ECOSTAR ECO 30 Installation, Operating And Maintenance Manual
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ECOSTAR ECO 30 Installation, Operating And Maintenance Manual

Monoblock dual fuel (gas-light oil) burners
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MONOBLOCK DUAL FUEL (GAS-LIGHT OIL)
BURNERS INSTALLATION, OPERATING AND
MAINTENANCE MANUAL
ONE STAGE, TWO-STAGE AND MODULATING OPERATION
ECO 2
ECO 30
ECO 45
02.12.2022 Rev. 12
www.ecostar.com.tr

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Summary of Contents for ECOSTAR ECO 30

  • Page 1 MONOBLOCK DUAL FUEL (GAS-LIGHT OIL) BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL ONE STAGE, TWO-STAGE AND MODULATING OPERATION ECO 2 ECO 30 ECO 45 02.12.2022 Rev. 12 www.ecostar.com.tr...
  • Page 2 DEAR USER, ECOSTAR ECO 2, ECO 30, ECO 45 Dual Fuel (Gas-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. 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-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 Dual Fuel (Gas-Light Oil) burners are designed and manufactured to work with liquid fuel with max. 2.5- 6 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-Light Oil) burners dependent on viscosity 02.12.2022 Rev. 12...

  • Page 10: Burner Components

    3.3. Burner Components ECO 2 KLC1-1a 02.12.2022 Rev. 12...
  • Page 11 Assembly No Part Name Assembly No Part Name Body group Fuel nozzle Klingerit gasket Combustion head Flame tube Electrode connection plate Boiler connection flange Ignition electrode Gasket Gas inlet pipe Flame tube extension Gas solenoid valve Air pressure switch Motor Pressure switch adaptor Electrical panel connection plate Pressure switch adaptor...
  • Page 12 ECO 45 KLC2-2a-2b 02.12.2022 Rev. 12...
  • Page 13 Assembly No Part Name Assembly No Part Name Body group Gas Ignition electrode Klingerit gasket Electrode connection plate Flame tube Liquid fuel Ignition electrode Boiler connection flange Fuel nozzle Gasket Lance Air Adjustment Mechanism Solenoid valve Manometer Motor Ball valve Electrical panel connection plate Fuel pipes Electrical panel...
  • Page 14 ECO 45 KLC3b 02.12.2022 Rev. 12...
  • Page 15 Assembly No Part Name Assembly No Part Name Body group Electrode connection plate Klingerit gasket Liquid fuel Ignition electrode Flame tube Fuel nozzle Boiler connection flange Centring wedge Gasket Lance Air Adjustment Mechanism Solenoid valve connection plate Solenoid valve Motor Manometer Electrical panel connection plate Ball valve...

  • Page 16: Gas, Flue Gas And Heating Water Schema

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

  • Page 17: Technical Data

    5. TECHNICAL DATA 5.1. Capacity Table GAS-LIGHT OIL DUAL BURNERS CAPACITY TABLE NATURAL GAS LIGHT OIL LIGHT OIL LIGHT OIL OIL PUMP MAIN BURNER TYPE MOTOR CAPACITY CAPACITY CONSUMPTION CAPACITY CAPACITY CONSUMPTION POWER SUPPLY POWER Min. Max. Min. Max. Min. Max.

  • Page 18: Back Pressure-Capacity Diagrams

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

  • Page 19: Burner Dimensions

    5.3. Burner Dimensions 02.12.2022 Rev. 12...

  • Page 20: 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 02.12.2022 Rev.

  • Page 21: Flame Length And Diameter

    5.5. Flame Length and Diameter Natural Gas Light Oil 5.6. Noise Level Product operates within the range of 75 decibels max. and 80 decibels. 02.12.2022 Rev. 12...

  • Page 22: Burner Handling Information

    Weight (kg) ECO 2 KLC1 71 X 50 X 37 ECO 2 KLC1a 71 X 50 X 37 ECO 30 KLC2 115 X 80 X 53 ECO 45 KLC2 115 X 80 X 53 ECO 45 KLC2b 115 X 80 X 53...

  • Page 23: 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 24: 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 25: 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 26 Operating with Gas ; Operation of one-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 1. Ø...

  • Page 27: 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 28 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 02.12.2022 Rev.
  • Page 29 Ø One Stage Light Oil Burner Fuel Circuit Ø Two Stages Light Oil Burner Fuel Circuit 02.12.2022 Rev. 12...
  • Page 30 Ø Modulating Light Oil Burner Fuel Circuit 02.12.2022 Rev. 12...
  • Page 31 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 32: Gas Adjustment

    8.5. Gas Adjustment 8.5.1. VGD 20 4011 - 5011 Series Gas Valve SKP 75 Connection Diagram 1 – Air-gas adjustment ratio 2 – Zero "0" point (start) adjustment 3 – Boiler counter pressure impulse connection 4 – Gas pressure impulse connection 5 –...

  • Page 33: Mb Dle Series Monoblock Gas Valve

    8.5.2. MB DLE Series Monoblock Gas Valve 1- Pressure switch 2- Pressure switch electrical connection 3- Electrical connection of the valve 4- Operation gauge 5- The sealing ring 6- Set cover 7- Hydraulic disk brakes or settings 8- Coil 9- Measuring element connection (1/8) 10- Measuring element connection (1/8) 11- Output flange 12- Measuring element connection (1/8)
  • Page 34 Consider the below torque values for bolts tightened on the valve. Tighten flange bolts according to cross ordering and use proper tools. Sealing and function check must be performed if the valve is dismantled and re-installed over the line due to any reason. Before dismantling the valve from the line, you can perform filter replacement according to the below order.

  • Page 35: Mb Zrd(Le) 405 - 412 Series Gas Valve

    8.5.3. MB ZRD(LE) 405 – 412 Series Gas Valve 02.12.2022 Rev. 12...

  • Page 36: 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 37: 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 38 If the value measure from PL point is below 0.5 bar, set the impulse pipe as follows. 02.12.2022 Rev. 12...
  • Page 39 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. 02.12.2022 Rev. 12...

  • Page 40: Light Oil Burner Fuel Ring Line

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

  • Page 41: 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 42: 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 43: 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 44: Troubleshooting

    10. TROUBLESHOOTING Problem Cause Explanation-Suggestion Light Oil or Gas is Light Oil or Gas valve might be closed. Open cut or does not come the valve. Check burner power supply. The fuse on the Fuse failure main panel or the fuse on the burner might be tripped.

  • Page 45: 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) 02.12.2022 Rev. 12...

  • Page 46: 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 47: 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 45Eco 2

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