Installation, Operation And Maintenance Manual Wood gasification boilers from 18-80 kW (85-275 kBtu) Orlan® ISO 9001 Often copied but never duplicated UL/CSA approved by Omni-Test Laboratories, Inc.
Table of Contents Introduction and Important Information Introduction............................................................................................................................................. 4 Wood Gasification.................................................................................................................................. 4 Cutaway Diagram and View of Gasification Flame................................................................................ 5 Safety.............
Troubleshooting Troubleshooting Guide......................................................................................................................... 23 Technical Data RK-2001UA Controller.......................................................................................................................... 25 Boiler....................................................................................................................................................
Introduction And Important Information Thank you for purchasing an Orlan EKO Wood Gasification boiler. This boiler is designed to operate in the 91% to 95% overall system efficiency range when properly installed and operated and burning sufficiently dry wood fuel. The boiler has been independently tested and has been certified to conform to ISO 9001, TUV, CE. Testing and certification for (North American certifications) UL 391, ETL and CSA are in progress.
Two views of the gasification chamber and nozzle burning at near 2,000 degrees, F. 9 1 Important Components 1.) Controller 2.) Loading Door 3.) Secondary Air Adjust 4.) Ash Door 5.) Forced Draft Fan 6.) Primary Burn Chamber 7.) Secondary Chamber 8.) Heat Exchanger Tubes 9.) Supply Water Outlet 10.
! Warning ! Attention to safety is critical in all phases of boiler system design, installation, operation and maintenance. Safety You must keep safety in mind during the installation, operation and maintenance of your boiler and heating system. During installation the boiler and some components may be heavy or sharp. During operation the boiler and associated plumbing can be very hot which can cause burns or fires. The proper methods need to be used while loading wood when the boiler is hot.
Expansion Tank 1,000 Gallon Hot Water Storage Tank EKO 60 with 1,000 gallons of pressurized hot water storage and expansion tank. be inspected and approved by qualified professionals (i.e., a chimney sweep, a licensed plumbing and heating contractor, electrician, etc.). Another important requirement is that the chimney and connecting pipe need to be insulated for safety and to prevent condensation and a reduction in the draft caused when the gas in the chimney cools too much.
• • • is preferable to have a non-electric dump zone valve. A primary loop pump must feed all zones. Each boiler should be connected to the heating capacity which equals that of the boiler output. To protect the boiler against low-temperature corrosion the end-user should assure return temperature does not reach lower than 120F. One way to do this is by installing a four-way mixing valve.
Packing List The complete EKO Orlan boiler is shipped from the warehouse in one crate. Inside the crate you will find: The boiler. The cleaning tools (two or three, depending on the model). Inside the boiler you will find: This manual. Pressure relief valve (30 psi). Refractory gasification bricks (two or more pieces that form a tunnel under the nozzle or nozzles). Boiler Set-Up The boiler is shipped completely assembled and ready for installation and use.
Cooling Pipe Outlet Pressure relief valve drain piping Photograph showing one of the cooling pipe outlets and the pressure relief valve piped to within 6 inches of the floor with rigid copper pipe. Four-Way Mixing Valve A four-way mixing valve is an essential component of any EKO boiler installation.
! Warning! EKO wood gasification boilers should be installed in accordance with local codes. The boiler should be part of a closed, pressurized system with a pressure relief valve, expansion tank and if possible, a hot water storage tank. System with gravity-feed overheat protection. 1. Outdoor thermostat 2. Feed water temp. sensor 3. Four-way mixing valve 4. Mixing valve controller 5. Circulating pump 6. Room temp. sensor 7. Boiler 8. Radiator (in living space) 9. Water heater vessel 10.
Piping Design Possibilities 12 EKO BOILER MANUAL
Filling the Boiler and Heating System. Plain water is the recommended fluid for filling the EKO boiler and system it is connected to. The easiest way to fill the boiler and heating system is through a regulator connected to the home’s domestic water supply. The regulator steps the pressure down to 12 psi, so that the boiler can be filled at the appropriate pressure. This connection to the home water supply can be left open or closed with a manual valve after the system is filled.
Controller Features, Specifications and Operation Front panel of the RK-2001UA controller. Features 1. Master switch 2. Display, indicating boiler temperature and parameters (Fahrenheit) 3. Room thermostat indicator 4. Boiler thermostat knob 5. Circulating pump indicator 6. STOP/choose paraters/clear alarms button 7. START/choose parameters button 8. Start programming in service mode/confirm settings button 9.
How the Controller Works Boiler's temperature setting from 140 up to 176F 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 194F. This causes the fan to switch on. Low fuel indicator If the boiler temperature does not reach 140F after 30 minutes the indicator (8) and the fan will turn on.
Boiler Operation ! Warning ! Please read the following items. • Please read the section about maintaining the boiler in the summer months carefully. Failure to protect your boiler from condensation during the warmer months can result in damage and voiding of your warranty. (See page 22) • The section about operating the boiler in the event of a power failure is important for the safety of the boiler itself as well as ensuring that you have heat during a power failure.
! Warning! Using fuel types other than the dry wood specified in the Wood Moisture Content chart may result in unpredictable operation and poor efficiency. Neither the manufacturer nor Eco Heat Sales are responsible for problems resulting from unapproved fuels. 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.
Ideally, the wood in the upper combustion chamber should be burned down to Warning! embers before reloading The yellow “no fuel”the lightboiler. indicates when the boiler needs to be reloaded. ! Warning ! ! Boiler Shutdown The boilerThe turnsyellow off in two ways: manually when the power switch the controller is turned off, or au“no fuel” light indicates when the on boiler needs to be reloaded. tomatically when the wood supply has burned out.
Example: The EKO 25 is an 85K Btu boiler burning wood at 25% moisture content with 0.04iwc draft in the chimney. By this calculation, the secondary air setting should be 3.5 turns out. Blower inlets (top) and secondary air adjustment on an EKO 60. View behind the blower plate of the primary air inlets (top) and the secondary air tubes and valves.
Maintenance Proper maintenance of the boiler is essential for reliable, efficient and safe operation. This will also contribute to longer boiler service life. There are specific maintenance guidelines to follow during the heating season, and others to follow during the off-season. Standard Cleaning Tools These are the tools supplied with a boiler. Note that the EKO Super 1 model is not shipped with a heat exchanger tube cleaner.
Cleaning the EKO Standard Model Heat Exchanger Tubes On the EKO standard models, the heat exchanger tubes should be manually cleaned every two weeks using the following procedure. (Note: The bi-weekly cleaning routine described as follows is not necessary with the Super 1 models). 1. Remove the back panel and unscrew the heat exchanger cover plate with a metric wrench (from 13 to 17mm, depending on the model). IMPORTANT: Use care when screwing and unscrewing the retaining nuts.
! Warning! Chimney inspection and maintenance is a critical part of any wood burning maintenance schedule. Inspect it at least once annually—preferably at the start of heating season. Clean as needed. Creosote - Formation and Need for Removal When wood is burned slowly, it produces tar and other organic vapors, which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow-burning fire.
Troubleshooting Problem Boiler does not reach the temperature needed Cause Remedy Suggested Problems starting fire Refer to page 17 Wood too moist Use properly seasoned wood Primary air conduit choked Call service – not covered by warranty Secondary air conduit choked Call service – not covered by warranty Smoke coming out of the cleaning cover Smoke coming out while loading (a little smoke is acceptable) Smoke coming out of the loading door when closed Smoke tube of heat exchanger choked Clea
Problem Regulator does not work Blower fan not working Blower fan making noise Blower fan working poorly Explosion or puffing in the firebox Cause Remedy Suggested No power Check the wiring and circuit breakers Fuse damaged Replace fuse – not covered by warranty Live wire conduit damaged Inspect and repair wire Temperature sensor damaged Call service Regulator damaged Call service Thermal protection engages Investigate reasons for boiler overheating No power in regulator Check fuse and wi
RK-2001UA Controller Technical Data Technical data for the RK 2001 controller.
Boiler Technical Data Boiler Type um ORLAN 18 ORLAN 25 ORLAN 40 ORLAN 60 ORLAN 80 Power kW 4+18 5+31 8+40 15+60 25+80 Efficiency % 85 91 91 91 91 Weight – STANDARD * lb 870 1124 1279 2006 2458 Weight – SUPER * lb 937 1157 1312 2150 2568 Casing height – approx A-inch 44 52.7 61.8 60.4 62 Heating water outlet height approx B-inch 47.6 51.4 61.4 62 64 Heating water inlet height approx C-inch 8.5 9.3 8.7 8.3 9.6 Waste outlet height - approx D-inch 5.
Boiler Type um Chimney flue needed Pa Electric protection range Max pressure ORLAN 18 ORLAN 25 ORLAN 40 ORLAN 60 ORLAN 80 15-20 IP 40 IWC 3.44 Average fumes temperature F 464 320 Note : Approx – approximate dimensions not for construction. Note: Approx — approximate dimensions are not are for construction Note: IWC or = iwc = inches of column water column. Note: IWC or iwc inches of water 5.
Warranty — USA and Canada Warranty – USA and CANADA Eco Heat Sales warrants the residential steel boiler identified below and the hot water tank or coil, and the cast iron doors and grates against defects in material and workmanship under normal home use and service, TO THE ORIGINAL PURCHASER AT THE ORIGINAL INSTALLATION SITE in the United States and Canada, under the following terms: BOILER BODY LIMITED 20 YEAR WARRANTY Subject to all the limitations stated below, Importer warrants the steel boiler body (
fan not working no power in regulator check fuse and wiring fan damaged call service - fan’s replacement regulator damaged functioning or malfunctioning of any such component. Repairs or replacements caused by thermal shock. call service fan blocked inspect and clean the fan PURCHASER'S LEGAL RIGHTS: This warranty gives you specific call legalservice rights, and you may also have other bearings damaged - fan’s replacement rights which may vary from state to state.
