Metal-Fach SD DUO BIO 16 Operator's manual

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Table of contents
Introduction 2
Symbols used in the manual 2
Definitions of terms used in the manual 2
Introductory acts 3
General information 4
Application 5
Boiler equipment 6
Basic elements of boiler construction 8
Technical data of the boiler 10
Boiler dimensions 12
Safety automation and control 14
Fuel 15
Requirements for the boiler room and boiler installation 16
Boiler installation 19
Connection of the boiler to the heating system 21
Connection of the boiler to a closed heating system 26
Requirements for the expansion vessel 29
Boiler connection to the electrical installation 30
Connection of boiler to chimney 33
Commissioning the boiler 34
Suggested boiler output settings 41
When using the boiler, remember 42
Cleaning and maintenance of the boiler 43
Instructions for disposal of the boiler at the end of its service life 44
List of spare parts 45
Examples of equipment failure 46
Warranty conditions 49
Confirmation of inspection, warranty repair, maintenance service 52
EC/EU Declaration of Conformity 55
Warranty card 57
Notification of complaint 59
Report on the first start-up of the boiler 61
Report on the first start-up of the boiler 63

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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 with strict observance of the instructions included in the manual attached to the appliance 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.
Definitions of terms used in the manual
(User | Installer)
Central heating boiler - a device for burning various types of solid fuels in order to heat the heat carrier
(usually water) circulating in the central heating circuit.
Burner - is a technical device for burning pellet fuel (trough burner).
Feeder - a component or assembly of the mechanism for supplying the burner with various types of fuel.
Biomass - in energy terms, is a primary energy source consisting of all substances of plant origin that are
biodegradable and whose use for energy purposes is not restricted by law.
Pellet - is a fuel derived from compressed under pressure, natural wood waste, mainly sawdust and shavings,
carpentry and sawmill waste, sometimes also with the use of wood bark, straw, sunflower and other organic
materials. Made in the form of granules in the shape of balls or cylinders.

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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 technical and operation documentation is one of the product parts, delivered together with the purchased
central heating boiler. The Operation and Technical Manual contains data on the construction and installation as
well as on the method of operation of boilers with a gutter burner of the SD DUOBIO 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)
Steel water boilers are designed for heating usable water in central heating systems. They are designed for heating
residential buildings such as: single-family and multi-family houses, farm buildings, public utility buildings. They are
equipped with an automatic system for filling the furnace chamber. Thanks to the use of modern construction solutions
the SD DUO BIO boiler reaches efficiency of ≤90%. Correct operation and achieving the full capacity of the boiler
depend on the quality of the executed 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 for damage during transport and checked for completeness. 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:
●boiler temperature sensor
●domestic hot water temperature sensor
●central heating temperature sensor supply return central heating 1 and
central heating 2
●boiler return temperature sensor
●external temperature sensor
●exhaust gas temperature sensor
●burner sensor
pcs.
1
Blower fan
pcs.
1
Fuel feed system with burner
cpl.
1
Fuel tank
pcs.
1
Tools for cleaning the boiler:
●poker
●brush
pcs.
1
Boiler levelling feet
pcs.
4
Additional equipment:
Unit of
measurement
Quantity
LAMBDA SONDA module
pcs.
1
Internet module
pcs.
1
Cooling coil for closed loop systems with valve
pcs.
1
LCD touch screen
pcs.
1
Expansion module
sh.
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
Operating instructions of the worm gearmotor
pcs.
1

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NOTE!
METAL-FACH company reserves the right to introduce changes in 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 sheets 5 mm thick P265GH (for elements in
contact with exhaust gases) and 4 mm thick S235JR+N (for other elements).
SD DUO BIO boiler
1. Exchanger
2. Storage tank
3. Feeder
4. Gearmotor
5. Burner
27. Opłomka
28. Exhaust gas swirler
29. Exhaust guide
30. Microprocessor controller
31. Chamotte screen

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6. Feeder cover
7. Water extinguishing system
8. Leakage I
9. Drain II
10. Inspection doors
11. Ash door
12. Supply connection with internal thread G1 ½"
13. Return stub with female thread G1 ½"
14. Drain connection with female thread G 3/4"
15. Flue pipe
16. Adjustable foot
17. Drain III
18. Cooling coil (optional)
19. Boiler temperature sensor sleeve
20. STB sensor bushing
21. Bushing for exhaust gas temperature sensor
22. Lambda sensor bushing
23. Detachable cover
24. Fan
25. Feeder temperature sensor sleeve
26. Ash drawer
32. Thermal insulation
33. Fan electrical connection
34. Feeder electrical connector
35. Electrical connector of the igniter
36. Feeder temperature sensor output
37. Valve connection VST 212 (optional)
38. Lambda sensor module

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Technical data of the boiler
(User | Installer)
Parameters
S.I. Unit.
Boiler model
SD DUO
BIO - 16
SD DUO
BIO - 20
SD DUO
BIO - 28
SD DUO
BIO - 34
Nominal heat output
[kw].
16
20
28
34
Boiler output range
[kw].
4,8-16
6-20
8,4-28
10,2-34
Heating surface
[m2]
2,33
2,62
2,85
3,10
Water capacity
[L]
78
84
90
100
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
≤90
≤90
≤90
Fuel tank capacity
[L]
300
300
300
300
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
[-]
5A; ~230V; 50Hz
Electrical power consumption
[W]
300
300
300
300
Electric power consumption
(instantaneous at start-up)
[W]
1000
1000
1000
1000
Setting range of temperature controller
[°C]
60-80 (in 1°C steps)
Required chimney draught
[Pa]
20
23
23
35
Design flow resistance ΔT [10K]
[mbar].
0,3
0,47
0,92
1,34
Design flow resistance ΔT [20K]
[mbar].
0,15
0,235
0,46
0,67
Boiler weight
[kg].
460
475
495
520
* Boiler weight +/- 5kg.

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Boiler dimensions
(User | Installer)
NOTE!
Boiler feet are present:
- from SD DUO BIO 16 to SD DUO BIO 34
Their height is 30 mm.

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Typ
e
SD DUO BIO - 16
SD DUO BIO - 20
SD DUO BIO - 28
SD DUO BIO - 34
A
1245
1245
1245
1300
B
541
541
541
591
C
1665
1665
1665
1665
D
653
703
753
753
E
1400
1400
1400
1400
F
442
487
537
537
G
3/4''
3/4''
3/4''
3/4''
H
1 ½"
1 ½"
1 ½"
1 ½"
I
180
180
180
180
J
1 ½"
1 ½"
1 ½"
1 ½"
K
244
244
244
244
L
144
144
144
144
M
680
680
680
680
N
595
595
595
595
O
125
125
125
125
P
830
880
930
930
R
-
-
-
-
S
-
-
-
-
T
-
-
-
-
U
338x198
338x198
338x198
388x198
*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 temperature in the central heating circuit C.O.1,C.O.2 ;
●the hot water temperature;
●room temperature;
●return water temperature from the central heating system (boiler exchanger protection function);
●the operating time of the igniter (depending on the type of fuel);
●fuel feeder operation;
●manual control of the feeder and fan;
●automatic burner power modulation (fuzzy logic);
●automatic air dosage (lambda sensor module).
2. Thermal sensor
Mechanical STB protection is located in the boiler and protects the heating system from overheating. It is set at
95Co. Above this temperature it switches off the fan, switching on the central heating and central water pumps,
as well as two additional ones, and opens the mixing valve.
3. Fuzzy Logic control method (advantages):
●a very sophisticated algorithm;
●reduces the amount of fuel burned, largely eliminating the formation of pollutants and soot in the boiler;
●high stabilisation of the boiler operating temperature - eliminates steam condensation in the boiler;
●the combustion chamber temperature is high and stable, thus reducing carbon monoxide emissions.
4. Lambda sensor
The probe continuously adjusts the amount of air supplied to ensure the best possible operation of the
appliance and to reduce carbon monoxide emissions to a minimum under the specified conditions of boiler
load, fuel type and weather. The adjustment takes place continuously during the entire operation cycle of the
boiler.
5. Exhaust temperature sensor
It is located in the boiler flue. Enables the measurement of the flue gas temperature. When the flue gas
temperature exceeds 250Co, the fan is automatically switched off until the combustion temperature decreases.
6. Mixer valve actuator x2
With this device, the set temperature of the heating circuit is set in the central heating system while maintaining
a constant temperature in the boiler. The temperature is calculated from the heating curve depending on the
outside temperature.

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Fuel
(User)
Fuel for boilers equipped with a screw feeder and retort burner or trough burner is respectively:
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.

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Requirements for the boiler room and boiler installation
(User | Installer)
In Poland, boiler houses built for solid fuel should meet the requirements of the PN-87/B-02411 standard "Boiler
houses built for solid fuel" and OJ. 2015.0.1422 These are divided into two types:
1. For small boiler plants up to 25 kW capacity, the following requirements should be met:
●The boiler should be placed as centrally as possible to the rooms to be heated and in a separate room;
●The material of which the boiler room floor is made should be non-flammable; in case of combustible
material, the floor should be covered with 0.7 mm thick steel sheet at a distance of at least 50 cm from
the edge of the boiler; the boiler should be placed on a foundation made of non-flammable materials,
protruding 0.05 m above the floor level and edged with steel angles;
●there should be artificial lighting in the room, natural lighting is also advisable;
●The distance from the back of the boiler to the wall should not be less than 70 cm, from the side of the
boiler to the wall not less than 100 cm and from the front of the boiler to the opposite wall not less than
200 cm;
●The height in new buildings should be at least 220 cm, in existing buildings the height of the boiler room
is at least 190 cm, with proper ventilation (supply and exhaust);
●Supply air ventilation shall be by means of an unsealed opening having a minimum cross-section of 200
cm 2and placed up to a maximum of 100 cm above floor level;
●exhaust ventilation should be carried out with an exhaust duct made of non-flammable material,
minimum cross-section 14 x 14 cm, with an inlet opening under the boiler room ceiling; the exhaust duct
should be led above the roof and located near the chimney; there must be no devices allowing to close it
on the exhaust duct
●the section of the chimney should not be smaller than 20 x 20 cm;
●there should be a floor drain in the floor of the boiler room;
●The optimal place for fuel storage is a separate room close to the boiler room;
●ash and slag must be collected in suitable containers which can be emptied daily.
2. Boilers with a heat output of 25 kW and over shall in addition meet the following requirements:
●The distance of the boiler furthest from the chimney, for gravity draught, must not exceed 50 cm of
chimney height;
●Fuel storage and slag storage should be located next to the boiler hall at a storage height of up to 220
cm with a minimum of 50 cm free space above the fuel;
●facilities and equipment must be provided to allow vertical and horizontal transport of fuel and slag;
●Fuel storage rooms shall have natural unforced ventilation, providing for one complete change of air per
hour in the fuel storage room and three complete changes of air in the slag storage room;
●the entrance door to the boiler room shall be non-combustible (class 0.5 fire resistance), minimum width
80 cm, opening outwards; it shall have a handleless locking system enabling it to be opened outwards
under pressure and inwards using a handle;
●ventilation requirements are the same as for boiler houses of smaller capacity; in addition, in boiler
houses whose capacity exceeds 400 kW, in addition to supply and exhaust ventilation, there should be

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mechanical ventilation, activated periodically during fuel filling and slagging of boilers, ensuring a
minimum of 10 full air changes per hour;
●natural lighting shall be provided in the boiler room, illuminating the boiler from the front, and the
window area shall be a minimum of 1/15 of the boiler room floor area; half of the installed windows
shall be operable; electric lighting and an electric socket, of a voltage not exceeding 24 V, shall also be
provided in the room;
●there shall be a sump in the floor to allow cooling of the water and its volume shall be equal to the water
capacity of the largest boiler but not more than 2 m3;
●in the boiler room, the thermal pipes should be insulated;
●The boiler position with the minimum required distances is shown in the boiler room diagram below.
Minimum distances for placing the boiler in the boiler room

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NOTE!
Mechanical exhaust ventilation should not be used in the boiler room.
NOTE!
Ensuring a sufficient supply of fresh air into the boiler room will enable efficient
combustion of the fuel.
NOTE!
Excessive carbon dioxide in the room should be prevented.
NOTE!
More detailed information on the requirements for the construction of a boiler house can
be found in the Regulation of the Minister of Infrastructure of 12 March 2009.
TIP!
The above-mentioned provisions are guidelines to be reviewed as the Regulation is subject
to revision.