Fröling BFSU Installation And Operating Instructions Manual
Sliding floor discharge unit with discharge screw
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Installation and operating instructions
Sliding floor discharge unit
with discharge screw
Translation of original German version of installation and operating instructions for technicians and
operators.
Read and follow all instructions and safety instructions.
All errors and omissions excepted.
M1510021_en | Edition 22/06/2022
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Table of Contents
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Summary of Contents for Fröling BFSU
- Page 1 Installation and operating instructions Sliding floor discharge unit with discharge screw Translation of original German version of installation and operating instructions for technicians and operators. Read and follow all instructions and safety instructions. All errors and omissions excepted. M1510021_en | Edition 22/06/2022...
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Page 2: Table Of Contents
Table of contents 1 General information ............................ 1.1 Functional description ........................... 2 Safety................................2.1 Hazard levels of warnings ........................2.2 Permitted uses ............................2.2.1 Permitted fuels ........................... 2.3 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 .................... - Page 3 Table of contents 6.1 Maintenance work by the operator......................45 6.2 Maintenance work by technicians ......................46 6.2.1 Maintenance instructions for hydraulic systems ................ 47 6.3 Replacement parts ..........................48 7 Troubleshooting ............................49 7.1 Troubleshooting the Lambdatronic H 3200 control system..............49 7.1.1 Procedure for fault messages ....................
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Page 4: General Information
1 | General information 1 General information 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
General information | 1 1.1 Functional description The Froling discharge system “Sliding floor“ consists of: Substructure of the sliding floor Bulkhead Metal tiebacks Light barriers Welded wings Hydraulic drive Slide rods Wall plate Fixed wedge Feeder unit Moveable wedge The FRÖLING sliding floor feed system is used to discharge combustion materials from a rectangular or square storeroom. -
Page 6: Safety
2 | Safety 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
Safety | 2 2.2 Permitted uses Fröling’s “Sliding floor” discharge system is only designed to discharge fuels from suitable storerooms. 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 8: Permitted Fuels
2 | Safety 2.2.1 Permitted fuels Wood chips Description according to Description EN ISO 17225-4 Water content max. 20% Water content max. 30% Water content max. 35% P16S Main proportion (at least 60% mass portion): 3.15 – 16 mm, max. length of 45 mm, previously referred to as fine wood chips G30 P31S Main proportion (at least 60% mass portion): 3.15 –... -
Page 9: Personal Protective Equipment For Assembly Staff
Safety | 2 2.3.2 Personal protective equipment for assembly staff You must ensure that staff have the protective equipment specified by accident prevention regulations! ▪ During transport, erection and installation: - wear suitable work wear - wear protective gloves - wear safety shoes (min. protection class S1P) 2.3.3 Qualification of operating staff CAUTION If unauthorised persons enter the Storeroom:... -
Page 10: Design Information
2 | Safety 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
Safety | 2 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. -
Page 12: Safety Devices
2 | Safety 2.5 Safety devices Safety equipment Safety function Limit switch for top of gravity Protection against access to the danger area of the feed screw shaft or discharge screw when the system is switched on r If the inspection cover is opened, the system is switched off via the limit switch Ä... -
Page 13: Residual Risks
Safety | 2 2.6 Residual risks The discharge system has been designed and built to comply with the relevant safety directives. Nevertheless, by the nature of its operation and function, there are residual risks which cannot be eliminated completely. DANGER Operating the system without the on-site safety equipment: Risk of serious injury from unprotected system components! For safe operation of the system:... -
Page 14: Technology
3 | Technology 3 Technology 3.1 Technical data Description Value width of wing/slide rod 1.5 – 3.0 m Storeroom length 4.6 – 16.2 m Bulk volume 27.6 – 129.6 m Max. load per slide rod 36 t Hydraulic units Overall output of the >... -
Page 15: Store Layout And Construction
Technology | 3 Discharge screw Overall output of the > 320 kW > 500 kW > 1,500 kW system Diameter Ø 150 mm Ø 200 mm Ø 250 mm Output 0.55 kW 0.55 kW 0.55 kW Speed 10.9 rpm 10.8 rpm 10.7 rpm Motor voltage 400 V / 50 Hz... -
Page 16: Design Data For The Sliding Floor Discharge Unit
3 | Technology 3.2.1 Design data for the sliding floor discharge unit The following tables indicate the maximum permissible dumping height as a function of the wing’s width and the store length. NOTICE! If the bulk density of the wood chips is more than 250 kg/m³ (e.g. due to moisture), the maximum dumping height is reduced accordingly. -
Page 17: Installation
Installation | 4 4 Installation 4.1 Transport and positioning The discharge system is supplied without a pallet and requires a loading area of up to 8 m, depending on the length of the profiles. r Follow the transport instructions on the packaging! r Transport components with care. -
Page 18: Positioning
4 | Installation 4.1.2 Positioning NOTICE Careful positioning of the components r Compliance with the maximum load capacity of the transporting equipment is mandatory r The lifting device must not damage the attached load r When attaching the lifting device, observe the load’s centre of gravity and consider the possibility that the load might slip. -
Page 19: Installation Site
Installation | 4 4.2 Installation site When planning the fuel store, compliance with the following design specifications is mandatory: Storeroom detail Design information Substructure of The substructure of the sliding floor muss be embedded in concrete. This the sliding floor process shall be the responsibility of the customer. -
Page 20: Wall Penetration
4 | Installation 4.2.1 Wall penetration Before installing the sliding floor, a wall opening must be provided for the trough of the discharge screw. This task is the responsibility of the customer. Section - Side view: Section - Top view: Experience indicates that an opening of 500 mm x 500 mm is sufficient. -
Page 21: Installation Of The Sliding Floor Discharge Unit
Installation | 4 4.3 Installation of the sliding floor discharge unit CAUTION Assembly and installation by unqualified persons: Risk of personal injury and damage to property During assembly and installation: r Observe the instructions and information in the manuals r Only allow appropriately qualified personnel to work on the system 4.3.1 Masonry and concreting work Base plate construction 1. - Page 22 4 | Installation Connection between base plate and sliding floor 1. Non-positive connection between base plate and sliding floor, using suitable fixings (e.g. heavy-duty anchors) 2. Reinforced steel mesh BSt 500 Q 257 A between the sliding floor elements with a concrete layer 30 mm thick –...
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Page 23: Installing The Substructure
Installation | 4 4.3.2 Installing the substructure The exact installation positions, dimensions and number of components are listed in the enclosed system diagram. Parts of the substructure are already pre-assembled and may consist of several components. r Insert the substructure into the shuttered recesses of the walled-off hydraulic chamber r If a two-part substructure is used, install the remaining substructure whilst in the storeroom r Use suitable material to adjust the height... - Page 24 4 | Installation Screw the substructure to the floor and wall r Copy the hole pattern of the anchor brackets to the floor r Drill the holes as marked - drill diameter 15 mm - min. drill depth 105 mm r Insert the heavy load anchors into the bore holes and tighten with a spanner (AF 17 Ø...
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Page 25: Installing The Transverse Conveyor Unit
Installation | 4 If a two-part substructure is used r Weld on the steel plates (A) at the end of the second part of the substructure r Position the anchor bracket as shown in the system diagram, screw it on and weld it to the substructure r Steel plates must also be welded to the first part of the substructure 4.3.3 Installing the transverse conveyor unit... - Page 26 4 | Installation r Apply a continuous weld to the individual trough parts (A), then grind them Ä At this point, sharp edges must have been removed r Mount the flange bearing (B) to the closed end of the trough - 4 hexagonal screws M12 x 35 r Thread the feed screw (A) into the trough on the boiler room side r Screw together the open trough and transition trough (B) including the seal (C)
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Page 27: Finishing Work On The Substructure
Installation | 4 4.3.4 Finishing work on the substructure r Put down the longitudinal sheets (A), use a pen to mark their position, then trim them to the appropriate length r Weld on the longitudinal plates and grind off the weld seams Ä... -
Page 28: Installing The Upper Structure
4 | Installation 4.3.5 Installing the upper structure NOTICE! Before installing the upper structure, the concrete must be fully cured. The upper structure is already pre-assembled and may consist of several components. r If a two-part substructure is used: At the connection of the substructure remove the steel sheets (A) and grind them smooth Ä... - Page 29 Installation | 4 r Weld the cover plate (B) onto the side parts of the retainers (A) Ä In order to ensure the necessary spacing to the slide rod, suitable material may be used to maintain this clearance r Weld the cover (D) onto the lead-through plates (C) Ä...
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Page 30: Installing The Hydraulic Unit And Cylinder
4 | Installation r Weld the limit switch (A) onto the wall plate and grind off the weld seams r Weld on the light barrier brackets (A) according to the system diagram and grind off the weld seams Ä Do this approx. 200 mm upstream of the shear edge in front of each slide rod and in front of the transition into the closed trough r Apply black paint to all weld seams inside the hydraulic compartment 4.3.6 Installing the hydraulic unit and cylinder... - Page 31 Installation | 4 r Drill the holes as marked - drill diameter 15 mm - min. drill depth 105 mm r Insert the heavy load anchors into the bore holes and tighten with a spanner (AF 17 r Fit the hydraulic cylinder into the recesses of the substructure and the slide rod r Adjust the position of the cylinders and slide rods in order to fit the pins through the eyelets r Use copper paste to grease the pins (A);...
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Page 32: Fitting The Upper Part Of The Gravity Shaft And Drive Unit
4 | Installation 4.3.7 Fitting the upper part of the gravity shaft and drive unit r Secure the upper part of the gravity shaft (A) with gasket (B) to the closed trough on the boiler room side - 4 hexagonal screws M12 x 35 r Secure the flange plate (C) with gasket (D) to top part of gravity shaft - 4 hexagonal screws M12 x 35 r Slide the flange bearing (A) onto the screw end and fix it to the upper part of the... - Page 33 Installation | 4 r Secure the torque support and bearing (A) to the geared motor as illustrated - 8 hexagonal screws M8 x 20 r Lubricate the shaft stub incl. key with copper paste r Push the geared motor (B) onto the screw end r Secure locking washer Ø...
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Page 34: Installing The Sensors
4 | Installation 4.3.8 Installing the sensors r Install the light barriers onto the bracket r Instal the limit switch sensor 4.3.9 Closing the wall penetration r Pack the space in the wall penetration with a non-flammable insulating material Ä Insulate the partition as per EN 1366-3 / EN 13501-2 r Close the wall penetration on the store side and the boiler room side with a non- flammable covering M1510021_en | Installation and operating instructions Sliding floor discharge unit... -
Page 35: Temperature Monitoring Device In The Fuel Store (Tmd)
Installation | 4 4.3.10 Temperature monitoring device in the fuel store (TMD): Ø 6 mm r Position the sensor plate above the transfer channel from open to closed trough (A) and transfer the holes to the wall r Drill the marked holes - Drill diameter 6 mm - Min. -
Page 36: Installing The Bulkhead
4 | Installation 4.3.11 Installing the bulkhead NOTICE! Depending on the specifications, the bulkhead’s design may differ from the following version. r Fasten the U-profiles (A) to the existing walls Ä If reinforced concrete walls are used, the use of dowels is usually sufficient Ä... - Page 37 Installation | 4 Design information about the bulkhead ▪ dimensioned assuming horizontal loads – Assumption: Applying a vertical load of moist wood chips with a dump height of 4 m horizontally – Compaction of the material must be taken into account when using vehicles to bring in the material –...
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Page 38: Connecting The System
4 | Installation 4.4 Connecting the system 4.4.1 Electrical connection DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: r Always have work carried out by a qualified electrician r Observe the applicable standards and regulations Ä... -
Page 39: Operating The System
Operating the System | 5 5 Operating the System 5.1 General information DANGER If the device is used incorrectly: Incorrect use of the system can cause severe injury and damage. When operating the system: r Observe the instructions and information in the manuals r Observe the details on procedures for operation, maintenance and cleaning, as well as troubleshooting in the respective manuals. -
Page 40: Filling The Store With Fuel
5 | Operating the System r Direction of rotation of the screw r On-site protective structure of the bulk chute Ä The bulk chute must be secured so that no one is at risk of injury while the system is in operation! Ä... -
Page 41: During Operation
Operating the System | 5 Filling the storeroom without moving the slide rods r Use the filling opening to add the fuel Ä The system does not have to be shut down during the filling process Filling the storeroom by moving the slide rods Only move the slide rods in compliance with the following instructions: r Fuel quantity of at least 30 cm on the slide rods r Do not drive on the wedges and longitudinal members of the sliding floor discharge. - Page 42 5 | Operating the System NOTICE When transporting wood chips or pellets using the feed screw, there may be noise, depending on the function. M1510021_en | Installation and operating instructions Sliding floor discharge unit...
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Page 43: Decommissioning
Operating the System | 5 5.5 Decommissioning 5.5.1 Disassembly To disassemble the system, follow the steps for assembly in reverse order. 5.5.2 Disposal r Disposal should be carried out according to the valid national regulations and guidelines. r You can separate and clean recyclable materials and send them to a recycling centre. M1510021_en | Installation and operating instructions Sliding floor discharge unit... -
Page 44: Servicing The System
6 | Servicing the system 6 Servicing the system DANGER Maintenance work if the system is switched on: Risk of severe injuries from system components or if the system is switched on without authorisation! Before starting any maintenance work on the system or in the storeroom: r Turn the safety switch inside the hydraulic chamber to the "0"... -
Page 45: Maintenance Work By The Operator
Servicing the system | 6 6.1 Maintenance work by the operator r Regular maintenance of the discharge extends the service life of the entire plant and is a basic requirement for trouble-free operation! Discharge screw Sliding floor W = weekly, M = monthly, Q = quarterly, F = prior to each filling of the storeroom M1510021_en | Installation and operating instructions Sliding floor discharge unit... -
Page 46: Maintenance Work By Technicians
6 | Servicing the system Components Intv Activity r General visual inspection of the drive motor Motor / gears Ä Large oil leaks must not be visible! - - A few drops of leaking oil do not adversely affect the function of the unit Ä... -
Page 47: Maintenance Instructions For Hydraulic Systems
Servicing the system | 6 NOTICE The prerequisite for the feasibility of the inspection and maintenance work is unrestricted access to the components of the discharge system! Therefore: r The storeroom must be empty on the agreed upon date r Provide for any service openings r Sufficient ventilation of the storeroom (CO concentration) Check the following components as part of the maintenance work: ▪... -
Page 48: Replacement Parts
6 | Servicing the system ▪ Fill the relevant hydraulic oil via a filter unit up to the mark on the gauge glass. ▪ In order to be able to remove the residual oil in the hydraulic cylinder the hydraulic hose at the opposite end of the cylinder that is pushed into the end position (the side that still contains old oil) must be closed. -
Page 49: Troubleshooting
Troubleshooting | 7 7 Troubleshooting There are two main types of fault: internal and external to the boiler. External faults: r Heating EMERGENCY OFF switch activated r 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 Troubleshooting the Lambdatronic H 3200 control system 7.1.1 Procedure for fault messages If a fault occurs on the boiler, it will be shown on the display. -
Page 50: Troubleshooting The Sps 4000 Control System
7 | Troubleshooting r Tap the Cancel icon to close the current fault and display the fault list r Tap the Cancel icon again and confirm that you have read all of the errors to return to the basic display Ä... - Page 51 Troubleshooting | 7 If the fault has been successfully acknowledged and is no longer present, the entry in the current fault is removed: r In the fault information, tap on the "Fault log" tab Ä The list of the last fault messages with additional information on occurrence, acknowledgement and associated times is displayed M1510021_en | Installation and operating instructions Sliding floor discharge unit...
- Page 52 Manufacturer’s address Froling srl Froling SARL Fröling Heizkessel- und Zweigniederlassung Behälterbau GesmbH Aschheim Industriestraße 12 Max-Planck-Straße 6 Via J. Ressel 2H 1, rue Kellermann A-4710 Grieskirchen 85609 Aschheim I-39100 Bolzano (BZ) F-67450 Mundolsheim +43 (0) 7248 606 0 +49 (0) 89 927 926 0 +39 (0) 471 060460 +33 (0) 388 193 269 info@froeling.com...
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