A.B.S. Flexilo TROUGH User manual

Assembly-, Operating-, and Filling Instructions
Flexilo TROUGH for wood pellets
Split Design
Construction: Plug-In System galvanized
Information on the manual:
The present assembly manual contains important information on safe and appropriate
assembly of the A.B.S. Flexilo TROUGH for the storage of wood pellets. The assembly
manual is intended for skilled mechanics, which have, based on expert training, the
respective knowledge and experience. As we are interested in continuously improving our
technical documentation, we would be pleased to get suggestions for improvement.
The manual has to stay with the heating system or the silo. Please make
sure that the manual is at any time on-hand if required.
A.B.S. Silo- und
Förderanlagen GmbH
Industriepark 100
74706 Osterburken - Germany
Tel. [phone]
Fax [phone]
[email protected]
www.abs-silos.de

Operating and Assembly Instructions – A.B.S. Flexilo TROUGH for wood pellets
Table of contents
Subject to technical change Issue 09/2016 Page 2 of 33
©A.B.S. Silo- und Förderanlagen GmbH
Table of contents:
1 Note ............................................................................................................................... 3
1.1 Symbols used.......................................................................................................... 3
1.2 Normative references.............................................................................................. 3
1.3 Pellet quality, Intended use ..................................................................................... 3
1.4 Approvals and Compatibility to Pellet Boilers........................................................... 4
1.5 Warranty and Guarantee......................................................................................... 5
2 Safety Information.......................................................................................................... 6
2.1 General safety information ...................................................................................... 6
2.2 Fire prevention........................................................................................................ 7
2.3 Earthing................................................................................................................... 7
2.4 Nameplate............................................................................................................... 7
2.5 Maintenance............................................................................................................ 7
2.6 Storage Aeration..................................................................................................... 8
3 Room Layout.................................................................................................................. 9
3.1 Room size............................................................................................................... 9
3.1.1 Distance from walls.............................................................................................. 9
3.1.2 Distance from ceiling ..........................................................................................10
3.2 Condition of the room.............................................................................................10
3.3 Room fixtures.........................................................................................................10
3.4 Room deaeration....................................................................................................11
3.5 Size / Storage Volume............................................................................................11
4 Scope of delivery...........................................................................................................12
5 Assembly.......................................................................................................................16
5.1 Pre-Assembly of the drawing irons.........................................................................16
5.2 Assembling the frame and struts............................................................................17
5.3 Assembling the Silo bag and support bar...............................................................19
5.4 Attaching the silo cover to the ceiling .....................................................................21
5.5 Fastening...............................................................................................................22
5.6 Mounting of Filling-set(s)........................................................................................22
5.7 Assembling the cone holding frame........................................................................23
5.8 Assembling the extraction system..........................................................................26
6 Final inspection.............................................................................................................27
7 Extract from accident prevention regulations.................................................................28
8 Filling instructions..........................................................................................................29
8.1 General instructions ...............................................................................................29
8.2 Filling nozzle(s)......................................................................................................30
8.3 Filling with two filling nozzles..................................................................................30
8.4 Filling techniques ...................................................................................................32
8.5 Filling......................................................................................................................32

Operating and Assembly Instructions – A.B.S. Flexilo TROUGH for wood pellets
General Information
Subject to technical change Issue 09/2016 Page 3 of 33
©A.B.S. Silo- und Förderanlagen GmbH
1 Note
Please read these Instructions prior to assembling the A.B.S. Flexilo TROUGH for wood
pellets.
1.1 Symbols used
Danger! This symbol identifies a hazard that could cause serious bodily injury or
even death if appropriate precautionary measures are not taken.
Caution: Risk of injury or damage to equipment!
Dangerous situations that can cause minor to serious bodily injury or damage to
equipment and property.
Risk of electric shock! Failure to observe the warning can endanger life and
limb through contact with electricity.
References and tips
1.2 Normative references
•ÖNORM M 7137: Wood pellets - Requirements for storage of pellets at the ultimate
consumer
•EN 303-5: Heating boilers for solid fuels
•EN14961-2: Wood pellets for non-industrial use
•ENplus – Handbook for the certification of wood pellets for heating use, version 2.0
•Sample fire ordinance 2005
•VDI guideline 3464 (green print 2012): storage of wood pellets by ultimate consumer
1.3 Pellet quality, Intended use
The Flexilo TROUGH for wood pellets is intended solely for the storage of wood pellets. The
maximum acceptable bulk good temperature is 50 °C.
If you want to store other materials you need to get in touch with the manufacturer
necessarily.
We assume use of quality pellets complying with EU-Norm EN 14961-2 respectively
complying with DINplus that have a diameter of 6 mm. According to the DEPV-guidelines
only certified ENplus A1 quality pellets are recommended.
Quality class A2 is used in larger boilers in excess of 100 kW like in the commercial area.
The quality classes are distinguished primarily by the ash content and the permissible ash
softening temperature. The boiler manufacturer must permit the use of the A2 quality pellets
in their boilers.

Operating and Assembly Instructions – A.B.S. Flexilo TROUGH for wood pellets
General Information
Subject to technical change Issue 09/2016 Page 4 of 33
©A.B.S. Silo- und Förderanlagen GmbH
Important criteria of wood pellets according to the ISO 17225-2 from 2014:
Quality A1
Quality A2
diameter (mm) 6 or 8
length(mm) 3,15 to 40
moisture content (% by mass) <=10
ash content (% by mass) <=0,7 <=1,2
mechanical strength (% by mass) >=97,5
finest content (% by mass) <=1
overlength (40 – 45 mm) <=1
heating value (kWh/kg) 4,6 to 5,3
bulk density (kg/m³) >=600 600 – 700
nitrogen content (% by mass) <=0,3 <=0,5
sulphur content (% by mass) <=0,04 <=0,05
chlorine content (% by mass) <=0,02
ash fusion temperature* (C°) >=1200 >=1100
* This value is only mandatory for ENplus certified pellets. It refers to the temperature at
which the wood ash deforms and thus can lead to scorification in the combustion chamber.
Poor quality pellets can impair operation of your heating system and have an adverse effect
on the storage and conveying equipment. Only high-grade pellets can assure reliable and
problem-free operation of the pellet-fired boiler and the conveying systems. If necessary,
have the supplier confirm the quality of the pellets.
ENplus certificate
ENplus certified pellets are available for quality classes A1
and A2. Manufacturers and suppliers of high quality wood
pellets and further information can be found under
www.enplus-pellets.de.
1.4 Approvals and Compatibility to Pellet Boilers
There are approvals of various boiler manufacturers for the A.B.S. Flexilo TROUGH.
Through individual solutions of extraction devices and conveying systems in special cases
connections to the silo can be created.
Please comply with your country-specific standards and directives regarding
assembly and operation of the silo! Observe the information contained in these
instructions! It is binding and must be observed.

Operating and Assembly Instructions – A.B.S. Flexilo TROUGH for wood pellets
General Information
Subject to technical change Issue 09/2016 Page 5 of 33
©A.B.S. Silo- und Förderanlagen GmbH
1.5 Warranty and Guarantee
The "General Terms and Conditions of Business of A.B.S.” apply in all cases. These are
available to the operator no later than upon conclusion of the sales agreement. Warranty and
liability claims associated with personal injury or property damage are excluded if they can
be attributed to any one or several of the following causes.
−Unintended and improper use of the equipment.
−Operation of the equipment when safety devices are defective, not properly attached or
when safety devices and guarding are not functioning properly.
−Failure to observe the information contained in the Operating Instructions with regard to
storage, transportation, assembly, start-up, operation, and maintenance.
−Unauthorized structural changes.
−Improperly performed repairs.
−Catastrophic incidents resulting from the action of a foreign object or force majeure.
−Use of not yet released additive pellets (PowerPlus, pelprotec ®, etc). Please contact us
for information on the current supply level.
−In case of white rust.
White rust can occur during transport, for example. Protect frame against water, water spray
is already enough to form white rust.
However, if this cannot be avoided, then the white rust can quite easily be removed with
RZ51 zinc cleaner.
The manufacturer’s warranty and guarantee are based on the assumption that the silo
system has been properly assembled and commissioned by qualified personnel.
Deficiencies and damage arising from improper assembly, start-up and operation are
excluded from any and all warranty and guarantee coverage.
To ensure operation of the system as intended, the manufacturer’s instructions must be
followed. In particular, the equipment must be operated with the pellets stipulated in Chapter
1.3.
Damage to the silo from rodents or attributable to other external forces is not covered by our
warranty.
Damage attributable to flying sparks caused by cutting and welding work is excluded from
warranty coverage.
The guarantee covers only the items supplied by us.
Only original replacement parts or parts expressly approved by the manufacture may be
installed in the system.

Operating and Assembly Instructions – A.B.S. Flexilo TROUGH for wood pellets
Safety Information
Subject to technical change Issue 09/2016 Page 6 of 33
©A.B.S. Silo- und Förderanlagen GmbH
2 Safety Information
Please observe the following safety information!
2.1 General safety information
Danger to life in the event of a dust exp
losion caused by electrostatic discharge
•The filling nozzle and frame of the silo must always be connected to the potential
equalization system of the building in order to prevent build-up of static electricity. If
several pipe segments are connected to one filling line, all of the connections must be
interconnected electrically to one another.
•The room where the silo is installed must not be hermetically sealed, since the
overpressure created during the filling process escapes into the storage room.
•An exhaust air opening of 200 cm² or rather according to VDI guideline 3464 in the
storage room is necessary. If necessary open a window during the filling process.
•Heating boilers and fuel supply systems need electricity to operate. Improper
installation can mean that life is endangered.
•When filling the silo with a tank truck, the boiler must always be switched off in time.
•Point out possible sources of danger to the customer. The currently valid fire
protection and VDI guidelines must be satisfied prior to start-up.
•In order to avoid hazards associated with improper handling of the system, have
installation, initial start-up and service performed only by suitably qualified personnel
in compliance with all applicable regulations and manufacturer's instructions.
•Use only metal piping with Ø DN 100 mm and a smooth inside edge for the extension
of the filling line (galvanized, without burrs or welding sputter; use of plastic pipes is
not allowed!).
•The filling-set and the filling hose of the tank truck should not be longer than 30 m.
•Keep the filling system within the building as short as possible in order to minimize the
physical load to which the pellets are subjected, thus keeping fines and powder
created by abrasion low. Avoid tight bends as much as possible!
•The fill coupling has to be accessible and unproblematicly reachable (without using
any ladders etc.) for the tank truck driver.
•Protect fabric silos from rodents
•Do not change any settings or make any modifications to the system; if these are
necessary, contact A.B.S. first to obtain approval.
•Knowledge of the operating instructions and maintenance procedures is a
prerequisite. Prior to start-up, please read these Operating Instructions carefully and
completely, and remember to observe the safety information in particular.

Operating and Assembly Instructions – A.B.S. Flexilo TROUGH for wood pellets
Safety Information
Subject to technical change Issue 09/2016 Page 7 of 33
©A.B.S. Silo- und Förderanlagen GmbH
2.2 Fire prevention
All fire prevention regulations must be satisfied prior to start-up. (subject to country-specific
modifications).
2.3 Earthing
Attention! Let the earthing of your pellet storage area be executed by a
specialized company.
•All conductive parts of the silo must be grounded expertly.
•In particular the removal system, the steel frame and the connecting armature have to be
earthed.
•The filling lines must also be connected conductive and grounded professionally with a
cable (4 mm ²) to the potential equalization conductor (by a qualified electrician for
example).
•Especially the earthing parts have to be connected to the potential equalization and/or the
main potential equalization with specific PA conductors.
2.4 Nameplate
The nameplate stating the calculated storage capacity must
be attached to the pellet silo at a readily visible location, e.g.
at the filling nozzle or on one of the frame’s legs. The
nameplate is included in the shipping documents that
accompany Flexilo TROUGH for wood pellets when it is
delivered.
Nameplate with calculated storage capacity
2.5 Maintenance
Regular cleaning of the bearing is required to ensure continuous, trouble-free and safe
heating operation. The fines content and the wood dust should be removed.
When cleaning, please note the following:
•Enter storage areas only when in compliance with safety regulations: Switch off
heating and discharge system, adequately ventilate before entering.
•Clean the removal system prior to new filling of dust and debris. Wear dust mask of
filter class P2.
•Heat silo sack empty regularly and clean the silo sack through movement from dust
while the removal system is uninstalled.
Vacuum the storage out. In private storage, the cleaning can be done with
commercial vacuum cleaners with HEPA filters. The vacuum cleaner should not work
at the highest level to avoid overheating and to prevent ignition hazards.
• For reasons of occupational health and safety, an industrial vacuum cleaner with filter
class M is required for cleaning pellet storages. Earth buried storage and all other
storages starting at a capacity of 40 tons may only be accessed with a CO warning
device.
•Until the next filling process please fill the silo manually with pellets in sacks (through
the manual filling nozzle).

Operating and Assembly Instructions – A.B.S. Flexilo TROUGH for wood pellets
Safety Information
Subject to technical change Issue 09/2016 Page 8 of 33
©A.B.S. Silo- und Förderanlagen GmbH
•Please check if the silo has damages caused by rodents or other external influences.
•The bolting of the steel frame should be checked as well.
•Please check the fastenings of the Filling and removal systems.
•Make sure that all other openings on the silo are closed.
After two to three deliveries
-
at least every two years
-
the time before the
next pellet delivery should be used to clean the storage.
Please observe the recommendations concerning the maintenance of the boiler
manufacturers.
2.6 Storage Aeration
Wood pellets are a fuel that is environmentally safe and from which no health risk arises, if
handled properly. Wood pellets can develop an odour depending on the type of wood used.
The reason for this lies in the extractive, the wood's own oils, fats and resins, which are
activated during the pressing process and slowly outgas in the following weeks or
decompose when in contact with the air. Compared to other wood products wood pellets
have a very large surface area and are heavily used in their cell structure by the pressing
process. The result is that the release of the volatile components is faster, especially in fresh
pellets and at high ambient temperatures. Emissions usually decrease after a few weeks and
the odour associated evaporates completely.
The emissions of wood pellets consist of volatile organic compounds (VOCs), carbon
monoxide (CO) and carbon dioxide (CO2). Among the VOCs are, for example, the so-called
terpenes that in rare cases occur and are responsible for a "chemical" odour (such as
turpentine). Other ingredients such as aldehydes and carbon monoxide can produce an
unhealthy effect and therefore should not enter into the living area. To avoid any risk, two
simple principles must be observed.
•The storage room, or the room where the final storage is set up, must be sealed off from
the living area.
•The storage room ventilation (> 200 cm ²) should be directly above the openings to the
outside or, if this is not possible, through openings in to a well-ventilated room.
Elaborate ventilation solutions are required for larger storages (> 10 t) and vent lines > 5 m.
These are described in detail in the VDI guideline 3464 "Storage of wood pellets at the end
user ".
Each pellet storage room or set up room for final storage must be ventilated.
The ventilation openings should be designed in a manner that they do not
end directly under windows or air intakes.

Operating and Assembly Instructions – A.B.S. Flexilo TROUGH for wood pellets
Room Layout
Subject to technical change Issue 09/2016 Page 9 of 33
©A.B.S. Silo- und Förderanlagen GmbH
3 Room Layout
Please observe the following planning steps; only in this way can
problem-free operation be assured.
Failure to comply can result in damage to the equipment and system
malfunctions or put individuals and equipment at risk.
Planning the room layout is a prerequisite and requirement for setting up the A.B.S. Flexilo
TROUGH for wood pellets. The plans for the rooms must have already been given some
thought when ordering the silo. Nevertheless, prior to installation, check the dimensions and
existing conditions (see the next chapter).
Compliance with local regulations and proper construction of the building are the
responsibility solely of the purchaser of the equipment and are prerequisites for coverage by
the warranty and guarantee.
3.1 Room size
The required silo size depends on the size of the room. Please check the dimensions of both
the silo and the room prior to installation. The dimensions of the silo frame are stated on the
delivery documents.
The dimensions of the silo frame can be determined by measuring the steel parts:
Length of the frame = Length of the long bars
Width of the frame = Length of the shorter bars
Height of the frame = Length of the frame feet (stands) + height of the top bar
In a split design
Length of the frame = length of the split support bar (mitred 90 °/ 45 °) 2 times
Width of the frame = length of the support bar (mitred 45 ° / 45 °)
Height of the frame = length of the frame feet (stands) + height of the support
The silo, the manual filling nozzle and the removal units must be easily accessible
for maintenance.
3.1.1 Distance from walls
A distance of 10 to 15 cm is required between the silo frame and walls in order to provide
ventilation at the back of the silo and protect against mechanical damage. Because of the
bulk nature of the pellets, the side walls of the silo may bulge slightly.
The side of the silo where the filling line is attached must have a clearance of at least
80 - 100 cm. If you fill from outside 30 cm are enough.
(Further instructions and examples for the installation can be found in our planning
documents).

Operating and Assembly Instructions – A.B.S. Flexilo TROUGH for wood pellets
Room Layout
Subject to technical change Issue 09/2016 Page 10 of 33
©A.B.S. Silo- und Förderanlagen GmbH
3.1.2 Distance from ceiling
A minimum distance of 20 cm is required between the upper edge of the silo frame and the
ceiling to provide space for the filling line. To prevent damaging the top fabric of the silo
during filling, no sharp or sharp-edge objects should be fastened to the ceiling.
3.2 Condition of the room
A stable supporting surface as the installation site is a prerequisite for setting up the silo. The
floor must be horizontal; if this is not the case, any unevenness must be corrected through
use of suitable underlay material (e.g.: steel plates). The load-bearing capacity of the floor
has to be checked according to the silo capacity.
For silos up to about 3.1 t, the plates at the bottom of the frame feet (stands) have
dimensions of 120x120 mm; starting at about 3.2 t, the dimensions are 140x140 mm. For
silos with a capacity of 8 t or higher, the load per frame feet (stand) can exceed 2,000 kg;
larger plates are available in such cases. Please consult the manufacturer directly with your
questions in this regard and check the permissible floor loading.
The base connectors must be secured by means of anchor bolts.
Rooms with moisture levels normally found in cellars do not present any problems; however,
condensation must not occur. In case of humidity the room must be ventilated properly. The
silo fabric is air-permeable and may cause the wood pellets to absorb humidity at the silo
walls.
Make also sure that humidity does not enter the filling pipe if it is directed from outside into
the storage area.
When setting up outdoors, the following applies:
A properly levelled and stable concrete foundation must be available for anchoring the frame
feet (stands). The foundation can be designed as a slab with strip footing or as individual
foundations. The silos should be protected against moisture from below. For outdoor
installation, the frame feet (stands) should be galvanized. The silo must be protected from
direct sunlight and the effects of weather (e.g. place in a wood or metal enclosure or a
coating).
3.3 Room fixtures
Room fixtures such as drain pipes, ceiling hooks, water pipes, etc. must already be
considered in the planning phase, or be removed before installing the Flexilo TROUGH for
wood pellets, if these interfere with the installation and proper operation of the silo.
There must be no sharp or sharp-edged objects near the silo bag. If it is not possible to
remove such objects, they must be covered.
There must be no lamps, lines of any kind, sharp, hot or damp contact surfaces above the
pellet silo.