Eko-Vimar Orlan Specifications

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.
1
Table of Contents
Introduction and Important Information
Introduction............................................................................................................................................. 4
Wood Gasification.................................................................................................................................. 4
Cutaway Diagram and View of Gasification Flame................................................................................ 5
Safety..................................................................................................................................................... 6
System Design and Installation
Chimney Requirements and Diagram.................................................................................................... 6
Hot Water Storage.................................................................................................................................. 7
Protecting the Boiler During Pump and Electrical Failures..................................................................... 7
Other Boiler Protection Considerations.................................................................................................. 7
The Importance of Boiler Placement and Location................................................................................ 8
The Role of Cumbustion Air................................................................................................................... 8
Packing List............................................................................................................................................ 9
Boiler Setup............................................................................................................................................ 9
Piping..................................................................................................................................................... 9
Four-Way Mixing Valve......................................................................................................................... 10
Gravity Overheat Protection Diagram...................................................................................................11
Incorporating Hot Water Storage Diagram............................................................................................11
Various Other Piping Possibilities......................................................................................................... 12
Filling the Boiler and Heating System.................................................................................................. 13
Connecting a Pump and Room Thermostat to the Controller............................................................... 13
Controller Features, Specifications and Operation
Controller Features............................................................................................................................... 14
Controller Functions............................................................................................................................. 14
How the Controller Works..................................................................................................................... 15
Operating Your Boiler
Before You Begin.................................................................................................................................. 16
Wood Fuel Considerations................................................................................................................... 16
Starting and Operating the Boiler for the First Time............................................................................. 17
Boiler Shutdown................................................................................................................................... 18
Operating Temperature......................................................................................................................... 18
Primary, Secondary and Blower Air Inlet Settings................................................................................ 18
Air Adjustment Guide............................................................................................................................ 18
What the Air Controls Do...................................................................................................................... 19
Maintaining Your Boiler
General Maintenance........................................................................................................................... 20
Standard Cleaning Tools...................................................................................................................... 20
Fan Maintenance.................................................................................................................................. 20
Routine Cleaning During the Heating Season...................................................................................... 20
EKO Super 1 Heat Exchanger Tubes................................................................................................... 20
Cleaning the EKO Standard Heat Exchanger Tubes........................................................................... 20
Maintaining Tight Seals........................................................................................................................ 20
Offseason Preparation.......................................................................................................................... 21
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EKO BOILER MANUAL
Troubleshooting
Troubleshooting Guide......................................................................................................................... 23
Technical Data
RK-2001UA Controller.......................................................................................................................... 25
Boiler.................................................................................................................................................... 26
Specifications and Dimensions............................................................................................................ 27
Warranty
EKO Warranty...................................................................................................................................... 28
Disposal and Recycling of Boiler Components
Notes on Proper Handling and Disposal of Boiler Components........................................................... 29
EKO Line Boiler
Manufactured by:
Eko-Vimar Orlanski
Nyska Street 17 b, 48-385 Otmuchów
Distributed by:
New Horizon Corporation, Inc.
Herold Bridge Rd
Sutton, WV 26601
www.newhorizoncorp.com
• DANGER: RISK OF FIRE OR EXPLOSION -- DO NOT BURN GARBAGE, GASOLINE, NAPHTHA, ENGINE
OIL, OR OTHER INAPPROPRIATE MATERIALS
• WARNING: RISK OF FIRE
DO NOT OPERATE WITH FLUE DRAFT EXCEEDING 0.085 INCHES WATER COLUMN
DO NOT OPERATE WITH FUEL LOADING OR ASH REMOVAL DOORS OPEN
DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN
MARKED INSTALLATION CLEARANCES
INSPECT AND CLEAN FLUES AND CHIMNEY REGULARLY
• CAUTION: HOT SURFACES
KEEP CHILDREN AWAY
DO NOT TOUCH DURING OPERATION
MAXIMUM DRAFT MARKED ON NAMEPLATE
SAVE THESE INSTRUCTIONS
EKO BOILER MANUAL
3
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.
As the owner you should familiarize yourself with the installation, operating and maintenance information included in this manual. Be sure to save it for future reference especially since it contains your
warranty information.
!
Warning !
There are a number of these Warning Alerts throughout this manual. Be sure that you
read, understand and follow each of them.
!
Warning !
All systems should be designed and installed by a professional contractor and installer
experienced and qualified in hydronic (hot water) heating systems. Local and national
codes for solid fuel boilers must be followed.
EKO Line boilers are versatile, efficient and environmentally friendly:
• home heating and domestic water heating; can work together with other heating systems.
• high efficiency: less wood needed.
• clean burning: no visible smoke when fully operating; environmentally friendly.
• safer: clean burning results in little or no creosote buildup with minimal risk of a chimney fire.
Wood Gasification
Downdraft wood gasification boilers work by what is known as the “pyrolytic wood distillation” process. Dry wood is burned in the (top) primary combustion chamber, where heat from the flame breaks
the wood structure down into charcoal and eventually, into combustible gas. This gas passes through
the ceramic nozzle (or nozzles, depending on the model) at the bottom of the primary combustion
chamber, where it is mixed with superheated air and burned cleanly at high temperatures (up to
2,000 degrees F) in the refractory-lined bottom chamber. This clean-burning flame produces little or
no smoke. This hot gas then exits the boiler through the heat exchanger tubes and into the chimney.
Gas which was 2,000 degrees in the secondary chamber is typically only 300 to 400 degrees when
it reaches the chimney, meaning that 1,600 to 1,700 degrees is being transferred into the hot water
jacket through the heat exchanger tubes.
A clean-burning flame which sheds most of its heat on its way through the heat exchanger is the definition of a very efficient boiler.
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EKO BOILER MANUAL
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.)Bypass Damper Lever
10
2
8
6
5
3
7
EKO BOILER MANUAL
4
5
!
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.
System Design
The plumbing diagrams in this manual are for basic information only and do not show all the valves,
vents, fittings, etc. that are normally included in a finished boiler installation, nor do they cover all possible installation options.
It is the responsibility of the installing contractor to see that all controls are installed, configured and
operating properly when the boiler installation is complete.
Chimney Specifications
The chimney or flue is one of the most critical factors in the successful operation of any solid fuel
heater, including your EKO Line boiler. A good chimney will provide a continuous and dependable
draft to pull the exhaust gases out of your boiler.The boiler must be connected to a tile-lined masonry
flue or to a Type HT approved chimney. Minimum required flue size is 8x8” with square tile or 8”
diameter round tile or stainless steel. No other appliance should be connected to this flue. The boiler
should be connected to the flue with the shortest, most direct run of black stove pipe. Maintain a minimum of 18” between the flue pipe and combustible surfaces. Prior to operation, the installation should
The chimney flue connected to the EKO boiler should conform to
the specifications specified below.
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EKO BOILER MANUAL
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. If there is still a problem with draft (too much or
too little), draft inducing fans or draft regulators may need to be considered.
Unit is not to be connected to a chimney flue serving another appliance.
Hot Water Storage
For the best results, the use of a heat storage tank is recommended. A properly sized storage tank
can cut wood consumption by as much as 40%. Hot water storage allows the boiler to run at optimum
capacity regardless of the demand for heat from the building being heated. The stored heat can be
recovered later, both stretching the time between boiler re-fuelings, and as an additional source of
heat on very cold days. Generally, the bigger the storage tank the better, as the boiler is most efficient
when running at full capacity. The rule of thumb on tank sizing is that 13 gallons of water can store
about 1KW of boiler heat. Using the EKO 25 as an example: 13 gal/1KW x 31KW = 421 gallons, 421
gallons x 91% efficiency = 383 gallon minimum size water tank. A hot water storage tank connected to
an EKO boiler can also be used to store hot water from a solar water heater.
Protecting the Boiler During a Pump or Power Failure
During the course of operating the boiler, there is always the possibility of a pump or power failure. It
is recommended that you install an auxiliary power supply (i.e. UPS) to power the boiler fan, pumps
and controller during a power failure. It is also a good idea to install a gravity feed storage tank above
the boiler. Typically, this would be a water storage tank connected to a normally-closed zone valve (or
at a minimum, a manual valve) that will allow hot water from the boiler to circulate into the tank in the
event of a power outage.
Other Boiler Protection Considerations
• Do not use self-contained non-electric zone valves on the main heating zone as it is to be used as
the overheat/dump zone. Such a valve would prevent the overheat control from cooling the boiler
when necessary.
• Do not use any radiant floor heat tubing that does not have an oxygen barrier otherwise you must
use a heat exchanger between the hard piping of the boiler and the radiant floor heat tubing.
• A backup power supply such as a UPS (battery-based Uninterruptible Power Supply) is required
to operate the primary loop pump and dump zone valve if it is of the electrically operated variety. It
EKO BOILER MANUAL
7
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.
Installation
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.
Location, Location, Location
You will need to have adequate room around the boiler for installation, operation, cleaning and maintenance. You will need plenty of room for loading the boiler and emptying the ash bin and room to
use the cleaning tools provided. You also need adequate clearances from combustibles. 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. The boiler must be positioned to provide minimal
clearances from combustibles and surfaces: Left and right side = 18,” top, rear and front = 36.”
The boiler can be placed in a utility room, basement or outbuilding, along with wood storage. Putting
the boiler in an outside location is recommended for easy access to wood storage, and to keep the
mess and flame out of the house.
The boiler must be located on a level concrete floor or an other non-flammable surface. Wood gasification boilers are heavy; be sure to consider the weight when planning the installation.
18”
36”
CAUTION: Do not store fuel within the
Boiler installation clearances or within the
space required for fueling, ash removal,
and other routine maintenance operations.
36”
18”
36” of headroom above the boiler
Recommended clearances.
Combustion Air
The boiler requires fresh air for combustion. It is critical not to starve the boiler of air, as the air supply
affects the quality of the burn as well as the strength of the chimney draft. If any fans are used in the
room where the boiler is located, they should be installed so as not to create negative pressure, i.e.,
they should not be pulling air from the room. Likewise, you do not want too much positive air pressure, as it can cause the boiler to burn out of control. You may need to pull outdoor combustion air
into the room if there are backdrafts, insufficient draft or improper combustion, among other problems.
You can easily check this by opening a window or door to see if the problem goes away.
Install in accordance with Appendix G of CAN/CSA-B365-M91.
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EKO BOILER MANUAL
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. The boiler should be
inspected inside and out for any defects or damage that may have occurred in shipping. After the
boiler is placed in its permanent location and before the first firing, the refractory tunnel will need to be
positioned directly under the nozzle or nozzles, so that the flame shoots directly down into the trough.
Piping
The direct connections to the boiler will be similar no matter which piping system you select (page
12). A detailed listing of pipe fittings, isolation valves, etc. is not part of this manual. If you have questions about designing your system, seek the advice of a hydronic heating professional.
However, some important piping considerations are included below:
A tee must be connected to the 2” NPT water inlet on the rear bottom of the boiler (return). In one port
of the tee install a drain valve that is piped to a floor drain. In the other port of the tee install a line to
the outlet of the circulating pump, upon which the inlet is connected to the outlet port of a 3- or 4-way
mixing valve. One inlet of the mixing valve is fed from the heat zone piping return lines. The other
inlet of the mixing valve is fed from a tee connected to the boiler outlet and the heat zone supply line.
The purpose of this valve is to prevent cold water from entering the boiler, which can result in thermal
shock causing mechanical warping and cracking, as well as creating condensation inside the firebox,
which will result in corrosion inside the boiler.
Connect another tee to the 2” NPT water outlet on the top of the boiler (supply). In one port of the tee
install the supplied pressure relief valve. Be sure to pipe the outlet of this valve with hard pipe (copper
or black iron) to within 6 inches of the floor, and be sure there are no shut-off valves or other obstructions on the pipe. When this relief valve opens, it means that the boiler pressure has reached or
exceeded 30 pounds per square inch. The steam and/or water released needs to flow freely and the
pipe must be no more than 6 inches from the floor to prevent injury to anyone nearby. In the other port
of the tee install a line to the tee connected to the boiler outlet and the heat zone supply line.
Connect a line from the building water supply through a back flow preventer valve to the boiler INLET
line. Water should only be introduced to the boiler when its temperature is below 160F.
There is a 3/4” NPT pipe sticking out each side of the boiler near the top. This is an emergency boiler
cooling system not used in North American installations. The outlets can be covered with 3/4” NPT
pipe caps with a 1/4” diameter hole drilled in each one. The caps cover the sharp threads and the
holes keep pressure from building up in the pipe during boiler operation. This system is independent
from the pressure vessel, so there is no boiler water involved.
EKO BOILER MANUAL
9
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. When properly
installed, it allows hot supply water to be automatically mixed with cooler return water to avoid low
return later 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
and can be used in either gravity or pumped hydronic systems.
10
EKO BOILER MANUAL
!
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. Differential valve
11. Pressure tank
12. Warm water exit
13. Cold water entry
System with hot water storage tank.
1. Boiler
2. Mixing valve
3. How water storage tank
4. Electric heating element
5. Three-way mixing valve
6. Circulating pump
7. Room temp. sensor
8. Return water
9. Mixing valve controller
10. Pressure tank
11. Outdoor temp sensor
12. Mixing valve
13. Feed water temp sensor
EKO BOILER MANUAL
11
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. The advantage to leaving it open is that any water lost
is immediately made up and the system stays full of water at all times, including occasions when the
pressure relief valve opens. The disadvantage to leaving the water connection open is that tap water
contains oxygen, which will corrode the boiler and other components over time if enough oxygen is
routinely let in, say by a leak.
If the use of glycol is desired for freeze protection, be sure to use non-toxic hydronic heating system
antifreeze, available from plumbing and heating supply outlets. Follow the directions carefully. The
use of automotive glycol is not recommended, in part because it is toxic and can present a serious
public health risk under some circumstances. For that reason, it is against code to use automotive
glycol in hydronic heating systems connected to a public water supply.
Connecting a Pump and Room Thermostat to the Controller
There are several electrical terminals on the back side of the RK-2001UA 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 the various electrical connections, switches and dials on the bottom of the
controller, as shown in the diagram below. It is always a good idea to check with your EKO dealer or
distributor to determine the proper connections for your system.
RK-2001UA Connection Scheme
EKO BOILER MANUAL
UM-1 Module Connection Scheme
13
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. Notes
Controller Functions
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EKO BOILER MANUAL
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.
Fuel shortage indicator
If the boiler does not reach 140F 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 149F. It will then run
until the temperature declines to 140F
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 140 and 149F).
“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.
!
Warning!
The main circulating pump on the system should be connected directly to the RK2001UA controller to assure proper operation and water circulation. This will help prevent overheating and result in the best performance.
1 // 2
EKO BOILER MANUAL
15
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. (See page 13)
• CAUTION: Do not use any flammable liquid (gasoline, lighter fluid, etc.) to help start or maintain a
fire in your boiler as this can result in serious injury and property damage.
•
CAUTION: Do not burn Garbage, Gasoline, Naphtha, Engine Oil, or other inappropriate materials.
• Be sure to keep all combustibles outside of the fire clearances as specified. (See page 8)
• Make sure that the nozzle does not become plugged with ash.
• See table of set up values for draft requirements during operation. (See page 18)
Wood Fuel Considerations
Dry firewood wood is the recommended fuel source for the EKO boiler. The optimum moisture content of the wood used to fuel the boiler should be between 15% and 20%. 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 hardwood.
The best way to determine wood moisture content is with a moisture meter. As a general rule, hardwood cut, split and stacked for
one year under cover is usually
Wood Moisture Content
ready for burning in an EKO
boiler. Wood properly stored for
two years is best. The manufacturer and distributor cannot
be responsible for problems
related to using wood that is
not adequately dry or dense.
The length of the wood pieces
should be at least two inches
shorter than the depth of the
firebox.
16
EKO BOILER MANUAL
!
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.
Starting and Operating the Boiler for the First Time
Before firing up the boiler for the first time, the installation should be inspected and approved by a
qualified individual (plumbing and heating contractor, electrician, etc.). The system should be full of
water and vented and all other settings checked and tested, especially the pressure relief valve.
When starting the boiler from a cold start, the following steps should be followed in sequence:
1. Switch off the controller power.
2. Push the bypass damper lever forward to open the burning chamber bypass.
3. Put paper, very dry kindling and a few larger pieces of dry wood into the burning chamber.
4. Start the fire.
5. Open the bottom combustion chamber door to provide a natural draft.
6. Let the fire burn for 10-15 minutes (WARNING!! NEVER leave the boiler unattended in this state.
7. Add more wood.
8. Wait another 15 to 20 minutes for a charcoal layer to accumulate.
9. Close both upper and lower doors.
10. Pull the bypass damper closed (toward you) and switch on the controller power.
11. Ensure that gasification is occurring;*
12. Repeat steps 1 and 2.
13. Fill up the entire upper combustion chamber with wood.
14. Repeat steps 9 and 10
A properly sized and installed EKO gasification boiler should require loading every 8-12 hours, depending on the heat load and fuel being burned.
It is important to avoid obstructing the chimney bypass damper with wood in the combustion chamber
when loading fuel. Ideally, reloading should occur when the fire has burned down to embers.
!
Warning!
Never turn on the controller power when the upper door is open.
Never force the fuel loading door closed. Doing so may damage the door or other parts
of the boiler. Use only properly-sized firewood.
*Gasification should begin at this point, although it may take a few minutes of operation to become
fully engaged. Gasification is occurring when 1.) you hear a soft rumble above the sound of the
blower; 2.) little or no smoke is being produced from the chimney; and/or, 3.) flame (and no smoke) is
visible coming from the nozzle when you open the gasification (bottom) chamber door.
Blue smoke coming from the chimney after gasification is initiated indicates wood that is either too
wet or a nozzle that is not covered with coals. If you know the wood is dry and you’re seeing blue
smoke, turn off the fan, open the bypass damper, open the fuel loading door and move the wood
around with the poker to better position the coals over the nozzle (or nozzles).
EKO BOILER MANUAL
17
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. NEVER turn the controller off for extended periods
when the boiler contains burning fuel, as doing so could cause to it overheat. If you want to shut down
Boiler
Shutdown
the
boiler,
set the controller setpoint to minimum and let the fuel burn out.
The boiler turns off in two ways : Manually when the power switch on the
Operating
controllerTemperature
is turned off, or automatically when the wood supply has burned out.
Maintaining
the the
proper
temperature
theextended
water in theperiods
boiler during
operation
is verycontains
important. For
NEVER turn
controller
offoffor
when
the boiler
proper
gasification
to
occur,
the
boiler
water
temperature
should
be
140F
or
greater.
burning fuel, as doing so could cause to it overheat. If you want to shutdown the
boiler, set the controller setpoint to minimum and let the fuel burn out.
At times, such as when there is a large call for heat, the return water temperature may become too
low. This can result in poor gasification and decreased efficiency, as well as creosote buildup in the
Operating temperature
gasification chamber, heat exchanger tubes and chimney. Low temperature return water entering the
Maintaining the proper temperature of the water in the boiler during operation is
boiler can also shorten the life of the boiler. The return water temperature should not be allowed to
verybelow
important.
gasification
to occur,
the
water
drop
140F. ThisFor
canproper
be achieved
with a properly
installed
3- boiler
or 4-way
mixingtemperature
valve.
should be 140F or greater.
Primary, Secondary and Blower Air Inlet Settings
t times,
such
as when there
large
for
theinvolves
returnsetting
waterthree air supply
AAcritical
phase
of successfully
settingisupaan
EKOcall
boiler
forheat,
operation
openings,
as
listed
below
and
shown
in
the
photographs
on
the
facing
page:
temperature may become too low. This can result in poor gasification and
1.
Primary Airefficiency,
Setting
decreased
as well as creosote buildup in the gasification chamber, heat
2.
Secondary tubes
Air Setting
exchanger
and chimney. Low temperature return water entering the boiler
3.
Blower
Inlet Setting
can
also Air
shorten
the life of the boiler. The return water temperature should not
be allowed to drop below 140F below the supply water temperature.
The following chart will help you determine how to set each one, depending on the model of boiler
and the variables affecting its operation, specifically wood moisture content and chimney draft:
EKO Boiler Air Adjustment Guide
Table of set up values for EKO line boilers.
Primary air opening (mm)
Model /
BTU
Output
Number of turns for secondary air
% of air blower opening
Chimney draft 0.04
IWC
Chimney draft 0.08
IWC
Chimney draft 0.04
IWC
Chimney draft 0.08
IWC
Chimney draft 0.04
IWC
Chimney draft 0.08
IWC
Wood Moisture %
Wood Moisture %
Wood Moisture %
Wood Moisture %
Wood Moisture %
Wood Moisture %
15 20 25 30 35 15 20 25 30 35 15 20 25 30 35 15 20 25 30 35 15 20 25 30 35 15 20 25 30 35
E18
65k BTU
9
9
10 11 12
9
9
9
10 11
3
3
3
3.
5
4
3
3
3
3
3.
5
30 30 30 30
4
0
30
30 30 30 30
E25
85k BTU
9
9
10 11 12
9
9
9
10 11
3
3
3.
5
3.
5
4
3
3
3
3.
5
4
50 50 50 60
7
0
50
50 50 50 60
E40
137k
BTU
9
10 10 11 12
9
9
10 10 11
3
3
3.
5
4
4
3
3
3.
5
3.
5
4
10 10 10 10
0
0
0
0
1
0
0
10
0
10 10 10 10
0
0
0
0
E60
205k
BTU
9
9
10 11 12
9
9
9
10 11
3
3
3.
5
4
4
3
3
3
3.
5
4
50 50 60 70
8
0
50
50 50 60 70
E80
275k
BTU
9
9
10 11 12
9
9
9
10 11
3
3
3.
5
4
4
3
3
3.
5
3.
5
4
10 10 10 10
0
0
0
0
1
0
0
10
0
10 10 10 10
0
0
0
0
18
22 // 34
EKO BOILER MANUAL
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.
What the Air Controls Do
The sliders on the blower (or blowers, depending on the model) determine how much air is available
to both primary and secondary combustion chambers. These openings are the sole source of air for
all combustion in the EKO boiler.
The primary air inlets determine how much air is available in the upper (primary) combustion chamber, where the fuel undergoes pyrolysis.
The secondary air inlets reulate how much air goes into the steel tubes (shown in the photograph),
where it is superheated before being used by the nozzle (or nozzles) to achieve secondary combustion (gasification).
Proper adjustment is critical to optimum boiler peformance. Smoke coming out of the chimney (if dry
wood is being burned and the fuel is properly positioned over the nozzle), usually indicates that not
enough air is reaching the secondary air tubes.
Note:
The steel plate upon which the fan (or fans) is mounted can be removed with 12 sheet metal screws
to gain access to the primary air inlet sliders (right photograph). When replacing the plate, be sure to
apply even pressure to all the screws to insure that the gasket forms a consistent seal. Failure to do
so will allow smoke to leak around the gasket and into the boiler room.
EKO BOILER MANUAL
19
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.
Poker
Ash Rake
Heat Exchanger Tube
Cleaner
Fan Maintenance
The blower fan (or fans) is an essential part of boiler operation, and should be kept clean. It is advisable to monitor the fan’s condition and clean it from time to time with a soft bristle brush.
!
Warning!
Operating the boiler with the bottom door open can cause the blower fan to overheat.
Routine Cleaning During the Heating Season
Ashes produced in the firebox during boiler operation fall down through the nozzle into the lower gasification chamber. During fuel loading, any ash remaining in the upper combustion chamber can be
pushed down through the nozzle with the tool provided, using care not to damage the nozzle. Accumulated ash should be cleaned out of the lower chamber as needed, typically every 3-5 days.
Disposal of Ashes - Ashes should be placed in a metal container with a tight-fitting led. The closed
container of ashes should be placed on a noncombustible floor or on the ground, well away from all
combustible materials, pending final disposal. Other waste shall not be placed in this container. If the
ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the
closed container until all cinders have thoroughly cooled
EKO Super 1 Model Heat Exchanger Tubes
The EKO Super 1 model boilers are equipped with a lever-operated heat exchanger cleaning device
consisting of spiral steel elements (turbulators) that clean the tubes as they are moved up and down.
Vigorously moving the handle back and forth either before or after each fuel loading will help assure
that the heat exchanger does not become clogged with creosote, soot or ash. The moving turbulators
knock any residue that has accumulated in the tubes back down into the ash pit/secondary combustion chamber, where it can be cleaned out with the ashes. The lever should not be operated while the
chimney bypass damper is open.
20
EKO BOILER MANUAL
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. Lubricate the threads before removing the nuts, and avoid excessive force when
tightening them back down.
2.Clean each heat exchanger tube for its entire length, using the tool provided. Be sure that soot and
creosote do not accumulate at the bottom of the tubes. Clean any soot that has accumulated in the
back of the boiler behind the tubes.
3. To facilitate cleaning, it is a good idea to burn dry potato skins (about 10 liters) in the boiler a day
or two prior to cleaning. The starch in the potato skins acts as a catalyst, allowing the boiler to burn
off accumulated soot and creosote more easily.
The heat exchanger tubes are susceptible to ash, soot and creosote buildup, which diminishes their
ability to transfer heat, making the boiler less efficient. A good way to monitor their condition is with an
instack probe thermometer. Dirty tubes will result in higher temperatures (above 350-400 degrees, F)
at the chimney outlet.
Maintaining Tight Seals
It is very important to maintain tight seals on the doors, heat exchanger cover plate and the firebox
bypass chimney damper. Poor seals can result in smoke and gases leaking out of the boiler and lead
to uncontrolled burning which may cause the boiler to overheat. The fiberglass rope used to seal both
doors and the heat exchanger cover should be inspected regularly and treated with graphite or some
other lubricant (i.e. motor oil or WD-40) as needed, to keep them flexible.
Over time (typically one heating season) the rope seals on the doors can become flattened through
normal use. When this occurs, the door hinges can be adjusted to compensate for the new shape of
the sealing rope, as follows:
1. Remove the door.
2.Loosen the cap.
3. Turn the hinge 360 degrees.
4. Tighten the blocking nut to block the hinge retaining screw.
!
Warning!
The upper and lower hinges should be
adjusted at the same time.
Blocking Nut
EKO BOILER MANUAL
21
!
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. As a result, creosote residue accumulates on the flue lining. When ignited, this
creosote makes an extremely hot fire. The chimney and chimney connector should be inspected at
least twice monthly during the heating season to determine if a creosote buildup has occured. If creosote has accumulated it should be removed to reduce the risk of a chimney fire.
CSA Suggestions:
Establish a routine for the storage of fuel, care of the appliance, and firing techniques.
Check daily for creostoe buildup until experience shows how often cleaning is necessary
Be aware that the hotter the fire, the less creosote is deposited, and that weekly cleanings may be
necessary in mild weather, even though monthly cleaning may be enough in the coldest months.
Have a clearly understood plan to handle a chimney fire.
Prolonged Power Failure
The boiler air intake flap is closed when fan is not in operation and therefore not designed to operate
in event of power failure. A water circulation loop should be installed that would dissipate at least
10% of the estimated rated heat output of the boiler should be installed and only made inoperative
by a deliberate manual action. The minimum pipe size should be 3/4” diameter with a room ambient
temperature of 65F and a mean water temperature of 180F. The loop should be positioned above the
boiler with feature that promote natural thermal circulation of the water. The recommended piping be
such that excessive pressure will not be developed in any portion of the boiler. See page 12 for piping diagrams.
Off Season Preparation
Acids produced during the woodburning process can form when exposed to moisture inside the firebox, heat exchanger tubes and secondary combustion chamber. It is important that the boiler be properly prepared for the off season (summer) idle period. The upper and lower combustion chambers,
heat exchanger tubes and chimney bypass damper should all be thoroughly cleaned of creosote, soot
and ash. After the boiler is cleaned, both doors should be left open to avoid condensation.
22
EKO BOILER MANUAL
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
Clean with supplied cleaning
shield or call service – not
covered by warranty
Wrong regulation of the air
and wood gas
Call service – not covered by
warranty
Nozzle damaged
Replacement part – not
covered by warranty
Fan's gasket damaged
Replacement – not covered
by warranty
Fan damaged
Replacement – not covered
by warranty
Leak on a seal rope
Repair/replace rope or call
service – not covered by
warranty
Seal rope worn
Rope's replacement – not
covered by warranty
Cover warped – overheating
Replace cover or call service
– not covered by warranty
Strong winds blow the smoke Consider installing a special
back into the chimney
chimney cap – not covered by
warranty
Inadequate chimney
Consult a chimney
maintenance professional
(chimney sweep)
Leak on a seal rope
Adjust door hinge per
instructions
Seal rope worn
Replace rope or call service –
not covered by warranty
Door damaged
Replace door – not covered
by warranty
1 // 3
EKO BOILER MANUAL
23
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 wiring
Fan damaged
Call service – fan
replacement
Regulator damaged
Call service
Fan blocked
Inspect and clean the fan
Bearings damaged
Call service – fan
replacement
Condenser damaged
Call service – fan
replacement
Fan clips loosened
Check, turn the clips tight
Fan blades dirty
Clean and check
Debris in fan cover
Clean and check
Dirty fan blades
Check and clean
Creosote on the fan cover
Check and clean
Problems with startup
Refer to page 17
Chimney draft too low (below Rebuild chimney. Consider
0.40”wc)
use of WKO exhaust fan
Chimney draft too intensive
(over .080”wc)
Use exhaust regulator
Wood too small or too dry
Mix with larger humidity fuel
as to increase humidity level
(should be about 15-35%)
Clogged heat exchanger
tubes
Clean the exchanger or call
service – not covered by
warranty
2 // 3
24
EKO BOILER MANUAL
RK-2001UA Controller Technical Data
Technical data for the RK 2001 controller.
Power
230V +/- 10%
Rate supply voltage (with no fan)
< 4VA
Temperature measurement range
32 - 210 +/-1 F
Temperature measurement sensors
KTY81 210
Temperature regulation range
140 – 176 F
Electrical protection (fuse)
1A / 220V
RK-2001UA Controller Service Parameters
1 // 2
EKO BOILER MANUAL
25
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
5.7
5.7
5.1
5.7
6.9
Chimney conduit height approx
E-inch
34.3
37.8
48
46
47.6
Casing width - approx
G-inch
21.5
23.6
23.6
29.1
29.1
Depth - approx
H-inch
37.8
40.9
40.2
52.8
67
Heating water outlet - approx
I-inch
13.4
12.6
13
22.6
23.6
Chimney conduit diameter approx
J-inch
7.1
7.9
7.9
8.3
8.3
Width with a coil - approx
K-inch
26
28.3
28.3
33.9
33.9
Height of coil connection approx
L-inch
39
43.3
52.4
51.6
51.2
Coil outlet - approx
M-inch
10.2
5.9
10.2
14.4
12.4
Diameter of feeding and return
ferrule
Q-inch
2
2
2
2-1/2
2-1/2
Diameter of the coil ferrule
R-inch
¾
¾
¾
¾
¾
Diameter of a drain valve
S-inch
½
½
½
½
1/2
Water capacity
gallons
14.5
19.75
24.5
47.5
54
4.1
6.5
11
16.4
Loading chamber capacity
(gasification)
ft3
Power consumption
W
50
50
50
100
100
inch
20
20
20
30
39
Wood length
Wood
humidity
recommended
%
15-25
admissible
%
15-25
V/Hz
230/50
Voltage / frequency
1 // 2
26
EKO BOILER MANUAL
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. Technical Specifications for the Orlan EKO Line
2 // 2
EKO BOILER MANUAL
27
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 (but not including cast-iron doors,
coil or other components) against defects in materials and workmanship resulting in breaks or leaks causing
significant impairment of performance.
IMPORTER'S OBLIGATION: The Importer's sole obligation under this limited warranty is to provide payment of
the below listed percentage of the cost of the repair of the warranted item. The importer may at their option decide
to use this sum as a partial allowance to replace the warranted items. Importe r will pay all required labor and the
cost of all materials for the repair of the boiler defects arising during the first five (5) years of the warranty period.
In years six (6) through twenty (20), Importer will pay for a percentage of labor and materials for the repair of the
boiler body up to a maximum of the same percentage of the Importer's retail price for the BioMass NextGen model
during the year in which the boiler was originally purchased. Shipping charges in connection with replacement or
repair shall be paid by the owner.
Warranty Year
1-5
6
7
8
9
10-20
21+
% of Coverage
100%
60%
50%
40%
30%
20%
0%
Example #1: Repair costing $250 in year 7. Importer will pay $125.00 (50%) of this repair.
OTHER COMPONENTS - LIMITED THREE YEAR WARRANTY
This limited warranty covers only repairs or replacements resulting from defects in materials and workmanship.
This warranty shall be void if the boiler is installe d by someone other than a qualified contractor whose
principal occupation is the sale or installation of plumbing and heating equipment.
This warranty shall be void if the owner fails to have the boiler serviced or inspected at least once every two
years by an experienced and qualified service person.
EXCLUSIONS: Expressly excluded from coverage by this limited warranty are the following:
Ordinary wear and tear, repairs or replacements necessitated by normal home use as described in the Installation
and Operation Manual.
Repairs or replacements arising from the effects of corrosive water supply or corrosive products of combustion.
Repairs or replacements arising from the us e of the boiler in a “cold start” system.
Repairs or replacements of fittings, motors, fuel units, oil and gas burners, and all other controls, relief or
regulating valves, transformers, and accessories.
Repairs or replacements to repair damage caused by operation in violation of the instructions or cautions set
forth in the installation and operation instruction manual.
The repair or replacement of any component furnished by any other manufacturer or damage caused by the
- 18 28
EKO BOILER MANUAL
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. This warranty shall not be construed as inconsistent with any federal,
condenser
damagedin connection herewith.
call service - condenser’s replacement
state or municipal law or any regulations
promulgated
fan making
noise
fanmay
clips
Questions
regarding
this warranty
beloosened
referred to
check, turn the clips tight
fan’s blades unclean
check and clean
New Horizon Corporation,Inc.
151 McGregor Drive
debris in fans cover
Sutton, West Virginia 26601
dirty fan blades
(304)765-7171, [email protected]
fan working poorly
check and clean
check and clean
pitch on the fan cover
check and clean
HOW AND WHERE TO GET SERVICE. Repairs or replacements under this limited warranty must be performed
by your dealer or someone authorized
by him.
may be required to
present
this limited
problems
withYou
startup
refer
to Section
6.5warranty to the dealer
before any work is performed. You must pay for any work performed which is not covered by this limited warranty
chimney
rebuild chimney. Consider use of WKO
or which is not authorized by the
dealer. draught to low
(below 10 Pa)
exhaust fan
chimney draught to intensive
use exhaust regulator
(over 20 Pa)
wood of
tooboiler
small orcomponents
too dry
mix with larger humidity fuel as to
recycling
level
(in to
about
EKO boilers contain steel, electronic components, insulation and otherincrease
materials humidity
that may be
subject
local,15state
35%)
or federal regulations as to their proper disposal. When retiring an EKO
boiler from service, make sure that all
applicable laws, rules and regulations
are heat
observed.
When in doubt, check
local regulating
clogged
exchanger
cleanwith
theyour
exchanger
or callauthority
service for
–
scrapping and disposal guidelines.
tubes
not covered by warranty
Explosion or
“puffing” in the
firebox and
Disposal
Disposal and Recycling of Boiler Components
Distributed in North America by:
9. Disposal and Recycling of Boiler Components
New Horizon Corporation,Inc.
151 McGregor Drive
Sutton, West Virginia 26601
(304)765-7171
EKO boilers contain steel,
electronic components, insulation and
[email protected]
other materials that may be subject to local, state or federal
regulations as to their proper disposal. When retiring an EKO boiler
from service, make sure that all applicable laws, rules and
regulations are observed. When in doubt, check with your local
regulating authority for scrapping and disposal guidelines.
17
- 19 -
EKO BOILER MANUAL
29