Dual fuel boiler SP Dual compact

Transcription

1 Installation Instructions Dual fuel boiler SP Dual compact Translation of the original German operating instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M _en Edition 24/03/2017 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

2 Contents Contents 1 General 4 2 Safety Hazard levels of warnings Qualification of assembly staff Personal protective equipment for assembly staff Design Information Notes on standards 6 General standards for heating systems 6 Standards for structural and safety devices 7 Standards for heating water 7 Regulations and standards for permitted fuels Installation and approval of the heating system General information for installation room (boiler room) Requirements for central heating water Notes for using pressure maintenance systems Return lift Combination with storage tank Chimney connection/chimney system 13 Draught limiter 13 Measuring port 14 Boiler data for planning the flue gas system 14 3 Technical information Dimensions SP Dual compact Components and connections Technical specifications SP Dual compact 15/ External suction module 19 4 Installation Materials supplied Transport Positioning Temporary storage Setting up in the boiler room 22 Removing the pellet unit from the pallet 22 Moving the boiler in the boiler room 23 Recommended clearances in the boiler room Preparing the firewood boiler Fitting the pellet unit 26 Assembly overview 26 Remove the cladding from the pellet unit 28 Screw the pellet unit to the firewood boiler 29 Laying cables 32 Hydraulic connection 34 Fitting the air connection 35 Fitting the cladding to the pellet unit Fitting the WOS drive (optional) 37 2 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

3 Contents Installing the discharge system 41 Installing the external suction module 41 Connecting suction hoses to the boiler Connecting the hydraulic safety devices Electrical connection 45 Connecting the external suction module Final installation steps 46 Positioning the boiler stickers correctly 46 5 Start-up Before commissioning / configuring the boiler Initial startup Permitted fuels 48 Wood pellets 48 Firewood Fuels permitted under certain conditions 49 Wood briquettes Non-permitted fuels Heating up for the first time 50 6 Decommissioning Mothballing Disassembly Disposal 51 7 Appendix Addresses Address of manufacturer Address of the installer 52 Installation Instructions SP Dual compact M _en 3

4 1 General 1 General Thank you for choosing a quality product from Froling. The product features a state-ofthe-art design and conforms to all currently applicable standards and testing guidelines. Please read and observe the documentation provided and always keep it close to the system for reference. Observing the requirements and safety information in the documentation makes a significant contribution to safe, appropriate, environmentally friendly and economical operation of the system. The constant further development of our products means that there may be minor differences from the pictures and content. If you discover any errors, please let us know: doku@froeling.com. Subject to technical change. Issuing a delivery certificate The EC Declaration of Conformity is only valid in conjunction with a delivery certificate, which has been filled in correctly and signed as part of the commissioning process. The original document remains at the installation site. Commissioning installers or heating engineers are requested to return a copy of the delivery certificate together with the guarantee card to Froling. On commissioning by FROLING Customer Service the validity of the delivery certificate will be noted on the customer service record. 4 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

5 Safety Hazard levels of warnings 2 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. Installation Instructions SP Dual compact M _en 5

6 2 Safety Qualification of assembly staff 2.2 Qualification of assembly staff CAUTION Assembly and installation by unqualified persons: Risk of personal injury and damage to property During assembly and installation: Observe the instructions and information in the manuals Only allow appropriately qualified personnel to work on the system Assembly, installation, initial startup and servicing must always be carried out by qualified personnel: - Heating technician / building technician - Electrical installation technician - Froling customer services The assembly staff must have read and understood the instructions in the documentation. 2.3 Personal protective equipment for assembly staff You must ensure that staff have the protective equipment specified by accident prevention regulations. For transportation, setup and assembly: - suitable work wear - protective gloves - sturdy shoes (min. protection class S1P) 2.4 Design Information Notes on standards The system must be installed and commissioned in accordance with the local fire and building regulations. Unless contrary to other national regulations, the latest versions of the following standards and guidelines apply: General standards for heating systems EN EN EN Boilers for solid fuels, manually and automatically fed combustion systems, nominal heat output up to 500 kw Heating systems in buildings - design of water-based heating systems Chimneys - Thermal and fluid dynamic calculation methods Part 1: Chimneys serving one appliance 6 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

7 Safety Design Information 2 ÖNORM H 5151 ÖNORM M ÖNORM M Planning of central hot water heating systems with or without hot water preparation Guidelines for checking central heating systems Part 1: General requirements and one-off inspections Guidelines for checking central heating systems Part 4: Simple check for heating plants for solid fuels Standards for structural and safety devices ÖNORM H 5170 ÖNORM M 7137 TRVB H 118 Heating installation - Requirements for construction and safety engineering, as well as fire prevention and environmental protection Compressed untreated wood Requirements for storing pellets at the end customer s site Technical directives for fire protection/prevention (Austria) Standards for heating water ÖNORM H VDI 2035 SWKI BT UNI 8065 Prevention of damage by corrosion and scale formation in closed warm water heating systems at operating temperatures up to 100 C (Austria). Prevention of damage hot water heating systems (Germany) Water quality for heating, steam, cooling and air conditioning systems (Switzerland) Technical standard regulating hot water preparation. DM (Ministerial Decree specifying the minimum requirements) Follow the instructions of this standard and any related updates. Regulations and standards for permitted fuels 1. BImSchV First Order of the German Federal Government for the implementation of the Federal Law on Emission Protection (Ordinance on Small and Medium Combustion Plants) in the version published on 26 January 2010, BGBl. JG 2010 Part I No. 4. EN ISO EN ISO EN ISO Solid bio-fuel - Fuel specifications and classes Part 2: Wood pellets for use in industrial and domestic systems Solid bio-fuel - Fuel specifications and classes Part 3: Wood briquettes for non-industrial use Solid bio-fuel - Fuel specifications and classes Part 5: Firewood for non-industrial use Installation Instructions SP Dual compact M _en 7

8 2 Safety Design Information Installation and approval of the heating system Note on standards The boiler should be operated in a closed heating system. The following standards govern the installation: EN 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: report to the construction authorities of the community or magistrate Germany: report new installations to an approved chimney sweep / the building authorities General information for installation room (boiler room) Boiler room characteristics The floor must be even, clean and dry and have an adequate load-bearing capacity. There must not be a potentially explosive atmosphere in the boiler room as the boiler is not suitable for use in potentially explosive environments. The boiler room must be frost-free. The boiler does not provide any light, so the customer must ensure sufficient lighting in the boiler room in accordance with national workplace design regulations. When using the boiler above 2000 metres above sea level you should consult the manufacturer. Danger of fire due to flammable materials. The floor of the boiler room must not be flammable. No flammable materials should be stored near the boiler. Flammable objects (e.g. clothing) must not be put on the boiler to dry. Damage due to impurities in combustion air. Do not use any solvents or cleaning agents containing chlorine and hydrogen halides in the room where the boiler is installed (e.g. chlorination units for swimming pools). Keep the air suction opening of the boiler free of dust. The system must be protected against the chewing or nesting of animals (e.g. rodents etc.). Ventilation of the boiler room Ventilation air for the boiler room should be taken from and expelled directly outside, and the openings and air ducts should be designed to prevent weather conditions (foliage, snowdrifts, etc.) from obstructing the air flow. 8 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

9 Safety Design Information 2 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: Note on standards ÖNORM H Construction and fire protection requirements TRVB H118 - Technical directives on fire protection/prevention Requirements for central heating water Unless contrary to other national regulations, the latest versions of the following standards and guidelines apply: Austria: Germany: ÖNORM H 5195 VDI 2035 Switzerland: Italy: SWKI BT UNI 8065 Observe the standards and also follow the recommendations below: Aim for a ph value of between 8.2 and If the central heating water comes into contact with aluminium, the ph value must be between 8.0 and 8.5 Use prepared water which complies with the standards cited above for filling and makeup water Avoid leaks and use a closed heating system to maintain water quality during operation When filling with make-up water, always bleed the filling hose before connecting, in order to prevent air from entering the system Advantages of prepared water: Complies with the applicable standards Less of a drop in output due to reduced limescale build-up Less corrosion due to fewer aggressive substances Long-term cost savings thanks to improved energy efficiency Limit values for filling and make-up water: Austria Germany Switzerland Total hardness 1.0 mmol/l 2.0 mmol/l < 0.1 mmol/l Conductivity - < 100µS/cm < 100 µs/cm ph value Chloride < 30 mg/l < 30 mg/l < 30 mg/l Installation Instructions SP Dual compact M _en 9

10 2 Safety Design Information Additional requirements for Switzerland: The filling and make-up water must be demineralised (fully purified) The water must not contain any ingredients that could settle and accumulate in the system This makes the water non-electroconductive, which prevents corrosion It also removes all the neutral salts such as chloride, sulphate and nitrate which can weaken corrosive materials in certain conditions If some of the system water is lost, e.g. during repairs, the make-up water must also be demineralised. It is not enough to soften the water. The heating system must be professionally cleaned and rinsed before filling the units. Inspection: After eight weeks, the ph value of the water must be between 8.2 and If the central heating water comes into contact with aluminium, the ph value must be between 8.0 and 8.5 Yearly. Values must be recorded by the owner Notes for using pressure maintenance systems Pressure maintenance systems in hot-water heating systems keep the required pressure within predefined limits and balance out volume variations caused by changes in the hot-water temperature. Two main systems are used: Compressor-controlled pressure maintenance In compressor-controlled pressure maintenance units, a variable air cushion in the expansion tank is responsible for volume compensation and pressure maintenance. If the pressure is too low, the compressor pumps air into the tank. If the pressure is too high, air is released by means of a solenoid valve. The systems are built solely with closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen into the heating water. Pump-controlled pressure maintenance A pump-controlled pressure maintenance unit essentially consists of a pressuremaintenance pump, relief valve and an unpressurised receiving tank. The valve releases hot water into the receiving tank if the pressure is too high. If the pressure drops below a preset value, the pump draws water from the receiving tank and feeds it back into the heating system. Pump-controlled pressure maintenance systems with open expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the water, exposing the connected system components to the risk of corrosion. These systems offer no oxygen removal for the purposes of corrosion control as required by VDI 2035 and in the interests of corrosion protection should not be used. 10 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

11 Safety Design Information Return lift If the hot water return is below the minimum return temperature, some of the hot water outfeed will be mixed in. CAUTION Risk of dropping below dew point/condensation formation if operated without return temperature control. Condensation water forms an aggressive condensate when combined with combustion residue, leading to damage to the boiler. Take the following precautions: Regulations stipulate the use of a return temperature control. The minimum return temperature is 60 C. We recommend fitting some sort of control device (e.g. thermometer) Combination with storage tank Observe the regional regulations for using a storage tank! Certain subsidy guidelines prescribe compulsory requirements for the installation of storage tanks. Up-to-date information about individual subsidy guidelines can be found at General information Channelling the heat generated by the Dual fuel boiler to a storage tank can bring major advantages, including: better utilisation of fuel more user-friendly operation in terms of reloading intervals maximum independence from instantaneous heating requirements minimal dirt in boiler and flue gas system As the boiler s minimum continuous heat output is 30% above the nominal heat output, we as boiler manufacturer are obliged under EN 303-5:2012, Section to advise that the Dual fuel boiler SP Dual compact must always be connected to a storage tank with adequate storage capacity. Certain countries have recommended storage capacities; these are listed below. The specified values apply when the nominal heat output of the boiler corresponds to the heating requirements of the building and a maximum of 50% of the nominal heat output can be dissipated to the building being heated under partial load conditions. The storage tank capacity can be calculated according to EN 303-5:2012 using the following formula: Installation Instructions SP Dual compact M _en 11

12 2 Safety Design Information V Sp = 15T B x Q N (1-0.3 x Q H /Q min ) V Sp Q N T B Q H Q min Storage tank capacity in [l] Nominal heat output of boiler in [kw] Burn-off period of boiler in [h] 1) Heating load of building in [kw] Minimum heat output of boiler in [kw] 2) 1.Sample combustion times for various fuels are provided in the technical data 2.The boiler s minimum output is the lowest value of the output range in the technical data. If there is no minimum heat output specified, use the nominal heat output (Q min = Q N ) Austria According to the relevant Austrian laws governing energy technology, which are based on Art. 15a B-VG "Agreement on protective measures for small furnaces" (2012): No storage tank is required on manually fed biomass boilers that have been positively tested at both nominal load and partial load (below 50% of nominal load) to ensure they adhere to the emissions limits specified in that agreement. Recommended storage tank capacity: Unit SP Dual compact 15 SP Dual compact 20 Recommended storage tank capacity 1) [l] Values for calculating the capacity can be found in the technical data or the technical data with partial load inspection (if available) Germany The first BImSchV (Ordinance on small and medium-sized heating plants of 26 January 2010, BGBl. I P. 38) stipulates a minimum water heat storage tank volume of 55 litres per kilowatt of rated heat output; a water heat storage tank with a volume of 12 litres per litre of fuel loading chamber is recommended. Recommended storage tank capacity: Unit SP Dual compact 15 SP Dual compact 20 Recommended storage tank capacity 1) [l] Values for calculating the capacity can be found in the technical data or the technical data with partial load inspection (if available) For the correct dimensions of the storage tank and the line insulation (e.g. in accordance with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling. 12 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

13 Safety Design Information Chimney connection/chimney system EN specifies that the entire flue gas system must be designed to prevent, wherever possible, damage caused by seepage, insufficient feed pressure and condensation. Please note in this respect that flue gas temperatures lower than 160K above room temperature can occur in the permitted operating range of the boiler. The flue gas temperatures (for clean systems) and additional flue gas values can be found in the table below. The connection between the boiler and the chimney system should be as short as possible. The upward angle of the connection should not exceed Insulate the connection. The entire flue gas system - chimney and connection - should be calculated in accordance with EN Local regulations and other statutory regulations also apply. NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney sweep. NOTICE! TRVB H 118 (Austria only) stipulates that an explosion flap must be installed in the connecting piece (flue pipe) directly next to the boiler. It should be situated in such a way that is poses no risk to persons! Draught limiter We generally recommend the installation of a draught limiter. A draught limiter must be installed if the maximum permissible feed pressure as given in the boiler data for planning the flue gas system is exceeded. NOTICE! Install the draught limiter directly under the mouth of the flue line, as the pressure is constantly low at this point. Installation Instructions SP Dual compact M _en 13

14 2 Safety Design Information Measuring port For measuring the emissions of the system, a suitable measuring port must be installed in the connecting piece between the boiler and chimney system. 2 x D D D M In front of the measuring port (M) a straight inlet section should be located at a distance corresponding to about twice the diameter (D) of the connecting piece. A straight outlet section at a distance corresponding to about the single diameter of the connecting piece should be provided after the measuring port. The measuring port must remain closed whenever the system is in operation. Ensure that the outside diameter of the sampling probes in the measuring port can accommodate up to 13 mm. To avoid the ingress of false air, the diameter of the measuring port must not exceed 21 mm. Boiler data for planning the flue gas system The chimney design data is the same as the values of the S1 Turbo firewood boiler. Description SP Dual compact 15 SP Dual compact 20 Flue gas temperature at nominal load C Flue gas temperature at partial load C Flue gas mass flow at nominal load kg/s Flue gas mass flow at partial load kg/s Minimum feed pressure at nominal load Pa 8 8 mbar Minimum feed pressure at partial load Pa 8 8 mbar Maximum permissible feed pressure Pa mbar Flue pipe diameter mm Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

15 Technical information Dimensions SP Dual compact 3 3 Technical information 3.1 Dimensions SP Dual compact L2 H5 H4 H1 H H2 H7 H6 H3 B1 B B2 L1 L Measur ement Description Unit Value L Total length, SP Dual compact incl. ID fan mm 1080 L1 Length, firewood boiler 1000 L2 Length, pellet boiler 895 W Total width, SP Dual compact incl. WOS lever 1105 W1 Width, firewood boiler 685 W2 Width, pellet unit 315 H Height, pellet unit 1335 H1 Height, firewood boiler 1235 H2 Height, flue pipe connection 1450 H3 Height, flow - firewood boiler connection 1055 H4 Height, return - firewood boiler connection 150 H5 Height, return - pellet unit connection 130 H6 Height, safety battery - firewood boiler connection 1040 H7 Height, suction system - pellet unit connection 1253 Installation Instructions SP Dual compact M _en 15

16 3 Technical information Components and connections 3.2 Components and connections Item Description Unit Value 1 Boiler flow connection inches 1 2 Boiler return connection inches 1 3 Drainage connection inches 1 / 2 4 Safety battery connection inches 1 / 2 5 Immersion sleeve for thermal discharge valve (supplied by the customer) inches 1 / 2 6 Flue gas pipe connection mm Immersion sleeve for boiler sensor and STL inches 1 / 2 8 Broadband probe connection inches 3 / 4 9 Flue gas temperature sensor connection inches 1 / 2 10 Pipe union 1) - Pellet unit outfeed to firewood boiler return inches 1 1.Included in delivery 16 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

17 Technical information Technical specifications Technical specifications SP Dual compact 15/20 Technical specifications of the firewood boiler The technical specifications of the firewood boiler can be found in the relevant assembly instructions. Technical specifications of the pellet unit Description Pellet unit - SP Dual compact Nominal output kw Output range - pellet operation kw Electrical connection 230V / 50Hz / fused C16A Power consumption in pellet mode W Weight kg Total boiler capacity (water) L Water pressure drop (ΔT = 10 / 20 K) mbar Min. boiler return temperature C 60 Max. permitted operating temperature C 90 Permitted operating pressure bar 3 Boiler class as per EN 303-5:1999 (pr EN 303-5:2012) Permitted fuel as per EN ISO Part 2: Wood pellets class A1 / D06 Airborne sound level db(a) <70 Pellet container capacity L Regulation (EU) 2015/1187 Energy efficiency A+ A+ Rated heat output kw Energy efficiency index of the boiler model Seasonal space heating energy efficiency % Energy efficiency index of the boiler in package with temperature control Energy efficiency class of the boiler in package with temperature control A+ A+ Installation Instructions SP Dual compact M _en 17

18 3 Technical information Technical specifications Test report data for pellet unit Description Pellet unit - SP Dual compact Testing institute TÜV 1) Test report no TÜV SÜD, Landesgesellschaft Österreich GmbH, Grazer Straße 18, A Bruck an der Mur, Austria Test data in pellet mode - Emissions in [mg/mj] (nominal load / partial load) Carbon monoxide (CO) mg/mj 18 / / 32 Nitrogen oxide (NOx) mg/mj 85 / / 74 Organic hydrocarbons (OGC) mg/mj 0.6 / / 1.3 Dust mg/mj 5.8 / / 8.7 Boiler efficiency % 95.0 / / 91.0 Test data in pellet mode - emissions in [mg/m³] 1) (nominal load/partial load) Carbon monoxide (CO) mg/m³ 28 / / 50 Nitrogen oxide (NOx) mg/m³ 133 / / 115 Organic hydrocarbons (OGC) mg/m³ 0.9 / / 2.0 Dust mg/m³ 9.0 / / 13.5 Boiler efficiency % 95.0 / / Emissions values based on dry flue gas at standard temperature and pressure (0 C, 1013 mbar) with a volume content of oxygen of 13% 18 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

19 Technical information External suction module External suction module Measur ement Description Unit Size 1 Size 2 B Width of suction module mm L Length of suction module H1 Height of suction module H2 Total height incl. hose connection Return-air line connection (line to suction point) 2 Return-air line connection (line to boiler) mm Installation Instructions SP Dual compact M _en 19

20 4 Installation 4 Installation Materials supplied The boiler is delivered packed in cardboard and on a pallet. A Pellet unit E Pipe union for hydraulic connection W 2x hose clamps F Flange seal C Linking plate with flange cutout G external suction module D SP Dual sticker H WOS drive (optional) 20 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

21 Installation Transport The product is delivered on pallet(s) in cardboard packaging. NOTICE Possibility of damage to components if handled incorrectly Follow the transport instructions on the packaging Transport components with care to avoid damage Protect components against damp Pay attention to the pallet's centre of gravity when lifting Positioning Position a fork-lift or similar lifting device at the pallet and bring in the components If the pellet unit cannot be brought in on the pallet: Remove the cardboard packaging and take the pellet unit off the pallet See "Removing the pellet unit from the pallet" [page 22] Installation Instructions SP Dual compact M _en 21

22 4 Installation Temporary storage If the system is to be assembled at a later stage: Store components at a protected location, which is dry and free from dust Damp conditions and frost can damage components, particularly electric ones! Setting up in the boiler room Removing the pellet unit from the pallet The component comes screwed to the pallet: Undo the wood screws (T30) and remove the angle clamp brackets Open the insulated door Undo the retaining screw (T25), slide the cover forwards and remove 22 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

23 Installation 4 Undo the two M4 x 8 lens-head screws on the side panel and remove the side panel Using a suitable pipe (e.g. 1 pipe), lift the pellet unit off the pallet Feed the pipe through the two eyelets on the boiler body Moving the boiler in the boiler room Using appropriate equipment (e.g. 1 pipe), lift and transport to the intended position in the installation room Observe recommended clearances in the boiler room Installation Instructions SP Dual compact M _en 23

24 4 Installation Recommended clearances in the boiler room The system should generally be set up so that it is accessible from all sides allowing quick and easy maintenance. Regional regulations regarding necessary maintenance areas for inspecting the chimney should be observed in addition to the specified minimum distances! Observe the applicable standards and regulations when setting up the system. Observe additional standards for noise protection (ÖNORM H Noise protection measures) Recommended clearances SP Dual compact B B1 A C D Measur ement Description Unit Value A Distance front of boiler to wall mm 800 B Distance boiler side with pellet unit to wall 500 W1 Distance boiler side without pellet unit to wall 815 C Distance back to wall 400 D Distance between side of boiler and wall 500 (200 1 ) 1.Maintenance work to boiler s heat exchanger only possible from front 24 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

25 Installation Preparing the firewood boiler Before fitting the pellet unit, please assemble the S1 Turbo F in accordance with the assembly instructions provided. If the pellet unit is being retrofitted, carry out the following steps to the firewood boiler: Undo the eight M4 x 8 lens-head screws and remove the cover plate with thermal insulation of the pellet flange Undo the four M8 x 25 countersunk head screws and remove the blanking plate Open the insulating door and the fuel loading door of the firewood boiler Remove the middle linking plate on the flange side Fit the linking plate provided to the flange cutout as shown Installation Instructions SP Dual compact M _en 25

26 4 Installation Fitting the pellet unit Assembly overview M4x8 M4x8 M4 M6x12 Ø6x20 Ø8x25 Ø8x25 M8 M M M8x40 Ø12x55 M8x50 M6x12 M6 M6x20 WOS drive Suction module 26 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

27 Installation 4 Item units Description Item units Description 1 1 Insulated door 2 1 Magnetic latch counterpart 3 1 Controller cover plate 4 1 Combustion chamber lid cover plate 5 1 Combustion chamber lid 6 1 Adjustable foot 7 1 Side panel 8 2 Threaded socket 5/4 to SIL seal 38 x 27 x Pipe union 11 1 Back panel 12 1 Cover 13 1 Air suction hose WOS drive (optional) 14 1 WOS cover plate 15 1 WOS drive cover 16 1 Spring 17 1 WOS shaft 18 1 Bracket with WOS drive Suction module 19 1 Suction module cover hood 20 1 Suction module bottom panel 21 4 Hinge pin clamp 22 1 Protective cap Item Description Item Description 101 Lens-head screw M4 x 8 black, galvanised T Lens-head screw M4 x 8 blue, galvanised 103 Contact washer M4 104 Lens-head screw M6 x 12 T Hinge pins Ø 6 x Hexagonal screw M8 x 25 AF Countersunk Allen head screw M8 x 25 AF Spacer washer M8 109 Spacer washer M8 110 Hexagonal screw M8 x 40 AF Lock bolt M8 112 Hexagonal screw M8 x 50 AF 13 WOS drive (optional) 113 Pipe locking pin 114 Spring cotter Ø 1.6 mm Suction module 115 Sound insulation dowel Ø 12 x Toothed washer M6 117 Spacer washer M6 118 Lens-head screw M6 x 20 with flange T30 NOTICE! Number varies depending on the model T20 Installation Instructions SP Dual compact M _en 27

28 4 Installation Remove the cladding from the pellet unit Components removed in the following steps must be kept in a dry, dust-free protected location until being refitted. Open the insulated door Undo the retaining screw (T25), slide the cover forwards and remove Push down the spring bolt on the top door bearing using, for example, a screwdriver Remove the insulated door from the front Undo the two M4 x 8 lens-head screws on the side panel and remove the side panel 28 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

29 Installation 4 Working on the firewood boiler: Screw an M8 lock bolt into centre left and centre right of the flange Place the seal on the pellet flange of the firewood boiler as shown Check that the seal is positioned correctly! Push in the top perforated opening (A) Twist out the bottom perforated opening (B) Working on the pellet unit: Tilt the bottom cover plate forwards and lift out When opening, use enough force to overcome the magnet Undo the two hexagonal screws M8 x 50 incl. spacer washers on the combustion chamber cover and remove the combustion chamber cover Screw the pellet unit to the firewood boiler Position the pellet unit alongside the firewood boiler so that the flange holes on the pellet unit are aligned with the previously fitted lock bolts on the flange of the firewood boiler Thread the pellet unit into the lock bolts and push towards the firewood boiler Installation Instructions SP Dual compact M _en 29

30 4 Installation Undo the four M4 x 8 lens-head screws on the cover plate of the controller and remove the cover plate Undo the two M4 x 8 lens-head screws on the back panel and remove the back panel The location holes (A) on the pellet unit flange are different (front small play, back large play). This allows you to align the pellet unit with the boiler. Using the adjustable foot (B), adjust the height of the pellet unit so that the distance between the top edge of the pellet unit frame to the firewood boiler s insulating cover is the same at the front and back. 30 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

31 Installation 4 Screw the pre-assembled adjusting screws (A - yellow galvanised steel - AF 13 mm) the whole way into the pellet unit flange on the left and right Screw the pellet unit to the flange of the firewood boiler at the right and left using four M8 x 40 hexagonal screws (B) Once you have done this, check that the clearance between the firewood boiler insulation and the pellet unit is consistent If the firewood boiler and pellet unit are not parallel, you can adjust the gap using the adjusting screws (A - yellow galvanised steel - AF 13 mm): Loosen the adjusting screw on the side with the biggest clearance and tighten the flanged connections (B) Repeat the process until the gap is consistent and then tighten all screw connections (B) again Join the base frames of the two units at the front and back with two M8 x 25 hexagonal screws incl. spacer washers Installation Instructions SP Dual compact M _en 31

32 Laying cables Lift off the cover of the firewood boiler Undo the M4 x 8 lens-head screw incl. contact washer on the back of the controller box Slide the controller cover forwards and remove Run the cable through the perforated opening to the firewood boiler controller box and plug into the boards: temperature sensor of the pellet unit to the core module Fühler 1 FRKEM Fühler 1 bus cable of the pellet unit to the hydraulic or return feed mixer module Bus FRHYU BUS AO- P1 AO- P Installation BUS Bus FRRLA 32 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

33 Installation 4 latch of the pellet unit to the core module Verriegelung FRKEM Verriegelung Power supply of the pellet unit to the terminal block Netz Netz Combi drive of the pellet unit to the core module Primärluft Primärluft FRKEM NOTICE! Observe additional information in the relevant boiler controller documentation! Installation Instructions SP Dual compact M _en 33

34 4 Installation Hydraulic connection When retrofitting the pellet unit to the S1 Turbo F, the return is connected to the pellet unit due to the different water flow. In such cases, you must remove the return line on the S1 Turbo F before connecting. Loosen the four M4 x 8 lens-head screws of the cover plate on the return and take off the cover plate Undo the plug on the left outflow (A) of the return and screw it into the rear outflow (B) so that it is sealed tight Undo the threaded socket from the pipe union provided and screw into the outfeed of the pellet unit (C) or the return feed of the firewood boiler (A) so that it is sealed tight Insert the pipe union as shown and fit to the screw connections Do not forget to fit the seals provided! Reattach the cover plate and secure with four M4 x 8 lens-head screws Connection diagram: 34 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

35 Installation 4 Fitting the air connection Run the air hose to the opening on the side panel of the firewood boiler and connect Fix hose with M4 x 8 lens-head screw as shown Fitting the cladding to the pellet unit Attach back panel to bottom of frame and secure with six M4 x 8 lens-head screws Fit the combustion chamber cover using two M8 x 50 hexagonal screws and spacer washers Installation Instructions SP Dual compact M _en 35

36 4 Installation Fix the top cover plate of the controller with four M4 x 8 lens-head screws Attach the side cut-outs in the cover plate to the bolts of the frame and flip the cover plate up The cover plate is held in place by a magnet Attach the bottom of the insulated door to the bolt (A) Press in the spring bolt (B) and slide in under the top door bearing When positioned correctly, the spring bolt will spring into the hole in the door bearing; the door is then secured Insert the side panel into the lugs on the boiler base and secure with two M4 x 8 lens-head screws 36 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

37 Installation Fitting the WOS drive (optional) Remove the controller cover and thermal insulation. Undo the WOS lever in the flat position (A) with spanner (AF 13 mm) Undo the four M4 x 8 lens-head screws and remove the cover plate with brush on the side panel Remove the end cap (A) of the control on the side with the door stop Pull the hinge pins (B) up and out and lift the insulated door (C) out of the door bearing (D) Undo the two M4 x 8 lens-head screws and remove the cover plate (E) Remove the pre-cut section of the thermal insulation Undo the two M8 x 25 hexagonal screws and the stop for the WOS lever In its place, fit the bracket incl. WOS drive with three M8 x 25 hexagonal screws Installation Instructions SP Dual compact M _en 37

38 4 Installation Undo the hexagonal screws (AF 13 mm) and remove the cleaning cover Use the socket wrench provided Remove the two pipe locking pins on the stay tube Pull the WOS shaft forwards and out Insert the WOS shaft provided and secure with pipe locking pin Slide the bolt (A) of the WOS shaft into the hole of the catch (B) and secure with spacer washer and spring cotter (C) Attach the spring provided to the cut-out on the side panel or on the bolt of the WOS shaft as shown Place the cleaning cover on the boiler body and secure with hexagonal screws (AF 13 mm) Use the socket wrench provided 38 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

39 Installation 4 Undo the M4 x 8 lens-head screw with contact washer (A) on the back of the controller box Slide the controller cover forwards and remove Run the cables to the boards and plug in as follows: WOS drive to the pellet module of the pellet unit FRPEM WOS- Antrieb WOS monitor to the core module of the firewood boiler Fühler 2 FRKEM Installation Instructions SP Dual compact M _en 39

40 4 Installation Put on the controller cover Thread the attachment hooks (B) of the cover through the dedicated openings on the controller box and slide back Secure the controller cover with M4 x 8 lens-head screw and contact washer (A) to the back of the controller box Secure the cover of the WOS drive to the bracket using two M6 x 12 lens-head screws Fit cover plate (A) using two M4 x 8 lens-head screws Attach bottom of insulated door (B) in door bearing (C) and secure at top with hinge pin (D) Slide in end cap (E) of control Remove the pre-cut section of the thermal insulation and place on cleaning cover Place the controller cover on the boiler Fit the WOS cover plate to side panel using six M4 x 8 lens-head screws 40 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

41 Installation Installing the discharge system Once the discharge system has been assembled in accordance with the assembly instructions enclosed, the suction and return air line needs to be connected to the boiler and the external suction module connected as well. Installing the external suction module The pellets are loaded using an external suction module. The suction module is installed in the return-air line between the boiler and the suction point. The following points should be noted for assembly: The position in the return air line can be chosen freely. Before assembly, check whether the supplied assembly material is suitable and, if required, needs to be replaced by suitable material for the base. No specific installation position is required for the suction turbine to operate smoothly. Preferably, the suction module should be mounted so that existing openings in the housing are not on the upper side and the suction turbine is protected against external influences. To prevent interference with moving parts, the electrical connection and the setup of the external suction module should be carried out only after connecting the hose lines. Depending on the boiler type, two different sized suction modules are used. The installation itself is the same for both sizes. Unscrew the screws on the side of the suction module and remove the cover hood Installation Instructions SP Dual compact M _en 41

42 4 Installation Ø 12 mm Install the bottom part with the included anchors and screws at any desired position in the return-air line. If the suction module is positioned at a maximum distance of 2 m to the boiler, the power supply line can be plugged in as is. At greater distances, the power supply line must be lengthened accordingly on-site! 1 2 Unwind the cable of the suction turbine and feed it through the opening of the housing underside Remove the protective cap on the underside of the suction module Lay the return-air line from the suction point to the suction module and fix it to the pressure side (position 1) with a hose clamp Fix the second part of the return-air line to the under-pressure side (position 2) with a hose clamp and lay the line to the boiler Then replace the cover hood 42 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

43 Installation 4 Connecting suction hoses to the boiler At the back of the boiler: Connect the suction hose of the discharge system to the right connection ( PELLETS label) Connect the return-air line of the discharge system from the external suction module to the left connection NOTICE! Ensure the potential equalisation matches the discharge system assembly instructions when connecting the hose lines! Installation Instructions SP Dual compact M _en 43

44 4 Installation Connecting the hydraulic safety devices SP Dual compact M 4 1 Thermal discharge valve The thermal discharge safety device must be connected in accordance with ÖNORM/DIN EN and as shown in the diagram above The discharge safety sensor must be connected to a pressurised cold water mains supply (temperature 15 C) in such a way that it cannot be shut off A pressure reducing valve (1.5) is required for a cold water pressure of 6 bar Minimum cold water pressure = 2 bar 1.1 Sensor of thermal discharge safety device 1.2 Thermal discharge valve (opens at approx. 95 C) 1.3 Cleaning valve (T-piece) 1.4 Dirt trap 1.5 Pressure reducing valve 1.6 Free outlet without counter pressure 2 Safety valve Safety valve as per ÖNORM EN ISO , diameter as per EN or national regulations The safety valve must be installed in an accessible place on the heat generator or in direct proximity in the flow pipe in such a way that it cannot be shut off 3 Return temperature control 4 Diaphragm expansion tank The diaphragm pressurised expansion tank must conform to EN and hold at least the maximum expansion volume of the system s heated water including a water seal Its size must comply with the design information in EN Appendix D Ideally it should be installed in the return line. Follow the manufacturer s installation instructions 5 Internal pipe connection Pellet unit outfeed to return firewood boiler (included in delivery) 44 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

45 Installation Electrical connection DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: Only have work carried out by a qualified electrician Observe the applicable standards and regulations Work must not be carried out on electrical components by unauthorised people Flexible sheathed cable must be used for the wiring; this must be of the correct size to comply with applicable regional standards and regulations. Power is supplied to the system via the firewood boiler control For connection and fusing see corresponding documentation for firewood boiler Connecting the external suction module On the suction turbine, lay the pre-installed supply line from the suction module to the boiler Connect the supply line to the Suction M3 (3) connection of the pellet module Installation Instructions SP Dual compact M _en 45

46 4 Installation Final installation steps Put the cover back on and secure with the retaining screw (T25) Close the insulated door Positioning the boiler stickers correctly The firewood boiler comes with the "S1 Turbo" sticker attached. It is only after the pellet unit is fitted that the complete system becomes the SP Dual compact. Remove the "S1 Turbo" sticker from the insulated door and affix the "SP Dual" sticker provided Align the new sticker to the top left edge of the insulated door 46 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

47 Start-up Before commissioning / configuring the boiler 5 5 Start-up 5.1 Before commissioning / configuring the boiler The boiler must be configured to the heating system on initial start-up. 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 NOTICE Foreign bodies in the heating system impair its operational safety and can result in damage to property. As a result: The whole system should be rinsed out before initial start-up in accordance with EN Recommendation: Make sure the hose diameter of the flush nozzles in the flow and return complies with ÖNORM H 5195 and is the same as the hose diameter in the heating system, however not more than DN 50. Turn on the main switch Set the boiler controller to the system type. Load the boiler default values. NOTICE! For the keypad layout and instructions for modifying the parameters, see the instruction manual for the boiler controller. Check the system pressure of the heating system. Check that the heating system is fully vented. Check that all water connections are tightly sealed Pay particular attention to those connections from which plugs were removed during assembly. Check that the safety devices are present and working efficiently. Check that there is sufficient ventilation in the boiler room. Check the seal of the boiler. All doors and inspection openings must be tightly sealed. Check that the drives and servo motors are working and turning in the right direction. Check that the door contact switch is working efficiently. NOTICE! Check the digital and analog inputs and outputs - See the instruction manual for the boiler controller. Installation Instructions SP Dual compact M _en 47

48 5 Start-up Initial startup 5.2 Initial startup Permitted fuels Wood pellets Note on standards Wood pellets made from natural wood with a diameter of 6 mm EU: Fuel acc. to EN ISO Part 2: Wood pellets class A1 / D06 and/or: ENplus / DINplus certification scheme General note: Before refilling the store, check for pellet dust and clean if necessary. Firewood Water content 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%) Note on standards EU: Fuel as per EN ISO Part 5: Firewood class A2 / D15 L50 Additional for Germany: Fuel class 4 ( 3 of the First Federal Emissions Protection Ordinance (BimSchV) in the last amended version) Tips for storing wood 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 Create a dry underlay, where possible with air access (line with round timber, pallets, etc.) stack split wood and store in such a way that it is protected from the elements If possible, stock fuel for the day in a warm place (e.g. in boiler room) (pre-heats the fuel!) Storage time dependent upon water content Wood type Water content 15 25% less than 15 % Storage in heated and ventilated room (approx. 20 C) Soft wood (e.g. spruce) approx. 6 months from 1 year Hardwood (e.g. beech) years from 2 years 48 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

49 Start-up Initial startup 5 Outdoor storage (protected from elements, exposed to wind) Wood type Water content Soft wood (e.g. spruce) Hardwood (e.g. beech) 15 25% less than 15 % 2 summers from 2 years 3 summers from 3 years Freshly cut wood has an approximate water content of 50 to 60%. As the above table shows, the water content of the firewood decreases the longer the wood is stored depending on how dry and warm the storage location is. The ideal water content of firewood is between 15 and 25%. If the water content falls below 15%, we recommend you adjust the combustion control to the fuel Fuels permitted under certain conditions Wood briquettes Note on standards Wood briquettes for non-industrial use with a diameter of 5-10 cm and 5-50 cm long. EU: Fuel as per EN ISO 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) - applicable version) Notes on use When burning wood briquettes use the settings for extremely dry fuel Wood briquettes must be heated up with firewood as per EN ISO (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 combustion problems. In such cases, repairs must be carried out by qualified staff. Please contact Froling customer services or your installer. Installation Instructions SP Dual compact M _en 49