Assembly Instructions - PDF Free Download

Assembly nstructions S4 Turbo Read and follow the assembly instructions and safety information. Subject to technical change. Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen

ntroduction Dear customer, The FRÖLNG 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. f 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 FRÖLNG Heizkessel- und Behälterbau GesmbH ndustriestraße 12 A-4710 Grieskirchen AUSTRA TEL +43 (0)7248 606 0 FAX +43 (0)7248 606 600 E-MAL info@froeling.com NTERNET www.froeling.com Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 3

C Contents 1 General information 6 1.1 Notes on standards 6 1.2 Design nformation 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 nstalling 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 nstallation 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 nstallation of S4 Turbo 15/22/28/34/40 22 3.5.1 Fitting the induced draught fan... 22 3.5.2 nstalling the flue gas pipe nozzle... 22 3.5.3 nstalling the WOS system... 22 3.5.4 nstalling the air flaps... 24 Air flaps for actuators right (delivery configuration)... 24 Air flaps for actuators left... 25 3.5.5 nstalling the insulation... 26 Page 4

Contents C 3.5.6 nstalling the actuators... 29 3.5.7 nstalling the Lambda probe... 30 3.5.8 nstalling the flue gas sensor... 31 3.5.9 nstalling the control unit... 31 3.5.10 nstalling the WOS lever... 32 3.5.11 nstall the insulating door... 34 3.5.12 nstalling the insulating cover... 35 3.5.13 nstalling the floor insulation... 35 3.6 nstalling the S4 Turbo 50/60 36 3.6.1 nstalling the WOS system... 36 3.6.2 nstalling the air flaps... 37 Air flaps for actuators right (delivery configuration)... 37 Air flaps for actuators left... 38 3.6.3 nstalling the insulation... 39 3.6.4 nstalling the actuators... 42 3.6.5 nstalling the flue gas sensor... 43 3.6.6 nstalling the Lambda probe... 43 3.6.7 nstalling the induced draught fan... 44 3.6.8 nstalling the control unit... 45 3.6.9 nstalling the WOS lever... 46 3.6.10 nstall the insulating door... 47 3.6.11 nstalling the insulating cover... 48 3.6.12 nstalling the floor insulation... 48 3.7 Electrical connection 49 3.8 Connecting the thermal discharge safety device 49 4 Startup 50 4.1 nitial 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 5

1 General Standards, Design, Assembly 1 General information CAUTON 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/DN EN 303-5 ÖNORM M 7510 ÖNORM / DN EN 12828 ÖNORM B 8130 ÖNORM B 8131 DN 4751 Parts 1-4 ÖNORM / DN EN 13384-1 ÖNORM M 7515 / DN 4705-1 ÖNORM H 5170 VD 2035 ÖNORM H 5195-1 VD 2035 SWK 97-1 Heating boilers for solid fuels, hand and automatically stocked, nominal heat output of up to 300 kw - Terminology, requirements, testing and marking Guidelines for checking central heating systems Heating systems in buildings - design of water-based heating systems Safety devices, open water-heating systems Closed water-heating systems, safety requirements Heating system safety equipment Chimneys serving one appliance Calculating chimney dimensions for combustion systems Requirements related to fire prevention, fire protection and building construction Prevention of damage in water heating installations - Scale formation in domestic hot water supply installations and water heating installations (Germany only) Prevention of damage by corrosion and scale formation in closed warm-waterheating systems at operating temperatures up to 100 C (Austria only). Prevention of damage in water heating installations - Scale formation in domestic hot water supply installations and water heating installations (Germany only) Lime scale and corrosion protection in heating systems (Switzerland only) Page 6

General Standards, Design, Assembly 1 1.2 Design nformation t 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 NOTCE 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: Germany: authorities. nform the civic/municipal building authorities. Register with an approved chimney sweep/the building 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: VD 2035 Switzerland: SWK 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. Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 7

1 General Standards, Design, Assembly 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 nstalling the heating system / Standards The following standards govern the installation of heating systems: Applicable standards: ÖNORM / DN 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 DN 4751 Part 2 - Open systems as per DN 4751 Part 1 Return feed lift f the hot water return feed is below the minimum return feed temperature, some of the hot water outfeed will be mixed in. CAUTON 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). Page 8

General Standards, Design, Assembly 1 Combination with storage tank n 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 mplementation of the Federal Emissions Control Act (1st BmSchV). 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 BmSchV. 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. n 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. t 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. f, 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.... n Austria: some subsidy guidelines of Austrian federal states (e.g. those of the Vorarlberg state government)... n Switzerland: The Quality Seal for Wood Burning Systems scheme from Holzenergie Schweiz Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 9

1 General Standards, Design, Assembly Other guidelines are based on tank size, e.g.... n Austria: Specific subsidy guidelines for Austrian states (e.g. Styrian state government guidelines: buffer storage tanks of at least 800 L)... n 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 1 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. t 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. nsulate the connecting piece. The entire flue gas system (chimney and connection) must be calculated as per ÖNORM/DN EN 13384-1 or prior standards ÖNORM M 7515/DN 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) nstall 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 / DN EN 303-5 Flue pipe diameter mm 150 150 150 150 150 150 150 RL = Rated Load, PL = Partial Load Page 10

Technology Connections, dimensions and performance data 2 2 Technology 2.1 Components and connections 8 5 6 7 5 6 7 1 1 4 4 S4 Turbo 15-40 S4 Turbo 50/60 2 3 2 3 S4 Turbo tem 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 1/2 1/2 1/2 the thermal discharge safety device nch 5 Flue gas sensor connector 1/2 1/2 1/2 6 Lambda probe connector 3/4 3/4 3/4 7 2 mmersion sleeves for - thermal discharge safety device sensor - boiler sensor, safety temperature limiter 1/2 1/2 1/2 8 Flue gas pipe nozzle mm 150 150 150 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 11

2 Technology Connections, dimensions and performance data 2.2 Dimensions S4 Turbo tem 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 mm 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 970 970 960 B Boiler width 570 670 670 mm B1 Total boiler width inc. actuators 635 735 735 L Boiler length 1125 1215 1215 L1 Total length inc. induced draught fan mm 1300 1390 L1* Total length inc. induced draught fan 1680 *) dimensions indicated only for S4 Turbo 50/60 Page 12

Technology Connections, dimensions and performance data 2 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 kw Fuel-heating efficiency at rated heat output 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 L Water capacity 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 C Permitted operating temperature 95 Permitted operating pressure bar 3 Permitted fuel Combustion time 1) Beech Spruce h 9.0-13.0 6.3-9.2 Firewood 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 Date of issue 16.11.2005 Carbon monoxide (CO) Nitrogen oxide (NOx) Organic hydrocarbons Dust Rated load Partial load Rated load Partial load Rated load Partial load Rated load Partial load mg/mj mg/mj mg/mj mg/mj 2) 4) 2) 3) 34 19 20 58 93 96 97 91 2 < 2 < 2 3 17 13 12 6 1) TÜV Austria, Environment and Chemistry Division, Thalheim bei Wels Test Centre 2) n accordance with ÖNORM / DN 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. 4) Values for the type S4 Turbo 22 are interpolated between the test protocol 07-UWC/Wels-EX-094/1 and 07-UWC/Wels-EX-094/2. Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 13

2 Technology Technical specifications 2.3.2 S4 Turbo 34/40 S4 Turbo Description Unit 34 40 Rated heat output 34 40 kw Fuel-heating efficiency at rated heat output 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 L Water capacity 175 175 Water side resistance (with 10/20 K temperature difference) mbar 5.1 / 1.7 6.0 / 1.9 Minimum return feed temperature 55 C Permitted operating temperature 95 Permitted operating pressure bar 3 Permitted fuel Combustion time 1) Beech Spruce kg/h 4.7-6.8 3.3-4.8 Firewood 3.9-5.7 2.8-4.0 Recommended buffer storage tank capacity L 1400 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 34 40 Testing institute TÜV Austria 1) Test report no. 2) 3) 07-UWC/Wels- EX-094/3 Date of issue 23.03.2007 Carbon monoxide (CO) Nitrogen oxide (NOx) Organic hydrocarbons Dust Rated load Partial load Rated load Partial load Rated load Partial load Rated load Partial load mg/mj mg/mj mg/mj mg/mj 1) TÜV Austria, Environment and Chemistry Division, Thalheim bei Wels Test Centre 2) n accordance with ÖNORM / DN 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 34 are interpolated between the test protocol 07-UWC/Wels-EX-094/2 and 07-UWC/Wels-EX-094/3. 37 51 98 88 < 2 3 13 7 54 45 99 85 < 2 3 14 7 Page 14

Technology Connections, dimensions and performance data 2 2.3.3 S4 Turbo 50/60 S4 Turbo Description Unit 50 60 Rated heat output 50 60 kw Fuel-heating efficiency at rated heat output 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 L Water capacity 170 170 Water side resistance (with 10/20 K temperature difference) mbar 7.0 / 2.0 8.0 / 2.5 Minimum return feed temperature 55 C Permitted operating temperature 95 Permitted operating pressure bar 3 Permitted fuel Combustion time 1) Beech Spruce kg/h 3.4-4.9 2.4-3.5 Firewood 2.8-4.1 2.0-2.9 Recommended buffer storage tank capacity L 1660 1660 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 50 60 Testing institute TÜV Austria 1) Test report no. 2) 3) 08-UW/Wels- EX-074 Date of issue 25.04.2008 Carbon monoxide (CO) Nitrogen oxide (NOx) Organic hydrocarbons Dust Rated load Partial load Rated load Partial load Rated load Partial load Rated load Partial load mg/mj mg/mj mg/mj mg/mj 1) TÜV Austria, Environment and Chemistry Division, Thalheim bei Wels Test Centre 2) n accordance with ÖNORM / DN 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 50 are interpolated between the test protocol 07-UWC/Wels-EX-094/3 and 08-UW/Wels-EX-074. 43 46 104 83 < 2 3 17 11 31 46 109 80 < 2 3 20 14 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 15

3 nstallation Transport and setup 3 nstallation 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 f 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. Page 16

nstallation 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 17

3 nstallation Materials supplied 3.3 Materials supplied A B Boiler nsulation B A E F C Flue gas pipe nozzle (S4 Turbo 15-40) D H D E nduced draught unit housing (S4 Turbo 50-60) nduced draught fan C G F G Cardboard box containing small parts Rods for primary and secondary air L J H Ash shovel Cleaning kit J Cleaning brush, small K K L Cleaning brush, large Control unit of the Lambdatronic S3200 M M Ash drawer 3.3.1 Tools required The following are also included in the materials supplied but not pictured: Lambdatronic control unit, installation instructions, operating instructions, guarantee certificate, identification plate 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 Page 18

nstallation Before installation 3 3.4 Before installation NOTCE 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. Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 19

3 nstallation Before installation 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 Page 20

nstallation Before installation 3 3.4.2 Fitting the door handles For the fuel loading chamber door: Position the door handle in the hole provided nsert 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 1 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 21

3 nstallation S4 Turbo 15-40 3.5 nstallation of S4 Turbo 15/22/28/34/40 NOTCE 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, nstalling 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 nstalling 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 nstalling 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 Page 22

nstallation S4 Turbo 15-40 3 nsert the turbulators into the linking plate as shown S4 Turbo 15-28 S4 Turbo 34-40 Remove the WOS cover nsert the turbulators at the heat exchanger pipes as shown above Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 23

3 nstallation S4 Turbo 15-40 3.5.4 nstalling the air flaps For both pneumatic rods: Remove the split pin opposite the spring and pull off one of the two air flaps. 1 NOTCE CAUTON! f 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) nsert 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 CAUTON: nstall the flaps in the same position! Secure the flaps with the split pins Check that the shaft can move freely 2 Page 24

nstallation S4 Turbo 15-40 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 lefthand side of the boiler. Only screw the screws of the air boxes in lightly. 2 2 nsert 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 CAUTON: nstall the flaps in the same position. Secure the flaps with the split pins Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 25

3 nstallation S4 Turbo 15-40 3.5.5 nstalling the insulation NOTCE The separate parts of the boiler insulation are fitted with a protective film. This must always be removed before installation. nsert the L-plate into the insulating side panel as shown and fix with 3 self-tapping screws nsert 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 1 Place a large spacer washer on each of the threaded bolts nsert 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 Page 26

nstallation S4 Turbo 15-40 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 27

3 nstallation S4 Turbo 15-40 Do not leave a gap! 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 selftapping 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 Page 28

nstallation S4 Turbo 15-40 3 3.5.6 nstalling 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. 1 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 2 nstall 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 nsert 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 29

3 nstallation S4 Turbo 15-40 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 nstalling 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 Page 30

nstallation S4 Turbo 15-40 3 3.5.8 nstalling 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 nstalling the control unit 1 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. 1 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) Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 31

3 nstallation S4 Turbo 15-40 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 nstalling 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 halfround 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 Page 32

nstallation S4 Turbo 15-40 3 1 1 S4 Turbo 15-28 S4 Turbo 34-40 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 33

3 nstallation S4 Turbo 15-40 3.5.11 nstall 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 nsert 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 Page 34

nstallation S4 Turbo 15-40 3 3.5.12 nstalling 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 nstalling the floor insulation Put the floor insulation assembly into the U-profiles in the base of the boiler and slide in fully Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 35

3 nstallation S4 Turbo 50-60 3.6 nstalling the S4 Turbo 50/60 NOTCE 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, nstallation of S4 Turbo 15/22/28/34/40 3.6.1 nstalling 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 nsert the turbulators into the linking plate as shown Remove the WOS cover nsert the turbulators at the front heat exchanger pipes Page 36

nstallation S4 Turbo 50-60 3 3.6.2 nstalling the air flaps For both pneumatic rods: Remove the split pin opposite the spring and pull off one of the two air flaps. 1 NOTCE CAUTON! f 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. nsert the pneumatic rod at the lefthand 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 CAUTON: nstall the flaps in the same position! Secure the flaps with the split pins Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 37

3 nstallation S4 Turbo 50-60 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 nsert 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 CAUTON: nstall the flaps in the same position! Secure the flaps with the split pins Page 38

nstallation S4 Turbo 50-60 3 3.6.3 nstalling the insulation NOTCE The separate parts of the boiler insulation are fitted with a protective film. This must always be removed before installation. nsert the L-plate into the insulating side panel as shown and fix with 3 self-tapping screws nsert 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 1 Place a large spacer washer on each of the threaded bolts nsert 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 39

3 nstallation S4 Turbo 50-60 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 Page 40

nstallation S4 Turbo 50-60 3 Do not leave a gap! 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 selftapping 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 41

3 nstallation S4 Turbo 50-60 3.6.4 nstalling 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 1 2 nstall 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 nsert 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 Page 42

nstallation S4 Turbo 50-60 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 nstalling 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 nstalling 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 43

3 nstallation S4 Turbo 50-60 3.6.7 nstalling 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 nstall 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 Page 44

nstallation S4 Turbo 50-60 3 3.6.8 nstalling the control unit 1 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. 1 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. Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 45

3 nstallation S4 Turbo 50-60 3.6.9 nstalling 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) 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 Page 46

nstallation S4 Turbo 50-60 3 3.6.10 nstall 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 nsert 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 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 47

3 nstallation S4 Turbo 50-60 3.6.11 nstalling 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 nstalling the floor insulation Put the floor insulation assembly into the U-profiles in the base of the boiler and slide in fully Page 48

nstallation Connecting the pellet boiler 3 3.7 Electrical connection Working on electrical components DANGER 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 NOTCE The thermal discharge safety device must be connected in accordance with ÖNORM/DN 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 1 Thermal discharge safety device sensor 2 Thermal discharge safety device (opens at approx. 95 C) 5 4 2 3 Cleaning valve (T-piece) 4 Dirt trap 5 Pressure reducing valve* 3 *) Required when the cold water pressure is greater than 6 bar. t must be not be possible to shut off the connection manually. Minimum cold water pressure is 2 bar. Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 49

4/5 nitial startup / Decommissioning 4 Startup 4.1 nitial startup/ configuring the boiler The boiler must be adjusted to the requirements of the heating system during initial startup NOTCE 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 5.2 Disassembly f the boiler is to remain out of service during the winter: Have the system completely drained by a qualified technician Protection against frost 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. Page 50

Appendix 6 6 Appendix 6.1 Delivery certificate S4 Turbo Customer no. Customer address: nstaller: Telephone number: Boiler type: S4 Turbo 15 S4 Turbo 22 S4 Turbo 28 S4 Turbo 34 S4 Turbo 40 S4 Turbo 50 Serial number: S4 Turbo 60 Following items checked: 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 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 nstaller Finally, we ask that you have the customer sign a copy of this confirmation and send it to FRÖLNG Ges.m.b.H. Fax: +43 (0)7248 606 600 Fröling Heizkessel- und Behälterbau Ges.m.b.H, ndustriestrasse 12, A-4710 Grieskirchen Page 51