Riello BGK1 Quick start guide

20136520 (2) - 05/2018
Installation, use and maintenance instructions
Instrucciones de instalación, uso y mantenimiento
Light oil burners
Quemadores de gasóleo
One stage operation
Funcionamiento a 1 llama
CODE - CÓDIGO MODEL - MODELO
3737006 - 3737066 BGK1
3737456 BGK2
20012189 BGK3
GB
E

Original instructions
Instructions originales

1 20136520
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Contents
1 Declaration..................................................................................................................................................................................3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
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
5 Technical description of the burner ......................................................................................................................................... 8
5.1 Technical data............................................................................................................................................................. 8
5.2 Electrical data.............................................................................................................................................................. 8
5.3 Burner equipment........................................................................................................................................................ 8
5.4 Maximum dimensions.................................................................................................................................................. 9
5.5 Burner description ....................................................................................................................................................... 9
5.6 Firing rate .................................................................................................................................................................. 10
5.6.1 Test boiler.................................................................................................................................................................. 10
5.6.2 Commercial boilers.................................................................................................................................................... 10
5.7 Electrical control box ................................................................................................................................................. 11
6 Installation ................................................................................................................................................................................ 12
6.1 Notes on safety for the installation ............................................................................................................................ 12
6.2 Instructions to avoid burnout or bad combustion of the burner ................................................................................. 12
6.3 Handling .................................................................................................................................................................... 12
6.4 Preliminary checks .................................................................................................................................................... 13
6.5 Operating position ..................................................................................................................................................... 13
6.6 Securing the burner to the boiler............................................................................................................................... 14
6.7 Combustion head adjustment.................................................................................................................................... 15
6.8 Air damper adjustment .............................................................................................................................................. 15
6.9 Electrodes setting...................................................................................................................................................... 16
6.10 Positioning the optical fiber ....................................................................................................................................... 16
6.11 Fuel heating............................................................................................................................................................... 16
6.12 Maintenance position ................................................................................................................................................ 17
6.13 Hydraulic systems ..................................................................................................................................................... 18
6.13.1 Combustion supply.................................................................................................................................................... 18
6.13.2 Pump......................................................................................................................................................................... 18
6.13.3 Pressure adjustment ................................................................................................................................................. 19
6.13.4 Pressurised one-pipe systems .................................................................................................................................. 19
6.13.5 Priming pump ............................................................................................................................................................ 19
6.13.6 Vacuum systems ....................................................................................................................................................... 19
7 Start-up, calibration and operation of the burner ................................................................................................................. 20
7.1 Notes on safety for the first start-up .......................................................................................................................... 20
7.2 Combustion adjustment............................................................................................................................................. 20
7.3 Recommended nozzles............................................................................................................................................. 21
7.4 Electrical system ....................................................................................................................................................... 22
7.5 Electrical diagram...................................................................................................................................................... 23

20136520 2
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Contents
7.6 Operating programme................................................................................................................................................24
7.7 Table of times ............................................................................................................................................................25
7.7.1 Operating status indication ........................................................................................................................................25
7.7.2 Fault diagnostics - lockouts........................................................................................................................................26
7.7.3 Fuel preheating function ............................................................................................................................................26
7.7.4 Shutdown test ............................................................................................................................................................26
7.7.5 Intermittent operation.................................................................................................................................................26
7.7.6 Recycle and limit of repetitions ..................................................................................................................................26
7.7.7 Presence of an extraneous light or parasite flame.....................................................................................................27
7.7.8 Pre and post-ignition of the discharge of the ignition transformer..............................................................................27
7.7.9 Reset by button and remotely of the burner...............................................................................................................27
7.7.10 Protection reset..........................................................................................................................................................27
7.7.11 Reset button/Remote reset anomaly .........................................................................................................................27
7.7.12 External lockout signal (S3) .......................................................................................................................................27
7.7.13 Hour counter function (B4).........................................................................................................................................27
7.7.14 Monitoring the power supply voltage .........................................................................................................................27
7.7.15 Frequency supply error ..............................................................................................................................................28
7.7.16 Internal voltage anomaly............................................................................................................................................28
7.7.17 Checking the fan motor..............................................................................................................................................28
7.7.18 Checking the electronic control circuit of the 1st stage valve ....................................................................................28
7.7.19 Checking the short-circuit of the 1st stage valve .......................................................................................................28
7.7.20 Post-purging...............................................................................................................................................................28
7.7.21 EEprom check............................................................................................................................................................28
7.7.22 Continuous purging....................................................................................................................................................28
7.7.23 Lockout log.................................................................................................................................................................29
7.7.24 Logging of burner operating parameters....................................................................................................................29
7.7.25 Admissible lengths of the external connections to the burner....................................................................................29
7.7.26 Long pre-purging........................................................................................................................................................29
7.8 Automatic pre-heating deactivation............................................................................................................................30
7.9 Programming menu ...................................................................................................................................................31
7.9.1 General notes ............................................................................................................................................................31
7.9.2 Block diagram for entering the menu .........................................................................................................................31
7.9.3 Shutdown test ............................................................................................................................................................32
7.9.4 Post-purging and continuous purging ........................................................................................................................32
7.9.5 Intermittent operation.................................................................................................................................................32
7.9.6 Setting a long pre-purging..........................................................................................................................................32
7.9.7 Displaying the lockout log ..........................................................................................................................................32
7.9.8 Resetting the programming menu parameters and the lockout log ..........................................................................33
7.10 Lockout types.............................................................................................................................................................33
8 Maintenance ..............................................................................................................................................................................34
8.1 Notes on safety for the maintenance .........................................................................................................................34
8.2 Maintenance programme ...........................................................................................................................................34
8.2.1 Maintenance frequency..............................................................................................................................................34
8.2.2 Checking and cleaning...............................................................................................................................................34
9 Faults / Solutions ......................................................................................................................................................................35
10 Appendix - Accessories ...........................................................................................................................................................36

3 20136520
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Declaration
1 Declaration
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: BGK1 - BGK2 - BGK3
These products are in compliance with the following Technical Standards:
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
Quality is ensured by means of an ISO 9001:2015 certified quality and management system.
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
This document certifies that the series of devices specified below is in compliance with the model described in the EC Declaration
of Conformity and has been manufactured and distributed in compliance with the requirements defined in the Legislative Decree of
January 8th 2004 and July 17th 2009.
Product type: Light oil burner
Model: BGK1 - BGK2 - BGK3
Applied standard: EN 267 and A.R. of January 8th 2004 - July 17, 2009
Controlling organisation: TÜV Industrie Service GmbH
TÜV SÜD Gruppe
Ridlerstrase, 65
80339 München DEUTSCHLAND
Values measured: BGK1 CO max: 1 mg/kWh
Max. NOx: 72 mg/kWh
BGK2 CO max: 4 mg/kWh
Max. NOx: 69 mg/kWh
BGK3 CO max: 31 mg/kWh
Max. NOx: 70 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 revision 26.01.2010”.
Product Type Model Output
Light oil burners 370T1 BGK1 17.8 - 35.6 kW
374T1 BGK2 32 - 59.3 kW
375T1 BGK3 45 - 73 kW
Legnago, 01.12.2015 General Manager
RIELLO S.p.A. - Burners Department
Research and Development Director
RIELLO S.p.A. - Burners Department
Eng. U. Ferretti Eng. F. Comencini

20136520 4
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 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 Assistance Cen-
tre 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.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
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
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE COVER
AND ALL THE SAFETY AND PROTECTION DE-
VICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

5 20136520
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Information and general warnings
2.1.4 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 Assis-
tance Centre
The system supplier must carefully inform the user about:
- the use of the system;
- any further tests that may be required before activating the
system;
- maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the date of
installation, in accordance with the regulations in force and/or the
sales contract. 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:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
continuation of use of the burner when a fault has occurred;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
use of non-original components, including spare parts, kits,
accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility 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 carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

20136520 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 technical
rules of safety and envisaging all the potential danger situations.
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 dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly named by the manufacturer;
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 cham-
ber and the ambient temperature must all be within the values in-
dicated 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;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, the user undertakes to ensure that everyone
knows the use and safety instructions for his own duties;
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.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

7 20136520
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Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4 Technical description of the burner
Designation Combustion head Voltage Code
BGK1 TC 1/230/50 3737006 - 3737066
BGK2 TC 1/230/50 3737456
BGK3 TC 1/230/50 20012189
Range:
Size
Fuel: Natural gas
Light oil
Variations:
Electrical supply 1/230/50
1/220/60
B G 1 1/230/50
BASIC DESIGNATION
EXTENDED DESIGNATION
1/230V/50Hz
1/220V/60Hz
K Conical head
M Ignition with reduced flow rate
R Light oil pre-heater
S
G
Head : TC Standard head
TL Extended head
of the system :
Standard Emission
Low NOx
R
B
DTwo-stage
BG1 1/230/50TCK

20136520 8
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Technical description of the burner
4.3 Technical data
Tab. B
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1013 mbar -Altitude 0m a.s.l. (Hi = 11.86 kWh/kg)
(2) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum output. The sound power
is measured with the “Free Field” method, as per EN 15036, and according to an accurate “Accuracy: Category 3” measurement, as described in
EN ISO 3746.
4.4 Electrical data
Tab. C
4.5 Burner equipment
Flange with insulating gasket ............................................. No. 1
Screw and nuts for flange .................................................. No. 1
Remote reset connection ................................................... No. 1
Screws and nuts for fixing the flange to the boiler ............. No. 4
Recirculating pipe ............................................................... No. 1
Flexible hoses with nipples ................................................ No. 2
7 pin plug ............................................................................ No. 1
Installer booklet................................................................... No. 1
Spare Parts List................................................................... No. 1
Remote reset kit
The burner has a remote reset kit (RS) consisting of a con-
nection and a push-button operating at a distance of 20
metres max.
In order to install it, remove the safety lockout device installed
at the factory and insert the lockout supplied with the burner
(see electrical diagram).
Model BGK1 BGK2 BGK3
Delivery (1)
Thermal power(1)
kg/h
kW
1.5 3.0
17.8 35.6
2.7 5.0
32 59.3
3.8 6.15
45.0 73.0
Fuel Light oil, viscosity 4 6 mm2/s at 20°C
Operation Intermittent (FS1)
Use Boilers: water and diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 40
Pump bar Pressure: 8  15
Noise levels (2) Sound pressure
Sound power dB (A) 62 73
63
74
62
73
Burner weight kg 13 13 16.5
Model BGK1 BGK2 BGK3
Electrical supply Single-phase, ~ 50Hz 230V ± 10%
Motor A
rpm
rad/s
0.8
2750
288
1.8
2800
294
Capacitor F 4 4 8
Ignition transformer Secondary 18 kV - 25 mA
Absorbed electric power kW 0.25 0.27 0.46
Protection level IP 40

9 20136520
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Technical description of the burner
4.6 Maximum dimensions
The maximum dimensions of the flange and burner are given in
Fig. 1.
4.7 Burner description
1 Oil pump
2 Air damper adjustment assembly
3 Nozzle-holder assembly
4 Flange with insulating gasket
5 Control box
6 Reset button with lock-out signal
7 Flame sensor
8 Combustion head
9 Recirculating pipe
10 Motor
11 Capacitor
Fig. 1
D7217
Type A B C D E Ø FØ GH I L
BGK1 255 280 202 230 192 87 89 10 28 107
BGK2 255 280 202 230 197 90 89 10 28 115
BGK3 300 345 230 285 222 90 89 12 34 140
2
7
6
1
3
10
59
4
8
11
Fig. 2
S9660
WARNING
To meet the required standards, the burner must
be protected by a pane or by the boiler door.
This protection must be removed only with a tool.

20136520 10
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Technical description of the burner
4.8 Firing rate
The burner output is chosen from within the diagram area (Fig. 3).
4.8.1 Test boiler
The firing rate has been defined on test boilers according to EN
267 standard.
4.8.2 Commercial boilers
The burner-boiler combination poses no problems if the boiler
conforms to EN 303 and its combustion chamber dimensions are
similar to those provided in EN 267.
If, on the other hand, the burner is combined with a commercial
boiler that does not conform to EN 303, or where the combustion
chamber is much smaller than the dimensions set out in EN 267,
please contact the manufacturers.
WARNING
To ensure the burner works correctly, the start-up
should always occur within the relative firing rate.
WARNING
The firing rates (Fig. 3) were obtained at an ambi-
ent temperature of 20 °C, at a barometric pressure
of 1013 mbar (about 0 m a.s.l.) and with the com-
bustion head regulated as indicated on page 20.
Light oil output – kg/h
Heat output – kW
Fig. 3
Pressure in the combustion
chamber – mbar
456
- 0.4
- 0.2
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
45 50 55 60 65 70 75 40
D9487
BGK3
12 Light oil output – kg/h
15 20 25 30 Heat output – kW
0.2
0
3
35 40 45
0.8
50 55
0.6
45
60
Pressure in the combustion
chamber – mbar
D7241
0.4
BGK1 BGK2

11 20136520
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Technical description of the burner
4.9 Electrical control box
The control box is a control and supervision system for forced
draught burners, for intermittent operation (at least one controlled
shutdown every 24 hours).
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation).
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
Falls and collisions can negatively affect the safety func-
tions. In this case, the control box must not be operated,
even if it displays no evident damage.
For safety and reliability, comply with the following instruc-
tions:
- Avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure the control box is perfectly dry.
- Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Installation notes
• Check the electrical wiring inside the boiler complies with the
national and local safety regulations.
• Install switches, fuses, earth connection etc. in compliance
with local regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as possi-
ble from the control box and the other cables.
• When wiring the unit, make sure the 230V AC mains voltage
cables are run strictly separate from extra low-voltage cables,
to avoid the risk of electrocution.
To remove the control box from the burner it is necessary to (Fig.
4):
disconnect all the connectors connected to it, all the plugs,
the high voltage cables and the earth wire (TB);
unscrew the screw (A) and pull the control box in the direc-
tion 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;
reconnect all previously disconnected connectors, making
sure to connect the 7 pin plug as the final step.
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 effi-
ciency at start up. The boiler limit thermostat (TL) normally
ensures the stopping of the burner. If this is not the case, it
is necessary to apply a timer switch in series to the limit
thermostat (TL) that turns off the burner at least once every
24 hours.
Electrical wiring of the flame sensor
It is important for signal transmission to be almost totally free
of any disturbances or loss:
• Always separate the flame sensor cables from the other ca-
bles:
- the line capacity reduces the magnitude of the flame sig-
nal.
Technical data
Tab. D
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
or modifying it, or forcing its operation. The Man-
ufacturer cannot assume any responsibility for
damage resulting from unauthorised work!
Mains voltage AC 210...230 V -15 % / +10 %
Mains frequency 50/60 Hz ±6 %
Built-in fuse T4A 250V
Energy consumption 40 VA
Protection level IP00
Fig. 4
E9275
A

20136520 12
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
5.2 Instructions to avoid burnout or bad combustion of the burner
1 The burner can not be installed outside as it is suitable for
operation in closed rooms only.
2 The premises the burner operates in must have openings
for the air need for the combustion.
To be sure about this, you have to control CO2 and CO in
the exhaust gases with all the windows and doors closed.
3 If there are air extractors in the premises the burner works,
make sure that there are openings for air to be taken in that
are big enough to ensure the required air change; In any
case, check that when the burner stops the extractors do
not draw hot fumes from pipes through the burner.
4 When the burner is stopped, the smoke pipe must be kept
open and a natural draft created in the combustion chamber.
If the smoke pipe is closed, the burner must be drawn back
till the extraction of blast tube from the furnace. Before oper-
ating in this way take the voltage off.
5.3 Handling
The transport weight is given in chapter 4.3 page 8.
Observe the permissible ambient temperatures for storage and
transport: -20... + 70 °C, with max. relative air humidity 80%.
5Installation
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.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation operations,
carefully clean all around the area where the burn-
er will be installed.
The operator must use the required equipment
during installation.

13 20136520
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Installation
5.4 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner, showing:
the model A) (Fig. 5) 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).
5.5 Operating position
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
makes any installation or maintenance work diffi-
cult.
Fig. 5
D9370
WARNING
The burner is designed to work only in the posi-
tions, 1 and 2.
Installation 1 is preferable, as it is the only one that
allows the maintenance operations as described
in this manual.
The installations 2 allows it to operate but not with
maintenance with hooking to the boiler.
Any other position could compromise the correct
operation of the appliance.
WARNING
Any other positioning could compromise the cor-
rect operation of the appliance.
Installations 3, 4 and 5 are forbidden for safety
reasons.
Fig. 6
D7088
1 2 3 4 5

20136520 14
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Installation
5.6 Securing the burner to the boiler
To install the burner on the boiler, do the following:
if necessary insert the recirculating pipe 1)(Fig. 8) onto the
blast tube of the burner 2) and fix it with the screw 3).
Insert on the flange 4)(Fig. 9) the screw and the two nuts 9).
if necessary, widen the holes of the insulating gasket 5) Fig.
7).
To the door of the boiler 6)(Fig. 10) fix the flange 4) using the
screws 7) and (if necessary) the nuts 8) placing the insulat-
ing gasket 5) in-between.
Provide an adequate lifting system of the burner.
WARNING
With some boilers it is possible that the CO values
exceed those stated in this manual. To lower
these emissions it is necessary to use the recircu-
lating pipe supplied.
WARNING
In any event, make sure that the combustion head
crosses the entire thickness of the boiler door.
WARNING
The seal between burner and boiler must be
airtight.
Fig. 7
D5012
5
Fig. 8
3
1 2
E9163
Fig. 9
9
4S7709
9
Fig. 10
S7708
7
7
8
4
6 5

15 20136520
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Installation
5.7 Combustion head adjustment
The adjustment of the combustion head varies depending on the
burner output. Do the following to adjust it:
turn the adjustment screw 2)(Fig. 11) clockwise or anti-clock-
wise until the notch on the regulating rod 3)(Fig. 11) lines up
with the outer surface of the nozzle-holder assembly 1)(Fig.
11).
In the example, the regulating rod 3) is set at notch 2; this
means that the burner is regulated for an output of 4.9 Kg/h
with the pump pressure at 12 bar and with the use of a noz-
zle of 1.25 GPH, as indicated in Tab. G page 20.
5.8 Air damper adjustment
To regulate the air damper, do the following:
Loosen the nut 5)(Fig. 11) and calibrate the damper using
the screw 4)(Fig. 11).
When the adjustment is completed screw in the nut 5) again.
For burners BGK1 and BGK3:
when the burner shuts down the air damper automatically closes,
up to a max. flue depression of 0.5 mbar.
For the burner BGK2:
when the burner stops the air damper remains open.
Fig. 11
D9547
4 52
1
3
1

20136520 16
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Installation
5.9 Electrodes setting
To access the electrodes carry out the operation described,
see paragraph “Operating position” on page 13.
To adjust, proceed as follows:
rest the diffuser disc-holder assembly 3)(Fig. 12) against the
nozzle holder 2)(Fig. 12) and lock it in place with the screw
4)(Fig. 12).
For any adjustments of the electrodes assembly 5),
loosen screw 6)(Fig. 12).
5.10 Positioning the optical fiber
To position the optical fiber, carry out the following procedure:
insert the optical fiber 1)(Fig. 12) into the diffuser disc-
holder assembly (3) making sure it goes all the way in.
Carefully tighten the screw 4)(Fig. 12) to lock the optical
fiber 1)(Fig. 12).
5.11 Fuel heating
In order to assure regular ignition and operation even at low tem-
peratures the burner has an oil heater fitted in combustion head.
The heater turns on when the thermostats close. The enabling
signal for burner start up comes through a thermostat on the noz-
zle holder once the optimal ignition temperature is reached. The
heating remains on during operation and cuts out when the burn-
er shuts-down.
WARNING
These dimensions Fig. 12 must be respected.
Fig. 12
D4222
4.5 - 0.5 mm
03 ±0.3 mm
5.5 ±0.3 mm
41
2
5 6
3

17 20136520
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Installation
5.12 Maintenance position
There are two ways to access the nozzle, the diffuser disc and
the electrodes:
1st Method (Fig. 13):
remove the wires 2)(Fig. 13) from the control box, the flame
sensor 8) and unscrew the nut 9) from the pump.
Loosen the screws 10) and extract the nozzle-holder
assembly 1) turning to the right.
Remove the wires 2) from the electrodes, loosen the screw
4)(Fig. 13) and remove the diffuser disc-holder assembly 3)
from the nozzle-holder assembly 1).
Screw on the nozzle 6) while holding the nozzle holder still
with a spanner.
Refit following the operations in the reverse order to the one
described above.
2nd Method (Fig. 13):
unscrew and remove the fixing nut to the flange and remove
the burner from the boiler.
Connect the burner to the flange 7)(Fig. 14), loosen the
screws 5) then take out the blast tube unit 4).
Loosen the screw 4)(Fig. 14) to remove the diffuser disc-
holder assembly 3) from the nozzle-holder assembly 1).
Fully unscrew the fixing screw 4)(Fig. 14) to extract the opti-
cal fiber 8) from the diffuser disc-holder assembly 3).
Remove the wires 2) from the electrodes.
Replace and correctly screw in the nozzle 6), tightening it as
shown in Fig. 14.
Refit following the procedure in the reverse order to the one
described above.
WARNING
Having put back the nozzle-holder assembly,
screw in the nut 9), as shown in Fig. 15.
Fig. 13
6
3
10
8
9
2 1
S7948
2
Fig. 14
7
8
3
2
4
5
E9286
1
6
Fig. 15
D5684
9
Tighten without
bringing right to
the end stop

20136520 18
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Installation
5.13 Hydraulic systems
5.13.1 Combustion supply
The burner is designed to allow entry of the flexible oil lines on
either side of the burner.
Depending on whether the pipe outlet is to the right or left of the
burner, it will be necessary to invert both the fixing plate 1) and
the closing bracket 2)(Fig. 16).
5.13.2 Pump
The pump is designed to allow working with two pipes.
Before starting up the burner, make sure that the return pipeline
is not clogged.
An excessive back pressure ( 1 bar) would cause the damage
of the pump seal, with subsequent fuel leaks inside the burner.
The pump has a delivery pressure regulation device 5). Pressure
increases if turned in a clockwise direction, and decreases if
turned in the other direction. An indication of sensitivity is 1 bar
per turn. The pressure can be regulated in a range of 8 - 15 bar.
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure the fuel interception tap is closed be-
fore performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
Fig. 16
D5345
11
2
WARNING
The suction plug 1) is made of plastic. Once re-
moved, it must not be used again.
In single-pipe installations, the plug in the return
line 2) must be totally in steel.
WARNING
Do not loosen the knob 9) and regularly check it is
tight for safety reasons.
WARNING
Check periodically the flexible pipes conditions.
If necessary, install a filter on the fuel supply line.
1Suction line
2Return line
3By-pass screw
4Gauge connection
5Pressure adjuster
6Vacuum gauge connection
7Valve
8Auxiliary pressure test point
9Knob
Fig. 17
D9630
1
7
4
3
2
5
6
9
8