Page 1
PE-K pellet boiler
35 to 90 kW
Installation
PE-K installation 35 to 90 kW
2012-02
2012-02-18 EN
Page 2
2
www.eta.co.at
Subject to change due to technical improvements
Conditions for warranty, guarantee, liability .... 4
Data and dimensions .................................. 6
Regulations, standards and guidelines ............ 7
Boiler room ............................................. 8
Electrical connection .................................. 9
Energy-saving pumps ................................. 9
Chimney ................................................. 10
Basics ................................................... 10
Dimensioning, requirements ........................ 11
Requirements, connecting pipe .................... 12
Deflagration damper ................................. 13
Water hardness and corrosion .....................14
Air venting, compensation, system separation . 15
Return riser and safety devices ....................16
Buffer ....................................................18
Hydraulic integration .................................20
Hydraulic integration of several buffers ........... 21
Parallel buffers with internal Tichelmann ........22
Parallel buffers with external Tichelmann ........ 23
Serial buffers ........................................... 24
Installation ............................................. 26
Minimum clearances for maintenance............. 26
Installing the stoker ..................................27
Attaching the pellet bin .............................. 28
Flue gas recirculation ................................. 29
Connecting cables ..................................... 32
Attach pellet hoses ...................................33
Attaching housing/panels ...........................34
Installing the ash box ................................35
Terminal diagram .....................................38
Remote control ........................................ 40
Requirements ..........................................40
Login data, network cable ..........................41
Network settings ...................................... 42
Registering the touchscreen ......................... 43
Contents
Meanings of symbols
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.
Pellet store ............................................45
Delivery, storage room, boiler room ............... 45
Discharge conveyor with screw ..................... 46
Discharge conveyor with suction heads ........... 47
Demands on the storage room .....................48
Calculating supply and store size ................... 49
Filling nozzle, earthing, electricity .................50
Dust-tight door, no cables/pipes ...................52
Tilted floor ............................................. 53
Checklist.................................................54
Commissioning ........................................55
Dismantling, disposal ................................ 55
Safety instructions ....................................60
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PE-K installation 35 to 90 kW
2012-02
Preface
Dear Customer
The satisfactory function of your new heating
system depends to a large extent on its installation.
So before starting the installation, please invest
15 minutes to get an overview with this manual.
Warranty and guarantee
You should also read the "Conditions for warranty,
guarantee, liability" on page 4 carefully. All of
the requirements we impose are intended to prevent
damage that neither you nor we wish to occur.
Training the customer
To avoid errors in operation, please explain to your
customer (preferably using the user manual) exactly
how the new heating system works and how it
should be operated and maintained.
Extended warranty for commissioning performed
by an authorised partner company
Commissioning by an expert ensures high efficiency,
clean combustion and safe operation. For these
reasons, 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.
Connecting the boiler to the Internet
The boiler can be operated remotely (mobile
phone, PC, ...) via the Internet.
For this purpose, a LAN cable from the Internet
modem to the boiler is needed.
Service agreement
You can ensure the best care for the heating system
by taking out a service agreement with one of our
certified contractors or our own customer service.
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Subject to change due to technical improvements
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 fi re protection regulations must
be observed.
The boiler is suitable for use with wood pellets
according to ÖNORM M 7135, DIN 51731,
EN 14961-2 class A1, EN plus class A1 or DINplus
with a diameter of 6 to 8 mm and a length of 15
to 40 mm. Operation with unsuitable fuels, in
particular those containing halogens (chlorine) or
high-slag pellets such as from grain waste, is not
permitted.
The combustion air must be free of aggressive
substances such as chlorine and fl uorine
from solvents, cleaning agents, adhesives and
propellants, or ammonia from cleaning agents, to
prevent corrosion of the boiler and chimney.
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 fi ll-up of the heating system and for
refi lling after repairs. For the initial fi ll-up of
the heating system, 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.
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.
The combustion air must be free of aggressive
substances such as chlorine and fl uorine
from solvents, cleaning agents, adhesives and
propellants, or ammonia from cleaning agents, to
prevent corrosion of the boiler and chimney.
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 suffi ciently large
expansion tank or a pressure maintenance
system. Suffi cient air venting must also be
ensured. Open expansion tanks or underfl oor
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
specifi ed 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.
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
specifi ed 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.
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PE-K installation 35 to 90 kW
2012-02
Conditions for warranty, guarantee, liability
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
modifi cations without notice. Printing and
typesetting errors or changes of any kind made
in the interim are not cause for claims. Individual
confi gurations 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.
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Subject to change due to technical improvements
Data and dimensions
PE-K pellet boiler
35 50 70 90
Rated capacity kW 9.4 - 35.0 14.1 - 49.0 21.0 - 70.0 28.4 - 95.0
Efficiency at partial/full load – wood pellets* % 90.8 / 94.1 93.1 / 93.5 92.3 / 93.3 91.6 / 93.0
Dimensions without casing, W x D x H mm 610 x 1,100 x 1,557 710 x 1,249 x 1,758
Weight with/without stoker kg 705 / 601 706 / 602 965 / 861 967 / 863
Water content Litres 117 196
Water-side pressure drop (ΔT = 20 °C)
Pa /
mH
2
O
280 / 0.028 550 / 0.055 480 / 0.048 880 / 0.088
Pellet bin on boiler (net) kg 60 (295 kWh)
Maximum distance to pellet store m 20
Ash box volume Litres 35 44
Flue gas mass flow rate, partial/full load g/s 8.3 / 21.3 11.5 / 30.0 17.5 / 42.8 21.8 / 58.0
CO2 content in dry flue gas, partial/full load* % 9.0 / 13.0 9.5 / 13.0 10.0 / 14.0 11.0 / 14.0
Exhaust temperature, partial/full load* °C 80 / 115 85 / 140 85 / 140 90 / 145
Flue draught
2 Pa at partial load / 5 Pa at full load required.
Draught limiter required for flue draught over 15 Pa.
Carbon monoxide (CO) emissions
partial/full load*
mg/MJ
mg/m³ 13% O
2
55 / 16
84 / 24
50 / 13
76 / 20
36 / 8
55 / 12
24 / 3
38 / 4
Dust emissions, full load*
mg/MJ
mg/m³ 13% O
2
4
8
12
18
10
16
4 / 8
7 / 13
Unburned hydrocarbons (CxHy)
partial/full load*
mg/MJ
mg/m³ 13% O
2
1 / <1
2 / 1
1 / <1
1 / <1
<1 / <1
<1 / <1
<1 / <1
<1 / <1
Electrical power consumption partial/full load* W 69 / 159 78 / 153 90 / 190 95 / 206
Maximum permissible operating pressure 3 bar
Temperature adjustment range 70° - 85 °C
Maximum permissible operating temperature 95 °C
Minimum return temperature 60 °C
Boiler class 3 according to EN 303-5
Tested fuel Beech up to W20
Electrical connection 1 x 230 V / 50 Hz / 13 A
* Data from test reports of BLT Wieselburg, report numbers 053/06, 054/06 and 043/10.
The test reports from the BLT Wieselburg test lab can be found on the Internet at: blt.josephinum.at
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PE-K installation 35 to 90 kW
2012-02
Regulations, standards and guidelines
Before setting up the boiler system,
consult the responsible chimney sweep
Standards and guidelines
• VDI 2035, prevention of damage due to corrosion
and scaling in hot-water heating systems with
flow temperatures up to 120°C.
Instead of the maximum hardness of 11.2 dH
for 20 to 50 lt/kW specific system volume, the
maximum lime content of the initial fill-up for
boilers up to 90 kW is limited to 20,000 lt°dH
(system volume in litres multiplied by the hardness
in degrees of German hardness).
• EN 12828, heating systems in buildings -
planning for hot-water heating systems.
The safety temperature limiter (100°C) is already
installed in the boiler described here.
The contractor must install a sufficiently large
expansion tank (at least 10% of the system
volume), a safety valve, a water shortage alert or
minimum pressure limiter and a thermal emergency cooling valve.
• EN 12831, heating systems in buildings - method
for calculating standard heating load
• EN 13384, flue systems - thermal and fluiddynamic calculation methods
• Only in Germany, DIN 18160, flue systems planning and design
• Only in Austria, ÖNORM H 5170, heating systems construction and fire safety requirements
The boiler complies with
98/37/EG Machinery directive
89/106/EWG Regulations for building products
73/23/EWG Low voltage directive
89/336/EWG EMC directive
93/68/EWG Amendment to 73/23/EWG
and 89/336/EWG
EN 287-1 Certification of welders
EN 303-5 Heating boilers for solid fuels
EN 60335-1/A1:96 Safety of electrical appliances
IEC 61000-6 3,4:01 EMC emitted interference
IEC 61000-6 1,2:01 EMC immunity
Conformity has been demonstrated. The relevant
documents and the original declaration of
conformity (CE) are in the manufacturer's files.
Regulations
• State building regulations
• Industrial and fire safety regulations
• State fire regulations
• In Germany, the EnEG (Energy Saving Act) with its
enacted EnEV ordinances for energy-saving insulation and energy-saving building technologies
• In Germany, 1.BImSchV, initial ordinance for
enforcement of the federal pollution control act for
small-scale furnaces.
• In Austria, Article 15 a, agreement on protective
measures regarding small-scale furnaces
• In Austria, Article 15 a, agreement on saving
energy
• In Switzerland, VKF/AEAI fire safety regulations
25-03 and 106-03
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Subject to change due to technical improvements
Boiler room
Requirements for the surroundings
The boiler may only be installed in dry surroundings.
The permitted ambient temperatures are between
5 and 30°C.
Ash
The ash must be kept in non-fl ammable containers
with covers.
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 fi re extinguisher should be kept outside the
boiler room, easily visible and easily accessible.
In Germany and Switzerland, no fi re extinguishers
are required for heating systems in private
residences. In spite of this, we recommend having
one in the house.
No heating appliances in the vicinity of escape
routes
No boiler may be installed in stairwells, hallways
or rooms through which escape routes lead to the
outside.
Installation or boiler room
A boiler room is required in Germany for 50 kW or
more, and in Switzerland for over 20 kW. Different
laws apply in the individual Austrian states
(boiler room in Upper Austria from 15 kW; Styria
from 18 kW; Lower Austria from 26 kW; Salzburg
from 35 kW; Burgenland, Tyrolia, Vorarlberg and
Vienna from 50 kW; for Carinthia a boiler room is
required for all central heating systems).
Boiler room
A boiler room must be built with fi re-resistant walls
and ceilings F90 (EI90), in Switzerland El30 up to
70 kW and EI60 above 70 kW. An escape door to
a corridor or to the outside is required. The door
F30 (El30) must open in the direction of escape and
be self-closing with a tight seal. Boiler room doors
that open into escape routes must be F90 (EI90).
In Germany there may be no connection to other
rooms. Minimum cross-sections for air inlets and
outlets are required.
Required cross-sections for air inlets and outlets
Boiler
output
Minimum areas including 20% extra for bars
Austria Germany Switzerland
Inlet Outlet Inlet/outlet Inlet
20 kW
>24 0 c m² >216 cm ²
>180 cm²
>206 c m ²
25 kW >25 8 cm ²
35 kW >361 cm²
50 kW >515 cm²
70 kW >22 8 cm ² >721 cm²
90 kW >276 c m ² >927 cm²
130 kW >347 cm² >252 c m² >372 cm² >1339 cm²
200 kW >533 cm² >336 cm² >540 cm² >2 0 60 c m²
400 kW >10 67 cm² >576 cm² >1020 cm² >4120 cm²
Installation room for smaller boilers
Smaller boilers can be installed in any room with
a suffi cient air supply. The area immediately
surrounding the boiler must be non-fl ammable.
In Germany, for up to 35 kW rated output, either at
least one door to the outside or one window that
can be opened (rooms with connection to outside),
and a room volume of at least 4 m³ per kW of boiler
output, is required. The room volume may also
include other rooms connected via air inlets in the
doors.
Fuel storage
In Germany, up to 10,000 litres (6.5 tons) of
pellets can be stored in the room where the boiler
is installed. For larger quantities, a separate fi reresistant F90 (EI90) storeroom is required.
In Austria, only a weekly's supply of wood may be
stored next to the boiler. For pellets, a separate
storeroom F90 (EI90) with a T30 (EI30) door is
required. As a result of amendments to building
laws, up to 10 tons of pellets may be stored in the
boiler room in some states.
In Switzerland, up to 10 m³ of pellets 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.
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PE-K installation 35 to 90 kW
2012-02
Electrical connection Energy-saving pumps
Not just for the subsidy
Many incentive programmes either demand energysaving pumps and hydraulic calibration or grant
extra bonuses for them. This is no coincidence, since
a single heating circuit with an old pump uses up
to 10% of the electricity in an average four-person
household.
Energy-saving pumps
For an underfl oor heating system that needs a large
amount of water circulation throughout the heating
season, an electronic pump with a fi xed speed
setting is suffi cient.
For individual room temperature control, the pump
must react to the heating in individual rooms being
switched on or off. It needs to adjust the amount of
water and the delivery height to current demand.
Differential pressure controlled energy saving pumps
with "Energy Label A" can do that perfectly.
Electrical connection
Observe the national regulations and any special
regulations of local energy utilities.
Supply cable ?? x ?? mm² with fl exible wires
???????????????????????????
A circuit breaker in the mains power input is
required.
Emergency stop switch
In Austria, heating systems installed in boiler
rooms must be equipped with an emergency stop
switch which may not affect the room's lighting.
The switch must be situated immediately outside
the access door and clearly marked. For boiler
rooms that are only accessible from outdoors, these
switches may also be within the boiler rooms,
immediately next to the access doors.
In Germany, a boiler room is only necessary
above 50 kW boiler output, so only then is an
emergency stop switch also required.
A single-pole emergency stop switch is integrated
into the boiler's safety chain. It only affects the
combustion air supply. The pumps continue
running to cool the boiler.
Supply cable 3 x 1.5 mm² with flexible wires
230 V AC / 50 Hz C13 A / L+N+PE
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Subject to change due to technical improvements
Basics Chimney
For every boiler a chimney of its own
The better the boiler and the chimney are matched,
the greater the energy of the fl ue gases leaving the
chimney and thus the certainty that they will rise
into the air from the top. If the diameter is too large,
the chimney will not be heated suffi ciently and the
exit velocity and temperature will be too low. The
fl ue gas then lacks the energy to rise and in extreme
cases, the smoke can sink down along the roof.
Chimneys with a diameter more than 50% greater
than needed must be renovated to reduce the
diameter.
If a chimney is designed for use with two
simultaneously operating boilers, it may prove to be
oversized for the partial load from only one boiler. If
there is really only one chimney available, a buffer
storage tank can help avoid a too-small partial load.
Chimney renovation - before it's too late
Compared to older boilers, modern ones are much
more effi cient and have lower amounts of fl ue gas
with considerably lower temperatures. The water
in the fl ue gas condenses and destroys old masonry
chimney walls, very slowly but also inexorably.
Timely renovation before the chimney wall has been
destroyed can be performed quickly and easily by
inserting a tube. But if the fl ue gas condensates
have penetrated the mortar joints, then the entire
fl ue must be dismantled and rebuilt.
Sewage connection for the chimney
For the condensation that forms in the chimney,
a DN 25 sewer connection via trap is needed. The
resulting amount of water is small. If no sewer
connection is possible, then a bucket that is checked
regularly can also be used.
A fan-assisted boiler and a gas-fi red boiler
may not be connected to the same chimney
Most gas-fi red boilers do not have a sealed air fl ap
and when the fan-assisted boiler is started while
the chimney is cold, the fl ue gas is pushed through
the gas boiler into the boiler room. Even a fl ue gas
damper in the gas boiler's fl ue pipe will hardly help
since these dampers are not certain to close with a
good seal.
With atmospheric gas boilers, old fi reclay chimneys
only stay dry with the gas boiler's overfl ow opening.
The water from the fl ue gas condenses in the
chimney. During pauses in fi ring, air fl ows through
the overfl ow opening and dries the chimney. If
this air stream is blocked by a fl ue gas damper, the
moisture can destroy an old fi reclay chimney.
Fan-assisted boiler and wood-burning stove
on the same chimney - a dangerous combination
This combination is not expressly forbidden, but it is
dangerous.
Every wood-burning stove has an air intake through
which any fan-assisted boiler, whether oil or wood,
will blow fl ue gas into the living area through a
cold chimney. If the wood-burning stove's fi rebox
door is not closed and the boiler is defective at the
same time, even acute carbon monoxide poisoning
is possible.
The wood-burning stove needs a signifi cantly larger
chimney cross section, which cannot be heated
by the fan-assisted boiler. Cold fl ue gas does not
rise from the opening; it sinks and can reach living
quarters through open windows.
It may also be possible to hear the boiler's fan in the
living quarters through the wood-burning stove.
Clarify with the chimney sweep
In any case, the chimney's suitability should be
clarifi ed with the chimney sweep.
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PE-K installation 35 to 90 kW
2012-02
Chimney Dimensioning, requirements
Obsolete regulations require
the wrong chimney
Laws and regulations demand a fl ue system that is
moisture-resistant for oil and gas and one that is
resistant to soot fi res for solid fuels.
Wood is a solid fuel. But in the lower output range,
the temperature of the fl ue gas can be under 100°C
and condensates can be deposited in the chimney.
So the chimney must be moisture-resistant, "against
regulations". Whoever builds a chimney resistant
to soot fi res can then look on helplessly as the
condensate destroys the chimney wall.
Soot fi res are possible in natural-draught boilers or
wood-burning stoves regulated by throttling the
air supply. When the wood fi re is at full intensity
and the boiler temperature has been reached,
a thermostat closes the air fl ap. That stops the
combustion, but since the combustion chamber
temperature doesn't fall, the wood continues to
gasify. Uncombusted wood gas condenses to tar in
the chimney; the tar can be ignited by sparks from
the fi re.
With modern lambda-controlled wood boilers, such
a soot fi re is nearly impossible since the control
system reduces the wood gasifi cation and not the
air. In modern lambda-controlled pellet boilers,
the control system shuts down the fi re by stopping
the pellet supply without closing off the air supply.
So there is no lack of air and no fl ammable tar in
the chimney. The low exhaust temperatures of a
modern boiler also provide no ignition source for a
soot fi re. With a modern and properly maintained
wood boiler, there is no danger to chimneys from
soot fi res.
Moisture-resistant W3G fl ue systems
Since 2005 there are W3G chimneys (classifi ed
according to the German DIN 18160), which are
resistant to both moisture and soot fi res. These
chimneys are approved for all fuels. Most of these
W3G chimneys have ceramic inner pipes, which
have a signifi cantly longer service life than metal
chimneys due to their acid resistance.
Small chimney diameter required
Please note that for partial-load operation with fl ue
gas temperature of only 100°C, the large chimney
cross sections that were previously typical for solid
fuel are no longer optimal. If the cross section is too
large, the fl ue gas is no longer certain to rise from
the chimney opening and may fl ow along the roof
and sink to the windows of the living quarters.
INSERT TABLE!
Normally no defl agration damper
The boiler is designed with safety routines in the
control system to prevent defl agrations, so no
defl agration damper (also often called a blowback
fl ap) is required if the connecting pipe is short and
ascends to the chimney. If a defl agration damper is
needed at high points before descending sections
or at the beginning of a long horizontal section
(L > 30 x D), it must be situated so that people are
not endangered by a defl agration.
Height
above
boiler
room
floor
Chimney diameter in cm
(required minimum diameter)
35 kW 50 kW 70 kW 90 kW
6 m 20 cm 20 cm* 22 cm 22 cm
7 m 18 (16) cm 20 cm 22 cm 22 cm
8 m 18 (15) cm 18 (16) cm 22 cm 22 cm
9 m 18 (15) cm 18 (15) cm 20 (18) cm 20 (18) cm
10 m 16 (14) cm 18 (15) cm 20 (18) cm 20 (18) cm
11 m 16 (14) cm 18 (15) cm 20 (18) cm 20 (18) cm
12 m 16 (14) cm 18 (15) cm 20 (18) cm 20 (18) cm
Values on grey background:
Connection from boiler to chimney with
same cross-section as chimney.
*) For boiler outputs over 30 kW and low chimney
heights, a chimney joint tilted 45° can help achieve
the required draught of 5 Pa at full load with
acceptable cross-sections (a size smaller than indicated in the table).
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Subject to change due to technical improvements
Requirements, connecting pipe Chimney
Connecting pipe to chimney insulated
The connection between the boiler and the chimney
should be insulated with at least 30 mm, preferably
50 mm, of mineral wool to avoid thermal losses that
can lead to a build-up of condensation.
Cleaning aperture in the connecting pipe
Easily accessible cleaning apertures must be available
for cleaning the fl ue pipe.
Install short, airtight and ascending connections
"Attractive" right-angle fl ue offsets with two or
more bends are bad in a fl ue gas conduit. The
optimum to strive for is the shortest pipe from the
boiler to the chimney with a minimum of direction
changes.
The fl ue gas conduit to the chimney must be
leakproof (use heat-resistant silicone covered with
pure aluminium adhesive tape to seal sleeved pipes
without gaskets); otherwise smoke emission into the
boiler room can be expected during ignition.
Install the fl ue gas conduit so it ascends toward the
chimney!
Long, horizontal fl ue gas conduits to the chimney
Use a tight cross section, apply above-average
insulation (50 mm and more) and provide enough
cleaning apertures.
Calculations indicate that a connecting pipe with
a large cross section would reduce the required
chimney cross section. However, with low fl ow
speeds ash deposits will form and then the
theoretically calculated fl ue draught will be lost
again.
With a large chimney cross section, the unbent
length of the connecting pipe can be at maximum
half of the effective chimney height (calculation
required).
Chimney renovation with stainless steel pipe???
Maybe the chimney has already been renovated
for oil or gas with a stainless steel pipe, and now
a conversion to wood or pellets is planned. Or
the chimney is too tight to install a ceramic pipe
with a sure seal. If a moisture-resistant inner pipe
is installed in a suffi ciently fi re-resistant casing,
the German association of chimney sweeps has
found the following solution to the standards and
regulations dilemma:
"in the certifi cation of suitability and safe use for
heating systems, it should be noted that after a
soot fi re the long-term durability cannot be ensured
and penetration of the chimney by moisture
cannot be ruled out so that it may be necessary to
replace the inner pipe (Criteria for Determination
of Suitability and Safe Use of Heating Systems -
October 29
th
2008, page 12).
Replace inner pipe after a soot fi re
After a soot fi re, the inner pipe is in all likelihood no
longer suffi ciently leakproof, making the chimney
subject to damage by moisture so that the inner
pipe needs to be replaced without fail, regardless of
whether its resistance to soot fi res has been checked
or not.
Fit the chimney connection
just under the ceiling!
Even though the current boiler can be connected to
the chimney at a low height, it is better if you fi t the
chimney connection just below the ceiling. The fl ue
pipe is easier to install, and the vertical connection
pipe is long enough for an emission measurement.
Structure-borne noise
To avoid structure-borne noise, there should not be
a fi xed connection between the fl ue pipe and the
chimney!
Good exhaust systems are acoustically isolated.
When steel pipes are connected to a fi reclay
chimney, ceramic fi bre bandages have proven
effective at preventing structure-borne noise as well
as damage to the refractory sleeve.
Page 13
13
PE-K installation 35 to 90 kW
2012-02
Chimney Deflagration damper
Normally no deflagration damper up to 50 kW
The boiler is designed with safety routines in the
control system to prevent deflagrations, so no deflagration damper (also often called a blowback flap) is
required if the connecting pipe is short and ascends
to the chimney.
From 70 kW we recommend a deflagration damper
Deflagration damper
for high points and long pipes
For high points before descending sections or at the
beginning of a long horizontal section (L > 30 x D),
a deflagration damper is required regardless of the
boiler output.
Position deflagration dampers so that
no people are endangered.
Page 14
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Subject to change due to technical improvements
Water hardness and corrosion
Softened water and shut-off valves
If a buffer storage tank is installed in the heating
system, the system should be fi lled with softened
water. The lime is deposited on a very small area in
the boiler and forms layers of insulating limescale.
The boiler wall is no longer suffi ciently cooled and
stress cracks can result. To keep the lime content to
a minimum during minor repairs, shut-off valves
are essential at all buffer connections and all heat
distribution branches.
When is decalcifying necessary?
For the initial fi ll-up of the heating system with the
boiler, the lime content of all water in the heating
system may not exceed the value of 20,000 lt°dH
(system volume in litres multiplied by the hardness
in degrees of German hardness).
20,000 lt°dH
= permitted hardness in °dH
litres of water
Example:
20,000 lt°dH
= 10 °dH
2000 litres
To maintain the limit of 20,000 lt°dH, the system
must be softened to 10°dH.
Softening with a salt-regeneration ion exchanger
We recommend softening water with salt-
regeneration ion exchangers, just as drinking water
is softened. This method does not remove salt
from the water. It exchanges the calcium in lime
against sodium from the salt and has considerable
advantages. It is cheap and chemically stable
against contamination. In addition, it has a natural
alkalinity that generally results in a suffi ciently
non-corroding pH value of around 8.
pH value between 8 and 9
may require dosing with trisodium phosphate
If the heating water's pH value is not greater
than 8 after a week of operation, increase it by
adding 10 g/m³ of trisodium phosphate (Na3PO4)
or 25 g/m³ of trisodium phosphate dodecahydrate
(Na3PO4.12H2O). Wait another 2-4 weeks before
making further corrections. The pH value may not
exceed 9.
No hybrid installations
A disadvantage of salt-regeneration ion exchange is
the salt content with its high electrical conductivity,
which can lead to electrolytic corrosion, especially of
aluminium or galvanized steel.
If only steel, brass, gunmetal and copper are used
in the heating system and the use of stainless steel
is limited to small areas, then no corrosion problems
should be expected even with salty water.
Inside a heating system, galvanized and aluminium
parts are always in danger of corrosion, especially
in combination with copper tubing. In practice
this means no hot-galvanized fi ttings and no mix
of galvanized tubing with copper tubing. There
is an illogical exception: galvanized steel tubing
combined with boilers or buffer storage tanks made
of steel. Presumably the uniform zinc layer dissolves
uniformly and is dispersed evenly throughout the
system without localised corrosion.
Complete desalination not required
If there is no aluminium (heat exchanger in the gas
boiler or aluminium radiator) in the system, then no
expensive desalination with ion exchange cartridges
or osmosis is required.
Lime stabilisation can be dangerous
The addition of lime stabilising agents prevents
limescale. However, we advise against doing so.
These agents increase the salt content and result in
an undefi ned pH value. If large amounts of water
are added, exactly the same agent must be used
again. Mixing with other water additives or with
antifreeze can result in corrosion.
Page 15
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PE-K installation 35 to 90 kW
2012-02
Air venting, compensation, system separation
Protect the expansion tank against shut-off
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.
Adjust expansion tank pressure
Most expansion tanks are delivered with primary
pressure of 1.5 bar. The pressure should be adjusted
by releasing nitrogen so that it is 0.3 bar higher than
the static pressure at the place of installation, but
the pressure should not fall below 0.9 bar.
Example 1:
height difference between expansion tank and
highest point in the system pst = 11 m = 1.1 bar:
1.1 bar + 0.3 bar = 1.4 bar pressure setting.
In this case, you can also contact our customer
service to set the system's cut-off pressure to
1.5 bar.
Example 2:
height difference between expansion tank and
highest point in the system pst = 5 m = 0.5 bar:
0.5 bar + 0.3 bar = 0.8 bar -> 0.9 bar pressure
setting.
Here the minimum pressure of 0.9 bar must be
chosen. The factory setting of 1.0 bar for the cut-off
pressure is compatible with this minimum pressure
setting.
No open expansion tanks
Open expansion tanks allow air into the system not allowed.
Impermeable plastic tubing
or system separation
"Impermeable" plastic tubing simply undercuts
a standard limiting value; there is no absolutely
impermeable tubing. Even composite tubing with
aluminium sheathing is not absolutely impermeable.
A rule of thumb: up to 3,000 running metres of
underfl oor heating pipe, use impermeable composite
tubing; for larger systems, system separation with a
heat exchanger is imperative. If a system separation
is installed, then common single-wall tubing can
also be used. For older underfl oor heating systems,
always install a system separation because their
tubing is not very airtight.
Initial protection with corrosion inhibitors
These agents line the new and still uncoated
internal surfaces with a protective fi lm; this is only
possible in a new system. If corrosion has already
begun, these agents cannot help anymore. Use
corrosion inhibitors sparingly. For systems with
buffers whose water volume is large in relation
to the internal surfaces, it is preferable to use half
rather than double the quantity specifi ed by the
manufacturer.
Protection against atmospheric corrosion
To reliably protect the entire heating system against
corrosion, air intrusion should be kept to a minimum
and any air that does gain entry must be released as
soon as possible. The most important measures are
described below.
Air vent at highest point in fl ow
No system is completely airtight. Air that gets into
the system is transported to the boiler with the
return fl ow since water can take up more air as it
gets colder and as the pressure increases. The air is
released again at the point in the system with the
highest temperature and the lowest pressure. The
two typical points for releasing gases are the hot
boiler and the highest point in the fl ow.
Install an air valve at the upper end of the line
from the boiler outlet (already installed in PU and
PC boilers) and also at the highest point in the fl ow
of the entire system. The boiler safety groups with
horizontal connection to the ascending fl ue pipe,
which have unfortunately become so common, are
not suitable for air venting.
For large, unseparated underfl oor heating systems,
an absorption fi lter for the entire water fl ow should
be installed in the fl ow after the boiler (Spirovent,
Flamco or Pneumatex are typical manufacturers).
At least 10% compensating volume
To minimise air suction through the system's
pipe connections (which are watertight but not
absolutely airtight) when the system cools, a
suffi ciently large expansion tank with at least 10%
of the system volume is needed.
Page 16
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Subject to change due to technical improvements
Return riser and safety devices
Return riser
Wood contains water. If the temperature in the
boiler is too low, steam condenses from the fl ue 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 fl ow to the
boiler return.
The mixer also allows the exploitation of residual
heat. After the fi re 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 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.
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 or
in the fl ow 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 fl ow 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.
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 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.
Thermal
emergency
cooling valve
Strainer
visible drain to
sewer
Cold water
connection
Isolating valve
Remove hand wheel
The discharge must be have an easily visible, open
fl ow 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.
Page 17
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PE-K installation 35 to 90 kW
2012-02
Page 18
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Subject to change due to technical improvements
Buffer storage tanks Buffer
At low heating loads,
either install a buffer
or set short heating time slots
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 underfl oor 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
underfl oor 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.
A suffi ciently large hot water tank
To operate the boiler without a buffer storage tank,
a hot water tank of suffi cient size (see table) to take
up the heat from an entire fi ring cycle is needed.
A suffi ciently large tank should also be chosen for
increased convenience.
Boiler
output
Supply
volume
Charging
volume
Total hot
watervolume
Exchanger
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
No buffer storage tank is needed if
no more than two heating circuits (without
individual room temperature control) are installed.
A buffer storage tank is needed
• if individual room temperature control is installed.
• if there are more than two heating circuits,
especially in buildings where the flats are
individually controlled.
• when a substantial portion of the boiler's
operating time is spent below its lowest
modulation ratio.
• during the transitional period in autumn/spring
when there is very low heating demand, such as
only for the bathroom.
• for radiators in wooden houses with low heat
capacity.
• 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
pellet boiler needs up to 20 minutes to reach its
maximum output from standby.
• if an air heating system is to be started without
warm-up time for the boiler.
• if a solar heating system is being integrated with a
low-temperature heating system.
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 fi nely 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.
Page 19
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PE-K installation 35 to 90 kW
2012-02
Buffer Buffer storage tanks
Buffers for multi-boiler systems
For systems with several boilers and also for those
with several very different heating circuits (especially
different times of operation or air and underfl oor
heating in the same heating system), a bypass is
needed between heat producers and consumers to
ensure stable hydraulic conditions for the individual
circuits. A bypass is nothing more than a pipe
connection between supply and return, having the
same diameter as the supply and return themselves.
The differential water quantities from heating and
boiler circuits fl ow through this bypass, resulting
in a neutral pressure point that ensures that the
heating circulation cannot infl uence the boiler water
circulation and vice versa.
A bypass that can do more than just stabilise
pressure conditions is the buffer. If a wood boiler
for the base-load range and an oil/gas boiler
for peak load/emergency reserve are operated
together in a heating system, a buffer storage tank
reduces the operating time of the peak-load boiler
by compensating for brief differences between
production and consumption. The number of boiler
starts/stops when consumption fl uctuates around
the rated load of a boiler is reduced, saving energy
and easing stress on the boiler.
To work as an output compensator and bypass for
several boilers, the buffer's storage capacity should
be chosen to match 20 to 30 minutes of full-load
operation for the largest automatic wood boiler
in the system. In special cases, peak loads and
noncontinuously operated air heating systems must
also be taken into account, or the morning peak if
the start of an oil/gas boiler is to be avoided. The
morning peaks themselves should be minimised
with staggered starting times for the heating circuits
as well as reasonable set-back temperatures.
Smaller buffers with low return temperatures
Even if subsidy guidelines demand "litres per
kilowatt" (BAFA subsidy in Germany demands
30 l/kW) and thereby specify a minimum buffer size,
one should arrange for a technically correct size.
The storage capacity of a buffer essentially depends
on the spread between the heating system's boiler
fl ow temperature and return temperature.
Example:
For a 90 kW boiler with 80°C fl ow temperature,
30 minutes of full-load operation with underfl oor
heating and 30°C return temperature (=50°C spread)
requires a buffer volume of 775 litres,
but with radiator heating and 60°C return
temperature (= 20°C spread), it requires 1,935 litres.
10°
50°
40°
30°
20°
Spread between flow and return
15
260
180
130
90
70
50
35
25
Boiler output in kW
825
1,100
1,650
3,300
4,950
6,600
8,250
2,200
Buffer volume in litres for 30 minutes full load
1,935 l
775 l
Required volume depending on output and spread
Spread
20 kW 25 kW 35 kW 50 kW 70 kW 90 kW 130 kW 200 kW 350 kW
10°C 900 l 1,100 l 1,500 l 2,200 l 3,000 l 3,900 l 5,600 l 8,600 l 15,000 l
20°C 450 l 550 l 750 l 1,100 l 1,500 l 1,950 l 2,800 l 4,300 l 7,500 l
30°C 300 l 400 l 500 l 750 l 1,000 l 1,300 l 1,900 l 2,900 l 5,000 l
40°C 250 l 300 l 400 l 550 l 750 l 1,000 l 1,400 l 2,150 l 3,750 l
50°C 200 l 200 l 300 l 450 l 600 l 800 l 1,150 l 1,750 l 3,000 l
Calculating minimum buffer volume
The minimum volume for the buffer can also be
calculated with the following formula:
minimum volume =
operating time (h) x output (kW) x 860
spread (°C)
Page 20
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Subject to change due to technical improvements
Hydraulic integration Buffer
ETA stratified buffer SP
Upper buffer sensor
Lower buffer sensor
Wood chip/pellet boiler flow
Heating circuits flow
Hot water tank flow
Oil/gas boiler flow
Wood chip/pellet boiler return
Heating circuits return
Oil/gas boiler return
With conventional hot water supply
ETA stratified buffer SP
Upper buffer sensor
Lower buffer sensor
Wood chip/pellet boiler flow
Heating circuits flow
Oil/gas boiler flow
Wood chip/pellet boiler return
Heating circuits return
Oil/gas boiler return
With fresh water module
Hot water tank return
Cold water
Hot water
Upper buffer sensor for hot water
ETA stratified buffer Solar SPS
With solar exchanger and fresh water module
ETA stratified buffer SP
Upper buffer sensor
Lower buffer sensor
Wood chip/pellet boiler flow
Heating circuits flow
Oil/gas boiler flow
Oil/gas boiler return
With stratified charging module and fresh water module
Cold water
Hot water
Upper buffer sensor for hot water
Upper buffer sensor
Lower buffer sensor
Wood chip/pellet boiler flow
Heating circuits flow
Oil/gas boiler flow
Oil/gas boiler return
Cold water
Hot water
Upper buffer sensor for hot water
Low-temperature circuits return
High-temperature circuits return
Buffer top solar
Solar flow
Solar return
Solar flow
Solar return
Lower buffer sensor
Low-temperature circuits return
High-temperature circuits return
Buffer bottom solar
Wood chip/pellet boiler return
Wood chip/pellet boiler return
For the largest possible buffer storage capacity and for
maximum solar yield even in winter, low return
temperatures are the goal.
The best stratified buffer can't unmix what has been
mixed by heat distributors. Especially in houses where
radiators and underfloor circuits are present, no mixing
heat distributors should be installed; the returns
should be connected directly to the buffer.
An underfloor heating system can still be operated with
the return from radiators.
If a solar heating system is connected, only the cold
returns from an underfloor 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.
An oil or gas boiler should always be connected only
through the upper quarter of the buffer.
Siphon loops downwards at all connections reduce heat
losses in summer.
Page 21
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PE-K installation 35 to 90 kW
2012-02
Buffer Hydraulic integration of several buffers
Parallel or serial connection
between several buffers
When there are several buffers, normally the parallel
connection (top with top and bottom with bottom)
is the better solution.
With a parallel connection, the entire buffer volume
is available to installed heat exchangers such as solar
heat exchangers or internal water heat exchangers
and suspended hot water tanks.
(Return)
Flow
Solar return
Return
Solar flow
If two buffer storage tanks of different dimensions
are connected in parallel, then the fl ow must be
connected to the higher one or the lower one must
be raised so that the upper connection can be
horizontal.
A serial connection between two buffers has no
advantages over a parallel connection; if anything
it is a disadvantage. For example, a suspended
hot water tank can get no heat from the second
buffer or an internal heat exchanger cannot heat
on both buffers. For this reason, with serial buffers
one should connect a solar supply using either
heat exchangers in both buffers or better with an
external heat exchanger.
Return
Flow
With rare exceptions, the use of the serial
connection (buffer 2 top and buffer 1 bottom
connected) is limited to overcoming spatial obstacles
in the given installation situation. Only a serial
connection is possible if the passage to a door
needs to be kept free or for large distances between
buffers.
Tichelmann connection for higher outputs
For parallel connection with one-sided connection,
the volume of the second buffer is integrated via
thermosiphon principle. The exchange between
the two tanks is driven only by gravity and limited
by the hydraulic resistance of the junctions, so
for medium outputs a Tichelmann connection is
required.
With a 6/4" connection, a maximum of 5,500 l/h
at 0.25 mH
2
O pressure loss is possible (for fl ow and
return connections together). This corresponds to
130 kW at a spread of 20°C. Therefore, for higher
outputs external piping, either symmetric or with
Tichelmann connection, is needed.
With more than two tanks, external piping with
Tichelmann connection is also needed to fi ll and
drain all tanks uniformly.
Buffer storage tanks demand softened water
If buffer storage tanks are installed in a heating
system, the system must be fi lled with softened
water. Around 0.25 kg of limescale will precipitate
from a cubic metre of water with 15° of German
hardness.
Parallel buffer storage
tanks
Buffer connections
5/4" DN32
Buffer connections
6/4"
DN40
one-sided connection
up to 25 kW
boiler output
up to 40 kW
boiler output
internal
Tichelmann connection
up to 80 kW
boiler output
up to 130 kW
boiler output
Symmetric connection
for more than
80 kW boiler output
for more than
130 kW boiler output
external piping with
Tichelmann connection
for more than
80 kW boiler output
for more than
130 kW boiler output
and/or
for more than two buffer storage tanks
Flow
Return
Flow
Return
Flow
Return
Maximum 2 buf fers
Maximum 2 buf fers
Flow
Return
Maximum 2 buf fers
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Subject to change due to technical improvements
Parallel buffers with internal Tichelmann Buffer
Cold water
Hot water
Solar flow
Solar return
Wood chip/pellet boiler return
DN32
DN32
ETA stratified buffer SP ETA stratified buffer SP
Upper
buffer sensor
Upper
buffer sensor
Wood chip/pellet boiler flow
Heating circuits flow
Hot water tank flow
Oil/gas boiler flow
Hot water tank return
Low-temperature circuits return
Oil/gas boiler return
For a sufficiently large hot water reserve, the enabling
temperatures of the heating circuits should be over 45°C!
Return lines with strongly differing temperatures
should be fed into the buffer storage tank separately.
To minimise pipe circulation losses it is helpful to make the connections with downward siphon loops.
DN32
DN32
ETA stratified buffer SP ETA stratified buffer SP
Upper buffer sensor
Lower buffer sensor
Buffer bottom solar
Wood chip/pellet boiler flow
Heating circuits flow
Oil/gas boiler flow
High-temperature circuits return
Low-temperature circuits return
Oil/gas boiler return
Return lines with strongly differing temperatures
should be fed into the buffer storage tank separately
Two parallel buffers and conventional hot water supply
Two parallel buffers with fresh water module and solar stratified charging
Buffer top solar
Upper buffer sensor for hot water
Wood chip/pellet boiler return
The basic principle of the internal Tichelmann is diagonal flow; two buffers are connected together at the top and bottom
(= parallel connection). For output up to 90 kW, a connection with DN32 (ETA buffer connection set) is sufficient, for 30 kW at
least R1” or 28 mm copper. On one tank, the boiler outlet is connected at the top; on the other the boiler return is connected
at the bottom.
Page 23
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PE-K installation 35 to 90 kW
2012-02
Buffer Parallel buffers with external Tichelmann
Wood chip/pellet boiler return
High-temperature circuits return
Stratified buffer with/without internal
water heat exchanger
ETA stratified buffer SP
ETA stratified buffer SP
ETA stratified buffer SP
ETA stratified buffer SP
ETA stratified buffer SP
Low-temperature
circuits return
Upper buffer sensor
Lower buffer sensor
Buffer bottom solar
Upper buffer sensor for hot water
Buffer top solar
Total output up to
Shut-off valves on buffer
Collector line at least
30 kW
DN 20
DN25
R 1“- 28x1.5
300 kW
DN 40
DN65
R 2½“- 76x2
160 kW
DN 32
DN50
R 2“- 54x1.5
90 kW
DN 32
DN40
R 1½“- 42x1.5
60 kW
DN 25
DN32
R 1¼“- 35x1.5
450 kW
DN 40
DN80
R 3“- 89x2
To minimise pipe circulation losses it is helpful to incorporate siphon loops downward in the connection lines.
Three or more parallel buffers with hot water tank or internal water heat exchanger
Three or more parallel buffers with fresh water module and solar stratified charging
Wood chip/pellet boiler flow
Heating circuits flow
Hot water tank flow
Oil/gas boiler flow
Wood chip/pellet
boiler return
Heating circuits return
Hot water tank return
Oil/gas boiler return
Upper buffer sensor
Lower buffer sensor
Buffer bottom solar
Wood chip/pellet boiler flow
Heating circuits flow
Oil/gas boiler flow
Cold water
Hot water
Solar flow
Solar return
Oil/gas boiler return
Cold water
Hot water
Lower boiler sensor solar
Solar flow
Solar return
For a small solar heating system, individual buffers can be
shut down in the summer to reduce the total volume.
The basic principle of the external Tichelmann is parallel flow through several buffer storage tanks, which is achieved with
diagonally alternating connection of the collectors. The last buffer on the flow collector is the first on the return collector.
To achieve uniform charging/discharging, the stub lines should be minimum one or two sizes smaller than the collector. There is
no output limit for this circuit.
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Subject to change due to technical improvements
Serial buffers Buffer
Solar flow
Solar return
High-temperature circuits return
Wood chip/pellet boiler return
ETA stratified buffer SP
Low-temperature circuits return
Upper buffer sensor
Lower buffer sensor
Buffer bottom solar
Upper buffer sensor for hot water
Buffer top solar
Total output up to
Number of buffer storage tanks
Connection line at least
30 kW
4
DN25
R1“- 28x1.5
140 kW
4
DN50
R2“- 54x1.5
100 kW
2
DN40
R1½“- 42x1.5
80 kW
4
DN40
R1½“- 42x1.5
170 kW
2
DN50
R2“- 54x1.5
50 kW
4
DN32
R1¼“- 35x1.5
To minimise pipe circulation losses it is helpful to incorporate siphon loops downward in the connection lines.
Serial connection and conventional hot water tank or fresh water module
Serially connected buffers with fresh water module and solar stratified charging
Wood chip/pellet boiler flow
Heating circuits flow
Oil/gas boiler flow
Wood chip/pellet
boiler return
Heating circuits return
Hot water tank return
Oil/gas boiler return
Upper buffer sensor
Lower buffer sensor
Wood chip/pellet boiler flow
Heating circuits flow
Oil/gas boiler flow
Cold water
Hot water
Solar flow
Solar return
Oil/gas boiler return
65 kW
2
DN32
R1¼“- 35x1.5
ETA stratified buffer SP ETA stratified buffer SP
ETA stratified buffer SP ETA stratified buffer Solar SPS ETA stratified buffer SP
Cold water
Hot water
Buffer bottom solar
Upper buffer sensor for hot water
If there are different buffer types, or if not all buffers can be set up in one group, serial connection of the buffers is
necessary. Note that in the case of a serial buffer connection, integration of a solar heating system will only work satisfactorily if a fresh water module is used for the hot water supply.
Solar tanks with internal solar exchangers are only of limited effectiveness. Combination tanks with suspended hot water
tanks or internal water heat exchangers are unsuitable for a serial buffer connection.
Page 25
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PE-K installation 35 to 90 kW
2012-02
Page 26
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Subject to change due to technical improvements
Minimum clearances for maintenance Installation
Position boiler in boiler room
Position the boiler in the boiler room while
complying with the minimum clearances for maintenance and installation.
If soundproofing is needed, place the optionally
available sound insulation strips under the boiler.
Level boiler
After positioning the boiler, level it on the floor.
For soundproofing, use the load distribution plates
from the sound insulation set for height adjustment. For strongly inclined floors, divide the load
distribution plates into halves or thirds.
Minimum clearances for maintenance for PE-K
The adjacent sketch shows the space requirements
and clearances for maintenance and installation of
the boiler.
at least 400 mm
610 mm
(710 mm)
at least
300 mm
at least 400 mm
Dimensions in parentheses
apply for 70 and 90 kW
1100 mm
(1249 mm)
at least 800 mm
(950 mm)
PE-K
35 - 90 kW
The dimensions in parentheses apply for 70 and
90 kW boilers.
The sketch shows a boiler with right-hand tundish;
for a left-hand tundish a mirror image applies.
Page 27
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PE-K installation 35 to 90 kW
2012-02
Installation Installing the stoker
Install extension frame
Attach the extension frame to the boiler with 2
M8 x 16 hex-head screws and washers.
Level extension frame
Using the levelling screws on the underside, level
both sides of the extension frame.
If soundproofing is needed, insert a sound insula-
tion strip with load distribution plate (from the
optional sound insulation set).
Inspect seal on stoker
Check the seal on the stoker for possible damage.
Install stoker on boiler
Install the stoker on the boiler with 4 M8 x 30
hex-head screws and washers.
Tighten the screws evenly.
Check seal
M8 x 16
Levelling screws
M8 x 30
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Subject to change due to technical improvements
Attaching the pellet bin Installation
Check freedom of movement of stoker screw
In the combustion chamber, check the stoker
screw's clearance (1 - 2 mm) from the bottom of
the stoker channel.
The stoker screw may not contact the channel
bottom.
Install pellet bin on stoker
Attach the pellet bin to the stoker with 4 M5 x 20
hex-head screws and 2 washers each.
Install struts on pellet bin
Install both struts to support the pellet bin; attach
them to the extension frame and the pellet bin
using 2 M8 x 16 hex-head screws and washers for
each.
Adjust pellet bin
Adjust for uniform spacing between pellet bin and
boiler to prevent contact with the casing later.
Screw
Channel base
M5 x 20
M8 x 16
Struts
Page 29
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PE-K installation 35 to 90 kW
2012-02
Installation Flue gas recirculation
Remove bottom insulation,
insert connection pipe
Using the round notches in the frame as a guide,
remove the bottom insulation with a knife.
Push bottom insulation under boiler
Install flue gas duct
Insert the seal between the flue gas duct and the
connection pipe.
Attach the flue gas duct with 4 M5 x 20 screws and
tighten them evenly.
Position the flue gas duct on the boiler. Insert the
threaded rod (with spring) on the air box into the
hole on the flue gas duct. Fasten the flue gas duct
to the boiler with 3 M5 x 20 screws.
Attach both covers with seal to the flue gas duct
with M5 countersunk screws.
Remove insulation
Connection pipe
Seal M5 x 20
Flue gas duct
Attach covers and seal with
M5 countersunk screws
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Subject to change due to technical improvements
Attaching the pellet bin Installation
Install flue pipe
Install the flue pipe on the rear side of the boiler.
Insert a seal into each of the connecting flanges at
the top and bottom.
Fasten the flue pipe with M5 x 15 hex-head
screws.
Flue pipe
Insert seal
Cleaning cover and seal
M5 x 15
M5 x 15
Insert seal
M5 x 15
Page 31
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PE-K installation 35 to 90 kW
2012-02
Installation Attaching the pellet bin
Attach cover,
do not block flue gas recirculation
The flue gas recirculation on PE-K boilers may
never be blocked.
Attach the cover (with a seal) to the flue outlet
using 2 wing screws.
Attach insulation to flue pipe
Attach the insulation to the flue pipe.
Insert ignition fan
Insert the ignition fan into the opening beside the
stoker and attach the spring to the casing.
Do not block Cover Seal
Attach insulation
Ignition fan
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Subject to change due to technical improvements
Connecting cables Installation
Remove panel from top of boiler
Remove the panel from the top of the boiler and
remove the cable duct covers.
Cables for vacuum motor, level sensor
Feed the cables for the vacuum motor and level
sensor downward between the pellet bin and the
boiler. Then use the included cable to extend the
level sensor cable.
Feed both cables through the opening in the
extension frame and over the cable ducts on the
rear side of the boiler to the boiler's circuit board.
Cables for ignition fan and stoker
Connect the stoker cable and feed it together with
the ignition fan cable through the opening in the
extension frame over the cable ducts to the boiler's
circuit board.
Extend the ignition fan cable in the cable duct on
the rear side of the boiler.
Connect cables
Connect the cables to the circuit board. See the
circuit diagram on page 38.
If you want to operate the boiler remotely via
Internet (www.meinETA.at), extend the network
cable out of the boiler with a suitable extension.
Feed all cables through opening
Feed cables downward
Page 33
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PE-K installation 35 to 90 kW
2012-02
Installation Attach pellet hoses
Expose earthing wire on pellet hose
Expose approx. 5 cm of earthing wire at both ends
of the pellet hoses (suction hose, return air hose).
This allows the formation of an earth connection
from the boiler to the discharge conveyor when
connecting the pellet hoses, preventing electrostatic
charge build-up.
Fasten pellet hoses to pellet bin
and earth them
Connect the pellet hoses to the connectors on the
pellet bin with hose clamps (from basic set for screw
conveyor).
Moisten the connectors with water if it is difficult to
fit the hoses over them (do not use grease).
Connect the earthing wire of both pellet hoses to the
yellow-green earthing cable.
Connect pellet hoses to discharge
conveyor in store and earth them
Expose approx. 5 cm of earthing wire at both ends
of the pellet hoses (suction hose, return air hose)
and bend it into the hoses.
The earthing wire must have good contact with
the nozzles on the discharge conveyor, so file away
paint/coating from the nozzle.
Slip the pellet hoses with hose clamps onto the
nozzles. Looking towards the storeroom at the
connection head, attach the return air hose on the
left and the pellet hose on the right.
Moisten the nozzles with water if it is difficult to fit
the hoses over them (do not use grease).
Tighten the hose clamps on both pellet hoses.
Back air
Suction nozzle
Expose earthing wire
Back air
Suction
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Subject to change due to technical improvements
Attaching housing/panels Installation
Attach pellet bin housing
After completing the wiring, fit the pellet bin
housing into the slits in the boiler housing.
The bottom of the housing is flush with the extension frame.
Fit cover
Attach cover for heat exchanger cleaner
Fasten the cover for the heat exchanger cleaner
with 2 black self-tapping screws.
Insert rubber plugs into housing
Fasten rear panel
Fit the rear panel into the slits in the boiler housing
and fasten it with 4 round-headed screws.
Affix label with safety notices
to door of store
Affix the label with pellet store safety notices to
the pellet store's door.
Housing
Round-headed screws
Cover for heat exchanger cleaner
Cover
Rubber plugs
Prevent moisture from damaging pellets!
Danger! Moving parts may cause injuries!
Open door to pellet store, filling and
venting nozzles for minimum 60 minutes
ventilation prior to entering storeage area!
Ensure that the ETA pellet boiler is in
automatic mode while store is being filled!
Switch main power supply to OFF
before entering the pellet storage area!
Smoking, naked flame or any other
ignition sources are prohibited!
No entry for unauthorized personnel!
Area unsafe for children!
www.eta.co.at
Wood Pellets - Storage Room
Only enter the pellet storeage area while in
the presence of a second person!
The second person should remain outside
the storage area in case of help is needed!
Page 35
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PE-K installation 35 to 90 kW
2012-02
Installation Installing the ash box
Attach handles to ash box
Attach both handles to the ash box with two M8 x
20 Allen screws each.
Screw in levelling feet
Attach an M8 hex nut to each levelling foot and
loosely screw the levelling feet into the underside
of the ash box.
Attach adjustment bracket for wheel
Attach the adjustment bracket to the ash box with
the M8 x 20 hex-head screws and M8 washers. Do
not tighten the screws yet.
Attach mounting bracket with round-headed
screws
Attach the mounting bracket for the handle bar
with the four M8 x 20 round-headed screws.
Attach axle and wheels
Insert the axle and slide a wheel onto it at each
end. Secure the wheels with the M8 acorn nuts.
Put cover on ash box
Place the cover on the ash box and secure it with
both latches.
Handle
Levelling
foot
Adjustment
bracket for wheel
Acorn nut
Cover
Mounting bracket
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Subject to change due to technical improvements
Attaching housing/panels Installation
Install ash box on boiler
Install the ash box on the boiler and secure it with
the side latches.
Adjust height of ash box
Use the adjustable bracket and the levelling feet to
adjust the height of the ash box.
Attach clamps for handle bar
If desired, the handle bar can be attached to the
side panel with the supplied clamps.
Attach both clamps to the side panel with the 4.2
x 16 self-tapping screws. Position them so that the
end of the handle bar is in contact with the fl oor.
Mount handle bar on ash box
Slip the handle bar into the mounting bracket on
the ash box and fi x it in place.
Now you can easily move the ash box to empty it.
Adjust height with bracket
and levelling feet
Attach clamps for handle bar
if desired
~5 cm
Page 37
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PE-K installation 35 to 90 kW
2012-02
Page 38
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Subject to change due to technical improvements
Terminal diagram
Mains protection: C13
Mains connection: 3 x 1.5²
Cable type: HO5VV-F
230 V AC devices: 1.0²
Temperature sensors: 0.5² to 1.0²
Power for direct connection
per pump output: 250 W maximum
all pumps together: 700 W maximum
Use only flexible cable with the specified
cross-sections! (otherwise no warranty for
the electronics)
Depending on the configuration, the sensor input T8 is available for "hot water tank bottom" or for the "primary return"
temperature for a fresh water module.
** configuration-dependent
Page 39
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PE-K installation 35 to 90 kW
2012-02
Terminal diagram
The network cable for remote operation via Internet is connected to the touchscreen; see page 41.
Page 40
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Subject to change due to technical improvements
Requirements Remote control
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.
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 home-
page <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).
Data transfers, downloading and fl at 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 fl at rate or a contract
with no data download limit for your Internet
connection.
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
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:
• a network cable from your modem to the touch
screen
or
• 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.:
• Mozilla Firefox
• Apple Safari
• Google Chrome
• Microsoft Internet Explorer version 9 or higher
• some default Android browsers 2.2 or higher
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).
Page 41
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PE-K installation 35 to 90 kW
2012-02
Remote control Login data, network cable
Requesting login data
You can request login data for using remote control
at <www.meinETA.at>. Each account is registered
to a person, not to the boiler.
Press the [Create account] button and enter the
required information in the corresponding fi elds.
Once you have entered all the data, press [Send].
Your details will be sent to ETA, and your personal
login data (username and password) will be sent to
the specifi ed e-mail address.
You can still change your personal data after
you have registered. It is recommended that you
change your password to a personal combination
that you will be able to remember.
Checking your Internet connection
In order to allow remote control of your boiler
via <www.meinETA.at>, the touch screen of your
boiler must be connected to the Internet.
This connection can be made via a network cable
or a wireless connection, e.g. ETA FreeLine.
Before connecting the touch screen to the network,
it is a good idea to use a laptop to check that the
Internet connection is working, To do this, plug the
cable into your laptop and test whether you can
access the Internet using this LAN connection.
Connecting the network cable to the touch screen
On PU and PC boilers, remove the upper casing.
You do not need to remove the front of the boiler
unless you are inserting the cable via the tube
running from the base of the boiler.
Plug the network cable into the port at the bottom
left-hand corner of the touch screen (under the
casing).
Port for network cable
On PE-K and HACK 20 to 130 boilers, remove
the upper boiler casing. The cable duct in the
electronics board houses the end of a patch cable
that protrudes from the door. A patch extension
cable (male/female) is required to extend this
connection.
On the HACK 200, the end of the patch cable is
located in the control box on the side of the boiler.
Controlling the touch screen in a control
extension (wall housing) by remote control?
If the control extension is connected to the boiler
via a CAN bus, a separate Internet connection is
not required.
A separate Internet connection is required if
you have an "island" control system that is not
connected to the boiler.
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Network settings Remote control
Checking the network settings
The network settings must be checked in order
to ensure that the touch screen can be controlled
remotely via <www.meinETA.at>. "Service" level
access is required to do this.
The network settings must be checked on every
touch screen that is intended for use by remote
control.
Make sure that the Internet connection network
cable is connected to the touch screen and that the
Internet connection is active.
Checking the network settings
Using "Service" level access, go to the toolbox by
pressing
.
Press the [Network Settings] button.
A screen opens:
Select [Automatic confi guration (DHCP)], then press
[Accept].
Once this option has been activated, the system
will check the network settings after it has
restarted and confi gure them automatically.
Restarting the boiler using the main switch
A message appears indicating that the changes
will not be applied until the next time the unit
is restarted.
Press [OK] and switch off the boiler at the main
switch. Wait for about 10 seconds, then switch it
back on again.
Page 43
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PE-K installation 35 to 90 kW
2012-02
Remote control Registering the touchscreen
Entering your personal login details
Enter your personal login details in the empty
fi elds. A keyboard appears when you tap each
fi eld.
t.mustermann
t.mustermann
Enter your username and press .
Use the same method to enter the remaining login
data.
Entering the boiler manufacturer number
Enter the manufacturer number of the boiler in the
fi eld marked "Boiler number". This is given on the
boiler's type plate.
After restarting change to "Service" level access
Once the boiler has been restarted, switch to
"Service" level access to register the touch screen.
Registering the touch screen
Once the network settings have been confi gured,
the touch screen must be registered in order for
it to become accessible via <www.meinETA.at>.
Each user registered at <www.meinETA.at> can be
granted access to any number of boilers. Access can
be granted by entering the user's personal login
data on the boiler.
Each touch screen for which remote control access
is required must fi rst be registered.
Using "Service" level access, press the
button
and select [System Settings].
Press .
Page 44
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Subject to change due to technical improvements
Registering the touchscreen Remote control
Once you have entered all your login data, press
to save the data.
t.mustermann t-online.at
my...
xxxx-yyyyy-zzzzz
Registering the touch screen
Once you have pressed the
button, the touch screen is registered at
<www.meinETA.at>.
The
symbol appears at the bottom
of the screen while the system is establishing an
Internet connection.
If the system is unable to establish an Internet
connection, check that the login data you have
provided is correct.
Internet connection status
After a delay of about 15 seconds, the screen
displays the current status of the Internet
connection.
Connecting
This symbol is displayed while the touch screen
is establishing an Internet connection, during
registration or after remote control has been
switched on.
Connected
The touch screen has an active Internet connection
to the homepage <www.meinETA.at>. The boiler
can be controlled remotely.
No connection possible
The touch screen is not currently connected to the
Internet. If this symbol is still being displayed after
one minute, there is a fault in the access cable,
with your Internet service provider or with the
meinETA server.
In order to locate the fault, it may help to test the
network connection by connecting a laptop to the
network instead of the boiler.
Page 45
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PE-K installation 35 to 90 kW
2012-02
Pellet store Delivery, storage room, boiler room
Delivery of pellets
The pellets are delivered with a tank truck and
blown into the storage room. The tank trucks
usually have a pump hose with a length of up
to 30 m. If you expect to need a longer pump
hose, consult your pellet supplier regarding their
technical capabilities.
Vehicle access should be at least 3 m wide and 4 m
high. The truck can only back up if the street and
gate are wide enough.
Check function before fi lling for the fi rst time!
Before fi lling 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 screw.
Only fi ll up the pellet store after this test has been
completed successfully. Noises result when the
conveyor is empty; they go away after fi lling.
Position of pellet store and boiler room
If possible, the pellet store should adjoin an
outer wall since the fi lling nozzle should be
accessible from outside.
For an interior storage room, the blower and
return air pipes should be extended to the outer
wall.
Position of boiler room
The boiler room should also adjoin an outer wall
to ensure direct supply of combustion air to the
pellet boiler. For interior boiler rooms, an air supply
channel must lead from the boiler room to the
outer wall.
Screw or suction discharge conveyor?
In general, discharge conveyors with screws are
preferable since they can completely empty the
storage room.
Screw discharge conveyors are available up to a
maximum length of 5.0 m in steps of 0.5 m.
For a discharge conveyor with suction heads,
the optimum length of the storage room is 3 m.
A greater length would result in too much
unusable storage space between the suction
heads. With a switch unit, up to 3 suction heads
can be installed.
Blower coupling
Pellet store
Boiler room
Filling hose, 30 m maximum length
Tank truck
Boiler
Return air coupling
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Subject to change due to technical improvements
Discharge conveyor with screw Pellet store
Open feeder screws with 1,000 mm,
1,500 mm and 2,000 mm, can be
combined for total length up to 5,000 mm.
Choose a screw length (open feeder) at least
100 mm shorter than the unobstructed room
length (length can be up to 600 mm shorter)
End bearing pin
(included in basic set)
Connection pin for connecting the screws
(fi rst connection pin included in basic set;
for each additional screw a pin is needed)
Flange plate with
bearing (included in
basic set)
Basic set for pellet discharge
conveyor channel
Wall sheath
Maintenance cover
Drive motor
Screw end piece
Hose connection DN50
back air from boiler
Hose connection DN50
Pellets to boiler
Wall, 300 mm
maximum
Hose connections
Maintenance cover
with fireproof wadding
Modular discharge screw system
Discharge conveyors with screws are preferable since they can completely empty the storage room.
Screw discharge conveyors are available up to a maximum length of 5.0 m in steps of 0.5 m.
ETA PE
max. 5.00 m
1.00 m
2.00 m
2.00 m
1.20 m
at least 0.36 m
0.66 m
max. 0.30 m
approx. 0.20 m
approx. 0.20 m
2
3
1
3
40°
at least 0.5 m
max. 6.50 m
0.5 m
Filling nozzle
(centred, 2 nozzles
offset in rooms
wider than 3m)
27 mm formwork panels
(smooth surface)
Wooden
beams
No transfer of forces from tilted
floor to walls with insufficient strength
Ventilation at least 200 cm²
Fireproof sleeve
Support frame
Pellet store
Panelling
Wooden
beams
Empty
space
Back air nozzle
Example for conveyor channel 2x2 m + 1x 1 m + 2x connection pin
Boiler room
Discharge screw
Impact protection
Pellet store door
T30 with wooden panelling
Longitudinal section Cross section
320 x 250 mm wall opening
Suction and back air hose, 20 m or less
sheet
Wall opening,
height 250
View against conveyor direction
25 Height adjustable +/-10
Wall opening, width 320
Page 47
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PE-K installation 35 to 90 kW
2012-02
Pellet store Discharge conveyor with suction heads
Discharge conveyor with suction heads
For discharge conveyors with suction heads, the optimum length of the storage room is 3 m. A greater
length would result in too much unusable storage space between the suction heads.
If a switch unit is used, up to 3 suction heads can be installed.
ETA PE
1.20 m
approx. 0.20 m
approx. 0.20 m
2
3
1
3
40°
at least 0.5 m
0.5 m
at least 300 mm
Filling nozzle
(centred, 2 nozzles
offset in rooms
wider than 3m)
27 mm formwork panels
(smooth surface)
Wooden beams
No transfer of forces from support
frame to walls with insufficient strength
Ventilation at least 200 cm²
Fireproof sleeve
Support frame
Maximum length of pellet store 3m for optimum emptying
Pellet store
Back air nozzle
Boiler room
Suction heads
Impact protection
Pellet store door
T30 with wooden panelling
Longitudinal section Cross section
sheet
at least 200
at least 320
at least 150
Ø 220
Dimensions for installation of the switch unit
395 mm
142 mm
268 mm
Fireproof door
Wooden boards
Z bracket
Back air nozzle
Filling nozzle
Switch unit
Mount suction
heads on a
board
0.3 m minimum
Impact
protection sheet
Flexible hoses
Support frame of
wooden beams
0.5 m
10 cm suction area
Pellet store, 3 m maximum length
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Subject to change due to technical improvements
Demands on the storage room Pellet store
Demands on the storage room
Static demands
The enclosing walls must withstand the load caused
by the weight of the pellets (bulk weight 650 kg/m³).
The plasterwork should be durable enough that it
cannot rub or fl ake off and contaminate the pellets.
If the forces from the tilted fl oor construction are
directed into the fl oor and not the wall, then the
following wall thicknesses have proven effective
in practice given proper anchoring in the enclosing
masonry:
• Concrete, 10 cm, reinforced (F90)
• Common brick, 17 cm, plastered on both sides
(F90)
• Post-and-beam walls with 12 cm beams;
separation 62.5 cm; with wooden panelling
15-20 mm on both sides
Dry storage is required for the pellets
Pellets are very hygroscopic. 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 humidity encountered in normal
residential construction throughout the year does
not harm the pellets.
• If there is a danger of moist walls from time to
time, such as in older buildings, we recommend
installing rear-ventilated wood facing on the walls
or storing the pellets in a fabric silo.
Determining the usable
storage volume
If a screw discharge conveyor is installed, the
discharge screw should be oriented along the
long axis of the storage room to achieve optimum
use of the space. For a maximum length of 5 m for
the discharge screw, the maximum accessible room
length is 6.5 m.
Due to the 40° tilted fl oor required in the store,
room widths greater than 3 m offer little or no
additional useful volume for rooms of normal height
(also applies for discharge conveyors with suction
heads).
Using a pellet store with screw discharge conveyor,
on the following pages we show the demands to
be met and how a pellet store can be adapted.
The same rules apply for a discharge conveyor with
suction heads.
Useful cross section of a pellet store in m²
40° tilted floor; 0.4 m free above; 0.13 m below for screw
Height of store in metres
2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6
Width of store in metres
2.0
2.10 2.50 2.90 3.30 3.70 4.10 4.50 4.90 5.30
2.2
2.22 2.66 3.10 3.54 3.98 4.42 4.86 5.30 5.74
2.4
2.32 2.80 3.28 3.76 4.24 4.72 5.20 5.68 6.16
2.6
2.40 2.92 3.44 3.96 4.48 5.00 5.52 6.04 6.56
2.8
2.47 3.03 3.59 4.15 4.71 5.27 5.83 6.39 6.95
3.0
2.52 3.12 3.72 4.32 4.92 5.52 6.12 6.72 7.32
3.2
3.20 3.84 4.48 5.12 5.76 6.40 7.0 4 7.6 8
3.4
3.93 4.61 5.29 5.97 6.65 7.33 8.01
3.6
4.73 5.45 6.17 6.89 7.6 1 8.33
3.8
5.60 6.36 7.12 7.88 8.64
4.0
6.52 7.32 8.12 8.92
Cross section x room length = pellet store volume
Store volume x 0.65 ton/m³ = pellet store in tons
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PE-K installation 35 to 90 kW
2012-02
Pellet store Calculating supply and store size
Calculating the pellet supply
Rule of thumb for determining the pellet supply in
tons: divide the heating load of the building by 3.
For the pellet supply in cubic metres (m³), divide
the heating load by 2.
Example for a single-family house with average
insulation and 12 kW heating load:
12 kW / 3 = 4 tons of pellets per year
12 kW / 2 = 6 m³ of pellets per year
Calculating pellet supply from
current fuel consumption
Using the current fuel consumption, you can
roughly estimate the annual pellet supply with the
conversion factors below.
Example for a single-family house with average
insulation and 12 kW heating load:
1,960 l heating oil x 2.04 = 4,000 kg of pellets
2,060 m³ natural gas x 1.94 = 4,000 kg of pellets
2,960 l LPG x 1.35 = 4,000 kg of pellets
1,560 kg LPG x 2.56 = 4,000 kg of pellets
2,660 kg coke x 1.50 = 4,000 kg of pellets
Ground source heat pump with COP 3.4
5,700 kWh of electricity
x 0.70 = 4,000 kg of pellets
Ground source heat pump with COP 2.1
9,500 kWh of electricity
x 0.42 = 4,000 kg of pellets
Heating value and density of pellets
Heating value of pellets = 4.9 kWh/kg
Density of pellets = 650 kg/m³
2 kg pellets = 1 l of extra-light heating oil
Required pellet store size
The required store size is based on the heating load.
Use the rule of thumb "heat load divided by 2" to
fi nd the minimum required store volume. For a
building with 12 kW heating load:
12 kW / 2 = 6 m³ minimum store volume
To be prepared for colder winters, the store should
hold around 20% more than a year's supply.
For this example, that means a store volume
of 7.2 m³ is needed. Using this volume, we can
determine the necessary room dimensions and the
length of the discharge screw.
Determining the length of the discharge screw /
pellet store
Using the table "Useful cross section of a pellet
store" on the previous page, we can determine
the length of the discharge screw for the amount of
pellets to be stored. That length also determines the
minimum length of the pellet store.
Example: Room width 2 m and height 2.4 m:
The table yields a usable cross section of 2.9 m².
The volume of pellets to be stored in the example
above is 7.2 m³:
=> 7.2 m³ / 2.9 m² = 2.5 m length
A discharge screw of 2.5 m length is needed.
Example: Room width 2.8 m and height 2.4 m:
The useful cross section of 3.59 m² yields a room
length or discharge screw length of:
=> 7.2 m³ / 3.59 m² = 2.0 m length
The screw should preferably be oriented along
the long axis of the room. The narrower the room,
the less space is lost under the 40° tilted fl oor. The
unobstructed room length of the pellet store
should be at least 100 mm longer than that of the
discharge screw.
The discharge screw can be as much as 0.6 m shorter
than the room without any problems. If the store is
also faced with tilted panels at the end, the screw
can even be up to 1.5 m shorter.
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Filling nozzle, earthing, electricity Pellet store
Installing the fi lling nozzles
in the short side of the pellet store
Two nozzles are installed 20 cm (mid-pipe) under
the ceiling in the shorter wall (preferably) of the
pellet store, one (centred) for blowing in the pellets
and the other (to the side) for back air. Opposite
the central nozzle, an impact protection sheet is
installed to prevent damage to both pellets and the
plasterwork on the opposite wall.
Discharge screw
Impact protection sheet
NW 100 coupling nozzle
(
Storz type A fire hose coupling
)
at least 50 cm
See detail drawing
(doors)
50 cm
Only in exceptions in the longer wall
In exceptional cases, when the shorter walls of the
pellet store are inaccessible from outside, the fi lling
nozzles can be installed in the longer wall with
one nozzle for each half of the room and an impact
protection sheet across from each. The disadvantage
is that halfway through the injection process, the
hoses must be exchanged.
Discharge screw
Two impact protection sheets
NW 100 coupling nozzle
(Storz type A fire hose coupling)
50 cm
4
1
/
/4
1
4
1
/
/4
1
Installing the fi lling nozzles
The fi lling nozzles must be fi rmly anchored in the
wall so they can withstand the movements of
the hoses from the delivery vehicle and cannot
rotate when the hoses are attached. They should
be mounted horizontally 20 cm (mid-pipe)
under the ceiling of the pellet store so that the
pellets are not blown against the ceiling. To install
the fi lling nozzles in smooth holes or sewer pipe
cut-outs so they cannot twist, the ETA fi lling nozzles
are equipped with a fl ange that transfers the forces
directly into the wall via four plug screws.
ETA fi lling nozzles with 108 mm diameter fi t exactly
in the cut-outs made for fi tting a sewer pipe with
110 mm outside diameter. The small gap between
nozzle and wall can be sealed with silicone; for
larger gaps, foam is used.
20 cm
Connect nozzle
with 6mm² to
house earth
Filling nozzles below ground level
If the fi lling nozzles are installed below ground in an
area, ensure that the hose can be led out of the area
in a straight line.
If that is not possible using the connector with 45°
bend, an additional 45° bend will be needed.
min. 60 cm
20 cm
The lever for tightening the coupling, around 30 cm
long, needs a working range of 120°. If that much
space is not available in the area, the nozzle must be
extended over the edge of the area with a straight
extension.
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PE-K installation 35 to 90 kW
2012-02
Pellet store Filling nozzle, earthing, electricity
min. 60 cm
20 cm
Earthing against electrostatic charge
Connect the fi lling nozzles to the earthing of the
house's electrical system with a 6 mm² earthing
cable.
Electrical socket for pellet supplier's blower
For the pellet supplier's suction blower, a 230V
electrical socket (C-13A fuse) in the vicinity of the
fi lling nozzle is useful.
CAUTION! Switch off the boiler before injecting
pellets
The authorities or the chimney sweep often require
that this notice be posted visibly on the fi lling
nozzle's caps. Burn-back fl aps and sliders at the
boiler's combustion chamber are open during
operation, so during boiler operation, hot gases
can be sucked into the path of the pellets (due to
underpressure in the fuel deposit) or air can be
blown through the fuel path (due to overpressure
in the fuel deposit). Both effects can cause a fi re.
Strictly speaking, the boiler should already be
switched off two hours before fi lling the pellet store,
because the burn-back fl aps and sliders do not
always close completely. So there should be no more
fi re in the boiler when fi lling pellets.
Better than a caution notice is a rotary valve
Since we at ETA don't want to leave the burn-back
protection of our boilers to chance, we equip all
ETA pellet boilers with a rotary valve so that
even during operation there is no open connection
between the combustion chamber and the pellet
store. Though it is not required that an ETA pellet
boiler be switched off while fi lling the pellet
store, you should do so anyway if the driver of the
delivery truck requests it.
Extension of the fi lling pipes
The ETA fi lling nozzles are made of steel,
108 x 3.2 mm, and can be extended with steel
pipe if needed. If the tank truck can approach close
to the fi lling nozzle so that its fi lling distance (30 m)
is not already exceeded outside the building, then
fi lling lines up to 20 m in length pose no problem.
Height differences of one fl oor, or even two for short
lines, can also be overcome without problems.
Extension with steel piping
• Only steel 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
electrostatic charges.
• The filling system must be smooth on the inside
throughout its length; do not use spiral ventilation
ducting.
• If lengths of pipe are welded, there must be no
welding seams or burrs inside; these could destroy
the pellets.
• If bends are used, their radius of curvature should
be at least five times the pipe's radius. As an
alternative, you can make 90° bends by using two
45° bends with a straight piece between them.
• The filling system should end in a bend. To ensure
that the pellets are blown out straight, a straight
length of pipe at least 50 cm long must come after
a bend.
Wooden boards
Door
Upper edge of tilted floor
Impact protection sheet
Filling nozzle
20 cm below the ceiling and
directed horizontally into the room
If possible, the
door should
be near the
filling nozzle
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Subject to change due to technical improvements
Dust-tight door, no cables/pipes Pellet store
Dust-tight, fi reproof T30 door
For pellet stores up to 6,500 kg there are no fi re
safety demands in Germany on doors or other
openings to the pellet store. Doors and other
openings must open outward and be furnished with
a circumferential dust-tight seal.
For doors or other openings to the pellet store,
wooden boards must be mounted on the inner
wall (30 mm thick with tongue and groove) so the
pellets cannot push against the door, or so that it
can be opened.
The door's lock must be sealed against dust on
the inner side. In spite of a widely circulated
construction document, the door handle on the
inner side may not be removed. In an emergency,
it must be possible to open the door from the inside.
Seal
Fireproof door
T30 80/200 or 70/80
No cables/pipes in the pellet store
In the pellet store, there should be no water pipes
or electrical cables. Water from a broken pipe would
cause the pellets to swell up. Uninsulated electrical
parts could ignite a dust explosion.
Shield cables/pipes that can't be removed,
insulate cold water pipes to prevent condensation
Existing cold water pipes that can only be removed
with unreasonable effort must be insulated against
condensation to ensure that the pellets cannot be
damaged by dripping condensation.
Pipes and cables in the path of pellets being
injected, especially those on the ceiling, must be
shielded. Ensure that the pellets are gently defl ected
by a protective plate.
Flight path
of pellets
Protective plate
Piping/cabling
to be protected
Flight path
of pellets
Protective plate
Piping/cabling
to be protected
Only explosion-proof electrical installations
No electrical equipment such as switches, lights,
junction boxes, etc. may be present in the pellet
store.
Unavoidable installations must be airtight and
moisture-proof to protect against explosions, and
in the fl ight path of pellets they must be protected
against damage. Existing junction boxes that cannot
be moved should at least be fi lled in with foam to
seal all exposed live parts.
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PE-K installation 35 to 90 kW
2012-02
Pellet store Tilted floor
Small stores with reserve
For small pellet stores, the tilted fl oor can be
truncated. A reserve of pellets will remain on the
resulting fl at surfaces; when the main store is
empty, the reserve pellets can be swept into the
main store manually.
This disadvantage of
this method is that the
reserve space must be
cleared at least every
3 years so that dust and
broken or moist pellets
cannot gather.
Tilted fl oor
The pellet store must have a fl oor with 40° tilt to
ensure that all pellets in the store can be used. This
applies for both discharge screws and suction
heads.
Construction of tilted fl oor for pellet store
For the tilted fl oor, three-ply concrete formwork
panels 27 mm thick have proven effective. Unplaned
wooden boards 25 mm thick with a smooth plasticlaminated surface can also be used.
The tilted fl oor should be fl ush with the
enclosing walls so that no pellets can fall into the
empty space. However, the support frame itself
may not lean against the walls since they may not
have the strength to resist the forces involved.
The tilted fl oor must withstand the weight of the
pellets (bulk weight 650 kg/m³). Assuming the usual
commercially available formwork panels with a
width of 100 cm, members of the support frame
should have a separation of 50 or 100 cm. For these
separations, the adjacent tables show the required
beam thicknesses depending on the room width.
Mount suction heads on a board
If the suction heads sit directly on a cold concrete
fl oor, water from the circulating air can condense on
the cold suction head. The condensation can cause
pellets and, in particular, pellet dust to form clumps
that can clog the pneumatic conveyor. To avoid this,
always mount the suction heads on an insulated
board (25/27 mm thick like the panelling).
Use padding when installing the screw channel in
the wall opening (structure-borne noise)
Sound from the screw can be transmitted through
the pellet store walls into the house. To avoid that,
encase the screw channel with soft material
(mineral wool) in the wall opening.
Under no circumstances should the screw channel
be cemented into a concrete wall without acoustic
insulation.
Beams for support frame. beam separation 50 cm
for room height of 2.5 m
Cross section in cm Separation in m Room width in m
8 x 4 1.50 2.25
10 x 5 2.20 3.30
12 x 6 3.00 4.50
10 x 10 3.40 5.10
Beams for support frame, beam separation 100 cm
for room height of 2.5 m
Cross section in cm Separation in m Room width in m
10 x 5 1.50 2.25
12 x 6 2.00 3.00
10 x 10 2.20 3.30
15 x 5 2.35 3.50
approx. 0.2m
2
3
1
3
40°
at least 0.5 m
Support frame
Back air nozzle
320 x 250 mm wall opening
Filling nozzle
(centred, 2 nozzles
offset in rooms
wider than 3m)
27 mm formwork panels
(smooth surface)
Wooden beams
No transfer of forces from support frame
to walls with insufficient strength
Separation
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Checklist
Boiler installation
Minimum wall clearances maintained (space for maintenance)
Safety valve without shut-off on boiler outlet
Expansion tank with gross capacity 10% of system volume installed directly in boiler return, for buffer systems in return between boiler
and buffer
Air valve directly at boiler outlet and at highest point in system
Without buffer, sufficiently large heat exchanger in the tank (0.8 m² for 10 kW, 1.5 m² up to 25 kW, 2.5 m² up to 50 kW, 4 m² up to 90 kW)
Return temperature raising facility with pump or mixing valve dimensioned for minimum return temperature 60°C
Safety heat exchanger with thermally actuated drain valve on water inlet and visible drain to sewer
Filling and drain valve for each area that can be shut off individually
Pressure gauge
Boiler set up on sound insulation mat if output greater than 30 kW and positioned near living quarters
Emergency stop switch always required in Austria, can be required by authorities in Germany above 50 kW
Buffer storage tank if present
For parallel connected buffers with 5/4" connections (values for 6/4" in parentheses): one-sided connection possible for two buffers up
to 25 (40) kW, Tichelmann connection for two buffers up to 80 (130) kW, over 80 (130) kW external piping symmetrical or Tichelmann,
external Tichelmann connection for more than two buffers in any case
Softened water for initial fill-up: 20,000 lt°dH for system volume (in litres) multiplied by the hardness (in degrees of German hardness)
may not be exceeded.
Air valve on top of buffer storage tank
Safety valve for buffers with solar charging
Shut-off valves on all buffer connections (minimises drain volume - minimum lime content)
Buffer sensors set so that the required supply volume is ensured for hot water or peak loads.
Return temperature from system low enough to achieve the required storage capacity. Check radiator systems in particular to ensure that
sufficiently adjustable radiator valves are installed. Throttle air heat exchangers to the amount of water actually needed
Chimney
Chimney cross-section not too large
Multi-layered, insulated, moisture-resistant chimney or chimney renovation with inserted pipe
Condensate drainage with siphon from chimney to sewer
Connection pipe from boiler to chimney, short with few bends, thermally insulated, ascending
Flue pipe inserted into chimney sleeve with padded seal (structure-borne noise)
Accessible cleaning apertures in chimney and flue pipe bends
For boiler output 70 kW or more, a deflagration damper (blowback flap) is required in the connection pipe between the boiler and the
chimney or in the chimney within the boiler room
Draught limiter for chimneys higher than 12 m above boiler room floor, set to 5 to 10 Pa
Air inlet and outlet
Sufficient air inlets/outlets in Austria (ÖN H 5170): Air supply 2 cm² per kW of fuel thermal input, at least 200 cm² free cross-section, for
up to 100 kW rated heat output, outlet at least 180 cm² free cross-section and for every additional kW another 1 cm², for wire screens
at least 20% extra, for air flow through ducts longer than 1 m larger cross-sections and documented calculations by an expert
Sufficient ventilation in Germany (MFeuVO): up to 35 kW, door/window to the outside and room volume of 4 m³/kW, 35 to 50 kW at
least 150 cm² free ventilation cross-section, over 50 kW at least 150 cm² free ventilation cross-section + 2 cm² per kW over 50 kW, for
wire screens at least 20% extra, for air flow through ducts considerably larger cross-sections (50 to 150% larger -> calculate)
Pellet store if present
There may be no electric lamps, switches, sockets, junction boxes, etc. in the pellet store (danger of dust explosion); if unavoidable,
then only using explosion-proof designs
Piping that cannot be removed must be covered by deflector sheets slanted away from the incoming pellets
Filling nozzles easily accessible for pellet supplier and firmly installed in the masonry
Filling and back air nozzles are earthed
Filling nozzle is installed 20 cm beneath the ceiling (centre of pipe) and directed horizontally into the room (not towards the ceiling)
Impact deflection sheet across from the filling nozzle
Tilted floor has a smooth surface
Doors and other openings into storeroom sealed all around. Keyhole sealed on the inside
Wooden boards installed on inner side of door
Entire storeroom dust-tight
Padded screw installation in wall opening (structure-borne noise)
Floor and walls of storeroom are dry
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PE-K installation 35 to 90 kW
2012-02
Commissioning Dismantling, disposal
Dismantling
Dismantling is done in the reverse order of
assembly.
Disposal
Disposal including all components must be done in
an environmentally friendly manner according to
waste disposal laws. Recyclable materials must be
cleaned and separated before recycling.
Commissioning
Before commissioning the boiler, ensure that the
entire heating system has been filled with enough
water and has been purged of air.
The control system must be configured for the
actual system. See the separate document "Control
parameters".
Commissioning must be performed by the heating
technician or another specialist.
Proper installation of all components and correct
configuration and function of all control and safety
mechanisms must be verified.
We recommend giving the operator a certification
to this effect. In addition, the heating technician must explain to the operator in detail the
operation and maintenance of the boiler system
including all peripheral equipment, especially the
function of the safety-related equipment and the
measures needed for continued safe operation.
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PE-K installation 35 to 90 kW
2012-02
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PE-K installation 35 to 90 kW
2012-02
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Subject to change due to technical improvements
Safety instructions
PE-K_Montage_Touch_2012-02_EN, subject to technical alterations
Prevent moisture from damaging pellets!
Danger! Moving parts may cause injuries!
Open door to pellet store, filling and
venting nozzles for minimum 60 minutes
ventilation prior to entering storeage area!
Ensure that the ETA pellet boiler is in
automatic mode while store is being filled!
Switch main power supply to OFF
before entering the pellet storage area!
Smoking, naked flame or any other
ignition sources are prohibited!
No entry for unauthorized personnel!
Area unsafe for children!
www.eta.co.at
Wood Pellets - Storage Room
Only enter the pellet storeage area while in
the presence of a second person!
The second person should remain outside
the storage area in case of help is needed!
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