Orlanski ORLIGNO 100 User manual

ORLIGNO 100
MANUAL AND SERVICE MANUAL

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Content
1. Boiler application ................................................................3
2. Installation ......................................................................4
2.1. Ventilation.............................................................4
2.2. Supply-air ventilation ...................................................4
2.3. Exhaust ventilation .....................................................4
2.4. Chimney connection ...................................................4
3. Technical data ...................................................................5
3.1. Dimensions............................................................6
3.2. Boiler construction .....................................................6
3.3. Safety valve connection ................................................7
4. Boiler startup ....................................................................9
4.1. Boiler stoking .........................................................10
4.2. Tarring and condensation ..............................................10
5. Maintenance ...................................................................11

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1. Boiler application
Steel boiler ORLIGNO 100 tested according to EN 303-5 is designed for central heating installations
with maximal temperature on the boiler 90ºC and working pressure 3 bar.
Recommended fuel for boiler: wood, coke, coal and in case of mounting pellet burner – pellets and
oats.
ATTENTION!
Using fuel different than the recommended not guarantees optimum boiler operation
and achieving parameters featured in technical data. It can also affect durability of the
boiler and its components.
A T T E N T I O N !
Using fuel different than the recommended is treated as wrong boiler operation and
resultant performance irregularities cannot be reason for complaint.

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2. Installation
2.1. Boiler-room ventilation
According to european safety regulations each boiler room should have supply-exhaust ventilation
ensuring correct boiler operation and user’s safety . Lack of ventilation or its obstruction is the main
reason of incorrect boiler operation (i.e. boiler cannot reach set temperature).Exhaust ventilation
removes from boiler room used air and harmful gases. Boiler room with natural draught cannot
have installed mechanical ventilation.
2.2. Supply air ventilation
1. Ventilating duct section should have at least 50% area of chimney’s section and not less than
20 x 20 cm. Duct should be placed 1m above the oor.
2. Ventilating duct should have installed device for air ow control; device shouldn’t limit duct
section above 1/5.Ventilating duct should be made of non-inammable material.
2.3. Exhaust ventilation
1. Exhaust duct should be made of bricks with section of at least 25% of chimney section not less
14 x 14 cm. Inlet hole cannot have any devices that reduce its section. Outlet hole should be
placed close to the ceiling led out 1,5 m above the roof. Ventilating duct should be made of
non-inammable material.
2. Height of the boiler room min. 2,2 m.
2.4. Chimmey connection.
Chimney ducts should be installed according to binding rules and norms in countries to which
boilers are sold. Part of chimney system connection boiler with chimney is called ue. In order to
lower ow resistance of exhaust gases this part should lead as a straight pipe with, if necessary,
joints up to 45°.
Because of exhaust gases temperature ORLIGNO 100’s need to be connected to heat-resistant.
30 cm above the oor closing door should be installed with tight closing.
Chimney section should be round or close to square shape because of low ow resistance.
Minimal ue diameter should be 160 mm.
Chimney should lead above the roof. Chimney outlet location is dependent on roof slope and its
combustibility.

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Power
wood
Coke/pellets
kW
kW
14
30/16
Boiler class acc. to EN-303-5 3
Efciency
coke
pellets %
76,5
86
Max working pressure bar 3
Max temperature °C 90
Min. temperature °C 60
Water capacity ltr. 60
Weight kg 305
Loading chamber capacity ltr. 70
Length mm 110 0
Width mm 675
Height mm 1220
Upper door dimensions mm 300x300
Water outlet inner thread inch 5/4”
Return inner thread inch 5/4”
Drain valve inner thread inch ½”
Cooling coil inner thread inch ½”
Min. cooling coil pressure bar 2
Flue diameter mm 160
Required chimney draft Pa 20
Max. moisture content: wood/pellets
%23/12
Exhaust gases temperature at nominal power °C 250-280
Burning period at nominal power coke h4,5
wood h2-2,5
Fuel parameters
wood/max length
mm 500
pellets/ diameter mm 6-8
Water resistance ∆t=20 K mbar 0,8
∆t=10 K mbar 3,4
3. ORLIGNO 100 – technical data

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3.1. Dimensions
3.2. Boiler construction

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3.3. Safety valve connection

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ORLIGNO 100 is equipped with copper cooling coil mounted in boiler body, protecting boiler from
overheating. To one of cooling coil tappings on right side of the boiler one should connect safety
valve.
When temperature increases above 95ºC safety valve opens and lets in cold water through cooling
coil. Water from mains at 10ºC temperature cools down boiler, water from boiler is removed to
drain.

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Before rst startup it is necessary to:
- Check water level in installation, pressure in installation should be 2 bar.
- Check re-grate location (re-grate gaps from bottom should be bigger than from top).
- Draft regulator seal with oakum and mount, t arm and block with screw.
Startup:
- Mount draft regulator horizontally, regulator set on 70°C.
- Open ue ap.
- Put on re-grate papers and small wood pieces; open bottom door .
- After lightning up put bigger wood logs and create ember layer (close bottom door and
unscrew primary air ap – opening in ap at least 2cm- regulation knob is located on bottom
door.
- After creating ember layer fully load boiler with wood or coke. Put wood logs along
chamber.
- Set chimney draft with ue ap
- Connect draft regulator chain with primary air ap. Burn in boiler up to 70°C then set draft
regulator on 70°C and shorten chain till primary air ap is barely opened. Draft regulator knob
is for temperature change. Marking on regulator is every 10°C.
ATTENTION!
Before stoking boiler open slowly open upper door to suck out gases.
ATTENTION!
It is not allowed to open bottom door during boiler burning – glow may fall out.
SECONDARY AIR SETTINGS:
- wood opening ½
- coke opening ¼ .
Troubleshooting
Reason Activity
Heat exchanger gets dirty to fast Use good quality wood, moisture content 18-23%.
Smoke leakage Seal chimney pipe, open more ue ap, check chimney draft
Too high temperature of exhaust
gases
Check fuel moisture content, cannot be too dry.
Check secondary air settings.
Too short burning period To high exhaust gases temperature: burning period depends on
used fuel and heat demand
4. Boiler startup

In order to stoke boiler:
1. Close primary air ap.
2. Open completely ue ap.
3. Open slightly upper door in order to suck out gases through chimney.
4. Open completely upper door and stoke boiler.
5. Close upper door, return to previous setting of ue ap and primary air.
4.1. Boiler stoking
4.2. Tarring and condensation
Lightning up in cold boiler may cause that water precipitated from fuel falls on boiler walls and runs
down to ash chamber. That may look like boiler leakage. It is important to keep boiler temperature
high enough at least 70°C. It is recommended to install four-way mixing valve which protects boiler
from low temperature return below 50°C. Too humid wood also causes that boiler works on low
temperatures, which leads to tarring. In order to avoid problem of tarring and condensation – keep
high boiler temperatures, boiler must be properly sized to heated space to avoid oversizing – boiler
then will work on low temperatures.
1. Boiler ORLIGNO 100
2. Pressure vessel
3 . R a d i a t o r
4. Safety valve- protection- from verheating
5. Four-way mixing valve
6. Safety group
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Advice:
Clean boiler works efciently. Boiler life is extended.
- Fire-grate and ash clean/remove daily.
- Boiler must be cool during this activities.
- Open upper door and remove cleaning ap.
- Check if heat exchanger surfaces are cleaned, clean with brush.
- Remove ash from bottom chamber ( ashpan may be hot).
- Fit cleaning ap.
- Each 2-4 weeks clean boiler depending on burning intensity.
5. Maintenance
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INSTRUCTION MANUAL
Contents
1. Basic informations ..............................................................14
1.1. Construction description and burner application ..........................14
1.2. Fuel characteristics ...................................................15
1.3. Transport and delivery specication.....................................16
2. Burner’s technical data ..........................................................17
3. Package .......................................................................18
4. Location and package installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1. Rules, norms, recommendations ........................................19
4.2. Boiler room recommendation ..........................................20
4.3. Ventilation ...........................................................20
4.4. Safe distance to inammable substances ................................20
5. Putting into operation ...........................................................22
5.1. Burner start...........................................................22
5.2. Burner’s assembly to ORLIGNO 100 ....................................22
5.3. Adjustment of ORLIGNO 100 to work with pellet burner ...................22
5.4. Tank assembly........................................................24
5.5. Before starting of the burner it is necessary ..............................25
6. Burner’s maintenance ...........................................................26
7. Troubleshooting ................................................................27
II. Instrukcja regulatora..............................................................28
8. Main functions of the controller. ..................................................28
9. Graphic display .................................................................29
10. Service.........................................................................30
11. Simple menu ..................................................................33
12. Main menu .....................................................................35
13. Heating .......................................................................36
14. Hot domestic water .............................................................38
15. Water tank .....................................................................40
16. Boiler. . . .......................................................................40
17. Settings .......................................................................41
18. Burner . . .......................................................................41
19. Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
20 Electric installation...............................................................44
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1. Basic informations
1.1. Construction description and burner application
Self- cleaning burner is a new look into the automatic burning of solid fuels in Europe – pellets of
6-8 mm of diameter or as a option oats with maintaining low emissions, complying with European
norms.
Burner doesn’t have any drawbacks of chute burners –gravitational, in which ash and sinter have
to be removed manually.
Main burner advantage is its simple service: just ll in hopper with pellets and press START button.
Reports are shown on big graphic display. Within few minutes burner will automatically select work
parameters, maintain constant room temperature and hot utility water.
Burner’s features:
- automatic burner’s start
- automatic modulation
- ame control through photo-cell
- low heat inertness during start and stop
- low electric energy consumption
- possibility to control 16 heating circuits (radiators and underoor heating or hot utility water)
– option
- control of burner’s temperature
- three phases of lightning up eliminate risk of explosions
- AUTOSTART function after power failure – memory of last settings
- separation of primary and secondary air – emissions on the same level as in gas and oil
burners
- efciency > 94,5%
- soot = 0
- self-cleaning function, automatically removes ash from the burner’s grate
- oats –burner’s construction enables to burn grain (oats) – option
2 years of warranty for appliance durability enables to decrease exploitation and service
costs.
Burner’s regulator can control:
- boiler pump
- 1-16 heating circuits (radiators or underoor heating) controlled according to outside
temperature
- room’s temperature
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Useful functions of controller:
You don’t have to keep in mind about next boiler service – it is shown on the display
Statistics – function enables to preview
- minimal, maximal and average burner’s power
- fuel usage: minimal, maximal and average.
Temperature’s parameters are shown as a digits and charts on big graphic display
1.2. Fuel characteristics
a) Pellet granulate made according to DIN 51731
- granulate 5-8 mm
- recommended caloric value 17500-19500 kJ/kg
- ash content 1,5%
- max moisture content 12%
- density 1-1,4 kg/dm³
b) Oats
- moisture content <15%
ATTENTION!
It is recommended to use fuel from reliable sources. Fuel should have appropriate
humidity and low content of small fractions. It is necessary pay attention especially
to mechanical pollution ( stones), which worsen burning process and may lead to
burner’s failure.
Eko-Vimar Orlański sp. z.o.o. is not responsible for appliance failure or improper burning process
when using inappropriate fuel.

1.3. Transport and delivery specication
Burner during transport should be secured with straps against leaning and movement.
Burner need to be stored in roofed and dry place.
Burner is delivered in separate boxes wrapped in foil. Boxes contains: pellet tank with lid, fuel
feeder, burner with controller and elastic feeding pipe. Before installation it is recommended to
check delivery completeness and its condition.
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2. Burner’s technical data
Parameter SI 16 kW
Pellet power range kW 4 – 16
Oats power range* kW 3,6 – 14,4
Efciency %>94,5
CO emission ppm <200
Weight kg 14
Feeder length standard m 1,3 – 1,6
Feeder length option m2.0;2.5;3.0
Fuel pelety
Fuel diameter mm 6 – 8
Fuel (option) humidity<15% owies
Voltage V 230
Power consumption W30
Protection level IP40
Tank dimensions mm 600x600x1400
Capacity L 305
ATTENTION!
Producer reserves the right for construction and documentation changes in order to
modernize the boiler.
1. Boiler
2. Burner
3. Fuel tank
4. Feed system
Pic.1. Basic package elements.

Pic.2. Burner construction
1. Burner’s body
2. Grate
3. Fan
4. Feeder casing ( worm+
igniter)
5. Drive plate
6. Plate for electric
connections
7. Sealant
8. Motoreducer
9. Burner’s casing
3. Package
Standard package:
- b u r n e r
- controller
- fuel feeder
- t a n k
- m a n u a l
- 4 refractory bricks
- Sensor sleeve ½”
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4. Location and package installation
4.1. Rules, norms, recommendations
Boiler room should comply with construction law valid in country where boiler is installed.
Pic.3. Package layout.

4.2. Boiler room recommendation
- Package ( boiler, burner, tank, feeder) should be placed in separate room, centrally to heated
rooms
- Front door should open outside and must be made of nonammable materials, with 0,8
width
- Floor should be made of nonammable materials or covered with 0,7 mm steel plate at
minimum 0,5 m distance to door edges. Boiler should be located on a nonammable
foundation, lifted 0,05 m above oor level
- Boiler room should have articial lightning but natural light is also recommended
- Distance to walls in boiler room should allow for easy access to all sides of the boiler
- Minimal distance from front side of the boiler to opposite wall should be 1m
- Minimal height of the boiler room: at least 2,2 m; in existing building it is allowed 1,9 m with
assured supply-exhaust ventilation.
- It is forbidden to install boiler and burner in damp rooms or with elevated humidity. Corrosion
process may in short time damage the boiler and burner.
4.3. Ventilation
- Boiler room should have 200 cm² supply-air duct
- Exhaust duct should have at least 14x14 cm section with inlet hole under boiler room ceiling
that should lead above roof and be placed near chimney.
- Ventilation ducts should be made of nonammable materials.
- It is forbidden to install mechanical ventilation
ATTENTION!
High risk of carbon monoxide poisoning exists if boiler is located in a room with
insufcient access to fresh air.
4.4. Safe distance to inammable substances
- During installation and exploitation it is advisable to maintain safe distance of 200 mm from
inammable substances
- For inammable substances with C3 grade of combustibility which rapidly and easy burn (ex.
paper, cardboard, wood, plastic) distance is minimum 400 mm;
- If combustibility grade is unknown safe distance should be doubled.
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