Fröling TGR 110 Installation Instructions Manual Download Page 41

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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

Installation Instructions TGR 110/150/200 | M1390116_en

Summary of Contents for TGR 110

Page 1: ...he original German installation instructions for technicians Read and follow the instructions and safety information Technical changes typographical errors and omissions reserved M1390116_en Edition 20 11 2017 Froling GesmbH A 4710 Grieskirchen Industriestraße 12 www froeling com ...

Page 2: ...3 3 Technical specifications 16 4 Assembly 17 4 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 torsion arm agitator 19 4 3 1 Materials supplied 19 4 3 2 Assembling the gears and feeder trough 20 4 3 3 Fitting the upper part of gravity shaft and drive unit 25 Assembly with screw Ø110 25 Assembly with screw Ø150 Ø200 26 4 ...

Page 3: ...itator 35 5 3 4 Blowing in fuel for an empty store with rotary agitator 36 Rotary agitator with combined drive system 37 5 4 During operation 37 5 5 Decommissioning 38 5 5 1 Disassembly 38 5 5 2 Disposal 38 6 Servicing 39 6 1 Maintenance schedule 39 6 2 Maintenance contract 40 7 Troubleshooting 41 7 1 Error message list 41 8 Appendix 42 8 1 Addresses 42 8 1 1 Address of manufacturer 42 Customer se...

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: ...he agitator head reducing the 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 using the pre tensioned rotary agitator arms and fed to the trough of the dosing screw The dosing screw feeds the material to the transfer position where it falls through the burn back protection system burn bac...

Page 6: ...llow 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 Haz...

Page 7: ...hich might impair safety are rectified immediately The manufacturer or supplier is not liable for any damage resulting from non permitted uses 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 cleanin...

Page 8: ...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 2 3 Qualification of staff 2 3 1 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 ...

Page 9: ...ff CAUTION If unauthorised persons enter the store 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 3 4 Protective equipment for operating staff You mus...

Page 10: ...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 prevention Austria ÖNORM H 5170 Construction and fire protection requirements Austria ÖNORM H 5190 Heating systems Acousti...

Page 11: ...of spring 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 th...

Page 12: ...sconnects 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 sys...

Page 13: ...at there 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 t...

Page 14: ...pment 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 or hardwood...

Page 15: ...ermined during planning of the store 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...

Page 16: ... edge transition from open to closed trough is at least 200 mm away from the wall 3 3 Technical specifications Description T4 24 75 T4 90 110 TM 150 TX 150 TM 220 320 TX 199 250 TM 400 500 Screw diameter 110 mm 150 mm 200 mm Drive motor Feed screw Power supply 400 VAC 50 Hz Power 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 VD...

Page 17: ...ormation 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 reason any gaps ar...

Page 18: ...m 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 the fuel The raised floor must also be self supporting and it should not be supported by the screw channel 4 2 1 Wa...

Page 19: ...room side 12 Stir plate 13 Intermediate plate 13a 2x Cover plates TGR 150 200 only 14 Support boiler room optional 15 Adjustable feet 15a Shorter adjustable feet optional for horizontal installation 16 Gear supports 16a Shorter gear supports optional for horizontal installation 17 Extensions for gear supports optional 18 Mitre gear 18a Spacer for agitator head TGR 150 only 18b Spacer for agitator ...

Page 20: ...nge plates Place the mitre gear and trough channel on the floor Secure the open trough to the mitre gear 4x hexagonal screw M16 x 35 mm 4x spacer washer M16 Fit the gear supports to the mitre gear as shown 4x hexagonal screw M16 x 35 mm 4x spacer washer M16 Do not fully tighten the screws yet When the unit has been screwed together insert it through the hole in the wall on the store side 4 Assembl...

Page 21: ...TGR 150 200 only Fit cover plates to intermediate plate 8x hexagonal screw M10 x 16 mm 8x spacer washers M10 Align the stirring head with the troughs in the store in accordance with the installation diagram Fix the stirring head to the floor Make 2 holes each in the floor on the left and right for the adjustable feet Drill the holes marked Drill diameter 15 mm Min drill depth 105 mm Insert the hea...

Page 22: ...ing plate for systems without a raised floor Trough coverings for operation with pellets Cover pellets optional Cover for pellets with raising plate for systems without a raised floor 4 Assembly Assembling the torsion arm agitator 22 Froling GesmbH A 4710 Grieskirchen Industriestraße 12 www froeling com ...

Page 23: ...t flange of the open trough on the left and right 4x hexagonal screw M12 x 35 mm 8x spacer washers M12 4x nuts M12 Only partially tighten the screws Fit the closed trough with ceramic fibre seal to the transfer channel 4x hexagonal screw M12 x 35 mm 4x spacer washers M12 4x nuts M12 Check the alignment of the flange plates Assembly 4 Assembling the torsion arm agitator Installation Instructions TG...

Page 24: ... necessary Fit the adjustable feet to the floor Make 1 hole in the floor on the left and right for each of the adjustable 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 SW 17 mm 4 Assembly Assembling the torsion arm agitator 24 Froling GesmbH A 4710 Grieskirchen Industriestraße 12 www froeling com...

Page 25: ...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 Assembly 4 Assembling the torsion arm agitator Installation Instruc...

Page 26: ...it the 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 Ø200 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 torsion arm agitator 26 Froli...

Page 27: ... Lubricate 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 ...

Page 28: ...elbow B 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 torsion arm agitator 28 Froling GesmbH A 4710 Grieskirchen Industriestraße 12 www froeling com ...

Page 29: ...R 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 B B B Pre tension joint 3 A A A Pre tension the torsion spring with the draw tube provided Insert nut into relevant perforation as indicated in the table Insert stop screw from above and turn nut Assembly 4 Assembling the to...

Page 30: ...osition Secure the brackets to the trough flange with the previously removed screws Position the supporting post at the bracket and screw together Screwing the adjustable feet to the floor Make two holes each in the floor on the left and right for the adjustable 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 wit...

Page 31: ...nents 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 unauthorised persons Lay cables of components 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 t...

Page 32: ... 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 Check that the safety limit sw...

Page 33: ...oiler is switched on Possible excess pressure could cause smoke to escape into the installation room possibly resulting in injury and damage Therefore before blowing in the fuel Switch off the power supply to the entire system Depending on the model via boiler expansion switch cabinet etc Allow the system to cool for at least two hours 5 3 1 Loading of fuel for a partially emptied store with rotar...

Page 34: ... you follow the procedure given below Disconnect the boiler s main switch Turn off the main switch on the expansion switch cabinet if installed Switch off main switch at feed system module Pile up the residual fuel in the corners and on the walls 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 c...

Page 35: ...ing the head of the rotary agitator approx 2 revolutions Add the rest of the fuel 5 3 3 Blowing in fuel for a partially emptied store with rotary agitator If there is still sufficient fuel in the store the head of the rotary agitator is completely covered with fuel and the rotary agitator arms are not extended the store can be filled as follows Switch off the boiler by pressing the standby key and...

Page 36: ...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 Disconnect the boiler s main switch Turn off the main switch on the expansion switch cabinet if installed Switch off main switch at feed system module Pile up the residual fuel in the corners and on the walls in the fuel store on and around th...

Page 37: ...torage tank must be able to store enough heat Wait until the rotary agitator arms spring blades are touching 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 When fillin...

Page 38: ...order 5 5 2 Disposal Disposal should be carried out according to the valid national regulations and guidelines You can separate and clean recyclable materials and send them to a recycling centre 5 Operating the system Decommissioning 38 Froling GesmbH A 4710 Grieskirchen Industriestraße 12 www froeling com ...

Page 39: ...hedule 2 4 8 9 3 1 5 6 7 10 W M VJ BF W M VJ BF W weekly M monthly Q quarterly F prior to each fill of the store No Component Int Operation 1 Motor gears W Carry out a general visual inspection of the drive motor 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 immedia...

Page 40: ...lean if necessary 8 Trough dosing screw Check the trough and dosing screw for dirt and damage Check the screw blades for wear 9 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 10 Flange bearing Lubricate bearing at lubricating nipple with grease gun 6 2 Maintenance c...

Page 41: ...idge 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 mes...

Page 42: ...USTRIA 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 8 1 2 Address of the installer Stamp 8 Appendix Addresses 42 Froling GesmbH A 4710 Grieskirchen Industriestraße 12 www froeling com ...

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