eta ePE-K 100 kW User manual

2022-04-04
EN
0000000441
V.005
3.55.0
5208, 01
939067-002
Pellet boiler
ePE-K 100-130 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

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Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Cleaning and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Maintenance notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Maintenance openings in the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Maintenance table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Regular maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Empty the ash box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Check pressure of the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Establish operational readiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Cleaning (customer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Empty the ash box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Check pressure of the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Check safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 Removing panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.7 Cleaning the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.8 Clean flue gas ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.9 Clean precipitator (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.10 Attaching panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.11 Establish operational readiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5 Maintenance (expert) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Empty the ash box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Check pressure of the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.4 Check safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.5 Chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.6 Removing panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.7 Cleaning the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.8 Clean flue gas ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.9 Clean precipitator (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.10 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.11 Clean draught fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.12 Check air valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.13 Check underpressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.14 Check de-ashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.15 Clean temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.16 Clean lambda probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.17 Attaching panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.18 Check boiler doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.19 Check pellet hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.20 Calibrate lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.21 Establish operational readiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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General information
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,
maintenance, 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):
_________________________________________
_________________________________________
_________________________________________

Cleaning and maintenance Maintenance notes
5
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
documentation 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)

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Maintenance notes Cleaning and maintenance
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
[Maintenance] 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.
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.

Cleaning and maintenance Maintenance notes
7
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.
Wear a protective mask to avoid damage to
the airways.
Seal the components. The sealant to be
used is listed in the respective step.
Insulate the components. The insulation ma-
terial to be used is indicated in the respective
step.
Use adhesive to affix, e.g. seals.
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.
Clean the components by rinsing them with
water.
Lubricate the components or contact surfac-
es with copper paste.
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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Maintenance openings in the boiler Cleaning and maintenance
2.2 Maintenance openings in the
boiler
Maintenance openings and components
The illustrations show a boiler with the pellet
module (pellet hopper with stoker) on the left
side. These are equally representative of a boiler with
the pellet module on the right side.
1 Pellets vacuum turbine
2 Fill level sensor for pellet hopper
3 Combustion chamber door
4 Firebed switch (safety switch)
5 Vacuum sensor
6 Firebed level sensor
7 Actuator for primary air
8 Grate drive
9Ash screw
10 Grate position switch
11 Connection for negative-pressure measurement

Cleaning and maintenance Maintenance openings in the boiler
9
1 Actuator for secondary air
2 Drive chain of the dosing screw
3 Position sensor for stoker screw
4 Drive chain of the stoker screw
5 Ignition
6 Retaining tube of the lambda probe
7 Heat exchanger cleaner maintenance cover
8 Safety switch for the maintenance cover
9 De-ashing drive
10 Flue gas temperature sensor in heat exchanger
11 Water pressure sensor
12 Draught fan
13 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
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
Clean the boiler 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 Regu-
larly
Cleaning
annually
Mainte-
nance
at least ev-
ery 3 years
to be per-
formed by
Empty ash box
• Empty ash box
•Check seals
X X X Customer
Check ash box position switch XSpecialist
Check the pressure of the heating system X X X Customer
Check safety devices
• Visual check of the safety valves
• Visual check of the thermal relief valve
X X Customer or
specialist
Chimney
• Clean the flue pipe
• 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 firebed lever and firebed switch
• Check fire clay
X X Customer or
specialist
Clean flue gas ducts
• Check the air valve for flue gas recirculation
• Clean the inner walls of the flue gas duct
• Clean the flue gas recirculation ducts
• Check the seal on the maintenance cover
X X Customer or
specialist
Clean precipitator (optional)
• Clean 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 heat exchanger
• Clean the heat exchanger
• Check the heat exchanger tubes
• Check the seal on the heat exchanger cover
XSpecialist
Clean draught fan XSpecialist
Check the air valve
• Clean the area behind the primary air valve
• Check the air valve for primary and secondary air
XSpecialist

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Maintenance table Cleaning and maintenance
Check the vacuum sensor
• Clean silicon hose and connection for the vacuum sen-
sor
• Calibrate the vacuum sensor
XSpecialist
Check the de-ashing XSpecialist
Clean temperature sensor XSpecialist
Clean the lambda probe XSpecialist
Check boiler doors XSpecialist
Check the pellet hopper
• Check the stoker drive chains
• Check the clearance/gap of the position sensor for the
stoker screw
• Clean the fill level sensor
• Clean strainer
XSpecialist
Calibrating the lambda probe XSpecialist
Reset maintenance counter XSpecialist
Perform heating test XSpecialist
Tasks Regu-
larly
Cleaning
annually
Mainte-
nance
at least ev-
ery 3 years
to be per-
formed by

Cleaning and maintenance Maintenance table
13

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Preparation Regular maintenance
3 Regular maintenance
3.1 Preparation
Stop heating
Stop the heating mode of the boiler with the on / off
switch in the overview of the boiler. The boiler
emits a glowing charge and then switches to operating
mode [Switched off]. Then press the [De-ashing]
key to allow the boiler to perform a final ash removal.
3.2 Empty the ash box
Emptying the ash box and checking 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 on the
boiler forward. Remove the ash box from the boiler.
Fig. 3-1: Locking lever
Close the flap on the ash box.
Fig. 3-2: Flap

Regular maintenance Empty the ash box
15
Open the lock for the lid and empty the ash box.
Fig. 3-3: Lid
Check the ashes for pieces of 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.
Check if the seal in the lid of the ash box is intact and
replace if necessary.
Fig. 3-4: Seal
Check that the ash box seal on the boiler is intact and
replace it if necessary.
Fig. 3-5: 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
connect it to the boiler with the locking lever.

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Check pressure of the heating system Regular maintenance
3.3 Check pressure of the heating
system
Checking the heating system's 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. 3-6: 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, because water expands as the
temperature rises and the water pressure also rises 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. treated water).
3.4 Establish operational readiness
Switching on the boiler
Switch the boiler back on using the on / off
switch .

Regular maintenance Establish operational readiness
17

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Preparation Cleaning (customer)
4 Cleaning (customer)
4.1 Preparation
Stop heating
Stop the heating mode of the boiler with the on / off
switch in the overview of the boiler. The boiler
emits a glowing charge and then switches to operating
mode [Switched off]. Then press the [De-ashing]
key to allow the boiler to perform a final ash removal.
WARNING!
Switch off the electricity to the boiler via the mains
switch
Switch off the power to the boiler at 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.
4.2 Empty the ash box
Emptying the ash box and checking 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 on the
boiler forward. Remove the ash box from the boiler.
Fig. 4-1: Locking lever
Close the flap on the ash box.
Fig. 4-2: Flap

Cleaning (customer) Empty the ash box
19
Open the lock for the lid and empty the ash box.
Fig. 4-3: Lid
Check the ashes for pieces of 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.
Check if the seal in the lid of the ash box is intact and
replace if necessary.
Fig. 4-4: Seal
Check that the ash box seal on the boiler is intact and
replace it if necessary.
Fig. 4-5: 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
connect it to the boiler with the locking lever.

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Check pressure of the heating system Cleaning (customer)
4.3 Check pressure of the heating
system
Checking the heating system's 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. 4-6: 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, because water expands as the
temperature rises and the water pressure also rises 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. treated water).
4.4 Check safety devices
Check safety valves
Check all safety valves of the heating system by
means of a visual inspection. The outlets of the safety
valves must not drip.
Fig. 4-7: Safety valve
If the safety valve drips, open and rinse the safety
valve with a 1/4 turn of the red cap (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. It is however very likely that the seal will
be damaged in the process and thus the outlet will drip.
Therefore, only carry out the check on weekdays,
never on weekends in the cold winter, because there is
probably no heating technician available if the seal is
defective.