Installation & Operating Instructions
Contents
1. 92018 QHVOSA3 t 3208 S IOHLNOO QNY 2N349S JH 000000 3d o 3 NOLLWNISWOO ONITOALNOO No AVIS NOLLVNISINOO 10 NOISSIWSNYHL TVIH3S NOLLVNIBINOO NOLLYNIAWOO lg 4 TVLLNSH3HHALNI LLNV IVILN3Y33 o HJTIOHLNOO H LNI LLNV IHL NI HBLLIWSNYHL No 10 NOLLVNIAWOO A ONITIOHLNOO HOSSHJOHdOHOIW 3d o No o NOLLVNIBINOO YOLIYAY 10 R TVLLNSH3HH3LNFLLNV AlddniS HAMOd vSC LX asn4 HOLIMS NIYIN HOSN3S AdNlVHHdWAiL 331104 1845 2 4 Boiler dimensions ORLAN SUPER 96kW 1804 5 734 i i Me IO 1368 714 B 1807 E N O 2 5 Boiler dimensions ORLAN SUPER 130kW i 1879 5 797 5 534 98 4 1845 1441 1432 300 890 um 2 5 Technical data of the boiler Power Power range Efficienc Boiler class EN 303 5 Boiler weight Water capacity Volume of loading chamber Loading hole width lenght Burning period Wood logs lenght Humidity recommended Power range for every kind of fuel Billets Fuel usage for power nominal minimal Max working pressure Minimal r2. 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 flap rod chimney flaps 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 23 is reached after 12 months of drying Recommended level of 15 20 6 is reached after 24 months of seasoning Pic 2 gt gt gt 5 2 Fuel stoking Burning period in ORLAN SUPER 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 flaps 3 Open upper door and start stoking fuel 4 Close upper door chimney flaps and turn on the controller Keep in mind that during the fuel stoking some wood parts may get between flue flange and chimney flap which would make impossible to close the flap 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 ATTENTION Lack of fuel in the boiler
3. EKOSTER 2 installation recommendations 2 9 EKOSTER 2 electric scheme uuo cuum oo wowoooocoooococo amp d coooco ta REGA 2 DOE dimen ONS had ben FRR had au das 2 5 Technical data of the boller 422 mr rem oem E e RR nn o 3 Connection of the boiler ee eee ranr 3 1 Accumulation gn eee ee ee ae TE T TOILET 3 2 Boiler thermal protection 21554 su SAR RE REE SEERE D e S A Troubleshooting sedoso a ia SENO asus case E rs daa bos BA ZA 1 Installation Boiler 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 Gasification boiler ORLAN SUPER is adjusted for installations in pressurized systems 1 Boiler room height should be at least gt 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 pictur
4. O are for blow through time setting in seconds Press dtill diode starts blinking With buttons G O set blow through pause in minutes stop TUL Press From now on controller at temperatures higher than set one will activate blow through ATTENTION 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 e turn off controller e turn on and during controller s software displaying ex 3 4 press and hold EQ button until parameter HI will display Controller displays in turn symbol and its value O buttons enables to change current STOP JUL parameter value and button is for moving on to next parameter Parameter order e HI temperature s hysteresis setting range 2 9 C how much temperature must fall from set temperature to turn the fan on e Po temperature of pump activation pre set 65 C setting range 65 90 C after room thermostat connecti
5. ocean eus een ir mde cad debe aes Rd E ea 3 2 Principle Ol WORK cy oso duran OEG GRP EO pur URS era diia acid gak 3 3 Description of the COMORES cabean ea ers ban MUERE ESSE 4 3 1 Front panel of EKOS TER 2 uoo seria dar ras dae son nenen Bank ou Wani 4 3 2 Main functions Of E KOS TER 2 weed d sai kaan wali magang dd 4 4 Gasilicallom POCS S cea pid ore zai cca wh ai OW aa Pd SA Space oa Pri ds 7 5 Boiler star FUP Lasso te is i does aed bo do duka 8 Sl MOM ORATOR 8 FAN el SORG oo cowo cused omer deen endedake but SER nde nde tp ena 8 Da BONEY NNO O where eo xm ae ah nba Do Aa an Rat Eo ean indie 9 5 4 Optimal boilerstemperature u aaaaaaaaaaaaaa nawa aaa n mnn 9 5 5 Power outage and pump failure 0 0 0 cee eee nnn 9 TAMU STAI GS gon a a caf in Prae a oe nc cura i UR er db n ein ch i a c i cuni 10 6 1 Boiler real te Hell Te Bes os hei e deor e ORA e a ec CER ERROR soda Ea ed de wr c o 10 0 2 Boller cleanin datan ei d Wa E Oa eds d Wa ERE E 10 Dos Boiler tighiness ne ded pad De FEG TAR OGG FAA SAKE Ia ZA 11 6 4 Far maintenance Moon pace dei own ad ORA UR DR d 12 1 Boiler application Orlanski s gasification boiler ORLAN SUPER is designed to burn wood As a main fuel it is recommended to use wood logs with moisture content 15 2596 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 b
6. by a registered competent electrician and in accordance with the requirements of the latest issue of BS 7671 Commissioning and handover Ensure all parts are fitted in accordance with the instructions On completion of the installation allow a suitable period of time for any fire cement and mortar to dry out before lighting the boiler Once the boiler is under fire check all seals for soundness and that the boiler and water system are operating correctly Ensure that the flue is functioning correctly and that all products of combustion are vented safely to atmosphere via the chimney terminal On completion of the installation and commissioning ensure that the operating instructions for the boiler are left with the customer Ensure to advise the customer on the correct use of the appliance and warn them to use only the recommended fuel for the boiler Advise the user what to do should smoke or fumes be emitted from the boiler The customer should be advised about restricting access to the boiler by children aged and or infirm people Page 4 of 7 angus USER MANUAL FOR BATCH FED INDEPENDENT WOOD LOG FIRED BOILERS SUPPLEMENTARY OPERATING INSTRUCTIONS FOR THE UK MARKET TO BE READ IN CONJUNCTION WITH THOSE IN THE INSTRUCTION BOOKLET READ THE INSTRUCTION BOOK AND THESE INSTRUCTIONS CAREFULLY BEFORE USING THE BOILER WARNING NOTE Properly installed operated and maintained this stove will not emit fumes into the dwelling Occasio
7. is signaled with STOP diode 5 3 Boiler turning off To turn off the boiler press power switch on the controller or boiler is automatically turn off 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 gasification 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 gasification efficiency 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 flowing through the valve ensures that return water to the boiler is high enough not to drastically lower temperature in gasification chamber in this way gasification 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
8. to binding rules and norms in countries to which boilers are sold Part of chimney system connection boiler with chimney is called flue In order to lower flow resistance of exhaust gases this part should lead as a straight pipe with if necessary joints up to 45 Because of exhaust gases temperature ORLAN SUPER needs to be connected to chimney system protected against condensate soaking Chimney section should be round or close to sguare shape because of low flow resistance Chimney should lead above the roof Chimney outlet location is dependent on roof slope and its combustibility Eko Vimar Orla ski Ltd recommends to install draught regulator which stabilizes chimney draught Minimal flue diameter should be 300 mm Itis recommended to use chimney selection diagram acc to norm DIN 4705 300 20 250 20 20 Internal diameter of 799 chimney flue mm 150 20 300 100 20 90 250 20 80 20 70 20 60 200 20 50 20 40 20 35 180 23 30 22 EE a D 25 21 D JE O 20 D 15 20 2 5 160 c eo 1076 10 15 20 25 Chimney height m 2 Technical data 2 1 EKOSTER 2 technical data 4 Blow through settings 1 15 minutes Blow through turn off PO 6 Input power pump setting range 30 to 100 Lt Protection class O 12 Insulation elass S E 2 2 EKOSTER 2 installation recommendations
9. 1 Controller is adjusted to cooperate with solid fuel boilers 2 Controller must be installed by qualified person 3 Controller cannot work at temperatures higher than 40 C 4 Controller should be protected against water flooding 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 Itis recommended to check controller s settings before lightning up of the boiler 8 Controller is equipped with two 3 15 A fuses Max 100W Max 100W N I o LO gt o e A 230V 50Hz amp 230V 50Hz x x BG CONTROL Ba EKOSTER 2 AC 230V sota IP 40 PEPEPE x x LL LxXxNNN UWAGA PRZED ZDJ CIEM OBUDOWY LUB WYMIAN BEZPIECZNIKA OD CZY OD SIECI CAUTION TO PREVENT ELECTRIC SHOCK DO NOT REMOVE SCREWS ACHTUNG VOR DEMONTAGE DER ABDECKUNG DEN NETZSTECKER VOR STECKDOSE HERAUSNEHMEN Pic 2 Ekoster 2 back panel view ATTENTION It is necessary to unplug controller when pump wires connection or fuse replacement 2 3 EKOSTER 2 electric scheme LATLNO SNIIOHINOO dWAd LAILNO ONTIOHLNOD NVA ZHOS NOET OV HIMOd 14 1NI JOLVINDIY NOOY i TANVd 1OH LNO2 SS4300V 30INH4S Y NOILVNISINOO TIVLLN3H3H83 LNI ILLNV
10. 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 fired 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 e 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 e 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 e EKOSTER CONTROL co operation Operation description After switching on controller is in STOP which is signaled by adequate diode Operation starts after pressing EO or automatically when boiler s temperature increases above operating threshold temperature difference between set temperature and DT parameter set in the service menu Status STOP is automatically activated after 30 minutes since temperature decrease below operating threshold CONTROL
11. 6 Circulation pump 7 Room thermostat 8 Outlet for heating installation 9 Pressurized vessel 10 h d w mixing valve 11 Coil 12 Solar collector 13 Solar pump 14 Safety group Pic 4 Connection scheme of accumulation tank with solar collectors 3 2 Boiler thermal protection In connection with thermostatic valve BVTS it protects the boiler from overheating Cooling coil needs to be connected to cold water installation through thermostatic valve BVTS Cooling coil outlet should be directed to drains Cooling coil tappings 3 4 are located at the sides of the boiler Pic 5 Safety valve BVTS connection to the boiler 3 1 ORLAN SUPER boiler 2 Pressurized vessel 3 Radiator 4 Thermal valve ex BVTS 5 Four way mixing valve 6 Safety group 4 Troubleshooting Boiler cannot reach Wrong lightning up Check 5 1 Lightning up SEL TEMIRErANIE Too humid wood Humidity control use wood with proper parameters Clogged primary air channels Call service after warranty service Clogged secondary air pipes Call service after warranty service Polluted heat exchanger s pipes Call service after warranty service Unproper mix of air with wood Call service after warranty service gases Damaged nozzle Smoking from fan gasket Damaged fan loading door into the chimney chimney draft WKO Smoking from door Leakiness from door Used rope leak Rope replacement or call service
12. after warranty service Damaged door Door replacement Controller doesn t No voltage in the grid Check electric installation work Damaged fuse Fuse replacement Fan doesn t work Loud work of fan Weak work of fan Explosions In boiler Too big chimney draft above 20 Install draft stabilizer Pa Too dry wood humidity below Mix with wood with higher humidity content 15 Yo Polluted heat exchanger s pipes Clean pipes or call service 5 Ending oe e p Present appliance is marked according to European Directive 2002 96 EC on waste electrical and electronic equipment Symbol placed on the components or attached documents means that appliance is not classified as a household waste Scrapping should take place in special collection point in order to reuse electrical and electronic components EKO VIMAR ORLANSKI Sp z o o 48 385 Otmuch w ul Nyska 17b POLSKA woj opolskie T 48 77 400 55 80 81 400 55 91 F 48 77 439 05 03 400 55 96 E biuroQorlanski pl www orlanski pl
13. e ORLAN SUPER placement 3 Boiler room should be free of any electric installation not intended for boiler installation h 2200 Pic 1 ORLAN SUPER 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 ND 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 floor 2 Ventilating duct should have installed device for air flow control device shouldn t limit duct section above 1 5 Ventilating duct should be made of non inflammable material 1 3 Exhaust ventilation ND 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 inflammable material 2 Height of the boiler room min 2 2 m 1 4 Chimney connection Chimney ducts should be installed according
14. ecialist guidance and use appropriate protective equipment Metal Parts When installing or servicing this boiler care should be taken to avoid the possibility of personal injury BOILER PERFORMANCE Refer to the main instruction manual for details of the boiler s performance PREPARATORY WORK AND SAFETY CHECKS IMPORTANT WARNING This boiler must not be installed into a chimney that serves any other heating appliance There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to emit fumes into the room Chimney In order for the boiler to perform satisfactorily the chimney height must be sufficient to ensure an adequate draught of approximately 15 Pa so as to clear the products of combustion and prevent smoke problems into the room NOTE A chimney height of not less than 4 5 metres measured vertically from the outlet of the boiler to the top of the chimney should be satisfactory Alternatively the calculation procedure given in EN 13384 1 may be used as the basis for deciding whether a particular chimney design will provide sufficient draught The outlet from the chimney should be above the roof of the building in accordance with the provisions of Building Regulations Approved Document J Because the boiler runs at high efficiencies the temperature of the flue gases is at times lower than conventional solid fuel appliances Although it is not classed as a condensing appliance the low flue gas t
15. emperature results in condensation occurring within the flue Any chimney flue system must therefore be able to withstand the effects of condensate and operate under wet conditions designation letter W In addition it should be soot fire resistant and able to withstand the corrosive effects of flue products generated by solid fuels designation G and 3 respectively If installation is into an existing masonry chimney then it will require re lining with a liner meeting the specification described above Existing concrete or clay lined chimneys are not suitable for this boiler and must be lined as described above All installations must be in accordance with Building Regulations Approved Document J Any existing chimney must be clear of obstruction and have been swept clean immediately before installation of the lining system Where the chimney is believed to have previously served an open fire installation it is possible that the higher flue gas temperature from a closed appliance may loosen deposits that were previously firmly adhered with the consequent risk of flue blockage It is therefore recommended that the chimney be swept a second time within a month of regular use after installation If there is no existing chimney then any new system must be to the designation described above and in accordance with Building Regulations Approved Document J A single wall metal fluepipe is suitable for connecting the boiler to the chimney but is not suitable fo
16. eturn water temperature Flow resistance t 20K t 10K Temperatures setting range Protection level of controller Voltage Frequenc Auxiliary power Exhaust gases parameters at nominal power temperature stream Exhaust gases parameters at minimal power temperature stream Required chimney draft Min water pressure in cooling coil Cooling coil water temperature Recommended capacity of accumulation tank z RW KW d d m o 3 k kg h mbar mbar C p EM o O W ko m m m h W ar E W C Pa EE 38 4 96 3 1360 340 605 605 285 580 15 25 38 4 96 20 3 14 6 W co Ola I OJN O1 O1 IA N 60 97 230 50 150 170 0 0332 lt 170 lt 0 0310 0 22 2 Ir IN Or IN 4000 5000 52 130 9 380 605 52 130 24 5 19 5 60 1 6 4 60 97 IP40 230 50 9 160 0 0332 160 0 0332 5 0 2 10 3 Connection of the boiler Necessary part of gasification 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
17. for detailed operating instructions Frequency of cleaning ash and residues from combustion chamber and ash box The owner is required to regularly carry out this cleaning operation and the frequency will depend on the heating load When first put to use the boiler should be checked on a daily basis and experience will show how often this will eventually be required Remember also that during the main heating season the cleaning interval will shorten as the load on the boiler will be higher Recommended fuels The boiler is designed to burn wood logs only as detailed in the main instruction book Under no circumstances should you attempt to burn any other type of fuel Page 6 of 7 angus General Maintenance It is important that any glass or other decorative surfaces are kept clean using the appropriate cleaning materials and techniques as to not damage the internal or external finishes of the boiler Spare Parts For more information on obtaining spare parts please revert to the specific page of the manufacturer s original instruction manual or contact details provided HETAS Ltd Approval This appliance has obtained HETAS Ltd approval for burning wood logs only as specified in the main instruction manual Approval does not cover the use of other fuels either alone or mixed with the recommended fuel nor does it cover instructions for the use of other fuels Page 7 of 7 INSTRUCTION MANUAL Content 1 Boiler application ua 42
18. h 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 gasification 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 Particles in exhaust gases flowing through the heat exchanger create on their surface deposit Deposition causes lowering of inner pipes dimension and lowering of heat exchange surface Thatis why it is necessary to clean heat exchanger pipes each time after boiler stoking with cleaning mechanism levers which are placed on both sides of boiler at the back Pic 4 View on cleaning mechanism lever ATTENTION It is necessary to use cleaning mechanism levers that are positioned on both sides of boiler each time after stoking the boiler otherwise pitch may clogged turbulators that affects boiler efficiency and boiler lifespan 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 pl Pic 5 Boiler tools gt gt 6 3 Boiler tightness It is important to assure boiler tightness mostly door tightness Leaks cause that exhaust gases escape to boiler room but mo
19. 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 flap 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 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 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 flap 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 Boiler cleaning Ash created during wood burning falls down through the nozzle to as
20. nal fumes from de ashing and re fuelling may occur However persistent fume emission is potentially dangerous and must not be tolerated If fume emission does persist then the following immediate action should be taken a Open doors and windows to ventilate the room and then leave the premises b Let the fire go out c Check for flue or chimney blockage and clean if required d Do not attempt to relight the fire until the cause of the fume emission has been identified and corrected If necessary seek expert advice The most common cause of fume emission is flueway or chimney blockage For your own safety these Must be kept clean at all times IMPORTANT NOTES General Before lighting the boiler check with the installer that the installation work and commissioning checks described above have been carried out correctly and that the chimney has been swept clean is sound and free from any obstructions As part of the boilers commissioning and handover the installer should have shown you how to operate the boiler correctly Do not light the boiler if there is a possibility that any part of the heating system may be frozen Please make sure the ash pit door and the hopper lid charging door are firmly closed at all times whilst the boiler is in operation CO Alarm Your installer should have fitted a CO alarm in the same room as the appliance If the alarm sounds unexpectedly follow the instructions given under Warning Note above B
21. oiler Access Access to the boiler should be restricted for children aged and or infirm persons by way of a lockable door to the room in which the boiler is installed Chimney cleaning The chimney should be swept at least twice a year It is important that the flue connection and chimney are swept prior to lighting up after a prolonged shutdown period Where the chimney is believed to have a served Page 5 of 7 angus an open fire installation it is possible that the higher flue gas temperature from a closed e ae kr pra aig appliance may loosen deposits that were previously firmly adhered with the consequent risk of flue blockage It is therefore recommended that the chimney be swept a second time within a month of regular use after installation In situations where it is not possible to sweep through the boiler the installer will have provided alternative means such as a soot door After sweeping the chimney the boiler flue outlet and the flue pipe connecting the boiler to the chimney must be cleaned with a flue brush Periods of Prolonged Non Use If the boiler is to be left unused for a prolonged period of time then it should be given a thorough clean to remove ash and unburned fuel residues Empty the hopper of unburned fuel To enable a good flow of air through the appliance to reduce condensation and to avoid door seals becoming stuck and subsequently damaged leave the filling hatch and combustion chamber doors slightly ajar The
22. oiler operation and achieving parameters featured in technical data It can also affect durability of the boiler and its components ATTENTION Using fuel different than the recommended is treated as wrong boiler operation and resultant performance irregularities cannot be reason for complaint ATTENTION 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 Gasification boilers utilize process of dry pyrolitic wood distillation During wood burning with limited amount of air wood changes into charcoal Gasification process creates large amount of wood gases which are directed to ceramic nozzle and burned in flame form in bottom chamber This method of wood burning efficiently make use of wood as a fuel STAGE FOUR Exhaust gases at temp 160 C are emitted through boiler flue 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 flame and heat emission at temp of 1200 C 3 Description of the controller 3 1 Front panel of EKOSTER 2 stop DIE Ge START gt e OKO SIE START Q O OB o O O Q STOP PUMP S OPERATION FAN S OPERATION FIRING UP MODE BLOW THROUGH INTERNAL TIME BLOW THROUGH OPERATING TIME Fi POWER SWITCH Pic 1 Controller s description
23. on change temperature below 65 C till rP parameter appears on display Ekoster based on signal from room thermostat will automatically control pump s operation e DT temperature s difference from operation threshold at what temperature s difference controller will enter STOP or START P 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 STOP diode e r fan power in percentages 3 30 10 100 ATTENTION It is recommended to set DT 20 Hl 2 C and boiler s temperature 90 C for connection with accumulation tank 4 Gasification process Gasification boiler ORLAN SUPER must operate in specified conditions Optimal boiler s temperature is 85 90 C At lower temperatures gasification 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 gasification process at lower temperatures boiler cannot reach right temperature and gasification process is disturbed Main source of heat in ORLAN SUPER boiler is gas flame created during gasification process if main conditions won t be met for proper gasification process amount and quality of flame will be inadequate Essential factor influencing right gasification process is quality moisture content and ty
24. open or pressurized systems 1 Four way mixing valve 2 Circulation pump 3 Room thermostat 4 OHLAN SUPER 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 ORLAN SUPER boiler with four way mixing valve and water heater 3 1 Accumulation The most effective way of utilizing gasification process is boiler installation with accumulation tank Such a installation allows to decrease fuel usage for about 40 Gasification process if proceeds in optimal way generates huge amount of wood gases while demand for heat from heating system is changeable Gasification process is only to some degree controlled fluctuation 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 1 ORLAN SUPER boiler with EKOSTER 2 controller 2 Thermoregulator 3 Accumulation tank 4 Heater 5 Three way mixing valve
25. orlanski the house INSTRUCTION MANUAL amp SERVICE MANUAL ORLAN SUPER 96 kW ORLAN SUPER 130 kW ISO 14001 ISO 9001 gt CE angus USER MANUAL FOR BATCH FED INDEPENDENT WOOD LOG FIRED BOILERS SUPPLEMENTARY INSTALLATION INSTRUCTIONS FOR THE UK MARKET TO BE READ IN CONJUNCTION WITH THOSE IN THE INSTRUCTION BOOKLET READ THE INSTRUCTION BOOKLET AND THESE SUPPLEMENTARY INSTRUCTIONS CAREFULLY BEFORE INSTALLATION These instructions together with those in the instruction booklet cover the basic principles to ensure the satisfactory installation of the boiler although detail may need slight modification to suit particular local site conditions In all cases the installation must comply with current Building Regulations Local Authority Byelaws and other specifications or regulations as they affect the installation of the boiler If any guidance contained within this manual contradicts advice given in the main manufacturer s instruction manual then the most stringent advice must apply It should be noted that the Building Regulations requirements may be met by adopting the relevant recommendations given in British Standards BS 8303 BS EN 15287 1 2007 as an alternative means to achieve an equivalent level of performance to that obtained following the guidance given in Approved Document J Please note that it is a legal requirement under England and Wales Building Regulations that the installation of the boiler is either carried o
26. pe 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 PC kg KCal KWh 4000 4 5 3700 4 3 3000 3 5 gt 2800 3 2 E gt ncn 2000 2 3 E Pic 2 Wood humidity chart E jet O 1000 1 2 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Wood humidity Outside drying in months p M MM Tree s chopping off 1812 6 8 0 Pic 3 Moisture meter 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 flap rod 2 combustion ducts open 3 Open upper door 4 Put the paper small pieces of wood and wood logs directly on the nozzles 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
27. r use as the complete chimney The chimney and connecting fluepipe must have a minimum diameter of 150 mm and its dimension should be not less than the size of the outlet socket of the boiler Any bend in the chimney or connecting fluepipe should not exceed 45 90 bends should not be used Combustible material should not be located where the heat dissipating through the walls of fireplaces or flues could ignite it Therefore when installing the boiler in the presence of combustible materials due account Page 2 of 7 angus must be taken of the guidance on the separation of combustible material given in Building e een bening Regulations Approved Document J and also in these boiler instructions If it is found that there is excessive draught in the chimney then a draught stabiliser should be fitted in the chimney above the chimney above the flue pipe connection Fitting of a draught stabiliser will affect the requirement for the permanent air supply into the room in which the boiler is fitted in accordance with Approved Document J see also combustion air supply Adequate provision e g easily accessible soot door or doors must be provided for sweeping the chimney and connecting fluepipe Hearth The hearth should be able to accommodate the weight of the boiler and its chimney if the chimney is not independently supported The weight of the boiler is indicated in the brochure The boiler should preferably be installed on a non combu
28. se actions will reduce the possibility of unnecessary damage and corrosion Extractor fan There must not be an extractor fan fitted in the same room as the boiler as this can cause the boiler to emit smoke and fumes into the room Aerosol sprays Do not use an aerosol spray on or near the boiler when it is alight Use of operating tools Always use the operating tools provided when handling parts likely to be hot when the boiler is in use Chimney Fires If the chimney is thoroughly and regularly swept chimney fires should not occur However if a chimney fire does occur turn off the boiler immediately and isolate the mains electricity supply and tightly close the doors of the boiler This should cause the chimney fire to go out If the chimney fire does not go out when the above action is taken then the fire brigade should be called immediately Do not relight the boiler until the chimney and flue ways have been cleaned and examined by a professional Permanent air vent The boiler requires a permanent and adequate air supply in order for it to operate safely and efficiently In accordance with current Building Regulations the installer may have fitted a permanent air supply vent into the room in which the boiler is installed to provide combustion air This air vent should not under any circumstances be shut off or sealed USER OPERATING INSTRUCTIONS Please read the important notices given above before referring to the main instruction book
29. socket which is located at the back panel of the controller is for connection of remote control EKOSTER CONTROL Buttons and O are for setting s changes During boiler operation pressing or O causes possibility to change desired boiler s temperature Pressing and withholding button causes increase of speed of temperature changing temperature below operating threshold turning on off of the controller signaled with diodes START or STOP ATTENTION 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 flashing PUMP P diode Function activates after 1 minute since controller s activation Pump activation in this mode causes that 14 days period is counted from 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 flashing STOP diode In such a case it is recommended to determine cause permanently In case of boiler sensor damage Blow through Buttons
30. st importantly it may leads to uncontrolled burning in the boiler To assure door tightness rope of upper must be greased at least once a 3 weeks if finally rope stays hard it must be 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 blocking nut ATTENTION Door adjustment needs to be done on both hinges 6 4 Fan maintenance ORLAN SUPER is equipped in 3 fans It is important to keep the fans cleaned Keeping the fan blades cleaned directly influences boiler lifespan It is recommended to take off front fan cover to remove ash deposited on fan blades that may lead 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 Clean the fan blades at least once a month Pic 6 Boiler view without fan cover SERVICE MANUAL Contents LS AAA PERTERRITI ESTA TT EE LETTO 1 1 Boiler room ventilation aco da od d id 3 acm d DR Ae a 1 2 Supply air ventilatio ours usan IS SUE Po LN LAGE GERE SEE dy 1 3 Exhaust VENS OR caca ben 95 29 9 440970 dd nada tou ue dr Me c GE dr d 14 Chimney CONFECIION savoir sac qubd b Ra lente p E ou 2 Technical data canes qs bla bdo coe ba der mo oi dr zda take dedii aed PE 2 1 EKOSTER 2 technical data 2 2
31. stible hearth of a size and construction that is in accordance with the provisions of the current Building Regulations Approved Document J The clearance distances to combustible material beneath surrounding or upon the hearth and walls adjacent to the hearth should comply with the guidance on the separation of combustible material given in Building Regulations Approved Document J and also in these boiler instructions If the boiler is to be installed on a combustible floor surface it must be covered with a non combustible material at least 12mm thick in accordance with Building Regulations Approved Document J to a distance of 30 cm in front of the boiler and 15 cm to each side measuring from the door of the combustion chamber Combustion air supply In order for the boiler to perform efficiently and safely there must be an adequate air supply into the room in which the boiler is installed to provide combustion air The provision of air supply to the boiler must be in accordance with current Building Regulations Approved Document J An opening window is not appropriate for this purpose Connection to chimney All boilers have a flue gas connector that allows connection to either a masonry chimney or a prefabricated factory made insulated metal chimney in accordance with the instructions This connection should never be reduced in diameter to lower than that of the flue gas connector of the boiler In some cases it may be necessary to fit an adap
32. ter in the connection pipe to increase the diameter to the required minimum diameter of 150 mm for burning wood fuel in accordance with UK regulations Any connections should be made gas tight and sealed with a suitable sealing agent such as fire cement Connection to the central heating system The boilers may be installed on either open vented or sealed fully pumped systems The water system must be properly vented and a double feed indirect cylinder to the current specification in issue BS 1566 Part 1 for double indirect cylinders is necessary where there is a combined hot water and central heating system During installation caution must be made on the need for a gravity heat leak radiator or towel rail to dissipate heat when the pump is off and the minimum load for this function The central heating system must be in accordance with BS EN 14336 2004 Heating Systems in Buildings Installation and commissioning of water based heating systems BS EN 12828 2003 Heating Systems in Buildings Design of water based heating systems BS EN 12831 2003 Heating Systems in Buildings Method for calculation of the design heat load and BS 6880 1988 Parts 1 to 3 Code of Practice for low temperature hot water heating systems of output greater than 45kW where appropriate Electrical connections Page 3 of 7 angus The installation of any electrical services during the installation of this boiler and the associated heating system must be carried out
33. ut under Local Authority Building Control approval or is installed by a Competent Person registered with a Government approved Competent Persons Scheme HETAS Ltd operate such a Scheme and a listing of their Registered Competent Persons can be found on their website at www hetas co uk CO Alarms Building regulations require that whenever a new or replacement fixed solid fuel or wood biomass appliance is installed in a dwelling a carbon monoxide alarm must be fitted in the same room as the appliance Further guidance on the installation of the carbon monoxide alarm is available in BS EN 50292 2002 and from the alarm manufacturer s instructions Provision of an alarm must not be considered a substitute for either installing the appliance correctly or ensuring reqular servicing and maintenance of the appliance and chimney system HEALTH AND SAFETY PRECAUTIONS Special care must be taken when installing the boiler such that the requirements of the Health and Safety at Work Act 1974 are met Handling Adequate facilities must be available for loading unloading and site handling Fire Cement Some types of fire cement are caustic and should not be allowed to come into contact with the skin In case of contact wash immediately with plenty of water Asbestos Page 1 of 7 angus This boiler contains no asbestos If there is a possibility of disturbing any asbestos in the E smile tora or gr being course of installation then please seek sp
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