eta Twin Screw Agitator User manual

2020-09-16
EN
0000000311
V.005
X.50.0
93123-001
Twin Screw
Agitator
Operating Instructions

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

3
Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Warranty, guarantee and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7 Concluding activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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General information General
1 General
1.1 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.
Software Description
The software version described in this documentation
corresponds to the version valid at the time of publica-
tion. The software version installed on your product
may differ from that described in this documentation.
A software update to a more recent version can
always be performed. With the appropriate au-
thorisation, the required files can be found at
"www.eta.co.at".
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 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 po-
sition can be determined, for example, when
mounting.
Wear a protective mask to avoid damage to
the airways.
Seal the components. The sealant to be
used 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 stated in each step.
Tighten screws and nuts alternately and
evenly.
Do not use compressed air to clean the com-
ponents.
Do not use cleaning brushes to clean the
components.
Do not use an ash vacuum or vacuum clean-
er.
Do not lubricate the components.

General Warranty, guarantee and liability
5
1.2 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.
Observe local building and fire safety regulations
Local building and fire safety regulations must be
observed.
Suitable fuels
• Wood chips according EN ISO 17225-4:2014,
quality classes A1/A2/B1/B2, size P16S-P31S,
maximum water content 35% (M35)
• Wood pellets according EN ISO 17225-2:2014,
quality class A1, ENplus-A1
• Shavings and swarf briquets according EN
ISO 17225-3:2014, quality classes A1/A2/B
• In Germany: fuel classes 4/5a according
1. BImSchV. Use fuel classes 5/6/7/8 only after
consultation with company ETA.
Operation with unsuitable fuels, in particular high-
slag pellets from grain waste, for example, or
corrosive fuels such as miscanthus fertilised with
potassium chloride, is prohibited.
Expanding the control system
Only components provided by us may be used for
expanding the control system, unless these are
generally available standard devices, such as thermo-
stats.
Regularly perform cleaning and maintenance
Cleaning and maintaining the product is essential. The
required steps and intervals are either contained in this
documentation or included as a separate document.
Repairs
Repairs are only permitted using spare parts provided
by us. The only exceptions are common standardised
parts such as electrical fuses or fastening materials, as
long as they possess the required features and do not
restrict the functionality of the system.
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.
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.
No tampering with boiler safety devices
Boiler safety devices such as those mentioned below
must not be tampered with: Temperature monitoring
and control devices, safety temperature limiters, safety
valves and thermal discharge valves.
No water or moisture in this area.
No leaks in the components, e.g. screw con-
nection or maintenance cover.

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Technical data
2 Technical data
Fig. 2-1: Side view
Fig. 2-2: Top view

Technical data
7
Deviations from these specifications are only possible in consultation with ETA Heiztechnik GmbH.
For pellet operation, an optional conversion kit for the floor agitator and the troughs is required.
Twin Screw Agitator
Discharge Unit BG 1 BG 2 BG 2.5
Compatible boilers kW 20 - 90 89 - 220 250 - 350
Boiler cascade - maximum output kW < 700
Trough - width W mm 140 190 190
Ball joint - diameter K mm 200 200 200 / 250
Agitator for wood chips
Discharge Unit BG 1 BG 2 BG 2.5
closed trough - total length L1m< 6
Floor agitator - diameter and drive power:
with leaf spring arm
m
kW
kW
3 - 4
3 x 0.37
-
3 - 4
3 x 0.37
-
4
1 x 0.37
2 x 1.1
with articulated arm
m
kW
kW
4.5 - 5
2 x 0.37
1 x 0.55
4.5 - 5
2 x 0.37
1 x 0.55
4.5 - 5
1 x 0.55
2 x 1.1
with double articulated arm
m
kW
kW
5.5 - 6
2 x 0.37
1 x 0.55
5.5 - 6
2 x 0.37
1 x 0.55
5.5 - 6
1 x 0.55
2 x 1.1
Number of spring arms 2
Fill height H m< 5
Inclination α < 15°
Agitator for pellets
Discharge Unit BG 1 BG 2 BG 2.5
closed trough - total length L1m< 1.5
Floor agitator - Diameter D and drive power:
with leaf spring arm
m
kW
kW
3 - 4
3 x 0.37
-
3 - 4
3 x 0.37
-
4
1 x 0.37
2 x 1.1
Number of spring arms 4
Fill height H m< 2
Inclination α < 12°

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Overview
3 Overview
Twin screw agitator with articulated arm
1 Spring arms
2 Agitator with articulated arm (variants with leaf spring or double articulated arm are also possible)
3 Open trough
4 Closed trough
5 Safety switch (detects whether the maintenance cover is open or closed)
6 Maintenance cover
7 Limit switch (triggers when fuel presses against the maintenance cover from below)
8 Drop chute
9 Agitator drive
10 Drive shaft
11 Guide pipe for the drive shaft
12 Start screw (for the drop chute)
13 Conveyor screw (for the closed trough)
14 Conveyor screw (progressive, for the open trough)
15 Gearbox

Installation
9
4 Installation
Technical illustrations
The following description depicts the installation of a
twin screw agitator with articulated arm. The illustra-
tions are representative of all versions of this
discharge. The representation of boilers has been
omitted.
Assembly and installation only by qualified
specialist personnel
The assembly and installation may be performed
by specialist personnel with the corresponding
qualifications only.
Placing the gearbox in the storeroom
Position the gearbox in the storeroom in such a way
that there is still enough space to mount the drive shaft
in the direction of the wall opening. Remove the
maintenance cover on the top of the gearbox.
Fig. 4-1: Maintenance cover
Loosen the flanges for the trough on both sides so that
they can move freely.
Fig. 4-2: Flanges for trough
Mounting the drive shaft
The drive shaft is located in the guide pipe from
factory. Affix seals to the flanges.
Fig. 4-3: Seals
Grease the drive stub of the conveyor screw with
Stauffer grease.
Fig. 4-4: Drive stub
The grease protects the connection from
moisture and thus prevents rust. Therefore the
connection can easily be detached later for necessary
repair, for example.

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Installation
Check the flange on the guide pipe. The smaller flange
is attached to the gearbox. Carefully slide the drive
shaft into the gearbox.
Fig. 4-5: Drive shaft
Fasten the guide pipe to the gearbox. Tighten the
screws alternately and evenly.
Fig. 4-6: Guide pipe
Position the gearbox approximately in the middle of the
storeroom (e.g. with a lift truck). Push the guide tube
through the wall opening to the boiler room. Place a
square timber under the guide pipe as a spacer in the
wall opening.
Adjust the inclination of the gear unit using the support
stands and tighten the screws hand-tight at first.
Fig. 4-7: Support stands
Attaching the open trough
The conveyor screws are already in the troughs
from factory.
The conveyor screw in the open trough has narrower
windings in the open area than in the closed area.
Check whether the conveyor screw is correctly
inserted in the open trough.
Fig. 4-8: Conveyor screw for the open trough
The conveyor screws are already in the troughs
from factory.
Affix seals to the flanges.
Fig. 4-9: Seals
Thread the open trough through the wall opening from
the storeroom into the boiler room. Place a square
timber under the trough as a spacer in the wall
opening. The closed part of the trough must be located
in the wall opening.
Fig. 4-10: Closed part of the trough

Installation
11
Grease the drive stub of the conveyor screw with
Stauffer grease.
Fig. 4-11: Drive stub
The grease protects the connection against
moisture and thus prevents rust. Therefore the
connection can easily be detached later for necessary
repair, for example.
Attach the open trough to the gearbox.
Fig. 4-12: Open trough
Grease the bearing with Stauffer grease. Carefully
insert the conveyor screw into the bearing.
Fig. 4-13: Conveyor screw
Mount the screw and slowly pull the conveyor
screw into the bearing. Never force the conveyor
screw into the bearing. Then tighten the screw.
Fig. 4-14: Screw for securing the conveyor screw
Mount the support stand on the trough.
Fig. 4-15: Support stand

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Installation
Adjust the height of the support stand. Rotate the
support stand for fine adjustment.
Attach closed troughs
Grease the drive stub of the conveyor screw with
Stauffer grease and connect it with the existing
conveyor screw.
Make sure that the winding is continuous.
Mount the closed trough on the open trough.
Fig. 4-16: Closed trough
Attach a seal to the flange. Repeat these steps if
several troughs are to be installed.
Fig. 4-17: Seal
Installing the drop chute
Grease both drive stubs of the conveyor screw with
Stauffer grease and connect them. Make sure that the
winding is continuous.
Fig. 4-18: Start screw

Installation
13
Install the drop chute on the trough.
Fig. 4-19: Drop chute
Attach a seal to the flange.
Fig. 4-20: Seal
Lift the discharge and carefully insert the ball joint
connection into the opening of the rotary valve.
Ensure that the ball joint connection lies
completely in the rotary valve and that it closes.
Fasten the ball joint connection on the drop chute with
the threaded rods. Only hand-tighten the nuts initially.
Repeat installation for the second discharge
Mount the troughs and conveyor screws for the second
boiler in the same way.
Checking the position of the discharge
Check the position of the gearbox in the
storeroom. The gearbox must be in the middle, so
that the spring arms do not scrape the walls later.
Mounting the spring arms
Re-attach the maintenance cover on the gearbox.
Fig. 4-21: Maintenance cover

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Installation
Grease the drive stub with Stauffer grease. Carefully
place the articulated arm on the drive stub and secure
it with the screw and washer.
Fig. 4-22: Articulated arm
Mount the spring arms on the articulated arm. The
articulated arm always rotates anti-clockwise. Note the
correct alignment of the claws on the spring arms, see
the figure below.
Fig. 4-23: Spring arms
Fasten the cover plate on the articulated arm.
Fig. 4-24: Cover plate
Adjusting the spring arms
Check the alignment of all spring arms. They must be
aligned parallel to the trough and may not touch either
the trough nor the rotary plate. Turn the rotary plate
manually and check all spring arms.
Fig. 4-25: Checking the alignment
To adjust, loosen the screws on the rotary plate and
correct the alignment of the spring arm.
Fig. 4-26: Spring arm parallel to trough
CAUTION!
Damage caused by incorrect trough clearance
If the trough distance is too small, the spring arms will
brush against the trough, causing noise and damage.
If the trough clearance is too large, the spring arms can
no longer completely retract under the cover plate and
are damaged.
Set all spring arms parallel to the trough.
CAUTION!
Damage caused by fixed spring arms
If multi-part spring arms are fixed, the elements cannot
move when they meet resistance. The spring arms
thus cannot compensate for such stresses and break
off.
The spring arms are pre-assembled at the factory.
Do not tighten or loosen the connecting screws.

Installation
15
Fig. 4-27: Screws
Checking the wall distance
Turn the floor agitator by hand and check the
clearance from the storeroom walls. Then align the
floor agitator in the centre of the storeroom, so that the
wall clearance is uniform.
Finally, turn the floor agitator one full turn and check
the clearances again.
If the spring arms scrape the walls, the walls must
be protected with boards.
Checking the floor distance
Turn the discharge by hand until the end of the leaf
spring reaches the lowest point in the storeroom. The
clearance between the spring arm and the floor must
be a minimum of 10 mm.
Fig. 4-28: Floor distance
If you install a slanted floor, also take the
thickness of the boards into account.
Check if the clearance is the same for all other spring
arms and adjust them if necessary.
Adjust the height of the support stand so that the
trough is not sagging or overhanging.
Fig. 4-29: Adjusting the support stand
Fill the wall opening with mineral wool and plaster
the wall.

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Installation
Setting the inclination
Position a pallet jack or a wooden block under the
gearbox to prevent the gearbox against falling down.
Then adjust the inclination of the conveying system. All
support stands must rest completely on the ground for
later attachment.
Fig. 4-30: Support stand
Mounting the fastening for the guide pipe
At first, mount the fastening only hand-tight on the
guide pipe.
Fig. 4-31: Fastening
Check the straight alignment of the guide pipe and
then fix the fastening to the wall with suitable screws.
Then tighten all screws.
Fixing the support stands to the floor
Fix the support stands to the floor with suitable screws.
Fig. 4-32: Support stands
Installing the agitator drive
Align the drive shaft with the drive using the feather
key.
Fig. 4-33: Drive

Installation
17
Slide the drive onto the drive shaft and fasten it.
Tighten the screws alternately and evenly.
Fig. 4-34: Screws
Installing the discharge drive
Align the screw conveyor with the drive using the
feather key.
Fig. 4-35: Drive
Slide the drive onto the screw conveyor and fasten it.
Tighten the screws alternately and evenly.
Fig. 4-36: Screws
Installing the bleed screw
The gearbox is already filled with oil from factory and
closed with a plug screw. Remove this plug screw and
keep it with the gearbox in event of a return, so that oil
does not run out.
Fig. 4-37: Plug screw
Install the bleed screw in place of the plug screw.
Fig. 4-38: Bleed screw
Tightening the screws
Tighten all the screws alternately and evenly.

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Electrical connections
5 Electrical connections
Circuit diagram in the appendix
The circuit diagramm is in the appendix, see
chapter 8 "Circuit diagram".
Assembly and installation only by qualified
specialist personnel
The assembly and installation may be performed
by specialist personnel with the corresponding
qualifications only.
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.
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.
Safety devices
Observe the necessary safety devices for the heating
system. Further information about this can be found in
the boiler's installation instructions.

Configuration
19
6 Configuration
Content of this configuration
Only the steps required for the configuration of this
product are described below. The configuration of the
complete heating system is described in the "Configu-
ration" manual supplied with the boiler.
Double screw agitator
This special conveyor has 2 conveyor screws and a separate drive just for the floor agitator. The conveyor screws
are each supplied and controlled by the relevant boiler.
The extension circuit board [HE-C] is located in the wall housing of the control extension. The power supply
must be provided according to the circuit diagram supplied. In the same way all safety devices must be
integrated into the safety chain of the boiler, they are also listed in the circuit diagram.
Fig. 6-1: Twin screw agitator

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Configuration
Connections
Circuit
board Function blocks Description
HA-C 0 Boiler Wood chip boiler 1
Settings:
Fuel Set the fuel type used
Conveyor type Special conveyor
Circuit
board Function blocks Description
HA-C 1 Boiler Wood chip boiler 2
Settings:
Fuel Set the fuel type used
Conveyor type Special conveyor
Circuit
board Function blocks Description
HE-C 0 Agitator Floor agitator
[Agitator drive] with 3-phase motor
Producers Consumers
HE-C 0: Agitator: Woodchips HA-C 0: Boiler: Fuel
HA-C 1: Boiler1.1: Fuel