Froling S4 Turbo 15, S4 Turbo 28, S4 Turbo 22, S4 Turbo 50, S4 Turbo 40 Installation Instructions Manual

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Installation Instructions

Firewood boiler S4 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!

M0971117_en | Edition 24/03/2017

Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of Contents

1 General 5

2 Safety 6

2.1 Hazard levels of warnings 6

2.2 Qualification of assembly staff 7

2.3 Personal protective equipment for assembly staff 7

2.4 Design Information 7

2.4.1 Notes on standards 7

General standards for heating systems

Standards for structural and safety devices

Standards for heating water

Regulations and standards for permitted fuels

2.4.2 Installation and approval of the heating system 8

2.4.3 General information for installation room (boiler room) 9

2.4.4 Requirements for central heating water 10

2.4.5 Notes for using pressure maintenance systems 11

2.4.6 Return lift 12

2.4.7 Combination with storage tank 13

2.4.8 Chimney connection/chimney system 14

Draught limiter

Measuring port

Boiler data for planning the flue gas system

3 Technology 17

3.1 Dimensions - S4 Turbo 17

3.2 SP Dual measurements 18

3.3 Components and connections 19

3.4 Note on SP Dual return feed connection 20

3.5 Technical specifications 21

4 Assembly 26

4.1 Materials supplied 26

4.1.1 Tools required 26

4.2 Positioning 27

4.2.1 Temporary storage 27

4.3 Setting up in the boiler room 28

4.3.1 Remove boiler from pallet 28

4.3.2 Moving the boiler in the boiler room 28

4.3.3 Minimum distances in the boiler room 28

4.4 Before Installation 30

4.4.1 Changing door stops (as needed) 30

4.4.2 Fitting the door handles 32

4.4.3 Adjusting the doors 32

Door stop side

Door handles

4.4.4 Setting and checking the seal on the doors 34

Checking the settings of the door stop

Checking the settings of the door handle

Table of Contents

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Checking the door stop seal

Checking the door handle seal

4.5 Assembling the S4 Turbo 15-40 36

4.5.1 Assembly overview 36

Air duct system

S4 Turbo 15-28 EOS system

S4 Turbo 32-40 EOS system

Insulation

Boiler with pellet flange

4.5.2 Installing the induced draught fan and flue gas pipe nozzle 41

4.5.3 Assembling the heat-exchanger lever bushing 41

4.5.4 Installing the pneumatic rods for the primary and secondary air 42

servo-motors on the right

servo-motors on the left

4.5.5 Installing the insulation 44

4.5.6 Installing the control 45

4.5.7 Installing the back panel 46

4.5.8 Installing the floor insulation 46

4.5.9 Installing the insulated door 47

4.5.10 Attaching the controller 49

4.5.11 Fitting the broadband probe, boiler sensor, flue gas temperature sensor and STL 51

4.5.12 Installing the servo-motors 52

4.5.13 Installing the WOS system 53

4.6 Assembling the S4 Turbo 50-60 57

4.6.1 Assembly overview 57

Air duct system

EOS system

Insulation

4.6.2 Assembling the heat-exchanger lever bushing 61

4.6.3 Installing the pneumatic rods for the primary and secondary air 61

servo-motors on the right

servo-motors on the left

4.6.4 Installing the insulation 64

4.6.5 Installing the control 65

4.6.6 Installing the back panel 66

4.6.7 Installing the floor insulation 66

4.6.8 Installing the insulated door 67

4.6.9 Attaching the controller 69

4.6.10 Fitting the broadband probe, boiler sensor, flue gas temperature sensor and STL 71

4.6.11 Installing the servo-motors 72

4.6.12 Installing the induced draught fan 73

4.6.13 Installing the WOS system 75

4.7 Electrical connection and wiring 76

4.7.1 Information on circulating pumps 77

4.7.2 Concluding work 78

4.8 Hydraulic connection 78

4.9 Connecting the hydraulic safety devices 79

5 Start-up 80

5.1 Before commissioning / configuring the boiler 80

5.2 Initial startup 81

5.2.1 Permitted fuels 81

Firewood

5.2.2 Fuels permitted under certain conditions 82

Wood briquettes

Table of Contents

Installation Instructions S4 Turbo | M0971117_en 3

5.2.3 Non-permitted fuels 82

5.2.4 Heating up for the first time 82

6 Decommissioning 84

6.1 Mothballing 84

6.2 Disassembly 84

6.3 Disposal 84

7 Appendix 85

7.1 Pressure equipment regulation 85

7.2 Technical specifications - S4 Turbo with partial load values 86

7.2.1 Test report data S4 Turbo 22-28 86

7.2.2 Test report data S4 Turbo 34-40 87

7.2.3 Test report data S4 Turbo 50-60 88

7.3 Addresses 89

7.3.1 Address of manufacturer 89

7.3.2 Address of the installer 89

Table of Contents

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1 General

Thank you for choosing a quality product from Froling. The product features a state-ofthe-art design and conforms to all currently applicable standards and testing guidelines.

Please read and observe the documentation provided and always keep it close to the system for reference. Observing the requirements and safety information in the documentation makes a significant contribution to safe, appropriate, environmentally friendly and economical operation of the system.

The constant further development of our products means that there may be minor differences from the pictures and content. If you discover any errors, please let us know: doku@froeling.com.

Subject to technical change.

The EC Declaration of Conformity is only valid in conjunction with a delivery certificate, which has been filled in correctly and signed as part of the commissioning process. The original document remains at the installation site. Commissioning installers or heating engineers are requested to return a copy of the delivery certificate together with the guarantee card to Froling. On commissioning by FROLING Customer Service the validity of the delivery certificate will be noted on the customer service record.

Issuing a delivery

certificate

General

Installation Instructions S4 Turbo | M0971117_en 5

2 Safety

2.1 Hazard levels of warnings

This documentation uses warnings with the following hazard levels to indicate direct hazards and important safety instructions:

DANGER

The dangerous situation is imminent and if measures are not observed it will lead to serious injury or death. You must follow the instructions!

WARNING

The dangerous situation may occur and if measures are not observed it will lead to serious injury or death. Work with extreme care.

CAUTION

The dangerous situation may occur and if measures are not observed it will lead to minor injuries or damage to property.

Safety

Hazard levels of warnings

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2.2 Qualification of assembly staff

CAUTION

Assembly and installation by unqualified persons:

Risk of personal injury and damage to property

During assembly and installation:

❒ Observe the instructions and information in the manuals ❒ Only allow appropriately qualified personnel to work on the system

Assembly, installation, initial startup and servicing must always be carried out by qualified personnel:

- Heating technician / building technician

- Electrical installation technician

- Froling customer services The assembly staff must have read and understood the instructions in the

documentation.

2.3 Personal protective equipment for assembly staff

You must ensure that staff have the protective equipment specified by accident prevention regulations.

▪ For transportation, setup and assembly:

- suitable work wear

- protective gloves

- sturdy shoes (min. protection class S1P)

2.4 Design Information

2.4.1 Notes on standards

The system must be installed and commissioned in accordance with the local fire and building regulations. Unless contrary to other national regulations, the latest versions of the following standards and guidelines apply:

General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fed

combustion systems, nominal heat output up to 500 kW

EN 12828 Heating systems in buildings - design of water-based heating

systems

EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methods

Part 1: Chimneys serving one appliance

Safety

Qualification of assembly staff

Installation Instructions S4 Turbo | M0971117_en 7

ÖNORM H 5151 Planning of central hot water heating systems with or without hot

water preparation

ÖNORM M 7510-1 Guidelines for checking central heating systems

Part 1: General requirements and one-off inspections

ÖNORM 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

ÖNORM H 5170 Heating installation - Requirements for construction and safety

engineering, as well as fire prevention and environmental protection

Standards for heating water

ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation in

closed warm water heating systems at operating temperatures up to 100°C (Austria).

VDI 2035 Prevention of damage hot water heating systems (Germany)

SWKI BT 102-01 Water quality for heating, steam, cooling and air conditioning

systems (Switzerland)

UNI 8065 Technical standard regulating hot water preparation.

DM 26.06.2015 (Ministerial Decree specifying the minimum requirements) Follow the instructions of this standard and any related updates.

Regulations and standards for permitted fuels

1. BImSchV First Order of the German Federal Government for the implementation of the Federal Law on Emission Protection (Ordinance on Small and Medium Combustion Plants) in the version published on 26 January 2010, BGBl. JG 2010 Part I No. 4.

EN ISO 17225-3 Solid bio-fuel - Fuel specifications and classes

Part 3: Wood briquettes for non-industrial use

EN ISO 17225-5 Solid bio-fuel - Fuel specifications and classes

Part 5: Firewood for non-industrial use

2.4.2 Installation and approval of the heating system

The boiler should be operated in a closed heating system. The following standards govern the installation:

EN 12828 - Heating Systems in Buildings

NOTICE! Each heating system must be officially approved.

Note on standards

Safety

Design Information

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The appropriate supervisory authority (inspection agency) must always be informed when installing or modifying a heating system, and authorisation must be obtained from the building authorities:

Austria: report to the construction authorities of the community or magistrate Germany: report new installations to an approved chimney sweep / the building

authorities.

2.4.3 General information for installation room (boiler room)

Boiler room characteristics

▪ The floor must be even, clean and dry and have an adequate load-bearing

capacity.

▪ There must not be a potentially explosive atmosphere in the boiler room as the

boiler is not suitable for use in potentially explosive environments. ▪ The boiler room must be frost-free. ▪ The boiler does not provide any light, so the customer must ensure sufficient

lighting in the boiler room in accordance with national workplace design

regulations. ▪ When using the boiler above 2000 metres above sea level you should consult the

manufacturer. ▪ Danger of fire due to flammable materials.

The floor of the boiler room must not be flammable. No flammable materials

should be stored near the boiler. Flammable objects (e.g. clothing) must not be put

on the boiler to dry. ▪ Damage due to impurities in combustion air.

Do not use any solvents or cleaning agents containing chlorine and hydrogen

halides in the room where the boiler is installed (e.g. chlorination units for

swimming pools). ▪ Keep the air suction opening of the boiler free of dust. ▪ The system must be protected against the chewing or nesting of animals (e.g.

rodents etc.).

Ventilation of the boiler room

Ventilation air for the boiler room should be taken from and expelled directly outside, and the openings and air ducts should be designed to prevent weather conditions (foliage, snowdrifts, etc.) from obstructing the air flow.

Unless otherwise specified in the applicable building regulations for the boiler room, the following standards apply to the design and dimensions of the air ducts:

ÖNORM H 5170 - Construction and fire protection requirements

Note on standards

Safety

Design Information

Installation Instructions S4 Turbo | M0971117_en 9

2.4.4 Requirements for central heating water

Unless contrary to other national regulations, the latest versions of the following standards and guidelines apply:

Austria: Germany:

ÖNORM H 5195 VDI 2035

Switzerland:

Italy:

SWKI BT 102-01 UNI 8065

Observe the standards and also follow the recommendations below:

❒ Aim for a pH value of between 8.2 and 10.0. If the central heating water comes

into contact with aluminium, the pH value must be between 8.0 and 8.5

❒ Use prepared water which complies with the standards cited above for filling and

makeup water

❒ Avoid leaks and use a closed heating system to maintain water quality during

operation

❒ When filling with make-up water, always bleed the filling hose before connecting,

in order to prevent air from entering the system

Advantages of prepared water:

▪ Complies with the applicable standards ▪ Less of a drop in output due to reduced limescale build-up ▪ Less corrosion due to fewer aggressive substances ▪ Long-term cost savings thanks to improved energy efficiency

Limit values for filling and make-up water:

Austria Germany Switzerland

Total hardness ≤ 1.0 mmol/L ≤ 2.0 mmol/L < 0.1 mmol/L

Conductivity - < 100µS/cm < 100 µS/cm

pH value 6.0 – 8.5 6.5 – 8.5 6.0 – 8.5

Chloride < 30 mg/L < 30 mg/L < 30 mg/L

Safety

Design Information

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Additional requirements for Switzerland:

The filling and make-up water must be demineralised (fully purified)

▪ The water must not contain any ingredients that could settle and accumulate in the

system ▪ This makes the water non-electroconductive, which prevents corrosion ▪ It also removes all the neutral salts such as chloride, sulphate and nitrate which can

weaken corrosive materials in certain conditions

If some of the system water is lost, e.g. during repairs, the make-up water must also be demineralised. It is not enough to soften the water. The heating system must be professionally cleaned and rinsed before filling the units.

Inspection:

▪ After eight weeks, the pH value of the water must be between 8.2 and 10.0. If the central

heating water comes into contact with aluminium, the pH value must be between 8.0 and

8.5

▪ Yearly. Values must be recorded by the owner

2.4.5 Notes for using pressure maintenance systems

Pressure maintenance systems in hot-water heating systems keep the required pressure within predefined limits and balance out volume variations caused by changes in the hot-water temperature. Two main systems are used:

Compressor-controlled pressure maintenance

In compressor-controlled pressure maintenance units, a variable air cushion in the expansion tank is responsible for volume compensation and pressure maintenance. If the pressure is too low, the compressor pumps air into the tank. If the pressure is too high, air is released by means of a solenoid valve. The systems are built solely with closed-diaphragm expansion tanks to prevent the damaging introduction of oxygen into the heating water.

Pump-controlled pressure maintenance

A pump-controlled pressure maintenance unit essentially consists of a pressuremaintenance pump, relief valve and an unpressurised receiving tank. The valve releases hot water into the receiving tank if the pressure is too high. If the pressure drops below a preset value, the pump draws water from the receiving tank and feeds it back into the heating system. Pump-controlled pressure maintenance systems with open expansion tanks (e.g. without a diaphragm) introduce ambient oxygen via the surface of the water, exposing the connected system components to the risk of corrosion. These systems offer no oxygen removal for the purposes of corrosion control as required by VDI 2035 and in the interests of corrosion protection should not be used.

Safety

Design Information

Installation Instructions S4 Turbo | M0971117_en 11

2.4.6 Return lift

If the hot water return is below the minimum return temperature, some of the hot water outfeed will be mixed in.

CAUTION

Risk of dropping below dew point/condensation formation if operated without return temperature control.

Condensation water forms an aggressive condensate when combined with combustion residue, leading to damage to the boiler.

Take the following precautions:

❒ Regulations stipulate the use of a return temperature control.

➥ The minimum return temperature is 60 °C. We recommend fitting some

sort of control device (e.g. thermometer).

Safety

Design Information

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2.4.7 Combination with storage tank

Observe the regional regulations for using a storage tank! Certain subsidy guidelines prescribe compulsory requirements for the installation of

storage tanks. Up-to-date information about individual subsidy guidelines can be found at www.froeling.com.

Channelling the heat generated by the Firewood boiler to a storage tank can bring major advantages, including:

❒ better utilisation of fuel ❒ more user-friendly operation in terms of reloading intervals ❒ maximum independence from instantaneous heating requirements ❒ minimal dirt in boiler and flue gas system

As the boiler’s minimum continuous heat output is 30% above the nominal heat output, we as boiler manufacturer are obliged under EN 303-5:2012, Section 4.4.6 to advise that the Firewood boiler S4 Turbo must always be connected to a storage tank with adequate storage capacity.

Certain countries have recommended storage capacities; these are listed below. The specified values apply when the nominal heat output of the boiler corresponds to the heating requirements of the building and a maximum of 50% of the nominal heat output can be dissipated to the building being heated under partial load conditions.

The storage tank capacity can be calculated according to EN 303-5:2012 using the following formula:

VSp= 15TBx QN(1 - 0.3 x QH/Q

min

)

min

Storage tank capacity in [l] Nominal heat output of boiler in [kW] Burn-off period of boiler in [h]

Heating load of building in [kW] Minimum heat output of boiler in [kW]

1.Sample combustion times for various fuels are provided in the technical data

2.The boiler’s minimum output is the lowest value of the output range in the technical data. If there is no minimum heat output specified, use the nominal heat output (Q

min

= QN)

According to the relevant Austrian laws governing energy technology, which are based on Art. 15a B-VG "Agreement on protective measures for small furnaces" (2012):

No storage tank is required on manually fed biomass boilers that have been positively tested at both nominal load and partial load (below 50% of nominal load) to ensure they adhere to the emissions limits specified in that agreement.

Recommended storage tank capacity:

Unit S4 Turbo

15 - 22

S4 Turbo

28 - 60

Recommended storage tank capacity

[l] 2000 1500

1.Values for calculating the capacity can be found in the technical data or the technical data with partial load inspection (if available)

General information

Austria

Safety

Design Information

Installation Instructions S4 Turbo | M0971117_en 13

The first BImSchV (Ordinance on small and medium-sized heating plants of 26 January 2010, BGBl. I P. 38) stipulates a minimum water heat storage tank volume of 55 litres per kilowatt of rated heat output; a water heat storage tank with a volume of 12 litres per litre of fuel loading chamber is recommended.

Recommended storage tank capacity:

Unit S4 Turbo

15 - 34

S4 Turbo

40 - 50

S4 Turbo

Recommended storage tank capacity

[l] 2000 2800 3300

1.Values for calculating the capacity can be found in the technical data or the technical data with partial load inspection (if available)

For the correct dimensions of the storage tank and the line insulation (e.g. in accordance with ÖNORM M 7510 or guideline UZ37) please consult your installer or Froling.

2.4.8 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 temperatures lower than 160K above room temperature can occur in the permitted operating range of the boiler.

The flue gas temperatures (for clean systems) and additional flue gas values can be found in the table below.

The connection between the boiler and the chimney system should be as short as possible. The upward angle of the connection should not exceed 30 - 45°. Insulate the connection. The entire flue gas system - chimney and connection - should be calculated in accordance with EN 13384-1.

Local regulations and other statutory regulations also apply. NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney

sweep.

Draught limiter

We generally recommend the installation of a draught limiter. A draught limiter must be installed if the maximum permissible feed pressure as given in the boiler data for planning the flue gas system is exceeded.

NOTICE! Install the draught limiter directly under the mouth of the flue line, as the pressure is constantly low at this point.

Measuring port

For measuring the emissions of the system, a suitable measuring port must be installed in the connecting piece between the boiler and chimney system.

Germany

Safety

Design Information

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2 x D

In front of the measuring port (M) a straight inlet section should be located at a distance corresponding to about twice the diameter (D) of the connecting piece. A straight outlet section at a distance corresponding to about the single diameter of the connecting piece should be provided after the measuring port. The measuring port must remain closed whenever the system is in operation.

Ensure that the outside diameter of the sampling probes in the measuring port can accommodate up to 13 mm. To avoid the ingress of false air, the diameter of the measuring port must not exceed 21 mm.

Boiler data for planning the flue gas system

Description S4 Turbo

15 22 28

Flue gas temperature at nominal load °C 140 160 180 140

Flue gas temperature at partial load - 110 130 110

Flue gas mass flow at nominal load kg/s 0.011 0.016 0.021 0.025

Flue gas mass flow at partial load - 0.007 0.010 0.012

Required feed pressure at nominal load Pa 8 8 8 8

mbar 0.08 0.08 0.08 0.08

Required feed pressure at partial load Pa - 8 8 8

mbar - 0.08 0.08 0.08

Maximum permissible feed pressure Pa 30 30 30 30

mbar 0.3 0.3 0.3 0.3

Flue pipe diameter mm 149 149 149 149

1.S4 Turbo 32 only available in Italy

Description S4 Turbo

34 40 50 60

Flue gas temperature at nominal load °C 140 170 150 170

Flue gas temperature at partial load 110 130 100 110

Flue gas mass flow at nominal load kg/s 0.025 0.030 0.033 0.041

Flue gas mass flow at partial load 0.012 0.015 0.016 0.020

Required feed pressure at nominal load Pa 8 8 8 8

mbar 0.08 0.08 0.08 0.08

Required feed pressure at partial load Pa 8 8 8 8

mbar 0.08 0.08 0.08 0.08

Safety

Design Information

Installation Instructions S4 Turbo | M0971117_en 15

Description S4 Turbo

34 40 50 60

Maximum permissible feed pressure Pa 30 30 30 30

mbar 0.3 0.3 0.3 0.3

Flue pipe diameter mm 149 149 149 149

Safety

Design Information

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3 Technology

3.1 Dimensions - S4 Turbo

L1*

H1*

H2*

Dim ensi

Description Unit S4 Turbo

15-28

S4 Turbo

32-40

S4 Turbo

50-60

L Length, boiler mm 1,125 1,215 1,215

L1 Total length including induced draught

fan

1,300 1,390 -

L1* Total length including induced draught

fan

- - 1,680

W Width, boiler 570 670 670

W1 Total width incl. actuators 635 735 735

H Height, boiler 1,565 1,565 1,565

H1 Total height incl. flue gas nozzle 1,610 1,610 -

H1* Height of induced draught unit housing - - 1,480

H2 Height, flue pipe connection 1,830 1,830 -

H2* Height, flue pipe connection - - 1,700

H3 Height, flow connection 1,360 1,360 1,360

H4 Height, return connection 140 140 140

H5 Height, safety battery connection 970 970 960

H6 Height, drainage connection 120 120 120

Technology

Dimensions - S4 Turbo

Installation Instructions S4 Turbo | M0971117_en 17

3.2 SP Dual measurements

The following measurements must be observed for retrofitting the pellet unit at a later date.

Dimen

sion

Description Unit SP Dual 15-28 SP Dual 32-40

L Length, firewood boiler mm 1125 1215

L1 Length, pellet unit mm 1285 1370

B SP Dual width mm 1000 1100

B1 Total width, SP Dual incl. heat-

exchanger lever

mm 1050 1150

B2 Width, firewood boiler mm 570 670

B3 Width, pellet unit mm 430 430

H Height, boiler mm 1565 1565

H1 Total height incl. flue gas nozzle mm 1610 1610

H2 Height, flue gas pipe connection mm 1830 1830

H3 Height, flow – firewood boiler

connection

mm 1360 1360

H4 Height, return – firewood boiler

connection

mm 140 140

H5 Height, safety heat exchanger

connection

mm 970 970

H6 Height of drainage connection mm 120 120

H7 Height, flow and return - pellet unit

connection

mm 140 160

H8 Height, suction system connection mm 1370 1360

H9 Height, pellet unit mm 1465 1465

H10 Total height, pellet unit, incl. suction

turbine

mm 1545 1545

H11 Total space with cover open mm 1865 1865

Flue pipe diameter mm 150 150

Weight – pellet unit kg 310 310

Technology

SP Dual measurements

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3.3 Components and connections

S4 Turbo 15 - 40

S4 Turbo 50 - 60

Item

Description Unit S4 Turbo

1 Boiler flow connection TU inches 6/4

2 Boiler return connection TU inches 6/4

3 Drainage connection TU inches 1/2

4 Safety battery connection TU inches 1/2

5 Flue gas temperature sensor connection mm 6

6 Broadband probe connection TU inches 3/4

7 2x immersion sleeves for:

▪ thermal discharge valve (installed by

the customer)

▪ Boiler sensor and STL

TU inches 1/2

8 Flue gas pipe connection mm 149

Technology

Components and connections

Installation Instructions S4 Turbo | M0971117_en 19

3.4 Note on SP Dual return feed connection

ca.300mm

ca.175mm

When retrofitting the pellet unit of the SP Dual, the return feed is connected to the pellet unit due to the different water flow.

Ensure to allow for the offset of the return feed connection (see illustration) in the piping of the S4 Turbo with pellet flange, so that the pellet unit can be retrofitted easily.

Technology

Note on SP Dual return feed connection

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3.5 Technical specifications

Description

S4 Turbo / S4 Turbo F

15 22 28

Rated heat output kW 15 22 28

Electrical connection 230 V / 50 Hz / fused C16A

Power consumption at nominal load W 40 50 50

Power consumption in slumber mode 3 3 3

Weight of boiler incl. insulation and control

kg 640 645 650

Total boiler capacity (water) L 115 115 115

Water pressure drop (ΔT = 10 / 20 K) mbar 6.5 / 2.0 12.0 / 3.1 12.0 / 3.1

Minimum boiler return temperature °C 60

Maximum permitted operating temperature

Permitted operating pressure bar 3

Airborne sound level dB(A) < 70

Permitted fuel as per EN 14961 Part 5: Firewood class A2 / D15 L50

Fuel loading door dimensions (width / height)

mm 380 / 360 380 / 360 380 / 360

Fuel loading chamber capacity L 145 145 145

Combustion time 2) - beech

h 8.3 – 11.8 5.7 – 8.1 4.5 – 6.4

Combustion time2) - spruce

5.9 – 8.3 4.0 – 5.7 3.1 – 4.5

1.With regards to the approval of drawings for “S4 Turbo xx F” type boilers, the test results on the heating technology requirements of the “S4 Turbo xx” wood chip boiler according to EN 303-5 can be used.

2.Values specified for combustion time are guideline values at nominal load and will vary depending on water content (15-25%) and fill level (80-100%).

Regulation (EU) 2015/1187

Energy efficiency A+ A+ A+

Rated heat output kW 15 22 28

Energy efficiency index of the boiler model 117 115 116

Seasonal space heating energy efficiency % 80 78 79

Energy efficiency index of the boiler in package with temperature control

119 117 118

Energy efficiency class of the boiler in package with temperature control

A+ A+ A+

Technology

Technical specifications

Installation Instructions S4 Turbo | M0971117_en 21

Description

S4 Turbo / S4 Turbo F

34 40

Rated heat output kW 32 34 40

Electrical connection 230 V / 50 Hz / fused C16A

Power consumption at nominal load W 50 50 50

Power consumption in slumber mode 3 3 3

Boiler weight incl. insulation and controller

kg 730 735 745

Total boiler capacity (water) L 175 175 175

Water pressure drop (ΔT = 10 / 20 K) mbar 6.0 / 1.6 6.0 / 1.6 6.0 / 1.6

Minimum boiler return temperature °C 60

Maximum permitted operating temperature

Permitted operating pressure bar 3

Airborne sound level dB(A) < 70

Permitted fuel as per EN 14961 Part 5: Firewood class A2 / D15 L50

Fuel loading door dimensions (width / height)

mm 380 / 360 380 / 360 380 / 360

Fuel loading chamber capacity L 190 190 190

Combustion time 3) - beech

h 4.6 - 7.1 4.3 – 6.7 3.9 – 5.7

Combustion time3) - spruce

3.5 – 5.0 3.3 – 4.7 2.8 – 4.0

2.S4 Turbo 32 only available in Italy

3.Values specified for combustion time are guideline values at nominal load and will vary depending on water content (15-25%) and fill level (80-100%).

Regulation (EU) 2015/1187

Energy efficiency A+ A+ A+

Rated heat output kW 32 34 40

Energy efficiency index of the boiler model 116 117 117

Seasonal space heating energy efficiency % 79 79 80

Energy efficiency index of the boiler in package with temperature control

118 119 119

Energy efficiency class of the boiler in package with temperature control

A+ A+ A+

Technology

Technical specifications

22 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Description

S4 Turbo

50 60

Rated heat output kW 50 60

Electrical connection 230 V / 50 Hz / fused C16A

Power consumption at nominal load W 100 100

Power consumption in slumber mode 3 3

Boiler weight incl. insulation and controller

kg 793 803

Total boiler capacity (water) L 170 170

Water pressure drop (ΔT = 10 / 20 K) mbar 23.0 / 8.0 23.0 / 8.0

Minimum boiler return temperature °C 60

Maximum permitted operating temperature

Permitted operating pressure bar 3

Airborne sound level dB(A) < 70

Permitted fuel as per EN 14961 Part 5: Firewood class A2 / D15 L50

Fuel loading door dimensions (width / height)

mm 380 / 360 380 / 360

Fuel loading chamber capacity L 200 200

Combustion time 1) - beech

h 3.4 – 4.9 2.8 – 4.1

Combustion time1) - spruce

2.4 – 3.5 2.0 – 2.9

1.Values specified for combustion time are guideline values at nominal load and will vary depending on water content (15-25%) and fill level (80-100%).

Regulation (EU) 2015/1187

Energy efficiency A+ A+

Rated heat output kW 50 60

Energy efficiency index of the boiler model 119 119

Seasonal space heating energy efficiency % 81 81

Energy efficiency index of the boiler in package with temperature control

121 121

Energy efficiency class of the boiler in package with temperature control

A+ A+

Technology

Technical specifications

Installation Instructions S4 Turbo | M0971117_en 23

Description

S4 Turbo / S4 Turbo F

15 22 28

Testing institute

TÜV Austria

Test report no. 11-UW/Wels-

EX-128/3

11-UW/Wels-

EX-128/1

11-U-285/SD

11-U-408/SD

Boiler class as per EN 303-5:2012 5 5 5

Boiler efficiency % 92.3 92.7 92.8

2.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

3.As per ÖNORM / DIN EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent nominal 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 fulfil the requirements of the norm, including those in a specific range that have not been tested, which have values that have been determined depending on nominal output by interpolation.

Test data - Emissions in [mg/MJ]1) (nominal load)

Carbon monoxide (CO) mg/MJ 41 40 46

Nitrogen oxide (NOx) mg/MJ 84 71 76

Organic hydrocarbons (OGC) mg/MJ 1 2 4

Dust mg/MJ 8 9 8

1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m³]1) (nominal load)

Carbon monoxide (CO) mg/m³ 61 59 68

Nitrogen oxide (NOx) mg/m³ 123 104 111

Organic hydrocarbons (OGC) mg/m³ 2 2 6

Dust mg/m³ 11 13 12

1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%

Description

S4 Turbo / S4 Turbo F

34 40

Testing institute

TÜV Austria

Test report no.

13-U-355/SD4)11-U-285/SD

11-UW/Wels-

EX-128/2

11-U-408/SD

Boiler class as per EN 303-5:2012 5 5 5

Boiler efficiency % 92.9 92.9 93.0

2.S4 Turbo 32 only available in Italy

3.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

4.As per ÖNORM / DIN EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent nominal 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 fulfil the requirements of the norm, including those in a specific range that have not been tested, which have values that have been determined depending on nominal output by interpolation.

Test report data

S4 Turbo 15 - 28

Test report data

S4 Turbo 32 - 40

Technology

Technical specifications

24 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Test data - Emissions in [mg/MJ]1) (nominal load)

Carbon monoxide (CO) mg/MJ 51 53 59

Nitrogen oxide (NOx) mg/MJ 79 80 85

Organic hydrocarbons (OGC) mg/MJ 6 7 9

Dust mg/MJ 7 7 6

1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m³]1) (nominal load)

Carbon monoxide (CO) mg/m³ 74 77 86

Nitrogen oxide (NOx) mg/m³ 115 117 124

Organic hydrocarbons (OGC) mg/m³ 8 9 13

Dust mg/m³ 11 10 9

1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%

Description S4 Turbo

50 60

Testing institute

TÜV Austria

Test report no.

11-U-560/SD

11-UW/Wels-EX-128/6

Boiler class as per EN 303-5:2012 5 5

Boiler efficiency % 94 94.9

1.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

2.As per ÖNORM / DIN EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent nominal 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 fulfil the requirements of the norm, including those in a specific range that have not been tested, which have values that have been determined depending on nominal output by interpolation.

Test data - Emissions in [mg/MJ]1) (nominal load/partial load)

Carbon monoxide (CO) mg/MJ 46 / - 33 / 44

Nitrogen oxide (NOx) mg/MJ 85 / - 85 / 82

Organic hydrocarbons (OGC) mg/MJ 5 / - 1 / 3

Dust mg/MJ 7 / - 8 / 14

1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m³]1) (nominal load/partial load)

Carbon monoxide (CO) mg/m³ 67 / - 48 / 65

Nitrogen oxide (NOx) mg/m³ 124 / - 124 / 120

Organic hydrocarbons (OGC) mg/m³ 8 / - 2 / 4

Dust mg/m³ 11 / - 12 / 20

1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%

Test report data

S4 Turbo 50 - 60

Technology

Technical specifications

Installation Instructions S4 Turbo | M0971117_en 25

4 Assembly

4.1 Materials supplied

The boiler comes on a pallet together with insulation, controller and accessories. Some of the components come in cardboard packaging.

1 Boiler 9 Flue gas pipe nozzle with seal

(S4 Turbo 15-40)

2 Insulation 10 Cleaning kit

3 Controller 11 Cleaning brush, small

4 Control 12 Cardboard boxes containing small

parts (handles, screws, etc.)

5 Induced draught fan 13 Pneumatic rods

6 Induced draught unit housing (S4

Turbo 50-60)

14 Ashcan

7 Adjusting spanner for locking cam 15 Cleaning brush, large

8 Ash shovel

Not pictured: installation and operating instructions, guarantee certificate, identification plate

4.1.1 Tools required

The following tools are required for assembly:

❒ Spanner or box wrench set (widths across flats 8 - 32 mm) ❒ Set of Allen keys ❒ Flat head and cross-head screwdrivers ❒ Hammer ❒ Diagonal cutting pliers ❒ Half-round file ❒ Power drill or cordless screwdriver with Torx bit insert

Assembly

Materials supplied

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4.2 Positioning

NOTICE

Damage to components if handled incorrectly

❒ Follow the transport instructions on the packaging ❒ Transport components with care to avoid damage ❒ Protect the packaging against damp conditions ❒ Pay attention to the pallet's centre of gravity when lifting

❒ Position a fork-lift or similar lifting device at the pallet and bring in the components

If the boiler cannot be brought in on the pallet:

❒ remove the cardboard and take the boiler off the pallet

⇨ See "Remove boiler from pallet" [page 28]

Positioning using a crane

❒ Attach the crane hook to the attachment point correctly and position the boiler

4.2.1 Temporary storage

If the system is to be assembled at a later stage:

❒ Store components at a protected location, which is dry and free from dust

➥ Damp conditions and frost can damage components, particularly electric ones!

Assembly

Positioning

Installation Instructions S4 Turbo | M0971117_en 27

4.3 Setting up in the boiler room

4.3.1 Remove boiler from pallet

❒ Remove the cardboard with the controller from the boiler and put in a safe place ❒ Lift the cardboard box with the insulation from the pallet

❒ Remove the transport locks on both sides ❒ Lift boiler off 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-bearing capacity at

the base frame

❒ Lift and transport to the intended position in the installation room

➥ Observe the minimum distances in the boiler room.

4.3.3 Minimum distances in the boiler room

▪ The system should generally be set up so that it is accessible from all sides

allowing quick and easy maintenance.

▪ Regional regulations regarding necessary maintenance areas for inspecting the

chimney should be observed in addition to the specified minimum distances! ▪ Observe the applicable standards and regulations when setting up the system. ▪ Observe additional standards for noise protection

(ÖNORM H 5190 - Noise protection measures)

Assembly

Setting up in the boiler room

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NOTICE! The heat-exchanger lever and air control servo-motors can be installed on the left or right.

Dimens

ion

Description Unit S4 Turbo

A Distance - front of boiler to wall mm 800

B Distance – side of boiler to wall

800 (200)

C Distance - back to wall of S4 Turbo 15-40 500

Distance - back to wall of S4 Turbo 50-60 800

D Distance – side of boiler to wall

200 (800)

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 maintenance work (e.g. induced draught).

The heat-exchanger lever must be installed on the right in order to retrofit the pellet unit at a later date. Note the following minimum distances:

Dime nsion

Description Unit SP Dual 15-28 SP Dual 32-40

A Distance - insulated door to wall mm 800 800

B Distance – boiler side with heat

exchanger lever and pellet unit to wall

600 700

B1 Distance – boiler side without pellet

unit to wall

1030 1130

C Distance – back to wall 500 500

D Distance – side of boiler to wall 200 200

E Space required for open cover (to be

taken into account if the flue gas can only be channelled to the right)

300 300

Minimum distances

S4 Turbo

Minimum distances

SP Dual

Assembly

Setting up in the boiler room

Installation Instructions S4 Turbo | M0971117_en 29

4.4 Before Installation

S4 Turbo boilers (without pellet flange) are delivered with a right-hand door stop; S4 Turbo F boilers (with pellet flange) are delivered with a left-hand door stop. To change the side the door stops are on, complete the following steps.

NOTICE! We recommend leaving the door stop on the left for better ease of use if you intend to retrofit a pellet unit at a later date.

4.4.1 Changing door stops (as needed)

Changing the fuel loading door stop

The following example using the fuel loading door shows how to change the door stop. The procedure is the same for changing the stop on the combustion chamber door and pre-heating chamber door!

❒ Loosen the retainer plates (1) on the top and bottom hinge pins

➥ to do so, we recommend using two screwdrivers

❒ Remove the top and bottom hinge pins (2) and lift off the door

❒ Remove the nuts and locking cam (1) and disassemble the hinge (2)

Assembly

Before Installation

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❒ Loosen the nuts and remove the locking plate (3)

❒ Remount the locking plate and hinge with spacer washers and nuts on the other

side

➥ Only partially tighten the nuts

Converting the fuel loading door

❒ Remove radiation plate (1) with fibre-glass seal (2) ❒ Carefully lift out the insulating plate (3) ❒ Rotate the insulating plate (3) 180° and position it so that it lines up with the holes

in the fuel loading door ❒ Re-install the radiation plate (1) ❒ Use contact adhesive to fix the fibre-glass seal (2) in place

Only for the fuel

loading door!

Assembly

Before Installation

Installation Instructions S4 Turbo | M0971117_en 31

❒ Rotate the door and rehang it with the stop on the other side

➥ Secure at the top and bottom with the hinge pins (2)

❒ Replace the retainer plates (1) on the top and bottom hinge pins

➥ to do so, we recommend using two screwdrivers

NOTICE! If the door stops have been changed, you must check the settings and seal of the door.

⇨ See "Adjusting the doors" [page 32] ⇨ See "Setting and checking the seal on the doors" [page 34]

4.4.2 Fitting the door handles

The procedure is the same for all doors.

❒ Insert the flange bushing (1) into the door handle (2) and position it alongside the

hole (3) provided

❒ Fix the door handle (2) in place using screws (4)

4.4.3 Adjusting the doors

The example below shows how to position the fuel loading door. The procedure is the same for the combustion chamber door and the pre-heating chamber door!

Assembly

Before Installation

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Door stop side

❒ Loosen the lock nuts (1) at the top and bottom of the locking cam ❒ Where necessary move the locking cam either back or forward using an Allen

wrench (32 mm) (2)

❒ Assemble the locking cam so that there is slight resistance at a gap of approx.

2-3 cm when the door is closed

➥ Caution: the locking cams must be aligned in the same way at the top and

bottom!

❒ Secure the position of the hinge at the top and bottom with the lock nuts (1)

Door handles

❒ Loosen the lock nuts (1) at the top and bottom of the locking plate ❒ Use suitable tools (e.g. screwdriver and hammer) to move the locking plate to the

rear or the front as needed

➥ Position the locking plate so that it is easy to close the door ➥ Caution: the locking plate must be aligned at the top and bottom.

❒ Secure the position of the locking plate at the top and bottom with the lock nuts (1)

Assembly

Before Installation

Installation Instructions S4 Turbo | M0971117_en 33

4.4.4 Setting and checking the seal on the doors

Setting and checking the seal are shown using the example of the fuel loading doors The procedure is the same for the combustion chamber door and the pre-heating chamber door!

Checking the settings of the door stop

❒ Close the door

➥ Slight resistance at a gap of 2 - 3 cm:

correct setting ➥ No resistance felt:

setting must be corrected - push the hinge toward the back

⇨ See "Adjusting the doors" [page 32]

➥ Resistance at a gap of >3 cm:

setting must be corrected - push the hinge toward the front

⇨ See "Adjusting the doors" [page 32]

Checking the settings of the door handle

❒ Close the door

➥ If the door can be closed with the usual force:

correct setting ➥ If the door cannot be closed with the usual force or must be forced closed:

push the locking plate toward the front

⇨ See "Adjusting the doors" [page 32]

Assembly

Before Installation

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Checking the door stop seal

❒ Open the door ❒ Insert a sheet of paper at both the top and the bottom area of the door stop

between the door and the boiler ❒ Close the door ❒ Try to pull out the sheets of paper

➥ If the paper cannot be removed:

the seal is correct

➥ If the paper can be removed:

the door is not sealed properly - push the hinge toward the back.

⇨ See "Adjusting the doors" [page 32]

Checking the door handle seal

❒ Open the door ❒ Insert a sheet of paper at both the top and the bottom area at the side of the door

handle between the door and the boiler ❒ Close the door ❒ Try to pull out the sheets of paper

➥ If the paper cannot be removed:

the seal is correct

➥ If the paper can be removed:

the door is not sealed properly - push the locking plate toward the back.

⇨ See "Adjusting the doors" [page 32]

Assembly

Before Installation

Installation Instructions S4 Turbo | M0971117_en 35

4.5 Assembling the S4 Turbo 15-40

4.5.1 Assembly overview

Air duct system

Item pc. Description

1 1 Induced draught fan

2 1 Flue gas pipe nozzle

3 1 Ceramic fibre seal

4 2 Pneumatic rods with air flap and springs

5 2 Air flap

6 2 Split pin

7 3 Door handle with flange bushing and screw

Assembly

Assembling the S4 Turbo 15-40

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S4 Turbo 15-28 EOS system

Item pc. Description

1 1 EOS lever, complete

2 1 Plastic cover

3 1 Brass bushing

4 4 EOS turbulator

5 1 Stay tube EOS

6 2 Pipe locking pin

7 1 EOS cover

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 37

S4 Turbo 32-40 EOS system

Item pc. Description

1 1 EOS lever, complete

2 1 Plastic cover

3 1 Brass bushing

4 1 Cover plate

5 8 EOS turbulator

6 2 Pipe locking pin

7 1 Stay tube EOS

8 1 EOS cover

Assembly

Assembling the S4 Turbo 15-40

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Insulation

Item pc. Description Item pc. Description Item pc. Description

1 1 Insulated door 12 1 Insul. mounting brackets,

right, 2 spacer washers

23 1 Upper spacer plate

2 2 Magnetic latches 13 2 Servo-motor cover plate 24 1 Control, buttons

3 2 Counter plate, magnetic

latches

14 1 Torque support 25 2 Control, touch panel

(optional)

4 4 Flange bushing 15 2 Servo-motor 26 1 Heat insulation mat, top

5 1 Insulating side panel, left 16 1 Door mount 27 1 Heat insulation mat, top/

rear

6 1 Insulation cover plate, left 17 1 Half-length taper groov. pin 28 1 Control plate

7 1 Cover plate 18 1 Floor insulation 29 1 Cover plate

(only S4 Turbo 32-40)

8 2 Bracket 19 1 Insul. cover plate, bottom 30 1 Controller box

9 1 Insul. mounting brackets,

left, 2 spacer washers

20 1 Thermal insulation, rear 31 1 Controller cover

10 1 Insul. side panel, right 21 1 Back panel 32 1 Insulating cover, back

11 1 Insul. cover plate, right 22 2 Cover plate for ID fan

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 39

Boiler with pellet flange

Item pc. Description

1 1 Insulating side panel, right

2 1 LTC 2004 flow sensor - air mass measurement

3 1 Cover plate

4 1 Blanking plate, complete

5 1 Insulation side panel with pellet flange

6 1 S4 Turbo boiler body with pellet flange

Assembly

Assembling the S4 Turbo 15-40

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4.5.2 Installing the induced draught fan and flue gas pipe nozzle

❒ Assemble the induced draught fan (1) on the back of the boiler

➥ Straight edge up

➥ Caution: do not overstress the flange! ❒ Place the ceramic fibre seal (2) in position ❒ Attach the flue gas pipe nozzle (3) using the pre-installed spacer washers and

nuts

➥ Warning: the ¾” connection must point to the right as seen from behind!

4.5.3 Assembling the heat-exchanger lever bushing

The heat-exchanger lever can be mounted on either the left or the right side on the boiler.

NOTICE! The heat-exchanger lever must be installed on the right-hand side of the boiler in order to retrofit the pellet unit at a later date.

❒ Remove the screw cap from the side on which the heat-exchanger lever will be

mounted later and replace it with a brass bushing

➥ Tighten the brass bushing with an Allen wrench (27 mm)

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 41

4.5.4 Installing the pneumatic rods for the primary and secondary air

The air control servo-motors can be mounted on either the left- or right-hand side of the boiler. There are no conditions regarding which side the servo-motor is to be installed on which need to be observed for retrofitting the pellet unit at a later date. Delivery configuration: servo-motors on the right

NOTICE! If the servo-motors are to be assembled on the left, the air ducts must be changed on both sides!

NOTICE! Unless otherwise indicated, “right” and “left” refer to the side of the boiler when standing in front of it.

❒ Remove the split pin on both pneumatic rods opposite the spring and pull one of

the air flaps off of each

➥ The pneumatic rods are packed along with the insulation

servo-motors on the right

Left-hand side: Right-hand side:

❒ Insert both pneumatic rods into the left-hand side of 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

➥ IMPORTANT: the air flaps must be in the same position as those on the

opposite side!

Assembly

Assembling the S4 Turbo 15-40

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❒ Turn both pneumatic rods anti-clockwise as far as the stop

➥ Check the pneumatic rods can move freely

servo-motors on the left

Disassembly on right-hand side: Assembly on left-hand side:

❒ Remove both air ducts on the left and right-hand sides ❒ Fit the air ducts back onto the other side

➥ The arrow on the air duct sticker should now point downwards!

➥ Only partially tighten the screws!

Right-hand side: Left-hand side:

❒ Insert both pneumatic rods into the right-hand side of the boiler

➥ The air flaps with springs lie flat on the right-hand air ducts! ❒ Insert the air flaps on the pneumatic rods on the left-hand side and secure them

with split pins

➥ IMPORTANT: the air flaps must be in the same position as those on the

opposite side!

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 43

❒ Turn both pneumatic rods anti-clockwise as far as the stop

➥ Check the pneumatic rods can move freely

❒ Tighten the screws on the air flaps

4.5.5 Installing the insulation

NOTICE

The individual parts of the boiler insulation covered with a protective film. You must remove the protective film before proceeding with installation.

❒ Inset the two L-shaped insulation cover plates (1) into the insulating side panels

on the left and right and secure them with thread forming screws

➥ Areas with slits (2) are in contact with the insulating material

❒ Insert the insulation mounting brackets (3) on both insulating side panels and

secure them with top thread forming screws

Assembly

Assembling the S4 Turbo 15-40

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❒ Place one large spacer washer (1) on each of the threaded bolts to the right and

the left above on the boiler

❒ Insert the insulating side panels (2) into the base of the boiler at the lug (3) and

push onto the boiler

➥ the holes in the insulation side panels must line up with the holes in the flap (3) ❒ Position the brackets on the insulation side panels (2) onto the threaded bolts and

secure lightly with a large and a small spacer washer and nut (4)

❒ Secure the insulating side panels (2) on the right and left at the flap on the boiler

base with thread forming screws (5)

4.5.6 Installing the control

❒ Hang the upper spacer plate on the rivets between the insulating side panels ❒ Position the control and remove the caps on the ends on each side

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 45

❒ Push through the hinge pins for the insulated door to the side of the door stop from

above

❒ Fix the control from below using an M5 x 12 mm countersunk head screw (1) and

bolts (2) to the left and right on the bracket

4.5.7 Installing the back panel

❒ Position the rear thermal insulation (1) on the back of the boiler ❒ Attach the back panel (2) to the side panel ❒ Install the cover plate for ID fan (3)

4.5.8 Installing the floor insulation

❒ Push in the floor insulation ❒ Insert the insulation cover plate under the combustion chamber door

➥ hook the angled lugs left and right into the opening on the boiler base

Assembly

Assembling the S4 Turbo 15-40

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4.5.9 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 with the sides reversed accordingly.

❒ Measure the diagonals (1) and align the insulating side panels so that the two

diagonals are the same

➥ Adjust the position of the side panels if necessary ❒ Tighten the bolts on both insulating door mounts

Place the lower door bracket on a flat surface and drive in a half-length taper grooved pin (1)

Mount the lower door bracket onto the boiler base with the half-length taper grooved pin facing outwards

Only partially tighten the M6x12 Allen screws (2)

❒ Measure the distance from the insulating side panel to the hinge pins on the upper

bracket (3)

❒ Measure the distance from the insulating side panel to the half-length taper

grooved pin on the lower door bracket (4)

➥ The two distances must be equal! ❒ If necessary, correct the position of the lower door bracket and secure in place

using an Allen screw

❒ Place the spacer washer on the half-length taper grooved pin

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 47

❒ Hang the insulated door (1) at the bottom onto the half-length taper grooved pin

(2) and secure at the top with the hinge pins (3)

❒ Attach the caps on the ends of the control (4) on each side

On the side opposite the door stop:

❒ Position magnetic latches on the inside of the insulated door at the top and bottom ❒ Mount counter plates for the magnetic latches onto the insulation side panel

Assembly

Assembling the S4 Turbo 15-40

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❒ Check to see if the gap between the insulation side panel and the insulated door is

the same along the entire height of the boiler

➥ If necessary, check the position of the lower door bracket

4.5.10 Attaching the controller

❒ Place the upper heat insulation mat (1) on the device

➥ The heat insulation mat must touch the front sheet ❒ Assemble the control plate (2) with pre-installed door contact switch ❒ Set the thread on the door contact switch so that it is activated when the insulated

door is closed

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 49

❒ Insert the controller box (1) lugs (2) into the opening on the control plate and slide

forwards

❒ Use three thread forming screws incl. contact washers (3) to install the controller

box (1)

❒ Install the cover plate (1) on the back of the controller cover plate

S4 Turbo 32-40:

Assembly

Assembling the S4 Turbo 15-40

50 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.5.11 Fitting the broadband probe, boiler sensor, flue gas temperature sensor and STL

1 Broadband probe 2 Boiler sensor

3 Flue gas temperature sensor with

brass bushing

4 STL

(high-limit thermostat)

❒ Unscrew the pre-installed bushing (1) from the broadband probe (2) ❒ Screw the bushing (1) into the flue gas nozzle and gently tighten ❒ Screw the broadband probe (2) into the bushing on the flue gas nozzle and gently

tighten using an Allen wrench (22 mm)

❒ Push the flue gas temperature sensor (3) in so that it protrudes approx. 20 mm

from the housing and secure the position with the wing screw (4)

❒ Connect the broadband probe extension cable

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 51

❒ Push the boiler sensor and STL capillary into the pre-installed immersion sleeve

(2) with the pressure spring (1) during boiler outfeed

❒ Run the cable from the broadband probe, flue gas temperature and boiler sensors

and STL capillary to the controller box via the cable duct

➥ Tuck any extra cable into the cable duct

4.5.12 Installing the servo-motors

NOTICE! The images show a boiler with the servo-motors installed in the right

❒ Remove the screws (1) at the bottom of each side of the air duct and then use

them to fix the bracket (2) in place on the duct

➥ helps stabilise the insulation side panels

On the servo-motor side:

❒ Fix the two-part cover plate (3) onto the insulation side panel and bracket (1) using

thread forming screws

On the opposite side:

❒ Fix the cover plate (5) onto the insulation side panel and bracket (1) using thread

forming screws

❒ Check that the air flaps are at the stop and are closed

Assembly

Assembling the S4 Turbo 15-40

52 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

❒ Set the direction of rotation of the servo-motor (1) to left (L) ❒ Press the unlock key (2) and turn the drive for the shaft to the air duct (3) in an

anti-clockwise direction as far as the stop ❒ Fit the servo-motors (4) onto the pneumatic rods ❒ Position the torque support (5) and partially tighten the screws ❒ Align the servo-motors (4) so that they are straight and tighten the screw on the

torque support ❒ Push in the pre-punched opening for the cable duct onto the insulation (6) ❒ Attach the sticker at the end of the servo-motor cable

➥ Primary air = upper servo-motor / secondary air = lower servo-motor

❒ Run the cable from the two servo-motors through the cable duct upward to the

controller

4.5.13 Installing the WOS system

S4 Turbo 15-28

❒ Loosen the lock nut (1) on the knob ❒ Turn the knob anti-clockwise and remove the heat exchanger cover ❒ Remove the pre-punched blanking (2) in the insulation side panel on the same

side as the brass bushing

➥ File rough edges using a half-round file and remove burrs ❒ Push the plastic cover (3) onto the heat-exchanger lever (4) ❒ Push the heat-exchanger lever (4) through the stay tube from the outside

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 53

❒ Fix the heat-exchanger lever (4) to the stay tube (5) using two pipe locking pins (6)

❒ Place the heat exchanger cover on top ❒ Turn the knob on the heat exchanger cover clockwise ❒ Tighten the knob against accidental opening using the lock nut (1)

Assembly

Assembling the S4 Turbo 15-40

54 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

S4 Turbo 32-40

❒ Loosen the lock nut (1) on the knob ❒ Turn the knob anti-clockwise and remove the heat exchanger cover ❒ Remove the front pre-punched blanking in the insulation side panel (2) on the

same side as the brass bushing

➥ File rough edges using a half-round file and remove burrs ❒ Install the cover plate (3) ❒ Push the plastic cover (4) onto the heat-exchanger lever (5) ❒ Push the heat-exchanger lever (5) through the stay tube from the outside

❒ Fix the heat-exchanger lever (5) to the stay tube (6) using two pipe locking pins (7)

Assembly

Assembling the S4 Turbo 15-40

Installation Instructions S4 Turbo | M0971117_en 55

❒ Place the heat exchanger cover on top ❒ Turn the knob on the heat exchanger cover clockwise ❒ Tighten the knob against accidental opening using the lock nut (1)

Assembly

Assembling the S4 Turbo 15-40

56 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.6 Assembling the S4 Turbo 50-60

4.6.1 Assembly overview

Air duct system

Item pc. Description

1 1 Induced draught fan

2 1 Induced draught unit housing

3 1 Mineral fibre seal

4 2 Pneumatic rods with air flap and springs

5 2 Air flap

6 2 Split pin

7 3 Door handle with flange bushing and screw

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 57

EOS system

Item pc. Description

1 1 EOS lever, complete

2 1 Plastic cover

3 1 Cover plate

4 1 Brass bushing

5 14 EOS turbulator

6 1 Stay tube EOS, double

7 1 Stay tube EOS, simple

8 2 Pipe locking pin

9 1 EOS cover

10 1 Shaft

Assembly

Assembling the S4 Turbo 50-60

58 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Insulation

Item pc. Description Item pc. Description Item pc. Description

1 1 Insulated door 13 2 Servo-motor cover plate 25 2 Cover plate for ID fan

2 2 Magnetic latches 14 1 Torque support 26 1 Upper spacer plate

3 2 Counter plate, magnetic

latches

15 2 Servo-motor 27 1 Heat insulation mat, top

4 4 Flange bushing 16 1 Door mount 28 1 Heat insul. mat, top/rear

5 1 Insulating side panel, left 17 1 Half-length taper groov.pin 29 1 Control plate

6 1 Insulation cover plate, left 18 1 Floor insulation 30 1 Cover plate

7 1 Cover plate 19 1 Insul. cover plate, bottom 31 1 Controller box

8 2 Bracket 20 1 Thermal insulation, rear 32 1 Controller cover

9 1 Insul. mounting brackets,

left, 2 spacer washers

21 1 Back panel 33 1 Insulating cover, back

10 1 Insul. side panel, right 22 1 Thermal insul., ID fan 34 1 Control, buttons

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 59

Item pc. Description Item pc. Description Item pc. Description

11 1 Insul. cover plate, right 23 1 Cladding, ID fan 35 1 Control, touch panel

(optional)

12 1 Insul. mounting brackets,

right, 2 spacer washers

24 1 Cover plate, draught fan

cladding with strain relief

Assembly

Assembling the S4 Turbo 50-60

60 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.6.2 Assembling the heat-exchanger lever bushing

❒ Remove the screw cap from the side on which the heat-exchanger lever will be

mounted later and replace it with a brass bushing

➥ Remove the screw cap closer to the front of the boiler

➥ Tighten the brass bushing with an Allen wrench (27 mm)

4.6.3 Installing the pneumatic rods for the primary and secondary air

Servo-motors can be mounted on either the left or the right side on the boiler. Delivery configuration: servo-motors on the right

NOTICE! The stop screws on the air duct must be on the same side as the servomotor.

NOTICE! Unless otherwise indicated, “right” and “left” refer to the side of the boiler when standing in front of it.

❒ Remove the split pin on both pneumatic rods opposite the spring and pull one of

the air flaps off of each

➥ The pneumatic rods are packed along with the insulation

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 61

servo-motors on the right

Left-hand side: Right-hand side:

❒ Insert both pneumatic rods into the left-hand side of the boiler

➥ The air flaps with springs lie flat on the left-hand air ducts!

❒ Loosen the stop screws (1) at the lower and upper air duct on the right-hand side

of the boiler far enough to allow the air flap to make contact with the thread

❒ Remove the stop screws from the lower and upper air ducts on the left-hand side

of the boiler

Right-hand side:

❒ Insert the air flaps on the pneumatic rods on the right-hand side and secure them

with split pins

➥ IMPORTANT: the air flaps must be in the same position as those on the

opposite side!

❒ Turn both pneumatic rods anti-clockwise as far as the stop

➥ Check the pneumatic rods can move freely

Assembly

Assembling the S4 Turbo 50-60

62 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

servo-motors on the left

Right-hand side: Left-hand side:

❒ Insert both pneumatic rods into the right-hand side of the boiler

➥ The air flaps with springs lie flat on the right-hand air ducts! ❒ Loosen the stop screws (1) at the lower and upper air duct on the left-hand side of

the boiler far enough to allow the air flap to make contact with the thread

❒ Remove the stop screws from the lower and upper air ducts on the right-hand side

of the boiler

Left-hand side:

❒ Insert the air flaps on the pneumatic rods on the left-hand side and secure them

with split pins

➥ IMPORTANT: the air flaps must be in the same position as those on the

opposite side!

❒ Turn both pneumatic rods anti-clockwise as far as the stop

➥ Check the pneumatic rods can move freely

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 63

4.6.4 Installing the insulation

NOTICE

The individual parts of the boiler insulation covered with a protective film. You must remove the protective film before proceeding with installation.

❒ Inset the two L-shaped insulation cover plates (1) into the insulating side panels

on the left and right and secure them with thread forming screws

➥ Areas with slits (2) are in contact with the insulating material

❒ Insert the insulation mounting brackets (3) on both insulating side panels and

secure them with top thread forming screws

Assembly

Assembling the S4 Turbo 50-60

64 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

❒ Place one large spacer washer (1) on each of the threaded bolts to the right and

the left above on the boiler

❒ Insert the insulating side panels (2) into the base of the boiler at the lug (3) and

push onto the boiler

➥ the holes in the insulation side panels must line up with the holes in the flap (3) ❒ Position the brackets on the insulation side panels (2) onto the threaded bolts and

secure lightly with a large and a small spacer washer and nut (4)

❒ Secure the insulating side panels (2) on the right and left at the flap on the boiler

base with thread forming screws (5)

4.6.5 Installing the control

❒ Hang the upper spacer plate on the rivets between the insulating side panels ❒ Position the control and remove the caps on the ends on each side

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 65

❒ Push through the hinge pins for the insulated door to the side of the door stop from

above

❒ Fix the control from below using an M5 x 12 mm countersunk head screw (1) and

bolts (2) to the left and right on the bracket

4.6.6 Installing the back panel

❒ Position the rear thermal insulation (1) on the back of the boiler ❒ Attach the insulating back panel (2) to the side panel

4.6.7 Installing the floor insulation

❒ Push in the floor insulation ❒ Insert the insulation cover plate under the combustion chamber door

➥ hook the angled lugs left and right into the opening on the boiler base

Assembly

Assembling the S4 Turbo 50-60

66 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.6.8 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 with the sides reversed accordingly.

❒ Measure the diagonals (1) and align the insulating side panels so that the two

diagonals are the same

➥ Adjust the position of the side panels if necessary ❒ Tighten the bolts on both insulating door mounts

Place the lower door bracket on a flat surface and drive in a half-length taper grooved pin (1)

Mount the lower door bracket onto the boiler base with the half-length taper grooved pin facing outwards

Only partially tighten the M6x12 Allen screws (2)

❒ Measure the distance from the insulating side panel to the hinge pins on the upper

bracket (3)

❒ Measure the distance from the insulating side panel to the half-length taper

grooved pin on the lower door bracket (4)

➥ The two distances must be equal! ❒ If necessary, correct the position of the lower door bracket and secure in place

using an Allen screw

❒ Place the spacer washer on the half-length taper grooved pin

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 67

❒ Hang the insulated door (1) at the bottom onto the half-length taper grooved pin

(2) and secure at the top with the hinge pins (3)

❒ Attach the caps on the ends of the control (4) on each side

On the side opposite the door stop:

❒ Position magnetic latches on the inside of the insulated door at the top and bottom ❒ Mount counter plates for the magnetic latches onto the insulation side panel

Assembly

Assembling the S4 Turbo 50-60

68 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

❒ Check to see if the gap between the insulation side panel and the insulated door is

the same along the entire height of the boiler

➥ If necessary, check the position of the lower door bracket

4.6.9 Attaching the controller

❒ Place the upper heat insulation mat (1) on the device

door is closed

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 69

❒ Insert the controller box (1) lugs (2) into the opening on the control plate and slide

forwards

❒ Use three thread forming screws incl. contact washers (3) to install the controller

box (1)

❒ Install the cover plate (1) on the back of the controller cover plate

Assembly

Assembling the S4 Turbo 50-60

70 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.6.10 Fitting the broadband probe, boiler sensor, flue gas temperature sensor and STL

1 Broadband probe 2 Boiler sensor

3 Flue gas temperature sensor with

brass bushing

4 STL

(high-limit thermostat)

tighten using an Allen wrench (22 mm) ❒ Screw the flue gas temperature sensor brass bushing (3) into the flue gas nozzle ❒ Push the flue gas temperature sensor (4) in so that it protrudes approx. 20 mm

from the housing and secure the position with the wing screw (5)

❒ Connect the broadband probe extension cable

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 71

❒ Push the boiler sensor and STL capillary into the pre-installed immersion sleeve

(2) with the pressure spring (1) during boiler outfeed

❒ Run the cable from the broadband probe, flue gas temperature and boiler sensors

and STL capillary to the controller box via the cable duct

➥ Tuck any extra cable into the cable duct

4.6.11 Installing the servo-motors

NOTICE! The images show a boiler with the servo-motors installed in the right

❒ Remove the screws (1) at the bottom of each side of the air duct and then use

them to fix the bracket (2) in place on the duct

➥ helps stabilise the insulation side panels

On the servo-motor side:

❒ Fix the two-part cover plate (3) onto the insulation side panel and bracket (1) using

thread forming screws

On the opposite side:

❒ Fix the cover plate (5) onto the insulation side panel and bracket (1) using thread

forming screws

❒ Check that the air flaps are at the stop and are closed

Assembly

Assembling the S4 Turbo 50-60

72 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

❒ Set the direction of rotation of the servo-motor (1) to left (L) ❒ Press the unlock key (2) and turn the drive for the shaft to the air duct (3) in an

torque support ❒ Push in the pre-punched opening for the cable duct onto the insulation (6) ❒ Attach the sticker at the end of the servo-motor cable

➥ Primary air = upper servo-motor / secondary air = lower servo-motor

❒ Run the cable from the two servo-motors through the cable duct upward to the

controller

4.6.12 Installing the induced draught fan

❒ Install the induced draught fan housing (1) with mineral fibre seal (2) onto the flue

gas nozzle ❒ Assemble the induced draught fan (3) on the induced draught fan housing (1)

➥ Caution: do not overstress the flange!

❒ Push the cable guides (4) in above the flue gas nozzle through the holes on the

insulating back panel

➥ Run the cable from the broadband probe and flue gas temperature sensor into

the cable guide

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 73

❒ Wrap the thermal insulation (1) around the ID fan housing and fix in place using

tension springs (2)

❒ Attach the ID fan cladding with the pre-mounted screws ❒ Attach the ID fan cover plates on the left and right side of the fan

❒ Attach both ID fan cables to the cladding using the cable duct (1) ❒ Clamp the cable from the broadband probe and flue gas temperature sensor into

the strain relief (2) ❒ Slide the strain relief (2) with the cables into the cover plate (3) and rotate 90° ❒ Mount the cover plate (3) onto the cladding ❒ Run the cables to the controller

Assembly

Assembling the S4 Turbo 50-60

74 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.6.13 Installing the WOS system

❒ Loosen the lock nut (1) on the knob ❒ Turn the knob anti-clockwise and remove the heat exchanger cover ❒ Remove the front pre-punched blanking in the insulation side panel (2) on the

same side as the brass bushing

❒ Fix the heat-exchanger lever (5) to the double stay tube (6) using two pipe locking

pins (7)

❒ Attach the connection lever (8) to both stay tubes and secure using bolts and a

split pin

Assembly

Assembling the S4 Turbo 50-60

Installation Instructions S4 Turbo | M0971117_en 75

❒ Place the heat exchanger cover on top ❒ Turn the knob on the heat exchanger cover clockwise ❒ Tighten the knob against accidental opening using the lock nut (1)

4.7 Electrical connection and wiring

DANGER

When working on electrical components:

Risk of electrocution!

When work is carried out on electrical components:

❒ Only have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations

➥ Work must not be carried out on electrical components by unauthorised

persons

❒ Run the cable of the broadband probe, servo-motors, flue 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 any extra cable into the cable duct

❒ Connect the components according to the power connection diagram

➥ The flexible sheathed cable must be used for the wiring; this must be of the

correct size to comply with applicable regional standards and regulations!

Once the individual components have been wired:

❒ Wire the mains connection in the controller box

➥ The power supply line (mains connection) must be fitted with a max. C16A fuse

by the customer!

➥ Observe the circuit diagrams in the boiler controller operating instructions.

Assembly

Electrical connection and wiring

76 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.7.1 Information on circulating pumps

NOTICE

According to 2012/622/EU external, wet running circulating pumps must comply with the following limit values of the Energy Efficiency Index (EEI):

- Effective from 01/01/2013: Wet running circulating pumps with EEI ≤ 0.27

- Effective from 08/01/2015: Wet running circulating pumps with EEI ≤ 0.23

Only high efficiency pumps with a connection option for a control signal (PDM / 0-10V) should be connected to speed-controlled pump outputs (pump 1 on the core module and pump outputs on the hydraulic module). In this case, the control line is connected to the corresponding PDM outputs of the boards. Observe the connection instructions in the boiler controller documentation!

CAUTION

When using high efficiency pumps without an additional control line at speedcontrolled pump outputs:

Malfunctions of the boiler, the pump and the hydraulic system may occur!

Therefore:

❒ Do not connect EC motor pumps without a control line to the speed-controlled

pump outputs of the boards.

➥ Only use special high efficiency pumps with a connection option for a

control line (PDM/0-10V)!

➥ Observe the additional instructions and information on board outputs in the

operation instructions for the boiler controller.

Assembly

Electrical connection and wiring

Installation Instructions S4 Turbo | M0971117_en 77

4.7.2 Concluding work

S4 Turbo 15-40: S4 Turbo 50-60:

❒ Place the controller cover (1) on top of the device and fix in place using screws

and contact washers (2) ❒ Place the thermal insulation (3) on the device ❒ Install the back insulating cover (4)

4.8 Hydraulic connection

The connection of the boiler to the hydraulic system depends on the components it consists of (storage tank, domestic hot water tank, solar panel system, heating circuits, etc). The circuit diagram leaflet we provide contains several suggestions for different systems.

Assembly

Electrical connection and wiring

78 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.9 Connecting the hydraulic safety devices

1.1

1.2

1.3

1.5

1.4

1 Thermal discharge valve

▪ The thermal discharge safety device must be connected in accordance with

ÖNORM/DIN EN 303-5 and as shown in the diagram above.

▪ The discharge safety device must be connected to a pressurised mains water

supply in such a way that it cannot be shut off

▪ A pressure reducing valve (1.5) is required for a cold water pressure of 6 bar

Minimum cold water pressure = 2 bar

1.1 Sensor of thermal discharge safety device

1.2 Thermal discharge valve (opens at approx. 95 °C)

1.3 Cleaning valve (T-piece)

1.4 Dirt trap

1.5 Pressure reducing valve

2 Safety valve

▪ Safety valve as per prEN 1268-1 with a diameter of DN15 ▪ The safety valve must be installed in an accessible place on the heat generator or

in direct proximity in the flow pipe in such a way that it cannot be shut off

3 Return temperature control with pump

4 Diaphragm expansion tank

▪ The diaphragm pressurised expansion tank must conform to EN 13831 and hold

at least the maximum expansion volume of the system’s heated water including a

water seal ▪ Its size must comply with the design information in EN 12828 - Appendix D ▪ Ideally it should be installed in the return line. Follow the manufacturer’s

installation instructions

Assembly

Connecting the hydraulic safety devices

Installation Instructions S4 Turbo | M0971117_en 79

5 Start-up

5.1 Before commissioning / configuring the boiler

The boiler must be configured to the heating system on initial start-up.

NOTICE

Optimum efficiency and efficient, low-emission operation can only be guaranteed if the system is set up by trained professionals and the standard factory settings are observed.

Take the following precautions:

❒ Initial startup should be carried out with an authorised installer or with Froling

customer services

NOTICE

Foreign bodies in the heating system impair its operational safety and can result in damage to property.

As a result:

❒ The whole system should be rinsed out before initial start-up in accordance

with EN 14336.

❒ Recommendation: Make sure the hose diameter of the flush nozzles in the

flow and return complies with ÖNORM H 5195 and is the same as the hose diameter in the heating system, however not more than DN 50.

❒ Turn on the main switch ❒ Set the boiler controller to the system type. ❒ Load the boiler default values.

NOTICE! For the keypad layout and instructions for modifying the parameters, see the instruction manual for the boiler controller.

❒ Check the system pressure of the heating system. ❒ Check that the heating system is fully vented. ❒ Check that all water connections are tightly sealed

➥ Pay particular attention to those connections from which plugs were removed

during assembly. ❒ Check that the safety devices are present and working efficiently. ❒ Check that there is sufficient ventilation in the boiler room. ❒ Check the seal of the boiler.

➥ All doors and inspection openings must be tightly sealed.

❒ Check that the drives and servo motors are working and turning in the right

direction.

❒ Check that the door contact switch is working efficiently.

NOTICE! Check the digital and analog inputs and outputs - See the instruction manual for the boiler controller.

Start-up

Before commissioning / configuring the boiler

80 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

5.2 Initial startup

5.2.1 Permitted fuels

Firewood

Firewood up to max. 55 cm long.

Water content (w) greater than 15% (equivalent to wood moisture u > 17%) Water content (w) less than 25% (equivalent to wood moisture u < 33%)

EU: Fuel as per EN ISO 17225 – Part 5: Firewood class A2 / D15 L50

Additional for Germany: Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance

(BimSchV) in the last amended version)

▪ Use wind-exposed areas where possible for storage (e.g. store at edge of forest instead

of in forest) ▪ Walls of buildings facing the sun are ideal ▪ Create a dry underlay, where possible with air access (line with round timber, pallets,

etc.) ▪ stack split wood and store in such a way that it is protected from the elements ▪ If possible, stock fuel for the day in a warm place (e.g. in boiler room) (pre-heats the

fuel!)

Storage time dependent upon water content

Wood type Water content

15 – 25% less than 15

Storage in heated and ventilated room (approx. 20°C)

Soft wood (e.g. spruce)

approx.

6 months

from 1 year

Hardwood (e.g. beech)

1 – 1.5 years from 2 years

Outdoor storage (protected from elements, exposed to wind)

Soft wood (e.g. spruce)

2 summers from 2 years

Hardwood (e.g. beech)

3 summers from 3 years

Freshly cut wood has an approximate water content of 50 to 60%. As the above table shows, the water content of the firewood decreases the longer the wood is stored depending on how dry and warm the storage location is. The ideal water content of firewood is between 15 and 25%. If the water content falls below 15%, we recommend you adjust the combustion control to the fuel.

The air duct should be adjusted accordingly for optimal burning of these fuels (w < 15%). Extra cleaning of flue gas paths

Water content

Note on standards

Tips for

storing wood

Start-up

Initial startup

Installation Instructions S4 Turbo | M0971117_en 81

5.2.2 Fuels permitted under certain conditions

Wood briquettes

Wood briquettes for non-industrial use with a diameter of 5-10 cm and 5-50 cm long.

EU: Fuel as per EN ISO 17225 - Part 3:

wood briquettes class B / D100 L500 Form 1 - 3

Additional for Germany: Fuel class 5a (§3 of the First Federal Emissions Protection Ordinance

(BImSchV) - applicable version)

▪ When burning wood briquettes use the settings for extremely dry fuel ▪ Wood briquettes must be heated up with firewood as per EN ISO 17225-5

(at least two layers of firewood under the wood briquettes)

▪ The fuel loading chamber must not be filled more than 3/4 full, as the wood briquettes

expand during combustion

▪ Even when using the settings for dry fuel, burning wood briquettes can cause

combustion problems. In such cases, repairs must be carried out by qualified staff. Please contact Froling customer services or your installer.

5.2.3 Non-permitted fuels

The use of fuels not defined in the "Permitted fuels" section, and particularly the burning of refuse, is not permitted.

CAUTION

In case of use of non-permitted fuels:

Burning non-permitted fuels increases the cleaning requirements and leads to a build-up of aggressive sedimentation and condensation, which can damage the boiler and also invalidates the guarantee. Using non-standard fuels can also lead to serious problems with combustion.

For this reason, when operating the boiler:

❒ Only use permitted fuels

5.2.4 Heating up for the first time

CAUTION

If the boiler heats up too quickly on initial start-up:

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!

For this reason the following applies the first time you heat up the boiler:

❒ Start the firewood boiler for the first time in accordance with the heating

instructions

Note on standards

Notes on

use

Start-up

Initial startup

82 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Heating instructions when starting up a firewood boiler for the first time

❒ Place a piece of wood diagonally across the combustion chamber (see diagram on

left)

➥ Load the boiler with a small amount of firewood (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 material in the boiler has burnt down, the boiler can be used in accordance with the operating instructions ("Operating the system" section).

NOTICE

If condensation escapes during the initial heat-up phase, this does not indicate a fault.

❒ Tip: If this occurs, clean up using a cleaning rag.

NOTICE! See boiler controller operating instructions for all the steps necessary to start up for the first time Lambdatronic S 3200

Start-up

Initial startup

Installation Instructions S4 Turbo | M0971117_en 83

6 Decommissioning

6.1 Mothballing

The following measures should be taken if the boiler is to remain out of service for several weeks (e.g. during the summer):

❒ Clean the boiler thoroughly and close the doors fully

If the boiler is to remain out of service during the winter:

❒ Have the system completely drained by a qualified technician

➥ Protection 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

with waste management regulations in the country (e.g. AWG in Austria)

❒ You can separate and clean recyclable materials and send them to a recycling

centre.

❒ The combustion chamber must be disposed of as builders' waste.

Decommissioning

Mothballing

84 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

7 Appendix

7.1 Pressure equipment regulation

Appendix

Pressure equipment regulation

Installation Instructions S4 Turbo | M0971117_en 85

7.2 Technical specifications - S4 Turbo with partial load values

7.2.1 Test report data S4 Turbo 22-28

Description

S4 Turbo / S4 Turbo F

22 28

Testing institute

BLT Wieselburg

2) 3)

Test report no. 001/08 - File 166/07

Z0640211

BLT 0499/11

Z0640211

Boiler class as per EN 303-5:2012 5 5

Nominal output / range kW 10.9 – 22.0 14.0 – 28.0

Boiler efficiency (nominal load / partial load)

% 90.7 / 93.7 90.8 / 93.4

2.Francisco Josephium Wieselburg, BLT Wieselburg, Rottenhauser Straße 1, A – 3250 Wieselburg

Test data - Emissions in [mg/MJ]1) (nominal load/partial load)

Carbon monoxide (CO) mg/MJ 35 / 162 41 / 123

Nitrogen oxide (NOx) mg/MJ 93 / 76 95 / 79

Organic hydrocarbons (OGC) mg/MJ 3 / 3 <3 / 3

Dust mg/MJ 12 / 4 13 / 5

1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m3]1) (nominal load/partial load)

Carbon monoxide (CO)

mg/m

52 / 244 61 / 185

Nitrogen oxide (NOx)

mg/m

140 / 114 142 / 118

Organic hydrocarbons (OGC)

mg/m

3 / 4 <3 / 4

Dust

mg/m

18 / 6 19 / 8

1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%

Regulation (EU) 2015/1187

Energy efficiency A+ A+

Rated heat output kW 22 28

Energy efficiency index of the boiler model

118 118

Seasonal space heating energy efficiency

% 80 80

Energy efficiency index of the boiler in package with temperature control

120 120

Energy efficiency class of the boiler in package with temperature control

A+ A+

Appendix

Technical specifications - S4 Turbo with partial load values

86 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

7.2.2 Test report data S4 Turbo 34-40

Description

S4 Turbo / S1 Turbo

34 40

Testing institute

TÜV Austria

Test report no.

Z0640211

07-UWC/Wels-EX-094/3

Z0640211

11-U-408/SD

Boiler class as per EN 303-5:2012 5 5

Nominal output / range kW 17 - 34 20 - 40

Boiler efficiency (nominal load / partial load)

% 90.8 / 93.1 90.9 / 92.8

2.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

Test data - Emissions in [mg/MJ]1) (nominal load/partial load)

Carbon monoxide (CO) mg/MJ 48 / 84 54 / 45

Nitrogen oxide (NOx) mg/MJ 97 / 82 99 / 85

Organic hydrocarbons (OGC) mg/MJ <3 / 3 <2 / 3

Dust mg/MJ 13 / 6 14 / 7

1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m3]1) (nominal load/partial load)

Carbon monoxide (CO)

mg/m

70 / 125 79 / 66

Nitrogen oxide (NOx)

mg/m

144 / 121 146 / 125

Organic hydrocarbons (OGC)

mg/m

<3 / 4 <3 / 4

Dust

mg/m

20 / 9 21 / 11

1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%

Regulation (EU) 2015/1187

Energy efficiency A+ A+

Rated heat output kW 34 40

Energy efficiency index of the boiler model

118 118

Seasonal space heating energy efficiency

% 80 80

Energy efficiency index of the boiler in package with temperature control

120 120

Energy efficiency class of the boiler in package with temperature control

A+ A+

Appendix

Technical specifications - S4 Turbo with partial load values

Installation Instructions S4 Turbo | M0971117_en 87

7.2.3 Test report data S4 Turbo 50-60

Description S4 Turbo

50 60

Testing institute

TÜV Austria

Test report no.

11-U-561/SD

11-UWC/Wels-EX-128/6

Boiler class as per EN 303-5:2012 5 5

Nominal output / range kW 25 - 50 30 - 60

Boiler efficiency (nominal load / partial load)

% 92.9 / 93.0 94.9 / 93.2

1.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels

Test data - Emissions in [mg/MJ]1) (nominal load/partial load)

Carbon monoxide (CO) mg/MJ 44 / 45 33 / 44

Nitrogen oxide (NOx) mg/MJ 92 / 84 85 / 82

Organic hydrocarbons (OGC) mg/MJ <2 / 3 1 / 3

Dust mg/MJ 11 / 11 8 / 14

1.The pollutant concentration is specified as a mass based on the energy content of the fuel fed to the combustion system in mg/MJ

Test data - Emissions in [mg/m3]1) (nominal load/partial load)

Carbon monoxide (CO)

mg/m

64 / 66 48 / 65

Nitrogen oxide (NOx)

mg/m

135 / 123 124 / 120

Organic hydrocarbons (OGC)

mg/m

<3 / 4 2 / 4

Dust

mg/m

16 / 16 12 / 20

1.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1,013 mbar) with a volume content of oxygen of 13%

Regulation (EU) 2015/1187

Energy efficiency A+ A+

Rated heat output kW 50 60

Energy efficiency index of the boiler model

119 119

Seasonal space heating energy efficiency

% 81 81

Energy efficiency index of the boiler in package with temperature control

121 121

Energy efficiency class of the boiler in package with temperature control

A+ A+

Appendix

Technical specifications - S4 Turbo with partial load values

88 Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

7.3 Addresses

7.3.1 Address of manufacturer

FRÖLING Heizkessel- und Behälterbau GesmbH

Industriestraße 12 A-4710 Grieskirchen AUSTRIA

TEL 0043 (0)7248 606 0 FAX 0043 (0)7248 606 600 INTERNET www.froeling.com

7.3.2 Address of the installer

Stamp

Appendix

Addresses

Installation Instructions S4 Turbo | M0971117_en 89

Froling S4 Turbo 15, S4 Turbo 28, S4 Turbo 22, S4 Turbo 50, S4 Turbo 40 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual