log boiler 20 - 60 kw service manual 2… · 2019-07-15 en 0000000301 v.007 3.47.0 110, 218, 121p,...

2019-07-15EN0000000301V.0073.47.0110, 218, 121P, 219P93317-002

Log boiler20 - 60 kW

Service manual

ETA Heiztechnik

Gewerbepark 1

A-4716 Hofkirchen an der Trattnach

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

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

[email protected]

www.eta.co.at

General information

1 General information

Support for cleaning and maintenance

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

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

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

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

Commissioning data

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

Copyright

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

Subject to technical changes

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

Explanation of symbols

Instructions and information

Layout of safety instructions

SIGNAL WORD!

Type and source of danger

Possible effects

• Measures for avoiding the danger

Types of safety instruction

CAUTION!

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

WARNING!

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

DANGER!

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

Commissioning data

Manufacturing number:

________________________________________

Commissioned on:

_________________________________________

Commissioned by (company):

_________________________________________

_________________________________________

_________________________________________

3

Maintenance notes Cleaning and maintenance

2 Cleaning and maintenance

2.1 Maintenance notes

Performing regular cleaning and maintenance

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

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

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

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

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

Operation only by trained personnel

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

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

Display maintenance steps on the screen

With this boiler, the maintenance steps can also bedisplayed on the ETAtouch control system screen. Therequired activities will be explained to you step-by-stepand supplemented with detailed graphics. Eachmaintenance is saved and the details can be viewed atany time. So you can maintain a long-term overview ofthe maintenance carried out. Of course, themaintenance can also be carried out using the serviceguide, without the support of the ETAtouch controlsystem.

To access maintenance, switch to settings in the boilerfunction block ( [Settings] button) and then selectthe function [Maintenance].

Fig. 2-1: Overview (example)

You can also access this overview by pressingthe maintenance switch. Also when the message

appears that maintenance of the boiler is required.

In the overview the different maintenance intervals arelisted in the upper area. This includes the maintenancealready carried out. With the button, informationabout the selected maintenance is displayed.Maintenance that you can carry out as an endcustomer is labelled with the symbol. All others arereserved for specialists and require authorisation.

Press the button to start the maintenance. Theindividual steps are displayed on the screen. You canswitch to the next or the previous screen respectivelywith the arrow keys on the left and right side of thescreen.

Fig. 2-2: Maintenance step (example)

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Cleaning and maintenance Maintenance notes

Follow the on-screen instructions and carry out allsteps carefully. Enter your name at the end ofmaintenance ( button) and save the maintenancewith the button.

Fig. 2-3: End of maintenance

To end maintenance prematurely, press the rightarrow key several times until you get to the end.

There you can end the maintenance with the button. Cancellation during a maintenance step is notpossible.

Explanation of the maintenance switch

The maintenance switch on the boiler is needed forperforming maintenance with the aid of the [Main-tenance] function in the ETAtouch control system. Thisdisplays the individual maintenance steps on the boilerscreen.

With this variant the heating mode is stopped, butthe boiler remains on at the mains switch. So that

all drives are disconnected, the safety chain of theboiler is disrupted with the maintenance switch. Thescreen will display a message when it is time to actuatethe maintenance switch.

Fig. 2-4: Maintenance switch

The maintenance switch is marked with the symbol and has two settings.

• "1" = regular operationThis is the standard position of the maintenanceswitch. The boiler can execute heating mode in thisposition.

• "0" = maintenance modeIn this position, all drives are disconnected toperform maintenance. The circuit boards,however, are still live.

Explanation of pictograms

Switch the boiler on/off with the mains switch.

Perform a visual check of the components.

Clean the components with a soft cloth, for example.

Remove deposits with a vacuum cleaner or an ash vacuum.

Remove deposits with the poker.

Remove deposits with the cleaning brush.

Replace the wear parts (e.g., seals) with new items.

Lubricate the components. The lubricant to use is listed in the respective step.

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

Tighten the components (e.g., screws or nuts) with a tool.

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

Handle the components carefully, since they break very easily.

Measure or check dimensions or clearances on the components.

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

5

Maintenance notes Cleaning and maintenance

Clean panels

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

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

lead to stress cracks and damage.

Technical illustrations

The technical illustrations in this documentation showan SH30 log boiler with the actuators for the air valveson the left side.

The illustrations are representative for all compatibleETA log boilers.

Wear a protective mask to avoid injuries to the airways.

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

Use adhesive to affix the seals, for example.

Only blow out the components with your mouth.

Affix a seal. The required cross-section and sealing material are given at each step.

Tighten the screws or nuts alternately and evenly.

Do not use compressed air to clean the components.

Do not use cleaning brushes to clean the components.

Do not use an ash vacuum or vacuum cleaner.

Do not lubricate the components.

No water or moisture in this area.

No leaks in the components, e.g. screw connection or maintenance cover.

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Cleaning and maintenance Maintenance notes

7

Maintenance openings in the boiler Cleaning and maintenance

2.2 Maintenance openings in the

boiler

Maintenance openings and components

The illustrations show a wood chip boiler with30 kW output and the actuators for the air valves

on the left side. The illustrations are representative forall compatible log boilers.

1 Door contact switch

2 Fuel chamber

3 Combustion chamber

4 Ash collection duct

5 Walls of ash collection duct

6 Cleaning lever for the turbulators in the heat ex-changer

7 Heat exchanger cover

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Cleaning and maintenance Maintenance openings in the boiler

1 Flue gas temperature sensor

2 Draught fan

3 Optional automatic heat exchanger cleaning

4 Actuator for primary air

5 Actuator for secondary air

6 Lambda probe

7 Turbulators in the heat exchanger

9

Maintenance table Cleaning and maintenance

2.3 Maintenance table

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

that you perform maintenance annually.

TasksRegular

ly

Cleaning

annually

Maintenance

at least every 3 years

to be performed by

Check the pressure of the heating system X X X Customer

De-ash boiler

• Actuate cleaning lever

• Remove ash from the boiler

• Check walls of ash collection duct

X X X Customer

Check the safety devices

• Visual check of the safety valves

• Visual check of the thermal relief valve

X XCustomer or

specialist

Clean fuel chamber

• Remove ash behind suspended panels

• Clean primary air openings

• Clean secondary air openings

X XCustomer or

specialist

Chimney

• Clean the flue tube

• Flush the chimney's condensate drain

X XCustomer or

specialist

Clean the draught fan X XCustomer or

specialist

Clean the heat exchanger

• Remove ash from the heat exchanger compartment

• Check the heat exchanger tubes

• Check the seal on heat exchanger cover

X XCustomer or

specialist

Check boiler doors X XCustomer or

specialist

Optional automatic ignition

• Clean the ignition tubesX X

Customer or specialist

Clean the lambda probe X Specialist

Clean the temperature sensor X Specialist

Check air valve X Specialist

Check the optional automatic heat exchanger cleaner X Specialist

Optional automatic ignition

• Dismantle the ignition and cleaning the ignition tubesX Specialist

Calibrate the lambda probe X Specialist

Reset the maintenance counter X Specialist

Perform heating test X Specialist

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Cleaning and maintenance Regular maintenance

2.4 Regular maintenance

2.4.1 Preparation

End heating mode, perform ember burnout

During the last heating mode, press the [Emberburnout] button in the boiler overview (the button isthen displayed in yellow ). Ember retention is thendeactivated and the boiler performs a complete emberburnout (duration approx. 1 hour). The majority of thecharcoal burns in the fuel chamber.

Only start the maintenance when the boiler hascooled down sufficiently.

2.4.2 Check pressure of the heating system

Checking the heating system's water pressure

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

Fig. 2-5: Pressure gauge

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

higher pressure, because water expands as thetemperature rises and the water pressure also rises inheating mode. The safety valve triggers at approx. 2.8bar.

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

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

2.4.3 De-ash boiler

Actuate cleaning lever

Close the insulation door and clean the heatexchanger by repeated movement (10 x) of thecleaning lever on the side.

Fig. 2-6: Cleaning lever

This step is omitted if the optional automatic heatexchanger cleaner is mounted on the boiler.

De-ash boiler

The ash in the fuel chamber is needed asinsulation for ember retention. Therefore, leave a

layer of ash approximately 3 cm thick in the fuelchamber. Only rake the excess ash in the primarycombustion chamber. Some pieces of charcoal willdrop into the primary combustion chamber during thisprocess; these are best left there. The charcoal willburn during the next combustion cycle and the ash willprotect the bottom of the combustion chamber againstpremature wear.

Fig. 2-7: Rake the excess ash and pieces of charcoal into the primary combustion chamber.

11

Regular maintenance Cleaning and maintenance

Check the openings for the primary air in thesuspension plates, and also the burn-through open-ings in the grate. These openings must be free; if not,clear them with the poker.

Fig. 2-8: Openings for primary air and burn-through openings

Pull most of the ash out of the primary combustionchamber into the ash box with the poker. Leave about1 cm of ash in the primary combustion chamber. Thisserves as insulation and protection.

Fig. 2-9: Removing ash from the combustion chamber

Pull the ash from the ash collection duct (under theprimary combustion chamber) into the ash box. Alsoclear the rear end of the ash collection duct, so there'sno ash in front of the lambda probe head.

Fig. 2-10: Removing ash from the ash collection duct

The draught fan runs during de-ashing. Pull the ashslowly and steadily out of the boiler so that not toomuch ash is stirred up and blown into the open airthrough the chimney.

If there are still embers in the ash, leave the ashin a closed, non-combustible container for at least

2 days. Only put the ash into the waste bin when youare sure that no more embers are present.

Do not push the ash box into the primarycombustion chamber. For the 40 - 60 kW boiler

this is possible, but the ash box is not designed for itand is destroyed by the high temperatures.

Checking the ash collection duct walls

Check the walls of the ash collection duct, they may bewhite to brown. If they are black with soot, either toomuch wood was burned at too low a heat consumption,the fire was not lit correctly at start-up or, in rare cases,the lambda probe gave incorrect measurement values.

Fig. 2-11: Checking the ash collection duct walls

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Cleaning and maintenance Cleaning (customer)

2.5 Cleaning (customer)

2.5.1 Preparation

Before this maintenance, perform all steps for thepreceding maintenance intervals

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

performed.




WARNING!

Switch off the electricity to the boiler via the mainsswitch

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

WARNING!

Burns caused by hot parts

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

Allow the boiler to cool down sufficientlybefore starting any activities.

2.5.2 Check safety devices

Check safety valves

Check all safety valves of the heating system bymeans of a visual inspection. The outlets of the safetyvalves must not drip.

Fig. 2-12: Safety valve

If the safety valve drips, open and rinse the safetyvalve with a 1/4 turn of the red cap (danger ofscalding). If the safety valve still cannot be sealedeffectively after being rinsed several times, it must becleaned or replaced by an installer (heating techni-cian).

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

safety valve. It is however very likely that the seal willbe damaged in the process and thus the outlet will drip.Therefore, only carry out the check on weekdays,never on weekends in the cold winter, because there isprobably no heating technician available if the seal isdefective.

13

Cleaning (customer) Cleaning and maintenance

Checking the thermal relief valve

Visually check the thermal relief valve. The outlet mustnot drip.

Fig. 2-13: Thermally actuated relief valve

If the relief valve drips, press the red button to rinse thevalve (danger of scalding). If the relief valve still cannotbe closed tightly after being rinsed several times, itmust be cleaned by an installer (heating technician) orreplaced.

Press the red button to manually check the reliefvalve. This rinses the relief valve. It is however

very likely that the seal will be damaged in the processand thus the outlet will drip. Therefore, only carry outthe check on weekdays, never on weekends in thecold winter, because there is probably no heatingtechnician available if the seal is defective.

2.5.3 Clean fuel chamber

Completely de-ash the boiler

Stoke all the ash and charcoal from the filling chamberthrough the burn-through openings into thecombustion chamber.

Fig. 2-14: Stoke the ash and pieces of charcoal into the combustion chamber

Pull all the ash and pieces of charcoal out of thecombustion chamber into the ash box with the poker.

Fig. 2-15: Removing ash from the combustion chamber

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Also pull the ash from the ash collection duct (underthe combustion chamber) with the poker into the ashbox.

Fig. 2-16: Removing ash from the ash collection duct

If there are still embers in the ash, leave the ashin a closed, non-combustible container for at least

2 days. Only put the ash into the waste bin when youare sure that no more embers are present.

Remove ash behind suspended panels

The suspended panels in the fuel chamber are hungfrom a bolt at the top. Lift the hanging plates slightly,detach them and remove them from of the fillingchamber.

Fig. 2-17: Suspended panels

After removing the front suspended panels, removethe guard plate between the filling chamber door andthe heating door so that it does not fall down later.

Fig. 2-18: Guard plate

Remove the ash deposits from the walls with the poker.You can leave the shiny soot on the walls. It is notnecessary to use chemical cleaning agents.

Fig. 2-19: Cleaning the walls

Cleaning the primary air openings

Clean the primary air opening with an ash vacuum.

Fig. 2-20: Primary air openings

15


Cleaning the secondary air openings

Take out both halves of the grate and remove the ashlying below.

Fig. 2-21: Grate

Remove the ash from both side openings for thesecondary air with an ash vacuum.

Fig. 2-22: Secondary air openings

Reinsert both grate halves. When inserting, makesure that the seal (above the secondary air

openings) is in the semicircular groove of the twogrates.

Fig. 2-23: Correct grate placement

Also ensure that the grate does not "wobble" and isfully inserted. Check the openings of the grates, theymust lie at the same height.

Fig. 2-24: Checking the grate position

Re-install the suspended panels and guard plate

Check the state of the suspended panels. If they aredistorted, knock them back into shape with a hammer.However, if holes (in addition to the existing holes) areburnt out of the suspended panels, they need to bereplaced.

Fig. 2-25: Suspended panel

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Re-attach the guard plate between the filling chamberdoor and ignition door.

Fig. 2-26: Guard plate

Re-attach the suspended panel to the bolts in the fillingchamber. First, mount the front suspended panel sothat the guard plate does not fall down.

Fig. 2-27: Suspended panels

2.5.4 Chimney

Clean flue tube

Sweep the flue duct from the flue outlet to the chimneyand remove the fly ash from the chimney with an ashvacuum cleaner.

Fig. 2-28: Flue duct

Only sweep the ash into the chimney and not intothe boiler. Otherwise, ash will collect in the

fan housing and can block the draught fan.

Rinse the chimney's condensate drain

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

Fig. 2-29: Condensate drain

17


2.5.5 Clean draught fan

Cleaning the draught fan

Unplug the draught fan's power supply. Loosen thewing screws and remove the draught fan.

Fig. 2-30: Draught fan

Remove the ash from the fan housing.

Fig. 2-31: Fan housing

Carefully clean the impeller with a soft brush (not awire brush) or compressed air to prevent imbalance.Replace the seal.

Fig. 2-32: Cleaning the impeller, replacing the seal

Lubricate the screws with heat-resistant lubricant andre-attach the draught fan to the boiler. Tighten the wingscrews alternately and evenly. The plug connectionmust point to the right when viewed from behind theboiler. Plug the power supply back into the draught fan.

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2.5.6 Cleaning the heat exchanger

Removing the heat exchanger cover

Remove the cover next to the flue gas connection.

Fig. 2-33: Cover

Remove the insulation over the heat exchanger cover.

Fig. 2-34: Insulation

Loosen the knurled nuts of the heat exchanger coverby turning anti-clockwise. Then turn the ball knob by180°.

Fig. 2-35: Knurled nut and ball knob

Remove the heat exchanger cover.

Fig. 2-36: Heat exchanger cover

19


Cleaning the heat exchanger box

Remove the ash from the heat exchanger box with anash vacuum.

Fig. 2-37: Heat exchanger box

Checking the heat exchanger tubes

Check the heat exchanger tubes and the turbulatorsfor "tar deposits" (shiny soot).

Fig. 2-38: Turbulators

The turbulators must be removed as soon as thecleaning lever (or the automatic heat exchanger

cleaner) becomes difficult to move.

If the turbulators and their supporting brackets have tardeposits, the cause is often:

• leaks around the boiler doors

• boiler overheating

• incorrect ignition

• unsuitable fuel

Checking the seal on heat exchanger cover

Check if the seal on the heat exchanger cover is intactand replace if necessary.


CAUTION!

Do not operate with damaged seals

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

Always replace damaged seals immediately.

Closing the heat exchanger cover

Re-attach the heat exchanger cover. Turn the ballknob up to the stop to suspend the heat exchangercover. Then tighten the knurled nut by turningclockwise.


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Replace the insulation on the heat exchanger cover.

Fig. 2-41: Insulation

Re-attach the cover.

Fig. 2-42: Cover

2.5.7 Check boiler doors

Checking the boiler door seals

Check the seals on the 3 boiler doors (filling chamberdoor, ignition door, combustion chamber door). To dothis, open the boiler doors and then close them again.When closing, make sure that the door can be closedfully and with force. The sealing edges of the doorframe must leave a clear indentation in the sealingcord of the boiler door.

Fig. 2-43: Check

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

Fig. 2-44: Seal between carbonization gas extraction duct and fuel chamber

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

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

Especially check the seal between the carboniza-tion gas extraction duct and the filling chamber.

21


To adjust, open the respective door, lift it out of thehinges and remove the door.

1 Closing roller holder

2 Hinge

Loosen the flange nuts (top and bottom) on the hingeand the closing roller holder, and evenly reduce thegap (only slightly) to the boiler with the setting screws(Phillips screws).

Fig. 2-45: Reduceing the gap

Retighten the flange nuts. Suspend the door andcheck whether it now closes fully. If not, repeat theprocess.

Fig. 2-46: Check

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

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2.5.8 Optional automatic ignition

Cleaning the ignition tubes

Clean the ignition tube by suction and carefully removeany deposits.

Fig. 2-47: Ignition tubes

2.5.9 Establish operational readiness

Switch on the boiler with the mains switch

Restore the power supply for the boiler and switch onthe boiler at the mains switch.

23

Maintenance (expert) Cleaning and maintenance

2.6 Maintenance (expert)

2.6.1 Preparation

Before this maintenance, perform all steps for thepreceding maintenance intervals

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

performed.

WARNING!

The following activities may only be performed byqualified specialist personnel.

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

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




WARNING!

Switch off the electricity to the boiler via the mainsswitch

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

WARNING!

Burns caused by hot parts

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

Allow the boiler to cool down sufficientlybefore starting any activities.

2.6.2 Clean lambda probe

Cleaning the lambda probe

Unscrew the retaining tube of the lambda sensor witha pipe wrench.

Fig. 2-48: Retaining tube

Remove the lambda probe and the sealing washer outof the boiler.

Fig. 2-49: Lambda probe and sealing washer

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Cleaning and maintenance Maintenance (expert)

Let the lambda probe cool down and clean it with anash vacuum. Particularly vacuum out the openings inthe head of the lambda probe.

Fig. 2-50: Head of lambda probe

Clean the sealing seat for the lambda sensor in theboiler. It must be absolutely clean. Check this with aflashlight and vacuum out the coupling with an ashvacuum.

Fig. 2-51: Vacuuming out the opening

Check the sealing washer to seal the flange of thelambda sensor and the seat in the boiler for damageand replace if necessary.

Fig. 2-52: Sealing washer

Screw the lambda probe with the retaining tube backinto the boiler.

Fig. 2-53: Installing the lambda probe

Retighten the retaining tube with a pipe wrench (with20 kg at 20 cm lever length).

Fig. 2-54: Tightening the retaining tube

Excessive wear on the combustion chamber isoften due to a leaky installation of the lambda

probe. Leak air penetrates the boiler and the controlsystem reduces the air intake too much and the tem-peratures in the combustion chamber reach impermis-sible levels.

25


2.6.3 Clean temperature sensor

Cleaning the flue gas temperature sensor

Loosen the screws and pull out the flue gastemperature sensor. Clean it with a soft cloth. Thenreplace the temperature sensor. Only hand-tighten thescrews so as not to damage the temperature sensor.

Fig. 2-55: Flue gas temperature sensor

2.6.4 Check air valve

Checking the air valve of the log boiler

Remove the rubber caps and check for dirt or depositson the air valves.

Fig. 2-56: Rubber caps

Actuate both actuators manually and check that theymove smoothly. For manual actuation, push theunlocking device (black button) and turn the drive 90°with a ring spanner.

Fig. 2-57: Actuators

Lubricate the air valves only with dry lubricant(e.g. PTFE spray) if they are difficult to move.

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2.6.5 Check the optional automatic heat exchanger cleaner

Checking the automatic heat exchanger cleaner

Remove the cover above the heat exchanger cleaner.

Fig. 2-58: Cover

Check the gap between the sensor and the connectingrod. The gap should be about 1 - 2 mm.

Fig. 2-59: Gap

Fig. 2-60: Connecting rod

CAUTION!

Do not lubricate the connecting rod

Never lubricate the bearing of theconnecting rod with oil, grease or otherlubricants. Dirt may stick to the lubricant,resulting in encrustation and stiffness.

Re-install the cover.

Fig. 2-61: Cover

27


2.6.6 Optional automatic ignition

Dismantling the ignition and cleaning the ignitiontubes

Loosen the screws and carefully remove the ignitions.Make sure that the included springs do not get lost.

Fig. 2-62: Springs

The ceramic igniter is very fragile. Make sure thatit is not damaged.

Fig. 2-63: Ceramic igniter

Check the ignition tubes for deposits and removethem, e.g. with a screwdriver.

Fig. 2-64: Cleaning the ignition tubes

Re-attach the ignitions with the screws and theretaining plate.

Only hand-tighten the screws, so that the ignitionis held by the springs. Do not overtighten the

screws, otherwise the ignition may be damaged.

Fig. 2-65: Only hand tighten the screws

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2.6.7 Calibrate lambda probe

Calibrating the lambda probe

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

it to control the combustion. To ensure reliability, thecontrol system autonomously performs an automaticcalibration after every 500 hours of operation. Thisalways occurs after an ember burnout and only at nightbetween the hours of 23:00 and 04:00. This calibrationcan also be initiated manually by opening the primaryand secondary air valves and purging the boiler withfresh air using the draught fan.

If you wish to perform a manual lambda probe calibra-tion, the control system provides the [Addl. calibration]function. This function can be selected with the[Service] access level and can be found under:

Switch on this function and the additional calibrationwill now start. If the boiler has not been started up forover 48 hours, this calibration takes only 30 minutes. Ifthe boiler was in operation until recently, the calibrationcan take up to 3 hours. If the boiler is started up duringcalibration, calibration will be aborted and restart9 days later.

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

tion.

2.6.8 Establish operational readiness

Reset maintenance counter

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

Perform heating test

To perform the heating test, put the log boiler intoemissions measurement mode. To do this, carry outthe following steps.

Place logs in the fuel chamber, ignite them, and wait15 minutes. In the log boiler overview, press the [Mea-surement] button to open the emissionsmeasurement settings window.

Fig. 2-66: Settings window for emission measurement

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

After around 10 minutes, a residual oxygen value of4.5% to 7% should be reached. The current residualoxygen content is displayed in the boiler's text menuunder:

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

The reason (leaky boiler doors, heat exchanger cover,lambda probe installation, etc.) must be identified andcorrected.

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

Inputs

Residual O2

Calibration

Addl. calibration

Counters

Full load hours since maint.

Reset counter?

Boiler

Residual O2

29


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

button in the settings window.

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log boiler 20 - 60 kw service manual 2… · 2019-07-15 en 0000000301 v.007 3.47.0 110, 218, 121p,...

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