Fröling GAR 110 User manual

Installation and Operating Instructions
Articulated arm rotary agitator GAR 110 / 150
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!
M2060120_en | Edition 06/11/2020
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 8
Wood chips 8
Wood pellets 8
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 9
2.3.4 Protective equipment for operating staff 10
2.4 Design information 10
2.4.1 Standards 10
2.4.2 Requirements at the installation site 11
Information about the fuel store 11
2.5 Safety devices 12
2.6 Residual risks 13
3 Technology 15
3.1 Dimensions 15
3.2 Store sizes 16
4 Assembly 17
4.1 Transport and handling 17
4.1.1 Temporary storage 17
4.2 Installation site 17
4.2.1 Wall penetration 18
4.3 Assembling the articulated arm rotary agitator 19
4.3.1 Materials supplied 19
4.3.2 Assembling the gears and feeder trough 20
4.3.3 Mounting the fibre shredder (optional) 26
4.3.4 Fitting the upper part of gravity shaft and drive unit 27
Assembly with screw Ø110 27
Assembly with screw Ø150 28
4.3.5 Fitting attachments 30
4.3.6 Fitting adjustable feet in boiler room (optional) 31
4.3.7 Closing the wall penetration 31
4.3.8 Temperature monitoring device in the fuel store (TMD): 32
4.4 Connecting the system 33
4.4.1 Electrical connection 33
4.4.2 Connecting the sprinkler system 33
5 Operating the system 34
5.1 General information 34
Table of contents
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5.2 Initial startup 34
5.3 Filling the store with fuel 35
5.3.1 Loading of fuel for a partially emptied store with rotary agitator 36
5.3.2 Loading fuel in an empty store space with a rotary agitator 36
Rotary agitator with combined drive system 37
5.3.3 Blowing in fuel for a partially emptied store with rotary agitator 38
5.3.4 Blowing in fuel for an empty store with rotary agitator 38
Rotary agitator with combined drive system 39
5.4 During operation 40
5.5 Decommissioning 40
5.5.1 Disassembly 40
5.5.2 Disposal 40
6 Servicing the system 41
6.1 Maintenance work by the operator 42
6.2 Maintenance work by technicians 44
6.3 Replacement parts 45
7 Troubleshooting 46
7.1 Error message list 46
8 Notes 47
9 Appendix 48
9.1 Addresses 48
9.1.1 Address of manufacturer 48
Customer service 48
9.1.2 Address of the installer 48
Table of contents
Installation and Operating Instructions GAR 110 / 150 | M2060120_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 discharge system “GAR articulated arm rotary agitator“ consists of:
11
2
2
3
4
5
6
8912
13
710
11
1Spring piles
2Articulated arms
3Rotary agitator
4Intermediate plate for connecting the raised floor to the stirring head
5Mitre gear
6Trough channel, open
7Discharge screw
8Cover plate for wood chips or pellets
9Raising plate for fuel store without raised floor
10 Transfer channel from open to closed trough channel
11 Trough channel, closed
12 Top part of gravity shaft with gravity shaft cover and water sprinkler system
13 Geared motor
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.
General 1
Functional description
Installation and Operating Instructions GAR 110 / 150 | M2060120_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 “GAR articulated arm rotary agitator” discharge system is only designed to
discharge fuels from suitable 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.
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:
❒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
Safety 2
Permitted uses
Installation and Operating Instructions GAR 110 / 150 | M2060120_en 7

2.2.1 Permitted fuels
Wood chips
Criterion Designation as per Description as per
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 as per EN 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)
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: ENplus / DINplus certification scheme
General note:
Before refilling the store, check for pellet dust and clean if necessary.
Note on standards
Note on standards
2Safety
Permitted uses
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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)
2.3.3 Qualification of operating staff
CAUTION
If unauthorised persons enter the Storeroom:
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.
Safety 2
Qualification of staff
Installation and Operating Instructions GAR 110 / 150 | M2060120_en 9

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
2Safety
Qualification of staff
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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.
Safety 2
Design information
Installation and Operating Instructions GAR 110 / 150 | M2060120_en 11

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.
2Safety
Safety devices
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2.6 Residual risks
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
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 GAR 110 / 150 | M2060120_en 13

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 35]
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
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3 Technology
3.1 Dimensions
B
α
D1
L1 L2
L3
D
Item Description GAR 110 GAR 150
L1 Length of open trough ⇨ See "Store sizes" [page 16]
L2 Length of closed trough Transfer channel + connected trough
L3 Length of discharge screw Determined during planning of the fuel store
DDiameter, rotary agitator ⇨ See "Store sizes" [page 16]
D1 Diameter, screw Ø 110 mm Ø 150 mm
BWidth of trough channel 140 mm 200 mm
αGradient angle 0 – 10° (wood chips)
0 – 3° (pellets)
NOTICE
Operating the discharge system with a gradient angle > 10°
The mitre gear can break due to insufficient lubrication!
When installing the discharge system, you should therefore ensure:
❒When operating with wood chips do not exceed a gradient angle α of 10°
❒When operating with pellets do not exceed a gradient angle α of 3°
➥The rotary agitator should always be fitted as flat as the place of
installation allows
Technology 3
Dimensions
Installation and Operating Instructions GAR 110 / 150 | M2060120_en 15

3.2 Store sizes
The diameter of the rotary agitator and the length of the open trough vary depending
on the size of the fuel store. The articulated arms of the agitator head have a uniform
length, the diameter is adjusted accordingly by extending them with the spring blades.
The table below shows the respective dimensions:
Store length in screw direction
≤ 3.5 m ≤ 4.0 m ≤ 4.5 m ≤ 5.0 m ≤ 5.5 m ≤ 6.0 m
Nominal diameter D [mm] 3500 4000 4500 5000 5500 6000
Length of spring blades
(L4) (mm)
605 875 1145 1415 1685 1955
Open trough (L1) [mm] 1545 1795 2045 2295 2545 2795
1.The rotary agitator arms have a certain excess to ensure optimum use of the fuel store!
A
D
L4
❒The nominal diameter of the discharge must be selected according to the lateral
length (A) of the space that runs parallel to the discharge screw.
❒The discharge must be positioned so that the shear edge (transition from open to
closed trough) is at least 200 mm away from the wall.
3Technology
Store sizes
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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!
A door should be provided in the store or a ceiling opening in the silo for bringing in
the unit
❒Observe the stirring head diameter of 1300 mm!
To prevent damage:
❒Transport components, particularly drive components, with care
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!
4.2 Installation site
When planning the fuel store, you should observe the following design information:
1
2
34
5
6
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”
Assembly 4
Transport and handling
Installation and Operating Instructions GAR 110 / 150 | M2060120_en 17

Store detail Design information
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.
4.2.1 Wall penetration
αβ
s
Section - Side view: Section - Top view
Before installing the rotary agitator, the customer must provide a wall penetration 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) or the angle of inclination (α) of the entire
system. Experience indicates that an opening of 500 mm x 500 mm is sufficient. You
should also note that the trough must not be connected to the wall, and that it should
be cladded in elastic at the end.
4Assembly
Installation site
18 Fröling Ges.m.b.H. | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com

4.3 Assembling the articulated arm rotary agitator
4.3.1 Materials supplied
12x spring piles 12 Rotary agitator head with articulated
arms
2Top part of gravity shaft 13 Intermediate plate
3Torque support 14 Support in the boiler room (option)
4Geared motor 15 Adjustable feet
5Feed screw 15a Shorter adjustable feet
(optional for horizontal installation)
6Trough cover - wood chips (standard) 16 Gear supports
7Trough cover - pellets (optional) 16a Shorter gear supports
(optional for horizontal installation)
8Raising plate for discharge without
raised floor
17 Extensions for gear supports
(optional)
9Trough open (store side) 18 Bracket with mitre gear
10 Transfer channel (hole in wall) 19 Accessories kit
11 Trough closed (boiler room side)
Assembly 4
Assembling the articulated arm rotary agitator
Installation and Operating Instructions GAR 110 / 150 | M2060120_en 19

4.3.2 Assembling the gears and feeder trough
NOTICE! The mitre gear is pre-assembled on the bracket. Tighten all screw
connections during installation!
❒Fit the open trough with ceramic fibre seal to the transfer channel
➥Check the alignment of the flange plates!
❒Fit bracket with mitre gear to open trough
❒Fit the gear supports to the mitre gear as shown
➥Observe the assembly height in the installation diagram!
➥Do not fully tighten the screws yet!
❒Place intermediate plate over bracket with mitre gear and secure it to the flange of
the open trough
4Assembly
Assembling the articulated arm rotary agitator
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