KOB KOB PYRTEC SERIES Manual

Operating and Maintenance Instructions
PYRTEC 390 to 1250
ID: 105174-F English

© by KÖB Holzfeuerungen GmbH
Flotzbachstrasse 33
A-6922 Wolfurt
All rights reserved, including photomechanical
reproduction and storage in electronic media.
Viessmann Group

1General information_________________________________________________ 5
1.1 Foreword _______________________________________________________________________ 5
1.2 Technical standing _______________________________________________________________ 5
1.3 Intended use ____________________________________________________________________ 5
1.4 Technical data___________________________________________________________________ 5
1.5 Information documented __________________________________________________________ 5
1.6 CE- Symbol _____________________________________________________________________ 5
2Important information _______________________________________________ 6
2.1 Safety information________________________________________________________________ 6
2.2 Excess temperature & power failures________________________________________________ 6
2.3 Lack of water & excess water pressure ______________________________________________ 6
2.4 Fire hazard______________________________________________________________________ 7
2.5 Minimum requirements for wood fuels_______________________________________________ 7
2.6 Filling the fuel storage space_______________________________________________________ 7
2.7 Correcting malfunctions of the feed systems _________________________________________ 7
3Design____________________________________________________________ 8
4Control system_____________________________________________________ 9
4.1 Touch screen, Masks 1-8 __________________________________________________________ 9
4.1.1 Navigation_______________________________________________________________________ 9
4.1.2 Mask 1 and how the mask is structured _______________________________________________ 10
4.1.3 Mask 2, Alarm List _______________________________________________________________ 11
4.1.4 Mask 3, Managing the User Status___________________________________________________ 12
4.1.5 Mask 4, Adjusting Settings & Process Parameters_______________________________________ 13
4.1.6 Mask 7, Overview, Wood-powered Boiler______________________________________________ 14
4.1.7 Mask, Additional Boilers ___________________________________________________________ 15
5Commissioning, Operation & Shut-down ______________________________ 16
5.1 The initial start-up_______________________________________________________________ 16
5.1.1 Inspection before the initial start-up __________________________________________________ 16
5.1.2 The softkeys in Mask 1: ___________________________________________________________ 16
5.2 Heating up without automatic ignition ______________________________________________ 17
5.2.1 Filling the burner trough ___________________________________________________________ 17
5.2.2 Heating up______________________________________________________________________ 17
5.2.3 Fuel >W40______________________________________________________________________ 17
5.2.4 Check of heat up successful?_______________________________________________________ 17
5.3 Heating up with automatic ignition _________________________________________________ 17
5.4 Operation______________________________________________________________________ 17
5.4.1 Full load operation _______________________________________________________________ 17
5.4.2 Output control ___________________________________________________________________ 17
5.4.3 Sustain ________________________________________________________________________ 17
5.4.4 Standby________________________________________________________________________ 17
5.4.5 Transition in output _______________________________________________________________ 18
5.4.6 Switching off ____________________________________________________________________ 18
5.5 Emergency operation ____________________________________________________________ 18
5.6 Measurement operation __________________________________________________________ 18
5.7 Operating modes _______________________________________________________________ 18

6Cleaning/Maintenance______________________________________________ 19
6.1 Boiler _________________________________________________________________________ 19
6.2 Feed systems __________________________________________________________________ 21
7Shutdowns _______________________________________________________ 22
8Waste disposal____________________________________________________ 22
9 Enclosures
- Spec Sheet 1010-1, 2
- Malfunction Messages / Correction of Malfunctions
- List of Parameters KPT-MOD

5
1 General information
1.1 Foreword
Dear System Owner, you have made a good se-
lection in the PYRTEC. It will provide you with all
the advantages of a modern, economically efficient
heating system. Fully developed technology in
combination with a sturdy design guarantee a high
degree of operational reliability and a long service
life.
These Operating and Maintenance Instructions
contain important information for the intended use,
correct operation and proper maintenance of the
PYRTEC.
Non-compliance with the Operating and Main-
tenance Instructions will result in loss of the
guarantee.
If you still need any further information after study-
ing the Operating and Maintenance Instructions:
The Assembly and Installation Instructions contain
important information about:
-Standards and regulations
-Structural surroundings of the burner
-Transport and assembly
-Water installation and electrical installation
-Fire protection
-Starting up
as well as an appendix with diagrams of connec-
tions and dimensions and the complete technical
specifications.
Our sales and services offices will be glad to pro-
vide you with any further information. Their ad-
dresses can be found on the reverse side of these
Operating and Maintenance Instructions.
1.2 Technical standing
The Operating and Maintenance Instructions are in
keeping with the PYRTEC at the time it is deliv-
ered. In the interest of our customers, we reserve
the right to make, without any notification require-
ment, subsequent changes resulting from further
technology developments.
1.3 Intended use
The intended use of the PYRTEC is for incinerat-
ing wood fuels.
The intended use of the PYRTEC is stipulated:
- in the regulations of the Assembly and Installa-
tion Instructions
- by the limits of the technical specifications
- in Spec Sheet 1010 "Minimum Requirements
for Wood Fuels / Instructions",
- by the safety regulations in these Operating
and Maintenance Instructions.
Any other use of the PYRTEC or use of it going
beyond this will be considered as unintended use
unless written approval by the manufacturer has
been obtained.
The following, among other things, will be consid-
ered as unintended use:
- Operation of the PYRTEC by unqualified per-
sonnel, without any training or knowledge of
the Operating and Maintenance Instructions.
- Disabling the safety or monitoring devices on
the PYRTEC.
- Removal of any protective covers or cladding
on the PYRTEC by unauthorised individuals.
-Making any conversions or alterations to the
PYRTEC without approval by the manufac-
turer.
- Using spare parts or accessories from other
manufacturers without approval by the manu-
facturer.
The operating organisation will be liable for
any damage or accidents in case of any unin-
tended use.
1.4 Technical data
The following important limits apply to the
PYRTEC heating boiler:
-Max. operating pressure allowed............ 6.0 bar
-Max. boiler temperature allowed...............100°C
-Min. return temperature ..............................65°C
The complete technical specifications are listed in
the appendix of the Assembly and Installation In-
structions.
1.5 Information documented
The Operating Instructions contain the information
required according to the EC Directive on Machin-
ery 98/37/EEC, Appendix 1, Number 1.7.4.
Issue: 2008-04_English
Prepared by: ShlM
1.6 CE- Symbol
The PYRTEC is delivered with a CE-symbol on its
type plate and an EC attestation of conformity in
accordance with Appendix II A of the EC Directive
on Machinery 98/37/EEC.
If the PYRTEC is altered by equipment from other
manufacturers being added, or the safety equip-
ment or control system are combined with a differ-
ent system and/or integrated into an overriding
system (building control system, etc.), then in the
European Union a new attestation of conformity
has to be issued before it is put on the market.

6
2 Important information
2.1 Safety information
When carrying out work on the heating system,
such as cleaning and maintenance, wear ap-
propriate protective equipping when required.
There is a danger of getting injured through:
burning, knocking against corners and edges,
crushing in moving parts and noise.
Mains supply 400V
In dangerous situations, the PYRTEC can be dis-
connected from the electric mains for all the pins
via the master switch on the control cabinet.
Doors
CAUTION
FIRE HAZARD:
The burner must never be operated with the
doors open! Any burning bits that escape
could start a fire.
CAUTION
DANGER OF INJURY:
If the doors are opened during operation,
sparks and tongues of fire could leap out.
Equipment for dissipating excess heat
The functioning of the thermal run-off safety valve
must be inspected every year by a competent spe-
cialist. The safety heat exchanger must not under
any circumstances be used as an operational heat
exchanger.
Seals
For the functioning and controllability of the burner,
it is important that no unwanted air can leak in, en-
tering unchecked through leaky spots.
The doors and lids have to shut tight −any dam-
aged seals must be replaced immediately.
Tighten the retaining screws and handles snugly.
Recirculating flue gas system:
The recirculating flue gas system returns some of
the emissions back into the combustion chamber
under pressure. That is why the piping after the fan
is designed to be pressure-tight. Before it is taken
into operation, the recirculating flue gas system
must be checked for leaks (no gas may escape
when the recirculating fan is in operation and the
flaps are closed).
CAUTION RISK OF CO POISONING from escap-
ing and perhaps odourless gas! Do not permit
operation if the recirculating pipes are leaking!
Operation, cleaning & maintenance
Bear in mind that only if operated and maintained
properly can even the best of products fulfil their
functions well, for a long time and free of malfunc-
tions. Compliance with the "Cleaning" section
is mandatory!
2.2 Excess temperature & power
failures
I M P O R T A N T DANGER of this SUDDENLY
GOING UP IN FLAMES!
Do not open doors or lids on the burner!
- Switch on additional heat consumers.
- The exhaust fan goes out of operation.
- The temperature-limiting safety switch triggers.
- The valve for the thermal run-off safety valve
opens at approx. 95°C. The excess heat is
conducted off into the channel.
If the temperature-limiting safety switch (TLSS)
has triggered, then it has to be manually un-
locked. The TLSS is situated at the top of the
burner.
To reset, unscrew the black cap and press the but-
ton.
IMPORTANT: Only as of a temperature of approx.
70°C resetting is possible.
Possible causes for excess temperature:
- Sudden drop in output to zero. Do not turn off
all the heat consumers at the same time.
- Defective component of the system (pump or
valve)
- Incorrect setting on the control module.
- "CYCLE, UNDERFEED AUGER, SUSTAIN
EMBERS" too high (see the section "Load
level" −Output control system −Sustain em-
bers)
2.3 Lack of water & excess water
pressure
Possible causes:
1. Lack of water: Leakage in the heating system.
2. Excess water pressure: The expansion system
not functioning.
In either case, the facility should be left for a com-
petent heating fitter to check.
Unlock this malfunction with either the reset
button for the water level control system or for
the overpressure monitor, and by pressing the
F1 key (Malfunction) on the control panel in the
control cabinet door.

7
2.4 Fire hazard
With underfeed firing systems, the conveying route
creates a connection between the silo and the
burning material in the burner. With the PYRTEC,
the underfeed auger is also the metering auger,
and is thus always filled up with material during
operation. There are various safety devices pro-
vided to prevent burn-back.
Temperature sensors:
By means of temperature sensors on the under-
feed auger, in case of excess temperature the
loading to the underfeed auger is interrupted, and
the underfeed auger's material is inserted into the
combustion chamber.
Slide valve (option):
This closes in case of a standstill, danger of burn-
back or power failure (spring return motor).
Rotary valve (option):
Instead of a slide valve, in silos with pressurisation.
Drop-off route:
A vertical drop-off route interrupts the connected
line of burning material.
Fire-extinguishing system (option):
This system, which functions independently of the
electrical power, brings about a flooding of the ma-
terial to be burned that is located in the underfeed
auger. The activation temperature is approx.
95°C.
2.5 Minimum requirements for wood
fuels
The PYRTEC is only suitable for incinerating the
fuels listed in Spec Sheet 1010 "Minimum Re-
quirements for Wood Fuels" (see enclosure).
If different fuels are used, KÖB will not assume
any liability for the functioning or service life of
the burner. Refer to the "Warranty" section in
the General Terms and Conditions of Delivery.
2.6 Filling the fuel storage space
Rotary sweep extraction and spring-operated
extraction
Switch off the facility using the function button on
the control panel and wait until there is no more
fuel in the feed auger. Fill the silo evenly to
approx. 30 cm above the articulated arm or over
the spring-mounted blades, switch on the facility
using the function button on the control panel and
wait until the articulated arms or the spring-
mounted blades go under the cup washer.
If any excess or negative pressure can develop in
the silo when the filling is being carried out, at this
point the facility has to be switched off again using
the function button on the control panel. After do-
ing so, finish filling the silo evenly and switch the
facility back on using the function button on the
control panel.
Carry out refilling in the same manner.
Pellet extraction auger
Switch off the facility using the function button on
the control panel and wait until there is no more
fuel in the feed auger. Slowly and evenly fill the
silo until the extraction auger is covered approx. 25
cm to 30 cm high over the entire open area. Level
out any mounds that form from pouring. Switch on
the facility using the function button on the control
panel and wait until the metering container on the
feed auger has filled.
If any excess or negative pressure can develop in
the silo when the filling is being carried out, at this
point the facility has to be switched off again using
the function button on the control panel. After do-
ing so, finish filling the silo slowly and evenly. The
facility can then be switched back on using the
function button on the control panel.
Carry out refilling in the same manner.
2.7 Correcting malfunctions of the
feed systems
The cause of motor malfunctions in feed systems
is usually clogging by large pieces of wood or for-
eign matter.
CAUTION
DANGER OF INJURY:
Always turn off the master switch before carry-
ing out any repair of a malfunction on feed sys-
tems and every time before a maintenance lid
is opened or a protective device is removed!
Due to the facility's automatic operation, the point
in time for the conveying means to be switched on
is not foreseeable.

8
3 Design
(Fig. PYRTEC 950, slide-in module on left) (Fig. PYRTEC 950 special-purpose design with re-
circulated flue gas)
(1) Combustion chamber door
(2) Pipe heat exchanger door
(3) Slide-in module
(4) De-ashing auger (optional)
(5) Extinguisher water container
(6) Cleaning lid
(7) Secondary fan
(8) Recirculated flue gas fan (optional)
(9) Grate drive motor
(10)Ignition fan
(11)Cleaning system (optional)
(12)Combustion box sensor
(13)Recirculated flue gas pipe
In models without the recirculated flue gas function, instead of the fan (item 8), two smaller fans are mounted
directly on the boiler. In such case there are no recirculated flue gas pipes (item 13).
1
2
3
4
5
6
4
7
8
9
10
11
12 13
13

9
4 Control system
The control system for the Pyrtec furnace firing process (Pyrocontrol) is effected via a freely programmable
SPS, which makes use of a visualisation system on a touch screen as the interface for navigation and pa-
rameterising.
4.1 Touch screen, Masks 1-8
The touch screen is 16 cm wide, 12 cm high and has a resolution of 640x480 pixels. The screen is a colour
display monitor. After switching on the masterswitch, the SPS starts up, and the Overview appears (Mask 1).
4.1.1 Navigation
The navigation program "Pyrocontrol" is a product of KÖB Holzfeuerungen GmbH. It is operated following
the same patterns as MS Windows programs. The selection of the softkey desired can be made with a fin-
gertip or even more exactly with a fingernail.
The arrangement of the softkeys is always the same throughout, i.e. once a keypad occurs, it is located at
the same position in all the masks, with the exception of the BACK key (arrow in blue circle) in Masks 7 and
8.
The hierarchy of Masks 1-7 (optional 8) ranges over the following levels:
Mask 1 Overview
Mask 3
Mask 2
Alarm List
Change User Status
Mask 4 Mask 7 Mask 8 (option)
Settings Overview, Wood-
powered Boiler Overview, Addi- tional Boilers
In Mask 1 you can choose between 7 or 8 different masks (8 being for an optional additional boiler).
When choosing by tapping one of the two boiler softkeys (photo and optional symbol), either 7 "Overview of
wood-powered boiler" or, optionally, 8 "Overview of additional boilers" appears (optional only with multiple-
boiler systems) in the mask title.
All Masks 1-8 can be parameterised in detail by touching the respective softkeys provided. Doing so opens
new windows in turn, and new input fields or softkeys are provided.

10
4.1.2 Mask 1 and how the mask is structured
The following applies to all the masks. The mask title and user status are shown at the top. In the mask title
you can tell which mask (1-8) you are in. In the centre of the mask the areas for display and call-up are al-
ways located for inputting parameters. The softkeys for navigation and input are located at the bottom, with
the exception of the combined user status display and the call for input.
Changeable softkeys for input are white (light). Display windows are always grey (dark). Softkeys for naviga-
tion are always provided in colour to select from.
Area of
mask
Mask 1 Overview Description
Top
Centre
Bottom
Mask title, e.g. "Overview"
User status (top right)
Alarm line (bottom left, red)
Date/Time (bottom right)
Displays of operating mode of KÖB
boiler (top left, grey),
e.g. "OFF" (no heating operation)
Display of actual value of boiler (grey):
Exhaust gas temperature (top left),
Residual O2(bottom left)
Displays of buffer charge state (grey)
Button for KÖB boiler (photo)
With object indicator lamps
(green/grey)
Button for additional boilers (option)
Sets of buttons, bottom right:
Boiler ON (green)
Boiler OFF (red)
Lock screen (yellow)
Sets of buttons, left bottom:
Navigation (orange) for Masks 4, 5 &
6: Settings, Analysis, Archive
Object indicator lamps, Mask 1:
Boiler pump and display of operational status of additional boilers. If the object indicator lamp lights up
green, then there is activity. Example: The pump is running and an additional boiler is in operation. If the ob-
ject indicator lamp is grey, the respective object (pump or additional boiler) is shut down.
Important: The object indicator lamp says nothing about the operating mode of the system.

11
4.1.3 Mask 2, Alarm List
Touching the red Alarm line softkey (in Mask 1) opens Mask 2 (Alarm List with alarm logs, red). Here all the
error messages are shown which have been registered but not yet acknowledged. Touching an alarm log
line chosen allows the respective error message to be displayed in detail or acknowledged.
A history of the error messages acknowledged can be called up in Mask 2.
Area of
mask
Mask 2 Description
Top
Centre
Bottom
Mask title, e.g. "Alarm List"
User status (top right)
Alarm logs (red) in rows according to
time
Back button (back to Mask 1)
Display alarm logs
Acknowledge all
The "Acknowledge all" softkey (bottom left) acknowledges the error messages listed in the centre of the
mask. The cause of the error should be remedied before acknowledging the error message. Otherwise the
error message will continue to be maintained. (It will be shown again in the Alarm List in a short period of
time.)
Touching the softkey "Display alarm log" (bottom right) will list all the past error messages. The softkey "As-
certain alarms in history" is displayed in the lower left of this new page. By touching this softkey, the period
can be specified in which the alarms saved are to be displayed.

12
4.1.4 Mask 3, Managing the User Status
Touching the softkey "Status Level 0", …1, 2 or 4 (at the top right of the mask), the user level can be
changed and thus the access rights for parameterising stipulated. To change the user level, no user name
need be entered, but rather all four possible levels are provided as buttons. When the user level desired (0-
4) is selected, a password in the form of a 4-digit code will be asked for, which has to be entered and con-
firmed with ENTER by touching the white input cell using the pop-up number keypad. The password will then
appear in four asterisks (****) and has to be confirmed again with OK.
Area of
mask
Mask 3 Description
Top
Centre
Bottom
Mask title "User Status"
Softkeys for selecting the user level
desired
Password query window: Always con-
firm with OK.
Input number keypad: Enter the 4-digit
code here and confirm with ↵.
Display: current level
Back button (back to Mask 1)
After making these entries, the newly selected status applies with the following user rights associated with it:
User level Password Rights
Standard Level 0
No password (Æautomatic
jump back to standard after
standstill period > 5 min-
utes).
No rights, no changing (only display)
Customer Level 1 1111 No selection of parameters with the trend display (Point 5.1)
Customer Level 2 2222
Parameter selection is possible
Administrator Level 4 No specification
Administrator, access to WinCE Desktop as well as
software updating possible
By introducing these user levels, KÖB Holzfeuerungen GmbH is making an effort to maintain the parameters
essential for quality-assured businesses. This guarantees good operational practice, as certain parameter
changes are reserved only for KÖB technicians. This gives the user greater certainty that one cannot acci-
dentally make any changes that would be technically less favourable.

13
4.1.5 Mask 4, Adjusting Settings & Process Parameters
In Settings, adjustable categories can be chosen and their parameters changed.
In the centre the parameters to be set are listed with their currently applicable values.
Area of
mask
Mask 4, Settings Description
Top
Centre
Bottom
Mask title "Settings >
AutoBoilerCleaning" (left)
User status (right)
Display
Parameters set
White fields can be changed by touch-
ing, provided a valid user status is set.
Softkey categories (orange)
The category activated is coloured yel-
low. Parameters can then be changed.
Back button (back to Mask 1)
If an attempt is made to change a parameter that is not cleared for change in the current user status, Mask 3
will be called up automatically. By changing the user status, here the authorisation required can be cleared
(see Changing User Status 4.1.4).
The value changes when the white "Setting input cell" is touched, which opens a pop-up number keypad.
Enter the value desired and confirm with ↵. The new value is immediately valid in the furnace-firing and/or
heat recovery process. If the value selected is outside the setting range, then the maximum or minimum
value possible will be automatically accepted.
Factory setting (default setting)
All the parameters in the Pyrocontrol, such as set point values and switching times, are already pre-set and
can be produced in Mask 4 as "Set-point values".
The values of the factory setting can be restored in User Level 2 or higher in the internal settings.

14
4.1.6 Mask 7, Overview, Wood-powered Boiler
Touching the KÖB Boiler softkey (photo in Mask 1) opens Mask 7 (sectional view of the boiler).
Here the most important process parameters, activity modes and operating hours are reproduced. The oper-
ating mode display is located in the centre upper left of the screen. (For explanations on the text displays,
see Section 5.7).
Measurement operation, emergency operation and the activity of the de-ashing system as well as that of the
underfeed auger can all be operated manually here.
Area of
mask
Mask 7, Overview, Wood-powered Boiler Description
Top
Centre
Bottom
Mask title, e.g. "Overview, Wood-
powered Boiler"
Alarm line (bottom left, red)
User status (top right)
Date/Time (bottom right)
Back button (back to Mask 1)
Displays of operating mode (top left,
grey), e.g. "Load" (heating operation)
Displays of forward/return flow tem-
perature (grey)
Displays of exhaust gas parameters
(right, grey)
Displays of furnace-firing parameters
(grey)
Displays of supply air fan (left, grey)
Object indicator lamps (green/grey)
Displays of operational statistics
Softkeys, bottom right:
Boiler ON (green)
Boiler OFF (red)
Lock screen (yellow)
Softkeys, left bottom:
Navigation (orange) for Masks 2, 3 &
4: Settings, Analysis, Archive
Exhaust gas parameters, centre of screen: Exhaust gas fan power (top), residual oxygen (centre), ex-
haust gas temperature (bottom)
Object indicator lamps (centre of mask, green or grey squares):
Light barriers for embers and metering container: If the object indicator lamp lights up green, then there is no
blockage of the light barrier. If the object indicator lamp is grey, the light barrier has been blocked (maximum
height of embers reached or metering container full). The object indicator lamp gives no information about
the presence of any malfunction.
Operational statistics: Here the respective sums of operating periods are listed for load, sustenance and
standby.
Softkeys (Mask 7, centre):
Measurement operation (see 5.6)
Emergency operation (see 5.5)
Ash, manual: When the softkey is touched, the colour of the field changes (dark/light). The de-ashing auger
runs until the softkey is touched again or until a change is made to another mask.
Underfeed Stop: When the softkey is touched, the colour of the field changes (dark/light). The supply of
material into the fire box is interrupted until the softkey is touched again or until a change is made to an-
other mask.
Underfeed ON: When the softkey is touched and held, the colour of the field changes (dark/light). Material
is supplied into the fire box until the softkey is released again.

15
4.1.7 Mask, Additional Boilers
When the softkey for additional boilers is touched (symbol in Mask 1), Mask 8 opens (symbol for oil or gas
boiler, enlarged).
Here the forward flow and return flow temperature of the additional boiler is reproduced. The KÖB Boiler op-
erating mode display is located in the centre upper left of the screen. (For explanations on the text displays,
see Section 5.7).
Here the additional boiler can be manually switched on or off, and automatic operation can be selected. The
operating hours counter is located in the centre left of the screen.
Area of
mask
Mask 8, Overview of Additional Boilers (option) Description
Top
Centre
Bottom
Mask title, "Overview of Additional
Boilers"
Alarm line (bottom right, red)
User status (top right)
Date/Time (bottom right)
BACK key (back to Mask 1)
Displays of operating mode for KÖB
Boiler (top left, grey)
Displays of forward/return flow tem-
perature (grey)
Display for clearance time
Softkeys for addition boilers:
Additional boiler, manual (dark/light)
Additional boiler, automatic (dark/light)
Additional boiler, OFF (dark/light)
Softkeys for KÖB boiler:
Boiler ON (green)
Boiler OFF (red)
Lock screen (yellow)
Softkeys, left bottom:
Navigation (orange) for Masks 4, 5 &
6: Settings, Analysis, Archive
Object indicator lamp (Mask 8, centre):
Clearance for burner: If the object indicator lamp lights up green, then the burner is in operation: If the object
indicator lamp is grey, the burner is inactive. The object indicator lamp gives no information about the pres-
ence of any malfunction.
Important: Only in Mask 8 can the additional boiler be switched on, off or to automatic operation. The softkey
selected by touching it will turn light. The operation selected is displayed in the operating mode display.
Important: In Masks 7 and 8 (optional for additional boilers), the BACK keys are positioned in the centre of
the mask.

16
5 Commissioning, Operation &
Shut-down
5.1 The initial start-up
The initial start-up is carried out either by KÖB
Holzfeuerungen GmbH or another competent in-
dividual named by it.
Be absolutely sure to follow the instructions in
the Assembly and Installation Instructions. No
guarantee may be claimed for damages in
cases of initial start-ups carried out improp-
erly at one's own initiative.
5.1.1 Inspection before the initial start-up
-Is there enough water in the heating system?
-Has the heating system been bled of air?
-Are the slide valves open for the heating-
system's forward and reverse flow?
-Can enough fresh air get into the heating
room?
-Are the doors and lids on the burner all closed
leak-tight?
5.1.2 The softkeys in Mask 1:
Softkey 1
Switch on boiler
When touched with the finger
or fingernail, the colour
changes (from light to dark)
Softkey 2
Switch off boiler
When touched, a confirma-
tion is requested, and then
the colour changes (from
light to dark).
Softkey 3
Lock screen
Unlock screen
When touched, a confirma-
tion is requested.
Softkey 4
Open settings
Touching it opens Mask 4 for
parameterising.
Softkey 7
Mask for KÖB
boiler
Overview, wood-powered
boiler
Touching it opens Mask 7.
Softkey 8
Symbol
Overview, additional boil-
ers
Touching it opens Mask 8.
Important: Mask 8 is only
available with optional multi-
ple-boiler systems-

17
5.2 Heating up without automatic
ignition
5.2.1 Filling the burner trough
When the system has switched off properly, there
is no more fuel in the burner trough or in the un-
derfeed auger.
With the fire block cooled down (fire box tempera-
ture below 250°C), touching softkey 1 "Boiler ON"
will automatically fill the burner trough with fuel.
5.2.2 Heating up
Light a fire with paper and kindling wood in the fire
box. After this, use the blade to push the fire back
to the filled burner trough. Then press Softkey 1
"Boiler ON" again (Softkey 1 "Boiler ON" is then
dark green). Operating mode "HEAT UP" shows
in the upper left of the display.
5.2.3 Fuel >W40
-With fuel that has water content greater than
W 40 moist, preheat the boiler with a chopped
wood fire. To do so, manually light chopped
wood in the fire box and use the shovel to
push it into the burner trough. If necessary,
add more chopped wood. Heat up the fireclay
brick lining like this for approx. one hour.
-Starting up the facility: Softkey 1 "Boiler ON"
The softkey "Underfeed ON" is for manually acti-
vating the underfeed auger in automatic operation
(= manual prompt for material). As long as this
softkey is touched, the underfeed auger moves
fuel into the burner trough. With the underfeed
auger stopped (softkey "Stop underfeed" light-
grey), the manual prompt for material cannot be
activated.
5.2.4 Check of heat up successful?
The fire box temperature should be over 180°C in
30 minutes (adjustable value). Otherwise the sys-
tem will automatically shut itself back down. In
such case press Softkey 1 "Boiler ON”.
5.3 Heating up with automatic
ignition
The boiler is simple to switch on:
-Press Softkey 1 "Boiler ON". The loader mod-
ules will be switched on in the appropriate or-
der. When the auger filling time or fire box fill-
ing time has lapsed and there is enough fuel
in the combustion chamber, the loader system
switches off.
-The automatic ignition then takes place. The
ignition process stops as soon as the fire is
started.
-The boiler then automatically switches to full
load operation. (If the material should be too
moist, it might be necessary to proceed fol-
lowing Item 5.2.3 "Heating up".)
5.4 Operation
5.4.1 Full load operation
As soon as a fire box temperature of approx.
180°C is reached (adjustable value), the system
switches, depending on the boiler temperature, to
operating mode "FULL LOAD" or "SUSTAIN",
which is shown in the upper left of the display.
5.4.2 Output control
The heat output to be produced is adapted to the
heat consumption in a range from 25% to 100% of
the boiler's nominal output. Depending on the de-
viation of the boiler temperature from the boiler
set-point temperature (75°C to 95°C), the air flow
rate is set by means of a fan with infinitely variable
control. The fire box and residual oxygen control
then resupplies the optimum amount of fuel for
lowest emissions.
If, through a corresponding rise in the boiler tem-
perature, the heat consumption drops below 25%
of the rated output, the system switches to "SUS-
TAIN", which is shown in the upper left of the dis-
play.
5.4.3 Sustain
In the operating mode "SUSTAIN", the exhaust
fan only runs at a minimum speed. The supply air
fans do not run.
The resupplying of material via the underfeed au-
ger has to be greater than the speed of back-burn
and can be set as a set-point value by touching
Softkey 4 "Settings" in Mask 4 (CYCLE for under-
feed auger SUSTAIN). This depends on the mate-
rial (light shavings require more resupplying of
material than do chippings).
"Cycle for underfeed auger sustain" too high:
Too much material is pushed into the burner
trough such that the embers are too large for the
sustain load operation. The further consequence
of this might bring about the malfunction back
burn, excess temperature or overfilling of the fire
box.
"Cycle for underfeed auger sustain" too low: Too
little material is pushed into the burner trough
such that the embers are too small for the sustain
load operation. This can bring about a back burn
or the fire will go out.
5.4.4 Standby
If too much heat is generated in sustain load op-
eration, the control system automatically goes into
standby operation. When this threshold value is
reached, first the isolating valve shuts, and the
auger module is slowly idled in the sustain mode.
For the standby mode, all the drive activities (fans
and auger modules) are stopped. Only then does
"Standby" appear in the operating mode display.
When the boiler temperature drops or a minimum
standby period lapses, in the case of a prompt an
automatic new start is carried out.

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5.4.5 Transition in output
To obtain a good structure of the fire and thus low
emissions of harmful substances, the switchover
from "SUSTAIN" to "FULL LOAD" is not carried
out suddenly but rather gently.
5.4.6 Switching off
Touching Softkey 2 "Boiler OFF" shuts down the
furnace firing process properly. "Burn-out" is indi-
cated on the display. The firing control system
continues to run until there is no more fuel in the
underfeed auger or the fire box temperature is be-
low the set-point value and then it switches off.
C A U T I O N: Do NOT use the masterswitch to
switch off ÆDANGER OF BACK BURN!
5.5 Emergency operation
The firing optimisation function can be switched
off in Mask 7 by touching the "Emergency opera-
tion" softkey. If a sensory mechanism is defective,
the switching off takes place automatically. Text
shown on display: "SYSTEM PRESENTLY RUN-
NING WITHOUT OPTIMISATION". The quantities
of material and air are then manually set as set-
point values under "Emergency operation output"
and "Emergency operation cycle of underfeed au-
ger". The negative pressure is no longer corrected
automatically. For this reason the fan settings
must be checked. No positive pressure must de-
velop in the burner. In case positive pressure
should develop, adjust the mechanical means of
throttling on the supply air fans.
5.6 Measurement operation
It is possible to switch the boiler control system
into "MEASUREMENT OPERATION" in Mask 7
by touching the softkey "Measurement operation"
while the indicator in the upper left of the display
is indicating "FULL LOAD". In "MEASUREMENT
OPERATION" the output control is blocked to
guarantee constant full load operation during the
measurement.
V E R Y I M P O R T A N T: In measurement
operation the system does not switch to
"SUSTAIN". Ensure heat consumption ÆDan-
ger of excess temperature!
5.7 Operating modes
The following terms are displayed in the operating
mode line depending on the situation:
Off The boiler is switched off.
Filling Cold start. The fire box trough is
being filled by the underfeed
auger.
Auger
filling Direct or hot start with fire box
still warm. The auger module is
being filled.
Igniting The ignition blower is running.
The system is being started.
Heating up The system is being slowly
started.
Full load The boiler is running in regular
operation.
Sustain Embers being sustained. Boiler
set-point temperature and the
switching threshold "Sustain on"
have been exceeded.
Standby The boiler temperature is over
the switching threshold for
standby and no prompt.
Auger
idling The isolating valve moves shut,
the boiler goes into standby.
Example: After malfunctions or
the boiler set-point temperature
being exceeded. Upon a prompt
for heat there will be an auto-
matic new start.
Burn-out There is a malfunction or Soft-
key 2 "Boiler OFF" has been
touched.
The fire box is cooling down.
Emergency
operation Non-optimised operation with
adjustable operational set-point
values. Example: If a sensory
mechanism necessary for opti-
mised operation is defective, the
switchover is being carried out
automatically.
Required sensory mechanisms:
lambda-sensor, fire box tem-
perature sensor & negative
pressure measuring system.
Measure-
ment opera-
tion
The output control is blocked to
guarantee constant full load op-
eration during the measurement.

19
6 Cleaning/Maintenance
6.1 Boiler
Regular cleaning and maintenance of the facility is the customer's most important job for years of
trouble-free operation and to obtain the greatest possible output with the best efficiency.
Here the cleaning intervals for chip material are listed as per ÖNORM M 7133 with clinging bark –
0.8% ash content. The cleaning intervals may vary, depending on the fuel, the amount of fine matter
and the operating method.
CAUTION – RISK OF INJURY: Before beginning cleaning work, put the facility out of operation. Be
absolutely sure to wear protective gloves, protective eyewear if required and use the cleaning uten-
sils that come with the facility (danger of blow-ups, burns and getting crushed)!
Approx. every 300 operating hours:
Clean the air vents for the burner trough and remove remaining ash from the fire box.
With pneumatic pipe cleaning system, after approx. 600 op-
erating hours; without pneumatic pipe cleaning system, after
approx. 300 operating hours:
Open boiler door and clean all the heat exchanger pipes with
wire cleaning brush.
IMPORTANT:
With pneumatic pipe-cleaning system, disconnect the com-
pressed air line before opening the boiler door – danger of
injury!
Approx. every 300 operating hours:
Clean the light barriers and inspection
windows above the underfeed auger,
and also opposite. Remove dust and
ash deposits in the openings.
Approx. every 300 operating hours:
Open all the lids on the insertion side or
across from the feed and remove ash.
After each manual
cleaning of the heat
exchanger:
Use kindling utensils to
draw ash to the front and
remove.
After each manual cleaning of
the heat exchanger:
Open lid on both sides and remove
ash.
Approx. every 300 operating hours:
Clean the light barriers and inspection windows above the de-ashing auger (optional),
and also opposite. Remove dust and ash deposits in the openings.

20
Pneumatic tube-cleaning system (optional)
- Operation and maintenance of the compressor
(optional) according to the manual that comes
with the facility.
- The timer that comes with the compressor is
for limiting the running time and should be
mounted between the compressor and the
power supply.
- When the compressed air system is provided
by the customer, the compressor has to be
suited for continuous operation or be secured
against continuous operation (e.g. timer for
limiting running time).
- Continuous operation of the compressor indi-
cates leakage in the air system. Check air sup-
ply line and valves for leakage.
Exhaust gas deduster (Option)
IMPORTANT: Never operate the boiler without
ash container!
Regularly drain condensation water in the
compressed air distribution bar.
Approx. every 1000 operating hours
Pull out plug, unscrew wing nuts, pull out
motor with impeller and clean with broom
or wire brush.
CAUTION DANGER OF INJURY – Turn
off master switch
Approx. every 300 operating hours
Open lid and clean the deduster´s guide
blades with a hand brusch.
Nach ca. 300 Betriebsstunden (Aschen-
tonne 240 Liter):
Aschenbehälter unterhalb des Entstaubers
After approx. 300 operating hours (240-
litre ash bin):
Empty ash bin beneath the de-duster.