eta Flex User manual

2020-09-30
EN
0000000487
V.002
X.49.0
939110-001
Pellet conveyor
"Flex"
Operating Instructions

ETA Heiztechnik
Gewerbepark 1
A-4716 Hofkirchen an der Trattnach
Tel: +43 (0) 7734 / 22 88 -0
Fax: +43 (0) 7734 / 22 88 -22
www.eta.co.at

3
Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Warranty, guarantee and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Dismantling, disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Tilted floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Attaching pellet hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Pellet store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Concluding activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6 ETAtouch controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1 [Pellet store] function block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Noise emission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 Pellet store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.2 Requirements for pellet store. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.3 Calculating pellet supply and store size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.4 Filling nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.5 No cables/pipes in the pellet store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.6 Tilted floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.7 Information about pellet hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.8 Fire safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.9 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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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 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.
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 determined, for example, when
mounting.
Wear a protective mask to avoid damage to
the airways.

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 fuel
The boiler is suitable for use with wood pellets
according to EN ISO 17225-2:2014, quality class A1,
ENplus-A1. Operation with unsuitable fuels, in
particular those containing halogens (chlorine) or high-
slag pellets such as from grain waste, is not permitted.
Installation in a dry, frost-proof room
A dry, frost-proof room is required for the installation.
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.
1.3 Dismantling, disposal
Dismantling
Dismantling takes place in reverse order to the instal-
lation. Clean the components and properly dismantle
them in accordance with the local regulations for
workplace safety and environmental protection.
Disposal
Disposal including all components must be done in an
environmentally friendly manner according to waste
disposal laws. Recycle any materials that can be
recycled.
Seal the components. The sealant to be
used 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 stated in each step.
Tighten screws and 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.
No water or moisture in this area.
No leaks in the components, e.g. screw con-
nection or maintenance cover.

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Description
2 Description
Pellet Conveyor Layout
This pellet conveyor is modular and can be used for storage rooms with a maximum length of 6 m. In the plastic
channel there is a shaftless screw conveyor for low-noise operation. To avoid damage, it is not permitted to turn the
screw conveyor against the conveying direction.
1 End piece of the channel (with internal pipe)
2 Supporting part (between all channels)
3 open channel (can be shortened on site)
4 Wall duct for maximum 300 mm thick walls (can be shortened on site)
5 Fire protection sleeve (for the wall duct from the pellet store to the installation room)
6 Transfer coupling
7 Conveying system drive
8 Shaftless screw conveyor (can be shortened on site)

Description
7
The pipe for the wall duct must protrude a little on each side for the installation of the fire protection sleeve,
supporting part and the transfer coupling. This results in storeroom lengths (uncut) in 0.5 m increments. The troughs
can be shortened on site, so any storeroom length up to 6 m is possible. The following illustration shows a conveying
system with a length of 3 m. With an additional trough, the conveying system would be 0.5 m longer.
Fig. 2-1: Example: conveying system with 3 m length
The open troughs and the pipe of the wall duct can be shortened on site. This allows the length of the conveying
system to be easily and precisely adapted to an existing room. After shortening the troughs, the screw conveyor
must also be shortened accordingly.
The conveying system is placed centrally (in width) in the storeroom. A round or rectangular section is required for
the wall duct. See the following illustration.
Fig. 2-2: Required opening for the wall duct

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Note Description
2.1 Note
Installation tips for thicker walls
This pellet conveying system is designed for wall
thicknesses of up to 30 cm. For thicker walls, the fire
protection sleeve can be rotated 180° and mounted
inside the wall, provided the opening is large enough.
This is possible for walls up to 36 cm in thickness.
Fig. 2-3: Fire protection sleeve installed inside the wall
If the walls are much thicker, the duct can also be
located inside the wall. As protection against foreign
bodies in the screw conveyor (e.g., loose brickwork
crumbling down from above), the duct inside the wall
must be covered with the supplied cover plate or
something similar.
Fig. 2-4: Cover plate
Fill the cavity in the wall above the screw conveyor with
mineral wool to reduce noise. Cut the supplied metal
covers to fit over the ducts and install metal covers in
the storeroom.
Fig. 2-5: Metal covers
Storerooms with uneven floors
The conveying system is mounted horizontally in the
storeroom. Small shim plates are supplied for the
supporting parts to compensate for small differences in
height. Larger differences in height can also be
compensated for example by underlaying wooden
boards, laminated panels or formwork panels.
However, wood for the underlay may only be used in a
storeroom with a dry floor. Otherwise, the wood may
swell and cause damage.
Fig. 2-6: level out uneven flooring
Wooden boards to compensate for height differences
can also be laid longitudinally over the whole length.
With these varieties the supporting parts can be
fastened to the wooden boards, as long as they are

Description Note
9
sufficiently thick (more than 30 mm). The wooden
boards (or panels) themselves are fixed to the floor
with suitable screws.
The thickness of the wooden boards (or panels)
must be taken into account when creating the
opening for the wall duct.
Storerooms with sealed floors
If the conveying system is installed in a storeroom with
a sealed floor (i.e,. a floor in which no holes may be
drilled), then fix the supporting parts for the ducts for
example to wooden boards, laminated panels or
formwork panels, and screw these to the slanted floor.
This avoids drilling holes in the sealed floor. The
conveying system and the supporting parts are thus
"floating" in the storeroom.
Fig. 2-7: Installation example with a sealed floor
The thickness of the wooden boards (or panels)
must be taken into account when creating the
opening for the wall duct.

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Installation
3 Installation
Assembly and installation only by qualified
specialist personnel
The assembly and installation may be performed
by specialist personnel with the corresponding
qualifications only.
Creating an opening for the wall duct
Mark the required opening for the wall duct in the
middle of the storeroom width. A square or round
section can be created; see the following illustration.
Fig. 3-1: Required opening for the wall duct
The conveying system is mounted horizontally in the
storeroom. Small shim plates are supplied for the
supporting parts to compensate for small differences in
height. For larger differences in height, please refer to
chapter 2.1 "Note".
Fig. 3-2: Shim plates
Check the evenness of the floor in the storage room
before making the opening. Also check the floor level
inside and outside the storeroom. If the floor level in
the storeroom is lower than outside, this must be taken
into account when creating the opening for the wall
duct.
Once the correct position is determined, create the
opening for the wall duct.
Fig. 3-3: Position
Mounting the transfer coupling in the wall duct
In the storeroom, fix the metal cover with the supplied
window frame screws. These screws are mounted
directly in the wall without dowels. Drill a 6 mm hole in
a brick wall and a 6.5 mm hole in a concrete wall.
Fig. 3-4: Metal cover
This metal cover is not required for precise core
drilling in the wall.

Installation
11
Fasten the support stand to the transfer coupling.
Initially only hand-tighten the screws.
Fig. 3-5: Support stands
Push the pipe for the wall duct into the transfer
coupling. Slide the fire protection sleeve onto the pipe
and then the entire unit through the opening in the wall.
Fig. 3-6: Pipe and fire protection sleeve
Fill the free space between the pipe and opening
with mineral wool. This serves as sound
insulation and fire protection.
Fig. 3-7: Mineral wool
Slide the metal cover against the wall and check that it
is level. For an uneven wall, the contact surface must
be adjusted accordingly. Apply fire protection acrylate
to the metal cover so it completely seals with the wall.
Outside the storeroom, fasten the metal cover with the
supplied window frame screws.
Fig. 3-8: Metal cover
This metal cover is not required for precise core
drilling in the wall. The fire protection sleeve can
also be fixed directly into the wall with the window
frame screws (without dowels).

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Installation
Mount the fire protection sleeve to the metal cover or
to the wall using the window frame screws.
Fig. 3-9: Fire protection sleeve
Check the minimum distance of approximately 20 mm
between the fire protection sleeve and the transfer
coupling.
Fig. 3-10: Minimum gap
Adjust the height of the support stands so that the
transfer coupling is level. Fasten the support stands to
the floor with suitable screws. Only hand-tighten the
screws.
Fig. 3-11: Support stand
Installing the first supporting part in the storeroom
Measure the protruding length of the pipe from the wall
duct. A minimum of 30 mm is required. The pipe can
be shortened if there is excess length.
Fig. 3-12: Measuring the length
By shortening the pipe for the wall duct, the screw
conveyor must also be shortened. You should,
therefore, save the separated section of the duct. You
can use it as a measure to shorten the screw conveyor.
Push the first supporting part flush onto the pipe of the
wall duct. Note the correct alignment of the supporting
part, the arrow must always point to the wall duct.
Fasten the supporting part to the floor with suitable
screws. Initially only hand-tighten the screws.
Fig. 3-13: Supporting part

Installation
13
Check the horizontal alignment of the pipe of the wall
duct. If necessary, place the shim plates supplied
under the supporting part.
Fig. 3-14: Aligning the wall duct pipe horizontally
Align the supporting part horizontally as well.
Fig. 3-15: Aligning the supporting part horizontally
All supporting parts must be aligned. Therefore
measure the gap from the first supporting part to the
wall and mark this distance at the end of the
storeroom. Mark this alignment on the floor of the
storeroom (e.g. with a chalk line).
Fig. 3-16: Drawing the mark on the floor
Assembling the troughs
Carefully slide the channel into the supporting part.
Make sure that the trough completely abuts the bar (in
the middle of the supporting part).
Fig. 3-17: Trough
Slide another supporting part on at the end of the
trough. Position this supporting part on the floor using
the marking previously created.
Make sure that the supporting part is correctly
inserted into the trough. Slide your finger along
the inside of the trough towards the supporting part.
There should be no difference in height.

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Installation
Repeat these steps for all other troughs and
supporting parts. Then push all the troughs together by
hand so that there is no empty space between them.
Fig. 3-18: Pushing the troughs together
The length of the ducts can be shortened to
precisely adapt the conveying system to an
existing room. But only shorten the penultimate trough
and not the last trough section. This ensures that the
pipe in the last trough section is long enough for the
end of the screw conveyor.
Cut the penultimate trough to the appropriate length
and deburr the cut edges. Make sure you cut ‘straight’
(e.g. with a mitre saw), so that the trough in the
supporting part is again flush.
Fig. 3-19: Only shorten the penultimate trough
By shortening the trough, the screw conveyor
must also be shortened. You should therefore
save the separated section of the duct. You can use it
as a measure to shorten the screw conveyor.
If the troughs are aligned and pushed together using
the marking on the floor, fix all supporting parts hand-
tight to the floor with suitable screws. For the time
being, only tighten the screws hand-tight so that the
shim plates can still be added to align the supporting
parts.
Fig. 3-20: Fastening the supporting parts hand-tight to the
floor
If a trough has been shortened, place the last
section of the trough next to it and do not attach it
to the floor yet. This way the length of the screw
conveyor can be checked later and adjusted if
necessary.
Fig. 3-21: Last trough section

Installation
15
Align all troughs horizontally with the washers included
in the delivery scope.
Fig. 3-22: Aligning horizontally
To set this up, you can also stretch a cord
between the first and last supporting part in the
storeroom. There are slits in the supporting parts for
threading the cord, see the following illustration.
Fig. 3-23: Slits
Threading in the screw conveyor
If the pipe of the wall duct and/or the last duct
piece has been shortened, the screw conveyor
must also be shortened. This can be done outside the
storeroom or later in the storeroom.
If shortening is to take place outside the storeroom,
unpack only the last piece of the screw conveyor for
the time being. Use the cut-off pieces from the wall
duct and/or duct to determine the length for shortening
the screw conveyor. The length of the cut pieces
corresponds to the length for shortening the screw
conveyor.
Fig. 3-24: use cut-off pieces to shorten the screw conveyor
Deburr the cut end of the screw conveyor so that
it does not rub against the pipe and damage it.
Fig. 3-25: Deburring the end
Carefully unpack the rolled-up screw conveyor so
that nobody is injured and the screw conveyor is
not kinked. This is because a kinked screw conveyor
chafes through the ducts in a short time.
Fig. 3-26: Screw conveyor

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Installation
Slowly push the screw conveyor into the troughs.
Fig. 3-27: Inserting the screw conveyor
Mounting the drive
Remove the screw and washer from the drive stub of
the screw conveyor. Lubricate the drive stub with
Stauffer grease and push it into the drive.
Fig. 3-28: Screw conveyor drive stub
Secure the screw conveyor with the screw and washer
and attach the drive to the transfer coupling.
Fig. 3-29: Drive
Tighten the screws on the support stand of the transfer
coupling.
Fig. 3-30: Support stand
Checking the length of the screw conveyor
Check that the screw conveyor at the last channel
extends about 130 mm into the closed pipe. This
distance is necessary for the mounting of the screw
conveyor and for quiet operation of the conveying
system.
Fig. 3-31: Checking the correct distance

Installation
17
If the distance is larger, the screw conveyor must be
shortened at the end.
Fig. 3-32: Shortening the screw conveyor
Deburr the cut end of the screw conveyor so that
it does not rub against the pipe and damage it.
Fig. 3-33: Deburring the end
If the gap is correct, thread the last trough section onto
the screw conveyor.
Fig. 3-34: Correct distance
Screwing all supporting parts to the floor
Position the last supporting part using the marking on
the floor. Align the duct horizontally in the longitudinal
and transverse directions with the washers.
Fig. 3-35: Longitudinal direction
Fig. 3-36: Transverse direction
Fasten the last supporting part to the floor with suitable
screws and tighten it.
Fig. 3-37: Supporting part

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Tilted floor Installation
Finally, tighten all screws on the supporting parts
evenly.
Fig. 3-38: Fastening the supporting parts
3.1 Tilted floor
Creating a slanted floor
Create the substructure for the slanted floor. A slope of
40° is sufficient.
Fig. 3-39: Required slope
Further information on the slanted floor can also be
found in chapter 8.6 "Tilted floor".
Fig. 3-40: Substructure
Let the slanted floor rest against the supporting
parts and troughs. The integrated seal on the
troughs then compensates for any unevenness.
Fig. 3-41: Slanted floor

Installation Tilted floor
19
The slanted floor can be attached to the supporting
parts. See the following illustration.
Fig. 3-42: Fastening the slanted floor to the supporting part
Installing a cover plate for the slanted floor
If there is a cavity at the end of the conveying system,
the cover plate from the delivery scope can be used to
close the cavity.
Fig. 3-43: Cover plate
Fasten the cover plate to the slanted floor with suitable
screws.
Fig. 3-44: Fastening the cover plate
A cover plate is also included in the delivery scope for
the front area (for the wall duct). If necessary, the
length of the plate can be shortened.

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Attaching pellet hoses Installation
3.2 Attaching pellet hoses
Note instructions about laying pellet hoses
When laying the pellet hoses, take note of the
comments; see 8.7 "Information about pellet
hoses".
Mounting fire protection sleeves (if required)
If the pellet hoses from the storeroom are routed
over a fire section (for example a room in-
between) to the boiler room, fire protection sleeves
must be fitted over both pellet hoses. In wall ducts, a
fire protection sleeve must be mounted on each side,
with ceiling ducts only positioned on the ceiling side.
Fig. 3-45: Fire protection sleeve
Use the concrete screws supplied to fasten the fire
protection sleeve. These screws are screwed directly
into the wall by pre-drilling, but without dowels.
In the event of a fire, the internal material of the fire
protection sleeve expands, and thus closes the pellet
hoses. So burn-back is prevented in rooms through
which the pellet hoses are fed.
CAUTION!
The copper wires must have good contact with the
connections for the pellet hoses.
Otherwise the hoses will not be earthed with the boiler
and there is a risk of electrostatic charge build-up.
Remove the paint or the coating from both pellet
hose connections.
Mounting the pellet hoses on the transfer coupling
On the ends of both pellet hoses, free around 5 cm of
the copper wire strands from the hoses. Bend the
copper wire strand inside the pellet hose.
Fig. 3-46: Copper wire strands
Push the two pellet hoses onto the connections and
secure them with hose clamps. The connection to the
transfer coupling for the pellet drop chute hose can be
freely selected.
Fig. 3-47: Mounting the pellet hoses
Attaching the pellet hoses to the boiler
On the ends of both pellet hoses, free around 10 cm of
the copper wire strands from the hoses.
Fig. 3-48: Exposing the copper wire
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