eta Hack 200 kW User manual

2018-05-16
EN
0000000299
V.005
3.43.0
3308
93710-001 Wood chip boiler
200 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):
_________________________________________
_________________________________________
_________________________________________

4 www.eta.co.at
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.
Explanation of pictograms
Clean panels
If necessary, clean the panels of the boiler and the
ETAtouch screen with a moist cloth.
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)withnew
items.
Lubricate the components. The lubricant to
use is listed in the respective step.
Mountthecomponents (e.g.,screwsornuts)
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.
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
5
Under no circumstances use aggressive
solvents, chemicals or scouring agents.They can
lead to stress cracks and damage.

6 www.eta.co.at
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 Secondary air actuator (mirrored for fuel discharge
installed on the right)
3 Drive for tilting grate (mirrored for fuel discharge
installed on the right)
4 Position switch for ash bins
5 Primary air actuator (mirrored for fuel discharge
installed on the right)
6 Firebed switch (mirrored for fuel discharge
installed on the right)
7 Drop chute safety switch
8 Drop chute maintenance cover

Cleaning and maintenance Maintenance openings in the boiler
7
1 Shut-off plug for optional flue gas recirculation
2 Flue gas temperature sensor
3 Heat exchanger cleaner (on both sides)
4 Release button for safety temperature limiter
(STB)
5 Frequency converter
6 Ignition
7 Stoker drive chain
8 Plug screw for lubricating the de-ashing system's
drive chain
9 Drive chain for optional flue gas recirculation
10 Draught fan

8 www.eta.co.at
Maintenance table Cleaning and maintenance
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
that you perform maintenance annually.
Tasks Regular
ly Cleaning
annually
Maintenan
ce
at least
every 3
years
to be
performed by
Empty the ash bins
• Remove excess ash from secondary combustion
chamber
• Empty the ash bins
• 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
• 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 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 the heat exchanger
• Clean heat exchanger and downdraft channel
• Clean the lambda probe
• Check the heat exchanger tubes
• Check heat exchanger cleaner
• Clean the housing of the frequency converter
• Inspect seals on heat exchanger covers
X X Customer or
specialist
Clean the flue gas recirculation (optional)
• Clean flue gas recirculation piping
• Lubricate the flue gas recirculation drive chain X X Customer or
specialist
Clean the draught fan XSpecialist
Clean the temperature sensor XSpecialist
Check air valve for primary and secondary air XSpecialist
Lubricate the grate drive XSpecialist
Check ash bin position switches XSpecialist
Check de-ashing system XSpecialist
Clean ignition XSpecialist
Check boiler doors XSpecialist

Cleaning and maintenance Maintenance table
9
Check stoker
• Check 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
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

10 www.eta.co.at
Regular maintenance Cleaning and maintenance
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 bins
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 ash bins, check seals
The sight glass can be used to check the fill level
of the ash bins without opening them.
Fig. 2-1: Sight glass
To remove the ash bins, pull the lever on the side
towards the ash bins to release them. Remove the ash
bins from the boiler.
Close the covers in the ash bin lids and fasten them
with the wing nuts.
Fig. 2-2: Covers

Cleaning and maintenance Regular maintenance
11
Open the fasteners on the lids and empty the ash bins.
Fig. 2-3: 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.
Inspect the seal in the ash bin lids to ensure it is in
good order, and replace if necessary.
Fig. 2-4: Seal
Inspect the ash bin seals on the boiler to ensure they
are in good order, replace them if necessary.
Fig. 2-5: Seal
Attach the ash bins to the boiler
Reattach the cover to the ash bins and secure with the
fasteners. Then re-open the covers in the lids.
Fig. 2-6: Covers
Push the ash bins over the connections on the boiler
and attach to the boiler with the lever.
Fig. 2-7: Attach the ash bins to the boiler with the lever

12 www.eta.co.at
Regular maintenance Cleaning and maintenance
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. 2-8: 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).
2.4.4 Establish operational readiness
Switching on the boiler
Switch the boiler back on with the On/Off
switch.

Cleaning and maintenance Cleaning (customer)
13
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 the boiler
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. 2-9: 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.

14 www.eta.co.at
Cleaning (customer) Cleaning and maintenance
Checking the thermal relief valve
Visually examine the thermal relief valve. The outlet
should not drip.
Fig. 2-10: Thermally actuated drain valve
If the relief valve is dripping, rinse it by pressing the red
button (risk 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.
A manual check of the relief valve is carried out
by pressing the red button. This rinses the relief
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.
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. 2-11: 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. 2-12: Condensate drain

Cleaning and maintenance Cleaning (customer)
15
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 secondary combustion chamber into
the primary combustion chamber with the poker.
Fig. 2-13: Secondary combustion chamber
Remove both halves of the combustion chamber cover
from the secondary combustion chamber.
Fig. 2-14: Combustion chamber cover
Clean tilting grate
The tilting grate cannot be rotated by hand. Therefore,
press the [De-ash] button to de-ash the boiler. The
grate is tilted and remains in this position for approxi-
mately 15 seconds.
WARNING!
Danger of crushing due to tilting grate
When the grate is tilted, switch off the boiler with
the mains switch. This causes the grate to remain
in this position so injuries while cleaning the grate
are prevented.
Use the poker to clean the tilting grate and the
openings in it; let the ash fall down.
Fig. 2-15: Tilting grate
Do not hit the tilting grate with the poker.
Clean secondary air openings
Clean secondary air openings (above the tilting grate).
Fig. 2-16: Secondary air openings

16 www.eta.co.at
Cleaning (customer) Cleaning and maintenance
Clean ignition tubes
Check the ignition tube for combustion residues and
clean it by vacuuming.
Fig. 2-17: Ignition tubes
Remove the cover on the front
Remove the screws for securing the cover. Push the
cover on the front up slightly, detach and remove it.
Fig. 2-18: Cover
Check firebed button and firebed switch
Check the mobility of the firebed button in the
combustion chamber by repeated lifting.
Fig. 2-19: Firebed button
The firebed switch on the front of the boiler must be
actuated when lifting.
Fig. 2-20: Firebed switch

Cleaning and maintenance Cleaning (customer)
17
Mount cover on the front
Mount the cover on the front of the boiler.Also re-install
the screws for securing the cover.
Fig. 2-21: Cover
Check refractory lining
Check the refractory lining of the primary and
secondary combustion chambers for damage and
cracks.
Replace the combustion chamber cover
Replace both halves of the combustion chamber
cover. Ensure that they are properly centred.
Fig. 2-22: Combustion chamber cover
The convex surface of the combustion chamber
cover must point to the top of the boiler.
2.5.5 Cleaning the heat exchanger
Remove heat exchanger cover
Remove the insulating lid on the top of the boiler.
Fig. 2-23: Insulating cover
Loosen the knurled nuts on the heat exchanger cover
by turning them anti-clockwise and rotate the
ball knobs by 180°.
Fig. 2-24: Knurled nuts and ball knobs
Remove the heat exchanger cover.
Fig. 2-25: Heat exchanger cover

18 www.eta.co.at
Cleaning (customer) Cleaning and maintenance
Remove internal cover
Detach the internal cover's retaining bracket. By
loosening the wing nuts and turning the retaining
bracket upwards.
Fig. 2-26: Locking
Loosen the screws on the internal cover's retaining
tabs and turn the tabs away from the cover. Than
remove the internal cover from the heat exchanger.
Fig. 2-27: Internal cover
Clean heat exchanger and downdraft channel
Brush out the downdraft channel and remove the flue
ash from the heat exchanger, for example with an
ash vacuum.
Fig. 2-28: Heat exchanger and downdraft channel
Clean lambda probe
Vacuum out the head of the lambda probe using a
vacuum cleaner. Do not dismantle the lambda probe.
Fig. 2-29: Head of the lambda probe
Insert internal cover
Check the ceramic seal on the internal cover and
replace it if necessary.
Fig. 2-30: Seal

Cleaning and maintenance Cleaning (customer)
19
Replace the internal cover, ensuring that it is
positioned properly. Fasten the retaining tabs in place
and secure the internal cover with the retaining
bracket.
Fig. 2-31: Internal cover
Fig. 2-32: Locking
Check heat exchanger tubes
Check the heat exchanger tubes and the turbulators
for tar deposits.
Fig. 2-33: Heat exchanger tubes
Tar deposits can have several causes, for
example:
• leak air through the heat exchanger cover, the
combustion chamber door or the lambda probe.
• an incorrectly calibrated lambda probe
• overly moist wood chips
• insufficient boiler runtime (start-stop operation)
Check heat exchanger cleaner
Remove the covers on both sides of the boiler.
Fig. 2-34: Cover
Fig. 2-35: Cover

20 www.eta.co.at
Cleaning (customer) Cleaning and maintenance
Manually operate the lever and check its ease of
movement on both sides of the boiler. Lubricate the
spring, guide and bearing with a heat-resistant
lubricant.
Fig. 2-36: Lever
Check the gap between the sensor and the spring arm
on both sides of the boiler. It must be 2 mm.
Fig. 2-37: Position sensor
Clean the housing of the frequency converter
Clean dust and dirt from the frequency converter
housing.
Fig. 2-38: Frequency converter
Attach covers
Re-install the covers on both sides of the boiler.
Fig. 2-39: Cover
Fig. 2-40: Cover