ETA HACK user manual
2012-03-06 EN
Wood chip boiler
20 to 200 kW
User Manual
User Manual Hack 20-200 kW, Software 1.20.0
2012-02
Contents
Conditions for warranty, guarantee,
liability ................................................... 4
How your new boiler works ......................... 6
Emission measurement ............................... 8
Fuel .................................................... 10
Suitable fuel ........................................... 10
Changing fuel, firebed level sensor ................ 11
Flue gas recirculation ................................. 12
Filling the bunker .....................................14
Before starting ........................................ 15
Everything closed and airtight? .................... 15
Malfunctions ...........................................16
Conveyor screw blockage ............................ 16
Ash screw jammed.................................... 17
Overtemperature protection ........................18
When fuel causes slag formation .................. 20
Changing the deashing interval .................... 20
Maintenance ........................................... 22
Overview of activities ................................ 22
Emptying the ash box ............................ 23
"Empty ash box" reminder ...................... 25
Water pressure, safety devices .................. 26
Every 2,500 h or yearly .............................. 27
Servicing by an expert ............................... 32
Approval, antifreeze, pressure equalisation,
venting ..................................................36
Softened water, corrosion, safety valve ......... 37
Return riser, safety devices .........................38
Overtemperature, safety shutdown,
chimney ................................................. 39
Buffer storage tanks .................................40
Miscanthus, carpentry waste ....................... 41
Efficient and low-emission operation ............ 42
User interface ..........................................44
Adjusting the date and time ........................44
Setting the language ................................. 45
Changing the names of the function blocks ......46
Alarm, error, warning, message .................... 47
Opening the text menu ..............................48
2
Subject to change due to technical improvements
Boiler
............................................50
Overview, buttons, functions ....................... 50
Counters, changing fuel.............................. 52
Changing fuel, water content and density........ 53
Adjusting idle time and duration of ash removal 54
Heating circuit
...................................56
Overview, buttons, functions ....................... 56
Operating modes ...................................... 58
Setting the heating time slots....................... 60
The heating curve..................................... 62
"Day Heating threshold" and "Night Heating
threshold".............................................. 63
Adjusting the heating curve .........................64
Setting the "enable temperature" .................. 66
Adjusting the "Set-back" ............................ 67
Special conveyor
............................68
Overview, buttons, functions .......................68
Intermediate conveyor screw ....................... 70
Several intermediate conveyor screws ......... 72
Double agitator........................................ 74
Adjusting the switching process ................ 76
Double screw agitator ................................ 77
Adjusting the boiler order ....................... 79
External ash removal
..........................80
Overview, buttons, functions ....................... 80
Remote operation
........................ 82
Requirements .......................................... 82
Changing the operating mode ...................... 83
Functions not available via remote operation ...84
Opening the touchscreen ............................ 85
Logging out ............................................ 86
Changing personal details ........................... 87
Wood chips .............................................88
Moist fuel...............................................88
Drying, harvesting, chopping ....................... 89
Judging the quality ...................................90
Other fuels, heating value ........................... 91
Standard size classes, waste wood classes ........ 92
Water content ......................................... 93
Service and maintenance records .................94
Safety instructions ....................................96
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Preface
Dear customer,
We are delighted to count you among our
customers.
To ensure satisfactory operation of your new boiler,
you need to know how to operate, clean and
maintain it. This manual contains information and
advice on much more than just the boiler itself.
Warranty and guarantee
You should also read the "Conditions for warranty,
guarantee, liability" on page 4 carefully. As
a rule, these conditions will be satisfied by a
professional heating technician. Nevertheless,
inform the technician of our warranty conditions.
All of the requirements we impose on the heating
system are intended to prevent damage that
neither you nor we wish to occur.
Optimum use of the control systems
installed in our boilers
There are two different access levels for the control
system:
At the CUSTOMER level, you can adjust the control
system to your wishes and needs without any risk
of altering the system configuration set by the
heating system expert.
Only your technician or a customer service
employee should change settings at the SERVICE
level. Before making any adjustments to these
settings yourself, it is essential that you consult
an expert.
User Manual Hack 20-200 kW
Please read this manual
carefully before starting up the system. This is the
only way to ensure that you can operate your new
boiler efficiently and with minimum environmental
impact.
Take advantage of the knowledge and skills of
an expert
Only allow an expert to assemble, install and
commission the system and make the basic
settings. Insist on receiving an explanation and
training on how your new boiler functions and
how to operate and maintain it.
Extended warranty for commissioning performed
by an authorised partner company
If your newly installed boiler is commissioned
by an authorised partner company or one of our
customer service employees, we offer an extended
warranty. Refer to our warranty conditions in
effect at the time of purchase.
Service agreement
You can ensure the best care for your heating
system by taking out a service agreement with
one of our certified contractors or our own
customer service.
2012-02
3
Conditions for warranty, guarantee, liability
We can only guarantee and accept liability for the
function of our boiler if it is properly installed and
operated.
Requirement for warranty, guarantee and liability
is that this boiler be used in accordance with its
intended purpose, only for heating and hot
water supply with no more than 2,000 fullload hours annually, and, in particular, that the
following general conditions be observed during
installation and operation:
For set-up, a dry room is required. In particular,
only condensation dryers may be used as clothes
dryers in the same room.
Local building and fire protection regulations must
be observed.
The boiler is suitable for use with wood chips
G20 to G50 - W 35 maximum (according to
ÖNORM M 7133) P16 to P45 - M 35 maximum
(EN 14961-4). With an optionally available flue
gas recirculation, wood pellets according to
ÖNORM M 7135, DIN 51731, EN 14961-2 class
A1, EN plus class A1 or DINplus, as well as
Miscanthus, very dry carpentry waste and
chipboard (fuel class 7 according to German air
pollution regulations, free of organohalogen
compounds and wood preservatives) can be
burned. Operation with unsuitable fuels, in
particular with high-slag pellets such as from
grain waste, or corrosive fuels such as Miscanthus
fertilised with potassium chloride, is not permitted.
The combustion air must be free of aggressive
substances such as chlorine and fluorine
from solvents, cleaning agents, adhesives and
propellants, or ammonia from cleaning agents, to
prevent corrosion of the boiler and chimney.
4
Subject to change due to technical improvements
Water is the intended heat-transfer medium. For
special anti-frost requirements, up to 30% glycol
may be added. Softened water is required for
the initial fill-up of the heating system and for
refilling after repairs. For the initial fill-up of
boilers up to 90 kW, the value of 20,000 lt°dH
for the system volume in litres multiplied by the
hardness (in degrees of German hardness) may not
be exceeded. For boilers over 90 kW, the limit is
30,000 lt°dH.
The pH value should be set between 8 and 9.
Addition of hard water should be minimised to
limit limescale build-up in the boiler. Set enough
shut-off valves to avoid bleeding large amounts of
water during repairs. Any leaks in the system must
be repaired at once.
A safety valve (3 bar) as protection against excess
pressure and a thermal relief valve (95 °C) to
protect against overheating must be installed by
the contractor.
To protect against air suction if the system cools
off, an expert must provide a sufficiently large
expansion tank or a pressure maintenance
system. Sufficient air venting must also be
ensured. Open expansion tanks or underfloor
heating with permeable piping also have a
high air intake, resulting in above-average boiler
corrosion. Corrosion damage to the boiler due to
improper air venting or high air intake is excluded
from warranty, guarantee and liability.
Operation at lower power than the lowest power
specified on the type plate is not permitted. For
design outputs that are considerably less than
the boiler's rated output, either a reduction of
the heating time slots or a buffer storage tank is
required.
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Conditions for warranty, guarantee, liability
Only components provided by us may be used
for expansion of the control system, except for
commonly used units such as thermostats.
Cleaning and maintenance are required as
specified in the user manual.
Repairs are only permitted with spare parts
provided by us. The only exceptions are common
standardised parts such as electrical fuses or
fastening materials, as long as they possess
the required features and do not restrict the
functionality of the system.
The installing contractor is liable for proper
installation according to the boiler's installation
instructions and the relevant rules and safety
regulations. If you as customer 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 consequential damages resulting
from this cause from our warranty, guarantee and
liability.
For repair of defects carried out by the
customer or by third parties, ETA only bears the
costs or remains obligated by warranty if this work
was approved in advance by the customer service
of ETA Heiztechnik GmbH.
Subject to technical alterations
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
optionally available. In the event of contradictions
between individual documents regarding delivery
scope, the information in our current price list
applies.
User Manual Hack 20-200 kW
Important NOTICES for operation.
CAUTION: Failure to observe these notices can result
in property damage.
STOP: Failure to observe these notices can result in
personal injury.
2012-02
5
How your new boiler works
Spring arms adjust to load
The wood chips are transported to the discharge
screw (4) by the floor agitator. The spring arms (1)
adjust themselves to the load above them. If the
bunker is full, the agitator is subject to a heavy load
and the spring arms are pressed against the agitator
plate (2). That reduces the driving power and the
electricity consumption. As the bunker empties, the
spring arms extend toward the wall and clear out
the bunker.
Floor agitator must turn during filling
To prevent the spring arms from being stuck in an
extended position under the pile of wood chips, the
floor agitator must be turning during filling.
To this end, press the "Emission measurement"
button to force the boiler into operation.
boiler output is more than 400 kW, or if carpentry
waste is burned.
Individual pieces of wood that are too long cannot
bring the fuel conveying system to a halt. They are
cut off by a hardened, replaceable blade on the edge
of the rotary valve chamber.
Optimised ignition
After short breaks in combustion, the refractorylined combustion chamber still remains hot enough
that any new fuel which is fed in can be ignited by
remaining embers. The ignition fan only needs to
be activated after longer pauses. To save electricity,
the ignition fan is deactivated immediately after
successful ignition, recognised by the lambda probe
and exhaust temperature.
Discharge screw torque control
The amount of electricity required by the motors is
monitored so that any sluggishness in the discharge
screws is immediately recognised, automatically
reversing the screws and repeating up to three times
if necessary. The floor agitator is simultaneously
decoupled via the clutch (3) so the motor's power
is exclusively available for unblocking the screw.
Jammed pieces of wood or even stones can be easily
loosened this way so fuel transport can resume.
4
1
2
3
Maximum protection against burn-back
The airtight one-chamber rotary valve (5) keeps
the combustion chamber safely separated from the
fuel deposit in all operating states. No hot gas can
enter the fuel conveying system and ignition of the
wood chips is impossible. This is the most reliable
protection against burn-back.
The prTRVB H118 from the Austrian fire prevention
bodies (often applied in Germany due to lack of
national standards there) also demands a water
sprinkler on the drop chute if the fuel deposit is in a
barn or loft, if the store is larger than 200 m³, if the
6
Subject to change due to technical improvements
Hot combustion chamber with tilting grate
The wood chips are pushed onto the side of the
grate by the stoker screw (6). A refractory-lined
combustion chamber (7) ensures a clean fire with
high burnout temperature. At intervals that depend
on the output level, the grate is tilted by 90° after a
controlled ember burnout in order to automatically
remove ash and foreign bodies from the combustion
chamber. Until the next time the grate is tipped,
the ash remains under the grate and can burn
out before it is transported by a screw (8) to the
detachable ash box (9).
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How your new boiler works
burned. Excessive air also draws too much heat out
of the boiler unused. The lambda probe ensures
optimum combustion and maximum fuel utilisation
in everyday operation.
Turbulent heat exchanger with cleaning
15
12
13
11
7
8
5
During cleaning (grate tipping) the turbulators (13)
are also moved to scrape the flue ash from the heat
exchanger tubes. The ash is transported to the ash
box (9) by a screw (14).
10
6
14
After complete combustion, the hot gas flows into
the cold section of the boiler, where it transfers
its heat to the boiler water. First it flows smoothly
through a downdraft channel (12) for ash
sedimentation and then turbulently through the
heat exchanger tubes (13), which are equipped with
turbulators. The more turbulent the flow, the more
the gas comes into contact with the tube walls, thus
ensuring maximum transfer of heat to the boiler
water. This ensures low exhaust gas temperatures
and high efficiency.
9
Highest safety with underpressure
The fire can be regulated between minimum and
maximum output. In autumn and spring, when
heating loads are smaller, the output is regulated
by pauses in combustion. To avoid a build-up of
smouldering tar in the boiler and chimney during
these pauses, the fire undergoes a controlled
burnout. Closing the primary (10) and secondary
(11) air flaps ensures that no air can flow through
the boiler in standby, thus preventing unused heat
from being drawn into the flue.
Draught fan
Combustion breaks with minimal heat loss
A draught fan (15) at the boiler outlet causes
underpressure throughout the boiler, thus ensuring
high operational safety without risk of deflagration
and burn-back. The airtight one-chamber rotary
valve (5) makes the usual combustion air fan
unnecessary. The required air is drawn into the
combustion chamber through the regulated primary
(10) and secondary (11) air flaps as a result of the
underpressure within the boiler.
Optimum fuel efficiency with lambda control
Wood gasification (output) can be controlled via the
primary airflow (10). Through use of the lambdacontrolled secondary air (11), combustion is kept
clean and highly efficient.
A lack of air means there is not enough oxygen for
complete combustion. On the other hand, too much
air also results in incomplete combustion as it cools
the fire. Below 700 °C, not all of the wood gas is
User Manual Hack 20-200 kW
Secondary
air
Primary air
2012-02
7
Emission measurement
Why measure emissions?
It is a requirement for the carbon monoxide
(CO) emissions of every boiler to be measured
periodically. In Germany, this periodical
measurement must also include a dust
measurement.
There are several aspects of this that could go
wrong, resulting in incorrect measurements even
though the boiler fully and consistently complies
with these limits when operating in accordance
with the relevant standards.
Boiler temperature at least 65°C
Before emission measurement, the
boiler
mustmust
be
pellet
boilers
in operation
for atfor
least
30 minutes
and the
have
been heating
at least
15 minutes,
and
boiler
temperature
must
be at
65 °C.
the
boiler
temperature
must
beleast
at least
65°C.
Wood chip boilers must have been heating for
at least 30 minutes, and the boiler temperature
must be at least 65°C.
Switching the boiler to emission measuring mode
Press
to switch the boiler to emission
measuring mode. This button lights up green to
confirm the change.
2 to 3 days before measurement, the boiler
and boiler tube must be cleaned thoroughly
min. 65°C
min. 65°C
The chimney sweep will contact the owner of the
boiler when the measurement is due to take place.
The boiler and boiler tube must be cleaned
thoroughly 2 to 3 days before the measurement
takes place. Once this is complete, the heating can
continue to be used as normal.
This delay between cleaning and measurement is
necessary in order to allow dust disturbed during
cleaning to settle again. If the chimney sweep
measures unsettled dust, the dust reading will be
higher than normal and thus inaccurate.
Under no circumstances clean the
boiler and flue tube on the day of the
measurement!
If possible, switch the boiler off before
measurement
If possible, switch the boiler off 3 to 5 hours
before measurement using the on/off button
.
The boiler is now run at full load for 30 minutes.
The control system ensures that sufficient heat
is channelled to the heating circuits and the hot
water tank.
Wait for 5 to 10 minutes, then measure
the emissions
Once emission measuring mode has been activated,
wait for 5 to 10 minutes until the boiler has
reached the required operating temperature and
stable combustion can be guaranteed. Then carry
out the emission measurement.
After the measurement
Ensure that there is sufficient heat consumption
and then switch the boiler back on
Open all the radiator valves and turn the radiator
thermostats to maximum.
Finally, switch the boiler back on using the on/off
button (
button lights up green).
8
Subject to change due to technical improvements
Switch the boiler back to normal mode by pressing
again.
If this button is not pressed, the boiler will
automatically switch back to normal mode after
30 minutes.
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User Manual Hack 20-200 kW
2012-02
9
Suitable fuel
Give preference to coarse wood chips G30 - G50
or P32- P45 with low fine content
The length of the individual wood chips should
be between 30 and 50 mm to ensure that air can
circulate well among the stored chips, moisture can
escape from them, and the tendency to decay and
become mouldy is low.
If the fine content (sawdust, bark, needles, soil,
sand) is too high, it can obstruct the airways. In
the warm interior of the pile, water evaporates. If
the vapour cannot escape, it will condense in the
upper part of the pile. A portion of the chips will
then suffer dry rot and turn to compost with no
heating value.
Fuel
Be especially careful with waste wood
When waste wood is on offer, it may be rotten
wood with no heating value; only buy waste wood
by weight and with limited water content (25 %
maximum). Also ensure that the wood contains no
contaminants. The applicable laws only allow the
use of untreated wood without foreign substances
for heating purposes.
Wood-processing businesses may burn chipboard
if it contains no halogens or wood preservatives.
Even if it is allowed by law, high chemical content
in the chipboard (often from "illegal" chlorine) can
cause corrosion and above-average wear in the
boiler.
Nails and stones
coarse + dry = good output
may not bring the boiler to a stop, but they cause
increased wear on the conveyor screws and the
blades in the rotary valve.
Sand and soil, more ash and slag
fine + dry = less output
Avoid green, moist wood chips
Only wood chips that are dry enough (water
content under 25 %) can be stored without
problems in a concrete bunker. Moist, coarsely
chopped chips stored in an open hall exposed
to the wind quickly reach a water content under
35 %, suitable for the boiler.
Above a threshold that varies from one batch of
chips to another, slag can build up on the grate
and must be removed by hand. Avoid high sand
and dirt content.
Flue gas recirculation for pellets, miscanthus and
very dry carpentry waste
For these fuels, a flue gas recirculator (available as
an option) is required.
Finely chopped chips from fresh wood, or chips
from green branches with a high fraction of bark
and needles circulate air poorly and can hardly
dry, so they decay quickly with great loss of
heating value.
coarse + moist = lower output
can only be stored with good ventilation
Flue gas recircu
lation
fine + moist = no output
10
Subject to change due to technical improvements
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Fuel
Changing fuel, firebed level sensor
What do you need to consider
when changing fuel type?
The amount of ash depends on the fuel
and the season
The control system includes these fuels: wood
chips, pellets and miscanthus.
If the fuel is changed, the control system must
also be set to the new fuel type. Depending on
fuel type, different parameters for combustion and
ash removal are stored and automatically adjusted.
If the water content and density are known, these
parameters must also be adjusted.
An adjustment of the firebed level sensor and
the flue gas recirculation is necessary. These steps
are explained on the following pages.
Changing the fuel, density and water content in the
control system is described on page 52.
Ash is the non-flammable residue from the
wood. It consists of minerals such as calcium and
potassium without which life cannot exist, but also
soil, sand and stones, i.e. dirt from the fuel.
A rule of thumb: the darker the fuel, the more
bark, dirt or decayed material (and therefore ash)
it contains.
In theory, both chips from pure wood and chips
from wood with bark have the same ash content
of around 0.5 %. In practice, there is always soil
and sand stuck to the bark.
Stems and leaves need potassium for rigidity and
their dirt-exposed surface is larger, so their ash
content is in the range between 3 and 6 %.
Dark material from thin branches usually also has
a high fraction of decayed material, meaning less
combustible material and more ash.
Set the firebed level sensor
to match the fuel
Simply put, the drier the fuel, the lower the
amount of it that must be on the grate. The firebed
level sensor must be adjusted to the type of fuel
currently in use.
Check ash box
The fuel's ash content and quality determine how
often the ash box must be emptied.
The firebed level sensor is behind the panel when
you open the insulation door.
Pellets
In summer
Peak of
heating
season
Wood chips
without bark
~5 weeks
weekly
Wood chips
with bark
~2 weeks
~3 days
Miscanthus
~10 days
~2 days
Shrubbery cuttings,
very thin branches,
high leaf content
~5 days
daily
Wood chips
Loose
miscanthus
For stoker on left
User Manual Hack 20-200 kW
For stoker on right
2012-02
11
Flue gas recirculation
Fuel
Flue gas recirculation on the boiler
For very dry fuels such as pellets, carpentry waste,
miscanthus), the optional flue gas recirculation
is required in order to lower the combustion
temperature.
Depending on the fuel, the flue gas recirculator
must blocked or opened with the shut-off plug.
Then the flue gas recirculation must be set
to "yes" or "no" in the control system; see
page 12.
Fuel
For wood chips, block flue gas recirculation
Remove the cover on the top side of the flue gas
duct and insert the shut-off plug.
When inserting or removing the shut-off plug,
inspect the seal and replace it if necessary.
Flue gas
recirculation
Pellets
Yes
Dry carpentry waste
Yes
Miscanthus
Yes
Wood chips W > 15 %
No
Installed flue gas recirculation
Flue gas duct
with shut-off
plug
Recirculation
pipe
Shut-off plug
Seal
If flue gas recirculation has been blocked, in the
control system the option [Flue gas recirculation]
must be set to "no"; see page 12.
Open the flue gas recirculator
for pellets and miscanthus
Remove the shut-off plug from the recirculation
pipe and store it near the boiler so it can't get lost
(tie on with wire).
Then set [Flue gas recirculation] to "yes" in the
control system; see page 12.
If the fuel type was set to "Wood pellets" earlier,
the "Flue gas recirculation" parameter is also
automatically set to "yes".
12
Subject to change due to technical improvements
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Fuel
Flue gas recirculation
What does flue gas recirculation do?
For very dry fuels (e.g. pellets, joinery waste
material, Miscanthus), optional flue gas
recirculation is required in order to lower the
combustion temperature.
A selection window appears.
If shut-off in the recirculation pipe of the flue gas
recirculation system has been installed or removed,
the flue gas recirculation function must likewise be
switched either on or off in the control system.
If the fuel type is set to "Wood pellets", the "Flue
gas recirculation" parameter is also automatically
set to "Yes".
Adjusting flue gas recirculation
Press the buttons
menu.
and
to open the text
Set flue gas recirculation to [Yes] and press
.
The text menu display appears again.
Tap the [Boiler] line and, in the submenu, tap
[Settings].
Double-tap on the [Flue gas recirculation] line.
2x
Press
User Manual Hack 20-200 kW
to return to the boiler overview.
2012-02
13
Filling the bunker
Before filling a bunker with a floor agitator, the
boiler must be completely connected.
Never drive over the floor agitator!
During filling
the floor agitator must be turning
If the bunker is empty, the floor agitator's arms are
extended. If the arms are deeply covered in this
position, they will be trapped and the agitator will
no longer be able to turn.
Start with a pile in the middle
With the agitator turning, begin filling in the
middle on the agitator.
If the agitator is fed from the side, the turning arms
plough through the chips and throw them back
into the still-empty bunker.
Dump slowly into bunker
If the bunker is filled through a hole from above,
the material must be fed onto the turning floor
agitator slowly.
An entire load emptied all at once onto the agitator
from a height of 3 m or even 6 m can damage it.
Maximum fill height on agitator
The maximum fill height depends on the material
or weight (density):
t Pellets up to 2.0 m
t Wood chips up to 5.0 m
Start floor agitator with
The boiler is forced into operation with the
button and material
"Emission measurement"
is transported to it.
Rotation of the floor agitator can be stopped by
pressing
again. In any event, the boiler stops
the emission measurement automatically after
30 minutes and the fuel conveying system is
switched off.
14
Subject to change due to technical improvements
Bunker with charging screws
Filling bunkers with charging screw
If the bunker is already almost empty, fill with
2 to 3 m³ of chips or pellets and only then start the
.
floor agitator with
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Before starting
Before starting the system
Before starting the system, check the following to
ensure smooth and problem-free operation.
Everything closed and airtight?
Combustion chamber door
Close it firmly (forcefully).
No leak air
Verify that all doors and maintenance covers are
tightly closed, especially before initial start-up and
after any maintenance.
Leak air can reduce boiler output, but above all it
shifts the lambda measurement to lower air supply,
which makes the combustion chamber become
hotter. This can cause slag to form and, in extreme
cases, can cause rapid wear of the refractory
lining. Insufficient air also results in incomplete
combustion, which can result in tar deposits on the
heat exchanger.
Ash box closed and tightly coupled
Both the connection seal and the lid seal must
be clean and intact, and all four latches must
be closed.
Internal cover on heat exchanger inlet
Look through the combustion chamber door and
verify that the internal cover is firmly seated in
its frame.
Check lambda probe
(only for commissioning)
The installation tube must be firmly tightened,
with 20 kg and 20 cm lever arm (pipe wrench).
Heat exchanger cover closed?
First twist the ball knob half a turn clockwise to
engage it. Pull on the ball knob to test whether it
holds. Then tighten the knurled nuts alternately.
If one side is tightened too much, the other side
cannot be closed with a proper seal.
Drop chute and maintenance cover closed?
An open drop chute cover or maintenance cover
on the base of the rotary valve will stop boiler
operation (safety switch).
alternately
User Manual Hack 20-200 kW
2012-02
15
Conveyor screw blockage
Malfunctions in material transport
The entire transport of fuel to the boiler is
monitored by the control system. If the discharge
screw or the stoker screw is blocked, the control
system tries to unblock the screw by reversing it.
If the blockage persists after 3 attempts to remove
it, an error message is displayed. The boiler then
begins the burnout and can no longer be switched
on. When burnout is complete, the boiler is in the
"malfunction" state.
Malfunctions
Removing a blockage
Switch off boiler with main switch
When a blockage or overload is recognised, the
boiler begins the burnout and then switches to the
"malfunction" state. This can take up to
30 minutes.
Only switch off the main switch when the
"malfunction" state is displayed. This will keep
the boiler from overheating.
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TUE 4/4/2011 11:25:45
Stoker screw current consumption too high
Drive unit for boiler feed is blocked
Open access covers, remove blockage
Access covers can be removed for access to the
conveyor screws to eliminate blockages.
Before opening the access covers, ensure that the
boiler has been switched off with the main switch!
Access
covers
Error: "Current draw too high"
Oversized piece of wood or a foreign object
An single oversized piece of wood or a foreign
object is blocking the screw, causing its motor to
draw more current.
If the blockage cannot be removed after 3 tries,
material transport is deactivated to protect the
screw, and an error message is displayed on the
screen.
Restart boiler
Error: "Overload"
Wood chips too fine or too long
Wood chips that are too fine or too long interfere
with the conveying system over time. That
overloads the motor, which is switched off by the
motor protection.
16
Subject to change due to technical improvements
When the blockage has been removed and the
covers replaced, the boiler can be restarted with
the main switch.
Heating operation can be resumed with
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.
Malfunctions
Ash screw blocked
If the ash screw is blocked, a warning will be
displayed on the screen. The most common cause
of a blockage is a full ash box.
Determine the ash level by knocking on the box.
Acknowledge the warning and empty the ash box;
see page 23.
Ash screw jammed
Remove ash screw under grate
The grate ash screw is positioned centrally under
the grate. If it remains jammed, it must be
removed. Release the screw from the shaft by
unscrewing the M8 screw (spanner size 13) and
then pull it out while turning it anticlockwise.
Clean out the ash duct with suitable tools and
reattach the screw.
If the ash box is not full, then it can be assumed
that a foreign object is blocking the ash screw.
Foreign object blocking ash screw
Stop the heating by pressing
in the boiler
overview. As soon as the boiler status is "Switched
off", switch it off with the main switch.
Remove the ash box. The foreign object may
already be found stuck crosswise at the end of the
ash screw.
Press the button to release the actuator. Now use
the included spanner to orient the grate vertically.
The ash screw becomes visible through the
combustion chamber door and the foreign object
can be removed.
The heat exchanger
ash screw seldom jams
If you are certain that the cause of the blockage
is not the grate ash screw, contact ETA customer
service for the next steps.
User Manual Hack 20-200 kW
2012-02
17
Overtemperature protection
Protection against boiler overheating
The boiler is factory-equipped with safety features
to prevent it from overheating.
During installation, additional equipment such as
thermal emergency cooling valve and safety
valve must be installed.
Safety valve
Thermally actuated drain valve
Thermal emergency cooling valve against
overheating
The safety heat exchanger built into the boiler must
be connected by the heating technician to the
house's cold water supply via a thermal relief valve
(opening temperature 95 °C) to protect the boiler
against overheating if the pump fails. The minimum
pressure in the cold water pipe must be 2 bar (3 bar
for HACK 130 kW).
Connect the supply line to the lower connector of
the safety heat exchanger; the upper connector is for
outlet to the sewer. To prevent the supply line from
being shut off accidently, remove the levers from
shut-off valves or the hand wheels from valves and
hang them there with a piece of wire.
The following safety chain takes effect if the boiler
exceeds the operating temperature for any reason:
Thermal
emergency
cooling valve
Strainer
t over 3 bar water pressure -> safety valve
Cold water
connection
t over 105 °C -> safety temperature limiter
Visible drain to
sewer
t over 95 °C -> thermal emergency cooling valve
Isolating valve
Remove hand wheel
t over 90 °C -> pump safety run
The discharge must be have an easily visible, open
flow path so malfunctions can be recognised. Direct
the discharged water to the sewer via a siphon
funnel or at least with a pipe into the ground so that
nobody can be scalded if the valve is activated.
Pump safety run,
Automatic heat dissipation at overtemperature
If the boiler temperature exceeds 90°C (factory
setting) for any reason, the pump safety run will
start. All heating pumps and boiler pumps that are
connected to the boiler control are switched on to
dissipate heat from the boiler.
This action prevents the boiler temperature from
rising further and triggering further safety devices
such as: safety temperature limiter and thermal
emergency cooling valve. This emergency cooling is
shown on the monitor "Emergency cooling".
Even for cold water coming from a domestic well
with its own pump, a thermal emergency cooling
valve must be installed on the boiler. With a
generously dimensioned air vessel, enough water for
cooling will come even if there is a power failure. If
the electricity supply is very uncertain, a dedicated
air vessel for the thermal emergency cooling valve is
required.
The heat dissipation is limited with the maximum
flow temperature set in the heating circuits and
the hot water setpoint temperature.
18
Subject to change due to technical improvements
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Overtemperature protection
Safety shutdown by safety temperature limiter
For additional safety against boiler overheating, a
safety temperature limiter is built into the boiler.
When a boiler temperature of 105°C (tolerance
100 to 106°C) is reached, the power supply to the
draught fan and the fuel intake is interrupted.
If the boiler temperature decreases below 70 °C
again, the safety temperature limiter can be
manually released for a restart of the boiler.
The reset button is recessed into the door frame
above the door of the secondary combustion
chamber. It must be pushed in deeply (ideally with
a match) to release it.
Have the thermal emergency cooling
valve or the safety valve activated?
Safety valve
Thermally actuated drain valve
Are the pumps OK and the heating lines open?
Verify whether the pumps are running by using a
screwdriver as a "stethoscope".
If the system is new of has been out of operation
for some time, verify whether the return riser
mixing valve is in "AUTO" position and the manual
knob has snapped into "AUTO" position.
Safety valve against overpressure
A safety valve with 3 bar opening pressure must be
installed on the boiler. No shut-off valve may be
installed between the boiler and the safety valve.
If solar or other heat sources provide energy to the
buffer storage tank via a heat exchanger, a safety
valve (3 bar maximum) is also required on the
buffer storage tank. Normally an expansion tank
that is too small or defective, or blocked heating
lines, are the cause for activation of the safety
valve.
The safety valve must be on top of the boiler or
in the flow in order to also discharge heat in an
emergency. Only this way can it discharge heat by
blowing out hot water and steam.
The discharge must be directed to the sewer via
an easily visible, open flow path (siphon funnel)
so malfunctions and, above all, a non-closing
valve can be recognised. If no sewer is available,
the discharge must be directed into the ground in
a pipe so nobody is endangered by hot water or
steam.
User Manual Hack 20-200 kW
Verify that all shut-off valves in the heating lines
are open. (Always open ball valves completely to
avoid ruining the seals. Open the valves by turning
the handle anticlockwise, and then turn back a
quarter of a turn from the fully open position to
relieve pressure on the valve stem.)
Pressure
AUTO
Open
AUTO
Add heating water if necessary
If the boiler temperature has decreased, it may be
necessary to add heating water.
In houses with up to three storeys, the pressure in
a cold system should be between 1 and 2 bar, for
a warm system between 1.5 and 2.5 bar.
2012-02
19
Changing the deashing interval
When fuel causes slag formation
When fuel causes slag formation
Slag in the ash box
If large pieces of slag are found in the ash box, the
cause usually lies in the fuel's ash content. The
boiler must be deashed more often.
Check flue draught,
flue gas recirculation
A too-high flue draught can also cause slag
by reducing the effectiveness of the flue gas
recirculation.
If the flue draught is over 15 Pa, a draught limiter
is essential, or a nozzle on the chimney opening,
with which higher exit velocities and better lift for
the flue gas are achieved.
Basically, as long as the slag does not clog the air
holes in the grate, there is no need to worry. If the
grate needs cleaning weekly or even more often,
then it is essential that you switch to a different
fuel that causes less slag formation: less bark, less
dirt, less decayed material.
Leak air caused by poor seals?
Verify that the boiler door, heat exchanger cover
and ash box are tightly closed and their seals
intact; see page 15.
Adjust deashing interval
The deashing interval specifies how much fuel
must be consumed before automatic ash removal
begins. During this process the grate is tipped and
the ash that falls off is transported to the ash box
by the ash screws. The boiler's deashing interval is
set with the parameters "Earliest ash removal after
kg" and "Latest ash removal after kg".
The deashing interval depends on the type of fuel
being used. The higher the ash content of the fuel
(e.g. if there are large pieces of slag in the ash box),
the shorter the deashing intervals must be.
If shortening the deashing interval
results in no improvement
If shortening the deashing interval does not yield
satisfactory results, please contact our customer
service.
Increasing the residual oxygen target value (around
1 to 2 %) or limiting the boiler output by reducing
the maximum exhaust temperature can also help.
The deashing interval should only be altered
after consultation with an expert or ETA customer
service.
20
Subject to change due to technical improvements
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When fuel causes slag formation
The deashing interval depends on the fuel type
The deashing interval defines how much fuel
must be consumed before automatic ash removal
begins. During this process the grate tips up and
the ash that falls off is transported to the ash box
by the ash screws.
The deashing interval depends on the type of fuel
being used. The higher the ash content of the fuel
(e.g. if there are large pieces of slag in the ash box),
the shorter the deashing intervals must be.
Changing the deashing interval
Changing the "Earliest ash removal after kg"
setting
Press the buttons
menu.
and
to go to the text
Tap the [Boiler] line and, in the submenu, tap the
[Ash removal] line. Double-tap on the [Earliest ash
removal after kg] line.
The parameters "Earliest ash removal after kg" and
"Latest ash removal after kg" define the boiler's
deashing interval.
2x
Before altering the interval
Check the following points before altering the
deashing interval:
t Is the correct fuel type set? -> page 53
23
t Does the boiler have flue gas recirculation?
-> page 24
12
A settings screen opens:
54 onwards
t idletimes for ash removal -> page 26
The deashing interval should only be altered
after consultation with an expert or ETA Customer
Service.
Deashing interval factory settings
20 - 49 kW:
At earliest after:
At latest after:
Wood
chips
Wood
pellets
Miscanthus
25 kg
50 kg
35 kg
60 kg
5 kg
10 kg
Enter the new value and press
menu display appears again.
63 - 90 kW:
At earliest after:
At latest after:
35 kg
65 kg
55 kg
90 kg
9 kg
15 kg
130 kW:
At earliest after:
At latest after:
45 kg 90 kg
100 kg 150 kg
11 kg
19 kg
200 kW:
At earliest after:
At latest after:
70 kg 140 kg
155 kg 230 kg
17 kg
30 kg
User Manual Hack 20-200 kW
. The text
Use the same method to alter the parameter "Latest
ash removal after kg".
Press
to return to the boiler overview.
2012-02
21
Overview of activities
Regular cleaning and servicing
Maintenance
Cleaning and maintenance overview
To ensure that the boiler operates reliably, it must
be cleaned and serviced at regular intervals.
Below is a table with an overview of the activities
to be performed for cleaning and maintenance.
However, maintenance and cleaning must be
performed within the specified duration (once per
year, every 3 years).
The "to be done by" column indicates which
activities you as customer can deal with and which
must be performed by an expert.
Frequency
Regularly
every 2,500 h
or at least 1x
yearly
every 5,000 h
or at least
3 years
to be done
by
Empty the ash box
X
X
X
Customer
Check seals on ash box and connection to boiler
X
X
X
Customer
Remove ash from secondary combustion chamber
X
X
X
Customer
Check water pressure
X
X
X
Customer
Check safety valve(s)
X
X
X
Customer
Inspect and clean grate
X
X
Customer
Check seal on combustion chamber door
X
X
Customer
Check firebed level sensor
X
X
Customer
Clean secondary air openings in secondary combustion chamber
X
X
Customer
Check refractory lining
X
X
Customer
Clean flue tube
X
X
Customer
Remove flue ash from chimney
X
X
Customer
Clean heat exchanger, remove flue ash
X
X
Customer
Inspect heat exchanger tubes for tar deposits
X
X
Customer
Vacuum out lambda probe (do not remove it)
X
X
Customer
Clean flue gas recirculator
X
X
Customer
Extinguishers, malfunction indicators or alarms
X
X
Customer
Trial heating and test residual oxygen / lambda probe
X
X
Customer
Clean control panel and casing
X
X
Customer
Inspect blades on rotary valve
X
Expert
Lubricate drive chains for stoker and ash screws
X
Expert
Perform and check ash removal process
X
Expert
Safety switches on drop chute and maintenance cover
X
Expert
Check closing of tilting grate
X
Expert
Clean draught fan and fan housing, replace seal
X
Expert
Inspect ash box position switch and seals
X
Expert
Perform emission measurement
X
Expert
Check safety temperature limiter
X
Expert
Reset maintenance counter
X
Expert
Activity
22
Subject to change due to technical improvements
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Maintenance
Emptying the ash box
Emptying the ash box
On-screen reminder to empty ash box
The ash box must be emptied regularly. In the
control system, you can enter a fuel consumption
amount, so that a reminder to empty the ash box
will appear on-screen once this amount of fuel has
been consumed.
Since the ash content depends on the type of fuel
being used, the default value is set to 0 kg. No
reminders are given if the setting is 0 kg.
However, the parameter can be changed at any
time as soon as you have some experience of your
fuel consumption rate; see page 25.
Stop heating,
draught fan switched off
Before emptying the ash box, switch off the
boiler in the overview with the
button. The
boiler performs a burnout. This can take up to
30 minutes.
Only when the draught fan is switched off and the
boiler status "Switched off" is displayed on the
screen is the burnout complete; then the ash box
can be removed.
If this is not done, leak air will transport flue ash
into the chimney and into the surroundings.
Boiler
TUE 4/4/2011 11:25:45
Reminder: Check ash box
When the ash box is removed, the counter is reset. Empty
the ash, check the water pressure and the safety valve.
(see user manual)
Open the side latches
Is the ash box full?
By knocking on the vertical wall of the ash box,
you can also check the ash level without opening
it. If it is full, it makes a dull thump. When empty
it makes a hollower sound like a drum.
User Manual Hack 20-200 kW
Open the side latches by pressing the safety catch
in the direction of the arrow. Take the ash box out
of the boiler.
open
2012-02
23
Overview of activities
Check the ash – are there
any large pieces of slag?
If there are many large pieces of slag in the ash,
check the grate (see page 27) and, if necessary,
shorten the deashing interval (see page 20).
Maintenance
Reattach ash box to boiler
Reattach the ash box to the boiler with the side
latches.
Ash deposits in secondary combustion chamber
steeper than 45 degrees
The ash in the secondary combustion chamber may
not be steeper than 45 degrees. Use the scraper to
push the excess ash into the combustion chamber
and start to deash the boiler.
Tap
on the screen. If necessary, start an
another deashing.
No embers in the rubbish bin
Take the opportunity to check the fit and seal of
the internal cover over the heat exchanger inlet.
If there are still embers in the ash, leave the ash
in a closed, non-flammable container for at least
2 days. Only put it in the rubbish bin when there
are really no more embers present.
Available accessories include a second ash box or
a 110-litre rubbish bin compatible with refuse
lorries, which can be attached directly to the boiler
in a prone position. Ask your heating specialist.
Inspect seals
Check the seals in the ash box's cover and on the
boiler's ash outlet. These must be undamaged;
otherwise leak air could be sucked in.
24
Subject to change due to technical improvements
Restart the boiler
The boiler can be restarted by tapping
www.eta.co.at
.
Maintenance
"Empty ash box" reminder
"Empty ash box" reminder
The ash box must be emptied regularly. In the
control system, you can enter a fuel consumption
level, so that a reminder to empty the ash box
will appear once this amount of fuel has been
consumed.
Since the ash content depends on the type of
fuel being used, the default value is set to 0 kg.
With this setting, the reminder does not appear
on the screen, and the ash box filling level must
be checked manually at regular intervals.
A settings screen opens:
However, the parameter can be changed at any
time as soon as you have some experience of your
fuel consumption rate.
Boiler
TUE 4/4/2011 11:25:45
Enter the new value. If the value is set to zero, this
message will no longer appear.
Reminder: check ash box
Press
to confirm.
Counter reset when ash box removed. Empty out ash,
check water pressure and safety valve. See user manual.
Press the
button to return to the overview.
Changing the "Empty ashbin after" setting
Press the buttons
menu.
and
to go to the text
Tap the [Boiler] line and, in the submenu, press the
[Ash removal] line.
Double-tap the [Empty ashbin after] line.
2x
User Manual Hack 20-200 kW
2012-02
25
Water pressure, safety devices
Optimum water pressure 1.5 - 2.5 bar
In houses with up to three storeys, the pressure in
a cold system should be between 1 and 2 bar, for
a warm system between 1.5 and 2.5 bar.
If the boiler pressure is too low, fill the cold
heating system to approx. 2.0 bar. Water expands
with increasing temperature. When heating to full
operating temperature, the safety cut-off pressure
of 2.8 bar should not be exceeded.
Only refill with softened water after major repairs.
If the heating water pressure is repeatedly too low,
the cause of the leak must be found.
Water pressure
Maintenance
No combustible material in the boiler room
No combustible materials may be present in the
boiler room.
Fire extinguisher in the vicinity of the boiler
As a precaution, keep a fire extinguisher within
reach in the passageway to the boiler, but not in
the boiler room.
Safety valve
Fire door for boiler room
The boiler room must be equipped with a selfclosing fire door.
Thermally actuated
drain valve
Check safety valve and
thermal emergency cooling valve
The safety valve and the thermal emergency
cooling valve may not drip. Dirt may be stuck in
the seal seat.
Perform further steps only on weekdays, never on
weekends in a cold winter as there will probably
be no heating technician available if the seal is
defective. 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 closed tightly after
being rinsed several times, it must be cleaned by a
plumber or replaced. If a solar buffer is equipped
with a safety valve, check that as well.
The thermal emergency cooling valve is cleaned by
pressing the red button.
26
Subject to change due to technical improvements
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Maintenance
Every 2,500 h or yearly
Maintenance every 2,500 hours or
yearly, for miscanthus after 1,250 h
When this maintenance is due, a message appears
on the screen.
Lift combustion chamber cover
Use the scraper to place the hot combustion
chamber cover in the rear of the secondary
combustion chamber to make the grate visible.
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Cleaning after 2500 hours
Reminder for periodic cleaning of the heating system as
per user manual
Clean vertically oriented grate
Clean the vertical grate with the scraper.
Check grate if ash has slag
If there are large and very hard, glassy pieces of
slag in the ash, the combustion chamber and grate
must be inspected. Individual small pieces of slag
are no cause for concern. The limit of acceptable
slag formation is reached when it clogs the air
holes in the grate.
Check movement of firebed level sensor.
Check the movement of the level sensor by
repeated lifting with the scraper.
See also the section "When fuel causes slag
formation" on page 20.
Check and clean air holes in grate
The combustion chamber is still hot, so a mirror
and a torch can be helpful. Use the poker to clean
the air holes.
Stop heating and start ash removal
Stop heating by tapping
. When the boiler
status is "Switched off", tap
. Use the scraper
to scrape the ash from the secondary combustion
chamber into the primary combustion chamber.
Replace combustion chamber cover
Replace the combustion chamber cover and then
.
start another ash removal with
User Manual Hack 20-200 kW
2012-02
27
Water pressure, safety devices
Check seal on combustion chamber door
Check the seal on the combustion chamber door.
The door handle must close firmly (with force), and
the sealing edges of the door frame must leave a
clear impression on the rope seal. Leaky sections
can be identified by variations in the colouring on
the rope seal or by using a cigarette lighter while
the induced draught fan is running. The flame will
be drawn through the leak.
If leaks are found, it is usually sufficient to adjust
the hinges and the closing roller mount (see
picture). If the hinges cannot be adjusted further,
then the seals must be replaced.
Maintenance
Check firebed level sensor
Check the movement of the level sensor by
repeated lifting with the scraper.
Check whether the switch for the firebed level
sensor (under the cover on the insulation door)
is activated when the sensor is lifted.
Adjust hinges:
Loosen hex nuts (13 mm
screw) and push hinge
bracket evenly about 0.5 to
1 mm toward the boiler.
Switch
Pictures for stoker on right,
mirror image for stoker on left
Clean secondary air openings
Check ash box seals
Check the integrity of the seals in the ash box's
cover and on the boiler's ash outlet.
Check whether all secondary air openings in the
secondary combustion chamber are clean.
Secondary air openings
28
Subject to change due to technical improvements
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Maintenance
Water pressure, safety devices
Inspect lining of secondary combustion chamber
Check the refractory lining of the secondary
combustion chamber for damage and cracks.
Remove flue ash
Remove the internal cover, brush out the
downdraft channel, and vacuum out the flue ash.
Wait to vacuum until certain that there are no more
embers, or use a vacuum cleaner with a heatresistant dust separator.
Clean flue tube
Brush out the connection pipe from the flue outlet
to the chimney if it is longer than 0.5 m.
Head of lambda probe
Remove flue ash from chimney
Use a vacuum cleaner to remove the flue ash from
the chimney.
Also clean the condensate drain.
Brush out downdraft channel
Clean the lambda probe
Cleaning the heat exchanger
Before cleaning, stop heating with
. Only begin
cleaning when the boiler status is "Switched off".
Open heat exchanger cover
The head of the lambda probe is accessible.
Vacuum it with a vacuum cleaner.
Do not remove the lambda probe.
Replace internal cover
Open the heat exchanger cover by turning the nuts.
Then turn the ball knob 180° anticlockwise and lift
the cover away.
After cleaning, carefully replace the internal cover.
Verify that it is seated tightly.
For Hack 130 kW and 200 kW, there are 2 heat
exchanger covers.
180°
User Manual Hack 20-200 kW
2012-02
29
Water pressure, safety devices
Check heat exchanger for tar deposits
Inspect the heat exchanger tubes for tar deposits. If
it is present, the turbulators must be removed and
cleaned.
Close heat exchanger cover
Maintenance
Clean flue gas recirculator
The flue gas recirculation tubes must be cleaned to
ensure satisfactory function.
Remove the covers, brush the tubes and then
vacuum them.
Remove maintenance cover
Re-engage the heat exchanger cover by turning the
ball knob 180° clockwise.
180 °
Then tighten the nuts alternately. If one side is
tightened too much, the other side cannot be
closed with a proper seal.
alternately
Maintenance cover
Finally, start ash removal for the boiler with
30
Subject to change due to technical improvements
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.
Maintenance
Water pressure, safety devices
Readiness of extinguishers
If an extinguisher is installed, check it and its
water supply.
Malfunction messages and alarms
Check malfunction indicators and alarms, for
example if messages from the boiler room
are displayed elsewhere, or if a temperaturemonitoring system (corresponding to TRVB H 118)
is installed in the fuel store.
Clean casing
Clean the boiler casing with a damp cloth and
(if necessary) a commonly available household
cleaner (no scouring agents).
User Manual Hack 20-200 kW
2012-02
31
Servicing by an expert
Servicing by an expert
every 5,000 hours or 3 years
If the boiler has reached 5,000 hours of operating
time, a message will appear to indicate that expert
maintenance is needed.
Maintenance
Check safety valve and
thermal emergency cooling valve
The safety valve and the thermal emergency
cooling valve may not drip. Dirt may be stuck in
the seal seat.
Safety valve
This maintenance must be performed by an expert
no later than every 3 years.
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Service by an expert after 5000 hours
Reminder to have the heating system checked and
serviced by an expert. (see user manual)
Thermally actuated
drain valve
In preparation, perform "regular" and
"2,500 hours" maintenance
For the 5,000-hour maintenance, the individual
steps for "regular" and "2,500 hours" maintenance
must be performed.
Inspect blades on rotary valve
Check the blade on the rotary valve. If there is
visible damage such as notches, replace the blade.
Check safety switches on drop chute
and maintenance cover
Check the safety switches on the drop chute and
the maintenance cover of the rotary valve.
32
Subject to change due to technical improvements
Perform further steps only on weekdays, never on
weekends in a cold winter as there will probably
be no heating technician available if the seal is
defective. 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 closed tightly after
being rinsed several times, it must be cleaned by a
plumber or replaced. If a solar buffer is equipped
with a safety valve, check that as well.
The thermal emergency cooling valve is cleaned by
pressing the red button.
Lubricate drive chains for
stoker and ash screw
Lubricate the drive chain for the stoker with spray
oil and check the chain tension. The chain may
sag by 1 - 2 cm without effort. The chain can be
tensioned by shifting the motor.
Lubricate the drive chain for the ash screws with
spray oil. To do so, start ash removal by tapping
to start the chain moving so that it can be
completely lubricated.
www.eta.co.at
Maintenance
Test automatic ash removal
Verify the function of the boiler's automatic ash
removal.
Servicing by an expert
Check seal,
close heat exchanger cover
Check the seal on the heat exchanger cover, replace
it if necessary, and close the heat exchanger cover.
Firebed level sensor
Check the movement of the firebed level sensor
(overfill protection).
Complete closing of tilting grate
Ensure that the tilting grate in the combustion
chamber closes completely.
Perform emission measurement
Perform the emission measurement with a
measuring device on the boiler; see page 8.
Switch the boiler into emission measurement mode
with the
button. The consumers are activated
to ensure that the heat is dissipated.
If no measuring device is available, at least the
lambda probe must be calibrated.
Safety temperature limiter
Draught fan and fan housing
Remove the draught fan and clean it. Also clean
ash from the fan housing.
Check the function of the safety temperature
limiter.
If necessary, replace the draught fan seal.
Reset maintenance counter
Ash box position switch and seals
Verify the function of the position switch for the
ash box. Inspect both of the ash box seals and
replace if necessary.
After expert maintenance, the maintenance counter
must be reset to zero. The "Service" access level is
required to do this.
Check heat exchanger tubes
Remove the heat exchanger cover.
Check the heat exchanger tubes for tar deposits.
If tar deposits are present, contact our customer
service.
User Manual Hack 20-200 kW
2012-02
33
Servicing by an expert
Automatic calibration of the lambda probe
The boiler's built-in lambda probe checks the
residual oxygen content of the flue gas and uses
this to control the combustion. In order to ensure
that this works correctly, the boiler automatically
calibrates the lambda probe at regular intervals
(factory setting: every 500 h).
Maintenance
Starting the "Additional calibration" function
In the submenu, scroll down and double-tap on
the [Additional calibration] line.
Calibrating the lambda probe with the
"Additional calibration" software function
2x
The access level "Service" is required for calibration.
If you wish to perform an additional calibration
between the automatic intervals, you can start the
calibration using the software function "Additional
calibration". When this is activated, the boiler
automatically stops heating, de-ashes and rinses
the boiler with fresh air using the draught fan. The
residual oxygen content is then measured and the
lambda probe is automatically calibrated to the set
value.
The calibration process takes approx. 1.5 –
2 hours.
Opening the boiler text menu
In the selection window that appears, press the
[On] button and confirm with
.
Using the access level "Service", open the text
menu by pressing
and
.
Tap the [Inputs] line. In the submenu, tap the
[Residual O2] line.
The lambda probe is calibrated automatically
The control system will now automatically calibrate
the lambda probe.
After 100 hours, the control system will
automatically re-calibrate the probe.
In the overview
Press
to return to the boiler overview. The
boiler is now in Calibrating lambda probe mode.
Once calibration is complete, the boiler
automatically returns to operation and begins
heating as required.
34
Subject to change due to technical improvements
www.eta.co.at
User Manual Hack 20-200 kW
2012-02
35
Approval, antifreeze, pressure equalisation, venting
Approval
Every heating system must be approved.
Inquire at you building authority and ask your
chimney sweep.
Operation only by trained personnel
The system may be operated only by trained
personnel. Instruction can be given by the heating
installer or our customer service. Please read this
user manual to be assured of avoiding errors in
operation and maintenance of the boiler.
Fire extinguisher
In Austria at least a powder extinguisher ABC 6 kg is
required. Better is a foam extinguisher AB 9 litre,
which causes less damage when extinguishing.
The fire extinguisher should be kept outside the
boiler room, easily visible and easily accessible.
In Germany and Switzerland, no fire extinguishers
are required for heating systems in private
residences. In spite of this, we recommend having
one in the house.
Keep children
awaybe
from
Children must
keptboiler
away room
from the boiler
and pellet
store
room and pellet store.
A special danger in the fuel store is the formation
of a hollow above the agitator. Children playing
on the pile of wood chips, or also careless adults,
Antifreeze
could fall in and get buried or caught up in the
Ifdischarge
a house screw.
with average insulation is unoccupied
in winter at low temperatures for more than five
days, check once a week (twice a week for very
low temperatures) to make certain that the boiler is
operating properly.
Antifreeze
building
unoccupied
in winter
for longer
IfIf athe
house
withisaverage
insulation
is unoccupied
intervals,
uplow
to 30%
antifreezefor
canmore
be added
in
winter at
temperatures
than five
to
the
heating
water.
To
compensate
for
thevery
days, check once a week (twice a week for
disadvantage
of
reduced
heat
capacity
and
low temperatures) to make certain that the boiler is
increased flproperly.
ow resistance, only slightly higher flow
operating
temperatures are needed.
If the building is unoccupied in winter for longer
intervals, up to 30% antifreeze can be added
to the heating water. To compensate for the
disadvantage of reduced heat capacity and
increased flow resistance, only slightly higher flow
temperatures are needed.
36
Subject to change due to technical improvements
Insulate contact sensors
If the pipe in the vicinity of a contact temperature
sensor is not insulated (e.g. in externally installed
heating circuit groups), lower than actual
temperatures will be measured. For this reason,
pipe insulation may not be recessed or weakened
for heating circuit flow sensors. For uninsulated
piping systems, the measurement area must be
insulated with mineral wool at least 20 mm thick
over a length of at least 20 cm of pipe.
Pressure equalisation
For pressure equalisation in the system, a
diaphragm expansion tank with a gross capacity of
around 10% of the system volume is needed (see
conditions for guarantee and warranty).
All shut-off valves along the path from the
expansion tank to the boiler and to the buffer
storage tank must be capped valves, or the hand
wheels or levers must be removed from the valves
(hang on the valve with a wire) to ensure that they
cannot be closed by accident.
If the pressure difference between cold and warm
heating system (buffer fully loaded if installed)
is greater than 1.0 bar for a single-floor system
or 0.5 bar for a three-storey system, then the
expansion tank is too small and absolutely must
be replaced with a larger one. If the installed
expansion tank is not large enough, the system
sucks in air when cooling and the air is absorbed
by the cold water and transported to the boiler.
At the point of highest temperature, the air
separates from the water again. This is the usual
situation in the boiler, and the inevitable result
is that the boiler wall will rust through at these
places.
Venting
Automatic venting valves in the boiler outlet, at
the highest point in the distribution network and
at the top of the buffer significantly reduce the
danger of rust and also the frequency of radiator
venting.
www.eta.co.at
Softened water, corrosion, safety valve
Initial fill-up with softened water and
enough shut-off valves
to keep the lime content to a minimum during
water additions.
All relevant standards demand softened water for
heating systems with larger water volumes.
For the
boilers
up atovalue
90 kW,
a value lt°dH
of 20,000
lt°dH
boiler
of 20,000
for system
for
system
volume
in
litres
multiplied
by
the
volume in litres multiplied by the hardness
hardness
(inofdegrees
German hardness)
should
(in degrees
Germanofhardness)
may not be
not
be exceeded. For boilers over 90 kW, the limit is
exceeded.
30,000 lt°dH.
A system volume of 300 litres (boiler and heating
Aelements)
system volume
of hard
500 litres
and heating
and very
water(boiler
with 30°dH
yields
elements)
and
very
hard
water
with
30°dH
yields
a value of 9,000 lt°dH. In this case, the system
cana
value
of
15,000
lt°dH.
In
this
case,
the
system
can
still be filled with unsoftened water.
still be filled with unsoftened water.
1000-litre buffer,
For a heating system with a 2,000-litre
buffer,for
a
system
volume
of 2,500
litres
results.
Even
with
example,
the total
volume
is 1300
litres.
Even
with
water that is not very hard, such as 15°dH,
20°dH, a value
of 37,500
lt°dH
results;
that
is
too
high.
26,000 lt°dH results; that is too high. The
For afilling
water
must
be
softened
to
8°dH
for
a
volume
of
volume of 1300 litres, the water must be softened
2,500
litres
(20,000
divided
by
2,500).
to less than 15°dH (20,000 divided by 1,300).
Around 0.25 kg of limescale will precipitate from
a cubic metre of water with 15°dH, resulting in
a limescale layer 0.2 mm thick on a quarter of
a square metre of the boiler's heat exchanger
surface; this small area in the boiler is where the
lime build-up is concentrated. This may not seem
serious, but with 2 m³ of buffer storage and a
system volume of 0.5 m³, a thickness of 0.5 mm
is reached. Thicker layers hinder the heat flow
through the boiler wall to the extent that it is no
longer cooled sufficiently and heat stress cracks can
form.
In practice, that means the boiler can tolerate a
buffer filled with unsoftened water as long as
no repairs and no leaks in the system (defective
air valves or safety valves that fail to close) force
water to be refilled during the further course of the
system's service life.
Protection against corrosion
To limit corrosion with softened water, the
pH value should be adjusted to between 8 and 9
using suitable inhibitors (trisodium phosphate).
Safety valve against overpressure
Install a safety valve with 3 bar opening pressure
on the boiler (is already installed for PU and
PC boilers). No shut-off valve may be installed
between the boiler and the safety valve. If solar
or other heat sources provide energy to the buffer
storage tank via a heat exchanger, a safety valve
(3 bar maximum) is also required on the buffer
storage tank. Normally an expansion tank that is
too small or defective, or blocked heating lines, are
the cause for activation of the safety valve.
The safety valve must be on top of the boiler in
the flow in order to also discharge heat in an
emergency. Only this way can it discharge heat
when it blows out hot water and also steam.
The discharge must be directed to the sewer via
an easily visible, open flow path (siphon funnel)
so malfunctions and, above all, a non-closing
valve can be recognised. If no sewer is available,
the discharge must be directed into the ground in
a pipe so nobody is endangered by hot water or
steam.
To have a sufficient safety reserve for additions,
the new system must be filled with softened
water, meaning that the empty system must really
be filled exclusively with softened water before
starting the boiler for the first time. Changing
the water after the boiler has already been in
operation is too late since the limescale from the
unsoftened water has already precipitated in the
boiler.
To reduce the amount of water replacement for
later repairs, it must be possible to shut off all large
volumes such as buffers, boiler and heating circuits
User Manual Hack 20-200 kW
2012-02
37
Return riser, safety devices
Install a safety valve with 3 bar opening pressure on
the boiler (is already installed for PU and PC boilers).
No shut-off valve may be installed between the
boiler and the safety valve. If solar or other heat
sources provide energy to the buffer storage tank via
a heat exchanger, a safety valve (3 bar maximum) is
also required on the buffer storage tank. Normally
an expansion tank that is too small or defective, or
blocked heating lines, are the cause for activation of
the safety valve.
The safety valve must be on top of the boiler or
in the flow in order to also discharge heat in an
emergency. Only this way can it discharge heat
when it blows out hot water and also steam.
Thermal
emergency
cooling valve
Safety valve against overpressure
Strainer
The return riser mixing valve controls the buffer
charging output. To reduce the output, the return
temperature is raised over 60°C to reduce the spread
compared to the boiler's setpoint temperature. With
the spread the output that can be consumed from
the boiler is limited.
Isolating valve
Remove hand wheel
The mixer also allows the exploitation of residual
heat. After the fire is extinguished, if the buffer is
colder than the boiler, the boiler control opens the
mixer again and switches on the boiler pump to
exploit the residual heat.
The safety heat exchanger built into the boiler must
be connected by the heating technician to the
house's cold water supply via a thermal outlet valve
(opening temperature 95 °C) to protect the boiler
against overheating if the pump fails. The minimum
pressure in the cold water line must be 2 bar.
Connect the supply line to the lower connector of
the safety heat exchanger; the upper connector is for
outlet to the sewer. To prevent the supply line from
being shut off accidently, remove the levers from
shut-off valves or the hand wheels from valves and
hang them there with a piece of wire.
Cold water
connection
Wood contains water. If the temperature in the
boiler is too low, steam condenses from the flue gas
onto the heat exchanger surfaces. Corrosion and a
leaky heat exchanger are the result. To prevent this,
the water temperature at the boiler inlet must be at
least 60°C. Since the return temperatures are usually
lower, a return riser is needed - preferably with a
mixer that provides controlled, heated flow to the
boiler return.
Thermal emergency cooling valve against
overheating
visible drain to
sewer
Return riser
The discharge must be have an easily visible, open
flow path so malfunctions can be recognised. Direct
the discharged water to the sewer via a siphon
funnel or at least with a pipe into the ground so that
nobody can be scalded if the valve is activated.
Even for cold water coming from a domestic well
with its own pump, a thermal emergency cooling
valve must be installed on the boiler. With a
generously dimensioned air vessel, enough water for
cooling will come even if there is a power failure. If
the electricity supply is very uncertain, a dedicated
air vessel for the thermal emergency cooling valve is
required.
The discharge must be directed to the sewer via an
easily visible, open flow path (siphon funnel) so
malfunctions and, above all, a non-closing valve
can be recognised. If no sewer is available, the
discharge must be directed into the ground in a pipe
so nobody is endangered by hot water or steam.
38
Subject to change due to technical improvements
www.eta.co.at
Overtemperature, safety shutdown, chimney
Pump safety run,
Automatic heat dissipation at overtemperature
If the boiler temperature exceeds 90°C (factory
setting) for any reason, the pump safety run will
start. All heating pumps and boiler pumps that are
connected to the boiler control are switched on to
dissipate heat from the boiler.
This action prevents the boiler temperature from
rising further and triggering further safety devices
such as: safety temperature limiter and thermal
emergency cooling valve. This emergency cooling is
shown on the monitor "Emergency cooling".
The heat dissipation is limited with the maximum
flow temperature set in the heating circuits and
the hot water setpoint temperature.
Safety shutdown by safety temperature limiter
For additional safety against boiler overheating, a
safety temperature limiter is built into the boiler.
When a boiler temperature of 105°C (tolerance
100 to 106°C) is reached, the power supply to the
draught fan and the fuel intake is interrupted.
If the boiler temperature decreases below 70 °C
again, the safety temperature limiter can be
manually released for a restart of the boiler.
The reset button is recessed into the door frame
above the door of the secondary combustion
chamber. It must be pushed in deeply (ideally with
a match) to release it.
Chimney renovation before it's too late
Compared to older boilers, modern ones are more
efficient and have lower amounts of flue gas and
considerably lower temperatures.
In particular, chimneys with "too large a crosssection" (over 20 cm) are no longer heated
adequately. The moisture contained in the flue
gases condenses in the flue, leading to the very slow
but inexorable destruction of old masonry chimneys.
Furthermore, if the diameter of the flue is too large,
the exit velocity and temperature are too low. The
exhaust gas does not have enough energy to rise
and, in extreme cases, the smoke can flow down
the roof.
If your flue does not have a moisture-resistant
lining or its diameter is too large, it will need to be
renovated with the addition of a moisture-resistant
inner lining. Narrow flues can also be renovated
with stainless steel pipes.
Also keep in mind that chimneys have a limited
service life. Timely renovation before the chimney
wall has been destroyed can be performed quickly
and easily by inserting a tube. But if the flue gas
condensates have penetrated the mortar joints, then
the entire flue must be dismantled and rebuilt.
Sealed and insulated connection pipe
to chimney
A sealed flue pipe is an absolute necessity. Joints
and bends can be sealed with heat-resistant
silicone (300 °C) and/or pure aluminium tape to
prevent the escape of dust or flue gas. Insulating
the pipe improves the flue draught, protects
against burns on accidental contact, and reduces
the fire hazard.
Technical requirements for the flue
can be found in the installation instructions
(a separate document from this user manual).
User Manual Hack 20-200 kW
2012-02
39
Buffer storage tanks
At low heating loads,
either install a buffer
or set short heating time slots
No buffer storage tank is needed if
no more than two heating circuits (without
individual room temperature control) are installed.
For very well-insulated brick walls (not for wooden
construction), the house itself is an excellent thermal
store. If the boiler output is too high, it can be
adjusted to the house's heating requirements by
limiting the heating time to three short time slots
spread over the day.
If there is very low heat consumption during the
transitional period in autumn/spring (e.g. heating
only in the bathroom), then a buffer storage tank is
needed for this low heating load.
A wooden house requires a buffer
For a wooden house with radiator heating, where
there is not even the screed of an underfloor heating
system to act as a thermal store, the installation of
a buffer should be considered. With a design output
less than 70% of the boiler's rated output, an
underfloor heating system operating only with time
slots will cause large temperature variations in the
rooms and a buffer storage tank is required. Heat
produced by the boiler and not currently needed in
the house can be stored in a buffer storage tank and
returned to the heating system when needed.
To operate the boiler without a buffer storage tank,
a hot water tank of sufficient size (see table) to take
up the heat from an entire firing cycle is needed.
A sufficiently large tank should also be chosen for
increased convenience.
Boiler
output
Supply
volume
Charging
Total hot
Exchanger
volume watervolume surface
up to 11 kW
100 l
100 l
200 l
0.8 m²
up to 25 kW
100 l
200 l
300 l
1.5 m²
up to 50 kW
150 l
350 l
500 l
2.5 m²
up to 90 kW
200 l
600 l
800 l
4.0 m²
up to 130 kW
300 l
800 l
1,100 l
5.5 m²
up to 200 kW
400 l
1,100 l
1,500 l
8.0 m²
Subject to change due to technical improvements
t if individual room temperature control is installed.
t if there are more than two heating circuits,
especially in buildings where the flats are
individually controlled.
t when a substantial portion of the boiler's
operating time is spent below its lowest
modulation ratio.
t during the transitional period in autumn/spring
when there is very low heating demand, such as
only for the bathroom.
t for radiators in wooden houses with low heat
capacity.
t if above-average hot water demand or high spikes
in hot water use are expected, e.g. in hotels,
blocks of flats, showers in sports facilities. A
wood boiler
chip boiler
45 minutes
to reach
pellet
needsneeds
up toup
20tominutes
to reach
its
its maximum
output
from
standby.
maximum
output
from
standby.
t if an air heating system is to be started without
warm-up time for the boiler.
t if a solar heating system is being integrated with a
low-temperature heating system.
A sufficiently large hot water tank
40
A buffer storage tank is needed
Finely adjustable radiator valves and fresh water
module
The lower the return temperature to the buffer,
the greater its heat storage capacity. The buffer
utilisation of radiators can be improved considerably
with very finely adjustable thermostat valves
(kvs less than 0.35).
With a fresh water module, the hot water supply
can be integrated in the buffer to save space, and
solar can also be integrated in the buffer very simply
and effectively.
www.eta.co.at
Miscanthus, carpentry waste
Miscanthus in wood chip boilers
Miscanthus needs a larger combustion chamber.
That reduces the maximum possible output of the
individual sizes of boiler; for miscanthus, it is about
30 % less than for wood chips.
20 kW wood chip boiler
25 kW wood chip boiler
35 kW wood chip boiler
50 kW wood chip boiler
-> 20 kW miscanthus
-> 25 kW miscanthus
-> 35 kW miscanthus
-> 35 kW miscanthus
70 kW wood chip boiler -> 63 kW miscanthus
90 kW wood chip boiler -> 63 kW miscanthus
130 kW wood chip boiler -> 95 kW miscanthus
200 kW wood chip boiler -> 140 kW miscanthus
The sintering point for miscanthus ash is around
860°, much lower than for wood ash. To prevent
slag formation in the combustion chamber, lower
combustion temperatures than those typical for
wood are needed. This can be achieved with flue
gas recirculation.
Theoretically, the larger boilers (from 35 kW rated
output) could also be made miscanthus-capable
by limiting their output, but normally their output
is needed, so from 35 kW flue gas recirculation is
indispensable for miscanthus.
Very dry carpentry waste
reaches very high combustion temperatures. Glue
and coatings can reduce the sintering point of the
ash. Both factors can lead to slag formation in the
combustion chamber.
The first action to take against slag is to shorten the
deashing intervals; see page 54 ff.
If that achieves no reduction, then a flue gas
recirculator (optional accessory) must be added.
Recirculating the flue gas from the boiler outlet
back into the combustion chamber increases the
gas flow through the grate as well as through the
fire, cooling the grate better. The distribution of
the fire's heat over a larger gas volume helps to
achieve a narrower and more stable temperature
window. Temperatures are held safely above
700 °C for complete, clean combustion and safely
below 860 °C, the sintering point for miscanthus
ash. For pellets, a somewhat higher temperature
window between 750 °C and 950 °C is used with
less oxygen (less air).
Less "fire" in the same size of combustion chamber
also results in lower combustion temperatures
and prevents slag formation. So in the "oversized"
combustion chambers of the 20 and 25 kW boilers,
chopped miscanthus (no pellets) can be burned
without flue gas recirculation. The fuel must be
changed to "Miscanthus" (see page 53) and
the "Flue gas recirculation" parameter to "No"
(see page 12). Here too, however, it should
be noted that dirty miscanthus can require flue
gas recirculation even with small combustion
chambers.
User Manual Hack 20-200 kW
2012-02
41
Efficient and low-emission operation
Dear customer,
Your new boiler is labelled with the "Blue
Angel" to indicate its environmental
friendliness.
With this in mind, please note the
following for efficient and low-emission
operation of your heating system:
1. The installation and adjustment of the heating
system must be performed only by qualified and
trained personnel.
2. Use only the fuels specified by us in the user
manual (in the warranty conditions). Only in this
way can low-emission, economical and fault-free
operation of your heating system be ensured.
3. Perform the maintenance and cleaning
procedures recommended by us on your heating
system at regular intervals. See your user manual
for information about these. In this way, you can
ensure that your heating system and its safety
features will work effectively to provide efficient
and low-emission operation. You can get the
best care for your heating system by concluding a
service contract.
4. Your boiler is adjustable within an output range
between 30% and 100% of its rated output.
To avoid unnecessary emissions in low-output
operation, the systems should be operated as
much as possible in the mid- to high-output range
(adjusted to the heating needs).
Please do not use any heating controller separate
from the boiler control. Use the heating circuit
control integrated in the boiler control in
combination with a room sensor.
5. From an energy perspective, a buffer storage
tank and a combination with a solar heating
system are recommended. That ensures efficient
and low-emission operation of your heating
system.
42
Subject to change due to technical improvements
The Clean Air Act 1993 and Smoke Control Areas
Under the Clean Air Act local authorities may
declare the whole or part of the district of the
authority to be a smoke control area. It is an
offence to emit smoke from a chimney of a
building, from a furnace or from any fixed boiler
if located in a designated smoke control area. It is
also an offence to acquire an „unauthorised fuel“
for use within a smoke control area unless it is
used in an „exempt“ appliance („exempted“ from
the controls which generally apply in the smoke
control area).
The Secretary of State for Environment, Food and
Rural Affairs has powers under the Act to authorise smokeless fuels or exempt appliances for use
in smoke control areas in England. In Scotland
and Wales this power rests with Ministers in the
devolved administrations for those countries.
Separate legislation, the Clean Air (Northern
Ireland) Order 1981, applies in Northern Ireland.
Therefore it is a requirement that fuels burnt or
obtained for use in smoke control areas have been
„authorised“ in Regulations and that appliances
used to burn solid fuel in those areas (other than
„authorised“ fuels) have been exempted by an
Order made and signed by the Secretary of State or
Minister in the devolved administrations.
The boiler is suitable for use in smoke control areas
when burning wood chips G20 to G50 - W 35
maximum (according to ÖNORM M 7133) P16 to
P45 - M 35 maximum (EN 14961-4) and with an
optionally available flue gas recirculation, wood
pellets according to ÖNORM M 7135, DIN 51731, EN
14961-2 class A1, EN plus class A1 or DINplus.
Further information on the requirements of the
Clean Air Act can be found here:
http://smokecontrol.defra.gov.uk
Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision of smoke control areas and
you can contact them for details of Clean Air Act
requirements.
www.eta.co.at
User Manual Hack 20-200 kW
2012-02
43
Adjusting the date and time
User interface
Getting to know the control system
Instead of buttons, the touchscreen is operated
using icons directly on the screen.
In order to familiarise yourself with how to operate
icon on the left of
the system, tap once on the
the screen.
Adjusting the date and time
Tap on the date or time at the bottom right-hand
corner of the touchscreen.
The touchscreen only displays those function blocks
that are required and configured to work with your
heating system.
You can use the horizontal buttons
,
... to flick between the
individual function blocks (FUBs).
,
,
These instructions
Description
of functioncontain
blocksdescriptions of all the
function blocks of the ETAtouch software.
This document only describes the boiler, heating
circuit and special conveyor function blocks.
The other function blocks are described in the
accompanying document "ETAtouch function
blocks - operation".
A screen appears for adjusting the date and time:
Moving on the touchscreen
The vertical buttons are used to open the different views for the
selected function block (FUB):
Use the horizontal buttons to select the individual
function blocks (FUBs) of the heating system.
44
Overview of the selected
function block.
Text menu for adjusting the
parameters of the selected
function block
Tap on the [Day], [Month], [Year] or [Time] fields to
alter the settings.
Once a field has been filled in by entering
numbers, the cursor automatically moves to the
next field.
I/O list allowing experts to
assign inputs and outputs
deletes the number to the left of the cursor.
Error messages
for the selected function
block
Toolbox
closes the screen without saving the
changes.
saves changes and closes the screen.
for experts
INFO
Help
Subject to change due to technical improvements
www.eta.co.at
User interface
Setting the language
Changing the language
It is possible to change the language on the screen.
Switching to the toolbox
Press the
button to switch to the toolbox.
Selecting a language
Select the language you require and
confirm by pressing the
button.
Tapping the button with the flag symbols
Tap the button with the flag symbols to go to the
language selection screen.
Back to overview
Press
User Manual Hack 20-200 kW
to return to the boiler overview screen.
2012-02
45
Changing the names of the function blocks
Changing the names of the
function blocks
User interface
Changing the name using the keyboard
The names of the function blocks can be changed
at any time in order to make them clearer to you.
For example, the names of the heating circuits HC,
HC2 etc. can be changed to ground floor, upper
floor, parents, living room or similar.
cancel
Example: Renaming HC1 "Ground floor"
Even though this example uses a long name, it is
best to choose short names so that you can reach
all the function blocks without having to use the
arrow buttons.
Selecting heating circuit 1
Double-tap
to rename this function block.
save
Use the keyboard to enter the new name for
heating circuit 1, in this example: FLOOR.
Then press the
name.
button to save the new
The
button cancels the renaming process
and changes back to the previous name.
2x
HC has now been renamed "FLOOR".
The names of all the function blocks can be
changed at any time.
A small screen appears for this function block.
Tap the [Change Name] button. An on-screen
keyboard appears.
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User interface
Message
This icon in the function block buttons indicates a
message. Messages do not interrupt operation of the
boiler, nor must they be confirmed.
For example, they may indicate that the ash box
needs emptying or inform the user of events outside
normal operation, e.g. in summer, the pump antiblocking protection begins every Saturday at 12 pm.
Alarm, error, warning, message
Displaying an error
Press the
button to go to the list of errors for
the current function block.
If an alarm or warning occurs in any function
block, this button changes the icon to
(Alarm)
(Warning).
or
Warning
This icon indicates a warning. Warnings are issued
when a function that is not essential to active
operation fails. A warning can be confirmed before
the error is resolved. However, it will continue to be
shown until the cause of the error has actually been
dealt with.
Error, Alarm
This icon indicates an alarm. Alarms are issued for
errors that halt operation. Some alarms can be
confirmed before the error is resolved. However, they
will continue to be shown until the cause of the error
has actually been dealt with.
Some alarms cannot be confirmed until the error has
been successfully resolved. The display windows for
such alarms can be removed using the [Confirm later]
button.
By selecting a line, you can view a help text at
the bottom of the screen.
Confirming an error
Select the line and double-tap or press the
button. A confirmation window appears.
Press "OK" to confirm the message and delete it
from the list. Press [Cancel] to close the window
without confirming the error.
2x
or
Confirming all errors
Double-tap on a function block to bring up a
menu where you can confirm all errors by tapping
[Confirm errors].
!!! Restart after an alarm !!!
Once the error has been resolved and the alarm has
been confirmed, the boiler or the affected heating
circuit must be switched back on using the on/off
button
.
Once they are switched on, the
button lights up
green.
User Manual Hack 20-200 kW
2x
2012-02
47
Opening the text menu
User interface
Example: Displaying the boiler counters
Function block text menus
There is a "text menu" for each function block. This
view shows the current parameter settings. It also
allows the user to make changes.
Tap the
button to open the "Boiler" function
block.
From the overview screen, press the
button to
go to the text menu.
Opening the text menu
Select the desired function block, e.g. by tapping
. Next, change the view to "text menu" by
button.
pressing the
The text menu for the selected function block
appears. The individual parameters for the selected
function block are displayed.
Lines preceded by Z have a submenu, which can
be opened by tapping the line. The submenu can
be closed again by tapping the upper-level line
that is marked with V.
Modifying parameters
It is possible to modify certain parameters in order
to adapt the heating to your needs. Tap these
field
parameters to select them. The
changes and the
button appears.
Change the parameters by double-tapping
on the line, or select the line and press the
button.
The boiler text menu appears.
Tap the [Counters] line. The submenu opens and
the boiler counters are displayed.
or
2x
Press the
button to return to the overview.
In case of doubt, consult an expert before
making any changes.
Only modify parameters if you know what their
function is. Read through the corresponding
section of the user manual before making changes.
If the explanation of the relevant function given
in the manual is not sufficient for your purposes,
confer with an expert.
48
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User Manual Hack 20-200 kW
2012-02
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Overview, buttons, functions
Boiler
"Boiler" overview
Tap
and
screen.
to open the "Boiler" overview
The overview screen shows you at a glance the
current operating state of the boiler and your
heating system.
You can switch the unit on and off, de-ash, and
measure emissions from this overview screen.
Current boiler flow temperature
Current boiler return temperature
Stoker screw in operation
The stoker screw and rotary valve are displayed
in green when they are turning in the discharge
direction.
Metering screw in operation
The metering screw is displayed in green when it is
turning in the discharge direction.
On/off button
This button is used to switch the boiler
on and off.
Green = On
Red = Off
Deash button
This button is used to begin the removal of ash
from the boiler.
Buffer storage tank
Displayed when the boiler is channelling heat into
the buffer storage tank.
Outdoor -12°C
Current outside temperature
The current outside temperature is measured by
the built-in outside temperature sensor.
Emission measurement
This button switches the boiler to full load
mode for a period of 30 minutes. The boiler
will then begin to run at full load. The heat will
be channelled into the hot water tank and the
heating circuits. After 30 minutes, the boiler
automatically returns to the original mode.
Heating Current operating mode
This line shows the current operating mode of the
boiler. Below is a list of the possible modes:
This button is also used to start the floor agitator
turning in order to fill the store.
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Boiler
Overview, buttons, functions
Switched off
The boiler is switched off.
The on/off button
is lit up red.
Failure
A malfunction has occurred, preventing the boiler
from heating. The cause can be found in the list of
error messages.
Warm Start
The boiler is attempting to start a new heating
cycle using only the embers remaining in the
combustion chamber. The electrical ignition is
not used.
Igniting
The fuel is ignited using the electrical ignition.
Failure during ash-removal
The ash screw has been switched off due to
excessive current consumption. This may be due
to the ash box being full or the ash screw being
blocked by foreign objects.
Empty the full ash box, then start a new deashing
sequence by pressing
or
. If the ash box
was not full or the malfunction recurs, the foreign
object blocking the ash screw must be found and
removed.
Heating
The boiler is in heating mode and is channelling
heat to the consumers.
Ember burnout - Error
Due to a malfunction, the current firing phase has
ended with a burnout.
Ember burnout
At the end of a firing phase, the fuel that is still
on the grate is burnt off. No more fuel is conveyed
into the boiler.
Ash box missing
The ash box is not connected. The position switch
for the ash box is not pressed.
Ready
Ember burnout - External Stop
Due to an external lock-out (Stop command), the
current firing phase has ended with a burnout.
Locked
Heating not possible, as the boiler has been locked
externally (Stop command).
Calibrating lambda probe
After burnout, the boiler is switched on and
standing by for a heating demand.
Ash removal
The grate tips up and the turbulators move to clean
the heat exchanger. The ash screws transport the
ash from the boiler to the ash box.
User Manual Hack 20-200 kW
The lambda probe is calibrated automatically.
Whilst in this mode, heating is not possible.
Emptying stoker
At the end of a firing phase, the fuel slot runs
empty in order to empty the stoker.
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Counters, changing fuel
Displaying counters
Press the
text menu.
and
buttons to go to the boiler
Tap the [Counters] line.
The submenu opens, displaying a list of the current
counters.
Boiler
What do you need to consider
when changing fuel type?
The control system displays a choice of fuels: wood
chips, wood pellets and Miscanthus (see also Terms
and Conditions of Warranty).
If the fuel is changed, the control system must
also be set to the new fuel type. Depending on
fuel type, different parameters are saved and
automatically adjusted for combustion and ash
removal.
It is also necessary to set the firebed level sensor
and the flue gas recirculation function.
See page 11 and page 12.
Flue gas recirculation
Press the
button to return to the overview.
Very dry fuels (e.g. pellets, joinery waste
material, Miscanthus) require the optional
flue gas recirculation. The "Flue gas
recirculation" parameter must be set to "Yes"
for the control system to be able to use such fuels
12).
(for more information, see page 24).
If the fuel type is set to "Wood pellets", the "Flue
gas recirculation" parameter is also automatically
set to "Yes".
Water content and density of fuel
Average water content and density values for each
fuel type are already stored in the system. If the
fuel is changed, these parameters are also changed
at the same time.
If you know the water content and density of the
fuel you are using, you must adjust these values
53).
(for more information, see page 23).
With the aid of the lambda probe this enables
optimum control of combustion right from the
start. Otherwise, it may take several days for the
control system to make the necessary adjustments
and reach optimum combustion control.
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Boiler
Changing fuel, water content and density
Changing fuel
Adjusting water content and density
Press the buttons
menu.
and
to go to the text
Tap the [Boiler] line and, in the submenu, tap
[Settings].
The display shows the current fuel type and the
settings for water content and density.
Double-tap on the [Fuel] line.
If you know the water content and density of the
new fuel type, you must adjust the corresponding
parameters in the text menu.
Tap the buttons
menu.
and
to go to the text
Tap the [Boiler] line and, in the submenu, tap
[Settings]. The display shows the current water
content and density settings.
Double-tap on the [Water content] line.
2x
2x
A fuel selection window appears.
A selection window appears.
Select the new fuel type and press
.
The water content and density are changed to the
average values stored for the selected fuel type.
Press
to return to the boiler overview.
Enter the water content of the new fuel and press
.
Follow the same procedure to adjust the density.
Press
User Manual Hack 20-200 kW
to return to the boiler overview.
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Adjusting idle time and duration of ash removal
Boiler
Deashing the boiler
When the heat exchanger is being cleaned, the
stroke mechanism of the turbulators is tensioned
against a spring and then released. The noise
generated by the beating of the turbulators and
the creaking of the ash screws can be transferred
into the house as structure-borne noise via the
floors and walls.
A settings screen opens:
The purpose of ash removal idletime
It is possible to select a time after which the boiler
should not be de-ashed. This prevents potential
noise pollution during the night. The duration of
this idletime can be altered using the "Duration
idletime" parameter.
The latest possible time should be chosen to
begin the idletime. Likewise, the duration of the
idletime should be as short as possible, otherwise
the combustion chamber may become excessively
soiled, thus reducing the efficiency of the boiler.
Enter the new time to start the idletime. After
this time, the boiler will not perform ash removal
for the length of time specified by the "Duration
idletime" parameter.
Press
to save.
The boiler text menu display appears again.
The factory setting for the start of idletime is 21:00.
Adjusting the ash removal idletime
Press the buttons
menu.
and
Press
to return to the boiler overview.
to go to the text
Tap the [Boiler] line and, in the submenu, tap the
[Ash removal] line.
Double-tap the [Start idletime] line.
2x
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Boiler
Adjusting idle time and duration of ash removal
Duration of ash removal idletime
Adjusting the duration of the idletime
From the start of the idletime (= "Start idletime"
parameter), boiler ash removal is locked. This
period of time is defined by the "Duration idletime"
parameter.
Make the duration of the idletime as short as
possible, otherwise the combustion chamber
may become excessively soiled, thus reducing the
efficiency of the boiler.
Press the buttons
menu.
and
to go to the text
Tap the [Boiler] line and, in the submenu, tap the
[Ash removal] line.
Double-tap on the [Duration idletime] line.
For this reason, the factory setting for the idletime
is zero.
2x
Do not set excessively long idletimes
The maximum idletime depends on the fuel
being used and the intervals between ash
removal operations. If the fuel type requires that
ash removal be performed at very short intervals, it
is only possible to set similarly short idletimes.
A settings screen opens:
Values for normal fuel:
Fuel
Maximum
Duration idletime
Wood
chips
Wood
pellets
Miscanthus
20 - 49 kW:
Not longer than:
8h
10 h
1.5 h
63 - 200 kW:
Not longer than:
6h
8h
1.2 h
Enter the idletime duration and press
.
The boiler text menu display appears again.
Press
User Manual Hack 20-200 kW
to return to the boiler overview.
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Overview, buttons, functions
Heating circuit
"Heating circuit" overview
Press
and
to open the "Heating circuit 1"
overview screen.
Each heating circuit has its own function block
(HC2, HC3...).
Slider
The slider is only shown if there is no room
temperature sensor installed. The slider can be
used to change the room temperature by approx.
+/- 5°C.
In the overview of the selected heating circuit,
the on/off button
can be used to switch the
heating circuit on and off.
The timer can be used to set 3 different time slots
for each day of the week. If there is a room sensor
installed, you can also adjust the desired room
temperature.
If not, a slider on the overview screen allows you
to adjust the room temperature.
"Day" and "Night" mode
During the time slots, the heating circuit is in
"Day" mode.
Outside the time slots, the heating circuit is in
"Night" mode.
Please bear in mind that this substitute function
cannot replace the precision of a room sensor.
Timer
The timer shows the set heating time slots for
the current day of the week. Tapping this timer
brings up a screen where it is possible to set 3 time
slots for each day of the week.
If a room sensor is installed, the desired room
temperature can be set for each time slot.
Likewise, the reduced room temperature (set-back
temperature) between the heating time slots can
also be adjusted.
Within a set time slot, the heating circuit will be in
"Day" mode. Outside of the time slots, it will be in
"Night" mode.
If the heating circuit is operated in "Auto"
mode (
button), this button changes
the icon depending on whether the heating
circuit is running at "Day"
or "Night"
temperature.
Current room temperature
(room sensor only)
Only displayed if a room sensor is installed
for this heating circuit. This displays the current
room temperature as measured by the room
sensor.
Heating circuit on/off
This button is used to switch the heating circuit on
and off.
The boiler has a separate on/off button.
Green = Heating circuit on
Current flow temperature
The current target flow temperature for the heating
circuit is only displayed if the heating circuit is
switched on and in operation.
Red = Heating circuit off
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Heating circuit
Overview, buttons, functions
Outdoor -13°C Current outside temperature
The current outside temperature is measured by
the built-in outside temperature sensor.
Constant "Day" mode
This button can be used to switch the heating
circuit to constant "Day" mode (button lights
up
).
If a room sensor is installed, the temperature will
be regulated to the highest room temperature
set for that day in the timer. If there is no room
sensor, the heating circuit runs using the heating
curve "Day".
"Auto" and "Night" modes can be ended by
pressing the
button.
Come
This function is only available in "Auto" mode.
Regardless of the current time slot, pressing the
button (when you come home) switches the
heating circuit to "Day" mode (button lights up
) until the next set time slot.
If the unit has a built-in room sensor, the heating
circuit is regulated to the set room temperature. If
there is no room sensor, the heating circuit runs
using the heating curve "Day".
When
“Come” is pressed
during a heating
Das Drücken
von „Kommen“
in
break, heating continues until the end of
einer
Heiz-Pause
heizt
bis
zu
Ende
the following heating time slot.
des folgenden Heiz-Zeitfensters.
0
3
6
9
12
15
18
21
24
When
“Come” is von
pressed
during a heating
time
Das Drücken
„Kommen“
während
slot, heating continues on through the following
eines
Heiz-Zeitfensters
überspringt
die
reduced heating phase.
folgende Absenkphase (heizt durch).
Constant "Night" mode
This switches the heating circuit to constant
"Night" mode so that it runs at the set-back
temperature (button lights up
).
If there is a built-in room sensor, the temperature
is regulated to the set-back temperature that is
set in the timer. If the unit does not have a room
sensor, the heating circuit runs using the heating
curve "Night".
"Auto" and "Day" modes can be ended by pressing
the
button.
"Auto" mode
"Auto" mode automatically switches between
"Day" and "Night" mode.
Within a set time slot, the heating circuit will be in
"Day" mode. Outside of the time slots, it will be in
"Night" mode.
The "Auto" display changes the icon depending
on whether the heating circuit is currently in "Day"
or "Night" mode.
0
3
6
9
12
15
18
21
24
Go
This function is only available in "Auto" mode.
Regardless of the current time slot, pressing the
button (when you go out) switches the heating
circuit to "Night" mode (button lights up
) until
the next set time slot.
If the unit has a built-in room sensor, the
heating circuit is regulated to the stored set-back
temperature. If there is no room sensor, the
heating circuit runs using the heating curve
"Night".
WhenDrücken
“Go” is pressed
during a heating
time slot,
Das
von „Gehen“
während
heatingHeiz-Zeitfenster
is reduced until the senkt
start of ab
the bis
next
eines
time slot.
zum
Beginn des nächsten Zeitfensters.
0
3
6
9
12
15
18
21
24
When “Go” is pressed during a
Das Drücken
von
in
heating
break, the
next„Gehen“
heating time
einer
Heiz-Pause überspringt
slot
is bypassed.
das nächste Heiz-Zeitfenster.
"Day" mode
"Night" mode
User Manual Hack 20-200 kW
0
3
6
9
12
15
18
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24
57
Operating modes
Heating circuit
On Night
Holiday mode
The "Holiday" button is used to set a period for
which the selected heating circuit will run in
"Night" mode.
Any adjustments made to the room temperature
also influence the "Day" temperature, and thus
the temperature for heating up at the end of the
holiday. As such, it is best not to adjust the room
sensor for holiday set-back.
If you wish to reduce the room temperature, you
can set an individual "set-back temperature" in the
timer. During "Holiday" mode, the lowest of all
the "set-back temperatures" in the timer is the
one that applies.
The heating circuit is outside of the timer's time
slots and in "Night" mode.
The flow temperature of the heating circuit is
regulated using the "Heating curve night".
If the unit has a built-in room sensor, the
temperature is regulated to the stored "set-back
temperature". The switch can be in either the
"Auto" or the "Night" position.
Holiday On
The heating circuit is switched on and in holiday
mode (= constant "Night" mode). It remains in this
state until the "End of holiday" date.
On Delay
The heating circuit is no longer demanding any
heat and is in delay mode. The boiler pump is still
running for a short time in order to channel the
heat out of the boiler.
On Freezing room
The heating circuit is in operation because the
current room temperature is below the freezing
protection temperature (10°C).
On Freezing flow
On Day
Current operating mode
This line shows the current operating mode of
the heating circuit. Below is a list of the possible
modes:
On Day
The heating circuit is within one of the timer's
time slots and in "Day" mode.
The flow temperature of the heating circuit is
regulated using the "Heating curve day".
If the unit has a built-in room sensor, the
temperature is regulated to the highest room
temperature set for the time slot. The switch can be
in either the "Auto" or the "Day" position.
58
Subject to change due to technical improvements
The heating circuit is in operation because the
current flow temperature is below the freezing
protection temperature (10°C).
On Heat dissipation
The heating circuit is in operation in order to cool
the boiler by dissipating excess heat. Also displayed
during emission measurement.
On Overtemperature
The heating circuit is in operation because
the boiler is running at overtemperature. The
heating circuit is running at the highest set flow
temperature in order to dissipate the heat from the
boiler (overheating protection).
www.eta.co.at
Heating circuit
On Screed
The heating circuit is in operation; the screed
drying program is being run.
Off Enable temp.
The heating circuit is still switched off because the
boiler is not yet able to supply sufficient heat. The
enable temperature for the heating circuit has not
yet been exceeded.
Off Target day
The heating circuit is switched off. The target flow
temperature calculated from the heating curve
"Day" is below the room temperature as measured
by the room sensor.
If the unit does not have a room sensor, the
calculated target flow temperature is below 18°C.
Off Target night
The heating circuit is switched off. The target
flow temperature calculated from the heating
curve "Night" is below the room temperature as
measured by the room sensor.
If the unit does not have a room sensor, the
calculated target flow temperature is below 18°C.
Off Target holiday
The heating circuit is within the set holiday time,
and thus switched off.
The target flow temperature calculated from
the heating curve "Night" is below the room
temperature as measured by the room sensor.
If the unit does not have a room sensor, the
calculated target flow temperature is below 18°C.
Operating modes
Off Hot water
The heating circuit is switched off because the hot
water is currently being heated.
Off Room night
The heating circuit is switched off and outside the
set time slots. The current room temperature is
higher than the stored set-back temperature by at
least the "RoomOffDiff" temperature.
Off Room holiday
The heating circuit is within the set holiday
time, and thus switched off. The current room
temperature is higher than the stored set-back
temperature by at least the "RoomOffDiff"
temperature.
Off Outside day
The heating circuit is switched off. The current
outside temperature is higher than the set
temperature for "Day Heating threshold".
Off Outside night
The heating circuit is switched off. The current
outside temperature is higher than the set
temperature for "Night Heating threshold".
Off Outside holiday
The heating circuit is within the set holiday
time, and thus switched off. The current outside
temperature is higher than the stored set-back
temperature.
Off Summer
Off Room day
The heating circuit is within a time slot, but
switched off. The current room temperature is
higher than the set "Room target" temperature by
at least the "RoomOffDiff" temperature.
The heating circuit is switched off. The only active
functions are the freezing protection and the boiler
pump's "anti-blocking protection", which runs at
midday every Saturday.
Off Sensor failure
The heating circuit is switched off due to a defect
in the flow temperature sensor.
User Manual Hack 20-200 kW
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Setting the heating time slots
Heating circuit
Setting the heating time slots
The heating circuit timer can be used to set 3
different time slots for the heating for each day of
the week.
If the unit has a room sensor, a target room
temperature can also be set for each time slot.
Likewise, the reduced room temperature (set-back
temperature) between the heating time slots can
also be adjusted for each day of the week.
Overview of current time slots
The current day of the week is selected
automatically. The set time slots for the current day
of the week are shown on the screen.
Days of the week
Room temperature only
Set-back temperature
between time slots
"Day" mode
During a set time slot, the heating circuit is in
"Day" mode.
If a room sensor is installed, this regulates the
heating circuit to the set target room temperature
for the time slot.
If there is no room sensor, the flow temperature
of the heating circuit is calculated using the
heating curve.
"Night" mode
Outside the time slots, the heating circuit is in
"Night" mode.
If a room sensor is installed, this regulates
the heating circuit to the stored "set-back
temperature" for the time slot.
If there is no room sensor, the flow temperature of
the heating circuit is calculated using the heating
curve.
3 adjustable time slots
for each day of the week
Target room temperature
room sensor only
Selecting a time slot
Tap the [Time slot 1] line. The time slot setting
screen opens.
The times for "Day" mode can now be altered.
If the unit has a built-in room sensor,
the target room temperature can also be set.
Adjusting the timer (with room sensor)
In the overview for the selected heating circuit, tap
the timer. The screen for setting the timer opens.
Room
sensor only
Press
to save the new settings. Use the
same method to adjust the other time slots.
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Heating circuit
Setting the heating time slots
Copying time slots to other days of the week
Once the time slots have been adjusted, they can
also be adopted for other days of the week.
In the time slot overview screen, tap the
button. A screen appears for selecting a
day of the week:
"Holiday" function
With this function, the
button can be used to
switch the heating circuit to constant "Night"
mode for an adjustable time period. This setting
only ever applies for the selected heating circuit.
The hot water supply from the hot water tank
or the fresh water module is not affected by the
"Holiday" function.
For "Holiday" mode, the heating circuit is regulated
to the lowest set-back temperature set in the timer.
If you wish to reduce the temperature for the
"Holiday" time period, you can set an individual
set-back temperature in the timer.
Adjusting the room sensor also affects the "Day"
temperature when heating up at the end of the
holiday. As such, it is best not to adjust the room
sensor for holiday set-back.
Tap to select the desired day of the week or [All]
and then press
. The time slots are
adopted for the selected days.
Setting a "Holiday" time period
In the "Heating circuit" overview screen, tap the
button. A screen opens:
The new time slots are displayed.
Finally, press
.
The heating circuit overview reappears.
Enter the time for the beginning of your holiday.
The
button can be used to switch between the
"Start" and "End" of the holiday.
Enter both times and press
.
The heating circuit overview reappears.
User Manual Hack 20-200 kW
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The heating curve
Heating circuit
Heating curve "Day"
The heating curve
The heating curve controls the flow temperature
for the "Day" and "Night" modes of the heating
circuit in question. During a set time slot, the
heating circuit is in "Day" mode. Outside the time
slots, the heating circuit is in "Night" mode.
During a set time slot, the heating circuit is in "Day"
mode. The heating curve for "Day" mode can be
adjusted using the parameters "Flow at -10°C" and
"Flow at +10°C". The control system uses these
parameters to plot a line: the heating curve "Day".
Each heating circuit has its own heating curve,
as underfloor heating requires different settings to
radiator heating.
The heating curve "Day" and the current outside
temperature are used to calculate the required flow
temperature for the heating circuit. Example:
at +3°C outside temperature => 44°C flow
at -5°C outside temperature => 54°C flow
The diagram shows a heating curve for radiator
heating. If the control settings have been adapted
to your system, lower heating curves may be
set for underfloor heating and higher heating
curves for radiator heating.
If the unit has a room sensor, the calculated
flow temperature is corrected. The actual flow
temperature may be higher or lower.
80
Maximum flow temperature
40 44°C Day
Nig
ht
30
29°C Night
10
Freezing protection
+3°C
20
Heating curve "Night"
Outside the set time slots, the heating circuit is in
"Night" mode.
Day heating limit
50
Day
Night heating limit
60
Transition period
set-point
(adjustable with SERVICE permission)
Winter set-point
Heating flow temperature (°C)
70
0
0 +5 +10 +15 +20
-20 -15 -10 -5
Outside temperature (°C)
Maximum flow temperature
This limit protects your heating system.
Underfloor heating is usually limited to 45°C, while
radiators with metal pipes can take temperatures
up to 85°C.
62
Subject to change due to technical improvements
The heating curve "Night" is set back from the
heating curve "Day" by the adjustable value "Setback". The heating curve "Night" and the current
outside temperature are used to calculate the
required flow temperature.
Factory settings for the heating circuit
With software versions 1.20.0 and higher,
the system configuration for the heating circuit
offers the user a choice between underfloor and
radiator heating.
This choice pre-sets some of the parameters in
the heating circuit. For information on these
parameters and their factory settings, see
page 64.
82.
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Heating circuit
"Day Heating threshold" and "Night Heating threshold"
The parameter "Day Heating threshold"
With the "Day Heating threshold" parameter, an
outside temperature is set which, when exceeded,
will result in the heating circuit being switched to
"Day" mode.
The factory setting for this parameter is 18°C.
The "Day Heating threshold" can be set
differently for each heating circuit.
Changing the parameter "Day Heating threshold"
Press
to open the text menu for the selected
heating circuit.
Tap the [Heating circuit] line to open the submenu.
Double-tap on the [Day Heating threshold] line
(or select the line and press the
button).
The parameter "Night Heating threshold"
If the heating circuit is in "Night" mode, an outside
temperature is set which, when exceeded, will
result in the heating circuit being switched off.
The factory setting for this value is 2°C. This applies
as the freezing protection limit for this heating
circuit. The "Night Heating threshold" can be set
differently for each heating circuit.
Changing the parameter "Night Heating
threshold"
Press
to open the text menu for the selected
heating circuit.
Tap the [Heating circuit] line to open the submenu.
Double-tap on the [Night Heating threshold] line
(or select the line and press the
button).
2x
2x
A settings screen opens:
A settings screen opens:
Enter the new heating threshold for "Day" mode.
Press
to save the new value.
Press
to open the "Heating circuit" overview.
Enter the new heating threshold for "Night" mode.
Press
to save the new value.
Press
User Manual Hack 20-200 kW
to open the "Heating circuit" overview.
2012-02
63
Adjusting the heating curve
Adjusting the heating curve
If the heating circuit is always too warm or too
cold, the flow temperature must be adjusted. This
can be done using two parameters:
"Flow at -10°C" and "Flow at +10°C".
No large jumps in temperature
Do not set any large jumps in temperature when
adjusting "Flow at +10°C" and "Flow at -10°C":
For underfloor heating, never more than 2°C
For radiators never more than 4°C
You may need to alter the flow temperatures
again after one or two days, but working in small
steps will help you to set the heating circuits more
precisely, thus saving energy.
During the transition period -> "Flow at +10°C"
If the heating circuit is always too warm or too cold
during the transition period (spring and autumn),
only the flow temperature for "Flow at +10°C" is
reduced or increased.
Heating circuit
Factory settings for the
heating circuit
With software versions 1.20.0 and higher,
the system configuration for the heating circuit
offers the user a choice between underfloor and
radiator heating.
This choice pre-sets some of the parameters in the
heating circuit. These parameters and their factory
settings can be seen in the table below:
Preset
Max flow
Flow at -10°C
Flow at +10°C
Set-back
Enable temperature
Room effect
If the heating circuit is always too cold or too warm
in winter, only the flow temperature
"Flow at -10°" is increased or reduced.
80
50
Nig
ht
30
20
10
0
0 +5 +10 +15 +20
-20 -15 -10 -5
Outside temperature (°C)
Do not change the flow temperature "Flow at
-10°C" during the transition period.
Subject to change due to technical improvements
60
50
40
30
Winter set-point
Da
y
Heating flow temperature (°C)
Heating flow temperature (°C)
60
Transition period
set-point
70
70
64
Radiator
65°C
55°C
35°C
15°C
40°C
4°C
In winter -> "Flow at -10°C"
80
40
Underfloor
45°C
33°C
25°C
3°C
25°C
1°C
Da
y
Nigh
t
20
10
0
0 +5 +10 +15 +20
-20 -15 -10 -5
Outside temperature (°C)
Do not change the flow temperature "Flow at
+10°C" in winter.
www.eta.co.at
Heating circuit
Adjusting the heating curve
Adjusting the heating curve for outside
temperatures above 0°C -> Changing
"Flow at +10°C"
Adjusting the heating curve for outside
temperatures below 0°C -> Changing
"Flow at -10°C"
If the heating circuit is always too cold or too warm
in the transition period, the flow temperature
"Flow at +10°C" is increased or reduced.
No large jumps in temperature
If the heating circuit is always too cold or too warm
in winter, the flow temperature "Flow at -10°C"
is increased or reduced.
No large jumps in temperature
For underfloor heating, never more than 2°C
For radiators, never more than 4°C
For underfloor heating, never more than 2°C
For radiators, never more than 4°C
Press
to open the text menu for the selected
heating circuit.
Press
to open the text menu for the selected
heating circuit.
Tap the [Heating circuit] line and, in the submenu,
tap the [Heating curve] line.
Double-tap on the [Flow at +10°C] line (or select
the line and press the
button).
Tap the [Heating circuit] line and, in the submenu,
tap the [Heating curve] line.
Double-tap on the [Flow at -10°C] line.
2x
2x
A settings screen opens:
A settings screen opens:
Enter the new flow temperature for this heating
to save the new value.
circuit. Press
Enter the new flow temperature for this heating
to save the new value.
circuit. Press
The text menu for the selected heating circuit is
displayed. Press
to open the "Heating circuit"
overview.
The text menu for the selected heating circuit is
displayed. Press
to open the "Heating circuit"
overview.
User Manual Hack 20-200 kW
2012-02
65
Setting the "enable temperature"
Heating circuit
Setting the parameter "enable temperature"
The heating circuit pump does not start until the
energy source (buffer or boiler) has exceeded the
"enable temperature". You can give a heating
circuit priority by setting the "enable temperature"
lower than that for all the other heating circuits in
the system.
Opening the heating circuit text menu
Press
to open the text menu for the selected
heating circuit.
Tap the line [Heating circuit] and, in the submenu,
double-tap the line [Enable temperature].
2x
A settings screen opens:
Enter the new enable temperature for this heating
circuit. Press
to save the new value.
The text menu for the selected heating circuit is
displayed. Press
to return to the heating circuit
overview.
66
Subject to change due to technical improvements
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Heating circuit
Adjusting the "Set-back"
The parameter "Set-back"
Changing the parameter "Set-back"
If the unit does not have a room sensor, the
parameter "Set-back" is used to adjust the night
mode. The control system subtracts the "Set-back"
parameter from the heating curve "Day" to get the
heating curve "Night".
Outside the time slots set in the timer, the heating
circuit is in "Night" mode, and runs using the
heating curve "Night".
Press
to open the text menu for the selected
heating circuit.
Tap the [Heating circuit] line and, in the submenu,
tap the [Heating curve] line.
Double-tap on the [Set-back] line.
The factory setting for this "Set-back" is 15°C.
2x
The "Set-back" can be adjusted for each
heating circuit. The following steps are the same
for all heating circuits.
A settings screen opens:
Do not use large set-backs
Do not overuse "set-back", as much higher air
temperatures will be required to ensure comfort
in the morning if the walls have cooled down too
much overnight. In addition to reducing comfort,
this also wastes the energy saved overnight.
Depending on the "Flow at -10°C" temperature
and the type of heating circuit used (radiator or
underfloor heating), the following guidelines apply
for the set-back:
Temperature
Radiator
60°C
Underfloor
Flow at -10°C
40°C
80°C
Set-back
5-8°C 10-15°C 15-22°C
30-40°C
3-5°C
Enter the new temperature difference for the "Setback". Subtracting the "Set-back" from the heating
curve "Day" gives you the heating curve "Night".
Press
to save the new value. The text
menu for the selected heating circuit is displayed
once more.
Press
User Manual Hack 20-200 kW
to return to the heating circuit overview.
2012-02
67
Overview, buttons, functions
Special conveyor
HACK "Special conveyor" – Overview
This FUB is only available on wood chip boilers
with the HE-C extension circuit board.
Light barrier red
Press
and
to open the "Special conveyor"
overview screen.
This screen is used to control the special fuel
conveyor variants for wood chip boilers. The
overview differs depending on the special variant:
There is sufficient fuel in the drop chute. The light
barrier has been interrupted and is displayed
in red, with fuel. The special conveyor screw is
switched off.
t Intermediate conveyor screw (also for silo
70.
conveying systems), see example on page 156.
Light barrier green
t Double agitator (2 agitators supplying
74.
one boiler), see example on page 162.
If the light barrier is displayed in green, there is no
fuel or insufficient fuel in the drop chute.
t Double discharge conveyor (one agitator
supplying 2 boilers), see example on page 77.
166.
If multiple special conveyor systems are installed,
each one is displayed in a separate FUB.
Example: Double agitator:(page 74):
Agitator 1 is displayed in the
FUB, and
agitator 2 is displayed in the
FUB.
Agitator on standby
The agitator and screw are displayed in grey when
not in operation or if the screw is turning against
the discharge direction, e.g. in order to remove a
blockage.
Optional light barrier
An optional light barrier is offered for ETA fuel
conveying systems to control the fuel conveyance
and the respective conveying system.
If the drop chute contains sufficient fuel, the light
barrier is interrupted, and the conveying system
stops to be continued at a later point. If a light
barrier is installed, it will be displayed in the
overview.
Operating state
Agitator conveying fuel
The agitator and screw are displayed in green
when the screw is turning in the discharge
direction.
Special conveyor screw
Ready
Current operating mode
This line shows the current operating mode of the
special conveyor. Below is a list of the possible
modes:
Ready
The special conveyor is not currently in operation.
There is no demand for fuel.
Full
There is sufficient fuel in the drop chute. The light
barrier has been interrupted.
Agitator
68
Optional light barrier
Subject to change due to technical improvements
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Special conveyor
Overview, buttons, functions
Conveying
Drop chute open
The agitator and screw of the special conveyor are
in operation. Fuel is being conveyed.
Error Self-check
The sensor on the drop chute has been triggered.
This may be due to a blockage.
Safety chain interrupted
A malfunction has occurred during the self-check.
Error conveyor
The special conveyor motor has caused a
malfunction.
The safety chain, e.g. water shortage, emergency
stop, safety temperature limited, ash box, rotary
valve maintenance cover... has been broken.
Heating is locked and cannot be resumed.
Intermediate conveyor screw
Conveys fuel to the boiler
Conveying system room
Ma
int
ena
nce
300
min
.
Maintenance
Special conveyor
Continuously
pivotable
Maintenance
Conveys fuel to the
intermediate conveyor screw
Boiler room
Conveying system room
Boiler room
Pivotable
to 30°
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2012-02
69
Intermediate conveyor screw
Special conveyor
"Intermediate conveyor
screw" overview
The "Intermediate conveyor screw" overview
in the special conveyor FUB is only displayed if
several conveying systems one after another
carry the fuel to the boiler.
(See example on next page.)
These additional conveying systems are also known
as "Intermediate conveyor screws", and they
carry the fuel to a subsequent conveying system or
the wood chip boiler.
Each individual conveying system or intermediate
conveyor screw is displayed in a separate FUB,
e.g.:
,
,
...
Light barrier red
There is sufficient fuel in the drop chute. The light
barrier has been interrupted and is displayed in
red, with fuel. The intermediate conveyor screw is
always switched off.
Operating modes
The different operating modes are listed on the
previous page.
Light barrier green
Optional light barrier
In order to control the fuel conveying system, a
light barrier can also be installed in the drop chute
of the intermediate conveyor screw.
If the drop chute contains sufficient fuel, the light
barrier is interrupted, the intermediate conveyor
screw stops, and then next conveying system
begins to operate.
If a light barrier is installed, it will be displayed
in the overview.
Intermediate conveyor screw for
Special conveyor 2 FUB
If the light barrier is displayed in green, there is no
fuel or insufficient fuel in the drop chute.
Intermediate conveyor screw on standby
The intermediate conveyor screw is displayed
in grey when not in operation or if it is turning
against the discharge direction, e.g. in order to
remove a blockage.
Intermediate conveyor screw conveying fuel
The intermediate conveyor screw is displayed in
green when it is turning in the discharge direction.
Intermediate conveyor screw
receives fuel from
FUB,
e.g.: Agitator
70
Optional light barrier
Subject to change due to technical improvements
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Special conveyor
Intermediate conveyor screw
Conveying system with intermediate
conveyor screws
No light barriers installed?
In this example, there are light barriers installed on
the discharge connection to intermediate conveyor
screw 1 and in the drop chute to intermediate
conveyor screw 2.
The existing silo conveying system is displayed in the
Special conveyor 1
FUB. This carries the fuel to
intermediate conveyor screw 1.
From there, it is conveyed further to intermediate
conveyor screw 2
, and eventually reaches
the boiler.
If no light barriers have been installed, the fuel
conveying system is controlled using the
runtime scale factor (see page 158).
This factor reduces the demand placed on the
previous conveying system in order to prevent
blockages.
Intermediate conveyor screw 1
is the
consumer and producer of the fuel. As such, the
"Producer demand" option must be selected in the
FUB system configuration.
Intermediate conveyor screw 1
Existing silo conveying system
Light barrier in drop
chute to intermediate
conveyor screw 2
Light barrier
in discharge
connection
Conveys fuel to intermediate conveyor screw 1
Existing silo conveying system with
light barrier in discharge connection
to intermediate conveyor screw 1
Supplies fuel to intermediate conveyor screw 2
Intermediate conveyor screw 1
with light barrier in drop chute to
intermediate conveyor screw 2
Intermediate
conveyor screw 2
Intermediate conveyor screw 2 included in boiler FUB
Intermediate conveyor screw 2 is connected
to the boiler. As such, the control system is
included in the boiler FUB.
Intermediate conveyor screw 2 therefore
does not require a separate special
conveyor FUB.
User Manual Hack 20-200 kW
Wood chip
boiler
2012-02
71
Several intermediate conveyor screws
Multiple intermediate
conveyor screws
Special conveyor
Modes for multiple conveying systems
The two conveying systems Agitator 1
and
Agitator 2
take turns in conveying the fuel
.
to Intermediate conveyor screw 1
From there, it is conveyed further to Intermediate
conveyor screw 2 and to the boiler.
The following modes are only displayed if a
conveying system FUB controls two additional
conveying systems.
(See example opposite.)
Intermediate conveyor screw 2 is connected to
the boiler. This means that the control system is
already contained in the Boiler FUB, and this
intermediate conveyor screw does not require a
separate Special conveyor FUB.
Conveyor 1
The conveying system 1 FUB is currently conveying
the fuel to the intermediate conveyor screw or to
another conveyor.
Intermediate conveyor screw 1
is the
consumer and producer of the fuel. As such, the
"Producer demand" option must be selected in
FUB system configuration.
the
Switching between conveying systems
The two conveying systems take it in turns to
supply Intermediate conveyor screw 1 with fuel. In
order to ensure that the fuel deposit is emptied at a
steady rate, the system switches between the two
agitators automatically.
This switch can also be actuated manually, for
example if you only want one agitator to convey
the fuel. How to change switching is described on
page 164.
76.
The discharge time for each conveyor is set in the
Boiler FUB, and can be changed at any time. The
factory setting for the shifting time is 5 hours.
For more information, see page 164.
76.
Waiting Conveyor 1
Fuel conveying is being switched to the Conveyor 1
FUB. This FUB will continue the conveying.
Self-check 1
The self-check for the conveying system 1 motors is
currently being carried out.
Conveyor 2
The conveying system 2 FUB is currently conveying
the fuel to the intermediate conveyor screw or to
another conveyor.
Waiting Conveyor 2
Fuel conveying is being switched to the conveying
system 2 FUB. This FUB will continue the
conveying.
Self-check 2
The self-check for the conveying system 2 motors is
currently being carried out.
Error
There are errors in the conveying system FUBs. Fuel
conveying cannot continue.
72
Subject to change due to technical improvements
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Special conveyor
Several intermediate conveyor screws
Conveying system 2
Conveying system 1
Alternately conveys fuel to the
intermediate conveyor screw
.
Intermediate conveyor screw 1
Alternately conveys fuel to the
intermediate conveyor screw
.
Intermediate conveyor
screw 2 is included in
boiler FUB
Conveys the fuel further to Intermediate
conveyor screw 2 at the boiler.
Intermediate conveyor screw 2 included in boiler FUB
Intermediate conveyor screw 2 is
connected to the boiler, and its control
system is contained in the Boiler FUB.
Intermediate conveyor screw 2 therefore
does not require a separate special
conveyor FUB.
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2012-02
73
Double agitator
Special conveyor
Double agitator 2 agitators
on one boiler
Light barrier red
The two conveying systems Agitator 1
and
Agitator 2
take turns in conveying the fuel
to the intermediate conveyor screw on the boiler.
There is sufficient fuel in the drop chute. The light
barrier has been interrupted and is displayed
in red, with fuel. The special conveyor screw is
switched off.
This intermediate conveyor screw is connected
to the boiler, and the control system is thus
contained in the Boiler FUB.
As such, the intermediate conveyor screw does not
require a separate Special conveyor FUB.
Light barrier green
If the light barrier is displayed in green, there is no
fuel or insufficient fuel in the drop chute.
Automatic switching
The two conveying systems take it in turns to
supply the intermediate conveyor screw with fuel.
In order to ensure that the fuel deposit is emptied
at a steady rate, the system switches between the
two agitators automatically.
This switching process and the discharge times
of the conveyors can be changed (for more
information, see page 164).
76).
Agitator on standby
The agitator and screw are displayed in grey when
not in operation or if the screw is turning against
the discharge direction, e.g. in order to remove a
blockage.
Overview of the conveying system
Agitator 1
The overview of the conveying system Agitator 2
FUB.
is displayed in the
Agitator conveying fuel
The agitator and screw are displayed in green
when the screw is turning in the discharge
direction.
Conveying system Agitator 1
Operating state
Special conveyor
screw
Ready
Current operating mode
This line shows the current operating mode of the
respective conveying system. Below is a list of the
possible modes:
Ready
The conveying system is not currently in operation.
There is no demand for fuel.
Full
Agitator
74
Optional light barrier
Subject to change due to technical improvements
There is sufficient fuel in the drop chute. The light
barrier is interrupted.
www.eta.co.at
Special conveyor
Double agitator
Conveying
Drop chute open
The conveying system is in operation and is
conveying the fuel to the intermediate conveyor
screw.
The sensor on the drop chute has been triggered.
This may be due to a blockage.
Safety chain interrupted
Error Self-check
The safety chain, e.g. water shortage, emergency
stop, safety temperature limited, ash box, rotary
valve maintenance cover... has been broken.
Heating is locked and cannot be resumed.
A malfunction has occurred during the self-check.
Error conveyor
The conveying system motor has caused a
malfunction.
Intermediate conveyor screw included in boiler FUB
The intermediate conveyor screw is
connected to the boiler. The control
system is included in the boiler FUB.
Conveying system 1
Alternately conveys fuel to the intermediate
conveyor screw or the boiler.
User Manual Hack 20-200 kW
Conveying system 2
Alternately conveys fuel to the intermediate
conveyor screw or the boiler.
2012-02
75
Adjusting the switching process
Switching between conveying systems,
"Shifting time" parameter in the Boiler FUB
The discharge time for a conveyor can be set using
the "Shifting time" parameter in the Boiler FUB.
This sets the length of time for which a conveying
system is in operation and supplying fuel. Once
this "Shifting time" has expired (factory setting:
5 hours), the system switches to the second
conveying system to continue the process.
Changing the shifting time between conveying
systems
Press the buttons
text menu.
and
to go to the boiler
Tap the [Intermediate conveyor screw] line and, in
the submenu, select [Double agitator].
Double-tap the [Shifting time] line.
Special conveyor
Manually switching between conveying systems
When using the factory settings, the system
switches automatically between the conveying
systems once the "Shifting time" has expired.
However, this switch can also be actuated
manually, for example if you only ever want one
agitator to convey the fuel.
You can switch manually between the conveying
systems using the "Switching" parameter in the
Boiler FUB.
Manually changing conveying system
Press the buttons
text menu.
and
to go to the boiler
Tap the [Intermediate conveyor screw] line and, in
the submenu, select [Double agitator].
Double-tap the [Switching] line. A settings screen
opens:
2x
2x
A settings screen opens:
Select the desired conveying system and press
.
Enter the new time and press
76
to save.
Subject to change due to technical improvements
Only the selected conveying system will now
be used to convey the fuel.
To re-activate automatic switching, repeat the
above procedure and select "automatic".
www.eta.co.at
Special conveyor
Double screw agitator
Double discharge conveyor one
agitator supplies 2 boilers
Agitator on standby
If one agitator is supplying two boilers, the
separate drive is only used to drive the agitator
with the flat springs.
The conveyor screws are driven by the
corresponding control system in the boiler.
The agitator is put into operation as soon as one
of the boilers demands fuel. At the same time, this
boiler sets its discharge screw into operation in
order to convey the fuel to the boiler.
The agitator is displayed in grey when not in
operation.
Agitator in operation
Alternating boiler operation, boiler order
In order to ensure that both boilers are used
equally, in the factory settings, only one boiler
is in operation and the heating switches to the
other boiler every 50 operating hours.
If one boiler can no longer meet the demand
from the consumers, the second boiler is
automatically put into operation.
However, if only one boiler is ever in operation,
e.g. in summer, when heating demand is low, the
priority of the boilers must be changed using the
"Boiler Order" parameter (for more information,
see page 79).
168).
The "Boiler Order" defines a "Main boiler" which
is always in operation. The other boilers are then
only switched on when demand is high.
In the factory settings, all the boilers have the
same boiler order, so they automatically alternate
operation after every 50 operating hours.
Operating state
Agitator with own drive
The agitator is displayed in green when it is in
operation and conveying fuel.
Conveying
Current operating mode
This line shows the current operating mode of the
agitator. Below is a list of the possible modes:
Ready
The agitator is not in operation. There is no
demand for fuel.
Conveying
The agitator is in operation and is conveying fuel to
one of the boilers.
Error Self-check
A malfunction has occurred during the agitator
motor self-check.
Error conveyor
The agitator motor has caused a malfunction.
Safety chain interrupted
The safety chain, e.g. water shortage, emergency
stop, safety temperature limited, ash box, rotary
valve maintenance cover... has been broken.
Heating is locked and cannot be resumed.
User Manual Hack 20-200 kW
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77
Adjusting the switching process
Special conveyor
Boiler 1
Agitator
The agitator only conveys the fuel to the
two discharge screws.
Boiler 1 controls discharge screw 1
Boiler 1
Discharge screw 1
Separate drive
Only for the
conveying system
agitator
Discharge screw 2
Boiler 2
Boiler 2
Boiler 2 controls discharge screw 2
78
Subject to change due to technical improvements
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Special conveyor
Adjusting the boiler order
Adjusting the boiler order
The parameter "Boiler Order" is used to adjust the
priority of each boiler. This can be given a setting
from 1 (highest) to 4 (lowest).
The boiler with the highest priority (1) is defined
as the "Main boiler" and is always in operation.
Boilers with the priorities 2, 3 and 4 are
automatically put into operation in this order if
the "Main boiler" can no longer meet the demands
of the consumers.
If 2 boilers have the same priority, the will be
put into alternating operation, and the system
will switch between them after every 50 operating
hours. In the factory settings, every boiler has a
priority of 1.
Changing the boiler order
The access level "Service" is required to change
the "Boiler Order". For safety purposes, the boiler
order should be checked for all boilers.
Select the corresponding
to open the text menu.
FUB and press
Tap the [Boiler] line and, in the submenu, tap
[Settings].
Double-tap the [Boiler Order] line.
2x
A settings screen opens:
Change the boiler order (priority ) for this boiler
and press
to save.
User Manual Hack 20-200 kW
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79
Overview, buttons, functions
External ash removal
"Ash removal" overview
Press
and
to open the "External ash
removal" overview screen.
This FUB is only available on wood chip boilers
with the HE-C extension circuit board.
With external ash removal, an additional ash screw
is installed in place of the ash box. This conveys
the ash from the boiler to a separate waste bin.
External ash removal with one ash screw
Optional ash flap
Operating state
Ash screw
Optional "Ash flap"
The ash flap is located in the drop chute of the
external ash removal unit to prevent the leak air
from reaching the boiler via the ash screw. The ash
flap is always closed, and only opens when the
grate in the boiler tips up during ash removal.
Optional "External ash screw 2"
If a second ash screw (the optional "External ash
screw 2") is configured, this is also shown in the
overview.
External ash removal with 2 ash screws
Optional
External ash screw 2
80
Subject to change due to technical improvements
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Optional
ash flap
External ash removal
Overview, buttons, functions
On
Current operating mode
This line shows the current operating mode of the
ash screw. Below is a list of the possible modes:
Ash screw on standby
The ash screw is displayed in grey when not in
operation.
Self-check screw 1
Ash screw 1 is performing a self-check on the
drive.
Ash screw in operation
Self-check screw 2 (external ash screw 2 only)
The ash screw is displayed in green when it is
turning in the discharge direction.
Ash screw 2 is performing a self-check on the
drive.
Ready
The ash screw is not currently in operation. There is
no demand from the control system.
Ash screw 2 on standby
Ash screw 2 is displayed in grey when not in
operation.
On
The ash screw is conveying the ash to the waste
bin.
Ash screw 2 in operation
Ash screw 2 is displayed in green when it is turning
in the discharge direction.
Error
There is an error. There was an error either in the
ash screw self-check or in the power supply, or the
ash flap is not opening or closing.
Ash flap closed
Ash flap open
User Manual Hack 20-200 kW
2012-02
81
Requirements
Using remote control
With remote control, you can control your ETA
boiler over long distances via the Internet with a
PC, smartphone or tablet (pad), just as if your were
standing in front of the boiler's touch screen.
For example, if you are away from home for a long
time, you can verify that the heating is switched
off. You can also switch it back on before you
return.
Remote operation
Boiler with touch screen and
software version 1.18.0 or higher
In order to use the remote control function, your
boiler must be equipped with an ETAtouch control
system (touch screen). The software installed on the
boiler must be version 1.18.0 or higher. If this is
not the case, the software must be updated.
Internet connection
The ETA boiler's touch screen is connected to the
Internet. Once you have registered your touch
screen, you can log in to the ETA homepage
<www.meinETA.at> using your access details.
You can access this homepage via a PC with
an Internet connection or a smartphone or
tablet with Internet capabilities. You can view the
touch screen at <www.meinETA.at> and control
your boiler remotely.
Creating a partner network
The "Partner Network" function allows you to
assign access rights to other users via the homepage <www.meinETA.at>. This gives multiple
users access to your boiler touch screen.
Example:
An installer can access customer touch screen
controls via <www.meinETA.at>. In order to allow
this, the customers simply need to authorise the
installer's access (see page 20 onward).
In order to establish an Internet connection to
your boiler, the touch screen must be connected
to the Internet. To do this, the house must have a
broadband Internet connection. The connection
can be established via:
t a network cable from your modem to the touch
screen
or
t the ETA FreeLine wireless connection
Browser for remote control
You can connect your PC, smartphone or tablet to
the boiler via <www.meinETA.at>.
In order to do this, you must have a browser that
supports HTML 5, e.g.:
t Mozilla Firefox
t Apple Safari
t Google Chrome
t Microsoft Internet Explorer version 9 or higher
t some default Android browsers 2.2 or higher
Data transfers, downloading and flat rates
As soon as remote control has been activated,
the touch screen automatically connects to
the Internet. The current status of the Internet
connection is indicated by an icon at the bottom
of the screen.
The data is transmitted via the Internet, adding
to the amount of data you download via your
connection. In order to avoid excessive costs, we
recommend that you use a flat rate or a contract
with no data download limit for your Internet
connection.
82
Subject to change due to technical improvements
Internet connection via
smartphone or tablet
In order to use the remote control function from
your smartphone or tablet (pad), your device
must use either Android or iOS (Apple) as its
operating system. Your network operator's Internet
service must provide at least "EDGE"-level service
("3G" recommended).
www.eta.co.at
Remote operation
Remote control operating modes
In the boiler overview, the current remote control
mode is shown at the bottom of the screen. The
remote control system has 3 different operating
modes.
Changing the operating mode
Changing the operating mode of the remote
control system
In the "Boiler" overview, tap the remote control
icon at the bottom of the screen.
A different operating mode can be selected for each
touch screen.
Remote control must always be set to "Off" or
"Only View" before rectifying errors or performing
maintenance work.
"On"
Remote control is on and the unit is connected to
the Internet. The heating system can be controlled
remotely.
A selection window appears:
"Off"
Remote control is switched off. The remote control
can only be switched on again directly via the
touch screen of the boiler or the control system.
"Only View"
In "Only View" mode, the touch screen is displayed
via the homepage <www.meinETA.at>. The
boiler can be monitored, but it is not possible
to send commands via remote control.
Remote control must always be set to "Off"
or "Only View" before rectifying errors
or performing maintenance work. This
prevents others from switching the boiler on via
remote control while an error is being fixed or
maintenance is being carried out.
Tap the operating mode you require to select it.
Switch remote control back on
If remote control has been switched off, it can only
be switched on again via the touch screen of the
boiler or the control system.
To re-activate remote control, tap the
icon on the touch screen and select "On"
in the window that appears.
The
symbol appears while the
connection is being established.
User Manual Hack 20-200 kW
2012-02
83
Functions not available via remote operation
For safety reasons, some commands can only be
executed at the boiler itself
With remote control, you can control the boiler as
if you were standing right in front of it.
However, for safety reasons, some parameters
and functions are unavailable remotely. These
can only be executed when somebody is by the
boiler itself. This also prevents somebody else from
activating a drive remotely while an error is being
fixed or maintenance work is being carried out.
Remote operation
Modifying parameters
Do not modify parameters unless you know
what their function is. Read the corresponding
section of the operating instructions before making
any modifications. If the explanation of the
relevant function given in the instructions is not
sufficient for your purposes, contact a technician.
Switching remote control back on
Tap the remote control icon on the touch screen.
For example, none of the drives (stoker, ash screw
etc.) can be set to manual operation using remote
control.
Remote control must always be set to "Off"
or "Only View" before rectifying errors or
83).
performing maintenance work (see page 14).
Note on blocked parameters/functions
If a blocked command is selected while remote
control is active, a notice window will appear.
A window appears:
If no buttons are pressed, this notice window
automatically disappears after 4 seconds.
"Only View” mode is selected,
If the
using remote control, the ETA customer service
is able to monitor and provide assistance, for
example, but is unable to make changes.
"On"
is the only available option.
"Only View" mode can only be selected when
remote control is "On".
"Off" mode, remote control is
In
switched off. Remote display of the touch screen
is therefore not possible.
84
Subject to change due to technical improvements
www.eta.co.at
Remote operation
Opening the touchscreen
Logging on at <www.meinETA.at>
Open the homepage <www.meinETA.at> and
enter your login data. Press the [Login] button to
log in.
Safety notice
Before the touch screen is displayed, a safety notice
appears. This notice must be observed in order to
ensure safe operation of the heating system.
Confirm that you have read and understood the
safety notice by pressing [I understand]. The touch
screen will then appear. The display is the same as
the current display on the boiler.
Once you have logged in successfully, the user
menu will appear.
Tap the [ETAtouch devices] button.
Opening the touch screen
The [Currently connected ETAtouch devices]
window shows the currently available touch
screens.
You can now control the boiler remotely, exactly as
if you were standing in front of it.
For safety reasons, some functions and parameters
cannot be changed via remote control
(page
84).15).
(see page
Errors and warnings may NOT be rectified
via <www.meinETA.at>
Press the button
touch screen.
to view the corresponding
In the [Registered ETAtouch devices] window, you
can use the button
to change the data for
each registered touch screen.
Any errors or warnings that are displayed can
and may only be rectified on site, i.e. directly
via the boiler.
Rectifying an error using the remote control is not
permitted. This is because doing so could injure
anyone who is working on the boiler to rectify the
error.
In particular, you should avoid switching
the boiler on via remote control if an error
message is present.
User Manual Hack 20-200 kW
2012-02
85
Logging out
Remote operation
Example: Switching on the boiler
Press the On/Off button
boiler.
to switch on the
Logging out of remote control
Once you have finished using remote control, press
the [Logout] button on the homepage.
The display returns to the start page.
Closing the touch screen display
Press [Back] to close the touch screen display.
Logging out minimises the data flow from the
touch screen to the homepage, thus significantly
reducing the download volume. This is especially
important for reducing the download volume for
Internet connections without a flatrate tariff.
The touch screen remains connected to the
meinETA server via the Internet.
The menu display appears again.
Automatic logout
after 10 minutes of inactivity
If the remote control remains unused for longer
than 10 minutes, you will be logged out
automatically.
Press the
button to view the corresponding
touch screen.
86
Subject to change due to technical improvements
www.eta.co.at
Remote operation
Changing personal details
Personal login data
Once you have registered, you will be sent your
personal login data (username and password).
For the login at <www.meinETA.at>, it is only
possible to change the password.
Your username will always stay the same, even if
you change the e-mail address in your personal
details.
If you change your password for logging in at
<www.meinETA.at>, your new password will also
be the password required to register another touch
screen.
If a touch screen is added at a later date, the
current login data (username and current
password) are always required.
Changing your password or personal details
Log in to the homepage <www.meinETA.at> using
your current login data.
You can now change your password and core
details.
Press the [Change password] or [Change data]
button to save your changes.
If a touch screen is added at a later date, the
current login data (username and current
password) are always required.
In the user menu, tap [Edit my account]. The screen
will display your current details.
User Manual Hack 20-200 kW
2012-02
87
Moist fuel
Decay and mould
For water content up to approx. 25 %, the water is
bound up in the wood fibres. Above 25 %, water
can be found between the fibre cells in pores and
capillary vessels. This unbound water is a habitat for,
and also a basis for the reproduction of, microbes
and fungi which can penetrate into the tree through
wounds in the wood structure, especially cuts or
breaks. These microbes convert cellulose and lignin
into the basic building blocks carbon dioxide and
water. The wood rots, hollows out and becomes
brittle, ultimately losing all of its heating value.
When a tree is felled, the race between drying and
decay begins. With decreasing water content, the
living conditions for microbes worsen until they die
off when the water content drops below 25 %. The
faster the drying process, the more heating value
remains in the wood.
For thin branches, the microbes have a very large
contact surface in comparison with the wood
volume. No matter how neatly the branches are
stacked, losses in heating value over 25 % are the
rule (considerably more in wet weather). This is why
forestry businesses don't even take part in this race
with branches smaller than 3 to 5 cm; the material is
left behind as nutrient material for the forest.
Easy recognition of moist or dry wood
Even if professionals who work daily with wood
chips only trust the oven test for measurements of the
exact water content, there is still a very simple way to
distinguish moist from dry. Chips that feel dry in the
hand have a water content below 25 % and can be
stored without problems. If they feel wet, the water
content is sure to be above 35 %.
If the wood chips are dark brown, light and already
crumbly, then you are holding rotten wood in your
hands, wood that has already lost the majority of
its heating value. From such "compost" you can only
expect problems, but not boiler output.
Wood chips – from best to worst
"Dream" wood chips would be finely chopped (G30)
hardwood without bark and with low dust content and a
water content less than 20 %. With the highest heating value
and the lowest storage volume requirement, it would be the
optimum fuel for any boiler.
Fine wood chips (G30 or finer) can be made from dry wood
to reach a higher storage density.
Wood chips with water content under 30 % are fit for storage.
Wood chips from a sawmill with a water content of 40 %
and coarsely chopped are also not to be sneezed at if they are
burned after a short time or can be kept in a well-ventilated
store. Due to the hot, refractory-lined combustion chamber,
the attainable boiler output decreases only slightly.
Wood that has been kept dry and stored for a long time
(10 years) has lost 10 % of its heating value.
Wood chips from dry branches and shrubbery cuttings
have a higher bark content and usually also large amounts
of fine splinters, dirt and decayed material, resulting in more
ash. If it was chopped from dry wood, there will be no storage
problems and the reduction in boiler output is tolerable.
Forest-chopped wood chips from fresh branches are not
fit for storage and reduce the attainable boiler output
significantly.
Wood that has stored in damp conditions for a long time
(10 years) has lost 50 % of its heating value. Chips from such
wood reduce the attainable boiler output significantly.
The final product from wet wood is compost, which
can be disposed of in a refuse incinerator but can hardly be
burned in a normal boiler. Ensure well-ventilated storage.
The higher the water content of the wood, the coarser
it should be chopped. Never store more than a year's
supply of wood chips (round logs can be stored more easily
and densely).
Be very careful where wood chips from waste wood are
on offer at especially low prices; the fraction of decayed
material or also the amount of foreign material (nails,
wood preservatives, sand, stones) can be very high.
Store moist wood chips in an open hall
Wood chips can only be stored without ventilation
(for example in a concrete cellar) with a water
content of no more than 30 %.
During the decay process, moist wood chips release
heat that drives out water. Wet areas form on the
surface, and rising water vapour may also be visible.
If the wind is given the chance to transport the
water away, coarse wood chips will dry while decay
and fungi will stay within acceptable limits.
If moist wood chips from a sawmill are to be used
anyway, then no more than three weeks' supply
should ever be kept in an unventilated bunker. An
air inlet and an outlet fan can remove water vapour
and at least limit mould growth.
Best is a flying roof separate from living and working
quarters, which keeps rain out but lets the wind
work unhindered. At least one side of the storage
hall should be completely open. Additional openings
in all other walls improve the storage conditions.
Do not store moist wood chips without ventilation
88
Wood chips
Subject to change due to technical improvements
www.eta.co.at
Wood chips
Drying, harvesting, chopping
Coarse wood chips with minimal fine content dry
fastest
Artificial ventilation
In spite of a few elaborate pilot projects with solar
energy, drying with heated air blown into the store
via channels in its floor has not proven itself very
economical thus far. The energy costs for drying often
exceed the attainable increase in heating value.
Coarse chips (chopped with sharp blades!!!) dry faster
with less loss of material due to better air circulation.
Fill heights between 4 and 6 m have proven effective.
This height is also safe as regards self-ignition, which
only becomes a danger at heights of about 8 m.
Even when coarsely chopped, very moist and green
material (leaves and needles) and bark have high
fine content (typical and unavoidable features of
shrubbery cuttings and delimbing material) and
higher biological activity, and allow only minimal air
circulation. In spite of higher self-heating, the low air
circulation slows the drying process and material loss
is considerably higher.
Dry wood before chopping,
fell in winter and chop in summer
It is much easier to dry the wood before chopping it.
With interim storage before chopping in summer, a
water content below 30 % can be reached, ensuring
problem-free storage for the wood chips.
Whether to dry entire trees, or trunks and branches
separately, depends largely on the accessibility of the
forest and the harvesting methods. Here are a few
tips for orientation:
Dry like hay on a hard surface
For your own use, spread out moist wood chips in a
layer 10 cm thick on an asphalt or concrete surface
on hot summer days. Good results can also be had
on sunny autumn days if you turn the chips over
several times. Two days are usually enough to attain
a water content below 30 %, making the chips fit for
storage even under poor conditions.
Well-ventilated piles, trunks with bark removed,
or entire trees dry faster and better. Sun helps, and
wind is indispensable for drying.
Softwood should be felled no later than December
and stored at least 50 m from the forest due to the
danger of beetles.
Drying in a covered mesh enclosure
If the first regeneration felling is done for softwood
in September, the wood will no longer be infested
by beetles in the spring. It can be left in the forest
without delimbing and chopped as entire trees in
summer.
When building a new wood chip storage facility,
roofed storage containers with mesh walls should
be considered for air-drying of moist chips. A windy
location is important. Southward orientation can
help with drying even in winter. The height of the
container depends on the height of the front end
loader needed for filling. The lowest wall element
must be removable to allow removal of the wood
chips. The depth can be up to 2 m. Drying time is
4 to 8 months and a water content below 20 % is
attainable.
Leave green branches in the forest as nutrients
Leave green branches and treetops in the forest;
as fuel they are only "air and water". As valuable
nutrients, they should remain in the forest.
70%
Water content
Felling in winter and chipping in summer
felling
60%
Spruce
50%
40%
30%
Willo
w
Haze
l
Beech
Fit for storage with water content < 30%
chipping
20%
Dec
Jan
Feb
User Manual Hack 20-200 kW
Mär
Apr
May
Jun
Jul
Aug
Sep
Oct
2012-02
Nov
89
Judging the quality
Wood chips
General quality requirements for wood chips
Criterion
Comments
Dust content
Dust burns poorly and is often a sign of decayed or contaminated wood chips; thus ÖNORM M 7133
"Holzhackgut für energetische Zwecke" (wood chips for energy generation) limits the dust content to 4 %.
Individual thick pieces up to 12 cm long may be present in the fuel. They are cut by the blade in the rotary
valve. The majority of the chips should be no longer than 5 cm to ensure that there are no blockages in the
fuel conveying system.
Soil and sand cause slag formation on the grate and result in more effort spent on cleaning.
A layer of chips from green branches with leaves or needles can cause a blockage in a pile of chips on which
rising moisture condenses, resulting in decay and mould.
Large pieces
Dirt
Green leaves
and needles
Metal/stones
Even though the boiler cannot be brought to a stop by nails and small stones, such foreign materials should be
avoided in wood chips because they cause increased wear in the fuel conveying system.
Judging wood chip quality when buying in loose cubic metres
Criterion
Comments
Effect on heating value
Water content The lower the water content, the higher the heating value. In addition, under
25 % water content the wood shrinks so a cubic metre of W20 contains
W20 (<20 %)
approx. 3 % more wood than a cubic metre of W30.
W30
(20-30 %)
Per ÖNORM M 7133, water content is given in percent of total weight (see
W35
(30-35
%)
"Determination of water content" on page 93).
W40 (35-40 %)
Wood chips can be stored without problems up to a water content of
W50 (40-50 %)
Storage
30 %. Above 35 % they begin to mould and decay over longer storage
periods, with loss of heating value.
+6 %
0%
-2.5 %
-4 %
-7 %
Chip size
The more finely the material is chopped, the more material fits in a cubic
(G20)
+10 %
metre. Per ÖNORM M 7133, the average length of the pieces in mm is given by
G30
0%
the size class (see "Standard size classes" on page 92).
G50
-16 %
Kind of wood Hardwood is denser and heavier and
Hornbeam, black locust +53 %
Pine, larch
+19 %
thus has a higher heat content
Beech
+44 %
Spruce, alder
0%
per cubic metre.
Oak, ash
+40 %
Fir, willow
-6 %
Birch, maple
+25 %
Poplar
-19 %
Bark content The lighter in colour the wood chips are, the lower their bark content. Wood
No bark
+5 %
chips from small branches or wood chips with bark from sawmills have a high
10 % bark
0%
bark content with high ash content and usually also higher dirt content.
30 % bark
-10 %
That results in more effort spent on cleaning.
From small branches app. -25 %
Small branches Wood chips from small branches usually have a high degree of decay.
Judging wood chip quality when buying by the kilogram
Criterion
Comments
Effect on heating value
Water content The lower the water content, the higher the heating value.
Per ÖNORM M 7133, water content is given in percent of total weight (see
"Determination of water content" on page 93).
Wood chips can be stored without problems up to a water content of
Storage
30 %. Above 35 % they begin to mould and decay over longer storage
periods, with loss of heating value.
Chip size
The chip size has no effect on the heating value per kilogram.
Kind of wood Heavy hardwood, when dried, has about 5 % less heating value than
softwood, and about 6 % less when moist; light hardwood has about 6 %
less when dried and 7 % less when moist.
Bark content The bark content has little influence on the heating value per kilogram, but high
bark content means higher ash content and more effort spent on cleaning.
Small branches Wood chips from small branches usually have a high degree of decay.
90
Subject to change due to technical improvements
W20 (<20 %)
W30 (20-30 %)
W35 (30-35 %)
W40 (35-40 %)
W50 (40-50 %)
+12 %
0%
-12 %
-20 %
-32 %
Softwood
Hardwood
0%
-5 to -7 %
From small branches app. -25 %
www.eta.co.at
Wood chips
Other fuels, heating value
Other fuels
Pellets
Pellets have a higher fuel density and can only be burned with a flue gas recirculator (available as an
accessory). Pellets are always sold by weight. The heating value of hardwood pellets (4.60 kWh/kg) is about
6 % less than that of softwood pellets (4.9 kWh/kg).
Miscanthus
The heating value is the same as for air-dried softwood; best bought by weight. Since its ash has a very
low sintering point, a flue gas recirculator (available as an accessory) is required to prevent slag formation.
To reduce boiler corrosion, ensure that chlorine-free fertiliser (potassium sulphate instead of potassium
chloride) is used. Regardless of whether it is chopped or made into pellets, miscanthus needs a very large
combustion chamber, so for size 35/50 a maximum of 35 kW heating output, for size 70/90 a maximum of
63 kW, for size 130 a maximum of 95 kW and for size 200 a maximum of 140 kW can be reached.
Old wood
Wood kept in dry storage loses only the volatile components (about 10 % of the heating value).
Wood stored in moist storage decays (cold oxidation process) to the point of total loss of heating value.
Wood
shavings
The heating value per cubic metre varies widely and is around 30 to 60 % less than that of G30-W30 wood
chips from the same wood. Since wood shavings are usually air-dried (15 to 20 % water content), they are
best bought by weight. Wood chips from some kinds of hardwood cause rapid wear on the combustion
chamber's refractory lining. With wood shavings, the full rated output of the boiler cannot be reached.
Sawdust
The heating value per loose cubic metre is between 25 and 50 % less than that of G30-W30 wood chips
from the same wood. Sawdust is best bought by weight, after determination of its water content. The boiler
described here is not suitable for operation with pure sawdust. A drastic reduction of output and higher
effort for cleaning must be expected.
Chipboard
Technically, the boiler is suitable for burning chipboard waste with the optional flue gas recirculator if the
waste free of formaldehyde, wood preservatives and PVC coatings. However, this is only allowed with an
official permit, which is usually only granted on a case-by-case basis to wood-processing facilities.
Demolition
wood
Only wood that is free of halogens and wood preservatives may be burned. The fraction of rotten wood is
often high, and the heating value low, and it is often contaminated with dust, metal and stones.
based on
Weight
Cubic metres
Round logs 1 m
Loose cubic metres
G30 wood chips
Cut logs 1 m
Loose cubic metres
G50 wood chips
Water content
Heating value Heating value Heating value
Weight
Heating value
Weight
Heating value
w=15 % w=30 % w=15 % w=30 % w=15 % w=30 % w=15 % w=30 % w=15 % w=30 % w=15 % w=30 % w=15 % w=30 %
Unit
kWh/kg kWh/kg kg/stere kg/stere kWh/stere kWh/stere kg/lcm
Softwood
Fir
Spruce
Douglas fir
Pine
Larch
Hardwood
Poplar
Willow
Alder
Maple
Birch
Ash
Oak
Beech
Hornbeam
Black locust
0.65 m³ per stere 0.56 m³ per stere
4.40
4.49
4.43
4.32
4.27
3.51 1,270 1,170 1,100 1,010
3.58 1,380 1,260 1,190 1,090
3.53 1,480 1,360 1,280 1,170
3.44 1,630 1,490 1,400 1,290
3.39 1,660 1,520 1,430 1,310
3.99
3.76
4.06
4.04
4.01
4.10
4.10
4.13
4.06
4.11
3.16 1,020 930 870
2.97 1,200 1,100 1,020
3.23 1,270 1,160 1,080
3.21 1,550 1,420 1,310
3.18 1,570 1,430 1,330
3.25 1,760 1,610 1,490
3.25 1,760 1,610 1,490
3.28 1,800 1,640 1,520
3.23 1,920 1,760 1,630
3.27 1,920 1,760 1,630
0.59 m³ per stere 0.50 m³ per stere
790
930
990
1,200
1,210
1,360
1,360
1,390
1,490
1,490
kg/lcm kWh/lcm kWh/lcm kg/lcm
1 lcm contains 0.40 m³
178
189
206
232
239
205
218
237
267
275
780
850
910
1,000
1,020
720
780
840
920
930
1 lcm contains 0.40 m³
174
217
212
260
265
291
291
295
321
317
200
250
245
300
305
335
335
340
369
365
690
810
860
1,050
1,060
1,190
1,190
1,220
1,300
1,300
630
740
790
960
970
1,090
1,090
1,110
1,190
1,190
kg/lcm kWh/lcm kWh/lcm
1 stere contains 0.33 m³
148
157
172
193
199
171
181
198
223
229
650
710
760
830
850
600
650
700
770
780
1 stere contains 0.33 m³
145
181
177
217
221
242
242
246
267
264
167
208
204
250
254
279
279
283
308
304
580
680
720
880
890
990
990
1,020
1,090
1,090
530
620
660
800
810
910
910
930
990
990
Factors for converting solid cubic metres to loose cubic metres according to A. Höldrich, H. Hartmann, M. Schardt (2006): "Rationelle Scheitholzbereitstellungsverfahren" (Efficient Methods for Preparing
Firewood), Report 11 TFZ Straubing
User Manual Hack 20-200 kW
2012-02
91
Standard size classes, waste wood classes
Wood chips
G30 wood chips
per ÖNORM M 7133
- 60 to 100 % main content
- maximum 20 % fine content
- cross-section between 2.8 and 16 mm
- maximum length (nominal length) 30 mm - cross-section less than 2.8 mm
- of this, maximum 4 % dust content
- cross-section below 1 mm
- maximum 20 % coarse content
- maximum cross-section 3 cm²
- maximum length 85 mm
G50 wood chips
per ÖNORM M 7133
- 60 to 100 % main content
- cross-section between 5.6 and 31.5 mm
- maximum 20 % fine content
- maximum length (nominal length) 50 mm - cross-section less than 5.6 mm
- of this, maximum 4 % dust content
- cross-section below 1 mm
- maximum 20 % coarse content
- maximum cross-section 5 cm²
- maximum length 120 mm
Size classes per ÖNORM M 7133
G 30 G 50 G 100
fine medium coarse
Max. cross-section
cm²
3
5
10
Max. length
mm
85
120
250
Coarse screen
nominal mesh size
mm
16
31.5
63
Main content Medium screen
60 to 100 % nominal mesh size
mm
2.8
5.6
11.2
1
1
1
Coarse
content
20 % max.
Fine content
20 % max.
Fine screen nominal
mm
mesh size
Dust contained in fine content, 4 % max.
Size classes per EN 14961-1
Total mass100 %
P31,5
P45
P63
Max. cross-section
cm²
2
5
10
Max. length
mm
120
120
350
Coarse screen
nominal mesh size
mm
45
63
100
Main content Medium screen
at least 75 % nominal mesh size
mm
31.5
45
63
Fine screen nominal
mm
mesh size
3.15
3.15
3.15
Coarse
content
6 % max.
Fine content
8 % max.
92
Subject to change due to technical improvements
Waste wood classes A1 to A4 (Germany)
In the boilers described here, maximum possible is P45 or G50.
Total mass
100 %
A1
Untreated wood without foreign substances.
May be burned without restrictions.
When A1 waste wood is on offer, it may be rotten
wood with no heating value; only buy waste wood by
weight and with limited water content (20 or at most
30 %).
A2
laminated, painted, coated Waste wood
without halogens or wood preservatives.
May be burned in wood-processing facilities (in
Germany from 50 kW as fuel Kl.7 (class 7) according
to BImSchV, emission control regulations)
A3
Waste wood with organohalogen compounds
in the coating without wood preservatives.
May be burned in wood-processing facilities with
suitable and approved boilers.
A4
Waste wood treated with wood preservatives.
May only be incinerated in properly equipped
hazardous waste disposal plants.
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Wood chips
Water content
Using an oven for determination of water content
Price correction depending on water content
To trade wood chips by weight, corrections depending on
water content are needed.
Typically, agreement is reached on a base price for water
content of 20 or 30 %. For an individual delivery, the
kilogram price is corrected based on the measured water
content, with percentage reductions for higher water
content and percentage increases for lower
water content.
60 %
58 %
56 %
54 %
52 %
50 %
48 %
46 %
44 %
42 %
40 %
38 %
36 %
34 %
32 %
30 %
28 %
26 %
24 %
22 %
20 %
18 %
16 %
14 %
12 %
10 %
8%
6%
4%
2%
0%
1.59
1.71
1.82
1.93
2.05
2.16
2.27
2.39
2.50
2.62
2.73
2.84
2.96
3.07
3.18
3.30
3.41
3.52
3.64
3.75
3.86
3.98
4.09
4.21
4.32
4.43
4.55
4.66
4.77
4.89
5.00
User Manual Hack 20-200 kW
Increase/decrease for base
water content of 20 %
Heating value
in kWh/kg
1.71
1.82
1.94
2.06
2.18
2.30
2.42
2.54
2.66
2.78
2.90
3.02
3.14
3.25
3.37
3.49
3.61
3.73
3.85
3.97
4.09
4.21
4.33
4.45
4.57
4.68
4.80
4.92
5.04
5.16
5.28
Increase/decrease for base
water content of 30 %
Water content
in % of total mass
-51.2 % -58.3 %
-47.8 % -55.4 %
-44.4 % -52.5 %
-40.9 % -49.6 %
-37.5 % -46.6 %
-34.1 % -43.7 %
-30.7 % -40.8 %
-27.3 % -37.9 %
-23.9 % -35.0 %
-20.5 % -32.1 %
-17.1 % -29.1 %
-13.6 % -26.2 %
-10.2 % -23.3 %
-6.8 % -20.4 %
-3.4 % -17.5 %
0.0 % -14.6 %
3.4 % -11.7 %
6.8 % -8.7 %
10.2 % -5.8 %
13.6 % -2.9 %
17.1 % 0.0 %
20.5 % 2.9 %
23.9 % 5.8 %
27.3 % 8.7 %
30.7 % 11.7 %
34.1 % 14.6 %
37.5 % 17.5 %
40.9 % 20.4 %
44.4 % 23.3 %
47.8 % 26.2 %
51.2 % 29.1 %
Hardwood
Heating value
in kWh/kg
Increase/decrease for base
water content of 20 %
Increase/decrease for base
water content of 30 %
Softwood
-51.7 % -58.8 %
-48.2 % -55.8 %
-44.8 % -52.9 %
-41.3 % -50.0 %
-37.9 % -47.0 %
-34.5 % -44.1 %
-31.0 % -41.1 %
-27.6 % -38.2 %
-24.1 % -35.3 %
-20.7 % -32.3 %
-17.2 % -29.4 %
-13.8 % -26.4 %
-10.3 % -23.5 %
-6.9 % -20.6 %
-3.4 % -17.6 %
0.0 % -14.7 %
3.4 % -11.8 %
6.9 % -8.8 %
10.3 % -5.9 %
13.8 % -2.9 %
17.2 % 0.0 %
20.7 % 2.9 %
24.1 % 5.9 %
27.6 % 8.8 %
31.0 % 11.8 %
34.5 % 14.7 %
37.9 % 17.6 %
41.3 % 20.6 %
44.8 % 23.5 %
48.2 % 26.4 %
51.7 % 29.4 %
A kilogram of wood chips is spread out on a baking
sheet and dried in an oven for 6 to 12 hours at
101 to 104 °C. To be certain of a temperature over
100 °C in a typical electric oven in spite of the inexact
thermostat, you can set it to 110 °C, but no higher as
the wood will begin outgassing even at slightly higher
temperatures. Fine and very moist pieces will need
to be turned a few times. The difference in weight
between the moist test material and the dry material
corresponds to the water content.
Longer interim storage of samples can falsify their
water content.
Take samples after transport
A pile of wood chips has 10 to 30 % more water content
in the upper layers than in the middle. The material is
mixed by the loading and unloading process during
transport. By taking about a litre from 5 different places
at a depth of at least 20 cm (never from the surface) in
each load, you can get a good average with low error.
Taking the test quantity from the total sample
From several transports, you will get more than 1 kg of
test material. To get a smaller quantity, mix the material
by rebuilding the pile, always emptying the shovel over
the top of the pile so that the material is distributed over
its entire surface. Then flatten the pile and remove the
two opposing quarters from it. Repeat the mixing and
extracting until you have two batches of test material of
1 kg each, 1 kg for the buyer, who usually determines
the water content in the oven, and 1 kg for the seller
as a control sample. The volume for one kilogram is
around 3 litres for wet, heavy wood chips and as much
as 5 litres for very dry and light material.
Water content and moisture
Water content has become the established
measurement for wood that is used for generating
energy; in the lumber business, the wood's moisture is
usually given.
water in wood [kg]
Water content [ %] = ______________________ x 100
total mass of wood [kg]
Water content [ %] =
0.25 kg
____________
x 100 = 25 %
1.0 kg
water in wood [kg]
Moisture [ %] = _______________________ x 100
dry mass of wood [kg]
Moisture [ %] =
0.25 kg
____________
x 100 = 33.3 %
0.75 kg
Converting moisture to water content
moisture [ %]
Water content [ %] = _________________ x 100
100 % + moisture [ %]
2012-02
93
Service and maintenance records
Keep records for service, maintenance or repairs
We recommend that you keep records about all service and maintenance work, as well as malfunctions. These records
can be entered in the following pages.
Then you and our customer service will always have an overview of the work performed on the system.
Date
Performed by
94
Subject to change due to technical improvements
Service / maintenance / cleaning
Work performed / parts replaced
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Service and maintenance records
Date
Performed by
User Manual Hack 20-200 kW
Service / maintenance / cleaning
Work performed / parts replaced
2012-02
95
96
Subject to change due to technical improvements
www.eta.co.at
Hack_Bedienung_Touch_2012-02_EN, subject to technical alterations
Switch main power supply to
OFF for maintenance work!
Entering the fuel deposit
is prohibited!
Area unsafe for children!
Floor agiator must operate
during filling, see user manual!
AT T ENTI O N !
Safety instructions
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