ECOSTAR ECO 55 K L C 2 Installation, Operating And Maintenance Manual
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ECOSTAR ECO 55 K L C 2 Installation, Operating And Maintenance Manual

Eco 50 series; eco 55 series; eco 60 series; eco 65 series; eco 70 series; eco 75 series monoblock dual fuel (gas-light oil) burners
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MONOBLOCK DUAL FUEL (GAS-LIGHT OIL)
BURNERS INSTALLATION, OPERATING AND
MAINTENANCE MANUAL
TWO STAGE AND MODULATING OPERATION
ECO 50
ECO 55
ECO 60
ECO 65
ECO 70
ECO 75
www.ecostar.com

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Summary of Contents for ECOSTAR ECO 55 K L C 2

  • Page 1 MONOBLOCK DUAL FUEL (GAS-LIGHT OIL) BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL TWO STAGE AND MODULATING OPERATION ECO 50 ECO 55 ECO 60 ECO 65 ECO 70 ECO 75 www.ecostar.com...
  • Page 2 We thank you for choosing ECOSTAR brand. Ecostar Dual Fuel (Gas-Light Oil) Burners are manufactured in compliance with TS EN 267 and TS EN 676 + A2 standards. This Operating Manual is an integral part of the burner and must be maintained in a plastic dossier and hung at a clearly visible place in the burner room.

  • Page 3: Table Of Contents

    CONTENTS WARNINGS ............................... 3 Warning Symbols and Descriptions ......................3 General Safety Rules ..........................4 TERMS OF WARRANTY ......................... 6 Out of Warranty Conditions ........................6 BURNER’S GENERAL FEATURES ......................7 Purpose of Use and Work Limits of Burners ..................7 Code Key ..............................

  • Page 4: Warnings

    WARNINGS Warning Symbols and Descriptions Symbols Symbol Descriptions Important information and useful hints. Warning of danger to life or property. Warning of electrical voltage. Product handling information. Impulse connection detecting combustion chamber pressure Impulse connection detecting combustion air pressure Impulse connection detecting burner gas head CLEAN THE GAS BURNER.

  • Page 5: General Safety Rules

    General Safety Rules • All personnel engaged in installation, disassembly, commissioning, operation, control, maintenance and repair should have received the necessary training and fully read and understood this manual. • No changes that might damage the safety of the burner unit must be made by persons and/or organizations on the burner unit.
  • Page 6 The burner installation must be carried out in accordance with the instructions. Vibration can damage the burner and its components. Keep boiler doors closed while starting burner and during burner operation. Check combustion values to be correct by using flue gas analyzer at the whole adjustment range between minimum, full load, and ignition load.

  • Page 7: Terms Of Warranty

    TERMS OF WARRANTY Main and auxiliary equipment and all components used in Ecostar Dual Fuel (Gas-Light Oil) burners are guaranteed for 1 year by TERMO ISI SİST. A.Ş starting from the date of commissioning under the maintenance, adjustment, operating conditions and relevant mechanic, chemical and thermal effects explained herein.

  • Page 8: Burner's General Features

    BURNER’S GENERAL FEATURES ECOSTAR Dual Fuel (Gas-Light Oil) burners are designed and manufactured to work with liquid fuel with max. 2.5- 6 Cst (mm s) viscosity. and Natural Gas and Liquid Petroleum Gas at gas pressures of min.20 mbar, max.300 mbar and at -%15 to +%10 of nominal voltages, under environmental temperature of max.60˚C with rated capacity and burner pressure ranges.
  • Page 9 Temperature change of fuel used in ECOSTAR Dual Fuel (Gas-Light Oil) burners dependent on viscosity 09.06.2017 Rev. 08...

  • Page 10: Burner Components

    Burner Components ECO 50 KLC2 09.06.2017 Rev. 08...
  • Page 11 Assembly No Part Name Assembly No Part Name Body group Gas ignition electrode Klingerit gasket Electrode connection plate Flame tube Liquid fuel ignition electrode Boiler connection flange Fuel nozzle Gasket Lance Flame tube extension Solenoid valve Manometer Motor connection flange Ball valve Motor Fuel pipes...
  • Page 12 ECO 55 KLC2-2a 09.06.2017 Rev. 08...
  • Page 13 Assembly No Part Name Assembly No Part Name Body group Gas Ignition electrode Klingerit gasket Electrode connection plate Flame tube Liquid fuel Ignition electrode Boiler connection flange Fuel nozzle Gasket Lance Flame tube extension Solenoid valve Manometer Motor Ball valve Electrical panel connection plate Fuel pipes Electrical panel...
  • Page 14 ECO 60 KLC2 09.06.2017 Rev. 08...
  • Page 15 Assembly No Part Name Assembly No Part Name Body group Combustion head Klingerit gasket Gas ignition electrode Flame tube Electrode connection plate Boiler connection flange Liquid fuel Ignition electrode Gasket Fuel nozzle Lance Motor connection flange Solenoid valve Motor Manometer Electrical panel connection plate Ball valve Electrical panel...
  • Page 16 ECO 65 KLC2 09.06.2017 Rev. 08...
  • Page 17 Assembly No Part Name Assembly No Part Name Body group Photocell Klingerit gasket Combustion head Flame tube Gas ignition electrode Boiler connection flange Electrode connection plate Gasket Liquid fuel Ignition electrode Flame tube extension Fuel nozzle Lance Motor connection flange Solenoid valve Motor Manometer...
  • Page 18 ECO 70 KLC2 09.06.2017 Rev. 08...
  • Page 19 Assembly No Part Name Assembly No Part Name Body group Combustion head Klingerit gasket Gas ignition electrode Flame tube Electrode connection plate Boiler connection flange Liquid fuel Ignition electrode Gasket Fuel nozzle Flame tube extension Lance Solenoid valve Motor Manometer Electrical panel connection plate Ball valve Electrical panel...
  • Page 20 ECO 50 KLC3 09.06.2017 Rev. 08...
  • Page 21 Assembly No Part Name Assembly No Part Name Body group Liquid fuel Ignition electrode Klingerit gasket Fuel nozzle Flame tube Centring wedge Boiler connection flange Lance Gasket Solenoid valve connection plate Flame tube extension Solenoid valve Manometer Motor connection flange Ball valve Motor Fuel pipes...
  • Page 22 ECO 55 KLC3-3a 09.06.2017 Rev. 08...
  • Page 23 Assembly No Part Name Assembly No Part Name Body group Liquid fuel Ignition electrode Klingerit gasket Fuel nozzle Flame tube Centring wedge Boiler connection flange Lance Gasket Solenoid valve connection plate Flame tube extension Solenoid valve Manometer Motor Ball valve Electrical panel connection plate Fuel pipes Electrical panel...
  • Page 24 ECO 60 KLC3 09.06.2017 Rev. 08...
  • Page 25 Assembly No Part Name Assembly No Part Name Body group Gas ignition electrode Klingerit gasket Electrode connection plate Flame tube Liquid fuel Ignition electrode Boiler connection flange Fuel nozzle Gasket Centring wedge Lance Motor connection flange Solenoid valve connection plate Motor Solenoid valve Electrical panel connection plate...
  • Page 26 ECO 65 KLC3 09.06.2017 Rev. 08...
  • Page 27 Assembly No Part Name Assembly No Part Name Body group Gas ignition electrode Klingerit gasket Electrode connection plate Flame tube Liquid fuel Ignition electrode Boiler connection flange Fuel nozzle Gasket Centring wedge Flame tube extension Lance Solenoid valve connection plate Motor connection flange Solenoid valve Motor...
  • Page 28 ECO 70 KLC3 09.06.2017 Rev. 08...
  • Page 29 Assembly No Part Name Assembly No Part Name Body group Gas ignition electrode Klingerit gasket Electrode connection plate Flame tube Liquid fuel Ignition electrode Boiler connection flange Fuel nozzle Gasket Centring wedge Flame tube extension Lance Solenoid valve connection plate Motor Solenoid valve Electrical panel connection plate...
  • Page 30 ECO 75 KLC3 09.06.2017 Rev. 08...
  • Page 31 Assembly No Part Name Assembly No Part Name Body group Lance Klingerit gasket Ignition transformer Flame tube Transformer box Boiler connection flange Solenoid valve connection plate Gasket Solenoid valve Manometer Motor Ball valve Electrical panel connection plate Fuel pipes Electrical panel Pump Handling rod Pump motor console...

  • Page 32: Technical Data

    ECO 50 K L C 2 215.000 1.290.000 1.500 26,1 156,4 337.750 1.351.000 1.571 33,1 132,5 2,20 0,75 3N 380 ECO 55 K L C 2 258.000 1.720.000 2.000 31,3 208,5 386.000 1.737.000 2.020 37,8 170,3 3,00 0,75 3N 380 ECO 55 K L C 2a 258.000...

  • Page 33: Back Pressure-Capacity Diagrams

    Back Pressure-Capacity Diagrams 09.06.2017 Rev. 08...

  • Page 34: Burner Dimensions

    Burner Dimensions 09.06.2017 Rev. 08...

  • Page 35: Gas Hood Pressure Loss Diagram

    Gas Hood Pressure Loss Diagram Gas hood pressure loss measurements are conducted in atmospheric pressure. Consider the below data while conducting measurement in counter pressure boilers. : Gas hood pressure while burner is connected to the boiler and working : Combustion chamber pressure : Burner net gas hood pressure 09.06.2017 Rev.
  • Page 36 09.06.2017 Rev. 08...
  • Page 37 09.06.2017 Rev. 08...

  • Page 38: Flame Length And Diameter

    Flame Length and Diameter Natural Gas Light Oil Noise Level Product operates within the range of 75 decibels max. and 85 decibels. 09.06.2017 Rev. 08...

  • Page 39: Burner Handling Information

    BURNER HANDLING INFORMATION • Lift the product by holding the handles as seen in the picture. • Prevent strong impacts on top of the product and vibration while handling the product. • Do not leave the product in wet environment. Dimensions of the box used for handling Burner L x W x H (cm)

  • Page 40: Installation

    INSTALLATION Burner Installation Picture 1- Drift Bolts 2- Burner 3- Boiler Connection Flange 4- Gasket 5- Boiler Studs Ø In the installation of the burner, use the installation materials supplied with the burner. Ø Secure the burner connection flange onto the burner cover by 4 bolts. Gasket must be connected such that it will remain between connecting flange and boiler cap.

  • Page 41: In Reverse Flame Front Mirror Boilers

    In reverse flame front mirror boilers While installing the burner in reverse flame front mirror boilers, flame tube tip must be adjusted such that it gets inside by 50 mm-100 mm from flue pipes (50mm≤A≤100mm). Otherwise flue gas temperature will rise and fuel consumption will increase. In cylindrical (straight flame) boilers 09.06.2017 Rev.

  • Page 42: Commissioning

    COMMISSIONING Before Commissioning Electrical Connection Perform electrical connections according to the diagram provided with the burner. Follow general security rules during installation of electric wiring and making connections. Connect the earthing terminal in electric panel to the earthing installation. General Controls Make sure to perform the following controls before commissioning the burner.
  • Page 43 Operating with Gas ; Operation of two-stage burner Ø Open the main gas valve, check the gas pressure from the manometer at the valve. (max.300 mbar) Ø Check the boiler thermostat or pressure switch settings. Ø Bring the operating switch on the burner panel to position 2. Ø...

  • Page 44: Combustion Adjustment

    Combustion Adjustment Ø Fuel nozzle Use proper wrench in installation and dismantle of the fuel nozzle. Use diesel oil to clean the fuel nozzle. Do not use thinner and its derivatives. Ø Photocell Check the photocell weekly. Clean the dust or fume stains on the glass of photocell by a dry cloth.
  • Page 45 TA Type 1-Suction 2-Nozzle outlet 3-Return 4-Manometer inlet 5-Vacuum or inlet manometer and internal return inlet 6-Pressure adjustment 7-Pre heater location 09.06.2017 Rev. 08...
  • Page 46 Ø Two Stages Light Oil Burner Fuel Circuit Ø Modulating Light Oil Burner Fuel Circuit 09.06.2017 Rev. 08...
  • Page 47 CAUTION! Ø End of the line to the main tank must be open to the atmosphere and line pressure must be zero, otherwise no healthy modulating operation can be ensured since the pressure, which is to form in return, will also affect nozzle pressure. Fuel may drop from nozzle end during stops.

  • Page 48: Gas Adjustment

    Gas Adjustment Ø VGD 20 4011 - 5011 Series Gas Valve SKP 75 Connection Diagram 1 – Air-gas adjustment ratio 2 – Zero "0" point (start) adjustment 3 – Boiler counter pressure impulse connection 4 – Gas pressure impulse connection 5 –...
  • Page 49 Ø MB ZRD(LE) 405 – 412 Series Gas Valve 09.06.2017 Rev. 08...

  • Page 50: Air Pressure Switch Adjustment

    Air Pressure Switch Adjustment While the burner is working without any problem, the air pressure switch is adjusted to desired minimum pressure as follows. Ø Unscrew the screw of the transparent cover and remove the cover. Ø Turn the adjustment wheel in the direction to increase the pressure, note the pressure value at which the burner is failed.
  • Page 51 Ø SQM10 I. Cam: Opening II. Cam: Resets the clamp III. Cam: Commissioning air IV. V.VI. and VII. Cam not used Do not open servomotor. Do not interfere with. It may damage servomotor or change burner settings. 09.06.2017 Rev. 08...
  • Page 52 Ø MODULATING MECHANISM ADJUSTMENT 1- Air adjustment disk 2- Fuel adjustment disk 3- Servomotor 4- Fuel regulator 5- Air control lever 6- Fuel control lever ADJUSTMENT: 1- Start positions prior to disc mechanism adjustment operation must be as follows: Ø Servomotor: 0° Ø...
  • Page 53 2 – If disc mechanism start positions are correct, start the burner and ensure that it activates in basic load. Detect min capacity activation fuel amount of the burner by checking min. return pressure. If the activation fuel amount is insufficient, set fuel regulator start adjustment to 9 or 8 value by changing spring adjustment from adjusting bolt on fuel disc number 2.When you start the burner again after this operation, you will see that your fuel return pressure has increased and hence activation fuel amount has risen.
  • Page 54 5 - Set the burner to the correct capacity required by the boiler by considering the below nozzle pressure and consumption values. Diagram valid for fuel nozzles having 45° spraying angle Diagram valid for fuel nozzles having 60° spraying angle 6 –...

  • Page 55: Emission Measurement

    Emission Measurement In emission measurements, the following values are accepted as reference according to TS EN 676 +A2 standard. Ø CO < 100 mg/ kWh Ø %3 ≤ O ≤ %5 Ø NO < 170 mg/ kWh Ø Excess air ratio 1,2≤ λ ≤ 1,3 In emission measurements, the following values are accepted as reference according to TS EN 267 standard.
  • Page 56 If the value measure from PL point is below 0.5 bar, set the impulse pipe as follows. 09.06.2017 Rev. 08...
  • Page 57 If the flame tube of the burner is longer than standard (standard flame tube length of the burner), please do not forget to support burner body during maintenance and installation/commissioning. 09.06.2017 Rev. 08...

  • Page 58: Light Oil Burner Fuel Ring Line

    Light Oil Burner Fuel Ring Line 09.06.2017 Rev. 08...

  • Page 59: Gas Pass Equipment Required In Gas Line

    Gas Pass Equipment Required in Gas Line Pe < 300 mbar Pe > 300 mbar Pe < 300 mbar Pe > 300 mbar Q<1200kW Q<1200kW Q>1200kW Q>1200kW 1- Compensator 1- Compensator 1- Compensator 1- Compensator 2- Ball valve 2- Ball valve 2- Ball valve 2- Ball valve 3- Gas filter...

  • Page 60: Maintenance

    MAINTENANCE Weekly Maintenance Weekly maintenance is a routine cleaning and adjustment procedure which is performed to ensure smooth and continuous operation of the system. Burner components must be adjusted after each maintenance work in accordance with the instructions. Otherwise, the burner cannot be operated efficiently.

  • Page 61: Seasonal Maintenance

    Seasonal Maintenance Comprehensive maintenance work when the burner is re-started after long periods of shut-down or interruptions. After completion of maintenance and adjustment processes, make sure to perform a combustion analysis. Ø Check insulation resistance of electric motor. Ø Make surface cleaning of ignition electrodes and porcelains. Replace cracked or broken porcelains.

  • Page 62: Troubleshooting

    TROUBLESHOOTING Problem Cause Explanation-Suggestion Light Oil or Gas valve might be closed. Open Light Oil or Gas is the valve. cut or does not come Check burner power supply. The fuse on the Fuse failure main panel or the fuse on the burner might be tripped.

  • Page 63: Periodical Flue Gas Measurement Report

    PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Fuel Yield Flue Consumption Consumption (ppm) (ppm) (ppm) Temp. Date Signature (kg/h) (ºC) 09.06.2017 Rev. 08...

  • Page 64: After Sales Services

    Fax: +90 282 685 42 09 Also you can contact with us: Web site : www.ecostar.com.tr E - mail : servis@ecostar.com.tr Please observe the following recommendations. • Use the product in accordance with the principles of this manual. • For any service demands regarding the product, please contact our Service Center from the abovementioned phone numbers.

  • Page 65: Notes

    NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 09.06.2017 Rev. 08...

This manual is also suitable for:

Eco 55 k l c 2aEco 50 k l c 2Eco 70 k l c 2Eco 50 k l c 3Eco 55 k l c 3Eco 55 k l c 3a ... Show all

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