eta HACK 130-200 Installation, Configuration And Maintenance Download

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2015-04-29
EN
0000000056
V.004
X.31.0

93921

Pellet suction system

for HACK

Installation, configuration and

maintenance

Summary of Contents for HACK 130-200

Page 1: ...2015 04 29 EN 0000000056 V 004 X 31 0 93921 Pellet suction system for HACK Installation configuration and maintenance ...

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: ...21 9 1 Starting the configuration assistant 21 9 2 Adjusting and adding function blocks 21 9 3 Creating connections 22 9 4 Showing terminal assignments 22 9 5 Installing a configuration 22 10 Electrical connection 24 10 1 HE C3 board 25 11 Concluding activities 26 11 1 Installing side panels 26 11 2 Remove carrying aids 26 11 3 Install bleed screw 26 11 4 Mounting the transfer coupling 27 11 5 Mou...

Page 4: ...Calculating pellet supply and store size 34 14 2 Requirements for pellet store 35 14 2 1 No cables pipes in the pellet store 36 14 2 2 Tilted floor 36 14 2 3 Filling nozzles 38 14 3 Filling the storage room 39 14 4 Fire safety regulations 40 ...

Page 5: ...idual configurations depicted or described here are only optionally available In the event of contradictions between individual documents regarding delivery scope the information in our current price list applies Explanation of symbols Instructions and information Layout of safety instructions SIGNAL WORD Type and source of danger Possible effects Measures for avoiding the danger Types of safety i...

Page 6: ...these conditions will be satisfied by a professional heating technician Nevertheless inform the technician of our warranty conditions All of the re quirements we impose are intended to prevent damage that neither you nor we wish to occur Training the customer To avoid errors in operation please explain to your customer exactly how his new product works and how it should be operated and maintained ...

Page 7: ...mer have installed the heating system partly or entirely without relevant training and in particular without up to date practical experience without having the installation checked by a trained and responsible expert we exclude defects in our delivery and conse quential damages resulting from this cause from our warranty guarantee and liability Wearing parts There is no guarantee or warranty for p...

Page 8: ...s During boiler operation If the boiler requests fuel during heating the aspirators start and convey the pellets from the pellet store to the pellet bin of the suction system If the pellet bin is full enough the fill level sensor reacts The aspirator is turned off and the pellet flap to the drop chute is opened The pellets fall through the drop chute onto the discharge screw and are transported to...

Page 9: ...live parts on the circuit boards If touched they can cause injury and property damage Before beginning any work isolate the system completely from all power sources ensure that it cannot be switched back on and verify that it is safely isolated from supply CAUTION Flexible stranded conductors If flexible stranded conductors are not used for the wiring the contacts in the plug connections will be s...

Page 10: ...10 www eta co at Technical data 6 Technical data Dimensions and connections 1 Connection for return pipe 2 Connections can be turned through 360 in 45 steps 3 Connection of the conveyor pipe ...

Page 11: ...consumption kW 6 Electrical connection 400 V AC 50 Hz 13 A 3P N PE Conveyor pipe Value Welded steel pipes DN 80 Minimum inside diameter 80 mm Maximum outside diameter 88 9 mm Maximum length 35 m Maximum height difference 5 m Maximum number of bends 7 Minimum radius of bends 400 mm EN 10253 1 Return pipe Value Welded steel pipes or PU hoses DN 100 smooth interior surface Temperature range 40 C to 1...

Page 12: ...oupling pellet store 9 Threaded rods 10 Transfer coupling 11 Circuit board carrier Fig 7 2 Drop chute 1 Fill level sensor of the drop chute 2 Actuator of the pellet flap 3 Pellet flap end position sensor 4 Circuit board HE C2 Fig 7 3 Cover 1 Maintenance cover 2 Fill level sensor of the pellet bin 3 Connection of the conveyor pipe 4 Connection for return pipe 5 Aspirators ...

Page 13: ...Overview 13 Fig 7 4 Transfer coupling 1 Connection of the conveyor pipe 2 Drive shaft stub for conveyor screw 3 Connection for return pipe ...

Page 14: ...t least two people Take the minimum clearances for maintenance and cleaning into account see page 10 Determine the positions for the connections The connections for the conveyor and return pipes can be turned in 45 steps 8 2 Attaching carrying aids 1 Remove the safety brackets from the pellet suction system and the transport pallet 2 Remove the 2 M10 x 25 hex screws on the bearing plate 3 Reattach...

Page 15: ...o the sides of the support stand 3 Lift the pellet suction system far enough so that the support stand can be positioned beneath it 4 Attach the support stand with 2 M10 x 25 hex screws with washers and nuts and fasten finger tight 8 4 Pellets suction system pre installed on boiler WARNING Injuries caused by moving parts Possible crushing injuries to limbs due to improper handling of parts Choose ...

Page 16: ...s Position and align the pellets suction system in its installation location 2 Lift the pellet suction system and place the transfer coupling into the rotary valve Ensure that the coupling is completely inserted into the rotary valve 3 Fasten the transfer coupling finger tight on both sides of the rotary valve with 1 M10 x 180 threaded rod and nut on each side ...

Page 17: ...on 2 Remove the 4 M5 x 10 screws from the top of the cover and remove the panel 3 Connect the cables for the aspirator and the fill level sensor with the appropriate extensions Find the shortest way to the HE C2 circuit board and run the connection cables downwards through this opening to the circuit board 4 Mount the panel with 4 M5 x 10 screws to the top of the cover ...

Page 18: ...Installation 5 Attach the lid to the pellet bin with 3 fasteners 8 6 Align pellet suction system 1 Use a spirit level to check the horizontal orientation of the cover 2 Remove one M10 x 25 hex screw and nut from the front side of the support stand ...

Page 19: ... support stand to the required height and tighten the 2 M10 x 25 hex screws 5 Check the horizontal orientation of the cover once again 8 7 Fastening the support stand 1 Fasten the support stand with 6 M10 x 25 hex screws nuts and washers 2 Fasten the support stand to the floor with suitable fasteners The scope of delivery includes fasteners for concrete floors ...

Page 20: ...at Mounting the pellets suction system on the boiler Installation 8 8 Mounting the pellets suction system on the boiler On both sides of the rotary valve tighten the 2 threaded rods and nuts on the transfer coupling ...

Page 21: ...Press Accept to save Make the following settings Press Options to save the settings The window with the options appears To finish press Accept to save the changes Adding the Pneumatic conveyor system function block This function block is preconfigured at the factory Select the required function block from the Possible FUBs column Press to add the function block A window with the options opens Clos...

Page 22: ...ration Continue the configuration by pressing Next 9 4 Showing terminal assignments Display and connect terminal assignments The terminal assignments for the individual components of the heating system are shown in this window All configured function blocks for the individual circuit boards are listed in the Selected FUBs window When a function block has been selected its terminal assignment is sh...

Page 23: ...Configuration Installing a configuration 23 ...

Page 24: ...n cause injury and property damage Before beginning any work isolate the system completely from all power sources ensure that it cannot be switched back on and verify that it is safely isolated from supply CAUTION Flexible stranded conductors 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 cas...

Page 25: ...or for pellet flap S69 230 V output Aspirator via contactor S560 CAN Bus to boiler S562 24 V input Pellet bin fill level sensor S563 24 V input Pellet flap end position sensor S564 24 V input Drop chute fill level sensor S565 24 V input Aspirators drive protection X2 CAN bus terminator resistor Wall housing terminal Function Default assignment X1 1 Series terminal Emergency stop switch from circui...

Page 26: ...ght side attach a connecting piece with 1 M5x10 round headed screw b The adjacent panel on the right is mounted on the connecting piece with 1 M5x10 round headed screw Mount all 4 side panels in the same manner 11 2 Remove carrying aids 1 Remove the 2 M10 x 25 hex screws and the 2 safety brackets from the bearing plate 2 Reattach the 2 M10 x 25 hex screws to the bearing plate 11 3 Install bleed sc...

Page 27: ...rew with the supplied bleed screw Keep the plug screw in the vicinity of the heating system so you can seal the gearbox if transport should become necessary 11 4 Mounting the transfer coupling Mount the transfer coupling to the fuel discharge trough with 4 hex screws and nuts ...

Page 28: ...mer mounts the conveyor pipe between transfer coupling and pellet suction system Conveyor pipe Value Welded steel pipes DN 80 Minimum inside diameter 80 mm Maximum outside diameter 88 9 mm Maximum length 35 m Maximum height difference 5 m Maximum number of bends 7 Minimum radius of bends 400 mm EN 10253 1 Return pipe Value Welded steel pipes or PU hoses DN 100 smooth interior surface Temperature r...

Page 29: ...ersons who lack experience and knowledge as well as children may not operate clean or maintain the product Maintenance interval Maintenance is to be carried out in the course of annual boiler maintenance Depending on the fuel quality earlier maintenance at shorter intervals may be necessary 12 1 Preparation Remove the cover panel Remove the cover panel by removing 8 M5 x 10 round headed screws 12 ...

Page 30: ...heck seal Inspect seals pellet bin 1 Optically check the maintenance cover seal 2 Inspect the integrity of the seal and replace if necessary 12 5 Lubricate lubricating nipple Conveyor screw of the pellets suction system Lubricate the lubricating nipple of the discharge screw with the help of a grease gun Discharge conveyor screw Lubricate the lubricating nipple of the conveyor screw with the help ...

Page 31: ...intenance Concluding activities 31 12 6 Concluding activities Install maintenance cover Mount the maintenance cover with 6 M5 x 12 hex screws Mount cover panel Attach the cover panel with 8 M5 x 10 round headed screws ...

Page 32: ...vidually and replace if defective Pellet bin fill level sensor is dirty Possible causes Dust Troubleshooting Clean the pellet bin fill level sensor Discharge screw Possible causes Discharge screw blocked Aspirator has malfunctioned Return hose strainers are blocked Troubleshooting Clean the return pipe strainers Functional testing of the individual aspirators Check the conveyor and return air pipe...

Page 33: ...es not open close Possible causes Pellet flap is stuck or defective Broken cable Defective end position sensor Troubleshooting Pellet flap Clean opening and check seal Functional test of the actuator Clean the pellet bin fill level sensor ...

Page 34: ...ed for the store volume can be determined using Tab 14 1 Useful cross section of store in m That length also determines the minimum 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...

Page 35: ...lls with 120 mm beams separation 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 humidity encountered in normal residential construction throughout ...

Page 36: ... and cables in the path of pellets being injected especially those on the ceiling must be shielded Ensure that the pellets are gently deflected by a protective plate Fig 14 1 Protective plate for pipes cables that cannot be removed 1 Pipes cables 2 Insulation for pipes 3 Protective plate Only explosion proof electrical installations DANGER No electrical equipment such as switches lights junction b...

Page 37: ...crew can be transmitted through the pellet store walls into the house To avoid that pad the wall opening for the troughs with soft material mineral wool Under no circumstances should the conveyor screw trough be cemented into a concrete wall without acoustic insulation Small stores with reserve For small pellet stores the tilted floor can be truncated A reserve of pellets will remain on the result...

Page 38: ... when no short wall of the pellet store is accessible from the outside can the filling nozzles be positioned in the long wall Each half of the room needs its own nozzle with impact protection sheet opposite The disadvantage is that halfway through the filling process the hoses must be exchanged Fig 14 4 Filling nozzles in the long side 1 Two impact protection sheets 2 Filling nozzle 3 Back air noz...

Page 39: ...ences 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 length do not use spir...

Page 40: ...room separation between heating appliance and fuel store 1 m or sheet metal heat deflector No other use For pellet conveying hoses through rooms outside the boiler room fire compartment fire resistant collars must be installed in the wall openings facing the boiler room Ventilation lines through other rooms F90 Fire extinguishers as initial firefighting aids are only legally regulated for commerci...

Page 41: ...el store or the pellet bin This alarm thermostat is not required for an ETA pellet system since the ETA rotary valve with pressure equalisation ensures that no gas can flow in either direction between the combustion chamber and the fuel store This has been confirmed by tests at the Institut für Brandschutz technik und Sicherheitsforschung institute for fire protection engineering and safety resear...

Page 42: ...42 www eta co at Appendix 15 Appendix ...

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