KWB Multifire USV 30/40/50/60 D/ZI User Manual

Biomass Heating Systems
KWB Multifire 15 - 100 kW
Heating System for Wood chips
and Pellets
Installation and Maintenance Manual

KWB Multifire USV 30/40/50/60 D/ZI Specifications

General

Brand	KWB
Model	Multifire USV 30/40/50/60 D/ZI
Category	Heating System
Language	English

Summary

1 Introduction

1.1 Safety instructions

General safety guidelines for KWB GmbH systems, emphasizing proper installation and handling.

1.2 Warranty

Information regarding the manufacturer's warranty conditions for the boiler system.

1.3 Structural prerequisites

Locally applicable legal construction permits and building guidelines for installation.

2 System installation

2.1 General information on installing the boiler system

Guidelines for installing the boiler system, including transport and setup.

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

Instructions for moving the boiler system into the designated installation area.

2.1.1.1 Required installation tools

List of essential tools needed for the installation process.

2.1.1.2 Taking the system off of the pallet

Detailed steps for safely removing the boiler system from its transport pallet.

2.1.2 Dismantling the system

Procedures for dismantling the boiler system if necessary for access.

2.1.2.1 Dismantling the vacuum conveyor unit

Step-by-step guide to remove the vacuum conveyor unit.

2.1.2.2 Dismantling the boiler cladding

Instructions for removing the boiler's outer casing and panels.

2.1.2.3 Preparation for dismantling the heat exchanger

Steps required to prepare the heat exchanger for removal.

2.1.2.4 Dismounting the container

Guide on how to remove the fuel container component.

2.1.2.5 Dismantling the burner

Procedure for safely removing the burner assembly.

2.1.3 Assembling the system

Steps for reassembling the boiler system components.

2.1.3.1 Installing the burner

Detailed instructions for installing the burner assembly.

2.1.3.2 Mounting the container and stoker drive

Guidance on installing the fuel container and its drive mechanism.

2.1.3.3 Mounting the ash worm drive

Steps for installing the drive system for the ash worm.

2.1.3.4 Installation of the heat exchanger

Instructions for installing the heat exchanger unit.

2.1.3.5 Installing the cladding

Procedure for fitting the boiler's external cladding panels.

2.1.3.7 Installing the vacuum conveyor unit

Steps to reinstall the vacuum conveyor unit.

2.1.3.8 Installing the cladding/concluding tasks

Final cladding installation and completion tasks.

2.1.4 Smoke pipe connection and induced draft fan

Guidelines for connecting the smoke pipe and induced draft fan.

2.1.5 Water connection

Instructions for connecting the boiler's water lines.

2.1.5.1 Thermal safety valve connection

Details on connecting the thermal safety valve.

2.1.6 Electrical connection

Essential information and requirements for electrical connections.

2.1.6.1 Power connection of the KWB system

Specifics for connecting the main power supply to the KWB system.

2.1.6.2 Junction box

Information on the junction box for electrical installations.

2.1.6.3 Cabling guidelines

General guidelines for cabling system components.

2.1.7 Control units & heating circuit expansion modules (HCM)

Details on control units and heating circuit expansion modules.

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

Installation and function of the optional boiler/digital room control unit.

2.1.7.2 Analogue room control unit (OPTION)

Installation and function of the optional analogue room control unit.

2.1.8 Plug-in module 1 (OPTION)

Information on the optional plug-in module 1.

2.1.8.1 Heating circuit 0 and / or second boiler switchover

Configuration for heating circuit 0 and second boiler switchover.

2.1.9 Boiler master-and-slave circuit

Details on setting up a boiler master-and-slave circuit configuration.

2.1.10 Heating circuit expansion module (OPTION)

Information on the optional heating circuit expansion module.

2.1.11 FE MODULE (OPTION)

Details on the optional FE module for fuel extractor control.

2.1.11.1 Installation

Installation guidelines for the FE module.

2.1.11.2 Electrical connection

Instructions for the electrical connection of the FE module.

2.1.11.3 Power supply

Details on the power supply connection for the FE module.

2.1.11.4 Fuel extractor motor

Connection instructions for the fuel extractor motor.

2.1.11.5 Inputs

Description of input signals used by the FE module.

2.1.11.6 Connection variants

Different connection variants for the FE module.

2.1.11.7 System bus connection

Instructions for connecting the system bus for the FE module.

2.1.11.8 Commissioning the FE module

Steps for commissioning the fuel extractor module.

2.1.11.9 Station number switch

Procedure for setting the station number switch.

2.1.11.10 LED functions

Explanation of the LED indicators on the FE module.

2.1.11.11 Troubleshooting

Guidance for troubleshooting issues with the FE module.

2.1.12 Equipotential bonding

Instructions for equipotential bonding to prevent electrical hazards.

2.1.13 Sensor check

Procedure for checking installed sensors and their resistance values.

2.2 Installing the fuel extractor

Comprehensive installation instructions for all fuel extractor variants.

2.2.1 Installing the fuel extractor Standard

Specific installation steps for the standard fuel extractor model.

2.2.1.1 Components of the FE standard

List and diagram of the components for the standard FE.

2.2.2 Installation – FE trough Standard

Installation guide for the standard FE trough.

2.2.3 Installing the worm drive

Instructions for installing the worm drive mechanism.

2.2.4 Installation, inspection box, cover, and overfill protection

Steps for installing the inspection box, cover, and overfill protection.

2.2.5 Transfer sloping floor plane

Procedure for transferring and marking the sloping floor plane.

2.2.6 Installing the articulated-blade rotary stirrer

Instructions for installing the articulated-blade rotary stirrer.

2.3 FINAL INSPECTION

Final checks and inspection before system operation.

3 Commissioning

3.1 Switching on the main switch

Procedure for switching on the main power switch of the system.

3.2 Setting the parameters

Guide to setting system parameters via the specialist level menu.

3.3 Function check of the system parts

Steps to check the functionality of various system components.

3.4 Switching on the system in the menu

Procedure for starting the system via the control unit menu.

4 Operation, specialist

4.1 Menu item – Heating Circuits

Configuration and operating values for heating circuits.

4.1.1 Operating values

Details on operating values for heating circuits like temperature and gradient.

4.1.2 Outdoor temperature dependent

Settings related to outdoor temperature influencing heating operation.

4.1.3 Menu item – DHWC

Settings for Domestic Hot Water Circulation (DHWC).

4.1.4 Menu item – Buffer

Configuration options for the buffer tank operation.

4.1.5 Menu item – Boiler Program

Settings for the boiler program, including times and sequence.

4.2 Menu item – Basic Settings

Core system settings for boiler and operational parameters.

4.2.1 Boiler temperature

Configuration of actual and target boiler water temperatures.

4.2.2 Return flow boost

Settings for boosting the boiler return flow temperature.

4.2.3 Mixer return flow boost

Adjustments for the mixer to boost return flow temperature.

4.2.4 Fuel extractor

Configuration settings for the fuel extractor container variants.

4.2.5 Fuel extractor fill time

Setting the maximum runtime for the fuel extractor.

4.2.6 Pump afterrun

Configuration of pump afterrun time to prevent heat accumulation.

4.2.7 Boiler pump

Settings for the boiler circuit pump speed.

4.2.8 Language

Selection of the operating language for the system.

4.2.9 Second boiler

Control options for an integrated second boiler.

4.2.10 Cleaning

Settings for the heat exchanger cleaning cycle.

4.2.11 Network settings

Configuration of network settings for system modules.

4.2.11.1 Boiler

Network settings specific to the boiler module.

4.2.11.1.1 EXT 2

Specification of the function for the External 2 input.

4.2.11.1.2 Power output

Specification of the function for the Power output.

4.2.11.2 Heating circuit

Configuration of heating circuit settings and sensor assignments.

4.2.11.3 DHWC

Settings for Domestic Hot Water Circulation (DHWC) usage.

4.2.11.4 Buffer

Configuration options for buffer tank usage.

4.2.11.5 Digital remote control

Adjustment of functions for the digital remote control unit.

4.2.11.6 Power measurement

Settings for power measurement configuration.

4.2.12 Hardware

Adjustment of available hardware modules in the system.

4.2.13 Frost protection

Configuration of frost protection settings for heating circuits.

4.2.14 Outputs

Configuration of output parameters, including time delays.

4.2.15 Fan

Settings for primary and secondary air fan outputs.

4.2.15.1 Primary

Specification of the factor for the primary air output.

4.2.15.2 Secondary

Specification of the factor for the secondary air output.

4.2.16 Boiler output

Selection of boiler type and settings for output levels.

4.2.17 Container side

Configuration for container placement (right/left).

4.2.18 Ignition

Settings related to the ignition process.

4.2.19 Light barriers (only for USD)

Control of container filling via light barriers.

4.2.20 Motor power

Specification of motor power for connected components.

4.2.21 Serial number

Information on product serial number and series production status.

4.2.22 Operating hours

Display of operating hours based on load.

4.2.23 Control unit

Pre-set values for PID control units (pressure, oxygen, air, temperature).

4.2.23.1 Negative pressure

Specification of values for the negative pressure input.

4.2.23.2 Oxygen

Specification of values for the oxygen input.

4.2.23.3 Secondary air

Specification of values for the secondary air input.

4.2.23.4 Boiler temperature

Specification of values for the boiler temperature input.

4.3 Menu item – Relay Test

Function to manually switch all outputs for testing purposes.

4.3.1 Boiler

Relay test options for the boiler functions.

4.3.2 Heating circuits

Relay test options for heating circuits.

4.3.3 DHWC

Relay test options for DHWC functions.

4.3.4 Buffer

Relay test options for buffer functions.

4.3.5 Fuel extractor

Relay test options for fuel extractor components.

4.3.6 Second boiler

Relay test options for the second boiler.

4.3.7 Supplemental fuel extractor

Relay test options for the supplemental fuel extractor.

4.4 Menu item – Network Analysis

Function to analyze problems with individual bus nodes.

4.4.1 Overview

Overview of all possible bus nodes for failure analysis.

4.4.2 Boiler module

Error counter for communication with the boiler I/O module.

4.4.3 Heating circuit module

Error counter for communication with heating circuit expansion modules.

4.4.4 Digital remote control unit

Error counter for communication with digital remote control units.

4.4.5 Fuel extractor module

Management and connection of fuel extractor modules.

4.5 Menu item – Save / Reset

Functions to save settings or reset to factory defaults.

4.6 Menu item – Measure Boiler

Function to make the power control unit inoperable for measurement.

4.7 Menu item – Start/Stop Log

Access to the start/stop log entries for system operation.

5 APPENDIX I

DIMENSION SHEETS

Technical drawings and dimension specifications for system components.

HYDRAULIC CIRCUIT DIAGRAMS

Schematic diagrams illustrating the hydraulic system configurations.

CONNECTION AND CABLING DIAGRAMS

Diagrams detailing electrical connections and cabling.

5.1 Dimension sheets

Overview of available dimension sheets for system installation.

5.1.1 Installation dimensions KWB Multifire USV V 15 – 25 kW

Installation dimensions for the KWB Multifire USV V 15–25 kW model.

5.1.2 Installation dimensions KWB Multifire USV D 15–25, 30–60 and 80–100 kW

Installation dimensions for KWB Multifire USV D models.

5.1.3 Installation dimensions KWB Multifire USV ZI 15–25, 30–60 and 80–100 kW

Installation dimensions for KWB Multifire USV ZI models.

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

Installation dimensions for KWB Multifire USV GS models.

5.1.5 Fuel extractor Ø 2.5 m–4 m (spring-blade rotary stirrer)_b

Installation dimensions for fuel extractor with spring-blade stirrer.

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

Installation dimensions for larger fuel extractors with spring-blade stirrer.

5.1.7 Ascending worm with upward transfer unit

Installation dimensions for ascending worm with upward transfer.

5.1.7.1 Ascending worm with drop shaft

Installation dimensions for ascending worm with drop shaft.

5.2 Hydraulic circuit diagrams

Overview of hydraulic circuit diagrams.

5.2.1 Hydraulic circuit – boiler circuit return flow boost

Hydraulic diagram for boiler circuit return flow boost.

5.2.2 Basic module with weather-sensitive control

Hydraulic diagram for a basic module with weather-sensitive control.

5.2.3 Basic module with weather-sensitive control and combination buffer as load-balancing buffer

Hydraulic diagram for buffer control with weather-sensitive control.

5.2.4 Basic module with weather-sensitive control and expansion module

Hydraulic diagram for control with expansion module.

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

Hydraulic diagram for control with second boiler switchover.

5.2.6 Basic module with weather-sensitive control, one expansion module and a long-term buffer

Hydraulic diagram for control with expansion and buffer.

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

Hydraulic diagram for control with a KWB special buffer.

5.2.8 Basic module with weather-sensitive control and buffer in adjacent building – expansion modules in the apartment buildings

Hydraulic diagram for control with adjacent building buffer and expansion modules.

5.3 Electrical diagrams (connection and cabling diagrams)

Collection of electrical diagrams for system connections and cabling.

5.3.1 Connection diagram for heating circuit module (HCM)

Electrical connection diagram for the heating circuit module.

5.3.2 Bus cabling

Diagram detailing bus cabling connections.

5.3.3 Cabling outputs heating circuit

Diagram showing cabling for heating circuit outputs.

5.3.4 Cabling inputs analogue and digital

Diagram showing cabling for analogue and digital inputs.

5.3.5 Cabling 400 VAC

Diagram for 400 VAC power cabling.

5.3.6 Connection diagram I/O board

Electrical connection diagram for the I/O board.

5.3.7 Connection diagram 1 / second boiler/ vacuum

Connection diagram for plug-in module 1 (second boiler/vacuum).

5.3.8 Boiler master-and-slave circuit

Electrical diagram for boiler master-and-slave circuit.

5.3.9 FE module

Electrical diagram for the fuel extractor module.

5.4 Chimney measurement

Form for data acquisition for chimney cross-section calculation.

5.5 Cross-section measurement

Diagram and data for cross-section measurement of wood chip firing.

Appendix II

FUEL EXTRACTOR VARIANTS

Overview of different fuel extractor variants.

6 FUEL EXTRACTOR with upward transfer

Detailed section on the fuel extractor with upward transfer.

7 DOUBLE FUEL EXTRACTOR

Detailed section on the double fuel extractor (D-FE).

8 FUEL EXTRACTOR WITH FALL PIPE

Detailed section on the fuel extractor with fall pipe.

9 FE WITH DOWNWARD TRANSFER AND ASCENDING WORM

Detailed section on FE with downward transfer and ascending worm.

10 FUEL EXTRACTOR pellets without stirrer

Detailed section on fuel extractor for pellets without stirrer.

6.1 Components – FE with upward transfer

List and diagram of components for the FE with upward transfer.

6.2 Installing the cast-iron head

Instructions for installing the cast-iron head component.

6.3 Floor assembly – fuel extractor trough (storage room)

Steps for floor assembly of the fuel extractor trough in the storage room.

6.4 Installing the transfer station (boiler room)

Instructions for installing the transfer station in the boiler room.

6.5 Installing the worm bearings

Procedure for installing the worm bearings.

6.6 Installing the ascending worm and fixing the FE in place

Steps for installing the ascending worm and securing the FE.

6.7 Installing the ascending worm drive

Instructions for installing the ascending worm drive.

6.8 Installing the inspection box and trough cover

Steps for installing the inspection box and trough cover.

6.9 FE cabling and cable layout

Guidance on FE cabling and cable layout.

6.10 Concluding tasks

Final tasks to complete after FE installation.

6.11 Final inspection

Final inspection checklist for the fuel extractor system.

7.1 Components

List and diagram of components for the double fuel extractor.

7.2 Aligning the stirrer channel, installing the crossbeam and feet

Steps to align the stirrer channel and install crossbeam/feet.

7.3 Installing the gear unit and drive shafts

Instructions for installing the gear unit and drive shafts.

7.4 Installing FE troughs and fixing them in place in the storage room

Steps for installing FE troughs in the storage room.

7.5 Installing the stirrer trough insulation and drive

Instructions for installing stirrer trough insulation and drive.

7.6 Installing the fuel extractor drive

Steps for installing the fuel extractor drive.

7.7 Open installation tasks – double FE

Open installation tasks for the double FE.

7.8 Cabling the double FE with common drive

Cabling instructions for double FE with a common drive.

7.9 Final inspection

Final inspection checklist for the double FE.

8 FUEL EXTRACTOR WITH FALL PIPE

Detailed section on the fuel extractor with fall pipe.

8.1 Components of the FE with fall pipe

List and diagram of components for FE with fall pipe.

8.3 Installing the RA head piece, downward transfer

Instructions for installing the RA head piece and downward transfer.

8.4 Cabling the FE with drop shaft

Cabling instructions for the FE with drop shaft.

8.5 Open installation tasks

Open installation tasks for FE with fall pipe.

8.6 Final inspection

Final inspection checklist for FE with fall pipe.

9 FE WITH DOWNWARD TRANSFER AND ASCENDING WORM

Detailed section on FE with downward transfer and ascending worm.

9.1 Components of the FE

List and diagram of components for FE with downward transfer and ascending worm.

9.3 Installing the ascending worm

Steps for installing the ascending worm component.

9.4 Installing the fuel extractor trough

Instructions for installing the fuel extractor trough.

9.6 Installing the ascending worm drive

Steps for installing the ascending worm drive.

9.8 Final inspection

Final inspection checklist for FE with downward transfer and ascending worm.

10 FUEL EXTRACTOR pellets without stirrer

Detailed section on fuel extractor for pellets without stirrer.

10.1 Installing the pellet worm

Instructions for installing the pellet worm.

10.2 Divided pellet worm (over 6 m in length)

Details on installing divided pellet worms longer than 6 meters.

10.3 Contents of this installation manual

Reference to preceding sections and concluding inspection.