RIELLO Burner, Furnace Manual L0805012

User Manual: RIELLO RIELLO Burner, Furnace Manual RIELLO Burner, Furnace Owner's Manual, RIELLO Burner, Furnace installation guides

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RIELLO

40 SERIES

MODELS
EQUIPPED

40 F3 & F5

WITH ELECTRONIC

AIR SHUTTER

INSTALLATION
& OPERATING
MANUAL
RESIDENTIAL
OIL BURNERS

NOTE: The settings in this manual are for retrofit applications. If this burner is being installed on a packaged
unit (burner comes with the boiler or furnace), then follow the settings on the OEM page, as settings may
differ. Burner is set for a single line system.

Standard

40 F3-F5 I-O manual

Rev4

l.doc

Page 1 of I

TABLE

OF CONTENTS

TECHNICAL DATA - Model F3 ......................................................................................
TECHNICAL DATA - Model F5 .....................................................................................
OIL BURNER COMPONENT IDENTIFICATION
.........................................................
Serial Number Identification_ .............................................................................................
INITIAL SET-UP ..............................................................................................................
ASSEMBLY OF AIR TUBE TO BURNER CHASSIS ....................................................
MOU2',_TING BURNER TO BOILER OR FURNACE .....................................................
Method 1-Universal Mounting Flange ...............................................................................
Method 2- Semi- flange Collar ............................................................................................
Method 3-Pedestal Mount ..................................................................................................
FACTORY WIR1NG .........................................................................................................
APPLICATION
FIELD WIR1NG .....................................................................................
NOZZLE PLACEMENT .................................................................................................
INSERTION/REMOVAL
OF DRAWER ASSEMBLY .................................................
ELECTRODE SETTING .................................................................................................
TURBULATOR
SETT1NG .............................................................................................
PUMP CONNECTIONS
AND PORT IDENTIFICATION
............................................
Single Line (Gravity Feed) ..............................................................................................
Two Line (Lift System) ....................................................................................................
PUMP PURGE .................................................................................................................
Single Line (Gravity System) ..........................................................................................
Two Line (Lift System) ....................................................................................................
SETTING THE AIR ADJUSTMENT
PLATE ................................................................
BURNER ADJUSTMENT
TABLES ..............................................................................
AMULET INSTALLATION
INSTRUCTIONS
.............................................................
SEQUENCE OF OPERATION ................................................................................
EXPLODED PARTS VIEW ............................................................................................
PARTS LIST ....................................................................................................................
START UP FORM ..........................................................................................................
INSTALLATION
PRECAUTIONS
................................................................................

3
4
5
5
5
6
6
7
7
8
8
9
10
10
11
11
11
12
12
13

PACKAGE

13
14
14
15
16
17&18
19
20
21
22

LIST

Your Riello 40 burner should include the following parts. Please check to make sure all parts are present before
beginning the installation.
QTY. DESCRIPTION
2
2
4
2
1
1
1
1
1
*

OEM

Standard

(parts bag)

Mounting flange bolts (short)
Semi-flange bolts (long)
Nuts
Chrome nuts
Oil pump connector (supply)
Oil pump connector (return)
Female ¼" NPT adapter
Male 3/8" NPT adapter
2.5 n_n Allen key
burners shipped with combustion head mounted
40 F3-F5 I-O manual

Rev4

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QTY. DESCRIPTION
112 111-

(carton)

Burner chassis with cover
Universal Mounting Flange
Semi- flanges
Mounting gasket
Installation Manual
By-pass plug

_' (Separate carton)
1Combustion Head

Page 2 of 2

RIELLO

40 F3 TECHNICAL

]
1

DATA

Im II

O
"'Z

(< )

DIMENSIONS
MODEL

Inches
lnm
El:

10-inch

8 15/32
215

9 59/64
252

6 15/32
164

3 1/2
89

6
152

8 29/32
226

long (2541ran)

tubes are also available.

SPECIFICATIONS
FUEL:

NO heavier

FIRING

RATE:

EFFECTIVE

than # 2 FUEL

OIL

0.50 to 0.95 US GPH

OUTPUT:

70,000

to 133,000

BTU/h

120V 60Hz (+ 10% - 15%)

VOLTAGE
(Single Phase):
ABSORBED
ELECTRICAL

POWER:

155 Watts

MOTOR
(rated):
CAPACITOR:

3250 rpln Run Current
12.5 Microfiarads

PUMP

PRES SURE:

PRIMARY

CONTROL:

130 to 200 psig
RIELLO 530 SE/C

IGNITION

TRANSFORMER:

8Kv 16mA

2.2 AMP

60°_

_B
ou

MOUNTING
MODEL

DIMENSIONS

Inch

1 1/4

1/4

7/16

2 3/16

lnm

Standard

FLANGE

40 F3-F5 I-O manual

Rev4

l.doc

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___,_,
//7//

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Page 3 of 3

RIELLO

40 F5 TECHNICAL

]
1

DATA

Im II

O
"'Z

(< )

DIMENSIONS
MODEL

Inches
lnm
El:

10-inch

9 11/64
233

10 11/16
272

7 3/32
180

3 1/2
89

6
152

9 13/32
239

long (2541ran)

tubes are also available.

SPECIFICATIONS
FUEL:

NO heavier

FIRING

RATE:

EFFECTIVE

than # 2 FUEL

OIL

0.75 to 1.65 US GPH

OUTPUT:

105,000

to 231,000

BTU/h

120V 60Hz (+ 10% - 15%)

VOLTAGE
(Single Phase):
ABSORBED
ELECTRICAL

POWER:

175 Watts

MOTOR
(rated):
CAPACITOR:

3250 rpln - 2.2 AMP
12.5 MicroFarads

PUMP

PRES SURE:

PRIMARY

CONTROL:

130 to 200 psig
RIELLO 530 SE/C

IGNITION

TRANSFORMER:

8Kv 16mA
60°_

_B
ou

MOUNTING
MODEL

DIMENSIONS

Inch

1 1/4

1/4

7/16

2 3/16

lnm

Standard

FLANGE

40 F3-F5 I-O manual

Rev4

l.doc

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___,_,
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i ",',_ ,..! o_

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!-......
-_-}_-.£
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Page 4 of 4

OIL BURNER

COMPONENTS

IDENTIFICATION

STANDARD RIELLO OIL BURNER MODELS 40 F3 & 40 F5 BURNER KEY COMPONENTS
1. 530 SE/C INTEGRATED PRIMARY CONTROL
2. PRIMARY CONTROL SUB-BASE

7. ELECTRONIC AIR SHUTTER ASSY.
8. WIRE HARNESS FOR AIR SHUTTER

3. FUEL UNIT (PUMP)
4. PSC MOTOR
5. CAPACITOR

9. COMBUSTION HEAD WITH DRAWER ASSY.
10. SEMI FLANGE 2 PIECES
11. UNIVERSAL MOUNTING FLANGE & GASKET

6. AIR ADJUSTMENT AND SHUTTER

12. AIR TUBE COVER PLATE
13 PUMP VALVE (COIL)

*PLEASE READ THE MANUAL FOR SPECIFIC INFORMATION ON COMPONENTS
**IF BURNER IS AN OEM BURNER KEY COMPONENTS MAY DIFFER SLIGHTLY

BURNER

SERIAL

NUMBER

IDENTIFICATION

The Riello 15 character serial number, exmnple, 99 A 8511111 00025, is identified as follows:
99 = last two digits of the year of manufacture; A = BI-week of manufacture; 8511111 = burner product code;
00025 = increment of 1 for each burner produced - specific to product code - reset to zero each January 1st.
...._/
Year ofmanuIhcture

(99)
(A)
...---I--I

BI-weekofmanufacture

8511111
]

00025

[ Burner product code ]

Sequence

]

INITIAL SET-UP
A) Remove burner and air tube from cartons. Check parts list (inside cover) to ensure all parts are present.
B) Remove burner cover by loosing the three screws securing it. Remove control box and air tube cover (see
page 8).
C) Remove drawer assembly from air tube, insert nozzle and set Turbulator adjusnnent for specific input
required (see pages 8 & 9), then set aside.
D) Mount air tube to burner chassis. (see next page)

Standard 40 F3-F5 I-O manual Rev4 l.doc

Page 5 of 5

ASSEMBLY

OF AIR

TUBE

TO BURNER

CHASSIS

The air tube and drawer assembly are shipped in a carton separate from the burner chassis. Choose the proper
air tube length to obtain the tube insertion for the specific installation.
A) Remove the AIR TUBE and BURNER CHASSIS from theft respective cartons.
B) Remove the DRAWER ASSEMBLY (1) from inside the MR TUBE by loosening the screw (2). Carefully
pull the DRAWER ASSEMBLY out of the AIR TUBE, install the required nozzle (see page 8) and set
aside.
C) Remove the two BOLTS (3) from FRONT PLATE (4) of the BURNER CHASSIS. Align the two holes on
the MR TUBE HOLD1NG PATE (5) with the two holes on the BUNNER CHASSIS FRONT PLATE with
the BOLTS (3) removed. Replace the BOLTS and fingers tighten only. Re-install DRAWER ASSEMBLY
into AIR TUBE. Tighten SCREW (2) securely (see page 8).
D) Tighten the two bolts (3) securely.

®
MOUNTING

THE

BURNER

TO THE

BOILER

OR FURNACE

There are three possible methods to mount the burner, depending on the individual application. These are:
1) Universal flange bolted to Boiler2umace unit.
2) Semi-flange collar bolted to Boiler2urnace unit.
3) Universal flange mounted to optional Pedestal
possible. Pedestal kit must be ordered separately.

Standard

40 F3-F5 I-O manual

Rev4

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mount, where

flange mounting

direct to appliance

Page 6 of 6

is not

METHOD

1 - UNIVERSAL

MOUNTING

FLANGE

A) Insert the two BOLTS (1) into the UNIVERSAL MOUWHNG FLANGE (10) from the flat side, ensuring
the bolt heads are flush with the flat surface. Secure in place using two special CHROME NUTS (2)
provided.

DRY
BASE
BOILER

®
/

COMBUSTION
CHAMBER

®® ®

B) Position the MOU2,_T1NG GASKET (3) between the flat surface of the UNIVERSAL
MOU2qT1NG
FLANGE (10) and the appliance. Line up the holes in the UNIVERSAL MOUNT1NG FLANGE with the
STUDS (4) on the appliance mounting plate and securely bolt the UNIVERSAL MOU2,_T1NG FLANGE to
the plate.
C) Secure the two semi-flanges of the ADJUSTABLE
COLLAR (9) to the AIR TUBE using the two long
BOLTS (6). Be sure that the ADJUSTABLE COLLAR (9) is properly positioned so the outside edge of the
END CONE will be at least */4inch (6.51ran) back from the inside wall of the refractory of the combustion
chamber (see dimension B above). The measured length (A) is to include MOU_NT1NG GASKET and
FLANGE, if used.
D) The bumer may now be attached to the heating unit by insetting the AIR TUBE through the BUNNER
ACCESS HOLE (8) and into the appliance, making sure the BOLTS (1) line up with the two HOLES (5) in
the ADJUSTABLE COLLAR (9). Secure the burner in place using two NUTS (7).
A visual verification of the air tube insertion into the combustion chamber of the heating unit is suggested.
Dimension B should be at least */4"(see drawing).
NOTE: A suggested method for creating mounting bolt holes in the mounting gasket: Hold the gasket against
the appliance mounting bolts using the mounting flange for proper positioning. Lightly tap the flange with a
halraner to form the holes.
METHOD

2 - SEMI-FLANGE

COLLAR

A) Follow item C from METHOD 1.
B) Align the air tube and attached adjustable collar so air tube is centered in the bumer access hole of the
boiler/furnace unit. Mark the center of the two holes in the ADJUSTABLE COLLAR on to the front plate of
the heating unit. Then drill */4inch (6.51run) holes through the front plate of the unit, using marks as a guide.
C) Install two short BOLTS (1) through the front plate of the heating unit from the inside, and secure on the
outside using the two special CHROME NUTS (2).
D) Follow item D from METHOD 1.

Standard 40 F3-F5 I-O manual Rev4 l.doc

Page 7 of 7

METHOD

3 - PEDESTAL

MOUNT

Secure the MOU2,,!T1NGFLANGE to MOUE'qT1NGPEDESTAL using the hardware provided with the pedestal.
Secure burner to MOU2,,!T1NGFLANGE as in METHOD 1, item A, C and D.
NOTE: It is suggested that the pedestal be anchored
pedestal tube and securing brackets to the floor.

in position on the floor by installing brackets over the

WARNING:
WHEN
THE
COMBUSTION
CHAMBER
IS
LINED
WITH
A
REFRACTORY
MATERIAL,
IT IS IMPERATIVE
THAT THE END CONE NOT
PROTRUDE
INTO THE CHAMBER
AREA, AS EXCESSIVE
HEAT AT BURNER
SHUT DOWN MAY DAMAGE THE END CONE.
INTERNAL

FACTORY

WIRING

RIELLO 40 F SERIES OIL BURNERS EQUIPPED
WITH AN ELECTRONIC
AIR SHUTTER
INTERNAL FACTORY WIRING

D
(COIL)
PUMP

VALVE
AaK

D
I-C

SEE FIELD
CAPA(ITOR

___

WIRING

r-tl--

LEGEND:
(A)
(B)
(C)
(D)
(6)
(11)
(®)
(AUX)

Standard

BROWN
WHITE
BLUE
BLACK
120V SOURCE ACTIVATES
SHUTTER OPEN
MOTOR LEAD 120V SOURCE
120V CONTROL
LOCK OUT ALARM TERMINAL
CONSTANT
120V AUXILIARY
TERMINAL
- ELECTRONIC

40 F3-F5 I-O manual Rev4

l.doc

AIR SHUTTER

Page 8 of 8

APPLICATION
WIRING DIAGRAM

FIELD

SHOWN BELOW FOR STANDARD

WIRING

RIELLO 530 SE/C PRIMARY

CONTROL

BOX

INSTALLATION
NOTE: ELECTRONIC AIR SHUTTER REQUIRES A CONSTANT 120V POWER
SUPPLY TO THE AUX TERMINAL, FAILURE TO PROVIDE THIS WILL RESULT 1N NO BURNER
OPERATION OR AIR SHUTTER WILL NOT CLOSE.

RECOMMENDED
TYPICAL
120V

OPERATED

FIELD
WIRING
APPLICATIONS
24V OPERATED

SYSTEMS

d _

FOR

SYSTEMS
_

SH_ER

Q
T

@,
D
120VAC

60HZ.

WIRIN(

1,I ( t ND:

PI,I ASI

NE)II

: OPI

120VAC

RAF[N(

DISCONNEC'I

l,IMIl

(1)

MAIN

(2)
(S)

MANUAL
"SAFE_IY"

(4)
(5}

"E)Pt'RA'IING
" I IMI'I
DEVICt"
t'AR'Itt
GROUND
CONNEC'IIE)N

SAFI'IY

I,IMI'I ARI

FWO

SI PARAFI

I,IMI'IS

FUSE

SERVICE
SWHCH
I,IMII"
DEVICt
"

(6)
BURNER
CON1ROL
(AUX)
AUXILIARY
SUB
(1
F)24V
FHERMOSFAF
M[N
\VIRI
[NSULA'IED

AND

60HZ.

SIZtI:
18 A\VG

BURNt'R

CtIASSIS

REMOI'E
LE)CK
OlJ'I ALARM
DtVICE
WIRt'D
_" SUPPIIED
BASE ADD
ON CE)NNt
C'IOR
(AIR SHU FI'ER)
CE)NNECl[E)NS
LE)W VOI'IACE
E)PERA
Ft'I) SYS1EMS

SOI1D

BY O FItteRS

1(_ S ['RI)

R A F B I) l 05 ° C
PROPt
ALL

R IARltt
WIRING

(ROUNDING
StIOWN

PROVIDED

MtANS

RIQ'D

BY O'[tI[

WARNING: DO NOT activate burner until proper oil line connections
failure of the pump shaft seal may occur.

have been made,

WARNING:
DO NOT activate burner until all safety and operating controls have been
wired in series with the burner, as required by local code authorities and/or as specified by
the appliance manufacturer.

Standard

40 F3-F5 I-O manual

Rev4

l.doc

I
I
I

Page 9 of 9

NOZZLE

PLACEMENT

A) Determine the proper firing rate for the boiler or fumace units, considering the specific application, and then
use the Burner Setup charts on page 15 to select the proper nozzle and pump pressure to obtain the required
input from the burner.
B) Remove the NOZZLE ADAPTER (2) from the DRAWER
ASSEMBLY by loosening the SCREW (1).
C) Insert the proper NOZZLE into the NOZZLE ADAPTER
and tighten securely (Do not over tighten).
D) Replace
adapter,
with
nozzle
installed,
into
drawer
assembly and secure with screw (1).

INSTALLATION/REMOVAL

OF DRAWER

ASSEMBLY

Removal:
A) Loosen offoil delivery tube nut from pump.
B) Loosen SCREW (3), and then unplug CONTROL BOX (1) by carefully pulling it back and then up.
C) Remove the AIR TUBE COVER PLATE (5) by loosening the retaining SCREW (4) (Two SCREWS
Model F5).
D) Loosen SCREW (2), and then slide the complete drawer assembly out of the combustion head as shown.
E) To insert drawer assembly, reverse the procedure in items A to D above.

Standard

40 F3-F5 I-O manual

Rev4

l.doc

Page l0 of l0

ELECTRODE
IMPORTANT:

THIS

DIMENSIONS

MUST

SETTING

BE OBSERVED

AND

VERIFIED.

I 3/64'
5mm

6/64" to 7/64" or 2 to2.Sn,m_-------_

TURBULATOR

SETTING

A) Loosen NUT (1), and then turn SCREW (2) until the INDEX MARKER (3) is aligned with the correct
index number as per the Burner Setup charts, or OEM specifications given with the appliance.
B) Retighten the RETAINING
NOTE:
OEM
specifications
specifications

shown

NUT (1).
take
priority

over

retrofit

in this manual.

MODEL F3 NOTE: Zero and four are scale indicators only
From left to fight the first line is 4 and the last line 0.
MODEL F5: Same as above, except, scale indicators are 0
and 3.

PUMP CONNECTIONS

AND PORT IDENTIFICATION

This burner is shipped with the oil pump set to operate on a single line system. To operate on a two-line system the bypass plug must be installed.
WARNING:
Do not operate a single line system with the by-pass plug installed. Operating a single line system with the
by-pass plug installed will result in damage to the pump shatl seal.
NOTE: Pump pressure must be set at time of burner start-up. A pressure gauge is attached to the PRESSURE
PORT (7)
tbr pressure readings. Two PIPE CONNECTORS
(4) are supplied with the burner tbr connection to either a single or
two-line system. A/so supplied are two ADAPTORS
(3), two t_male 1/2' NPT, to adapt oil lines to burner pipe
connectors. All pmnp port threads are British Parallel Thread
design. Direct connection of NPT threads to the pmnp will
damage the pump body.
Riello manometers and vacuum gauges do not require any adapters, and can be sat_ly connected to the pump ports. An
NPT (metric) adapter must be used when connecting other gauge models.

PUMP

LEGEND

1PUMP
2. PUMP

COVER
COVER

O-RING

3 BSPP TO NPT ADAPTERS
4. SUPPLY
AND RETURN
OILLINES
5
6

RETURN
NOZZLE

7. PUMP
8PUMP
9. PUMP

PORT
PORT-

BY PASS SCREW
PUMP
OULET TO

PRESSURE
PORT
SUPPLY
PORT
RETURN
PORT

AND

10. PUMP
PRESSURE
REGULATING
11VACUUM
PORT
12PUMP
VALVE
STEM

Standard

40 F3-F5 I-O manual

Rev4

l.doc

NOZZLE

BLEEDER

PORT

SCREW

Page 11 of 11

SINGLE

LINE

(GRAVITY

FEED

SYSTEM)

A) The burner is shipped configured for use in single line applications. No changes to the oil pump are required
for use in single line applications.
NOTE: If the pump cover (1) is removed for any reason, be sure the O-ring (2), is properly seated in the pump
cover (1) before re-attaching the pump cover to the pump housing.
SINGLE

LINE

SYSTEM-PIPE

LENGTHS

3/8" OD

1/2" OD

1.5

0.5

3.0

1.0

130

5.0

1.5

130

260

6.5

2.0

195

325

100

B) Connect the pipe connector to the SUPPLY PORT (5) of the
pump. Attach the NPT adapter to the pipe connector.
Attach the required piping to this pipe adapter. Be sure that
the plug in the RETURN PORT (7) is tightened securely.

TWO LINE (LIFT

1
P

NOTE: Do not exceed pipe lengths indicated in
chart.

SYSTEM)

2 LINE (LIFT) SYSTEM-PIPE
LENGTHS
H

3/8" OD

1/2" OD

0.0

ll5

330

100

1.5

0.5

100

330

100

3.0

1.0

330

100

5.0

1.5

295

6.5

2.0

230

9.5

3.0

100

3.5

NOTE: Do not exceed pipe lengths indicated in
chart.

A) If a two-line system is required, install the By-pass plug provided. The by-pass plug is installed in the return
port of the pump. A 2.5-1ran hexagonal key provided with the by-pass plug is to be used to install the plug.
DO NOT use an inch size hexagonal key; damage to the by-pass plug may result. When operating on a twoStandard

40 F3-F5 I-O manual

Rev4

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Page 12 of 12

line system, supply and remm lines should be the same diameter and both should extend to the same depth
inside the fuel tank. Be sure there are no air leaks or blockages in the piping system. Any obstructions in
the remm line will cause Failure of the pump shaft seal. Do not exceed the pipe lengths indicated in the
tables on page 10.
To install the by-pass plug:
1) Remove the return plug (7)
2) Install the by-pass plug (4) using the 2.5 rain hexagonal key
B) Attach the two PIPE CONNECTORS
(6) to the pump SUPPLY and pump RETURN PORTS (5 and 7).
Attach the required piping to these two pipe connectors using the NPT/ METRIC ADAPTERS that are
supplied with the burner.
i WARNING:
Pipe dope or Teflon tapes are NOT to be used on any direct oil connection to the 1
i

..........................................................................................................................................
i

L_W_._A__I_N._G_.'._Tl?_.e,.h_e_i.ght
'P' in e_._e.Le.ng.t.hCharts should not exceed 13 feet (.4..m_)_.
...............................

...................................................
i
i IMPORTANT:
i

An external,

appropriatelylisted and certified oil filter must be placed in the fuel i
i

@2t.®.k....me.burn.e .......................................................................................
i
PUMP

PURGE

NOTE: To protect the pump gears, it is advisable to lubricate the pump prior to purging a lift system. Apply oil
through the VACUUM PORT (C).
A) SINGLE

LINE

(GRAVITY

FEED

SYSTEM)

Loosen the bleeder valve (A) until oil flows out. Tighten the bleeder
valve securely and start burner.
II. When bleeding the pump by pressure:
1) Loosen the bleeder valve (A).
2) Disconnect nozzle oil supply line at the pump nozzle port (B).
3) Attach a flexible plastic robe to the pump nozzle, port directing
the oil flow into a bucket.
4) Loosen the screw(s) securing the air tube cover, allowing it to be

removed freely.
5) Holding the air tube cover in its proper location start the burner.
6) When the solenoid valve is engaged approximately 10 seconds
after starting, remove the air tube cover and shine a light source on the photocell, allowing it to see False

light.
7) Run the burner until the fuel pump has
immediately shut down the burner.
8) Reinstall the air tube cover and nozzle line
9) The burner can now be started normally.
WARNING:

been purged

of air, then tighten

the bleeder

valve

Omitting steps 2 and 3 will result in a collection ofunbumed oil in the combustion chmnber
creating a hazardous situation upon burner startup.

Standard 40 F3-F5 I-O manual Rev4 l.doc

Page 13 of 13

and

B) TWO
LINE
(LIFT
SYSTEM)
Turn off the main power source to the burner and remove the air tube cover. Shines a light source on the
photocell (now visible where the air tube cover was removed), return power to the burner and activate the
burner. With the light source in place, the burner will operate in prepurge only. When the pump is sufficiently
purged, the hydraulic air shutter will open. Once the burner is purged, turn off the power source and replace the
air robe cover. Return power to the burner. The burner is now ready to operate.
ATTENTION:
It is important that the fuel line be completely
any internal blockages.

sealed and free from air leaks or

WARNING!
WHEN THE BYPASS PLUG IS INSTALLED, A TWO-PIPE
BE USED OR FAILURE OF THE PUMP SHAFT WILL OCCUR.

SETTING

THE

AIR

ADJUSTMENT

SYSTEM

MUST

I
I
I

PLATE

The electronic air shutter assembly (1) is operated on a 120v 60Hz.
motor, and the burner motor will not operate until the air shutter is in its
fully open position.

Set the air plate (4) setting according to OEM setup information or by
following the Retrofit settings listed in this manual. To adjust the air
plate (4) to the desired set point indicator (2), loosen the center air
shutter assembly screw (5) and loosen the side air plate screw (3), move
air plate (4) by using the air plate adjust ann. After adjustments are
made please retighten screws (3) & (5).
The final position of the air adjusnnent plate will vary on each
installation. Using proper combustion test instruments to establish the
proper setting of the air gate setting to achieve safe and efficient results
according the appliance information or if not available.
NOTE: Variations in flue gas, smoke, CO2 and temperature readings may be experienced when burner cover is
put in place. Therefore, the burner cover must be in place when making final combustion instrument readings,
to ensure proper test results are obtained.

Standard

40 F3-F5 I-O manual

Rev4

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Page 14 of 14

BURNER
NON-RETROFIT

ADJUSTMENT

TABLES

APPLICATIONS

If this burner is being installed in a packaged unit (i.e. Burner comes with a boiler or furnace), follow the
installation
and set-up instructions
supplied with the heating appliance, as settings will differ from those
shown in this manual.
MODEL
F3 BURNER
SETUP
CHART

ACTUAL
RATE

NOZZLE
SIZE
GPH
.40 x 60°/80 °
.50 x 60°/80 °
.60 x 60°/80 °
.65 x 60°/80 °
.75 x 60°/80 °

FIRING
5% ±

US GPH
0.50
0.60
0.75
0.80
0.95

MODEL
ACTUAL FIRING
RATE 5% ±
US GPH
0.75
0.85
1.00
1.10

TURBULATOR
SETTING

DAMPER

BAR

160

11.0

0.0

2.3

150

10.4

0.5

2.7

150

10.4

1.5

3.4

150

10.4

2.0

3.6

160

11.0

3.0

4.3

SETUP

PUMP
PRESSURE

GPH

AIR

PSI

F5 BURNER

NOZZLE
SIZE

SETTING

CHART

TURBULATOR

PSI

BAR

145

0.0

.65 x 60/80

145

0.5

2.5

.85 x 60/80

145

1.0

2.75

145

2.0

3.0

1.10 x 60/80

SETTING

AIR DAMPER

.60 x 60/80

1.00 X 60/80 °

1.25
1.50
1.65

PUMP
PRESSURE

SETTING
2.25

145

2.5

3.5

1.25 x 60/80 °

145

3.0

4.25

1.35 X 60/80 °

145

4.0

6.0

NOTE:
The above set up charts are a starting
up using proper
combustion
testing equipment.

point

only. The burner

and

appliance

must

be properly

set

Note: any approved oil burner nozzle type, angle and manufacturer
maybe used, as long as input
is corresponding
the correct BTU/hr. or US gph input rating of the appliance.
COMBUSTION

CHAMBER

Follow the instructions furnished by the boiler/furnace manufacturer.
appropriate installation codes (e.g. CSA B 139 or NFPA #31).

Standard

40 F3-F5 I-O manual

Rev4

l.doc

Size retrofit application

according

to the

Page 15 of 15

AMULET

INSTALLATION

(Required

INSTRUCTIONS

on some

models)

The amulets provided have been selected by Riello to protect the combustion
flame. This protection may be needed in applications where the combustion
chamber refractory is larger than the tube outside dimneter.

tube from bt exhaust gases and
tube opening in the combustion

The mnulet has been sized to fit Riello Model 40 sizes F3 and F5 plus the Riello Model R35.
When installing this amulet, handle it carefully. Do not exert undue pressure when pushing the mnulet over the
combustion tube. Excessive force can result in a broken amulet!
If the mnulet will not fit easily onto the tube, remove a small amount of the inner diameter with a sharp knife to
provide the necessary clearance.

The diagrmn below shows the proper position of the mnulet after installation.

Amulet shown in
mounted position

Head Receeded

"If-t

the flush
--_
1/4 inch max. *"-_

4__

NO AMULET

AMULET

flue
gases

gases

tapered combustion
chamber causes

increase in pressure
inside
LOW PRESSURE

]

increase
LOW PRESSURE

}n pressure
inside

heat
air tube
increase

air tube

heat

pressure down air
tube due to
increase in
combustion

increase in pressure down air
tube due to increase in
combustion chamber

AMULET HELPS
PREVENT HOT
GASES FROM

pressure

TRAVELLING
DOWN AIR
TUBE

chamber pressure

Standard

40 F3-F5 I-O manual

i H'GHPRESSU
I
E

Rev4

l.doc

ncrease

in pressure

down

air

tube due to increase in
combustion chamber
pressure

Page 16 of 16

RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC
SHUTTER NORMAL OPERATIONAL SEQUENCE
POWER

STANDY BY

CALL
FOR
HEAT
AIR
SHUTTER

open

MOTOR /
PREPURGE

IGNITION

Ol L VALVE

'
._

FLAME
HEAT
SATISFIED

AIR
SHUTTER

I
n i
n i
n i

ELECTRIC

AIR SHUTTER

ELECTRIC AIR SHUTTER

CLOSED ~ WAITING

AIR
©

FOR CALL FOR HEAT

OPENS - ONCE FULLY OPEN SWITCHES POWER T+ BURNER MOTOR

[
[
I

[
[
n
i

_q
I

BURNER

MOTOR STOPS ~ ELECTRIC

AIR SHUTTER

CLOSES
¢S

THERMOSTAT

OR LIMIT CONTROL

ELECTRIC

AIR SHUTTER

MODES

40 SERIES OIL BURNER

MODES

CONSTANT UNITERUPTED
120V POWER SUPPLY
TO ELECTRIC AIR SHUTTER ASSEMBLY

J
J

mEl,l_

RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR
SHUTTER NO FLAME OPERATIONAL SEQUENCE
AC

POWER

STANDY

ELECTRIC

AIR SHUTTER

CLOSED

- WAITING

FOR CALL FOR HEAT

CALL FOR
HEAT

open

AIR
SHUTTER

MOTOR/
PREPURGE

IGNITION

OI L VALVE

FLAME

LOCK OUT
AIR
SHUTTER

ELECTRIC

AIR SHUTTER

OPENS

~ ONCE FULLY OPEN

SWITCHES

POWER

TO BURNER

MOTOR

[
[
[
[
I

[
I

BURNER

THERMOSTAT

40 SERIES

MOTOR

STOPS

OR LIMIT CONTROL

OIL BURNER

MODES

- ELECTRIC

AI}R SHUTTER

CLOSES

ELECTRIC

AIR SHUTTER

MODES

CONSTANT
UNITERUPTED
120V POWER
TO ELECTRIC AIR SHUTTER ASSEMBLY

SUPPLY

&
4:_

11
10

4:_

_"o

:1:=,

_m
'!3

!
49

RIELLO SPARE PARTS
• Indicates applicable
No

CODE

1
2
3

3007232

Burner Back Cover

3007233

Burner Back Cover

27
28
29

3005854
3005855
3005856

C7001081
C7001082

3007207

Air Intake Housing

35
36

3007208
3005844
3005708
C6950050

Air Intake Housing
Capacitor 12.5!JF
Fan
Acoustic Liner

3007320
3007221

Acoustic Liner
Chassis Front Plate

3007222

Chassis Front Plate

3006992

Pipe Connector Supply
3/8" NPT/Metric

4
5
6
7

3006993
3005847
3007077
3007568

Pipe Connector Return
t/2' NPT/Metric Adapter - Female
Crushable Metal Washer 3/8" ID
Bleeder

8
9

3007028
3007202

O-Ring - Pump Pressure Regulator
Regulator Screw

10
11
12
13

C7010002
3005719
3006925
3007203

3007029

O-Ring - Valve Stem Upper

15
16
17

3007156
3007268
3007087

O-Ring - Valve Stem Lower
Nozzle Outlet Fitting
Crushable Metal Washer 5/8" ID

18
19

N/A
3006553

Primary Control Sub-Base
Coil U-Bracket and Knuded Nut

3002279

Coil

21
22
23

3007802
3000443
3005843

Pump
Pump Drive Key
Motor 120VOLT 60Hz

3007315
3007316

Air Tube Cover
Air Tube Cover

3002280

Photocell

O-Ring-

_BT

Adapter - Male

Pump Cover (3007162)
Pump Screen
Valve Stem
Valve Stem Plate

37
38

C7001033

C7001066

51
52

2623141
3000932

VSBT Combustion

3948976
3006968

VSBT Combustion
Head 3"
Turbulator Disc

3006977

Turbulator

Head 3"

Disc

4O
41
42

3006965
3008627

Nozzle Adapter
Nozzle Oil Tube

3008629

Nozzle Oil Tube

3008633

Regulator Assembly

3008634
3008630

Regulator Assembly
Electrode Assembly

3008631
3005869

Electrode Assembly
Electrode Porcelain

3008623

Air Tube only

3008626

Air Tube only
N _8;:;;:

_7/8"
40

3_B_STION

44
45
46

Mounting Gasket
F3 replacement air damper kit
F5 replacement air damper kit

Amulet - Cerafelt Sleeve Kit
Type L 24 volt switching

relay

Capillary port plug
Adjustable Steel Flange

3948873

Short Combustion
Head 6" (271T1)
Short Combustion
Head 6" (271T1)
Turbulator Disc

3948973
3006968
3006977
3006966

Turbulator
Electrode

3006965
3006969

3006966

Electrode Support

3006965

Nozzle Adapter

3008970
3008628

45
46

Disc
Support

Nozzle Adapter
Nozzle Oil Tube - Short

3006973
3006324

Regulator

Nozzle Oil Tube - Short

3006323
3006330

Regulator Assembly - Short
Electrode Assembly - Short

3006329
3005869

Electrode AssemblyShort
Electrode Porcelain

3007592

Air Tube only
LOi |GC_

Combustion
Head 8 7/8"
Combustion
Head 8 7/8"
Turbulator Disc
Turbulator Disc

Primary Control
Semi Flange (2 Required)
Universal Mounting Flange

3007594

3948877
3948975
3006968
3006977

DESCRIPTION

COMBU_ION

3948876

Electrode Support

N/A

3006966

iiiiiii_iiii_i`i_i_i`i_i_i_i`i_i_i`i_i_i`i_i_i`i_i_i`i_i_i`i_i_i`i_i_i`i_i_i`i_i_i`i_i_i`i_i_i`
_i`i_i_i`i_i_i`i_i_i`i_i_i`i_i`i_i_i`i_i_i`i_i_i`i_i_i`i_i_i_i`i_i_i`i_

CODE

6, 2002

DESCRIPTION

3006571

LIST revised November
model for each part.

Assembly - Short

Air Tube only
BEAD

3948874
3948974
3006968
3006977

Long Combustion
Head 10" (271T2)
Long Combustion
Head 10" (271T2)
Turbulator Disc
Turbulator Disc

3006966

Electrode Support

3006965

Nozzle Adapter

Nozzle Oil Tube
Nozzle Oil Tube

3006970
3006974

Nozzle Oil Tube - Long
Nozzle Oil Tube - Long

3008846
3008635

Regulator Assembly
Regulator Assembly

3005867
3005878

Regulator Assembly
Regulator Assembly

3008789
3008632
3005869

Electrode Assembly
Electrode Assembly
Electrode Porcelain

3005870
3005880
3005869

Electrode Assembly - Long
Electrode Assembly - Long
Electrode Porcelain

3008788

Air Tube only

3007593

Air Tube only

3007595

Air Tube only

- Long
- Long

48
48

3008625

Standard

40 F3-F5 I-O manual

Air Tube only

Rev4

l.doc

Page 20 of 20

mB,++o
35 Pond Park Rd.
Hingham, MA 02043
Phone: 781-749-8292
Toll Free: 800-992-7637
Fax: 781-740-2069

2165 Meadowpine Blvd.
Mississauga, On L5H R2
Phone: 905-542-0303
Toll Free: 800-387-3898
Fax: 905-542-1525

BURNERS

BURNER START-

UP FORM *

Burner S/N. or
Model:

Appliance:

Installer name:
Installation
date:

Company:
Address:
Phone:

Fax:

Owner Name:
Address:
Phone:

E-mail:

Burner Start-up Info (GAS)
Gas Supply Pressure:
Pump
pressure:
Turbulator
setting:

Air Setting:

Draft
breech:

:)raft Over fire:

002:

02:

This form

was designed

with the information

Standard

40 F3-F5 I-OmanualRev4

02:

Manifold pressure:

Tw°[_l
Lines: I

technical
information,
assistance
is required.

Draft
breech:
CO:

002:

(Bacharach)

Single [_1
Line: I
I

Head Setting:

Draft Over fire:

CO:

+Smoke density:
:
::i

Air Setting:

and provided

in the installation

Ionization Reading
(pAd.c.):
manual

for reference

Input
BTU/Hr:
and also for providing

which can be faxed or mailed to our technical
hot-line coordinator
when technical
Please complete
this form, fax it or mail it at the addresslfax
above, or sendane-mail
listed

l.doc

below

to:

techservices(_,riellocanada.com

Page 21 of 21

INSTALLATION
AIR

FOR

PRECAUTIONS

COMBUSTION

Do not install bumer in room with insufficient air for combustion. Be sure there is an adequate air supply for
combustion if the boiler/furnace room is enclosed. It may be necessary to create a window to permit sufficient
air to enter the boiler/furnace room. The installer must follow local ordinances in this regard.
CANADA: It is suggested that the installer follow CSA standard B139.
USA: It is suggested that the installer follow NFPA manual #31.

CHIMNEY
Be sure chimney is sufficient to handle the exhaust gases. It is recommended that only the burner be connected
to the chimney. Be sure that it is clean and clear of obstructions.
OIL

FILTER

An external oil filter is REQUIRED, even though there is an internal strainer in the pump. The filter should be
replaced at least once a year, and the filter container should be thoroughly cleaned prior to installing a new filter
cartridge.

DRAFT
Follow the instructions furnished with the heating appliance.
The pressure in the combustion area should be kept as close to zero as possible. The burner will operate with a
slight draft or pressure in the chamber.
ELECTRICAL
CONNECTIONS
CANADA
All electrical connections should be done in accordance with the C.E.C. Part 1, and all local codes. The system
should be grounded.
USA
All electrical connections should be done in accordance with the National Electrical Code, and all local
ordinances,

The system should be grounded.

CONTROL

BURNER

OPERATION

Check out the bumer and explain its operation to the homeowner. Be sure to leave the Owner's Instruction sheet
with the homeowner.
FIRE EXTINGUSHER
If required by local codes, install an approvedfire extinguisher.

ELECTRICAL

CONNECTIONS

In most localities, a number 14 wire should be used inside a metal conduit. The system should be grounded. A
service switch should be placed close to the burner on a fireproof wall in an easily accessible location.

Standard

40 F3-F5 I-O manual

Rev4

l.doc

Page 22 of 22

Standard 40 F3-F5 I-O manual Rev4 l.doc

Page 23 of 23

E[L0

BURNERS
35 Pond Park Road
Hingham, MA 02043
Phone 781-749-8292
Toll Free 800-992-7637
Fax 781-740-2069
wx_w.riellousa.com

2165 Meadowpine
Blvd
Mississauga,
ON L5N 6H6
Phone 905-542-0303
Toll Free 800-387-3898
Fax 905-542-1525
x_ww.rie!locanada.com

Technical Support Hotline
1- 800 -4-RIELLO
1-800-474-3556

Standard 40 F3-F5 I-O manual Rev4 l.doc

Page 24 of 24

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Author                          : 
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RIELLO Burner, Furnace Manual L0805012

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