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eta TWIN Service Manual
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eta TWIN Service Manual

eta TWIN Service Manual

Pellet burner 40-50 kw
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2022-04-05
EN
0000000374
V.007
3.55.0
2503
939026-002
TWIN pellet burner
40-50 kW
Service manual

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Summary of Contents for eta TWIN

  • Page 1 2022-04-05 0000000374 V.007 3.55.0 2503 939026-002 TWIN pellet burner 40-50 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 Contents General information ..............5 Cleaning and maintenance .
  • Page 4 5.22 Establish operational readiness ........... . . 57 www.eta.co.at...
  • Page 5 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 6 So you can maintain a long-term overview of maintenance carried out. course, the maintenance can also be carried out using the service Fig. 2-2: Maintenance step (example) guide, without the support of the ETAtouch control system. www.eta.co.at...
  • Page 7 Cleaning and maintenance Maintenance notes Follow the on-screen instructions and carry out all The maintenance switch is marked with the steps carefully. Enter your name at the end of symbol and has two settings. maintenance ( button) and save the maintenance •...
  • Page 8 No leaks in the components, e.g. screw con- nection or maintenance cover. Clean panels If necessary, clean the panels of the boiler and the ETAtouch screen with a moist cloth. Under circumstances aggressive solvents, chemicals or scouring agents. They can lead to stress cracks and damage. www.eta.co.at...
  • Page 9 Cleaning and maintenance Maintenance openings in the boiler Maintenance openings in the boiler Maintenance openings and components The illustrations show a boiler with pellet burner on the left side. Door contact switch 10 Heat exchanger cover Fuel chamber Combustion chamber Ash collection duct Position switch for ash box Ignition...
  • Page 10 Heat exchanger cleaning Vacuum sensor Fill level sensor for pellet hopper Outer combustion chamber cover Firebed switch Actuator for secondary air De-ashing the drive chain 10 Actuator for primary air 11 Lambda probe 12 Turbulators in the heat exchanger www.eta.co.at...
  • Page 11 Cleaning and maintenance Maintenance table Maintenance table Clean the boiler at least once a year or when requested by the control system. Maintenance is necessary at least every 3 years or when requested by the control system. We recommend you perform maintenance annually.
  • Page 12 Check the pellet hopper • Clean the fill level sensor Specialist • Clean strainer Check the vacuum sensor • Clean the silicon hoses Specialist • Calibrate the vacuum sensor Calibrating the lambda probe Specialist Reset maintenance counter Specialist Perform heating test Specialist www.eta.co.at...
  • Page 13 Cleaning and maintenance Maintenance table...
  • Page 14 The safety valve triggers at approx. 2.8 bar. If the water pressure drops several times a year, contact a heating professional. When refilling water in the heating system, the same water as used during initial filling should be used whenever possible (e.g. treated water). www.eta.co.at...
  • Page 15 Regular maintenance De-ash boiler De-ash boiler Pull most of the ash out of the primary combustion chamber into the ash box with the poker. Leave about 1 cm of ash in the primary combustion chamber. This De-ashing the boiler serves as insulation and protection. The ash in the fuel chamber is needed as insulation for ember retention.
  • Page 16 Fig. 3-6: Checking the ash collection duct walls Fig. 3-8: Ash box Open the fasteners and remove the ash box lid. Empty the ash box. Fig. 3-9: Lid Check the ashes for pieces of embers. Never put hot ash into the waste bin! www.eta.co.at...
  • Page 17 Regular maintenance Establish operational readiness Check if the seal in the lid of the ash box is intact and replace if necessary. Fig. 3-10: Seal Check that the ash box seal on the boiler is intact and replace it if necessary. Fig.
  • Page 18 If the water pressure drops several times a year, Allow the boiler to cool down sufficiently contact a heating professional. When refilling before starting any activities. water in the heating system, the same water as used during initial filling should be used whenever possible (e.g. treated water). www.eta.co.at...
  • Page 19 Cleaning (customer) Check safety devices Check safety devices Checking the thermal relief valve Visually check the thermal relief valve. The outlet must not drip. Check safety valves Check all safety valves of the heating system by means of a visual inspection. The outlets of the safety valves must not drip.
  • Page 20 Fig. 4-7: Ash box Open the fasteners and remove the ash box lid. Empty the ash box. Fig. 4-5: Condensate drain Fig. 4-8: Lid Check the ashes for pieces of embers. Never put hot ash into the waste bin! www.eta.co.at...
  • Page 21 Cleaning (customer) Clean draught fan Clean draught fan Check if the seal in the lid of the ash box is intact and replace if necessary. Clean draught fan Disconnect the power supply for the draught fan. Loosen the wing screws and remove the draught fan. Fig.
  • Page 22 Remove the cover next to the flue gas connection. boiler. Reconnect the power supply to the draught fan. Fig. 4-15: Cover Remove the insulation over the heat exchanger cover. Fig. 4-16: Insulation www.eta.co.at...
  • Page 23 Cleaning (customer) Cleaning the heat exchanger Loosen the knurled nuts of the heat exchanger cover Cleaning the heat exchanger box by turning anti-clockwise. Then turn the ball knobs Remove the ash from the heat exchanger box with an 180°. ash vacuum. Fig.
  • Page 24 Closing the heat exchanger cover Re-attach the heat exchanger cover. Turn the ball knob up to the stop to suspend the heat exchanger cover. Then tighten the knurled nuts alternately and evenly by turning clockwise. Fig. 4-24: Cover Fig. 4-22: Heat exchanger cover www.eta.co.at...
  • Page 25 Cleaning (customer) Clean fuel chamber Clean fuel chamber Also pull the ash from the ash collection duct (under the combustion chamber) with the poker into the ash box. Completely de-ash the boiler Stoke all the ash and charcoal from the filling chamber through burn-through openings...
  • Page 26 (above the secondary air Cleaning the primary air openings openings) is in the semicircular groove of the two Clean the primary air opening with an ash vacuum. grates. Fig. 4-31: Primary air openings Fig. 4-34: Correct grate placement www.eta.co.at...
  • Page 27 Cleaning (customer) Clean fuel chamber Also ensure that the grate does not "wobble" and is Re-attach the guard plate between the filling chamber fully inserted. Check the openings of the grates, they door and ignition door. must lie at the same height. Fig.
  • Page 28 Open the insulation door and the combustion chamber door. Fig. 4-39: Checking the ash collection duct walls Fig. 4-40: Burn-through opening Use the angled brush to sweep the burn-through opening between the combustion chamber of the pellet burner and the log boiler. Fig. 4-41: Angled brush www.eta.co.at...
  • Page 29 Cleaning (customer) Check boiler doors 4.10 Check boiler doors To adjust, open the respective door, lift it out of the hinges and remove the door. Checking the boiler door seals Check the seals on the 3 boiler doors (filling chamber door, ignition door, combustion chamber door).
  • Page 30 Switch on the boiler with the mains switch Restore the power supply for the boiler and switch on the boiler at the mains switch. Switch pellet burner back to automatic mode Switch the pellet burner back into automatic mode with the On/off switch www.eta.co.at...
  • Page 31 Cleaning (customer) Establish operational readiness...
  • Page 32 This prevents injuries caused by switching the boiler on inadvertently. WARNING! Burns caused by hot parts Risk of burning on parts located behind the boiler housing, even after shutting the boiler down. Allow the boiler to cool down sufficiently before starting any activities. www.eta.co.at...
  • Page 33 Maintenance (expert) Check safety devices Check safety devices Checking the thermal relief valve Visually check the thermal relief valve. The outlet must not drip. Check safety valves Check all safety valves of the heating system by means of a visual inspection. The outlets of the safety valves must not drip.
  • Page 34 Fig. 5-7: Ash box Open the fasteners and remove the ash box lid. Empty the ash box. Fig. 5-5: Condensate drain Fig. 5-8: Lid Check the ashes for pieces of embers. Never put hot ash into the waste bin! www.eta.co.at...
  • Page 35 Maintenance (expert) Empty the ash box Check if the seal in the lid of the ash box is intact and Attaching the ash box to the boiler replace if necessary. Re-attach the lid to the ash box. Push the ash box over the connection on the boiler and fix it with the clamping lever.
  • Page 36 Remove the ash from the fan housing. Fig. 5-15: Fan housing Carefully clean the impeller with a soft brush (not a wire brush) or compressed air to prevent imbalance. Replace the seal. Fig. 5-16: Clean the impeller, replace the seal www.eta.co.at...
  • Page 37 Maintenance (expert) Check the automatic heat exchanger cleaner Check the automatic heat Lubricate the screws with heat-resistant lubricant and re-attach the draught fan to the boiler. Tighten the wing exchanger cleaner screws alternately and evenly. The plug connection must point to the right when viewed from behind the boiler.
  • Page 38 Never lubricate bearing connecting rod with oil, grease or other Remove the insulation over the heat exchanger cover. lubricants. Dirt may stick to the lubricant, resulting in encrustation and stiffness. Re-install the cover. Fig. 5-22: Insulation Fig. 5-20: Cover www.eta.co.at...
  • Page 39 Maintenance (expert) Cleaning the heat exchanger Loosen the knurled nuts of the heat exchanger cover Cleaning the heat exchanger box by turning anti-clockwise. Then turn the ball knobs Remove the ash from the heat exchanger box with an 180°. ash vacuum. Fig.
  • Page 40 Closing the heat exchanger cover Re-attach the heat exchanger cover. Turn the ball knob up to the stop to suspend the heat exchanger cover. Then tighten the knurled nuts alternately and evenly by turning clockwise. Fig. 5-30: Cover Fig. 5-28: Heat exchanger cover www.eta.co.at...
  • Page 41 Maintenance (expert) Clean lambda probe 5.10 Clean lambda probe Let the lambda probe cool down and clean it with an ash vacuum. Particularly vacuum out the openings in the head of the lambda probe. Cleaning the lambda probe Unscrew the retaining tube of the lambda sensor with a pipe wrench.
  • Page 42 Excessive wear on the combustion chamber is often due to a leaky installation of the lambda probe. Leak air penetrates the boiler and the control system reduces the air intake too much and the temperatures in the combustion chamber reach impermissible levels. www.eta.co.at...
  • Page 43 Maintenance (expert) Clean fuel chamber Also pull the ash from the ash collection duct (under After removing the front suspended panels, remove the combustion chamber) with the poker into the ash the guard plate between the filling chamber door and box.
  • Page 44 Fig. 5-46: Secondary air openings Reinsert both grate halves. When inserting, make sure that the seal (above the secondary air openings) is in the semicircular groove of the two grates. Fig. 5-49: Suspended panel Fig. 5-47: Correct grate placement www.eta.co.at...
  • Page 45 Maintenance (expert) Clean fuel chamber Re-attach the guard plate between the filling chamber Checking the ash collection duct walls door and ignition door. Check the walls of the ash collection duct, they may be white to brown. If they are black with soot, either too much wood was burned at too low a heat consumption, the fire was not lit correctly at start-up or, in rare cases, the lambda probe gave incorrect measurement values.
  • Page 46 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. Especially check seal between carbonization gas extraction duct and the filling chamber. www.eta.co.at...
  • Page 47 Maintenance (expert) Optional automatic ignition 5.13 Optional automatic ignition Retighten the flange nuts. Suspend the door and check whether it now closes fully. If not, repeat the process. Dismantling the ignition and cleaning the ignition tubes Loosen the screws and carefully remove the ignitions. Make sure that the included springs do not get lost.
  • Page 48 Removing the pellet burner cover Remove the cover from the top. Fig. 5-60: Only hand tighten the screws Fig. 5-61: Cover on the top Remove the front cover. Fig. 5-62: Front cover www.eta.co.at...
  • Page 49 Maintenance (expert) Clean pellet burner's combustion chamber Remove the cover from the rear. Loosen the wing screws and remove the outer combustion chamber cover. Fig. 5-65: Outer combustion chamber cover Loosen the screws and remove the inner combustion chamber cover. Fig.
  • Page 50 Otherwise, leak air is sucked in, disturbing the combustion process and causing increased wear.  Always replace damaged seals immediately. Re-installing the combustion chamber cover Fig. 5-69: Firebed lever Clean the sealing surface on the inner combustion chamber cover. Fig. 5-72: Inner combustion chamber cover www.eta.co.at...
  • Page 51 Maintenance (expert) Clean pellet burner's combustion chamber Replace the inner combustion chamber cover and Dismantle the ignition and clean the ignition tube tighten the screws alternately and evenly. Loosen the screws and carefully remove the ignition. Make sure that the included springs do not get lost. Fig.
  • Page 52 Lubricate the drive chain with chain spray. Only hand-tighten the screws, so that the ignition is held by the springs. Do not overtighten the screws, otherwise the ignition may be damaged. Fig. 5-80: Stoker drive chain Fig. 5-79: Only hand tighten the screws www.eta.co.at...
  • Page 53 Maintenance (expert) Check de-ashing 5.16 Check de-ashing 5.17 Check air valve Check the de-ashing drive chain Checking the air valve of the pellet burner Check the chain tension. The chain may sag by 1 cm Actuate both actuators manually and check that they without any force applied.
  • Page 54 Clean the fill level sensor with a soft cloth. Fig. 5-85: Actuators Lubricate the air valves only with dry lubricant (e.g. PTFE spray) if they are difficult to move. Fig. 5-88: Checking the seal, cleaning the fill level sensor www.eta.co.at...
  • Page 55 Maintenance (expert) Check underpressure sensor 5.19 Check underpressure sensor Cleaning the strainer in the pellet hopper Clean the strainer in the pellet hopper by tapping and vacuuming. Clean silicon hose and connection for the vacuum sensor The vacuum sensor is mounted on the pellet hopper. Remove the silicone hose from the vacuum sensor as well as from the connection on the boiler.
  • Page 56 Reconnect the silicone hose to the boiler as well as to the vacuum actuator. Ensure the correct position when connecting. The silicone hose may not be kinked. Fig. 5-94: Rear cover Re-install the front cover. Fig. 5-95: Front cover Fig. 5-93: Connect the silicone hose www.eta.co.at...
  • Page 57 Maintenance (expert) Calibrate lambda probe 5.21 Calibrate lambda probe Mount the cover on the top. Calibrating the lambda probe The boiler's built-in lambda probe checks the residual oxygen content of the flue gas and uses it to control the combustion. To ensure reliability, the control system autonomously performs an automatic calibration after every 500 hours of operation.
  • Page 58 If the value does not drop below 12% residual oxygen content, the boiler is receiving leak air. The reason (leaky boiler doors, heat exchanger cover, lambda probe installation, etc.) must be identified and corrected. If possible, perform a flue gas measurement during the heating test. www.eta.co.at...
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