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eta 13180 LP-D, Installation Manual

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Contents

1 

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 

Warranty, guarantee and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 

Energy Labelling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 

Regulations, standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 

CE-Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 

Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 

Safety  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.1 

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.2 

Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7 

Information for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.1 

Chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1.1  Planning and layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1.2  Renovation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.2 

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.3 

Water hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.4 

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.5 

Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.6 

Pressure equalisation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.7 

Noise emission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8 

Buffer storage tank  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1 

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.2 

Hydraulic integration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.3 

Connection between multiple buffer storage tanks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8.4 

Parallel buffer connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.5 

External Tichelmann  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8.6 

Serial buffer connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9 

Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9.1 

Placement of the boiler  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9.2 

Mount flue gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

9.3 

Installing flue gas recirculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

9.4 

Removing panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9.5 

Align boiler horizontally  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9.6 

Installing the pellet bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9.7 

Ash box  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9.8 

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9.9 

Bottom insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

9.10  Connecting piping  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.11  Attaching pellet hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.12  Filling the heating system  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Summary of Contents for 13180 LP-D

Page 1: ...2020 04 21 EN 0000000475 V 006 5402 00 939091 002 Pellet boiler ePE K 180 240 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: ...5 Bleeding 24 7 6 Pressure equalisation 25 7 7 Noise emission 26 8 Buffer storage tank 27 8 1 General information 27 8 2 Hydraulic integration 28 8 3 Connection between multiple buffer storage tanks 31 8 4 Parallel buffer connection 34 8 5 External Tichelmann 36 8 6 Serial buffer connection 38 9 Installation 40 9 1 Placement of the boiler 40 9 2 Mount flue gas connection 41 9 3 Installing flue gas...

Page 4: ... 5 Circuit board HA C5 62 10 6 Circuit board GM C3 66 11 Concluding activities 69 12 Dismantling disposal 70 13 Pellet store 71 13 1 General information 71 13 2 Requirements for pellet store 72 13 3 Calculating pellet supply and store size 73 13 4 Filling nozzles 74 13 5 No cables pipes in the pellet store 76 13 6 Tilted floor 77 13 7 Ventilation 80 13 8 Information about pellet hoses 81 13 9 Fire...

Page 5: ...the LAN cable see 9 13 Network connection Extended warranty We grant an extended warranty if the product is com missioned by an authorised partner company or by our own customer service In this regard please note the warranty conditions applicable at the time of purchase Service agreement You can ensure the best care for your heating system by taking out a service agreement with one of our certifi...

Page 6: ...5195 1 Details can be found in chapter 7 3 Water hardness pH value between 8 and 9 The pH value of water used to fill the heating system must be between 8 and 9 Use a sufficient number of shut off valves Set enough shut off valves to avoid bleeding large amounts of water during repairs Any leaks in the system must be repaired at once Install safety valve and thermal relief valve A safety valve tri...

Page 7: ...er 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 Potential equalization is needed for the boiler The boiler must be connected to the potential equaliza tion of the boiler room or the...

Page 8: ...h the pellet module on the left side 1 Connection for safety valve pressure gauge and bleed valve R5 4 2 Flow R2 3 Return R2 4 Filling and draining valve 5 Safety heat exchanger R1 2 6 Maintenance area to be kept clear For maintenance on the boiler an area which is to be kept clear is required on the side of the boiler on which the pellet module is mounted No expansion tanks or other devices may b...

Page 9: ...distance to pellet store m 20 Ash box volume litres 94 Flue gas mass flow rate partial full load g s 41 120 45 130 48 139 51 148 CO2 content in dry exhaust gas partial full load 11 1 13 2 11 2 13 4 11 2 13 7 11 3 13 9 Exhaust temperature at partial full load C 70 130 Required flue draught Pa 5 Pa A draught limiter is always required 15 Pa Carbon monoxide CO emissions at partial full load mg MJ 19 ...

Page 10: ...0 30 Temperature controller integrated in the boiler yes no yes Temperature controller class VIII Contribution of the temperature con troller to the energy efficiency of the package system 5 Condensing boiler yes no no Combination boiler for hot water and heating yes no no Combined heat and power yes no no Preferred fuel Pellets Maximum load kW 179 9 199 9 219 9 239 9 Partial load kW 53 9 59 9 65 ...

Page 11: ...space heating emissions OGC mg m 10 O2 20 20 20 20 20 20 20 20 Seasonal space heating emissions CO mg m 10 O2 500 500 500 500 500 500 500 500 Seasonal space heating emissions NOx mg m 10 O2 200 200 200 200 200 200 200 200 Pellet boiler ePE K 180 240 kW Unit Model identification 180 180EP 200 200EP 220 220EP 240 240EP ...

Page 12: ...imum requirements for the heating water If stricter country specific regulations exist they are to be heeded VDI 2035 Prevention of damage due to corrosion and scaling in hot water heating systems with feed temperatures up to 120 C EN 12828 Heating systems in buildings planning for hot water heating systems The safety temperature limiter 100 C is already installed in the boiler A sufficiently larg...

Page 13: ...ating boilers for solid fuels manually and automatically stoked nominal heat output of up to 500 kW Terminology requirements testing and marking EN ISO 12100 2011 Safety of machinery General principles for design risk assessment and risk reduction EN 60335 1 2012 Safety of household and similar electrical appliances Part 1 General requirements EN 60335 2 102 2016 Safety of household and similar el...

Page 14: ...e in stallation and commissioning of the boiler There must be no heating appliances in the vicinity of escape routes Boilers may not be installed in stairwells corridors or rooms through which escape routes lead to the outside Free minimum cross sections for the air intake openings The boiler requires air for combustion That is why free minimum cross sections are required in the boiler room for th...

Page 15: ...Fire extinguisher Storage of ash The ash must be kept in non flammable containers with covers for cooling Never put hot ash into the waste bin DANGER Do not carry out work on high voltage units The housing of the high voltage unit may not be opened or damaged as there are parts inside it that are under high voltage Non compliance with the above may result in serious or fatal injuries DANGER Cautio...

Page 16: ... cooling valve 5 Visible outlet to sewer The outlet must have an easily visible flow path so mal functions can be recognised Direct the discharged water to the sewer via a siphon funnel or at least with a pipe into the ground so that nobody can be scalded if the valve is activated Even for cold water coming from a domestic well with its own pump a thermal emergency cooling valve must be installed ...

Page 17: ...ht line in the nominal diameter of the valve inlet DANGER Safety valve outlet The safety valve outlet must be directed to the ground in a pipe so nobody is endangered by hot water or steam The safety valve outlet vent pipe must have at least the same nominal diameter as the valve outlet be installed with a consistent gradient and be routed to a sewage system e g duct The vent pipe may contain a ma...

Page 18: ...onnection pipe in a chimney with a 20 cm diameter Clarify with the chimney sweep A specialist or a chimney sweep must inspect the dimensions and suitability of existing chimneys especially before boiler installation Every boiler must have its own chimney The better the boiler and the chimney are matched the greater the energy with which the flue gas exits the chimney and therefore the certainty th...

Page 19: ...a flue gas damper the moisture can destroy an old fireclay chimney Obsolete regulations stipulate the wrong chimney Laws and regulations demand a moisture resistant flue system for oil and gas and one that is resistant to soot fires for solid fuels Wood is a solid fuel However in the lower output range the temperature of the flue gas can be below 100 and condensates can be deposited in the chimney...

Page 20: ...fective chimney height calculation required A draught limiter is required for boilers with flue gas recirculation If the boiler is equipped with flue gas recirculation such as the PE K pellet boiler or eHack wood chip boilers with optional flue gas recirculation a draught limiter must always be installed in the chimney Fig 7 1 Draught limiter Flue gas recirculation conveys a portion of the flue ga...

Page 21: ...ning aperture in the connecting pipe Easily accessible cleaning apertures must be available for cleaning the flue pipe Fig 7 4 Cleaning aperture Fit the chimney connection just under the ceiling Even if the current boiler can be connected to the chimney at a low height it is better if you fit the chimney connection just below the ceiling The flue pipe is easier to install and the vertical connecti...

Page 22: ...the chimney has already been renovated for oil or gas with a stainless steel pipe and now a conversion to wood or pellets is planned Or the chimney is too narrow to install a ceramic pipe with a reliable seal If a moisture resistant inner pipe is installed in a sufficiently fire resistant casing the German Association of Chimney Sweeps has found the following solution to the standards and regulati...

Page 23: ...ng water s pH value has not itself changed to more than 8 after a week of operation increase it by adding 10 g m of trisodium phosphate Na3PO4 or 25 g m of trisodium phosphate dodecahydrate Na3 PO4 12H2O Wait another 2 4 weeks before making further corrections The pH value must not exceed 9 No hybrid installations A disadvantage of salt regeneration ion exchange is the salt content with its high e...

Page 24: ...int in the system with the highest temperature and the lowest pressure The two typical points for releasing gas are the hot boiler and the highest point in the heating system flow 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 dimensioned the same as the ...

Page 25: ...nce between cold and warm heating system buffer fully loaded if installed is greater than 1 0 bar for a single storey system or 0 5 bar for a three storey system then the expansion tank is too small and absolutely must be replaced with a larger one If the installed expansion tank is not large enough the system sucks in air when cooling and the air is absorbed by the cold water and transported to t...

Page 26: ... of systems without measures to counteract structure borne noise transmission the limit value of 30 dB a for domestic technical systems can be exceeded in the adjacent living rooms for 10 of systems For this reason cover the screw in the wall opening with mineral wool to prevent noise being introduced into the wall In the same way the store room should be set up on a floating screed to acousticall...

Page 27: ...t compensator and bypass for several boilers the buffer s storage capacity should be chosen to match 20 to 30 minutes of full load operation for the largest automatic wood boiler in the system In special cases peak loads and non continuously operated air heating systems must also be taken into account or the morning peak if the start of an oil gas boiler is to be avoided Whereby first the morning ...

Page 28: ...er can t unmix what has been mixed by heat distributors Particularly in houses where radiators and underfloor circuits are present no mixing heat distributors should be installed the returns should be connected directly to the buffer An underfloor heating system can still be operated with the return from radiators If a solar heating system is connected only the cold returns from an underfloor heat...

Page 29: ...ensor Sensor 3 must always be positioned just above the lowest return connection This is also important for buffers from third parties so that they are not positioned beneath the lowest return connection With fresh water module 1 Fresh water module flow 2 Boiler heating circuits oil gas boiler flow 3 Temperature sensor Sensor 1 upper 4 Oil gas boiler return 5 Temperature sensor Sensor 2 6 High tem...

Page 30: ... return 9 Temperature sensor Sensor 4 10 Solar return 11 Fresh water module return 12 Low temperature circuits return With stratified charging module and fresh water module 1 Fresh water module flow 2 Temperature sensor Sensor 1 upper 3 Boiler heating circuits oil gas boiler flow 4 Solar flow top 5 Temperature sensor Sensor 2 6 Oil gas boiler return 7 Temperature sensor Sensor 3 8 Solar flow lower...

Page 31: ... be horizontal 1 Flow 2 Solar heating system flow 3 Return 4 Solar heating system return 5 Return Serial connection A serial connection between two buffers has no advantages over a parallel connection but it does dis advantages For example a suspended hot water tank can get no heat from the second buffer or an internal heat exchanger cannot heat to both buffers For this reason with serial buffers ...

Page 32: ...pread of 20 C Therefore external piping either symmetric or with Tichelmann connection is needed for higher outputs With more than two tanks external piping with Tichelmann connection is also needed to fill and drain all tanks uniformly Parallel connection between buffer stor age tanks Buffer con nections 5 4 DN 32 Buffer con nections 6 4 DN 40 one sided connection 25 kW boil er output maximum 2 b...

Page 33: ...Buffer storage tank Connection between multiple buffer storage tanks 33 ...

Page 34: ... On one tank the boiler outlet is connected at the top on the other the boiler return is connected at the bottom Return lines with greatly differing temperatures should be fed into the buffer storage tank separately To minimize pipe circulation losses it is helpful to make the connections with downward siphon loops With hot water tank 1 Boiler flow heating circuits hot water tank oil gas boiler fl...

Page 35: ...h temperature circuit return 4 Low temperature circuits return 5 Fresh water module flow 6 Temperature sensor Sensor 1 upper 7 Temperature sensor Sensor 2 8 Solar flow top 9 Temperature sensor Sensor 3 10 Solar flow lower 11 Temperature sensor Sensor 4 12 Fresh water module return solar For a sufficient hot water reserve the release temperatures of the heating circuits must be over 45 C ...

Page 36: ...is circuit To minimize pipe circulation losses it is helpful to make the connections with downward siphon loops For a small solar heating system the total volume can be reduced in the summer by locking individual buffers With hot water tank or internal water heat exchanger 1 Boiler heating circuits oil gas boiler flow 2 Temperature sensor Sensor 1 upper 3 Temperature sensor Sensor 2 4 Oil gas boil...

Page 37: ...or 2 5 Solar flow top 6 Temperature sensor Sensor 3 7 Solar flow lower 8 Temperature sensor Sensor 4 9 Fresh water module return solar and low temperature circuits 10 Oil gas boiler return 11 Boiler high temperature circuit return 90 kW DN 32 DN 40 R 1 42 x 1 5 160 kW DN 32 DN 50 R 2 54 x 1 5 300 kW DN 40 DN 65 R 2 76 x 2 450 kW DN 40 DN 80 R 3 89 x 2 maximum total output Connecting ball valves on...

Page 38: ... immersed hot water tanks or internal water heat exchangers are unsuitable for a serial buffer connection To minimize pipe circulation losses it is helpful to make the connections with downward siphon loops With fresh water module 1 Fresh water module flow 2 Temperature sensor Sensor 1 upper 3 Boiler heating circuits oil gas boiler flow 4 Temperature sensor Sensor 2 5 Oil gas boiler return 6 Solar...

Page 39: ...4 Temperature sensor Sensor 2 5 Temperature sensor Sensor 3 6 Solar flow top 7 Oil gas boiler return 8 Temperature sensor Sensor 4 9 High temperature circuits return 10 Solar flow lower 11 Fresh water module and solar return 12 Boiler and low temperature circuit return 100 kW 2 DN 40 R1 42 x 1 5 140 kW 4 DN 50 R2 54 x 1 5 170 kW 2 DN 50 R2 54 x 1 5 maximum total output Number of buffers Connecting...

Page 40: ...he boiler into the boiler room Transport the boiler into the boiler room The required clearances for installation and maintenance must be maintained see chapter 2 Technical data Lifting lug for transporting the boiler Lifting lugs are located on the top side for lifting the boiler The weight of the boiler is approx 2000 kg Placing the pellet module near the boiler The pellet module is delivered fr...

Page 41: ...under the boiler s base frame and also under the stoker s levelling screws 9 2 Mount flue gas connection Mounting the flue gas connection Remove the cover from the top of the boiler Fig 9 4 Cover Check the flue gas connection seal for damage Attach the flue gas connection to the boiler with the nuts Tighten the nuts alternately and evenly Fig 9 5 Flue gas connection Mount the flue gas temperature ...

Page 42: ...ust be 90 offset to the screw on the actuator Fig 9 8 Adapter Turn the actuator in the closed position see sticker Also turn the air valve shaft to the fully closed position Place the air valve on the shaft and fix it in the actuator with the screw Fig 9 9 Actuator Fig 9 10 Screw Then connect the actuator to the line already laid on the top of the boiler Fig 9 11 Electrically connecting the actuat...

Page 43: ...ecause the electrode in the precipitator must be an equal distance away from the inner walls on all sides Even if the boiler is not equipped with a precipi tator it must still be horizontally aligned because the precipitator may be retrofitted at a later time Horizontal alignment is also important for the separate ventilation connection For this reason never align the boiler to be rising or fallin...

Page 44: ...ent of the stoker and correct it with the levelling feet Fig 9 17 Checking the horizontal alignment Tighten the screws alternately and evenly Fig 9 18 Tightening the screws Installing the pellet hopper Remove the cover from the top Fig 9 19 Cover Unscrew the levelling feet on the pellet hopper so that it is positioned higher Fig 9 20 Setting the pellet hopper higher Carefully push the pellet hoppe...

Page 45: ...the stoker with nuts Tighten the nuts alternately and evenly Check the alignment of the pellet hopper and correct it with the levelling feet if necessary Fig 9 22 Checking the alignment Rotating the connections for pellet hoses If required the pellet hose connections can be rotated by 90 or 180 If this is necessary carry out the following steps 1 Push up the rear cover and remove it Fig 9 23 Cover...

Page 46: ...he desired position In this example the connection is rotated by 90 Fig 9 26 Replacing the connection and blind cover Replace the connection and blind cover and reinstall them on the pellet hopper Make sure not to damage the included seal during installation 5 Turn the lid and re attach it Both connectors for the pellet hoses must point in the same direction Fig 9 27 Attaching the lid 6 Re attach ...

Page 47: ...rear of the boiler Left means that the pellet module is installed on the left side of the boiler 1 Pellet module on the left side of the boiler 2 Attach the seal and mount the ash duct to the ash box Note the alignment of the ash duct see graphic Tighten the screws alternately and evenly Fig 9 30 Ash duct stoker on left 3 Mount the flap on the ash duct Do not tighten the nut so that the flap is st...

Page 48: ...stoker on right Fig 9 33 Flap Attaching the ash box Open the flap on the ash box Fig 9 34 Flap Fold the locking lever on the boiler forwards Fig 9 35 Locking lever Push the ash box over the connection on the boiler and connect it to the boiler with the locking lever Set the height of the attached ash box so that the ash box lies evenly on the floor ...

Page 49: ...cal unit next to the boiler circuit board Fig 9 38 Electrical unit The cable lengths of the cable harness are defined from factory and fixed with cable ties so that the cable harness can be laid quickly These cable ties should not be removed If there are excess cable lengths create a loop near the circuit boards and fasten with a cable tie Thread the cable harness into the electrical unit and guid...

Page 50: ... 9 41 Cable guide Connect boiler to potential equalisation The boiler must be connected to the potential equaliza tion of the boiler room or the building Country specific regulations must be observed The runners of the boiler features holes to connect the potential equalisation minimum cross section 6 mm Fig 9 42 Connect potential equalisation 9 9 Bottom insulation Pushing in floor insulation Conn...

Page 51: ...Fig 9 45 Floor pan Then pull the metal strips out of the floor pan and dispose of them Fig 9 46 Metal strips 9 10 Connecting piping Connecting the piping to the boiler 1 Connection for safety valve pressure gauge and bleed valve 2 Flow 3 Return 4 Filling and draining valve Installing the thermal emergency cooling valve Remove the plug screw from the top of the boiler and install the immersion slee...

Page 52: ...ying the pellet hoses take note of the comments see 13 8 Information about pellet hoses Reinforced pellet hoses are required Reinforced pellet hoses are also required due to the higher pellet discharge rate They have a larger external diameter and require larger hoses clamps All these components are available separately from ETA Mount fire resistant collars if required If the pellet hoses from the...

Page 53: ... from both pellet hoses to the yellow green earthing cable next to the connections Fig 9 52 Connecting the copper wire strands to the earth Mounting the pellet hoses on the discharge On the ends of both pellet hoses free around 5 cm of the copper wire strands from the hoses Bend the copper wire strand inside the pellet hose Fig 9 53 Copper wire strands Push the two pellet hoses onto the connection...

Page 54: ...n 0 2 bar for bleeding Bleeding the heating system Open the ball valves on the heating circuits and bleed the heating system completely After bleeding check the water pressure and adjust if necessary Checking the water tightness of the piping Check the water tightness of all piping If there is any water leakage its cause must be found and eliminated 9 13 Network connection Connecting the network a...

Page 55: ...Installation Network connection 55 ...

Page 56: ... cross section 6 mm DANGER Do not carry out work on high voltage units The housing of the high voltage unit may not be opened or damaged as there are parts inside it that are under high voltage Non compliance with the above may result in serious or fatal injuries DANGER Electric shock There are live parts on the circuit boards If touched they can cause injury and property damage Before beginning a...

Page 57: ...ine A strain relief is required for the supply line to the boiler A strap is available near the cable channels for attachment Fig 10 1 Strain relief Connection diagrams Fig 10 2 Analogue input Fig 10 3 Digital switch Fig 10 4 Speed controlled pump Fig 10 5 Special function pump with supply extension 230 V Fig 10 6 Special function changeover valve with three point controlling Fig 10 7 Special func...

Page 58: ... the pellet module stoker screw dosing screw vacuum turbine sensors are already pre wired to the electrical unit from factory Connect all plugs to the circuit board HA C5 and the 230 V power supply at the terminal blocks See the following graphic Fig 10 8 Installing the electrical unit The pellet discharge a screw discharge in this example is connected to the orange plug of S40 L1 ...

Page 59: ...conveyor screws then it is connected to circuit board GM C and IN E The plug in circuit board IN E has already been installed at the factory In the following example a switching unit for 8 suction probes is used as pellet discharge conveyor The position switch of the switching unit is connected to the circuit board IN E at S610 and the reference point switch to terminal S611 The sensor required fo...

Page 60: ...60 www eta co at Overview of circuit boards Electrical connections 10 4 Overview of circuit boards Overview of boiler circuit boards ...

Page 61: ...Electrical connections Overview of circuit boards 61 ...

Page 62: ...se terminals can be used depending on the configuration Terminal Function Minimum cross sec tion Default assignment Series terminal Mains power input 3 x 1 5 mm S40 L1 230 V output 3 x 1 mm Conveying system see graphic Fig 10 8 Installing the electrical unit S49 230 V input 3 x 1 mm Water shortage switch S52 230 V input 3 x 1 mm Emergency stop switch S62 Potential free output special function S542...

Page 63: ...to circuit board GM C terminal S1 S53 STB 230 V input Safety temperature limiter Safety temperature lim iter STB S53 ASCHENKÜBEL 230 V input Ash box switch S53 ROST 230 V input Grate switch S53 GLUTBETT 230 V input Firebed switch S54 230 V input Cannot be used S55 230 V input Cannot be used S56 230 V input Cannot be used S57 230 V output Pellet vacuum turbine via contactor S58 230 V output Drive f...

Page 64: ...cuit board GM C terminal S512 S555 AI Analogue input Firebed level sensor S555 DI 24 V input S556 AI Analogue input Flow rate sensor S556 DI 24 V input S557 Analogue output Target speed of the draught fan S558 T1 Temperature input Boiler S558 T2 Temperature input Return S558 T3 Temperature input Flue gas temperature sensor in heat exchanger S558 T4 Temperature input Flue gas temperature sensor on ...

Page 65: ...Electrical connections Circuit board HA C5 65 ...

Page 66: ...3 x 1 mm Heating circuit 2 heating circuit pump S7 230 V output 3 x 1 mm Heating circuit 1 heating circuit pump S8 230 V output 4 x 1 mm Heating circuit 1 heating circuit mixing valve Switching unit see graphic Fig 10 9 Con necting the switch unit S9 230 V supply extension 3 x 1 mm to circuit board MK E terminal S15 S10 Potential free output special function Circulation pump burner S500 T1 Tempera...

Page 67: ... for pump on terminal S2 S505 PWM output analogue output 2 x 0 5 mm Speed for pump on terminal S3 S506 PWM output analogue output 2 x 0 5 mm Speed for pump on terminal S4 S507 PWM output analogue output 2 x 0 5 mm Speed for pump on terminal S5 S508A CAN Bus 2 x 0 6 mm S511 RS 485 bus 2 x 0 6 mm Digital room sensor Plug in circuit board IN E at X8 S610 Analogue input 3 x 0 5 mm Switching unit posit...

Page 68: ...grate 2 S514 Analogue input Vacuum sensor X2 CAN Bus supply GND for standalone mode X3 Boot jumper X4 CAN Bus terminal resistor X5 RS 485 terminal resistor X8 Terminal for plug in circuit board X9 Terminal for plug in circuit board X24 CAN Bus supply 24 V for stand alone operation These terminals have already been pre wired at the factory Terminal Function Default assignment ...

Page 69: ...iler casing Reinstall the parts of the boiler casing that were removed during the assembly Removing protective film Remove protective film from all covers After longer periods of operation of the boiler the film can no longer be removed without damaging the paint ...

Page 70: ...er and possibly also the fuel conveying system from all power sources Dismantling is done in the reverse order of assembly Clean the parts and remove them in accordance with the local regulations for workplace safety and environ mental protection Disposal Disposal including all components must be done in an environmentally friendly manner according to waste disposal laws Recycle any materials that...

Page 71: ...vents air circulation from the lower boiler to the pellet store Testing before initial fill up Before filling the pellet store test the functionality of the entire heating system and the pellet conveying system For this purpose deposit some pellets bagged product in the storage room near the discharge conveyor Only fill up the pellet store after this test has been completed successfully Burn back ...

Page 72: ...on brick 170 mm thick and plastered on both sides Post and beam walls with 120 mm beams clearance 625 mm with wooden panelling 15 20 mm thick on both sides Dry storage for pellets Pellets are very hygroscopic they absorb moisture from the environment On contact with water or moist walls they swell up and break apart becoming unusable The pellet store must stay dry throughout the year The normal hu...

Page 73: ...m length of the pellet store Example Room width 2 0 m and height 2 4 m The table yields a usable cross section of 2 9 m The volume of pellets to be stored in the example above is 7 2 m 7 2 m 2 9 m 2 5 m length A discharge screw with a length of 2 5 m is required Example Room width 2 8 m and height 2 4 m The table yields a usable cross section of 3 59 m The volume of pellets to be stored in the exa...

Page 74: ...side 1 Filling nozzle 2 Conveyor screw 3 Impact protection mat 4 Back air nozzle Opposite the central nozzle an impact protection mat is installed 500 mm from the wall to prevent damage to both pellets and the plasterwork on the wall The filling nozzles must be installed 200 mm below the ceiling to keep the pellets from scraping on the ceiling during injection Only in exceptional cases when no sho...

Page 75: ...ing To install the filling nozzles in smooth holes or sewer pipe cut outs so they cannot twist the ETA filling nozzles are equipped with a flange that transfers the forces directly into the wall via 4 screws ETA filling nozzles with 100 mm diameter fit exactly in the cut outs made for fitting a sewer pipe with 110 mm outside diameter The small gap between nozzle and wall can be sealed with silicon...

Page 76: ...blem Height differences of one floor or even two for short lines can also be overcome without problems Extension with aluminium piping only Only aluminium piping may be used for the filling system Do not use plastic piping danger due to electrostatic charge build up The filling system must be earthed against electro static charges The filling system must be smooth on the inside throughout its leng...

Page 77: ...t have a floor with 40 tilt to ensure that all pellets in the store can be extracted This applies for systems with conveyor screws as well as for suction heads Construction of tilted floor for pellet store For the tilted floor three ply concrete formwork panels 27 mm thick have proven effective Unplaned wooden boards 25 mm thick with a smooth plastic laminated surface can also be used The tilted f...

Page 78: ...ater from the circulating air can condense on them The condensation can cause pellets and in particular pellet dust to form clumps that can clog the pneumatic conveyor To avoid this always mount the suction heads on a wooden board 25 or 27 mm thick and fasten it to the floor Pad wall opening for conveyor screw trough Sound from the screw can be transmitted through the pellet store walls into the h...

Page 79: ...ncated A reserve of pellets will remain on the resulting flat surfaces when the main store is empty the reserve pellets can be swept into the main store manually The disadvantage of this method is that the reserve space must be cleared at least every 3 years so that dust and broken or moist pellets cannot gather ...

Page 80: ...ngth of the venti lation line Store size 10 tonnes Store size 10 tonnes 2 m Ventilation via sealing cover with the follow ing requirements Two ventilated sealing caps on two Storz A couplings Ventilation to the outside or in ventilated installation room of the heating system Ventilation via sealing cap only in stores up uo 40 t with the following requirements minimum 2 ventilated sealing caps on t...

Page 81: ...ng nozzles protrude into a room in which ventilation is available ÖNORM M 7137 recommends using only sealed unventilated sealing covers Fig 13 12 Filling nozzles in the boiler room 1 Ventilating the room 2 Sealed unventilated sealing cover 3 Ventilation opening outside If the pellets are stored in a bag that positioned in the same room as the boiler ventilation must be available in this room Opera...

Page 82: ...13 17 Use pipe guides or pipe supports Single piece suction hose The suction hose for the pellets must always consist of a single piece Suction hoses made from several parts have higher friction on the inner walls which can result in damage to the pellets Only the pellet hose for the back air may be made of multiple parts Straight paths Lay out the pellet hoses as straight as possible Suction hose...

Page 83: ... states though all state legislation is based on the TRVB H 118 Technische Richtlinien vorbeu gender Brandschutz automatische Holzfeuerungsan lagen technical directives for preventive fire safety for automated wood combustion systems For questions about details consult an expert or the building inspectorate or the regional fire prevention agency Wood and fuel storage rooms within a building All wa...

Page 84: ...gs and doors and no usage restrictions are stipulated Pellet stores over 10 000 litres 6 5 tons Walls and ceilings REI90 F90 no lines through walls No other use Doors self closing and fire resistant EI30 T30 Pellet filling lines through other rooms EI90 F90 Rated heat output of boiler less than 50 kW boiler room No requirements for the room Not permitted installation in required stairwells in room...

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