KWB Multifire USV 15/25 V Installation And Maintenance Manual

Multifire heating system for wood chips and pellets

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KWB Multifire 15 - 100 kW

Heating System for Wood chips

and Pellets

Biomass Heating Systems

Installation and Maintenance Manual

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Page 1 KWB Multifire 15 - 100 kW Heating System for Wood chips and Pellets Biomass Heating Systems Installation and Maintenance Manual...
Page 2 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.
Page 3: Table Of Contents
Power supply ......................... 2.1.11.4 Fuel extractor motor ....................... 2.1.11.5 Inputs ..........................2.1.11.6 Connection variants ....................... 2.1.11.7 System bus connection ....................2.1.11.8 Commissioning the FE module ..................© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 3...
Page 4 4.2.11.2 Heating circuit ........................ 4.2.11.3 DHWC ..........................4.2.11.4 Buffer ..........................4.2.11.5 Digital remote control ..................... 4.2.11.6 Power measurement ...................... 4.2.12 Hardware ..........................4.2.13 Frost protection ......................... Page 4 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 5 Installation dimensions KWB Multifire USV V 15 – 25 kW .......... 5.1.2 Installation dimensions KWB Multifire USV D 15 – 25, 30 – 60 and 80 – 100 kW ..5.1.3 Installation dimensions KWB Multifire USV ZI 15 – 25, 30 – 60 and 80 – 100 kW 5.1.4...
Page 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 ............
Page 7 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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 7...
Page 9: Introduction
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.
Page 10: General Requirements Imposed On Fuel Storage Rooms
(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.
Page 11: Chimney Requirements
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...
Page 13: System Installation
2 system installation 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.
Page 14: Taking The System Off Of The Pallet
Lift the system simultaneously with hoisting winch and fork lift truck until the pallet is free. Remove the pallet. Page 14 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 15 Lower the system. Use all of the adjustable feet to align the system. fig. 13: lower the system © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 15...
Page 16: Dismantling The System
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. Page 16 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 17: Dismantling The Boiler Cladding
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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 17...
Page 18 I / O board. Carefully pull the cabling downward and roll it together. detail f fig. 21: disconnect the I/o board cable detail g Page 18 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 19 (Detail G). Tip the rear wall back and lift it off. detail f detail g fig. 25: take off the rear wall © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 19...
Page 20 (Detail F). attention danger of tipping! 2. dismantling the stoker container 2.a dismantling the burner. detail f fig. 28: Insulation removed Page 20 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 21: Preparation For Dismantling The Heat Exchanger
Loosen the set screw on the chain wheel and pull it off with a puller (Detail G). detail f fig. 31: dismantling the cleaning system motor detail g © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 21...
Page 22: Dismounting The Container
Details: See point 9.5. Pull out the stoker worm. detail g fig. 44: dismantle the stoker bearing detail h Page 22 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 23 Only the threaded unions of the intermediate cladding on the container must be loosened (Detail G). detail g fig. 49: container with stoker worm © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 23...
Page 24: Dismantling The Burner
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).
Page 25: Assembling The System
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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 25...
Page 26: Mounting The Container And Stoker Drive
(2) slide on the shaft protection sleeve (3) 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).
Page 27: Mounting The Ash Worm Drive
Place the ratchet drive on the AW extension (Detail D). detail d AW = Ash Worm detail e fig. 64: mount the aW connecting chain detail f © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 27...
Page 28: Installation Of The Heat Exchanger
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 Page 28 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 29 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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 29...
Page 30: Installing The Cladding
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 Page 30 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 31: Installing The Vacuum Conveyor Unit
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. © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 31...
Page 32: Installing The Cladding/Concluding Tasks
(Detail F). detail f Protect the control unit with a cover foil (Detail G). fig. 83: clean the system detail g detail h Page 32 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 33: Smoke Pipe Connection And Induced Draft Fan
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.
Page 34: Thermal Safety Valve Connection
• 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 •...
Page 35 • 1 analogue room control unit configuration + room sensor • 1 digital room control unit + room sensor © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 35...
Page 36 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 Page 36 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 37: Junction Box
– Protection against shock – connections are not short-circuit proof – control system must be switched off to initialise. fig. 89: disconnect the Bcu cable © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 37...
Page 38: Cabling Guidelines
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 Page 38 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 39 5. – Terminate the shielding (with cable clamp) 3. – Mark the cables coming / going (e.g. with arrows) fig. 92: terminals of the bus cable © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 39...
Page 40: Control Units & Heating Circuit Expansion Modules (Hcm)
Carefully press the screwdriver in the direction shown. Repeat the process on the opposite side. fig. 99: open the control unit Page 40 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 41: Plug-In Module 1 (Option)
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) © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 41...
Page 42: Heating Circuit 0 And / Or Second Boiler Switchover
Settings / Network settings / Boiler. The consumers are connected and the network settings are made on the network of the main boiler. (HCEM, DRCU, etc). Page 42 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 43: Heating Circuit Expansion Module (Option)
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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 43...
Page 44 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 Page 44 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 45: Fe Module (Option)
24 v dc control unit right side 400 vac power unit © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 45...
Page 46: Power Supply
(Details B and C). Detail B Detail C Pin assignment, fuel extractor motor: Wire markings – cable terminal connection – power unit Yellow-green Earthing bar Page 46 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 47: Inputs
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. © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 47...
Page 48: Commissioning The Fe Module
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) Page 48 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 50: Sensor Check
4: sensor values Kty 81-110 flue gas sensor (Pt100): temperature resistance temperature resistance temperature resistance [°c] [ohm] [°c] [ohm] [°c] [ohm] table 5: sensor values Pt100 Page 50 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 52: Installing The Fuel Extractor Standard
2 system installation 2.2.1 Installing the fuel extractor standard 2.2.1.1 components of the fe standard fig. 112: overview presentation – fe standard Page 52 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 53 1x L, 1x R Washer M12 Anchor bolt M10x85 2x washer large M12 Hex nut M10 SS 4x flange screw M12x20 fig. 114: fe standard: detail – storage room © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 53...
Page 54 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 Page 54 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 55: Installation - Fe Trough Standard
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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 55...
Page 56 • 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 Page 56 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 57: Installing The Worm Drive
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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 57...
Page 58 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 Page 58 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 59: Installation, Inspection Box, Cover, And Overfill Protection
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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 59...
Page 60 (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 Page 60 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 61 • 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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 61...
Page 62: Transfer Sloping Floor Plane
Before tensIonIng the sPrIngs detach the steel arm transPort safeguard! after mounting, the steel arms are under high mechanical tension! Page 62 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 63 (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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 63...
Page 64: Installing The Spring-Blade Rotary Stirrer
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 Page 64 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 67: Commissioning
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.
Page 68: Function Check Of The System Parts
Now instruct the system owner in how to operate the system; proceed as specified in the operating manual for this. Page 68 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 69: Operation, Specialist
= 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. © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 69...
Page 70 °c 2,75 2,25 1,75 1,25 0,75 **+ 10 °c *0 °c ***– 10 °c outdoor temperature °c Outdoor temperature °C fig. 161: heating curve diagram Page 70 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH D:Daten/Berech/heizung.xls...
Page 71: Outdoor Temperature Dependent
Temperature limit for operation with the day room temperature. heating limit night: Temperature limit for operation with the night room temperature. © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 71...
Page 72: Menu Item - Dhwc
“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 Page 72 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 73: Menu Item - Basic Settings
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. © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 73...
Page 74: Return Flow Boost
Fuel extraction with hopper (200 l – 15 to 100 kW) Direct fuel extraction (15 to 100 kW), stoker and fuel extractor run parallel Vacuum conveyor system with worm Vacuum conveyor system with suction lance Page 74 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 75: Fuel Extractor Fill Time
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. © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008...
Page 76: Boiler Pump
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) Page 76 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 77: Network Settings
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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 77...
Page 78: Heating Circuit
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. Page 78 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 79: Buffer
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] © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 79...
Page 80: Hardware
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“. Page 80 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 81: Outputs
Secondary air setting in the specific air levels 0 to 100 % sl corr. factor: Factor can be set between 80 and 120 % Secondary correction value, i.e. the result of setting and correction. © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 81...
Page 82: Boiler Output
(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 Page 82 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 83: Motor Power
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 % © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 83...
Page 84: Control Unit
0.03 – 0.12 Tv = D / P = 25 / 15 = 1.67 [sec] 10 – 50 target: 7 – 13 % actual: – – – Page 84 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 85: Secondary Air
Tn = P / I = 8 / 0.01 = 800 [sec] 0.01 0.005 – 0.02 Tv = D / P = 50 / 8 = 6.25 [sec] 25 – 75 target: – – actual: – – © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 85...
Page 86: Menu Item - Relay Test
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 Page 86 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 87: Heating Circuits
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.
Page 88: Fuel Extractor
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) Page 88 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 89: Menu Item - Network Analysis
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. © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008...
Page 90: Fuel Extractor Module
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. 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.
Page 91: Appendix I
5 appendix I aPPendIx I dImensIon sheets hydraulIc cIrcuIt dIagrams connectIon and caBlIng dIagrams © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 91...
Page 92: 5.1 Dimension Sheets
Installation dimensions KWB multifire usv v 15 – 25 kW 5.1.2 Installation dimensions KWB multifire usv d 15 – 25, 30 – 60 and 80 – 100 kW 5.1.3 Installation dimensions KWB multifire usv zI 15 – 25, 30 – 60 and 80 – 100 kW 5.1.4...
Page 93: Installation Dimensions Kwb Multifire Usv V 15 - 25 Kw
© KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 93 Techn. MBL-USV_Einbaumaße_a KWB Multifire install dimensions: USV V 15-25 kW and 30-40 kW This data sheet is the Data sheet: property of KWB Auth.: StHo Date: 19-04-06...
Page 94: Installation Dimensions Kwb Multifire Usv D 15 - 25, 30 - 60 And 80 - 100 Kw
The fuel extractor trough must be within the specified angle (max.: 230° horizontal, 25° vertical, *45° for ascending worms). Techn. MBL-USV_Einbaumaße_a This data sheet is the Data sheet: KWB Multifire install dimensions: USV D 15-25 kW, 30-60 kW and 80-100 kW...
Page 95: Installation Dimensions Kwb Multifire Usv Zi 15 - 25, 30 - 60 And 80 - 100 Kw
5.1 dimension sheets 5.1.3 Installation dimensions KWB multifire KWB Multifire USV ZI 15-25 kW, 30-60 and 80-100 kW usv zI 15 – 25, 30 – 60 and 80 – 100 kW Technical data sheet: MBL-USV-installation dimensions_a_sheet 3 Version 19.04.2006 Fuel extractor...
Page 96: Installation Dimensions Kwb Multifire Usv Gs 40 - 60 And 80 - 100 Kw
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 Dimensions in cm Room length The distance specifications are minimum dimensions! Boiler dimensions are absolute dimensions...
Page 97: Fuel Extractor Ø 2.5 M - 4 M (Spring-Blade Rotary Stirrer)_B
H 60 cm Worm length WL = total Property Techn. MBL-USV-RA-Standard_b Installation dimensions: KWB Multifire fuel extractor “Standard” © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 of KWB Data sheet: Page 97 Property Techn.
Page 98: Ascending Worm With Upward Transfer Unit
Sloped floor or dead floor can be USV: Max. 115° Free pivoting dismantled 30 cm around the trough! TDS 150/151: Max. 115° Fuel extractor “Standard” downward transfer, ascending worm (for KWB Multifire and Powerfire 150 kW) Property Techn. data of KWB sheet: Auth.: StHo...
Page 99: 5.2 Hydraulic Circuit Diagrams
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 ©...
Page 100: Hydraulic Wiring - Boiler Circuit Return Flow Boost
These illustrations are principle representations. The hydr. configuration/detail planning must be executed by the installer. These illustrations are principle representations. The hydr. configuration/detail planning must be executed by Suitable armatures for the return flow boost are available from KWB. the installer. Suitable return flow boost armatures are available from KWB.
Page 101: Basic Module With Weather-Sensitive Control
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...
Page 102 1 Heating circuit 1 – 2 DHWC 0 – 0 Buffer 0 – 0 hardware Heating circuit modules Digital remote control Plug-in modules Page 102 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 103: Basic Module With Weather-Sensitive Control And Combination Buffer As Load-Balancing Buffer
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...
Page 104 1 Heating circuit 1 – 2 DHWC 0 – 0 Buffer 0 – 0 hardware Heating circuit modules Digital remote control Plug-in modules Page 104 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 105: Basic Module With Weather-Sensitive Control And Expansion Module
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...
Page 106 Boiler Digital remote control 2 Heating circuit 3 – 4 or 1 – 4 DHWC 0 – 0 Buffer – – – hardware Heating circuit modules Page 106 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 107: Basic Module With Weather-Sensitive Control And Second Boiler Switchover
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...
Page 108 1 Heating circuit 1 – 2 DHWC 0 – 0 Buffer – – – hardware Heating circuit modules Digital remote control Plug-in modules Page 108 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 109: Basic Module With Weather-Sensitive Control, One Expansion Module And A Long-Term Buffer
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...
Page 110 Boiler Digital remote control 2 Heating circuit 3 – 4 or 1 – 4 DHWC 0 – 1 Buffer – – – hardware Heating circuit modules Page 110 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 111: Basic Module With Weather-Sensitive Control And Kwb Special Buffer
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...
Page 112 Digital remote control 1 Heating circuit 1 – 2 DHWC 0 – 0 Buffer 0 – 0 hardware Heating circuit modules Digital remote control Plug-in modules Page 112 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 113: Basic Module With Weather-Sensitive Control And Buffer In Adjacent Building - Expansion Modules In The Apartment Buildings
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...
Page 116 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...
Page 117 Group no. 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...
Page 119: Electrical Diagrams (Connection And Cabling Diagrams)
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...
Page 120: Connection Diagram For Heating Circuit Module (Hcm) Tdb-Els-Tyü-Hcm_Xl_A
5.3 electrical diagrams 5.3.1 connection diagram for heating circuit module (hcm) tdB-els-tyÜ-hcm_xl_a Page 120 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 121: Bus Cabling / Ebaa1018G_15.7.2008
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...
Page 122: Cabling Outputs Heating Circuit / Eaaa1046C
5.3 electrical diagrams 5.3.3 cabling outputs heating circuit / eaaa1046c Page 122 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 123: Cabling Inputs Analogue And Digital / Ebaa1047A
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...
Page 124: Power Cabling 400 Vac / Ebaa1047A
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...
Page 125: Connection Diagram I/O Board / Eaaa1054
5.3 electrical diagrams 5.3.6 connection diagram I/o board / eaaa1054 5.3.6.1 Without heating circuit © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 125...
Page 126: One Heating Circuit
5.3 electrical diagrams 5.3.6.2 one heating circuit Page 126 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 127: Two Heating Circuits
5.3 electrical diagrams 5.3.6.3 two heating circuits © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 127...
Page 128: Supplemental Heating Circuit
5.3 electrical diagrams 5.3.6.4 supplemental heating circuit Page 128 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 129: Connection Diagram Plug-In Module 1 / Second Boiler / Vacuum / Eaaa1206A
5.3 electrical diagrams 5.3.7 connection diagram plug-in module 1 / second boiler / vacuum / eaaa1206a © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 129...
Page 130: Boiler Master-And-Slave Circuit Els-Tyü-Kfs-0001
5.3 electrical diagrams 5.3.8 Boiler master-and-slave circuit els-tyÜ-Kfs-0001 Page 130 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 131: Fuel Extractor Module
Art. no. 13–1000624 Fuel Extractor Module The mains connection must be executed via a CEE plug-in connector. Station number Earthing bar FE motor Mains 400 VAC © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 131...
Page 132: 5.4 Chimney Measurement
For the correctness of the data: Schichtdicke 3 Material Place & date: ..................... Signature: ......................Für die Richtigkeit der Daten: Ort, Datum: Version: 30.09.2003 Unterschrift: Stand: 30.09.2003 Formblatt_Kamin.dot Page 132 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 133: Cross-Section Measurement
– 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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 133...
Page 135: Appendix Ii
............... 149 fuel extractor WIth fall PIPe ............163 fe WIth doWnWard transfer and ascendIng Worm ....169 10 fuel extractor Pellets WIthout stIrrer ........177 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 135...
Page 136: Fuel Extractor With Upward Transfer
6 fe with upward transfer fuel extractor WIth uPWard transfer components – fe with upward transfer fig. 162: explosion drawing Page 136 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 137 6 fe with upward transfer fig. 163: detail – ascending worm drive fig. 164: detail – transfer station © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 137...
Page 138: Installing The 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 Page 138 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 139: Floor Assembly - Fuel Extractor Trough (Storage Room)
Lift the worm into the trough and slide it into the adapter until the stop. fig. 172: connect the worm and gear unit © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 139...
Page 140: Installing The Transfer Station (Boiler Room)
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 Page 140 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 141: Installing The Worm Bearings
Loosen the 3 clamp jaws (2) below on the FSS and align the FSS on the upward transfer bracket. fig. 181: Prepare fs © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 141...
Page 142 • 2 large washers (spacers) for each foot • 2 flange screws M8 x 30, 2 hex flange nuts fig. 185: fix the upward transfer bracket in place Page 142 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 143: Installing The Ascending Worm Drive
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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 143...
Page 144 154 and 159). fig. 195: seal ascending worm Page 144 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 145: Installing The Inspection Box And 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. 200: transfer hole pattern © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 145...
Page 146 204: 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 Page 146 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 149: Double Fuel Extractor (D-Fe)
7 double fe douBle fuel extractor (d-fe) components fig. 209: explosion drawing d-ra © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 149...
Page 150 7 double fe fig. 210: detail d-fe crossbeam Page 150 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 151 7 double fe fig. 211: detail d-fe crossbeam © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 151...
Page 152: Aligning The Stirrer Channel, Installing The Crossbeam And Feet
• The stirrer trough has the same incline as the reference aid • Comply with the information specified in the installation and construction diagram fig. 215: Precisely place the stirrer trough Page 152 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 153: Installing The Gear Unit And Drive Shafts
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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 153...
Page 154: Installing Fe Troughs And Fixing Them In Place In The Storage Room
Bore a Ø 14 hole laterally into the tab on the stirrer trough. Cut the 3 support to size and bolt it to the stirrer trough. • Flange screw M10 x 25, flange nut fig. 226: Install stirrer trough support Page 154 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 155 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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 155...
Page 156: Installing The Stirrer Trough Insulation And Drive
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. Page 156 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 157 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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 157...
Page 158 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 Page 158 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 159: Installing The Fuel Extractor Drive
(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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 159...
Page 160 249: chain installation Install the cover of the chain wheel box. Seal the joint between chain wheel box and ascending worm. fig. 250: seal fe Page 160 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 163: Fuel Extractor With Fall Pipe
8 fe with fall pipe fuel extractor WIth fall PIPe components of the fe with fall pipe fig. 251: components of the fe © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 163...
Page 164 8 fe with fall pipe fig. 252: components of the fe fig. 253: head piece and chain wheel box Page 164 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 165 8 fe with fall pipe fig. 254: Installation example © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 165...
Page 166: Contents Of This Installation Manual
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 Page 166 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 169: Fe With Downward Transfer And Ascending Worm
9 fe+downward transfer+ascending worm fe WIth doWnWard transfer and ascendIng Worm components of the fe fig. 260: explosion drawing © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 169...
Page 170 9 fe+downward transfer+ascending worm fig. 261: detail 1: transfer station fig. 262: detail 2: transfer station Page 170 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 171 9 fe+downward transfer+ascending worm fig. 263: detail – chain wheel box, ascending worm © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 171...
Page 172 (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 Page 172 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 173: Contents Of This Installation Manual
(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 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 173...
Page 174: Installing The Fuel Extractor Trough
(3) Seal the gap at the FS/hopper sheet metal with silicon. fig. 269: Bolt the ascending worm 2 Installing the fe worm drive Follow the instructions in point 2.2.3 of the manual Page 174 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 177: Fuel Extractor Pellets Without Stirrer
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! © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 177...
Page 179 External 1 37 Mixer motor connection 36 External 2 37, 102, 104, 106, 108, 110, 112, 116 Mixer return flow boost 67, 74, 87 Mounting location 40 © KWB – Kraft und Wärme aus Biomasse GmbH MA Multifire 08/2008 Page 179...
Page 180 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 Page 180 BA Multifire 08/2008 © KWB – Kraft und Wärme aus Biomasse GmbH...
Page 182 We provide Energy for Life! www.kwb.at Biomass Heating Systems Printed with Öko-Plus vegetable dyes – dyes have mineral-oil free base to protect the environment.

This manual is also suitable for:

Multifire usv 30/40 v Multifire usv 80/100 d/zi Multifire usv 40/50/60 g Multifire usv 30/40/50/60 d/zi

KWB Multifire USV 15/25 V Installation And Maintenance Manual

1 Introduction

2 System Installation

3 Commissioning

4 Operation, Specialist

Appendix I

5 Appendix I

Appendix II

6 Fuel Extractor with Upward Transfer

7 Double Fuel Extractor (D-Fe)

8 Fuel Extractor with Fall Pipe

9 Fe with Downward Transfer and Ascending Worm

10 Fuel Extractor Pellets Without Stirrer

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