Solarbayer HVS E ECONOMIC User manual

© Solarbayer GmbH [11.13] 1
PRODUCT INFORMATION
Instrucon manual
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SOLARBAYER WOOD LOG BOILER
boiler sizes
from 16 kW to 100 kW
HVS E ECONOMIC
HVS LC LAMBDA CONTROL

2© Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
General informaon
Codes of pracce, regulaons, norms, safety instrucons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety regulaons for fire protecon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety regulaons for operaon and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Seconal model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Calculaon example for dimensioning the wood log boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Technical data.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installaon
Tank sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Boiler charging unit (mandatory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Thermal discharge safety valve (mandatory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust gas fan (oponal accessory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flue pipe and barometric damper (oponal accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical connecon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electric circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inial operaon of the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operaon
Descripon of control panel and display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Descripon of icons and basic parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Basic menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
How to set the parameters (example: me). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Important parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Return to factory sengs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Expert level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Heang up the boiler – control panel funcon (without exhaust gas fan). . . . . . . . . . . . . . . . . . . . . . . . . . 32
Heang up the boiler – control panel funcon (with exhaust gas fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Heang up the boiler – ignite the fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Turn-off the boiler (automacally). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Turn-off the boiler (manually) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Type of fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Contents

© Solarbayer GmbH [11.13] 3
PRODUCT INFORMATION Wood log boiler HVS
Maintenance
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Protecon bricks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Ceramic nozzle/nozzle brick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Combuson chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Primary and secondary air duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adjusng the secondary air (only for HVS E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Forced dra fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Lambda servo motor and air blind (only with HVS LC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lambda sensor (only with HVS LC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Safety temperature limiter - STB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Exhaust gas turbulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cleaning the fuel chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cleaning the primary and secondary air ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Exhaust gas measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Maintenance instrucon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Trouble shoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Error message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Maintenance report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Declaraon of conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
General information
Maintenance Operation Installation

4© Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
Principle of operation
The Solarbayer wood log boiler HVS is a state-of-the-art device for heang with solid wood.
It is easy to handle aer the installaon has been carried out by a professional installer.
All naonal and local regulaons and the requirements stated in this manual (see page 6) have to be
fulfilled both during installaon and operaon by the installer and the operator of the system.
The Solarbayer HVS LC wood log boiler is characterized by a modern and modular control concept
which ensures more performance and a low, environmentally friendly pollutant emission due to the
serially integrated lambda sensor which permanently observes the exhaust gas value.
With the help of the integrated boiler and exhaust gas logic the intelligent control recognizes the
requirements of energy. Due to the modulang air supply the boiler is able to react to a possible
power reserve and can therefore ensure an almost perfect exploitaon of combusbles. This means
the highest possible comfort for you and a steady and even combuson for your wood.
You can only achieve an opmal efficiency factor with a perfectly aligned system. Therefore, we
generally recommend our high quality straficaon tanks SPS with integrated, patented, straficaon
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 heang system when needed.
This keeps your fuel consumpon as low as possible and even preserves the environment.
The HVS wood log boiler is easy to handle, it can be refuelled and cleaned without the slightest
effort. Just fill in logs, ignite them and everything else is working just by itself. The large fuel
chamber provides a long combuson period. The integrated fan guarantees an unproblemac
start. The fuel chamber door and its bolt do not give way for smoke emission. Moreover, the
combuson is stabilized throughout the whole combuson period by the fan and enables an
unproblemac operaon.
For planning means please refer to the follwoing pages, especially the calculaon 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 1st 2013)

© Solarbayer GmbH [11.13] 5
PRODUCT INFORMATION Wood log boiler HVS
General information
General Information

6© Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
General information
Codes of pracce, regulaons, norms, safety regulaons
Please read the manual carefully to prevent damages due to improper installation. The installation has to be
carried out by a specialized company in accordance with the „generally accepted codes of practice“ as well as with
the valid regulations and norms. Non-professional installation as well as other than the intended use will lead to
the expiration of warranty.
All national and local regulations concerning the installation, operation and maintenance have to be regarded.
The following engineering rules have to be particularly regarded:
DIN 1988 Codes of practice for drinking water systems
It has to be checked before the installaon if the drinking water installaon, especially the connecon to the public
drinking water network, fulfill the requirements of DIN 1988 and if the regulated maintenance (as described in Part 8) had
been carried out. The proper funcon of security-relevant parts (e.g. pressure relief valve) has to be checked in any case.
DIN 4751 Safety requirements for heating installations
DIN 4753 Water heaters and water heating installations for drinking water and service water;
requirements, marking, equipment and testing
DIN 4807 Expansion vessels
DIN EN 12828 Heating systems in buildings - Design for water-based heating systems
DIN 18380 Systems for heating and central water heating
DIN 18381 Gas, water and sewage plumbing works inside of buildings
VDI Richtlinie 2035 Prevention of damage in water heating installations
DIN 18382 Electric Cable and Wiring Systems Inside Buildings
VDE 0100 Erection of power installations
VDE 0105 Operation of electrical installations
VDE 0190 Potential equalizing of electrical installations
Fireplace regulations in the relevant version
- The boiler has to be installed in a closed, suitable boiler room
- The boiler has to placed on solid, sustainable ground
- The boiler room has to be aired by a permanent opening with a diameter of at least 250 cm². The opening for the air supply has to
almost the same size as the one for the air exhaust.
- The intended application of the wood log boiler involves the exclusive application for hot water heating systems in accordance
with DIN EN 12828.
- The wood log boilers have to be equipped with a type-tested safety valve. The connection between boiler and safety valve has to
be non-lockable.
- The thermal discharge safety valves applied have to be tested and registered in accordance with DIN 3440.
- Safety and monitoring devices are not allowed to be removed, bridged or shut off in any other way.
- The opening temperature of the boiler charging unit should be set at 72°C to prevent condensation and corrosion.
- Installation dimensions and wall distances have to be regarded, see chapter: [General Informaon] Technical data.
- The central heating has to be designed in such a way that a minimum of power drain is guaranteed in case of a breakdown of the
boiler circuit pump (the pipe routing to the buffer tank has to designed according to the principles of gravity).
- The boiler has to be connected to the chimney in the correct and shortest way. Carefully seal the exhaust gas pipes.
- No further heating systems have to be connected to the flue except oil/gas boilers that are equipped with an automatic locking
device (exhaust gas thermostat).

© Solarbayer GmbH [11.13] 7
PRODUCT INFORMATION Wood log boiler HVS
General information
Safety regulaons for fire protecon
The boiler has to be installed in accordance with the valid fire
protection regulations and norms. The determined clearance distances
from inflammable material have to be regarded when installing the
boiler. For wood log boilers up to 50 kW a safety distance from material
labeled with level B, C1 and C2 of at least 200 mm and labeled with
level C3 a distance of at least 400 mm has to be maintained. The safety
distance could be reduced to half the distance if an incombustible plate
with a thickness of at least 5 mm is applied 25mm away from the
inflammable object/material. The plate has to overlap the boiler’s
outline (full length: including the exhaust stack) at least 150 mm. Above
the consumer’s upper area there has to be a clearance distance of at
least 300 mm.
Level A: incombustible building material (concrete, mortar, clay bricks,
glas, fireclay, etc.)
Level B: very difficult to ignite (drywall, etc.)
Level C1: difficult to ignite (lignate plates, chipboards, etc.)
Level C2: normal combustibility (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 regulaons for operaon and maintenance
1. No interventions at the electrical devices and electric conducts are allowed during the operation of the boiler,
f. e.:
- removing the casing of the electric device (electronics assembly, forced draft fan ...)
- exchanging fuses
- repairing defective boiler insulation, etc.
2. Maintenance and repair are only to be carried out by authorized qualified persons.
3. Before removing the boiler’s casing or any other electrical appliance connected to the boiler it is necessary to
disconnect the power supply of all devices.
4. If defects are detected at the electric installation or damages at the boiler installatio it is necessary to observe
the following rules:
- do NOT touch any part of the boiler,
- IMMEDIATELY disconnect the boiler’s power supply; inform an authorized service technician who solves the
problem
Example for placing the protecon
plate on inflammable floor
(dimensions in mm)

8© Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
General information
Complete combuson of the
wood gases in the lower
combuson chamber
Seconal model
1Control unit
graphic display with permanent
presentation of the system’s operating
status
2Fuel chamber door
large-size fuel chamber door
3Forced draught fan
the quantity of air, necessary for a
perfect combustion, is supplied by the
infinitely variable forced draught fan
equipped as standard
4Bottom door
cleaning door for the removal of ash
5Fuel chamber
large fuel chamber (0,5m up to 1m logs,
depending on boiler size)
5a Conical fuel chamber walls*
for a steady inlet of embers to the
ceramic nozzle
6Primary air duct
pre-heated primary air is lead into the
fuel chamber by the rear air duct
7Ceramic nozzle with secondary air duct
creates the perfect gas mixture and
guarantees a clean downward wood gas
flame
8Slide-in combustion chamber
with high temperature resistant fireclay
bricks for a complete burnout of the
wood gases
9Exhaust gas heat exchanger with
turbulators
for best possible hand-over of exhaust
gas heat to the heating water
10 Exhaust gas damper with draft bar
prevents outlet of flue gas when
refueling the boiler
11 Safety heat exchanger
for cooling down in case of
overheating
12 Boiler flow line
2
3
4
6
8
5
9
12
11
10
1
7
A
5a
1
ALambda servo motor (only with HVS LC)
The secondary air is adjusted by the lambda sensor via a
servo motor, depending on the emission values.
With the boiler series HVS E (without lambda control) the
secondary is adjusted via regulating screws.
Graphic display with pre-defined
Solarbayer hydraulic scheme.
seconal model shows HVS LC
*only with HVS 16, HVS 25 and HVS 40

© Solarbayer GmbH [11.13] 9
PRODUCT INFORMATION Wood log boiler HVS
Calculaon example for dimensioning the wood log boiler
Please note that with solid fuel boilers the specified output is guaranteed under full load only. You heat up
the boiler and it will take about 30 minutes until the boiler will operate with its maximum output. The
stated output will last for approximately 2,5 hrs. Now the burn-off period begins for about an hour with
decreased performance
. The firebed remaining in the combustion chamber will post-heat for about an
hour. Afterwards the combustible is completely used up.
For an easier calculaon we presume a burning period of approximately 4 hrs (at nominal output). .
Note:
This is imperative for the rating of the boiler to avoid that the boiler output is rated too weak
Rough estimation of the boiler size by means of living space:
Example: building (new building) with 150 m² living area, desired boiler size HVS 25 kW
Required heat output per m² living area:
old building 0,12 Kilowa per m²
new building 0,08 Kilowa per m²
low energy building 0,05 Kilowa per m²
Required heat output of the building (at an outside temperature of –16°C)
e. g. living area 150 m², new building => 0,08 kW per m²
150 m² x 0,08 kW per m² = 12 kW
The heat requirement of the new building with an outside temperature of –16°C is thus 12 kW.
Calculaon of the building’s daily heat requirement (with an outside temperature of –16°C):
24 Std. x 12 kW = 288 kWh
The necessary heat energy with an outside temperature of –16°C is 288 kWh/day.
Calculaon of the required heat energy per filling (example HVS 25 kW):
25 kW x 4 hrs. (equivalent full load burning period) = 100 kWh
The burn-off energy of the 25 kW boiler in 4 hrs full load is thus approx. 100 kWh.
Esmaon of the daily fillings (with an outside temperature of –16°C):
288 kWh : 100 kWh (burn-of energy) ≈ 3 boiler fillings
With an outside temperature of – 16°C the boiler has to filled approx. 3x in order to guarantee the
required energy demand of the building. With milder temperatures you have less fillings.
This calculation is for general information only and does not replace professional planning!
* If the boiler is dimensioned too small you will achieve a boiler temperature of 70 – 80 °C but the desired heating flow line
temperature is not achieved.
[e.g. building size 220 m² (old building): a desired nominal boiler output of 25 kW would be miscalculated.
Correct would be a nominal boiler output of 40-60 kW].
General information

10 © Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
General information
fuel chamber/fuel consumption
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
admissible fuel untreated, split wood log with residual moisture of <20%
max. wood log length mm 350 550 550 700 1000
fuel chamber depth mm 370 560 560 750 1085
fuel chamber height mm 490 490 750 730 730
fuel chamber width mm 440 440 440 575 575
dimension of the filling hole w/h mm 435/255 435/255 435/255 575/318 575/318
fuel chamber capacity, volume liter approx. Liter 80 116 180 310 455
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
chimney/draft requirements/
exhaust gas values
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 15-25 15-25 15-30 15-30
effective minimum chimney height meter approx. 7 Meter
exhaust gas mass flow (Bezug 13% CO2) kg/s 0,019 0,023 0,029 0,035 0,035
modulating exhaust gas temperature °C approx. 150-260
barometric damper recommended
technical facts
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
nominal output in kW kW 16 25 40 60 100
boiler output with kW 12-18 5 - 31 8 - 41 15 - 72 25 - 100
efficiency factor % 86 – 92 %
water capacity Liter 60 75 93 180 215
max. operating pressure bar 3 3 3 3 3
pressure loss at nominal load (Δt 10 K) mbar 9,35 9,75 10,48 12,77 11,5
pressure loss at nominal load (Δt 20 K) mbar 1,00 1,05 2,55 3,19 2,82
permissible pressure range safety valve bar min. 1 to max. 4
water inlet temperature safety valve °C 4 - 15°C
opening temperature safety valve °C at 95°C
noise level dB 45,0 45,5 47,7 51,4 54,2
Technical data
Hydraulic
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. buffer tank volume1Liter 1000 1500 2200 3300 5500
manufacturer’s recommendation1Liter 1500 2000 3000 5000 6000
min. tube dimension (CU-/steel presision tube)² mm Ø 28 Ø 28 Ø 35 Ø 42 Ø 54
min. tube dimension (steel tube)² – DN25/1” DN25/1” DN32/1¼” DN40/1½” DN50/2”
recommended boiler return line temperature °C 70°C
1
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 [11.13] 11
PRODUCT INFORMATION Wood log boiler HVS
General information
dimension and weight
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
height A mm 1135 1135 1370 1420 1420
width B mm 590 590 590 760 760
width inlcuding slider 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 inch 2” IG 2” IG 2” IG 2” IG 2” IG
safety heat exchanger Ø inch ¾” ¾” ¾” ¾” ¾”
immersion sleeve for safety heat exchanger Ø inch ½” ½” ½” ½” ½”
draining Ø inch ½” ½” ½” ¾” ¾”
boiler weight kg 400 430 460 760 950
Electrical data
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
mains voltage/frequency V/Hz 230/50
power consumption – standby W0,35
power consumption – operation W63 126 (2x 63)
Technical changes and errors reserved
It is necessary that you follow the minimal installation distances
A
B
C
wall distance both sides
min. 400 mm
D
E
F
G
H
I
min. 300 mm
HVS 16 to 50
min. 800 mm
HVS 80
min.1600 mm

12 © Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
Installation

Since the wood log boiler has a heavy weight (up to 950 kg depending on boiler size) it is mandatory to
follow all necessary PPE* and CoSHH** requirements such as protective foot wear and gloves, etc.
© Solarbayer GmbH [11.13] 13
PRODUCT INFORMATION Wood log boiler HVS
Installation
Installation
Both installer and wood log boiler have to be protected during transport
* PPE = Personal Protecve Equipment
** CoSHH = Control of Substances Hazardous to Health

14 © Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
Installation
Tank sensor
The buffer tank sensor (PT 1000) has to be installed at the corresponding position in the buffer tank.
The measurement of the tank temperature is for information use only and has no influence on the control of the
boiler.
tank sensor
The buffer tank sensor should be installed aer ⅔ of
the buffer tank volume.
tank sensor

© Solarbayer GmbH [11.13] 15
PRODUCT INFORMATION Wood log boiler HVS
Installation
Boiler charging unit (mandatory)
A boiler charging unit is obligatory for the operation of a SOLARBAYER wood log boiler in order to prevent the
accumulation of condensing water and corrosion at the boiler body as a result of that. We recommend to only use
the Solarbayer boiler charging units. With those a boiler flow line temperature of approx. 70-85°C is achieved.
The unit’s pump is directly connected to the wood log boiler control unit,
see chapter: [Installation] Electric circuit diagram
When in „heating“ mode the pump will be switched on at a temperature of approx. 40°C. The pump is working
permanently, independent of the operating mode, when the pre-set boiler flow line temperature is exceeded
(overheat control).
In case of breakdown/failure of the boiler/exhaust gas sensor the pump is working permanently for safety reasons.
The activity of the pump is displayed be a rotating line on the control panel.
79°C
07:16
79.2°C

← to buffer tank
→ from buffer tank
example
Laddomat
Technical information and instructions for the installation come with the product and could be
downloaded on: www.solarbayer.de

16 © Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
Installation
Thermal discharge safety valve (mandatory)
In accordance with DIN 4751-2 a thermal discharge safety valve is prescribed for heating systems with solid fuels.
Safety heat exchanger and thermal discharge safety valve:
The safety heat exchanger with the thermal discharge safety valve conduces to the boiler’s protection against
overheating.
Installation of the thermal discharge safety valve:
It is important that the thermal discharge safety valve is installed in such a way that the heat exchanger is
depressurized during regular operation, meaning that it is not in a closed system. The 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 tube heat exchanger
(18 mm)
Sealing of the copper tube
for the thermal discharge safety valve
double nipple
flat seal
washer
①
②
③
④⑤
⑥
⑦
The double nipple together with the flat
seals and the shims for sealing the safety
heat exchanger from the boiler water are
already equipped by the manufacturer.
Do not turn the double nipple in order to
adjust or to hold in place. In case of a
leakage at the safety outlet the double
nipple have to be retightened with a pipe
wrench.

© Solarbayer GmbH [11.13] 17
PRODUCT INFORMATION Wood log boiler HVS
Thermal discharge safety valve

Thermal discharge safety valve ¾“, cold water inlet
 Immersion sleeve with double temperature protector
 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 25 kW and 40 kW
Solarbayer 50 kW and 80 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.

18 © Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
Installation
Technical information and instructions for the installation come with the product and could be
downloaded on: www.solarbayer.de
ON
25 kW
46.2°C300s

+60 0
The activity of the exhaust gas fan is displayed by a rotating line on the
control panel.
When operating the system with an exhaust gas fan this mode has to
be activated on the control panel!
see chapter: [Operation] Expert level (2.5: Configuration)

2.5.1.1 HVS25L

yes
yes
yes
Exhaust gas fan (oponal 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 is
open.
The exhaust gas fan is directly connected to the HVS control unit,
see chapter: [Installation] Electric circuit diagram

© Solarbayer GmbH [11.13] 19
PRODUCT INFORMATION Wood log boiler HVS
Flue pipe and barometric damper (oponal accessory)
• The chimney has to be designed according to DIN 4705 respectively EN 13384. Please contact the responsible
inspecting authority (e.g. chimney sweeper) in case of ambiguities.
• The fume outlet tube has to be connected to the chimney ascending, in the correct and shortest way.
A maximum of two bends may be installed, each other formed part causes a higher decrease in pressure.
• When connecting a fireplace to an exhaust gas system a secure exxhaust gas outlet has to be provided.
The exhaust gas systems have to be 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.
baromteric damper
Installation
In order to guarantee a clear combustion we recommend to install a barometric damper that ensure the
required chimney draft (see diagram).
effective chimney height
exhaust gas routing to the chimney:
straight length < 1,5 m

20 © Solarbayer GmbH [11.13]
PRODUCT INFORMATION Wood log boiler HVS
Installation
Electrical connecon
The regulations and standards of the VDE (German Association for Electrical, Electronic & Information
Technologies) and of the local power utilities have to be regarded.
The connection has to be carried out by a concessionary electrician.
Disconnect all components from power!
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
AK 3000 S (motherboard) AK 3000 L (lambda control board)
safety temperature limiter
connecon possibilty for AK 3000 M (SD card reader for soware update)
extensibility
plug connecon to control panel AK 3000 D
grounding
control panel
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Disconnect power before opening the control unit’s casing.
Never touch any system component that is current-carrying – danger to life exists!