Twin Heat M20i-CS Safety guide

MANUAL FOR INSTALLATION
M20i-CS  M40i-CS  M80i-CS
Version 2.0 - May 2011
This manual should be read carefully before the installation commences!
How to assemble the plant.............................................................................page 1
Connection to the heating system..................................................................page 2
Connection of the auger from extern fuel silo.................................................page 3
Connection of the sprinkler.............................................................................page 3
Connection of the safety heat exchanger.......................................................page 4
(Only for boilers provided with safety heat exchanger)
Connection to the chimney.............................................................................page 4
Connection to the electrical net......................................................................page 5
Diagram 1 – How to fit the water cooled burner tube, (side) ..........................page 6
Diagram 1.1 – How to fit the water cooled burner tube, (rear)........................page 7
Diagram 2 – Connection to the heating system..............................................page 8
Diagram 3 – Connection of auger from extern fuel silo ..................................page 9
Diagram 4 – Connection to the chimney ......................................................page 10
Diagram 5 – Electrical diagram 400V – 3 phase ..........................................page 11
Diagram 5.1 – Electrical diagram 230V – 1 phase .......................................page 12
Starting up the boiler – See users manual section 2
Nørrevangen 7 DK-9631 Gedsted Phone [phone] Fax. [phone]
Mail: [e-mail] Web: www.twinheat.dk

1
MANUAL FOR INSTALLATION - M-CS
The installation of this plant must be made in accordance with the local rules and
regulations on the place of installation
Before the plant is placed on its final place it should be inspected carefully for
transport damages. Possible damages should be reported to the forwarder.
How to assemble the plant
The plant is delivered on 2 Euro pallets and consists of a boiler, a stoker and a
burner tube which must be assembled before installation.
1. The water cooled burner tube is fixed on the stoker unit by means of bolts
included. The gasket plus bolts for the fixation are included.
2. The stoker unit with the now fitted burner tube is pushed into the pre made hole
with flange in the boiler.
3. Before you fixate the stoker and burner tube to the boiler (with 2 bolts) you must
adjust the height of the stoker by means of 2 adjustment screws on the leg, that it
is placed horizontal and in a 90 º angle to the boiler. It is absolutely important, that
the water cooled burner tube is horizontals as you otherwise might experience air
pockets in the system.
4. The water cooling of the burner tube can now be installed as shown on diagram
1 and diagram 1.1 All parts included fittings and circulation pump are in the
accessories box included. (Please note, that the circulation pump is for circulation
between boiler and burner tube only)
5. The combustion fan is fitted on the square stud of the burner tube, no gasket
needed.
6. The hose for pressure equalising in the stoker is fitted on the stud on the burner
tube
7. The draft regulator, needed by manual heating, is fixed on the top of the boiler in
the same side as the door hinges for the combustion room door. The chain is
connected to the lower air inlet on the boiler.
8. The plug for power to the boiler is pushed in and secured by a screw. The cable is
placed in the tray underneath the plug. Cable W7 is for circulation pump.

2
INSTALLATION M-CS
The sketch indicates the recommended minimum distances in the boiler room.
According to Danish fire rules the room must be equipped with a ½ to ¾ inch high
pressure water tap and a ventilation opening, either as a window or as a ventilation
grill
Recommended minimum distances in the boiler room
(the stoker is placed at the right ore left side of the boiler)
Measures in cm
A
8012 20 1207 12020
10
10 20
20
160
160 160
16012
10 20
20
80
80
A
Recommended minimum distances in the boiler room
(the stoker is placed at the rear side of the boiler)
A B
C
C
B D
C
C
A B
B
D
Measures in cm
M20i-CS
M40i-CS
M80i-CS
M20i-CS
M40i-CS
M80i-CS
Connection to the heating system
See diagram 2
The boiler must be connected as shown in diagram 2 or as demanded by local
statutes.
Further information is in the users manual, section. 7
The minimum amount of water passing through the boiler must be (see table)
Plant type Nom. effect
[kW] Min. Amount of water [m³/h]
M20i 29 2,5
M40i 48 4,1
M80i 80 6,9
Water returning to the boiler must always be min. 60°C
If the above is not adhered to you will risk increased tear of the steel in the boiler,
resulting in a shorter life expectation for the plant.

3
INSTALLATION M-CS
According to Danish laws and regulations this boiler must be connected to a system
with “open” expansion tank. Please check you local regulations
General
The expansion tank must be able to contain at least 4 % of the total amount of water
in the heating system. Should the plant be installed with an accumulation tank, then
the expansion tank must be able to contain at least 8 % of the total amount of water
in the heating system.
The boiler must be in non blockage connection to the expansion tank (You must not
be able to block the pipe between)
Should the open expansion tank be placed in a not frost safe place, the tank itself
must be protected against frost. The circulation to the tank may be controlled by a
thermostatic valve or similar in order to secure, that the boiler water is getting
minimum access to oxygen.
Connection of auger from extern fuel silo
See diagram no 3
The auger must give a certain amount, compared to the boiler type. See table below.
If you try to enter an amount which lies outside the area listed in the table, the control
unit will write “Error in weight”. It is described in section 2 in the Users guide how to
weigh the fuel amount and key it into the control unit.
Permissible fuel amount for auger
Boiler type Auger Kg/min
M20i-CS 0,8 – 11,5
M40i-CS 1,4 - 19
M80i-CS 2,2 - 32
The connection must be made with a flexible hose. The auger must not support on
the stoker unit and vibrations from the auger must not be transmitted to the stoker
unit.
In case the plant is connected to a silo placed at the loft above you should also use a
flexible hose, which must be emptied after each filling. The hole through the ceiling
must be made fire-proof.
Connection of the sprinkler
The sprinkler system for the boiler must be under constant water pressure from a ½
inch tap with a safety faucet and be connected to the dirt collector under the pressure
tank.
Please make sure, that pipes / hoses are free of dirt or metal shavings.
You must test the system, when it has come under pressure.
The easiest way to test the sprinkler system is to unscrew the hose from the
thermostatic valve to the auger channel. Then press the red cap under the valve to
activate it
After testing the sprinkler system it is important to check that the valve is closing
properly! (Dirt ore the like, in the valve seat, can prevent this)

4
INSTALLATION M-CS
Connection of the safety heat exchanger (Quenching coil)
(only for boilers provided with safety heat exchanger)
The boiler has a build-in safety
heat exchanger which cools the
boiler in case of pump failure or
the like. The system will be
activated if the water
temperature in the boiler
exceeds 95°C.
The thermal safety valve must
be connected to constant water
pressure from a G¾”/22mm
pipe. The water pressure must
be minimum 2 bar and the
temperature maximum 15°C
There must be no shutoff valves
on the pipe supplying the valve.
Flush the pipes before
connecting to the thermal safety
valve. Dirt or metal shavings
can cause the valve to
malfunction.
The return drain from the safety heat exchanger G¾” must be connected to a drain.
The pipe used to connect to the drain must have a sufficient size to avoid the
emergence of backpressure.
After installation the system must be tested to ensure free passage trough the safety
heat exchanger. The thermal safety valve can be manually activated by pressing the
red cap.
Connection to the chimney
See diagram 4
Further information is in the users manual, section. 7
In order to get a good heating economy and to avoid smoke problems you must
connect the boiler to a suitable chimney. The boiler should be placed as close to the
chimney as possible.
Should the chimney be too unsuitable or under difficult draft conditions you might
have to install a flue fan.
It is in general recommended to install a draft stabilizer (See diagram 4)
A chimney with unstable draft can case unstable running conditions of the plant.
Thermal safety valve - 95°C
Supply cold water for
quenching coil
Temperature sensor
for thermal safety valve
Drain from quenching coil

5
INSTALLATION M-CS
It is important that the flue pipe is insulated with a 30mm fire resistant mat, to
avoid that the flue gasses are condensing in it.
.
Recommended chimney dimensions.
Plant
type Max. effect, input Flue outlet on boiler Free opening in chimney Height of chimney
M20i 34 kW. Ø 155 mm Ø 160-180 mm 5-6 metre
M40i 55 kW. Ø 187 mm Ø 180-200 mm 5-8 metre
M80i 92 kW. Ø 215 mm Ø 200-250 mm 6-8 metre
Connection to the electrical net
See diagram no 5 / 5.1
The boiler can be built for both 400V 3 phase and 230V single phase connection.
Check boiler data plate for electrical connection.
In Denmark the installation must be made by an authorised electrician. Here too we
ask you to check your local regulations
Electrical supply for the stoker plant:
There should be specific switch for this plant only
Electrical supply for the internal circulation pump:
The internal circulation pump (placed under the burner tube) is connected to cable
W7.
The pump must not be started before filled with water, as this might damage it.
Setting of the internal circulation pump:
The pump must be set to run in a fixed step. It must not run in Auto mode!
Boiler Pump step
M20i I
M40i I
M80i II
The connection of start – stop signal for auger from extern silo:
See diagram no 5
The motor protection relay (contact) for the external auger must be supplied with a
230V start – stop signal from the controlling unit of the plant.

6
DIAGRAM 1
Diagram 1 - How to fit the water cooled burner tube by plants
with stoker placed at the side of the boiler

7
DIAGRAM 1.1
Diagram 1.1 - How to fit the water cooled burner tube by plants
with stoker placed at the rear end of the boiler

8
DIAGRAM 2
Diagram 2 – Connection to the heating system
Open expansion vessel EÅ
shutoff valve V1-V2 shutoff valves on supply and return, in the boiler
room. More can be installed if needed.
3 way thermostat
controlled mixing valve
(shunt valve) V3 Boiler shunt valve secure that the return water to the
boiler always is over 60°C.
Manuel regulation valve
(return valve) V4 To protect open expansion vessel against frost
Can be thermostatic return valve
Airing V5 Airing, possible automatic, placed where needed.
Thermometer T1-T4
Thermometer for supply, water return before and
after shunt valve and for flue temperature
Temperature sensor TF1 Temperature sensor to regulate shunt valve.
Manometer M1 Manometer for boiler pressure.
Pump P1 Circulation pump for heating system

9
DIAGRAM 3
Diagram 3 – connection of the external auger

10
DIAGRAM 4
Diagram 4 – Connection to the chimney
*Prefabricated module chimneys should not be placed on top of the flue outlet,
as this allows rainwater or possible condense water to run directly down into the
heat exchanger of the boiler, where it will cause corrosion !
Brick-build or block-build chimney
*Module chimney with steel or ceramic liners
Insulated tee module with
draft stabilizer
Insulated tee module with
clean out
Wall support
Draft stabilizer mounted
in chimney
Clean out
Draft stabilizer mounted
on flue pipe
Clean out
Brick-build or block-build chimney
Elbow with clean out hole
*Module chimney with steel or ceramic liners
Insulated tee module with
clean out
Elbow with clean out hole
Draft stabilizer mounted
on flue pipe
Wall support
Insulation
Insulation

11
DIAGRAM 5
Diagram 5 – Electrical diagram 400V – 3 phase
Power Supply
3 x 400V AC
+ N + PE
El-Diagram 3x400V AC + N +PE TWIN HEAT
JE776
24VAC
NW3
W1 NU1 V1
NW4
JP3
NW5
12VAC
0V
White
Orange
Red
Pink
Blue
Brown
Grey
Black
Blue
Yellow/
Green
Black
White
Brown
F1
4AT
F4
315mAT
F3
315mAT
NW2
L1 L2 L3
N
12VDC
12VAC
0VDC
0VAC
M
Cirkulation
Pump
Burner
Transformer
19.11.2007 AaS
L1 L2 L3
T1 T2 T3
A1
A2
13
14 0VAC
24VAC
Blower
49
50
51
X12
22
23
X4
O2 +Signal
O Volt Signal
0V AC
Black
Grey
78
56
7856
Lambda Probe
High Temperatur
Watertemp
Contaktor
Siloauger/Doseauger
X3
24
12V AC
25
26
28
27
29
30
32
31
12
34
12 34
NTC
X5
12VDC
0VDC
White
41
42
44
43
45
46
X1
0
5
6
4
8
9
7
11
12
10
13
1
2
3
X6
0-10 VDC
15
16
14
18
19
17
21
20
X11
Stok
er
Moto
r
U2
N2
U
X7
W
V
N
U1
W1
V1
X8X9X1
12VAC
12VAC
0VAC
33
34
36
35
37
38
40
39
X2
blå
gul
0VAC
24VAC
24VAC
Alarm
0VDC
12 VDC
L1 L3L2
A1 A21411
N4A
K1
White
F2
4AT
Black
White
Brown
Blue
Yellow/
Green
TH2006 O2 Controller M20-80 CSi
24VAC
W
NPE
VU

12
DIAGRAM 5.1
Diagram 5.1 – Electrical diagram 230V – 1 phase
PowerSupply
1x230VAC
+N+PE
Electrical-Diagram1x230AC+N+PE TWINHEAT
JE776
24VAC
N
W3
W1N
U1V1
N
W4
JP3
NW5
12VAC
0V
White
Orange
Red
Pink
Blue
Brown
Grey
Black
Blue
Yellow/
Green
Black
White
Brown
F1
4AT
F4
315mAT
F3
315mAT
N
W2
N
12VDC
12VAC
0VDC
0VAC
M
Cirkulation
Pump
Burner
Transformer
09.01.12MM
L1L2L3
T1T2T3
A1
A2
13
140VAC
24VAC
Blower
49
50
51
X12
22
23
X4
O2+Signal
OVoltSignal
0VAC
Black
Grey
7856
7856
Lambda
Probe
HighTemperatur
Watertemp
X3
24
12VAC
25
26
28
27
29
30
32
31
12
34
1234
NTC
X5
12VDC
0VDC
White
41
42
44
43
45
46
X10
5
6
4
8
9
7
11
12
10
13
1
2
3
X6
0-10VDC
15
16
14
18
19
17
21
20
X11
U2
N2
U
X7
W
V
N
U1
W1
V1
X8
X9
X1
12VAC
12VAC
0VAC
33
34
36
35
37
38
40
39
X2
blå
gul
0VAC
24VAC
24VAC
Alarm
0VDC
12VDC
A1
A2
14
11
White
F2
4AT
Black
White
Brown
Blue
Yellow/
Green
TH2006M20-80CSiInverter
UVW
PE
L1N
0.55k
W
24VAC
1236
Inverter
Steeringbox
Stoker-motor
Stoker
Motor
1114
A1
A2
230VAC
L1N
Contaktor
Siloauger/Doseauger
K1