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 40 F3 & F5

EQUIPPED 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 ...................................................................................... 3

TECHNICAL DATA - Model F5 ..................................................................................... 4

OIL BURNER COMPONENT IDENTIFICATION ......................................................... 5

Serial Number Identification_ ............................................................................................. 5

INITIAL SET-UP .............................................................................................................. 5

ASSEMBLY OF AIR TUBE TO BURNER CHASSIS .................................................... 6

MOU2',_TING BURNER TO BOILER OR FURNACE ..................................................... 6

Method 1-Universal Mounting Flange ............................................................................... 7

Method 2- Semi- flange Collar ............................................................................................ 7

Method 3-Pedestal Mount .................................................................................................. 8

FACTORY WIR1NG ......................................................................................................... 8

APPLICATION FIELD WIR1NG ..................................................................................... 9

NOZZLE PLACEMENT ................................................................................................. 10

INSERTION/REMOVAL OF DRAWER ASSEMBLY ................................................. 10

ELECTRODE SETTING ................................................................................................. 11

TURBULATOR SETT1NG ............................................................................................. 11

PUMP CONNECTIONS AND PORT IDENTIFICATION ............................................ 11

Single Line (Gravity Feed) .............................................................................................. 12

Two Line (Lift System) .................................................................................................... 12

PUMP PURGE ................................................................................................................. 13

Single Line (Gravity System) .......................................................................................... 13

Two Line (Lift System) .................................................................................................... 14

SETTING THE AIR ADJUSTMENT PLATE ................................................................ 14

BURNER ADJUSTMENT TABLES .............................................................................. 15

AMULET INSTALLATION INSTRUCTIONS ............................................................. 16

SEQUENCE OF OPERATION ................................................................................ 17&18

EXPLODED PARTS VIEW ............................................................................................ 19

PARTS LIST .................................................................................................................... 20

START UP FORM .......................................................................................................... 21

INSTALLATION PRECAUTIONS ................................................................................ 22

PACKAGE 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 (parts bag) QTY. DESCRIPTION (carton)

2-Mounting flange bolts (short) 1 -

2-Semi-flange bolts (long) 1 -

4 - Nuts 2 -

2 - Chrome nuts 1 -

1 - Oil pump connector (supply) 1 -

1 - Oil pump connector (return) 1-

1 - Female ¼" NPT adapter

1 - Male 3/8" NPT adapter

1 - 2.5 n_n Allen key

* OEM burners shipped with combustion head mounted

Burner chassis with cover

Universal Mounting Flange

Semi- flanges

Mounting gasket

Installation Manual

By-pass plug

_' (Separate carton)

1-Combustion Head

Standard 40 F3-F5 I-O manual Rev4 l.doc Page 2 of 2

RIELLO 40 F3 TECHNICAL DATA

(< )"'Z

EIm II I_ ,

DIMENSIONS

MODEL F3 A B C D E F

Inches 8 15/32 9 59/64 6 15/32 3 1/2 6 8 29/32

lnm 215 252 164 89 152 226

El: 10-inch long (2541ran) tubes are also available.

SPECIFICATIONS

FUEL:

FIRING RATE:

EFFECTIVE OUTPUT:

VOLTAGE (Single Phase):

ABSORBED ELECTRICAL POWER:

MOTOR (rated):

CAPACITOR:

PUMP PRES SURE:

PRIMARY CONTROL:

IGNITION TRANSFORMER:

MOUNTING FLANGE DIMENSIONS

MODEL F3 A B C D

Inch 1 1/4 1/4 7/16 2 3/16

lnm 32 6 11 56

NO heavier than # 2 FUEL OIL

0.50 to 0.95 US GPH

70,000 to 133,000 BTU/h

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

155 Watts

3250 rpln Run Current 2.2 AMP

12.5 Microfiarads

130 to 200 psig

RIELLO 530 SE/C

8Kv 16mA

60°_ _B

ou A

'_ ___,_, , I

/__\ K#_.,\ 1

//7// i ",',_ ,..! o_

-(-_-.......!-......-_-}_-.£

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Standard 40 F3-F5 I-O manual Rev4 l.doc Page 3 of 3

RIELLO 40 F5 TECHNICAL DATA

(< )"'Z

EIm II I_ ,

DIMENSIONS

MODEL F5 A B C D E F

Inches 9 11/64 10 11/16 7 3/32 3 1/2 6 9 13/32

lnm 233 272 180 89 152 239

El: 10-inch long (2541ran) tubes are also available.

SPECIFICATIONS

FUEL:

FIRING RATE:

EFFECTIVE OUTPUT:

VOLTAGE (Single Phase):

ABSORBED ELECTRICAL POWER:

MOTOR (rated):

CAPACITOR:

PUMP PRES SURE:

PRIMARY CONTROL:

IGNITION TRANSFORMER:

MOUNTING FLANGE DIMENSIONS

MODEL F5 A B C D

Inch 1 1/4 1/4 7/16 2 3/16

lnm 32 6 11 56

NO heavier than # 2 FUEL OIL

0.75 to 1.65 US GPH

105,000 to 231,000 BTU/h

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

175 Watts

3250 rpln - 2.2 AMP

12.5 MicroFarads

130 to 200 psig

RIELLO 530 SE/C

8Kv 16mA

60°_ _B

ou A

'_ ___,_, . I

/__\ K#_.,\ 1

//7// i ",',_ ,..! o_

-(-_-.......!-......-_-}_-.£

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

3. FUEL UNIT (PUMP)

4. PSC MOTOR

5. CAPACITOR

6. AIR ADJUSTMENT AND SHUTTER

7. ELECTRONIC AIR SHUTTER ASSY.

8. WIRE HARNESS FOR AIR SHUTTER

9. COMBUSTION HEAD WITH DRAWER ASSY.

10. SEMI FLANGE 2 PIECES

11. UNIVERSAL MOUNTING FLANGE & GASKET

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.

...._/ (99) (A) 8511111 00025

...---I--I

Year ofmanuIhcture IBI-weekofmanufacture ] [ Burner product code ] I 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 mount, where flange mounting direct to appliance is not

possible. Pedestal kit must be ordered separately.

Standard 40 F3-F5 I-O manual Rev4 l.doc Page 6 of 6

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.

®® ®

COMBUSTION

CHAMBER :

DRY

BASE

BOILER

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 in position on the floor by installing brackets over the

pedestal tube and securing brackets to the floor.

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

PUMP VALVE

(COIL)

A-

I--

CAPA(ITOR

r-tl--

SEE FIELD ___

WIRING

LEGEND:

(A) BROWN

(B) WHITE

(D) BLACK

(6) 120V SOURCE ACTIVATES SHUTTER OPEN

(11) MOTOR LEAD 120V SOURCE

(®) 120V CONTROL LOCK OUT ALARM TERMINAL

(AUX) CONSTANT 120V AUXILIARY TERMINAL - ELECTRONIC AIR SHUTTER

Standard 40 F3-F5 I-O manual Rev4 l.doc Page 8 of 8

APPLICATION FIELD WIRING

WIRING DIAGRAM SHOWN BELOW FOR STANDARD 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 FIELD WIRING FOR

TYPICAL APPLICATIONS

120V OPERATED SYSTEMS

120VAC 60HZ.

24V OPERATED SYSTEMS

Nd _ L _ SH_ER

120VAC 60HZ.

WIRIN( 1,I ( t ND:

PI,I ASI NE)II : OPI RAF[N( l,IMIl AND SAFI'IY I,IMI'I ARI FWO SI PARAFI I,IMI'IS

(1) MAIN DISCONNEC'I FUSE

(2) MANUAL SERVICE SWHCH

(S) "SAFE_IY" I,IMII" DEVICt "

(4) "E)Pt'RA'IING " I IMI'I DEVICt"

(5} t'AR'Itt GROUND CONNEC'IIE)N BURNt'R CtIASSIS

(6) BURNER CON1ROL REMOI'E LE)CK OlJ'I ALARM DtVICE WIRt'D _" SUPPIIED BY O FItteRS

(AUX) AUXILIARY SUB BASE ADD ON CE)NNt C'IOR (AIR SHU FI'ER)

(1 F)24V FHERMOSFAF CE)NNECl[E)NS LE)W VOI'IACE E)PERA Ft'I) SYS1EMS

M[N \VIRI SIZtI:

[NSULA'IED 18 A\VG SOI1D OR 1(_ S ['RI)

R A F B I) l 05 ° C

PROPt R IARltt (ROUNDING MtANS RIQ'D

ALL WIRING StIOWN PROVIDED BY O'[tI[ RS

WARNING: DO NOT activate burner until proper oil line connections have been made, or I

failure of the pump shaft seal may occur. I

WARNING: DO NOT activate burner until all safety and operating controls have been I

wired in series with the burner, as required by local code authorities and/or as specified by I

the appliance manufacturer.

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

IMPORTANT: THIS DIMENSIONS MUST BE OBSERVED AND VERIFIED.

I 3/64'

5mm

6/64" to 7/64" or 2to2.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 NUT (1).

NOTE: OEM specifications take priority over retrofit

specifications shown 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 by-

pass 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 COVER

2. PUMP COVER O-RING

3 BSPP TO NPT ADAPTERS

4. SUPPLY AND RETURN OILLINES

5 RETURN PORT BY PASS SCREW

6 NOZZLE PORT- PUMP OULET TO NOZZLE

7. PUMP PRESSURE PORT AND BLEEDER PORT

8PUMP SUPPLY PORT

9. PUMP RETURN PORT

10. PUMP PRESSURE REGULATING SCREW

11VACUUM PORT

12PUMP VALVE STEM

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

H3/8" OD 1/2" OD

FT M FT M FT M

1.5 0.5 33 l0 65 20

3.0 1.0 65 20 130 40

5.0 1.5 130 40 260 80

6.5 2.0 195 60 325 100

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.

NOTE: Do not exceed pipe lengths indicated in

chart.

TWO LINE (LIFT SYSTEM)

NOTE: Do not exceed pipe lengths indicated in

chart.

2 LINE (LIFT) SYSTEM-PIPE

LENGTHS

H 3/8" OD 1/2" OD

FT M FT M FT M

0.0 0.0 ll5 35 330 100

1.5 0.5 100 30 330 100

3.0 1.0 80 25 330 100

5.0 1.5 65 20 295 90

6.5 2.0 50 15 230 70

9.5 3.0 25 8 100 30

11 3.5 20 6 65 20

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 two-

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

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

i IMPORTANT: An external, appropriatelylisted and certified oil filter must be placed in the fuel 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)

II.

Loosen the bleeder valve (A) until oil flows out. Tighten the bleeder

valve securely and start burner.

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 been purged of air, then tighten the bleeder valve and

immediately shut down the burner.

8) Reinstall the air tube cover and nozzle line

9) The burner can now be started normally.

WARNING: 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 13of 13

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 sealed and free from air leaks or I

any internal blockages. I

WARNING! WHEN THE BYPASS PLUG IS INSTALLED, A TWO-PIPE SYSTEM MUST I

BE USED OR FAILURE OF THE PUMP SHAFT WILL OCCUR. I

SETTING THE AIR ADJUSTMENT 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 l.doc Page 14 of 14

BURNER ADJUSTMENT TABLES

NON-RETROFIT 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 FIRING

RATE 5% ±

US GPH

0.50

0.60

0.75

0.80

0.95

NOZZLE

SIZE

GPH

.40 x 60°/80 °

.50 x 60°/80 °

.60 x 60°/80 °

.65 x 60°/80 °

.75 x 60°/80 °

PUMP

PRESSURE

PSI BAR

160 11.0

150 10.4

160 11.0

TURBULATOR

SETTING

0.0

0.5

1.5

2.0

3.0

MODEL F5 BURNER SETUP CHART

AIR DAMPER

SETTING

2.3

2.7

3.4

3.6

4.3

ACTUAL FIRING

RATE 5% ±

US GPH

0.75

0.85

1.00

1.10

1.25

1.50

1.65

NOZZLE

SIZE

GPH

PUMP

PRESSURE

PSI BAR

TURBULATOR

SETTING

.60 x 60/80 ° 145 10 0.0

.65 x 60/80 ° 145 10 0.5

.85 x 60/80 ° 145 l0 1.0

1.00 X 60/80 ° 145 10 2.0

1.10 x 60/80 ° 145 10 2.5

1.25 x 60/80 ° 145 10 3.0

1.35 X 60/80 ° 145 10 4.0

AIR DAMPER

SETTING

2.25

2.5

2.75

3.0

3.5

4.25

6.0

NOTE: The above set up charts are a starting point only. The burner and appliance must be properly set

up using proper combustion testing equipment.

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. Size retrofit application according to the

appropriate installation codes (e.g. CSA B 139 or NFPA #31).

Standard 40 F3-F5 I-O manual Rev4 l.doc Page 15 of 15

AMULET INSTALLATION INSTRUCTIONS

(Required on some models)

The amulets provided have been selected by Riello to protect the combustion tube from bt exhaust gases and

flame. This protection may be needed in applications where the combustion tube opening in the combustion

chamber refractory is larger than the tube outside dimneter.

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

the flush --_

mounted position _

Head Receeded "If-t

1/4 inch max. *"-_

4__

NO AMULET AMULET

LOW PRESSURE ]

air tube

increase in

pressure down air

tube due to

increase in

combustion

chamber pressure

flue

gases

tapered combustion

chamber causes

increase in pressure

inside

increase in pressure down air

tube due to increase in

combustion chamber

pressure

LOW PRESSURE I

air tube

AMULET HELPS

PREVENT HOT

GASES FROM

TRAVELLING

DOWN AIR

TUBE

gases

tapered combustion

chamber causes

increase }n pressure

inside

heat

i H'GHPRESSU EI

heat

ncrease in pressure down air

tube due to increase in

combustion chamber

pressure

Standard 40 F3-F5 I-O manual Rev4 l.doc Page 16 of 16

RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR

SHUTTER NORMAL OPERATIONAL SEQUENCE

POWER

STANDY BY

_m CALL FOR

HEAT

AIR

open SHUTTER

_3 MOTOR /

PREPURGE

(_ IGNITION

Ol L VALVE

' FLAME

._ HEAT

SATISFIED

_ AIR

SHUTTER

n i

[

ELECTRIC AIR SHUTTER CLOSED ~WAITING FOR CALL FOR HEAT

ELECTRIC AIR SHUTTER OPENS -ONCE FULLY OPEN SWITCHES POWER T+ BURNER MOTOR

BURNER MOTOR STOPS ~ELECTRIC AIR SHUTTER CLOSES

THERMOSTAT OR LIMIT CONTROL

40 SERIES OIL BURNER MODES

ELECTRIC AIR SHUTTER MODES

CONSTANT UNITERUPTED 120V POWER SUPPLY

TO ELECTRIC AIR SHUTTER ASSEMBLY

¢S

_t3

fmEl,l_

open

POWER

STANDY BY

CALL FOR

HEAT

AIR

SHUTTER

MOTOR/

PREPURGE

IGNITION

OI L VALVE

FLAME

LOCK OUT

AIR

SHUTTER

RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR

SHUTTER NO FLAME OPERATIONAL SEQUENCE

ELECTRIC AIR SHUTTER CLOSED - WAITING FOR CALL FOR HEAT

ELECTRIC AIR SHUTTER OPENS ~ ONCE FULLY OPEN SWITCHES POWER TO BURNER MOTOR

[

IBURNER MOTOR STOPS - ELECTRIC AI}R SHUTTER CLOSES

THERMOSTAT OR LIMIT CONTROL ELECTRIC AIR SHUTTER MODES

40 SERIES OIL BURNER MODES CONSTANT UNITERUPTED 120V POWER SUPPLY

TO ELECTRIC AIR SHUTTER ASSEMBLY

4:_

_"o

:1:=,

'!3

No CODE F3 F5

RIELLO SPARE PARTS LIST revised November 6, 2002

•Indicates applicable model for each part.

DESCRIPTION No CODE F3 F5 DESCRIPTION

1 3007232 Burner Back Cover

2 3007233 Burner Back Cover

3006992 Pipe Connector Supply

33006571 3/8" NPT/Metric Adapter - Male

4 3006993 Pipe Connector Return

5 3005847 t/2' NPT/Metric Adapter - Female

6 3007077 Crushable Metal Washer 3/8" ID

7 3007568 Bleeder

8 3007028 O-Ring - Pump Pressure Regulator

9 3007202 Regulator Screw

10 C7010002 O-Ring- Pump Cover (3007162)

11 3005719 Pump Screen

12 3006925 Valve Stem

13 3007203 Valve Stem Plate

14 3007029 O-Ring - Valve Stem Upper

15 3007156 O-Ring - Valve Stem Lower

16 3007268 Nozzle Outlet Fitting

17 3007087 Crushable Metal Washer 5/8" ID

18 N/A Primary Control Sub-Base

19 3006553 Coil U-Bracket and Knuded Nut

20 3002279 Coil

21 3007802 Pump

22 3000443 Pump Drive Key

23 3005843 Motor 120VOLT 60Hz

3007315 Air Tube Cover

24 3007316 Air Tube Cover

25 3002280 Photocell

26 N/A

27 3005854

28 3005855

29 3005856

C7001081

30 C7001082

Primary Control

Semi Flange (2 Required)

Universal Mounting Flange

Mounting Gasket

F3 replacement air damper kit

F5 replacement air damper kit

3007207 Air Intake Housing

34 3007208 Air Intake Housing

35 3005844 Capacitor 12.5!JF

36 3005708 Fan

C6950050 Acoustic Liner

37 3007320 Acoustic Liner

3007221 Chassis Front Plate

38 3007222 Chassis Front Plate

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_i_i_i`i_i_i`i_i_i`i_i_`_`i_iiiiii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:iii_i_:i

49 C7001033 Amulet - Cerafelt Sleeve Kit

50 C7001066 Type L 24 volt switching relay

51 2623141 Capillary port plug

52 3000932 Adjustable Steel Flange

_BT COMBU_ION

3948876 VSBT Combustion Head 3"

4O 3948976 VSBT Combustion Head 3"

3006968 Turbulator Disc

41 3006977 Turbulator Disc

42 3006966 Electrode Support

43 3006965 Nozzle Adapter

3008627 Nozzle Oil Tube

44 3008629 Nozzle Oil Tube

3008633 Regulator Assembly

45 3008634 Regulator Assembly

3008630 Electrode Assembly

46 3008631 Electrode Assembly

47 3005869 Electrode Porcelain

3008623 Air Tube only

48 3008626 Air Tube only

3948873

4O 3948973

3006968

41 3006977

42 3006966

43 3006965

3006969

44 3006973

3006324

45 3006323

3006330

46 3006329

47 3005869

3007592

48 3007594

Short Combustion Head 6" (271T1)

Turbulator Disc

Electrode Support

Nozzle Adapter

Nozzle Oil Tube - Short

Regulator Assembly - Short

Electrode Assembly - Short

Electrode Assembly- Short

Electrode Porcelain

Air Tube only

_7/8" 3_B_STION N_8;:;;: LOi |GC_ BEAD

40 3948877 Combustion Head 87/8" 40 3948874 Long Combustion Head 10" (271T2)

3948975 Combustion Head 8 7/8" 3948974 Long Combustion Head 10" (271T2)

3006968 Turbulator Disc 3006968 Turbulator Disc

41 41

3006977 Turbulator Disc 3006977 Turbulator Disc

42 3006966 Electrode Support 42 3006966 Electrode Support

43 3006965 Nozzle Adapter 43 3006965 Nozzle Adapter

44 3008970 Nozzle Oil Tube 44 3006970 Nozzle Oil Tube - Long

3008628 Nozzle Oil Tube 3006974 Nozzle Oil Tube - Long

45 3008846 Regulator Assembly 45 3005867 Regulator Assembly - Long

3008635 Regulator Assembly 3005878 Regulator Assembly - Long

46 3008789 Electrode Assembly 46 3005870 Electrode Assembly - Long

3008632 Electrode Assembly 3005880 Electrode Assembly - Long

47 3005869 Electrode Porcelain 47 3005869 Electrode Porcelain

3008788 Air Tube only 3007593 Air Tube only

48 3008625 Air Tube only 3007595 Air Tube only

Standard 40 F3-F5 I-O manual Rev4 l.doc Page 20 of 20

35 Pond Park Rd.

Hingham, MA 02043

Phone: 781-749-8292

Toll Free: 800-992-7637

Fax: 781-740-2069

mB,++o

BURNERS

2165 Meadowpine Blvd.

Mississauga, On L5H R2

Phone: 905-542-0303

Toll Free: 800-387-3898

Fax: 905-542-1525

BURNER START- UP FORM *

Burner S/N. or

Model: Appliance:

Installer name:

Installation

Company: date:

Address:

Phone: Fax:

Owner Name:

Address:

Phone: E-mail:

Turbulator

Air Setting: setting:

Draft

:)raft Over fire: breech:

002: CO: 02:

+Smoke density: (Bacharach)

: Single [_1 Tw°[_l

::i Line: I I Lines: I I

Burner Start-up Info (GAS)

Gas Supply Pressure:

Pump

pressure:

Air Setting:

Draft Over fire:

002:

Head Setting:

Draft

breech:

CO: 02:

Manifold pressure:

Ionization Reading Input

(pAd.c.): BTU/Hr:

This form was designed and provided in the installation manual for reference and also for providing

technical information, which can be faxed or mailed to our technical hot-line coordinator when technical

assistance is required. Please complete this form, fax it or mail it at the addresslfax above, or sendane-mail

with the information listed below to: techservices(_,riellocanada.com

Standard 40 F3-F5 I-OmanualRev4 l.doc Page 21 of 21

INSTALLATION PRECAUTIONS

AIR FOR 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, installan approvedfire extinguisher.

ELECTRICAL CONNECTIONS

In most localities, anumber 14 wire should be used inside ametal conduit. The system should be grounded. A

service switch should be placed close to the burner on afireproof 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

35 Pond Park Road

Hingham, MA 02043

Phone 781-749-8292

Toll Free 800-992-7637

Fax 781-740-2069

wx_w.riellousa.com

BURNERS

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

RIELLO Burner, Furnace Manual L0805012

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