Orlanski ORLIGNO 400 User manual

ORLIGNO 400
INSTRUCTION MANUAL
& SERVICE MANUAL
ISO 9001ISO 14001

2 3
Content
1. Delivery ................................................................................................... 3
2. Boiler view after assembly .....................................................................................4
3. Pellet tank assembly ...........................................................................................5
4. Dimensions ....................................................................................................6
4.1. ORLIGNO 400 16kW ...........................................................................6
4.2. ORLIGNO 400 30kW ...........................................................................6
5. Technical data .................................................................................................7
6. Orligno 400 package assembly ...............................................................................8
7. Before starting of the burner ..................................................................................8
8. Fuel characteristics ............................................................................................8
9. Cleaning instructions ..........................................................................................9
10. Location and package installation ..........................................................................14
10.1. Boiler room recommendation ................................................................15
10.2. Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
10.3. Chimney system ..............................................................................15
10.4. Safe distance to inammable substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2 3
Thank You for choosing a ORLIGNO 400 pellet burner from Eko-Vimar Orlanski.
We ask you review this operating and installation manual before you start installing your new
ORLIGNO 400 pellet boiler in order to avoid harm to people and product.
We recommend that the boiler is installed by a licensed plumber.
This manual contains information that is protected under copyright law.
1. Delivery
ORLIGNO 400 package is packed on one pallet wrapped up with foil. External elements of ORLIGNO
400 are packed in cardbox:
- pellet tank with elastic pipe and clamps
- auqer with motoreducer
- documentation inside of the boiler
- cleaning tools are attached to the pallet
ORLIGNO 400 boiler
Pellet tank
Feeder

4 5
1. Boiler controller
2. Pellet tank
3. External auger
4. Feeding pipe
5. Burner
6. Lever for burner cleaning
7. Burner bin
8. Tube exchanger
9. Turbulators
10. Chimney ue
2. Boiler view after assembly

4 5
I x 1 M8 x100
Bolt
B x 12
Bolt
M5 x 16 C x 46
Washer
M5 D x 18
Washer
M8 E x 46
Nut
M5
F x 5
Nut
M8
Plug
G x 1 H x 1
Clamp
8 13
1
2
3
4
G
1
E
C
B
D
2
D
F
Bolt M8
3
C
E
B
I
F
D
D
H
4
x 3
x 1
x 1 x 1
A x 34
Bolt
M5 x 8
3. Pellet tank assembly

4. Dimensions
4.1. ORLIGNO 400 16kW
6 7
4.2. ORLIGNO 400 30kW

6 7
Type unit 16kW 30kW
Weight kg 142,5 190
Flue mm 133 155
Water outlet, return inch 1 1
Eciency %89,4 91,8
Power range kW 3,9-16 7,8-30
boiler class EN 303-5 3 3
Required draft Pa min 10 min 10
Max working pressure Bar 2,5 2,5
Water content l49 57
Max boiler temp. °C 80 80
Min boiler temp. °C 60 60
Flue gas temp.
nominal
minimal
°C 130-150
77
155-170
84
Flue gas ow
nominal
minimal
kg/h 33
13
60,1
19,6
Fuel usage
nominal
minimal
kg/h 4
0,8
7,5
1,5
5. Technical data

Mounting external equipment:
1. Attach burner plug to the burner socket (pic 1)
2. Assemble fuel tank acc. to enclosed manual.
3. Insert external feeder in to the tank:
4. Attach the elastic pipe between external feeder and the metal
connector. Tighten elastic pipe to feeder and metal connector with
clamp.
5. Make sure the elastic pipe is near vertical (no bends), so the pellets
drop directly into the hearth.
6. Attach the connector from the controller to feeder's motoreducer.
7. Fit the plug 230V to socket from the controller to the 230V socket.
6. Orligno 400 package assembly
pic. 1
8. Fuel characteristics - recommendations
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
7. Before starting of the burner it is necessary:
1. Check installation condition.
2. Fill in pellet to the tank.
3. Check if fuel contains any unwanted elements ( rocks, metal elements).
4. Connect burner's and feeder's plugs.
5. Turn on controller.
6. Feed fuel (SIMPLE MENU: Feed fuel: Yes) from the tank till it shows up on a burner.
7. Turn off fuel feed and hold ON/OFF button - boiler starts automatic lightning up.
ATTENTION!
Elastic pipe connected between burner and feeder must be under 45° angle so that pellets drops
feely to the burner!
8 9

9. Cleaning instructions
Cleaning should be done regularly and as needed.
The boiler should be cleaned weekly to achieve the best eciency.
This ensures the best fuel economy and operation.
You increase the cleaning interval if you use the best quality of pellets.
Maintenance - chamber cleaning
Disconnect burner plug from the burner and take out burner.
Clean burning chamber with poker from ashes.
8 9
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.

Remove the fi xing screw holding basket to the burner
Remove burner’s basket Clean burner body and basket
WARNING!
Check permeability of basket holes.
Maintenance – burner cleaning
Maintenance – heat exchanger’s cleaning
Unscrew upper cover Remove upper cover
Take out the burner
10 11

Unscrew upper exchanger cover
Pull out all turbulators Clean heat exchanger’s pipes and turbulators
10 11

12 13
WARNING!
If boiler is not used for over 14 days it is necessary to empty pellet tank and feeding
auger.
Cleaning of pellet tank:
Occasionally you have to empty the tank completely, in order to clean the area around the feeder inlet from
pellet dust.
Themoredustthere isinthetank andaroundthefeederinlet, may lead tofewer pillsinthefeederand theboiler
will come out of alignment with the risk of downtime.
How often to do tank clean, depends entirely on silo design and the quality of fuel.

12 13
ASSEMBLY OF CLEANING MECHANISM - OPTION

300
min 100
790
790
600 680
min
500
Recommended distances to the walls in the boiler room.
10. Location and package installation
14 15

14 15
10.1. 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
- Floorshouldbemadeofnonflammablematerialsorcoveredwith0,7mmsteelplateatminimum0,5mdistance
todooredges.Boilershouldbe locatedona nonflammablefoundation,lifted0,05mabovefloorlevel
- 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.
10.2. 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 insufficient access to fresh air.
10.3. Chimney system
Chimney draft:
If the chimney draft is exceeding 15 Pa, a draft stabilizer should be mounted in the chimney.
WARNING!
Bychimneytemperatuelessthan180°Catratedoutput,youshouldbeawarethatsmokedosenot
condensein the chimney asitgivessoot.Atparticularlylowsmoketemperature itmaybenecessaryto
put a ceramic or stainless steel sleeve in the chimney.
pic. Exemplary boiler connection to stainless steel chimney

Combustibility grade of building products Building products
A – non-burning sandstone, concrete, bricks, re plaster, Mortar, tile,
granite
B - hard burning cement board, berglass, mineral insulation
C1- hard burning beech tree, oak tree, plywood
C2 – middle burning pine, larch, spruce tree, cork, rubber oor cover
C3 – easy burning tarmac plywood, celuloids, polyurethane, Polystyrene,
polyethylene, plastic
User please remember:
- Only adult person acquainted with this manual may operate the burner It is forbidden for kids to stay in
close distance to burner without presence of adult person.
- If inammable gases penetrate boiler room during activities (varnishing, gluing) it is recommended to
turn o the burner.
- It is forbidden to use inammable substances for lightning up the burner, burner will light up
automatically.
- High risk of re exist when using open re or inammable substances close to installed boiler package.
- Burner should be turned o during maintenance (position OFF).
- Pay attention on hot burner’s surfaces – risk of burn.
- It is forbidden to lay inammable items on the burner or nearby.
- All defects should be removed at once.
- After heating season it is recommended to clean the burner and pellet tank thoroughly.
- Oversee the burner during power failure
- It is forbidden to manipulate with any electric parts or interfere in burner’s construction.
16 17
10.4. 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.

16 17
Controller's manual
Contents
11. Connection - electric scheme ..............................................................................19
12. Overview of the basic functions ...........................................................................21
12.1. Control panel .................................................................................21
12.1.1 The status LED ........................................................................21
12.1.2 Buttons............................................................................... 22
12.1.3 Graphic display ...................................................................... 23
12.2. Statuses of furnace .......................................................................... 23
13. Handling ...................................................................................................24
13.1. Navigation in the menu ......................................................................24
13.2. Starting regulator - ON .......................................................................24
13.3. Switching o the regulator - OFF.............................................................24
13.4. Time scheduling ............................................................................ 25
13.5. Service password............................................................................ 26
14. Simple menu ...............................................................................................27
14.1. Simple menu screens .........................................................................27
15. Main menu ................................................................................................ 29
15.1. Heating....................................................................................... 30
15.1.1 Selection of circuit ................................................................... 30
15.1.2 State .................................................................................. 30
15.1.3 Settings ...............................................................................31
15.1.4 Time program.........................................................................31
15.1.5 Service ................................................................................31
12.2. Hot water .....................................................................................33
12.2.1 Selection of circuit ....................................................................33
12.2.2 State .................................................................................33
12.2.3 Settings.............................................................................. 30
12.2.4 Time program........................................................................ 34
12.2.5 Service............................................................................... 34
15.3. Buer .........................................................................................35
15.3.1 State...................................................................................35
15.3.2 Settings. ..............................................................................35
15.3.3 Time program ........................................................................35
15.3.4 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
15.4. Boiler......................................................................................... 36
15.4.1 State.................................................................................. 36
15.4.2 Settings. ............................................................................. 36
15.4.3 Service............................................................................... 36

15.5. Settings .......................................................................................37
15.5.1 Date and time.........................................................................37
15.5.2 Language.............................................................................37
15.5.3 General settings ......................................................................37
15.5.4 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
15.6. Burner........................................................................................ 39
15.6.1 State.................................................................................. 39
15.6.2 Settings .............................................................................. 40
15.6.3 Service ............................................................................... 40
15.7. Alarms.........................................................................................41
15.7.1 Alarm codes...........................................................................41
15.8. Solar ..........................................................................................47
15.8.1 State...................................................................................47
15.8.2 Settings ..............................................................................47
15.8.3 Service ................................................................................47
15.9. Info...........................................................................................48
16. Expansion of the system - CAN bus ....................................................................... 48
16.1. Sonda Lambda................................................................................51
16.2. Solars .........................................................................................53
17. Specication................................................................................................55
18. Ending ...................................................................................................55
18 19

18 19
11. Connection - electric scheme
ORLIGNO 400 is equipped in boiler sensor. Boiler sensor is inserted into sleeve in boiler body together with STB
thermal protection. Burner contains termic sensor glued to burner body as a burn-back protection.
WARNING!
External sensors for installation control such as hot domestic water HW1 or central
heating CH1 are an option. They are not included in standard ORLIGNO 400 package.
The device supply voltage is ~ 230V/50Hz. Plug the power cord to the controller in accordance with the posted
signs.
Attach to the controller for operating the boiler sensors and actuators as needed. The drawings
shows the connection scheme of equipment. In the tables, a description of the inputs and out-
puts.
WARNING!
Under no circumstances connect the protective conductor (PE) with a neutral (N).
WARNING!
Wiring must be done with the device disconnected from the power supply.
Connections should be exercised by a person possessing adequate powers in this regard.

INPUTS
Description Explanation
Tboiler Boiler temperature sensor
Teg Exhaust gas temperature sensor
Tburner The temperature sensor burner
Thw The temperature sensor hot water
Troom Room temperature sensor / regulator (CTP)
Tch The temperature sensor central heating
Tout Outdoor temperature sensor (CTZ)
12V +12V output to supply optional equipment
5V +5V output to supply optional equipment
GND Mass electric to connect sensors
OUTPUTS
Description Explanation
1 (CH) Central heating circulating pump
2 (HW) Circulating pump for hot water
3 (Ign) Burner igniter
4 (Mo) Opening the central heating mixer
5 (Mc) Closing the central heating mixer
6 (Blo) Burner blower
7 (Ftan) Feeder tank, or if burning wood, it's blower
8 (Fbur) Burner feeder
STB Protection STB
NNeutral standing
N1 Neutral separable such as by STB
PE Protective
20 21
Recommended burner settings in BURNER/SERVICE
Type 16kW 30kW
air min (20%)
20 20
air max (100%)
50 70
feeding max (100%) 4 7,5
photo threshold 10 10
test fuel mass 20 20
fuel caloric value 4,5 4,5
fuel start - dose 55 55