eta Pellets Compact User manual

2019-09-11
EN
0000000400
V.004
3.47.0
2803
93134-001
PelletsCompact
60-105 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
1 Heat exchanger cover
2 Fill level sensor for pellet hopper
3 Vacuum turbine for pellet transport
4 Firebed switch
5 Stoker drive chain
6 Actuator for secondary air
7Ignition
8 Maintenance cover of the combustion chamber
9 Position switch for ash box

Cleaning and maintenance Maintenance openings in the boiler
9
1 Safety valve
2 Draught fan
3 Lambda probe
4 Water pressure sensor
5 Filling and draining valve
6 Actuator for primary air
7 Drive chain for de-ashing
8 Grate drive chain

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Maintenance table Cleaning and maintenance
2.3 Maintenance table
Clean the boiler at least once per 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 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 inside of the secondary combustion chamber
• Clean the inner walls of the combustion chamber
• Clean the ignition tube
• Check the movability of the firebed switch
• Check seal on the maintenance cover
X X Customer or
specialist
Clean the draught fan XSpecialist
Clean the temperature sensor XSpecialist
Clean the heat exchanger
• Clean the topside of the heat exchanger
• Check the heat exchanger tubes
• Clean the lambda probe
• Check seal on heat exchanger cover
XSpecialist
Check the combustion chamber
• Checking the firebed lever and firebed switch
• Dismantle the ignition and clean the ignition tube
XSpecialist
Check the pellet hopper
• Clean the fill level sensor
• Clean the strainer
XSpecialist
Check the stoker unit
• Check the stoker drive chain XSpecialist
Check the drive chains
• Check the grate drive chain
• Check the de-ashing drive chain
XSpecialist
Check the air valves for primary and secondary air XSpecialist
Checking the ash box position switch XSpecialist
Calibrate the lambda probe XSpecialist
Reset the maintenance counter XSpecialist

Cleaning and maintenance Maintenance table
11
Performing a heating test XSpecialist
Tasks Regular
ly
Cleaning
annually
Maintenan
ce
at least
every 3
years
to be
performed by

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Regular maintenance Cleaning and maintenance
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 inspecting the seals
Open the boiler door and fold the locking lever on the
boiler forward. Remove the ash box from the boiler.
Fig. 2-5: Locking lever
The openings on the ash box can be closed with
the supplied cover plate. Slide the cover plate
over the openings until it snaps into place.
Fig. 2-6: Cover plate
Fig. 2-7: Cover plate locked in place
Open the lock for the lid and empty the ash box.
Fig. 2-8: Lid
Check the ashes for pieces of embers. Never put
hot ash into the waste bin!
Check if the seal in the lid of the ash box is intact and
replace if necessary.
Fig. 2-9: Seal

Cleaning and maintenance Regular maintenance
13
Check that the ash box seal on the boiler is intact and
replace it if necessary.
Fig. 2-10: Seals
Attaching the ash box to the boiler
Remove the cover plate again and store it at the boiler.
Fig. 2-11: Cover plate
Re-attach the lid to the ash box. Push the ash box over
the connection on the boiler and connect it to the boiler
with the locking lever.
Fig. 2-12: 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. 2-13: Pressure gauge
The control system gives a warning on the screen
as soon as the boiler pressure is too low. If the
boiler pressure falls below 0.8 bar or rises above 2.8
bar, the control system automatically switches the
boiler off.
Adjust the pressure of the heating system on the filling
and draining connection of the boiler.
Fig. 2-14: Filling and draining connection
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).

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Regular maintenance Cleaning and maintenance
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. 2-15: 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. 2-16: 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. 2-17: 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. 2-18: Condensate drain

Cleaning and maintenance Cleaning (customer)
17
2.5.4 Cleaning the combustion chamber
Removing the maintenance cover for the
combustion chamber
Open the boiler door.
Fig. 2-19: Boiler door
Remove the nuts on the maintenance cover and
carefully remove it too.
Fig. 2-20: Maintenance cover
Cleaning the inside of the combustion chamber
Remove the ash from the inner areas of the
combustion chamber with an ash vacuum.
Fig. 2-21: Combustion chamber
Removing the combustion chamber cover
Remove the combustion chamber cover from the
combustion chamber with the poker.
Fig. 2-22: Combustion chamber cover

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Cleaning (customer) Cleaning and maintenance
Cleaning the inner walls of the combustion
chamber
Strip off the ashes on the inner walls of the combustion
chamber and stoke them on the grate.
Fig. 2-23: Cleaning the inner walls
Cleaning the ignition tube
Clean the ignition tube by suction and carefully remove
any deposits.
Fig. 2-24: Ignition tube
Checking the movability of the firebed switch
Check the movement of the firebed lever in the
combustion chamber by repeated lifting.
Fig. 2-25: Firebed lever
Replacing the combustion chamber cover
Clean the combustion chamber cover and replace it
into the combustion chamber.
Fig. 2-26: Combustion chamber cover

Cleaning and maintenance Cleaning (customer)
19
Checking the seal on the maintenance cover
Clean the maintenance cover. Check if the seal on the
maintenance cover is intact and replace if necessary.
Fig. 2-27: Maintenance cover
CAUTION!
Do not operate with damaged seals
Never operate the boiler with damaged seals.
Otherwise, unwanted air is sucked in, disturbing the
combustion process and causing increased wear.
Always replace damaged seals immediately.
Re-attaching the maintenance cover for the
combustion chamber
Re-attach the maintenance cover. Tighten the nuts
alternately and evenly.
Fig. 2-28: Maintenance cover
2.5.5 Establish operational readiness
Switch the boiler on via the mains switch and start
ash removal
Switch the boiler back on at the mains switch. Press
the [De-ash] button for the boiler to start the de-
ashing process. Switch the boiler back on using the on
/ off switch .

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Maintenance (expert) Cleaning and maintenance
2.6 Maintenance (expert)
2.6.1 Preparation
Before this maintenance, perform all steps for the
preceding maintenance intervals
Before this maintenance, all steps for the
preceding maintenance intervals must be
performed.
WARNING!
The following activities may only be performed by
qualified specialist personnel.
If you carry out these activities without the correspond-
ing specialist training, and above all without the
required experience, safe operation is no longer
guaranteed. The resulting defects and consequential
damage are excluded from the guarantee and
warranty.
Equally an incorrect performance of these activities
can lead to serious injuries.
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.
2.6.2 Removing panels
Removing the cover
Remove the cover from the top of the boiler.
Fig. 2-29: Cover
Removing the side cover
Remove the side cover.
Fig. 2-30: Side cover