ecostar COMBUSTION SYSTEMS PROCESS BURNERS DUAL FUEL (GAS-HEAVY OIL) INSTALLATION, OPERATING AND MAINTENANCE MANUAL ONE STAGE, TWO STAGE AND MODULATING OPERATION

DEAR USER, ECOSTAR FPB 200, FPB 300, FPB 400, FPB 550, FPB 870, FPB 1200, FPB 1600, FPB 2000, FPB 2500, FPB 3500, FPB 5000 Dual Fuel (Gas-Heavy Oil)process 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...

COMBUSTION SYSTEMS Warning Symbols and Descriptions

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...

Main and auxiliary equipment and all components used in Ecostar Dual Fuel (Gas-Heavy Oil) process 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...

BURNER’S GENERAL FEATURES ECOSTAR Dual Fuel (Gas-Heavy Oil) burners are designed and manufactured to work with liquid fuel with max. 2.5- 20 Cst (mm2/s) viscosity. and Natural Gas / Liquid Petroleum Gas at gas pressures 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; - High temperature industrial appliances. In direct and indirect hot air...

COMBUSTION SYSTEMS Temperature (°C) • 1 Temperature change of fuel used in ECOSTAR Dual Fuel (Gas-Heavy Oil) process burners dependent on viscosity

Process Burner Components 1- Pneumatic Cylinder* 2- Casing Flange 3- Nozzle 4- Gas Intake Pipe 5- Ignition Electrodes 6- Body 7- Flame Tube 8- Photocell 9- Combustion Air Intake

TECHNICAL DATA Capacity Table Hu Natural Gas =8250 kcal/Nm3 Hu LPG=22500 kcal/Nm3 Hu Heavy Oil (S) = 9650 kcal/kg

INSTALLATION Burner Installation Picture 1 - Air inlet 2 - Connecting Flange 3- Sealing (Gasket) 4 - Refractory combustion chamber 5 - Flame tube After completing the installation of the burner on the boiler: Sealing between the combustion chamber and burner must be ensured Device must be shipped in original packaging! Do not lift the device holding from servomotor, gas valve, impulse pipes or pressure switch during installation! Connect the oil feed pipes. Connect the burner panel to the mains by a cable suitable for the rated power. Clean the inside of fuel line thoroughly before installing...

COMMISSIONING General Controls Make sure to perform the following controls before commissioning the burner. • Has heat demand been formed? • Are the thermostat and other thermo-elements for control purposes working properly? • Are the electrical connections correct? • Is there electricity current? • Is there gas? • Has the boiler explosion lid been controlled? • Is there sufficient air flow? (capacity kW x 7 = ventilation section area cm2) • Has the boiler been installed correctly? • Has the sealing of fuel lines been controlled? • Check the temperature of the heavy-oil coming from the daily...

Operation of two-stage burner • Open the main gas valve, check the gas pressure from the manometer at the valve. (max.300 mbar) • Check the boiler thermostat or pressure switch settings. • Bring the operating switch on the burner panel to position 2. • Burner fan motor will be activated. • Ignition will take place at the end of pre-purge process. • 3 sec. later, the gas valve will be opened and combustion will occur. • Flame control system (ionization) will start flame control. • Burner will switch to the second stage (max. capacity) according to the heat requirement. • Burner is deactivated...

Oil inlet connection Pressure adjustment screw Oil return connection Manometer connection Pressurized oil outlet connection Gas Adjustment Follow the instructions of the valve manufacturer during installation, dismantling and adjustment of the gas valve 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

Ø MB DLE Series Monoblock Gas Valve 1- Pressure switch 2- Pressure switch electrical connection 3- Electrical connection of the valve 4- Operation gauge 5- The sealing ring 6- Set cover 7- Hydraulic disk brakes or settings 8- Coil 9- Measuring element connection (1/8) 10- Measuring element connection (1/8) 11- Output flange 12- Measuring element connection (1/8) 13- Gas flow way 14- Measuring element connection (1/8) 15- The vent plug 16- Filter chamber cover 17- Inlet flange 18- Measuring element connection (1/8) 19- Measuring element connection (1/8)