MONOBLOCK HEAVY OIL BURNERS INSTALLATION,

OPERATING AND MAINTENANCE MANUAL

ONE STAGE, TWO STAGE AND MODULATING OPERATION

ECO 2
ECO 30
ECO 45
www.ecostar.com.tr
DEAR USER,

ECOSTAR ECO 2, ECO 30, ECO 45 Heavy Oil burners are prepared and
manufactured according to the latest technical developments and safety rules. It is easy to
use for our customers.

We recommend that you read this manual and safety warnings thoroughly before the
use of the device in order to ensure safe, cost effective and environmental-friendly use.

If you encounter any issue that is not explained clearly in this manual or you could
not understand, please contact with our service department.

We thank you for choosing ECOSTAR brand.

Ecostar Heavy Oil Burners are manufactured in accordance with TS EN 267

standards.

This Operating Manual is an integral part of the burner and must be maintained in a
plastic dossier and hung at a clearly visible place in the burner room.

TERMO ISI SİSTEMLERİ SAN.VE TİC.A.Ş.

Esentepe Mah.Milangaz Cad. No:75 K:3
Kartal Monumento Plaza
Kartal/İSTANBUL/TÜRKİYE
Tel: +90 216 442 93 00
Fax: +90 216 370 45 03
www.ecostar.com.tr
e-mail:[email protected]

11.01.2017 Rev. 05 1
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................................................................................................................................ 21
Capacity Table ...................................................................................................................................... 21
Back Pressure-Capacity Diagrams ........................................................................................................ 22
Burner Dimensions ............................................................................................................................... 24
Flame Length and Diameter .................................................................................................................. 24
Noise Level ........................................................................................................................................... 24
BURNER HANDLING INFORMATION................................................................................................ 25
INSTALLATION ..................................................................................................................................... 26
Burner Installation Picture .................................................................................................................... 26
In reverse flame front mirror boilers ..................................................................................................... 27
In cylindrical (straight flame) boilers .................................................................................................... 27
COMMISSIONING .................................................................................................................................. 28
Before Commissioning ......................................................................................................................... 28
General Controls ................................................................................................................................... 28
Combustion Adjustment ....................................................................................................................... 29
Fuel Pumps ........................................................................................................................................... 29
Servomotor Adjustment ........................................................................................................................ 34
Emission Measurement ......................................................................................................................... 35
Program Relay ...................................................................................................................................... 35
Heavy Oil Burner Fuel Ring Line ......................................................................................................... 37
MAINTENANCE ..................................................................................................................................... 38
Weekly Maintenance ............................................................................................................................ 38
Monthly Maintenance ........................................................................................................................... 38
Seasonal Maintenance........................................................................................................................... 39
Installation and Disassembly Instructions for Maintenance Purposes ................................................... 40
TROUBLESHOOTING............................................................................................................................ 41
PERIODICAL FLUE GAS MEASUREMENT REPORT ........................................................................ 42
AFTER-SALES SERVICES .................................................................................................................... 43
NOTES ..................................................................................................................................................... 44

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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 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.

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TERMS OF WARRANTY

Main and auxiliary equipment and all components used in Ecostar heavy oil burners are guaranteed
for 1 year by TERMO ISI SİST. A.Ş starting from the date of commissioning under the maintenance,
adjustment, operating conditions and relevant mechanic, chemical and thermal effects explained herein.

Please note that this warranty is only valid if the device(s) is commissioned and maintained by our
authorized services.

Our company reserves the right to make any modifications on the product and all instructions
thereof for improvement purposes.

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

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Burner Components

ECO 2 OSC1-1a

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 Assembly No Part Name Assembly No Part Name
1 Body Group 17 Pump Connection Elbow
2 Motor 18 Pump Connection Elbow
3 Fan 19 Solenoid Valve
4 Air Damper 20 Photocell
5 Klingerit Gasket 21 Pump
6 Flame Tube 22 Handling Shaft
7 Boiler Connection Flange 23 Electrical Panel Mounting Plate
8 Gasket 24 Electrical Panel
9 Air Damper Gauge 25 Thermometer
10 Flame Tube Extension 26 Thermometer Connection Adaptor
11 Combustion Head 27 Pot heater
12 Electrode Restrain Plate 28 Pot Heater Protection Cover
13 Ignition Electrodes 29 Fan Coupling
14 Fuel Pipes 30 Coupling Connection Pipe
15 Lance 31 Pump Coupling
16 Fuel Nozzle 32 Pot heater Connection

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ECO 30 OSC1-1a

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Assembly No Part Name Assembly No Part Name
1 Body 19 Shaft Fixing Plate
2 Air Intake 20 Thermometer
3 Flame Tube 21 Thermometer Connection Adaptor
4 Flame Tube Extension 22 Pot heater
5 Motor 23 Pot Heater Protection Cover
6 Fan 24 Pot heater Connection
7 Motor Connection Flange 25 Solenoid Valve
8 Pump 26 Combustion Head
9 Servomotor 27 Fuel Nozzle
10 Transformer 28 Fuel Pipes
11 Transformer Mounting Plate 29 Observation Glass
12 Lance 30 Electrical Panel
13 Air Damper 31 Electrical Panel Mounting Plate
14 Servomotor Coupling 32 Ignition Electrodes
15 Klingerit Gasket 33 Electrode Restrain Plate
16 Gasket 34 Pump Elbow
17 Boiler Connection Flange 35 Pump Elbow
18 Handling Shaft

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ECO 30 OSC2-2a

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Assembly No Part Name Assembly No Part Name
1 Body 18 Handling Shaft
2 Air Intake 19 Shaft Fixing Plate
3 Flame Tube 20 Thermometer
4 Flame Tube Extension 21 Thermometer Connection Adaptor
5 Motor 22 Pot heater
6 Fan 23 Pot Heater Protection Cover
7 Motor Connection Flange 24 Pot heater Connection
8 Pump 25 Solenoid Valve
9 Servomotor 26 Combustion Head
10 Transformer 27 Fuel Nozzle
11 Transformer Mounting Plate 28 Fuel Pipes
12 Lance 29 Observation Glass
13 Air Damper 30 Electrical Panel
14 Servomotor Coupling 31 Electrical Panel Mounting Plate
15 Klingerit Gasket 32 Electrode Restrain Plate
16 Gasket 33 Ignition Electrode
17 Boiler Connection Flange

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ECO 45 OSC1-1a-1b

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

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ECO 45 OSC2-2a-2b

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

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ECO 45 OSC3b

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

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TECHNICAL DATA

Capacity Table

HEAVY OIL BURNERS CAPACITY TABLE

FAN
HEAVY OIL OIL MAIN
BURNER TYPE CAPACITY CAPACITY MOTOR
CONSUMPTION HEATER SUPPLY
POWER

Min. Max. Min. Max. Min. Max.

kW kW VAC
kcal/h kcal/h kW kW kg/h kg/h

ONE STAGE HEAVY OIL BURNERS

ECO 2 O (S) C 1 77.200 144.750 90 168 8 15 0,37 1,5 3N 380

ECO 2 O (S) C 1a 96.500 250.900 112 292 10 26 0,37 1,5 3N 380
ECO 30 O(S) C 1 96.500 347.400 112 404 10 36 0,37 3,0 3N 380

ECO 30 O(S) C 1a 96.500 482.500 112 561 10 50 0,37 3,0 3N 380

ECO 45 O (S) C 1 173.700 559.700 202 651 18 58 1,10 3,0 3N 380
ECO 45 O (S) C 1a 173.700 772.000 202 898 18 80 1,50 6,0 3N 380
ECO 45 O (S) C 1b 241.250 868.500 281 1.010 25 90 1,50 6,0 3N 380

TWO STAGE HEAVY OIL BURNERS

ECO 30 O(S) C 2 96.500 386.000 112 449 10 40 0,37 3,0 3N 380

ECO 30 O(S) C 2a 96.500 627.250 112 729 10 65 0,75 3,0 3N 380

ECO 45 O (S) C 2 173.700 646.550 202 752 18 67 1,10 3,0 3N 380

ECO 45 O (S) C 2a 173.700 772.000 202 898 18 80 1,10 6,00 3N 380

ECO 45 O (S) C 2b 212.300 1.013.250 247 1.180 22 105 1,50 6,0 3N 380

MODULATING HEAVY OIL BURNERS

ECO 45 O (S) C 3b 212.300 1.013.250 247 1.180 22 105 1,50 6,0 3N 380

Hu Heavy Oil (S) = 9650 Kcal/kg

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Back Pressure-Capacity Diagrams

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11.01.2017 Rev. 05 23
Burner Dimensions

Flame Length and Diameter

Noise Level

Product operates within the range of 75 decibels max. and 80 decibels.

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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 2 OSC1 71 X 50 X 37 38
ECO 2 OSC1a 71 X 50 X 37 38
ECO 30 OSC1 90 X 57 X 40 60
ECO 30 OSC1a 90 X 57 X 40 60
ECO 30 OSC2 90 X 57 X 40 60
ECO 30 OSC2a 90 X 57 X 40 60
ECO 45 OSC1 105 X 60 X 46 82
ECO 45 OSC1a 105 X 60 X 46 82
ECO 45 OSC1b 105 X 60 X 46 82
ECO 45 OSC2 105 X 60 X 46 82
ECO 45 OSC2b 105 X 60 X 46 82
ECO 45 OSC3b 105 X 60 X 46 82

11.01.2017 Rev. 05 25
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.

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.

11.01.2017 Rev. 05 26
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

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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.

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 (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 (heavy oil: 18 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.

11.01.2017 Rev. 05 28
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

D Type

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

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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

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 Ø One Stage Heavy Oil Burner Fuel Circuit

Ø Two Stages Heavy Oil Burner Fuel Circuit

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 Ø Modulating Heavy Oil Burner Fuel Circuit

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 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.

11.01.2017 Rev. 05 33
 Ø Burner preheater

1. Fuel inlet
2. Fuel outlet
3. Discharge
4. Fixing plate
5. Resistance
6. Thermostat bulb pipe
7. Housing cover

Servomotor Adjustment

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.

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

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Emission Measurement

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

Ø CO < 100 mg/ kWh (93 ppm)

Ø %3 ≤ O2 ≤ %5
Ø NOx < 170 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

LOA 24

Ø Red led on: Indicates burner malfunction.

Ø If the burner switches to the fault mode, please wait at least 30 seconds and reset the program relay.

Press and hold the light button for 2 sec. to reset the program relay.

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 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.

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Heavy Oil Burner Fuel Ring Line

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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: 18 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.

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 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.

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Installation and Disassembly Instructions for Maintenance Purposes

1. Remove 3 bolts connecting the burner

body to the flame tube

2. Pull the burner body back

3. Remove and perform maintenance of fuel
nozzle, diffuser and ignition electrodes.

Be careful to connect the components correctly during

installation after maintenance.

Perform the installation by following the reverse of the method you have followed during
disassembly.

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TROUBLESHOOTING

Problem Cause Explanation-Suggestion

Fuel is cut or does not Fuel valve might be closed. Open the valve.
come
Check burner power supply. The fuse on the
Fuse failure main panel or the fuse on the burner might be
tripped.
Reset the thermal relay. Check adjustment of
Burner cannot be the thermal relay according to the current in
commissioned Relay failure
motor label. If the failure is not removed,
replace the thermal relay.
If there is a problem with the burner
Boiler thermostat, thermostats, pressure switches and steam
pressure switch tank this may be due to an unadjusted or
failure faulty water level device; adjust it and if
broken, replace it.

Fuel pressure error Circuit fuel pressure might have dropped.

Flame appears and goes Photocell may be faulty or contaminated.

into failure mode. Photocell failure
Remove and clean..

Program relay failure Replace it with a new one.

Program relay failure Replace it with a new one.

Burner starts up, but fails
after 10 seconds.

Check fan motor coils, motor contactor and

Fan motor failure
outlet from program relay.
Fuel valve might be closed. Supply fuel
Fuel valve, fuel pressure might be low. Check fuel inlet
pressure drop manometer.

Burner starts up, but fails

after 30 seconds. Ignition electrodes might be misadjusted or
Ignition electrode ignition cables might have come out of their
failure terminals. Adjust ignition electrodes with a
distance of 3-5 mm. between them.

Ensure sealing between the boiler cover and

Boiler cover is burner. If required, use insulating material
Sealing problem
overheating. between the boiler connecting flange and
boiler cover.

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 PERIODICAL FLUE GAS MEASUREMENT REPORT
Fuel CO O2 CO2 NOX Yield Flue
Consumption (ppm) (%) (ppm) (ppm) (%) Temp. Date Signature

(kg/h) (ºC)

11.01.2017 Rev. 05 42
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: +90 216 442 93 00
Fax: +90 216 370 45 03

Factory Contact Details

Türkgücü OSB
Bülent Ecevit Bulvarı No:11
ÇORLU/TEKİRDAĞ/TÜRKİYE
Tel: +90 282 685 44 80-81
Fax: +90 282 685 42 09

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.

11.01.2017 Rev. 05 43
NOTES

Please record and forward your measurements and observations to us

www.ecostar.com.tr

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