KWB Multifire USV 15/25 D/ZI Manual

Biomass Heating Systems
KWB Multifire 15-100 kW
Heating System for Wood chips
and Pellets
Installation and Maintenance Manual

INFORMATION CONCERNING THIS MANUAL
This manual is designed for specialists from the installation company who have read and understood the operating
manual. Here you will find the necessary information on installation, adjustment and commissioning of the wood-chip
boiler. Participation in a training course at KWB is recommended for safe and proper installation.
The Appendix includes installation guidelines, hydraulic diagrams, as well as connection and terminal diagrams, that help
the installation and service engineer with the installation and when servicing the system. Manuals for special accessories
are enclosed directly with the products.
When the documents were created they corresponded to the released development status of the products.
Our objective is to constantly improve our products and manuals – we would appreciate your comments and
suggestions!
KWB – Kraft und Wärme aus Biomasse GmbH
Industriestr. 235
A-8321 St. Margarethen an der Raab
Tel.: [phone]
Fax: [phone]
email: [email protected]
Internet: www.kwb.at
This symbol is used to highlight important information.
Version: 09/15/2008 – art. no.: 21-2000084
Subject to change. No responsibility accepted for errors and omissions!
© The information in this document is the property of KWB GmbH.
Any duplication, disclosure to third parties or usage for other purposes is subject to the owner’s written approval.

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 3
Content
INHALTSVERZEICHNIS
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 imposed on fuel storage rooms ................................................ 10
1.3.3 Chimney requirements ..................................................................................................... 11
2 SYSTEM INSTALLATION ........................................................................... 13
2.1 General information on installing the boiler system ............................... 13
2.1.1 Bringing the non-dismantled system into the set-up room ......................................... 13
2.1.1.1 Required installation tools .............................................................................................. 13
2.1.1.2 Taking the system off of the pallet ................................................................................. 14
2.1.2 Dismantling the system ................................................................................................... 16
2.1.2.1 Dismantling the vacuum conveyor unit .......................................................................... 16
2.1.2.2 Dismantling the boiler cladding ...................................................................................... 17
2.1.2.3 Preparation for dismantling the heat exchanger ............................................................ 21
2.1.2.4 Dismounting the container ............................................................................................. 22
2.1.2.5 Dismantling the burner ................................................................................................... 24
2.1.3 Assembling the system .................................................................................................... 25
2.1.3.1 Installing the burner ....................................................................................................... 25
2.1.3.2 Mounting the container and stoker drive ....................................................................... 26
2.1.3.3 Mounting the ash worm drive ........................................................................................ 27
2.1.3.4 Installation of the heat exchanger .................................................................................. 28
2.1.3.5 Installing the cladding .................................................................................................... 30
2.1.3.7 Installing the vacuum conveyor unit .............................................................................. 31
2.1.3.8 Installing the cladding/concluding tasks ........................................................................ 32
2.1.4 Smoke pipe connection and induced draft fan .............................................................. 33
2.1.5 Water connection .............................................................................................................. 33
2.1.5.1 Thermal safety valve connection: .................................................................................. 34
2.1.6 Electrical connection ........................................................................................................ 34
2.1.6.1 Power connection of the KWB system ......................................................................... 34
2.1.6.2 Junction box .................................................................................................................. 37
2.1.6.3 Cabling guidelines .......................................................................................................... 38
2.1.7 Control units & heating circuit expansion modules (HCM) ......................................... 40
2.1.7.1 Boiler control unit/digital room control unit (OPTION) .................................................... 40
2.1.7.2 Analogue room control unit (OPTION) ............................................................................ 40
2.1.8 Plug-in module 1 (OPTION) .............................................................................................. 41
2.1.8.1 Heating circuit 0 and /or second boiler switchover ....................................................... 42
2.1.9 Boiler master-and-slave circuit ....................................................................................... 42
2.1.10 Heating circuit expansion module (OPTION) ................................................................. 43
2.1.11 FE MODULE (OPTION) ...................................................................................................... 45
2.1.11.1 Installation ...................................................................................................................... 45
2.1.11.2 Electrical connection ...................................................................................................... 45
2.1.11.3 Power supply ................................................................................................................. 46
2.1.11.4 Fuel extractor motor ....................................................................................................... 46
2.1.11.5 Inputs ............................................................................................................................. 47
2.1.11.6 Connection variants ....................................................................................................... 47
2.1.11.7 System bus connection .................................................................................................. 47
2.1.11.8 Commissioning the FE module ....................................................................................... 48

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2.1.11.9 Station number switch ................................................................................................... 48
2.2.11.10 LED functions ................................................................................................................. 48
2.2.11.11 Troubleshooting .............................................................................................................. 48
2.1.12 Equipotential bonding ....................................................................................................... 49
2.1.13 Sensor check ..................................................................................................................... 50
2.2 Installing the fuel extractor ..................................................................... 51
2.2.1 Installing the fuel extractor Standard ............................................................................. 52
2.2.1.1 Components of the FE standard ..................................................................................... 52
2.2.2 Installation – FE trough Standard .................................................................................... 55
2.2.3 Installing the worm drive ................................................................................................. 57
2.2.4 Installation, inspection box, cover, and overfill protection .......................................... 59
2.2.5 Transfer sloping floor plane .............................................................................................. 62
2.2.6 Installing the articulated-blade rotary stirrer ................................................................. 62
2.2.7 Installing the spring-blade rotary stirrer ......................................................................... 64
2.3 FINAL INSPECTION .................................................................................. 65
3 COMMISSIONING .................................................................................... 67
3.1 Switching on the main switch ................................................................. 67
3.2 Setting the parameters ............................................................................ 67
3.3 Function check of the system parts ........................................................ 68
3.4 Switching on the system in the menu ..................................................... 68
4 OPERATION, SPECIALIST .......................................................................... 69
4.1 Menu item – Heating Circuits .................................................................. 69
4.1.1 Operating values ................................................................................................................ 69
4.1.2 Outdoor temperature dependent ..................................................................................... 71
4.1.3 Menu item – DHWC .......................................................................................................... 72
4.1.4 Menu item – Buffer ........................................................................................................... 72
4.1.5 Menu item – Boiler Program ........................................................................................... 72
4.2 Menu item – Basic Settings .................................................................... 73
4.2.1 Boiler temperature ............................................................................................................ 73
4.2.2 Return flow boost .............................................................................................................. 74
4.2.3 Mixer return flow boost .................................................................................................... 74
4.2.4 Fuel extractor ..................................................................................................................... 74
4.2.5 Fuel extractor fill time ....................................................................................................... 75
4.2.6 Pump afterrun .................................................................................................................... 75
4.2.7 Boiler pump ....................................................................................................................... 76
4.2.8 Language ............................................................................................................................ 76
4.2.9 Second boiler ..................................................................................................................... 76
4.2.10 Cleaning .............................................................................................................................. 76
4.2.11 Network settings ............................................................................................................... 77
4.2.11.1 Boiler .............................................................................................................................. 77
4.2.11.1.1 EXT 2 ......................................................................................................................... 77
4.2.11.1.2 Power output .............................................................................................................. 77
4.2.11.2 Heating circuit ................................................................................................................ 78
4.2.11.3 DHWC ............................................................................................................................ 78
4.2.11.4 Buffer ............................................................................................................................. 79
4.2.11.5 Digital remote control ..................................................................................................... 79
4.2.11.6 Power measurement ...................................................................................................... 79
4.2.12 Hardware ............................................................................................................................ 80
4.2.13 Frost protection ................................................................................................................. 80

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Content
4.2.14 Outputs: .............................................................................................................................. 81
4.2.15 Fan ....................................................................................................................................... 81
4.2.15.1 Primary ........................................................................................................................... 81
4.2.15.2 Secondary ...................................................................................................................... 81
4.2.16 Boiler output ...................................................................................................................... 82
4.2.17 Container side .................................................................................................................... 82
4.2.18 Ignition ................................................................................................................................ 82
4.2.19 Light barriers (only for USD) ............................................................................................ 82
4.2.20 Motor power ...................................................................................................................... 83
4.2.21 Serial number ..................................................................................................................... 83
4.2.22 Operating hours ................................................................................................................. 83
4.2.23 Control unit ......................................................................................................................... 84
4.2.23.1 Negative pressure .......................................................................................................... 84
4.2.23.2 Oxygen ........................................................................................................................... 84
4.2.23.3 Secondary air ................................................................................................................. 85
4.2.23.4 Boiler temperature ......................................................................................................... 85
4.3 Menu item – Relay Test ........................................................................... 86
4.3.1 Boiler ................................................................................................................................... 86
4.3.2 Heating circuits ................................................................................................................. 87
4.3.3 DHWC ................................................................................................................................. 87
4.3.4 Buffer .................................................................................................................................. 87
4.3.5 Fuel extractor ..................................................................................................................... 88
4.3.6 Second boiler ..................................................................................................................... 88
4.3.7 Supplemental fuel extractor ............................................................................................. 88
4.4 Menu item – Network Analysis ............................................................... 89
4.4.1 Overview ............................................................................................................................ 89
4.4.2 Boiler module ..................................................................................................................... 89
4.4.3 Heating circuit module ..................................................................................................... 89
4.4.4 Digital remote control unit ............................................................................................... 89
4.4.5 Fuel extractor module ....................................................................................................... 90
4.5 Menu item – Save/Reset ......................................................................... 90
4.6 Menu item – Measure Boiler ................................................................... 90
4.7 Menu item – Start/Stop Log ................................................................... 90
5 APPENDIX I ............................................................................................ 91
5.1 Dimension sheets ..................................................................................... 92
5.1.1 Installation dimensions KWB Multifire USV V 15–25 kW .......................................... 93
5.1.2 Installation dimensions KWB Multifire USV D 15–25, 30–60 and 80–100 kW .... 94
5.1.3 Installation dimensions KWB Multifire USV ZI 15–25, 30–60 and 80–100 kW ... 95
5.1.4 Installation dimensions KWB Multifire USV GS 40–60 and 80–100 kW ................ 96
5.1.5 Fuel extractor Ø 2.5 m–4 m (spring-blade rotary stirrer)_b ....................................... 97
5.1.6 Fuel extractor Ø 4 m–5.5 m (spring-blade rotary stirrer) ........................................... 97
5.1.7 Ascending worm with upward transfer unit ................................................................. 98
5.1.7.1 Ascending worm with drop shaft ................................................................................... 98
5.2 Hydraulic circuit diagrams ....................................................................... 99
5.2.1 Hydraulic wiring – boiler circuit return flow boost ....................................................... 100
5.2.2 Basic module with weather-sensitive control ............................................................... 101
5.2.3 Basic module with weather-sensitive control and combination buffer
as load-balancing buffer ................................................................................................... 103
5.2.4 Basic module with weather-sensitive control and expansion module ...................... 105

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Content
5.2.5 Basic module with weather-sensitive control and second boiler switchover .......... 107
5.2.6 Basic module with weather-sensitive control, one expansion module
and a long-term buffer ...................................................................................................... 109
5.2.7 Basic module with weather-sensitive control and KWB special buffer .................... 111
5.2.8 Basic module with weather-sensitive control and buffer in adjacent building –
expansion modules in the apartment buildings ............................................................ 113
5.3 Electrical diagrams (connection and cabling diagrams) ........................ 119
5.3.1 Connection diagram for heating circuit module (HCM) TDB-ELS-TYÜ-HCM_XL_a . 120
5.3.2 Bus cabling/EBAA1018g_15.7.2008 ............................................................................. 121
5.3.3 Cabling outputs heating circuit/EAAA1046c ................................................................ 122
5.3.4 Cabling inputs analogue and digital/ EBAA1047a ........................................................ 123
5.3.5 Power cabling 400 VAC/EBAA1047a ............................................................................ 124
5.3.6 Connection diagram I/O board/EAAA1054 ................................................................... 125
5.3.6.1 Without heating circuit .................................................................................................. 125
5.3.6.2 One heating circuit ......................................................................................................... 126
5.3.6.3 Two heating circuits ....................................................................................................... 127
5.3.6.4 Supplemental heating circuit .......................................................................................... 128
5.3.7 Connection diagram plug-in module 1/ second boiler/ vacuum /EAAA1206a .......... 129
5.3.8 Boiler master-and-slave circuit ELS-TYÜ-KFS-0001 ..................................................... 130
5.3.9 Fuel extractor module ....................................................................................................... 131
5.4 Chimney measurement ............................................................................ 132
5.5 Cross-section measurement .................................................................... 133
APPENDIX II .................................................................................................. 135
6 FUEL EXTRACTOR WITH UPWARD TRANSFER ............................................ 136
6.1 Components – FE with upward transfer ................................................. 136
6.2 Installing the cast-iron head .................................................................... 138
6.3 Floor assembly – fuel extractor trough (storage room) ......................... 139
6.4 Installing the transfer station (boiler room) ............................................ 140
6.5 Installing the worm bearings ................................................................... 141
6.6 Installing the ascending worm and fixing the FE in place ..................... 141
6.7 Installing the ascending worm drive ....................................................... 143
6.8 Installing the inspection box and trough cover ...................................... 145
7 DOUBLE FUEL EXTRACTOR (D-FE) ............................................................. 149
7.1 Components .............................................................................................. 149
7.2 Aligning the stirrer channel, installing the crossbeam and feet ............ 152
7.3 Installing the gear unit and drive shafts ................................................. 153
7.4 Installing FE troughs and fixing them in place in the storage room ...... 154
7.5 Installing the stirrer trough insulation and drive .................................... 156
7.6 Installing the fuel extractor drive ............................................................ 159
7.7 Open installation tasks – double FE ........................................................ 161
7.8 Cabling the double FE with common drive ............................................. 161
7.9 Final inspection ........................................................................................ 161

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Content
8 FUEL EXTRACTOR WITH FALL PIPE ........................................................... 163
8.1 Components of the FE with fall pipe ....................................................... 163
8.2 Contents of this installation manual ....................................................... 166
8.3 Installing the RA head piece, downward transfer .................................. 166
8.4 Cabling the FE with drop shaft ................................................................ 167
8.5 Open installation tasks ............................................................................ 167
8.6 Final inspection ........................................................................................ 167
9 FE WITH DOWNWARD TRANSFER AND ASCENDING WORM ....................... 169
9.1 Components of the FE .............................................................................. 169
9.2 Contents of this installation manual ....................................................... 173
9.3 Installing the ascending worm ................................................................ 173
9.4 Installing the fuel extractor trough ......................................................... 174
9.5 Installing the FE worm drive .................................................................... 174
9.6 Installing the ascending worm drive ....................................................... 175
9.7 Cabling ...................................................................................................... 175
9.8 Final inspection ........................................................................................ 175
10 FUEL EXTRACTOR PELLETS WITHOUT STIRRER .......................................... 177
10.1 Installing the pellet worm ........................................................................ 177
10.2 Divided pellet worm (over 6 m in length) ................................................ 177
10.3 Contents of this installation manual ....................................................... 177

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© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 9
Introduction
1 INTRODUCTION
1.1 Safety instructions
The KWB GmbH systems 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 and are a hazard source if not handled properly. Therefore installation, commissioning and
service should only be executed by sufficiently qualified specialists in compliance with all applicable regulations and
the manufacturer’s instructions. Knowledge with the operating and maintenance manual is prerequisite for performing
these tasks.
Important instructions or warnings are highlighted in this document with the hazard symbol and
must always be complied with.
1.2 Warranty
The manufacturer’s warranty specifies proper installation and commissioning of the boiler system as the prerequisite.
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 appendix), 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 is a prerequisite for the warranty.
KWB does not accept any liability, nor does it offer any warranty 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 for floor, walls, ceiling, must be fire-resistant in F90; boiler room door (see Tab. 1) executed as an
automatically closing fire protection door (T30) that opens in the direction of escape, connection door to the fuel storage
room executed as an automatically closing fire protection door (T30), boiler room windows non-opening G30; non-closing
air intake opening of 5 cm² per kW nominal power of the heating system, however at least 400 cm². For boiler output >
60 kW it is necessary to integrate one ventilation opening near the 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 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 inflammable
materials in the boiler room outside the boiler system, storage container or hopper; no direct connection to rooms where
inflammable gases or liquids (garage) are stored.

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Introduction
System dimensions for bringing the system into the boiler room in cm, width × height
(Door clearances must be at least 6 cm larger)
System type Dismantled Non-dismantled
USV 15/25 V 65 ×104 105 ×157
USV 30/40 V 72 ×129 105 ×183
USV 15/25 D/ZI 65 ×104 80 × 157
USV 30/40/50/60 D/ZI 72 ×129 88 × 183
USV 80/100 D/ZI 72 ×149 89 × 203
USV 40/50/60 GS 72 ×129 88 × 183
USV 80/100 GS 72 ×149 89 × 207
1.3.2 General requirements imposed on fuel storage rooms
The constructional on-site requirements for the boiler room
also apply to the fuel storage room. If it is possible to store
fuel volumes of 50 m³ and even more, a manually triggered,
portable fire extinguishing device must be connected to
a pressurized water line (from the boiler room), executed
as empty piping at least 3/4” or DN 20, must be installed
directly above the passage of the fuel extractor trough that
discharges in the fuel storage room. The armature must be
marked with the warning: “Fire extinguisher – fuel storage
room”. The stirrer is installed in the middle of the storage
room and is fastened to the concrete floor with anchor
screws. A rear-ventilated dead floor must be installed in
the same plane with the upper edge of the fuel extractor
trough. 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 chosen,
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 overpressure created during the filling process. Avoid
electrical installations in the fuel storage room; if this is
not possible, the electrical installations must be explosion
proof. For storage rooms in the utility outbuildings often
it is possible to dispense with F90 sheathing of the
fuel storage room. The fuel must be stored so that it is
separated (by wooden planking) from other goods, the
fire section or compartment must be less than 500 m².
Additional statutory safety and acceptance conditions
apply to storage rooms and silos that are continuously
suction-fed with shavings or grinding dust. Above-ground
fuel stores must be accessible to the outside by means
of a door with at least 1.80 m cross-section, and must be
planked to prevent the fuel from pouring out should the door
be opened by mistake. The planking should be removable
from the outside. A inspection opening (F90 lock-up) must
be installed above the fuel extractor trough. Comply with
the installation examples.
To avoid ignition sources, do not install lights, switches, outlets, or junction boxes in the fuel storage
room. If electrical installations are necessary they must be established in explosion-protected
design in accordance with the local applicable regulations.
For the size of the storage room, the following rules of thumb apply for average conditions (weather conditions,
detached house):
Fuel Wood chips 25 % water content,
30 mm, soft wood
Pellets 10 % water content
6 mm diameter
Storage space for 1 year = 3.7 m³ × Heat load = 0.7 m³ × Heat load in kW
Consumption for 1 year = 2 – 2.5 m³ × Heat load = 400 kg × Heat load in kW
Table 2: Rules of thumb for storage room size and fuel requirements