Fröling BFSV-H User manual

Installation- and Operating Intructions
Bunker filling system BFSV-H / BFSU-H
Translation of the original German operating instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1690116_en | Edition 08/08/2016
Froling GesmbH | 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 Technology 16
3.1 Dimensions BFSV-H 16
3.1.1 Design with recessed bulk chute 19
3.1.2 Dimensions of extension shaft 19
3.2 Dimensions BFSU-H 20
3.2.1 Design with recessed bulk chute 22
3.3 Technical data 22
4 Assembly 23
4.1 Transport and handling 23
4.1.1 Temporary storage 23
4.2 Assembly Aids 23
4.3 Installation site 25
4.3.1 Position of horizontal distributor screw 25
4.3.2 Installation with mobile bulk chute 27
4.3.3 Installation with recessed bulk chute 28
4.4 Installation variants BFSV - H 29
4.5 Installation variants BFSU - H 29
4.6 Install Bunker Filling System 30
4.6.1 Install vertical screw 30
4.6.2 Fitting the extension shaft (optional) 32
4.6.3 Installing the horizontal distributor screw 32
Welding the coreless screw together 32
Assembling the troughs 33
Installing the adjustable feet 34
Table of contents
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Attaching the horizontal distributor screw to the ceiling 34
4.6.4 Preparing the bulk chute 35
Fit the cover plates 36
4.6.5 Position bulk chute 36
4.6.6 Turning the fitting frame 37
4.6.7 Final installation steps 38
Positioning the stickers 38
5 Electrical connection 40
5.1 Mains connection 40
5.2 Time relay settings in the control cabinet 40
6 Operating the system 41
6.1 Initial start-up 41
6.2 Adjust Filling Area to Loading Vehicle 42
6.3 Adjust the feed output to the fuel 42
6.4 Fill the store with fuel 43
6.4.1 Switching on the power supply 43
6.4.2 Start filling process 43
6.4.3 Stop filling process 45
6.4.4 Switch off the power supply 46
7 Servicing the system 47
7.1 Maintenance schedule 48
8 Troubleshooting 49
9 Appendix 50
9.1 Addresses 50
9.1.1 Address of manufacturer 50
9.1.2 Address of the installer 50
Table of contents
Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_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 Fröling bunker filling system comprises:
BFSV-H
BFSU-H
1
1
2
3
4
56
4
3
1Bulk chute
2Vertical screw
3Horizontal distributor screw with geared motor
4Filling level sensor
5Control cabinet with main switch
6Control unit with control line, plug and mating plug
The Fröling bunker filling system has been designed for the automatic filling of a fuel
store. The bunker filling system, which can either be a stationary unit or equipped with
wheels, is loaded with fuel via the bulk chute (1) located outside the store space. 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 to the
socket. The horizontal screw of the bulk chute feeds the fuel to the transfer position.
From there the fuel is fed to the horizontal distributor screw (3) either directly (with
BFSU-H) or via the vertical screw (2 - with BFSV-H). The horizontal distributor screw
(3) is powered by the geared motor installed in the fuel store and transports the fuel
into the fuel store, where it is discharged through the open trough. The flange plate of
the geared motor of the horizontal distributor screw is equipped with a filling level
General 1
Functional description
Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en 5

sensor (4), which stops the fuel store from filling when the fuel store is full. The filling
level sensor is connected to the control unit which indicates on the control unit at
“Sensor right” whether the fuel store has reached the maximum filling level.
1.1.1 Control unit
7Emergency stop for shutting down the system immediately with any risk
8Key-operated selector switch (NOT IN USE)
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.
10 Status LED to display the operating status
- GREEN constant: STANDBY
- RED constant: FAULT
11 Status LED (NOT IN USE)
12 Status LED for right filling level sensor (filling level sensor to flange plate of geared
motor in fuel store)
- GREEN constant: Fuel store can be filled with fuel
- RED constant: Fuel store is full, no more fuel can be brought into fuel store
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 or damage to property.
Safety 2
Hazard levels of warnings
Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_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 its manufacturer’s CE conformity. 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 attach the new CE label to 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 Intructions BFSV-H / BFSU-H | M1690116_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 Froling GesmbH | 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 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
Design information
Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_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 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
▪ The screw of the mobile bulk chute cannot be divided. To remove the screw, there
must be sufficient space behind the bulk chute to pull it out.
▪ An on-site weather guard must be provided by the customer in order to avoid
water ingress into the bunker.
▪ Provide inspection opening at the end of the horizontal distributor screw for
cleaning the filling level sensor
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
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2.5 Safety devices
Designation 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. When one or both buttons are released, the vertical
screw and the horizontal distributor screw runs for a
preset delay time.
Filling level sensor Protection from overfilling the fuel store.
The flange plate of the geared motor of the horizontal
distributor screw is equipped with a filling level sensor,
which is connected to an LED display on the control. The
filling level sensor indicates whether the maximum filling
level of the fuel store is reached, or whether fuel can still
be transported into the fuel store. If the sensor responds,
further operation of the system is not possible.
Safety switch of bulk chute Protection from the system being switched on without
attachments.
When the bulk chute is disconnected, the safety switch is
force-actuated, so preventing the system from being
used without attached components (vertical screw /
horizontal distributor screw).
Safety 2
Safety devices
Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_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
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DANGER
Delayed automatic start-up of individual components
Serious injury possible due to moving parts with automatic start-up!
When switching on the system, remember the following:
❒ Check that there is no-one in the danger zone of the system
❒ Press both push-buttons of the two-hand tripping device
➥Depending on the function time-delayed activation of the individual units
will take place
➥This process may take a few seconds and is not a fault
DANGER
Automatic run-on of individual components
Serious injury possible due to moving parts with automatic run-on!
❒ Release one or both buttons on the control unit
➥Depending on the function, the vertical screw and also the horizontal
distributor screw/centrifugal disc are switched off with a time delay
➥This process may take a few seconds and is not a fault
Safety 2
Residual Risks
Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en 15

3 Technology
3.1 Dimensions BFSV-H
The following diagram with associated matrix lists the possible system lengths and
system heights which are important for design of the fuel store and the wall opening.
All dimensions are specified in mm.
Height-adjustable from 0 to +200
Horizontal distributor screw
swivelling
+90° to -90°
593
505
738
1258
752
1345
max. 2000 550
694
Maintenance area Gravity shaft
Maintenance area
Ø303
950
Extension pipe (420 - 5760) 300
100
V2
Extension pipe
(0 - 3840)
Distributor trough end
(1000)
500
400
V1
Distributor trough open (0 - 10000)
(Distrib. trough length 500, 1000 und 2000)
System length of horizontal distributor screw (2400 - 12400)
n303
System height vertical (1820 - 7580) + 50
300 52
203
min. 160
Distributor trough
start
(1000)
50mm (0 to +840)
(Min. clearance ceiling to top of flange)
Bulk chute (900, 1900, 2900)
300
470
System length (1500 - 7340)
50
T-piece (1920mm)
50
Extension pipe
(420 - 3840)
250
max. 980
Bulk chute 900 = 1570
Bulk chute 1900 = 2570
Bulk chute 2900 = 3570
400 - 4240
150
8070
n303
3Technology
Dimensions BFSV-H
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System length of horizontal distributor screw
BM V1
(in 500 mm steps)
BM V2 BM
Distributor trough end Distributor trough open Distributor trough start Extension pipe Gravity shaft
1000 0 – 10000 1000 - 400
0 – 9000 420
0 – 9000 920
0 – 8000 1340 (920+420)
0 – 8000 1920
0 – 7000 2340 (1920+420)
0 – 7000 2840 (1920+920)
0 – 6000 3260 (1920+920+420)
0 – 6000 3840 (1920+1920)
System length (max. 12400 mm) = GM + V1 + GM + V2 + GM
Matrix of system heights
Base unit of vertical
screw
Possible
system heights
Necessary
extension pipes
Screw length Number of wall
fixings
Weight
1920 1820 - 2330 1 244
2240 420 2750 1 261
2740 920 3250 2 279
3160 1340 (920+420) 3670 2 296
3740 1920 4250 2 315
4160 2340 (1920+420) 4670 2 332
4660 2840 (1920+920) 5170 3 350
5080 3260 (1920+920+420) 5590 3 367
5660 3840 (1920+1920) 6170 3 386
6080 4260 (1920+1920+420) 6590 3 403
6580 4760 (1920+1920+920) 7090 4 421
7000 5180
(1920+1920+920+420)
7510 4 438
7580 5760 (1920+1920+1920) 8090 4 457
Technology 3
Dimensions BFSV-H
Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en 17

Matrix of system lengths
Length of bulk chute Possible system lengths Necessary extension pipes Screw length Weight
900 1520 - 1560 277
1920 420 1980 294
2420 920 2480 312
2840 1340 (920+420) 2900 330
3420 1920 3480 348
3840 2340 (1920+420) 3900 365
4340 2840 (1920+920) 4400 383
4760 3260 (1920+920+420) 4820 400
5340 3840 (1920+1920) 5400 419
Length of bulk chute Possible system lengths Necessary extension pipes Screw length Weight
1900 2500 - 2560 376
2920 420 2980 393
3420 920 3480 411
3840 1340 (920+420) 3900 428
4420 1920 4480 447
4840 2340 (1920+420) 4900 464
5340 2840 (1920+920) 5400 482
5760 3260 (1920+920+420) 5820 499
6340 3840 (1920+1920) 6400 518
Length of bulk chute Possible system lengths Necessary extension pipes Screw length Weight
2900 3500 - 3560 474
320 420 3980 491
4420 920 4480 509
4840 1340 (920+420) 4900 526
5420 1920 5480 545
5840 2340 (1920+420) 5900 562
6340 2840 (1920+920) 6400 580
6760 3260 (1920+920+420) 6820 597
7340 3840 (1920+1920) 7400 616
3Technology
Dimensions BFSV-H
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3.1.1 Design with recessed bulk chute
The following diagram shows the BFSV-H variant with a recessed bulk chute and is
also particularly useful when dimensioning the shaft size. The system lengths possible
are based on the matrix given above. All dimensions are specified in mm.
bulk chute 900 = 1570
bulk chute 1900 = 2570
bulk chute 2900 = 3570
400 - 4240
Extension pipe
(420 - 3840) 300 bulk chute (900, 1900, 2900) 50
470
System length bulk chute (1500 - 7340)
950
250
945
Ø303
160
Fitting frame 1110
1150
950
575 575
400
Shaft length = System length bulk chute + 1030
150
8070
n303
3.1.2 Dimensions of extension shaft
An extension is necessary for the wall duct depending on the conditions on site. It
should be remembered that depending on the extension shaft used, the system height
will reduce by either 50 or 500 mm. All dimensions are specified in mm.
Extension shaft 140 mm:
200
Ø303
140
System height vertical - 50mm
302
151
400
1050
n303
Extension shaft 707 mm:
600
Ø303
707
System height vertical - 450mm
551
400 703
1450
n303
Technology 3
Dimensions BFSV-H
Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en 19

3.2 Dimensions BFSU-H
The following diagram with associated matrix lists the possible system lengths and
system heights which are important for design of the fuel store and the wall opening.
All dimensions are specified in mm.
505
738
593 752
1345
1258400 - 1400
Distributor trough end
(1000)
500
V1
Distributor trough open (0 - 10000)
(Distributor trough length
500, 1000 and 2000)
System length horizontal distributor screw (2400 - 12400)
300
550
694
430
450
50mm (0 to +840)
(Min. clearance ceiling to top of flange)
Height-adjustable -0 bis +200
Maintenance area
Ø303
Bulk chute (900, 1900, 2900)
System length bulk chute (1500 - 7340)
Extension pipe
(420 - 3840)
250
150
80 Bulk chute 900 = 1570
Bulk chute 1900 = 2570
Bulk chute 2900 = 3570
400 - 4240
300
400 + Extension gravity shaft
550 + Extension gravity shaft
70
Distributor trough
start
(1000)
V2
Extension pipe
(0 - 3840) 400
107
500
Ø303
Extension gravity shaft 250 - 1000
Gravity shaft
50
470
300
min. 700
500
1150
Horizontal distributor screw
swiveling
+90° to -90°
System length of horizontal distributor screw
BM V1
(in 500 mm steps)
BM V2 BM
Distributor trough end Distributor trough open Distributor trough start Extension pipe Gravity shaft
1000 0 – 10000 1000 - 400
0 – 9000 420
0 – 9000 920
0 – 8000 1340 (920+420)
0 – 8000 1920
0 – 7000 2340 (1920+420)
0 – 7000 2840 (1920+920)
0 – 6000 3260 (1920+920+420)
0 – 6000 3840 (1920+1920)
System length (max. 12400 mm) = GM + V1 + GM + V2 + GM
3Technology
Dimensions BFSU-H
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