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eta Hack 200 kW Service Manual
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eta Hack 200 kW Service Manual

Wood chip boiler
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2018-05-16
EN
0000000299
V.005
3.43.0
3308
93710-001
Wood chip boiler
200 kW
Service manual

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Summary of Contents for eta Hack 200 kW

  • Page 1 2018-05-16 0000000299 V.005 3.43.0 3308 93710-001 Wood chip boiler 200 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

    No water or moisture in this area. Remove deposits with a vacuum cleaner or an ash vacuum. Clean panels Remove deposits with the poker. If necessary, clean the panels of the boiler and the ETAtouch screen with a moist cloth. www.eta.co.at...
  • Page 5 Cleaning and maintenance Maintenance notes Under circumstances aggressive solvents, chemicals or scouring agents. They can lead to stress cracks and damage.
  • Page 6 Drop chute safety switch Drive for tilting grate (mirrored for fuel discharge Drop chute maintenance cover installed on the right) Position switch for ash bins Primary air actuator (mirrored for fuel discharge installed on the right) www.eta.co.at...
  • Page 7 Cleaning and maintenance Maintenance openings in the boiler Shut-off plug for optional flue gas recirculation Flue gas temperature sensor Heat exchanger cleaner (on both sides) Release button for safety temperature limiter (STB) Frequency converter Ignition Stoker drive chain Plug screw for lubricating the de-ashing system's drive chain Drive chain for optional flue gas recirculation 10 Draught fan...

  • Page 8: Maintenance Table

    Clean the draught fan Specialist Clean the temperature sensor Specialist Check air valve for primary and secondary air Specialist Lubricate the grate drive Specialist Check ash bin position switches Specialist Check de-ashing system Specialist Clean ignition Specialist Check boiler doors Specialist www.eta.co.at...
  • Page 9 Cleaning and maintenance Maintenance table Maintenan Cleaning Regular to be Tasks at least performed by annually every 3 years Check stoker • Check the stoker drive chain Specialist • Check gap of the rotary valve position sensor Check drop chute safety switch Specialist Check end position of the rotary valve Specialist...

  • Page 10: Regular Maintenance

    Close the covers in the ash bin lids and fasten them The ash in the secondary combustion chamber with the wing nuts. may not be steeper than 45°. To remove this ash, initiate boiler de-ashing by pressing the [De-ash] button. Fig. 2-2: Covers www.eta.co.at...
  • Page 11 Cleaning and maintenance Regular maintenance Open the fasteners on the lids and empty the ash bins. Inspect the ash bin seals on the boiler to ensure they are in good order, replace them if necessary. Fig. 2-5: Seal Attach the ash bins to the boiler Fig.
  • 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 Cleaning (customer) Cleaning (customer) 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. End the boiler's heating mode with the On/Off switch in the boiler overview window.
  • 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. 2-12: Condensate drain www.eta.co.at...
  • Page 15 Cleaning and maintenance Cleaning (customer) 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 The firebed switch on the front of the boiler must be Remove the cover on the front actuated when lifting. Remove the screws for securing the cover. Push the cover on the front up slightly, detach and remove it. Fig. 2-20: Firebed switch Fig. 2-18: Cover www.eta.co.at...
  • Page 17 Cleaning and maintenance Cleaning (customer) 2.5.5 Cleaning the heat exchanger Mount cover on the front Mount the cover on the front of the boiler. Also re-install the screws for securing the cover. Remove heat exchanger cover Remove the insulating lid on the top of the boiler. Fig.
  • Page 18 Do not dismantle the lambda probe. Fig. 2-27: Internal cover Fig. 2-29: Head of the lambda probe Insert internal cover Check the ceramic seal on the internal cover and replace it if necessary. Fig. 2-30: Seal www.eta.co.at...
  • Page 19 Cleaning and maintenance Cleaning (customer) Replace the internal cover, ensuring that it is Tar deposits can have several causes, for positioned properly. Fasten the retaining tabs in place example: and secure the internal cover with the retaining • leak air through the heat exchanger cover, the bracket.
  • Page 20 Check the gap between the sensor and the spring arm Attach covers on both sides of the boiler. It must be 2 mm. Re-install the covers on both sides of the boiler. Fig. 2-37: Position sensor Fig. 2-39: Cover Fig. 2-40: Cover www.eta.co.at...
  • Page 21 Cleaning and maintenance Cleaning (customer) Inspect seals on heat exchanger covers Turn the ball knobs by 180° to secure the heat exchanger covers. Then tighten the knurled nuts Inspect the integrity of the seals on the heat exchanger evenly and alternately by turning them clockwise. covers and replace if necessary.
  • Page 22  Always replace seals as soon as they are damaged. Fig. 2-45: Shut-off plug Re-install the shut-off plug. Clean the pipe of the flue gas recirculation with downward strokes of a brush. Fig. 2-46: Pipe www.eta.co.at...
  • Page 23 Cleaning and maintenance Cleaning (customer) Lubricate the flue gas recirculation drive chain Re-install the chain protector and the cover. Remove the cover and the chain protection. Fig. 2-48: Cover Fig. 2-49: Chain protector Lubricate the drive chain with chain spray. Fig.
  • Page 24 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. www.eta.co.at...
  • Page 25 Cleaning and maintenance Maintenance (expert) Maintenance (expert) 2.6.2 Clean draught fan Clean the draught fan 2.6.1 Preparation Unplug the power supply and remove the draught fan from the boiler by removing the wing screws. Before this maintenance, perform all steps for the preceding maintenance intervals Before this maintenance, all steps for the preceding...
  • Page 26 To clean, loosen the screw and pull out the flue gas temperature sensor. Clean the sensor with a soft cloth and then re-install it. When fixing the temperature sensor in place, only tighten the screw hand-tight so as not to damage the sensor. Fig. 2-54: Flue gas temperature sensor www.eta.co.at...
  • Page 27 Cleaning and maintenance Maintenance (expert) 2.6.4 Check air valve For manual operation, push the release button (red button) and manually turn the actuator through 90° with the set screw. Remove the cover on the front Remove the screws for securing the cover. Push the cover on the front up slightly, detach and remove it.
  • Page 28 They must be actuated when the ash bin is attached to the boiler. Fig. 2-58: Drive and gear teeth Fig. 2-60: Position switch Mount cover on the front Mount the cover on the front of the boiler. Also re-install the screws for securing the cover. Fig. 2-59: Cover www.eta.co.at...
  • Page 29 Cleaning and maintenance Maintenance (expert) 2.6.7 Check de-ashing 2.6.8 Clean ignition Lubricating the de-ashing drive chain Clean ignition fan and photocell On the rear of the boiler, remove the plug screw from Remove the ignition fan from the boiler. the cover next to the de-ashing drive. Fig.
  • Page 30 Fig. 2-66: Seal Also check if the sealing cord is already "hard". To check, press on the sealing cord with your finger nail. If it can no longer be pressed, it is "hard" already and must be replaced. www.eta.co.at...
  • Page 31 Cleaning and maintenance Maintenance (expert) Adjustment requires the removal of the combustion Tighten the flange nuts. Attach the door and check chamber door. To do so, open the combustion whether it closes fully. If not, repeat the process. chamber door, lift it slightly, remove it and carefully place it next to the boiler.
  • Page 32 Lubricate the drive chain with chain spray. Fig. 2-69: Cover Check the tension of the stoker drive chain. The chain may sag by 1 - 2 cm without effort. Fig. 2-72: Lubricate drive chain Fig. 2-70: Stoker drive chain www.eta.co.at...
  • Page 33 Cleaning and maintenance Maintenance (expert) 2.6.11 Inspect safety switch on the drop Check gap of the rotary valve position sensor chute Check the gap between the screw in the gear and the sensor. The gap should be about 1 - 2 mm. Check the contact switch on the drop chute Check the contact switch on the drop chute.
  • Page 34 [Yes], either the sensor is faulty or the gap between the screw in the gear and the sensor is too large and must be adjusted. The gap should be about 1 - 2 mm. www.eta.co.at...
  • Page 35 Cleaning and maintenance Maintenance (expert) 2.6.13 Calibrate lambda probe 2.6.14 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 36 Maintenance (expert) 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 37 Cleaning and maintenance Maintenance (expert)
  • Page 38 Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean the flue gas recirculation (optional) • Clean flue gas recirculation piping • Lubricate the flue gas recirculation drive chain performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 39 Records Cleaning (customer) Cleaning (customer) Cleaning of the boiler must be carried out at least once a year, or when requested by the control system. Tasks Notes Empty the ash bins • Remove excess ash from secondary combustion chamber • Empty the ash bins •...
  • Page 40 Check air valve for primary and secondary air Lubricate the grate drive Check ash bin position switches Check de-ashing system Clean ignition Check boiler doors Check stoker • Check the stoker drive chain • Check gap of the rotary valve position sensor www.eta.co.at...
  • Page 41 Records Maintenance (expert) Tasks Notes Check drop chute safety switch Check end position of the rotary valve Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 42 Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean the flue gas recirculation (optional) • Clean flue gas recirculation piping • Lubricate the flue gas recirculation drive chain performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 43 Records Cleaning (customer) Cleaning (customer) Cleaning of the boiler must be carried out at least once a year, or when requested by the control system. Tasks Notes Empty the ash bins • Remove excess ash from secondary combustion chamber • Empty the ash bins •...
  • Page 44 Check air valve for primary and secondary air Lubricate the grate drive Check ash bin position switches Check de-ashing system Clean ignition Check boiler doors Check stoker • Check the stoker drive chain • Check gap of the rotary valve position sensor www.eta.co.at...
  • Page 45 Records Maintenance (expert) Tasks Notes Check drop chute safety switch Check end position of the rotary valve Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 46 Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean the flue gas recirculation (optional) • Clean flue gas recirculation piping • Lubricate the flue gas recirculation drive chain performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 47 Records Cleaning (customer) Cleaning (customer) Cleaning of the boiler must be carried out at least once a year, or when requested by the control system. Tasks Notes Empty the ash bins • Remove excess ash from secondary combustion chamber • Empty the ash bins •...
  • Page 48 Check air valve for primary and secondary air Lubricate the grate drive Check ash bin position switches Check de-ashing system Clean ignition Check boiler doors Check stoker • Check the stoker drive chain • Check gap of the rotary valve position sensor www.eta.co.at...
  • Page 49 Records Maintenance (expert) Tasks Notes Check drop chute safety switch Check end position of the rotary valve Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 50 Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean the flue gas recirculation (optional) • Clean flue gas recirculation piping • Lubricate the flue gas recirculation drive chain performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 51 Records Cleaning (customer) 3.11 Cleaning (customer) Cleaning of the boiler must be carried out at least once a year, or when requested by the control system. Tasks Notes Empty the ash bins • Remove excess ash from secondary combustion chamber •...
  • Page 52 Check air valve for primary and secondary air Lubricate the grate drive Check ash bin position switches Check de-ashing system Clean ignition Check boiler doors Check stoker • Check the stoker drive chain • Check gap of the rotary valve position sensor www.eta.co.at...
  • Page 53 Records Maintenance (expert) Tasks Notes Check drop chute safety switch Check end position of the rotary valve Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 54 Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean the flue gas recirculation (optional) • Clean flue gas recirculation piping • Lubricate the flue gas recirculation drive chain performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 55 Records Cleaning (customer) 3.14 Cleaning (customer) Cleaning of the boiler must be carried out at least once a year, or when requested by the control system. Tasks Notes Empty the ash bins • Remove excess ash from secondary combustion chamber •...
  • Page 56 Check air valve for primary and secondary air Lubricate the grate drive Check ash bin position switches Check de-ashing system Clean ignition Check boiler doors Check stoker • Check the stoker drive chain • Check gap of the rotary valve position sensor www.eta.co.at...
  • Page 57 Records Maintenance (expert) Tasks Notes Check drop chute safety switch Check end position of the rotary valve Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 58 Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean the flue gas recirculation (optional) • Clean flue gas recirculation piping • Lubricate the flue gas recirculation drive chain performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 59 Records Cleaning (customer) 3.17 Cleaning (customer) Cleaning of the boiler must be carried out at least once a year, or when requested by the control system. Tasks Notes Empty the ash bins • Remove excess ash from secondary combustion chamber •...
  • Page 60 Check air valve for primary and secondary air Lubricate the grate drive Check ash bin position switches Check de-ashing system Clean ignition Check boiler doors Check stoker • Check the stoker drive chain • Check gap of the rotary valve position sensor www.eta.co.at...
  • Page 61 Records Maintenance (expert) Tasks Notes Check drop chute safety switch Check end position of the rotary valve Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 62 Clean the housing of the frequency converter • Inspect seals on heat exchanger covers Clean the flue gas recirculation (optional) • Clean flue gas recirculation piping • Lubricate the flue gas recirculation drive chain performed on: _________________________ performed by: _________________________ Comments: www.eta.co.at...
  • Page 63 Records Cleaning (customer) 3.20 Cleaning (customer) Cleaning of the boiler must be carried out at least once a year, or when requested by the control system. Tasks Notes Empty the ash bins • Remove excess ash from secondary combustion chamber •...
  • Page 64 Check air valve for primary and secondary air Lubricate the grate drive Check ash bin position switches Check de-ashing system Clean ignition Check boiler doors Check stoker • Check the stoker drive chain • Check gap of the rotary valve position sensor www.eta.co.at...
  • Page 65 Records Maintenance (expert) Tasks Notes Check drop chute safety switch Check end position of the rotary valve Calibrate the lambda probe Reset the maintenance counter Perform heating test performed on: _________________________ performed by: _________________________ Comments:...
  • Page 66 www.eta.co.at...
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