wood chip boiler 20 - 90 kw service manual€¦ · you will receive a timely reminder about this...

2018-05-16EN0000000295V.0053.43.03007, 310893528-001

Wood chip boiler20 - 90 kW

Service manual

ETA Heiztechnik

Gewerbepark 1

A-4716 Hofkirchen an der Trattnach

Tel: +43 (0) 7734 / 22 88 -0

Fax: +43 (0) 7734 / 22 88 -22

[email protected]

www.eta.co.at

General information

1 General information

Support for cleaning and maintenance

This document provides support for cleaning andmaintaining the product. The required steps are listedin detail here.

Take note of the date of the cleaning or maintenanceand any faults that may have occurred. This facilitatestroubleshooting for the expert (system operator,heating technician...).

For services (such as commissioning, mainte-nance, fault fixing) provided by ETA customer

service, the service reports are provided in digital form.For clarity, you should staple these reports to thisdocument or enclose them.

Commissioning data

Enter the manufacturing number of the product(printed on the type plate), the date of commissioningas well as the heating technician who commissionedthe system.

Copyright

All contents of this document are property of ETAHeiztechnik GmbH and are protected by copyright.Any reproduction, transfer to third parties or use forother purposes is prohibited without written permissionfrom the owner.

Subject to technical changes

We reserve the right to make technical modificationswithout notice. Printing and typesetting errors orchanges of any kind made in the interim are not causefor claims. Individual configurations depicted ordescribed here are only available optionally. In theevent of contradictions between individual documentsregarding delivery scope, the information in our currentprice 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 instruction

CAUTION!

On non-compliance with this safety instruction, there isa risk of material damage.

WARNING!

On non-compliance with this safety instruction, there isa risk of physical injury.

DANGER!

On non-compliance with this safety instruction, there isa risk of major physical injury.

Commissioning data

Manufacturing number:

________________________________________

Commissioned on:

_________________________________________

Commissioned by (company):

_________________________________________

_________________________________________

_________________________________________

3

Maintenance notes Cleaning and maintenance

2 Cleaning and maintenance

2.1 Maintenance notes

Performing regular cleaning and maintenance

To ensure satisfactory functionality, cleaning andmaintenance must be performed at regular intervals.You will receive a timely reminder about this from theETAtouch control system.

Cleaning of the boiler must be carried out at leastonce a year, or when requested by the control

system. Maintenance is necessary at least every3 years, or when requested by the control system. Werecommend that you perform maintenance annually.You can also enter into a service agreement for yourheating system. Find out more from your heatingcontractor or customer service.

All tasks where the maintenance table reads"Customer" or "Customer or expert" in the column

"To be carried out by" can be carried out by any trainedadult. Instruction may be provided by the heatingtechnician or our customer service.Steps that are marked with "Expert" only can only becarried out by the heating technician or our customerservice.

Operation only by trained personnel

The product may be operated by trained adults only.Training may be provided by the heating technician orour customer service. Please read the associated doc-umentation carefully in order to avoid errors duringoperation and maintenance.

Persons who lack experience and knowledge as wellas children may not operate, clean, or maintain theproduct.

Explanation of pictograms

Clean panels

If necessary, clean the panels of the boiler and theETAtouch screen with a moist cloth.

Switch the boiler on/off with the mains switch.

Perform a visual check of the components.

Clean the components with a soft cloth, for example.

Remove deposits 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 use is listed in the respective step.

Mount the components (e.g., screws or nuts) by hand only, without tools.

Install the components with some force (e.g., the retaining tube or the Lambda probe).

Handle the components carefully, since they break very easily.

Measure or check dimensions or clearances on the components.

Mark the components so that the correct position can be found, for example, when mounting.

Wear a protective mask to avoid injuries to the airways.

Seal the components. The sealant to use is listed in the respective step.

Use glue to adhere the seals, for example.

Do not use compressed air to clean the components.

Do not use cleaning brushes to clean the components.

Do not use an ash vacuum or vacuum cleaner.

Do not lubricate the components.

No water or moisture in this area.

4 www.eta.co.at

Cleaning and maintenance Maintenance notes

Under no circumstances use aggressivesolvents, chemicals or scouring agents. They can

lead to stress cracks and damage.

5

Maintenance openings in the boiler Cleaning and maintenance

2.2 Maintenance openings in the

boiler

Maintenance openings and components

The illustrations show a boiler with a size of 2 (63- 90 kW) with its fuel discharge on the left side.

The fuel discharge depicted here is the standard con-figuration.

1 Combustion chamber door

2 Secondary air actuator (mirrored for fuel dischargeinstalled on the right)

3 Actuator for tilting grate

4 Maintenance cover for optional flue gas recircula-tion

5 Primary air actuator (mirrored for fuel dischargeinstalled on the right)

6 Firebed switch (mirrored for fuel dischargeinstalled on the right)

7 Safety switch for rotary valve maintenance cover

8 Plug screw for lubricating the stoker drive chain

9 Turnbuckle for the stoker drive chain

10 Drop chute safety switch

11 Drop chute maintenance cover

6 www.eta.co.at

Cleaning and maintenance Maintenance openings in the boiler

1 Shut-off plug for optional flue gas recirculation


3 Flue gas temperature sensor

4 Heat exchanger cleaner

5 Ignition

6 Stoker drive chain


8 Plug screw for lubricating the de-ashing system'sdrive chain

9 Draught fan

7

Maintenance table Cleaning and maintenance

2.3 Maintenance table

Cleaning of the boiler must be carried out at least once a year, or when requested by the control system.Maintenance is necessary at least every 3 years, or when requested by the control system. We recommend

that you perform maintenance annually.

TasksRegular

ly

Cleaning

annually

Maintenance

at least every 3 years

to be performed by

Empty the ash box

• Remove excess ash from secondary combustion chamber

• Empty the ash box

• Check the seals

X X X Customer

Check the pressure of the heating system X X X Customer

Check the safety devices

• Visual check of the safety valves

• Visual check of the thermal relief valve

• Check operational readiness of the safety devices in the fuel path

X XCustomer or

specialist

Chimney

• Clean the flue tube

• Flush the chimney's condensate drain

X XCustomer or

specialist

Clean the combustion chamber

• Clean inside of the secondary combustion chamber

• Clean tilting grate

• Clean secondary air openings

• Clean the ignition tube

• Check the firebed button and firebed switch

• Check refractory lining

X XCustomer or

specialist

Clean the heat exchanger

• Clean heat exchanger and downdraft channel

• Clean the lambda probe

• Check the heat exchanger tubes

• Check heat exchanger cleaner

• Check the seal on heat exchanger cover

X XCustomer or

specialist

Clean the flue gas recirculation (optional)

• Clean flue gas recirculation piping

• Inspecting seals on maintenance covers

X XCustomer or

specialist

Clean the draught fan X Specialist

Clean the temperature sensor X Specialist

Check air valve for primary and secondary air X Specialist

Check the ash box position switch X Specialist

Check de-ashing system X Specialist

Clean ignition X Specialist

Check boiler doors X Specialist

8 www.eta.co.at

Cleaning and maintenance Maintenance table

Check stoker

• Check the stoker drive chain

• Check gap of the rotary valve position sensor

X Specialist

Check drop chute safety switch X Specialist

Check end position of the rotary valve X Specialist

Calibrate the lambda probe X Specialist

Reset the maintenance counter X Specialist

Perform heating test X Specialist

TasksRegular

ly

Cleaning

annually

Maintenance

at least every 3 years

to be performed by

9

Regular maintenance Cleaning and maintenance

2.4 Regular maintenance

2.4.1 Preparation

Stop heating

End the boiler's heating mode with the On/Off switch in the boiler overview window. The boiler

performs an ember burnout and then changes to[Switched off] mode. Press the [De-ash] button tomake the boiler perform a final de-ashing.

2.4.2 Empty the ash box

Remove excess ash from secondary combustionchamber

Open the combustion chamber door and use the pokerto scrape the excess ash into the combustionchamber.

The ash in the secondary combustion chambermay not be steeper than 45°.

To remove this ash, initiate boiler de-ashing bypressing 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 safetycatches in the direction of the arrow. Remove the ashbox from the boiler.

Fig. 2-1: Fastener

Remove the lid by opening the fasteners and emptythe ash box.

Fig. 2-2: Check ash

If there are large pieces of slag in the ash, thecombustion chamber and the tilting grate must be

checked and the de-ashing interval reduced, ifnecessary.

10 www.eta.co.at

Cleaning and maintenance Regular maintenance

Inspect the seal on the ash box lid to ensure it is ingood order, and replace it if necessary.

Fig. 2-3: Seal

Inspect the integrity of the ash box seals on the boiler,replace them if necessary.

Fig. 2-4: Seal

Attaching the ash box to the boiler

Reattach the cover of the ash box and secure with thefasteners. Push the ash box over the connection onthe boiler and attach it to the boiler with the fasteners.

2.4.3 Check pressure of the heating system

Check the heating system water pressure

In buildings with up to three storeys, the optimumwater pressure in a cold heating system is between 1and 2 bar. For a warm heating system, the optimumwater pressure is between 1.5 and 2.5 bar.

Fig. 2-5: Pressure gauge

If the water pressure is too low, fill the coldheating system to approx. 2 bar. Do not fill to a

higher pressure, as water expands with increasingtemperature and the water pressure also rises whenthe boiler is in heating mode. The safety valve triggersat approx. 2.8 bar.

If the water pressure drops several times a year,contact a heating professional. When refilling

water in the heating system, the same water as usedduring initial filling should be used whenever possible(e.g., prepared water).

2.4.4 Establish operational readiness

Switching on the boiler

Switch the boiler back on with the On/Off switch.

11

Cleaning (customer) Cleaning and maintenance

2.5 Cleaning (customer)

2.5.1 Preparation

Stop heating



WARNING!

Switch off the electricity to the boiler via the mainsswitch

Switch off the electricity to the boiler via the mainsswitch. This prevents injuries caused by switchingthe boiler on inadvertently.

WARNING!

Burns caused by hot parts

Risk of burning on parts located behind theboiler housing, even after shutting the boilerdown.

Allow the boiler to cool down sufficientlybefore starting any activities.

2.5.2 Check safety devices

Checking the safety valves

Perform a visual check of all safety valves of theheating system. The outlets of the safety valves maynot drip.

Fig. 2-6: Safety valve

If the safety valve drips, open it with a quarter turn ofthe red cap and rinse it out (danger of scalding). If thesafety valve still cannot be sealed effectively afterbeing rinsed several times, it must be cleaned orreplaced by an installer (heating technician).

A manual check of the safety valve is carried outwith a 1/4 turn of the red cap. This rinses the

safety valve. However it is very likely that the seal willbe damaged in the process and thus the outlet will drip.That is why you should only perform this check onweekdays and never on weekends in cold winter, as noheating technician may be available if the seal isdefective.

Check function of safety devices in fuel path

Check the safety devices in the fuel path, such as thetemperature-monitoring system, the manuallyoperated extinguishing system or the automatic extin-guishing system.

Also check malfunction indicators and alarms, forexample if messages from the boiler room aredisplayed elsewhere.

12 www.eta.co.at

Cleaning and maintenance Cleaning (customer)

Checking the thermal relief valve

Visually examine the thermal relief valve. The outletshould not drip.

Fig. 2-7: Thermally actuated drain valve

If the relief valve is dripping, rinse it by pressing the redbutton (risk of scalding). If the relief valve still cannotbe closed tightly after being rinsed several times, itmust be cleaned by an installer (heating technician) orreplaced.

A manual check of the relief valve is carried outby pressing the red button. This rinses the relief

valve. However it is very likely that the seal will bedamaged in the process and thus the outlet will drip.That is why you should only perform this check onweekdays and never on weekends in cold winter, as noheating technician may be available if the seal isdefective.

2.5.3 Chimney

Clean the flue tube

Sweep the flue tube from the flue outlet to the chimneyand remove flue ash from the chimney using a vacuumcleaner.

Fig. 2-8: Flue tube

Sweep the ash into the chimney, not into theboiler. Otherwise, ash will collect in the

fan housing and can block the draught fan.

Rinse the chimney's condensate drain

Check the chimney's condensate drain to make sure itis free, as ash can block the outlet. To check, rinse theoutlet with some water.

Fig. 2-9: Condensate drain

13


2.5.4 Cleaning the combustion chamber

Clean inside of the secondary combustionchamber

Open the combustion chamber door and scrape all ofthe ash from the secondary combustion chamber intothe primary combustion chamber with the poker.

Fig. 2-10: Secondary combustion chamber

Remove the combustion chamber cover in thesecondary combustion chamber.

Fig. 2-11: Combustion chamber cover

Remove the cover on the front

Remove the screws for securing the cover. Push thecover 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 tiltthe grate with the supplied tool.

Fig. 2-13: Actuator

Use the poker to clean the tilting grate and theopenings in it; let the ash fall down.

Fig. 2-14: Tilting grate

14 www.eta.co.at


Do not hit the tilting grate with the poker.

Clean secondary air openings

Clean secondary air openings (above the tilting grate).

Fig. 2-15: Secondary air openings

Clean the ignition tube

Check the ignition tube for combustion residues andclean it by vacuuming.

Fig. 2-16: Ignition tube

Check firebed button and firebed switch

Check the mobility of the firebed button in thecombustion chamber by repeated lifting.

Fig. 2-17: Firebed button

The firebed switch on the front of the boiler must beactuated when lifting.

Fig. 2-18: Firebed switch

Check refractory lining

Check the refractory lining of the primary andsecondary combustion chambers for damage andcracks.

15


Replace the combustion chamber cover

Reinsert the combustion chamber cover, ensuring thatit is properly centred.

Fig. 2-19: Combustion chamber cover

The convex surface of the combustion chambercover must point to the top of the boiler.

Mount cover on the front

Mount the cover on the front of the boiler. Also re-installthe 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 boilercasing and remove the insulating cover.

Fig. 2-21: Insulating cover

Loosen the knurled nuts on the heat exchanger coverby turning it anti-clockwise and rotate the ball knobs by180°.

Fig. 2-22: Knurled nuts and ball knobs

Remove the heat exchanger cover.

Fig. 2-23: Heat exchanger cover

16 www.eta.co.at


Clean heat exchanger and downdraft channel

Remove the internal cover between the secondarycombustion chamber and the heat exchanger.

Fig. 2-24: Internal cover

Brush out the downdraft channel and remove the flueash from the heat exchanger, for example with anash vacuum.

Fig. 2-25: Heat exchanger and downdraft channel

After cleaning, replace the internal cover. Ensure thatit is firmly seated.

Clean lambda probe

Vacuum out the head of the lambda probe using avacuum 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 turbulatorsfor tar deposits.

Fig. 2-27: Heat exchanger tubes

17


Tar deposits can have several causes, forexample:

• leak air through the heat exchanger cover, thecombustion chamber door or the lambda probe.

• an incorrectly calibrated lambda probe

• overly moist wood chips

• insufficient boiler runtime (start-stop operation)

Check heat exchanger cleaner

Remove the cover for the heat exchanger cleanerdrive.

Fig. 2-28: Cover

Manually operate the lever and check its ease ofmovement. Lubricate the spring, guide and bearingwith 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 cover

Inspect the integrity of the seal on the heat exchangercover and replace if necessary.


18 www.eta.co.at


CAUTION!

Avoid operation with damaged seals

Never operate the boiler with damaged seals.Otherwise, leak air is sucked in, disturbing thecombustion process and causing increased wear.

Always replace seals as soon as they aredamaged.

Close heat exchanger cover

Position the heat exchanger cover carefully.


Turn both ball knobs through 180° to secure the heatexchanger cover. Then tighten the two knurled nutsevenly and cross-wise by turning them clockwise.

Fig. 2-33: Knurled nuts and ball knobs

Put the insulating cover back on.

Fig. 2-34: Insulating cover

19


2.5.6 Clean flue gas recirculator (optional)

Remove the maintenance cover for flue gas recir-culation

Remove the two maintenance covers for the flue gasrecirculation 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 thefront side of the boiler.


Clean flue gas recirculation piping

Brush out the pipes of the flue gas recirculation withthe brush and remove the ash with a vacuum cleaner.

Fig. 2-38: Pipes

Fig. 2-39: Pipes

20 www.eta.co.at


Also brush out and clean out the pipes on the front sideof the boiler.

Fig. 2-40: Pipes

Inspecting seals on maintenance covers

Check all seals for the maintenance cover of the fluegas recirculation to ensure they are in good 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 thecombustion process and causing increased wear.

Always replace seals as soon as they aredamaged.

Re-install maintenance cover.

Replace the shut-off plug (if this was already installed).

Fig. 2-42: Shut-off plug

Re-install all maintenance covers for flue gas recircu-lation.


21




Switch the boiler on via the mains switch and startde-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.

22 www.eta.co.at

Cleaning and maintenance Maintenance (expert)

2.6 Maintenance (expert)

2.6.1 Preparation

Before this maintenance, perform all steps for thepreceding maintenance intervals

Before this maintenance, all steps for thepreceding maintenance intervals must be

performed.

WARNING!

The following activities may only be performed byqualified specialist personnel.

If you carry out these activities without the correspond-ing specialist training, and above all without therequired experience, safe operation is no longerguaranteed. The resulting defects and consequentialdamage are excluded from the guarantee andwarranty.

Equally an incorrect performance of these activitiescan lead to serious injuries.

Stop heating



WARNING!

Switch off the electricity to the boiler via the mainsswitch

Switch off the electricity to the boiler via the mainsswitch. This prevents injuries caused by switchingthe boiler on inadvertently.

WARNING!

Burns caused by hot parts

Risk of burning on parts located behind theboiler housing, even after shutting the boilerdown.

Allow the boiler to cool down sufficientlybefore starting any activities.

2.6.2 Clean draught fan

Clean the draught fan

Unplug the power supply and remove the draught fanfrom the boiler by removing the wing screws.

Fig. 2-45: Draught fan

Remove the ash from the fan housing on the boiler.

Fig. 2-46: Clean the fan housing

Carefully clean the impeller of the draught fan with asoft brush (not a wire brush) or with compressed air, sothat the impeller does not move out of balance.Replace the seal on the draught fan.

Fig. 2-47: Clean impeller; replace seal

23

Maintenance (expert) Cleaning and maintenance

Lubricate the screws with heat-resistant lubricant andreattach the draught fan to the fan housing. Tighten thescrews evenly. The plug connection must point to theright 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 gastemperature sensor. Clean the sensor with a soft clothand then re-install it. When fixing the temperaturesensor in place, only tighten the screw hand-tight so asnot to damage the sensor.

Fig. 2-48: Flue gas temperature sensor

24 www.eta.co.at


2.6.4 Check air valve

Remove the cover on the front

Remove the screws for securing the cover. Push thecover on the front up slightly, detach and remove it.

Fig. 2-49: Cover

Check air valve

Manually operate both air valve actuators and checktheir movement.

Fig. 2-50: Air valve actuators

For manual operation, push the release button (redbutton) and manually turn the actuator through 90°with the set screw.

Fig. 2-51: Manual operation of actuator

If there is resistance in the movement of the airvalves, lubricate only with dry lubricant (e.g.

PTFE spray).

Mount cover on the front

Mount the cover on the front of the boiler. Also re-installthe screws for securing the cover.

Fig. 2-52: Cover

25


2.6.5 Check ash box position switch

Check the ash box position switch

Inspect the function of the ash box position switch. Itmust be actuated when the ash box is fitted.

Fig. 2-53: Position switch for ash box

2.6.6 Check de-ashing

Lubricating the de-ashing drive chain

On the rear of the boiler, remove the plug screw fromthe cover next to the de-ashing drive.

Fig. 2-54: Plug screw

Through this opening, lubricate the de-ashing drivechain with chain spray. The easiest way to do this is tostart de-ashing. This sets the chain in motion so it canbe completely lubricated.

Check de-ashing system

Start de-ashing in order to check de-ashing of theboiler. The movement of the turbulators in the heatexchanger must be audible, the tilting grate must tipand then close again, and the ash screws mustoperate without malfunction.

26 www.eta.co.at


2.6.7 Clean ignition

Clean ignition fan and photocell

Remove the ignition fan from the boiler.

Fig. 2-55: Removing the ignition fan

Detach the ignition tube by loosening the 4 screws andremove the ignition rod. Clean the photocell with a softcloth. Then reattach the ignition tube.

Fig. 2-56: Photocell

Also clean the opening in the boiler for the ignitiontube.

Fig. 2-57: Ignition tube

Re-install the ignition fan and attach it to the boiler withthe chain.

27


2.6.8 Check boiler doors

Check airtightness of combustion chamber door

Open and then close the combustion chamber door.When closing, make sure that it closes tightly and withforce. The sealing edges of the door frame must leavea clear indentation in the sealing cord of thecombustion chamber door.

Fig. 2-58: Checks

Leaks can be detected by variations in the colourationof the sealing cord. If leaks are found, it is usuallysufficient to adjust the hinges and the closing rollermount. If the hinges cannot be adjusted any further,the sealing cord must be replaced.

Fig. 2-59: Seal

Also check if the sealing cord is already "hard". Tocheck, press on the sealing cord with your finger

nail. If it can no longer be pressed, it is "hard" alreadyand must be replaced.

Adjustment requires the removal of the combustionchamber door. To do so, open the combustionchamber door, lift it slightly, remove it and carefullyplace it next to the boiler.

1 Closing roller mount

2 Hinge

Loosen the flange nuts (top and bottom) on the hingeand the closing roller mount and evenly make the gapto the boiler a bit smaller.

Fig. 2-60: Reduce gap

28 www.eta.co.at


Tighten the flange nuts. Attach the door and checkwhether it closes fully. If not, repeat the process.

Fig. 2-61: Checks

Always adjust the hinges and the closing roll-er mount so that the seal is evenly compressed.

2.6.9 Check stoker

WARNING!

Injuries caused by moving parts

Possible danger of crushing by stoker drivechain.

The boiler must be switched off. This preventsinjuries caused by switching the boiler on inadver-tently.

Check stoker drive chain

Remove the drive chain cover by loosening the acornnuts.

Fig. 2-62: Cover

29


Check the tension of the stoker drive chain. The chainmay sag by 1 - 2 cm without effort.

Fig. 2-63: Stoker drive chain

If it sags more, the chain must be tensioned with theturnbuckle.

Fig. 2-64: Turnbuckle

Lubricate the drive chain with chain spray.

Fig. 2-65: Lubricate drive chain

Check gap of the rotary valve position sensor

Check the gap between the screw in the gear and thesensor. The gap should be about 1 - 2 mm.

Fig. 2-66: Gap between sensor and screw

30 www.eta.co.at


Mount the drive chain cover

Remount the drive chain cover.

Fig. 2-67: 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. 2-68: 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. 2-69: Drop chute safety switch

31


2.6.11 Check end position of the rotary valve

WARNING!

Injuries caused by moving parts

Possible danger of crushing by convey-or screw.

Opening the drop chute cover results in a risk ofcrushing by the accessible conveyor screw.Therefore, perform only a visual check. Neverreach into the conveyor screw.

Check end position of the rotary valve

The end position of the rotary valve is checked whenfilling using the [Rotary valve stop test] function. Thefunction is found in the boiler text menu under:

When this function is activated, the rotary valve rotatesuntil it is detected by the rotary valve position sensorand then it stops.

Next perform a visual check of the rotary valve endposition. To do so, remove the locking nut and thespring and raise the drop chute cover.

Fig. 2-70: Visual check

The rotary valve is positioned correctly if theopening in the rotary valve is completely visible

from above (through the open drop chute cover). Therotary valve can then fully receive the discharge screwfuel.

Fig. 2-71: Correct and incorrect position of the rotary valve

If the opening is not completely visible, the endposition must be adapted with the [Stoker delay]parameter. This parameter specifies the delay time forthe rotary valve after it has been detected by theposition sensor.

After setting the delay time, repeat the process tocheck the setting. To do so, restart the [Rotary

valve stop test] function and then perform a visualcheck.

Check the setting for the [RotValveStop] function

If the discharge screw and the stoker screw are inoperation simultaneously, use the [Service] authorisa-tion in the boiler text menu to check the setting for the[RotValveStop] function. The factory setting is [Yes].The function can be seen under:

It can be deliberately set to [No] if the used fuelrequires it.

If the discharge screw and the stoker screw are inoperation simultaneously and the function is set to[Yes], either the sensor is faulty or the gap between thescrew in the gear and the sensor is too large and mustbe adjusted. The gap should be about 1 - 2 mm.

Conveying system

Stoker unit

RotValveInPos

Rotary valve stop test

Conveying system

Stoker unit

RotValveStop

32 www.eta.co.at


2.6.12 Calibrate lambda probe

Calibrating the lambda probe

The boiler's built-in lambda probe checks theresidual oxygen content of the flue gas and uses

it to control the combustion. To ensure reliability, thecontrol system autonomously performs an automaticcalibration 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 and the additional calibrationwill now start. If the boiler is heating, it is automaticallystopped first. De-ashing begins, then the boiler ispurged with fresh air. After this, the residual oxygencontent is measured and the lambda probe is automat-ically calibrated. Altogether, these steps last approxi-mately 1.5 to 2 hours. When the calibration iscomplete, the boiler goes back into operation andstarts heating, if necessary.

After another 100 hours of operation, the controlsystem automatically performs another calibra-

tion.


Reset maintenance counter

When maintenance is complete, reset the counter.With the [Service] access level, it will be visible in theboiler text menu under:

Perform heating test

To perform the heating test, put the boiler intoemissions measurement mode. To do this, carry outthe following steps. In the boiler overview window,press the [Measurement] button in order to enterthe emissions measurement settings window.

Fig. 2-72: Settings window for emissions measurement

Press the [Start now] button so the boiler will startimmediately. The control system ensures thatsufficient heat is channelled to the buffer, the heatingcircuits and the hot water tank.

After around 10 minutes of heating, the residualoxygen value should reach 6% to 9%. The currentresidual oxygen content is displayed in the boiler's textmenu under:

If the value does not drop below 12% residualoxygen, the boiler is receiving leak air. The

reason (leaky combustion chamber door, heatexchanger cover, etc.) must be identified andcorrected.

If possible, perform a flue gas measurementduring the heating test.

Inputs

Residual O2

Calibration

Addl. calibration

Counters

Full load hours since maint.

Reset counter?

Boiler

Residual O2

33


After the heating test, switch the boiler back to normalmode. To do this, press the [Deactivate measurement]

button in the settings window.

34 www.eta.co.at


35

Cleaning (customer) Records

3 Records


Cleaning of the boiler must be carried out at least once a year, or when requested by the control system.

Comments:

Tasks Notes

Empty the ash box



• Check the seals

Check the pressure of the heating system _________ bar





Chimney



















performed on: _________________________

performed by: _________________________

36 www.eta.co.at

Records Cleaning (customer)



Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

37

Maintenance (expert) Records


Maintenance is necessary at least every 3 years, or when requested by the control system. We recommendthat you perform maintenance annually.

Tasks Notes

Empty the ash box



• Check the seals






Chimney




















Clean the temperature sensor

Check air valve for primary and secondary air



Clean ignition

Check boiler doors

Check stoker




38 www.eta.co.at

Records Maintenance (expert)

Comments:


Calibrate the lambda probe

Reset the maintenance counter


Tasks Notes

performed on: _________________________

performed by: _________________________

39




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

40 www.eta.co.at




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

41




Tasks Notes

Empty the ash box



• Check the seals






Chimney
























Clean ignition

Check boiler doors

Check stoker




42 www.eta.co.at


Comments:





Tasks Notes

performed on: _________________________

performed by: _________________________

43




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

44 www.eta.co.at




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

45




Tasks Notes

Empty the ash box



• Check the seals






Chimney
























Clean ignition

Check boiler doors

Check stoker




46 www.eta.co.at


Comments:





Tasks Notes

performed on: _________________________

performed by: _________________________

47




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

48 www.eta.co.at




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

49




Tasks Notes

Empty the ash box



• Check the seals






Chimney
























Clean ignition

Check boiler doors

Check stoker




50 www.eta.co.at


Comments:





Tasks Notes

performed on: _________________________

performed by: _________________________

51




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

52 www.eta.co.at




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

53




Tasks Notes

Empty the ash box



• Check the seals






Chimney
























Clean ignition

Check boiler doors

Check stoker




54 www.eta.co.at


Comments:





Tasks Notes

performed on: _________________________

performed by: _________________________

55




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

56 www.eta.co.at




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

57




Tasks Notes

Empty the ash box



• Check the seals






Chimney
























Clean ignition

Check boiler doors

Check stoker




58 www.eta.co.at


Comments:





Tasks Notes

performed on: _________________________

performed by: _________________________

59




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

60 www.eta.co.at




Comments:

Tasks Notes

Empty the ash box



• Check the seals






Chimney



















performed on: _________________________

performed by: _________________________

61




Tasks Notes

Empty the ash box



• Check the seals






Chimney
























Clean ignition

Check boiler doors

Check stoker




62 www.eta.co.at


Comments:





Tasks Notes

performed on: _________________________

performed by: _________________________

63

www.eta.co.at

www.eta.co.at/downloads

DOWNLOAD

wood chip boiler 20 - 90 kw service manual€¦ · you will receive a timely reminder about this...

Documents