eta HACK 130-200 Quick guide

2015-04-29
EN
0000000056
V.004
X.31.0
93921 Pellet suction system
for HACK
Installation, configuration and
maintenance

ETA Heiztechnik
Gewerbepark 1
A-4716 Hofkirchen an der Trattnach
Tel: [phone] / 22 88 -0
Fax: [phone] / 22 88 -22
[e-mail]
www.eta.co.at

3
Contents
1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Warranty, guarantee and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.2 Attaching carrying aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.3 Support stand pre-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.4 Pellets suction system pre-installed on boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.5 Installing the suction compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.6 Align pellet suction system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.7 Fastening the support stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.8 Mounting the pellets suction system on the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.1 Starting the configuration assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.2 Adjusting and adding function blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.3 Creating connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.4 Showing terminal assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.5 Installing a configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.1 HE-C3 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11 Concluding activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11.1 Installing side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11.2 Remove carrying aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11.3 Install bleed screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11.4 Mounting the transfer coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11.5 Mounting the conveyor pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.6 Mounting the return hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12 Cleaning and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.2 Clean the fill level sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.3 Clean the return pipe strainers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12.4 Check seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12.5 Lubricate lubricating nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12.6 Concluding activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
13 Rectifying problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4 www.eta.co.at
14 Pellet store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
14.1 Calculating pellet supply and store size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
14.2 Requirements for pellet store. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
14.2.1 No cables/pipes in the pellet store. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
14.2.2 Tilted floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
14.2.3 Filling nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14.3 Filling the storage room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
14.4 Fire safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

General information
5
1 General information
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 alterations
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 optionally available. 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 withthis safety instruction, there is
a risk of material damage.
WARNING!
On non-compliance withthis safety instruction, there is
a risk of physical injury.
DANGER!
On non-compliance withthis safety instruction, there is
a risk of major physical injury.

6 www.eta.co.at
Preface
2 Preface
Dear Customer,
Safe and satisfactory operation of the product
depends, above all, on correct installation. In this user
manual, you can find out all the important installation
steps, information and instructions for this product
beforehand.
Please take the time to look through it.
Warranty and guarantee
You should also read the "Conditions for warranty,
guarantee, liability" (see page 7) carefully. As a rule,
these conditions will be satisfied by a professional
heating technician. Nevertheless, inform the
technician of our warranty conditions. All of the re-
quirements we impose are intended to prevent
damage that neither you nor we wish to occur.
Training the customer
To avoid errors in operation, please explain to your
customer exactly how his new product works and how
it should be operated and maintained.
Extended warranty
We grant an extended warranty if the product is com-
missioned by an authorised partner company or by our
own customer service.
In this connection, please note the warranty conditions
applicable at the time of purchase.

Warranty, guarantee and liability
7
3 Warranty, guarantee and liability
Requirements
We can only accept liability for the function of our
products if they are correctly installed and operated.
This is only possible if the conditions below are
complied with.
Suitable fuel – pellets
The boiler is suitable for use with wood pellets
according to EN14961-2 class A1, EN plus class A1 or
DINplus with a diameter of 6 to 8 mm and a length of
15 to 40 mm. Operation with unsuitable fuels, in
particular those containing halogens (chlorine) or high-
slag pellets such as from grain waste, is not permitted.
Proper installation
The installing contractor is liable for proper installation
according to the corresponding installation instructions
and the relevant rules and safety regulations. If you as
customer have installed the heating system partly or
entirely without relevant training and in particular
without up-to-date practical experience, without having
the installation checked by a trained and responsible
expert, we exclude defects in our delivery and conse-
quential damages resulting from this cause from our
warranty, guarantee and liability.
Wearing parts
There is no guarantee or warranty for product
components that are labelled as wearing parts in this
document.
Repairs
Repairs are only permitted using spare parts provided
by us. The only exceptions are commonly available
standard parts such as electrical fuses or fastening
materials, provided such parts have the necessary
features and do not compromise the safety of the
system.
Repair of defects
For repairs of defects carried out by the customer or by
a third party, ETA shall only bear the costs or remain
obligated by warranty if this work was approved in
writing in advance by the customer service of ETA
Heiztechnik GmbH.

8 www.eta.co.at
Functional description
4 Functional description
Commissioning the boiler
As soon as the boiler conveys fuel after commission-
ing, the pellet bin and the drop chute are completely
emptied.
The pellet suction system opens the pellet flap to the
drop chute. When the fill level sensor of the drop chute
registers no content, the pellet flap is closed again.
The process requires 5 - 6 minutes.
During boiler operation
If the boiler requests fuel during heating, the aspirators
start and convey the pellets from the pellet store to the
pellet bin of the suction system.
If the pellet bin is full enough, the fill level sensor
reacts. The aspirator is turned off and the pellet flap to
the drop chute is opened.
The pellets fall through the drop chute onto the
discharge screw and are transported to the wood chip
boiler.
The fill level sensor reacts before the supply of pellets
in the drop chute is used up. The pellet flap is closed
again and the aspirator conveys more pellets into the
pellet bin.

Safety
9
5 Safety
WARNING!
Injuries caused by tipping parts
Possible injuries or damage caused by in-
adequately secured parts.
Secure all parts adequately against tipping.
WARNING!
Injuries caused by moving parts
Possible crushing injuries to limbs due to
improper handling of parts.
Choose a carrying position beyond the reach of
moving parts.
DANGER!
Electric shock
There are live parts on the circuit boards. If
touched, they can cause injury and
property damage.
Before beginning any work, isolate the system
completely from all power sources, ensure that it
cannot be switched back on, and verify that it is
safely isolated from supply.
CAUTION!
Flexible stranded conductors
If flexible stranded conductors are not used for the
wiring, the contacts in the plug connections will be
subjected to excessive mechanical strain. In this case,
the warranty for the electronics would become null and
void.
Only flexible stranded conductors may be used for
the wiring.

10 www.eta.co.at
Technical data
6 Technical data
Dimensions and connections
1 Connection for return pipe
2 Connections can be turned through 360° in 45°
steps
3 Connection of the conveyor pipe

Technical data
11
Pellet suction system Unit Value
Compatible boilers HACK 130-200,
HACK VR 333-350
Suitable fuel Pellets EN 14961-2,
ENplus A1
Volume of pellet bin Litres
kg 210 150
Dimensions W x D x H
(Height depends on support stand, depth on installation angle) mm 874 x 1,454 x 2,385
Total weight kg 260
Electrical power consumption kW 6
Electrical connection 400 V AC / 50 Hz / 13 A /
3P+N+PE
Conveyor pipe Value
Welded steel pipes DN 80
Minimum inside diameter 80 mm
Maximum outside diameter 88.9 mm
Maximum length 35 m
Maximum height difference 5m
Maximum number of bends 7
Minimum radius of bends 400 mm (EN 10253-1)
Return pipe Value
Welded steel pipes or PU hoses DN 100 (smooth interior
surface)
Temperature range -40 ° C to 100 ° C
Maximum length 35 m
Maximum height difference 5m
Minimum radius of bends 300 mm
Earthing Yes
Segmentation possible Yes

12 www.eta.co.at
Overview
7 Overview
Fig. 7-1: Overall view
1 Cover panel
2Cover
3 Pellet bin
4 Drop chute
5 Side panel
6 Guard plate
7 Adjustable support stand
8 Transfer coupling (pellet store)
9 Threaded rods
10 Transfer coupling
11 Circuit board carrier
Fig. 7-2: Drop chute
1 Fill level sensor of the drop chute
2 Actuator of the pellet flap
3 Pellet flap end position sensor
4 Circuit board [HE-C2]
Fig. 7-3: Cover
1 Maintenance cover
2 Fill level sensor of the pellet bin
3 Connection of the conveyor pipe
4 Connection for return pipe
5 Aspirators

Overview
13
Fig. 7-4: Transfer coupling
1 Connection of the conveyor pipe
2 Drive shaft stub for conveyor screw
3 Connection for return pipe

14 www.eta.co.at
Preparation Installation
8 Installation
Assembly and installation only by qualified
specialist personnel
The assembly and installation may be performed
by specialist personnel with the corresponding
qualifications only.
Technical illustrations
The technical illustrations in this documentation show
the pellet suction system of the HACK 200 kW wood
chip boiler (which is representative of all compatible
ETA boilers).
8.1 Preparation
Preparing the pellet store
See page 34 for details.
Determining the installation position
• We recommend installing the pellet suction system
with at least two people.
• Take the minimum clearances for maintenance
and cleaning into account, see page 10.
• Determine the positions for the connections.
The connections for the conveyor and return pipes
can be turned in 45° steps.
8.2 Attaching carrying aids
1. Remove the safety brackets from the pellet suction
system and the transport pallet.
2. Remove the 2 M10 x 25 hex screws on the bearing
plate.
3. Reattach both safety brackets with the 2 M10 x 25
hex screws.
8.3 Support stand pre-assembly
WARNING!
Injuries caused by tipping parts
Possible injuries or damage caused by in-
adequately secured parts.
Secure all parts adequately against tipping.
The required height for the support stand
depends on the ETA boiler being used.
1 Hole for HACK VR 333 - 350 kW
2 Hole for HACK 200 kW
3 Hole for HACK 110-130 kW

Installation Pellets suction system pre-installed on boiler
15
1. Select the required height and fit the M10 x 25 hex
screw with nut to the appropriate hole in the front
side of the support stand.
2. Install 2 M10 x 25 hex screws with washers and
nuts to the sides of the support stand.
3. Lift the pellet suction system far enough so that the
support stand can be positioned beneath it.
4. Attach the support stand with 2 M10 x 25 hex
screws with washers and nuts and fasten finger-
tight.
8.4 Pellets suction system pre-
installed on boiler
WARNING!
Injuries caused by moving parts
Possible crushing injuries to limbs due to
improper handling of parts.
Choose a carrying position beyond the reach of
moving parts.

16 www.eta.co.at
Pellets suction system pre-installed on boiler Installation
1. Lift the pellets suction system far enough that the
support stand swings downwards. Position and
align the pellets suction system in its installation
location.
2. Lift the pellet suction system and place the transfer
coupling into the rotary valve.
Ensure that the coupling is completely
inserted into the rotary valve.
3. Fasten the transfer coupling finger-tight on both
sides of the rotary valve with 1 M10 x 180 threaded
rod and nut on each side.

Installation Installing the suction compartment
17
8.5 Installing the suction
compartment
1. Turn the cover in 45° steps to align the suction
connection and return connection.
2. Remove the 4 M5 x 10 screws from the top of the
cover and remove the panel.
3. Connect the cables for the aspirator and the fill
level sensor with the appropriate extensions.
Find the shortest way to the [HE-C2] circuit
board and run the connection cables
downwards through this opening to the circuit
board.
4. Mount the panel with 4 M5 x 10 screws to the top
of the cover.

18 www.eta.co.at
Align pellet suction system Installation
5. Attach the lid to the pellet bin with 3 fasteners. 8.6 Align pellet suction system
1. Use a spiritlevelto check the horizontal orientation
of the cover.
2. Remove one M10 x 25 hex screw and nut from the
front side of the support stand.

Installation Fastening the support stand
19
3. Lift the pellet suction system and loosen the 2 M10
x25hexscrewsonboth sidesofthe supportstand.
4. Slide the support stand to the required height and
tighten the 2 M10 x 25 hex screws.
5. Check the horizontal orientation of the cover once
again.
8.7 Fastening the support stand
1. Fasten the support stand with 6 M10 x 25 hex
screws, nuts and washers.
2. Fasten the support stand to the floor with suitable
fasteners. The scopeof delivery includes fasteners
for concrete floors.

20 www.eta.co.at
Mounting the pellets suction system on the boiler Installation
8.8 Mounting the pellets suction
system on the boiler
On both sides of the rotary valve, tighten the 2
threaded rods and nuts on the transfer coupling.