eta ePE-K User manual

2019-07-10
EN
0000000453
V.002
3.47.0
5300, 00
939076-001
Pellet boiler
ePE-K 140-170 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 and the details can be viewed at
any time. So you can maintain a long-term overview of
the maintenance carried out. Of course, the
maintenance can also be carried out using the service
guide, without the support of the ETAtouch control
system.
To access maintenance, switch to settings in the boiler
function block ( [Settings] button) and then select
the function [Maintenance].
Fig. 2-1: Overview (example)
You can also access this overview by pressing
the maintenance switch. Also when the message
appears that maintenance of the boiler is required.
In the overview the different maintenance intervals are
listed in the upper area. This includes the maintenance
already carried out. With the button, information
about the selected maintenance is displayed.
Maintenance that you can carry out as an end
customer is labelled with the symbol. All others are
reserved for specialists and require authorisation.
Press the button to start the maintenance. The
individual steps are displayed on the screen. You can
switch to the next or the previous screen respectively
with the arrow keys on the left and right side of the
screen.
Fig. 2-2: Maintenance step (example)

Cleaning and maintenance Maintenance notes
5
Follow the on-screen instructions and carry out all
steps carefully. Enter your name at the end of
maintenance ( button) and save the maintenance
with the button.
Fig. 2-3: End of maintenance
To end maintenance prematurely, press the right
arrow key several times until you get to the end.
There you can end the maintenance with the
button. Cancellation during a maintenance step is not
possible.
Explanation of the maintenance switch
The maintenance switch on the boiler is needed for
performing maintenance with the aid of the [Main-
tenance] function in the ETAtouch control system. This
displays the individual maintenance steps on the boiler
screen.
With this variant the heating mode is stopped, but
the boiler remains on at the mains switch. So that
all drives are disconnected, the safety chain of the
boiler is disrupted with the maintenance switch. The
screen will display a message when it is time to actuate
the maintenance switch.
Fig. 2-4: Maintenance switch
The maintenance switch is marked with the
symbol and has two settings.
•"1" = regular operation
This is the standard position of the maintenance
switch. The boiler can execute heating mode in this
position.
•"0" = maintenance mode
In this position, all drives are disconnected to
perform maintenance. The circuit boards,
however, are still live.
Explanation of pictograms
Switch the boiler on/off with the mains
switch.
Perform a visual check of the components.
Clean the components with a soft cloth, for
example.
Remove deposits with a vacuum cleaner or
an ash vacuum.
Remove deposits with the poker.
Remove deposits with the cleaning brush.
Replace the wear parts (e.g., seals) with new
items.
Lubricate the components. The lubricant to
use is listed in the respective step.
Mount the components (e.g., screws or nuts)
by hand only, without tools.
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
position can be found, for example, when
mounting.

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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.
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
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.
No leaks in the components, e.g. screw
connection or maintenance cover.

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 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 Firebed level sensor
6 Grate drive
7 Actuator for primary air
8Ash screw
9 Grate position switch
10 Connection for underpressure measurement
11 Vacuum sensor

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 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
• Visual check of the thermal relief valve
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 the inside of the secondary combustion chamber
• Clean the primary and secondary combustion chamber
• Clean the tilting grate
• Clean the secondary air openings
• Clean the ignition tubes
• Check the 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 the 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 heat exchanger cover
XSpecialist
Check the ash box position switch 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 the silicon hose and connection for the vacuum
sensor
• Calibrate the vacuum sensor
XSpecialist
Check the de-ashing system XSpecialist
Clean the temperature sensor XSpecialist
Clean the lambda probe XSpecialist
Check the 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 the strainer
XSpecialist
Calibrate the lambda probe XSpecialist
Reset the maintenance counter XSpecialist
Perform a 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
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-ash] key
to allow the boiler to perform a final ash removal.
2.4.2 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. 2-5: Locking lever
Close the flap on the ash box.
Fig. 2-6: Flap
Open the lock for the lid and empty the ash box.
Fig. 2-7: 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. 2-8: Seal

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Regular maintenance Cleaning and maintenance
Check that the ash box seal on the boiler is intact and
replace it 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
connect it to the boiler with the locking lever.
2.4.3 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. 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, 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).
2.4.4 Establish operational readiness
Switching on the boiler
Switch the boiler back on using the on / off
switch .

Cleaning and maintenance Cleaning (customer)
15
2.5 Cleaning (customer)
2.5.1 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-ash] 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 electricity to the boiler via the mains
switch. This prevents injuries caused by switching
the boiler on inadvertently.
WARNING!
Burns caused by hot parts
Risk of burning on parts located behind the
boiler housing, even after shutting the boiler
down.
Allow the boiler to cool down sufficiently
before starting any activities.
2.5.2 Check safety devices
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. 2-11: 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 techni-
cian).
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.

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Cleaning (customer) Cleaning and maintenance
Checking the thermal relief valve
Visually check the thermal relief valve. The outlet must
not drip.
Fig. 2-12: Thermally actuated relief valve
If the relief valve drips, press the red button to rinse the
valve (danger of scalding). If the relief valve still cannot
be closed tightly after being rinsed several times, it
must be cleaned by an installer (heating technician) or
replaced.
Press the red button to manually check the relief
valve. This rinses the relief 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.
2.5.3 Chimney
Clean flue tube
Sweep the flue duct from the flue outlet to the chimney
and remove the fly ash from the chimney with an ash
vacuum cleaner.
Fig. 2-13: Flue duct
Only sweep the ash into the chimney and 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. 2-14: Condensate drain

Cleaning and maintenance Cleaning (customer)
17
2.5.4 Cleaning the combustion chamber
Cleaning the inside of the combustion chamber
Open the combustion chamber door and use the poker
to scrape off the ash from the inner surfaces of the
combustion chamber.
Fig. 2-15: Combustion chamber
Cleaning the primary and secondary combustion
chamber
In the primary combustion chamber remove the two-
part combustion chamber cover.
Fig. 2-16: Combustion chamber cover
Using the poker, stoke all the ash out of the primary
combustion chamber into the secondary combustion
chamber.
Fig. 2-17: Combustion chamber
Do not vacuum the ash at the outer edge or under
the combustion chamber cover. This is because
there is a ceramic fibre fleece in this area, which is
otherwise removed by vacuuming.
Fig. 2-18: Ceramic fibre fleece

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Cleaning (customer) Cleaning and maintenance
Cleaning the tilting grate
Clean the tilting grate as well as the openings in the
tilting grate with the poker. Allow the ash to fall down.
Fig. 2-19: Tilting grate
Do not hit the tilting grate with the poker.
Cleaning the secondary air openings
Clean the opening for the secondary air (above the
tilting grate) with an ash vacuum, for example.
Fig. 2-20: Secondary air openings
Cleaning the ignition tubes
Clean both ignition tubes by suction and carefully
remove any deposits.
Fig. 2-21: Ignition tubes
Remove the cover on the front
Remove the cover from the front of the boiler.
Fig. 2-22: Cover

Cleaning and maintenance Cleaning (customer)
19
Checking the firebed lever and firebed switch
Check the movement of the firebed lever in the
combustion chamber by repeated lifting.
Fig. 2-23: Firebed lever
The firebed switch on the front of the boiler must be
actuated when lifting.
Fig. 2-24: Firebed switch
Check fire clay
Check the fire clay in the primary and secondary
combustion chamber for damage and cracks.
Replacing the combustion chamber cover
Re-install the two-part combustion chamber cover
again and ensure that it is centred.
Fig. 2-25: Combustion chamber cover
The convex surface of the combustion chamber
cover must point to the top of the boiler.
Mounting the cover on the front
Mount the cover on the front of the boiler.
Fig. 2-26: Cover

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Cleaning (customer) Cleaning and maintenance
2.5.5 Clean flue gas ducts
Remove the cover on the top
Remove the cover from the top of the boiler.
Fig. 2-27: Cover
Checking the air valve for flue gas recirculation
Actuate the air valve actuator manually and check that
it moves smoothly.
Fig. 2-28: Actuator of flue gas recirculation
For manual actuation, push the unlocking device (red
button) and turn the drive 90° with the locking screw.
Fig. 2-29: Manually actuating the actuator
If the actuator is difficult to move, remove it.
Fig. 2-30: Actuator
Clean the PTFE sealing washer on the air valve or
replace it if damaged.
Fig. 2-31: PTFE sealing washer
Clean the sealing area for the air valve on the inside of
the flue duct.
Fig. 2-32: Sealing area