ECOSTAR ECO 55 NG Installation guide

10.08.2020 Rev. 00
www.ecostar.com
MONOBLOCKNGSERIESDUAL FUEL (GAS-
LIGHT OIL) BURNERS INSTALLATION,
OPERATING ANDMAINTENANCE MANUAL
TWO STAGE ANDMODULATING OPERATION
ECO 50NG
ECO 55NG
ECO 60NG
ECO 65NG
ECO 70NG
ECO 75NG

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DEAR USER,
ECOSTAR ECO 50 NG, ECO 55 NG, ECO 60 NG, ECO 65 NG, ECO 70 NG,
ECO 75 NG Dual Fuel (Gas-Light Oil) burners are prepared andmanufactured
accordingto the latest technical developments andsafety rules. It iseasy touse forour
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.
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................................................................... 10
5. TECHNICAL DATA .......................................................................................................................... 11
5.1. Capacity Table.............................................................................................................................. 11
5.2. Back Pressure-Capacity Diagrams............................................................................................... 12
5.3. Burner Dimensions....................................................................................................................... 13
5.4. Gas HoodPressureLoss Diagram................................................................................................ 14
5.5. FlameLength and Diameter......................................................................................................... 17
5.6. NoiseLevel................................................................................................................................... 17
6. BURNER HANDLING INFORMATION.......................................................................................... 18
7. INSTALLATION................................................................................................................................ 19
7.1. Burner Installation Picture............................................................................................................ 19
7.2. In reverseflamefront mirror boilers............................................................................................ 20
7.3. In cylindrical (straight flame)boilers........................................................................................... 20
8. COMMISSIONING............................................................................................................................. 21
8.1. BeforeCommissioning................................................................................................................. 21
8.2. General Controls .......................................................................................................................... 21
8.3. Combustion Adjustment............................................................................................................... 23
8.4. Fuel Pumps................................................................................................................................... 23
8.5. Gas Adjustment............................................................................................................................ 27
8.5.1. VGD 40… Series Gas Valve.................................................................................................... 27
8.6. Air PressureSwitchAdjustment .................................................................................................. 27
8.7. BT 300.......................................................................................................................................... 28
8.7.1. Operating Control and Displays ............................................................................................... 29
8.7.2. Menu Functions........................................................................................................................ 30
8.7.3. BT300 Connecting Diagram..................................................................................................... 31
8.8. LeakageTest for Main Gas Valves.............................................................................................. 32
8.9. Servomotors.................................................................................................................................. 34
8.10. Function Controls and Adjustments......................................................................................... 35
8.11. Final Checks ............................................................................................................................. 35
8.12. Pilot Ignition System................................................................................................................ 38
8.13. Emission Measurement............................................................................................................. 38
8.14. Light Oil Burner Fuel Ring Line.............................................................................................. 40
8.15. Gas Pass Equipment Requiredin Gas Line.............................................................................. 41
9. MAINTENANCE................................................................................................................................ 42
9.1. Weekly Maintenance.................................................................................................................... 42
9.2. Monthly Maintenance................................................................................................................... 42
9.3. SeasonalMaintenance.................................................................................................................. 43
10. TROUBLESHOOTING................................................................................................................... 44
11. PERIODICAL FLUE GASMEASUREMENT REPORT.............................................................. 45
12. AFTER SALESSERVICES............................................................................................................ 46
13. NOTES............................................................................................................................................. 47

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1. WARNINGS
1.1. Warning Symbols and Descriptions
Symbols Symbol Descriptions
Important information and useful hints.
Warning of danger to lifeor property.
Warning of electrical voltage.
Product handling information.
PFImpulseconnection detecting combustion chamber pressure
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.Protectagainst water.

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1.2. General Safety Rules
•All personnelengagedininstallation, disassembly,commissioning, operation,control,
maintenance and repair should havereceivedthenecessary training andfully readand understood
this manual.
•No changesthatmight damagethesafety of theburnerunit must bemadeby persons and/or
organizations on theburner unit.
•All operation, commissioningand 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 fromexplosiveand 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 and lighter.
•Informthegas company.
Do not storeany inflammablematerials in boilerroom.
Wear hearing protectors if thereis noisein boiler room.
Incaseof fıre orother emergency;
Switch off themain switch
Closethemain fuel shut-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 fan motor, if necessary
During thefirst commissioning of theburner or in caseof any revision carriedout in theelectrical
systemor motor cables by anyreason, direction of thefan rotation mustcertainly bechecked by
theauthorizedtechnical service.
For products that havenot been comissioned or started morethan 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 withminimumexternal air openings and sufficient to
ensu reperfectcombustion, incompliance with current regulations.
Never obstructair openings of theburner room,burner fan intakevents or air ducts in order to
prevent:
a.Thebuild up of toxic/explosivegasmixtures in theburner room,
b.Combustion with insufficient air,resulting in hazardous, anti-economical and polluting ope-
ration.
Theburnermust bealways protected fromrain, snow and frost to prevent corrosion and paint
deformations.
Keeptheburner roomclean and freeof solid volatilesubstances, which could besucked into thefan
and clog theinternalburner or combustion head air ducts.

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2. TERMSOF WARRANTY
Main andauxiliaryequipment and allcomponents usedinEcostarDualFuel(Gas-Light Oil)
burners areguaranteedfor 1yearby TERMO ISIS ST. A.Şstartingfromthedateofcommissioning
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 makeanymodifications 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 damagethatmay 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 thestampand signatureof theauthorizeddealer or service,
•Deviceswith any falsification on thewarranty certificateorwithout an originalserial 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
ECOSTAR DualFuel(Gas-Light Oil)burners aredesignedand manufacturedto work with liquid
fuelwith max. 2.5- 6Cst (mm2/s) viscosity. and NaturalGasand Liquid PetroleumGasatgaspressures
of min.20mbar, max.300 mbarandat-%15to +%10 of nominalvoltages, underenvironmental
temperatureof max.60˚C with ratedcapacity and burner pressureranges.
3.1. Purposeof Useand WorkLimits of Burners
•This productworks atany loadvalueequivalentto its max. capacityor coveredby its capacity
range;
-In hot water and steamboilers,
-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. CodeKey

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

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3.3. Burner Components
ECO 55 KL

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4. GAS, FLUE GASAND HEATING WATER SCHEMA

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5. TECHNICAL DATA
5.1. Capacity Table
HuNatural Gas =8250 kcal/Nm3
Hu Light Oil (L) = 10200 Kcal/kg

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5.2. BackPressure-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

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5.5. FlameLengthandDiameter
Natural Gas
Light Oil
5.6. NoiseLevel
Product operates within therangeof 75 decibels max. and 85 decibels.

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6. BURNERHANDLING INFORMATION
•Lift theproduct by holding thehandles as seen in thepicture.
•Prevent strong impacts on top of theproduct and vibration whilehandling theproduct.
•Do not leavetheproduct in wet environment.
Dimensions of thebox used for handling
Burner Lx WxH(cm) Weight (kg)
ECO 50 KLC2NG 160X 100 X 80 130
ECO 50 KLC3NG 160X 100 X 80 130
ECO 55 KLC2NG 160X 100 X 80 170
ECO 55 KLC2a NG
160X 100 X 80
170
ECO 55 KLC3NG 160X 100 X 80 170
ECO 55 KLC3a NG
160X 100 X 80
170
ECO 60 KLC2NG 160X 115 X 74 195
ECO 60 KLC3NG 160X 115 X 74 195
ECO 65 KLC2NG 170X 115 X 74 200
ECO 65 KLC3NG 170X 115 X 74 200
ECO 70 KLC2NG 170X 115 X 74 180
ECO 70 KLC3NG 170X 115 X 74 180
ECO 75 KLC3NG 190X 120 X 85 270

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7. INSTALLATION
7.1. Burner InstallationPicture
1- Drift Bolts
2- Burner
3- BoilerConnection Flange
4- Gasket
5- BoilerStuds
ØIn theinstallation oftheburner, usetheinstallationmaterials suppliedwith theburner.
ØSecuretheburnerconnectionflangeonto theburnercoverby 4bolts.Gasketmust beconnected
such thatit will remain between connecting flangeand boiler cap.
After completing theinstallationof theburner ontheboiler:
ØConnecttheoil feedpipes.
ØConnecttheburnerpanelto themains by acablesuitablefortheratedpower.
Device must beshipped in original packaging!
Do not lift thedeviceholdingfromservomotor, gasvalve,impulse pipesorpressureswitch
during installation!
Cleantheinsideof fuellinethoroughly beforeinstalling theburnerto thefuelline.Any damage
thatmayoccur dueto solid objects and metalparticlesfromthefuellineshallnot becoveredby
our company.