KWB Easyfire Manual

Biomass Heating Systems
Pellet boilers
KWB Easyfire 10-30kW
Installation and Maintenance
Manual
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INFORMATION ABOUT THIS MANUAL
This manual contains all information required for specialists. Read it carefully.
There is no warranty claim for damage due to failure to comply with the maintenance instructions.
Our desire is to continuously improve our products and services, we would be pleased to get your feedback.
KWB – Kraft und Wärme aus Biomasse GmbH
Industriestr. 235
A – 8321 St. Margarethen an der Raab
Tel.: [phone]
Fax: [phone]
email: [e-mail]
Web site: www.kwb.at
Instructions that must always be complied with
in your own interest are marked as shown.
Dated: 08. October 2008 – art. no. 21-2000097
Subject to change. No responsibility accepted for errors and omissions!
© 2008, KWB – Kraft und Wärme aus Biomasse Gesellschaft mbH
All content of this document is the property of KWB and thus is protected by copyright. Any form of duplication, forwarding to thirdpar-
ties or use for other purposes without the owner’s written consent is prohibited.
Hereinafter KWB – Kraft und Wärme aus Biomasse Gesellschaft mbH, including its national representatives and the authorised
KWB Competence Partners are referred to as KWB.
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© KWB – Kraft und Wärme aus Biomasse GmbH IM Easyfire 10/2008 Page 3
Table of contents
Table of contents
Table of contents
1 INTRODUCTION....................................................................................................................9
1.1 Safety instructions...................................................................................................................................9
1.2 Warranty..................................................................................................................................................9
1.3 Structural prerequisites ...........................................................................................................................9
1.3.1 Boiler room requirements ........................................................................................................................................9
1.3.2 General requirements for pellet storage rooms......................................................................................................10
1.3.3 Chimney requirements...........................................................................................................................................10
2 SYSTEM INSTALLATION.....................................................................................................13
2.1 Installation of the boiler .........................................................................................................................13
2.1.1 Bringing in the boiler..............................................................................................................................................13
2.1.1.1 Dismantling the system.........................................................................................................................................13
2.1.1.2 Bringing the dismantled system into the boiler room.............................................................................................19
2.1.2 Left/right system conversion................................................................................................................................20
2.1.3 Changing the stop side of the boiler room door......................................................................................................22
2.1.4 Boiler set-Up..........................................................................................................................................................22
2.1.5 Automatic ash removal (AR)..................................................................................................................................23
2.1.6 Final inspection......................................................................................................................................................26
2.1.7 First commissioning, ash removal.........................................................................................................................26
2.1.8 Emptying the ash container...................................................................................................................................26
2.1.8.1 Removing the ash container..................................................................................................................................26
2.1.9 Smoke pipe connection and induced draft fan.......................................................................................................27
2.1.10 Water connection..................................................................................................................................................27
2.1.11 Electrical connection..............................................................................................................................................28
2.1.11.1 Electrical connections of the system.....................................................................................................................28
2.1.11.2 Mains supply.........................................................................................................................................................31
2.1.11.3 Junction box..........................................................................................................................................................31
2.1.11.4 Cabling guidelines..................................................................................................................................................33
2.1.11.5 Control units & heating circuit expansion modules (HCM).....................................................................................35
2.1.11.5.1 Boiler control unit/digital room control unit (OPTION).........................................................................................35
2.1.11.5.2 Analogue room control unit (OPTION)...................................................................................................................36
2.1.11.5.3 Heating circuit expansion module (HCM):............................................................................................................37
2.1.11.6 Plug-in module 1 (suction conveyor system, second boiler, heating circuit 0).......................................................40
2.1.11.6.1 Suction conveyor system and/or second boiler switchover................................................................................40
2.1.11.6.2 Heating circuit 0 and/or second boiler switchover...............................................................................................40
2.1.11.7 Boiler master-and-slave circuit..............................................................................................................................40
2.1.11.8 External smoke extractor.......................................................................................................................................40
2.1.11.9 Stop switch...........................................................................................................................................................40
2.1.11.10 Equipotential bonding ............................................................................................................................................41
2.1.11.11 Sensor check.........................................................................................................................................................41
2.2 Installation, suction conveyor unit (see also section 13 to 16)...............................................................42
3 COMMISSIONING...............................................................................................................43
3.1 Switching on the main switch...............................................................................................................43
3.2 Setting the parameters..........................................................................................................................43
3.3 Function check of the system parts.......................................................................................................44
3.4 Switching on the boiler in the menu......................................................................................................45
4 OPERATION SPECIALIST....................................................................................................47
4.1 Menu item – Heating Circuits................................................................................................................47
4.1.1 Operating values....................................................................................................................................................47
4.1.2 Dependant on outdoor temperature.......................................................................................................................49
4.1.3 Legionella protection..............................................................................................................................................49
4.2 Menu item – Basic Settings..................................................................................................................50
4.2.1 Boiler temperature.................................................................................................................................................50
4.2.2 Return flow boost..................................................................................................................................................50
4.2.3 Mixer return flow boost.........................................................................................................................................51
4.2.4 Pellet conveyor system..........................................................................................................................................51
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4.2.5 Pump afterrun........................................................................................................................................................51
4.2.6 Boiler pump...........................................................................................................................................................52
4.2.7 Language...............................................................................................................................................................52
4.2.8 Second boiler.........................................................................................................................................................52
4.2.9 Cleaning.................................................................................................................................................................52
4.2.10 Network settings...................................................................................................................................................53
4.2.10.1 Boiler.....................................................................................................................................................................53
4.2.10.1.1 EXT 2 ....................................................................................................................................................................53
4.2.10.1.2 Power output.........................................................................................................................................................53
4.2.10.2 Heating circuit.......................................................................................................................................................53
4.2.10.3 DHWC....................................................................................................................................................................54
4.2.10.4 Buffer.....................................................................................................................................................................54
4.2.10.5 Digital remote control............................................................................................................................................55
4.2.11 Hardware...............................................................................................................................................................55
4.2.12 Frost protection .....................................................................................................................................................56
4.2.13 Outputs:.................................................................................................................................................................56
4.2.14 Menu item – Rotary Grate.....................................................................................................................................57
4.3 Menu item – Relay Test.........................................................................................................................57
4.3.1 Boiler.....................................................................................................................................................................57
4.3.2 Heating circuits......................................................................................................................................................58
4.3.3 DHWC....................................................................................................................................................................58
4.3.4 Buffer.....................................................................................................................................................................58
4.3.5 Fuel extractor.........................................................................................................................................................58
4.3.6 Second boiler.........................................................................................................................................................59
4.4 Menu item – Network Analysis.............................................................................................................59
4.4.1 Overview ...............................................................................................................................................................59
4.4.2 Boiler module.........................................................................................................................................................59
4.4.3 Heating circuit module...........................................................................................................................................59
4.4.4 Dig. remote control unit.........................................................................................................................................59
5 OPERATION, FACTORY CUSTOMER SERVICE ....................................................................61
5.1 Menu item – Basic Settings..................................................................................................................61
5.1.1 Fan.........................................................................................................................................................................61
5.1.2 Boiler output..........................................................................................................................................................61
5.1.3 Ignition...................................................................................................................................................................61
5.1.4 Serial number.........................................................................................................................................................62
5.1.5 Operating hours.....................................................................................................................................................62
5.2 Menu item – Ash Extractor....................................................................................................................62
5.3 Menu item – Save/Reset......................................................................................................................63
5.4 Menu item – Start/Stop Log.................................................................................................................63
6 BOILER, MEASURING.........................................................................................................65
6.1 Menu item – Measure Boiler.................................................................................................................65
6.2 Preparations for measuring the boiler....................................................................................................65
6.3 Adjusting combustion (CO2value).........................................................................................................66
6.4 Re-adjusting the air stages....................................................................................................................67
6.5 Boiler analysis: Fuel...............................................................................................................................68
6.6 Boiler analysis: Flame aspect................................................................................................................69
6.7 Boiler analysis: Odour............................................................................................................................69
6.8 Boiler analysis: Ash...............................................................................................................................69
6.9 Boiler analysis: Coatings in the combustion chamber............................................................................69
7 MEASURING FLUE GAS – GENERAL INFORMATION.........................................................71
7.1 Brief information on flue gas values.......................................................................................................71
7.1.1 Emission value units..............................................................................................................................................71
7.1.2 Conversion factors for emission values for wood-fired furnaces ...........................................................................72
7.1.3 Conversion, combustion efficiency .......................................................................................................................73
7.1.4 Information on carbon dioxide (CO2)......................................................................................................................74
7.1.5 Residual oxygen (02)..............................................................................................................................................74
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7.1.6 Air ratio number.....................................................................................................................................................74
7.1.7 Carbon monoxide (CO)...........................................................................................................................................74
7.1.8 Nitrogen oxides (NOX)............................................................................................................................................75
7.1.9 Hydrocarbons (HC, CxHy, Corg).............................................................................................................................75
7.1.10 Dust.......................................................................................................................................................................75
7.1.11 Efficiency (η)........................................................................................................................................................76
7.1.12 Draught..................................................................................................................................................................76
7.2 Incorrect measurements – causes.........................................................................................................76
7.2.1 Causes associated with operation.........................................................................................................................76
7.2.2 Causes associated with the measuring device......................................................................................................77
7.2.3 Causes associated with the boiler.........................................................................................................................77
7.2.4 Causes for the measurement sensor......................................................................................................................77
8 SOFTWARE MAINTENANCE...............................................................................................79
8.1 Software transfer with PC .....................................................................................................................79
8.1.1 Prerequisites..........................................................................................................................................................79
8.1.2 Software transfer to the boiler control unit............................................................................................................80
8.1.3 Software transfer to the handheld programming unit.............................................................................................81
8.2 Software transfer with handheld programming unit...............................................................................83
8.2.1 Prerequisites..........................................................................................................................................................83
8.2.2 Description, handheld programming unit...............................................................................................................83
8.2.3 Software transfer to the boiler control unit............................................................................................................83
8.3 Troubleshooting ....................................................................................................................................84
9 FABRIC TANK......................................................................................................................85
9.1 General information about the fabric tank..............................................................................................85
9.2 Fabric tank and fuel extractor................................................................................................................85
9.3 Room size..............................................................................................................................................86
9.4 Room fixtures........................................................................................................................................86
9.5 Room condition......................................................................................................................................86
9.6 Room ventilation....................................................................................................................................87
9.7 Fire safety..............................................................................................................................................87
9.7.1 Austria...................................................................................................................................................................87
9.7.2 Switzerland............................................................................................................................................................87
9.7.3 Germany................................................................................................................................................................87
9.8 Completion and concluding inspection ..................................................................................................87
9.9 Filling instructions
(see also the posted information in the storage room and the last page of this manual)......................89
9.9.1 Prior to filling..........................................................................................................................................................89
9.9.1.1 Fill pressure...........................................................................................................................................................90
9.9.2 Number and position of the fill nozzles:..................................................................................................................90
9.9.3 Filling.....................................................................................................................................................................90
9.9.4 Emptying the fill line: .............................................................................................................................................90
9.10 Fabric tank scope of delivery.................................................................................................................91
9.11 Installing the fabric tank and filling system............................................................................................92
9.12 Installing the fill system.........................................................................................................................95
9.13 Final inspection......................................................................................................................................95
10 FUEL EXTRACTOR TYPE S – worm extractor..................................................................................99
10.1 Pellet storage room requirements (FE type S)........................................................................................99
10.2 Installation instructions, FE type S.......................................................................................................100
10.3 Installing the pellet worm ....................................................................................................................100
10.4 Mounting the extensions.....................................................................................................................102
10.5 Installing the elbow worm...................................................................................................................104
10.6 Installing the head piece with drop shaft.............................................................................................106
10.7 FE connection on the burner................................................................................................................107
10.8 Final inspection....................................................................................................................................107
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11 FE “S” INCLINED WORM, FABRIC TANK..........................................................................109
11.1 Pellet storage room requirements (FE type S with fabric tank) ...........................................................109
11.2 Installing the inclined worm extraction system....................................................................................110
11.2.1 FE connection on the burner see point 10.7.............................................................................................113
11.3 Final inspection....................................................................................................................................113
12 FE “S”, PELLET STIRRER PLUS, ELBOW WORM..............................................................115
12.1 Pellet storage room requirements (FE type S with Pellet Stirrer Plus).............................................115
12.2 Installation instructions, FE type S.......................................................................................................116
12.3 Installing the pellet worm ....................................................................................................................116
12.4 Mounting the extensions.....................................................................................................................117
12.5 Installing the elbow worm...................................................................................................................120
12.6 Installing the head piece with drop shaft.............................................................................................120
12.7 FE connection on the burner................................................................................................................120
12.8 Installing the Stirrer Plus......................................................................................................................120
12.9 Final inspection....................................................................................................................................124
13 FE “GS” SUCTION CONVEYOR, PELLET WORM...............................................................125
13.1 Requirements, pellet storage room (type GS fan, pellet worm, V-sloping floor)..................................125
13.2 Installing the pellet worm see point 10.3.............................................................................................126
13.2.1 Connection, pellet worm – connecting piece.......................................................................................................126
13.2.2 Installing the pellet worm drive............................................................................................................................127
13.3 Installing the transport hose................................................................................................................127
13.3.1 Equipotential bonding ..........................................................................................................................................127
13.3.2 Hose connection and grounding (storage system)...................................................................................128
13.3.3 Fire safety............................................................................................................................................................129
13.3.4 Hose connection
(boiler room)...............................................................................................................129
13.4 Final inspection....................................................................................................................................130
14 FE “GS” SUCTION CONVEYOR, PELLET STIRRER PLUS...................................................131
14.1 Pellet storage room requirements (FE type GS with Pellet Stirrer Plus)............................................131
14.2 Installation instructions FE type GS.....................................................................................................132
14.3 Final inspection....................................................................................................................................132
15 FE “GL” LANCE, FABRIC TANK .........................................................................................133
15.1 Pellet storage room requirements (FE type GL with lance and fabric tank).........................................133
15.2 Installation, removal pot with lance.....................................................................................................134
15.3 Lay out transport hose see point 13.3..................................................................................................134
15.4 Fabric tank see section 9.....................................................................................................................134
15.5 Final inspection....................................................................................................................................134
16 RA “GL” SUCTION CONVEYOR, LANCE WITH BURIED TANK ..........................................135
16.1 Pellet storage room requirements (FE type GL, fan and lance with buried fabric tank).......................135
16.2 Lay out transport hose see point 13.3..................................................................................................136
16.3 Buried tank..........................................................................................................................................136
16.4 Final inspection....................................................................................................................................136
17 FUEL EXTRACTOR SYSTEM, TYPE R pellet stirrer.......................................................................137
17.1 Requirements, pellet storage room (for type R)...................................................................................137
17.2 Install the fuel extractor (FE)................................................................................................................138
17.3 FE connection on the burner see point 10.7.........................................................................................142
17.4 Final inspection....................................................................................................................................142
18 TECHNICAL DATA SHEETS FOR SPECIALISTS.................................................................143
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Technical data sheets
for specialists
18.1 Dimension sheets
Dimensions and minimum fitting dimensions, KWB Easyfire..........................................................................................................................145
Fitting dimensions, KWB Easyfire...................................................................................................................................................................146
Pellet blow-in nozzle........................................................................................................................MBEZ0001_d sheet 1/3.........................147
Pellet blow-in nozzle........................................................................................................................MBEZ0001_d sheet 2/3.........................148
Pellet blow-in nozzle........................................................................................................................ MBEZ0001_e sheet 3/3.........................149
Fitting dimensions, KWB Easyfire S.........................................................................................TDB-MBL-USP-S-Einbaum_c .........................150
Sectional drawing, pellet storage room.......................................................................................TDB-MBL-USP-MBDK0008 .........................151
Sectional drawing, pellet storage room...........................................................................................................................................................152
FE conveyor worm system, construction kit...........................................................................TDB-MBL-USP-MBDK0001_e .........................153
Fitting dimensions, FE ascending worms (elbow worms).......................................................TDB-MBL-USP-MBDK0002_d .........................154
Construction kit, FE type S (pellet worms and suction conveyor)..............................TDB-MBL-USP-MBDS0001_d (part 1) .........................155
Construction kit, FE type S (pellet worms and suction conveyor)..............................TDB-MBL-USP-MBDS0001_d (part 2) .........................156
Fitting dimensions KWB Easyfire S with inclined worm and fabric tank.........................................................................................................157
Installation example, KWB Easyfire GL
with suction conveyor unit and lance..................................................................TDB-EBB-USP-Einbaubsb. 7_B sheet 7/11 .........................158
Fitting dimensions, KWB Easyfire GL, GS with suction conveyor unit and worm............................................................................................159
Pellet fabric tank, dimension sheet for all sizes ......................................................................TDB-MBL-USP-MBDK0007_d .........................160
Fitting dimensions, KWB Easyfire R stirrer................................................................TDB-MBL-USP-Einbaumaße_d sheet 2 .........................161
18.2 Hydraulic diagrams
Return flow boost, hydr. circuit boiler circuit...................................................................................................MBEH0001_e .........................163
Base module with weather-sensitive control system......................................................................MBEH0002_b sheet 1/2 .........................164
Base module with weather-sensitive control system......................................................................MBEH0002_a sheet 2/2 .........................165
Base module with weather-sensitive control system......................................................................MBEH0003_b sheet 1/2 .........................166
Base module with weather-sensitive control system......................................................................MBEH0003_a sheet 2/2 .........................167
Base module with weather-sensitive control system, combination load-balancing tank.................MBEH0004_b sheet 1/2.........................168
Base module with weather-sensitive control system, combination load-balancing tank.................MBEH0004_a sheet 2/2 .........................169
Base module with weather-sensitive control system & second boiler switchover .........................MBEH0005_b sheet 1/2.........................170
Basic module with weather-sensitive control system & second boiler switchover.........................MBEH0005_a sheet 2/2 .........................171
Basic module with weather-sensitive control system, one expansion module
and a buffer as long-term buffer......................................................................................................MBEH0006_b sheet 1/2 .........................172
Basic module with weather-sensitive control system, one expansion module
and a buffer as long-term buffer......................................................................................................MBEH0006_a sheet 2/2.........................173
Base module with weather-sensitive control system, one expansion module
and a combination buffer as load compensator...............................................................................MBEH0007_b sheet 1/2 .........................174
Base module with weather-sensitive control system, one expansion module
and a combination buffer as load compensator.............................................................................. MBEH0007_A sheet 2/2 .........................175
Basic module with weather-sensitive control system
and boiler master-and-slave system...............................................................................................MBEH0009_b sheet 1/2.........................176
Basic module with weather-sensitive control system
and boiler master-and-slave system...............................................................................................MBEH0009_a sheet 2/2 .........................177
Basic module with weather-sensitive control system, expansion module
and buffer as long-term buffer.........................................................................................................MBEH0010_c sheet 1/2 .........................178
Basic module with weather-sensitive control system, expansion module and buffer as long-term buffer ......................................................179
Basic module with weather-sensitive control system, one buffer with solar register
and a fresh-water module as long-term buffer....................................................................................MBEH0011 sheet 1/2.........................180
Basic module with weather-sensitive control system, one buffer as long-term buffer and a fresh-water module as long-term buffer............181
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18.3 Electrical diagrams
KWB Easyfire, analogue & digital inputs.......................................................................................TDB-ELS-USP-EBAA1011 .........................183
KWB Easyfire, outputs, basic module.......................................................................................TDB-ELS-USP-EBAA1012_a .........................184
KWB Easyfire, ABM motor connection.....................................................................................TDB-ELS-USP-EBAA1014_b .........................185
Bus data cable, KBG..................................................................................................................TDB-ELS-USP-EBAA1015_a .........................186
KWB Easyfire, analogue inputs and safety thermostat..............................................................TDB-ELS-USP-EBAA1016_b .........................187
KWB Easyfire, HCM connection diagram............................................................................................. ELS-TYÜ-HKM_XL_a .........................188
Bus cabling...............................................................................................................................TDB-ELS-USP-EBAA1018_g .........................189
KWB Easyfire, outputs, heating circuits....................................................................................TDB-ELS-USP-EBAA1019_c .........................190
KWB Easyfire, analogue and digital inputs heating circuits.......................................................TDB-ELS-USP-EBAA1020_a .........................191
Boiler, plug-in module 1 HC-0+second boiler............................................................................TDB-ELS-USP-EBAA1021_f .........................192
Boiler, Burner plug-in panel...........................................................................................................TDB-ELS-USP-EBAA1022 .........................193
Boiler, burner drive........................................................................................................................TDB-ELS-USP-EBAA1023 .........................194
Boiler, induced draught/cleaning system...................................................................................TDB-ELS-USP-EBAA1024_b .........................195
Boiler, supply I/O+plug-in module............................................................................................TDB-ELS-USP-EBAA1025_a .........................196
Boiler, plug-in module 1 suction system+second boiler..........................................................TDB-ELS-USP-EBAA1026_e .........................197
Boiler, Easyfire GS, Easyfire GL.................................................................................................TDB-ELS-USP-EBAA1027_c .........................198
Fitting dimensions, KWB Easyfire I/O module (board)...............................................................TDB-ELS-USP-EBAA1028_a .........................199
KWB Easyfire I/O plug-in module 1...........................................................................................TDB-ELS-USP-EBAA1029_a .........................200
House junction box for KWB Easyfire.......................................................................................TDB-ELS-USP-EBAA1030 _a .........................201
KWB Easyfire – ash removal system............................................................................................TDB-ELS-USP-EBAA1031 .........................202
KWB Easyfire – mains cable.........................................................................................................TDB-ELS-USP-EBAA1046 .........................203
KWB Easyfire – chimney sweep button........................................................................................TDB-ELS-USP-EBAA1042 .........................204
KWB Easyfire – STOP SWITCH...................................................................................................TDB-ELS-USP-EBAA1044a .........................205
KWB Easyfire – fan with Hall sensor ebm.....................................................................................TDB-ELS-USP-EBAA1032 .........................206
KWB Easyfire – Hall sensor Hanning.............................................................................................TDB-ELS-USP-EBAA1048 .........................207
KWB Easyfire – induced draught Hanning...................................................................................TDB-ELS-USP-EBAA1034b .........................208
KWB Easyfire – induced draught with Hall sensor ebm................................................................TDB-ELS-USP-EBAA1033 .........................209
KWB Easyfire – safety thermostat................................................................................................TDB-ELS-USP-EBAA1040 .........................210
18.4 Chimney
Data capture for chimney cross-section calculation .......................................................................................................................................211
Chimney – cross-section measurement..........................................................................................................................................................212
18.5 Hinweise für Pellet-Zulieferbetriebe.............................................................................213
18.6 Aufkleber und Warnhinweise........................................................................................215
Index ......................................................................................................................................217
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1 Introduction
1 Introduction
1 INTRODUCTION
1.1 Safety instructions
The systems manufactured by KWB GmbH are state-of-the-art and satisfy the applicable safety regulations. Boiler
and fuel supply operate with electrical power. Improper installation can mean life-threatening danger. Heating
boilers are firing systems andare a hazardsource if nothandled properly.Therefore installation, commissioningand
service should only be executed by sufficiently qualified specialists in compliance with all applicable regulations
and the manufacturer’s instructions. Knowledge of the operating and maintenance manual is the prerequisite for
performing these tasks.
Strictly comply with all instructions with this symbol.
Compliance with these instructions prevents personal injury and damage to the system!
1.2 Warranty
Themanufacturer’swarrantyspecifiesproperinstallationandcommissioningoftheboilersystemastheprerequisite.
Defects and damage due to improper installation, commissioning and operation are excluded from the warranty.
The manufacturer’s instructions must be complied with to ensure proper system function. In addition, only original
parts, or parts expressly approved by the manufacturer, should be installed in the system.
1.3 Structural prerequisites
When establishing the structural prerequisites the locally applicable legal construction permits, building, and
execution guidelines, as well as the dimension specifications in the installation guidelines (see section 17),
installation examples, and technical data must be complied with! Compliance with the locally applicable guidelines,
and proper execution of the structural measures lies solely within the system owner’s sphere of responsibility
and such compliance is the prerequisite for the warranty. KWB does not accept any liability, nor does it offer any
warranties for any type of constructional measures. Without laying claim to an exhaustive treatment of the issue
at hand and without suspension of any conditions imposed by the authorities, based on the Austrian directive
TRVB H 118 and ÖKL technical bulletin No. 56 and No. 66, we recommend the configurations described below.
1.3.1 Boiler room requirements
Concrete flooring, plain or tiled; height-adjustable
boiler feet or shims can be used to compensate minor
unevenness. All materials forfloors, walls,ceilings must
be fire resistant F90; (see Table 1) fire protection doors
(T30) executed as automatically closing doors that open
in the direction of escape, connection door to the fuel
storage room executed as an automatically closing fire
door (T30), boiler room windows, non-opening G30;
non-closingair intakeopening 5cm²per kWfuel thermal
outputoftheheatingsystem,howeveratleast.400cm².
For boiler output > 60 kW it is necessary to provide one
ventilationopening nearthe floor and another ventilation
opening near the ceiling; the supply-air ducting must be
routed directly into the open; if it crosses other rooms,
the air duct must feature an F90 envelope; a protective
grille with a mesh width < 5 mm must be fitted on
the outside of ventilation openings to the outside.
Permanently installed lighting and electrical supply
line to the heating system; light switch and marked
stop switch (emergency-stop) for the heating system
in an easily accessible location outside the boiler room
near the boiler room door. A portable fire extinguisher
(6 kg filling weight, EN3 standard) must be installed
outside the boiler room near the boiler room door. The
boiler room as well as water lines and district heating
pipes must be frost resistant. No storage of flammable
materials in the boiler room outside the boiler system,
storage container or hopper; no direct connection to
rooms where flammable gases or liquids (garage) are
stored.
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1 Introduction
1 Introduction
Clear door widths for bringing in the boiler, in cm, width x height
Boiler type Dismantled Not dismantled
Easyfire USP 10/15/20 75x180 85x180
Easyfire USP 25/30 80x180 95x180
1.3.2 General requirements for pellet storage rooms
The constructional on-site requirements for the boiler
room also apply to the fuel storage room. If it is possible
to store a volume of 50 m³ or more of fuel, then a fire
extinguisher with manual release with a frost-proof
connection (from the boiler room) must be connected
to a pressurised water line executed as empty piping
of at least 3/4” or DN 20, must be installed directly
above the passage of the fuel extractor trough in the
fuel storage room The armature must be marked with
the warning: “Fire extinguisher – fuel storage room”. If
a pumping car is used to fill the fuel storage room with
wood chips or pellets, it is necessary to install hose
couplings and pipelines (that must be earthed). These
are available from KWB. If this filling method is selected,
dustproof sealing of the fuel storage room is required.
The escaping air is removed through a second earthed
pipeline and hose coupling, or it is blown off into the
open air after having passed through a filtering section.
Suction removal or filtration of the transport air is the
responsibility of the fuel supplier. The walls, windows
and doors must withstand the excess pressure that
occurs during the filling process. Wood planking is
necessary on the inside in order to open the door when
the pellet storage room is full. The fuel storage area
must be designed in such a manner that it is dry and
dust-proof! Specific requirements for the fuel extractor
variants are provided in section 10.
Ignition sources (lights, switches, power outlets and distributor boxes) are prohibited!
Electrical installations must be established in explosion-protected design in accordance
with the local applicable regulations.
Rule of thumb for dimensioning the storage room: (*Average variables: Weather, detached house, fuel quality)
Fuel Pellets 10 % water content 6 mm diameter
Storage space for 1 year = 0.9 m³ heat load in kW
Consumption for 1 year = 400 kg heat load in kW
1.3.3 Chimney requirements
Duetothehighboilerefficiency,thechimneydesignshould
be resistant to moisture. A moisture-resistant chimney
design means that there will be no moisture penetration
or damage to the brickwork, even though the temperature
level in the flue-gas path remains permanently below the
flue-gas dew point (see DIN 18160)!
Exceptions are only possible if the flue gas temperature is
increasedduetointerventionsinthedevice.Howeverboiler
efficiency is reduced through such a measure. The guide
values for chimney diameter are specified in the technical
data (see operating manual, point 8). They are valid for
the applicable system size, given average constructional
conditions, i.e.: Effective chimney height 8-10 m, smoke-
pipe length 1.5 m, 2 90° segment bends, 1 contraction,
1 T-connectionat 90°.Thecross-sectiondiagramsprovided
bythechimneymanufacturerareaquickreferenceaid,ifthe
circumstances are not less favourable than the conditions
specifiedinthecross-sectiondiagrams.Ifconditionsdiffer,
or if conditions are less favourable in terms of space, it is
necessary to execute a chimney calculation in accordance
with EN 13384. The boiler parameters required for the
calculation are specifiedin the technical boilerdata. Adata
entry sheet is available as an electronic form from KWB
(section 17). Upon request, KWB will provide the chimney
calculation based on the information provided on the form.
This is a chargeable service. The local expert for these
issues is your responsible chimney sweep. It is advisable
to involve the chimney sweep during the planning phase
as he is the one who will have to issue the acceptance
certificate for the flue gas system.
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1 Introduction
1 Introduction
Flue gas pipes Example, chimney structure
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2 System installation
2 System installation
2 SYSTEM INSTALLATION
The system parts must be installed by qualified personnel from KWB, or by KWB’s competence partner in
accordance with the set-up plan/submitted plan and the manufacturer’s instructions. The connection (smoke pipe,
water, electrical) must be executed by certified HVAC engineers and electricians. This manual only describes the
boiler installation. Installation of the fuel extractor is described in separate manuals.
2.1 Installation of the boiler
2.1.1 Bringing in the boiler
The system isdeliveredreadyto beplugged-in and can bebroughtdirectly into the room whereitwillbe set up.Due
to the not inconsiderable weight of the boiler, we recommend preparing the transport path, e.g. cover stairs with
wooden planking or place steel pipes underneath the pallet as rollers, in order to more easily move the boiler in sliding
or rolling movements. Strictly ensure that you have implemented measures to prevent unintentional slipping.
2.1.1.1 Dismantling the system
If the system must be dismantled in order to bring it into the set-up room (door clearances are too small, transport
path is too difficult, etc.), or if a left/right conversion must be executed, then the following dismantling steps are
necessary.
1.) Open the cladding cover
Delivery variants:
Burner design cladding (Fig.)
Suction tank (type GL, GS) executed.
Lift the boiler cover.
Delivery status
2.) Remove the front cladding
Pay attention to the connecting cable!
Lift the front cladding out of the holder.
Lean the front cladding on the system with the outside facing the system.
This will prevent damage.
The connecting cable can only be detached after dismounting
the control unit cover, (connector 26).
Front cladding
3.) Dismount the boiler cover
Remove the insulating block.
Insulating block
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2 System installation
2 System installation
Loosen the 4 fixing screws:
Turn the boiler cover counter clockwise.
Remove the boiler cover.
Boiler cover
4.) Remove the combustion chamber parts
Remove the combustion chamber cover.
Combustion chamber cover Lift the post-combustion ring out of the holder.
Post-combustion ring
5.) Open the junction box
Loosen the screws.
Remove the cover.
Control unit cover
6.) Dismount the burner cladding
6a Design cladding:
Slightly lift the cladding and remove it.
Loose the screws under the cover if necessary.
Design cladding
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2 System installation
2 System installation
6b Suction tank GS, GL:
Loosen the screws of the cover.
Lift off the cover from the top.
Cover of the full cladding Loosen the two fixing screws.
Unhook the full cladding.
Tip: If space is at a premium:
Remove the bolted connection of the division joint
on the full cladding.
Full cladding
7.) Dismount the suction tank GS, GL:
Loosen the 4 screws of the acoustic insulation hood.
Lift the acoustic insulation hood off from the top.
Acoustic insulation hood Loosen the screw of the cable channel.
Pull the cable channel upward and out of the guide
Cable channel Unplug the connector.
Suction removal
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2 System installation
2 System installation
Disconnect the earth connection on the burner.
Unplug the plug-type connector 23 (overfill-protection sensor).
Unplug the plug-type connector Remove the hose clamp from the connecting hose between the suction
tank and the cellular wheel sluice.
Connecting hose Loosen the screws.
Unhook the suction tank.
Tank holder
All types
Unplug all connectors from the plug-in panel.
Unplug the connector of the radial fan.
Unplug the burner
8.) Dismantle the burner
Unscrew the burner from the boiler.
Loosen the burner flange
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2 System installation
2 System installation
Pull the burner straight out of the boiler.
Dismantle the burner
9.) Dismount the cabling
Dismount the plug-in panel.
Dismantle the plug-in panel Disconnect all plug-type connectors from the boiler I/O module.
Thread these connectors through the penetration rings.
Disconnect the boiler I/O Dismount the holder bracket for main switch, chimney sweep button and
safety thermostat.
Switch panel Disconnect the earth connections on the corner points.
Disconnect the ground connections
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2 System installation
2 System installation
Detach the cable ties on the rear wall.
Detach cable ties Unscrew the connectors from the rear wall.
Unscrew connectors
10.) Take off the cladding cover
Unscrew the screws of the hinge.
Unscrew the hinge Unscrew the hinge from the cover.
Take off the cover.
Unscrew the cover hinge
11.) Dismount the junction box
Loosen the 4 fixing screws and unhook the junction box from the front.
Unhook the junction box
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2 System installation
2 System installation
12.) Take off the cladding
Unscrew the wing screws.
Unhook the rear wall.
Dismount the rear wall Unscrew the screws of both side cladding elements.
Remove the side cladding Unhook the side cladding elements.
Unhook the side cladding elements
To convert the system from left orientation to right orientation, continue with point 2.1.2 “Left/right system
conversion”.
The steps for bringing the system into the boiler room in dismantled status are provided in the next section.
2.1.1.2 Bringing the dismantled system into the boiler room
After the system has been prepared to be brought into the boiler room in dismantled status as specified in point 2.1.1.1,
proceed as follows.
11.) Take off the door cladding
Unscrew the side screws of the door cladding.
Take off the door cladding.
Dismount the cladding for transport with the hand truck!
This will prevent damage to the cladding.
Door cladding
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2 System installation
2 System installation
The boiler is now completely dismantled and can be transported
via hand truck.
Dismantled boiler
In this manner the system can be transported on almost all substrates
without damage.
Bring the boiler into the boiler room
Always have a second person assist you in difficult passages!
Moving the boiler over steps, steep ramps. etc.
Assemble the boiler in the reverse sequence listed in steps 2.1.1.2 and 2.1.1.1.
2.1.2 Left/right system conversion
Dismantle the system as specified in section 2.1.1.1.
Dismount the blind flange.
Mount the blind flange on the desired side.
Burner blind flange
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Transfer the screws of the side cladding elements from the front
to the rear.
Transfer screws (1) Transfer the following screws into the adjacent pressed-in nuts:
Screws for the burner cover
or
screws for fastening the suction tank
Transfer screws (2)
Assemble the boiler in the reverse sequence of steps 2.1.1.1 and 2.1.1.2.
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