inspection and cleaning intervals in
the operating instructions should be observed. Ensure that any faults which might im‐
pair safety are rectified immediately.
The manufacturer or supplier is not liable for any damage resulting from non-permitted
uses.
2.4.1 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 acc. to EN 14961 - Part 5: Firewood class A2 / D15 L50
Germany
also:
Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance
(BimSchV) in the last amended version)
▪ Values in practice:
- Hardwood: 2 years in dry storage
- Soft wood: 1 year in dry storage
▪Store stacks of split wood sheltered from the rain
▪ Create a dry underlay, where possible with air access (line with round timber, pallets,
etc.)
▪ 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
▪ If possible, stock fuel for the day in a warm place (e.g. in boiler room) (pre-heats the
fuel!)
NOTICE! Use fuels that are consistent in size and water content.
NOTICE! Burning extremely dry fuels (w < 15%) may require repairs by qualified staff.
Please contact Froling customer services or your installer.
Water content
Note on standards
Tips for
storing wood
2Safety
Permitted uses
10 Froling GesmbH | A-4710 Grieskrichen, Industriestraße 12 | www.froeling.com

2.4.2 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 acc. to 14961 - 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) in the last amended version)
▪ When burning wood briquettes use the settings for extremely dry fuel
▪Wood briquettes must be heated up with firewood as per EN 14961-5
(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 combus‐
tion problems. In such cases, repairs must be carried out by qualified staff. Please con‐
tact Froling customer services or your installer.
2.4.3 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐
ing 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
Note on standards
Notes on
use
Safety 2
Permitted uses
Operating Instructions S4 Turbo | B0510512_en 11

2.5 Qualification of operating staff
CAUTION
If unauthorised persons enter the installation room / boiler 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 pre‐
vention regulations.
▪ For operation, inspection and cleaning:
- suitable work wear
- protective gloves
- sturdy shoes
2.7 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 oper‐
ating the boiler system, and follow the operating instructions and mandatory regula‐
tions that apply in the country in which the boiler is operated.
2.7.1 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.
Note on standards
2Safety
Qualification of operating staff
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2.7.2 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.
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
2.7.3 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.
Note on standards
Note on standards
Safety 2
Design information
Operating Instructions S4 Turbo | B0510512_en 13

2.7.4 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).
2.7.5 Combination with storage tank
You can find more detailed information about storage tank design in the boiler assem‐
bly instructions.
NOTICE! See "Design Information" section in the assembly instructions S4 Turbo
2.7.6 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.
NOTICE! Please see the technical data contained in the assembly instructions for fur‐
ther information about standards and regulations as well as the flue gas temperatures
when clean and the other flue gas values!
2Safety
Design information
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2.8 Safety devices
1311
TA SV
Underneath the back insulating cover (9):
11 MAIN SWITCH
(switches off the power supply)
For shutting down the entire system
❒ The power to all components is switched off.
➥ WARNING! Only switch off the boiler when it has burnt down and cooled off.
13 HIGH-LIMIT THERMOSTAT (STL)
(protection against overheating)
The STL switches off the combustion system when the boiler reaches 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 a valve at approx. 100°C and feeds cold water to
the safety heat exchanger to lower the boiler temperature
SV SAFETY VALVE
(protection against overheating/excessive 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.
2.9 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
Safety 2
Safety devices
Operating Instructions S4 Turbo | B0510512_en 15

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 in a controlled way (operating status "Off") and allow it to
cool down
❒ Protective gloves must generally be worn for work on the boiler, and it should
only be operated using the handles provided
❒ Insulate the flue pipes or simply avoid touching them during operation.
WARNING
When inspecting and cleaning the boiler with the main switch on:
Serious injuries possible due to boiler/individual components starting up automati‐
cally (induced draught)!
Before inspection and cleaning work in/on the boiler:
❒ Allow the fuel in the boiler to burn off
❒ Allow boiler to cool off and switch off main switch
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 acci‐
dents!
Take the following precautions:
❒ Only use fuels specified in the "Permitted fuels" section of these operating in‐
structions.
CAUTION
Automatic ignition attempt failed:
damage to equipment may occur
Damage to heating system (e.g. from frost) because automatic ignition was set in‐
correctly or not carried out.
❒ Before leaving the boiler check the start time that has been set for automatic
ignition.
❒ Within an appropriate time ensure that automatic ignition has been carried out
successfully.
➥Due to the different types of wood, Froling cannot guarantee successful
automatic ignition. The manufacturer/supplier is not responsible for result‐
ing damage.
2Safety
Residual risks
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2.10 Emergency procedure
2.10.1 Overheating of the system
If the system overheats and the safety devices fail, 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 available radiator thermostat valves
If the temperature does not drop:
❒ Contact the installer or Froling customer services
⇨ See "Addresses" [page 40]
2.10.2 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
❒ Shut down the boiler according to procedure
❒ Ventilate the room where the boiler is installed
❒ Close the fire door and doors to living areas
Safety 2
Emergency procedure
Operating Instructions S4 Turbo | B0510512_en 17

3 Operating the System
3.1 Assembly and initial startup
Assembly, installation and initial startup of the boiler must only be carried out by quali‐
fied staff, and these procedures are described in the accompanying assembly instruc‐
tions.
NOTICE! See assembly instructions for the S4 Turbo
NOTICE
Optimum efficiency and efficient, low-emission operation can only be guaranteed
if the system is set up by trained professionals and the standard factory settings
are observed.
Take the following precautions:
❒Initial startup should be carried out with an authorised installer or with Froling
customer services
The individual steps for initial start-up are explained in the operating instructions for
the controller
NOTICE! See operating instructions for the Lambdatronic S 3200
The customer is responsible for ensuring the following prior to initial start-up of the
system by Froling customer services:
▪Electrical installation
▪ Installation of water pipes
▪ Connect flue gas including all insulation work
▪ Work must comply with local fire protection regulations
▪ When heating up the boiler for the first time to dry out the fireclay concrete, the
customer must provide approx. 0,5 m³ of dry firewood.
▪ It is essential that the electrician who has carried out the installation work is availa‐
ble when starting up the system for the first time to make any changes to the wir‐
ing which may become necessary.
▪ During initial start-up, operating staff are shown how to use the boiler. It is impera‐
tive for proper handover of the product that those involved are present as this is a
one-off opportunity.
NOTICE
If condensation escapes during the initial heat-up phase, this does not indicate a
fault.
❒Tip: If this occurs, clean up using a cleaning rag.
3Operating the System
Assembly and initial startup
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3.2 Heating up the boiler
3.2.1 Switching on the power supply
❒ Turn on the main switch
➥There is voltage at all of the boiler's components
➥When the control has completed the system start, the boiler is ready for opera‐
tion
3.2.2 Switching on the boiler
❒ Press the standby key
➥Automatic mode is active
➥The heating system is controlled via the controller according to the selected
mode in automatic mode
❒For other modes press the relevant function key
➥Information on function keys in the relevant operating instructions for the
"Lambdatronic S 3200" boiler controller
NOTICE! The storage tank can be loaded in all operating modes to ensure constant
heat consumption.
3.2.3 Before heating up the boiler
Reloading intervals when operating with storage tank
Reloading intervals and amounts should be determined exclusively according to the
storage tank for efficient and environmentally-friendly heating.
❒ Check the store load status on the display
Load status Procedure
No bars or one bar in the store load status means that the stor‐
age tank needs to be heated up by approx. 35°C.
⇨ See "Determining the right amount of fuel" [page 20]
Two bars in the store load status mean that the storage tank
needs to be heated up by approx. 20°C.
⇨ See "Determining the right amount of fuel" [page 20]
Three or four bars in the store load status mean that the storage
tank cannot take any more heat, or only a small amount. In this
case do not add fuel!
Operating the System 3
Heating up the boiler
Operating Instructions S4 Turbo | B0510512_en 19

Determining the right amount of fuel
The amount of fuel added should allow the storage tank to be constantly heated to the
max. storage tank temperature (= boiler target temperature). Please note that the
amount to reload also depends on the type of fuel.
Example: Heat a 2000 litre storage tank by 30°C
The calculation below only takes into account the storage tank. It does not take into
account the boiler efficiency, pipe losses and the energy required to heat the boiler
and heating system.
Assumption: The storage tank currently has a temperature of 50°C and should be
heated to 80°C. The calculation below shows how much fuel is required for heating.
First we calculate the energy required:
As the medium to be heated is water and the mass is roughly the same as the volume (2000
litres = 2000 kg), we can use the simplified formula Q = m x c x Δt.
Q = energy required
m = mass of the medium to be heated
c = heat capacity of the medium to be heated (constant for water)
Δt = temperature difference between start and end temperature1)
Mass (m) x heat capacity (c) x temperature difference (Δt) = energy (Q)
2000 kg x 1.163 Wh/kgK x 30 K = 69 780 Wh
69 780 Wh = 69.8 kWh
Heating a 2000 litre storage tank from 50°C to 80°C requires approx. 69.8 kWh of energy.
1.Temperature difference in Kelvins (K). As these are not absolute temperatures the value can be entered in degrees Celsius (°C). (30°C
equals 30°K)
The amount of fuel can now be calculated from the energy required:
For our sample calculation we used beech with a water content w=20%. The energy content
of the fuel varies according to the type of wood and the water content. (⇨ See "Fuel table"
[page 21])
Energy required = 69.8 kWh (from calculation above)
Energy content of fuel = 3.8 kWh/kg (beech, w=20%)
Energy required / energy content of fuel = amount of fuel
69.8 kWh / 3.8 kWh/kg = 18.4 kg
Approx. 18.4 kg beech wood (w=20%) is required to heat a 2000 litre storage tank from 50
°C to 80 °C.
3Operating the System
Heating up the boiler
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