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ECOSTAR ECO 60 Installation, Operating And Maintenance Manual

Monoblock heavy oil burners
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MONOBLOCK 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
26.03.2020 Rev. 11
www.ecostar.com.tr

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  • Page 1 MONOBLOCK 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 26.03.2020 Rev. 11 www.ecostar.com.tr...
  • Page 2 DEAR USER, ECOSTAR ECO 50, ECO 55, ECO 60, ECO 65, ECO 70, ECO 75 Heavy 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. 26.03.2020 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 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 Heavy Oil burners are designed to operate with oil at 2.5 – 20 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 heavy oil burners dependent on viscosity 26.03.2020 Rev. 11...

  • Page 10: Burner Components

    3.3. Burner Components ECO 50 OSC2 26.03.2020 Rev. 11...
  • Page 11 Assembly No Part Number Assembly No Part Number Body Purger Air Intake Electrical Panel Mounting Plate Flame Tube Electrical Panel Boiler Connection Flange Sheet Metal Observation Glass Flame Tube Extension Handling Shaft Lance Handling Shaft Fixing Plate Combustion Head Pump Fuel Nozzle Pump Coupling Ignition Electrode...
  • Page 12 ECO 50 OSC3 26.03.2020 Rev. 11...
  • Page 13 Assembly No Part Number Assembly No Part Number Body Electrical Panel Air Intake Observation Glass Flame Tube Handling Shaft Boiler Connection Flange sac Handling Shaft Fixing Plate Flame Tube Extension Solenoid Valve Connection Plate Lance Pump Combustion Head Pump Coupling Fuel Nozzle Disc Control Group Ignition Electrode...
  • Page 14 ECO 55 OSC2 26.03.2020 Rev. 11...
  • Page 15 Assembly No Part Number Assembly No Part Number Body Electrical Panel Mounting Plate Air Intake Electrical Panel Flame Tube Observation Glass Boiler Connection Flange sac Handling Shaft Flame Tube Extension Handling Shaft Fixing Plate Lance Pump Combustion Head Pump Coupling Fuel Nozzle Servomotor Ignition Electrode...
  • Page 16 ECO 55 OSC3-3a 26.03.2020 Rev. 11...
  • Page 17 Assembly No Part Number Assembly No Part Number Body Handling Shaft Air Intake Handling Shaft Fixing Plate Flame Tube Solenoid Valve Connection Plate Boiler Connection Flange Pump Flame Tube Extension Disc Control Group Lance Pump Coupling Combustion Head Air Damper Modulating Motion Rod Fuel Nozzle Air Damper Modulating Spring Ignition Electrode...
  • Page 18 ECO 60 OSC2 26.03.2020 Rev. 11...
  • Page 19 Assembly No Part Number Assembly No Part Number Body Group Purger Flame Tube Eye Bolt Lance Gas Solenoid Valve Klingerit Gasket Servomotor Combustion Head Servomotor Coupling Air Adjustment Mechanism Air Damper Boiler Connection Flange Air Damper Gasket Air Damper Motion Rod Air Damper Air Damper Motion Transfer Fan Motor Fan Motor Connection Flange...
  • Page 20 ECO 60 OSC3 26.03.2020 Rev. 11...
  • Page 21 Assembly No Part Number Assembly No Part Number Body Handling Shaft Air Intake Handling Shaft Fixing Plate Flame Tube Eye Bolt Boiler Connection Flange Disc Control Group Air Adjustment Mechanism Servomotor Lance Air Damper Plate Combustion Head Air Damper Shaft Fuel Nozzle Air Damper Adjustment Rod Lance Centering Console...
  • Page 22 ECO 65 OSC2 26.03.2020 Rev. 11...
  • Page 23 Assembly No Part Number Assembly No Part Number Body Group Purger Flame Tube Eye Bolt Lance Gas Solenoid Valve Klingerit Gasket Servomotor Combustion Head Servomotor Coupling Flame Tube Extension Air Damper Boiler Connection Flange Air Damper Gasket Air Damper Motion Rod Air Damper Air Damper Motion Transfer Fan Motor Fan Motor Connection Flange...
  • Page 24 ECO 65 OSC3 26.03.2020 Rev. 11...
  • Page 25 Assembly No Part Number Assembly No Part Number Body Handling Shaft Fixing Plate Air Intake Eye Bolt Flame Tube Disc Control Group Boiler Connection Flange Servomotor Flame Tube Extension Air Damper Plate Lance Air Damper Shaft Combustion Head Air Damper Adjustment Rod Fuel Nozzle Air Damper Motion Rod Lance Centering Console...
  • Page 26 ECO 70 OSC2 26.03.2020 Rev. 11...
  • Page 27 Assembly No Part Number Assembly No Part Number Body Group Purger Flame Tube Eye Bolt Lance Gas Solenoid Valve Klingerit Gasket Servomotor Combustion Head Servomotor Coupling Flame Tube Extension Air Damper Boiler Connection Flange Air Damper Gasket Air Damper Motion Rod Air Damper Air Damper Motion Transfer Fan Motor Fan Motor Connection Flange...
  • Page 28 ECO 70 OSC3 26.03.2020 Rev. 11...
  • Page 29 Assembly No Part Number Assembly No Part Number Body Handling Shaft Fixing Plate Air Intake Eye Bolt Flame Tube Disc Control Group Boiler Connection Flange Servomotor Flame Tube Extension Air Damper Lance Air Damper Combustion Head Air Damper Adjustment Rod Fuel Nozzle Air Damper Motion Rod Air Damper Air Damper Motion Transfer...
  • Page 30 ECO 75 OSC3 26.03.2020 Rev. 11...
  • Page 31 Assembly No Part Number Assembly No Part Number Body Handling Shaft Fixing Plate Air Intake Transformer Box Klingerit Gasket Ignition Transformer Lance Centering Console Servomotor Lance Centering Bushing Disc Control Group Lance Air Damper Gauge Fuel Nozzle Air Damper Modulating Motion Rod Combustion Head Connection Part Air Damper Plate Combustion Head...

  • Page 32: Flue Gas And Heating Water Schema

    4. FLUE GAS AND HEATING WATER SCHEMA 26.03.2020 Rev. 11...

  • Page 33: Technical Data

    2.020 3,00 12,0 3N 380 ECO 55 O (S) C 2a 386.000 2.123.000 2.469 3,00 12,0 3N 380 ECO 60 O (S) C 2 598.300 2.576.550 3.000 4,00 0,75 14,0 3N 380 ECO 65 O (S) C 2 733.400 3.010.800 3.500...

  • Page 34: Back Pressure-Capacity Diagrams

    5.2. Back Pressure-Capacity Diagrams 26.03.2020 Rev. 11...

  • Page 35: Burner Dimensions

    5.3. Burner Dimensions 26.03.2020 Rev. 11...

  • 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. 26.03.2020 Rev. 11...

  • Page 37: Burner Handling Information

    135 X 82 X 70 ECO 55 OSC3 135 X 82 X 70 ECO 55 OSC3a 135 X 82 X 70 ECO 60 OSC2 136 X 90 X76 ECO 60 OSC3 136 X 90 X76 ECO 65 OSC2 170 X 90 X 85...

  • Page 38: 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 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  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 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 26.03.2020 Rev. 11...
  • Page 43  Two Stages Heavy Oil Burner Fuel Circuit  Modulating Heavy Oil Burner Fuel Circuit 26.03.2020 Rev. 11...
  • Page 44 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 45: Servomotor Adjustment

     Burner preheater 1. Fuel inlet 2. Fuel outlet 3. Discharge 4. Fixing plate 5. Resistance 6. Thermostat bulb pipe 7. Housing cover 8.5. Servomotor Adjustment  SQN70 At Two-stage Burners; I. Red Cam: Adjusts 2nd level max. air. II. Blue Cam: Resets the clamp. III.
  • Page 46  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. 26.03.2020 Rev. 11...
  • Page 47  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:  Servomotor: 0° ...
  • 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.  CO < 110 mg/ kWh  %3 ≤ O ≤ %5  NO < 250 mg/ kWh  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 length of the burner), please do not forget to support burner body during maintenance and installation/commissioning. 26.03.2020 Rev. 11...

  • Page 52: Heavy Oil Burner Fuel Ring Line

    8.8. Heavy Oil Burner Fuel Ring Line 26.03.2020 Rev. 11...

  • 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.  Check insulation resistance of electric motor.  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 (ºC) (kg/h) 26.03.2020 Rev. 11...

  • 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 26.03.2020 Rev. 11...

This manual is also suitable for:

Eco 55Eco 50Eco 65Eco 70Eco 75

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