Metal-Fach GRAND PELLET 15 Operator's manual

METAL-FACH Heating Technology
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Table of contents
Introduction 2
Symbols used in the manual 2
Introductory acts 3
General information 4
Application 5
Boiler equipment 6
Basic elements of boiler construction 7
Technical data of the GRAND PELLET 15-34 boiler 12
Technical data of the GRAND PELLET 50-150 boiler 13
Dimensions of the GRAND PELLET 15-34 boiler 14
Dimensions of the GRAND PELLET 50-150 boiler 16
Safety automation and control 18
Fuel 18
Requirements for the boiler house and boiler installation 19
Boiler installation 22
Connection of the boiler to the heating system 23
Connection of the boiler to a closed heating system 28
Requirements for the expansion vessel 29
Boiler connection to the electrical installation 30
Connection of boiler to chimney 33
Boiler start-up 34
When using the boiler, remember 36
Cleaning and maintenance of the boiler 37
Instructions for disposal of the boiler at the end of its service life 37
List of spare parts 38
Examples of equipment failure 39
Warranty conditions 41
Confirmation of inspection, warranty repair, maintenance service 44
EC/EU Declaration of Conformity 47
Warranty card 49
Notification of complaint 51
Report on the first start-up of the boiler 53
Report on the first start-up of the boiler 55

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Introduction
Dear customer, thank you for purchasing METAL-FACH heating boiler. We hope that the operation of the device
will meet your expectations and provide much satisfaction. The heating boiler has been designed and
manufactured in accordance with applicable norms and standards, which guarantee safe and reliable operation.
Operation of the boiler in strict observance of the instructions included in the manual attached to the device will
ensure optimal and reliable operation of the central heating boiler for many years. The product is not intended
for use by persons of diminished physical / mental capacity or lack of experience and knowledge, if such
persons are supervised or instructed by a person responsible for their safety. Operation by children is
prohibited.
Symbols used in the manual
NOTE!
Very important information, always read it if it is present.
TIP!
It is worth familiarising yourself with this information, it makes it easier to use.

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Introductory acts
(User)
Activities to be performed during the METAL-FACH boiler acceptance:
●Check carefully that the boiler has been delivered complete (Chapter: Boiler accessories) and that it has
not been damaged in transit,
●Compare the rating plate mounted on the boiler casing on the left or right side with your order,
●Carefully read this manual - it contains information you need to use the boiler correctly.
In case of any problems, please contact the service department or METAL-FACH Jacek Kucharewicz authorized
service. These persons have appropriate training and access to original parts, which enable the proper
performance of service and installation of boilers METAL-FACH Jacek Kucharewicz, confirmed by a certificate
issued in the seat of the company.

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General information
(User)
The Operation and Technical Manual is one of the product parts which are supplied together with the purchased
central heating boiler. The Operation and Technical Manual includes data concerning the construction and
installation as well as the method of operation of boilers with a self-cleaning pellet burner of the GRAND PELLET
series. Careful reading of this manual ensures correct and safe operation of our boiler.
NOTE!
The user is advised to observe all instructions regarding the appliance contained in this
Operation and Maintenance Manual, the Warranty Conditions and the generally applicable
legal provisions.
The boilers are delivered in an assembled condition. They are set up and fixed permanently to a pallet.
Additional protection in the form of foil packaging is used.
When transporting the boiler, it is necessary to secure it against shifting or rotation on the truck body by means
of securing devices, e.g. belts. The transport of boilers should be carried out in accordance with the rules
concerning the transport of materials. Loading and unloading should be carried out with lifting devices (forklift)
with a lifting capacity of more than 1000 kg.

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Application
(User | Installer)
The boilers are designed for heating facilities of the following types: single-family and multi-family houses, farm
buildings, public utility facilities, and for heating usable hot water. They are equipped with an automatic fuel feeding
system, ash removal and exchanger cleaning. Thanks to the use of modern construction solutions the GRAND
PELLET boiler achieves efficiency ≤90%. Correct operation and achieving the full potential of the boiler depend on the
quality of the installation, appropriate chimney draught, correct operation and maintenance of the boiler.
NOTE!
The boilers are designed for operation in open and closed water systems with gravity or
forced circulation, with safeguards in accordance with the requirements of the current
standard PN-B-02413 Heating and Heat Engineering and closed system in accordance with
PN-EN 12828 Heating Installations in Buildings. Design.

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Boiler equipment
(User)
The scope of delivery includes both basic and additional elements, depending on the order. Upon receipt, the
product must be carefully inspected to ensure that it has not been damaged during transport and to check that
the equipment is complete. The elements included in the basic and additional equipment are described below.
Basic equipment:
Unit of
measurement
Quantity
Central heating boiler
pcs.
1
Microprocessor controller - supports:
Refer to the controller's operating instructions.
pcs.
1
Internet module
pcs.
1
Ash removal system
pcs.
2/1
Exchanger cleaning system
cpl.
1
Exhaust fan
cpl.
1
Fuel feed system with self-cleaning pellet burner
cpl.
1
Fuel tank
pcs.
1
Tools for cleaning the boiler:
●poker
●brush
●scraper
pcs.
1
Additional equipment:
Unit of
measurement
Quantity
LAMBDA SONDA* module
pcs.
1
Device for dissipating excess heat power
pcs.
1
Documentation:
Unit of
measurement
Quantity
Technical and propulsory documentation of the boiler
pcs.
1
Operating instructions and warranty card for the controller
pcs.
1
Operating instructions and warranty card for the blower fan
pcs.
1
NOTE!
The user should carefully read the operating instructions for the controller, fan and
feeder together with the self-cleaning pellet burner.
NOTE!
METAL-FACH reserves the right to introduce changes to the technical parameters,
equipment and specifications of the offered goods without prior notice.

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Basic elements of boiler construction
(User | Installer)
The water body is made as a welded structure from approved steel plates P265GH with a thickness of 5 mm (for
elements in contact with fire and flue gas) and S235JR+N with a thickness of 4 mm (for elements of the water
jacket)
The automatic feeder delivers fuel (pellets) to a self-cleaning insertion burner located, depending on the model,
up to 34kW on the side of the boiler, above in a door. A ceramic plate is placed in front of the burner, in the rest
of the combustion chamber boilers above 50kw are equipped with steel screens.
The convection part of the boiler consists of a tubular exchanger equipped with flue gas swirlers. Once a day
automated movement of the above mentioned swirlers keeps the exchanger clean.
Under the combustion chamber and exchanger there are systems for ash removal to containers located outside
the boiler.
The boiler exchanger is insulated with mineral wool covered with a thin-walled sheet. The insulated bottom of
the boiler is not water cooled.
The flue gas flue has no damper and is equipped with an exhaust fan.
The boiler is equipped with the following connections: boiler water supply and return with diameter G 1 ½",
water drain connection with diameter G ¾".
The boiler operation and combustion process is controlled by a microprocessor controller.

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Boiler GRAND PELLET 15-34

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1. Exchanger
2. Self-cleaning pellet burner
3. Fireplace
4. Fuel tank
5. Filling door
6. Upper cleanout door
7. Upper cleanout door aperture
8. Bottom cleanout door
9. Cover for the bottom cleanout
door
10. Firebox doors
11. Ceramic hob
12. Tubular exchanger
13. Cleaning and swirling system
14. Ash removal system
15. Ash box
16. Supply spigot with thread G 1
1/2"
17. Return stub with thread G 1
1/2"
18. Drain stub with thread G 3/4"
19. Flue
20. Exhaust fan
21. Lambda sensor
22. Exhaust temperature sensor
23. Boiler temp. sensor bushings
24. Levelling feet
25. Fuse
26. STB
27. Main switch
28. Controller display
29. Controller

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Boiler GRAND PELLET 50-150

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1. Fireplace
2. Self-cleaning pellet burner
3. Cleaning and swirling system
4. Ceramic hob
5. Ash removal system
6. Covers
7. Flue
8. Steel screens
9. Exhaust fan
10. Lambda sensor
11. Tubular exchanger
12. Ash box
13. Control system panel
14. Fuse
15. STB
16. Switch
17. Return stub gw. G 11/2"
18. Gearmotor cover
19. Exhaust temperature sensor
20. Upper cleanout door I
21. Upper cleanout door II
22. Supply spigot thread G 11/2"
23. Bottom cleanout door
24. Control modules
25. Controller
26. Drain stub gw. G 3/4"
27. -
28. Bottom cleanout plug

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Technical data of the GRAND PELLET 15-34 boiler
(User | Installer)
Parameters
S.I. Unit.
Boiler model
GRAND
PELLET 15
GRAND
PELLET 20
GRAND
PELLET 25
GRAND
PELLET 34
Nominal heat output
[kw].
15
20
25
34
Boiler output range
[kw].
4,5-15
6-20
7.5-20
10,2-34
Heating surface
[m2]
1,45
1,9
1,9
2,5
Water capacity
[L]
70
92
92
128
Maximum operating pressure
[bar].
3
3
3
3
Maximum operating temperature
[°C]
80
80
80
80
Test pressure
[bar].
4,5
4,5
4,5
4,5
Boiler class
[-]
5
5
5
5
Boiler efficiency
[%]
91,3
91,7
91,5
90,7
Fuel tank capacity
[L]
270
270
270
290
Fuel
[-]
Wood pellets of class C in accordance with pt. 5.3
(Table 7) of PN EN 303-5:2012 standard:
(diameter: 6 ± 1 mm; 8 ± 1mm, length 3.15 ≤ L ≤ 40,
moisture content ≤ 12%, ash content ≤ 0.5%, calorific
value >17 MJ / kg)
Electrical connection
[-]
2A; ~230V; 50Hz
Electrical power consumption
[W]
141
141
180
185
Electric power consumption
(instantaneous at start-up)
[W]
600
600
630
630
Setting range of temperature controller
[°C]
60-80 (in 1°C steps)
Required chimney draught
[Pa]
17
15
17
16
Exhaust mass flow
[g/s].
11,52
15,94
16,1
23,95
Design flow resistance ΔT [10K]
[mbar].
5,47
8,79
12,33
35,16
Design flow resistance ΔT [20K]
[mbar].
1,19
2,19
3,8
8,79
Boiler weight
[kg].
400*
440*
445*
585*
* Boiler weight +/- 5kg.

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Technical data of the GRAND PELLET 50-150 boiler
(User | Installer)
Parameters
S.I. Unit.
Boiler model
GRAND
PELLET 50
GRAND
PELLET 70
GRAND
PELLET 100
GRAND
PELLET 150
Nominal heat output
[kw].
50
75
100
150
Boiler output range
[kw].
15-50
22,5-75
30-100
45-150
Heating surface
[m2]
5
5
7,5
7,5
Water capacity
[L]
245
245
360
360
Maximum operating pressure
[bar].
3
3
3
3
Maximum operating temperature
[°C]
80
80
80
80
Test pressure
[bar].
4,5
4,5
4,5
4,5
Boiler class
[-]
5
5
5
5
Boiler efficiency
[%]
90,6
91,6
90,2
90,6
Fuel tank capacity
[L]
1000
Fuel
[-]
Wood pellets of class C in accordance with pt. 5.3
(Table 7) of PN EN 303-5:2012 standard:
(diameter: 6 ± 1 mm; 8 ± 1mm, length 3.15 ≤ L ≤ 40,
moisture content ≤ 12%, ash content ≤ 0.5%, calorific
value >17 MJ / kg)
Electrical connection
[-]
3,2A;~230V; 50Hz
4,5A;~230V; 50Hz
Electrical power consumption
[W]
300
300
320
320
Electric power consumption
(instantaneous at start-up)
[W]
750
750
1050
1050
Setting range of temperature controller
[°C]
60-80 (in 1°C steps)
Required chimney draught
[Pa]
26
29
38
38
Exhaust mass flow
[g/s].
31,3
45,9
63,2
91,9
Design flow resistance ΔT [10K]
[mbar].
60,88
136,98
243,52
-
Design flow resistance ΔT [20K]
[mbar].
15,47
34,24
60,88
-
Boiler weight
[kg].
880*
880*
1095*
1125*
* Boiler weight +/- 5kg.

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Dimensions of the GRAND PELLET 15-34 boiler
(User | Installer)
Boiler GRAND PELLET 15-34

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Type
GRAND PELLET 15
GRAND PELLET 20
GRAND PELLET 25
GRAND PELLET 34
A
1400
1400
1400
1450
B
508
508
508
560
C1
1300
1300
1300
1475
C2
1300
1265
1265
1440
D
760
900
900
900
E
1030
1200
1200
1200
F
319
345
345
405
G
G 1 1/2''
G 1 1/2''
G 1 1/2''
G 1 1/2''
H
G 1 1/2''
G 1 1/2''
G 1 1/2''
G 1 1/2''
I
G 3/4''
G 3/4''
G 3/4''
G 3/4''
J
Ø100
Ø100
Ø100
Ø100
K
785
785
785
960
L
125
125
125
125
M
1240
1285
1285
1460
N
905
1085
1085
1085
O
420
420
420
471
P
402
402
402
455
R
620
620
620
620
S
940
940
940
940
*Dimension does not include the height of the boiler levelling feet.

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Dimensions of the GRAND PELLET 50-150 boiler
(User | Installer)
Boiler GRAND PELLET 50-150

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Type
GRAND PELLET 50
GRAND PELLET 70
GRAND PELLET 100
GRAND PELLET 150
A
1255
1255
1255
1255
B
815
815
815
815
C
1475
1475
1715
1715
D
625
625
625
625
E
2190
2190
2500
2600
F
1890
1890
2130
2230
G
1450
1450
1600
1600
H
560
560
610
610
I
180
180
185
185
J
290
290
300
300
K
790
790
920
920
L
1235
1235
1565
1565
M
970
970
1250
1250
N
220
220
220
220
O
125
125
130
130
P
115
115
115
115
R
145
145
145
145
*Dimension does not include the height of the boiler levelling feet.

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Safety automation and control
(User | Installer)
1. Boiler automatics enables setting:
●boiler temperature;
●the hot water temperature;
●fuel feeder operation;
●manual control of the feeder fan
2. Thermal sensor
Mechanical STB protection is located in the boiler and protects the heating system from overheating. It is set at
95oC. Above this temperature it switches off the fan, switching on the central heating and hot water pumps, as
well as two additional ones, and opens the mixing valve.
Fuel
(User)
The fuel for boilers equipped with a self-cleaning pellet burner is:
Wood pellets of class C in accordance with pt. 5.3 (Table 7) of PN EN 303-5:2012 standard:
●diameter: 6 ± 1mm; 8 ± 1mm;
●length 3,15 ≤ L ≤ 40;
●moisture content ≤ 12%;
●ash content ≤ 0.5%;
●calorific value >17 MJ/kg;
The fuel should not contain stones, pieces of wood or other impurities.