Froling SP Dual Manuel utilisateur

Operating Instructions

Dual fuel boiler SP Dual (Touch)

Translation of the original German operating instructions for the operator

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

B0900113_en | Edition 18/09/2013

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 Pictograms used 6

2.3 General safety information 7

2.4 Permitted uses 8

2.4.1 The Clean Air Act 1993 and Smoke Control Areas 8

2.4.2 Permitted fuels 9

Firewood

Wood pellets

2.4.3 Fuels permitted under certain conditions 9

Wood briquettes

2.4.4 Non-permitted fuels 10

2.5 Qualification of operating staff 10

2.6 Protective equipment for operating staff 10

2.7 Design information 11

2.7.1 Installation and approval of the heating system 11

2.7.2 General information for installation room (boiler room) 11

2.7.3 Requirements for central heating water 12

2.7.4 Notes for using pressure maintenance systems 12

2.7.5 Return lift 13

2.7.6 Combination with storage tank 13

2.7.7 Chimney connection/chimney system 13

2.8 Safety Devices 14

2.9 Residual risks 15

2.10 Emergency procedure 17

2.10.1 Overheating of the system 17

2.10.2 Smell of flue gas 17

2.10.3 Fire in the system 17

3 Operating the system 18

3.1 Assembly and initial startup 18

3.2 Filling the pellet store 19

3.2.1 General advice for working in the store 19

3.3 Heating up the boiler 20

3.3.1 Switching on the power supply 20

3.3.2 Before heating up the boiler 20

Reloading intervals when operating with storage tank

Determining the right amount of fuel

Fuel table

Fill level in boiler

Reloading intervals when operating without storage tank or if the storage tank is too small

3.3.3 Heating the boiler with firewood 23

3.3.4 Reloading firewood 25

3.3.5 Boiler in combi mode 26

Switching on the boiler

How combi mode works

Contents

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

Switching off the boiler

3.3.6 Controlling the boiler 27

3.3.7 Switching off the power supply 27

4 Boiler Servicing 28

4.1 General information on servicing 28

4.2 Inspection and cleaning 29

4.2.1 Prior to heating up 29

Always move the WOS lever

4.2.2 Inspection 30

Checking the system pressure

Checking the thermal discharge safety device

Checking the safety valve

Checking the quick vent valve

4.2.3 Cleaning 31

Emptying ash

Cleaning the grating

Emptying the ash drawer of the pellet unit

4.2.4 Annual inspection 33

Cleaning the carbonisation gas duct

Checking the primary air openings

Cleaning the heat exchanger pipes

Checking the seal on the doors

Cleaning the flue gas temperature sensor

Clean the flue gas pipe

Checking the draught controller flap

Cleaning the induced draught fan

4.3 Emissions measurement by chimney sweep or regulatory body 38

4.3.1 Measuring at rated load in pellet mode 38

4.3.2 Measuring at rated load in firewood mode 38

4.3.3 Measuring at partial load in firewood mode (if required) 38

4.4 Maintenance agreement / Customer service 39

4.5 Replacement parts 39

4.6 Disposal information 39

4.6.1 Disposal of the ash 39

4.6.2 Disposal of system components 39

5 Troubleshooting 40

5.1 General fault with power supply 40

5.1.1 Behaviour of system after a power failure 40

5.2 Excessive temperature 40

5.3 Faults with fault message 41

5.3.1 Procedure for fault messages 41

5.3.2 Acknowledging a fault message 41

6 Appendix 42

6.1 Addresses 42

6.1.1 Address of manufacturer 42

6.1.2 Address of the installer 42

Contents

Operating Instructions SP Dual (Touch) | B0900113_en 3

1 General

Thank you for choosing a quality product from Fröling. 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 the

system for reference. Observing the requirements and safety information in the docu‐

mentation makes a significant contribution to safe, appropriate, environmentally friend‐

ly and economical operation of the system.

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].

Subject to technical change.

Guarantee conditions

Our sale and delivery conditions generally apply. These conditions have been made

available to customers, and customers have been made aware of them at the time of

order completion.

You can also find the guarantee conditions on the enclosed guarantee 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

Operating Instructions SP Dual (Touch) | B0900113_en 5

2.2 Pictograms used

The following symbols are used in the documentation and/or on the boiler to show

what is required and forbidden and to give warnings.

In accordance with the Machinery Directive, signs fitted directly within the danger area

of the boiler indicate immediate hazards or safety procedures. These stickers must not

be removed or covered.

Refer to the operating instruc‐

tions

Wear safety shoes

Wear protective gloves Turn off the main switch

Keep the doors closed Wear a dust mask

Work under the supervision of a

second person

Lock

Unauthorised access prohibited No fire, open flames or smoking

Warning - hot surface Warning - hazardous electrical

voltage

Warning - hazardous or irritant

materials

Warning - automatic boiler start‐

Warning of injury to fingers or

hands, automatic fan

Warning of injury to fingers or

hands, automatic screw

Warning of injury to fingers or

hands, gear/chain drive

Warning of injury to fingers or

hands, cutting edge

Hand injury warning Warning of injury from being

pulled into rotating shafts

Increased CO concentration

warning

Slipping hazard warning

2Safety

Pictograms used

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

2.3 General safety information

DANGER

If the device is used incorrectly:

Incorrect use of the system can cause severe injury and damage.

When operating the system:

❒ Observe the instructions and information in the manuals

❒ Observe the details on procedures for operation, maintenance and cleaning,

as well as troubleshooting in the individual manuals.

❒ Any work above and beyond this should be carried out by authorised heating

engineers or by Froling customer services.

WARNING

External influences:

Negative external influences, such as insufficient combustion air or non-standard

fuel, can cause serious faults in combustion (e.g. spontaneous combustion of car‐

bonisation gases or flash fires) which can in turn cause serious accidents!

When operating the boiler, please note the following:

❒ Instructions and information regarding versions and minimum values, as well

as standards and guidelines for heating components in the instructions must

be observed.

WARNING

Severe injuries and damage can be caused by an inadequate flue gas system.

Problems with the flue gas system, such as poor cleaning of the flue pipe or insuf‐

ficient chimney draught, can cause serious faults in combustion (such as sponta‐

neous combustion of carbonisation gases or flash fires).

Take the following precautions:

❒ Optimum boiler performance can only be guaranteed if the flue gas system is

functioning correctly.

Safety 2

General safety information

Operating Instructions SP Dual (Touch) | B0900113_en 7

2.4 Permitted uses

The Froling Dual fuel boiler SP Dual is designed solely for heating domestic water.

Only use fuels specified in the "Permitted fuels" section.

⇨ See "Permitted fuels" [page 9]

The unit should only be operated when it is in full working order. It should be operated

in accordance with the instructions, observing safety precautions, and you should en‐

sure you are aware of the potential hazards. The inspection and cleaning intervals in

the operating instructions should be observed. Ensure that any faults which might im‐

pair safety are rectified immediately.

The manufacturer or supplier is not liable for any damage resulting from non-permitted

uses.

2.4.1 The Clean Air Act 1993 and Smoke Control Areas

Under the Clean Air Act local authorities may declare the whole or part of the district of

the authority to be a smoke control area. It is an offence to emit smoke from a chim‐

ney of a building, from a furnance or from any fixed boiler if located in a designated

smoke control area. It is also an offence to acquire an „unauthorised fuel“ for use with‐

in a smoke control area unless it is used in an „exempt“appliance („exempted“ from

the controls which generally apply in the smoke control area). The Secretary of State

for Environment, Food and Rural Affairs has powers under the Act to authorise

smokeless fuels or exempt appliances for use in smoke control areas in England. In

Scotland and Wales this power rests with Ministers in the devolved administrations for

those countries. Separate legislation, the Clean Air (Northern Ireland) Order 1981, ap‐

plies in Northern Ireland. Therefore it is a requirement that fuels burnt or obtained for

use in smoke control areas have been „authorised“ in Regluations and that appliances

used to burn solid fuel in those areas (other than „authorised“ fuels) have been ex‐

empted by an Order made and signed by the Secretary of State or Minister in the de‐

volved administrations.

Further information on the requirements of the Clean Air Act can be found here: http://

smokecontrol.defra.gov.uk

Your local authority is responsible for implementing the Clean Air Act 1993 including

designation and supervision of smoke control areas and you can contact them for de‐

tails of Clean Air Act requirements.

The Froling SP Dual 15, SP Dual 22, SP Dual 28, SP Dual 34 and SP Dual 40 have

been recommended as suitable for use in smoke control areas when burning fuels as

listed under "Permitted fuels".

2Safety

Permitted uses

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

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

Germany

also:

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

(BimSchV) in the last amended version)

▪ 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 instead

of 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 the

fuel!)

NOTICE! 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.

Wood pellets

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

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

and/or: Certification program EN

plus

or DIN

plus

General note:

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

2.4.3 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.

Water content

Note on standards

Tips for

storing wood

Note on standards

Safety 2

Permitted uses

Operating Instructions SP Dual (Touch) | B0900113_en 9

EU: Fuel acc. to 14961 - 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) in the last amended version)

▪ When burning wood briquettes use the settings for extremely dry fuel

▪Wood briquettes must be heated up with firewood as per EN 14961-5

(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 combus‐

tion problems. In such cases, repairs must be carried out by qualified staff. Please con‐

tact Froling customer services or your installer.

2.4.4 Non-permitted fuels

The use of fuels not defined in the "Permitted fuels" section, and particularly the burn‐

ing 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

2.5 Qualification of operating staff

CAUTION

If unauthorised persons enter the installation room:

Risk of personal injury and damage to property

❒ The operator is responsible for keeping unauthorised persons, in particular

children, away from the system.

Only trained operators are permitted to operate the unit. The operator must also have

read and understood the instructions in the documentation.

2.6 Protective equipment for operating staff

You must ensure that staff have the protective equipment specified by accident pre‐

vention regulations.

Note on standards

Notes on

use

2Safety

Permitted uses

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

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