eta BG 1 User manual

2020-03-12
EN
0000000381
V.003
X.47.0
93118-002
Intermediate Conveyor Screw
Operating Instructions

ETA Heiztechnik
Gewerbepark 1
A-4716 Hofkirchen an der Trattnach
Tel: [phone] / 22 88 -0
Fax: [phone] / 22 88 -22
[email protected]
www.eta.co.at

3
Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Warranty, guarantee and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 Concluding activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 Rectifying problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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General information General
1 General
1.1 General information
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.
Software Description
The software version described in this documentation
corresponds to the version valid at the time of publica-
tion. The software version installed on your product
may differ from that described in this documentation.
A software update to a more recent version can
always be performed. With the appropriate au-
thorisation, the required files can be found at
"www.eta.co.at".
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 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.
Tighten the components (e.g., screws or
nuts) with a tool.
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 po-
sition can be found, for example, when
mounting.
Wear a protective mask to avoid injuries to
the airways.
Seal the components. The sealant to use is
listed in the respective step.
Use adhesive to affix the seals, for example.
Only blow out the components with your
mouth.
Affix a seal. The required cross-section and
sealing material are given at each step.
Tighten the screws or nuts alternately and
evenly.
Do not use compressed air to clean the com-
ponents.
Do not use cleaning brushes to clean the
components.
Do not use an ash vacuum or vacuum clean-
er.
Do not lubricate the components.

General Warranty, guarantee and liability
5
1.2 Warranty, guarantee and liability
Requirements
We can only accept liability for the function of our
products if they are correctly installed and operated.
This is only possible if the conditions below are
complied with.
Observe local building and fire safety regulations
Local building and fire safety regulations must be
observed.
Suitable fuels
• Wood chips according EN ISO 17225-4:2014,
quality classes A1/A2/B1/B2, size P16S-P31S,
maximum water content 35% (M35)
• Wood pellets according EN ISO 17225-2:2014,
quality class A1, ENplus-A1
• Shavings and swarf briquets according EN
ISO 17225-3:2014, quality classes A1/A2/B
• In Germany: fuel classes 4/5a according
1. BImSchV. Use fuel classes 5/6/7/8 only after
consultation with company ETA.
Operation with unsuitable fuels, in particular high-
slag pellets from grain waste, for example, or
corrosive fuels such as miscanthus fertilised with
potassium chloride, is prohibited.
Expanding the control system
Only components provided by us may be used for
expanding the control system, unless these are
generally available standard devices, such as thermo-
stats.
Regularly perform cleaning and maintenance
Cleaning and maintaining the product is essential. The
required steps and intervals are either contained in this
documentation or included as a separate document.
Repairs
Repairs are only permitted using 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.
Proper installation
The installing contractor is liable for proper installation
according to the corresponding 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 conse-
quential damages resulting from this cause from our
warranty, guarantee and liability.
Repair of defects
For repairs of defects carried out by the customer or by
a third party, ETA shall only bear the costs or remain
obligated by warranty if this work was approved in
writing in advance by the customer service of ETA
Heiztechnik GmbH.
No tampering with boiler safety devices
Boiler safety devices such as those mentioned below
must not be tampered with: Temperature monitoring
and control devices, safety temperature limiters, safety
valves and thermal discharge valves.
No water or moisture in this area.
No leaks in the components, e.g. screw con-
nection or maintenance cover.

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Technical data
2 Technical data
Fig. 2-1: Side view
Fig. 2-2: Top view

Technical data
7
For pellet operation, a conversion kit for the floor agitator is required. Deviations from these specifications are
only possible in consultation with ETA Heiztechnik GmbH.
Discharge Unit BG 1 BG 2 BG 2.5 BG 3
Trough - width W mm 140 190 230
Ball joint - diameter K1mm 200 250
compatible boilers:
eHACK kW 20 - 80 100 - 170 180 - 240
HACK VR kW 250 333 - 350 500
Intermediate Conveyor Screw Unit BG 1 BG 2 BG 2.5 BG 3
Trough - width W mm 140 190 230
Ball joint - diameter K2mm 200 250
Drive power kW 0.37 1.1 1.5
closed trough:
Total length L2(for wood chips) m< 6 < 8 < 10
Total length L2 (for pellets) m< 3
Inclination β (for wood chips) < 30° / 40° a
Inclination β (for pellets) < 15°
a. with an optional conversion kit for the trough

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Overview
3 Overview
Intermediate conveyor screw with drop chute
1 Drop chute
2 Maintenance cover
3 Safety switch (detects whether the maintenance cover is open or closed)
4 Limit switch (triggers when fuel presses against the maintenance cover from below)
5 Drop chute lower part (with light barriers)
6 Closed trough
7 Conveyor screw (for drop chute lower part)
8 Conveyor screw (for the closed trough)

Installation
9
4 Installation
Assembly and installation only by qualified
specialist personnel
The assembly and installation may be performed
by specialist personnel with the corresponding
qualifications only.
Installing support stands
Mount the both support stands on the lower part of the
drop chute.
Fig. 4-1: Support stands
Assembling the light barrier
Screw the transmitter (as well as the receiver) of the
light barrier into the mounting plate. Only hand-tighten
the lock nut initially.
Fig. 4-2: Transmitter/receiver in the mounting plate
Only install the transmitter and receiver hand-tight on
the lower part of the drop chute.
Fig. 4-3: Light barrier in lower part of drop chute
There is no defined mounting side for the
transmitter and receiver of the light barrier.
Check the position of the transmitter and receiver. The
curvature of the lens must overhang on the inside so
that it is cleaned by the falling fuel.
Fig. 4-4: Correct position
If the lens protrudes further into the interior, dust
can accumulate and thus interfere with the
function of the light barrier. If the curvature of the lens
protrudes too far, twist the transmitter (or receiver) out
of the mounting plate accordingly and fix it in the
correct position with the lock nut. Then carefully tighten
all screws.

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Installation
Mounting the trough on the lower part of the drop
chute
Affix a seal to the flange.
Fig. 4-5: Seal
Grease the drive stub of the conveyor screw with
Stauffer grease and connect it with the existing
conveyor screw.
The grease protects the connection from
moisture and thus prevents rust. Therefore the
connection can easily be detached later for necessary
repair, for example.
Fig. 4-6: Conveyor screw
Make sure that the thread is continuous.
Fig. 4-7: Continuous thread
Mount the closed trough on the lower part of the drop
chute.
Fig. 4-8: Closed trough
Attach a seal to the flange. Repeat these steps if
several troughs are installed.
Fig. 4-9: Seal
Mounting the drop shaft for the start of the inter-
mediate screw
The drop chute from the delivery scope of the in-
termediate conveyor screw is always mounted on
the lower part of the drop chute, i.e. always at the start
of the intermediate conveyor screw. See the following
graphic.

Installation
11
The drop chute from the delivery scope of the
discharge (e.g. from floor agitator) is mounted on the
boiler rotary valve.
Fig. 4-10: Drop chute from the delivery scope of the interme-
diate screw
Grease both drive stubs of the conveyor screw with
Stauffer grease and connect them. Make sure that the
thread is continuous.
Fig. 4-11: Start screw
Install the drop chute on the trough.
Fig. 4-12: Drop chute
Attach a seal to the flange.
Fig. 4-13: Seal
Lift the discharge and carefully insert the ball joint
connection into the opening of the drop chute lower
part.
Ensure that the ball joint lies completely within the
lower part of the drop chute and that it closes.

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Installation
Fasten the ball joint connection to the drop chute with
the threaded rods. Only hand-tighten the nuts initially.
Fig. 4-14: Threaded rod
Installing the drop chute
Grease both drive stubs of the conveyor screw with
Stauffer grease and connect them. Make sure that the
winding is continuous.
Fig. 4-15: Start screw
Install the drop chute on the trough.
Fig. 4-16: Drop chute
Attach a seal to the flange.
Fig. 4-17: Seal
Lift the discharge and carefully insert the ball joint
connection into the opening of the rotary valve.
Ensure that the ball joint connection lies
completely in the rotary valve and that it closes.

Installation
13
Fasten the ball joint connection on the drop chute with
the threaded rods. Only hand-tighten the nuts initially.
Adjusting the support stands
As soon as the end position and alignment of the inter-
mediate conveyor screw has been determined, adjust
the support stands. They must rest completely on the
ground for later attachment.
Fig. 4-18: Support stands
Installing the discharge drive
Align the screw conveyor with the drive using the
feather key.
Fig. 4-19: Drive
Slide the drive onto the screw conveyor and fasten it.
Tighten the screws alternately and evenly.
Fig. 4-20: Screws
Installing the bleed screw
The gearbox is already filled with oil from factory and
closed with a plug screw. Remove this plug screw and
keep it with the gearbox in event of a return, so that oil
does not run out.
Fig. 4-21: Plug screw

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Installation
Install the bleed screw in place of the plug screw.
Fig. 4-22: Bleed screw
Mounting the support stands on the floor
Fix the support stands to the floor with suitable screws.
Fig. 4-23: Support stands
The support stands can be extended by the
customer. The lower part of the drop chute can
also be suspended from the ceiling.
Tightening the screws
Tighten all the screws alternately and evenly.

Electrical connections
15
5 Electrical connections
Circuit diagram in the appendix
The circuit diagramm is in the appendix, see
chapter 9 "Circuit diagram".
Assembly and installation only by qualified
specialist personnel
The assembly and installation may be performed
by specialist personnel with the corresponding
qualifications only.
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.
DANGER!
Electric shock
There are live parts on the circuit boards. If
touched, they can cause injury and
property damage.
Before beginning any work, isolate the system
completely from all power sources, ensure that it
cannot be switched back on, and verify that it is
safely isolated from supply.
CAUTION!
Flexible stranded conductors
If flexible stranded conductors are not used for the
wiring, the contacts in the plug connections will be
subjected to excessive mechanical strain. In this case,
the warranty for the electronics would become null and
void.
Only flexible stranded conductors may be used for
the wiring.
Safety devices
Observe the necessary safety devices for the heating
system. Further information about this can be found in
the boiler's installation instructions.
Establishing a CAN bus connection
Establish the CAN-bus connection between the boiler
circuit boards and the optional wall mounted boxes.
For details, see document "CAN-Bus Connetions
- Installation" (93969)

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Example 1 Configuration
6 Configuration
Content of this configuration
Only the steps required for the configuration of this
product are described below. The configuration of the
complete heating system is described in the "Configu-
ration" manual supplied with the boiler.
6.1 Example 1
Floor agitator with one intermediate conveyor screw
Configuration
Circuit
board Function blocks Description
HA-C 0 Boiler Wood chip boiler
Settings:
Fuel Set the used fuel type
Conveyor type: Special conveyor To regulate the special conveyor
Circuit
board Function blocks Description
HE-C 0 Special conveyor Intermediate conveyor screw (=floor agita-
tor)
Settings:
Motor rated output See drive type plate
Options:
Light barrier in drop chute The light barrier is included in the delivery
scope
Connections
Producers Consumers
HE-C 0: SpConv: Woodchips HA-C 0: Boiler: Fuel

Configuration Example 2
17
6.2 Example 2
Floor agitator with intermediate conveyor screws
Configuration
Circuit
board Function blocks Description
HA-C 0 Boiler Wood chip boiler
Settings:
Fuel Set the used fuel type
Conveyor type: Special conveyor To regulate the special discharge.
The intermediate conveyor screw
mounted on the stoker is controlled by
the boiler.
Circuit
board Function blocks Description
HE-C 0 Special conveyor Intermediate conveyor screw (between agi-
tator and intermediate conveyor screw on
stoker)
Settings:
Motor rated output See drive type plate
Options:
Light barrier in drop chute The light barrier is included in the delivery
scope
Consumers and producers Because the intermediate conveyor
screw conveys the fuel from the floor
agitator to the next intermediate conveyor
screw on the stoker.

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Example 2 Configuration
HE-C 0 Special conveyor Floor agitator (=SpConv2)
Settings:
Motor rated output See drive type plate
Options:
Light barrier in drop chute The light barrier is included in the delivery
scope
Circuit
board Function blocks Description
Connections
Producers Consumers
HE-C 0: SpConv 2: Woodchips HE-C 0: SpConv: Fuel
HE-C 0: SpConv: Woodchips HA-C 0: Boiler: Fuel

Concluding activities
19
7 Concluding activities
Check the drive connection data in the control
system
Check the connection data of the drive based on the
settings in the control system. The connection data is
listed on the name plate of the motor.
The parameters for the drive of the boiler are shown in
the text menu of the respective function block [Boiler]:
The parameters for all further drive components are
shown in the text menu of the respective function block
[SpConv]:
Checking the drive's direction of rotation
Mark the drive by drawing a line over the screw,
washer and drive.
Fig. 7-1: Marking
In the function block of the boiler, switch to the inputs
and outputs menu. Select the stoker unit [Stoker unit]
and press the button for manual operation. Only
start the discharge drive with the [Fwd] button.
Fig. 7-2: Menu for manual operation
Check the direction of rotation of the drive with the aid
of the marking. The correct rotation direction is shown
in the following diagram.
If the rotation direction is not correct, check the drive's
electrical connection.
Fig. 7-3: Correct direction of rotation
Checking the direction of rotation of all other
drives
In the same way (as described before), check the
correct direction of rotation for all other drives.
Switch to the special conveyor function block and start
manual operation in the inputs and outputs menu.
Outputs
Stoker unit
Intermediate conveyor screw
Current
Max. current
NominCurr
Outputs
Motor rated output
Outputs
Conveying system
Current
Max. current
NominCurr

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Rectifying problems
8 Rectifying problems
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.
Cleaning the light barrier
If the discharge does not convey any fuel or if the
control indicates the "light barrier dirty" error, the
light barrier in the drop chute must be checked and
cleaned.
Remove the maintenance cover to reach the internal
space.
Fig. 8-1: Maintenance cover
Perform a visual check. Possibly a foreign body or a
long piece of wood has become wedged in the drop
chute. Remove it if required.
Fig. 8-2: Visual check
Use a soft cloth to clean the lenses of the light barrier
transmitter and receiver.
Fig. 8-3: Lenses