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Installation and Operating Instructions
Modular electrostatic precipitator system EF 250-500
EF 250
EF 500
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!
M2140120_en | Edition 08/09/2020
Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Summary of Contents for Fröling EF 250
- Page 1 Installation and Operating Instructions Modular electrostatic precipitator system EF 250-500 EF 250 EF 500 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! M2140120_en | Edition 08/09/2020 Fröling 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 Operating principle Safety Hazard levels of warnings Pictograms used General safety information Permitted uses Qualification of staff 2.5.1 Qualification of assembly staff 2.5.2 Personal protective equipment for assembly staff 2.5.3 Qualification of operating staff 2.5.4 Protective equipment for operating staff Chimney connection/chimney system... - Page 3 Checking the fill level of the ash container and emptying if required Periodic inspection and cleaning Cleaning electrodes and the interior Decommissioning Disassembly Disposal Notes Appendix 11.1 Addresses 11.1.1 Address of manufacturer Customer service 11.1.2 Address of the installer Installation and Operating Instructions EF 250-500 | M2140120_en...
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Page 4: General
General Operating principle 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: Safety
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. Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 6: Pictograms Used
Safety Pictograms used 2.2 Pictograms used The following symbols are used in the documentation and/or on the electrostatic precipitator system to show what is required and forbidden and to give warnings. In accordance with the Machinery Directive, signs fitted directly within the danger area of the electrostatic precipitator system indicate immediate hazards or safety procedures. -
Page 7: General Safety Information
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. Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 8: Qualification Of Staff
Safety Qualification of staff 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. -
Page 9: Qualification Of Operating Staff
EN 13384-1. Local regulations and other statutory regulations also apply. NOTICE! The chimney must be authorised by a smoke trap sweeper or chimney sweep. Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 10: Measuring Port
Safety Chimney connection/chimney system 2.6.1 Measuring port For measuring the emissions of the system, a suitable measuring port must be installed in the connecting piece between the electrostatic precipitator system and chimney system. 2 x D In front of the measuring port (M) a straight inlet section should be located at a distance corresponding to about twice the diameter (D) of the connecting piece. - Page 11 Possible interference of the pacemaker by electromagnetic fields of the electrostatic precipitator system! Therefore: ❒ Maintain a safety distance of at least one metre from the electrostatic precipitator system ❒ Perform work only when the electrostatic precipitator system is switched off Installation and Operating Instructions EF 250-500 | M2140120_en...
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Page 12: Design Information
Design information Boiler room characteristics 3 Design information Boiler room characteristics ▪ The floor must be even, clean and dry and have an adequate load-bearing capacity. ▪ There must be no explosive atmosphere in the boiler room as the system is not suitable for use in a potentially explosive environment. -
Page 13: Technical Information
Length without container 1589 Length of electrostatic precipitator 1275 system Height of electrostatic precipitator 1950 system Height of clean gas outlet connection 1578 Height of raw gas inlet connection 1178 Flue spigot diameter (outside) Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 14: Technical Specifications
Technical information Technical specifications 4.2 Technical specifications Description Electrostatic precipitator system EF 250 EF 500 Electrical connection 400 V / 50 Hz / fused C13A Power consumption Insulation thickness Weight Efficiency (separation rate) up to 85% Volume of ash container... -
Page 15: Assembly
If the system is to be assembled at a later stage: ❒ Store components at a protected location, which is dry and free from dust ➥ Damp conditions and frost can damage components, particularly electric ones! Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 16: Positioning
Assembly Positioning 5.3 Positioning ❒ Position a fork-lift or similar lifting device at the pallet and bring in the components If the electrostatic precipitator system cannot be brought in on the pallet: ❒ Remove system from pallet ⇨ See "Removing the electrostatic precipitator system from the pallet" [page 16] Positioning using a crane: ❒... -
Page 17: Recommended Clearances In The Boiler Room
EF 500 Description Ash container maintenance area 200 mm Left maintenance area 400 mm Geared motor maintenance area 200 mm 400 mm Right maintenance area 1. Only for electrostatic precipitator system EF 500 Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 18: Adjusting The Height Of The Ash Container
Assembly Adjusting the height of the ash container 5.5 Adjusting the height of the ash container ❒ Pull out the spring cotter on the transport wheels and adjust the height ➥ The wheels rest on the ground when the ash container is mounted! ❒... -
Page 19: Fitting The Flue Gas Temperature Sensor
❒ Run the flue gas temperature sensor cable to the boiler controller and connect it according to the enclosed wiring diagram, ⇨ See "Electrical connection" [page Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 20: Adapting The Electrostatic Precipitator System (If Required)
The following modification work shows the necessary steps on an EF 250 electrostatic precipitator system. Unless otherwise stated, all work on an EF 500 electrostatic precipitator system must be carried out in the same way. -
Page 21: Modification Of The Ash Container On The Opposite Side Of The Filter System
Removing the ash container and fittings ❒ Remove the key plate from the safety switch ❒ Push the locking lever up to release the ash container ❒ Pull out the ash container ❒ Remove the cover plate Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 22: Removing The Drive And Fittings
Assembly Adapting the electrostatic precipitator system (if required) ❒ Remove entire ash removal flange ❒ Dismantle safety limit switch and remove downwards ❒ Remove the cover of the control cabinet ❒ Position the safety limit switch on the opposite side of the filter system ➥... - Page 23 ➥ Pull out the cable of the proximity sensor from the control cabinet until the cable length is sufficient ❒ Lay the cable of the proximity sensor in the cable duct ❒ Loosen the screw connection and unthread the securing plate Installation and Operating Instructions EF 250-500 | M2140120_en...
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Page 24: Installing The Drive And Fittings On The Opposite Side
Assembly Adapting the electrostatic precipitator system (if required) ❒ Dismantle gear unit incl. drive linkage ❒ Remove key from shaft groove ❒ Dismantle ash removal flange incl. ash screw Installing the drive and fittings on the opposite side ❒ Install the previously dismantled ash removal flange incl. ash screw on the opposite side of the filter system ❒... - Page 25 ❒ Attach the tension spring to the tension lever and to the stop lever and press downwards ➥ Attach to the previously used hole (A) ❒ Secure the position of the clamping lever with eyebolt and spring cotter Installation and Operating Instructions EF 250-500 | M2140120_en...
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Page 26: Installing The Ash Container And Fittings On Opposite Side
Assembly Adapting the electrostatic precipitator system (if required) ❒ Loosen the cover plate and mount it so that the right opening is closed ❒ Lead out the cable of the geared motor at the middle cut-out and mount the cover plate ❒... -
Page 27: Modification Of The Bypass Flap Drive On The Opposite Side
❒ Loosen the wing screw on the lower flue pipe connection and remove the temperature sensor ❒ Dismantle the cover plates on the flue pipe connections and remove the thermal insulation (A) ❒ Dismantle flue pipe flanges Installation and Operating Instructions EF 250-500 | M2140120_en... - Page 28 Assembly Adapting the electrostatic precipitator system (if required) ❒ Remove the cover plates on the side of the control cabinet ❒ Loosen torque support on drive ❒ Remove drive from shaft ❒ Remove the thermal insulation ❒ Remove the mounting bracket from the shaft and remove the washers and silicone foam seal ❒...
- Page 29 ❒ Insert previously removed thermal insulation ❒ Position the shaft bypass flap to the left stop ❒ Push the drive of the bypass flap onto the shaft so that the direction of rotation left ("L") is visible Installation and Operating Instructions EF 250-500 | M2140120_en...
- Page 30 Assembly Adapting the electrostatic precipitator system (if required) ❒ Secure drive with torque arm and install cover plates ❒ Install the flue pipe flange on the side of the control cabinet ❒ Insert thermal insulation and install flue pipe cover plates If the flue pipe flange of the flue gas outlet is mounted centrally on the upper side: ❒...
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Page 31: Installing The Electrostatic Precipitator System On Turbomat Tm
Connections: ▪ A – Lower flue gas connection: Raw gas inlet (pipe from boiler) ▪ B – Upper flue gas connection: Clean gas outlet (pipe to the induced draught) Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 32: Electrical Connection
Assembly Electrical connection 5.10 Electrical connection DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: ❒ Always have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥... -
Page 33: Commissioning
All values can be configured in the following menu: System menu Heating circuits & Flue gas Flue gas filter system treatment For other settings, refer to the operating instructions for the boiler controller supplied. Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 34: Check The Direction Of Rotation Of The Ash Screw
Commissioning Check the direction of rotation of the ash screw 6.3 Check the direction of rotation of the ash screw When commissioning the modular electrostatic precipitator, check the direction of rotation of the ash screw as follows: ❒ Remove the key plate of the ash container from the safety limit switch and re- insert it ➥... -
Page 35: Operation / Maintenance
Therefore: ❒ Have the electrostatic precipitator checked by professionals at appropriate intervals ➥ Froling accepts no liability for damage caused by unqualified personnel Installation and Operating Instructions EF 250-500 | M2140120_en... - Page 36 Operation / maintenance WARNING Inspection and cleaning work with the boiler switched on Serious injuries from automatic startup of the boiler and severe burns from hot parts and the flue gas pipe are possible. Therefore: ❒ Only carry out work on the boiler when the main switch is turned off ❒...
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Page 37: Checking The Fill Level Of The Ash Container And Emptying If Required
NOTICE! Dispose of the ash in accordance with national regulations! NOTICE! After installing the ash container and inserting the key plate into the safety limit switch, the ash screw rotates for a few seconds. Installation and Operating Instructions EF 250-500 | M2140120_en... -
Page 38: Periodic Inspection And Cleaning Cleaning Electrodes And The Interior
Periodic inspection and cleaning Cleaning electrodes and the interior 8 Periodic inspection and cleaning The electrostatic precipitator system must be inspected and cleaned at appropriate intervals depending on the operating hours and fuel quality. Inspection and cleaning must be repeated after not more than 1000 operating hours or at least every six months. - Page 39 ➥ IMPORTANT: Use a dust mask (filter class FFP2 or higher)! ➥ CAUTION: Clean the baskets very carefully, they must not be deformed! ❒ Check all seals for damage and replace if necessary Installation and Operating Instructions EF 250-500 | M2140120_en...
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Page 40: Decommissioning
Decommissioning Disassembly 9 Decommissioning 9.1 Disassembly To disassemble the system, follow the steps for assembly in reverse order. 9.2 Disposal ❒ Ensure that they are disposed of in an environmentally friendly way in accordance with waste management regulations. ❒ You can separate and clean recyclable materials and send them to a recycling centre. -
Page 41: Notes
Notes 10 Notes Installation and Operating Instructions EF 250-500 | M2140120_en... - Page 42 Notes Fröling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
- Page 43 Notes Installation and Operating Instructions EF 250-500 | M2140120_en...
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Page 44: Appendix Addresses
Appendix Addresses 11 Appendix 11.1 Addresses 11.1.1 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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