Eko-Vimar Orlanski Orlan 18 Manuale utente

Owner’s Manual

Wood gasification boilers from 18-80 kW (85-275 kBtu)

rlan

SO 9001

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.

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.

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

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.

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.

5. Technical Specifications for the Orlan EKO Line

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

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.

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

hydrometer is used to measure the

moisture content of wood.

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