Eko-Vimar Orlanski Orlan 18 User manual

Owner’s Manual
Wood gasification boilers from 18-80 kW (85-275 kBtu)
O
rlan
®
I
SO 9001
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Contents
1. Using the boiler........................................................................................................... 3
2. Understanding wood gasification................................................................................ 3
3. Installation guidelines and clearances ........................................................................ 4
3.1.Clearance diagram............................................................................................... 4
3.2.Chimney specifications......................................................................................... 5
4. Controller specifications and features.........................................................................5
4.1.Technical data for the RK 2001 controller ............................................................ 5
4.2.How the controller works...................................................................................... 6
4.3.Connecting a pump or room thermostat to the RK2001 controller........................ 7
5. Technical data for the EKO boiler line......................................................................... 8
6. Connecting and operating the EKO boiler................................................................... 9
6.1. Installation guidelines........................................................................................... 9
6.2.Conditions for successful wood gasification .........................................................9
6.3. Wood fuel considerations................................................................................... 10
6.4.Hot water storage............................................................................................... 11
6.5.Starting and operating the boiler for the first time............................................... 11
6.6.Fuel loading........................................................................................................12
6.7.Boiler shutdown.................................................................................................. 12
6.8.Operating temperature ....................................................................................... 13
6.9.Protecting the boiler during a pump or power failure.......................................... 13
7. Boiler maintenance................................................................................................... 14
7.1. Offseason preparation ....................................................................................... 14
7.2. Maintaining the fan............................................................................................. 14
7.3. Routine cleaning................................................................................................ 14
7.4. Maintaining tight seals ....................................................................................... 15
7.5. Standard cleaning tools ..................................................................................... 15
7.5. Cleaning the EKO Super 1 model...................................................................... 16
8. Troubleshooting guide .............................................................................................. 16
9. Disposal and recycling of boiler components............................................................ 17

1. Using the Boiler
Dry, seasoned wood is the recommended main fuel source for the EKO boiler. Optimum
wood moisture should be between 20 and 25 percent. The length of the wood pieces should
be about two inches shorter than the depth of the burning chamber.
Warning!
Using fuel types other than the dry wood specified above may result in unpredictable
operation and poor efficiency. Neither the manufacturer nor New Horizon Corp. are
responsible for problems resulting from the use of unapproved fuels.
Warning!
EKO wood gasification boilers should be installed in accordance with local codes. The
boilers should be part of a closed, pressurized system with a pressure relief valve,
expansion tank and if possible with a hot water storage tank.
Warning!
The main circulating pump on the system should be connected directly to the RK 2001
controller to assure proper operation and water circulation. This will help prevent overheating
and result in the best performance.
2. Understanding Wood Gasification
Wood gasification boilers work by the pyrolitic wood distillation process, whereby heat is
used to break down the wood structure into charcoal and eventually, into combustible gas.
This is done by limiting the air intake during the initial combustion process. When the
resulting wood gas passes through the ceramic nozzle at the bottom of the top combustion
chamber, it is mixed with air and burned cleanly at high temperatures (up to 2,000 degrees,
Fahrenheit) in the bottom chamber. A hot, clean-burning flame is produced, with little or no
smoke. This hot gas exits the boiler through the heat exchanger tubes and into the chimney.
If burning pellets or other wood particles of the proper moisture content, be sure to place this
material on top of larger pieces of wood to avoid clogging the ceramic nozzle.
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3. Installation Guidelines and Clearances
Orlan EKO boilers are designed to conform to, and be installed in accordance with, the
stringent European regulations known as PN 87/B 02411 and PN-91/B-02413. When
installed in the United States, all applicable local codes and regulations should be
observed. Note: New Horizon recommends the use of a triple insulated, Class A stainless
steel chimney. The company does not take responsibility for installations utilizing any other
type of chimney.
1. The chimney flue connected to the EKO boiler should conform to the specifications
indicated by the chart on page 5.
2. The boiler room should be large enough to allow the boiler to be cleaned and maintained
(>2.2 m).
3. The distance between the boiler and the surrounding walls should be sufficient to allow
access to all of the boiler’s parts, as specified in the clearance diagram below.
4. The boiler room should not contain any wiring or electric components not required for the
operation of the boiler.
3.1. Clearance diagram
Prior to operation, the installation should be inspected and approved by qualified
professionals (i.e., a chimney sweep, a licensed plumbing & heating contractor,
electrician, etc.).
The installation of a hot water storage tank is recommended.
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3.2. Chimney specifications
Thrust needed [Pa]
Chimney height [m]
4. Controller Specifications and Features
Since 2006, all Orlan EKO wood gasification boilers have been equipped with the RK 2001
controller.
4.1. Technical data for the RK 2001 controller
Power 230V +/- 10%
Rate supply voltage (with no fan) < 4VA
Temperature measurement range 0 do 99 +/- 1 °C
Temperature measurement sensors KTY 81 210
Temperature regulation range 60 - 80 °C
Electrical protection (fuse) 1A/220V
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Front panel of the RK 2001 controller
1. Power ON/OFF
2. Boiler water temperature
3. Gasification status
4. Overheat indicator
5. Room thermostat indicator
6. Boiler thermostat knob
7. Pump status indicator
8. Fuel level indicator
9. Room thermostat knob
10. Boiler temperature setting test
4.2. How the controller works
Boiler’s temperature setting
from 60 up to 80°C
The desired boiler temperature is set with a knob (6). Current
temperature is displayed on the screen (2).
Boiler overheat indicator The LED (4) indicates when the boiler temperature exceeds
90°C. This causes the fan to switch off
Low fuel indicator If the boiler temperature doesn’t reach 60°C after 30 minues, the
indicator (8) and the fan will turn on.
Fuel shortage indicator If the boiler doesn’t reach 60°C during burning (up to 2 hours) ,
the indicator (8) will light up and the fan will turn off.
Fan status A regulator modulates the fan speed, slowing the fan as the
boiler approaches the target temperature.
Pump status
If a pump is connected to the regulator, the pump will remain off
until the boiler temperature reaches 65°C. It will then run until the
temperature declines to 60 degrees.
Room temperature control
The controller can work together with a room thermostat so that
the boiler maintains the temperature desired in the room. If there
is a room sensor or thermostat connected to the controller, then
the boiler will remain in surveillance stage (maintaining a boiler
temperature between 60 and 65°C).
“Flushing” during idle
The controller can be set to blow purge air into the upper burning
chamber to get rid of accumulated wood gas when the boiler has
reached its set temperature and is in idle mode. This keeps the
fire from going out. The purging time is five seconds. The timing
interval between “flushes” can be set between 1 and 9 minutes.
Note: Flushing settings should be made by a qualified
technician.
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4.3. Connecting a pump and room thermostat to the controller
There are several electrical terminals on the back side of the RK 2001 controller where a
pump and room thermostat can be connected. Access is through the bottom of the controller
housing, which is attached to the top front boiler panel with four screws. There are numbers
and graphic symbols indicating the function of various electrical connections, switches and
dials on the bottom of the controller. It is always a good idea to check with your EKO dealer
or distributor to determine the proper connections for your system.
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5. Technical Specifications for the Orlan EKO Line
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6. Connecting and Operating the EKO Boiler
6.1. Installation guidelines
A four-way mixing valve is an essential component of any EKO boiler installation. When
properly installed, it allows hot supply water to be automatically mixed with cooler return
water to avoid low return water corrosion at the boiler return water connection and maintain
a relatively stable boiler water temperature. Four-way mixing valves also make it possible to
maintain a steadier house temperature. Mixing valves can be used in either gravity or
pumped hydronic systems.
Note: Set mixing valve at 50%
Schematic of a system incorporating a four-way mixing valve
1. Four-way mixing valve
2. Circulating pump
3. Room temperature sensor (for the PK
2001 controller) or room thermostat.
4. Orlan boiler with RK 2001
5. Heater, radiator, etc.
6. OKCV operational water heater
7. Differential valve
8. Pressure tank
9. Warm water exit
10. Cold water entr
y
6.2. Conditions for successful wood gasification
Wood gasification boilers require specific conditions for optimum performance and
efficiency. For best results, the boiler water temperature should be in the 70-80°C range.
Lower temperatures will result in incomplete gasification, resulting in poor efficiency and the
accumulation of unburned residue. Because the wood is dried in the top chamber prior to
gasification, incomplete gasification in the lower chamber will affect the fire’s ability to
sustain itself. The main cause of poor gasification, therefore, is the failure to use adequately
dry wood.
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6.3. Wood fuel considerations
As noted earlier in this manual, the moisture content of the wood used to fuel the boiler
should be between 20 and 25%. Hardwoods such as beech, oak, maple, hickory, etc. are
best. While it is possible to burn dry softwood such as pine, spruce, fir, hemlock, etc,. they
will burn faster and require more frequent loading of the boiler than with hardwood. One way
to determine wood moisture content is with a moisture meter (see next page). As a general
rule, hardwood cut, split and stacked for one year under cover is usually ready for burning in
an EKO boiler. Wood properly stored for two years is best. The manufacturer and distributor
are not responsible for problems related to using wood that is not adequately dry or dense.
Wood density table
wood type density of green wood [kg/m]3] density of dry wood [kg/m]3]
pine 700 480
larch 760 600
spruce 740 430
fir 1000 450
elm 950 680
ash 920 750
beech 990 730
hornbeam 1080 830
alder 690 530
birch 650 650
maple 870 660
A
hydrometer is used to measure the
moisture content of wood.
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6.4. Hot water storage
For the best results, the use of a heat storage tank is recommended. A properly sized
storage tank can cut wood consumption by as much as 40%. Hot water storage allows the
boiler to run at optimum capacity regardless of the demand for heat from the building being
heated. The stored heat can be recovered later, both stretching the time between boiler
refuelings, and as an additional source of heat on very cold days. Generally speaking, the
bigger the storage tank the better, as the boiler is most efficient when running at full
capacity. The rule of thumb on tank sizing is that 50 litres of water can store about 1 KW of
boiler heat. A hot water storage tank connected to an EKO boiler can also be used to store
hot water from a solar hot water heater.
.
System set up with a heat storage tank and coil, domestic hot water heat option
and solar panel.
1. EKO boiler with RK 2001
controller
2. Laddomat 21 thermoregulator
3. Hot water storage tank
4. Electric water heater
5. Three-way mixing valve
6. Circulating pump
7. Room temperature sensor or
programmable room thermostat
8. Supply to heated space
9. Expansion tank
10. Domestic hot water mixing
valve
11. Heat exchanger coil
12. Solar panel
13. Pump
6.5. Starting and operating the boiler for the first time
Before firing up the boiler for the first time, the installation should be inspected and approved
by a qualified individual (plumbing & heating contractor, electrician, etc.) The system should
be full of water and vented and all other settings checked and tested, especially the pressure
relief valve.
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When starting the boiler, the following steps should be followed in sequence:
1.) Switch off the power.
2.) Push the chimney damper lever in to open the burning chamber bypass.
3.) Put paper, kindling and a few larger pieces of dry wood in the burning chamber.
4.) Start the fire.
5.) Open the bottom combustion chamber door to provide natural draft.
6.) Let the fire burn for 15 to 20 minutes (WARNING!! NEVER leave the boiler unattended
at this stage.)
7.) Add more wood
8.) Wait another 15 to 20 minutes for a charcoal layer to accumulate
9.) Fill up the entire upper combustion chamber with wood.
10.) Close both upper and lower doors.
11.) Pull the bypass damper closed and switch on the regulator.
WARNING!
Never switch on the regulator when the upper door is open.
CAUTION!
Never force the fuel loading door closed. Doing so may damage the door
or other parts of the boiler. Use only properly sized wood.
6.6. Fuel loading
A properly sized and installed EKO gasification boiler should require loading every 8-12
hours. To add wood, following the following procedure:
1. Switch off the boiler with the main switch on the controller.
2. Open the combustion chamber bypass chimney damper.
3. Open the upper door and load the chamber if necessary,
4. Close the door, pull the chimney flap closed and switch on the boiler
It is important to avoid obstructing the chimney bypass damper with wood in the
combustion chamber when loading fuel.
Ideally, the wood in the upper combustion chamber should be burned down to embers
before reloading the boiler.
NOTE:
The yellow “no fuel” light indicates when the boiler needs to be reloaded.
6.7. Boiler shutdown
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The boiler turns off in two ways: Manually when the power switch on the controller is turned
off, or automatically when the wood supply has burned out. NEVER turn the controller off for
extended periods when the boiler contains burning fuel, as doing so could cause it to
overheat.

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6.8. Operating temperature
Maintaining the proper temperature of the water in the boiler during operation is very
important. For proper gasification to occur, the boiler water temperature should be 70°C or
greater.
At times, such as when there is a large call for heat, the return water temperature may
become too low. This can result in poor gasification and decreased efficiency, as well as
creosote buildup in the gasification chamber, heat exchanger tubes and chimney. Low return
water temperature can also shorten the life of the boiler. The return water temperature
should not be allowed to drop below 20°C below the supply water temperature.
A three-or four-way mixing valve should be installed at the boiler outlet in such a way that
supply water can be mixed with return water before it enters the bottom of the boiler. Check
with your dealer or installer for details.
6.9. Protecting the boiler during a pump or power failure
During the course of operating the boiler, there is always the possibility of a pump or power
failure. NEVER refuel the boiler during a power failure or power outage. NEVER attempt to
operate the boiler with natural draft by opening the chimney bypass damper or the bottom
gasification chamber door during a power outage, as the boiler will likely overheat. It is
advisable to install an auxiliary power supply to power the boiler fan and pump during a
power failure. It is also a good idea to install a gravity feed storage tank directly above the
boiler. Typically, this would be a 40- or 50-gallon electric water heater connected to a
normally-closed zone valve (or at minimum, a manual valve) that will allow hot water from
the boiler to circulate into the tank in the event of a power outage.

7. Boiler Maintenance
7.1. Offseason preparation
It is important that the boiler be properly prepared for the offseason (summer) idle period.
The upper and lower combustion chambers, heat exchanger tubes and chimney bypass
damper should all be thoroughly cleaned. After the boiler is cleaned, both doors should be
left open to avoid condensation in the boiler.
7.2. Fan maintenance
The fan is an essential part of boiler operation, and it should be kept clean. It is advisable to
monitor the fan’s condition and clean it from time to time with a soft bristle brush.
WARNING!!: Operating the boiler with the bottom door open can cause the
fan to overheat.
7.3. Routine cleaning
Ashes produced during boiler operation fall down through the nozzle into the lower
gasification chamber. During fuel loading, any ash remaining in the upper combustion
chamber can be pushed down through the nozzle with the tool provided, using care not to
damage the nozzle. Accumulated ash should be cleaned out of the lower chamber as
needed, typically every 3-5 days.
Once a month, the upper combustion chamber should be cleaned out as well. Creosote
which has accumulated on the firebox walls should be scraped out. It can be allowed to fall
through the nozzle and into the ash pit, where it can be easily removed.
The heat exchanger tubes at the back of the boiler are also susceptible to carbon and
creosote buildup, which diminishes their ability to transfer heat. On the EKO Standard
models, the heat exchanger pipes should be manually cleaned every two weeks using the
following procedure. (Note: The Super 1 models have a lever-activated heat exchanger
cleaner which should be operated every time the boiler is loaded with fuel. The tubes should
be inspected on a regular basis, but the bi-weekly cleaning routine described below is not
necessary with the Super 1 models).
1.) Remove the back panel and unscrew the heat exchanger cover plate with a metric
wrench (from 13 to 17 mm, depending on the model). IMPORTANT: Use care when
screwing and unscrewing the retaining nuts. Lubricate the threads before removing the
nuts, and avoid excessive force when tightening them back down.
2.) Clean each heat exchanger tube for its entire length, using the tool provided. Be sure that
soot and creosote do not accumulate at the bottom of the tubes. Clean any soot that has
accumulated in the back of the boiler behind the tubes.
3.) To facilitate cleaning, it is a good idea to burn dry potato skins (about 10 litres) in the
boiler a day or two prior to cleaning. The starch in the potato skins acts as a catalyst,
allowing the boiler to burn off accumulated soot and creosote more easily. No kidding.
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7.4. Maintaining tight seals
It is very important to maintain tight seals on the doors, heat exchanger cover plate and the
firebox bypass chimney damper. Poor seals can result in smoke and gasses leaking out of
the boiler, and lead to uncontrolled burning which may cause the boiler to overheat. The
insulation rope used to seal both doors and the heat exchanger cover should be inspected
regularly and treated with graphite or some other lubricant as needed, to keep them flexible.
Over time, (one heating season, for example), the rope seals on the doors can become
flattened through normal use. When this occurs, the door hinges can be adjusted to
compensate for the new shape of the sealing rope, as follows:
1.) Remove the door.
2.) Loosen the cap.
3.) Turn the hinge 360 degrees
4.) Tighten the blocking nut to block the
hinge retaining screw.
Note: The upper and lower
hinges should be adjusted at
the same time
Note: Chimney inspection and maintenance is a critical part of any wood-
burning maintenance schedule. Make sure that the chimney connection is
secure and airtight. Inspect chimney regularly and clean as needed.
7.5. Standard Cleaning Tools
Heat exchanger cleaning tool not included with
Super 1 model.
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7.6 Cleaning the EKO Super 1 model
The EKO Super 1 model boilers are equipped with a lever-operated heat exchanger cleaning
device consisting of spiral steel elements that clean the tubes as the elements are moved up
and down. Vigorously moving the handle back and forth either before or after each fuel
loading will help assure that the heat exchanger does not become clogged with creosote,
carbon or ash. The lever should not be operated while the chimney bypass damper is open.
8. Troubleshooting Guide
Problem Cause Remedy suggested
problems starting fire refer to Section 6.5
wood too moist use properly seasoned wood
primary air conduit choked call service – not covered by warranty
secondary air conduit
choked call service – not covered by warranty
smoke tube of heat
exchanger choked clean with supplied cleaning shield or call service – not covered by warranty
boiler doesn’t reach
the temperature
needed wrong regulation of the air
and wood gas call service – not covered by warranty
nozzle damaged replacement – not covered by warranty
fan’s gasket damaged replacement – not covered by warranty
fan damaged replacement – not covered by warranty
leak on a seal rope door regulation or call service – not
covered by warranty
smoke out of the
cleaning cover seal rope worn rope’s replacement – not covered by
warranty
cover warped - overheating cover’s replacing or call service – not
covered by warranty
intensive -Heavy wind blows
the fumes into the chimney consider installing a special chimney
cap – not covered by warranty
smoke coming out
while loading (little
smoke is
acceptable) Inadequate chimney consult a chimney maintenance
professional (chimney sweep).
leak on a seal rope adjust door hinge per instructions.
smoke out of the
boiler’s door seal rope worn replace rope or call service – not
covered by warranty
door damaged replace door – not covered by warranty
no power check the wiring and circuit breakers
fuse damaged replace fuse – not covered by warranty
regulator doesn’t
work live wire conduit damaged Inspect and repair wire

temperature sensor
damaged call service
regulator damaged call service
thermal protection engages investigate reasons for boiler
overheating
no power in regulator check fuse and wiring
fan damaged call service - fan’s replacement
regulator damaged call service
fan not working
fan blocked inspect and clean the fan
bearings damaged call service - fan’s replacement
condenser damaged call service - condenser’s replacement
fan making noise fan clips loosened check, turn the clips tight
fan’s blades unclean check and clean
debris in fans cover check and clean
dirty fan blades check and clean
fan working poorly pitch on the fan cover check and clean
problems with startup refer to Section 6.5
chimney draught to low
(below 10 Pa) rebuild chimney. Consider use of WKO exhaust fan
chimney draught to intensive
(over 20 Pa) use exhaust regulator
wood too small or too dry mix with larger humidity fuel as to
increase humidity level (in about 15-
35%)
Explosion or
“puffing” in the
firebox
clogged heat exchanger
tubes clean the exchanger or call service – not covered by warranty
9. Disposal and Recycling of Boiler Components
EKO boilers contain steel, electronic components, insulation and
other materials that may be subject to local, state or federal
regulations as to their proper disposal. When retiring an EKO boiler
from service, make sure that all applicable laws, rules and
regulations are observed. When in doubt, check with your local
regulating authority for scrapping and disposal guidelines.
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Distributed in North America by:
New Horizon Corporation, Inc.
151 McGregor Drive
Sutton, WV 26601
[phone]
[email protected]