ECOSTAR ECO 50 G C 2 Operating instructions

09.10.2018Rev. 10
www.ecostar.com.tr
MONOBLOCKGASBURNERSINSTALLATION,
OPERATINGAND MAINTENANCE MANUAL
TWOSTAGEANDMODULATING OPERATION
ECO50
ECO55
ECO60
ECO65
ECO70
ECO75

09.10.2018 Rev. 10 1
DEAR USER,
ECOSTARECO50,ECO 55,ECO 60,ECO 65,ECO 70,ECO75Gas burners
arepreparedandmanufacturedaccording tothelatest technical developments andsafety
rules. Itis easyto use forour customers.
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]

09.10.2018 Rev. 10 2
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..................................................................13
5. TECHNICAL DATA ........................................................................................................................14
5.1. Capacity Table...........................................................................................................................14
5.2. BackPressure-Capacity Diagrams.............................................................................................15
5.3. Burner Dimensions.....................................................................................................................17
5.4. Gas Hood PressureLoss Diagram..............................................................................................19
5.5. FlameLength andDiameter.......................................................................................................22
5.6. NoiseLevel ................................................................................................................................22
6. BURNER HANDLING INFORMATION ........................................................................................22
7. INSTALLATION..............................................................................................................................24
7.1. Burner InstallationPicture..........................................................................................................24
8. COMMISSIONING..........................................................................................................................25
8.1. Before Commissioning...............................................................................................................25
8.1.1. Ignitionand Ionizasyon System..............................................................................................25
8.2. General Controls........................................................................................................................26
8.3. Combustion Adjustment.............................................................................................................27
8.3.1. Gas Adjustment......................................................................................................................27
8.3.1.1. VGD 20 4011 -5011SeriesGas Valve...............................................................................27
8.3.1.2. MBDLESeries MonoblockGasValve..............................................................................28
8.3.1.3. MBZRD(LE) 415–420SeriesGasValve.........................................................................30
8.4. AirPressure SwitchAdjustment.................................................................................................31
8.5. Servomotor Adjustment.............................................................................................................31
8.6. EmissionMeasurement ..............................................................................................................32
8.7. Capacity Adjustment..................................................................................................................32
8.8. ProgramRelay............................................................................................................................32
8.9. FunctionControls and Adjustments...........................................................................................33
8.10. FinalChecks...........................................................................................................................33
8.11. Gas PassEquipmentRequiredinGasLine.............................................................................36
9. MAINTENANCE..............................................................................................................................37
9.1. MonthlyMaintenance.................................................................................................................37
9.2. Seasonal Maintenance................................................................................................................37
9.3. InstallationAndDisassembly InstructionsForMaintenancePurposes ......................................38
10. TROUBLESHOOTING.................................................................................................................41
11. PERIODICAL FLUEGASMEASUREMENTREPORT.............................................................42
12. AFTER-SALES SERVICES..........................................................................................................43
13. NOTES..........................................................................................................................................44

09.10.2018 Rev. 10 3
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.

09.10.2018 Rev. 10 4
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

09.10.2018 Rev. 10 5
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
During thefirstcommissioning oftheburner or incase of any revisioncarried out inthe electrical
systemor motor cables byanyreason,directionofthefan rotation mustcertainly be checkedby
the authorizedtechnical service.
Forproductsthathave notbeen comissionedorstarted morethan 6months, before activatingthe
servomotor;
Ingasandair dampers,servomotor andair damper connections must becheckedtoensurethatthey
are freerunning inspite of immobilityand 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.

09.10.2018 Rev. 10 6
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 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 orour factory in case ofunavailability ofauthorized
service stations.
•Customers may apply consumer protectionarbitrator committeewith regardsto thisreport and
requestfor anexpert report.

09.10.2018 Rev. 10 7
3. BURNER’SGENERAL FEATURES
ECOSTARgas burnersaremanufacturedsuchthat theyoperate in gaspressure ofmin.20 mbar
and max.300 mbar.,at 15%...+10% ofnominal voltage,betweenthe ambient temperaturerangeof -
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

09.10.2018 Rev. 10 8
3.3. Burner Components
ECO 50,ECO55
Assembly No PartName AssemblyNo PartName
1 BodyGroup 17 Servomotor
2 Fan 18 Servomotor Coupling
3 Fan Motor MountingFlange 19 Air Damper Short
4 Fan Motor 20 Air Damper Long
5 Gasket 21 Damper Motion Rod
6 FlameTube 22 Air Damper Motion Transfer Rod
7 FlameTubeExtension 23 LanceCover
8 Transformer 24 PressureSwitch
9 Gas Train Pipe 25 PressureSwitchAdaptor
10 Combustion Head Elbow 26 PressureSwitchAdaptor Pipe
11 Combustion Head 27 Purger
12 Ignition Electrode 28 Electrical PanelMountingPlate
13 IonizationElectrode 29 Electrical Panel
14 Observation Glass 30 Gasket
15 HandlingShaft 31 Boiler Connection Flange
16 HandlingShaft FixingPlate 32 Gas Valve

09.10.2018 Rev. 10 9
ECO 50,ECO 55 Mechanical Modulation
AssemblyNo
PartName AssemblyNo PartName
1 Body Group 21 Lance Cover
2 Fan 22 Purger
3 Fan Motor Mounting Flange 23 Gasket
4 Fan Motor 24 Boiler Connection Flange
5 Gasket 25 Servomotor
6 FlameTube 26 Servomotor Coupling
7 FlameTube Extension 27 Air Damper
8 Transformer 28 Air Damper
9 Combustion Head Elbow 29 DamperMotion Rod
10 Combustion Head 30 Air DamperMotion Transfer Rod
11 Ignition Electrode 31 Lever MountingShaft
12 IonizationElectrode 32 Cam
13 ObservationGlass 33 Lever
14 HandlingShaft 34 BearingGroup
15 HandlingShaft FixingPlate 35 ConnectingRod
16 Electrical Panel MountingPlate 36 Gas Adjustment Arm
17 Electrical Panel 37 Gas Adjustment Valve
18 PressureSwitch 38 Gas SupplyPipe
19 PressureSwitchAdaptor 39 Gas Valve
20 PressureSwitchAdaptorPipe 40 Gas Flanges 1 1/2"

09.10.2018 Rev. 10 10
ECO 60
Assembly No
PartName AssemblyNoPartName
1 BodyGroup 18 PressureSwitch
2 Fan 19 Purger
3 Fan Motor 20 Gasket
4 Fan Motor MountingFlange 21 CombustionHeadElbow
5 Transformer MountingPlate 22 CombustionHead
6 Transformer 23 FlameTube
7 Air DamperLong 24 GasTrainPipe
8 Air DamperShort 25 Boiler ConnectionFlange
9 Servomotor Coupling 26 Gasket
10 Servomotor 27 HandlingShaft
11 Damper Motion Rod 28 MilFixingPlate
12 Motion HandlingRod 29 Bearing
13 LanceCover 30 IgnitionElectrode
14 Observation Glass 31 Ionization Electrode
15 Observation GlassFrame 32 Electrical Panel MountingPlate
16 PressureSwitchPipe 33 Electrical Panel
17 PressureSwitchAdaptor 34 GasValve

09.10.2018 Rev. 10 11
ECO 65-ECO70
Assembly No PartName Assembly No PartName
1 BodyGroup 19 Purger
2 Fan 20 Gasket
3 Fan Motor 21 CombustionHeadElbow
4 Fan Motor MountingFlange 22 CombustionHead
5 Transformer MountingPlate 23 FlameTube
6 Transformer 24 GasTrainPipe
7 Air DamperLong 25 Boiler ConnectionFlange
8 Air DamperShort 26 Gasket
9 Servomotor Coupling 27 HandlingShaft
10 Servomotor 28 MilFixingPlate
11 Damper Motion Rod 29 Bearing
12 Motion HandlingRod 30 IgnitionElectrode
13 LanceCover 31 Ionization Electrode
14 Observation Glass 32 Electrical Panel MountingPlate
15 Observation GlassFrame 33 Electrical Panel
16 PressureSwitchPipe 34 GasValve
17 PressureSwitchAdaptor 35 FlameTube Extension
18 PressureSwitch

09.10.2018 Rev. 10 12
ECO 75
Assembly No PartName Assembly No PartName
1 BodyGroup 19 Eyebolt
2 FlameTube20 Purger
3 Gas Train Pipe 21 Transformer Box
4 LanceCover 22 Servomotor
5 Gasket 23 Servomotor Coupling
6 Combustion Head 24 PressureSwitch
7 Boiler Connection Flange 25-1 PressureSwitch Adaptor Pipe
8 Gasket 25-2 PressureSwitch Adaptor
9 Fan Motor 26 Servomotor MountingConsole
10 Fan 27 Servomotor Gauge
11-1 Observation Glass 28 Damper Gauge
11-2 Observation GlassFrame 29 Air Damper Plate(Wide)
12 HandlingShaft 30 Air Damper Plate(Narrow)
13 HandlingShaft FixingPlate 31 Damper Shaft (with Groove)
14-1 Electrical Panel 32 Damper Shaft (Straight)
14-2 ProcessController 33 MotionHandlingRod
15 Electrical PanelMounting Plate 34 MotionHandlingRod
16 Anti-VibrationMount 35 MotionHandlingRodShaft
17 Photocell 36 SolenoidValve
18 Solenoid Valve

09.10.2018 Rev. 10 13
4. GAS, FLUE GAS AND HEATING WATERSCHEMA

09.10.2018 Rev. 10 14
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
ECO50 GC2 215.000 1.290.000 250 1.500 26,1 156,4 9,6 57,3 2,20 3N380
ECO55 GC2 258.000 1.720.000 300 2.000 31,3 208,5 11,5 76,4 3,00 3N380
ECO55 GC2a 258.000 2.150.000 300 2.500 31,3 260,6 11,5 95,6 3,00 3N380
ECO60 GC2 369.800 2.580.000 430 3.000 44,8 312,7 16,4 114,7 4 3N380
ECO65 GC2 430.000 3.010.000 500 3.500 52,1 364,8 19,1 133,8 5,5 3N380
ECO70 GC2 498.800 3.500.200 580 4.070 60,5 424,3 22,2 155,6 7,5 3N380
ECO50 GC3 215.000 1.290.000 250 1.500 26,1 156,4 9,6 57,3 2,20 3N380
ECO55 GC3 258.000 1.720.000 300 2.000 31,3 208,5 11,5 76,4 3,00 3N380
ECO55 GC3a 258.000 2.150.000 300 2.500 31,3 260,6 11,5 95,6 3,00 3N380
ECO60 GC3 369.800 2.580.000 430 3.000 44,8 312,7 16,4 114,7 4,00 3N380
ECO65 GC3 430.000 3.010.000 500 3.500 52,1 364,8 19,1 133,8 5,5 3N380
ECO70 GC3 498.800 3.500.200 580 4.070 60,5 424,3 22,2 155,6 7,5 3N380
ECO75 GC3 686.280 4.800.000 798 5.581 83,2 581,8 30,5 213,3 11,00 3N380
MODULATINGGASBURNERS
TWOSTAGEGASBURNERS
GASBURNERSCAPACITYTABLE
BURNERTYPE CAPACITY CAPACITY NATURALGAS
CONSUMPTION LPGGAS CONSUMPTION FANMOTOR POWER MAIN SUPPLY
HuNatural Gas=8250 kcal/Nm3
HuLPG=22500 kcal/Nm3

09.10.2018 Rev. 10 15
5.2. BackPressure-Capacity Diagrams

09.10.2018 Rev. 10 16

09.10.2018 Rev. 10 17
5.3. Burner Dimensions

09.10.2018 Rev. 10 18
ECO 50,ECO 55 Mechanical Modulation
*Fdimensionmayvarydepending on the valvemodel.

09.10.2018 Rev. 10 19
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