Operating Instructions S4 Turbo
Contents
1. For heat consumption ensure Ensure that heating pumps are switched on Open mixer valves and radiator valves Set the boiler loading time to the current time 1 Force partial load Reduce the boiler temperature setpoint by 5 10 C When is it possible to measure lt gt Flue gas temperature at approx 140 C ts CO2 content of the flue gas between 10 and 14 t Boiler temperature above 65 C After measurement all adjusted parameters e g boiler loading times must be reset to their original value Page 26 froling Boiler servicing 4 Inspection cleaning and maintenance 4 4 Maintenance agreement Customer service e We recommend a yearly inspection by Fr ling customer services or an authorised partner third party maintenance Regular maintenance and servicing by a heating specialist will ensure a long trouble free service life for your heating system It will ensure that your system stays environmentally friendly and operates efficiently and cost effectively In the course of this maintenance the entire system is inspected and optimised particularly regulation and control of the boiler The emission measurement carried out can also be used to draw conclusions about the combustion performance of the boiler For this reason FR LING offers a service agreement which optimises operating safety Please see the details in the accompanying guarantee certificate Your Fr ling customer service office2. O Remove the two part grating OM Remove the ash deposits under the grating to ensure problem free intake of secondary air ct Tip Use an ash vacuum Cleaning the flue gas sensors g Release the retaining screw and remove the flue gas sensor 1 from the flue gas pipe OF Wipe off the flue gas sensor with a clean cloth O Push in the flue gas sensor until about 20 mm of the sensor remains protruding from the bushing 4 2 4 Annual maintenance Checking the primary air openings g Open the insulating door and fuel loading chamber door O Unhinge the cladding plates 5g Check the primary air openings C for unobstructed air flow J If necessary clean the openings 5g Unhinge the front air guide plate and clean the slits t For cleaning use the door adjusting Spanner provided if appropriate Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com 4 Boiler servicing Inspection cleaning and maintenance Cleaning the heat exchanger pipes O Remove the upper insulating cover and the cleaning access cover g Dismantle the fixing bolts 2 and remove the WOS lever O Take out the turbulators upwards together with the mounting bracket O Remove the ash build up in the pipes using the cleaning brush ct The cleaning brush must be pushed all the way through before pulling it up co Th
3. green flashing light boiler active flashing red light warning or fault persists Navigation keys to move around in the menus and to change the parameter values 7 4 Function keys to call up individual boiler functions directly D For key layout see control unit operating instructions e smemee OZ O O O 9 STL Safety Temperature Limiter Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 7 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 2 Safety Safety Information 2 Safety 2 1 Safety I nformation DANGER Non permitted use I ncorrect use of the boiler can cause severe injuries and damage The instructions and information provided in the manual must be observed Details on procedure for operation maintenance and cleaning as well as troubleshooting for the boiler are included in the individual instructions Any further work should be carried out by authorised heating engineers or by Fr ling customer services External influences Negative external influences such as insufficient combustion air or non standard fuel can cause serious faults in combustion e g spontaneous combustion of carbonisation gases or flash fires which can in turn cause serious accidents Instructions and information for versions and minimum values as well as norms and guidelines for heating components in the instructions
4. e 12 A 4710 Grieskirchen Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com C0130107 Fr ling Heizkessel und Beh lterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 31 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108
5. authorised installer or with Froling customer services The individual steps for initial startup are explained in the operating instructions for the controller D See the operating instructions for the Lambdatronic S 3200 NOTI CE If condensation escapes during the initial heatup phase this does not indicate a fault co If this occurs clean up using a cleaning rag Heating up the boiler too rapidly on initial startup Possible damage to the equipment If the output during the heating up process is too great the combustion chamber may be damaged as a result of drying out too rapidly w Drying fissures on the other hand are normal and do not indicate a malfunction For this reason the following applies for the first time you heat up the boiler ts Place 1 piece of wood diagonally 1 across the combustion chamber J Load the boiler with a small amount of firewood max 10 20 of the fuel loading chamber O Ignite it and allow it to burn up with the central pre heating chamber door open Page 16 Froling Lambdatronic P 3100 control system 4 Menus and parameters 3 2 Heating the boiler 3 2 1 Switching on the boiler g Press this function key 6 4 briefly The heating system is controlled via the control system according to the selected mode in automatic mode froling g For other modes press the relevant function key D Operating instructions for the Lambdatronic S 3200 Open the
6. insulating door and the fuel loading door The induced draught fan switches on g Fill the fuel loading chamber in accordance with the output first layer of small pieces of wood second layer of cardboard Y third layer with more small pieces of wood TA A fill the rest with firewood AXN t Definition of small pieces of wood y N E NUW We TE Firewood with a maximum length of 10 cm INWEVMN fi along the edge to the cut i ves Aw c Use firewood with a length of approximately 50 cm and arrange it lengthwise t The burn out opening in the grate must remain free Close the fuel loading door It is recommended that you do not remove the ash in the combustion chamber during each heating up process to protect the combustion chamber v Press this navigation key 6 3 briefly The induced draught fan switches off Open the pre heating chamber door and ignite the cardboard Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 17 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 3 Operating the system Heating the boiler g Q Press this navigation key 6 3 briefly The induced draught fan switches on Leave the pre heating chamber door open for approximately 5 minutes A bed of embers forms g Close the pre heating chamber door and the insulating door 3 2 3 Heating up the boiler with automati
7. is also glad to provide consultation 4 5 Replacement parts With Fr ling original replacement parts in your boiler you are using parts which are perfectly matched to each other As the parts fit together so well installation times are shortened and lifespan is maintained NOTI CE I nstalling non original parts voids the guarantee 1 Only replace components or parts with original replacement parts 4 6 Disposal information 4 6 1 Disposal of the ash t The ash should be disposed of in accordance with waste management law AWG 4 6 2 Disposal of system components Ensure that they are disposed of in an environmentally friendly way in accordance with waste management law You can separate and clean recyclable materials and send them to a recycling centre Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 27 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 5 Troubleshooting 5 Troubleshooting 5 1 General faults in the power supply Nothing is shown on the General power failure display Fl circuit breaker or line Switch on the FI circuit breaker or line No power to the controls protection is switched off protection Faulty fuse in the controls Replace fuse note the current 10AT 5 1 1 Behaviour of system after a power failure When the power supply has been restored the boiler returns to the previously specified
8. mode and is controlled according to the specified program t Keep the doors of the boiler closed during and after the power failure 5 2 Excessive temperature The safety temperature limiter STL switches off the blower fan at the maximum boiler temperature of 105 C The pumps continue to run Once the temperature falls below approx 95 C the STL can be reset mechanically J Remove the back insulating cover Unscrew the cap on the STL g Unlock the STL by pressing with a screwdriver Page 28 B0510108 Troubleshooting 5 3 Faults with fault codes froling 2 If a fault has occurred and has not yet been cleared w Status LED 1 flashes red A fault message is shown on the display 2 5 3 1 Procedure for fault messages The procedure for a fault message as well as causes for faults and procedure for troubleshooting are described in the operating instructions of the boiler controls D See the operating instructions for the Lambdatronic S 3200 5 3 2 Acknowledging a fault message Trace and remove the fault and then g Press this key w Status LED flashes green Fr ling Heizkessel und Beh lterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 29 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 6 Appendix Manufacturer information 6 Appendix 6 1 Guarantee conditions Our sale and delivery conditions shall always apply Thes
9. must be observed i Severe injuries and damage can be caused by an inadequate flue gas system Problems with the flue system such as poor cleaning of the flue pipe or insufficient chimney draught can cause serious faults in combustion such as spontaneous combustion of carbonisation gases or flash fires You can only be guaranteed of optimum performance from the boiler if the flue gas system is running smoothly an froling Safety Permitted Uses 2 2 Permitted Uses The boiler should only be operated when it is in full working order It Should be operated in accordance with the instructions observing safety precautions and you should ensure you are aware of the potential hazards Ensure that any faults which might impair safety are rectified immediately The Froling S4 Turbo is intended exclusively for heating up central heating water Use only the fuels specified under 2 2 1 The manufacturer or supplier is not liable for any damages resulting from non permitted uses 2 2 1 Permitted fuels For Austria Firewood with a max length of 55cm w lt 25 For Germany Fuel class 4 3 of the 1st BimSchV i d g F Values in practice Hardwood 2 years in dry storage Soft wood 1 year in dry storage Coarse wood chips 1 year in dry storage D Further information on fuel in the in the assembly instructions section 2 3 2 2 2 Non permitted fuels The use of fuels not defined under 2 2 1 and pa
10. supply under any circumstances R Keep all the doors on the boiler closed Open all mixer taps switch on all pumps Fr ling heating circuit control takes over this function in automatic operation Leave the boiler room and close the door Open any available radiator thermostat valves Q UU If the temperature does not drop inform the installer or Fr ling customer services D Page 30 6 2 Address of manufacturer 2 7 2 Smell of flue gas Smell of flue gas Flue gases can cause fatal poisoning Keep all the doors on the boiler closed O Air the room where the boiler is installed 1 Close the fire protection door and doors to living areas 2 7 3 Fire A DANGER A Fire In case of fire there is a risk of burns and explosions 1 Turn off the boiler Use a tested fire extinguisher for fire class AB to fight the fire P AB powder Fr ling Heizkessel und Beh lterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 15 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 Operating the system Initial startup 3 Operating the system 3 1 Initial startup NOTICE w Optimum efficiency and efficient low emission operation can only be guaranteed if the system is set up by trained professionals and observing the standard factory settings Take the following precautions O Initial startup should be carried out with an
11. thermal discharge safety device senesrerererrererrrrsrerrererrrrrrererree 22 Checking the system pressure ssssnsrerrererrrrrrerrrrerrrrrrsrrrrerrrrrrrrerrererrrrrrererree 22 423 MONCALY MaNtendNCG rreren rE EE E EENE 23 Clean linG Negral ereer ar are rA E EET 23 Cleaning the flue GAS SENSOSMS cc cece cece eeeee sees ee eeeeeeeeeeeeeeeeeeeeeeeeeegaeeteeeeettanagaas 23 4 2 4 Anhilal Ma INteCnanGes sssr E E inna wey ea seats E weed maa 23 Checking the primary air OPQNINGS cccccccee eee e cece ee eeeseeseeeeeeeeeseenaeeeeeeeeeteneggges 23 Cleaning the heat exchanger PIPES ccc cecee cece cece ee eeeeeeeeeeeeeeeeeeeenaeeeeeeeeetenegages 24 Cleaning the carbonisation gas dUCt sesssserererrererrrrrrsrerrersrerrerrrrrrererrrrerrrre 24 Checking the Seal ON the doors ccc ccccccceee esse cette AREA E E 25 cleaning ENG MUEG 3S DIDE rrer inr E E A ees 25 Checking the draught controller flap and explosion flap c cece eee e cece ee eeeeeeeees 25 Cleaning the induced draught Ventilator cc ccccccceee essence cece eeeeeeeeeeeeeeeeeteneeeaes 26 4 3 Testing Emissions 26 4 3 1 Measurement at rated lO ccc cccccc cece eee e eee eeeeeeee eee eeeeeeeeegaeeeeeeeeesenegaeeeeeeeeegs 26 4 3 2 Measurement at partial load if necessary cee cece cece eens eeee eee eeeeeeeeeeeeneeeeeeeeegs 26 4 4 Maintenance agreement Customer service 27 4 5 Replacement parts 27 4
12. wear protective gloves should be worn when working on the boiler g Only operate the boiler using the handles provided for this purpose Insulate the flue pipes or simply avoid touching them during operation Opening the combustion chamber door during operation This may cause injury damage and smoke Do not open the doors behind the insulating door while the system is operating Use of non permitted fuel Non standard fuels can cause serious faults in combustion e g spontaneous combustion of carbonisation gases flash fires which can lead to serious accidents Only use fuels specified in the chapter on Permitted Uses in these operating instructions RA Automatic ignition attempt failed Possible damage to the equipment Damage to heating system e g by frost because automatic ignition was set incorrectly or not carried out 1 Before leaving the boiler check the start time that has been set for automatic ignition 1 Within an appropriate time ensure that automatic ignition has been carried out successfully gt Due to the different types of wood Fr ling cannot guarantee successful automatic ignition The manufacturer supplier is not responsible for resulting damage ae Frolingo Safety 2 Residual risks 2 7 Emergency procedure 2 7 1 Overheating of the system If the system overheats in spite of the safety devices proceed as follows Do not interrupt the power
13. 14 2 7 Emergency procedure 15 2 7 OVERNCaAUNG OF UME SY SLE Miseiieinusendsrraerereasiner EEEa 15 2 92 SN eWSOL MU COS NE E E met tcinn tricia ned teeter be E E A ie 15 Cio OTA E A E A P A E E E A E E T 15 3 Operating the system 16 3 1 Initial startup 16 3 2 Heating the boiler 17 3 2 1 Switching on the boiler seseseseserererrrrrrnrrrrrrrrrrrnrnrnrnreruerurrrrrrrrrrrurnrnrnrrrerrrrrereren 17 S212 E U the DOIGT serria En N T EE E NE NE yee 17 3 2 3 Heating up the boiler with automatic ignition cece cece eeeeeeee eee eeeeeeeeenenneenes 18 32A CONTON TMe DOIG ae er en aa ee rr 18 31200 ROTO Wit WUC i ruccrteens Fuddean i ease reheat tn ceed E Euan 19 Operating with a storage TANK sits costaviraxseanasaceneiraneeceraesagriawinasmieeae ES aar 19 Operating without a storage Tank srprirsorisetsis t rone anaa a AE aA 19 4 Boiler servicing 20 4 1 General information on servicing 20 4 2 Inspection cleaning and self maintenance 21 4 2 1 Daily maintenance Each time before heating Up s srserersrrererrrrererrrrererrrrerrrrne 21 Cleaning the heat exchanger PIPES ccc cccee cece cece da eraran NE a ENA 21 Page 4 B0510108 Contents C Checking ignition pipe only with automatic ignition esesseserserererrererrrrerererree 21 4 2 2 Weekly maintenance essssersrerrererrrrererrrrerrrrrrrrrrrrrsrrrrerrrrrrererrererrrrrrerrrrerrrre 22 REMOVING A hersiene Ee EAE A EIRENE A AEA ARLAN 22 Checking the
14. 6 Disposal information 27 7022 DISOOSal OF NEAS agerii tiara vecrassdanareeuentri stannneteentarcidantetadanenin Gets eewerbageiaeeunaten 27 4 62 Disposal Of system COMPONENTS wrsisvindivsdsvecvniesawtisedertacnnvawereniriaebekccans ieee andere 27 5 Troubleshooting 28 5 1 General faults in the power supply 28 5 1 1 Behaviour of system after a power failUre ssssrererrerererrrrererrrrererrererrrrrrerrrree 28 5 2 Excessive temperature 28 5 3 Faults with fault codes 29 5 3 1 Procedure for fault MESSAGES ccccccccee sees cece ENEK EASE EEEn 29 5 3 2 Acknowledging a fault message ccccccee sees cece eee eeeeeeeeeeeeeeeeeeeeeeaeeeeeettstegaaeenenegs 29 6 Appendix 30 6 1 Guarantee conditions 30 6 2 Address of manufacturer 30 6 3 Declaration of Conformity 31 Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 5 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 1 Product Overview 1 Product Overview Page 6 B0510108 Product Overview 1 _ Item Description Pol Insulating door Ca Fuel loading door 3 Pre heating chamber door a Combustion chamber door with inspection glass 5 Actuators for automatic regulation of primary and secondary air 6 Lever of the heat exchanger cleaner WOS system Lambdatronic 3200 control system 7 1 Graphical display to show operating statuses and parameters 7 2 Status LED operating status
15. ays be informed when installing or modifying a heating system and authorisation obtained from the building authorities Austria Inform the civic municipal building authorities Germany Register with an approved chimney sweep the building authorities 2 3 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 S Austria NORM H 5195 1 Germany VDI 2035 Switzerland SWKI 97 1 There are no other special requirements for central heating water ct Note on filling with make up water bleed the filling hose before connecting to prevent air from getting into the system Page 10 B0510108 Safety 2 Design Information 2 3 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 lt gt 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 standard shall apply Applicable standard ONORM H 5170 2 3 4 Installing the heating system Standards The following standards govern the installation of heating systems Applicable standards ONORM DIN EN 12828 Heatin
16. c ignition Open the insulating door and the fuel loading door The induced draught fan switches on g Check the combustion chamber for residual embers t Residual embers could ignite wood before the automatic start g If necessary clean the combustion chamber fully D See 4 2 Inspection cleaning and self maintenance J Open the ignition pipe IP to check for dirt and clean if necessary g Fill the fuel loading chamber in accordance with the output first layer of small pieces of wood second layer of cardboard and next to the ignition pipe third layer with more small pieces of wood fill the rest with firewood t Definition of small pieces of wood Firewood with a maximum length of 10 cm i SL along the edge to the cut c Use firewood with a length of approximately 50 cm and arrange it lengthwise c The burn out opening in the grate must remain free Close the fuel loading door and insulating door The boiler changes to preventilation status To guarantee a safe boiler operating status and to rule out possible ignition by residual embers due to incomplete cleaning of the combustion chamber the boiler attempts to reach Heating status within a Specified safety time without activating the ignition w After this time has elapsed the boiler remains in ignition wait status until the time specified in the ignition menu for automatic ignition has been reached D See b
17. cr leads E E EEE A E A EO ventas 9 2 2 3 Who May Operate the DOIIE vcssvitinisdsiaiataderdesanwei ed aaoi ANNANN ed sontetadendenanwen eis 9 2 3 Design Information 10 2 3 1 Approval and obligation tO rQpOrt cc cece cece cece teense eee eee eeeeeeeeeeeeeeeeestseennaeneenngs 10 2 3 2 Requirements for central heating water ccc cccece cece eee e cece ee eeeeeeeeeeeeeeeteneeennntengs 10 2 3 3 Ventilation Of Doiler TOOM cece ee ee ee seen ee eee eeeeeeeeeeeeeeeeeeeeeeeeaeeeeeettanegagnnnengs 11 2 3 4 Installing the heating system Standards cece cece cece eeeeeeeeeeeeeeeeeseeeneneenees 11 RECUR TEC WN cure cecacansaicsl ean taaeian E serena eu 11 COMDINATION With storage TANK navscidnnrcs sawn rcir kikini nda ari AAEE anika 12 2 3 5 Chimney connection chimney system sesererserererrererrrrererrererrrrrrerrrrerrrrrrerre 12 Blac Wis aia E errana ee E EE A E A E eT 12 Boiler data relating to design of the flue gas system ssssererrerererrererrrrerrrrrre 12 2 4 Safety Devices 13 2 4 1 Devices for preventing the boiler from overheating sssserererrererrrrerererrerrrrererre 13 Thermal discharge Safety device ccc cece cece eteeeeeneeeeeeeeeeeeneeeeeeeeeeeeeegaaeeneeeteenas 13 Safety Temperature Limiter STL cccccccceeeeee cece anae Ena E E 13 F VAI coca rca costae E wesyane soon ramon EEEE AE EE 13 2 5 Safety instructions for the installation room 13 2 6 Residual risks
18. e 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 6 2 Address of manufacturer FROLING Heizkessel und Behalterbau GesmbH Industriestrafge 12 A 4710 Grieskirchen AUSTRIA TEL 43 0 7248 606 0 FAX 43 0 7248 606 600 E MAIL info froeling com INTERNET www froeling com Page 30 B0510108 Appendix 6 Declaration of Conformity 6 3 Declaration of Conformity frolingo EU DECLARATION OF CONFORMITY Product Firewood boiler Types S4 Turbo 15 S4 Turbo 22 S4 Turbo 28 S4 Turbo 34 S4 Turbo 40 S4 Turbo 50 S4 Turbo 60 EU Directives 89 392 EEC Legal Regulations for Machinery 73 23 EEC Legal Regulations for Electrical Equipment Low Voltage Directive 89 336 EEC Electromagnetic Compatibility EMC Directive 97 23 EC Pressure equipment directive in accordance with Appendix 1 Applied harmonised standards NORM EN 303 5 Boilers for Solid Fuels up to 300 kW Requirements Testing and Designation NORM EN ISO 3834 2 Welding Quality Specifications We hereby certify that the serially produced versions of the above products comply with the directives guidelines and standards specified Grieskirchen 15 01 2007 Be Fi p VLU A Quality assurance Technical services Fr ling Heizkessel und Beh lterbau Ges m b H Industriestra
19. e bristles cannot be turned in the pipe ag Feed the ash from the lower channel of the combustion chamber forwards into the ash drawer provided using the furnace tool g Feed the turbulators into the heat exchanger pipes Insert the WOS lever and fix with screws g Fit the cleaning cover and top insulating cover Cleaning the carbonisation gas duct O Open the insulating door and fuel loading chamber door O Clean the carbonisation gas duct with a small brush t Carbonisation gases are sucked out when the insulating door is opened Page 24 B0510108 Boiler servicing 4 Inspection cleaning and maintenance Checking the seal on the doors O Close the respective door and check its seal O Check seal D for perfect alignment on the door frame Imprint in the seal If the seal is coloured black at several points or the imprint is disjointed The seal is no longer efficient w Tighten the door latches or replace the seal Positioning the doors O Loosen the locknuts 1 of the locking cam Press the door onto the door frame and set the contact pressure using the locking cam t The adjusting spanner is included in delivery O Fix the position by tightening the locknuts O Set the contact pressure on the door handle side by moving the locking plate Cleaning the flue gas pipe O Clean the pipe connecting the boiler and the chimney with a chimney sweeping brush t Depending on the layout
20. eratures 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 technical specification sheets D See Boiler data relating to design of the flue gas system Connect to the chimney via the shortest path preferably with a vertical gradient of less than 30 45 Insulate the connecting piece The entire flue gas system chimney and connection must be calculated as per ONORM DIN EN 13384 1 or prior standards ONORM M 7515 DIN 4705 1 Local regulations and other statutory regulations also apply t The chimney must be authorised by a smoke trap sweeper or chimney sweep Draught limiter e We recommend that a draught limiter is fitted 1 ct Install the draught limiter directly under the mouth of the flue line as there is always low pressure there Boiler data relating to design of the flue gas system S4 Turbo Description Unit m 15 28 34 22 Flue gas temperature 160 180 140 170 150 170 110 130 110 130 100 110 Flue gas mass flow koje 0 011 0 016 0 021 0 025 0 030 0 033 0 041 a J 0 007 0 010 0 012 0 015 0 016 0 020 mbar Maximum permissible feed 5 pressure as per ONORM DIN EN 303 5 RL Rated Load PL Partial Load Page 12 B0510108 Safety 2 Safety Devices 2 4 Safety Devices 2 4 1 Devices for preventing the boiler from overheating Thermal discha
21. froling Operating I nstructions S4 Turbo Be sure to read and comply with the operating instructions and safety information Subject to technical change Fr ling Heizkessel und Beh lterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com Introduction i Dear customer Congratulations on choosing a quality product from FR LING The FR LING S4 Turbo is a state of the art design that conforms to all currently applicable standards and testing guidelines Please read and observe the operating instructions and always keep them close to the boiler for reference Observing the requirements and safety information in the instruction manual makes a significant contribution to safe appropriate environmentally friendly and economical operation of the system The continuous development of our products means that there may be minor differences between the illustrations and other content of the document If you discover any errors please let us know Subject to technical change Fr ling Heizkessel und Beh lterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 3 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 C Contents 1 Product Overview 6 2 Safety 2 1 Safety Information 2 2 Permitted Uses Zila SE Di T teearinpene E EE E E E P E E E T 9 2 2 Noi permed TUG cininccatie
22. g Systems in Buildings The following prior standards still apply Austria Closed systems as per ONORM B 8131 Open systems as per ONORM B 8130 Germany Closed systems as per DIN 4751 Part 2 Open systems as per DIN 4751 Part 1 Return feed lift If the hot water return feed is below the minimum return feed temperature some of the hot water outfeed will be mixed in 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 tc The minimum return feed temperature is 55 C We recommend fitting some kind of control device e g thermometer Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 11 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 2 Safety Design Information Combination with storage tank You can find more detailed information about storage tank design in the boiler assembly instructions D See assembly instructions 1 2 Design information 2 3 5 Chimney connection chimney system EN 303 5 specifies that the entire flue gas system must be designed to prevent wherever possible damage caused by seepage insufficient feed pressure and condensation Please note in this respect that flue gas temp
23. g and maintenance Page 22 B0510108 4 2 2 Weekly maintenance Removing ash g g Open the insulating door and pre heating chamber door Scrape the ash from the fuel loading chamber into the combustion chamber Open the combustion chamber door Remove the ash using the rounded ash shovel Feed the ash from the lower channel of the combustion chamber forwards into the ash drawer provided using the furnace tool Shovel the ash into container provided Fire proof container with cover Checking the thermal discharge safety device g g Check the seal of the discharge valve The discharge pipe must not drip Exception Boiler temperature gt approx 100 C If water is dripping from the discharge pipe g Clean the discharge safety device or have the installer replace it if necessary Checking the system pressure g Check the system pressure on the pressure gauge The value must be 20 over the pre stressed pressure of the expansion tank D See the expansion tank s operating instructions If the system pressure decreases g Reload with water i If this happens frequently check the seal of the heating system If large pressure fluctuations are observed g Have the expansion tank checked Boiler servicing Inspection cleaning and maintenance 4 2 3 Monthly maintenance Cleaning the grating O Open the insulating door and fuel loading chamber door
24. icient cleaning and maintenance of the boiler can cause serious faults in combustion e g spontaneous combustion of carbonisation gases flash fires and this can lead to serious accidents Clean the boiler following the instructions Follow the boiler operating instructions pA NOTI CE te We recommend that you keep a maintenance book in accordance with ONORM M7510 of the Technical Directive for Fire Prevention TRVB Page 20 froling Boiler servicing 4 Inspection cleaning and maintenance 4 2 Inspection cleaning and self maintenance t Regular cleaning of the boiler extends its life and is a basic requirement for smooth running So clean the boiler regularly e Recommended When cleaning use an ash vacuum 4 2 1 Daily maintenance Each time before heating up Cleaning the heat exchanger pipes O Move the lever of the cleaning system several times before the heating up process 5 10 times up and down Checking ignition pipe only with automatic ignition in Sie Ie D fa AWE Th 1 RNS H Wa Sih H OO Before filling the combustion chamber check the ignition pipe of the automatic ignition for dirt and clean if necessary Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 21 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 Boiler servicing Inspection cleanin
25. max 80 90 C w The amount to reload also depends on the type of fuel Operating without a storage tank NOTICE Feed based on output t Only replenish the fuel if energy is needed If too much fuel is loaded the boiler drops below its minimum output limit and goes over to constant burn mode blower fan switches off w The level of efficiency drops in constant burn mode the emissions increase and the boiler can tar up pitch formation Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 19 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 4 Boiler servicing Inspection cleaning and maintenance 4 Boiler servicing 4 1 General information on servicing A DANGER Working on electrical components Risk of serious injuries from electric shocks g Work on electrical components should only be carried out by authorised technicians Carrying out maintenance when the boiler ts hot Hot parts and the flue pipe can cause serious burns It should be standard practice to wear protective gloves Should be worn when working on the boiler 1 Only operate the boiler using the handles provided for this O purpose Before starting any maintenance work Allow the fuel in the boiler to burn off Allow the boiler to cool down for at least 1 hour Non permitted cleaning and maintenance Incorrect or insuff
26. of the flue pipes and the chimney draught cleaning yearly may not be enough Checking the draught controller flap and explosion flap O Check the draught controller flap and explosion flap for ease of operation Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 25 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 4 Boiler servicing Inspection cleaning and maintenance Cleaning the induced draught ventilator Detach the induced draught ventilator on the back of the boiler J Check for dirt and damage g Clean the blower wheel inside and out using a soft brush or paint brush gt Do not move the balancing weights on the blower wheel Remove dirt and deposits from the induced draught housing using a scraper Remove any fallen ash using an ash vacuum 4 3 Testing Emissions 4 3 1 Measurement at rated load g Press this key w The boiler is operated for 30 min at rated load Boiler temperature setpoint is set to 85 C Heating pumps switch on and the mixer valves open Boiler loading is activated When is it possible to measure ct Flue gas temperature at approx 170 C ts CO2 content of the flue gas between 10 and 14 ct Boiler temperature above 65 C 4 3 2 Measurement at partial load if necessary After measurement at rated load in chimney sweep mode g Press this key Automatic operation is activated
27. oiler control unit operating instructions 3 2 4 Controlling the boiler Necessary control steps Displaying or modifying parameters D See the operating instructions for the Lambdatronic P 3200 nn Froling Lambdatronic P 3100 control system 4 Menus and parameters 3 2 5 Refilling with fuel Touching hot surfaces behind the insulating door Risk of burns from hot surfaces By the nature of its operation the surfaces and operating elements in the area behind the insulating door get hot When working with firewood there is also a risk of injury from splinters OM When working on the boiler during operation particularly when reloading fuel it should be standard practice to wear protective gloves O Open the central pre heating chamber door and check the fuel If the fuel in the boiler has burned up Open the fuel loading door and top up the fuel Further information for efficient and environmentally friendly heating Operating with a storage tank The reloading intervals should depend exclusively on the storage tank If the temperature of the storage tank above has dropped to a certain temperature floor heating approx 30 40 C radiator heating approx 50 C reload fuel lt gt With the Lambdatronic S3200 observe the storage tank loading status on the display The amount of fuel should be measured so as to ensure that the storage tank is continuously warmed to the maximum storage temperature
28. rge safety device At around 100 C a valve opens and sends cold water to the safety heat exchanger to reduce the temperature Switches off the blower fan at the maximum boiler temperature of 105 C The pumps continue to run Once the temperature falls below approx 95 C the STL can be reset mechanically Remove the back insulating cover O Unscrew the cap on the STL O Unlock the STL by pressing with a screwdriver Safety valve Protection against over heating excessive pressure When the boiler pressure reaches a maximum of 3 bar the safety valve opens and the heating water is released in the form of steam 2 5 Safety instructions for the installation room 1 Danger of fire due to flammable materials No flammable materials should be stored near the boiler 2 Damage due to impurities in combustion air Do not use any hydrogen halides or any cleaning agents containing chlorine in the room where the boiler is installed 3 Keep the air suction opening of the boiler free of dust 4 The room where the boiler is installed must be frost proof Fr ling Heizkessel und Beh lterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 13 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 2 Safety Emergency procedure 2 6 Residual risks Touching hot surfaces Hot parts and the flue pipe can cause serious burns It should be standard practice to
29. rticularly the burning of refuse is not permitted Non permitted fuels Burning non permitted fuels increases the cleaning requirements and leads to a build up of aggressive sedimentation and condensation which can lead to damage to the boiler and also voids the warranty Using non standard fuels can lead to severe faults in combustion 2 2 3 Who may operate the boiler a Se Only trained operators are permitted to operate the boiler No unauthorised access to the boiler room Risk of personal injury and damage to property It is the responsibility of the operator to ensure that unauthorised persons especially children are kept away from the boiler Fr ling Heizkessel und Behalterbau Ges m b H Industriestrasse 12 A 4710 Grieskirchen Page 9 Tel 43 0 7248 606 0 Fax 43 0 7248 606 600 info froeling com www froeling com B0510108 2 Safety Design Information 2 3 Design Information It is forbidden to carry out modifications to the boiler or to change or deactivate safety equipment Always comply with all fire building and electrical regulations when installing or operating the boiler system in addition to following the operating instructions and mandatory regulations that apply in the country in which the boiler is operated 2 3 1 Approval and obligation to report NOTICE Each heating system must be officially authorised The appropriate supervisory authority inspection agency must alw
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