ECOSTAR NG Series Installation guide

02.02.2021 Rev. 01
www.ecostar.com.tr
MONOBLOCKNGSERIES LOWNOx ANDULTRA
LOWNOxSERIES GAS BURNERS
INSTALLATION,OPERATING ANDMAINTENANCE
MANUAL
MODULATING OPERATION
ECO NG LNX 90 G (FGR)
ECO NG LNX 120 G (FGR)
ECO NG LNX 200 G (FGR)
ECO NG LNX 300 G (FGR)
ECO NG LNX 400 G (FGR)

02.02.2021 Rev 01. 1
DEAR USER,
ECOSTAR ECO NGLNX90 G(FGR), ECO NGLNX120 G(FGR), ECO NGLNX200 G
(FGR), ECO NGLNX300 G(FGR), ECO NGLNX400G(FGR)) Series Low NOx andUltra
Low NOx Gas 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]

02.02.2021 Rev 01. 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. GAS,FLUE GASAND HEATING WATER SCHEME ..................................................................... 8
4.1.New Generation Low NOx Gas Burner Gas, FlueGas, and Heating WaterScheme........................ 8
4.2.New Generation UltraLow NOx Gas BurnerGas, FlueGas, and Heating Water Scheme............... 8
5. TECHNICAL DATA ............................................................................................................................ 9
5.1. Capacity Table................................................................................................................................ 9
5.2. Back Pressure-Capacity Diagrams............................................................................................... 10
5.3. Burner Dimensions....................................................................................................................... 11
6. FGR NOxREDUCTION SYSTEM.................................................................................................... 13
6.1. FGR SystemFactory Control Parameters.................................................................................... 13
6.2. FGR SystemPipeDiameter, Length ,andEquivalent Length Informations................................ 15
6.3. FlameLength and Diameter......................................................................................................... 16
6.4. NoiseLevel................................................................................................................................... 16
7. BURNER HANDLING INFORMATION.......................................................................................... 16
8. INSTALLATION................................................................................................................................ 17
8.1. Burner Installation Picture............................................................................................................ 17
9. COMMISSIONING............................................................................................................................. 18
9.1. BeforeCommissioning................................................................................................................. 18
9.2. General Controls .......................................................................................................................... 19
9.3. Combustion Adjustment............................................................................................................... 20
9.3.1. Gas Adjustment........................................................................................................................ 20
9.3.1.1. VGD 40… Series Gas Valve................................................................................................ 20
9.4. Air pressureswitchadjustment .................................................................................................... 21
9.5. BT 300.......................................................................................................................................... 22
9.6. Control SystemMounting andFunctions SystemOverview....................................................... 23
9.6.1. Operating Control and Displays ............................................................................................... 25
9.7. LeakageTest for Main Gas Valves.............................................................................................. 26
9.8. Servomotors.................................................................................................................................. 27
9.9. Function Controls and Adjustments............................................................................................. 28
9.10. Final Checks ............................................................................................................................. 28
9.11. Emission Measurement............................................................................................................. 28
9.12. Gas Pass Equipment Requiredin Gas Line.............................................................................. 29
10. MAINTENANCE............................................................................................................................ 30
10.1. Monthly Maintenance............................................................................................................... 30
10.2. SeasonalMaintenance.............................................................................................................. 30
11. PERIODICAL FLUE GASMEASUREMENT REPORT.............................................................. 31
12. AFTER-SALESSERVICES............................................................................................................ 32
13. NOTES............................................................................................................................................. 33

02.02.2021 Rev 01. 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.
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.

02.02.2021 Rev 01. 4
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 fire orother emergency;
Switch off themain switch
Closethemain fuel shut-off valveoutsidetheplant.
Takeappropriateactions

02.02.2021 Rev 01. 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 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 andair 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. Thebuildup of toxic/ explosivegas mixtures intheburner room,
b. Combustionwithinsufficient air, resulting inhazardous,anti-economical andpolluting 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.

02.02.2021 Rev 01. 6
2. TERMSOF WARRANTY
Main and auxiliary equipment and all components usedin Ecostargasburners areguaranteedfor 1
yearby TERMO ISISST. 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,
•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.

02.02.2021 Rev 01. 7
3. BURNER’SGENERAL FEATURES
ECOSTARNG SeriesLowNOx and UltraLowNOx gasburners aremanufacturedsuchthat
theyoperatein gaspressureof min. 20mbarand max. 300mbar. at15%...+10% of nominalvoltage,
betweentheambient temperaturerangeof -15ºC….+60˚Cand declaredcapacity andboilerpressure
ranges with NaturalGas.
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.
-Operation with Natural gas and LPG.
This devicemust never beoperated withopen flame!
3.2. CodeKey

02.02.2021 Rev 01. 8
4. GAS, FLUE GASAND HEATING WATER SCHEME
4.1.NewGenerationLowNOx Gas Burner Gas, FlueGas, and Heating Water Scheme
4.2.NewGenerationUltra LowNOx Gas Burner Gas, FlueGas,and Heating Water Scheme

02.02.2021 Rev 01. 9
5. TECHNICAL DATA
5.1. Capacity Table
NEW GENERATION LOW NOx GAS BURNERS CAPACITY TABLE
BURNERTYPE THERMALCAPACITY NATURALGAS
CONSUMPTION NOx EMISSIONS
FAN
MOTOR
POWER
MAIN
SUPPLY
Min.
kcal/h Max. kcal/h Min. kW Max. kW Min. Nm³/h Max. Nm³/h Standard mg/kWh kW VAC
ECO NG LNX 90 G 154.800 774.000 180 900 18,8 93,8 80 1,50 3N 380
ECO NG LNX 120 G 215.0001.032.000 250 1.200 26,1 125,1 80 2,20 3N 380
ECO NG LNX 200 G 404.2001.720.000 470 2.000 49,0 208,5 80 3,00 3N 380
ECO NG LNX 300 G 369.8002.580.000 430 3.000 44,8 312,7 80 4,00 3N 380
ECO NG LNX 400 G 498.8003.440.000 580 4.000 60,5 417,0 80 7,50 3N 380
NEW GENERATION ULTRA LOW NOx GAS BURNERS CAPACITY TABLE
BURNERTYPE THERMALCAPACITY NATURALGAS
CONSUMPTION NOx EMISSIONS
FAN
MOTOR
POWER
MAIN
SUPPLY
Min.
kcal/h Max.kcal/h Min. kW Max. kW Min. Nm³/h Max. Nm³/h Standard mg/kWh kW VAC
ECO NG LNX 90 G FGR 154.800 774.000 180 900 18,8 93,8 50 1,50 3N 380
ECO NG LNX 120 G FGR 215.000 989.000 250 1.150 26,1 120 50 2,20 3N 380
ECO NG LNX 200 G FGR 404.200 1.651.200 470 33.604 49 200 50 3,00 3N 380
ECO NG LNX 300 G FGR 378.400 2.580.000 440 3.000 45,9 312,7 50 4,00 3N 380
ECO NG LNX 400 G FGR 498.800 3.371.200 580 3.920 60,5 409 50 7,50 3N 380
HuNatural Gas =8250 kcal/Nm3
NOx emissions aregiven on thecapacity tables according to EN 676+A2 standard.

02.02.2021 Rev 01. 10
5.2. BackPressure-Capacity Diagrams
Boilerbackpressurevaluesaremeasuredatbackpressuredtest boilerusing G20 referencegas
according to EN 676+ A2, with net calorificvalueis 8250 kcal/Nm³.

02.02.2021 Rev 01. 11
5.3. Burner Dimensions
ECO NG LNX 90 G , ECO NG LNX 120 G, ECO NG LNX 200 G, ECO NG LNX 300 G, ECO NG LNX 400 G

02.02.2021 Rev 01. 12
ECO NG LNX 90 G FGR , ECO NG LNX 120 G FGR , ECO NG LNX 200 G FGR , ECO NG LNX 300 G FGR ,
ECO NG LNX 400 G FGR

02.02.2021 Rev 01. 13
6. FGR NOx REDUCTION SYSTEM
External FlueGas Recirculation(FGR) is effectiveand low cost solution to achievevery low NOx
emissions.Somefluegasfromchimneyis ledbacktathecombustion chamberthroughburner; which
reducesNOx emissions by cooling down flamepeaktemperatureandby slowing combustion reactions.
Achivable reductiondepends on burnertype, boiler; combustion air temperatureand otherfactors.
6.1. FGR System Factory Control Parameters
ParameterDefault Set Value Operating Mode
402 1 FGR active
319 140 s Pre purge time
331 195 s FGR system activating time at burner maximum heat capacity
332 110 °C Minimum flue gastemperature for FGR
402 1 FGR channel function 3
414 30 s FGR flap starting time – During the burner prepurge
FGR systeminstall parameters can bechanged by themanufacturer.

02.02.2021 Rev 01. 14
FGR Operating Conditions are ListedBelow:
1. Burner safety control isdone withair presostat.
2. Flow rate iscontrolled with butterfly valve .
3. Flue gasflow rate iscontrolled by a butterfly valve integrated with servomotor.
4. Burner O2 emission valuesmustbe setted over 0,5 –0,7% when FGR isclosed. O ≤%3, when FGR is
closed; 3,5 ≤%O ≤3,7, when FGR isopened.
5. If operation set value of inverter and O / CO control burner issetted while FGR isactive.
6. FGR flap must be closed position while burner issetting for ignition.
7. Leak proofing of FGR flap must be controlled.
8. FGR flap isclosed at the beginning of pre purge time.
9. Air control actuator ispositioned for ignition, after prepurging iscompleted.
10.
Fuel and air flapsarepositionedfor ignition when FGR flap isclosed.After they arepositioned,ignition
starts.
11.
Burner issetted up to maximum heat capacity when FGR systemisclosed.
12.
Maximum flue gasflow rate of burner shouldn’t be excessedof %20, when burner at minimum and
maximum heat capacity.
13.
FGR systemflue gastemperature mustbe between80°C and120°C on setting 332 parameter. If the
temperature range isnot among the defined temperature range, FGR flap isnot move.
14.
PT100 temperature sensor must be positioned on aspiration line .
15.
Electric scheme mustbe linked to 28-29-30terminal.
16.
If the burner reachestemperatureand pressure limit values, air, fuel and FGRflapsare closed.
17.
One direction flow flap should be used, if combustion air suction isprovided by combusiton fan on the
conventional monoblock burners.
18.
Straight pipesshouldbe placed at the flow direction with 1–2°angle to provide condensingwater flow
easily.
19.
The channel mustbe linked to flue gasoutlet with 45° angle. The center of the cut mustcoincidewith the
center of the chimney.
20.
The componentsof pipe channelto create anair leakproof channel should be welded, flanged, andscrewed
professionally. Maintenance of the air channel should be done periodically.

02.02.2021 Rev 01. 15
6.2. FGR System PipeDiameter,Length,and Equivalent LengthInformations
Pipe
Diameter ECO NG LNX 90 G ECO NG LNX 120G
ECO NG
LNX 200G ECO NG LNX 300G ECO NG LNX 400G
DN 50 2,4 1,2 - - -
DN 65 9,1 4 2 1,5 -
DN 80 25 13 7 4 3
DN 100 52 35 25 14 8
DN 125 - 104 72 40 25
DN 150 - - - - 70
FGR Line Pipe Diameter and Length (L, m) at %20 Load
Pipe
Diameter 90° Elbow 45° Elbow
90° ''T''
Shape
Drainage
Return
DN 50 1 0,4 4
DN 65 2,5 1,1 4,5
DN 80 2,7 1,3 6
DN 100 4 2,2 7,5
DN 125 4 2,5 9
DN 150 5 3 12
FGR Line P Equivalent Length (m)

02.02.2021 Rev 01. 16
6.3. FlameLengthandDiameter
6.4. NoiseLevel
Product operates within therangeof 75 decibels max. and 85 decibels.
7. 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.

02.02.2021 Rev 01. 17
8. INSTALLATION
8.1. Burner InstallationPicture
1. Burner
2. Boiler Connection Flange
3. Gasket
4. Boiler Flange
5. FGR Flap
6. Condensation Outlet
7. FGR FlapServomotor
You must definitely ensuresealing between boiler and burner!
Device must beshipped in original packaging!
Do not liftthedevice holdingfromservomotor, gasval
ve,impulsepipesor pressureswitch
during installation!
Cleantheinsideoffuellinethoroughly beforeinstalling theburnerto thefuelline.Any
damagethatmayoccur duetosolid objects and metalparticlesfromthefuellineshallnot be
covered by our company.

02.02.2021 Rev 01. 18
Whileinstalling theburnerin reverseflamefront mirror boilers, flametubetip must beadjusted
suchthatitgets insideby 50 mm-100 mm fromfluepipes(50mm≤A≤100mm).Otherwisefluegas
temperaturewill riseand fuelconsumption will increase.
9. COMMISSIONING
9.1. Before Commissioning
Electricalconnection
Performelectricalconnectionsaccording to thediagramprovidedwith theburner. Follow general
securityrulesduringinstallationof electricwiring and making connections. Connecttheearthing terminal
in electricpanelto theearthing installation.

02.02.2021 Rev 01. 19
9.2. GeneralControls
Makesureto performthefollowing controls beforecommissioning theburner.
ØAretheelectrical connections correct?
ØIs thereelectricity current?
ØIs theregas?
ØHas theheating systembeen filled with water?
ØIs thethermostat set at therequired temperature?
ØHas theboilerexplosion lid been controlled?
ØIs theresufficient airin boiler room(ventilation section cm² =boilercapacity kWx 7)
ØHas theboiler beeninstalled correctly?Has theboilercover beenclosed properly?
ØHas theair of thegas linebeen removed?Has asealing test beenmade?
Operationof a modulatingburner
ØOpen themain gasvalve; checkmax 300mbar gas pressurefromthemanometer.
ØOpen operating switch on theburner panel.
ØSwitch on themodulating control switch.
ØSwitch automatic-hand switch to automatic.
ØCheck thetemperatureand pressureset values fromthemodulating control unit.
ØIgnition will takeplace at theend of pre-purgeprocess.
Ø3 sec. later, thegasvalvewill beopenedand combustion willoccur.
ØFlamecontrol system(ionization) will start flamecontrol.
ØIn modulating burner, theburnergoesinto max. capacityaccording to thesignalfromthe
modulating control unit.
ØWhentheboilerwatertemperatureor steampressureincrease,themodulating control unitwill
causeburner to run with min. capacity.
ØIf theboilerwatertemperatureor steampressureincreasesdespitetheoperation of burnerwith
min. capacity, themodulating control unit will stop theburner.