Fröling 250 User manual

Installation and Operating Instructions
Bunker filling screw 250
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!
M2080017_en | Edition 22/05/2018
Fröling Ges.m.b.H. | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

Table of contents
1 General 4
1.1 Functional description 5
1.1.1 Control unit 6
2 Safety 7
2.1 Hazard levels of warnings 7
2.2 Permitted Uses 8
2.2.1 Permitted fuels 8
Wood chips 8
2.2.2 Non-permitted fuels 9
2.3 Qualification of staff 9
2.3.1 Qualification of assembly staff 9
2.3.2 Personal protective equipment for assembly staff 9
2.3.3 Qualification of operating staff 10
2.3.4 Protective equipment for operating staff 10
2.4 Design information 11
2.4.1 Standards 11
2.4.2 Requirements at the installation site 12
2.5 Safety devices 13
2.6 Residual risks 14
3 Technical information 15
3.1 Dimensions 15
3.2 Weights 16
3.3 Technical data 16
4 Assembly 17
4.1 Transport and handling 17
4.1.1 Temporary storage 17
4.1.2 Materials supplied 17
4.1.3 Dismantling for locations difficult to access 18
4.2 Assembly aids 19
4.3 Wall opening 20
4.4 Assembly of the geared motor 20
4.5 Fitting the bunker filling screw 21
4.6 On-site final work 22
5 Electrical connection 23
5.1 Wiring the control unit 23
5.2 Mains connection 23
6 Operating the system 24
6.1 Initial start-up 24
6.2 Fill the store with fuel 24
Table of contents
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6.2.1 Switching on the power supply 25
6.2.2 Start filling process 25
6.2.3 Stop filling process 26
6.2.4 Switch off the power supply 26
7 Servicing the System 27
7.1 Maintenance schedule 28
8 Troubleshooting 29
9 Appendix 30
9.1 Addresses 30
9.1.1 Address of manufacturer 30
Customer service 30
9.1.2 Address of the installer 30
Table of contents
Installation and Operating Instructions Bunker filling screw 250 | M2080017_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
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1.1 Functional description
The Froling bunker filling screw 250 comprises:
1Inlet opening
2Outlet opening
3Troughs with internal screw 250
4Geared motor
5Control cabinet
6Control
7Protective structures
The Froling bunker filling screw 250 has been designed for the automatic filling of a
fuel store. The screw is loaded with fuel via the inlet opening (1) located outside the
store. The system is started using the two-hand tripping device of the mobile control
unit (6), which is connected to the stationary control cabinet (5) via a flexible control
line.
The screw driven by a geared motor (4) then transports the fuel up to the outlet
opening (2), after which the material is discharged in the fuel store via the discharge
system.
General 1
Functional description
Installation and Operating Instructions Bunker filling screw 250 | M2080017_en 5

1.1.1 Control unit
7Emergency stop for shutting down the system immediately in a hazardous
situation
8Key-operated selector switch for changing the direction of rotation of the screw
9Start button for two-hand tripping device (one push-button on the left and right-
hand side).
Both push-buttons have to be pressed to start the system.
1General
Functional description
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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.
NOTICE
The dangerous situation may occur and if measures are not observed it will lead
to damage to property or pollution.
Safety 2
Hazard levels of warnings
Installation and Operating Instructions Bunker filling screw 250 | M2080017_en 7

2.2 Permitted Uses
The Froling bunker filling system is solely designed for transporting fuels into suitable
store spaces. Only use fuels specified in the "Permitted fuels" section.
The unit should only be operated when it is in full working order. It must 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 must 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.
Only original spare parts or specific alternative spare parts authorised by the
manufacturer may be used. Any kind of change or modification made to the product
will 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 the rights
and responsibilities of a manufacturer.
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
2Safety
Permitted Uses
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2.2.2 Non-permitted fuels
The use of fuels not defined in the "Permitted fuels" section is not permitted.
NOTICE
The system is not permitted to be used for supplying other fuel types, which the
underlying heating system may also be suitable for, e.g. pellets, shavings or
miscanthus.
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 instructions and information in the manuals
❒ Only allow trained staff to carry out assembly and installation
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 workwear
- protective gloves
- sturdy shoes
Safety 2
Permitted Uses
Installation and Operating Instructions Bunker filling screw 250 | M2080017_en 9

2.3.3 Qualification of operating staff
CAUTION
If unauthorised persons enter the store / working range:
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 inspection and cleaning:
- suitable workwear
- protective gloves
- sturdy shoes
▪ Additional for operating:
- Hearing protection (sound level > 70 dB)
- Protective goggles
2Safety
Qualification of staff
10 Fröling Ges.m.b.H. | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.4 Design information
Carrying out modifications to the system and changing or deactivating safety
equipment is prohibited.
Always comply with all fire, building, and electrical regulations when installing or
operating the system, in addition to following the operating instructions and mandatory
regulations that apply in the country in which the system is operated.
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 always be
observed:
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
EN 13501 Fire classification of construction products and building
elements
Safety 2
Design information
Installation and Operating Instructions Bunker filling screw 250 | M2080017_en 11

2.4.2 Requirements at the installation site
▪ The installation site must have a suitable, level surface within the working range of
the system (filling area, switching unit with operating elements)
▪ The assembly material and the structure of the ceiling construction to which the
filling screw is mounted must be designed and approved for the loads.
▪ The operating area must be designed so as to avoid risks posed by the loading
vehicle
▪ The system does not provide any light, so the customer must provide sufficient
lighting in accordance with national workplace design regulations.
▪ The switching unit must be installed indoors with protection from the weather
▪ The wall duct for the connection cable of the control unit must be positioned so
that the length of the cable allows the control unit to be located outside the danger
zone. The filling area must be visible during operation
▪ Protective structures must be designed in accordance with the applicable
standards and regulations
▪ On-site weather protection over the filling area must be provided.
▪ When working in the fuel store, observe the information on the “fuel store” notice
(supplied).
▪ Low outside temperatures in conjunction with wet wood chips can cause system
components to freeze. Protect the system from frost!
2Safety
Design information
12 Fröling Ges.m.b.H. | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

2.5 Safety devices
Description Description
Main switch on the control cabinet For switching off the entire system.
When working on the system or in the store space,
always padlock the main switch to ensure it cannot be
switched on without authorisation.
EMERGENCY STOP button For shutting down the system with any danger.
There is imminent risk:
❒ Press emergency stop on control
➥All units will stop immediately
➥The power supply remains switched on
When there is no longer any risk:
❒ Rest the emergency stop button by rotating
Safety two-hand tripping device Safety switch for operating the system.
The bunker filling system can only be activated by
constantly pressing the two buttons mounted on each
side.
Safety 2
Safety devices
Installation and Operating Instructions Bunker filling screw 250 | M2080017_en 13

2.6 Residual risks
DANGER
Operating the system without the safety equipment provided by the customer:
Risk of serious injury from unprotected system components!
For safe operation of the system:
❒ Only operate the system once the required safety equipment has been
installed
➥Observe the instructions and information about safety equipment to be
provided by the customer in the manuals
➥Compliance with open provisions in the declaration of installation as per
Machinery Directive 2006/42/EC must be verified.
DANGER
If the bunker filling screw is switched on when someone is in the danger zone:
Risk of serious injury from rotating feed screw!
Therefore:
❒ Ensure that there is no one in the filling area of the bunker filling screw and
that no one enters the danger zone for the duration of the filling process
❒ Ensure that no one is in the store and that the entrance to the store is secured
against entry for the duration of the filling process
❒ Only start the filling process once these conditions have been met
DANGER
Maintaining the system when the main switch is switched on:
Risk of serious injury from unauthorised switching on!
When maintaining the system or in the storage area:
❒ Switch off the main switch of the bunker filling system and re-secure it against
unauthorized restarting using a padlock
❒ Switch off any other devices in the fuel store which potentially have
dangerous movements (e.g. discharge system) and take precautions to
prevent accidental switching on.
➥Also observe the information on the notice (supplied) for working in the fuel
store.
2Safety
Residual risks
14 Fröling Ges.m.b.H. | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

3 Technical information
3.1 Dimensions
D1
A-A
D2
L1
L2
L3
L5
L4
A
A
L3
Item Description Unit Value
L1 System length mm 4050
4500
4950
5400
5850
6300
6750
7200
7650
8100
L2 Length of geared motor with bearing flange 592
L3 Length of inlet / outlet 500
L4 Trough length 900
1350
1800
L5 Offset of the half shells 450
D1 Diameter, screw 250
D2 Diameter, trough channel 300
αGradient angle ° 0 – 60
Technical information 3
Dimensions
Installation and Operating Instructions Bunker filling screw 250 | M2080017_en 15

3.2 Weights
Description Weight of bunker filling screw [kg]
without wood
chips
with wood chips 1)
Geared motors:
Geared motor 4.0 kW (ATEX) 37
Geared motor 5.5 kW (ATEX) 46
Filling screw incl. geared motor (5.5 kW):
System length 4050 mm 206 267
System length 4500 mm 224 292
System length 4950 mm 248 323
System length 5400 mm 267 348
System length 5850 mm 285 373
System length 6300 mm 302 397
System length 6750 mm 320 422
System length 7200 mm 339 447
System length 7650 mm 357 472
System length 8100 mm 382 504
1.As a rough estimate, 15 kg of wood chips per meter of screw length are assumed. The value depends on the quality, water content and
grain size of the wood chips.
3.3 Technical data
Designation Value
Feed output of filling screw 1) approx. 30 m³/h
Electrical connection 230 / 400 V / 50 Hz
Electric fuses C 20 A
Power consumption of drive 2) 4 kW
5.5 kW
Output speed of drive 4.0 kW 162 rpm
5.5 kW 229 rpm
1.Depending on the type of wood chips and the structural design of the filling area
2.Depending on system – see circuit diagram
3Technical information
Weights
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4 Assembly
4.1 Transport and handling
The filling screw comes pre-assembled and packed on a pallet.
NOTICE
Possibility of damage to components if handled incorrectly
❒ Follow the transport instructions on the packaging
❒ Transport components, in particular drive components, with care to avoid
damage
4.1.1 Temporary storage
If the system 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!
4.1.2 Materials supplied
Position Description
ABunker filling screw 250 (mounted on a pallet)
BGeared motor incl. torque support
CSupport for floor mounting
DAssembly material (heavy duty anchors, etc.)
EControl cabinet, control, plug connection
Assembly 4
Transport and handling
Installation and Operating Instructions Bunker filling screw 250 | M2080017_en 17

4.1.3 Dismantling for locations difficult to access
If positioning of the entire discharge is not possible due to its length, the screw can be
taken apart at a specified point. The following table shows the position in the trough
where it can be taken apart (C):
A B
L1
System length L1 Distance A (inlet side) Distance B (outlet side)
4050 cannot be taken apart
4500 cannot be taken apart
4950 2616 2334
5400 2616 2784
5850 2616 3234
6300 2616 3684
6750 4416 2334
7200 4416 2784
7650 4416 3234
8100 4416 3676
❒ Dismantle the upper half shell of the trough at the connection point
❒ Remove the spring pin
➥Use a 14 mm punch
Dismantling:
4Assembly
Transport and handling
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❒ Loosen the screw connection on the lower half shells
❒ Carefully separate both halves and insert components
After positioning, assembly is carried out in the reverse order!
4.2 Assembly aids
Suitable lifting equipment with sufficient load-bearing capacity is required on site to
manoeuvre the components. The bunker filling screw is designed for transport and
installation with eye bolts.
NOTICE! Lifting with suitable lifting equipment should only be carried out by
technicians with a specific knowledge of lifting loads!
NOTICE! Lifted components must be secured by the lifting equipment until firmly
attached!
When performing assembly at great heights, suitable scaffolding or elevating work
platforms are necessary on site. Their design and dimensioning in relation to the
permissible working height and load capacity should be selected according to the
accident prevention regulations!
Lifting
Working height
Assembly 4
Assembly aids
Installation and Operating Instructions Bunker filling screw 250 | M2080017_en 19

4.3 Wall opening
Section - side view:
Section - top view:
Before installing the discharge system, the customer must provide a wall opening for
the trough. The dimensions of the opening are calculated from the wall thickness (S)
and the angle of the trough to the wall (β) as well as the angle of inclination (α) of the
entire discharge system. Experience has shown that for right angles an opening of
600 mm x 600 mm is sufficient. You should also note that the discharge must not be
connected to the wall in order to avoid vibration transmission (structure-borne noise)
and noise generation. Finally, the wall opening must be elastically lined with a non-
combustible material in accordance with ÖNORM B 3836 or DIN 4102-11.
4.4 Assembly of the geared motor
The geared motor is delivered individually packaged to avoid damage. Carry out
assembly as follows:
❒ Position the rubber buffer (B) with hexagon screw (C) in the geared motor (A).
❒ Lubricate the inside of the screw shaft stub and gears with copper paste
❒ Push the geared motor (A) onto the shaft stub
➥Position the shaft stub so that the groove is aligned with the groove of the
gears
❒ Fix torque support to bearing flange (E) with two hexagon nuts (D)
4Assembly
Wall opening
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