eta HACK 20 kW User manual

2017-01-09
EN
0000000295
V.002
X.38.0
3004, 3105
93528-001 Wood chip boiler
20 - 90 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]o.at
www.eta.co.at

General information
3
1 General information
Support for cleaning and maintenance
This document helps support you with the cleaning
and maintenance of the boiler. 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 boiler number (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
Boiler 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 functioning, cleaning and
maintenance must be performed at regular intervals.
Carry out this work within the intervals stated here.
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. Instructions can 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.
Explanation of pictograms
Switch the boiler on/off with the mains switch.
Perform a visual check of the components.
Clean the components, for example, with a
soft cloth.
Remove deposits with a vacuum or an ash
vacuum.
Remove deposits with the poker.
Remove deposits with the cleaning brush.
Replace the wear parts (e.g. seals) on the
components.
Lubricate the components. The lubricant to
use is listed in the respective step.
Install the components with some force (for
example the retaining tube or the Lambda
probe).
Handle the components carefully, since they
break very easily.
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.
Checking the boiler counters
The counters can be seen in the boiler's text menu.
Counter [Full load hours since maint.] is used for the
service intervals. If it has reached one of the listed
intervals, maintenance is required. This counter is in:
Counters
Full load hours since maint.

Cleaning and maintenance Maintenance notes
5

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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 a size of 2 (63
- 90 kW) with its fuel discharge on the left side.
The fuel discharge depicted here is the standard con-
figuration.
1 Combustion chamber door
2 Secondary air actuator (mirrored for fuel discharge
installed on the right)
3 Actuator for tilting grate
4 Maintenance cover for optional flue gas recircula-
tion
5 Primary air actuator (mirrored for fuel discharge
installed on the right)
6 Firebed switch (mirrored for fuel discharge
installed on the right)
7 Safety switch for rotary valve maintenance cover
8 Plug screw for lubricating the stoker drive chain
9 Turnbuckle for the stoker drive chain
10 Drop chute safety switch
11 Drop chute maintenance cover

Cleaning and maintenance Maintenance openings in the boiler
7
1 Shut-off plug for optional flue gas recirculation
2 Maintenance cover for optional flue gas recircula-
tion
3 Flue gas temperature sensor
4 Heat exchanger cleaner
5 Ignition
6 Stoker drive chain
7 Maintenance cover for optional flue gas recircula-
tion
8 Plug screw for lubricating the de-ashing system's
drive chain
9 Draught fan

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Maintenance table Cleaning and maintenance
2.3 Maintenance table
Tasks Regular
ly
Every
2500 h
or
1 year
Every
5000 h
or
3years
to be
performed by
Empty the ash box
• Remove excess ash from secondary combustion chamber
• Empty the ash box
• Check the seals
X X X Customer
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
• 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 combustion chamber
• Clean inside of the secondary combustion chamber
• Clean tilting grate
• Clean secondary air openings
• Clean the ignition tube
• Check firebed button and firebed switch
• Check refractory lining
X X Customer or
specialist
Clean heat exchanger
• Clean heat exchanger and downdraft channel
• Clean lambda probe
• Check heat exchanger tubes
• Check heat exchanger cleaner
• Check seal on heat exchanger cover
X X Customer or
specialist
Clean flue gas recirculator (optional)
• Clean flue gas recirculation piping
• Inspecting seals on maintenance covers X X Customer or
specialist
Clean the draught fan XSpecialist
Clean the temperature sensor XSpecialist
Check air valve for primary and secondary air XSpecialist
Check the ash box position switch XSpecialist
Check de-ashing system XSpecialist
Clean ignition XSpecialist
Check boiler doors XSpecialist
Check stoker
• Check 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
Calibrate the lambda probe XSpecialist

Cleaning and maintenance Maintenance table
9
Reset the maintenance counter XSpecialist
Perform heating test XSpecialist
Tasks Regular
ly
Every
2500 h
or
1 year
Every
5000 h
or
3years
to be
performed by

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Regularly Cleaning and maintenance
2.4 Regularly
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
Remove excess ash from secondary combustion
chamber
Open the combustion chamber door and use the poker
to scrape the excess ash into the combustion
chamber.
The ash in the secondary combustion chamber
may not be steeper than 45°.
To remove this ash, initiate boiler de-ashing by
pressing the [De-ash] button.
Empty the ash box, 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.
Open both lateral fasteners by pressing their safety
catches in the direction of the arrow. Remove the ash
box from the boiler.
Fig. 2-1: Fastener
Remove the lid by opening the fasteners and empty
the ash box.
Fig. 2-2: Check ash
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.