eta HACK 350 User manual

2016-04-05

EN

0000000305

V.001

X.36.0

3503

93824-001

Moving-grate boiler

Size 2

Service guide

ETA Heiztechnik

Gewerbepark 1

A-4716 Hofkirchen an der Trattnach

Tel: +43 (0) 7734 / 22 88 -0

Fax: +43 (0) 7734 / 22 88 -22

[email protected]

www.eta.co.at

General information

3

1 General information

Support for cleaning and maintenance

This document helps support you with the cleaning

and maintenance of the boiler. The required steps are

listed in detail here.

Take note of the date of the cleaning or maintenance

and any faults that may have occurred. This facilitates

troubleshooting for the expert (system operator,

heating technician...).

For services (such as commissioning, mainte-

nance, fault fixing provided by ETA customer

service), the service reports are provided in digital

form. For clarity, you should staple these reports to this

document or enclose them.

Commissioning data

Enter the boiler number (printed on the type plate), the

date of commissioning as well as the heating

technician who commissioned the system.

Copyright

All contents of this document are property of ETA

Heiztechnik GmbH and are protected by copyright.

Any reproduction, transfer to third parties or use for

other purposes is prohibited without written permission

from the owner.

Subject to technical alterations

We reserve the right to make technical modifications

without notice. Printing and typesetting errors or

changes of any kind made in the interim are not cause

for claims. Individual configurations depicted or

described here are only optionally available. In the

event of contradictions between individual documents

regarding delivery scope, the information in our current

price list applies.

Explanation of symbols

Instructions and information

Layout of safety instructions

SIGNAL WORD!

Type and source of danger

Possible effects

• Measures for avoiding the danger

Types of safety instruction

CAUTION!

On non-compliance with this safety instruction, there is

a risk of material damage.

WARNING!

On non-compliance with this safety instruction, there is

a risk of physical injury.

DANGER!

On non-compliance with this safety instruction, there is

a risk of major physical injury.

Commissioning data

Boiler number:

________________________________________

Commissioned on:

_________________________________________

Commissioned by (company):

_________________________________________

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Cleaning and maintenance

2 Cleaning and maintenance

Maintenance openings and components

1 Draught fan of flue gas recirculation

2 Maintenance cover for flue gas recirculation piping

3 Draught fan

4 Heat exchanger cover

5 Maintenance cover for reversing chamber on heat

exchanger

6 Combustion chamber door

7 Maintenance cover for flue gas recirculation

(behind panel)

8 Ignition fan

9 Actuator for primary air

10 Maintenance cover for secondary combustion

zone

Cleaning and maintenance

5

1 Drive of heat exchanger cleaner

2 Temperature sensor of combustion chamber

3 Actuator for flue gas recirculation flap

4 Maintenance cover for flue gas recirculation

(behind panel)

5 Boiler mains switch

6 Maintenance cover for reversing chamber on heat

exchanger

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Cleaning and maintenance

The conveyor depicted here is the standard con-

figuration.

1 Drop chute maintenance cover

2 Rotary valve maintenance cover

3 Safety switch for rotary valve maintenance cover

4 Drop chute safety switch

Fig. 2-1: Rotary valve position sensor

Cleaning and maintenance General information

7

2.1 General information

Operation only by trained personnel

The product may be operated by trained adults only.

Training may be provided by the heating technician or

our customer service. Please read the associated doc-

umentation carefully in order to avoid errors during

operation and maintenance.

Persons who lack experience and knowledge as well

as children may not operate, clean, or maintain the

product.

Performing regular cleaning and maintenance

To ensure satisfactory functioning, cleaning and

maintenance must be performed at regular intervals.

Carry out this work within the intervals stated here.

All tasks where the maintenance table reads

"Customer" or "Customer or expert" in the column

"To be carried out by" can be carried out by any trained

adult. Instructions can be provided by the heating

technician or our customer service.

Steps that are marked with "Expert" only can only be

carried out by the heating technician or our customer

service.

Checking the boiler counters

The counters can be seen in the boiler's text menu.

Counter [Full load hours since maint.] is used for the

service intervals. If it has reached one of the listed

intervals, maintenance is required. This counter is in:

Counters

Full load hours since maint.

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Maintenance table Cleaning and maintenance

2.2 Maintenance table

Tasks

Regular

ly

Every

3,000 h

or once

a year

Every

6,000 h

or

every

2years

to be done by

Check fill level of ash bins X X X Customer

Check heating system's water pressure X X X Customer

Check air intake in installation room X X Customer

Clean flue tube X X Customer

Clean combustion chamber X X Customer

Check lining of the combustion chamber X X Customer

Check the firebed switch X X Customer

Visual check of the stoker screw X X Customer

Clean ignition fan and openings X X Customer

Check protective elements and grate elements X X Customer

Visual check of the ash cross screw X X Customer

Check grate ash screw X X Customer

Clean roller guide of the moving grate X X Customer

Remove ash from the reversing chamber X X Customer

Check turbulators X X Customer

Clean flue gas recirculation ducts X X Customer/expert

Clean the heat exchanger X X Customer/expert

Clean connection pipe to draught fan X X Customer/expert

Visual check of the heat exchanger screw X X Customer/expert

Clean flue gas temperature sensor X X Customer/expert

Clean flue gas recirculation piping, check flue gas recirculation

flap

X X Customer/expert

Clean draught fan of the flue gas recirculation X X Customer/expert

Lubricate heat exchanger cleaner drive X X Customer/expert

Check stoker drive chain X X Customer/expert

Check the seal of the ash bin or the transfer coupling X X Customer/expert

Check heat exchanger ash screw X X Customer/expert

Clean the lambda probe X X Customer/expert

Visually check safety valves X X Customer/expert

Visually check thermal relief valves X X Customer/expert

Check operational readiness of safety devices in fuel path X X Customer/expert

Clean the upper area of the heat exchanger X Expert

Clean draught fan X Expert

Check seal on heat exchanger cover X Expert

Check safety switch of the discharge X Expert

Check rotary valve stop X Expert

Check silicon hoses for differential pressure switch and

transmitter

X Expert

Check air valve X Expert

Check automatic closing of the actuators X Expert

Cleaning and maintenance Maintenance table

9

Check seal on combustion chamber door X Expert

Calibrate lambda probe X Expert

Perform heating test X Expert

Reset maintenance counter X Expert

Tasks

Regular

ly

Every

3,000 h

or once

a year

Every

6,000 h

or

every

2years

to be done by

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Regular maintenance Cleaning and maintenance

2.3 Regular maintenance

Check fill level of ash bins

The boiler does not have to be switched off to

empty the ash bins or container.

Before starting the de-ashing emptying, press the

[De-ash] button. This prevents the ash screw

from switching on during the emptying process. If the

ash screw already has a malfunction, first empty the

ash bins or the container and then acknowledge the

fault.

De-ashing with transfer flap

1. Lift the protective mat from the underside. Move

the container to the side and empty.

Fig. 2-2: Protective mat

2. Before placing the protective mat, make sure the

adhesive seal is in a good condition to prevent ash

from escaping.

Fig. 2-3: Seal on the sealing plate

De-ashing with ash bins

1. Turn the locks on the ash bin lid upwards by 90°.

Fig. 2-4: Open the locks

2. Push the lid up and fix in "Park position".

Fig. 2-5: Park position

3. Empty the ash bins. Unhook the lid from "Park

position" and fix to the ash bin with the locks.

DANGER!

Risk of injury from the ash screw

If only one ash bin or none at all is

connected, the ash screw is accessible

from below.

For this reason, operation with only one ash

bin or none at all is prohibited. In addition,

the boiler would take in leak air and hot ash

would fall to the ground, increasing the fire

risk.

 The boiler may not be operated for more than

2 minutes without ash bins or an ash container.

Cleaning and maintenance Regular maintenance

11

Check heating system's water pressure

The heating system's water pressure is

measured by the control system and displayed

on the screen. A visual check is still necessary though.

In buildings with up to three storeys, the optimum

water pressure in a cold heating system is between 1

and 2 bar. For a warm heating system, the optimum

water pressure is between 1.5 and 2.5 bar.

If the water pressure is too low, fill the cold heating

system to approx. 2 bar. Do not fill to a higher

pressure, as water expands with increasing

temperature and the water pressure also rises when

the boiler is heating. The safety valve triggers at

approx. 2.8 bar.

If the boiler is operated at maximum 6 bar water

pressure, the values listed above must be

increased accordingly.

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Every 3000 hours / annually Cleaning and maintenance

2.4 Every 3000 hours / annually

Before this maintenance, perform all steps for the

preceding maintenance intervals

Before this maintenance, all steps for the

preceding maintenance intervals must be

performed.

Stop heating

End the boiler's heating mode with the On/Off switch

in the boiler overview window. The boiler

performs an ember burnout and then changes to

[Switched off] mode. Press the [De-ash] button to

make the boiler perform a final de-ashing.

Switch off boiler via mains switch

WARNING!

 Switch off the electricity to the boiler via the mains

switch. This prevents injuries caused by switching

the boiler on inadvertently.

WARNING!

Burns caused by hot parts

Even after the boiler has been switched off,

there will still be a danger of burns caused

by the cleaning and maintenance covers of

the combustion chamber and the heat

exchanger, and by the combustion chamber door.

These parts cool off more slowly, so they may still be

hot.

 Allow the boiler cool off long enough, or wear

appropriate protective clothing.

Air intake in installation room must be clear

Air intake for the boiler in installation room must be

clear. It may not be shut or closed.

Cleaning the flue pipe

Sweep the flue pipe from the flue outlet to the chimney,

and remove flue ash from the chimney using a vacuum

cleaner.

Sweep the ash into the chimney, not into the

boiler.

Clean combustion chamber

Carefully pull the temperature sensor of the

combustion chamber out by loosening the screw on

the boiler.

Fig. 2-6: Temperature sensor of combustion chamber

Take off the maintenance cover of the secondary

combustion zone by loosening the 4 screws.

Fig. 2-7: Maintenance cover

Cleaning and maintenance Every 3000 hours / annually

13

Using the poker, remove loose and baked on ash from

the upper part of the combustion chamber. Sweep the

ash backwards into the heat exchanger or forwards

onto the moving grate.

Fig. 2-8: Upper part of the combustion chamber

A thin coating of ash (~ 5 mm) may remain on the

lining. This does not adversely affect operation

and acts as an additional protective layer. Significant

discolouration of the lining is normal.

CAUTION!

Never treat the lining with force, as this may cause

parts of it to be knocked off.

Open the combustion chamber door and remove

baked on ash deposits from around the opening and

from the combustion chamber door

Fig. 2-9: Combustion chamber door

Next, using the poker, remove baked on ash deposits

from inside the combustion chamber and sweep onto

the moving grate.

Fig. 2-10: Lower part of the combustion chamber

A thin coating of ash (~ 5 mm) may remain on the

lining. This does not adversely affect operation

and acts as an additional protective layer. Significant

discolouration of the lining is normal.

Then re-insert the combustion chamber temperature

sensor in the opening and secure with the screw.

Removing ash deposits near the opening of the

secondary combustion zone

Remove ash deposits around the opening of the

secondary combustion zone and also from the

maintenance cover.

Fig. 2-11: Opening of secondary combustion zone

Otherwise, the maintenance cover will not seal

tightly when it is subsequently closed.

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Every 3000 hours / annually Cleaning and maintenance

Fit maintenance cover for secondary combustion

zone

Remove the ash from the opening for the

maintenance cover with a vacuum cleaner so the

maintenance cover can form a proper seal.

Attach the maintenance cover for the secondary

combustion zone to the boiler using the 4 screws.

Tighten the screws evenly and cross-wise.

Fig. 2-12: Maintenance cover

Cleaning openings in the lining

Clean the openings on both sides of the lining and

remove any baked on ash deposits. Then vacuum the

openings with an ash or vacuum cleaner

Fig. 2-13: Openings in the lining

Check lining of the combustion chamber

After cleaning, check the combustion chamber lining

for cracks or damage.

Significant discolouration of the lining is normal.

Fig. 2-14: Discolourations

Check the firebed switch

Manually actuate the firebed switch and check that it

moves easily.

Fig. 2-15: Firebed switch

In the combustion chamber, check the position of the

firebed switch actuating lever.

Fig. 2-16: Firebed switch actuating lever

Cleaning and maintenance Every 3000 hours / annually

15

Visual check of the stoker screw

Visually check the stoker screw for damage from the

combustion chamber. It can be a bit burnt on the ends

due to the high levels of heat.

It must be replaced if the stoker screw is partially

burnt on the ends.

Fig. 2-17: Stoker screw

Clean ignition fan and photocell

Remove both ignition fans from the boiler.

Fig. 2-18: Removing the ignition fan

Detach the ignition tube by loosening the 4 screws and

remove the ignition rod.

Clean the visible photocell with a soft cloth. Then

reattach the ignition tube.

Also clean the openings in the boiler for the ignition

tube.

Fig. 2-19: Ignition openings

Re-install both ignition fans and attach them to the

boiler with the chain.

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Every 3000 hours / annually Cleaning and maintenance

Check protective elements and grate elements

Check the protective elements for damage or warping

on both sides of the moving grate.

Fig. 2-20: Protective elements

Also check the individual grate elements for damage.

Fig. 2-21: Grate elements

Visual check of the ash cross screw

From the combustion chamber, visually check the ash

cross screw for damage.

Fig. 2-22: Ash cross screw

Checking the grate ash screw

Lift up the panel slightly and remove from the boiler.

Fig. 2-23: Cover panel

Take off the maintenance cover by loosening the

screws and nuts.

Fig. 2-24: Maintenance cover

Carry out a visual check and remove any possible

foreign bodies (nails, stones...).

Fig. 2-25: Grate ash screw

Inspect the seal of the maintenance cover to ensure it

is in good order, and replace if necessary.

WARNING!

 Never operate the boiler with defective seals.

Clean roller guide of the moving grate

Clean the 4 rollers as well as the guides of the moving

grate and check for any possible foreign bodies.

Cleaning and maintenance Every 3000 hours / annually

17

For better checking and cleaning, remove the

panel as well as the maintenance cover on the

opposite side.

Fig. 2-26: Roller guide of the moving grate

Finally, replace the seals of the maintenance cover,

reinstall it on the boiler and hook in the panel.

Remove ash from the reversing chamber

The maintenance covers for the reversing chamber

are situated on each side of the heat exchanger. Take

off both maintenance covers by unscrewing the four

screws on each one and remove the ash with the

poker.

Fig. 2-27: Maintenance cover of the reversing chamber

Fig. 2-28: Maintenance cover of the reversing chamber

Check the seals on both maintenance covers to

ensure they are in good condition, replace if

necessary.

Cleaning the turbulators

Check the ends of the turbulators for deposits and

remove them if necessary.

Fig. 2-29: Turbulators

Clean flue gas recirculation ducts

Remove the panels on both sides of the boiler by

unscrewing the screws on the top and bottom.

Fig. 2-30: Cover panel

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Every 3000 hours / annually Cleaning and maintenance

Remove the two maintenance covers of the flue gas

recirculation ducts on both sides of the boiler.

Fig. 2-31: Maintenance cover for flue gas recirculation

Using an ash vacuum cleaner, remove ash from the

ducts. Likewise, clean the round openings of the flue

gas recirculation on both sides.

Fig. 2-32: Clean ducts

Fig. 2-33: Clean ducts

Check the seals of both maintenance covers to ensure

they are in good condition, replace if necessary.

CAUTION!

 Never operate the boiler with damaged seals.

Reinstall the maintenance cover for the flue gas recir-

culation and also the panels.

Clean the heat exchanger

First, loosen the two knurled nuts of the heat

exchanger covers by turning them anti-clockwise.

Fig. 2-34: Knurled nut

Next, turn each of the ball knobs by 180°.

Fig. 2-35: Ball knob

Cleaning and maintenance Every 3000 hours / annually

19

Lift the two heat exchanger covers and open fully.

Fig. 2-36: Heat exchanger cover

WARNING!

Injuries caused by heavy moving parts

Possible crushing injuries due to the two

heavy heat exchanger covers.

 Work carefully around the open heat exchanger

covers so that they do not accidentally fall shut.

Remove the flue cover by unscrewing the two screws.

Fig. 2-37: Flame pipe cover

When this is removed, the first tube of the heat

exchanger is visible. Clean it with the poker. Sweep

ash that has collected at the top down into the

reversing chamber.

Fig. 2-38: First tube of the heat exchanger

Clean connection pipe to draught fan

Check the connection pipe from the heat exchanger to

the draught fan for contamination and remove if

necessary.

Fig. 2-39: Connection pipe to draught fan

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Every 3000 hours / annually Cleaning and maintenance

Visual check of the heat exchanger ash screw

Perform a visual check of the cyclone tubes. You

should be able to see the heat exchanger ash screw

below them.

Fig. 2-40: Heat exchanger ash screw

If it is not visible, close the heat exchanger

covers, switch on the boiler via the mains switch

and press [De-ash] to begin de-ashing. Perform the

visual check once again and again switch off the

electricity to the boiler via the mains switch.

Close heat exchanger cover

Carefully close both heat exchanger covers. Next, turn

the two ball knobs clockwise until the stop.

Then tighten the two knurled nuts evenly and cross-

wise by turning them clockwise.

Clean flue gas temperature sensor

The temperature sensor is located in the flue

connection. To clean, loosen the screw and pull out the

flue gas temperature sensor.

Fig. 2-41: Flue gas temperature sensor

Clean the sensor with a soft cloth and then re-install it.

When fixing the temperature sensor in place, only

tighten the screw hand-tight so as not to damage the

sensor.

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eta HACK 350 User manual

eta HACK 350 User manual

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