HKS lazar Smart Fire Specification sheet

Operation and installation manual
pellets burning automatic boiler
Smart Fire
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.
All rights reserved.
Last update 14/ 8/2 12
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Dear User
Thanks for your trust in our product. We hope and will take all steps necessary to make you
satisfied with it.
The Smart Fire boiler you purchased belongs to the most advanced of pellets burning systems in the
market. Pellets are recognised environmentally friendly solid fuel. The boiler has been designed and
manufactured following the latest trends and the most advanced technology available. These
solutions provide for a very high heat efficiency – above 91% for a boiler model SF21 – within the
entire range of the assumed output.
The Smart Fire boiler has been supplied with the following parts and fixtures that reduce your
hustle while operating:
•advanced ceramic burner with automating clearing system;
•heat exchanger manual cleaning system;
•automatic lighter.
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 General information..........................................................................................................................4
2 Recommendations............................................................................................................................4
3 Safety rules.......................................................................................................................................4
4 Boiler's data......................................................................................................................................6
5 Boiler construction...........................................................................................................................8
6 Type of fuel.....................................................................................................................................13
7 Safety and measurement devices....................................................................................................14
7.1 Capacitive proximity sensor....................................................................................................14
7.2 Primary and secondary air intakes...........................................................................................17
8 User's operations manual................................................................................................................18
8.1 Launch of the boiler operation................................................................................................18
8.2 Boiler's operation.....................................................................................................................18
8.3 Maintenance and cleaning.......................................................................................................19
8.4 Extinguishing of the boiler......................................................................................................22
8.5 Burner band adjustment instructions.......................................................................................22
9 Installation of the boiler..................................................................................................................24
9.1 Transport of the boiler into the building..................................................................................24
9.2 Boiler room – placement of the boiler.....................................................................................24
9.3 Chimney system......................................................................................................................25
9.4 Boiler's installation..................................................................................................................27
9.5 The hydraulic Kit.....................................................................................................................3
1 Service operations manual............................................................................................................32
1 .1 Launch control.......................................................................................................................32
1 .2 Launch...................................................................................................................................32
1 .3 Repairs of the break downs...................................................................................................33
1 .4 Annual inspection..................................................................................................................33
11 Scraping of the system after its lifetime.......................................................................................34
12 Terms of warranty and liability ....................................................................................................34
13 Declarations and licensing............................................................................................................36
14 Electric connections......................................................................................................................41
15 Default settings of the boiler........................................................................................................42
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1 General information
Smart Fire boiler is an advanced heating system burning pellets. The system includes: a boiler
regulator with weather control, a system facilitating manual cleaning of the heat exchanger,
advanced ceramic burner, automatic system of burner clearing, and an automatic lighter. The boiler
can provide heat to the central heating system in a building, with pump or gravitational circulation,
as well as hot tap water (domestic hot water).
Smart Fire has been rated as low-temperature system and therefore needs no registration with the
local authorities in most jurisdictions.
Solid fuel boilers operating in a closed circuit are sometimes subject to a limited technical
supervision. Once the boiler is installed, the user may need to notify the local supervising
authorities before launching operation.
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.
3 Safety rules
Read these rules before launching operation. Failure in submission to the Operation and
installation manual may lead to: casualty, loss of health, life hazard, damage to the system, the
heating installation and the building!
Only persons holding necessary licences, knowledge, skills and equipment can be trusted with
assembly of the boiler.
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The installation must satisfy all standards and rules in force and the principles of construction craft.
The boiler can only be operated when both the boiler and the heating installation are in perfect state
of repair. Breaks, defects and disturbances in operation must be immediately reported to the relevant
authorities.
Before launch and then regularly every six months, check if the heating system contains enough
water.
Never open the inspection openings when the boiler is working as this may release dust and exhaust
that next can ignite and explode.
Never attempt any repairs or reassembly.
Never remove the covers as movable parts and electric devices are installed behind.
Extinguish the boiler and wait till it cools down before start of any maintenance work with the
boiler.
At least once a month check the doors, the water inlets and outlets and chimney connection for
tightness.
At least once a year check operation of the STB fuse.
Facilitate the boiler room with a sign prohibiting smoking and use of fire.
Ventilating system must be operable and satisfy all relevant requirements.
Operable extinguisher must be available in the boiler room.
The boiler room must be secured against entry of unauthorised persons, in particular children.
Never remove or disable any safety or measurement devices.
Use gloves, dust mask and overalls when clearing ash and cleaning the boiler.
The boiler must only be installed in the premises designated thereof and satisfying the applicable
requirements.
Extinguish the boiler when fuel is delivered.
If the temperature of tap water has been set up above 6 ºC, warrant admixture of cold water as this
creates risk of burning injury.
Facilitate proper air removal off the boiler and the heating system.
Use only manufacturer's spare parts.
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4 Boiler's data
odel
Parameter Unit SF 21 SF 41
Class Class 3 (topmost)
Efficiency % 92,1% 9 , %
Nominal output kW 21 41
Range of output kW 6 ÷ 21 12 ÷ 41
Fuel consumption at nominal output kg/h c. 4,5 c. 9,
Time till burn-out at nominal output
fuel container type hc. 32
fuel container 240 L
c. 16
fuel container 240 L
Width
fuel container type – width mm
150 L - 96
240 L - 114
470 L - 142
150 L - 1 9
240 L - 127
470 L - 155
Height mm 148 148
Depth
fuel container type – depth mm
150 L - 685
240 L - 685
470 L - 835
150 L - 8
240 L - 8
470 L - 835
Water volume dm364 11
Exhaust outlet diameter ext./int. mm 12 / 11 16 / 15
Water feeding and return connectors cal 1¼
Top operation water pressure
* depending on boiler version bar 1,5 / 3, *
Top test water pressure
* depending on boiler version bar 2,5 / 5, *
Safety vent
* depending on boiler version bar 1,5 / 3, *
Water flow resistance in the boiler ΔT=1 K mbar 1,9 9,
Water flow resistance in the boiler ΔT=2 K mbar 7,5 32,
Average exhaust temperature at maximum output C 1 11
Average exhaust temperature at minimum output C 5 65
Maximum temperature of the boiler C 85
Maximum recommended exhaust temperature C 18
Recommended temperature of the boiler C 65 ÷ 8
Minimum temperature of the returning water C 55
Table 1. Smart Fire boiler specifications
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odel
Parameter Unit SF 21 SF 41
Exhaust flow at the nominal output g/s 15 33
Exhaust flow at the minimal output g/s 5 16
CO emission at the nominal output (1 % O2) mg/m3 151 36
CO emission at the minimal output (1 % O2) mg/m38 37
CO emission at the nominal output (13% O2) mg/m3116 262
CO emission at the minimal output (13% O2) mg/m3582 269
Required chimney draught Pa / mbar 1 ÷ 5 / , 1 ÷ , 5
Noise dB below 75
Electricity plug-in 1 PEN ~5 Hz 23 V TN-S
Electric insulation IP 2
Electric power consumption (fans and
motoreducer) W 11 155
Ambient temperature C 15 ÷ 4
Humidity % 1 ÷ 9 %
without condensation
Fuel container capacity
dm3
15
24
47
Ash tray volume dm37 15
Outlet fan model Z-A RH15Z Z-A RH18Z
Motoreducer model ABM 4.5 ABM 7.5
Table 2. Smart Fire boiler specifications
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5 Boiler construction
Smart Fire boiler has been designed as compact structure. Most of the boiler parts are hidden behind
the covers which protects them against elements and mechanical damage. Smart Fire boiler, its
dimensions and placement of the connectors to the heating system and the chimney outlet have been
shown at the fig. 1. Figures 2 - 4 show the boiler specifying its main systems.
There two main elements within the Smart Fire chassis: the boiler's body and the fuel feeding
system. The body includes: a collector. a steel heat exchanger, the combustion chamber and the ash
tray chamber. Inside the steel heat exchanger you will find vertical hot gas pipes. The exchange
features a manual cleaning system. On top of the exchange rest the upper collector and the ceramic
deflector made of vermiculite. The exchanger rests on the lower part of the body which consist of:
the combustion chamber, the ash tray chamber, the exhaust collector. A ceramic burner fits inside
the combustion chamber. The burner is fit with an automatic clearing system. Fuel falls down from
the auger feeder having its outlet placed above and equipped with rotary valve. Burner's ash falls
from the combustion chamber to the ash tray in the chamber underneath. An exhaust collector is
placed behind the ash tray chamber. Exhaust of the combustion is sucked to the exhaust collector
with an outlet fan and then directed to the exhaust collar.
The other main system supplies fuel. It is integrated in the external chassis of the boiler covers.
These includes: fuel container,the auger feeder with a motoreducer and rotary valve. Fuel falls from
the main fuel container to the auger feeder. This in turn, pushes fuel into the rotary valve, which
separates the fuel located in the auger feeder from flame in the burner. When the fuel leaves the
rotary valve, it falls directly into the burner. The boiler body connects to the fuel supply system with
the collar of the auger feeder.
Two covering panels are fixed in front of the boiler. The upper panel is fixed and it is the upper part
of boiler body. You can access the combustion chamber and the ash try chamber with the pair of
inspection doors behind the bottom panel. A control display showing current status of the boiler is
fixed at the front wall of the fuel container.
The inlet and outlet of the heating system water are located at the back wall of the boiler. These are
threaded pipe ends with a 1¼ " internal thread. The back wall also holds the exhaust collar
connecting the boiler to the flue system. The exhaust collar contains exhaust gas temperature sensor.
The placement of the connectors has been detailed on the fig. 1. An outlet fan is fixed to the back
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wall next to the exhaust collar. Amount of air flown by the fan is controlled by the boiler regulator.
The boiler's body is insulated with mineral wool to reduce heat loss in operation. The covers are
made of steel sheets covered with high quality powder paint.
Dimensions: odel
SF21 / 150L SF21 / 240L SF21 / 470L SF41 / 150L SF41 / 240L SF41 / 470L
Height: 148 148 148 148 148 148
Width: 96 114 142 1 9 127 155
Depth: 685 685 835 8 8 835
A: 42 6 88 42 6 88
B: 44 44 44 57 57 57
C: 58 58 79 58 58 79
D: 58 58 58 71 71 71
E: 265 265 265 39 39 39
F: 4 5 4 5 4 5 38 38 38
G: 135 135 135 175 175 175
H: 275 275 275 22 22 22
I: 12 12 12 16 16 16
Fig. 1 Dimensions of the Smart Fire boiler
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Front view
Top view
Fig. 2 Schema of the Smart Fire boiler:
1 display; 2 the STB thermostat reset (under the plastic cap); 3 inspection hole of the
controller; 4 fuel container clap door 5 knob of the heat exchange cleaner; 6 heat exchange
covering panel; 7 boiler door cover;
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2
4
5
3
6
7
1

Back view
Side view (from the container's side)
Fig. 3 Schema of the Smart Fire boiler:
8 heating water outlet; 9 returning water inlet; 10 Exhaust temperature sensor; 11 Exhaust
exit collar; 12 cleaning hatch; 13 inspection hole; 14 outlet fan;
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13
8
9
10
11
14
12

Front view (open panel)
Fig. 4 Schema of the Smart Fire boiler:
15 limiting cut off switch; 16 combustion chamber door. 17 burner cleaning hatch; 18 ash try
chamber door;
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15
17
18

6 Type of fuel
Smart Fire has been designed for pellet burning. Pellets are made of wood waste compressed to
pieces of ball or cylinder shape.
The fuel used shall satisfy the standards applied to pellets. This applies particularly to the heating
(energy) capacity of the fuel and its moisture.
PELLETS
Ö-Standard DIN-Standard DINplus
Heating output 18 MJ/kg 18 MJ/kg 18 MJ/kg
Density 1,12 kg/dm31, - 1,4 kg/dm31,12 kg/dm3
oisture max. 1 , % max. 12, % max. 1 , %
Ash deposit max. ,5 % max. 1,5 % max. ,5 %
Length max. 5 x diameter max. 5 mm max. 5 x diameter
Diameter 6 mm 6 mm 6 mm
Dust fuel content max. 2,3 % max. 2,3 %
Ingredients wood wood wood
Table 3. Fuel standards and characteristics
NOTE! FUEL UST NOT EXCEED THE RECO ENDED OISTURE CONTENT.
DAMP FUEL REDUCED THE BOILER'S OUTPUT CONSIDERABLE (EVEN BY 5 %) AND
REDUCES LIFE SPAN OF THE PARTS THAT ARE AFFECTED BY DAMP FUEL MANY
TIMES OVER. USE OF INADEQUATE QUALITY FUEL OR DAMP FUEL WILL VOID
WARRANTY ON THESE PARTS.
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Safety and measurement devices
.1 Capacitive proximity sensor
Capacitive proximity sensor is located in the upper part of the feeder pipe, next to geared whiles
rotating the rotary valve – fig. 5. Its function is to detect fuel stockpiling in the feeder pipe, which
can take place after miss-detection of the burning process, during firing up process. This kind of
action protects the feeding system from being jammed by stockpiling fuel.
Fig. 5 Location of the capacitive proximity sensor
The capacitive sensor is connected in serial with door's limit switch – as it is shown at fig. 6.
Boiler's regulator detects triggering of the capacitive sensor the same as triggering the door's limit
switch – by displaying alarm “BOILER UNSEALED” and stopping both, feeder and exhaust fan
work.
The capacitive sensor circuit is equipped with Sensor disabling switch. Setting on that switch,
makes that boiler's regulator will ignore detection of the stockpiling fuel by the sensor. This feature
is used while removing stockpiling fuel from the feeding system. The Sensor disabling switch is
located next to STB Reset button – fig. 7. By default switch should be set to “ ”.
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Capacitive
proximity
sensor
Red LED
indicator
Rotary valve Feeder pipe

Fig. 6 Diagram of electric connection for the capacitive proximity sensor
Fig. 7 Location of the Sensor disabling switch – default set: position marked “0”
When boiler alerts „BOILER UNSEALED” error it should be checked if alarm is triggered by not
closed boiler door or activation of capacitive proximity sensor. When the sensor is detects
stockpiling fuel, it is indicated by its red LED indicator. After checking that boiler isn't burning, the
burner chamber should be opened and cleaned of unburned pellets. It is also recommended to open
the burner cleaning system, which allow additional unburned pellets to drop into ash box. After
cleaning the burner chamber it is possible to remove pellets stockpiling in the feeding system. Do to
this, follow the procedure:
•Set the Sensor disabling switch into position marked “1”;
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Sensor disabling
switch
STB Reset
button

•In Manual control start burner cleaning system and open the grid below the burner;
•In Manual control turn on the feeder and let it work for about 5 minutes.
After the procedure set the Sensor disabling switch back into position marked “ ”, start up the
boiler and check if feeding system is working normally.
All activities during cleaning of the combustion chamber and the burner itself should be done
after extinguishing and cooling down the boiler – especially after cooling down the ceramic
burner. During operations involving the burner chamber and the burner protective clothing
must be used!
It is possible to change sensor's sensitivity, which is preset by the boiler manufacturer. Sensitivity
regulation is done by rotation of the screw located in the bottom of the sensor, next to the red LED
indicator. The capacitive sensor mustn’t detect pellets normally feed by the feeder, wood dust
gathering on it, rotation of the auger. If situation like that accrues it is necessary to correct sensor's
sensitivity:
•rotate the screw counter-clockwise – decrease sensor's sensitivity;
•rotate the screw clockwise – increase sensor's sensitivity;
The sensitivity shouldn't be change at once more the half of turn – 18 º. New sensitivity must
provide proper detection of pellets stockpiling in the pipe.
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7.2 Primary and secondary air intakes.
The Smart Fire boiler is equipped with individual air intakes for primary and secondary air, airs
which are used during burning process. Each intake is equipped in a throttle, which allows to
change a cross-section of intake and by that to change amount of sucked primary and secondary air.
By default both throttles should be fully opened, but in some cases it is possible to change primary /
secondary air ratio. Adaptation of throttle's settings must be done on the basics:
•Visual observation of the flame, by using the service door for the burner chamber, in which
serviceman are equipped.
•Indication of exhaust gas analyser, by interpretation of the exhaust gas parameters.
If necessary air intakes throttles can be closed down to limit excess air. It isn't recommended to
close throttles more than show at fig. 8.
Secondary air throttle
Primary air throttle
Fig. 8 Maximum recommended closing for throttles
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25 mm

8 User's operations manual
Please read this manual as well as that of the system controller. Detailed information concerning the
controller setup are to be found in the controller's manual.
8.1 Launch of the boiler operation
Before launching the boiler:
•Check if the heating system has enough water;
•Load adequate amount of fuel in the container.
The boiler will start the ignition process once the controller is activated. The process includes
several tasks that conclude with ignition of the fuel in the burner. Then the boiler will switch to
automatic operation. If the ignition process fails (the exhaust temperature does not rise high
enough) three consecutive attempts of ignition will be taken. If the third attempt fails the controller
will display an alarm. This may happen when setup or fuel are not correct. Contact the service if it
happens.
8.2 Boiler's operation
After the boiler switched from the ignition mode to the operation mode, the amount of fuel fed in
and the fan air flow are set. This is why it offers high efficiency within the entire range of output.
Report all disturbances to the service immediately quoting the messages from the display.
Adjust the setup only when you are certain about its meaning and how it will affect the boiler's
operation. Record all alterations in order to facilitate restoration of a previous setup. This will help
the service and call centre consultation.
•The boiler doses the fuel in regular intervals. The feeding cycle and the length of a
dose are factory set for the nominal, medium and lowest output. However, lower quality fuel
may require adjustments to these parameters. The reasons may be the following: the boiler
does not switch to the preservation mode or floods the burner with excessive amount of
pellets. Consult the controller's manual before adjustment of these parameters. Check quality
of the pellets before adjustments of the setup. In particular, check moisture, hardness and
dust content soaking a sample in water.
•Factory temperature setup offers proper operation of the system. However,
occasionally necessity to change this parameter may arise. Follow the recommendations
concerning boiler temperature range and the controller's manual.
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•Set the central heating temperature, tap water temperature, the heating profile and the
night cool-down for a weekly cycle. Initial parameters shall be set by the service. Read the
controller's manual thoroughly before attempting any alterations. Remember that it may take
a few hours before response of the system to setup change is perceived.
•You can also set up the parameters of the mixing valve should you install one. Initial
parameters shall be set by the service. Always record the current setup before attempting any
adjustments so you can restore it should the alterations prove unwelcome.
•Clean the heat exchange regularly using the knob of the manual cleaning system.
•The burner is cleared automatically following the intervals in the setup measured by
operation hours.
Load systemically the fuel container, preventing the boiler to run out of fuel. When the boiler
is working, fuel container clap door must be closed.
All hatches and inspection doors must be shut when the boiler is working!
In case of faults, smoke leak or other leak detection – the boiler must be immediately
extinguished (v. 8.4), then contact the service in order to determine the cause of malfunction!
8.3 Maintenance and cleaning
Extinguish the boiler and wait at least one hour to cool it down before attempting any
maintenance or cleaning works. Only then you can open safely the doors or the access
openings and start cleaning.
Within the cleaning and maintenance routine during operation you should:
•Replenishment fuel in the container regularly;
•Clear ash off the ash tray - check amount of ash once a week.
•Remove ash from the combustion chamber;
•Clean the heat exchange using the manual cleaning system.
Amount of ash deposit depends on the fuel quality and the amount of fuel burned. Except of ash,
trace amounts of creosote are deposited. To open ash tray chamber door, unscrew the two butterfly
handles at the sides of the door. You simply need to pull the ash tray off the chamber. While
removing ash always clean the ash tray chamber.
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Ash in the combustion chamber falls down from the heat exchanger when it is being cleaned.
Access the combustion chamber unscrewing two handles holding the chamber's door. Sweep the ash
to the ash tray.
Clean the heat exchange regularly using the manual cleaning system. Its enough to make a few
swings of the knob. Repeat it at least once a week. Long periods without cleaning may incapacitate
the manual cleaning systems as it jams.
Clean the boiler thoroughly and service it each time after the heating season, before long lay off, or
when occasional necessity arises. Furthermore boiler condition should be checked every two
mounts and boiler should be cleaned if necessary. For this purpose the boiler has been facilitated
with the cleaning access openings to:
•the burner cleaning hatch;
•exhaust collector hatch;
•exhaust collar hatch;
•cover of the upper exhaust collector,
The typical symptom indicating that there is need to clean the boiler is increasing exhaust gas
temperature during normal boiler work. If exhaust gas temperature increases beyond maximum
recommended exhaust gas temperature, then boiler should be cleaned.
Presented periods of individual activities performed in the cleaning and maintenance of the
boiler by the user are average, and their frequency is highly dependent on the quality of fuel
used and the conditions of the boiler work.
You need to remove the covers of the upper collector to remove the ash accumulated there. You may
hire the authorised service to clean the collector.
The access opening to the exhaust collector is located in the ash tray chamber. In order to open it –
slide it upwards from locks. After cleaning and maintenance access opening must be tightly closed
by sliding cover downwards into locks, paying particular attention to the tightness of the closure.
It is recommended to check the surface of the ceramic burner - in case of dirtinesses in the form of
sintered ash, they should be gently cleaned. Furthermore, during the control of the burner, check for
correct operation mechanism of the burner cleaning system. Steel grate underneath the burner
should move along the guides without significant resistance, without interfering with the burner,
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