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Summary of Contents for ECOSTAR NG Series
- Page 1 MONOBLOCK NG SERIES LOW NOx AND ULTRA LOW NOx SERIES GAS BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL MODULATING OPERATION ECO NG LNX 90 G (FGR) ECO NG LNX 120 G (FGR) ECO NG LNX 200 G (FGR) ECO NG LNX 300 G (FGR) ECO NG LNX 400 G (FGR) 02.02.2021 Rev.
- Page 2 DEAR USER, ECOSTAR ECO NG LNX 90 G (FGR), ECO NG LNX 120 G (FGR), ECO NG LNX 200 G (FGR), ECO NG LNX 300 G (FGR), ECO NG LNX 400 G (FGR)) Series Low NOx and Ultra Low NOx Gas burners are prepared and manufactured according to the latest technical developments and safety rules.
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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 NG Series Low NOx and Ultra Low NOx gas burners are manufactured such that they operate in gas pressure of min. 20 mbar and max. 300mbar. 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. -
Page 9: Gas, Flue Gas And Heating Water Scheme
4. GAS, FLUE GAS AND HEATING WATER SCHEME 4.1.New Generation Low NOx Gas Burner Gas, Flue Gas, and Heating Water Scheme 4.2.New Generation Ultra Low NOx Gas Burner Gas, Flue Gas, and Heating Water Scheme 02.02.2021 Rev 01. -
Page 10: Technical Data
5. TECHNICAL DATA 5.1. Capacity Table NEW GENERATION LOW NOx GAS BURNERS CAPACITY TABLE NATURAL GAS MAIN BURNER TYPE THERMAL CAPACITY MOTOR CONSUMPTION EMISSIONS SUPPLY POWER Min. Max. Min. Max. Min. Max. Standard kcal/h kcal/h Nm³/h Nm³/h mg/kWh ≤80 ECO NG LNX 90 G 154.800 774.000 18,8... -
Page 11: Back Pressure-Capacity Diagrams
5.2. Back Pressure-Capacity Diagrams Boiler back pressure values are measured at back pressured test boiler using G20 reference gas according to EN 676+ A2, with net calorific value is 8250 kcal/Nm³. 02.02.2021 Rev 01. -
Page 12: Burner Dimensions
5.3. Burner Dimensions ECO NG LNX 90 G , ECO NG LNX 120 G, ECO NG LNX 200 G, ECO NG LNX 300 G, ECO NG LNX 400 G 02.02.2021 Rev 01. - Page 13 ECO NG LNX 90 G FGR , ECO NG LNX 120 G FGR , ECO NG LNX 200 G FGR , ECO NG LNX 300 G FGR , ECO NG LNX 400 G FGR 02.02.2021 Rev 01.
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Page 14: Fgr Nox Reduction System
6. FGR NOx REDUCTION SYSTEM External Flue Gas Recirculation (FGR) is effective and low cost solution to achieve very low NOx emissions. Some flue gas from chimney is led back ta the combustion chamber through burner; which reduces NOx emissions by cooling down flame peak temperature and by slowing combustion reactions. Achivable reduction depends on burner type, boiler;... - Page 15 FGR Operating Conditions are Listed Below: Burner safety control is done with air presostat. Flow rate is controlled with butterfly valve . Flue gas flow rate is controlled by a butterfly valve integrated with servomotor. Burner O2 emission values must be setted over 0,5 – 0,7% when FGR is closed. O ≤ %3, when FGR is closed;...
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Page 16: Fgr System Pipe Diameter, Length ,And Equivalent Length Informations
6.2. FGR System Pipe Diameter, Length ,and Equivalent Length Informations Pipe ECO NG ECO NG ECO NG ECO NG ECO NG Diameter LNX 90 G LNX 120 G LNX 200 G LNX 300 G LNX 400 G DN 50 DN 65 DN 80 DN 100 DN 125... -
Page 17: Flame Length And Diameter
6.3. Flame Length and Diameter 6.4. Noise Level Product operates within the range of 75 decibels max. and 85 decibels. 7. 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 18: Installation
8. INSTALLATION 8.1. Burner Installation Picture Burner Boiler Connection Flange Gasket Boiler Flange FGR Flap Condensation Outlet FGR Flap Servomotor 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 19: 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. 9. -
Page 20: General Controls
9.2. 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 21: Combustion Adjustment
9.3. Combustion Adjustment 9.3.1. Gas Adjustment Follow the instructions of the valve manufacturer during installation, dismantling and adjustment of the gas valve 9.3.1.1. VGD 40… Series Gas Valve Technical Features Gas Multiblock Valve integrates filter, regulator, valves and pressure switches in one compact fitting. Ø... -
Page 22: Air Pressure Switch Adjustment
9.4. 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 23: Bt 300
9.5. BT 300 The BT 300 is available in these functions: Ø 2 (Standard) or 3 (FGR used) motorized control outputs, Ø 1 continuous output 0 ... 10 V, 0/4 ... 20 mA for speed control of the combustion air fan using VSM100 (optional), Ø... -
Page 24: Control System Mounting And Functions System Overview
9.6. Control System Mounting and Functions System Overview 02.02.2021 Rev 01. - Page 25 02.02.2021 Rev 01.
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Page 26: Operating Control And Displays
9.6.1. Operating Control and Displays 1 Display 2 Back key 3 Cursor keys 4 Enter key Display: The display shows in pictograms: 1 - The menu structure 2 - Operating status 3 - Parameters 4 - Error messages Back key: Jump to previous window. Cursor keys: You navigate in the menu using the cursor keys. -
Page 27: Leakage Test For Main Gas Valves
9.7. Leakage Test for Main Gas Valves 02.02.2021 Rev 01. -
Page 28: Servomotors
9.8. Servomotors Servomotors drive air dampers, gas butterfly valve and oil regulator. With the help of servomotors electronic air and fuel ratio control is carried out, controlled by burner control. Ø Static electricity can damage servomotor. Ø Do not open servomotor. Do not interfere with or modify unit or equipment connected to it. It may damage servomotor or change burner settings. -
Page 29: Function Controls And Adjustments
9.9. Function Controls and Adjustments The BT300 combines the benefits of an electronic fuel-air ratio control system with up to three motorized actuating devices and an optional module like an analogue output for speed control of the combustion air fan with an electronic burner control unit. The leakage test, flame monitoring system, power control unit and (optional) CO/O2 controller for control and optimization of an oil or gas-fired forced-draught burner are all integrated. -
Page 30: Gas Pass Equipment Required In Gas Line
9.12. 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 31: Maintenance
10. MAINTENANCE 10.1. 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 32: Periodical Flue Gas Measurement Report
11. PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Yield Flue Consumption (ppm) (ppm) (ppm) Temp. Date Signature (m³/h) (ºC) 02.02.2021 Rev 01. -
Page 33: 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 34: Notes
13. NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 02.02.2021 Rev 01.
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