eta eHACK 20-50 kW User manual

2018-05-14

EN

0000000262

V.006

3.43.0

5007

93032-002

Wood chip boiler

eHACK 20-50 kW

Service manual

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 provides support for cleaning and

maintaining the product. 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 manufacturing number of the product

(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 changes

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 available optionally. 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

Manufacturing number:

________________________________________

Commissioned on:

_________________________________________

Commissioned by (company):

_________________________________________

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Maintenance notes Cleaning and maintenance

2 Cleaning and maintenance

2.1 Maintenance notes

Performing regular cleaning and maintenance

To ensure satisfactory functionality, cleaning and

maintenance must be performed at regular intervals.

You will receive a timely reminder about this from the

ETAtouch control system.

Cleaning of the boiler must be carried out at least

once a year, or when requested by the control

system. Maintenance is necessary at least every

3 years, or when requested by the control system. We

recommend that you perform maintenance annually.

You can also enter into a service agreement for your

heating system. Find out more from your heating

contractor or customer service.

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. Instruction may 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.

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.

Display maintenance steps on the screen

With this boiler, the maintenance steps can also be

displayed on the ETAtouch control system screen. The

required activities will be explained to you step-by-step

and supplemented with detailed graphics. Each

maintenance is saved and the details can be viewed at

any time. So you can maintain a long-term overview of

the maintenance carried out. Of course, the

maintenance can also be carried out using the service

guide, without the support of the ETAtouch control

system.

To access maintenance, switch to settings in the boiler

function block ( [Settings] button) and then select

the function [Maintenance].

Fig. 2-1: Overview (example)

You can also access this overview by pressing

the maintenance switch. Also when the message

appears that maintenance of the boiler is required.

In the overview the different maintenance intervals are

listed in the upper area. This includes the maintenance

already carried out. With the button, information

about the selected maintenance is displayed.

Maintenance that you can carry out as an end

customer is labelled with the symbol. All others are

reserved for specialists and require authorisation.

Press the button to start the maintenance. The

individual steps are displayed on the screen. You can

switch to the next or the previous screen respectively

with the arrow keys on the left and right side of the

screen.

Fig. 2-2: Maintenance step (example)

Cleaning and maintenance Maintenance notes

5

Follow the on-screen instructions and carry out all

steps carefully. Enter your name at the end of

maintenance ( button) and save the maintenance

with the button.

Fig. 2-3: End of maintenance

To end maintenance prematurely, press the right

arrow key several times until you get to the end.

There you can end the maintenance with the

button. Cancellation during a maintenance step is not

possible.

Explanation of the maintenance switch

The maintenance switch on the boiler is needed for

performing maintenance with the aid of the [Main-

tenance] function in the ETAtouch control system. This

displays the individual maintenance steps on the boiler

screen.

With this variant the heating mode is stopped, but

the boiler remains on at the mains switch. So that

all drives are disconnected, the safety chain of the

boiler is disrupted with the maintenance switch. The

screen will display a message when it is time to actuate

the maintenance switch.

Fig. 2-4: Maintenance switch

The maintenance switch is marked with the

symbol and has two settings.

• "1" = regular operation

This is the standard position of the maintenance

switch. The boiler can execute heating mode in this

position.

• "0" = maintenance mode

In this position, all drives are disconnected to

perform maintenance. The circuit boards,

however, are still live.

Explanation of pictograms

Switch the boiler on/off with the mains

switch.

Perform a visual check of the components.

Clean the components with a soft cloth, for

example.

Remove deposits with a vacuum cleaner or

an ash vacuum.

Remove deposits with the poker.

Remove deposits with the cleaning brush.

Replace the wear parts (e.g., seals) with new

items.

Lubricate the components. The lubricant to

use is listed in the respective step.

Mount the components (e.g., screws or nuts)

by hand only, without tools.

Install the components with some force (e.g.,

the retaining tube or the Lambda probe).

Handle the components carefully, since they

break very easily.

Measure or check dimensions or clearances

on the components.

Mark the components so that the correct

position can be found, for example, when

mounting.

Wear a protective mask to avoid injuries to

the airways.

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Maintenance notes Cleaning and maintenance

Clean panels

If necessary, clean the panels of the boiler and the

ETAtouch screen with a moist cloth.

Under no circumstances use aggressive

solvents, chemicals or scouring agents. They can

lead to stress cracks and damage.

Seal the components. The sealant to use is

listed in the respective step.

Use glue to adhere the seals, for example.

Do not use compressed air to clean the

components.

Do not use cleaning brushes to clean the

components.

Do not use an ash vacuum or vacuum

cleaner.

Do not lubricate the components.

No water or moisture in this area.

Cleaning and maintenance Maintenance notes

7

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Maintenance openings in the boiler Cleaning and maintenance

2.2 Maintenance openings in the

boiler

Maintenance openings and components

The illustration shows a boiler with its fuel

discharge on the left side. The fuel discharge

depicted here is the standard configuration.

1 Combustion chamber door

2 Firebed switch (safety switch)

3 Firebed level sensor

4 Grate position switch

5 Actuator for primary air

6 Ash screw

7 Grate drive

8 Connection for measuring underpressure

9 Safety switch for rotary valve maintenance cover

10 Plug screw for lubricating the stoker drive chain

11 Turnbuckle for the stoker drive chain

12 Drop chute safety switch

13 Drop chute maintenance cover

Cleaning and maintenance Maintenance openings in the boiler

9

1 Underpressure sensor

2 Actuator for secondary air

3 Stoker drive chain

4 Ignition

5 Retaining tube of the lambda probe

6 Heat exchanger cleaning maintenance cover

7 Safety switch for the maintenance cover

8 De-ashing drive

9 Flue gas temperature sensor in heat exchanger

10 Water pressure sensor

11 Draught fan

12 Flue gas temperature sensor on flue gas

connector

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Maintenance openings in the boiler Cleaning and maintenance

1 Actuator of flue gas recirculation (optional)

2 Precipitator maintenance cover

3 Heat exchanger cover

4 Release button for safety temperature limiter

(STB)

5 Mains switch (symbol )

6 Maintenance switch (symbol )

7 Door contact switch

Cleaning and maintenance Maintenance table

11

2.3 Maintenance table

Cleaning of the boiler must be carried out at least once a year, or when requested by the control system.

Maintenance is necessary at least every 3 years, or when requested by the control system. We recommend

you perform maintenance annually.

Tasks

Regular

ly

Cleaning

annually

Maintenan

ce

at least

every 3

years

to be

performed by

Empty the ash box

• Empty the ash box

• Check the seals

X X X Customer

Check the pressure of the heating system X X X Customer

Check the safety devices

• Visual check of the safety valves

• Check operational readiness of the safety devices in the

fuel path

X X

Customer or

specialist

Chimney

• Clean the flue tube

• Flush the chimney's condensate drain

X X

Customer or

specialist

Clean the combustion chamber

• Clean inside of the secondary combustion chamber

• Clean primary and secondary combustion chamber

• Clean tilting grate

• Clean secondary air openings

• Clean the ignition tubes

• Check the firebed button and firebed switch

• Check refractory lining

X X

Customer or

specialist

Clean flue gas duct X X

Customer or

specialist

Clean the flue gas recirculation (optional)

• Check air valve for flue gas recirculation

• Clean flue gas recirculation ducts

• Check seal on the maintenance cover

X X

Customer or

specialist

Clean precipitator (optional)

• Clean the upper section of the precipitator

• Clean the flushing air opening

• Clean and inspect the electrode holder

• Check the alignment of the electrodes

X X

Customer or

specialist

Clean the draught fan X Specialist

Clean the heat exchanger

• Clean the heat exchanger

• Check the heat exchanger tubes

• Check the seal on the heat exchanger cover

X Specialist

Check the ash box position switch X Specialist

Check the air valve

• Check air valve for primary and secondary air

• Perform function test for closing the primary air supply

X Specialist

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Maintenance table Cleaning and maintenance

Check the underpressure sensor

• Clean silicon hose and connection for the underpressure

sensor

• Calibrate the underpressure sensor

X Specialist

Check de-ashing system X Specialist

Clean the temperature sensor X Specialist

Clean the lambda probe X Specialist

Check stoker

• Checking the stoker drive chain

• Check gap of the rotary valve position sensor

X Specialist

Check drop chute safety switch X Specialist

Check end position of the rotary valve X Specialist

Check boiler doors X Specialist

Calibrate the lambda probe X Specialist

Reset the maintenance counter X Specialist

Perform heating test X Specialist

Tasks

Regular

ly

Cleaning

annually

Maintenan

ce

at least

every 3

years

to be

performed by

Cleaning and maintenance Regular maintenance

13

2.4 Regular maintenance

2.4.1 Preparation

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.

2.4.2 Empty the ash box

Empty the ash box and inspect the seals

By knocking on the vertical wall of the ash box,

you can also check the ash level without opening

the box. A full ash box makes a short, dull thump.

When empty it makes a hollower sound like a drum.

To empty the ash box, fold the locking lever forwards

on the boiler. Remove the ash box from the boiler.

Fig. 2-5: Locking lever

Close the flap on the ash box.

Fig. 2-6: Flap

The ash box can be lifted on the bottom with a

handcart and transported.

Open the latch on the lid and empty the ash box.

Fig. 2-7: Lid

Check the ash for embers. Never put hot ash into

the waste bin!

If there are large pieces of slag in the ash, the

combustion chamber and the tilting grate must be

checked and the de-ashing interval reduced, if

necessary.

14 www.eta.co.at

Regular maintenance Cleaning and maintenance

Inspect the seal on the ash box lid to ensure it is in

good order, and replace it if necessary.

Fig. 2-8: Seal

Inspect the ash box seals on the boiler to ensure they

are in good order; replace them if necessary.

Fig. 2-9: Seal

Attaching the ash box to the boiler

Open the flap on the ash box.

Push the ash box over the connection on the boiler and

attach it to the boiler with the locking lever.

2.4.3 Check pressure of the heating

system

Check the heating system water pressure

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.

Fig. 2-10: Pressure gauge

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 in heating mode. The safety valve triggers

at approx. 2.8 bar.

If the water pressure drops several times a year,

contact a heating professional. When refilling

water in the heating system, the same water as used

during initial filling should be used whenever possible

(e.g., prepared water).

Cleaning and maintenance Regular maintenance

15

2.4.4 Establish operational readiness

Switching on the boiler

Switch the boiler back on with the On/Off

switch.

16 www.eta.co.at

Cleaning (customer) Cleaning and maintenance

2.5 Cleaning (customer)

2.5.1 Preparation

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.

WARNING!

Switch off the electricity to the boiler via the mains

switch

 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

Risk of burning on parts located behind the

boiler housing, even after shutting the boiler

down.

Allow the boiler to cool down sufficiently

before starting any activities.

2.5.2 Check safety devices

Checking the safety valves

Perform a visual check of all safety valves of the

heating system. The outlets of the safety valves may

not drip.

Fig. 2-11: Safety valve

If the safety valve drips, open it with a quarter turn of

the red cap and rinse it out (danger of scalding). If the

safety valve still cannot be sealed effectively after

being rinsed several times, it must be cleaned or

replaced by an installer (heating technician).

A manual check of the safety valve is carried out

with a 1/4 turn of the red cap. This rinses the

safety valve. However it is very likely that the seal will

be damaged in the process and thus the outlet will drip.

That is why you should only perform this check on

weekdays and never on weekends in cold winter, as no

heating technician may be available if the seal is

defective.

Check function of safety devices in fuel path

Check the safety devices in the fuel path, such as the

temperature-monitoring system, the manually

operated extinguishing system or the automatic extin-

guishing system.

Also check malfunction indicators and alarms, for

example if messages from the boiler room are

displayed elsewhere.

Cleaning and maintenance Cleaning (customer)

17

2.5.3 Chimney

Clean the flue tube

Sweep the flue tube from the flue outlet to the chimney

and remove flue ash from the chimney using a vacuum

cleaner.

Fig. 2-12: Flue tube

Sweep the ash into the chimney, not into the

boiler. Otherwise, ash will collect in the

fan housing and can block the draught fan.

Rinse the chimney's condensate drain

Check the chimney's condensate drain to make sure it

is free, as ash can block the outlet. To check, rinse the

outlet with some water.

Fig. 2-13: Condensate drain

2.5.4 Cleaning the combustion chamber

Clean inside of the secondary combustion

chamber

Open the combustion chamber door and scrape all of

the ash from the inside of the secondary combustion

chamber with the poker. Also remove the flue ash from

the top of the heat exchanger, for example, with an ash

vacuum.

Fig. 2-14: Secondary combustion chamber

Clean primary and secondary combustion

chamber

In the secondary combustion chamber, lift the ash rake

and remove the combustion chamber cover.

Fig. 2-15: Remove the combustion chamber cover

18 www.eta.co.at

Cleaning (customer) Cleaning and maintenance

Scrape all of the ash from the secondary combustion

chamber into the primary combustion chamber with

the poker.

Fig. 2-16: Combustion chamber

Clean tilting grate

Use the poker to clean the tilting grate and the

openings in it; let the ash fall down.

Fig. 2-17: Tilting grate

Do not hit the tilting grate with the poker.

Clean secondary air openings

Clean secondary air openings (above the tilting grate).

Fig. 2-18: Secondary air openings

Clean ignition tube

Free both ignition tubes of deposits.

Fig. 2-19: Ignition tubes

Remove the cover on the front

Remove the cover on the front of the boiler.

Fig. 2-20: Cover

Cleaning and maintenance Cleaning (customer)

19

Check firebed button and firebed switch

Check the mobility of the firebed button in the

combustion chamber by repeated lifting.

Fig. 2-21: Firebed button

The firebed switch on the front of the boiler must be

actuated when lifting.

Fig. 2-22: Firebed switch

Check refractory lining

Check the refractory lining of the primary and

secondary combustion chambers for damage and

cracks.

Replace combustion chamber cover

Reinsert the combustion chamber cover, ensuring that

it is properly centred.

Fig. 2-23: Combustion chamber cover

The convex surface of the combustion chamber

cover must point to the top of the boiler.

Mount cover on the front

Mount the cover on the front of the boiler.

Fig. 2-24: Cover

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Cleaning (customer) Cleaning and maintenance

2.5.5 Clean flue gas duct

Remove the panel on the top

Remove the panel on the top of the boiler.

Fig. 2-25: Panel

Removing the maintenance cover

Remove the insulation over the maintenance cover.

Fig. 2-26: Insulation

Remove the maintenance cover.

Fig. 2-27: Maintenance cover

Clean inner walls of the flue gas duct (only applies

to boilers without precipitator)

Clean the inner walls of the flue gas duct with the

cleaning brush.

Fig. 2-28: Flue duct

Check seal on the maintenance cover

Inspect the seal of the maintenance cover to ensure it

is in good working order, replace if necessary.

Fig. 2-29: Seal

CAUTION!

Avoid operation with damaged seals

Never operate the boiler with damaged seals.

Otherwise, leak air is sucked in, disturbing the

combustion process and causing increased wear.

 Always replace seals as soon as they are

damaged.

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eta eHACK 20-50 kW User manual

eta eHACK 20-50 kW User manual

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