Operation PC 20 to 32 kW, Software 1.20.0
2011-12
PelletsCompact
20 to 32 kW
Operation
2012-01-30 EN
2
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Subject to change due to technical improvements
Conditions for warranty, guarantee, liability .... 4
Emission measurement ............................... 6
Operation with external air supply ................ 7
Chimney .................................................. 8
Boiler functionality .................................... 9
Maintenance ...........................................10
Overview of activities ................................10
Every 2,200 kg ........................................ 11
Check boiler pressure .............................11
Empty the ash box ................................ 12
„Empty ash box“ reminder ......................13
After 6,000 kg .........................................14
Empty ash box, check boiler pressure ......... 14
Clean flue tube ....................................14
Remove flue ash from chimney ................. 14
Clean combustion chamber ...................... 15
Expert maintenance after 10,000 kg .............. 17
Approval, antifreeze, pressure equalisation,
venting ..................................................22
Softened heating water, Safety valve ............23
Buffer, hot water tank...............................24
Overtemperature, safety temperature limiter .. 25
Operation ............................................... 26
Adjusting the date and time ........................26
Changing the language .............................. 27
Renaming function blocks ...........................28
Error, Alarm, Warning, Message ....................29
Opening the text menu ..............................30
Boiler .............................................31
Overview, buttons, functions ....................... 31
Operating modes ...................................... 32
Changing the fill-up time ............................ 33
Filling up the storage tank ..........................33
Adjusting the ash removal idletime ................34
Changing the deashing interval ....................35
Meanings of symbols
Important NOTICES for operation.
CAUTION: Failure to observe these notices can
result in property damage.
STOP: Failure to observe these notices can result in
personal injury.
Contents
Heating circuit ....................................36
Overview, buttons, functions ....................... 36
Operating modes ......................................38
Heating time slots .....................................40
Heating curve .......................................... 42
„Day and Night Heating threshold“ ................ 43
Adjusting the heating curve .........................44
Setting the „enable temperature“ .................46
Adjusting the „Set-back“ ............................ 47
Room sensor with remote control .................48
Pellet store .......................................49
Overview, buttons, functions ....................... 49
Entering stock .........................................50
Store with switching unit ....................51
Overview, buttons, functions ....................... 51
Locking and changing heads ........................ 53
Entering stock .........................................54
The „Switching at“ parameter ...................... 54
Remote Control ........................... 55
Requirements .......................................... 55
Changing the operating mode ......................56
Functions not available via remote control .......57
Opening the touch screen ...........................58
Logging out ............................................ 59
Changing personal details ...........................60
Efficient and low-emission operation ............61
Service and maintenance records .................62
Safety instructions ....................................64
3
Operation PC 20 to 32 kW
2011-12
Preface
Dear customer,
We are delighted to count you among our customers.
To ensure satisfactory operation of your new boiler,
you need to know how to operate, clean and
maintain it. This manual contains information and
advice on much more than just the boiler itself.
Warranty and guarantee
You should also read the "Warranty, guarantee and
liability conditions" (page 4) carefully. As a rule,
these conditions will be satisfied by a professional
heating technician. Nevertheless, inform the
technician of our warranty conditions. All of the
requirements we impose are intended to prevent
damage that neither you nor we wish to occur.
Information worth knowing in this regard can also
be found from page 22.
Optimum use of the ETAtouch control system
installed in our boilers
There are two different access levels for the control
system:
At the CUSTOMER level, you can adjust the control
system to your wishes and needs without any risk of
altering the system configuration set by the heating
system expert.
Only your technician or a customer service employee
should change settings at the SERVICE level. Before
making any adjustments to these settings yourself, it
is essential that you consult an expert.
Please read this manual
carefully before starting up the system. This is the
only way to ensure that you can operate your new
boiler efficiently and with minimum environmental
impact.
Take advantage of the knowledge and skills of
an expert
Only allow an expert to assemble, install and
commission the equipment and make the basic
boiler settings. Insist on receiving an explanation
and training on how your new boiler functions and
how to operate and maintain it.
Extended warranty for commissioning performed
by an authorised partner company
If your newly installed boiler is commissioned by an
authorised partner company or one of our customer
service employees, we offer an extended warranty.
Refer to our warranty conditions in effect at the time
of purchase.
Service agreement
You can ensure the best care for your heating system
by taking out a service agreement with one of our
certified contractors or our own customer service.
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Subject to change due to technical improvements
Conditions for warranty, guarantee, liability
We can only guarantee and accept liability for the
function of our boiler if it is properly installed and
operated.
Requirement for warranty, guarantee and liability
is that this boiler be used in accordance with its
intended purpose, only for heating and hot
water supply with no more than 2,000 full-
load hours annually, and, in particular, that the
following general conditions be observed during
installation and operation:
For set-up, a dry room is required. In particular,
only condensation dryers may be used as clothes
dryers in the same room.
Local building and fi re protection regulations must
be observed.
The connecting pipe to the chimney must be
constructed with a maximum diameter of 130 mm
and at least 30 mm of insulation. For lengths
over 2 m, correspondingly more insulation is
needed.
The boiler is suitable for use with wood pellets
according to ÖNORM M 7135, DIN 51731,
EN 14961-2 class A1, EN plus class A1 or DINplus
with a diameter of 6 to 8 mm and a length of 15
to 40 mm. Operation with unsuitable fuels, in
particular those containing halogens (chlorine) or
high-slag pellets such as from grain waste, is not
permitted.
The combustion air must be free of aggressive
substances such as chlorine and fl uorine
from solvents, cleaning agents, adhesives and
propellants, or ammonia from cleaning agents, to
prevent corrosion of the boiler and chimney.
Water is the intended heat-transfer medium. For
special anti-frost requirements, up to 30% glycol
may be added. Softened water is required for
the initial fi ll-up of the heating system and for
refi lling after repairs. For the initial fi ll-up of the
heating system and for refi lling, the lime content
of all water in the heating system may not exceed
the value of 20,000 lt°dH (system volume in litres
multiplied by the hardness in degrees of German
hardness).
The pH value should be set between 8 and 9.
Set enough shut-off valves to avoid bleeding large
amounts of water during repairs. Any leaks in the
system must be repaired at once.
To protect against air suction if the system cools
off, an expert must provide a suffi ciently large
expansion tank or a pressure maintenance
system. Suffi cient air venting must also be
ensured. Open expansion tanks or underfl oor
heating with permeable piping also have a
high air intake, resulting in above-average boiler
corrosion. Corrosion damage to the boiler due to
improper air venting or high air intake is excluded
from warranty, guarantee and liability.
Operation at lower power than the lowest power
specifi ed on the type plate is not permitted. For
design outputs that are considerably less than
the boiler's rated output, either a reduction of
the heating time slots or a buffer storage tank is
required.
Only components provided by us may be used
for expansion of the control system, except for
commonly used units such as thermostats.
Cleaning and maintenance are required as
specifi ed in the user manual.
Conditions for warranty, guarantee, liability
5
Operation PC 20 to 32 kW
2011-12
Conditions for warranty, guarantee, liability
Repairs are only permitted with spare parts
provided by us. The only exceptions are common
standardised parts such as electrical fuses or
fastening materials, as long as they possess
the required features and do not restrict the
functionality of the system.
The installing contractor is liable for proper
installation according to the boiler's installation
instructions and the relevant rules and safety
regulations. If you as customer have installed
the heating system partly or entirely without
relevant training and in particular without
up-to-date practical experience, without having
the installation checked by a trained and
responsible expert, we exclude defects in our
delivery and consequential damages resulting
from this cause from our warranty, guarantee and
liability.
For repair of defects carried out by the
customer or by third parties, ETA only bears the
costs or remains obligated by warranty if this work
was approved in advance by the customer service
of ETA Heiztechnik GmbH.
Subject to technical alterations
We reserve the right to make technical
modifi cations without notice. Printing and
typesetting errors or changes of any kind made
in the interim are not cause for claims. Individual
confi gurations 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.
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Subject to change due to technical improvements
Emission measurement
Emission measurement
Boiler temperature at least 65°C
Before emission measurement, pellet boilers must
have been heating for at least 15 minutes, and
the boiler temperature must be at least 65°C.
Wood chip boilers must have been heating for
at least 30 minutes, and the boiler temperature
must be at least 65°C.
Switching the boiler to emission measuring mode
Press to switch the boiler to emission
measuring mode. This button lights up green to
confi rm the change.
min. 65°C
The boiler is now run at full load for 30 minutes.
The control system ensures that suffi cient heat
is channelled to the heating circuits and the hot
water tank.
Wait for 5 to 10 minutes, then measure
the emissions
Once emission measuring mode has been activated,
wait for 5 to 10 minutes until the boiler has
reached the required operating temperature and
stable combustion can be guaranteed. Then carry
out the emission measurement.
After the measurement
Switch the boiler back to normal mode by pressing
again.
If this button is not pressed, the boiler will
automatically switch back to normal mode after
30 minutes.
Why measure emissions?
It is a requirement for the carbon monoxide
(CO) emissions of every boiler to be measured
periodically. In Germany, this periodical
measurement must also include a dust
measurement.
There are several aspects of this that could go
wrong, resulting in incorrect measurements even
though the boiler fully and consistently complies
with these limits when operating in accordance
with the relevant standards.
2 to 3 days before measurement, the boiler
and boiler tube must be cleaned thoroughly
The chimney sweep will contact the owner of the
boiler when the measurement is due to take place.
The boiler and boiler tube must be cleaned
thoroughly 2 to 3 days before the measurement
takes place. Once this is complete, the heating can
continue to be used as normal.
This delay between cleaning and measurement is
necessary in order to allow dust disturbed during
cleaning to settle again. If the chimney sweep
measures unsettled dust, the dust reading will be
higher than normal and thus inaccurate.
Under no circumstances clean the
boiler and fl ue tube on the day of the
measurement!
If possible, switch the boiler off before
measurement
If possible, switch the boiler off 3 to 5 hours
before measurement using the on/off button
.
Ensure that there is suffi cient heat consumption
and then switch the boiler back on
Open all the radiator valves and turn the radiator
thermostats to maximum.
Finally, switch the boiler back on using the on/off
button (
button lights up green).
Emission measurement
7
Operation PC 20 to 32 kW
2011-12
Operation with external air supply
Operation with external air supply
Heating appliances, cooker hoods and
central vacuum cleaners need air supply
To keep ventilation heat losses under control,
airtightness (blower door test) is a crucial issue in
today's new buildings.
In an airtight house, the boiler receives air from the
outside via a dedicated pipe. This is described as
"operation with external air supply".
A cooker hood or a central vacuum cleaner also
need air in order to generate suction. Without an
air supply, their effectiveness tends towards zero.
Worse yet, underpressure results inside the house,
which can cause combustion gases to be sucked
into the living quarters if a pellet boiler with
external air supply is installed there.
There are several different ways to ensure the
air supply for cooker hoods and central vacuum
cleaners:
Air supply from the ventilation system
If an open air supply path is guaranteed for all of
the ventilation system's operating conditions, then
the ventilation system can be used to supply air to
the cooker hood and central vacuum cleaner. This
is a simple and proven solution.
If a heat exchanger installed in the air supply path
is protected against frost by a shut-off damper, a
bypass damper for the heat exchanger is needed.
Recirculation cooker hood
a proven solution for passive houses
A recirculation cooker hood needs no air supply.
In passive houses with controlled ventilation in
the living quarters, this is the preferred solution to
keep the ventilation heat loss to a minimum.
Supply air position switch on window
The power supply for the cooker hood and central
vacuum cleaner is only activated when the
window is open or tilted.
Air supply via blinds
The slats in the blinds open due to the pressure
difference and admit air into the room. This
solution is safe and simple but can be an
unpleasant source of leaks in rooms with
mechanical ventilation (controlled ventilation
of living quarters).
Air supply via motorised flap
An air inlet damper (diameter approx. 300 mm) is
opened when the cooker hood or central vacuum
cleaner is switched on. Only when the open
position is reached is the fan for the cooker hood
or central vacuum cleaner activated via a position
switch in the flap actuator.
To avoid condensation
on the air supply duct,
it must be insulated against cold.
If the outside temperature is low, condensation can
form on the cold pipe surface. An air supply duct
separate from the chimney needs to be insulated
against condensation (with tightly sealed plastic
foam insulation) to prevent structural damage
along the duct's path through the house.
If the duct goes through the chimney, the air
will be preheated slightly. It this case, it may be
possible to forego insulation if no damage results
from the condensation on a few cold days.
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Subject to change due to technical improvements
Chimney
Chimney renovation before it's too late
Compared to older boilers, modern ones are much
more efficient and have lower amounts of flue gas
with considerably lower temperatures.
Flues with "too large a cross-section" (over 18 cm)
in particular are no longer heated adequately. The
moisture contained in the exhaust gases condenses
in the flue and in this way leads to very slow but
inexorable destruction of old masonry chimneys.
Furthermore, if the diameter of the flue is too large,
the exit velocity and temperature are too low. The
flue gas then lacks the energy to rise and in extreme
cases, the smoke can sink down along the roof.
If your flue does not have a moisture-resistant
lining or its diameter is too large, it will need to be
renovated with the addition of a moisture-resistant
inner lining. Narrow flues can also be renovated
with stainless steel pipes.
Also keep in mind that chimneys have a limited
service life. Timely renovation before the chimney
wall has been destroyed can be performed quickly
and easily by inserting a tube. But if the flue gas
condensates have penetrated the mortar joints, then
the entire flue must be dismantled and rebuilt.
Sealed connection pipe to chimney
A sealed flue pipe is an absolute necessity. Joints can
be sealed with heat-resistant silicone (300 °C) and/
or pure aluminium tape to prevent the escape of
dust or flue gas.
Technical requirements for the flue
can be found in the installation instructions
(a separate document from this user manual).
Chimney
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Operation PC 20 to 32 kW
2011-12
Boiler functionality
Boiler functionality
Beneath the grate and the heat exchanger, two ash
screws (7) move the ash to a detachable ash box
(8); with its 24-litre capacity, the box only needs to
be emptied two to three times per heating season.
In an uncooled, hot combustion chamber made of
stainless steel (9), hot and complete burnout occurs
before the combustion gases transfer the heat to the
boiler water in the heat exchanger (10). Movement
of the turbulators (11) cleans the heat exchangers
automatically once a day.
The boiler pump (15) and the return riser mixing
valve (14) for the return riser are already integrated
in the boiler. The safety valve, a pressure gauge
with water shortage switch-off, and an air vent
in the boiler outlet are also built in.
The lambda probe (12) together with the variable-
speed draught fan (13) ensures high efficiency.
The boiler can be operated with an external air
supply (19) using a heat-resistant air supply duct.
The pellets are sucked with a vacuum motor (1)
from the storage room (up to 20 m away) into the
pellet bin (2) in the boiler. The pellet bin (2) has a
capacity of 60 kg. Suction takes place once a day
at a time that can be set as needed. Only on very
cold days might it be necessary for pellets to be
transported to the boiler a second time.
The pellets are fed from the pellet bin with the
metering screw (3) to avoid overfilling the rotary
valve (4); this avoids the need to cut pellets and
prevents wear on the sealing edges. The rotary valve
(4) separates the pellet bin from the combustion
chamber to prevent back burning in the pellet bin.
The stoker screw (5) pushes the pellets into the
combustion chamber.
The pellets are burned on the movable grate (6).
Automated cleaning takes place during pauses in
combustion. The grate is rotated against a comb,
cleaning the air gaps in the grate.
When restarting, the pellets are ignited with a
ceramic igniter.
1 Vacuum motor for pellets
2 Pellet bin
3 Metering screw
4 Rotary valve
5 Stoker screw
6 Movable, self-cleaning rotating grate
7 Ash screw
8 Detachable ash box
9 Hot stainless steel combustion
chamber
10 Heat exchanger
11 Agitated turbulators
12 Lambda probe
13 Draught fan
14 Return riser mixing valve
15 Boiler pump
16 Bypass
17 Flow
18 Return
19 Air connection for
operation with external air supply
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
11
19
7
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Subject to change due to technical improvements
Overview of activities Maintenance
Activity
Interval every
to be done by
2,200 kg
or at least
1x yearly
6,000 kg
or at least
1x yearly
10,000 kg
or at least
3 years
Check boiler pressure X X X Customer
Empty the ash box X X X Customer
Check safety valve(s) X X X Customer
Clean flue tube X X Customer
Remove flue ash from chimney X X Customer
Clean combustion chamber and flue collector box in front of fan X X Customer
Inspect heat exchanger tubes for pitch deposits X X Customer
Vacuum out lambda probe (do not remove it) X X Customer
Clean draught fan and fan housing, replace seal X Expert
Clean flue gas temperature sensor X Expert
Check firebed level sensor X Expert
Clean fill level sensor on pellet bin X Expert
Lubricate drive chains for stoker, cleaner and grate X Expert
Inspect ash box position switch and seals X Expert
Check strainer in pellet bin X Expert
Measuring orifice and hoses on differential pressure transmitter X Expert
Inspect seal on heat exchanger cover X Expert
Perform emission measurement X Expert
Calibrate lambda probe X Expert
Check safety temperature limiter X Expert
Reset maintenance counter X Expert
Regular cleaning and servicing
To ensure that the boiler operates optimally and
reliably, it must be cleaned and serviced at regular
intervals. These intervals depend primarily on the
pellet consumption.
However, maintenance and cleaning must be
performed within the specified duration (once per
year, every 3 years).
Cleaning and maintenance overview
The table provides an overview of the required
cleaning and maintenance.
The "to be done by" column indicates which
activities you as customer can deal with and which
must be performed by an expert.
Maintenance
Overview of activities
11
Operation PC 20 to 32 kW
2011-12
Maintenance Every 2,200 kg
Maintenance every
2,200 kg of pellets
After every 2,200 kg of pellets or at least once
per heating season, check the boiler pressure and
adjust it if necessary.
Also check how full the ash box is and empty it.
Boiler
TU 4.4.2011 11:25:45
Reminder: check ash box after 2200 kg
Counter reset when ash box removed. Empty out ash,
check water pressure and safety valve. See user manual.
Check boiler pressure
In the overview of the "Boiler" function block, the
current pressure in bar is displayed.
Boiler pressure between 1.6 and 2.5 bar
The boiler pressure should be at least 1.6 bar
for a cold heating system and no more than
2.5 bar for a hot heating system.
If the boiler pressure is too low
If the boiler pressure is too low (under 1.6 bar),
fill the cold heating system to approx. 2.0 bar.
Do not fill to a higher pressure as water expands
with increasing temperature and the pressure
will continue to rise while heating up to the full
operating temperature.
Every 2,200 kg
Check boiler pressure
Warning message "Water pressure too low"
For "Water pressure too low" (warning at
1.5 bar and shutdown at 1.0 bar), fill the cold
heating system to approx. 1.8 bar and the hot
heating system to approx. 2.2 bar.
Confirm the warning message and restart the
heating with the on/off switch .
Alarm "Water pressure too high"
After a shutdown "Water pressure too high"
(over 2.8 bar), let the boiler cool. Then drain
water to reduce the current pressure by 0.2 to
0.4 bar.
Boiler
TU 4.4.2011 11:25:45
Water pressure too high 2,90 bar
Water pressure exceeds maximum value. Decrease
pressure or check sensor!
Confirm the alarm and restart the heating with the
on/off switch .
Check safety valve
Check the safety valve to ensure that it is closed
tightly. The outlet must not drip.
Siphon funnel
Perform further steps only on weekdays,
never on weekends in a cold winter as there will
probably be no heating technician available if the
seal is defective. If the valve drips, open the safety
valve with a quarter turn of the red cap and rinse
it out (danger of scalding). If the valve still cannot
be closed tightly after being rinsed several times, it
must be cleaned by a plumber or replaced. If a solar
buffer is equipped with a safety valve, check that
as well.
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Subject to change due to technical improvements
Overview of activities Maintenance
Empty the ash box
Empty the ash box
The control system issues reminders about
emptying the ash box after a set pellet
consumption.
The factory setting is 2,200 kg of pellets. If the ash
box is only partly full or overfilled, this value can
be changed. See page 13.
Stop heating,
draught fan switched off
Before emptying the ash box, switch off the boiler
in the overview with the
button. The boiler
performs a burnout.
Only when the draught fan is switched off and the
boiler status "Switched off" is displayed on the
screen is the burnout complete; then the ash box
can be removed.
Push up the front panel
The front panel stays in place in every position.
Ash box
Open the side latches
Open the side latches by pressing the safety catch
in the direction of the arrow. Pull the ash box
straight out from the front of the boiler.
Safety catch
Open latch
Empty the ash box; are there any embers?
Check the ash to see if there are any embers
present. Do not put hot ash in the waste bin due
to risk of fire.
Inspect the seals on the boiler.
Check the integrity of both seals. If the seals are
damaged, the boiler can draw in leak air. That
would reduce the boiler output.
Inspect seals
Attach ash box, restart heating
Reattach the ash box to the boiler and secure it
with the side latches.
In the "Boiler" overview, restart the boiler with the
on/off button
. The boiler automatically starts
heating if required.
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Operation PC 20 to 32 kW
2011-12
Maintenance Overview of activities
"Empty ash box" reminder
"Empty ash box" reminder
The ash box should be emptied regularly. As such,
the factory settings contain a pellet consumption
level at which a reminder to empty the ash box
appears.
If the ash box is only part full after this time, the
value in the "Empty ashbin after" parameter can be
increased. If the value is set to zero, the message
will no longer appear. The fi lling level must then
be checked manually at regular intervals.
Boiler
TUE 4/4/2011 11:25:45
Reminder: check ash box
Counter reset when ash box removed. Empty out ash,
check water pressure and safety valve. See user manual.
Changing the "Empty ashbin after" setting
Press the buttons and to go to the text
menu.
Tap the [Boiler] line and, in the submenu, tap the
[Ash removal] line.
Double-tap the [Empty ashbin after] line.
2x
A settings screen opens:
Enter the new pellet consumption value after
which a reminder will appear to empty the ash
box, then press to confi rm.
Press the
button to return to the overview.
„Empty ash box“ reminder
14
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Subject to change due to technical improvements
After 6,000 kg Maintenance
Maintenance after 6,000 kg of pellets
When 6,000 kg of pellets have been used, a
screen message appears to notify of the need for
maintenance.
This maintenance must be performed at least once
per heating season.
Boiler
TU 4.4.2011 11:25:45
Cleaning after 6000 kg
Reminder for periodic cleaning of the boiler according to
user manual.
Confirm the message and then begin with the
maintenance.
Empty the ash box, check the boiler pressure
Empty the ash box and check the boiler pressure.
See page 11 and page 12.
Stop heating,
let boiler cool for at least 2 hours
Before starting this maintenance, stop the current
heating operation. In the "Boiler" overview, press
the on/off button
.
Then let the boiler cool off for at least 2 hours
before starting the maintenance.
After 6,000 kg
Empty ash box, check boiler pressure
Clean flue tube
Remove flue ash from chimney
Clean flue tube
Brush out the connection pipe from the flue outlet
to the chimney if it is longer than 0.5 m.
Remove flue ash from chimney
Use a vacuum cleaner to remove the flue ash from
the chimney.
Clean the condensate drain.
15
Operation PC 20 to 32 kW
2011-12
Maintenance After 6,000 kg
Clean the combustion chamber and flue
collection box
To gain access to the combustion chamber and the
flue collection box in front of the fan, the panel
on top of the boiler and the heat exchanger cover
must be removed.
Removing panels
Loosen the screw next to the flue pipe and press
the button on the side of the panel. Then the
panel can be removed from the top of the boiler.
Screw
Lift off insulating cover
Remove heat exchanger cover
Loosen the wing nuts and remove the cover.
Clean with the poker
Use the poker (stored behind the front panel
above the ash box) to remove the combustion
chamber cover from the combustion chamber and
scrape the ash from the walls. Sweep the ash into
the combustion chamber and the tubular heat
exchanger.
Combustion chamber coverFlue collection box
Remove the ash, which is now on the grate and in
the tubular heat exchanger, from the boiler with
an ash removal.
An ash removal can be started by pushing the
button in the "Boiler" overview.
The turbulators do not need to be
removed.
Are there tar deposits on the tubular heat
exchanger?
If there are tar deposits on the tubular heat
exchanger, contact customer service. The cause for
the incorrect air measurement must be identified
and corrected (leak air through lambda flange or
heat exchanger cover, incorrectly calibrated lambda
probe, incorrect differential pressure measurement
at the air intake).
Clean combustion chamber
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Subject to change due to technical improvements
After 6,000 kg Maintenance
Clean the lambda probe
The head of the lambda probe is accessible.
Vacuum it with a vacuum cleaner.
Do not remove the lambda probe.
Head of lambda probe
Clean and insert the combustion chamber cover
Clean the combustion chamber cover and insert it
into the combustion chamber.
Inspect seal on heat exchanger cover
Clean the heat exchanger cover and check the
integrity of the seal.
Put on heat exchanger cover,
insulating cover and panel
Replace the heat exchanger cover and fasten it
with the wing nuts.
Replace the insulating cover.
Replace the panel on the top of the boiler.
Screw
The maintenance is now completed.
17
Operation PC 20 to 32 kW
2011-12
Maintenance Expert maintenance after 10,000 kg
Expert maintenance after 10,000 kg
Maintenance after 10,000 kg
by an expert
When 10,000 kg of pellets have been used, a
screen message demands maintenance by an
expert.
This maintenance must be performed by an expert
no later than every 3 years.
Boiler
TU 4.4.2011 11:25:45
Maintenance by professional after 10000 kg
Reminder for maintenance by professional. See also user
manual.
In preparation, perform the maintenance
for 2,200 kg and 6,000 kg
For the 10,000 kg maintenance, the maintenance
work required after the consumption of 2,200 kg
and 6,000 kg of pellets must also be performed.
Check safety valve
Check the safety valve to ensure that it is closed
tightly. The outlet must not drip.
Siphon funnel
If it drips, open the safety valve with a quarter
turn of the red cap and rinse it out. Only rinse the
safety valve on a weekday, never on weekends in
a cold winter as there will probably be no heating
technician available if the valve no longer seals.
If the valve still cannot be closed tightly after
being rinsed several times, it must be cleaned or
replaced.
Buffer storage tanks with solar charging must also
be equipped with a safety valve; its seal must also
be checked.
To permit this inspection, the valve's outlet must
be routed through an exposed area, either via a
siphon funnel leading to the sewer or a pipe to the
floor (to prevent scalding).
Draught fan and fan housing
Remove the draught fan and clean it. Also clean
ash from the fan housing.
If necessary, replace the draught fan seal.
Firebed level sensor
Check the movement of the firebed level sensor
(overfill protection).
Check fill level sensor on pellet bin
and strainer in pellet bin
Remove the fill level sensor on the pellet bin. Do
not take apart the sensor itself, but open the larger
inspection cover. Use a marker to mark the cover
and the bin so that you can reinstall the cover in
the right orientation after the maintenance work.
Clean the sensor with a soft cloth.
Tap and vacuum the strainer on the inlet to the
vacuum motor.
Inspect the seal on the inspection cover and
reinstall the cover with sensor.
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Subject to change due to technical improvements
Expert maintenance after 10,000 kg Maintenance
Check seal,
close heat exchanger cover
Check the seal on the heat exchanger cover, replace
it if necessary, and close the heat exchanger cover.
Perform emission measurement
Perform the emission measurement with a
measuring device on the boiler; see page 6.
Switch the boiler into emission measurement mode
with the
button. The consumers are activated
to ensure that the heat is dissipated.
If no measuring device is available, at least the
lambda probe must be calibrated.
Safety temperature limiter
Check the function of the safety temperature
limiter.
Reset maintenance counter
After maintenance, the maintenance counter
must be reset to zero. The "Service" access level is
required to do this.
Drive chains for stoker, cleaner and grate
Lubricate the drive chain for the stoker with spray
oil and check the chain tension. The chain can be
tensioned by shifting the motor.
Lubricate the drive chain for the grate and cleaning
drive with spray oil. To do so, start ash removal by
pressing
to start the chain moving so that it
can be completely lubricated.
Ash box position switch and seals
Verify the function of the position switch for the
ash box. Inspect both of the ash box seals and
replace if necessary.
Test measuring orifice and hoses
on differential pressure transmitter
With the boiler switched off and hoses removed
from the differential pressure transmitter, a
measured value of 0 Pa must be displayed.
Otherwise, the measuring orifice must be
calibrated; see page 20.
Check the hoses of the differential pressure
transmitter at the air intake and blow them out if
necessary. The hoses may not be kinked or crossed.
Check heat exchanger tubes
Remove the heat exchanger cover.
Check the heat exchanger tubes for pitch deposits.
If tar deposits are present, contact our customer
service.
Calibrate lambda probe
If no emission measurement is possible, the
lambda probe must be calibrated with the heat
exchanger cover open; see next page.
19
Operation PC 20 to 32 kW
2011-12
Maintenance Expert maintenance after 10,000 kg
Starting the "Additional calibration" function
In the submenu, scroll down and double-tap on
the [Additional calibration] line.
2x
In the selection window that appears, press the
[On] button and confi rm with .
The lambda probe is calibrated automatically
The control system will now automatically calibrate
the lambda probe.
After 100 hours, the control system will
automatically re-calibrate the probe.
In the overview
Press to return to the boiler overview. The
boiler is now in
Calibrating lambda probe
mode.
Once calibration is complete, the boiler
automatically returns to operation and begins
heating as required.
"Additional calibration" for lambda probe
Automatic calibration of the lambda probe
The boiler's built-in lambda probe checks the
residual oxygen content of the fl ue gas and uses
this to control the combustion. In order to ensure
that this works correctly, the boiler automatically
calibrates the lambda probe at regular intervals
(factory setting: every 500 h).
Calibrating the lambda probe with the
"Additional calibration" software function
The access level "Service" is required for calibration.
If you wish to perform an additional calibration
between the automatic intervals, you can start the
calibration using the software function "Additional
calibration". When this is activated, the boiler
automatically stops heating, de-ashes and rinses
the boiler with fresh air using the draught fan. The
residual oxygen content is then measured and the
lambda probe is automatically calibrated to the set
value.
The calibration process takes approx. 45 minutes.
Opening the boiler text menu
Using the access level "Service", open the text
menu by pressing
and .
Tap the [Inputs] line. In the submenu, tap the
[Residual O2] line.
20
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Subject to change due to technical improvements
Expert maintenance after 10,000 kg Maintenance
Differential pressure transmitter
The "Measuring orifice" signal from the differential
pressure transmitter must show a measured value
of 0 Pa when the boiler is switched off and both
hoses are disconnected. The measurement must
be calibrated in the event of deviating measured
values. The "Service" access level is required to
do this.
Differential pressure transmitter
Calibrating the differential pressure measurement
Switch off the boiler with the on/off button
. As soon as the boiler status is "Switched
off", detach both hoses from the differential
pressure transmitter.
Using the "Service" access level, tap the [Inputs]
line in the boiler's text menu. Select [Measuring
orifice] from the submenu and read the current
value.
For a correct measurement, the value for the
[Measuring orifice] parameter must be 0 Pa.
2x
If a deviating value is shown, the measurement
must be calibrated.
Tap the [Offset] parameter twice and enter the
difference from the target value of 0 Pa in the
settings window, e.g.:
Measuring orifice 2 Pa --> Offset = -2
Measuring orifice -4 Pa --> Offset = 4
If a deviation of more than +/- 10 Pa is shown, the
differential pressure transmitter must be replaced.
Blow out the hoses on the differential pressure
transmitter and reconnect them. The hoses may
not be kinked or crossed.
The boiler can then be returned to operation.
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