ECOSTAR ECO 60 Installation guide

26.03.2020 Rev. 11

www.ecostar.com.tr

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

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.

If you encounter any issue that is not explained clearly in this manual or you could

not understand, please contact with our service department.

We thank you for choosing ECOSTAR brand.

Ecostar Heavy Oil Burners are manufactured in accordance with TS EN 267

standards.

This Operating Manual is an integral part of the burner and must be maintained in a

plastic dossier and hung at a clearly visible place in the burner room.

TERMO ISI SİSTEMLERİ SAN.VE TİC.A.Ş.

Esentepe Mah.Milangaz Cad. No:75 K:3

Kartal Monumento Plaza

Kartal/İSTANBUL/TÜRKİYE

Tel: +90 216 442 93 00

Fax: +90 216 370 45 03

www.ecostar.com.tr

e-mail:[email protected]m.tr

26.03.2020 Rev. 11

CONTENTS

1. WARNINGS.......................................................................................................................................... 3

1.1. Warning Symbols and Descriptions............................................................................................... 3

1.2. General Safety Rules...................................................................................................................... 4

2. TERMS OF WARRANTY.................................................................................................................... 6

2.1. Out of Warranty Conditions.......................................................................................................... 6

3. BURNER’S GENERAL FEATURES................................................................................................... 7

3.1. Purpose of Use and Work Limits of Burners................................................................................. 7

3.2. Code Key........................................................................................................................................ 7

3.3. Burner Components........................................................................................................................ 9

4. FLUE GAS AND HEATING WATER SCHEMA............................................................................. 31

5. TECHNICAL DATA........................................................................................................................... 32

5.1. Capacity Table.............................................................................................................................. 32

5.2. Back Pressure-Capacity Diagrams............................................................................................... 33

5.3. Burner Dimensions....................................................................................................................... 34

5.4. Flame Length and Diameter......................................................................................................... 35

5.5. Noise Level................................................................................................................................... 35

6. BURNER HANDLING INFORMATION.......................................................................................... 36

7. INSTALLATION................................................................................................................................ 37

7.1. Burner Installation Picture............................................................................................................ 37

7.2. In reverse flame front mirror boilers............................................................................................ 38

7.3. In cylindrical (straight flame) boilers........................................................................................... 38

8. COMMISSIONING............................................................................................................................. 39

8.1. Before Commissioning................................................................................................................. 39

8.2. General Controls........................................................................................................................... 39

8.3. Combustion Adjustment............................................................................................................... 40

8.4. Fuel Pumps................................................................................................................................... 40

8.5. Servomotor Adjustment ............................................................................................................... 44

8.6. Emission Measurement ................................................................................................................ 49

8.7. Program Relay.............................................................................................................................. 49

8.8. Heavy Oil Burner Fuel Ring Line................................................................................................ 51

9. MAINTENANCE................................................................................................................................ 52

9.1. Weekly Maintenance.................................................................................................................... 52

9.2. Monthly Maintenance................................................................................................................... 52

9.3. Seasonal Maintenance.................................................................................................................. 53

9.4. Installation and Disassembly Instructions for Maintenance Purposes......................................... 54

10. TROUBLESHOOTING................................................................................................................... 55

11. PERIODICAL FLUE GAS MEASUREMENT REPORT.............................................................. 56

12. AFTER SALES SERVICES............................................................................................................ 57

13. NOTES............................................................................................................................................. 58

26.03.2020 Rev. 11

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. 11

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.

All operation, commissioning and installation works (except for burning adjustment) should be

carried out when the burner is not operating and after disconnecting the power supply.

Noncompliance with these rules may lead to serious bodily injuries and even death by electrical

shocks or uncontrolled flame formation.

Repairs concerned with safety elements should be carried out only by the manufacturing company.

The device should never be used by children, mentally handicapped and inexperienced persons.

Children must not be allowed to play with the device.

Keep the device away from explosive and flammable materials.

Device must intake air, ventilation and air discharge holes must not be closed.

Do not store any inflammable materials in boiler room.

Wear hearing protectors if there is noise in boiler room.

In case of fıre or other emergency;

●Switch off the main switch

●Take appropriate actions

26.03.2020 Rev. 11

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.

Use lifting device or belt for lifting fan motor, if necessary

During the first commissioning of the burner or in case of any revision carried out in the electrical

system or motor cables by any reason, direction of the fan rotation must certainly be checked by

the authorized technical service.

For products that have not been comissioned or started more than 6 months, before activating the

servomotor;

In air dampers and oil regulators, servomotor and air damper connections must be checked to

ensure that they are free running in spite of immobility and oil freezing.

BURNER ROOM

Install the burner in a suitable room/floor with minimum external air openings and sufficient to

ensu re perfect combustion, in compliance with current regulations.

Never obstruct air openings of the burner room, burner fan intake vents or air ducts in order to

prevent:

a.The build up of toxic / explosive gas mixtures in the burner room,

b.Combustion with insufficient air, resulting in hazardous, anti-economical and polluting ope-

ration.

The burner must be always protected from rain, snow and frost to prevent corrosion and paint

deformations.

Keep the burner room clean and free of solid volatile substances, which could be sucked into the fan

and clog the internal burner or combustion head air ducts.

26.03.2020 Rev. 11

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.

Please note that this warranty is only valid if the device(s) is commissioned and maintained by our

authorized services.

Our company reserves the right to make any modifications on the product and all instructions

thereof for improvement purposes.

2.1. Out of Warranty Conditions

Any damage arising out of or in relation to customers’ non-compliance to their responsibilities

with regards to installation, commissioning, operation and maintenance,

Any damage arising out of or in relation to commissioning, repairs and maintenance carried out by

unauthorized services,

Any damage that may occur during transportation or storage of the product,

Not preserving the product in its original packaging until the installation stage,

Incorrect and poor electrical connections, Failures due to incorrect voltage applications, frequent

repetition of voltage fluctuations,

Any damage that may occur as a result of incorrect fuel usage or, foreign substances in the fuel

used or using of the product without any fuel,

Any damage that may occur due to foreign particles entered into the product during installation

and operation,

Failures due to incorrect device selection,

Any damage to unit due to natural disasters,

Devices without any warranty certificates,

Warranty Certificates without the stamp and signature of the authorized dealer or service,

Devices with any falsification on the warranty certificate or without an original serial number.

The risks during transportation of device under the responsibility of customer belong to the

customer.

Presence of misuse faults are indicated in the reports issued by authorized service stations or our

authorized agent, dealer, representative or our factory in case of unavailability of authorized

service stations.

Customers may apply consumer protection arbitrator committee with regards to this report and

request for an expert report.

26.03.2020 Rev. 11

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

This product works at any load value equivalent to its max. capacity or covered by its capacity

range;

-In hot water and steam boilers,

-In direct and indirect hot air generators,

-Industrial appliances operating at temperature below 600 0C,

--15 0C…+60 0C ambient temperature range,

-1N 230 VAC/3N 380VAC /50 Hz feed voltage (-%15…+%10) values,

-Max. 95% relative humidity,

-In well-ventilated open and closed spaces compatible with protection class IP 40.

This device must never be operated with open flame!

3.2. Code Key

26.03.2020 Rev. 11

Temperature change of fuel used in ECOSTAR heavy oil burners dependent on viscosity

26.03.2020 Rev. 11

3.3. Burner Components

ECO 50 OSC2

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