Twin Heat M20i Safety guide

MANUAL FOR INSTALLATION
M20i  M40i  M80i
Version 1.5 – May 2011
This manual should be read carefully before the installation commences!
How to assemble the plant.............................................................................page 2
Connection to the heating system..................................................................page 4
Connection of the sprinkler.............................................................................page 4
Connection of the safety heat exchanger.......................................................page 5
(Only for boilers provided with safety heat exchanger)
Connection to the chimney.............................................................................page 6
Connection of the external auger ...................................................................page 6
(Only for plants provided with automatic fill in)
Connection to the electrical net......................................................................page 7
Diagram 1 – How to fit the water cooled burner tube, boiler side...................page 8
Diagram 1.1 – How to fit the water cooled burner tube, boiler rear ................page 9
Diagram 2 – Connection to the heating system............................................page 10
Diagram 3 – Connection to the chimney ......................................................page 11
Diagram 4 – Connection of the external auger.............................................page 12
(Only for plants provided with automatic fill in)
Diagram 5 – Electrical diagram 400V – 3 phase 500&700 l fuel store..........page 13
Diagram 5.1 – Electrical diagram 230V – 1 phase 500&700 l fuel store.......page 14
Diagram 5.2 – Electrical diagram 400V – 3 phase 1400 l fuel store.............page 15
Diagram 5.3 – Electrical diagram 230V – 1 phase 1400 l fuel store.............page 16
Diagram 6 – Electrical diagram, start-stop signal for external auger ...........page 17
(Only for plants provided with automatic fill in)
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

2
INSTALLATION
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
You should not fit any parts of the permanent buildings installations onto this
plant, as this inconveniences later service and repair work.
The plant is delivered on 2 Euro pallets and consists of a boiler, a fuel store and a
burner tube, which must be assembled before installation.
Fuel store can either be type 500/700 litre or type 800/1400 litre.
800/1400 litre fuel store must be sealed in the joint between lower and upper part.
Unscrew the 4 bolts in the joint and the clamp holding the pressure equalising pipe,
and then lift the upper parts app. 20mm up. Seal the joint with the included sealing
compound. Lift the upper part down again and mount all 48 bolts
1. The water cooled burner tube is fixed on the fuel store by means of bolts included.
The gasket for the flange is under the fuel store lid.
2. The fuel store with the now fitted burner tube is pushed into the pre made hole
with flange in the boiler.
3. Before you fixate the fuel store and burner tube to the boiler (with 2 bolts) you
must adjust the height of the fuel store by means of the 4 adjustment screws on
the legs, so 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 horizontal as you
otherwise might experience air pockets in the system.
(By 800 and 1400 litre fuel store, mount wheels under fuel store and adjust
height.)
4. The water cooling of the burner tube can now be fitted as shown on diagram 1.
or diagram 1.1, depending on plant layout. All parts including 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 on the side of the burner tube, no
gasket needed.
6. The hose for pressure equalising in the fuel store is fitted on opposite square stud
on 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 the circulation pump.
9. Only by 500/700 fuel store: If you want to use a fuel which is likely to build
bridges* in the fuel store you must fit the included chain and the stirrer wings
(according to demand). See enclosure 1 in Users manual (* wood chips,
sawdust, wood shavings and the like)

3
INSTALLATION
The sketches indicate the recommended minimum distances in the boiler room.
The boiler 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
E
A
Recommended minimum distances in boiler room (seen from above)
Stoker inlet on side of boiler with 500 or 700 litre fuel store
All dimensions in centimetres
C
B
F
EA
C
B
F
Flue outlet spigot
80
D
D
4040
Flue outlet spigot
Recommended minimum distances in boiler room (seen from above)
Stoker inlet on rear of boiler with 500 or 700 litre fuel store.
All dimensions in centimetres
E
A
Recommended minimum distances in boiler room (seen from above)
Stoker inlet on side of boiler with 800 or 1400 litre fuel store
All dimensions in centimetres
C
B
F
EA
C
B
F
Flue outlet spigot
80
D
D
40
40
Flue outlet spigot
Recommended minimum distances in boiler room (seen from above)
Stoker inlet on rear of boiler with 800 or 1400 litre fuel store.
All dimensions in centimetres
5
Dimensions Clerance Recommended
size of boiler room
M20i
M40i
M80i
ABCDEF
265
290
350
116 120 7 312 220
164 160 10 337 290
171 160 10 397 320
Dimensions Clerance Recommended
size of boiler room
M20i
M40i
M80i
ABCDEF
285
350
380
77 120 12 445 169
77 160 12 550 169
96 160 10 580 186
Dimensions Clerance Recommended
size of boiler room
M20i
M40i
M80i
ABCDEF
272
297
357
140 120 7 319 254
164 160 10 347 311
171 160 10 407 311
Dimensions Clerance Recommended
size of boiler room
M20i
M40i
M80i
ABCDEF
304
371
407
121 120 7 453 208
121 160 10 561 211
133 160 10 591 223

4
INSTALLATION
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 user 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]
M 20i 29 2,5
M 40i 48 4,1
M 80i 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.
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 must be
controlled by a thermostatic valve or similar in order to secure, that the boiler
water is getting minimum access to oxygen.
Connection of the sprinkler
The sprinkler system on the fuel store 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)
By an extended auger channel (750 mm) we deliver the sprinkler system
separately. The sprinkler including pressure tank must be fitted on the wall next
to the auger channel.

5
INSTALLATION
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.
Thermal safety valve - 95°C
Supply cold water for
quenching coil
Temperature sensor
for thermal safety valve
Drain from quenching coil

6
INSTALLATION
Connection to the chimney
See diagram 3
Further information is in the user 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 3)
A chimney with unstable draft can case unstable running conditions of the plant.
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 of the external auger
(Only for plants provided with automatic fill in)
See diagram no 4
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.

7
INSTALLATION
Connection to the electrical net
See diagram no 5 / 5.1
The boiler can be built for either 400V 3 phase or 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 a specific switch for this plant only
Electrical supply for the internal circulation pump:
The internal circulation pump (placed under the burner tube) is to be connected
to cable no. 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
Extended auger channel
If you request an extended auger channel, we supply the control as a separate
unit to be fitted on the wall above the auger channel, in the boiler room.
Check cable length before you decide where to place the control
Connection of start – stop signal for external auger:
(Only for plants provided with automatic fill in)
See diagram no 6
The motor protection relay (contact) for the external auger must be supplied
with a start – stop signal from the controlling unit of the plant, which is placed in
a plastic box at the side of the fuel valve, on top of the fuel store.

8
DIAGRAM 1
Diagram 1 - How to fit the water cooled burner tube by
plants with stoker placed at the side of the boiler
By M40 is included a 3/4" connection sleeve
Elbows and valves are to
be placed horizontal, to
avoid airpockets in the
hoses!
Connection for sprinkler
Hose for pressure
equalising pipe
Fan (no gasket)
Draft regulator Supply boiler
Boiler Burner-
Fuel store
tube
Included fittings
2 pcs. ¾" hose
1 pcs. ¾" safety valve
2 pcs. ¾" shutoff valve
1 pcs. ½" shutoff valve
1 pcs. cirkulation pump
5 pcs. ¾" hexagon nipple
1 pcs. ¾" ¾" ½" tee
1 pcs. 1" ¾" hexagon nipple
1 pcs. ¾" tee
2 pcs. ¾" elbow
2 pcs. ¾" union joint for pump

9
DIAGRAM 2
Diagram 1.1 - How to fit the water cooled burner tube by
plants with stoker placed at the rear end of the boiler
Elbows and valves are to
be placed horizontal, to
avoid airpockets in the
hoses!
Included fittings
2 pcs. ¾" hose
1 pcs. ¾" safety valve
1 pcs. cirkulation pump
2 pcs. ¾" union joint, for pump
2 pcs. ¾" shutoff valve
1 pcs. ½" shutoff valve
5 pcs. ¾" hexagon nipple
1 pcs. ¾" tee
1 pcs. ¾" x ¾" x ½" tee
1 pcs. ¾" plug
M20: ¾" x 1" hexagon nipple
M40: ¾" x 1½" hexagon nipple
M80: ¾" x 2" connection nipple + ¾" hexagon nipple
Connection for sprinkler
Hose for pressure
equalising pipe
Fan (no gasket)
Draft regulator Supply boiler
Boiler
Burnertube
Fuel store

10
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

11
DIAGRAM 3
Diagram 3 – Connect 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

12
DIAGRAM 4
Diagram 4 – Connection of the external auger
(only for plants provided with automatic fill in)
Fuel from silo placed at
the loft above
Automatic fire damper
closes incase of fire in the
boiler room
Flexible hose
Fuel Valve
Fuel from external silo
Flexible hose
Fuel valve
The auger must not support on the stoker
unit and vibrations from the auger must
not be transmitted to the stoker unit.

13
DIAGRAM 5
Diagram 5 – Electrical diagram 400V – 3 phase 500&700
fuel store
Cont akt or Saf et y
24
15
16
14
18
19
17
21
20
5
6
4
8
9
7
11
12
10
13
1
2
3
33
34
36
35
37
38
40
39
12VAC
Whi t e
Whi t e
U2
N2
U
W
V
N
Condensat or
U1
W1
V1
Relay Belimo motor
Relay Sil o auger
24VAC
W1NU1 V1
L1 L2 L3
T1 T2 T3
JP3
NW5
12VAC
0V
whit e
orange
rød
lysrød
F1 4AT
F3
315mAT
F2
4AT
NU3
WVUN
A1
A2
Silo-auger
12VDC
0VAC
12VAC
12VAC
0VDC
AC-1
0VAC
24VAC
0VAC
12VDC
12VDC
Cont akt
Belimo
Capaci t ive
sensor
Brown
Whit e
Bl ue
AC-GND
22
23
O2 + Signal
OV Si gnal
0VAC
Black
Grey
Hot boiler t hermost at
LidSafety-Switch 25
26
28
27
29
30
32
31
41
42
44
43
45
46
Boiler t emp sensor
NTC
12VDC
12VDC
24VAC
Capacitive
sensor

14
DIAGRAM 5.1
Diagram 5.1 – Electrical diagram 230V – 1 phase 500&700
fuel store
Power Supplay
1 x 230V AC
+ N + PE
El-diagram 1 x 230VAC + 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
Brown
White
Black
F1
4AT
F4
315mAT
F3
315mAT
F2
4AT
NW2
L1
N
12VDC
12VAC
0VDC
0VAC
M
Cirkulations
pump
Burner
Trafo
09.01.2012 MM
L1 L2 L3
T1 T2 T3
A1
A2
13
14
Blower
22
23
X4
O2 +Signal
O Volt Signal
0V AC
Black
Grey
78
56
7856
Lambda Sonde
High Tempartur
Watertemp
X3
24
12V AC
White
25
26
28
27
29
30
32
31
12
34
12 34
NTC
X5
White
41
42
44
43
45
46
X10
5
6
4
8
9
7
11
12
10
13
1
2
3
X6
15
16
14
18
19
17
21
20
X11
U2
N2
U
X7
W
V
N
U1
W1
V1
X8X9X1
12VAC
12VAC
0VAC
33
34
36
35
37
38
40
39
X2
24VAC
Alarm
0VDC
12 VDC
TH2006 M20-80 Inwerter
NPE
WVU
White
Black
Brown
Blue
Yellow/
Green
1236
Inverter
11 14
A1
A2
Steering box
Stoker-
motor
230VAC
Stoker
Motor

15
DIAGRAM 5.2
Diagram 5.2 – Electrical diagram 400V – 3 phase 1400 fuel
store
Contaktor Safty
24
15
16
14
18
19
17
21
20
5
6
4
8
9
7
11
12
10
13
1
2
3
33
34
36
35
37
38
40
39
12V AC
Hvid
Hvid
U
W
V
N
24VAC
W1 NU1 V1
L1 L2 L3
T1 T2 T3
JP3
NW5
12VAC
0V
white
orange
rød
lysrød
F1
4AT
F3
315mAT
F2
4AT
NU3
WVUN
A1
A2
12VDC
12VAC
12VAC
0VDC
AC-1
0VAC
0VAC
AC-
GND
22
23
O2 +Signal
O Volt Signal
0V AC
Sort
Grå
Hot Bolier sensor
Lid Safety Switch 25
26
28
27
29
30
32
31
41
42
44
43
45
46
Bolier tempsensorNTC
12VDC
12VDC
U2
N2
Condensator
U1
W1
V1

16
DIAGRAM 5.3
Diagram 5.3 – Electrical diagram 230V – 1 phase 1400 fuel
store
Power Supplay
1 x 230V AC
+ N + PE
El-diagram 1 x 230VAC + 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
Brown
White
Black
F1
4AT
F4
315mAT
F3
315mAT
F2
4AT
NW2
L1
N
12VDC
12VAC
0VDC
0VAC
M
Cirkulations
pump
Burner
Trafo
09.01.2012 MM
L1 L2 L3
T1 T2 T3
A1
A2
13
14
Blower
22
23
X4
O2 +Signal
O Volt Signal
0V AC
Black
Grey
78
56
7856
Lambda Sonde
High Tempartur
Watertemp
X3
24
12V AC
White
25
26
28
27
29
30
32
31
12
34
12 34
NTC
X5
White
41
42
44
43
45
46
X10
5
6
4
8
9
7
11
12
10
13
1
2
3
X6
15
16
14
18
19
17
21
20
X11
U2
N2
U
X7
W
V
N
U1
W1
V1
X8X9X1
12VAC
12VAC
0VAC
33
34
36
35
37
38
40
39
X2
24VAC
Alarm
0VDC
12 VDC
TH2006 M20-80 Inwerter 1400L
NPE
WVU
White
Black
Brown
Blue
Yellow/
Green
1236
Inverter
11 14
A1
A2
Steering box
Stoker/
Rotor-
motor
230VAC
Stoker
Motor
Rotor
Motor

17
DIAGRAM 6
Diagram 6 – Electrical diagram, Start – stop signal for
external auger
(Only for plants provided with automatic fill in)