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Installation- and Operating Intructions
Bunker filling system BFSV-H / BFSU-H
Translation of the original German operating instructions for technicians
Read and follow the instructions and safety information!
Technical changes, typographical errors and omissions reserved!
M1690116_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-H
- Page 1 Installation- and Operating Intructions Bunker filling system BFSV-H / BFSU-H Translation of the original German operating instructions for technicians Read and follow the instructions and safety information! Technical changes, typographical errors and omissions reserved! M1690116_en | Edition 08/08/2016 Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 2: Table Of Contents
Protective equipment for operating staff Design information 2.4.1 Standards 2.4.2 Requirements at the installation site Safety devices Residual Risks Technology Dimensions BFSV-H 3.1.1 Design with recessed bulk chute 3.1.2 Dimensions of extension shaft Dimensions BFSU-H 3.2.1 Design with recessed bulk chute Technical data... - 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-H / BFSU-H | M1690116_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
From there the fuel is fed to the horizontal distributor screw (3) either directly (with BFSU-H) or via the vertical screw (2 - with BFSV-H). The horizontal distributor screw (3) is powered by the geared motor installed in the fuel store and transports the fuel into the fuel store, where it is discharged through the open trough. -
Page 6: Control Unit
General Functional description sensor (4), which stops the fuel store from filling when the fuel store is full. The filling level sensor is connected to the control unit which indicates on the control unit at “Sensor right” whether the fuel store has reached the maximum filling level. 1.1.1 Control unit Emergency stop for shutting down the system immediately with any risk Key-operated selector switch (NOT IN USE) -
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-H / BFSU-H | M1690116_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-H / BFSU-H | M1690116_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-H / BFSU-H | M1690116_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
Protection from the system being switched on without attachments. When the bulk chute is disconnected, the safety switch is force-actuated, so preventing the system from being used without attached components (vertical screw / horizontal distributor screw). Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_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-H / BFSU-H | M1690116_en...
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Page 16: Technology
Technology Dimensions BFSV-H 3 Technology 3.1 Dimensions BFSV-H The following diagram with associated matrix lists the possible system lengths and system heights which are important for design of the fuel store and the wall opening. All dimensions are specified in mm. - Page 17 2340 (1920+420) 4670 4660 2840 (1920+920) 5170 5080 3260 (1920+920+420) 5590 5660 3840 (1920+1920) 6170 6080 4260 (1920+1920+420) 6590 6580 4760 (1920+1920+920) 7090 7000 5180 7510 (1920+1920+920+420) 7580 5760 (1920+1920+1920) 8090 Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en...
- Page 18 Technology Dimensions BFSV-H 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)
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Page 19: Design With Recessed Bulk Chute
Dimensions BFSV-H 3.1.1 Design with recessed bulk chute The following diagram shows the BFSV-H 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 20: Dimensions Bfsu-H
Technology Dimensions BFSU-H 3.2 Dimensions BFSU-H The following diagram with associated matrix lists the possible system lengths and system heights which are important for design of the fuel store and the wall opening. All dimensions are specified in mm. System length bulk chute (1500 - 7340) Extension pipe 1345 (420 - 3840) - Page 21 Screw length Weight 2900 3500 3560 3980 4420 4480 4840 1340 (920+420) 4900 5420 1920 5480 5840 2340 (1920+420) 5900 6340 2840 (1920+920) 6400 6760 3260 (1920+920+420) 6820 7340 3840 (1920+1920) 7400 Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en...
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Page 22: Design With Recessed Bulk Chute
Technology Dimensions BFSU-H 3.2.1 Design with recessed bulk chute The following diagram shows the BFSU-H 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. Shaft length = System length bulk chute + 930 System length bulk chute (1500 - 7340) Extension pipe... -
Page 23: Assembly
NOTICE! Lifting with suitable lifting equipment should only be carried out by technicians with a specific knowledge of lifting loads! NOTICE! Lifted components must be secured by the lifting equipment until firmly attached! Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en... - Page 24 Assembly Assembly Aids Working height When performing assembly at great heights, suitable scaffolding or elevating work platforms are necessary on site. Their design and dimensioning in relation to the permissible working height and load capacity should be selected according to the accident prevention regulations! NOTICE! Installation and operation should only be carried out by technicians with a specific knowledge of lifting persons!
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Page 25: Installation Site
In the case of rectangular fuel stores, the filling with fuel should preferably be carried out on the narrow side. Positioning in the centre of the narrow side (ideal) Fill level Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en... - Page 26 Assembly Installation site Positioning off-centre or on the long side (not ideal) Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com...
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Page 27: Installation With Mobile Bulk Chute
Installation site 4.3.2 Installation with mobile bulk chute With all assembly variants of the BFSV-H 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 28: Installation With Recessed Bulk Chute
Assembly Installation site 4.3.3 Installation with recessed bulk chute If the filling system is operated with a stationary recessed bulk chute, the following design information should be noted: Protective structure to prevent operator from reaching over during operation. Dimensioning of structure acc. to EN ISO 13857. Cover over filling area to prevent operator from climbing in during operation. -
Page 29: Installation Variants Bfsv - H
Vertical screw inside Vertical screw outside with extension shaft Vertical screw outside Bulk chute outside with extension pipe 4.5 Installation variants BFSU - H Bulk chute outside with extension pipe Bulk chute outside Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en... -
Page 30: Install Bunker Filling System
Assembly Install Bunker Filling System 4.6 Install Bunker Filling System CAUTION The suitability of the fasteners supplied (e.g. heavy duty anchor) for the respective attachment basis must be checked by the assembly staff and operator. If the fasteners supplied are not suitable, then responsibility for selecting the fasteners lies with the assembly staff. - Page 31 ❒ 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-H / BFSU-H | M1690116_en...
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Page 32: Fitting The Extension Shaft (Optional)
Assembly Install Bunker Filling System 4.6.2 Fitting the extension shaft (optional) ❒ Screw the extension shaft and vertical screw with the 4 hexagonal screws M10x 30, spacer washers and safety nuts 4.6.3 Installing the horizontal distributor screw Depending on the conditions on site, the horizontal distributor screw is delivered as individual parts or already fully assembled. -
Page 33: Assembling The Troughs
8 lock washers and hexagonal screws M8x16 on the gearbox flange ❒ Insert the fitting key into the groove on the shaft and secure it with a locking screw ❒ Screw filling level sensor in gearbox flange Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en... -
Page 34: Installing The Adjustable Feet
Assembly Install Bunker Filling System Installing the adjustable feet ❒ Attach the adjustable feet on the side of the horizontal distributor screw with cup square bolts, spacer washers and hexagonal nuts ➥ The number of adjustable feet depends on the system length of the horizontal distributor screw! Attaching the horizontal distributor screw to the ceiling 14 mm... -
Page 35: Preparing The Bulk Chute
➥ If the bulk chute is to be installed at fixed points, it can be secured to the floor using heavy duty anchors ❒ Regulate the height of the bulk chute by adjusting the wheels or adjustable feet to the flange of the extension pipe or vertical screw Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en... -
Page 36: Fit The Cover Plates
Assembly Install Bunker Filling System Fit the cover plates ❒ Screw the cover plate (number depends on the length of the bulk chute) using the 4 hexagonal screws M10x30 to the bulk chute ➥ The position of the cover plate depends on the wood chip size ⇨... -
Page 37: Turning The Fitting Frame
❒ Turn the fitting frame by 180° and place it on the bulk chute ❒ 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! Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en... -
Page 38: Final Installation Steps
Assembly Install Bunker Filling System 4.6.7 Final installation steps Positioning the stickers ❒ Attach the “FRÖLING” sticker to the vertical screw pipe ❒ Attach 2x stickers “CAUTION – DELAYED AUTOMATIC START-UP OF FILLING SYSTEM” on the inside of the fitting frame Froling GesmbH | A-4710 Grieskirchen, Industriestraße 12 | www.froeling.com... - Page 39 Assembly Install Bunker Filling System ❒ Attach 2x stickers “Cover plate adjustment” on the left and right outer edge of the fitting frame Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en...
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Page 40: Electrical Connection
Electrical connection Mains connection 5 Electrical connection DANGER When working on electrical components: Risk of electrocution! When work is carried out on electrical components: ❒ Only have work carried out by a qualified electrician ❒ Observe the applicable standards and regulations ➥... -
Page 41: Operating The System
❒ Perform a test run and fill the store space with fuel ❒ Observe the fuel transport around the bulk chute (e.g. bridge formation) and if necessary, regulate by adjusting cover plates Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en... -
Page 42: Adjust Filling Area To Loading Vehicle
Operating the system Adjust Filling Area to Loading Vehicle 6.2 Adjust Filling Area to Loading Vehicle The front part of the bulk chute is adjustable, which means that it can be quickly adapted to the sill of the loading vehicle. ❒... -
Page 43: Fill The Store With Fuel
❒ Ensure that no one is in the store and that the entrance to the store is secured against entry for the duration of the filling process ❒ Only start the filling process once these conditions have been met Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en... - Page 44 Operating the system Fill the store with fuel DANGER Delayed automatic start-up of individual components Serious injury possible due to moving parts with automatic start-up! When switching on the system, remember the following: ❒ Check that there is no-one in the danger zone of the system ❒...
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Page 45: 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-H / BFSU-H | M1690116_en... -
Page 46: Switch Off The Power Supply
Operating the system Fill the store 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 47 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-H / BFSU-H | M1690116_en...
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Page 48: 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 49: Troubleshooting
Vertical screw blocked ❒ Activate the screw briefly ▪ Wood chips frozen in several times vertical screw Horizontal distributor screw ▪ Filling level sensor has stops activated Installation- and Operating Intructions BFSV-H / BFSU-H | M1690116_en... -
Page 50: 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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