eta eHACK 20 Installation Manual
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eta eHACK 20 Installation Manual

Wood chip boiler
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2022-01-25
EN
0000000260
V.016
3.54.0
5011
93030-007
Wood chip boiler
eHACK 20-50 kW
Installation

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  • Page 1 2022-01-25 0000000260 V.016 3.54.0 5011 93030-007 Wood chip boiler eHACK 20-50 kW Installation...
  • 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: Table Of Contents

    Contents General ................5 Preface.
  • Page 4 13.6 Technical data ..............83 www.eta.co.at...

  • Page 5: General

    ETAtouch control system of your ETA boiler. A LAN cable is required for the connection Types of safety instruction from the ETAtouch control system to the internet modem.

  • Page 6: Warranty, Guarantee And Liability

    Use adhesive to affix, e.g. seals. Observe local building and fire safety regulations Only blow out the components with your Local building and fire safety regulations must be mouth. observed. www.eta.co.at...
  • Page 7 "Water hardness". For repairs of defects carried out by the customer or by a third party, ETA shall only bear the costs or remain pH value between 8 and 9 obligated by warranty if this work was approved in writing in advance by the customer service of ETA The pH value of water used to fill the heating system must be between 8 and 9.

  • Page 8: Dismantling, Disposal

    Clean the parts and remove them in accordance with the local regulations for workplace safety and environmental protection. Disposal Disposal including all components must be done in an environmentally friendly manner according to waste disposal laws. Recycle any materials that can be recycled. www.eta.co.at...
  • Page 9 General Dismantling, disposal...

  • Page 10: Technical Data

    Technical data Technical data eHACK 20-50 kW wood chip boiler The boiler can optionally be supplied with the stoker on either the right or the left side. The illustration shows a boiler with the stoker on the left side. Connection for safety valve, pressure gauge and bleed valve R1/2" internal thread Flow, R5/4“...
  • Page 11 Technical data The flue gas connection on the boiler does not yet give any indication of the required chimney diameter. Information on the required chimney diameter can be found in the installation instructions for the boiler in the chimney chapter. The emission values refer to a residual oxygen content of 13% O Wood chip boiler Unit Rated capacity, wood chips M25 BD 150...

  • Page 12: Energy Labelling

    "package-system" (boiler with temperature controller). The emission values refer to a residual oxygen content of 10% O Manufacturer: ETA Heiztechnik GmbH, Gewerbepark 1, A-4716 Hofkirchen an der Trattnach eHACK 20-50 kW wood chip boiler Unit...
  • Page 13 Technical data Energy Labelling eHACK 20-50 kW wood chip boiler Unit 20EP 25EP 32EP 45EP 50EP Value for III (294/(11*Pr)) 1.34 1.34 1.05 1.05 0.84 0.84 0.59 0.59 0.54 0.54 Value for IV (115/(11*Pr)) 0.53 0.53 0.41 0.41 0.33 0.33 0.23...
  • Page 14 Energy Labelling Technical data eHACK 20-50 kW wood chip boiler Unit 20EP 25EP 32EP 45EP 50EP Electrical power consumption at par- 0.044 0.064 0.044 0.064 0.044 0.064 0.046 0.076 tial load Electrical power consumption in ready 0.012 0.012 0.012 0.012 0.012 0.012 0.015 0.015...

  • Page 15: Regulations, Standards And Guidelines

    Regulations, standards and guidelines Regulations, standards and guidelines Regulations • Local building regulations • Industrial fire safety ordinances regulations • State fire regulations • In Germany, the EnEG (Energy Saving Act) with its enacted EnEV ordinances for energy-saving insulation and energy-saving building technologies •...

  • Page 16: Ce-Conformity

    We hereby declare that the product in its standard design as stated here corresponds to the above provisions. The sole responsibility for issuing this declaration of conformity lies with the manufacturer. The technical documentation for this product is administered by ETA Heiztechnik GmbH. Signed for and on behalf of: Hofkirchen, 16/12/2020 Ing.

  • Page 17: Boiler Room

    [kW] tion from land Requirements for the boiler room ETA) Boiler rooms must be built with fire-resistant F90 (EI90) walls and ceilings; in Switzerland El30 up to 70 kW and EI60 over 70 kW. An escape door to a corridor or to the outside is required.

  • Page 18: Safety

    This action prevents the boiler temperature from rising further and triggering further safety devices such as the safety temperature limiter and the thermal relief valve. www.eta.co.at...

  • Page 19: Emergency Stop Switch

    Safety Emergency stop switch The heat dissipation is limited by the maximum A separate connection is already available on the flow temperature set in the heating circuits and boiler for the safety valve (see following graphic). the target hot water temperature. The safety valve must be connected to it.

  • Page 20: Safety Devices In The Fuel Path

    European standard EN 303-5 In Austria, a capillary thermostat is supplied With EN 303-5 "Heating boilers for solid fuels... up to with all ETA wood chip boilers for this 500 kW" safety requirements have now been purpose. harmonised across Europe.
  • Page 21 Safety Safety devices in the fuel path as well as the requirements of TRVB 118 H. That be connected to a pressurised water supply and provides reliable protection against back burning for equipped with a shut-off valve (a ball valve, for wood chips and pellets.
  • Page 22 If a fuel conveyor screw goes through the wall separating two fire compartments, then special measures are needed. The fire protection insulation recommended by the relevant standards for the conveyor screw in this situation is exposed to a high risk of damage due to the required maintenance www.eta.co.at...

  • Page 23: Information For Installation

    Information for installation Chimney Information for installation Chimney 7.1.1 Planning and layout Required chimney diameter Please note that in partial-load operation the exhaust temperature is lower and the large chimney diameters, normally used for solid fuel, are no longer ideal. If the cross section is too large, the flue gas no longer safely rises from the chimney opening and may flow along the roof and sink to the windows of the living quarters.
  • Page 24 The flue pipe must always be laid so that it 100?, and condensates can be deposited in the ascends towards the chimney. chimney. The chimney must therefore be moisture- resistant, "contrary to regulations". Builders making a www.eta.co.at...
  • Page 25 Information for installation Chimney Long horizontal flue pipes to the chimney must have a chimney immediately, thus rendering the flue gas narrow cross-section and above-average insulation (> recirculation ineffective. This leads to slag formation 50 mm). Provide enough cleaning openings in the flue and increased wear on the boiler.
  • Page 26 Fig. 7-5: Measurement opening The measurement opening must be created in the vertical portion of the flue pipe. A straight section of a suitable length must be present before and after the www.eta.co.at...

  • Page 27: Renovation

    Information for installation General information measurement opening because, otherwise, turbulence Furthermore, the exit velocity and temperature are too at the measurement points will prevent meaningful low if the diameter of the chimney is too large. The flue measurements. The clearance from the boiler's flue gas then lacks the energy to rise and, in extreme duct connection or from a pipe bend must be at least cases, the smoke can sink down along the roof.
  • Page 28 For uninsulated pipe systems, mineral wool insulation at least 20 mm thick is required for the measurement area over a pipe length of 20 cm minimum. www.eta.co.at...

  • Page 29: Water Hardness

    Information for installation Water hardness Water hardness Determine the permissible water hardness for the heating water according to ÖNORM H 5195-1 Table 1 Table 2 Heat producer with large (> 0.3 l/ Heat producer with small (≤ 0.3 l/ kW) water content kW) water content Specific water content ≥...

  • Page 30: Corrosion

    For boilers of the eHACK series, a separate connection is available on the boiler for the safety valve, pressure gauge and bleed valve. The piping to the safety valve and the bleed valve must be www.eta.co.at...

  • Page 31: Pressure Equalisation

    A system separation nitrogen so that it is 0.3 bar higher than the static module with these specifications is available from ETA. pressure at the installation location, but make sure the pressure does not fall below 0.9 bar.

  • Page 32: Noise Emission

    In normal operation, the airborne noise emissions from ETA sound-insulation set. Design the rigidly a pellet or wood chip boiler is between 40 and 50 dB(a) connected installation (flow and return, thermal...

  • Page 33: Buffer Storage Tank

    Buffer storage tank General information Buffer storage tank General information Choosing buffer size for systems with automatic fuel supply Even if some subsidy guidelines demand "litres per Finely adjustable radiator valves and fresh water kilowatt" and thereby specify a minimum buffer size, module one should arrange for a technically correct size.

  • Page 34: Hydraulic Integration

    In all cases, an oil or gas boiler should be connected to the top part of the buffer only. Siphon loops downwards at all connections reduce heat losses in summer. www.eta.co.at...
  • Page 35 Buffer storage tank Hydraulic integration Hot water tank or fresh water module Solar exchanger and fresh water module Boiler flow, heating circuits, hot water tank, oil/gas Boiler, heating circuits, oil/gas boiler flow boiler Oil/gas boiler return Oil/gas boiler return Boiler, high-temperature circuits return Hot water tank return, high-temperature circuit Low-temperature circuits return return...

  • Page 36: Connection Between Multiple Buffer Storage Tanks

    10 Temperature sensor [Sensor 2] for the solar heating system, top Return 11 Temperature sensor [Sensor 3] for the differential temperature control between the boiler and the buffer 12 Temperature sensor [Sensor 4] for the differential temperature control between the solar heating system and the buffer www.eta.co.at...
  • Page 37 Buffer storage tank Connection between multiple buffer storage tanks Serial connection Tichelmann connection for higher outputs A serial connection between two buffers has no For parallel connection with one-sided connection, the advantages over a parallel connection; but it does volume of the second buffer is integrated using the disadvantages.

  • Page 38: Parallel Buffer Connection

    The basic principle of the internal Tichelmann is diagonal flow. Two buffers are connected together at the top and bottom (= parallel connection). For output up to 90 kW, a connection with DN 32 (ETA buffer connection set) is sufficient, for 30 kW use at least R1" or 28 mm copper. On one tank, the boiler outlet is connected at the top; on the other the boiler return is connected at the bottom.
  • Page 39 Buffer storage tank Parallel buffer connection...

  • Page 40: External Tichelmann

    11 Hot water 12 Cold water Connecting ball valves on buf- maximum total output Collector line at least 30 kW DN 20 DN 25 R 1" 28 x 1.5 60 kW DN 25 DN32 R 1¼" 35 x 1.5 www.eta.co.at...
  • Page 41 Buffer storage tank External Tichelmann Connecting ball valves on buf- maximum total output Collector line at least 90 kW DN 32 DN 40 R 1½" 42 x 1.5 160 kW DN 32 DN 50 R 2" 54 x 1.5 300 kW DN 40 DN 65 R 2½"...

  • Page 42: Serial Buffer Connection

    Number of buffers Connecting line, minimum 30 kW DN 25 R 1" 28 x 1.5 50 kW DN32 R 1¼" 35 x 1.5 65 kW DN32 R1¼" 35 x 1.5 80 kW DN 40 R1½" 42 x 1.5 www.eta.co.at...
  • Page 43 Buffer storage tank Serial buffer connection maximum total output Number of buffers Connecting line, minimum 100 kW DN 40 R1½" 42 x 1.5 140 kW DN 50 R2" 54 x 1.5 170 kW DN 50 R2" 54 x 1.5 With fresh water module and stratified charging module Fresh water module flow Temperature sensor [Sensor 1 (top)] Boiler, heating circuits, oil/gas boiler flow...

  • Page 44: Installation

    An optional sound-insulation set is available Fig. 9-2: Seal An optional sound-insulation set is available for the boiler. If you use this, insert the sound- insulation strips longitudinally under the boiler's base frame and also under the stoker's levelling screws. www.eta.co.at...
  • Page 45 Installation Stoker Mount the levelling screws on the underside of the Fasten the rotary valve on the stoker. Tighten the stoker. Fasten the stoker to the boiler. Tighten the screws alternately and evenly. screws alternately and evenly. Fig. 9-4: Rotary valve Attaching the stoker drive First insert the lowest screw on the stoker and only hand-tighten the nut.

  • Page 46: Assembling The Conveyor

    Check whether the conveyor screw is correctly repair, for example. inserted in the open trough. Attach the open trough to the gearbox. Fig. 9-7: Conveyor screw for the open trough Fig. 9-10: Gearbox www.eta.co.at...
  • Page 47 Installation Assembling the conveyor Carefully insert the conveyor screw into the gearbox. Mount the support stand on the trough. Fig. 9-11: Conveyor screw Thread the open trough through the wall opening from Fig. 9-13: Support stand the storeroom into the boiler room. Place a square Adjust the height of the support stand.
  • Page 48 Stauffer grease and connect them. Make sure that the winding is continuous. Make sure that the winding is continuous. Fig. 9-16: Start screw Mount the closed trough on the open trough. Install the drop chute on the trough. Fig. 9-14: Closed trough Fig. 9-17: Drop chute www.eta.co.at...
  • Page 49 Installation Assembling the conveyor Attach a seal to the flange. Installing the discharge drive Align the screw conveyor with the drive using the feather key. Fig. 9-18: Seal Lift the discharge and carefully insert the ball joint connection into the opening of the rotary valve. Fig.
  • Page 50 Install the bleed screw in place of the plug screw. rotary plate. The rotary plate always rotates anti- clockwise. Note the correct alignment of the claws on the spring arms, see figure below. Fig. 9-22: Bleed screw Fig. 9-24: Spring arms www.eta.co.at...
  • Page 51 Installation Assembling the conveyor 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.
  • Page 52 10 mm. Fig. 9-31: Support stands Tightening the screws Tighten all the screws alternately and evenly. Fig. 9-29: Floor distance If you install a slanted floor, also take the thickness of the boards into account. www.eta.co.at...

  • Page 53: Installing The Drive Chain

    Installation Installing the drive chain Installing the drive chain Adjust the chain tension with the turnbuckle. Fixing the ball joint connection Secure the ball joint connection with the two threaded rods and nuts. Tighten the nuts alternately and evenly. Fig. 9-34: Turnbuckle Then tighten the three M16 x 45 screws.

  • Page 54: Align Boiler Horizontally

    Aligning the boiler horizontally Fig. 9-37: Flap Check the horizontal alignment of the boiler covers and adjust them by placing metal plates underneath. Fold the locking lever on the boiler forwards. Fig. 9-38: Locking lever Fig. 9-36: Checking the alignment www.eta.co.at...

  • Page 55: Cables

    Installation Cables Cables Push the ash box over the connection on the boiler and connect it to the boiler with the locking lever. Routing the lines to the circuit boards Route the lines (ignition, discharge...) to the circuit boards using the cable ducts. Set the height of the attached ash box with the adjustable feet on the underside, so that the ash box lies evenly on the floor.

  • Page 56: Bottom Insulation

    Filling and draining valve dispose of them. Installing the safety valve, pressure gauge and bleed valve A safety valve, pressure gauge and bleed valve must be installed on the boiler. They are not included in the delivery scope. Fig. 9-43: Metal strips www.eta.co.at...

  • Page 57: Filling The Heating System

    Installation Filling the heating system Bleeding the heating system DANGER! Open the ball valves on the heating circuits and bleed Safety valve outlet the heating system completely. After bleeding, check The safety valve outlet must be directed to the ground the water pressure and adjust if necessary.

  • Page 58: Network Connection

    Fig. 9-48: Network cable If the network cable is long enough, connect the plug directly into the router or the ETA PowerLine. If it is not long enough, use a network extension (1x plug / 1x socket) to connect to the router or ETA PowerLine.

  • Page 59: 10 Electrical Connections

    Electrical connections Requirements 10 Electrical connections 10.1 Requirements Electrical connection must only be made by qualified specialist personnel The electrical installation must only be performed by specialist personnel with the corresponding qualifications. Requirements Observe the regulations and special regulations of local energy utilities.
  • Page 60 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, Fig. 10-7: Digital switch the warranty for the electronics would be invalidated.  Only use flexible stranded conductors for the wiring. www.eta.co.at...
  • Page 61 Electrical connections Requirements Fig. 10-8: Speed-controlled pump Fig. 10-9: Special function - pump (with supply extension 230 Fig. 10-10: Special function - changeover valve with three- point control Fig. 10-11: Special function - burner Fig. 10-12: Switch...

  • Page 62: Overview Of Circuit Boards

    Overview of circuit boards Electrical connections 10.2 Overview of circuit boards Overview of boiler circuit boards The [HE-C] circuit board is an extension board and is required for special conveyors, intermediate conveyor screws, etc . www.eta.co.at...
  • Page 63 Electrical connections Overview of circuit boards...

  • Page 64: Circuit Board Ha-C6

    Conveying system (intermediate conveyor 400 V output screw) 400 V output Stoker screw 400 V supply Mains power input 230 V input 3 x 1 mm² Water shortage switch 230 V input 3 x 1 mm² Emergency stop switch www.eta.co.at...
  • Page 65 Electrical connections Circuit board HA-C6 These terminals can be used (depending on the configuration): Minimum Terminal Function cross-sec- Standard assignment tion Safety switch for rotary valve maintenance 230 V input cover Safety switch at drop chute of intermediate 230 V input conveyor screw 230 V input Safety switch drop chute conveying system...
  • Page 66 Lambda probe RS-485 bus terminal resistor for analogue input to terminal [S555] Jumper (without jumper: 0-10 V; with jumper: 0-20 mA) for analogue input to terminal [S556] Jumper (without jumper: 0-10 V; with jumper: 0-20 mA) CAN-Bus terminal resistor www.eta.co.at...
  • Page 67 Electrical connections Circuit board HA-C6...

  • Page 68: Circuit Board Gm-C3

    2 x 0.5 mm² S500 T4 Temperature input 2 x 0.5 mm² S500 T5 Temperature input 2 x 0.5 mm² Outside temperature sensor S500 T6 Temperature input 2 x 0.5 mm² Collector S501 T7 Temperature input 2 x 0.5 mm² Hot water www.eta.co.at...

  • Page 69: Terminal Function

    Electrical connections Circuit board GM-C3 These terminals can be used (depending on the configuration): Minimum Terminal Function cross-sec- Standard assignment tion Buffer temperature sensor 1 (top) This temperature sensor is always mounted at the top of the buffer. If, for S501 T8 Temperature input 2 x 0.5 mm²...
  • Page 70 Circuit board GM-C3 Electrical connections These terminals are already wired at the factory: Terminal Function Standard assignment Terminal for plug-in circuit board Terminal for plug-in circuit board CAN-Bus supply +24 V (for standalone mode) www.eta.co.at...

  • Page 71: 11 Commissioning

    Commissioning 11 Commissioning Maintenance openings and components The illustration shows a boiler with its fuel conveying on the left side. The fuel conveying depicted here is the standard configuration. Combustion chamber door Firebed switch (safety switch) Vacuum sensor Firebed level sensor Grate position switch Actuator for primary air Ash screw...
  • Page 72 Retaining tube of the lambda probe Heat exchanger cleaner maintenance cover Safety switch for the maintenance cover De-ashing drive Flue gas temperature sensor in heat exchanger Water pressure sensor 10 Draught fan 11 Flue gas temperature sensor on flue gas connector www.eta.co.at...
  • Page 73 Commissioning Actuator of flue gas recirculation (optional) Precipitator maintenance cover Heat exchanger cover Release button for safety temperature limiter (STB) Mains switch (symbol Maintenance switch (symbol Door contact switch...

  • Page 74: Checklist

    2) Check the alignment of the discharge electrodes. This must hang down vertically and must not touch any other components. Configuration 1) Configure the heating system and the environment with the configuration wizard. www.eta.co.at...
  • Page 75 2) Compare the output of the drives of the stoker and the fuel conveying system on the basis of the type plates with the values set in the control system. 3) Only for eHACK 20-80 kW: –Check the correct direction of rotation of the primary air valve using the ETAtouch con- trol system.
  • Page 76 4) Save the configuration of the heating system in the ETAtouch control. 5) Inform the customer about the remote control option by registering on www.meinETA.at. This means that the customer can also operate their boiler remotely. www.eta.co.at...

  • Page 77: 12 Concluding Activities

    Concluding activities 12 Concluding activities Check the direction of rotation of the drive with the aid Reinstall boiler casing of the marking. The correct rotation direction is shown Reinstall the parts of the boiler casing that were in the following diagram. removed during the assembly.

  • Page 78: 13 Fuel Store

    Once the filling method has been clarified, determine the storeroom dimensions. In principle, this should be dimensioned as large as possible, so that less frequent filling is required. www.eta.co.at...
  • Page 79 Plans Determining the number of refills for this are available from ETA. With an agitator with a diameter of 4 m and a maximum filling height of 5 m, a storage volume of...

  • Page 80: Tilted Floor

    Benefits of the slanted floor: • The flat spring arms move along the floor and cannot "float" over the fuel. • The fuel is not compacted in the outer area of the floor. Fig. 13-4: 45° chamfer floor agitator size 2 www.eta.co.at...

  • Page 81: Pellet Operation

    For the fuel discharge, either an agitator or a pellet discharge screw can be used. Special requirements apply to pellet storage rooms. For more information, please contact ETA. Floor agitator for pellets For pellet operation with a floor agitator, the following points must be observed: Fig.

  • Page 82: Heating Value

    A cubic metre (rm) corresponds to 1 m³ layered logs (1 m length) with air gaps. b. A loose cubic metre (srm) corresponds to 1 m³ of loosely dumped wood chips. c. A solid cubic metre (fm) corresponds to 1 m³ wood without air gaps. www.eta.co.at...

  • Page 83: Technical Data

    Maximum lengths and inclines Below you will find the information on the maximum lengths and inclinations for conveying systems of different sizes. If deviations from the stated values are necessary, please consult ETA Heiztechnik GmbH. Fig. 13-8: Side view Fig. 13-9: Top view...
  • Page 84 Total length L < 6 Inclination α < 15° Fill height H < 5 Number of spring arms Deviations from these specifications are only possible in consultation with ETA Heiztechnik GmbH. Agitator for pellets Discharge Unit BG 1 BG 2 BG 2.5...
  • Page 86 www.eta.co.at...
  • Page 88 DOWNLOAD www.eta.co.at...

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