ECOSTAR ECO 1.0 Installation, Operating And Maintenance Manual

ECOSTAR ECO 1.0 Installation, Operating And Maintenance Manual

Square body monoblock gas burners

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SQUARE BODY MONOBLOCK GAS BURNERS
INSTALLATION, OPERATING AND
MAINTENANCE MANUAL
ONE STAGE AND TWO-STAGE OPERATION
ECO 1.0
ECO 2.0
ECO 30.0
19.10.2018 Rev. 07
www.ecostar.com.tr

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Summary of Contents for ECOSTAR ECO 1.0

  • Page 1 SQUARE BODY MONOBLOCK GAS BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL ONE STAGE AND TWO-STAGE OPERATION ECO 1.0 ECO 2.0 ECO 30.0 www.ecostar.com.tr 19.10.2018 Rev. 07...
  • Page 2 DEAR USER, ECOSTAR ECO 1.0, ECO 2.0, ECO 30.0 Square Body Gas burners are prepared and manufactured according to the latest technical developments and safety rules. It is easy to use for our customers. We recommend that you read this manual and safety warnings thoroughly before the use of the device in order to ensure safe, cost effective and environmental-friendly use.
  • Page 3: Table Of Contents

    CONTENTS WARNINGS ............................3 1.1. Warning Symbols and Descriptions ..................... 3 1.2. General Safety Rules ........................4 TERMS OF WARRANTY ........................6 2.1. Out of Warranty Conditions ......................6 BURNER’S GENERAL FEATURES ....................7 3.1. Purpose of Use and Work Limits of Burners ................7 3.2.
  • Page 4: Warnings

    1. WARNINGS 1.1. 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

    1.2. 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

    2. TERMS OF WARRANTY Main and auxiliary equipment and all components used in Ecostar gas 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

    3. BURNER’S GENERAL FEATURES ECOSTAR gas burners are manufactured such that they operate in gas pressure of min. 20 mbar and max. 300 mbar., at -15%...+10% of nominal voltage, between the ambient temperature range of -15ºC….+60˚C and declared capacity and boiler pressure ranges with Natural Gas and Liquid Petrol Gas.
  • Page 9: Burner Components

    3.3. Burner Components ECO 1.0 Assembly No Part Name Assembly No Part Name Housing cover Boiler connection flange Relay Gasket Relay main connection shaft Rubber gasket Transformer Gas intake pipe Pressure switch Socket Installation sheet Air klappe Caudal elbow Spiral casing...
  • Page 10 ECO 2.0-ECO 30.0 Assembly No Part Name Assembly No Part Name Housing cover Flame tube Relay Gas tip Relay main connection shaft Gas intake pipe Transformer Air klappe Pressure switch Service cover Servomotor Elbow Installation sheet Bulls eye Nipple Spiral casing Motor Relay ignition transformer Gas valve...
  • Page 11: Technical Data

    Nm³/h Nm³/h Nm³/h Nm³/h ONE STAGE GAS BURNERS ECO 1.0 G C 1 8.600 43.000 0,11 1N 230 ECO 1.0 G C 1 a 8.600 51.600 0,11 1N 230 ECO 1.0 G C 1 b 17.200 73.100 0,11 1N 230 ECO 1.0 G C 1 c...
  • Page 12: Back Pressure-Capacity Diagrams

    4.2. Back Pressure-Capacity Diagrams 19.10.2018 Rev. 07...
  • Page 13 19.10.2018 Rev. 07...
  • Page 14 19.10.2018 Rev. 07...
  • Page 15: Burner Dimensions

    4.3. Burner Dimensions 19.10.2018 Rev. 07...
  • Page 16: Gas Hood Pressure Loss Diagram

    4.4. 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 good pressure while burner is connected to the boiler and working : Combustion chamber pressure : Burner net gas hood pressure 19.10.2018 Rev.
  • Page 17: Flame Length And Diameter

    4.5. Flame Length and Diameter 4.6. Noise Level Product operates within the range of 68 decibels max. and 70 decibels. 19.10.2018 Rev. 07...
  • Page 18: Burner Handling Information

    • Do not leave the product in wet environment. Dimensions of the box used for handling Burner L x W x H (cm) Weight (kg) ECO 1.0 70 X 33 X 35 65 X 36 X 47 ECO 2.0 75 X 43 X 54 ECO 30.0...
  • Page 19: Installation

    6. INSTALLATION 6.1. Burner Installation Picture 1- Drift Bolts 2- Burner Body 3- Boiler Connection Flange 4- Gasket 5- Boiler Studs 1- Burner Body 2- Boiler Connection Flange 3- Nut 4- Bolt You must definitely ensure sealing between boiler and burner! Device must be shipped in original packaging! Do not lift the device holding from gas valve, impulse pipes or pressure switch during...
  • Page 20 1- Gas Head Adjusting Nut 2- Gas Head Drive Shaft • When gas head adjusting nut is rotated clockwise, gas head is withdrawn and operation at high capacity is ensured. • When gas head adjusting nut is rotated anti-clockwise, gas head moves forward and capacity is reduced.
  • Page 21: Commissioning

    7. COMMISSIONING 7.1. Before Commissioning 7.1.1. Ignition and Ionizasyon System 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. 7.2.
  • Page 22: Combustion Adjustment

    Operation of one-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 1. Ø...
  • Page 23 Consider the below torque values for bolts tightened on the valve. Tighten flange bolts according to cross ordering and use proper tools. Sealing and function check must be performed if the valve is dismantled and re-installed over the line due to any reason. Before dismantling the valve from the line, you can perform filter replacement according to the below order.
  • Page 24: Mb Zrd(Le) 405 - 412 Series Gas Valve

    7.3.1.2. MB ZRD(LE) 405 – 412 Series Gas Valve 19.10.2018 Rev. 07...
  • Page 25: Le Series Monoblock

    7.3.1.3. GB-LE Series Monoblock 7.4. 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...
  • Page 26: Servomotor Adjustment

    7.5. Servomotor Adjustment The amount of air is adjusted by means of the servomotor. The servomotor adjustment at two-stage and modulating burners is made by the cams on the servomotor. Ø SQN70 At Two-Stage Burners; I. Red Cam: Adjusts 2nd level max. air. II.
  • Page 27: Emission Measurement

    7.6. 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 It is important for the boiler to be sealed in order to avoid incorrect measurements during emission measurements.
  • Page 28: Function Controls And Adjustments

    7.9. Function Controls and Adjustments Ø Operation testing: If the burner switch is turned on and safety circuit is complete (gas pressure switch, thermostat, water level gauge, lower pressure gas pressure switch, upper pressure gas pressure switch, gas leakage control device), turn on the ball valve, burner will start working and turn off the gas valve.
  • Page 29: Gas Pass Equipment Required In Gas Line

    7.11. Gas Pass Equipment Required in Gas Line Pe ≤ 300 mbar Pe ≥ 300 mbar 1- Compensator 1- Compensator 2- Ball valve 2- Ball valve 3- Gas filter 3- Gas filter 4- Inlet manometer + valve 4- Inlet manometer + valve 8-Multi-block (safety and operation solenoids) 5- Regulator 9- Sealing Control Set 6- Outlet manometer + valve...
  • Page 30: Maintenance

    8. MAINTENANCE 8.1. Monthly Maintenance Monthly maintenance is a comprehensive process where general checks of burner and peripheral components are performed to prevent possible faults. After completion of maintenance and adjustment processes, make sure to perform an emission analysis. Ø Clean the filters on the main line and multiblock. Ø...
  • Page 31: Installation And Disassembly Instructions For Maintenance Purposes

    8.3. Installation And Disassembly Instructions For Maintenance Purposes Disassembly: 1. Remove the plastic cover fixing bolts on the body and take out the cover. 2. Turn off the gas cut-off valve before gas valve. 3. Take out electric connection sockets. 4.
  • Page 32 12. Detach gas inlet pipe and gas tip from the body. For intervention to ignition system only 1. Remove the plastic cover fixing bolts on the body and take out the cover. 2. Loosen and remove control device installation sheet screws. 3.
  • Page 33: Troubleshooting

    9. TROUBLESHOOTING Problem Cause Explanation-Suggestion Gas is cut or does not Gas valve might be closed. Open the valve. come Check burner power supply. The fuse on the Fuse failure main panel or the fuse on the burner might be tripped.
  • Page 34: Periodical Flue Gas Measurement Report

    10. PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Yield Flue Consumption (ppm) (ppm) (ppm) Temp. Date Signature (m³/h) (ºC) 19.10.2018 Rev. 07...
  • Page 35: 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 36: Notes

    12. NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 19.10.2018 Rev. 07...

This manual is also suitable for:

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