ECOSTAR ECO 60 Installation guide

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www.ecostar.com.tr
MONOBLOCK HEAVY OIL BURNERS INSTALLATION,
OPERATING AND MAINTENANCE MANUAL
TWO STAGE AND MODULATING OPERATION
ECO 50
ECO 55
ECO 60
ECO 65
ECO 70
ECO 75

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DEAR USER,
ECOSTAR ECO 50, ECO 55, ECO 60, ECO 65, ECO 70, ECO 75 Heavy Oil
burners are prepared and manufactured according to the latest technical developments and
safety rules. It is easy to use for our customers.
We recommend that you read this manual and safety warnings thoroughly before the
use of the device in order to ensure safe, cost effective and environmental-friendly use.
If you encounter any issue that 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.
Ecostar Heavy Oil Burners are manufactured in accordance with TS EN 267
standards.
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.
TERMO ISI SİSTEMLERİ SAN.VE TİC.A.Ş.
Esentepe Mah.Milangaz Cad. No:75 K:3
Kartal Monumento Plaza
Kartal/İSTANBUL/TÜRKİYE
Tel: [phone]
Fax: [phone]
www.ecostar.com.tr
e-mail:[email protected]m.tr

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CONTENTS
1. WARNINGS.......................................................................................................................................... 3
1.1. Warning Symbols and Descriptions............................................................................................... 3
1.2. General Safety Rules...................................................................................................................... 4
2. TERMS OF WARRANTY.................................................................................................................... 6
2.1. Out of Warranty Conditions.......................................................................................................... 6
3. BURNER’S GENERAL FEATURES................................................................................................... 7
3.1. Purpose of Use and Work Limits of Burners................................................................................. 7
3.2. Code Key........................................................................................................................................ 7
3.3. Burner Components........................................................................................................................ 9
4. FLUE GAS AND HEATING WATER SCHEMA............................................................................. 31
5. TECHNICAL DATA........................................................................................................................... 32
5.1. Capacity Table.............................................................................................................................. 32
5.2. Back Pressure-Capacity Diagrams............................................................................................... 33
5.3. Burner Dimensions....................................................................................................................... 34
5.4. Flame Length and Diameter......................................................................................................... 35
5.5. Noise Level................................................................................................................................... 35
6. BURNER HANDLING INFORMATION.......................................................................................... 36
7. INSTALLATION................................................................................................................................ 37
7.1. Burner Installation Picture............................................................................................................ 37
7.2. In reverse flame front mirror boilers............................................................................................ 38
7.3. In cylindrical (straight flame) boilers........................................................................................... 38
8. COMMISSIONING............................................................................................................................. 39
8.1. Before Commissioning................................................................................................................. 39
8.2. General Controls........................................................................................................................... 39
8.3. Combustion Adjustment............................................................................................................... 40
8.4. Fuel Pumps................................................................................................................................... 40
8.5. Servomotor Adjustment ............................................................................................................... 44
8.6. Emission Measurement ................................................................................................................ 49
8.7. Program Relay.............................................................................................................................. 49
8.8. Heavy Oil Burner Fuel Ring Line................................................................................................ 51
9. MAINTENANCE................................................................................................................................ 52
9.1. Weekly Maintenance.................................................................................................................... 52
9.2. Monthly Maintenance................................................................................................................... 52
9.3. Seasonal Maintenance.................................................................................................................. 53
9.4. Installation and Disassembly Instructions for Maintenance Purposes......................................... 54
10. TROUBLESHOOTING................................................................................................................... 55
11. PERIODICAL FLUE GAS MEASUREMENT REPORT.............................................................. 56
12. AFTER SALES SERVICES............................................................................................................ 57
13. NOTES............................................................................................................................................. 58

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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.
Electric motor direction of rotation
Carry in an upright position. Fragile Item. Protect against water.

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1.2. General Safety Rules
All personnel engaged in installation, disassembly, commissioning, operation, control,
maintenance and repair should have received the necessary training and fully read and understood
this manual.
No changes that might damage the safety of the burner unit must be made by persons and/or
organizations on the burner unit.
All operation, commissioning and installation works (except for burning adjustment) should be
carried out when the burner is not operating and after disconnecting the power supply.
Noncompliance with these rules may lead to serious bodily injuries and even death by electrical
shocks or uncontrolled flame formation.
Repairs concerned with safety elements should be carried out only by the manufacturing 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 from explosive and flammable materials.
Device must intake air, ventilation and air discharge holes must not be closed.
Do not store any inflammable materials in boiler room.
Wear hearing protectors if there is noise in boiler room.
In case of fıre or other emergency;
●Switch off the main switch
●Take appropriate actions

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The burner installation must be carried out in accordance with the instructions. Vibration can
damage the burner and its components.
Keep boiler doors closed while starting burner and during burner operation.
Check combustion values to be correct by using flue gas analyzer at the whole adjustment range
between minimum, full load, and ignition load.
Use lifting device or belt for lifting fan motor, if necessary
During the first commissioning of the burner or in case of any revision carried out in the electrical
system or motor cables by any reason, direction of the fan rotation must certainly be checked by
the authorized technical service.
For products that have not been comissioned or started more than 6 months, before activating the
servomotor;
In air dampers and oil regulators, servomotor and air damper connections must be checked to
ensure that they are free running in spite of immobility and oil freezing.
BURNER ROOM
Install the burner in a suitable room/floor with minimum external air openings and sufficient to
ensu re perfect combustion, in compliance with current regulations.
Never obstruct air openings of the burner room, burner fan intake vents or air ducts in order to
prevent:
a.The build up of toxic / explosive gas mixtures in the burner room,
b.Combustion with insufficient air, resulting in hazardous, anti-economical and polluting ope-
ration.
The burner must be always protected from rain, snow and frost to prevent corrosion and paint
deformations.
Keep the burner room clean and free of solid volatile substances, which could be sucked into the fan
and clog the internal burner or combustion head air ducts.

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2. TERMS OF WARRANTY
Main and auxiliary equipment and all components used in Ecostar heavy oil burners are guaranteed
for 1 year by TERMO ISI SİST. A.Ş starting from the date of commissioning under the maintenance,
adjustment, operating conditions and relevant mechanic, chemical and thermal effects explained herein.
Please note that this warranty is only valid if the device(s) is commissioned and maintained by our
authorized services.
Our company reserves the right to make any modifications on the product and all instructions
thereof for improvement purposes.
2.1. Out of Warranty Conditions
Any damage arising out of or in 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 that may occur during transportation or storage of the product,
Not preserving the product in its original packaging until the installation stage,
Incorrect and poor electrical connections, Failures due to incorrect voltage applications, frequent
repetition of voltage fluctuations,
Any damage that may occur as a result of incorrect fuel usage or, foreign substances in the fuel
used or using of the product without any fuel,
Any damage that may occur due to foreign particles entered into the product during installation
and operation,
Failures due to incorrect device selection,
Any damage to unit due to natural disasters,
Devices without any warranty certificates,
Warranty Certificates without the stamp and signature of the authorized dealer or service,
Devices with any falsification on the warranty certificate or without an original serial number.
The risks during transportation of device under the responsibility of customer belong to the
customer.
Presence of misuse faults are indicated in the reports issued by authorized service stations or our
authorized agent, dealer, representative or our factory in case of unavailability of authorized
service stations.
Customers may apply consumer protection arbitrator committee with regards to this report and
request for an expert report.

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3. BURNER’S GENERAL FEATURES
ECOSTAR Heavy Oil burners are designed to operate with oil at 2.5 –20 Cst (mm²/s) viscosity, at
rated capacity and pressure ranges and -15% to +10% nominal voltage.
3.1. Purpose of Use and Work Limits of Burners
This product works at any load value equivalent to its max. capacity or covered by its capacity
range;
-In hot water and steam boilers,
-In direct and indirect hot air generators,
-Industrial appliances operating at temperature below 600 0C,
--15 0C…+60 0C ambient temperature range,
-1N 230 VAC/3N 380VAC /50 Hz feed voltage (-%15…+%10) values,
-Max. 95% relative humidity,
-In well-ventilated open and closed spaces compatible with protection class IP 40.
This device must never be operated with open flame!
3.2. Code Key

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Temperature change of fuel used in ECOSTAR heavy oil burners dependent on viscosity

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3.3. Burner Components
ECO 50 OSC2

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Assembly No
Part Number
Assembly No
Part Number
1
Body
23
Purger
2
Air Intake
24
Electrical Panel Mounting Plate
3
Flame Tube
25
Electrical Panel
4
Boiler Connection Flange Sheet Metal
26
Observation Glass
5
Flame Tube Extension
27
Handling Shaft
6
Lance
28
Handling Shaft Fixing Plate
7
Combustion Head
29
Pump
8
Fuel Nozzle
30
Pump Coupling
9
Ignition Electrode
31
Servomotor
10
Electrode Connection Sheet Metal
32
Servomotor Coupling
11
Pot Heater Connection
33
Air Damper
12
Lance Centering Console
34
Air Damper
13
Klingerit Gasket
35
Air Damper Motion Rod
14
Gasket
36
Air Damper Motion Transfer Rod
15
Fan Motor
37
Pot Heater
16
Fan Motor Connection Flange
38
Pot Heater Protection Cover
17
Fan
39
Thermometer
18
Fan Coupling
40
Thermometer Connection Adaptor
19
Coupling Connection Pipe
41
Solenoid Valve
20
Ignition Transformer
42
Ball Valve
21
Transformer Mounting Plate
43
Manometer
22
Photocell
44
Fuel Pipes

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ECO 50 OSC3

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Assembly No
Part Number
Assembly No
Part Number
1
Body
25
Electrical Panel
2
Air Intake
26
Observation Glass
3
Flame Tube
27
Handling Shaft
4
Boiler Connection Flange sac
28
Handling Shaft Fixing Plate
5
Flame Tube Extension
29
Solenoid Valve Connection Plate
6
Lance
30
Pump
7
Combustion Head
31
Pump Coupling
8
Fuel Nozzle
32
Disc Control Group
9
Ignition Electrode
33
Servomotor
10
Electrode Connection Sheet Metal
34
Air Damper Modulating Motion Rod
11
Pot Heater Connection
35
Air Damper Modulating Spring
12
Lance Centering Console
36
Servomotor Coupling
13
Klingerit Gasket
37
Air Damper
14
Gasket
38
Air Damper
15
Fan Motor
39
Air Damper Motion Rod
16
Fan Motor Connection Flange
40
Air Damper Motion Transfer Rod
17
Fan
41
Pot Heater
18
Fan Coupling
42
Pot Heater Protection Cover
19
Coupling Connection Pipe
43
Thermometer
20
Ignition Transformer
44
Thermometer Connection Adaptor
21
Transformer Mounting Plate
45
Solenoid Valve
22
Photocell
46
Ball Valve
23
Purger
47
Manometer
24
Electrical Panel Mounting Plate
48
Fuel Pipes

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ECO 55 OSC2

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Assembly No
Part Number
Assembly No
Part Number
1
Body
23
Electrical Panel Mounting Plate
2
Air Intake
24
Electrical Panel
3
Flame Tube
25
Observation Glass
4
Boiler Connection Flange sac
26
Handling Shaft
5
Flame Tube Extension
27
Handling Shaft Fixing Plate
6
Lance
28
Pump
7
Combustion Head
29
Pump Coupling
8
Fuel Nozzle
30
Servomotor
9
Ignition Electrode
31
Servomotor Coupling
10
Electrode Connection Sheet
Metal
32
Air Damper
11
Pot Heater Connection
33
Air Damper
12
Lance Centering Console
34
Air Damper Motion Rod
13
Klingerit Gasket
35
Air Damper Air Damper Motion
Transfer Rod
14
Gasket
36
Pot Heater
15
Fan Motor
37
Pot Heater Protection Cover
16
Fan
38
Thermometer
17
Fan Coupling
39
Thermometer Connection Adaptor
18
Coupling Connection Pipe
40
Solenoid Valve
19
Ignition Transformer
41
Ball Valve
20
Transformer Mounting Plate
42
Manometer
21
Photocell
43
Fuel Pipes
22
Purger

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ECO 55 OSC3-3a

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Assembly No
Part Number
Assembly No
Part Number
1
Body
25
Handling Shaft
2
Air Intake
26
Handling Shaft Fixing Plate
3
Flame Tube
27
Solenoid Valve Connection Plate
4
Boiler Connection Flange
28
Pump
5
Flame Tube Extension
29
Disc Control Group
6
Lance
30
Pump Coupling
7
Combustion Head
31
Air Damper Modulating Motion Rod
8
Fuel Nozzle
32
Air Damper Modulating Spring
9
Ignition Electrode
33
Servomotor Coupling
10
Pot Heater Connection
34
Air Damper
11
Lance Centering Console
35
Air Damper
12
Klingerit Gasket
36
Air Damper Motion Rod
13
Gasket
37
Air Damper Air Damper Motion Transfer Rod
14
Fan Motor
38
Pot Heater
15
Fan
39
Pot Heater Protection Cover
16
Fan Coupling
40
Thermometer
17
Coupling Connection Pipe
41
Thermometer Connection Adaptor
18
Ignition Transformer
42
Solenoid Valve
19
Transformer Mounting Plate
43
Ball Valve
20
Photocell
44
Manometer
21
Purger
45
Fuel Pipes
22
Electrical Panel Mounting Plate
46
Electrode Connection Plate
23
Electrical Panel
47
Servomotor
24
Observation Glass

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ECO 60 OSC2

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Assembly No
Part Number
Assembly No
Part Number
1
Body Group
20
Purger
2
Flame Tube
21
Eye Bolt
3
Lance
22
Gas Solenoid Valve
4
Klingerit Gasket
23
Servomotor
5
Combustion Head
24
Servomotor Coupling
6
Air Adjustment Mechanism
25
Air Damper
7
Boiler Connection Flange
26
Air Damper
8
Gasket
27
Air Damper Motion Rod
9
Fan Motor
28
Air Damper Air Damper Motion Transfer
Rod
10
Fan Motor Connection Flange
29
Air Damper Modulating Spring
11
Fan
30
Pump Housing Cover
12
Observation Glass
31
Photocell
13
Observation Glass Frame
32
Liquid Fuel Solenoid Valve
14
Handling Shaft
33
Lance Centering Console
15
Handling Shaft Fixing Plate
34
Ignition Electrode
16
Electrical Panel
35
Electrode Connection Plate
17
Electrical Panel Mounting Plate
36
Pilot Ignition
18
Transformer Mounting Plate
37
Pilot Ignition Pipe
19
Ignition Transformer
38
Fuel Nozzle

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ECO 60 OSC3