ECOSTAR ECO 55 K L C 2 Installation guide

www.ecostar.com
MONOBLOCKDUALFUEL(GAS-LIGHTOIL)
BURNERS INSTALLATION, OPERATINGAND
MAINTENANCE MANUAL
TWOSTAGEANDMODULATINGOPERATION
ECO50
ECO55
ECO60
ECO65
ECO70
ECO75

09.06.2017 Rev. 08 1
DEAR USER,
ECOSTAR ECO 50,ECO 55,ECO 60,ECO 65,ECO70,ECO 75 DualFuel
(Gas-LightOil) burnersarepreparedandmanufacturedaccordingtothelatest technical
developments andsafetyrules. It iseasytouse for ourcustomers.
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-Light Oil)Burnersaremanufacturedin compliancewith TS
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: [phone]
Fax:[phone]
www.ecostar.com.tr
e-mail:[e-mail]

09.06.2017 Rev. 08 2
CONTENTS
WARNINGS...............................................................................................................................................3
Warning Symbols andDescriptions........................................................................................................3
GeneralSafety Rules..............................................................................................................................4
TERMS OFWARRANTY.........................................................................................................................6
Out of Warranty Conditions...................................................................................................................6
BURNER’SGENERALFEATURES........................................................................................................7
Purposeof Useand Work LimitsofBurners..........................................................................................7
CodeKey................................................................................................................................................7
Burner Components................................................................................................................................9
TECHNICAL DATA................................................................................................................................31
Capacity Table......................................................................................................................................31
Back Pressure-CapacityDiagrams........................................................................................................32
Burner Dimensions...............................................................................................................................33
Gas Hood PressureLossDiagram.........................................................................................................34
FlameLength andDiameter..................................................................................................................37
Noise Level...........................................................................................................................................37
BURNER HANDLING INFORMATION................................................................................................38
INSTALLATION.....................................................................................................................................39
Burner InstallationPicture....................................................................................................................39
In reverse flamefrontmirror boilers.....................................................................................................40
In cylindrical(straightflame) boilers....................................................................................................40
COMMISSIONING..................................................................................................................................41
Before Commissioning.........................................................................................................................41
GeneralControls...................................................................................................................................41
Combustion Adjustment.......................................................................................................................43
Fuel Pumps...........................................................................................................................................43
Gas Adjustment....................................................................................................................................47
Air pressure SwitchAdjustment ...........................................................................................................49
Servomotor Adjustment........................................................................................................................49
Emission Measurement.........................................................................................................................54
ProgramRelay......................................................................................................................................54
LightOil Burner Fuel RingLine...........................................................................................................57
Gas PassEquipmentRequired inGasLine...........................................................................................58
MAINTENANCE.....................................................................................................................................59
Weekly Maintenance............................................................................................................................59
MonthlyMaintenance...........................................................................................................................59
Seasonal Maintenance...........................................................................................................................60
TROUBLESHOOTING............................................................................................................................61
PERIODICAL FLUEGASMEASUREMENTREPORT........................................................................62
AFTERSALES SERVICES.....................................................................................................................63
NOTES.....................................................................................................................................................64

09.06.2017 Rev. 08 3
WARNINGS
WarningSymbols andDescriptions
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.

09.06.2017 Rev. 08 4
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 becarried out 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

09.06.2017 Rev. 08 5
The burner installation must becarried out inaccordance withtheinstructions.Vibrationcan
damage the burner and itscomponents.
Keep boiler doorsclosedwhilestartingburner and duringburner operation.
Check combustionvalues tobe correct byusingflue gasanalyzer at the whole adjustmentrange
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.

09.06.2017 Rev. 08 6
TERMS OF WARRANTY
Main and auxiliaryequipment and all componentsused inEcostarDualFuel(Gas-LightOil)
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 makeanymodificationson the product and all instructions
thereof for improvement purposes.
Out ofWarranty 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 servicestationsor our
authorizedagent,dealer,representative orour factory in case ofunavailability ofauthorized
service stations.
•Customers may apply consumer protectionarbitrator committeewith regardsto thisreport and
requestfor anexpert report.

09.06.2017 Rev. 08 7
BURNER’SGENERALFEATURES
ECOSTARDual Fuel(Gas-Light Oil)burnersaredesigned and manufacturedto work with liquid
fuelwith max.2.5- 6Cst(mm2/s)viscosity.and Natural Gas andLiquid PetroleumGas atgas pressures
of min.20 mbar,max.300 mbar and at -%15 to +%10 ofnominalvoltages,underenvironmental
temperature ofmax.60˚Cwithrated capacity and burner pressureranges.
Purpose ofUseand WorkLimits ofBurners
•Thisproduct works at any load value equivalentto itsmax.capacity or covered by itscapacity
range;
-In hotwater andsteamboilers,
-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!
Code Key

09.06.2017 Rev. 08 8
Temperature changeoffuelusedin ECOSTARDual Fuel (Gas-Light Oil) burnersdependent on
viscosity

09.06.2017 Rev. 08 9
BurnerComponents
ECO 50KLC2

09.06.2017 Rev. 08 10
Assembly No PartName Assembly NoPartName
1 Body group 24 Gas ignition electrode
2 Klingerit gasket 25 Electrodeconnection plate
3 Flame tube26 Liquid fuel ignition electrode
4 Boilerconnection flange 27 Fuel nozzle
5 Gasket 28 Lance
6 Flame tubeextension 29 Solenoidvalve
7 Fan 30 Manometer
8 Motorconnection flange 31 Ball valve
9 Motor32 Fuel pipes
10 Electrical panelconnectionplate 33 Airdamper motion rod
11 Electrical panel 34 Airdamper transmission rod
12 Handlingrodfixingplate 35 Airdamper
13 Handlingrod 36 Airdamper
14 Observation glass 37 Servomotorcoupling
15 Purger 38 Servomotor
16 VPS 39 Pump housingcover
17 Gas solenoid valve 40 Airpressure switch
18 Gas inletpipe 41 Pressure switch adaptor
19 Transformerconnection plate 42 Pressure switch adaptor
20 Transformerconnection plate(dual) 43 Pump
21 Ignition transformer 44 Pump motorconsole
22 Photocell 45 Motor
23 Combustion head

09.06.2017 Rev. 08 11
ECO 55KLC2-2a

09.06.2017 Rev. 08 12
Assembly No PartName Assembly NoPartName
1 Body group 23 Gas Ignition electrode
2 Klingerit gasket 24 Electrodeconnection plate
3 Flame tube25 Liquid fuel Ignitionelectrode
4 Boilerconnection flange 26 Fuel nozzle
5 Gasket 27 Lance
6 Flame tubeextension 28 Solenoidvalve
7 Fan 29 Manometer
8 Motor30 Ball valve
9 Electrical panel connectionplate 31 Fuel pipes
10 Electrical panel 32 Airdamper motion rod
11 Handlingrodfixingplate 33 Airdamper transmission rod
12 Handlingrod 34 Airdamper
13 Observation glass 35 Airdamper
14 Purger 36 Servomotorcoupling
15 VPS 37 Servomotor
16 Gas solenoid valve 38 Pump housingcover
17 Gas inletpipe 39 Airpressure switch
18 Transformerconnection plate 40 Pressure switch adaptor
19 Transformerconnection plate(dual) 41 Pressure switch adaptor
20 Ignition transformer 42 Pump
21 Photocell 43 Pump motorconsole
22 Combustion head 44 Motor

09.06.2017 Rev. 08 13
ECO 60KLC2

09.06.2017 Rev. 08 14
Assembly No PartName Assembly No PartName
1 Body group 25 Combustion head
2 Klingerit gasket 26 Gas ignition electrode
3 Flametube 27 Electrodeconnectionplate
4 Boiler connection flange 28 Liquid fuelIgnition electrode
5 Gasket 29 Fuel nozzle
6 Fan 30 Lance
7 Motorconnectionflange 31 Solenoidvalve
8 Motor32 Manometer
9 Electrical panel connection plate 33 Ball valve
10 Electrical panel 34 Fuel pipes
11 Handlingrod fixingplate 35 Airdamper motion rod
12 Handlingrod 36 Airdamper transmission rod
13 Bearing 37 Airdamper
14 Observationglass frame 38 Airdamper
15 Observationglass 39 Servomotorcoupling
16 Eyebolt 40 Servomotor
17 VPS 41 Pump housingcover
18 Gas solenoid valve 42 Airpressure switch
19 Gas inlet pipe 43 Pressure switch adaptor
20 Purger 44 Pressure switch adaptor
21 Transformer connectionplate 45 Pump
22
Transforme
r connectionplate
(dual) 46 Pump motorconsole
23 Ignition transformer 47 Motor
24 Photocell

09.06.2017 Rev. 08 15
ECO 65KLC2

09.06.2017 Rev. 08 16
Assembly No PartName Assembly NoPartName
1 Body group 25 Photocell
2 Klingerit gasket 26 Combustion head
3 Flame tube27 Gas ignition electrode
4 Boilerconnection flange 28 Electrode connectionplate
5 Gasket 29 Liquid fuel Ignition electrode
6 Flame tubeextension 30 Fuel nozzle
7 Fan 31 Lance
8 Motorconnection flange 32 Solenoid valve
9 Motor33 Manometer
10 Electrical panelconnectionplate 34 Ball valve
11 Electrical panel 35 Fuel pipes
12 Handlingrodfixingplate 36 Air damper motion rod
13 Handlingrod 37 Air damper transmission rod
14 Bearing 38 Air damper
15 Observation glass frame 39 Air damper
16 Observation glass 40 Servomotor coupling
17 Eyebolt 41 Servomotor
18 VPS 42 Pumphousing cover
19 Gas solenoid valve 43 Air pressure switch
20 Gas inletpipe 44 Pressure switchadaptor
21 Purger 45 Pressure switchadaptor
22 Transformerconnection plate 46 Pump
23 Transformerconnection plate(dual) 47 Pumpmotorconsole
24 Ignition transformer 48 Motor

09.06.2017 Rev. 08 17
ECO 70KLC2

09.06.2017 Rev. 08 18
Assembly No PartName Assembly No PartName
1 Body group 25 Combustion head
2 Klingerit gasket 26 Gas ignition electrode
3 Flame tube27 Electrode connectionplate
4 Boilerconnection flange 28 Liquid fuel Ignition electrode
5 Gasket 29 Fuel nozzle
6 Flame tubeextension 30 Lance
7 Fan 31 Solenoid valve
8 Motor32 Manometer
9 Electrical panelconnectionplate 33 Ball valve
10 Electrical panel 34 Fuel pipes
11 Handlingrodfixingplate 35 Air damper motion rod
12 Handlingrod 36 Air damper transmission rod
13 Bearing 37 Air damper
14 Observation glass frame 38 Air damper
15 Observation glass 39 Servomotor coupling
16 Eyebolt 40 Servomotor
17 VPS 41 Pumphousing cover
18 Gas solenoid valve 42 Air pressure switch
19 Gas inletpipe 43 Pressure switchadaptor
20 Purger 44 Pressure switchadaptor
21 Transformerconnection plate 45 Pump
22 Transformerconnection plate(dual) 46 Pumpmotorconsole
23 Ignition transformer 47 Motor
24 Photocell

09.06.2017 Rev. 08 19
ECO 50KLC3