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Installation Instructions

DDual fuel boiler SP Dual 15-40

Translation of the original German operating instructions for techniciansRead and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!M1300212_en | Edition 24/09/2012

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

CContents

1 General 4

2 Safety 52.1 Hazard levels of warnings 52.2 Qualification of assembly staff 62.3 Protective equipment for assembly staff 62.4 Design Information 72.4.1 Notes on Standards 7 General standards for heating systems 7 Standards for structural and safety devices 7 Standards for heating water 7 Standards for permitted fuels 82.4.2 Installation and approval of the heating system 82.4.3 General information for installation room (boiler room) 82.4.4 Requirements for central heating water 92.4.5 Return lift 92.4.6 Combination with storage tank 102.4.7 Chimney connection/chimney system 11 Draught limiter 11 Boiler data for planning the flue gas system 11

3 Technology 123.1 Dimensions 123.2 Technical specifications 133.2.1 SP Dual 15/22/28 133.2.2 SP Dual 34/40 15

4 Installation 174.1 Transport 174.2 Positioning 174.3 Temporary storage 174.4 Setting up in the boiler room 174.4.1 Removing the pellet unit from the pallet 174.4.2 Moving the boiler in the boiler room 194.4.3 Minimum distances in the boiler room 19

4.5 Preparing the firewood boiler 204.6 Fitting the pellet unit 214.6.1 Removing the cladding from the pellet unit 214.6.2 Screwing the pellet unit to the firewood boiler 224.6.3 Installing the WOS lever 244.6.4 Fitting the flow sensor and laying the cables 26

4.7 Connecting the discharge system 284.8 Hydraulic connection 284.9 Electrical connection 294.10 Positioning the boiler stickers correctly 29

Contents

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

55 Start-up 305.1 Before commissioning / configuring the boiler 305.1.1 Setting the "Max level and Min level” sensor 31

5.2 Initial startup 315.2.1 Permitted fuels 31 Wood pellets 31 Firewood 315.2.2 Heating up for the first time 32

6 Decommissioning 336.1 Mothballing 336.2 Disassembly 336.3 Disposal 33

7 Appendix 347.1 Addresses 347.1.1 Address of manufacturer 347.1.2 Address of the installer 34

Contents

Installation Instructions SP Dual 15-40 | M1300212_en 3

11 GeneralThank you for choosing a quality product from Froling. The product features a state-of-the-art design and conforms to all currently applicable standards and testing guide‐lines.Please read and observe the documentation provided and always keep it close to thesystem for reference. It contains important safety information and all the operation andmaintenance specifications needed to operate the system safely, properly, environ‐mentally friendly and cost-effectively.The constant further development of our products means that there may be minor dif‐ferences from the pictures and content. If you discover any errors, please let us know:[email protected] 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 orheating engineers are requested to return a copy of the delivery certificate togetherwith the guarantee card to Froling. On commissioning by FROLING Customer Servicethe validity of the delivery certificate will be noted on the customer service record.

Issuing a delivery cer‐tificate

1 General


22 Safety

2.1 Hazard levels of warningsThis documentation uses warnings with the following hazard levels to indicate directhazards and important safety instructions:

DANGER

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

WARNING

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

CAUTION

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

Safety 2Hazard levels of warnings


22.2 Qualification of assembly staff

CAUTION

Assembly and installation by untrained personnel:

Risk of personal injury and damage to property.

During assembly and installation:❒ Observe the instructions and information in the manuals❒ Only allow trained staff to carry out assembly and installation

Assembly, installation, initial startup and servicing must only be carried out by qualifiedpersonnel:- Heating technician / building technician- Electrical installation technician- Froling customer servicesThe assembly staff must have read and understood the instructions in the documenta‐tion.

2.3 Protective equipment for assembly staffYou must ensure that staff have the protective equipment specified by accident pre‐vention regulations.

▪ For transportation, setup and assembly:- suitable workwear- protective gloves- sturdy shoes

2 SafetyQualification of assembly staff


22.4 Design Information

2.4.1 Notes on StandardsThe system must be installed and commissioned in accordance with the local fire andbuilding regulations. The following standards and regulations should always be ob‐served:

General standards for heating systems

EN 303-5 Boilers for solid fuels, manually and automatically fed combus‐tion systems, nominal output up to 300 kW

EN 12828 Heating systems in buildings - Design of water-based heatingsystems

EN 13384-1 Chimneys - Thermal and fluid dynamic calculation methodsPart 1: Chimneys serving one appliance

ÖNORM M 7510-1 Guidelines for checking central heating systemsPart 1: General requirements and one-off inspections

ÖNORM M 7510-4 Guidelines for checking central heating systemsPart 4: Simple check for heating plants for solid fuels

Standards for structural and safety devices

ÖNORM H 5170 Heating installation - Requirements for construction and safetyengineering, as well as fire prevention and environmental pro‐tection

ÖNORM M 7137 Compressed untreated wood – Requirements for storing pelletsat the end customer’s site

TRVB H 118 Technical directives for fire protection/prevention (Austria)

Standards for heating water

ÖNORM H 5195-1 Prevention of damage by corrosion and scale formation inclosed warm water heating systems at operating temperaturesup to 100 °C (Austria).

VDI 2035 Sheet 1 Prevention of damage in water heating systems - Scale forma‐tion in domestic water heating systems and hot water heatingsystems (Germany)

SWKI 97-1 Water quality for heating, steam, cooling and air conditioningsystems (Switzerland)

D.P.R. no. 412 Regulations for the planning, installation, running/operation andmaintenance of heating systems in buildings to reduce energyconsumption with reference to Article 4, Comma 4 of the Legis‐lative Decree of 9 January 1991, No. 10 (Italy)

Safety 2Design Information


SStandards for permitted fuels

EN 14961-2 Solid biofuel, fuel specifications and classes.Part 2: Wood pellets for non-industrial use

EN 14961-3 Solid biofuel, fuel specifications and classes.Part 2: Wood briquettes for non-industrial use

EN 14961-5 Solid biofuel, fuel specifications and classes.Part 5: Firewood for non-industrial use

1. BImSchV First Ordinance of the German Federal Government for imple‐mentation of the Federal Emission Protection Law, BGBl. I P.491, in the applicable version.

2.4.2 Installation and approval of the heating systemThe boiler should be operated in a closed heating system. The following standardsgovern the installation:

ÖNORM / DIN EN 12828 Heating Systems in Buildings

NOTICE! Each heating system must be officially approved.The appropriate supervisory authority (inspection agency) must always be informedwhen installing or modifying a heating system, and authorisation must be obtainedfrom the building authorities:Austria: Inform the civic/municipal building authorities.Germany: Notify an approved chimney sweep and the building authorities.

2.4.3 General information for installation room (boiler room)

Boiler room characteristics▪ 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 provide sufficient light‐

ing in the boiler room in accordance with national workplace design regulations.▪ When using the boiler over 2000 metres above sea level you should consult the

manufacturer.▪ Danger of fire due to flammable materials.

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 in the room wherethe boiler is installed.

▪ Keep the air suction opening of the boiler free from dust.

Note on standards

2 SafetyDesign Information


VVentilation of the boiler roomVentilation 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 (foli‐age, 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 requirementsTRVB H118 - Technical directives on fire protection/prevention

2.4.4 Requirements for central heating waterThe following standards and guidelines apply:

Austria:Germany:Switzerland:Italy:

ÖNORM H 5195-1VDI 2035SWKI 97-1D.P.R. no. 412

NOTICE! Note on filling with make-up water: Always bleed the filling hose before con‐necting, in order to prevent air from entering the system.

2.4.5 Return liftIf the hot water return is below the minimum return temperature, some of the hot wateroutfeed will be mixed in.

CAUTION

Risk of dropping below dew point/condensation formation if operated without re‐turn temperature control.

Condensation water forms an aggressive condensate when combined with com‐bustion 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 somesort of control device (e.g. thermometer).

Note on standards

Note on standards



22.4.6 Combination with storage tankAlways observe and abide by regionally binding regulations when using a storagetank. Certain subsidy guidelines also prescribe compulsory requirements for the instal‐lation of buffer storage tanks. Up-to-date information relating to specific subsidy guide‐lines for your region can be found on our website www.froeling.com. Combining the system with a buffer storage tank offers significant advantages whenusing a firewood boiler, such as better utilisation of the fuel, more user-friendly opera‐tion in terms of reloading intervals (which means the greatest possible independencefrom instantaneous heating requirements), and less soiling of the boiler and flue gassystem. In addition to the above, as the manufacturer of the boiler we have to adviseon how the heat generated can be dissipated. This is because compliance with theemissions limits and minimum levels of efficiency at a minimum heat output of max.30% of the rated heat output, as specified in Section 4.2.5 of EN 303-5, has not beendemonstrated for all variants of the system.The recommended storage volume for each boiler is given in the technical specifica‐tions. The specified value applies under the following conditions: the rated heat outputof the boiler corresponds to the heating requirements of the building and a maximumof 50% of the rated heat output can be dissipated to the building being heated underpartial load conditions.Calculating the storage tank volume as per EN 303-5:

VSp = 15TB x QN (1 - 0.3 x QH/Qmin)

VSp

QN

TB

QH

Qmin

Storage tank capacity in [l]Nominal output of the boiler in [kW]Combustion period of the boiler in [h]Heating load of building in [kW]Minimum output of boiler in [kW] 1)

1.The boiler’s minimum output is the lowest value of the output range in the technical data. If there is no minimum output specified, use thenominal output (Qmin = QN)

In accordance with the relevant Austrian laws governing energy technology, which arebased on Art. 15a B-VG "Agreement on protective measures for small furnaces" datedNovember 1994, no buffer storage tank is required on manually fed biomass boilersthat have been positively tested at both nominal load and partial load (below 50% ofnominal load) to ensure they adhere to the emissions limits specified in that agree‐ment. The first BImSchV (Ordinance on small and medium-sized heating plants of 26 Janu‐ary 2010, BGBl. I P. 38) stipulates a minimum water heat storage tank volume of 55litres per kilowatt of rated heat output; a water heat storage tank with a volume of 12litres per litre of fuel loading chamber is recommended.

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 orFroling.

General information

Austria

Germany

2 SafetyDesign Information


22.4.7 Chimney connection/chimney systemEN 303-5 specifies that the entire flue gas system must be designed to prevent, wher‐ever possible, damage caused by seepage, insufficient feed pressure and condensa‐tion. Please note in this respect that flue gas temperatures lower than 160K aboveroom temperature can occur in the permitted operating range of the boiler. The flue gas temperatures (for clean systems) and additional flue gas values can befound in the table below. The connection between the boiler and the chimney system should be as short aspossible. The upward angle of the connection should not exceed 30 - 45°. Insulate theconnection. The entire flue gas system - chimney and connection - should be calcula‐ted 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 chimneysweep.NOTICE! TRVB H 118 (Austria only) stipulates that an explosion flap must be installedin the connecting piece (flue pipe) directly next to the boiler. It should be situated insuch a way that is poses no risk to persons!

Draught limiterThe installation of a draught limiter is recommended.NOTICE! Install the draught limiter directly under the mouth of the flue line, as thepressure is constantly low at this point.

Boiler data for planning the flue gas systemThe chimney design data is the same as the values of the S4 Turbo firewood boiler.

Name SP Dual

15 22 28 34 40

Flue gas temperature at nominal load °C 140 160 180 140 170

Flue gas temperature at partial load 100 110 130 110 130

Flue gas mass flow at nominal load kg/s 0.011 0.016 0.021 0.025 0.030

Flue gas mass flow at partial load 0.004 0.007 0.010 0.012 0.015

Minimum feed pressure mbar 0.08 0.08 0.08 0.08 0.08

Maximum permissible feed pressure as per ÖNORM/DIN EN 303-5

Flue pipe diameter mm 150 150 150 150 150



33 Technology

3.1 Dimensions

Dimension Name Unit SP Dual 15-28 SP Dual 34-40

L Length, firewood boiler mm 1125 1215

L1 Length, pellet unit 1285 1370

W SP Dual width mm 1000 1100

W1 Total width, SP Dual incl. heat exchanger lever 1050 1150

W2 Width, firewood boiler 570 670

W3 Width, pellet unit 430 430

H Height, boiler mm 1565 1565

H1 Total height incl. flue gas nozzle 1610 1610

H2 Height, flue pipe connection 1830 1830

H3 Height, flow – firewood boiler connection 1360 1360

H4 Height, return – firewood boiler connection 140 140

H5 Height, safety heat exchanger connection 970 970

H6 Height, drainage connection 120 120

H7 Height, flow and return - pellet unit connection 140 160

H8 Height, suction system connection 1370 1360

H9 Height, pellet unit 1465 1465

H10 Total height, pellet unit incl. suction turbine 1545 1545

H11 Total space with cover open 1865 1865

Flue pipe diameter mm 150 150

3 TechnologyDimensions


33.2 Technical specifications

3.2.1 SP Dual 15/22/28

Technical specifications of the firewood boiler

The technical specifications of the firewood boiler can be found in the relevant assem‐bly instructions.

Technical specifications of the pellet unit

Name Pellet unit - SP Dual

15 22 28

Rated heat output kW 15.6 22 25

Output range kW 4.7 - 15.6 4.7 – 22 4.7 – 25

Electrical connection 230V / 50Hz / C16A

Power consumption in pellet mode W 38 - 60 38 - 67 38 - 70

Boiler weightincl. pellet unit

kg 945 955 965

Total boiler capacity (water) L 157 157 157

Water pressure drop (ΔT = 10 / 20 K)

mbar 7.5 / 1.5 14.5 / 7.5 18.5 / 5.9

Min. boiler return temperature °C 60

Max. permitted operating temperature °C 90

Permitted operating pressure bar 3

Boiler class as per EN 303-5:1999(pr EN 303-5:2012)

3 (5)

Permitted fuel as per EN 14961 Part 2: Wood pellets class A1 / D06

Airborne sound level dB(A) < 70

Technology 3Technical specifications


TTest report data for pellet unit


15 22 28

Testing institute TÜV Austria1) 2) 3) TÜV Austria1)

Test report no. 11-UW/Wels-EX-300/1

11-UW/Wels-EX-300/2

1.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels2.As per EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent structure it is sufficient, if the ratio of rated heat output

from the largest to the smallest boiler ≤ 2 : 1, to carry out the tests with the smallest and the largest boilers. The boiler manufacturer mustensure that all boilers, including those that have not been tested in the range, whose values have been determined depending on the ratedheat output by interpolation, fulfil the requirements of the norm.

3.Values for the type SP Dual 22 are interpolated between the SP Dual 15 and SP Dual 28 of test protocols 11-UW/Wels-EX-300/1 and 11-UW/Wels-EX-300/2.

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

Carbon monoxide (CO) mg/MJ 5 / 37 4 / 37 4 / 37

Nitrogen oxide (NOx) mg/MJ 73 / 57 75 / 57 76 / 57

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

Dust mg/MJ 11 / 14 13 / 14 14 / 14

Boiler efficiency % 93.6 / 90.5 93.5 / 90.5 93.4 / 90.5

Test data in pellet mode - Emissions in [mg/m³]1) (Nominal load / partial load)

Carbon monoxide (CO) mg/m³ 8 / 55 7 / 55 6 / 55

Nitrogen oxide (NOx) mg/m³ 107 / 84 110 / 84 112 / 84

Organic hydrocarbons (OGC) mg/m³ <2 / <3 <2 / <3 <2 / <3

Dust mg/m³ 16 / 20 19 / 20 20 / 20

Boiler efficiency % 93.6 / 90.5 93.5 / 90.5 93.4 / 90.51.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%

3 TechnologyTechnical specifications


33.2.2 SP Dual 34/40

Technical specifications of the firewood boiler

The technical specifications of the firewood boiler can be found in the relevant assem‐bly instructions.

Technical specifications of the pellet unit


34 40

Rated heat output kW 34 38

Output range kW 9.3 - 34 9.3 – 38

Electrical connection 230V / 50Hz / C16A

Power consumption in pellet mode W 41 - 72 41 - 73

Boiler weightincl. pellet unit

kg 1055 1075

Total boiler capacity (water) L 220 220

Water pressure drop (ΔT = 10 / 20 K)

mbar 37 / 8.2 341) / 13

Min. boiler return temperature °C 60

Max. permitted operating temperature °C 90

Permitted operating pressure bar 3

Boiler class as per EN 303-5:1999(pr EN 303-5:2012)

3 (5)

Permitted fuel as per EN 14961 Part 2: Wood pellets class A1 / D06

Airborne sound level dB(A) < 701.Water pressure drop at ΔT = 12K

Technology 3Technical specifications


TTest report data for pellet unit


34 40

Testing institute 2) 3) TÜV Austria1)

Test report no. 12-U-277/SD11-UW/Wels-EX-300

1.TÜV Austria Services GmbH, Geschäftsbereich Umweltschutz, Am Thalbach 15, A-4600 Thalheim/Wels2.As per EN 303-5, Section 5.1.3 type test: for a boiler from a range with a consistent structure it is sufficient, if the ratio of rated heat output

from the largest to the smallest boiler ≤ 2 : 1, to carry out the tests with the smallest and the largest boilers. The boiler manufacturer mustensure that all boilers, including those that have not been tested in the range, whose values have been determined depending on the ratedheat output by interpolation, fulfil the requirements of the norm.

3.Values for the type SP Dual 34 are interpolated between the SP Dual 28 and SP Dual 40 of test protocols 11-UW/Wels-EX-300/2 and 12-U-277/SD 11-UW/Wels-EX-300.

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

Carbon monoxide (CO) mg/MJ 7 / 13 8 / 13

Nitrogen oxide (NOx) mg/MJ 85 / 69 89 / 69

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

Dust mg/MJ 13 / 7 12 / 7

Boiler efficiency % 93.8 / 93 94 / 93

Test data in pellet mode - Emissions in [mg/m³]1) (Nominal load / partial load)

Carbon monoxide (CO) mg/m³ 10 / 19 12 / 19

Nitrogen oxide (NOx) mg/m³ 124 / 102 130 / 102

Organic hydrocarbons (OGC) mg/m³ <2 / <3 <2 / <3

Dust mg/m³ 19 / 10 18 / 10

Boiler efficiency % 93.8 / 93 94 / 931.Emissions values based on dry flue gas at standard temperature and pressure (0°C, 1013 mbar) with a volume content of oxygen of 13%

3 TechnologyTechnical specifications


44 Installation

4.1 TransportThe product is delivered on pallet(s) in cardboard packaging.

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❒ Pay attention to the pallet's centre of gravity when lifting

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

If the pellet unit cannot be brought in on the pallet:❒ Remove the cardboard packaging and take the pellet unit off the pallet

⇨ See "Removing the pellet unit from the pallet" [page 17]

4.3 Temporary storageIf the system is to be assembled at a later stage:❒ Store components at a protected location, which is dry and free from dust

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

4.4 Setting up in the boiler room

4.4.1 Removing the pellet unit from the palletThe component comes screwed to the pallet:❒ Remove the transport locks❒ Pull out floor insulation❒ Lift unit off pallet

Installation 4Transport


To lift using a crane:

❒ Unscrew the retaining screw beside the handle and open the cover of the pellet

unit

❒ Undo the screw connection of the gas spring on the cover❒ Unscrew the two screws on the hinge of the cover and remove the cover

❒ Remove the cover plate beside the control cover❒ Secure the crane hook to the crane eye below and lift the pellet unit

44 InstallationSetting up in the boiler room


44.4.2 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.

4.4.3 Minimum distances in the boiler room▪ The system should generally be set up so that it is accessible from all sides allow‐

ing 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)

Di‐men‐sion

Name Unit SP Dual 15-28 SP Dual 34-40

A Distance - insulated door to wall mm 800 800

B Distance – boiler side with heat ex‐changer lever and pellet unit to wall

600 700

B1 Distance – boiler side without pelletunit to wall

1030 1130

C Distance – back to wall 500 500

D Distance – boiler side to wall 200 200

E Space required for open cover 300 300

Installation 4Setting up in the boiler room


44.5 Preparing the firewood boilerBefore fitting the pellet unit, please assemble the S4 Turbo F in accordance with theassembly instructions provided. If the pellet unit is being retrofitted, prepare the fire‐wood boiler as follows:

❒ Push in the pre-cut cover of the air suction channel❒ Remove the cover plate of the flange

❒ Remove the blind plate❒ Screw in a lock bolt on the left and centre right

❒ Open the insulated door and combustion chamber door of the firewood boiler❒ Remove the middle linking plate on the flange side❒ Fit the linking plate provided to the flange cutout as shown

4 InstallationPreparing the firewood boiler


44.6 Fitting the pellet unit

4.6.1 Removing the cladding from the pellet unit

❒ Unscrew the retaining screw beside the handle and open the cover of the pellet

unit❒ Remove the bottom screw connections from the side cladding

❒ Remove the top screw connections from the side cladding❒ Tip the side cladding back and lift away

❒ Unhinge the fixing springs and remove the thermal insulation❒ Undo the screws from the back cover plate and remove the cover plate

Installation 4Fitting the pellet unit


❒ Undo the screws on the back cladding (2x top, 1x bottom) and remove the clad‐

ding

44.6.2 Screwing the pellet unit to the firewood boiler

❒ Take the flange seal out of the ash drawer❒ Place the seal on the pellet flange of the firewood boiler as shown

➥ Check that the seal is positioned correctly!

❒ Position the pellet unit at the firewood boiler so that the flange holes on the pellet

unit are aligned with the previously fitted lock bolts on the flange of the firewoodboiler

❒ Thread the pellet unit into the lock bolts and push towards the firewood boiler

4 InstallationFitting the pellet unit


The location holes on the pellet unit flange are different (front small play, back largeplay). This allows you to align the pellet unit with the boiler.❒ Adjust the height of the pellet unit using the adjustable feet so that the top edge of

the pellet unit is parallel with the edge on the insulating cover of the firewood boiler

❒ Screw the pre-assembled adjusting screws the whole way into the flange of the

pellet unit❒ Screw the pellet unit to the flange of the firewood boiler at the right and left

- 4x hexagonal screws M8 x 40- 4x spacer washers M8

❒ Once you have done this, check that the clearance between the firewood boiler in‐sulation and the pellet unit is consistent

IInstallation 4Fitting the pellet unit


If the firewood boiler and pellet unit are not parallel, you can adjust the gap using theadjusting screws (yellow galvanised steel): ❒ Loosen the adjusting screw on the side with the biggest clearance and tighten the

flanged connections❒ Repeat the process until the gap is consistent and retighten all screw connections

❒ Screw the base frame of the two units from the front and back

- 2x hexagonal screws M8 x 25- 2x spacer washers M8- 2x hexagonal nuts M8

44.6.3 Installing the WOS lever

❒ Remove the back insulating cover of the firewood boiler and loosen the lock nut on

the heat exchanger cover❒ Loosen the heat exchanger cover at the star-shaped screw knob and remove❒ Break off the pre-stamped cutout for the WOS lever and deburr any rough edges

with a half-round file



❒ Fit the brass bushing and counter nut to the WOS lever❒ Thread in the WOS lever and secure to the securing plate with brass bushing and

counter nut

❒ Lift the linking plate and WOS springs and thread in the WOS lever❒ Push the WOS lever all the way in and thread into the opposite side with the brass

bushing already fitted❒ Turn the WOS lever until the holes in the shaft and linking plate are aligned and

secure with pipe locking pin ❒ Then replace and secure the heat exchanger cover

IInstallation 4Fitting the pellet unit


44.6.4 Fitting the flow sensor and laying the cables

❒ Remove the flow sensor from the sleeve

➥ The flow sensor is packaged on the side of the pellet heat exchanger

❒ Fix the flow sensor with 2x self-tapping screws to the side plate of the firewood

boiler➥ The cutout is at the front of the pellet unit between the pellet heat exchanger

and inside panel

❒ Remove the screws from the back of the control casing❒ Push the control cover back and lift off



SSP Dual 15/22/28 wiring

❒ Run the cable of the pellet unit through the side cable duct of the firewood boiler

up into the control box➥ When laying the cables, ensure that they are not next to moving or hot parts!

❒ Connect the cables to the individual boards (cables indicated from left to right):- Pellet unit sensor 1 → “Sensor 1" connection on core module- Bus cable → free bus interface on hydraulic or return feed mixer module- Latch → “Latch" connection on core module- Power supply → mains supply clamping block

SP Dual 34/40 wiring

❒ Unscrew the retaining screws on the controller cover and remove the cover❒ Run the cables through the top cable duct to the control box of the firewood boiler

and connect to the boards (see "SP Dual 15/22/28 wiring") NOTICE! Observe additional information in the relevant boiler controller documenta‐tion!

Installation 4Fitting the pellet unit


44.7 Connecting the discharge system Once the discharge system has been assembled in accordance with the assembly in‐structions enclosed, the suction and return air line need to be connected to the pelletunit. On the back of the pellet unit:❒ Run the suction line to the left connection (pellet label)❒ Run the return-air line to the right connection

NOTICE! Ensure the potential equalisation matches the discharge system assemblyinstructions when connecting the hose lines!

4.8 Hydraulic connectionWhen retrofitting the pellet unit of the SP Dual, the return feed is connected to the pel‐let unit due to the different water flow. In such cases, you must remove the return lineon the S4 Turbo before connecting.

❒ Remove the protective cap from the pellet unit outfeed connection❒ Fit the screw connection to the outfeed connection as shown

❒ Fit the second screw connection to the firewood boiler's return feed connection❒ Fit the pipe union to the screw connections as shown

➥ Do not forget to fit the seals provided!

4 InstallationConnecting the discharge system


44.9 Electrical connection

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 unauthorisedpeople

❒ Flexible sheathed cable must be used for the wiring; this must be of the correct

size to comply with applicable regional standards and regulations.❒ Power is supplied to the system via the firewood boiler control

➥ For connection and fusing see corresponding documentation for firewood boiler

4.10 Positioning the boiler stickers correctly

The firewood boiler comes with the "S4 Turbo" sticker attached. It is only after the pel‐let unit is fitted that the entire system becomes the SP Dual.❒ Remove the "S4 Turbo" sticker from the insulated door and affix the "SP Dual"

sticker provided➥ Use the markings in the top left corner of the insulated door to align the new

sticker

Installation 4Electrical connection


55 Start-up

5.1 Before commissioning / configuring the boilerThe boiler must be adjusted to the heating system during commissioning.

NOTICE

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

Take the following precautions:❒ Initial startup should be carried out with an authorised installer or with Froling

customer services

❒ Adjust the boiler controller to the system type❒ Apply boiler standard values

NOTICE! The keypad assignment and the steps necessary to modify the parametersare detailed in the operating instructions for the boiler control unit.❒ Check the system pressure of the heating system❒ Check that the heating system is completely vented❒ Check that the safety devices are present and working correctly❒ 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 drives and actuators are working and turning in the right direction

NOTICE! For how to check the analogue and digital outputs, see the operating instruc‐tions for the boiler controller ❒ Check that the door contact switch is working correctly

NOTICE! For how to check the digital inputs see the operating instructions for the boil‐er controller.

5 Start-upBefore commissioning / configuring the boiler


55.1.1 Setting the "Max level and Min level” sensor

In delivery configuration, the factory settings of the sen‐sor are secured with a seal. Changes to the settingsshould only be carried out by qualified technicians.The monitoring LED should only light up when materi‐als are detected.❒ If the monitoring LED stays on permanently, the

sensitivity is set too high➥ Reduce the sensitivity by turning the adjusting

screw to the left❒ If the monitoring LED does not react when pellets

are being fed in, the sensitivity is set too low.➥ Increase the sensitivity of the adjusting screw

by turning to the right

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5.2 Initial startup

5.2.1 Permitted fuels

Wood pelletsWood pellets made from natural wood with a diameter of 6 mm

EU: Fuel acc. to EN 14961 - Part 2: Wood pellets class A1 / D06

Also: ENplus / DINplus certification scheme

General note:Before refilling the store, check for pellet dust and clean if necessary.

FirewoodFirewood 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 acc. to EN 14961 - Part 5: Firewood class A2 / D15 L50

Germanyalso: Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance

(BimSchV) in the last amended version)

Note on standards

Water content

Note on standards

Start-up 5Before commissioning / configuring the boiler


▪ Values in practice:- Hardwood: 2 years in dry storage- Soft wood: 1 year in dry storage

▪ Store stacks of split wood sheltered from the rain

▪ Create a dry underlay, where possible with air access (line with round timber, pallets,etc.)

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

▪ Walls of buildings facing the sun are ideal

▪ If possible, stock fuel for the day in a warm place (e.g. in boiler room) (pre-heats thefuel!)

NNOTICE! Use fuels that are consistent in size and water content.NOTICE! Burning extremely dry fuels (w < 15%) may require repairs by qualified staff.Please contact Froling customer services or your installer.

5.2.2 Heating up for the first timeFollow the relevant assembly instructions for the firewood boiler when heating up infirewood mode for the first time or when screed drying the combustion chamber.

NOTICE

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

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

Tips forstoring wood

5 Start-upInitial startup


66 Decommissioning

6.1 MothballingThe following measures should be taken if the boiler is to remain out of service forseveral 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 DisassemblyTo 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.❒ 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 6Mothballing


77 Appendix

7.1 Addresses

7.1.1 Address of manufacturer

FRÖLINGHeizkessel- und Behälterbau GesmbH Industriestaße 12A-4710 GrieskirchenAUSTRIA TEL 0043 (0)7248 606 0FAX 0043 (0) 7248 606 600INTERNET www.froeling com

7.1.2 Address of the installer

Stamp

7 AppendixAddresses


dual fuel boiler sp dual 15-40 - fge biomass · dual fuel boiler sp dual 15-40 ... 4.4 setting up...

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