ECOSTAR ECO 1.0 Installation guide

19.10.2018 Rev. 07 www.ecostar.com.tr
SQUARE BODYMONOBLOCKGAS BURNERS
INSTALLATION, OPERATINGAND
MAINTENANCE MANUAL
ONESTAGEANDTWO-STAGEOPERATION
ECO1.0
ECO2.0
ECO30.0

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DEAR USER,
ECOSTAR ECO1.0,ECO 2.0,ECO 30.0SquareBodyGas burnersareprepared
andmanufacturedaccording tothelatesttechnicaldevelopmentsandsafetyrules.Itis
easytouse for our customers.
We recommendthat you readthis manual andsafety warningsthoroughlybeforethe
useof the deviceinordertoensure safe, cost effective andenvironmental-friendly use.
Ifyouencounteranyissuethat is notexplainedclearlyinthismanual oryoucould
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. TECHNICAL DATA ........................................................................................................................10
4.1. Capacity Table...........................................................................................................................10
4.2. BackPressure-Capacity Diagrams.............................................................................................11
4.3. Burner Dimensions.....................................................................................................................14
4.4. Gas Hood PressureLoss Diagram..............................................................................................15
4.5. FlameLength andDiameter.......................................................................................................16
4.6. NoiseLevel ................................................................................................................................16
5. BURNER HANDLING INFORMATION ........................................................................................17
6. INSTALLATION..............................................................................................................................18
6.1. Burner InstallationPicture..........................................................................................................18
7. COMMISSIONING..........................................................................................................................20
7.1. Before Commissioning...............................................................................................................20
7.1.1. Ignitionand Ionizasyon System..............................................................................................20
7.2. General Controls........................................................................................................................20
7.3. Combustion Adjustment.............................................................................................................21
7.3.1. Gas Adjustment......................................................................................................................21
7.3.1.1. MBDLESeries MonoblockGasValve..............................................................................21
7.3.1.2. MBZRD(LE) 405–412SeriesGasValve.........................................................................23
7.3.1.3. GB-LESeries Monoblock..................................................................................................24
7.4. Air pressure switch adjustment...................................................................................................24
7.5. Servomotor Adjustment.............................................................................................................25
7.6. EmissionMeasurement ..............................................................................................................26
7.7. Capacity Adjustment..................................................................................................................26
7.8. ProgramRelay............................................................................................................................26
7.9. FunctionControls and Adjustments...........................................................................................27
7.10. FinalChecks...........................................................................................................................27
7.11. Gas PassEquipmentRequiredinGasLine.............................................................................28
8. MAINTENANCE..............................................................................................................................29
8.1. MonthlyMaintenance.................................................................................................................29
8.2. Seasonal Maintenance................................................................................................................29
8.3. InstallationAndDisassembly InstructionsForMaintenancePurposes ......................................30
9. TROUBLESHOOTING....................................................................................................................32
10. PERIODICAL FLUEGASMEASUREMENTREPORT.............................................................33
11. AFTERSALES SERVICES..........................................................................................................34
12. NOTES..........................................................................................................................................35

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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.
Flametube adjustment
1stand 2ndStageselection switch
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 sensescent ofgas;
•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 at the whole adjustmentrange
between minimum,fullload, and ignitionload.
Use liftingdeviceorbelt for liftingfanmotor,ifnecessary
Duringthefirstcommissioning of theburner orincaseofany revisioncarriedout inthe electrical
systemor motor cablesbyanyreason, direction of the fanrotation must certainly bechecked by
theauthorized technicalservice.
For products thathavenotbeencomissioned or startedmorethan 6months,before activating the
servomotor;
In gas andairdampers,servomotor andair damper connectionsmust be checkedto ensurethat
theyare freerunninginspite ofimmobility 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
Mainand auxiliary equipmentand all componentsused inEcostargas burners are guaranteed for 1year
by TERMOISIS ST.A.Şstartingfromthe date ofcommissioning underthe maintenance,adjustment,
operating conditionsand relevant mechanic, chemical and thermaleffects explainedherein.
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 toincorrectdeviceselection,
•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 or our factory in case ofunavailability ofauthorized
service stations.
•Customers may apply consumer protectionarbitrator committeewith regardsto thisreport and
requestfor anexpert report.

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3. BURNER’SGENERAL FEATURES
ECOSTARgas burnersaremanufacturedsuch thattheyoperate in gaspressure ofmin.20 mbarand max.
300 mbar.,at -15%...+10% ofnominal voltage,between the ambient temperaturerange of -15ºC….+60˚C
and declaredcapacity and boiler pressurerangeswith Natural GasandLiquidPetrol Gas.
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 1.0
Assembly No
PartName Assembly No PartName
1 Housingcover 13 Boiler connectionflange
2 Relay 14 Gasket
3 Relaymainconnection shaft 15 Rubber gasket
4 Transformer 16 Gas intake pipe
5 Pressureswitch 17 Socket
6 Installationsheet 18 Air klappe
7 Fan 19 Caudal elbow
8 Spiralcasing 20 Gas tipadjustingnut
9 Filter 21 Bulls eye
10 Gas tip driveshaft 22 Motor
11 Gas tip 23 Gas valve
12 Flametube

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ECO 2.0-ECO 30.0
Assembly No
PartName Assembly No PartName
1 Housingcover 14 Flame tube
2 Relay15 Gas tip
3 Relaymainconnection shaft 16 Gas intake pipe
4 Transformer 17 Air klappe
5 Pressureswitch18 Servicecover
6 Servomotor 19 Elbow
7 Installationsheet 20 Bulls eye
8 Fan 21 Nipple
9 Spiralcasing 22 Motor
10 Relayignition transformer 23 Gas valve
11 Flametube extension 24 El. installationsheet
12 Gasket 25 Reset button
13 Boiler connectionflange

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4. TECHNICAL DATA
4.1. CapacityTable
SQUAREBODYMONOBLOCK GASBURNERS CAPACITYTABLE
BURNER TYPE CAPACITY CAPACITY NATURAL GAS
CONSUMPTION
LPGGAS
CONSUMPTION
FAN
MOTOR
POWER
MAIN
SUPPLY
Min.
Kcal/h Max. Kcal/h Min. kW Max. kW Min. Nm³/h Max. Nm³/h Min. Nm³/h Max. Nm³/h kW VAC
ONESTAGE GAS BURNERS
ECO1.0GC1 8.600 43.000 10 50 1,0 5,2 0,4 1,9 0,11 1N230
ECO1.0GC1 a 8.600 51.600 10 60 1,0 6,3 0,8 3,8 0,11 1N230
ECO1.0GC1 b 17.200 73.100 20 85 2,1 8,9 1,8 4,8 0,11 1N230
ECO1.0GC1 c 17.200 86.000 20 100 2,1 10,4 2,8 5,8 0,11 1N230
ECO2.0GC1 43.000 129.000 50 150 5,2 15,6 1,9 5,7 0,11 1N230
ECO2.0GC1a 60.200 172.000 70 200 7,3 20,8 2,7 7,6 0,11 1N230
ECO2.0GC1b 77.400 215.000 90 250 9,4 26,1 3,4 9,6 0,11 1N230
ECO2.0GC1c 103.200 301.000 120 350 12,5 36,5 4,6 13,4 0,15 1N230
TWO STAGEGAS BURNERS
ECO2.0GC2 43.000 129.000 50 150 5,2 15,6 1,9 5,7 0,11 1N230
ECO2.0GC2a 60.200 172.000 70 200 7,3 20,8 2,7 7,6 0,11 1N230
ECO2.0GC2b 86.000 215.000 100 250 10,4 26,1 3,8 9,6 0,11 1N230
ECO2.0GC2c 103.200 301.000 120 350 12,5 36,5 4,6 13,4 0,15 1N230
ECO30.0GC2 86.000 309.600 100 360 10,4 37,5 3,8 13,8 0,25 1N230
ECO30.0GC2a 129.000 387.000 150 450 15,6 46,9 5,7 17,2 0,25 1N230
ECO30.0GC2b 146.200 473.000 170 550 17,7 57,3 6,5 21,0 0,55 1N230
ECO30.0GC2c 163.400 533.200 190 620 19,8 64,6 7,3 23,7 0,55 1N230
HuNatural Gas=8250 kcal/Nm3
HuLPG=22500 kcal/Nm3

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4.2. BackPressure-Capacity Diagrams

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4.3. Burner Dimensions

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

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4.5. Flame Lengthand Diameter
4.6. Noise Level
Product operateswithinthe range of 68decibelsmax.and70 decibels.

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5. BURNER HANDLINGINFORMATION
•Lifttheproduct byholdingthehandlesasseeninthe picture.
•Prevent strong impactsontopoftheproductandvibrationwhile handlingtheproduct.
•Donotleavetheproductinwet environment.
Dimensions of the box usedfor handling
Burner LxW x H (cm) Weight(kg)
ECO1.0 70X 33 X35 24
ECO2.0
65 X36X47
36
ECO30.0
75 X43X54
36

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6. INSTALLATION
6.1. Burner Installation Picture
1- DriftBolts
2- BurnerBody
3- Boiler Connection Flange
4- Gasket
5- Boiler Studs
1- BurnerBody
2- Boiler Connection Flange
3- Nut
4- Bolt
You must definitely ensure sealingbetweenboilerand burner!
Devicemustbeshipped inoriginal packaging!
Donot lift the deviceholding fromgasvalve,impulse pipes orpressure switch during
installation!
Clean theinsideof fuel linethoroughly beforeinstallingthe burnerto thefuelline.Any
damage that may occur due to solidobjectsand metal particlesfromthe fuel lineshallnotbe
covered by our company.

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1- GasHead Adjusting Nut
2- GasHead Drive Shaft
•When gas head adjustingnutisrotated clockwise,gashead is withdrawnandoperationathigh
capacity is ensured.
•When gas head adjustingnutisrotated anti-clockwise,gashead moves forward and capacity is
reduced.
While installing the burnerin reverseflamefront mirror boilers,flametubetipmustbeadjusted
suchthat itgetsinside by 50 mm-100mm fromsmokepipes(50mm≤A≤100mm). Otherwiseflue
gastemperaturewillrise andfuel consumption willincrease.