eta HACK 20 kW Service Manual Download Page 1

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2017-01-09
EN
0000000295
V.002
X.38.0
3004, 3105
93528-001

Wood chip boiler

20 - 90 kW

Service manual

Summary of Contents for HACK 20 kW

Page 1: ...2017 01 09 EN 0000000295 V 002 X 38 0 3004 3105 93528 001 Wood chip boiler 20 90 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: ... the owner Subject to technical changes We reserve the right to make technical modifications without notice Printing and typesetting errors or changes of any kind made in the interim are not cause for claims Individual configurations depicted or described here are only available optionally In the event of contradictions between individual documents regarding delivery scope the information in our c...

Page 4: ...ence and knowledge as well as children may not operate clean or maintain the product Explanation of pictograms Switch the boiler on off with the mains switch Perform a visual check of the components Clean the components for example with a soft cloth Remove deposits with a vacuum or an ash vacuum Remove deposits with the poker Remove deposits with the cleaning brush Replace the wear parts e g seals...

Page 5: ...Cleaning and maintenance Maintenance notes 5 ...

Page 6: ...tion chamber door 2 Secondary air actuator mirrored for fuel discharge installed on the right 3 Actuator for tilting grate 4 Maintenance cover for optional flue gas recircula tion 5 Primary air actuator mirrored for fuel discharge installed on the right 6 Firebed switch mirrored for fuel discharge installed on the right 7 Safety switch for rotary valve maintenance cover 8 Plug screw for lubricatin...

Page 7: ... gas recirculation 2 Maintenance cover for optional flue gas recircula tion 3 Flue gas temperature sensor 4 Heat exchanger cleaner 5 Ignition 6 Stoker drive chain 7 Maintenance cover for optional flue gas recircula tion 8 Plug screw for lubricating the de ashing system s drive chain 9 Draught fan ...

Page 8: ...ignition tube Check firebed button and firebed switch Check refractory lining X X Customer or specialist Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check heat exchanger cleaner Check seal on heat exchanger cover X X Customer or specialist Clean flue gas recirculator optional Clean flue gas recirculation piping Inspecting seals on m...

Page 9: ...leaning and maintenance Maintenance table 9 Reset the maintenance counter X Specialist Perform heating test X Specialist Tasks Regular ly Every 2500 h or 1 year Every 5000 h or 3 years to be performed by ...

Page 10: ...y combustion chamber may not be steeper than 45 To remove this ash initiate boiler de ashing by pressing the De ash button Empty the ash box inspect the seals By knocking on the vertical wall of the ash box you can also check the ash level without opening the box A full ash box makes a short dull thump When empty it makes a hollower sound like a drum Open both lateral fasteners by pressing their s...

Page 11: ...m water pressure in a cold heating system is between 1 and 2 bar For a warm heating system the optimum water pressure is between 1 5 and 2 5 bar Fig 2 5 Pressure gauge If the water pressure is too low fill the cold heating system to approx 2 bar Do not fill to a higher pressure as water expands with increasing temperature and the water pressure also rises when the boiler is in heating mode The saf...

Page 12: ...ystem The outlets of the safety valves may not drip Fig 2 6 Safety valve If the safety valve drips open it with a quarter turn of the red cap and rinse it out danger of scalding If the safety valve still cannot be sealed effectively after being rinsed several times it must be cleaned or replaced by an installer heating technician A manual check of the safety valve is carried out with a 1 4 turn of...

Page 13: ...is very likely that the seal will be damaged in the process and thus the outlet will drip That is why you should only perform this check on weekdays and never on weekends in cold winter as no heating technician may be available if the seal is defective 2 5 3 Chimney Clean the flue tube Sweep the flue tube from the flue outlet to the chimney and remove flue ash from the chimney using a vacuum clean...

Page 14: ...y combustion chamber Remove the combustion chamber cover in the secondary combustion chamber Fig 2 11 Combustion chamber cover Remove the cover on the front Remove the screws for securing the cover Push the cover on the front up slightly detach and remove it Fig 2 12 Cover Clean tilting grate Press the button on the tilting grate s actuator and tilt the grate with the supplied tool Fig 2 13 Actuat...

Page 15: ...be for combustion residues and clean it by vacuuming Fig 2 16 Ignition tube Check firebed button and firebed switch Check the mobility of the firebed button in the combustion chamber by repeated lifting Fig 2 17 Firebed button The firebed switch on the front of the boiler must be actuated when lifting Fig 2 18 Firebed switch Check refractory lining Check the refractory lining of the primary and se...

Page 16: ...he front Mount the cover on the front of the boiler Also re install the screws for securing the cover Fig 2 20 Cover 2 5 5 Cleaning the heat exchanger Remove heat exchanger cover Open the maintenance cover in the top of the boiler casing and remove the insulating cover Fig 2 21 Insulating cover Loosen the knurled nuts on the heat exchanger cover by turning it anti clockwise and rotate the ball kno...

Page 17: ... ash from the heat exchanger for example with an ash vacuum Fig 2 25 Heat exchanger and downdraft channel After cleaning replace the internal cover Ensure that it is firmly seated Clean lambda probe Vacuum out the head of the lambda probe using a vacuum cleaner Do not dismantle the lambda probe Fig 2 26 Head of the lambda probe Check heat exchanger tubes Check the heat exchanger tubes and the turb...

Page 18: ...t exchanger cleaner Remove the cover for the heat exchanger cleaner drive Fig 2 28 Cover Manually operate the lever and check its ease of movement Lubricate the spring guide and bearing with a heat resistant lubricant Fig 2 29 Lever Check the gap between the sensor and the spring arm It must be 2 mm Fig 2 30 Position sensor Finally re attach the cover to the boiler Check seal on heat exchanger cov...

Page 19: ...increased wear Always replace seals as soon as they are damaged Close heat exchanger cover Position the heat exchanger cover carefully Fig 2 32 Heat exchanger cover Turn both ball knobs through 180 to secure the heat exchanger cover Then tighten the two knurled nuts evenly and cross wise by turning them clockwise Fig 2 33 Knurled nuts and ball knobs Put the insulating cover back on Fig 2 34 Insula...

Page 20: ... recirculation from the back side of the boiler Fig 2 35 Maintenance cover Also remove the shut off plug if present Fig 2 36 Shut off plug Also remove the two maintenance covers from the front side of the boiler Fig 2 37 Maintenance cover Clean flue gas recirculation piping Brush out the pipes of the flue gas recirculation with the brush and remove the ash with a vacuum cleaner Fig 2 38 Pipes Fig ...

Page 21: ...condition replace if necessary Fig 2 41 Seal CAUTION Avoid operation with damaged seals Never operate the boiler with damaged seals Otherwise leak air is sucked in disturbing the combustion process and causing increased wear Always replace seals as soon as they are damaged Re install maintenance cover Replace the shut off plug if this was already installed Fig 2 42 Shut off plug Re install all mai...

Page 22: ... Maintenance cover 2 5 7 Establish operational readiness Switch the boiler on via the mains switch and start de ashing Establish the boiler s power supply at the mains switch Press the De ash button to de ash the boiler Switch the boiler back on with the On Off switch ...

Page 23: ...ler performs an ember burnout and then changes to Switched off mode Press the De ash button to make the boiler perform a final de ashing Switch off boiler via mains switch WARNING Switch off the electricity to the boiler via the mains switch 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 ho...

Page 24: ... must point to the right when viewed from behind the boiler 2 6 3 Clean temperature sensor Clean the flue gas temperature sensor To clean loosen the screw and pull out the flue gas temperature sensor Clean the sensor with a soft cloth and then re install it When fixing the temperature sensor in place only tighten the screw hand tight so as not to damage the sensor Fig 2 48 Flue gas temperature sen...

Page 25: ...d check their movement Fig 2 50 Air valve actuators For manual operation push the release button red button and manually turn the actuator through 90 with the set screw Fig 2 51 Manual operation of actuator 1 Set screw 2 Release button If there is resistance in the movement of the air valves lubricate only with dry lubricant e g PTFE spray Mount cover on the front Mount the cover on the front of t...

Page 26: ...of the boiler remove the plug screw from the cover next to the de ashing drive Fig 2 54 Plug screw Through this opening lubricate the de ashing drive chain with chain spray The easiest way to do this is to start de ashing This sets the chain in motion so it can be completely lubricated Check de ashing system Start de ashing in order to check de ashing of the boiler The movement of the turbulators ...

Page 27: ... Removing the ignition fan Detach the ignition tube by loosening the 4 screws and remove the ignition rod Clean the photocell with a soft cloth Then reattach the ignition tube Fig 2 56 Photocell Also clean the opening in the boiler for the ignition tube Fig 2 57 Ignition tube Re install the ignition fan and attach it to the boiler with the chain ...

Page 28: ... Seal Also check if the sealing cord is already hard To check press on the sealing cord with your finger nail If it can no longer be pressed it is hard already and must be replaced Adjustment requires the removal of the combustion chamber door To do so open the combustion chamber door lift it slightly remove it and carefully place it next to the boiler 1 Closing roller mount 2 Hinge Loosen the fla...

Page 29: ... by loosening the acorn nuts Fig 2 61 Cover Check the tension of the stoker drive chain The chain may sag by 1 2 cm without effort Fig 2 62 Stoker drive chain If it sags more the chain must be tensioned with the turnbuckle Fig 2 63 Turnbuckle Lubricate the drive chain with chain spray Fig 2 64 Lubricate drive chain ...

Page 30: ...ew Mount the drive chain cover Remount the drive chain cover Fig 2 66 Cover 2 6 10 Inspect safety switch on the drop chute Check the contact switch on the drop chute Check the contact switch on the drop chute To do so raise the drop chute cover Fig 2 67 Contact switch on the drop chute Check drop chute safety switch Check the safety switch on the drop chute To do so raise the drop chute cover Fig ...

Page 31: ...he rotary valve rotates until it is detected by the rotary valve position sensor and then it stops Next perform a visual check of the rotary valve end position To do so remove the locking nut and the spring and raise the drop chute cover Fig 2 69 Visual check The rotary valve is positioned correctly if the opening in the rotary valve is completely visible from above through the open drop chute cov...

Page 32: ... 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 If you wish to perform an additional lambda probe cal ibration the control system features the Addl calibra tion function This function can be selected with the Service access level and can be found under Switch on this function ...

Page 33: ... the boiler will start immediately The control system ensures that sufficient heat is channelled to the buffer the heating circuits and the hot water tank After around 10 minutes of heating the residual oxygen value should reach 6 to 9 The current residual oxygen content is displayed in the boiler s text menu under If the value does not drop below 12 residual oxygen the boiler is receiving leak ai...

Page 34: ...ces in the fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger...

Page 35: ...uel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check...

Page 36: ...ndary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check heat exchanger cleaner Check seal on heat exchanger cover Clean flue gas recirculator optional Clean flue gas recirculatio...

Page 37: ...cords Maintenance expert 37 Comments Calibrate the lambda probe Reset the maintenance counter Perform heating test Tasks Notes performed on _________________________ performed by _________________________ ...

Page 38: ...n the fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tube...

Page 39: ...uel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check...

Page 40: ...ndary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check heat exchanger cleaner Check seal on heat exchanger cover Clean flue gas recirculator optional Clean flue gas recirculatio...

Page 41: ...cords Maintenance expert 41 Comments Calibrate the lambda probe Reset the maintenance counter Perform heating test Tasks Notes performed on _________________________ performed by _________________________ ...

Page 42: ...n the fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tube...

Page 43: ...uel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check...

Page 44: ...ndary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check heat exchanger cleaner Check seal on heat exchanger cover Clean flue gas recirculator optional Clean flue gas recirculatio...

Page 45: ...cords Maintenance expert 45 Comments Calibrate the lambda probe Reset the maintenance counter Perform heating test Tasks Notes performed on _________________________ performed by _________________________ ...

Page 46: ...in the fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tub...

Page 47: ...fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Chec...

Page 48: ...ndary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check heat exchanger cleaner Check seal on heat exchanger cover Clean flue gas recirculator optional Clean flue gas recirculatio...

Page 49: ...cords Maintenance expert 49 Comments Calibrate the lambda probe Reset the maintenance counter Perform heating test Tasks Notes performed on _________________________ performed by _________________________ ...

Page 50: ...in the fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tub...

Page 51: ...fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Chec...

Page 52: ...ndary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check heat exchanger cleaner Check seal on heat exchanger cover Clean flue gas recirculator optional Clean flue gas recirculatio...

Page 53: ...cords Maintenance expert 53 Comments Calibrate the lambda probe Reset the maintenance counter Perform heating test Tasks Notes performed on _________________________ performed by _________________________ ...

Page 54: ...in the fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tub...

Page 55: ...fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Chec...

Page 56: ...ndary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check heat exchanger cleaner Check seal on heat exchanger cover Clean flue gas recirculator optional Clean flue gas recirculatio...

Page 57: ...cords Maintenance expert 57 Comments Calibrate the lambda probe Reset the maintenance counter Perform heating test Tasks Notes performed on _________________________ performed by _________________________ ...

Page 58: ...in the fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tub...

Page 59: ...fuel path Chimney Clean the flue tube Flush the chimney s condensate drain Clean combustion chamber Clean inside of the secondary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Chec...

Page 60: ...ndary combustion chamber Clean tilting grate Clean secondary air openings Clean the ignition tube Check firebed button and firebed switch Check refractory lining Clean heat exchanger Clean heat exchanger and downdraft channel Clean lambda probe Check heat exchanger tubes Check heat exchanger cleaner Check seal on heat exchanger cover Clean flue gas recirculator optional Clean flue gas recirculatio...

Page 61: ...cords Maintenance expert 61 Comments Calibrate the lambda probe Reset the maintenance counter Perform heating test Tasks Notes performed on _________________________ performed by _________________________ ...

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Summary of Contents for HACK 20 kW

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