KWB Easyfire Page 6 Installation And Maintenance Manual Download

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IM Easyfire 10/2008

Table of contents

FE “S” INCLINED WORM, FABRIC TANK .......................................................................... 109

11.1

Pellet storage room requirements (FE type S with fabric tank) ........................................................... 109

11.2

Installing the inclined worm extraction system....................................................................................110

11.2.1

FE connection on the burner

see point 10.7 ............................................................................................. 113

11.3 Final

inspection

....................................................................................................................................113

FE “S”, PELLET STIRRER PLUS, ELBOW WORM .............................................................. 115

12.1

Pellet storage room requirements (FE type S with Pellet Stirrer Plus) ............................................. 115

12.2

Installation instructions, FE type S .......................................................................................................116

12.3

Installing the pellet worm ....................................................................................................................116

12.4

Mounting the extensions .....................................................................................................................117

12.5

Installing the elbow worm ...................................................................................................................120

12.6

Installing the head piece with drop shaft .............................................................................................120

12.7

FE connection on the burner ................................................................................................................120

12.8

Installing the Stirrer Plus ......................................................................................................................120

12.9 Final

inspection

....................................................................................................................................124

FE “GS” SUCTION CONVEYOR, PELLET WORM ............................................................... 125

13.1

Requirements, pellet storage room (type GS fan, pellet worm, V-sloping floor) .................................. 125

13.2

Installing the pellet worm see point 10.3 ............................................................................................. 126

13.2.1

Connection, pellet worm – connecting piece ....................................................................................................... 126

13.2.2

Installing the pellet worm drive ............................................................................................................................ 127

13.3

Installing the transport hose ................................................................................................................127

13.3.1 Equipotential

bonding

.......................................................................................................................................... 127

13.3.2

Hose connection and grounding

(storage system) ................................................................................... 128

13.3.3 Fire

safety

............................................................................................................................................................ 129

13.3.4 Hose

connection

(boiler room) ............................................................................................................... 129

13.4 Final

inspection

....................................................................................................................................130

FE “GS” SUCTION CONVEYOR, PELLET STIRRER PLUS ................................................... 131

14.1

Pellet storage room requirements (FE type GS with Pellet Stirrer Plus) ............................................ 131

14.2

Installation instructions FE type GS .....................................................................................................132

14.3 Final

inspection

....................................................................................................................................132

FE “GL” LANCE, FABRIC TANK ......................................................................................... 133

15.1

Pellet storage room requirements (FE type GL with lance and fabric tank) ......................................... 133

15.2

Installation, removal pot with lance .....................................................................................................134

15.3

Lay out transport hose see point 13.3 .................................................................................................. 134

15.4

Fabric tank see section 9 ..................................................................................................................... 134

15.5 Final

inspection

....................................................................................................................................134

RA “GL” SUCTION CONVEYOR, LANCE WITH BURIED TANK .......................................... 135

16.1

Pellet storage room requirements (FE type GL, fan and lance with buried fabric tank) ....................... 135

16.2

Lay out transport hose see point 13.3 .................................................................................................. 136

16.3 Buried

tank

..........................................................................................................................................136

16.4 Final

inspection

....................................................................................................................................136

FUEL EXTRACTOR SYSTEM, TYPE R

pellet stirrer ....................................................................... 137

17.1

Requirements, pellet storage room (for type R) ................................................................................... 137

17.2

Install the fuel extractor (FE) ................................................................................................................138

17.3

FE connection on the burner see point 10.7. ........................................................................................ 142

17.4 Final

inspection

....................................................................................................................................142

TECHNICAL DATA SHEETS FOR SPECIALISTS ................................................................. 143

MA-Easyfire 10.2008_EN.indd 6

30.03.2009 13:29:42 Uhr

Summary of Contents for Easyfire

Page 1: ...Biomass Heating Systems Pellet boilers KWB Easyfire 10 30kW Installation and Maintenance Manual...

Page 2: ...at Web site www kwb at Instructions that must always be complied with in your own interest are marked as shown Dated 08 October 2008 art no 21 2000097 Subject to change No responsibility accepted for...

Page 3: ...tion box 31 2 1 11 4 Cabling guidelines 33 2 1 11 5 Control units heating circuit expansion modules HCM 35 2 1 11 5 1 Boiler control unit digital room control unit OPTION 35 2 1 11 5 2 Analogue room c...

Page 4: ...4 4 Dig remote control unit 59 5 OPERATION FACTORY CUSTOMER SERVICE 61 5 1 Menu item Basic Settings 61 5 1 1 Fan 61 5 1 2 Boiler output 61 5 1 3 Ignition 61 5 1 4 Serial number 62 5 1 5 Operating hour...

Page 5: ...ing 84 9 FABRIC TANK 85 9 1 General information about the fabric tank 85 9 2 Fabric tank and fuel extractor 85 9 3 Room size 86 9 4 Room fixtures 86 9 5 Room condition 86 9 6 Room ventilation 87 9 7 F...

Page 6: ...he pellet worm drive 127 13 3 Installing the transport hose 127 13 3 1 Equipotential bonding 127 13 3 2 Hose connection and grounding storage system 128 13 3 3 Fire safety 129 13 3 4 Hose connection b...

Page 7: ...ol system MBEH0003_b sheet 1 2 166 Base module with weather sensitive control system MBEH0003_a sheet 2 2 167 Base module with weather sensitive control system combination load balancing tank MBEH0004...

Page 8: ...upply I O plug in module TDB ELS USP EBAA1025_a 196 Boiler plug in module 1 suction system second boiler TDB ELS USP EBAA1026_e 197 Boiler Easyfire GS Easyfire GL TDB ELS USP EBAA1027_c 198 Fitting di...

Page 9: ...equisite for the warranty KWB does not accept any liability nor does it offer any warranties for any type of constructional measures Without laying claim to an exhaustive treatment of the issue at han...

Page 10: ...ed Electrical installations must be established in explosion protected design in accordance with the local applicable regulations Rule of thumb for dimensioning the storage room Average variables Weat...

Page 11: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 11 1 Introduction 1 Introduction Flue gas pipes Example chimney structure...

Page 12: ...wooden planking or place steel pipes underneath the pallet as rollers in order to more easily move the boiler in sliding or rolling movements Strictly ensure that you have implemented measures to prev...

Page 13: ...r cover 4 Remove the combustion chamber parts Remove the combustion chamber cover Combustion chamber cover Lift the post combustion ring out of the holder Post combustion ring 5 Open the junction box...

Page 14: ...rews Unhook the full cladding Tip If space is at a premium Remove the bolted connection of the division joint on the full cladding Full cladding 7 Dismount the suction tank GS GL Loosen the 4 screws o...

Page 15: ...on sensor Unplug the plug type connector Remove the hose clamp from the connecting hose between the suction tank and the cellular wheel sluice Connecting hose Loosen the screws Unhook the suction tank...

Page 16: ...bling Dismount the plug in panel Dismantle the plug in panel Disconnect all plug type connectors from the boiler I O module Thread these connectors through the penetration rings Disconnect the boiler...

Page 17: ...h cable ties Unscrew the connectors from the rear wall Unscrew connectors 10 Take off the cladding cover Unscrew the screws of the hinge Unscrew the hinge Unscrew the hinge from the cover Take off the...

Page 18: ...right orientation continue with point 2 1 2 Left right system conversion The steps for bringing the system into the boiler room in dismantled status are provided in the next section 2 1 1 2 Bringing t...

Page 19: ...rted on almost all substrates without damage Bring the boiler into the boiler room Always have a second person assist you in difficult passages Moving the boiler over steps steep ramps etc Assemble th...

Page 20: ...sfer the screws of the side cladding elements from the front to the rear Transfer screws 1 Transfer the following screws into the adjacent pressed in nuts Screws for the burner cover or screws for fas...

Page 21: ...e on the boiler room door Use the holder and locking bracket to adjust the boiler room door until it seals when it closes Boiler room door install the door handle Attention Install the boiler room doo...

Page 22: ...the auto ash removal system Please note In the front cover there is a limit switch safety STOP switch The system is switched off when the ash container is removed 1 Introduce the ash worm Open the bo...

Page 23: ...worm Install and cable the ash worm motor rear of boiler 4 Connect the ash worm motor Connect the ash worm motor Diagram EBAA1031 section 17 Fasten the cable tie on the motor strain relief Cabling dri...

Page 24: ...oor from the front Tighten both hex nuts Position the sealing ring as shown Installation cover panel Adapting and installing the ash container 10 Adjust the set screw of the ash container Adjust the h...

Page 25: ...fertiliser and can be disposed of on the compost heap or scattered in the forest 2 1 8 1 Removing the ash container 1 Open the toggle type fasteners Open both of the side toggle type fasteners Pull t...

Page 26: ...e of the return flow boost the boiler control unit can activate 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 Suita...

Page 27: ...ation is excluded Always unplug the mains plug or switch off the main switch before opening the junction box 2 1 11 1 Electrical connections of the system Mains connection Single phase connection 230...

Page 28: ...ered for this Optional Plug in module 1 Only for type GL and GS suction conveyor second boiler switchover specific pin assignment according to the configuration see connection diagrams heating circuit...

Page 29: ...ct to indicate faults Fault 2 NO contact to indicate faults Power output NO configurable for Burner operating display output stage partial load medium load nominal load Boiler master and slave circuit...

Page 30: ...module of the system Main switch 2 1 11 3 Junction box All connection points for the electrical installation are provided in the junction box that is arranged below the boiler cladding Proceed as foll...

Page 31: ...led outside of the boiler room Connection stop switch plug type connector section 17 When connecting sensors and motors strictly ensure that the control system is de energized for the following reason...

Page 32: ...Control option 2 ARCUs HCM 4 to 16 BOILER I O module GM Cabling diagram for networks for the KWB Comfort control unit Dated December 2007 HCM 1 HCM 3 HCM 4 to 18 HCM 1 Legend BCU Boiler control unit...

Page 33: ...circuit an analogue room control unit ARCU can be used independent of the bus stations The cabling is executed as is usual for analogue room sensors i e it is routed directly to the boiler I O module...

Page 34: ...s 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 instructions in this manual mu...

Page 35: ...circuit on an inside wall not in the vicinity of heating elements or in the vicinity of other heating devices and not on doors or windows For mounting or connection of the analogue room control unit t...

Page 36: ...of each building in the network Supply pumps zone valves or buffer charge pumps for distributed stations should also be placed in a distributed arrangement If this is not the case additional to the bu...

Page 37: ...to the other narrow side as shown and repeat the previously described process in the same manner Open the HCM 1 Press on the long side approximately 1 cm off centre with the screwdriver in the direct...

Page 38: ...ss After completing and checking the cabling introduce the upper shell with the pin connectors into the block terminals and join the two shells together tilt free until the locking mechanism engages 2...

Page 39: ...suction conveyor units types GS GL between the 6 pole Wieland plug type connector marked FE GS GL attached to the rear of the boiler and the fuel extractor drive can vary greatly depending on the cons...

Page 40: ...ohm Temperature C Resistance ohm Temperature C Resistance ohm Short circuit 30 C Interruption 130 C 20 684 62 3 794 55 14 915 66 19 690 78 2 801 36 15 923 14 18 696 98 1 808 21 16 930 65 17 703 21 0 8...

Page 41: ...llation suction conveyor unit see also section 13 to 16 The entire transport hose and fuel extractor system must be connected so that it is electrically conductive and it must be earthed via the equip...

Page 42: ...itching the system on the header screen will appear on the display of the boiler control unit Reasons why alarms appear on the display The control system is not completely adjusted Some parameter assi...

Page 43: ...ee 4 1 Operating values see 4 1 1 Dependant on outdoor temperature see 4 1 2 If all parameters are set save them with the menu item 5 2 Save Delete see point 5 2 The settings are now permanently saved...

Page 44: ...empts are required This process can be shortened by switching the system off and on again after the Ignition feeding cycle to bypass ignition heating After successful ignition the flue gas temperature...

Page 45: ......

Page 46: ...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 1 C 2 C under the ta...

Page 47: ...list Heating curve diagram KWB Comfort Room temperature 20 C reference point offset 0 10 10 C Forward flow temperature C 0 2 0 5 0 75 1 1 25 1 5 1 75 2 2 25 2 5 2 75 3 0 10 20 30 40 50 60 70 80 90 20...

Page 48: ...nd idle time determine the set speed of the mixer motor when opening and closing It can be adjusted to the sluggishness of the temperature measurement on the forward flow sensor If the mixer motor is...

Page 49: ...t In this manner the setpoint can slide between the set minimum value and max 80 C In the example above Target 1 can slide between 70 and 80 C depending on the consumer request Target 2 is the max boi...

Page 50: ...cuum fan it runs independently until the tank is full and switches off approximately 10 seconds later S Fuel extractor with worm conveyor Runtime and idle time settings are ignored R Fuel extractor wi...

Page 51: ...erheating Boiler pump 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 The hydraulic circuit of...

Page 52: ...e set date of holiday end is not effective Thus telephone remote switching for the heating system of vacation homes for example can be implemented 4 2 10 1 2 Power output Specification of the function...

Page 53: ...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 shar...

Page 54: ...s must be assigned in sequence without any gaps Dig remote control units Set the number of digital remote control units 0 34 On each dig remote control unit the station number must be set starting wit...

Page 55: ...uit Temp difference Switch on delay for boiler master and slave circuit In this menu the individual parameters for power output can be set if under point 4 2 10 1 2 the setting Boiler sequ circuit is...

Page 56: ...anently specified The factory setting for idle time is 7 min For pellets with higher ash content set the idle time appropriately shorter 4 3 Menu item Relay Test In the relay test all outputs can be s...

Page 57: ...itch off 1 limit switch on Power output Relay output NO contact for power rust removal system or boiler master and slave circuit Fault 1 Relay output fault 1 NC contact Fault 2 Relay output fault NO c...

Page 58: ...cation with the network station 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 wit...

Page 59: ......

Page 60: ...0 50 available and 0 corresponds to idle and 50 corresponds to the maximum speed To prevent boiler puff back when switching down from nominal load to medium load or from medium load to partial load al...

Page 61: ...s the control system reports a fault and switches the boiler off see the operating manual point 7 Troubleshooting 5 1 4 Serial number The serial number provides the customer service organization with...

Page 62: ...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 w...

Page 63: ......

Page 64: ...function Only select this function if you are prepared to constantly monitor the system 6 2 Preparations for measuring the boiler The following points must be complied with in order to obtain meaning...

Page 65: ...ting on Measuring NL see point 6 1 Check the draught setpoint 0 1 to 0 2 mbar 10 to 20 Pa and adjust via the draught control shutter Check the flame aspect 6 Combustion process on the burner plate Com...

Page 66: ...27 40 47 Explanation Fan Fan stage of the combustion air fan stages 6 50 Induced draft Fan stage of the induced draught fan stages 9 50 P M N Partial load medium load nominal load Rules for adjusting...

Page 67: ...pection of surface and colour The pellets should have a smooth shiny surface that is free of transverse or longitudinal cracks They should have the colour of wood chips or they should only be slightly...

Page 68: ...occur Charcoal pieces fine Fine fuel particles are blown off of the plate Should not occur measurements are required Charcoal pieces coarse Coarse fuel particles are overthrust Should not occur measu...

Page 69: ......

Page 70: ...complex measurement Dust 50 mg Nm 13 O2 Fine fly ash and particles of soot depending on the dust content of the fuel Firing efficiency Eta 88 95 depends on CO2 content and flue gas temperature approxi...

Page 71: ...oxide ppm at 13 O2 ppm at 10 O2 mg Nm at 13 O2 mg Nm at 10 O2 mg MJ mg kWh 1 ppm at 13 O2 1 00 1 38 2 05 2 82 1 40 5 03 1 ppm at 10 O2 0 73 1 00 1 49 2 05 1 02 3 66 1 mg Nm at 13 O2 0 49 0 67 1 00 1 3...

Page 72: ...91 4 89 9 88 5 87 0 85 6 84 1 82 7 10 10 9 1 90 96 9 95 3 93 8 92 2 90 7 89 1 87 6 86 0 84 5 82 9 81 4 11 9 9 2 09 96 6 94 9 93 3 91 6 89 9 88 2 86 5 84 8 83 1 81 5 79 8 12 8 9 2 33 96 3 94 5 92 6 90...

Page 73: ...02 Residual oxygen Remains after combustion Unit to be more precise Percentage by volume based on the dry flue gas Is required for all combustion and for every life process breathing decomposition Odo...

Page 74: ...Significantly increased measured values always indicate such impurities 7 1 9 Hydrocarbons HC CxHy Corg Hydrocarbons many different substances gases tar smoke acids Units ppm mg Nm at 13 O2 mg MJ CxHy...

Page 75: ...mbient pressure Units 1 hPas hectopascal 100 Pas 1 mbar Optimal value 0 1 0 2 mbar Chimney draught can be adjusted via the draught regulating shutter With the induced draught fan the conveyor pressure...

Page 76: ...For ash removal systems fill the ash worm holes in the ash box with ash and press lightly Entry of secondary air between flue gas collector and measurement bore The measurement bore should be 50 cm b...

Page 77: ......

Page 78: ...tor they can only be updated in the factory If this instruction is not complied with the devices can be damaged 8 1 Software transfer with PC With a personal computer the software can be transferred t...

Page 79: ...nit must be de energized for the connection 3 Connect the null modem cable to a serial interface of your PC 4 Connect the other end of the null model cable to the programming adapter 5 Connect the pro...

Page 80: ...ate 2 Connect the null modem cable to a serial interface of your PC 3 Connect the other end of the null model cable to the handheld programming unit Switch on Slide the on off switch up HAND PG 7 2 1...

Page 81: ...ad button so that the device is ready to receive 3 On the PC start the download tool for the software version that will be transferred Start Download 4 Select the serial port that is connected to the...

Page 82: ...s used to transfer the current software version to the electronics It has four program memory locations This means that four software versions can be stored For example for different boiler products I...

Page 83: ...eld programming device will return to the switch on message During the transfer process all buttons are blocked If a transfer error is present the handheld programming device will beep five times and...

Page 84: ...also installing the sloped floor Ensure that all structural requirements are strictly satisfied Point 1 3 to 1 3 2 in the introduction Point 9 2 to 9 7 3 Inform the owner of the system of any defects...

Page 85: ...room width must be at least 30 cm greater than the minimum dimension After cleaning re check the minimum room size Minimum fill quantity at a room height of 220 cm Minimum fill quantity at a room hei...

Page 86: ...utdoor setup F90 cladding is not required if the minimum clearances for flashover are maintained information Municipal authorities Lights switches and power outlets are permitted in the set up room no...

Page 87: ...y have occurred Verification Proper fastening of the bolts on the fabric tank Proper fastening of the fabric tank on the floor Proper placement of the vertical supports in the floor plates Slightly lo...

Page 88: ...sing the included emergency gate must be pushed in Ensure that all openings on the fabric tank that are not fitted with a fill unit are sealed air tight Ensure that the fill nozzle is mounted in such...

Page 89: ...ing via nozzle 1 to maximum 9 9 2 Number and position of the fill nozzles The number and position of the fill units blow in nozzles depend on the size of the tank and the available space To optimally...

Page 90: ...10 Fabric tank scope of delivery Fabric sack Base plate for vertical support Vertical support Horizontal support Braces A Storz fill coupling Fill unit with hose clamps 90 110 mm Bolts M10 x 35 Clamp...

Page 91: ...of the fabric sack 9 11 Installing the fabric tank and filling system 1 Forming pairs of braces Take 2 braces and join them together at this point with the 3 bores Use 2 M10 x 25 bolts 2 M10 washers a...

Page 92: ...addle to the vertical support with the M10 shim and M10 nut Do the same for all four vertical supports Install the base plate Now bolt one finished vertical support unit together with a completed brac...

Page 93: ...ook in the horizontal supports Now you can introduce the other two horizontal supports If space is limited for threading in the horizontal supports pull the two loops of the fabric tank together at do...

Page 94: ...et horizontally In this process you must strictly ensure that the M10x30 bolt is tightened with a self locking M10 nut 9 12 Installing the fill system Use the supplied clamp to install the A Storz fil...

Page 95: ......

Page 96: ...ned worm and fabric tank Solid ceiling F90 Min RL 235 Worm can be extended with worm conveyor extension Extractor worm 1 L1 184 2 Extractor worm 2 L2 139 2 Section 12 Elbow worm Pellet Stirrer Plus Ve...

Page 97: ...or Lance with fabric tank Solid ceiling F90 Solid ceiling F90 ank let transport hose ax length 25 m M in 3 0 without step max 300 Boiler Room Pellet Storage Room Section 16 Suction conveyor Lance with...

Page 98: ...ation After installing the FE the customer must provide a sloping floor that is as smooth possible that slopes toward the worm trough at an angle of less than 35 the sloping floor should consist of fo...

Page 99: ...ensure accessibility for possible repairs wall clearances of at least 10 cm on the penetration side and least 15 cm to the flange plate must be maintained The resulting dead space should be covered To...

Page 100: ...nveyors put on the next trough piece with enough clearance that it is flush with the preceding piece Place the trough ends without permanently welded on support brackets Pull the worm a little out of...

Page 101: ...xtractor part If you require a worm extension go to step 6 if not continue with step 11 Mount the connecting piece 10 4 Mounting the extensions 6 Extension of the worm conveyor system Different possib...

Page 102: ...bearing 9 Extension trough without intermediate bearing Guide the extension trough over the projecting worm and bolt the flanges together Channel extension without intermediate bearing The prepared bo...

Page 103: ...sition as part of the alignment of the fuel extractor When installing an elbow worm proceed with step 12 When installing a worm with drop shaft proceed with step 18 Install the support bracket 10 5 In...

Page 104: ...bearing 15 Install the ascending worm Guide the ascending worm into the universal joint from above Align the feather key so that it is flush with the hub Use a rubber mallet to knock on the drive end...

Page 105: ...this process ensure that the feather key has been removed from the motor shaft if this is not the case the bearing cannot be pushed on Manually lift the motor shaft so that you can align the bearing B...

Page 106: ...ut the connecting hose to size and fasten it on the eject connection and on the burner connection with the supplied clamps 10 Burner connection 2 Install the burner design cladding The burner cladding...

Page 107: ......

Page 108: ...he fabric tank will be set up in a separate room ventilation with at least 400 cm2 must be provided 11 1 Pellet storage room requirements FE type S with fabric tank Comply with the instructions in poi...

Page 109: ...unscrew the worm screw from the inner ring of the flange bearing Connect the gate valve to the inclined worm To do this use the connecting clamp and tighten it If you require a worm extension go to st...

Page 110: ...Guide the fastening bolts of the intermediate bearing through the prepared bore of the side wall of the trough Tighten the connection and ensure that the bearing bush is in the aligned position To do...

Page 111: ...6 without intermediate bearing Otherwise continue with step 8 Worm extension without intermediate bearing 8 Install the trough support Adjust the height of the trough support as needed Mount the troug...

Page 112: ...ubber mallet to avoid damage Install the flange bearing 12 Install the drive motor Slide the drive motor onto the motor shaft Bolt the end of the motor shaft with the large shim and tighten the bolt T...

Page 113: ......

Page 114: ...eal after installation trough is acoustically decoupled Fire safety collar Drop hose 7 5 cm Comply with floor load specifications Max 25 Elbow worm Elbow worm Pellet Stirrer Plus Elbow worm Pellet Sti...

Page 115: ...and incline of the floor Use shims to align the support points horizontally Maintenance distances storage room MBDK0001 in section 17 Wall penetration side at least 10 cm Worm end side at least 15 cm...

Page 116: ...ntermediate bearing must be set see drawing MBDK0001 in the attachment Seal bores that are not required with the supplied bolt 5 Mount the intermediate bearing Mount the intermediate bearing and align...

Page 117: ...o be supported Extending the worm 9 Prepare the intermediate bearing The trough extensions must be prepared for the intermediate bearing To do this enlarge the small bore in the side wall of the troug...

Page 118: ...9 without intermediate bearing Otherwise continue with step 11 If additional extensions are necessary repeat the process from step 6 with intermediate bearing or step 9 without intermediate bearing Ot...

Page 119: ...connecting hose should be installed vertically if possible 2 Adjust the support angle of the gear unit bracket Adjust the height of the gear unit using the two gear unit support brackets The trough ce...

Page 120: ...t 8 Install conveyor trough Connect the conveyor worm of the stirrer to the connecting FE components For example Front conveyor worm of the extensions Drive shaft for suction conveyor or Drop shaft At...

Page 121: ...s should be placed under each leg 12 Place insulating boards under the fuel extractor 2 pc insulating boards should be properly shortened and placed underneath Attention Ensure that the gear unit shaf...

Page 122: ...sen the floor plugs or re adjust the support brackets 16 Place the stirrer disk Ensure the correct seat of the feather key of the vertical gear unit shaft Grease the gear unit shaft and place the stir...

Page 123: ...ith cladding The low residual quantity of pellets can be used as an iron reserve If you clad the floor in the storage room follow the instructions below Lay out the cladding to the inner edges of the...

Page 124: ...ift 5 m without step max 300 Pellet transport hose max length 25 m Chimney diameter and smoke pipe execution in accordance with the Technical Data Table energy saving damper 15 cm with explosion door...

Page 125: ...acket lubricating nipple pointing upward Do not tighten the screws yet Remove the worm screws of the inner bearing ring these are no longer required Introduce the worm shaft into the intermediate bear...

Page 126: ...r Close all inspection covers 13 3 Installing the transport hose 13 3 1 Equipotential bonding The earthing strand of the conveyor hose must be connected to the fuel extractor and it must be further co...

Page 127: ...se must be fastened to the container connection nozzle with an overfit hose and two hose clamps Fig 13 Hose connection on the container The hose system incl suction tank must be sealed The connection...

Page 128: ...ty sleeve KWB special accessory is required on the boiler room side of the hose passage All additional fire safety requirements naturally apply without limitation 1 7 5 103 05 6 3 7 5 120 62 52 20 Con...

Page 129: ...hem with water Do not use grease Mount the conveyor hose return flow hose Connect the pellet hose to the tank cover Install the conveyor hose supply hose Place the suction turbine hood on the tank cov...

Page 130: ...chet protection mat Solid ceiling F90 Solid ceiling F90 M i n 3 0 Conveyor height without step max 300 g p g Fire safety collar 14 1 Pellet storage room requirements FE type GS with Pellet Stirrer Plu...

Page 131: ...iagrams Install the FE so that the storage room space is optimally utilised Ensure that the eject point is correctly positioned Ensure that there is adequate space for maintenance tasks Mark the posit...

Page 132: ...ceiling F90 Solid ceiling F90 Outline USP GL with fabric tank and suction system Pellet transport hose max length 25 m No sharp objects above the fabric tank M i n 3 0 without step max 300 Boiler Roo...

Page 133: ...or system must be connected in a manner that is electrically conductive and it must they grounded via the equipotential busbar Strip the earth strand 5 cm Bend the earthing strand into the hose Earthi...

Page 134: ...ft 5 m Max total lift without step 3 m At the latest after 3 m height difference 1 m route horizontally All conveyor hose bend radii at least 30 cm 16 1 Pellet storage room requirements FE type GL fan...

Page 135: ...ied tank 16 2 Lay out transport hose see point 13 3 16 3 Buried tank The buried tank and its components are not included in the scope of delivery or services provided by KWB 16 4 Final inspection Ensu...

Page 136: ...ion Boiler room and storage room construction KWB Easyfire Fuel extractor with stirrer Fire extinguisher Boiler room door T30 100 120 Boiler room Pellet storage Rock wool Incline max 30 Storage room d...

Page 137: ...The worm trough is supported in the wall penetration until the trough supports are installed Align the trough 2 Installation of the gear unit First dismount the worm trough cover on the open trough se...

Page 138: ...position centre stirrer 2 Align the stirrer 5 System alignment If after aligning the worm trough the drop shaft is no longer concentric with the burner connector on the pellet boiler you must either s...

Page 139: ...de of the penetration Penetration sleeve 7 Install the connecting hose Measure the length of the connecting hose and cut it to size Lift the worm trough and connect the connecting hose including the h...

Page 140: ...e shaft end in this process ensure that the direction of rotation is correct Install the drive motor Use the bolt and large washer to fasten the motor Tighten the connection Fix in place axially 10 Ca...

Page 141: ...gear unit Slide the bearing housing onto the drive shaft The long part of the bearing sleeve must be on top Then place the stirrer cover disk with the reinforcements on top on the bearing housing and...

Page 142: ...Easyfire 10 2008 Page 143 18 Technical data sheets 18 Technical data sheets 18 TECHNICAL DATA SHEETS FOR SPECIALISTS 18 1 Dimension sheets 18 2 Hydraulic diagrams 18 3 Electrical diagrams 18 4 Chimne...

Page 143: ......

Page 144: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 145 18 1 Dimension sheets 18 1 Dimension sheets Dimensions and minimum fitting dimensions KWB Easyfire Dimensions in cm 26 11 2007...

Page 145: ...Page 146 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 1 Dimension sheets 18 1 Dimension sheets Fitting dimensions KWB Easyfire...

Page 146: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 147 18 1 Dimension sheets 18 1 Dimension sheets Pellet blow in nozzle MBEZ0001_d sheet 1 3 Specific parts for special solutions...

Page 147: ...Page 148 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 1 Dimension sheets 18 1 Dimension sheets Pellet blow in nozzle MBEZ0001_d sheet 2 3 Routing through other rooms Dimensions in cm...

Page 148: ...t und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 149 18 1 Dimension sheets 18 1 Dimension sheets Pellet blow in nozzle MBEZ0001_e sheet 3 3 Variants for light shafts Dimensions in cm KWB art no...

Page 149: ...Page 150 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 1 Dimension sheets 18 1 Dimension sheets Fitting dimensions KWB Easyfire S TDB MBL USP S Einbaum_c...

Page 150: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 151 18 1 Dimension sheets 18 1 Dimension sheets Sectional drawing pellet storage room TDB MBL USP MBDK0008...

Page 151: ...tomatically by the conveyor worm Attachment at least 27 mm thick plates with smooth surface or rough boarding 25 mm with hard fibre support surface Sloping floor support or squared timber e g 8x8 cm P...

Page 152: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 153 18 1 Dimension sheets 18 1 Dimension sheets FE conveyor worm system construction kit TDB MBL USP MBDK0001_e...

Page 153: ...worm 1 Ascending worm 2 Ascending worm 3 Ascending worm 4 12 1001448 12 1001451 12 1001454 12 1001457 Storage A 785 mm A 910 mm A 1010 mm A 1160 mm room lowering C 487 mm C 599 mm C 679 C 808 mm 0 0 0...

Page 154: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 155 18 1 Dimension sheets 18 1 Dimension sheets Construction kit FE type S pellet worms and suction conveyor TDB MBL USP MBDS0001_d part...

Page 155: ...age 156 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 1 Dimension sheets 18 1 Dimension sheets Construction kit FE type S pellet worms and suction conveyor TDB MBL USP MBDS0001_d part 2...

Page 156: ...orm 2 L2 139 2 Incline 30 Outline Ground plan at least 30 on the fill side The rear of the boiler must be accessible On one side at least 60 cm on the other side at least 20 cm At least 30 cm must rem...

Page 157: ...d ceiling F90 fabric tank system Pellet transport hose max length 25 m M i n 3 0 without step max 300 Boiler Room Pellet Storage Room Outline USP GL with fabric tank and suction system If the fabric t...

Page 158: ...id ceiling F90 Solid ceiling F90 Min RL 200 Ricochet protection mat Conveyor Worm Inclined floor Wooden boards Min 100 per step Total lift 5 m without step max 300 Pellet transport hose max length 25...

Page 159: ...m m 2350 2650 2650 3250 3250 3250 B1 Fram e ex terior dim ens ions width m m 1970 1970 2270 1970 2270 2870 B2 A x ial dim ens ion floor plate width m m 1780 1780 2080 1780 2080 2680 B3 M ax width for...

Page 160: ...side at least 60 cm on the other side at least 20 cm At least 30 cm must remain free on the fill side of the fabric tank The fire door control system F90 wall is only necessary in Austria Germany Min...

Page 161: ......

Page 162: ...diagram 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 Variant 3 Return flow boost with therm...

Page 163: ...Page 164 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 2 Hydraulic diagrams 18 2 Hydraulic diagrams Base module with weather sensitive control system MBEH0002_b sheet 1 2...

Page 164: ...n 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 Har...

Page 165: ...ge 166 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 2 Hydraulic diagrams 18 2 Hydraulic diagrams Base module with weather sensitive control system MBEH0003_b sheet 1 2 Subject to chang...

Page 166: ...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 i...

Page 167: ...re 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 2 Hydraulic diagrams 18 2 Hydraulic diagrams Base module with weather sensitive control system combination load balancing tank MBEH0004_b sheet 1 2...

Page 168: ...heating circuit is equipped with a digital room control unit option for remote control Menu basic settings Parameters Settings Return flow boost Thermal valve Network settings Boiler External 2 Heat t...

Page 169: ...syfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 2 Hydraulic diagrams 18 2 Hydraulic diagrams Base module with weather sensitive control system second boiler switchover MBEH0005_b sheet 1 2 Sub...

Page 170: ...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 op...

Page 171: ...KWB Kraft und W rme aus Biomasse GmbH 18 2 Hydraulic diagrams 18 2 Hydraulic diagrams Basic module with weather sensitive control system one expansion module and a buffer as long term buffer MBEH0006_...

Page 172: ...r External 2 Heat to target 2 Power output Heating mode Boiler dependence Yes Heating circuit heating circuit 0 Room sensor Boiler 0 Outdoor sensor Boiler Function No Group no 0 Heating circuit heatin...

Page 173: ...08 KWB Kraft und W rme aus Biomasse GmbH 18 2 Hydraulic diagrams 18 2 Hydraulic diagrams Base module with weather sensitive control system one expansion module and a combination buffer as load compens...

Page 174: ...s Boiler External 2 Heat to target 2 Power output Heating mode Boiler dependence Yes Heating circuit heating circuit 0 Room sensor Boiler 0 Outdoor sensor Boiler Function No Group no 0 Heating circuit...

Page 175: ...10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 2 Hydraulic diagrams 18 2 Hydraulic diagrams Basic module with weather sensitive control system and boiler master and slave system MBEH0009_b sheet 1...

Page 176: ...he request comes even if the master boiler has been switched off via the software If the boiler temperature of the master boiler increases above the described value after the switch off delay 30 min a...

Page 177: ...ire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 2 Hydraulic diagrams 18 2 Hydraulic diagrams Basic module with weather sensitive control system expansion module and buffer as long term buffer MBE...

Page 178: ...xternal 2 Heat to target 2 Power output Heating mode Heating circuit heating circuit 0 Room sensor Boiler 0 Outdoor sensor Boiler Function No Group no 0 Heating circuit heating circuit 1 Room sensor D...

Page 179: ...WB Kraft und W rme aus Biomasse GmbH 18 2 Hydraulic diagrams 18 2 Hydraulic diagrams Basic module with weather sensitive control system one buffer with solar register and a fresh water module as long...

Page 180: ...trol unit option for remote control Basic settings menu Parameter Settings Return flow boost Thermal valve Network settings Boiler External 2 Heat to target 2 Power output Heating mode Boiler dependen...

Page 181: ......

Page 182: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 183 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire analogue digital inputs TDB ELS USP EBAA1011...

Page 183: ...Page 184 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire outputs basic module TDB ELS USP EBAA1012_a...

Page 184: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 185 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire ABM motor connection TDB ELS USP EBAA1014_b...

Page 185: ...Page 186 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams Bus data cable KBG TDB ELS USP EBAA1015_a...

Page 186: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 187 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire analogue inputs and safety thermostat TDB ELS USP EBAA1016_b...

Page 187: ...Page 188 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire HCM connection diagram ELS TY HKM_XL_a...

Page 188: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 189 18 3 Electrical diagrams 18 3 Electrical diagrams Bus cabling TDB ELS USP EBAA1018_g...

Page 189: ...Page 190 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire outputs heating circuits TDB ELS USP EBAA1019_c...

Page 190: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 191 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire analogue and digital inputs heating circuits TDB ELS USP EBAA1020_a...

Page 191: ...Page 192 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams Boiler plug in module 1 HC 0 second boiler TDB ELS USP EBAA1021_f...

Page 192: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 193 18 3 Electrical diagrams 18 3 Electrical diagrams Boiler Burner plug in panel TDB ELS USP EBAA1022...

Page 193: ...Page 194 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams Boiler burner drive TDB ELS USP EBAA1023...

Page 194: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 195 18 3 Electrical diagrams 18 3 Electrical diagrams Boiler induced draught cleaning system TDB ELS USP EBAA1024_b...

Page 195: ...Page 196 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams Boiler supply I O plug in module TDB ELS USP EBAA1025_a...

Page 196: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 197 18 3 Electrical diagrams 18 3 Electrical diagrams Boiler plug in module 1 suction system second boiler TDB ELS USP EBAA1026_e...

Page 197: ...Page 198 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams Boiler Easyfire GS Easyfire GL TDB ELS USP EBAA1027_c...

Page 198: ...ure Bus 24 V DC Supply Fill level sensor TM Limit sw FS Klixon stoker Reserve Reserve Speed induced draught reserve Plug in module 1 Speed fan Ash container Klixon f extractor Operation Bus All connec...

Page 199: ...Softwarekonfiguration Software configuration Set Connect no Heat circuit second boiler Suction system second boiler 51 FF sensor HC 0 Boiler sensor second boiler 52 Remote thermostat HC 0 53 Boiler s...

Page 200: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 201 18 3 Electrical diagrams 18 3 Electrical diagrams House junction box for KWB Easyfire TDB ELS USP EBAA1030 _a...

Page 201: ...Page 202 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire ash removal system TDB ELS USP EBAA1031...

Page 202: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 203 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire mains cable TDB ELS USP EBAA1046...

Page 203: ...e 204 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire chimney sweep button TDB ELS USP EBAA1042 Cable OZ 2 x 0 5 Art no 13 1000...

Page 204: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 205 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire STOP SWITCH TDB ELS USP EBAA1044a...

Page 205: ...Page 206 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire fan with Hall sensor ebm TDB ELS USP EBAA1032...

Page 206: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 207 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire Hall sensor Hanning TDB ELS USP EBAA1048...

Page 207: ...Page 208 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire induced draught Hanning TDB ELS USP EBAA1034b...

Page 208: ...KWB Kraft und W rme aus Biomasse GmbH IM Easyfire 10 2008 Page 209 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire induced draught with Hall sensor ebm TDB ELS USP EBAA1033...

Page 209: ...Page 210 IM Easyfire 10 2008 KWB Kraft und W rme aus Biomasse GmbH 18 3 Electrical diagrams 18 3 Electrical diagrams KWB Easyfire safety thermostat TDB ELS USP EBAA1040...

Page 210: ...e gas line Other Form Round Rectangular Clear width x mm Position In the building On the building Free standing Offset No Yes horizontal vertical m Eff length m Connection T 45 T 90 Eff height Hw Cold...

Page 211: ...m Flue gas temperature 190 C Heating system boiler with draft required Basic data Combustion temperature 190 C Necessary conveyor pressures of the fireplace in accordance with manufacturer s informat...

Page 212: ...ill nozzle for residual emptying Step 4 Details in this regard are provided under point 9 9 4 Filling instructions KWB fabric tank 1 Switch off the pellet heating system 2 Connect all parts of the fil...

Page 213: ......

Page 214: ...200x115mm 5 x 6 Stk pro Bogen 1 30 Bogen 12 08 04 KWB DEU USP Unplug the power plug before opening Install 55 C return flow boost Mains 230 V Return flow Forward flow Forward flow Return flow Main sw...

Page 215: ...mbustible I AVVERTENZA Prima di entrare nel deposito combustibile disattivare l impianto e metterlo in sicurezza contro eventuali riattivazioni Non entrare nel deposito combustibile senza sorveglianza...

Page 216: ...7 E Efficiency 73 Electric shock 32 Emission 45 65 71 72 75 77 Escape switch 9 28 Expansion module 29 30 34 35 37 39 53 55 59 173 175 Extension 110 111 External 30 40 50 53 56 F Fabric tank 87 88 93 9...

Page 217: ...put 40 44 53 56 177 Pump afterrun 44 51 Pump connection 29 30 R Relay test 44 57 Remote control unit 44 53 55 59 Removal nozzle 87 Requirement 9 10 22 28 30 40 45 50 53 54 56 85 99 109 115 125 131 133...

Page 218: ...Notes...

Page 219: ...Notes...

Page 220: ...to protect the environment KWB Kraft und W rme 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 alterati...

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KWB Easyfire, Installation And Maintenance Manual

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