Wood gasification process.....................................................3

Wood as a fuel ......................................................................3

Boiler construction - its elements ..........................................4

Boiler construction - materials ...............................................4

...................................................................4

Boiler construction - schematics ...........................................5

Boiler dimensions ..................................................................6

Boiler sizeing..........................................................................7

ORLAN SUPER .....................................................................8

Basic information about boiler assembly ...............................8

Boiler interaction with a four-way mixing valve ......................9

Boiler interaction with operational water heater .....................9

Boiler connection scheme - examples ..................................10

Additional equipment:Hydrometer ...........................................................................11

ORLAN SUPER additional equipment:Thermal safety device (cooling coil) .....................................11

Additional equipment:LADDOMAT 21 thermoregulator ..........................................12

EKO advantages

2

Raw wood humidity ranges from 60%(wood cut in winter) to 80% (cut in

summer). Most favorable wood humidityis obtained after 12-18 months of storing.

Wood gasification proces

Wood as a fuel

Gasification process in our central heating boileris divided into 4 stages:

1. Drying and release of wood gases inside theloading chamber in slow glowing process.

2. Burning of gas mixture with secondary airin the lower chamber at 2200°F.

3. Flame reheating and heat exchange.

4. Combustion gases ejecting through chimney flueafter the boiler will reach desized oprationaltem-perature.

Wood is a renewable resource like solar, water, orwind power. They are all energy sources, whichnever become depleted, unless improperlymanaged. Wood is also a fuel, which may be storedand preserved without energy loss. Wood storingreduces its moisture and simultaneously increasesits heating value (energy volume, which may be usedup during burning process).

Modern boilers utilizing wood in gasificationprocesses use energy contained in wood withefficiency that is three times higher than traditionalboilers. Smoke and other emissions are cut to a verylow level, making our boilers very nature friendly.

ORLAN boilers are adapted for burning of any kind ofwood ranging from sawdust to chunks of wood. Thebest way to achieve recommended wood humidity isto cut the timber during springtime, and let it seazonunder a covering like a wood shed or a trap.

The best indicator ofsuccessful wood gasification is the lack ofsmoke exiting the chimney.

3

Burning Zones

Wood too dry (less than 15%)or too wet (more than 25%)

will reduce boiler efficiency.

Best humidi ty forgasification should be

in 20% range.

STAGE 4Ejecting combustiongases throughsmoke stack

STAGE 1Wood dryingand breakdowninto gases

STAGE 2Burning of mixedwood gases withsecondary air

STAGE 3Releasing heattrough heatexchanger

DRYING ZONE

CARBONIZATION ZONE

OXIDATION ZONEREDUCTION ZONE

STAGE 4

STAGE 1

STAGE 2

STAGE 3

Boiler construction - its elements

Sealed wood gasification chamber

nozzle

Exhaust reheat space

smoke tube heat exchangerfan

Safe guard thermostat

Steel turbulators

that is simultaneously used as a loadingchamber. When appropriate amount of primary air supplied by the pressure fan is de-livered, wood gas is generatedA , made of refractory concrete, mixes wood gases with the secondary air and aflammable mixture is produced that undergoes self-ignition at about 1000°F

- the main combustion chamber, where temperature reaches about2000°F serves as an ash pitA (flue gas to water) heats up the installation waterA that communicates with the microchip controller monitors the quality of the whole burningprocess

- each boiler is equipped with an additional safe guard thermostat, whichswitches off the fan while the water gets up to 180°F

in heat exchanger tubes.

4

Boiler construction - materials

Boiler body

Heat exchangerInsulation

NozzleChimney flap

Boiler regulator

Chimney flue -Ash pit

Boiler door

- boiler casing is made of welded metal sheets that are 1/4 inch thick, whereas theremaining walls are 1/16 inch thick.

- smoke tube heat exchanger made of tube with dimensions 2 1/5 inch x x1/16 inch- boiler thermal insulation is composed of glass wool of Nobasil 3/4 inch thick, while the

external casing consists of metal sheet panels 0.8mm thick (powder painted)- ceramic element made of refractory concrete (working temp. up to 2100°F)

- made of high quality steel. Tight flap adhesion to the combustion duct assuresthe burning chamber tightness

- placed on upper boiler cover. The regulator is fixed to the boiler coverby stuck catch

made of 1/14 inch steel tube- steel bottom of the burning chamber, ceramic ash pit added (working temp. ) and

additionally covered by refractory concrete- produced of high quality steel, insulated with Nobasil thermal insulation and inside covered

by refractory concrete layer.Also protected with heat-resisting fiberglass cord.

2100°F

EKO advantages

Orlan boilers are produced as:with cooling coil and mechanical

cleaning device

efficiency 91% (ORLAN 18-85%)ow exploitation costseasy and simple servicesmall quantity of ashone loading for 8÷12 hourspower range from 85 kBtu up to 275 kBtupower modulation from 40÷100%adapted for forced (pump) systemequipped with electronic regulator and roomtemperatur sensornature friendlyproduced of boiler steel

ORLAN SUPER

Boiler construction

1. Chimney flue

2. Heat exchanger cleaning cover

3. Chimney flap

4. Hot water exit

5. Thermometer sensor

6. Safe guard thermometer

sensor

7. Boiler controller

8. Upper door

9. Closing/opening

door handle

10. Loading chamber

(wood gasification)

11. Fan flap

12. Fan

13. Fan casing

14. Nozzle

(refractory)

15. Secondary air

adjustment

16. Combustion

chamber

17. Lower door

18. Smoke tube heat

exchanger

19. Primary airflow

20. Flue gas exit

21. Heating water entry

22. Drain valve

23. Secondary airflow

24. Water grate

25. Thermal insulation

26. Ash pit

5

Boiler construction

1 2 3 4 5 6 7

9

8

10

11

12

13

14

15

16

17

22

21

20

24

23

19

18

28

25

26

Boiler dimensions

Boiler dimensions scheme

6

25

85

1080

51.5

48.5

8.3

5.1

37.4

24.8

23.6

41.1

12.6

7.8

2.0

2.0

thread

0.5

20

31

35

7

20

40

137

1212

59

56

6.0

2.7

50.0

24.8

23.6

41.1

12.6

7.8

2.0

2.0

thread

0.5

25

49

35

7

20

460

60

205

1808

60.5

56.5

7.9

5.1

45.7

30.3

29.1

53.5

24.0

8.2

2.5

2.5

flange

0.5

47

82

55

7

25

80

275

2315

60.5

56.5

7.9

5.1

45.7

30.3

29.1

52.7

24.0

8.2

2.5

2.5

flange

0.5

54

123

55

7

39

ORLAN

kBtu

Lb

A inch

B inch

C inch

D inch

E inch

F inch

G inch

H inch

I inch

J mm

inch

inch

-

inch

Gal

Gal

W

%

%

inch

inch

F

PSI

Pa

V/Hz

Boiler type

Power range

Weight

Height

Height of heating water exit

Height of heating water entry

Height of outlet valve

Height of chimney flue

Width including handle

Width including casing

Depth

Hot water exit

Diameter of chimney flue

Diameter of hot water exit

Diameter of hot water entry

Kind of connection

Diameter of drain valve

Water capacity

Volume of loading chamber (gasification)

Power consumption

Moisture of wood:

- recommended

- acceptable

Maximum log diameter

Maximum length of logs

Average temperature of flue gas

Max. working pressure

Required chimney draught

Voltage / frequency

25

15 - 20

12V/60Hz

15 - 25

10 - 35

Boiler sizeing

ORLAN boilers may be used for heating any

kind of building. They are mostly used in

o n e - f a m i l y h o u s e s , d r y k i e l n s ,

workshops, halls, or greenhouses.

However, boiler placement is not

limited to these applications; the

above are just examples of where

ORLAN boilers have worked

with success.

Selecting a boiler that ad-

equately fits ones output is

very important. An impro-

perly chosen boiler may

subject the end-user to

unnecessary expen-ses

during boiler usage.

Boiler output should be

based on a building's

heat demand, calculated

by a qualified central

heating designer. To

select the appropriate

boiler, the a/m calculated

value should be increased

by 20%. If this calculation

isn't performed, boiler sizing

may be chosen using the heat

factor in relation to m of

building cubature. Heat factor

values should be determined as

30-50 W/m depending on heat

insulation.

3

3

REMARK!

The scheme is only an example and New

Horizon is not responsible for the wrong

boiler choice.

7

Boiler sizeing

800

750

700

650

600

550

500

450

400

350

300

250

200

150

100

50

0

buildingswell

insulated

buildingsmiddle

insulated

buildingswithout anyinsulation

He

ate

dsu

rfa

ce

[m]

he

igh

t2

,7m

2

25

40

60

80

25

40

60

80

®

25

40®

60®

®

80

RK 2001 R4E Regulator

Basing information about boiler assembly

STANDARD type boilers are equipped with RK 2001 R4E enabling:

Interaction with circulating pump

Interaction with room temperature sensor, installed in the room and

connected with the boiler regulator by two-strand wire

Modulation of fan rotation Boiler output adapting to actual weather

conditions

Interaction with EUROSTER room thermostat

Each boiler is able to work without room temperature sensor as well.

Boiler can be placed in the heating room, basement, or in an outsidewood storage building. There should be enough space toaccommodate fuel storage for the whole heating season.

Each boiler should be connected to the heating system of which theheating capacity 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

12°F. It is possible by installing of four way mixing valve.

Boiler has to be connected to the chimney duct in the smallestdistance possible. Chimney duct should be insulated to prevent

condensation (low exhaust temperature).The chimney should have the section and height assuring required

chimney draught.

1. Boiler placing.

2. Boiler start-up rules

STANDARD

1. Master switch

2. Boiler temperature indicator

3. Boiler fire-up mode indicator

4. Boiler overheating indicator

5. Room thermostat indicator

6. Boiler thermostat knob

7. Circulating pump indicator

8. Fuel shortage indicator

9. Room thermostat knob

1 2 3 4 5 6

9 8 7

STANDARDSTANDARD

8

RK 2001 R4E Regulator

9

Boiler interaction with four-way

mixing valve

Mixing function

Boiler protection from low temperature corrosion -

Preheating of warm operational water

is related to necessary temperature

changing in central heating system considering outside

temperature changes. For proper boiler operation, a

suitable high temperature inside of gasification chamber

is needed; then the water temperature upon boiler exit will

achieve 140-180°F. Using four-way mixing valve enables

to mix adequate water quantity, heated directly by the

boiler, together with returning water from the system. As

the result, the proper water temperature in the boiler is

attained.

is analogous to mixing function but also functions to

increase temperature of the water returning from system

by mixing of the water directly heated into the boiler.

is related to

necessary disconnecting of system during summer

season. Water is heated in universal pre-heater linked

with the boiler on gravitation.

The central heating system should be closed during

summer by mixing valve switching off, and then fast and

efficient water heating is achieved.

Boiler interaction with operational

water heater

To protect the boiler against overheating, the collector is

needed to gather minimal theoretical boiler output on

gravitation.

For this purpose, the best way is to use operational water

heater together with single function boiler without

charging pump. By this gravitational connection, the

system takes over the minimal boiler output in case of

feeding shortage.

1. Outdoors temp. sensor2. Feeding water temp. sensor3. Four-way mixer DUOMIX C,

DUOMIX AO, DUOMIX P, DUOMIX Z4. MK.CS assisting drive5. Circulating pump6. Room temp. sensor7. Boiler8. Heater9. Operational water heating

10. Differential valve11. Compensating vessel12. Exit for warm operational water13. Cold water entry

8

1

62

5

3

1013

1211

7

9

M4

Low temperature corrosion occurs if

the internal boiler walls are in

contact with combustion gases

having a lower temperature than

the temperature of humidity

causing condensation of the

combustion gases.

If there is more acetic acid

into condensate, the low

temperature process is

more intensive.

Example of boiler’s connectingwith four-way mixing valveAnd water heater

ORLAN boilermodel

Heat collectoroutput

Recommended volumeof the operationalwater pre-heater

Recommendedmixing valve diameter

25406080

17 kBtu27 kBtu51 kBtu

85.5 kBtu

DN 25, DN 32DN 32, DN 40

DN 50DN 50, DN 65

OKCV 42 galOKCV 48 galOKCV 53 galOKCV 53 gal

If the boiler is connected into the forced

(pump) system it has to be protected in case

of power deficiency by adding power backup

unit. If boiler operates in closed loop system

temperature-pressure relief valve has to be

installed!

The best way is to connect a water heater

into the heating system, which works

together with boiler without pump service.

This gravitational arrangement enables

collecting of boiler minimal output during

power deficiency.

Boiler connection scheme - examples

1. ORLAN boiler2. MK.CS mixing valve drive3. Circulating pump4. Differential valve5. Operational water heater6. Compensating vessel7. Exit for warm operational water heater8. Cold water entry9. Four-way mixing valve DUOMIX C (DUOMIX

AP, DUOMIX A0 , DUOMIX Z )10. Outside temperature sensor

1. ORLAN PLUS, SUPER with A 3000 EVregulator

2. LADDOMAT 21 thermoregulator3. NAD, NADO accumulation tank4. Electrical heater5. Three-way mixing valve MIX C

(MIX BP, MIX AP, MIX P)6. Circulating pump7. CZ04 room temperature sensor8. Heating system exit9. Mixing valve drive

10. Opened compensatingvessel

11. CZ03 outer temperaturesensor

12. Mixing valve13. CZ02 feeding water

temperaturesensor

Connection scheme of two boilers working in cascade

Connection scheme of heat accumulation system

1. ORLAN PLUS, SUPER with A 3000regulator

2. LADDOMAT 21 thermoregulator3. Accumulation tanks4. Mixing valve drive

5. Heating system exit6. Three-way mixing valve7. Opened compensating

vessel8. Circulating pump

9. CZ04 room temperature sensor10. CZ03 outer temperature sensor11. CZ02 feeding water temperature

sensor

109

2

3 3 3

CWU

7

M4

8

11

5

61

LA

DD

OM

AT

21

LA

DD

OM

AT

21

11

7

2

CWU

10

M

9

68

51

3

LA

DD

OM

AT

21

LA

DD

OM

AT

21 4

220V380V

12

13

1

3

4

5

6

7

8

9

10

R

1

28

7

5

Connection scheme of the heat accumulation

set with one vessel

Boilers connected in cascade enables

the heating of bigger buildings.

Boilers should be of the same

output. Such a system gives

better possibilities of heat

source dynamics than a sys-

tem with only one boiler.

Particularly in "transition

period" (springtime or

autumn) boilers may be

serviced alternately.

Boilers with such a con-

nection enables for its

utilization with the

output close to nomi-

nal, which warrants

boiler longer dura-

bility.

Heat accumula-

tion tanks allows

for boilers better

a d j u s t m e n t

according to

actual weather

conditions. In

transition pe-

riod (the spring,

autumn) any

boiler without

heat accumu-

la t ion set is

switched on and

off very often. If

the set is con-

nected, the boiler

works constantly

and the energy is

lost into the ves-

sels. Each boiler

switching on and off

means fuel losses. It

may be avoided if the

heat accumulation set

is used. Simultaneously,

in the transition period

(the lowest temperature in

winter time) the accu-

mulation set helps to reheat

the whole central heating

system.

Also it should be mentioned that

few heat sources such as solar

collector, heating pump, or similar

may be connected to the heat

accumulation set.

10

Additional equipment

Wood hydrometer

The hydrometer is needed for measuring of wood proper humidity during fuel

purchasing but also for current control of stored wood.

Boiler fired with wood of proper humidity warrants complete and correct fuel

utilization. Long term use of inappropriate wood causes the onset of tar on boiler

internal walls, which causes difficulty in correct boiler operation.

1. ORLAN SUPER2. Opened compensating

vessel3. Radiator4. Thermal safety device5. Four-way mixing valve6. Circulating pump

7. Difference valve

ORLAN additional equipment

Thermal safety cooling device

To protect the boiler against overheating, any collector is

needed to collect the heat surplus.

For this purpose, the best way is to use any device able to work

on gravitation such as water heater or heat accumulation tank.

There is also a new solution, accessible only in ORLAN, where

a TS 130 thermostatic draining valve is con-nected (produced

by Honeywell).

If the water excess temperature of 200°F the draining valve

opens the cooling water flow (from water-pipe network)

through the thermal cooling heat exchanger, built-in the boiler

upper part.

If the thermostatic draining valve is used there is no need to

connect any other heat collector on the central heating

system. The solution with draining valve is recommended

when there is no place for placing of water heater and also

when the warm operational water is heated in other device

(e.g. in flow water heater).

Boiler connecting

scheme with

thermostatic

draining valve

Wood

hydrometer

1

23

4

5

67

Draining

valve

11

1. RS 25-6-3circulating pump

2. Return tempera-ture indicator

3. Heating watertemperature indicator

4. Mixed watertemperature indicator

5. 1 ¼ “ IG ball valve6. Thermostatic valve7. Automatic valve for regu-

lation of gravitation circle8. Deposit collector9. Exit for filling out

Additional equipment

LADDOMAT 21 thermoregulator

Laddomat 21 is a charging unit for a solid fuel boiler to a storage

tank with hot water heater and mixing valve for the heating system.

Laddomat 21 enables the boiler to attain a proper boiler working

temperature in a very short time.

Charging is continued by means of a slow flow of hot water.

During the final part of the burnout, Laddomat 21 charges thestorage tank fully due to the unique thermal valve, which closes thebypass opening completely.

When the fire has gone out, Laddomat makes use of the remainingheat in the boiler and ember by the self-circulation of hot water fromthe top of the boiler into the storage tank. Energy is stored in thetank instead of being lost through the chimney.

In the event of a power failure Laddomat 21 starts charging the con-tainer immediately by self-circulation.

The same happens if the pump breaks down. Reverse circulationis prevented during periods of non-firing, which means almostno loss of heat.

Heating medium flow by Laddomat

LADDOMAT 21

basing elements

Stage 4

Discharging of energy from the

boiler during power failure

Stage 1

Boiler fire up, temperature in the

heating system lower than

120°F

Stage 2

Heat accumulation charging

begin, heating medium is mixed

into termo regulator

Stage 3

Full charging, heating medium

from boiler feeding is mixed with

secondary medium in small

quantities

LA

DD

OM

AT

21

2

5

9

5

3

6

1

4

5

7 8

354

254

L a d d o m a t 2 1 w o r k sautomatically on the

condition that pumpswitches on / off auto-

matically.

Laddomat 21works efficien-tly during allstages of theboiler ope-ration.