ECOSTAR PB 200 Installation guide

DIESEL-OIL PROCESS BURNERS
INSTALLATION, OPERATING AND MAINTENANCE
MANUAL
ONE-STAGE,TWO-STAGE AND MODULATING OPERATION
FPB 200
FPB 300
FPB 400
FPB 550
FPB 870
FPB 1200
FPB 1600
FPB 2000
FPB 2500
FPB 3500
FPB 5000

DIESEL-OIL PROCESS BURNERS INSTALLATION, OPERATING AND MAINTENANCE MANUAL
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DEAR USER,
ECOSTAR FPB 200,FPB 300,FPB 400,FPB 550,FPB 870,
FPB1200,FPB1600,FPB2000,FPB 2500, FPB3500,
FPB5000 DIESEL-OIL process burners are prepared andmanufactured
accordingto the latest technical developments andsafety rules. It iseasy touse forour
customers.
We recommend that you read thismanual and safety warnings thoroughly before theuse
of the device in order to ensure safe, cost effective and environmental-friendly use.
If you encounterany issue that is not explained clearly inthis manual or you could not
understand, please contactwith our service department.
We thank you for choosing ECOSTAR brand.
This Operating Manual is an integral part of the burner and must be maintained in a
plastic dossier and hung at a clearly visible place in the burner room.

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INDEX
1. WARNINGS3
1.1. Warning Symbols and Descriptions 3
1.2. General Safety Rules4
2. TERMS OF WARRANTY4
2.1. Out Of Warranty Conditions5
3. BURNER’S GENERAL FEATURES 5
3.1. Purpose Of Use and Work Limits Of Burners 5
3.2. Process Burner Components 7
4. TECHNICAL DATA 8
4.1. Capacity and Technical Chart8
4.2. Outer Dimensions 9
5. INSTALLATION 10
5.1. Burner Installation Picture 10
6. COMMISSIONING 11
6.1. Before Commissioning 11
6.2. General Controls and Commissioning 11
6.3. Fuel Adjustment 11
6.4. Combustion Adjustment 12
6.5. Fuel Diagrams 13
6.6. Servomotor Adjustment 15
6.7. ProgramRelay20
7. MAINTENANCE 22
7.1. Weekly Maintenance 22
7.2. Monthly Maintenance 22
7.3. Seasonal Maintenance 22
8. TROUBLESHOOTING 23
9. PERIODICAL FLUE GAS MEASUREMENT REPOR 24
10. AFTER-SALES SERVICES 25
11. NOTES 26

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1. WARNINGS
1.1. Warning Symbols and Descriptions
Symbols Symbol Descriptions
Important information and useful hints.
Warning of danger to life or property.
Warning of electrical voltage.
Product handling information.
Carry in an upright position. Fragile Item.Protectagainst water.

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1.2. General Safety Rules
•All personnel engaged ininstallation, disassembly,commissioning, operation,control,
maintenance and repair should have received the necessary training andfully readand understood
this manual.
•No changes that might damage the safety of theburner unit must be made by persons and/or
organizations on the burner unit.
•All operation, commissioningand installation works (except for burning adjustment) should be
carried out when the burneris not operatingand afterdisconnecting thepower supply.
Noncompliancewiththeserules may lead toserious bodilyinjuries and even deathby electrical
shocks or uncontrolled flame formation.
•Repairs concerned with safety elements should be carried outonly by themanufacturing company.
•The device should never be used by children, mentally handicapped and inexperienced persons.
•Children must not be allowed to play with the device.
•Keep the device away fromexplosive and flammable materials.
•Device must intakeair, and ventilation and air discharge holesmust notbe closed.
2. TERMS OF WARRANTY
Main and auxiliary equipment and all components used in Ecostar diesel-oilprocess burners are
guaranteedfor 1year by TERMO ISISST. A.Şstartingfromthe dateof commissioning underthe
maintenance, adjustment, operating conditions and relevant mechanic, chemicaland thermal effects
explained herein.
Please notethat this warranty isonly validif the device(s) is commissioned and maintainedby our
authorizedservices.
Our company reserves the right to make anymodifications on theproduct and all instructions
thereof forimprovement purposes.

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2.1. Out of Warranty Conditions
•Any damage arisingout of orin relation to customers’ non-compliance to their responsibilities
with regards to installation, commissioning, operation and maintenance,
•Any damage arising out of or in relation to commissioning, repairs and maintenance carried out by
unauthorized services,
•Any damage thatmay occur during transportation or storage of the product,
•Not preserving the product in its originalpackaging until the installation stage,
•Incorrect and poor electricalconnections, Failures due to incorrect voltageapplications,frequent
repetition of voltage fluctuations,
•Any damage that may occur as aresultof incorrectfuelusage or, foreign substances inthefuel
used or using of the product without anyfuel,
•Any damage that may occur due to foreign particles entered into theproduct during installation
and operation,
•Failures due to incorrect device selection,
•Any damage to unit due to natural disasters,
•Devices without anywarranty certificates,
•Warranty Certificates without the stampand signature of the authorizeddealer or service,
•Devices with any falsification on the warranty certificate orwithout an originalserial number.
•The risks during transportation of device underthe responsibilityof customer belong to the
customer.
•Presence of misuse faults areindicated inthe reports issued by authorized servicestations or our
authorizedagent, dealer, representativeor our factory incase of unavailability of authorized
service stations.
•Customersmay apply consumer protection arbitrator committee withregards to this report and
request for an expert report.
3. BURNER’S GENERAL FEATURES
ECOSTAR diesel-oil burnersare designed to operatewithoil at2.5 –6Cst (mm²/s)
viscosity, at rated capacity andpressure ranges and -15% to +10% nominal voltage.
3.1. Purpose of Use and Work Limits of Burners
•This product works at any load value equivalentto its max. capacityor covered by its capacity
range;
--15 0C…+60 0C ambient temperature range,
-220 V/380V/50 Hz feed voltage (-%15…+%10) values,
-Max. 95% relative humidity,
-in well-ventilated open and closed spacescompatible with protection class IP 40.
This devicemust never be operated withopen flame!

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Temperature change of fuel used in ECOSTAR diesel-oil process burners dependent on viscosity
L: Diesel-Oil

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3.2. Process Burner Components
1- Ignition Electrodes
2- Photocell
3- Casing Flange
4- Diffuser and Nozzle Centering Pipe
5- Nozzle
6- Flame Tube
7- Diffuser
8- Body

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4. TECHNICAL DATA
4.1. Capacity and Technical Chart
BURNER TYPE
CAPAC TY CAPAC TY DIESEL- OIL CONSUMPTION
Min. Max. Min. Max. Min. Max.
FAN
RATE
MAIN SUPPLY
Kcal/h kW Kg/h Nm³/h V
ONE STAGE PROCESS BURNERS
FPB 200 L1 40.000 200.000 47 233 3,9 19,6 350 220-380
FPB 300 L1 60.000 300.000 70 349 5,9 29,4 500 220-380
FPB 400 L1 80.000 400.000 93 465 7,8 39,2 650 220-380
TWO STAGE PROCESS BURNERS
FPB 400 L2 80.000 400.000 93 465 7,8 39,2 650 220-380
FPB 550 L2 110.000 550.000 128 640 10,8 53,9 900 220-380
FPB 870 L2 174.000 870.000 202 1.012 17,1 85,3 1.400 220-380
FPB 1200 L2 240.0001.200.000
279 1.395 23,5
117,6 2.000 220-380
FPB 1600 L2 320.0001.600.000
372 1.860 31,4
156,9 2.500 220-380
FPB 2000 L2 400.0002.000.000
465 2.326 39,2
196,1 3.150 220-380
FPB 2500 L2 500.0002.500.000
581 2.907 49
245,1 4.000 220-380
MODULATING PROCESS BURNERS
FPB 550 L3 110.000 550.000 128 640 10,8 53,9 900 220-380
FPB 870 L3 174.000 870.000 202 1.012 17,1 85,3 1.400 220-380
FPB 1200 L3 240.0001.200.000
279 1.395 23,5
117,6 2.000 220-380
FPB 1600 L3 320.0001.600.000
372 1.860 31,4
156,9 2.500 220-380
FPB 2000 L3 400.0002.000.000
465 2.326 39,2
196,1 3.150 220-380
FPB 2500 L3 500.0002.500.000
581 2.907 49
245,1 4.000 220-380
FPB 3500 L3 700.0003.500.000
814 4.070 68,6
343,1 5.500 220-380
FPB 5000 L3 1.000.000
5.000.000 1.163 5.814 98
490,2 7.800 220-380
L: Diesel -Oil Hu= 10200 Kcal/kg

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4.2. Outer Dimensions
TYPE ØD F ØP ØM
FPB 200 100 R 2" 12 198
FPB 300 140 NW 80 15 220
FPB 400 140 NW 80 15 220
FPB 550 177 NW 100 15 243
FPB 870 219 NW 150 17 330
FPB 1200* 219 NW 150 17 330
FPB 1600* 219 NW 150 17 330
FPB 1200 308 NW 150 17 330
FPB 1600 308 NW 150 17 330
FPB 2000 219 NW 150 17 330
FPB 2500 240 NW 250 14 380
FPB 3500 323 NW 350 17 480
FPB 5000 323 NW 350 17 480
* For low temperature appliances in . (Up to 600 ºC max.)

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5. INSTALLATION
5.1. Burner Installation Picture
1 - Liquid fuel valves
2 - Air inlet
3- Connecting Flange
4 - Sealing (Gasket)
5 - Installation bolt
6 - Flametube
7 - Refractory combustion chamber
After completing the installation of the burner on the boiler:
ØConnect the oil feedpipes.
ØConnect the burner panel to themains by a cable suitable forthe rated power.
Cleantheinside offuel linethoroughly beforeinstalling theburnertothefuelline. Any damage
that may occur dueto solid objects and metal particles fromthe fuel line shallnot be covered by
our company.

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6. COMMISSIONING
6.1. Before Commissioning
Make sureto performthe following controls before commissioning theburner.
•Has heat demand been formed?
•Are the thermostat and other thermo-elements for control purposes working properly?
•Are the electrical connections correct?
•Is there electricity current?
•Is there sufficient airflow? (capacity kW x 7 = ventilationsection area cm2)
•Has the boiler been installed correctly?
•Has the sealing of fuel lines been controlled?
•Check the fuel line (are the pipe diameters and the pipe installation correct?).
•Check the fuel nozzles according to the capacity.
6.2. GeneralControls and Commissioning
•Open the fuel tank valve.
•Open the valve upstreamof the fuel filter.
•Open the pump’s vent plug and place themanometer (0-40 bar).
•Switch on the burner's switch.
•When theburner starts up, the motor is activated and turns the pump at the sametime.
•After the pre-purge,fuel is delivered fromthe nozzle. The fuel meets with the flame fromthe ignition
electrodes and the combustion starts.
•Pump pressure is adjusted afterthe burner is burnt.
•If the burner has twostages, the switch isbrought to position “2”, and the capacity of the burner is
increased through servomotor.
•Thermostat is adjusted upon request.
•For the safety of the system, check the thermostats and observe the deactivation of the burner.
6.3. Fuel Adjustment
One-stage burners
-Pumppressure (14 bar for diesel –oil)is adjusted and hourly fuel consumption is realized according to
the selected fuel nozzle.
Two-stage burners
-Pumppressure (14 bar for diesel –oil) isadjusted and hourly fuel consumption is realized according to
the selected fuel nozzle.
Modulating burners
-Fuel regulator, diskmechanismand servomotoradjustments are made and the minimumand
maximumcapacity values are set, so that the rotation pressure is 10 bar and maximumreturn pressure is
20 bar at the inlet pressure of 25 bar.

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6.4. Combustion Adjustment
ØFuel nozzle
Use proper wrench in installation and dismantle of the fuel
nozzle.
Use dieseloil to clean the fuelnozzle. Do not use thinner
and its derivatives.
ØPhotocell
Check the photocell weekly. Clean the dust or fume
stains on the glass of photocell by a dry cloth.
ØOil pump
1. Oil inlet connection
2. Pressure adjustment screw
3. Oil return connection
4. Manometer connection
5. Pressurized oil outlet connection

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6.5. Fuel Diagrams
ØSingle Stage Diesel Oil Burner Fuel Diagram
1- Fuel inlet
2. Pump
3. Fuel return
4. Solenoid valve
5. Fuel nozzle
ØTwoStage Diesel Oil Burner Fuel Diagram
1. Fuel inlet
2. Pump
3. Fuel return
4. 1st Stage solenoid valve(NO ,220V ,50Hz,10W)
5. 2nd Stage solenoid valve (NO ,220V ,50Hz,10W)
6. Lance
7. 1. Stage oil nozzle
8. 2. Stage oil nozzle

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ØModulating Diesel Oil Burner Fuel Diagram
H” TYPE RETURN HYDRAULICNOZZLE
1 – Fuel filter
2 – Pump
3 – Inlet valve
4 – Hydraulic control valve
5 – Inlet manometer
6 – Piston
7 – Nozzle closing spring
8 – Rod
9 – Nozzle bearing
10 – Fuel nozzle
11 – Nozzle filter
12 – O-ring
13 – Nozzle mechanism
14 – Returnmanometer
15 – Oil adjustment valve
WARNINGS
CAUTION!
ØEnd of thelineto the main tank mustbe open to the atmosphere and line pressure
must be zero, otherwise nohealthy modulating operation can beensured since the
pressure, which istoform in return, will also affect nozzle pressure. Fuel may drop
from nozzle end during stops.
ØFor good pulverization, periodically check durability of the o-ring number 12. Inthe
event of earing of the o-ring number 12, fuel to the nozzle can by-pass and godirectly
to the return and reduces the workingperformance of the nozzle.
ØMaximum operating pressure of thenozzle is 30 bars, while its maximum operating
temperature is 140ºC. These values shouldnotbe exceeded during working. Evenif
these outof control valueare exceeded, nozzle must be taken to emergency
maintenance and all O-rings must be replaced.
ØDo not use solvent based materials (thinner andderivatives) during cleaning of the
fuel nozzle; clean withgas oil or diesel oil. Fuel nozzle inner kit is very sensitive and
even invisible deformations can reduceworkingperformance; dismantling-installing
work must be performed only by trained personnel.
ØSpring number 7has lost its function if droppingfrom fuel nozzle or fuel exit at large
scale is observed whenthenozzle performs circulation. It must be checked and
replaced if necessary.

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6.6. Servomotor Adjustment
ØSQN70
At Two-stage Burners;
I. Red Cam: Adjusts 2nd levelmax. air.
II. Blue Cam: Resets the clamp.
III. Orange Cam: Adjusts 1st levelmin. air.
IV. Black Cam: Adjusts 2nd level valve opening degree.
At Modulating Burners;
I. Red Cam:Performance max. air adjustment.
II. Blue Cam: Resets the clamp.
III. Orange Cam: Performsmin. air adjustment.
IV. BlackCam: Notused.
ØSQM10
I. Cam: Opening
II. Cam: Resets the clamp
III. Cam: Commissioning air
IV. V.VI. and VII. Cam not used

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ØMODULATING MECHANISM ADJUSTMENT
1- Air adjustment disk
2- Fuel adjustment disk
3- Servomotor
4- Fuel regulator
5- Air control lever
6- Fuel control lever
ADJUSTMENT:
1- Start positions prior to disc mechanism adjustmentoperation must be as follows:
ØServomotor: 0°
ØFuel adjustment disc at start position
ØAir adjustment disc at start position
ØFuel regulator at position 10
ØAir klappes at fully closed position: 0°
Start position for discs
Start position for fuel regulator

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2–If discmechanismstart positions arecorrect, start theburner and ensure that itactivates in basic load.
Detectmincapacityactivation fuel amount ofthe burner by checking min. return pressure. If the
activationfuel amount is insufficient, set fuel regulator start adjustment to 9or 8value by changing
spring adjustment fromadjusting bolt onfuel disc number 2.When you start theburner again after this
operation,you willsee that your fuelreturn pressure has increased and henceactivation fuel amount has
risen.
3–Slowly increase the capacityfollowing burner basic load adjustment providedthat modulating control
device is inmanual position. By setting7 or 8 points during capacity increase, atthese points:
ØMeasure emission values
ØRecord fuel return pressure
ØObserve air klappe position
ØCheck fuelregulator scale value moves from 10 to 0.
4-If you haven'tbeen abletoreach themax capacity required by theboilerin90° position of theair
klappeand0° position of the fuelregulatoronceyou have completedthe maximumadjustment, follow
the below fuel regulator adjustment procedure:
1- Connecting rod
2- scale coupler
3- fuel connection points
4- adjustment fixing bolt
5- adjustment bolt
6- housingcover (screw hood)
Fuel regulator adjustment
1- Remove the housing cover number 6
2- Loosen the fixing bolt number4
3- When yourotate the shaft number 5 (when looked from the shaftend) clockwise, the pressure value
you observe from return manometer will increase, and burner consumption will also increase since
nozzle pressure increases.
4- When yourotate the shaft number 5 (when looked from the shaftend) anti-clockwise, the pressure
value you observe from return manometer will decrease, and burner consumption willalso decrease
since nozzle pressure decreases.
5- When the adjustment is completed, make sure that the adjustment you have made is permanent by
tightening the fixing bolt number 4.
6- Place the housing cover number 6.

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5 - Set the burner to the correct capacity requiredby the boiler by considering the below nozzle pressure
and consumption values.
Diagram valid for fuel nozzles having 45° spraying angle
Diagram valid for fuel nozzles having 60° spraying angle
6 – Once the burner modulating adjustment is completed, setmodulating controldevice to automatic
position, change set values andobserve capacity changes. Airand fuel will increase and decrease
simultaneously according to the adjustment you previously made.