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Installation Instructions
Torsion arm agitator TGR 110/150/200
Translation of the original German installation instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1390116_en | Edition 20/11/2017
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Table of Contents
Related Manuals for Fröling TGR 110
Summary of Contents for Fröling TGR 110
- Page 1 Installation Instructions Torsion arm agitator TGR 110/150/200 Translation of the original German installation instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M1390116_en | Edition 20/11/2017 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 2: Table Of Contents
Table of Contents Table of Contents General Functional description Safety Hazard levels of warnings Permitted uses 2.2.1 Permitted fuels Wood chips Wood pellets Qualification of staff 2.3.1 Qualification of assembly staff 2.3.2 Personal protective equipment for assembly staff 2.3.3 Qualification of operating staff 2.3.4 Protective equipment for operating staff Design information... - Page 3 Rotary agitator with combined drive system During operation Decommissioning 5.5.1 Disassembly 5.5.2 Disposal Servicing Maintenance schedule Maintenance contract Troubleshooting Error message list Appendix Addresses 8.1.1 Address of manufacturer Customer service 8.1.2 Address of the installer Installation Instructions TGR 110/150/200 | M1390116_en...
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Page 4: General
General 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. -
Page 5: Functional Description
The dosing 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. Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 6: Safety
Safety Hazard levels of warnings 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. -
Page 7: Permitted Uses
❒ 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 Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 8: Permitted Fuels
Safety Permitted uses 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 air-dried suitable for storage limited suitability for storage Size P16S Fine wood chip P31S Medium-sized wood chip Note on standards... -
Page 9: Personal Protective Equipment For Assembly Staff
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 Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 10: Design Information
Safety Design information 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. -
Page 11: Requirements At The Installation Site
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. Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 12: Safety Devices
Safety Safety devices 2.5 Safety devices Safety equipment Safety function Limit switch for top of gravity Protection against access to the danger area of the feed/ shaft: discharge screw when the system is switched on ❒ If the inspection cover is opened, the system is switched off via the limit switch ➥... -
Page 13: Residual Risks
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. Installation Instructions TGR 110/150/200 | M1390116_en... - Page 14 Safety Residual risks 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 ❒...
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Page 15: Technology
❒ 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 Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 16: Store Sizes
≤ 3.5 m ≤ 4.0 m ≤ 4.5 m ≤ 5.0 m ≤ 5.5 m ≤ 6.0 m Articulated arm diameter (D) [mm] 3500 4000 4500 5000 5500 6000 Open trough (L1) TGR 110/150 [mm] 1545 1795 2045 2295 2545 2795 Open trough (L1) TGR 200 [mm]... -
Page 17: Assembly
The store door must be a fire door with an EI 30-C fire resistance rating; it store door 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. Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 18: Wall Penetration
Assembly Installation site Store detail Design information 4 Inspection Maintenance opening with class EI 90-C fire resistance rating (e.g. chimney opening 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. -
Page 19: Assembling The Torsion Arm Agitator
(optional for horizontal installation) Shorter gear supports Extensions for gear supports (optional for horizontal installation) (optional) Mitre gear Spacer for agitator head (TGR 150 only) Spacer for agitator head (TGR 200 Accessories kit only) Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 20: Assembling The Gears And Feeder Trough
Assembly Assembling the torsion arm agitator 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 closed trough with ceramic fibre seal to the open trough - 4x hexagonal screw M12 x 35 mm - 4x spacer washers M12 - 4x nuts M12... - Page 21 ❒ Insert the heavy load anchors into the bore holes and tighten with a spanner (SW 17 mm) ❒ Fit the trough cover on the open trough (depending on design) ➥ Countersunk Allen screws M8 x 25 mm (number of screws depends on the length of the trough) Installation Instructions TGR 110/150/200 | M1390116_en...
- Page 22 Assembly Assembling the torsion arm agitator Trough coverings for operation with wood chips: Cover - wood chips (standard): Cover for wood chips with raising plate for systems without a raised floor: Trough coverings for operation with pellets: Cover - pellets (optional): Cover for pellets with raising plate for systems without a raised floor: Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
- Page 23 ❒ Fit the closed trough with ceramic fibre seal to the transfer channel - 4x hexagonal screw M12 x 35 mm - 4x spacer washers M12 - 4x nuts M12 ➥ Check the alignment of the flange plates! Installation Instructions TGR 110/150/200 | M1390116_en...
- Page 24 Assembly Assembling the torsion arm agitator ❒ Insert the dosing screw into the trough on the boiler room side ❒ Grease the square shaft of the mitre gear well and put the screw on ❒ Align the troughs in a row, and adjust with the adjustable feet if necessary Fit the adjustable feet to the floor: ❒...
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Page 25: Fitting The Upper Part Of Gravity Shaft And Drive Unit
The pin and screw end must be at the same height ➥ Centre distance of pin and screw end: 150 mm ❒ Secure torque support with bearing (C) to the geared motor as illustrated Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 26: Assembly With Screw Ø150 / Ø200
Assembly Assembling the torsion arm agitator ❒ Lubricate shaft stub incl. key with copper paste ❒ Push the geared motor (A) onto the screw end ❒ Secure locking washer (B) with hexagonal screw and washer If the geared motor cannot be installed as shown above for reasons of space, it is possible to turn the drive unit: ❒... - Page 27 ❒ Turn the torque support with bearing 180° and secure to geared motor ❒ Turn the geared motor and torque support 180° and fit to the screw end and torque support as explained above Installation Instructions TGR 110/150/200 | M1390116_en...
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Page 28: Fitting Attachments
Assembly Assembling the torsion arm agitator 4.3.4 Fitting attachments ❒ Secure limit switch (A) to upper part of gravity shaft - 2 cylinder head screws M5x40 ➥ The reel of the safety limit switch (A) must be positioned as illustrated ❒... -
Page 29: Setting The Tension Of The Torsion Springs
Pre-tension joint 2 Pre-tension joint 3 ❒ Pre-tension the torsion spring with the draw tube provided ❒ Insert nut into relevant perforation as indicated in the table ❒ Insert stop screw from above and turn nut Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 30: Fitting Adjustable Feet In Boiler Room (Optional)
Assembly Assembling the torsion arm agitator ❒ Slowly loosen tension of torsion spring as far as stop, remove draw tube and tighten screw 4.3.6 Fitting adjustable feet in boiler room (optional) If the closed duct in the boiler room exceeds 2m, an additional support is recommended: Ø... -
Page 31: Closing The Wall Penetration
When connecting the sprinkler system, please also note: ❒ Put a stopcock and bolted joint in front of the thermal discharge safety device ➥ Important for easy dismantling in the event of maintenance work! Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 32: Operating The System
Operating the system General information 5 Operating the system 5.1 General information The steeper the angle (maximum 10°) at which a rotary agitator is fitted, the more likely that fuel will remain behind when the bunker empties. When operating with pellets it is particularly important to note: ▪... -
Page 33: Filling The Store With Fuel
If there is still sufficient fuel in the store (the head of the rotary agitator is completely covered with fuel and the rotary agitator arms are not extended), the store can be filled: ❒ Load the fuel at the filling opening Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 34: Loading Fuel In An Empty Store Space With A Rotary Agitator
Operating the system Filling the store with fuel 5.3.2 Loading fuel in an empty store space with a rotary agitator NOTICE Filling an empty store space with a rotary agitator: With the store space completely empty or almost empty, the rotary agitator arms / spring blades are fully extended. -
Page 35: Rotary Agitator With Combined Drive System
❒ Switch off the boiler by pressing the standby key and allow to cool down for at least two hours ❒ Close all openings to the store to seal out dust ❒ Blow the fuel into the store Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 36: Blowing In Fuel For An Empty Store With Rotary Agitator
Operating the system Filling the store with fuel 5.3.4 Blowing in fuel for an empty store with rotary agitator NOTICE Filling an empty store space with a rotary agitator: With the store space completely empty or almost empty, the rotary agitator arms / spring blades are fully extended. -
Page 37: Rotary Agitator With Combined Drive System
For the necessary steps, and how to display and alter parameters: NOTICE! See operating instructions for boiler controller NOTICE When transporting wood chips or pellets using the feed screw, there may be noise, depending on the function. Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 38: Decommissioning
Operating the system Decommissioning 5.5 Decommissioning 5.5.1 Disassembly To disassemble the system, follow the steps for assembly in reverse order. 5.5.2 Disposal ❒ Disposal should be carried out according to the valid national regulations and guidelines. ❒ You can separate and clean recyclable materials and send them to a recycling centre. -
Page 39: Servicing
❒ Open the inspection cover of the gravity shaft ➥ The system should switch off immediately. ❒ Check the inlet area for material build-up and clean where necessary. ❒ Close gravity shaft cover ❒ Check fault message on the controller Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 40: Maintenance Contract
Servicing Maintenance contract Component Int. Operation Sprinkler system Sprinkler system function test: ❒ Open ball valve only slightly ❒ Heat the sensor to above 95°C (e.g. with a lighter) ➥ The valve should open and water should flow out. ❒ Press the button on the valve briefly ➥... -
Page 41: Troubleshooting Error Message List
❒ Bunker full - / bunker empty – check circuit Frequent ❒ ❒ Check circuit overcurrent rotary ❒ Change pre-run/run-on time agitator ❒ Bunker full - / bunker empty – check circuit Installation Instructions TGR 110/150/200 | M1390116_en... -
Page 42: Appendix Addresses
Appendix Addresses 8 Appendix 8.1 Addresses 8.1.1 Address of manufacturer FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL 0043 (0)7248 606 0 FAX 0043 (0)7248 606 600 EMAIL info@froeling.com INTERNET www.froeling.com Customer service Austria 0043 (0)7248 606 7000 Germany 0049 (0)89 927 926 400 Worldwide...
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