ECOSTAR ECO 50 NG Installation guide

www.ecostar.com.tr
MONOBLOCKNG SERIESGAS BURNERS
INSTALLATION,OPERATING AND MAINTENANCE
MANUAL
MODULATINGOPERATION
ECO50NG
ECO55NG
ECO60NG
ECO65NG
ECO70NG

13.06.2017 Rev. 01 1
DEAR USER,
ECOSTAR ECO50NG, ECO55 NG, ECO60 NG, ECO 65NG,ECO 70 NG
SeriesGas burnersarepreparedand manufacturedaccording tothelatest technical
developments andsafetyrules. It iseasytouse 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.
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]

13.06.2017 Rev. 01 2
CONTENTS
WARNINGS...............................................................................................................................................3
Warning Symbols andDescriptions........................................................................................................3
GeneralSafety Rules..............................................................................................................................4
TERMS OFWARRANTY.........................................................................................................................6
Out of Warranty Conditions...................................................................................................................6
BURNER’SGENERALFEATURES........................................................................................................7
Purposeof Useand Work LimitsofBurners..........................................................................................7
CodeKey................................................................................................................................................7
TECHNICAL DATA..................................................................................................................................8
Capacity Table........................................................................................................................................8
Back Pressure-CapacityDiagrams..........................................................................................................9
Burner Dimensions...............................................................................................................................10
FlameLength andDiameter..................................................................................................................11
Noise Level...........................................................................................................................................11
BURNER HANDLING INFORMATION................................................................................................11
INSTALLATION.....................................................................................................................................12
Burner InstallationPicture....................................................................................................................12
COMMISSIONING..................................................................................................................................13
Before Commissioning.........................................................................................................................13
GeneralControls...................................................................................................................................13
Combustion Adjustment.......................................................................................................................14
Gas Adjustment....................................................................................................................................14
VGD 40… Series GasValve................................................................................................................14
Air pressure switchadjustment.............................................................................................................15
BT 300......................................................................................................................................................15
Operating Controland Displays............................................................................................................16
Leakage Test forMain GasValves.......................................................................................................17
Servomotors..........................................................................................................................................18
FunctionControlsandAdjustments......................................................................................................19
FinalChecks.........................................................................................................................................19
PilotIgnition System ............................................................................................................................20
Emission Measurement.........................................................................................................................20
Gas PassEquipmentRequired inGasLine...........................................................................................21
MAINTENANCE.....................................................................................................................................22
MonthlyMaintenance...........................................................................................................................22
Seasonal Maintenance...........................................................................................................................22
PERIODICAL FLUEGASMEASUREMENTREPORT........................................................................23
AFTER-SALES SERVICES ....................................................................................................................24
NOTES.....................................................................................................................................................25

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WARNINGS
WarningSymbols andDescriptions
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.
Electric motor direction ofrotation
Carry inanupright position.Fragile Item.Protectagainstwater.

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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 installationworks (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 bythemanufacturingcompany.
•The deviceshouldnever be usedbychildren,mentally handicapped and inexperienced persons.
•Children mustnot be allowed to playwith the device.
•Keep the deviceaway fromexplosiveand flammable materials.
•Devicemustintakeair,and ventilationand air discharge holesmust notbe closed.
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 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.

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TERMS OF WARRANTY
Main andauxiliary equipmentand all componentsused in Ecostar gas burners areguaranteed for 1
year byTERMOISISST.A.Şstarting fromthedateof commissioning under the maintenance,
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.
Out ofWarranty 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 anyfalsificationonthewarranty certificate or without an originalserial number.
•The risks during transportation ofdevice undertheresponsibilityof customerbelong to the
customer.
•Presenceofmisuse faults areindicated in the reportsissued by authorized servicestationsor our
authorizedagent,dealer,representative orour factory in case ofunavailability ofauthorized
service stations.
•Customers may apply consumer protectionarbitrator committeewith regardsto thisreport and
requestfor anexpert report.

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BURNER’SGENERALFEATURES
ECOSTARgas burnersaremanufacturedsuchthat theyoperate in gaspressure ofmin.20 mbar
and max.300mbar. at15%...+10% ofnominalvoltage,betweenthe ambient temperature range of
-15ºC….+60˚Cand declared capacity andboiler pressure ranges withNatural Gas andLiquid PetrolGas.
Purpose ofUseand WorkLimits ofBurners
•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.
Thisdevicemustnever be operated withopen flame!
Code Key

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TECHNICAL DATA
Capacity Table
NEWGENARATION MODULATING GASBURNERS CAPACITY TABLE
BURNERTYPE CAPACITY CAPACITY NATURAL GAS
CONSUMPTION LPG CONSUMPTION FANMOTOR 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
ECO50 GC3NG 215.000
1.290.000 250 1.500 26,1 156,4 9,6 57,3 2,20 3N 380
ECO55 GC 3 NG 258.000
1.720.000 300 2.000 31,3 208,5 11,5 76,4 3,00 3N 380
ECO55 GC 3a NG 258.000
2.150.000 300 2.500 31,3 260,6 11,5 95,6 3,00 3N 380
ECO60 GC 3 NG 369.800
2.580.000 430 3.000 44,8 312,7 16,4 114,7 4 3N 380
ECO65 GC 3 NG 430.000
3.010.000 500 3.500 52,1 364,8 19,1 133,8 5,5 3N 380
ECO70 GC 3 NG 498.800
3.500.200 580 4.070 60,5 424,3 22,2 155,6 7,5 3N 380
HuNatural Gas=8250 kcal/Nm3
HuLPG=22500 kcal/Nm3

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BackPressure-Capacity Diagrams

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BurnerDimensions

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Flame LengthandDiameter
NoiseLevel
Product operateswithinthe range of 75decibelsmax.and85 decibels.
BURNER HANDLING INFORMATION
•Lifttheproduct byholdingthehandlesasseeninthe picture.
•Prevent strong impactsontopoftheproductandvibrationwhile handlingtheproduct.
•Donotleavetheproductinwet environment.

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INSTALLATION
BurnerInstallation Picture
1- Burner
2- BoilerConnection Flange
3- Gasket
4- BoilerFlange
You mustdefinitely ensuresealingbetween boilerand burner!
Device mustbe shippedinoriginal packaging!
Do not liftthe deviceholding fromservomotor,gas valve,impulsepipesorpressure switch
during installation!
Cleantheinside of fuel linethoroughly beforeinstalling the burner to thefuel line.Any
damagethat mayoccur due to solid objects andmetal particles from the fuel line shall not be
covered by our company.

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While installing the burnerin reverseflamefront mirror boilers,flametubetipmustbeadjusted
such thatit gets inside by 50 mm-100 mm fromflue pipes (50mm≤A≤100mm).Otherwiseflue gas
temperature willriseand fuel consumption will increase.
COMMISSIONING
BeforeCommissioning
Electrical connection
Performelectricalconnections according to thediagram provided with the burner.Follow general
securityrules duringinstallationof electricwiring and makingconnections. Connect the earthing terminal
in electric panel tothe earthinginstallation.
General Controls
Make suretoperformthe following controls beforecommissioningtheburner.
ØArethe electrical connectionscorrect?
ØIsthereelectricity current?
ØIstheregas?
ØHastheheatingsystembeenfilled withwater?
ØIsthethermostat set atthe requiredtemperature?
ØHastheboiler explosionlidbeen controlled?
ØIstheresufficient air inboilerroom(ventilationsectioncm²=boiler capacity kW x7)
ØHastheboiler been installed correctly?Hastheboiler cover been closed properly?
ØHastheair ofthegas linebeen removed? Hasasealing test been made?

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Operationofamodulatingburner
ØOpen the main gasvalve; check max300 mbar gaspressurefromthe manometer.
ØOpen operating switchon the burner panel.
ØSwitchonthemodulating control switch.
ØSwitchautomatic-hand switch to automatic.
ØCheckthe temperatureandpressuresetvaluesfromthemodulating control unit.
ØIgnitionwilltake place at theend of pre-purge process.
Ø3sec.later,the gasvalve will be openedand combustionwilloccur.
ØFlamecontrolsystem(ionization) willstartflamecontrol.
ØIn modulating burner,the burnergoesinto max.capacity according to thesignal fromthe
modulating controlunit.
ØWhen the boilerwater temperature or steampressure increase,the modulating control unitwill
cause burner torunwith min.capacity.
ØIftheboiler watertemperatureorsteam pressure increasesdespite the operation ofburnerwith
min. capacity, themodulating control unit will stoptheburner.
CombustionAdjustment
Gas Adjustment
Follow theinstructions ofthevalvemanufacturerduringinstallation,dismantling andadjustment ofthe
gas valve
VGD 40…Series GasValve

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Air pressureswitchadjustment
While the burner is working withoutany problem, theairpressureswitch
is adjusted todesired minimumpressure as follows.
ØUnscrew the screwofthe transparent cover andremovethe cover.
ØTurn the adjustment wheel in the direction to increase thepressure,
notethepressure value atwhich the burner isfailed.
ØSet thepressure switchto avalue1mbar lowerthanthe pressure
valueatwhichtheburner failed and closethe pressure switch lid.
ØIt isrecommendedthat this adjustment is carriedout when the
burner isat minimumload.
BT300

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OperatingControlandDisplays
1Display
2Backkey
3Cursorkeys
4Enter key
Display: Thedisplayshows inpictograms:
1-Themenu structure
2-Operating status
3-Parameters
4-Errormessages
Backkey: Jumpto previouswindow.
Cursorkeys: You navigate in the menuusingthe cursor keys.You use the "left''and
''right''keys tomovestep by steptotheselectedrow.At the end of the selected row,the
cursor jumpsto thenext rowdown,ifpossibleIf the menuhasmultiple rows,youcanuse
the "up" and "down"keysto switch rowsTo display theparameters,switchbetween the
individualfields.
Enterkey: PressENTER tocall up the menu on the start screen.You opentheselected
submenu fromamenu window.Bypressing theENTERkey,you transferthe settingvalues
fromaparameter window.

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LeakageTest forMain Gas Valves

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Servomotors
Servomotorsdrive air dampers,gasbutterfly valve and oil regulator.With thehelp ofservomotors
electronic air and fuelratiocontrolis carriedout, controlledbyburnercontrol.
ØStaticelectricitycan damageservomotor.
ØDonot openservomotor.Do not interferewith or modify unit orequipment connected to it. It may
damage servomotoror change burner settings.
ØCompletelyisolateequipmentfromthemain supply beforeperforming any wiring changes in
servomotor connection area.
ØCheckthat wiringisinanorderly state.
ØProtectequipment fromcondensation,water and ice.
ØFall or shock canadversely affect safety functions.Suchservomotorsmay not be put into
operation.
Do not open servomotor.Do not interferewith.It maydamage servomotororchangeburner
settings.

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Function Controls andAdjustments
The BT300 combines the benefitsofanelectronic fuel-airratio control systemwith up to three
motorizedactuatingdevicesand anoptional module like ananalogueoutput for speedcontrol ofthe
combustion airfan with an electronicburner control unit.The leakage test,flamemonitoringsystem,
power control unit and (optional)CO/O2controller for control andoptimizationofanoil orgas-fired
forced-draught burner areall integrated.TheBT300 issuitablefor virtually all combustionplants.Safety
interlock chains,monitors (e.g.gasandairpressure) andsensorsare wireddirectly to theBT300.This
greatly reducesthecostofadditional relays and wiring.The BT300was designedto beattachedto the
burner. Theshort wiringpathsalsosave money. Asaresult,the BT300 isparticularly suitable asstandard
equipmentfor monoblock burners.The compact design oftheBT300 burnercontrol systemalsohasits
advantagesduring commissioning.Standardizing the wiring and theunifiedoperator interfaceminimizes
sourcesof errorsfromthe start,while intelligent information in the display makes searching for errors
much easier.
Magneticvalves must notbe energized during pre-purge.Checkifvalvesarein closed
position!
Final Checks
ØSwitchofall purgesafter completion ofall necessarymeasurements.
ØStartand stop the burner atleast3times to check theoperation oftheprogram.
ØMakesurethat all safetycircuits on the burnerandboileroperate properly before leaving the
installationsite.