Metal-Fach SEMAX OPTI Operating instructions

Technical and operating documentation
SEMAX OPTI
Original instructions, edition 01/2022English language

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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 boiler 10
Safety automation and control 11
Fuel 11
Requirements for the boiler house and boiler installation 12
Boiler installation 15
Connection of the boiler to the heating system 17
Requirements for the expansion vessel 20
Boiler connection to the electrical installation 21
Connection of boiler to chimney 21
Boiler start-up 22
When using the boiler, remember 24
Cleaning and maintenance of the boiler 25
Instructions for disposal of the boiler at the end of its service life 25
List of spare parts 26
Examples of equipment failure 27
Warranty conditions 29
Confirmation of inspection, warranty repair, maintenance service 32
EC/EU Declaration of Conformity 35
Warranty card 37
Notification of complaint 39
Report on the first start-up of the boiler 41
Report on the first start-up of the boiler 43

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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 Documentation is one of the product parts delivered with the purchased central
heating boiler. The Operation and Technical Manual includes data concerning the construction and assembly as
well as the way of using the SEMAX OPTI boilers. Careful reading of the manual content 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 boiler is designed to supply heat to central heating systems (radiators and floor standing) and to obtain hot
utility water. The boiler should operate at full nominal output in a system with a buffer to store excess heat. An
example scheme of a boiler with a buffer is given in Fig. 5.1. Boiler operation at nominal output allows better
fuel utilisation and better flue gas quality for the atmosphere. Proper operation and achieving the full capacity
of the boiler depends on the quality of the installation, adequate flue draught, correct operation and
maintenance of the boiler.
Boiler diagram with buffer
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.
NOTE!
A buffer to store excess heat must be installed in the heating system!

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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
Controller
pcs.
1
Exhaust fan
pcs.
1
Thermometer
pcs.
1
Boiler levelling feet
pcs.
1
Tools for cleaning the boiler:
●poker
●brush
●scraper
pcs.
4
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 guarantee card for the exhaust fan
pcs.
1
NOTE!
The user should carefully read the operating instructions of the controller and the fan.
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 appearance and construction of the boiler are shown on the technical drawing. Some parts of the boiler are
marked with numbers on the drawing.
There are four doors on the front wall of the boiler:
●Clearance door (1) for access for cleaning and observation of the boiler convection ducts.
●The loading door (2) is needed for filling the boiler with firewood, cleaning and observing the
combustion chamber.
●Grate door (3) and pre-grate door (19) to allow the placement and ignition of the ignition layer,
rearrangement, cleaning and observation of the combustion chamber and the condition of the cast iron
grate (18).
●Ash door (4) for removing the ash drawer (20) and cleaning the ash pan. The door has a built-in hinged
flap which regulates the primary air supply for fuel combustion. The flap can be raised or lowered by
means of a built-in knob.
●½" female thread connection for insertion of round thermometer (6).
●The linkage (5) is used to close and open the smoke extraction damper in the loading chamber during
fuel loading into the boiler. When opened, the flap allows the excess smoke to be discharged by a
shorter route to the chimney. The flap must be closed during boiler operation.
On the rear wall of the boiler there are:
●Stub pipe (11) with ¾" internal thread for filling and draining the boiler.
●Stub (13) with internal thread 1½" being the return connection of water from the central heating system.
●The secondary air intake (10), where the air required for complete combustion of the fuel is sucked in
through 6 holes. The amount of air can be adjusted with the sliders (17).
●Flue with cleanout (8) and (9); in the cover of the cleanout (9) there is an opening for the flue gas
temperature sensor.
●The exhaust fan (7) is attached by means of an adapter to the rear vertical flue wall. The fan generates
the necessary draught for fuel combustion and is an essential accessory of this boiler.
On the upper wall of the boiler there are:
●The connection (12) with internal thread 1½" is a connection for warm water supply to all heat
appliances connected to the boiler.
●Cover giving access to the sleeves (21) and (22) in which the boiler temperature sensor and STB sensor
are placed.
●Boiler operation controller (25) - for detailed description refer to the controller documentation enclosed
with the boiler.

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On the left and right wall of the boiler there are plugs which allow access to the protection (23) of the ceramic
channel. The protection should be removed if the duct plates need to be replaced.
Boiler interior:
●Ceramic channel (16), in which combustion and postcombustion of the gases generated in the
combustion zone on the boiler grate takes place.
●Smoke flap (15).
SEMAX OPTI boiler

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1. Clearance doors
2. Loading doors
3. Slatted doors
4. Ash door
5. Smoke flap lever
6. Thermometer
7. Exhaust fan
8. Cover for the rear clean-out hatch
9. Upper cleanout cover
10. Secondary air intake
11. Drain stub
12. Supply spigot
13. Return spigot
14. Chimney adapter
15. Smoke flap
16. Ceramic channel
17. Adjustment of secondary air supply
18. Cast iron grate
19. Front doors
20. Ash drawer
21. Boiler temperature sensor sleeve
22. STB sensor bushing
23. Ceramic channel protection
24. Firewood loading chamber
25. Controller

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Technical data of the boiler
(User | Installer)
Parameters
S.I. Unit.
Boiler model
SE MAX OPTI 20
SE MAX OPTI 30
SE MAX OPTI 40
Nominal heat output
[kW].
23
30
40
Heating surface
[m2]
2,8
3,5
4,1
Water capacity
[L]
97
120
170
Maximum operating pressure
[bar].
3
3
3
Maximum operating temperature
[°C]
80
80
80
Test pressure
[bar].
4,5
4,5
4,5
Boiler class
-
5
5
5
Boiler efficiency
[%]
≤90
≤90
≤90
Fuel
[-]
Firewood - hornbeam logs with moisture content of
Wc=15-20%
Circumference of logs
[cm].
30-40
Length of billets
[cm].
26
Electrical connection
-
1A; ~230V; 50Hz
Electrical power consumption
[W]
70
70
70
Electric power consumption
(instantaneous at start-up)
[W]
70
70
70
Setting range of temperature controller
[°C]
60-80 (in 1°C steps)
Required chimney draught
[Pa]
23
35
35
Design flow resistance ΔT [10K]
[mbar].
12,3
24,75
29,83
Design flow resistance ΔT [20K]
[mbar].
3,8
5,05
7,45
Boiler mass *
[kg].
414
477
569
Volume of heat storage tank (buffer)
[L]
900
1200
1600
* Boiler weight +/- 5kg.

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Safety automation and control
(User | Installer)
1. Boiler automatics enables setting:
●boiler temperature;
●the hot water temperature;
●temperature in the central heating system;
●operation of auxiliary pumps;
●manual fan control.
2. Thermal sensor
Mechanical STB protection is located in the controller and protects the heating system from overheating.
Fuel
(User)
The fuel for firing the boiler is hornbeam logs, dimensions and moisture content are given in chapter "Technical
data of the boiler".
●ash content ≤ 1%,
●calorific value >17 MJ/kg.

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Requirements for the boiler house 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 ventilation should be by means of an unsealed opening with a minimum cross-section of 200 cm2
and 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. Boiler houses 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 windows shall be
operable; electrical lighting and an electrical outlet, not exceeding 24 V, shall also be provided in the
room;
●there should be a drainage sump in the floor to allow cooling of the water and its capacity should 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 positioning 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.

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Boiler installation
(User | Installer)
An important element of installation is the correct positioning and levelling of the SEMAX OPTI type boiler, these
boilers do not require special foundations. Boiler leveling is facilitated by adjustable feet. The boiler must stand
vertically.
1. Check that the four feet are included.
2. Use a spirit level to level the boiler with the ground. If the boiler is in a horizontal position, the
installation of feet is not required.
3. Screw the four feet into the designated holes.
4. Use a spirit level to align the boiler
Installation of the boiler levelling feet
1. Adjustment foot, pcs. 4
2. Nut M10, pcs. 8
3. Washer Ø10, pcs. 8
NOTE!
An improperly leveled boiler can be damaged.
NOTE!
It is not permissible to place the boiler in a damp or wet room as this accelerates the
corrosion phenomenon, leading in a short time to the destruction of the boiler.

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The boiler should be placed on a heat insulating non-flammable base, which on each side of the boiler should
be larger than the base of the boiler by 2 cm. If the boiler is located in a cellar, it is recommended that it is
placed on a foundation of at least 5 cm. The strength of the foundation as well as the fire protection conditions
are key guidelines when placing the boiler in the right location, these include:
●20 cm safety distance from flammable materials,
●40 cm for flammable materials of flammability grade C3,
●40 cm if flammability is not known.
Flammability of building masses and products
Building materials and products
A - Non-flammable
Sandstone, concrete, bricks, fireproof plaster, mortar,
ceramic tiles, granite
B - Hard to burn
Wood and cement boards, fibreglass, mineral
insulation
C1 - Hard to burn
Beech wood, oak wood, plywood
C2 - Medium flammability
Pine, larch and spruce cork, sawn wood planks, rubber
floor coverings
C3 - Readily combustible
Asphalt plywood, celluloid, polyurethane, polystyrene,
polyethylene, plastic, PVC

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Connection of the boiler to the heating system
(Installer)
Boiler connection to the central heating system should be performed by a firm authorized by the manufacturer
and the fact of a proper connection should be confirmed on a guarantee card attached to this manual. Boiler
should be connected according to producer recommendations, in accordance with this manual.
NOTE!
It is recommended to perform the first start-up of the boiler in accordance with the
guidelines included in the Operation and Technical Documentation by a person holding a
valid license (information about persons authorised to start up the boiler is available from
the Producer - phone: [phone]).
NOTE!
The return water temperature from the system to the central heating boiler should not be
lower than 45ºC.
NOTE!
APV valve must be installed (min. 45ºC)

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Boiler connection diagrams to the heating system in accordance with DIN 91/B-02420
Designation
Description
RO
Vent pipe
RW
Expansion pipe
RS
Signal tube
RP
Overflow pipe
RB
Safety pipe
T1
Temperature
P1
Pressure