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Preparing the heat exchanger

Installation

9

Installation

Assembly and installation only by qualified
specialist personnel

The assembly and installation may be performed
by specialist personnel with the corresponding

qualifications only.

9.1

Preparing the heat exchanger

Installing the levelling feet of the heat exchanger

Install the four levelling feet on the floor of the heat
exchanger and secure them with the nuts.

Fig. 9-1: Installing levelling feet

Positioning the heat exchanger

The heat exchanger can be moved either with a crane
or a lifting device (forklift truck or pallet jack).

Fig. 9-2: Heat exchanger

When lifting with a crane, a 4-strand chain sling
must be used. The chain angle may not exceed

45°.
When lifting with a forklift truck, the length of the fork
must be at least 1100 mm.

WARNING!

Danger of the heat exchanger tipping over during
lifting.

There  is  an  increased  danger  of  tipping
over  when  lifting  via  pallet  jack.  Possible
injuries  and  property  damage  could  then
occur.



Adequately secure the heat exchanger against
accidents during transport.

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Содержание 13250

Страница 1: ...2020 12 17 EN 0000000421 V 005 3400 939054 001 Moving grate boiler 250 kW Installation...

Страница 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...

Страница 3: ...and layout 25 7 1 2 Renovation 29 7 2 General information 29 7 3 Water hardness 31 7 4 Bleeding 32 7 5 Corrosion 33 7 6 Pressure equalisation 33 8 Buffer storage tank 34 8 1 General information 34 9...

Страница 4: ...14 1 De ashing with downpipe 53 9 14 2 De ashing with ash flap 57 10 Electrical connections 63 11 Fuel store 65 11 1 Requirements 65 11 2 Dimensioning 65 11 3 Tilted floor 67 11 4 Pellet operation 68...

Страница 5: ...ed warranty if the product is com missioned by our own customer service technicians In this regard please note the warranty conditions applicable at the time of purchase Service agreement You can ensu...

Страница 6: ...with a vacuum cleaner or an ash vacuum Remove deposits with the poker Remove deposits with the cleaning brush Replace the wear parts e g seals with new items Lubricate the components The lubricant to...

Страница 7: ...As an option the boiler may be operated at a maximum operating pressure of 6 bar For this all other system components also have to be designed for this higher operating pressure Provide a sufficiently...

Страница 8: ...temperature limiters safety valves and thermal discharge valves 1 4 Dismantling disposal Dismantling Before dismantling Stop heating Switch off the boiler with the mains switch and ensure that it can...

Страница 9: ...General Dismantling disposal 9...

Страница 10: ...ge 2 Return with DN50 connecting flange 3 Safety heat exchanger of the grate duct connection R1 2 inside thread 4 Safety heat exchanger for heat exchanger connection R1 2 inside thread 5 Discharge wit...

Страница 11: ...mass flow rate with spruce wood chips at full load g s 138 Flue gas mass flow rate with pellets at full load g s 140 CO2 content in dry exhaust gas partial full load 12 5 14 7 Exhaust temperature at...

Страница 12: ...l so the ash bins can be exchanged later 2 De ashing with an ash flap A flap in the ejector dumps the ash into a container underneath ETA offers an ash bin with a 770 litre or 320 litre capacity for t...

Страница 13: ...Fuel supply manual automatic automatic Proportion of the partial load referred to the full load 30 50 30 Temperature controller integrated in the boiler yes no yes Temperature controller class VIII C...

Страница 14: ...Partial load kW 74 9 99 105 126 135 Efficiency in terms of gross calorific value at maximum load 82 3 83 0 83 0 83 2 83 3 Efficiency in terms of gross calorific value at partial load 82 4 83 0 83 1 8...

Страница 15: ...quirements 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...

Страница 16: ...lers Part 5 Heating 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 Gen...

Страница 17: ...for the 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...

Страница 18: ...6 1 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 WARNING Danger of fire due to hot parts Even after th...

Страница 19: ...ng with a piece of wire WARNING The outlet from the thermal emergency cooling valve must be directed to the sewer via an easily visible open flow path siphon funnel so that malfunctions especially a n...

Страница 20: ...vailable for this purpose Fig 6 7 Connection for safety valve on flow DANGER Safety valve outlet The safety valve outlet must be directed to the ground in a pipe so nobody is endangered by hot water o...

Страница 21: ...en The fuel supply is stopped and heating mode ends with burnout of the embers Fig 6 9 Pressure sensor The minimum pressure limiter is activated as soon as the pressure falls below the minimum level s...

Страница 22: ...air flaps If there is a fault in the fan or the air flaps a safety shutdown takes place Fire compartments in larger buildings If a secure fire compartment is required between the boiler room and the f...

Страница 23: ...re sensor Manually activated fire extinguishing system This safety device floods the fuel store with water in the event of a fire This system consists of non flammable empty piping with a minimum nomi...

Страница 24: ...20 litres The tank must be equipped with a filling level monitor that can trigger an acoustic or visual alarm Securing the fire compartment in larger buildings or between a house and barn An open fire...

Страница 25: ...diameter can be used No cross sectional taper is permitted such as a DN300 flue pipe in a chimney with a 28 cm diameter Diameter of the flue pipe from boiler to chimney Chimney height above the boile...

Страница 26: ...of this kind are virtually impossible as the control system restricts wood gasification not the air In mod ern lambda controlled wood boilers the control system shuts down the fire by stopping the fue...

Страница 27: ...er An overly strong flue draught prevents the recirculation to the boiler and the flue gas reaches the chimney immediately thus rendering the flue gas recir culation ineffective This leads to slag for...

Страница 28: ...emission measurement A second chimney connection below the first one enables simple installation of a draught limiter if this is required Measurement opening for the emissions measurement Create a se...

Страница 29: ...of Chimney Sweeps has found the following solution to the standards and regulations dilemma in the certification of suitability and safe use for heating systems it should be noted that after a soot fi...

Страница 30: ...opens the mixer and switches on the boiler pump to exploit the residual heat Insulate pipelines at the buffer The pipes to and from the storage tank should be insulated to minimise heat loss The recom...

Страница 31: ...g 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 12H...

Страница 32: ...boiler s flow connection so that no air pocket may form Likewise the boiler body must be oriented horizontally or ascending slightly toward the flow connection so that air can escape For large unsepa...

Страница 33: ...pressure maintaining device is required To equalise pressure in the system a diaphragm expansion tank with a gross capacity of around 10 of the system volume is required or a pressure maintaining devi...

Страница 34: ...ompensator 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...

Страница 35: ...r up to 500 kW rated capacity requires a minimum buffer volume of 25 litres per kW rated capacity Hence a wood chip boiler with 100 kW needs a minimum buffer volume of 2500 l 100x25 However pellet boi...

Страница 36: ...Fig 9 1 Installing levelling feet Positioning the heat exchanger The heat exchanger can be moved either with a crane or a lifting device forklift truck or pallet jack Fig 9 2 Heat exchanger When lifti...

Страница 37: ...st be used The chain angle may not exceed 45 When lifting with a forklift truck the length of the fork must be at least 1700 mm Fitting the stoker to the combustion chamber Slide the stoker unit onto...

Страница 38: ...Attach screws M8 x 20 to the inside of the combustion chamber to fasten the duct Fig 9 8 Grate ash screw duct Secure the end of the duct in the direction of the heat exchanger with 4 M8 x 20 screws on...

Страница 39: ...thus ensuring correct air flow for combustion Affix seal to maintenance cover Affix the self adhesive ceramic fiber seals around the circumference of the maintenance cover Fig 9 12 Seal Re attaching t...

Страница 40: ...ries caused by heavy moving parts Possible crushing injuries due to the two heavy heat exchanger covers Work carefully around the open heat exchanger covers so that they do not accidentally fall shut...

Страница 41: ...n the desired direction and re tighten the screws again evenly Fig 9 17 Rotating the housing After rotation of the housing the draught fan must be turned back into the horizontal position To do this l...

Страница 42: ...e pipe Insulate the flue pipe between the draught fan and the heat exchanger with the supplied insulation provided by the metre and cover with adhesive aluminium tape 9 7 Flue gas recirculation piping...

Страница 43: ...of the ash duct flange Fig 9 23 Affixing the seal Fasten the trough of the cross ash screw to the flange with 8 M8 x 25 screws and nuts Ensure the seal is not damaged during installation Fig 9 24 Mou...

Страница 44: ...w and fasten to the trough with four M10 x 25 screws Fig 9 27 Drive Next insert the feather key in the groove and secure with the washer and the screw Fig 9 28 Feather key 9 9 Heat exchanger ash screw...

Страница 45: ...9 32 Heat exchanger ash screw Install the pre assembled heat exchanger ash screw hand tight with 4 M8 x 16 screws and washers To prevent tension during installation only hand tighten the screws Fig 9...

Страница 46: ...ond heat exchanger ash screw hand tight Fig 9 36 second heat exchanger ash screw Have a seal ready for the flange on the cross ash screw trough and fasten the second heat exchanger ash screw hand tigh...

Страница 47: ...rnately and evenly tighten the screws to secure the heat exchanger ash screw Fig 9 39 Tightening the screws Tighten the nuts in the trough of the cross ash screw Installing the drive for the first hea...

Страница 48: ...he drive Secure the drive with the spacer bushing screw and washer Mount the screw and washer on the torque arm Fig 9 42 Securing the drive Installing the drive for the second heat exchanger ash screw...

Страница 49: ...sh screw Mount the position sensor in the bracket and adjust to a clearance of 3 mm with the nuts Fig 9 46 Position sensor Attach the cover to the bracket Fig 9 47 Cover Installing the position sensor...

Страница 50: ...he ignition fans Push both ignition fans into the apertures on the front of the combustion chamber Hook the chains of the ignition fans into the openings in the boiler to secure Fig 9 52 Ignition 9 11...

Страница 51: ...serted in the immersion sleeve in order for it to measure the correct temperature Fig 9 54 Ash duct temperature sensor Installing the flow and return temperature sensors Insert the temperature sensor...

Страница 52: ...ger Deflagration damper mounted Mount the deflagration damper in the flue tube connection from the boiler to the chimney The defla gration damper must be installed horizontally and the damper must be...

Страница 53: ...h ETA offers an ash bin with a 770 litre or 320 litre capacity for this purpose With this de ashing variant the customer can also use a different ash bin or container Fig 9 61 De ashing with an ash fl...

Страница 54: ...coupling of the external de ashing into the drop chute s ball joint connection Secure this connection with the screws Only hand tighten the nuts initially Fig 9 66 Universal joint Check the height Che...

Страница 55: ...lectrical cables Fig 9 72 Pipe for electrical cables Install the connection unit for the ash bin Slide the bellows with the hose clamps onto the downpipe Thread the connection unit into the downpipe a...

Страница 56: ...the position switch on the screw cap Only hand tighten the nut initially Fig 9 76 Position switch Lock the screw cap on the ash bin The switch must be actuated in this position If not adjust the switc...

Страница 57: ...rnal de ashing with an ash flap and an ETA ash bin with 770 litre capacity The assembly steps are essentially the same for other ash bins provided Assembling the ash ducts Affix a sealing strip to bot...

Страница 58: ...trough Initially only hand tighten the screws Fig 9 86 Support stand Install transfer coupling on the boiler Fit the transfer coupling of the external de ashing into the drop chute s ball joint connec...

Страница 59: ...l pipe to the trough for the protected in stallation of the electrical cables Fig 9 92 Pipe for electrical cables Mount connection flange Fasten the impact protection mat to the connection flange with...

Страница 60: ...If a 320 litre ash bin is used then the metal flange must be removed from the top of the ash bin Fig 9 97 Metal flange Inspect the affixed seal to ensure it is in good order replace it if necessary F...

Страница 61: ...tion flange rests fully on the ash bin The impact protection mat and the chain must still be loose in this position Fig 9 102 Check height with ash bin If the correct height is set fasten the support...

Страница 62: ...witch is in the correct position carefully tighten the screws Fig 9 106 Check actuation Secure the electric cable with a cable tie This prevents inadvertent removal of the protective switch cap which...

Страница 63: ...ncy converters An unsuitable ground fault inter rupter may not activate immediately or at all under certain conditions Fig 10 1 Ground fault interrupter DANGER Electric shock There are live parts on t...

Страница 64: ...r the boiler with the aid of the supplied circuit diagram The control cabinet is on the side opposite the combustion chamber door The supply cable runs through the cable gland on the underside of the...

Страница 65: ...y differ depending on the country specific standards Enquire about this with your au thorities If no rules exist we recommend using the Austrian minimum cross sections as a guide Maintenance opening I...

Страница 66: ...lways remain unused in the corners To use all of the fuel a round storeroom maximum diameter 6 m would be preferable For a storeroom with for example interior dimensions of 4 x 4 m a floor agitator wi...

Страница 67: ...spring arms is filled first when filling the fuel store This volume is not accessible to the flat spring arms and remains unused and over time the material there will decay Fig 11 2 Slanted floor Bene...

Страница 68: ...with a floor agitator the following points must be observed Pellets are much heavier than wood chips Which is why floor agitators may only be filled with pellets up to a height of 2 metres To ensure...

Страница 69: ...4 27 3 39 370 426 1580 1450 239 275 1020 930 199 229 850 780 Hardwood 1 rm 0 59 fm c 1 rm 0 50 fm c 1 srm 0 40 fm c 1 rm 0 33 fm c Poplar 3 99 3 16 256 295 1020 930 174 200 690 630 145 167 580 530 Wi...

Страница 70: ...imum lengths and inclines Below you will find the information on the maximum lengths and inclinations for conveying systems of different sizes If deviations from the stated values are necessary please...

Страница 71: ...0 compatible boilers eHACK kW 20 80 100 170 180 240 HACK VR kW 250 333 350 500 Agitator for wood chips Discharge Unit BG 1 BG 2 BG 2 5 BG 3 Floor agitator Diameter D and drive power with leaf spring a...

Страница 72: ...www eta co at www eta co at downloads DOWNLOAD...

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