Metal-Fach SEG PELLET Operator's manual

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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
Boiler dimensions 12
Safety automation and control 14
Fuel 15
Requirements for the boiler house 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
Boiler start-up 34
When using the boiler, remember 36
Cleaning and maintenance of the boiler 37
Instructions for disposal of the boiler at the end of its service life 38
List of spare parts 38
Examples of equipment failure 39
Warranty conditions 41
Confirmation of inspection, warranty repair, maintenance service 44
EC/EU Declaration of Conformity 47
Warranty card 49
Notification of complaint 51
Report on the first start-up of the boiler 53
Report on the first start-up of the boiler 55

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

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

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

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Application
(User | Installer)
The boilers are designed for heating 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 construction solutions the SEG PELLET 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 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
pcs.
1
Blower fan
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
Device for dissipating excess heat power
pcs.
1
Documentation:
Unit of
measurement
Quantity
Technical and propulsory documentation of the boiler
pcs.
1
Operating instructions and warranty card for the controller
pcs.
1
Operating instructions and warranty card for the blower fan
pcs.
1
NOTE!
The user should carefully read the operating instructions for the controller, fan and
feeder together with the self-cleaning pellet burner.
NOTE!
METAL-FACH reserves the right to introduce changes to the technical parameters,
equipment and specifications of the offered goods without prior notice.

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Basic elements of boiler construction
(User | Installer)
The water body is made as a welded structure from approved steel sheets P265GH with a thickness of 5mm (for
furnace elements) and S235JR with a thickness of 4mm (for water jacket elements)
The automatic feeder delivers fuel (pellets) to a pellet burner located in the combustion chamber at the side of
the boiler. A ceramic plate is placed in front of the burner, steel screens are placed in the rest of the combustion
chamber.
The convection part of the boiler consists of horizontal water channels with flue gas swirlers. The boiler
exchanger is insulated with mineral wool covered with a thin-walled sheet. The insulated bottom of the boiler is
not water cooled.
The flue gas flue with diameter ɸzew = 180mm (in 15, 20, 25, 30 kW outputs) does not have a damper.
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", connection for boiler temperature sensor and STB. The boiler
operation and combustion process is controlled by a microprocessor controller.

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SEG PELLET boiler

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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 "Flue gas turbulators
10. Supply spigot with thread
G11/2"
11. Return stub with thread G
11/2"
12. Drain stub with thread G3/4"
13. Flue
14. Bushing for boiler temperature
sensor
15. STB bushing
16. Boiler doors
17. Burner head
18. Ash drawer Ash drawer
19. Levelling feet
20. Steel screens
21. STB
22. Fuse
23. Main switch
24. Controller display
25. Controller

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Technical data of the boiler
(User | Installer)
Parameters
S.I. Unit.
Boiler model
SEG PELLET
15
SEG PELLET
20
SEG PELLET
25
SEG PELLET
30
Nominal heat output
[kw].
15
20
25
30
Boiler output range
[kw].
4,5-15
6-20
7,5-25
9-30
Heating surface
[m2]
2,10
2,54
2,85
3,11
Water capacity
[L]
66
74
83
95
Maximum operating pressure
[bar].
3
3
3
3
Maximum operating temperature
[°C]
80
80
80
80
Test pressure
[bar].
4,5
4,5
4,5
4,5
Boiler class
[-]
5
5
5
5
Boiler efficiency
[%]
≤90,6
≤90,3
≤91,2
≤91,1
Fuel tank capacity
[L]
150
220
230
230
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]
120
120
120
120
Electric power consumption
(instantaneous at start-up)
[W]
420
420
420
420
Setting range of temperature controller
[°C]
60-80 (in 1°C steps)
Required chimney draught
[Pa]
24
26
28
30
Exhaust mass flow
[g/s].
10,19
13,87
17,88
19,29
Design flow resistance ΔT [10K]
[mbar].
5,47
9,74
12,33
15,8
Design flow resistance ΔT [20K]
[mbar].
1,36
2,43
3,80
4,3
Boiler weight
[kg].
379
453
484
488,5
* Boiler weight +/- 5kg.

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Boiler dimensions
(User | Installer)
NOTE!
Boiler feet are present:
- from SEG PELLET 15 to SEG PELLET 30
Their height is 30 mm.

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Type
SEG PELLET 15
SEG PELLET 20
SEG PELLET 25
SEG PELLET 30
A
1150
1150
1110
1160
B
530
530
530
580
C
1185
1380
1440
1440
D
780
815
860
860
E
908
1105
1162
1162
F
413
423
472
472
G
G3/4''
G3/4''
G3/4''
G3/4''
H
G11/2''
G11/2''
G11/2''
G11/2''
I
180
180
180
180
J
G11/2''
G11/2''
G11/2''
G11/2''
K*
214
250
246
246
L*
214
210
206
206
M
615
615
570
540
O
125
125
125
125
P
930
970
1020
1020
*Dimension does not include the height of the boiler levelling feet.

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Safety automation and control
(User | Installer)
1. Boiler automatics enables setting:
●boiler temperature;
●the hot water temperature;
●temperature in the central heating system;
●operation of auxiliary pumps;
●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.

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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.

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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 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. 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 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 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;

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●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

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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.