Metal-Fach GHT Installation guide

GHT
Operation and maintenance documentation
Transtlation of the original manual
Issue I 05/05/2020 ENGLISH

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MANUFACTURER'S OPERATIONAL NOTES
●METAL-FACH Technika Grzewcza shall not be liable for damage resulting from the use of
fuel other than the one recommended by the manufacturer (such as: sawdust, eco-pea
and other carbon derivatives, organic and inorganic waste (rubbish), wood chips or sawmill
chips with parameters exceeding the fraction recommended by the manufacturer
described in point 1.4 of this manual).
●The GHT boiler is not maintenance-free and, like any other appliance, is powered
by electricity and operates at high temperatures, which requires supervision and
necessary maintenance during its lifetime.
●The manufacturer is not responsible for any damage resulting from improper
connection, installation and use of the device.
●It is forbidden to touch and disassemble the plate on the side of the boiler (Drawing 4 item
no.8 and on the picture 6). Contact with the element heated up as a result of operation
may cause burns.
●As a result of boiler operation, condensation may occur on its walls, which is a natural
physical process.
●Excessive amount of water accumulating in the vicinity of the boiler may be a sign of
leakage of the installation or the operation of the extinguishing system (Fireman). The user
should immediately report the situation to an authorized service.
●This original User Manual is intended for users of GHT boilers of 22 and 40 kW.

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CONTENTS:
1. Introduction ...........................................................................................................................3
1.1. Markings ...........................................................................................................................3
1.1.1. General information....................................................................................................4
1.1.2 certificates and certificates ..........................................................................................4
1.1.3. Conditions for safe operation of boilers.......................................................................5
1.1.4. Legal conditions of manufacturer's liability..................................................................7
1.2. General characteristics of the boiler..................................................................................8
1.3. Delivery and assembly specifications................................................................................8
1.4. Fuel...................................................................................................................................8
1.4.1. Basic information on combustion of wood-based fuel.....................................................9
1.4.2. Basic information on burning wood chips ....................................................................10
1.4.3. Basic information on the combustion of wood pellets ..................................................11
1.4.4. Minimum exhaust gas requirements ............................................................................12
2. The purpose of the boiler....................................................................................................13
3. Construction and technical data of the boiler ...................................................................14
4. Installation of the boiler ......................................................................................................17
4.1 general requirements .......................................................................................................17
4.2. Boiler transport................................................................................................................18
4.3. Installation of the boiler in the boiler room.......................................................................19
4.4. Boiler connection to the chimney.....................................................................................20
5. Instructions for connecting the boiler to central heating systems..................................20
5.1 installation of the boiler in an open system.......................................................................21
5.2 installation of the boiler in a closed system.......................................................................21
6. Operation and use of the boiler..........................................................................................23
6.1 basics of boiler operation .................................................................................................23
6.2 filling with water................................................................................................................24
6.3 firing-up and correct operation of the boiler......................................................................24
6.4 refuelling ..........................................................................................................................24
6.5 maintenance and cleaning of the boiler............................................................................24
6.5.1. Longer boiler downtime ............................................................................................24
6.5.2. Service activities performed by the user ...................................................................25
6.5.3. Maintenance activities performed by the service.......................................................25
6.6 emergency stopping of the boiler .....................................................................................25
6.7. Shutting down the boiler from operation..........................................................................25
7. Identification of disturbances in the correct operation of the boiler ...............................26
8. Spare parts...........................................................................................................................28
8.1 list of main spare parts.....................................................................................................28
8.2 list of spare parts for natural wear and tear ......................................................................28
9. Disposal ...............................................................................................................................28
10. The photo index.................................................................................................................29
Attachments:
BOILER INSTALLATION CONFIRMATION...............................................................................31
DECLARATION OF CONFORMITY ..........................................................................................34
WARRANTY CARD ..................................................................................................................36
PERIODIC REVIEW TABLE......................................................................................................39
WARRANTY REPAIRS .............................................................................................................40
Thank you for choosing METAL-FACH Heating Technology GHT boiler.

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1.INTRODUCTION
1.1. Markings
Please take the time to read this manual. This will enable you to get to know the boiler better and
to understand its operation. Adaptation to the requirements, recommendations and advice
contained herein will allow you to operate your boiler for a long, trouble-free and, above all, safe.
The device shall be unambiguously and declaratively marked on name plates permanently affixed
in a visible position.
In the description of the user manual, additional markings are used, which should be read as:
Important information related to the safety of boiler operation and use.
Information relevant to the operation as recommended by the manufacturer.
The manufacturer of the boiler is a company:
METAL-FACH Heating Technology
Jacek Kucharewicz
Information and pictograms
The following information pictograms have been used to mark dangerous places on the device.
These operating instructions are an integral part of the device and serve to guarantee its correct
and safe operation. It contains safety instructions which must be observed for transportation,
storage, installation, technical acceptance, operation and maintenance of the boiler.
No part of this document or parts thereof may be copied or transmitted to a third party
without the express permission of the manufacturer. The device is protected by a patent
issued by the Patent Office of the Republic of Poland No. 227736 for the invention entitled
Piston Feeder of central heating boiler. All activities related to the attempt to copy the
device will constitute the basis for initiating court proceedings.

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1.1.1 General information.
The correct and safe operation, long service life and high operating values of the boilers
are guaranteedby observing the information contained in this manual concerning the construction,
installation and use of the boiler.
Before putting the boiler into operation, you must
●check the boiler and its completeness of equipment in accordance with the included
delivery note
●read this boiler manual carefully.
INCORRECT OPERATION OF THE BOILER RESULTING FROM IMPROPER
OPERATION IS NOT SUBJECT TO COMPLAINT.
In particular:
●Incorrect connection of the boiler, not according to the documentation,
●Using the wrong fuel (type, fraction, calorific value),
●Boiler protection not compliant with PN-91/B-02413 standard,
●Failure to comply with the guidelines for chimney and ventilation installation of
the boiler room,
●The use of chimneys which do not comply with building standards,
●Failure to perform basic periodic cleaning and maintenance of the boiler,
●Mechanical damage.
Following the recommendations and advice given in this manual will ensure long-term
and trouble-free operation of the boiler.
We wish you full satisfaction from the operation of the boiler.
1.1.2 Certificates.
The boilers were subjected to a conformity assessment procedure and tests were carried out in
accordance with the applicable Polish and EU regulations.
THE BOILERS MEET THE REQUIREMENTS OF EU DIRECTIVES ON PRODUCT SAFETY
CONFIRMED BY THE DECLARATION OF CONFORMITY AND ARE MARKED WITH "CE"
MARK
Biomass boilers manufactured by METAL-FACH Technika Grzewcza are characterized by high
thermal efficiency (average efficiency ≥88.4%) and emission factors in accordance with PN-EN
303-5:2012 standard, and are in accordance with the EU Commission Regulation No 2015/1189
of 28 April 2015, the so-called Ecodesign, according to the marking on the nameplate placed on
the casing of each boiler.

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Federal Emissions Protection Ordinance in Germany (1. BImSchV).
Germany has a Pollution Emission Control Regulation (1. BImSchV) which regulates the following
for small and medium-sized biomass firing installations which do not require a permit:
▪Conditions for installation and operation of small and medium-sized biomass firing
systems.
▪Determination of emission limits for small and medium-sized installations
▪Frequency and scope of installation supervision required to protect the atmosphere from
the emission of pollutants.
Amendment of Regulation 1. BImSchV - tightening of emission limits
As of 22 March 2010, the amendment to the 1st BImSchV Regulation entered into force,
containing the following important new points:
▪Regulation of emission limits for solid-fuel
boilers with a rated thermal input of 4 to
1000 kW
▪Confirmation of the required emission limits
as part of repeated on-site measurements
by the chimney sweep when starting up
new installations (repeated
check every 2 years)
▪Tightening of the dust emission limit values
- 20 mg/m³ and CO - 400 mg/m³ in 1st
degree BImSchV regulation 2.
▪After the transition period, the emission
limits also apply to old installations.
▪Design of heating water buffer heaters for
manually loaded installations: Minimum 12
l for every litre
fuel input chamber capacity or 55 l/kW rated
thermal output of the boiler
▪Design of heating water buffer heaters for
installations with automatic loading: Min.
20 l/kW of rated heating output of the boiler
Emission limit values for dust and carbon monoxide (CO) according to 1. BImSchV regulation grade
2 (§ 5)
Note: Emission limit values for repeated on-site measurements (related to 13% oxygen)
Depending on the fuel used, e.g. wood pellets, wood chips and fuel quality (according to EN ISO 17225),
additional emission control measures such as a fine dust filter (e.g. electrostatic filter) or third order
measures in the form of the participation of a METAL-FACH Heating Technician in measurement and
service work may be necessary to meet the BImSchV requirements. Please contact METAL-FACH
Technika heater for this.

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1.1.3 Conditions for safe operation of boilers
The basic condition for safe operation of the boilers is to make the installation in
accordance with PN-91/B-02413. Furthermore, the following rules must be observed:
1. It is forbidden to operate the boiler if the water level in the system falls below the level
specified in the boiler room operation manual.
2. Use gloves, safety glasses and a headgear to operate the boilers.
3. When opening the door, do not stand in front of the exposed hole, but on the side. While
the fan is running, do not open the feeder's charging door and check the correct setting of
the inspection flap (Fig. 2 and 3)!
4. Maintain order in the boiler room, where there should be no objects unrelated to boiler
service.
5. When working on the boiler, use lighting with power supply not exceeding 24V.
6. Take care of good technical condition of the boiler and related c. o. installation, in particular
the tightness of the fire door and the ashtray door.
7. Any faults in the boiler must be rectified immediately.
8. In winter, do not use heating interruptions that could cause water in the system or parts of
it to freeze, which is particularly dangerous, as firing up in the boiler when the c. o. system
is not expensive can lead to very serious damage.
9. The filling of the installation and its start-up in winter must be carried out carefully. Filling
of the system during this period must be carried out with hot water so that the water in the
system does not freeze during filling.
CAUTION!
If there is any suspicion of the possibility of water freezing in the c. o. installation, and in
particular in the boiler safety system, check the patency of the system. In the case of lack
of patency it is forbidden to start up the boiler!
10. It is not allowed to light up in the boiler using such means as petrol, kerosene and other
flammable and explosive agents.
11. It is forbidden to allow cold water into a hot boiler.
12. It is forbidden to flood the fireplace with water, unless it is a result of the fire system
(Firefighter).
13. The electrical installation may be operated by an authorised electrician.
Residual risk
Although METAL-FACH Technika Grzewcza takes responsibility for the design and construction
in order to eliminate the danger, some risk elements during the operation of the boiler are
unavoidable. The residual risk results from incorrect behaviour of the operator. The greatest
danger occurs when performing the following prohibited activities:
•allowing an untrained person to work on the device,
•opening and removing covers when the engine is in motion,
•operation without drive guard or with a defective guard,
•reaching into the interior of the device during operation, and especially into the fuel tank,
•operation within the drive unit and moving parts of the device or operation without covers
when the device is connected to the power supply,
•Checking the drive gears during operation (Fig. 11).

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When presenting the residual risk, the boiler is considered to be a machine that has been
designed and manufactured according to the state of the art and in accordance with the
product documentation approved by the manufacturer until production starts.
Residual risk assessment
When following recommendations such as:
•Carefully read and follow the instructions in the manual - accidents and misuse are
prevented,
•Only trained persons who are familiar with the operation of the device are allowed to work
- elimination of the risk of misbehaviour by the operator,
•No putting your hands in prohibited areas - no danger of crushing or being caught,
•Only persons who have been adequately trained to inspect and repair the unit, only when
the power supply is disconnected and when all moving parts of the unit are stationary -
eliminating the risk of electric shock,
•During repairs and inspections, use gloves, shoes and protective clothing - eliminating the
risk of injury,
•to prevent children from entering the feeder's workplace,
the residual risk can be eliminated when using the device without endangering people and
the environment.
NOTE!
There is a residual risk in case of non-compliance with the specified
recommendations and instructions.
We recommend it:
•All persons must have access to the operating instructions and must be familiar with them
and comply with their instructions before starting to operate the device.
•The operating instructions must always be complete to ensure that they are legible.
•In the case of damage to the instructions, ask the manufacturer immediately for a new
copy.
•The instructions may not include the customer-specific parts of the device.
•Additional information or documentation will be included in the unit documentation upon
delivery.
•All information in the manual should be clear and understandable. If you have any
questions, please contact your dealer or manufacturer.
1.1.4 Legal conditions of manufacturer's liability.
The Company is not responsible for any damage or disruption that may occur as a result:
●errors in boiler operation,
●failure to comply with the recommendations described in this manual,
●make any changes to the boiler design yourself,
●improper use of the boiler, changed operating conditions,
●incorrect use of thefuel or its change to other than that recommended by themanufactur-
er, ●The warranty does not cover cases for which there is no warranty liability.
●A fire and other randomevents, including loss of property as aresult, arerandom situations
for which the boiler manufacturer is not responsible, in particular where the product was
not the source of the event.

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Changing the fuel to one other than the one recommended by the manufacturer is
not allowed and the responsibility for such action lies solely with the User. The
consequences of incorrect operation of the boiler resulting from the above do not
constitute grounds for considering the incorrect operation of the boiler as a
physical defect of the product.
1.2 General characteristics of the boiler
Water boilers are a steel construction adapted for highly efficient combustion of sawmill
chips, the boilers are equipped with a combustion chamber where a burner with automatic ignition
is placed (the igniter may be optional in some versions of the device), a high-performance heat
exchanger, electronic controller and fuel tank.
The combustion process in the boiler is controlled by a microprocessor controller, which allows
the boiler to operate with a constant, preset temperature of the heating medium max. up to 90 oC
by feeding an appropriate amount of fuel to the burner part.
The controller is equipped with an additional temperature limiter, which causes complete stopping
of the combustion process in case the temperature of water leaving the boiler increases to 95 oC.
BIOMASS BOILERS ARE LOW-TEMPERATURE WATER BOILERS AND ARE NOT
SUBJECT TO REGISTRATION BY THE TECHNICAL SUPERVISION AUTHORITY.
1.3 Delivery and assembly specifications.
The central heating boiler is delivered in an assembled condition, i.e. including thermal insulation,
doors, connection spigots, clean hatch covers and control unit, feeder and fuel tank.
Installation of the boiler unit in a household-level boiler room is recommended under the
supervision of an authorised installer. The installation should be collected by an authorised
technical service or an authorised employee of an authorised service centre.
Installation in accordance with the manufacturer's recommendations is required in the
process of granting the warranty for the boiler unit. The connection of the boiler unit to
the chimney system should be made using a RCW-S type chimney draught regulator,
e.g. from DARCO (fig. 19 , p. 31), under supervision or checked by the appropriate
technical service (chimney sweep).
The user should ensure the correct operation of the boiler:
●Correct flue gas discharge by verifying the cleanliness and technical condition of the
chimney and, if necessary, installing additional devices improving the air throughput in the
chimney (fixed heads, rotating heads, self-adjusting sockets) at the chimney outlet.
●Uninterrupted access to the tap water system used in the boiler fire protection system
(Fireman).
●Correct ventilation in the room where the boiler is installed.
1.4 Fuel
The basic fuel recommended by the manufacturer is wood chips (photos 18 and 19) type B1 or
pellets type C with parameters:
fraction (chipset size) from 3.15-40 mm, deciduous and coniferous trees (for detailed
recommendations see table of fraction description according to EN ISO 17225-4 for
chipset type P31S, pt. 1.4.2)
maximum contaminants (ashes) ≤ 1.5%,
humidity 10-30%,
minimum energy efficiency (calorific value) 15 MJ/kg, recommended ≤ 17 MJ/kg.

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Altereco B1 type wood chips are delivered to the customer in plastic bags weighing
about 14 kg and transported on pallets (fig. 15), the packaging method protects them
from excessive moisture, but does not release them from storage under a roof, in order
to avoid the direct impact of adverse weather conditions that may reduce fuel quality.
1.4.1 Basic information on the combustion of wood-based fuel to produce heat.
General information.
Calorific value of wood-based biomass depending on water content
The energy efficiency of wood is determined by its calorific value (Hu). The calorific value is
the energy obtained by burning one kilogram of wet wood. The water contained in the flue gas
is transformed into steam. The calorific value (Ho) additionally contains the condensation heat
of the water vapour that is generated by cooling down to the initial temperature. The amount
of water contained in the fuel batch is the basic amount that affects the combustion. It
determines the energy efficiency and thus the potential energy yield during combustion. The
calorific value of wood-based fuels ranges in practice from 5.0 kWh/kg (18MJ/kg) with a water
content of 5% to 1.5 kWh/kg (5.4 MJ/kg) with a water content of 60%. This value depends on
the species of wood and to a large extent on the water content or moisture content of the
wood. The water content has a decisive influence on theregulation of partial load and emission
properties of the installation.
Determination of water content
The water content shall be determinedon the basis of the drying process inthe dryer, on which
the CEN standard is also based. A fuel test is carried out using damp wood, the material is
dried for several hours in a cupboard dryer at a temperature of about 105°C and then analysed
again. The amount of water in the fuel is given as water content (w).
Range of application of the fuel depending on water content
The boiler can burn wood-based biomass with a water content of 5 to 30%.
Table of calorific values of different types of wood.

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Relationship between water content and fuel humidity
The amount of water in fuels is given as eitherwater content orfuel humidity. The water content
(in %) refers to the moisture content of the fuel or the fresh matter (LSD) and the moisture
content of the fuel to the completely dry matter (SS).
Example:
If 100 kg of fuel contains 50 kg of water, the water content is 50% (w50) and the fuel humidity
is 100% (u=100).
Determination of fuel requirements
From the calorific value and the required rated thermal output you can calculate the fuel
requirement. Important factors influencing this parameter are the water content of the fuel and
the efficiency of the installation.
1.4.2 Basic information on the combustion of wood chips to produce heat.
What's woodchips?
The raw material for wood chips comes from 100 percent natural forest and plantation wood.
This raw material has theform of trunks or branches. The chips are produced using fast cutting
tools as defined in EN ISO 17225-4.

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Definition of size classes of wood chips according to EN ISO 17225-4
(a) The number in the size class refers to the maximum particle size in the main fraction. The particles must fit into a round mesh
sieve (ISO 17827-1) of the size determined for that class in mm. The lowest possible property class must be given.
(b) The length and area of the section should be determined only for particles in the coarse fraction. In a sample of about 10 l, a
maximum of 2 pieces may exceed the maximum length if the cross-sectional area is < 0,5 cm2.
(c) For measuring the cross-sectional area, it is recommended to use a transparent ekier with a protractor, position the particles
vertically behind and estimate the maximum cross-sectional area of these particles using the cm2 graduation.
Requirements for wood chips
For combustion in the GHT boiler, use wood chips with a maximum thickness of ≤ 6% (> 45
mm), 4 cm2 section and a maximum length of 15 cm (P31S). The water content of wood chips
can be max. 30% (M30).
Bulk density of wood chips depending on water content according to EN ISO 17225-4
Quality characteristics of wood chips
Good quality wood chips:
■ low, homogeneous water content, without
moisture or mould clusters
■ small proportion of needles, leaves, small
twigs and bark
■ small proportion of the wood fineness (very
few particles < 3 mm)
■ no contamination with earth or other
substances or bodies
strangers
■ uniformly shaped particles (no particles too
long)
■ Smoothly cut, unframed edges
Poor quality wood chips:
■ Frayed surface or edges
■ high proportion of needles, leaves, small twigs
and bark
■ contamination with soil or other foreign
substances and bodies
■ different particle sizes
■ high proportion of fine fraction and water
content
Basic information on burning wood pellets to
produce heat
1.4.3 Basic information on the combustion of wood pellets to produce heat.
What is a wood pellet?
The raw material for the production of wood pellets comes 100 percent from natural wood
waste. This material occurs in large quantities as waste from the woodworking industry in the
form of shavings and sawdust. This waste is compacted under high pressure and granulated,

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i.e. pressed into a cylindrical shape. The raw material is stored and transported in perfectly dry
conditions. The plant operator must also store the pellets in a perfectly dry place. This is the
only way to guarantee correct and efficient combustion.
Requirements for wood pellets
For combustion in the GHT boiler, wood pellets with a diameter of 6 mm and a length of 3.15
to 40 mm should be used. 1% of the wood pellet can be longer than 40 mm, but not longer than
45 mm. The residual moisture content maybe up to 10%.Wood pellets intended for combustion
in the GHT boiler must meet the requirements of EN ISO 17225-2.
Quality characteristics of wood pellets
Good quality wood pellets:
■ smooth, glossy surface
■ even length
■ low dust content
■ in the water it falls to the bottom
Poor quality wood pellets:
■ cracked, rough surface
■ large length differences
■ high dust content
■ floats
1.4.4 Minimum fuel requirements.
Ingredients
When buying wood for combustion, choose wood that does not contain other elements (e.g.
stones, metal parts, mortar residues, plastics, etc.). They change the composition of the material
to be burned and thus the basic parameters of the combustion process. For all types of fuels, the
rule is that they must not contain foreign bodies such as metal parts, stones, fragments of masonry
or plastics.
Do not exceed the following limits (per kg of dry fuel) for non-flammable components (ash when
analysed at 815°C).
The consequence of exceeding the above limits is a shortened service life of the combustion
chamber and solid fuel boiler. As a result, the workload associated with maintaining the unit in
good technical condition increases and the intervals between maintenance intervals are
shortened.

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Biomass fuels, not containing wood
Non-timber biomass fuels such as needles, leaves, grain, hay, husks, moist seeds, etc., are
usually not suitable for use as fuel, do not ensure trouble-free operation and are therefore not
allowed. The properties of this fuel (chemical composition, ash softening temperature, etc.) are
very differentfrom thoseof wood. Burning it in asolid fuel boiler can causethe combustionprocess
to deteriorate and heavily burden the chamotte and heat exchanger surfaces. Therefore, warranty
claims can only be asserted if authorised fuels are used.
NOTE!
METAL-FACH Technika Grzewcza shall not be liable for damage caused by the
use of fuel other than that recommended by the manufacturer, or for a decrease
in the thermal efficiency of the boiler as a result of using the wrong fuel, thus it
does not constitute grounds for a complaint and a finding that the goods do not
comply with the contract.
2. the purpose of the boiler
Water boilers are designed for preparation of hot water in central heating systems to the
temperature at the boiler outlet not exceeding 95 oC. They can be used in central heating and
domestic hot water systems, both gravitational and forced circulation, so called pumping.
They are designed for heating residential buildings, public buildings such as: offices, commercial
pavilions and schools, production facilities and others.
THE BOILER CAN ONLY BE INSTALLED IN AN OPEN SYSTEM ACCORDING TO
STANDARD-91/B-02413 HEATING AND HEATING SYSTEM. PROTECTION OF
OPEN SYSTEM WATER HEATING INSTALLATION.
Simple construction, high thermal efficiency of the boilers and the possibility of using cheap
biomass fuel (chips) definitely distinguishes our boilers as an alternative to oil and gas boilers,
due to low operating costs.
Advantages of the GHT boiler
●Easy operation, cleaning and maintenance of the boiler due to the use of
opening hatches at the front of the boiler.
●The use of a feeder enables smooth regulation and operation of the boiler
depending on the external temperature.
●Large fuel tank capacity ensures long-term operation of the boiler
●Ash removal is done every few days.

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3. construction and technical data of the boiler
Boilers of GHT series are welded steel sheet structures. Fuel combustion takes place in
the combustion chamber . Above the chamber there are ceramic catalysts (picture 14), whose
task is to afterburning the gases and other volatile compounds that escape during combustion,
reducing their emission outside (they help in more accurate afterburning of fuel).
The fuel needed for
combustion is supplied from a tank
located in the boiler casing using a
feeder. The amount of fuel fed and
the feeding frequency are
regulated by the controller settings
(fig. 4).
The air needed for combustion in
the combustion chamber is
supplied through a blower which is
mounted to the combustion
chamber. The amount of air is
regulated by the controller settings.
The boiler is equipped with an
extinguishing system (firefighter)
powered from the home water
system. It is used for emergency
extinguishing of the firebox. Under
the combustion chamber there is
an ashtray. Periodic cleaning of
the boiler exhaust system takes
place through the inspection
openings placed on the chimney
outlet (Drawing 4 element no. 7, picture 8) of the boiler, through the cleanings marked on
Drawing 4 element no. 6.
In the front part of the top panel there is an electronic controller, while in the rear part there is a
control unit enclosed in a housing in which fuses are mounted (picture 5). In order to reduce
heat loss, the exchanger is protected by mineral insulation. The external casing of the boiler is
made of powder-coated steel sheet.
Drawing 2. location and method of boiler connection in the
domestic c. o. installation.
A- the compensatory tank,
B- ball check valve,
C- the C.O. pump.
D- heater,
E- four-way valve,
F- check valve,
G- C.W.U. heater.
H- kettledrum
Methods of connecting the boiler in a central heating installation are available on the website of
METAL-FACH Technika Grzewcza. The selection of the installation method depends on the heat
Fig. 1.
1
2
3
4
1
2
3
4
5
5
6
6
7
7
5
6
7

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demand calculations made by the installer or another person with building permits at
the boiler installation site.
Drawing 3. basic overall dimensions of the GHT 22 kW boiler - front view.
Valve Internal valve
security water supply for central heating.
Fig. 4. Basic overall dimensions of the boiler - side - rear view.
1. fuel tank
filling flap
External hot water
supply valve
Safety valve
2. the controller
control panel
3. cleaning
door
4. the firebox
door
5. ashtray door
Internal water refill
Internal water return
valve c. o.
6. chimney
sweepings
7 The flue pipe
is additionally
terminated with a
circular orifice of
160 mm diameter
8. burner input
(for left-hand
feeder
mounting)
9. optional
water tank for
the 'firefighter'
system

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Drawing 5. Detailed dimensions of the 22 kW Drawing 6 Detailed boiler dimensions 40 kW
Drawing 7. Electrical diagram of the GHT 22 kW boiler.
Drawing 8. electrical diagram of GHT 40 kW boiler.

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Attention!
The manufacturer reserves the right to make structural changes to the boiler,
related to technical progress, its constant modernisation and improvement. These
changes must not affect the energy and emission parameters of the boiler and must
comply with certification tests.
4. installation of the boiler
4.1 General requirements.
●The boiler should beconnected to the heating system in accordance with the requirements
included in this manual and the boiler house heating system design,
●The boiler room in which the boiler will be installed must comply with the requirements of
the PN-87/B-02411 standard for ventilation and flue gas discharge,
●Water for supplying boilers and heating installations must be free of mechanical impurities
and should be characterised by parameters in accordance with the PN-85/C-04601
standard. In the case of new installations, the first water is the so-called raw water and the
remaining water is complementary. Both raw and supplementary water should have a
hardness not exceeding =< 4°n.
TECHNICAL AND OPERATIONAL DATA OF THE BOILER
Table 1. GHT 22kW
Nominal heat output
kW
22
Water capacity
dm2
100
Fuel consumption at maximum power
kg/h
5,3
Boiler weight
kg
630
Maximum operating temperature
0C
95
Chimney draught
Pa
10-17
Approximate chimney height
m
8
Stack section
mm
160x250
Working pressure
MPa
0,1
Storage capacity
dm3
360 (6 bags)
Thermal efficiency
%
88,4
Area of the room to be heated
m2
150-250

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Table 2. GHT 40 kW
Nominal heat output
kW
40
Water capacity
dm3
200
Fuel consumption at maximum power
kg/h
9,5
Boiler weight
kg
840
Maximum operating temperature
0C
95
Chimney draught
Pa
10-17
Approximate chimney height
m
8
Stack section
mm
160x250
Working pressure
MPa
0,1
Storage capacity
dm3
700 (13 bags)
Thermal efficiency
%
88,4
Area of the room to be heated
m2
250-450
.
Explanations:
- In order to ensure proper boiler operation, the chimney section should be min. 150 mm for
boilers up to 30 kW.
- the area of the room related to well and medium insulated buildings with a heat loss factor of
80-110 W/m2
4.2. Boiler transport
Lifting and lowering of the boiler should be done by means of metal rods through the cleaning
door and the boiler flue gas outlet.When transporting the boiler, it must be secured against shifting
and tilting on the vehicle platform with belts, wedges or wooden blocks. The boiler must be
transported in vertical position. Otherwise, the steel jacket of the boiler insulation may be
damaged.
The boiler is delivered in an assembled condition. To make it easier to bring the boiler to its
destination, the fuel feeder can be disassembled by removing the boiler covers beforehand, and
the ceramic inserts can be removed from inside the furnace (fig. 14). When reassembling the
burner, seal it again with heat-resistant silicone (min. 300OC) and screw it on. The manufacturer
is not responsible for any disturbances caused by improperly assembled feeder parts. Removal
of such faults will be made against payment.
The device is individually assembled from parts. The scope of delivery can be checked on the
basis of shipping documents.
Immediately upon receipt of the machine, it must be ascertained whether the scope of delivery is
in accordance with the delivery note. In the case of a delayed claim for defects, the supplier shall
not be liable.
Any identified transport damage should be immediately reported to the supplier, and deficiencies
or discrepancies should be reported to the manufacturer.

20
Before setting up and connecting the boiler, it is necessary to check that all components
are operational and that the boiler is fully equipped for operation.
4.3. Installation of the boiler in the boiler room
The boiler doesn't need a foundation. It is placed directly on the floor. It should be exactly
levelled! The strength of the floor as well as fire protection conditions must be taken into account.
Installation of the boiler should take into account the possibility of free cleaning of the boiler and
access to its every part. The room where the boiler is installed should have two gravitational
ventilation openings, min. 15 x 15 cm (applies to small boilers, for larger ones, the ventilation
system should be recalculated by an authorized person, one at the boiler room floor and one
under the ceiling. Holes should be secured with steel mesh. Do not cover boiler ventilation
openings, do not use empty spaces in the boiler casing for waste storage, etc.
The use of mechanical exhaust ventilation in the boiler room is prohibited.
It is permissible to use the above mentioned exhaust system under the condition that a
mechanical supply system with the capacity compensating for the amount of exhaust air is
installed in accordance with PN-87\B-02411.
Room of the boiler room
The room in which the boiler is installed must not be intended for permanent or temporary
residence of people. In new buildings, the minimum room height is 2.2 m and in existing buildings
1.9 m. The boiler must be placed on a non-flammable surface. The boiler must be positioned so
as to ensure trouble-free operation, cleaning and maintenance.
Ventilation
In boiler plants up to 25 kW, the supply air ventilation should be carried out by means of
an unclosed opening of at least 200 cm2, while the exhaust air should be in theform of an exhaust
grille of at least 14 x 14 cm.
In boiler plants with power outputs from 25-2000 kW, there should be an air supply duct with a
cross-section of not less than 50% of the chimney section area, but nevertheless less than 20x20
cm. The outlet should beup to 1 m above floor level. The boiler room should also have an exhaust
duct of not less than 25% of the chimney section area with an inlet opening under the boiler room
ceiling, led above the roof and placed, if possible, next to the chimney. The minimum dimensions
of the chimney section are 15x15 cm.
Heating installation - boiler installation
The feeder can be assembled to the boiler by persons with the appropriate permissions,
who have familiarized themselves with the technical and operating documentation of the feeder.
It is the user's responsibility to ensure that the installation of the boiler is carried out in accordance
with the applicable regulations. The assembling company should issue a guarantee for the works
performed and confirm their execution with the installation protocol attached to this manual.
The customer should have a statement from the chimney sweep regarding the passage and
draught of the flue to which the boiler will be connected.
The boiler must be levelled and positioned so that the connection to the boiler is tight. Boiler
equipment includes a set of temperature sensors.
Boiler operation in adverse weather conditions
In case of unfavourable conditions for chimney draught or unfavourable weather
conditions, it is necessary to make sure that the chimney is unobstructed. If there is no other