KWB Multifire 15 - 100 kW

Heating System for Wood chips

and Pellets
Installation and Maintenance Manual Biomass Heating Systems

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 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.: +43 (0) 3115 6116-0
Fax: +43 (0) 3115 6116-4
email: office@kwb.at
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.

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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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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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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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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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 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 or filtration of the transport air is the responsibility of the
also apply to the fuel storage room. If it is possible to store fuel supplier. The walls, windows and doors must withstand
fuel volumes of 50 m³ and even more, a manually triggered, the overpressure created during the filling process. Avoid
portable fire extinguishing device must be connected to electrical installations in the fuel storage room; if this is
a pressurized water line (from the boiler room), executed not possible, the electrical installations must be explosion
as empty piping at least 3/4” or DN 20, must be installed proof. For storage rooms in the utility outbuildings often
directly above the passage of the fuel extractor trough that it is possible to dispense with F90 sheathing of the
discharges in the fuel storage room. The armature must be fuel storage room. The fuel must be stored so that it is
marked with the warning: “Fire extinguisher – fuel storage separated (by wooden planking) from other goods, the
room”. The stirrer is installed in the middle of the storage fire section or compartment must be less than 500 m².
room and is fastened to the concrete floor with anchor Additional statutory safety and acceptance conditions
screws. A rear-ventilated dead floor must be installed in apply to storage rooms and silos that are continuously
the same plane with the upper edge of the fuel extractor suction-fed with shavings or grinding dust. Above-ground
trough. If a pumping car is used to fill the fuel storage room fuel stores must be accessible to the outside by means
with wood chips or pellets, it is necessary to install hose of a door with at least 1.80 m cross-section, and must be
couplings and pipelines (that must be earthed). These planked to prevent the fuel from pouring out should the door
are available from KWB. If this filling method is chosen, be opened by mistake. The planking should be removable
dustproof sealing of the fuel storage room is required. The from the outside. A inspection opening (F90 lock-up) must
escaping air is removed through a second earthed pipeline be installed above the fuel extractor trough. Comply with
and hose coupling, or it is blown off into the open air after the installation examples.
having passed through a filtering section. Suction removal

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):

Wood chips 25 % water content, Pellets 10 % water content

Fuel
30 mm, soft wood 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

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 Introduction

1.3.3 Chimney requirements

Due to the high boiler efficiency rate, the chimney design aid, if the site conditions are not less favourable than
should be executed so that it is resistant to moisture. the conditions specified in the cross-section diagrams.
A moisture-resistant chimney design means that there will If conditions differ, or if conditions are less favourable in terms
be no moisture penetration or damage to the brickwork of space, it is necessary to execute a chimney calculation in
although the temperature level in the flue-gas path accordance with EN 13384. The boiler parameters required
remains permanently below the flue-gas dew point (see for the calculation are specified in the technical boiler data.
DIN 18160)! A data entry sheet is available as an electronic form from
The guide values for chimney diameter are specified in the KWB (see Appendix). Upon request, KWB will provide the
technical data (see operating manual, point 8). They are valid chimney calculation based on the information provided on
for the applicable system size, given average constructional the form. This is a chargeable service. The local expert
conditions, i.e.: Effective chimney height 8 – 10 m, smoke- for these issues is your responsible chimney sweep. It is
pipe length 2.50 m, 2 90° segment bends, 1 contraction, advisable to involve the chimney sweep during the planning
1 T‑connection at 90°. The cross-section diagrams provided phase as he is the one who will have to issue the acceptance
by the chimney manufacturer can serve as a quick reference certificate for the flue gas system.

Fig. 1: Flue gas pipes Fig. 2: Chimney example

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 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.

2.1 General information on installing the boiler system

The system is delivered ready to be plugged-in and can be directly brought into the set-up room.
Caution: The system is extremely heavy and can easily tip over due to the high centre of gravity!
Ensure that the route is level and the substrates are stable. Strictly ensure that you have implemented measures to
prevent unintentional slipping.
Protect the transport paths from damage – place panels on tile floors. Use the required personal protective equipment,
e.g. steel-toed shoes, gloves, etc.

2.1.1 Bringing the non-dismantled system into the set-up room

System dimensions are provided on page 10. If the required height is not available you can take the pallet out and place
the boiler directly on the lift truck. Pay attention to the slipping hazard. Use rubber pads.

2.1.1.1 Required installation tools

• Lifting aid for systems from15 to 100 kW

Fig. 3: Lifting aid USV 15 – 100

Art no. 07-1000091

• Hoisting winch (2-tons) for system, system, parts, fuel extractor, etc.
• Fork lift truck
• Hand tools
• One-hand angle grinder
• Cordless screwdriver
• Erection bar
• Jack hammer
• Hammer drill

Fig. 6: Hoisting winch (2-tons)

Art no. 18-1000046

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 2 System installation

2.1.1.2 Taking the system off of the pallet

The substrate must be stable and load-bearing! It should be horizontal and level. Place the system precisely in its final
position. For all the following steps bear in mind that there is a hazard of tipping and slipping!
Dismount the transport safeguards for the feet
of the system.

Fig. 7: Boiler foot mounting

Slide the lifting aid over the ash removal
pipes.

Fig. 8: Position the lifting aid

Lift carefully!
Danger of tipping and slipping!

Use the hoisting winch to lift the system

1 to 2 cm.

Fig. 9: Lift the system 1

Lift carefully!
Danger of tipping and slipping!

Also lift the system 1 to 2 cm on the container

side.
Use the fork lift truck.

Fig. 10: Lift the system 2

Lift carefully!
Danger of tipping and slipping!

Lift the system simultaneously with hoisting

winch and fork lift truck until the pallet is free.
Remove the pallet.

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 2 System installation

Bringing the system into a set-up room with low room height or low door height.

Place squared timber (8 × 8 cm) under the

boiler feet and container feet.
Lower the system.

Place a non-slip mat on the forks of the

lift truck!
>
Fig. 12: Jack up the system

Danger of tipping and slipping!

Carefully lift the system as shown.

Place the system precisely in its
­final position.

Place the elements (rubber substrate and

sheet metal) under all adjustable feet for
acoustic decoupling
Lower the system.

Use all of the adjustable feet to align the

system.
Fig. 13: Lower the system

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 2 System installation

2.1.2 Dismantling the system

The system can be dismantled if it is only possible to bring into the set-up room via passages that are too narrow or
difficult.
Dismantle as little of the system as possible! (It is possible that specific steps will not apply for different models)

2.1.2.1 Dismantling the vacuum conveyor unit

Dismantle the cladding of the vacuum conveyor

unit.

Loosen the screws of the front cover (Detail A).

Flip up the front cover and unhook it.

Do not subject the cables to tension!

Detail A

Unplug the plug-in connector of the vacuum

conveyor unit from the I/O board.
Thread the cable through the cable bushing.

Loosen the screws on the floor of the bracket of

the vacuum conveyor unit.

Attention danger of tipping!

Lift off the console with the vacuum tank.

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 2 System installation

2.1.2.2 Dismantling the boiler cladding

Only for 80 / 100 kW systems.

Loosen the screw on the lid of the cover of the

cleaning system motor (Detail A).

Detail A

Unscrew the cap and the nut of the safety

thermostat (Detail B).

Fig. 15: Cladding cleaning system motor Detail B

Lift up the cover and pull it off to the front.
Place the box with the safety thermostat to
the side.

Fig. 16: Remove the cover

Loosen the nuts (Detail C).
Lift the cladding lid off from the top.

Detail C

Fig. 17: Remove the cladding cover

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 2 System installation

Loosen the screws of the front cover (Detai lA).

Flip up the front cover and unhook it. Unplug
the cable of the boiler control unit on the
I / O board (Detail B).

Detail A

Fig. 18: Taking off the front cover

Loosen the screws of the side covers and
remove them (Details C and D).
Remove the screws on the intermediate
cladding for the tank (lower left and right, Detail B
Detail E).

Fig. 19: Take off the side sheet metal

Take off all covers. Now remove the hose of Detail C
the extinguishing water tank.
Open the clip on the thermal valve (Detail F)
and pull off the hose.

Detail D

Fig. 20: Open the intermediate cladding

Detach the cable ties on the strain relief comb
(Detail G) and unplug all cables from the
I / O board. Detail E
Carefully pull the cabling downward and roll
it together.

Detail F

Fig. 21: Disconnect the I/O board cable

Detail G

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 2 System installation

Open the cladding door.

First loosen the upper hinge, then loosen the
lower hinge (Detail A).

For 15 / 25 kW systems you must only loosen

the upper hinge.
Detail A
Unhook the door from the top.

Fig. 22: Remove the cladding door

Loosen the screws of the upper and lower
front cladding (Detail B). Lift off the front
cladding parts individually.
Detail B
For the 15 / 25 kW systems the cladding
parts are fastened on top on the boiler plate
(Detail F).
For systems from 30 kW the cladding parts
are on the base plate and are bolted on top on
opposite sides.

Detail C
Fig. 23: Take off the front wall
Remove the caps on the rear wall (Detail D).
Remove the screws (Detail E). Dismount the
sensor of the ash container.
Remove the side cladding.
Detail D

Detail E
Fig. 24: Take off the side cladding
Remove the induced-draft plug-in connector
on the rear wall (Detail G). Tip the rear wall
back and lift it off.

Detail F

Detail G

Fig. 25: Take off the rear wall

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Loosen the screws of the insulating cover

(Detail A, B).

(From 30 kW)
Take off the insulating cover

Lift the side wall with the intermediate

cladding up and off. Detail A

Fig. 26: Dismount the interm. cladding. Detail B

Take off the cabling on the heat exchanger.
Unhook the retaining springs of the insulating
mat and put the mat down (Detail C).
Take the insulating plates from the substructure
(Detail D).

Detail C

Detail D
Fig. 27: Boiler cladding dismantled
Decide whether you must dismantle more of
the system!

1. Dismantling the heat exchanger:

Eye bolts for chain suspension tackle are
provided for this purpose (Detail E). Alter- Detail E
natively you can also use an assembly dolly
(Detail F).

Attention danger of tipping!

2. Dismantling the stoker container

2.a Dismantling the burner.

Detail F
Fig. 28: Insulation removed

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 2 System installation

2.1.2.3 Preparation for dismantling the heat exchanger

Open the clip on the branch neck of the secondary
air hose.
Pull the hose down (Detail A).

To 60 kW:
The secondary air hose is routed directly upward on
the heat exchanger.

Take the post-combustion dome out of the

combustion chamber (Detail B).
Lift the post-combustion ring upward and take it out Detail A
(Detail C).

Loosen the screw of the fuel bed sensor (Detail D).

Take out the sensor (Detail E).
Fig. 29: Take off the air channel (80/100)

Detail B

Loosen the screws on the boiler floor.

Detail C

Fig. 30: Loosen the boiler screws

To 60 kW:
The cleaning system motor can be dismounted.

From 80 kW: Detail D

Cleaning system motor and flange can be
dismounted.

Loosen the screws on the motor flange (Detail F).

Loosen the drive chain: Detail E

– Slide the motor
or
– Open the master link of the drive chain.

Loosen the set screw on the chain wheel and pull it

off with a puller (Detail G).

Fig. 31: Dismantling the cleaning Detail F

system motor

Detail G

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 2 System installation

2.1.2.4 Dismounting the container

To dismount the container the stoker worm and both
ash worms must be removed.
For container variant ZI the connecting rod drive
must be dismounted. Loosen the screw on the
tailpiece (Detail A) and pull the tailpiece off using
a puller (Detail B). Detail A

Fig. 41: Substructure with container

Take off the ash worm drive (Detail C). Open the
connecting link of the drive chain and take off the Detail B
chain (Detail D).

Detail C

Fig. 42: Stoker drive unit

Loosen the set screw on the chain wheel (Detail E)
and pull off the chain wheel (Fig. 43).
Loosen the nuts of the bearing flange.
Loosen the two set screws of the container flange
bearing (Detail F). Detail D
Take the feather key out of the groove and pull off
the bearing (Detail G).

Detail E

Fig. 43: Pull off the stoker chain wheel

Loosen the nuts of the bearing flange on the ash
container side. Pull off the bearing shell of the stoker
worm glide bearing by turning two M8 screws
in the pull-off thread openings (Fig. 44). Loosen
Detail F
the set screw on the bearing bushing and pull off
the bushing and the stuffing box holder. Details:
See point 9.5. Pull out the stoker worm.

Detail G
Fig. 44: Dismantle the stoker bearing

Detail H

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 2 System installation

Dismantling the ash worms.

Remove the bolt on the ash worm extension
(Detail A). Loosen the bearing screws of the ash
worm (AW) extension (Detail B).
Pull out the ash worm extension.

AW = Ash Worm
Detail A
Fig. 45: Dismantle stoker worm
Loosen the set screw on both chain wheels of the
AW drive (Detail C).
Pull off both chain wheels simultaneously with the
chain.
Loosen the set screws on the two bearings of both
Detail B
ash worms (Detail D).

Fig. 46: Ash worms – drive chain

Pull out the ash worms from the AC side.
Detail C
AC = Ash Container

Detail D

Fig. 47: Dismantle ash worm

Loosen the screws on the flange of the burner
(Detail E and F). Pull the container away
­horizontally.

Detail E

Fig. 48: Lift out the container

Fig. 49 shows the system with cladding and installed Detail F
stoker worm.
Depending on the situation the cladding of the boiler
can remain set-up.
The process for dismantling the container remains
the same.
Only the threaded unions of the intermediate cladding
on the container must be loosened (Detail G).

Detail G
Fig. 49: Container with stoker worm

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 2 System installation

2.1.2.5 Dismantling the burner

Loosen the screws of the burner flange to the
substructure (Detail A).
For systems from 30 kW unscrew the cap of the
cast iron ash removal unit (Detail B).
Push out the burner flange using an erection bar,
by placing the erection bar on cast iron head in the
combustion chamber (Detail C). Detail A

Fig. 50: Remove burner

Fig. 51 Shows the removal of the burner flange on
a system with set-up boiler cladding.
Detail B

IntCl = Intermediate Cladding

Detail C
Fig. 51: Remove burner with IntCl
For the systems from 30 kW the KWB Multifire
includes the Multiflex burner extension: You can
dismantle the ash ring of the Multiflex burner
extension (Details D and E).

Detail D

Detail E

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 2 System installation

2.1.3 Assembling the system

2.1.3.1 Installing the burner

The instructions for assembling a system show the most important details. The specific steps should be viewed as the
reverse sequence of dismantling and are not described in more detail. Because there are many system types in different
models, it is possible that specific steps will not apply.

Remove the residues of the sealing compound on

the substructure, burner flange, and heat exchanger
(Detail A to C).

Detail A

Fig. 52: Seal the burner flange on

the substructure
Carefully apply the prescribed sealant on all sealing
surfaces that are affected by temperature (Fig. 52,
Detail D).
Detail B
Prescribed sealant:
Epple 37 – KWB art. no. 26-2000035

Fig. 53: Seal substructure Detail C

Slide the burner into the substructure.
Lift the burner on the container side (Fig. 54).
Tighten the nuts.

Seal the muffs of the cast iron head ash-removal unit

with the prescribed sealant (Detail E).
Detail D
Prescribed sealant:
Gomasit 405 – KWB art. no. 26-2000036

Fig. 54: Install the burner

Seal the flange to the container with the prescribed
sealant (Detail F).
Detail E

Prescribed sealant:
Transparent silicon KWB art. no. 26-2000034

Fig. 55: Apply silicon to the flange

Detail F

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 2 System installation

2.1.3.2 Mounting the container and stoker drive

Remove the silicon residues on the container
(Fig. 56). Align the container horizontally relative to
the substructure or heat exchanger. Introduce the
stoker worm.

Detail A

Fig. 56: Remove residues

Apply transparent silicon on the flange bearing and Detail B
on the protective sheet metal (Detail A).
Slide the protective sheet metal and flange bearing
over the bolts.
Only tighten the nuts slightly!

Detail C
Apply a new seal to the flange of the stoker worm
slide bearing
(Gomasit 405 – KWB art no. 26-2000036, see
Fig. 57: Mount the container bearing Detail C).
Mount the stuffing box holder (1 – Detail D). After the
4 thrust washer (2) slide on the shaft protection sleeve (3)
3 2 1
and push it against the thrust washer (Detail E). Place Detail D
the seal (Klingerit seal, KWB art. no. 07‑1010014) on
the set screw and tighten the set screw on the shaft
protection sleeve (Detail F).
Mount the bearing flange (4) and slightly tighten the
Fig. 58: Parts – stoker worm slide bearing
nuts.
Place the chain wheel on the stoker worm.
Detail E
Align the stoker worm by turning it. It must turn freely
(Detail G). Ensure that the worm on the container
side bearing has the stop (Detail B).

Detail F

Fig. 59: Mount the bearing flange

Tighten the nuts on both bearings without inter-
ruption (Fig. 60).
Tighten the set screw on the container stoker
bearing.
Mount the chain wheels, tighten the set screw Detail G
(Detail H) and put on the drive chain.

Fig. 60: Tighten the stoker bearing

Detail H

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 2 System installation

Close the chain link (Detail I), tension the chain with
the motor (Detail J) and check the chain tension.
You must be able to deflect the chain by approxi-
mately 0.5 cm (Fig. 61).

Detail I

Fig. 61: Check the belt tension

Detail J

2.1.3.3 Mounting the ash worm drive

Introduce the ash worms (Detail A) The longer one
on the drive side. Mount the chain wheels with chain
placed on. Tighten both set screws (Detail F).

Detail A

Fig. 62: Mount the AW extension

Introduce the stoker worm extension. Mount the
stud bolt (Fig. 62) and the bearing on the drive side Detail B
(Fig. 63).
Align the chain wheels parallel to the container wall
(Fig. 64) and tighten the two set screws on all five
bearings (Details B and C).

Detail C

Fig. 63: Mount the AW bearing

Check the ash worm movement (Detail E). Re-adjust
the bearing arrangement if necessary.
Place the ratchet drive on the AW extension
(Detail D).
Detail D

AW = Ash Worm

Fig. 64: Mount the AW connecting chain Detail E

Detail F

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 2 System installation

2.1.3.4 Installation of the heat exchanger

Apply sealing compound (Epple 37) on the upper
flange of the substructure (Fig. 65).
Remove the residues on the flange of the heat
exchanger (Detail A).

Detail A

Fig. 65: Apply Epple on the SS (HE)

Place the heat exchanger on the substructure
(Fig. 66).
Ensure that the heat exchanger is aligned parallel to
the substructure. Screw fasten the heat exchanger
(HE) to the substructure (SS) (Detail B).
For the 80 kW and 100 kW heat exchangers the Detail B
screw for the air channel must be on top so that the
channel can be hooked in.
Only for 80kw and 100 kW systems: Mount the
air channel and connect it to the secondary air hose
(Details C & D).
For systems to 60 kW the hose is routed upward
outside of the insulation (Detail E).

Detail C

Fig. 66: Heat exchanger placed on

Carefully wrap the insulating mat around the heat
exchanger and the panels around the substructure
(Fig. 67) and close them carefully.
Detail D

Fig. 67: Insulate the heat exchanger Detail E

For all systems the insulating mat is held in place
with retaining springs (Detail F).
The but joint of the 100 KW furnace is covered with
an adhesive strip.
Detail F
SS = Substructure
HE = Heat Exchanger

Fig. 68: Close the insulation jacket

Detail G

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 2 System installation

Fasten the upper sensor on the heat exchanger (do not bolt too tightly)
A The flue gas sensor is secured in the protective sleeve with a locking screw.
B Screw-fasten the plastic bush and lambda control system
C Safety thermostat + boiler sensor (the sensors are held in place in the immersion sleeves with clips)
D Clip for securing the sensor
A B C D

Lay out the cables on the outside of the insulating mat.

Do not use any cable ties to bundle the cables – this makes replacement easier.

Detail cabling

Fig. 69: Cabling 80 kW & 100 kW Fig. 70: Cabling HT 30-60 Detail cabling

Detail – post-combustion ring

Detail – water tank hose Fig. 71: Hose – negative pressure control Detail – post-combustion dome

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2.1.3.5 Installing the cladding

Insert the rear wall, introduce the induced draft cable
through the cable opening (Detail A). Screw-fasten
the side wall and rear wall (Detail B).
Insert the side wall on the AC side and bolt it to the
rear wall on top. Introduce the ash container sensor
through the cable opening (Detail E). Detail A
Screw fasten the rear wall with the side parts in the
middle (Detail C).

AC = Ash Container

Detail B

Fig. 72: Installation of the rear wall

Mount the induced draft plug-in connector
(Detail D).
Insert the cladding at the lower front and bolt it to
the side parts (Fig. 73).
Detail C
Does not apply for 15 and 25 kW systems.

Fig. 73: Install the front wall, bottom

Detail D
Hook in the front cladding part on top and bolt it top
and bottom to the side parts (Fig. 74).
Mount the ash container sensor.
Mount the insulating cover (Detail H).

Detail E

Fig. 74: Hook in the front wall, top

Installing the cladding door:

Systems to 25 kW. Detail F

Hook the door in at the bottom and adjust the door
with the upper screw.
Systems from 30 kW:
Screw in both hinge screws but do not tighten them
at first. Then fix the lower hinge screw in the middle
of the long slot. Use the upper screw to adjust the Detail G
door in such a manner that the closure locks in
place. Then readjust with the lower screw (Fig. 75,
Fig. 75: Install the cladding door Details F & G). Use a flat fork spanner to make the
adjustment.

Detail H

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 2 System installation

Lay out the cable and connect it to the control unit

(Detail A).

Detail A

Fig. 76: Cable layout – intermediate

cladding
Fasten the cable on the strain relief comb with cable Detail B
ties (Fig. 77). Also connect the cable to the burner.

Detail C

Fig. 77: Fastening the cable

Close the side cover of the intermediate cladding
(Fig. 79).
Detail D

Detail E
Fig. 79: Installation of the side sheet-metal
panels
Close the side covers (Details B to F).
Mount the boiler cover (Fig. 80, Detail H).
Detail F

Detail G
Fig. 80: Install the cladding cover

Detail H

2.1.3.7 Installing the vacuum conveyor unit

Execute point 2.1.2.1 in the reverse sequence.

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 2 System installation

2.1.3.8 Installing the cladding/concluding tasks

Connect all cables to the I/O board.

Mount the front cover on the middle part.

For the 80 kW and 100 kW systems mount the

box with the safety thermostat in the cover of
the cleaning system motor and hook in the cover
(Fig. 81).
Bolt the lid of the cover to the cover (Detail A).
Mount the cap of the safety thermostat (Detail C).
Detail A

Detail B

Fig. 81: Install the RM cover

Align the ash container horizontally via the supplied
set screws (Detail H). Detail C
Adjust the sensor of the ash container in such
a manner that the cover has a gap of 1 mm to the
sensor (Detail B).
Mount the flue gas box (Fig. 82).

Attention!
Seal all bores – secondary air can enter! Detail D

Fig. 82: Install the FG box

Mount the caps on the rear wall (Detail D).
Clean the system and ensure that all stickers and
the brief instructions for specialists are present
(Detail F). Detail F
Protect the control unit with a cover foil (Detail G).

Fig. 83: Clean the system Detail G

Detail H

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 2 System installation

2.1.4 Smoke pipe connection and induced draft fan

As a general rule, the dimensions of the smoke-pipe connection between boiler and chimney should be identical to the
dimensions of the connection on the boiler. The chimney connection must be at least as high as the smoke-pipe connection
on the boiler. If not required by local regulations, we recommend that a draft limiter and a detonation damper be built into
the smoke pipe or chimney-side wall, and arranged in such a way as to exclude any danger to persons. Keep the smoke
pipe as short as possible. The smoke pipe must be insulated and connected, and should at least ascend slightly towards
the chimney, preferably with an inclination of less than 45°. The smoke pipe should be thermally insulated and feature
suitable easily accessible cleaning openings. The chimney connection should be 20 mm larger than the smoke‑pipe
diameter. In this way, it is possible to integrate a suitable acoustic transmission decoupler between the smoke pipe and
the chimney. The KWB system is equipped with an induced-draft fan as standard equipment.

2.1.5 Water connection

For wood chip boilers, the return-flow inlet temperature into the boiler must be at least 55°, otherwise there is an
increased risk of corrosion, which also has the effect of voiding the warranty. To increase the temperature of the return
flow, the boiler control unit can actuate a mixing control unit or a mixing pump. For systems to 60 kW the return
flow boost can also be executed via a thermal control valve. Suitable fittings to increase the return flow temperature
are available from KWB. With the exception of return flow boost with bypass pump, the heating system must feature
a pressureless distribution system (switch, distributor, load-balancing accumulator, buffer, etc.) and a safety group that
complies with the relevant regulations (e.g. in accordance with ÖNORM B 8130, or ÖNORM B 8131, DIN EN 4751 T1‑4).
A load-balancing accumulator or buffer tank is not required, but it is useful in some cases, for instance if a solar power
system or a log-wood boiler is connected, or if there is a need to achieve a very low continuous heating output during
the summer months. For acoustic decoupling of the water connections, ensure that they are impermeable to oxygen,
otherwise there is an increased risk of corrosion, which also has the effect of voiding the warranty. If plastic pipes
for underfloor heating or district heating pipes are connected, it is necessary to integrate a limiting thermostat for the
circulation pumps to provide additional protection against excessive temperatures. With respect to the condition of the
boiler water, VDI 2035 and ÖNORM H 5195 T1 and T2 must be strictly adhered to, otherwise there is a risk of corrosion,
which may void the warranty.
Boiler circuit pumps Min. required Control valve
Core values volume flow V / delivery head H or return flow mixer
Spread ∆ [K] via the boiler 10 15 20
Boiler output Minimum diameter V H V H V H Kvs
[kW] forward-, return flow [m³/h] [m] [m³/h] [m] [m³/h] [m] [m³/h]
15 1” 1,29 0.64 0.86 0.28 0.64 0.16 9
25 5/4” 2,15 0.72 1,43 0.32 1,07 0.18 14
30 5/4” 2,58 1,23 1,82 0.61 1,29 0.31 14
40 5/4” 3,44 2,19 2,29 0.97 1,72 0.55 14
50 6/4” 4,30 1,67 2,86 0.74 2,15 0.42 17
60 6/4” 5,16 2,41 3,44 1,07 2,58 0.60 17
80 2” 6,87 4,79 4,58 2,13 3,44 1,20 44
100 2” 8,59 6,38 5,73 2,84 4,30 1,60 44
Table 3: Configuration data for the boiler circuit
The pump data applies for average local conditions and must be checked by specialists for heating circuits or building
equipment planners.

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 2 System installation

2.1.5.1 Thermal safety valve connection:

The boiler must be connected to a thermal safety valve. The forward flow and
return flow is on the rear.
The sensor and the thermal safety valve are not included in the boiler scope
of delivery.
The admission pressure of the thermal safety valve must be between 2 and
6 bar.

2.1.6 Electrical connection

Always unplug the power plug before opening the junction box or switch the main switch off.

Avoid ignition sources in the fuel storage room!

Electrical installations (lights, switches, power outlets, distributors, etc.) are only permitted in the
fuel storage room in explosion protected versions, and they must be executed in accordance with
the locally applicable regulations!

Ensure that there is no possibility of damage to the electrical system due to heat radiation.

Comply with all applicable regulations.

Comply with EN 60204‑1 “Electrical equipment of machines – general requirements”.

Connections that are required on the customer side:

• Supply CEE. 5-pole socket (3L/N/PE), 400 V AC,

Rotary field RIGHT!
Connect the neutral conductor!

In addition: • Type “C” lightning arrester at the distribution board of the house
(recommended as lightning protection)
• Danger switch (“emergency-stop”) in accordance with applicable prTRVB H 118
If the KWB system is supplied with emergency power via power generators, a relay should be installed to detect the
rotary field.

2.1.6.1 Power connection of the KWB system

• CEE plug-in connector, five-pole, 3 m cable, cross-section 1.5 mm²

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 2 System installation
05 


06


07 

14

15

16



08

• Installed 10A fuse






 






09 


Scope of delivery variants: Configuration, see boiler wall sticker:



10

11

12

13
Attention! Installation instructions, electrical connections


{

HC1 + HC2 – heating circuit 1 and 2 assigned

HC1 – heating circuit 1 assigned, HC2 – heating circuit 2 not assigned
(
17

(Model is marked) 

HC0 – assigned on plug-in module 1
 
No heating circuits assigned (HC1 + HC2 not assigned)

{
18 
Unplug the power plug before opening!

• 1 boiler I/O board without released heating circuits

19 • 1 safety thermostat


• 1 boiler temperature sensor } cabled / mounted by KWB
Without heating circuit
(Boiler I/O board
without heating circuit)

• 1 boiler sensor (pin sensor ∅ 6 mm)
• 2 buffer sensors (pin sensor ∅ 6 mm)
• 1 return flow sensor (contact sensor)

{
• 1 lambda control system
• 1 negative pressure measuring cell
(0 – 1 mbar)

• 1 boiler I/O board with one released

heating circuit
• 1 safety thermostat
• 1 boiler temperature sensor
} cabled / mounted by KWB

• 1 boiler sensor (pin sensor ∅ 6 mm)

Ordering option: • 2 buffer sensors (pin sensor ∅ 6 mm)

}
1 heating circuit • 1 return flow sensor (contact sensor)
(Boiler I/O board
• 1 Outdoor sensor with housing
with one heating circuit)
• 1 forward flow sensor (contact sensor)
Ordering option:
• 1 analogue room control unit in addition for heating circuit
+ room sensor configuration
or
• 1 digital room control unit
+ room sensor

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 2 System installation

{
• 1 boiler I/O board with 2 released heating circuits
• 1 safety thermostat
• 1 boiler temperature sensor } cabled/mounted by KWB

• 1 boiler sensor (pin sensor ∅ 6 mm)

• 2 buffer sensors (pin sensor ∅ 6 mm)

}
Ordering option: • 1 return flow sensor (contact sensor)
2 heating circuits • 1 Outdoor sensor with enclosure
(Boiler I/O board • 2 forward flow sensors
with two heating circuits) (contact sensor)
Ordering option:
in addition for heating circuit
• 2 analogue room control units
configuration
+ room sensor
or
• 2 digital room control units

{ }
+ room sensor

• 1 Outdoor sensor with enclosure

• 2 forward flow sensors
(contact sensor)
• 1 boiler sensor (pin sensor ∅ 6 mm)
Ordering option: Heating • 2 buffer sensors (pin sensor ∅ 6 mm) Expansion module (bus capable)
circuit expansion module Ordering option: distributed placement
(HCM) • 2 analogue room control units
with room sensor
or
• 2 digital room control units
with room sensor

Ordering option:
Plug-in module 1 { • Heating circuit 0 + second boiler
switchover incl. forward flow
sensor (contact sensor)
} Specific pin assignment according
to the configuration:
See Connection diagrams

Comply with the connection diagrams!

The following equipment can be connected:

VARIANTS EQUIPMENT:
0 heating circuits: 1 boiler circuit pump, 1 boiler pump, 1 return flow mixer
1 heating circuit: 1 boiler circuit pump, 1 boiler pump, 1 heating circuit pump, 1 heating circuit mixer,
1 return flow mixer, 1 analogue or digital room control unit (optional)
2 heating circuits: 1 boiler circuit pump, 2 boiler pumps, 2 heating circuit pumps, 2 heating circuit mixers,
1 return flow mixer, 2 analogue or digital room control units (optional)
Heating circuit
expansion module 1 Supply pump, 1 boiler pump, 2 heating circuit pumps, 2 heating circuit mixers,
(HCM): 2 analogue or digital room control devices (optional)
Pump connection: 230 VAC, max. 200 W, speed-regulated output for boiler circuit pump
(Suitable for speed regulation of fixed-speed pumps).
Mixer motor
Connection: 230 VAC, open/off/closed (three-step)
Outputs: Floating contacts with max. 2 A switching current, 230 VAC
Fault warning Buzzer fault alarm contact
output: (E.g. for remote alarm via telephone dialling)
Fault 1: NC contact to indicate faults
Fault 2: NO contact to indicate faults

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 2 System installation

Power output: NO, configurable for:

•B urner operation display
(output stage “partial load/medium load/nominal load”)
• Boiler master-and-slave circuit to request a second boiler
• Fuel extractor for common stirrer drive
Smoke extractor: NO contact for activating an external smoke extractor
The boiler is released in this case by the control unit of the external smoke
extractor via External 1 (floating contact).
Inputs: 24 VDC supply to connect floating contacts.
External 1: Connect external safety devices here.
(Low water pressure switch, release for ext. smoke extractor, etc.)
If this input is not used, it must be short-circuited.
External 2: Multi-function input:
•H  eat to target 2: To request the boiler with the second boiler target
temperature or as a request contact for external third-party control
devices (duration of the request, at least 30 min).
•H  oliday remote control:
(Does not function if there is an external boiler request)
•B  oil seq. If a boiler master-and-slave circuit is present this selection
must be made for the main boiler.
Stop switch*: Connect the danger switch here.
(Plug-in connector 71) You must be able to switch off the system outside of the boiler room with this switch.
*Stop switch in accordance with applicable prTRVB H 118

NO voltage on “External 1” and “External 2” – check the pin assignment before commissioning!

• Do not shorten sensor cables so that they are less than 1 m in length
• Extend sensor cable with 2 × 0.5 mm²
• Cables to analogue room control units must be executed with shielding!
Always connect the shielding on the boiler side!

2.1.6.2 Junction box

All electrical installations lead into the intermediate cladding and are brought together in the junction box.
Comply with the connection diagrams.

The cables of the system side consumers (pumps, etc.) are connected
to the I/O board via plug-in connectors. Unplug the plug-in connectors
from the board. Clamp the wires Plug the plug-in connectors back into
the board.

When connecting sensors and motors to the connection

points it is imperative that the controller be de-energized,
for the following reasons:
– Protection against shock
– Connections are not short-circuit proof
– Control system must be switched off to initialise.

Fig. 89: Disconnect the BCU cable

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 2 System installation

All cabling and connection diagrams that you require for proper installation are included in the Appendix. Wiring that is
more extensive than that shown in the diagrams, or that deviates from that shown in the diagrams is beyond our sphere
of responsibility and invalidates warranty claims.

2.1.6.3 Cabling guidelines

Boiler control unit Digital remote control unit

BUS RS 485
24 V DC

BUS RS 485 Supply

2-pole A+B 24 V DC 2-pole

BUS RS 485
2-pole A+B

Heating circuit expansion module

Boiler I/O module

Fig. 91: Simple circuit

Fig. 91a: Network cabling

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 2 System installation

• Bus cable: 8-pole shielded, CAT 5e LF-2YACVY 4 × 2 × 0.52 – 100GR, length max. 850 m.
• Lay out in a separate conduit (not together with 230 / 400 VAC).
• Network stations in one line (no branches, no ring!).
• If the BCU is used in the room you must mount the empty wall socket.
• Maximum 2 digital room control units (DRCU) can be jointly supplied with power (24 V DC) from one HCM or the
boiler I/O module. The supply should not be further terminated. However the bus cable must be consistently looped
through.
• The network can be extended with a boiler I/O module (2 heating circuits) with up to 16 heating circuit expansion
modules (two heating circuits each, and 34 digital room control units.
• For each heating circuit, an analogue room control unit (ARCU), can be used independent of the bus nodes. The
cabling is executed as is usual for analogue room sensors, i.e. directly to the boiler I/O module or to the HCM (not to
a bus node!).

Bus lines laid out in a star configuration can only be cabled “in line“:
• If the overall length of 850 m is not exceeded and
• If the terminal clamping points are executed as listed below.
* Pay attention to the length of the to and from line

Execution example with one terminal point:

Type CAT 5e LF-2YACVY 4 × 2 × 0.52 – 100GR

1. – Insulate the wires (with shrink hose) 4. – Connect the wires (through twisting)
2. – Strain relief (with a cable tie) 5. – Terminate the shielding (with cable clamp)
3. – Mark the cables coming / going (e.g. with arrows)

Fig. 92: Terminals of the bus cable

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 2 System installation

2.1.7 Control units & heating circuit expansion modules (HCM)

All control units and heating circuit modules (HCM) are manufactured in a 2-shell enclosure design made of plastic.
A screw-less locking mechanism for the enclosure parts enables easy and fast unlocking. The undershell serves as
a wall socket or install socket, and is fitted with one or two RIA block terminals where the cabling must be connected
as specified in the connection diagram (see Appendix). The upper shell bears the control elements in the front and bears
the electronics in the rear with pin connectors. When the two shells are joined together the electrical connection to the
block terminals is established.
To prevent damage to the enclosure or to the pin connectors the handling described in this manual
must be strictly complied with!
Room control units with room sensor influence should only be mounted on the wall – do not mount
in-wall, fitted or installed!

2.1.7.1 Boiler control unit/digital room control unit (OPTION)

With the digital room control unit, operating and monitoring functions of the heat distribution and of the dissipation system
(with the boiler control unit, also that of the boiler) can be located in the living room. The mounting location, if room sensor
influence is used, should be in the main room on an inside wall, but not in the vicinity of heating elements or other heat
devices, and not on doors or windows. For mounting or connection of the digital room control unit, or of the boiler control
unit (only for use as digital room control unit), the plastic enclosure must be opened in the manner described below.

2.1.7.2 Analogue room control unit (OPTION)

With the analogue room control unit a room influence of ± 5° can be exerted on the connected heating circuit from the
living room. In addition the modes Frost protection  , Continuous day mode  , Continuous night lowering operation 
 , Automatic can be set according to the heating program  . The mounting location should be in the main room of the
respective heating circuit, on an inside wall, not in the vicinity of heating elements, or in the vicinity of other heat devices,
and not on doors or windows. The room control unit can also be assigned to several heating circuits (see 4.2.1)
Open the plastic housing for mounting and connection as described below.

Carefully introduce a flat-head screwdriver (width = 4 mm) into the slot

on a narrow side of the enclosure division.

Carefully press the screwdriver in the direction shown.

Repeat the process on the opposite side.

Fig. 99: Open the control unit

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 2 System installation

Pull the enclosure shells apart, straight.

Do not tilt the parts.

Fig. 101: Open the control unit (4)

Use the undershell to mark the bores on the wall.
Mount the undershell (scope of delivery includes the fastening
I set) – tighten the screws but not too tightly. The undershell could be
S
GND
deformed.
Connect the cable 2 × 0.5 mm² (shielded) to the terminals I and GND
of the inputs for the analogue room control unit (remote thermostat).
(Diagram no. EBAA1017, EBAA1047, EBAA1021)
Fig. 102: Open the control unit (5)

Check the sensor resistance with the upper shell removed, on the contacts “S” and “GND”. See point 2.1.6.9 – “Sensor
check” (type KTY81‑110) for the temperature-dependent setpoints. Only the total resistance can be tapped on contacts “I”
and “GND”, which is comprised of the fixed resistance of the respective set mode, the resistance of the setpoint thermostat
(dial ± 5°) and the resistance of the room sensor. The resistance differential when changing the slide switch setting can
be measured again for fault diagnostics. The target difference between the two switch settings is 500 ohm.

Check the setpoint thermostat (dial ± 5 °C) by determining the resistance differential between the left stop and right stop.
The target difference is 72 ohm.

Close the enclosure:

Introduce the upper shell with the pin connector into the block terminal.
Fit the parts together straight, without tilting until the locking mechanism engages.

2.1.8 Plug-in module 1 (OPTION)

This hardware plug-in module extends the functions of the control unit.
(Second boiler switchover; vacuum conveyor unit, additional single heating circuit)
• Installed in the junction box
• Multi-functional configuration
• Can be used individually or combined for different functions (depending on the system type)
• The system detects available hardware automatically.

Set the desired use in the “Basic Settings / Hardware” menu.

Second boiler switchover:

Connection of the second boiler thermostat is OPTIONAL. If the thermostat is not connected the overheating protection
will be triggered from the second boiler sensor (when the set value is exceeded – the factory setting is 80 °C).
If both systems are routed into the same chimney the flue gas thermometer must be connected!
If this is not the case the contact must be electrically debounced.
Connect the second boiler hydraulically. (Diagram no. MAEH0004)

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 2 System installation

2.1.8.1 Heating circuit 0 and / or second boiler switchover

The options “HC0” for use of a single heating circuit (heating circuit 0) and “SB” for an automatic switchover between
a manually charged second boiler and the wood chip boiler can be configured independently or jointly. With this setting
the use of the respective outputs/inputs is assigned.
See the included connection diagram no. EBAA1021 for pin assignment and associated cabling.

2.1.9 Boiler master-and-slave circuit

The parallel circuit of two boilers to cover the heat demand in a heat distribution network is referred to as a boiler master-
and-slave circuit. The two boilers are referred to below as main boiler and auxiliary boiler. The boiler at which the requests
from the consumers (buffer, HC, DHWC) are cabled is referred to as the main boiler. Either boiler can work as master or
slave boiler.

Settings for the boiler master-and-slave circuit:

On the main boiler the boiler program offers the following selection:
• Request, time program, continuous operation
The main boiler is the master boiler, the request is based appropriately on the selected boiler program.
• Slave boiler
The auxiliary boiler is not always the slave boiler.
• Alternating operation
The role of the master boiler is swapped between the two boilers in an adjustable rhythm. The rhythm can be set
under the boiler program – sequence times.
• Double operation
Both systems run in parallel operation in response to a request

Additional required settings for main boiler and auxiliary boiler:

• The two boilers must be set to BMSC when using the power output for boiler master-and-slave circuit, the power
output must be set under Basic Settings – Network Settings – Boiler Output.
• The auxiliary boiler must always be set to continuous operation in the boiler program. Due to the cabling and the
settings on the main boiler, then the request of the auxiliary boiler occurs.
• The set boiler target temperature should be the same on the two boilers.
• For the main boiler the External2 function must be set to boiler master-and-slave. This is done under Basic
Settings / Network settings / Boiler. The consumers are connected and the network settings are made on the
network of the main boiler. (HCEM, DRCU, etc).

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 2 System installation

Operating behaviour of the master-and-slave circuit:

The slave boiler will be requested by the master boiler, if on the master boiler
• The boiler temperature underranges the setpoint by at least the set temperature differential value,
factory setting = 5°C,
• Or if a fault is present that causes the master boiler to switch off.
This involves the following switch delays:
• On the master boiler this condition must be present for at least the duration of the switch-on delay for the power
output, so that slave boiler is requested.
• Once a request of the slave boiler has been triggered, the switch-on delay remains intact for at least the duration
of one switch off delay period after this condition has ceased to exist.

Factory settings:
(Basic settings – Outputs)
• Switch-on delay = 30 minutes.
• Switch-off delay = 60 minutes.
• Temperature differential for request of the slave boiler 5°.
Attention: In summer mode (only DHWC charging) the heat-up time of the boiler must be considered and the switch-
on delay must be adjusted to this heat-up time, so that the slave boiler does not prematurely start operation.

Cabling for the boiler master-and-slave circuit:

The boiler master-and-slave circuit, or the power output of the main boiler must be applied on the External 1 output of the
slave boiler, the boiler master-and-slave output, or the power output of the auxiliary boiler must be applied on the External
2 input of the main boiler.

2.1.10 Heating circuit expansion module (OPTION)

The system can be extended in a distributed manner via network technology with the heating circuit expansion
modules.
Mount these modules near the sensors and aggregates that will be activated by these modules!
(Example: On the heat distributor station of the respective building in the network)

Place the supply pumps, zone valves, or buffer charging pumps for distributed nodes in distributed
locations. Otherwise the 230 V activation and the bus cabling must be routed back to the respective
device.

Please note:
• Outputs: O3 – O10, relay outputs 230 VAC, 2 A in accordance with connection diagram
all other outputs are not used currently
• Inputs: I1 - I8: Analogue inputs in accordance with the connection diagram,
• Analogue input 0 – 20 mA (connection heat meters for power measurement)
• Mains connection: 230 VAC 3-pole
• LED Power: Flashes at one second intervals if voltage is applied, off for Power off, flashes rapidly if the
fuse is defective
• LED Bus: Flashes in one second intervals if the buss communication is intact
• LEDs for the outputs: Indicate whether the output is switched on.
• If the bus communication is interrupted for longer than 10 seconds, all outputs switch off
• If a defective fuse or phase is detected, all outputs switch off

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 2 System installation

Installation instructions:
• Open the enclosure precisely as described, with a screwdriver (width 4 mm).
• Cable strain relief: The cabling to the module must be routed in cable ducts
or customer-supplied strain relief must be provided.
• Setting the station number switch with screwdriver
• Apply the safety sticker in the national language.
• Check the conductors and N-conductors from the power side – do not swap!

Attention! The heating circuit module only functions with a software version greater than 3.38.
(“Customer Service” menu)
Scope of delivery:
•  Heating circuit expansion module (2-pc. enclosure)
•  Replacement fuses: 1 x  250 V 6.3 AT, 1 x  250 V 3.15 AT
•  Fastening set
•  Safety sticker art. no. 27-2000099
•  Connection diagrams – heating circuit expansion module and bus cabling

Open the enclosure for installation and connection precisely as specified in the following description.
Carefully introduce a flat-head screwdriver (width = 4 mm) into the slot
on a narrow side of the enclosure division.

Carefully press the screwdriver in the direction shown.

Repeat the process on the opposite side.

Open the HCM 1

Press on the division joint with the screwdriver at a point that is
approximately 1 cm away from the middle on a long side.

If this does not loosen the locking mechanism, press the side wall of the
undershell to the outside with a lever movement.
If the locking mechanism should not yet be loosened repeat the process
on the opposite side.

Open the HCM 2

Pull the enclosure shells apart, straight.
Do not tilt the parts.

Open the HCM 3

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 2 System installation

Use the undershell to mark the bores on the wall.

Mount the undershell (in the fastening set scope of delivery) – tighten
the screws, but not too tightly. The undershell could be deformed.

HCM undershell

Danger due to electric shock!

Do not switch the polarity of the HCM supply under any circumstances!
Live parts (pole conductor bar) would be exposed in this process!

Flexibly connect all cables (except the bus cable and sensor cable) YMM 1.5 mm². (Diagram no. EBAA1017)
Connect the bus cables/data cables. (Diagram no. EBAA1018)
Check the cabling.

Close the enclosure:

Introduce the upper shell with the pin connector into the block terminal.
Fit the parts together straight, without tilting until the locking mechanism engages.

2.1.11 FE MODULE (OPTION)

The FE module (fuel extractor module) controls the drive of second fuel extractor.

2.1.11.1 Installation
The fuel extractor module is designed exclusively for wall-mount installation. Ensure that the rear of the wall housing
is not accessible in mounted status. In operation the device must be protected from moisture, dirt, and damage.
The permissible ambient temperature is 0 to 50 °C. The accessories for wall mounting (plugs and screws) are included
in the scope of delivery.
The safety sticker in the national language must be affixed to the top side of the module in such a manner that it is clearly
visible when the module is opened.

2.1.11.2 Electrical connection

The cable entries on the wall enclosure are suitable for flexible lines with an outer diameter of 5 mm to 12 mm. Introduce
the lines into the line cable entries and bend them into the guide channels. All lines must be fastened on the wall directly
below the wall enclosure with prescribed strain relief, or laid out in a cable duct.

Left side 24 V DC control unit Right side 400 VAC power unit

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 2 System installation

2.1.11.3 Power supply

The electrical connection must be executed via a 5-pole CEE plug-in connector to enable a disconnect from the power
supply. The connection cable must be a wet-duty room line (or equivalent) with a cross-section of at least 1.5 mm².
For the connection, ensure that neutral conductor and phase sequence agree with the markings on the terminals
(see Detail A). The protective conductor must be connected to the grounding bar.

Detail A: Cabling of the FE module

2.1.11.4 Fuel extractor motor

The fuel extractor motor must be connected via the supplied 4-pole extension cable with AMP plug-in connectors on the
power unit. In this process it is necessary to remove the 4-pole receptacle connector on the one side, strip off 3-4 cm and
crimp on end sleeves (Details B and C).

Detail B Detail C
Pin assignment, fuel extractor motor:
Wire markings – cable Terminal connection – power unit
1 U1
2 V1
3 W1
Yellow-green Earthing bar

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 2 System installation

2.1.11.5 Inputs
The inputs are used depending on the variant:
Wire markings – cable Terminal connection – control unit
Klixon fuel extractor motor 1 I2
2 24 VDC bar
Limit switch, fuel extractor lid 1 I3
2 24 VDC bar
Request, fuel extractor 1 I5
2 24 VDC bar
Overfill protection, light curtain 1 I6
2 24 VDC bar
3 GND

For the Klixon fuel extractor motor, the supplied extension cable with the AMP pin connector on one side and an AMP
socket connector on the other side, is used. The AMP socket connector must be removed, the cable must stripped
approximately 10 cm and end sleeves must be crimped on.

2.1.11.6 Connection variants

Control signal Connection terminal (wire 1) Connection terminal (wire 2)

Ascending worm extension with an FE module
Klixon supplement FE motor I2 + 24 V supply bar
Connection terminals 13 and 16 must be connected with the + 24 V supply bar because the limit switches and light
barriers are not present.
Ascending worm drop shaft with an FE module
Klixon supplement FE motor I2 + 24 V supply bar
Overfill protective cover I3 + 24 V supply bar
Connection terminal 16 must be connected to the + 24 V supply bar because a light barrier is missing.
Double boiler system – activation of a common stirrer with an FE module in the bus of boiler 1
Klixon supplement FE motor I2 + 24 V supply bar
(common stirrer)
Supplemental request FE I5 + 24 V supply bar
(Boiler 2, power output)
Connection terminals 13 and 16 must be connected with the + 24 V supply bar because the limit switches and light
barriers are not present.
Please note: Supplemental connection variants are provided in the installation manual for the fuel extractor module.

2.1.11.7 System bus connection

For connection of the system bus a flexible, shielded, 2-wire cable with a minimum diameter of 0.5 mm² is recommended.
The shielding must be terminated on the GND bar, the two data lines must be terminated on terminals A and B (Detail D).
Ensure that all connections for the system bus have the same polarity (A to A and B to B). The 24 V terminal is not wired
(exception: When connecting a digital remote control unit)!
The precise circuit diagram is provided in section 5 – Electrical diagrams.

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 2 System installation

2.1.11.8 Commissioning the FE module

Only qualified specialists should commission the fuel extractor module.

2.1.11.9 Station number switch

The station number must be set on the front-side rotary switch. Multiple fuel extractor modules in one network are
consecutively numbered (starting with 1). This numbering is executed independently of the heating circuit modules and
digital remote control devices.

2.2.11.10 LED functions

BUS-LED: (Bus communication)

Communication OK: LED flashes regularly
No communication: LED off

Power-LED: (Operation)
Supply OK: LED flashes regularly
Fuse defective/ outdoor sensor missing: LED off

Motor-LED: (Display motor status)

Motor off: LED off
Motor on, forward flow: LED on
Motor on, return flow: LED flashes

2.2.11.11 Troubleshooting
BUS-LED: OFF
1. Check the line voltage to the module (also on the boiler)
2. Check the bus cabling
3. Check the station number (position 1)
4. Check the hardware settings on the boiler control unit
5. Module defective ∞ replace

Power-LED: OFF
1. Check the line voltage to the module (3P+N+PE)
2. Check the glass-tube fuses in the module
3. Module defective ∞ replace

Motor-LED: OFF
1. Fuel extractor is not required (no activation via bus)
2. Overfill protection cover is open or not available (fault 28 on the boiler control unit)

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 2 System installation

No. Alarms and their causes Remedy

26 A motor of the supplemental fuel extractor is overloaded!
There are foreign objects in the fuel that overload the Open the overfill protection cover on the worm
fuel extractor motor. trough and remove foreign objects from the worm
trough.
The wood chips are too large (or too fine) Use standardised wood chips (G30 = max. piece
length approximately 30 mm).
A mains phase has failed. Check the power supply.
27 A motor of the supplemental fuel extractor is overheated!
Thermal motor protection has tripped. Open the overfill protection cover on the worm
trough and remove foreign objects from the worm
trough.
28 An overfill protection switch of the fuel extractor is overloaded!
The overfill protection cover opens if the shaft Switch off the main switch and switch it on
is clogged, so that the worm does not get stuck. again, this opens the fire shutter. Open the overfill
protection cover and remove all the wood chips in
this area.
245 The supply on the fuel extractor module has been interrupted!
The fuel extractor module is not plugged in. Check CEE plug-in connector.
One or more glass-tube fuses have tripped due to Notify customer service
a short circuit.The connector of the three-phase current
module does not switch as intended.The 24-volt supply
voltage is missing or is short circuited
246 Defective triac on the fuel extractor module!
Defect in the electronics Notify customer service
247 Network error on the fuel extractor module!
Communication problem on the internal bus between Check whether the bus cabling is in order and
boiler control unit and fuel extractor module. whether power is supplied; if the alarm cannot be
eliminated: Notify customer service

2.1.12 Equipotential bonding

Danger of injury due to electric shock! Damage to the electronics!
Connect the pipelines to the equipotential busbar as prescribed.
The equipotential bonding prevents voltage differentials within the system!

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 2 System installation

2.1.13 Sensor check

Please see the temperature/resistance characteristics below for the function check of the installed sensor:

All sensors, except flue gas sensor (KTY 81‑110):

Temperature Resistance Temperature Resistance Temperature Resistance
[°C] [ohm] [°C] [ohm] [°C] [ohm]
– 20 684.62 – 3 794.55 14 915.66

Interruption 130 °C (at room sensor 50 °C)

– 19 690.78 – 2 801.36 15 923.14

Short circuit – 30 °C (at room sensor – 10 °C)

– 18 696.98 – 1 808.21 16 930.65
– 17 703.21 0 815.11 17 938.20
– 16 709.48 1 822.04 18 945.79
– 15 715.79 2 829.01 19 953.42
– 14 722.14 3 836.02 20 961.00
– 13 728.53 4 843.06 25 1.000.00
– 12 734.96 5 850.15 30 1.040.00
– 11 741.42 6 857.27 40 1.122.00
– 10 747.93 7 864.44 50 1.209.00
– 9 754.47 8 871.64 60 1.299.00
– 8 781.06 9 878.88 70 1.392.00
– 7 767.67 10 886.16 80 1.490.00
– 6 774.33 11 893.48 90 1.591.00
– 5 781.03 12 900.83 100 1.696.00
– 4 787.77 13 908.23
Table 4: Sensor values KTY 81-110

Flue gas sensor (PT100):

Temperature Resistance Temperature Resistance Temperature Resistance
[°C] [ohm] [°C] [ohm] [°C] [ohm]
0 100 100 139 200 176
10 104 110 142 210 179 Short circuit – 30 °C
20 108 120 146 220 183 Interruption 350 °C
30 112 130 150 230 187
40 115 140 154 240 190
50 119 150 157 250 194
60 123 160 161 260 197
70 127 170 165 270 201
80 131 180 168 280 204
90 135 190 172 290 208
300 212
Table 5: Sensor values PT100

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 2 System installation

2.2 Installing the fuel extractor

These warning and safety instructions apply for all fuel extractor variants (FE)!

Attention! Danger of entanglements at inspection openings, stirrer and open FE trough!

Electrically de-energise FE and system and safeguard against restart before opening!

Use SELV lights for installation and maintenance tasks!

To avoid ignition sources, do not install lights, switches, outlets, or junction boxes in the fuel
­storage room.

The customer-supplied connections must correspond to the local guidelines, regulations, and laws.
Specifically the electrical equipment of the machine must satisfy the specifications of EN 60204-1,
prEN 60204-11 and EN 60204-1.

The customer must supply earthing or equipotential bonding in accordance with EN 60204-1.
Also comply with the local regulations, guidelines, and laws.

The customer must provide appropriate lightning protection devices if the FE, or parts of the
FE project, outdoors.

Pay attention when removing blockages!

When loosening blocked moving parts, there is danger of injury.

If the FE is stored for an interim period:

• Store electrical parts where they are dry and protected from mechanical damage!
• Store FE where it is stable and cannot slip – secure in place if necessary!

All threaded unions are provisional and are only designed for transport!
All threaded unions must be tightened during installation!
The FE only becomes stable when the threaded unions are firmly tightened during the
­installation process!

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 Wall-duct box (inspection box)

Page 52 
2.2.1
Spring-blade rotary stirrer
Articulated rotary-blade stirrer
2 System installation

Worm gear unit

(31013021)

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Fig. 112: Overview presentation – FE Standard
Position – temperature monitor
(59000040)

BA Multifire 08/2008 
Spur-wheel back-geared motor
Inspection cover with sticker:
(3010550V)
Attention: Danger of entanglement!
2.2.1.1 Components of the FE standard

Prior to opening, switch off the worm

and safeguard against restart!

Inspection cover with sticker:

Attention: Danger of entanglement!
Installing the fuel extractor Standard

Prior to opening, switch off the worm

and safeguard against restart!

Partial cover conveyor worm,

storage room side

Cover – chain wheel box Cover conveyor worm,

boiler room side

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 2 System installation

Washer, M12 (level compensation)

4x flange screws M8 x 30

Flange screw M8 x 25
2x hex nut M8 SS

Hex cap nut M8

Washer M8
Compression spring
Washer M8, large
3x hex nut M8, flat

Limit switch

Feather key 10x8x40

Shim ring ø 35/45, s = 2 mm

2x stud bolt M8 x 10 Flange nut M8

Washer M8

Chain wheel z = 15 Hex nut M8 SS

Connecting link 1x L, 1x R
Stud bolt M10 x 35 Flange screw M8 x 30
Bearing ø 35
4x flange nut
Cover plate (silicon)
Chain wheel z = 30
1x flange screw M10x20 Chain, 451xlinks
hex screw M12x55 2x hex nut M12 SS 4x anchor bolts M10x85
8x flange screw M12x25 12x saucer-head screw M10x20 6x washer M12 6x flange screw M8x25
1xFE
Fig. 113: hexStandard:
screw M12x35 12x hex nut M10 SS
Detail – boiler room 1x lock washer M12

Hex screw M12x35

(bond, e.g. with Loctite 243)
Standard_RA\Schraubensatz_Standard_RA_Bunkerseitig_080506.pdf
T:\PLAN\A_Hackschnitzelheizung\AD_Raumaustragung\ADZ_Gesamtzeichnung\ADZZ_0-100kW\Explosionsdarst_Doku

Lock washer M12

Washer Ø60
Threaded union trough cover:
Saucer-head screw M10x20
Hex nut M10 SS

Flange screw M10x20

4x flange screw M12x20

4x washer large M12

Saucer-head screw M10x20 Hex nut M10 SS

1x L, 1x R
Hex nut M12 SS 2x flange screw M12x25
1x L, 1x R
1x L, 1x R Hex nut M12 SS
Washer M12
Anchor bolt M10x85
2x washer large M12

Hex nut M10 SS

4x flange screw M12x20

Fig. 114: FE Standard: Detail – storage room

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 2 System installation

Fig. 115: Detail – articulated rotary-blade stirrer

All threaded unions must be tightened during installation! Exceptions in this regard are the
­connecting screws of the leaf spring extensions; strictly ensure that these remain movable!
All FE variants only become stable when the threaded unions are firmly tightened during the
­installation process!
All threaded unions are provisional and are only designed for transport!

The FE is partially pre-assembled and brought into the installation room – if necessary the FE can be dismantled. For a
worm length starting at 5 m one support is supplied; for worm length over 8 m, 2 supports are supplied. These supports
must be adjusted in such a manner that the trough is aligned.

If the incline of the FE is greater than 15° the sheet metal at the
predetermined breaking point of the fire shutters (FS) must be removed.

Caution!
If the fuel extractor incline is too great it can slip downward. When
aligning and installing the fuel extractor should be held in position
by an installation person!

Fig. 116: Remove the FS sheet metal

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 2 System installation

2.2.2 Installation – FE trough Standard

Loosen the screws that clamp the FS to the tank. Align the FS to what
will later be the trough position; initially leave the screws loose.
Slide the trough through the wall opening between boiler room and fuel
storage room, and place it on the FS shutter. In this process the U-profile
U-profile of the FE must engage in the drop shaft upper edge of the FS. If necessary
correct the alignment of the FS.

Fig. 117: Place the trough

Bolt on the foot fastening bracket (2) for the squared hole of the trough
floor.

• Saucer-head screw M10 x 20 screw, self-locking hex nut

Bolt 1x

Fig. 118: Bolt the bracket to the trough

Lift the trough with a winch far enough that the planned extension of the
trough upper edge (laser) is also located at the lowest point of each wall
position, at least 5 cm above the floor.

at least
distance 5 cm

Fig. 119: Adjust the FE height

Cut the foot brace to the correct length (maximum length is one centimetre
below the upper edge of the FE trough).

Fig. 120: Cut the feet to size

Bolt the feet to the trough and the foot fastening bracket.

• 2 flange screws M12 x 25 (from inside to outside)

• 2 washers, 2 self-locking hex nuts

Fig. 121: Bolt the feet

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Fix the feet in place below with the mounting aid. Lift the
gear unit with the second mounting aid into the trough and bolt it to the
foot fastening bracket and trough. Do not tighten the screws.

• 4 flange screws M12 x 25, 2 large washers

Fig. 122: Bolt the gear unit

Grease the worm-side toothing.

Slide the adapter (cast-iron claw coupling) onto the spline of the gear
unit to the stop. Lift the worm into the trough and slide it into the adapter
until the stop.

Fig. 123: Connect the worm to the gear unit

Worms over 6 m in length are delivered in parts.

DO NOT weld the worm – axial forces are absorbed by the gear unit of the stirrer.
Insert the worm elements into each other in such a manner that the volution is continuous (Fig. 125)!

Grease the plug-in

connection!

Fig. 124: Worm connection Fig. 125: Continuous volution

Bolt the conveyor trough cover / gear unit cover to the trough.

• Foot fastening bracket: Hex flange screw M10 x 20

• Gear unit: 4 hex flange screws M12 x 25, 4 large washers
• Trough seam: Saucer-head screws M10 x 20, self-locking nuts

Now also tighten the screws under the gear unit and remove the
wood batten.
Fig. 126: Screw on the cover

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 2 System installation

Position the fuel extractor in the bunker. In this process the spline (centre
of stirrer) should be centred to max. 20 cm left (viewing direction from
the stirrer to the boiler room).

The supports for the gear unit box should contact the floor full surface.
Place the four bolt anchors (bore Ø10).

• 4 bolt anchors M10 x 85

Fig. 127: Fix the FE in place in the storage room

Bolt the fuel extractor to the fire shutter.

Two connections:
• 2 hex screws M10 x 120, 2 washers
• 4 hex nuts (counter)
• 2 washers, 2 self-locking nuts

Fig. 128: Connect the FE to the FS

Now firmly clamp the fire shutter onto the tank and seal the gap near the
drop shaft with silicon.

Fig. 129: Safety shutter, clamp and seal

2.2.3 Installing the worm drive

Screw in the 4 M10 x 35 stud bolts on the face side.

Fig. 130: Place the stud bolts

The chain wheel box can be mounted right or left. The worm must always
be fastened in the lower hole group.
Slide the chain wheel box onto the stud bolts of the FE trough, and first
slide 2 spacer washer on the worm end to the stop.

(The number of spacer washers may need to be corrected, as described

later)

Fig. 131: Fasten the chain wheel box

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Slide the flange bearing over the end of the worm onto the stud bolts
Bearing flange
(lubricating nipple on the side).

When bolted together the worm should have max. axial play of 2 mm.
Spacer This distance, which is set by adding or removing the spacer washers,
washers must be strictly maintained.

Fig. 132: Adjust the axial play

Centre the worm by lightly lifting it and firmly screwing the bearing flange
into this position.

• 4 flange nuts

Afterward check the required 2 mm axial play again and if necessary

correct the play via the spacer washers.

Fig. 133: Bolt on the bearing flange

Do not tighten the two set screws.
Cover sheet
Fasten the cover sheet metal with silicon.

Fig. 134: Shaft & cover sheet metal fastening

Bolt the motor to the chain wheel box. Do not tighten the nuts.
Grease the shaft end.

Place the feather keys in the shaft grooves and carefully place the chain
wheels onto the shaft ends with the soft-faced hammer.
(Chain wheel Z30 on worm, chain wheel Z15 on motor)

Fig. 135: Motor installation

The two chain wheels must be mounted flush.

Compare the distances of the two chain wheel front edges to the gear
box (measuring tape).
If necessary slide the motor side chain wheel until the chain wheels are
same distance from the chain wheel box.
Then fix the chain wheels in place on the shafts with the set screws.

Fig. 136: Chain wheels

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Before putting on the chain, check the parallel clearance of the leaf springs to the FE trough. To do
this install the stirrer and the leaf springs as described in point 2.2.3 and 2.2.4. During one complete
rotation, check for the prescribed parallel distance as described in Fig. 154 and 159).

Place the drive chain over the chain wheels and connect with the
connecting link.

Tension the chain by sliding the motor. The chain should allow deflection
of approximately one cm. Then tighten the screws to fasten the motor.

Grease the chain and mount the lid of the chain wheel box.

Fig. 137: Chain installation

2.2.4 Installation, inspection box, cover, and overfill protection

Bond the sealing tapes along the upper edge until you reach the cover
sheet metal of the FE trough.

Fig. 138: Apply the sealing tapes

Position the inspection box (IB) on the bunker side, flush with the wall.
Drill two Ø 8.5 mm bores into the FE trough in accordance with the IB
hole pattern.

Fig. 139: Fasten inspection box

Bolt the inspection box to the trough. Compensate the level with an M12
washer.
In the storage room:
Sealing strip
• 2 flange screws M8 x 30
• 1 washer M12 (level compensation)
• 2 washers M8
• 2 self-locking hex nuts (storage room side)

Then drill and fasten the inspection box on the boiler room side as well.
Washer M12
• 2 flange screws M8 x 30, 2 hex flange nuts M8

Fig. 140: Detail – inspection box fastening

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Now determine the required length for the trough cover. To do this,
measure the distance from the chain wheel box to the front edge of the
inspection box and add 15 mm as overlap area!
dge,
Front e x
. b o
insp Shorten the trough cover to this length:
Deburr all interfaces.
When installing use 1 mm shims.
This prevents damage to the paint finish.
,
gth et
Len er she
cov
Fig. 141: Size the trough cover
Bolt the baffle plate and limit switches onto the trough cover and lock
the limit switches.

Pos. 1 hex flat nut M8

Pos. 2 limit switch brass nut, lock nut

Fig. 142: Baffle plate/limit switch installation 1

Insert the cable bushing, lay out the cable as shown and tension it slightly.
This position prevents damage to the cable due to the worm!

Fig. 143: Baffle plate/limit switch installation 2

The baffle plate (1) must be in front of the floor sheet metal (2)
This is the only way to ensure that the fuel is conveyed into the
fire shutter without obstruction.

Fig. 144: Baffle plate/limit switch installation 3

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 2 System installation

Bolt the cover onto the trough.

Pos. 3
• These screws are only introduced from below:
• 2 hex flange screws M8 x 30, 2 hex flange nuts M8

Pos. 4
• These screws are only introduced from above:
• Hex flange screw M8 x 25, hex flange nut M8

Fig. 145a: Bolt on the trough cover

If the last pair of holes is more than 10 cm away from the inspection
box you must re-bore and re-bolt.

Fig. 145b: Transfer hole pattern

First firmly clamp the upper inspection cover up near the compression
springs. Tightly screw on the flat cap nut.

• Large washer, compression spring, washer, hex cap nut M8, flat
Then carefully screw down the two other nuts. The seal must be pressed
uniformly all around the cover.
• 2 self-locking hex nuts M8
Seal the joint all around between trough and chain wheel box with
silicon.

Affix the warning sign on the inspection cover!

Fig. 146: Mount the inspection cover
Slide the temperature monitoring sensor into the fuel storage room from
the heating room, far enough into the guide pipe that wall thickness is
overcome and the sensor is located in the storage room. However the
sensor should not project over the pipe or be exposed.
To fix the cable in place, seal the inlet point of the guide tube with
silicon.

Fig. 147 Thread in the boiler room temperature

monitor
Bolt the cover of the inspection box (wall duct box). Bond the rock wool
insulation around the inspection box and seal the insulation with the
aluminium edge protection.

• 4 screws M8 x 20, 4 washers,

• Rock wool, aluminium adhesive tape

Affix the warning sign on the inspection cover!

Fig. 148: Install inspection lid, insulation

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 2 System installation

To conclude, cable the fuel extractor and connect the plug-in connector
to the I/O board in accordance with the numbering.

Fig. 149: Cable guide

2.2.5 Transfer sloping floor plane

Transfer the sloping floor plane (of the circulating stirrer elements) onto
the bunker walls. To do this, place a laser levelling device on the drive
shaft and rotate it by 360°; have a second installer mark the height on
the bunker walls. The laser levelling device must always rest flat on the
shaft end in this process!
Ensure that the laser beam shows a height offset by “X“! The marking for
the upper edge of the sloped floor must also be marked with a downward
Sloped floor
upper edge offset by “X“!

Fig. 150: Sloping floor level

For this use a template (wood, sheet metal, cardboard, marked with the
“X” value).
y
Laser displa Align on the laser. The upper edge of the template marks the upper edge
of the sloping floor. Mark the corners of the bunker walls and connect the
markings with a chalk line.
Sloped floor This consistent reference line is the upper edge for the sloping that the
upper edge
customer must provide.

Fig. 151: Mark the sloping floor

2.2.6 Installing the articulated-blade rotary stirrer

If you are not installing an articulated-blade rotary stirrer, proceed to the next section (2.2.7).

The mechanism is pre-set in the factory with reference to parallelity, opening angle and clearing diameter 4.5 – 5 m.
For safety reasons the only tension and secure the tension springs on site with set screw (Fig. 152, Pos. 2); tension to
the pair of hex nuts.
(For a clearing diameter of 5.5 m the tensile force of the springs must be increased.)

Attention! Danger of injury due to opening of the steel arms!

FIRST MOUNT THE STIRRER ON THE GEAR UNIT!
BEFORE TENSIONING THE SPRINGS DETACH THE STEEL ARM TRANSPORT SAFEGUARD!
After mounting, the steel arms are under high mechanical tension!

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 2 System installation

Grease the spline of the worm gear unit and set the stirrer on it.
Remove the transport safeguard of the steel arms.

Bolt the stirrer onto the drive shaft.

Pos. 1 washer Ø 60, lock washer, hex screw M12 x 55

This connection must be additionally secured with thread lock

“Loctite 243” (or equivalent).

Pos. 2 for clearing diameter 5.5 m:

Readjust the spring force – screw the pair of hex nuts 10 mm in the
direction of the springs.
When the transport safeguard is removed tension the spring to the hex
pair of nuts (Pos. 2). The steel arms will increasingly open in this process.
Fig. 152: Mount stirrer & adjust spring force
Fix this unit in this position with the hex nut.

Install the pre-bolted leaf springs with the steel arms.

Insert the M10 screws through the leaf springs and steel arms counter
to the direction of rotation (the M8 screws of the pre-bolted leaf springs
will point in the direction of rotation).
Align the leaf springs to the height of the steel arms. The steel arms and
leaf springs must be flush and run parallel to the FE trough Tighten
the nuts.

Per arm:
• 2 hex screws M10 x 45, 4 large washers, 2 self-locking hex nuts M10

Fig. 153: Install leaf springs

Check the parallel spacing of the leaf springs and steel arms relative to
the FE trough. Target distance is 15 – 25 mm above the FE trough.

Install the clearing rakes (carriers) on the ends of the leaf springs (these
may possibly be pre-installed).
The tips must point in the direction of rotation.

Fig. 154: Leaf spring – trough clearance

If the clearing rakes of the leaf springs scrape against the walls
(in rectangular bunkers and for wall-duct boxes), then hardwood boards
(20 x 3 cm) must be mounted for the customer-supplied sloped floor
installation.

This prevents wall parts from detaching and getting into the FE.
In addition this measure also reduces noise.

Fig. 155: Leaf spring travel

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 2 System installation

Bolt on the stirrer disk.

• 6 flange screws M8 x 25

Fig. 156: Install steel arm – stirrer disk

2.2.7 Installing the spring-blade rotary stirrer

Bolt the leaf springs to the stirrer disk with the nut on the inside.
(The M8 screws of the pre-bolted leaf springs will point in the direction
of rotation in this process).
The leaf springs must run parallel to the cover plate of the stirrer disk.

Per spring:
• 2 hex screws M10 x 45, 2 large washers, 2 self-locking nuts
Attention: Do not tighten the screws of the leaf springs!

Fig. 157: Install the leaf springs 2

Grease the spline of the worm gear unit. Lift the stirrer disk onto the drive
shaft and bolt it on.

• Hex screw M12 x 35, washer Ø 60, lock washer

This connection must be secured with a thread lock adhesive
­“Loctite 243” (or equivalent).

Fig. 158: Install spring-blade rotary stirrer

Check the parallel spacing of the leaf springs relative to the FE trough.
Target clearance is 15 – 25 mm above the FE trough.

Install the clearing rakes (carriers) on the ends of the leaf springs (these
may possibly be pre-installed).
The tips must point in the direction of rotation.

Fig. 159: Leaf spring – trough clearance

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 2 System installation

If the clearing rakes (carriers) of the leaf springs scrape against the walls
(in rectangular bunkers and for wall-duct boxes), then hardwood boards
(20 x 3 cm) must be mounted for the customer-supplied sloped floor
installation.

This prevents wall parts from detaching and getting into the FE.
In addition this measure also reduces noise.

Fig. 160: Install leaf springs

2.3 FINAL INSPECTION

To conclude, check whether all covers are installed!
Check whether all stickers are affixed and that all documents concerning the system are present!
Clean the system and clean the construction site. Always leave a clean room after installation!

Check whether the installation and establishment of all connections have been correctly executed.
To conclude, check whether the conveying system is free of foreign objects.

Check whether all electrical connections have been correctly established before energising
­the system!

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 3 Commissioning

3 Commissioning
Only qualified specialists should commission the system. Before you can start the commissioning process the connec-
tions of the boiler system and of the hydraulic system must be finished. Check whether the installation and establishment
of all connections (water, chimney, electrical) have been properly executed in accordance with point 2 “System instal-
lation”. If the fuel storage room or the storage container has not yet been adequately filled with fuel, execute this task in
accordance with the point 4.3 – Filling / adding fuel” of the operating manual. If all prerequisites are satisfied, then ensure
that the entire heating system is filled with water and that the heat can be dissipated. If this is the case you can start the
commissioning process.
Ensure that the direction of rotation of the motors is correct!!

3.1 Switching on the main switch

The main switch of the system is on the front side of the intermediate cladding (see operating manual point 5.1. – “Main
switch”). A short time after switching on, the KWB Comfort control unit will display the header screen on the boiler control
unit. If the control unit is not completely set, or if all parameter-assigned devices are not connected or are defective, then
alarms will be output on the display.
Activate the “Set” button to delete the displayed alarm, but as before it will still be queued (alarm icon in the lower right
corner of the display). Use the dial to display other alarms that may have occurred. You must acknowledge each of these
alarms in the manner described.
(See point 7 “Troubleshooting” in the operating manual for more information)

3.2 Setting the parameters

If you are not yet familiar with the KWB Comfort control unit, first read point 5.2 “Menu-driven operation” in the operating
manual.
If the alarm, “00” The control unit is not completely set” occurs when switching on the main switch, you must set date
and time in accordance with point 5.2.3.9 in the operating manual.
In the main menu select the item “Specialist Level” and enter the code “100”. Now you have access to the settings for
the specialist level. Proceed chronologically through the following menu levels of item 4 “Specialist Operation” and make
the desired settings.
Basic settings......................................................................................................................... see 4.2
Boiler temperature . ...................................................................................................................... see 4.2.1
Return flow boost ......................................................................................................................... see 4.2.2
Mixer return flow boost . .............................................................................................................. see 4.2.3
Fuel extractor ............................................................................................................................... see 4.2.4
Fuel extractor fill time . ................................................................................................................. see 4.2.5
Pump afterrun . ............................................................................................................................. see 4.2.6
Boiler pump .................................................................................................................................. see 4.2.7
Language . .................................................................................................................................... see 4.2.8
Second boiler ............................................................................................................................. see 4.2.59
Cleaning ..................................................................................................................................... see 4.2.10
Network settings . ...................................................................................................................... see 4.2.11
Boiler ................................................................................................................................ see 4.2.1
EXT 2 ............................................................................................................ see 4.2.11.1.1
Power output ................................................................................................ see 4.2.11.1.2
Heating circuit ............................................................................................................. see 4.2.11.2
DHWC ......................................................................................................................... see 4.2.11.3
Buffer . ......................................................................................................................... see 4.2.11.4
Digital remote control .................................................................................................. see 4.2.11.5
Power measurement..................................................................................................... see 4.2.11.6
Hardware ................................................................................................................................... see 4.2.12
Frost protection .......................................................................................................................... see 4.2.13
Outputs: ..................................................................................................................................... see 4.2.14
Fan.............................................................................................................................................. see 4.2.15
When all parameters are set, save them with menu item 5.2 – “Save / Reset”.
The settings are now permanently saved. They will not be lost if there is a power failure.

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 3 Commissioning

3.3 Function check of the system parts

Relay test..........................................................................................................................  see 4.3
Boiler....................................................................................................................................... see 4.3.1
Heating circuits....................................................................................................................... see 4.3.2
DHWC..................................................................................................................................... see 4.3.3
Buffer...................................................................................................................................... see 4.3.4
Fuel extractor.......................................................................................................................... see 4.3.5
Second boiler.......................................................................................................................... see 4.3.6
Supplemental fuel extractor.....................................................................................................  see 4.3.7
Network analysis.............................................................................................................  see 4.4
Overview................................................................................................................................. see 4.4.1
Boiler module.......................................................................................................................... see 4.4.2
Heating circuit module............................................................................................................ see 4.4.3
Digit. remote control unit.........................................................................................................  see 4.4.4

3.4 Switching on the system in the menu

Now switch the system “on” with the main menu item “System On/Off”. Ensure that a heat request is present (e.g. activate
boiler charging). Thereafter the system will start up as follows:

• The fire shutter opens (approximately 2 min) then the fuel extractor starts up and conveys fuel into the hopper.
The stoker worm is in continuous operation after the system is switched on and conveys fuel to the burner plate
until the minimum level is reached.
• Supply conveyance of the fuel extractor stops when the container is filled with fuel. For USV D systems the fire
shutter remains open as long as the burner is in operation; for USV ZI systems the fire shutter closes.
• When there is a proper heat request fuel is pushed onto the burner plate to the ignition level; after the ignition wait
phase the ignition process begins. During the ignition process the fire shutter is closed.
• After ignition the flue gas temperature increases. The fuel bed is formed in a ring-shape.
• The system then switches to “Operation”, heats up the boiler, and starts to supply consumers. When heat
consumption abates the boiler automatically cuts back its capacity and finally transitions to “Ready” operating
status when the target boiler temperature is reached.

Taking system measurements is an important step, however this step can only be executed
after an extended period of operation.
Initially the emission values are influenced by the residues of the boiler paint finish!

At least the CO2 content of the flue gases should be measured immediately after commissioning.

Now instruct the system owner in how to operate the system; proceed as specified in the operating manual for this.

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 4 Operation, specialist

4 Operation, specialist
In the main menu select the item “Specialist Level” and enter the code “100”.
Now you have access to the settings for the specialist level.

4.1 Menu item – Heating Circuits

4.1.1 Operating values

Maximum temp.: Maximum forward flow temperature.

Minimum temp.: Minimum forward flow temperature.
Gradient: The control unit calculates the necessary forward flow temperature for the heating circuits
from the outdoor temperature, the target room temperature, and the heating curve gradient.
This temperature is adjusted through mixer control (colder return flow water mixed with the
forward flow water).
Reference point offset: For the heating curves, setting of a reference point offset of ± 10° is possible. The gradient
of the heating curve is then changed automatically so that the forward flow temperature
remains constant at – 20°. See the diagram on the next page!
Room influence: The room influence indicates whether the room temperature should be considered in the
calculation of the forward flow temperature setpoint. The factory setting is 0, i.e. room
temperature is not considered. If a temperature sensor is connected to the heating circuit
then a factor can be entered for the room influence. This factor is entered as a percentage
value, the actual calculation is executed according to the following formula: Correction value
for the forward flow temperature_target = I_room influence / 10 * (room_temp_target –
room_temp_actual).
Pump enable: The pump enable conditions can be selected. Settings: See table.
Enable temperature: Minimum temperature, starting at which the pump starts up.

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 4 Operation, specialist Heating curve diagram KWB Comfort
Room temperature 20°C
Reference point offset 0, +10 , -10 °C
Heating curve diagram – KWB Comfort
Room temperature 20°C, reference point offset *0,  **+ 10, ***– 10 °C

2 2,25 2,5 2,75 3

90

1,75

80

1,5

70

1,25

60

1
 C °C
temperature
temperature

50
0,75
Forward
Forward flow
flow

40
0,5

30

0,2 **+ 10 °C

20
*0 °C

10
***– 10 °C

0
0
2
4
6
8
-8
-6
-4
-2

10
12
14
16
18
20
22
24
26
28
30
32
34
-20
-18
-16
-14
-12
-10

Outdoor
Outdoor temperature
temperature °C °C
Fig. 161: Heating curve diagram

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The heating curve shows the relationship between outdoor temperature and forward flow temperature at a specific
room temperature. It must be adjusted by changing the gradient on the house and heating system. The heating curves
at different gradients are shown in Fig. 72. This diagram only applies for a room temperature of 20 °C. If the room
temperature deviates the curves will shift upward or downward accordingly. If room temperature deviates, only the level
changes, the gradient will remain the same.
Usual values for the gradient:
Underfloor heating system .............................................................. 0.3 – 1.0
Radiator heating . ............................................................................ 1.2 – 2.0
Convector heating . ......................................................................... 1.5 – 2.0

Well-insulated structures with low-temperature heating elements require small gradients.

The room influence and fast reduction must be switched off to adjust the heating curve. Every day the steepness is
increased by 0.1 (room is too cold) or lowered (room is too hot) until the target temperature agrees with the actual
temperature. The heating element valves should be open during the adjustment process (thermostat valve completely
open). The outdoor temperature should be under 0 °C. Additional heat sources (chimney) or consumers (ventilation)
should not be used during this period.

Room influence: Here you can enter the extent to which the calculated forward flow temperature will be corrected by
the room sensor. If the actual temperature is greater by 1 °C than the target room temperature, then the
forward flow temperature at 100 % (200 %) room influence, will be calculated for a room temperature that
is one 1 °C (2 °C) under the target room temperature.
Fast reduction: If this function is switched on the heating circuit pump will switch off when the actual temperature exceeds
the target room temperature by 1 °C.
Pump enable: Enable condition Heating DHWC Buffer
circuit
Boiler or buffer temperature must be
Auto(matic) greater than the target forward flow × × ×
temperature of boiler and buffer
Boiler or buffer temperature must be
Temp(erature) × – –
greater than the enable temperature
On None × × ×
Runtime, mixer: Runtime of the mixer for one cycle in seconds (factory setting is 5s).
Idle time, mixer: Idle time of the mixer for one cycle in seconds (factory setting is10s).
Table 6: Heating circuit settings
Runtime and idle time determine the set speed of the mixer motor for opening and closing. It can be adjusted to the
sluggishness of the temperature measurement on the forward flow sensor. If the mixer motor is fast and the temperature
sensor responds slowly (e.g. contact sensor without insulation) overshooting of the control unit can occur. In this case
the mixer will open and close constantly. A uniform temperature is not set on the forward flow. Overshoot is corrected
by reducing the runtime or increasing the idle time. Mixer travel is limited to 50 cycles in one direction. Consequently the
runtime must be at least as great as 1/50th of the time that the mixer requires to move from the “Closed” position to the
“Open” position in continuous operation.

4.1.2 Outdoor temperature dependent

Outdoor temperature If this function is switched on, the heating circuit switches to “Off” in heating programs 1 and 2, when
dependent switch-off: the heating limit is exceeded on the outdoor sensor.

Heating limit day: Temperature limit for operation with the day room temperature.
Heating limit night: Temperature limit for operation with the night room temperature.

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 4 Operation, specialist

4.1.3 Menu item – DHWC

Legionella protection: With the legionella protection function the DHWC temperature is heated to 65 °C on a selectable
day of the week. This function can also be switched off.
Pump enable: Adjustable enable criteria (Table 6)

4.1.4 Menu item – Buffer

Pump enable criteria can also be set for buffer operation. (Table 6)

4.1.5 Menu item – Boiler Program

Boiler program: Selection of the boiler program

Changing times: You can change the factory settings for each day as desired. For switch points that are not
required, select the same value for “Begin Time & “End Time”. Use the setting “Monday-Sunday”
to make changes that are valid for all weekdays.
Boiler
sequence times: Adjustable for alternating operation: Capacity utilisation of the specific boilers

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 4 Operation, specialist

Request The boiler maintains the boiler temperature only at the request of a heat consumer. Other than in
special cases this setting should always be selected.
Time program: At the specified times the boiler always maintains its boiler temperature. In the interim it is only
activated on request from a heat consumer.
Continuous operation: The boiler always maintains its boiler temperature.
Slave boiler: The auxiliary boiler is always the slave boiler.
Alternating operation: The role of master boiler is swapped between the two boilers in an adjustable rhythm.
The rhythm can be set under the boiler program – sequence times.
Double operation: Both systems run in parallel operation in response to a request.

4.2 Menu item – Basic Settings

4.2.1 Boiler temperature

Actual temp.: Actual temperature of the boiler water

Target temp. 1: Target temperature of the boiler water at normal operation.
Target temp. 2: Target temperature of the boiler water on request via the “External 2” input
(External 2 – mode must be set to “Heat to target 2”, see point 4.2.10.1.1).
Ext. target temp.: External target temperature of the boiler water
Ext. target temp.: Status display on/off
Function: Status display on/off
Strength of the analogue signal: 4 to 20 mA or 0 to 20 mA
Range: Control unit range 50 – 90 °C
Analogue input: Momentary value
Ext. target temp.: Actual value
The control unit has an automatic setpoint calculation feature. The value set for “Target” (1st or 2nd setpoint) is the
minimum setpoint (setting range 65 to 90 °C) of the boiler water temperature. If the value determined from the highest
requested consumer forward flow temperature is +3 °C greater, it is specified as the calculated setpoint. In this manner
the setpoint can glide between the set minimum value and max. 90 °C. In the example above “Target 1” can glide
between 70 and 90 °C, and “Target 2” can glide between 80 and 90 °C depending on the consumer request. If there is no
specification from the consumers (e.g. without heating circuit module) then the system is regulated to the set minimum
setpoint.

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 4 Operation, specialist

4.2.2 Return flow boost

Thermal valve: The minimum temperature on the boiler return flow is regulated by a thermal valve.
Mixer regulation: The minimum temperature on the boiler return flow is regulated by a mixer connected to the
control system.
Bypass pump: The minimum temperature on the boiler return flow is governed by a speed-regulated pump
in the bypass between boiler forward flow and boiler return flow. This hydraulic circuit is not
possible in combination with a buffer.
The set variant is shown by the initials in the header.
The possible circuit variants of the return flow boost are provided in the Appendix, drawing no. MBEH0001.
When the return flow temperature drops below 47 °C for 30 minutes, alarm 10 appears in the display.

4.2.3 Mixer return flow boost

Runtime / idle time Controls the set speed of the mixer – compensates for product-specific differences.
Temperature: Desired return flow temperature (at least 55 °C)
Adjustment of the set speed of the mixer for boosting the return flow.

4.2.4 Fuel extractor

Setting the container variant

V Storage container system 1 m³ (15 to 40 kW)
ZI Fuel extraction with hopper (200 l – 15 to 100 kW)
D Direct fuel extraction (15 to 100 kW), stoker and fuel extractor run parallel
GS Vacuum conveyor system with worm
GL Vacuum conveyor system with suction lance

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 4 Operation, specialist

4.2.5 Fuel extractor fill time

Max. fill time: Setting of the maximum runtime of the fuel extractor. This should not be too short and depends
on the boiler output.
Last filling: On/Off
Time: Time entry for the last filling to prevent possible noise development during the night hours.
As soon as the container is emptied the fuel extraction switches on again.
Pellet suction system General information on the vacuum conveyor system (GS + GL)
If the vacuum container requests fuel, the vacuum fan starts up. Approximately 10 seconds
later the motor of the extractor worm starts up and moves pellets into the air current. At runtime
“100 s” (factory setting) the extractor motor runs for 100 seconds until the container is full.
If an idle time is not entered (“0 s” is factory setting), the extractor will immediately run another
100 seconds, etc. Thus the idle time always interrupts the runtime phases. (There are no
settings for the vacuum fan – it runs independently until the container is full and switches off
approximately 10 seconds later)
Runtime: Runtime is that interval and period during which the fuel extractor runs, and during which the
extractor worm transports pellets into the conveyor hose.
Idle time: Idle time is that interval and period during which the fuel extractor is at a standstill and no pellets
are transported into the extractor trough.
We recommend “runtime 10 s” and “idle time 3 s” for
•  Significant fine content, long conveyor distances,
•  A significant height differential,
•  High quantities of pellets in the conveyor hose (underground tank)

4.2.6 Pump afterrun

After switching off the boiler the boiler circuit pump and the last consumer pump will still run for another 300 seconds to
prevent heat accumulation in the boiler due to the residual heat of the fuel bed. If in spite of this measure, problems due
to the boiler overheating occur, then the afterrun time can be increased.
For troubleshooting it can be helpful to briefly set the afterrun time to “0”. With this measure you can immediately tell
whether the observed aggregate actually switches off at the control system’s command.

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 4 Operation, specialist

4.2.7 Boiler pump

Speed: Setting of the maximum speed of the boiler circuit pump.

Min-speed: When setting the return flow boost to “Bypass” the minimum speed of the boiler circuit pump can be set
here, the minimum is 35 %.

4.2.8 Language

Select the language version.

System operation is possible in German, Italian, French, Slovenian, English, and Spanish.

4.2.9 Second boiler

If the plug-in module is installed, a log wood boiler (second boiler) can be controlled:

Switchover at: When this temperature is exceeded the wood chip boiler is switched off (with an hysteresis
of +/– 2 °C). Status of the second boiler: “Normal operation”.
Overheating at: When this temperature is exceeded, all heat consumers are switched to maximum heat
withdrawal. Status of the second boiler: “Overheating”.
Operation – boiler p.: On: The boiler pump of the automatic boiler runs in tandem with the second boiler pump.
Off: The boiler pump of the automatic boiler does not run in tandem.
(Diagram no. MAEH0004 – hydraulic circuit for the connection of a second boiler) (log-wood boiler)

4.2.10 Cleaning

Time: At this time the heat exchanger cleaning system is switched on.
The mixer and pump blocking protection is coupled with the heat exchanger cleaning system.
The pumps and mixers are also activated to prevent blocking after a longer period of standstill.
Duration: Duration of the cleaning interval (5 to 20 seconds)

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 4 Operation, specialist

4.2.11 Network settings

The function units available in the total system are configured in the network settings. The settings must be made
beforehand in the “Hardware” menu.

4.2.11.1 Boiler

4.2.11.1.1 EXT 2
Specification of the function of the “External 2” input.

Heat to target 2: If the input is closed, the boiler heats up to the “Target 2” temperature, regardless of the
temperature of an existing buffer. Otherwise it works in normal mode. Thus for example you can
implement: The legionella program from an external control system, activation of the chesse
factory boiler for disinfection, or of the fan in the workshop, request of supplemental control
system for additional heating circuits.
Holiday If the input is closed the boiler works in normal mode. If the contact is open boiler and heating
remote control: circuit are switched to frost protection mode, and the set date of holiday end is not effective.
Thus telephone remote switching for the heating system of vacation homes, for example, can
be implemented.
Boil seq. If a boiler master-and-slave circuit is present this selection must be made for the main boiler.

4.2.11.1.2 Power output

Specification of the function of the “Power” output.
Heating mode: The output is set if the burner is running.
Boiler master-and- Request of a second boiler via this output (for information on setting the parameters: see
slave circuit: point 4.2.13 – “Outputs”).
Fuel extractor: Activation for the drive of a common stirrer (for execution with a double room extractor) on
the fuel extractor module. The floating relay output is set when the FE is running. Scope of
delivery: Connection cable 10 m, 2-pole. 0.5 mm² with AMP mini 3-pole. plug-in connector
Art no. 13-1000439

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 4 Operation, specialist

4.2.11.2 Heating circuit

Room sensor: Specification of the room temperature sensor assignment for the selected heating circuit.
Boiler / 0: Room sensor is connected on plug-in module 1 (plug-in connector 52).
Boiler / 1: Room sensor is connected on the boiler I / O module (plug-in connector 27).
Boiler / 2: Room sensor is connected on the boiler I / O module (plug-in connector 31).
HCM 1 / 1: Room sensor is connected on heating circuit expansion module 1 (terminal 1 2).
HCM 1 / 2: Room sensor is connected on heating circuit expansion module 2 (terminal 1 1).
HCM 2 / 1, etc.: As above for the additional heating circuit expansion modules
DRCU 1: Room sensor on the digital remote control unit 1
DRCU 2, etc.: Room sensor on the other digital remote control units
Boiler CU: Room sensor on the boiler control unit. Optimally an analogue room control unit should be placed
next to it, because the sensor of the boilerCU can only be used while the boilerCU is plugged
into the wall socket.
Outdoor sensor: Specification of the outdoor sensor assignment to the selected heating circuit
Boiler: Outdoor sensor is connected on the boiler I / O module (plug-in connector 35).
HCM 1: Outdoor sensor is connected on the heating circuit expansion module 1 (terminal I 5).
HCM 2, etc.: Outdoor sensor is connected on the other heating circuit expansion modules.
Function: Specifies whether the selected heating circuit is used. If “No” is specified, then the sensors
do not need to be connected for the heating circuit, and the other settings in this menu are
irrelevant.
Group no: A group is assigned to each heating circuit. The group number is the same as the number of
the heating circuit expansion module to which the shared supply pump for the entire group is
connected.

4.2.11.3 DHWC

Function: Specifies how the selected DHWC is used.

Yes: If a DHWC is present.
No: A DHWC sensor does not need to be installed.
Before: If the DHWC will be charged with priority at request – all heating circuits in the same group are
switched off.
Group no: Same as point 4.2.10.2.

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 4 Operation, specialist

4.2.11.4 Buffer

Function: Specifies how the selected buffer is used.

No: If a buffer is not present.

VAR1: Buffer as load-balancing buffer (buffer switched in bypass): The buffer is always charged from
the boiler if the consumers require less heat than is offered by the boiler. The consumers are
supplied by the buffer or by the boiler, depending on which one first provides the required
temperature level.
VAR2: Buffer as central heat accumulator and distributor (buffer switched directly). First the buffer is
heated up to target temperature, before the heat consumers obtain an enable.

4.2.11.5 Digital remote control

Adjustment of the function units that are shown on the selected remote control unit, and that can be operated via the
selected remote control unit.

Outdoor sensor: Displayed outdoor temperature value (see point 4.2.10.2)

Heating circuit: Range of the heating circuits (closed number range). If no heating circuit should be displayed use
“–”. The number “0” is also available here. This applies analogously for DHWC and buffer.

4.2.11.6 Power measurement

Function: Yes / no
Max: Adjustable depending on the heat meter [kW]
Selection
of the signal: Ranges 0 – 20 mA or 4 – 20 mA can be selected
Analogue input: Shows the analogue input in [mA]
Measured power: Shows the actual measured power
Energy: Shows the total energy [kWh]

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 4 Operation, specialist

4.2.12 Hardware

Adjustment of the hardware modules that are available in the system:

Heating circuit Set the number of heating circuit expansion modules (0 – 16)
modules: You must set a station number on each module via the coding switch, starting with the number
1. The numbers must be assigned in sequence without any gaps.
D.-Remote control Set the number of digital remote control units (0 – 34)
units: On each dig. remote control unit the station number must be set, starting with number 1.
The numbers must be assigned in sequence without any gaps. If the device is not detected
when it is inserted in the wall outlet (supply voltage must be present), press the “Esc” button 5
times. Enter the access code “100” (specialist level) to go to station number entry.
Fuel extractor
modules: This is where the number of installed fuel extractor modules can be entered (up to three).
Plug-in modules: Some of the existing hardware components are detected automatically by the control unit itself
(plug-in module 1, heating circuit configuration on the boiler I/O module).
The use of the plug-in module can be set.
Invalid entries are corrected automatically.
Meaning of the abbreviations:
Off Boiler I/O module without addition.
HC 0 Individual heating circuit (heating circuit 0) on plug-in module 1
SB Second boiler
Vacuum Vacuum conveyor
In addition the following combinations are possible:
HK 0 / ZK Meaning of the abbreviations: See above
ZK /
vacuum Meaning of the abbreviations: See above

4.2.13 Frost protection

Room temperature: Target room temperature in frost protection mode for all heating circuits
Heating limit: If this temperature is exceeded on the outdoor sensor, then all heating circuits in frost protection
mode switch to “Off“.

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 4 Operation, specialist

4.2.14 Outputs:

Time delay:
Switch-on: Switch-on delay for boiler master-and-slave circuit
Switch-off: Switch-off delay for boiler master-and-slave circuit
Temp. differential: Temperature differential for boiler master-and-slave circuit
In this menu the individual parameters for the power output can be set, if under point 4.2.10.1.2 the setting “Boiler
master-and-slave circuit is selected. The switch-on delay starts running as soon as the actual boiler temperature (forward
flow temperature) drops below the boiler setpoint temperature, minus the “Temp. differential” of the power output, and
a boiler request is present. After the switch-on delay has elapsed the second boiler is requested.
As soon as the forward flow temperature exceeds the described temperature, the switch-off delay starts running and
again cancels the boiler request after the set time. The output is not set when the input “External1” is open (Stop‑function).
The output is also set when the boiler is switched off with the “Boiler on/off”, function or if a fault occurs.

4.2.15 Fan

4.2.15.1 Primary
Specification of the factor of the “Primary air” output.

PL: Primary air setting in the specific air levels 0 to 100 %

PL corr. factor: Factor can be set between 80 and 120 %
PK: Primary correction value, i.e. the result of setting and correction.

4.2.15.2 Secondary
Specification of the factor of the “Secondary air” output.
SL: Secondary air setting in the specific air levels 0 to 100 %
SL corr. factor: Factor can be set between 80 and 120 %
SK: Secondary correction value, i.e. the result of setting and correction.

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 4 Operation, specialist

4.2.16 Boiler output

Type: Selection of the boiler, values from 15 to 100 kW

Switch off: Factory setting 50 % of output
Switch-on: Factory setting 60 % of output
Shutdown time: Afterrun time of the fan

4.2.17 Container side

Right/left: Placement of the container

4.2.18 Ignition

Wait: Time until electrical ignition

Time: Duration of electrical ignition
Limit temp. RG: Limit temperature of the flue gas, when this temperature is underranged ignition is executed
immediately
RG.temp.increase: Required temperature increase of the flue gas within the wait time; if this is underranged ignition
can be dispensed with
Ignition attempts: Number of ignition attempts before the boiler transitions to a fault status

4.2.19 Light barriers (only for USD)

Time delays: Controls the filling of the container via light barriers
Switch-on: Factory setting is 20 seconds
Switch-off: Factory setting is 5 seconds

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 4 Operation, specialist

4.2.20 Motor power

Only in combination with plug-in module 2

Only in conjunction with at least one fuel

extractor module

Main drive: Specification of motor power in watt

Fuel extractor: Specification of motor power in watt
Supplemental
fuel extractor: Specification of motor power in watt
Main drive: Specification of motor power in watt
Fuel extractor: Specification of motor power in watt
Fuel extractor
modules: Information about the number and motor power of all connected fuel extractor modules

4.2.21 Serial number

Series production Information on type: Transfer this specification from the type plate before commissioning
status: (B corresponds to 2 | C corresponds to 3)
Boiler number: Serial number of the boiler

4.2.22 Operating hours

Load: Operating hours in the specific load range

Full load hours: Total of all load hours, converted to 100 %

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 4 Operation, specialist

4.2.23 Control unit

Pre-set values of the PID control unit for negative pressure, oxygen, secondary air, and boiler temperature.

4.2.23.1 Negative pressure

Specification of the values of the “negative pressure” input.

Factory setting Setting range Reset time => Tn

Rate time => Tv
P: 80 50 – 100 Tn = P / I = 80 / 2 = 40 [sec]
I: 2 1 – 4 Tv = 0
Target: USV 15 – 60: 0.2 mbar  0,15 – 0,5
USV 80 – 100: 0.5 mbar
Actual: – – –
Transient time: 5 min. 1 – 5 min

4.2.23.2 Oxygen
Specification of the values of the “Oxygen” input.

Factory setting Setting range Reset time => Tn

Rate time => Tv
P: 15 10 – 20 Tn = P / I = 15 / 0.06 = 250 [sec]
I: 0.06 0.03 – 0.12 Tv = D / P = 25 / 15 = 1.67 [sec]
D: 25 10 – 50
Target: 9% 7 – 13 %
Actual: – – –

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 4 Operation, specialist

4.2.23.3 Secondary air

Specification of the values of the “Secondary air” input.

Factory setting Setting range Reset time => Tn

Rate time => Tv
P: 0.1 0.03 – 0.1 Tn = P / I = 0.1 / 0.00015 = 666 [sec]
I: 0.00015 0.0001 – 0.00025 Tv = 0
Target: – ­–
Actual: – –

4.2.23.4 Boiler temperature

Specification of the value of the “Boiler temperature” input (maximum 90 °C).

Factory setting Setting range Reset time => Tn

Rate time => Tv
P: 8 6 – 10 Tn = P / I = 8 / 0.01 = 800 [sec]
I: 0.01 0.005 – 0.02 Tv = D / P = 50 / 8 = 6.25 [sec]
D: 50 25 – 75
Target: – –
Actual: – –

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 4 Operation, specialist

4.3 Menu item – Relay Test

You can switch all outputs manually. In this menu all other control unit functions are inactive.

4.3.1 Boiler

Main contactor: This contactor switches the main drive motor, the fuel extractor drive motor, the fan, the induced
draft fan, and the boiler circuit pump
Main drive: Triac main drive motor (display of current draw)
Return: Return flow of the main drive motor
Ignition – Relay heating insert of the ignition device. The relay can only be switched on if the fan is running
heating system: (prevents overheating of the electrical heating insert)
Ignition – fan: Relay fan of the ignition device
Main relay: 400 V 3-phase relay
Primary air: Speed level of the primary combustion air fan
Secondary air: Speed level of the secondary combustion air fan
Induced draft: Speed level of the induced draft fan
HE-cleaning: Relay, cleaning motor
Rotary grate: Relay, burner plate ash removal drive
Supply VBS: Transformer of the heating voltage of the lambda control system
Oxygen: Shows the measured oxygen proportion
Fault 1: Relay output fault 1 (NC) for buzzer fault message
Fault 2: Relay output fault 2 (NC contact) for buzzer fault message
Power output: Relay output power
Boiler pump: Speed level of the boiler circuit pump

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 4 Operation, specialist

Mixer return
flow boost: Mixer output for the return flow boost
Smoke extractor: Output for external SE
Boiler seq.: Plug-in connector no. 74 of the I/O board, KWB art. no. 13-1000063
Calib. lambda: Activation of the calibration: Lambda voltage [mV], off/start, status display and remaining time

Lambda control system calibration:

IMPORTANT! Because fresh air is used as the reference gas for the calibration, ensure that there
is sufficient ambient air in the boiler room. Also ensure that the boiler is free of embers and that
no CO2 occurs.

To ensure precise calibration, when the system is in cold status set the induced draft fan to the
maximum level of 100 % in the “Relay Test” menu, and open the door.

The calibration process is triggered in the “Calib Lambda > Start” menu. The pre-heat time of
the lambda control system is 360 seconds.
Initially the voltage display shows – 22.18 mV. After approximately 2 minutes the lambda control
system reaches its working temperature and the display voltage changes.
After an additional 4 minutes the voltage should be in the range of – 8 mV to – 17 mV. At this
point a correction factor is calculated: If successful “OK” will be shown in the “Status” field.
If the calibration is not successful, the alarm 244 is triggered (“244 Lambda control system
calibration error!”). In this case the lambda control system must be replaced.

4.3.2 Heating circuits

Mixer: Mixer output for the forward flow temperature control

Pump: Relay, heating circuit pump

4.3.3 DHWC

Pump: Relay, DHWC charge pump

4.3.4 Buffer

Pump: Relay, buffer charge pump or supply pump for the group with the number of the selected buffer.
Buffer 0 is charged with the boiler circuit pump and thus it does not have its own charge
pump.

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 4 Operation, specialist

4.3.5 Fuel extractor

Drive fire shutter: Drive motor of the fire shutter.

Limit switch closed: Limit switch of the fire shutter
Limit switch open: Limit switch of the fire shutter
Drive: Drive motor of the fuel extractor worm or supplemental fuel extractor worm
Return: Return of the drive motor of the FE worm or supplemental FE worm
Current indicator: Current consumption of the drive motor in ampere
(0.0 A)
Vacuum system: Below
Drive – fire shutter: Drive motor of the fire shutter
Limit switch open: Limit switch of the fire shutter
Cellular wheel sluice: Drive motor of the cellular wheel sluice
Vacuum turbine: Motor, vacuum turbine
Drive FE: Drive motor of the fuel extractor

4.3.6 Second boiler

Boiler pump SB: Boiler pump of the second boiler.

4.3.7 Supplemental fuel extractor

Drive: Drive motor of the supplemental fuel extractor worm.

Return: Return of the drive motor of the supplemental fuel extractor worm.
Current indicator: Current consumption of the drive motor in ampere.
(0.0 A)

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 4 Operation, specialist

4.4 Menu item – Network Analysis

The network analysis function is used to analyze problems with individual bus nodes. The counters are reset to 0 each
time there is a power failure. Additional analyses are possible with the alarm log and the alarm statistics.

4.4.1 Overview

In this screen all possible bus nodes are presented in order to analyze failures. A “–” indicates that communication with
the network node is functioning. If this is not the case the last digit of the failed node is displayed.

4.4.2 Boiler module

The error counter shows the number of communication errors with the boiler I/O module.

4.4.3 Heating circuit module

The error counter shows the number of communication errors with the heating circuit expansion modules. In columns two
to five the errors are displayed for four devices, starting with the device that has its station number in the first column.

4.4.4 Digital remote control unit

The error counter shows the number of communication errors with the digital remote control units. In columns two to five
the errors are displayed for four devices, starting with the device that has its station number in the first column.

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 4 Operation, specialist

4.4.5 Fuel extractor module

Up to three fuel extractor modules can be connected and managed.

4.5 Menu item – Save / Reset

Save: Saves the settings to read-only memory

Reset: Resets the read-only memory, activation of the factory settings

The control unit’s parameters are stored in volatile data memory. This memory loses its values several weeks (power
reserve) after switching off the mains voltage. Consequently the parameters are copied to read-only memory every
15 minutes.
When commissioning, or after control unit reset, the settings must always be saved once. If they are not saved then
the factory settings are reactivated. In addition, the settings must be saved if within 15 minutes after a change, the
power supply (main switch) is switched off and will remain switched off over a period of several weeks (e.g. when
commissioning in summer).

Resetting the control unit resets all parameters to the factory settings.
The menu item “Reset” is shown in the specialist level, however it is only active in the KWB customer service level.

4.6 Menu item – Measure Boiler

This function is used to render the power control unit inoperable and to maintain the burner power constant at a specific
level. To do this change from normal mode to measuring mode.

Service mode: Select between normal mode and measuring

Burner power: Sets the burner power at a value between 30 and 100 %

4.7 Menu item – Start / Stop Log

Index: Number of the entry in the ring memory

Start: Switch-on time
Stop: Switch-off time

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 5 Appendix I

5 Appendix I

DIMENSION SHEETS

HYDRAULIC CIRCUIT DIAGRAMS

CONNECTION AND CABLING DIAGRAMS

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 91

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 5.1 Dimension sheets

5.1 Dimension sheets

Overview of the dimension sheets

Designation Version Page

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 13.02.2008 96
5.1.5 Fuel extractor Ø 2.5 m – 4 m (spring-blade rotary stirrer) 01.06.2006 97
5.1.6 Fuel extractor Ø 4.5 m – 5.5 m (spring-blade rotary stirrer) 01.06.2006 97
5.1.7 Ascending worm with upward transfer unit 09.05.2006 98

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 5.1 Dimension sheets

5.1.1 Installation
KWB Multifire USV Vdimensions KWB
15-25 kW and Multifire
30-40 kW USV V 15 – 25 kW
Technical data sheet: MBL-USV-installation dimensions_a_sheet 1 Version 19.04.06

Cover open

RH: 190, 200

Storage container

Dimensions
Room length: 365, 369 in cm

Room width: 218

The distance specifications are minimum dimensions! Boiler dimensions are absolute dimensions!
Framed dimensions (FD): 1st FD = 15 / 25 kW, 2nd FD = 30 / 60 kW
* The clearances to the wall must be 70 cm or 40 cm so that the rear of the boiler is accessible.

The distance specifications are minimum dimensions! Boiler dimensions are absolute dimensions
Framed dimensions (FD): 1st FD = 15/25 kW, 2nd FD = 30/60 kW
* The clearances to the wall must be 70 cm or 40 cm so that the rear of the boiler is accessible.

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 93
Techn.
KWB Multifire install dimensions: USV V 15-25 kW and 30-40 kW
This data sheet is the
property of KWB
Data sheet: MBL-USV_Einbaumaße_a
Auth.: StHo Date: 19-04-06 Sheet 1/3

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 5.1 Dimension sheets

5.1.2 Installation dimensions KWB Multifire

KWB Multifire USV ZI 15-25
USV D 15 – 25, 30 – 60kW,
and30-60 andkW
80 – 100 80-100 kW
Technical data sheet: MBL-USV-installation dimensions_a_sheet 2 Version 19.04.2006

RH: 180, 200, 240

Fuel extractor

Dimensions
Room length: 310, 314, 314
in cm

Room width: 182, 207, 217

tor
rac
ext
l
Fue

The distance specifications are minimum dimensions! Boiler dimensions are absolute dimensions!
Framed dimensions (FD): 1st FD = 15/25 kW, 2nd FD = 30/60 kW, 3rd FD = 80 – 100 kW
The fuel extractor trough must be within the specified angle (max.: 230° horizontal, 25° vertical, *45° for ascending worms).
* The clearances to the wall must be 70 cm or 40 cm so that the rear of the boiler is accessible.
The distance specifications are minimum dimensions! Boiler dimensions are absolute dimensions
Framed dimensions (FD): 1st FD = 15/25 kW, 2nd FD = 30/60 kW, 3rd FD = 80-100 kW
* The clearances to the wall must be 70 cm or 40 cm so that the rear of the boiler is accessible.
Page 94  BA Multifire 08/2008  © KWB – Kraft und Wärme aus Biomasse GmbH
The fuel extractor trough must be within the specified angle (max.: 230° horizontal, 25° vertical, *45° for ascending worms).

Techn.
Downloaded from www.Manualslib.com manuals search engine
KWB Multifire install dimensions: USV D 15-25 kW, 30-60 kW and 80-100 kW
This data sheet is the Data sheet: MBL-USV_Einbaumaße_a
 5.1 Dimension sheets

5.1.3 Installation dimensions KWB Multifire

KWB Multifire
USV ZI USV ZI 15-25
15 – 25, kW,
30 – 60 30-60
and and 80-100
80 – 100 kW kW
Technical data sheet: MBL-USV-installation dimensions_a_sheet 3 Version 19.04.2006

Fuel extractor

RH: 180, 205, 240

Dimensions
Room length: 326, 330, 330 in cm

Room width: 197,218, 218

tor
rac
ext
l
Fue

The distance specifications are minimum dimensions! Boiler dimensions are absolute dimensions!
Framed dimensions (FD): 1st FD = 15/25 kW, 2nd FD = 30/60 kW, 3rd FD = 80 – 100 kW
* The clearances to the wall must be 70 cm or 40 cm so that the rear of the boiler is accessible.
The fuel extractor trough must be within the specified angle
(max.: 230° horizontal, 25° vertical, *45° for ascending worms).
The distance specifications are minimum dimensions! Boiler dimensions are absolute dimensions
Framed dimensions (FD): 1st FD = 15/25 kW, 2nd FD = 30/60 kW, 3rd FD = 80-100 kW
* The–clearances
© KWB to the wall
Kraft und Wärme ausmust be 70 cm
Biomasse or 40 cm so that the rear of
GmbH MA theMultifire
boiler is 08/2008
accessible. Page 95
The fuel extractor trough must be within the specified angle (max.: 230° horizontal, 25° vertical, *45° for ascending worms).

Downloaded from www.Manualslib.com manuals search engine Techn.

This data sheet is the Data sheet: MBL-USV_Einbaumaße_a
 5.1 Dimension sheets

5.1.4 Installation dimensions KWB Multifire USV GS 40 – 60 and 80 – 100 kW

Technical data sheet: MBL-USV-installation dimensions 4_a Version 13.02.2008

Room height Dimensions

in cm
Room length

Rm
in.
30
Room height

The distance
The distance specifications
specifications are minimum
are minimum dimensions!
dimensions! BoilerBoiler dimensions
dimensions are are absolute
absolute dimensions
dimensions!
Framed dimensions (FD):st1st FD = 40-60 kW, 2nd nd FD = 80-100 kW
Framed dimensions (FD): 1 FD = 40/60 kW, 2 FD = 80/100 kW
Also comply with the
* The clearances instructions
to the wall must befor
70 mounting
cm or 40 cm the conveyor
so that the rear ofair
theand
boilerreturn air hose!
is accessible.
* The Comply
clearances tofuel
with the theextraction
wall must be 70 incm
instructions theor 40 cm so
appropriate that the rear of the boiler is accessible.
documentation!

Page 96  BA Multifire 08/2008  Property of © KWB – Kraft und Wärme aus Biomasse GmbH
Techn.
KWB Multifire USV GS 40-100 kW KWB Data sheet: MBL-USV_Einbaumaße 4
Auth.: StHo Date: 13-02-2008 Index: a

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 5.1 Dimension sheets

Fuel extractors:
Fuel extractors:
5.1.5 Fuel extractor Ø 2.5 m – 4 m (spring-blade rotary stirrer)_b
Spring-stirrer
Spring-stirrer
Version 10.1.2008
diameter
diameter 2.5
2.5 m
m –– 44 m
m (4.5
(4.5 m
m for
for pellets)
pellets)
Stirrer ø 2.5 m; 3,0 m; 3.5 m and 4.0 m
(4.5
Stirrer ø 2.5 m;m3,0
form;pellets)
3.5 m and 4.0 m
(4.5 m for pellets) If you recess the fuel extractor into the floor,
you gain
If you 20 cm
recess theinfuel
storage roominto
extractor height.
the floor,
you gain 20 cm in storage room height.

Centre stirrer
Min. Installation clearance Centre stirrer
Min. Installation clearance

20 cm
in
20depth
cm
in depth
Wall opening W 50
cm
Wallx opening
H 60 cmW 50
WL = open
cm x H 60 cm
WL = open Wall opening W 50
Worm length WL = total cm
Wallx opening
H 60 cmW 50
Worm length WL = total cm x H 60 cm

5.1.6 Fuel extractor Ø 4 m – 5.5 m (spring-blade rotary stirrer)

Steel
Steel arm
arm stirrer
stirrer diameter
Version 10.1.2008 diameter 4.5
4.5 m
m –– 5.5
5.5 m
m
Stirrer ø 4.5 m; 5.0 m; 5.5 m
Stirrer ø 4.5 m; 5.0 m; 5.5 m

If you recess the fuel extractor into the floor,

you gain
If you 20 cm
recess theinfuel
storage roominto
extractor height.
the floor,
you gain 20 cm in storage room height.
Centre stirrer
Min. Installation clearance
Centre stirrer
Min. Installation clearance

20 cm
in
20depth
cm
Wall opening
W 50opening
cm x H 60 cm in depth
Wall
W 50 cm x H 60 cm

WL = open
WL = open Wall opening W 50
Worm length WL = total cm
Wallx opening
H 60 cmW 50
Worm length WL = total cm x H 60 cm

Property Techn.
© Installation dimensions:
KWB – Kraft und Wärme ausKWB Multifire
Biomasse GmbHfuel
extractor “Standard” of KWB
MA Multifire 08/2008
Property Data sheet:
Techn. MBL-USV-RA-Standard_b
Page 97
Installation dimensions: KWB Multifire fuel extractor “Standard” of KWB Data
Auth.:sheet:
StHo MBL-USV-RA-Standard_b
Date: 10-01-2008 Sheet: 1/1
Auth.: StHo Date: 10-01-2008 Sheet: 1/1

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 5.1 Dimension sheets

5.1.7 Ascending worm with upward transfer unit

Version 09.05.06

Outline (cropped)
Max. 212

Worm length WL = max. 12 m

Max. 300
(install horizontally)
Connection point Connection point
Fire shutter Upward transfer worm WL = open
KWB Multifire

0 to max. 130

Ground plan Stirrer centre

Pivoting 360°
Connection KWB Multifire
max. angle 230° Articulated rotary-blade
stirrer ø 110

5.1.7.1 Ascending worm with drop shaft

Version 19.11.07 Fuel extractor “Standard” – upward transfer and This data sheet is
the property of
Techn. data
sheet:
ascending worm (for KWB Multifire) KWB
Auth.: StHo} Date: 19-11-2007 Sheet 1/1

View from the right (cropped)

at 15° max. 582 cm Worm length WL = max. 12 m to 15°

at 45° max. 437 cm max. 6 m at 15° - 25°
WL = open
Connection point to
15
Fire shutter °m
KWB Multifire ax
.1
KWB Powerfire 2m
,1
5°
-45
°m
ax Max. 25°
.6
USV ZI: Max. 330 cm m
USV D: Max. 354 cm
Connection point
TDS 150/151: Max. 358 cm
Head piece drop shaft 0°-25° min. 45 cm
26°-35° min. 50cm
36°-45° min. 60 cm

View from above

Stirrer centre Spring-blade
Pivot range rotary stirrer
(Connection to the fire shutter) ø 110
USV: Max. 115°
TDS 150/151: Max. 105°

USV: Max. 115° Free pivoting Sloped floor or dead floor can be
TDS 150/151: Max. 115° dismantled 30 cm around the trough!

Property
Fuel extractor “Standard” downward transfer, ascending worm (for KWB Multifire and Powerfire 150 kW)
Techn. data
of KWB sheet:
Auth.: StHo Date: 19-11-2007 Sheet 1/1

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 5.2 Hydraulic circuit diagrams

5.2 Hydraulic circuit diagrams

Overview

5.2.1 Hydraulic circuit – boiler circuit return flow boost........................................................... 100

5.2.2 Basic module with weather-sensitive control unit........................................................... 101

5.2.3 Basic module with weather-sensitive control unit

and combination buffer as load compensating buffer....................................................... 103

5.2.4 Basic module with weather-weather-sensitive control and expansion module.............. 105

5.2.5 Basic module with weather-sensitive control and second boiler switchover................. 107

5.2.6 Basic module with weather-sensitive control,

an expansion module and a buffer as long-term buffer.................................................... 109

5.2.7 Basic module with weather-sensitive control and the 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

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 99

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 5.2 Hydraulic circuit diagrams

5.2.1 Hydraulic wiring – boiler circuit return flow boost

Variant 1: Return flow boost with bypass pump

– Only for distributors under pressure (no short-circuit!)

– No buffer, hydraulic shunt is not possible!
– Bypass pump is speed-regulated (output, see terminal diagram)
USP, USV

RF M

Variant 2: Return flow boost with motor mixing valve (or thermal valve)
– Use for installation of a buffer or a hydraulic shunt
– No distributor short circuit
– Either thermal valve or motor mixer (mixer output, see terminal diagram)

USP, USV, SHV, TDS (TDS only with motor mixing valve)
Hydr. shunt or buffer

RF

M
USP: Min. 55
USV, SHV, TDS: Min. 55

Variant 3: Return flow boost with thermal mixing valve (or motor mixing valve)
– Without buffer or hydr. shunt the distributor must be de-pressurized (short circuit!)
– Short circuit: DN should equal DNv, however minimum DNk! Pressure loss < 5 mbar
– Either thermal valve or motor mixer (mixer output, see terminal diagram)
(Pressure loss must be less than 5 mbar)

USP, USV , SHV

DNk
DNv
Short circuit
DN

RS

DNv
DNk
Valve core 55 °C

Theseillustrations
These illustrationsare
areprinciple
principlerepresentations.
representations. The hydr.
hydr.configuration/detail
configuration/detailplanning
planningmust
mustbebe
executed by by
executed the installer.
Suitable armatures for the return flow boost are available from KWB.
the installer. Suitable return flow boost armatures are available from KWB.

Page 100  BA Multifire 08/2008  © KWB – Kraft und Wärme aus Biomasse GmbH
Techn.
Hydraulic circuit – boiler circuit return flow boost This data sheet is the
property of KWB
data
TDB-HYD-TYÜ-MBEH0001_e
sheet:
(diagram valid for different types) Auth.: StHoDate: 12-02-07 Sheet: 1/1

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 5.2 Hydraulic circuit diagrams

5.2.2 Basic module with weather-sensitive control

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 101

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 5.2 Hydraulic circuit diagrams

System description:
The hydraulic system, consists of boiler circuit and distributor and is de-coupled by a shunt. The return flow boost is
executed via a thermal valve at min. 55°. The base module for boiler / DHWC regulation is equipped with a weather-
sensitive control unit for 2 heating circuits (option). One heating circuit is equipped with an analogue room control unit
(option), the second heating circuit is equipped with a digital room control unit (option) for remote control.

Menu ­– Basic Settings

Parameter Settings
Network settings Boiler External 2 Heat to target 2
Power output Heating mode
Heating circuit /  Room sensor Boiler / 1
heating circuit 1 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor DRCU 1
heating circuit 2 Outdoor sensor Boiler
Function Yes
Group no. 0
DHWC / DHWC 0 Function Yes
Group no. 0
Buffer / buffer 0 Function No
Digital remote control /  Outdoor sensor Boiler
digital remote control 1 Heating circuit 1 – 2
DHWC 0 – 0
Buffer 0 – 0
Hardware Heating circuit modules 0
Digital remote control 1
Plug-in modules Off

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 5.2 Hydraulic circuit diagrams

5.2.3 Basic module with weather-sensitive control

and combination buffer as load-balancing buffer

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 103

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 5.2 Hydraulic circuit diagrams

System description:
The hydraulic system consists of the boiler circuit (without main pump), and a distributor that is under pressure. The
return flow boost is executed via a bypass pump (4) in fixed speed execution, which is activated via speed-regulation.
Speed level switching must be set to the highest speed. The basic module for boiler & buffer control is equipped with
a weather-sensitive control unit for 2 heating circuits (option). One heating circuit is equipped with an analogue room
control unit (option), the second heating circuit is equipped with a digital room control unit (option) for remote control.

Menu – Basic Settings

Parameter Settings
Network settings Boiler External 2 Heat to target 2
Power output Heating mode
Heating circuit /  Room sensor Boiler / 0
heating circuit 0 Outdoor sensor Boiler
Function No
Group no. 0
Heating circuit /  Room sensor Boiler / 1
heating circuit 1 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor DRCU 1
heating circuit 2 Outdoor sensor Boiler
Function Yes
Group no. 0
DHWC / DHWC 0 Function Yes or before
Group no. 0
Buffer / buffer 0 Function Var 1
Digital remote control /  Outdoor sensor Boiler
digital remote control 1 Heating circuit 1 – 2
DHWC 0 – 0
Buffer 0 – 0
Hardware Heating circuit modules 0
Digital remote control 1
Plug-in modules Off

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 5.2 Hydraulic circuit diagrams

5.2.4 Basic module with weather-sensitive control and expansion module

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 105

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 5.2 Hydraulic circuit diagrams

System description:
The hydr. system consists of the boiler circuit, the buffer switched as long-term buffer (VAR 2), and the distributor. The
return flow boost is executed via a thermal mixing valve (28) at min. 55 °C. The basic module for boiler / DHWC, and buffer
control is equipped with a weather-sensitive control unit for 2 heating circuits (option), and combined with a bus-capable
heating circuit expansion module (25). Two heating circuits are equipped with analogue room control units (option), the
two other heating circuits are equipped with digital room control units (option) for remote control.

Menu – Basic Settings

Parameter Settings
Network settings Boiler External 2 Heat to target 2
Power output Heating mode
Heating circuit /  Room sensor Boile r/ 0
heating circuit 0 Outdoor sensor Boiler
Function No
Group no. 0
Heating circuit /  Room sensor DRCU 1
heating circuit 1 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor Boiler / 2
heating circuit 2 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor DRCU 2
heating circuit 3 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor HCM 1 / 1
heating circuit 4 Outdoor sensor Boiler
Function Yes
Group no. 0
DHWC / DHWC 0 Function Yes or before
Group no. 0
DHWC / DHWC 1 Function No
Group no. 0
Buffer / buffer 0 Function VAR 1
Buffer / buffer 1 Function No
Digital remote control /  Outdoor sensor Boiler
Digital remote control 1 Heating circuit 1 – 2 or 1 – 4
DHWC 0 – 0
Buffer 0 – 0
Digital remote control /  Outdoor sensor Boiler
Digital remote control 2 Heating circuit 3 – 4 or 1 – 4
DHWC 0 – 0
Buffer –––
Hardware Heating circuit modules 1

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 5.2 Hydraulic circuit diagrams

5.2.5 Basic module with weather-sensitive control

and second boiler switchover

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 107

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 5.2 Hydraulic circuit diagrams

System description:
The hydraulic system consists of boiler circuit and distributor and is de-coupled by a shunt. The return flow boost is
executed via a thermal valve at min. 55 °C. The basic module for boiler / DHWC and buffer regulation is equipped with
a weather-sensitive control unit for 2 heating circuits (option). One heating circuit is equipped with analogue room control
unit (option), the second heating circuit is equipped with digital room control unit (option) for remote control.
Automatic second boiler switchover is activated via plug-in module 1 (option) After heating up the second boiler the
automatic boiler is switched off via the flue gas thermostat (22) that is only required for a shared chimney, or via the
second boiler sensor (3) at the switchover temperature (65 °C, adjustable). The second boiler pump is switched on. When
exceeding the overheating temperature (80 °C adjustable), the connected heating circuits run at maximum temperature
and the boiler is charged until it reaches the target temperature. If the second boiler cools off to a temperature below the
switchover temperature the automatic boiler goes into operation again. The second boiler pump switches off.

Menu – Basic Settings

Parameter Settings
Hardware Second boiler Switchover at 65 °C
Overheating at 80 °C
Operation boiler Off
pump
Network settings Boiler External 2 Heat to target 2
Power output Heating mode
(Third heating circuit) Heating circuit /  Room sensor Boiler / 0
heating circuit 0 Outdoor sensor Boiler
Function No
Group no. 0
Heating circuit /  Room sensor Boiler / 1
heating circuit 1 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor DRCU 1
heating circuit 2 Outdoor sensor Boiler
Function Yes
Group no. 0
DHWC / DHWC 0 Function Yes or before
Group no. 0
Buffer / buffer 0 Function No
Digital remote control /  Outdoor sensor Boiler
digital remote control 1 Heating circuit 1 – 2
DHWC 0 – 0
Buffer –––
Hardware Heating circuit modules 0
Digital remote control 1
Plug-in modules SB

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 5.2 Hydraulic circuit diagrams

5.2.6 Basic module with weather-sensitive control,

one expansion module and a long-term buffer

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 109

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 5.2 Hydraulic circuit diagrams

System description:
The hydr. system consists of the boiler circuit, the buffer switched as long-term buffer (VAR 2), and the distributor. The
return flow boost is executed via a thermal mixing valve (28) at min. 55 °C. The basic module for boiler / DHWC, and buffer
control is equipped with a weather-sensitive control unit for 2 heating circuits (option), and combined with a bus-capable
heating circuit expansion module (25). Two heating circuits are equipped with analogue room control units (option), the
two other heating circuits are equipped with digital room control units (option) for remote control.

Menu – Basic Settings

Parameter Settings
Network settings Boiler External 2 Heat to target 2
Power output Heating mode
Heating circuit /  Room sensor Boiler / 0
heating circuit 0 Outdoor sensor Boiler
Function No
Group no. 0
Heating circuit /  Room sensor DRCU 1
heating circuit 1 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor Boiler / 2
heating circuit 2 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor DRCU 2
heating circuit 3 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor HCM 1/1
heating circuit 4 Outdoor sensor Boiler
Function Yes
Group no. 0
DHWC / DHWC 0 Function No
Group no. 0
DHWC / DHWC 1 Function Yes or before
Group no. 0
Buffer / buffer 0 Function VAR 1
Buffer / buffer 1 Function No
Digital remote control /  Outdoor sensor Boiler
Digital remote control 1 Heating circuit 1 – 2 or 1 – 4
DHWC 0 – 1
Buffer 0 – 0
Digital remote control /  Outdoor sensor Boiler
Digital remote control 2 Heating circuit 3 – 4 or 1 – 4
DHWC 0 – 1
Buffer –––
Hardware Heating circuit modules 1

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 5.2 Hydraulic circuit diagrams

5.2.7 Basic module with weather-sensitive control and KWB special buffer

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 111

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 5.2 Hydraulic circuit diagrams

System description:
The hydraulic system consists of the boiler circuit, the distributor, and a combination buffer that is switched as load
compensator (VAR 1) in the bypass. The return flow boost is executed via a thermal valve (28) at min. 55 °C The basic
module for boiler / DHWC, and buffer control is equipped with a weather-controlled regulator for 2 heating circuits (option),
and combined with a bus-capable heating circuit expansion module (25). Two heating circuits are equipped with analogue
room control units (option), the two other heating circuits are equipped with digital room control units (option) for remote
control.

Menu – Basic Settings

Parameter Settings
Return flow boost Thermal valve
Network settings Boiler External 2 Heat to target 2
Power output Heating mode
Heating circuit /  Room sensor Boiler / 0
heating circuit 0 Outdoor sensor Boiler
Function No
Group no. 0
Heating circuit /  Room sensor DRCU 1
heating circuit 1 Outdoor sensor Boiler
Function Yes
Group no. 0
Heating circuit /  Room sensor Boiler / 2
heating circuit 2 Outdoor sensor Boiler
Function Yes
Group no. 0
DHWC / DHWC 0 Function Yes or before
Group no. 0
Buffer / buffer 0 Function VAR 1
Digital remote control /  Outdoor sensor Boiler
Digital remote control 1 Heating circuit 1 – 2
DHWC 0 – 0
Buffer 0 – 0
Hardware Heating circuit modules 0
Digital remote control 1
Plug-in modules Off

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 5.2 Hydraulic circuit diagrams

5.2.8 Basic module with weather-sensitive control and buffer in adjacent

building – expansion modules in the apartment buildings

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 113

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 5.2 Hydraulic circuit diagrams

Page 114  BA Multifire 08/2008  © KWB – Kraft und Wärme aus Biomasse GmbH

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 5.2 Hydraulic circuit diagrams

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 115

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 5.2 Hydraulic circuit diagrams

System description in the adjacent house:

The hydraulic system consists of the boiler circuit with a long-term buffer switched in the bypass (VAR 1) and the main
distributor in the heating house. The return flow boost is executed via a motor mixing valve (32) set at a min. of 55 °C.
On the main distributor houses are equipped with sub-distributors that are hydraulically decoupled via a switch.
The basic module for boiler and buffer control in the heating house is connected with bus-capable heating circuit expansion
modules in a distributed arrangement in house 1 and 2.

Menu Basic Settings – heating system (outbuilding)

Parameter Settings
Return flow boost Mixer regulation

Network settings Boiler External 2 Heat to target 2

Power output Heating mode
Heating circuit /  Room sensor
heating circuit 0 Outdoor sensor
Function No
Group no.
Heating circuit /  Room sensor
heating circuit 1 Outdoor sensor
Function No
Group no.
Heating circuit /  Room sensor
heating circuit 2 Outdoor sensor
Function No
Group no.
DHWC / DHWC 0 Function No
Group no. 0
Buffer / buffer 0 Function VAR 1 or VAR 2
Hardware Heating circuit modules 3
Digital remote control 2
Plug-in modules Off

Comments:
The heating circuit expansion modules must be placed where the associated sensors and actuators that will be actuated
are located. The supply pumps must be installed in the area of the subdistributors if possible.

Page 116  BA Multifire 08/2008  © KWB – Kraft und Wärme aus Biomasse GmbH

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 5.2 Hydraulic circuit diagrams

Menu Basic Settings in “House 1”

Parameter Settings
Network settings Heating circuit /  Room sensor DRCU 1
heating circuit 3 Outdoor sensor HCM 1
Function Yes
Group no. 1
Heating circuit /  Room sensor HCM 1/2
heating circuit 4 Outdoor sensor HCM 1
Function Yes
Group no. 1
Heating circuit /  Room sensor HCM 2/1 (not connected)
heating circuit 5 Outdoor sensor HCM 1
Function Yes
Group no. 1
Heating circuit /  Room sensor HCM 2/2
heating circuit 6 Outdoor sensor HCM 1
Function No (not used)
Group no. 1
DHWC / DHWC 1 Function Yes or before
Group no. 1
DHWC / DHWC 2 Function No
Group no. 1
Digital remote control /  Outdoor sensor HCM 1
digital remote control 1 Heating circuit 3 – 5
DHWC 1 – 1
Buffer –––

Menu Basic Settings in “House 2”

Parameter Settings
Network settings Heating circuit /  Room sensor HCM 3/1
heating circuit 7 Outdoor sensor HCM 3
Function Yes
Group no. 3
Heating circuit /  Room sensor DRCU 2
heating circuit 8 Outdoor sensor HCM 3
Function Yes
Group no. 3
DHWC / DHWC 3 Function Yes or before
Group no. 3
Digital remote control /  Outdoor sensor HCM 3
digital remote control 1 Heating circuit 7 – 8
DHWC 3 – 3
Buffer –––

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 117

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 Page 118  BA Multifire 08/2008  © KWB – Kraft und Wärme aus Biomasse GmbH

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 5.3 Electrical diagrams

5.3 Electrical diagrams (connection and cabling diagrams)

Designation No. & version

5.3.1 Connection diagram for heating circuit module (HCM).................. TDB-ELS-TYÜ-HCM_XL_a
5.3.2 Bus cabling ......................................................................................... EBAA1018g_15.7.2008
5.3.3 Cabling outputs heating circuit ............................................................................ EAAA1046c
5.3.4 Cabling inputs analogue and digital ..................................................................... EBAA1047a
5.3.5 Cabling 400 VAC.................................................................................................... EAAA1064a
5.3.6 Connection diagram I/O board................................................................................ EAAA1054
5.3.7 Connection diagram 1 / second boiler / vacuum.................................................... EBAA1206a
5.3.8 Boiler master-and-slave circuit.................................................................ELS-TYÜ-KFS-0001
5.3.9 FE module.................................................................................................................. ERAA1200

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 119

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 5.3 Electrical diagrams

5.3.1 Connection diagram for heating circuit module

(HCM) TDB-ELS-TYÜ-HCM_XL_a

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 5.3 Electrical diagrams

5.3.2 Bus cabling / EBAA1018g_15.7.2008

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 121

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 5.3 Electrical diagrams

5.3.3 Cabling outputs heating circuit / EAAA1046c

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 5.3 Electrical diagrams

5.3.4 Cabling inputs analogue and digital / EBAA1047a

Art. no. 50015001

© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 123

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 5.3 Electrical diagrams

5.3.5 Power cabling 400 VAC / EAAA1064a

Page 124  BA Multifire 08/2008  © KWB – Kraft und Wärme aus Biomasse GmbH

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5.3 Electrical diagrams

Attention! Installation instructions, electrical connections 0

Page 125
No heating circuits assigned (HC1 + HC2 not assigned)
GND GND
Buffer DHWC FF sensor Rem. Th. Boiler Boiler RFC Ext. Smoke Power Fault Fault Boiler bypass Return flow HC pump HC mixer HC pump HC mixer DHWC
temp. Ext.
sensor 1 sensor HC 1 HC 1 target output button 1 2 extract 1 2 pump mixer 1 1 2 2 pump
30 29 28 27 88 87 24 22 21 7.4 7.3 7.2 7.1 15 14 12 11 10 9 8

400 V AC
Supply

Fuel extractor
1
GND GND GND GND GND GND 24 V B A

2
Outdoor Buffer RF FF sensor Rem. Th. Buffer Bus/24 V DC
sensor sensor 2 sensor HC 2 HC 2 sensor 3 RC supply
35 34 33 32 31 75 25
Flue-gas
39 76 Reserve
sensor
Boiler Limit switch
38 77 Reserve 23

MA Multifire 08/2008
sensor Ash container
TM 20
O2
Sensor 37 78 Reserve 49
specialised employees or by a licensed electrical company,
All connection work must be executed by manufacturer's
5.3.6 Connection diagram I/O board / EAAA1054

Main drive
Reserve Limit switch
VBS 2 36 79 19
F-shutter
Klixon
18
Main drive
Combustion
67 chamber

Safety thermostat
Reserve 17

STOP SWITCH
Fuel bed

L
40 potentiomete
Klixon F.

50
with the system de-energised!

13

Lx
Plug-in module 1

Extraction
72

PE
Limit switch
6
Bus/24 V DC

Reserve
FE lid

71
Supply
26

Reserve 4
Speed Float switch
73 3
Prim. fan
Boiler master- Light barrier,
74 and-slave
16
top

48
Light barrier, 45
bottom
Without heating circuit

Operation

© KWB – Kraft und Wärme aus Biomasse GmbH

Bus
Heat exchanger cleaning system
46

Secondary air fan

Induced draft fan

Primary air fan

KWB art. no.:

Rotary grate
Transformer
Fire shutter

Relay
41
13-1000063

43

42

Ignition

68

44
5

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70
Assigned electrical connections (terminals)
No. 30 No. 7.3 No. 8 No. 71
5.3.6.1 No. 29 No. 7.2 No. 35
No. 22 No. 7.1 No. 34
No. 21 No. 15 No. 33
No. 7.4 No. 14 No. 25
 Attention! Installation instructions, electrical connections 1

Page 126 
HC1 heating circuit 1 assigned, HC2 heating circuit 2 not assigned

GND GND
Buffer DHWC FF sensor Rem. Th. Boiler Boiler RFC Ext. Smoke Power Fault Fault Boiler bypass Return flow HC pump HC mixer HC pump HC mixer DHWC
temp. Ext.
sensor 1 sensor HC 1 HC 1 target output button 1 2 extract 1 2 pump mixer 1 1 2 2 pump
30 29 28 27 88 87 24 22 21 7.4 7.3 7.2 7.1 15 14 12 11 10 9 8
5.3 Electrical diagrams

1
Supply
400 V AC
2
GND GND GND GND GND GND 24 V B A
Outdoor Buffer RF FF sensor Rem. Th. Buffer Bus/24 V DC
sensor sensor 2 sensor HC 2 HC 2 sensor 3 RC supply

Fuel extractor
35 34 33 32 31 75 25

Flue-gas
Reserve

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sensor 39 76

Boiler Limit switch

38 77 Reserve 23
sensor Ash container

TM 20
5.3.6.2 One heating circuit

O2
37 78 Reserve 49
Sensor

Main drive
Reserve Limit switch
VBS 2 36 79 19
F-shutter

Klixon
18
Main drive
Combustion
67 chamber
Reserve 17

L
Fuel bed

BA Multifire 08/2008 
40 potentiomete
Klixon F.

50
Lx
13
Extraction

PE
72

STOP SWITCH

Safety thermostat
Limit switch
Reserve 6

71
FE lid

26
Supply

Plug-in module 1
Bus/24 V DC
Reserve 4

Speed Float switch

73 3
Prim. fan

Boiler master- Light barrier,

All connection work must be executed by manufacturer's

specialised employees or by a licensed electrical company,
with the system de-energised!
74 and-slave
16
top
48

Light barrier, 45
bottom

Bus
Operation
Heat exchanger cleaning system

46

KWB art. no.:

41
5

43
42
68
44

Relay

13-1000063
70
Rotary grate

Ignition
Transformer

Fire shutter

Primary air fan

Induced draft fan

Secondary air fan

Assigned electrical connections (terminals)

No. 30 No. 21 No. 15 No. 35
Nr. 29 No. 7.4 No. 14 No. 34
No. 28 No. 7.3 No. 12 No. 33
No. 27 No. 7.2 No. 11 No. 25
Nr. 22 No. 7.1 No. 8 No. 71

© KWB – Kraft und Wärme aus Biomasse GmbH

5.3 Electrical diagrams

Attention! Installation instructions, electrical connections 2

Page 127
Heating circuit 1 and Heating circuit 2 (HC1 + HC2) assigned
GND GND
Buffer DHWC FF sensor Rem. Th. Boiler Boiler RFC Ext. Smoke Power Fault Fault Boiler bypass Return flow HC pump HC mixer HC pump HC mixer DHWC
temp. Ext.
sensor 1 sensor HC 1 HC 1 target output button 1 2 extract 1 2 pump mixer 1 1 2 2 pump
30 29 28 27 88 87 24 22 21 7.4 7.3 7.2 7.1 15 14 12 11 10 9 8

400 V AC
Supply

Fuel extractor
1
GND GND GND GND GND GND 24 V B A

2
Outdoor Buffer RF FF sensor Rem. Th. Buffer Bus/24 V DC
sensor sensor 2 sensor HC 2 HC 2 sensor 3 RC supply
35 34 33 32 31 75 25
Flue-gas
39 76 Reserve
sensor
Boiler Limit switch
38 77 Reserve 23

MA Multifire 08/2008
sensor Ash container
TM 20
O2
Sensor 37 78 Reserve 49
specialised employees or by a licensed electrical company,
All connection work must be executed by manufacturer's

Main drive
Reserve Limit switch
VBS 2 36 79 19
F-shutter
Klixon
18
Main drive
Combustion
67 chamber

Safety thermostat
Reserve 17

STOP SWITCH
Fuel bed

L
40 potentiomete
Klixon F.

50
with the system de-energised!

13

Lx
Plug-in module 1

Extraction
72

PE
Limit switch
6
Bus/24 V DC

Reserve

71
FE lid
Supply
26

Reserve 4
Speed Float switch
73 3
Prim. fan
Boiler master- Light barrier,
74 and-slave
16
top

48
Light barrier, 45
bottom
Operation

© KWB – Kraft und Wärme aus Biomasse GmbH

Bus
5.3.6.3 Two heating circuits

Heat exchanger cleaning system

46

Secondary air fan

Induced draft fan

Primary air fan

KWB art. no.:

Rotary grate
Transformer
Fire shutter

Relay
41
13-1000063

43

42

Ignition

68

44
5

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70
Assigned electrical connections (terminals)
No. 30 No. 21 No. 15 No. 9 No. 32
No. 29 No. 7.4 No. 14 No. 8 No. 31
No. 28 No. 7.3 No. 12 No. 35 No. 25
No. 27 No. 7.2 No. 11 No. 34 No. 71
No. 22 No. 7.1 No. 10 No. 33
 5.3 Electrical diagrams

5.3.6.4 Supplemental heating circuit

Attention! Installation instructions, electrical connections +1

HC0 assigned on plug-in module 1
No. 55
No. 53
No. 52
No. 51
Assigned electrical connections (terminals)
No. 61
No. 60
No. 59
No. 56

Configuration-specific plug-in connector assignment

Software configuration
Plug-in module 1

Set
Plug-in connector no. Heating circuit/second boiler Vacuum system/second boiler
51 FF sensor HC 0 Boiler sensor, second boiler
52 Remote thermostat, HC 0 -
53 Boiler sensor, second boiler -
54 - -
55 Thermostat, second boiler Thermostat, second boiler
Flue gas thermostat, Flue gas thermostat,
56 second boiler second boiler
57 - -
58 - -
59 HC pump 0 -
Vacuum turbine L
60 HC mixer 0
Filter cleaning system L
61 Pump, second boiler Pump, second boiler
Supply Supply
62
230 V AC 230 V AC

KWB art. no.: 50014002

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 5.3 Electrical diagrams

5.3.7 Connection diagram plug-in module 1 / 

second boiler / vacuum / EAAA1206a

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 5.3 Electrical diagrams

5.3.8 Boiler master-and-slave circuit ELS-TYÜ-KFS-0001

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 5.3 Electrical diagrams

5.3.9 Fuel extractor module

Art. no. 13–1000624 Fuel Extractor Module

The mains connection must be executed via a CEE plug-in connector.

Klixon FE
Limit switch FE lid

Request FE
Light barrier
Shield

remove I 6 for use

Station number
Pull the power plug
before opening!

Attention!

Earthing bar

FE motor Mains 400 VAC

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 Datenerfassung zur
Kaminquerschnittsberechnung
5.4 Chimney measurement
Auftraggeber: Bauvorhaben:

5.4 Chimney measurement

Data acquisition for calculating the chimney cross-section
Höhe ü. d. Meeresspiegel: m
Client:
Kesseldaten: Construction project:

...................................................................................................................... ..............................................................................................................
Fabrikat: KWB Type: Baujahr: ..............................................................................................................
...................................................................................................................... Brennstoff:
Altitude above sea level: ................................................................. m
Daten des Verbindungsstückes:
Boiler data:
Make: KWB ......................................     Type: ......................................    Year of manufacture: ..................................    Fuel: .......................................
Material: Stahlblech Edelstahl Sonstiges: Isolierstärke: mm
Joining piece
Durchmesser (Dv):data: mm gestreckte Länge (Lv): m wirksame Höhe (Hv): m
Material: o Sheet steel    o Stainless steel    o Other: ..........................................     Insulation thickness: ........................................................  mm
Wandstärke (Sv): mm Umlenkungen (z): x 45° x 90° x °
Diameter (Dv): ......................................... mm Effective length (Lv): ............................... . m   Effective height (Hv): ...................................  m
Wall thickness (Sv): ................................ mm
Rauchfangdaten: Bends (ζ): ......................  × 45°    ....................... × 90°    ........................  × .............................  °

Chimney flue data:

Fabrikat/Typ: Montagefang
Make / Type: ....................... o Flue installation     Fertigteilfang
o Flue of pre-assembled units    o Flue gas Abgasleitung Sonstiges
line    o Other: ............................................................

Form: Shape: 
rund eckig
o Round     lichte Weite: width: ...............
o Rectangular   Clear Lage:
x  × ................. mm   Location: 
mm oim
 InGebäude
the building    o Onam
the Gebäude freistehend
building    o Free-standing
Offset: o No    
Versprung: Nein o Yes Ja Horizontal .
Horizontal...........  m    Vertical ..............
, Vertikal m m
Eff. length: ..................... m Connection: o T-45°    o T-90°    o ...........  
Gestr. Länge: m Anschluß: T-45° T-90°
Eff. height (Hw): .............   Cold area (Hk): ..............    Free (Hf): ...............  m
Wirks. Höhe (Hw): , Kaltbereich (Hk): , Freien (Hf): m
Head cladding:   o No     o Yes     Material: ...........     Thickness: ..........  m 
Kopfverkleidung: Neino Yes   Clearance (Ad): ..........
Roof cowl:   o No      Ja Material Dicke  m  mm

Kamindach:
Thermal resistanceNein Ja IIa     oAbstand
group: o I     o  II     o III (Ad): m
Structure: Layer thickness 1 ......................  mm
Wärmedurchlaßwiderstandsgruppe: I Material .....................
IIa II III
Layer thickness 2 ......................  mm Material .....................
Aufbau: Schichtdicke 1 mm Material
Layer thickness 3 ......................  mm Material .....................
Schichtdicke 2 mm Material
Secondary air fixture: o No    o Yes 
Schichtdicke o In 3the chimney flue    o
mm In theMaterial
joining piece
Nebenluftvorrichtung: Nein
Existing chimney prior to reconstruction: Ja

im Rauchfang
Shape: o Round    o Rectangular Clear width: ............... × ..im Verbindungsstück
............  mm
Structure:
Vorhandener Kamin Layer thickness 1 ......................  mm
vor Sanierung: Material .....................
Layer thickness 2 ......................  mm Material .....................

Form: rund Layer thickness 3 ......................

eckig lichte Weite:  mm Material .....................
x mm

Aufbau: Schichtdicke 1 mm Material

Schichtdicke
For the correctness of2the data: mm Material
Schichtdicke 3 mm Material
Place & date: ......................................................................................................

Für die Signature: ..........................................................................................................

Richtigkeit der Daten:

Ort, Datum:
Version: 30.09.2003

Unterschrift:

Stand: 30.09.2003 Formblatt_Kamin.dot

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 5.5 Cross-section measurement

5.5 Cross-section measurement

Cross-section measurement

Diagram
Wood chip firing
Cross-section measurement

Diagram
Wood chips W 30/S 200
in accordance
Wood chipwith ÖNORM M 7133
firing
Calorific value 3.45 kWh/kg
Flue gas temperature 200 °C
Heating system boiler with draft required
Wood chips W 30/S 200
in accordance with ÖNORM M 7133
Calorific value 3.45 kWh/kg
Flue gas temperature 200 °C
Heating system boiler with draft required

Clear chimney diameter in cm

heat output in kilowatt
in kilowatt
Nominal heat outputNominal

Effective chimney height in meters

Basic data:
Combustion temperature 200 °C
Necessary combustion pressure as specified by manufacturer
Joining piece: – thermally insulated
– ø identical Effective
to flue øchimney
or boiler connection
height in meters
– effective length 1 ⁄ 7 of the effective height, max. 3.0 m
Basic data: – redirectors 2 bends 90°, 1 inlet 90° + 1 contraction
Combustion temperature 200 °C
Necessary combustion pressure as specified by manufacturer
Joining piece: – thermally insulated
– ø identical to flue ø or boiler connection
– effective length 1 ⁄ 7 of the effective height, max. 3.0 m
– redirectors 2 bends 90°, 1 inlet 90° + 1 contraction

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 Appendix II

Appendix II

Fuel extractor variants

6 FUEL EXTRACTOR with upward transfer  ......................................... 136

7 DOUBLE FUEL EXTRACTOR  ........................................................................ 149

8 FUEL EXTRACTOR WITH FALL PIPE  ........................................................... 163

9 FE WITH DOWNWARD TRANSFER AND ASCENDING WORM  ................. 169

10 FUEL EXTRACTOR pellets without stirrer  ....................................... 177

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 6 FE with upward transfer

6 Fuel extractor with upward transfer

6.1 Components – FE with upward transfer

Fig. 162: Explosion drawing

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 6 FE with upward transfer

Fig. 163: Detail – ascending worm drive

Fig. 164: Detail – transfer station

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 6 FE with upward transfer

All threaded unions must be tightened during installation!

All threaded unions are provisional and are only designed for transport!
All FE variants only become stable when the threaded unions are firmly tightened during
­the installation process!

Comply with the safety instructions in point 2.2

The installation tasks listed here are described in point 2.2 of this installation manual.

The FE is partially pre-assembled and brought in to the installation room – if necessary the FE can be dismantled.
For a worm length starting at 5 m one support is supplied; for worm length over 8 m, 2 supports are supplied.
These supports must be adjusted in such a manner that the trough is aligned.

6.2 Installing the cast-iron head

Dismount the cover of the FE trough and position the fuel extractor trough
in the bunker.

Fig. 165: Bringing in the FE & dismantling

Remove the U-shaped flange from the trough extension and seal all
facing surfaces with silicon.

• Ratchet/fork spanner SW 17
• Silicon

Flange

Fig. 166: Remove flange, seal FE ext.

Bolt the cast-iron head to the FE trough extension.

Flange
Fig. 167: Bolt FE channel & cast-iron head
Seal the corners of the channel extension with silicon.

Before you bolt the upward transfer bracket to the cast-iron head, the
tasks in the storage room must be completed.

Fig. 168: Seal trough extension

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 6 FE with upward transfer

6.3 Floor assembly – fuel extractor trough (storage room)

The FE trough should be installed horizontal on the storage room side, however within an angle of ±3°
Use the holes in the support foot to make adjustments. Usually long feet are delivered and cut to size and installed as
described in point 2.2.2. Installation with short feet is described here as an alternative.
Bolt on the foot fastening bracket (2) for the squared hole of the trough
floor.

• Saucer-head screw M10 x 20 screw, self-locking hex-nuts

Fig. 169: Install the foot fastening bracket

Bolt the feet to the trough and the foot fastening bracket.

Pay attention to the horizontal alignment of the FE trough (tolerance ±3°)

and select the appropriate hole pattern.

• 2 M12 x 25 flange screws from inside to outside

Fig. 170: Install the short feet

To install the gear unit lift the FE 10 cm. Select a robust and non-slip
substrate (wood batten).

Use the installation aid to lift the gear unit into the trough and bolt it to
the foot fastening bracket and trough. Do not tighten the screws yet.

• 4 hex flange screws M12 x 25, 2 large washers

Fig. 171: Install gear unit

Grease the worm-side spline.
Slide the adapter (cast-iron claw coupling) onto the spline of the gear
unit to the stop. Lift the worm into the trough and slide it into the adapter
until the stop.

Fig. 172: Connect the worm and gear unit

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 6 FE with upward transfer

Bolt the conveyor trough cover / gear unit cover to the trough.

• Foot fastening bracket: Hex flange screw M10 x 20

• Gear unit: 4 hex flange screws M12 x 25, 4 large washers
• Trough seam: Saucer-head screws M10 x 20, self-locking nuts

Now also tighten the screws under the gear unit and remove the wood
batten.

Fig. 173: Install cover & gear unit

6.4 Installing the transfer station (boiler room)

Install the upward transfer bracket on the cast iron head in the boiler
room. Seal the flange on the front side with silicon.
Then place the upward transfer bracket on the cast-iron head.

Fig. 174: Seal the cast-iron

head transfer bracket
First screw-fasten the screws on top slightly.

• 3 counter-sunk head screws M8 x 20

• 2 flange screws M8 x 16

Fig. 175: Bolt the upward transfer bracket 1

Bolt the upward transfer bracket onto the front of the cast-iron head.

• 4 flange screws M10 x 30, flange nuts

Only tighten the screws as a final step.

Fig. 176: Bolt the upward transfer bracket 2

Firmly slide the black edge guard with sealing lip onto the receptacle
ring. Use a wire cutter to cut it to size and carefully knock the edge guard
with the soft-faced hammer.

Seal the upward transfer opening with silicon.

Fig. 177: Seal the upward transfer bracket

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 6 FE with upward transfer

6.5 Installing the worm bearings

When the worm bearing is bolted to the upward transfer bracket the worm should have maximum
axial play of 2 mm.
This distance must be strictly and precisely maintained; it is adjusted by adding or removing spacer
washers. Before mounting the bearing ensure that worm and claw coupling are seated all the way
to the rear.

Step 1:
If the worm is seated all the way back, determine (e.g. by using an angle
bracket) the distance between the bearing support surface (chain wheel
box) and the worm stop.

Fig. 178: Determine worm play 1

Step 2:
Now determine the level difference between the bearing flange and
worm bearing.

If the sum of these two distances (step 1 and 2) is greater than 2 mm the
distance spacer washers must be pushed onto the worm accordingly.
(The spacer washers are 2 mm thick)

Fig. 179: Determine worm play 2

Then slide the bearing (Ø 35) onto the stud bolts of the upward transfer
bracket. Centre the worm and tighten the nuts.

• 4 flange nuts M10

Fig. 180: Install the worm bearing

6.6 Installing the ascending worm and fixing the FE in place

Remove the two hex screws (1) of the fire shutter – they will be inserted
with the head pointing upward when the ascending worm is screw
fastened.

Loosen the 3 clamp jaws (2) below on the FSS and align the FSS on the
upward transfer bracket.

Fig. 181: Prepare FS

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 6 FE with upward transfer

Remove the lower inspection cover of the ascending worm.

Now lift the ascending worm onto the FS and the upward transfer unit
bracket. On top, the U-profile for the FS must sit cleanly on the seal (1).
At the bottom, the admission trough must be pushed into the upward
transfer bracket to the stop (2).

Ensure precise seat – if necessary rotate the FS and upward transfer unit
bracket to adjust.

Fig. 182: Place the ascending worm

The correct location and relative position of the parts is a result of the optimal seat of the connecting parts as specified in
the construction and installation diagram.

Check:
•  Position of the stirrer (also remove the substrate)
•  Position and seat of the transfer station (upward transfer sheet metal – ascending worm)
•  Position and seat of the ascending worm on the FS
Bolt the ascending worm to the upward transfer unit bracket. Drill two
opposing bores Ø 8.5 in the right angle (90°) on the ascending worm axis.

• 2 M8 x 25 saucer-head screws from inside to outside

• 2 large washers, 2 self-locking nuts

Fig. 183: Bolt the ascending worm 1

(1) Firmly clamp the fire shutter onto the container.

(2) Bolt the ascending worm to the FS (screw head pointing up).

• 2 hex screws M10 x 120, 2 washers

• 4 hex nuts (lock)
• 2 washers, 2 self-locking nuts

(3) Seal the gap at the FS / hopper sheet metal with silicon.

Fig. 184: Bolt the ascending worm 2

Now fix the transfer station in place on the boiler room floor with
M10 x 85 anchor bolts.
Var. 1 fastening below (Fig.):
• 2 washers Ø 35 should be placed under
Var. 2 lateral fastening with short feet:
• 2 large washers (spacers) for each foot
• 2 flange screws M8 x 30, 2 hex flange nuts
Alternatively:
Var. 3 lateral fastening with long feet:
• 2 large washers (spacers) for each foot
Fig. 185: Fix the upward transfer bracket • 2 flange screws M8 x 30, 2 hex flange nuts
in place

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 6 FE with upward transfer

Now fasten the fuel extractor in the storage room.

In this process the spline (centre of stirrer) should be centred to max.
20 cm left (viewed from the stirrer to the boiler room). The supports of
the gear unit box should rest completely on the floor.

Place the four bolt anchors (bore Ø10).

• 4 bolt anchors M10 x 85

Fig. 186: FE – fix the position

6.7 Installing the ascending worm drive

Screw the 4 M10 x 45 stud bolts into the ascending worm.

Fig. 187: Screw in the stud bolts

The chain wheel box can be mounted right or left. The worm must be in
the higher positioned hole group.

Slide the chain wheel box onto the stud bolts of the FE trough

Fig. 188: Place the chain wheel box

Slide the Ø 50 onto the stud bolts, centre the worm, and tighten it.

• 4 flange nuts M10

Fig. 189: Install the ascending worm bearing

(1) Bolt the motor as close as possible to the worm and the chain wheel
box. Do not tighten the nuts.

Grease the shaft ends.

(2) Seal the joint under the bearing with silicon.

Fig. 190: Install the ascending worm drive

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 6 FE with upward transfer

Place the feather keys in the shaft grooves and carefully place the chain
wheels onto the shaft ends with the soft-faced hammer.

Motor: Chain wheel Z15

Screw the chain wheel Z22 onto the worm.

• Washer Ø 60, hex-screw M10 x 35, spring-lock washer

Fig. 191: Chain wheel installation

(ascending worm)
The two chain wheels must be mounted flush.

Compare the distances of the two chain wheel front edges to the gear
box (measuring tape).
If necessary slide the motor-side chain wheel until it shows the same
distance to the chain wheel box.

Fix the chain wheel onto the shaft with the stud bolt.

Fig. 192: Chain wheel adjustment

Place the drive chain over the chain wheels and connect with the
connecting link.

Tension the chain by sliding the motor. The chain should allow deflection
of approximately one centimetre. Then tighten the screws to fasten the
motor.

Grease the chain.

Fig. 193: Chain installation

Install the cover of the chain wheel box.
Seal the joint between chain wheel box and ascending worm.

Now install the stirrer and the leaf springs as described in point 2.2.6
and 2.2.7.

Fig. 194: Seal ascending worm

Then install the FE drive (2.2.3 Fig. 135 to 137).

Before putting on the chain, check the parallel clearance of the leaf
springs to the FE trough.
During a complete rotation check for the prescribed parallel distance
as described in Fig. 154 and 159).

Fig. 195: Seal ascending worm

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 6 FE with upward transfer

6.8 Installing the inspection box and trough cover

On the boiler-room side bond the sealing tapes along the upper edge of
the FE trough into the storage room.

Fig. 196: Fasten inspection box

Position the inspection box (IB) flush with the wall on the storage room
side. Drill two Ø 8.5 mm bores into the FE trough in accordance with the
IB hole pattern.

Fig. 197: Fasten inspection box

Screw the inspection box to the trough. Compensate the level with an
Sealing strip M12 washer.
2 flange screws M8 x 30
1 washer M12 (level compensation)
2 self-locking nuts

Drill and fasten the inspection box on the boiler room side as well.
Washer, M12 2 flange screws M8 x 30, 2 flange nuts
level compensation
Fig. 198: Detail – inspection box fastening
Now determine the required length for the trough cover.
The cover has overlapping areas on both sides.
dge,
Front e ox
insp .  b
To do this measure the distance from the cast part of the transfer station
to the front edge of the inspection box and add an additional 15 mm!
Shorten the trough cover to this length and deburr the interfaces.

, To prevent damage to the coating, use a 1 mm cut-off wheel!

gth et
Len er she
cov
Fig. 199: Size the trough cover
Slide the cover under the upward transfer unit bracket and transfer the
hole pattern of the cover onto the trough.
(The number of bores depends on the length of the cover)

If the last pair of holes is more than 10 cm away from the

inspection box you must re-bore and re-bolt.

Fig. 200: Transfer hole pattern

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 6 FE with upward transfer

(1) Bolt the cover to the FE trough.

• Flange screw M8 x 25, self-locking nuts

(2) Install inspection box cover

(3) Install ascending worm inspection cover

Fig. 201: Install cover and insp. cover

6.9 FE cabling and cable layout

For FE with special lengths, extension cables with a length of 4 m and cable ducts with a length of 2 m are provided.
Install the cable duct on the side of the ascending worm, flush with the
upper edge.
(If cable ducts were installed in the middle the screws would project into
the worm!)

• Self-drilling screws

Fig. 202: Install cable channel

Slide the temperature monitoring sensor into the fuel storage room (TÜB)
from the boiler room, far enough into the guide pipe that wall thickness
is overcome and the sensor is located in the storage room. However the
sensor should not project over the pipe or be exposed.

To fix the cable in place, seal the inlet point of the guide tube
with silicon.

Fig. 203: Install boiler room temp. monitor

Cabling:
• Stirrer
In accordance with electrical diagram 5.3.9 FE module
• Ascending worm
In accordance with the plug-in connectors on the motherboard

Correct the numbering of the plug-in connectors!

Fig. 204: Cable routing bottom

Subsequently cable the FE and connect the individual plug-in connectors
of the cable to the I/O board.

Fig. 205: Cable routing top

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 6 FE with upward transfer

6.10 Concluding tasks

Bond the rock wool insulation around the inspection box.

Fig. 206: Insulate the RK

Seal the joint between trough cover and upward transfer bracket
with silicon.

Fig. 207: Seal trough

Warning stickers

Affix the three warning signs to the inspection cover!

Fig. 208: Affix the warning signs

6.11 Final inspection

To conclude, check whether all covers are installed!
Check whether all stickers are affixed and that all documents concerning the system are present!
Clean the system and clean the construction site. Always leave a clean room after installation!

Check whether the installation and establishment of all connections has been correctly executed,
and then in conclusion check whether the conveyor system is free of foreign objects.

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 7 Double FE

7 Double fuel extractor (d-fe)

7.1 Components

Standard foot
Long foot
Crossbeam
Gear unit

Fig. 209: Explosion drawing D-RA

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 2x L, 2x R

Page 150 
7 Double FE

Saucer-head screw M8x25

2x saucer-head screw M8x25

Fig. 210: Detail D-FE crossbeam

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BA Multifire 08/2008 
2x L, 2x R
Washer M8

2x L, 2x R
Hex nut M8 SS
2x washer M8
2x hex nut M8 SS

© KWB – Kraft und Wärme aus Biomasse GmbH

General tol. Scale 1:20
DIN 7168-m

Date Name
Auth.
Double fuel extra
 2x L, 2x R
Saucer-head screw M8x25
1x L, 1x R Hex nut M8 SS
Flange screw M10x20
Hex nut M10 SS

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Fig. 211: Detail D-FE crossbeam
2x L, 2x R
4x L, 4x R
Saucer-head screw M8x25
Hex nut M10 SS
Hex nut M8 SS
Washer M10

© KWB – Kraft und Wärme aus Biomasse GmbH

9x flange screw M12x25

7x washer M12 large

MA Multifire 08/2008
1x L, 1x R 16x flange screw M10x20
Flange screw M12x25
Flange screw M10x20
Hex nut M10 SS
Washer M10

Page 151
7 Double FE

General tol. Scale 1:20

DIN 7168 - m

Date Name
Auth.
Double fuel extractor
 7 Double FE

All threaded unions must be tightened during installation!

All threaded unions are provisional and are only designed for transport!
All FE variants only become stable when the threaded unions are firmly tightened
during the installation process!

Comply with the safety instructions in point 2.2

The troughs of the double fuel extractor (D-FE) are delivered and brought in preassembled. If needed the D-FE can be
dismantled.

7.2 Aligning the stirrer channel, installing the crossbeam and feet
Bring the FE parts into the boiler room and storage room and place the
stirrer channel into its probable location.

Fig. 212: Bring in D-FE

Align the reference aid (upper edge of the FE trough):

String a cord to the opposite storage room wall 130 mm above the FS
hopper sheet metal.
Fasten the cord on the storage room wall at least 50 mm above the floor;
this cord should remain as highly tensioned as possible.

Fig. 213 Reference aid

To install the crossbeam (3) elevate the stirrer trough with
a robust, non-slip substrate (wood batten) and bolt it.
• 4 screws M6 x 16, 4 hex flange nuts M6

Bring the stirrer trough into its precise position:

• The tabs (2) are at the height of the reference aid (winch)
• The middle of the stirrer (1) is centred a max. of 20 cm to the left:
Fig. 214: Install crossbeam position FE (viewed from the stirrer to the boiler room)
• The stirrer trough is at the same height as the reference aid
• The stirrer trough has the same incline as the reference aid
•C omply with the information specified in the installation and
construction diagram

Fig. 215: Precisely place the stirrer trough

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 7 Double FE

Bolt the support feet onto the side of the crossbeam

• 4 flange screws M12 x 25

Fig. 216: Install support feet

7.3 Installing the gear unit and drive shafts

Remove the inspection lid (1).

Use the installation aid (2) to lift the gear unit into the stirrer trough.
(3) Before tightening, first screw in all screws (top and bottom) a short
distance.

Top: 5 flange screws M12 x 25, 5 large washers

Bottom: 4 flange screws M12 x 25, 4 spring-lock washers,
large washers

Fig. 217: Install gear unit

Grease the spline.
Slide the adapter (1) onto the spline of the gear unit until the stop.
Apply a little silicon to the flanks of the spline to reduce noise.

Fig. 218: Install gear unit and adapter

From the boiler room, slide the drive shaft (2) through the stirrer trough.
Adapter (1) and drive shaft (2) must be pushed to the rear until the
stop.

Close the inspection opening.

• 4 screws M6 x 16, 4 lock washers

Fig. 219: Install drive shaft

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 7 Double FE

7.4 Installing FE troughs and fixing them in place in the

­storage room
Remove the covers of the FE troughs, remove the worms and lift the FE
troughs onto the crossbeam.

Fig. 220: Position the FE troughs

Loosen the clamp jaws at the bottom of the FS.
Align the FS to the FE and place the troughs on the FS.
Ensure that the U-profiles are precisely seated on the hopper sheet metal
and re-check to ensure the exact position of the middle of the stirrer in
the storage room.

Fig. 221: Install drive shaft

Install the second crossbeam ADFZ0003 at a distance of 15 cm, parallel
to the wall in the storage room (see Fig. 209 and 210)

To ensure that the worm does not shear on the screws, drill two Ø 8.5
bores into the FE troughs offset to the outside as far as possible (Fig. 223
to 225)
The stirrer trough is screwed to the crossbeam via a tab (Fig. 209
and 224).
• 6 saucer-heads crews M8 x 25, 6 self-locking nuts

Fig. 222: Install top crossbeam

Fig. 223: Bolt front cross beam 1 Fig. 224: Bolt front cross beam 2 Fig. 225: Bolt front cross beam 3

Bore a Ø 14 hole laterally into the tab on the stirrer trough. Cut the 3rd
support to size and bolt it to the stirrer trough.

• Flange screw M10 x 25, flange nut

Fig. 226: Install stirrer trough support

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 7 Double FE

Fix the 3 support feet of the D-FE in place in the storage room with
6 anchor bolts.

• 3 bolt anchors M10 x 85

Fig. 227: Install stirrer trough support

To ensure that the worm does not shear on the screws, also drill two Ø 8.5 bores into the FE troughs at the rear, offset to
the outside as far as possible (Fig. 211 to 229 and 230). Then bolt the troughs to the crossbeam.

• 4 saucer-head screws M8 x 25, 6 self-locking nuts

Fig. 228: Bolt rear crossbeam 1 Fig. 229: Bolt rear crossbeam 2 Fig. 230: Bolt rear crossbeam

(1) Check whether the end flange is firmly bolted!

(2) Lift the worms into the troughs.

(3) Slide the worm bearing over the worm and bolt it.

• 4 washers M10, 4 self-locking nuts M10 per trough

Fig. 231: Worm bearing

(1) Install the covers of the FE troughs. First insert all saucer-head
screws into the apertures and after this has been done, tighten
them.
Install the 2 reinforcement sheets first on the stirrer trough, then on
the FE troughs.

(2) Flange screw M10 x 25

(3) In each case 2 saucer-head screws M8 x 25, self-locking nuts

Fig. 232: Trough reinforcement

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 7 Double FE

7.5 Installing the stirrer trough insulation and drive

If there is a wall duct, bond the F90 insulation around the stirrer
channel.

Screw the 4 stud bolts M10 x 35 into the stirrer trough.

Slide the chain wheel box onto the stud bolts.

The chain wheel box can be mounted right or left. The drive shaft can
be fastened in the lower-positioned hole groups as well as the higher-
positioned hole group.
Fig. 233: Install insulation & chain wheel box

Fig. 234: Detail – drive

If the shaft bearing is bolted to the chain wheel box the worm should have maximum axial play
of 2 mm.
This distance must be strictly and precisely maintained; it is adjusted by adding or r­ emoving
spacer washers. Before mounting the bearing the worm MUST be all the back in the
­claw coupling, and it must be seated all the way back on the splined shaft of the gear unit.

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 7 Double FE

Step 1:
If the shaft is seated all the way back, determine (e.g. by using an angle
bracket) the distance between the bearing support surface (chain wheel
box) and the shaft stop.

Fig. 235: Determine shaft play 1

Step 2:
Now determine the level difference between the bearing flange and shaft
bearing (Ø 35)

Fig. 236: Determine worm play 2

If the sum of these two distances (step 1 and 2) is greater than 2 mm, you
must slide the spacer washers onto the shaft accordingly (each 2 mm).

Fig. 237: Slide on the spacer washers

Slide the bearing (Ø 35) over the shaft end onto the stud bolts (lubricating
nipple on the side) and bolt it.

• 4 flange nuts M10

Seal the joint for the bearing flange with silicon.

Fig. 238: Trough reinforcement

Do not tighten the two M6 stud bolts.

Fig. 239: Shaft & cover sheet metal fastening

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 7 Double FE

Bolt the motor to the chain wheel box. Do not tighten the nuts.
Grease the shaft end.

Place the feather keys in the shaft grooves and carefully place the chain
wheels onto the shaft ends with the soft-faced hammer.

(Chain wheel Z30 on worm, chain wheel Z15 on motor)

Fig. 240: Motor installation

The two chain wheels must be mounted flush.

Compare the distances of the two chain wheel front edges to the gear
box (measuring tape).
If necessary slide the motor side chain wheel until the chain wheels are
same distance from the chain wheel box.

Then fix the chain wheels in place on the shafts with the set screws.

Fig. 241: Chain wheels

Before putting on the chain, check the parallel clearance of the leaf springs to the FE trough. To do this
install the stirrer and the leaf springs as described in point 2.2.3 and 2.2.4.
During one complete rotation, check for the prescribed parallel distance as described in Fig. 146 and 151).

Place the drive chain over the chain wheels and connect with the
connecting link.

Tension the chain by sliding the motor. The chain should allow deflection
of approximately one cm. Then tighten the screws to fasten the motor.

Grease the chain and mount the lid of the chain wheel box.

Fig. 242: Chain installation, motor installation

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 7 Double FE

7.6 Installing the fuel extractor drive

Screw in the 4 M10 x 45 stud bolts on the face side.

Fig. 243: Place the stud bolts

The chain wheel box can be mounted right or left. The worm must always
be fastened in the lower hole group.
Slide the chain wheel box onto the stud bolts of the FE trough

Fig. 244: Fasten the chain wheel box

Slide the Ø 50 bearing onto the stud bolts.
Centre the worm and tighten it.

• 4 flange nuts M10

Fig. 245: Bearing installation

(1) Bolt the motor as close as possible to the worm and the chain wheel
box. Do not tighten the nuts.

Grease the shaft ends.

(2) Fasten the cover sheet metal with silicon.

Fig. 246: Install FE drive

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 7 Double FE

Place the feather keys in the shaft grooves and carefully place the chain
wheels onto the shaft ends with the soft-faced hammer.

Motor: Chain wheel Z15

Bolt the chain wheel Z30 onto the worm.

• Washer Ø60, hex screw M10 x 35, spring-lock washer

Fig. 247: Chain wheel installation

The two chain wheels must be mounted flush.

Compare the distances of the two chain wheel front edges to the gear
box (measuring tape).
If necessary slide the motor-side chain wheel until it shows the same
distance to the chain wheel box.

Fix the chain wheel onto the shaft with the stud bolt.

Fig. 248: Chain wheel adjustment

Before putting on the chain, check the parallel clearance of the leaf springs to the FE trough. To do
this install the stirrer and the leaf springs as described in point 2.2.3 and 2.2.4. During one complete
rotation, check for the prescribed parallel distance as described in Fig. 146 and 151).

Place the drive chain over the chain wheels and connect with the
connecting link.

Tension the chain by sliding the motor. The chain should allow deflection
of approximately one cm. Then tighten the screws to fasten the motor.

Grease the chain.

Fig. 249: Chain installation

Install the cover of the chain wheel box.
Seal the joint between chain wheel box and ascending worm.

Fig. 250: Seal FE

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 7 Double FE

7.7 Open installation tasks – double FE

All D-FE installation tasks that have not yet been executed are described in point 2.2 (main part of this installation
manual.

7.8 Cabling the double FE with common drive

For the cabling of the double fuel extractor with a common drive an additional cable set is included with circuit diagram
and control unit information (art. no. 59000066).

See also:
•  Electrical diagram FE module . .............................. point 5.3.9
•  Control unit, fuel extractor .................................... Point 4.2.11.1.2

Execute all cabling that does not affect the common drive in the standard manner.

7.9 Final inspection

To conclude, check whether all covers are installed!
Check whether all stickers are affixed and that all documents concerning the system are present!
Clean the system and clean the construction site. Always leave a clean room after installation!

Check whether the installation and establishment of all connections has been correctly executed,
and then in conclusion check whether the conveyor system is free of foreign objects.

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 8 FE with fall pipe

8 Fuel extractor with fall pipe

8.1 Components of the FE with fall pipe

Fig. 251: Components of the FE

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 8 FE with fall pipe

Fig. 252: Components of the FE

Fig. 253: Head piece and chain wheel box

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 KWB installation examples

KWB USV ZI 80-100 kW with fuel extraction from above-situated

storage room

Conveyor channel recessed blind floor Wall opening: Ceiling opening: 30 x30 cm
Outline
(rear ventilation recommended) H 60 x W 50 cm (Close again after assembly –

Fig. 254: Installation example

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trough acoustically uncoupled)

Solid ceiling F90

© KWB – Kraft und Wärme aus Biomasse GmbH

MA Multifire 08/2008
Comment: If the smoke pipe is
connected in this manner then

Page 165
the minimum clearance to the
chimney must be taken into
8 FE with fall pipe

Ground plan consideration.

 8 FE with fall pipe

8.2 Contents of this installation manual

The installation tasks listed here are described in point 2.2 of this installation manual.

8.3 Installing the RA head piece, downward transfer

Comply with the safety instructions in point 2.2

The troughs of the fuel extractor (FE) are delivered and brought in preassembled. In cases where there is not enough
space for this the FE can be dismantled.

• Connect the FE trough to the fall pipe.

Insert the head piece into the fall pipe bend (art. no. ZARB180) and bolt
the connection 2 times (bottom 90° on the FE trough – opposite with the
nuts outward!).

• 2 saucer-head screws M8 x 25, 2 washers

• Seal the joint between head piece and drop pipe bend with silicon.

Fig. 255: Bolt FE channel & cast-iron head

Drill bores right and left on the side of the chain wheel box to mount the
support feet ADEZ0002.
Bolt the support feet (drawing point 9.1.1)

Alternatively you can also use the long support feet (ADEZ0001).
For anything beyond this the customer-side adaptations are required!

• 2 spacer washers Ø 35, flange screws M8 x 30,

2 flange nuts M8 in each case

Fig. 256: Install feet

Establish the connection to the FS. If necessary use pipe bends (ZARB180)
or fall pipes (ZAR180).

For each connection:

3 x on the perimeter (offset 120° each time) self-drilling screws 5.5 x 16

Seal all connections with silicon. Ensure that the trough rout-
ing is as vertical as possible (max. 20° off vertical).

Fig. 257: Fall pipe connection

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 8 FE with fall pipe

Fasten the cable trough to the fall pipe with self-drilling screws.

Fig. 258: Install cable channel

8.4 Cabling the FE with drop shaft

For drop shaft version, extension cables with a length of 4 m and cable ducts with a length of 2 m are provided.

Layout the cables with plug-type connectors in the cable duct. The cable
connectors should be connected with the master board according to the
numbers.

Fig. 259: Lay cables

8.5 Open installation tasks

All FE installation tasks that have not yet been executed are described in the main part of this installation manual:
Installation of the fuel extractor Standard point 2.2

8.6 Final inspection

To conclude, check whether all covers are installed!
Check whether all stickers are affixed and that all documents concerning the system are present!
Clean the system and clean the construction site. Always leave a clean room after installation!

Check whether the installation and establishment of all connections has been correctly executed,
and then in conclusion check whether the conveyor system is free of foreign objects.

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 9 FE+downward transfer+ascending worm

9 Fe with downward transfer and ascending worm

9.1 Components of the FE

Fig. 260: Explosion drawing

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 9 FE+downward transfer+ascending worm

Fig. 261: Detail 1: Transfer station

Fig. 262: Detail 2: Transfer station

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 9 FE+downward transfer+ascending worm

Fig. 263: Detail – chain wheel box, ascending worm

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 KWB installation examples

9 FE+downward transfer+ascending worm

KWB USV ZI 40 kW with horizontal fuel extractor
and ascending worm with drop shaft

Outline

Solid ceiling F90

(to W
15 orm
°= i
W nclin
W L ma e 0°
L m x. to
ax 12 ma
. 6 m x.
m) ; 15 45
°-4 °
5°
=

to 25° = at least 45 cm
26°-35° = min. 50 cm
at 15° = max. 582 cm 36°-45° = min. 60 cm
at 45° = max. 437 cm

Ground plan

Stop switch

Fire
extinguisher

Cut out as
needed

Wall duct
H40/B50 shaft parallel
m
2.0
to 1
=
WL

Provide installation and

removal space Extraction from silo
(dumping height on request)

Transfer station

Ventilation 5 cm2 per kW, however at

least 400 cm2

Fig. 264: Installation example KWB USV ZI 80 – 100 kW

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 9 FE+downward transfer+ascending worm

9.2 Contents of this installation manual

The installation tasks listed here are described in the following points of this installation manual.

Ascending worm:
• Installing the ascending worm drive . ..................................................... Point 7.1.7
• Installing the inspection box & trough cover .......................................... Point 7.1.8
• FE cabling and cable layout . .................................................................. Point 7.1.9
Fuel extractor trough:
• Installing the fuel extractor trough standard . ......................................... Point 2.2.2
• Installing the worm drive . ...................................................................... Point 2.2.3
• Installation, inspection box, cover, and overfill protection ...................... Point 2.2.4
• Floor assembly FE (storage room) . ........................................................ Point 7.1.3
• Concluding tasks . .................................................................................. Point 7.1.10
Stirrers:
• Installing the articulated-blade rotary stirrer . ......................................... Point 2.2.6
• Installing the spring-blade rotary stirrer . ................................................ Point 2.2.7

9.3 Installing the ascending worm

The troughs of the fuel extractor (FE) are delivered and brought in preassembled. If needed the FE can be
dismantled. For a worm length starting at 5 m one support is supplied; for worm length over 8 m, 2 supports are
supplied. These supports must be adjusted in such a manner that the trough is aligned.

All threaded unions must be tightened during installation!

All threaded unions are provisional and are only designed for transport!
All FE variants only become stable when the threaded unions are firmly tightened during the installation
process!

Comply with the safety instructions in point 2.2

(1) Remove the two hex screws (1) of the fire-safety shutters – they
will be screwed in with the heads pointing upwards when the ascending
worm is bolted.

(2) Loosen the 4 bottom clamp jaws on the FSS and align the FSS on the
ascending worm.

Fig. 265: Prepare FS

Now lift the ascending worm onto the FSS.

(1) On top, the U-profile for the FS hopper sheet must sit cleanly on the
seal.
Ensure precise seat – if necessary turn the FS or ascending worm to
make adjustments.

Fig. 266: Place the ascending worm

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 9 FE+downward transfer+ascending worm

Install the support feet on the channel of the ascending worm.

Fig. 267: Install support feet

9.4 Installing the fuel extractor trough

Follow the instructions in the installation manual, point 2.2.2 to Fig. 121. (Also comply with the instructions in 10.1.2)
Install the edge protection with sealing lip on the connecting pipe of the ascending worm.
Then insert the FE trough into the ascending worm.

Correctly align the troughs.

Drill (Ø 8.5) and bolt the connection 2x on opposing sides (under 90° on
the FE trough).
(Nuts outside)

• 2 saucer-head screws M8 x 25, 2 large washers, 2 self-locking Nuts

(outside)

Place the 4 anchor bolts M10 x 85

Fig. 268: Bolt on the ascending worm 1

To conclude fix the ascending worm on the FS.
(1) Firmly clamp the fire shutter onto the container.

(2) Bolt the ascending worm to the FS.

(Screw head pointing up).

• 2 hex screws M10 x 120, 2 washers, 4 hex nuts, 2 washers,

2 self-locking nuts

(3) Seal the gap at the FS/hopper sheet metal with silicon.

Fig. 269: Bolt the ascending worm 2

9.5 Installing the FE worm drive

Follow the instructions in point 2.2.3 of the manual

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 9 FE+downward transfer+ascending worm

9.6 Installing the ascending worm drive

Follow the instructions in point 7.1.7 of the manual

Worms greater than 6 m in length are delivered in parts.

Insert the worm elements into each other in such a manner that volution is continuous! (Point 2.2.2 fig.125)
Bevel the shaft ends and weld the worms.
The axial forces are absorbed by the upper bearing Ø 50.

9.7 Cabling
For FEs with special lengths, extension cables with a length of 4 m, and cable ducts with a length of 2 m are provided.

Install the cable duct on the side of the ascending worm, flush with the
upper edge.
(If cable ducts were installed in the middle the screws would project into
the worm!)

• Self-drilling screws

Fig. 270: Install cable channel

Cabling, FE:
• Stirrer
In accordance with electrical diagram 5.3.9 FE module
• Ascending worm
In accordance with the plug-in connectors on the master board

Correct the numbering of the plug-in connectors!

Fig. 271: Cable routing top

9.8 Final inspection

To conclude, check whether all covers are installed!
Check whether all stickers are affixed and that all documents concerning the system are present!
Clean the system and clean the construction site. Always leave a clean room after installation!

Check whether the installation and establishment of all connections has been correctly executed,
and then in conclusion check whether the conveyor system is free of foreign objects.

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 10 FE pellets without stirrer

10 FUEL EXTRACTOR pellets without stirrer

All threaded unions must be tightened during installation!
All threaded unions are provisional and are only designed for transport!
All FE variants only becomes stable when the threaded unions are firmly tightened during the installation process!

Comply with the safety instructions in point 2.2

All FE variants can also be executed without stirrer. Installation is executed as described in the respective sections and points.

10.1 Installing the pellet worm

For the version with pellet worm the axial forces must be absorbed by the bearing in the boiler room.
Deviating from the standard versions a bearing Ø 50 mm must be installed as it is for the ascending worms.
A separate screw set is supplied for installation of the bearing Ø 50.

The 35 mm bearing for the standard screw set is installed on the storage room side.

10.2 Divided pellet worm (over 6 m in length)

• Worms greater than 6 m in length are delivered in parts.
• Grease the plug-in connection.
• Always put the worms together in such a manner that volution is continuous (Fig. 125)!
• Welding is not necessary.

On the bunker side the axial play between bearing and worm collar must be compensated with spacer washers.
Max. worm play is 2 mm!

10.3 Contents of this installation manual

Installation tasks not listed here are described in the preceding sections and points.
Comply with points of the concluding inspection!

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 Index

Index
B F
Basic settings 67, 73, 102, 104, 106, 108, 110, 112, Factory setting 72
116, 117 Fast reduction 71
Blocking protection 76 Fault 36, 81, 86
Block terminal 40, 41, 45 Flue gas dew point 11
Boiler circuit pump 33, 36, 75, 76, 86, 87 Flue gas thermostat 41, 108
Boiler control unit 35, 36, 40, 67 Front cladding 19
Boiler I/O 39, 80, 89 Frost protection 40, 67, 80
Boiler master-and-slave circuit 37, 42, 77, 81 Fuel extractor 62, 67, 68, 74, 75, 88
Boiler module 68 Fuel storage room 9, 10
Boiler output 33
Boiler program 72 H
Boiler pump 67, 76, 86, 88, 108 Hardware 41, 67, 77, 80, 102, 104, 106, 108, 110, 112,
Boiler request 81 116
Boiler room 9, 10 Heat exchanger cleaning system 76
Boiler temperature 67, 68, 73 Heating circuit 36, 39, 40, 42, 67, 68, 69, 71, 77, 78,
Bringing the system into the storage location 10 79, 80, 87, 102, 104, 106, 108, 110, 112, 116, 117
Buffer 33, 67, 68, 71, 72, 74, 77, 79, 87, 88, 102, 104, Heating circuit expansion module 40, 78, 80, 106, 110,
106, 108, 110, 112, 116 112, 116
Buffer tanks 33 Heating circuit module 68, 73, 120
Burner 24, 25, 31, 68, 77 Heating circuit pump 36, 71, 87
Bus cable 39 Heating curve gradient 69
Bypass pump 33, 74, 104 Heating curves 69, 71
C Heating limit 71, 80
Heating limit night 71
Cable layout 39 Heating mode 77, 102, 104, 106, 108, 110, 112, 116
Cabling 18, 20, 29, 38, 42, 45, 121, 122, 123 Heating program 40, 71
Chimney 11, 33, 67, 71, 108, 132 Holiday remote control 37, 77
Chimney connection 33
Chimney designs 11 I
Chimney diameter 11 Idle time, mixer 71
Cleaning 67, 76, 86 Ignition 68, 86
Components FE 136, 149 Inputs 37, 41, 123
Connection diagram 36, 38, 40, 42 Installation 2, 9, 13, 28, 30, 31, 32, 40, 65, 67, 147,
Continuous operation 73 161, 167, 175
Control system 37, 67, 69, 71, 73, 74, 75, 77, 80, 86,
90, 102, 104, 106, 108, 110, 112 J
D Junction box 34
DHWC 67, 68, 71, 72, 77, 78, 79, 87, 102, 104, 106, L
108, 110, 112, 116, 117
Digital remote control 67, 79, 102, 104, 106, 108, 110, Language 67, 76
112, 116 Level 71
Digital remote control unit 80 Lightning protection 34
Limiting thermostat 33
E Load balancing accumulator 33
Emission values 68 M
Enclosure 35, 36, 40
Equipotential bonding 49 Main room 40
Escape switch 9, 34 Mains supply 34
Expansion module 89 Main switch 34, 67, 90
EXT 2 81 Medium load 37
External 1 37 Mixer control unit 33, 74, 116
External 2 37, 102, 104, 106, 108, 110, 112, 116 Mixer motor connection 36
Mixer return flow boost 67, 74, 87
Mounting location 40

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 Index

N S
Network 39, 43 Save 67
Network analysis 68 Second boiler 67, 68, 76, 80, 81, 88, 108
Network settings 67, 77, 102, 104, 106, 108, 110, 112, Second boiler pump 76
116, 117 Second boiler switchover 36, 41, 42, 107, 108
Nominal load 37, 68 Second boiler thermostat 41
Sensor cable 37
O Sensor check 41, 50
Operating values 69 Sensor resistance 41
Outdoor sensor 35, 36, 71, 78, 79, 80, 102, 104, 106, Set-up room 13
108, 110, 112, 116, 117 Setpoint thermostat 41
Outputs 36, 67, 77, 81, 86, 122 Short circuit 50
Output stage 37 Smoke pipe connection 33
Overheating protection 41 Specialist level 67, 69, 80, 90
Speed level 86
P Stop switch 34
Supply 37, 39, 90
Partial load 37
Pin connectors 40, 41, 45 T
Plug-in module 41, 76, 78, 80, 108
Power output 67, 77, 81, 86, 102, 104, 106, 108, 110, Taking system measurements 68
112, 116 Terminals 39, 41
Power plug 34 Thermal valve 74, 75, 112
Protection against shock 37 Third-party control devices 37
Pump afterrun 67, 75 Time program 73

R W
Relay test 68, 86 Wall socket 39, 80
Remote control unit 68, 80 Warranty 9, 33, 38
Request 37, 73, 77, 78 Water connection 33
Return flow boost 33, 67, 74, 87, 100, 102, 104, 106,
108, 110, 112, 116
Room control unit 39, 40, 41, 102, 104, 108
Room influence 40, 71
Room sensor 50, 71, 78, 102, 104, 106, 108, 110, 112,
116, 117
Runtime 75
Runtime, mixer 71

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for Life!
www.kwb.at
We provide Energy

Printed with Öko-Plus vegetable dyes – dyes have mineral-oil free base to protect the environment.
Biomass Heating Systems

KWB - Kraft und Wärme aus Biomasse GmbH . Industriestr. 235, A-8321 St. Margarethen/Raab
Tel.: +43 (3115) 6116-0 Fax DW 4 . office@kwb.at . www.kwb.at . Dated: August 2008.
Subject to alterations . Photos: Thomas Kunz, panthermedia . Art. no. 21-2000085