ECOSTAR ECO 50, ECO 55, ECO 60, ECO 70, ECO 65 Installation, Operating And Maintenance Manual

MONOBLOCK DUAL FUEL (GAS-LIGHT OIL)
BURNERS INSTALLATION, OPERATING AND
MAINTENANCE MANUAL

TWO STAGE AND MODULATING OPERATION

ECO 50
ECO 55
ECO 60
ECO 65
ECO 70
ECO 75

www.ecostar.com

DEAR USER,

ECOSTAR ECO 50, ECO 55, ECO 60, ECO 65, ECO 70, ECO 75 Dual Fuel

(Gas-Light 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 Dual Fuel (Gas-Light Oil) Burners are manufactured in compliance with TS

EN 267 and TS EN 676 + A2 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.

Kartal Monumento Plaza

Kartal/İSTANBUL/TÜRKİYE

www.ecostar.com.tr

09.06.2017 Rev. 08 1

Esentepe Mah.Milangaz Cad. No:75 K:3

Tel: [phone]
Fax: [phone]

e-mail:[email protected]

CONTENTS

WARNINGS ............................................................................................................................................... 3

Warning Symbols and Descriptions ........................................................................................................ 3

General Safety Rules .............................................................................................................................. 4

TERMS OF WARRANTY ......................................................................................................................... 6

Out of Warranty Conditions ................................................................................................................... 6

BURNER’S GENERAL FEATURES ........................................................................................................ 7

Purpose of Use and Work Limits of Burners .......................................................................................... 7

Code Key ................................................................................................................................................ 7

Burner Components ................................................................................................................................ 9

TECHNICAL DATA ................................................................................................................................ 31

Capacity Table ...................................................................................................................................... 31

Back Pressure-Capacity Diagrams ........................................................................................................ 32

Burner Dimensions ............................................................................................................................... 33

Gas Hood Pressure Loss Diagram ......................................................................................................... 34

Flame Length and Diameter .................................................................................................................. 37

Noise Level ........................................................................................................................................... 37

BURNER HANDLING INFORMATION ................................................................................................ 38

INSTALLATION ..................................................................................................................................... 39

Burner Installation Picture .................................................................................................................... 39

In reverse flame front mirror boilers ..................................................................................................... 40

In cylindrical (straight flame) boilers .................................................................................................... 40

COMMISSIONING .................................................................................................................................. 41

Before Commissioning ......................................................................................................................... 41

General Controls ................................................................................................................................... 41

Combustion Adjustment ....................................................................................................................... 43

Fuel Pumps ........................................................................................................................................... 43

Gas Adjustment .................................................................................................................................... 47

Air pressure Switch Adjustment ........................................................................................................... 49

Servomotor Adjustment ........................................................................................................................ 49

Emission Measurement ......................................................................................................................... 54

Program Relay ...................................................................................................................................... 54

Light Oil Burner Fuel Ring Line ........................................................................................................... 57

Gas Pass Equipment Required in Gas Line ........................................................................................... 58

MAINTENANCE ..................................................................................................................................... 59

Weekly Maintenance ............................................................................................................................ 59

Monthly Maintenance ........................................................................................................................... 59

Seasonal Maintenance ........................................................................................................................... 60

TROUBLESHOOTING ............................................................................................................................ 61

PERIODICAL FLUE GAS MEASUREMENT REPORT ........................................................................ 62

AFTER SALES SERVICES ..................................................................................................................... 63

NOTES ..................................................................................................................................................... 64

09.06.2017 Rev. 08 2

WARNINGS

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.

PF Impulse connection detecting combustion chamber pressure

P

L

P

BR

Impulse connection detecting combustion air pressure

Impulse connection detecting burner gas head

CLEAN THE GAS BURNER.

CLEAN GAS LINE.
ЧИСТАЯ ЛИНИЯ ГАЗ.

09.06.2017 Rev. 08 3

"Clean the gas line" warning on gas line.

Electric motor direction of rotation

Carry in an upright position. Fragile Item. Protect against water.

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.

If you sense gas leakage;

• Shut down valves of all gas devices.

• Open all doors and windows.

• Do not turn on electric devices or do not turn them off if they are working.

• Do not use burner derived tools such as match and lighter.

• Inform the gas company.

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

● Close the main fuel shut-off valve outside the plant.

● Take appropriate actions

09.06.2017 Rev. 08 4

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.

09.06.2017 Rev. 08 5

TERMS OF WARRANTY

Main and auxiliary equipment and all components used in Ecostar Dual Fuel (Gas-Light 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.

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.

09.06.2017 Rev. 08 6

BURNER’S GENERAL FEATURES

ECOSTAR Dual Fuel (Gas-Light Oil) burners are designed and manufactured to work with liquid
fuel with max. 2.5- 6 Cst (mm
of min.20 mbar, max.300 mbar and at -%15 to +%10 of nominal voltages, under environmental
temperature of max.60˚C with rated capacity and burner pressure ranges.

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!

2

s) viscosity. and Natural Gas and Liquid Petroleum Gas at gas pressures

/

Code Key

09.06.2017 Rev. 08 7

Temperature change of fuel used in ECOSTAR Dual Fuel (Gas-Light Oil) burners dependent on

viscosity

09.06.2017 Rev. 08 8

Burner Components

ECO 50 KLC2

09.06.2017 Rev. 08 9

Assembly No Part Name Assembly No Part Name

1 Body group 24
2 Klingerit gasket 25 Electrode connection plate
3 Flame tube 26 Liquid fuel ignition electrode
4 Boiler connection flange 27 Fuel nozzle
5 Gasket 28 Lance
6 Flame tube extension 29 Solenoid valve
7 Fan 30 Manometer
8 Motor connection flange 31 Ball valve

9 Motor 32 Fuel pipes
10 Electrical panel connection plate 33 Air damper motion rod
11 Electrical panel 34 Air damper transmission rod
12 Handling rod fixing plate 35 Air damper
13 Handling rod 36 Air damper
14 Observation glass 37 Servomotor coupling
15 Purger 38 Servomotor
16 VPS 39 Pump housing cover
17 Gas solenoid valve 40 Air pressure switch
18 Gas inlet pipe 41 Pressure switch adaptor
19 Transformer connection plate 42 Pressure switch adaptor
20 Transformer connection plate (dual)
21 Ignition transformer 44 Pump motor console
22 Photocell 45 Motor
23 Combustion head

43 Pump

Gas ignition electrode

09.06.2017 Rev. 08 10

ECO 55 KLC2-2a

09.06.2017 Rev. 08 11

Assembly No Part Name Assembly No Part Name

1 Body group 23

2 Klingerit gasket 24 Electrode connection plate

3 Flame tube 25 Liquid fuel Ignition electrode

4 Boiler connection flange 26 Fuel nozzle

5 Gasket 27 Lance

6 Flame tube extension 28 Solenoid valve

7 Fan 29 Manometer

8 Motor 30 Ball valve

9 Electrical panel connection plate 31 Fuel pipes
10 Electrical panel 32 Air damper motion rod
11 Handling rod fixing plate 33 Air damper transmission rod
12 Handling rod 34 Air damper
13 Observation glass 35 Air damper
14 Purger 36 Servomotor coupling
15 VPS 37 Servomotor
16 Gas solenoid valve 38 Pump housing cover
17 Gas inlet pipe 39 Air pressure switch
18 Transformer connection plate 40 Pressure switch adaptor
19 Transformer connection plate (dual)
20 Ignition transformer 42 Pump
21 Photocell 43 Pump motor console
22 Combustion head 44 Motor

41 Pressure switch adaptor

Gas Ignition electrode

09.06.2017 Rev. 08 12

ECO 60 KLC2

09.06.2017 Rev. 08 13

Transforme

r connection plate

Assembly No Part Name Assembly No Part Name

1 Body group 25
2 Klingerit gasket 26
3 Flame tube 27 Electrode connection plate
4 Boiler connection flange 28 Liquid fuel Ignition electrode
5 Gasket 29 Fuel nozzle
6 Fan 30 Lance
7 Motor connection flange 31 Solenoid valve
8 Motor 32 Manometer

9 Electrical panel connection plate 33 Ball valve
10 Electrical panel 34 Fuel pipes
11 Handling rod fixing plate 35 Air damper motion rod
12 Handling rod 36 Air damper transmission rod
13 Bearing 37 Air damper
14 Observation glass frame 38 Air damper
15 Observation glass 39 Servomotor coupling
16 Eyebolt 40 Servomotor
17 VPS 41 Pump housing cover
18 Gas solenoid valve 42 Air pressure switch
19 Gas inlet pipe 43 Pressure switch adaptor
20 Purger 44 Pressure switch adaptor
21 Transformer connection plate 45 Pump

Combustion head
Gas ignition electrode

22
23 Ignition transformer 47 Motor

24 Photocell

(dual)

46 Pump motor console

09.06.2017 Rev. 08 14

ECO 65 KLC2

09.06.2017 Rev. 08 15

Assembly No Part Name Assembly No Part Name

1 Body group 25
2 Klingerit gasket 26
3 Flame tube 27
4 Boiler connection flange 28 Electrode connection plate
5 Gasket 29 Liquid fuel Ignition electrode
6 Flame tube extension 30 Fuel nozzle
7 Fan 31 Lance
8 Motor connection flange 32 Solenoid valve

9 Motor 33 Manometer
10 Electrical panel connection plate 34 Ball valve
11 Electrical panel 35 Fuel pipes
12 Handling rod fixing plate 36 Air damper motion rod
13 Handling rod 37 Air damper transmission rod
14 Bearing 38 Air damper
15 Observation glass frame 39 Air damper
16 Observation glass 40 Servomotor coupling
17 Eyebolt 41 Servomotor
18 VPS 42 Pump housing cover
19 Gas solenoid valve 43 Air pressure switch
20 Gas inlet pipe 44 Pressure switch adaptor
21 Purger 45 Pressure switch adaptor
22 Transformer connection plate 46 Pump
23 Transformer connection plate (dual) 47 Pump motor console
24 Ignition transformer 48 Motor

Photocell
Combustion head
Gas ignition electrode

09.06.2017 Rev. 08 16

ECO 70 KLC2

09.06.2017 Rev. 08 17

Assembly No Part Name Assembly No Part Name

1 Body group 25

2 Klingerit gasket 26

3 Flame tube 27 Electrode connection plate

4 Boiler connection flange 28 Liquid fuel Ignition electrode

5 Gasket 29 Fuel nozzle

6 Flame tube extension 30 Lance

7 Fan 31 Solenoid valve

8 Motor 32 Manometer

9 Electrical panel connection plate 33 Ball valve
10 Electrical panel 34 Fuel pipes
11 Handling rod fixing plate 35 Air damper motion rod
12 Handling rod 36 Air damper transmission rod
13 Bearing 37 Air damper
14 Observation glass frame 38 Air damper
15 Observation glass 39 Servomotor coupling
16 Eyebolt 40 Servomotor
17 VPS 41 Pump housing cover
18 Gas solenoid valve 42 Air pressure switch
19 Gas inlet pipe 43 Pressure switch adaptor
20 Purger 44 Pressure switch adaptor
21 Transformer connection plate 45 Pump
22 Transformer connection plate (dual)
23 Ignition transformer 47 Motor
24 Photocell

46 Pump motor console

Combustion head
Gas ignition electrode

09.06.2017 Rev. 08 18

ECO 50 KLC3

09.06.2017 Rev. 08 19

Assembly No Part Name Assembly No Part Name

1 Body group 26 Liquid fuel Ignition electrode
2 Klingerit gasket 27 Fuel nozzle
3 Flame tube 28 Centring wedge
4 Boiler connection flange 29 Lance
5 Gasket 30 Solenoid valve connection plate
6 Flame tube extension 31 Solenoid valve
7 Fan 32 Manometer
8 Motor connection flange 33 Ball valve

9 Motor 34 Fuel pipes
10 Electrical panel connection plate 35 Air damper motion rod
11 Electrical panel 36 Air damper transmission rod
12 Handling rod fixing plate 37 Air damper
13 Handling rod 38 Air damper
14 Observation glass 39 Coupling
15 Purger 40 Air dumper adjustment rod
16 VPS 41 Pump housing cover
17 Gas solenoid valve 42 Air pressure switch
18 Gas inlet pipe 43 Pressure switch adaptor
19 Transformer connection plate 44 Pressure switch adaptor
20 Transformer connection plate (dual) 45 Disc console group
21 Ignition transformer 46 Servomotor
22 Photocell 47 Pump
23 Combustion head 48 Pump motor console
24 Gas ignition electrode 49 Motor
25 Electrode connection plate

09.06.2017 Rev. 08 20

ECO 55 KLC3-3a

09.06.2017 Rev. 08 21

Assembly No Part Name Assembly No Part Name

1 Body group 25 Liquid fuel Ignition electrode

2 Klingerit gasket 26 Fuel nozzle

3 Flame tube 27 Centring wedge

4 Boiler connection flange 28 Lance

5 Gasket 29 Solenoid valve connection plate

6 Flame tube extension 30 Solenoid valve

7 Fan 31 Manometer

8 Motor 32 Ball valve

9 Electrical panel connection plate 33 Fuel pipes
10 Electrical panel 34 Air damper motion rod
11 Handling rod fixing plate 35 Air damper transmission rod
12 Handling rod 36 Air damper
13 Observation glass 37 Air damper
14 Purger 38 Coupling
15 VPS 39 Air dumper adjustment rod
16 Gas solenoid valve 40 Pump housing cover
17 Gas inlet pipe 41 Air pressure switch
18 Transformer connection plate 42 Pressure switch adaptor
19 Transformer connection plate (dual) 43 Pressure switch adaptor
20 Ignition transformer 44 Disc console group
21 Photocell 45 Servomotor
22 Combustion head 46 Pump
23 Gas ignition electrode 47 Pump motor console
24 Electrode connection plate 48 Motor

09.06.2017 Rev. 08 22

ECO 60 KLC3

09.06.2017 Rev. 08 23

Assembly No Part Name Assembly No Part Name

1 Body group 26 Gas ignition electrode

2 Klingerit gasket 27 Electrode connection plate

3 Flame tube 28 Liquid fuel Ignition electrode

4 Boiler connection flange 29 Fuel nozzle

5 Gasket 30 Centring wedge

6 Fan 31 Lance

7 Motor connection flange 32 Solenoid valve connection plate

8 Motor 33 Solenoid valve

9 Electrical panel connection plate 34 Manometer
10 Electrical panel 35 Ball valve
11 Handling rod fixing plate 36 Fuel pipes
12 Handling rod 37 Air damper motion rod
13 Bearing 38 Air damper transmission rod
14 Observation glass frame 39 Air damper plate
15 Observation glass 40 Air damper shaft
16 Eyebolt 41 Air dumper adjustment rod
17 VPS 42 Pump housing cover
18 Gas solenoid valve 43 Air pressure switch
19 Gas inlet pipe 44 Pressure switch adaptor
20 Purger 45 Pressure switch adaptor
21 Transformer connection plate 46 Disc console group
22 Transformer connection plate (dual) 47 Servomotor
23 Ignition transformer 48 Pump
24 Photocell 49 Pump motor console
25 Combustion head 50 Motor

09.06.2017 Rev. 08 24

ECO 65 KLC3

09.06.2017 Rev. 08 25

Assembly No Part Name Assembly No Part Name

1 Body group 27 Gas ignition electrode

2 Klingerit gasket 28 Electrode connection plate

3 Flame tube 29 Liquid fuel Ignition electrode

4 Boiler connection flange 30 Fuel nozzle

5 Gasket 31 Centring wedge

6 Flame tube extension 32 Lance

7 Fan 33 Solenoid valve connection plate

8 Motor connection flange 34 Solenoid valve

9 Motor 35 Manometer
10 Electrical panel connection plate 36 Ball valve
11 Electrical panel 37 Fuel pipes
12 Handling rod fixing plate 38 Air damper motion rod
13 Handling rod 39 Air damper transmission rod
14 Bearing 40 Air damper plate
15 Observation glass frame 41 Air damper shaft
16 Observation glass 42 Air dumper adjustment rod
17 Eyebolt 43 Pump housing cover
18 VPS 44 Air pressure switch
19 Gas solenoid valve 45 Pressure switch adaptor
20 Gas inlet pipe 46 Pressure switch adaptor
21 Purger 47 Disc console group
22 Transformer connection plate 48 Servomotor
23 Transformer connection plate (dual) 49 Pump
24 Ignition transformer 50 Pump motor console
25 Photocell 51 Motor
26 Combustion head

09.06.2017 Rev. 08 26

ECO 70 KLC3

09.06.2017 Rev. 08 27

Assembly No Part Name Assembly No Part Name

1 Body group 26 Gas ignition electrode

2 Klingerit gasket 27 Electrode connection plate

3 Flame tube 28 Liquid fuel Ignition electrode

4 Boiler connection flange 29 Fuel nozzle

5 Gasket 30 Centring wedge

6 Flame tube extension 31 Lance

7 Fan 32 Solenoid valve connection plate

8 Motor 33 Solenoid valve

9 Electrical panel connection plate 34 Manometer
10 Electrical panel 35 Ball valve
11 Handling rod fixing plate 36 Fuel pipes
12 Handling rod 37 Air damper motion rod
13 Bearing 38 Air damper transmission rod
14 Observation glass frame 39 Air damper plate
15 Observation glass 40 Air damper shaft
16 Eyebolt 41 Air dumper adjustment rod
17 VPS 42 Pump housing cover
18 Gas solenoid valve 43 Air pressure switch
19 Gas inlet pipe 44 Pressure switch adaptor
20 Purger 45 Pressure switch adaptor
21 Transformer connection plate 46 Disc console group
22 Transformer connection plate (dual)
23 Ignition transformer 48 Pump
24 Photocell 49 Pump motor console
25 Combustion head 50 Motor

47 Servomotor

09.06.2017 Rev. 08 28

ECO 75 KLC3

09.06.2017 Rev. 08 29

Assembly No Part Name Assembly No Part Name

1 Body group 29 Lance

2 Klingerit gasket 30 Ignition transformer

3 Flame tube 31 Transformer box

4 Boiler connection flange 32 Solenoid valve connection plate

5 Gasket 33 Solenoid valve

6 Fan 34 Manometer

7 Motor 35 Ball valve

8 Electrical panel connection plate 36 Fuel pipes

9 Electrical panel 37 Pump
10 Handling rod 38 Pump motor console
11 Handling rod fixing plate 39 Motor
12 Bearing 40 Pump housing cover
13 Observation glass 41 Air damper spring
14 Observation glass frame 42 Air damper transmission rod
15 Eyebolt 43 Air damper motion rod
16 Purger 44 Air damper plate
17 Photocell 45 Air damper shaft
18 Pilot gas solenoid valve 46 Air damper plate
19 Pilot gas pipe 47 Air damper shaft
20 Pilot electrode clamp 48 Air damper shaft
21 Pilot Combustion head 49 Air damper gauge
22 Pilot Ignition electrode 50 Air dumper adjustment rod
23 Gas inlet pipe 51 Servomotor
24 Gas solenoid valve 52 Disc console group
25
26 Fuel nozzle 54 Pressure switch adaptor
27
28

VPS

Centring wedge
Combustion head

53 Air pressure switch

55

Pressure switch adaptor

09.06.2017 Rev. 08 30

Min.

Max.

Min.

Max.

LIGHT OIL

TECHNICAL DATA

Capacity Table

GAS-LIGHT OIL DUAL BURNERS CAPACITY TABLE

BURNER TYPE

CAPACITY

kcal/h

GAS

kcal/h

GAS

CAPACITY

Min. kWMax. kWMin.

NATURAL GAS

CONSUMPTION

Nm3/h

Max.

Nm3/h

LIGHT OIL
CAPACITY

kcal/h

kcal/h

CAPACITY

Min. kWMax. kWMin.

LIGHT OIL

CONSUMPTION

kg/h

Max.
kg/h

FAN
MOTOR
POWER

OIL PUMP

POWER

kW kW VAC

TWO STAGE GAS-LIGHT OIL DUAL BURNERS

ECO 50 K L C 2 215.000 1.290.000 250 1.500 26,1 156,4 337.750 1.351.000 393 1.571 33,1 132,5 2,20 0,75 3N 380
ECO 55 K L C 2 258.000 1.720.000 300 2.000 31,3 208,5 386.000 1.737.000 449 2.020 37,8 170,3 3,00 0,75 3N 380
ECO 55 K L C 2a 258.000 2.150.000 300 2.500 31,3 260,6 386.000 2.123.000 449 2.469 37,8 208,1 3,00 0,75 3N 380
ECO 60 K L C 2 369.800 2.580.000 430 3.000 44,8 312,7 598.560 2.580.000 696 3.000 58,7 252,9 4,00 0,75 3N 380
ECO 65 K L C 2 430.000 3.010.000 500 3.500 52,1 364,8 733.580 3.010.000 853 3.500 71,9 295,1 5,50 0,75 3N 380
ECO 70 K L C 2 498.800 3.500.200 580 4.070 60,5 424,3 916.760 3.500.200 1.066 4.070 89,9 343,2 7,50 0,75 3N 380

MODULATING GAS-LIGHT OIL DUAL BURNERS

MAIN

SUPPLY

ECO 50 K L C 3 215.000 1.290.000 250 1.500 26,1 156,4 337.750 1.351.000 393 1.571 33,1 132,5 2,20 0,75 3N 380
ECO 55 K L C 3 258.000 1.720.000 300 2.000 31,3 208,5 386.000 1.737.000 449 2.020 37,8 170,3 3,00 1,10 3N 380
ECO 55 K L C 3a 258.000 2.150.000 300 2.500 31,3 260,6 386.000 2.123.000 449 2.469 37,8 208,1 3,00 1,10 3N 380
ECO 60 K L C 3 369.800 2.580.000 430 3.000 44,8 312,7 598.560 2.580.000 696 3.000 58,7 252,9 4,00 1,10 3N 380

ECO 65 K L C 3 430.000 3.010.000 500 3.500 52,1 364,8 733.580 3.010.000 853 3.500 71,9 295,1 5,50 1,50 3N 380
ECO 70 K L C 3 498.800 3.500.200 580 4.070 60,5 424,3 916.760 3.500.200 1.066 4.070 89,9 343,2 7,50 1,50 3N 380

ECO 75 K L C 3 686.000 4.800.000 798 5.581 83,2 581,8 1.003.620 4.824.600 1.167 5.610 98,4 473,0 11,00 1,50 3N 380

Hu Natural Gas =8250 kcal/Nm

3

Hu Light Oil (L) = 10200 Kcal/kg

09.06.2017 Rev. 08 31

Back Pressure-Capacity Diagrams

09.06.2017 Rev. 08 32

Burner Dimensions

09.06.2017 Rev. 08 33

Gas Hood Pressure Loss Diagram

Gas hood pressure loss measurements are conducted in atmospheric pressure. Consider the
below data while conducting measurement in counter pressure boilers.

Pm: Gas hood pressure while burner is connected to the boiler and working
PF: Combustion chamber pressure
PBr: Burner net gas hood pressure

PBr = Pm - P

09.06.2017 Rev. 08 34

F

09.06.2017 Rev. 08 35

09.06.2017 Rev. 08 36

Flame Length and Diameter

Natural Gas

Light Oil

Noise Level

Product operates within the range of 75 decibels max. and 85 decibels.

09.06.2017 Rev. 08 37

136 X 90 X 66

136 X 90 X 66

136 X 90 X 66

136 X 90 X 66

136 X 90 X 66

BURNER HANDLING INFORMATION

• Lift the product by holding the handles as seen in the picture.

• Prevent strong impacts on top of the product and vibration while handling the product.

• Do not leave the product in wet environment.

Dimensions of the box used for handling

Burner L x W x H (cm) Weight (kg)

ECO 50 KLC2 136 X 90 X 66 130
ECO 50 KLC3
ECO 55 KLC2
ECO 55 KLC2a
ECO 55 KLC3
ECO 55 KLC3a
ECO 60 KLC2 160 X 115 X 74 195
ECO 60 KLC3 170 X 115 X 74 195
ECO 65 KLC2 170 X 115 X 74 200
ECO 65 KLC3 170 X 115 X 74 200
ECO 70 KLC2 170 X 115 X 74 180
ECO 70 KLC3 170 X 115 X 74 180
ECO 75 KLC3 165 X 118 X 80 270

09.06.2017 Rev. 08 38

130
170
170
170
170

INSTALLATION
Burner Installation Picture

1- Drift Bolts
2- Burner
3- Boiler Connection Flange
4- Gasket
5- Boiler Studs

Ø In the installation of the burner, use the installation materials supplied with the burner.
Ø Secure the burner connection flange onto the burner cover by 4 bolts. Gasket must be connected

such that it will remain between connecting flange and boiler cap.

After completing the installation of the burner on the boiler:

Ø Connect the oil feed pipes.
Ø Connect the burner panel to the mains by a cable suitable for the rated power.

Device must be shipped in original packaging!

Do not lift the device holding from servomotor, gas valve, impulse pipes or pressure switch
during installation!

Clean the inside of fuel line thoroughly before installing the burner to the fuel line. Any damage
that may occur due to solid objects and metal particles from the fuel line shall not be covered by
our company.

09.06.2017 Rev. 08 39

In reverse flame front mirror boilers

While installing the burner in reverse flame front mirror boilers, flame tube tip must be adjusted
such that it gets inside by 50 mm-100 mm from flue pipes (50mm≤A≤100mm). Otherwise flue gas
temperature will rise and fuel consumption will increase.

In cylindrical (straight flame) boilers

09.06.2017 Rev. 08 40

COMMISSIONING

Before Commissioning

Electrical Connection

Perform electrical connections according to the diagram provided with the burner. Follow general
security rules during installation of electric wiring and making connections. Connect the earthing terminal
in electric panel to the earthing installation.

General Controls

Make sure to perform the following controls before commissioning the burner.

Ø Installation of the burner to the boiler is checked.
Ø Check the fuel line (are the pipe diameters and the pipe installation correct?).
Ø Check energy input cables and voltages.
Ø Check the boiler safety thermostats and, if it is a two-stage burner, then make sure that there are

two thermostats.

Ø Check the fuel nozzles according to the boiler capacity.
Ø Prior to operating the burner, control the boiler water level.
Ø Make sure water circulation system is turned on, and steam boiler and water feed pumps and

boiler inlet - outlets are open.

Ø Is there electricity current?
Ø Is there gas?
Ø Has the boiler explosion lid been controlled?
Ø Is there sufficient air in boiler room (ventilation section cm² = boiler capacity kW x 7)
Ø Has the air of the gas line been removed? Has a sealing test been made?

Commissioning order

Operating with Light Oil ;

Ø After performing the above mentioned controls, open the fuel tank valve.
Ø Open the valve upstream of the fuel filter.
Ø Check direction of motor rotation.
Ø Open the pump’s vent plug and place the manometer (0-40 bar).
Ø Turn on the burner switch (turn to position 1).
Ø When the burner starts up, the motor is activated and turns the pump at the same time.
Ø It actuates pre-purge and discharges the residual gases remaining in the boiler from the funnel.
Ø After the pre-purge, fuel is delivered from the nozzle. The fuel meets the flame from the ignition

electrodes and the combustion starts.

Ø After combustion of the burner, the pump pressure is adjusted (light oil: two stage; 14 bar,

modulating; 25 bar).

Ø If the burner has two stages, the switch is brought to position “2”, and the capacity of the burner is

increased through servomotor. Ideal combustion is obtained by increasing the amount of air by the
fuel given according to analyses value.

Ø The boiler thermostat is adjusted as desired (70-90°C for central heating boilers).
Ø For the safety of the system, check the boiler thermostats and observe the deactivation of the

burner.

09.06.2017 Rev. 08 41

Operating with Gas ;

Operation of two-stage burner

Ø Open the main gas valve, check the gas pressure from the manometer at the valve. (max.300

mbar)

Ø Check the boiler thermostat or pressure switch settings.
Ø Bring the operating switch on the burner panel to position 2.
Ø Burner fan motor will be activated.
Ø Ignition will take place at the end of pre-purge process.
Ø 3 sec. later, the gas valve will be opened and combustion will occur.
Ø Flame control system (ionization) will start flame control.
Ø Burner will switch to the second stage (max. capacity) according to the heat requirement.
Ø After the boiler water heated up or the boiler pressure has risen, the burner will turn off.

Operation of a modulating burner

Ø Open the main gas valve; check max 300 mbar gas pressure from the manometer.
Ø Open operating switch on the burner panel.
Ø Switch on the modulating control switch.
Ø Switch automatic-hand switch to automatic.
Ø Check the temperature and pressure set values from the modulating control unit.
Ø Ignition will take place at the end of pre-purge process.
Ø 3 sec. later, the gas valve will be opened and combustion will occur.
Ø Flame control system (ionization) will start flame control.
Ø In modulating burner, the burner goes into max. capacity according to the signal from the

modulating control unit.

Ø When the boiler water temperature or steam pressure increase, the modulating control unit will

cause burner to run with min. capacity.

Ø If the boiler water temperature or steam pressure increases despite the operation of burner with

min. capacity, the modulating control unit will stop the burner.

09.06.2017 Rev. 08 42

Combustion Adjustment

Ø Fuel nozzle

Use proper wrench in installation and dismantle of the fuel
nozzle.

Use diesel oil to clean the fuel nozzle. Do not use thinner
and its derivatives.

Ø Photocell

Check the photocell weekly. Clean the dust or fume stains on the glass of
photocell by a dry cloth.

Fuel Pumps

E Type

1- Suction or vacuum manometer connection
2- Return and internal bypass
3- Nozzle outlet
4- Manometer connection
5- Vacuum manometer connection
6- Pressure adjustment

09.06.2017 Rev. 08 43

TA Type

1-Suction
2-Nozzle outlet
3-Return
4-Manometer inlet
5-Vacuum or inlet manometer and internal return inlet
6-Pressure adjustment
7-Pre heater location

09.06.2017 Rev. 08 44

Ø Two Stages Light Oil Burner Fuel Circuit

Ø Modulating Light Oil Burner Fuel Circuit

09.06.2017 Rev. 08 45

CAUTION!

Ø End of the line to the main tank must be open to the atmosphere and line pressure must be

zero, otherwise no healthy modulating operation can be ensured since the pressure, which is
to form in return, will also affect nozzle pressure. Fuel may drop from nozzle end during
stops.

Ø For good pulverization, periodically check durability of the o-ring. In the event of earing of

the o-ring, fuel to the nozzle can by-pass and go directly to the return and reduces the
working performance of the nozzle.

Ø Maximum operating pressure of the nozzle is 30 bars. This value should not be exceeded

during working. Even if these out of control value are exceeded, nozzle must be taken to
emergency maintenance and all O-rings must be replaced.

Ø Do not use solvent based materials (thinner and derivatives) during cleaning of the fuel

nozzle; clean with gas oil or diesel oil. Fuel nozzle inner kit is very sensitive and even
invisible deformations can reduce working performance; dismantling-installing work must
be performed only by trained personnel.

Ø Spring has lost its function if dropping from fuel nozzle or fuel exit at large scale is observed

when the nozzle performs circulation. It must be checked and replaced if necessary.

09.06.2017 Rev. 08 46

Gas Adjustment

Ø VGD 20 4011 - 5011 Series Gas Valve

SKP 75 Connection Diagram

1 – Air-gas adjustment ratio
2 – Zero "0" point (start) adjustment
3 – Boiler counter pressure impulse connection
4 – Gas pressure impulse connection
5 – Air pressure impulse connection

09.06.2017 Rev. 08 47

Ø MB ZRD(LE) 405 – 412 Series Gas Valve

09.06.2017 Rev. 08 48

Air Pressure Switch Adjustment

While the burner is working without any problem, the air pressure switch
is adjusted to desired minimum pressure as follows.

Ø Unscrew the screw of the transparent cover and remove the cover.
Ø Turn the adjustment wheel in the direction to increase the pressure,

note the pressure value at which the burner is failed.

Ø Set the pressure switch to a value 1 mbar lower than the pressure

value at which the burner failed and close the pressure switch lid.

Ø It is recommended that this adjustment is carried out when the

burner is at minimum load.

Servomotor Adjustment

The amount of air is adjusted by means of the servomotor. The servomotor adjustment at two-stage

and modulating burners is made by the cams on the servomotor.

Ø SQN70

At Two-stage Burners;

I. Red Cam: Adjusts 2nd level max. air.
II. Blue Cam: Resets the clamp.
III. Orange Cam: Adjusts 1st level min. 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: Performs min. air adjustment.
IV. Black Cam: Not used.

09.06.2017 Rev. 08 49

Ø SQM10

Do not open servomotor. Do not interfere with. It may damage servomotor or change burner
settings.

I. Cam: Opening
II. Cam: Resets the clamp
III. Cam: Commissioning air
IV. V.VI. and VII. Cam not used

09.06.2017 Rev. 08 50

Ø MODULATING 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 adjustment operation must be as follows:

Ø Servomotor: 0°
Ø Fuel adjustment disc at start position
Ø Air adjustment disc at start position
Ø Fuel regulator at position 10
Ø Air klappes at fully closed position: 0°

Start position for discs Start position for fuel regulator

09.06.2017 Rev. 08 51

2 – If disc mechanism start positions are correct, start the burner and ensure that it activates in basic load.
Detect min capacity activation fuel amount of the burner by checking min. return pressure. If the
activation fuel amount is insufficient, set fuel regulator start adjustment to 9 or 8 value by changing
spring adjustment from adjusting bolt on fuel disc number 2.When you start the burner again after this
operation, you will see that your fuel return pressure has increased and hence activation fuel amount has
risen.

3 –Slowly increase the capacity following burner basic load adjustment provided that modulating control
device is in manual position. By setting 7 or 8 points during capacity increase, at these points:

Ø Measure emission values
Ø Record fuel return pressure
Ø Observe air klappe position
Ø Check fuel regulator scale value moves from 10 to 0.

4- If you haven't been able to reach the max capacity required by the boiler in 90° position of the air
klappe and 0° position of the fuel regulator once you have completed the maximum adjustment, 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- Housing cover (screw hood)

Fuel Regulator Adjustment

1- Remove the housing cover number 6
2- Loosen the fixing bolt number 4
3- When you rotate the shaft number 5 (when looked from the shaft end) clockwise, the pressure

value you observe from return manometer will increase, and burner consumption will also
increase since nozzle pressure increases.

4- When you rotate the shaft number 5 (when looked from the shaft end) anti-clockwise, the

pressure value you observe from return manometer will decrease, and burner consumption
will also 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.

09.06.2017 Rev. 08 52

5 - Set the burner to the correct capacity required by 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, set modulating control device to automatic

position, change set values and observe capacity changes. Air and fuel will increase and decrease
simultaneously according to the adjustment you previously made.

09.06.2017 Rev. 08 53

Emission Measurement

In emission measurements, the following values are accepted as reference according to TS EN 676 +A2
standard.

Ø CO < 100 mg/ kWh
Ø %3 ≤ O2 ≤ %5
Ø NOx < 170 mg/ kWh
Ø Excess air ratio 1,2≤ λ ≤ 1,3

In emission measurements, the following values are accepted as reference according to TS EN 267
standard.

Ø CO < 110 mg/ kWh
Ø %3 ≤ O2 ≤ %5
Ø NOx < 250 mg/ kWh
Ø Excess air ratio 1,2≤ λ ≤ 1,3

It is important for the boiler to be sealed in order to avoid incorrect measurements during
emission measurements.

Boiler temperature must be between 40 C˚ and 80 C˚ while making emission measurement in
hot water boilers.

Program Relay

LFL 1.32

09.06.2017 Rev. 08 54

If the value measure from PL point is below 0.5 bar, set the impulse pipe as follows.

09.06.2017 Rev. 08 55

If the flame tube of the burner is longer than standard (standard flame tube length of the burner),
please do not forget to support burner body during maintenance and installation/commissioning.

09.06.2017 Rev. 08 56

Light Oil Burner Fuel Ring Line

09.06.2017 Rev. 08 57

Gas Pass Equipment Required in Gas Line

Pe < 300 mbar

Q<1200kW

1- Compensator 1- Compensator 1- Compensator 1- Compensator

2- Ball valve 2- Ball valve 2- Ball valve 2- Ball valve

3- Gas filter 3- Gas filter 3- Gas filter 3- Gas filter

4- Inlet manometer + valve 4- Inlet manometer + valve 4- Inlet manometer + valve 4- Inlet manometer +

8 – Multi-block (safety and
operation solenoids)

9- Sealing Control Set 6- Outlet manometer + valve 9- Sealing Control Set 6- Outlet manometer +

7- Safety discharge valve 7- Safety discharge valve

8 – Multi-block (safety and

9- Sealing Control Set 9- Sealing Control Set

Pe > 300 mbar

Q<1200kW

5- Regulator 8 – Multi-block (safety and

operation solenoids)

Pe < 300 mbar

Q>1200kW

operation solenoids))

8 – Multi-block (safety

Pe > 300 mbar

Q>1200kW

valve

5- Regulator

valve

and operation solenoids)

Threaded and flanged connections may vary depending on the gas pressure and consumption.

09.06.2017 Rev. 08 58

MAINTENANCE

Weekly Maintenance

Weekly maintenance is a routine cleaning and adjustment procedure which is performed to ensure
smooth and continuous operation of the system. Burner components must be adjusted after each
maintenance work in accordance with the instructions. Otherwise, the burner cannot be operated
efficiently.

Ø Clean all filters in fuel ring system.
Ø Clean fuel nozzle of the burner.
Ø If the fin spaces and surface of the diffuser are covered with particles and formed a layer, clean it

with a wire brush.

Ø Clean heads of ignition electrodes. Check by performing manual ignition, adjust the distance

between the ignition electrode and diffuser according to the adjustment instructions.

Monthly Maintenance

Monthly maintenance is a more comprehensive maintenance compared to weekly maintenance,
where general checks of burner and peripheral components are performed to prevent possible faults. After
completion of maintenance and adjustment processes, make sure to perform a combustion analysis.

Ø Clean the filters on the fuel line to the burner.
Ø Clean fuel nozzle of the burner.
Ø Clean the surface of the diffuser.
Ø Clean flame pipe.
Ø Check all wiring points. Tighten loose connections.
Ø Clean the solenoid valves.
Ø Clean the photocell.
Ø Clean the dust and layers accumulated on the fan and air valves.
Ø Check pump pressure. Check if necessary (Light Oil: Two stage 14 bar, modulating; 25 bar)
Ø Check ignition electrodes. Adjust it if necessary. Check ignition cables and sockets.
Ø Perform cleanliness control of inside panel. Clean if necessary.
Ø Check all bolts of the burner. Tighten loose bolts.
Ø Clean the filters on the main line and multiblock.
Ø Check the burner gas tip.
Ø Check gas line pressure, it must be the same with the first adjusted pressure, otherwise burner load

and emission values will also have changed.

Ø After starting the burner and adjusting air klappe, perform flue gas analysis and check if there is

an ideal combustion.

09.06.2017 Rev. 08 59

Seasonal Maintenance

Comprehensive maintenance work when the burner is re-started after long periods of shut-down or
interruptions. After completion of maintenance and adjustment processes, make sure to perform a
combustion analysis.

Ø Check insulation resistance of electric motor.
Ø Make surface cleaning of ignition electrodes and porcelains. Replace cracked or broken

porcelains.

Ø Clean air fan and clamps.
Ø Check the operating function.
Ø Check cleanliness of the nozzle. Replace it if necessary.
Ø Clean the N.C. solenoid valve. Measure the coil winding resistance.
Ø Clean the strainer (filter) under the pump cover.
Ø Clean the photocell.
Ø Clean fuel filter. Replace it if necessary.
Ø Check boiler thermostats.
Ø Check cleanliness of boiler inside and clean if necessary.

09.06.2017 Rev. 08 60

TROUBLESHOOTING

Problem Cause Explanation-Suggestion

Burner cannot be

commissioned

Flame appears and goes

into failure mode.

Light Oil or Gas is

cut or does not come

Fuse failure

Relay failure

Boiler thermostat,

pressure switch

failure

Light Oil or Gas

pressure error

Photocell failure

Program relay failure

Light Oil or Gas valve might be closed. Open
the valve.

Check burner power supply. The fuse on the
main panel or the fuse on the burner might be

tripped.

Reset the thermal relay. Check adjustment of the

thermal relay according to the current in motor

label. If the failure is not removed, replace the

thermal relay.

If there is a problem with the burner thermostats,

pressure switches and steam tank this may be due

to an unadjusted or faulty water level device;

adjust it and if broken, replace it.

Circuit light oil or gas pressure might have

dropped.

Photocell may be faulty or contaminated. Remove

and clean..

Replace it with a new one.

Burner starts up, but fails

after 10 seconds.

Program relay failure

Air pressure switch

adjustment

Air pressure switch might be adjusted to a high

value. There may be dirt in the air pressure switch.

Replace it with a new one.

Air pressure switch might be broken.

Check fan motor coils, motor contactor and outlet

from program relay.

Light Oil or Gas valve might be closed. Circuit
fuel oil or gas pressure might have dropped.
Check Light Oil or Gas inlet manometer.

Ignition electrodes might be misadjusted or

ignition cables might have come out of their

terminals. Adjust ignition electrodes with a

Burner starts up, but fails

after 30 seconds.

Fan motor failure

Light Oil or Gas

valve, fuel oil or gas

pressure drop

Ignition electrode

failure

distance of 3-5 mm. between them.

Ensure sealing between the boiler cover and

Boiler cover is

overheating.

Sealing problem

burner. If required, use insulating material

between the boiler connecting flange and boiler

cover.

09.06.2017 Rev. 08 61

PERIODICAL FLUE GAS MEASUREMENT REPORT

Fuel
Consumption

(kg/h)

Fuel
Consumption

(m3/h)

CO

(ppm)

O

2

(%)

CO

2

(ppm)

NO

X

(ppm)

Yield

(%)

Flue
Temp.

(ºC)

Date

Signature

09.06.2017 Rev. 08 62

AFTER SALES SERVICES

Dear Customer,

We believe that providing a good service is as important as providing a good product. Therefore, we
continue offering wide range of comprehensive services to our conscious customers.

Our contact details for your requests and complaints

Esentepe Mah.Milangaz Cad. No:75 K:3

Kartal Monumento Plaza

KARTAL/İSTANBUL/TÜRKİYE

Tel: [phone]
Fax: [phone]

Factory Contact Details

Türkgücü OSB

Bülent Ecevit Bulvarı No:11

ÇORLU/TEKİRDAĞ/TÜRKİYE

Tel: [phone]

Fax: [phone]

Also you can contact with us:

Web site : www.ecostar.com.tr

E - mail : [email protected]

Please observe the following recommendations.

• Use the product in accordance with the principles of this manual.

• For any service demands regarding the product, please contact our Service Center from the

abovementioned phone numbers.

• Upon your purchase, register your warranty certificate during installation.

09.06.2017 Rev. 08 63

NOTES

Please record and forward your measurements and observations to us

www.ecostar.com.tr

09.06.2017 Rev. 08 64