Fröling S3 Turbo Installation Instructions Manual Download Page 1

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Installation Instructions

Firewood boiler S3 Turbo

Translation of the original German installation instructions for technicians

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

M1081217_en | Edition 23/03/2017

Froeling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.at

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Summary of Contents for S3 Turbo

Page 1: ...ns for technicians Read and follow the instructions and safety information Technical changes typographical errors and omissions reserved M1081217_en Edition 23 03 2017 Froeling GesmbH A 4710 Grieskirc...

Page 2: ...mney system 14 Draught limiter 14 Measuring port 14 Boiler data for planning the flue gas system 15 3 Technology 16 3 1 Dimensions 16 3 2 Components and connections 17 3 3 Technical specifications 18...

Page 3: ...rol 50 Fit the cover plate 51 4 6 Power connection and wiring 52 4 6 1 S Tronic Plus S Tronic Lambda control 52 Power connection 52 Hydraulic system 53 4 6 2 Information on circulating pumps 54 Connec...

Page 4: ...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...

Page 5: ...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 CA...

Page 6: ...uilding 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...

Page 7: ...s and one off inspections NORM M 7510 4 Guidelines for checking central heating systems Part 4 Simple check for heating plants for solid fuels Standards for structural and safety devices NORM H 5170 H...

Page 8: ...report to the construction authorities of the community or magistrate Germany report new installations to an approved chimney sweep the building authorities 2 4 3 General information for installation...

Page 9: ...andards and guidelines apply Austria Germany NORM H 5195 VDI 2035 Switzerland Italy SWKI BT 102 01 UNI 8065 Observe the standards and also follow the recommendations below Aim for a pH value of betwee...

Page 10: ...ken 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 syste...

Page 11: ...f 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...

Page 12: ...can be calculated according to EN 303 5 2012 using the following formula VSp 15TBx QN 1 0 3 x QH Qmin VSp QN TB QH Qmin Storage tank capacity in l Nominal heat output of boiler in kW Burn off period o...

Page 13: ...S3 Turbo 40 45 Recommended storage tank capacity2 l 1700 3000 1 Applies for S3 Turbo 18 as well only available in Italy 2 Values for calculating the capacity can be found in the technical data or the...

Page 14: ...miter 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...

Page 15: ...028 0 033 Flue gas mass flow at partial load 0 011 0 013 0 016 Required feed pressure at nominal load Pa 8 mbar 0 08 Required feed pressure at partial load Pa 8 mbar 0 08 Maximum permissible feed pre...

Page 16: ...l height incl flue gas nozzle 1530 1630 H2 Height of flue pipe connection 1750 1850 H3 Height of flow connection 1280 1380 H4 Height of return connection 140 140 H5 Height of safety battery connection...

Page 17: ...1 2 5 Immersion sleeve for thermal discharge valve supplied by the customer inches 1 2 6 Immersion sleeve for boiler sensor and STL inches 1 2 7 Flue gas pipe connection mm 149 8 Flue gas temperature...

Page 18: ...uel loading chamber capacity l 140 Combustion time2 beech h 4 3 6 3 4 7 6 9 Combustion time2 spruce 3 0 4 4 3 3 4 8 1 S3 Turbo 18 only available in Italy 2 Values specified for combustion time are gui...

Page 19: ...chamber capacity l 140 Combustion time2 beech h 3 9 5 6 Combustion time2 spruce 2 8 3 9 1 S3 Turbo 30 with 31 kW nominal output only available in Austria and Italy 2 Values specified for combustion ti...

Page 20: ...mm 330 370 Fuel loading chamber capacity l 210 Combustion time1 Beech h 4 1 6 0 3 9 5 6 Combustion time1 Spruce 2 9 4 2 2 7 4 0 1 Values specified for combustion time are guideline values at nominal l...

Page 21: ...ominal output kW 30 31 Boiler class as per EN 303 5 2012 5 5 4 with partial load inspection 1 S3 Turbo 30 with 31 kW nominal output only available in Austria and Italy Test data Emissions in mg MJ 1 n...

Page 22: ...pecified as a mass based on the energy content of the fuel fed to the combustion system in mg MJ Test data Emissions in mg m 1 nominal load partial load Carbon monoxide CO mg m 69 435 81 280 Nitrogen...

Page 23: ...brush small 6 Ceramic fibre seal 13 Cleaning brush large 7 Induced draft fan Not pictured installation and operating instructions guarantee certificate identification plate 4 1 1 Tools required The fo...

Page 24: ...ought in on the pallet remove the cardboard and take the boiler off the pallet See Remove boiler from pallet page 25 Positioning using a crane Attach the crane hook to the attachment point correctly a...

Page 25: ...from pallet TIP use Froling s KHV 1400 boiler lifting system to help remove the pallet 4 3 2 Moving the boiler in the boiler room Position a fork lift or similar lifting device with a suitable load b...

Page 26: ...stance side of boiler to wall 200 800 1 1 The side of the boiler where the WOS lever is located B or D should be at least 800 mm from the wall to allow easy access for connecting the appliance and for...

Page 27: ...cer washers and nuts on the other side Only partially tighten the nuts NOTICE At this point the fuel loading door must be rebuilt if the stop of the door is being changed See Converting the fuel loadi...

Page 28: ...e settings and seal of the door See Setting and checking the seal on the doors page 29 Converting the fuel loading door Remove the radiation plate B together with the seal A Carefully lift out the ins...

Page 29: ...n chamber door and the pre heating chamber door On the side with the door stop Close the door A slight resistance must be felt when there is a gap of 2 3 cm Setting OK No resistance or only very sligh...

Page 30: ...ard the back See Positioning the doors page 31 On the side with the door handle Close the door The door can be closed with a normal amount of effort Setting OK If the door cannot be closed with the us...

Page 31: ...doors page 31 Positioning the doors Using an Allen key SW 13 mm loosen the nuts on the locking plate and or hinge at the top and bottom Use suitable tools e g screwdriver and hammer to move the locki...

Page 32: ...14 15 16 16 17 20 21 22 22 18 19 23 24 25 26 27 28 29 30 31 32 33 35 34 36 38 39 S3 Turbo 40 45 S3 Turbo 20 30 S Tronic Lambda S Tronic Plus 37 4 Assembly Installing the boiler 32 Froeling GesmbH A 47...

Page 33: ...ning door complete 11 1 Blanking plate side cleaning door 31 1 Door handle cleaning door 12 1 Cover plate 32 1 Round head screw M8 x 30 13 1 Bracket left 33 1 Cover plate 14 1 Thermal insulation rear...

Page 34: ...Flue gas pipe nozzle 150 3 1 Ceramic fibre seal 210 x 144 x 12 4 2 Pneumatic rods complete 5 2 Sliding valve 100 6 2 Split pin 3 2 x 20 7 3 Door handle black 8 3 Bushing 10 x 20 9 3 Hexagonal screw M8...

Page 35: ...er complete 2 1 Grey cast iron bushing 3 1 Plastic cover 4 1 WOS lever 5 1 WOS bracket complete 6 x 3 6 2 Pipe locking pin 7 4 WOS turbulator 50 x 6 x 3 x 837 Assembly 4 Installing the boiler Installa...

Page 36: ...t iron bushing 3 1 Plastic cover 4 1 WOS lever 5 10 WOS turbulator 50 x 6 x 3 x 932 6 1 WOS bracket complete 6 x 3 7 2 Pipe locking pin 4 Assembly Installing the boiler 36 Froeling GesmbH A 4710 Gries...

Page 37: ...rimary and secondary air Manual controllers or servo motors can be mounted on either the left or the right side on the boiler Remove the split pin on both pneumatic rods opposite the spring and pull o...

Page 38: ...the boiler The air flaps with springs lie flat on the left hand air ducts Insert the air flaps on the pneumatic rods on the right hand side and secure them with split pins A CAUTION the air flaps must...

Page 39: ...n the S3 Turbo with S Tronic Lambda the broadband probe will be mounted here later 4 5 5 Installing the insulation NOTICE The individual parts of the boiler insulation covered with a protective film Y...

Page 40: ...ets at both insulating side panels and secure them with the two top thread forming screws B At the front the bracket will be secured later when the upper spacer plate is inserted Cut the perforated fl...

Page 41: ...o the threaded bolts and secure them lightly with a large and a small spacer washer and nut Hang the upper spacer plate on the rivets between the insulating side panels and attach with thread forming...

Page 42: ...plate 4 5 7 Installing the back panel Position the rear thermal insulation on the rear side of the boiler Insert back panel over induced draught fan Secure the left and right back panel to the side pa...

Page 43: ...side panels Secure the insulating side panels to the right and left at the flap on the boiler base with thread forming screws Measure the diagonals and align the insulating side panels so that the tw...

Page 44: ...ontroller box on the boiler Use eight thread forming screws incl contact washers A to install controller box on the cable duct of the side panels Screw in two carrying bolts B hexagonal bolts M6 x 100...

Page 45: ...pposite side 4 5 10 Installing the insulated door The illustrations show the assembly for the door stop on the right If the insulated door is attached on the left complete the following procedures wit...

Page 46: ...ide panel to the centre of the borehole on the lower door bracket The two distances must be equal If necessary correct the position of the lower door bracket Secure the two hexagonal screws of lower d...

Page 47: ...ide of the insulated door at the top and bottom Mount counter plates for the magnetic latches A to the left insulation side panel Check to see if the gap between the insulation side panel and the insu...

Page 48: ...rough the cable duct C to the controller box Tuck any extra cable into the cable duct 4 5 12 Install the broadband probe only with S Tronic Lambda Unscrew the pre installed bushing A from the broadban...

Page 49: ...D S3 Turbo 20 30 E S3 Turbo 40 45 Make sure that you fit the turbulators in the right direction Hold the linking plate with the edge toward the top Hang the WOS turbulators over the edge Position the...

Page 50: ...the manual controller is at the left stop and secure them with one thread forming screw each Place the handle onto the pneumatic rod Check to see if the air flaps can be opened to the right The exact...

Page 51: ...rews Align the actuators so that they are straight and tighten the screws Attach the sticker at the end of the actuator cable Primary air top actuator Secondary air bottom actuator Push in the pre pun...

Page 52: ...ue gas temperature sensor boiler sensor induced draught STL display and door switch to the controller and connect the wiring in accordance with the operating instructions of the boiler control Tuck an...

Page 53: ...Pump assembly OE DHW tank Unicell NT S Note Controller S Tronic Plus Temp sensor 0 1 Temp sensor 0 2 Return sensor With heating circuit modules Bus connection up to heating circuits are available 18...

Page 54: ...ing pumps with EEI 0 23 Pumps which do not comply with this EEI are referred to as squirrel cage standard pumps and were distributed until the end of 2012 If a high efficiency pump with additional con...

Page 55: ...nic Plus or S Tronic Lambda controller the connection diagram above must be followed for using a high efficiency pump with control line Connecting a squirrel cage standard pump If a squirrel cage stan...

Page 56: ...Use the two thread forming screws incl contact washers to secure the controller cover Put on the back heat insulation mat Put on the rear insulating cover 4 Assembly Power connection and wiring 56 Fro...

Page 57: ...Free outlet without counter pressure 2 Safety valve Safety valve as per NORM EN ISO 4126 1 diameter as per EN 12828 or national regulations The safety valve must be installed in an accessible place o...

Page 58: ...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 control...

Page 59: ...ce 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 app...

Page 60: ...y 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 5 2 3 Non permitted...

Page 61: ...max 10 20 of the fuel loading chamber Ignite it and allow it to burn slowly with the central pre heating chamber door open NOTICE Fissures are normal and do not indicate a malfunction Once the materi...

Page 62: ...ame settings as for short split hardwood The table shows the setting values for the manual controller of the air flap which ensures a smooth start up The setting values for the manual controller may n...

Page 63: ...lue gas system page 15 Once the manual controller has been correctly set secure it in that position Setting the secondary air The secondary air sets the O2 content of the flue gas and thus the quality...

Page 64: ...s used get a qualified technician to check the air flap setting and adjust if necessary 5 Start up Initial startup 64 Froeling GesmbH A 4710 Grieskirchen Industriestra e 12 www froeling at All manuals...

Page 65: ...n against frost 6 2 Disassembly To disassemble the system follow the steps for assembly in reverse order 6 3 Disposal Ensure that they are disposed of in an environmentally friendly way in accordance...

Page 66: ...Pressure equipment regulation 7 Appendix Pressure equipment regulation 66 Froeling GesmbH A 4710 Grieskirchen Industriestra e 12 www froeling at All manuals and user guides at all guides com a l l g u...

Page 67: ...GesmbH Industriestra e 12 A 4710 Grieskirchen AUSTRIA TEL 0043 0 7248 606 0 FAX 0043 0 7248 606 600 INTERNET www froeling com 7 2 2 Address of the installer Stamp Appendix 7 Addresses Installation Ins...

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Fröling S3 Turbo, Installation Instructions Manual

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