eta HACK 200 User manual

2015-02-06
EN
0000000135
V.002
X.29.0
93706 Flue Gas Recirculation
HACK 200 kW
Installation

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

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Contents
1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Installing the flue gas duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Adjusting the gearbox motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Installing the drive chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Adjusting the shutoff device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Installing the flue gas pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Fuel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Adjusting software parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2.1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2.2 Flue gas recirculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3 Setting the firebed level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4 Closing the flue gas recirculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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General information
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.

Functional description
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2 Functional description
Flue gas recirculation lowers the combustion
temperature in the boiler's combustion chamber.
Lowering the combustion temperature is necessary for
very dry heating material:
• Pellets
• Wood chips (water content < 15%)
• Carpentry material (water content < 15%)
• Sawdust (water content < 15%)
• Miscanthus
The combustion temperature increases significantly
with these fuels, resulting in an increased risk of slag
formation and wear in the boiler.
Recirculating the flue gas from the boiler outlet back
into the combustion chamber increases the gas flow
through the grate and the fire.
Distributing the heat over a larger gas volume reduces
the combustion temperature. This also provides a
narrower and more stable temperature range. The
result is cleaner and more complete combustion and
prevention of slag build-up in the boiler.

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Overview
3 Overview
1 Flue gas pipe
2 Turbulator
3 Flue gas duct
4 Chain protector
5Cover

Overview
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Flue gas duct
1 Hexagonal screw M5 x 12
2 M8 hexagonal nut
3 Flange bearing
4 Ceramic fibre seal
5 M8 x 235 threaded rod
6 M8 x 30 hexagonal long nut
7 Flue gas duct
8 Fibre glass seal
9 Self-locking M8 hexagonal nut
10 Hexagonal screw M8 x 35
11 Drive shaft stub
12 Guard plate
13 Rear side of the chain protector
14 Chain wheel
15 Drive chain
16 Key
17 Washer
18 Hexagonal screw M8 x 16

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Overview
Flue gas pipe
1 Hexagonal screw M5 x 16
2 Silicon foam seal
3 Insulation

Installation
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4 Installation
Switch-off the system
Isolate the system from all power sources, ensure that
it cannot be switched back on, and verify that it is
safely isolated from the power supply.
Preparations
1. Remove the precut recess onthe back wall and cut
out the insulation.
2. Remove the cover behind the recess by removing
four M8 hex nuts.
3. Glue the fibre glass seal to the flue gas duct flange
on the boiler side.

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Installing the flue gas duct Installation
4.1 Installing the flue gas duct
1. Mount the flue gas duct on the boiler with four M8
x 30 hex long nuts.
The flue pipe opening is at the top.
2.Glue the ceramic fibre seal to the flue gas
duct flange.
3. Screw the four M8 x 235 threaded rods into the
long nuts.
4. Thread the flue gas recirculation turbulator into the
flue gas duct.

Installation Adjusting the gearbox motor
11
5. Push the flange bearing onto the drive shaft stub
and fix it with four M8 hex nuts to the threaded
rods.
4.2 Adjusting the gearbox motor
1. Remove the guard plate from the drive motor by
removing two M5 x 8 round head screws.
2. Remove the M8 x 16 hex screw, the washer, the
activation plate and the short spacer from the drive
shaft stub.
3. Install the drive shaft stub of the flue gas recircula-
tion unit with an M8 x 35 hex screw and an M8 self-
locking hexagonal nut.

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Installing the drive chain Installation
4. Mount the new guard plate with two M5 x 8 round
head screws.
4.3 Installing the drive chain
1. Hand-tighten the rear of the chain protector to the
flange bearing with three M5 x 12 hex screws.
2. Make sure you insert a key in the drive shaft stub.
Grease the drive shaft stub.
3. Place the drive chain on both gears.
4. Push both gears with the drive chain onto the drive
shaft stub.
5. Mount both gears with an M8 x 16 hex screw and
washer to the drive shaft stub.

Installation Installing the drive chain
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6. Set the chain tension by raising/lowering the flue
gas duct until the drive chain has lateral play of
max. 5 mm.
7. Tighten the four M8 hex nuts on the threaded rods
and check the chain tension again.
Mounting the cover
1. Place the chain protector on the rear side of the
chain protector.
2. Mount the chain protector to the rear chain
protector with four M5 x 12 hex screws.

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Adjusting the shutoff device Installation
4.4 Adjusting the shutoff device
1. Remove the shutoff device with seal on the flue
gas duct by removing four M5 x 16 hex screws.
2. Place the seal of the shutoff device on the flange.
Rotate the shutoff device and install it with four M5
x 16 hex screws.
4.5 Installing the flue gas pipe
1. Thread the flue gas pipe into the opening of the
flue gas duct.
2. Mount the flue gas pipe on the flue gas duct with
four M5 x 16 hex screws and a silicon foam seal.

Installation Installing the flue gas pipe
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3. Seal all around the connection between the flue
gas pipe and flue gas duct with heat-resistant
silicon.
4. Mount the cover on the chain protector and boiler
with seven M5 x 12 hex screws and washers.
5. Place the insulation on the flue pipe and secure it
with aluminium adhesive tape.

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Overview Fuel change
5 Fuel change
5.1 Overview

Fuel change
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Adaptations for
HACK 200 kW
Fuel Pellets Wood chips Carpentry material Miscanthusa
a. Reduced max. output: 150 kW
Water content < 15% < 15% 15 - 25% 25 - 35% < 15% < 20%
Ash/dust content low high low high low high low high low high low high
Software parameters [Fuel] [Pellets] [Woodchips] [Woodchips] [Miscanthus]
Firebed level sensor
Position 2 4 5 4 5
De-ashing interval (boiler with buffer storage tank)
Software parameters [De-ash after min.] 140 kg 50 kg 70 kg 18 kg 70 kg 18 kg 70 kg 18 kg 35 kg 18 kg 35 kg 10 kg
[De-ash after max.] 230 kg 173 kg 155 kg 78 kg 155 kg 78 kg 155 kg 78 kg 155 kg 78 kg 80 kg 24 kg
De-ashing interval (boiler without buffer storage tank)
Software parameters [De-ash after min.] 140 kg 99 kg 70 kg 35 kg 70 kg 35 kg 70 kg 56 kg 70 kg 35 kg 35 kg 10 kg
[De-ash after max.] 230 kg 173 kg 155 kg 78 kg 155 kg 78 kg 155 kg 78 kg 155 kg 78 kg 80 kg 24 kg
Boiler with flue gas recirculation installed
Software parameters [Flue gas recirculation] [Yes] [Yes] [Yes]
(recom-
mended) [Yes] [No] [Yes] [Yes]
Flue gas recirculation status Open Open Open
(recom-
mended) Open Closed Open Open
Boiler without flue gas recirculation
Software parameters [Flue gas recirculation] [No]

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Adjusting software parameters Fuel change
5.2 Adjusting software parameters
Setting the [Service] access level
For setting some parameters, the [Service] access
level is required.
To set this access level, press [Toolbox] in the
overview screen.
Next, press [Change authorisation]. A window opens.
Enterthe password"135"and press[Log in]to confirm.
5.2.1 Fuel
Explanation [Fuel]
This parameter sets the type of fuel used. The control
system contains appropriate values for each type of
fuel, to ensure optimum combustion and ash removal.
This parameter is factory-set to [Woodchips].
Changing the parameter
Press [Boiler] to select the function block.
Press to go to the function block's text menu. The
parameter is at:
Select the parameter and press [Change].
A settings window opens:
Make your selection and press [Accept] to save.
If the fuel is set to [Pellets] or [Miscanthus], the
setting for flue gas recirculation is automatically
changed to [Yes].
If the fuel is [Woodchips], the [No] setting is made au-
tomatically.
If you know the water content and density of the
fuel you are using, you must also adjust these two
parameters. You can find them in the same submenu.
Changing the de-ashing interval
Open the settings by pressing the button in boiler
overview. A settings window will open. Select the
desired parameter in this. Enter the new value and
press [Accept] to save.
The de-ashing interval can also be changed in the
text menu. The parameters can be found under:
The de-ashing interval may only be modified after
consultation with a specialist or ETA customer
service.
5.2.2 Flue gas recirculation
Explanation of [Flue gas recirculation]
When the fuel setting is changed in the control system,
the status of the flue gas recirculation is adjusted auto-
matically.
If the fuel is set to [Pellets] or [Miscanthus], the
setting for flue gas recirculation is changed to
[Yes].
If the fuel is [Woodchips], the setting is [No].
However, if wood chips with less than 15% water
content are used, the [Yes] setting must be made
manually.
Checking the setting
The current setting can be checked in the [Boiler]
function block's text menu at:
BoilerSettings
Fuel
BoilerAsh removal
De-ash after min.
De-ash after max.
BoilerSettings
Flue gas recirculation

Fuel change Setting the firebed level sensor
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5.3 Setting the firebed level sensor
Firebed level sensor
The boiler is suitable for the combustion of wood
chips, pellets and miscanthus. Please refer to the
operating manual of the boiler for more details on fuel.
The better the fuel, the smaller the amount needed on
the tilting grate. Therefore, when the fuel is changed,
the position of the firebed level sensor must also be
changed. The sensor is behind the front cover of the
boiler.
Fig. 5-1: Firebed level sensor
The different positions for boilers with the stoker
on the left side are described below.
For a boiler with the stoker on the right, a mirror image
of these illustrations applies.
To adjust the position, loosen the screw, turn the
firebed level sensor and fix it with the screw.
5.4 Closing the flue gas recirculation
Install shutoff device
1. Remove the shutoff device with seal on the flue
gas duct by removing four M5 x 16 hex screws.
2. Place the seal of the shutoff device on the flange.
Rotate the shutoff device and install it with four M5
x 16 hex screws.

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