ECOSTAR ECO 55 Installation guide

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www.ecostar.com.tr
MONOBLOCK LIGHT OIL BURNERS INSTALLATION,
OPERATING ANDMAINTENANCE MANUAL
TWO-STAGE ANDMODULATINGOPERATION
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 Light Oil
burners are prepared andmanufactured accordingto 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 LIGHT OIL Burners aremanufactured in accordance with TS EN 267
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.
TERMO ISI S STEMLER SAN.VE T C.A.Ş.
Esentepe Mah.MilangazCad. No:75 K:3
Kartal Monumento Plaza
Kartal/ STANBUL/TÜRK YE
Tel: [phone]
Fax: [phone]
www.ecostar.com.tr
e-mail:[e-mail]

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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. 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. FlameLength and Diameter......................................................................................................... 35
5.5. NoiseLevel................................................................................................................................... 35
6. BURNER HANDLING INFORMATION.......................................................................................... 35
7. INSTALLATION................................................................................................................................ 37
7.1. Burner Installation Picture............................................................................................................ 37
7.2. In reverseflamefront mirror boilers............................................................................................ 38
7.3. In cylindrical (straight flame)boilers........................................................................................... 38
8. COMMISSIONING............................................................................................................................. 39
8.1. BeforeCommissioning................................................................................................................. 39
8.2. General Controls .......................................................................................................................... 39
8.3. Combustion Adjustment............................................................................................................... 40
8.4. FuelPumps................................................................................................................................... 40
8.5. Servomotor Adjustment............................................................................................................... 44
8.6. Emission Measurement................................................................................................................ 49
8.7. ProgramRelay.............................................................................................................................. 49
8.8. Light Oil Burner Fuel Ring Line.................................................................................................. 51
9. MAINTENANCE................................................................................................................................ 52
9.1. Weekly Maintenance.................................................................................................................... 52
9.2. Monthly Maintenance................................................................................................................... 52
9.3. SeasonalMaintenance.................................................................................................................. 53
9.4. Installation and Disassembly Instructions for Maintenance Purposes......................................... 54
10. TROUBLESHOOTING................................................................................................................... 55
11. PERIODICAL FLUE GASMEASUREMENT REPORT.............................................................. 56
12. AFTER-SALESSERVICES............................................................................................................ 57
13. NOTES............................................................................................................................................. 58

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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.
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.
Do not storeany inflammablematerials in boilerroom.
Wear hearing protectors if thereis noisein boiler room.
Incaseof fıre orotheremergency;
Switch offthemain switch
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 air dampers and oil regulators, servomotor and air damperconnections must becheckedto
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 and auxiliary equipmentand all componentsusedin Ecostarlight oil burners areguaranteed
for 1yearby TERMO ISIS ST. A.Şstarting from thedateof commissioning underthemaintenance,
adjustment, operating conditions and relevant mechanic,chemical and 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
ECOSTARlight oilburners aredesignedto operatewith oil at2.5 –6Cst (mm²/s) viscosity, at
ratedcapacity and pressureranges and -15% to +10% nominal voltage.
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 fuel used in ECOSTAR light oil burners dependent on viscosity

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3.3. Burner Components
ECO 50 OLC2

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Assembly No Part Name Assembly No Part Name
1 Body 19 Servomotor
2 KlingeritGasket 20 Servomotor Coupling
3 FlameTube21 Air Damper
4 FlameTubeExtension 22 Air Damper
5 Gasket 23 Air Damper MotionRod
6 Boiler ConnectionFlange 24 Air Damper MotionTransfer Rod
7 Fan 25 FanCoupling
8 FanMotor ConnectionFlange 26 CouplingConnectionPipe
9 Motor 27 PumpCoupling
10 ElectricalPanel 28 Pump
11 ElectricalPanel Mounting Plate 29 FuelPipe
12 HandlingShaft 30 SolenoidValve
13 Shaft Fixing Plate 31 Lance
14 ObservationGlass 32 LanceCentring Console
15 IgnitionTransformer 33 IgnitionElectrode
16 Transformer ConnectionPlate 34 Electrode ConnectionSheet Metal
17 Photocell 35 CombustionHead
18 Purger 36 FuelNozzle

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ECO 50 OLC3

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Assembly No Part Name Assembly No Part Name
1 Body 22 IgnitionElectrode
2 KlingeritGasket 23 Lance
3 FlameTube24 LanceCentring Console
4 FlameTubeExtension 25 SolenoidValveConnectionPlate
5 Gasket 26 SolenoidValve
6 Boiler ConnectionFlange 27 FuelPipes
7 Fan 28 Manometer
8 FanMotor ConnectionFlange 29 Ball Valve
9 Motor 30 Pump
10 ElectricalPanel 31 PumpCoupling
11 ElectricalPanel Mounting Plate 32 CouplingConnectionPipe
12 HandlingShaft 33 FanCoupling
13 Shaft Fixing Plate 34 Air Damper MotionTransfer Rod
14 ObservationGlass 35 Air Damper MotionRod
15 IgnitionTransformer 36 Air Damper
16 Transformer Mounting Plate 37 Air Damper
17 Photocell 38 Coupling
18 Purger 39 Air Damper Adjustment Rod
19 FuelNozzle 40 Disc ControlGroup
20 CombustionHead 41 Servomotor
21 Electrode ConnectionSheet Metal

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ECO 55 OLC2-2a

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Assembly No Part Name Assembly No Part Name
1 Body 19 Servomotor Coupling
2 KlingeritGasket 20 Air Damper
3 FlameTube21 Air Damper
4 FlameTubeExtension 22 Air Damper MotionRod
5 Gasket 23 Air Damper MotionTransfer Rod
6 Boiler ConnectionFlange 24 FanCoupling
7 Fan 25 CouplingConnectionPipe
8 Motor 26 PumpCoupling
9 ElectricalPanel 27 Pump
10 ElectricalPanel Mounting Plate 28 FuelPipe
11 HandlingShaft 29 SolenoidValve
12 Shaft Fixing Plate 30 Lance
13 ObservationGlass 31 LanceCentring Console
14 IgnitionTransformer 32 IgnitionElectrode
15 Transformer Mounting Plate 33 Electrode ConnectionSheet Metal
16 Photocell 34 CombustionHead
17 Purger 35 FuelNozzle
18 Servomotor

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ECO 55 OLC3-3a

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Assembly No Part Name Assembly No Part Name
1 Body21 IgnitionElectrode
2 KlingeritGasket 22 Lance
3 FlameTube23 LanceCentring Console
4 FlameTubeExtension 24 SolenoidValveConnectionPlate
5 Gasket 25 SolenoidValve
6 Boiler ConnectionFlange 26 FuelPipes
7 Fan 27 Manometer
8 Motor 28 Ball Valve
9 ElectricalPanel 29 Pump
10 ElectricalPanel Mounting Plate 30 PumpCoupling
11 HandlingShaft 31 CouplingConnectionPipe
12 Shaft Fixing Plate 32 FanCoupling
13 ObservationGlass 33 Air Damper MotionTransfer Rod
14 IgnitionTransformer 34 Air Damper MotionRod
15 Transformer Mounting Plate 35 Air Damper
16 Photocell 36 Air Damper
17 Purger 37 Coupling
18 FuelNozzle 38 Air Damper Adjustment Rod
19 CombustionHead 39 Disc ControlGroup
20 Electrode ConnectionSheet Metal 40 Servomotor

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ECO 60 OLC2

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Assembly No Part Name Assembly No Part Name
1 Body 23 Electrode Clamp
2 KlingeritGasket 24 Pilot IgnitionElectrode
3 FlameTube25 Pilot CombustionHead
4 Air Adjustment Mechanism 26 Servomotor
5 Boiler ConnectionFlange 27 Servomotor Coupling
6 Gasket 28 Air Damper
7 Fan 29 Air Damper
8 FanMotor ConnectionFlange 30 Air Damper MotionRod
9 Motor 31 Air Damper MotionTransfer Rod
10 ElectricalPanel 32 Air Dumper Spring
11 ElectricalPanel Mounting Plate 33 PumpCover
12 HandlingShaft 34 Motor
13 Shaft Fixing Plate 35 PumpMotor Console
14 ObservationGlass 36 Pump
15 ObservationFrame 37 Ball Valve
16 IgnitionTransformer 38 Manometer
17 Transformer Mounting Plate 39 FuelPipes
18 Photocell40 SolenoidValve
19 Eyebolt 41 Lance
20 Purger 42 LanceCentring Console
21 Gas Solenoid Valve 43 CombustionHead
22 Pilot Gas Pipe 44 FuelNozzle

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ECO 60 OLC3