Riello BGK3 Quick start guide

20013962 (7) - 01/2012
Installation, use and maintenance instructions
Instrucciones de instalación, montaje y funcionamiento
Light oil burners
Quemadores de gasóleo
One stage operation
Funcionamiento a 1 llama
CODE
CODIGO MODEL MODEL0 TYPE TIPO
20012189 - 20015628 BGK3 375T1
GB
E

1 20013962
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Contents
1 Declaration.................................................................................................................................................................................. 3
2 Information and general instructions....................................................................................................................................... 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 Overall dimensions......................................................................................................................................................... 8
4.5 Firing rate........................................................................................................................................................................ 8
4.6 Burner description........................................................................................................................................................... 9
4.7 Burner equipment........................................................................................................................................................... 9
4.8 Accessories .................................................................................................................................................................... 9
4.8.1 Diagnostic software kit.................................................................................................................................................... 9
5 Installation ................................................................................................................................................................................ 10
5.1 Notes on safety for the installation................................................................................................................................ 10
5.2 Handling........................................................................................................................................................................ 10
5.3 Preliminary checks........................................................................................................................................................ 10
5.4 Operation position......................................................................................................................................................... 11
5.5 Securing the burner to the boiler .................................................................................................................................. 11
6 Hydraulic system...................................................................................................................................................................... 13
6.1 Pump ............................................................................................................................................................................ 13
6.2 Pressurised one pipe systems...................................................................................................................................... 13
6.2.1 Pump priming................................................................................................................................................................ 13
6.3 Depressurised systems ................................................................................................................................................ 14
6.3.1 Pump priming................................................................................................................................................................ 14
7 Electrical system...................................................................................................................................................................... 15
7.1 Control box ................................................................................................................................................................... 15
7.2 Electrical connections................................................................................................................................................... 16
7.2.1 Testing.......................................................................................................................................................................... 16
8 Operation .................................................................................................................................................................................. 17
8.1 Notes on safety for the first start-up.............................................................................................................................. 17
8.2 Combustion setting....................................................................................................................................................... 17
8.3 Nozzles recommended................................................................................................................................................. 17
8.4 Pump pressure ............................................................................................................................................................. 18
8.5 Combustion head setting.............................................................................................................................................. 18
8.6 Air damper adjustment.................................................................................................................................................. 18
8.7 Electrodes adjustment.................................................................................................................................................. 18
8.8 Positioning optical fibre................................................................................................................................................. 18
8.9 Operation programme................................................................................................................................................... 19
8.9.1 Normal operation with preheating................................................................................................................................. 19
8.9.2 Block due to non-ignition .............................................................................................................................................. 20
8.9.3 Block due to extraneous light during the pre-purging................................................................................................... 20
8.10 Fuel heating.................................................................................................................................................................. 20

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Contents
9 Maintenance ..............................................................................................................................................................................21
9.1 Notes on safety for the maintenance.............................................................................................................................21
9.2 Maintenance programme ..............................................................................................................................................21
9.2.1 Maintenance frequency.................................................................................................................................................21
9.2.2 Checking and cleaning..................................................................................................................................................21
9.3 Maintenance position ....................................................................................................................................................22
9.4 Control box visual diagnostics.......................................................................................................................................23
9.4.1 Led colour code of the control box reset button ............................................................................................................23
9.4.2 Block types and intervention times if the burner fails....................................................................................................24
9.4.3 Resetting the control box...............................................................................................................................................24
9.4.4 Recycle function............................................................................................................................................................24
9.4.5 Logging of burner operating parameters.......................................................................................................................24
9.5 Supplementary, programmable control box functions...................................................................................................24
9.5.1 Post-purging function (t6)..............................................................................................................................................24
9.5.2 Continuous purging function, (only for applications in which this is provided for) .........................................................25
9.5.3 Long pre-purging (t7) operation.....................................................................................................................................25
9.5.4 Function setting procedure using reset button ..............................................................................................................25
10 Faults / Solutions......................................................................................................................................................................26
10.1 Burner start-up difficulties..............................................................................................................................................26
10.2 Operating faults.............................................................................................................................................................27

3 20013962
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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: BGK3
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
Producer: 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.
Product type: Light oil burners
Model: BGK3
Standard applied: EN 267 and A.R. dated January 8, 2004 - July 17, 2009
Measured value: CO max: 31 mg/kWh
NOx max: 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 reliese 26.01.2010”.
Product Type Model Power
Light oil burners 375T1 BGK3 45 - 73 kW
Legnago, 02.01.2012 Mr. G. Conticini
Burners Division Department
RIELLO S.p.A.

20013962 4
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Information and general instructions
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
Pag. 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 supplied 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 carefully informs the user about:
- the use of the system,
- any further tests that may be necessary before the sys-
tem is started up,
- maintenance and the need to have the system checked
at least once a year by the manufacturer or another spe-
cialised technician.
To ensure a periodic check, recommends the
drawing up of a Maintenance Contract.
2 Information and general instructions
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 20013962
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Information and general instructions
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:
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 non authorised modifications on the equip-
ment;
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 power supply system;
use of the burner even following an error and/or an irregu-
larity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the flame, as structur-
ally established;
insufficient and inappropriate surveillance and care of those
burner components most subject to wear and tear;
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 non authorised modifi-
cations will result in the annulment by of
the guarantee that it supplies with the burner.

20013962 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 follow all the danger and caution indications
shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel are obliged to 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 all responsibility for any damage that may
be caused by the use of non-original parts.
3 Safety and prevention

7 20013962
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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
Series : B Low NOx burner
Fuel : G Light oil
Variation : K Cone shaped head
Size
Electrical supply to the system : 1/230V/50Hz
B G K 3 1/230/50
Designation Electrical supply Code
BGK3 1/230V/50Hz 20012189 - 20015628
Type 375T1
Output - Thermal power 3.8 - 6.15 Kg/h – 45 - 73 kW
Fuel Light oil, viscosity 4 - 6 mm2/s a 20 °C (Hi = 11.86 kWh/kg)
Electrical supply Single phase, ~ 50Hz 230V ± 10%
Motor Run current 1.8A – 150W
2800 rpm – 294 rad/s
Capacitor 6,3 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 8 – 15 bar
Absorbed electrical power 0,46 kW
Operation temperature -10°C + 40 °C
Atmospheric pressure Max. 1013 mbar

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Technical description of the burner
4.4 Overall dimensions
The burner and flange dimensions are indicated in Fig. 1.
4.5 Firing rate
The burner delivery must be selected within area of the diagrams
(Fig. 2). This area is called firing rates and provides the maximum
delivery of the burner in relation 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 rates.
Fig. 1
230
11
45°
45°
ø89
222 300 189
106
140
168
12
83
83
285
345
ø90
140
D7217
34
WARNING
The firing rate area values have been obtained
considering a surrounding temperature of 20 °C,
and an atmospheric pressure of 1013 mbar (ap-
prox. 100 m above sea level) and with the combu-
stion head adjusted as shown on Tab. A.
Fig. 2
Pressure in combustion
chamber – mbar
Light oil output – kg/h
Thermal power – kW
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

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Technical description of the burner
4.6 Burner description
One stage light oil burner with low pollutant emissions (Nitric Oxide NOx, Carbon monoxide CO and unburnt Hydrocarbons).
1Oil pump
2Air damper adjustment assembly
3Nozzle holder assembly
4Flange with insulating gasket
5Control box
6Reset button with lock-out lamp
7Amplified photoresistance
8Combustion head
9Recirculation pipe
10 Motor
11 Capacitor
4.7 Burner equipment
Flange with insulating gasket ..............................................No. 1
Screws 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
7 pin plug.............................................................................No. 1
Recirculating pipe................................................................No. 1
Instruction and spare part list...............................................No. 1
4.8 Accessories
4.8.1 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:
Connect the kit supplied separately to the appropriate soc-
ket on the control box.
The information is read after the software program in the kit
is booted.
Fig. 3
D9577
2
7
6
1
3
10
59
4
8
11

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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 packaging of the burner includes a wooden platform, so it is
possible 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 (see A in Fig. 4) and type of burner (B);
the year of manufacture, in cryptographic form (C);
the serial number (D);
the electrical input power (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 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 output of the burner must be within the boil-
er'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.
D9370 Fig. 4

11 20013962
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Installation
5.4 Operation position
5.5 Securing the burner to the boiler
To fit the burner to the boiler it is necessary to carry out the fol-
lowing:
if necessary insert the recirculating pipe 1) (Fig. 6) on the
burner blast tube 2) and fix it with the screw 3).
Put on the flange 4) (Fig. 7) the screw and two nuts 9).
Widen, if necessary, the insulating gasket holes 5) (Fig. 7).
WARNING
The burner is designed for operation in positions
1and 2only.
Installation 1 is the preferred option as it is the
only one that enables maintenance to be perfor-
med as described later on in this manual.
Operation is possible with installation option 2
though maintenance cannot be performed with
the burner connected to the boiler.
DANGER
Note that any other installation position is likely to
hinder the unit’s proper operation. Installations 3,
4and 5are prohibited as safety is compromised.
D7088
1
Fig. 5
2 3 4 5
WARNING
With some boilers it is possible that the CO
values exceed those declared in this manual.
To reduce these emissions, the recirculation
pipe supplied must be used.
WARNING
Respect the dimensions, as described in para-
graph 4.4 “Overall dimensions” page 8.
Fig. 6
3
1 2
D7088
Fig. 7
9
4S7709
D5012
5
9

20013962 12
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Installation
Fix the flange 4) (Fig. 8) to the boiler door 6) using screws
7) and (if necessary) the nuts 8) interposing the insulating
gasket 5).
WARNING
Boiler door must have a max. thickness of
80 mm, refractory linig included.
S7708 Fig. 8
7
7
8
4
6 5

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Hydraulic system
6.1 Pump
The pump (Fig. 9) is designed to allow working with two
pipes.
In the two pipes systems, before starting the burner make
sure that the return pipe-line 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.
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 plug 2) with a tightening torque of
0.5 Nm.
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.
6.2 Pressurised one pipe systems
Pressurised one pipe systems (Fig. 10) 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.
SYSTEM ONLY FOR ITALY:
Automatic shutoff device as per DM 28/4/2005.
H= difference of level;
L= max. length of the suction pipe;
Øi = internal diameter of the oil pipe.
In the system in Fig. 10, the table shows the maximum indicated
lengths for the supply line, depending on the difference in level,
length and the diameter of the oil pipes.
6.2.1 Pump priming
It is sufficient to loosen the vacuometer connection 6) (Fig. 9) and
wait until oil flows out.
6 Hydraulic system
WARNING
The burner is designed to allow installation of the
oil-lines on either side of the burner.
It is necessary to install a filter on the fuel supply
line
WARNING
The suction plug 1) is made of plastic.
Once removed, it must not be used again.
In one-pipe installations, the plug in the return line
2) must be totally in steel.
WARNING
Do not loosen the knob 9) and periodically check
that it is firmly fixed, for safety reasons.
1Suction line
2Return line
3Screw for by-pass
4Pressure gauge attachment
5Pressure governor
6Suction gauge connection
7Valve
8Auxiliary pressure gauge
9Knob
Fig. 9
D9630
1
7
4
3
2
5
6
9
8
H
meters
L meters
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. 4 m
D6328

SYSTEM NOT PERMITTED
IN GERMANY
Fig. 10
H

20013962 14
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Hydraulic system
6.3 Depressurised systems
Depressurised systems (Fig. 11 and Fig. 12) have a negative fuel
pressure (depression) on intake to the burner.
Usually the tank is lower than the burner.
SYSTEM 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 pipe;
Øi = internal diameter of the oil pipe.
In the systems in Fig. 11 and Fig. 12, the table shows the maxi-
mum indicated lengths for the supply line, depending on the dif-
ference in level, length and the diameter of the oil pipes.
6.3.1 Pump priming
On the systems in Fig. 11 and Fig. 12 it is necessary to start the
burner and wait for the 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. 12) the return line should ter-
minate within the oil tank at the same level 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 is not above 0.4 bar (30 cm Hg).
Above that level, gas leaks out from the fuel.
The pipes must all be perfectly sealed.
H
max. 4 m
H
D9550

Fig. 11
H
max. 4 m
D9551

Fig. 12
H
meters
L meters
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

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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, the 7-pin plug, the high vol-
tage cables and the earth wire (TB);
unscrew the bolt A) (Fig. 13) and pull the control box in the
direction of the arrow.
To install the control box it is necessary to:
screw the bolt A) in at a torque of 1 - 1.2 Nm;
reconnect all the connectors previously disconnected.
NOTE:
The burners have been type-approved for intermittent opera-
tion.
This means they must stop at least once every 24 hours in or-
der to allow 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).
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 carried out by qualified personnel and in compliance with the regulations currently in
force in the country of destination. Refer to the wiring diagrams.
declines all responsibility for modifications or connections different from those shown in the electrical
layouts.
Do not invert the neutral with the phase in the electrical 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 device.
For the main power supply of the device from the electricity mains:
- do not use adapters, multiple sockets or extensions;
- use an omnipolar switch with an opening of at least 3 mm (overvoltage category) between the contacts, as
indicated by the current 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. 13
E9275
A

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Electrical system
7.2 Electrical connections
C– Capacitor
E–Electrode
F– Photoresistance
h1 – Hour counter
K– Thermostat enabling start-up after preheating
MV – Motor
PH – Oil heater
RS – Remote reset
SER – Safety lockout device
S3 – Lock-out signal
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
7.2.1 Testing
Check the burner has stopped by opening the thermostats.
Make sure the operating burner locks out by covering the
photoresistance.
TO BE DONE BY
THE INSTALLER
CARRIED-OUT
IN FACTORY
Fig. 14
230V ~ 50Hz
CONTROL BOX
MO550
D7240
Main switch
Black
Blue
Brown
Black
White
Blue
WARNING
The section of the conductors must be at least
1mm2. (Unless requested otherwise by local stan-
dards and legislation)

17 20013962
GB
Operation
8.1 Notes on safety for the first start-up
8.2 Combustion setting
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 proper nozzle,
adjust the pump pressure, the position of the mixing unit, the flue
gases recirculation slotted holes, and the air damper adjustment
in accordance with the following schedule.
The values shown in the table are measured on a CEN boiler (as
per EN 267), and they refer to 13% CO2at sea level (1013 hPA)
and with light oil and room temperature of 20°C, and combustion
chamber pressure of 0 mbar.
Tab. A
8.3 Nozzles recommended
Steinen type 60° H;
Danfoss type 60° H;
Delavan type 60° W.
The burner complies with the emission requirements of the EN
267 standard.
In order to guarantee that emissions do not vary, recommended
and/or alternative nozzles specified by Riello in the Instruction
and warning booklet should be used.
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
Check the correct working of 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 shown. E.g.: outside air temper-
ature 10 °C, regulate the CO2to 12.5% (± 0.2%).
% CO2
Outside air temperature (°C)
14,5
14,0
13,5
13,0
12,5
12,0
11,5 0 5 10 15 20 25 30 35 40
D4604
Fig. 15
Nozzle Pump
pressure Burner output Combustion head adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
1.00 60° H 12 3.8 11.5
1.10 60° H 12 4.3 1.5 2
1.25 60° H 12 4.9 2 3
1.35 60° H 12 5.2 2.5 3.5
1.50 60° H 12 6.0 4 5
WARNING
To achieve CLASS 3 (EN267:1999) emissions,
hollow-cone nozzles have been used
WARNING
It is advisable to replace nozzles every year dur-
ing regular maintenance operations.
CAUTION
The use of nozzles other than those specified by
Riello S.p.A. and inadequate regular maintenance
may result into emission limits non-conforming to
the values set forth by the regulations in force, and
in extremely serious cases, into potential hazards
to people and objects.
The manufacturing company shall not be liable for
any such damage arising from nonobservance of
the requirements contained in this manual.

20013962 18
GB
Operation
8.4 Pump pressure
The pump leaves the factory set at 12 bar.
To change it act on pump pressure adjust screw 5) (Fig. 9).
8.5 Combustion head setting
Combustion head adjustment varies depending on burner de-
livery.
To adjust, proceed as follows:
turn adjusting screw 2) (Fig. 16) clockwise or anticlockwise
until the notch on the regulating rod 3) is lined up with the
outer surface of the nozzle-holder assembly 1).
In the example, the regulating rod 3) is set to setpoint 2; this
means the burner is adjusted for an output of 4.9 Kg/h with
a pump pressure of 12 bar using a 1.25 GPH nozzle, as
indicated in the reference Tab. A page 17.
8.6 Air damper adjustment
To adjust the air damper proceed as follows:
loosen nut 5) (Fig. 16) and set the valve by adjusting the
screw 4).
When the adjustment is complete screw down nut 5).
8.7 Electrodes adjustment
To reach the electrodes, proceed as described in the paragraph
9.3 “Maintenance position” page 22.
Do the following make the regulation:
lean the diffuser disc-holder assembly 3) (Fig. 17) on the
nozzle-holder 2) and lock it by screw 4).
For prospective adjustments of the electrodes assembly 5),
loosen screw 6).
8.8 Positioning optical fibre
To position the optical fibre, you must proceed as follows:
insert optical fibre 1) (Fig. 17) in the diffuser disc support
assembly 3), making sure it is pushed in all the way.
Tighten screw 4) carefully to hold optical fibre 1) in place.
WARNING
When the burner stops, the air damper closes au-
tomatically until maximum negative flue pressure
is 0.5 mbar.
Fig. 16
D9547
4 52
1
3
1
WARNING
MEASURES MUST BE RESPECTED.
Fig. 17
6
D9548
4.5 –0.5mm
0
3±0.3mm
5.5 ±0.3mm
5
2
34 1