ECOSTAR ECO 8 NG, ECO 9 NG Installation, Operating And Maintenance Manual

MONOBLOCK HEAVY OIL BURNERS INSTALLATION,
OPERATING AND MAINTENANCE MANUAL

MODULATING OPERATION

ECO 8 NG
ECO 9 NG

www.ecostar.com.tr

DEAR USER,

ECOSTAR EC0 8 NG, ECO 9 NG 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.

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

13.06.2017 Rev. 01 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

TECHNICAL DATA .................................................................................................................................. 9

Capacity and Technical Chart ................................................................................................................. 9

Back Pressure-Capacity Diagrams ........................................................................................................ 10

Outer Dimensions ................................................................................................................................. 11

Flame Length and Diameter .................................................................................................................. 12

INSTALLATION ..................................................................................................................................... 13

Burner Installation Picture .................................................................................................................... 13

COMMISSIONING .................................................................................................................................. 14

General Controls ................................................................................................................................... 14

Combustion Adjustment ....................................................................................................................... 15

Fuel Pumps ........................................................................................................................................... 15

BT 300 ...................................................................................................................................................... 19

Operating Control and Displays ............................................................................................................ 20

Menu Functions .................................................................................................................................... 21

BT300 Connecting Diagram ................................................................................................................. 22

Servomotor ........................................................................................................................................... 23

Function Controls and Adjustments ...................................................................................................... 24

Final Checks ......................................................................................................................................... 24

Pilot Ignition System ............................................................................................................................ 27

Emission Measurement ......................................................................................................................... 27

Heavy Oil Burner Fuel Ring Line ......................................................................................................... 28

MAINTENANCE ..................................................................................................................................... 29

Weekly Maintenance ............................................................................................................................ 29

Monthly Maintenance ........................................................................................................................... 29

Seasonal Maintenance ........................................................................................................................... 30

FAULT HISTORY ................................................................................................................................... 31

PERIODICAL FLUE GAS MEASUREMENT REPORT ........................................................................ 32

AFTER SALES SERVICES ..................................................................................................................... 33

NOTES ..................................................................................................................................................... 34

13.06.2017 Rev. 01 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.

Electric motor direction of rotation

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

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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 analysis 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.

13.06.2017 Rev. 01 5

TERMS OF WARRANTY

Main and auxiliary equipment and all components used in Ecostar Heavy Oıl 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.

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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.

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!

Code Key

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

13.06.2017 Rev. 01 8

Min.

Max.

TECHNICAL DATA

Capacity and Technical Chart

NEW GENARATION MODULATING HEAVY-OIL BURNERS CAPACITY TABLE

BURNER TYPE CAPACITY CAPACITY

ECO 8 O(S) C 3 NG
ECO 8 O(S) C 3 a NG
ECO 8 O(S) C 3 b NG

ECO 9 O(S) C 3 NG
ECO 9 O(S) C 3a NG

ECO 9 O(S) C 3b NG
ECO 9 O(S) C 3c NG

Min.

kcal/h

722.400 5.160.000 840 6.000 74,9 534,7 11,00 3N 380

842.800 6.020.000 980 7.000 87,3 623,8 11,00 3N 380

963.200 6.880.000 1.120 8.000 99,8 713,0 15,00 3N 380

1.023.400 7.310.000 1.190 8.500 106,1 757,5 18,50 3N 380

1.083.600 7.740.000 1.260 9.000 112,3 802,1 22,00 3N 380

1.324.400 9.030.000 1.540 10.500 137,2 935,8 22,00 3N 380

1.806.000 10.320.000 2.100 12.000 187,2 1.069,4 22,00 3N 380

Max.

kcal/h

kW

kW

HEAVY OIL

CONSUMPTION

Min.
kg/h

Max.
kg/h

FAN MOTOR

POWER

kW VAC

MAIN

SUPPLY

Hu Heavy Oil (S) = 9650 Kcal/kg

13.06.2017 Rev. 01 9

Back Pressure-Capacity Diagrams

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Outer Dimensions

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Flame Length and Diameter

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INSTALLATION
Burner Installation Picture

Fuel Pumping Station Interconnection of pressure transmitters

13.06.2017 Rev. 01 13

COMMISSIONING

General Controls

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.

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.
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.

Commissioning order

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.
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 (modulating 25 bar).
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.

13.06.2017 Rev. 01 14

Combustion Adjustment

Ø Photocell

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

Fuel Pumps

MF Type

13.06.2017 Rev. 01 15

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

13.06.2017 Rev. 01 16

Ø Modulating Heavy Oil Burner Fuel Circuit

13.06.2017 Rev. 01 17

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, while its maximum operating

temperature is 140ºC. These values 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.

Ø Burner preheater

1. Fuel inlet

2. Fuel outlet

3. Discharge

4. Fixing plate

5. Resistance

6. Thermostat bulb pipe

7. Housing cover

13.06.2017 Rev. 01 18

BT 300

13.06.2017 Rev. 01 19

Operating Control and Displays

1 Display
2 Back key
3 Cursor keys
4 Enter key

Display: The display shows in pictograms:

1 - the menu structure
2 - operating status
3 - parameters
4 - error messages

Back key: Jump to previous window.

Cursor keys: You navigate in the menu using the cursor keys. You use the "left'' and
''right'' keys to move step by step to the selected row. At the end of the selected row, the
cursor jumps to the next row down, if possible If the menu has multiple rows, you can use
the "up" and "down" keys to switch rows To display the parameters, switch between the
individual fields.

Enter key: Press ENTER to call up the menu on the start screen. You open the selected
submenu from a menu window. By pressing the ENTER key, you transfer the setting values
from a parameter window.

13.06.2017 Rev. 01 20

Menu Functions

The menu is divided intothree paths:

INFO

MANUAL

SETTINGS

INFO

Select the INFO path for information about the following:

•

the burner

•

errors that have occurred

•

the software version

•

display of check sums

•

the serial number

•

actuating drive positions (current damper position for each channel)

•

digital inputs/outputs

MANUAL

Select the MANUAL to

•

start and stop the burner manually

•

adjust the internal burner firing-rate

SETTINGS

Select the SETTINGS path for information on, and to make settings for, the following:

•

the password

•

the burner settings (display and settings)

•

the actuator device settings (display)

•

the air/fuel control system

•

the "delete" curve

•

the display settings

13.06.2017 Rev. 01 21

BT300 Connecting Diagram

X30 = User Interface UI 300
X31 = LSB Option
X32 = continuous output 1, e.g. air damper
X33 = continuous output 2, e.g. gas damper
X34 = continuous output 3 (optional)

(1) SIC = safety interlock chain
(2) 230V AC 47 - 63Hz external fuse protection required (max 10A slow-blow)
(3) 230V AC for power supply to external devices

Maximum Cable Length:
X01-X10: 10m X30: 1m

X20-X21: 3m X31: 1m
X22-X23: unlimited X32-X34: 3m
X24-X26: 10m

13.06.2017 Rev. 01 22

Servomotor

Servomotors drive air dampers, gas butterfly valve and oil regulator. With the help of servomotors
electronic air and fuel ratio control is carried out, controlled by burner control.

Ø Static electricity can damage servomotor.
Ø Do not open servomotor. Do not interfere with or modify unit or equipment connected to it. It may

damage servomotor or change burner settings.

Ø Completely isolate equipment from the main supply before performing any wiring changes in

servomotor connection area.

Ø Check that wiring is in an orderly state.
Ø Protect equipment from condensation, water and ice.
Ø Fall or shock can adversely affect safety functions. Such servomotors may not be put into

operation.

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

13.06.2017 Rev. 01 23

Function Controls and Adjustments

The BT300 combines the benefits of an electronic fuel-air ratio control system with up to three
motorised actuating devices and an optional modules like an analogue output for speed control of the
combustion air fan with an electronic burner control unit. The leakage test, flame monitoring system,
power control unit and (optional) CO/O2 controller for control and optimi-sation of an oil or gas-fired
forced-draught burner are all integrated. The BT300 is suitable for virtually all combustion plants. Safety
interlock chains, monitors (e.g. gas and air pressure) and sensors are wired directly to the BT300. This
greatly reduces the cost of additional relays and wiring. The BT300 was designed to be attached to the
burner. The short wiring paths also save money. As a result, the BT300 is particularly suitable as standard
equipment for monoblock burners. The compact design of the BT300 burner control system also has its
advantages during commissioning. Standardising the wiring and the unified operator interface minimises
sources of errors from the start, while intelligent information in the display makes searching for errors
much easier.

Magnetic valves must not be energized during pre-purge. Check if valves are in closed
position!

Final Checks

Ø Switch of all purges after completion of all necessary measurements.
Ø Start and stop the burner at least 3 times to check the operation of the program.
Ø Make sure that all safety circuits on the burner and boiler operate properly before leaving the

installation site.

13.06.2017 Rev. 01 24

Ø Oil adjustment regulator

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.

1- Connecting rod
2- Scale coupler
3- Fuel connection points
4- Adjustment fixing bolt
5- Adjustment bolt
6- Housing cover (screw hood)

13.06.2017 Rev. 01 25

13.06.2017 Rev. 01 26

Pilot Ignition System

Pilot gas burner inlet pressure Pmax= 200 mbar

Emission Measurement

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.

13.06.2017 Rev. 01 27

Heavy Oil Burner Fuel Ring Line

13.06.2017 Rev. 01 28

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 (Heavy-Oil: 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 After starting the burner and adjusting air klappe, perform flue gas analysis and check if there is

an ideal combustion.

13.06.2017 Rev. 01 29

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.

13.06.2017 Rev. 01 30

FAULT HISTORY

Reading fault situation from the control panel

Active fault situation is shown on display. Enter-button is lit. Fault
history can be read from the control panel.

See more precise fault codes in the brochure on burner control.

Resetting fault

Example

● 01: fault code H333

● D1: diagnostic code (additional information)

● D2: diagnostic code (additional information)

● clock: running hours counter in fault situation

Burner control can be reset immediately after lockout. After resetting the actuators drive to stand by
position. In stand by position control unit allows burner to restart.

13.06.2017 Rev. 01 31

PERIODICAL FLUE GAS MEASUREMENT REPORT

Fuel
Consumption

(kg/h)

CO

(ppm)

O

2

(%)

CO

2

(ppm)

NO

X

(ppm)

Yield

(%)

Flue
Temp.

Date

(ºC)

Signature

13.06.2017 Rev. 01 32

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.

13.06.2017 Rev. 01 33

NOTES

Please record and forward your measurements and observations to us

www.ecostar.com.tr

13.06.2017 Rev. 01 34