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Installation and operating instructions
FBR-G2 / GAR-G2
with separate rotary agitator drive and 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.
M2070323_en | Edition 06/11/2023
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Summary of Contents for Fröling FBR-G2
- Page 1 Installation and operating instructions FBR-G2 / GAR-G2 with separate rotary agitator drive and 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.
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Page 2: Table Of Contents
6.5 Closing the wall penetration ........................52 6.6 Temperature monitoring device in the fuel store (TMD):............... 53 6.7 Connecting the system.......................... 54 6.7.1 Electrical connection ........................54 6.7.2 Connecting the sprinkler system....................54 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 3 7.5.2 Disposal ............................. 60 8 Servicing the system ..........................61 8.1 Maintenance work by the operator......................62 8.2 Maintenance work by technicians ......................64 8.3 Replacement parts ..........................64 9 Troubleshooting ............................65 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 4: General
Directive 2006/42/EC. Compliance with the open provisions and verification of the correct installation must be confirmed in the delivery certificate of the declaration of installation (included in documentation). M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 5: Functional Description
Irrespective of the discharge screw, the feed output can be varied by means of the separate drive of the agitator. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 6: 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. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
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 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 8: Permitted Fuels
Fuel acc. to EN ISO 17225 - Part 2: Wood pellets class A1 / D06 and/or: ENplus / DINplus certification scheme General note: Before refilling the store, check for pellet dust and clean if necessary. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
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. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 10: Protective Equipment For Operating Staff
Heating systems - Acoustic insulation EN ISO 13857 Safety of machines; Safety distances for maintaining a safe distance from hazardous areas EN 13501 Fire classification of construction products and building elements M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 11: Requirements At The Installation Site
Unauthorized access prohibited! Keep children away! Design the fuel store in such a way that it is safe to access and keep it locked. Keep the key in a safe place. No fire, open flames or smoking! Protect the fuel against moisture. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 12: Safety Devices
TMF: Temperature monitoring device in the fuel store (as per TRVB H118, Austria only) which activates the customer’s alarm(s) when the temperature in the fuel store exceeds 70°C. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 13: Residual Risks
The drive would be overloaded r Take the following precautions: Ä The discharge system must be switched on during filling, see the section “Filling/ refilling the store with fuel” M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 14 GAR with wood chips gradient angle α maximum 10° r GAR with pellets gradient angle α maximum 3° Ä The rotary agitator should always be fitted as flat as the place of installation allows M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 15: Technical Information
0 – 10 ° Gradient angle for pellets 0 – 5 ° 0 – 3 ° 0 – 5 ° 0 – 3 ° 0 – 5 ° 0 – 3 ° M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 16: Store Sizes
1. The spring blades have a certain oversize to ensure optimum use of the fuel store 2. Available only for screw Ø 110 3. The greater the height of the pile of dumped material, the greater the likelihood of creation of voids M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 17: Technical Specifications
1. The data are applicable for wood chip fuel. If the fuel used is pellets the data may vary depending on the system. Geared motor power supply 400 VAC / 50 Hz Safety switch 24 VDC M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 18: Design Information
(approx. 70 °C or a maximum of 20 °C above the highest store (TMF) anticipated ambient temperature), warning device(s) provided by the customer will be triggered. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 19: Information About Setup
Take the following precautions: r Install the discharge screw together with supplied trough holder (A) on the support kit (B) Ü "Installing the agitator drive" [} 40] M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 20 These illustrations apply in the same way to an FBR. Standard discharge screw, right Standard discharge screw, left Discharge screw standard right and extra long Discharge screw standard left and extra long left right M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 21: Wall Opening
▪ Square hole: Side length min. 200 mm / max. 270 mm NOTICE! Do not fix the rotary agitator duct to the wall! NOTICE! Line the hole in the wall with a flexible material! M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 22: Transport And Handling
If the system is not going to be assembled immediately: r Store components at a protected location, which is dry and free from dust Ä Damp can lead to damage to individual parts, particularly in the motor! M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 23: Assembly
Spring blades Agitator plate 6.1.2 Support kit FBR-G (RI 125) GAR-G (RI 130) FBR-G / GAR-G (RI 150) Floor bracket Cover plate Adjustable foot Intermediate plate Gearbox support Adapter Mitre gear M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 24: Discharge Screw
Extension trough pellet cover plate Geared motor Wood chips extension trough cover plate Closed trough for middle screw (optional) Base trough raising plate Middle screw (optional) Base trough pellet cover plate M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 25: Agitator Drive
Torque support with bearing Wall module Geared motor Adjustable foot support Spacer ring Adjustable foot Drive shaft Adjustable foot for geared motor Basic module Wall lining Calotte holder Heavy duty anchor Fibreglass gasket M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 26: Installing The Discharge Screw
Extension trough L=1545 L=1000 Transfer channel Ø 5,0 m Base trough Extension trough L=1295 L=1500 Transfer channel Ø 5,5 m Extension trough Base trough L=1545 L=1500 Transfer channel Ø 6,0 m M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 27 L=1345 L=1500 Ø 5,5 m Base trough Extension trough Transfer channel L=1595 L=1500 Ø 6,0 m Extension screw Middle screw (optional) Wood chips plate / pellets plate Raising plate Transfer channel M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 28: Overview Of Trough Arrangement With Extended Length
Extension trough L=750 Base trough Extension trough L=1500 L=1295 L=1500 Transfer channel Ø 5,5 m Extension trough Extension trough L=1500 L=1000 Extension trough Base trough L=1545 L=1500 Transfer channel Ø 6,0 m M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 29 L=1000 Base trough Extension trough Transfer channel L=1595 L=1500 Ø 6,0 m Extension screw Middle screw (optional) Raising plate Pellets plate wood chips plate / pellets plate Raising plate Transfer channel M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 30: Fitting The Troughs
Ä 3 adjustable feet for each discharge screw without extended length Ä 5 adjustable feet for each discharge screw with extended length NOTICE! No adjustable feet are fitted to the trough holder (E) M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 31 Ü "Overview of trough arrangement" [} 26] Ü "Overview of trough arrangement with extended length" [} 28] NOTICE! The rear end of the cover plate rests on the cutting edge (D) of the open trough. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 32: Mounting The Fibre Shredder (Optional)
Fix the clamping jaw (C) and cutting jaw (E) to the screw shaft - 2x cylinder head screw M8 x 25 r Secure screws against loosening with Loctite (Froling item no.: 50378) M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 33: Fitting The Upper Part Of Gravity Shaft And Drive Unit
Ä Centre distance of pin and screw end: 150 mm r Install the torque support and bearing (A) to the geared motor as shown - 8 hexagon head screws M8 x 20 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 34 Fit the torque support with pin on the opposite side r Turn the geared motor and torque support through 180° and fit them to the screw stub and torque support as explained above M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 35 Secure the torque support with a pin (D) to the upper part of the gravity shaft - 2 hexagon head screws M12 x 20 Ä Centre distance of pin and screw stub: 150 mm M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 36 Turn the torque support with bearing 180° and secure it to the geared motor r Turn the geared motor and torque support 180° and fit to the screw end and torque support as explained above M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 37: Fitting Attachments
The following support kits are installed depending on the design of the system: RI 125 RI 130 RI 150 Ü "Mitre gear RI 125" [} 38] Ü "Mitre gear RI 130" [} 38] Ü "Mitre gear RI 150" [} 39] M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 38 - 8x hexagon head screws M12 x 25 r Insert the intermediate plate and mitre gear into the gearbox support and install them - 7x hexagon head screws M12 x 25 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 39 - 1x hexagon head screw M16 x 45 r Insert the intermediate plate and mitre gear into the gearbox support and install them - 7x hexagon head screws M12 x 25 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 40: Installing The Agitator Drive
Fit the adapter flange (B) to the agitator channel - 4x hexagon head screws M12 x 20 r Mount the flange bearing (C) on the intermediate flange - 4x hexagon head screws M12 x 25 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 41 Ä When doing so, slide the drive shaft on to the shaft stub of the mitre gear r Fit the cover plate to the agitator channel and intermediate plate - 4x hexagon head screws M6 x 12 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 42 - 2x hexagon head screws M12 x 40 per adjustable foot r Fit the trough holder for the discharge screw on to the support kit - 1x hexagon head screw M12 x 40 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 43 2x heavy duty anchors for each adjustable foot Ä Drill diameter 15 mm Ä Drill depth at least 105 mm r Shorten the adjustable feet using an angle grinder so that the agitator arms are not obstructed M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 44 For the STM geared motor: r Remove the blanking plug from the highest point of the geared motor and insert the vent screw that is supplied M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 45: Installing The Raised Floor (Optional)
- 6x hexagon head screws M12 x 30 For mitre gear RI 150 r Install the spacer ring (A) and agitator plate on the flange of the mitre gear - 6x hexagon head screws M12 x 80 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 46 - 2x hexagon head screws M8 x 16 for each cover plate 30-50 mm r Fit the spring packets parallel to the upper edge of the open trough (A) at a distance of 30-50 mm M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 47: Installing The Gar-G Articulated Arm Agitator
Ä Eye bolts are no longer required r Remove the cable ties (transport lock) on both articulated arms r Remove the cover of the basic module - 4x hexagon head screw M12 x 30 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 48 - 2x hexagon head screw M12 x 30 r Install the agitator head on the mitre gear - 6x hexagon head screws M12 x 80 r Remove eye bolts Ä Eye bolts are no longer required M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 49 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 r Lock screw connection with second nut (E) M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 50 CAUTION: Do not tighten the screw connections to the spring blades (D). The number of parts required varies depending on the store size and the length of the packs of springs. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 51 Ä Hook (B) must point in the direction of the clamping plate (A – in the direction of rotation) 30-50 mm r Fit the spring blades parallel to the upper edge of the open trough (A) at a distance of 30-50 mm M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 52: 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. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 53: Temperature Monitoring Device In The Fuel Store (Tmd)
Guide the sensor through the wall at a suitable point and push it into the sensor plate Ä CAUTION: Do not kink the capillary tube! r Further cabling of the on-site warning device(s) according to the enclosed installation instructions M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 54: Connecting The System
Slide sensor (C) of the thermal discharge safety valve into the immersion sleeve and secure with screw r Connect the thermal discharge safety sensor to a pressurised cold water mains supply M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 55: Operating The System
Check that the motor overload for the drive motor is working r Check the connection of the sprinkler device When the check is finished: r Fill the store with fuel M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 56: Filling/Refilling The Store With Fuel
If there is still sufficient fuel in the fuel store (the rotary agitator head is completely covered with fuel and the rotary agitator arms / spring blades are not extended), the store can be filled. r Load the fuel at the filling opening M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 57: Loading Fuel Into An Empty Fuel Store With A Rotary Agitator
Switch off the boiler by tapping “Boiler off” at the mode icon and allow to cool for at least two hours r Close all openings to the store to seal out dust r Blow the fuel into the fuel store M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 58: Blowing In Fuel For An Empty Store With Rotary Agitator
Blow the fuel into the fuel store If the fuel store is completely empty and there is no residual fuel to redistribute: r Contact Froling and seek advice before filling the fuel store M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 59: Drainage Of Fuel Store
The boiler is controlled by the boiler controller. The discharge system switches on and off automatically when material is requested. NOTICE When transporting wood chips or pellets using the feed screw, there may be noise, depending on the function. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 60: Decommissioning
7.5.2 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. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 61: Servicing The System
Incorrect or insufficient inspection and cleaning of the discharge can cause serious faults and subsequently result in accidents and damage to property. Therefore: r Carry out maintenance of the discharge according to the instructions! M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 62: Maintenance Work By The Operator
W = weekly, M = monthly, Q = quarterly, F = prior to each filling of the store Articulated arm agitator Spring blade agitator W = weekly, M = monthly, Q = quarterly, F = prior to each filling of the store M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 63 General visual inspection of the rotary agitator arms and screw joints for Rotary agitator damage arms r Check chain for wear / damage Chain guide r Use a grease gun to grease the bearing at the grease nipple Flange bearing unit M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
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Page 64: Maintenance Work By Technicians
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. r Only replace components or parts with original replacement parts. M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... -
Page 65: Troubleshooting
▪ Heating EMERGENCY STOP activated ▪ Household fuse (FI circuit breaker) or component fuse blown Internal faults: ▪ are displayed as error messages on the boiler controller see boiler operating instructions M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2... - Page 66 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 67 M2070323_en | Installation and operating instructions FBR-G2 / GAR-G2...
- Page 68 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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