ECOSTAR FPB 200 Installation guide

09.01.2020 Rev. 10
www.ecostar.com.tr
PROCESS BURNERSDUAL FUEL (GAS-HEAVYOIL)
INSTALLATION,OPERATING ANDMAINTENANCE
MANUAL
ONE STAGE, TWO STAGE ANDMODULATING OPERATION
FPB200
FPB300
FPB400
FPB550
FPB870
FPB1200
FPB1600
FPB2000
FPB2500
FPB3500
FPB5000

09.01.2020 Rev. 10 1
DEAR USER,
ECOSTAR FPB 200, FPB 300, FPB 400, FPB 550, FPB 870, FPB 1200, FPB
1600, FPB 2000,FPB 2500, FPB 3500, FPB 5000 DualFuel (Gas-Heavy Oil)process
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.
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. Process Burner Components .......................................................................................................... 9
4. GAS,FLUE GASAND HEATING WATER SCHEMA................................................................... 10
5. TECHNICAL DATA .......................................................................................................................... 11
5.1. Capacity Table.............................................................................................................................. 11
6. INSTALLATION................................................................................................................................ 12
6.1. Burner Installation Picture............................................................................................................ 12
7. COMMISSIONING............................................................................................................................. 13
7.1. General Controls .......................................................................................................................... 13
7.2. Combustion Adjustment............................................................................................................... 14
7.2.1. Oil pump................................................................................................................................... 15
7.2.2. Gas Adjustment........................................................................................................................ 15
7.2.2.1. VGD 20 4011 - 5011 Series Gas Valve................................................................................ 15
7.2.2.2. MB DLE Series Monoblock Gas Valve................................................................................ 16
7.2.2.3. MB ZRD(LE) 405 –412 Series Gas Valve.......................................................................... 18
7.3. Fuel Diagrams.............................................................................................................................. 19
7.4. Air pressureswitchadjustment .................................................................................................... 22
7.5. Servomotor Adjustment............................................................................................................... 22
7.6. ProgramRelay.............................................................................................................................. 27
7.7. Heavy OilBurner Fuel Ring Line................................................................................................ 27
7.8. Gas Pass Equipment Requiredin Gas Line.................................................................................. 28
8. MAINTENANCE................................................................................................................................ 30
8.1. Weekly Maintenance.................................................................................................................... 30
8.2. Monthly Maintenance................................................................................................................... 30
8.3. SeasonalMaintenance.................................................................................................................. 31
9. TROUBLESHOOTING...................................................................................................................... 32
10. PERIODICAL FLUE GASMEASUREMENT REPORT.............................................................. 33
11. AFTER SALESSERVICES............................................................................................................ 34
12. NOTES............................................................................................................................................. 35

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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

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Install burner firmly. Vibrationmay damageburner or its components.
Keep boiler doors closed whilestarting burner and during burner operation.
During thefirst commissioning of theburneror incaseof any revision carriedout in theelectrical
systemor motor cablesby anyreason, direction ofthefanrotation must certainly becheckedby
theauthorizedtechnical service.
For products that havenot been comissioned or started morethan 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.
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.

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2. TERMSOF WARRANTY
Main andauxiliaryequipment and all components usedinEcostarDualFuel(Gas-Heavy Oil)
process burners areguaranteedfor1yearbyTERMO ISISST. A.Şstartingfromthedateof
commissioning underthemaintenance,adjustment, operatingconditions and relevant mechanic,chemical
and thermal effects 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.

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3. BURNER’SGENERAL FEATURES
ECOSTAR DualFuel(Gas-Heavy Oil) burners aredesignedand manufacturedto work with liquid
fuelwith max. 2.5- 20 Cst (mm2/s) viscosity. and NaturalGas/LiquidPetroleumGasatgaspressuresof
min.20 mbar, max.300 mbarand at-%15 to +%10 of nominalvoltages, underenvironmentaltemperature
of max.60˚C with rated capacity and burner pressureranges.
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,
-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!

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Temperaturechangeof fuelusedinECOSTAR DualFuel(Gas-Heavy Oil) process burners
dependent on viscosity

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3.2. Process Burner Components
1- PneumaticCylinder*
2- Casing Flange
3- Nozzle
4- Gas IntakePipe
5- Ignition Electrodes
6- Body
7- FlameTube
8- Photocell
9- Combustion Air Intake
* It is availableas anoption.

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4. GAS, FLUE GASAND HEATING WATER SCHEMA

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5. TECHNICAL DATA
5.1. Capacity Table
FPB PROCESS BURNERS
CAPAC TY CAPAC TY GAS
CONSUMPTION
LPG
CONSUMPTION
HEAVY OIL
CONSUMPTION
FAN
FLOW
RATE
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
Kcal/h kW Nm³/h Nm³/h kg/h Nm³/h
FPB 200 40.000 200.000 46,5 232,6 4,8 24,2 1,8 8,9 4,1 20,7 350
FPB 300 60.000 300.000 69,8 348,8 7,3 36,4 2,7 13,3 6,2 31,1 500
FPB 400 80.000 400.000 93,0 465,1 9,7 48,5 3,6 17,8 8,3 41,5 650
FPB 550 110.000 550.000 127,9 639,5 13,3 66,7 4,9 24,4 11,4 57,0 900
FPB 870 174.000 870.000 202,3 1011,6 21,1 105,5 7,7 38,7 18,0 90,2 1.400
FPB 1200 240.000 1.200.000 279,1 1395,3 29,1 145,5 10,7 53,3 24,9 124,4 2.000
FPB 1600 320.000 1.600.000 372,1 1860,5 38,8 193,9 14,2 71,1 33,2 165,8 2.500
FPB 2000 400.000 2.000.000 465,1 2325,6 48,5 242,4 17,8 88,9 41,5 207,3 3.100
FPB 2500 500.000 2.500.000 581,4 2907,0 60,6 303,0 22,2 111,1 51,8 259,1 4.000
FPB 3500 700.000 3.500.000 814,0 4069,8 84,8 424,2 31,1 155,6 72,5 362,7 5.500
FPB 5000 1.000.0005.000.000 1162,8 5814,0 121,2 606,1 44,4 222,2 103,6 518,1 7.800
HuNatural Gas =8250 kcal/Nm3
HuLPG=22500 kcal/Nm3
Hu HeavyOil (S) = 9650 kcal/kg

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6. INSTALLATION
6.1. Burner InstallationPicture
1 - Air inlet
2 - Connecting Flange
3- Sealing (Gasket)
4 - Refractory combustion chamber
5 - Flametube
After completing theinstallationof theburner ontheboiler:
Sealing between thecombustion chamber and burnermust beensured
Device must beshipped in original packaging!
Do not liftthedevice holdingfromservomotor, gasvalve,impulse pipesorpressureswitch
during installation!
Connecttheoil feedpipes.
Connecttheburnerpanelto themains by acablesuitablefortheratedpower.
Clean theinsideof fuellinethoroughly beforeinstallingtheburnerto thefuelline.Any damage
thatmay occur dueto solid objects and metal particles fromthefuel lineshall not becovered by
our company.

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7. COMMISSIONING
7.1. GeneralControls
Makesureto performthefollowing controls beforecommissioning theburner.
•Has heat demand been formed?
•Arethethermostat and other thermo-elements for control purposes working properly?
•Aretheelectrical connections correct?
•Is thereelectricity current?
•Is theregas?
•Has theboilerexplosion lid been controlled?
•Is theresufficient airflow? (capacity kW x 7 = ventilationsectionarea cm2)
•Has theboiler beeninstalled correctly?
•Has thesealing of fuel lines been controlled?
•Checkthetemperatureof theheavy-oilcoming fromthedaily storagetank totheburner(should be
50°C ±5).
•Check thefuel line(arethepipediameters and thepipeinstallation correct?).
•Check thefuel nozzles according to thecapacity.
Commissioning order
OperatingwithHeavy Oil;
•Open thefuel tank valve.
•Open thevalveupstreamof thefuel filter.
•Open thepump’s vent plug and placethemanometer (0-40 bar).
•Switch on theburner's switch.
•When theburner starts up, themotor is activatedand turns thepump at thesametime.
•After thepre-purge,fuel is delivered fromthenozzle.Thefuelmeets with theflamefromtheignition
electrodes and thecombustion starts.
•Pump pressureis adjusted aftertheburner is burnt.
•If theburner has twostages, theswitch isbrought to position “2”, and thecapacity of theburner is
increasedthrough servomotor.
•Thermostat is adjusted upon request.
•For thesafety of thesystem, check thethermostats and observethedeactivation of theburner.
OperatingwithGas;
Operationof one-stageburner
ØOpenthemain gasvalve,checkthegaspressurefromthemanometeratthevalve.(max.300
mbar)
ØCheck theboilerthermostat or pressureswitch settings.
ØBring theoperating switch on theburnerpanelto position 1.
ØBurner fanmotor will beactivated.
ØIgnition will takeplace at theend of pre-purgeprocess.
Ø3 sec. later, thegasvalvewill beopenedand combustion willoccur.
ØFlamecontrol system(ionization) will start flamecontrol.
ØBurner is deactivated aftertherequiredcapacity is formed.

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Operationof two-stageburner
ØOpenthemain gasvalve,checkthegaspressurefromthemanometeratthevalve.(max.300
mbar)
ØCheck theboilerthermostat or pressureswitch settings.
ØBring theoperating switch on theburnerpanelto position 2.
ØBurner fanmotor will beactivated.
ØIgnition will takeplace at theend of pre-purgeprocess.
Ø3 sec. later, thegasvalvewill beopenedand combustion willoccur.
ØFlamecontrol system(ionization) will start flamecontrol.
ØBurner will switch to thesecond stage(max. capacity) according to theheat requirement.
ØBurner is deactivated aftertherequiredcapacity is formed.
Operationof a modulatingburner
ØOpen themain gasvalve; checkmax 300mbar gas pressurefromthemanometer.
ØOpen operating switch on theburner panel.
ØSwitch on themodulating control switch.
ØSwitch automatic-hand switch to automatic.
ØCheck thetemperatureand pressureset values fromthemodulating control unit.
ØIgnition will takeplace at theend of pre-purgeprocess.
Ø3 sec. later, thegasvalvewill beopenedand combustion willoccur.
ØFlamecontrol system(ionization) will start flamecontrol.
ØIn modulating burner, theburnergoesinto max. capacityaccording to thesignalfromthe
modulating control unit.
ØWhen thecapacity increases, modulating control unit will switch theburner to min. capacity.
ØIf theboilerwatertemperatureor steampressureincreasesdespitetheoperation of burnerwith
min. capacity, themodulating control unit will stop theburner.
7.2. CombustionAdjustment
ØFuel nozzle
Useproper wrench in installation and dismantleof thefuel
nozzle.
Usedieseloil to clean thefuelnozzle. Do not usethinner
and its derivatives.
ØPhotocell
Check thephotocell weekly. Cleanthedust or fume
stains on theglass of photocell by adry cloth.

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7.2.1. Oil pump
1. Oil inlet connection
2. Pressureadjustment screw
3. Oil return connection
4. Manometer connection
5. Pressurized oil outlet connection
7.2.2. Gas Adjustment
Follow theinstructions of thevalvemanufacturerduring installation, dismantling and adjustment of
thegas valve
7.2.2.1. VGD 20 4011 - 5011 SeriesGas Valve
SKP 75 ConnectionDiagram
1 – Air-gas adjustment ratio
2 – Zero "0" point (start) adjustment
3 – Boilercounter pressureimpulseconnection
4 – Gas pressureimpulseconnection
5 – Air pressureimpulseconnection

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7.2.2.2. MB DLE Series MonoblockGas Valve
1- Pressureswitch
2- Pressureswitchelectricalconnection
3- Electricalconnection of thevalve
4- Operation gauge
5- Thesealing ring
6- Set cover
7- Hydraulicdisk brakes or settings
8- Coil
9- Measuring element connection (1/8)
10- Measuring element connection (1/8)
11- Output flange
12- Measuring element connection (1/8)
13- Gas flow way
14- Measuring element connection (1/8)
15- Thevent plug
16- Filterchamber cover
17- Inlet flange
18- Measuring element connection (1/8)
19- Measuring element connection (1/8)

09.01.2020 Rev. 10 17
-Consider thebelow torquevalues for bolts tightened on thevalve.
-Tighten flangebolts accordingto cross ordering and useproper tools.
-Sealing andfunctioncheckmust beperformedif thevalveisdismantledand re-installedover
thelinedueto any reason.
-Beforedismantling thevalvefromtheline,you canperformfilterreplacement accordingto
thebelow order.
oCut off thegas flow(turn off theball valve)
oRemovethe4 bolts (1,2,3,4) on thecover seen in thepictureand takeout thecover (5).
oTakethefilter cartridge(6) out of its socket and replacewithanew one
oClosethecoverandtightenthebolts. In frequently performedfilterreplacement
operations, useM4x14 bolt instead of self-tapping bolts used for fixingthecover.
oPerformsealing andfunction control
Max. torquevalues;

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7.2.2.3. MB ZRD(LE) 405 – 412 Series Gas Valve

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7.3. Fuel Diagrams
ØOneStageHeavy Oil BurnerFuel Circuit
ØTwoStages Heavy Oil BurnerFuel Circuit