HKS lazar Holz Master Operation and Installation Manual

Brand: HKS lazar

Model: Holz Master

Type: Operation and Installation Manual

Operation and installation manual

of the wood gasification boiler

Holz Master

This manual shall be kept by the user.

Obey thoroughly instruction found here to facilitate long and safe operation of the boiler and preserve the warranty.

Last update: 22/05/2012

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Dear User of the Holz Master boiler

Thank you for the trust you have bestowed upon us. We will make every effort to ensure that use of

our equipment was flawless, comfortable and bringing much satisfaction to you.

The Holz Master boiler, purchased by you, is one of the most modern devices of this type, suitable

for burning wood using gasification processes. Design solutions of the exchanger and burner make

the boiler achieve high performance while maintaining simplicity of operation and low emissions to

the environment. Due to these features the Holz Master boiler was granted a certificate confirming

the device meets the power and ecology standard criteria.

Please read the Manual and the attached manual of the boiler regulator, as this is necessary for safe

operation of the boiler. Do not hesitate to contact us should you had any enquires.

Best regards,

Marcin Lazar

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Index

1 Overview..........................................................................................................................................4

2 Recommendations............................................................................................................................4

3 Safety precautions............................................................................................................................5

4 Boiler's data......................................................................................................................................6

5 Boiler construction...........................................................................................................................8

6 Types of fuel...................................................................................................................................13

7 Instrukcja obsługi dla użytkownika................................................................................................14

7.1 Firing up the boiler..................................................................................................................14

7.2 Maintaining fire in the boiler..................................................................................................15

7.3 Maintenance and cleaning of the boiler..................................................................................16

7.4 Boiler shutdown......................................................................................................................18

7.5 Damper settings......................................................................................................................19

8 Operating instructions for the installer...........................................................................................20

8.1 Boiler carrying into a building................................................................................................20

8.2 Boiler room – placement of the boiler....................................................................................20

8.3 Chimney system......................................................................................................................21

8.4 Heating installation.................................................................................................................23

8.5 The hydraulic Kit....................................................................................................................27

9 Service operations manual..............................................................................................................29

9.1 Launch control........................................................................................................................29

9.2 Launch....................................................................................................................................29

9.3 Repairs of the break downs.....................................................................................................30

9.4 Annual inspection...................................................................................................................30

10 Scraping of the system after its lifetime.......................................................................................31

11 Terms of warranty and liability ....................................................................................................31

12 Declarations and licensing............................................................................................................34

13 Electric connections......................................................................................................................35

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1 Overview

The Holz Master boiler is a universal wood gasification boiler, design of which is based on a steel

exchanger equipped with a ceramic burner for burning wood gas. The boiler equipment consists of:

weather adjustable controller, manual system of the heat exchanger cleaning and the ceramic burner.

The boiler is used to heat buildings through the installation of open and closed central heating

systems and for water heating in domestic hot water heaters.

As a standard the Holz Master boiler is delivered with:

•Operation and installation manual;

•Regulator manual.

The Holz Master boiler belongs to the group of low-temperature devices and is not subject to

registration in the District Office of Technical Inspection.

Solid fuel boilers adapted for operation in a closed system are subject to limited technical

supervision. The user of the boiler, after installation and before enabling the boiler to operate,

should report it to the Office of Technical Inspection.

2 Recommendations

Always obey the Operation and installation manual and requirements set in it.

Initial launch and all relating tasks and any service work can only be completed by the

manufacturer's or authorised service team.

Only fuel specified herein can be burned.

The boiler must be regularly maintained as specified in this manual.

You shall observe the general rules applicable to heating technology to protect the system of

Legionellosis.

Failure in submission to the provisions of the manual will result in loss of warranty and exempt the

manufacturer of responsibility of the outcome of the system's operation.

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3 Safety precautions

Before using the boiler, the following precautions should be read and understood. Failure to

follow this manual instruction, and in particular the following precautions could lead to

injury, loss of health, life-threatening, damage to the equipment, installation and building!

Installation of the boiler can be executed only by persons with appropriate authority, knowledge,

skills and tools.

Installation must be performed in accordance with applicable regulations, standards and the art of

building.

The boiler may be operated only if the boiler itself and the installation are in perfect technical

condition. Failures, damage and disruption in operation must be immediately reported to the

relevant departments.

Before the first use and then periodically (at least every six months) one should check whether there

is enough water in the central heating system.

It is strictly forbidden to open the inspection hatch during boiler operation, because of the danger of

dust and gases escaping and their firing up or explosion.

Do not make any repairs or alterations yourself.

Prior to any work on the boiler, the boiler shutdown should be done and you should wait until the

temperature drops.

Regularly (at least once a month) the boiler door and connections should be monitored for leaks.

At least once a year, proper operation of the STB fuse should be checked.

The boiler can be installed only in rooms designed for this purpose, suitably equipped and meeting

the relevant requirements.

In the boiler room a warning label must be affixed on the prohibition of smoking and use of fire.

The boiler room must be equipped with an efficient fire extinguisher.

Ventilation and air supply to the boiler room must be efficient and meet the relevant requirements.

The boiler room must be protected from access of unauthorized persons, especially children.

Under no circumstances the measuring and security devices should be removed or immobilized.

During boiler handling and ash removal, use protective clothing and measures: gloves, dust mask

and work clothes.

If the domestic hot water temperature reaches above 60oC, ensure adequate mixing with cold water,

because of the danger of burns.

Adequate venting of the boiler and installation should be ensured.

Only the original manufacturer’s spare parts should be used.

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4 Boiler's data

Model

Parameter Unit HM 20

Boiler class Class 3 (the highest)

Efficiency % 90,7%

Nominal output – fuel wood chip

Q=15 MJ/kg

kW 20

Fuel consumption at nominal output – fuel

wood chip Q=15 MJ/kg

kg/h c. 5,5

Time till burn-out at nominal power – fuel

wood chip Q=15 MJ/kg

h c. 5

Width mm 770

Height mm 1565

Depth mm 1075

Water volume dm3132

Exhaust outlet diameter ext./int. mm 160 / 150

Water feeding and return connections inch 1¼

Top operational water pressure

* - depending on boiler version bar 1,5 / 3,0*

Top test water pressure

* - depending on boiler version bar 2,5 / 5,0*

Safety vent

* - depending on boiler version bar 1,5 / 3,0*

Water flow resistance in the boiler ΔT=10K mbar 7

Water flow resistance in the boiler ΔT=20K mbar 1,8

Table 1. Holz Master boiler specifications

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Model kotła

Parametr Jednostka HM 20

Required chimney draught Pa / mbar 5 ÷ 15 / 0,05 ÷ 0,15

Required chimney diameter mm 160 ÷ 180

Average exhaust temperature at nominal

output

0C 140

Maximum temperature of the boiler 0C 80

Recommended temperature of the boiler 0C 70 ÷ 80

Minimum temperature of the returning water 0C 65

Exhaust flow at the nominal output g/s 15

CO emission at the nominal output (10% O2) mg/m3 300

CO emission at the nominal output (13% O2) mg/m3 220

Noise level dB below 75

Electricity plug-in 1 PEN ~50Hz 230V TN-S

Electric insulation IP 20

Electric power consumption (exhaust fans) W 75

Ambient temperature 0C 15 ÷ 40

Humidity % 10 ÷ 90%

without condensation

Capasity of loading chamber dm3125

Exhaust fan model R2E180-CG82 / WC.170

Table 2. Holz Master boiler specifications

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5 Boiler construction

The Holz Master boiler design is based on a steel heat exchanger, that ensures simple operation,

high efficiency and long life. The advantages of steel heat exchanger are combined with a modern

ceramic burner. This solution has enabled the construction of solid fuel-fired device that combines

the advantages of the boiler with manual loading with the ecological advantages of biomass-fired

boilers.

The Holz Master boiler, its size and layout of heating system connections and chimney are shown in

Fig. 1. The boiler diagram with distinguished the most important assembles is shown in: Fig. 2, Fig.

3 and Fig. 4. They include views showing the boiler from all sides.

Two chambers can be distinguished in the boiler construction - the upper and lower one. The upper

chamber functions as a combustion chamber, to which timber is loaded, which is then ignited and

will be gasified. The door situated at the chamber top serves for fuel loading, cleaning and

maintenance of the upper chamber. In addition, the chamber has a bottom cleaning hatch, closed

with two butterfly handles. It is used for removing ash accumulated on the bottom of the upper

chamber.

The upper and lower chambers are separated with the ceramic burner, used for combustion of gases

generated during pyrolysis of wood burning in the upper chamber. Gases flowing through the

burner are burnt in the lower chamber. Inspection door serves for the lower chamber's handling,

maintenance and cleaning of the chamber itself and surfaces of the ceramic burner.

At rear of the boiler there is situated the tube heat exchanger constructed of vertical fire tubes. It

connects the lower chamber of the boiler with the flue gas collector, located in the rear part of the

boiler. Exchanger is equipped with a manual cleaning system, enabling to maintain the surface

clean.

Air for combustion in the ceramic burner and in the upper chamber is sucked by the exhaust fan

located in the flue gas collector. The amount of air sucked into the burner and the upper chamber

can be individually adjusted with dampers located at the rear of the boiler. The flue gases from the

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exchanger go into the flue gas collector, then are directed by the exhaust fan to the flue at the top of

the boiler.

Inlet and outlet of heating water, used to connect the boiler to the central heating system, are located

respectively on the back and top of the boiler. They have the form of nozzles with G 1¼ " female

thread. At the top of rear part of the boiler there is the flue used to carry away flue gases to the

chimney. Detailed location of connections on the boiler is shown in Fig. 1.

Exchanger of the boiler is insulated with mineral wool, which protects it from heat loss during

operation. The boiler casing is made of steel plates covered with high quality, durable powder coat.

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Dimension: Model

HM 20

Height: 1565

Width: 770

Depth: 1075

A: 650

B: 1455

C: 135

D: 290

E: 935

F: 160

Fig. 1 Dimensions of the Holz Master boiler

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Front view (without cover)

Rear view

Fig. 2 Description of the Holz Master:

1-wyświetlacz; 2-drzwi górnej komory; 3-wyczystka górnej komory; 4-drzwi dolnej komory;

5-wentylator wyciągowy; 6-wyczystka wentylatora; 7-przepustnica powietrza komory spalania;

8-przepustnica powietrza; 9-króciec wody powrotnej; 10-reset termostatu bezpieczeństwa STB (pod

plastikową nakrętką);

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Side view

Top view

Fig. 3 Description of the Holz Master:

11-króciec zaworu termostatycznego wężownicy schładzającej; 12-dźwignia manualnego systemu

czyszczenia wymiennika; 13-czopuch spalinowy; 14-przyłącza wężownicy schładzającej;

15-króciec wody zasilającej;

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14 11

6 Types of fuel

The basic fuel for the Holz Master boiler are wooden logs and chips. It is recommended to use

wood of deciduous trees, which is characterized by compact structure and high hardness. Calorific

values of individual species of deciduous wood (with moisture content from 15 to 20%) are listed in

the Table 3. Unlike deciduous trees, conifer wood due to contained resins cause formation of large

amounts of soot in the furnace. For these reasons, combustion of coniferous wood is not

recommended.

Wood species The calorific value of timber

kWh/m3kWh/kg

Hornbeam 2200 4,2

European beech 2100 4,2

Oak 2100 4,2

Ash 2100 4,2

Locust 2100 4,1

Birch 1900 4,3

Elm 1900 4,1

Maple 1900 4,1

Alder 1500 4,1

Willow 1400 4,1

Poplar 1400 4,2

Average calorific value of

deciduous trees 2100 4,2

Table 3. Calorific values of individual species of deciduous trees

It is recommend to use wooden chips with a diameter of 70 to 100 mm and a length of 500 mm. It is

recommended to use fuel with a moisture content not exceeding 20%. With the increase of wood

moisture content, its calorific value decreases. Wood moisture content reaches about 15 to 20%

after appropriate drying or after 2 years of storage. Fresh wood is characterized by more than twice

lower calorific value, than its dried equivalent, and during its combustion steam is condensed on the

boiler walls and large amount of soot is formed and deposited in the combustion chamber and the

chimney.

The Holz Master boiler is not designed to burn waste, flammable liquids and any other fuels

not indicated in this manual!

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7 Instrukcja obsługi dla użytkownika.

Dear User, to use all advantages of the Holz Master boiler, read these instructions and the

instructions accompanying the controller before operation - this will ensure comfortable and long

lasting boiler operation. Detailed information on the electronic control of the boiler are contained in

the said manual instruction of the controller.

7.1 Firing up the boiler.

Before firing the boiler:

Check that there is enough water in the central heating system;

Check that the air supply system is not blocked – during all combustion time, it must

provide fresh air supply needed for the combustion process;

Check that the chimney is not blocked - it can become clogged after long breaks in

operation;

Adjust the chimney draft lever opening, if installed, so as to provide adequate chimney draft;

Check that the exhaust system is not blocked;

Check for proper connection of the thermostatic valve – if the cooling coil is used.

In order to fire up the boiler:

Load fuel to the upper chamber of the boiler;

Turn the boiler controller on;

Put a dry paper on the fuel, then fine, dry wooden chips or good-quality light-up barbecue

fuel in solid form;

Fire the paper and after firing up the wood or barbecue fuel, switch the boiler controller into

the firing mode;

After ignition of the fuel and increase of the device temperature, the controller changes into

operating mode.

In order to accelerate and facilitate the process of fuel ignition it is possible to open slightly the

cleaning hatch of the upper chamber, allowing for sucking extra air for the firing process. To do

this, loosen the butterfly handles of the cleaning hatch so it is loosely based on them, without

falling down and without opening the inspection hatch. The firing process should be then

continuously monitored, paying particular attention to whether the no smoke or flames are emitted

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by the unsealed cleaning hatch. After firing the fuel, the upper chamber cleaning hatch should be

tightly closed.

Details of the controller modes and its parameter settings can be found in the manual instruction of

the boiler controller.

To light a fire in the boiler do not use: gasoline, alcohol, solvents or any other light-up fuels

(e.g. for barbecue) in liquid form!

7.2 Maintaining fire in the boiler

After firing the fuel and entering into operating mode, the boiler controller automatically adjusts the

boiler operation based on user parameter settings and/or measurements of temperature sensors. Due

to that the device achieves high efficiency within the entire power range. Any disruption of boiler

operation should be immediately reported to the Service Partner providing messages that appear on

the display.

All flaps and inspection door must be strictly closed during operation of the boiler!

During boiler operation, depending on the needs and intensity of combustion, the fuel in the upper

combustion chamber should be regularly refilled. Fuel must be added to the furnace when the

previous fuel portion has burned almost to the phase of embers. Before opening the upper chamber

door, use the control switch to change into manual control mode and turn on the exhaust fan, then

check that the exhaust fan is running. The door should be opened slowly to avoid turbulence of air

masses. Doing so will ensure optimum operation of a flue gas short circuit pocket and prevent

smoke escaping from the boiler to the boiler room. After adding a fresh portion of fuel, return to the

operating mode to enable the boiler controller to re-set the intensity of combustion.

The added fuel in the form of wood chips or logs of deciduous timber should be arranged in layers

so that the logs were directed along the depth of the loading chamber. Fuel must be laid in layers of

2 or 3 logs, as close as possible to the rear wall of the furnace, so that in case of log slipping they do

not adhere to the chamber door and were not able to fall down from the boiler when the chamber

door is open. Do not exceed the load of 12 to 14 logs in a single loading.

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During operation of the boiler, the rules of anti-fire protection must be strictly observed,

within the heat radiation area and beyond!

During performing any operations on the device not operating properly, provide intensive

ventilation of rooms, and all actions should be protected by another person equipped with a

powder extinguisher.

In case of boiler operation with exceeded fuel amount or its wrong type, there is a danger of

overheating and fire!

In case of unfavourable chimney draft and bad weather conditions, that might cause flue gas

reversing, the boiler should be extinguished. Before reigniting the boiler, wait until the

operating conditions improve.

In case of chimney fire, close the chimney louver, thus cutting off the chimney from the device

and then use ash or sand to extinguish the fuel burning in the combustion chamber. In case of

fire, evacuate endangered persons from the premises and call the fire brigade.

In case of faulty operation, immediately extinguish the boiler (see 7.5). If the problem repeats,

contact the Service Partner of HKS Lazar to determine the cause of incorrect operation!

7.3 Maintenance and cleaning of the boiler

Before starting the boiler maintenance and cleaning procedures, extinguish the boiler and

wait at least 1 hour until its temperature drops. Only then you can safely open the cleaning

hatches of the boiler and start cleaning.

The routine activities of the Holz Master boiler maintenance include:

Removal of ash from the upper and lower chambers (wearing protective gloves is

necessary);

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Cleaning the exchanger using the manual cleaning system;

Cleaning the ceramic burner surfaces;

Cleaning the heat exchange surfaces of the boiler body (stainless steel plates, exchanger

walls, fire tubes etc.) and the flue gas collector;

Dry brush cleaning of the external fan housing - during these operations the boiler should be

disconnected from the power supply, moreover, due to high engine temperature, do not

touch it with bare hands.

Amount of ash produced in the process of fuel combustion depends on the quality of used fuel and

the amount used by the boiler. Besides the ash, trace amounts of soot are deposited. In order to

remove the ash, open the lower chamber door and the upper chamber cleaning hatch, unscrewing

the two butterfly handles located on the sides. Ash and embers should be removed from the

extinguished boiler by means of a scoop. The ash must be disposed in a heat-resistant container

with a lid, where it should be stored for at least 24 hours until extinguished.

During ash removal and boiler cleaning it is essential to wear gloves and other necessary

personal protective equipment!

During ash removal it is also recommended to clean the upper chamber, by brushing the ash and

fuel residues located inside.

Regular exchanger cleaning is recommended by use of the manual cleaning system. It involves

repeated lever movements. This operation should be performed at least once a week. Long-term

non-use of the manual cleaning system can cause its permanent immobilization.

During continuous operation of the boiler, it is recommended to clean thoroughly, once a week, the

inside of the chambers, stainless steel plates, heat exchange surface and the ceramic burner by use

of brushes and hooks. The main cleaning hatches of the Holz Master boiler are:

door of the upper chamber;

door of the lower chamber ;

the upper chamber cleaning hatch

cleaning hatch of the flue gas collector;

cleaning hatch of the flue.

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Each time after the heating season and during prolonged shutdowns, the boiler should be thoroughly

cleaned and subjected to maintenance.

The proposed intervals of the individual activities carried out by the user under boiler

cleaning and maintenance procedures are approximate, and their frequency is strictly

dependent on the quality of fuel used and the working conditions of the boiler.

To remove the ash contained in the flue gas collector, remove the collector grille on top of the boiler

and remove the collector cover. Cleaning of the collector can be entrusted to the Service Partner of

HKS Lazar company.

Cleaning the exhaust flue and the located nearby exhaust fan is possible after removing the fan

(disassembly should be performed by the Service Partner) or after opening the flue cleaning hatch

and flue gas collector cleaning hatch. Regularly check the fan operation. Do not allow the exhaust

fan to immobilize by the pollutants accumulating in the flue gas collector and around the fan.

It is recommended to monitor the status and operation of the exhaust fan, with special attention paid

to the seals, possible leaks, noise level and its possible growth, uniformity of operation, the state of

bolted connections. Do not touch the engine with unprotected hands, because its temperature can

reach 75oC and even 100°C. Replacement of the fan motor condenser is recommended every two

years.

Before performing any activity related to the fan maintenance, disconnect the boiler from the

power supply and check that the fan impeller is not moving!

7.4 Boiler shutdown

In order to shutdown the boiler:

By means of the boiler controller switch into the stop mode and turn off the exhaust fan;

Close the dampers supplying air to the upper combustion chamber;

Remove embers from the upper and lower chambers to the heat-resistant container with a

lid;

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Close the chimney louver (if installed);

Turn off the boiler;

For several tens minutes after extinguishing, control whether there is no re-ignition of

fuel!

If the boiler shutdown period is longer than 2 days and always after the heating season, remove fuel

from the boiler and leave it with the door slightly open. After the heating season or before major

shutdown, the boiler should be thoroughly cleaned

7.5 Damper settings

To maintain proper boiler operation and proper course of wood pyrolysis, the following air damper

settings are recommended:

•Air dampers of the upper combustion chamber - opening 30 - 40 mm – fig. 4;

•Air dampers of the lower combustion chamber - opening 30 - 40 mm – fig. 5;

•Recommended power of the exhaust fan - 40% - 80%.

Fig. 4 Air damper setting of the upper combustion chamber

Fig. 5 Air damper setting of the lower combustion chamber

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30 - 40 mm

8 Operating instructions for the installer

Dear Installer, the Holz Master boiler is a precise, high-tech and highly efficient device. Therefore

we ask for careful and thoughtful work during its installation.

The boiler may be installed only by persons with appropriate qualifications, authority, expertise and

equipment. While commissioning, maintenance and repairs may only be performed by the Service

Partners of HKS Lazar company.

During installation of the Holz Master boiler, all valid national and European standards and local

regulations applicable to the boiler installation should be followed!

8.1 Boiler carrying into a building

During boiler carrying in, pay special caution, particularly onto the electronics and wiring. If there

is a need to dismantle any element, remember how it was attached, make notes and preferably take

pictures. This will allow for efficient reassembly of the removed parts and will help the serviceman.

8.2 Boiler room – placement of the boiler

The room where the boiler is installed must satisfy the applicable regulations and standards

concerning solid fuel boilers. In particular, pay attention to safety of the water and electricity

installations, adequate ventilation, exhaust system and fire safety. The boiler room must be airtight,

with adequate ventilation and air supply, separated from other rooms with permanent walls and

airtight doors preventing eventual spreading of smoke, particularly rooms where there are people.

Assure the mandatory clearance from walls and other items:

front of the boiler– min. 1000 mm;

side of the boiler – min. 500 mm;

rear of the boiler – min. 400 mm;

top of the boiler – min. 400 mm.

Example of the Holz Master boiler location in the boiler room, while keeping the space necessary

for its operation, is illustrated in Fig. 6.

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HKS lazar Holz Master Operation and Installation Manual

Brand: HKS lazar

Model: Holz Master

Type: Operation and Installation Manual

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HKS lazar Holz Master Operation and Installation Manual

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