Riello BG6.1D Quick start guide

20015403 (5) - 01/2012
Installation, use and maintenance instructions
Instrucciones de instalación, montaje y funcionamiento
Light oil burners
Quemadores de gasóleo
Two stage operation
Funcionamiento a 2 llamas
CODE
CODIGO MODEL MODELO TYPE TIPO
20015692 - 20015693 BG6.1D 985T
20015694 BG6.1D TL 985T
20015695 - 20015696 BG7.1D 986T
GB
E

1 20015403
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual........................................................................................................................ 4
2.1.1 General dangers............................................................................................................................................................. 4
2.1.2 Danger: live components................................................................................................................................................ 4
2.2 Guarantee and responsibility.......................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction..................................................................................................................................................................... 6
3.2 Personnel training........................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation.......................................................................................................................................................... 7
4.2 Models available............................................................................................................................................................. 7
4.3 Technical data ................................................................................................................................................................ 7
4.4 Max. dimensions............................................................................................................................................................. 8
4.5 Firing rate........................................................................................................................................................................ 8
4.6 Description of the burner ................................................................................................................................................ 9
4.7 Burner equipment........................................................................................................................................................... 9
4.8 Accessories .................................................................................................................................................................. 10
5 Installation ................................................................................................................................................................................ 11
5.1 Notes on safety for the installation................................................................................................................................ 11
5.2 Handling........................................................................................................................................................................ 11
5.3 Preliminary checks........................................................................................................................................................ 11
5.4 Operating position......................................................................................................................................................... 11
5.5 Securing the burner to the boiler .................................................................................................................................. 12
5.5.1 Adjusting the choke ...................................................................................................................................................... 12
6 Hydraulic system...................................................................................................................................................................... 13
6.1 Fuel supply ................................................................................................................................................................... 13
6.2 Pump ............................................................................................................................................................................ 13
6.3 Pressurised one-pipe systems...................................................................................................................................... 14
6.3.1 Priming pump................................................................................................................................................................ 14
6.4 Vacuum systems .......................................................................................................................................................... 14
6.4.1 Priming pump................................................................................................................................................................ 15
7 Electrical system...................................................................................................................................................................... 16
7.1 Control box ................................................................................................................................................................... 16
7.2 Electrical wiring............................................................................................................................................................. 17
7.2.1 Testing.......................................................................................................................................................................... 17
8 Operation .................................................................................................................................................................................. 18
8.1 Notes on safety for the first start-up.............................................................................................................................. 18
8.2 Adjusting combustion.................................................................................................................................................... 18
8.3 Nozzles recommended................................................................................................................................................. 19
8.4 Adjusting pump pressure.............................................................................................................................................. 19
8.5 Adjusting the combustion head..................................................................................................................................... 19
8.6 Adjusting the air damper............................................................................................................................................... 20
8.7 Adjusting the flame detector......................................................................................................................................... 20
8.8 Adjusting the electrodes ............................................................................................................................................... 21
8.9 Operating programme................................................................................................................................................... 22
8.9.1 Normal operation with pre-heating................................................................................................................................ 22
8.9.2 Lockout due to ignition failure....................................................................................................................................... 23
8.9.3 Lockout due to extraneous light during pre-purging ..................................................................................................... 23
9 Maintenance.............................................................................................................................................................................. 24
9.1 Notes on safety for the maintenance............................................................................................................................ 24

20015403 2
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Contents
9.2 Maintenance programme ..............................................................................................................................................24
9.2.1 Maintenance frequency.................................................................................................................................................24
9.2.2 Checking and cleaning..................................................................................................................................................24
9.3 Maintenance position ....................................................................................................................................................25
9.4 Visual diagnostics of the control box.............................................................................................................................26
9.4.1 Colour code of the control box reset button LED ..........................................................................................................26
9.4.2 Lockout types and triggering times in case of burner malfunction ................................................................................27
9.4.3 Control box reset...........................................................................................................................................................27
9.4.4 Recycle function............................................................................................................................................................27
9.4.5 Logging of burner operating parameters.......................................................................................................................27
9.5 Additional, programmable control box functions ...........................................................................................................27
9.5.1 Post-purging function (t6)..............................................................................................................................................27
9.5.2 Continuous purging function (only for applications in which this is provided for) ..........................................................28
9.5.3 Long pre-purging function (t7).......................................................................................................................................28
9.5.4 Function setting procedure using the reset button ........................................................................................................28
10 Faults / Solutions......................................................................................................................................................................29
10.1 Start-up problems..........................................................................................................................................................29
10.2 Operating faults.............................................................................................................................................................30

3 20015403
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Light oil burners
Model: BG6.1D - BG6.1D TL
BG7.1D
These products are in compliance with the following Technical Standards:
EN 267
EN 12100
and according to the European Directives:
BED 92/42/EEC Efficiency Directive
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Declaration of Conformity A.R. 8/1/2004 & 17/7/2009 – Belgium
Manufacturer: RIELLO S.p.A.
37045 Legnago (VR) Italy
Tel. ++39.0442630111
www.rielloburners.com
Distributed by: RIELLO NV
Ninovesteenweg 198
9320 Erembodegem
Tel. [phone]
Fax. [phone]
e-mail. [email protected]
URL. www.riello.be
It is hereby certified that the apparatuses specified below conform with the model of the type described n the CE conformity declara-
tion and they are produced and placed in circulation in conformity with the provisions defined in L.D. dated January 8, 2004 and July
17, 2009.
Type of product: Light oil burners
Model: BG6.1D - BG6.1D TL
BG7.1D
Regulation applied: EN 267 and A.R. dated January 8, 2004 - July 17, 2009
Values measured: BG6.1D - BG6.1D TL
BG7.1D
CO max: 5 mg/kWh
NOx max: 81 mg/kWh
CO max: 1 mg/kWh
NOx max: 78 mg/kWh
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard
“1. BImSchV reliese 26.01.2010”.
Product Type Model Power
Light oil burners 985T BG6.1D - BG6.1D TL 53.8 - 104 kW
986T BG7.1D 77.7 - 149.5 kW
Legnago, 02.01.2012 Mr. G. Conticini
Burners Division Department
RIELLO S.p.A.

20015403 4
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Information and general warnings
2.1 Information about the instruction manual
Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the
burner even if it is transferred to another owner or user, or
to another system. If the manual is lost or damaged,
another copy must be requested from the Technical Assist-
ance Service of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.1 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.2 Danger: live components
Other symbols
This symbol indicates a list.
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
Delivery of the system and the instruction manual
When the system is delivered, it is important that:
the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
The instruction manual shows:
- the serial number of the burner;
- the address and telephone number of the nearest Assist-
ance Centre.
The system supplier must carefully inform the user about:
- how to use the system,
- any further tests that may be required before activating
the system,
- maintenance, and the fact that the system should be
checked at least once a year by a representative of the
manufacturer or another specialised technician.
To ensure a periodic check, recommends the
drawing up of a Maintenance Contract.
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
........................................................................................
........................................................................................
........................................................................................
........................................................................................

5 20015403
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Information and general warnings
2.2 Guarantee and responsibility
guarantees its new products from the installation date, in
accordance with the regulations in force and/or the sales con-
tract. At the moment of the first start-up, check that the burner is
integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
the incorrect installation, start-up, use and maintenance of
the burner;
the improper, incorrect or unreasonable use of the burner;
the intervention of unqualified personnel;
the carrying out of unauthorised modifications on the equip-
ment;
the use of the burner with safety devices that are faulty,
incorrectly applied and/or not working;
the installation of untested supplementary components on
the burner;
the powering of the burner with unsuitable fuels;
faults in the fuel power supply system;
the use of the burner even following an error and/or an
irregularity;
repairs and/or overhauls incorrectly carried out;
the modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
the insufficient and inappropriate surveillance and care of
those burner components most likely to be subject to wear
and tear;
the use of non-original components, including spare
parts, kits, accessories and optionals;
force majeure.
furthermore declines any and every responsibility
for the failure to observe the contents of this manual.
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and the carrying out of unauthorised modifica-
tions will result in the annulment by of the
guarantee that it supplies with the burner.

20015403 6
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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance
with current regulations and directives, applying the known tech-
nical rules of safety and envisaging all the potential danger situ-
ations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore
dangerous.
In particular:
it can be applied to boilers operating with water, steam, dia-
thermic oil, and to other users expressly named by the man-
ufacturer;
the type and pressure of the fuel, the voltage and frequency
of the electrical power supply, the minimum and maximum
deliveries for which the burner has been regulated, the
pressurisation of the combustion chamber, the dimensions
of the combustion chamber and the room temperature must
all be within the values indicated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety
must be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
must take all the measures necessary to prevent unauthor-
ised people gaining access to the machine;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
must inform the manufacturer if faults or malfunctioning of
the accident prevention systems are noticed, along with any
presumed danger situation.
Personnel must always use the personal protective equip-
ment envisaged by legislation and follow the indications
given in this manual.
Personnel must observe all the danger and caution indica-
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel must inform their superiors of every problem or
dangerous situation that may arise.
The assembly of parts of other makes or any modifications
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
3 Safety and prevention

7 20015403
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Technical description of the burner
4.1 Burner designation
4.2 Models available
4.3 Technical data
4 Technical description of the burner
Range : B Burners, Low NOx
Fuel : G Light oil
Sizes
Variations : D Two-stage
Electrical supply of the system : 1/230V/50Hz
B G 6.1 D1/230/50
Designation Voltage Code
BG6.1D 1/230V/50Hz 20015692 - 20015693
BG6.1D TL 1/230V/50Hz 20015694
BG7.1D 1/230V/50Hz 20015695 - 20015696
Type 985T 986T
Output
Thermal power 4.5/5.5 - 8.7 kg/h 53.8/65.8 - 104 kW 6.5/7.7 - 12.5 kg/h 77.7/92 - 149.5 kW
Fuel Light oil, viscosity 4 - 6mm2/s at 20 °C (Hi = 11.86 kWh/kg)
Electrical supply Single phase, ~ 50Hz 230V ± 10%
Motor Run current 1.8A – 2800 rpm –
294 rad/s Run current 1.9A – 2720 rpm – 288 rad/s
Capacitor 6.3 F8 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 8 - 15 bar
Absorbed electrical power 0.39 kW 0.47 kW
Operation temperature -10°C + 40°C
Atmospheric pressure Max. 1013 mbar

20015403 8
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Technical description of the burner
4.4 Max. dimensions
The maximum dimensions of the burner and flange are shown in Fig. 1.
4.5 Firing rate
The burner output is chosen from within the diagram area (Fig. 2).
This area is known as the "firing rate" and provides the burner
output according to the pressure in the combustion chamber.
The work point may be found by plotting a vertical line from the
desired delivery and a horizontal line from the pressure in the
combustion chamber. The intersection of these two lines is the
work point which must lie within the firing rate.
Fig. 1
L
O
P
11
N
M
45°
45°
A
B
C
DE
F
G
Ø H Ø I
N
D9675
Model A B C D E F G Ø H Ø I L M N O P
BG6.1D 300 345 285 228 284 12 36 97 131 189 106 83 140 170
BG6.1D TL 300 345 285 228 363 12 36 97 131 189 106 83 140 170
BG7.1D 300 345 285 247 394 12 36 116 165 213 127 99 160 190
WARNING
The firing rate was obtained considering an ambi-
ent temperature of 20 °C and an atmospheric
pressure of 1013 mbar (approx. 100 m above sea
level), with the combustion head adjusted as
shown in Tab. A.
50 60 70 80 90 100 110 120 130 140 150
456789
10 11 12 13
2,6
2,4
2,2
2,0
1,8
1,6
1,4
1,2
1,0
0,8
0,6
0,4
0,2
0
0,3
0,2
Fig. 2
Pressure in combustion
chamber - mbar
Light oil output – kg/h
Thermal power – kW
D9674
EN 303-2
986T
985T

9 20015403
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Technical description of the burner
4.6 Description of the burner
Two-stage light oil burner with low pollutant emissions (Nitric Oxide NOx, Carbon monoxide CO and unburned Hydrocarbons).
1Pump with pressure variator
2Recirculating pipe
3Control box
4Reset button with lockout signal
5Flange with insulating gasket
62nd stage air damper adjustment assembly
7Nozzle-holder assembly
8Flame detector
9Hydraulic jack
10 4 pole socket
11 2nd stage valve
12 1st stage valve
13 Choke
14 Motor
15 Combustion head
16 1st stage damper adjustment assembly
4.7 Burner equipment
Flange with insulating gasket ..............................................No. 1
Screws and nuts for fixing the flange to the boiler...............No. 4
Screw and nuts for flange....................................................No. 1
Flexible hoses with nipples..................................................No. 2
4-pin plug.............................................................................No. 1
Choke..................................................................................No. 1
Recirculating pipe................................................................No. 1
Set of instructions and spare parts list.................................No. 1
Remote reset connection (*)................................................No. 1
(*) The burner has a connection and a push-button operating at
a distance of 20 metres max. For the installation, remove the
safety lockout device installed in the factory, and install the
one supplied with the burner (see "Electrical wiring").
Fig. 3
D9642
674
1
8
14
3
2
5
15
10
9
11
12
13
16

20015403 10
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Technical description of the burner
4.8 Accessories
Tester
Oil filter kit
Oil filter kit/degaser unit
7 pin plug kit
Software diagnostics kit
A special kit is available that, by means of an optical link to a PC,
shows the burner life together with operating hours, type and
number of failures, serial number, etc.
To view diagnostics, proceed as follows:
connect the kit (supplied separately) to the appropriate
socket on the control box.
Reading of the information begins when the software pro-
gramme included in the kit starts.
Burner Code
Gulliver BG6.1D
Gulliver BG7.1D 3087211
Burner Codice Filtering degree
Gulliver BG6.1D
Gulliver BG7.1D 3006561 60 m
Burner Code Filtering degree
Gulliver BG6.1D
Gulliver BG7.1D 3000926 100 m
Burner Code
Gulliver BG6.1D
Gulliver BG7.1D 3000945
Burner Code
Gulliver BG6.1D
Gulliver BG7.1D 3002731

11 20015403
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
5.2 Handling
The burner packaging includes a wooden platform, so it is possi-
ble to move the burner (still packaged) with a transpallet truck or
fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner, showing:
the model A)(Fig. 4) and type of burner B);
the year of manufacture, in cryptographic form C);
the serial number D);
the electrical power consumption E);
the types of fuel used and the relative supply pressures F);
the data of the burner's minimum and maximum output pos-
sibilities G) (see Firing rate).
5.4 Operating position
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can quick-
ly move if the burner should fall).
During the handling, keep the load at not more
than 20-25 cm from the ground.
CAUTION
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
Before proceeding with the installation operations,
carefully clean all around the area where the burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of
danger and pollution; they should be collected
and disposed of in the appropriate places.
WARNING
The burner output must be within the boiler's firing
rate;
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
and makes any installation or maintenance work
difficult.
WARNING
The burner is designed to work only in positions 1
and 2 (Fig. 5).
Installation1is preferable, as it is the only one that
allows the maintenance operations as described
in this manual. Installation 2allows operation, but
not maintenance with hooking to the boiler.
DANGER
Any other position could compromise the correct
operation of the appliance. Installations 3, 4 and 5
are forbidden for safety reasons.
D9370 Fig. 4
Fig. 5
1 2 3
4 5

20015403 12
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Installation
5.5 Securing the burner to the boiler
To install the burner on the boiler, do the following:
insert the screw and two nuts 9) on the flange 1) (Fig. 6);
if necessary, widen the holes of the insulating gasket
4) (Fig. 6);
fix the flange 1) to the boiler door 3) (Fig. 7), using the
screws 5) and (if necessary) the nuts 2), interposing the
insulating gasket 4);
open the boiler door and insert the choke 9) on the recir-
culating pipe 6), adjusting it according to the calibrations
in Tab. A page 18;
insert the recirculating pipe 6) on the blast tube of the
burner 7), and fix it with the nut 8).
When the installation is complete, check the burner is
slightly tilted, as shown in Fig. 8. 5.5.1 Adjusting the choke
In certain applications, e.g. on boilers with three flue gas passes
or systems with particularly long flues (or flues with a wide sec-
tion), flame instability is possible due to the excessive recircula-
tion of flue gases through the recirculating pipe 1).
In these cases it is possible to adjust the choke 2) to reduce the
section through which the flue gases pass, referring to Tab. A
page 18.
WARNING
Boiler door must have a max. thickness of
180 mm, refractory lining included.
Fig. 6
9
1
D9618
9
D5012
4
D9619
Fig. 7
7
5
4
3
1
6
9
5
28
Fig. 8
D5025
21
mm
Fig. 9
D9687

13 20015403
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Hydraulic system
6.1 Fuel supply
Depending on whether the pipe output is to the right or left of the
burner, it will be necessary to invert both the fixing plate 1) and
the fair leads 2) (Fig. 10).
6.2 Pump
The pump (Fig. 11) is suitable for two-pipe operation. For
single pipe operation it is necessary to loosen the return line
nut 2), remove the by-pass screw 3), then retighten the nut
2) (Fig. 11).
Before starting up the burner, make sure that the return
pipeline is not clogged.
An excessive back pressure (1 bar) would cause the dam-
age of the pump seal, with subsequent fuel leaks inside the
burner.
Key (Fig. 11)
1Suction line
2Return line
3By-pass screw
4Gauge connection
52nd stage pressure adjuster
6Vacuometer connection
71st stage pressure adjuster
8Pressure variator piston
92nd stage valve
10 1st stage valve
11 Auxiliary pressure test point
6 Hydraulic system
WARNING
The burner is designed for the installation of light
oil supply pipes on both sides.
It is necessary to install a filter on the fuel feed
line.
Fig. 10
2
1 1
D5345
WARNING
The closure plug of the oil supply (Suction line 1)
(Fig. 11) is plastic. Once removed, you must throw
it away and not re-use it under any circumstances.
In one-pipe systems, the plug supplied on the re-
turn line 2) of the pump is steel.
IT IS VERY IMPORTANT that the steel plug
is used EXCLUSIVELY for this purpose.
Fig. 11
12
D9709
10 9
78
11
1
2
3
4
5
6

20015403 14
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Hydraulic system
6.3 Pressurised one-pipe systems
Pressurised one-pipe systems (Fig. 12) have a positive fuel pres-
sure on intake to the burner.
Usually the tank is higher than the burner, or the fuel pumping
systems are on the outside of the boiler.
ONLY FOR ITALY:
Automatic shutoff device as per DM 28/4/2005.
H= difference of level;
L= max. length of the suction line;
Øi = internal diameter of the pipe.
In the system in Fig. 12, the table shows the maximum approxi-
mate lengths for the supply line, depending on the difference in
level, length, and the diameter of the fuel conduit.
6.3.1 Priming pump
It is sufficient to loosen the vacuometer connection 6) (Fig. 11)
and wait until fuel flows out.
6.4 Vacuum systems
Vacuum systems (Fig. 13 and Fig. 14) have a negative fuel pres-
sure (depression) on intake to the burner.
Usually the tank is lower than the burner.
ONLY FOR ITALY:
Automatic shutoff device as per Ministry of Internal Affairs’ regu-
lation no. 73, dated 7/29/71.
H= difference of level;
L= max. length of the suction line;
Øi = internal diameter of the pipe.
H
metres
L metres
Øi
8 mm Øi 10 mm
0.5 10 20
120 40
1.5 40 80
260 100
WARNING
The installer must ensure that the supply pressure
is not above 0.5 bar.
Above that level, the pump seal is subject to too
much stress.
max. 4m
D5414

SYSTEM NOT PERMITTED
IN GERMANY
Fig. 12
H
H
metres
L metres
Øi
8 mm Øi 10 mm
035 100
0.5 30 100
125 100
1.5 20 90
215 70
3 8 30
3.5 620
H
max. 4m
H
D9620
Fig. 13

H
max. 4m
D9621

Fig. 14

15 20015403
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Hydraulic system
In the systems in Fig. 13 and Fig. 14, the table shows the maxi-
mum approximate lengths for the supply line, depending on the
difference in level, length, and the diameter of the fuel conduit.
6.4.1 Priming pump
In the systems of Fig. 13 and Fig. 14, it is necessary to start up
the burner and wait for priming.
Should lockout occur prior to the arrival of the fuel, await at least
20 seconds before repeating the operation.
In two-pipe vacuum systems (Fig. 14), you are advised to bring
the return line to the same height as the suction line. In this case
a non-return valve is not required.
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.
WARNING
The installer must ensure that the supply de-
pression never exceeds 0.4 bar (30cm Hg).
Above that level, gas leaks out from the fuel.
The pipes must all be perfectly sealed.

20015403 16
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Electrical system
7.1 Control box
To remove the control box from the burner it is necessary to:
disconnect all the connectors connected to it, the 7-pin plug,
the high voltage cables, and the earth wire (TB);
loosen the screw A) (Fig. 15) and pull the control box in the
direction of the arrow.
To install the control box it is necessary to:
tighten the screw A) with a tightening torque of 1 - 1.2 Nm;
connect all the connectors that were previously discon-
nected.
NOTE:
The burners have been approved for intermittent operation.
This means that they must stop once every twenty four hours to
permit the electrical control box to check its efficiency at start up.
Normally the boiler's limit thermostat (TL) ensures the stopping of
the burner.
If this is not the case, it is necessary to apply in series with (TL)
a timer switch that turns off the burner at least once every twenty-
four hours.
7 Electrical system
Notes on safety for the electrical wiring
DANGER
The electrical wiring must be carried out with the electrical supply disconnected.
Electrical wiring must be made in accordance with the regulations currently in force in the country of destination
and by qualified personnel. Refer to the wiring diagrams.
declines all responsibility for modifications or connections different from those shown in the wiring dia-
grams.
Do not invert the neutral with the phase wire in the electricity supply line. Any inversion would cause a lockout
due to firing failure.
The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,
made according to current standards. It is necessary to check this fundamental safety requirement. In the event
of doubt, have the electrical system checked by qualified personnel.
The electrical system must be suitable for the maximum input power of the device,as indicated on the label and
in the manual, checking in particular that the section of the cables is suitable for the input power of the appliance.
For the main power supply of the device from the electricity mains:
- do not use adapters, multiple sockets or extensions;
- use a multiple pole switch with at least a 3 mm gap between the contacts (overvoltage category), as foreseen
by the present safety standards.
Do not touch the device with wet or damp body parts and/or in bare feet.
Do not pull the electric cables.
WARNING
This operation must be performed with the
burner turned off and mains power discon-
nected.
Fig. 15
E9275
A

17 20015403
GB
Electrical system
7.2 Electrical wiring
Key (Fig. 16)
B5 – 2nd stage operation signal
(230V ~ - 0.1A max.)
C– Capacitor
E–Electrode
F– Flame detector
h1 – Hour counter (230V ~ - 0.1A max.)
h2 – Hour counter (230V ~ - 0.1A max.)
MV – Motor
P– Bridge socket
RS – Remote reset
S3 – Remote lockout signal
(230V ~ - 0.5A max.)
T6A –Fuse
TB – Burner-earth
TL – Limit thermostat
TR – Adjusting thermostat
TS – Safety thermostat
V1 – Oil valve 1st stage
V2 – Oil valve 2nd stage
X4 – 4-pin plug
X7 – 7-pin plug
XP4 – 4-pole socket
XP7 – 7-pole socket
7.2.1 Testing
Check the shut down of the burner by opening the thermo-
stats.
Check the burner's lockout during operation by interrupting
the flame detector.
TO BE DONE BY
THE INSTALLER
CARRIED OUT
IN THE FACTORY
Fig. 16
230V ~ 50Hz
Switch
CONTROL BOX
MO550-PI
WARNING
The section of the conductors must be at least
1mm
2(unless requested otherwise by local
standards and legislation).
WARNING
If there is an automatic interception device in
some hydraulic systems (230V - 0.5A max.), it is
necessary to connect it to terminals N - T2 of the
7-pin plug (see ‘Hydraulic system” page 13).

20015403 18
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Operation
8.1 Notes on safety for the first start-up
8.2 Adjusting combustion
In conformity with Efficiency Directive 92/42/EEC the application
of the burner on the boiler, adjustment and testing must be car-
ried out observing the instruction manual of the boiler, including
verification of the CO and CO2concentration in the flue gases,
their temperatures and the average temperature of the water in
the boiler.
To suit the required appliance output, choose the nozzle, pump
pressure, the position of the choke, air adjustment and the setting
of the combustion head in accordance with the following table.
The values shown in Tab. A are measured on a CEN boiler (as
per EN267), and refer to 12.5% CO2at seat level (1013 hPA) and
with a light oil and ambient temperature of 20°C, with combustion
chamber pressure at 0 mbar.
Tab. A
8Operation
WARNING
The first start-up of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
WARNING
Checkthecorrectworkingof the adjustment, com-
mand and safety devices.
WARNING
The combustion air must be sucked in from out-
side, there therefore might be considerable varia-
tions in temperature that can influence the CO2
percentage value.
It is therefore advisable to regulate the CO2on the
basis of the graph (Fig. 17).
E.g. outside air temperature 20°C, regulate the
CO2to 12.5% (± 0.2%).
05
10 15 20 25 30 35 40
11.5
12.0
12.5
13.0
13.5
14.0
% CO2
Outside air temperature (°C)
D9673
Fig. 17
TYPE
Nozzle Pump pressure Burner
output
Combustion
head
adjustment
Air damper
adjustment
Air pressure on
combustion
head
Choke
opening
GPH Angle bar kg/h ± 4% Notch Notch mbar mm
1st stage 2nd stage 1st stage 2nd stage 1st stage 2nd stage 1st stage 2nd stage
985T
1.25 60° A 914.5 4.5 5.5 10.4 2.2 4.4 710
1.35 60° A 914.5 4.7 5.9 1.5 0.4 2.5 4.4 710
1.50 60° A 914.5 5.3 6.7 2.5 0.5 34.3 7.3 10
1.65 60° A 914.5 5.7 7.5 30.6 3.5 4.3 7.5 10
1.75 60° A 914.5 6.1 83.5 0.75 44.5 810
2.00 60° A 913.5 78.7 4.5 14.5 5 8 10
986T
1.75 80° B 10 15 6.5 7.7 10.25 0.6 7.1 9.3 10
2.00 80° B 10 15 7 9 1.5 0.25 1.1 6.4 10 30
2.25 80° B 10 15 7.8 9.8 20.35 1.5 6.4 10 30
2.50 60° W 914 8.9 11 30.45 1.5 6.4 9.5 20
2.75 60° W 10 15 9.8 12.5 40.6 2.5 6.5 10.1 10
WARNING
On inversion boilers, it is necessary to open
the choke more compared with the calibra-
tions shown in Tab. A.