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HVS E 

ECONOMIC

HVS LC 

LAMBDA CONTROL

© Solarbayer GmbH [02.16]

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P R O D U C T   I N F O R M AT I O N

Instruction Manual

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Solarbayer control unit „SB4.0”

Summary of Contents for HVS 100 E

Page 1: ...HVS E ECONOMIC HVS LC LAMBDA CONTROL Solarbayer GmbH 02 16 1 P RO D U C T I N FO R M AT I O N Instruction Manual S O L A R B AY E R W O O D L O G B O I L E R Solarbayer control unit SB4 0 ...

Page 2: ...ue pipe and barometric damper optional accessory 19 Electrical connection 20 Electric circuit diagram HVS E 21 Electric circuit diagram HVS LC 22 Checklist for initial operation of the boiler 24 Operation Description of control panel and display 26 Description of icons and basic parameters 27 Basic menu 28 Important parameters 30 Return to factory settings 31 Expert level 32 Heating up the boiler ...

Page 3: ...ber 55 Cleaning the heat exchanger 56 Cleaning the primary and secondary air ducts 57 Maintenance plan 58 Maintenance report 59 Exhaust gas measurement 60 Trouble shooting 61 Error messages 62 Declaration of conformity 66 Manufacturers delcaration 67 General Information Maintenance Operation Installation Please pay attantion to the checklist for initial operation before first operation see chapter...

Page 4: ...for you and a steady and even combustion for your wood You can only achieve an optimal efficiency factor with a perfectly aligned system Therefore we generally recommend our high quality stratification tanks SPS with integrated patented stratification system The produced heat of the wood log boiler can be perfectly stored in this kind of tank The stored thermal energy is relieved into the heating syst...

Page 5: ... Solarbayer GmbH 02 16 5 PRODUCT INFORMATION Wood log boiler HVS General Information General information ...

Page 6: ...ing the installation operation and maintenance have to be regarded When installed in the UK all buidling regulations including Part G J and L have to be strictly adhered to The following engineering rules have to be particularly regarded DIN EN 303 5 Heating boilers for solid fuels manually and automatically stoked DIN 1988 Codes of practice for drinking water systems DIN EN 806 Codes of practice ...

Page 7: ...ty wood oak alder larch spruce chipboards etc Level C3 easily ignited wood pine beech ash poplar fibreboards cork foil polystyrene polyethylene bituminized boards cellulose plywood etc 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 Safety...

Page 8: ... by the rear air duct 7 Ceramic nozzle with secondary air duct creates the perfect gas mixture and guarantees a clean downward wood gas flame 8 Slide in combustion chamber with high temperature resistant fireclay bricks for a complete burnout of the wood gases 9 Exhaust gas heat exchanger with turbulators for best possible hand over of exhaust gas heat to the heating water 10 Exhaust gas damper wi...

Page 9: ... chamber will post heat for about an hour Afterwards the combustible is completely used up For an easier calculation we presume a burning period of approximately 4 hrs at no minal output Attention This is imperative for the rating of the boiler to avoid that the boiler output is rated too weak daily heat requirement kWh d The daily heat requirement of the building in kWh at an outside temperature ...

Page 10: ...10 455 max filling weight beech approx kg 20 30 48 80 120 fuel consumption at nominal load beech approx kg h 4 5 7 1 11 2 17 25 combustion period at nominal load beech approx hrs 4 4 4 2 4 3 4 5 4 5 Exhaust gas routing HVS 16 LC HVS 25 E HVS 25 LC HVS 40 E HVS 40 LC HVS 60 E HVS 60 LC HVS 100 E HVS 100 LC recommended min chimney cross section Ø mm 140 150 180 180 200 draft requirements Pa 15 25 15...

Page 11: ...er C mm 645 645 645 785 785 depth D mm 840 1070 1070 1260 1650 height flow line E mm 1075 1075 1310 1400 1400 height exhaust pipe middle F mm 890 890 1110 1170 1170 height return line G mm 115 115 125 215 215 height draining H mm 55 55 70 135 135 flue spigot Ø mm Ø 159 Ø 159 Ø 196 Ø 196 Ø 196 boiler flow line boiler return line Ø DN50 2 IG safety heat exchanger Ø DN20 immersion sleeve for safety h...

Page 12: ...tween boiler and safety valve has to be unlockable 3 Thermal discharge safety valve according to DIN EN 14597 see chapter Installation Thermal discharge safety valve The thermal discharge safety has to be unlockable connected to a pressurized mains water system When the cold water pressure is 6 bar a pressure relief valve is necessary 4 Membrane expansion vessel according to DIN EN 13831 The vesse...

Page 13: ... Solarbayer GmbH 02 16 13 PRODUCT INFORMATION Wood log boiler HVS Installation Installation ...

Page 14: ...nce on the control of the boiler tank sensor The buffer tank sensor should be installed after of the buffer tank volume 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 rapid ...

Page 15: ...ging units shall be used for that The integrated pump is connected directly to the HVS motherboard control board see chapter Installation Electric circut diagram During operation the pump is running at a flow line temperature of approximately 40 C Independent of the ope rating mode the pump is running when the maximum boiler flow line temperature set is exceeded overheat control In case of a break...

Page 16: ... thermal discharge safety valve has to be connected unlockable to a pressurized mains water network The drain outlet has to lead free Operating mode The valve that is independent of pressure opens a waterway at a flow line temperature of approx 95 C and thus prevents a temperature increase over a maximum of 110 C 1 boiler wall 2 welded seam 3 welded socket 4 flat seal 5 washer 6 double nipple 7 CU...

Page 17: ...ctor cold water outlet Please check the safety valve s function when heating up the boiler for the first time by heating up the boiler to opening temperature Solarbayer 16 kW 25 kW and 40 kW Solarbayer 60 kW und 100 kW Installation According to regulation DIN 4751 2 the operator of the system is obligated to get the thermal discharge safety valve checked by a specialist at least once a year ...

Page 18: ...g the boiler with an exhaust gas fan the corresponding mode has to set in the menu of the control panel see chapter Operation Expert level 2 5 Configuration λ 2 5 1 1 HVS25L λ yes yes yes Exhaust gas fan optional accessory In order to support the fume outlet while putting more fuel into the boiler an exhaust gas fan can be retrofitted Thus the fume outlet is minimized while the fuel chamber door i...

Page 19: ...e designed according to clear section height and thermal resistance in such a way that the exhaust gases are during all normal operating modes only lead to the outside through the chimney no overpressure occurs and that the fireplaces have enough combustion air It is NOT allowed to connect more than one fireplace to the chimney when using a wood gasification boiler due to the forced draft fan baro...

Page 20: ... 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 mm exhaust gas fan optional cable 3x 1 5 mm safety temperature limiter STB grounding boiler cover Disconnect power before opening the control unit s casing Never touch any system component that is current carrying danger to life exists conn...

Page 21: ...TER Typ AK4000S Imax 5A Nap 100 240V 50 60Hz F3 15A 230V F1A SICHERUNG FUSE 110V F1 5A FUSE 5X20 FUSE 5X20 Solarbayer GmbH exhaust gas fan boiler circuit pump female 4P4C female 4P4C PT1000 mains 50Hz 230V AC connection box temperature sensor coupling Lambda board coupling Lambda board STB safety temperature limiter boiler sensor A female 4P4C grounding controller cover grounding controller casing...

Page 22: ...R Typ AK4000SL Imax 5A Nap 100 240V 50 60Hz F3 15A 230V F1A SICHERUNG FUSE 110V F1 5A FUSE 5X20 FUSE 5X20 exhaust gas fan boiler circuit pump female 4P4C rt rt bl bl gnge bl br PT1000 T1 mains 50Hz 230V AC coupling Lambda board coupling Lambda board bl br gnge STB safety temperature limiter tank sensor connection box temperature sensor A Solarbayer GmbH female 4P4C female 4P4C grounding boiler bod...

Page 23: ... GmbH 02 16 23 PRODUCT INFORMATION Wood log boiler HVS Installation sw gr bl br T2 T3 A Temperatursensor PT1000 Abgas fühler PT1000 Puffer fühler Smoke Abgas Tank Speicher The connection boxes are placed on the boiler s backside and are already pre wired AK 4000 L lambda board switched mode power supply only HVS LC connection box temperature sensors ws gr sw ws br gr sw bl ws ws g sw B Lambdasonde...

Page 24: ...ystem check and barometric damper adjusted steel tub fireclay bricks and plates placed correctly see chapter maintenance Combustion chamber catalyzer bricks placed correctly only with HVS 25E and HVS 25 LC see chapter maintenance Combustion chamber start up flap is flexible and firmly closing place turbulators inside exhaust gas heat exchanger checked secondary air settings only HVS E heat consump...

Page 25: ... Solarbayer GmbH 02 16 25 PRODUCT INFORMATION Wood log boiler HVS Operation Operation ...

Page 26: ...de control key ENTER OFF 25 kW 07 16 29 8 C λ current time display of current values selection with display of hydraulic scheme symbols exhaust gas fan lambda sensor exhaust gas temperature operating mode operating mode when the boiler is OFF the nominal boiler output is displayed How to use the control keys confirm Enter escape ESC select mode of operation battery only with LC ...

Page 27: ...ion of lambda servo motor only with HVS LC servo 90 Monitoring the different values OFF 25 kW 07 16 29 8 C λ ON 07 16 25 0 C λ 79 C 07 16 79 2 C λ 79 C 07 16 103 7 C λ END 07 16 77 7 C λ MAX 07 16 90 6 C λ boiler OFF start menu heating mode begins heating mode leave heating mode heating mode stopped maximum temperature exceeded All current values are displayed when pressing the left or the right k...

Page 28: ...HVS Operation OFF 25 kW 07 16 29 8 C λ long press 1 boiler max temperature 1 2 control panel settings 2 3 time 3 4 error search 4 Err 6 software information 6 Info start menu Basic menu How to use the control keys confirm Enter escape ESC select mode of operation ...

Page 29: ...ues λ 2 1 1 min 0 86 33 Roll no 3 1 2013 03 18 Mon 19 33 25 date YYY MM DD time hh mm ss 4 Err No Error 6 1 Info SB4 0D Info SB4 0S Info SB4 0L 6 1 1 Mon SB4 0D 9BHC S4 06DSP 13 02 19 15 23 SW SB4 0D HW01 Display S1 05 R05 13 03 26 15 16 display information 6 1 2 Mon SB4 0S 5BHC S1 06PWR 13 03 11 15 06 SW SB4 0S HW02 Power S1 07 50Hz 13 03 11 15 08 control panel information 6 1 3 Mon SB4 0L 5BHC S...

Page 30: ...prox 14 increase or decrease in performance Modifications should only be made with difficult chimney conditions Minimum fan performance recommendation 0 The control panel is able to infinitely adjust the motor speed between the minimum performance and the chosen maximum fan performance Display brightness Adjusting the background light of the control panel Display contrast Shifting values with yes ...

Page 31: ...ory settings No escape 1 Default cfg Yes No confirm return to factory settings choose value yes no save escape Yes return to factory settings No escape 1 HVS25L set boiler type choose value type of boiler save escape 1 yes activate de activate exhaust gas fan choose value yes no save escape Yes activate exhaust gas fan No de activate exhaust gas fan PIN 2522 Solarbayer GmbH 02 16 31 PRODUCT INFORMA...

Page 32: ...on 2 5 λ 2 5 1 2 10 SD card reader 2 10 SD 2 12 functional check 2 12 on off 2 12 1 OFF OFF OFF OFF 2 12 1 OFF Expert level 1 1 0000 PIN Password area expert level long press 4x PIN 0000 when ON long press 2 10 1 config SD config SD firmware SD Erase SD 2 10 1 mon no SD SB4 0S SD SB4 0L SD ...

Page 33: ...ration to HVS control panel read configuration from HVS control upload software into display delete information on SD card function not available upload software to control board upload software to lambda board forced draft fan check exhaust gas fan check when activated pump check servo motor check closed servo motor check open 1 ON OF Yes No 2 λ 1 when retrofitting the boiler control from HVS T t...

Page 34: ... 0 C λ Heating mode begins The boiler is in heating up mode as long as the temperature is lower than the pre set boiler shut down temperature plus additional 20 C Note If the temperature does not cross this mark in between 30 minutes the boiler will automatically turn to end 90 C λ END 79 C 07 16 79 2 C λ Heating mode After several minutes the boiler turns to heating mode when the shut down temper...

Page 35: ... 60 ON 0 Exhaust gas fan is activated select parameter 60 running time of the fan is elongated for 60 s press ON turn on boiler 0 turn off exhaust gas fan select the values that are going to be displayed ON 07 16 25 0 C λ Heating mode begins The boiler is in heating up mode as long as the temperature is lower than the pre set boiler shut down temperature plus additional 20 C Note If the temperature...

Page 36: ...e pushed to the correct position open see picture 1 in order to open the exhaust gas damper Thus pressure flue gas can escape through the chimney The bottom door stays closed Anheizen Nachlegen Hea ng up Refill Échau er Recharger Accendere Riempire Heizbetrieb Normal hea ng mode Mode chau age régulier Funzione riscaldamento Auf Open Ouvert Aperto Zu Close Fermé Chiuso activate exhaust gas fan only...

Page 37: ...Open bottom door And let it burn for approx 5 minutes 7 Completely close the bottom door and fill upper fuel chamber with logs 8 Lock all doors completely 9 Set the draft bar to position close normal heating mode 10 Boiler start without exhaust gas fan is installed 11 OFF 25 kW 07 16 25 0 C λ ON 07 16 25 0 C λ start menu boiler starts with heating mode The control LED is green OFF 25 kW 25 0 C 60s ...

Page 38: ...ning time of the fan only when installed start boiler 0 turn off exhaust gas fan only when installed select the values that are going to be displayed ON 07 16 25 0 C λ Heating mode begins The boiler is in heating up mode as long as the temperature is lower than the pre set boiler shut down temperature plus additional 20 C Note If the temperature does not cross this mark in between 30 minutes the bo...

Page 39: ...el cancel and return select the values that are going to be displayed OFF 25 kW 07 16 25 0 C λ Boiler off The control panel automatically switches to the start menu 79 C 07 16 103 7 C λ Escape heating mode When the boiler temperature falls below the set turn off temperature plus approx 20 C the control unit starts escaping the heating mode The control LED does not shine end 90 C λ END 07 16 77 7 C λ...

Page 40: ... an optimal storing of split timber store stack of woods protected from rain split into logs before storing create dry ground for storing and keep of the ground to ensure air circulation e g pile on long timbers etc store in wind exposed places if possible e g at the edge of the forest not inside it when stored closed to buildings ensure gap is left between buildings and logs try to store logs sou...

Page 41: ... Solarbayer GmbH 02 16 41 PRODUCT INFORMATION Wood log boiler HVS Maintenance Maintenance ...

Page 42: ...ith 2 hinges and the closing In case of leakages the door can be adjusted at the hinge side The door hinge can be adjusted by turning the hinge screw Therefore you have to loosen the screw nuts a little Afterwards tighten them again The threads of the hinge and the closing have to be greased from time to time sealing hinge boiler door hinge door handle brass disk ...

Page 43: ...nd bottom boiler doors have to be closed tightly When removing the top plate at the side of the hinges the screw nuts that are rested against the galvanized support have to be loosened At the side of the closing you have to remove the two screws that are next to the door closing Afterwards remove the casing of the forced draft fan Unscrew all self cutting screws at the backside of the boiler casin...

Page 44: ...en the boiler is refueled incautiously Cracks are no reason for a replacement of the nozzle The conical form enables an easy exchange of the nozzles If the nozzle is damaged it is necessary to replace it Afterwards you put the new nozzle into the opening Please check if the nozzle fits in tight If it does not fit in tight the opening has to be adjusted NOT the nozzle After the new nozzle is put in...

Page 45: ...cks are placed on both the left and the right side of the fuel chamber Protection bricks In order to improve the performance the HVS 16 LC has 3 protection bricks both on the left and right side of the inner walls of the combustion chamber The protection bricks are wear parts and have to be replaced when necessary ...

Page 46: ... approx 20 mm Steel tub replaceable A deformation or an erosive burning of the steel tub do not affect the furnace capacity and are not a defect This is a normal process HVS 16 LC HVS 25 E and HVS 25 LC 5 fireclay bricks HVS 40 E HVS 40 LC 8 fireclay bricks HVS 60 E HVS 60 LC 9 fireclay bricks HVS 100 E HVS 100 LC 13 fireclay bricks Catalyzer bricks only HVS 25 E and HVS 25 LC Both catalyzer brick...

Page 47: ...h heat impact and possible dama ges our wood log boilers are equipped with re fractory plates that are placed underneath the combustion chamber HVS 25 HVS 40 HVS 16 HVS 60 HVS 100 Position of the fireclay plates on the boiler bottom Fireclay bricks plates and the steel tub are wear parts and need to be replaced when necessary Only use original spare parts ...

Page 48: ...d The secondary air ducts lead combustion air towards the nozzle s lateral boreholes The primary air duct leads the air over the ducts into the fuel chamber primary air duct The primary air ducts of the HVS 16 HVS 25 and HVS 40 are placed on the side 2 on each side left and right The primary air steadily pours into the fuel chamber ober the air ducts primary air duct The primary air ducts of the H...

Page 49: ...VS E Forced draft fan The forced draft fan is mounted on the fan carrier sheet The boilers HVS 16 25 and 40 have one forced draft fan and the HVS 60 and 100 have two fans The forced draft fan consists of 4 components forced draft fan body motor capacitor fan wheel Note A clean and dust free environment is the basis for a reliable ope ration of the fan Dirt on the wings causes loud operation and le...

Page 50: ... is as close to the boiler body as possible when installing it again Push the shaft as far as it goes to the boiler body locking screws servo motor forced draft fan The automatic adjustment of the air supply is carried out electronically With the aid of the servo motor the lambda sensor measures the air supply via the air blind The position of the air blind is found automatically by the servo moto...

Page 51: ...VS LC boiler has an integrated lambda sensor in the flue outlet The connection is made by the connection box at the boiler s backside Lambda sensor connection box 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 ...

Page 52: ... removing the front top plate you have to unscrew the 2 self cutting screws at the front Afterwards remove the caps which are located in the corners of the front plate with a slotted screwdriver Underneath the caps are self cutting screws which only should be loosened Pull the front plate approx 2 cm to the front and then tilt it carefully to the front sensor characteristics Disconnect mains suppl...

Page 53: ...he forced draft fan is going to be deactivated the boiler circuit pump Laddomat is activated the boiler shuts off OFF and a starting of the boiler is impossible Mode of operation for starting the boiler again The safety temperature limiter can only be unlocked manually after the boiler temperature falls below the set boiler maximum temperature Remove the black safety cap of the STB and press the g...

Page 54: ... HVS 16 40 6 turbulators HVS 60 16 turbulators HVS 100 24 turbulators Exhaust gas turbulators The exhaust gas turbulators can be inserted into the exhaust gas heat exchangers like demonstrated in the picture When heating with very resinous wood and or with scrap wood the turbulators should not be installed ...

Page 55: ...walls of the fuel chamber You do not have to remove this tar layer it does not affect the boiler performance Never try to remove this tar layer mechanically e g by scarping with a putty knife etc because this might cause a damage at the boiler walls If there is a large amount of ash in the fuel chamber that cannot slide through the nozzle this as has to be removed new fuel chamber fuel chamber aft...

Page 56: ...er of the heat exchangers flat wrench n 13 Clean the heat exchangers with the round scraper In order to clean the heat exchanger pipes the turbulators have to be removed Put the turbulators back in place after cleaning A weekly cleaning interval is necessary when operating the boiler with turbulators Depending on the degree of dirt the cleaning interval might be extended The boiler has to be cooled...

Page 57: ... air ducts Cleaning the primary and secondary air ducts The aeration is one of the most important premises for a perfect combustion The primary and secondary air ducts should be cleaned at least once a season By dismantling the fan casing and the fan s assembly group the way to the air ducts is cleared The air ducts have to be cleaned with a vacuum cleaner Afterwards the air permeability has to be...

Page 58: ...here area any signs of damage wearing Nozzle make sure all ducts are permeable check for damages signs of wearing Flue gas heat exchanger flue gas turbulators clean Start up flap check if start up flap is closing tightly remove deposits on the sealing face Lambda sensor check probe in the flue gas pipe for dirt clean with soft dry cloth sensor is heated during boiler operation could be hot Risk of...

Page 59: ...lations check operability the thermal discharge safety valve opens automatically in case of overheating and cools the boiler over the safety heat exchanger with tap water the manometer shows the recent overpressure of the system the pressure relief valve opens when necessay and thus limits the overpressure to a max of 3 bar Sealings sensors fireclay and flame swept parts are wear parts We recommen...

Page 60: ...mined value at the boiler corresponds to the average value of the exhaust gas Thus it is possible that the temperature during the measurement in the core stream of the exhaust gas might be higher The test record displays the heating phase Pay attention to the fact the a firebed has been created over a period of 1 5 hrs before the heating phase The exhaust gas measurement by the chimney sweeper has ...

Page 61: ...ealing The damper does not open The damper is covered with tar The moisture content of the fuel used is too high wrong log length Adjust the boiler exhaust gas and switch off temperature to the Solarbayer settings Adjust log length Smoke comes into the boiler room after opening the damper and the fuel chamber door Low chimney draft The chimney has to match the technical requirements chapter Technic...

Page 62: ...ck siwtched mode power supply and control board AK 4000 SL check control panel SB4 0 D and connection cable system test OFF 25 kW 11 00 69 9 C Aut system test 271s routine check pump protection In order to maintain the operability of the electrical components over a longer period of idleness the boiler initializes a service check each Sunday at 11 00 am This process which only takes a couple of mi...

Page 63: ... T2 PT1000 4 1 x SB4 0S T2 PT interruption in the exhaust gas sensor circuit affected parts AK 4000 SL AK 4000 S connection box temperature sensor exhaust gas sensor check contacts and sensor resistance SB4 0S T2 PT1000 4 1 x SB4 0S T2 PT short circuit in the exhaust gas sensor circuit affected parts AK 4000 SL AK 4000 S connection box temperature sensor exhaust gas sensor check contacts and senso...

Page 64: ...rts AK 4000 L connection box lambda sensor lambda sensor check contacts and connection cable between lambda sensor and lambda control board AK 4000 L SB4 0L Heating Error λ λ 4 1 SB4 0L Heating x short circuit in the lambda sensor circuit affected parts AK 4000 L connection box lambda sensor lambda sensor check contacts and connection cable between lambda sensor and lambda control board AK 4000 L ...

Page 65: ...d affected parts safety temperature limiter STB fuse F1A when boiler is overheated STB unlock see chapter Maintenance Safety temperature limiter STB when fuse is interrupted check forced draft fan and exhaust gas fan including connection cables short circuit replace fuse F1A control board AK 4000 SL Error messages only HVS LC Error message only HVS E error only with HVS E error identificationg men...

Page 66: ...LC HVS 40E HVS 40LC HVS 60E HVS 60LC HVS 100E HVS 100LC Manufacturer SOLARBAYER GmbH 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 66 Solarbayer GmbH 02 16 PRODUCT INFORMATION Wood log boiler HVS Declaration of confirmity Kraus Martin CEO Solarbayer GmbH ...

Page 67: ...Control are designed solely for the use of timber based biomass fuels 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: ...n each case is the current version on our homepage www solarbayer de IStorage systems IFresh water systems IWood log boiler ISolar systems IHeat pumps Solarbayer Sale Installation Maintenance Duurzame Energie Technieken van der Zwaag Rengerslaan 25 9615AJ Kolham The Netherlands Distirbution address Wolweg 40 Foxhol www duurzame energie technieken nl info duurzame energie technieken nl ...

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