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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
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Summary of Contents for Fröling GAR 110
- Page 1 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.
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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 Servicing the system Maintenance work by the operator Maintenance work by technicians Replacement parts Troubleshooting Error message list Notes Appendix Addresses 9.1.1 Address of manufacturer Customer service 9.1.2 Address of the installer Installation and Operating Instructions GAR 110 / 150 | M2060120_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 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. Installation and Operating Instructions GAR 110 / 150 | M2060120_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 and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 8: Permitted Fuels
Safety Permitted uses 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 air-dried suitable for storage limited suitability for storage Size P16S Fine wood chip P31S Medium-sized wood chip Note on standards... -
Page 9: Qualification Of Staff
❒ 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. Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 10: Protective Equipment For Operating Staff
Safety Qualification of 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 2.4 Design information Carrying out modifications to the system and changing or disabling safety equipment is prohibited. -
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 and Operating Instructions GAR 110 / 150 | M2060120_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
❒ 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. Installation and Operating Instructions GAR 110 / 150 | M2060120_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 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 and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 16: Store Sizes
Technology Store sizes 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 ≤... -
Page 17: Assembly
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” Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 18: Wall Penetration
Assembly Installation site Store detail Design information 3 Boarding the 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. -
Page 19: Assembling The Articulated Arm Rotary Agitator
Raising plate for discharge without Extensions for gear supports raised floor (optional) Trough open (store side) Bracket with mitre gear Transfer channel (hole in wall) Accessories kit Trough closed (boiler room side) Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 20: Assembling The Gears And Feeder Trough
Assembly Assembling the articulated arm rotary 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 open trough with ceramic fibre seal to the transfer channel ➥... - Page 21 ❒ Shorten the adjustable feet using an angle grinder so that the rotary agitator arms are not obstructed ❒ Fit the closed trough with ceramic fibre seal to the transfer channel ➥ Check the alignment of the flange plates! Installation and Operating Instructions GAR 110 / 150 | M2060120_en...
- Page 22 Assembly Assembling the articulated arm rotary agitator ❒ Only for screw Ø 110 mm: Push both feed screws together (A) and fix with spring pin ❒ Insert the feed screw into the trough on the boiler room side ❒ Grease the square shaft of the mitre gear with copper paste and attach the feed screw ❒...
- Page 23 ❒ Remove the fitting screws (A) on the top of the housing and fold out the articulated arms completely ❒ Fix the tension springs with previously removed fitting screws (A) ❒ Fully tighten nut (B) on the inner joint and lock with second nut (C) Installation and Operating Instructions GAR 110 / 150 | M2060120_en...
- Page 24 Assembly Assembling the articulated arm rotary agitator ❒ Tighten the nut (D) on the outer joint until the chain is slightly tensioned and a play of approx. 2-3 mm remains to the stop ❒ Lock screw connection with second nut (E) ❒...
- Page 25 ❒ Fit spring blades with clamping plates (A) to the rotary agitator arms ➥ Hook (B) must point in the direction of the clamping plate (A – in the direction of rotation) Installation and Operating Instructions GAR 110 / 150 | M2060120_en...
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Page 26: Mounting The Fibre Shredder (Optional)
Assembly Assembling the articulated arm rotary agitator 4.3.3 Mounting the fibre shredder (optional) ❒ Remove the screws on the side of the top part of gravity shaft ❒ Instead, mount the shearing jaw (A) on the inside of the top part of gravity shaft as shown ❒... -
Page 27: 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 and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 28: Assembly With Screw Ø150
Assembly Assembling the articulated arm rotary 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 29 ❒ 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 and Operating Instructions GAR 110 / 150 | M2060120_en...
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Page 30: Fitting Attachments
Assembly Assembling the articulated arm rotary agitator 4.3.5 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 31: Fitting Adjustable Feet In Boiler Room (Optional)
❒ Close the wall penetration on the store side and the boiler room side with a non- flammable covering NOTICE Do not connect the transfer channel to the brickwork (with concrete), as this will transfer sound through all the brickwork. Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 32: Temperature Monitoring Device In The Fuel Store (Tmd)
Assembly Assembling the articulated arm rotary agitator 4.3.8 Temperature monitoring device in the fuel store (TMD): Ø 6 mm ❒ Position the sensor plate above the transfer channel from open to closed trough (A) and transfer the holes to the wall ❒... -
Page 33: Connecting The System
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 and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 34: 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 35: Filling The Store With Fuel
❒ Switch off the power supply to the entire system ➥ Depending on the model via boiler, expansion switch cabinet, etc. ❒ Allow the system to cool for at least two hours Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 36: Loading Of Fuel For A Partially Emptied Store With Rotary Agitator
Operating the system Filling the store with fuel 5.3.1 Loading of fuel for a partially emptied store with rotary agitator 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: ❒... -
Page 37: Rotary Agitator With Combined Drive System
➥ the storage tank must be able to store enough heat ❒ Wait until the rotary agitator arms / spring blades are touching the head of the rotary agitator (approx. 2 revolutions) ❒ Add the rest of the fuel Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 38: Blowing In Fuel For A Partially Emptied Store With Rotary Agitator
Operating the system Filling the store with fuel 5.3.3 Blowing in fuel for a partially emptied store with rotary agitator 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 as follows: ❒... -
Page 39: Rotary Agitator With Combined Drive System
➥ the storage tank must be able to store enough heat ❒ Wait until the rotary agitator arms / spring blades are touching the head of the rotary agitator (approx. 2 revolutions) Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 40: During Operation
Operating the system During operation ❒ Switch off the boiler by tapping “Boiler off” at the mode icon and allow to cool for at least two hours ❒ Close all openings to the store to seal out dust ❒ Add the rest of the fuel 5.4 During operation The boiler is controlled by the boiler controller. -
Page 41: Servicing The System
❒ 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 Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 42: Maintenance Work By The Operator
Servicing the system Maintenance work by the operator 6.1 Maintenance work by the operator ❒ Regular maintenance of the discharge extends the service life of the entire plant and is a basic requirement for trouble-free operation! W = weekly, M = monthly, Q = quarterly, F = prior to each fill of the store Component Int. - Page 43 ❒ Check the shear plate in the entry area of the transfer trough for wear Flange bearing ❒ Lubricate bearing at lubricating nipple with grease Installation and Operating Instructions GAR 110 / 150 | M2060120_en...
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Page 44: Maintenance Work By Technicians
Servicing the system Maintenance work by technicians 6.2 Maintenance work by technicians NOTICE! An annual inspection by an authorized partner (external maintenance) or the Fröling factory customer service is recommended! Regular maintenance and servicing by a heating specialist will ensure a long, trouble- free service life for your discharge. -
Page 45: Replacement Parts
As the parts fit together so well, installation times are shortened and a long service life is maintained. NOTICE Installing non-original parts will invalidate the guarantee. ❒ Only replace components or parts with original replacement parts. Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 46: Troubleshooting
Troubleshooting Error message list 7 Troubleshooting There are two main types of fault: internal and external to the boiler. External faults: ❒ Heating EMERGENCY OFF switch activated ❒ Household fuse (FI circuit breaker) or component fuse blown Internal faults are shown in the form of error messages on the boiler controller: 7.1 Error message list Error message Possible cause... -
Page 47: Notes
Notes 8 Notes Installation and Operating Instructions GAR 110 / 150 | M2060120_en... -
Page 48: Appendix Addresses
Appendix Addresses 9 Appendix 9.1 Addresses 9.1.1 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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