Froling SP Dual 15-40 Manuel utilisateur

Installation Instructions

Dual fuel boiler SP Dual 15-40

Translation of the original German operating instructions for technicians

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

M1300517_en | Edition 28/03/2017

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

Contents

1 General 4

2 Safety 5

2.1 Hazard levels of warnings 5

2.2 Qualification of assembly staff 6

2.3 Personal protective equipment for assembly staff 6

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) 8

2.4.4 Requirements for central heating water 9

2.4.5 Notes for using pressure maintenance systems 10

2.4.6 Return lift 11

2.4.7 Combination with storage tank 12

2.4.8 Chimney connection/chimney system 13

Draught limiter

Measuring port

Boiler data for planning the flue gas system

3 Technology 15

3.1 Dimensions 15

3.2 Technical specifications 16

3.2.1 SP Dual 15/22/28 16

3.2.2 SP Dual 34/40 18

4 Installation 20

4.1 Assembly overview 20

4.2 Materials supplied 21

4.3 Transport 21

4.4 Positioning 22

4.5 Temporary storage 22

4.6 Setting up in the boiler room 22

4.6.1 Removing the pellet unit from the pallet 22

4.6.2 Moving the boiler in the boiler room 24

4.6.3 Recommended clearances in the boiler room 24

4.7 Preparing the firewood boiler 25

4.8 Fitting the bracket with drive (optional) 26

4.9 Fitting the pellet unit 27

4.9.1 Removing the cladding from the pellet unit 27

4.9.2 Screwing the pellet unit to the firewood boiler 29

4.9.3 Installing the WOS lever 32

4.9.4 Fitting the shaft of the WOS drive (optional) 33

4.9.5 Fitting the flow sensor and laying the cables 35

Contents

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4.9.6 Fitting the cladding to the pellet unit 38

4.10 Connecting the discharge system 40

4.11 Hydraulic connection 40

4.12 Electrical connection 41

4.13 Positioning the boiler stickers correctly 41

5 Start-up 42

5.1 Before commissioning / configuring the boiler 42

5.2 Initial startup 43

5.2.1 Permitted fuels 43

Wood pellets

Firewood

5.2.2 Fuels permitted under certain conditions 44

Wood briquettes

5.2.3 Non-permitted fuels 45

5.2.4 Heating up for the first time 45

6 Decommissioning 46

6.1 Mothballing 46

6.2 Disassembly 46

6.3 Disposal 46

7 Appendix 47

7.1 Addresses 47

7.1.1 Address of manufacturer 47

7.1.2 Address of the installer 47

Contents

Installation Instructions SP Dual 15-40 | M1300517_en 3

1 General

Thank 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

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: [email protected].

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

1General

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

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 2

Hazard levels of warnings

Installation Instructions SP Dual 15-40 | M1300517_en 5

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)

2Safety

Qualification of assembly staff

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

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

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

ÖNORM M 7137 Compressed untreated wood – Requirements for storing pellets

at 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 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.

Safety 2

Design Information

Installation Instructions SP Dual 15-40 | M1300517_en 7

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 17225-2 Solid bio-fuel - Fuel specifications and classes

Part 2: Wood pellets for use in industrial and domestic systems

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.

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.

Note on standards

2Safety

Design Information

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▪ 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

TRVB H118 - Technical directives on fire protection/prevention

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

Note on standards

Safety 2

Design Information

Installation Instructions SP Dual 15-40 | M1300517_en 9

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

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 pressure-

maintenance 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

2Safety

Design Information

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

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