ECOSTAR ECO 50 K L C 2, Installation, Operating And Maintenance Manual

Page 1: ...www ecostar com 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...

Page 2: ...ssue 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...

Page 3: ...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 Genera...

Page 4: ...rical voltage Product handling information PF Impulse connection detecting combustion chamber pressure PL Impulse connection detecting combustion air pressure PBR Impulse connection detecting burner g...

Page 5: ...airs 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...

Page 6: ...ck 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 Du...

Page 7: ...uct 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 dama...

Page 8: ...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...

Page 9: ...09 06 2017 Rev 08 8 Temperature change of fuel used in ECOSTAR Dual Fuel Gas Light Oil burners dependent on viscosity...

Page 10: ...09 06 2017 Rev 08 9 Burner Components ECO 50 KLC2...

Page 11: ...el 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 Ob...

Page 12: ...09 06 2017 Rev 08 11 ECO 55 KLC2 2a...

Page 13: ...l 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 damp...

Page 14: ...09 06 2017 Rev 08 13 ECO 60 KLC2...

Page 15: ...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 fram...

Page 16: ...09 06 2017 Rev 08 15 ECO 65 KLC2...

Page 17: ...al 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...

Page 18: ...09 06 2017 Rev 08 17 ECO 70 KLC2...

Page 19: ...3 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...

Page 20: ...09 06 2017 Rev 08 19 ECO 50 KLC3...

Page 21: ...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 dump...

Page 22: ...09 06 2017 Rev 08 21 ECO 55 KLC3 3a...

Page 23: ...el 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 adju...

Page 24: ...09 06 2017 Rev 08 23 ECO 60 KLC3...

Page 25: ...l 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 Ob...

Page 26: ...09 06 2017 Rev 08 25 ECO 65 KLC3...

Page 27: ...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...

Page 28: ...09 06 2017 Rev 08 27 ECO 70 KLC3...

Page 29: ...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 Obs...

Page 30: ...09 06 2017 Rev 08 29 ECO 75 KLC3...

Page 31: ...mp 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 A...

Page 32: ...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 00...

Page 33: ...09 06 2017 Rev 08 32 Back Pressure Capacity Diagrams...

Page 34: ...09 06 2017 Rev 08 33 Burner Dimensions...

Page 35: ...asurements 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 worki...

Page 36: ...09 06 2017 Rev 08 35...

Page 37: ...09 06 2017 Rev 08 36...

Page 38: ...09 06 2017 Rev 08 37 Flame Length and Diameter Natural Gas Light Oil Noise Level Product operates within the range of 75 decibels max and 85 decibels...

Page 39: ...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 136 X 90 X 66 130 ECO 55 KLC2 136 X 90 X 66 170 ECO 55 KLC2a 136 X 90 X 66 170 ECO 55 KLC3 136 X 90 X...

Page 40: ...cting flange and boiler cap After completing the installation of the burner on the boiler Connect the oil feed pipes Connect the burner panel to the mains by a cable suitable for the rated power Devic...

Page 41: ...lling 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 an...

Page 42: ...er room ventilation section cm boiler capacity kW x 7 Has the air of the gas line been removed Has a sealing test been made Commissioning order Operating with Light Oil After performing the above ment...

Page 43: ...f a modulating burner Open the main gas valve check max 300 mbar gas pressure from the manometer Open operating switch on the burner panel Switch on the modulating control switch Switch automatic hand...

Page 44: ...n the fuel nozzle Do not use thinner and its derivatives 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 vacu...

Page 45: ...09 06 2017 Rev 08 44 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...

Page 46: ...09 06 2017 Rev 08 45 Two Stages Light Oil Burner Fuel Circuit Modulating Light Oil Burner Fuel Circuit...

Page 47: ...zle 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 a...

Page 48: ...t 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...

Page 49: ...09 06 2017 Rev 08 48 MB ZRD LE 405 412 Series Gas Valve...

Page 50: ...failed and close the pressure switch lid 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 s...

Page 51: ...17 Rev 08 50 SQM10 I Cam Opening II Cam Resets the clamp III Cam Commissioning air IV V VI and VII Cam not used Do not open servomotor Do not interfere with It may damage servomotor or change burner s...

Page 52: ...l lever 6 Fuel control lever ADJUSTMENT 1 Start positions prior to disc mechanism adjustment operation must be as follows Servomotor 0 Fuel adjustment disc at start position Air adjustment disc at sta...

Page 53: ...f 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...

Page 54: ...alid 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 p...

Page 55: ...3 In emission measurements the following values are accepted as reference according to TS EN 267 standard CO 110 mg kWh 3 O2 5 NOx 250 mg kWh Excess air ratio 1 2 1 3 It is important for the boiler to...

Page 56: ...09 06 2017 Rev 08 55 If the value measure from PL point is below 0 5 bar set the impulse pipe as follows...

Page 57: ...2017 Rev 08 56 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 commissi...

Page 58: ...09 06 2017 Rev 08 57 Light Oil Burner Fuel Ring Line...

Page 59: ...ometer valve 4 Inlet manometer valve 4 Inlet manometer valve 8 Multi block safety and operation solenoids 5 Regulator 8 Multi block safety and operation solenoids 5 Regulator 9 Sealing Control Set 6 O...

Page 60: ...components are performed to prevent possible faults After completion of maintenance and adjustment processes make sure to perform a combustion analysis Clean the filters on the fuel line to the burne...

Page 61: ...f electric motor Make surface cleaning of ignition electrodes and porcelains Replace cracked or broken porcelains Clean air fan and clamps Check the operating function Check cleanliness of the nozzle...

Page 62: ...tocell may be faulty or contaminated Remove and clean Program relay failure Replace it with a new one Burner starts up but fails after 10 seconds Program relay failure Replace it with a new one Air pr...

Page 63: ...09 06 2017 Rev 08 62 PERIODICAL FLUE GAS MEASUREMENT REPORT Fuel Consumption kg h Fuel Consumption m3 h CO ppm O2 CO2 ppm NOX ppm Yield Flue Temp C Date Signature...

Page 64: ...RK YE Tel 90 216 442 93 00 Fax 90 216 370 45 03 Factory Contact Details T rkg c OSB B lent Ecevit Bulvar No 11 ORLU TEK RDA T RK YE Tel 90 282 685 44 80 81 Fax 90 282 685 42 09 Also you can contact wi...

Page 65: ...09 06 2017 Rev 08 64 NOTES Please record and forward your measurements and observations to us www ecostar com tr...