ECOSTAR GRM Series Installation guide

08.10.2018 Rev. 04 www.ecostar.com.tr
GRM SERIESNOZZLE MIXBURNERS
INSTALLATION, OPERATINGAND
MAINTENANCE MANUAL
MODULATING OPERATION
GRM15
GRM30
GRM60
GRM80

08.10.2018 Rev. 04 1
DEAR USER,
ECOSTARGRM15,GRM 30,GRM 60,GRM80GRM Series burnersare
prepared and manufacturedaccordingtothe latest technical developments and safetyrules.
It is easyto use for ourcustomers.
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 youforchoosing ECOSTAR 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]

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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. Burner Components......................................................................................................................8
4. GAS,FLUEGASANDHEATING WATER SCHEMA..................................................................10
5. TECHNICAL DATA ........................................................................................................................11
5.1. Capacity Table...........................................................................................................................11
ModulationRates..................................................................................................................................11
5.2. Burner Dimensions.....................................................................................................................12
6. BURNER HANDLING INFORMATION ........................................................................................13
7. INSTALLATION..............................................................................................................................14
7.1. Burner InstallationPicture..........................................................................................................14
8. COMMISSIONING..........................................................................................................................15
8.1. General Controls........................................................................................................................15
8.2. Operating GazoramBurner ........................................................................................................15
8.3. FunctionControls.......................................................................................................................15
8.4. AirPressure SwitchAdjustment.................................................................................................16
8.5. Servomotor Adjustment.............................................................................................................16
8.6. ProgramRelay............................................................................................................................16
9. GAS VALVE ADJUSTMENT..........................................................................................................17
9.1. BANICOZEVR.........................................................................................................................17
9.2. ELEKTROGASVMR................................................................................................................18
9.3. BRAHMA EG............................................................................................................................19
9.4. Gas PassEquipmentRequiredinGasLine................................................................................20
10. AIR/FUELADJUSTMENT...........................................................................................................21
11. MAINTENANCE..........................................................................................................................22
11.1. Daily Maintenance..................................................................................................................22
11.2. MonthlyMaintenance.............................................................................................................22
11.3. Seasonal (6 Months)Maintenance..........................................................................................22
12. ELECTRICDIAGRAM ................................................................................................................23
13. TROUBLESHOOTING.................................................................................................................27
Burner is not working...........................................................................................................................27
Fan motor fails ashort timeafter it starts..............................................................................................27
14. PERIODICAL FLUEGASMEASUREMENTREPORT.............................................................28
15. AFTER-SALES SERVICES..........................................................................................................29
16. NOTES..........................................................................................................................................30

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1. WARNINGS
1.1. WarningSymbolsandDescriptions
Symbols SymbolDescriptions
Important information and usefulhints.
Warning of danger to lifeor property.
Warningofelectrical voltage.
Product handling information.
Electricmotor direction ofrotation
Carry inanupright position.Fragile Item.Protectagainstwater.

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1.2. General Safety Rules
•All personnel engagedininstallation,disassembly,commissioning,operation,control,
maintenanceand repair should havereceived thenecessarytrainingandfullyread and understood
thismanual.
•Nochangesthatmightdamage thesafety oftheburner unit 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,and ventilationand air discharge holesmust notbe closed.
Ifyou sensescent ofgas;
•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 burnerinstallation must be carriedoutinaccordancewith theinstructions.Vibration can
damage the burner and itscomponents.
Keep combustionroomdoors closed while startingburnerand duringburner operation.
Check combustion values to be correctby using flue gas analyzeratthe wholeadjustment range
between minimum,fullload, and ignitionload.
During the first commissioning oftheburner or in case ofany revision carried out in the electrical
systemor motor cables by any reason,direction of the fan rotationmust certainly be checked by
the authorizedtechnical service.
Forproducts thathave notbeen comissioned orstarted morethan6months,beforeactivating the
servomotor;
Ingasandair dampers, servomotor andair damper connections must be checkedtoensurethat
they are free running inspite of immobility and 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.

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2. TERMS OF WARRANTY
Main andauxiliary equipment and allcomponents used inEcostar gasburners areguaranteed
for 1yearby TERMOISIS ST.A.Şstarting fromthe date of commissioning under themaintenance,
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. OutofWarrantyConditions
•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 packaging untiltheinstallationstage,
•Incorrectand poor electrical connections,failuresdue to incorrect voltageapplications,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,
•Deviceswithany falsification on thewarranty certificateor withoutanoriginalserialnumber.
•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.

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3. BURNER’SGENERALFEATURES
ECOSTARgasburners aremanufacturedsuch thatthey operate in gaspressure ofmax.50 mbar, at
-15%...+10% ofnominal voltage,between theambient temperaturerange of-15ºC….+60˚Cand declared
capacity and boilerpressure ranges withNaturalGas and LiquidPetrol Gas.
3.1. Purpose ofUseand WorkLimitsof Burners
•Thisproduct works at any load value equivalentto itsmax.capacity or covered by itscapacity
range;
-Notused infurnacesperformingdirectdrying withnatural gasand drying cabinets,
-In vacuumor"0"(zero) pressure combustionchambers,
-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.
-Notused incombustion chamberswithpositive pressure.
This devicemust never beoperatedwithopenflame!

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3.2. Burner Components

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No Part Name No Part Name
1
Body
22
Gasket
2
FlameTube
23
ObservationGlassFrame
3
Relay MountingPlate
24
ObservationGlass
4
Gas Diffuser
25
Linkage
5
Swirler Disc
26
SteelNipple
6
Ionization Electrode
27
Servomotor ConnectionFlange
7
IgnitionElectrode
28
Copper Washer
8
Relay
29
Purger
9
Relay Socket
30
Purger Needle
10
WallType 24PinSocket
31
FanGroup
11
Transformer
32
Socket Screw
12
Gas Valve
33
Washer
13
Hex Bolt
34
Socket Screw
14
SolenoidValve
35
Bolt
15
Air Damper
36
Washer
16
Air Damper MotionRod
37
Carriage Bolt
17
PressureSwitch
38
Socket Screw
18
Servomotor
39
Bolt
19
Servomotor Shaft
40
Socket Screw
20
StudBolt
41
Socket Screw
21
Gas Pipe

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4. GAS, FLUEGASANDHEATING WATER SCHEMA

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5. TECHNICALDATA
5.1. CapacityTable
GRM SERIES BURNER CAPACITYTABLE
BURNERTYPE CAPACITY CAPACITY NATURALGAS
CONSUMPTION MAIN
SUPPLY
Min.
kcal/h
Max.
kcal/h
Min.
kW
Max.
kW
Min.
Nm3/h
Max.
Nm3/h VAC
GRM15 3.300 150.000 3,84 174,42 0,40 18,18 1N220
GRM30 8.500 300.000 9,88 348,84 1,03 36,36 1N220
GRM6015.000 550.000 17,44 639,53 1,82 66,67 1N220
GRM80 15.000 750.000 17,44 872,09 1,82 90,91 1N220
HuNatural Gas=8250 kcal/Nm3
HuLPG=22500 kcal/Nm3
Modulation Rates
GRM 15: 45:1 GRM30: 35:1 GRM60: 36:1 GRM 80: 50:1

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5.2. Burner Dimensions

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6. BURNER HANDLING INFORMATION
•Lifttheproduct byholdingthehandlesasseeninthe picture.
•Prevent strong impactsontopoftheproductandvibrationwhile handlingtheproduct.
•Donotleavetheproductinwet environment.
Devicemustbe shippedinoriginal packaging!

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7. INSTALLATION
7.1. Burner Installation Picture
1-Flametube
2- ConnectingFlange(welded to the body)
3- Body
4- Gasintake flange
5-Fan
6- Installation bolt
7- Installation gasket
8- Combustionchamber wall
9- Insulationmaterial
It ispossible to performinstallation inGRM Series Burners suchthat combustion air ventilator
andgaspatharein different axes.Suggested method ofinstallationisthe installation,inwhich
gas line is parallel to theaxissothatitiseasier to interferegaslineequipment.The hole tobe
opened on combustion chamber wall mustbe20mmlargerthanthediameter oftheflametube.
Installationsurfacemustbe coatedwith insulationmaterial(9) in orderforburner equipmentnot
to beaffected bycombustionchamber.
Use suitablecompensator or flexhosewhile connecting thegasline reaching outtheburner tothe
burner gas line.
Do not liftthe deviceholding fromservomotor,gas valve,impulsepipesor pressureswitch during
installation!
Clean the inside offuel line thoroughly beforeinstalling the burner to the fuel line.Any damage
that may occur duetosolidobjectsand metal particlesfromthefuelline shallnot be covered by
our company.

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ElectricalConnection
Performelectrical connectionsaccordingto thediagramprovidedwiththeburner.Follow
general security rules duringinstallationofelectric wiringand makingconnections.Connectthe
earthingterminal inelectric panel tothe earthing installation.
8. COMMISSIONING
8.1. General Controls
•Aretheelectrical connectionscorrect?
•Has thesealing of gas linesbeen controlled?
•Isthepressure provided totheburner suitable?(max.50mbar)
•Isthesuction ventilator connected tothecombustion chamber working?
•Isthewallelement checkingcombustionchamber temperatureworkingcorrectly?
8.2. OperatingGazoramBurner
•Verifythatthecombustionchamber suction ventilator isworking.
•Insertplugsockets,which ensureelectric connection,intheir holes.
•Sincethegas valve is turnedoff,gaspressureswitch willnotlet the burner towork.
•Turn onthegasshut-offvalve.
•Having detectedgaspressure, gas pressure switch will sendoperatingvoltage tothe programrelay
andrelay'soperational stepswillcommence.
•When fanmotor startsand pre-purge commences,airpressure switch will verifytheexistenceof
combustion airand commencerelay ignition operation.
•Ignition step iscomposed oftwo stages:pre-ignition and final(safety) ignition.Gassolenoid
valveturnson attheend ofpre-ignition period (3 seconds) and flameisformed; ignition is active
for 3secondsmoredespite formation offlame.
•Afterthe flamedetector detects flameexistence,burner continues its normal operation.Working
loadisautomaticallychangedby the proportionalcontrol deviceaccording tothe signalarriving
fromcombustionchamber heatsensitive element.
•In thatcase,commissioningprocessissuccessful.
8.3. Function Controls
a. First commissioningwithclosed gas valve
Following fault, relaymust switch tofaultposition oncethesafety period ends.
b. In firstcommissioning, turnoff thegasvalve while burneris working.
After the flamegoes out,relay should transit tofault position.
c. Cut offair pressure switchduring pre-purgeorworking infirstcommissioning
Burner control unit shouldimmediately bringthedeviceto fault position.
d. Bridge theair pressure switch beforestarting.
Fan motorstarts working for2-3 secondsandswitches to fault at the end ofthisperiod.In
secondtry,devicestartsthe fan motor again and makes another try after 10seconds.Ifthe
contactsof theairpressure switch arestillbridged,itswitches tofaultposition.Assoonas
the unitstartsworking,itchecksif the air pressureswitch isbrought to ON position from
OFFposition.

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8.4. AirPressureSwitchAdjustment
Whiletheburner isworking withoutanyproblem, theair pressure
switchisadjustedtodesired minimumpressure asfollows.
ØUnscrew the screwofthe transparent cover andremovethe cover.
ØTurn theadjustment wheelin the direction toincreasethepressure,
notethepressure value atwhich the burner isfailed.
ØSet the pressure switch toavalue 1mbar lowerthan thepressure
valueatwhichtheburner failed and closethe pressure switch lid.
ØIt isrecommendedthat this adjustment is carried out whenthe
burner isat minimumload.
8.5. ServomotorAdjustment
The amount of air is adjustedby meansofthe servomotor.The servomotor adjustment at two-stage
and modulating burnersismadeby the camson theservomotor.
ØSQN70/SQN71
At ModulatingBurners;
I. RedCam:Performancemax. airadjustment.
II.BlueCam:Resets the clamp.
III.Orange Cam:Performsmin.air adjustment.
IV.Black Cam:Not used.
Do notopen servomotor.Donot interferewith.It may damageservomotor orchangeburner
settings.
8.6. Program Relay
LFL 1.335

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9. GASVALVEADJUSTMENT
9.1. BANICO ZEVR
Adjusting Gas Flow
Follow the stepsbelowfor adjustingmaximumcapacity:
1. Releasethecover ofgassolenoid valve.
2. Remove thestopperwitha4mmallen.
3. Turn the adjustment screw clockwiseinorder toreduce the flowrateand
counter clockwisetoincrease flow rate.
4. After adjustingthe flow rate fastenthestopper and cover.

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9.2. ELEKTROGASVMR
Adjusting Gas Flow
Follow the stepsbelowfor adjustingmaximumcapacity:
1. Release thecover ofgassolenoid valve.
2. Removethe stopperwitha4mmallen.
3. Turnthe adjustment screw clockwiseinorder toreduce the flow rateand
counter clockwise toincrease flow rate.
4. After adjustingthe flowrate fastenthestopper and cover.

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9.3. BRAHMA EG
AdjustingGasFlow
Followthesteps belowfor adjustingcombustion:
1- Remove thebottomcover inorder toadjustgasflow rate.
2- Turn the adjustment screw, shown asnumber 1inFigure 2,clockwiseto
reduce the flow rateandcounterclockwisetoincrease theflowrate.
3- Fastenthebottomcover after adjustingthe flowrate.