Froling FT 119 User manual

Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen
Tel [phone] Fax [phone] [email protected] www.froling.com
Installation and Operating Instructions
Energy tank Indirect Water Heater FT 119
Read and follow the installation instructions and safety instructions!
Subject to technical change.

Contents
Page 2
M 153 00 12 v
C
1General Information 4
1.1Installation and Warranty Requirements 4
2Safety 5
2.1About Safety Instructions 5
2.2General Safety Information 6
2.3Installation Information 7
2.3.1Local Installation Regulations .............................................................................7
2.3.2Before Installation ............................................................................................7
2.3.3Location..........................................................................................................8
2.3.4Plumbing.........................................................................................................8
2.3.5Requirements for domestic hot water ..................................................................9
Cold Water Inlet ..............................................................................................9
Domestic Hot Water Outlet................................................................................9
Expansion tank for potable water..................................................................... 10
Thermostatic mixing valve .............................................................................. 10
Vacuum breaker (if required) .......................................................................... 10
3Technology 11
3.1Technical description 11
3.2Technical specifications 11
3.3Dimensions and Connections 12
4Installation 13
4.1Inspect Shipment 13
4.2Transport 13
4.2.1Positioning..................................................................................................... 13
4.2.2Temporary storage ......................................................................................... 13
4.3Setting up in the boiler room 14
4.3.1Recommended distances in the boiler room........................................................ 14
4.4Connecting the tank 15
4.4.1Connecting the heating ................................................................................... 15
4.4.2Domestic Hot Water connection........................................................................ 16
4.4.1Domestic Hot Water connection with recirculation line.......................................... 17
4.5Installing the sensors 18
5Operating Information 19
5.1Initial startup of the tank 19
5.1.1Filling the Heater Coils .................................................................................... 19
5.1.2Filling the Heater Tank .................................................................................... 20

Contents
Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen Page 3
Tel [phone] Fax [phone] [email protected] www.froling.com M 153 00 12
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5.2Operating the tank 20
5.3Maintenance of the tank 21
5.3.1Cleaning the tank ...........................................................................................21
5.3.2Water piping ..................................................................................................21
5.3.3Temperature and pressure relief valve...............................................................21
5.4Warranty information 22

General Information
Installation and Warranty Requirements
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M 153 00 12 v
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1General Information
Your Froling Indirect Water Heater has been carefully assembled and
factory tested to provide years of trouble-free service. In order to insure
the service intended, the following information is provided to enable
proper installation, operation, safety precautions and maintenance of
this product.
Modifying the tank or modifying/deactivating any safety equipment
relating to the system is generally prohibited.
Always comply with all fire, building, and electrical regulations when
installing or operating the system, in addition to following the operating
instructions and mandatory regulations that apply in the country in
which the tank is operated.
The instructions in this manual and in supporting documentation
(additional instructions, diagrams and component information provided
by the importer) must be followed. If the instructions are in
conflict with local code requirements, the local code requirements will
control. When in doubt, contact your dealer or importer. The manual
and supporting documentation must be retained and reviewed by the
owner / system operator for reference and future use.
The installer is responsible for familiarizing the owner / system operator
with all aspects of safety procedures, monitoring and cleaning
requirements and annual maintenance requirements.
NOTICE
Save these instructions!
1.1 Installation and Warranty Requirements
This product is provided with a limited warranty which is described in
Chapter 5.4 within this manual. The warranty is contingent upon the
successful and legal installation of the Water Heater. At a minimum, the
installation, start up, service and maintenance of this product must be
performed by a licensed professional heating system installer. Where
applicable, the installation must be inspected and accepted by the
legally responsible entity. Conditions described in the text of the
warranty for keeping it in force must be followed by the owner / system
operator.
If the water heater has been purchased through a dealer, the warranty
claim must be made to the dealer. Otherwise, claims may be made
directly to the importer.
Please read the literature enclosed by the manufacturer regarding the
various accessory devices. These devices are warranted by the
manufacturer, NOT BY the importer. These accessory devices must be
installed and used according to the recommendations of the
manufacturer.

Safety
About Safety Instructions
Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen Page 5
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2Safety
The important safeguards and instructions appearing in this
manual are not meant to cover all possible conditions and
situations that may occur. It should be understood that common
sense, caution, and care are factors which cannot be built into
every product. These factors must be supplied by the person(s)
caring for and operating the unit.
2.1 About Safety Instructions
This manual contains paragraphs that require your special attention.
These paragraphs are marked with the symbols described below:
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.

Safety
General Safety Information
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2.2 General Safety Information
Be sure to read and understand the entire
Manual before attempting to install or
operate this water heater. Pay particular
attention to the following General Safety
Precautions. Failure to follow these warnings
could cause property damage, bodily injury
or death. Should you have any problems
understanding the instructions in this
manual, STOP, and get help from a qualified
installer or technician.
Maximum water temperature occurs just
after burner or the energy source has shut
off. To find hot water temperature being
delivered, turn on a hot water faucet and
place a thermometer in the hot water stream
and read the thermometer.
The following chart details the relationship of
water temperature and time with regard to
scald injury and may be used as a guide in
determining the safest water temperature for
your applications.
TIME VS. TEMPERATURE RELATIONSHIPS IN SCALDS
Temperature Time to Produce Serious Burn Temperature Time to Produce Serious Burn
120 °F More than 5 minutes 140 °F Less than 5 seconds
125 °F 1-1/2 to 2 minutes 145 °F Less than 3 seconds
130 °F About 30 seconds 150 °F About 1-1/2 seconds
135 °F About 10 seconds 155 °F About 1 second
There is a hot water scald potential if the aquastat is set too high. When
this water heater is supplying general purpose hot water requirements
for use by individuals, a thermostatically controlled mixing valve for
reducing point-of-use water temperature is recommended to reduce the
risk of scald injury. Contact a licensed plumber or local plumbing
authority for further information.

Safety
Installation Information
Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen Page 7
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2.3 Installation Information
CAUTION
Assembly and installation by untrained personnel!
Risk of injury and damage to equipment!
The instructions and information provided in the instructions
should be observed!
Only allow trained staff (heating engineers) to carry out assembly
and installation!
2.3.1 Local Installation Regulations
This water heater must be installed in accordance with these instructions
and must conform to local, or in the absence of local codes, with the
current edition of the National Plumbing Code and the National Electric
Code. In any case where instructions in this manual differ from local or
national codes, the local or national codes take precedence.
2.3.2 Before Installation
In some jurisdictions the boiler’s operating pressure must be limited to
30 psi (200 kPa) by a safety relief valve. When a higher operating
pressure level is needed, select a boiler which is certified to operate at
the required pressure.
The boiler’s output rating must be within the heater’s recommended
sizing guide specifications. Too low an output rating may cause
excessive condensation in the boiler. Too high an output rating may
cause a boiler short cycling condition. Either of these conditions could be
detrimental to the life and performance of the system.
The flow of hot boiler water to the water heater can be controlled with
either a pump or a motorized valve. If a zone valve is to be used, the
space heating system circulator must have an adequate flow rate to
allow proper heat transfer of BTUs from the hot boiler water stored in
the tank to the domestic water flowing inside the water heater’s heat
exchanger. Be sure the space heating zone valve chosen has maximum
pressure drop to insure proper boiler water flow to the heater. The
recommended way to provide adequate boiler water flow through the
water heater is to use a separate dedicated circulator. This option may
be used even though the heating system utilizes zone valves.
The heat transfer medium must be water or other non-toxic fluid having
a toxicity rating or class of 1, as listed in Clinical Toxicology of
Commercial Products, 5th edition

Safety
Installation Information
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2.3.3 Location
The water heater must be installed vertically and should be installed in a
clean, dry location as close as practical to the boiler or the heat source.
Long hot water lines should be insulated to conserve water and energy.
The water heater and water lines should be protected from exposure to
freezing temperatures.
All models can be installed on combustible floors and in alcoves.
Minimum clearance from combustible construction is 0 inches on all
sides. A minimum 3 inch clearance on both sides and in the rear and a
minimum 24 inch clearance in front and on top should be available for
adequate inspection and servicing.
This unit must be placed where leakage from the relief valve, leakage
from the related piping, or leakage from the tank or connections, will
not result in damage to the surrounding areas, or to the lower floors of
the building. A water heater should always be located in an area with a
floor drain or installed in a drain pan suitable for waterheaters. The
manufacturer or supplier shall not be held liable for any such water
damage.
2.3.4 Plumbing
It is mandatory that all plumbing is done in accordance with all local and
state plumbing codes, or warranty will be voided. It is also necessary on
all mechanical connections, that you use both thread tape and pipe
dope.
The manufacturer’s warranty does not cover any damage or defect
caused by installation or attachment or use of any special attachment
other than those authorized by the manufacturer into, onto, or in
conjunction with the water heater. The use of such unauthorized devices
may shorten the life of the water heater and may endanger life and
property. The manufacturer disclaims any responsibility for such loss or
injury resulting from the use of such unauthorized devices.
WHEN FILLING THE TANK, MAKE SURE THAT YOU OPEN THE HOTWATER
TAP TO RELEASE AIR IN THE TANK AND PIPING.
The boiler supply connection of the tank is to be connected to the "HOT
OUTLET" side of the boiler. The boiler return connection of the tank is to
be connected to the inlet of the circulator, the outlet of the circulator to
the return connection of the boiler. Be sure that the arrow on the
circulator is facing toward the flow direction. The return(s) from heating
loop(s) should have a flow check or swing check valve installed before
the return pipe from the tank.
In a steam boiler, the tank supply must be connected to the boiler, well
below the minimum water level. A strainer and a drain valve should be
installed at the boiler for periodic draining of scale and sludge. Banging
and steam bound traps will occur if the boiler water supplied to heat
exchange has steam, or is slightly above the low water cut-out.
Precautions should be taken so that the boiler return is above the boiler
manufacturer’s lowest recommended temperature. Most hot water
heating systems use standard, non-condensing boilers (cast iron or
steel), which must be operated above 140°F in order to prevent the
corrosion that is associated with flue gas condensation.

Safety
Installation Information
Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen Page 9
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2.3.5 Requirements for domestic hot water
To avoid a build-up of scale (precipitation of calcium bicarbonate
dissolved in water) in the stainless steel corrugated pipe element, for
water hardnesses > 15°dH (267.7 ppm), we recommend that you use
softening systems to prepare the drinking water. The maximum chlorine
content of drinking water should not exceed 70 mg/L.
This water heater may be connected individually, in multiples with
others, or with an external hot water storage tank. If two tanks or more
are installed, the piping method to be used to connect the tanks in
parallel should be “reverse-return piping”, so domestic water flow rate
through each tank is equal.
The installation of copper unions or copper alloy unions is recommended
on the HOT and COLD water lines, so that the water heater may be
easily disconnected for servicing if necessary. Install cut-off (ball) valves
for servicing convenience.
Never use dielectric unions or galvanized steel fittings on any domestic
water connections. Use only copper or brass fittings. Teflon thread
sealant must be used on all connections.
Use only clean copper or approved plastic pipe for water connections.
Local codes or regulations shall govern the exact type of material to be
used.
Cold Water Inlet
Use both thread tape and pipe dope and connect an NPT brass tee.
On the branch, install a brass drain valve. In the run, install an NPT
male X ¾“ (minimum) tube adapter. A cut-off valve between city water
supply and tank inlet is recommended for ease of service at a later date.
It may be recommended to use a back flow preventer – check your local
codes. If a back flow preventer, or a no return valve is used; a thermal
expansion tank must be installed on the cold water supply, between the
tank and valve.
Domestic Hot Water Outlet
An automatic temperature & pressure relief valve with a temperature
probe of sufficient length must be installed at the time of the
installation. No valve of any type should be placed between the T&P
relief valve and the water heater. Use a tee to install the relief valve
onto the hot water outlet. The pressure rating of the relief valve must
not exceed 150 psi. The BTU per hour rating of the relief valve must
equal or exceed the BTU per hour input of the boiler(s) or heat source(s)
as marked on the boiler(s) rating plate.
Connect the outlet of the relief valve to a suitable open drain. The
discharge must exit no higher than 6” above the structural floor; and
cannot contact any live electrical parts. The discharge line must pitch
downward from the valve to allow complete draining (by gravity) of the
relief valve and discharge line, and be no smaller than the outlet of the
valve. The end of the discharge line should not be threaded or concealed
and should be protected from freezing. No valve of any type, restriction
or reducer coupling should be installed in the discharge line. Local codes
shall govern the installation of relief valves.

Safety
Installation Information
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To minimize heat loss during non-draw periods, a heat trap formed from
piping can be used. Insulate all pipes containing hot water, especially in
unheated areas.
Thermometer(s) should be installed to indicate the temperature of the
water at or near the outlet of the water heater and storage tank(s), if
provided.
Expansion tank for potable water
Determine if there is a check valve, a back flow preventer, a pressure-
reducing valve, a water meter or a water softener in the cold water
supply line.
A check valve creates a closed system and prevents the water, as it is
being heated, from expanding back into the cold water supply line.
Pressure can build up within the water heater, causing the relief valve to
operate during a heating cycle. This excessive operation can cause
premature failure of the relief valve and possibly of the water heater
itself.
Replacing the relief valve will not correct the problem. One method of
preventing pressure build-up is to install an expansion tank for potable
water in the cold water supply line between the heater and check valve.
Contact your installing contractor, water supplier, local plumbing
inspector or plumbing supply house for assistance.
Thermostatic mixing valve
When this water heater is supplying general-purpose hot water
requirements for use by individuals, a thermostatically controlled mixing
valve is recommended to reduce the risk of scald injury. Contact a
licensed plumber or the local plumbing authority for further information.
Keep temperature control of the mixing valve at the lowest setting which
is satisfactory.
When installing a mixing valve, locate it at the bottom of anti-
thermosiphon loop at least 24” high to prevent excessive hot water from
entering mixed water supply.
Vacuum breaker (if required)
Install a vacuum breaker (or vacuum relief valve) for water heater
protection. A vacuum breaker prevents siphoning of the water from the
system and collapse of the water heater.

Technology
Technical description
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3Technology
3.1 Technical description
Layered tank made of sheet steel S235JRG2, upright, with integrated
stainless steel corrugated pipe element for hygienic hot water
preparation for indirect heating using solid fuel boilers, electric heating,
oil or gas boilers.
Domestic hot water preparation uses the flow principle:
The relatively small volume in the corrugated pipe element means that
the domestic hot water is always heated to the maximum temperature
and very frequently renewed, preventing legionella build-up.
The thermal expansion of the corrugated pipe element prevents
limescale deposits; the limescale particles that are created are broken
off by the movement of the element pipe and are washed away with the
flow of water.
The boiler water in the tank constitutes a store of heat energy ready to
heat fresh domestic water. The volume of boiler water stored in the tank
provides enough heat to keep your domestic water hot while the boiler
heats up. In fact, it acts as a buffer which prevents domestic hot water
or boiler water temperature swings.
3.2 Technical specifications
Description FT 119
Capacity (total) 119 gal
Tank Capacity 108 gal
Maximum Tank Pressure 43.5 psi
Weight 260 lbs
Specification DHW Coil
Heat Exchanger Surface 64.5 sq.ft.
Maximum Coil Pressure 87 psi
Coil Capacity (Domestic Hot Water) 11 gal
Maximum Temperature Domestic Hot Water 203 °F
Recommended Flow Rate 4 gal/min
Pressure Drop (feet) 2.6 psi
180° Boiler Water First Hour Rating1) 140 °F 103 gal
115 °F 133 gal
1) DOE test method base on 90°F. Temperature rise, 50°/140° W/Boiler water at 180°F

Technology
Dimensions and Connections
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3.3 Dimensions and Connections
C1
C2
C1
C2
C1
C2
C3
C4
C5
C5
C3
C4
SB
C7 C6
C7
C6
30“
4.3“
66.7“
46.5“
72.8“
22“
Connections
C1 Boiler Supply 1 ½"
C2 Boiler Return 1 ½"
C3 Cold Water Inlet 1 ¼"
C4 Hot Water Outlet 1 ¼"
C5 Drain Valve ¾"
C6 Air Vent 1 ½"
C7 Safety valve (T&P valve) ¾"
SB Sensor bar

Installation
Inspect Shipment
Froling GmbH, Industriestrasse 12, A-4710 Grieskirchen Page 13
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4
4Installation
4.1 Inspect Shipment
Inspect the water heater for possible shipping damage. The
manufacturer’s responsibility ceases upon delivery of goods to the
carrier in good condition. Consignee must file any claims for damage,
shortage in shipments, or non-delivery immediately against carrier.
4.2 Transport
The tank is delivered on a pallet.
Move the tank without jarring or jolting
We recommend you take the tank off the pallet to position it
4.2.1 Positioning
The tank has recesses on the bottom for transport with a hand lift
truck.
If the tank cannot be brought in vertically, it can also be transported
to the boiler room horizontally.
However you should ensure that the threaded connector supports are
not damaged.
4.2.2 Temporary storage
If the system is to be installed at a later date:
Store the tank in a safe, dry place and protect from frost
Damp and frost reduce the effectiveness of the insulation

Installation
Setting up in the boiler room
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4.3 Setting up in the boiler room
4.3.1 Recommended distances in the boiler room
Set up the boiler according to the applicable standards and regulations.
The following distances are recommended:
A Distance from tank to boiler 12"
B Distance from tank to Smoke flue pipe 20"
C Distance from tank to wall 4"
Clearance in front of the tank 24"

Installation
Connecting the tank
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4.4 Connecting the tank
4.4.1 Connecting the heating
The tank should be connected to the heating system at the relevant
outfeed and return feed pipes and must be fitted with a tested
temperature and pressure relief valve (T&P valve). It is best to install
the T&P valve at the top of the tank, so the tank does not have to be
emptied to replace it.
The information on the position and description of the sensors should be
taken from the relevant controller instructions.
This is a simplified conceptual drawing only! Plumbing and necessary
componentry must be field verified. Proper installation and functionality
in the field is the responsibility of the heating contractor.
12 3 14
5
6
C2
C1
Sensor 0.1
Sensor 0.2
Pump 0.1
Boiler Supply
Hot Out
Boiler Control
Boiler Return
1 Cut-off valve 2 Check valve
3 Circulator 4 Expansion tank
5 T&P valve 6 Drain valve
C1 Boiler supply connection C2 Boiler return connection

Installation
Connecting the tank
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4.4.2 Domestic Hot Water connection
The cold water must be connected in accordance with local codes.
We also recommend that you install a thermostatic mixing valve at the
hot water outlet, as the drinking water can reach the hot water
temperature, leading to a risk of scalding (hot water > 125 °F).
This is a simplified conceptual drawing only! Plumbing and necessary
componentry must be field verified. Proper installation and functionality
in the field is the responsibility of the heating contractor.
H
MC
1 2 34561 4 8
9
11
7
C3
C4
Sensor 0.3
Boiler Control
Tap Connections
Cold Water Supply
min. 24“
1 Cut-off valve 2 Pressure-reducing valve
3 Drinking water filter 4 Drain valve
5 Check valve 6 Pressure gauge connection
7 Pressure relief valve 8 Expansion tank for potable water
9 Thermostatic mixing valve
C3 Cold water inlet of heating coil C4 Hot water outlet of heating coil

Installation
Connecting the tank
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4.4.1 Domestic Hot Water connection with recirculation line
If a recirculation line is installed, the return connection should be made
to a tee close to the inlet connection to the tank. A check valve should
always be installed in the recirculation line to prevent cold water from
entering.
The cold water must be connected in accordance with local codes.
We also recommend that you install a thermostatic mixing valve at the
hot water outlet, as the drinking water can reach the hot water
temperature, leading to a risk of scalding (hot water > 125 °F).
This is a simplified conceptual drawing only! Plumbing and necessary
componentry must be field verified. Proper installation and functionality
in the field is the responsibility of the heating contractor.
H
MC
1 2 34561 4 8
5
10
11
7
C3
C4
Sensor 0.3
Boiler Control
Cold Water Supply
Tap Connections
min. 24“
9
1 Cut-off valve 2 Pressure-reducing valve
3 Drinking water filter 4 Drain valve
5 Check valve 6 Pressure gauge connection
7 Pressure relief valve 8 Expansion tank for potable water
9 Thermostatic mixing valve 10 Circulator
C3 Cold water inlet of heating coil C4 Hot water outlet of heating coil

Installation
Installing the sensors
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4.5 Installing the sensors
After the system has been plumbed, you have to install the necessary
sensors at the sensor bar.
Open the zipper at the outershell
Loose fixing screws of the sensor bar
Position the sensors according to the plumbing schematics
(see chapter 4.4 "Connecting the tank")
After positioning of the sensors tighten the fixing screws of the
sensor bar carefully
Lay sensor cables behind the outershell to the top of the tank
Close the zipper at the outershell
Lay sensor cables to the boiler by using a cable duct
Connect cables according to the manual of the boiler control

Operating Information
Initial startup of the tank
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5
5Operating Information
After the water heater has been plumbed and wired, it is now ready to
be set for automatic operation.
Before operating this water heater, be sure to read and follow these
instructions, as well as the warnings printed in this manual. Failure to do
so can result in unsafe operation of the water heater resulting in
property damage, bodily injury, or death. Should you have any
problems reading, following or difficulty in understanding the
instructions in this manual, STOP, and get help from a qualified person.
Do not turn on the water heater unless it is filled with water.
Do not turn on water heater if cold water supply cut-off valve is closed.
5.1 Initial startup of the tank
The initial startup must be performed by the system designer or a
specialist technician designated by the designer. In addition, the owner
must be informed of the need for regular maintenance.
The whole system should be carefully rinsed out before the initial
startup. Foreign matter in the system may affect the operating safety of
the device.
5.1.1 Filling the Heater Coils
Initially the domestic hot water coil should be filled with cold water.
Make sure all drains valves on the cold or hot water supply piping are
closed.
Open the nearest hot water faucet and any cut-off valves on the
domestic hot water supply piping from the heater’s domestic hot
water outlet (the top copper pipe connection).
Open the cut-off valve on the cold water supply piping to the heater’s
domestic cold water inlet.
Pressure-check the safety valve in the cold water supply line for
operability.
A safety valve, which is not operating perfectly, can lead to
damage from excessive pressure.
When water discharges from faucet, close it.
Check for system leaks and repair if necessary.
Any other water faucets fed by this heater should be opened to
purge air from their supply piping, and then shut off after a steady
flow of water is observed from the faucet.

Operating Information
Operating the tank
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5.1.2 Filling the Heater Tank
The Heater Tank must be filled only after filling the domestic hot water
coil!
Open the cut-off valve on the supply piping from the boiler.
(and on a zone valve system, manually open zone valve)
Open cold water supply valve (fill or makeup water valve) to boiler.
To let the air out of the tank during the fill process open the relief
valve on top of the tank
Leave all cut-off valves open.
After filling the system return zone valve to automatic operation.
Check system for leaks and repair if necessary.
Purge air from the remaining zones, if necessary.
Check boiler pressure gage reading afterwards.
15 psi is normal for most installations
5.2 Operating the tank
After the system has been manually purged of its air, and all
components (valves, vents, controllers) have been set properly, the
boiler can be started. Never operate this heater until this has been done.
The system installer must train the operator to operate the system. The
installer must also familiarize the operator with the modes of operation,
with special emphasis on the function and meaning of the safety devices
and their maintenance requirements.
The outlet line of the safety valve must always remain open.
The temperature and pressure relief valve must be periodically checked
for correct functioning by releasing the pressure.
When there is a danger of freezing, the tank must either be heated up
or completely emptied.
For long absences or periods of inactivity (vacations) hot water
preparation should be deactivated. When doing this, however, ensure
that the temperatures at the installation location of the hot water
preparer and in the connected piping system are above the freezing
point to prevent damage due to freezing. In case of prolonged
stagnation in the pipes and the tank, the water quality can be affected
by increased build-up of germs. For this reason, before starting up the
system again after prolonged absence, we recommend that you heat the
water to at least 140 °F through rarely used tap connections and allow it
to circulate freely for around 5 minutes before use.