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ECOSTAR ECO 2 Installation, Operating And Maintenance Manual

Monoblock light oil burners
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MONOBLOCK LIGHT OIL BURNERS INSTALLATION,
OPERATING AND MAINTENANCE MANUAL
ONE STAGE, TWO STAGE AND MODULATING OPERATION
ECO 1
ECO 2
ECO 30
ECO 45
27.03.2020 Rev. 11
www.ecostar.com.tr

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  • Page 1 MONOBLOCK LIGHT OIL BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL ONE STAGE, TWO STAGE AND MODULATING OPERATION ECO 1 ECO 2 ECO 30 ECO 45 27.03.2020 Rev. 11 www.ecostar.com.tr...
  • Page 2 DEAR USER, ECOSTAR ECO 1, ECO 2, ECO 30, ECO 45 Light Oil 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. Electric motor direction of rotation Carry in an upright position. Fragile Item. Protect against water. 27.03.2020 Rev.

  • 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 light oil 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 light oil burners are designed to operate with oil at 2.5 – 6 Cst (mm²/s) viscosity, at rated capacity and pressure ranges and -15% to +10% nominal voltage. 3.1. Purpose of Use and Work Limits of Burners ...
  • Page 9 Temperature change of fuel used in ECOSTAR light oil burners dependent on viscosity 27.03.2020 Rev. 11...

  • Page 10: Burner Components

    3.3. Burner Components ECO 1 OLC1-1a 27.03.2020 Rev. 11...
  • Page 11 Assembly No Part Name Assembly No Part Name Body Gasket Flame Tube Lance Mechanism Transformer Mounting Plate Air Adjustment Mechanism Ignition Transformer Air Damper Control Relay Air Damper Gauge Ignition Electrode Photocell Observation Glass Motor Lance Cover Pump Lance Plate Combustion Head Fuel Pipe Boiler Connection Flange...
  • Page 12 ECO 2 OLC1-1a 27.03.2020 Rev. 11...
  • Page 13 Assembly No Part Name Assembly No Part Name Body Handling Shaft Flame Tube Observation Glass Flame Tube Extension Air Damper Gauge Boiler Connection Flange Air Damper Gasket Coupling Connection Pipe Klingerit Gasket Pump Coupling Fan Coupling Motor Pump Ignition Transformer Lance Photocell Ignition Electrode...
  • Page 14 ECO 30 OLC1-1a 27.03.2020 Rev. 11...
  • Page 15 Assembly No Part Name Assembly No Part Name Body Observation Glass Flame Tube Damper Gauge Flame Tube Extension Air Damper Boiler Connection Flange Coupling Connection Pipe Gasket Pump Coupling Klingerit Gasket Fan Coupling Pump Motor Lance Ignition Transformer Ignition Electrode Photocell Electrode Connection Sheet Metal Fan Motor Connection Flange...
  • Page 16 ECO 30 OLC2-2a 27.03.2020 Rev. 11...
  • Page 17 Assembly No Part Name Assembly No Part Name Body Observation Glass Flame Tube Damper Gauge Flame Tube Extension Air Damper Boiler Connection Flange Coupling Connection Pipe Gasket Pump Coupling Klingerit Gasket Fan Coupling Pump Motor Lance Ignition Transformer Ignition Electrode Photocell Electrode Connection Sheet Metal Fan Motor Connection Flange...
  • Page 18 ECO 45 OLC1-1a-1b 27.03.2020 Rev. 11...
  • Page 19 Assembly No Part Name Assembly No Part Name Body Air Damper Klingerit Gasket Air Damper Flame Tube Air Damper Motion Rod Flame Tube Extension Air Damper Motion Transfer Rod Gasket Fan Coupling Boiler Connection Flange Coupling Connection Pipe Pump Coupling Motor Pump Electrical Panel...
  • Page 20 ECO 45 OLC2-2a-2b 27.03.2020 Rev. 11...
  • Page 21 Assembly No Part Name Assembly No Part Name Body Servomotor Coupling Klingerit Gasket Air Damper Flame Tube Air Damper Flame Tube Extension Air Damper Motion Rod Gasket Air Damper Motion Transfer Rod Boiler Connection Flange Fan Coupling Coupling Connection Pipe Motor Pump Coupling Electrical Panel...
  • Page 22 ECO 45 OLC3b 27.03.2020 Rev. 11...
  • Page 23 Assembly No Part Name Assembly No Part Name Body Ignition Electrode Klingerit Gasket Lance Flame Tube Lance Centring Console Flame Tube Extension Solenoid Valve Connection Plate Gasket Solenoid Valve Boiler Connection Flange Fuel Pipes Manometer Motor Ball Valve Electrical Panel Pump Electrical Panel Mounting Plate Pump Coupling...

  • Page 24: Flue Gas And Heating Water Schema

    4. FLUE GAS AND HEATING WATER SCHEMA 27.03.2020 Rev. 11...

  • Page 25: Technical Data

    ECO 1 O (L) C 1 10.200 51.000 0,11 1N 230 ECO 1 O (L) C 1a 40.800 81.600 0,11 1N 230 ECO 2 O (L) C 1 81.600 153.000 0,37 3N 380 ECO 2 O (L) C 1a 102.000 265.200 0,37 3N 380 ECO 30 O(L) C 1 102.000...

  • Page 26: Back Pressure-Capacity Diagrams

    5.2. Back Pressure-Capacity Diagrams 27.03.2020 Rev. 11...
  • Page 27 27.03.2020 Rev. 11...

  • Page 28: Burner Dimensions

    5.3. Burner Dimensions 27.03.2020 Rev. 11...

  • Page 29: Flame Length And Diameter

    5.4. Flame Length and Diameter 5.5. Noise Level Product operates within the range of 75 decibels max. and 80 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 30 Weight(kg) ECO 1 OLC1 65 X 43 X 37 ECO 1 OLC1a 65 X 43 X 37 ECO 2 OLC1 71 X 50 X 37 ECO 2 OLC1a 71 X 50 X 37 ECO 30 OLC1 80 X 54 X 40...

  • Page 31: Installation

    7. INSTALLATION 7.1. Burner Installation Picture 1- Drift Bolts 2- Burner 3- Boiler Connection Flange 4- Gasket 5- Boiler Studs  In the installation of the burner, use the installation materials supplied with the burner.  Secure the burner connection flange onto the burner cover by 4 bolts. Gasket must be connected such that it will remain between connecting flange and boiler cap.

  • Page 32: In Reverse Flame Front Mirror Boilers

    7.2. In reverse flame front mirror boilers 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. 7.3.

  • Page 33: Commissioning

    8. COMMISSIONING 8.1. Before Commissioning 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. 8.2.

  • Page 34: Combustion Adjustment

    8.3. Combustion Adjustment  Fuel nozzle Use proper wrench in installation and dismantle of the fuel nozzle. Use diesel oil to clean the fuel nozzle. Do not use thinner and its derivatives.  Photocell Check the photocell weekly. Clean the dust or fume stains on the glass of photocell by a dry cloth.
  • Page 35 D Type 1- Suction 2- Return and internal bypass 3- Nozzle outlet 4- Manometer connection 5- Vacuum manometer connection 6- Pressure adjustment E Type 1- Suction or vacuum manometer connection 2- Return and internal bypass 3- Nozzle outlet 4- Manometer connection 5- Vacuum manometer connection 6- Pressure adjustment 27.03.2020 Rev.
  • Page 36  One Stage Light Oil Burner Fuel Circuit  Two Stages Light Oil Burner Fuel Circuit 27.03.2020 Rev. 11...
  • Page 37  Modulating Light Oil Burner Fuel Circuit 27.03.2020 Rev. 11...
  • Page 38 CAUTION!  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 39: Servomotor Adjustment

    8.5. Servomotor Adjustment  SQN70 At Two-stage Burners; I. Red Cam: Adjusts 2nd level max. air. II. Blue Cam: Resets the clamp. III. Orange Cam: Adjusts 1st level min. air. IV. Black Cam: Adjusts 2nd level valve opening degree. At Modulating Burners; I.

  • Page 40: Program Relay

    8.7. Program Relay LOA 24  Red led on: Indicates burner malfunction.  If the burner switches to the fault mode, please wait at least 30 seconds and reset the program relay. Press and hold the light button for 2 sec. to reset the program relay. 27.03.2020 Rev.
  • Page 41 If the flame tube of the burner is longer than standard (standard flame tube lenght of the burner), please do not forget to support burner body during maintenance and installation/commissioning. 27.03.2020 Rev. 11...

  • Page 42: Light Oil Burner Fuel Ring Line

    8.8. Light Oil Burner Fuel Ring Line 27.03.2020 Rev. 11...

  • Page 43: Maintenance

    9. MAINTENANCE 9.1. 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 44: Seasonal Maintenance

    9.3. 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.  Check insulation resistance of electric motor.  Make surface cleaning of ignition electrodes and porcelains. Replace cracked or broken porcelains.

  • Page 45: Installation And Disassembly Instructions For Maintenance Purposes

    9.4. Installation and Disassembly Instructions for Maintenance Purposes 1. Remove 3 bolts connecting the burner body to the flame tube 2. Pull the burner body back 3. Remove and perform maintenance of fuel nozzle, diffuser and ignition electrodes. Be careful to connect the components correctly during installation after maintenance.

  • Page 46: Troubleshooting

    10. TROUBLESHOOTING Problem Cause Explanation-Suggestion Fuel is cut or does not Fuel 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 47: Periodical Flue Gas Measurement Report

    11. PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Yield Flue Consumption (ppm) (ppm) (ppm) Temp. Date Signature (ºC) (kg/h) 27.03.2020 Rev. 11...

  • Page 48: 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 49: Notes

    13. NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 27.03.2020 Rev. 11...

This manual is also suitable for:

Eco 1Eco 30Eco 45

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