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Metal-Fach GRAND PELLET 100, Technical And Operational Documentation

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Metal-Fach GRAND PELLET 100 Technical And Operational Documentation Download Page 7

METAL-FACH 

Heating Technology 

 

 

5 

 

Application 

(User | Installer) 

The  boilers  are  designed  for  heating  facilities  of  the  following  types:  single-family  and  multi-family  houses,  farm 

buildings, public utility facilities, and for  heating usable hot water. They are  equipped with  an automatic fuel feeding 

system,  ash  removal  and  exchanger  cleaning.  Thanks  to  the  use  of  modern  construction  solutions  the  GRAND 

PELLET boiler achieves efficiency ≤90%. Correct operation and achieving the full potential 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. 

 

 

 

 

Summary of Contents for GRAND PELLET 100

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Page 3: ...ion 22 Connection of the boiler to the heating system 23 Connection of the boiler to a closed heating system 28 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...

Page 4: ...ct 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...

Page 5: ...e 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 boile...

Page 6: ...erve 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 shift...

Page 7: ...truction solutions the GRAND PELLET boiler achieves efficiency 90 Correct operation and achieving the full potential 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 ...

Page 8: ...stem cpl 1 Exhaust fan cpl 1 Fuel feed system with self cleaning pellet burner cpl 1 Fuel tank pcs 1 Tools for cleaning the boiler poker brush scraper pcs 1 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 instruct...

Page 9: ...w are equipped with steel screens The convection part of the boiler consists of a tubular exchanger equipped with flue gas swirlers Once a day automated movement of the above mentioned swirlers keeps the exchanger clean Under the combustion chamber and exchanger there are systems for ash removal to containers located outside the boiler The boiler exchanger is insulated with mineral wool covered wi...

Page 10: ...METAL FACH Heating Technology 8 Boiler GRAND PELLET 15 34 ...

Page 11: ...anout door 10 Firebox doors 11 Ceramic hob 12 Tubular exchanger 13 Cleaning and swirling system 14 Ash removal system 15 Ash box 16 Supply spigot with thread G 1 1 2 17 Return stub with thread G 1 1 2 18 Drain stub with thread G 3 4 19 Flue 20 Exhaust fan 21 Lambda sensor 22 Exhaust temperature sensor 23 Boiler temp sensor bushings 24 Levelling feet 25 Fuse 26 STB 27 Main switch 28 Controller disp...

Page 12: ...METAL FACH Heating Technology 10 Boiler GRAND PELLET 50 150 ...

Page 13: ...9 Exhaust fan 10 Lambda sensor 11 Tubular exchanger 12 Ash box 13 Control system panel 14 Fuse 15 STB 16 Switch 17 Return stub gw G 11 2 18 Gearmotor cover 19 Exhaust temperature sensor 20 Upper cleanout door I 21 Upper cleanout door II 22 Supply spigot thread G 11 2 23 Bottom cleanout door 24 Control modules 25 Controller 26 Drain stub gw G 3 4 27 28 Bottom cleanout plug ...

Page 14: ...3 91 7 91 5 90 7 Fuel tank capacity L 270 270 270 290 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 141 141 180 185 Electric power consumption instantaneous at start up W 600 600 630 630 S...

Page 15: ...6 91 6 90 2 90 6 Fuel tank capacity L 1000 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 3 2A 230V 50Hz 4 5A 230V 50Hz Electrical power consumption W 300 300 320 320 Electric power consumption instantaneous at start up W 750 750 105...

Page 16: ...METAL FACH Heating Technology 14 Dimensions of the GRAND PELLET 15 34 boiler User Installer Boiler GRAND PELLET 15 34 ...

Page 17: ... 760 900 900 900 E 1030 1200 1200 1200 F 319 345 345 405 G G 1 1 2 G 1 1 2 G 1 1 2 G 1 1 2 H G 1 1 2 G 1 1 2 G 1 1 2 G 1 1 2 I G 3 4 G 3 4 G 3 4 G 3 4 J Ø100 Ø100 Ø100 Ø100 K 785 785 785 960 L 125 125 125 125 M 1240 1285 1285 1460 N 905 1085 1085 1085 O 420 420 420 471 P 402 402 402 455 R 620 620 620 620 S 940 940 940 940 Dimension does not include the height of the boiler levelling feet ...

Page 18: ...METAL FACH Heating Technology 16 Dimensions of the GRAND PELLET 50 150 boiler User Installer Boiler GRAND PELLET 50 150 ...

Page 19: ... 1475 1715 1715 D 625 625 625 625 E 2190 2190 2500 2600 F 1890 1890 2130 2230 G 1450 1450 1600 1600 H 560 560 610 610 I 180 180 185 185 J 290 290 300 300 K 790 790 920 920 L 1235 1235 1565 1565 M 970 970 1250 1250 N 220 220 220 220 O 125 125 130 130 P 115 115 115 115 R 145 145 145 145 Dimension does not include the height of the boiler levelling feet ...

Page 20: ...verheating It is set at 95 o C 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 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...

Page 21: ...oss section of 200 cm 2 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 duc...

Page 22: ... the boiler from the front and the window area shall be a minimum of 1 15 of the boiler room floor area half of the windows installed shall be operable electric lighting and an electric outlet not exceeding 24 V shall also be provided in the room there should be a drainage sump in the floor to allow cooling of the water and its capacity should be equal to the water capacity of the largest boiler b...

Page 23: ... 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 ...

Page 24: ...de 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 mater...

Page 25: ... recommendations in accordance with this manual NOTE It is recommended to perform the first start up of the boiler in accordance with the guidelines included in the Operation and Technical Documentation by a person holding a valid license information about persons authorised to start up the boiler is available from the Producer phone 48 85 711 94 56 NOTE The return water temperature from the syste...

Page 26: ...chnology 24 Boiler connection diagrams to the heating system in accordance with DIN 91 B 02420 Designation Description RO Vent pipe RW Expansion pipe RS Signal tube RP Overflow pipe RB Safety pipe T1 Temperature P1 Pressure ...

Page 27: ...chnology 25 Boiler connection diagrams to the heating system in accordance with DIN 91 B 02420 Designation Description RO Vent pipe RW Expansion pipe RS Signal tube RP Overflow pipe RB Safety pipe T1 Temperature P1 Pressure ...

Page 28: ...ump C O 9 Domestic hot water DHW pump 10 Circulation pump 11 Auxiliary pump P3 12 Buffer 13 Laddomat 14 Heating circuit pumps1 2 3 4 15 Thermostatic mixing valve Designation Description T Temperature sensor Tk Boiler temperature sensor Tz Outdoor temperature sensor Tcw Domestic hot water temperature sensor Tco Central heating temperature sensor Tpw Boiler return temperature sensor Tpod Feeder temp...

Page 29: ... heating pump C O 9 Domestic hot water DHW pump 10 Circulation pump 11 Auxiliary pump P3 12 Buffer 13 Laddomat 14 Heating circuit pumps1 2 3 4 15 Thermostatic mixing valve Designation Description T Temperature sensor Tk Boiler temperature sensor Tz Outdoor temperature sensor Tcw Domestic hot water temperature sensor Tco Central heating temperature sensor Tpw Boiler return temperature sensor Tpod F...

Page 30: ...ers of the GRAND PELLET range only an external device for removal of excess heat can be installed Boiler manufacturer is not responsible for quality selection and correctness of assembly of the system protecting the boiler against heating medium temperature increase over 95 degrees Celsius and pressure over 0 20 MPa This work must be carried out by a qualified installer The figure shows an example...

Page 31: ...pipe and its associated vent The diameter of the vent pipe and overflow pipe shall be at least mm boiler output kW The most important requirements for safety devices are as follows The expansion vessel should have a volume of approximately 3 5 of the volume of water contained in the heating system including the boiler Every boiler should absolutely have a safety pipe and an overflow pipe the syste...

Page 32: ...cuit Completion of the installation and the heating test must be recorded in the Warranty Card The completed Warranty Card should be sent to the manufacturer s address by the user in order to register the user in the company s system NOTE The first start up of the boiler must be carried out only by a service technician trained by the manufacturer with a valid certificate of METAL FACH Authorised S...

Page 33: ...ixer circuit type CT4 BH upper temperature sensor of buffer type CT4 BL bottom temperature sensor of buffer type CT4 OS optical flame brightness sensor WS weather temperature sensor type CT6 P FT flue gas temperature sensor type CT2S RT universal mixer thermostat No Nc ED ecoDRIVE module module controlling the grate servo DS input for fuel tank opening sensor or door L N PE mains supply 230V GR gr...

Page 34: ...xer 4 CT4 RM3 Mixer room thermostat 3 RM4 room thermostat for mixer 4 FS fuel level sensor for BU feeder operation H2 voltage input to control the reserve boiler or to signal alarms or for the hot water circulation pump RELAY relay L N PE mains supply 230V PM 3 4 mixer pump 3 4 SM 3 4 3 4 mixer actuator BU fuel feeder from the bunker to the hopper in the boiler CPU control A ecoMAX 860P2 T regulat...

Page 35: ...re at nominal boiler output can cause emission of damp flue gases soot deposition insufficient chimney draught This can lead to dampness and corrosion of brick chimneys It is recommended to use a chimney insert For new buildings a ceramic flue system resistant to condensation thermally insulated and with a condenser is recommended In existing buildings it is advisable to upgrade the brick chimney ...

Page 36: ... manual intended for the user and enclosed with this manual Periodically through the viewing door check the combustion process Ash and cinders from burnt fuel gradually fall into the container in the ash pan causing the burner to self clean If a piece of slag hangs between the boiler wall and the burner remove it with a rake or hook The regulator protects the boiler against exceeding the acceptabl...

Page 37: ...hould be determined individually on the basis of experience On average refilling takes place every 1 3 days Empty the ashpan with the same frequency Lack of fuel causes a permanent stop of the combustion process and requires re lighting in the boiler It is necessary to keep the combustion chamber and the boiler convection ducts clean in order to save fuel It is necessary to clean walls and firebox...

Page 38: ...ion and cooled down The boiler must not overheat in any way during operation Do not place flammable objects on the boiler or in its immediate vicinity When removing the ashes flammable materials must not be located within 150 cm of the boiler The ashes must be put into heatproof dishes with a lid When the boiler is operated at a temperature lower than 60 C the steel exchanger can dampen and corrod...

Page 39: ...odic boiler standstill preferably every 100 hours of boiler operation Thorough cleaning of the boiler should be done once a month Instructions for disposal of the boiler at the end of its service life User Before scrapping the boiler all electronic components must be disconnected from the boiler They must be disposed of in accordance with the European Directive 2002 96 EC concerning the disposal o...

Page 40: ...sor Feeder sensor HUW sensor Controls Regulator PLUM860xx Fans Fan DM 80 Fan RMS 120 Igniter Igniter 300W Probe Lambda sensor kit Sleeve for Lambda Probe Feeder Burner feeder screw Tray feeder Instrumentation Rubber grommet Tank seal Revision gasket Gasket under the flap Gasket under the feeder Door holder ...

Page 41: ...Before you call for service read the frequently asked questions Online notification www metalfachtg com pl zglos problem online Hotline 48 85 711 94 54 ext 17 Instructional videos www youtube com c METALFACHTechnikaGrzewcza FAQ www metalfachtg com pl contact service faq ...

Page 42: ...METAL FACH Heating Technology 40 ...

Page 43: ...the manufacturer also referred to as the Guarantor Jacek Kucharewicz operating under the business name Metal Fach Jacek Kucharewicz 16 100 Sokółka 66 Sikorskiego Street Tax Identification Number NIP 545 100 10 62 Business Identification Number REGON 050073833 phone 48 85 711 94 56 3 Under the guarantee the User shall have the right to free of charge repair of the device if the defects of the devic...

Page 44: ...ermissions a sample list of specialist companies is available from the Manufacturer under 48 85 711 94 56 and recording their performance in the warranty card Inspection of the device is a chargeable service 7 Servicing of the appliance e g adjustment of the appliance cleaning measurements analyses of flue gases should be performed by specialised companies with appropriate authorisation a sample l...

Page 45: ...liged to ensure free access to the appliance in particular to allow the removal of the housing of the appliance access to the valves 5 Warranty repairs will be performed by the Guarantor or a specialised company indicated by the Guarantor 6 The fulfilment of the obligations under the guarantee will take place within 14 working days counting from the day when the device is made available at its pla...

Page 46: ...ACH Heating Technology 44 Confirmation of inspection warranty repair maintenance service L p Date of implementation Description of the activities carried out Signature and stamp of the contractor 1 2 3 4 5 6 7 ...

Page 47: ...METAL FACH Heating Technology 45 L p Date of implementation Description of the activities carried out Signature and stamp of the contractor 8 9 10 11 12 13 14 ...

Page 48: ...METAL FACH Heating Technology 46 ...

Page 49: ...ower up to 500 kW 2 PN EN ISO 12100 2012 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology 3 PN EN 1708 1 2010 Welding Basic solutions for steel welded joints Part 1 Pressure parts 4 PN EN ISO 9606 1 2014 02 Welding Examination of welders Steels 5 PN EN 60335 1 2012 Household and similar electrical appliances Safety Part 1 General requirements 6 ...

Page 50: ...METAL FACH Heating Technology 48 ...

Page 51: ...s contained in the warranty conditions in accordance with the Act of 29 August 1997 on personal data protection consolidated text Journal of Laws 2014 item 1182 The user has the right to access the content of his personal data to correct them to request the cessation of data processing and to object to the processing of data in cases indicated by law Any correspondence relating to the processing o...

Page 52: ...METAL FACH Heating Technology 50 ...

Page 53: ...f unjustified calling of the service team or failure to meet points 1 or 2 each started hour of the service technician work 70 PLN net travel 1 PLN net km round trip 4 The legible signature of the applicant confirms that he she has read the basic conditions of the complaint procedure Legible signature of the complainant Signature of complainant I declare that I have read the terms and conditions o...

Page 54: ... Journal of Laws 2014 item 1182 The user has the right to access the content of his personal data to correct them to request the cessation of data processing and to object to the processing of data in cases indicated by law Any correspondence relating to the processing of personal data shall be directed to the address Metal Fach Jacek Kucharewicz 16 100 Sokółka 66 Sikorskiego St Providing personal...

Page 55: ...itions in the DTR in chapter Connecting the boiler to the heating system are observed The conditions in the DTR chapter Requirements for the expansion vessel are complied with There is no other source of heating If there is does it affect the operation of the boiler and how Protection of the system against freezing Connecting components to the electrical installation Meets Does not meet Comment Th...

Page 56: ... Signature Signature Personal data provided in this form shall be processed by Jacek Kucharewicz conducting business activity under the name Metal Fach Jacek Kucharewicz 16 100 Sokółka ul Sikorskiego 66 NIP 545 100 10 62 telephone 48 85 711 94 56 for the purpose of implementing the provisions contained in the warranty conditions in accordance with the Act of 29 August 1997 on personal data protect...

Page 57: ... in the DTR in chapter Connecting the boiler to the heating system are observed The conditions in the DTR chapter Requirements for the expansion vessel are complied with There is no other source of heating If there is does it affect the operation of the boiler and how Protection of the system against freezing Connecting components to the electrical installation Meets Does not meet Comment The cond...

Page 58: ...nature Signature Personal data provided in this form shall be processed by Jacek Kucharewicz conducting business activity under the name Metal Fach Jacek Kucharewicz 16 100 Sokółka ul Sikorskiego 66 NIP 545 100 10 62 telephone 48 85 711 94 56 for the purpose of implementing the provisions contained in the warranty conditions in accordance with the Act of 29 August 1997 on personal data protection ...

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