Fröling BFSU User manual

Installation and operating instructions
Sliding floor discharge unit
with discharge screw
Translation of original German version of installation and operating instructions for technicians and
operators.
Read and follow all instructions and safety instructions.
All errors and omissions excepted.
M1510021_en | Edition 22/06/2022

Table of contents
ii M1510021_en | Installation and operating instructions Sliding floor discharge unit
1 General information .................................................................................................................................... 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 ........................................................................................................................... 8
2.3 Qualification of staff............................................................................................................................... 8
2.3.1 Qualification of assembly staff ................................................................................................... 8
2.3.2 Personal protective equipment for assembly staff ..................................................................... 9
2.3.3 Qualification of operating staff ................................................................................................... 9
2.3.4 Protective equipment for operating staff .................................................................................... 9
2.4 Design information ................................................................................................................................ 10
2.4.1 Standards................................................................................................................................... 10
2.4.2 Requirements at the installation site .......................................................................................... 11
2.5 Safety devices....................................................................................................................................... 12
2.5.1 External safety devices .............................................................................................................. 12
2.6 Residual risks........................................................................................................................................ 13
3 Technology .................................................................................................................................................. 14
3.1 Technical data....................................................................................................................................... 14
3.2 Store layout and construction................................................................................................................ 15
3.2.1 Design data for the sliding floor discharge unit .......................................................................... 16
4 Installation ................................................................................................................................................... 17
4.1 Transport and positioning...................................................................................................................... 17
4.1.1 Temporary storage..................................................................................................................... 17
4.1.2 Positioning ................................................................................................................................. 18
4.2 Installation site ...................................................................................................................................... 19
4.2.1 Wall penetration ......................................................................................................................... 20
4.3 Installation of the sliding floor discharge unit ........................................................................................ 21
4.3.1 Masonry and concreting work .................................................................................................... 21
4.3.2 Installing the substructure .......................................................................................................... 23
4.3.3 Installing the transverse conveyor unit....................................................................................... 25
4.3.4 Finishing work on the substructure ............................................................................................ 27
4.3.5 Installing the upper structure...................................................................................................... 28
4.3.6 Installing the hydraulic unit and cylinder .................................................................................... 30
4.3.7 Fitting the upper part of the gravity shaft and drive unit............................................................. 32
4.3.8 Installing the sensors ................................................................................................................. 34
4.3.9 Closing the wall penetration....................................................................................................... 34
4.3.10 Temperature monitoring device in the fuel store (TMD): ........................................................... 35
4.3.11 Installing the bulkhead ............................................................................................................... 36
4.4 Connecting the system.......................................................................................................................... 38
4.4.1 Electrical connection .................................................................................................................. 38
4.4.2 Connecting the sprinkler system................................................................................................ 38
5 Operating the System ................................................................................................................................. 39
5.1 General information............................................................................................................................... 39
5.2 Initial start-up......................................................................................................................................... 39
5.3 Filling the store with fuel........................................................................................................................ 40
5.4 During operation.................................................................................................................................... 41
5.5 Decommissioning.................................................................................................................................. 43
5.5.1 Disassembly............................................................................................................................... 43
5.5.2 Disposal ..................................................................................................................................... 43
6 Servicing the system .................................................................................................................................. 44

Table of contents
M1510021_en | Installation and operating instructions Sliding floor discharge unit iii
6.1 Maintenance work by the operator........................................................................................................ 45
6.2 Maintenance work by technicians ......................................................................................................... 46
6.2.1 Maintenance instructions for hydraulic systems ........................................................................ 47
6.3 Replacement parts ................................................................................................................................ 48
7 Troubleshooting .......................................................................................................................................... 49
7.1 Troubleshooting the Lambdatronic H 3200 control system................................................................... 49
7.1.1 Procedure for fault messages .................................................................................................... 49
7.2 Troubleshooting the SPS 4000 control system ..................................................................................... 50
7.2.1 Procedure in case of malfunctions............................................................................................. 50

1 | General information
4 M1510021_en | Installation and operating instructions Sliding floor discharge unit
1 General information
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.
Issuing a delivery
certificate 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).
Warranty and Guarantee Conditions
Our sale and delivery conditions will be applicable. These conditions have been made
available to customers, and customers have been made aware of them at the time of
order completion.
You can also find the guarantee conditions on the enclosed guarantee certificate.

General information | 1
M1510021_en | Installation and operating instructions Sliding floor discharge unit 5
1.1 Functional description
The Froling discharge system “Sliding floor“ consists of:
5
6
1
11
8
4
3
2
9
7
10
1Substructure of the sliding floor 7Bulkhead
2Metal tiebacks 8Light barriers
3Welded wings 9Hydraulic drive
4Slide rods 10 Wall plate
5Fixed wedge 11 Feeder unit
6Moveable wedge
The FRÖLING sliding floor feed system is used to discharge combustion materials from a
rectangular or square storeroom. The sliding floor feed system can be equipped with one
or more slide rods (4) and is installed on the flat floor of the storeroom. The slide rod (4) is
a horizontal I-beam with wing-type components (3) welded to the beam’s side. Metal
tiebacks (2) are used to secure these wing-type components on the outside and prevent
them from standing up. The substructure of the sliding floor is anchored in the base plate
and embedded in concrete. This process shall be the responsibility of the customer.
The hydraulic drive (9) is used to move the slide rods back and forth. In the direction of
conveyer movement, the end faces of the wedges are vertical and push the fuel material
during the forward stroke in the direction of the conveyor (11) lying transverse to the
sliding floor. During the return stroke, the tapered side of the wedges undercuts the bulk
material. At the same time, the vertical end faces of the fixed wedges prevent the bulk
material from moving backwards.
The light barriers (8) detect the amount of fuel quantity, based on which the sliding floor's
feed output rate is controlled. The feeder conveys the material to the boiler.

2 | Safety
6 M1510021_en | Installation and operating instructions Sliding floor discharge unit
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
M1510021_en | Installation and operating instructions Sliding floor discharge unit 7
2.2 Permitted uses
Fröling’s “Sliding floor” discharge system is only designed to discharge fuels from suitable
storerooms. 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.
DANGER
If the device is used incorrectly:
Incorrect use of the system can cause severe injury and damage.
When operating the system:
rObserve the instructions and information in the manuals
rObserve the details on procedures for operation, maintenance and cleaning, as well
as troubleshooting in the respective manuals.
rAny 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 | Safety
8 M1510021_en | Installation and operating instructions Sliding floor discharge unit
2.2.1 Permitted fuels
Wood chips
Description according to
EN ISO 17225-4
Description
M20 Water content max. 20%
M30 Water content max. 30%
M35 Water content max. 35%
P16S Main proportion (at least 60% mass portion): 3.15 – 16 mm, max.
length of 45 mm, previously referred to as fine wood chips G30
P31S Main proportion (at least 60% mass portion): 3.15 – 31.5 mm, max.
length of 150 mm, previously referred to as medium-sized wood
chips G50
From 400 kW: P45S Main proportion (at least 60% mass portion): 3.15–45 mm, max.
length 200 mm, previously referred to as medium-sized wood chips
G50
P63 1) Main proportion (at least 60% mass portion): 3.15–63 mm, max.
length 350 mm, previously referred to as coarse wood chips G100
Note on standards EU: Fuel according to EN ISO 17225 – Part 4: Wood chips class A2 / P16S-P31S
M35
Additional for
Germany:
Fuel class 4 (§3 of the First Federal Emissions Protection Ordinance
(BimSchV) in the last amended version)
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:
rObserve the instructions and information in the manuals
rOnly allow appropriately qualified personnel to work on the system
Assembly, installation, initial startup and servicing must only be carried out by qualified
personnel:
▪ Heating technicians/building technicians
▪ Electrical installation technicians
▪ Froling customer services
The assembly staff must have read and understood the instructions in the documentation.

Safety | 2
M1510021_en | Installation and operating instructions Sliding floor discharge unit 9
2.3.2 Personal protective equipment for assembly staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations!
▪ During transport, erection and installation:
- wear suitable work wear
- wear protective gloves
- wear safety shoes (min. protection class S1P)
2.3.3 Qualification of operating staff
CAUTION
If unauthorised persons enter the Storeroom:
Risk of personal injury and damage to property
rThe 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 | Safety
10 M1510021_en | Installation and operating instructions Sliding floor discharge unit
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
M1510021_en | Installation and operating instructions Sliding floor discharge unit 11
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.

2 | Safety
12 M1510021_en | Installation and operating instructions Sliding floor discharge unit
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 screw
or discharge screw when the system is switched on
rIf the inspection cover is opened, the system is switched off
via the limit switch
ÄThe power supply remains switched on
Water sprinkler system Self-activating extinguisher system to limit burn back around the
top of the trough.
If the temperature in the trough rises above 95 °C, the valve of
the sprinkler system opens, water flows out and thus prevents a
fire from spreading to the fuel store.
TMF Temperature monitoring device in the fuel store (according to
TRVB H118, only in Austria), which activates the on-site warning
device(s) if 70 °C is exceeded in the fuel store.
2.5.1 External safety devices
Hydraulic chamber safety switch
Before starting any maintenance work in the hydraulic chamber of the sliding floor:
rTurn the safety switch to the "0" position
ÄThe boiler follows the shutdown procedure and the discharge is deactivated
rIf turning the selector switch past the "0" position, the locking lever can be depressed
ÄUse a padlock to secure the switch and prevent the system from starting
accidentally
After the maintenance work in the hydraulic chamber of the sliding floor has been
completed:
rRemove the padlock
rTurn the selector switch past the "0" position. This automatically releases the locking
switch. Now, the selector switch can be turned back to the "1" position
rAcknowledge fault that has occurred on the boiler

Safety | 2
M1510021_en | Installation and operating instructions Sliding floor discharge unit 13
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
Operating the system without the on-site safety equipment:
Risk of serious injury from unprotected system components!
For safe operation of the system:
rOnly operate the system once the required safety equipment has been installed
ÄObserve the instructions and information about on-site safety equipment in the
manuals
ÄCompliance with open provisions in the declaration of installation as per Machinery
Directive 2006/42/EC must be verified!
DANGER
If the device is used incorrectly:
Incorrect use of the system can cause severe injury and damage.
When operating the system:
rObserve the instructions and information in the manuals
rObserve the details on procedures for operation, maintenance and cleaning, as well
as troubleshooting in the respective manuals.
rAny 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
DANGER
Maintenance work if the system is switched on:
Risk of severe injuries from system components or if the system is switched on
without authorisation!
Before starting any maintenance work on the system or in the storeroom:
rTurn the safety switch inside the hydraulic chamber to the "0" position
rUse a padlock to secure the switch and prevent the system from starting accidentally

3 | Technology
14 M1510021_en | Installation and operating instructions Sliding floor discharge unit
3 Technology
3.1 Technical data
Description Value
width of wing/slide rod 1.5 – 3.0 m
Storeroom length 4.6 – 16.2 m
Bulk volume 27.6 – 129.6 m3
Max. load per slide rod 36 t
Hydraulic units
Overall output of the
system
> 500 kW > 1,000 kW > 1,500 kW
Output 4 kW 7.5 kW 11 kW
Air volume flow 12 L/min 16 L/min 24 L/min
Motor voltage 400 V / 50 Hz
Solenoid valve 24 VDC

Technology | 3
M1510021_en | Installation and operating instructions Sliding floor discharge unit 15
Discharge screw
Overall output of the
system
> 320 kW > 500 kW > 1,500 kW
Diameter Ø 150 mm Ø 200 mm Ø 250 mm
Output 0.55 kW 0.55 kW 0.55 kW
Speed 10.9 rpm 10.8 rpm 10.7 rpm
Motor voltage 400 V / 50 Hz
Safety switch 24 VDC
3.2 Store layout and construction
4.6 – 16.2 m
max. 150 mm
max. 150 mm
1.5 – 3.0 m
max. 500 mm

3 | Technology
16 M1510021_en | Installation and operating instructions Sliding floor discharge unit
3.2.1 Design data for the sliding floor discharge unit
The following tables indicate the maximum permissible dumping height as a function of
the wing’s width and the store length.
NOTICE!If the bulk density of the wood chips is more than 250 kg/m³ (e.g. due to
moisture), the maximum dumping height is reduced accordingly.
Cylinder in tension
3,00 2,75 2,50 2,25 2,00 1,75 1,50
200/100-500
~ 12,8 m
10
9
8
7
6
5
4
8
7
6
5
4
180/90-500
~ 11,6 m
~ 10,4 m
~ 9,3 m
~ 8,1 m
~ 7,0 m
~ 5,8 m
~ 4,6 m
~ 9,3 m
~ 8,1 m
~ 7,0 m
~ 5,8 m
~ 4,6 m
4,5 5,211
4,3 4,9 5,7
4,3 4,8 5,8 6,4
4,3 4,8 5,4 6,2 7,2
4,1 4,5 4,9 5,5 6,2 7,0 8,2
4,8 5,2 5,7 6,4 7,2 8,2 9,6
5,7 6,3 6,9 7,7 8,6 9,9 11,5
7,2 7,8 8,6 9,6 10,8 12,3 14,4
4,4 5,0 5,8
4,0 4,4 5,0 5,7 6,7
4,2 4,7 5,2 5,8 6,7 7,8
4,7 5,1 5,6 6,2 7,0 8,0 9,3
5,8 6,3 7,0 7,8 8,7 10,0 11,6
Cylinder Number of
movable
wedges
Length
of store
room
Width of wing [m]
Maximum dumping height [m]
Cylinder pressurised
NOTICE!If the cylinder is pressurised, the transmission of power can be increased.
3,00 2,75 2,50 2,25 2,00 1,75 1,50
200/100-200
~ 16,2 m
13
12
11
10
9
8
7
10
9
8
7
6
180/90-500
~ 15,1 m
~ 13,9 m
~ 12,8 m
~ 11,6 m
~ 10,4 m
~ 9,3 m
~ 8,1 m
~ 11,6 m
~ 10,4 m
~ 9,3 m
~ 8,1 m
~ 7,0 m
4,0 4,6 5,314
4,3 4,9 5,7
4,2 4,7 5,3 6,2
4,1 4,5 5,1 5,8 6,8
3,7 4,1 4,5 5,0 5,6 6,4 7,5
4,2 4,5 5,0 5,5 6,2 7,1 8,3
4,7 5,1 5,6 6,2 7,0 8,0 9,3
5,3 5,8 6,4 7,1 8,0 9,1 10,7
4,0 4,5 5,2 6,1
4,0 4,5 5,0 5,8 6,7
4,1 4,5 5,0 5,7 6,5 7,6
4,3 4,7 5,2 5,8 6,5 7,4 8,6
5,2 5,5 6,1 6,7 7,6 8,6 10,1
Cylinder
Number of
movable
wedges
Length
of store
room
Width of wing [m]
Maximum dumping height [m]

Installation | 4
M1510021_en | Installation and operating instructions Sliding floor discharge unit 17
4 Installation
4.1 Transport and positioning
The discharge system is supplied without a pallet and requires a loading area of up to 8
m, depending on the length of the profiles.
rFollow the transport instructions on the packaging!
rTransport components with care.
A door should be provided to access the store or a ceiling opening for bringing in the unit.
NOTICE
Possibility of damage to components if handled incorrectly
rFollow the transport instructions on the packaging
rTransport components with care to avoid damage
rProtect components against damp
rUnloading, positioning and installation should only be performed by appropriately
trained professionals. Staff must be trained in techniques for moving heavy loads
(correct tools and lifting equipment, hooking and slinging points, etc.)
4.1.1 Temporary storage
If the system is to be assembled at a later stage:
rStore components at a protected location, which is dry and free of dust
ÄDamp can damage components, particularly in the motor.

4 | Installation
18 M1510021_en | Installation and operating instructions Sliding floor discharge unit
4.1.2 Positioning
NOTICE
Careful positioning of the components
rCompliance with the maximum load capacity of the transporting equipment is
mandatory
rThe lifting device must not damage the attached load
rWhen attaching the lifting device, observe the load’s centre of gravity and consider
the possibility that the load might slip. After raising the load initially, stop and readjust
the load if necessary
rDo not raise the load higher than necessary for the transport
rAvoid abrupt movements of the load
rUse suitable lifting gear to transport individual parts of the sliding floor into the store
and hydraulic chamber
ÄConnect the parts to the four attachment points

Installation | 4
M1510021_en | Installation and operating instructions Sliding floor discharge unit 19
4.2 Installation site
When planning the fuel store, compliance with the following design specifications is
mandatory:
3
1
2
5
4
6
Storeroom detail Design information
1Substructure of
the sliding floor
The substructure of the sliding floor muss be embedded in concrete. This
process shall be the responsibility of the customer.
2Access opening Depending on the length of the profiles, a door or an opening in the
ceiling must be provided in order to insert the sliding floor.
3Walls and ceilings The walls and ceiling of the storeroom and boiler room must be fire-proof
in compliance with local regulations.
The storeroom must be rectangular or square.
4Material fracture If the dumping height exceeds 4m, the use of horizontal structural tubing
is highly recommended in order to reduce material fracture.
5Bulkhead Height of fuel passage below the bulkhead
▪ 500 mm
▪ 350 mm – if using a raking chain conveyor and conveyor belt
The bottom 1,000 mm of the bulkhead shall be removable.
6Wall duct and
inspection
opening
The shapes of the wall duct and inspection opening can be different for
the various discharge systems.
Dimensions of the opening Ü "Wall penetration" [}20]
Maintenance opening with class EI290-C fire resistance rating (e.g.
chimney door) immediately above the hole in the wall for easy clearance
of any blockages from oversized material around the shear edge of the
discharge duct.
NOTICE!For special installations (raking chain conveyors with slide system, centre
discharges, etc.) consulting Fröling GesmbH is highly recommended.

4 | Installation
20 M1510021_en | Installation and operating instructions Sliding floor discharge unit
4.2.1 Wall penetration
Before installing the sliding floor, a wall opening must be provided for the trough of the
discharge screw. This task is the responsibility of the customer.
Section - Side view: Section - Top view:
Experience indicates that an opening of 500 mm x 500 mm is sufficient.