assembly instructions - pth hout-cv · read and follow the assembly instructions and safety...

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com

Assembly Instructions

S4 Turbo

Read and follow the assembly instructions and safety information. Subject to technical change.

Introduction

Fröling Heizkessel- und Behälterbau Ges.m.b.H, Industriestrasse 12, A-4710 Grieskirchen Tel +43 (0) 7248 606-0 Fax +43 (0) 7248 606-600 [email protected] www.froeling.com M0970208

I

Dear customer, The FRÖLING S4 Turbo is a state-of-the-art design that conforms to all currently applicable standards and testing guidelines. Please read and follow the assembly instructions. They contain safety instructions and comprehensive information relating to transporting, setting up and assembling the boiler. The continuous development of our products means that there may be minor differences between the illustrations and other content of the document. If you discover any errors, please let us know. Subject to technical change.

Delivery Certificate Keeping a record that the delivery was received correctly and collecting customer-specific data relating to the system allows us to respond quickly should problems arise. We would therefore ask you to confirm that you have received the product in good condition. Please send Fröling a copy of the delivery certificate, filled in and signed by the customer.

Guarantee conditions Our sale and delivery conditions shall always apply. These are made available to customers in advance, and are deemed to have been accepted at the time the contract is concluded. The warranty conditions can also be found in the enclosed guarantee certificate.

Address of manufacturer

FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL +43 (0)7248 606 0 FAX +43 (0)7248 606 600 E-MAIL [email protected] INTERNET www.froeling.com

Contents

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C

1 General information 6

1.1 Notes on standards 6 1.2 Design Information 7

1.2.1 Approval and obligation to report ...................................................................... 7 1.2.2 Requirements for central heating water.............................................................. 7 1.2.3 Ventilation of boiler room................................................................................. 8 1.2.4 Installing the heating system / Standards........................................................... 8

Return feed lift .............................................................................................. 8 Combination with storage tank......................................................................... 9

1.2.5 Chimney connection/chimney system .............................................................. 10 Draught limiter ............................................................................................ 10 Boiler data relating to design of the flue gas system.......................................... 10

2 Technology 11

2.1 Components and connections 11 2.2 Dimensions 12 2.3 Performance data 13

2.3.1 S4 Turbo 15/22/28 ....................................................................................... 13 Test report data........................................................................................... 13

2.3.2 S4 Turbo 34/40 ............................................................................................ 14 Test report data........................................................................................... 14

2.3.3 S4 Turbo 50/60 ............................................................................................ 15 Test report data........................................................................................... 15

3 Installation 16

3.1 Transport 16 3.1.1 Positioning ................................................................................................... 16 3.1.2 Remove boiler from pallet .............................................................................. 16 3.1.3 Temporary storage........................................................................................ 16

3.2 Setting up in the boiler room 17 3.2.1 Moving the boiler in the boiler room................................................................. 17 3.2.2 Minimum distances in the boiler room.............................................................. 17

3.3 Materials supplied 18 3.3.1 Tools required .............................................................................................. 18

3.4 Before installation 19 3.4.1 Fitting doors on the left ................................................................................. 19 3.4.2 Fitting the door handles ................................................................................. 21 3.4.3 Positioning doors .......................................................................................... 21

3.5 Installation of S4 Turbo 15/22/28/34/40 22 3.5.1 Fitting the induced draught fan ....................................................................... 22 3.5.2 Installing the flue gas pipe nozzle.................................................................... 22 3.5.3 Installing the WOS system ............................................................................. 22 3.5.4 Installing the air flaps.................................................................................... 24

Air flaps for actuators right (delivery configuration)........................................... 24 Air flaps for actuators left .............................................................................. 25

3.5.5 Installing the insulation.................................................................................. 26

Contents


C 3.5.6 Installing the actuators .................................................................................. 29 3.5.7 Installing the Lambda probe ........................................................................... 30 3.5.8 Installing the flue gas sensor .......................................................................... 31 3.5.9 Installing the control unit ............................................................................... 31 3.5.10 Installing the WOS lever................................................................................. 32 3.5.11 Install the insulating door............................................................................... 34 3.5.12 Installing the insulating cover ......................................................................... 35 3.5.13 Installing the floor insulation........................................................................... 35

3.6 Installing the S4 Turbo 50/60 36 3.6.1 Installing the WOS system.............................................................................. 36 3.6.2 Installing the air flaps .................................................................................... 37

Air flaps for actuators right (delivery configuration) ........................................... 37 Air flaps for actuators left .............................................................................. 38

3.6.3 Installing the insulation.................................................................................. 39 3.6.4 Installing the actuators .................................................................................. 42 3.6.5 Installing the flue gas sensor .......................................................................... 43 3.6.6 Installing the Lambda probe ........................................................................... 43 3.6.7 Installing the induced draught fan ................................................................... 44 3.6.8 Installing the control unit ............................................................................... 45 3.6.9 Installing the WOS lever................................................................................. 46 3.6.10 Install the insulating door............................................................................... 47 3.6.11 Installing the insulating cover ......................................................................... 48 3.6.12 Installing the floor insulation........................................................................... 48

3.7 Electrical connection 49 3.8 Connecting the thermal discharge safety device 49

4 Startup 50

4.1 Initial startup/ configuring the boiler 50

5 Decommissioning 50

5.1 Mothballing 50 5.2 Disassembly 50 5.3 Disposal 50

6 Appendix 51

6.1 Delivery certificate S4 Turbo 51

General Standards, Design, Assembly

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1 General information

CAUTION

Assembly and installation by untrained personnel. Risk of personal injury and damage to property.

The instructions and information provided in the manual must be observed. Assembly and installation must only be carried out by qualified personnel (heating installers or licensed electricians).

1.1 Notes on standards

The boiler must be installed and commissioned in compliance with local fire and building regulations and the following standards:

ÖNORM/DIN EN 303-5 Heating boilers for solid fuels, hand and automatically stocked, nominal heat output of up to 300 kW - Terminology, requirements, testing and marking

ÖNORM M 7510 Guidelines for checking central heating systems

ÖNORM / DIN EN 12828 Heating systems in buildings - design of water-based heating systems

ÖNORM B 8130 Safety devices, open water-heating systems

ÖNORM B 8131 Closed water-heating systems, safety requirements

DIN 4751 Parts 1-4 Heating system safety equipment

ÖNORM / DIN EN 13384-1

Chimneys serving one appliance

ÖNORM M 7515 / DIN 4705-1

Calculating chimney dimensions for combustion systems

ÖNORM H 5170 Requirements related to fire prevention, fire protection and building construction

VDI 2035 Prevention of damage in water heating installations - Scale formation in domestic hot water supply installations and water heating installations (Germany only)

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 only).

VDI 2035 Prevention of damage in water heating installations - Scale formation in domestic hot water supply installations and water heating installations (Germany only)

SWKI 97-1 Lime scale and corrosion protection in heating systems (Switzerland only)



1

1.2 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.

1.2.1 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 obtained from the building authorities. Austria: Inform the civic/municipal building authorities. Germany: Register with an approved chimney sweep/the building authorities.

1.2.2 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.

§


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1.2.3 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 standard: - ÖNORM H 5170

1.2.4 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).

§

§



1 Combination with storage tank

In accordance with the relevant Austrian laws governing energy technology, which are based on Art. 15a B-VG “Agreement on protective measures for small furnaces” dated November 1994, no buffer storage tank is required on manually fed biomass boilers that have been positively tested at both rated load and partial load (below 50% of rated load) to ensure they adhere to the emissions limits specified in that agreement.

Germany has specified its own emissions limits in the “First Ordinance on Implementation of the Federal Emissions Control Act (1st BImSchV)”. Provided that commissioning is carried out by our customer services or an authorised partner company, it can be assumed that these requirements will also be complied with under partial load conditions in accordance with § 6 (3) of the 1st BImSchV. This means that the complete range of firewood boilers can be used in Germany without requiring a mandatory buffer storage tank.

Combining the system with a buffer storage tank does however offer significant advantages when using a firewood boiler, such as better utilisation of the fuel, more user-friendly operation in terms of reloading intervals (which means the greatest possible independence from instantaneous heating requirements), and less soiling of the boiler and flue gas system. In addition to the above, as the manufacturer of the boiler we have to advise on how the heat generated can be dissipated. This is because compliance with the emissions limits and minimum level of efficiency at a minimum heat output of 30% of the rated heat output, as specified in Section 4.2.5 or EN 303-5, has not been demonstrated for all variants of the system.

The opportunities for heat dissipation are particularly good if the central heating system has sufficient capacity for heat uptake, for example through underfloor heating circuits with a suitable water volume or hot water tanks with appropriate reserve capacity. It should also be noted that the integral thermal discharge safety device ensures that the boiler will operate safely even if it is overfilled or has too little load reduction. If, however, the amount of heat that can be temporarily dissipated within the building being heated is limited, then additional heat dissipation can be provided by a buffer storage tank.

The recommend storage volume for each boiler is given in the technical specifications. The specified value applies under the following conditions: the rated heat output of the boiler corresponds to the heating requirements of the building and a maximum of 50% of the rated heat output can be dissipated to the building being heated under partial load conditions. Certain subsidy guidelines also prescribe compulsory requirements for the installation of buffer storage tanks: Some guidelines relate to minimum storage volume in accordance with EN 303-5, as given in the technical specifications. ... In Austria: some subsidy guidelines of Austrian federal states (e.g. those of the Vorarlberg state government) ... In Switzerland: The “Quality Seal for Wood Burning Systems” scheme from Holzenergie Schweiz


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1 Other guidelines are based on tank size, e.g. ... In Austria: Specific subsidy guidelines for Austrian states (e.g.

Styrian state government guidelines: buffer storage tanks of at least 800 L)

... In Germany: “BAFA Förderung” guidelines on measures to promote a better use of renewable energies of the Federal Office of Economics and Export Control (BAFA): buffer storage tanks of at least 55 L/kW

Up to date information relating to specific subsidy guidelines for various regions can be found on our website at www.froeling.com.

1.2.5 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. It should be noted here that flue gas temperatures of less than 160 K above room temperature can occur within 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.

See “Boiler data relating to design of 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 the pressure is lower at this location.

Boiler data relating to design of the flue gas system

S4 Turbo

Description Unit 15 22 28 34 40 50 60

Flue gas temperature RL PL °C 140

- 160 110

180 130

140 110

170 130

150 100

170 110

Flue gas mass flow RL PL kg/s 0.011

- 0.016 0.007

0.021 0.010

0.025 0.012

0.030 0.015

0.033 0.016

0.041 0.020

Minimum feed pressure 0.08 0.08 0.08 0.08 0.08 0.08 0.08

Maximum permissible feed pressure

mbar as per ÖNORM / DIN EN 303-5

Flue pipe diameter mm 150 150 150 150 150 150 150

RL = Rated Load, PL = Partial Load

1

Technology Connections, dimensions and performance data


2

2 Technology

2.1 Components and connections

S4 Turbo

Item Description Unit 15/22/28 34/40 50/60

1 Boiler outfeed connection 6/4 6/4 6/4

2 Boiler return feed connection 6/4 6/4 6/4

3 Connection for filling/drainage cock 1/2 1/2 1/2

4 2 safety heat-exchanger connection sleeves for the thermal discharge safety device 1/2 1/2 1/2

5 Flue gas sensor connector 1/2 1/2 1/2

6 Lambda probe connector 3/4 3/4 3/4

7 2 Immersion sleeves for - thermal discharge safety device sensor - boiler sensor, safety temperature limiter

Inch

1/2 1/2 1/2

8 Flue gas pipe nozzle mm 150 150 150

2

1

3

8

4

6 7 5

2

1

3

4

6 7 5

S4 T

urb

o 1

5-4

0

S4 T

urb

o 5

0/6

0


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2.2 Dimensions

S4 Turbo

Item Description Unit 15/22/28 34/40 50/60

H Boiler height 1565 1565 1565

H1 Total height, inc. flue gas pipe 1610 1610

H1* Height of induced draught unit housing 1480

H2 Height of flue gas pipe connection 1830 1830

H2* Height of flue gas pipe connection 1700

H3 Height of outfeed connection 1360 1360 1360

H4 Height of return feed connection 140 140 140

H5 Height of safety heat exchanger connection

mm

970 970 960

B Boiler width 570 670 670

B1 Total boiler width inc. actuators mm

635 735 735

L Boiler length 1125 1215 1215

L1 Total length inc. induced draught fan 1300 1390

L1* Total length inc. induced draught fan

mm

1680

*) dimensions indicated only for S4 Turbo 50/60



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2.3 Performance data

2.3.1 S4 Turbo 15/22/28

S4 Turbo

Description Unit 15 22 28

Rated heat output 15 22 28

Fuel-heating efficiency at rated heat output kW

16.1 24.0 30.7

Boiler class 3

Electrical connection 230 V / 50 Hz / fused 16 amps

Electrical output W 105 125 125

Boiler weight kg 640 640 640

Fuel loading door dimensions (width / height) mm 380 / 360 380 / 360 380/360

Fuel loading chamber capacity 145 145 145

Water capacity L

115 115 115

Water side resistance (with 10/20 K temperature difference) mbar 6.5 / 2.0 4.0 / 2.0 4.2 / 2.5

Minimum return feed temperature 55

Permitted operating temperature °C

95

Permitted operating pressure bar 3

Permitted fuel Firewood

Combustion time1) Beech Spruce h 9.0 - 13.0

6.3 - 9.2 5.6 - 8.1 3.9 - 5.7

4.4 - 6.4 3.1 - 4.5

Recommended buffer storage tank capacity L 2000 2000 1400

1) The values specified for combustion time are guideline values for firewood at rated load and will vary depending on water content (15-25%) and fill level (80-100%).

Test report data

S4 Turbo

Description Unit 15 22 28

Testing institute TÜV Austria 1)

Test report no. 07-UWC/Wels-EX-094/1

2) 4) 2) 3)

Date of issue 16.11.2005

Carbon monoxide (CO) Rated load Partial load mg/MJ 34

19 20

58

Nitrogen oxide (NOx) Rated load Partial load mg/MJ 93

96 97

91

Organic hydrocarbons Rated load Partial load mg/MJ 2

< 2 < 2

3

Dust Rated load Partial load mg/MJ 17

13 12

6

1) TÜV Austria, Environment and Chemistry Division, Thalheim bei Wels Test Centre

2) In accordance with ÖNORM / DIN EN 303-5, section 5.1.3 Type Test: for a boiler from a range with a consistent structure it is sufficient, if the ratio of rated heat output from the largest to the smallest boiler ≤ 2 : 1, to carry out the tests with the smallest and the largest boilers. The boiler manufacturer must ensure that all boilers, including those that have not been tested in a range, whose values have been determined depending on rated heat output by interpolation, fulfil the requirements of the norm.

3) Values for the type S4 Turbo 28 are interpolated between the test protocol 07-UWC/Wels-EX-094/2 and 07-UWC/Wels-EX-094/3.


Technology Technical specifications

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2 2.3.2 S4 Turbo 34/40

S4 Turbo

Description Unit 34 40

Rated heat output 34 40


37.2 43.8

Boiler class 3

Electrical connection 230 V / 50 Hz / fused 16 A

Electrical output W 110 110

Boiler weight kg 740 740

Fuel loading door dimensions (width / height) mm 380 / 360 380 / 360

Fuel loading chamber capacity 190 190

Water capacity L

175 175

Water side resistance (with 10/20 K temperature difference) mbar 5.1 / 1.7 6.0 / 1.9



95



Combustion time1) Beech Spruce kg/h 4.7 - 6.8

3.3 - 4.8 3.9 - 5.7 2.8 - 4.0

Recommended buffer storage tank capacity L 1400 1400


Test report data

S4 Turbo



Test report no. 2) 3) 07-UWC/Wels-

EX-094/3



51 54 45


88 99 85

Organic hydrocarbons Rated load Partial load mg/MJ < 2

3 < 2 3


7 14 7






2 2.3.3 S4 Turbo 50/60

S4 Turbo


Rated heat output 50 60


54.9 65.9

Boiler class 3

Electrical connection 230 V / 50 Hz / fused 16 A

Electrical output W 180 180

Boiler weight kg 798 798

Fuel loading door dimensions (width / height) mm 380 / 360 380 / 360

Fuel loading chamber capacity 200 200

Water capacity L

170 170

Water side resistance (with 10/20 K temperature difference) mbar 7.0 / 2.0 8.0 / 2.5



95



Combustion time1) Beech Spruce

kg/h 3.4 - 4.9 2.4 - 3.5

2.8 - 4.1 2.0 - 2.9

Recommended buffer storage tank capacity L 1660 1660


Test report data

S4 Turbo



Test report no. 2) 3) 08-UW/Wels-

EX-074



46 31 46


83 109 80

Organic hydrocarbons Rated load Partial load mg/MJ < 2

3 < 2 3


11 20 14



3) Values for the type S4 Turbo 50 are interpolated between the test protocol 07-UWC/Wels-EX-094/3 and 08-UW/Wels-EX-074.

Installation Transport and setup

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3 Installation

3.1 Transport

The boiler comes packed on a pallet. Move the boiler without jarring or jolting Follow the instructions on the packaging when moving the boiler

3.1.1 Positioning

Use a fork-lift or similar lifting device to move the pallet and position the boiler or

Attach a cable winch or similar lifting device to the eyelet on the boiler and position the boiler

3.1.2 Remove boiler from pallet

At the front of the boiler: Remove securing devices used during transportation on the left and

right side of the base. At the back of the boiler:

Remove securing devices used during transportation on the left and right side of the base.

3.1.3 Temporary storage

If the system is to be installed at a later date: Store the boiler, insulation and control unit in a safe, dust-free, and

dry location Moisture and frost reduce the effectiveness of insulation and can destroy electronic components.

Installation Transport and setup


3

3.2 Setting up in the boiler room

3.2.1 Moving the boiler in the boiler room

Position a fork-lift or similar lifting device at the base frame of the

boiler and move it to the designated position To prevent damage:

Move the boiler without jarring or jolting Risk of damage to firebrick-lined combustion chamber.

Move the packing units carefully Risk of scratching the insulation

Position the boiler at the designated location

The boiler must be positioned so that it rises slightly towards the outfeed

Observe the minimum distances from other objects in the boiler room

3.2.2 Minimum distances in the boiler room

Set up the boiler according to the applicable standards and regulations. The following minimum distances must be observed in all cases:

A Distance between insulated door and wall 800 mm

B Distance between side of boiler and wall 300 mm

C Distance between rear of boiler and wall S4 Turbo 15-40 S4 Turbo 50-60

500 mm 800 mm

Installation Materials supplied

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3.3 Materials supplied

A Boiler

B Insulation

C Flue gas pipe nozzle (S4 Turbo 15-40)

D Induced draught unit housing (S4 Turbo 50-60)

E Induced draught fan

F Cardboard box containing small parts

G Rods for primary and secondary air

H Ash shovel

I Cleaning kit

J Cleaning brush, small

K Cleaning brush, large

L Control unit of the Lambdatronic S3200

M Ash drawer

The following are also included in the materials supplied but not pictured: Lambdatronic control unit, installation instructions, operating instructions, guarantee certificate, identification plate

3.3.1 Tools required

The following tools are required for the installation of the S4 Turbo: - Hexagonal spanners or hexagonal sockets with widths across flats: 8, 10, 13, 17, 22 mm - Flat head and cross-head screw drivers - Hammer, side cutters and half-round file - Power drill or cordless electric screwdriver with Torx 30 bit insert

A

B

I

E F

H

G

J

K

C

D

M

L

Installation Before installation


3

3.4 Before installation

NOTICE

The boiler doors are attached on the right hand side when delivered. Carry out the following assembly steps if the doors need to be attached on the left:

3.4.1 Fitting doors on the left

Detach the doors Unscrew the hinge and back

plate, swap them over and reattach.

The top and bottom locking cams should be installed in mirrored positions, with the groove of the adjustable area facing the middle of the door hinge in each case.

Position the door hinge on the abutting side of the door Push the cup square bolts through and place the locking cams on

as shown Fix the door hinge finger tight with a hexagonal nut and a spacer

washer Rotate the pre-heating chamber door and the combustion chamber

door and attach them on the left hand side.


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Additional steps for the fuel loading chamber door:

Remove the radiation plate together with the seal

Detach the insulating plate from the ceramic fibre seal

Carefully lift out the insulating plate

Turn the insulating plate by 180° and position it so that it lines up with the holes provided

Re-install the radiation plate Fix the seal in place using

contact adhesive



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3.4.2 Fitting the door handles

For the fuel loading chamber door:

Position the door handle in the hole provided

Insert flange bushing into

door handle

Fasten the door handle in place

Repeat the above steps for

the pre-heating chamber door and the combustion chamber door

3.4.3 Positioning doors

Loosen the locknut (1) of the locking cam Press the door onto the door frame and set the contact pressure

using the locking cam The adjusting spanner is included in delivery.

Fix the setting by tightening the locknut

Set the contact pressure on the door handle side by moving the locking plate

Repeat the steps for both the other doors

1

Installation S4 Turbo 15-40

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3.5 Installation of S4 Turbo 15/22/28/34/40

NOTICE

The following assembly steps are for installing the S4 Turbo in boiler sizes 15/22/28/34/40!

The steps for boiler sizes 50/60 are on page 36, Installing the S4 Turbo 50/60

3.5.1 Fitting the induced draught fan

Fit the induced draught fan on the

rear of the boiler as shown Caution: Do not overstress the flange

3.5.2 Installing the flue gas pipe nozzle

Place the ceramic fibre seal in position

Place the flue gas pipe nozzle in position and secure

Both sleeves must point towards the centre of the boiler

3.5.3 Installing the WOS system

Determine which side the cleaning

lever will be installed Remove the screw cap from the

required side

Screw in the brass bushing



3

Insert the turbulators into the linking plate as shown

Remove the WOS cover Insert the turbulators at the heat

exchanger pipes as shown above

S4 Turbo 34-40 S4 Turbo 15-28


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3.5.4 Installing the air flaps

For both pneumatic rods:

Remove the split pin opposite the spring and pull off one of the two air flaps.

NOTICE

CAUTION! If the actuators are mounted on the left, the left and right air boxes must be swapped over.

See air flaps for actuators left

Air flaps for actuators right (delivery configuration)

Insert the pneumatic rod at the

left-hand side of the boiler The flap with the spring (1) must be at the left-hand air duct.

The stop bolt (2) of the air flaps must be installed on the right-hand side of the boiler.

Position the flaps on the opposite

side CAUTION: Install the flaps in the same position!

Secure the flaps with the split pins Check that the shaft can move

freely

1

2



3

Air flaps for actuators left

Remove the air boxes on both sides

Reinstall both the air boxes on the opposite side

The stop bolts (2) are now at the top of the air box and on the left-hand side of the boiler.

Only screw the screws of the air boxes in lightly.

Insert the pneumatic rod at the right-hand side of the boiler

The flap with the spring must be at the right-hand air duct.

Push the pneumatic rod all the way through and only then fix the air boxes.

When you do this, check that the pneumatic rods can move freely.

Position the flaps on the left-hand side

CAUTION: Install the flaps in the same position.

Secure the flaps with the split pins

2

2


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3.5.5 Installing the insulation

NOTICE

The separate parts of the boiler insulation are fitted with a protective film. This must always be removed before installation.

Insert the L-plate into the insulating side panel as shown and fix

with 3 self-tapping screws

Insert the insulation brackets at the top of both insulating side panes as shown and fix with thread forming screws

Use a battery drill with Torx-30 bit insert for fixing

Place a large spacer washer on each of the threaded bolts Insert the insulating side panels to the base of the boiler at the lug

(1) and push it onto the boiler

Place the side panels with the door bracket onto the threaded bolts Put on the large and small spacer washers and secure lightly with a

nut

1



3

Attach the insulating wool pad to the back of the boiler

Put the insulating back panel on above the induced draught fan and fix it once on each side to the side panel

Put in the spacer plate between the insulating side panels

Put on the control unit as shown and fix with 2 countersunk crosshead bolts and nuts


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Slide the complete insulation assembly towards the rear Align the insulating side panels by measuring the diagonal in the

corner and tighten the nuts on the threaded bolts

Put the top insulating wool mat on The insulating wool must be right next to the front plate

Put the cable tray on and secure it to the insulating side panels with 4 self-tapping screws

Fix the insulating side panels to the

lug on the boiler base with thread forming screws

Use a drill with Torx-30 bit insert for fixing

Do not leave a gap!



3

3.5.6 Installing the actuators

Using pliers, turn the pneumatic rods anti-clockwise until the left-hand limit stop is reached

All 4 air flaps must be closed.

Press the safety-release button (1) and turn the actuator anti-clockwise to the “0” position

Turn the selector switch (2) to position “0” using a screw-driver

Install the 2-part cover plate on the same side as the actuators and install the 1-part cover plate opposite with self-tapping screws

Put both actuators onto the pneumatic rods

Insert the torque support at the actuators

Align the actuators horizontally and

fix the torque support to the cover plate with 3 self-tapping screws

Label the cables for the actuators using the stickers provided

Top actuator = primary air Bottom actuator = secondary air

1

2


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3 Pull the cable upwards behind the

insulating back panel Screw the insulating back panel into

final position with the insulating side panels

Push on the cable covers and fix in

position using self-tapping screws

Thread the actuator cables into the cable duct on the cable tray as shown and pull forwards

Fit the induced draught cover plates to the insulating back plate

3.5.7 Installing the Lambda probe

Unscrew the pre-installed bushing from the lambda probe Screw the bushing into the flue gas nozzle and tighten gently Screw the lambda probe into the bushing and tighten gently



3 3.5.8 Installing the flue gas sensor

Screw-in the brass bushing for the flue gas sensor Push in the flue gas sensor until about 20 mm of the sensor

remains protruding from the bushing and fix lightly using the fixing screw

3.5.9 Installing the control unit

Put the control board on the cable tray Ensure that the pins are inserted correctly. Secure the control board to the cable tray with self-tapping screws

Place a contact washer (1) on each screw.

Lay the cable of the lambda probe and the flue gas sensor through

the cable duct to the control unit. Pull the cables for the boiler sensor and the safety temperature

limiter (STL) back and insert them into the right immersion sleeve with a clamp spring (1)

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3 For the S4 Turbo 34/40 also:

Fit additional cover plate to the back of the control board

When carrying this out, ensure that it fits between the guide plate and the insulating side panel.

3.5.10 Installing the WOS lever

On the same side as the brass bushing:

Remove the pre-punched perforation from the insulating side panel using side cutters

File rough edges using a half-

round file and remove burrs

Put the cover plate on the cleaning lever

Raise the turbulators in the flue gas collection chamber and push in the cleaning lever from outside



3

Secure the cleaning lever with bolts Ø6 x 30 (1)

Place the upper cleaning cover in

position and lock the rod into place by turning it clockwise to tighten

Secure the shutter mask to the insulating side panel

S4 Turbo 15-28

1

1

S4 Turbo 34-40


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3

3.5.11 Install the insulating door

Hammer the fitting grooved pin in at the door bearing Fit the door bearing to the boiler base as shown with 2 Allen

hexagonal screws Use the same distance from the hole as for the top insulating door bracket

Insert flange bushings at the top and the bottom on the abutting side of the insulating door

Put the insulating door on at the door bearing and secure it to the

door bracket at the top with hinge bolts Put magnetic latches on the inside of the insulating door at the top

and bottom

Fit the side covers to the control unit



3 3.5.12 Installing the insulating cover

Put through the rest of the cables

See control unit operating instructions

Put on the insulating cover and move it back and forth until the pins

fit into position

Fix the insulating cover to the control plate with self-tapping screws

and contact washers Put on the back insulating cover

3.5.13 Installing the floor insulation

Put the floor insulation assembly into the U-profiles in the base of the boiler and slide in fully


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3

3.6 Installing the S4 Turbo 50/60

NOTICE

The following assembly steps are for installing the S4 Turbo in boiler sizes 50/60.

For assembly steps for boiler sizes 15/22/28/34/40 see page 22, Installation of S4 Turbo 15/22/28/34/40

3.6.1 Installing the WOS system

Determine which side the cleaning

lever will be installed Remove the front screw cap of the

two on the desired side Screw in the brass bushing

Insert the turbulators into the linking plate as shown

Remove the WOS cover Insert the turbulators at the front

heat exchanger pipes



3

3.6.2 Installing the air flaps

For both pneumatic rods:

Remove the split pin opposite the spring and pull off one of the two air flaps.

NOTICE

CAUTION! If the actuators are installed on the left, the stop screws must be changed from the right to the left.

See air flaps for actuators left

Air flaps for actuators right (delivery configuration)

Unscrew the stop screws on the right-hand side of the boiler far enough to allow the air flap to make contact with the thread.

Insert the pneumatic rod at the left-hand side of the boiler

The flap with the spring (1) must be at the left-hand air duct.

Position the flaps on the opposite side

CAUTION: Install the flaps in the same position!


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3 Air flaps for actuators left

Unscrew and remove the stop screws on the right-hand side of the boiler and fit to the left-hand side

Fit the screw so that the air flap can stop against the thread

Insert the pneumatic rod at the right-hand side of the boiler

The flap with the spring (1) must be at the right-hand air duct.

Position the flaps on the opposite side

CAUTION: Install the flaps in the same position!




3

3.6.3 Installing the insulation

NOTICE

The separate parts of the boiler insulation are fitted with a protective film. This must always be removed before installation.

Insert the L-plate into the insulating side panel as shown and fix

with 3 self-tapping screws

Insert the insulation brackets at the top of both insulating side panes as shown and fix with thread forming screws

Use a battery drill with Torx-30 bit insert for fixing

Place a large spacer washer on each of the threaded bolts Insert the insulating side panels to the base of the boiler at the lug

(1) and push it onto the boiler

Place the side panels with the door bracket onto the threaded bolts Put on the large and small spacer washers and secure lightly with a

nut

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3

Attach the insulating wool pad to the back of the boiler

Put the insulating back panel over the flue gas pipe

Fix the back panel once on the left and the right to the side panel

Put in the spacer plate between the insulating side panels

Put on the control unit as shown and fix with 2 countersunk crosshead bolts and nuts



3

Slide the complete insulation assembly towards the rear Align the insulating side panels by measuring the diagonal in the

corner and tighten the nuts on the threaded bolts

Put the top insulating wool mat on The insulating wool must be right next to the front plate

Put the cable tray on and secure it to the insulating side panels with 4 self-tapping screws

Fix the insulating side panels to the

lug on the boiler base with thread forming screws

Use a drill with Torx-30 bit insert for fixing

Do not leave a gap!


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3

3.6.4 Installing the actuators

Using pliers, turn the pneumatic rods anti-clockwise until the left-hand limit stop is reached

All 4 air flaps must be closed.

Press the safety-release button (1) and turn the actuator anti-clockwise to the “0” position

Turn the selector switch (2) to position “0” using a screw-driver

Install the 2-part cover plate on the same side as the actuators and install the 1-part cover plate opposite with self-tapping screws

Put both actuators onto the pneumatic rods

Insert the torque support at the actuators

Align the actuators horizontally and

fix the torque support to the cover plate with 3 self-tapping screws

Label the cables for the actuators using the stickers provided

Top actuator = primary air Bottom actuator = secondary air

1

2



3

Pull the cable upwards behind the insulating back panel

Screw the insulating back panel into final position with the insulating side panels

Push on the cable covers and fix in

position using self-tapping screws

Thread the actuator cables into the cable duct on the cable tray as shown and pull forwards

3.6.5 Installing the flue gas sensor

Screw-in the brass bushing for the flue gas sensor Push in the flue gas sensor until about 20 mm of the sensor

remains protruding from the bushing and fix lightly using the fixing screw

3.6.6 Installing the Lambda probe

Unscrew the pre-installed bushing from the lambda probe Screw the bushing into the flue gas nozzle and tighten gently Screw the lambda probe into the bushing and tighten gently


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3 3.6.7 Installing the induced draught fan

Fit the induced draught cover plates to the insulating back plate

Put the ceramic fibre seal onto the induced fan housing

Install the induced draught fan housing at the flange of the flue gas nozzle as shown

Mount and secure the induced draught fan

The straight edge of the flange must be at the top



3

3.6.8 Installing the control unit

Put the control board on the cable tray Ensure that the pins are inserted correctly. Secure the control board to the cable tray with self-tapping screws

Place a contact washer (1) on each screw.

Lay the cable of the lambda probe and the flue gas sensor through

the cable duct to the control unit. Pull the cables for the boiler sensor and the safety temperature

limiter (STL) back and insert them into the right immersion sleeve with a clamp spring (1)

Fit additional cover plate to the back of the control board

When carrying this out, ensure that it fits between the guide plate and the insulating side panel.

1

1


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3 3.6.9 Installing the WOS lever

On the same side as the brass bushing:

Remove the front pre-punched perforation from the insulating side panel using side cutters

File rough edges using a half-round file and remove burrs

Remove the top cleaning cover Feed the WOS lever through the

cover plate

Raise the turbulators in the flue gas collection chamber and push in the cleaning lever from outside

Secure the WOS lever with 2 bolts Ø6 x 30 (1)

Connect both WOS rods together using the connecting lever

Secure the bolts with split pins

Secure the shutter mask to the insulating side panel

1



3 3.6.10 Install the insulating door

Hammer the fitting grooved pin in at the door bearing Fit the door bearing to the boiler base as shown with 2 Allen

hexagonal screws Use the same distance from the hole as for the top insulating door bracket

Insert flange bushings at the top and the bottom on the abutting side of the insulating door

Put the insulating door on at the door bearing and secure it to the

door bracket at the top with hinge bolts Put magnetic latches on the inside of the insulating door at the top

and bottom

Fit the side covers to the control unit


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3 3.6.11 Installing the insulating cover

Put through the rest of the cables See control unit operating instructions

Put on the insulating cover and move it back and forth until the

pins fit into position

Fix the insulating cover to the control plate with self-tapping screws

and contact washers Put on the back insulating cover

3.6.12 Installing the floor insulation

Put the floor insulation assembly into the U-profiles in the base of the boiler and slide in fully

Installation Connecting the pellet boiler


3

3.7 Electrical connection

DANGER

Working on electrical components Risk of serious injuries from electric shocks

Work on electrical components should only be carried out by authorised

technicians

Wire up the components according to the electrical connection

diagram Flexible sheathed cable must be used for the wiring; this must be of the correct size to comply with applicable regional standards and guidelines.

The supply line (mains connection) must be fitted with a maximum 16 A fuse by the customer.

See boiler control unit operating instructions for circuit diagrams

3.8 Connecting the thermal discharge safety device

NOTICE

The thermal discharge safety device must be connected in accordance with ÖNORM/DIN EN 303-5 as shown in the following diagram.

The discharge safety device must be connected to a pressurised mains water supply in such a way that it cannot be shut off.

1 Thermal discharge safety device sensor

2 Thermal discharge safety device (opens at approx. 95 °C)

3 Cleaning valve (T-piece)

4 Dirt trap

5 Pressure reducing valve*

*) Required when the cold water pressure is greater than 6 bar. It must be not be possible to shut off the connection manually. Minimum cold water pressure is 2 bar.

1

2

3

4

5

Initial startup / Decommissioning

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4 Startup

4.1 Initial startup/ configuring the boiler

The boiler must be adjusted to the requirements of the heating system during initial startup

NOTICE

Optimum performance and efficient operation with low emissions can only be guaranteed if the system is set up by a qualified technician and the specified factory settings are observed.

Take the following precautions:

We recommend that the system is commissioned by Fröling customer services or an authorised installer.

Before heating up the boiler for the first time:

Adjust the control unit to the system type The keypad assignment and the steps necessary to modify the control parameters are detailed in the accompanying operating instructions for the boiler control unit.

5 Decommissioning

5.1 Mothballing

The following tasks should be carried out if boiler is to remain out of service for several weeks (e.g. during the summer):

Clean the boiler thoroughly and close the doors fully If the boiler is to remain out of service during the winter:

Have the system completely drained by a qualified technician Protection against frost

5.2 Disassembly

To disassemble the boiler, perform the assembly process in reverse order.

5.3 Disposal

Dispose of all waste in an environmentally-friendly manner and in accordance with waste disposal regulations.

Separate and clean recyclable materials and send them to a recycling centre.

Appendix


6

6 Appendix

6.1 Delivery certificate S4 Turbo

Customer no.

Customer address:

Installer:

Telephone number:

S4 Turbo 15

S4 Turbo 22

S4 Turbo 28

S4 Turbo 34

S4 Turbo 40

Boiler type:

S4 Turbo 50

Serial number: S4 Turbo 60

System operation discussed

System maintenance discussed

Operating principle and self-checking of safety devices discussed

All technical documentation handed over (documentation, certificates of conformity, ...)

Test heating performed

Commissioning report handed over

Telephone number for manufacturer’s service department indicated

Rating plate attached

Following items checked:

No defects found

Notice: All national and regional regulations relating to initial testing and subsequent testing of the system must be observed. Please be advised that, in Austria, commercial systems with a rated heat output ≥ 50 kW must be regularly tested at yearly intervals in accordance with the Heating Plant Regulations (FeuerungsanlagenVO).

Date Customer Installer

Finally, we ask that you have the customer sign a copy of this confirmation and send it to

FRÖLING Ges.m.b.H . Fax: +43 (0)7248 606 600

assembly instructions - pth hout-cv · read and follow the assembly instructions and safety...

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