ECOSTAR ECO 75 NG Installation guide

06.12.2022 Rev. 00
www.ecostar.com.tr
MONOBLOCKLIGHT OILBURNERS
INSTALLATION, OPERATING AND
MAINTENANCE MANUAL
MODULATINGOPERATION
ECO 50NG
ECO 55NG
ECO 60NG
ECO 65NG
ECO 70NG
ECO 75NG

06.12.2022 Rev. 00
1
DEAR USER,
ECOSTAR ECO50 NG, ECO55 NG,ECO 60NG, ECO 65 NG, ECO 70 NG,
ECO 75 NG, Light Oil burners are prepared andmanufactured accordingto 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.
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]

06.12.2022 Rev. 00
2
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
4. FLUE GASAND HEATING WATER SCHEMA............................................................................... 9
5. TECHNICAL DATA .......................................................................................................................... 10
5.1. Capacity Table.............................................................................................................................. 10
5.2. Back Pressure-Capacity Diagrams............................................................................................... 11
5.3. Burner Dimensions....................................................................................................................... 12
5.4. FlameLength and Diameter......................................................................................................... 13
6. INSTALLATION................................................................................................................................ 14
6.1. Burner Installation Picture............................................................................................................ 14
7. COMMISSIONING............................................................................................................................. 15
7.1. General Controls .......................................................................................................................... 15
7.2. Combustion Adjustment............................................................................................................... 16
7.3. FuelPumps................................................................................................................................... 16
7.4. BT 300.......................................................................................................................................... 22
7.4.1. Operating Control and Displays ............................................................................................... 23
7.4.2. Menu Functions........................................................................................................................ 24
7.4.3. BT300 Connecting Diagram..................................................................................................... 25
7.5. Servomotor................................................................................................................................... 26
7.6. Function Controls and Adjustments............................................................................................. 27
7.7. Final Checks................................................................................................................................. 27
7.8. Pilot Ignition System.................................................................................................................... 30
7.9. Emission Measurement................................................................................................................ 30
7.10. Light Oil Burner Fuel Ring Line............................................................................................. 31
8. MAINTENANCE................................................................................................................................ 32
8.1. Weekly Maintenance.................................................................................................................... 32
8.2. Monthly Maintenance................................................................................................................... 32
8.3. SeasonalMaintenance.................................................................................................................. 33
9. FAULTHISTORY .............................................................................................................................. 34
10. PERIODICAL FLUE GASMEASUREMENT REPORT.............................................................. 35
11. AFTER SALESSERVICES............................................................................................................ 36
12. NOTES............................................................................................................................................. 37

06.12.2022 Rev. 00
3
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.
Electricmotor direction of rotation
Carry in an upright position. FragileItem. Protect against water.

06.12.2022 Rev. 00
4
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.
Do not storeany inflammablematerials in boilerroom.
Wear hearing protectors if thereis noisein boiler room.
Incaseof fıre orotheremergency;
Switch offthemain switch
Takeappropriateactions

06.12.2022 Rev. 00
5
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 air dampers and oil regulators, servomotor and air damperconnections must becheckedto
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.

06.12.2022 Rev. 00
6
2. TERMS OF WARRANTY
Main and auxiliary equipmentand all componentsusedin Ecostarlight oil burners areguaranteed
for 1yearby TERMO ISIS ST. A.Şstarting from thedateof commissioning underthemaintenance,
adjustment, operating conditions and relevant mechanic,chemical and 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,
•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.

06.12.2022 Rev. 00
7
3. BURNER’SGENERAL FEATURES
ECOSTARlight-oilburners aredesignedto operatewith oil at2.5 –6Cst(mm²/s) viscosity, at
ratedcapacity and pressureranges and -15% to +10% nominal voltage.
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

06.12.2022 Rev. 00
8
Temperaturechangeof fuel used in ECOSTAR Light-Oil burners dependent on viscosity

06.12.2022 Rev. 00
9
4. FLUE GASAND HEATING WATER SCHEMA

06.12.2022 Rev. 00
10
5. TECHNICAL DATA
5.1. Capacity Table
Min.
kcal/h
Max.
kcal/h
Min.
kW
Max.
kW
Min.
kg/h
Max.
kg/h kW kW VAC
ECO50O(L)C3NG 337.980 1.351.060 393 1571 33,1 132,5 2,2 - 3N400
ECO55O(L)C3NG 386.140 1.737.200 449 2020 37,9 170,3 3 - 3N400
ECO55O(L)C3aNG 386.140 2.123.340 449 2469 37,9 208,2 3 - 3N400
ECO60O(L)C3NG 598.560 2.580.000 696 3000 58,7 252,9 4 1,1 3N400
ECO65O(L)C3NG 733.580 3.010.000 853 3500 71,9 295,1 5,5 1,5 3N400
ECO70O(L)C3NG 916.760 3.500.200 1066 4070 89,9 343,2 7,5 1,5 3N400
ECO75O(L)C3NG 1.003.620 4.824.600 1167 5610 98,4 473,0 11 1,5 3N400
FUEL
HEATER MAIN SUPPLY
NEWGENARATIONMODULATINGLIGHTOILBURNERSCAPACITYTABLE
BURNERTYPE CAPACITY CAPACITY LIGHTOIL
CONSUMPTION
FUEL
PUMP
POWER
L: LightOil Hu= 10200 Kcal/kg

06.12.2022 Rev. 00
11
5.2. Back Pressure-Capacity Diagrams

06.12.2022 Rev. 00
12
5.3. Burner Dimensions

06.12.2022 Rev. 00
13
5.4. FlameLengthand Diameter

06.12.2022 Rev. 00
14
6. INSTALLATION
6.1. Burner InstallationPicture
Interconnectionof pressure transmitters

06.12.2022 Rev. 00
15
7. COMMISSIONING
7.1. GeneralControls
ElectricalConnection
Perform electrical connections according to thediagram provided with theburner.Follow general
security rules during installation of electricwiring and making connections. Connecttheearthing terminal
in electricpanelto theearthing installation.
Makesureto perform thefollowing controls beforecommissioning theburner.
ØInstallation of theburner to theboiler is checked.
ØCheck thefuel line(arethepipediameters and thepipeinstallation correct?).
ØCheck energy input cables andvoltages.
ØCheck theboiler safety thermostats.
ØCheck thefuel nozzles according to theboilercapacity.
ØPrior to operating theburner,control theboiler waterlevel.
ØMakesurewatercirculation systemis turnedon,and steamboilerand waterfeedpumps and
boilerinlet - outlets areopen.
Commissioning order
ØAfter performing theabovementioned controls, open thefuel tank valve.
ØOpen thevalveupstream of thefuel filter.
ØCheck direction of motor rotation.
ØOpen thepump’s vent plug and placethemanometer (0-40 bar).
ØTurn on theburner switch.
ØWhen theburner starts up, themotor is activatedand turns thepump at thesametime.
ØIt actuatespre-purgeand discharges theresidual gases remaining in theboiler from thefunnel.
ØAfterthepre-purge,fuelis deliveredfromthenozzle.Thefuelmeets theflamefrom theignition
electrodes and thecombustionstarts.
ØAfter combustion of theburner, thepump pressureis adjusted (modulating 25 bar).
ØTheboilerthermostat is adjusted as desired (70-90°C for central heatingboilers).
ØFor thesafetyof thesystem,checktheboilerthermostatsand observethedeactivation of the
burner.

06.12.2022 Rev. 00
16
7.2. CombustionAdjustment
ØPhotocell
Check thephotocell weekly. Cleanthedust or fumestains ontheglass of photocell by adrycloth.
7.3. Fuel Pumps
MF Type

06.12.2022 Rev. 00
17
TA Type
1-Suction
2-Nozzleoutlet
3-Return
4-Manometer inlet
5-Vacuum or inlet manometer and internal return inlet
6-Pressureadjustment
7-Preheaterlocation
ApplicationLimits
Delivery pressure
setting
30 bars
Oper
ating viscosity
4
-
450 cSt
Oil temperature
0
-
140°C max. in thepump
Inlet pressurelight oil : 0,45 bars max. Vacuum to prevent air separation from oil
heavy oil :5 bars max.
Return pressure light oil : 5 bars max.
heavy oil :5 bars max.
Rat
ed speed
3600 rpm max.
Star
ting torque
0,3 N.m
Choice of heater
Cartridge
Ø 12 mm
Fitting according to
DIN 40430,
NFC 68190 (N°9 elec.)
Rating
80
-
100 W

06.12.2022 Rev. 00
18
HP-UHE
MainDimensions
InspectionandMaintenance
ØThepumpor motor-pump group is maintenance-free.
ØEvery pump requiresasuction filteronthesuction side.Thesuctionfilterof thesystemmust be
open regularly.Soiling and leaks arechecked. Themesh size of heatingoil shouldbe80 to 100 microns.
In thecaseofheavy oil, ameshsize of540 micronsmust beprovidedbecauseof thefibrous
components.
However, it is recommended, becauseof welded pipes at thebeginning over aperiod of 1 - 2
Months also to drivewith amesh size of approx. 100 microns, until all scaleand other
Welding residuesarefilteredout. Afterthis period haspassed,filterwithamesh size of approx.
540 microns bechanged.
ØMakesurethatthesuction connectionof thepump (measuredattheconnection for thevacuum
meter - seefig.) no vacuum greater than-0.4 bar occurs.
ØIf thepump is operated with inlet pressure, this must not exceed 5 bar

06.12.2022 Rev. 00
19
Applicationlimits
Delivery rate 375 ± 25 l/ h
Max. Pressure
(adjustableon theinte
grated overflow valve)
up to 25 bar
Min. Admissiblepre-pressure - 0.4 bar
Max. Admissiblepre-pressure 5.0 bar
Max.permissiblepump speed 2800 min-1 at 50 Hz
Breakaway torque 1.6 Nm
Temperatureup to 150 ° C
Perm. Test pressurefor approvals Max. 45 bar with theshaft seal removed
(Shaft sealing arealocked with abush)