ECOSTAR ECO 50 Installation guide

22.11.2022 Rev. 12
www.ecostar.com.tr
MONOBLOCKDUAL FUEL(GAS-HEAVYOIL)
BURNERSINSTALLATION,OPERATING AND
MAINTENANCE MANUAL
TWO STAGE ANDMODULATING OPERATION
ECO 50
ECO 55
ECO 60
ECO 65
ECO 70
ECO 75

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DEAR USER,
ECOSTAR ECO 50, ECO 55, ECO 60, ECO 65, ECO 70, ECO 75 Dual Fuel (Gas-
Heavy Oil) burners areprepared 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 safetywarnings thoroughly before the
use of the device in order to ensuresafe, cost effective and environmental-friendly use.
If you encounterany issuethat 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 Dual Fuel (Gas-Heavy Oil) Burners aremanufactured in compliance withTS
EN 267 and TS EN 676 + A2 standards.
This Operating Manual is an integral partof the burner andmust bemaintained in a
plastic dossier and hung at a clearly visible place in the burner room.

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CONTENTS
1. WARNINGS.......................................................................................................................................... 3
1.1. Warning Symbols and Descriptions............................................................................................... 3
1.2. General Safety Rules...................................................................................................................... 4
2. TERMSOFWARRANTY.................................................................................................................... 6
2.1. Out of Warranty Conditions.......................................................................................................... 6
3. BURNER’SGENERAL FEATURES................................................................................................... 7
3.1. Purposeof Useand Work Limits of Burners................................................................................. 7
3.2. CodeKey........................................................................................................................................ 7
3.3. Burner Components........................................................................................................................ 9
4. GAS, FLUE GASAND 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. Gas HoodPressureLoss Diagram................................................................................................ 35
5.5. FlameLength and Diameter......................................................................................................... 38
5.6. NoiseLevel................................................................................................................................... 38
6. BURNER HANDLING INFORMATION.......................................................................................... 39
7. INSTALLATION................................................................................................................................ 40
7.1. Burner Installation Picture............................................................................................................ 40
7.2. In reverseflamefront mirror boilers............................................................................................ 41
7.3. In cylindrical (straight flame)boilers........................................................................................... 41
8. COMMISSIONING............................................................................................................................. 42
8.1. BeforeCommissioning................................................................................................................. 42
8.2. General Controls .......................................................................................................................... 42
8.3. Combustion Adjustment............................................................................................................... 44
8.4. FuelPumps................................................................................................................................... 44
8.5. Gas Adjustment............................................................................................................................ 48
8.5.1. VGD 20 4011 - 5011 Series Gas Valve.................................................................................... 48
8.6. Air PressureSwitchAdjustment .................................................................................................. 49
8.7. Servomotor Adjustment............................................................................................................... 49
8.8. Emission Measurement................................................................................................................ 54
8.9. ProgramRelay.............................................................................................................................. 54
8.10. Heavy OilBurner Fuel Ring Line............................................................................................ 57
8.11. Gas Pass Equipment Requiredin Gas Line.............................................................................. 58
9. MAINTENANCE................................................................................................................................ 59
9.1. Weekly Maintenance.................................................................................................................... 59
9.2. Monthly Maintenance................................................................................................................... 59
9.3. SeasonalMaintenance.................................................................................................................. 60
10. TROUBLESHOOTING................................................................................................................... 61
11. PERIODICAL FLUE GASMEASUREMENT REPORT.............................................................. 62
12. AFTER SALESSERVICES............................................................................................................ 63
13. NOTES............................................................................................................................................. 64

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1. WARNINGS
1.1. WarningSymbols and Descriptions
Symbols Symbol Descriptions
Importantinformation and useful hints.
Warning of danger to lifeor property.
Warning of electrical voltage.
Product handling information.
PFImpulseconnection detecting combustion chamberpressure
PL Impulseconnection detecting combustion air pressure
PBR Impulseconnection detecting burner gashead
CLEAN THE GASBURNER.
CLEAN GASLINE.
ИСТАЯ ЛИНИЯ ГАЗ.
"Cleanthegas line"warning on gas line.
Electricmotor direction of rotation
Carry in an upright position. FragileItem. Protect against water.

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1.2. General Safety Rules
•All personnelengagedininstallation, disassembly, commissioning, operation,control,
maintenance and repair shouldhavereceivedthenecessary training, qualifiedand fully readand
understood this manual.
•No changesthatmight damagethesafety of theburnerunit must bemadeby persons and/or
organizations on theburner unit.
•All operation, commissioning and installation works (except for burning adjustment) should be
carriedout whentheburneris not operatingand afterdisconnecting thepowersupply.
Noncompliancewiththeserulesmayleadtoserious bodilyinjuriesand evendeathby electrical
shocks or uncontrolled flameformation.
•Repairs concerned with safety elements should becarried outonly by themanufacturing company.
•Thedeviceshould never beused by children, mentally handicappedand inexperienced persons.
•Childrenmust not beallowedto play with thedevice.
•Keep thedeviceaway from explosiveand flammablematerials.
•Device must intakeair, ventilation and air dischargeholesmust not beclosed.
If yousensegas leakage;
•Shut down valves of all gas devices.
•Open all doors and windows.
•Do not turn on electricdevices or do not turn themoff if theyareworking.
•Do not useburner derivedtools such as match andlighter.
•Inform thegas company.
Do not storeany inflammablematerials in boilerroom.
Wear hearing protectors if thereis noisein boiler room.
Incaseof f re orotheremergency;
Switch offthemain switch
Closethemain fuelshut-off valveoutsidetheplant.
Takeappropriateactions

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Theburner installation must becarried out in accordance with theinstructions. Vibration can
damagetheburnerand its components.
Keep boiler doors closed whilestarting burner and during burner operation.
Check combustion values to becorrectby using fluegas analyzer at thewholeadjustment range
betweenminimum,full load, and ignition load.
Useliftingdeviceor belt for lifting fanmotor, if necessary
During thefirst commissioning of theburner or in caseof any revision carriedout in theelectrical
system or motor cables by anyreason, direction of thefan rotation mustcertainly bechecked by
theauthorizedtechnical service.
For products that havenot been comissioned or startedmorethan 6 months, beforeactivating the
servomotor;
In gas, air dampers and oil regulators, servomotor and damper connections must bechecked to
ensurethat theyarefree running in spiteof immobility and oil freezing.
BURNERROOM
Install theburner in asuitableroom/floor with minimum externalair openings and sufficient to
ensu reperfectcombustion, incompliance with current regulations.
Never obstructair openings of theburner room, burnerfan intakevents or air ducts in order to
prevent:
a.Thebuild up of toxic/explosivegas mixtures in theburner room,
b.Combustion with insufficient air,resulting in hazardous, anti-economicaland polluting ope-
ration.
Theburner must bealways protected from rain, snow and frost to prevent corrosion and paint
deformations.
Keeptheburner room clean and freeof solid volatilesubstances, which could besucked into thefan
and clog theinternalburner or combustion head air ducts.

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2. TERMS OF WARRANTY
Main andauxiliaryequipment and all components usedinEcostarDualFuel(Gas-Heavy Oil)
burners areguaranteedfor 1yearby TERMO ISIS ST. A.Şstartingfrom thedateofcommissioning
underthemaintenance,adjustment,operating conditions and relevant mechanic,chemicaland thermal
effects explained herein.
Pleasenotethatthis warranty isonly validif thedevice(s) is commissionedand maintainedby our
authorizedservices.
Our company reservestheright to makeany modifications on theproductand all instructions
thereof forimprovement purposes.
2.1. Out of Warranty Conditions
•Any damagearisingout of orin relation to customers’ non-compliance to their responsibilities
with regards to installation, commissioning, operation and maintenance,
•Any damagearising out of or in relation to commissioning, repairs and maintenance carriedout by
unauthorized services,
•Any damagethat may occur during transportation or storageof theproduct,
•Not preserving theproduct in its originalpackaging until theinstallation stage,
•Incorrectand poor electricalconnections, Failuresdueto incorrectvoltageapplications,frequent
repetition of voltagefluctuations,
•Any damagethatmayoccur asaresultof incorrectfuelusageor, foreign substancesinthefuel
used or using of theproduct without anyfuel,
•Any damagethatmayoccur dueto foreign particlesenteredinto theproductduring installation
and operation,
•Failures dueto incorrect deviceselection,
•Any damageto unit dueto natural disasters,
•Devices without anywarranty certificates,
•Warranty Certificates without thestamp and signatureof theauthorizeddealer or service,
•Deviceswith any falsification on thewarranty certificateorwithout an originalserial number.
•Therisks during transportation of device undertheresponsibilityof customerbelong to the
customer.
•Presence of misusefaults areindicatedinthereports issuedby authorizedservicestations or our
authorizedagent, dealer, representativeor our factory incaseof unavailability of authorized
service stations.
•Customersmayapply consumerprotection arbitrator committee withregards to this report and
request for an expert report.

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3. BURNER’SGENERAL FEATURES
ECOSTARDualFuel(Gas-Heavy Oil)burners aredesignedand manufacturedto work with liquid
fuelwith max. 2.5- 20 Cst (mm2/s) viscosity. and NaturalGasand Liquid Petroleum Gasatgaspressures
of min.20mbar, max.300 mbarandat-%15to +%10 of nominalvoltages, underenvironmental
temperatureof max.60˚C with ratedcapacity and burner pressureranges.
3.1. Purposeof Useand Work Limits of Burners
•This productworks atany loadvalueequivalentto its max. capacityor coveredby its capacity
range;
-In hot water and steam boilers,
-In direct and indirect hot air generators,
-Industrialappliances operatingat temperaturebelow 600 0C,
--15 0C…+60 0C ambient temperaturerange,
-1N 230 VAC/3N 380VAC /50 Hzfeed voltage(-%15…+%10) values,
-Max. 95% relativehumidity,
-In well-ventilated open and closed spacescompatiblewith protection class IP40.
This devicemust never beoperated withopen flame!
3.2. Code Key

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Temperaturechangeof fuelusedin ECOSTAR DualFuel(Gas-Heavy Oil) burners dependent on
viscosity

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3.3. Burner Components
ECO 50 KSC2

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Assembly No Part Name Assembly No Part Name
1 Body26 Oilpre-heater connectionpart
2 KlingeritGasket 27 Thermometer connectionadapter
3 FlameTube28 Thermometer
4 FlameTubeextension 29 Purger
5 Boiler ConnectionFlange 30 Combustionhead
6 Gasket 31 Fuelnozzle
7 Fan 32 Lance
8 Motor connectionflange 33 Solenoidvalve
9 Motor 34 Fuelpipes
10 ElectricalPanel Mounting Plate 35 Manometer
11 ElectricalPanel 36 Ball valve
12 HandlingRodFixingPlate 37 Air dampermotionrod
13 Handlingrod 38 Air dampertransmissionrod
14 ObservationGlass 39 Air damper
15 Gas Solenoid Valve 40 Air damper
16 VPS 41 Servomotor coupling
17 Gas IntakePipe 42 Servomotor
18 IgnitionTransformer 43 Pumphousingcover
19 Photocell 44 Pressureswitch
20 Pilot Igniter Gas Solenoid Valve 45 Pressureswitchadaptor
21 Pilot igniter pipe 46 Pressureswitchadaptor
22 Pilot igniter electrode 47 Pipeelbow
23 Pilot combustionhead 48 Pump
24 Oilpre-heater 49 Pumpmotor console
25 Oilpre-heaterhousing 50 Motor

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ECO 55 KSC2-2a

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Assembly No Part Name Assembly No Part Name
1 Body26 Thermometer connectionadapter
2 KlingeritGasket 27 Thermometer
3 FlameTube28 Purger
4 FlameTubeextension 29 Combustionhead
5 Boiler ConnectionFlange 30 Fuelnozzle
6 Gasket 31 Lance
7 Fan 32 Solenoidvalve
8 Motor 33 Fuelpipes
9 ElectricalPanel Mounting Plate 34 Manometer
10 ElectricalPanel 35 Ball valve
11 HandlingRodFixingPlate 36 Air dampermotionrod
12 Handlingrod 37 Air dampertransmissionrod
13 ObservationGlass 38 Air damper
14 Gas Solenoid Valve 39 Air damper
15 VPS 40 Servomotor coupling
16 Gas IntakePipe 41 Servomotor
17 IgnitionTransformer 42 Pumphousingcover
18 Photocell 43 Pressureswitch
19 Pilot Igniter Gas Solenoid Valve 44 Pressureswitchadaptor
20 Pilot igniter pipe 45 Pressureswitchadaptor
21 Pilot igniter electrode 46 Pipeelbow
22 Pilot combustionhead 47 Pump
23 Oilpre-heater 48 Pumpmotor console
24 Oilpre-heaterhousing 49 Motor
25 Oilpre-heater connectionpart

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ECO 60 KSC2

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Assembly No Part Name Assembly No Part Name
1 Body23 Pilot Igniter Gas Solenoid Valve
2 KlingeritGasket 24 Pilot igniter pipe
3 FlameTube25 Pilot igniter electrode
4 Boiler ConnectionFlange 26 Pilot combustionhead
5 Gasket 27 Purger
6 Fan 28 Combustionhead
7 Motor connectionflange 29 Fuelnozzle
8 Motor 30 Lance
9 ElectricalPanel Mounting Plate 31 Solenoidvalve
10 ElectricalPanel 32 Fuelpipes
11 HandlingRodFixingPlate 33 Manometer
12 Handlingrod 34 Ball valve
13 ObservationGlass frame 35 Air dampermotionrod
14 ObservationGlass 36 Air dampertransmissionrod
15 Bearing 37 Air damper
16 Eyebolt 38 Air damper
17 VPS 39 Servomotor coupling
18 Gas Solenoid Valve 40 Servomotor
19 Gas IntakePipe 41 Pumphousingcover
20 Transformer connectionplate 42 Pressureswitch
21 IgnitionTransformer 43 Pressureswitchadaptor
22 Photocell 44 Pressureswitchadaptor

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ECO 65 KSC2

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Assembly No Part Name Assembly No Part Name
1 Body24 Pilot Igniter Gas Solenoid Valve
2 KlingeritGasket 25 Pilot igniter pipe
3 FlameTube26 Pilot igniter electrode
4 Boiler ConnectionFlange 27 Pilot combustionhead
5 Gasket 28 Purger
6 FlameTubeextension 29 Combustionhead
7 Fan 30 Fuelnozzle
8 Motor connectionflange 31 Lance
9 Motor 32 Solenoidvalve
10 ElectricalPanel Mounting Plate 33 Fuelpipes
11 ElectricalPanel 34 Manometer
12 HandlingRodFixingPlate 35 Ball valve
13 Handlingrod 36 Air dampermotionrod
14 ObservationGlass frame 37 Air dampertransmissionrod
15 ObservationGlass 38 Air damper
16 Bearing 39 Air damper
17 Eyebolt 40 Servomotor coupling
18 VPS 41 Servomotor
19 Gas Solenoid Valve 42 Pumphousingcover
20 Gas IntakePipe 43 Pressureswitch
21 Transformer connectionplate 44 Pressureswitchadaptor
22 IgnitionTransformer 45 Pressureswitchadaptor
23 Photocell

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ECO 70 KSC2

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Assembly No Part Name Assembly No Part Name
1 Body23 Pilot Igniter Gas Solenoid Valve
2 KlingeritGasket 24 Pilot igniter pipe
3 FlameTube25 Pilot igniter electrode
4 Boiler ConnectionFlange 26 Pilot combustionhead
5 Gasket 27 Purger
6 FlameTubeextension 28 Combustionhead
7 Fan 29 Fuelnozzle
8 Motor 30 Lance
9 ElectricalPanel Mounting Plate 31 Solenoidvalve
10 ElectricalPanel 32 Fuelpipes
11 HandlingRodFixingPlate 33 Manometer
12 Handlingrod 34 Ball valve
13 ObservationGlass frame 35 Air dampermotionrod
14 ObservationGlass 36 Air dampertransmissionrod
15 Bearing 37 Air damper
16 Eyebolt 38 Air damper
17 VPS 39 Servomotor coupling
18 Gas Solenoid Valve 40 Servomotor
19 Gas IntakePipe 41 Pumphousingcover
20 Transformer connectionplate 42 Pressureswitch
21 IgnitionTransformer 43 Pressureswitchadaptor
22 Photocell 44 Pressureswitchadaptor

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ECO 50 KSC3