Fröling SP Dual compact Installation Instructions Manual Download Page 1

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Installation instructions

Dual fuel boiler SP Dual compact

Translation of original German version of installation instructions for technicians.

Read and follow all instructions and safety instructions.

All errors and omissions excepted.

M1820921_en | Edition 12/07/2021

Summary of Contents for SP Dual compact

Page 1: ...uel boiler SP Dual compact Translation of original German version of installation instructions for technicians Read and follow all instructions and safety instructions All errors and omissions excepte...

Page 2: ...bustion air 12 3 5 1 Combustion air supply at the installation room 12 3 5 2 Simultaneous operation with other air drawing systems 13 3 6 Domestic hot water 14 3 7 Pressure maintenance systems 15 3 8...

Page 3: ...e cladding to the pellet unit 54 6 8 Connecting the discharge system 56 6 8 1 Installing the external suction module 56 6 8 2 Connecting the hose lines 58 6 8 3 Assembly information for hose lines 59...

Page 4: ...r 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...

Page 5: ...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 l...

Page 6: ...em Assembly installation initial startup and servicing must always be carried out by qualified personnel Heating technician building technician Electrical installation technician Froling customer serv...

Page 7: ...1 General requirements and one off inspections NORM M 7510 4 Guidelines for checking central heating systems Part 4 Simple check for heating plants for solid fuels 3 1 2 Standards for structural and s...

Page 8: ...llation Note on standards EN 12828 Heating Systems in Buildings IMPORTANT Every heating system must be officially approved The appropriate supervisory authority inspection agency must always be inform...

Page 9: ...regulations and other statutory regulations are also applicable EN 303 5 specifies that the entire flue gas system must be designed to prevent wherever possible damage caused by seepage insufficient f...

Page 10: ...tem is in operation The diameter of the measuring probe used by Froling customer service is 14 mm To avoid measuring errors due to the ingress of false air the diameter of the measuring port must not...

Page 11: ...he flue gas line D D M 2 x D E For planning and installation comply with the following points Position the measuring port M downstream of the electrostatic particle separator E as specified in the ins...

Page 12: ...flue mode i e the combustion air required to operate the boiler is drawn from the installation room Requirements Opening to the atmosphere Weather conditions must not affect the air flow in any way e...

Page 13: ...an approved under pressure monitoring system such as air pressure monitor P4 which monitor the maximum under pressure to 4 Pa must be installed in the installation room In addition at least one of th...

Page 14: ...ing 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...

Page 15: ...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 e...

Page 16: ...ank capacity 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...

Page 17: ...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 t...

Page 18: ...gas pipe connection and side of boiler 665 B6 Distance between safety heat exchanger connection and side of boiler 430 B7 Distance between safety heat exchanger connections 65 B8 Distance between flo...

Page 19: ...nage connection 1 2 IT 4 Safety heat exchanger connection 1 2 IT 5 Immersion sleeve sensor connection for thermal discharge valve installed by the customer 1 2 IT 6 Flue gas pipe connection external d...

Page 20: ...3 Power consumption in slumber mode 3 Boiler weight incl pellet unit kg 645 655 Weight of pellet unit 190 Total boiler capacity water l 105 Pellet container capacity 40 Water pressure drop T 10 20 K m...

Page 21: ...1 87 3 Fuel efficiency at 30 of rated heat output p 84 3 84 3 Auxiliary current consumption at rated heat output elmax kW 0 056 0 063 Auxiliary current consumption at 30 of rated heat output p 0 037 0...

Page 22: ...C 150 170 Flue gas temperature at partial load C 120 130 CO2 volume concentration at nominal load partial load firewood operation 12 3 CO2 volume concentration at nominal load partial load pellet ope...

Page 23: ...dule B1 H1 H2 L1 1 2 Dimensi on Description Unit Size 1 Size 2 L1 Length of suction module mm 220 265 B1 Width of suction module 235 290 H1 Height of suction module 225 235 H2 Total height incl hose c...

Page 24: ...20 L1 Length firewood boiler mm 1250 L2 Length pellet unit 1200 B1 Width firewood boiler 935 B2 Width pellet unit 690 H1 Height firewood boiler 1690 H2 Height pellet unit 1540 Weight of firewood boile...

Page 25: ...vice at the pallet and bring in the components If the firewood boiler cannot be brought in on the pallet r remove the cardboard and take the boiler off the pallet Removing boiler from pallet 25 If the...

Page 26: ...pallet r Remove the top frame of the pallet r Remove the wood screws and clamping angles r Lift the boiler using a fork lift or similar lifting device with the appropriate load bearing capacity and re...

Page 27: ...nts in a protected area that is dry and free of dust until they are reinstalled r Remove the wood screws and clamping angles on the pallet r Open the insulated door and remove the retaining screw on t...

Page 28: ...through both eyelets A and lift the pellet unit off the pallet 5 4 3 Operating and maintenance areas of the equipment The system should generally be set up so that it is accessible from all sides allo...

Page 29: ...enance work to boiler s heat exchanger only possible from front 2 Maintenance area to expand the WOS springs upwards Operating and maintenance areas of the SP Dual compact D C 1 2 B B1 A E 1 Firewood...

Page 30: ...ths across flats 8 32 mm r Set of Allen keys r Flat head and cross head screwdrivers r Hammer r Diagonal cutting pliers r Half round file r Power drill or cordless screwdriver with Torx bit insert r S...

Page 31: ...4 Hinge pin clamp 3 1 Combustion chamber lid 10 1 Back panel 4 1 Cover plate for controller box 11 1 Pipe union 5 1 Flange seal 12 1 Side panel right 6 3 Lock bolt M8 13 1 Adjustable foot 7 1 Air suct...

Page 32: ...20921_en Installation instructions Dual fuel boiler SP Dual compact 6 4 Assembly overview S1 Turbo F 1 2 3 4 6 7 7 8 9 10 11 12 13 17 16 15 14 21 21 22 23 26 27 28 29 30 31 33 34 35 36 37 38 39 40 32...

Page 33: ...boiler return 28 1 Thermal insulation for top of boiler 9 1 Cable duct cover 29 1 Controller box complete 10 1 Side panel right 30 1 Thermal insulation for cleaning cover 11 1 Thermal insulatio pellet...

Page 34: ...for changing the stop on the combustion chamber door NOTICE If there is a pellet unit we recommend having the door stop on the left side of the boiler for ease of operation r Open the fuel loading doo...

Page 35: ...the other side and insert the flange sleeve r Attach the door handle using a hexagon screw r Remount the door with the stop on the other side and fix it in place with hinge pins at the top and bottom...

Page 36: ...a sheet of paper at the top between the door and the boiler and then close the door r Try to pull out the sheets of paper If the paper cannot be removed The door seal is OK and the settings are corre...

Page 37: ...gap of approx 2 to 3 cm there should be a noticeable resistance r If the resistance is too low or too high move the locking cams backwards or forwards using the key provided SW 32 mm The movement of...

Page 38: ...rew r Fasten the induced draught fan using four hexagon screws including washers 6 6 2 Installing the insulation IMPORTANT The individual parts of the boiler insulation covered with a protective film...

Page 39: ...ing tension springs r Position the rear thermal insulation on the back wall and attach to the boiler using tension springs Right door stop Left door stop r Screw the nuts and bolts as shown on to the...

Page 40: ...olt B on the bottom of the boiler r Attach the side panel and bracket to the boiler Tighten the screws only slightly so the side panel can be aligned later A B r Remove the rectangular thermal insulat...

Page 41: ...rear panel to the side panels r Attach the ID fan cover plate to the back panel r Fit the control screw heads into the cutouts on the side panels r Insert the spacer plate beneath the control r Attach...

Page 42: ...ockwise r Set the direction of rotation of the servo motor 1 to left L r Press the release button 2 and turn the shaft receptacle 3 to the left until it stops r Put the servomotor on the shaft and use...

Page 43: ...SW 13 mm r Loosen the screws slightly and unhook the cover plate from the left side panel r Screw the WOS lever into shaft and place the wrench on the flattened area to tighten 6 6 5 Install the driv...

Page 44: ...pplied AF 13 socket wrench to do so r Install the WOS bracket as shown r Fix the WOS drive and WOS monitor in position on the strain relief A using a cable tie r Remove the pipe locking pin from the W...

Page 45: ...tch and secure with spacer washer and spring cotter r Mount the WOS spring on the hook of the rod and on the top of the side panel r Place the cleaning cover on the boiler and attach using a socket wr...

Page 46: ...the side panel on the opposite side of the door stop NOTE counter plate may already be mounted on one side r Hang the insulated door at the bottom onto the half length taper grooved pin and secure at...

Page 47: ...uctions Dual fuel boiler SP Dual compact 47 r For automatic WOS Fit the cover on the WOS bracket A r Place the thermal insulation on the boiler as shown For automatic WOS Separate the thermal insulati...

Page 48: ...charge valve r Screw bushing 1 into flue pipe nozzle and tighten slightly r Screw adapter 2 into bushing r Screw the Lambda probe 3 into the adapter on the flue pipe nozzle and tighten slightly using...

Page 49: ...n sleeve on the thermal discharge valve r Slide the sensor and metal tube insulation into the immersion sleeve and secure with slotted screw 6 6 9 Attaching the induced draught cable r Run the induced...

Page 50: ...insulating door and the fuel loading door of the firewood boiler r Remove the middle linking plate on the flange side r Fit the linking plate provided to the flange cutout as shown r Remove the cover...

Page 51: ...Slide the flange seal supplied over the lock bolts Projecting lugs A must face the front of the boiler The seal must slide smoothly over the three lock bolts The seal must not be laid so as to obstru...

Page 52: ...read the pellet unit into the lock bolts and push towards the firewood boiler r Adjust the height of the pellet unit using the adjustable feet so that the top edge of the pellet unit is parallel with...

Page 53: ...tighten the flange screw connections B until the size of the gap is the same both front and back r Tighten all of the screw connections A and B once again Example 2 Large gap X on the bottom X r Loos...

Page 54: ...el of the firewood boiler and connect r Attach the air hose using lens head screw 6 7 3 Fitting the cladding to the pellet unit r Install combustion chamber cover Use the socket wrench provided r Atta...

Page 55: ...tions in the gap around the unit the cladding of the pellet unit can be adjusted to some extent r Open the insulated door and fold forward the cover plate behind it When opening the cover plate use en...

Page 56: ...upplied 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 P...

Page 57: ...on the underside of the suction module r 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 r Fix the second part of the...

Page 58: ...tem has been assembled in accordance with the assembly instructions enclosed the suction and return air line need to be connected to the pellet unit On the back of the pellet unit r Run the return air...

Page 59: ...ort sections away from walking areas Hose lines are not UV proof Therefore Do not lay the hose lines outdoors Hose lines are suitable for temperatures up to 60 C Therefore Hose lines must not come int...

Page 60: ...on open along the wire with a knife r Bend the earth wire inwards in a loop This prevents the earth wire from being damaged by the pellet movement r Slide the hose clamp onto the hose line r Attach th...

Page 61: ...low A of the return and screw it into the rear outflow B so that it is sealed tight r Undo the threaded socket from the pipe union provided and screw into the outfeed of the pellet unit C or the retur...

Page 62: ...utlet without counter pressure with observable flow path e g discharge funnel 2 Safety valve Safety valve according to EN 12828 with a minimum diameter of DN15 50 kW or DN20 50 100 kW The setting pres...

Page 63: ...cal components r Always have work carried out by a qualified electrician r Observe the applicable standards and regulations Work must not be carried out on electrical components by unauthorised person...

Page 64: ...HY RL Item Designation Item Designation 1 Device connection terminal 5 Service interface 2 Main switch 6 Core module 3 Mains connection plug 7 Return mixer module optional 4 High limit thermostat STL...

Page 65: ...N L N L N LV LV L Sig 5V N L N AUF ZU N AUF ZU KM 26 KM 25 KM 24 KM 23 KM 22 KM 21 KM 20 KM 19 KM 18 KM 17 KM 16 KM 15 KM 14 KM 13 KM 12 Mains fuse Core module End jumper Bus Bus Bus COM 2 COM 1 Brei...

Page 66: ...instructions Flexible sheathed cable must be used for the wiring this must be of the correct size to comply with applicable regional standards and regulations 6 10 3 Connect the components of the pel...

Page 67: ...KM 24 KM 23 KM 22 KM 21 KM 20 KM 19 KM 18 KM 17 KM 16 KM 15 KM 14 KM 13 KM 12 Mains fuse Core module End jumper Bus Bus Bus COM 2 COM 1 Breitbandsonde Luftklappe Kombiantrieb Verriegelung STB NOT HALT...

Page 68: ...bine Stokermotor R ttler Verriegelung R ckbrandklappe Rostantrieb Niveau Max Unterdruckmessdose Bus Bus T rkontaktschalter T rkontaktschalter St rmeldung Pelletmodulerweiterung Pellet module End jumpe...

Page 69: ...power supply for the pellet unit to the terminal block of the firewood boiler NOTICE Compliance with additional information in the relevant boiler controller documentation is mandatory 6 10 4 Potenti...

Page 70: ...ce using two screws and contact washers r Install the cover for the cable duct In so doing position the cable in the cutout 1 of the cover r For automatic WOS Remove the precut area of the thermal ins...

Page 71: ...lide it forward r Secure the cover with a retaining screw r Stick the supplied quick reference guide to the insulated door of the pellet unit in a visible location r Close the insulating door 6 11 1 P...

Page 72: ...t unit B in a free space on the boiler 6 11 3 Insulate the connection line When using the optionally available thermal insulation supplied by Fr ling GesmbH perform the following steps r Cut the half...

Page 73: ...n Installation instructions Dual fuel boiler SP Dual compact 73 6 11 4 Install the brackets for accessories r Using appropriate fasteners attach the brackets to the wall on the boiler r Attach the acc...

Page 74: ...he main switch r Set the boiler controller to the system type r Load the boiler default values NOTICE For the keypad layout and instructions for modifying the parameters see the instruction manual for...

Page 75: ...ent 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 17225 Part 5 Firewood class A...

Page 76: ...15 we recommend you adjust the combustion control to the fuel 7 2 2 Fuels permitted under certain conditions Wood briquettes Wood briquettes for non industrial use with a diameter of 5 10 cm and 5 50...

Page 77: ...non standard fuels can also lead to serious problems with combustion For this reason when operating the boiler r Only use permitted fuels 7 2 4 Heating up for the first time NOTICE If condensation esc...

Page 78: ...in out of service during the winter r Have the system completely drained by a qualified technician Protection against frost 8 2 Disassembly To disassemble the system follow the steps for assembly in r...

Page 79: ...Appendix 9 M1820921_en Installation instructions Dual fuel boiler SP Dual compact 79 9 Appendix 9 1 Pressure equipment regulation...

Page 80: ...a e 6 85609 Aschheim 49 0 89 927 926 0 info froeling com Froling srl Via J Ressel 2H I 39100 Bolzano BZ 39 0 471 060460 info froeling it Froling SARL 1 rue Kellermann F 67450 Mundolsheim 33 0 388 193...

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