ECOSTAR ECO 8 NG Installation guide

www.ecostar.com.tr
MONOBLOCKHEAVY OIL BURNERSINSTALLATION,
OPERATING ANDMAINTENANCEMANUAL
MODULATINGOPERATION
ECO8 NG
ECO9 NG

13.06.2017 Rev. 01 1
DEAR USER,
ECOSTAR EC08NG, ECO 9NGHeavy Oil burnersarepreparedand
manufacturedaccordingto thelatesttechnical developmentsand safetyrules. Itis easyto
useforourcustomers.
We recommendthat you readthis manual andsafety warningsthoroughlybeforethe
useof the deviceinordertoensure safe, cost effective andenvironmental-friendly use.
Ifyou encounterany issuethat isnotexplainedclearly inthismanual or youcould
not understand,please contact withour service department.
We thank youforchoosingECOSTAR brand.
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]

13.06.2017 Rev. 01 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
TECHNICAL DATA..................................................................................................................................9
Capacity and TechnicalChart.................................................................................................................9
Back Pressure-CapacityDiagrams........................................................................................................10
Outer Dimensions.................................................................................................................................11
FlameLength andDiameter..................................................................................................................12
INSTALLATION.....................................................................................................................................13
Burner InstallationPicture....................................................................................................................13
COMMISSIONING..................................................................................................................................14
GeneralControls...................................................................................................................................14
Combustion Adjustment.......................................................................................................................15
Fuel Pumps...........................................................................................................................................15
BT 300......................................................................................................................................................19
Operating Controland Displays............................................................................................................20
Menu Functions....................................................................................................................................21
BT300 Connecting Diagram.................................................................................................................22
Servomotor ...........................................................................................................................................23
FunctionControlsandAdjustments......................................................................................................24
FinalChecks.........................................................................................................................................24
PilotIgnition System ............................................................................................................................27
Emission Measurement.........................................................................................................................27
Heavy OilBurnerFuel RingLine.........................................................................................................28
MAINTENANCE.....................................................................................................................................29
Weekly Maintenance............................................................................................................................29
MonthlyMaintenance...........................................................................................................................29
Seasonal Maintenance...........................................................................................................................30
FAULTHISTORY ...................................................................................................................................31
PERIODICAL FLUEGASMEASUREMENTREPORT........................................................................32
AFTERSALES SERVICES.....................................................................................................................33
NOTES.....................................................................................................................................................34

13.06.2017 Rev. 01 3
WARNINGS
WarningSymbols andDescriptions
Symbols SymbolDescriptions
Important information and usefulhints.
Warning of danger to lifeor property.
Warningofelectrical voltage.
Product handling information.
Electricmotor direction ofrotation
Carry inanupright position.Fragile Item.Protectagainstwater.

13.06.2017 Rev. 01 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 becarriedout only bythemanufacturingcompany.
•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.
Do not store any inflammablematerialsinboiler room.
Wear hearingprotectorsifthereisnoiseinboiler room.
Incaseoffıreorother emergency;
Switchoff the mainswitch
Takeappropriate actions

13.06.2017 Rev. 01 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 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.

13.06.2017 Rev. 01 6
TERMS OF WARRANTY
Main and auxiliary equipment and all componentsusedin Ecostar Heavy Oılburnersare
guaranteed for1year by TERMO ISISST.A.Şstartingfromthedateof commissioning under the
maintenance,adjustment,operating conditionsand relevant mechanic,chemical and thermal effects
explainedherein.
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 inthe 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.

13.06.2017 Rev. 01 7
BURNER’SGENERALFEATURES
ECOSTARHeavyOil burnersaredesigned to operate withoil at2.5–20 Cst (mm²/s)viscosity,at
rated capacity andpressure ranges and-15% to+10% nominalvoltage.
PurposeofUseand WorkLimitsofBurners
•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

13.06.2017 Rev. 01 8
Temperature change of fuel used inECOSTARheavy oilburnersdependent on viscosity

13.06.2017 Rev. 01 9
TECHNICAL DATA
Capacity andTechnicalChart
NEW GENARATION MODULATING HEAVY-OILBURNERSCAPACITYTABLE
BURNERTYPE CAPACITY CAPACITY HEAVY OIL
CONSUMPTION FANMOTOR POWER MAIN SUPPLY
Min.
kcal/h Max. kcal/h
Min.
kW
Max.
kW Min. kg/h Max. kg/h kW VAC
ECO8 O(S) C 3 NG 722.400 5.160.000 840 6.000 74,9 534,7 11,00 3N 380
ECO8 O(S) C 3 a NG 842.800 6.020.000 980 7.000 87,3 623,8 11,00 3N 380
ECO8 O(S) C 3 b NG 963.200 6.880.000 1.120 8.000 99,8 713,0 15,00 3N 380
ECO9 O(S) C 3 NG 1.023.400
7.310.000 1.190 8.500 106,1 757,5 18,50 3N 380
ECO9 O(S) C 3a NG 1.083.600
7.740.000 1.260 9.000 112,3 802,1 22,00 3N 380
ECO9 O(S) C 3b NG 1.324.400
9.030.000 1.540 10.500 137,2 935,8 22,00 3N 380
ECO9 O(S) C 3c NG 1.806.000
10.320.000 2.100 12.000 187,2 1.069,4 22,00 3N 380
Hu Heavy Oil(S)=9650Kcal/kg

13.06.2017 Rev. 01 10
BackPressure-Capacity Diagrams

13.06.2017 Rev. 01 11
Outer Dimensions

13.06.2017 Rev. 01 12
Flame LengthandDiameter

13.06.2017 Rev. 01 13
INSTALLATION
BurnerInstallation Picture
Fuel PumpingStationInterconnection ofpressure transmitters

13.06.2017 Rev. 01 14
COMMISSIONING
General Controls
ElectricalConnection
Performelectricalconnections according to thediagramprovided withthe burner.Followgeneral
securityrules duringinstallationofelectric wiringand making connections. Connect the earthingterminal
in electric panel tothe earthing installation.
Make suretoperformthe following controlsbeforecommissioningtheburner.
ØInstallationoftheburner totheboileris checked.
ØCheckthe fuel line(are the pipediametersand thepipe installation correct?).
ØCheckenergy input cablesand voltages.
ØCheckthe boiler safety thermostats.
ØCheckthe fuel nozzles according totheboiler capacity.
ØPriortooperating the burner, controlthe boilerwater level.
ØMakesure water circulation systemisturnedon,and steamboiler andwaterfeedpumps and
boilerinlet -outletsareopen.
Commissioningorder
ØAfter performingtheabovementioned controls,open the fuel tankvalve.
ØOpenthevalve upstreamofthe fuel filter.
ØCheck direction ofmotor rotation.
ØOpenthepump’s vent plugand placethe manometer (0-40bar).
ØTurn ontheburner switch.
ØWhen theburner startsup,themotor isactivated and turns thepumpatthe sametime.
ØIt actuatespre-purgeanddischarges theresidual gases remaining intheboiler fromthe funnel.
ØAfter thepre-purge,fuel is deliveredfromthe nozzle.The fuelmeetstheflamefromtheignition
electrodesandthe combustionstarts.
ØAfter combustionoftheburner,thepumppressure isadjusted (modulating25bar).
ØThe boiler thermostat is adjustedasdesired(70-90°Cfor central heating boilers).
ØFor the safety of thesystem,check the boilerthermostats and observe the deactivation ofthe
burner.

13.06.2017 Rev. 01 15
CombustionAdjustment
ØPhotocell
Check the photocell weekly.Cleanthedustorfumestains ontheglassof photocellbyadrycloth.
FuelPumps
MF Type

13.06.2017 Rev. 01 16
TA Type
1. Suction
2. Nozzleoutlet
3. Return
4. Manometer inlet
5. Vacuumor inletmanometer and internal returninlet
6. Pressureadjustment
7. Pre heater location

13.06.2017 Rev. 01 17
ØModulatingHeavyOilBurnerFuelCircuit

13.06.2017 Rev. 01 18
CAUTION!
ØEnd oftheline tothemaintankmustbe opento the atmosphereandline pressure mustbe
zero,otherwise no healthy modulating operation can beensured since the pressure,which is
to form inreturn,willalsoaffectnozzlepressure.Fuelmay drop from nozzle end during
stops.
ØFor good pulverization,periodically checkdurability ofthe o-ring.Inthe event of earing of
the o-ring,fuel tothe nozzle can by-pass andgo directly to the return and reduces the
workingperformanceof thenozzle.
ØMaximumoperating pressure of the nozzleis30bars,whileitsmaximum operating
temperatureis140ºC.Thesevaluesshouldnotbe exceeded during working.Even if these
out of control valueare exceeded,nozzle mustbe takentoemergencymaintenanceand all
O-ringsmustbe replaced.
ØDonot use solventbasedmaterials (thinner and derivatives) during cleaning ofthe fuel
nozzle; clean withgas oil ordiesel oil.Fuelnozzleinner kit is very sensitive and even
invisibledeformations canreduce workingperformance;dismantling-installingworkmust
be performed onlybytrainedpersonnel.
ØSpringhaslostitsfunctionif droppingfrom fuelnozzle orfuel exitatlargescaleis observed
whenthe nozzleperforms circulation.Itmust bechecked andreplaced if necessary.
ØBurnerpreheater
1. Fuel inlet
2. Fuel outlet
3. Discharge
4. Fixingplate
5. Resistance
6. Thermostat bulbpipe
7. Housingcover

13.06.2017 Rev. 01 19
BT300