Pellet suction system GA kW

Transcription

1 Installation and Operating Instructions Pellet suction system GA kW 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! M _en Edition 27/01/2016 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

2 Table of contents Table of contents 1 General Product overview and functional description 5 2 Safety Hazard levels of warnings Permitted uses Area of application Permitted fuels 8 Wood pellets Qualification of staff Qualification of assembly staff Personal protective equipment for assembly staff Qualification of operating staff Protective equipment for operating staff Design information Standards Requirements at the installation site Safety devices Residual risks 11 3 Technical information Dimensions Technical specifications 14 4 Installation Transport Temporary storage Materials supplied Installation positions Installing the pellet suction system Install hose lines Assembly information for hose lines Potential equalisation Connecting the system Electrical connection Power supply Connecting the sprinkler system Wiring 26 5 Operating the system Initial start-up During operation 28 6 Servicing Maintenance schedule 29 2 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

3 Table of contents 6.2 Maintenance contract 30 7 Troubleshooting Procedure for fault messages 31 8 Appendix Addresses Address of manufacturer Address of the installer 32 Installation and Operating Instructions M _en 3

4 1 General 1 General Thank you for choosing a quality product from Froling. The product features a state-ofthe-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. Observing the requirements and safety information in the documentation makes a significant contribution to safe, appropriate, environmentally friendly and economical operation of the system. The constant further development of our products means that there may be minor differences from the pictures and content. If you discover any errors, please let us know: doku@froeling.com. Subject to technical change. Issuing a delivery certificate This is an incomplete machine as defined by the Machinery Directive. The incomplete machine must only be started up when it has been confirmed that the machine, in which the incomplete machine has been installed, conforms to the provisions of 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). Warranty and Guarantee Conditions Our sale and delivery conditions will be applicable. These conditions have been made available to customers, and customers have been made aware of them at the time of order completion. 4 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

5 General Product overview and functional description Product overview and functional description A Cyclone container E Connections for suction hoses I Sensor B Gate valve F Adjustable foot J Upper part of gravity shaft C Filling level sensor G Channel feed screw K Geared motor D Cyclone cover H Bottom part of gravity shaft L Expansion switch cabinet The Froling pellet suction system GA kW consists of 2 cyclone containers (A) on a feed screw which is mounted on the stoker unit of the boiler in order to supply it with pellets. The cyclone containers are filled alternately with pellets from the store via their own discharge system (e.g. Froling pellet suction system RS4 / RS8). Each cyclone container has a filling level sensor (C), which ends the suction process when the cyclone container is full. Sensors (I) are located in the bottom part of the gravity shaft (H), which respond when there are no more pellets in the cyclone container. Subsequently, the sensors close the associated cyclone container using the gate valve (B) and the suction process for filling the cyclone container is started. The gate valve therefore enables the suction process during operation. In normal operation, one of the gate valves below the cyclones is always open and supplies the feed screw with pellets. This ensures that the boiler is supplied with pellets at all times, thus guaranteeing reliable 24h full load operation (depending on type of boiler used). Installation and Operating Instructions M _en 5

6 2 Safety Hazard levels of warnings 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. You must follow the instructions! WARNING The dangerous situation may occur and if measures are not observed it will lead to serious injury or death. 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. 2.2 Permitted uses The Froling Pellet suction system GA kW is intended solely for the loading of wood pellets for Froling boilers which are listed in the Area of Application section. For the loading of wood pellets from the store to the Froling Pellet suction system GA kW, only the discharge systems that are listed in the Area of Application section may be used. Only use fuels specified in the Permitted fuels section. The unit should only be operated when it is in full working order. It should be operated in accordance with the instructions, observing safety precautions, and you should ensure you are aware of the potential hazards. The inspection and cleaning intervals in the operating instructions should 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. 6 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

7 Safety Permitted uses 2 DANGER If the device is used incorrectly: Incorrect use of the system can cause severe injury and damage. When operating the system: Observe the instructions and information in the manuals Observe the details on procedures for operation, maintenance and cleaning, as well as troubleshooting in the respective manuals. 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 Area of application Permitted boilers The Froling Pellet suction system GA may only be used in conjunction with the following Froling boilers: Wood chip and pellet boilers T Wood chip and pellet boilers TX Wood chip and pellet boilers TI 350 Turbomat TM Permitted discharge systems The Froling Pellet suction system GA may only be used in conjunction with the following Froling discharge systems: RS4 pellet suction system RS8 pellet suction system E3 pellet mole Suction screw system Pellet bag silo types 7-50 NOTICE Each cyclone container needs its own discharge system, therefore two discharge systems are always required. The discharge systems must be the same type (e.g. 2x E3 pellet mole or 2x RS4 pellet suction system,...) Installation and Operating Instructions M _en 7

8 2 Safety Permitted uses Permitted fuels Wood pellets Note on standards Wood pellets made from natural wood with a diameter of 6 mm EU: Fuel acc. to EN ISO 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. 2.3 Qualification of staff Qualification of assembly staff CAUTION Assembly and installation by unqualified persons: Risk of personal injury and damage to property During assembly and installation: Observe the instructions and information in the manuals Only allow appropriately qualified personnel to work on the system Assembly, installation, initial startup and servicing must always be carried out by qualified personnel: - Heating technician / building technician - Electrical installation technician - Froling customer services The assembly staff must have read and understood the instructions in the documentation 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 work wear - protective gloves - sturdy shoes (min. protection class S1P) 8 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

9 Safety Qualification of staff Qualification of operating staff CAUTION If unauthorised persons enter the installation room / boiler room: 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. The operator must also have read and understood the instructions in the documentation Protective equipment for operating staff You must ensure that staff have the protective equipment specified by accident prevention regulations. For inspection and cleaning: - suitable workwear - protective gloves - sturdy shoes Additional for operating: - Hearing protection (sound level > 70 db) - Protective goggles 2.4 Design information Carrying out modifications to the system and changing or deactivating safety equipment is prohibited. Always comply with all fire, building, and electrical regulations when installing or operating the system, in addition to following the operating instructions and mandatory regulations that apply in the country in which the system is operated Standards The system must be installed and commissioned in accordance with the local fire and building regulations. The following standards and regulations should be observed in any case: ÖNORM / DIN EN Safety of machines; Electrical equipment of machines, Part 1: General requirements TRVB H 118 ÖNORM H 5170 Technical directives for fire protection/prevention (Austria) Construction and fire protection requirements (Austria) Installation and Operating Instructions M _en 9

10 2 Safety Design information ÖNORM H 5190 EN ISO Heating systems - Acoustic insulation Safety of machines; Safety distances for maintaining a safe distance from hazardous areas Requirements at the installation site CAUTION Noise pollution during operation of the pellet suction system Due to the suction of the pellets in the cyclone container, the system generates a high level of noise. Therefore: Install the pellet suction system only in areas which are suitable for high levels of operational noise. Wear ear protection when working in the installation room All walls and load-bearing elements must support the static load. The structural requirements may need to be discussed with a structural engineer. Local fire regulations must be respected. Water lines should not be located in close proximity to the pellet store or the feeder units due to the dangers posed by condensation and bursting water pipes. NOTICE! Observe the additional requirements at the installation site according to the instructions for the boiler used! NOTICE! Observe the information regarding the equipment of the pellet store according to the instructions for the discharge system! 10 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

11 2 Safety Safety devices 2.5 Safety devices Safety equipment Safety function Gate valve: The gate valve closes the cyclone container when the sensor detects that no more pellets are present in the cyclone container, therefore enabling the suction during operation Safety switch, upper part of gravity shaft: Protection against access to the danger area of the dosing screw when the system is switched on If the inspection cover is opened, the system is switched off via the safety switch The power supply remains switched on Rotary valve: Burn back protection system (BPS) directly below the top of the gravity shaft. During the heating up phase, after loading has taken place and in the event of a fault, it reliably disconnects the discharge and infeed devices, preventing fire from spreading to the fuel store. Water Sprinkler System: Self-activating extinguisher system to limit burn back around the top of the gravity shaft. If the temperature in the top of the gravity shaft rises above 95 C, the valve of the sprinkler system opens, water flows out and prevents the fire from spreading to the fuel store. 2.6 Residual risks The suction 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. Installation and Operating Instructions M _en 11

12 2 Safety Residual risks 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 Work must not be carried out on electrical components by unauthorised persons DANGER When working on the unit with a live power supply: Serious injury possible due to automatic startup! When working on the system or in the store, it is essential that the five safety directives are followed: Disconnect all poles on all sides Secure so that it cannot be switched on again Check that there is no power Earth and short circuit Cover any adjacent live parts and limit area of risk CAUTION If unauthorised fuel types are used: Non-standard fuels can cause stiffness and block the system, resulting in the failure/breakage of components. Therefore: Only use fuels specified in the "Permitted uses" section of these operating instructions. CAUTION Crushing hazard when operating the suction system without protective cover for gate valve Therefore: Ensure that the protective cover for the gate valve is fitted 12 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

13 Technical information Dimensions 3 3 Technical information 3.1 Dimensions Item Description Unit Suction system with feed screw 15 Suction system with feed screw 30 α Angle of feed screw H1 Overall height mm H2 Height, upper part of gravity shaft mm L Length of feed screw to centre of upper part of gravity shaft mm D Diameter of cyclone container mm 480 Installation and Operating Instructions M _en 13

14 3 Technical information Technical specifications 3.2 Technical specifications Description Power supply to control cabinet Power consumption of suction turbine Suction system with feed screw 15 with feed screw V / 50Hz / fused C16A 1850 W Weight, complete unit 270 kg 260 kg Capacity of each cyclone container (gross) Capacity of each cyclone container (net) Feed screw drive Description T TM/TX Power supply to geared motor 205 l 110 kg 400 V / 50 Hz TM 320 TI 350 Power consumption of geared motor 0.25 kw 0.37 kw Speed of screw 4.5 rpm 10.5 rpm Safety limit switch 24 VDC 14 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

15 Installation Transport 4 4 Installation 4.1 Transport The product is delivered on pallet(s). NOTICE Possibility of damage to components if handled incorrectly Follow the transport instructions on the packaging Transport components with care to avoid damage Protect components against damp Pay attention to the pallet's centre of gravity when lifting 4.2 Temporary storage 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! 4.3 Materials supplied A Feed screw, complete D Cardboard box containing accessories B 2 cyclone containers with gate valve E H3200 only: Expansion switch cabinet for H3200 with mounting bracket C 2 cyclone covers with bracket for suction turbine and connection of suction hoses Not illustra ted SPS only: Add-on module for SPS Installation and Operating Instructions M _en 15

16 4 Installation Installation positions 4.4 Installation positions CAUTION Noise pollution during operation of the pellet suction system Due to the suction of the pellets in the cyclone container, the system generates a high level of noise. Therefore: Install the pellet suction system only in areas which are suitable for high levels of operational noise. Wear ear protection when working in the installation room The position of the suction system in relation to the boiler can be flexibly selected using the pivot point above the rotary valve. The pellet discharge system can therefore be positioned as required. Some of the possible installation positions are illustrated in the following: NOTICE! These figures show the 15 pellet discharge system. For a 30 pellet discharge system, the space required is smaller! Installation position T4: Depending on which side the stoker is mounted, the pellet suction system can occupy any position between item A and item B. 16 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

17 4 Installation Installation positions Installation positions TM / TX / TI The following installation positions are shown for the Turbomat TM 150; these positions also apply for TM , TX and TI The pellet suction system can occupy any position between item A and item B. Installation and Operating Instructions M _en 17

18 4 Installation Installing the pellet suction system 4.5 Installing the pellet suction system The installation of the pellet suction system is illustrated below using the Froling T4 150 wood chip boiler as an example. Installation of the Froling TX wood chip boiler, TI 350 and Turbomat TM is carried out in the same manner. Install the feed screw on the stoker of the boiler For 30 suction system: Install the flange of the extension piece (A) at the upper part of the gravity shaft to the flange of the stoker For 15 suction system: Install the flange at the upper part of the gravity shaft to the flange of the stoker Align the feed screw, as required, and secure it to the floor of the store room using the adjustable foot NOTICE! Position the feed screw so that the cyclone container sits exactly perpendicular to the flanges Fixing the adjustable foot: Make 1 hole in the floor on the left and right Drill the holes marked Drill diameter 15 mm Min. drill depth 105 mm Insert the heavy load anchors into the bore holes and tighten with a spanner (SW 17 mm) 18 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

19 Installation Installing the pellet suction system 4 Install safety switch (A), thermal discharge safety device (B) and elbow (C) to upper part of gravity shaft Install 2 sensors (D) to the sides of the bottom part of the gravity shaft Install both cyclone containers to upper part of gravity shaft The quick release fasteners determine how the cyclone cover is to be fitted later on position the cyclone container so that the hose line connections on the cyclone cover are pointing in the desired direction Check that the cyclone container lies horizontally if necessary, correct the alignment of the feed screw Installation and Operating Instructions M _en 19

20 4 Installation Installing the pellet suction system Install 1 filling level sensor each with seal washer (A) and space washer (B) to both cyclone containers Fit the cyclone cover with bracket for the suction connections onto the cyclone container and secure it using the quick release fasteners on the side Check that the connections for the hose lines (A) are pointing in the desired direction If required, correct the position of the cyclone container 20 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

21 Installation Installing the pellet suction system 4 Remove the screws at the duct of the feed screw Fit securing plate for the controller at the duct with the screws previously removed The securing plate can also be installed so that the edge faces upwards (A) Fit control box to the securing plate Fit cover to the control box Installation and Operating Instructions M _en 21

22 4 Installation Installing the pellet suction system Install hose lines NOTICE! Observe the installation instructions for hose lines! See "Installation instructions for hose lines" [page 23] NOTICE! Do not mix up the connections for the suction hose and return air line! Remove the cover on the brackets for the suction connections Install suction hose (A): NOTICE! The suction hose must be in a single section! Fit suction hose at the inlet nozzle (B) with a hose clip The inlet nozzle for the suction hose is identified by a sticker labelled Pellets! Fit the return-air line (C): Fix the suction hose to the suction turbine (D) with a hose clip Lay hose lines to the suction point and cut to length, if required Refit the covers The exhaust air grille (E) on both sides of the covers must not be obscured! 22 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

23 Installation Assembly information for hose lines Assembly information for hose lines Please note the following with regard to the hose lines used in Froling vacuum discharge systems: Do not kink the hose lines! Minimum bending radius = 30cm Lay the hose lines as straight as possible! Sagging lines can lead to so-called pockets, which may cause problems with the pellet feed. Lay the hose lines in short sections away from walking areas Hose lines are not UV-proof. Therefore: Do not lay the hose lines outdoors Hose lines are suitable for temperatures up to 60 C. Therefore: Hose lines must not come into contact with flue gas pipes or uninsulated heating pipes. Hose lines must be earthed on both sides to ensure that no static charge builds up as a result of transporting the pellets. The suction hose to the boiler must be in a single section The return-air line can be made up of several sections, but consistent potential equalisation must be established throughout the line For systems over 130 kw, only suction hoses with PU inlet may be used due to the increased load. Installation and Operating Instructions M _en 23

24 4 Installation Assembly information for hose lines Potential equalisation When connecting the hose lines to the individual connections, ensure there is consistent potential equalization throughout the line Expose approximately 3 cm of the earth wire at the end of the hose line TIP: Slit the insulation open along the wire with a knife Bend the earth wire inwards in a loop This prevents the earth wire from being damaged by the pellet movement. Slide the hose clamp onto the hose line Attach the hose line to the connector Ensure that contact is established between the earth wire and the connector Secure the hose line with a hose clamp 24 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

25 Installation Connecting the system Connecting the system 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 Work must not be carried out on electrical components by unauthorised persons Lay cables of components to control cabinet Lay the cables so that nobody will trip over them! Do not lay the cable over or around sharp edges! Wire the connections according to the wiring diagram Power supply Lay the mains cable to the expansion switch cabinet Connect the mating plug (included) to the mains cable Flexible sheathed cable must be used for the wiring; this must be of the correct size to comply with applicable regional standards and regulations The power supply line (mains connection) must be fitted with a C16A fuse by the customer. Connect the power supply cable at the mains connection provided Connecting the sprinkler system Connection should only be carried out by authorised technicians. When connecting the sprinkler system, please also note: Put a stopcock and bolted joint in front of the thermal discharge safety device Important for easy dismantling in the event of maintenance work! Installation and Operating Instructions M _en 25

26 4 Installation Connecting the system Wiring Expansion switch cabinet H3200 Expansion switch cabinet SPS BUS connection Suction turbine Power supply Power supply Filling level sensors Cyclone container Bag silo vibration motor Sensors Bottom part of gravity shaft Gate valve Connection box for pellet mole For H3200: Establish the BUS connection (item A) for the controller (wood chip module or hydraulic module) For SPS: Connect BT9100 module (on the boiler control cabinet) via X2X link (item no /18948/18949) with BR9300 module (on the expansion switch cabinet item B) according to wiring diagram Wire the components listed on the expansion switch cabinet Item 1: Cyclone container 1 Item 2: Cyclone container 2 26 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

27 Installation Connecting the system 4 Cyclone container Suction turbine 1 release 1 (pellet mole, vibration motor) sensor 1 transmitter receiver Filling level sensor cyclone container 1 gate valve 1 brown blue yellow green brown blue yellow green brown blue brown black blue brown blue white blue black yellow brown red green Wire the components as shown in the figure Cyclone container Suction turbine 2 release 2 (pellet mole, vibration motor) transmitter sensor 2 receiver filling level sensor cyclone container 2 gate valve 2 brown blue yellow green brown blue yellow green brown blue brown black blue brown blue white blue black yellow brown red green Wire the components as shown in the figure Installation and Operating Instructions M _en 27

28 5 Operating the system Initial start-up 5 Operating the system 5.1 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 Description of cyclone container: (1): Cyclone container 1 (2): Cyclone container 2 Configure the pellet suction system according to the information contained in the H3200 boiler controller and SPS operating instructions. NOTICE! Caution: As soon as the cyclone containers are activated, the suction process starts, even if the boiler is in Boiler OFF status! 5.2 During operation The pellet suction system is controlled by the boiler controller. CAUTION Noise pollution during operation of the pellet suction system Due to the suction of the pellets in the cyclone container, the system generates a high level of noise. Therefore: Install the pellet suction system only in areas which are suitable for high levels of operational noise. Wear ear protection when working in the installation room NOTICE! When switching the suction process from cyclone container 1 to cyclone container 2, there can be a temporary undersupply of pellets, however, this does not lead to a system fault! 28 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

29 Servicing Maintenance schedule 6 6 Servicing 6.1 Maintenance schedule W 1 W M Q 3 2 M Q F 4 F W = weekly, M = monthly, Q = quarterly, F = prior to each fill of the store No. Element Interval Operation 1 Motor / gears W Carry out a general visual inspection of drive motors No major oil leaks should be visible. 2 Gravity shaft / safety switch M Function test of the safety switch: Open the inspection cover of the gravity shaft The system should switch off immediately. Check the inlet area for material build-up and clean where necessary. Close gravity shaft cover Check fault message on the controller 3 Sprinkler system Q Sprinkler system function test: Open ball valve only slightly Heat the sensor to above 95 C (e.g. with a lighter) The valve should open and water should flow out. Press the button on the valve briefly Water should flow out Check the opening of the sensor for dirt (dust, fuel, etc.) and clean if necessary 4 Flange bearing F Lubricate bearing at lubricating nipple with grease gun Hose lines F Check hose lines for damage and wear and replace if necessary Installation and Operating Instructions M _en 29

30 6 Servicing Maintenance contract 6.2 Maintenance contract Long service life with a maintenance contract! Regular maintenance and servicing by a qualified technician will ensure a long, trouble-free service life for the whole system. For this reason, FROLING offers a maintenance contract, which optimises operating safety. Please see the details in the accompanying guarantee certificate. Your Froling customer service office will also be happy to advise you. 30 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12

31 Troubleshooting Procedure for fault messages 7 7 Troubleshooting The term "fault" is a collective term for warnings, errors and alarms. The boiler reacts differently to the three types of message: WARNING ERROR ALARM In case of warnings the status LED flashes orange and the boiler initially continues controlled operation. When there is an error, the status LED flashes red, the boiler follows the shutdown procedure and remains in Fault status until the problem is resolved. An alarm triggers a system emergency stop. The status LED flashes red, the boiler switches off immediately and the heating circuit controller and pumps remain active. A window with the corresponding fault text will also appear. Pressing the Cancel icon takes you back to the basic display. If the quick select icon and the warning triangle flash alternately, there is still a fault. The Error display button will now appear in the quick menu. 7.1 Procedure for fault messages When a fault occurs a window with the corresponding fault text will appear. The right arrow will take you to possible causes of the fault. Tapping Solution will also display action to be taken to resolve the problem. If there are several options available, these will be listed one below the other. NOTICE! For more information about troubleshooting see operating instructions for the boiler controller. Once the fault has been resolved, tap the Cancel icon to return to the basic display. Installation and Operating Instructions M _en 31

32 8 Appendix Addresses 8 Appendix 8.1 Addresses Address of manufacturer FRÖLING Heizkessel- und Behälterbau GesmbH Industriestraße 12 A-4710 Grieskirchen AUSTRIA TEL 0043 (0) FAX 0043 (0) INTERNET Address of the installer Stamp 32 Fröling GesmbH A-4710 Grieskirchen, Industriestraße 12