ECOSTAR ECO 55 Installation, Operating And Maintenance Manual
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ECOSTAR ECO 55 Installation, Operating And Maintenance Manual

Monoblock light oil burners
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MONOBLOCK LIGHT OIL BURNERS INSTALLATION,
OPERATING AND MAINTENANCE MANUAL
TWO-STAGE AND MODULATING OPERATION
ECO 50
ECO 55
ECO 60
ECO 65
ECO 70
ECO 75
02.12.2022 Rev. 12
www.ecostar.com.tr

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  • Page 1 MONOBLOCK LIGHT OIL BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL TWO-STAGE AND MODULATING OPERATION ECO 50 ECO 55 ECO 60 ECO 65 ECO 70 ECO 75 02.12.2022 Rev. 12 www.ecostar.com.tr...
  • Page 2 DEAR USER, ECOSTAR ECO 50, ECO 55, ECO 60, ECO 65, ECO 70, ECO 75 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. 02.12.2022 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, 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 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 02.12.2022 Rev. 12...

  • Page 10: Burner Components

    3.3. Burner Components ECO 50 OLC2 02.12.2022 Rev. 12...
  • Page 11 Assembly No Part Name Assembly No Part Name Body Servomotor Klingerit Gasket Servomotor Coupling Flame Tube Air Damper Flame Tube Extension Air Damper Gasket Air Damper Motion Rod Boiler Connection Flange Air Damper Motion Transfer Rod Fan Coupling Fan Motor Connection Flange Coupling Connection Pipe Motor Pump Coupling...
  • Page 12 ECO 50 OLC3 02.12.2022 Rev. 12...
  • Page 13 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 Fan Motor Connection Flange Ball Valve Motor Pump Electrical Panel...
  • Page 14 ECO 55 OLC2-2a 02.12.2022 Rev. 12...
  • Page 15 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 16 ECO 55 OLC3-3a 02.12.2022 Rev. 12...
  • Page 17 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 18 ECO 60 OLC2 02.12.2022 Rev. 12...
  • Page 19 Assembly No Part Name Assembly No Part Name Body Electrode Clamp Klingerit Gasket Pilot Ignition Electrode Flame Tube Pilot Combustion Head Air Adjustment Mechanism Servomotor Boiler Connection Flange Servomotor Coupling Gasket Air Damper Air Damper Fan Motor Connection Flange Air Damper Motion Rod Motor Air Damper Motion Transfer Rod Electrical Panel...
  • Page 20 ECO 60 OLC3 02.12.2022 Rev. 12...
  • Page 21 Assembly No Part Name Assembly No Part Name Body Pilot Combustion Head Klingerit Gasket Fuel Nozzle Flame Tube Combustion Head Air Adjustment Mechanism Lance Boiler Connection Flange Lance Centring Console Gasket Solenoid Valve Connection Plate Solenoid Valve Fan Motor Connection Flange Fuel Pipes Motor Manometer...
  • Page 22 ECO 65 OLC2 02.12.2022 Rev. 12...
  • Page 23 Assembly No Part Name Assembly No Part Name Body Pilot Ignition Electrode Klingerit Gasket Pilot Combustion Head Flame Tube Servomotor Air Adjustment Mechanism Servomotor Coupling Boiler Connection Flange Air Damper Gasket Air Damper Air Damper Motion Rod Motor Air Damper Motion Transfer Rod Electrical Panel Air Dumper Spring Electrical Panel Mounting Plate...
  • Page 24 ECO 65 OLC3 02.12.2022 Rev. 12...
  • Page 25 Assembly No Part Name Assembly No Part Name Body Fuel Nozzle Klingerit Gasket Combustion Head Flame Tube Centring Wedge Air Adjustment Mechanism Lance Boiler Connection Flange Lance Centring Console Gasket Solenoid Valve Connection Plate Solenoid Valve Motor Fuel Pipes Electrical Panel Manometer Electrical Panel Mounting Plate Ball Valve...
  • Page 26 ECO 70 OLC2 02.12.2022 Rev. 12...
  • Page 27 Assembly No Part Name Assembly No Part Name Body Pilot Ignition Electrode Klingerit Gasket Pilot Combustion Head Flame Tube Servomotor Air Adjustment Mechanism Servomotor Coupling Boiler Connection Flange Air Damper Gasket Air Damper Air Damper Motion Rod Motor Air Damper Motion Transfer Rod Electrical Panel Air Dumper Spring Electrical Panel Mounting Plate...
  • Page 28 ECO 70 OLC3 02.12.2022 Rev. 12...
  • Page 29 Assembly No Part Name Assembly No Part Name Body Pilot Combustion Head Klingerit Gasket Fuel Nozzle Flame Tube Combustion Head Air Adjustment Mechanism Centring Wedge Boiler Connection Flange Lance Gasket Lance Centring Console Solenoid Valve Connection Plate Motor Solenoid Valve Electrical Panel Fuel Pipes Electrical Panel Mounting Plate...
  • Page 30 ECO 75 OLC3 02.12.2022 Rev. 12...
  • Page 31 Assembly No Part Name Assembly No Part Name Body Fuel Nozzle Klingerit Gasket Lance Flame Tube Ignition Transformer Air Adjustment Mechanism Transformer Box Gasket Solenoid Valve Connection Plate Boiler Connection Flange Solenoid Valve Fuel Pipes Motor Manometer Electrical Panel Mounting Plate Ball Valve Electrical Panel Pump...

  • Page 32: Flue Gas And Heating Water Schema

    4. FLUE GAS AND HEATING WATER SCHEMA 02.12.2022 Rev. 12...

  • Page 33: Technical Data

    TWO STAGE LIGHT OIL BURNERS ECO 50 O (L) C 2 336.600 1.346.400 1571 3N 400 ECO 55 O (L) C 2 387.600 1.734.000 2020 3N 400 ECO 55 O (L) C 2a 387.600 2.121.600 2469 3N 400 ECO 60 O (L) C 2 601.800...

  • Page 34: Back Pressure-Capacity Diagrams

    5.2. Back Pressure-Capacity Diagrams 02.12.2022 Rev. 12...

  • Page 35: Burner Dimensions

    5.3. Burner Dimensions 02.12.2022 Rev. 12...

  • Page 36: Flame Length And Diameter

    5.4. Flame Length and Diameter 5.5. 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 37 Weight(kg) ECO 50 OLC2 135 X 82 X 70 ECO 50 OLC3 135 X 82 X 70 ECO 55 OLC2 135 X 82 X 70 ECO 55 OLC2a 135 X 82 X 70 ECO 55 OLC3 136 X 90 X 75...

  • Page 38: 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 39: 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 40: 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 41: 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 42 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 02.12.2022 Rev. 12...
  • Page 43 Ø Two Stages Light Oil Burner Fuel Circuit Ø Modulating Light Oil Burner Fuel Circuit 02.12.2022 Rev. 12...
  • Page 44 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 45: Servomotor Adjustment

    8.5. Servomotor Adjustment Ø 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 46 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. 02.12.2022 Rev. 12...
  • Page 47 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 48 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 49 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 50: Emission Measurement

    8.6. Emission Measurement In emission measurements, the following values are accepted as reference according to TS EN 267 standard. Ø CO < 110 mg/ kWh Ø %3 ≤ O ≤ %5 Ø NO < 250 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 51 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. 02.12.2022 Rev. 12...

  • Page 52: Light Oil Burner Fuel Ring Line

    8.8. Light Oil Burner Fuel Ring Line 02.12.2022 Rev. 12...

  • Page 53: 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 54: 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 55: 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 56: 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 57: Periodical Flue Gas Measurement Report

    11. PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Yield Flue Consumption (ppm) (ppm) (ppm) Temp. Date Signature (kg/h) (ºC) 02.12.2022 Rev. 12...

  • Page 58: 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 59: Notes

    13. NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 02.12.2022 Rev. 12...

This manual is also suitable for:

Eco 50Eco 60Eco 65Eco 70Eco 75

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