Fröling RS4 User manual

Model
Fire protection package
Installation and operating instructions
Pellet suction system RS 4 / RS 8
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.
M1890721_en | Edition 14/05/2021

Table of contents
ii M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
1 General ......................................................................................................................................................... 4
2 Safety............................................................................................................................................................ 5
2.1 Hazard levels of warnings..................................................................................................................... 5
2.2 Permitted uses...................................................................................................................................... 6
2.2.1 Permitted fuels........................................................................................................................... 6
2.3 Qualification of assembly staff .............................................................................................................. 7
2.4 Personal protective equipment for assembly staff ................................................................................ 7
2.5 Qualification of operating staff .............................................................................................................. 7
2.6 Protective equipment for operating staff ............................................................................................... 8
2.7 Design information................................................................................................................................ 8
2.7.1 Standards................................................................................................................................... 8
2.7.2 Requirements at the installation site.......................................................................................... 9
3 Technical information ................................................................................................................................. 10
3.1 Dimensions and recommended distances............................................................................................ 10
4 Store layout and construction.................................................................................................................... 12
4.1 Size of store space ............................................................................................................................... 13
4.2 Buffer mat ............................................................................................................................................. 13
4.3 Planking on the store door.................................................................................................................... 14
4.4 Sloping floor.......................................................................................................................................... 14
4.5 Filling couplings .................................................................................................................................... 15
4.5.1 Position within the store............................................................................................................. 15
4.5.2 Installing the filling couplings ..................................................................................................... 16
4.6 Probe distribution with four suction probes........................................................................................... 17
4.6.1 Store size up to 4m²................................................................................................................... 17
4.6.2 Store size from 4 m²................................................................................................................... 18
4.7 Probe distribution with eight suction probes ......................................................................................... 19
4.7.1 Store size up to 8 m².................................................................................................................. 19
4.7.2 Store size from 8 m²................................................................................................................... 19
4.8 Store pyramids (optional)...................................................................................................................... 20
5 Assembly...................................................................................................................................................... 21
5.1 Materials supplied - RS 4...................................................................................................................... 21
5.2 Materials supplied – RS8...................................................................................................................... 22
5.3 Transport .............................................................................................................................................. 23
5.4 Temporary storage ............................................................................................................................... 23
5.5 Correct assembly position .................................................................................................................... 23
5.6 Fitting the fire protection package......................................................................................................... 24
5.7 Installing the RS 4 pellet suction system .............................................................................................. 27
5.8 Installing the RS 8 pellet suction system .............................................................................................. 28
5.9 Installing the suction probes and lines.................................................................................................. 29
5.10 Sealing the fire protection panels (for fire protection package) ............................................................ 30
5.11 Hose feed-through to boiler room (depending on model)..................................................................... 31
5.11.1 Installing the fire protection collar in the boiler room.................................................................. 31
5.12 Installing fuel store pyramid(s) (optional).............................................................................................. 31
5.13 Assembly information for hose lines..................................................................................................... 32
5.13.1 Potential equalisation................................................................................................................. 33
5.14 Installation information for hose clips (optional).................................................................................... 34
5.15 Electrical connection............................................................................................................................. 34

Table of contents
M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8 iii
5.16 Configuring the discharge system in the controller............................................................................... 36
5.17 Upgrade of RS 4 manual pellet suction system.................................................................................... 36
6 Operating the system.................................................................................................................................. 37
6.1 Cleaning and inspection ....................................................................................................................... 37
6.2 Decommissioning ................................................................................................................................. 38
6.2.1 Disassembly............................................................................................................................... 38
6.2.2 Disposal ..................................................................................................................................... 38

1 | General
4 M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
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. 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:
[email protected].
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.
You can also find the guarantee conditions on the enclosed guarantee certificate.

Safety | 2
M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8 5
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.
NOTICE
The dangerous situation may occur and if measures are not observed it will lead to
damage to property or pollution.

2 | Safety
6 M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
2.2 Permitted uses
The Froling RS 4 / RS 8 pellet suction system is solely designed for discharging fuels
from suitable stores. 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. The inspection and cleaning intervals in the
operating instructions must 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.
Only original spare parts or specific alternative spare parts authorised by the
manufacturer may be used. Any kind of change or modification made to the product will
invalidate its manufacturer’s CE conformity. In such cases, the product will need to
undergo new hazard evaluation procedures by the operator. The operator will then be
fully responsible for the declaration of conformity according to the valid guideline(s) for
the product and will need to attach the new CE label to the device. This person will then
assume all of the rights and responsibilities of a manufacturer.
2.2.1 Permitted fuels
Wood pellets
Wood pellets made from natural wood with a diameter of 6mm
Note on standards EU: 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.

Safety | 2
M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8 7
2.3 Qualification of assembly staff
CAUTION
Assembly and installation by unqualified persons:
Risk of personal injury and damage to property
During assembly and installation:
rObserve the instructions and information in the manuals
rOnly 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.
2.4 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)
2.5 Qualification of operating staff
CAUTION
If unauthorised persons enter the Installation room:
Risk of personal injury and damage to property
rThe 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.

2 | Safety
8 M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
2.6 Protective equipment for operating staff
You must ensure that staff have the protective equipment specified by accident
prevention regulations.
▪ For operation, inspection and cleaning:
- suitable work wear
- protective gloves
- sturdy shoes
2.7 Design information
Carrying out modifications to the system and changing or disabling 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 tank is operated.
NOTICE!All design information such as installation and approval of the system,
chimney connection/chimney system etc., see installation instructions for the
boiler.
2.7.1 Standards
The system must be installed and commissioned in accordance with the local fire and
building regulations. The following standards and regulations should always be observed:
ÖNORM / DIN EN 60204 Safety of machines; Electrical equipment of machines, Part 1:
General requirements
TRVB H 118 Technical directives for fire protection/prevention (Austria)
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
EN 13501 Fire classification of construction products and building elements

Safety | 2
M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8 9
2.7.2 Requirements at the installation site
▪ 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.
▪ Pipes that cannot be removed at justifiable expense and which intersect the path of
the pellets during filling should be clad to protect against the flow and prevent
breakage (e.g. deflector plate, wooden boarding). The cladding should be designed to
divert the pellets without damaging them.
▪ There must not be any electrical installations such as switches, lights, distribution
boxes or other ignition sources in the pellet store. The necessary installations must be
explosion-proof and installed according to the locally applicable regulations.
▪ Doors, windows and hatches to the pellet store must open outwards and be fitted with
a dust-proof seal all the way round, to prevent dust escaping from the store,
particularly into other rooms.
▪ The system is only suitable for interior rooms, which are frost-proof and protected
against the elements.
Ü "Assembly information for hose lines" [}32]
For further information about the technical features of the pellet store:
Ü "Store layout and construction" [}12]

3 | Technical information
10 M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
3 Technical information
3.1 Dimensions and recommended distances
RS4:
H1
B1 L1
B2
B3
H2 H3
B4
B6
B7
B5
L3
L2
H5
H4
B8
L4
B10
B9
L5
L4
L6
H6
H7
H8
RS8:
L4
B10
B9
L5
B2
B4
H2 H3
B6
B7
B5
L1
L3
L2
H5 H4
H1
B1
B3
B8
L4
L6
H6
H7
H8

Technical information | 3
M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8 11
Item Description Unit Value
RS 4 RS 8
H1 Height of cover plate mm 352
H2 Recommended distance, floor to mounting bracket >800 >990
H3 Recommended distance, mounting bracket to hose
line attachment
>1,175
H4 Height of suction unit 375
H5 Height of suction unit, including mounting bracket 665 985
H6 Height of suction probe 180
H7 Recommended height for cut-out sections for hose
lines
>140
H8 Height of fuel store pyramid 355
B1 Width of cover plate 700
B2 Width of suction unit 740 1235
B3 Distance between mounting bracket holes 573 1258
B4 Distance between external hose line connections 330 770
B5 Distance between hose lines 62
B61) Recommended distance, suction unit to hose line
attachment / wall
>400
B7 Overall width >1240 >1635
B8 Recommended distance, suction unit to wall >150
B9 Width of suction probe 175
B10 Distance between suction probe holes 138
L1 Recommended length of straight suction hose line
piece
>100
L2 Length of suction unit 315
L3 Distance between hose line and wall 50
L4 Length of suction probe 237
L5 Distance between suction probe holes 187
L6 Length of fuel store pyramid 760
1. If the hose lines run toward the top, the distance from the suction unit to the wall can be reduced to 150mm
NOTICE
Depending on the characteristics of the surface, the fixings supplied must be
replaced with suitable components!

4 | Store layout and construction
12 M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
4 Store layout and construction
1
3
2
4
6
5
1
2
5
3
6
7
1Store for wood pellets
Ü "Size of store space" [}13]
2Buffer mat opposite inlet nozzle
Ü "Buffer mat" [}13]
3Boarding the store door
Ü "Planking on the store door" [}14]
4Sloping floor in larger stores
Ü "Sloping floor" [}14]
5Filling couplings for loading the fuel
Ü "Filling couplings" [}15]
6Suction probes for fuel removal
Ü "Probe distribution with four suction probes" [}17]
Ü "Probe distribution with eight suction probes" [}19]
7Store pyramids for optimised fuel removal (optional)
Ü "Store pyramids (optional)" [}20]

Store layout and construction | 4
M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8 13
4.1 Size of store space
The storage area should be able to hold approximately 1.5 times the annual amount of
pellets needed independently of the system heating load.
Rule of thumb: 1m3 store space / kW heating load
NOTICE
Formation of dust from pellets
Dust formed over time from the pellets which sinks to the floor can impair the
discharge of pellets from the store space
rCompletely empty and clean the store space on a regular basis
rCheck the store space before refilling and clean if necessary
TIP: We recommend that you fit the PST pellet deduster to guarantee a long and reliable
service life for the boiler system.
4.2 Buffer mat
NOTICE!During the filling process, the buffer mat stops pellets from hitting the
wall and breaking up as well as knocking plaster off the wall. Broken pieces of
masonry, plaster and other foreign objects can block the discharge system and
disrupt the pellet feed into the boiler thus causing a system failure. Warranty
claims are not covered by such faults.
200 mm
▪ Install buffer mat opposite the inlet nozzle
▪ Install at a right angle to the trajectory of the pellets
▪ Minimum distance of 200 mm to the wall

4 | Store layout and construction
14 M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
4.3 Planking on the store door
▪ Install a fire door on the pellet store in accordance with local regulations
▪ Board the inside of the store with wooden boards
– Door rails and baffle boards for the door are available from Fröling GesmbH
▪ TIP: Install a viewing window
4.4 Sloping floor
m
i
n
.
4
0
°
300
140
▪ Position the suction probes in the centre of the room
▪ Leave a distance of 300 mm between the cross-pieces
▪ Design the construction in such a way that the weight of the pellets is absorbed and is
transferred to the substrate
Rule of thumb for calculating the total weight: 1 m³ pellets ≙ 650kg
▪ Ensure the sloping floor has an angle of at least 40° (optimum 45° to 50°)
▪ The sloping floor must not touch the walls to ensure vibrations are not transferred to
the brickwork (structure-borne noise)
▪ Smooth surface of sloping floor so pellets can slide down
▪ No edges and ridges
▪ Ensure the sloping floor is sealed against surrounding walls to ensure pellets do not
fall behind the sloping floor

Store layout and construction | 4
M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8 15
4.5 Filling couplings
4.5.1 Position within the store
Suction nozzle
Filling nozzle
Buffer mat
Blow-in direction
min. 500
Half
room width
max. 30 m
Blow-in direction
Blow-in direction
200 200
Fig.1 Fig.2
min. 600
approx. 400
▪ Position the filling nozzle (A) centrally within the store so that the trajectory of the
pellets is towards the buffer mat.
▪ Install the suction nozzle (B) off-centre at a distance of at least 300 mm from the filling
nozzle.
▪ The filling pipe of the pellet delivery truck (C) has a maximum length of 30 m.
Therefore ensure that the pellet delivery truck can drive up as close as possible to the
filling couplings.
▪ Install the filling couplings at least 200 mm from the ceiling of the store and approx.
400 mm above the ground outside the store.
▪ The filling couplings can be installed through the building wall as straight pipes (D) or
as angled pipes in a light well (E). In the latter case, it must be ensured that the
connection to the blow-in pipe is a straight extension (F) out of the light well.
TIP: Attach unambiguous labels to filling couplings to ensure connections cannot be
mixed up.
CAUTION: If the openings of filling couplings are located outdoors, ventilated covers
must be fitted (included in scope of supply). However, if the filling couplings are located in
an adjoining room, the covers must be fully sealed. In that case, ventilation of the store
from outdoors must be provided by other means.
IMPORTANT: Protect filling couplings fitted with ventilated covers from the rain to prevent
the ingress of moisture into the pellet store. This must not restrict ventilation.
The ventilation of the store must be implemented in accordance with applicable regional
regulations and standards.

4 | Store layout and construction
16 M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
4.5.2 Installing the filling couplings
Fig.3 Fig.4
approx. 100
max.
500
min. 500
min. 500
Filling couplings with flange (G)
▪ Use suitable installation materials to attach the flange of the filling coupling to the
external wall
▪ Fill the gap between the coupling and masonry with foam compound
Filling couplings with rotation protection (H)
▪ Embed or enclose the filling couplings in the wall leaving a distance of approx. 100
mm from the wall (Fig. 4). The rotation protection must be positioned within the wall
– Filling couplings secured with foam compound may work loose as a result of
connecting the filling hose
Earth (I)
▪ Connect the filling couplings to the earth in the building, using a 4 mm² earth wire
–IMPORTANT: Only use metal pipes to extend the filling couplings, to ensure any
electrostatic charges are discharged
Extension and attachment of the filling couplings (Fig. 4)
▪ When extending filling couplings, a 45° elbow must be followed by a straight section of
pipe (J) with a length of at least 300 mm. Secure the sections of pipe with suitable
pipe clamps (K), so that the joints will not loosen due to the pressure used to blow in
the pellets.
–IMPORTANT: Do not use 90° elbows
▪ Do not terminate the filling pipe with an elbow. A straight section of pipe (L) with a
length of at least 300 mm is required to ensure the pellets are ejected in the desired
direction.

Store layout and construction | 4
M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8 17
4.6 Probe distribution with four suction probes
4.6.1 Store size up to 4m²
▪ Max. 1m² of storage space per suction probe
▪ Distance of at least 150 mm between suction probe and hose lines
▪ Distance of 500 to 1000 mm between suction probes
– The greater the distance, the more pellets will be left in the store
Planning proposal for square rooms:
<1m²
L
L/4 L/4L/2
B
B/2B/4 B/4
11
11
1 … withdrawal area of suction probes (diameter approx. 400 mm)
Planning proposal for rectangular rooms:
<1m²
L
L/8 L/4L/4 L/4 L/8
B
1111
1 … withdrawal area of suction probes (diameter approx. 400 mm)

4 | Store layout and construction
18 M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
4.6.2 Store size from 4 m²
Planning proposal for rooms with a sloping floor:
L
300 mm
L/8 L/4L/4 L/4 L/8
B

Store layout and construction | 4
M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8 19
4.7 Probe distribution with eight suction probes
4.7.1 Store size up to 8 m²
▪ Max. 1m² of storage space per suction probe
▪ Distance of at least 150 mm between suction probe and hose lines
▪ Distance of 500 to 1000 mm between suction probes
– The greater the distance, the more pellets will be left in the store
Planning proposal:
<1m²
L
L/8 L/4
B
B/2
B/4 B/4
L/4 L/4 L/8
1111
1111
1 … withdrawal area of suction probes (diameter approx. 400 mm)
4.7.2 Store size from 8 m²
Planning proposal for rooms with a sloping floor:
L
300 mm
L/8 L/4L/4 L/4 L/8
B

4 | Store layout and construction
20 M1890721_en | Installation and operating instructions Pellet suction system RS 4 / RS 8
4.8 Store pyramids (optional)
Store pyramids are available from Fröling GmbH to reduce the number of pellets left in
the store.
▪ Distance of at least 150 mm between store pyramids and the suction probe and hose
lines
Planning proposal for rooms with 8 suction probes:
L
BB/2
L/4 L/4 L/4L/4
1 … withdrawal area of suction probes (diameter approx. 400 mm)