Solarbayer 15 Technical Handbook
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Solarbayer 15 Technical Handbook

Gasifying log burner
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PRODUKTINFORMATION
PRODUKTINFORMATION
Technical Hand Book
Solarbayer-Gasifying Log Burner 1

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Summary of Contents for Solarbayer 15

  • Page 1 PRODUKTINFORMATION PRODUKTINFORMATION Technical Hand Book Solarbayer-Gasifying Log Burner 1...
  • Page 2 2 Solarbayer-Gasifying Log Burner...
  • Page 3 Exhaust Heat Exchanger For best energy transfer to the heating system Flue Vent to be used when lighting up the burner (Draft Regulation) Safety Heat Exchanger will cool down burner in case of overheating Flow Return Chimney Connection Solarbayer-Gasifying Log Burner 3...

  • Page 4: Table Of Contents

    Contents Sizing your Boiler The SOLARBAYER - Gasifying Log Burner Description Construction Technical Details Measurements Boiler Schematics Safety Regulations Mounting and Setup Fire Safety Safety Instruction for use and maintenance Additional Equipment Safety Heat Exchanger Laddomat, Shunt Valve with Pump...
  • Page 5 SOLARBAYER-Gasifying Log Burner Control Factory Settings Using the SOLARBAYER-Log Burner Start the burner Refuelling with logs Heat Value Chart / How to store logs Cleaning and measuring of the exhaust gases How to clean the burner How to measure the exhaust gases...
  • Page 6 If the boiler is dimensioned too small you will achieve boiler temperatures of 70 – 80°C, but the desired heating supply line tempera- ture will not be achieved. e.g. building size 220 m² old building: boiler output 25 kW (wrong rating!), correct would be Solarbayer® 50kW. Solarbayer-Gasifying Log Burner...

  • Page 7: Description

    ZO 1250. The replaceable heat-resistant jet is made of fireproof mate- rial ZO 1400. Boilers of 15 – 40 kW are equipped with a combustion air ventilator; from 50 kW onwards two ventilators are provided. A glass fibre door seal with a square cross section (25 mm) is used.

  • Page 8: Technical Details

    2.3 Technical Details Solarbayer Log Burner 14,9 Nominal Boiler Output in kW 3 bis 21 5 bis 31 8 bis 42 15 bis 72 25 bis 92 Boiler output with output regulation 85 – 91 % Height 1120 1120 1370...

  • Page 9: Measurements

    2.4 Dimensions Dimensions of the SOLARBAYER-Log Burner 2.5 Boiler Cross-section SOLARBAYER 25 SOLARBAYER 40 SOLARBAYER 50-80 Control 15 Heat Exchanger Cover Upper Door 16 Draft Control Lid Draft Control Rod 17 Upper Cove Rear Fuel Chamber 18 CH Flow Primary Air Flow...

  • Page 10: Safety Regulations

    In case of temporary danger of fire, i.e. if combustible gases or vapours escape into the boiler room/combustion chamber the boiler has to be shut down in due time (fire extinguished). 10 Solarbayer-Gasifying Log Burner...

  • Page 11: Safety Instruction For Use And Maintenance

    If defects at the electrical installation or defects at the installation of the boiler are detected it is necessary to observe the following rules: • Do not touch any part of the boiler • Disconnect the boiler from power supply; call the responsible service engineer to solve the problem. Solarbayer-Gasifying Log Burner 11...

  • Page 12: Safety Heat Exchanger

    Cooper Pipe sealing for the Thermal Safety Vale SOLARBAYER- Technologie 1 Outer Boiler Wall 2 Welded Seam 3 Welded Nipple 4 EPDM Seal 5 Screw In Nipple 6 Copper Pipe Heat Exchanger 18mm 12 Solarbayer-Gasifying Log Burner...
  • Page 13 At first use please bring burner above safety temperature to insure proper safety valve opera- tion. Thermal Safety Valve Assembly Note: according to DIN 4751-2 Pkt. 10 you are asked to have an inspection carried out by a suitable qualified person. Solarbayer-Gasifying Log Burner 13...

  • Page 14: Laddomat, Shunt Valve With Pump

    Function of the shunt valve: Die Pumpe wird beim Anstellen des SOLARBAYER Holzvergasers sofort eingeschaltet, damit der Once SOLARBAYER-Log burner is switched on, the pump is activated, to ensure the boiler is Kessel gleichmäßig hochgeheizt wird. evenly heated up. Die Pumpe ist ausgeschaltet, wenn der Kessel aus- bzw. abgestellt ist. Wenn jedoch die Kes- When the boiler is switched off, the pump stops.

  • Page 15: Exhaust Fan

    4.3 Exhaust Fan (optional) The standard SOLARBAYER® boiler is equipped with a fresh air fan. With the electronic control unit it is possible to additionally control a waste gas fan. The waste gas fan provides for the optimum removal of flue gases out of the fuel cham-...
  • Page 16 The vessels need to be checked every 2 years by relieving the heating pressure and measuring of the diaphragm pressure. Afterwards the cold heating installation must be filled to 1.2 bar. During heating up the heating pressure will increase a little and drop again during cooling down. 16 Solarbayer-Gasifying Log Burner...

  • Page 17: Main Parts

    The inside of the SOLARBAYER® 15, 25, 40 boiler bodies is protected by a sprayed-on alumi- nium coat which is burned in up to 200°C. On the outside all boiler parts are protected by a water based varnish coat.

  • Page 18: Covers

    Three colours are used: grey, silver and SOLARBAYER®-orange. Grey is used for the cover plates of the upper and lower doors, the ventilator casing is varnished with SOLARBAYER®-orange and silver is used for the remaining jacket of the boiler.

  • Page 19: Door Fuel Chamber

    5.3 Door Seal on the Fuel Chamber Location of joint of sealing cord Generally, SOLARBAYER® boilers have two different doors: the upper doors to close the fuel chamber and the lower doors to close the combustion chamber. Doors consist of a cover plate, insulation under the cover plate, welding seam of the insulation, door closure and hinged-joints.
  • Page 20 Parts of the Door Hinge Adj Nut Threaded hinge Nut with welded Shim Bracket Hinge holel Washer Split Pint Parts of the Closing Handle Head Threaded Handle The threads of hinge and handle must be greased on occassion. 20 Solarbayer-Gasifying Log Burner...

  • Page 21: Fan

    SOLARBAYER® boilers are constructed as overpressure boilers, i.e. the air volume required for combustion is supplied by air fans. Boilers type 15 – 40 are equipped with one ventilator, in boi- ler types 50, 80, and 100 two ventilators are installed. The fan consists of 4 basic parts: 1.

  • Page 22: Secondary Air Adjustment

    Adjustmet Plate Adjustment Srews for secondary air flow The fans used in the SOLARBAYER-boiler 15 and 25, are fitted with an intake cover which is used to regulate the air flow, to adjust the power output. 22 Solarbayer-Gasifying Log Burner...

  • Page 23: Jet And Fire Bricks

    Primary air volume is not regulated but dependant on the ventilator type. The se- condary air is regulated by the groove between the damper-controlled screw on the lower plate of the ventilator and the duct of the secondary air line. Primary Air channel Rear Air Ducts Secondary Air Channel Solarbayer-Gasifying Log Burner 23...

  • Page 24: Burner Control Unit

    5.9 Basic design of Solarbayer Control Unit The control unit is designed for control of SOLARBAYER®-boilers. The fundamental principle of the control consists in temperature control of the heating water coming out of the boiler. The de- sired temperature is reached by air volume control which is carried out by continuous control of the ventilator speed.
  • Page 25 Control Board Exhaust Modul Exhaust Probe Control Unit Burner Sensor Control Unit with Display (Rear and Front View) Solarbayer-Gasifying Log Burner 25...
  • Page 26 A PT 1000 type sensor is used to detect the exhaust gas temperature, which is connected to the AK 2000 MMKT controller. The performance of the sensor is shown in the graph below. (i.e. 25 °C 1000 Ohm) PT 1000 Sensor 26 Solarbayer-Gasifying Log Burner...
  • Page 27 The parameter in the menu can be called upon with the button or button ▲ ▼ ▲ ▼ Values which are flashing can be adjusted; with the button or button After altering a value confirm new value with button Solarbayer-Gasifying Log Burner 27...

  • Page 28: Flow Diagram Of The Controller

    6.2 Flow Chart of the SOLARBAYER-Abgastronic Boiler off „Basic Menu“ www.solarbayer.de Parameter,”Heating”,”Program”,” Basic menu and “Decrease” Setting temp. ▲ ▼ Select with key ▲ ▼ Select parameter “Language English”, “ Basic menu “Combustion wood”, “Shut down” and “Ser- Configuration vice”...

  • Page 29: Preset Of The Solarbayer-Abgastronic Controller

    The Parameter values are listed and explained on the following pages. Note: The Values on the yellow field are pre set for Germany, Austria and Switzerland and for sy- stem with buffer tanks. Do not alter! To change service data, go to CODE (Menu 6.4). Solarbayer-Gasifying Log Burner 29...

  • Page 30: Adjusting The Boiler Temperature

    Confirm with”F” key, display stops flashing In a cold boiler the permitted exhaust gas value cannot be maintained, therefore the boiler temperature has to be set between 80 and 90 degrees Celsius. Only with this setting is an optimal combustion possible. 30 Solarbayer-Gasifying Log Burner...

  • Page 31: Adjusting The Switch Off Temperature

    With the tow buttons, up or down,select temperature ▲ from 35 - 150 °C Preset = 50 °C ▼ We recommend 80 °C Confirm with “ F “ button.Value stops flashing. Switch Off Temperature is set. Solarbayer-Gasifying Log Burner 31...

  • Page 32: Setting The Clock Display

    Time setting 10:02 ▲ ▼ Week day starts flashing; adjust with confirm with Hour setting starts flashing. Adjust as before and repeat for minutes. Confirm with To go back in to the “ Basic Menu” press 32 Solarbayer-Gasifying Log Burner...

  • Page 33: Settings For The Operation Of Solarbayer-Abgastronic

    6.4 Adjustment of the SOLARBAYER-Abgastronic To change the parameter exhaust temperature, minimum fan speed, burner type and program of the SOLARBAYER-Abgastronic, go to CODE in the service mode.To enter the service mode, please follow the steps showing below Basic menu Setting temp ▲...

  • Page 34: Adjusting The Exhaust Temperature

    Max spaliny °C Press key Service Param. Max spaliny °C Use keys to adjust "Max spaliny ___°C" from 150 - 250 °C ▲ Factory setting = 150 °C ▼ We recommend 180 °C Press to confirm 34 Solarbayer-Gasifying Log Burner...

  • Page 35: Adjusting The Minimal Fan Speed

    + and - buttons set the new value ▲ "Min.Vent.DRZ __%" between 3% - 69% . ▼ SOLARBAYER - Setting = 42% press F to store. The minimum fan speed is now set to the new value. Solarbayer-Gasifying Log Burner 35...

  • Page 36: Selecting The Burner Type

    6.4.3 Selecting the burner type To select the burner type go to the “ Service “menu. (see chapter 6.4 ) The SOLARBAYER-Control contains to types of burners: Type „0“ – Standard Burner SOLARBAYER Type „1“ – Pellet Burner SOLARBAYER The SOLARBAYER-Controller is preset Type „0“.
  • Page 37 Each software has a programme number allo- cated to it. The process of changing the control software is described in chapter 8. Program 16 with SOLARBAYER Abgastronik The programme is designed 1 SOLARBAYER-Burner...
  • Page 38 3Put paper, wood chips, small wood (splinters) onto the jet of the boiler through the upper door, approx. 5 – 15 cm high place a fire lighter on top and light the fire cover the burning fuel tablet with small wood...
  • Page 39 During combustion the fuel in the boiler changes into the glowing fire. The ash falls through the nozzle and deposits in the combustion chamber. The output of the boiler is controlled automatically in accordance with the temperature set. During the heating up period, the burner shall not be left unattended. Solarbayer-Gasifying Log Burner 39...
  • Page 40 “Turbo” . SOLARBAYER-Recommendation: By using the Laddomat for the optimum performance of your log burner and the Solarbayer range of cylinders and buffer tanks and the implementation of the Solarbayer pipe schematics your gasifying log burner system will operate in the most efficient and economical way for many years to come.

  • Page 41: Refuelling With Logs

    °C ▼ press once => fan runs for 15 sec. Ventilation 15s Each time the button is pressed again, another 15 sec is boiler temp. °C added to the running time off the fan. To avoid smoke rising out off the burner, open door slightly and wait for a few seconds, before open fuel chamber door fully.
  • Page 42 Refuelling the burner, with exhaust fan „optional“ The SOLARBAYER Log Burner comes with a pressure fan as standard. In addition, the burner can be equipped with an exhaust fan. The exhaust fan is used when the burner is refuelled, while some burning timber is still present in the fuel chamber.

  • Page 43: Heat Value Chart / How To Store Logs

    Festmeter (fm) in Ster or Raummeter (rm) 1 fm 1,4 rm 1,0 m 1 Festmeter (fm) 0,7 fm = 1,4 Raummeter (rm) 1,0 rm 1 Raummeter (rm) [bayerisch 1 Ster] 1,0 m = 0,7 Festmeter (fm) Solarbayer-Gasifying Log Burner 43...
  • Page 44 Since the interior walls of the boiler are provided with an aluminium paint coat tar should not be scraped off (ap- plies to SOLARBAYER® 25, 40). Primary AirDucts Fuel Chamber New Primary Air ducts must be cleaned if they are clogged.
  • Page 45 5 hours at maximum output to burn down the remaining tar completely. Remove Heat Exchanger Cover Carefully (Always were protective gloves) Loosen top of Heat Exchanger using 13mm spanner (Careful to replace correctly) Clean heat exchanger with round scraper. (Boiler room must be properly ventilated while cleaning) Solarbayer-Gasifying Log Burner 45...
  • Page 46 Disconnect Cables to ventilator Loosen two screws on ventilation cover Disconnect mains at wall before touching ventilator cables! Remove housing with ventilator attached Suck debris from air ducts as shown Warning! Before removing ventilator cover disconnect mains supply! 46 Solarbayer-Gasifying Log Burner...

  • Page 47: How To Measure The Exhaust Gases

    Abbrandphase Ausbrand Anheizen ca. 40 min ca. 3 Std. ca. 1 Std. Diagram shows that carbon monoxide output is highest during lighting up Therefore accurate measurement can only be taken in the middle of burn cycle: Solarbayer-Gasifying Log Burner 47...

  • Page 48: Burner- And Exhaust Gas Temperatures At The Start

    9.3 Boiler and exhaust temperatures during operation Kesseltemperaturen während des Heizvorgangs 48 Solarbayer-Gasifying Log Burner...

  • Page 49: Maintenance And Repair Of The Burner

    Refractory nozzle, same for all boilers seals of boiler doors, 14, 9 S, 25 S, 40 S seals of chimney lid, 14, 9S, 25 S, 40 S lining of combustion chamber (fireclay bricks P5), same for all boilers Solarbayer-Gasifying Log Burner 49...

  • Page 50: Troubleshooting

    Chimney height shall be at least 8 m for 15, 25, 40 kW and at least 12 m for 60, 80, 100 kW Install an induced draught ventilator...
  • Page 51 Display shows ERR instead of temperature Flashes Malfunction-thermometer de- Temperature sensor is defective. Replace fective Malfunction in communication between display and power unit panel. Possible: communication Flashes Malfunction – SLEEP. cable between (X1-X1) damaged, display or power unit panel defective Solarbayer-Gasifying Log Burner 51...
  • Page 52 12 Schematics 12.1 Typical connection diagrams without oil/gas boiler Note: These drawings are schematic diagrams by Solarbayer® GmbH and do not replace a professional design Log Boiler - Buffer tank - Domestic Hot water store Solar-Speicher Log Boiler-two Buffer tanks-Domestic hot water store...
  • Page 53 Log Boiler – Buffer tank with Solar Coil – Domestic Hot Water – Solar Solar-Speicher Log Boiler – 2 Buffer tanks with Solar Coil – Domestic Hot Water – Solar Solar-Speicher Solarbayer-Gasifying Log Burner...

  • Page 54: Typical Schematics With Oil Burner

    12.2 Typical Connection Diagrams with Oil/Gas Boilers Boiler circuit with oil/gas with boiler charge control .Note: These drawings are schematic diagrams by Solarbayer® GmbH and do not replace a professional design Log Boiler – Oil/Gas Boiler – Buffer Tank – Domestic Hot Water Store WW-Speicher Log Boiler –Oil/Gas Boiler –...
  • Page 55 Log Burner –Oil/Gas –2 Buffer tanks (1 with solar coil) – Domestic Hot Water – Solar Solar-Speicher Log Burner – Oil/Gas – 3 Buffer tanks(1 with solar coil) – Domestic hot water – Solar Solar-Speicher Solarbayer-Gasifying Log Burner 55...

  • Page 56: Electrical Diagram

    Always disconnect mains power supply before opening electrical covers to avoid electric shock. All wiring should be carried out by qualified personnel only! Components to connect at installation by qualified electrician: (Laddomat) □ Cable 3x 1,5 Exhaust fan (optional) Cable 3x 1,5 □ 56 Solarbayer-Gasifying Log Burner...
  • Page 57 Notes Solarbayer-Gasifying Log Burner 57...

  • Page 58: Warranty

    - otherwise, the regulations of the Civil Code apply to the guarantee. SOLARBAYER® reserves the right of changes made to the product within the scope of product innovation. 58 Solarbayer-Gasifying Log Burner...

  • Page 59: Statement Of Conformity

    Go- vernment. Product: Thermal boilers SOLARBAYER® 14.9 to 80 Type: Solarbayer® 14.9, Solarbayer® 25, Solarbayer® 40, Solarbayer® 50, Solarbayer® 80 Importer: Solarbayer® GmbH The products listed are in accordance with the following standards:...
  • Page 60 Phone: +49 (0) 84 21 / 90 39 27 Fax: +49 (0) 84 21 / 90 39 28 E-Mail: info@solarbayer.de www.solarbayer.de This manual and the pictures and drawings within are protected by the copyright of SOLARBAYER GmbH Technical changes and errors are reserved (3307) 60 Solarbayer-Gasifying Log Burner...

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