Riello Gulliver BG1 Quick start guide

Instrucciones de instalación, uso y mantenimiento
Installatie-, gebruiks- en onderhoudsvoorschriften
Installation, use and maintenance instructions
2903399 (3) - 09/2009
Light oil burners
Stookoliebranders
Quemadores de gasóleo
CODE - CÓDIGO MODEL - MODELE
MODELO TYPE - TYP TIPO
3737125 - 3737155 BG1 371 T1
3737225 - 3737255 BG2 372 T1
3737325 - 3737355 BG3 373 T1
3738725 - 3738755 BG4 387 T1
GB
NL
E
One stage operation
Eentrapsbranders
Funcionamiento a 1 llama

MANUFACTURER'S DECLARATION
RIELLO S.p.A. declares that the following products comply with the NOx limits specified by
German standard “1. BImSchV 2009”.
VERKLARING VAN DE FABRIKANT
RIELLO S.p.A. verklaart dat de volgende producten de NOx-limietwaarden in acht nemen die
vereist worden door het Duitse normenstelsel “1. BImSchV 2009”.
DECLARACIÓN DEL FABRICANTE
RIELLO S.p.A. declara que los siguientes productos respetan los valores límite de emisión
de los NOx impuestos por la legislación alemana “1. BImSchV 2009”.
Product - Produkt - Producto Tipe -Typ - Tipo Model - Modele
Modelo
Light oil burners
Stookoliebranders
Quemadores de gasóleo
371 T1
372 T1
373 T1
387 T1
BG1
BG2
BG3
BG4
Legnago, 01.09.2009 Ing./Mr. G. Conticini
Burners Division Department
Directie Afdeling Branders
Dirección División Quemadores
RIELLO S.p.A.

3399 1GB
INDEX
1. BURNER DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Firing rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. WORKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Combustion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Recommended nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Electrodes adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Maintenance position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Air damper adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Slots setting for the flue gases recirculating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.7 Pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.8 Flame detector adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.9 Fuel heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.10 Operating programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.10.1 Normal operation with preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.10.2 Lockout due to firing failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.10.3 Lock out due to extraneous light during pre-purging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.10.4 Lockout types and triggering times in case of burner malfunction. . . . . . . . . . . . . . . . . . . . . . . 12
4.10.5 Control box reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.10.6 Re-cycle function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.10.7 Logging of burner operation parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.11 Additional programmable control box functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.11.1 Post-purging function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.11.2 Continuous purging function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.11.3 Long pre-purging function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.11.4 Function setting procedure using reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Control box visual diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Start-up problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Trouble during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7. WARNINGS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1 Burner identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 Basic safety measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3399 2GB
1. BURNER DESCRIPTION
1.1 BURNER EQUIPMENT
Flange with insulating gasket. . . . . No. 1 Screw and nuts for flange to be fixed to boiler . . . . . .No. 4
Screw and nuts for flange . . . . . . . No. 1 Flexible oil pipes with nipples . . . . . . . . . . . . . . . . . . .No. 2
Remote reset connection . . . . . . . . No. 1
1.2 ACCESSORIES
SOFTWARE DIAGNOSTIC KIT
A special kit is available that, by an optical link to a PC, shows the burner life together with operating hours,
type and number of failures, serial number, etc
To visualise the diagnostics proceed as follows:
³Connect the kit supplied separately to the control box socket.
Reading of the information begins when the software programme included in the kit starts.
REMOTE RESET KIT
The burner has a remote reset kit (RS) consisting of a connection and a push-button operating at a dis-
tance of 20 metres max.
In order to install it remove the protective lock-out installed at the factory and insert the lock-out supplied
with the burner (see electrical diagram on page 6).
One stage light oil burner with low pollutant emissions (Nitric Oxide NOx, Carbon monoxide CO and unburnt
Hydrocarbons).
The burner has a device (compensator) which is integral with the air damper that sets the air output.
This device keeps the oxigen level as necessary for the combustion despite any changing of the room tempe-
rature. The dimension of the boiler’s combustion chamber must respond to specific values, in order to gua-
rantee a combustion with the lowest polluting emissions rate. The RIELLO Technical Service Personnel will
be glad to give you all the imformation for a correct matching of this burner to the boiler.
³Burner with CE marking in conformity with EEC directives: EMC 89/336/EEC - 2004/108/EC, Low Voltage
73/23/EEC - 2006/95/EC, Machines 98/37/EEC and Efficiency 92/42/EEC.
³The burner meets protection level of IP X0D (IP 40) as EN 60529.
³The burner is approved for intermittent operation as per standard EN 267.
³CE Certification No.: 0036 0264/99 (371T1) – 0036 0265/99 (372T1) – 0036 0266/99 (373T1) –
0036 0267/99 (387T1), as 92/42/CEE.
1– Oil pump
2– Air damper adjustment assembly
3– Nozzle holder assembly
4– Control-box
5– Reset button with lock-out lamp
6– Flame detector
7– Temperature probe of the compensator
D8004
Fig. 1
26 3 5
4
7
1

3399 3GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 FIRING RATE (as EN 267)
TYPE 371T1 372T1 373T1 387T1
Output kg/h 1.35 ÷ 2.2 2 ÷ 2.9 2.6 ÷ 3.3 3 ÷ 4.6
Thermal power kW 16 ÷ 26 24 ÷ 34.5 31 ÷ 39 35.5 ÷ 54.5
Fuel Light oil, viscosity 4 ÷ 6 mm2/s at 20°C
Electrical supply Single phase, 230V ± 10% ~ 50Hz
Motor 0.8A Run current
2750 rpm
288 rad/s
1.8A Run current
2800 rpm
294 rad/s
Capacitor 4 µF6.3µF
Ignition transformer Secondary 8 kV - 16 mA
Pump Pressure: 8 ÷ 15 bar
Absorbed electrical power kW 0.27 0.27 0.28 0.46
TYPE A B C D Ø E F G H I L M N O P
371T1 255 280 199 230 80 25 7 280.5 130 150 180 91 72 72
372T1 255 280 202 230 89 28 10 287.5 140 168 189 106 83 83
373T1 255 280 202 230 89 28 10 287.5 140 168 189 106 83 83
387T1 300 345 230 285 97 34 12 307 140 168 189 106 83 83
D5758
C
11
45°
45°
Ø E
HAM
N
I
L
G
F
P
O
D
B
D8007
Light oil output – kg/h
Thermal power – kW
Pressure in combustion chamber – mbar
- 0.3
- 0.2
- 0.1
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
11.522.533.544.5
12 15 18 21 24 27 33 36 39 42 45 48 51 5430
387T1
371T1
372T1
373T1

3399 4GB
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 WORKING POSITION
The burner is designed for operation in positions 1and 2only. Installation 1is the preferred option as it is the
only one that enables maintenance to be performed as described later on in this manual. Operation is possible
with installation option 2though maintenance cannot be performed with the burner connected to the boiler. Note
that any other installation position is likely to hinder the unit’s proper operation. Installations 3, 4 and 5are pro-
hibited as safety is compromised.
3.2 BOILER FIXING
To fit the burner to the boiler it is necessary to carry out the following:
³Put on the flange (1) the screw and two nuts, (see fig. 3);
³Widen, if necessary, the insulating gasket holes (5) (see fig.4);
³Fix the flange (1) to the boiler door (4) using screws (2) and (if necessary) the nuts (3)
interposing the insulating gasket (5), (see fig. 2).
IMPORTANT: Boiler door must have a max. thickness of 180 mm.
Refractory linig included.
3.3 FUEL SUPPLY
The burner is designed to allow entry of the oil supply pipes on either side.
Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate
(1) and closing plate (2) should be reversed (see fig. 5).
D7088
12345
S7263
Fig. 2
Fig. 4
Fig. 3
D5012
D5709
121
Fig. 5

3399 5GB
3.4 HYDRAULIC SYSTEMS
It is necessary to install a filter on the fuel supply line.
* ONLY FOR ITALY: Automatic shut-off device as per Ministry of Internal Affairs’ regulation no. 73 dated 7/29/71.
H= difference of level; L= max. length of the suction line; I. D. = internal diameter of the oil pipes.
PRIMING PUMP
On the system in fig. 6 it is sufficient to loosen the suction gauge
connection (6, fig. 7) and wait until oil flows out.
On the systems in fig. 8 and 9 start the burner and wait for the priming.
Should lock-out occur prior to the arrival of the fuel, await at least 20 seconds
before repeating the operation.
The pump suction should not exceed a maximum of 0.4 bar (30 cm Hg).
Beyond this limit gas is released from the oil. Oil pipes must be completely tight.
In the vacuum systems (fig. 9) the return line should terminate within the oil tank
at the same level as the suction line. In this case a non-return valve is not
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.
H
meters
L meters
I. D.
8 mm I. D. 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
³
The pump is designed to allow working with two pipes.
In order to obtain one pipe working it is necessary to
unscrew the return plug (2), remove the by-pass screw
(3) and then screw again the plug (2). (See fig. 7).
³
Before starting the burner make sure that the return
pipe-line is not clogged. An excessive back pressure
would cause the damage of the pump seal.
WARNING:
H
meters
L meters
I. D.
8 mm I. D. 10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
SYSTEM NOT PERMITTED
IN GERMANY
1- Suction line
2- Return line
3- By-pass screw
4- Gauge connection
5- Pressure adjuster
6- Suction gauge connection
7- Valve
H
max. 4 m
max. 4 m
H
H
H
D5760
**
H
max. 4 m
*D5759
1
324 76
D5487
5
Fig. 6
Fig. 7
Fig. 8 Fig. 9

3399 6GB
3.5 ELECTRICAL WIRING
TESTING
³Check the burner has stopped by opening the thermostats.
³Make sure the operating burner locks out by covering the flame detector.
CONTROL BOX, (see fig. 10)
To remove the control box from the burner it is necessary to:
³Disconnect all the connectors, the 7-pin plug, the high voltage cables and
the earth wire (TB);
³Unscrew the bolt (A) and pull the control box in the direction of the arrow.
To install the control box it is necessary to:
³Screw the bolt (A) in at a torque of 1 - 1.2 Nm;
³Reconnect all the connectors previously disconnected.
NOTE:
The burners have been type-approved for intermittent operation.
This means they must stop at least once every 24 hours in order to 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).
AE9275
KEY
C– Capacitor
E–Electrode
F– Flame detector
h1 – Hours counter
(230V ~ - 0.1A max.)
K– Thermostat enabling start-
up after preheating
MV –Motor
PH – Oil heater
RS – Remote reset
SER – Safety lockout device
S3 – Remote lockout signal
(230V ~ - 0.5A max.)
T6A –Fuse
TB – Burner earth
TL – Limit thermostat
TS – Safety thermostat
V1 – Oil valve
V2 – Safety lockout device
X7 – 7 pin plug
XP7 – 7 pole socket
TO BE DONE BY
THE INSTALLER
CARRIED-OUT
IN THE FACTORY
CONTROL BOX
MO550
D7240
Main
switch
230V ~ 50Hz
Fig. 10
ATTENTION:
³Do not swap neutral and phase over, follow the dia-
gram shown carefully and carry out a good earth con-
nection.
³The section of the conductors must be at least 1mm2.
(Unless requested otherwise by local standards and legis-
lation).
³The electrical wiring carried out by the installer must be in
compliance with the rules in force in the country.
*(See “Hydraulic systems” on page 5).
If any of the hydraulic systems feature
the automatic shutoff device (230V -
max. 0.5A), it must be connected to
terminals N - T2 in the 7-pin plug.

3399 7GB
4
4. WORKING
4.1 COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjustment and
testing must be carried out observing the instruction manual of the boiler, including verification of the CO and
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 and adjust the pump pressure, the air damper
opening in accordance with the following schedule:
4.2 RECOMMENDED NOZZLES
Delavan 80° W with filter DROPSTOP type 60030.
4.3 ELECTRODES ADJUSTMENT
TYPE
Nozzle Pump pressure Burner output Air damper adjustment
GPH Angle bar kg/h ±4% Set-point
371T1
0.40 80° 12 1.35 0.25
0.50 80° 12 1.7 1.1
0.60 80° 12 / 14 2.0 / 2.2 2.0
372T1
0.60 80° 12 2.0 1.1
0.65 80° 12 2.3 2.0
0.75 80° 12 2.9 2.5
373T1
0.75 80° 11 2.6 2.2
0.85 80° 12 3.0 2.9
0.85 80° 14 3.3 4.0
387T1
0.85 80° 12 3.0 2.2
1.00 80° 12 3.8 4.2
1.10 80° 14 4.6 6.0
QUALIFIED PERSONNEL WITH THE RIGHT INSTRUMENTS MUST HANDLE THE BURNER'S START-UP .
!
WARNING
D5757
2
8 mm
Fig. 12
3
1
D5756
2
MEASURES MUST BE RESPECTED AND ALSO THE UPWARDS POSITION.
Lean insulators (1) to disc (2), (see fig. 11 - 12).
To have access to the electrodes carry out operation as described in chapter 4.4 – “MAINTENANCE POSITION”.
ATTENTION
6 mm
371T1 - 372T1 - 373T1
3
1
Fig. 11
0
6.5 + 0.5 mm
0
5 + 0.5 mm
387T1

3399 8GB
4.4 MAINTENANCE POSITION
THE ACCESSIBILITY TO THE NOZZLE, THE DIFFUSER DISC AND THE ELECTRODES IS MADE
EASY IN 2 WAYS:
³Remove the burner out of the boiler, after loosing
the fixing nut to the flange.
³Hook the burner to the flange (1), by removing the
flame tube (2) after loosing the fixing screws (3).
³Remove the small cables (4) from the electrodes
and the diffuser disc-holder assembly (5) from
the nozzle-holder assembly after loosing its fixing
screw (3, fig. 11-12, page 7).
³Screw the nozzle (6) correctly and tighten it as
shown in the figure.
³Remove nozzle-holder assembly (1) after loosing
screws (2) and nut (3), remove the small cables
(6) from the control box, the socket (4) and the
flame detector (5).
³Withdraw the small cables (6) from the electro-
des, remove the diffuser disc-holder assembly (9)
from the nozzle-holder assembly (1) after loosing
screw (3, fig. 11-12, page 7).
³Screw the nozzle (10) correctly and tighten it as
shown in figure.
Fig. 13
TIGHTEN WITHOUT MOVING
BACKWARDS TO THE END D5684
9Fig. 15
D8220 Fig. 14
5
ATTENTION
³During the reassembly of the nozzle-holder assembly screw the nut (3) as shown in fig. 15.
³In order to guarantee the sealing of the fan in its seat, make sure that there is at least 1 mm of spring tension
between nozzle-holder assembly and casing. Therefore the fixing split pin (11) will have to be extended at
least of 1 mm beyond the flange of the nozzle-holder assembly.
D8217
4
6
3
1
2