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: [phone] / 22 88 -0
Fax: [phone] / 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 andthe 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 displayamessage whenitis timetoactuate
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 boilercan 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.
Replacethewearparts(e.g.,seals)with new
items.
Lubricate the components. The lubricant to
use is listed in the respective step.
Mountthecomponents(e.g.,screwsor nuts)
by hand only, without tools.
Installthecomponentswithsomeforce(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 XSpecialist
Clean the heat exchanger
• Clean the heat exchanger
• Check the heat exchanger tubes
• Check the seal on the heat exchanger cover
XSpecialist
Check the ash box position switch XSpecialist
Check the air valve
• Check air valve for primary and secondary air
• Perform function test for closing the primary air supply XSpecialist

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Maintenance table Cleaning and maintenance
Check the underpressure sensor
• Cleansilicon hoseandconnection for theunderpressure
sensor
• Calibrate the underpressure sensor
XSpecialist
Check de-ashing system XSpecialist
Clean the temperature sensor XSpecialist
Clean the lambda probe XSpecialist
Check stoker
• Checking the stoker drive chain
• Check gap of the rotary valve position sensor XSpecialist
Check drop chute safety switch XSpecialist
Check end position of the rotary valve XSpecialist
Check boiler doors XSpecialist
Calibrate the lambda probe XSpecialist
Reset the maintenance counter XSpecialist
Perform heating test XSpecialist
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.

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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.

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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
boilerhousing,evenafter shutting theboiler
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

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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.