ECOSTAR ECO 50 G C 2 Operating And Maintenance Manual
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ECOSTAR ECO 50 G C 2 Operating And Maintenance Manual

Monoblock gas burners
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MONOBLOCK GAS BURNERS INSTALLATION,
OPERATING AND MAINTENANCE MANUAL
TWO STAGE AND MODULATING OPERATION
ECO 50
ECO 55
ECO 60
ECO 65
ECO 70
ECO 75
09.10.2018 Rev. 10
www.ecostar.com.tr

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Summary of Contents for ECOSTAR ECO 50 G C 2

  • Page 1 MONOBLOCK GAS BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL TWO STAGE AND MODULATING OPERATION ECO 50 ECO 55 ECO 60 ECO 65 ECO 70 ECO 75 09.10.2018 Rev. 10 www.ecostar.com.tr...
  • Page 2 DEAR USER, ECOSTAR ECO 50, ECO 55, ECO 60, ECO 65, ECO 70, ECO 75 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 50, ECO55 Assembly No Part Name Assembly No Part Name Body Group Servomotor Servomotor Coupling Fan Motor Mounting Flange Air Damper Short Fan Motor Air Damper Long Gasket Damper Motion Rod Flame Tube Air Damper Motion Transfer Rod Flame Tube Extension Lance Cover Transformer...
  • Page 10 ECO 50, ECO 55 Mechanical Modulation Assembly No Part Name Assembly No Part Name Body Group Lance Cover Purger Fan Motor Mounting Flange Gasket Fan Motor Boiler Connection Flange Servomotor Gasket Servomotor Coupling Flame Tube Air Damper Flame Tube Extension Air Damper Transformer Combustion Head Elbow...
  • Page 11 ECO 60 Assembly No Part Name Assembly No Part Name Body Group Pressure Switch Purger Fan Motor Gasket Fan Motor Mounting Flange Combustion Head Elbow Transformer Mounting Plate Combustion Head Transformer Flame Tube Air Damper Long Gas Train Pipe Air Damper Short Boiler Connection Flange Servomotor Coupling Gasket...
  • Page 12 ECO 65 - ECO 70 Assembly No Part Name Assembly No Part Name Body Group Purger Gasket Fan Motor Combustion Head Elbow Fan Motor Mounting Flange Combustion Head Transformer Mounting Plate Flame Tube Transformer Gas Train Pipe Air Damper Long Boiler Connection Flange Air Damper Short Gasket...
  • Page 13 ECO 75 Assembly No Part Name Assembly No Part Name Body Group Eye bolt Flame Tube Purger Gas Train Pipe Transformer Box Lance Cover Servomotor Gasket Servomotor Coupling Combustion Head Pressure Switch Boiler Connection Flange Pressure Switch Adaptor Pipe 25-1 Gasket 25-2 Pressure Switch Adaptor...

  • Page 14: Gas, Flue Gas And Heating Water Schema

    4. GAS, FLUE GAS AND HEATING WATER SCHEMA 09.10.2018 Rev. 10...

  • Page 15: Technical Data

    Max. Min. Max. Min. Max. kcal/h kcal/h Nm ³/h Nm ³/h Nm ³/h Nm ³/h TWO STAGE GAS BURNERS ECO 50 G C 2 215.000 1.290.000 1.500 26,1 156,4 57,3 2,20 3N 380 ECO 55 G C 2 258.000 1.720.000 2.000...

  • Page 16: Back Pressure-Capacity Diagrams

    5.2. Back Pressure-Capacity Diagrams 09.10.2018 Rev. 10...
  • Page 17 09.10.2018 Rev. 10...

  • Page 18: Burner Dimensions

    5.3. Burner Dimensions 09.10.2018 Rev. 10...
  • Page 19 ECO 50, ECO 55 Mechanical Modulation * F dimension may vary depending on the valve model. 09.10.2018 Rev. 10...

  • Page 20: 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.
  • Page 21 09.10.2018 Rev. 10...
  • Page 22 09.10.2018 Rev. 10...

  • Page 23: 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 24 Dimensions of the box used for handling Burner L x W x H (cm) Weight (kg) ECO 50 GC2 133 X 68 X 75 ECO 50 GC3 133 X 68 X 75 ECO 55 GC2 133 X 68 X 75 ECO 55 GC2a 133 X 68 X 75 ECO 55 GC3...

  • Page 25: Installation

    7. INSTALLATION 7.1. Burner Installation Picture 1- Burner 2- Drift Bolts 3- Gasket 4- 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 26: 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 27: 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 28: 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 29: Mb Dle Series Monoblock Gas Valve

    8.3.1.2. 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 30 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 31: Mb Zrd(Le) 415 - 420 Series Gas Valve

    8.3.1.3. MB ZRD(LE) 415 – 420 Series Gas Valve 09.10.2018 Rev. 10...

  • Page 32: 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 33: 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 34: Function Controls And Adjustments

    8.9. 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 35 If the value measure from PL point is below 0.5 bar, set the impulse pipe as follows. 09.10.2018 Rev. 10...
  • Page 36 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...

  • Page 37: 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 38: 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 39: Installation And Disassembly Instructions For Maintenance Purposes

    9.3. Installation And Disassembly Instructions For Maintenance Purposes ECO 50, ECO 55 For Intervention to Ignition System Ø Remove 3 bolts number 1 that connect the body group and gas tip, and pull back the body group. Ø Remove bolts number 2 from the gas tip and interfere the ignition system.
  • Page 40 ECO 60, ECO 65, ECO 70 For Intervention to Ignition System Ø Remove 3 bolts number 1 that connect the body group and gas tip, and pull back the body group. Ø Remove bolts number 2 from the gas tip and interfere the ignition system.
  • Page 41 ECO 75 For Intervention to Ignition System Ø Remove 3 bolts number 1 that connect the body group and gas tip, and pull back the body group. Ø Remove bolts number 2 from the gas tip and interfere the ignition system. For Intervention to Fan and Motor: Ø...

  • Page 42: 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 43: 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 44: 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 45: Notes

    13. NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 09.10.2018 Rev. 10...

This manual is also suitable for:

Eco 55 g c 2Eco 55 g c 2aEco 60 g c 2Eco 65 g c 2Eco 70 g c 2Eco 50 g c 3 ... Show all

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