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

Page 1: ...al 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 G...

Page 2: ...oom size 9 3 1 1 Distance from walls 9 3 1 2 Distance from ceiling 10 3 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 5 Assembly 16 5 1 Pre Assembly of the drawing irons 16 5 2 Assembling the frame and struts 17 5 3 Assembling the Silo bag and support bar 19 5 4 Attaching the silo cover to the ceiling 21 5 5 Fastening 22 5 ...

Page 3: ... Heating 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 TROUGH for wood pellets is intended solely for the storage of wood pellets The maximum ...

Page 4: ...ombustion chamber 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...

Page 5: ... Use of not yet 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...

Page 6: ...t 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: ...the shipping documents that accompany Flexilo TROUGH 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 sa...

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: ...nsions of both the silo and the 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 In a split design Length of...

Page 10: ...ase connectors must be secured by means of anchor bolts Rooms with moisture 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...

Page 11: ...aerating the Flexilo TROUGH Only on customer request the Flexilo TROUGH 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 combined ...

Page 12: ... bag which is packed in a carton together with accessories and hardware required for assembly Delivery of the components Pos Illustration Description and quantity 1 1 each Silo bag of the appropriate size packed in a plastic bag 2 4 each Frame feet Split Design 6 each Frame feet 3 Supporting bar 45 45 plug in Supporting bars Supporting bar 90 45 C Profil In brackets only by Split Design 4 each Sup...

Page 13: ...t Design 6 each Base connectors 6 Top connector Top connector for the middle Frame feet In brackets only by Split Design 4 each Top connectors Split Design 4 each Top connectors 2 each Top connectors for the middle Frame feet 7 4 x corner angel 4 x 6 x cone holding frame 16 x 24 x 16 x 24 x 32 x 48x 2 x coupler for the cone holding frame In brackets only by Split Design OPTIONAL 4 each cone holdin...

Page 14: ... x 12 x 8 x 12 x In brackets only by Split Design Screw sack with connecting material for supporting bolt 8 screws M12 with shaft 16 washers U13 8 screw nuts M12 self locking Split Design 12 screws M12 with shaft 24 washers U13 12 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 Fill...

Page 15: ...3 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 per filling pipe Hose clamp for ø 90 to ø 100 mm 18 OPTIONAL Support ...

Page 16: ...shorter and 8 longer drawing irons These are assembled to 4 drawing irons for the long and 4 drawing irons for the shorter silo side Split Design 8 drawing irons with the same length for the face side 16 drawing irons with the same length for the long side Screwed connection of the divided drawing irons 18 1 x Assembly Instructions 1 x Filling Instructions 1 x Nameplate included in delivery note b...

Page 17: ... the room layout with regard to entry door and filling set Check the room height If filling is executed inside the room please note that the minimum distance from the wall to the frame has to be 80 100 cm on the side where the silo will be filled Plug the plug in elements into the frame stands and then connect the drawing irons to the outer side To connect the drawing irons with the stands and the...

Page 18: ... Page 18 of 33 A B S Silo und Förderanlagen GmbH Assembly of the plug in elements Assemble the steel frame until all top and base connectors as well as the drawing irons are connected Assembly of the frame construction Hint Support the frame feet with draw bars on the ground see picture Head plate of middle support on middle support ...

Page 19: ...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 Please clean the floor before spreading the silo...

Page 20: ... 33 A B S Silo und Förderanlagen GmbH Insert the C profiles and bolt them to the middle support and the head plate of the middle support Take care that the opening of the C profile points outwards Then loop the silo onto the C profile and slide the second support bar over the C profile In confined spaces slide the cone mounting frame in first ...

Page 21: ...he ceiling that could damage the silo cover Take particular care to attach the 3 loops 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 sli...

Page 22: ...nnections Fasten the frame to the floor Earth all steel parts as described in chapter Earthing 5 6 Mounting of Filling set s 1 Using the illustration below as a reference assemble the individual components of the filling line with the aid of the clamp rings Earth the filling set as described in chapter Earthing I II Pay attention that the rubber lip shows inside Please cover the sealing ring over ...

Page 23: ... mm moderating line 6 Always furnish the couplings with a temporary cover Attaching the filling set 5 7 Assembling the cone holding frame During assembly of different silos an additional cone holding frame must be mounted The four cone support bars must be inserted into the loops provided for on the silo sack The support bars of the cone holding frame must be screwed together by using the steel an...

Page 24: ...ilo und Förderanlagen GmbH Cone holding frame with corner angle Split Design All six bars of the cone holding frame are to be bolted together after they have been inserted into the intended loops on the silo sack The two cone support bars on the long side the side with the split bars are to be bolted together using the connection piece see pictures below ...

Page 25: ...side to the outside Cone holding frame Split Design In confined spaces this step can be carried out parallel with 5 3 i e when inserting the cone support bar into the loop for the cone support bar Afterwards slide the support into the intended loop and bolt the support to the frame foot so that the cone support bar is already hanging in the loop for the cone support bar Silo with cone holding fram...

Page 26: ... filled for the first time This stretching is considered in the production and the Flexilo TROUGH is manufactured shorter ccordingly When the silo is filled the extraction system rises additionally depending on the silo size because the sides of the silo sack are pressed outwards during filling In general the silo extraction units should NOT be bolted to the ground to enable the rising and lowerin...

Page 27: ...k that the nameplate is attached in a clearly visible location on a frame leg or the filling line 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 co...

Page 28: ... 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 29: ...y 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 flight path of the pellets ...

Page 30: ... centered 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 TROUGH 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 sucke...

Page 31: ...16A protection must be accessible outside the storage room This power connection can be used for a possible suction blower Note before filling Switch off the heating system prior to starting the filling process Check prior to filling that the filling line and items attached to it are assembled as shown in the adjacent sketch and are not direct air upward towards the ceiling or downward into the si...

Page 32: ...d the 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 TROUGH will be filled starting from the back of the silo When filling first inflate the Flexilo TROUGH for wood pelle...

Page 33: ...t 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 All parts of ...