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ECOSTAR ECO 250 Operating And Maintenance Manual

Duoblock heavy oil burners
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DUOBLOCK HEAVY OIL BURNERS INSTALLATION,
OPERATING AND MAINTENANCE MANUAL
MODULATING OPERATION (ELECTRONIC)
ECO 250
ECO 300
ECO 350
ECO 400
ECO 450
ECO 500
ECO 600
ECO 700
ECO 800
ECO 900
08.03.2024 Rev. 00
www.ecostar.com.tr

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  • Page 1 DUOBLOCK HEAVY OIL BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL MODULATING OPERATION (ELECTRONIC) ECO 250 ECO 300 ECO 350 ECO 400 ECO 450 ECO 500 ECO 600 ECO 700 ECO 800 ECO 900 08.03.2024 Rev. 00 www.ecostar.com.tr...
  • Page 2 DEAR USER, ECOSTAR ECO 250, ECO 300, ECO 350, ECO 400, ECO 450, ECO 500, ECO 600, ECO 700, ECO 800, ECO 900 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. Electric motor direction of rotation Carry in an upright position. Fragile Item. Protect against water. 08.03.2024 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 oıl 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 08.03.2024 Rev. 00...

  • Page 10: Technical Data

    4. TECHNICAL DATA 4.1.Capacity Table HEAVY OIL BURNER TYPE CAPACITY CONSUMPTION Max. Max. Max. kcal/h kg/h ECO-250.1 1.600.000 165,8 ECO-250.2 2.250.000 233,2 ECO-300.1 2.900.000 300,5 ECO-300.2 3.600.000 373,1 ECO-350.1 4.300.000 445,6 ECO-350.2 5.300.000 549,2 ECO-350.3 6.300.000 652,8 ECO-400.1 7.000.000 725,4 ECO-400.2 7.600.000 787,6...

  • Page 11: Burner Dimensions

    4.2.Burner Dimensions  Fuel Oil Asfalt Plant 08.03.2024 Rev. 00...
  • Page 12  Fuel Oil Steam Boiler 08.03.2024 Rev. 00...

  • Page 13: Installation

    5. INSTALLATION 5.1.Burner Installation Picture Installation on the Boiler  In the installation of the burner, please only use the installation materials supplied with the burner.  Make sure that there are no gaps between the flange and boiler cover and ensure a full sealing by a gasket.

  • Page 14: Commissioning

    6. COMMISSIONING 6.1.General Controls Make sure to perform the following controls before commissioning the burner.  Installation of the burner to the boiler is checked.  Check the fuel line (are the pipe diameters and the pipe installation correct?).  Check energy input cables and voltages. ...

  • Page 15: Combustion Adjustment

    6.2. Combustion Adjustment 6.2.1. Pilot İgnition System Pilot gas burner inlet pressure Pmax=150-200 mbar. Operation should be set to 80-100mbar. 08.03.2024 Rev. 00...
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  • Page 17: Pal

    6.2.2.PAL Gas inlet pressure:35mbar Air pressure:17mbar Qmax:4,5m³/h Flame length:400mm 08.03.2024 Rev. 00...
  • Page 18 Flame Monitor 03U1 Structure of the flame monitor   Electronic flame monitoring circuit,  A relay with bipolar-bidirectional free contact output  A bargraph or dotmatrix led set, displaying flame existance or level  Buttons to set the delay time of the flame relay ...
  • Page 19 03A1 Structure of the flame monitor  Electronic flame monitoring circuit,  A relay with bipolar-bidirectional free contact output  A operation lamp that is integrated to the electronic circuit which operates according to the flame’s existance and strength,  Buttons to set the delay time of the flame relay ...

  • Page 20: Photocell

    6.3.Photocell Check the photocell weekly. Clean the dust or fume stains on the glass of photocell by a dry cloth.  QRA10  QRA2  FFS08 08.03.2024 Rev. 00...
  • Page 21  FFS07  F200K, F300K 08.03.2024 Rev. 00...

  • Page 22: Nozzle

    6.4. Nozzle  HA-D Nozzle 32-HA-D is a needle closed lance with return line. Shut down needle (4) make press to nozzle plate (6) through a spiral on pushing piston. Shut down needle is opened by pneumatic way. 08.03.2024 Rev. 00...
  • Page 23  HA-D Nozzle Hydraulic Diagram Double Ball Valve 2- Pressure Switch Min. (Optional) 3- Filter 4- Selenoid Valve 5- Manometer and Tap 6- 3/4” Oil Adjustment Valve and Servomotor 7- Pressure Switch Max. (Optional) 8- Selenoid Valve 9- Thermostat 10- Pneumatic Air İnlet 11- 3/2 Way Valve (Compressor Air) 08.03.2024 Rev.
  • Page 24  SK Nozzle 08.03.2024 Rev. 00...
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  • Page 26  SK Type Nozzle Hydraulic Diagram 08.03.2024 Rev. 00...
  • Page 27  H Type Nozzle Hydraulic Diagram 08.03.2024 Rev. 00...

  • Page 28: Curves According To Fuel Consumption (Fuel Nozzles)

    6.5. Curves According To Fuel Consumption (Fuel Nozzles)  ECO 250.1 & ECO 350.2  ECO 350.3 & ECO 400.1 Pump Operating Pressure 25 Bar 08.03.2024 Rev. 00...
  • Page 29  ECO 400.2 & ECO 400.3 & ECO 450.1  ECO 450.2 & ECO 450.3 Pump Operating Pressure 25 Bar 08.03.2024 Rev. 00...
  • Page 30  ECO 500.1 & ECO 500.2  ECO 500.3 & ECO 600.1 Pump Operating Pressure 25 Bar 08.03.2024 Rev. 00...
  • Page 31  ECO 600.2  ECO 600.3 & ECO 700.1 & ECO 700.2 & ECO 700.3 Pump Operating Pressure 25 Bar 08.03.2024 Rev. 00...
  • Page 32  ECO 800.1 & ECO 800.2  ECO 800.3 & ECO 900.1 Pump Operating Pressure 25 Bar 08.03.2024 Rev. 00...
  • Page 33  ECO 900.3 Pump Operating Pressure 25 Bar 08.03.2024 Rev. 00...

  • Page 34: Oil Adjustment Regulator

    6.6.Oil Adjustment Regulator 1- Connecting rod 2- Scale coupler 3- Fuel connection points 4- Adjustment fixing bolt 5- Adjustment bolt 6- Housing cover (screw hood) Fuel Regulator Adjustment 1-Remove the housing cover number 6 2-Loosen the fixing bolt number 4 3-When you rotate the shaft number 5 (when looked from the shaft end) clockwise, the pressure value you observe from return manometer will increase, and burner consumption will also increase since nozzle pressure increases.

  • Page 35: Oil Burner Ring Line

    6.7.Oil Burner Ring Line 08.03.2024 Rev. 00...

  • Page 36: Servomotor Adjustment

    6.8.Servomotor Adjustment  Actuator SQM33  Actuator SQM45/48 08.03.2024 Rev. 00...

  • Page 37: Emission Measurement

    Servomotors drive air dampers, gas butterfly valve and oil regulator. With the help of servomotors electronic air and fuel ratio control is carried out, controlled by burner control.  Static electricity can damage servomotor.  Do not open servomotor. Do not interfere with or modify unit or equipment connected to it. It may damage servomotor or change burner settings.

  • Page 38: Program Relay

    6.10. Program Relay  BT 300 08.03.2024 Rev. 00...
  • Page 39 Operating Control and Displays 1 Display 2 Back key 3 Cursor keys 4 Enter key Display: The display shows in pictograms: 1- the menu structure 2- operating status 3- parameters 4- error messages Back key: Jump to previous window. Cursor keys: You navigate in the menu using the cursor keys. You use the "left'' and ''right'' keys to move step by step to the selected row.
  • Page 40 Menu Functions The menu is divided intothree paths: INFO MANUAL SETTINGS INFO Select the INFO path for information about the following: the burner • errors that have occurred • the software version • display of check sums • the serial number •...
  • Page 41 BT300 Connecting Diagram X30 = User Interface UI 300 X31 = LSB Option X32 = continuous output 1, e.g. air damper X33 = continuous output 2, e.g. gas damper X34 = continuous output 3 (optional) SIC = safety interlock chain 230V AC 47 - 63Hz external fuse protection required (max 10A slow-blow) 230V AC for power supply to external devices Maximum Cable Length:...
  • Page 42 Leakage Test for Main Gas Valves 08.03.2024 Rev. 00...
  • Page 43 Gas with pilot burner and leakage test BT300 08.03.2024 Rev. 00...
  • Page 44  ETAMATIC OEM 08.03.2024 Rev. 00...
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  • Page 46 Etamatic OEM Digital Inputs 08.03.2024 Rev. 00...
  • Page 47 ETAMATIC Connection Diagram 08.03.2024 Rev. 00...
  • Page 48 Fault Codes 08.03.2024 Rev. 00...
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  • Page 69 If a fault occurs that is not listed in the fault list, please contact Ecostar after-sales support or your system's commissioning technical personnel. 08.03.2024 Rev. 00...
  • Page 70  LMV 5… Basic Diagram AZL52 08.03.2024 Rev. 00...
  • Page 71 Description of connection terminals (AC 230 V) 08.03.2024 Rev. 00...
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  • Page 73: Maintenance

    7. MAINTENANCE 7.1.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 74: Seasonal Maintenance

    7.3.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 75: Troubleshooting

    8. 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 76: Periodical Flue Gas Measurement Report

    9. PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Yield Flue Consumption (ppm) (ppm) (ppm) Temp. Date Signature (kg/h) (ºC) 08.03.2024 Rev. 00...

  • Page 77: 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 78: Notes

    11. NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 08.03.2024 Rev. 00...

This manual is also suitable for:

Eco 300Eco 350Eco 400Eco 450Eco 500Eco 600 ... Show all

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