ECOSTAR ECO 250 Guía de instalación

06.11.2018 Rev. 08

www.ecostar.com.tr

DUOBLOCKDUAL FUEL(GAS-HEAVY OIL)

BURNERS INSTALLATION, OPERATINGAND

MAINTENANCE MANUAL

MODULATINGOPERATION

ECO250

ECO300

ECO350

ECO400

ECO450

ECO500

ECO600

ECO700

ECO800

ECO900

06.11.2018 Rev. 08 1

DEAR USER,

ECOSTARECO250,ECO 300,ECO350,ECO400,ECO 450,ECO500,ECO

600,ECO700,ECO 800,ECO 900DualFuel (Gas-Heavy Oil) burnersareprepared

andmanufacturedaccording tothelatesttechnicaldevelopmentsandsafetyrules.Itis

easytouse for our customers.

We recommendthat you readthis manual andsafety warningsthoroughlybeforethe

useof the deviceinordertoensure safe, cost effective andenvironmental-friendly use.

Ifyouencounteranyissuethat is notexplainedclearlyinthismanual oryoucould

not understand,please contact withour service department.

We thank youforchoosingECOSTAR brand.

EcostarDual Fuel (Gas-HeavyOil) BurnersaremanufacturedincompliancewithTS

EN 267andTS EN 676 + A2standards.

This OperatingManualisanintegralpartof theburnerand must bemaintainedin a

plasticdossierand hungat a clearlyvisible placeinthe burnerroom.

TERMO ISI S STEMLER SAN.VET C.A.Ş.

EsentepeMah.MilangazCad. No:75 K:3

KartalMonumentoPlaza

Kartal/ STANBUL/TÜRK YE

Tel: +90 216 442 93 00

Fax:+90 216 370 45 03

www.ecostar.com.tr

e-mail:servis@ecostar.com.tr

06.11.2018 Rev. 08 2

CONTENTS

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

1.1. Warning Symbolsand Descriptions .............................................................................................3

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

2. TERMS OFWARRANTY..................................................................................................................6

2.1. Out ofWarranty Conditions.........................................................................................................6

3. BURNER’SGENERALFEATURES.................................................................................................7

3.1. Purposeof Use and Work Limits ofBurners................................................................................7

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

4. TECHNICAL DATA ..........................................................................................................................9

4.1. Capacity Table.............................................................................................................................9

4.2. Burner Dimensions.....................................................................................................................10

5. INSTALLATION..............................................................................................................................11

5.1. Burner InstallationPicture..........................................................................................................11

6. COMMISSIONING..........................................................................................................................12

6.1. General Controls........................................................................................................................12

6.2. Combustion Adjustment.............................................................................................................13

6.3. AirPressure SwitchAdjustment.................................................................................................16

6.4. Servomotor Adjustment.............................................................................................................17

6.5. EmissionMeasurement ..............................................................................................................17

6.6. ProgramRelay............................................................................................................................17

6.7. Gas PassEquipmentRequiredinGasLine................................................................................18

7. MAINTENANCE..............................................................................................................................19

7.1. Weekly Maintenance..................................................................................................................19

7.2. MonthlyMaintenance.................................................................................................................19

7.3. Seasonal Maintenance................................................................................................................20

8. TROUBLESHOOTING....................................................................................................................21

9. PERIODICAL FLUEGASMEASUREMENTREPORT.................................................................22

10. AFTERSALES SERVICES..........................................................................................................23

11. NOTES..........................................................................................................................................24

06.11.2018 Rev. 08 3

1. WARNINGS

1.1. WarningSymbolsandDescriptions

Symbols SymbolDescriptions

Important information and usefulhints.

Warning of danger to lifeor property.

Warningofelectrical voltage.

Product handling information.

PFImpulseconnection detectingcombustion chamberpressure

PL Impulseconnection detecting combustion airpressure

PBR Impulse connection detecting burner gas head

CLEANTHE GASBURNER.

CLEAN GAS LINE.

ИСТАЯ ЛИНИЯ ГАЗ.

"Cleanthegasline" warningongasline.

Electricmotor direction ofrotation

Carry inanupright position.Fragile Item.Protectagainstwater.

06.11.2018 Rev. 08 4

1.2. General Safety Rules

•All personnel engagedininstallation,disassembly,commissioning,operation,control,

maintenanceand repair should havereceived thenecessarytrainingandfullyread and understood

thismanual.

•Nochangesthatmightdamage thesafety oftheburnerunit must be madeby persons and/or

organizations onthe burnerunit.

•All operation,commissioning and installation works (except for burningadjustment) should be

carried out when theburnerisnotoperating and afterdisconnecting the power supply.

Noncompliancewith theserules may lead to seriousbodilyinjuriesand even death by electrical

shocksoruncontrolled flameformation.

•Repairs concerned withsafety elementsshould becarriedout only bythemanufacturing company.

•The deviceshouldnever be usedbychildren,mentally handicapped and inexperienced persons.

•Children mustnot be allowed to playwith the device.

•Keep the deviceaway fromexplosiveand flammable materials.

•Devicemustintakeair,ventilation andair discharge holesmust not beclosed.

Ifyou sensegas leakage;

•Shutdownvalvesofall gasdevices.

•Open all doorsand windows.

•Donotturnonelectricdevices or donot turn themoffifthey areworking.

•Donotuseburner derived tools such as match andlighter.

•Informthe gascompany.

Do not store any inflammablematerialsinboiler room.

Wear hearingprotectorsifthereisnoiseinboiler room.

Incaseoffıreorother emergency;

Switchoff the mainswitch

Closethemain fuel shut-offvalveoutside the plant.

Takeappropriate actions

06.11.2018 Rev. 08 5

The burner installation mustbecarried out inaccordancewiththeinstructions. Vibrationcan

damage theburner and its components.

Keep boiler doorsclosedwhilestartingburner and duringburner operation.

Check combustionvalues tobe correct byusingflue gasanalysis atthewhole adjustment range

between minimum,fullload, and ignitionload.

Use liftingdeviceorbelt for liftingfanmotor,ifnecessary

During thefirstcommissioning oftheburner or incase of any revisioncarried out inthe electrical

systemor motor cables byanyreason,directionofthefan rotation mustcertainly be checkedby

the authorizedtechnical service.

Forproducts thathavenotbeencomissionedorstarted morethan 6months, before activatingthe

servomotor;

In gas,air dampersand oilregulators, servomotorand damper connectionsmust be checkedto

ensure that they arefreerunning inspiteofimmobilityand oilfreezing.

Incaseoftwo-pieceflame tubesof ECO 450 and uppercombined burner models being

demountedonthe field,afterthe burner is mountedonthe boiler,heat resistantsilicone

shouldbe appliedtothejoints.

BURNER ROOM

Installtheburner inasuitable room/floor withminimumexternalairopenings and sufficient to

ensu reperfect combustion,incompliancewith current regulations.

Never obstruct airopenings oftheburner room,burner fan intake vents or airducts inorder to

prevent:

a.Thebuildupoftoxic /explosive gas mixtures inthe burner room,

b.Combustionwith insufficient air, resultingin hazardous, anti-economical and polluting ope-

ration.

Theburner mustbealways protectedfromrain,snowand frosttoprevent corrosionand paint

deformations.

Keeptheburner roomclean and freeofsolidvolatile substances,which could besuckedintothefan

and clog theinternalburnerorcombustion head airducts.

06.11.2018 Rev. 08 6

2. TERMS OFWARRANTY

Main and auxiliaryequipmentand allcomponentsusedinEcostarDualFuel (Gas-Heavy Oil)

burnersare guaranteed for1year byTERMOISISST.A.Şstartingfromthedateofcommissioning

under themaintenance,adjustment,operatingconditionsand relevant mechanic,chemical and thermal

effectsexplained herein.

Pleasenote that thiswarranty isonlyvalidifthedevice(s)is commissioned and maintained by our

authorizedservices.

Our company reserves the right to make anymodificationson the product and all instructions

thereof for improvement purposes.

2.1. OutofWarranty Conditions

•Any damage arising out oforin relation to customers’non-complianceto their responsibilities

with regardstoinstallation, commissioning,operation andmaintenance,

•Any damage arising out ofor inrelation to commissioning,repairsand maintenancecarried out by

unauthorized services,

•Any damage thatmayoccur during transportationorstorageofthe product,

•Not preserving the productinits original packaginguntiltheinstallationstage,

•Incorrectand poorelectrical connections,Failuresdue toincorrect voltage applications,frequent

repetition ofvoltage fluctuations,

•Any damagethat may occur as aresultofincorrect fuel usage or,foreign substancesinthe fuel

used or using ofthe productwithoutanyfuel,

•Any damage that mayoccur dueto foreignparticles entered into theproduct during installation

andoperation,

•Failuresdue toincorrectdeviceselection,

•Any damage tounitduetonatural disasters,

•Deviceswithoutany warranty certificates,

•Warranty Certificateswithoutthe stampand signature oftheauthorizeddealer or service,

•Devices with anyfalsification onthewarranty certificate or without an originalserial number.

•The risks during transportation ofdevice undertheresponsibilityof customerbelong to the

customer.

•Presenceofmisuse faults areindicated in the reportsissued by authorized servicestations or our

authorizedagent,dealer,representative orour factory in case ofunavailability ofauthorized

service stations.

•Customers may apply consumer protectionarbitrator committeewith regardsto thisreport and

requestfor anexpert report.

06.11.2018 Rev. 08 7

3. BURNER’SGENERAL FEATURES

ECOSTARDual Fuel(Gas-Heavy Oil) burners are designedand manufactured to workwith liquid

fuelwith max.2.5-20 Cst(mm2/s) viscosity.and NaturalGas and Liquid PetroleumGasat gaspressures

of min.100mbar,max.300 mbar and at -%15 to +%10 ofnominal voltages,underenvironmental

temperature ofmax.60˚Cwithrated capacity and burner pressureranges.

3.1. Purpose ofUseand WorkLimitsof Burners

•Thisproduct works at any load value equivalentto itsmax.capacity or covered by itscapacity

range;

-In hotwater and steamboilers,

-In directand indirecthot airgenerators,

-Industrialappliancesoperatingattemperature below 600 0C,

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

-1N230VAC/3N 380VAC/50Hz feed voltage(-%15…+%10) values,

-Max.95%relative humidity,

-In well-ventilatedopenandclosed spaces compatible withprotection class IP40.

This devicemust never beoperatedwithopenflame!

3.2. CodeKey

06.11.2018 Rev. 08 8

Temperature change of fuel usedinECOSTARDual Fuel (Gas-HeavyOil) burnersdependent on

viscosity

06.11.2018 Rev. 08 9

4. TECHNICAL DATA

4.1. CapacityTable

BURNER

TYPE CAPACITY NATURALGAS

CONSUMPTION

HEAVY OIL

CONSUMPTION

Max.

kcal/h

Max.

Nm³/h

Max.

kg/h

ECO-250.1 1,9 1.600.000 193,9 165,8

ECO-250.2 2,6 2.250.000 272,7 233,2

ECO-300.1 3,4 2.900.000 351,5 300,5

ECO-300.2 4,2 3.600.000 436,4 373,1

ECO-350.1 5,0 4.300.000 521,2 445,6

ECO-350.2 6,2 5.300.000 642,4 549,2

ECO-350.3 7,3 6.300.000 763,6 652,8

ECO-400.1 8,1 7.000.000 848,5 725,4

ECO-400.2 8,8 7.600.000 921,2 787,6

ECO-400.3 9,7 8.300.000 1006,1 860,1

ECO-450.1 11,5 9.900.000 1200,0 1025,9

ECO-450.2 12,9 11.100.000 1345,5 1150,3

ECO-450.3 14,5 12.450.000 1509,1 1290,2

ECO-500.1 16,2 13.900.000 1684,8 1440,4

ECO-500.2 17,8 15.300.000 1854,5 1585,5

ECO-500.3 19,4 16.650.000 2018,2 1725,4

ECO-600.1 20,8 17.900.000 2169,7 1854,9

ECO-600.2 23,4 20.150.000 2442,4 2088,1

ECO-600.3 25,0 21.500.000 2606,1 2228,0

ECO-700.1 26,2 22.500.000 2727,3 2331,6

ECO-700.2 27,3 23.500.000 2848,5 2435,2

ECO-700.3 29,1 25.000.000 3030,3 2590,7

ECO-800.1 32,1 27.600.000 3345,5 2860,1

ECO-800.2 33,5 28.850.000 3497,0 2989,6

ECO-800.3 35,2 30.250.000 3666,7 3134,7

ECO-900.1 36,7 31.600.000 3830,3 3274,6

ECO-900.2 39,2 33.750.000 4090,9 3497,4

ECO-900.3 40,8 35.050.000 4248,5 3632,1

HuNatural Gas= 8250 Kcal/Nm3

Hu Heavy Oil(S)=9650Kcal/kg

Mechanical ModulatingBurner-Modulation Ratio: NaturalGas5:1, LiquidFuel 3:1

ElectronicModulatingBurner-ModulationRatio: Natural Gas 10:1, LiquidFuel5:1

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