A.B.S. Flexilo FLAT BOTTOM, Assembly-, Operating-, And Filling Instructions

Page 1: ... is intended for skilled mechanics which have based on expert training the respective knowledge and experience As we are interested in continuously improving our technical documentation we would be pleased to get suggestions for improvement The manual has to stay with the heating system or the silo Please make sure that the manual is at any time on hand if required A B S Silo und Förderanlagen Gmb...

Page 2: ...2 Condition of the room 10 3 3 Room fixtures 10 3 4 Room deaeration 11 3 5 Size Storage Volume 11 4 Scope of delivery 12 4 1 Scope of delivery standard 12 4 2 Optional Accessories 16 5 Assembly 17 5 1 Pre Assembly of the drawing irons 17 5 2 Assembling the frame and struts 17 5 3 Assembling the silo bag to the top bars 19 5 4 Attaching the silo cover to the ceiling 21 5 5 Fastening 22 5 6 Mounting...

Page 3: ...ting boilers for solid fuels EN14961 2 Wood pellets for non industrial use ENplus Handbook for the certification of wood pellets for heating use version 2 0 Sample fire ordinance 2005 VDI guideline 3464 green print 2012 storage of wood pellets by ultimate consumer 1 3 Pellet quality Intended use The Flexilo FLAT BOTTOM for wood pellets is intended solely for the storage of wood pellets The maximum...

Page 4: ...r Poor quality pellets can impair operation of your heating system and have an adverse effect on the storage and conveying equipment Only high grade pellets can assure reliable and problem free operation of the pellet fired boiler and the conveying systems If necessary have the supplier confirm the quality of the pellets ENplus certificate ENplus certified pellets are available for quality classes...

Page 5: ...t released additive pellets PowerPlus pelprotec etc Please contact us for information on the current supply level In case of white rust White rust can occur during transport for example Protect frame against water water spray is already enough to form white rust However if this cannot be avoided then the white rust can quite easily be removed with RZ51 zinc cleaner The manufacturer s warranty and ...

Page 6: ... out possible sources of danger to the customer The currently valid fire protection and VDI guidelines must be satisfied prior to start up In order to avoid hazards associated with improper handling of the system have installation initial start up and service performed only by suitably qualified personnel in compliance with all applicable regulations and manufacturer s instructions Use only metal ...

Page 7: ... shipping documents that accompany Flexilo FLAT BOTTOM for wood pellets when it is delivered Nameplate with calculated storage capacity 2 5 Maintenance Regular cleaning of the bearing is required to ensure continuous trouble free and safe heating operation The fines content and the wood dust should be removed When cleaning please note the following Enter storage areas only when in compliance with ...

Page 8: ... used in their cell structure by the pressing process The result is that the release of the volatile components is faster especially in fresh pellets and at high ambient temperatures Emissions usually decrease after a few weeks and the odour associated evaporates completely The emissions of wood pellets consist of volatile organic compounds VOCs carbon monoxide CO and carbon dioxide CO2 Among the ...

Page 9: ... room prior to installation The dimensions of the silo frame are stated on the delivery documents The dimensions of the silo frame can be determined by measuring the steel parts Length of the frame Length of the long bars Width of the frame Length of the shorter bars Height of the frame Length of the frame feet stands height of the top bar The silo the manual filling nozzle and the removal units m...

Page 10: ...levels normally found in cellars do not present any problems however condensation must not occur In case of humidity the room must be ventilated properly The silo fabric is air permeable and may cause the wood pellets to absorb humidity at the silo walls Make also sure that humidity does not enter the filling pipe if it is directed from outside into the storage area When setting up outdoors the fo...

Page 11: ...ing the Flexilo FLAT BOTTOM Only on customer request the Flexilo FLAT BOTTOM for wood pellets can be supplied with a filling line and an exhaust air line in case of rooms without exhaust air or in specific cases But from the technical aspect this is not necessary and gives no advantage Please provide for a power connection for the suction blower when installing a suction line This can also be comb...

Page 12: ...is shipped bundled on a pallet and a silo bag which is packed in a carton together with accessories and hardware required for assembly Delivery of the components 4 1 Scope of delivery standard Pos Illustration Description and quantity 1 1 each Silo bag of the appropriate size packed in a plastic bag 2 4 each Frame feet 3 4 each Supporting bars 4 16 each drawing irons divided In the case of rectang...

Page 13: ...gon screws M12 x 30 16 hexagon nuts M12 48 washers U13 8 included 16x 8x 8x Screw sack with connecting material for supporting bolt 8 screws M12 with shaft 16 washers U13 8 screw nuts M12 self locking Supporting bolt screws after support 60x60 M12 x 90 80x60 M12 x 110 80x80 M12 x 110 120x80 M12 x 150 140x80 M12 x 170 10 resp 1 2 pieces Filling pipe respectively filling injector At a rack width of ...

Page 14: ...fastener 2 hex screws M12 x 25 2 spring washers Ø 12 2 4 washers Ø 13 13 1 piece per filling pipe 1 ground strap clamp NW 3 8 4 14 2x 2x 4x Screw set for filling set pre assembled on the filling pipe 2 hex screws M10 x 140 4 washers M10 2 nuts M10 15 1 piece per filling pipe Tension rings with sealing compound 16 1 piece per filling pipe Aluminium coupling with temporary cover Storz A 17 1 piece p...

Page 15: ...ood pellets Scope of delivery Subject to technical change Issue 09 2016 Page 15 of 32 A B S Silo und Förderanlagen GmbH 19 1 x Assembly Instructions 1 x Filling Instructions 1 x Nameplate included in delivery note bag Table listing items included in the shipment ...

Page 16: ... GmbH 4 2 Optional Accessories Depending on boiler type different types of suction probes and manual switching units will be installed Pos Illustration Description 1 HP SBH 5 manual switching unit suction station Supplies 1 x shift plank 4 x blind plank 2 HP SS A B S suction probe Ø 50 50 3 HP SS 50 45 suction probe black Ø 50 45 4 Hose clamps Ø 40 60 mm Optional accessories ...

Page 17: ... 2 Assembling the frame and struts Do not start assembling the silo until you have become familiar with the situation at the installation site and the room layout discussed in Section 3 CAUTION RISK OF INJURY Wear safety gloves during assembly of the steel frame as protection against sharp edged metal components Pay attention to the room layout with regard to entry door and filling set Check the r...

Page 18: ...sue 09 2016 Page 18 of 32 A B S Silo und Förderanlagen GmbH Connecting the frame feet to the plug in elements of the top and base connectors Assembly of the plug in elements Assemble the steel frame until all top and base connectors as well as the drawing irons are connected Stand with drawing irons pre assembled ...

Page 19: ...the silo bag the lifting bar must have boreholes for the filling set 3 Align the silo bag 4 Make the necessary arrangements regarding the fastening of the silo lid according to point 5 4 5 Loop the lifting bars into the silo loops side by side 6 Lay the looped supports onto the head plates and attach these immediately by passing the bolt through and fastening it Supporting bar looped on one side P...

Page 20: ...ellets Assembly Subject to technical change Issue 09 2016 Page 20 of 32 A B S Silo und Förderanlagen GmbH Details of the corner bolting Pay attention to the alignment of the silo when connecting the angles check the right angle of the whole silo Attaching the silo bag ...

Page 21: ...s for the baffle that is sewn into the cover fabric opposite the filler neck Take care of the position of the supporting loops prior to attach the ceiling holders to the spread silo The loops must be attached one at a time during the following steps HINT Ideally use our supporting structure for cover loops and slide a galvanized pipe or a copper pipe through the loops on the cover fabric As an alt...

Page 22: ...arth the filling set as described in chapter Earthing I II III 2 Use the bolts provided to attach the filling line to the top bar 3 Slide the filler neck over the filling line and beaded edge of the filling pipe as far as possible and secure with the aid of the hose clamp provided 4 Only use A B S metallic filling pipes with smooth edges on the inside 5 Always finish with the provided 500 mm moder...

Page 23: ...be positioned in the middle of the 4 sub squares Secure the suction probes using appropriate fixings to the floor of the Flexilo FLAT BOTTOM The surface on which the silo stands must be suitable for the purpose and tested Ideally the suction probes should be anchored to the concrete floor Use a soldering iron to burn holes in the fabric for the screw fixings and seal any leaks arising with silicon...

Page 24: ...ly 4 5 cm and bend it inwards into the hose 5 8 Connecting the suction probes Number the suction probes as shown in the diagram above Connect the suction probes to the connection station from left to right in ascending order from 1 to 5 the figure only shows the connection station with 4 connections Here do also ensure that you fasten the suction probes and the suction station correctly depending ...

Page 25: ...that a stove or separate storage container can be supplied Alternatively an ascending screw conveyor can be inserted to convey pellets to a storage container for a system in close proximity or directly to a burner 5 10 Installation opening The position of the installation opening must be specified for the order Ensure the installation opening is in the correct position during installation This ope...

Page 26: ...e Check the room layout wall and ceiling clearance condition of the room fixtures in the room room ventilation Have the frame earthed by a licensed electrician The earth resistance must not exceed 106 Ω Check that the silo frame is anchored to the floor properly Check that the silo cover is suspended correctly Check the stability of the silo frame overall Close any unused filling openings attached...

Page 27: ... fixtures and swivelling jib 3 Climbing equipment The contractor must ensure that 1 Storage facilities whose upper edges are more than 1 m above the floor and must be mounted for regular operational work must be equipped with secure climbing equipment Instruction guidelines re item 1 The requirement is regarded as fulfilled for silos when e g stairs with railings are attached on the free sides or ...

Page 28: ...ould be attached directly to the filling couplings 8 1 General instructions Look after the accessibility of the filling nozzle s Make sure that that you have an adequate access road to your storage system 3 m width and 4 m headroom are needed at least The A B S silo for wood pellets has to be filled in the way that the pellets build up from behind The filling pressure has to be set up that the fli...

Page 29: ...ntered on the narrow side of the silo 8 3 Filling with two filling nozzles From a frame width of 2 5 m silos are equipped with a second filling nozzle In this case a better filling level will be reached Flexilo FLAT BOTTOM for wood pellets with 2 filling sets While filling with line 1 you can optionally exhaust with the second nozzle In this case you have to make sure that the fabric won t get suc...

Page 30: ...ction can be used for a possible suction blower A house junction box with 230V and 16A must be accessible outside of the storage room This power connection can be used for a possible extraction fan Here an automatic power cut off for the heating system can be integrated too Note before filling Switch off the heating system prior to starting the filling process Check prior to filling that the filli...

Page 31: ...hose length The filling pressure should be between 0 3 bars for a hose length of about 10 m and 0 6 bars for a hose length of about 30 m The required filling pressure and air flow rate can vary depending on the installation conditions They must be adjusted so that the Flexilo FLAT BOTTOM will be filled starting from the back of the silo When filling first inflate the Flexilo FLAT BOTTOM for wood p...

Page 32: ...ng set bracket must be bolt together with the lifting bar o The filling pipes must be bolt together among each other by clamping rings so that no rotation occurs o The filling coupling must be easily accessible without using ladders etc and reachable o The fabric neck on the filter lid must be pulled as far as possible over the filling pipe and beading rim and it must be fixed with a hose clamp o ...