ECOSTAR FPB 200 Installation, Operating And Maintenance Manual

ECOSTAR FPB 200 Installation, Operating And Maintenance Manual

Process burners dual fuel

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PROCESS BURNERS DUAL FUEL (GAS-HEAVY OIL)
INSTALLATION, OPERATING AND MAINTENANCE
MANUAL
ONE STAGE, TWO STAGE AND MODULATING OPERATION
FPB 200
FPB 300
FPB 400
FPB 550
FPB 870
FPB 1200
FPB 1600
FPB 2000
FPB 2500
FPB 3500
FPB 5000
09.01.2020 Rev. 10
www.ecostar.com.tr

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Summary of Contents for ECOSTAR FPB 200

  • Page 1 PROCESS BURNERS DUAL FUEL (GAS-HEAVY OIL) INSTALLATION, OPERATING AND MAINTENANCE MANUAL ONE STAGE, TWO STAGE AND MODULATING OPERATION FPB 200 FPB 300 FPB 400 FPB 550 FPB 870 FPB 1200 FPB 1600 FPB 2000 FPB 2500 FPB 3500 FPB 5000 09.01.2020 Rev.
  • Page 2 DEAR USER, ECOSTAR FPB 200, FPB 300, FPB 400, FPB 550, FPB 870, FPB 1200, FPB 1600, FPB 2000, FPB 2500, FPB 3500, FPB 5000 Dual Fuel (Gas-Heavy Oil)process burners are prepared and manufactured according to the latest technical developments and safety rules.
  • 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 Install burner firmly. Vibration may damage burner or its components. Keep boiler doors closed while starting burner and during burner operation. During the first commissioning of the burner or in case of any revision carried out in the electrical system or motor cables by any reason, direction of the fan rotation must certainly be checked by the authorized technical service.
  • Page 7: Terms Of Warranty

    2. TERMS OF WARRANTY Main and auxiliary equipment and all components used in Ecostar Dual Fuel (Gas-Heavy Oil) process 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 Dual Fuel (Gas-Heavy Oil) burners are designed and manufactured to work with liquid fuel with max. 2.5- 20 Cst (mm s) viscosity. and Natural Gas / 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-Heavy Oil) process burners dependent on viscosity 09.01.2020 Rev. 10...
  • Page 10: Process Burner Components

    3.2. Process Burner Components 1- Pneumatic Cylinder* 2- Casing Flange 3- Nozzle 4- Gas Intake Pipe 5- Ignition Electrodes 6- Body 7- Flame Tube 8- Photocell 9- Combustion Air Intake It is available as an option. 09.01.2020 Rev. 10...
  • Page 11: Gas, Flue Gas And Heating Water Schema

    4. GAS, FLUE GAS AND HEATING WATER SCHEMA 09.01.2020 Rev. 10...
  • Page 12: Technical Data

    CONSUMPTION FLOW RATE Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Kcal/h Nm³/h Nm³/h kg/h Nm³/h FPB 200 40.000 200.000 46,5 232,6 24,2 20,7 FPB 300 60.000 300.000 69,8 348,8 36,4 13,3 31,1 FPB 400 80.000 400.000 93,0...
  • Page 13: Installation

    6. INSTALLATION 6.1. Burner Installation Picture 1 - Air inlet 2 - Connecting Flange 3- Sealing (Gasket) 4 - Refractory combustion chamber 5 - Flame tube After completing the installation of the burner on the boiler: Sealing between the combustion chamber and burner must be ensured Device must be shipped in original packaging! Do not lift the device holding from servomotor, gas valve, impulse pipes or pressure switch during installation!
  • Page 14: Commissioning

    7. COMMISSIONING 7.1. General Controls Make sure to perform the following controls before commissioning the burner. • Has heat demand been formed? • Are the thermostat and other thermo-elements for control purposes working properly? • Are the electrical connections correct? •...
  • Page 15: Combustion Adjustment

    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 16: Oil Pump

    7.2.1. Oil pump 1. Oil inlet connection 2. Pressure adjustment screw 3. Oil return connection 4. Manometer connection 5. Pressurized oil outlet connection 7.2.2. Gas Adjustment Follow the instructions of the valve manufacturer during installation, dismantling and adjustment of the gas valve 7.2.2.1.
  • Page 17: Mb Dle Series Monoblock Gas Valve

    7.2.2.2. MB DLE Series Monoblock Gas Valve 1- Pressure switch 2- Pressure switch electrical connection 3- Electrical connection of the valve 4- Operation gauge 5- The sealing ring 6- Set cover 7- Hydraulic disk brakes or settings 8- Coil 9- Measuring element connection (1/8) 10- Measuring element connection (1/8) 11- Output flange 12- Measuring element connection (1/8)
  • Page 18 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 19: Mb Zrd(Le) 405 - 412 Series Gas Valve

    7.2.2.3. MB ZRD(LE) 405 – 412 Series Gas Valve 09.01.2020 Rev. 10...
  • Page 20: Fuel Diagrams

    7.3. Fuel Diagrams Ø One Stage Heavy Oil Burner Fuel Circuit Ø Two Stages Heavy Oil Burner Fuel Circuit 09.01.2020 Rev. 10...
  • Page 21 Ø Modulating Heavy Oil Burner Fuel Circuit 09.01.2020 Rev. 10...
  • Page 22 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 23: Air Pressure Switch Adjustment

    Ø Burner preheater 1. Fuel inlet 2. Fuel outlet 3. Discharge 4. Fixing plate 5. Resistance 6. Thermostat bulb pipe 7. Housing cover 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.
  • Page 24 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. Burner’s actuators should not be installed closer to high temperature zones, max allowed ambient temperature should be 60 °C for actuator’s operation safety 09.01.2020 Rev.
  • Page 25 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 26 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 27 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 28: Program Relay

    7.6. Program Relay LFL 1.32 7.7. Heavy Oil Burner Fuel Ring Line 09.01.2020 Rev. 10...
  • Page 29: Gas Pass Equipment Required In Gas Line

    7.8. Gas Pass Equipment Required in Gas Line 09.01.2020 Rev. 10...
  • Page 30 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 3- Gas filter 3- Gas filter...
  • Page 31: Maintenance

    8. MAINTENANCE 8.1. 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 32: Seasonal Maintenance

    8.3. Seasonal Maintenance Comprehensive maintenance work when the burner is restarted 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 33: Troubleshooting

    9. TROUBLESHOOTING Problem Cause Explanation-Suggestion Heavy Oil or Gas valve might be closed. Open Heavy 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 34: Periodical Flue Gas Measurement Report

    10. PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Fuel Yield Flue Consumption Consumption (ppm) (ppm) (ppm) Temp. Date Signature (kg/h) (ºC) 09.01.2020 Rev. 10...
  • 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 09.01.2020 Rev. 10...

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