Orlanski ORLIGNO 200 User manual

ORLIGNO 200
INSTRUCTION MANUAL
& SERVICE MANUAL

INSTRUCTION MANUAL
Content
1. Boiler application ................................................................3
2. Principle of work .................................................................3
3. Description of the controller .......................................................4
3.1. Front panel of EKOSTER 2 ...............................................4
3.2. Main functions of EKOSTER 2 ...........................................4
4. Gasication process..............................................................7
5. Boiler start-up ...................................................................8
5.1. Lightning up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2. Fuel stoking ...........................................................8
5.3. Boiler turning off .......................................................9
5.4. Optimal boiler’s temperature ............................................9
5.5. Power outage and pump failure..........................................9
6. Maintenance ...................................................................10
6.1. Boiler maintenance ....................................................10
6.2. Boiler cleaning .......................................................10
6.3. Boiler tightness .......................................................11
6.4. Fan maintenance .....................................................11
2

3
1. Boiler application
Orlanski’s gasication boilers are designed to burn wood. As a main fuel it is recommended to
use wood logs with moisture content 15-25% and max. length 5 cm shorter than loading chamber
depth depending on boiler size; wood log diameter: 15-25 cm.
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.
A T T E N T I O N !
Boiler is equipped with controller that enables to operate in right temperature’s range
and protects the boiler against overheating by fan activation.
2. Principle of work
Gasication boilers utilize process of dry, pyrolitic wood distillation. During wood burning with
limited amount of air, wood changes into charcoal. Gasication process creates large amount of
wood gases which are directed to ceramic nozzle and burned in ame form in bottom chamber.
This method of wood burning efciently make use of wood as a fuel.

4
STOP
PUMP’S OPERATION
FAN’S OPERATION
FIRING-UP MODE
BLOW-THROUGH - INTERNAL TIME
BLOW-THROUGH - OPERATING TIME
POWER SWITCH
Pic.1 Controller’s description.
3.1. Front panel of EKOSTER 2
3. Description of the controller
3.2. Main functions of EKOSTER 2
Application
The microprocessor temperature’s controller for central heating boiler is designed to control the
air blow in wood-red boiler and to actuate circulating pump in central heating systems.
Controller performs the following functions:
• maintaining set temperature of boiler by controlling air blow,
• smooth start-up of a blower,
• setting the blower power (service mode),
• programmable boiler „blow-through”,
• automatic control switch-off after boiler burnout (extinguish),
• blower interlocking when feeding the boiler,
• control of central heating circulating pump depending on its set operating temperature,
• „COMFORT SYSTEM” mode,
• protection against freezing or overheating of boiler,
• signalling of temperature sensor’s damage,
• regulating the brightness of display - increased during readout and change of regulator
settings,
• room thermostat cooperation,
• automatic turning off in case of wrong burning up in the boiler,
• EKOSTER CONTROL co-operation.

5
Operation description
After switching on, controller is in , , which is signaled by adequate diode. Operation
starts after pressing or automatically, when boiler’s temperature increases above operating
threshold – temperature difference between set temperature and DT parameter set in the service
menu. Status is automatically activated after 30 minutes since temperature decrease
below operating threshold. CONTROL socket which is located at the back panel of the controller
is for connection of remote control EKOSTER CONTROL.
Buttons and służą do zmiany nastaw. During boiler operation, pressing or causes
possibility to change desired boiler’s temperature. Pressing and withholding button causes
increase of speed of temperature changing
Pressing button causes:
• temperature below operating threshold:turning on/off of the controller signaled with diodes
or ,
• at temperature above operating threshold:fan operation blockade signaled by blinking
, diode, which makes possible to stoke the boiler. Return to automatic operation after
pressing button.
A T T E N T I O N !
Displaying „Er” on the controller informs about temperature increase above 99 °C,
below -9 °C or boiler sensor damage. To secure the boiler till sensor replacement,
pump will be automatically activated.
COMFORT SYSTEM
COMFORT SYSTEM function in controller prevents pump’s rotor from stone deposition.
Controller automatically activates pump after heating season for 30 seconds every 14 days.
Pump operation in this mode is signaled with ashing POMPA diode. Function activates after
1 minute since controller’s activation. Pump activation in this mode causes that 14 days period is
counted at the beginning.
Freezing and overheating function
Controller enables to turn on circulation pump In case if temperature drops to 4 °C or lower.
Exceeding 97°C causes fan to turn off and circulation pump activation. Boiler overheating is
signaled with ashing diode. In such a case it is recommended to determine cause
of overheating, eliminate and turn on the boiler pressing button. Pump is activated
permanently In case of boiler sensor damage.
Blow-through
• Press and hold for 3 s till diode starts blinking,
• przyciskami , are for blow-through time setting in seconds,
• Press dtill diode starts blinking,
• With buttons , set blow- through pause in minutes,
• Press .
From now on controller at temperatures higher than set one will activate blow-through.

6
A T T E N T I O N !
- Setting blow-through on „0” will deactivate blow-through,,
- Above 98 °C blow-through is turned off not to overheat the boiler.
Remote control
Controller is adjusted to install remote control „EKOSTER CONTROL” that enables to control and
change the boiler’s temperature, displays of pump condition and mode START-STOP, at the same
time remote control can activate alarm in case of temperature sudden increase to alarming level.
Remote control with 10 or 15 meters cable is an accessory appliance.
Service mode
Service mode is for settings changes. To enter service mode:
• turn off controller,
• turn on and during controller’s software displaying (ex. 3.4) press and hold button until
parameter “HI” will display.
Controller displays in turn symbol and its value. , buttons enables to change current
parameter value and button is for moving on to next parameter:
Parameter order:
• „HI” temperature’s hysteresis (setting range: 2 – 9 °C) how much temperature must fall from
set temperature to turn the fan on.
• „Po” temperature of pump activation - preset 65°C (setting range: 65-90°C), after room
thermostat connection, change temperature below 65°C, till „rP” parameter appears on
display– Ekoster based on signal from room thermostat will automatically control pump’s
operation.
• „DT” temperature’s difference from operation threshold: at what temperature’s difference
controller will enter or status (setting range: 10-30°C) for example DT=20,
set temperature = 70°C, after falling below 50°C
( temperature decreased below DT parameter) controller will wait 30 minutes and will turn off
fan signaling it with diode.
• „┌ ┐”: fan power in percentages (3: 30% - 10:100%)
A T T E N T I O N !
It is recommended to set DT=20 HI=2°C and boiler’s temperature 90°C for connection
with accumulation tank.

7
4. Gasication process
Gasication boilers must operate in specied conditions.
Optimal boiler’s temperature is 85 - 90 °C. At lower temperatures gasication process is not
running correctly – boiler cannot reach nominal power and fuel usage is relatively higher. Wood
drying in loading chamber is crucial stage in gasication process – at lower temperatures boiler
cannot reach right temperature and gasication process is disturbed. Main source of heat in
Orlan boilers is gas ame created during gasication process, if main conditions won’t be met for
proper gasication process, amount and quality of ame will be inadequate.
Essential factor inuencing right gasication process is quality, moisture content and type of
burned wood. The best is hardwood (beech, oak, harnbeam) with moisture content 15-20%.
Usage other types of wood like spruce is acceptable, however heat exchanger pollution will
increase and time between boiler stoking will decrease. In order to determine proper moisture
content it is recommended to use moisture meter (pic. 3)
Appropriate wood assures correct boiler operation. Usage of wood with different parameters
other than recommended will affect proper work of boiler.
Tree’s chopping off
Optimum humidity
Outside drying
- in months
Wood humidity [%]
Pic.2 Wood humidity chart.
Pic.3 Moisture meter

8
5. Boiler start-up
Before boiler start-up it is advisable to check tightness of screw connections (leakages), level of
water in installation and properly set controller’s parameters.
5.1. Lightning up
In order to light up in the boiler:
1. Turn off controller.
2. Push in the chimney ap ( combustion duct open).
3. Open upper door.
4. Put the paper, small pieces of wood and wood logs directly on the nozzle.
5. Light the paper and close the upper door.
6. Half-open bottom door to ensure natural draft.
7. Wait 15-20 minutes to create ember layer ( should be at least 10 cm of ember layer covering
whole loading chamber).
8. Fully load the boiler with wood; put the wood logs along the loading chamber.
9. Close hermetically upper and bottom door.
10. Pull chimney ap rod (chimney ap closed) and turn the fan on.
ATTENTION!
It is forbidden to turn the fan on with opened upper door.
ATTENTION!
Take into consideration loading chamber depth while stoking the boiler. Wood
dimensions larger than recommended may cause troubles during closing the upper
door. It is necessary to avoid closing upper door with force – it may damage the door.
ATTENTION!
Acceptable wood humidity of 25% is reached after 12 months of drying.
Recommended level of 15-20% is reached after 24 months of seasoning (Pic. 2)
5.2. Fuel stoking.
Burning period in Orlan boilers is 7-12 hours. In order to avoid discomfort with fuel stoking it is
recommended to check fuel level each 5-7 hours. To check fuel level and possibly stoke the boiler
one should:
1. Turn off the controller.
2. Open the chimney ap.
3. Open upper door and start stoking fuel.
4. Close upper door, chimney ap and turn on the controller.
Keep in mind that during the fuel stoking some wood parts may get between ue ange and
chimney ap which would make impossible to close the ap tightly.
During fuel stoking (it is recommended to stoke the fuel after wood fully burned till glow layer) stir
with poker ash deposited on the sides of loading chamber.

9
ATTENTION!
Lack of fuel in the boiler is signaled with diode.
5.3. Boiler turning off.
To turn off the boiler press main switch on the controller or automatically in case of lack of fuel.
5.4. Optimal boiler’s temperature.
Main factor assuring trouble-free boiler operation is to keep right boiler’s temperature.
Proper wood gasication process is assured when boiler’s temperature is at least 85°C.
During big demand for heat it is possible that return water temperature will decrease. If return
water temperature will be more than 20°C lower than hot water from the boiler, loading chamber
may partially be cooled, that leads to drop in gasication efciency. As a result pitch deposits on
the sides of boiler in larger amounts. To avoid this issue, boiler installation should have small water
circulation. This can be achieved through 4 way valve installation (or 3 way valve with accumulation
tank) on the hot water outlet. Four way valve works on principle of hot water mixing with return
water from heating installation. Right setting of hot and return water streams owing through the
valve, ensures that return water to the boiler is high enough not to drastically lower temperature in
gasication chamber – in this way gasication process proceeds correctly. Temperature’s difference
15-20°C does not strain boiler body, consequently prolonging boiler lifespan.
5.5. Power outage and pump failure.
During boiler operation power outage or pump failure may happen. If failure occurs during
heating season, it is necessary to stop stoking the boiler. It is forbidden to run the boiler with
opened chimney ap. Boiler operation on full draft results in its uncontrolled work that may lead
to boiler’s overheating.
In case of boiler installation in forced circulation, power outage causes fan and pump turning off.
Poor heat collection from heating installation (radiators) may also leads to boiler’s overheating.
W celu uniknięcia problemu przegrzania kotła zalecane jest zainstalowanie dodatkowego
odbiornika ciepła w postaci podgrzewacza wody użytkowej.
In order to avoid boiler overheating it is recommended to install additional heat collector ex. water
heater, which ensures minimal power output collection ex. 5kW for boiler 25 kW. Thanks to that
boiler overheating is avoided.
ATTENTION!
In order to secure boiler and electric installation against sudden rise of voltage in the
grid, it is recommended to use surge protectors like power strips.

10
6. Maintenance
6.1. Boiler maintenance.
Boiler needs to be serviced for idle time ( summer season, absence of user).
Sides of loading, ash chamber, chimney ap and heat exchanger needs to be cleaned regularly (it
is advisable to burn softwood like spruce to remove pitch before summer season). After burning
softwood leave the boiler open – in this way damp is not condensing on the sides of boiler.
ATTENTION!
It is advisable to control the boiler annually in order to prepare it well for the next
heating season.
6.2. Fan’s conservation
Ash created during wood burning falls down through the nozzle to ash chamber, that’s why it is
advisable to remove the ash from bottom chamber. Each time before lightning up the boiler it is
recommended to clean loading chamber. Ash needs to be removed through the nozzle. Use the
tools supplied with the boiler.
Pitch is created during gasication process. Amount of created pitch depends on wood type,
humidity and water temperature coming out and into the boiler. It is recommended to clean
loading chamber at least once a month.
ATTENTION!
It is necessary to use clearing mechanism lever each time after stoking the boiler,
otherwise pitch may clogged turbulators.
ATTENTION!
To avoid accumulation of ash in bottom chamber especially at the back side below
heat exchanger pipes, it is necessary to remove the ash with boiler tools.
Particles in exhaust gases owing through the heat exchanger create on their surface deposit.
Deposition causes lowering of inner pipes dimension and lowering of heat exchange surface.
That is why it is necessary to clean heat exchanger pipes each time after boiler stoking with
cleaning mechanism lever.

11
Pic.4 Boiler tools.
6.3. Boiler tightness.
It is important to assure boiler tightness, mostly door tightness. Leaks cause that exhaust gases
escape to boiler room but most importantly it may leads to uncontrolled burning in the boiler. To
assure door tightness, silicone rope of upper door needs to be controlled and in case of damage
of silicone coat – replaced. Rope in bottom door must be greased ( at least once a month) with oil
or graphite grease.
To adjust boiler door one should
a) Remove the door
b) Loosen screw
c) Rotate both hinges 360°
d) Screw up the nut.
ATTENTION!
Door adjustment needs to be done on both hinges!
6.4. Fan maintenance.
It is important to keep the fan cleaned. Keeping the fan blades cleaned directly inuences boiler
and pump lifespan. It is recommended to take off front fan cover to remove ash that may leads to
fan power decrease and may damage the fan. It is acceptable to clean the fan blades with brush
with soft bristle.
blocking nut

12
SERVICE MANUAL
Contents
1. Installation .....................................................................13
1.1. Boiler-room ventilation.................................................14
1.2. Supply air ventilation .................................................14
1.3. Exhaust ventilation ....................................................14
1.4. Chimney connection ..................................................14
2. Technical data ..................................................................15
2.1. EKOSTER 2- technical data .............................................15
2.2. EKOSTER 2 – installation recommendations .............................15
2.3. EKOSTER 2 – electric scheme ..........................................17
2.4. Boiler dimensions.....................................................18
2.5. Technical data of the boiler .............................................18
3. Connection of the boiler .........................................................20
3.1. Accumulation.........................................................20
3.2. Boiler thermal protection ..............................................21
4. Troubleshooting ................................................................22
5. Ending .......................................................................23

13
1. Installation
Boilers should be installed according to binding rules and norms. The requirements of norm
PN 87/B 02411 according building of solid fuel boiler room, norm PN 91/B 02413 according
open system boilers’ production and norm PN-B-02414:1999 according to safety appliances in
pressurized systems should be taken into account.
These norms and rules should be followed, however, caution is required as national rules in
countries to which the product is sold may replace above mentioned norms.
In case of boiler assembly outside Poland, rules and norms should be followed according to solid
fuel boiler assembly in countries in which the boiler is sold.
Gasication boilers ORLIGNO 200 are adjusted for installations in pressurized systems.
1. Boiler room height should be at least >2,2 m for easier boiler cleaning.
2. Distance from boiler room walls should allow for free access to boiler sides and should be at
least as shown on picture „ORLIGNO 200 placement”.
3. Boiler room should be free of any electric installation not intended for boiler installation.
Pic.1 ORLIGNO 200 placement.

1.1. 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.
1.2. 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.
1.3. 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.
1.4. Chimney 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 200’s need to be connected to chimney system
protected against condensate soaking.
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:
ORLIGNO 200 18, 25, 40 kW - 200 mm
ORLIGNO 200 60, 80 kW - 210 mm
Chimney should lead above the roof. Chimney outlet location is dependent on roof slope and its
combustibility.
Eko-Vimar Orlański Ltd. recommends to install draught regulator which stabilizes chimney draught.
14

1. Temperatures range -9 °C +99 °C
2. Temperatures settings +60 °C do +97 °C
3. Pump temperatures range +65 °C do +90 °C
4. Blow-through settings
work time 0-90 seconds
pause 1-15 minutes
Blow-through turn off P-0
5. Hysteresis od 2 °C do 9 °C
6. Input power: fan 100 W
pump 100 W
7. Voltage AC 230 V AC, 50 Hz
8. Input volatge 275 VA
9. Fan power in percentages % x 10 (setting range 30 % to 100 %)
10. Relative air temperature ≤95 %
11. Protection class IP 40
12. Insulation class I
13. Ambient temperature 0-40 °C
14. Disconnection type full
15. Electric protection 2 x 1.25 A (fusible)
2. Technical data
2.1. EKOSTER 2 – technical data
2.2. EKOSTER 2 – installation recommendations
1. Controller is adjusted to cooperate with solid fuel boilers.
2. Controller must be installed by qualied person.
3. Controller cannot work at temperatures higher than 40°C.
4. Controller should be protected against water ooding and steam condensation.
5. Controller should be installed and used according to handling rules with electric equipment.
6. Fuse burning as a result of wrong pump connection is not considered as a warranty matter.
7. It is recommended to check controller’s settings before lightning up of the boiler.
8. Controller is equipped with two 1,25 A fuses
15

16
Pic.2 Ekoster 2 – back panel view.
ATTENTION!
It is necessary to unplug controller when pump wires connection or fuse replacement.

17
2.3. EKOSTER 2 – electric scheme.

18
2.4. Boiler dimensions.
2.5. Technical data of the boiler.
Nominal power output kW 18 25 40 60 80
Hot water outlet (overall height) B- mm 1315 1315 1575 1555 1555
Return water inlet C- mm 230 230 220 200 200
Drain valve height D- mm 140 140 140 140 140
Flue height E- mm 960 960 1210 1160 1170
Casing width G - mm 600 600 600 740 740
Overall lenght H - mm 1060 1060 1040 1360 1720
Hot water outlet I - mm 320 320 310 580 610
Flue diameter J - mm 200 200 200 210 210
Overall width K - mm 670 670 670 810 810
Cooling coil tappings (height) L- mm 110 0 110 0 1330 1310 1300
Hot and return water diameter Q - inch 2” 2” 2” 2” 2”
Cooling coil diameter R - inch 3/4” 3/4” 3/4” 3/4” 3/4”
Drain valve diameter S - inch 1/2” 1/2” 1/2” 1/2” 1/2”

19
Power kW 18 25 40 60 80
Power range kW 7-18 10-25 16-40 24-60 32-80
Efciency %91
Boiler class (EN 303-5) 3
Boiler weight kg 546 546 634 1037 1242
Water capacity dm3
l
75
75
75
75
93
93
180
180
205
205
Volume of loading chamber dm3
l
120
120
120
120
185
185
310
310
465
465
Loading hole width/lenght mm 260/432 260/432 260/432 285/580 285/580
Burning period h7-12
Wood logs lenght cm 50 50 50 75 100
Humidity - recommended %15-25
Power range for every kind of fuel:
Billets kW 7-18 10-25 16-40 24-60 32-80
Fuel usage for power:
- nominal
- minimal
kg/h 6,8
3,9
8,2
5,7
10,1
7,9
15,1
11,9
19,8
15,8
Max working pressure bar 3
Minimal return water temperature °C 60
Flow resistance
- t = 20 K
- t = 10 K
mbar
mbar
1,2
4,0
1,4
4,3
1,6
4,9
1,7
4,9
1,6
4,8
Temperatures setting range °C 60-97
Protection level of controller IP 40
Voltage/Frequency V/Hz 230/50
Auxiliary power W50 50 50 100 100
Exhaust gases parameters (at nominal
power):
- temperature
- stream
°C
kg/s
160
0,0066
160
0,0088
160
0,0144
160
0,0216
160
0,0272
Exhaust gases parameters (at minimal
power):
- temperature
- stream
°C
kg/s
160
<0,0066
160
<0,0088
160
<0,0144
160
<0,0216
160
<0,0272
Required chimney draft mbar
Pa
0,15-0,20
15-20
Min water pressure in cooling coil bar 2
Cooling coil water temperature °C 10
Recommended capacity of accumulation
tank l750-1500 1000-2000 2000-3000 3000-4000 4000-5000
Main construction parameters’ listing

20
3. Connection of the boiler.
Necessary part of gasication boiler installation is four way mixing valve ( if boiler is connected
without accumulation tank). Hot water supplied from boiler is mixed with return water from
installation in four way valve in order to avoid „cold return” and keep stable, high temperature in
the boiler – at the same time temperature of water feeding heating installation is high enough to
maintain comfort conditions in rooms. Valves can be installed in open or pressurized systems.
1. Four way mxing valve,
2. Circulation pump
3. Room thermostat
4. ORLIGNO boiler with Ekoster 2
5. Radiator
6. Water heater
7. Differential valve
8. Pressurized vessel
9. Hot water outlet
10. Cold water inlet
11. Safety group
Pic.3 Connection scheme of ORLIGNO boiler with four way mixing valve and water heater.
3.1. Accumulation
The most effective way of utilizing gasication process is boiler installation with accumulation
tank.
Such a installation allows to decrease fuel usage for about 40%. Gasication process ( if proceeds
in optimal way) generates huge amount of wood gases, while demand for heat from heating
system is changeable.
Gasication process is only to some degree controlled, uctuation in heating system are much
more dynamic – possibility to overheat rooms or removal of extra heat (exhaust gases) through
the chimney. Installation with accumulation tank allows to collect whole created gas ( after
burning) in form of heat in the tank. Heating system is feed with accumulation tank for up to 48 h(
depends on accumulation tank capacity and thermal conditions – on the assumption that 1 kw of
installed power = 55 litres of water in tank .
Boiler installation with accumulation tank allows to prolong boiler lifespan.