Riello BG5 Quick start guide

2903402 (3) - 09/2009
Installation, use and maintenance instructions
Instrucciones de instalación, uso y mantenimiento
Light-oil burner
Quemador de gasóleo
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3738855 BG5 388 T1
GB
E
One stage operation
Funcionamiento a 1 llama

MANUFACTURER'S DECLARATION
RIELLO S.p.A. declares that the following products comply with the NOx limits specified by
German standard “1. BImSchV 2009”.
DECLARACIÓN DEL FABRICANTE
RIELLO S.p.A. declara que los siguientes productos respetan los valores límite de emisión
de los NOx impuestos por la legislación alemana “1. BImSchV 2009”.
Product - Produkto Type - Tipo Model - Modelo
Light oil burner
Quemador de gasóleo 388 T1 BG5
Legnago, 01.09.2009 Ing./Mr. G. Conticini
Burners Division Department
Dirección División Quemadores
RIELLO S.p.A.

3402 1GB
INDEX
1. BURNER DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Firing rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Electrode positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. WORKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Combustion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Recommended nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Pump pressure and air output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Flame detector adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Fuel heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.6 Operating programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6.1 Normal operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6.2 Lockout due to firing failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6.3 Lockout due to extraneous light during pre-purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6.4 Lockout types and triggering times in case of burner malfunction. . . . . . . . . . . . . . . . . . . . . . . 13
4.6.5 Control box reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.6.6 Re-cycle function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.6.7 Logging of burner operation parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7 Additional programmable control box functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7.1 Post-purging function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7.2 Continuous purging function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7.3 Long pre-purging function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7.4 Function setting procedure using reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Visual diagnostic control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Start-up problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Trouble during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. SAFETY WARNINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1 Burner identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2 Basic safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3402 2GB
1. BURNER DESCRIPTION
1.1 BURNER EQUIPMENT
Flange with insulating gasket. . . .No. 1 Screw and nuts for flange to be fixed to boiler . . . No. 4
Screw and nuts for flange . . . . . .No. 1 Flexible oil pipes with nipples. . . . . . . . . . . . . . . . No. 2
Remote reset connection . . . . . .No. 1
1.2 ACCESSORIES
DIAGNOSTIC SOFTWARE KIT
A special kit is available that detects the life of the burner through optical connections with a PC showing
the duty hours, number and types of lockout, control box serial number etc...
Do the following to display the diagnostic:
³Connect the kit supplied separately to the appropriate socket on the control box.
The information is read after the software program in the kit is booted.
REMOTE RESET KIT
The burner is fitted with a remote reset kit (RS) consisting of a connection to which a button can be con-
nected up to a distance of 20 meters.
For the installation, remove the protection block installed in the factory and install the block that is supplied
with the burner (see wiring diagram on page 7).
One stage light oil burner with low pollutant emissions (Nitric Oxide NOx, Carbon monoxide CO and unburnt
Hydrocarbons). The burner has a device (compensator) which is integral with the air damper that sets the air
output. This device keeps the oxigen level as necessary for the combustion despite any changing of the
room temperature.
The dimension of the boiler’s combustion chamber must respond to specific values, in order to guarantee a
combustion with the lowest polluting emissions rate.
The RIELLO Technical Service Personnel will be glad to give you all the imformation for a correct matching of
this burner to the boiler.
³CE Certification No.: 0036 0268/99 as 92/42/EEC.
³The burner meets protection level of IP X0D (IP 40), EN 60529
³Burner with CE marking in conformity with EEC directives: EMC 89/336/EEC - 2004/108/EC, Low Volt-
age 73/23/EEC - 2006/95/EC, Machines 98/37/EEC and Efficiency 92/42/EEC.
Fig. 1
1–Oilpump
2– Control-box
3– Reset button with lock-out lamp
4– Air damper adjustment assembly
5– Nozzle holder assembly
6 – Flame detector
7 – Hydraulic jack
8 – Temperature probe of the compensator
9 – Start delaying device
5
42 3
8
9
7
1
6
D8012

3402 3GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 FIRING RATE (as EN 267)
TYPE 388 T1
Output - Thermal power 4.3 – 6.1 kg/h - 51 – 72.3 kW
Fuel Light oil, viscosity 4 – 6 mm2/s at 20 °C
Electrical supply Single phase, 230V ±10% ~50Hz
Motor Run current 1.8A – 2750 rpm – 289 rad/s
Capacitor 6.3 µF
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure 8 – 15 bar
Absorbed electrical power 0.47 kW
230 307 300 189
140
170
12
34
285
345
11
83
83
106
45°
45°
D5485
ø97
Light oil output – kg/h
Thermal power – kW
Pressure in combustion
chamber – mbar
60 65 70
1,0
0,6
0,4
0,2
0
D4530
5,74,5
50
0,8
55
4,3 4,7 5,1 5,3 5,5 5,9 6,14,5
-0,2

3402 4GB
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 WORKING POSITION
The burner is designed to work only in the positions, 1and 2.
Installation 1is preferable, as it is the only one that allows performing maintenance operations as de-
scribed in this manual. Installations 2allow working operations but not maintenance with hooking to the
boiler. Any other position could compromise the correct working of the appliance.
Installations 3, 4 and 5are forbidden for safety reasons.
3.2 BOILER FIXING
To install the burner on the boiler, do the following:
³Put on the flange (1) the screw and two nuts, (see fig. 3);
³Widen, if necessary, the insulating gasket holes (5), (see fig. 4);
³Fix the flange (1) to the boiler door (4) using screws (2) and (if necessary) the nuts (3) interposing the
insulating gasket (5), (see fig. 2).
³After installation ensure that burner is lightly inclined as in fig. 5.
Boiler door must have a max. thickness of 180 mm, refractory linig included.
D7088
1 2 3 4 5
ATTENTION:
S7144
D5012
D5025
Fig. 4
Fig. 5
Fig. 3
Fig. 2

3402 5GB
3.3 FUEL SUPPLY
The burner is designed to allow entry of the oil supply pipes on either side.
Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate
(1) and cable clamp (2) should be reversed, (see fig. 6).
3.4 ELECTRODES ADJUSTMENT, (see fig. 7)
D5530
121
Fig. 6
Fig. 7
D5757
6,5 +0,5 mm
0
3
1
2
8mm
MEASURES MUST BE RESPECT-
ED AND ALSO THE UPWARDS PO-
SITION.
Lean insulators (1) to disc (2), (see
fig. 7).
To have access to the electrodes
carry out operation as described in
chapter 4.2 (page 8) “RECOMMEND-
ED NOZZLES”.
ATTENTION:

3402 6GB
3.5 HYDRAULIC SYSTEMS
It is necessary to install a filter on the fuel supply line.
* ONLY FOR ITALY: Automatic shut-off device as per Ministry of Internal Affairs’ regulation no 73 dated 7/29/71.
H= difference of level; L= max. length of the suction line; I. D. = internal diameter
5
3
2
7
6
1
Fig. 9
D5527
PRIMING PUMP
On the system in fig. 8 it is sufficient
to loosen the suction gauge connection
(6, fig. 9) and wait until oil flows out.
On the systems in fig. 10 and 11 start the burner and wait for the priming.
Should lock-out occur prior to the arrival of the fuel, await at least 20 seconds
before repeating the operation.
The pump suction should not exceed a maximum of 0.4 bar (30 cm Hg).
Beyond this limit gas is released from the oil. Oil pipes must be completely tight.
In the vacuum systems (fig. 11) the return line should terminate within the oil tank
at the same level as the suction line. In this case a non-return valve is not re-
quired. Should however the return line arrive over the fuel level, a non-return
valve is required.
This solution however is less safe than previous one, due to the possibility of
leakage of the valve.
³Before starting the burner make sure that the return pipe-line is not
clogged. An excessive back pressure would cause the damage of
the pump seal.
³The pump is designed to allow working with two pipes. In order to
obtain one pipe working it is necessary to unscrew the return plug
(2), remove the by-pass screw (3) and then screw again the pin (2),
(see fig. 9).
ATTENTION:
H
meters
L meters
ø i
8 mm
ø i
10
mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
SYSTEM NOT ALLOWED
IN GERMANY
max. 4 m
H
Fig. 8
*
D5488
H
meters
L meters
ø i
8 mm ø i 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
D5489
H
H
Hmax. 4 m
max. 4 m
**
H
Fig. 10 Fig. 11
4
1- Suction line
2- Return line
3- By-pass screw
4- Gauge connection
5- Pressure adjuster
6- Suction gauge connection
7- Valve

3402 7GB
3.6 ELECTRICAL WIRING
CONTROL BOX (see fig.12)
To remove the control box from the burner it is necessary to:
³disconnect all the connectors, the 7-pin plug, the high voltage
cables and the earth wire (TB);
³unscrew the bolt (A) and pull the control box in the direction of the
arrow.
To install the control box it is necessary to:
³screw the bolt (A) in at a torque of 1 - 1.2 Nm;
³reconnect all the connectors previously disconnected.
NOTE:
The burners have been type-approved for intermittent operation.
This means they must stop at least once every 24 hours in order to al-
low the electrical control box to check its efficiency on start-up.
The boiler limit thermostat (TL) normally ensures the burner halts. If
this does not happen a time switch halting the burner at least once
every 24 hours must be applied in series to (TL).
AE9275
KEY TO LAY-OUT:
C–Capacitor
E–Electrode
F–Flame detector
h1 –Hour counter
(230V ~ - 0,1A max.)
K–Thermostat enabling
start-up after preheating
MV –Motor
PH –Oil heater
RS –Remote reset
SER –Safety lockout device
S3 –Remote lockout signal
(230V ~ - 0,5A max.)
T6A –Fuse
TB –Burner earth
TL –Limit thermostat
TS –Safety thermostat
V1 –Oil valve
V2 –Safety lockout device
X7 –7 pin plug
XP7 –7 pole socket
TO BE DONE BY
THE INSTALLER
CARRIED-OUT
IN THE FACTORY
TESTING
³Check the burner has stopped by
opening the thermostats.
³Check the burner's lockout dur-
ing operation by interrupting the
flame detector.
CONTROL BOX
MO550
D7240
Main switch
230V ~ 50Hz
Fig. 12
³Do not swap neutral and phase over, follow the dia-
gram shown carefully and carry out a good earth con-
nection.
³The cross section of the wires must be at least 1 sq. mm.
(Unless requested otherwise by local standards and legis-
lation).
³The electrical wiring carried out by the installer must com-
ply with the rules in force in the country.
ATTENTION:
*(See “Hydraulic systems” on pag
e
6). If any of the hydraulic systems fea
-
ture the automatic shutoff device (230
V
- max. 0.5A), it must be connected t
o
terminals N - T2 in the 7-pin plug.

3402 8GB
4. WORKING
4.1 COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjustment and
testing must be carried out observing the instruction manual of the boiler, including verification of the CO and CO2
concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.
To suit the required appliance output, choose the proper nozzle, adjust the pump pressure and the air damper
opening in accordance with the following schedule.
The high-flame values in the table refer to 12.5% CO2at sea level and to “zero” pressure in the combustion
chamber.
4.2 RECOMMENDED NOZZLES:
Delavan 80° W with filter DROPSTOP type
60030.
TO FIT NOZZLE CARRY OUT THE FOLLOW-
ING ACTIONS (see fig. 13):
³Remove nozzle-holder assembly (1) after
loosing screws (3) and nut (5), remove the
small cables (7) from the control box, the
socket (6) and the flame detector (4).
³Withdraw the small cables (7) from the
electrodes, remove the diffuser disc-hold-
er assembly (8) from the nozzle-holder as-
sembly (1) after loosing screw (3, fig. 7,
page 5).
³Screw the nozzle (9) correctly and tighten
it as shown in figure.
³During the reassembly of the nozzle-
holder assembly screw the nut (5) as
shown in the fig. 14.
³In order to guarantee the sealing of the
fan in its seat, make sure that there is at
least 1 mm of spring tension between
nozzle-holder assembly and casing.
Therefore the fixing split pin (2) will have
to be extended at least of 1 mm beyond
the flange of the nozzle-holder assembly.
Nozzle Pump
pressure Burner output Air damper adjustment
Low-flame High-flame
GPH Angle bar kg/h ± 4% Set-point Set-point
1.10 80° 13 4.3 0.3 3.1
1.25 80° 14 5.1 0.6 3.9
1.35 80° 14 5.5 0.7 4.7
1.50 80° 14.5 6.2 0.9 6.0
QUALIFIED PERSONNEL WITH THE RIGHT INSTRUMENTS MUST HANDLE THE BURNER'S START-UP.
!
ATTENTION
Fig. 13
D8216
ATTENTION:
Fig. 14
5
D5684
TIGHTEN WITHOUT
MOVING BACKWARDS
TO THE END