Fröling FBR-G User manual

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

Table of contents
1 General 4
1.1 Functional description 5
2 Safety 6
2.1 Hazard levels of warnings 6
2.2 Permitted uses 7
2.2.1 Permitted fuels 7
Wood chips 7
Wood pellets 8
2.3 Qualification of staff 8
2.3.1 Qualification of assembly staff 8
2.3.2 Personal protective equipment for assembly staff 8
2.3.3 Qualification of operating staff 9
2.3.4 Protective equipment for operating staff 9
2.4 Design information 9
2.4.1 Standards 9
2.4.2 Requirements at the installation site 10
Information about the fuel store 10
2.5 Safety devices 11
2.6 Residual risks 12
3 Technical information 14
3.1 Dimensions 14
3.2 Store sizes 15
3.3 Technical specifications 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 discharge screw 24
4.3.6 Fitting the rotary agitator 28
4.3.7 Aligning the trough of the discharge screw 31
4.3.8 Securing the adjustable feet and support elements 32
4.3.9 Setting the tension of the torsion springs 32
4.3.10 Closing the wall penetration 33
4.4 Connecting the system 34
4.4.1 Electrical connection 34
4.4.2 Connecting the sprinkler system 34
Table of contents
2 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

5 Operating the system 35
5.1 General information 35
5.2 Initial startup 35
5.3 Filling the store with fuel 36
5.3.1 Loading of fuel for a partially emptied store with rotary agitator 37
5.3.2 Loading fuel in an empty store space with a rotary 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
Installation and Operating Instructions | M1730116_en 3

1 General
Thank you for choosing a quality product from Froling. The product features a state-of-
the-art design and conforms to all currently applicable standards and testing
guidelines.
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
documentation makes a significant contribution to safe, appropriate, environmentally
friendly and economical operation of the system.
The constant further development of our products means that there may be minor
differences from the pictures and content. If you discover any errors, please let us
know: [email protected].
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 of
Directive 2006/42/EC.
Compliance with the open provisions and verification of the correct installation must be
confirmed in the delivery certificate of the declaration of installation (included in
documentation).
Issuing a delivery
certificate
1General
4 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

1.1 Functional description
TGR torsion arm agitator: FBR spring blade agitator:
A Rotary agitator geared motor F Rotary agitator mitre gear
B Rotary agitator duct with drive shaft G Discharge screw geared motor
C Rotary agitator plate H Gravity shaft
D Articulated arms with torsion springs
(TGR)
I Discharge screw closed trough
E Spring piles (FBR) J Discharge screw open trough
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. 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 screw of the boiler that is positioned below or into another feed screw.
The feed output can be variably adjusted regardless of the discharge screw thanks to
the separate drive of the rotary agitator.
General 1
Functional description
Installation and Operating Instructions | M1730116_en 5

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.
2Safety
Hazard levels of warnings
6 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.2 Permitted uses
Froling’s “FBR-G / TGR-G with separate rotary agitator drive and discharge screw“ is
solely designed for discharging fuels from dedicated stores. Only use fuels specified in
the “Permitted fuels” section.
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
ensure 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
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 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 services
2.2.1 Permitted fuels
Wood chips
Criterion Designation as per Description acc. to
ÖNORM M 7133
ÖNORM M 7133 EN ISO 17225
Water content W20 M20 air-dried
W30 M30 suitable for storage
W35 M35 limited suitability for
storage
Size G30 P16S Fine wood chip
G50 P31S Medium-sized wood
chip
EU: Fuel acc. to EN ISO 17225 - Part 4: Wood chips class A1 / P16S-P31S
Additional for
Germany:
Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance
(BimSchV) - applicable version)
Note on standards
Safety 2
Permitted uses
Installation and Operating Instructions | M1730116_en 7

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: EN plus / DIN plus 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 unqualified persons:
Risk of personal injury and damage to property
During assembly and installation:
❒ Observe the instructions and information in the manuals
❒ Only allow 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 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)
Note on standards
2Safety
Permitted uses
8 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.3.3 Qualification of operating staff
CAUTION
If unauthorised persons enter the installation room / boiler 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.
2.3.4 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For operation, inspection and cleaning:
- suitable work wear
- protective gloves
- sturdy shoes
2.4 Design information
Carrying out modifications to the system and changing or disabling 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 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 - Acoustic insulation
EN ISO 13857 Safety of machines; Safety distances for maintaining a safe
distance from hazardous areas
Safety 2
Qualification of staff
Installation and Operating Instructions | M1730116_en 9

2.4.2 Requirements at the installation site
▪ Protect the store against all weather conditions.
▪ Protective structures must be designed in accordance with the applicable
standards and regulations
Information about the fuel store
NOTICE! The fuel store plate provided must be affixed in a conspicuous place in the
access area of the store
When FILLING the fuel store, observe the system DOCUMENTATION.
The filling procedures may vary depending on the discharge system, type of fuel and
fill level of the fuel store. Only use fuels permitted according to the boiler’s operating
instructions.
SWITCH OFF the HEATING AND FEED SYSTEM before ENTERING the fuel store.
Risk of injury due to moving parts and automatic startup. Shut off the feeder unit
before entering the fuel store and secure it so that it cannot be switched on again.
There is a further risk of injury from the uncontrolled rotation 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 the store. Therefore, do not enter the fuel area!
Slick surfaces in the fuel store present a slipping hazard and fuel supply points
present a risk of falling.
As a rule, personal protective equipment (work clothing, protective gloves, sturdy
shoes) should be worn when working in the store and on the conveyor.
Unauthorized access prohibited! Keep children away! Design the fuel store in such a
way that it is safe to access and keep it locked. Keep the key in a safe place. No fire,
open flames or smoking! Protect the fuel from moisture.
Affix this notice in a conspicuous place in the access area of the fuel store.
2Safety
Design information
10 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.5 Safety devices
Safety equipment Safety function
Limit switch for top of gravity
shaft:
Protection against access to the danger area of the feed/
discharge screw when the system is switched on
❒ If the inspection cover is opened, the system is switched
off via the limit switch
➥The power supply remains switched on
Burn back flap: Burn back protection system (BPS) directly below the top of
the gravity shaft. During the heating up phase, after loading
has taken place and in the event of a fault, it reliably
disconnects 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 system opens, water flows out
and prevents the fire from spreading to the fuel store.
TMF: Temperature monitoring device in the fuel store (as per TRVB
H118, Austria only) which activates the customer’s alarm(s)
when the temperature in the fuel store exceeds 70 °C.
Safety 2
Safety devices
Installation and Operating Instructions | M1730116_en 11

2.6 Residual risks
The discharge system has been designed and built to comply with the relevant safety
directives. Nevertheless by the nature of its operation and function, there are residual
risks which cannot be eliminated completely.
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 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
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.
2Safety
Residual risks
12 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

NOTICE
Filling the store when the discharge system is switched off
Equipment damage hazard.
Due to the high resistance from the weight of the fuel on the rotary agitator arms,
the system cannot be started. The drive would be overloaded
❒ Take the following precautions:
➥The discharge system must be switched on during filling
⇨ See "Filling the store with fuel" [page 36]
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 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 to the
silo wall.
➥Froling offers a ready-made wall protection pack for this purpose.
The staff at Froling will be happy to advise you.
Safety 2
Residual risks
Installation and Operating Instructions | M1730116_en 13

3 Technical information
3.1 Dimensions
Item Description FBR
110
TGR
110
FBR
150
TGR
150
FBR
200
TGR
200
DDiameter of spring blade
(FBR) / articulated arm
(TGR)
⇨ See "Store sizes" [page 15]
D1 Diameter of rotary agitator
plate
900
mm
1660
mm
900
mm
1660
mm
900
mm
1660
mm
D2 Diameter of screw 110 mm 150 mm 190 mm
D3 Diameter of drive shaft 40 mm
B1 Width of trough screw 140 mm 200 mm 250 mm
B2 Width of rotary agitator duct 80 mm
H1 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 store
αGradient angle for wood
chips
0 – 15 ° 0 – 10 ° 0 – 15 ° 0 – 10 ° 0 – 15 ° 0 – 10 °
Gradient angle for pellets 0 – 5 ° 0 – 3 ° 0 – 5 ° 0 – 3 ° 0 – 5 ° 0 – 3 °
3Technical information
Dimensions
14 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

NOTICE
Operating the discharge system at too steep a gradient angle
The mitre gear can break due to insufficient lubrication!
When installing the discharge system, you should therefore ensure:
❒ FBR with wood chips gradient angle α maximum 15°
❒ FBR with pellets gradient angle α maximum 5°
❒ TGR with wood chips gradient angle α maximum 10°
❒ TGR with pellets gradient angle α maximum 3°
➥The rotary agitator should always be fitted as flat as the place of
installation allows
3.2 Store sizes
The spring blade / articulated arm diameter and the length of the open trough / rotary
agitator duct vary depending on the size of the store. The tables below show the
respective dimensions:
FBR
2.0
FBR
2.5
FBR
3.0
FBR
3.5
FBR
4.0
FBR
4.5
FBR
5.0
Store length in rotary
agitator direction
≤ 2.0 m ≤ 2.5 m ≤ 3.0 m ≤3.5 m ≤ 4.0 m ≤ 4.5 m ≤ 5.0 m
Nominal 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 excess to ensure optimum use of the fuel store.
TGR
3.5
TGR
4.0
TGR
4.5
TGR
5.0
TGR
5.5
TGR
6.0
Store length in rotary agitator direction ≤ 3.5 m ≤ 4.0 m ≤ 4.5 m ≤ 5.0 m ≤ 5.5 m ≤ 6.0 m
Articulated arm diameter (D)[mm] 3500 4000 4500 5000 5500 6000
Length of rotary agitator duct (L1)
[mm]
2900 3150 3400 3650 3900 4150
Length of open trough (L3) [mm]
▪ with screw Ø 110 1545 1795 2045 2295 2545 2795
▪ with screw Ø 150 / 200 1795 1795 2045 2295 2545 2795
▪ with long screws 3045 3545 4045 4545 5045 5545
FBR spring blade
agitator
TGR torsion arm
agitator
Technical information 3
Store sizes
Installation and Operating Instructions | M1730116_en 15

❒ The nominal diameter of the discharge system must be selected according to the
side length (A) of the space that runs parallel to the rotary agitator duct.
3.3 Technical specifications
Rotary agitator
Description FBR TGR
Geared motor Power 0.37 kW 0.55 kW
Speed 10.5 rpm 10.5 rpm
Discharge screw
Description T4 24-75 T4 90-110 TM 150
TX 150
T4 130-150
TM 220-320
TX 199-250
TI 350
TM 400-500
Diameter of screw 110 mm 150 mm 200 mm
Geared motor 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 speed 4.5 rpm 10.5 rpm 4.5 rpm 4.5 rpm 10.5 rpm
Safety switch 24 VDC
Operation with wood
chips
Operation with pellets
3Technical information
Technical specifications
16 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4 Installation
4.1 Transport and handling
The discharge system is part-assembled and comes packed on a pallet.
❒ Follow the transport instructions on the packaging!
To prevent damage:
❒ Transport components, particularly drive components, with care
A door should be provided in the store or a ceiling opening in the silo for bringing in
the unit
❒ Note the diameter of the rotary agitator plate! ⇨ See "Dimensions" [page 14]
4.1.1 Temporary storage
If the rotary agitator is not going to be assembled immediately:
❒ Store components at a protected location, which is dry and free from dust
➥Damp can lead to damage to individual parts, particularly in the motor!
4.2 Installation site
When planning the fuel store, you should observe the following design information:
Store detail Design information
1Walls and
ceilings
The walls and ceilings of the store and the boiler room must be fire-proof
(REI 90) in compliance with local regulations
2Hole 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 around holes made in
walls must be filled with insulating material in compliance with the
standards ÖNORM B 3836 or DIN 4102-11.
For dimensions of the opening see “Hole in wall”
3Boarding the
store door
The store door must be a fire door with an EI230-C fire resistance rating; it
must have a seal. Wooden boards should also be fitted on the interior of
the store so that the fuel does not press against the door.
Installation 4
Transport and handling
Installation and Operating Instructions | M1730116_en 17

Store detail Design information
4Inspection
opening
Maintenance opening with class EI290-C fire resistance rating (e.g. chimney
door) immediately over the hole in the wall for easy clearance of any
blockages from oversized material around the shear edge of the discharge
screw. The inspection opening must be designed in such a way that it can
only be opened with a tool. The operator must highlight residual risks at the
inspection opening.
5Side wall
protection
If the structure of the store means that the arms come into contact with the
wall (rectangular room), we recommend that you fit an approx. 300 mm
high covering made of sheet metal or hardwood to the wall of the store.
This prevents pieces of the wall and plaster from breaking off and blocking
the discharge system.
6Raised
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 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 store at an angle of
90° to the wall.
❒ The discharge screw must be positioned so that the shear edge (transition from
open to closed trough) is at least 200 mm away from the wall.
Correct position of the discharge screw
NOTICE
Malfunctioning of discharge system because discharge screw is in incorrect
position
Positioning the open trough of the discharge screw next to the rotary agitator
plate may cause bridge formation and malfunctioning in the discharge when the
bunker is full.
Therefore:
❒ Position all, or at least half, of the open trough of the discharge screw under
the rotary agitator plate
4Installation
Installation site
18 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

YES: all/at least half of the screw under rotary
agitator plate
NO: screw beside rotary agitator plate
NOTICE! All, or at least half, of the discharge screw must be positioned beneath the
rotary agitator plate!
NOTICE! If using the FBR with raising plate, the raising plate must be cut out
accordingly.
Distance between articulated arms / spring blades
TGR
FBR
0mm
Ø1660mm
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 screw must be
parallel to the effective area of the rotary agitator!
TGR
FBR
Installation 4
Installation site
Installation and Operating Instructions | M1730116_en 19

Fitting options for discharge screw
The separate rotary agitator drive means that the discharge screw can be set up in
different ways. Below are some examples using a separate rotary agitator drive with
TGR. These illustrations apply to 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
4Installation
Installation site
20 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com