ECOSTAR ECO 50 Installation, Operating And Maintenance Manual

ECOSTAR ECO 50 Installation, Operating And Maintenance Manual

Monoblock dual fuel (gas-heavy oil) burners

Advertisement

Quick Links

MONOBLOCK DUAL FUEL (GAS-HEAVY OIL)
BURNERS INSTALLATION, OPERATING AND
MAINTENANCE MANUAL
TWO STAGE AND MODULATING OPERATION
ECO 50
ECO 55
ECO 60
ECO 65
ECO 70
ECO 75
22.11.2022 Rev. 12
www.ecostar.com.tr

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ECO 50 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for ECOSTAR ECO 50

  • Page 1 MONOBLOCK DUAL FUEL (GAS-HEAVY OIL) BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL TWO STAGE AND MODULATING OPERATION ECO 50 ECO 55 ECO 60 ECO 65 ECO 70 ECO 75 22.11.2022 Rev. 12 www.ecostar.com.tr...
  • Page 2 DEAR USER, ECOSTAR ECO 50, ECO 55, ECO 60, ECO 65, ECO 70, ECO 75 Dual Fuel (Gas- Heavy Oil) burners are prepared and manufactured according to the latest technical developments and safety rules. It is easy to use for our customers.
  • 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, qualified 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 Dual Fuel (Gas-Heavy 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 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 and 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) burners dependent on viscosity 22.11.2022 Rev. 12...
  • Page 10: Burner Components

    3.3. Burner Components ECO 50 KSC2 22.11.2022 Rev. 12...
  • Page 11 Assembly No Part Name Assembly No Part Name Body Oil pre-heater connection part Klingerit Gasket Thermometer connection adapter Flame Tube Thermometer Flame Tube extension Purger Boiler Connection Flange Combustion head Gasket Fuel nozzle Lance Motor connection flange Solenoid valve Motor Fuel pipes Electrical Panel Mounting Plate Manometer...
  • Page 12 ECO 55 KSC2-2a 22.11.2022 Rev. 12...
  • Page 13 Assembly No Part Name Assembly No Part Name Body Thermometer connection adapter Klingerit Gasket Thermometer Flame Tube Purger Flame Tube extension Combustion head Boiler Connection Flange Fuel nozzle Gasket Lance Solenoid valve Motor Fuel pipes Electrical Panel Mounting Plate Manometer Electrical Panel Ball valve Handling Rod Fixing Plate...
  • Page 14 ECO 60 KSC2 22.11.2022 Rev. 12...
  • Page 15 Assembly No Part Name Assembly No Part Name Body Pilot Igniter Gas Solenoid Valve Klingerit Gasket Pilot igniter pipe Flame Tube Pilot igniter electrode Boiler Connection Flange Pilot combustion head Gasket Purger Combustion head Motor connection flange Fuel nozzle Motor Lance Electrical Panel Mounting Plate Solenoid valve...
  • Page 16 ECO 65 KSC2 22.11.2022 Rev. 12...
  • Page 17 Assembly No Part Name Assembly No Part Name Body Pilot Igniter Gas Solenoid Valve Klingerit Gasket Pilot igniter pipe Flame Tube Pilot igniter electrode Boiler Connection Flange Pilot combustion head Gasket Purger Flame Tube extension Combustion head Fuel nozzle Motor connection flange Lance Motor Solenoid valve...
  • Page 18 ECO 70 KSC2 22.11.2022 Rev. 12...
  • Page 19 Assembly No Part Name Assembly No Part Name Body Pilot Igniter Gas Solenoid Valve Klingerit Gasket Pilot igniter pipe Flame Tube Pilot igniter electrode Boiler Connection Flange Pilot combustion head Gasket Purger Flame Tube extension Combustion head Fuel nozzle Motor Lance Electrical Panel Mounting Plate Solenoid valve...
  • Page 20 ECO 50 KSC3 22.11.2022 Rev. 12...
  • Page 21 Assembly No Part Name Assembly No Part Name Body group Fuel nozzle Klingerit Gasket Centring wedge Flame Tube Combustion head Boiler Connection Flange Lance Gasket Solenoid valve Connection plate Flame Tube extension Solenoid valve Manometer Motor Ball valve Electrical Panel Mounting Plate Fuel pipes Electrical Panel Air damper motion rod...
  • Page 22 ECO 55 KSC3-3a 22.11.2022 Rev. 12...
  • Page 23 Assembly No Part Name Assembly No Part Name Body group Fuel nozzle Klingerit Gasket Centring wedge Flame Tube Combustion head Boiler Connection Flange Lance Gasket Solenoid valve Connection plate Flame Tube extension Solenoid valve Manometer Motor Ball valve Electrical Panel Mounting Plate Fuel pipes Electrical Panel Air damper motion rod...
  • Page 24 ECO 60 KSC3 22.11.2022 Rev. 12...
  • Page 25 Assembly No Part Name Assembly No Part Name Body group Klingerit Gasket Gas Solenoid Valve Flame Tube Gas Intake Pipe Boiler Connection Flange Fuel nozzle Gasket Centring wedge Combustion head Motor connection flange Lance Motor Solenoid valve connection plate Electrical Panel Mounting Plate Solenoid valve Electrical Panel Manometer...
  • Page 26 ECO 65 KSC3 22.11.2022 Rev. 12...
  • Page 27 Assembly No Part Name Assembly No Part Name Body group Pilot combustion head Klingerit Gasket Flame Tube Gas Solenoid Valve Boiler Connection Flange Gas Intake Pipe Gasket Fuel nozzle Flame Tube extension Centring wedge Combustion head Motor connection flange Lance Motor Solenoid valve connection plate Electrical Panel Mounting Plate...
  • Page 28 ECO 70 KSC3 22.11.2022 Rev. 12...
  • Page 29 Assembly No Part Name Assembly No Part Name Body group Klingerit Gasket Gas Solenoid Valve Flame Tube Gas Intake Pipe Boiler Connection Flange Fuel nozzle Gasket Centring wedge Flame Tube extension Combustion head Lance Motor Solenoid valve connection plate Electrical Panel Mounting Plate Solenoid valve Electrical Panel Manometer...
  • Page 30 ECO 75 KSC3 22.11.2022 Rev. 12...
  • Page 31 Assembly No Part Name Assembly No Part Name Body group Eyebolt Klingerit Gasket Purger Flame Tube Boiler Connection Flange Gas Solenoid Valve Gasket Gas Intake Pipe Fuel nozzle Motor Centring wedge Electrical Panel Mounting Plate Combustion head Electrical Panel Lance Air damper plate Ignition transformer Air damper plate...
  • Page 32: Gas, Flue Gas And Heating Water Schema

    4. GAS, FLUE GAS AND HEATING WATER SCHEMA 22.11.2022 Rev. 12...
  • Page 33: Technical Data

    Min. Max. Min. Max. Min. Max. kcal/h kcal/h kcal/h kcal/h kg/h kg/h TW O STAGE GAS/HEAVY OIL DUAL BURNERS ECO 50 K S C 2 215.000 1.290.000 1500 26,1 156,4 337.750 1.351.000 1571 35,00 140,00 0,75 3N 400 ECO 55 K S C 2 258.000...
  • Page 34: Back Pressure-Capacity Diagrams

    5.2. Back Pressure-Capacity Diagrams 22.11.2022 Rev. 12...
  • Page 35: Burner Dimensions

    5.3. Burner Dimensions 22.11.2022 Rev. 12...
  • Page 36: 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 22.11.2022 Rev.
  • Page 37 22.11.2022 Rev. 12...
  • Page 38 22.11.2022 Rev. 12...
  • Page 39: Flame Length And Diameter

    5.5. Flame Length and Diameter Natural Gas Heavy Oil 5.6. Noise Level Product operates within the range of 80 decibels max. and 85 decibels. 22.11.2022 Rev. 12...
  • Page 40: Burner Handling Information

    • Do not leave the product in wet environment. Dimensions of the box used for handling Burner L x W x H (cm) Weight(kg) ECO 50 KSC(2,3) 136 X 90 X 66 ECO 55 KSC(2,3) 136 X 90 X 66 ECO 55 KSC(2,3)a...
  • Page 41: Installation

    7. INSTALLATION 7.1. Burner Installation Picture 1- Drift Bolts 2- Burner 3- Boiler Connection Flange 4- Gasket 5- Boiler Studs Ø In the installation of the burner, use the installation materials supplied with the burner. Ø 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 42: 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 43: 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 44 Operating with Gas ; 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 45: Combustion Adjustment

    8.3. Combustion Adjustment Ø 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. Ø Photocell Check the photocell weekly. Clean the dust or fume stains on the glass of photocell by a dry cloth.
  • Page 46 TA Type 1. Suction 2. Nozzle outlet 3. Return 4. Manometer inlet 5. Vacuum or inlet manometer and internal return inlet 6. Pressure adjustment 7. Pre heater location 22.11.2022 Rev. 12...
  • Page 47 Ø Two Stages Heavy Oil Burner Fuel Circuit Ø Modulating Heavy Oil Burner Fuel Circuit 22.11.2022 Rev. 12...
  • Page 48 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 49: Gas Adjustment

    Ø Burner preheater 1. Fuel inlet 2. Fuel outlet 3. Discharge 4. Fixing plate 5. Resistance 6. Thermostat bulb pipe 7. Housing cover 8.5. Gas Adjustment 8.5.1. VGD 20 4011 - 5011 Series Gas Valve SKP 75 Connection Diagram 1 – Air-gas adjustment ratio 2 –...
  • Page 50: Air Pressure Switch Adjustment

    8.6. 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 51 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. 22.11.2022 Rev. 12...
  • Page 52 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 53 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 54 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 55: Emission Measurement

    8.8. 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 In emission measurements, the following values are accepted as reference according to TS EN 267 standard.
  • Page 56 If the value measure from PL point is below 0.5 bar, set the impulse pipe as follows. 22.11.2022 Rev. 12...
  • Page 57 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. 22.11.2022 Rev. 12...
  • Page 58: Heavy Oil Burner Fuel Ring Line

    8.10. Heavy Oil Burner Fuel Ring Line 22.11.2022 Rev. 12...
  • Page 59: 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 60: 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 61: Seasonal Maintenance

    9.3. Seasonal Maintenance Comprehensive maintenance work when the burner is re-started 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 62: Troubleshooting

    10. TROUBLESHOOTING Problem Cause Explanation-Suggestion Heavy Oil or Gas is Heavy Oil or Gas valve might be closed. Open cut or does not come the valve. Check burner power supply. The fuse on the main Fuse failure panel or the fuse on the burner might be tripped. Reset the thermal relay.
  • Page 63: Periodical Flue Gas Measurement Report

    11. PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Fuel Yield Flue Consumption Consumption (ppm) (ppm) (ppm) Temp. Date Signature (kg/h) (ºC) 22.11.2022 Rev. 12...
  • Page 64: 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 65: Notes

    13. NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 22.11.2022 Rev. 12...

Table of Contents