Metal-Fach SMART EKO-CARBON Series Installation guide

SMART EKO-CARBON
OPERATION AND MAINTENANCE DOCUMENTATION
ENGLISH
TRANSLATION OF THE ORIGINAL MANUAL
ISSUE I 2018/04/01

1
INTRODUCTION
Dear User, Thank you for choosing the heating boiler from Metal-Fach. We hope that the device will meet your requirements and bring much satisfaction. The heating boiler was designed and
manufactured according to the most important, current norms and standards, guaranteeing safety and dependable use. Using the device in accordance with the provided manual ensures effective and
dependable operation.
The boiler is not meant to be operated by persons of lowered mental or physical independence or by persons with no experience or limited knowledge about the product if they are not supervised or
instructed by the person responsible for their safety. Operation by children is prohibited.

2
Table of Contents
1. Initial activities .............................................................................................................................3
2. Applied symbols ..........................................................................................................................3
3. General information ...................................................................................................................3
4. Boiler equipment ........................................................................................................................4
5. Use................................................................................................................................................4
6. Basic elements of the boiler.......................................................................................................5
7. Basic dimentions of the boiler SMART EKO-CARBON..............................................................6
8. Technical specifications SMART EKO-CARBON.........................................................................7
9. Control and safety.......................................................................................................................8
10. Fuel ...............................................................................................................................................8
11. Requirements for the boiler room and boiler installation......................................................8
12. Boiler installation ........................................................................................................................9
13. Connecting the boiler to the heating system .........................................................................10
14. Connection of boiler to heating installation in closed-loop system.....................................13
15. Requirements for the expansion vessel .................................................................................14
16. Connecting the boiler to the power supply............................................................................14
17. Connecting the boiler to the chimney.....................................................................................17
18. Boiler start-up............................................................................................................................17
19. Tips when using the boiler .......................................................................................................18
20. Boiler maintenece and cleaning ..............................................................................................18
21. Istruction for utilising the boiler ..............................................................................................18
22. Spare parts list...........................................................................................................................19
23. Possible faults and malfunctions.............................................................................................19
Warranty conditions....................................................................................................................23
Confirmation of performance of inspection, guarantee repair, maintenance service: .............25
Conformity declaration WE/UE..................................................................................................27
Warranty Card for the steel boilers, central heating water boilers............................................28
Warranty claim............................................................................................................................30
Start-up report.............................................................................................................................32
Start-up report.............................................................................................................................34
List of tables
Tab. 4.1 Boiler equipment..................................................................................................................... 4
Tab. 7.1 Boiler dimentions (mm) SMART EKO-CARBON..................................................................... 6
Tab. 8.1 Technical specifications SMART EKO-CARBON..................................................................... 7
Tab. 12.1 Flammability of construction products:............................................................................ 10
Tab. 13.1 Symbols applied in the schematics ................................................................................... 11
Tab. 13.2 Symbols applied in the schematics ................................................................................... 11
Tab. 14.1 Examples of devices enabling heating systems protection ............................................ 13
Tab. 22.1 Spare parts........................................................................................................................... 19
Description of schematics
Schematic 1.1 Serial plate ..................................................................................................................... 3
Schematic 6.1 Basic elements of the boiler SMART EKO-CARBON................................................... 5
Schematic 7.1 Boiler dimentions SMART EKO-CARBON .................................................................... 6
Schematic 11.1 Minimal requirements for the boiler room.............................................................. 9
Schematic 13.1 Connecting the boiler to the heating system diagram.......................................... 11
Schematic 13.2 Connecting boilers to the heating system diagram............................................... 11
Schematic 13.3 Connecting the boiler to the heating system......................................................... 12
Schematic 13.4 Connecting the boiler to the heating system with Laddomat and buffer........... 12
Schematic 14.1 Safety schematics of the boiler with the cooling coil and thermal protection ... 13
Schematic 14.2 BVTS Valve ................................................................................................................. 14
Schematic 16.1 Electrical schematics for connecting the boiler–controller PLATINUM. ............. 15
Schematic 16.2 Electrical schematics for connecting the boiler. .................................................... 16

3
1. Initial activities
(USER)
Procedure to follow on delivery of the METAL-FACH boiler
check if the boiler is complete (tab 4.1) and if it has not been damaged during delivery
confront your order with the data plate, that is placed on the left or right on the boiler body
read the user's manual carefully as it contains all the information required for safe
operation of the boiler
If you happen to encounter any problems, please contact our service department or dedicated
METAL- FACH service centre. The staff are trained and certified and have access to the original
parts which ensure proper servicing and boiler installation.
Schematic 1.1 Serial plate
2. Applied symbols
(USER/INSTALLER)
ATTENTION!
Very important piece of information that needs to be read
TIP!
Information that should be read to make operation easier.
3. General information
(USER)
The maintenance and operation documentation is a part of the product that comes with the
delivered boiler. The Operation and Maintenance Documentation contains data concerning the
design, installation and method of using SMART EKO-CARBON series boilers with a retort burner. A
thorough study of the manual enables a proper and safe operation of the boiler.
ATTENTION!
The user is advised to follow all guidelines concerning the appliance given in this
Operation and Maintenance Documentation, Guarantee Terms as well as in
generally applicable law.
Our boilers are shipped assembled. They are tightly attached to a pallet. Some other forms of
securing the boiler are used e.g. foil wrapping.
During the shipping, the boiler should be tightly secured (e.g.with transport belts) so that it
does not turn or move. The delivery should meet the requirements set in the general rules for
transporting materials. The loading and unloading of the boilers should be carried out using lifting
devices (fork lift truck) of lifting capacity over 1000kg.

4
4. Boiler equipment
(USER)
The delivery includes basic as well as additional elements depending on the type of order. On
receiving the boiler you should carefully inspect the boiler to ensure that it has been delivered
undamaged and complete. The additional and basic elements are listed below (Tab 4.1).
Tab. 4.1 Boiler equipment
Basic equipment
Unit
Number
of items
Central heating boiler
pcs.
1
Microprocessor regulator operates:
See regulator’s instruction manual.
pcs.
1
Blower fan
pcs.
1
Fuel feeding system with burner
kpl.
1
Fuel bin
pcs.
1
Boiler cleaning equipment
poker
brush
scraper
pcs.
1
Adjustable screws
pcs.
4
Additional equipment
Unit
Number
of items
LAMBDA SENSOR module*
pcs.
1
Cooling coil
pcs.
1
Documentation
Unit
Number
of items
Boiler maintenance and operation documentation
pcs.
1
Controller user's manual and warranty card
pcs.
1
Blower fan user's manual and warranty card
pcs.
1
Screw motoreducer user's manual
pcs.
1
ATTENTION!
The user should thoroughly read the instruction manual of the regulator, fan and
feeder along as well as the burner.
ATTENTION!
METAL-FACH reserves the right to implement changes to the parametres, equipment
and specification of the offered products without prior notice.
5. Use
(USER/INSTALLER)
Boilers intended for heating of residential buildings like: single-family and multi-family homes,
utility buildings, public buildings, and for heating of domestic hot water are equipped with an
automatic fuel feeding system. Thanks to the newest construction solutions, the SMATY EKO-
CARBON boilers can reach the capacity of 90%. The proper operation and highest performance of
the boiler depends on the quality of installation, right flue and appropriate service and
maintenance.
ATTENTION!
Boilers are intended for work in open- and closed-loop water systems with gravity or
forced circulation, with safeguards compliant with the requirements of the
applicable standard PN-B-02413 Heating and Heat Engineering, as well as with a
closed-loop system compliant with standard PN-EN 12828 Heating installations in
buildings. Designing.

5
6. Basic elements of the boiler
(USER/INSTALLER)
The water tank’s body is made as a structure welded from certified P265GH steel sheet of a
thickness of 6mm (for elements of the furnace) and S235JR steel sheet 4mm thick (for elements of
the water jacket).
The automatic feeder supplies fuel to the retort burner situated on one side of the boiler, in the
furnace chamber. A ceramic plate is situated above the burner, and steel shields line the remaining
part of the furnace chamber.
The boiler’s convective part is made up of horizontal water channels in which air swirlers have
been placed. The boiler’s exchanger is insulated with mineral wool shielded by a thin-walled sheet.
The boiler's insulated bottom is not cooled by water.
The flue, with a diameter of ɸext = 160mm (for powers 15, 20, 25kW) (SMART ECO-CARBON 30
=180mm), does not have a damper.
The ash pan for waste material from the furnace is situated under the burner. The steel door is
lined with insulating panels from the inside.
The boiler is equipped with connector pipes: feed and return for boiler water with diameter G 1
½”, water drain pipe with diameter G ¾”, connector tube of regulator sensor and STB. A
microprocessor-based regulator controls the boiler’s work and the combustion process.
Schematic 6.1 Basic elements of the boiler SMART EKO-CARBON
Schematics description
1. Exchanger
2. Feeder- burner system
3. Fuel bin
4. Feeder cover
5. Cleaning door
6. Inspection door
7. Ash door
8. Bin cover
9. Infeed stub with G11/2 ext. thread
10. Return stub with G1 1/2 ext. Thread
11. Discharge stub with G3/4 int. thread
12. Flue
13. Boiler temperature sensor settling sleeve
14. STB sensor settling sleeve
15. Ceramic plate
16. Burner head
17. Ash drawer
18. Controller
19. Electrical feedthrough
20. Pressure equalizing unit
21. Cooling coil (optional)
22. Steel shields

6
7. Basic dimentions of the boiler SMART EKO-
CARBON
(USER/INSTALLER)
ATTENTION!
Feet are present on boilers:
- from SMART EKO-CARBON 16 to SMART EKO-CARBON 30
Their height is 30 mm.
Schematic 7.1 Boiler dimentions SMART EKO-CARBON
Tab. 7.1 Boiler dimentions (mm) SMART EKO-CARBON
TYPE
SMART EKO-
CARBON 15
SMART EKO-
CARBON 20
SMART EKO-
CARBON 25
SMART EKO-
CARBON 30
A
1270
1270
1310
1310
B
545
545
590
590
C
1300*
1350*
1350*
1450*
D
545
615
710
710
E
1100*
1150*
1150*
1250*
E1
80
75
80
80
F
375
445
535
535
G
G3/4''
G3/4''
G3/4''
G3/4''
H
G11/2''
G11/2''
G11/2''
G11/2''
I
160
160
160
180
J
G11/2''
G11/2''
G11/2''
G11/2''
K
140*
140*
140*
140*
L
115*
115*
115*
115*
M
680
680
680
680
N
610
620
620
620
O
140
140
140
140

7
8. Technical specifications SMART EKO-CARBON
(USER/INSTALLER)
Tab. 8.1 Technical specifications SMART EKO-CARBON
PARAMETERS
UNIT
TYPE OF BOILERS
SMART EKO-CARBON 16
SMART EKO-CARBON 20
SMART EKO-CARBON 25
SMART EKO–CARBON 30
Nominal thermal output
[kW]
16
20
25
30
Boiler power range
[kW]
4,8 - 16
6 - 20
7,5 - 25
9 - 30
Heating surface
[m2]
1,63
2,0
2,6
3,08
Boiler water capacity
[L]
48
60
71
80
Maximum working pressure
[bar]
3
3
3
3
Maximum working temperature
[°C]
95
95
95
95
Test pressure
[bar]
4,5
4,5
4,5
4,5
Boiler class
-
5
5
5
5
Boiler efficiency
[%]
≤90
≤90
≤90
≤90
Single fuel load
[L]
200
200
200
200
Fuel
[-]
eco-pea coal
Power supply
-
~230V; 50Hz
Electrical power consumption during boiler work at
nominal power
[W]
230
230
230
230
Electric- power consumption (temporarily
maximum)
[W]
-
-
-
-
Temperature controller setting range
[°C]
60-85 (1 at a time)
Required chimney flue [pa]
[Pa]
20
20
23
30
Flue gas mass flow
[g/s]
10,4
14,16
16,5
20,62
Flow resistance δT [10k]
[mbar]
5,47
9,74
12,33
15,8
Flow resistance δT[20k]
[mbar]
1,36
2,43
3,80
4,3
Boiler weight
[kg]
345
370
427
460

8
9. Control and safety
(USER/INSTALLER)
1) Automatic control of the boiler can adjust:
boiler temperature
hot water temperature
fuel feeder operation time
feeder and vent manual control time
2) Temperature sensor
The STB mechanical protection is situated inside the boiler and prevent the heating system
from overheating. it is set by default at 95oC. if temperature exceeds 95, the vent is turned off. at
the same time central heating hot water pumps come on and the mixer valve opens.
10. Fuel
(USER)
The fuel for firing boilers equipped with a wormscrew feeder and retort burner is:
1) Grade II class a1 hard coal compliant with section 5.3 (Table 7) of standard PN EN 303-
5:2012
calorific value: > 26MJ/kg;
moisture: 11% in working condition;
ash content: 2 - 7 % in working condition of mass in dry state;
volatile element content: 15 -30% in working condition of mass in dry state;
11. Requirements for the boiler room and
boiler installation
(USER/INSTALLER)
In Poland, all the soild fuels boilers should be made in accordance with PN- 87/B-02411 Norm
„Soild fuels boilers”. The have been divided into two categories.
1) For small boilers under 25 kW, the following requirements should be met:
the boiler should be placed in the central position to the heated rooms and in a seperate
room.
the floor surface should be inflammable. If the floor is flammable, it should be covered
with steel metal sheet of 0,7 mm thickness and exceed the boiler contour by at least 50
cm. the boiler should be placed on inflammable base of 0,05 m above the floor and
secured by steel angles.
the boiler room can be lit naturally as well as artificially.
the location of the boiler in the room should enable free access to the boiler during
cleaning and maintenance works. The distance between the back of the boiler and a wall
should be at least 70 cm, the side of the boiler and a wall should be at least 100 cm and
the front of the boiler and a wall opposite should be at least 200 cm;
the height in a new building should be at least 220 cm. in old buildings the the boiler room
should be at least 190 cm high as long as the ventilation inside is sufficient (supply-
exhaust ventilation)
supply ventilation should be provided by an open slot of 200 cm2 in diameter and placed
up to 100 cm over the floor surface.
the exhaust ventilation should be provided by an exhaust duct of 14 x 14 diameter and
made from noncombustible material. Its outlet should be installed under the ceiling of the
boiler room. The exhaust duct should lead out over the roof and placed in the close vicinity
of the chimney. No shut down equipment can be installed on the duct.
2) Boiler rooms of heating power greater than 25kW should meet extra requirements, such
as:
the distance to the far-most chimney, at gravitional draught, cannot exceed 50 cm of the
chimney height.
the fuel and slag store should be located by the boiler room. The storing height up to 220
cm with a 50 cm free space above it.
the equipment for vertical and horizontal delivery of the fuel and slag should be
considered.
the fuel store should be equipped with natural ventilation that allows for full airing once an
hour in the fuel store and three airing circles an hour in the slag store.
the entrance door to the boiler room should be fire- resistant (0,5 class of fire resistance),
the minimum width 80cm and should open outside. the door should have a handle- free
system when opened from the inside and have a door handle when coming inside
the requirements for the ventilation are the same as those for the boiler rooms of lower
power; additionaly, in the boiler rooms of power greater than 400 kW, the supply exhaust
ventilation should be accompanied by mechanical ventilation that can be periodically
activated when feeding the fuel and removing slag. it must also be able to provide 10 airing
circles an hour
natural lightning which can light the front of the boiler should be considered in the room.
the total surface of the windows should equal at least 1/15 of the floor surface; half of the
windows in the room should open; the electrical lightining and electrical socket of max. 24
V should also be located in the room
inspection chamber that will allow cooling water should be located in the floor; its capacity
should equal the water capacity of the biggest boiler but not exceed 2m3
in the boiler room all the heating pipes should be insulated
The placing of the boiler together with the minimum distance requirements is presented in
the boiler room (Schematic 11.1)
ATTENTION!
The mechanical exhaust ventilation should not be used in the boiler room
ATTENTION!
Correct fresh air infeed to the boiler room will ensure efficient fuel burn.
ATTENTION!
Ensure that the carbon dioxide level in the room is not too high.

9
ATTENTION!
For more information on boiler room construction, refer to the 12.03.2009 Minister
of Infrastructure Law.
TIP!
The rules included in the law serve only as guidelines which must be verified as the
law is amended.
Schematic 11.1 Minimal requirements for the boiler room
12. Boiler installation
(USER/INSTALLER)
The important element of installation is correct setting and levelling of the SMART EKO-
CARBON boilers. The boilers do not require special base and need to be leveled with adjustable
feet. The boiler must be set in the vertical position.
1. Check that four adjustable feet have been provided
2. Level the boiler in relation to the floor (if the position
of the boiler is level, there is no need for the feet)
3. Place the feet into the dedicated slots.

10
4. Level the position of the boiler.
ATTENTION!
If the boiler is not levelled properly it can be damaged.
The boiler must be placed on a flameproof pad that exceeds the boiler outline by 2 cm. if the
boiler is located in the basement, it is recommended that it is placed on a base of at least 5 cm
thick. The bearing of the floor and the fire hazard conditions are the key elements of choosing the
right location for the boiler i.e:
20 cm - from any flammable materials
40 cm - from any flammable materials of C3 flammability
40 cm - from any flammable materials of unknown flammability
Tab. 12.1 Flammability of construction products:
Flammability of construction
products:
Construction products
A - noncombustible
Sandstone, concrete, bricks, fire-resistant plaster,
(concrete/ cement) mortar, tiles, granite
B - difficult to ignite
Wood- cement boards/beams, fibreglass, mineral
insulation
C1 - difficult to ignite
Beech wood, oak wood, plywood
C2 - normal combustibility
Pine, larch and spruce wood, corck, plank boards,
rubber floorings
C3 - Easily ignited
Asphalt plywood, celluloid compound, polyurethane,
polystyrene, polyethylene, plastics, PVC
13. Connecting the boiler to the heating
system
(INSTALLER)
The connecting of the boiler to the central heating system should be contracted to a producer-
certified company. This procedure should be confirmed in the warranty card which is attached to
this manual. The boiler must be connected according to the manufacturer’s guidelines and this
manual.
ATTENTION!
It is recommended for first start-up of the boiler to be performed according to
the guidelines given in the Operation and Maintenance Documentation, by a person
holding a valid license - (Information concerning persons licensed to start up the
boiler is available from the Manufacturer - tel. [phone]).
ATTENTION!
The temperature of the return water from the central heating boiler should not be
lower than 45C.
ATTENTION!
It is required that the boiler is connected to the heating installation by a four- way
valve.
The schematics of the connecting the boiler to the heating installation meet the PN- 91/B-
02420 requirements.
ATTENTION!
The boiler must not be placed in a damp and wet room as the enhanced corrosion
process will shortly damage the boiler.

11
Schematic 13.1 Connecting the boiler to the heating system diagram
Tab. 13.1 Symbols applied in the schematics
Designation
Key
RO
Deaeration pipe
RW
Expansion pipe
RS
Signal pipe
RP
Spill pipe
RB
Safety pipe
T1
Temperature
P1
Pressure
Schematic 13.2 Connecting boilers to the heating system diagram
Tab. 13.2 Symbols applied in the schematics
Designation
Key
T
Temperature sensor
Tk
Boiler temperature sensor
Tz
Outside temperature sensor
Tcw
Hot tap water temperature sensor
Tco
Central heating temperature sensor
Tpw
Return water temperature
Tpod
Feeder temperature sensor

12
Schematic 13.3 Connecting the boiler to the heating system
Figure description:
Opis rysunku:
1. Outside the building
2. Expansion vessel
3. Room regulator
4. Mixer
5. Heater
6. Heating circle
7. Floor heating
8. Central heating pump (CO)
9. Na zewnątrz budynku
10. Naczynie wzbiorcze
11. Regulator pokojowy
12. Mieszacz
13. Podgrzewacz
14. Obwód grzewczy
15. Ogrzewanie podłogowe
16. Pompa centralnego ogrzewania (C.O.)
Schematic 13.4 Connecting the boiler to the heating system with Laddomat and buffer
9. Central heating pump (CO)
10. Hot tap water pump (CWU)
11. Circulation pump
12. Additional pump P3
13. Block
14. Laddomat
15. 1,2,3,4 heating circle pumps
16. Thermostat mixing valve

13
14. Connection of boiler to heating
installation in closed-loop system
(INSTALLER)
ATTENTION!
The central heating system in the open system must meet the requirements set in
the PN-EN 12828:2006 norm- Heating systems in buildings and the PN-EN 303-
5:2012 Solid fuel boilers with manual and automatic feeding.
When installing the boiler in the closed system, it is important to use elements that prevent
overheating, excessive increase of pressure and use the controller of temperature during burning
process.
In the SMART EKO-CARBON boilers , there is a copper coil that is installed inside the boiler
exchanger. The coil is made from ribbed copper pipe.
Tab. 14.1 Examples of devices enabling heating systems protection
Part
Description
STB
Safety temperature stop with manual return to start position
Cooling coil
Cooling coil cools the system when the temperature exceeds
97C
BVTS Valve
BVTS valve prevents the flame from returning back into the
solid fuel feeder through flooding the fuel in heightened
temperature situation.
Pressure expansion tank
Preventing heightened pressure
Safetly fixtures
It includes safety valve, manometer and deaerator
ATTENTION
The boiler installed in the closed system must be equipped with all the safety
devices listed in Tab. 14.1.
ATTENTION!
The cooling coil should be connected to the water system. The power supply cannot
be the pressure tank unit because it needs power supply for its operation.
Schematic 14.1 Safety schematics of the boiler with the cooling coil and thermal
protection
The exchanger that is installed in the water coat is connected to the cold water cable, that
flows through it only when the thermal valve opens up when it exceeds the given temperature.
The water goes through the exchanger and receives the heat from boiler water coat and then is
led to the sewage system as hot water might damage it.
The exchanger is able to lower the temperature in the water coat by few degrees within
several seconds. If the temperature in the boiler coat drops below the set temperature then the
valve cuts off the water to the exchanger. In this solution, the high quality of the exchanger and
valve allows several consecutive switch off and on of the protection
In the solution with a built in safety coil e.g thermal protection is used (Schematic 14.2).

14
Schematic 14.2 BVTS Valve
The solid fuel boilers with an automatic feeding feature carry very little risk of an uncontrolled
rise in central heating temperature as the amount of the fed fuel is small. Moreover, in case of a
sudden temperature rise, the safety procedure will activate without the user.
If anything goes wrong, the controller will switch off the feeder for 30 sec in order to remove
the ember. If after 2 min from the ember removal, the feeder temperature does not drop, the
controller will try again. After four consecutive trials to reach 85oC the controller fails to lower the
feeder temperature, the boiler stops and emergency extinguishing will start.
The emergency extinguisher, that prevents from combustion of fuel in the tank, can also be
connected to the water system. In case the set temperature is exceeded, the extinguisher opens
the water valve and activated regardless of the power supply.
Thanks to the special design of SMART EKO-CARBON series boilers, the risk of flame
penetrating into the fuel dispenser is negligible and is counteracted by:
hermetic design/limit switch protection of the fuel dispenser;
device equalizing pressure between the furnace chamber and fuel dispenser
ATTENTION!
The gas pressure in the expansion vessel should be checked before use and
properly adjusted. The vessel should be inspected once a year.
ATTENTION!
The safety valve should be installed in the heat source or its closest vicinity e.g
power cable to the system in an easily accessible spot.
ATTENTION!
The safety valve should prevent the max excessing of work pressure no more than
10%
15. Requirements for the expansion vessel
(INSTALLER)
Every open water heating installation should be equipped with an expansion vessel, which
receives excess water volume and deaerates the installation. The vessel should be installed in the
top-most point of the installation, and if possible, vertically above the boiler (boilers).
The capacity of the vessel should be calculated using the unit capacity for every kW of power at
1-2 dm 3.
The expansion vessel is equipped in stubs to connect a riser safety tube, safety downpipe, and
a spill pipe and - connected to it - deaeration.
The diameter of the deaeration and spill pipe should be at least
[MM]
- Boiler efficiency [kW]
The most important requirements on the operation of the device are the following:
The expansion vessel should be about 3.5% of the total water volume in the water heating
installation and boiler.
Each boiler must have a safety tube and spill-pipe.
Installation should be equipped with a signal pipe and expansion pipe, and a stub for
deaerating the expansion vessel.
In the case of several boilers, each should have its own safety pipe in accordance with the
guidelines in PN-91/B-02413. Safety and spill pipes should not have any closing valves, and the
pipes and vessel should be protected from freezing.
16. Connecting the boiler to the power supply
(INSTALLER)
The boiler is designed for 230V/50 Hz voltage. Such connection should be carried out by a
certified specialist. The 230V/10A connection socket with grounding should be easily accessible.
The power supply to the boiler and room lighting should have own circuit.
The finishing and heating test should be noted in the Warranty Card. the Warranty Card
should then be sent over to the manufacturer in order for the user to be registered in the
company system.
ATTENTION!
First start-up of the boiler must be performed solely by service personnel trained by
the manufacturer, holding a current Authorized Service Technician or Distributor
certificate issued by METAL-FACH, or by a person holding an Electrician's license up
to 1.5 kW.
ATTENTION!
All the pumps, mixers, transmitters, ignition etc. are not parts of the controller
equipment.

15
Schematic 16.1 Electrical schematics for connecting the boiler–controller PLATINUM.
Electrical connection diagram of regulator:
Panel - control panel, and additionally, ecoSTER200/ecoSTER TOUCH room panel, λ- Lambda sensor module, B -module for support of additional heating circulations, BT –CT4 boiler temperature sensor, FS
–CT4 fuel feeder temperature sensor, CWU –domestic hot water temp. sensor, RS - CT4 return water temp. sensor, M1/M2 –CT4 temp. sensor of regulated mixer’s circulation, BH-upper CT4 buffer temp.
sensor, BL- lower CT4 buffer temp. sensor, WS- CT6-P weather temperature sensor, FT- CT2S flue gas temp. sensor, TR- universal thermostat of mixer (open-close), H- outlet for control of back-up boiler or
signaling of alarms, RE- relay (12V, max 80mA) for connection of back-up boiler/alarm, DS- inlet to fuel dispenser cover flap or door opening sensor, RMP- inlet of RPM sensor, L N PE- 230V~ grid power supply,
GR –earthing strip, STB –inlet to safety temp. limiter, PO –main feeder, W- fan, PM-domestic hot water circulating pump, PCO- boiler pump charging the buffer, IG-igniter, PCW- domestic hot water pump,
SM1/SM2- mixer’s actuator, PM1/PM2- mixer’s pump, CPU- control

16
Schematic 16.2 Electrical schematics for connecting the boiler.
Schematics of electric connections –additional B MODULE,
where
M3- regulated circuit temperature sensor (mixer 3) CT4 type
M4- regulated circuit temperature sensor (mixer 4) CT4 type
RM3- mixer 3 room thermostat
RM4- mixer 4 room thermostat
FS- BU feeder fuel level sensor
H2- outlet to the back-up boiler control or alarm or hot tap water
circulation pump
Relay
L N PE- power supply 230V~
P/M ¾ - mixer pump
SM ¾ - mixer servo
BU - The fuel tank from the bunker to the tank in the boiler
CPU- control
A -ecoMAX 860P2-T controller, module A

17
17. Connecting the boiler to the chimney
(INSTALLER)
Smoke flue
The flue pipes extract the fumes outside and intake air used for burning fuel. The necessary
draught depends on:
the temperature difference between the hot fumes and cold air
proper chimney height
the chimney diameter should be no less than 20 x 20 cm
chimney properties (smooth surfaces inside and outside) grout tightness
The effective height of the chimney is the difference between the highest grate and the flue
outlet. The effective height of the individual chimneys must be at least 4 m and of collective
chimneys for solid and liquid fuels should be at least 5 m. the difference between the two grates
can’t be greater than 6,5 m.
In case of sloping roofs, the chimneys should end at the ridge, in the area of free wind. It
prevents any draught brakes. Pay attention to the location of the building in relation to the
buildings around.
Choosing chimney
In most cases, choosing the right chimney is done by using an approximation method or
according to manufacturer’s recommendations. In special cases (bad pressure conditions, large
volume of fumes) the chimneys are chosen according to the PN-EN 13384-1+A2:2008 Norm.
Chimneys for solid fuels boilers
It must be noted that the solid fuel grates of nominal thermal power of >20 kW and without
vent require separate chimney.For the solid fuel grates, single-layer brick chimneys can be used.
Today, three-layer chimneys of smooth surface and good thermal insualtion are commonly used.
Flue
The boiler is connected to the chimney with a flue and smoke flue. The smoke flue consists of
pipes and fittings which are set in rooms. The smoke flues meet the requirements set in the
chimney fire hazard regulations and are often made from the same material as the main chimney.
The smoke flues should be made from non-flammable materials. The smoke flues or their
housings should meet the requirements set in the small chimneys fire test Polish Norm. It is
allowed to build the housing from solid bricks of 12 cm thickness. The bricks should be set on the
cement- plaster mortar with outer plaster or binder. The connections should be kept as short as
possible and set in the upright direction to the chimney in order to avoid heat losses and
additional resistance. They cannot be set to other rooms. The fumes pipes should not be set in
rooms where furnaces cannot be installed, moreover, they cannot installed in walls and ceilings.
Due to low fumes temperature, in order to protect the chimney from dampness and draught limit,
use the acid- resistant or ceramic chimney liners with condensate discharge to the waste drain.
The distance between the chimney and the closest tree top line should be at least 6m.
18. Boiler start-up
(USER/INSTALLER)
ATTENTION!
The controller settings can be regulated depending on the variety of the existing
central heating systems, heating requirements of the bulding and calorific value of
the fuel. The boiler parameters are set by the user and it is not serviced by the
company.
Before starting fire in the boiler, make sure that the central heating installation has been
installed properly and filled with water- until it flows over through the overflow pipe from the
expansion vessel.
For the best results, the installation should ideally be filled with softened water/ chemically
treated water, distilled water or rain water.
Moreover, it must be checked whether the retort burner has been cleaned from residue of
unburnt fuel, ash and slag from the previous burning and whether ash has been removed from
the ash pan.
Close all doors for the duration of firing up. After a stable flame is obtained, switch the
regulator to automatic work, causing the fuel feeder and fan to activate automatically.
Set the desired boiler work temperature, typically 70-80 ºC. From now on, the boiler will work
automatically, as per the settings configured by the user on the regulator according to the
regulator's instruction manual, intended for the user and attached to this instruction manual.
Inspect the burning process periodically through the observation door. Ash and slag from the
burnt fuel gradually fall into the container in the ash pan, meaning that the burner is self-cleaning.
In the event where a piece of slag is suspended between the boiler’s wall and the burner, remove
it using a poker or hook.
The regulator protects the boiler against: exceeding maximum water temperature in the
boiler, blowback of embers into the fuel feeder, and shuts down the entire system in the absence
of fuel.
A sensor reacting to flame reversion from the burner to the feeder is located on the feeder's
pipe between the retort burner and fuel dispenser. In such a case, the fan is shut down
immediately and the continuous feeder work is initiated until the burning or smoldering coal is
pushed from the feeder and retort burner into the ash pan.
The boiler’s user should read the user’s manual of the microprocessor-based regulator
thoroughly.
After starting a cold boiler, or at first start-up, the boiler can “sweat”. It may seem like it is
leaking. In such case, you must perform intense combustion (70-80ºC) in order to dry and warm
the boiler and chimney vent through, even for 2-3 days.
To ensure longer boiler operation, it advised to keep the fumes temperature 180C above the
outside temperature and the water temperature in the boiler should not be lower than 60C. In
such situation, keeping an appropriately low temperature in the radiators in the autumn-spring
season can be done, amongst others, by:

18
Properly selecting the boiler to the heated rooms.
Using, between the infeed and return of water, three- of four-way mixing valves, operated
manually or automatically.
Maintaining the continuity of the burning process requires periodical replenishment of fuel in
the dispenser. The frequency of replenishment depends on the intensity of the burning process
and should be determined individually based on experience. Replenishment is done every 1-3
days on average. The ash pan is to be emptied with the same frequency.
An insufficient amount of fuel in the dispenser causes dust to rise when the cover is opened
while the boiler is working. The absence of fuel causes the burning process to come to a complete
stop and requires the boiler to be fired up again.
In order to save fuel, the burner chamber as well as the convection channels must be kept
clean. The walls and water tubes in the furnace chamber are to be cleaned through the cleanout
and inspection doors.
ATTENTION!
Remember to close the feeder cover tightly.
ATTENTION!
Do not stand in front of the boiler when opening the boiler door as you may run
the risk of getting burn.
19. Tips when using the boiler
(USER)
the boiler can be operated by two adults who have familiried themselves with the manual
the presence of unsupervised children in the boiler room, or allowing them to operate the
boiler is forbidden.
ensure that the boiler is switched off during any works with flammable materials that
emimt flammable gases or fumes e.g glueing, painting etc.)
turn off the boiler before clearing out the exhaust carbon from the retort, gutter etc.(
„STOP” position)
turn off the boiler before stoking the boiler („STOP” position)
firing up on a layer of fuel, through the observation door, arrange crumpled pieces of
paper and lay small pieces of wood on them. Next, switch on the controller, light up the
paper and close the door. Do not use flammable liquids to fire up the boiler!
turn off the boiler before cleaning („STOP” position)
do not overheat the boiler
do not place any flammable material in the close vicinity of the boiler
during ash removal, any flammable materials should be kept at a distance of 150 cm from
the boiler
the ash should be placed in heat resistant containers with a lid
if the boiler operates at the temperature lower that 60C, the steel exchanger may „sweat”
and cause corrosion that shorten the boiler life span. That is why the minimum operation
temperature of the boiler should be 60C
after the heating season is over, the boiler and the smoke duct must be thoroughly
cleaned
the boiler room should be kept tidy and dry
ATTENTION!
The boiler is not meant to be operated by persons of lowered mental or physical
independence or by persons with no experience or limited knowledge about the
product if they are not supervised or instructed by the person responsible for their
safety.
ATTENTION!
Any tampering with the boiler electronic system or boiler construction is forbidden.
20. Boiler maintenece and cleaning
(USER)
ATTENTION!
Clean the boiler only when it is disconnected from the power supply.
In order to save fuel, the burner chamber as well as the convection channels must be kept
clean. The walls and the grates in the burner chamber should be cleaned through the charger and
burner doors. The boiler exchanger should also be cleaned regularly.
The convection channels and the flue should be cleaned through cleaning hatch on the boiler
flue or at the bottom in the side wall. It should be carried out with expendable metal brushes. The
boiler should be cleaned during the idle period, preferably every 100 hours. A thorough cleaning
of the boiler should be done monthly.
If the fuel is of low quality, cleaning should be done more often.
21. Istruction for utilising the boiler
(USER)
Before scrapping the boiler, all the electronic elements should be removed. They should be
disposed of according to the 2002/96/WE Electric and Electronic Equipment. In order to dispose of
the electronic elements you should contact the manufacturer.
The steel elements the boiler is made from should be scrapped in the dedicated locations
(scrap yards).
ATTENTION!
The boiler and its elements should not be disposed of toghether with other waste.

19
22. Spare parts list
(USER/INSTALLER)
Tab. 22.1 Spare parts
Spare parts
Article
Sensors
Boiler sensor
Feeder sensor
Hot Tap Water Sensor
Controllers
PLUM 860xx Regulator
Fan
DM 80 Fan
RMS-120 Fan
Sensor
Lambda sensor set
Lambda sensor case
Feeder
Motoreducer with engine
Feeder motor
Feeder screw
Instrumentation
Rubber loop
Bin sealing
Eye-hole sealing
Door sealing
Feeder sealing
Door handle
23. Possible faults and malfunctions
(USER)
Before calling the helpline read the FAQ section of the manual.
ATTENTION!
Please remember that in the case of unnecessary customer support, the customer
covers the costs of calling and work of the support unit. (price list available at
www.metalfachtg.com.pl).
You can also report problems online: www.metalfachtg.com.pl/zglos-problem-online.
Infoline: Paweł Czepiel
(Russian, English)
mobile [phone]
e-mail: [e-mail]