eta PelletsCompact, Installation Manual

Page 1: ...2020 07 21 EN 0000000061 V 022 1513 93003 003 PelletsUnit 7 15 kW Installation ...

Page 2: ...ETA Heiztechnik Gewerbepark 1 A 4716 Hofkirchen an der Trattnach Tel 43 0 7734 22 88 0 Fax 43 0 7734 22 88 22 info eta co at www eta co at ...

Page 3: ...rmation 22 7 3 Water hardness 23 7 4 Corrosion 24 7 5 Bleeding 24 7 6 Pressure equalisation 25 7 7 Noise emission 26 8 Operation with external air supply 27 9 Buffer storage tank 29 9 1 General information 29 9 2 Hydraulic integration 30 10 Installation 33 10 1 Placement of the boiler 33 10 2 Removing panels 33 10 3 Connecting piping 35 10 4 Conversion for buffer operation 36 10 5 Cables 38 10 6 F...

Page 4: ...nformation 53 12 2 Requirements for pellet store 54 12 3 Calculating pellet supply and store size 55 12 4 Filling nozzles 56 12 5 No cables pipes in the pellet store 58 12 6 Tilted floor 59 12 7 Information about pellet hoses 61 12 8 Fire safety regulations 62 12 9 Ventilation 64 ...

Page 5: ...the LAN cable see 10 8 Network connection Extended warranty We grant an extended warranty if the product is com missioned by an authorised partner company or by our own customer service In this regard please note the warranty conditions applicable 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 certifi...

Page 6: ...ed to limit limescale build up in the boiler In order to protect the boiler from calcification the water hardness of the heating water must be taken into account Observe the indications outlined in ÖNORM H 5195 1 Details can be found in chapter 7 3 Water hardness pH value between 8 and 9 The pH value of water used to fill the heating system must be between 8 and 9 Use a sufficient number of shut o...

Page 7: ...ty if this work was approved in writing in advance by the customer service of ETA Heiztechnik GmbH No tampering with boiler safety devices Boiler safety devices such as those mentioned below must not be tampered with Temperature monitoring and control devices safety temperature limiters safety valves and thermal discharge valves 1 4 Dismantling disposal Dismantling Before dismantling Stop heating ...

Page 8: ...nd hot water tank R3 4 coupling 4 Optional heating circuit 2 return R3 4 coupling 5 Optional heating circuit 2 flow R3 4 coupling 6 Flow for hot water tank R3 4 coupling 7 Heating circuit 1 flow R3 4 coupling 8 Discharge fitted with 1 2 filling and drainage valve 9 Outlet for the safety valve flat sealing union nut R1 10 Air connection for external air operation DN80 ...

Page 9: ...e to pellet store m 20 Ash box volume litres 12 Flue gas mass flow rate at partial full load g s 1 9 4 4 1 9 6 4 2 8 8 4 CO2 content in dry flue gas at partial full load 10 14 10 14 5 12 14 Exhaust temperature at partial full load C 80 150 Required flue draught Pa 3 Pa a draught limiter is required above 15 Pa Carbon monoxide CO emissions at partial full load mg MJ 88 8 88 6 18 4 mg m 13 O2 134 13...

Page 10: ...ary solid fuel boiler and additional heater 0 Value for III 294 11 Pr 3 82 2 39 1 79 Value for IV 115 11 Pr 1 49 0 93 0 70 Condensing boiler yes no no yes no yes no yes Combination boiler for hot water and heating yes no no Combined heat and power yes no no Preferred fuel Pellets Maximum load kW 7 7 11 2 14 9 Partial load kW 2 3 2 3 4 4 Efficiency in terms of gross calorific value at maxi mum load...

Page 11: ...015 1189 Seasonal space heating emissions OGC mg m 10 O2 20 20 20 20 20 20 Seasonal space heating emissions CO mg m 10 O2 500 500 500 500 500 500 Seasonal space heating emissions NOx mg m 10 O2 200 200 200 200 200 200 PelletsUnit 7 15 kW Unit Model identification PU7 PU7 BW PU11 PU11 BW PU15 PU15 BW ...

Page 12: ...as minimum requirements for the heating water If stricter country specific regulations exist they are to be heeded VDI 2035 Prevention of damage due to corrosion and scaling in hot water heating systems with feed temperatures up to 120 C EN 12828 Heating systems in buildings planning for hot water heating systems A safety valve 3 bar and a safety temperature limiter 100 C are already installed in ...

Page 13: ...art 5 Heating boilers for solid fuels manually and automatically stoked nominal heat output of up to 500 kW Terminology requirements testing and marking EN ISO 12100 2011 Safety of machinery General principles for design risk assessment and risk reduction EN 60335 1 2012 Household and similar electrical appliances Safety Part 1 General requirements EN 60335 2 102 2016 Safety of household and simil...

Page 14: ...e must be no heating appliances in the vicinity of escape routes Boilers may not be installed in stairwells corridors or rooms through which escape routes lead to the outside Free minimum cross sections for the air intake openings The boiler requires air for combustion That is why free minimum cross sections are required in the boiler room for the air intake openings In Austria these are defined i...

Page 15: ... a result of amendments to building laws up to 10 tonnes of pellets may be stored in the boiler room in some states In Switzerland up to 10 m of wood can be stored in separate boiler rooms EI60 the clearance from the boiler must be 1 m For larger quantities a separate storeroom EI60 separated from the building is required here wood may be stored together with straw or hay ...

Page 16: ...ations do not prescribe a fire extinguisher we still recommend that you keep one in house Fig 6 1 Fire extinguisher Storage of ash The ash must be kept in non flammable containers with covers for cooling Never put hot ash into the waste bin Emergency stop switch for the boiler In Austria heating systems installed in boiler rooms must be equipped with an emergency stop switch The switch must be sit...

Page 17: ...ning pressure has already been installed on the boiler at the factory 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 Fig 6 3 Safety valve Normally an expansion tank that is too small or defective or blocked heating lines are the cause of the safety valve activation DANGER Safety ...

Page 18: ...used These values are listed in brackets Example PU 7 with a 9 m chimney height and DN100 flue pipe a chimney with 12 cm diameter is required Al ternatively a chimney with 10 cm diameter can be used No cross sectional taper is permitted such as a DN113 connection pipe in a chimney with a 10 cm diameter Diameter of the flue pipe from boiler to chimney Chimney height above the boiler room floor Requ...

Page 19: ...open windows Moreover it may be possible to hear the boiler s fan in the living quarters through the wood burning stove DANGER Do not connect fan assisted boilers and gas boilers to the same chimney Most gas fired boilers do not have a sealed air flap and if the fan assisted boiler is started when the chimney is cold the flue gas is pushed through the gas boiler into the boiler room This is not gr...

Page 20: ...himney with a minimum of directional changes The flue pipe to the chimney must be leakproof Use heat resistant silicone as a sealant for unsealed sleeve pipes Otherwise you can expect smoke to escape into the boiler room as the boiler heats up The flue pipe must always be laid so that it ascends towards the chimney Long horizontal flue pipes to the chimney must have a narrow cross section and abov...

Page 21: ...s flue duct connection or from a pipe bend must be at least twice the diameter of the flue duct No draught limiter and no deflagration damper with external air supply For operation with external air supply the chimney must be absolutely airtight with respect to the room No draught limiters or deflagration dampers often also called blowback flaps may be installed in the flue gas line Deflagration d...

Page 22: ...ipe is installed in a sufficiently fire resistant casing the German Association of Chimney Sweeps has found the following solution to the standards and regulations dilemma in the certification of suitability and safe use for heating systems it should be noted that after a soot fire the long term durability cannot be ensured and penetration of the chimney by moisture cannot be ruled out so that it ...

Page 23: ...ng water s pH value has not itself changed to more than 8 after a week of operation increase it by adding 10 g m of trisodium phosphate Na3PO4 or 25 g m of trisodium phosphate dodecahydrate Na3 PO4 12H2O Wait another 2 4 weeks before making further corrections The pH value must not exceed 9 No hybrid installations A disadvantage of salt regeneration ion exchange is the salt content with its high e...

Page 24: ... two typical points for releasing gas are the hot boiler and the highest point in the heating system flow Install a bleed valve at the upper end of the pipe from the boiler outlet already installed in PelletsUnit and PelletsCompact boilers and also at the highest point in the flow of the entire system Fig 7 5 correct positioning of the bleed valve The T piece of the bleed valve must be the same si...

Page 25: ...or systems If there is a buffer storage tank an additional expansion tank will be needed 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 insufficient air venting or high air intake is excluded from warranty guarantee and liabilit...

Page 26: ...ures are listed in the following Squeaking and creaking of the fuel conveyor screws Squeaking and creaking from the fuel conveyor screw depends on the fuel used which is why the volume can have a wide range Even if these noise sources are negligible in 90 of systems without measures to counteract structure borne noise transmission the limit value of 30 dBA for domestic technical systems can be exc...

Page 27: ...re can cause hot combustion gases to be sucked from the boiler into the air supply duct To prevent this we recommend a ventilation shaft in the chimney The boiler is connected to the air supply from the chimney with an 80 mm pipe resistant to 120 C Systems with an annular air supply LAS systems can also be used as long as they have an insulated inner pipe and a corresponding certification Heating ...

Page 28: ...r inlet damper diameter approx 300 mm is opened when the cooker hood or the central vacuum cleaner is switched on Only when the open position is reached is the fan for the cooker hood or the central vacuum cleaner activated via a position switch in the flap actuator Maximum length of air supply duct PelletsUnit Maximum length 7 15 kW 15 m duct 80 mm diameter and no more than 5 bends Each additiona...

Page 29: ... be chosen for increased convenience When is a buffer storage tank necessary A buffer has to be installed for the boiler under the following conditions if individual room temperature control is installed for more than two heating circuits especially in apartment buildings where the flats are individually controlled in low energy houses when a substantial portion of the boiler s operating time is s...

Page 30: ...derfloor heating system or from a fresh water module may be fed into the solar heated lower third of the buffer This results in lower solar panel working temperatures with significantly higher efficiencies and also significantly higher solar yield In all cases an oil or gas boiler should be connected at the top part of the buffer only Siphon loops downwards at all connections reduce heat losses in...

Page 31: ...ensor Sensor 3 8 Fresh water module return 9 Boiler low temperature circuit return With solar exchanger and fresh water module 1 Fresh water module flow 2 Temperature sensor Sensor 1 upper 3 Boiler heating circuits oil gas boiler flow 4 Temperature sensor Sensor 2 5 Oil gas boiler return 6 Temperature sensor Sensor 3 7 Solar flow 8 Boiler high temperature circuit return 9 Temperature sensor Sensor...

Page 32: ... Temperature sensor Sensor 1 upper 3 Boiler heating circuits oil gas boiler flow 4 Solar flow top 5 Temperature sensor Sensor 2 6 Oil gas boiler return 7 Temperature sensor Sensor 3 8 Solar flow lower 9 Boiler high temperature circuit return 10 Temperature sensor Sensor 4 11 Fresh water module return solar 12 Low temperature circuits return ...

Page 33: ...ng tubes Remove the rubber caps on the right side of the boiler and screw the shorter tubes into the boiler frame Screw both longer tubes into the left side Fig 10 1 Carrying tubes Transport the boiler into the boiler room The required clearances for installation and maintenance must be maintained see 2 Technical data 10 2 Removing panels Remove the cover on the top Remove the cover from the top o...

Page 34: ...and remove it Then the levelling feet are accessible from below Fig 10 5 Panel Use the four levelling feet on the bottom to level the boiler Fig 10 6 Levelling feet Remove the cover for the circuit boards Open the boiler door and remove the cover over the circuit boards Fig 10 7 Cover The boiler s circuit boards are located behind it Fig 10 8 Circuit boards ...

Page 35: ...ing on its shaft must face upwards Indicating that the bypass pipe is blocked Fig 10 9 Return riser mixing valve Connecting the piping for the safety valve outlet A safety valve is already installed on the boiler and its discharge pipe extends out of the boiler 3 4 coupling Fig 10 10 Boiler safety valve On site further piping is to be connected to this coupling for the discharge pipe of the safety...

Page 36: ...n of the boiler with a buffer Removing the actuator from the flow mixing valve Remove the actuator from the flow mixing valve Do this by removing the screw from the knob and then detaching the actuator Fig 10 12 Actuator on flow mixing valve Turning the flow mixing valve Turn the flow mixing valve s shaft until the flattening faces the middle horizontal connection This blocks the return pipe Fig 1...

Page 37: ...on by pressing the button and turning it towards the hand symbol with a screwdriver Then turn the actuator to the middle position Fig 10 16 Setting actuator to manual mode Fit the actuator to the return riser mixing valve and secure it with the screw in the knob Fig 10 17 Installing the actuator on the return riser mixing valve Finally turn the actuator to the automatic position Do this by pressin...

Page 38: ...angeover valve The actuator is no longer required You can disconnect its cable from the circuit board and leave it on the boiler 10 5 Cables Connecting the boiler to potential equalisation The boiler must be connected to the potential equaliza tion of the boiler room or the building Country specific regulations must be observed while doing this Fig 10 21 Connecting the potential equalisation The b...

Page 39: ...es must be fitted over both pellet hoses In wall ducts a fire protection sleeve must be mounted on each side with ceiling ducts only positioned on the ceiling side Fig 10 22 Fire protection sleeve Use the supplied concrete screws to fasten the fire protection sleeve These screws are screwed directly into the wall by pre drilling but without dowels In the event of a fire the internal material of th...

Page 40: ...o pellet hoses onto the connections and secure them with hose clamps 10 8 Network connection Connecting the network adapter for the boiler From factory a network cable is already connected to the control panel which extends out of the cable duct Fig 10 25 Network cable If the network cable is long enough connect the plug directly into the router or the ETA PowerLine If it is not long enough use a ...

Page 41: ...Installation Network connection 41 ...

Page 42: ...ectric shock There are live parts on the circuit boards If touched they can cause injury and property damage Before beginning any work isolate the system completely from all power sources ensure that it cannot be switched back on and verify that it is safely isolated from supply CAUTION Flexible stranded conductors If flexible stranded conductors are not used for the wiring the contacts in the plu...

Page 43: ...ctions Requirements 43 Fig 11 4 Speed controlled pump Fig 11 5 Special function pump with supply extension 230 V Fig 11 6 Special function changeover valve with three point controlling Fig 11 7 Special function burner ...

Page 44: ...44 www eta co at Overview of circuit boards Electrical connections 11 2 Overview of circuit boards Overview of boiler circuit boards ...

Page 45: ...Electrical connections Overview of circuit boards 45 ...

Page 46: ...the configuration Terminal Function Minimum cross sec tion Standard assignment S20 230 V supply 3 x 1 5 mm Mains power input S28 230 V input 3 x 1 mm Emergency stop switch S29 230 V output 3 x 1 mm Conveying system S37 Potential free output special function Malfunction message changeover valve so lar heating system S520 24 V input 3x 0 75 mm Switching unit reference point switch termi nal S10 S521...

Page 47: ...ating circuit operation return riser mixing valve for buffer operation S30 STB 230 V input Safety temperature limiter Safety temperature lim iter STB S30 ASCHENKÜBEL 230 V input Ash box switch S30 ROST 230 V input switch de ashing and grate S30 GLUTBETT 230 V input Firebed switch S31 230 V output Draught fan S32 230 V output De ashing and grate S33 230 V output Stoker screw S34 230 V output S35 23...

Page 48: ...48 www eta co at PE C4 circuit board Electrical connections X9 CAN Bus terminal resistor These terminals have already been pre wired at the factory Terminal Function Standard assignment ...

Page 49: ...Electrical connections PE C4 circuit board 49 ...

Page 50: ...xing valve S7 230 V output 3 x 1 mm heating circuit 1 heating circuit pump for buffer operation S8 230 V output 4 x 1 mm heating circuit 1 heating circuit mixing valve for buffer operation S9 230 V supply extension 3 x 1 mm to circuit board MK E terminal S15 S10 Potential free output special function Circulation pump burner S500 T5 Temperature input 2 x 0 5 mm Outside temperature sensor S500 T6 Te...

Page 51: ... 0 6 mm S511 RS 485 bus 2 x 0 6 mm Digital room sensor These terminals can be used depending on the configuration Terminal Function Minimum cross sec tion Standard assignment These terminals have already been pre wired at the factory Terminal Function Default assignment CAN Node CAN Bus node switch F1 Fuse T 500 mA 24 V supply S1 230 V supply from circuit board PE C terminal S26 S2 230 V output Bo...

Page 52: ...uring the assembly Removing protective film Remove protective film from all covers After longer periods of operation of the boiler the film can no longer be removed without damaging the paint X9 Terminal for plug in circuit board X24 CAN Bus supply 24 V for stand alone operation These terminals have already been pre wired at the factory Terminal Function Default assignment ...

Page 53: ...vents air circulation from the lower boiler to the pellet store Testing before initial fill up Before filling the pellet store test the functionality of the entire heating system and the pellet conveying system For this purpose deposit some pellets bagged product in the storage room near the discharge conveyor Only fill up the pellet store after this test has been completed successfully Burn back ...

Page 54: ...on brick 170 mm thick and plastered on both sides Post and beam walls with 120 mm beams clearance 625 mm with wooden panelling 15 20 mm thick on both sides Dry storage for pellets Pellets are very hygroscopic they absorb moisture from the environment On contact with water or moist walls they swell up and break apart becoming unusable The pellet store must stay dry throughout the year The normal hu...

Page 55: ...om Example Room width 2 m and height 2 4 m The table shows a usable cross section of 3 m The volume of pellets to be stored in the example above is 7 2 m 7 2 m 3 m 2 4 m minimum room length A conveying system with a length of 2 5 m is required Example room width 2 8 m and height 2 4 m The table yields a usable cross section of 3 73 m The volume of pellets to be stored in the example above is 7 2 m...

Page 56: ...the suction nozzle so that the pellet supplier recognises which nozzle the pellets are blown into Opposite the middle filling nozzle an impact protection mat is installed 500 mm from the wall to prevent damage to both pellets and the plasterwork on the wall The filling nozzles must be installed 200 mm below the ceiling to keep the pellets from scraping on the ceiling during injection Usable cross ...

Page 57: ...der the ceiling of the pellet store so that the pellets are not blown against the ceiling To install the filling nozzles in smooth holes or sewer pipe cut outs so they cannot twist the ETA filling nozzles are equipped with a flange that transfers the forces directly into the wall via 4 screws ETA filling nozzles with 100 mm diameter fit exactly in the cut outs made for fitting a sewer pipe with 11...

Page 58: ...0 m in length pose no problem Height differences of one floor or even two for short lines can also be overcome without problems Extension with aluminium piping only Only aluminium piping may be used for the filling system Do not use plastic piping danger due to electrostatic charge build up The filling system must be earthed against electro static charges The filling system must be smooth on the i...

Page 59: ...pplies for systems with conveyor screws as well as for suction heads Construction of tilted floor for storeroom For the slanted floor three ply concrete formwork panels 27 mm thick have proven effective Unplaned wooden boards 25 mm thick with a smooth plastic laminated surface can also be used The slanted floor should be flush with the enclosing walls so that no pellets can fall into the empty spa...

Page 60: ... thick and fasten it to the floor Fig 12 11 Suction probe on a wooden board Pad wall opening for conveyor screw trough Sound from the screw can be transmitted through the pellet store walls into the house To avoid that pad the wall opening for the troughs with soft material mineral wool Under no circumstances should the conveyor screw trough be cemented into a concrete wall without acoustic insula...

Page 61: ...g 12 14 Note bending radius Fig 12 15 Avoid twisting pellet hoses Fig 12 16 Use pipe guides or pipe supports Single piece suction hose The suction hose for the pellets must always consist of a single piece Suction hoses made from several parts have higher friction on the inner walls which can result in damage to the pellets Only the pellet hose for the back air may be made of multiple parts Straig...

Page 62: ...ulations in Austria Legally fire safety is regulated in the various building codes of the states though all state legislation is based on the TRVB H 118 Technische Richtlinien vorbeu gender Brandschutz automatische Holzfeuerungsan lagen technical directives for preventive fire safety for automated wood combustion systems For questions about details consult an expert or the building inspectorate or...

Page 63: ...doors and no usage restrictions are stipulated Pellet stores over 10 000 litres 6 5 tons Walls and ceilings REI90 F90 no lines through walls No other use Doors self closing and fire resistant EI30 T30 Pellet filling lines through other rooms EI90 F90 Rated heat output of boiler less than 50 kW boiler room No requirements for the room Not permitted installation in required stairwells in rooms betwe...

Page 64: ...ngth of the venti lation line Store size 10 tonnes Store size 10 tonnes 2 m Ventilation via sealing cover with the follow ing requirements Two ventilated sealing caps on two Storz A couplings Ventilation to the outside or in ventilated installation room of the heating system Ventilation via sealing cap only in stores up uo 40 t with the following requirements minimum 2 ventilated sealing caps on t...

Page 65: ...ilated sealing cover 2 Ventilation opening outside Even if the filling nozzles protrude into a room in which ventilation is available ÖNORM M 7137 recommends using only sealed unventilated sealing covers Fig 12 20 Filling nozzles in the boiler room 1 Ventilating the room 2 Sealed unventilated sealing cover 3 Ventilation opening outside If the pellets are stored in a bag that positioned in the same...

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