ECOSTAR ECO 250 Installation guide

06.11.2018 Rev. 08
www.ecostar.com.tr
DUOBLOCKDUAL FUEL(GAS-HEAVY OIL)
BURNERS INSTALLATION, OPERATINGAND
MAINTENANCE MANUAL
MODULATINGOPERATION
ECO250
ECO300
ECO350
ECO400
ECO450
ECO500
ECO600
ECO700
ECO800
ECO900

06.11.2018 Rev. 08 1
DEAR USER,
ECOSTARECO250,ECO 300,ECO350,ECO400,ECO 450,ECO500,ECO
600,ECO700,ECO 800,ECO 900DualFuel (Gas-Heavy Oil) burnersareprepared
andmanufacturedaccording tothelatesttechnicaldevelopmentsandsafetyrules.Itis
easytouse for our customers.
We recommendthat you readthis manual andsafety warningsthoroughlybeforethe
useof the deviceinordertoensure safe, cost effective andenvironmental-friendly use.
Ifyouencounteranyissuethat is notexplainedclearlyinthismanual oryoucould
not understand,please contact withour service department.
We thank youforchoosingECOSTAR brand.
EcostarDual Fuel (Gas-HeavyOil) BurnersaremanufacturedincompliancewithTS
EN 267andTS EN 676 + A2standards.
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]

06.11.2018 Rev. 08 2
CONTENTS
1. WARNINGS .......................................................................................................................................3
1.1. Warning Symbolsand Descriptions .............................................................................................3
1.2. General Safety Rules....................................................................................................................4
2. TERMS OFWARRANTY..................................................................................................................6
2.1. Out ofWarranty Conditions.........................................................................................................6
3. BURNER’SGENERALFEATURES.................................................................................................7
3.1. Purposeof Use and Work Limits ofBurners................................................................................7
3.2. Code Key......................................................................................................................................7
4. TECHNICAL DATA ..........................................................................................................................9
4.1. Capacity Table.............................................................................................................................9
4.2. Burner Dimensions.....................................................................................................................10
5. INSTALLATION..............................................................................................................................11
5.1. Burner InstallationPicture..........................................................................................................11
6. COMMISSIONING..........................................................................................................................12
6.1. General Controls........................................................................................................................12
6.2. Combustion Adjustment.............................................................................................................13
6.3. AirPressure SwitchAdjustment.................................................................................................16
6.4. Servomotor Adjustment.............................................................................................................17
6.5. EmissionMeasurement ..............................................................................................................17
6.6. ProgramRelay............................................................................................................................17
6.7. Gas PassEquipmentRequiredinGasLine................................................................................18
7. MAINTENANCE..............................................................................................................................19
7.1. Weekly Maintenance..................................................................................................................19
7.2. MonthlyMaintenance.................................................................................................................19
7.3. Seasonal Maintenance................................................................................................................20
8. TROUBLESHOOTING....................................................................................................................21
9. PERIODICAL FLUEGASMEASUREMENTREPORT.................................................................22
10. AFTERSALES SERVICES..........................................................................................................23
11. NOTES..........................................................................................................................................24

06.11.2018 Rev. 08 3
1. WARNINGS
1.1. WarningSymbolsandDescriptions
Symbols SymbolDescriptions
Important information and usefulhints.
Warning of danger to lifeor property.
Warningofelectrical voltage.
Product handling information.
PFImpulseconnection detectingcombustion chamberpressure
PL Impulseconnection detecting combustion airpressure
PBR Impulse connection detecting burner gas head
CLEANTHE GASBURNER.
CLEAN GAS LINE.
ИСТАЯ ЛИНИЯ ГАЗ.
"Cleanthegasline" warningongasline.
Electricmotor direction ofrotation
Carry inanupright position.Fragile Item.Protectagainstwater.

06.11.2018 Rev. 08 4
1.2. 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 bythemanufacturing company.
•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.
Ifyou sensegas leakage;
•Shutdownvalvesofall gasdevices.
•Open all doorsand windows.
•Donotturnonelectricdevices or donot turn themoffifthey areworking.
•Donotuseburner derived tools such as match andlighter.
•Informthe gascompany.
Do not store any inflammablematerialsinboiler room.
Wear hearingprotectorsifthereisnoiseinboiler room.
Incaseoffıreorother emergency;
Switchoff the mainswitch
Closethemain fuel shut-offvalveoutside the plant.
Takeappropriate actions

06.11.2018 Rev. 08 5
The burner installation mustbecarried out inaccordancewiththeinstructions. Vibrationcan
damage theburner and its components.
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.
Forproducts thathavenotbeencomissionedorstarted morethan 6months, before activatingthe
servomotor;
In gas,air dampersand oilregulators, servomotorand damper connectionsmust be checkedto
ensure that they arefreerunning inspiteofimmobilityand oilfreezing.
Incaseoftwo-pieceflame tubesof ECO 450 and uppercombined burner models being
demountedonthe field,afterthe burner is mountedonthe boiler,heat resistantsilicone
shouldbe appliedtothejoints.
BURNER ROOM
Installtheburner inasuitable room/floor withminimumexternalairopenings and sufficient to
ensu reperfect combustion,incompliancewith current regulations.
Never obstruct airopenings oftheburner room,burner fan intake vents or airducts inorder to
prevent:
a.Thebuildupoftoxic /explosive gas mixtures inthe burner room,
b.Combustionwith insufficient air, resultingin hazardous, anti-economical and polluting ope-
ration.
Theburner mustbealways protectedfromrain,snowand frosttoprevent corrosionand paint
deformations.
Keeptheburner roomclean and freeofsolidvolatile substances,which could besuckedintothefan
and clog theinternalburnerorcombustion head airducts.

06.11.2018 Rev. 08 6
2. TERMS OFWARRANTY
Main and auxiliaryequipmentand allcomponentsusedinEcostarDualFuel (Gas-Heavy Oil)
burnersare guaranteed for1year byTERMOISISST.A.Şstartingfromthedateofcommissioning
under themaintenance,adjustment,operatingconditionsand relevant mechanic,chemical and thermal
effectsexplained herein.
Pleasenote that thiswarranty isonlyvalidifthedevice(s)is commissioned and maintained by our
authorizedservices.
Our company reserves the right to make anymodificationson the product and all instructions
thereof for improvement purposes.
2.1. OutofWarranty 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 in the reportsissued by authorized servicestations or our
authorizedagent,dealer,representative orour factory in case ofunavailability ofauthorized
service stations.
•Customers may apply consumer protectionarbitrator committeewith regardsto thisreport and
requestfor anexpert report.

06.11.2018 Rev. 08 7
3. BURNER’SGENERAL FEATURES
ECOSTARDual Fuel(Gas-Heavy Oil) burners are designedand manufactured to workwith liquid
fuelwith max.2.5-20 Cst(mm2/s) viscosity.and NaturalGas and Liquid PetroleumGasat gaspressures
of min.100mbar,max.300 mbar and at -%15 to +%10 ofnominal voltages,underenvironmental
temperature ofmax.60˚Cwithrated capacity and burner pressureranges.
3.1. Purpose ofUseand WorkLimitsof Burners
•Thisproduct works at any load value equivalentto itsmax.capacity or covered by itscapacity
range;
-In hotwater and steamboilers,
-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!
3.2. CodeKey

06.11.2018 Rev. 08 8
Temperature change of fuel usedinECOSTARDual Fuel (Gas-HeavyOil) burnersdependent on
viscosity

06.11.2018 Rev. 08 9
4. TECHNICAL DATA
4.1. CapacityTable
BURNER
TYPE CAPACITY NATURALGAS CONSUMPTION
HEAVY OIL
CONSUMPTION
Max.
MW
Max.
kcal/h
Max.
Nm³/h
Max.
kg/h
ECO-250.1 1,9 1.600.000 193,9 165,8
ECO-250.2 2,6 2.250.000 272,7 233,2
ECO-300.1 3,4 2.900.000 351,5 300,5
ECO-300.2 4,2 3.600.000 436,4 373,1
ECO-350.1 5,0 4.300.000 521,2 445,6
ECO-350.2 6,2 5.300.000 642,4 549,2
ECO-350.3 7,3 6.300.000 763,6 652,8
ECO-400.1 8,1 7.000.000 848,5 725,4
ECO-400.2 8,8 7.600.000 921,2 787,6
ECO-400.3 9,7 8.300.000 1006,1 860,1
ECO-450.1 11,5 9.900.000 1200,0 1025,9
ECO-450.2 12,9 11.100.000 1345,5 1150,3
ECO-450.3 14,5 12.450.000 1509,1 1290,2
ECO-500.1 16,2 13.900.000 1684,8 1440,4
ECO-500.2 17,8 15.300.000 1854,5 1585,5
ECO-500.3 19,4 16.650.000 2018,2 1725,4
ECO-600.1 20,8 17.900.000 2169,7 1854,9
ECO-600.2 23,4 20.150.000 2442,4 2088,1
ECO-600.3 25,0 21.500.000 2606,1 2228,0
ECO-700.1 26,2 22.500.000 2727,3 2331,6
ECO-700.2 27,3 23.500.000 2848,5 2435,2
ECO-700.3 29,1 25.000.000 3030,3 2590,7
ECO-800.1 32,1 27.600.000 3345,5 2860,1
ECO-800.2 33,5 28.850.000 3497,0 2989,6
ECO-800.3 35,2 30.250.000 3666,7 3134,7
ECO-900.1 36,7 31.600.000 3830,3 3274,6
ECO-900.2 39,2 33.750.000 4090,9 3497,4
ECO-900.3 40,8 35.050.000 4248,5 3632,1
HuNatural Gas= 8250 Kcal/Nm3
Hu Heavy Oil(S)=9650Kcal/kg
Mechanical ModulatingBurner-Modulation Ratio: NaturalGas5:1, LiquidFuel 3:1
ElectronicModulatingBurner-ModulationRatio: Natural Gas 10:1, LiquidFuel5:1

06.11.2018 Rev. 08 10
4.2. Burner Dimensions

06.11.2018 Rev. 08 11
5. INSTALLATION
5.1. Burner Installation Picture
Installationonthe Boiler
ØIn theinstallation oftheburner,pleaseonly usethe installation materialssuppliedwiththeburner.
ØMake surethatthere are no gapsbetween theflangeand boilercover andensureafullsealingbya
gasket.
Make surethat, when installingburnerattree pass boilers,theend pointofflamepipeshouldbeon
the sameplanewiththecoverinsulationmaterial.
Asphaltplantapplication

06.11.2018 Rev. 08 12
6. COMMISSIONING
6.1. General Controls
Make suretoperformthe following controlsbeforecommissioningtheburner.
ØInstallationoftheburner totheboileris checked.
ØCheckthe fuel line(are the pipediametersand thepipe installation correct?).
ØCheckenergy input cablesand voltages.
ØCheckthe fuel nozzles according totheboiler capacity.
ØPriortooperating the burner, controlthe boilerwater level.
ØMakesure water circulation systemisturnedon,and steamboiler andwaterfeedpumps and
boilerinlet -outletsareopen.
ØIsthereelectricity current?
ØIstheregas?
ØHastheboiler explosionlidbeen controlled?
ØIstheresufficient air inboilerroom?
ØHastheair ofthegas linebeen removed? Hasasealing test been made?
Commissioningorder
OperatingwithHeavy Oil;
ØOpenthemain gasvalves.
ØOpenoperating switchon theburner panel.
ØTurnmodulating control switchtoautomatic.
ØTurnthe fuelselector switchto“Heavy Oil”position.
ØCheckthetemperatureand pressure setvaluesfromthemodulatingcontrolunit.
ØBurner fanmotorwill beactivated.
ØCheckifthe gaspressure fromtheinletmanometer is30bar.
ØAirdamperswillopenduring pre-purge and ignitionwilltakeplace once airdampersare instartposition.
Ø3sec. later, theF.O. operatingvalvewill beopenedandcombustion willoccur.
ØFlame control systemwillstarttoflame control.
ØInmodulating burner, theburnergoesintomax.capacityaccordingto thesignalfromthemodulating
control unit.
ØWhentheboiler water temperature orsteampressureincrease,themodulating controlunitwillcause
burner torun withmin. capacity.
ØIftheboiler watertemperature orsteampressure increasesdespitetheoperationofburnerwith min.
capacity, the modulatingcontrolunitwill stop theburner.
OperatingwithGas;
Operationofamodulatingburner
ØOpenthemain gasvalve;checkmax300 mbar gaspressure from the manometer.
ØOpenoperating switchon theburner panel.
ØTurnmodulating control switchtoautomatic.
ØTurnthe fuelselector switchto“GAS” position.
ØCheckthetemperatureand pressure setvaluesfromthemodulatingcontrolunit.
ØBurner fanmotorwill beactivated.
ØAirdamperswillopenduring pre-purge and ignitionwilltakeplace once airdampersareinstartposition.
Ø3sec. later, thegasvalvewill beopenedandcombustion willoccur.
ØFlame control systemwillstarttoflame control.
ØInmodulating burner, theburnergoesintomax.capacityaccordingto thesignalfromthemodulating
control unit.
ØWhentheboiler water temperature orsteampressureincrease,themodulating controlunitwillcause
burner torun withmin. capacity.
ØIftheboiler watertemperature orsteampressure increasesdespitetheoperation ofburnerwith min.
capacity, the modulatingcontrolunitwill stop theburner.

06.11.2018 Rev. 08 13
6.2. CombustionAdjustment
ØPhotocell
Check the photocell weekly.Cleanthedustorfumestains ontheglassof photocellbyadrycloth.
QRA10 QRA2
ØPilotIgnition System
Pilotgasburner inlet pressurePmax=200mbar

06.11.2018 Rev. 08 14
ØHA-DNozzle
32-HA-D isaneedle closedlance with returnline.Shutdownneedle (4) makepresstonozzle plate (6)
through aspiralonpushingpiston.Shutdown needle isopenedbypneumatic way.

06.11.2018 Rev. 08 15
HA-D Nozzle HydraulicDiagram

06.11.2018 Rev. 08 16
ØOilAdjustment Regulator
1- Connectingrod
2- Scale coupler
3- Fuel connection points
4- Adjustment fixingbolt
5- Adjustment bolt
6- Housingcover (screw hood)
FuelRegulatorAdjustment
1-Removethehousing cover number 6
2-Loosenthe fixingboltnumber 4
3-When yourotate the shaftnumber 5(when looked fromtheshaftend)clockwise,thepressure value
you observefromreturnmanometer will increase,and burnerconsumption will alsoincreasesince nozzle
pressure increases.
4-When you rotate the shaftnumber5(when lookedfromthe shaft end) anti-clockwise,the pressure
value you observe fromreturnmanometerwill decrease,and burner consumption will also decrease since
nozzlepressuredecreases.
5-When the adjustment is completed;makesurethatthe adjustment you havemadeispermanent by
tighteningthefixingbolt number 4.
6-Place thehousingcover number 6.
6.3. AirPressureSwitchAdjustment
While the burner is working withoutany problem, theairpressureswitch isadjusted todesiredminimum
pressure asfollows.
ØUnscrew the screwofthe transparent cover andremovethe cover.
ØTurn theadjustment wheelin the direction toincreasethepressure,
notethepressure value atwhich the burner isfailed.
ØSet the pressure switch toavalue 1mbar lowerthan thepressure
valueatwhichtheburner failed and close the pressure switch lid.
ØIt isrecommendedthat this adjustment is carried out whenthe
burner isat minimumload.

06.11.2018 Rev. 08 17
6.4. ServomotorAdjustment
Do not openservomotor.Donot interfere with.Itmay damageservomotor or changeburner
settings.
6.5. Emission Measurement
Inemissionmeasurements,thefollowingvaluesare acceptedasreference according toTS EN676+A2
standard.
ØCO<100mg/ kWh
Ø%3 ≤O2 ≤%5
ØNOx<170mg/ kWh
ØExcess air ratio1,2≤λ≤1,3
Inemission measurements,the following values are accepted asreferenceaccording to TSEN267
standard.
ØCO<110mg/ kWh
Ø%3 ≤O2 ≤%5
ØNOx<250mg/ kWh
ØExcess air ratio 1,2≤λ≤1,3
It is important for theboilerto be sealed in order to avoid incorrectmeasurementsduring
emissionmeasurements.
Boiler temperature mustbebetween40 C˚and 80C˚whilemakingemissionmeasurement in
hotwater boilers.
6.6. Program Relay
LFL1.322

06.11.2018 Rev. 08 18
6.7. GasPassEquipment Requiredin GasLine
Pe < 300mbar
Q<1200kW
Pe > 300mbar
Q<1200kW
Pe< 300 mbar
Q>1200kW
Pe> 300 mbar
Q>1200kW
1- Compensator 1- Compensator 1- Compensator 1-Compensator
2- Ballvalve 2- Ball valve 2- Ball valve 2-Ballvalve
3- Gas filter 3- Gas filter 3- Gas filter 3-Gas filter
4- Inlet manometer + valve4- Inletmanometer + valve 4- Inletmanometer + valve4-Inlet manometer +
valve
8–Multi-block (safetyand
operation solenoids) 5- Regulator 8–Multi-block (safetyand operation solenoids)) 5-Regulator
10-max.gaspressure
switch 6- Outletmanometer +valve
9- SealingControl Set 6-Outlet manometer +
valve
11-min.gaspressure
switch 7- Safety dischargevalve 10-max.gaspressure switch 7-Safety discharge valve
8–Multi-block (safety and
operation solenoids) 11-min.gaspressure switch 8–Multi-block (safety andoperation solenoids)
10-max.gaspressure
switch 9-SealingControlSet
11- min. gaspressureswitch 10-max.gaspressure
switch
11-min.gaspressure
switch

06.11.2018 Rev. 08 19
7. MAINTENANCE
7.1. Weekly Maintenance
Weekly maintenanceisaroutinecleaning and adjustment procedurewhich isperformedto ensure
smooth and continuousoperationofthesystem.Burnercomponents mustbeadjusted aftereach
maintenance workin accordance with theinstructions.Otherwise,the burnercannotbe operated
efficiently.
ØClean all filtersinfuel ringsystem.
ØClean fuel nozzle ofthe burner.
ØCheck the burnergastip.
ØIfthe fin spaces and surfaceofthediffuser arecovered with particlesand formedalayer,clean it
with awirebrush.
ØClean heads ofignitionelectrodes.Check by performingmanual ignition,adjust the distance
between the ignitionelectrode and diffuser according tothe adjustment instructions.
7.2. MonthlyMaintenance
Monthly maintenance isamorecomprehensive maintenance compared to weekly maintenance,
where generalchecks ofburnerand peripheralcomponentsare performed to prevent possible faults.
After completion ofmaintenanceandadjustment processes,makesure to performacombustion
analysis.
ØClean thefilterson thefuel linetotheburner.
ØClean fuelnozzleoftheburner.
ØClean the surface ofthediffuser.
ØClean flamepipe.
ØCheck allwiring points. Tightenlooseconnections.
ØClean the solenoidvalves.
ØClean the photocell.
ØClean the dustand layers accumulatedon thefanand air valves.
ØCheck pumppressure. Check if necessary (Heavy Oil:25bar)
ØCheck ignitionelectrodes. Adjustit if necessary.Check ignition cables and sockets.
ØPerformcleanlinesscontrol of inside panel. Clean ifnecessary.
ØCheck all bolts oftheburner.Tightenloosebolts.
ØAfter starting the burnerand adjusting airklappe,performfluegasanalysis and checkifthere is
an idealcombustion.
ØClean the filters onthe main lineand multiblock.
ØCheck the burnergastip.
ØCheck gas linepressure,it must bethesame with the first adjusted pressure,otherwise burner load
andemissionvalues willalsohave changed.
ØAfterstarting the burnerandadjustingairklappe,performflue gasemissionmeasurement and
check if there is an ideal combustion.