ORLIGNO 500
Contents
1. 089 cog abr du RR a 23 7 eid iara der ced hee ded FETU WI Ham e wed d pid SE 24 aue 24 8 1 Supply air ventilation 6 05 obo ire sled 24 8 2 Exhaust vennal dc de hu e de e ui 24 9 Chimney Conte OD DEL civ ous dente Sonus E eR RN aed Seti a 24 10 Boiler placement in boiler TOOL a mae s nsnm rS er RE Sau drea NIA EGG ened 25 11 LEE 26 mili crm 27 1 Installation Boilers should be installed according to binding rules and norms The requirements of norm PN 87 B 02411 according building of solid fuel boiler room and the norm PN 91 B 02413 according open system boilers production 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 Boiler ORLIGNO 500 is adjusted for installation in pressurized systems Eko Vimar Orlanski Ltd recommends to use stainless steel flue liners that protect the chimney from damagi2. BOILER TEMP 70 BOILER EXHAUST TEMP 110 calculated 70 C BURNER POWER 609 mode auto ON HP fee m 30 service h 5000 hysteresis 02 HEATING gt boiler progr 60 C heating on reduction 15 C HOT WATER progr h w 45 C MAIN MENU hot water on gt BOILER prioryty no HEATING hysteresis 02C HOT WATER boiler h w INPUT MANUAL MODE OFF INPUT LANGUAGE boiler 70 BUFFER exhaust temp 110 C BURNER feedertemp 20 C TEST OFF hot water temp 45 heating temp 60 buffer top 41 C buffer down 28C buffer energy 22 thermostat yes feeder no blower no LANGUAGE selected polski 2 1 Burning up 1 Pour the pellets into the hopper and tightly close the lid 2 Connect the main power plug into the 230V 50 socket ATTENTION Socket should be protected with min 10A fuse and 20 mA RCD residual current device 3 Start the controller To start the controller it is necessary to press the ON OFF ESC button for seconds The same operation with turning off the controller Present status is shown on the display OFF active control of alarm parameters manual mode of blower and feeder ON ATTENTION When is shown on the display device is in standby mode and is still live In case of alarm controller will activate all pumps or feeders ATTENTION It is forbidden to use for boiler lightning up any flammable substances If boiler is in idle time or maintenance is made it s essent
3. Loud blower 12 Ending 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 48 385 Otmuchow ul Nyska 17b POLSKA woj opolskie T 48 77 400 55 80 81 400 55 91 48 77 439 05 03 400 55 96 E biuro orlanski pl www orlanski pl
4. correct regulation a disassembly the door b loosen the adjusting nut adjusting nut c turn the hinge at 360 d tighten up an adjust nut Warning Regulation should be made on both upper and bottom hinges at the same time All threaded door parts should be greased periodically for exemple with a grease or an oil as well as hinges SERVICE MANUAL CONTENTS Ime PEPPER EET TESTA TTE ETT IT TETTE 15 2 Recommended controller s settings lesleleeeeee nnn 16 ae BOCKI CETTE TOT LT 16 aq OR 17 17 4 2 Boiler technical iu icu dica ea de 17 4 3 Controller s technical data 18 4 4 Electric data or 0 8 19 4 5 Mechanical data of gear motors 19 Heater s technical data dist asd 19 5 Boiler s electric E M cdd c ues 20 6 Boiler connection eu ico c tien Je P B dE Moe Dep Shes 22 6 1 Connection scheme m Ron om ER m cns 22 6 2 Hydraulic CORMECIIONS sesso PsUbUSS UR ORE REPE 23 p 29 Cooling
5. menu Buffer menu Menu for adjustment of buffer parameters Buffer menu view is shown below BUFFER progr top 60 C progr down 60 C Pic 10 Buffer menu PARAMETERS Programmed top programmable temperature in the upper part of the buffer Programmed down programmable temperature in the upper part of the buffer OPERATION DESCRIPTION Buffer pump will be on when temperature in upper part of the buffer drops below programmed temperature Buffer charging lasts until both programmed temperatures are reached ATTENTION Buffer menu is only available in ADVANCED menu PARAMETERS Burner power available in two modes auto recommended and manual In auto mode controller selects burner power accordingly to energy demand of the house Programmed power in auto mode is displayed actual power of the burner in manual mode burner power can be set as a constant ATTENTION Burner menu is only available in ADVANCED menu Language menu Controller is equipped with multilingual menu polish english german french lithuanian and russian Language selection is made in Language menu 3 2 Alarm status and safety devices Alarm status is indicated with blinking backlight on the controller s display After pressing type of alarm is displayed Types of alarms boiler overheating Alarm is indicated after exceeding 97 C pre set on the boiler Controller will activate all connecte
6. p Description Boiler output Power range 4 3 Efficiency 5 Fuel pellets lenght diameter moisture content Fuel consumption nominal minimal mm mm kg h kg h 5 Boiler class norm 10 50 6 8 8 12 5 5 1 5 Approximate heating space to 250 8 Max working pressure 9 Max water temp Min return water temp _ 0 o Flue diameter Required chimney draught from 0 1 to 0 2 13 Fumes temp nominal C 160 minimal 130 Fumes flow nominal kg s 0 02 minimal kg s 0 01 Em BULL 4 3 Controller s technical data VIHz Power consumption controller VA OUTPUT LOAD ceami Gearmotor2 W Ambettmpetue Value 230 50 10 ee ojojo 60 85 35 70 4 4 Electric data of gear motors Cue www Teo motornih 1 2 o e without load 0 65 159 4 in t power FR I rot min 5 4 1090 otation V 161 MAX Start voltage Load characteristic after 1 min since start of motor Limit load Acceptable load Start load Dielectric resistance Motor resistant voltage 1500V RMS through 1 min 1800V RMS through 1 sec measured between coil and motor s core test current 3 mA Insulation coefficient 100 MO minimum at 500V of voltage measured Lied 3 coil and cover 9 Thermal
7. protection Motor Thermal protection Motor protected 120 C up 120 C 4 5 Heater s technical data 8 Lubrication Mineral oil and grease TEE Ww 22 na e 00 Nm Nm Nm 4 6 Heater s technical data m e BE voltage range cooperate with adapter 230 120 120 15 10 102 132 1 0 hetero SP UGZ OXE H3MO 8 LUWOG LXE I AUG 1 0x9 11 S ddddOH HalvaH B OXZ ZHOS A0EZ 5 ANCAS3S YIWNN AOLL OE OSO0E190L AMOSOWLVA H3 HOJSNVHL THOS ADEE SINVISVZ Filed LI ENG qup qeu nu fe m j 1 4 i M A 3aoia 2 915 4 091 0 8 n sol S 00000000000 5 Boiler s electric scheme Pic 3 Electric scheme Electric connection of equipment to the boiler s controller Low voltage contact Tco temperature sensor connection for central heating Tcwu sensor connection for hot water pump Tbg sensor connection in upper part of the buffer Tbd sensor connectio
8. water heating Boiler h w only in ADVANCED menu temperature value that need to increase to programmed temperature during hot water heating i e if programmed temp of hot water 60 C and boiler h w 10 then programmed temperature during heating hot water is 70 ADVANCED PRIORITY OF HOT WATER Controller can operate in two modes of hot water heating known only in gas and oil boilers hot water priority recommended and without priority During boiler operation with priority mode with hot water heating works only hot water pump reaching set temp much faster In order to avoid temperature drop in the house during hot water heating and the pump works longer than 20 minutes pre set and programmed temperature of hot water is not reached central heating pump will start working on 5 minutes Parameters available in service menu stop central heating pump with hot water pump stop HP HWP and work central heating pump with hot water pump work HP HWP stop HP HWP work HP HWP work HWP work HWP HP Pic 8 Pump operation during hot water heating in priority mode Input menu Input menu shows temperatures from all connected sensors to the controller Input menu view is shown below INPUT boiler 70 C exhaust temp 110 C feedertemp 20 C hot water temp 45 heating temp 60 buffer top 41 C buffer down 28C buffer energy 22 thermostat yes Pic 9 Input
9. 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 8 2 Exhaust ventilation 1 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 9 Chimney connection Chimney ducts should be installed according 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 ORLIGNO 500 s need to be connected to chimney system protected against condensate soaking 30 cm above the floor closing door should be installed with tight closing Chimney section should be round or close to square shape because of low flow resistance Minimal flue diameter at least 160 mm Chimney should lead above the roof Chimney outlet location is dependent on roof slope and its combustibility Eko Vimar Orlanski Ltd recommends to install draught regulator which stabilizes chimney draught 10 Boi
10. d pumps until temperature will decrease ATTENTION With temperature 2 C lower than alarm temperature pumps are activated in a initial alarm mode If temperature do not exceed alarm temperature it will not be remembered in controller s memory no fuel fire Alarm is activated in case of lack of fuel or fire in the burner feeder overheating Alarm is activated when permissible feeder s temperature is exceeded ATTENTION After noticing alarm status it is recommended to determine cause and remove it thermal boiler protection independent from boiler s controller In case of exceeding boiler s temperature of 94 C thermal boiler protection will turn off blower ATTENTION After alarm occured it is recommended to determine cause of alarm remove it and manually unblock thermostat 4 Feed system 1 Pellet container 2 Motoreductor of a feeder no 1 3 Motoreductor of a feeder no 2 4 Feeder no 1 5 Feeder no 2 6 Fan 7 Burner 8 Heater Pic 11 Feed system section 4 1 Feed system status In case of exceeding 60 in the feed system alarm is activated with blinking display feeder overheating ATTENTION After alarm occured it is recommended to determine cause of alarm and remove it 4 2 Feed system protection Feed system is designed in such a way that flame from burner is not able to get to the pellet hopper Safe feeding is assured by system of two feeders jointed together with flexible
11. ial to unplug the boiler from the main power Display shows current state of individual devices Picture shows main menu view BOILER TEMP 70 C EXHAUST TEMP 110 C BURNER POWER 60 ON HP fee 30 Pic 2 Main display Last line on display shows through abbreviations active devices buffer pump operation Tab 1 Abbreviation table with devices names After pouring pellets it is recommended to manually start the feeder in order to transport fuel to the burner Go to menu MANUAL MODE which is displayed below feeder no blower no Pic 3 Manual mode To turn on off the feeder press Q To turn on off the blower press Feeders should work until filling the burner with fuel Next switch the controller in ON mode fuel will be automatically light up 3 Controller s menu description 3 1 Menu handling Controller has two types of menus SIMPLE MENU and ADVANCED MENU ATTENTION N To change type of menu SIMPLE or ADVANCED press at the same time buttons After 10 minutes of inaction from user menu will automatically be changed on SIMPLE ATTENTION Instruction manual contains all control parameters available both in SIMPLE or ADVANCED menu Parameters from ADVANCED menu are written in italics To go in to the main menu press ENTER button main menu written with capital letters buttons Q and are for move within main menu to go in to submenu press ENTER To go out f
12. ler placement in boiler room 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 picture ORLIGNO 500 placement 3 Boiler room should be free of any electric installation not intended for boiler installation 800 1000 h gt 2200 1500 Pic 7 ORLIGNO 500 placement 11 Troubleshooting Symptom Reason Alarm No fire fuel Lack of Refill hopper acc to point Lightning up Wrong lightning up Check Lightning up Check moisture use pellet with required Too moisture pellet parameters Boiler Clogged primary air channels Call service after warranty service programmed Clean pipes call service after warrant temp Clogged heat exchanger s pipes 2 Damaged gasket on blower s or burner s flange Replace after warranty service Damaged blower Replace after warranty service Clogged or unproper chimney Get the chimney sweeper opinion Strong wind forces fumes into the Consider installation of devices regulating chimney chimney draught Gasket leak Regulate the door s hinges Door is fuming Damaged rope Replace the rope after warranty service No voltage in the grid Check the protection devices in the electric Controller doesn t installation work Damaged wire Wire and connection control
13. n in down part of the buffer Rpok room thermostat connection High voltage contact M co mixing valve s actuator connection P cwu hot water pump connection P bu buffer pump connection pump responsible for maintaining right return temperature to the boiler P co central heating pump connection Room thermostat Controller enables to cooperate with any room thermostat with closing contact Room thermostat should be installed in a representative room in the house with respect to temperature at 1 5 2 m height One shouldn t install room thermostat close to any heat source TV radiator direct sun radiation places exposed to draught Room thermostat ex Boiler controller EUROSTER AURATON Pellets control jejsouueu Pic 4 Room thermostat connection 6 Boiler connection 6 1 Connection scheme 19 Pic 5 Boiler connection scheme Connection scheme 1 Pellet boiler ORLIGNO 500 2 Buffer boiler pump 3 Supply manifold 4 Three way mixing valve 5 Circulation pump 6 Differential valve 7 Return manifold 8 Radiator 9 Hot water pump 10 Hot water tank 11 Hot water outlet 12 Cold water inlet 13 Pressure tank 14 Safety group 15 Buffer tank 16 Set of solar collectors 17 central heating sensor 18 Upper part sensor 19 Down part sensor 20 Solar collector pump 21 Hot water measureme
14. ng effect of wood tar Company Eko Vimar Orlanski does not take responsibility for not complying to above recommendation and damage resulting from it During boiler transport boiler flue may be disassembled by unscrewing nuts 8 8 and detaching flue from the flange At the bottom chamber wrapped in a foil are ceramic moulders which need to be placed on the burner as shown on below picture S burner Ceramics layout Pic 1 Ceramics layout on the burner 2 Recommended controller s settings 1 1 Underfloor heating temperature max Thermostat G Proiy 0 0 0 0 0 0 0 0 amp j Bolerhw OQ Buffer upper temperatue o 3 Block diagram POWER SUPPLY 230VAC OPERATOR FILTER CONTROL PANEL RFI LCD KEYBOARD POWER SUPPLY ADAPTOR ZERO 230VAC 12VDC 5SVDC DETECTION SYSTEM CONTROLLER S PROCESS A D CONVERTER RELAY OUTPUTS MULTIPLEXER CONTROLLER OPTICAL ISOLATION FILTER SEMICONDUCTOR MEASUREMENT SURGE SURGE INPUTS PROTECTOR PROTECTOR mm E E E m E m SENSORS EXECUTIVE ELEMENTS EXECUTIVE ELEMENTS Pic 2 Controller s block diagram 4 Technical data 4 1 Dimensions 1374 1005 1197 1411 L 1392 4 2 Boiler technical data L
15. nt 6 2 Hydraulic connections Cooling coil tappings 2 x DN 20 Supply to installation DN 50 Return from installation DN 50 Drain valve DN 15 6 3 Cooling coil 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 Pic 6 BVTS connection scheme T Boiler tightness It is very important to assure boiler tightness especially door tightness Leakiness causes that fumes may get out to the boiler room and lead to uncontrolled burning To assure proper door tightness rope need to be checked periodically and in case of damage replaced Insulation rope in bottom door need to greased at least once a month with oil or graphite grease 8 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 8 1 Supply air ventilation 1 Ventilating duct section should have at least 5096 area of chimney s section and not less than 20 x 20 cm Duct should be placed
16. ontroller Boiler controller is a modern microprocessor system which controls not only the boiler but also central heating system and hot domestic water Device controls quantity of feed fuel through periodic operation of feeder s engine and amount of supplied air for burning process Thanks to semiconductor transmitters power of the blower is fluently adjusted thus increasing reliability of control system of feeder s engine Automatic burning up Controller enables automatic burning up of the fuel on the burner Measurement of fumes temperature Controller enables reading fumes temperature it is necessary for boiler operation with automatic igniting Measurement of fumes temperature is important for control and boiler adjustment Thanks to advanced algorithm and possibility to adjust many parameters system can be easily adapted to the heating system needs Controller is equipped with output test function that enables to check correct electric connections and executive devices pump blower feeder mixing valve s actuator before boiler is put into action Alphanumeric display makes easier to communicate between user and controller easy handling New intuitive controller s menu with 6 languages at choice polish english german french lithuanian and russian progr top 60 C progr down 60 C TEST OFF Pic 1 Controller s menu
17. orlanski the house INSTRUCTION MANUAL amp SERVICE MANUAL ORLIGNO 500 MANUAL INSTRUCTION CONTENTS 1 Boiler application 3n doe ht Ear m ke ee ER Sere mk ad du ps darem EU dud E 3 2 Description of the controller llli hh hr 3 edad SEK MUKA UPS NUMEN ds 5 3 Controller s menu description auae wem bowie Rua E EE UE ee ee ee RR Rn RI ee tones 6 211 2 OIN ITO A 6 3 2 Alarm status and safety devices 11 4 Feed S aeu Rue S Ses hk oe ele 12 4 1 Feed system alarm status 1 soseniszwsERZeEGscEREEREAWERRESS EGG RES RSEN 12 4 2 Feed system protectio dade 12 Os Mainte an CE a m tc cabarets unae 13 1 Boiler application Low temperature pellet boiler Orligno 500 produced by Eko Vimar Orlanski Ltd is adapted for central heating installations also for hot utility water heating Main fuel use in ORLIGNO 500 is pellet with 6 8 mm diameter and length 10 50 mm Capacious pellet hopper lets for very long boiler operation without need to refill the hopper Boiler is adapted for installation in open or pressurized system with pressure vessel allowing to work with working pressure 2 Description of the c
18. ors underfloor heating during demand from room thermostat Heating parameter for turning off on heating Reduction only in ADVANCED menu parameter for adjusting the temperature value ATTENTION In case if mixing valve with actuator is not installed in central heating circuit parameters and reduction are turned off ATTENTION In case if mixing valve with actuator is not installed in central heating circuit during the first start of the boiler parameter mixer need to changed on in SERVICE menu Menu hot water Pellet boiler is perfectly matched for hot water heating both during the heating season and summer season Menu HOT WATER is shown below HOT WATER progr h w 45 C hot water on prioryty no hysteresis 02 boiler h w 10 C Pic 7 Menu HOT WATER PROGR H W PROGRAMMED HOT WATER Hot water tank need to be equipped with temperature sensor PARAMETERS Programmable hot water temperature progr h w hot water temperature kept in the tank Hot water parameter for turning on off hot water function Priority only in ADVANCED menu with priority parameter on during hot water heating rest of the pumps in the installation are off in order to faster heat the water Hysteresis only in ADVANCED menu temperature value that need to decrease temperature of hot water to start heating hot water and temp value that need to increase to turn off hot
19. rom submenu press ESC Main menu is shown on pic 1 submenu is for displaying and changing operation parameters In order to change the parameter press ENTER Changing parameter will be displayed periodically Changing parameter on different one press Q or Q To withdraw from changed parameter press ESC To accept the changes press ENTER Menu is shown in point 2 Controller description MAIN MENU BOILER HEATING HOT WATER INPUT MANUAL MODE OFF LANGUAGE BUFFER BURNER TEST OFF Pic 4 Main Menu Menu Boiler Boiler can operate in one of two operation modes manual and auto BOILER gt calculated 70 auto service h 5000 hysteresis 02 Pic 5 Menu BOILER ATTENTION Operation modes decide only about setting method of the boiler temperature PARAMETERS Auto mode recommended mode Boiler s temperature is automatically set depending on heat demand Manual mode Boiler s temperature is set by user Service parameter informing about next boiler maintenance Hysteresis only in ADVANCED menu parameter deciding about required difference between actual boiler s temperature and set one to start the burner Menu heating Menu for central heating settings Menu HEATING is shown on picture HEATING gt boiler progr 60 heating on reduction 15 C Pic 6 Menu HEATING CIRCUIT PARAMETERS Progr kept temperature in heating circuit radiat
20. vertical chute Fuel feeding is continually monitored by boiler s controller Proper feeders cooperation guarantees that vertical chute is always empty it is a burn back protection 5 Maintenance Ash created during pellet burning is deposited in bottom chamber Bottom chamber needs to be cleaned once a month with tools scraper cleaning shield It is advisable to clean heat exchanger at least once a month to assert permeability of pipes If fumes temperature exceeds max value which will be displayed it is necessary to clean heat exchanger pipes and boiler Once a week burner need to be checked thoroughly because of possibility of depositing unburned parts of pellets especially when pellet quality is bad which may block pellet feeding and cause uncontrolled burning Attention If unproper pellet issue will repeat it is necessary to fully open blower s screen Attention It is necessary to remove pellets from tank upper and bottom auger in case if boiler is not used for over 2 weeks In order to clean heat exchanger 1 Open upper door 2 Unscrew two nuts with M13 wrench they secure heat exchanger s plate behind which horizontal pipes are placed 3 Remove turbulators and clean pipes with shield and turbulators with brush 4 Place turbulators back into the heat exchanger Attention If unproper pellet issue will repeat it is necessary to fully open blower s screen Pic 12 Turbulators Steps for door
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