Metal-Fach WF Operator's manual

METAL-FACH Heating Technology
1
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 9
Boiler dimensions 10
Safety automation and control 12
Fuel 13
Requirements for the boiler house and boiler installation 14
Boiler installation 17
Connection of the boiler to the heating system 19
Connection of the boiler to a closed heating system 24
Requirements for the expansion vessel 26
Boiler connection to the electrical installation 27
Connection of boiler to chimney 30
Boiler start-up 31
When using the boiler, remember 33
Cleaning and maintenance of the boiler 34
Instructions for disposal of the boiler at the end of its service life 34
List of spare parts 35
Examples of equipment failure 36
Warranty conditions 37
Confirmation of inspection, warranty repair, maintenance service 40
EC/EU Declaration of Conformity 43
Warranty card 45
Notification of complaint 47
Report on the first start-up of the boiler 49
Report on the first start-up of the boiler 51

METAL-FACH Heating Technology
2
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.

METAL-FACH Heating Technology
3
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.

METAL-FACH Heating Technology
4
General information
(User)
The Operation and Technical Manual is one of the product parts, delivered together with the purchased central
heating boiler. The Operation and Technical Manual includes data concerning the construction and assembly as
well as the method of operation of boilers with a self-cleaning pellet burner of the SMART PELLET WF series.
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.

METAL-FACH Heating Technology
5
Application
(User | Installer)
The boilers are designed for heating residential buildings such as: single-family and multi-family houses, farm
buildings, public utility buildings, and domestic hot water. They are equipped with an automatic fuel feeding system.
Thanks to the use of modern structural solutions SMART PELLET WF boiler achieves efficiency ≥90%. Correct
operation and achieving the full capacity 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.

METAL-FACH Heating Technology
6
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
Fuel feed system with a pellet burner, self-cleaning
cpl.
1
Fuel tank
pcs.
1
Tools for cleaning the boiler:
●poker
●brush
●scraper
pcs.
1
Boiler levelling feet
pcs.
4
Additional equipment:
Unit of
measurement
Quantity
LAMBDA SONDA* module
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.

METAL-FACH Heating Technology
7
Basic elements of boiler construction
(User | Installer)
The water body is made as a welded structure from approved steel sheets P265GH with a thickness of 5mm (for
walls washed by flue gases) and S235JR with a thickness of 4mm (for elements of the water jacket).
The automatic feeder delivers fuel (pellets) to the pellet burner located in the combustion chamber at the side of
the boiler. In a part of the combustion chamber, there are horizontal slabs of refractory concrete.
The convection part of the boiler consists of horizontal water channels in which flue gas turbulators are placed.
The boiler exchanger is insulated with mineral wool covered with a thin-walled sheet. The insulated bottom of
the boiler is water cooled.
Flue gas flue is not equipped with a throttle. It is possible to change location of the flue on the rear wall
(horizontally directed) or on the upper boiler wall (vertically directed).
The ash pan for combustion waste is located under the burner. The steel door is lined with insulating panels on
the inside.
The boiler is equipped with boiler water supply and return connections of diameter
G 1 ½", water drain connection diameter G ¾", regulator sensor connection and STB. Boiler operation and
combustion process is controlled by a microprocessor regulator.

METAL-FACH Heating Technology
8
SMART PELLET WF boiler
1. Exchanger
2. Self-cleaning pellet burner
3. Fuel tank
4. Tank inspection door
5. Clean-out doors
6. Inspection doors
7. Ash door
8. Exhaust gas turbochargers
9. Supply spigot with thread
G11/2"
10. Return stub with thread G
11/2"
11. Drain stub with thread G3/4"
12. Flue
13. Bushing for boiler temperature
sensor
14. STB bushing
15. Boiler doors
16. Burner head
17. Ash drawer
18. Levelling feet
19. Laying of the refractory
concrete slabs during boiler
operation
20. STB
21. Main switch
22. Fuse
23. Controller display
24. Controller

METAL-FACH Heating Technology
9
Technical data of the boiler
(User | Installer)
Parameters
S.I. Unit.
Boiler model
SMART
PELLET WF
16
SMART
PELLET WF
20
SMART
PELLET WF
25
SMART
PELLET WF
30
Nominal heat output
[kw].
16
20
25
30
Boiler output range
[kw].
4,8-16
6-20
7,5-25
9-30
Water capacity
[L]
48
60
71
80
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
[%]
91,2
91,1
91,2
91,3
Fuel tank capacity
[L]
160
175
200
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]
115
115
115
115
Electric power consumption
(instantaneous at start-up)
[W]
415
415
415
415
Setting range of temperature controller
[°C]
60-80 (in 1°C steps)
Required chimney draught
[Pa]
24
25
24
24
Exhaust mass flow
[g/s].
10,19
13,87
17,88
19,29
Exhaust temperature at nominal output
[°C]
147,2
140,0
124,4
142,4
Exhaust temperature at minimum power
[°C]
77,8
75,2
69,8
72,2
Design flow resistance ΔT [10K]
[mbar].
0,57
0,90
1,41
2,03
Design flow resistance ΔT [20K]
[mbar].
0,14
0,22
0,35
0,50
Boiler weight
[kg].
335*
405*
445*
495*
* Boiler weight +/- 5kg.

METAL-FACH Heating Technology
10
Boiler dimensions
(User | Installer)
NOTE!
Boiler feet are present:
- from SMART PELLET WF16 to SMART PELLET WF 30
Their height is 30 mm.

METAL-FACH Heating Technology
11
Type
SMART PELLET WF 16
SMART PELLET WF 20
SMART PELLET WF 25
SMART PELLET WF 30
A
Min1150
Min1150
Min1200
Min1200
B
530
530
580
580
C*
1295
1350
1350
1450
C1*
1100
1155
1155
1190
C2*
1345
1400
1400
1490
D
646
716
806
806
E*
1100
1160
1160
1255
E1
140
140
140
145
F
520
590
680
665
F1
770
840
930
955
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
615
615
615
615
N
712
716
806
806
O
140
140
140
140
P
665
730
826
826
*Dimension does not include the height of the boiler levelling feet.

METAL-FACH Heating Technology
12
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.
3. A rising screw feeder feeding fuel to the burner.

METAL-FACH Heating Technology
13
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.

METAL-FACH Heating Technology
14
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 placed close to 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 shall be provided to enable the 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 must be non-combustible (class 0.5 fire resistance), at least 80 cm
wide, opening outwards; it must have a handleless locking system enabling it to be opened outwards
under pressure and inwards using a handle;

METAL-FACH Heating Technology
15
●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
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 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

METAL-FACH Heating Technology
16
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.

METAL-FACH Heating Technology
17
Boiler installation
(User | Installer)
An important element of installation is the correct positioning and levelling of the SMART PELLET WF type boiler,
the 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
corrosion, leading to the destruction of the boiler in a short time.

METAL-FACH Heating Technology
18
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
Changes to the flue pipe fixing