ECOSTAR ECO 30 Installation guide

02.12.2022 Rev. 12
www.ecostar.com.tr
MONOBLOCKDUAL FUEL(GAS-LIGHT OIL)
BURNERSINSTALLATION,OPERATING AND
MAINTENANCE MANUAL
ONE STAGE, TWO-STAGE ANDMODULATING OPERATION
ECO 2
ECO 30
ECO 45

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DEAR USER,
ECOSTAR ECO 2, ECO 30, ECO 45 Dual Fuel (Gas-Light Oil) burners are
preparedand 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 safetywarnings thoroughly before the
use of the device in order to ensuresafe, cost effective and environmental-friendly use.
If you encounterany issue that is not explained clearly inthis manual oryou could
not understand, please contact with our service department.
We thank you for choosing ECOSTAR brand.
Ecostar Dual Fuel (Gas-Light Oil) Burners aremanufactured in compliance with TS
EN 267 and TS EN 676 + A2 standards.
This Operating Manual is an integral partof the burner andmust bemaintained in a
plastic dossier and hung at a clearly visible place in the burner room.
TERMO ISI S STEMLER SAN.VE T C.A.Ş.
Esentepe Mah.MilangazCad. No:75 K:3
Kartal Monumento Plaza
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 Symbols and Descriptions............................................................................................... 3
1.2. General Safety Rules...................................................................................................................... 4
2. TERMSOFWARRANTY.................................................................................................................... 6
2.1. Out of Warranty Conditions.......................................................................................................... 6
3. BURNER’SGENERAL FEATURES................................................................................................... 7
3.1. Purposeof Useand Work Limits of Burners................................................................................. 7
3.2. CodeKey........................................................................................................................................ 7
3.3. Burner Components........................................................................................................................ 9
4. GAS, FLUE GASAND HEATING WATER SCHEMA................................................................... 15
5. TECHNICAL DATA .......................................................................................................................... 16
5.1. Capacity Table.............................................................................................................................. 16
5.2. Back Pressure-Capacity Diagrams............................................................................................... 17
5.3. Burner Dimensions....................................................................................................................... 18
5.4. Gas HoodPressureLoss Diagram................................................................................................ 19
5.5. FlameLength and Diameter......................................................................................................... 20
5.6. NoiseLevel................................................................................................................................... 20
6. BURNER HANDLING INFORMATION.......................................................................................... 21
7. INSTALLATION................................................................................................................................ 22
7.1. Burner Installation Picture............................................................................................................ 22
7.2. In reverseflamefront mirror boilers............................................................................................ 23
7.3. In cylindrical (straight flame)boilers........................................................................................... 23
8. COMMISSIONING............................................................................................................................. 24
8.1. BeforeCommissioning................................................................................................................. 24
8.2. General Controls .......................................................................................................................... 24
8.3. Combustion Adjustment............................................................................................................... 26
8.4. FuelPumps................................................................................................................................... 26
8.5. Gas Adjustment............................................................................................................................ 31
8.5.1. VGD 20 4011 - 5011 Series Gas Valve.................................................................................... 31
8.5.2. MB DLE Series Monoblock Gas Valve................................................................................... 32
8.5.3. MB ZRD(LE) 405 –412 Series Gas Valve.............................................................................. 34
8.6. Air PressureSwitchAdjustment .................................................................................................. 35
8.7. Servomotor Adjustment............................................................................................................... 35
8.8. Emission Measurement................................................................................................................ 36
8.9. ProgramRelay.............................................................................................................................. 36
8.10. Light Oil Burner Fuel Ring Line.............................................................................................. 39
8.11. Gas Pass Equipment Requiredin Gas Line.............................................................................. 40
9. MAINTENANCE................................................................................................................................ 41
9.1. Weekly Maintenance.................................................................................................................... 41
9.2. Monthly Maintenance................................................................................................................... 41
9.3. SeasonalMaintenance.................................................................................................................. 42
10. TROUBLESHOOTING................................................................................................................... 43
11. PERIODICAL FLUE GASMEASUREMENT REPORT.............................................................. 44
12. AFTER SALESSERVICES............................................................................................................ 45
13. NOTES............................................................................................................................................. 46

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1. WARNINGS
1.1. WarningSymbols and Descriptions
Symbols Symbol Descriptions
Importantinformation and useful hints.
Warning of danger to lifeor property.
Warning of electrical voltage.
Product handling information.
PFImpulseconnection detecting combustion chamberpressure
PL Impulseconnection detecting combustion air pressure
PBR Impulseconnection detecting burner gashead
CLEAN THE GASBURNER.
CLEAN GASLINE.
ИСТАЯ ЛИНИЯ ГАЗ.
"Cleanthegas line"warning on gas line.
Electricmotor direction of rotation
Carry in an upright position. FragileItem. Protect against water.

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1.2. General Safety Rules
•All personnelengagedininstallation, disassembly, commissioning, operation,control,
maintenance and repair shouldhavereceivedthenecessary training, qualifiedand fully readand
understood this manual.
•No changesthatmight damagethesafety of theburnerunit must bemadeby persons and/or
organizations on theburner unit.
•All operation, commissioning and installation works (except for burning adjustment) should be
carriedout whentheburneris not operatingand afterdisconnecting thepowersupply.
Noncompliancewiththeserulesmayleadtoserious bodilyinjuriesand evendeathby electrical
shocks or uncontrolled flameformation.
•Repairs concerned with safety elements should becarried outonly by themanufacturing company.
•Thedeviceshould never beused by children, mentally handicappedand inexperienced persons.
•Childrenmust not beallowedto play with thedevice.
•Keep thedeviceaway from explosiveand flammablematerials.
•Device must intakeair, ventilation and air dischargeholesmust not beclosed.
If yousensegas leakage;
•Shut down valves of all gas devices.
•Open all doors and windows.
•Do not turn on electricdevices or do not turn themoff if theyareworking.
•Do not useburner derivedtools such as match andlighter.
•Inform thegas company.
Do not storeany inflammablematerials in boilerroom.
Wear hearing protectors if thereis noisein boiler room.
Incaseof fıre orotheremergency;
Switch offthemain switch
Closethemain fuelshut-off valveoutsidetheplant.
Takeappropriateactions

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Theburner installation must becarried out in accordance with theinstructions. Vibration can
damagetheburnerand its components.
Keep boiler doors closed whilestarting burner and during burner operation.
Check combustion values to becorrectby using fluegas analyzer at thewholeadjustment range
betweenminimum,full load, and ignition load.
Useliftingdeviceor belt for lifting fanmotor, if necessary
During thefirst commissioning of theburner or in caseof any revision carriedout in theelectrical
system or motor cables by anyreason, direction of thefan rotation mustcertainly bechecked by
theauthorizedtechnical service.
For products that havenot been comissioned or startedmorethan 6 months, beforeactivating the
servomotor;
In gas, air dampers and oil regulators, servomotor and damper connections must bechecked to
ensurethat theyarefree running in spiteof immobility and oil freezing.
BURNERROOM
Install theburner in asuitableroom/floor with minimum externalair openings and sufficient to
ensu reperfectcombustion, incompliance with current regulations.
Never obstructair openings of theburner room, burnerfan intakevents or air ducts in order to
prevent:
a.Thebuild up of toxic/explosivegas mixtures in theburner room,
b.Combustion with insufficient air,resulting in hazardous, anti-economicaland polluting ope-
ration.
Theburner must bealways protected from rain, snow and frost to prevent corrosion and paint
deformations.
Keeptheburner room clean and freeof solid volatilesubstances, which could besucked into thefan
and clog theinternalburner or combustion head air ducts.

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2. TERMS OF WARRANTY
Main andauxiliaryequipment and allcomponents usedinEcostarDualFuel(Gas-Light Oil)
burners areguaranteedfor 1yearby TERMO ISIS ST. A.Şstartingfrom thedateofcommissioning
underthemaintenance,adjustment,operating conditions and relevant mechanic,chemicaland thermal
effects explained herein.
Pleasenotethatthis warranty isonly validif thedevice(s) is commissionedand maintainedby our
authorizedservices.
Our company reservestheright to makeany modifications on theproductand all instructions
thereof forimprovement purposes.
2.1. Out of Warranty Conditions
•Any damagearisingout of orin relation to customers’ non-compliance to their responsibilities
with regards to installation, commissioning, operation and maintenance,
•Any damagearising out of or in relation to commissioning, repairs and maintenance carriedout by
unauthorized services,
•Any damagethat may occur during transportation or storageof theproduct,
•Not preserving theproduct in its originalpackaging until theinstallation stage,
•Incorrectand poor electricalconnections, Failuresdueto incorrectvoltageapplications,frequent
repetition of voltagefluctuations,
•Any damagethatmayoccur asaresultof incorrectfuelusageor, foreign substancesinthefuel
used or using of theproduct without anyfuel,
•Any damagethatmayoccur dueto foreign particlesenteredinto theproductduring installation
and operation,
•Failures dueto incorrect deviceselection,
•Any damageto unit dueto natural disasters,
•Devices without anywarranty certificates,
•Warranty Certificates without thestamp and signatureof theauthorizeddealer or service,
•Devices with any falsification on thewarranty certificateor without anoriginal serial number.
•Therisks during transportation of device undertheresponsibilityof customerbelong to the
customer.
•Presence of misusefaults areindicatedinthereports issuedby authorizedservicestations or our
authorizedagent, dealer, representativeor our factory incaseof unavailability of authorized
service stations.
•Customersmayapply consumerprotection arbitrator committee withregards to this report and
request for an expert report.

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3. BURNER’SGENERAL FEATURES
ECOSTARDualFuel(Gas-LightOil) burners aredesignedandmanufacturedto workwith liquid
fuelwith max. 2.5- 6Cst (mm2/s) viscosity. and NaturalGasand Liquid Petroleum Gasatgaspressures
of min.20mbar, max.300 mbarandat-%15to +%10 of nominalvoltages, underenvironmental
temperatureof max.60˚C with ratedcapacity and burner pressureranges.
3.1. Purposeof Useand Work Limits of Burners
•This productworks atany loadvalueequivalentto its max. capacityor coveredby its capacity
range;
-In hot water and steam boilers,
-In direct and indirect hot air generators,
-Industrialappliances operatingat temperaturebelow 600 0C,
--15 0C…+60 0C ambient temperaturerange,
-1N 230 VAC/3N 380VAC /50 Hzfeed voltage(-%15…+%10) values,
-Max. 95% relativehumidity,
-In well-ventilated open and closed spacescompatiblewith protection class IP40.
This devicemust never beoperated withopen flame!
3.2. Code Key

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Temperaturechangeof fuelusedin ECOSTAR DualFuel(Gas-Light Oil) burners dependent on
viscosity

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3.3. Burner Components
ECO 2 KLC1-1a

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Assembly No Part Name Assembly No Part Name
1 Bodygroup 16 Fuelnozzle
2 Klingeritgasket 17 Combustionhead
3 Flametube 18 Electrode connectionplate
4 Boiler connectionflange 19 Ignitionelectrode
5 Gasket 20 Gas inletpipe
6 Flametube extension 21 Gas solenoid valve
7 Fan 22 Air pressureswitch
8 Motor 23 Pressureswitchadaptor
9 Electricalpanel connectionplate 24 Pressureswitchadaptor
10 Electricalpanel 25 Air dampergauge
11 Handlingrod 26 Air damper
12 Observationglass 27 Fuelpipe
13 Ignitiontransformer 28 Pump
14 Photocell 29 Motor
15 Purger 30 Pumpmotor console

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ECO 45 KLC2-2a-2b

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Assembly No Part Name Assembly No Part Name
1 Bodygroup 23 Gas Ignitionelectrode
2 Klingeritgasket 24 Electrode connectionplate
3 Flametube 25 Liquidfuel Ignitionelectrode
4 Boiler connectionflange 26 Fuelnozzle
5 Gasket 27 Lance
6 Air Adjustment Mechanism 28 Solenoidvalve
7 Fan 29 Manometer
8 Motor 30 Ball valve
9 Electricalpanel connectionplate 31 Fuelpipes
10 Electricalpanel 32 Air dampermotionrod
11 Handlingrodfixingplate 33 Air dampertransmissionrod
12 Handlingrod 34 Air damper
13 Observationglass 35 Air damper
14 Purger 36 Servomotor coupling
15 VPS 37 Servomotor
16 Gas solenoid valve 38 Air pressureswitch
17 Gas inletpipe 39 Pressureswitchadaptor
18 Transformer connectionplate 40 Pressureswitchadaptor
19 Transformer connectionplate(dual) 41 Pump
20 Ignitiontransformer 42 Pumpmotor console
21 Photocell 43 Motor
22 Combustionhead

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ECO 45 KLC3b

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Assembly No Part Name Assembly No Part Name
1 Bodygroup 24 Electrode connectionplate
2 Klingeritgasket 25 Liquidfuel Ignitionelectrode
3 Flametube 26 Fuelnozzle
4 Boiler connectionflange 27 Centring wedge
5 Gasket 28 Lance
6 Air Adjustment Mechanism 29 Solenoidvalveconnectionplate
7 Fan 30 Solenoidvalve
8 Motor 31 Manometer
9 Electricalpanel connectionplate 32 Ball valve
10 Electricalpanel 33 Fuelpipes
11 Handlingrodfixingplate 34 Air dampermotionrod
12 Handlingrod 35 Air dampertransmissionrod
13 Observationglass 36 Air damper
14 Purger 37 Air damper
15 VPS 38 Air dumperadjustment rod
16 Gas solenoid valve 39 Air pressureswitch
17 Gas inletpipe 40 Pressureswitchadaptor
18 Transformer connectionplate 41 Pressureswitchadaptor
19 Transformer connectionplate(dual) 42 Disc consolegroup
20 Ignitiontransformer 43 Servomotor
21 Photocell 44 Pump
22 Combustionhead 45 Pumpmotor console
23 Gas Ignitionelectrode 46 Motor

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4. GAS, FLUE GASAND HEATING WATER SCHEMA

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5. TECHNICAL DATA
5.1. Capacity Table
Min.
kcal/h
Max.
kcal/h
Min.
kW Max. kW Min. Nm3/h Max. Nm 3/h
Min.
kcal/h
Max.
kcal/h Min. kW Max. kW Min. kg/h Max. kg/h kW kW VAC
ECO2 KL C1 51.600 172.000 60 200 6,3 20,8 77.400 144.480 90 168 7,6 14,2 0,15 0,15 1N240
ECO2 KL C1 a 86.000 299.280 100 348 10,4 36,3 96.320 251.120 112 292 9,4 24,6 0,15 0,15 1N240
ECO45 KLC2 172.000 645.000 200 750 20,85 78,18 172.000 645.000 200 750 16,86 63,24 0,75 0,37 3N400
ECO45 KLC2a 172.000 860.000 200 1000 20,85 104,24 212.420 851.400 247 990 20,83 83,47 1,1 0,37 3N400
ECO45 KLC2b 172.000 1.032.000 200 1200 20,85 125,09 212.420 1.014.800 247 1180 20,83 99,49 1,5 0,37 3N400
ECO45 KLC3b 172.000 1.032.000 200 1200 20,85 125,09 212.420 1.014.800 247 1180 20,83 99,49 1,5 0,37 3N400
BURNERTYPE GAS
CAPACITY GAS CAPACITY NATURALGAS CONSUMPTION LIGHTOIL CAPACITY
LIGHTOIL
CAPACITY LIGHTOIL CONSUMPTION
FAN
MOTOR
POWER
OILPUMP
POWER MAIN SUPPLY
MODULATINGGAS-LIGHTOILDUALBURNERS
ONESTAGEGAS-LIGHTOILDUALBURNERS
TWOSTAGEGAS/LIGHTOILDUALBURNERS
GAS-LIGHTOILDUALBURNERSCAPACITYTABLE
HuNatural Gas =8250 kcal/Nm3
Hu LightOil (L) = 10200 Kcal/kg

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5.2. Back Pressure-Capacity Diagrams

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5.3. Burner Dimensions

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5.4. Gas HoodPressure Loss Diagram
Gashood pressureloss measurementsareconductedin atmosphericpressure.Considerthe
below datawhileconducting measurement in counter pressureboilers.
Pm: Gas hood pressurewhileburner is connected to theboiler and working
PF: Combustion chamber pressure
PBr: Burner net gas hood pressure
PBr = Pm-PF