Metal-Fach SMART EKO-CARBON, SMART EKOCARBON 20, SMART EKOCARBON 25, SMART EKOCARBON 15 Maintance Manual

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SMART EKO-CARBON

ENGLISH

TRANSLATION OF THE ORIGINAL MANUAL

OPERATION AND MAINTENANCE DOCUMENTATION

ISSUE I 2018/04/01

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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 en sures 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.

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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

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ATTENTION!

Very important piece of information that needs to be read

TIP!

Information that should be read to make operation easier.

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.

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)

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.

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.

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Basic equipment

Unit

Number of items

Central heating boiler

pcs.

Microprocessor regulator operates:

See regulator’s instruction manual.

pcs.

Blower fan

pcs.

Fuel feeding system with burner

kpl.

Fuel bin

pcs.

Boiler cleaning equipment

 poker  brush  scraper

pcs.

Adjustable screws

pcs.

Additional equipment

Unit

Number of items

LAMBDA SENSOR module*

pcs.

Cooling coil

pcs.

Documentation

Unit

Number of items

Boiler maintenance and operation documentation

pcs.

Controller user's manual and warranty card

pcs.

Blower fan user's manual and warranty card

pcs.

Screw motoreducer user's manual

pcs.

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.

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.

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

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 EKOCARBON 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.

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6. Basic elements of the boiler

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

(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 ɸ ext = 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

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ATTENTION!

Feet are present on boilers:

- from SMART EKO-CARBON 16 to SMART EKO-CARBON 30 Their height is 30 mm.

TYPE

SMART EKO-

CARBON 15

SMART EKO-

CARBON 20

SMART EKO-

CARBON 25

SMART EKO-

CARBON 30

1270

1310

1310 B 545

545

590

590 C 1300* 1350* 1350* 1450

545

615

710

710 E 1100* 1150* 1150* 1250

375

445

535

535 G G3/4''

G3/4''

G11/2''

160

180

G11/2''

140* 140* 140* 140

115* 115* 115* 115

680

680 N 610

620

620 O 140

140

7. Basic dimentions of the boiler SMART EKO-

CARBON

(USER/INSTALLER)

Tab. 7.1 Boiler dimentions (mm) SMART EKO-CARBON

Schematic 7.1 Boiler dimentions SMART EKO-CARBON

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8. 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]

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]

Maximum working pressure

[bar] 3 3 3 3

Maximum working temperature

[°C]

Test pressure

[bar]

4,5

Boiler class

- 5 5 5 5

Boiler efficiency

[%]

≤90

Single fuel load

[L]

200

Fuel

[-]

eco-pea coal

Power supply

~230V; 50Hz

Electrical power consumption during boiler work at

nominal power

[W]

230

Electric- power consumption (temporarily

maximum)

[W] - - - -

Temperature controller setting range

[°C]

60-85 (1 at a time)

Required chimney flue [pa]

[Pa]

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

(USER/INSTALLER)

Tab. 8.1 Technical specifications SMART EKO-CARBON

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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. 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 (supplyexhaust 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)

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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.

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.

12. Boiler installation

(USER/INSTALLER)

The important element of installation is correct setting and levelling of the SMART EKOCARBON 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.

Schematic 11.1 Minimal requirements for the boiler room

Page 11

4. Level the position of the boiler.

ATTENTION!

If the boiler is not levelled properly it can be damaged.

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

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. +48 85 711 94 56).

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.

ATTENTION!

The boiler must not be placed in a damp and wet room as the enhanced corrosion

process will shortly damage the boiler.

13. Connecting the boiler to the heating

system

(INSTALLER)

The connecting of the boiler to the central heating system should be contracted to a producercertified 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.

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:

The schematics of the connecting the boiler to the heating installation meet the PN- 91/B-

02420 requirements.

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Designation

Key

Deaeration pipe

Expansion pipe

Signal pipe

Spill pipe

Safety pipe

Temperature

Pressure

Designation

Key

Temperature sensor

Boiler temperature sensor

Outside temperature sensor

Tcw

Hot tap water temperature sensor

Tco

Central heating temperature sensor

Tpw

Return water temperature

Tpod

Feeder temperature sensor

Schematic 13.1 Connecting the boiler to the heating system diagram

Tab. 13.1 Symbols applied in the schematics

Schematic 13.2 Connecting boilers to the heating system diagram

Tab. 13.2 Symbols applied in the schematics

Page 13

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.)

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

Schematic 13.3 Connecting the boiler to the heating system

Schematic 13.4 Connecting the boiler to the heating system with Laddomat and buffer

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14. Connection of boiler to heating

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.

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.

installation in closed-loop system

(INSTALLER)

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

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).

Page 15

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%

[MM]

- Boiler efficiency [kW]

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. 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

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

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.

Page 16

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

Page 17

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

Page 18

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.

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)

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:

Page 19

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.

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.

ATTENTION!

Clean the boiler only when it is disconnected from the power supply.

ATTENTION!

The boiler and its elements should not be disposed of toghether with other waste.

 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.

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

20. Boiler maintenece and cleaning

(USER)

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).

Page 20

22. Spare parts list

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

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).

(USER/INSTALLER)

Tab. 22.1 Spare parts

23. Possible faults and malfunctions

(USER)

Before calling the helpline read the FAQ section of the manual.

You can also report problems online: www.metalfachtg.com.pl/zglos-problem-online.

Infoline: Paweł Czepiel

(Russian, English)

mobile +48 663 453 222

e-mail: p.czepiel@metalfach.com.pl

Page 21

Question

Answer

Explanation

How long can the boiler operate on full tank?

There is no simple answer. It can be assumed that the boiler can operate for 3-4 days.

The continuous burn time depends on:

 fuel calorific value, heating insulation of the building  kind of installation i.e. floor heating, radiators, boiler  boiler exchanger cleanliness, amount of ash in the ash tray  outside temperature, inside temperature, combustion quality

What is the lowest temperature of the boiler?

The higher the temperature the better but the lowest temperature should not fall below 60oC.

The boiler should be adjusted in the way so that when the boiler temperature is 60oC, the fumes temperature is 140oC. It ensures the best efficiency of the boiler. At such temperatures, the boiler will not „sweat” and get wet as there is no fumes gas condensation

What is the minimum return temperature?

The recommended return temperature is 10oC lower than the feeding temperature.

In practice, without any mixing valves or other mixing devices it is impossible. It is recommended to install a four-way valve to make the boiler operate on short circulation at high temperature and the installation on any set temperature. The protection of the boiler is still in place and equals the boiler feeding temperature.

How is the boiler protected against freezing?

The boiler is protected against freezing with the controller software.

At the temperature below 8oC, the controller opens up the mixing valve and turns on the central heating pump in order to prevent the water in the installation from freezing. Additionally, all the pipes that are exposed to heat loss should be extra insulated. Check if all the windows in the vicinity of the piping are complete and shut and there are no holes in the walls etc.

During the initial start-ups the boiler „sweats”.

It is due to condensation.

Heat the boiler above 80oC and keep this temperature for at least 6 hours. If necessary, repeat.

Why is the fuel combustion so rapid?

The chimney diameter is too big. Air flow is too high. Controller set is incorrect.

Close the throttle on the flue. Check the sealant on the door. Regulate the airflow. Regulate the controller or call the helpline.

Why is there grime in the boiler?

There are few conditions in which grime collects in the boiler e.g. wet fuel, bad combustion conditions, oversized boiler, low boiler temperature.

In the first case, the wet fuel produces low fumes temperature causing fumes condensation. In such case, not only does the boiler get dirty but the chimney as well. In the second case, it is usually caused by insufficient amount of air in the combustion chamber. It is enough to let in some more air and the flame with gases will burn completely. In the case of an oversized boiler, the temperature is reached very quickly making the boiler idle and the fumes gases burn out causing grime collection. The worst scenario is when the temperature is too low. If the boiler is not connected properly, it becomes a thermostat, which means that if you want ot lower the temperature in your house, you need to lower the boiler temperature. It is recommended to install mixing valves.

What to do when the water in the boiler boils ?

Do not panic. Nothing serious usually happens. The reason for that might be lack of heat reception, open ash tray door, feeding easily burnt materials e.g. paper.

In such case, when the temperature exceeds 90oC, the controller activates all the pumps( even the ones that are switched off) and opens up the mixing valve in order to cool down the boiler. If the door is open please close it. It is essential not to let cold water into the installation as it may cause an explosion. In the case of an oversized boiler, the temperature is reached very quickly making the boiler idle and the fumes gases burn out causing grime collection. The worst scenario is when the temperature is too low. If the boiler is not connected properly, it becomes a thermostat, which means that if you want ot lower the temperature in your house, you need to lower the boiler temperature. It is recommended to install mixing valves.

What is a heating curve?

Heating curve is an outside temperature graph in relation to the central heating water temperature. The heating curve is a calculated heating temperature in relation to the outside temperature.

The heating curve graph is included in the controller manual.

Page 22

Question

Answer

Explanation

The blower fan is not working?

The blower fan is not working because it might be unplugged. The boiler has overheated and STB protection has intervened.

Put the blower plug back in. After the boiler has cooled down, press the STB button.

Is it allowed to fill up the installation with water while the boiler is working?

Filling up the installation while the boiler is working is absolutely forbidden.

Letting water into the boiler runs the risk of unsealing the boiler and installation. If the boiler is overly heated it may unseal and crack. In the case of an oversized boiler, the temperature is reached very quickly making the boiler idle and the fumes gases burn out causing grime collection. The worst scenario is when the temperature is too low. If the boiler is not connected properly, it becomes a thermostat, which means that if you want to lower the temperature in your house, you need to lower the boiler temperature. It is recommended to install mixing valves.

Is it advisable to install a fourway valve?

Yes, it is advisable to install a four-way valve.

A four- way valve is a very useful device which:

 protects the boiler against low temperature corrosion, mixes the infeed water with return so as to

achieve a stable agent for the central and floor heating

 enables smooth temperature control by an actuator, saves fuel, protects the boiler from corrosion and

prolongs boiler life span.

What is central tap water priority?

The central hot tap water priority is a controller feature that heats up the hot tap water vessel and then activates the central heating.

The feature is used in hot tap water consumpiton conditions.

What is hot tap water decontamination?

It is a feature of the controller that heats up the tap water tank to 70oC in order to decontaminate it.

The feature kills the Lagionaella bacteria in the central tap water circuit. If the water in the tank is kept below 50oC, the bacteria settles. The situation is possible to take place when the tank temperature is kept below 50oC or when the taps are rarely open.

What is the anti-lock?

Antilock feature works only with pellet.

The main purpose of the device is to keep the heat in the furnace. If the boiler shuts off after reaching the required temperature then, provided the temperature does not fall, the antilock ativates for 5-10 seconds every 20 minutes. The antilock can be set according to the preferences and boiler power. Usually, it is set for 5 seconds.

The feeder engine is working but not stoking.

The engine is working but not stoking because the pin is off or the feeding screw is worn off.

Replace the pin. Replace the feeding screw.

What fuel can I use in boilers with a gutter feeder?

Pellet can be burned in boilers with a gutter feeder.

Pellet with granulation Φ 6-8

The feeder does not work and the engine is humming.

The feeder does not work and the engine is humming because it is probably blocked and the pin is off. Another reason might be that the engine capacitor is worn off.

Open the cleaning hatch door, remove the „foreign body” e.g. a stone. Replace the engine capacitor.

The feeder engine is overheating.

The feeder engine is overheating because the capacitor is worn off.

Replace the engine capacitor.

Why is the pin off?

The pin is off because the pellet granulation is different than recommended, there are too much saw dust in pellet. The fuel might be wet or there is sinter in the burner.

Change pellet. Dry off the fuel. Clean the burner.

The fuel is burning on one side of the burner only.

It happens because the burner air chamber is dirty. There is no sealing under the retort collar or the ventilator is broken.

Clean the burner air chamber. Put on the sealing cord. Clean the ventilator.

Why is the fuel burning in the boilers with automatic feeding.

It is due to bad feeding times. Blower settings are wrong.

Adjust fuel feeding and/or the blower (see the setting table). Call the helpline.

Page 23

Question

Answer

Explanation

Why is there sinter on the burner?

Sinter is made by excessive air infeed.

Regulate the blower operation.

Why does the unburt coal fall into the ash tray?

The unburnt coal falls into the ash tray because the coal feeing rate is too big.

Lower the feeding by 2-3% and check for improvement.

What does the „clean the boiler” alarm mean?

It means that the boiler exchanger is dirty. The fumes temperature is higher than 280oC.

Clean the boiler exchanger. Lower the fuel feeding.

Why does the unburnt pellet fall into the ash tray?

Because the pellet feeing rate or ventilation are too big.

Lower the feeding by 2-3% and check for improvement, if necessary, repeat the procedure. Lower the ventilation by 2-3% and check for improvement, if necessary, repeat the procedure.

What does the „feeder overheat” mean?

The overheated feeder can mean that the fuel bin door is open. The seal under the bin is broken. The cleaning hatch seal is broken. The seal between the burner and feeder pipe is broken. Loose screws on the connections of the basket between the feeder and burner.

Close the fuel bin door replace the seal under the bin door. Replace the seal under the basket. Replace the seal. Tighten all the screws. What does the „boiler overheat” alarm mean?

The boiler overheats when the temperature exceeds 90oC The hold time is too short.

Cool down the boiler.

What does the „fumes sensor damaged” alarm mean?

It means that the fumes temperature has exceeded 320oC. The fumes temperature sensor is broken.

Lower the fuel feeding. Replace the fumes temperature sensor.

Smoke coming from the boiler door.

It means that there is no draught.

Tighten wall in the connection between the flue pipe and the chimney. Check if the patency of the chimney, and its parameters are as recommended by the manufacturer. Seal the outlet of the boiler to the chimney vent, preventing the suction of cool air. If the chimney diameter is too small, you can install an extraction fan.

There is water coming from the convection channels.

The fuel used is wrong or the humidity is too high. Combustion temperature is too low. Too little air feed. Fumes throttle is closed. Controller is set incorrectly.

Use fuel of proper energy value and humidity. Open the air throttle. Open the fumes throttle. Set the controller right.

During the initial start-ups the boiler „sweats”.

It is due to condensation.

Heat the boiler above 80oC and keep this temperature for at least 6 hours. If necessary, repeat.

Why is the fuel combustion so rapid?

The chimney diameter is too big. Air flow is too high. Controller set is incorrect.

Close the throttle on the flue. Check the sealant on the door. Regulate the airflow. Regulate the controller or call the helpline.

What features does the microprocessor regulator have?

See regulator’s instruction manual

Page 24

Warranty conditions

(USER)

User’s Declaration: I hereby declare that the boiler (hereinafter also referred to as the “appliance”) has been delivered

to me as per my order, new and complete. The Seller has familiarized me with the appliance’s

operation and provided a complete set of documentation (including, in particular: Operation and Maintenance Documentation including, among other things, instructions for installation and use of the

appliance, guarantee terms). I take note of the manufacturer’s recommendation to conduct annual

technical inspections of the appliance, which are to be confirmed on the guarantee card.

…………………………………………………………….

Date and legible signature of the User

Scope of the guarantee:

1. Liability arising from the guarantee covers only defects resulting from causes present in the appliance at the time of its issue to the User.

2. A guarantee on the appliance is granted by the manufacturer (also referred to as the

"Guarantor”): Jacek Kucharewicz, conducting economic activity under the company name Metal

Fach Jacek Kucharewicz, 16-100 Sokółka, ul. Sikorskiego 66, NIP (Taxpayer Identification Number): 545-100-10-62, REGON 050073833, telephone +48 85 711 94 56).

3. Under the guarantee, the User obtains the right to free repair of the appliance if defects of the appliance are revealed during the guarantee period. In the event where the Guarantor determines that it is impossible to repair the appliance or part thereof, the Guarantor reserves the right to replace the appliance or part thereof with a new one.

Guarantee period:

On the appliance (boiler) – 2 years from the date of sale, but no longer than 36 months from the

date of its production, with the exception of:

a) the exchanger – the guarantee on which has a duration of 5 years from the date of sale; b) moving parts, cast iron, mechanical parts, parts of the worm, igniter – the guarantee on which

has a duration of 1 year from the date of sale;

c) consumables (e.g. sealing cord, seals, vermiculite, chamotte), electrical components, bolt

securing the worm’s clutch, pins – which are not covered by the guarantee.

Terms of exercising rights under the guarantee:

1. Installation of the appliance according to the Operation and Maintenance Documentation (particularly connection of the boiler to a properly built installation, performance of first start-up according to the guidelines of the appliance’s manufacturer, application of devices protecting the boiler against return of cold water (four-way valve with actuator, laddomat, etc.)

2. Sending a copy of the guarantee card, properly filled out, signed and sealed by the Seller, to the Manufacturer’s address within 30 days from the date of the appliance’s sale

3. Presentation of the guarantee card, properly filled out (signed and sealed by the seller), at the time of filing a claim, along with proof of the appliance's purchase (e.g. receipt, invoice). In the event of the User’s loss of the guarantee card, a duplicate will not be issued.

4. Adherence by the User to the guidelines given in the appliance’s Operation and Maintenance Documentation.

5. Performance of first boiler start-up within 6 months from the date of the appliance’s installation by the fitter in accordance with the guidelines given in the Operation and Maintenance Documentation, by a person holding a valid license to do so (Information concerning persons licensed to start up the boiler is available from the Guarantor - +48 85 711 94 56), confirmation of this fact in the guarantee card, and submission of a start-up report to the Guarantor. First boiler start-up is a paid service, and its cost is covered by the User.

6. Performance of annual inspections of the appliance according to the guidelines given in the Operation and Maintenance Documentation, by specialized companies holding the relevant licenses (a list of examples of specialized companies is available from the Manufacturer telephone number

7. +48 85 711 94 56), and recording of their performance on the guarantee card. Inspection of the appliance is a paid service.

8. Performance of maintenance of the appliance (e.g. adjustment, cleaning, measurement of the appliance, analysis of flue gas) by specialized companies holding the relevant licenses (a list of examples of specialized companies is available from the Manufacturer – telephone number +48 85 711 94 56), according to the guidelines given in the Operation and Maintenance Documentation, and recording of maintenance services on the guarantee card. The User may report a need for intervention by service technicians to the Guarantor (Infoline +48 858 880011, www.metalfachtg.pl/zglos-problem-online). The maintenance service is a paid service.

9. Performance of guarantee repairs solely by specialized companies holding the relevant licenses (a list of specialized companies is available from the Guarantor - tel. +48 85 711 94 56), and recording of their performance on the guarantee card.

10. Use of spare parts and consumables meeting the manufacturer’s specifications. It is recommended to use original spare parts.

11. The guarantee covers the territory of the Republic of Poland.

The guarantee does not cover defects of the appliance arising from:

1. Failure by the User to adhere to the conditions specified in the Operation and Maintenance Documentation and the instructions given therein concerning transportation, installation, operation, use and maintenance of the appliance;

2. Improper storage and transportation by the User;

3. Damage to subassemblies of the appliance due to the application of improper electrical voltage by the User. In the case of direct or indirect power supply to the appliance from power generators, UPS systems or devices, the User should consult the specifications of power supply devices with the manufacturer;

4. Defects of the appliance caused by a defective heating installation connected to the appliance;

5. Overheating of the boiler by the User;

6. Connection, by the User, of the boiler to a closed-loop system without the application of the appropriate cooling device.

7. Application by the User of improper fuel or fuel of poor quality;

8. Independent modification of the appliance by the User.

Page 25

Claim procedure:

1. In the event where improper work of the appliance is detected, prior to filing a claim, make sure that all steps were taken according to the Operation and Maintenance Documentation.

2. The User should report the need to repair the appliance under the guarantee without delay, preferably within 7 days from the date on which the defect is detected. A claim may be filed directly to the Seller or Guarantor (Infoline +48 858 880011, www.metalfachtg.pl/zglos-problemonline).

3. It is recommended to cease use of a defective appliance.

4. The User is obligated to provide free access to the appliance (particularly in a manner enabling removal of the appliance’s housing, access to valves).

5. Guarantee repairs will be performed by the Guarantor or by a specialized company indicated by the Guarantor.

6. Performance of the obligations arising from the guarantee will occur within 14 work days, counting from the date on which the appliance is made available (at the place of its installation) by the User.

7. The User arranges the date on which the appliance is to be made available with the Guarantor.

8. Depending on the scope of repair, it may be performed at the User’s location, at the place where the appliance is installed, or at the establishment of the Guarantor or specialized company performing activities in the Guarantor’s name.

9. Repair performed under the guarantee is to be confirmed on the guarantee card.

10. The guarantee is extended by the time during which the user was unable to use the appliance due to a defect of the appliance covered by the guarantee.

11. The guarantee does not exclude, limit or suspend the buyer’s rights arising from laws concerning guarantees on defects of a sold object.

Page 26

Confirmation of performance of inspection, guarantee repair, maintenance service:

Item

no.

Date of performance

Description of performed activities

Contractor’s signature and seal

Page 27

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Page 28

Conformity declaration WE/UE

Person approving the documentation:

Location: Sokółka Date 04.2017

Włodzimierz Lewko

(Name, Surname, Signature)

Location: Sokółka Date 04.2017

Jacek Kucharewicz (Name, Surname, Signature)

1. Manufacturer:

2. Product name and intended use

Relevant documents:

1. Act of 19 April 2016 on conformity assessment and market monitoring systems (Journal of Laws item 542).

2. Regulation of the Polish Minister of Economy of 21.10.2008 on the essential requirements of mechanical devices ( Polish Journal of Laws no. 199 item 1228) with change published in Polish Journal of Laws 2011

Technical documentation:

METAL-FACH Jacek Kucharewicz Ul. Sikorskiego 66 16-100 Sokółka NIP 545-100-10-62

Solid fuel steel central heating boiler with automatic feeder. Type SMART EKO-CARBON …………………………………………. Manufacturer’s number………………..………………………………. Year of production 20……………………………………………………….

Electromagnetic compatibility directive -2014/30/UE

no. 124 item 701. Directive 2006/42/WE Machinery.

1. Norm PN-EN 303-5:2012: Heating boilers for solid fuels, hand and automatically stocked of nominal power of 500 kW.

2. Norm PN EN ISO 12100:2012 Safety of machinery –Basic concepts, principles for design – part 1: Basic terminology, Methodology.

3. Norm PN EN 1708-1:2010 Welding — Basic welded joint details in steel Part 1: Pressurized components

4. Norm PN EN ISO 9606-1:2014-02 Welder Approval Testing.Steel

5. Norm PN-EN 60335-2-102 Household and similar electrical appliances. Safety. General requirements

6. Norm PN EN 60335-2-102:2006/A1:2010 Household and similar electrical appliances. Safety. General requirements of gas, oil and solid fuel burning devices with electrical connections.

7. Norm PN EN 61000-6-2:2008 on electromagnetic compatibility (EMC)-Part 6-3 General norms- Reistance in industrial environments

8. Norm PN EN 61000-6-3:2008/A1:2012 on electromagnetic compatibility (EMC)-Part 6-3 General norms-Emission norms in environments: habitated, retail and of low industry

The product has the marks

Page 29

Power: ……………………………………….……………. [kW]

Type: …………………………………………………………….

Number: ……………………………………………………………….

Production date: ……………………………………….……………………………………….……………………………………….………………………………………………………………………………………………..……….

Purchase date: ……………………………………….……………………………………….……………………………………….…………………………………………………………………………………………………..……...

Buyer’s name: ………………………..……………………………………….……………………………………….……………………………………….…………………………………………………………………………………

Address: ……………………………………….……………………………………….……………………………………….……………………………………….……………………………………………………………………

……………………………………….

Date of purchase and seal

……………………………………….

I agree to the warranty conditions

Buyer’s signature

Warranty Card for the steel boilers, central heating water boilers

Personal data given in this form are processed by Jacek Kucharewicz, conducting economic activity under the company name Metal Fach Jacek Kucharewicz, 16-100 Sokółka, ul. Sikorskiego 66, NIP (Taxpayer Identification Number): 545-100-10-62, telephone number +48 85 711 94 for the purpose of performing the provisions set forth in the guarantee terms - pursuant to the act of 29 August 1997 on personal data protection (consolidated text: Journal of Laws of 2014, item 1182). The User has the right to access their personal data, correct them, demand cessation of processing of their personal data, as well as to raise an objection against processing of data in cases specified by the law. Any correspondence concerning processing of personal data is to be addressed to: Metal Fach Jacek Kucharewicz, 16-100 Sokółka, ul. Sikorskiego 66. Providing personal data is voluntary. Pursuant to the act of 29 August 1997 on personal data protection (consolidated text: Journal of Laws of 2014, item 1182), we hereby inform that the personal data given in this form will be subject to protection against access by unauthorized persons.

Page 30

Page 31

Client's details: ………………………………………………………………………………… ………………………………………………………………………………….………………

(first name, second name, address, contact number)

Purchase document number: date: …………………………………………………………… Payment document number: ………..……….………………………………………………. Seller’s signature: …………………………………………………………………………

Batch and product number: …………………………………….………………………… ………………………………….………….……………………………………………… Name of the product under warranty: ……………………………………………… ………………………………………………………………………………………………….

Warranty period:: valid invalid

Detailed description of the fault: ………………………………………………………………….. …………………………………………………………………………………………………. ………………………………………………………………………………………………….

Warranty comencement conditions:

1. Payment confirmation from the point of sale is the condition of warranty procedure comencement.

2. The warranty card is the only condition for free repair.

3. A person filing a claim assumes the obligation to reimburse expenses incurred by METAL FACH Jacek Kucharewicz in the event of an unjustified call of the service team or failure to meet the conditions specified in points 1 or 2 (net cost of every commenced hour of one service technician’s work - PLN 70, net travel cost PLN 1/km in both directions).

4. Legible signature of the Purchaser to confirm the familiarisation with the warranty procedure conditions

………………………………………………………………………… …………………………………………………………………………

(legible signature of Purchaser) (Warrant's signature)

I declare, that I have read and understood the Warranty Conditions under which I am claiming warranty and I allow my personal data to be processed for the purpose of warranty, in accordance with the Personal

Data Protection Act dated 29/08/1997 (Dz. Ust. No. 133, item 883).

…………………………………………………………………………

(legible signature of Purchaser)

The Producer is obligated to take warranty actions within 14 days from receiving the claim in writing on the producer’s form.

Warranty claim

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Page 33

Boiler room

Valid

Invalid

Comments

In compliance with the conditions of chapter 13. Boiler room and boiler installation requirements

In compliance with the conditions of chapter 19. Connecting the boiler to the chimney

Central heating system

Valid

Invalid

Comments

In compliance with the conditions of chapter 15 Connecting the boiler to the heating system

In compliance with the conditions of chapter 17. Expansion vessel requirements

There is no other heating source. If there is, how does it affect the operation of the boiler?

Anti-freeze protection of the boiler

Connecting the components to the electrical system

Valid

Invalid

Comments

The conditions are in accordance with the Operation and Mainteneance Documentation in the chapter:

18. Connecting the components to the electrical system.

Components test

Valid

Invalid

Comments

The sensors are placed in the correct places.

The readings are in accordance with the actual state.

The fan rotation is correct.

Opening the blower door with blow power.

The screw rotation is correct.

Boiler start-up

Valid

Invalid

Comments

The hydraulic connection to the system is tight.

Fireman/Strażak system test (if installed)

Checking the connection between the fuel feeder and boiler.

Stoking fuel to the fuel bin.

Checking the coal feed by the feeder

Boiler start-up in accordance with chapter 20. Boiler start-up

Initial regulation of the boiler parameters settings.

Final regulation of the boiler parameters settings.

Start-up report

(Owner’s copy)

In order to verify your purchase and warranty validity please send the report on the start-up within 30 days. You can do it by:

1. E- mailing the scan or photo of the report.

2. Sending a letter with the copy of the report, the company's address can be found at the end of the manual.

1182), we hereby inform that the personal data given in this form will be subject to protection against access by unauthorized persons.

Page 34

User's training certificate on

YES

Comments

Start-up date

………………………..

Boiler name

………………………..

Boiler power (kW)

………………………..

Serial number

………………………..

Training on safe operation of the boiler is included in chapter 21. When operating the boiler you should remember

…………………………………………………….

(TECHNICIAN’S NAME)

…………………………………………………….

(ADDRESS)

…………………………………………………….

(COMPANY SEAL)

…………………………………………………….

(OWNER’S NAME)

…………………………………………………….

(ADDRESS)

…………………………………………………….

CONTACT NUMBER

Training on boiler regulator and combustion control.

Blower rpm

Boiler maintenance chapter 22. Cleaning and maintenance of the boiler

Required fuel quality chapter 12. Fuel

…………………………………………………….

(SIGNATURE)

…………………………………………………….

(SIGNATURE)

Procedure to follow in emergency situation 25. Examples of device faults and malfunctions

Page 35

Boilre room

Valid

Invalid

Comments

In compliance with the conditions of chapter 13. Boiler room and boiler installation requirements

In compliance with the conditions of chapter 19. Connecting the boiler to the chimney

Central heating system

Valid

Invalid

Comments

In compliance with the conditions of chapter 15 Connecting the boiler to the heating system

In compliance with the conditions of chapter 17. Expansion vessel requirements

There is no other heating source. If there is, how does it affect the operation of the boiler?

Anti-freeze protection of the boiler

Connecting the components to the electrical system

Valid

Invalid

Comments

The conditions are in accordance with the Operation and Mainteneance Documentation in the chapter:

18. Connecting the components to the electrical system.

Components test

Valid

Invalid

Comments

The sensors are placed in the correct places.

The readings are in accordance with the actual state.

The fan rotation is correct.

Opening the blower door with blow power.

The screw rotation is correct.

Boiler start-up

Valid

Invalid

Comments

The hydraulic connection to the system is tight.

Fireman/Strażak system test (if installed)

Checking the connection between the fuel feeder and boiler.

Stoking fuel to the fuel bin.

Checking the coal feed by the feeder

Boiler start-up in accordance with chapter 20. Boiler start-up

Initial regulation of the boiler parameters settings.

Final regulation of the boiler parameters settings.

Start-up report

(METAL FACH Jacek Kucharewicz company's copy)

In order to verify your purchase and warranty validity please send the report on the start-up within

30 days. You can do it by:

1. E- mailing the scan or photo of the report.

2. Sending a letter with the copy of the report, the company's address can be found at the end of the manual.

1182), we hereby inform that the personal data given in this form will be subject to protection against access by unauthorized persons.

Page 36

User's training certificate on

YES

Comments

Start-up date

………………………..

Boiler name

………………………..

Boiler power (kW)

………………………..

Serial number

………………………..

Training on safe operation of the boiler is included in chapter 21. When operating the boiler you should remember

…………………………………………………….

(TECHNICIAN’S NAME)

…………………………………………………….

(ADDRESS)

…………………………………………………….

(COMPANY SEAL)

…………………………………………………….

(OWNER’S NAME)

…………………………………………………….

(ADDRESS)

…………………………………………………….

CONTACT NUMBER

Training on boiler regulator and combustion control.

Blower rpm

Boiler maintenance chapter 22. Cleaning and maintenance of the boiler

Required fuel quality chapter 12. Fuel

…………………………………………………….

(SIGNATURE)

…………………………………………………….

(SIGNATURE)

Procedure to follow in emergency situation 25. Examples of device faults and malfunctions

Page 37

Page 38

METAL-FACH JACEK KUCHAREWICZ

UL. SIKORSKIEGO 66, 16-100 SOKÓŁKA

TEL. +48 85 711 94 54

WWW.METALFACH.COM.PL

SERVICE INFOLINE

CALL US

+48 663 453 222

p.czepiel@metalfach.com.pl

WRITE TO US

Metal-Fach SMART EKO-CARBON, SMART EKOCARBON 20, SMART EKOCARBON 25, SMART EKOCARBON 15 Maintance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual