Fröling BFSV Installation And Operating Intructions
Bunker filling system
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Installation- and Operating Intructions
Bunker filling system BFSV / BFSU
Translation of the original German operating instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1420116_en | Edition 08/08/2016
Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com
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Summary of Contents for Fröling BFSV
- Page 1 Installation- and Operating Intructions Bunker filling system BFSV / BFSU Translation of the original German operating instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M1420116_en | Edition 08/08/2016 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 2: Table Of Contents
Installation site 4.3.1 Position of ejection head 4.3.2 Installation with mobile bulk chute 4.3.3 Installation with recessed bulk chute Installation variants - BFSV 4.4.1 All components in external area 4.4.2 Bulk chute and vertical screw outside 4.4.3 Bulk chute outside 4.4.4... - Page 3 6.4.2 Start filling process 6.4.3 Stop filling process 6.4.4 Switch off the power supply Servicing the System Maintenance schedule Troubleshooting Appendix Addresses 9.1.1 Address of manufacturer 9.1.2 Address of the installer Installation- and Operating Intructions BFSV / BFSU | M1420116_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
If a sensor responds, the direction of rotation of the centrifugal disc must be changed manually. Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 6: Control Unit
General Control Unit 1.2 Control Unit Emergency stop for shutting down the system immediately with any risk Key-operated selector switch for changing the direction of rotation of the centrifugal disc Start button for two-hand tripping device (one push-button on the left and right-hand side). -
Page 7: Safety
Work with extreme care. CAUTION The dangerous situation may occur and if measures are not observed it will lead to minor injuries or damage to property. Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 8: Permitted Uses
Safety Permitted Uses 2.2 Permitted Uses The Froling bunker filling system is solely designed for transporting fuels into suitable store spaces. 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. -
Page 9: Non-Permitted Fuels
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 workwear - protective gloves - sturdy shoes Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 10: Qualification Of Operating Staff
Safety Qualification of staff 2.3.3 Qualification of operating staff CAUTION If unauthorised persons enter the store / working range: 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. -
Page 11: Design Information
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 Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 12: Requirements At The Installation Site
Safety Design Information 2.4.2 Requirements at the installation site ▪ The installation site must have a suitable, level surface within the working range of the system (filling area, switching unit with operating elements) ▪ The operating area must be designed so as to avoid risks posed by the loading vehicle ▪... -
Page 13: Safety Devices
When the bulk chute is disconnected, the safety switch is force-actuated, so preventing the system from being used without attached components (vertical screw / centrifugal disc / oblique screw depending on design). Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 14: Residual Risks
Safety Residual Risks 2.6 Residual Risks DANGER Operating the system without the safety equipment provided by the customer: Risk of serious injury from unprotected system components! For safe operation of the system: ❒ Only operate the system once the required safety equipment has been installed ➥... - Page 15 ➥ Depending on the function, the vertical screw and also the horizontal distributor screw/centrifugal disc are switched off with a time delay ➥ This process may take a few seconds and is not a fault Installation- and Operating Intructions BFSV / BFSU | M1420116_en...
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Page 16: Technology
Technology Dimensions BFSV 3 Technology 3.1 Dimensions BFSV The following diagram with associated matrix lists the possible system lengths and system heights which are important for design of the store space and the wall opening. All dimensions are specified in mm: min. - Page 17 Weight 1900 2500 2560 2920 2980 3420 3480 3840 1340 (920+420) 3900 4420 1920 4480 4840 2340 (1920+420) 4900 5340 2840 (1920+920) 5400 5760 3260 (1920+920+420) 5820 6340 3840 (1920+1920) 6400 Installation- and Operating Intructions BFSV / BFSU | M1420116_en...
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Page 18: Design With Recessed Bulk Chute
7400 3.1.1 Design with recessed bulk chute The following diagram shows the BFSV variant with a recessed bulk chute and is also particularly useful when dimensioning the shaft size. The system lengths possible are based on the matrix given above. All dimensions are specified in mm:... -
Page 19: Dimensions Bfsu
Bulk chute (900, 1900, 2900) Bulk chute 900 = 1570 Bulk chute 1900 = 2570 Bulk chute 2900 = 3570 400 - 4240 Mounting frame 300 / 600 min. 700 Mounting frame Installation- and Operating Intructions BFSV / BFSU | M1420116_en... - Page 20 Technology Dimensions BFSU Matrix of system lengths Length of bulk chute Possible system lengths Necessary extension pipes Screw length Weight 1520 1560 1920 1980 2420 2480 2840 1340 (920+420) 2900 3420 1920 3480 3840 2340 (1920+420) 3900 4340 2840 (1920+920) 4400 4760 3260 (1920+920+420)
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Page 21: Design With Recessed Bulk Chute
Fitting frame 1110 Bulk chute 900 = 1540 Bulk chute 1900 = 2540 1150 Bulk chute 2900 = 3540 400 - 4240 Mounting frame 300 / 600 min. 700 Mounting frame Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 22: Dimensions Of Extension Shaft
Technology Dimensions of extension shaft 3.3 Dimensions of extension shaft An extension is necessary for the wall duct depending on the conditions on site. It should be remembered that using an extension shaft will reduce the system height by 500 mm. All dimensions are specified in mm: Extension shaft 140 mm: Extension shaft 707 mm: Ø303... -
Page 23: Dimensions Of Mounting Frame
The following diagram is used for positioning and dimensioning of the wall opening. The lower edge of the opening is the system height minus 240 mm. All dimensions are specified in mm. Mounting frame Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 24: Technical Specifications
Technology Technical Specifications 3.5 Technical Specifications Description Value Electrical connection 400 VAC / 50 Hz Electric fuses C35A Bulk chute drive - Power consumption 3.0 kW Bulk chute drive - Speed 65 rpm Vertical screw drive - Power consumption 4.0 kW Vertical screw drive - Speed 85 rpm Centrifugal disc drive - Power consumption... -
Page 25: Assembly
NOTICE! Installation and operation should only be carried out by technicians with a specific knowledge of lifting persons! Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 26: Installation Site
Assembly Installation site 4.3 Installation site 4.3.1 Position of ejection head The filling level in the fuel store depends on the position of the centrifugal disc. The attempt should always be made to position the centrifugal disc as high as possible, as well as centrally, in the fuel store. - Page 27 Assembly Installation site Positioning on the long side (not recommended): Installation- and Operating Intructions BFSV / BFSU | M1420116_en...
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Page 28: Installation With Mobile Bulk Chute
Installation site 4.3.2 Installation with mobile bulk chute With all assembly variants of the BFSV the vertical screw is secured to the wall of the fuel store with clips and sections. The bracket of the vertical screw is additionally affixed to the floor with heavy duty anchors. Both the brickwork and the floor must have sufficient load capacity. -
Page 29: Installation With Recessed Bulk Chute
The material should be transferred to the bulk chute on the opposite side. Operating position within view of the bulk chute Protective structure to prevent operator from reaching over during operation Cover over filling area to prevent operator from climbing in during operation Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 30: Installation Variants - Bfsv
Assembly Installation variants - BFSV 4.4 Installation variants - BFSV 4.4.1 All components in external area Depending on the thickness of the wall it should be borne in mind that a wall duct (300 mm / 600 mm) is necessary for mounting the ejection head. When using a wall duct, the ejection head is directly mounted in place, and no other fixing brackets are necessary. -
Page 31: Bulk Chute Outside
Alternatively, the bulk chute can be recessed in a shaft. Here the built-in bulk chute is used instead of the standard bulk chute. During planning additional design information should be noted in this case. ⇨ See "Installation with recessed bulk chute" [page 29] Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 32: Installation Variants - Bfsu
Assembly Installation variants - BFSU 4.5 Installation variants - BFSU 4.5.1 Bulk chute outside Depending on the thickness of the wall it should be borne in mind that a wall duct (300 mm / 600 mm) is necessary for mounting the ejection head. When using a wall duct, the ejection head is directly mounted in place, and no other fixing brackets are necessary. -
Page 33: Install Bunker Filling System
❒ Install the sensor brackets with filling level sensors below the wall opening ➥ Use suitable assembly material ➥ Filling level sensors must not impair the trajectory of the wood chips Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 34: Install Vertical Screw
Assembly Install Bunker Filling System If the ejection head away from the wall is fitted, wall brackets (optional) are necessary: Ø 14 mm ❒ Mark holes for wall brackets on wall and drill ❒ Hammer the dowels into the wall ❒... - Page 35 ❒ Hammer in the heavy duty anchors and fix the bracket to the floor Ø 14 mm ❒ Mark holes for cantilever bracket on wall and drill ❒ Hammer dowels into wall and screw the cantilever bracket to the wall using frame screws M12x80 Installation- and Operating Intructions BFSV / BFSU | M1420116_en...
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Page 36: Fitting The Extension Shaft (Optional)
Assembly Install Bunker Filling System 4.6.3 Fitting the extension shaft (optional) ❒ Screw the extension shaft and vertical screw with the 4 hexagonal screws M10x 30, spacer washers and safety nuts 4.6.4 Preparing the bulk chute Version with wheels: Version with adjustable feet: ❒... -
Page 37: Fit The Cover Plates
4 hexagonal screws M10x30 to the bulk chute ➥ The position of the cover plate depends on the wood chip size ⇨ See "Adjust the feed output to the fuel" [page 43] Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 38: Position Bulk Chute
Assembly Install Bunker Filling System 4.6.5 Position bulk chute ❒ Position the bulk chute on the flange of the vertical screw ❒ Regulate the height of the bulk chute by adjusting the wheels to the flange of the vertical screw ❒... -
Page 39: Turning The Fitting Frame
❒ Screw the fitting frame onto the bulk chute using the previously loosened screws NOTICE! The position of the motor for the screw must not be changed! 4.6.7 Final installation steps Positioning the stickers ❒ Attach the “FRÖLING” sticker to the vertical screw pipe Installation- and Operating Intructions BFSV / BFSU | M1420116_en... - Page 40 Assembly Install Bunker Filling System ❒ Attach 2x stickers “CAUTION – DELAYED AUTOMATIC START-UP OF FILLING SYSTEM” on the inside of the fitting frame ❒ Attach 2x stickers “Cover plate adjustment” on the left and right outer edge of the fitting frame Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 41: Power Connection
Function setting on Time setting [s] the time relay K3.1 Vertical screw shutdown delay K1.3 Vertical screw startup delay K1.2 Centrifugal disc/ horizontal distributor screw shutdown delay K2.1 Bulk chute startup delay Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 42: Operating The System
Operating the System Initial start-up 6 Operating the System 6.1 Initial start-up NOTICE Efficient operation can only be guaranteed if the system is set by specialist staff and the default factory settings are observed. Therefore: ❒ Initial startup should be carried out with an installer approved by Fröling Heizkessel- und Behälterbau GesmbH or with Froling customer services During initial start-up: ❒... -
Page 43: Adjust Filling Area To Loading Vehicle
STAGE 3 STAGE 2 STAGE 1 A 1339 00 12 Adjust cover plates: ❒ Remove bolts from cover plate ❒ Move cover plate into the required position and with fix with bolts Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 44: Fill Store Space With Fuel
Operating the System Fill Store space with Fuel 6.4 Fill Store space with Fuel NOTICE Before starting with the filling process, check that the bunker filling system is working properly. CAUTION If unauthorised fuel types are used: Non-standard fuels can cause stiffness and block the system, resulting in the failure/breakage of components. - Page 45 ❒ Load bulk chute with fuel ➥ The filling system will continue to feed material until one of the two start buttons is released, or the filling level sensor for the preselected direction of rotation responds Installation- and Operating Intructions BFSV / BFSU | M1420116_en...
- Page 46 Operating the System Fill Store space with Fuel NOTICE! If the filling system is stopped because of the filling level sensor, the bulk chute and the vertical screw are filled with material, which can no longer be brought in the fuel store! NOTICE! When filling the bulk chute with a dumper or front loader, fuel may well fall past the bulk chute.
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Page 47: Stop Filling Process
➥ Depending on the function, the vertical screw and also the horizontal distributor screw/centrifugal disc are switched off with a time delay ➥ This process may take a few seconds and is not a fault Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 48: Switch Off The Power Supply
Operating the System Fill Store space with Fuel 6.4.4 Switch off the power supply ❒ Turn the main switch on the switching unit to "O" ➥ The power supply is switched off ➥ The components in the switching unit are no longer live NOTICE! The main terminal in the switching unit is still live! ❒... - Page 49 We recommend performing each point after every filling process. You should also check for visible signs of damage after the filling process. Installation- and Operating Intructions BFSV / BFSU | M1420116_en...
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Page 50: Servicing The System Maintenance Schedule
Servicing the System Maintenance schedule 7.1 Maintenance schedule Item Component Operation Motor/gears ❒ Carry out a general visual inspection of the drive motors and gears ➥ No major oil leaks should be visible! Bulk chute / trough / feed screw ❒... -
Page 51: Troubleshooting
Centrifugal disc blocked ❒ Mechanically release or ▪ Centrifugal disc frozen warm up centrifugal disc Vertical screw blocked ❒ Activate the screw briefly ▪ Wood chips frozen in several times vertical screw Installation- and Operating Intructions BFSV / BFSU | M1420116_en... -
Page 52: 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 INTERNET www.froeling.com 9.1.2 Address of the installer Stamp Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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