Solarbayer 15 Release Note

Solarbayer-Gasifying Log Burner 1
PRODUKTINFORMATION
PRODUKTINFORMATION
Technical Hand Book
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2Solarbayer-Gasifying Log Burner

Solarbayer-Gasifying Log Burner 3
1Control
Simple controller for efficient burn
cycle
2Large Fuel Chamber Door
3Blower Motor
A variable speed motor supplies
the air needed for the gasification
process in the burner.
4Bottom Door
Easy access to bottom of the
burner for cleaning
5Fuel Chamber
For logs sizes from 50cm up to
100cm (depending on model)
6Primary Air Channel
Due to the air channel at the back,
pre heated air is added to achieve
clean combustion.
7Ceramic Jet with secondary air
channel
Brings about the right air to gas
mix, which creates the best
possible flame
8Combustion Chamber
Made of high temperature
resistant fireclay, to com-
plete gasification process
which results in minimal
amount of ashes
9Ash Chamber
10 Exhaust Heat Exchanger
For best energy transfer to
the heating system
11 Flue Vent
to be used when lighting up
the burner (Draft Regulation)
12 Safety Heat Exchanger
will cool down burner in case
of overheating
13 Flow
14 Return
15 Chimney Connection
Upper Fire Box Gasification at the jet in the
Lower Chamber
15
1
2
13
3
4
5
12
11
10
14
7
8
6
9
Inside the burner
7
1

4Solarbayer-Gasifying Log Burner
Contents
1 Sizing your Boiler 6
2 The SOLARBAYER - Gasifying Log Burner
2.1 Description 7
2.2 Construction 7
2.3 Technical Details 8
2.4 Measurements 9
2.5 Boiler Schematics 9
3 Safety Regulations
3.1 Mounting and Setup 10
3.2 Fire Safety 10
3.3 Safety Instruction for use and maintenance 11
4 Additional Equipment
4.1 Safety Heat Exchanger 12
4.2 Laddomat, Shunt Valve with Pump 14
4.3 Exhaust Fan 15
5 Main Parts
5.1 Boiler Inner Body 17
5.2 Covers 18
5.3 Door Fuel Chamber 19
5.4 Fan 21
5.5 Secondary Air Adjustment 22
5.6 Jet and Fire Bricks 23
5.7 Layout of Fire Bricks 23
5.8 Primary and Secondary Air Flow 23
5.9 Burner Control Unit 24
6 Menu Functions
6.1 How to use the Controller 27
6.2 Flow Diagram of the Controller 28
6.3 Preset of the SOLARBAYER-Abgastronic Controller 29
6.3.1 Adjusting the Boiler Temperature 30
6.3.2 Adjusting the Switch Off Temperature 31
6.3.3 Setting the Clock Display 32
6.4 Settings for the operation of SOLARBAYER-Abgastronic 33
6.4.1 Adjusting the Exhaust Temperature 34
6.4.2 Adjusting the Minimal Fan Speed 35
6.4.3 Selecting the Burner Type 36

Solarbayer-Gasifying Log Burner 5
7 SOLARBAYER-Gasifying Log Burner Control
7.1 Factory Settings 37
8 Using the SOLARBAYER-Log Burner
8.1 Start the burner 38
8.2 Refuelling with logs 41
8.3 Heat Value Chart / How to store logs 43
9 Cleaning and measuring of the exhaust gases
9.1 How to clean the burner 44
9.2 How to measure the exhaust gases 47
9.3 Burner- and exhaust gas temperatures at the start 48
10 Maintenance and repair of the burner 49
11 Trouble Shooting 50
12 Connection Diagrams
12.1 Typical schematics without oil burner 52
12.2 Typical schematics with oil burner 54
13 Appendix
13.1 Software 56
13.2 Electrical diagram 56
Warranty 58
Statement of Conformity 59

6Solarbayer-Gasifying Log Burner
1. Sizing the Boiler
Please note that the boiler output specified can only be achieved under full load. To heat up the boiler will take approx. 30 min until
full load is reached. The boiler output is kept for a period of approx. 2 hours, after that the burn-out phase follows with reduced out-
put for a period of approx. 1.5 hours. The residual glowing fire in the combustion chamber coasts the temperature for about one more
hour, after that the fuel is completely used up. The duration of the burn cycle - approx. 4 hours.
The boiler will be heated up in the morning and in the evening, thus a burning time of approx. 8 hours is achieved.
Warning: This is imperative for the rating of the boiler to avoid that the boiler output is rated too weak.
Rough estimate of boiler size by means of living space:
e.g. building with 150 m² living space: Boiler size required Solarbayer® 25 kW
Old building 0.12 kilowatt per m²
New building 0.08 kilowatt per m²
Low energy house 0.05 kilowatt per m²
Calculation of the daily output of the building
e.g. living space 150 m², e.g. new building => 0.08 kW/h per m²
150 m² x 0.08 kW/h
= 12 kW/h
The hourly output for the new building with an outdoor temperature of -16°C results in 12 kW/h
Daily requirements 24 hr x 12 kW/h
= 288 kW
The heat output required at -16°C outdoor temperature is 288 kW per day.
Calculation of the boiler output: e.g. Solarbayer® 25:
Output 25 kW x 4 hours (full load)
= 100 kW
The burning-down heat output of a 25 kW solid fuel boiler at approx. 4 hrs full load results in 100 kW.
Daily requirements of the new building 288 kW : 100 kW (burning-down heat output)
= 2.88 boiler fillings to achieve the necessary heat output of the building.
With this building you must fill the boiler around 3 times per day with an outdoor temperature of -16°C. Given an average annual tem-
perature of +7°C you can manage with about 2 fillings.
This calculation is for general information only and does not replace professional design!
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 7
2. General Information SOLARBAYER boiler
2.1 Technical Description
Thermal boilers SOLARBAYER ® 15, 25, 40, 50, 80, 100 are designed for the combustion of
dry wood, starting from sawdust up to logs, length corresponding to the size of the fuel cham-
ber, max. length 14 cm. Sawdust, chippings and wood splinters need to be burnt along with
wood logs.
The interior of the boiler consists of a fuel chamber where the fuel is dried and gasified. The
wood gas developed is led through a fire resistant jet into the combustion chamber where it
starts burning by means the addition of secondary air. Waste gases are intensively cooled
down in the heat exchanger. The unburned waste products shall be swept out of the combu-
stion chamber. For heating up the boiler is equipped with a damper which is operated by a
connecting rod at the front of the boiler.
For smooth operation the boiler is provided with the control unit AK 2000 located in the upper
part of the boiler.
2.2 Construction
The boilers are made of 4 and 6 mm thick steel panels which are welded together. The inner
steel parts which are in direct contact with the waste gases are 6 mm thick. The heat exchan-
ger consists of welded steel tubes, diameter 57 x 5 mm. The heat exchangers are single-row (boi-
ler types SOLARBAYER® 15, 25, 40) or two-row (boiler types SOLARBAYER® 50, 80). With
boiler SOLARBAYER® 100 a three-row exchanger is used.
Standard SOLARBAYER® boilers are provided with a safety heat exchanger to prevent overhea-
ting. The safety heat exchanger is made of a copper tube, diameter 18 mm and permanently in-
stalled.
Manually-welded boilers are welded together in a CO2 protective atmosphere using MIG-tech-
nology. The boilers welded at robot production places are welded together by using MAG-tech-
nology.
The boiler covers are made of powder-coated steel sheet. The lower combustion chamber is
lined with standard fireclay bricks P4 (40 mm thick). The floor of the fuel chamber is filled with fi-
reproof mortar, named 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. As insulation of the heat exchanger cover glass fibre with round cross section (8 mm) is
used.
Thermal insulation of the boiler consists of insulation material NOBASIL (20 and 40 mm thick).
Waste gases are removed through an exhaust air duct of steel, diameter 160 mm (SOLAR-
BAYER ® 15, 25) and diameter 196 mm (SOLARBAYER ® 40, 50, 80, 100).

8Solarbayer-Gasifying Log Burner
2.3 Technical Details
Calculation of Buffer Volume:
Recommended
Per kW nominal boiler output at least 55 litres of buffer water are needed.
A maximum of 100 litres per kW nominal boiler output must not be exceeded
Buffer storage tanks must be installed with each wood-fired boiler system.
Solarbayer Log Burner 14,9 25 40 50 80
Nominal Boiler Output in kW kW 3 bis 21 5 bis 31 8 bis 42 15 bis 72 25 bis 92
Boiler output with output regulation 85 – 91 %
Height A mm 1120 1120 1370 1420 1420
Height Supply Line B mm 1045 1045 1310 1400 1400
Height Return Line C mm 115 115 125 215 215
Height Drain Valve D mm 60 60 70 135 135
Height exhaust outlet centre E mm 890 890 1110 1170 1170
Width incl. Gate valve F mm 645 645 645 785 785
Width G mm 590 590 590 760 760
Depth H mm 1070 1070 1070 1260 1650
Depth Supply line I mm 240 240 240 520 520
Exhaust Outlet Diameter J mm 160 160 200 200 200
Distance to boiler edge K mm 305 305 305 880 1210
Distance mm 402 402 402 70 70
Recommended Chimney Diameter mm 140 150 180 180 200
Max. Operating pressure bar 3 3 3 3 3
Noise level dB 45,5 45,5 47,7 51,4 54,2
Waste Gas mass flow at 13% CO2 kg/s 0,019 0,023 0,029 0,035 0,035
Waste Gas Temperature °C 190-260 190-260 190-260 190-260 190-260
Required Chimney Draft Pa 15-20 15-20 15-21 15-23 15-23
Boiler Connection Zoll IG 2 “ IG 2 “ IG 2 “ IG 2 “ IG 2 “
Boiler water volume Liter 75 75 93 180 205
Combustion Chamber Volume Liter 120 120 185 315 483
Chamber Door access mm 435 / 255 435 / 255 435 / 255 575 / 318 575 / 318
Max. Log length mm 550 550 550 750 1100
Fuel Volume beech wood approx. 20% res.moisture kg 47 47 72 122 186
Energy Content Beech wood kWh 190 190 290 490 750
Burning time beech wood h 6,3 5,1 5,4 6,3 6,9
Heating of water from 50 -85 degrees C beech Liter 3270 3270 4990 8430 12900
Fuel Volume fir wood approx. 20% res. moisture kg 33 33 52 88 135
Energy content fir wood kWh 140 140 215 365 560
Burning time fir wood h 4,8 4,5 4,6 4,8 5,1
Heating of water from 50 -85 degrees C fir Liter 2400 2400 3700 6280 9630
Weight of Boiler kg 430 430 480 780 950
Approval EN 303-5,DIN 4702,EMV89/336,EMR98/37
STN070240/070245/920300, TGM/VA/HL7043/2 and CE tested EN303-5 EN303-5 EN303-5 EN303-5 EN303-5
Recommended min. buffer storage volume Liter 1000 1500 2200 3000 4400

Solarbayer-Gasifying Log Burner 9
2.4 Dimensions
Dimensions of the SOLARBAYER-Log Burner
1 Control
2 Upper Door
3 Draft Control Rod
4 Fuel Chamber
5 Primary Air Flow
6 Fan Plate
7Fan
8 Fan Cover
9 Fire Jet
10 Secondary Air Flow
11 Door Handle
12 Fire Clay Blocks
13 Bottom Door
14 Chimney Connection
15 Heat Exchanger Cover
16 Draft Control Lid
17 Upper Cove Rear
18 CH Flow
19 Thermal Safety Heat Exchange
20 Thermometer
21 Upper Cover Front
22 Tubes Heat Exchanger
23 Fireproof Cladding
24 Secondary Air Flow
25 Combustion Chamber
26 Direction of Flow of Smoke
27 CH Return
28 Drain
2.5 Boiler Cross-section
SOLARBAYER 25 SOLARBAYER 40
SOLARBAYER 50-80

10 Solarbayer-Gasifying Log Burner
3 Safety Regulations
3.1 Assembly and Installation
• The boiler can be only operated within a central heating system with a heat capacity corre-
sponding to the output of the boiler.
• When using forced circulation the central heating must be designed in such a way that the mi-
nimum heat consumption of 5 kW of the boiler output is guaranteed in case of power failure
(boiler and pump being switched off) (pipelines to the buffer storage tank should be installed
with automatic transition into gravitation flow). Non-compliance can result in overheating of
the boiler. This is prevented by the safety heat exchanger with drain valve (valve is not inclu-
ded in the scope of delivery for the boiler).
• The boiler must be connected to the chimney in a workmanlike manner and by the shortest
way. No other electrical devices must be connected to the chimney. The air duct must be in
accordance with standard STN 734201 and STN 734210.
• The drain valve of the safety heat exchanger shall be installed at the exchanger inlet to avoid
that the pressure within the system is increased in case of a leaking valve. The maximum per-
missible pressure is 3 bar.
• The boiler must be placed on a firm, load-bearing floor.
• The minimum temperature of the return line water at the boiler inlet must be 72°C.
• The room where the boiler is installed must be ventilated by means of a permanent opening
with a diameter of at least 250 cm. Openings for air supply and air exhaust shall be around the
same size.
• The boiler must be erected in a normal room in acc. with standard STN 33 0300.
• With regard to health and safety at work the regulations of the valid publications by the De-
partment for the Maintenance of Safety and Health at Work, No. 74/1996 of the compendium
of laws as amended hereafter shall be observed.
3.2 Safety - Fire protection
The boiler shall be installed in accordance with the applicable fire protection regulations, stan-
dards and STN 92 0300 (publication 84/1997 of the compendium of laws). With regard to in-
stallation specified safe distances from combustible and inflammable materials and objects have
to be observed. For thermal boilers with an output up to 50 kW the specified safe distance from
combustible materials of class B, C1 and C2 must be at least 200 mm and of class C3 at least
400 mm in accordance with standard. The safe distance is reduced to half if a non-combustible
thermal insulation board (asbestos board with a minimum thickness of 5 mm) is installed 25 mm
from protected combustible material. The board shall project at least 150 mm above the outline
of the boiler with smoke exhaust and above the upper surface of the consumer must be at least
300 mm free space. For your information we quote an extracts from standard STN 730823 for
combustible building materials.
Class A: non-combustible building materials (asbestos, concrete, mortar, brick, glass, fireclay,
etc.)
Class B: very hardly combustible materials (gypsum cardboard, etc.)
Class C1: hardly combustible materials (lignite boards, chip boards in acc. with STN 492615, etc.)
Class C2: moderately combustible materials (wood – oak, alder, larch, fir, wood chip boards, etc)
Class C3: easily combustible materials (wood – pine, beech, ash, poplar, wood fibre boards,
cork, foil sheets, polystyrene, polyethylene, bituminous cardboard, pulp, plywood, etc)
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).

Solarbayer-Gasifying Log Burner 11
Sample of size of floor cover
3.3 Safety regulations for operation & maintenance
The staff operating the boiler must observe the rules and regulations and standards in connec-
tion with operation, in particular standard STN 34 1010 and other principles:
1. During operation of the boiler, electrical equipment and cables of the boiler must not
be intervened with, for example :
• removal of covers of electrical systems such as boiler electronics, ventila-
tor, thermostat
• exchange of fuses
• repair of damaged cable insulation etc.
2. Maintenance or repair work that requires removal of covers of electrical parts of the
boiler must only be performed by the person entitled in accordance with publication
No. 74/1996 of the compendium of laws.
3. Prior to removal of the covers of the boiler or an electrical device connected to the
boiler it is necessary to switch off any mains supply to the boiler.
4. 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.

4
4.1 Boiler Body
Mounting of the Safety Valve STN20:
It is important, to fit the Thermal Safety Vale in such a way, that, under operation conditions, the
Safety Heat Exchange is under no pressure and is not connected to the pressurised part of the
heating system. The Thermal Safety Valve has to be connected to the pressurised mains water
line, without any means of shutting of the water supply ( Stopcocks, valves, etc.). The drain side
has to be run unobstructed into a gully or drain.
Note: The Thermal Safety Valve has to be fitted before the system is filled or put into operation.
Observe local guide lines.
Function of the Safety Vale :
The pressure independent valve opens when the flow temperature of aprox. 95 °C is reached.
By opening the valve, it will cause a constant drain of water which inhibits the temperature to rise
above 110 °C.
NOTE: The galvanised nipple of the safety heat exchanger is seal gainst the coper pipes with a
washer seal, if a water leak shall occur between the different fittings, tighten the galvanised nip-
ple or replace the washer seal.
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
Cooper Pipe sealing for the Thermal
Safety Vale
12 Solarbayer-Gasifying Log Burner

Solarbayer-Gasifying Log Burner 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.
Wasserzulauf
Überlauf
Ablaufsicherung
Thermische
Temperatur-
Fühler




Thermostatic Safety Valve
( Watts STN20 ¾“)
Sensor Pocket with
dual thermostat
integrated
Safety Heat Exchanger
Cold Mains in
Outlet into drain

4.2 Kesselkreispumpe
SOLARBAYER-Hinweis: Für den Betrieb des SOLARBAYER-Holzvergasers ist eine Rück-
laufanhebung zwingend vorgeschrieben, um eine lange Lebensdauer zu garantieren.
Diese soll eine Kesselrücklauftemperatur von 72 °C gewährleisten. SOLARBAYER empfiehlt
Laddomat 21.
Elektrischer Anschluss:
Der elektrische Anschluss der Kesselkreispumpe erfolgt an der Klemmleiste der Regelungspla-
tine (Anschlussbelegung siehe Schaltplan Kapitel 13.2).
Die maximale elektrische Leistungsaufnahme beträgt 200 W.
Arbeitsweise:
Die Pumpe wird beim Anstellen des SOLARBAYER-Holzvergasers sofort eingeschaltet, damit der
Kessel gleichmäßig hochgeheizt wird.
Die Pumpe ist ausgeschaltet, wenn der Kessel aus- bzw. abgestellt ist. Wenn jedoch die Kes-
seltemperatur die Solltemperatur (z.B. 85 °C) überschreitet, schaltet die Pumpe ein um eine
Überhitzung zu vermeiden.
Der Betriebsstand der Pumpe wird durch die LED-Diode auf dem Display angezeigt.
Achtung: Beim Betrieb des Kessels ohne thermische Rücklaufanhebung besteht die Gefahr
der Kondensbildung und somit zur Zerstörung der
Kesselwandung.
Für eine ordentliche Verbrennung ist eine Kessel-
temperatur zwischen 75 und 90 °C erforderlich.
Dies ist nur mit dem Laddomat zu erreichen.
Bei einer Störung/Fehlfunktion des Kesseltemperaturfühlers ist die Pumpe immer ein!
4.2 Shunt Valve with pump
To run the boiler efficiently and to guarantee a long service live,
it is important
to operate the burner with a shunt valve system that ensures a return temperature of 72 °C
to the burner. We recommend the Laddomat 21.
Electrical Connection:
Connect the pump of the shunt valve to the connection rail on the control panel
(see chapter 13.2 for layout ).
Maximum load 200 W.
Function of the shunt valve:
Once SOLARBAYER-Log burner is switched on, the pump is activated, to ensure the boiler is
evenly heated up.
When the boiler is switched off, the pump stops. In the event that the boiler temperature exceeds
the set temperature (i.e. 85 °C) the pump starts again to prevent over heating.
Operation status of the pump.
Note : To run the boiler without the shunt valve, will
result in build up of condensation, which will lead to
rapid corrosion of the boiler walls.
For a clean and efficient combustion a boiler tem-
perature between 75 and 90 °C is necessary. This
can only be achieved with a Laddomat valve.
In case of a malefunction or fault of the temperature sensor, the pump switches on !
Deckel
Kolben
Patrone
Feder
Rückschlag-
ventilscheibe
Halterung
Feder
Deckel
Laddomat 21
with temperature set at 72 °C
14 Solarbayer-Gasifying Log Burner

Solarbayer-Gasifying Log Burner 15
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-
ber during loading of fuel and thus no flue
gas escapes out of the fuel chamber during
loading.
The draught fan is not included in the standard equipment of the boiler. It
is available in sizes 160 mm and 200 mm as optional accessory.
The waste gas fan for direct attachment to the flue pipe is suitable for all boilers.
d
Exhaust Fan 90s
boiler temp.-- C
▲
+After pressing key “+” at module AK 2000 D the flue venti-
lator is put into operation for 90 s. After pressing the key
again further 90 s are added, maximum running time of the
ventilator is 300 s. During operation of the flue ventilator
fuel can be refilled.
Warning:
Do not install motor vertically!
Correctly Installed
(motor horizontal)

16 Solarbayer-Gasifying Log Burner
Note for correct sizing of expansion vessel:
Dimensioning of the expansion vessel (10% of heating water volume)
e.g. 2000 litre heating water = 200 litre expansion vessel.
Warning: The expansion vessels are factory-preset to 1.5 bar diaphragm pressure. It is necessary
that the vessels are adjusted to the height of your installation. Measure the installation height of your
house, from the basement to the topmost radiator. Example: installation height 7 metres + 2 met-
res extra = 9 metres.
9 metres correspond to 0.9 bar diaphragm pressure at the expansion vessel.
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.
Technical Data:
Electrical connection to boiler control unit.
Connecting box shall be fastened
with sheet metal screws to the boiler jacket
and connect the cable of the exhaust fan to
the exhaust fan terminal.
Technical Data Exhaust Fan
Max. Temperature (°C) 600
Motor Speed (1/min) 2780
Output (Watt) 48
Mains Supply (V/Hz) 230/50
Protection IP 20
Weight (kg) 13
Max. Temp. Motor (°C) 80
Overall length A 385 mm
Width 235 mm
Height with Motor C 247/280 mm
Exhaust Inlet/Outlet D 70 mm
Outlet/ Inlet Diameter 160/200 mm
If you have too much smoke through poor draw while refuelling the burner we recom-
mend that you obtain the exhaust fan.

5. Main Parts SOLARBAYER-Boilers
5.1 Boiler Body
The boiler body is factory-welded and provided with fireclay bricks (formed parts) in the combu-
stion chamber, a heat resistant nozzle and a heat resistant brick lining.
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.
In case of an irreparable defect the boiler body can be replaced by a new one.
Hinged Joint at Right Side of Boiler Body
Solarbayer-Gasifying Log Burner 17

18 Solarbayer-Gasifying Log Burner
5.2 Cover plates of Boiler body
The cover plates are the covering of the boiler body and made of powder-coated steel sheet and
treated with fired colour to protect the plates from corrosion. 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. Underneath all silver-painted steel sheet parts and underneath all cover pla-
tes of the upper and lower door the thermal insulation material NOBASIL is provided.
The upper front plate where the control unit is located needs to be dismantled most often. To dis-
mantle this plate, the two self-cutting screws at the front must be loosened first. Then you remove
the cover caps located at the corners of the upper front plate with a slot-head screw driver. Below
the cover caps are self-cutting screws which shall only be loosened. At first, you push the upper
front plate 10 cm to the front and then you tilt it carefully from the front to the back. Under this
plate the ventilator cables, the cable of the fuse and the thermometer are located.
Note:
Prior to removal of the boiler jacket or one of the electrical devices connected to the boiler, all
cables must be disconnected from the mains supply.
The side cover plates shall be dismantled as follows: At first, the upper front plate must be re-
moved as described above. Then the upper plate at the back needs to be dismantled. The upper
and lower boiler door must be tightly locked. To dismantle the cover plate on the hinged side the
nuts pressing on the galvanized shims shall be loosened. When dismantling the plate on the clo-
sure side the two screws located under the closure of the door shall be removed. There the ven-
tilator casing shall be removed. At the back side all self-cutting screws shall be removed and
then the two side cover plates can be dismantled.
The door cover plates shall be dismantled as follows: at first, the entire doors shall be dismant-
led in such a way that the pin can be pulled out of the hinge. The closure of the door shall be dis-
mantled. The doors shall be laid down in such a way that the interior side lies on the floor. The
cover plate of the long sides shall be pulled out and laid down. The cover plate is only put on to
the doors.

Solarbayer-Gasifying Log Burner 19
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.
All doors are provided with a fire-resistant fill.
Replacement of thermal insulation
The most frequent repair work at the doors is the replacement of the insulation as the doors are
quickly covered with smoke. Replacement or turning around of the insulation is performed as fol-
lows:
1. Open the door completely
2. Find the joint of the insulation at hinged side of the door using a screw driver
3. Remove the hardened insulation gradually using the screw driver
4. Match the ends of the old or new sealing cord and press them in the groove between
the hinged joints starting in the middle. If there are leakages put some heat-resistant
silicone into the groove at the corners.
5. Distribute the remainder of the insulation evenly to the sides and press it together in
the middle.
6. Always start in the middle in direction of the corners when inserting the door insulation.
Take care, that the insulation is not turned round and that the corners are filled well.
As the inside of the door is made of heat resistant concrete care must be taken that the upper
door is not used to press the fuel into the boiler because this leads to damage of the lining.
For repair of damaged the doors must be removed. The damaged lining shall be hollowed out.
The thermal insulation material NOBASIL which is located underneath shall not be removed.
The lining shall be replaced , using heat resisting cement. Mixing of the lining shall be performed
in accordance with the directions for use.
Note: The refractory concrete mixture in which the setting process already started cannot be di-
luted with water any longer. The mixture shall be prepared not until everything else is prepared.
The door must only be used 24 hours later.

20 Solarbayer-Gasifying Log Burner
Adjustment of Doors
The boiler doors are fastened at three points: at two turning pins and the closure. If the doors are
not tight enough they can be adjusted at the hinged side. If the nuts are loosened and retighte-
ned afterwards the hinge screw can be turned and the door pushed into the direction wanted.
Note: For adjustment of the door at the hinged side the door must be closed. If the nuts at this
side were loose the door would “hang”.
pin
Split Pint
Bracket
Nut with welded
Shim
Hinge holel
Threaded hinge
Adj Nut
Washer
Parts of the Closing Handle
Parts of the Door Hinge
The threads of hinge and handle must be greased on occassion.
Head
Threaded
Handle