ECOSTAR ECO 1 Installation guide

09.10.2018 Rev.10
www.ecostar.com.tr
MONOBLOCKGAS BURNERS INSTALLATION,
OPERATING ANDMAINTENANCEMANUAL
ONE-STAGE, TWO-STAGEANDMODULATINGOPERATION
ECO1
ECO2
ECO30
ECO45

09.10.2018 Rev.10 1
DEAR USER,
ECOSTAR ECO1,ECO 2,ECO 30,ECO 45GAS burnersarepreparedand
manufacturedaccordingto thelatesttechnical developmentsand safetyrules. Itis easyto
useforourcustomers.
We recommendthat you readthis manual andsafety warningsthoroughlybeforethe
useof the deviceinordertoensure safe, cost effective andenvironmental-friendly use.
Ifyou encounterany issuethat isnotexplainedclearly inthismanual or youcould
not understand,please contact withour service department.
We thank youforchoosingECOSTAR brand.
EcostarGas Burners are manufacturedinaccordancewithTSEN 676+A2standards.
This OperatingManualisanintegralpartof theburnerand must bemaintainedin a
plasticdossierand hungat a clearlyvisible placeinthe burnerroom.
TERMO ISI S STEMLER SAN.VET C.A.Ş.
EsentepeMah.MilangazCad. No:75 K:3
KartalMonumentoPlaza
Kartal/ STANBUL/TÜRK YE
Tel: [phone]
Fax:[phone]
www.ecostar.com.tr
e-mail:[e-mail]

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CONTENTS
1. WARNINGS .......................................................................................................................................3
1.1. Warning Symbolsand Descriptions .............................................................................................3
1.2. General Safety Rules....................................................................................................................4
2. TERMS OFWARRANTY..................................................................................................................6
2.1. Out ofWarranty Conditions........................................................................................................6
3. BURNER’SGENERALFEATURES.................................................................................................7
3.1. Purposeof Use and Work Limits ofBurners................................................................................7
3.2. Code Key......................................................................................................................................7
3.3. Burner Components......................................................................................................................8
4. GAS,FLUEGASANDHEATING WATER SCHEMA..................................................................11
5. TECHNICAL DATA ........................................................................................................................12
5.1. Capacity Table...........................................................................................................................12
5.2. BackPressure-Capacity Diagrams.............................................................................................13
5.3. Burner Dimensions.....................................................................................................................14
5.4. Gas Hood PressureLoss Diagram..............................................................................................15
5.5. FlameLength andDiameter.......................................................................................................18
5.6. NoiseLevel ................................................................................................................................18
6. BURNER HANDLING INFORMATION ........................................................................................18
7. INSTALLATION..............................................................................................................................20
7.1. Burner InstallationPicture..........................................................................................................20
8. COMMISSIONING..........................................................................................................................21
8.1. Before Commissioning...............................................................................................................21
8.1.1. Ignitionand Ionizasyon System..............................................................................................21
8.2. General Controls........................................................................................................................22
8.3. Combustion Adjustment.............................................................................................................23
8.3.1. Gas Adjustment......................................................................................................................23
8.3.1.1. VGD 20 4011 -5011SeriesGas Valve...............................................................................23
8.3.1.2. MBDLESeries MonoblockGasValve..............................................................................23
8.4. AirPressure SwitchAdjustment.................................................................................................26
8.5. Servomotor Adjustment.............................................................................................................26
8.6. EmissionMeasurement ..............................................................................................................27
8.7. Capacity Adjustment..................................................................................................................27
8.8. ProgramRelay............................................................................................................................28
8.9. FunctionControls and Adjustments...........................................................................................28
8.10. FinalChecks...........................................................................................................................28
8.11. Gas PassEquipmentRequiredinGasLine.............................................................................31
9. MAINTENANCE..............................................................................................................................32
9.1. MonthlyMaintenance.................................................................................................................32
9.2. Seasonal Maintenance................................................................................................................32
9.3. InstallationAndDisassembly InstructionsForMaintenancePurposes ......................................33
10. TROUBLESHOOTING.................................................................................................................36
11. PERIODICAL FLUEGASMEASUREMENTREPORT.............................................................37
12. AFTER-SALES SERVICES..........................................................................................................38
13. NOTES..........................................................................................................................................39

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1. WARNINGS
1.1. WarningSymbolsandDescriptions
Symbols SymbolDescriptions
Important information and usefulhints.
Warning of danger to lifeor property.
Warningofelectrical voltage.
Product handling information.
PFImpulseconnection detectingcombustion chamberpressure
PL Impulseconnection detecting combustion airpressure
PBR Impulse connection detecting burner gas head
CLEANTHE GASBURNER.
CLEAN GAS LINE.
ИСТАЯ ЛИНИЯ ГАЗ.
"Cleanthegasline" warningongasline.
Electricmotor direction ofrotation
Carry inanupright position.Fragile Item.Protectagainstwater.

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1.2. General Safety Rules
•All personnel engagedininstallation,disassembly,commissioning,operation,control,
maintenanceand repair should havereceived thenecessarytrainingandfullyread and understood
thismanual.
•Nochangesthatmightdamage thesafety oftheburnerunit must be madeby persons and/or
organizations onthe burnerunit.
•All operation,commissioning and installation works (except for burningadjustment) should be
carried out when theburnerisnotoperating and afterdisconnecting the power supply.
Noncompliancewith theserules may lead to seriousbodilyinjuriesand even death by electrical
shocksoruncontrolled flameformation.
•Repairs concerned withsafety elementsshould becarriedout only bythemanufacturing company.
•The deviceshouldnever be usedbychildren,mentally handicapped and inexperienced persons.
•Children mustnot be allowed to playwith the device.
•Keep the deviceaway fromexplosiveand flammable materials.
•Devicemustintakeair,ventilation andair discharge holesmust not beclosed.
Ifyou sensegas leakage;
•Shutdownvalvesofall gasdevices.
•Open all doorsand windows.
•Donotturnonelectricdevices or donot turn themoffifthey areworking.
•Donotuseburner derived tools such as match andlighter.
•Informthe gascompany.
Do not store any inflammablematerialsinboiler room.
Wear hearingprotectorsifthereisnoiseinboiler room.
Incaseoffıreorother emergency;
Switchoff the mainswitch
Closethemain fuel shut-offvalveoutside the plant.
Takeappropriate actions

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The burner installation must becarried out inaccordance withtheinstructions.Vibrationcan
damage the burner and itscomponents.
Keep boiler doorsclosedwhilestartingburner and duringburner operation.
Check combustionvalues tobe correct byusingflue gasanalyzer atthewholeadjustmentrange
between minimum,fullload, and ignitionload.
Use liftingdeviceorbelt for liftingfanmotor,ifnecessary
During thefirstcommissioning oftheburner or incase of any revisioncarried out inthe electrical
systemor motor cables byanyreason,directionofthefan rotation mustcertainly be checkedby
the authorizedtechnical service.
Forproducts thathave notbeen comissioned orstarted morethan6months,beforeactivating the
servomotor;
Ingasandair dampers, servomotor andair damper connections must be checkedtoensurethat
they are free running inspite of immobility and oilfreezing.
BURNER ROOM
Installthe burner inasuitable room/floor withminimumexternalairopenings and sufficient to
ensu reperfect combustion,incompliancewith current regulations.
Never obstruct airopenings oftheburner room,burner fan intake vents or airducts inorder to
prevent:
a.Thebuildupoftoxic /explosive gas mixtures inthe burner room,
b.Combustionwith insufficient air, resultingin hazardous, anti-economical and polluting ope-
ration.
Theburner mustbealways protectedfromrain,snowand frosttoprevent corrosionand paint
deformations.
Keeptheburner roomclean and freeofsolidvolatile substances,which could besuckedintothefan
and clog theinternalburnerorcombustion head airducts.

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2. TERMS OFWARRANTY
Main andauxiliary equipment and allcomponents used inEcostar gasburners areguaranteed for 1
year by TERMOISIS ST.A.Şstartingfromthe date ofcommissioning underthemaintenance,
adjustment, operatingconditionsand relevant mechanic,chemical and thermal effectsexplainedherein.
Pleasenote that thiswarranty isonlyvalidifthedevice(s)is commissioned and maintained by our
authorizedservices.
Our company reserves the right to makeanymodificationson the product and all instructions
thereof for improvement purposes.
2.1. OutofWarranty Conditions
•Any damage arising out oforin relation to customers’non-complianceto their responsibilities
with regardstoinstallation, commissioning,operation andmaintenance,
•Any damage arising out ofor inrelation to commissioning,repairsand maintenancecarried out by
unauthorized services,
•Any damage thatmayoccur during transportationorstorageofthe product,
•Not preserving the productinits original packaginguntiltheinstallationstage,
•Incorrectand poorelectrical connections,Failuresdue toincorrect voltage applications,frequent
repetition ofvoltage fluctuations,
•Any damagethat may occur as aresultofincorrect fuel usage or,foreign substancesinthe fuel
used or using ofthe productwithoutanyfuel,
•Any damage that mayoccur dueto foreignparticles entered into theproduct during installation
andoperation,
•Failuresdue toincorrect deviceselection,
•Any damage tounitduetonatural disasters,
•Deviceswithoutany warranty certificates,
•Warranty Certificateswithoutthe stampand signature oftheauthorizeddealer or service,
•Devices with anyfalsification onthewarranty certificate or without an originalserial number.
•The risks during transportation ofdevice undertheresponsibilityof customerbelong to the
customer.
•Presenceofmisuse faults areindicated in the reportsissued by authorized servicestations or our
authorizedagent,dealer,representative orour factory in case of unavailability ofauthorized
service stations.
•Customers may apply consumer protectionarbitrator committeewith regardsto thisreport and
requestfor anexpert report.

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3. BURNER’SGENERAL FEATURES
ECOSTARgasburnersare manufacturedsuchthattheyoperateingaspressure ofmin.20mbar
and max. 300 mbar., at15%...+10% of nominal voltage, betweentheambient temperature range of -
15ºC….+60˚Cand declared capacity andboiler pressure ranges withNaturalGasandLiquid PetrolGas.
3.1. Purpose ofUseand WorkLimitsof Burners
•Thisproduct works at any load value equivalentto itsmax.capacity or covered by itscapacity
range;
-In hotwater andsteamboilers,
-In directand indirecthot airgenerators,
-Industrialappliancesoperatingattemperature below 600 0C,
--15 0C…+60 0Cambient temperature range,
-1N230VAC/3N 380VAC/50Hz feed voltage(-%15…+%10) values,
-Max.95%relative humidity,
-In well-ventilatedopenandclosed spaces compatible withprotection class IP40.
-Operation with Naturalgasand LPG.
This devicemust never beoperatedwithopenflame!
3.2. CodeKey

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3.3. Burner Components
ECO 1
AssemblyNo
PartName AssemblyNo PartName
1 Body Group 11 Air Damper
2 Fan 12 GasPipeConnection Flange
3 CombustionHead 13 Transformer-Relay Plate
4 FanMotor 14 Gasket
5 FlameTube 15 PressureSwitch Adaptor
6 Control Relay 16 Observation Glass
7 Transformer 17 Boiler ConnectionFlange
8 PressureSwitch 18 IgnitionElectrode
9 GasPipe 19 Ionization Electrode
10 Damper Gauge 20 GasValve

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ECO 2
Assembly NoPartName Assembly NoPartName
1 Body Group 14 PressureSwitch
2 FlameTube 15 PressureSwitchAdaptor
3 Gasket 16 Fan
4 FlameTubeExtension 17 Purger
5 Boiler ConnectionFlange 18 Relay MountingPlate
6 Gasket 19 Transformer
7 GasIntake Pipe 20 PressureSwitchAdaptor
8 CombustionHead 21 Fan Motor
9 Diffuser 22 Observation Glass
10 Ionization Electrode 23 HandlingShaft
11 Ignition Electrode 24 ControlRelay
12 Air Damper 25 Gas Valve
13 DamperGauge

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ECO 30-45
Assembly No
PartName AssemblyNo PartName
1 Body Group 16 PressureSwitchAdaptor
2 Gasket 17 Air Damper Long
3 FlameTube 18 Air Damper Short
4 FlameTubeExtension 19 Servomotor Coupling
5 Fan Motor 20 Servomotor
6 Fan 21 Damper Motion Rod
7 Transformer 22 Air Damper Motion Transfer Rod
8 Electrical PanelMountingPlate 23 Gas Intake Pipe
9 Electrical Panel 24 Combustion Head
10 HandlingShaft 25 Diffuser
11 Fixing Plate 26 Ionization Electrode
12 ObservationGlass 27 Ignition Electrode
13 Purger 28 Boiler Connection Flange
14 PressureSwitch 29 Gasket
15 PressureSwitchAdaptor 30 Gas Valve

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4. GAS, FLUE GAS AND HEATING WATERSCHEMA

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5. TECHNICAL DATA
5.1. CapacityTable
Min.
kcal/h Max. kcal/h
Min.
kW
Max.
kW
Min.
Nm³/h Max. Nm³/h Min. Nm³/h Max. Nm³/h kW VAC
ECO1GC1 8.600 43.000 10 50 1,0 5,2 0,4 1,9 0,11 1N230
ECO1GC1a 17.200 86.000 20 100 2,1 10,4 0,8 3,8 0,11 1N230
ECO2GC1 51.600 172.000 60 200 6,3 20,8 2,3 7,6 0,15 1N230
ECO2GC1a 86.000 299.280 100 348 10,4 36,3 3,8 13,3 0,15 1N230
ECO2GC2 51.600 172.000 60 200 6,3 20,8 2,3 7,6 0,15 1N230
ECO2GC2 a 86.000 299.280 100 348 10,4 36,3 3,8 13,3 0,15 1N230
ECO30 GC2 163.400 387.000 190 450 19,8 46,9 7,3 17,2 0,37 1N230
ECO30 GC2a 223.600 602.000 260 700 27,1 73,0 9,9 26,8 0,75 3N380
ECO45 GC2 288.100 645.000 335 750 34,9 78,2 12,8 28,7 0,75 3N380
ECO45 GC2/L 288.100 749.920 335 872 34,9 90,9 12,8 33,3 0,75 3N380
ECO45 GC2a 331.100 928.800 385 1.080 40,1 112,6 14,7 41,3 1,10 3N380
ECO45 GC2b 331.100 1.075.000 385 1.250 40,1 130,3 14,7 47,8 1,50 3N380
ECO2GC3 51.600 172.000 60 200 6,3 20,8 2,3 7,6 0,15 1N230
ECO2GC3 a 86.000 299.280 100 348 10,4 36,3 3,8 13,3 0,15 1N230
ECO30 GC3 163.400 387.000 190 450 19,8 46,9 7,3 17,2 0,37 1N230
ECO30 GC3a 223.600 602.000 260 700 27,1 73,0 9,9 26,8 0,75 3N380
ECO45 GC3 288.100 645.000 335 750 34,9 78,2 12,8 28,7 0,75 3N380
ECO45 GC3/L 288.100 749.920 335 872 34,9 90,9 12,8 33,3 0,75 3N380
ECO45 GC3a 331.100 928.800 385 1.080 40,1 112,6 14,7 41,3 1,10 3N380
ECO45 GC3b 331.100 1.075.000 385 1.250 40,1 130,3 14,7 47,8 1,50 3N380
MODULATINGGASBURNERS
TWOSTAGEGASBURNERS
ONE STAGEGASBURNERS
GASBURNERSCAPACITYTABLE
BURNERTYPE CAPACITY CAPACITY NATURALGAS
CONSUMPTION LPGGAS CONSUMPTION FANMOTOR POWER MAIN SUPPLY
HuNatural Gas=8250 kcal/Nm3
HuLPG=22500 kcal/Nm3

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5.2. BackPressure-Capacity Diagrams

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5.3. Burner Dimensions

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5.4. GasHoodPressureLossDiagram
Gashood pressure loss measurements are conducted in atmospheric pressure.Consider the
below data while conducting measurement incounter pressure boilers.
Pm:Gashood pressure while burner isconnected to the boiler andworking
PF:Combustionchamber pressure
PBr:Burner netgashood pressure
PBr =Pm-PF

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5.5. Flame Lengthand Diameter
5.6. Noise Level
Product operateswithinthe range of 75decibelsmax.and85 decibels.
6. BURNER HANDLINGINFORMATION
•Lifttheproduct byholdingthehandlesasseeninthe picture.
•Prevent strong impactsontopoftheproductandvibrationwhile handlingtheproduct.
•Donotleavetheproductinwet environment.

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Dimensionsofthe box used for handling
Burner Lx W xH(cm) Weight(kg)
ECO1 GC1(300 mbar) 65X 43X37 18
ECO1 GC1a(300mbar) 65X 43X37 18
ECO2 GC1(300 mbar) 65X 43X37 22
ECO2 GC1(21 mbar) 65X 43X37 26
ECO2 GC1a(300mbar) 65X 43X37 22
ECO2 GC1a(21 mbar) 65X 43X37 26
ECO2 GC2(300 mbar) 65X 43X37 24
ECO2 GC2(21 mbar) 65X 43X37 24
ECO2 GC2a(21 mbar) 65X 43X37 26
ECO2 GC2a(300mbar) 65X 43X37 24
ECO2 GC3(300 mbar)
65X 43X37
26
ECO2 GC3a(300mbar)
65X 43X37
26
ECO30 GC2(300mbar) 80X 54X40 40
ECO30 GC2(21mbar) 80X 54X40 40
ECO30 GC2a(300mbar) 80X 54X40 46
ECO30 GC2a(21mbar) 80X 54 X40 50
ECO30 GC3(300mbar) 80X 54X40 42
ECO30 GC3(21mbar) 80X 54X40 42
ECO30 GC3a(300mbar) 80X 54X40 48
ECO30 GC3a(21mbar) 81X 54X40 44
ECO45 GC2(300mbar) 97X 56X45 52
ECO45 GC2(21mbar) 97X 54X40 56
ECO45 GC2a(300mbar) 97X 54X45 56
ECO45 GC2a(21mbar) 97X 54X45 60
ECO45 GC2b(300 mbar) 97X 54X45 62
ECO45 GC2L(300mbar) 97X 56X45 52
ECO45 GC2L(21mbar) 97X 54X40 56
ECO45 GC3(21mbar) 97X 54X45 58
ECO45 GC3a(300mbar) 97X 54X45 60
ECO45 GC3b(300 mbar) 97X 54X45 64
ECO45 GC3L(300mbar) 97X 54X45 54
ECO45 GC3L(21mbar) 97X 54X45 58