ECOSTAR ECO 50 HP Installation, Operating And Maintenance Manual
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ECOSTAR ECO 50 HP Installation, Operating And Maintenance Manual

Monoblock hp gas burners
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MONOBLOCK HP GAS BURNERS
INSTALLATION, OPERATING AND
MAINTENANCE MANUAL
ONE-STAGE, TWO STAGE AND MODULATING OPERATION
ECO 50 HP
ECO 100 HP
ECO 200 HP
ECO 350 HP
ECO 450 HP
ECO 700 HP
ECO 1100 HP
ECO 1500 HP
ECO 2000 HP
ECO 3000 HP
ECO 4500 HP
28.11.2023 Rev. 01
www.ecostar.com.tr

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  • Page 1 MONOBLOCK HP GAS BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL ONE-STAGE, TWO STAGE AND MODULATING OPERATION ECO 50 HP ECO 100 HP ECO 200 HP ECO 350 HP ECO 450 HP ECO 700 HP ECO 1100 HP ECO 1500 HP ECO 2000 HP...
  • Page 2 DEAR USER, ECOSTAR ECO 50 HP, ECO 100 HP, ECO 200 HP, ECO 350 HP, ECO 450 HP, ECO 700 HP, ECO 1100 HP, ECO 1500 HP, ECO 2000 HP, ECO 3000 HP, ECO 4500 HP, Gas burners are prepared and manufactured according to the latest technical developments and safety rules.

  • 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 line"...

  • 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 gas 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 gas burners are manufactured such that they operate in gas pressure of min. 20 mbar and max. 300 mbar., at 15%...+10% of nominal voltage, between the ambient temperature range of - 15ºC….+60˚C and declared capacity and boiler pressure ranges with Natural Gas and Liquid Petrol Gas.

  • Page 9: Burner Components

    3.3.Burner Components One Stage HP Burners ECO 50 HP G C1 SV 28.11.2023 Rev. 01...
  • Page 10 ASEEMBLY DESCRIPTION FLAME PIPE GAS ENTRY PIPE GAS HEAD TURBULATOR ELECTRODE IGNITION ELECTRODE IONIZATION PURGER FRONT COVER SHEET BACK COVER LOGO CLAMP PIPE TRANSFORMER RELAY FLAME PIPE EXTENSION AIR SWITCH AIR SWITCH PURGER GASKET CLAMP SHEET BOILER CONNECTION FLANGE RECYCLE CLAMP CLAMP SPACER RELAY CONNECTION SHEET GAS ENTRY PIPE...
  • Page 11 ECO 100 HP G C1 SV 28.11.2023 Rev. 01...
  • Page 12 ASEEMBLY DESCRIPTION FLAME PIPE GAS ENTRY PIPE GAS HEAD TURBULATOR ELECTRODE IGNITION ELECTRODE IONIZATION PURGER FRONT COVER SHEET BACK COVER LOGO CLAMP PIPE TRANSFORMER RELAY FLAME PIPE EXTENSION AIR SWITCH AIR SWITCH PURGER GASKET CLAMP SHEET BOILER CONNECTION FLANGE RECYCLE CLAMP CLAMP SPACER RELAY CONNECTION SHEET GAS ENTRY PIPE...
  • Page 13 ECO 200 HP G C1 3/4" D 28.11.2023 Rev. 01...
  • Page 14 ASEEMBLY DESCRIPTION FLAME PIPE GAS ENTRY PIPE GAS HEAD TURBULATOR ELECTRODE IGNITION ELECTRODE IONIZATION PURGER VALVE ENTRY FLANGE FRONT COVER SHEET BACK COVER LOGO CLAMP PIPE TRANSFORMER RELAY FLAME PIPE EXTENSION AIR SWITCH AIR SWITCH PURGER GASKET CLAMP SHEET BOILER CONNECTION FLANGE RECYCLE CLAMP CLAMP SPACER RELAY CONNECTION SHEET...
  • Page 15 ECO 200 HP G C1 SV 28.11.2023 Rev. 01...
  • Page 16 ASEEMBLY DESCRIPTION FLAME PIPE GAS ENTRY PIPE GAS HEAD TURBULATOR ELECTRODE IGNITION ELECTRODE IONIZATION PURGER FRONT COVER SHEET BACK COVER LOGO CLAMP PIPE TRANSFORMER RELAY FLAME PIPE EXTENSION AIR SWITCH AIR SWITCH PURGER GASKET CLAMP SHEET BOILER CONNECTION FLANGE RECYCLE CLAMP CLAMP SPACER RELAY CONNECTION SHEET GAS ENTRY PIPE...
  • Page 17 ECO 200 HP G C1 1/2" D 28.11.2023 Rev. 01...
  • Page 18 ASEEMBLY DESCRIPTION FLAME PIPE GAS ENTRY PIPE GAS HEAD TURBULATOR ELECTRODE IGNITION ELECTRODE IONIZATION PURGER ENTRY FLANGE FRONT COVER SHEET BACK COVER LOGO CLAMP PIPE TRANSFORMER RELAY FLAME PIPE EXTENSION AIR SWITCH AIR SWITCH PURGER GASKET CLAMP SHEET BOILER CONNECTION SHEET RECYCLE CLAMP CLAMP SPACER RELAY CONNECTION SHEET...
  • Page 19 ECO 350 HP G C1 3/4" D 28.11.2023 Rev. 01...
  • Page 20 ASEEMBLY DESCRIPTION FLAME PIPE GAS ENTRY PIPE GAS HEAD TURBULATOR ELECTRODE IGNITION ELECTRODE IONIZATION PURGER VALVE ENTRY FLANGE FRONT COVER SHEET BACK COVER LOGO CLAMP PIPE TRANSFORMER RELAY FLAME PIPE EXTENSION AIR SWITCH AIR SWITCH PURGER GASKET CLAMP SHEET BOILER CONNECTION FLANGE RECYCLE CLAMP CLAMP SPACER RELAY CONNECTION SHEET...
  • Page 21 Two Stage HP Burners ECO 450 HP G C2 28.11.2023 Rev. 01...
  • Page 22 ASEEMBLY DESCRIPTION BODY OBSERVATION GLASS KLINGRITE GASKET MOTOR SECURITY ROVE FLAME PIPE GAS ENTRY PIPE HANDLING SHAFT SHAFT FIXING PLATE PURGER BOILER CONNECTION GASKET FLAME PIPE EXTENSION PANEL CONNECTION SHEET PANEL GAS HEAD TURBULATOR ELECTRODE IGNITION ELECTRODE IONIZATION TRANSFORMER AIR CAGE CLAMP SHAFT CLAMP SHEET SERVOMOTOR...
  • Page 23 ECO 700 HP G C2 28.11.2023 Rev. 01...
  • Page 24 ASEEMBLY DESCRIPTION BODY OBSERVATION GLASS KLINGRITE GASKET MOTOR SECURITY ROVE FLAME PIPE GAS ENTRY PIPE HANDLING SHAFT SHAFT FIXING PLATE PURGER BOILER CONNECTION GASKET FLAME PIPE EXTENSION PANEL CONNECTION SHEET PANEL GAS HEAD TURBULATOR ELECTRODE IGNITION ELECTRODE IONIZATION TRANSFORMER AIR CAGE CLAMP SHAFT CLAMP SHEET SERVOMOTOR...
  • Page 25 ECO 1100 HP G C2 28.11.2023 Rev. 01...
  • Page 26 ASEEMBLY DESCRIPTION BODY AIR SWITCH AIR SWITCH ADAPTER OBSERVATION GLASS AIR SWTICH PURGER SERVOMOTOR SERVOMOTOR COUPLING MOTOR MOTOR SECURITY ROVE TRANSFORMER GAS HEAD GAS ENTRY PIPE PURGER ELECTRODE IGNITION TURBULATOR ELECTRODE IONIZATION KLINGRITE GASKET FLAME PIPE HANDLING SHAFT SHAFT FIXING PLATE FLAME PIPE EXTENSION BOILER CONNECTION FLANGE GASKET...
  • Page 27 Modulating HP Burners ECO 700 HP G C3 28.11.2023 Rev. 01...
  • Page 28 ASEEMBLY DESCRIPTION BODY OBSERVATION GLASS KLINGRITE GASKET MOTOR SECURITY ROVE FLAME PIPE GAS ENTRY PIPE HANDLING SHAFT SHAFT FIXING PLATE PURGER BOILER CONNECTION GASKET FLAME PIPE EXTENSION PANEL CONNECTION SHEET PANEL GAS HEAD TURBULATOR ELECTRODE IGNITION ELECTRODE IONIZATION PROPORTIONAL DISC MOVEMENT LEVER DISC GROUP PROPORTIONAL TRANSFORMER VALVE GAS ADJUSTMENT...
  • Page 29 ECO 1100 HP G C3 28.11.2023 Rev. 01...
  • Page 30 ASEEMBLY DESCRIPTION BODY AIR SWITCH AIR SWITCH ADAPTER OBSERVATION GLASS AIR SWITCH PURGER SERVOMOTOR SERVOMOTOR COUPLING MOTOR MOTOR SECURITY ROVE TRANSFORMER GAS HEAD GAS ENTRY PIPE PURGER ELECTRODE IGNITION TURBULATOR ELECTRODE IONIZATION KLINGRITE GASKET FLAME PIPE HANDLING SHAFT SHAFT FIXING PLATE FLAME PIPE EXTENSION BOILER CONNECTION FLANGE GASKET...
  • Page 31 ECO 1500 HP G C3 28.11.2023 Rev. 01...
  • Page 32 ASEEMBLY DESCRIPTION BODY MOTOR FLAME PIPE GAS ENTRY PIPE GAS HEAD TURBULATOR FRONT COVER FLAME PIPE CONICAL AIR CAGE OBSERVATION GLASS OBSERVATION FRAME HINGE GROUP SERVOMOTOR SERVOMOTOR COUPLING CLAMP SHAFT CLAMP SHEET KLINGRITE GASKET AIR SWITCH TRANSFORMER PANEL SHEET ELECTRICAL PANEL AIR SWITCH ADAPTER IONIZATION ELECTRODE ELECTRODE IGNITION...
  • Page 33 ECO 2000 HP G C3 28.11.2023 Rev. 01...
  • Page 34 ASEEMBLY DESCRIPTION BODY MOTOR FLAME PIPE GAS ENTRY PIPE GAS HEAD FRONT COVER TURBULATOR FLAME PIPE CONICAL ELECTRODE IGNITION IONIZATION ELECTRODE BOILER CONNECTION FLANGE BOILER CONNECTION GASKET KLINGRITE GASKET AIR CAGE SERVOMOTOR SERVOMOTOR COUPLING CLAMP SHAFT CLAMP SHEET AIR SWITCH ADAPTER AIR SWITCH PURGER TRANSFORMER PANEL SHEET...
  • Page 35 ECO 3000 HP G C3 28.11.2023 Rev. 01...
  • Page 36 ASEEMBLY DESCRIPTION BODY MOTOR AIR CAGE FLAME PIPE GAS ENTRY PIPE COMBUSTION HEAD TURBULATOR IONIZATION ELECTRODE ELECTRODE IGNITION OBSERVATION GLASS FRAME SERVOMOTOR AIR SWITCH FLAME PIPE CONICAL OBSERVATION GLASS SERVOMOTOR COUPLIN CLAMP SHAFT CLAMP SHEET PURGER HINGE GROUP KLINGRITE GASKET AIR SWITCH ADAPTER BOILER CONNECTION FLANGE BOILER CONNECTION GASKET...
  • Page 37 ECO 4500 HP G C3 28.11.2023 Rev. 01...
  • Page 38 ASEEMBLY DESCRIPTION BODY MOTOR FLAME PIPE AIR CAGE FAN FIXING WASHER GAS INLET PIPE COMBUSTION HEAD TURBULATOR FLAME PIPE EXTENSION BOLT BOILER CONNECETION FLANGE GASKET BOILER CONNECTION FLANGE SUPPORT FEET HINGE GROUP HINGE TRANSFORMER SERVOMOTOR COUPLIN CLAMP SHAFT CLAMP SHEET PURGER PRESSURESTAT ADAPTER PRESSURESTAT PURGER...

  • Page 39: Gas, Flue Gas And Heating Water Schema

    4. GAS, FLUE GAS AND HEATING WATER SCHEMA 28.11.2023 Rev. 01...

  • Page 40: Technical Data

    Max. Gas Inlet Min. kW Max. kW Min. Nm ³/h Gas Valve kcal/h kcal/h Nm ³/h Diameter ECO 50 HP G C1 SV 8.600 43.000 1N 230 ZEVR DN15 1/2" 17.200 86.000 1N 230 ZEVR DN20 3/4" ECO 100 HP G C1 SV 68.800...
  • Page 41 Two Stage HP Burners HIGH FAN PRESSURE TWO STAGE GAS BURNERS CAPACITY TABLE NATURAL GAS FAN MOTOR MAIN CAPACITY CAPACITY GAS INLET DIAM ETER CONSUM PTION POWER SUPPLY BURNER TYPE M in. M ax. M ax. Gas Inlet Min. kW M ax. kW Min.
  • Page 42 Modulating HP Burners HIGH FAN PRESSURE MODULATING GAS BURNERS CAPACITY TABLE NATURAL GAS FAN MOTOR MAIN CAPACITY CAPACITY GAS INLET DIAMETER CONSUMPTION POWER SUPPLY BURNER TYPE Min. Max. Max. Gas Inlet Min. kW Max. kW Min. Nm³/h Gas Valve kcal/h kcal/h Nm ³/h Diameter...

  • Page 43: Back Pressure And Gas Line Selection Table

    5.2.Back Pressure and Gas Line Selection Table One Stage HP Burners ECO 50 HP G C1 ECO 100 HP G C1 28.11.2023 Rev. 01...
  • Page 44 ECO 200 HP G C1 ECO 350 HP G C1 28.11.2023 Rev. 01...
  • Page 45 Two Stage HP Burners ECO 200 HP G C2 ECO 350 HP G C2 ECO 450 HP G C2 28.11.2023 Rev. 01...
  • Page 46 ECO 700 HP G C2 ECO 1100 HP G C2 ECO 1500 HP G C2 28.11.2023 Rev. 01...
  • Page 47 ECO 2000 HP G C2 ECO 3000 HP G C2 ECO 4500 HP G C2 28.11.2023 Rev. 01...
  • Page 48 Modulating HP Burners ECO 200 HP G C3 ECO 350 HP G C3 ECO 450 HP G C3 28.11.2023 Rev. 01...
  • Page 49 ECO 700 HP G C3 ECO 1100 HP G C3 ECO 1500 HP G C3 28.11.2023 Rev. 01...
  • Page 50 ECO 2000 HP G C3 ECO 3000 HP G C3 ECO 4500 HP G C3 28.11.2023 Rev. 01...

  • Page 51: Gas Valve Outlet Pressure

    5.3.Gas Valve Outlet Pressure  MB-DLE/ZRDLE 407  MB-DLE/ZRDLE 407 28.11.2023 Rev. 01...
  • Page 52  MB-DLE/ZRDLE 412  MB-DLE/ZRDLE 420 28.11.2023 Rev. 01...
  • Page 53  VGD 20.4011  VGD 20.4011 28.11.2023 Rev. 01...
  • Page 54  VGD 40.065  VGD 20.4011 28.11.2023 Rev. 01...

  • Page 55: Burner Dimensions

    5.4.Burner Dimensions 28.11.2023 Rev. 01...
  • Page 56 28.11.2023 Rev. 01...

  • Page 57: Flame Length And Diameter

    5.5.Flame Length and Diameter 5.6.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 58: Installation

    7. INSTALLATION 7.1.Burner Installation Picture 1- Boiler Flange 2- Gasket 3- Boiler Connection Flange 4- Burner You must definitely ensure sealing between boiler and burner! Device must be shipped in original packaging! Do not lift the device holding from servomotor, gas valve, impulse pipes or pressure switch during installation! Clean the inside of fuel line thoroughly before installing the burner to the fuel line.
  • Page 59 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. 28.11.2023 Rev.

  • Page 60: Commissioning

    8. COMMISSIONING 8.1.Before Commissioning 8.1.1. Ignition and Ionizasyon System 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.General Controls Make sure to perform the following controls before commissioning the burner.
  • Page 61 Operation of two-stage burner  Open the main gas valve, check the gas pressure from the manometer at the valve. (max.300 mbar)  Check the boiler thermostat or pressure switch settings.  Bring the operating switch on the burner panel to position 2. ...

  • Page 62: Combustion Adjustment

    8.3.Combustion Adjustment 8.3.1. Gas Adjustment Follow the instructions of the valve manufacturer during installation, dismantling and adjustment of the gas valve 8.3.1.1.VGD 20 4011 - 5011 Series Gas Valve SKP 75 Connection Diagram 1 – Air-gas adjustment ratio 2 – Zero "0" point (start) adjustment 3 –...

  • Page 63: Mb Dle Series Monoblock Gas Valve

    8.3.1.2.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 64 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 65: Mb Zrd(Le) 415 - 420 Series Gas Valve

    8.3.1.3.MB ZRD(LE) 415 – 420 Series Gas Valve 28.11.2023 Rev. 01...

  • Page 66: Air Pressure Switch Adjustment

    8.4.Air Pressure Switch Adjustment While the burner is working without any problem, the air pressure switch is adjusted to desired minimum pressure as follows.  Unscrew the screw of the transparent cover and remove the cover.  Turn the adjustment wheel in the direction to increase the pressure, note the pressure value at which the burner is failed.

  • Page 67: Emission Measurement

    8.6.Emission Measurement In emission measurements, the following values are accepted as reference according to TS EN 676 +A2 standard.  CO < 100 mg/ kWh  %3 ≤ O ≤ %5  NO < 170 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 68: Burner Control System

    8.8.Burner Control System The burner control system SIEMENS LME7... is a microprocessor-based burner control with matching system components for the control and supervision of forced draft burners of medium to high capacity. LME7… are used for the startup and supervision of 1- or 2-stage forced draft gas burners in intermittent operation.

  • Page 69: Inputs And Outputs / Internal Connection Diagram

    8.8.1. Inputs and Outputs / Internal Connection Diagram 28.11.2023 Rev. 01...

  • Page 70: Error Code List With Operation Via Internal Led

    8.8.2. Error code list with operation via internal led 28.11.2023 Rev. 01...

  • Page 71: Operating Control And Displays (Optional Usage)

    8.8.3. Operating Control and Displays (Optional Usage) Display of operating states, program phases and fault codes  Setting of parameters and ratio curves  8-digit LCD with bars  LCD with backlit (support dependent on respective burner control)  5 multifunction buttons with reset facility ...
  • Page 72 28.11.2023 Rev. 01...
  • Page 73 If the value measure from PL point is below 0.5 bar, set the impulse pipe as follows. 28.11.2023 Rev. 01...

  • Page 74: Gas Pass Equipment Required In Gas Line

    8.9.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 75: Maintenance

    9. MAINTENANCE 9.1.Monthly Maintenance Monthly maintenance is a comprehensive process where general checks of burner and peripheral components are performed to prevent possible faults. After completion of maintenance and adjustment processes, make sure to perform an emission analysis.  Clean the filters on the main line and multiblock. ...

  • Page 76: Troubleshooting

    10. TROUBLESHOOTING Problem Cause Explanation-Suggestion Gas is cut or does not Gas 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 77: Periodical Flue Gas Measurement Report

    11. PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Yield Flue Consumption (ppm) (ppm) (ppm) Temp. Date Signature (m³/h) (ºC) 28.11.2023 Rev. 01...

  • Page 78: 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 79: Notes

    13. NOTES Please record and forward your measurements and observations to us www.ecostar.com.tr 28.11.2023 Rev. 01...

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