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Summary of Contents for Solarbayer HVS Series
- Page 1 P R O D U C T I N F O R M AT I O N S O L A R B A Y E R W O O D L O G B O I L E R Solarbayer control unit „SB4.0” HVS E...
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Page 2: Table Of Contents
Type of fuel ................40 © Solarbayer GmbH [02.16]... - Page 3 Please pay attention to the correct position of the steel tub in the combustion chamber, as well as to the correct position of the fireclay bricks and plates. see chapter [Maintenance] Combustion chamber Please pay attantion to the „checklist for initial operation” before first operation, see chapter [Installation] Checklist for initial operation of the boiler © Solarbayer GmbH [02.16]...
- Page 4 For planning means please refer to the follwoing pages, especially the calculation example for dimensioning the wood log boiler. The usage of the Solarbayer wood log boiler HVS in smokeless zones in the UK is NOT granted by the DEFRA since the company Solarbayer did not apply for it (dated March 1 2013) ©...
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Page 5: General Information
PRODUCT INFORMATION Wood log boiler HVS General information © Solarbayer GmbH [02.16]... -
Page 6: Regulations
VDI 2035 Prevention of damage in water heating installations VDE 0100 Erection of power installations VDE 0105 Operation of electrical installations * This list is not exhaustive, updates and new releases have to be regarded. © Solarbayer GmbH [02.16]... -
Page 7: Safety Regulations For Fire Protection
The SOLARBAYER wood log gasification boiler has to placed on a protection plate (see sketch above) in case of doubt. In case of ambiguity please inquire with the local supervisory body (chimney sweeper ...) beforehand. -
Page 8: Sectional Model
With the boiler series HVS E (without lambda control) the secondary is adjusted via regulating screws. *only with HVS 16, HVS 25 and HVS 40 sectional model shoes HVS LC © Solarbayer GmbH [02.16]... -
Page 9: Calculation Aid For Dimensioning The Wood Log Boiler
40 to 60 W/m² Thermal Insulation Ordinance since 1994 of an ordinary oil/gas boiler EnEV 2002 20 to 45 W/m² that produces thermal heat for 24 hrs. EnEV 2009 15 to 30 W/m² source: Book of Tables SHK © Solarbayer GmbH [02.16]... -
Page 10: Technical Data
Regulatory framework and government grants should to be paid attention to. ²Depending on tube length, number of elbows installed, mixing valves, changeover valves, etc., you might need a bigger dimension. The above mentioned tube dimensions are only a recommendation and do not replace professional technical planning. © Solarbayer GmbH [02.16]... -
Page 11: Mounting Dimensions
HVS 100 LC mains voltage/frequency V/Hz 230/50 power consumption – standby (AK4000D/AK4000S) 1,22 power consumption – standby (AK4000D/AK4000S) 1,67 power consumption – operation (HVS E/LC) 40 / 55 40 / 55 80 / 95 80 / 95 © Solarbayer GmbH [02.16]... -
Page 12: Safety Regulations - Installation Guidelines
We recommend the installation of a strification buffer tank with a tank capacity of at least 55 liters per kW nominal boiler out‐ put. General local requirements and criteria for eligibilty have to be regarded. *The installation notes of the manufacturer have to be regarded. An annual check of the safety devices by a specialized company is mandatory. © Solarbayer GmbH [02.16]... - Page 13 PRODUCT INFORMATION Wood log boiler HVS Installation © Solarbayer GmbH [02.16]...
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Page 14: Tank Sensor
Buffer tank (mandatory) To improve the effificiency of the wood log boiler and to ensure low emission operation it is mandatory to use Solarbayer SPS buffer tanks with their patented SLS®‐system. The advantages are: ‐ immediate availability of heat ‐ perfect stratification ‐... -
Page 15: Boiler Charging Unit (Mandatory)
A boiler charging unit is obligatory to achieve the required combustion values as well as to prevent the accumulation of condensing water and thus the corrosion of the boiler body. Only Solarbayer boiler charging units shall be used for that. -
Page 16: Thermal Discharge Safety Valve (Mandatory)
⑦ double nippel ③ flat washer flat seal 1 boiler wall 2 welded seam 3 welded socket 4 flat seal 5 washer 6 double nipple 7 CU tube heat exchanger (18 mm) © Solarbayer GmbH [02.16]... - Page 17 PRODUCT INFORMATION Wood log boiler HVS Solarbayer 16 kW, 25 kW and 40 kW Solarbayer 60 kW und 100 kW thermal discharge safety valve ¾“, cold water inlet Immersion sleeve with double temperature protector ...
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Page 18: Exhaust Gas Fan (Optional Accessory)
Technical information and installation manual come with the product and could be downloaded on: www.solarbayer.de 2.5.1.1 HVS25L When operating the boiler with an exhaust gas fan the corresponding λ λ mode has to set in the menu of the control panel see chapter: [Operation] Expert level (2.5: Configuration) © Solarbayer GmbH [02.16]... -
Page 19: Flue Pipe And Barometric Damper (Optional Accessory)
It is only with a barometric damper that the combustion values and the chimney draft can be guaranteed permanently. Chimney draft: see chapter: [General information] Technical data barometric damper mandatory accessory exhaust gas routing to the chimney: straight length < 1,5 m © Solarbayer GmbH [02.16]... -
Page 20: Electrical Connection
Never touch any current‐carrying parts, danger to life exists! The boiler is equipped with a shockproof plug. The following components have to be connected at site: boiler circuit pump (original Solarbayer boiler circuit unit) cable 3x 1,5 mm² exhaust gas fan (optional) cable 3x 1,5 mm²... -
Page 21: Electric Circuit Diagram Hvs E
(Lambda board) gnge exhaust gas boiler circuit pump mains connection grounding groun- 50Hz controller ding boiler 230V AC (temperature cover boiler sensor sensor) body see the following pages for a connection diagram of the temperature sensors → © Solarbayer GmbH [02.16]... -
Page 22: Electric Circuit Diagram Hvs Lc
(Lambda board) AK 4000 SL control/lambda board Solarbayer GmbH female 4P4C coupling (Lambda board) exhaust gas boiler circuit pump mains connection 50Hz gnge tank sensor 230V AC (temperature sensor) grounding grounding boiler controller body cover © Solarbayer GmbH [02.16]... - Page 23 The connection boxes are placed on the boiler’s servo backside and are already pre‐wired. motor connection (secondary air) (lambda sensor) switched mode power supply gnge (only HVS LC) INPUT: 100-240VAC 0.7A 50/60Hz OUTPUT: +12V 2.1A © Solarbayer GmbH [02.16]...
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Page 24: Checklist For Initial Operation Of The Boiler
Record the pressure test and the correct filling of the system in accordance with VDI 2035 and let the customer confirm this. Manufacturer number Boiler number Type of boiler (type plate) (above fuel chamber door) Herewith I confirm the proper initial operation stamp / date / signature installer © Solarbayer GmbH [02.16]... -
Page 25: Operation
PRODUCT INFORMATION Wood log boiler HVS Operation © Solarbayer GmbH [02.16]... -
Page 26: Description Of Control Panel And Display
[selection with▲▼] λ display of hydraulic scheme 25 kW symbols: exhaust gas fan, lambda sensor, exhaust gas temperature operating mode operating mode (when the boiler is „OFF” the nominal boiler output is displayed) © Solarbayer GmbH [02.16]... -
Page 27: Description Of Icons And Basic Parameters
λ 1.33 λ 82.3 C 96.4 C 85.4 C heating mode stopped servo 90% You will return to the current menu when pressing the left or right key again 07:16 79.2°C maximum temperature exceeded λ ° © Solarbayer GmbH [02.16]... -
Page 28: Basic Menu
° 07:16 29.8 λ boiler max. 25 kW [long press] temperature start menu How to use the control keys control panel settings confirm (Enter) escape (ESC) select mode of operation time error search Info software information © Solarbayer GmbH [02.16]... - Page 29 Display S1.05,R05 13/03/26 15:16 6.1.2 Mon SB4.0S: 5BHC S1.06PWR control panel 13/03/11 15:06 information SW SB4.0S,HW02: Power S1.07,50Hz 13/03/11 15:08 6.1.3 Mon SB4.0L: 5BHC S1.04LMB lambda board 12/12/20 08:53 SW SB4.0L,HW01: information Lambda S1.06 13/03/26 15:12 © Solarbayer GmbH [02.16]...
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Page 30: Important Parameters
Adjusting the background light of the control panel. ❼ Display contrast ❽ Shifting values with [yes] the values displayed are shifting automatically with [no] the values can be inquired manually See following page for the return to factory settings © Solarbayer GmbH [02.16]... -
Page 31: Return To Factory Settings
= return to factory settings; = escape set boiler type choose value [type of boiler] HVS25L save escape activate/de‐activate exhaust gas fan choose value [yes/no] save escape = activate exhaust gas fan; = de‐activate exhaust gas fan © Solarbayer GmbH [02.16]... -
Page 32: Expert Level
[long press] 0000 Password area (expert level) 2.5.1 2.5] λ configuration 2.10 2.10.1 -> config 2.10] <- config SD card reader -> firmware Erase 2.10.1 -> -> SB4.0S -> SB4.0L 2.12 2.12.1 2.12] functional check 2.12.1 © Solarbayer GmbH [02.16]... - Page 33 The terminals can be switched manually. Please check before heating on the boiler for the first forced draft fan check time! exhaust gas fan check (when activated) pump check servo motor check [closed] servo motor check [open] © Solarbayer GmbH [02.16]...
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Page 34: Heating Up The Boiler - Control Panel (Without Exhaust Gas Fan)
07:16 79.2°C After several minutes the boiler turns to heating mode when the shut down λ ° temperature is exceeded by approx. 20°C λ Note: The pump starts at a boiler temperature of approx. 40°C. ° © Solarbayer GmbH [02.16]... -
Page 35: Heating Up The Boiler - Control Panel (With Exhaust Gas Fan)
07:16 79.2°C After several minutes the boiler turns to heating mode when the shut down λ ° temperature is exceeded by approx. 20°C λ Note: The pump starts at a boiler temperature of approx. 40°C. ° © Solarbayer GmbH [02.16]... -
Page 36: Heating Up The Boiler - Ignite The Fire
Place them over the nozzle as shown in the picture Ignite f.e. a heat tablet Place the tablet on the charcoal leftovers Position 2 wood logs on each side of the boiler wall Place some splinters on the heat tablet © Solarbayer GmbH [02.16]... - Page 37 flame downwards into ‐ During heating mode the exhaust gas damper the combustion and all doors must be closed. chamber. © Solarbayer GmbH [02.16]...
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Page 38: Refueling
Note: The pump starts at a boiler temperature of approx. 40°C. ° Set the draft bar to the position „open/heating‐up” before refueling. After having closed the boiler door set the draft bar to the position „close/normal heating mode“ © Solarbayer GmbH [02.16]... -
Page 39: Turn-Off The Boiler (Automatically)
⌧ cancel and return ▲▼ select the values that are going to be displayed Boiler off 07:16 25.0°C The control panel automatically switches to the start menu. λ 25 kW © Solarbayer GmbH [02.16]... -
Page 40: Type Of Fuel
Type of fuel The SOLARBAYER wood log boilers are suitable for the combustion of dry wood (split wood logs with less than 20% residual moisture) with a length that fits the fuel chamber and a maximum edge length of approx. 8x14 cm. Wood shavings and splinters have to be burned in combination with wood logs. -
Page 41: Maintenance
PRODUCT INFORMATION Wood log boiler HVS Maintenance © Solarbayer GmbH [02.16]... -
Page 42: Doors
Afterwards tighten them again brass disk hinge door handle sealing hinge boiler door The threads of the hinge and the closing have to be greased from time to time. adjustable hinge © Solarbayer GmbH [02.16]... -
Page 43: Boiler Casing
Place the door with the inner side facing downwards on a stable ground. Now the casing can easily be removed. Disconnect boiler form the mains supply before removing the casing. Never touch conducting devices – danger to life exists! © Solarbayer GmbH [02.16]... -
Page 44: Ceramic Nozzle/Nozzle Brick
HVS 16 LC HVS 25 E HVS 40 E HVS 60 E HVS 100 E HVS 25 LC HVS 40 LC HVS 60 LC HVS 100 LC 1 nozzle block 1 nozzle 1 nozzle 2 nozzles 2 nozzles © Solarbayer GmbH [02.16]... -
Page 45: Protection Bricks
The protection bricks are wear parts and have to be replaced when necessary. Only with HVS 16 LC: 3 protection bricks are placed on both, the left and the right side of the fuel chamber. © Solarbayer GmbH [02.16]... -
Page 46: Combustion Chamber
Thus, the bricks stand on the fireclay plates and are fixed by the retaining ledges from above. catalyzer catalyzer brick brick retaining ledges catalyzer bricks view from above front view © Solarbayer GmbH [02.16]... - Page 47 HVS 16 combustion chamber. HVS 25 HVS 40 HVS 60 HVS 100 Fireclay bricks, plates and the steel tub are wear parts and need to be replaced when necessary. Only use original spare parts! © Solarbayer GmbH [02.16]...
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Page 48: Primary And Secondary Air Duct
The primary air ducts of the HVS 16, HVS 25 and The primary air steadily pours into the fuel chamber HVS 40 are placed on the side (2 on each side, left and ober the air ducts. right) © Solarbayer GmbH [02.16]... -
Page 49: Adjusting The Secondary Air (Only For Hvs E)
Thus, a clean combustion is no longer guaranteed. The fan wings should be cleaned from time to time. Disconnect boiler form the mains supply before removing the casing. Never touch conducting devices – danger to life exists! © Solarbayer GmbH [02.16]... -
Page 50: Lambda Servo Motor And Air Blind (Only With Hvs Lc)
Push the shaft as far as it goes to the boiler body. servo motor forced draft fan © Solarbayer GmbH [02.16]... -
Page 51: Lambda Sensor (Only With Hvs Lc)
The connection is made by the connection box at the boiler’s backside. Lambda sensor connection Position the draft bar during heating phase is „normal heating mode”/”close”. An open exhaust gas damper may harm the lambda sensor when touched by the flames. © Solarbayer GmbH [02.16]... -
Page 52: Sensor
Pull the front plate approx. 2 cm to the front and then tilt it carefully to the front. Disconnect mains supply before removing the boiler casing. Never touch conducting devices – danger to life exists! sensor characteristics © Solarbayer GmbH [02.16]... -
Page 53: Safety Temperature Limiter - Stb
„boiler maximum temperature“. Remove the black safety cap of the STB and press the green release knob. By pressing the „ENTER” key afterwards the control unit is returning to the main menu again, the error message disappears. Now the boiler can be operated again. © Solarbayer GmbH [02.16]... -
Page 54: Exhaust Gas Turbulators
Number of turbulators needed: HVS 16 ‐ 40 6 turbulators HVS 60 16 turbulators HVS 100 24 turbulators When heating with very resinous wood and/or with scrap wood the turbulators should not be installed © Solarbayer GmbH [02.16]... -
Page 55: Cleaning The Fuel Chamber
Attention ‐ danger of burns! Only clean boiler when cooled down! included in scope of delivery: scraper poker round scraper © Solarbayer GmbH [02.16]... -
Page 56: Cleaning The Heat Exchanger
A weekly cleaning interval is necessary when operating the boiler with turbulators. Depending on the degree of dirt the cleaning interval might be extended. Attention ‐ risk of burns! Only clena the boiler when cooled down! © Solarbayer GmbH [02.16]... -
Page 57: Cleaning The Primary And Secondary Air Ducts
Check if air is coming out of the primary air ducts (with compressed air). If the primary air duct is blocked it can be demounted and cleaned. Test on operability after reinstalling. © Solarbayer GmbH [02.16]... -
Page 58: Maintenance Plan
Doors grease moveable parts with copper paste [especially the thread of the door handle; door hinge] – – – when necessary re‐adjust door hinges [in order to compensate ‚fading‘ of the door sealing] © Solarbayer GmbH [02.16]... -
Page 59: Maintenance Report
We recommend the annual maintenance to be carried out by a professional HVAC installer in accordance with the valid safety and technical regulations. Let your installer cofirm the annual maintenance operations. Bitte kopieren Sie dieses Wartungsprotokoll für weitere Einträge © Solarbayer GmbH [02.16]... -
Page 60: Exhaust Gas Measurement
1,5 hrs before the heating phase. The exhaust gas measurement by the chimney sweeper has to take place during the heating phase. During the heating phase the carbon monoxide value is at its lowest point (see diagram above). This is why the measurement has to take place during the heating phase. © Solarbayer GmbH [02.16]... -
Page 61: Trouble Shooting
Boiler circuit pump (Laddomat) does No power supply Check fuse and replace when necessary not operate Fuse F1 on the control board is broken replace control board (AK 3000 S) Control board (AK 3000 S) is broken © Solarbayer GmbH [02.16]... -
Page 62: Error Messages
FUSE 3.15 A Err limiter STB; fuse F3.15A) ! ! ! ! ! ! ‐ check pump incl. cable (short circuit?) 25 kW F3.15 ‐ replace fuse F3.15A (control board AK 4000 SL) LED flashes red © Solarbayer GmbH [02.16]... - Page 63 ‐ check contacts and sensor resistance →← LED flashes red SB4.0S T3 PT1000 Kurzschlussin the tank sensor circuit (affected parts: AK 4000 SL/AK 4000 S; SB4.0S T3 PT connection box temperature sensor; sensor boiler temperature) ‐ check contacts and sensor resistance © Solarbayer GmbH [02.16]...
- Page 64 (affected parts: AK 4000 SL/L; cable servo motor; servo motor) ‐ check contacts and connection cable λ between servo motor and lambda control board AK 4000 L ‐ check 2‐pin coupling AK4000 L / AK 4000 SL λ © Solarbayer GmbH [02.16]...
- Page 65 ‐ the safety temperature limiter has to ‐ boiler start is not possible be unlocked manually after the LED flashes red temperature has fallen below the set maximum temperature see chapter: [Maintenance] Safety temperature limiter ‐ STB © Solarbayer GmbH [02.16]...
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Page 66: Declaration Of Conformity
HVS 100 , HVS 100 SOLARBAYER GmbH Manufacturer: Directives and regulations used: machinery directive 2006/42/EG DIN EN 303-5: 1999-06 DIN EN 303-5: 2012 MV directive 2004/108/EG directive 97/23/EG directive 2006/95/EG Pollenfeld, 01.03.2014 Kraus Martin CEO Solarbayer GmbH © Solarbayer GmbH [02.16]... -
Page 67: Manufacturers Delcaration
Seasoned logs are the preferred biomass fuel type. The Solarbayer wood gasification boilers are not suitable for the combustion of fossil fuels including oil or solid fuels such as coal or smokeless ovoid coals. The use of any fuels other than timber based biomass fuel will void the manufacturer warranty. - Page 68 IHeat pumps www.duurzame-energie-technieken.nl info@duurzame-energie-technieken.nl This manual and the pictures and drawings within are protected by the copyright of SOLARBAYER GmbH. Technical changes and errors are reserved. The effective one in each case is the current version on our homepage www.solarbayer.de...
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