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eta PE-K Service Manual
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eta PE-K Service Manual

Pellet boiler 105-140 kw
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2017-01-09
EN
0000000310
V.002
X.38.0
3204
93218-001
PE-K Pellet Boiler
105-140 kW
Service manual

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Summary of Contents for eta PE-K

  • Page 1 2017-01-09 0000000310 V.002 X.38.0 3204 93218-001 PE-K Pellet Boiler 105-140 kW Service manual...
  • Page 2 ETA Heiztechnik Gewerbepark 1 A-4716 Hofkirchen an der Trattnach Tel: +43 (0) 7734 / 22 88 -0 Fax: +43 (0) 7734 / 22 88 -22 info@eta.co.at www.eta.co.at...

  • Page 3: General Information

    Commissioned by (company): _________________________________________ _________________________________________ _________________________________________ 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.

  • Page 4: Cleaning And Maintenance

    Remove deposits with a vacuum or an ash vacuum. Remove deposits with the poker. Remove deposits with the cleaning brush. Replace the wear parts (e.g. seals) on the components. Lubricate the components. The lubricant to use is listed in the respective step. www.eta.co.at...
  • Page 5 Cleaning and maintenance Maintenance notes...
  • Page 6 Drive for tilting grate (mirrored for pellet hopper on the right side) Maintenance cover for flue gas recirculation Primary air actuator (mirrored for pellet hopper on the right side) Firebed switch (mirrored for pellet hopper on the right side) www.eta.co.at...
  • Page 7 Cleaning and maintenance Maintenance openings in the boiler Maintenance cover for flue gas recirculation Flue gas temperature sensor Heat exchanger cleaner Frequency converter Fill level sensor in pellet hopper Ignition Stoker drive chains Maintenance cover for flue gas recirculation Plug screw for lubricating the de-ashing system's drive chain 10 Draught fan...

  • Page 8: Maintenance Table

    Specialist Check boiler doors Specialist Check the stoker unit Specialist • Check the stoker drive chains Clean ignition Specialist Check the pellet hopper • Clean the fill level sensor Specialist • Clean the strainer Calibrate the lambda probe Specialist www.eta.co.at...
  • Page 9 Cleaning and maintenance Maintenance table Every Every Regular 2500 h 5000 h to be Tasks performed by 1 year 3 years Reset the maintenance counter Specialist Perform heating test Specialist...
  • Page 10 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. Close the covers on the ash box and fasten them with the wing nuts. Fig. 2-2: Covers www.eta.co.at...
  • Page 11 Cleaning and maintenance Regularly Open the fasteners on the lid and empty the ash box. Inspect the integrity of the ash box seals on the boiler, replace them if necessary. Fig. 2-5: Seal Fig. 2-3: Check ash Attaching the ash box to the boiler Reattach the cover of the ash box and secure with the If there are large pieces of slag in the ash, the fasteners.
  • Page 12 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. www.eta.co.at...
  • Page 13 Cleaning and maintenance 2500 h / annually 2500 h / annually 2.5.2 Check safety devices Checking the safety valves 2.5.1 Preparation Perform a visual check of all safety valves of the heating system. The outlets of the safety valves may Stop heating not drip.
  • Page 14 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. Fig. 2-11: Condensate drain www.eta.co.at...
  • Page 15 Cleaning and maintenance 2500 h / annually 2.5.4 Cleaning the combustion chamber Use the poker to clean the tilting grate and the openings in it; let the ash fall down. 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.
  • Page 16 Fig. 2-19: Firebed switch Fig. 2-17: Cover Mount cover on the front Mount the cover on the front of the boiler. Also re-install the screws for securing the cover. Fig. 2-20: Cover www.eta.co.at...
  • Page 17 Cleaning and maintenance 2500 h / annually 2.5.5 Cleaning the heat exchanger Check refractory lining Check the refractory lining of the primary and secondary combustion chambers for damage and Remove heat exchanger cover cracks. Open the maintenance cover in the top of the boiler casing and remove the insulating cover.
  • Page 18 Check heat exchanger tubes Check the heat exchanger tubes and the turbulators for tar deposits. Fig. 2-26: Heat exchanger and downdraft channel After cleaning, replace the internal cover. Ensure that it is firmly seated. Fig. 2-28: Heat exchanger tubes www.eta.co.at...
  • Page 19 Cleaning and maintenance 2500 h / annually Tar deposits can have several causes, for Clean the housing of the frequency converter example: Clean dust and dirt from the frequency converter • leak air through the heat exchanger cover, the housing. combustion chamber door or the lambda probe.
  • Page 20 Fig. 2-35: Insulating cover Fig. 2-33: Heat exchanger cover Turn the ball knobs by 180° to secure the heat exchanger covers. Then tighten the knurled nuts evenly and alternately by turning them clockwise. Fig. 2-34: Knurled nuts and ball knobs www.eta.co.at...
  • Page 21 Cleaning and maintenance 2500 h / annually 2.5.6 Clean flue gas recirculator Clean flue gas recirculation piping Brush out the pipes of the flue gas recirculation with Remove the maintenance cover for flue gas recir- the brush and remove the ash with a vacuum cleaner. culation Remove the two maintenance covers for the flue gas recirculation from the back side of the boiler.
  • Page 22 Otherwise, leak air is sucked in, disturbing the combustion process and causing increased wear.  Always replace seals as soon as they are damaged. Re-install maintenance cover. Re-install all maintenance covers for flue gas recircu- lation. Fig. 2-42: Maintenance cover www.eta.co.at...
  • Page 23 Cleaning and maintenance 2500 h / annually 2.5.7 Establish operational readiness Switch the boiler on via the mains switch and start de-ashing. Establish the boiler's power supply at the mains switch. Press the [De-ash] button to de-ash the boiler. Switch the boiler back on with the On/Off switch.
  • Page 24 Replace the seal on the draught fan. Allow the boiler to cool down sufficiently before starting any activities. Fig. 2-46: Clean impeller; replace seal www.eta.co.at...
  • Page 25 Cleaning and maintenance 5000 h / 3 years 2.6.3 Clean temperature sensor Lubricate the screws with heat-resistant lubricant and reattach the draught fan to the fan housing. Tighten the screws evenly. The plug connection must point to the Clean the flue gas temperature sensor right when viewed from behind the boiler.
  • Page 26 Fig. 2-50: Manual operation of actuator Set screw Manually operate both air valve actuators and check their movement. Release button If there is resistance in the movement of the air valves, lubricate only with dry lubricant (e.g. PTFE spray). Fig. 2-49: Air valve actuators www.eta.co.at...
  • Page 27 Cleaning and maintenance 5000 h / 3 years 2.6.5 Lubricate the grate drive 2.6.6 Check ash box position switch Lubricate the grate drive Check the ash box position switch Lubricate the drive gear teeth of the tilting grate with Inspect the function of the ash box position switch. It heat-resistant grease or copper paste.
  • Page 28 Adjustment requires the removal of the combustion chamber door. To do so, open the combustion chamber door, lift it slightly, remove it and carefully place it next to the boiler. Closing roller mount Hinge www.eta.co.at...
  • Page 29 Cleaning and maintenance 5000 h / 3 years 2.6.9 Check stoker unit Loosen the flange nuts (top and bottom) on the hinge and the closing roller mount and evenly make the gap to the boiler a bit smaller. Remove hopper panel Remove the panel on the top of the pellet hopper by unscrewing the screws.
  • Page 30 Check the stoker drive chains Check the chain tension. The chain may sag by 2-3 cm without any force applied. Tension the chain by shifting the motor. Lubricate the drive chains with chain spray. Fig. 2-63: Photocell Fig. 2-61: Stoker drive chains www.eta.co.at...
  • Page 31 Cleaning and maintenance 5000 h / 3 years 2.6.11 Check pellet hopper Also clean the opening in the boiler for the ignition tube. Clean the fill level sensor Detach the mounting panel of the fill level sensor by loosening the round-headed screws. Fig.
  • Page 32 Make sure the installation position is correct. Fig. 2-68: Mounting the panel for the fill level sensor Re-install hopper panel Fig. 2-70: Panel Re-install the side panels on the boiler. Fig. 2-71: Panel Fig. 2-69: Panel www.eta.co.at...
  • Page 33 Cleaning and maintenance 5000 h / 3 years 2.6.12 Calibrate lambda probe 2.6.13 Establish operational readiness Calibrating the lambda probe Reset maintenance counter The boiler's built-in lambda probe checks the When maintenance is complete, reset the counter. residual oxygen content of the flue gas and uses With the [Service] access level, it will be visible in the it to control the combustion.
  • Page 34 5000 h / 3 years Cleaning and maintenance After the heating test, switch the boiler back to normal mode. To do this, press the [Deactivate measurement] button in the settings window. www.eta.co.at...
  • Page 35 Cleaning and maintenance 5000 h / 3 years...
  • Page 36 Check heat exchanger cleaner • Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean flue gas recirculator • Clean flue gas recirculation piping • Inspecting seals on maintenance covers performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 37 Records Cleaning (customer) Cleaning (customer) Cleaning is to be carried out once a year or after 2500 hours. Tasks Notes Empty the ash box • Remove excess ash from secondary combustion chamber • Empty the ash box • Check the seals Check the pressure of the heating system _________ bar Check safety devices...
  • Page 38 Clean the temperature sensor Check air valve for primary and secondary air Lubricate the grate drive Check the ash box position switch Check de-ashing system Check boiler doors Check the stoker unit • Check the stoker drive chains Clean ignition www.eta.co.at...
  • Page 39 Records Maintenance (expert) Tasks Notes Check the pellet hopper • Clean the fill level sensor • Clean the strainer Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 40 Check heat exchanger cleaner • Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean flue gas recirculator • Clean flue gas recirculation piping • Inspecting seals on maintenance covers performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 41 Records Cleaning (customer) Cleaning (customer) Cleaning is to be carried out once a year or after 2500 hours. Tasks Notes Empty the ash box • Remove excess ash from secondary combustion chamber • Empty the ash box • Check the seals Check the pressure of the heating system _________ bar Check safety devices...
  • Page 42 Clean the temperature sensor Check air valve for primary and secondary air Lubricate the grate drive Check the ash box position switch Check de-ashing system Check boiler doors Check the stoker unit • Check the stoker drive chains Clean ignition www.eta.co.at...
  • Page 43 Records Maintenance (expert) Tasks Notes Check the pellet hopper • Clean the fill level sensor • Clean the strainer Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 44 Check heat exchanger cleaner • Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean flue gas recirculator • Clean flue gas recirculation piping • Inspecting seals on maintenance covers performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 45 Records Cleaning (customer) Cleaning (customer) Cleaning is to be carried out once a year or after 2500 hours. Tasks Notes Empty the ash box • Remove excess ash from secondary combustion chamber • Empty the ash box • Check the seals Check the pressure of the heating system _________ bar Check safety devices...
  • Page 46 Clean the temperature sensor Check air valve for primary and secondary air Lubricate the grate drive Check the ash box position switch Check de-ashing system Check boiler doors Check the stoker unit • Check the stoker drive chains Clean ignition www.eta.co.at...
  • Page 47 Records Maintenance (expert) Tasks Notes Check the pellet hopper • Clean the fill level sensor • Clean the strainer Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 48 Check heat exchanger cleaner • Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean flue gas recirculator • Clean flue gas recirculation piping • Inspecting seals on maintenance covers performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 49 Records Cleaning (customer) 3.11 Cleaning (customer) Cleaning is to be carried out once a year or after 2500 hours. Tasks Notes Empty the ash box • Remove excess ash from secondary combustion chamber • Empty the ash box • Check the seals Check the pressure of the heating system _________ bar Check safety devices...
  • Page 50 Clean the temperature sensor Check air valve for primary and secondary air Lubricate the grate drive Check the ash box position switch Check de-ashing system Check boiler doors Check the stoker unit • Check the stoker drive chains Clean ignition www.eta.co.at...
  • Page 51 Records Maintenance (expert) Tasks Notes Check the pellet hopper • Clean the fill level sensor • Clean the strainer Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 52 Check heat exchanger cleaner • Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean flue gas recirculator • Clean flue gas recirculation piping • Inspecting seals on maintenance covers performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 53 Records Cleaning (customer) 3.14 Cleaning (customer) Cleaning is to be carried out once a year or after 2500 hours. Tasks Notes Empty the ash box • Remove excess ash from secondary combustion chamber • Empty the ash box • Check the seals Check the pressure of the heating system _________ bar Check safety devices...
  • Page 54 Clean the temperature sensor Check air valve for primary and secondary air Lubricate the grate drive Check the ash box position switch Check de-ashing system Check boiler doors Check the stoker unit • Check the stoker drive chains Clean ignition www.eta.co.at...
  • Page 55 Records Maintenance (expert) Tasks Notes Check the pellet hopper • Clean the fill level sensor • Clean the strainer Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 56 Check heat exchanger cleaner • Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean flue gas recirculator • Clean flue gas recirculation piping • Inspecting seals on maintenance covers performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 57 Records Cleaning (customer) 3.17 Cleaning (customer) Cleaning is to be carried out once a year or after 2500 hours. Tasks Notes Empty the ash box • Remove excess ash from secondary combustion chamber • Empty the ash box • Check the seals Check the pressure of the heating system _________ bar Check safety devices...
  • Page 58 Clean the temperature sensor Check air valve for primary and secondary air Lubricate the grate drive Check the ash box position switch Check de-ashing system Check boiler doors Check the stoker unit • Check the stoker drive chains Clean ignition www.eta.co.at...
  • Page 59 Records Maintenance (expert) Tasks Notes Check the pellet hopper • Clean the fill level sensor • Clean the strainer Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 60 Check heat exchanger cleaner • Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean flue gas recirculator • Clean flue gas recirculation piping • Inspecting seals on maintenance covers performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 61 Records Cleaning (customer) 3.20 Cleaning (customer) Cleaning is to be carried out once a year or after 2500 hours. Tasks Notes Empty the ash box • Remove excess ash from secondary combustion chamber • Empty the ash box • Check the seals Check the pressure of the heating system _________ bar Check safety devices...
  • Page 62 Clean the temperature sensor Check air valve for primary and secondary air Lubricate the grate drive Check the ash box position switch Check de-ashing system Check boiler doors Check the stoker unit • Check the stoker drive chains Clean ignition www.eta.co.at...
  • Page 63 Records Maintenance (expert) Tasks Notes Check the pellet hopper • Clean the fill level sensor • Clean the strainer Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
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