Fröling FBR-G User manual

Installation and Operating Instructions
FBR-G / GAR-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!
M2070119_en | Edition 04/06/2019
Fröling Ges.m.b.H. | 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 Assembly 17
4.1 Transport and handling 17
4.1.1 Temporary storage 17
4.2 Installation site 18
4.2.1 Information about setup 19
4.2.2 Wall opening 22
4.3 Installing the discharge system 23
4.3.1 Materials supplied with discharge screw 23
4.3.2 Materials supplied with agitator head 24
4.3.3 Materials supplied with basic kit 24
4.3.4 Materials supplied with separate drive 25
4.3.5 Installing the discharge screw 26
Overview of trough arrangement 26
Overview of trough arrangement with extended length 28
Installing the discharge screw 30
4.3.6 Fitting the upper part of gravity shaft and drive unit 32
Assembly with screw Ø110 32
Assembly with screw Ø150 33
4.3.7 Fitting attachments 35
4.3.8 Fitting the rotary agitator 35
4.3.9 Installing the spring blade agitator (FBR) 40
Fitting the spring blades 41
Table of contents
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4.3.10 Assembling the articulated arm rotary agitator (GAR) 42
4.3.11 Fitting adjustable feet in boiler room (optional) 45
4.3.12 Closing the wall penetration 45
4.4 Connecting the system 46
4.4.1 Electrical connection 46
4.4.2 Connecting the sprinkler system 46
5 Operating the system 47
5.1 General information 47
5.2 Initial startup 47
5.3 Filling the store with fuel 48
5.3.1 Loading of fuel for a partially emptied store with rotary agitator 49
5.3.2 Loading fuel in an empty store space with a rotary agitator 49
5.3.3 Blowing in fuel for a partially emptied store with rotary agitator 50
5.3.4 Blowing in fuel for an empty store with rotary agitator 51
5.3.5 Drainage of fuel store 52
5.4 During operation 53
5.5 Decommissioning 53
5.5.1 Disassembly 53
5.5.2 Disposal 53
6 Servicing 54
6.1 Maintenance schedule 54
6.2 Maintenance contract 55
7 Troubleshooting 56
7.1 Procedure for fault messages 56
8 Notes 57
9 Appendix 60
9.1 Addresses 60
9.1.1 Address of manufacturer 60
Customer service 60
9.1.2 Address of the installer 60
Table of contents
Installation and Operating Instructions FBR-G / GAR-G | M2070119_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
GAR articulated arm rotary agitator: FBR spring blade agitator:
ARotary agitator geared motor F Rotary agitator mitre gear
B Rotary agitator duct with drive shaft G Discharge screw geared motor
C Rotary agitator H Top part of gravity shaft
D Articulated arms with spring piles
(GAR)
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 FBR-G / GAR-G | M2070119_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.
NOTICE
The dangerous situation may occur and if measures are not observed it will lead
to damage to property or pollution.
2Safety
Hazard levels of warnings
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2.2 Permitted uses
Froling’s “FBR-G / GAR-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 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.
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 FBR-G / GAR-G | M2070119_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
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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 FBR-G / GAR-G | M2070119_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
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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: The burn back protection system (BPS) is part of the boiler
and is located directly below the top part 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 FBR-G / GAR-G | M2070119_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 Fröling Ges.m.b.H. | 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 48]
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 FBR-G / GAR-G | M2070119_en 13

3 Technical information
3.1 Dimensions
Item Description FBR
110
GAR
110
FBR
150
GAR
150
FBR
200
GAR
200
DDiameter of spring blade
(FBR) / articulated arm
(TGR)
⇨ See "Store sizes" [page 15]
D1 Diameter of rotary agitator
plate
900 mm 1300
mm
900 mm 1300
mm
900 mm 1300
mm
D2 Diameter, screw 110 mm 150 mm 190 mm
D3 Diameter of drive shaft 40 mm
W1 Width of trough screw 140 mm 200 mm 250 mm
W2 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 194 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 100 mm
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
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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°
❒ GAR with wood chips gradient angle α maximum 10°
❒ GAR 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 2000 2500 3000 3500 4000 4500 5000
Spring blade diameter
(D)1)
2400 2950 3450 4000 4500 5050 5600
Length of rotary agitator
duct (L1)
1650 1900 2150 2400 2650 2900 3150
Length of open trough
(L3)
1045 2) 1295 2) 1545 1795 2045 2295 2545
Length of open trough
(L3) 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.
2.Only available for screw Ø 110
All dimensions in mm
GAR 5.0 GAR 5.5 GAR 6.0
Store length in rotary agitator direction ≤ 5.0 m ≤ 5.5 m ≤ 6.0 m
Articulated arm diameter (D) 5000 5500 6000
Length of rotary agitator duct (L1) 3165 3415 3665
Length of open trough (L3) 2545 2795 3045
Length of open trough (L3) with long
screws
4545 5045 5545
All dimensions in mm
FBR spring blade
agitator
GAR articulated arm
rotary agitator
Technical information 3
Store sizes
Installation and Operating Instructions FBR-G / GAR-G | M2070119_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 GAR
Geared motor Power 0.37 kW 0.55 kW
Speed 10.5 rpm 10.5 rpm
Discharge screw
Description T4 24-75
T4e 20-60
T4 90-110
T4e
80-110
TM 150
T4 130-150
TM 220-320
T4e 200-250
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
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4 Assembly
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! Dimensions
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!
Assembly 4
Transport and handling
Installation and Operating Instructions FBR-G / GAR-G | M2070119_en 17

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.
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.
4Assembly
Installation site
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4.2.1 Information about setup
90°
❒ 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 discharge screw with supplied trough holder (A)
⇨ See "Fitting the rotary agitator" [page 35]
NOTICE! When fitting the discharge screw on the left side, the raising plate (B) in the
area of the intermediate plate (C) must be shortened accordingly!
Assembly 4
Installation site
Installation and Operating Instructions FBR-G / GAR-G | M2070119_en 19

Distance between articulated arms / spring blades
FBR / GAR FBR: Ø 900 mm
GAR: Ø 1300 mm
0mm
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!
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
GAR. These illustrations apply to an FBR accordingly.
1x standard discharge screw right 1x standard discharge screw left
2x standard discharge screws 2x long discharge screws
FBR / GAR
4Assembly
Installation site
20 Fröling Ges.m.b.H. | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com