ECOSTAR FPB 20 Installation guide

09.01.2020 Rev. 10
www.ecostar.com.tr
GAS PROCESSBURNERS INSTALLATION,
OPERATING ANDMAINTENANCE MANUAL
ONE STAGE, TWO-STAGE ANDMODULATING OPERATION
FPB20FPB1200
FPB80 FPB1600
FPB200 FPB2000
FPB300FPB2500
FPB400 FPB3500
FPB550 FPB5000
FPB870

09.01.2020 Rev. 10 1
DEAR USER,
ECOSTAR FPB (20, 80, 200, 300, 400, 550, 870, 1200, 1600, 2000, 2500, 3500,
5000) gas process burnersare 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 issue that is not explained clearly inthis manual oryou could
not understand, please contact with our service department.
We thank you for choosing ECOSTAR brand.
Ecostar Gas Process Burners are manufactured inaccordance withTS EN746-2
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]

09.01.2020 Rev. 10 2
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. Process Burner Components .......................................................................................................... 8
4. GAS,FLUE GASAND HEATING WATER SCHEMA................................................................... 15
5. TECHNICAL DATA .......................................................................................................................... 16
5.1. Capacity and Technical Chart...................................................................................................... 16
5.2. Outer Dimensions......................................................................................................................... 17
6. INSTALLATION................................................................................................................................ 19
6.1. Burner Assembly Drawing........................................................................................................... 19
7. COMMISSIONING............................................................................................................................. 20
7.1. Ignition and Ionizasyon System................................................................................................... 20
7.2. General Controls .......................................................................................................................... 21
7.3. Combustion Adjustment............................................................................................................... 22
7.3.1. Gas Adjustment........................................................................................................................ 22
7.3.1.1. VGD 20 4011 - 5011 Series Gas Valve................................................................................ 22
7.3.1.2. MB DLE Series Monoblock Gas Valve................................................................................ 22
7.3.1.3. MB ZRD(LE) 405 –412 Series Gas Valve.......................................................................... 24
7.4. Air pressureswitchadjustment .................................................................................................... 25
7.5. Servomotor Adjustment............................................................................................................... 25
7.6. Pilot Ignition System.................................................................................................................... 27
7.7. ProgramRelay.............................................................................................................................. 27
7.8. Function Controls and Adjustments............................................................................................. 28
7.9. Final Checks................................................................................................................................. 28
7.10. Gas Pass Equipment Requiredin Gas Line.............................................................................. 29
8. MAINTENANCE................................................................................................................................ 31
8.1. Monthly Maintenance................................................................................................................... 31
8.2. SeasonalMaintenance.................................................................................................................. 31
9. TROUBLESHOOTING...................................................................................................................... 32
10. PERIODICAL FLUE GASMEASUREMENT REPORT.............................................................. 33
11. AFTER-SALESSERVICES............................................................................................................ 34
12. NOTES............................................................................................................................................. 35

09.01.2020 Rev. 10 3
1. WARNINGS
1.1. Warning Symbols and Descriptions
Symbols Symbol Descriptions
Important information and useful hints.
Warning of danger to lifeor property.
Warning of electrical voltage.
Product handling information.
PFImpulseconnection detecting combustion chamber pressure
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.
Carry in an upright position. FragileItem.Protectagainst water.

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1.2. General Safety Rules
•All personnelengagedininstallation, disassembly,commissioning, operation,control,
maintenance and repair should havereceivedthenecessary training andfully readand understood
this manual.
•No changesthatmight damagethesafety of theburnerunit must bemadeby persons and/or
organizations on theburner unit.
•All operation, commissioningand 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 fromexplosiveand flammablematerials.
•Device must intakeair, ventilation and air dischargeholesmust not beclosed.
If yousensescent of gas;
•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 and lighter.
•Informthegas company.
Do not storeany inflammablematerials in boilerroom.
Wear hearing protectors if thereis noisein boiler room.
Incaseof fıre orother emergency;
Switch off themain switch
Closethemain fuel shut-off valveoutsidetheplant.
Takeappropriateactions

09.01.2020 Rev. 10 5
Install burner firmly. Vibrationmay damageburner or its components.
Keep boiler doors closed whilestarting burner and during burner operation.
During thefirst commissioning of theburner or in caseof any revision carriedout in theelectrical
systemor motor cables by anyreason, direction of thefan rotation mustcertainly bechecked by
theauthorizedtechnical service.
For products that havenot been comissioned or started morethan 6 months, beforeactivating the
servomotor;
In gas andair dampers, servomotor and air damper connections must becheckedto ensurethat
they arefree runningin spiteofimmobility and oil freezing.
In products used in high temperatureoven applications; When theburners arenot operated /are
switchedoff, Theair flaps must beset toremain in thehalf-open position, to prevent theburner
components being damaged by hot air.
BURNERROOM
Install theburner in asuitableroom/floor withminimumexternal air openings and sufficient to
ensu reperfectcombustion, incompliance with current regulations.
Never obstructair openings of theburner room,burner fan intakevents or air ducts in order to
prevent:
a.Thebuild up of toxic/explosivegasmixtures in theburner room,
b.Combustion with insufficient air,resulting in hazardous, anti-economical and polluting ope-
ration.
Theburnermust bealways protected fromrain, snow and frost to prevent corrosion and paint
deformations.
Keeptheburner roomclean and freeof solid volatilesubstances, which could besucked into thefan
and clog theinternalburner or combustion head air ducts.

09.01.2020 Rev. 10 6
2. TERMSOF WARRANTY
Main and auxiliaryequipment and allcomponents usedin Ecostargasprocess burners are
guaranteedfor 1yearby TERMO ISISST. A.Şstartingfromthedateof commissioning underthe
maintenance,adjustment, operating conditions and relevant mechanic,chemicaland thermaleffects
explainedherein.
Pleasenotethatthis warranty isonly validif thedevice(s) is commissionedand maintainedby our
authorizedservices.
Our company reservestheright to makeanymodifications 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 damagethatmay 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 thestampand 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.

09.01.2020 Rev. 10 7
3. BURNER’SGENERAL FEATURES
ECOSTAR gasprocess burners aremanufacturedsuchthattheyoperatein gaspressureat
15%...+10% of nominalvoltage,betweentheambienttemperaturerangeof-15ºC….+60˚Cand declared
capacity and boilerpressureranges with NaturalGas and Liquid Petrol Gas.
3.1. Purposeof Useand WorkLimits of Burners
•This productworks atany loadvalueequivalentto its max. capacityor coveredby its capacity
range;
-High temperatureindustrialappliances.
-In direct and indirect hot air generators,
--15 0C…+60 0C ambient temperaturerange,
-In accordance with themodel, 1N 230 VAC / 3N 380VAC 50 Hzsupply voltage(-%15 ...
+ 10%)
-Max. 95% relativehumidity,
-In well-ventilated open and closed spacescompatiblewith protection class IP40.
-Operation with Natural gas and LPG.
This devicemust never beoperated withopen flame!

09.01.2020 Rev. 10 8
3.2. Process Burner Components
FPB 80
Nu. Part Name Nu. Part Name
1 Body 18 Plug reduction
2 Gasket 19 Plug porcelaın
3 Gas intakeflange 20 Washer
4 Nipple 21 Nut
5 Ball valve 22 Plug head
6 Washer 23 Ignitionionizationhead
7 Purger 24 Washer
8 Purger needle 25 Bolt
9 Bulls eye 26 Bolt
10 Bulls eyehousing 27 Nipple
11 Diffuser adjustingnut 28 Klappecomplete
12 Diffuser 29 Klappelabel
13 Ionizationelectrodewire 30 Stay Bolt
14 Porcelain 31 Klappeindicator
15 Pin 32 Bolt
16 Electrodewire 33 Flametube
17 Plug porcelaın

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FPB 200
Nu. Part Name Nu. Part Name
1 Body 18 Plug reduction
2 Gasket 19 Plug porcelaın
3 Gas intakeflange 20 Washer
4 Nipple 21 Nut
5 Ball valve 22 Plug head
6 Washer 23 Ignitionionizationhead
7 Purger 24 Washer
8 Purger needle 25 Bolt
9 Bulls eye 26 Bolt
10 Bulls eyehousing 27 Nipple
11 Diffuser adjustingnut 28 Klappecomplete
12 Diffuser 29 Klappelabel
13 Ionizationelectrodewire 30 Stay Bolt
14 Porcelain 31 Klappeindicator
15 Pin 32 Bolt
16 Electrodewire 33 Flametube
17 Plug porcelaın

09.01.2020 Rev. 10 10
FPB 400
Nu. Part Name Nu. Part Name
1 Body 22 Purger
2 Gas intakeflange 23 Purger needle
3 Diffuser 24 Bulls eyehousing
4 Nut 25 Bulls eye
5 Porcelain 26 Nipple
6 Ionizationelectrodewire 27 Ball valve
7 Pin 28 Washer
8 Plug electrodewire 29 Bolt
9 Plug porcelaın30 Bolt
10 Plug reduction 31 Bolt
11 Plug porcelaın32 Nut
12 Washer 33 Stay Bolt
13 Nut 34 Gasket
14 Plug head 35 Bolt
15 Ignitionionizationhead 36 Nut
16 Flametube 37 Bolt
17 Klappesheet 38 Pul
18 Klappeshaft 39 Bolt
19 Klappeindicator 40 Capacity label
20 Klappeindicator bar 41 Rivet
21 Washer 42 Washer

09.01.2020 Rev. 10 11
FPB 550
Nu. Part Name Nu. Part Name
1 Body 22 Purger
2 Gas intakeflange 23 Purger needle
3 Diffuser 24 Bulls eyehousing
4 Nut 25 Bulls eye
5 Porcelain 26 Nipple
6 Ionizationelectrodewire 27 Ball valve
7 Pin 28 Washer
8 Plug electrodewire 29 Bolt
9 Plug porcelaın30 Bolt
10 Plug reduction 31 Bolt
11 Plug porcelaın32 Nut
12 Washer 33 Stay Bolt
13 Nut 34 Gasket
14 Plug head 35 Bolt
15 Ignitionionizationhead 36 Nut
16 Flametube 37 Bolt
17 Klappesheet 38 Pul
18 Klappeshaft 39 Bolt
19 Klappeindicator 40 Capacity label
20 Klappeindicator bar 41 Rivet
21 Washer 42 Washer

09.01.2020 Rev. 10 12
FPB 870 – FPB 1200
Nu. Part Name Nu. Part Name
1 Body 22 Purger
2 Gas intakeflange 23 Purger needle
3 Diffuser 24 Bulls eyehousing
4 Nut 25 Bulls eye
5 Porcelain 26 Nipple
6 Ionizationelectrodewire 27 Ball valve
7 Pin 28 Washer
8 Plug electrodewire 29 Bolt
9 Plug porcelaın30 Bolt
10 Plug reduction 31 Bolt
11 Plug porcelaın32 Nut
12 Washer 33 Stay Bolt
13 Nut 34 Gasket
14 Plug head 35 Bolt
15 Ignitionionizationhead 36 Nut
16 Flametube 37 Washer
17 Klappesheet 38 Bolt
18 Klappeshaft 39 Washer
19 Klappeindicator 40 Bolt
20 Klappeindicator bar 41 Capacity label
21 Washer 42 Rivet

09.01.2020 Rev. 10 13
FPB 1600- FPB 2000 – FPB 2500
Nu. Part Name Nu. Part Name
1 Body 20 Klappeindicator bar
2 Gas intakeflange 21 Washer
3 Diffuser 22 Purger
4 Nut 23 Purger needle
5 Porcelain 24 Bulls eyehousing
6 Ionizationelectrodewire 25 Bulls eye
7 Pin 26 Nipple
8 Plug electrodewire 27 Ball valve
9 Plug porcelaın28 Washer
10 Plug reduction 29 Bolt
11 Plug porcelaın 30 Bolt
12 Washer 31 Bolt
13 Nut 32 Nut
14 Plug head 33 Stay Bolt
15 Ignitionionizationhead 34 Washer
16 Flametube 35 Bolt
17 Klappesheet 36 Bolt
18 Klappeshaft 37 Washer
19 Klappeindicator

09.01.2020 Rev. 10 14
FPB 3500– FPB 5000
Nu. Part Name Nu. Part Name
1 Body 20 Klappeindicator bar
2 Gas intakeflange 21 Washer
3 Diffuser 22 Purger
4 Nut 23 Purger needle
5 Porcelain 24 Bulls eyehousing
6 Ionizationelectrodewire 25 Bulls eye
7 Pin 26 Nipple
8 Plug electrodewire 27 Ball valve
9 Plug porcelaın28 Washer
10 Plug reduction 29 Bolt
11 Plug porcelaın 30 Bolt
12 Washer 31 Bolt
13 Nut 32 Nut
14 Plug head 33 Stay Bolt
15 Ignitionionizationhead 34 Washer
16 Flametube 35 Bolt
17 Klappesheet 36 Bolt
18 Klappeshaft 37 Washer
19 Klappeindicator

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4. GAS, FLUE GASAND HEATING WATER SCHEMA

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5. TECHNICAL DATA
5.1. Capacity and Technical Chart
FPB PROCESS BURNERS
CAPACITY CAPACITY NATURAL GAS
CONSUMPTION LPG GAS CONSUMPTION
FAN
RATE
Min. Max. Min. Max. Min. Max. Min. Max.
Kcal/h kW Nm³/h Nm³/h Nm³/h
FPB 20 4.000 20.000 4,7 23,3 0,5 2,4 0,2 0,9 30
FPB 80 16.000 80.000 18,6 93,0 1,9 9,7 0,7 3,6 150
FPB 200 40.000 200.000 46,5 232,6 4,8 24,2 1,8 8,9 350
FPB 300 60.000 300.000 69,8 348,8 7,3 36,4 2,7 13,3 500
FPB 400 80.000 400.000 93,0 465,1 9,7 48,5 3,6 17,8 650
FPB 550 110.000 550.000 127,9 639,5 13,3 66,7 4,9 24,4 900
FPB 870 174.000 870.000 202,3 1011,6 21,1 105,5 7,7 38,7 1.400
FPB 1200
240.000 1.200.000 279,1 1395,3 29,1 145,5 10,7 53,3 2.000
FPB 1600
320.000 1.600.000 372,1 1860,5 38,8 193,9 14,2 71,1 2.500
FPB 2000
400.000 2.000.000 465,1 2325,6 48,5 242,4 17,8 88,9 3.100
FPB 2500
500.000 2.500.000 581,4 2907,0 60,6 303,0 22,2 111,1 4.000
FPB 3500
700.000 3.500.000 814,0 4069,8 84,8 424,2 31,1 155,6 5.500
FPB 5000
1.000.000 5.000.000 1162,8 5814,0 121,2 606,1 44,4 222,2 7.800
HuNatural Gas =8250 kcal/Nm3
HuLPG=22500 kcal/Nm3

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5.2. Outer Dimensions

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6. INSTALLATION
6.1. Burner Assembly Drawing
1. Gas Intake
2. Air Inlet
3. Connecting Flange
4. Insulation Material (Gasket)
5. Installation Bolt
6. FlameTube
7. Combustion Chamber Refractory
Sealing betweenthecombustion chamber and burnermust beensured
Device must beshipped in original packaging!
Do not lift thedevice holdingfromservomotor, gasvalve,impulsepipesor pressureswitch
during installation!
Cleantheinsideoffuellinethoroughly beforeinstalling theburnerto thefuelline.Any
damagethatmayoccur duetosolid objects and metalparticlesfromthefuellineshall notbe
covered by our company.