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Summary of Contents for ECOSTAR ECO 1
- Page 1 MONOBLOCK GAS BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL ONE-STAGE, TWO-STAGE AND MODULATING OPERATION ECO 1 ECO 2 ECO 30 ECO 45 www.ecostar.com.tr 09.10.2018 Rev.10...
- Page 2 DEAR USER, ECOSTAR ECO 1, ECO 2, ECO 30, ECO 45 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.
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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.
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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 Assembly No Part Name Assembly No Part Name Body Group Air Damper Gas Pipe Connection Flange Combustion Head Transformer-Relay Plate Fan Motor Gasket Flame Tube Pressure Switch Adaptor Control Relay Observation Glass Transformer Boiler Connection Flange... - Page 10 ECO 2 Assembly No Part Name Assembly No Part Name Body Group Pressure Switch Flame Tube Pressure Switch Adaptor Gasket Flame Tube Extension Purger Boiler Connection Flange Relay Mounting Plate Gasket Transformer Gas Intake Pipe Pressure Switch Adaptor Combustion Head Fan Motor Diffuser Observation Glass...
- Page 11 ECO 30-45 Assembly No Part Name Assembly No Part Name Body Group Pressure Switch Adaptor Gasket Air Damper Long Flame Tube Air Damper Short Flame Tube Extension Servomotor Coupling Fan Motor Servomotor Damper Motion Rod Transformer Air Damper Motion Transfer Rod Electrical Panel Mounting Plate Gas Intake Pipe Electrical Panel...
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Page 12: Gas, Flue Gas And Heating Water Schema
4. GAS, FLUE GAS AND HEATING WATER SCHEMA 09.10.2018 Rev.10... -
Page 13: Technical Data
Min. Max. Min. Max. kcal/h kcal/h Nm ³/h Nm ³/h Nm ³/h Nm ³/h ONE STAGE GAS BURNERS ECO 1 G C 1 8.600 43.000 0,11 1N 230 ECO 1 G C 1a 17.200 86.000 10,4 0,11 1N 230 ECO 2 G C 1 51.600... -
Page 14: Back Pressure-Capacity Diagrams
5.2. Back Pressure-Capacity Diagrams 09.10.2018 Rev.10... - Page 15 09.10.2018 Rev.10...
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Page 16: Burner Dimensions
5.3. Burner Dimensions 09.10.2018 Rev.10... -
Page 17: Gas Hood Pressure Loss Diagram
5.4. 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 hood pressure while burner is connected to the boiler and working : Combustion chamber pressure : Burner net gas hood pressure 09.10.2018 Rev.10... - Page 18 09.10.2018 Rev.10...
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Page 19: Flame Length And Diameter
5.5. Flame Length and Diameter 5.6. Noise Level Product operates within the range of 75 decibels max. and 85 decibels. 6. 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. •... - Page 20 Dimensions of the box used for handling Burner L x W x H (cm) Weight (kg) ECO 1 GC1(300 mbar) 65 X 43 X 37 ECO 1 GC1a(300 mbar) 65 X 43 X 37 ECO 2 GC1(300 mbar) 65 X 43 X 37...
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Page 21: Installation
7. INSTALLATION 7.1. Burner Installation Picture 1- Burner 2- Burner connection flange 3- Drift Bolts 4- Gasket 5- Boiler flange You must definitely ensure sealing between boiler and burner! Device must be shipped in original packaging! Do not lift the device holding from servomotor, gas valve, impulse pipes or pressure switch during installation! Clean the inside of fuel line thoroughly before installing the burner to the fuel line. -
Page 22: Commissioning
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. 8. -
Page 23: General Controls
8.2. General Controls Make sure to perform the following controls before commissioning the burner. Ø Are the electrical connections correct? Ø Is there electricity current? Ø Is there gas? Ø Has the heating system been filled with water? Ø Is the thermostat set at the required temperature? Ø... -
Page 24: Combustion Adjustment
8.3. Combustion Adjustment 8.3.1. Gas Adjustment Follow the instructions of the valve manufacturer during installation, dismantling and adjustment of the gas valve 8.3.1.1. VGD 20 4011 - 5011 Series Gas Valve SKP 75 Connection Diagram 1 – Air-gas adjustment ratio 2 –... - Page 25 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 26 8.3.1.3. MB ZRD(LE) 405 – 412 Series Gas Valve 09.10.2018 Rev.10...
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Page 27: Air Pressure Switch Adjustment
8.4. 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 Turn the adjustment wheel in the direction to increase the pressure, note the pressure value at which the burner is failed. -
Page 28: Emission Measurement
8.6. 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 29: Program Relay
8.8. Program Relay LME 22 Ø Yellow led on: Indicates that the burner is making pre-purge. Ø Yellow led flashing: Indicates that the burner is igniting. Ø Green led flashing: Indicates poor combustion. Ø Red led on: Indicates burner malfunction. Press and hold the light button for 2 sec. - Page 30 If the value measure from PL point is below 0.5 bar, set the impulse pipe as follows. 09.10.2018 Rev.10...
- Page 31 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. 09.10.2018 Rev.10...
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Page 32: Gas Pass Equipment Required In Gas Line
8.11. 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 33: Maintenance
9. MAINTENANCE 9.1. 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 34: Installation And Disassembly Instructions For Maintenance Purposes
9.3. Installation And Disassembly Instructions For Maintenance Purposes ECO 1 For Intervention to Ignition System Ø Remove 3 bolts number 1, which fix the flame tube on the Body, and pull back and lower the body provided that the flame tube stays on the boiler. - Page 35 ECO 2 For Intervention to Ignition System Ø Remove 3 bolts number 1 that fix the body on the flame tube and pull back the body by sliding it on the lift shaft. For Intervention to Fan and Motor: Ø Remove cable of the electric motor from program relay.
- Page 36 ECO 30, ECO 45 For Intervention to Ignition System Ø Remove 3 bolts number 1 that fix the body on the flame tube and pull back the body by sliding it on the lift shaft. For Intervention to Fan and Motor: Ø...
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Page 37: Troubleshooting
10. 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 38: Periodical Flue Gas Measurement Report
11. PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Yield Flue Consumption (ppm) (ppm) (ppm) Temp. Date Signature (m³/h) (ºC) 09.10.2018 Rev.10... -
Page 39: 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 40: Notes
13. NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 09.10.2018 Rev.10...
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