Fröling FBR-G Installation And Operating Instructions Manual Download Page 1

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Installation and Operating Instructions

FBR-G / TGR-G

with separate rotary agitator drive and discharge screw

Translation of the original German operating and installation instructions for technicians and operators

Read and follow the instructions and safety information!

Technical changes, typographical errors and omissions reserved!

M1730116_en | Edition 29/02/2016

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

Summary of Contents for FBR-G

Page 1: ...tion of the original German operating and installation instructions for technicians and operators Read and follow the instructions and safety information Technical changes typographical errors and omissions reserved M1730116_en Edition 29 02 2016 Froling GesmbH A 4710 Grieskirchen Industriestraße 12 www froeling com ...

Page 2: ...cations 16 4 Installation 17 4 1 Transport and handling 17 4 1 1 Temporary storage 17 4 2 Installation site 17 4 2 1 Information about setup 18 4 2 2 Wall opening 21 4 3 Installing the discharge system 22 4 3 1 Materials supplied with discharge screw 22 4 3 2 Materials supplied with FBR 22 4 3 3 Materials supplied with TGR 23 4 3 4 Materials supplied with rotary agitator 23 4 3 5 Installing the di...

Page 3: ...ary agitator 37 5 3 3 Blowing in fuel for a partially emptied store with rotary agitator 38 5 3 4 Blowing in fuel for an empty store with rotary agitator 39 5 4 During operation 40 5 5 Decommissioning 40 5 5 1 Disassembly 40 5 5 2 Disposal 40 6 Servicing 41 6 1 Maintenance schedule 41 6 2 Maintenance contract 42 7 Troubleshooting 43 7 1 Procedure for fault messages 43 Table of contents Installatio...

Page 4: ... 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 This is an incomplete machine as defined by the Machinery Directive The incomplete machine must only be started up when it has been confirmed that the machine in which the incomplete machine has been installed conforms to the provision...

Page 5: ...e during system operation due to the smaller diameter If fuel is requested using the boiler controller the system starts and the material is loosened by the pre tensioned rotary agitator arms and fed to the trough of the discharge screw The discharge screw feeds the material to the transfer position where it falls through the burn back protection system burn back flap rotary valve into the stoker ...

Page 6: ...t 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 2 Safety Hazard levels of warnings 6 Froling GesmbH A 4710 Gri...

Page 7: ...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 respective manuals Any work above and beyond this e g servicing must be carried out by a heating engineer approved by Fröling Heizkessel und Behälterbau GesmbH or by Froling customer ser...

Page 8: ...w 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 2 Personal protective equipment for assembly staf...

Page 9: ...ling safety equipment is prohibited Always comply with all fire building and electrical regulations when installing and operating the system in addition to following the assembly and operating instructions and mandatory regulations that apply in the country of use 2 4 1 Standards The system must be installed and commissioned in accordance with the local fire and building regulations The following ...

Page 10: ... loaded components These must be secured during work There is a risk of carbon monoxide poisoning in the pellet stores Adequately ventilate the store before entering at least 15 mins Only enter the store under the supervision of a second person While in the store keep the door open and use a dust mask There is a risk of collapse and being buried alive as a result of cavity formation in the store T...

Page 11: ... discharge and infeed devices preventing fire from spreading to the fuel store Depending on the design of the system a burn back flap or a rotary valve is fitted Rotary valve Water Sprinkler System Self activating extinguisher system to limit burn back around the top of the gravity shaft If the temperature in the top of the gravity shaft rises above 95 C the valve of the sprinkler system opens wat...

Page 12: ... is no power Earth and short circuit Cover any adjacent live parts and limit area of risk DANGER When working on rotary agitator arms Serious injuries possible from pre tensioned rotary agitator arms When working on the rotary agitator arms you must therefore Loosen the tension in the rotary agitator arms or secure them so they cannot spring back in an uncontrolled way before dismantling them CAUT...

Page 13: ...ge to equipment may occur If the structural layout means that the rotary agitator arms come into contact with the silo wall The rotary agitator arms can dislodge pieces of plaster Pieces of wall or plaster that have broken off can block the discharge system or disrupt the material feed into the boiler causing a system failure If this happens Fit an approx 300 mm high covering made of sheet metal o...

Page 14: ...Height of rotary agitator duct 80 mm L1 Length of rotary agitator duct See Store sizes page 15 L2 Length of geared motor 410 mm L3 Length of open trough See Store sizes page 15 L4 Length of transfer channel 600 mm L5 Length of closed trough Varies available in lengths from 100mm L6 Length of gravity shaft top geared motor 590 mm 600 mm 750 mm L7 Length of screw Determined during planning of the st...

Page 15: ...l diameter mm 2000 2500 3000 3500 4000 4500 5000 Spring blade diameter D 1 mm 2400 2950 3450 4000 4500 5050 5600 Length of rotary agitator duct L1 mm 2150 2400 2650 2900 3150 3400 3650 Length of open trough L3 mm with screw Ø 110 795 1295 1295 1545 1795 2045 2295 with screw Ø 150 200 1295 1795 1795 2045 2295 with long screws 1545 2045 2545 3045 3545 4045 4545 1 The spring blades have a certain exc...

Page 16: ...otor power supply 400 VAC 50 Hz Geared motor output 0 37 kW 0 55 kW 0 37 kW 0 75 kW 1 1 kW Gear output speed 4 5 rpm 10 5 rpm 4 5 rpm 10 5 rpm 10 5 rpm Safety switch 24 VDC Description T4 24 75 T4 90 110 TM 150 320 TX 150 250 TI 350 T4 130 150 TM 400 500 Diameter of screw 110 mm 150 mm Geared motor power supply 400 VAC 50 Hz Geared motor output 0 37 kW 0 55 kW 0 37 kW 0 37 kW 0 75 kW Gear output s...

Page 17: ...lowing design information Store detail Design information 1 Walls and ceilings The walls and ceilings of the store and the boiler room must be fire proof REI 90 in compliance with local regulations 2 Hole in wall Do not fix or cement the transfer trough and rotary agitator duct to the brickwork as this can create a bridge transferring all mechanical noise and vibrations to the brickwork For this r...

Page 18: ...ffect the heating value For this reason we recommend that the customer installs a raised floor The construction should be dimensioned so that the raised floor is not deformed under the static load of the fuel The raised floor must also be self supporting and it should not be supported by the screw channel 4 2 1 Information about setup The rotary agitator duct should be fitted in the centre of the ...

Page 19: ...Ø900mm 0mm Distance between top edge of trough of discharge screw and bottom edge of articulated arms min 50 mm max 90 mm 1 Distance between top edge of trough of discharge screw and bottom edge of spring blades min 30 mm max 50 mm 2 NOTICE Intermediate plate and top edge of trough of discharge screw should be on the same level 3 NOTICE The rotary agitator duct and top edge of trough of discharge ...

Page 20: ... an FBR accordingly NOTICE If using pellets it is preferable to use a long discharge screw s 1x standard discharge screw right 1x standard discharge screw left 1x long discharge screw right 1x long discharge screw left 2x standard discharge screws 2x long discharge screws 1x standard discharge screw and 1x long discharge screw 4 Installation Installation site 20 Froling GesmbH A 4710 Grieskirchen ...

Page 21: ...t an opening of 500 mm x 500 mm is sufficient NOTICE Do not fix the trough to the wall NOTICE Line the hole in the wall with a flexible material See Seal the hole in the wall page 33 Rotary agitator duct α 200mm 270mm The dimensions of the hole depend on the system s angle of inclination α Therefore Round hole Ø min 250 mm max 270 mm Square hole Side length min 200 mm max 270 mm NOTICE Do not fix ...

Page 22: ...er tube torque support D3 Trough cover pellets optional K Support element boiler room optional E Raising plate for discharge without raised floor L1 Adjustable feet 808 mm 4x F Flange plate bearing end friction bearing friction bearing support L2 Adjustable feet 1108mm optional G1 Screw Ø 110 two part L3 Adjustable feet 185mm optional 4 3 2 Materials supplied with FBR L 2x spring piles N Rotary ag...

Page 23: ...shortened for horizontal installation optional B Drive shaft G3 Extension for gear supports optional C Flange plate H Torque support spacer tube D Counter bearing for torque support flange bearing I Geared motor E Mitre gear J Intermediate plate F Adjustable feet K Cover for hole in wall G1 Gear supports Installation 4 Installing the discharge system Installation and Operating Instructions M173011...

Page 24: ...g support to flange Grease bearing end with copper paste Fit trough cover for wood chips D1 standard OR wide trough cover for wood chips D2 optional OR trough cover for pellets D2 optional Where required fit raising plate E for discharge without raised floor Fit 2x adjustable feet each at start and end of open trough Adjust height as required Use shortened adjustable feet for horizontal installati...

Page 25: ...ecuring the adjustable feet and support elements page 32 Lubricate shaft stub with copper paste Where required stick together two part screw and fix with sleeve only for screw Ø110 Slide screw into trough as far as bearing unit Prepare the geared motor Remove the transport lock Fit the vent screw supplied to the highest point Installation 4 Installing the discharge system Installation and Operatin...

Page 26: ... onto shaft stub Thread torque support into counter bearing Ensure groove in shaft stub is aligned with groove in geared motor Slide key into groove and fit shaft retainer Fit safety switch elbow and thermal discharge valve to top of gravity shaft H2 Slide top of gravity shaft over screw and fit to closed trough with seal Discharge screw 110 Discharge screw 110 Discharge screw 150 200 4 Installati...

Page 27: ...bove for reasons of space it is possible to turn the drive unit Fit the counter plate of the torque support to the opposite side Turn the geared motor and torque support 180 and fit to the shaft and counter plate as explained above Remove screws from trough cover as appropriate Fit bracket of support element to closed trough with screws previously removed Fit support element to bracket and secure ...

Page 28: ...ive shaft and bearing shaft of mitre gear with copper paste Fit flange plate C counter flange for torque support and flange bearing D to rotary agitator duct Fit mitre gear E to flange of rotary agitator duct Thread bearing shaft of mitre gear correctly into drive shaft Prepare the geared motor Remove the transport lock Fit the vent screw supplied to the highest point 4 Installation Installing the...

Page 29: ...shaft stub Thread torque support into counter bearing Ensure groove in shaft stub is aligned with groove in geared motor Slide key into groove and fit shaft retainer Align rotary agitator in store as per installation diagram The rotary agitator duct should be fitted in the centre of the store at an angle of 90 to the wall Secure gear supports and adjustable feet to floor See Securing the adjustabl...

Page 30: ... for hole in wall K on boiler room side Pre drill holes in wall FBR 110 200 Fit spring piles L with clamping plates M to ring of rotary agitator plate N The bend in the clamping plates must face away from the rotary agitator plate Tighten the left and right screw connections alternately by 2 3 turns each until the spring pile is right next to the ring of the rotary agitator plate Fit cover plates ...

Page 31: ...rallel to the effective area of the rotary agitator Note the distance between the top edge of the trough and the bottom edge of the articulated arms spring blades See Information about setup page 18 Intermediate plate and top edge of trough of discharge screw should be on the same level See Information about setup page 18 If necessary correct the height of the adjustable feet accordingly Installat...

Page 32: ...The joints are fitted with torsion springs for setting the spring pre tension The table below shows the basic settings depending on the rotary agitator diameter Torsion arm agitator TGR 3 5 TGR 4 0 TGR 4 5 TGR 5 0 TGR 5 5 TGR 6 0 Rotary agitator diameter mm 3500 4000 4500 5000 5500 6000 Segments per arm 2 2 2 3 3 3 Spring pre tension Level Pre tension joint 1 B B B B B B Pre tension joint 2 A A A ...

Page 33: ...e space in the wall penetration with a non flammable insulating material The partition must be insulated to conform with ÖNORM B 3836 or DIN 4102 11 Close the wall penetration on the store side and the boiler room side with a non flammable covering NOTICE Do not connect the transfer channel rotary agitator duct to the brickwork with concrete as this will transfer sound through all the brickwork In...

Page 34: ...o control cabinet Lay the cables so that nobody will trip over them Do not lay the cable over or around sharp edges Wire the connections according to the wiring diagram 4 4 2 Connecting the sprinkler system Connection should only be carried out by authorised technicians When connecting the sprinkler system please also note Put a stopcock and bolted joint in front of the thermal discharge safety de...

Page 35: ...list staff and the default factory settings are observed Therefore Initial startup should be carried out with an installer approved by Fröling Heizkessel und Behälterbau GesmbH or with Froling customer services Before commissioning or before the first filling carry out the following checks Check the direction of rotation of the screw Check the direction of rotation of the rotary agitator arms Chec...

Page 36: ...stem Depending on the model via boiler expansion switch cabinet etc For blowing in fuel the following precautions also apply CAUTION Blowing in fuel when the boiler is switched on The underpressure generated from blowing in fuel can lead to smoke being sucked back into the store if the boiler is switched on Possible excess pressure could cause smoke to escape into the installation room possibly re...

Page 37: ... the rotary agitator arms spring blades are fully extended If the rotary agitator arms spring blades are covered in this position with a large amount of fuel the weight of the fuel will stop them from working properly Therefore when filling an empty store space or when the rotary agitator arms are extended First of all place a small amount of fuel approx 2 3 m on and around the head of the rotary ...

Page 38: ...ch on the power supply to the entire system Depending on the model of system via boiler expansion switch cabinet etc Tap On in Bunker filling rotary agitator during manual operation The rotary agitator head runs for approx 3 minutes Wait until the rotary agitator arms spring blades are touching the head of the rotary agitator approx 2 revolutions Add the rest of the fuel 5 3 3 Blowing in fuel for ...

Page 39: ...head of the rotary agitator Only add the rest of the fuel once the rotary agitator arms are back on the head of the rotary agitator It is important you follow the procedure given below Switch off the power supply to the entire system Depending on the model via boiler expansion switch cabinet etc Pile up residual fuel in the corners and on the walls in the fuel store on and around the head of the r...

Page 40: ...uching the head of the rotary agitator approx 2 revolutions Close all openings to the store to seal out dust Add the rest of the fuel 5 4 During operation The boiler is controlled by the boiler controller The discharge system switches on and off automatically when material is requested NOTICE When transporting wood chips or pellets using the feed screw there may be noise depending on the function ...

Page 41: ...out a general visual inspection of drive motors No major oil leaks should be visible 2 Gravity shaft safety switch M Function test of the safety switch Open the inspection cover of the gravity shaft The system should switch off immediately Check the inlet area for material build up and clean where necessary Close gravity shaft cover Check fault message on the controller Servicing 6 Maintenance sch...

Page 42: ... if necessary Replace broken screws immediately Check that the connections of the spring piles have a little play approx 1mm Tighten or loosen the screws if necessary 9 Clamping plates of spring piles Check that the screws of the clamping plate are firmly in position and tighten if necessary 10 Rotary agitator arms General visual inspection of the rotary agitator arms and screw joints for damage 1...

Page 43: ...so appear Pressing the Cancel icon takes you back to the basic display If the quick select icon and the warning triangle flash alternately there is still a fault The Error display button will now appear in the quick menu 7 1 Procedure for fault messages When a fault occurs a window with the corresponding fault text will appear The right arrow will take you to possible causes of the fault Tapping S...

Page 44: ... 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 8 1 2 Address of the installer Stamp 8 Appendix Addresses 44 Froling GesmbH A 4710 Grieskirchen Industriestraße 12 www froeling com ...

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