Fröling GAR 110 Installation And Operating Instructions Manual Download Page 46

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7 Troubleshooting

There are two main types of fault: internal and external to the boiler.

External faults:

❒

Heating EMERGENCY OFF switch activated

❒

Household fuse (FI circuit breaker) or component fuse blown

Internal faults are shown in the form of error messages on the boiler controller:

7.1 Error message list

Error message

Possible cause

Error resolution

Discharge empty

(level sensor!)

❒

No fuel in the container

❒

Motor defective

❒

Bridge formation in the gravity
shaft

❒

Check the store and refill with fuel if necessary

❒

Check the motor and wiring for damage

❒

Open the inspection cover and check the gravity shaft
for material build-up

Gravity shaft

cover

is open!

❒

Gravity shaft opened manually

❒

Position switch defective

❒

Bridge formation in the gravity
shaft

❒

Wood chips too large for gravity
shaft

❒

Close gravity shaft cover

❒

Check the position switch and wiring for damage

❒

Open the inspection cover and check the gravity shaft
for material build-up

Gravity shaft

empty

(level sensor!)

❒

No fuel in the container

❒

Motor defective

❒

Bridge formation in the gravity
shaft

❒

Discharge screw blocked

❒

Check the store and refill with fuel if necessary

❒

Check the motor and wiring for damage

❒

Open the inspection cover and check the gravity shaft
for material build-up

❒

Free the screw

Gravity shaft does

not fill

❒

Discharge screw blocked

❒

Move the discharge screw backwards and forwards
briefly a few times in test mode/manual mode

If the error message does not disappear:

❒

Check the discharge screw for blockages and free if
necessary

Gravity shaft full

Motor prot.

disch conv!

Motor prot.

fault feed conv.

❒

Feed screw blocked

❒

Move the feed screw backwards and forwards briefly a
few times in test mode/manual mode

If the error message does not disappear:

❒

Check the screw for blockages and free if necessary

Freq. o/current

disch conv.

❒

Revised too often on blockage

❒

Free the discharge screw and clear blockage (foreign
body)

Motor protection

rotary agitator

❒

Blockage of the rotary agitator
head

❒

Change pre-run/run-on time

❒

Bunker full - / bunker empty – check circuit

Frequent

overcurrent rotary

agitator

❒

Check circuit

❒

Change pre-run/run-on time

❒

Bunker full - / bunker empty – check circuit

Troubleshooting

Error message list

Fröling Ges.m.b.H. | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Summary of Contents for GAR 110

Page 1: ...iginal German operating and installation instructions for technicians and operators Read and follow the instructions and safety information Technical changes typographical errors and omissions reserved M2060120_en Edition 06 11 2020 Fröling Ges m b H A 4710 Grieskirchen Industriestraße 12 www froeling com ...

Page 2: ...1 Transport and handling 17 4 1 1 Temporary storage 17 4 2 Installation site 17 4 2 1 Wall penetration 18 4 3 Assembling the articulated arm rotary agitator 19 4 3 1 Materials supplied 19 4 3 2 Assembling the gears and feeder trough 20 4 3 3 Mounting the fibre shredder optional 26 4 3 4 Fitting the upper part of gravity shaft and drive unit 27 Assembly with screw Ø110 27 Assembly with screw Ø150 2...

Page 3: ...mpty store with rotary agitator 38 Rotary agitator with combined drive system 39 5 4 During operation 40 5 5 Decommissioning 40 5 5 1 Disassembly 40 5 5 2 Disposal 40 6 Servicing the system 41 6 1 Maintenance work by the operator 42 6 2 Maintenance work by technicians 44 6 3 Replacement parts 45 7 Troubleshooting 46 7 1 Error message list 46 8 Notes 47 9 Appendix 48 9 1 Addresses 48 9 1 1 Address ...

Page 4: ...eans 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 provisions ...

Page 5: ...haft cover and water sprinkler system 13 Geared motor When the store is full the rotary agitator arms are positioned at the rotary agitator plate reducing resistance 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...

Page 6: ...ow 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 NOTICE The dangerous situation may occur and if measures are not observed it will lead to damage to property or pollution 2 Safety Hazar...

Page 7: ... invalidate the manufacturer s conformity with the applicable guideline s In such cases the product will need to undergo new hazard evaluation procedures by the operator The operator will then be fully responsible for the declaration of conformity according to the valid guideline s for the product and will need to issue a corresponding declaration for the device This person will then assume all of...

Page 8: ...16S P31S M35 Additional for Germany Fuel class 4 3 of the First Federal Emissions Protection Ordinance BimSchV in the last amended version Wood pellets Wood pellets made from natural wood with a diameter of 6 mm EU Fuel acc to EN ISO 17225 Part 2 Wood pellets class A1 D06 and or ENplus DINplus certification scheme General note Before refilling the store check for pellet dust and clean if necessary...

Page 9: ...tructions in the documentation 2 3 2 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 3 3 Qualification of operating staff CAUTION If unauthorised persons enter the Storeroom Risk of ...

Page 10: ...tory 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 standards and regulations should be observed in any case ÖNORM DIN EN 60204 Safety of machines Electrical equipment of machines Part 1 General requirements TRVB H 118 Technical directives for fire protection prevent...

Page 11: ...ring 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 sto...

Page 12: ...connects the 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 syst...

Page 13: ... the rotary agitator arms or secure them so they cannot spring back in an uncontrolled way before dismantling them NOTICE If the rotary agitator arms touch the silo wall Damage 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...

Page 14: ...ecautions The discharge system must be switched on during filling See Filling the store with fuel page 35 CAUTION If unauthorised fuel types are used Non standard fuels can cause stiffness and block the system resulting in the failure breakage of components Therefore Only use fuels specified in the Permitted uses section of these operating instructions 2 Safety Residual risks 14 Fröling Ges m b H ...

Page 15: ...h channel 140 mm 200 mm α Gradient angle 0 10 wood chips 0 3 pellets NOTICE Operating the discharge system with a gradient angle 10 The mitre gear can break due to insufficient lubrication When installing the discharge system you should therefore ensure When operating with wood chips do not exceed a gradient angle α of 10 When operating with pellets do not exceed a gradient angle α of 3 The rotary...

Page 16: ... 3500 4000 4500 5000 5500 6000 Length of spring blades L4 mm 605 875 1145 1415 1685 1955 Open trough L1 mm 1545 1795 2045 2295 2545 2795 1 The rotary agitator arms have a certain excess to ensure optimum use of the fuel store A D L 4 The nominal diameter of the discharge must be selected according to the lateral length A of the space that runs parallel to the discharge screw The discharge must be ...

Page 17: ...n the motor 4 2 Installation site When planning the fuel store you should observe the following design information 1 2 3 4 5 6 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 ...

Page 18: ... the wall and plaster from breaking off and blocking the discharge system 6 Raised floor This prevents material from remaining below the rotary agitator arms This material would decay and this could affect 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 ...

Page 19: ...for horizontal installation 6 Trough cover wood chips standard 16 Gear supports 7 Trough cover pellets optional 16a Shorter gear supports optional for horizontal installation 8 Raising plate for discharge without raised floor 17 Extensions for gear supports optional 9 Trough open store side 18 Bracket with mitre gear 10 Transfer channel hole in wall 19 Accessories kit 11 Trough closed boiler room ...

Page 20: ...f the flange plates Fit bracket with mitre gear to open trough Fit the gear supports to the mitre gear as shown Observe the assembly height in the installation diagram Do not fully tighten the screws yet Place intermediate plate over bracket with mitre gear and secure it to the flange of the open trough 4 Assembly Assembling the articulated arm rotary agitator 20 Fröling Ges m b H A 4710 Grieskirc...

Page 21: ...7 mm Ø 15mm Fit adjustable feet on both sides of the open trough Secure the adjustable feet to the floor Make a hole in the floor for the adjustable feet Drill the holes marked Drill diameter 15 mm Drill depth at least 105 mm Insert the heavy duty anchors into the bore holes and tighten with a spanner SW 17 mm Shorten the adjustable feet using an angle grinder so that the rotary agitator arms are ...

Page 22: ...open trough as follows Pellet cover plate A For pellet version Wood chips cover plate B For wood chips version Raising plate C When no raised floor is used Grease the multi tooth shaft of the mitre gear with copper paste Place the rotary agitator head on the multi tooth Use mounted eye bolts for this purpose NOTICE The rear end of the cover plate rests on the cutting edge D of the open trough D 4 ...

Page 23: ...wing steps for both articulated arms in the same way A Remove the fitting screws A on the top of the housing and fold out the articulated arms completely Fix the tension springs with previously removed fitting screws A B C Fully tighten nut B on the inner joint and lock with second nut C Assembly 4 Assembling the articulated arm rotary agitator Installation and Operating Instructions GAR 110 150 M...

Page 24: ... the stop Lock screw connection with second nut E Check the screws on the joints for tightness Max tightening torques 300 Nm Re install cover of basic module and rotary disc on basic module 4 Assembly Assembling the articulated arm rotary agitator 24 Fröling Ges m b H A 4710 Grieskirchen Industriestraße 12 www froeling com ...

Page 25: ...ip of the tearing hook C points in the direction of rotation of the rotary agitator CAUTION Screw connections of the spring blades D should have about 1 mm of play so they should not be fully tightened Depending on the size of the fuel store the number of parts required as well as the length of the spring piles varies Fit spring blades with clamping plates A to the rotary agitator arms Hook B must...

Page 26: ...ter plate B from the screw shaft 542 GEWINDEDICHTUNG Position the clamping jaw C on the screw shaft pushing the spring pin D into the hole Fix the clamping jaw C and cutting jaw E to the screw shaft with screws Secure screws against loosening with Loctite Fröling Art No 50378 4 Assembly Assembling the articulated arm rotary agitator 26 Fröling Ges m b H A 4710 Grieskirchen Industriestraße 12 www f...

Page 27: ...ge bearing C onto the screw end and secure to top part of gravity shaft Push the spacer ring D onto the screw end Insert key A into nut on screw end Secure torque support with pin B to top part of gravity shaft The pin and screw end must be at the same height Centre distance of pin and screw end 150 mm Secure torque support with bearing C to the geared motor as illustrated Flange Ball Assembly 4 A...

Page 28: ...e torque support with pin on the opposite side Turn the geared motor and torque support 180 and fit to the screw end and torque support as explained above Assembly with screw Ø150 Secure top part of gravity shaft A with seal B to the closed trough on the boiler room side Secure flange plate C with seal D to top part of gravity shaft 4 Assembly Assembling the articulated arm rotary agitator 28 Fröl...

Page 29: ...shaft stub incl key with copper paste Push the geared motor B onto the screw end Secure locking washer C with hexagonal screw and washer If the geared motor cannot be installed as shown above for reasons of space it is possible to turn the drive unit Turn the torque support with bearing 180 and secure to geared motor Turn the geared motor and torque support 180 and fit to the screw end and torque ...

Page 30: ... of the water sprinkler system to the upper sleeve on the upper part of gravity shaft Fit the immersion sleeve C of the water sprinkler system to the side sleeve Prepare the geared motor Remove the transport lock Fit the vent screw supplied to the highest point 4 Assembly Assembling the articulated arm rotary agitator 30 Fröling Ges m b H A 4710 Grieskirchen Industriestraße 12 www froeling com ...

Page 31: ...table feet Drill the holes marked Drill diameter 15 mm Min drill depth 105 mm Insert the heavy load anchors into the bore holes and tighten with a spanner AF 17 mm 4 3 7 Closing the wall penetration Pack the 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 ...

Page 32: ... Hammer dowel into wall and mount sensor plate Mount the housing outside the fuel store Guide the sensor through the wall at a suitable point and push it into the sensor plate CAUTION Do not kink the capillary tube Further cabling of the on site warning device s according to the enclosed installation instructions 4 Assembly Assembling the articulated arm rotary agitator 32 Fröling Ges m b H A 4710...

Page 33: ...nents to 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 sa...

Page 34: ...actory 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 Check that the safety limit swit...

Page 35: ... system 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...

Page 36: ... 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 agitator On...

Page 37: ...ator is not adequately covered by the remaining fuel Load a small amount of fuel approx 2 3 m Pile it up on and around the head of the rotary agitator The head of the rotary agitator should be completely covered Rotary agitator with combined drive system After working in the store Turn on the boiler s main switch Turn on the main switch on the expansion switch cabinet if installed Switch on main s...

Page 38: ... Switch off the boiler by pressing the standby key and allow to cool down for at least two hours Switch off the boiler by tapping Boiler off at the mode icon and allow to cool for at least two hours Close all openings to the store to seal out dust Blow the fuel into the store 5 3 4 Blowing in fuel for an empty store with rotary agitator 5 Operating the system Filling the store with fuel 38 Fröling...

Page 39: ...s in the fuel store on and around the head of the rotary agitator and on the discharge screw by hand The head of the rotary agitator should be completely covered Follow the instructions on working in the fuel store NOTICE Refer to the notice supplied with the boiler at the entrance to the store If the head of the rotary agitator is not adequately covered by the remaining fuel Close all openings to...

Page 40: ...y steps and how to display and alter parameters NOTICE See operating instructions for boiler controller NOTICE When transporting wood chips or pellets using the feed screw there may be noise depending on the function 5 5 Decommissioning 5 5 1 Disassembly To disassemble the system follow the steps for assembly in reverse order 5 5 2 Disposal Disposal should be carried out according to the valid nat...

Page 41: ...tions DANGER When working on the unit with a live power supply Serious injury possible due to automatic startup When working on the system or in the store it is essential that the five safety directives are followed Disconnect all poles on all sides Secure so that it cannot be switched on again Check that there is no power Earth and short circuit Cover any adjacent live parts and limit area of ris...

Page 42: ...p and clean where necessary Close gravity shaft cover Check fault message on the controller 3 Sprinkler system Sprinkler system ready for operation Check the position of the sensor Visual inspection of the sensor and the capillary tube Check water supply for sufficient pressure 4 Spring piles F Check that the connecting screws of the clamping plate are firmly in position and tighten if necessary R...

Page 43: ... Check the rotary plate for material build up and clean if necessary 9 Trough dosing screw Check the trough and dosing screw for dirt and damage Check the screw blades for wear 10 Inlet area transfer channel Check the inlet area for material build up or jammed fuel and clean if necessary Check the shear plate in the entry area of the transfer trough for wear 11 Flange bearing Lubricate bearing at ...

Page 44: ...vise you IMPORTANT An annual inspection by a specialist does not replace the maintenance work to be carried out by the operator in accordance with the maintenance plan NOTICE The prerequisite for the feasibility of the inspection and maintenance work is unrestricted access to the components of the discharge system Therefore Empty fuel store on the agreed date Provide for any service openings Suffi...

Page 45: ... fit together so well installation times are shortened and a long service life is maintained NOTICE Installing non original parts will invalidate the guarantee Only replace components or parts with original replacement parts Servicing the system 6 Replacement parts Installation and Operating Instructions GAR 110 150 M2060120_en 45 ...

Page 46: ...tion in the gravity shaft Discharge screw blocked Check the store and refill with fuel if necessary Check the motor and wiring for damage Open the inspection cover and check the gravity shaft for material build up Free the screw Gravity shaft does not fill Discharge screw blocked Move the discharge screw backwards and forwards briefly a few times in test mode manual mode If the error message does ...

Page 47: ...8 Notes Notes 8 Installation and Operating Instructions GAR 110 150 M2060120_en 47 ...

Page 48: ...STRIA TEL 0043 0 7248 606 0 FAX 0043 0 7248 606 600 EMAIL info froeling com INTERNET www froeling com Customer service Austria 0043 0 7248 606 7000 Germany 0049 0 89 927 926 400 Worldwide 0043 0 7248 606 0 9 1 2 Address of the installer Stamp 9 Appendix Addresses 48 Fröling Ges m b H A 4710 Grieskirchen Industriestraße 12 www froeling com ...

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