Orlanski Orligno 600 User manual

ORLIGNO 600
INSTRUCTION MANUAL
& SERVICE MANUAL
HOT AIR BLOWER

INSTRUCTION MANUAL
Content
1. Hot air blower destination ........................................................3
2. Principle of work .................................................................3
3. Delivery specication.............................................................4
4. Description of the controller .......................................................4
4.1. Front panel of EKOSTER 3 ...............................................4
4.2. Controller switch-on....................................................4
4.3. Boiler working parameters setting and lightning up ........................4
4.4. Service mode - OPERATION PARAMETERS...............................6
4.5. Service mode - LANGUAGE .............................................9
4.6. Service mode - TEST ..................................................10
4.7. Service mode - SERVICE SETTINGS.....................................10
4.8. Room temperature controller ..........................................11
4.9. Temperature sensor damage ...........................................11
5. Boiler start-up ..................................................................13
5.1. Lightning up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2. Stoking hot air blower .................................................14
6. Maintenance ...................................................................15
6.1. Hot air blower maintenance ............................................15
6.2. Hot air blowers tightness ..............................................17
6.3. Fan maintenance......................................................17
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3
1. Hot air blower destination
Wood gasication hot air blower type ORLIGNO 600 is commonly used in industrial buildings or
other facilities as: warehouses,workshops, hangars,tents or outbuildings in places where there's
no heating installation. They're also used as a source of hot air in technological purposes in drying
houses of wood, grains, herbs or fruits.
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 !
ORLIGNO 600 is equipped in controller with wide temperature range t for every
purposes. Controller protects boiler against overheating with blow fan turning off and
back 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.
Heat is transfered through loading, burning chamber's walls and vertical heat exchanger to
circulating cold air between inner and outer ORLIGNO 600 bodies.
Heated air is then blown directly through outlet located in upper part of hot air blower to the
premise.
STAGE FOUR
Exhaust gases at temp. 160°C
are emitted through boiler ue
STAGE ONE
Wood drying
and degassing temp. 450°C
STAGE TWO
Burning of mixed wood gases with
secondary air at temp. 560°C
STAGE THREE
Burning up the ame and heat
emission at temp. of 1200°C

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4.1. Front panel of EKOSTER 3
4. Description of the controller
1. Device symbols
2. Display
3. Failure diode
4. Lightning-up / Pause / Return button
5. Increase temperature button
3. Delivery specication
ORLIGNO 600 hot air blower is delivered fully assembled, attached with screws to pallet and
wrapped in foil. ORLIGNO 600 comes with: set of cleaning tools 3 pcs and documentation (manual,
warranty card and quality certicate).
ORLIGNO 600 must be stored in dry and indoor places.
6. MENU button
7. Switch on / off
8. Decrease temperature button
9. 2,5 A fuses
10. Power supply socket for remote CONTROL panel

5
Display symbols description
front fan
heater
ATTENTION!
If the display of the controller doesn't turn on after switching on check the power
supply and fuses. If the fuses are damaged replace them both with new 2,5 A ones. If
the display is still off – contact the service.
A T T E N T I O N !
The fuses should be replaced with the controller switched off and unplugged.
4.2. Controller switch-on
Turn on the controller using on/off switch. The display should show the name of the controller and
the programme number.
Next the display will show the temperature from the sensor and the current working condition of
the connected devices.
4.3. Boiler working parameters setting and lightning up
During boiler operation the display shows the current temperature from the sensor.

By pressing or , it is possible to adjust the temperature setting of the boiler. Temperature
range from 50 °C to 120 °C .
ATTENTION!
Symbol or symbol on the display inform about the current temperature change
in the boiler means that the temperature is changing toward desired, means that
the temperature is decreasing towards the “HI” parameter.
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4.4. Service mode - OPERATION PARAMETERS
Fan hysteresis
This parameter shows how much the temperature must fall from set temperature to turn the fan
on. Temperature setting range: 0 °C to 9 °C.
Service mode is for setting changes and various parameters of the devices, e.g. fan and
heater operation. Press for a few seconds to enter service mode. The display will show
WORK PARAM. Further pressing results in entering settings for various operation
parameters. Use and buttons to change the selected parameters.

7
Blower modulation
This parameter turns on or off the modulation of the blower. With modulation ON (YES on the
display) the blower will slow down when the temperature reaches the set level and will speed when
the temperature falls down. Modulation OFF is signalled by “NO” on the display. Change range:
YES / NO.
ATTENTION!
Fan modulation is limited to hysteresis i.e. it works within the range of set boiler
temperature and set hysteresis parameter. Below hysteresis the fan works with
maximum set power.
Maximal fan power control
This parameter allows for setting the maximum fan power. Setting range: 30 % - 100 %
Minimal fan power control
This parameter allows for setting the minimal fan power. Setting range: 30 % - 70 %
ATTENTION!
Some fans do not turn on when the power is set at the lowest minimum. It is
recommended to increase the fan power in such cases.

8
Heater turn-on temperature
This parameter sets the temperature above which the heater turns on and starts operating. The
heater will turn off when the temperature falls down by 10 °C below the temperature set on the
sensor. Temperature change range: 40 °C to 120 °C.
Extinguish time control
This parameter allows for setting the fan operation (extinguish) when the temperature on the
sensor falls down to 30 °C . Setting range: 0 - 45 minutes.
Blow through - operation time
This parameter sets the fan time operations when the BLOW THROUGH function is on. Time range:
0 to 90 seconds.
Blow through - pause time
This parameter sets the pause time for fan operation (in minutes) between blowthroughs. Time
range: 1 - 60 minutes.

9
ATTENTION!
Blow through function is activated when the boiler reaches the set temperature.
ATTENTION!
Blow through will not activate when:
1. The temperature on the sensor will be 10 °C higher than the temperature set for the boiler.
2. The temperature will be lower than set by the “HI” parameter.
ATTENTION!
Setting the operation time for 0 will turn off the blow through function
Fan pause - stoking
Parameter setting the fan pause time necessary for stoking the boiler. Time range: 0:30 to 9:30
minutes.
4.5. Service mode - LANGUAGE
Service mode is for setting the language of the control panel. To enter the LANGUAGE service
mode press for a few second until WORK PARAM. shows on the display. Choose the language
(Polish/English/German) using button.

4.6. Service mode - TEST
This function helps with checking the accuracy of connection. To enter TEST service mode press
for a few seconds until WORK PARAM.; shows on the display. Choose TEST using button.
Each consecutive pressing the button will result in showing the symbol by the icon
representing individual device: fan / heater. By pressing or , buttons individual devices are
turned on / off.
4.7. Service mode - SERVICE SETTINGS
This function cancels all settings entered by the user and returns devices to service settings. To
enter SERVICE SETTINGS mode press for a few seconds until WORK PARAM. shows on the
display and then using button change to SERVICE SETTINGS screen.
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By pressing button again changes to service settings save screen. To save the changes press .

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4.8. Room temperature controller
To install the room temperature controller:
1. Remove circuit armature from the socket marked , on the back of the controller.
2. Install the room temperature controller in the socket.
4.9. Temperature sensor damage
If the temperature sensor is damaged the controller will STOP and - will appear on the display
instead of the temperature. The red diode FAILURE will be on .
It is possible to install room temperature controller which will turn on/off the heater depending on
the temperature in the room. The heater will turn on when the temperature on the sensor reaches
the minimal set level.

Temperature range - 58 °C to + 390 °C
Boiler temperature settings + 50 °C to + 120 °C
Heater temperature settings + 40 °C to + 120 °C
Smooth blow-through control yes
Controllable min. fan power 30 - 70 %
Controllable max. fan power 30 - 100 %
Fan hysteresis 0 °C to 9 °C
Heater hysteresis 10 °C
Blow-through control work time: 0 - 90 sec.
pause: 1 - 60 min.
Controllable boiler extinguishing time 0 - 45 min.
Input power fan: 100 VA / 230 V
heater: 100 VA / 230 V
Voltage AC 230 V, 50 Hz
Electrical protection 2 x 1,25 A
Relative air humidity < 95 %
Protection class IP 40
Insulation class II
Ambient temperature 0 °C to + 40 °C
Software class A
Operation type fan: 1Y
heater: 1B
4.10. Technical data of the controller
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4. Gasication process
Gasication hot air blower ORLIGNO 600 must operate in specied conditions.
Optimal hot air blower temperature is 85 - 90 °C. At lower temperatures gasication process is not
running correctly – hot air blower 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
hot air blower cannot reach right temperature and gasication process is disturbed. Main source
of heat in Orligno 600 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%. Lenght of
wood should be the same as depth of loading chamber. 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 dif ferent 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
Main fuel wood logs, wood in halves and quarters
alternative fuel small pieces of wood, shavings, briquettes
must be burned together with wood logs
lenght 50 cm
diameter 15 - 25 cm
moisture content 15 - 25 %
caloric value 4,1 - 4,4 kW
Fuel specication

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5.1. Lightning up
In order to light up in the hot air blower:
1. Pull in chimney ap lever (exhaust gases duct opened).
2. Open upper door.
3. Put papers, small wood pieces and light up.
4. Close upper door and open bottom one thus creating natural draft.
5. Wait 15-20 minutes to create ember layer covering whole upper chamber.
6. Fully load the chamber with halves of wood logs put along the chamber.
7. Close upper and bottom door.
8. Close chimney ap lever (IMPORTANT!).
9. Turn on fan on the controller by pressing .
Display will show informing about lightning up process.
ATTENTION!
It is forbidden to turn the fan on with opened upper door.
ATTENTION!
Take into consideration loading chamber depth while stoking the hot air blower. 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. Boiler start-up
Before rst start-up of Orligno 600 it is advisable to check:
-if there’s no ammable substances close to hot air blower
-tightness of connecting pipe between ue and chimney
-placement of bottom chamber’s rebricks as they must be placed directly under the nozzle hole
-if 230 V power plug is connected to socket
-if front fan is blowing the air to upper chamber through primary air channels located on front left
and right side of upper chamber (fan is activated with ).
-if front fan is blowing air through holes in nozzle

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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.
6. Maintenance
6.1. Hot air blower 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 hot air blower annually in order to prepare it well for the
next heating season.
5.2. Stoking hot air blower
Burning period in ORLIGNO 600 hot air blower 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 blower one should:- Turn the fan off before stoking the boiler by pressing which is signalled
on the display by along with the countdown to restart. Stoking time is set in the service mode
OPERATION PARAMETERS – see Fan Pause - stoking.
- Open chimney ap lever
- Open upper door and stoke upper chamber.
- Close the door, chimney ap and turn on the fan on the controller

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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.
Follow the steps of how to clean heat exchanger’s pipes:
1. Remove back upper heat exchangers panel.
2. Unscrew bolts holding heat exchangers' lid.
3. Clean each of pipes with round tools moving it up and down.
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.

17
1
2
3

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!
6.3. Fan maintenance
It is important to keep both fans cleaned. Keeping the fan blades cleaned directly inuences hot air
blower. 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 or vacuum cleaner.
Cleaning of both fans should be done at least once a year after or before heating season.
blocking nut
6.2. Hot air blower tightness
It is important to assure tightness, mostly door tightness. Leaks cause that exhaust gases escape
to boiler room but most importantly it may leads to uncontrolled burning. To assure door tightness,
rope of upper door needs to be controlled and qresed at least once a 2 weeks with any gresce or oil.
This assures that rope adhesives correctly to door frame. Hot air blower tightness can be assured
also by hinges regulation.

SERVICE MANUAL
Contents
1. Installation .....................................................................19
1.1. Hot air blower-room ventilation .........................................20
1.2. Supply air ventilation .................................................20
1.3. Exhaust ventilation ....................................................20
1.4. Hot air blower connection to chimney system ............................20
2. Technical data ..................................................................22
2.1. EKOSTER 3 – technical data ............................................22
2.2. EKOSTER 3 – installation recommendations..............................22
2.3. Technical data of heater ...............................................23
2.4. Electric scheme ......................................................24
2.5. Dimensions ..........................................................25
2.6. Construction of the wood gasication hot air blower ......................26
3. Troubleshooting ................................................................28
4. Ending .......................................................................28

20
1. Installation
Hot air blowers should be installed according to binding rules and norms.
Rules and norms should be followed according to solid fuel boiler assembly in countries in which
the hot air blower is sold.
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 600 placement”.
3. Boiler room should be free of any electric installation not intended for boiler installation.
Pic.1 ORLIGNO 600 placement