ECOSTAR GRM 40 Installation guide

01.06.2021 Rev. 05 www.ecostar.com.tr
GRM SERIESNOZZLE MIX BURNERS
INSTALLATION, OPERATING AND
MAINTENANCE MANUAL
MODULATING OPERATION
GRM 15
GRM 30
GRM 40
GRM 60
GRM 70
GRM 80
GRM 100

01.06.2021 Rev. 05 1
DEAR USER,
ECOSTAR GRM 15, GRM 30, GRM 40, GRM 60, GRM 70, GRM 80 GRM 100,
GRM Series burners areprepared and 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 issuethat is not explained clearly in this manual or you 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]

01.06.2021 Rev. 05 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. Burner Components........................................................................................................................ 8
4. GAS,FLUE GASAND HEATING WATER SCHEMA................................................................... 10
5. TECHNICAL DATA .......................................................................................................................... 11
5.1. Capacity Table.............................................................................................................................. 11
Modulation Rates.................................................................................................................................... 11
5.2. Burner Dimensions....................................................................................................................... 12
6. BURNER HANDLING INFORMATION.......................................................................................... 13
7. INSTALLATION................................................................................................................................ 14
7.1. Burner Installation Picture............................................................................................................ 14
8. COMMISSIONING............................................................................................................................. 15
8.1. General Controls .......................................................................................................................... 15
8.2. Operating GazoramBurner.......................................................................................................... 15
8.3. Function Controls......................................................................................................................... 15
8.4. Air PressureSwitchAdjustment .................................................................................................. 16
8.5. Servomotor Adjustment............................................................................................................... 16
8.6. ProgramRelay.............................................................................................................................. 16
9. GASVALVE ADJUSTMENT........................................................................................................... 17
9.1. BANICO ZEVR........................................................................................................................... 17
9.2. ELEKTROGASVMR.................................................................................................................. 18
9.3. BRAHMA EG.............................................................................................................................. 19
9.4. Gas Pass Equipment Requiredin Gas Line.................................................................................. 20
10. AIR/FUEL ADJUSTMENT ............................................................................................................ 21
11. MAINTENANCE............................................................................................................................ 22
11.1. Daily Maintenance.................................................................................................................... 22
11.2. Monthly Maintenance............................................................................................................... 22
11.3. Seasonal (6 Months) Maintenance............................................................................................ 22
12. ELECTRIC DIAGRAM.................................................................................................................. 23
13. TROUBLESHOOTING................................................................................................................... 27
Burner is not working ............................................................................................................................. 27
Fanmotor fails ashort timeafter it starts............................................................................................... 27
14. PERIODICAL FLUE GASMEASUREMENT REPORT.............................................................. 28
15. AFTER-SALESSERVICES............................................................................................................ 29
16. NOTES............................................................................................................................................. 30

01.06.2021 Rev. 05 3
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.
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, and ventilation and air dischargeholesmust notbeclosed.
If yousensescent of gas;
•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

01.06.2021 Rev. 05 5
Theburnerinstallation must becarriedout in accordance with theinstructions. Vibration can
damagetheburnerand its components.
Keep combustion roomdoors closed whilestartingburner and during burner operation.
Checkcombustion valuesto becorrectby using fluegasanalyzeratthewholeadjustment range
betweenminimum,full load, and ignition load.
During thefirst commissioning of theburneror incaseof any revision carriedout in theelectrical
systemor motor cablesby anyreason, direction ofthefanrotation must certainly becheckedby
theauthorizedtechnical service.
For products that havenot been comissioned or started morethan 6 months, beforeactivating the
servomotor;
In gas and air dampers,servomotor and air damper connections must becheckedto ensurethat
they arefree runningin spiteofimmobility 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 and auxiliary equipment and all components used in Ecostar gasburners areguaranteed
for 1yearby TERMO ISIS ST. A.Şstarting fromthedateof commissioningunderthemaintenance,
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 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,
•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
ECOSTAR gasburners aremanufacturedsuchthattheyoperatein gaspressureof max.50mbar, at
-15%...+10% of nominalvoltage,betweentheambient temperaturerangeof -15ºC….+60˚Cand declared
capacity and boilerpressureranges with NaturalGas and Liquid Petrol Gas.
3.1. Purposeof Useand WorkLimits of Burners
•This productworks atany loadvalueequivalentto its max. capacityor coveredby its capacity
range;
-Not used in furnaces performing direct drying with natural gas and drying cabinets,
-In vacuumor "0" (zero) pressurecombustion chambers,
-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.
-Operation with natural gas and LPG.
-Not used in combustion chambers with positivepressure.
This devicemust never beoperated withopen flame!

01.06.2021 Rev. 05 8
3.2. Burner Components

01.06.2021 Rev. 05 9
No Part Name No Part Name
1
Body
22
Gasket
2
FlameTube
23
Observation Glass Frame
3
Relay Mounting Plate
24
Observation Glass
4
Gas Diffuser
25
Linkage
5
Swirler Disc
26
Steel Nipple
6
IonizationElectrode
27
Servomotor Connection Flange
7
Ignition Electrode
28
Copper Washer
8
Relay
29
Purger
9
Relay Socket
30
Purger Needle
10
Wall Type24 Pin Socket
31
Fan Group
11
Transformer
32
Socket Screw
12
Gas Valve
33
Washer
13
Hex Bolt
34
Socket Screw
14
Solenoid Valve
35
Bolt
15
Air Damper
36
Washer
16
Air Damper Motion Rod
37
CarriageBolt
17
PressureSwitch
38
Socket Screw
18
Servomotor
39
Bolt
19
Servomotor Shaft
40
Socket Screw
20
Stud Bolt
41
Socket Screw
21
Gas Pipe

01.06.2021 Rev. 05 10
4. GAS, FLUE GASAND HEATING WATER SCHEMA

01.06.2021 Rev. 05 11
5. TECHNICAL DATA
5.1. Capacity Table
GRM SERIES BURNER CAPACITY TABLE
BURNER TYPE CAPACITY CAPACITY NATURAL GAS
CONSUMPTION MAIN SUPPLY
Min.
kcal/h
Max.
kcal/h
Min.
kW
Max.
kW
Min.
Nm3/h
Max.
Nm3/h VAC
GRM 15 4.500 150.000 5,18 174,42 0,54 18,18 1N 230/3N 400
GRM 30 8.500 300.000 9,88 348,84 1,03 36,36 1N 230/3N 400
GRM 40 11.500 400.000 13,33 465,12 1,39 48,48 1N 230/3N 400
GRM 60 15.000 550.000 17,44 639,53 1,82 66,67 1N 230/3N 400
GRM 70 20.000 700.000 23,21 814,11 2,42 84,85 1N 230/3N 400
GRM 80 21.500 750.000 25,03 872,09 2,61 90,91 1N 230/3N 400
GRM 100 28.5001.000.000
33,19 1162,79 3,46 121,21 1N 230/3N 400
HuNatural Gas =8250 kcal/Nm3
HuLPG=22500 kcal/Nm3
ModulationRates
•GRM 15: 33:1
•GRM 30: 35:1
•GRM 40: 35:1
•GRM 60: 36:1
•GRM 70: 35:1
•GRM 80: 35:1
•GRM 100: 35:1

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5.2. Burner Dimensions

01.06.2021 Rev. 05 13
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.
Device must beshipped in original packaging!

01.06.2021 Rev. 05 14
7. INSTALLATION
7.1. Burner InstallationPicture
1- Flametube
2- Connecting Flange(weldedto thebody)
3- Body
4- Gas intakeflange
5- Fan
6- Installation bolt
7- Installation gasket
8- Combustion chamber wall
9- Insulation material
It is possibleto performinstallation in GRM SeriesBurners suchthatcombustion air ventilator
and gaspath arein different axes. Suggestedmethod of installation is theinstallation, inwhich
gaslineisparalleltotheaxisso thatit is easierto interferegaslineequipment. Theholeto be
opened oncombustion chamber wall must be20 mmlarger than thediameter oftheflametube.
Installationsurface must becoatedwithinsulationmaterial(9) in orderfor burnerequipment not
to beaffected by combustion chamber.
Usesuitablecompensator or flex hosewhileconnecting thegas linereaching out theburnerto the
burner gasline.
Do not liftthedeviceholding fromservomotor, gasvalve,impulsepipesor pressureswitchduring
installation!
Cleantheinsideof fuellinethoroughly beforeinstalling theburnertothefuelline.Any damage
thatmayoccur dueto solid objects andmetalparticlesfromthefuellineshallnot becoveredby
our company.

01.06.2021 Rev. 05 15
ElectricalConnection
Performelectricalconnectionsaccording to thediagramprovidedwith theburner. Follow
generalsecurity rulesduring installationof electricwiring and makingconnections. Connectthe
earthing terminal in electricpanel to theearthing installation.
8. COMMISSIONING
8.1. GeneralControls
•Aretheelectrical connections correct?
•Has thesealing of gas lines been controlled?
•Is thepressureprovided to theburner suitable? (max. 50 mbar)
•Is thesuction ventilator connected to thecombustion chamber working?
•Is thewallelement checking combustion chamber temperatureworkingcorrectly?
8.2. Operating Gazoram Burner
•Verify that thecombustion chambersuction ventilator is working.
•Insert plug sockets, which ensureelectricconnection, in their holes.
•Since thegas valveis turned off, gas pressureswitch will not lettheburner to work.
•Turn on thegas shut-off valve.
•Having detectedgaspressure,gaspressureswitch will send operating voltageto theprogramrelay
and relay'soperational steps will commence.
•Whenfanmotor starts and pre-purgecommences, air pressureswitchwill verify theexistence of
combustion air and commence relayignition operation.
•Ignition stepis composedof two stages: pre-ignition andfinal(safety)ignition. Gassolenoid
valveturnson attheend of pre-ignition period (3 seconds) and flameis formed; ignition is active
for 3 seconds moredespiteformation of flame.
•Aftertheflamedetector detectsflameexistence,burnercontinuesits normaloperation. Working
loadis automaticallychangedby theproportional controldeviceaccording tothesignalarriving
fromcombustion chamber heat sensitiveelement.
•In thatcase, commissioning process is successful.
8.3. FunctionControls
a. First commissioning with closed gas valve
Following fault, relaymust switch to faultposition once thesafety period ends.
b. In first commissioning, turn off thegas valvewhileburner is working.
After theflamegoes out, relay should transit to fault position.
c. Cut off airpressureswitch during pre-purgeor working in first commissioning
Burner control unit should immediately bring thedevice to fault position.
d. Bridgetheair pressureswitchbeforestarting.
Fanmotorstarts workingfor2-3 secondsandswitchestofault at theend ofthis period.In
second try, device starts thefanmotoragainand makes another tryafter10seconds.If the
contacts of theairpressure switchare stillbridged,it switchestofault position.Assoonas
theunit starts working, it checksif theairpressure switchis broughtto ON positionfrom
OFF position.

01.06.2021 Rev. 05 16
8.4. AirPressure SwitchAdjustment
Whiletheburner is working without any problem, theair pressure
switch is adjusted to desiredminimumpressureas follows.
ØUnscrew thescrewof thetransparent cover and removethecover.
ØTurn theadjustment wheel in thedirection to increasethepressure,
notethepressurevalueat which theburner is failed.
ØSet thepressureswitch to avalue1 mbar lower than thepressure
valueat which theburner failed and closethepressureswitchlid.
ØIt is recommended that this adjustment is carriedout when the
burner is atminimumload.
8.5. ServomotorAdjustment
Theamount of air isadjustedby means of theservomotor. Theservomotor adjustment attwo-stage
and modulating burners is madeby thecams on theservomotor.
ØSQN70/SQN71
At Modulating Burners;
I. Red Cam:Performance max. air adjustment.
II. BlueCam: Resets theclamp.
III. OrangeCam: Performsmin. air adjustment.
IV. BlackCam: Not used.
Do not open servomotor. Do not interferewith. It may damageservomotor or changeburner
settings.
8.6. Program Relay
LFL 1.335

01.06.2021 Rev. 05 17
9. GASVALVE ADJUSTMENT
9.1. BANICO ZEVR
Adjusting Gas Flow
Follow thesteps below for adjusting maximumcapacity:
1. Releasethecover of gas solenoid valve.
2. Removethestopperwith a4 mmallen.
3. Turn theadjustment screw clockwisein order to reduce theflow rateand
counterclockwiseto increaseflow rate.
4. After adjusting theflow ratefasten thestopper andcover.

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9.2. ELEKTROGASVMR
Adjusting Gas Flow
Follow thesteps below for adjusting maximumcapacity:
1. Releasethecover of gas solenoid valve.
2. Removethestopperwith a4 mmallen.
3. Turn theadjustment screw clockwisein order to reduce theflow rateand
counterclockwiseto increaseflow rate.
4. After adjusting theflow ratefasten thestopper andcover.

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9.3. BRAHMA EG
AdjustingGas Flow
Follow thesteps below for adjusting combustion:
1- Removethebottomcover in order to adjust gas flow rate.
2- Turn theadjustment screw, shown as number 1 in Figure2, clockwiseto
reducetheflow rateand counterclockwiseto increasetheflow rate.
3- Fasten thebottomcover afteradjusting theflow rate.